COPYRIGHT

No copies or reproductions may be made from this manual, parts lists or illustrations without written
prior consent of Finlay Hydrascreens (Omagh) Ltd. This manual complete or in part must not be
loaned to a third party.

Finlay Hydrascreen is a registered trademark for portable screening plant manufactured by Finlay
Hydrascreens (Omagh) Ltd.

ISSUE NO. 010502/01

FINLAY HYDRASCREENS (OMAGH) LTD.

DRUMQUIN ROAD, OMAGH, Co.TYRONE N.IRELAND, BT78 5PN
TEL: +44(0)2882 418700
FAX: +44(0)2882 244294 (SALES) 243487 (SPARES) 252740 (TECHNICAL).
EMAIL: [email protected]
WEBSITE: www.finlayhydrascreens.com

FINLAY HYDRASCREENS USA, INC

11001 Electron Drive, Louisville, KY 40299, USA
TEL: 001 502 267 2314 FAX: 001 502 267 0396
EMAIL: [email protected]
WEBSITE: www.finlayhydrascreens.com

Finlay Hydrascreens reserve the right to change specification without prior notice.

CO - 1
 CONTENTS:
SECTION 1 : SAFETY .....................................................................................................SA - 2
1.1 SAFETY INTRODUCTION ................................................................................ SA - 2
1.2 HYDRAULIC SAFETY ....................................................................................... SA - 7
1.3 ELECTRICAL AND ENGINE SAFETY ............................................................ SA - 8
1.4 SAFETY BEFORE AND DURING OPERATION ........................................... SA - 9
1.5 SAFETY BEFORE AND DURING MAINTENANCE ..................................... SA - 10
1.6 SAFETY BEFORE AND DURING TRANSPORT ......................................... SA - 12
1.7 SAFETY SIGNS IN THIS MANUAL ................................................................. SA - 13
1.8 SAFETY SIGNS ON YOUR MACHINE ........................................................... SA - 14
1.9 EMERGENCY STOPS ON YOUR MACHINE ............................................... SA - 15
1.10 SAFETY GUARDS ON YOUR MACHINE ...................................................... SA - 16
1.11 NOISE LEVELS AROUND YOUR MACHINE ................................................ SA - 17

SECTION 2 : TECHNICAL INFORMATION ................................................................TE - 3

2.1 FAMILIARISATION .............................................................................................. TE - 3
2.2 KEY COMPONENTS ......................................................................................... TE - 4
2.3 OPTIONS .............................................................................................................. TE - 6
2.4 TECHNICAL DATA ............................................................................................. TE - 7
2.5 TRANSPORT POSITION DIMENSIONS ........................................................ TE - 8
2.6 WORKING POSITION DIMENSIONS .............................................................. TE - 9
2.7 CORRECT USE OF MACHINE ........................................................................ TE - 10

SECTION 3 : INSTALLATION ........................................................................................IN - 2

3.1 SAFETY INTRODUCTION ................................................................................ IN - 2
3.2 STARTING ENGINE ........................................................................................... IN - 6
3.3 STARTER PANEL INDICATORS ..................................................................... IN - 7
3.4 MOVING THE MACHINE .................................................................................. IN - 8
3.5 LOWERING SUPPORT LEGS .......................................................................... IN - 9
3.6 FITTING DEFLECTOR DOORS (OPTIONAL) ............................................... IN - 10
3.7 LEVELLING .......................................................................................................... IN - 11
3.8 UNFOLDING THE FINES CONVEYOR .......................................................... IN - 12
3.9 UNFOLDING THE MIDDLE GRADE CONVEYOR ....................................... IN - 14
3.10 UNFOLDING THE OVERSIZE CONVEYOR ................................................. IN - 16
3.11 RAISING VIBRATING GRID TO WORKING POSITION (OPTIONAL) ....... IN - 17
3.12 RAISING REMOTE GRID TO WORKING POSITION ................................... IN - 17
3.13 LOWERING CUTTER UNIT INTO WORKING POSITION (OPTIONAL) ... IN - 18

SECTION 4 : OPERATION .............................................................................................OP - 2

4.1 SAFETY INTRODUCTION ................................................................................ OP - 2
4.2 SAFETY BEFORE AND DURING OPERATION ........................................... OP - 6
4.3 OPERATING MACHINE .................................................................................... OP - 7

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4.4 SCREENING........................................................................................................ OP - 8
4.5 BELTFEEDER SPEED CONTROL ................................................................. OP - 9
4.6 CONVEYORS SPEED CONTROLS (OPTIONAL) ........................................ OP - 9
4.7 RADIO CONTROL REJECT TIPPING GRID (OPTIONAL) .......................... OP - 10
4.8 CHANGING FREQUENCY IN RADIO CONTROL RECEIVER .................. OP - 11

SECTION 5 : MAINTENANCE .......................................................................................MA - 2

5.1 SAFETY INTRODUCTION ................................................................................ MA - 2
5.2 SAFETY BEFORE AND DURING MAINTENANCE ..................................... MA - 6
5.3 HYDRAULIC SAFETY ....................................................................................... MA - 8
5.4 ELECTRICAL AND ENGINE SAFETY ............................................................ MA - 9
5.5 HYDRAULIC SYSTEM ...................................................................................... MA - 10
5.6 HYDRAULIC FLUIDS ......................................................................................... MA - 10
5.7 FILTRATION ......................................................................................................... MA - 11
5.8 OIL TANK, PIPES AND FITTINGS ................................................................... MA - 11
5.9 DIESEL ENGINE ................................................................................................. MA - 12
5.10 TROMMEL SCREEN ......................................................................................... MA - 12
5.11 BELT TRACKING ................................................................................................ MA - 13
5.12 BELT TRACKING ON YOUR MACHINE ....................................................... MA - 14
5.13 BELT TENSIONING ON YOUR MACHINE ................................................... MA - 15
5.14 CHANGING SCREEN MESHES .................................................................... MA - 16
5.15 CHANGING INNER BARREL APERATURE ................................................. MA - 17
5.16 ADJUSTING NYLON BRUSHES ..................................................................... MA - 18
5.17 CHANGING NYLON BRUSHES ...................................................................... MA - 18
5.18 TENSIONING BARREL CHAIN ........................................................................ MA - 19
5.19 TENSIONING BELTFEEDER CHAIN ............................................................. MA - 20
5.20 CHANGING FUEL FILTER ................................................................................ MA - 21
5.21 WATERTRAP ...................................................................................................... MA - 21
5.22 CHANGING HYDRAULIC FILTERS & OIL ..................................................... MA - 22
5.23 CHANGING ENGINE FILTERS & OIL ............................................................. MA - 25
5.24 CHANGING FEED CONVEYOR GEARBOX OIL .......................................... MA - 28
5.25 HYDRAULIC RAM MAINTENANCE ............................................................... MA - 29
5.26 RECOMMENDED LUBRICANTS ..................................................................... MA - 30
5.27 Remote Greasing schedule ............................................................................... MA - 31
5.28 MAINTENANCE SCHEDULES ........................................................................ MA - 34

SECTION 6 : TRANSPORT ............................................................................................TR - 2

6.1 SAFETY INTRODUCTION ................................................................................ TR - 2
6.2 SAFETY BEFORE AND DURING TRANSPORT ......................................... TR - 4
6.3 STOPPING THE MACHINE .............................................................................. TR - 5
6.4 PREPARING FOR TRANSPORT .................................................................... TR - 5

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6.5 LOWERING VIBRATING GRID TO TRANSPORT POSITION .................... TR - 6
6.6 LOWERING REMOTE GRID TO TRANSPORT POSITION ........................ TR - 6
6.7 FOLDING THE OVERSIZE CONVEYOR ....................................................... TR - 7
6.8 FOLDING THE MIDDLE GRADE CONVEYOR ............................................ TR - 8
6.9 FOLDING THE FINE GRADE CONVEYOR ................................................... TR - 9
6.10 RETURNING DEFLECTOR DOORS TO THE TRANSPORT POSITION TR - 10
6.11 RAISING SUPPORT LEGS ............................................................................... TR - 11
6.12 RETURNING THE DRAWBAR TO THE TRANSPORT POSITION .......... TR - 12
6.13 RAISING JACKLEGS ......................................................................................... TR - 12
6.14 READY FOR TRANSPORT .............................................................................. TR - 13
6.15 PRIOR TO HAULAGE: ....................................................................................... TR - 13

SECTION 7 : FAULTFINDING .......................................................................................FA - 2

7.1 NO RESPONSE FROM ANY HYDRAULIC SYSTEM ................................ FA - 2
7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAK .................. FA - 2
7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP ........................................ FA - 3
7.4 TROMMEL BARREL NOT WORKING ............................................................ FA - 3
7.5 VIBRATING GRID WILL NOT START ............................................................. FA - 3
7.6 BELTFEEDER NOT WORKING WHEN CONVEYOR IS RUNNING......... FA - 4
7.7 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING. ..................... FA - 4
7.8 CONVEYOR BELT NOT RUNNING ................................................................ FA - 4
7.9 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED WITH A LOAD ON
THE BELT .................................................................................................................... FA - 5
7.10 REJECT GRID WILL NOT HINGE ................................................................... FA - 5
7.11 Vibrating Grid and Screen Bearings fail prematurely .................................... FA - 5
7.12 Engine Fails to Start ............................................................................................ FA - 6
7.13 Belt Stops Under Load ........................................................................................ FA - 6
7.14 Engine Stops ........................................................................................................ FA - 6
7.15 Conveyor Belts Running out of line .................................................................. FA - 7
7.16 Trommel Barrel running out of line. ................................................................. FA - 7
7.17 Chain Slipping. .................................................................................................... FA - 7
7.18 Screen Mesh Clogging ...................................................................................... FA - 7

SECTION 8 : SPARE PARTS .........................................................................................SP - 2

9. WARRANTY ........................................................................................................ WA - 1

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

1.2 HYDRAULIC SAFETY ......................................................................................SA - 7

1.3 ELECTRICAL AND ENGINE SAFETY ...........................................................SA - 8

1.4 SAFETY BEFORE AND DURING OPERATION ..........................................SA - 9

1.5 SAFETY BEFORE AND DURING MAINTENANCE ................................. SA - 10

1.6 SAFETY BEFORE AND DURING TRANSPORT ..................................... SA - 12

1.7 SAFETY SIGNS IN THIS MANUAL ............................................................. SA - 13

1.8 SAFETY SIGNS ON YOUR MACHINE ....................................................... SA - 14

1.9 EMERGENCY STOPS ON YOUR MACHINE ........................................... SA - 15

1.10 SAFETY GUARDS ON YOUR MACHINE .................................................. SA - 16

1.11 NOISE LEVELS AROUND YOUR MACHINE ............................................ SA - 17

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SECTION 1 : SAFETY

1.1 SAFETY INTRODUCTION

1.1.1

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.

1.1.2

Overleaf are listed all the safety signs used throughout this manual and on your machine.
Take time to familiarise yourself with the symbols and explainations.

These signs are used frequently throughout this manual to indicate any potential warning or
danger when operating this machine.

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DANGER
1. Entanglement Hazard. Do not
reach into an unguarded machine
you can be pulled in.
2. In-running nip points can cause
serious injury or even death. Your
arm could be pulled in and ampu-
tated.
3. Switch off and lockout machine
before opening or removing guard
doors.

1.Beware of escaping Hydraulic oil.

DANGER
High pressure hydraulic oil can
penetrate the skin causing serious
injuries.

2.Always relieve pressure from the

hydraulic system before attempting
maintenance or adjustment. Use a
piece of cardboard to check for oil
leaks.

3. If oil is injected under the skin, it

must be surgically removed or
gangrene will result. Get medical
help immediately.

DANGER
1.Electrical Hazard. Risk of serious
injury or death.
2. Never work on the electrical sys-
tem of any equipment unless you
are thoroughly familiar with system
details.
3. Work on the electrical system
must only be carried out by a quali-
fied electrician.

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DANGER
1. Shredding Hazard. Do not reach
into an unguarded machine.

2. In-running nip points can cause

serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

WARNING 1. Read and understand the opera-

tors manual before you work at
this machine.

2. Study the different safety signs

on this machine.

3. Only qualified and trained per-

sonnel should attempt to work at
this machine.

WARNING
1. Loose or baggy clothing can get
caught in running machinery.
2. Always wear correctly fitting (EN/
ANSI approved) protective cloth-
ing.
3. Protective clothing includes Hard
Hat, Safety Glasses, Ear Defend-
ers, Overalls, Steel Toed Boots
and a High Visibilty Vest.

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WARNING 1. Falling Rock Hazard. Do not walk

near material discharge areas.You
are at risk of serious injury or
death.

2. Wear a hard hat at all times when

working in the vicinity of the ma-
chine.

WARNING 1. Crush Hazard. Beware of danger-

ous 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/of mechanical

supports provided.

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.

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WARNING 1. Fall Hazard. Do not climb onto mov-

ing or working machinery. You could
fall and be seriously injured.
2. Switch off and lockout machine be-
fore attempting maintenance or ad-
justment to this machine.

3. Always use a suitable lifting platform

before attempting any maintenance
work above 2 metres(6-6”).

CAUTION 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.

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1.2 HYDRAULIC SAFETY

1. Never disable or alter any hydraulic circuit or component without consulting with
Finlay Hydrascreens or your local dealer.

2. Any work carried out on a hydraulic system must be performed by an engineer with
special knowledge and experience in hydraulics.

3. Relieve all pressure in hydraulic system by returning controls to the neutral position.
Turn machine off and isolate power supply before any pipes, filter caps, filters or
hydraulic fittings are disconnected or removed.

4. Ensure replacement hydraulic components are the same standard and quality as
the original parts. Ensure they are fitted correctly.

5. Beware of hydraulic oil leaks. Hydraulic fluid under pressure can penetrate the skin
or damage eyes. Fluid leaks under pressure may not be visible. Use a piece of
cardboard to find leaks but do not use bare hand.

6. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate
medical attention.

7. Replace any damaged hydraulic pipe. Leaks can cause fires. Always ensure a
replacement pipe has the same specification as the original pipe, length, fittings,
orientation and diameter. Ensure pipes are laid and fitted correctly.

8. Do not exceed safe limits. Never set a pressure relief valve to a pressure higher
than that set at the factory. 175 Bar (2500 PSI).

DANGER
HIGH PRESSURE
HYDRAULIC FLUID
CAN PENETRATE THE
SKIN CAUSING SERI-
OUS INJURIES

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1.3 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 mainte-
nance or servicing to your engine.
7. Battery posts, terminals and related accessories contain lead and lead com-
pounds, chemicals known to the State of California to cause cancer and reproduc-
tive 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 ex-
haust 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

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1.4 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

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1.5 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 alltim es.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 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 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.

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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.

WARNING
PRACTICE SAFE
MAINTENANCE READ
AND UNDERSTAND
THE OPERATORS
MANUAL BEFORE
DOING ANY WORK

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1.6 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 manualfor

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 trans-
port.

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

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.
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1.7 SAFETY SIGNS IN THIS MANUAL

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 situation

which, if not avoided, could result in death or
serious injury.

CAUTION
This indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
It may also be used to alert against unsafe prac-
tices.

IMPORTANT This indicates a statement of company policy,

which if not adhered to will result in damage to your
machine and/or other peoples property.

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1.8 SAFETY SIGNS ON YOUR MACHINE

Safety Signs are important features of your Finlay machine. Please take time to
familiarise yourself with their meaning and locations on the machine as seen below.

IMPORTANT
ANY DAMAGED, MISSING OR PAINTED
OVER SAFETY SIGNS MUST BE
REPLACED IMMEDIATELY

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1.9 EMERGENCY STOPS ON YOUR MACHINE

There are 4 off Emergency Stop Buttons on your machine. Please take time to
familiarise yourself with their locations on the machine as seen below.

IMPORTANT
EMERGENCY STOP BUTTONS ARE AN
IMPORTANT SAFETY FEATURE IF
DAMAGED OR BROKEN THEY MUST BE
REPLACED IMMEDIATELY

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1.10 SAFETY GUARDS ON YOUR MACHINE

Safety Guards are important features of the Finlay 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 17 18 19 20

WARNING
1. Vibrating Grid Non Drive Guard
2. Vibrating Grid Drive Guard
3. Chain and Sprocket Guard(Behind Guard) ALWAYS REPLACE SAFETY GUARDS
4. Feedboot Guard AFTER MAINTENANCE.
NEVER START THE MACHINE WITH
5. Transfer Conveyor Side Guards (Both Sides) FAULTY OR MISSING GUARDS.
6. Chain and Sprocket Side Guards(Both Sides)
7. Chain and Sprocket Top Guard
8. Oversize Conveyor Side Guards (Both Sides)
9. Oversize Conveyor Cheeseguard
10.Beltfeeder Rear Guard (Behind Door)
11.Beltfeeder Side Guards (Behind Doors)
12.Beltfeeder Inverted Guard
13.Transfer Conveyor Rear Guard
14..Engine Compartment Guarding
15Side Conveyor Cheeseguard (Not Shown)
16.Trommel Frame Side Guards(Both Sides)
17.Middle Grade Feedboot Rear Guard
18.Middle Grade Feedboot Inverted Guard
19.Oversize Conveyor Rear Guard
20.Oversize Conveyor Return Roller Nip Guard

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1.11 NOISE LEVELS AROUND YOUR MACHINE

Noise Levels for the Finlay 798 Trommel - Engine BF4M 1012C (Running on Empty)

81dB

86dB
10 METRE(32’-8”) RADIUS 79dB

89dB
5 METRE(16’-4”) RADIUS 83dB

1 METRE(3’-3”) RADIUS

89dB

79dB
83dB

90dB

86dB

84dB

WARNING
CONSTANT HIGH
NOISE LEVELS
EAR PROTECTION
MUST BE WORN

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 SECTION 2: TECHNICAL ENG
INFORMATION 010502/01

Contents
2.1 FAMILIARISATION .............................................................................................TE - 3

2.2 KEY COMPONENTS ........................................................................................TE - 4

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

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

2.5 TRANSPORT POSITION DIMENSIONS .......................................................TE - 8

2.6 WORKING POSITION DIMENSIONS .............................................................TE - 9

2.7 CORRECT USE OF MACHINE .................................................................... TE - 10

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SECTION 2 : TECHNICAL INFORMATION

2.1 FAMILIARISATION
1 2 3 4 6 7 8
5

9 10 11 12 13 14 15 19 16 17 18

Left Hand Side

Rear Front

1. Vibrating Grid (Optional)

2. Cutter Unit (Optional)
Right Hand Side 3. Feed in Conveyor
4. Chain and Sprocket Tension Adjuster
5. Nylon Brushes
6. Trommel Screen Side Door(Both
Sides)
7. Trommel Screen Inner Barrel
Right and Left hand sides:- 8. Oversize Conveyor
9. Rear Support Leg
As viewed from the Rear of the machine 10.5th Wheel Coupling
11.Hopper & Beltfeeder(Behind Doors)
Front:-
12.Jack Leg(4 Off)
The Oversize conveyor end of the machine 13.Engine Compartment
14.Fines Conveyor
Rear:- 15.Main Control Panel
16.Trommel Screen Door Latch
The Hopper end of the machine 17.Control Valve for Oversize Conveyor
18.Middle Grade Conveyor
19. Transfer Conveyor

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2.2 KEY COMPONENTS

2.2.1 Engine Compartment
The machine is powered by a Deutz BF4M
1012C water cooled -72 kW (96hp) diesel
engine coupled to hydraulic pumps.
Fitted in a purpose built compartment it is
situated next to the hydraulic tank providing
easy access to all filters and gauges.
Access to the engine compartment area is
gained through access doors on each side
of the compartment.

2.2.2 Trommel Screen

The Trommel Screen consists of two screen-
ing drums.The inner drum has variable
aperature sizes which are varied by altering
the straps fitted around the inner drum.
The outer drum is fitted with 9 interchange-
able meshes for quick and efficient fitting.
The Trommel screen is driven by sprocket
and chain drive and supported by 4 nylon
wheels fitted with heavy-duty bearings, with
variable speed as standard.

2.2.3 Hopper & Beltfeeder

The Loading Hopper fitted beneath the grid
area is designed with a 6.8 cu metre(8.9 cu
yds) capacity and tapered sides for greater
efficiency.
The variable speed inclined beltfeeder fitted
with a 1050mm(42”) wide belt has a speed
of 0-16m/min.Driven by chain & sprocket the
beltfeeder can handle the most difficult ma-
terial with maximum efficiency.

2.2.4 Product Conveyors

The Fines, Middle grade and Oversize con-
veyors can be hydraulically folded from the
transport to working positions from their con-
trol panels at ground level providing easy ac-
cess and vision to each conveyor.
This facility can leave the machine ready for
road or site within minutes.
A standard feature of each conveyor is a vari-
able speed control to vary their independent
speed to match the material split through the
machine.

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2.2.5 Nylon Brushes

The Trommel screen meshes are continu-

ously cleaned and maintained by 3 off
Nylon bristle brushes.
Each brush is mounted on an adjustable
frame ensuring the brushes continually
contact the screen to enable efficient
cleaning and maintenance of the meshes.

2.2.6 Central Control Panel

The Main 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.
The control panel is enclosed in a vandal
proof enclosure with a lockable hinged
front panel for added security.

2.2.7 Low Level Greasing

The 798 Trommel has central greasing to

all bearings.Grease pipes are returned
from each bearing to 3 panels at ground
level where maintenance can be per-
formed with ease.
(see the maintenance schedule in
Section:5 for a detailed checklist)

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2.3 OPTIONS
2.3.1 Vibrating Grid
The Vibrating grid with loading dimensions
3.7m (12’-2”) x 1.9m (6’-2”) is designed with
split level scalping grizzly to achieve higher
screening efficiency. The grid is fitted with
interchangeable cassettes for desired bar
spacing. Cassettes are also interchange-
able with heavy duty mesh or punch plate
depending on application.The grid is sup-
ported on spring mounts giving excellent
support to the vibrating system.

2.3.2 Reject Grid

The Reject grid with loading dimensions
3.65m(12’-0”) x1.65m( 5’-4”) can be fitted
as a Manual tipping grid or it may be con-
trolled by Radio control operation.
The Reject grid hydraulically operates when
the radio control handset is operated.The
grid raises to a near vertical position and
then returns to the lowered position auto-
matically ready to loaded again.

2.3.3 Cutter Unit

The Cutter unit is fitted with a single shafts hav-
ing the option of fixed blades or flails which
can easily pulversise friable material. The cut-
ter unit will not pulversise stone, hard rock or
woody materials. The complete unit can be
hydraulically lifted into “out of line” operation
with a safety device built into the hydraulic sys-
tem to prevent the shaft from rotating when it
is lifted out of line.

2.3.4 Electric/ Hydraulic Drive

2.3.5 TUV Specification

2.3.6 Tri-Axle Suspension

2.3.7 Blower Unit (On Middle Grade)

2.3.8 Hydraulically driven Magnet &

discharge chute

2.3.9 Deflector Doors

2.3.10 Lightboard
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2.4 TECHNICAL DATA

2.4.1 Conveyor Speeds METRES/MIN. FEET/MIN.

Beltfeeder (Variable Speed) 0-16 0-52

Transfer Conveyor Variable speed

Fines & Middlegrade Conveyor Variable Speed

Oversize Conveyor Variable Speed

2.4.2 Engine Speed 2200 RPM

2.4.3 Trommel Barrel Speed 18 RPM

2.4.4 Hydraulic Pressures BAR PSI

Maximum Working Pressure 172 2500

Pressure Rating on Hydraulic Hoses 3/8” 330 4800

1/2” 275 4000

3/4” 215 3125

2.4.5 Machine Weight TONNES US TONS

26 28.6

(Inc. Vibrating Grid) 31.8 35

2.4.6 Noise Levels

Sound Level at Operators Position 89 dB(A)

Performance Sound Level 93 dB(A)

2.4.7 Tank Capacities LITRES GALLONS

Diesel Tank Capacity 324 71

Hydraulic Tank Capacity 720 159

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2.5 TRANSPORT POSITION DIMENSIONS

20825mm [68'-4" ]

16634mm [54'-7" ]

4034mm [13'-3" ]
15895mm [52'-2" ]

WIDTH 2600mm [8' 6"]

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2.6 WORKING POSITION DIMENSIONS

21189mm [69'-6" ]
4154mm [13'-8" ]

11316mm [37'-2" ]

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2.7 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 surge
blockages 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 and along the
chassis . Ensuring that the weight of the machine is evenly distributed. (See Section
3.5 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 -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.

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

3.2 STARTING ENGINE ...........................................................................................IN - 6

3.3 STARTER PANEL INDICATORS .....................................................................IN - 7

3.4 MOVING THE MACHINE ..................................................................................IN - 8

3.5 LOWERING SUPPORT LEGS ..........................................................................IN - 9

3.6 FITTING DEFLECTOR DOORS (OPTIONAL) .............................................IN - 10

3.7 LEVELLING ........................................................................................................IN - 11

3.8 UNFOLDING THE FINES CONVEYOR ........................................................IN - 12

3.9 UNFOLDING THE MIDDLE GRADE CONVEYOR .....................................IN - 14

3.10 UNFOLDING THE OVERSIZE CONVEYOR ...............................................IN - 16

3.11 RAISING VIBRATING GRID TO WORKING POSITION (OPTIONAL) .....IN - 17

3.12 RAISING REMOTE GRID TO WORKING POSITION .................................IN - 17

3.13 LOWERING CUTTER UNIT INTO WORKING POSITION .........................IN - 18

IN - 1
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SECTION 3 : INSTALLATION

3.1 SAFETY INTRODUCTION

DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.
2. In-running nip points can cause
serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

1.Beware of escaping Hydraulic oil.

DANGER
High pressure hydraulic oil can
penetrate the skin causing serious
injuries.

2.Always relieve pressure from the

hydraulic system before attempting
maintenance or adjustment.

3. If oil is injected under the skin, it

must be surgically removed or
gangrene will result. Get medical
help immediately.

DANGER
1.Electrical Hazard. Risk of serious
injury or death.
2. Never work on the electrical sys-
tem of any equipment unless you
are thoroughly familiar with system
details.
3. Work on the electrical system
must only be carried out by a quali-
fied electrician.

IN - 2
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DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.

2. In-running nip points can cause

serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

WARNING 1. Read and understand the opera-

tors manual before you work at
this machine.
2. Study the different safety signs
on this machine.

3. Only qualified and trained per-

sonnel should attempt to work at
this machine.

WARNING
1. Loose or baggy clothing can get
caught in running machinery.
2. Always wear correctly fitting (EN/
ANSI approved) protective cloth-
ing.

3. Protective clothing includes Hard

Hat, Safety Glasses, Ear Defend-
ers, Overalls, Steel Toed Boots
and a High Visibilty Vest.

IN - 3
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WARNING 1. Falling Rock Hazard. Do not walk

near material discharge areas.You
are at risk of serious injury or
death.

2. Wear a hard hat at all times when

working in the vicinity of the ma-
chine.

WARNING 1. Crush Hazard. Beware of danger-

ous 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/of mechanical

supports provided.

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.

IN - 4
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WARNING 1. Fall Hazard. Do not climb onto mov-

ing or working machinery.
2. Switch off and lockout machine be-
fore attempting maintenance or ad-
justment to this machine.

3. Always use a suitable lifting platform

before attempting any maintenance
work above 2 metres(6-6”).

CAUTION 1. Burn or Heat Hazard. Beware of

hot surfaces at engine and exhaust
areas.

IN - 5
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WARNING
3.2 STARTING ENGINE
The Engine must be started to provide hy-
draulic power to all functions.
BEFORE INSTALLATION
YOU MUST READ AND
Before Starting: UNDERSTAND
THE SAFETY SECTION IN
(i) Check the Engine oil level and the Fuel SECTION 1 OF THIS
level and replenish if necessary. MANUAL

(ii) Adjust throttle lever(Item C) to approxi- A

mately halfway. Ensure the Emergency
stops around the machine or on the B
remote or wanderleadhandsets are
not engaged
C
D
(iii) Turn the ignition key to position (Item
F) the “ON” position.

The following warning lights on the control E

panel will illuminate.
Starter Control Panel & Throttle
(1) A Red light(Item A) Alternator F

(2) A Red light(Item B) Oil Pressure

(3) A Green light (Item D) should il- G

luminate indicating power on. (If the
light does not come on then an
Emergency stop button has been
engaged).
Disengage it to regain power.

Do not start engine without the above H

mentioned lights being illuminated
Key Positions
(iv) Fully depress and hold the safety sys-
tem Override button (Item E).

(v) Now turn the key to position(Item H)

the engine will crank and start after the
warning beeper has sounded for ap-
proximately 7 seconds.

(vi) All the lights (with the exception of the

green light)should extinguish after
start-up.If they remain illuminated or il-
luminate during operation, there is a
fault relevant to that indicator.
(See 3.3 Starter Panel Indicators)

IN - 6
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(vii) Should preheating be necessary hold

the key at position (Item F) for up to 1
minute (depending on ambient tem- IMPORTANT
perature). PREHEATING IS NORMALLY NECESSARY
WHEN AMBIENT TEMPERATURE IS
(viii) The engine should be cranked for a BELOW ZERO DEGREES CELSIUS
maximum of 20 seconds only. If the (32 DEGREES FAHRENHEIT)

engine does not start wait for one

minute before following the above pro-
cedure again.
If the engine does not start on the sec-
ond attempt, refer to the engine op-
erator’s manual.

(ix) When stopping the engine, ensure all

control levers are in neutral. Reduce
engine speed gradually by adjusting
the throttle lever. Then turn the key to
position(Item G) and the engine will
stop.

3.3 STARTER PANEL INDICATORS A

B
Each light on the starter box (Item A-G) will
illuminate when the following occur. C
D
Item A Alternator Failure
E
Item B Low Oil Pressure F
Item C High Engine Temperature G
Starter Control Panel
H
Item D Preheat On

Item E Low Coolant Level

Item F Air Filter Element Restricted

DANGER
Item G Low Hydraulic Oil Level ALL ELECTRICAL
WORK MUST BE
Item H Emergency Stop Engaged CARRIED OUT BY A
QUALIFIED
ELECTRICIAN

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3.4 MOVING THE MACHINE

Each 798 Trommel is fitted with a braked

axle. A
Therefore the machine cannot be moved on
site once it has been removed from the lorry
without draining the air tank(Item A) to re-
lieve the pressure on the brakes.
B
To Drain the Air tank on your machine.

(i) Locate the Air tank drain cord situated Machine Air Tank
between the wheels at (Item C).
C
(ii) Pull cord downwards to relieve pres-
sure at the drain tap(Item B) on the
airtank.

3.4.1 Moving The Machine On Site

To move the machine on site the Site Draw-

bar must be fitted to its working position.

(i) Remove pin (Item D) holding drawbar Air Tank Drain Cord Location
in transport position.

(ii) Lower the drawbar(Item E) to the work-

ing position. D
(iii) Place the Drawbar securing member
(Item F) into position and secure with E
the securing pin (Item G).

Move the machine onto its operating site,

position it on a level firm foundation with ad-
equate space around the machine for Site Drawbar In Closed Position
operation,material stockpiles, maintenance
and vechicular movement.

WARNING
F

DO NOT USE THE SITE DRAWBAR TO G

MOVE THE MACHINE ON PUBLIC ROADS

EXTREME CAUTION REQUIRED WHEN

MOVING MACHINE ON UNEVEN OR SOFT
GROUND (SEE SAFETY SECTION 1.6)
Site Drawbar In Working Position

IN - 8
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3.5 LOWERING SUPPORT LEGS

The Rear support legs (Item A) should now

be lowered and secured with the pins pro-
vided on both sides(Item B).
A
The rear of the machine(Hopper end) may
have to be raised using the Rear hydraulic
jacking legs to align the support leg pin holes
so pins may be inserted and secured in
place.
Rear Support Legs in Raised Position

CAUTION
THE SUPPORT CHANNELS ARE HEAVY B
OBJECTS THEY WILL REQUIRE 2
PERSONS TO FIT THEM INTO POSITION

Rear Support Legs in Working Position

IN - 9
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3.6 FITTING DEFLECTOR DOORS

(OPTIONAL)

When you receive your Machine it will ar-

rive with the Deflector doors in the transport
position.To put the deflector doors to the A
working position.

(i) Remove thePin (Item B) holding the

Deflector door in the transport posi-
tion at either side and store them in
the toolbox. Deflector Door in Transport Position

(ii) Next rotate the Deflector door(Item A).

Unfold the Deflector door and secure
with bolt at Securing poit (Item C)
B
(iii) Place the deflector door in the Work-
ing position (Item D) and secure in
position.

IMPORTANT
Deflector Door Transport
Securing Pin
THIS MACHINE MUST NOT LOADED
WITH MATERIAL UNTIL THE
DEFLECTOR DOORS
ARE FITTED IN WORKING POSITION
C

Deflector Door Unfolded

Deflector Door in Working Position

IN - 10
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3.7 LEVELLING

(i) (ii) (iii)

To ensure accurate level guidance 6 level
indicators (Item A) have been fitted to your
machine.Three on each side.
Level indicators are located at three posi-
tions namely:

(i) Rear Jacking Legs

(ii) Chassis Frame A
(iii) Front Jacking Legs

Move the jacking legs using control lever

(Item B) for the Rear jack Legs(i) and con- Level Indicator
trol levers(Items C&D) for the Front jack
legs(iii) until the level indicators are in the
correct position
B
To maintain weight on the hydraulic jacking
legs a pin (Item E) should be placed in a
relevant hole to keep the machine level.
Ensure that the weight of the machine is
evenly spread over the support legs, chas-
sis base and axles. C
D

IMPORTANT Jack Leg Controls

IT IS IMPORTANT THAT THE MACHINE

IS COMPLETELY LEVEL TO ENSURE
OPTIMUM PERFORMANCE
E

WARNING
HAZARDOUS NIP
AND CRUSH
POINTS IN THIS
AREA Rear Jacking Leg Pin

IN - 11
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3.8 UNFOLDING THE FINES

CONVEYOR A
When you receive your Machine it will ar-
rive with theFines Conveyor folded(Item A)
in the transport position.To put the conveyor
to the working position.

(i) Remove nut and washer from the

securing chain(Item B) holding the
Fines conveyor in the transport
position.Use a 19mm spanner. Conveyor in the Transport Position

(ii) Next to unfold the conveyor operate

the control lever (Item C).
Ensure there is adequate space for B
the conveyor to fold out into its work-
ing position(Item D).

IMPORTANT
USE THE CONTROL LEVERS IN A SMOOTH
AND CONTROLLED MANNER. Conveyor Transport Securing Chain
DO NOT RUSH OR JERK THE CONTROLS.
THIS WILL DAMAGE THE CONVEYOR

WARNING C

HAZARDOUS NIP
AND CRUSH
POINTS IN THIS
AREA
Conveyor Control Bank

Conveyor in the Working Position

IN - 12
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(iii) When the conveyor unfolds to the

working position.
Secure it in position with the pins pro- E
vided (Item E) on either side of the
conveyor.

Fines Conveyor Securing Pin

IN - 13
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3.9 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 put
the conveyor to the working position.

(i) Remove nut and washer from the se-

curing chain(Item B) holding the Mid-
dle grade conveyor in the transport
position. Use a 19mm spanner. Conveyor in the Transport Position

(ii) Next to unfold the conveyor operate

the control lever (Item C). Ensure there
is adequate space for the conveyor B
to fold out into its working
position(Item D).

(iii) Place a pin at each side of te con-

veyor (Item D) to secure in position.

IMPORTANT Conveyor Transport Securing Chain

USE THE CONTROL LEVERS IN A SMOOTH C

AND CONTROLLED MANNER.
DO NOT RUSH OR JERK THE CONTROLS.
THIS WILL DAMAGE THE CONVEYOR

WARNING
HAZARDOUS NIP
AND CRUSH
POINTS IN THIS Conveyor Control Bank
AREA

Conveyor in the Working Position

IN - 14
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(iii) When the conveyor unfolds to the

working position.
Secure it in position with the pins E
provided (Item E) on either side of
the conveyor.

Middle Grade Conveyor Securing Pin

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3.10 UNFOLDING THE OVERSIZE

CONVEYOR

When you receive your Machine it will

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

(i) Remove the chains (Item B) holding B

the Oversize conveyor in the transport
position . Oversize in the Transport Position

(ii) Next to unfold the conveyor operate

the control lever (Item D).Ensure there C
is adequate space for the conveyor to
fold out.

(iii) Secure the conveyor in the working

position by placing securing pins (Item
E) into position.
D

IMPORTANT Oversize Conveyor Control Bank

USE THE CONTROL LEVERS IN A SMOOTH
AND CONTROLLED MANNER.
DO NOT RUSH OR JERK THE CONTROLS.
THIS WILL DAMAGE THE CONVEYOR

WARNING E
HAZARDOUS NIP
AND CRUSH
POINTS IN THIS
AREA Oversize Conveyor Securng Pin

(iii) Remove the Telescopic holding pins

from the hole at (Item F). Extend the
Top section by operating the control
lever (Item C) until the second set of F
holes in the inner telescopics have
aligned , reinsert the pins into the holes
to hold the conveyor in the working po-
sition.

Oversize Telescopic

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3.11 RAISING VIBRATING GRID TO

WORKING POSITION (OPTIONAL)
If your machine is fitted with a Vibrating
grid you must raise it to a working position A
before loading material onto it.
B
The Grid Working position is variable to
suit different applications and materials.To
Raise grid from its Transport position to a
Working position (Item A).

(i) Operate the control lever (Item C) at

the Main hydraulic control panel. Vibrating Grid in Working Position

(ii) Fit pins in telescopic legs(Item B) in

holes provided on either side of grid
to hold position.
Use the same hole on either side to
keep the grid level.
C
3.12 RAISING REMOTE GRID TO
WORKING POSITION
If your machine is fitted with a Remote grid
you must raise it to a working position
before loading material onto it.To Raise: Main Hydraulic Control Panel

(i) Raise the Grid (Item F) by pressing the

button (Item D) on the remote receiver.
The grid will now remain in the raised
position. Switch Engine off and Lock- D
out.

(ii) Raise the three Support legs (Items G) E

and secure in the working position with
the securing pins(Item H)

(iii) Start the machine and lower the Grid Radio Control Receiver
(Item F) by pressing the button (Item
E). The grid will now rest upon the sup- F
port legs

WARNING
G

USE A SUITABLE LIFTING H

PLATFORM WHEN
WORKING ABOVE
2 METRES (6’- 6”)
FALL HAZARDS EXIST
Remote Grid Raised

IN - 17
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3.13 LOWERING CUTTER UNIT INTO

WORKING POSITION
(OPTIONAL)

If your machine is fitted with a Cutter unit

you must lower it into its working position
before processing material through it or if
the material does not need to be proc- B
essed by the Cutter, then it can be lifted
‘out off line’ to the raised position.

NOTE: Cutter Unit in Raised Position

When the Cutter unit is raised it will not
operate due to the safety valve fitted to it. C
To Raise the Cutter unit:

(i) Remove the safety pin from its stor

age position.

(ii) Operate the control lever (Item C) at

the Cutter unit control panel.

(iii) Fit safety pin at (Item B) to secure Cutter Unit Control Panel

WARNING
the cutter in the ‘out off line’ position.

To Lower the Cutter unit: HAZARDOUS NIP

AND CRUSH
(i) Remove the safety pin from its hold POINTS IN THIS
ing position (Item B) and return to its AREA
storage position.

(ii) Operate the control lever (Item C) at

the Cutter unit control panel.

IN - 18
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Contents
4.1 SAFETY INTRODUCTION .............................................................................. OP - 2

4.2 SAFETY BEFORE AND DURING OPERATION ......................................... OP - 6

4.3 OPERATING MACHINE .................................................................................. OP - 7

4.4 SCREENING...................................................................................................... OP - 8

4.5 BELTFEEDER SPEED CONTROL ............................................................... OP - 9

4.6 CONVEYORS SPEED CONTROLS (OPTIONAL) ...................................... OP - 9

4.7 RADIO CONTROL REJECT TIPPING GRID (OPTIONAL) ...................... OP - 10

4.8 CHANGING FREQUENCY IN RADIO CONTROL RECEIVER .............. OP - 11

OP - 1
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SECTION 4 : OPERATION
4.1 SAFETY INTRODUCTION

DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.

2. In-running nip points can cause

serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

1.Beware of escaping Hydraulic oil.

DANGER
High pressure hydraulic oil can
penetrate the skin causing serious
injuries.

2.Always relieve pressure from the

hydraulic system before attempting
maintenance or adjustment.
3. If oil is injected under the skin, it
must be surgically removed or
gangrene will result. Get medical
help immediately.

DANGER
1.Electrical Hazard. Risk of serious
injury or death.
2. Never work on the electrical sys-
tem of any equipment unless you
are thoroughly familiar with system
details.

3. Work on the electrical system

must only be carried out by a quali-
fied electrician.

OP - 2
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DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.
2. In-running nip points can cause
serious injury or even death. Your
arm could be pulled in and ampu-
tated.
3. Switch off and lockout machine
before opening or removing guard
doors.

WARNING 1. Read and understand the opera-

tors manual before you work at
this machine.
2. Study the different safety signs
on this machine.
3. Only qualified and trained per-
sonnel should attempt to work at
this machine.

WARNING
1. Loose or baggy clothing can get
caught in running machinery.

2. Always wear correctly fitting (EN/

ANSI approved) protective cloth-
ing.

3. Protective clothing includes Hard

Hat, Safety Glasses, Ear Defend-
ers, Overalls, Steel Toed Boots
and a High Visibilty Vest.

OP - 3
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WARNING 1. Falling Rock Hazard. Do not walk

near material discharge areas.You
are at risk of serious injury or
death.
2. Wear a hard hat at all times when
working in the vicinity of the ma-
chine.

WARNING 1. Crush Hazard. Beware of danger-

ous 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/of mechanical

supports provided.

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.

OP - 4
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WARNING 1. Fall Hazard. Do not climb onto mov-

ing or working machinery.

2. Switch off and lockout machine be-

fore attempting maintenance or ad-
justment to this machine.

3. Always use a suitable lifting platform

before attempting any maintenance
work above 2 metres(6-6”).

CAUTION 1. Burn or Heat Hazard. Beware of

hot surfaces at engine and exhaust
areas.

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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 remote 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 remote stop buttons or remote 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 prob-
lems in your machine.

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4.3 OPERATING MACHINE

Before loading material onto the Grid, the

entire machine must be running.
WARNING
BEFORE OPERATION
The sequence to start the machine is 4.3.1
YOU MUST READ AND
to 4.3.6 UNDERSTAND
Before starting the engine ensure that all THE SAFETY SECTION IN
Conveyor belts are sufficiently SECTION 1 OF THIS
tensioned(see section 5.13). MANUAL

4.3.1 Start the Engine and gradually in-

crease speed to maximum (2200
RPM)

4.3.2 Start the Fines Transfer, Fines Dis-

A
charge, Middle Grade and Over-
size Conveyors by operating the B
control lever (Item.C). If the belts are
not travelling straight or equally on
the idler and drive drums, the belts C
will need “Tracking”(see section D
5.11- 5.12).
E Main Control Panel
4.3.3 Start the Trommel Screen by oper-
ating the control lever (Item.B).
DANGER
4.3.4 Start the Feed Conveyor by oper- DO NOT REACH INTO
ating the control lever (Item.D). A MOVING MACHINE
DANGEROUS
4.3.5 Start the Beltfeeder, by operating NIP POINTS EXIST
the control lever (Item A). The belt
may require tracking . DO NOT CLIMB ONTO
OR ACROSS MOVING
4.3.6 Start the Vibrating Grid(If fitted) by BELTS
operating the control lever (Item.E). FALL HAZARDS EXIST

4.3.7 Following the above sequence en-

sures no material will accumulate
at transfer points and effect the run-
ning of the machine. Also when
stopping, except for in an remote,
the above sequence should be re-
versed to ensure all belts are clear
of material.

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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 bet-
ter reach into the Hopper.
If you do build a ramp avoid contact with the
side of the machine.

IMPORTANT Loading Shovel Feeding Hopper

AVOID ANY CONTACT WITH THE

SHOVEL OR RAMP AGAINST THE SIDE
OF THE MACHINE

Initial feed rate should be low gradually in-

creasing up to normal rate over first hours
of operation.

During this period the belt pressure on each

conveyor should be checked to ensure they
are running at the correct pressure (Max Checking Hydraulic Pressures
pressure is 172 Bar-2500psi).

After initial period stop the machine and

visually check belts, scrapers, skirting rub-
bers, rollers and nip guards for abnormal
wear and obstructions.

Conveyor belts may behave different with

material on them, retracking may be
necessary(see section 5.11-5.12).

Check the quality of the screened material.

DANGER
SWITCH OFF AND
LOCKOUT BEFORE
WORKING AT A MACHINE
DANGEROUS
NIP POINTS EXIST

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4.5 BELTFEEDER SPEED CONTROL

To INCREASE the Beltfeeder speed move A

the flow control knob (Item A) CLOCKWISE.

To DECREASE the beltfeeder speed move

the flow control knob (Item A) ANTI-
CLOCKWISE.

When you have acheived your desired

speed the Adjustment knob can be locked
in position with the screw fitted on the ad- Beltfeeder Control Valve
justment knob.
This will prevent any accidental movement.
DANGER
HIGH PRESSURE
4.6 CONVEYORS SPEED HYDRAULIC FLUID
CONTROLS (OPTIONAL) CAN PENETRATE THE
SKIN CAUSING SERI-
All the conveyors have their speeds set at OUS INJURIES
the factory, but these can be changed if the
product is building up on one particular con-
veyor due to the split of material through the
Trommel.

By moving the flow control knob (Item B)

ANTI-CLOCKWISE you will increase the
speed of the Oversize and Middle Grade
conveyors and reduce the speed of the
Fines and Fines transfer conveyors.

By moving the flow control knob (Item B) B

CLOCKWISE you will increase the speed
of the Fines and Fines transfer conveyors
Conveyors Speed Control Valve
and reduce the speed of the Oversize and
Middle Grade conveyors.

When you have acheived your desired

speed the Adjustment knob can be locked
in position with the Screw (Item C) fitted at
the side of the adjustment knob.
This will prevent any accidental movement.

NOTE:
When the speed of one Conveyor is in-
creased it will decrease the speed of
the other Conveyor and vice versa.

OP - 9
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4.7 RADIO CONTROL REJECT

TIPPING GRID (OPTIONAL)
A
If your machine is fitted with a Radio con-
trol tipping grid(Item A). It can be operated
by 2 methods either Manually or by Radio
Control.

4.7.1 Manual Control

It is operated Manually at the Receiver

unit(Item B). Radio Control Reject Tipping Grid

Press button(Item C) to RAISE the grid. B

Press button(Item D) to LOWER the grid.
C
4.7.2 Radio Control
D
It is operated by Radio Control using the
handset(Item E).

Press and hold down the button(Item F)

for approximately 2 seconds to RAISE the Radio Control Receiver
grid on its cycle.

To STOP the grid in its cycle press the E

button(Item G).

To LOWER the grid press the button (Item

F
F). The grid will then finish its cycle.

WARNING
Radio Control Handset

HAZARDOUS NIP
AND CRUSH POINTS
BETWEEN THE GRID
AND HOPPER

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4.8 CHANGING FREQUENCY IN

RADIO CONTROL RECEIVER

To Program a hand held transmitter to a

receiver proceed as follows. A
(i) Open the Receiver unit(Item A)with a
Starhead screwdriver.

(ii) Identify the Programming switch(Item

D) and the LED (Item C).
Radio Control Receiver
(iii) Press the Programming switch. The
Programming LED will turn on.

(iv) Press one of the buttons on the hand

held transmitter (Item B) and release, B
the programming LED will go out.

(v) Press one of the buttons on the trans-

mitter again and release, the program-
ming LED will go out.

(vi) Press one of the buttons on the trans- Radio Control Handset
mitter again and release, the program-
ming LED will flash for approximately
10 seconds.
C
(vii) Wait for programming LED to stop
flashing.
D
(viii) The Handset is how programmed to
the receiver

To Erase all transmitters from the receiver

Radio Control Receiver Open
(i) Press and hold the programming
switch (Item D).

(ii) The programming LED will remain on

for approximately 10 seconds and then
go out.

(iii) All transmitters are now erased from

the receiver memory.

OP - 11
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Contents
5.1 SAFETY INTRODUCTION ..................................................................... MA - 2
5.2 SAFETY BEFORE AND DURING MAINTENANCE .............................. MA - 6
5.3 HYDRAULIC SAFETY ............................................................................ MA - 8
5.4 ELECTRICAL AND ENGINE SAFETY ................................................... MA - 9
5.5 HYDRAULIC SYSTEM ......................................................................... MA - 10
5.6 HYDRAULIC FLUIDS ........................................................................... MA - 10
5.7 FILTRATION ...........................................................................................MA - 11
5.8 OIL TANK, PIPES AND FITTINGS .........................................................MA - 11
5.9 DIESEL ENGINE .................................................................................. MA - 12
5.10 TROMMEL SCREEN ........................................................................... MA - 12
5.11 BELT TRACKING.................................................................................. MA - 13
5.12 BELT TRACKING ON YOUR MACHINE .............................................. MA - 14
5.13 BELT TENSIONING ON YOUR MACHINE .......................................... MA - 15
5.14 CHANGING SCREEN MESHES .......................................................... MA - 16
5.15 CHANGING INNER BARREL APERATURE ........................................ MA - 17
5.16 ADJUSTING NYLON BRUSHES ......................................................... MA - 18
5.17 CHANGING NYLON BRUSHES .......................................................... MA - 18
5.18 TENSIONING BARREL CHAIN ............................................................ MA - 19
5.19 TENSIONING BELTFEEDER CHAIN ................................................... MA - 20
5.20 CHANGING FUEL FILTER ................................................................... MA - 21
5.21 WATERTRAP ....................................................................................... MA - 21
5.22 CHANGING HYDRAULIC FILTERS & OIL ........................................... MA - 22
5.23 CHANGING ENGINE FILTERS & OIL .................................................. MA - 25
5.24 CHANGING FEED CONVEYOR GEARBOX OIL ................................. MA - 28
5.25 HYDRAULIC RAM MAINTENANCE .................................................... MA - 29
5.26 CHECKING GUIDE WHEEL ALIGNMENT ........................................... MA - 30
5.27 RECOMMENDED LUBRICANTS ........................................................ MA - 31
5.28 REMOTE GREASING SCHEDULE ...................................................... MA - 32
5.29 MAINTENANCE SCHEDULES ............................................................ MA - 35

MA - 1
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SECTION 5 : MAINTENANCE
5.1 SAFETY INTRODUCTION

DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.

2. In-running nip points can cause

serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

1.Beware of escaping Hydraulic oil.

DANGER
High pressure hydraulic oil can
penetrate the skin causing serious
injuries.

2.Always relieve pressure from the

hydraulic system before attempting
maintenance or adjustment.

3. If oil is injected under the skin, it

must be surgically removed or
gangrene will result. Get medical
help immediately.

DANGER
1.Electrical Hazard. Risk of serious
injury or death.
2. Never work on the electrical sys-
tem of any equipment unless you
are thoroughly familiar with system
details.

3. Work on the electrical system

must only be carried out by a quali-
fied electrician.

MA - 2
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DANGER
1. Nip Hazard. Do not reach into an
unguarded machine.

2. In-running nip points can cause

serious injury or even death. Your
arm could be pulled in and ampu-
tated.

3. Switch off and lockout machine

before opening or removing guard
doors.

WARNING 1. Read and understand the opera-

tors manual before you work at
this machine.

2. Study the different safety signs

on this machine.

3. Only qualified and trained per-

sonnel should attempt to work at
this machine.

WARNING
1. Loose or baggy clothing can get
caught in running machinery.

2. Always wear correctly fitting (EN/

ANSI approved) protective cloth-
ing.

3. Protective clothing includes Hard

Hat, Safety Glasses, Ear Defend-
ers, Overalls, Steel Toed Boots
and a High Visibilty Vest.

MA - 3
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WARNING 1. Falling Rock Hazard. Do not walk

near material discharge areas.You
are at risk of serious injury or
death.

2. Wear a hard hat at all times when

working in the vicinity of the ma-
chine.

WARNING 1. Crush Hazard. Beware of danger-

ous 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/of mechanical

supports provided.

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.

MA - 4
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WARNING 1. Fall Hazard. Do not climb onto mov-

ing or working machinery.

2. Switch off and lockout machine be-

fore attempting maintenance or ad-
justment to this machine.

3. Always use a suitable lifting platform

before attempting any maintenance
work above 2 metres(6-6”).

CAUTION 1. Burn or Heat Hazard. Beware of

hot surfaces at engine and exhaust
areas.

MA - 5
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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 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 pres-
sure 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 6’-6” (2m) always use an approved (EN/ANSI) safety harness.
Always use walkways and platforms provided or a safe secure platform approved by the
machine operators management. Do not use any unauthorised or unsafe platforms.

10. Never operate any type of engine without proper ventilation – EXHAUST FUMES CAN
KILL. (See Electrical and Engine Safety for more detailed checklist).

11. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can penetrate the
skin or damage eyes. Fluid leaks under pressure may not be visible. Use a piece of
cardboard to find leaks but do not use bare hand.

12. Wear safety goggles for eye protection. If fluid enters skin or eye, get immediate medical
attention. (See Hydraulic Safety for more detailed checklist).

13. Clean or replace damaged, missing or painted over safety signs that cannot be read.

14. Rotating and moving parts must be inspected during maintenance and replaced if
cracked or damaged. Excessively worn or damaged parts can fail and cause injury or
death.

MA - 6
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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.

WARNING
PRACTICE SAFE
MAINTENANCE READ
AND UNDERSTAND
THE OPERATORS
MANUAL BEFORE
DOING ANY WORK

MA - 7
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5.3 HYDRAULIC SAFETY

1. Never disable or alter any hydraulic circuit or component without consulting with Finlay
Hydrascreens 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

MA - 8
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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. 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 correctly
connected.

6. Disconnect the battery ground leads whenever performing any electrical maintenance or
servicing to your engine.

7. Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.

8. Never short across the starter terminals of a battery as this can cause a fire and could
also damage the electrical system.

9. Battery electrolyte contains acid and can cause serious injury. Avoid contact with skin
and eyes. Use gloves and protective glasses.
10. Diesel engine exhaust emissions contain products of combustion which may be harmful
to your health. Always operate the machine in a well ventilated area and if operating in an
enclosed area, vent the emissions outside.

11. Do not touch any part of the engine or exhaust system. Allow the engine and exhaust to
cool before performing any repair or maintenance.

12. Never fill the fuel tank with the engine running, while smoking or when near an open
flame.

13. Never overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.

DANGER
ALL ELECTRICAL
WORK MUST BE
CARRIED OUT BY A
QUALIFIED
ELECTRICIAN

MA - 9
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5.5 HYDRAULIC SYSTEM

The Hydraulic system which is used in your Some adverse effects of incorrect viscosity
machine was chosen for its effectiveness are:
and resistance to climatic and operating > Increased power consumption
conditions. > High oil temperatures
This must be kept topped up with the cor- > Entrapment of air in oil,
rect hydraulic fluid and regular checks must > Increase pressure drop.
be made to ensure this. > Excessive wear or even seizure
Regular monitoring of the gauges on the under heavy loads,
Filters is essential. The filter element re- > Poor pump performance.
quires changing when the indicator is in the
red at operating temperature. In addition to the qualities outlined earlier
The system should be checked for leaks and the selected fluid should also:
the hydraulic oil analysed after 1500 hours
and every 500 hours afterwards and re- > Prevent rot
placed if necessary. > Depress foaming
> Prevent formation of sludge, gum and
varnish
5.6 HYDRAULIC FLUIDS > Retain its own stability, thereby reduc
ing fluid replacement.
Hydraulic fluids play an important part in any > Prevent corrosion and pitting.
hydraulic system. They have two main func-
tions. For best operating results it is strongly rec-
ommended that the hydraulic fluid used is
> To transmit power.
selected from the recommended range
> To lubricate moving parts listed in
5.23 “Recommended Lubricants”.
As a power transmitting medium the fluid
In the service it is recommended that the
must flow easily and be as incompressible
hydraulic system is analysed every 500
as possible.
hours and the oil changed if necessary. The
In most hydraulic components, the fluid pro-
hydraulic fluid should be changed after the
vides internal lubrication only. For long com-
machine has stopped work. The drain plug
ponent life, fluids are available containing
for the hydraulic system is mounted under-
additives that have high anti-wear proper-
neath the tank. In the event of pump or mo-
ties. The fluids are known as anti-wear type
tor failure, both suction line and return line
hydraulic oils, which are recommended for
filters must be changed.
your machine
In most cases the fluid is the only oil seal

WARNING
present. For example, there are no sealing
rings between the spool and the body of the
directional valve. As the sealing character-
istics of the fluid depend on its retaining vis- BEFORE MAINTENANCE
YOU MUST READ AND
cosity, it is important that the oil selected is
UNDERSTAND
capable of maintaining the minimum viscos- THE SAFETY SECTIONS
ity change over a wide range of operating IN THIS MANUAL
temperatures.

MA - 10
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5.7 FILTRATION

In order to maintain the hydraulic oil at its

peak performance, three different types of
filter namely:-
(i) Air breather(Item A) A
(ii) Suction line filters(Item B)
(iii) Return line filters(Item C)
are fitted to the hydraulic system

Air breather:- This combined unit, which

also acts as a filter cap, filters oil and the Air Breather
displacement of air into the reservoir. The
filter is rated at 40 microns, and is of non-
replacement type. This must not be left of
the machine at any time.

Suction Line Filter:- 5 x 125 microns filter,

which are matched to pump capacity, are fit-
ted inside the hydraulic tank where they are B
readily accessible. New filter element should
be fitted at regular intervals (see routine
maintenance schedule for frequency).
Return Line Filter:- The 2 x 25 micron fil-
Suction Line Filters
ters, which are fitted on the tank, remove any
tiny particles which can cause damage to
the pumps and motors etc. The filter ele-
ments should be checked regularly and
changed in accordance with the routine C
maintenance schedule.

5.8 OIL TANK, PIPES AND FITTINGS

In order to prevent contamination, the Oil

Tank on your machine is of sealed construc-
tion. Access to the tank, if required is via in-
spection covers which are mounted on the Return Line Filters
top of the tank, underneath the filler cap. 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 DANGER
hoses are checked regularly for leaks, scuff- HIGH PRESSURE
ing and wear. Loose fittings should be se- HYDRAULIC FLUID
curely tightened. Worn or leaking hoses CAN PENETRATE THE
should be replaced. Replacement hoses are SKIN CAUSING
available on request. SERIOUS INJURIES

MA - 11
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5.9 DIESEL ENGINE

The diesel engine is the heart of your ma-

chine and a great deal of care and thought
has gone into its selection. The engine has
a max. fuel capacity of 20 Litres per hour.
In the interest of continued peak perform-
ance from your machine the engine must be
maintained and cared for with meticulous at-
tention in accordance with the manufactur-
ers instructions as detailed in “Operators
Handbook”, a copy of which is included
with this manual. Air Cooled Engine-BF4L 913 Turbo

5.10 TROMMEL SCREEN

Maintenance of your Trommel screen is

minimal. However, we recommend the fol-
lowing guide to increase its effectiveness
and prolong its life span.
After the initial 10 hours of operation

(i) Visually check all the screen meshes

for clogging
(ii) Check and tension the clamping bolts Trommel Screen Meshes
where necessary
(iii) Check for wear and replace where
necessary

CAUTION
MESH SECTIONS ARE VERY HEAVY A
IT WILL REQUIRE TWO PERSONS
TO FIT EACH SECTION
INTO POSITION

It is important for the efficient running of the Trommel Side Doors

machine that the Trommel screen is kept

WARNING
clean.
To prevent a build up of Fines on the Trom-
mel doors a rubber curtain has been fitted
which can be accessed and disturbed re- SWITCH OFF AND
moving any built up material. LOCKOUT BEFORE
Use a long stick or bar and insert into the WORKING AT A MACHINE
holes (Item.A) to disturb the rubber curtain. DANGEROUS
Ensure machine is switched off before at- NIP POINTS EXIST
tempting this operation.
MA - 12
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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 Travel

Insufficient aligning of a. Align all drums, carrying

drums and Idlers idlers and return idlers at right
angles to the travelling direc-
tion 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 in-
dicated on Figs.1,2&3 by
turning drums and carrying Fig.2 Turn drums.
idlers in direction of arrow un-
til 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 Fig.3. Turning both drum and
adjustment can be made. 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 Clean idlers and drums.
drums and idlers. Check belt cleaners and re-
place if necessary. Possibly
change to more efficient type.

MA - 13
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5.12 BELT TRACKING ON YOUR

MACHINE

Belt tracking is performed at the idler drum

of each conveyor. Both sides of the idler
drum are adjustable.

(i) Firstly determine which side requires

adjusting.

(ii) To adjust the belt rotate the nut (ItemA) A

on the idler drum adjuster. Use the 7/ Beltfeeder Idler Drum Adjuster
8”spanner supplied in the toolbox.

A small movement in the adjuster i.e. less

than 10mm should be sufficient. A greater
movement will effect the tension of the belt.

IMPORTANT
BELT TRACKING AND TENSIONING ARE THE
ONLY MAINTENANCE TASKS PERMITTED A
WHEN THE MACHINE IS RUNNING
Feed Conveyor Idler Drum Adjuster

DANGER
DO NOT REACH INTO A
A MOVING MACHINE
DANGEROUS
NIP POINTS EXIST
DO NOT CLIMB ONTO
OR ACROSS MOVING
BELTS
FALL HAZARDS EXIST
Transfer Conveyor Idler Drum Adjuster

Middle Grade Idler Drum Adjuster

MA - 14
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5.13 BELT TENSIONING ON YOUR

MACHINE

Belt tensioning is performed at the idler drum A

of each conveyor. Both sides of the idler
drum are adjustable.

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.
Fines Conveyor Idler Drum Adjuster
The belt should be sufficiently tight to pre-
vent slippage at the drive drum.
If over tight the life of the belt will decrease.

IMPORTANT A
BELT TRACKING AND TENSIONING ARE THE
ONLY MAINTENANCE TASKS PERMITTED
WHEN THE MACHINE IS RUNNING

DANGER Oversize Conveyor Idler Drum Adjuster

DO NOT REACH INTO
A MOVING MACHINE
DANGEROUS
NIP POINTS EXIST
DO NOT CLIMB ONTO
OR ACROSS MOVING
BELTS
FALL HAZARDS EXIST

MA - 15
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5.14 CHANGING SCREEN MESHES

(i) Open up the Trommel side doors and

secure with the door prop(Item A)either
side.

(ii) With two off 24mm spanners loosen

bolts (Item B) holding the mesh to the A
barrel and the bolts (Item C) holding
the meshes together.

(iii) Now remove each mesh section Side Door Prop

(iv) Next clean the barrel around the

clamping area and bolt on the new B
meshes.

(v) Tighten the meshes evenly.

C

IMPORTANT
DO NOT OVERTIGHTEN MESHES
THIS WILL CAUSE DIPS IN THE MESH Standard Mesh Securing Bolts
WHICH WILL EFFECT THE PERFORMANCE
OF THE MESH AND BRUSHES.

WARNING
SWITCH OFF AND
LOCKOUT BEFORE
WORKING AT A MACHINE
DANGEROUS
NIP POINTS EXIST

CAUTION
MESH SECTIONS ARE VERY HEAVY
IT WILL REQUIRE TWO PERSONS
TO FIT EACH SECTION
INTO POSITION

MA - 16
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5.15 CHANGING INNER BARREL

A
APERATURE

To vary the size of the Middle Grade Product

on your machine the aperture of the inner bar-
rel can be adjusted to three different sizes by
adding or removing straps.

The 3 sizes are:

B
(i) 100mm x 225mm. The inner drum has
no straps (Item B) fitted between the Trommel Inner Drum Straps
inner drum sections (Item A).

(ii) 100mm x 100mm. The inner drum has

1 stap (Item B) fitted between the in-
ner drum sections (Item A). C

(iii) 100mm x 60mm. The Inner Drum has

2 straps (Item B) fitted between the
inner drum section (Item A)

To Remove or Fit straps:

Side Door Prop
Open up the Trommel side doors and
secure with the door prop (Item C) on
either side. D
The inner barrel straps can only be
changed when the outer barrel meshes
have been removed. See section 5.14
E
Each strap consists of 2 halves(Item E)
held together by 2 cap head screws
(Item D).
Strap Securing Cap Head Screws
(i) Remove the Cap head screws (Item
D) using a 17mm spanner and a 8mm

WARNING
hex key.

(ii) Remove,add or relocate straps to ob-

tain the desired aperature.(See above) SWITCH OFF AND
LOCKOUT BEFORE
(iii) Repace cap head screws(Item D) and WORKING AT A MACHINE
tighten. DANGEROUS
NIP POINTS EXIST

MA - 17
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5.16 ADJUSTING NYLON BRUSHES

Brushes are preset leaving the factory.

If they are not cleaning the meshes ad-
equately readjustment will be required.

To Adjust the brushes: A

(i) Rotate the bolt (Item A)on each side

of each brush.Use a 24mm spanner.
B
This will tension the spring so the brushes
will penetrate through the mesh as shown in
the diagram.
It is recommended that the bristles of the
brush do not penetrate the mesh more than
approximately 3-5mm(1/5”).
Otherwise it will adversely effect the clean-
ing efficiency and cause greater wear in your
nylon brushes.
(A)

IMPORTANT Maximum penetration at point (A) 3-5mm

DO NOT ALLOW THE BRUSHES TO
PENETRATE THE MESH MORE THAN
3-5MM

5.17 CHANGING NYLON BRUSHES

To Change the brushes:

(i) Remove the U bolts(Item B).

Use 2 off 17mm spanners.

(ii) Remove the brushes and replace with

new brushes.

(iii) Reset the brush adjuster (Item A) to

suit new brushes(See 5.16).

WARNING
DO NOT CLIMB ONTO
MOVING MACHINERY
SWITCH OFF AND LOCKOUT
HEIGHT RISK EXISTS
ENSURE SAFE ACCESS

MA - 18
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5.18 TENSIONING BARREL CHAIN

To Tension the chain on the barrel: A

(i) Shut off the machine.

(ii) Open The Chain Cover Guard (ItemA)

on the left hand side of the machine to
view the tension of the chain.(Use a T-
Key)

(iii) Rotate the nut (Item B)Clockwise to Chain Tensioner Guard

tension the chain. Use a 30mm span-
ner.

(iv) Close the Chain Cover Guard (Item A)

DANGER
B

SWITCH OFF AND

LOCKOUT BEFORE
WORKING AT A
MACHINE Barrel Chain Tensioner

DANGEROUS
NIP POINTS EXIST
CLOSE GUARDS
AFTER MAINTENANCE

MA - 19
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5.19 TENSIONING BELTFEEDER

CHAIN

To Tension the Chain on the beltfeeder:

(i) Shut off the machine.

(ii) Open the Beltfeeder Guard Door A

(Item A) on the left hand side of the
machine.Inside you will see the
Sprocket guard (Item B).Remove the
sprocket guard to view the tension Beltfeeder Guard Door
of the chain.
To open Chain & Sprocket guards
remove bolts. Use a 19mm spanner.

(iii) To tension the chain firstly loosen the

bolt holding the tensioner sprocket
(Item C). Use 2 off 30 mm spanners.
B
You will have to open the beltfeeder
guard door to gain access to the rear
of the tensioner bolt.
Beltfeeder Chain & Sprocket Guard
(iv) With leverage slide the tensioner
sprocket (Item C) towards the large
sprocket (Item D). When the chain is C
sufficently tensioned retighten the bolt
on the tensioner sprocket.
D

IMPORTANT
DO NOT OVERTIGHTEN AS THIS
WILL CAUSE EXCESSIVE WEAR ON
THE CHAIN AND SPROCKET. Beltfeeder Idler Sprocket

DANGER
(v) Replace the Sprocket Guard (Item SWITCH OFF AND
B) and the Beltfeeder Guard Door LOCKOUT BEFORE
(Item A). Use a 19mm spanner. WORKING AT A
MACHINE
DANGEROUS
NIP POINTS EXIST
CLOSE GUARDS
AFTER MAINTENANCE

MA - 20
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5.20 CHANGING FUEL FILTER

(i) Unscrew the fuel filter (Item A) and

carefully dispose off.
A
(ii) Fill the new filter with diesel and fit into
position.

(iii) Hand tighten the new filter.

Engine Fuel Filter

5.21 WATERTRAP

5.21.1 Draining the Watertrap

(i) Open the watertrap access door (Item

B)
B
Loosen the draintap(Item E) on the
base of the watertrap.

(ii) Allow the water to drain off. Tighten the

draintap when all the excess water has Watertrap Access Door
been drained off.

5.21.2 Cleaning Watertrap Filter

C
(i) Remove the Bowl(Item D) by rotating
Anti-clockwise
D
(ii) Remove the filter inside and clean it
out with diesel to remove dirt particles E
etc.
Watertrap
(iii) Fill the filter and Bowl(Item D) with die-

CAUTION
sel and reattach tightening clockwise.

(v) It may be necessary to bleed air from

AVOID NAKED FLAMES WHEN
system. To bleed the watertrap loosen
WORKING ON THE FUEL SYSTEM.
the nut (Item C) until all air has been
DO NOT SMOKE
removed.

MA - 21
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5.22 CHANGING HYDRAULIC

FILTERS & OIL

It is strongly recommended to change both A

Suction filter and Return filter elements when
the Hydraulic oil is being changed.

5.22.1 Changing Return Filters

(i) Run the engine at full speed and en-

sure all the hydraulic equipment is Hydraulic Tank Protection Cover
operating.

(ii) Rotate open the hydraulic tank access B

covers(Item A) on the roof of the en-
gine compartment at the left and right
hand sides.

(iii) Turn engine off and return all control C

levers to the neutral position.

(iv) Open the Filler cap to release pres-

sure inside the tank.
Return Line Filters

DANGER
(v) Clean the area around the Return fil-
ters to prevent dirt contaminating the
hydraulic oil when the filters are re-
moved. SWITCH OFF AND
LOCKOUT.
(vi) Loosen the bolts(Item B) on each fil- RELIEVE ALL HYDRAULIC
ter (Use a 13mm spanner). PRESSURE BEFORE
WORKING AT A MACHINE
(vii) Rotate the Top plate(Item.C) slightly to
HIGH PRESSURE
remove.
HYDRAULIC FLUID
CAN PENETRATE THE
(viii) Remove the Filter element by pulling SKIN CAUSING
the removal handles. Dispose of the SERIOUS INJURIES
old filters safely.

(ix) Insert new filter elements and replace

Top Plate (Item.C).

(x) Tighten the filter retaining bolts.

MA - 22
 ENG
SECTION 5: MAINTENANCE 011203/02

5.22.2 Changing Suction Filters

(i) Turn engine off and return all control

levers to the neutral position.
A
(ii) Open the Filler cap (Item A) to relieve
any pressure inside the tank.
B

(iii) Remove the bolts (Item B)(Use a C

17mm spanner) holding thei n s p e c -
tion plate(Item C) down.
Hydraulic Tank Inspection Plate &
(iv) The Suction filters are fitted to the in- Filler Cap
side of the inspection cover. To Re- D
move 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.

(vi) Replace inspection covers and filler E

cap.

Internal Suction Filters

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 - 23
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5.22.3 Changing Hydraulic Oil

It is recommended that the machines hy-

draulic 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 hy-
draulic oil back to the tank as possi-
ble.

(ii) Turn engine off and return all control

levers to the neutral position. Hydraulic Tank Inspection Plate

(iii) Remove the drain plug(Use a 27mm

spanner) at the base of the tank and
drain to an external container large
enough to hold all the oil. B
(Hydraulic Tank Capacity:=720 litres
159 gallons).

(iv) Remove the inspection plate(Item A)

on the hydraulic tank and flush the tank
out with hydraulic oil to remove dirt or
other particles.Use a 17mm spanner. Hydraulic Oil Level Guage

(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.
(vi) Run the machine and operate hydrau- RELIEVE ALL HYDRAULIC
lic equipment to circulate oil. PRESSURE BEFORE
WORKING AT A MACHINE
(vii) Stop the machine and top up the hy-
draulic system. HIGH PRESSURE
HYDRAULIC FLUID

DANGER
CAN PENETRATE THE
SKIN CAUSING
SERIOUS INJURIES
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 - 24
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5.23 CHANGING ENGINE FILTERS &

OIL
(See the engine Operators Manual for
more detailed information regarding the
Engine)
5.23.1 Checking Engine Oil

(i) Turn off the engine. Open the Engine

Inspection Doors (Item A).
A
(ii) Remove dipstick(Item C) from the
engine and clean.
Re-insert the dipstick fully. Engine Filters Inspection Door
(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 minimum mark oil has to
be added through the fillercap(Item B).

(iv) It is important the oil level is not above B

the maximum level. If this happens
some oil must be removed.

5.23.2 Changing Engine Oil

Engine Oil Filler Cap
(i) Operate the engine to ensure the oil is
warm, this enables the oil to flow more
easily.
(ii) Stop the engine and open the fillercap.

(iii) Remove the drain plug located under-

neath the engine and drain the oil to C
an external container large enough to
hold all the oil.(Approx Oil capacity: D
8.5litres-1.85gallons).

(iv) When all the oil has drained off replace Engine Oil Filter & Dipstick

CAUTION
the drain plug and refill. Dip the engine.
See 5.19.1

5.23.3 Changing Engine Oil Filter HOT SURFACES

It is recommended to change the Oil filter BEWARE OF BURNS

when changing the oil. FROM HOT OIL
(i) Loosen the Filter(Item D) and dis-
pose off properly.
(ii) Replace with new filter and hand
tighten on.

MA - 25
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5.23.4 Changing Air Filter Element

(For more details of Engine Air Filter Main-

A
tenance view the Engine Operators
Manual)

The Air filter will require changing if the light

(Item A) illuminates on the starter 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 B

unclipping the holding clamps(Item B).

(iii) Carefully remove the Filter element.

Clean inside the filter and insert a new C
filter element.

(iv) Re-attach the filter cover and reclip the

holding clamps(Item B).
Air Filter Housing

MA - 26
 ENG
SECTION 5: MAINTENANCE 011203/02

5.23.5 Checking Engine Coolant Level

(For more details of Engine Coolant Level

view the Engine Operators Manual)

(i) Turn off the engine A

(ii) Open the Engine Inspection doors

(Item A).

(iii) View the Coolant Level Guage(ItemB), Engine Inspection Doors

if the level is below the minimum level
mark top up with coolant through the
filler cap(Item C) situated above the
radiator.
B
5.23.6 Topping up coolant level

Refer to Engine Manual for Fill and

Bleed procedures.

Engine Coolant Level Guage

Engine Coolant Filler Cap

MA - 27
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SECTION 5: MAINTENANCE 011203/02

5.24 CHANGING FEED CONVEYOR

GEARBOX OIL
(see Maintenance Schedule for frequency) A
(i) Turn off the engine and lockout.

(ii) Open The Gearbox Access Guard B

(Item A) on the left hand side of the
machine to view the gearbox.
To open guard remove bolt(Item B).
Use a 19mm spanner.
Gearbox Access Guard
(iii) To Drain the Gearbox. Remove the Fill
plug (Item C) this will allow air into the
gearbox to allow it to drain.(Use a
17mm socket or 7mm allen key de-
pending on which plug has been fitted). C
(iv) Remove the Drain plug (Item D) and
drain the oil to an external container
large enough to hold all the oil. (Gear- D
box oil capacity:0.6 litres)
(Use a 5mm allen key depending on
which plug has been fitted). Feed Conveyor Gearbox

(v) Replace the Drain Plug (Item D).

DANGER
(vi) Now refill the Gearbox through the SWITCH OFF AND
Filler plug with the exact amount of oil LOCKOUT BEFORE
required. WORKING AT A
(Gearbox oil capacity:0.6 litres) Use MACHINE
Gearbox oil:
ISO VG 150 or SAE 80W/90 DO NOT DANGEROUS
OVERFILL THE GEARBOX. NIP POINTS EXIST
CLOSE GUARDS
(vii) Replace the Filler plug (Item C). AFTER MAINTENANCE
(viii) Close the Gearbox Access Guard.

WARNING
IMPORTANT USE A SUITABLE LIFTING
PLATFORM WHEN
WORKING ABOVE
THE BELTFEEDER GEARBOX OIL MUST BE 2 METRES (6’- 6”)
CHANGED IN ACCORDANCE WITH THE
FALL HAZARDS EXIST
MAINTENANCE SCHEDULES IN
SECTION 5.21 OTHERWISE YOUR
WARRANTY WILL BE EFFECTED

MA - 28
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5.25 HYDRAULIC RAM

MAINTENANCE
A
As part of the finish process in our chrome
rod manufacturing a natural lubricant is
rolled into the surface. 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
SWITCH OFF AND
B
LOCKOUT. BEFORE
WORKING AT A MACHINE

HIGH PRESSURE
HYDRAULIC FLUID
CAN PENETRATE THE
SKIN CAUSING
SERIOUS INJURIES Greased Chrome Rod

MA - 29
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SECTION 5: MAINTENANCE 011203/02

5.26 CHECKING GUIDE WHEEL

ALIGNMENT

It is important that the running wheels (Item

C) are aligned correctly to prevent prema-
ture guide wheel or running wheel damage
and possible need for replacement.

To check alignment:
A
(i) Observe the guide wheel (Item B) Guide wheel location
which is situated at location (Item A)
while the machine is in operation. Do
not make contact with guide wheel.

DANGER B

DO NOT REACH INTO

A MOVING MACHINE
DANGEROUS
NIP POINTS EXIST. THE
GUIDE WHEEL MOST Guide wheel
ONLY BE OBSERVED

(ii) Under normal conditions the guide

wheel should be briefly touching or
skimming guide rim (Item E). C

(iii) The guide wheel should not be running

constantly against the guide rim (Item
D). If it is, check the machine is level
and all running wheels (Item C) are free
moving and clear from obstruction (us- Running wheel
ing level indicators (See section 3 in-
stallation)). If problem persists then
contact your dealer to realign the run- BELTFEEDER BARREL OVERSIZE
ning wheel. SIDE SIDE

IMPORTANT
GUIDE GUIDE
FAILURE TO DO SO WILL RESULT IN PREMA- RIM RIM

TURE GUIDE WHEEL OR RUNNING WHEEL

DAMAGE AND POSSIBLE NEED FOR RE-
E D
GUIDE WHEEL ASSEMBLY
PLACEMENT.
Guide wheel assembly

MA - 30
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5.27 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.

Hydrauilc Oil Type : ISO 46 or oil Equivalent

Beltfeeder Gearbox Oil: ISO VG 150 or SAE 80W/90

MA - 31
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5.28 REMOTE GREASING SCHEDULE

* The Vibrating Grid bearings require Screen grease see Lubrication chart.

MA - 32
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5.28 REMOTE GREASING

SCHEDULE

MA - 33
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SECTION 5: MAINTENANCE 011203/02

5.28 REMOTE GREASING SCHEDULE

MA - 34
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5.29 MAINTENANCE SCHEDULES DATE

5.29.1 Daily Maintenance
(10Hour) Schedule

General Maintenance
Maintenance Task Notes Signature

Check For Material Bulid up Check/Remove

Check Level indicators to ensure machine is level Check/Level

Check All Safety Guards are in Place Check/Replace

Check For Loose parts, missing nuts & bolts Tighten/Replace

Check Hydraulic hoses, Rams & pumps for leaks

(When tightening fittings use a Torque wrench and Tighten/Replace
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
Maintenance Task Notes Signature

Check Conveyor belts for rips and tears Check/Repare

Check Belt Tension Check/Tension

Check Belt Alignment Check/Align

Check All rollers are free moving and free from

Check/Free
obstruction

Barrel Maintenance
Maintenance Task Notes Signature

Check Barrel Running Wheels for damage or wear Check/Replace

Check Barrel Guide wheels for alignment,damage or

Check/Replace
wear

Check Mesh Securing bolts are tight Check/Tighten

Check Meshes for wear Check Change

Engine Maintenance (See Engine operators manual for more details)

Maintenance Task Notes Signature

Check Engine Oil Level Check/Top up

MA - 35
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5.29.2 Weekly Maintenance DATE

(50Hour) Schedule

General Maintenance
Maintenace Task Notes Signature

After First 50Hrs Change Transfer Gearbox oil Change

Grease all bearing (See greasing Schedule) Grease

Drain the Watertrap Drain

After first 50Hrs replace Return Filters Remove & Replace

Conveyor Maintenance
Maintenance Task Notes Signature

Check Tension of belt scrapers Check/Adjust/Replace

Check Tension of Belt Skirting Rubbers - No spillage Check/Adjust/Replace

Check For Obstruction to drums Check/Remove obstruction

Barrel Maintenance
Maintenance Task Notes Signature

Check Brushes to ensure they are cleaning barrel Check/adjust/Replace

Check Tension of Barrel Chain Check/Tension

Engine Maintenance (See Engine operators m anual for m ore details)

Maintenance Task Notes Signature

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 Torque Torque Torque

Siz e Ft/Lb. Kg/Mtr. N/Mtrs
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" B S P 85 11.75 115.2
1¼" BSP 110 15.20 149.0
1½" BSP 130 17.98 176.2

MA - 36
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SECTION 5: MAINTENANCE 011203/02

5.29.3 Monthly Maintenance DATE

(250Hour) Schedule

General Maintenance
C h eck Maintenace Task Notes Signature

Drain the Watertrap Drain

Engine Maintenance (See Engine operators m anual for m ore details)

C h eck Maintenance Task Notes Signature

Air Filter Elements Check/Replace

MA - 37
 ENG
SECTION 5: MAINTENANCE 011203/02

5.29.4 2 Monthly Maintenance DATE

(500Hour) Schedule

MA - 38
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SECTION 5: MAINTENANCE 011203/02

5.29.5 4 Monthly Maintenance DATE

(1000Hour) Schedule

General Maintenance
C h an g e Maintenace Task Notes Signature

Analysis Oil and change if

Hydraulic Oil
required **

Suction Filters Remove & Replace

** Your local oil supplier will be able to analysis your hydraulic oil. If your hydraulic oil
does not need to be changed after initial 4 months the oil should be analysised again every
2 weeks until an oil change is required.

MA - 39
 ENG
SECTION 5: MAINTENANCE 011203/02

5.29.6 8 Monthly Maintenance

DATE
(2000Hour) Schedule

Engine Maintenance (See Engine operators m anual for m ore details)

Maintenance Task N otes Signature

Alternator and Starter Motor C heck

MA - 40
 ENG
SECTION 5: MAINTENANCE 011203/02

5.29.7 Yearly Maintenance DATE

(2500Hour) Schedule

General Maintenance
Maintenace Task Notes Signature

Change the Transfer Conveyor gearbox oil Drain/refill

MA - 41
 ENG
SECTION 6: TRANSPORT 010502/01

Contents
6.1 SAFETY INTRODUCTION .............................................................................. TR - 2

6.2 SAFETY BEFORE AND DURING TRANSPORT ....................................... TR - 4

6.3 STOPPING THE MACHINE ............................................................................ TR - 5

6.4 PREPARING FOR TRANSPORT .................................................................. TR - 5

6.5 LOWERING VIBRATING GRID TO TRANSPORT POSITION .................. TR - 6

6.6 LOWERING REMOTE GRID TO TRANSPORT POSITION ...................... TR - 6

6.7 FOLDING THE OVERSIZE CONVEYOR ..................................................... TR - 7

6.8 FOLDING THE MIDDLE GRADE CONVEYOR .......................................... TR - 8

6.9 FOLDING THE FINE GRADE CONVEYOR ................................................. TR - 9

6.10 RETURNING DEFLECTOR DOORS TO TRANSPORT POSITION ..... TR - 10

6.11 RAISING SUPPORT LEGS ........................................................................... TR - 11

6.12 RETURNING THE DRAWBAR TO THE TRANSPORT POSITION ...... TR - 12

6.13 RAISING JACKLEGS ..................................................................................... TR - 12

6.14 READY FOR TRANSPORT .......................................................................... TR - 13

6.15 PRIOR TO HAULAGE: ................................................................................... TR - 13

TR - 1
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SECTION 6: TRANSPORT 010502/01

SECTION 6 : TRANSPORT
6.1 SAFETY INTRODUCTION

DANGER 1.Nip Hazard. Do not reach into an

unguarded machine.
2.In-running nip points can cause
serious injury or even death. Your
arm could be pulled in and ampu-
tated.
3.Switch off and lockout machine
before opening or removing guard
doors.

WARNING 1.Read and understand the opera-

tors manual before you work at
this machine.
2.Study the different safety signs
on this machine.
3.Only qualified and trained per-
sonnel should attempt to work at
this machine.

WARNING 1.Fall Hazard. Do not climb onto

moving or working machinery.

2.Switch off and lockout machine

before attempting maintenance or
adjustment to this machine.

3.Always use a suitable lifting plat-

form before attempting any main-
tenance work above 2 metres(6-
6”).

TR - 2
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SECTION 6: TRANSPORT 010502/01

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.

WARNING
1.Loose or baggy clothing can get
caught in running machinery.

2.Always wear correctly fitting (EN/

ANSI approved) protective cloth-
ing.
3.Protective clothing includes Hard
Hat, Safety Glasses, Ear Defend-
ers, Overalls, Steel Toed Boots
and a High Visibility Vest.

WARNING 1.Crush Hazard. Beware of danger-

ous Hand and Foot crush points.
2.Do not use any body parts e.g.
hands or feet to check hole align-
ment or support machinery.

3.Always use pins and/or mechanical

supports provided.

TR - 3
 ENG
SECTION 6: TRANSPORT 010502/01

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

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 con-
tacting 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 - 4
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SECTION 6: TRANSPORT 010502/01

WARNING
6.3 STOPPING THE MACHINE

The sequence to stop the machine is 6.3.1

BEFORE TRANSPORT
to 6.3.6.
YOU MUST READ AND
UNDERSTAND
Before stopping any parts off this machine THE SAFETY SECTION IN
ensure all material has been processed SECTION 1 OF THIS
through the machine. MANUAL

6.3.1 Gradually decrease engine speed A

to minimum using throttle (Item A)
Do not stop the Engine.
B
6.3.2 Stop the Vibrating grid(If fitted) by
operating the control lever (Item F). C

6.3.3 Stop the Beltfeeder, by operating the

control lever (Item B). D

6.3.4 Stop the Feed Conveyor, by oper-

E
ating the control lever (Item E) F Main Control Panel

DANGER
6.3.5 Stop the Trommel Screen by oper-
ating the control lever (Item.C).

6.3.6 Stop all the conveyors by operating DO NOT REACH INTO

the control lever (Item D). A MOVING MACHINE
DANGEROUS
NIP POINTS EXIST
6.4 PREPARING FOR TRANSPORT

Inspect theHopper,Trommel Screen and all WARNING

the Conveyors to ensure that the machine HAZARDOUS NIP
is clear of all material.The machine should AND CRUSH
be washed to remove all debris. POINTS IN THIS
It is advisable to have an operator on the AREA
opposite side of the machine to ensure
areas around machine are clear of person- ENSURE ALL PERSONNEL ARE
nel when folding conveyors, as serious crush CLEAR BEFORE PUTTING
points exist with folding conveyors. MACHINE INTO THE TRANSPORT
POSITION
CRUSH POINTS EXIST

TR - 5
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SECTION 6: TRANSPORT 010502/01

6.5 LOWERING VIBRATING GRID TO

TRANSPORT POSITION A
(OPTIONAL)
B
If your machine is fitted with a Vibrating
grid you must you must lower it to the
transport position prior to transport.
To Lower the grid from its Working posi-
tion (Item A) to the Transport position.

(i) Operate the control lever (Item C) at Vibrating Grid in Working Position
the Main hydraulic control panel to re-
move weight from the pins in the tel-
escopic legs (Item B).
C
(ii) Remove pins in telescopic legs
(ItemB) on either side of grid and store
them in the transport hole at the top of
the telescopic.

(iii) Lower grid by operating the control le-

ver (Item C) at the Main hydraulic con-
trol panel.
Main Control Panel

6.6 LOWERING REMOTE GRID TO

TRANSPORT POSITION
If your machine is fitted with a Remote grid D
you must lower it to transport position to
meet transport regulations. To Lower:
E
(i) Raise the Grid (Item F) by pressing the
button (Item D) on the remote receiver.
The grid will now remain in the raised
position. Switch Engine off and Lock- Radio Control Receiver
out.

(ii) Lower the three Support legs (Items F

G) and secure in the transport position
with the securing pins(Item H) G
(iii) Start the machine and lower the Grid
(Item F) by pressing the button (Item
H
E). The grid will now lower to the trans-
port position

Remote Grid Raised

TR - 6
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SECTION 6: TRANSPORT 010502/01

6.7 FOLDING THE OVERSIZE

CONVEYOR

To put the Oversize Conveyor in the Trans-

port position.

(i) Remove the Telescopic holding pins A

from the hole at(Item A).
Retract the Top section by operating
the control lever (Item B). Reinsert the
pins into the holes to hold the conveyor Oversize in the Working Position
in the Transport position.
B
(ii) Remove the pin (Item D) securing the
conveyor in the Transport position.

(iii) Fold the Connveyor to the transport po-

sition (Item E) by operating the con-
trol lever (Item C)

(iv) Attach the securing chains (Item F) to C

hold the Oversize conveyor in the trans-
port position. Oversize Conveyor Control Bank

IMPORTANT
USE THE CONTROL LEVERS IN A SMOOTH
AND CONTROLLED MANNER.
DO NOT RUSH OR JERK THE CONTROLS.
D
THIS WILL DAMAGE THE CONVEYOR

WARNING Oversize Conveyor Securing Pin

HAZARDOUS NIP
AND CRUSH
POINTS IN THIS
AREA E
ENSURE ALL PERSONNEL ARE
CLEAR BEFORE PUTTING F
MACHINE INTO THE TRANSPORT
POSITION
CRUSH POINTS EXIST

Oversize in the Transport Position

TR - 7
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SECTION 6: TRANSPORT 010502/01

6.8 FOLDING THE MIDDLE GRADE

CONVEYOR
To Return the Middle Grade conveyor from
the Working position(Item A) to the Trans- A
port position(Item D).

(i) Remove the pins (Item A) from either

side of the conveyor.

(ii) To fold the Middle grade conveyor

operate the control lever (Item B). Fold Conveyor in the Working Position
the conveyor back slowly to its trans-
port position. B
(iii) When the conveyor has been folded.
Fit the transport securing chain(Item
C).Use a 19mm Spanner.

(iv) Your Middle Grade conveyors should

now be secured into the transport po-
sition.

Conveyor Control Bank

IMPORTANT
USE THE CONTROL LEVERS IN A SMOOTH
AND CONTROLLED MANNER. C
DO NOT RUSH OR JERK THE CONTROLS.
THIS WILL DAMAGE THE CONVEYOR

WARNING
HAZARDOUS NIP Conveyor Transport Securing Chain
AND CRUSH
POINTS IN THIS
AREA D

Conveyor in the Transport Position

TR - 8
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SECTION 6: TRANSPORT 010502/01

6.9 FOLDING THE FINE GRADE

CONVEYOR

To Return the Fines conveyor from the

Transport position(Item A) to the Working
position (Item D). A
(i) Remove the pins (Item B) from either
side of the conveyor.

(ii) To fold the Fines conveyor operate the

control lever (Item C). Fold the con- Conveyor in the Working Position
veyor back slowly to its transport po-
sition.

(iii) When the conveyor has been folded. B

Fit the transport securing chain(Item
D).Use a 19mm Spanner.

(iv) Your Fines conveyors should now be

secured into the transport position.

Fine Grade Conveyor Securing Pin

IMPORTANT
USE THE CONTROL LEVERS IN A SMOOTH
AND CONTROLLED MANNER.
DO NOT RUSH OR JERK THE CONTROLS. C
THIS WILL DAMAGE THE CONVEYOR

WARNING
HAZARDOUS NIP Conveyor Control Bank
AND CRUSH
POINTS IN THIS
AREA
D

Conveyor Transport Securing Chain

TR - 9
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SECTION 6: TRANSPORT 010502/01

6.10 RETURNING DEFLECTOR

DOORS TO THE TRANSPORT
POSITION(IF FITTED)

To Return the Deflector doors to the trans- A

port position(Item D) from the working po-
sition (Item A).

(i) Remove the pins holding the Deflec-

tor door in the transport position at
either side and store them in the Deflector Door in Working Position
toolbox.

(ii) Next rotate the Deflector door(Item A)

towards the machine chassis.

(iii) To place the deflector door in trans- B

port they must first be folded. To fold
the door remove the bolt securing the
door at the securing point (Item B).

(iv) Rotate the doors to the transport po-

sition and secure inplace by inserting Deflector Door Unfolded
pin (Item C)

Deflector Door Transport

Securing Pin

Deflector Door in Transport Position

TR - 10
 ENG
SECTION 6: TRANSPORT 010502/01

6.11 RAISING SUPPORT LEGS

The Rear support legs (Item A) should now

be raised and secured with the pins pro-
vided on both sides(Item B).
A
The rear of the machine(Hopper end) may
have to be raised using the Rear hydraulic
jacking legs to remove weight from the sup-
port legs
Rear Support Legs in Working Position

DANGER
HAZARDOUS NIP
AND CRUSH
POINTS IN THIS B
AREA
HIGH PRESSURE
HYDRAULIC FLUID
CAN PENETRATE THE
SKIN CAUSING
SERIOUS INJURIES Rear Support Legs in Raised Position

TR - 11
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SECTION 6: TRANSPORT 010502/01

6.12 RETURNING THE DRAWBAR TO

THE TRANSPORT POSITION

The Machine Site Drawbar must be returned F

to its Transport position prior to any trans-
port on public roads.
G
(i) Remove pin (Item G) holding drawbar
in the Working position.

(ii) Push the drawbar support member Site Drawbar In Working Position
(Item F) inwards to the transport posi-
tion.

(iii) Raise the drawbar (Item E). And place

pin (Item D) in position to secure in D
transport.
E

WARNING
DO NOT USE THE SITE DRAWBAR
Site Drawbar In Closed Position
TO MOVE THE MACHINE ON
PUBLIC ROADS

F
6.13 RAISING JACKLEGS

Prior to transport all the Jacklegs must be

raised. To raise:

(i) Remove the securing pin (Item I) from G

each jackleg and place in the toolbox
H
for transport.
Jack Leg Controls
(ii) Raise all the Jacklegs by operating the
control levers (Items F, G & H)

Rear Jacking Leg Pin

TR - 12
 ENG
SECTION 6: TRANSPORT 010502/01

6.14 READY FOR TRANSPORT

The Machine should now be Ready for

Transport. Fully cleaned down, packed and
secured.

Machine Ready For Transport

6.15 PRIOR TO HAULAGE:

(i) Recheck for loose parts or debris on

WARNING
the machine BEFORE TRANSPORTING
THIS MACHINE YOU
MUST READ AND
(ii) Ensure all pins are secured with ‘R’ UNDERSTAND SAFETY
and Split pins SECTIONS IN THIS
MANUAL
(iii) Raise the chassis using the jacking
legs to the lorry table height using the
relevant controls.Connect to the lorry
and link up the air brakes and light
board (if fitted).

(iv) Raise the jacking legs fully

(v) Ensure wheel nuts are torqued

between 500 to 550 Ft.lb (69 to 76 CAUTION
kg.m) prior to transport
PRIOR TO TRANSPORT
(vi) Ensure persons transporting the ma (1) Check tyre pressures
chine adhere to the safety sign fitted
(2) Check wheel nut torque
at the towbar end of the machine as
seen here. (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.

TR - 13
 ENG
SECTION 7: FAULT FINDING 010502/01

Contents
7.1 NO RESPONSE FROM ANY HYDRAULIC SYSTEM .................................. FA - 2

7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAK .................... FA - 2

7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP .......................................... FA - 3

7.4 TROMMEL BARREL NOT WORKING .............................................................. FA - 3

7.5 VIBRATING GRID WILL NOT START ............................................................... FA - 3

7.6 BELTFEEDER NOT WORKING WHEN CONVEYOR IS RUNNING........... FA - 4

7.7 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING. ....................... FA - 4

7.8 CONVEYOR BELT NOT RUNNING .................................................................. FA - 4

7.9 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED ........................... FA - 5

7.10 REJECT GRID WILL NOT HINGE ..................................................................... FA - 5

7.11 VIBRATING GRID AND SCREEN BEARINGS FAIL PREMATURELY ....... FA - 5

7.12 ENGINE FAILS TO START ................................................................................. FA - 6

7.13 BELT STOPS UNDER LOAD ............................................................................. FA - 6

7.14 ENGINE STOPS .................................................................................................... FA - 6

7.15 CONVEYOR BELTS RUNNING OUT OF LINE ............................................... FA - 7

7.16 TROMMEL BARREL RUNNING OUT OF LINE. ............................................ FA - 7

7.17 CHAIN SLIPPING. ................................................................................................. FA - 7

7.18 SCREEN MESH CLOGGING ............................................................................ FA - 7

WARNING DANGER
PRACTICE SAFE
SWITCH OFF AND
MAINTENANCE READ
LOCKOUT BEFORE
AND UNDERSTAND
WORKING AT A MACHINE
THE OPERATORS
MANUAL BEFORE DANGEROUS
DOING ANY WORK NIP POINTS EXIST

FA - 1
 ENG
SECTION 7: FAULT FINDING 010502/01

SECTION 7 : FAULTFINDING
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 Hydraulic Pressure/Adjust

7.2 MACHINE OPERATING SLOWLY. NO EXTERNAL OIL LEAK

POSSIBLE FAULT REMEDY

Low oil level Top up hydraulic system with correct fluid

Incorrect hydraulic fluid Drain tank and replace with correct fluid
Choked suction line filter Replace filter element
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 - 2
 ENG
SECTION 7: FAULT FINDING 010502/01

7.3 EXCESSIVE NOISE FROM HYDRAULIC PUMP

POSSIBLE FAULT REMEDY

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 TROMMEL BARREL NOT WORKING

POSSIBLE FAULT REMEDY

Drive Chain Loose, broken or off sprocket Adjust or repair as necessary

Taperlock bush not tight or broken Replace or repair Taperlock bush.

Hydraulic motor shaft broken Replace hydraulic motor

Bearing seized in Guide or Running Wheel Replace Bearing

7.5 VIBRATING GRID WILL NOT START

POSSIBLE FAULT REMEDY

When machine is new grease may Remove weights cover turn weight to top
have settled in bearings dead centre, replace cover, restart grid
Grid Bearing seized Replace bearings
Hydraulic motor coupling broken Replace coupling
Hydraulic motor shaft broken Replace hydraulic motor

FA - 3
 ENG
SECTION 7: FAULT FINDING 010502/01

7.6 BELTFEEDER NOT WORKING WHEN CONVEYOR IS RUNNING

POSSIBLE FAULT REMEDY

Drive chain loose or broken Adjust or repair as necessary

Taper lock bushes not tight or broken Repair or replace Taperlock Bushes
Key missing Replace key
Faulty control valve Replace or adjust
Flow control valve incorrectly set Reset flow control valve
Belt is Loose Tighten the belt
Kickout pushes control valve into neutral Check setting of sequence valve

7.7 SCHREECHING NOISE WHEN CONVEYOR IS RUNNING.

POSSIBLE FAULT REMEDY

Lack of bearing lubrication Grease all bearings

Conveyor belt wedged or rubbing against Clear obstruction, adjust and track con-
fixed parts veyor 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

7.8 CONVEYOR BELT NOT RUNNING

POSSIBLE FAULT REMEDY

Belt drive coupling broken or loose Replace or tighten coupling

Bearing collapsed or seized Replace bearing
Debris obstructing end drum Remove obstruction
Skirting Rubber to tight Adjust skirting rubber
Material Build up around return rollers Clean build-up of material
Belt Stopped with to much load Clear material of belt and restart.

FA - 4
 ENG
SECTION 7: FAULT FINDING 010502/01

7.9 CONVEYOR BELT TENDS TO RUN BACK IF STOPPED WITH A LOAD ON

THE BELT

POSSIBLE FAULT REMEDY

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 re-
due to soiled hydraulic fluid quired. Clean/Replace Valve

7.10 REJECT GRID WILL NOT HINGE

POSSIBLE FAULT REMEDY

Leaking relief valve Repair or replace valve

Remote control system not working.
Fuse blown Replace fuse in the starter box
Batteries flat in hand held transmitter Replace batteries
Broken wire in electrical circuit Repair or replace wire
Faulty control valve. Replace or adjust valve

7.11 VIBRATING GRID AND SCREEN BEARINGS FAIL PREMATURELY

POSSIBLE FAULT REMEDY

Wrong Grease is being used Use Proper Grease

To 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 - 5
 ENG
SECTION 7: FAULT FINDING 010502/01

7.12 ENGINE FAILS TO START

POSSIBLE FAULT REMEDY

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 is faulty Replace heater plug

7.13 BELT STOPS UNDER LOAD

POSSIBLE FAULT REMEDY

Skirting rubbers to tight Adjust Skirting Rubber

Plough Scraper to 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

7.14 ENGINE STOPS

POSSIBLE FAULT REMEDY

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 -tempera-
ture switch/oil pressure switch/fan belt switch/
stop buttons/electrical short.

FA - 6
 ENG
SECTION 7: FAULT FINDING 010502/01

7.15 CONVEYOR BELTS RUNNING OUT OF LINE

POSSIBLE FAULT REMEDY

Belt Running of the Idler Drum Adjust Idler Drum
Belt Running of the Drive Drum Adjust Drive Drum
Belt wanders under load If the belt wanders to the right underload,push
the right handside of the centre rollers for-
ward or the left hand side back. (Switch off
machine and lockout before carrying out any
repairs.

7.16 TROMMEL BARREL RUNNING OUT OF LINE.

POSSIBLE FAULT REMEDY

Guide wheel broken Replace guide wheel

Running wheel out of line Refer problem to local Finlay Dealer

Chassis not level Level Chassis (See Installation Section)

7.17 CHAIN SLIPPING.

POSSIBLE FAULT REMEDY

Tensioner slack or damaged Adjust, repair or replace as required.

Damaged Sprocket Replace Sprocket

7.18 SCREEN MESH CLOGGING

POSSIBLE FAULT REMEDY

Brushes damaged/worn Replace brushes

Brushes not adjusted properly Adjust Brushes (See Maintenance sec-

tion)

FA - 7
 ENG
SECTION 8: SPARE PARTS 010502/01

Contents
8.1 SPARE PARTS ORDERING PROCEDURE ......................................................SP - 2

8.2 SPARE PARTS ORDER FORM ...........................................................................SP - 3

8.3 SPARE PARTS INDEX ..........................................................................................SP - 4

SP - 1
 ENG
SECTION 8: SPARE PARTS 010502/01

SECTION 8 : SPARE PARTS

8.1 SPARE PARTS ORDERING PROCEDURE

Ordering Procedure:-To ensure delivery of your parts, when ordering please quote:

· machine serial number

· illustration number and item number

· part number

· part description

· quantity required

EXAMPLE:

If you wanted to order Jack Leg Ram, place your order in the following fashion:-

Machine serial number - FG 510052

Illustration number - 8.3.1

Item number - 6

Part number - 10.28.0701

Part description - Ram

Quantity required - 1

This information will enable us to supply the correct parts with the minimum of delay.

NOTE:

For ordering spare parts related to the engine, a parts list issued by the manufacturers has

been included with this manual. Follow the procedure as laid down within this parts list.

SP - 2
 Parts Ordering Form

Customer Name Customer Address

MACHINE DETAILS MANUAL DETAILS
Machine Machine Illustration Item No. Parts No. Part Description Quantity
Type Serial No. Number Required
8.2 SPARE PARTS ORDER FORM

SP - 3
SECTION 8: SPARE PARTS
ENG
010502/01
 ENG
SECTION 8: SPARE PARTS 010502/01

8.3 SPARE PARTS INDEX

8.3.1 Chassis Assembly ............................................................................................ SP - 6

8.3.2 Chassis Tail Assembly ..................................................................................... SP - 7

8.3.3 Beltfeeder Cassette Assembly ........................................................................ SP - 8

8.3.4 Beltfeeder Assembly ........................................................................................ SP - 9

8.3.5 Reject GridAssembly ....................................................................................... SP - 10

8.3.6 Vibrating Grid Assembly .................................................................................. SP - 12

8.3.7 Main Conveyor Assembly ............................................................................... SP - 14

8.3.8 Trommel Barrel Assembly ............................................................................... SP - 16

8.3.9 Transfer Conveyor Assembly .......................................................................... SP - 18

8.3.10 Trommel Doors & Brushes Assembly ........................................................... SP - 20

8.3.11 Fines Feedboot Assembly ............................................................................... SP - 22

8.3.12 Fines Conveyor Assembly .............................................................................. SP - 23

8.3.13 Middle Grade Feedboot Conveyor Assembly .............................................. SP - 24

8.3.14 Middle Grade Conveyor Assembly ................................................................ SP - 25

8.3.15 Discharge Chutes Assembly ........................................................................... SP - 26

8.3.16 Oversize Tail Section Assembly .................................................................... SP - 28

8.3.17 Oversize Top Section Assembly ..................................................................... SP - 29

8.3.18 Oversize Telescopics Assembly ..................................................................... SP - 30

8.3.19 Power Unit Assembly ........................................................................................ SP - 32

8.3.20 Engine Assembly ............................................................................................. SP - 34

8.3.21 Tandem Axle Assembly .................................................................................. SP - 36

8.3.22 Triple Axle Assembly ....................................................................................... SP - 37

8.3.23 Hydraulic Diagram ............................................................................................ SP - 38

8.3.24 Hydraulic Schmatic Diagram .......................................................................... SP - 44

SP - 4
 ENG
SECTION 8: SPARE PARTS 010502/01

8.3.25 Electric Wiring Diagram - 1012C Engine ..................................................... SP - 48

8.3.26 Electric Wiring Diagram - Remote Tipping Grid ......................................... SP - 49

8.3.27 Electric Wiring Diagram - Lightboard ............................................................ SP - 50

8.3.28 Electric Wiring Diagram - Fuse Designation ............................................... SP - 52

8.3.29 Machine Belt List & Deutz Engine Filters ...................................................... SP - 53

SP - 5
8.3.1 Chassis Assembly
SP-6
8.3.2 Chassis Tail Assembly
SP-7
8.3.3 Beltfeeder Cassette Assembly
SP-8
8.3.4 Beltfeeder Assembly
SP-9
 PARTS LIST

8.3.5 Reject GridAssembly

INDEX PART NAME DESCRIPTION QTY REV NOTES ECO NO.
1 683.09.06 CENTRE CROSSMEMBER 1 -
2 683.09.07 FRONT CROSSMEMBER 1 - 4
3 683.09.01 BACK PLATE 1 -
4 683.09.02 U-FRAME 1 -
5 683.09.08 GRID FLAP-LEFT 1 -
6 683.09.09 INNER TELESCOPIC 3 -

REJECT GRID-OPTION
7 683.09.13 GRID FLAP-RIGHT 1 -
8 683.09.14 REJECT BAR GUIDE 4" 1 -

683_09
8a 683.09.22 REJECT BAR GUIDE 6" 1 -
9 683.09.17 REJECT BAR(QTY 4" - QTY 6") 28-20 -
10
10 683.09.18 REJECT BAR MTG ANGLE 4" 1 -
10a 683.09.20 REJECT BAR MTG ANGLE 6" 1 -
11 683.09.19 REJECT BAR GUIDE 4" 1 -
11a 683.09.21 REJECT BAR GUIDE 6" 1 -
12 683.09.03 GRID SIDE LEFT 1 - 9
13 683.09.04 GRID SIDE RIGHT 1 -
14 10.28.0106 HYDRAULIC RAM 2 -
15 683.09.23.01 SHROUD RUBBER CLAMP (SIDE) 2 -
19
16 683.09.02.15 SHROUD RUBBER CLAMP (BACK) 1 -
17 20.683.09.01 SHROUD RUBBER (BACK) 1 -
17a * 20.683.09.01 SHROUD RUBBER CHUTE 1 0 1 piece old type 1073
18 20.683.09.02 SHROUD RUBBER (SIDE) 2 -
19 663.09.30.01 SHROUD CORNER CLAMP 4 -
* If grid has been fitted with one piece rubber it should be replaced by items 17,18 & 19
1
7
12
5
3
SP-10

15 17
16
18
8
6

11
13

14
2

DESCRIPTION: 683 TIPPING GRID -

SCALE 1:100 DWG: M683_09_TIPPINGGRID
REV:
SCALE: 3:100
DATE: 26-May-03 B
SP-11
8.3.6 Vibrating Grid Assembly
SP-12
SP-13
8.3.7 Main Conveyor Assembly
SP-14
SP-15
8.3.8 Trommel Barrel Assembly
SP-16
SP-17
8.3.9 Transfer Conveyor Assembly
SP-18
SP-19
8.3.10 Trommel Doors & Brushes Assembly
SP-20
SP-21
8.3.11 Fines Feedboot Assembly
SP-22
8.3.12 Fines Conveyor Assembly
SP-23
8.3.13 Middle Grade Feedboot Conveyor Assembly
SP-24
8.3.14 Middle Grade Conveyor Assembly
SP-25
 PARTS LIST
INDEX PART NAME DESCRIPTION QTY REV
1 10.03.1100 1/8 M/F BULKHEAD ADAPTER 8 0

8.3.15
2 12.09.5030 TANK MTG RUBBERS 4
3 20.799.16.01 MID-GRADE FEEDBOOT SIDE RUBBER 1 1
4 20.799.16.02 MID-GRADE FEEDBOOT SIDE RUBBER 1 1
5 20.799.16.03 FEEDBOOT BACK RUBBER 1 1
6 20.799.16.04 OVERSIZE CURTAIN RUBBER 1 1
7 20.799.16.05 MID-GRADE DEFLECTOR CURTAIN 1 0
8 20.799.16.06 CHUTE SEAL RUBBER 1 0
9 799.16.01 MID-GRADE CHUTE MTG - RGT 1 4
10 799.16.02 MID-GRADE CHUTE MTG - LFT 1 3

Discharge Chutes Assembly

11 799.16.03 MID-GRADE CHUTE LHS EXIT 1 0
12 799.16.04 RUBBER MTG PLATE - LONG 2 2
13 799.16.05 RUBBER MTG PLATE - SHORT 2 0
14 799.16.06 MID-GRADE CHUTE FRONT PLATE 1 0
15 799.16.07 OVERSIZE CHUTE 1 4
16 799.16.08 RUBBER CLAMP 1 0
17 799.16.09 RUBBER CLAMP 2 0
18 799.16.10 RUBBER CLAMP 2 0
19 799.16.11 RUBBER CLAMP 1 1
20 799.16.13 GUIDE WHEEL ACCESS PLATE 1 0
21 799.16.14 DEFLECTOR CURTAIN MTG. ANGLE 1 0
22 799.16.15 DEFLECTOR CURTAIN MTG. ANGLE 1 0
23 799.16.16 CLAMP FLAT 1 0
24 799.16.17 CLAMP FLAT 1 0
25 799.16.18 SEAL RUBBER CLAMP 1 0
SP-26
SP-27
 8.3.16
This is incorrect
partcode the ram was
never this partcode. See
next page for correct
details

Oversize Tail Section Assembly

SP-28

Partcode is incorrect it should

be 790.18.04
 PARTS LIST

8.3.16
INDEX PART NAME DESCRIPTION QTY REV NOTES ECO NO.
1 10.28.0112 HYDRAULIC RAM 2 0 up to serial No.FTV520523 18
from Serial No.FTV520524
1 10.28.0158 HYDRAULIC RAM 2 - 8
2 11.05.0221 BEARING 2 -
3 19.22.0789 BASE PLATE 4 -
12
4 19.22.4020 WING ROLLER 8 - 13
5 19.22.4689 CENTRE ROLLER 4 -

Oversize Tail Section Assembly

OVERSIZE TAIL SECT
6 19.30.1119 DISC RETURN ROLLER 1 -

770_04A
7 20.770.04.01 V-SCRAPER RUBBER 1 -
8 20.770.04.02 FEEDBOOT SIDE RUBBER 2 -
9 20.770.04.03 FEEDBOOT REAR RUBBER 1 -
10 770.04.01 O/S CONVEYOR BOTTOM SECTION 1 -
11 770.04.07 V - SCRAPER 1 -
12 770.04.08 RUBBER CLAMP 2 -
28
13 770.04.09 RUBBER CLAMP 2 -
14 770.04.10 ADJUSTER BAR 2 -
15 770.04.11 NIP GUARD 1 -
19
16 770.04.17 RUBBER CLAMP 2 -
17 770.04.24 FEEDBOOT - RHS 1 -
17
9
18 770.04.25 FEEDBOOT - LHS 1 -
19 770.04.26 FEEDBOOT BACK 1 -
27
20 770.04.27 RUBBER CLAMP 1 -
20
21 770.04.28 IDLER DRUM COVER GUARD 1 -
22 770.04.29 TAIL SECTION RHS 1 -
23 770.04.30 TAIL SECTION LHS 1 -
24 770.04.31 TAIL SECTION BACK PLATE 1 -
25 770.04.32 TAIL DRUM ADJUSTER - RHS 1 -
23
SP-28

26 770.04.33 TAIL DRUM ADJUSTER - LHS 1 -

27 770.04.35 FEEDBOOT BACK GUARD - RHS 1 - 16
28 770.04.36 FEEDBOOT BACK GUARD - LHS 1 -
7
29 770.04.39 O/S UNDERSIDE GUARD 2 -
30 790.18.04 TAIL DRUM 1 -
11

26
30
21
10
15
6
14
1
4
3
29
5
22
25
SCALE 1:50 DESCRIPTION: 770 OVERSIZE TAIL SECTION
2
DWG: M770_04-1ST
24
SCALE: 1:40 REV:
DATE: 10-Jan-02 0
8.3.17 Oversize Top Section Assembly
SP-29
8.3.18 Oversize Telescopics Assembly
SP-30
SP-31
8.3.19 Power Unit Assembly
SP-32
SP-33
 9 10 11 12 13

8.3.20
Engine Assembly
2 3 4
1

7
6
5

38
SP-34

37 14
36 15
35 16
17
18
19
34 20
33
32 21 22
23
26 24
27 25
28
29
26A
26B
30
31
ILLUSTRATION 8.3.20 BF4M 1012C DEUTZ ENGINE ASSEMBLY
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
1 ___________ Battery Lead (Negative) 1
2 12.09.0028 Grommet 1
3 ___________ Battery Lead (Positive) 1
4 12.14.3005 Battery 1
5 ___________ Silencer Flexible Pipe 1
6 ___________ U Bolt 1
7 693.17.24 Exhaust Flange 1
8 15.02.0089 Air Filter Complete 1
9 15.02.0798 Air Filter Safety Element 1
10 15.02.0799 Air Filter Element 1
11 693.17.18 Air Duct 1
12 26.24.08020 Bolt 10
13 32.02.01008 Washer 10
14 683.43.04 Alternator Guard 1
15 15.02.0116 Diesel Filter 1
16 15.02.0020 Oil Filter 1
17 26.44.12030 Bolt 2
18 32.04.01012 Spring Washer 2
19 26.44.12100 Spring Washer 4
20 32.02.01012 Washer 4
21 26.24.00012 Nut 4
22 10.24.3028 Pump(Remote Grid) 1
22a 10.24.3036 Pump (Vibrating Grid) 1
23 __________ Outer Spline 1
24 __________ Circlip 1
25 26.44.10130 Bolt 4
26 10.24.3031 Single Pump 1
26a __________ Spring Washer 1
26b __________ Nut 1
27 32.02.01012 Washer 8
28 26.50.12040 Cap Head Screw 8
29 __________ Pump Drive Wheel 1
30 32.02.01010 Washer 12
31 26.44.10030 Bolt 12
32 26.44.12040 Bolt 4
33 32.02.01012 Washer 4
34 10.24.3056 Tandem Pump(Standard) 1
34a 10.24.3081 Triple Pump(Cutter fitted) 1
39-41 15.35.0097 Pump Mounting Plate c/w Coupling 1
35 __________ Pump Mounting Plate 1
36 __________ Hub 1
37 __________ Coupling Plate 1
38 15.02.0790 Engine 1

SP-35
8.3.21 Tandem Axle Assembly
SP-36
8.3.22 Triple Axle Assembly
SP-37
8.3.23 Hydraulic Diagram
SP-38
SP-39
ILLUSTRATION 8.3.23 HYDRAULIC DIAGRAM
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
1 7992.01 Hydraulic Hose 1
2 7992.02 Hydraulic Hose 1
3 7992.03 Hydraulic Hose 1
4 7992.04 Hydraulic Hose 1
5 7992.05 Hydraulic Hose 1
6 7992.06 Hydraulic Hose 1
7 7992.07 Hydraulic Hose 1
8 7992.08 Hydraulic Hose 1
9 7992.09 Hydraulic Hose 1
10 7992.10 Hydraulic Hose 1
11 7992.11 Hydraulic Hose 1
12 7992.12 Hydraulic Hose 1
13 7992.13 Hydraulic Hose 1
14 7992.14 Hydraulic Hose 1
15 7992.15 Hydraulic Hose 1
16 7992.16 Hydraulic Hose 1
17 7992.17 Hydraulic Hose 1
18 7992.18 Hydraulic Hose 1
19 7992.19 Hydraulic Hose 1
20 7992.20 Hydraulic Hose 1
21 7992.21 Hydraulic Hose 1
22 7992.22 Hydraulic Hose 1
23 7992.23 Hydraulic Hose 1
24 7992.24 Hydraulic Hose 1
25 7992.25 Hydraulic Hose 1
26 7992.26 Hydraulic Hose 1
27 7992.27 Hydraulic Hose 1
28 7992.28 Hydraulic Hose 1
29 7992.29 Hydraulic Hose 1
30 7992.30 Hydraulic Hose 1
31 7992.31 Hydraulic Hose 1
32-35 Blank
36 7990.02 Hydraulic Hose 1
37 Blank
38 7990.04 Hydraulic Hose 1
39 7990.05 Hydraulic Hose 1
40 7990.06 Hydraulic Hose 1
41 7990.07 Hydraulic Hose 1
42 7990.08 Hydraulic Hose 1
43 7990.09 Hydraulic Hose 1
44 Blank
45 Blank
46 7990.12 Hydraulic Hose 1
47 7990.13 Hydraulic Hose 1
48 Blank
49 Blank
50 7990.16 Hydraulic Hose 1
51 7990.17 Hydraulic Hose 1
52 Blank
53 7990.19 Hydraulic Hose 1
54-59 Blank
60 7990.26 Hydraulic Hose 1
61-63 Blank
64 7990.30 Hydraulic Hose 1
65-74 Blank
75 7990.41 Hydraulic Hose 1

SP-40
ILLUSTRATION 8.3.23 HYDRAULIC DIAGRAM
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
76 7990.42 Hydraulic Hose 1
77 7990.43 Hydraulic Hose 1
78 7990.44 Hydraulic Hose 1
79 7990.45 Hydraulic Hose 1
80 7990.46 Hydraulic Hose 1
81 7990.47 Hydraulic Hose 1
82 7990.48 Hydraulic Hose 1
83 7990.49 Hydraulic Hose
84 7990.50 Hydraulic Hose
85 7990.51 Hydraulic Hose 1
86 Blank
87 7990.53 Hydraulic Hose 1
88 7990.54 Hydraulic Hose 1
89 7990.55 Hydraulic Hose 1
90 7990.56 Hydraulic Hose 1
91-98 Blank
99 7990.65 Hydraulic Hose 1
100 7990.66 Hydraulic Hose 1
101 7990.67 Hydraulic Hose 1
102 7990.68 Hydraulic Hose 1
103 7990.69 Hydraulic Hose 1
104 7990.70 Hydraulic Hose 1
105 7990.71 Hydraulic Hose 1
106 7990.72 Hydraulic Hose 1
107 7990.73 Hydraulic Hose 1
108 7990.74 Hydraulic Hose 1
109 7990.75 Hydraulic Hose 1
110 6832.01 Hydraulic Hose 1
111 Blank
112 6832.03 Hydraulic Hose 1
113 Blank
114 6832.05 Hydraulic Hose 1
115 6832.91 Hydraulic Hose 1
116 6832.92 Hydraulic Hose 1
117 6832.93 Hydraulic Hose 1
118 6832.94 Hydraulic Hose 1
119-126 Blank
127 6832.101 Hydraulic Hose 1
128 6832.102 Hydraulic Hose 1
129 6832.103 Hydraulic Hose 1
130 6832.104 Hydraulic Hose 1
131 6832.105 Hydraulic Hose 1
132 68303.111 Hydraulic Hose 1
133 68303.112 Hydraulic Hose 1
134 68303.113 Hydraulic Hose 1
135 68303.114 Hydraulic Hose 1
136 68303.115 Hydraulic Hose 1
137 68303.116 Hydraulic Hose 1
138 68303.117 Hydraulic Hose 1
139 68303.118 Hydraulic Hose 1
140 68309.145 Hydraulic Hose 1
141 68309.146 Hydraulic Hose 1
142 68309.147 Hydraulic Hose 1
143 68309.148 Hydraulic Hose 1
144 68309.149 Hydraulic Hose 1
145 68309.150 Hydraulic Hose 1

SP-41
ILLUSTRATION 8.3.23 HYDRAULIC DIAGRAM
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
146 Blank
147 68309.160 Hydraulic Hose 1
148 68309.161 Hydraulic Hose 1
149 68309.162 Hydraulic Hose 1
150-151 Blank
152 68309.168 Hydraulic Hose 1
153 10.24.3056 Tandem Pump 1
154 10.24.3036 Single Pump 1
155 10.24.3031 Tandem Pump 1
156 10.16.5308 1 Bank Control Valve 2
157 10.24.3028 Single Pump
158 10.16.5342 2 Bank Control Valve 1
159 10.16.5333 2 Bank Control Valve 1
160 10.24.3081 Triple Pump 1
161 10.25.4217 Beltfeeder Motor 1
162 10.27.1023 Main Conveyor Motor 1
163 10.25.4207 Fines Conveyor Motor 1
164 10.25.4217 Barrel Motor 1
165 10.25.4210 Oversize Conveyor Motor 1
166 10.25.4209 Middle Grade Conveyor Motor (+ 1 Cutter) 2
167 10.25.3151 Vibrating Grid Motor 1
168 10.16.5149 High Pressure Ball Valve 1
169 10.16.6115 Webtec 2
170 10.16.5935 Dump Valve (1 for Grid) 2
171 10.16.5060 Non Return Valve 4
172 10.16.0054 Check Valve 1
173 10.16.5245 One Way Restrictor 2
174 10.01.1113 ½" M/M Restrictor Drilled 2
175 10.01.1117 ½" M/M Restrictor Drilled 1.5mm 9
176 10.21.5102 Suction Filter 4
177 10.21.3403 Return Filter 2
178 10.35.0007 Oil Cooler 1
179 10.16.5070 ¾" Non Return Valve 1
180 10.28.0701 Jackleg Rams 4
181 10.28.0112 Oversize Fold rams 2
182 10.28.0590 Oversize Telescopic Ram 1
183 10.28.0163 Side Conveyor Fold Rams 2
184 10.01.1118 ¾" x ¾" M/M Adaptor
185 10.12.0027 ¾" Bonded Seal
186 10.02.1219 ¾" M/F 90 Swept
187 10.12.0028 1" Bonded Seal
188 10.01.1119 1" x ¾" M/M Adaptor
189 10.12.0024 ¼" Bonded Seal
190 10.01.1106 ¼" x 3/8" M/M Adaptor
191 10.02.1218 ¾" x¾" Elbow
192 10.04.0018 ¾" x ¾" Cross Tee
193 10.04.1118 ¾" Equal Tee
194 10.01.1115 ½" x ¾" M/M Adaptor
195 10.12.0026 ½" Bonded Seal
196 10.09.0018 ¾" Blanking Plug
197 10.01.1213 ¾"F x ½"M Adaptor
198 10.04.1109 3/8" Equal Tee
199 10.01.1105 ¼" x ¼" M/M Adaptor
200 10.09.0022 1" Blanking Plug
201 10.16.5245 ½" Restrictor Valve
202 10.01.1114 ½" x ½" M/M Adaptor

SP-42
ILLUSTRATION 8.3.23 HYDRAULIC DIAGRAM
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
203 10.16.5148 ½" Ball Valve
204 10.01.0806 ½" x 3/8" M/M Adaptor
205 10.01.1206 3/8" F to ¼"M Adaptor
206 10.12.0027 3/8" Bonded Seal
207 10.01.1109 3/8" x 3/8" M/M Adaptor
208 10.36.0010 ¾" Test Point
209 10.01.2218 3/4" F x 3/4" F Adaptor
210 10.09.5363 High Pressure Carry Over
211 10.01.1215 ½"M to 3/4"F Adaptor
212 10.01.1218 ¾"M x ¾" F Adaptor
213 10.03.1115 ½" x ½" x 2" Bulkhead
214 10.03.1118 ¾" x¾" x 2" Bulkhead
215 10.24.3077 ¾" Pump Connector
216 10.24.3070 3/4" Pump- Connector
217 10.01.1122 1" x 1" M/M Adaptor
218 Blank
219 10.15.0018 Stud Stand Pipe
220 10.28.0142 Grid Lift Ram
221 10.01.2240 ¾" x ¾" F/F Swept Bend
222 10.16.5259 Diverter Valve
223 10.16.5705 Sequence Valve
224 10.16.5317 3 Bank Control Valve
225 10.15.0038 Equal Tee
226 10.30.0005 16mm Steel Pipe
227 10.16.5708 Safety Cut Out Valve
228 10.24.3072 1" Suction Flange
229 10.04.1121 3/8" Hex Equal Cross
230 10.04.1210 3/8" M/M/F Swivel Tee
231 10.03.1110 3/8" x 2" Bulkhead Adaptor
232 10.01.1206 ¼" x 3/8" M/F Swivel Adaptor
233 10.12.0030 1½" Bonded Seal
234 10.01.1129 1½" x 1¼" M/M Adaptor
235 10.04.1218 ¾" x ¾" x ¾" M/F/M Tee
236 10.01.1221 1" x ¾" M/F Swivel Adaptor
237 10.15.0018 Stud Stand Pipe
238 10.28.0106 Remote Grid Ram
239 10.16.5460 Solenoid Valve
240 10.24.3074 3/4" Pump Connector
241 10.24.3076 1" Pump Connector
242 10.04.1210 3/8" M/M/F Swivel Tee
243 10.02.1209 3/8" x 3/8" M/F 90 Swept
244 10.01.1111 3/4 "x 3/8" M/M Adaptor
245 10.02.1215 3/4" x 3/4" M/F 45 Swept
246 10.01.1218 3/4" x 3/4" M/F Adaptor
247 10.12.0029 1¼" Bonded Seal
248 10.16.5300 CV400 Kickout
249 Blank
250 10.28.0145 Cutter Ram
251 10.01.1119 3/4" x 1" M/M Adaptor
252-253 Blank
254 10.19.5363 3/4" HPCO CV400
255 10.04.1209 3/8" M/F/M Swivel Tee
256 10.16.5705 Sequence Valve
257 10.01.1123 1¼" x 1" M/M Adaptor
258 10.08.0019 3/4" F CAP Tapped 1/4" 1
259 10.23.5020 Pressure Clock 1

SP-43
 8.3.24
TIPPING GRID RAMS

PILOT LINE

AC

AI

Hydraulic Schmatic Diagram- Tipping Grid & Cutter Unit

82 BAR

35 L.P.M

ENGINE
BARREL MOTOR 1PL070
DANFOSS OMV 800 DAVID BROWN
FRONT JACK LEGS
COMMERICIAL
14.6 GAL

150 BAR
10.5 GAL KICK OUT

SEQUENCE VALVE

9 GAL
HPCO
MID-GRADE FOLD B/FEEDER DRIVE MOTOR
DANFOSS OMV 800
SP-44

LHS REAR JACKLEG

MID-GRADE MOTOR
DANFOSS OMT 315

TRANS CONV MOTOR

DANFOSS OMT 250
RHS REAR JACKLEG HPCO
FEED CONV. DRIVE MOTOR
FINES CONV. MOTOR BREVINI CTM1022 GEARBOX
DANFOSS OMT 250 + 130CC/REV MOTOR
OVERSIZE FOLD

OVERSIZE MOTOR OVERSIZE TELESCOPIC

DANFOSS OMT 500

FINES FOLD
CUTTER RAM 150 BAR

AE

AD SEQUENCE VALVE

4.5 BAR

CUTTER MOTOR

NO
 Hydraulic Schmatic Diagram- Vibrating Grid
VIB GRID
PILOT LINE LIFT RAMS

VIB GRID MOTOR

CASSAPPA 51CC/REV

COMMERICIAL HPCO
2px28

ENGINE
BARREL MOTOR 1PL070
DANFOSS OMV 800 DAVID BROWN
FRONT JACK LEGS
COMMERICIAL
14.6 GAL

150 BAR
10.5 GAL

SEQUENCE VALVE
KICK OUT
SP-45

MID-GRADE FOLD B/FEEDER DRIVE MOTOR

DANFOSS OMV 800

LHS REAR JACKLEG

MID-GRADE MOTOR
DANFOSS OMT 315

RHS REAR JACKLEG FEED CONV. DRIVE MOTOR

TRANS CONV MOTOR HPCO
DANFOSS OMT 250 BREVINI CTM1022 GEARBOX
OVERSIZE FOLD + 130CC/REV MOTOR

OVERSIZE
TELESCOPIC

OVERSIZE MOTOR
DANFOSS OMT 500
FINES CONV. MOTOR FINES FOLD
DANFOSS OMT 250
AE

AD

4.5 BAR

NO
ILLUSTRATION HYDRAULIC SCHMATIC DIAGRAM
ITEM NO. PART NO. DESCRIPTION QTY. NOTES
A 10.24.3056 Tandem Pump 1
B 10.24.3036 Single Pump 1
C 10.24.3031 Single Pump 1
D 10.24.3081 Triple Pump 1
E 10.24.3028 Single Pump 1
F 10.16.5308 1 Bank Control Valve 2
G 10.16.5342 2 Bank Control Valve 3
H 10.16.5317 3 Bank Control Valve 2
I 10.16.5149 High Pressure Ball Valve 1
J 10.25.4217 Beltfeeder Motor 1
K 10.27.1023 Main Conveyor Motor 1
L 10.25.4217 Barrel Motor 1
M 10.25.4209 Mid-Grade Conveyor Motor 1
N 10.25.4210 Oversize Conveyor Motor 1
O 10.25.4207 Transfer & fines Conveyor Motor 2
P N/A
Q 10.25.3151 Vibgrating Grid Motor 1
R 10.16.6115 Webtec 2
S 10.16.5935 Dump Valve (1 Grid) 2
T 10.16.0054 Check Valve 4
U 10.01.1117 1/2" M/M Restrictor Drilled 1.5mm 12
V 10.21.5102 Suction Filter 5
W 10.21.3403 Return Filter 2
X 10.28.0701 Jackleg Ram 4
Y 10.28.0163 Mid-Grade & Fines Fold Ram 2
Z 10.28.0112 Oversize Conveyor Fold Ram 1
AA 10.28.0590 Oversize Conveyor Telescopic Ram 1
AB 10.28.0142 Vibgrating Grid Ram 2
AC 10.16.5245 One Way Restrictor 4
AD 10.35.0007 Oil Cooler 1
AE 10.16.5070 Non Return Valve 1
AF 10.16.5705 Sequence Valve 3
AG 10.16.0055 Shuttle Valve 1
AH 10.16.5460 Tipping Grid Solenoid 1
AI 10.28.0106 Tipping Grid Rams 2
AJ 10.28.0145 Cutter Ram 1
AK 10.25.4209 Cutter Motor 1
AL 10.16.5259 Diverter Valve 1

SP-46
SP-47
 8.3.28
OVER RIDE

Electric Wiring Diagram - BF4L 2012C Engine

AIR FILTER RESTRICTION
START DELAY

TEMPERATURE
OIL PRESSURE

START DELAY

OIL PRESSURE
IGNITION FUEL SOLENOID

ENGINE TEMPERATURE
HYDRAULIC OIL

STOP SWITCHES
TRACK REMOTE

OIL PRESSURE
STOP SWITCHES

STOP SWITCH
TRACK MANUAL FUEL HOUR
START DELAY LOW HYDRAULIC

AIR FILTER
ENGINE

STARTER
SP-51

COLOUR CODE

B = BLACK R = RED
G = GREEN S = SLATE

N = BROWN U = BLUE

O = ORANGE W = WHITE

P = PURPLE Y = YELLOW
 LOWER TIME ADJUSTER RAISE TIME ADJUSTER
FUSE

ANTENNA
8.3.26

REMOTE CONTROL

IGNITION

PROGRAMMING SWITCH PROGRAMMING LED

GRID RAISE GRID LOWER

WIRING DIAGRAM FOR FINLAY HYDRASCREENS RADIO REMOTE CONTROL TIPPING GRID 17/02/01 (HIRK RECEIVER)
TRAMSMITTER AND RECEIVER ARE FITTED WITH RED LABELS

PROGRAMMING INSTRUCTIONS

SP-49
Electric Wiring Diagram - Remote Tipping Grid

To erase all transmitters from the receiver proceed as follows.

8.3.27 Electric Wiring Diagram - Lightboard
SP-50
 LIGHTBOARD ASSEMBLY

5 1 2

6 3

DESCRIPTION PARTCODE

1. Reflector 14.87.0001
2 Lightboard Complete 14.50.0001
3 Fog Lamp 14.91.0001
3a. Fog Bulb 14.89.0006
4. Numberplate lamp 14.93.0001
4a. Numberplate bulb 14.89.0003
5. Side Marker Lamp 14.92.0001
5a. Side Marker Lens Red 14.88.0002
5b Side Marker Lens Clear 14.88.0003
5c Side Marker Bulb 14.89.0005
6. Rear Lamp 14.90.0001
6a. Lens 14.88.0001
6b. Brake Bulb 14.89.0002
6c. Indicator Bulb 14.89.0001
6d. Tail Light Bulb 14.89.0004

SP-51
8.3.28 Electric Wiring Diagram - Fuse Designation
SP-52
8.3.29 Machine Belt List & Deutz Engine Filters

Item No. Part Number Description

BELTS
1 20.03.68302 Beltfeeder Belt
2 20.03.79903 Transfer Belt
3 20.03.79901 Fines Conveyor Belt
4 20.03.77001 Oversize Conveyor Belt
5 20.03.79902 Main Conveyor Belt
6 20.03.79904 Middle Grade Conveyor Belt

FILTERS
1 15.02.0020 Engine Oil Filter
2 15.02.0116 Engine Fuel Filter
3 15.02.0089 Engine Air Filter (Complete)
4 15.02.0799 Engine Air Filter Element (Main)
5 15.02.0798 Engine Air Filter Element (Safety)

SP-53
 ENG
SECTION 9: WARRANTY 010502/01

9. 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 Finlay Hydrascreens 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 Finlay Hydrascreens in the manufacture
of their machinery, to the best of their knowledge, are the highest available quality of their re-
spective kinds. Finlay Hydrascreens undertake to replace or repair free of cost any part sup-
plied to them direct to the customer of which they shall receive notice and which shall be proved
to the satisfaction of Finlay Hydrascreens within a period of six months of delivery to be defec-
tive 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 Finlay Hydrascreens and shall, in the event of
replacement become their property.

C:- That Finlay Hydrascreens 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 Finlay Hydrascreens, 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 Finlay Hydrascreens 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 Finlay Hydrascreens 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 ex-
pressed or implied, statuary or otherwise. In no event shall Finlay Hydrascreens be liable (ex-
cept 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 Finlay Hydrascreens customer and
may not be assigned.

WA - 1