ST356 OM Complete

ST356

OPERATOR’S MANUAL Applies to serial numbers R2220702 and after

METSO MINERALS ST356 IS A TRADEMARK OF METSO MINERALS CHAPPAGH N.IRELAND. and MIDDLEBORO, MA USA This manual refers to many different products. In all cases, these products are claimed as trademarks or registered trademarks by their respective companies. ©1999 METSO MINERALS. All rights reserved. Printed USA Issued: 6/18/02nth

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ST356

Operator's Manual TABLE OF CONTENTS

SECTION 1 INTRODUCTION SECTION 1 INTRODUCTION..................................................................................................................... 1 1-1-1 INTRODUCTION ............................................................................................................................... 1 1-2-2 RELATED PUBLICATIONS.............................................................................................................. 2 1-3-1 DEALER AND MANUFACTURER ASSISTANCE............................................................................. 3 Deutz Engines ........................................................................................................................................... 3 Crawler Track Systems Ltd ....................................................................................................................... 3 NBB Controls ............................................................................................................................................. 3 Sauer Danfoss ........................................................................................................................................... 3 Mannesmann Rexroth ............................................................................................................................... 3 1-4-2 WARRANTY ..................................................................................................................................... 4 DEUTZ....................................................................................................................................................... 4 CRAWLER TRACK SYSTEMS LTD. ........................................................................................................ 4 NBB CONTROLS ...................................................................................................................................... 4 SECTION 2 - SAFETY SECTION 2 - SAFETY ................................................................................................................................ 1 2-2-1 UNDERSTAND SIGNAL WORDS..................................................................................................... 2 2-2-2 FOLLOW SAFETY INSTRUCTIONS ................................................................................................ 2 2-2-3 LEARN MACHINE SAFETY .............................................................................................................. 2 2-3-1 AVOID FALLING OBJECTS .............................................................................................................. 3 2-3-2 AVOID MOVING PARTS ................................................................................................................... 3 2-3-3 MAINTENANCE SAFETY.................................................................................................................. 3 2-3-4 WEAR PROTECTIVE CLOTHING .................................................................................................... 3 2-4-1 PREPARE FOR EMERGENCIES ..................................................................................................... 4 2-4-2 PROTECT AGAINST NOISE............................................................................................................. 4 2-4-3 HANDLE FUEL SAFELY - AVOID FIRES ......................................................................................... 4 2-4-4 AVOID HIGH-PRESSURE FLUIDS................................................................................................... 4 2-5-1 PREVENT BATTERY EXPLOSIONS................................................................................................ 5 2-5-2 AVOID ACID BURNS ........................................................................................................................ 5 2-5-3 DISPOSE OF WASTE PROPERLY .................................................................................................. 5 SECTION 3 MAIN COMPONENTS SECTION 3 MAIN COMPONENTS ............................................................................................................ 1 3-2-1 IDENTIFICATION AND SPECIFICATIONS ...................................................................................... 2 Conveyors.................................................................................................................................................. 2 3-3-1 IDENTIFICATION AND SPECIFICATION......................................................................................... 3 Hopper ....................................................................................................................................................... 3 Screen-Box ................................................................................................................................................ 3 3-4-1 IDENTIFICATION AND SPECIFICATION......................................................................................... 4 Main Dimensions, Transport...................................................................................................................... 4 Shipping Specifications ............................................................................................................................. 4 Power Pack (Engine / Motor)..................................................................................................................... 4 Tanks ......................................................................................................................................................... 4 3-5-1 IDENTIFICATION AND SPECIFICATION......................................................................................... 5 Crawler Tracks........................................................................................................................................... 5 3-6-1 VALVE PLACEMENT ........................................................................................................................ 6

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SECTION 4 APPLICATIONS SECTION 4 APPLICATIONS ...................................................................................................................... 1 4-2-1 MATERIALS MACHINE IS CAPABLE OF PROCESSING ............................................................... 2 4-3-1 SITE PREPARATION ........................................................................................................................ 3 4-3-2 OPERATING TECHNIQUES ............................................................................................................. 3 4-4-1 SCREEN MESH SELECTION ........................................................................................................... 4 4-4-2 SCREEN SPEED............................................................................................................................... 4 4-5-1 SCREEN ANGLE SELECTION ......................................................................................................... 5 4-6-1 DIVERTER PLATE ADJUSTMENT .................................................................................................. 6 4-7-1 SHREDDER-HAMMERMILL APPLICATIONS .................................................................................. 7 4-8-1 EFFICIENT LOADING OF THE HOPPER/GRIZZLY ........................................................................ 8 4-8-2 REMOVING GRIZZLY TAILINGS...................................................................................................... 8 SECTION 5 OPERATIONS SECTION 5 OPERATIONS......................................................................................................................... 1 5-3-1 PRE-START CHECKLIST ................................................................................................................. 3 Engine Compartment:................................................................................................................................ 3 Hopper, Grid Bars, and Feeder Belt .......................................................................................................... 3 Main Conveyor........................................................................................................................................... 3 Screen Box ................................................................................................................................................ 3 Side / Product Conveyors.......................................................................................................................... 3 5-4-1 ENGINE START UP .......................................................................................................................... 4 5-5-1 ENGAGING HYDRAULICS ............................................................................................................... 5 Startup/Shutdown ...................................................................................................................................... 5 5-5-2 HYDRAULIC STARTUP PROCEDURE ............................................................................................ 5 5-6-1 DAILY OPERATIONAL CHECKS...................................................................................................... 6 5-6-2 SHUTDOWN PROCEDURE............................................................................................................. 6 5-7-1 EMERGENCY SHUTDOWN ............................................................................................................ 7 5-7-2 CONTROL PANEL ........................................................................................................................... 7 5-7-3 FUNCTION ACTIVATION INDICATORS ......................................................................................... 7 5-8-1 HOUR METER................................................................................................................................... 8 5-8-2 WORK LAMP TOGGLE SWITCH ..................................................................................................... 8 5-8-3 FEEDER / MAIN TOGGLE SWITCH................................................................................................. 8 5-8-4 GRID ISOLATOR TOGGLE SWITCH ............................................................................................... 8 5-8-5 GRID UP/DOWN TOGGLE SWITCH ................................................................................................ 8 5-9-1 TRACK TOGGLE SWITCH ............................................................................................................... 9 5-9-2 SAFETY WARNING INDICATORS ................................................................................................... 9 5-9-3 SCREEN TOGGLE SWITCH............................................................................................................. 9 5-9-4 TAIL/SIDE TOGGLE SWITCH........................................................................................................... 9 5-9-5 OVERRIDE BUTTON ........................................................................................................................ 9 5-9-6 WIRE REMOTE OUTLET.................................................................................................................. 9 5-10-1 KEY SWITCH ................................................................................................................................ 10 5-10-2 GRID SUB-FRAME OPERATION ................................................................................................. 10 RAISEING THE GRID SUB-FRAME........................................................................................................ 10 LOWERING THE GRID SUB-FRAME ...................................................................................................... 10 5-11-1 GRID DECK MANUALTIPPING FUNCTONS ............................................................................... 11 RAISE........................................................................................................................................................ 11 LOWER ..................................................................................................................................................... 11 5-11-2 GRID DECK REMOTE TIPPING FUNCTIONS............................................................................. 11 UNFOLD.................................................................................................................................................... 13 FOLD......................................................................................................................................................... 13 5-14-1 PRODUCT CONVEYOR ADJUSTMENT ...................................................................................... 14 TO CHANGE THE PRODUCT CONVEYOR ANGLE............................................................................... 14

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5-15-1 SIDE CONVEYOR FOLD HYDRAULICS...................................................................................... 15 UNFOLD.................................................................................................................................................... 15 FOLD......................................................................................................................................................... 15 5-16-1 SIDE CONVEYOR RAISE HYDRAULICS..................................................................................... 16 RAISE........................................................................................................................................................ 16 LOWER ..................................................................................................................................................... 16 5-17-1 SIDE CONVEYOR OPERATING HYDRAULICS .......................................................................... 17 RUN........................................................................................................................................................... 17 OVERS SIDE CONVEYOR SPEED CONTROL .............................................................................................. 17 FASTER .................................................................................................................................................... 17 SLOWER................................................................................................................................................... 17 STOP......................................................................................................................................................... 17 5-18-1 SCREEN ANGLE HYDRAULICS .................................................................................................. 18 RAISE........................................................................................................................................................ 18 LOWER ..................................................................................................................................................... 18 5-19-1 SCREEN DRIVE OPERATING HYDRAULICS ............................................................................. 19 RUN........................................................................................................................................................... 19 STOP......................................................................................................................................................... 19 5-20-1 MAIN CONVEYOR/FEEDER OPERATING HYDRAULICS.......................................................... 20 RUN........................................................................................................................................................... 20 STOP......................................................................................................................................................... 20 5-21-1 SHREDDER OPERATING HYDRAULICS (option)...................................................................... 21 5-22-1 RADIO REMOTE OPERATION .................................................................................................... 22 RADIO TRANSMITTER FUNCTIONS .............................................................................................................. 22 5-22-2 Remote Lock Out Key .................................................................................................................. 22 5-22-3 Indicator Light............................................................................................................................... 22 5-22-4 Track Enable / Dis-Able Start/Stop .............................................................................................. 22 5-23-1 Track Motion Controls. ................................................................................................................. 23 5-24-1 Grid Cycle Start/Stop. .................................................................................................................. 24 5-24-2 Engine Stop.................................................................................................................................. 24 5-24-3 Feeder Belt Start/Stop.................................................................................................................. 24 5-25-1 Battery .......................................................................................................................................... 25 5-25-2 Battery Charger............................................................................................................................ 25 5-26-1 RADIO FREQUENCY CHANGE ................................................................................................... 26 5-27-1 WIRED REMOTE .......................................................................................................................... 27 5-28-1 LOAD/UNLOAD INSTRUCTIONS................................................................................................. 28

SECTION 6 SET-UP SECTION 6 SET-UP ................................................................................................................................... 1 6-2-1 SITE PREPARATION ........................................................................................................................ 2 6-3-1 SCREENING PREPARATION........................................................................................................... 3 Un-Folding ................................................................................................................................................. 3 Folding ....................................................................................................................................................... 3 Motion / Transport .................................................................................................................................. 3 Checks and Adjustments........................................................................................................................... 4 6-5-1 HOPPER SUPPORT LEGS............................................................................................................... 5 EXTEND...................................................................................................................................................... 5 RETRACT ................................................................................................................................................... 5 6-6-1 SIDE CONVEYORS .......................................................................................................................... 6 UNFOLD...................................................................................................................................................... 6 FOLD........................................................................................................................................................... 7 6-8-1 PRODUCT CONVEYOR ................................................................................................................... 8 UNFOLDING FOR SCREENING OPERATION.......................................................................................... 8 FOLDING .................................................................................................................................................... 9

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6-10-1 MAIN CONVEYOR ........................................................................................................................ 10 RAISE/LOWER ..........................................................................................................................................10 6-11-1 GRID DECK ................................................................................................................................... 11 SET-UP for operation ................................................................................................................................ 11 LOWER for transport................................................................................................................................. 11 6-12-1 CATWALK PLATFORMS .............................................................................................................. 12 SET-UP ..................................................................................................................................................... 12 6-13-1 SCREEN ANGLE........................................................................................................................... 13 RAISE........................................................................................................................................................ 13 LOWER ..................................................................................................................................................... 13

SECTION 7 TRANSPORT SECTION 7 TRANSPORT .......................................................................................................................... 1 7-2-1 Unloading The ST356........................................................................................................................ 2 7-2-2 ST356 – Motion instructions .............................................................................................................. 2 7-4-1 Site Preparation ................................................................................................................................. 4 7-5-1 Preparing for Transport...................................................................................................................... 5 SECTION 8 MAINTENANCE SECTION 8 MAINTENANCE ...................................................................................................................... 1 8-3-1 MAINTENANCE SCHEDULING ........................................................................................................ 3 8-5-1 FILTERS ............................................................................................................................................ 5 8-5-2 CAPACITIES...................................................................................................................................... 5 8-5-3 LUBRICANTS .................................................................................................................................... 5 8-5-4 SCREEN BEARINGS GREASE ........................................................................................................ 5 8-5-4 PILLOW BLOCK BEARINGS ............................................................................................................ 5 8-6-1 ENGINE OIL VISCOSITY .................................................................................................................. 6 8-6-2 ENGINE MAINTENANCE.................................................................................................................. 6 8-6-3 CHECK ENGINE OIL LEVEL ............................................................................................................ 6 8-6-4 REPLACE ENGINE OIL AND FILTER .............................................................................................. 6 8-7-1 CHECK AIR FILTER RESTRICTION INDICATOR ........................................................................... 7 8-7-2 REPLACE AIR FILTER ELEMENT ................................................................................................... 7 8-7-3 CHECK DIESEL FUEL LINES AND FITTINGS................................................................................. 7 8-7-4 REPLACE FUEL FILTER ELEMENT ................................................................................................ 7 8-8-1 FUEL PRE-FILTER / WATER TRAP................................................................................................. 8 8-8-2 BLEEDING THE FUEL SYSTEM ...................................................................................................... 8 8-8-3 COOLING SYSTEM MAINTENANCE ............................................................................................... 8 8-8-4 CHECK V-BELTS .............................................................................................................................. 8 8-8-5 PERFORM ENGINE TUNE UP ......................................................................................................... 8 8-8-6 CHECK VALVE CLEARANCE........................................................................................................... 8 8-8-7 CHECK TIMING BELT....................................................................................................................... 8 8-9-1 SERVICE THE BATTERY ................................................................................................................. 9 8-9-2 CHECK HYDRAULIC OIL LINES AND FITTINGS ............................................................................ 9 8-9-3 CHECK HYDRAULIC OIL LEVEL ..................................................................................................... 9 8-9-4 RETURN FILTER REPLACEMENT .................................................................................................. 9 8-10-1 SUCTION FILTER REPLACEMENT ............................................................................................. 10 8-10-2 BLEEDING HYDRAULIC OIL SYSTEM ........................................................................................ 10 8-10-3 REPLACE THE HYDRAULIC OIL ................................................................................................. 10

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8-11-1 HYDRAULIC TROUBLESHOOTING............................................................................................. 11 Pump cavitates ........................................................................................................................................ 11 Pump over-pressurized ........................................................................................................................... 11 Pump flow appears inadequate or non-existent ...................................................................................... 11 Moving parts on or connected to the machine slow down ...................................................................... 11 Hydraulic pipes burst ............................................................................................................................... 11 8-12-1 HOPPER, GRIZZLY BARS AND FEEDER BELT MAINTENANCE.............................................. 12 8-12-2 REMOTE CONTROL FOR GRIZZLY BAR OPERATION ............................................................. 12 8-12-3 FEEDER BELTGEAR BOX MAINTENANCE ................................................................................ 12 8-13-1 CONVEYOR TROUBLE SHOOTING............................................................................................ 13 Oblique travel........................................................................................................................................... 13 Belt tracking ............................................................................................................................................. 13 8-14-1 CONVEYOR MAINTENANCE ....................................................................................................... 14 8-14-2 CONVEYOR BELT OBLIQUE ALIGNMENT ................................................................................. 14 8-15-1 CONVEYOR BELT TRACKING ALIGNMENT .............................................................................. 15 8-16-1 CONVEYOR BELT TENSIONING................................................................................................. 16 8-17-1 SCREEN MAINTENANCE............................................................................................................. 17 8-18-1 SCREEN BOX SPEED ADJUSTMENT......................................................................................... 18 8-19-1 THROTTLE SET ............................................................................................................................ 19 8-20-1 SCREEN MESH CHANGE ............................................................................................................ 20 Handling of meshes:................................................................................................................................ 20 Tools & Equipment required: ................................................................................................................... 20 Changing the meshes:............................................................................................................................. 20 8-21-1 Preparation for screen change ...................................................................................................... 21 8-22-1 Mesh Removal – FEED END......................................................................................................... 22 Un-clamping the Screen mesh: ............................................................................................................... 22 Taking the mesh out: ............................................................................................................................... 22 8-22-1 Mesh replacement - FEED END.................................................................................................... 23 8-23-1 Mesh removal – DISCHARGE END .............................................................................................. 24 Un-clamping the Screen mesh: ............................................................................................................... 24 Taking the mesh out: ............................................................................................................................... 25 8-26-1 Mesh replacement – DISCHARGE END ....................................................................................... 26 8-26-2 HYDRAULIC SCREEN TENSIONING .......................................................................................... 28 8-21-3 SPHERICAL ROLLER BEARING REPLACEMENT ..................................................................... 29

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Operator's Manual INTRODUCTION Table of contents

SECTION 1 INTRODUCTION

SECTION 1 INTRODUCTION...................................................................................................................... 1

1-1-1 INTRODUCTION ................................................................................................................................ 1

1-2-2 RELATED PUBLICATIONS ............................................................................................................... 2

1-3-1 DEALER AND MANUFACTURER ASSISTANCE.............................................................................. 3 •

Deutz Engines........................................................................................................................................... 3

•

Crawler Track Systems Ltd....................................................................................................................... 3

•

Hetronic Controls ...................................................................................................................................... 3

•

Sauer Danfoss .......................................................................................................................................... 3

•

Mannesmann Rexroth .............................................................................................................................. 3 1-4-2 WARRANTY ...................................................................................................................................... 4

•

DEUTZ ...................................................................................................................................................... 4

•

CRAWLER TRACK SYSTEMS LTD. ....................................................................................................... 4

•

HETRONIC CONTROLS .......................................................................................................................... 4

1-1-1 INTRODUCTION

This manual is organized by sections to familiarize you with the Metso ST356, its use, care, and most importantly, with safe setup and operating practices. •

SECTION 1 – INTRODUCTION: Describes the manual organization, related publications, and information on dealer/manufacturer assistance and the equipment warranty.

•

SECTION 2 – SAFETY: Describes safety procedures, identifies and describes the safety labels found in various locations on the machine.

•

SECTION 3 – MAIN CONPONENTS: Describes General identification of components, specifications and valve control stations.

•

SECTION 4 – APPLICATIONS Describes screen types, combinations, production, efficiency and site preparation.

•

SECTION 5 – OPERATION: Describes the detail procedures for engine start-up/shut-down and hydraulic and remote operating controls.

•

SECTION 6 – SET-UP: Describes fold and unfolding procedures for safe machine operation.

•

SECTION 7 – TRANSPORTING: Describes the detail procedures for preparing the ST356 for operations and relocation to another site or for moving the machine within a site.

•

SECTION 8 – MAINTENANCE: Describes maintenance scheduling and the procedures for routine service required keeping your machine operating safely and efficiently.

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Operator's Manual INTRODUCTION

1-2-2 RELATED

PUBLICATIONS

Your Metso ST356 is equipped with quality components including; Diesel engine manufactured by DEUTZ and Crawler tracks manufactured by CRAWLER TRACK SYSTEMS LTD. A division of the STRICKLAND group. These components have their own Parts, Maintenance and operations manuals. Detailed engine and track service procedures are beyond the scope of the Metso parts and operators manual and are contained in the related publications. IE: DEUTZ ENGINE manuals and CRAWLER TRACK SYSTEMS LTD. manuals. Metso ST356 spare part identifications are contained in the Metso ST356 Spare Parts Manual. The manuals available are:

TITLE DEUTZ Operation Manual (1013C) DEUTZ Spare parts catalogue (BFM1013) ST356 Operators Manual ST356 Parts Manual HETRONIC Radio operation manual NBB Radio operation manual DANFOSS PVG 32 Proportional valve service manual CRAWLER TRACK SYSTEMS LTD. Parts & Service

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1-3-1 DEALER AND MANUFACTURER ASSISTANCE

Metso encourages you to discuss with your dealer or directly with Metso any aspect of the machine or its applications. The production efficiency of your operation depends to a great extent on selecting the proper type of screens for a given application. We are happy to share our experiences with you. To find a dealer near you, visit; http://www.metsominerals.com/ then click on contact us, and find the distributors for your area. Component information: • Deutz Engines To find a dealer near you, visit the Deutz web site at: http://www.deutz.de/framee.htm and click on “Deutz world wide” and pick the continent, country and state you are located. •

Crawler Track Systems Ltd Crawler Track Systems Limited The Heath Works Evesham Road Cropthorne, Pershore Worcs. WR10 3JU Tel no. (+44) 0990 872257 Fax no. (+44) 01386 860057 E-Mail [email protected]

•

Hetronic Controls

To find a dealer near you, visit; http://www.hetronic.com/hetronic/hetronic.nsf/pages/index1 Dealers located in: EUROPE SOUTH ASIA AMERICA NORTH AUSTRAILIA AMERICA OCEANIA

•

Sauer Danfoss

To find a dealer near you, visit the Sauder-Danfoss web site at: http://www.sauer-

danfoss.com/Distributor/index.html Sauer – Danfoss (US) Company 2800 East 13th Street Ames, IA 50010 USA Tel no. +1 515 239 6000 Fax no. +1 515 239 6618 •

Sauer – Danfoss (Neumunster) Gmbh & Co. OHG Postfash 2460, D-24531 Neumunster Krokamp 35, D24539 Neumunster, Germany Telefon: +49 4321871-0 Telefax: +49 4321 871-122

Mannesmann Rexroth

To find a dealer near you visit; http://www.bru-hyd.com/indexlocation.e.htm Mannesmann Rexroth Corp. 2 Prudential Plaza 180 N. Stetson Avenue, Suite 3000 USA-Chicago, IL 60601 Telefon +1 (312) 297-4100 Telefax +1 (312) 861-0566 Email: [email protected]

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Bosch Rexroth AG Industrial Hydraulics Postfach 97813 Lohr am Main Zum Eisengießer 1 97816 Lohr am Main Telefon: +49 (9352) 18-0 Fax: +49 (9352) 18-39 72

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1-4-2

WARRANTY

For complete Metso limited warranty coverage information consult with your local Metso representative. •

DEUTZ

Deutz engines carry a manufacturer separate limited warranty. Warranty issues on DEUTZ components should be submitted to the local Deutz dealer. •

CRAWLER TRACK SYSTEMS LTD.

Carries a manufacturers separate limited warranty. Warranty issues on Crawler track system components should be submitted to the local dealer or contact: Crawler Track Systems Limited The Heath Works Evesham Road Cropthorne, Pershore Worcs. UK WR10 3JU Tel no. (+44) 0990 872257 Fax no. (+44) 01386 860057 E-Mail [email protected] •

HETRONIC CONTROLS

Warranty considerations solely held by HETRONIC. Return and inspection may be required. Warranty validity is based on regular inspection and cleaning of the radio control equipment.

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Operator's Manual SAFETY Table of contents

SECTION 2 - SAFETY

SECTION 2 - SAFETY ................................................................................................................................. 1

2-2-1 UNDERSTAND SIGNAL WORDS...................................................................................................... 2

2-2-2 FOLLOW SAFETY INSTRUCTIONS.................................................................................................. 2

2-2-3 LEARN MACHINE SAFETY ............................................................................................................... 2

2-3-1 AVOID FALLING OBJECTS ............................................................................................................... 3

2-3-2 AVOID MOVING PARTS .................................................................................................................... 3

2-3-3 MAINTENANCE SAFETY................................................................................................................... 3

2-3-4 WEAR PROTECTIVE CLOTHING ..................................................................................................... 3

2-4-1 PREPARE FOR EMERGENCIES ...................................................................................................... 4

2-4-2 PROTECT AGAINST NOISE.............................................................................................................. 4

2-4-3 HANDLE FUEL SAFELY - AVOID FIRES .......................................................................................... 4

2-4-4 AVOID HIGH-PRESSURE FLUIDS.................................................................................................... 4

2-5-1 PREVENT BATTERY EXPLOSIONS ................................................................................................. 5

2-5-2 AVOID ACID BURNS.......................................................................................................................... 5

2-5-3 DISPOSE OF WASTE PROPERLY ................................................................................................... 5

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Operator's Manual SAFETY

The Nordberg ST356 is a powerful machine designed to perform demanding tasks in the safest possible manner. However, misuse or failure to follow the operating, maintenance or safety procedures found in the manual could result in injury or damage.

2-2-1 UNDERSTAND SIGNAL WORDS

Signal words DANGER WARNING CAUTION are used to identify hazards.

DANGER

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING CAUTION

WARNING: Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates an imminently hazardous situation which, if not avoided, may result in death or serious injury.

2-2-2 FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and on your machine. Follow recommended precautions and safe operating practices. Keep safety signs in good condition. Replace missing or damaged safety signs.

2-2-3 LEARN MACHINE SAFETY

Carefully read this manual. Learn how to operate the machine and how to use its controls properly. Do not let anyone operate this machine without proper instruction. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

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2-3-1 AVOID FALLING OBJECTS

Keep well clear of screens and conveyors in motion.

2-3-2 AVOID MOVING PARTS

Moving conveyors have the potential hazard of entanglement caused by items such as loose clothing, long hair and jewelry.

2-3-3 MAINTENANCE SAFETY

DO NOT attempt to lubricate moving conveyors. DO NOT adjust or perform any maintenance when conveyor is in motion. If maintenance can only be done while the machine is in motion, only qualified and trained personnel who are aware of the hazard of the conveyor in motion shall be allowed to perform maintenance.

2-3-4 WEAR PROTECTIVE CLOTHING

Avoid loose fitting clothing that could become tangled in machine. Always use appropriate safety equipment and wear your personal protective clothing.

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2-4-1 PREPARE FOR EMERGENCIES

Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

2-4-2 PROTECT AGAINST NOISE

Prolonged exposure to loud noises can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

2-4-3 HANDLE FUEL SAFELY - AVOID FIRES

Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop the engine before refueling the machine. Fill fuel tank outdoors, or in well ventilated areas. Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

2-4-4 AVOID HIGH-PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles that eject fluid under high pressure. Use a piece of cardboard or paper to search for leaks. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

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2-5-1 PREVENT BATTERY EXPLOSIONS

Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove the grounded (-) battery clamp first and replace it last.

2-5-2 AVOID ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothes, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoid breathing fumes when electrolyte is added. 4. Avoid spilling or dripping electrolyte.

2-5-3 DISPOSE OF WASTE PROPERLY

Improperly disposed waste can threaten the environment and ecology. Potentially harmful waste includes items such as oil, fuel, coolant, filters and batteries. Use leak proof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Inquire on the proper way to dispose of waste from your local environmental agency. Do not pour waste onto the ground, down a drain, or into any water source.

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Operator's Manual MAIN COMPONENTS Table of contents

SECTION 3 MAIN COMPONENTS

SECTION 3 MAIN COMPONENTS.............................................................................................................. 1 3-2-1 IDENTIFICATION AND SPECIFICATIONS........................................................................................ 2 Conveyors................................................................................................................................................. 2 3-3-1 IDENTIFICATION AND SPECIFICATION .......................................................................................... 3 Hopper ...................................................................................................................................................... 3 Screen-Box ............................................................................................................................................... 3 3-4-1 IDENTIFICATION AND SPECIFICATION .......................................................................................... 4 Main Dimensions, Transport..................................................................................................................... 4 Shipping Specifications ............................................................................................................................ 4 Power Pack (Engine / Motor).................................................................................................................... 4 Tanks ........................................................................................................................................................ 4 3-5-1 IDENTIFICATION AND SPECIFICATION .......................................................................................... 5 Crawler Tracks.......................................................................................................................................... 5 3-6-1 VALVE PLACEMENT ......................................................................................................................... 6

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Operator's Manual MAIN COMPONENTS

1 5

2

3

4

6 1. Main conveyor 2. Side Conveyors 3. Product conveyor 4. Hopper and feeder assy. 5. Screen-box and subframe 6. Chassis 7. Power pack and Tanks 8. Track assy.

7

8

3-2-1 IDENTIFICATION AND SPECIFICATIONS 1

2

3

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Conveyors

English

Metric

Main Conveyor Height (Ctr) Main Conveyor Angle Main Conveyor Speed

16’-9” 22 deg 325 ft/min

5.1 m 22 deg 99 m/min

Wing Conveyor Width Wing Conveyor Height (Ctr) Wing Conveyor Angle Wing Conveyor Speed #1 (Var) Wing Conveyor Speed #1 (Fixed)

26” 13’-5” 15° To 25° 0-279 ft/min 279 ft/min

650 mm 4.1 m 15° To 25° 0-85 m/min 85 m/min

Product Conveyor Width Product Conveyor Height (Ctr) Product Conveyor Angle Product Conveyor Speed

40” 17’-5” 6° To 23° 395 ft/min

1000 mm 5.3 m 6° To 23° 120 m/min

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3-3-1 IDENTIFICATION AND SPECIFICATION 4

Hopper Feed Conveyor Width Feed Conveyor Speed Hopper capacity Hopper loading width Hopper loading height Grid deck area Grid spacing: 5” Std. 4” and 6” are optional

English 48” 0-81 ft/min 11.1 cu. yd. 14'-6" 13'-11" 92 sq. ft.

Metric 1200mm 0-25m/min 8.4 cu. m. 4.4 m 4.2 m 8.4 sq. m.

5

Screen-Box Screen-box Size Nominal Screen Area: Length Width Screen Angle:

English 16’x5’

Metric 4.8m x 1.5m

160 sq ft 16’ 5’ 15 to 25 degrees 2

10.2 sq m 4.8m 1.5m

Number of decks: Screen Speed (Shaft): 950 ± 25 rpm Top Deck Accepts: Square mesh, harpwire, “Z” wire, rubber decks Bottom Deck Accepts: Square mesh, harpwire, “Z” wire, rubber decks Tensioning: End to End Deck Aperture: Upper Up to 3” 75mm Lower .078” 2mm Screen Eccentric (Circle .283in (7.2mm) Size): Bearings: 2

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ST356



Main Dimensions, Operation (working; with standard equipment) Length: Width: Height:

English 65'-0" 46'-7" 18'-4"

Metric 19.8 m 14.2 m 5.6 m

Main Dimensions, Transport English (folded; with standard equipment) Length: Width: Height:

54'-3" 9'-6” 10'-9"

Metric 16.3 m 2.9 m 3.3 m

Shipping Specifications English Metric Overall Width 9’6" 2.9 m Overall Length 54'-3" 16.3 m Overall Weight 60,000 lbs. 27,200 kgs Options weights Shredder Vibrating grid deck Side walkways 1760 lbs. 800 kgs Accurate manufactured weight found on specific machines Serial # tag.

7

REV. C

Power Pack (Engine / Motor) English Metric Standard Manufacturer / Model: Deutz, BF4M1013C Type / # Cylinders: Turbo charged, Liquid Cooled, 4 Cyl, Diesel Power @ Operating RPM 148 hp @ 2050 110 kw @ 2050 Fuel Consumption Rate 75% load 3.5 75% load 13.4 (Base Config) gph lph Operational Speed 2050 rpm 2050 rpm Idle Speed 650 rpm 650 rpm Tanks English Metric Hydraulic, volume 153 Gal 580 liters Fuel, volume 79 Gal 300 liters

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ST356



REV. C

Crawler Tracks English Metric Standard Manufacturer / Model: Crawler Track Systems LTD. Strickland Group Type : Single speed / Hydraulic drive /triple grouser steel shoe 3280mm (nominal) Track pitch length 10’-9” 4025mm (nominal) Track OAL 13’2 ½” Track height OAL (Base Config) 30 ½” 777mm Track width 15 ¾” 400mm Approx. operational speed 1 mph 1.6 km/h Grade ability 25 degrees 25 degrees Ground pressure 15 Psi 10548 kg/m

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ST356

3-6-1 VALVE PLACEMENT

Screen Angle Raise Lower

Main Conveyor Raise Lower

Product Conveyor Unfold Fold

2

1

3. Top deck side conveyor Fold / Unfold and Raise / Lower. Hopper support legs Raise / Lower

REV. C

Sid eC Lo we o n v e y r or Ra ise

2. Main conveyor Raise / Lower Product Conveyor Fold / Unfold Screen Angle

Ho p Lo per s we up por r Ra t le ise gs

r eyo onv eC Sid e s i Ra e r r eyo Low onv eC Sid d Fol old f Un

Valve location 1. Second deck side conveyor Raise / Lower and Fold / Unfold.

Sid eC Un fold onve yor Fo ld


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ST356

Operator's Manual APPLICATIONS Table of contents

SECTION 4 APPLICATIONS

SECTION 4 APPLICATIONS....................................................................................................................... 1

4-2-1 MATERIALS MACHINE IS CAPABLE OF PROCESSING ................................................................ 2

4-3-1 SITE PREPARATION......................................................................................................................... 3

4-3-2 OPERATING TECHNIQUES.............................................................................................................. 3

4-4-1 SCREEN MESH SELECTION............................................................................................................ 4

4-4-2 SCREEN SPEED ............................................................................................................................... 4

4-5-1 SCREEN ANGLE SELECTION.......................................................................................................... 5

4-6-1 DIVERTER PLATE ADJUSTMENT .................................................................................................. 6

4-7-1 SHREDDER-HAMMERMILL APPLICATIONS................................................................................... 7

4-8-1 EFFICIENT LOADING OF THE HOPPER/GRID ............................................................................... 8

4-8-2 REMOVING GRID TAILINGS ............................................................................................................ 8

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ST356

Operator's Manual APPLICATIONS

The METSO ST356 is a hydraulically operated portable screening plant capable of producing a wide range of product sizes. The two bearing, two deck screen box can be equipped with various screen size combinations to produce sized product down to 1 mm while maintaining high productivity levels. Raw material is fed onto a variable speed belt feeder through a tapered grid deck, which rejects oversized material. The feeder belt delivers the material onto the main conveyor and then to the screen box where separation and sizing takes places. The separated products are stockpiled via a product conveyor and two side conveyors

4-2-1 MATERIALS MACHINE IS CAPABLE OF PROCESSING

The ST356 can be used for screening and sizing the following materials: •

Sand

•

Clay

•

Gravel

•

Iron ore

•

Granite

•

Top soil

•

Limestone

•

Slag

•

Sandstone

•

Concrete Debris

•

Coal

•

Grain

For screening requirement not listed above, contact your authorized METSO Distributor for assistance.

Note: The performance of the ST356 can vary depending on the type and moisture content of the raw feed material. It may be required that you contact your local authorized Metso distributor for guidance on your specific application.

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4-3-1 SITE PREPARATION Proper site preparation and machine placement will provide a safe, efficient atmosphere conducive to high productivity. The following site preparations procedures are recommended: •

Select an area with adequate clearance around the machine

•

Place the METSO ST356 as close to the raw material stockpile as possible

•

Position the machine on a firm, level foundation

•

Ensure that no hazards to operation are present

The ST356 is designed to be supported on the hydraulic hopper support legs. It is recommended that the ST356 be level in both longitudinal and lateral planes.

4-3-2 OPERATING TECHNIQUES

To achieve maximum efficiency and production from the ST356, a number of factors should be considered: •

Screen size

•

Screen angle

•

Feeder belt speed adjustment

•

Main conveyor diverter plate adjustment

•

Main conveyor height above screen

•

Overs side conveyor speed adjustment

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ST356


4-4-1 SCREEN MESH SELECTION

Selecting the proper screen media, type and appature is the most important factor influencing production efficiency. Choosing the correct screen size can influence production output by as much as 50%. If the majority of product is sliding off the top deck, a larger top deck opening should be considered. This is especially true for sticky material such as clay and wet topsoil. However, a top deck screen size that is too large for the bottom deck size will cause a similar situation at the second deck where an excessive amount of desired product fails to pass through the bottom screen. The usual method of choosing screen sizes is to select the bottom screen opening based on final size requirements and then choose a top screen that adequately protects the bottom deck while not allowing excessive runoff. As a means of example refer to the following illustration.

TOP MESH TOO SMALL

TOP MESH TOO LARGE

TOP MESH CORRECT

If production problems are encountered and an alternate screen combination is believed to be required, contact your local authorized METSO Distributor.

4-4-2 SCREEN SPEED

The screen speed of the ST356 is factory set. Adjustment may be required overtime. See: Section 6 of this manual. Overloading can cause a reduction in screen speed. If the screen is not overloaded and a reduction in screen speed is noticed, the screen has experienced either a hydraulic or mechanical malfunction, which should be corrected immediately. Over-speed can cause structural fatigue and damage. See: Section 6 for correct operational speeds. NOTE : When hydraulic fluid reaches normal operating temperature, there may be a fluctuation in screen speed of 50-100 rpm.

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ST356


4-5-1 SCREEN ANGLE SELECTION

Proper screen angle is determined by the nature of the material being screened and the size of the screens being used. Steeper screen angles minimize the amount of time the material spends on the screen. A material that requires more time on the screen to separate will require a shallower screen angle than a material, such as dry sand or loose gravel, which separates easily. Square mesh screens generally require a shallower screen angle than a slotted screen. A harp wire screen requires a very steep angle. Choosing the correct screen angle can greatly improve production. The screen angle of the METSO ST356 is adjustable from 15 to 25 degrees. As a general rule, the following screen angles are recommended for the listed square aperture size:

APERTURE

SCREEN ANGLE

-3/4”

25 deg.

+3/4” - 3”

20 deg.

+2” -3”

15 deg.

Slotted wire generally requires a steep screen angle (20 degrees or greater) depending on the nature of the material to be screened. Harp wire requires a very steep angle, generally 25 degrees to achieve high production rates. Harp wire screens “cut” through material, acting more like knife-edges than a screen, hence the need for steep screen angles. NOTE: Changing the screen angle requires removal of trestle pins and adjustment of trestles. (Refer to Section 4, Operations for adjustment details).

25° Approximate 22° screen angles 20° 171/2°

Product Conveyor Fold Unfold

Screen / Main trestle

Main Conv./Screen Lower Raise


15°

Adjusting holes Screen angle trestle pin (transport position)

Valve bank

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ST356


4-6-1 DIVERTER

PLATE ADJUSTMENT

The diverter plate should be adjusted to distribute the material across the full width of the feed box just before it reaches the screen. This adjustment permits full use of the available screen area while distributing the material across the full width of the screen box. Diverter plate adjustments are necessary when: •

The screen angle is adjusted.

•

Main conveyor angle is adjusted

•

Minor adjustments to improve screening capacity.

Whenever the screen angle or main conveyor is adjusted, the diverter plate position should be checked. If the screen angle is adjusted to a very low angle it may be necessary to lower the feed plate to the low position. All adjustments are made at the diverter plate mount. NOTE: Changing screen angle requires checking adjustment of diverter plate. Operations for adjustment details.

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Refer to Section 4,

4-6

ST356


4-7-1 SHREDDER-HAMMERMILL APPLICATIONS

The METSO ST356 may be equipped with an optional hammermill type shredder which is used to process agglomerations of topsoil, peat and similar material. The shredder-hammermill is equipped with a variable speed drive feature enabling the operator to match the shredder-hammermill shaft speed to the characteristics of material being screened. To produce a fine grade of material: •

Increase shredder-hammermill shaft speed to maximum.

•

Decrease feed belt speed to optimize efficiency.

To produce a coarse grade of material: •

Decrease shredder-hammermill shaft speed

•

Increase feeder belt speed to flood the shredder-hammermill chamber with material.

When the shredder-hammermill is not required the shaft must be stopped and the assembly lifted and stowed via the supplied lift cylinder chain (for a single shaft shredder) or the shredder lift trestle assembly (for the dual shaft shredder). (Refer to Section 4, Operations ). DANGER: SHREDDER-HAMMERMILL SHOULD NEVER BE RUN IN THE RAISED POSITION AS EXTREME DANGER WILL RESULT TO THE OPERATOR OR PERSONS NEARBY FROM MATERIAL EXITING FROM THE SHREDDER-HAMMERMILL CHAMBER. IMPORTANT: DO NOT RUN THE SHREDDER-HAMMERMILL WHEN PROCESSING STONE OR SAND AS EXCESSIVE WEAR TO THE HAMMERS AND INTERNAL ROTATING MEMBERS WILL RESULT.

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ST356


4-8-1 EFFICIENT LOADING OF THE HOPPER/GRID

There are a few considerations to keep in mind when feeding material onto the hopper/Grid section of the METSO ST356. To avoid damage to the hopper section, material should never be dropped from a high bucket angle onto the Grid section. Material should be “rolled” onto the Grid section from as low an angle as possible allowing the material to slide off the hopper feed plate and across the Grid section for classification.

4-8-2 REMOVING GRID TAILINGS

The oversized material from the Grid bars should not be allowed to accumulate above the underside of the feeder belt guard doors. To remove, push the tailings with the loader by coming along side of the ST356. Do not charge the ST356 broadside, using the ST356 as a backstop.

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ST356

Operator's Manual OPERATIONS Table of contents

SECTION 5 OPERATIONS

SECTION 5 OPERATIONS.......................................................................................................................... 1

5-3-1 PRE-START CHECKLIST .................................................................................................................. 3 Engine Compartment: .................................................................................................................................. 3 Hopper, Grid Bars, and Feeder Belt............................................................................................................. 3 Main Conveyor ............................................................................................................................................. 3 Screen Box ................................................................................................................................................... 3 Side / Product Conveyors............................................................................................................................. 3

5-4-1 ENGINE START UP ........................................................................................................................... 4

5-5-1 ENGAGING HYDRAULICS ................................................................................................................ 5 Startup/Shutdown ......................................................................................................................................... 5

5-5-2 HYDRAULIC STARTUP PROCEDURE ............................................................................................. 5

5-6-1 DAILY OPERATIONAL CHECKS....................................................................................................... 6

5-6-2 SHUTDOWN PROCEDURE.............................................................................................................. 6

5-7-1 EMERGENCY SHUTDOWN ............................................................................................................. 7

5-7-2 CONTROL PANEL ............................................................................................................................. 7

5-7-3 FUNCTION ACTIVATION INDICATORS .......................................................................................... 7

5-8-1 HOUR METER.................................................................................................................................... 8

5-8-2 WORK LAMP TOGGLE SWITCH....................................................................................................... 8

5-8-3 FEEDER / MAIN TOGGLE SWITCH .................................................................................................. 8

5-8-4 GRID ISOLATOR TOGGLE SWITCH ................................................................................................ 8

5-8-5 GRID UP/DOWN TOGGLE SWITCH ................................................................................................. 8

5-9-1 TRACK TOGGLE SWITCH................................................................................................................. 9

5-9-2 SAFETY WARNING INDICATORS .................................................................................................... 9

5-9-3 SCREEN TOGGLE SWITCH.............................................................................................................. 9

5-9-4 TAIL/SIDE TOGGLE SWITCH............................................................................................................ 9

5-9-5 OVERRIDE BUTTON ......................................................................................................................... 9

5-9-6 WIRE REMOTE OUTLET ................................................................................................................... 9

5-10-1 KEY SWITCH.................................................................................................................................. 10

5-10-2 GRID SUB-FRAME OPERATION .................................................................................................. 10 RAISEING THE GRID SUB-FRAME ............................................................................................................ 10 LOWERING THE GRID SUB-FRAME ........................................................................................................... 10

5-11-1 GRID DECK MANUAL TIPPING FUNCTONS ............................................................................... 11 RAISE............................................................................................................................................................. 11 LOWER .......................................................................................................................................................... 11

5-11-2 GRID DECK REMOTE TIPPING FUNCTIONS.............................................................................. 11 UNFOLD ........................................................................................................................................................ 13 FOLD.............................................................................................................................................................. 13

5-14-1 PRODUCT CONVEYOR ADJUSTMENT ....................................................................................... 14 TO CHANGE THE PRODUCT CONVEYOR ANGLE ................................................................................... 14

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ST356

Operator's Manual OPERATIONS

5-15-1 SIDE CONVEYOR FOLD HYDRAULICS ....................................................................................... 15 UNFOLD ........................................................................................................................................................ 15 FOLD.............................................................................................................................................................. 15

5-16-1 SIDE CONVEYOR RAISE HYDRAULICS...................................................................................... 16 RAISE............................................................................................................................................................. 16 LOWER .......................................................................................................................................................... 16

5-17-1 SIDE CONVEYOR OPERATING HYDRAULICS ........................................................................... 17 RUN................................................................................................................................................................ 17 TOP DECK SIDE CONVEYOR SPEED CONTROL...................................................................................... 17 FASTER ..................................................................................................................................................... 17 SLOWER .................................................................................................................................................... 17 STOP .......................................................................................................................................................... 17

5-18-1 SCREEN ANGLE HYDRAULICS ................................................................................................... 18 RAISE............................................................................................................................................................. 18 LOWER .......................................................................................................................................................... 18

5-19-1 SCREEN DRIVE OPERATING HYDRAULICS .............................................................................. 19 RUN................................................................................................................................................................ 19 STOP.............................................................................................................................................................. 19

5-20-1 MAIN CONVEYOR/FEEDER OPERATING HYDRAULICS ........................................................... 20 RUN................................................................................................................................................................ 20 STOP.............................................................................................................................................................. 20

5-21-1 SHREDDER OPERATING HYDRAULICS (option)....................................................................... 21

5-22-1 RADIO REMOTE OPERATION ............................................................................................................. 22 RADIO TRANSMITTER FUNCTIONS ........................................................................................................... 22 5-22-2 Remote Lock Out Key..................................................................................................................... 22 5-22-3 Indicator Light ................................................................................................................................. 22 5-22-4 Track Enable / Dis-Able Start/Stop ................................................................................................. 22 5-23-1 Track Motion Controls..................................................................................................................... 23 5-24-1 Grid Cycle Start/Stop. ..................................................................................................................... 24 5-24-2 Engine Stop. ................................................................................................................................... 24 5-24-3 Feeder Belt Start/Stop .................................................................................................................... 24 5-25-1 Battery............................................................................................................................................. 25 5-25-2 Battery Charger............................................................................................................................... 25

5-26-1 RADIO FREQUENCY CHANGE .................................................................................................... 26

5-27-1 WIRED REMOTE............................................................................................................................ 27

5-28-1 LOAD/UNLOAD INSTRUCTIONS .................................................................................................. 28

This page contains links for computer users. Click on desired page number to view information.

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5-2

ST356


Before operating your Nordberg ST356 a few DAILY PRE-START CHECKS and DAILY OPERATIONAL CHECKS are necessary. Read and perform the necessary checks before you begin screening. Some of these checks are actually preventive maintenance. They are listed in the following text because they must be performed on a DAILY basis. In addition to the daily checks, there are other scheduled maintenance tasks required at intervals specified in Section 6, Service. CAUTION: BE SURE THE OPERATOR HAS READ THIS MANUAL AND UNDERSTANDS ALL OPERATION AND SAFETY PROCEDURES

5-3-1 PRE-START CHECKLIST

1. Perform the following checks. 2. Check the hour meter for any scheduled maintenance tasks that may be required. Hydraulic motor mounting hardware secure • Engine Compartment: Bulges or leaks in hydraulic hoses • Engine fluid levels (oil & coolant ) • •

Air cleaner duct and mounting hardware secure

•

•

Air filter restriction indicator

•

•

Top and bottom screens clear of debris

Diesel fuel & hydraulic oil levels

•

•

Fuel lines secure & no leaks

Top and bottom screens for wear or damage

•

Hydraulic hoses for bulges or leaks

•

•

Verify that the hydraulic shut off valves are open

Top and bottom screens, clamps, and hardware properly tensioned

•

Wear or damage to channel rubber

•

Condition of the screen box springs

•

Screen is properly seated on the springs

•

Counterweight guards in place and secure

•

Top deck chutes secure

•

Screen box angling trestle sleeves set with pins and clips secure

•

Screen box bearing assembly hardware secure

•

Hydraulic motor mounting hardware secure

•

Bulges or leaks in hydraulic hoses

• •

Screen Box

Verify that all hydraulic controls are in the neutral or stop position Hydraulic oil coolers are clear of debris Hopper, Grid Bars, and Feeder Belt

•

Hopper support legs are set and machine is level

•

Grid bars are clear of debris

•

Grid support frame raised in operation position and pinned

•

All guards & doors are in place and secure

•

Feeder belt is clear of debris

•

Condition and tension of feeder belt and skirt rubbers Main Conveyor

Target plate secure and adjusted.

Side / Product Conveyors •

Tail drum area clear of debris

•

All conveyor trestles pinned and secure

•

Lifting trestle pins and retaining clips secure

•

Condition of belt and skirting rubber (in place and adjusted cuts, rips, holes, etc.)

•

All conveyor guards in place and secure

•

•

Conveyor belt clear of debris

All Trough and return rollers are free from obstructions

•

Condition of belt and skirting rubber (in place and adjusted)

•

Tail drum belt scraper clean and adjusted for proper tension and tracking

•

All trough and return rollers are free from obstructions

•

Head drum belt scrapers clean and adjusted

•

Belt scrapers and curtains clean and properly adjusted Bulges or leaks in hydraulic hose

•

All conveyor guards in place and secure

•

Hydraulic motor mounting hardware secure

•

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ST356


5-4-1 ENGINE START UP

1. Perform the pre-start checks listed at the beginning of this section. . IMPORTANT: BEFORE STARTING THE ENGINE, INSURE THAT ALL THE HYDRAULIC CONTROL LEVERS AND CONTROL PANEL SWITCHES ARE IN THE STOP, NEUTRAL OR OFF POSITION NOTE: Starting the engine requires the use of two hands. 2. Set manual throttle control lever to idle speed position. 3. Turn the engine control panel key switch to the ON position. 4. Depress and hold the MANUAL OVERRIDE button. 5. Turn the engine control panel key switch to the PRE-HEAT position. 6. When the DIESEL PRE-HEAT indicator has extinguished, turn the engine control panel key switch to the START position. 7. Hold Key in the start position until warning horn stops (Approx. 7 seconds) and the engine has started. IMPORTANT: DO NOT CRANK THE ENGINE FOR MORE THAN 30 SECONDS. IF IT DOES NOT START, CHECK EMERGENCY STOP BUTTONS ARE RESET, WAIT 2 MINUTES BEFORE TRYING AGAIN. AFTER FOUR ATTEMPTS CONTACT YOUR AUTHORIZED NORDBERG DISTRIBUTOR FOR SERVICE. NOTE: The engine control panel key switch must be returned to the OFF position after a failed start attempt. 8. After the engine has started, continue to depress the MANUAL OVERRIDE button until the oil pressure reaches normal and the LOW OIL PRESSURE indicator light extinguishes. 9. After the engine has been operating and warmed up for a few minutes, check around the engine compartment area for engine oil, fuel, coolant or hydraulic fluid leaks. 10. Check the engine control panel indicators for normal operation. If operation is not normal, stop the engine and determine the cause. 11. Set manual throttle to the operational speed position. Before moving the machine refer to sections “5-22-1 RADIO REMOTE OPERATION and 5-28-1 LOAD/UNLOAD INSTRUCTIONS ” of this manual. For screening operations refer to the following sections of “5-5-1 ENGAGING HYDRAULICS”.

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ST356


5-5-1 ENGAGING HYDRAULICS

The details of operation for each of the hydraulic control levers are listed on the following pages. The operator must be knowledgeable in the operation of all controls before engaging any hydraulics. Some hydraulic functions require additional actions to be performed, such as removing safety pins or lowering guards, before engaging. Normal sequence of operations: (1.) Engage the product and side conveyors, (2,) Screen-box, (3) Main conveyor and feeder conveyor. Conversely ALL conveyors should be run until empty then stopped in reverse order (3,2,1,). If equipped with a shredder, additional considerations must be made. IMPORTANT: INCORRECT SEQUENCING OF HYDRAULIC OPERATIONS CAN RESULT IN JAMMING THE CONVEYORS AND MAY DAMAGE THE MACHINE. Startup/Shutdown The following procedures assume the Nordberg ST356 is equipped with a shredder. The shredder, is a single shaft, single speed unit, which was designed to only be used as an aid to material separation for the screen media. The intended use of shredder is to break up light conglomerated soils. Heavy gravel and aggregates will severely shorten the life expectancy of the Hammers/Blades. The shredder is secured in the raised (non-operational position) by safety chains, and lowered to the operational position for transport and operation.

5-5-2 HYDRAULIC STARTUP PROCEDURE

The following procedures assume the Nordberg ST356 is equipped with a shredder.

( * ) Omit these steps if shredder is not installed. See: Page 4-15 for shredder operation procedures if equipped. Before startup, ensure all items stored for transport are removed from the hopper and conveyors are clear. 1. Familiarize yourself with the location of the (3) Yellow and Red EMERGENCY SHUTDOWN buttons 2. Ensure all hydraulic control levers and switches are in the stop/off position. 3. Turn FEEDER BELT SPEED CONTROL knob to -O- position (clockwise). 4. * Ensure the SHREDDER CONTROL levers are in the stop position. 5. Start the engine. (Refer to page 4-2 for detailed procedure). 6. * Raise shredder to non-operating position using SHREDDER RAISE/LOWER hydraulics. 7. * Secure shredder in the non-operating position using the securing devices. 8. Move TAIL/SIDE CONVEYOR hydraulic control switch to ON position. 9. Move SCREEN hydraulic control switch to the ON position. 10. Move MAIN CONVEYOR/FEEDER hydraulic control switch to the on position. 11. Turn FEEDER BELT SPEED CONTROL knob counter clockwise to start feeder belt. 12. Perform the daily operational checks. (Refer to 5-5-1) 13. To achieve maximum efficiency and productivity from the ST356, a number of factors should be considered: •

screen angle adjustments

•

feeder belt speed adjustments

•

side belt adjustments

•

main belt adjustment

•

product belt adjustment

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5-5

ST356


5-6-1 DAILY OPERATIONAL CHECKS Some operational checks can be performed only after engaging hydraulics. They are listed below because they must be performed on a daily basis in addition to the daily pre-start checks. Note: Failure to perform these checks may result in premature equipment failure. •

Emergency stop system.

•

Tipping grid manual and remote operation functioning properly

•

Product and Side conveyors straight at hinge points

•

Feeder, main, product and side conveyor belts are tracking straight.

•

Guards and skirting rubber adjusted and in place

•

Vibration of screen box, sub-frame (if excessive vibration occurs, shut down and source the cause).

•

Listen for unusual noises on all moving components. (Bearing growl, metal scraping).

•

Check for Hydraulic leaks.

5-6-2

SHUTDOWN PROCEDURE

(*) The shredder is optional. Omit these steps if shredder is not installed. 1. Clear debris from GRID BARS. 2. Allow feeder belt to run until hopper is clear of material. 3. * Move SHREDDER hydraulic control lever to the STOP position. 4. * Raise shredder using SHREDDER RAISE/LOWER lever. DANGER: NEVER RAISE THE SHREDDER WHEN IT IS RUNNING AS EXTREME DANGER WILL RESULT TO THE OPERATOR OR PERSONS NEARBY FROM MATERIAL EXITING FROM THE SHREDDER CHAMBER. 5. Let feeder run out and then turn the FEEDER BELT SPEED CONTROL knob to -O- position (anticlockwise). 6. Allow main conveyor to run out the material. Move MAIN CONVEYOR / FEEDER hydraulic control switch to the OFF position. 7. Allow screen box to run until clear of material. Move SCREEN hydraulic control switch to the OFF position. 8. Allow product conveyor and side conveyors to run until clear of material. Move SIDE/PRODUCT CONVEYOR hydraulic control switch to the OFFposition. 9. Idle engine down, allow cool down time. 10. Turn the engine control panel key switch to the OFF (0) position to shut down the engine. 11. Remove the key, close and lock the engine compartment door whenever the machine is left unattended.

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5-6

ST356


5-7-1 EMERGENCY SHUTDOWN IF AT ANY TIME DURING THE OPERATION OF THIS MACHINE A SITUATION ARISES THAT COULD IN ANY WAY THREATEN THE SAFETY OF A PERSON OR THE EQUIPMENT, IMMEDIATELY TURN THE ENGINE CONTROL PANEL SWITCH TO THE OFF POSITION OR DEPRESS ANY ONE OF THE (3) YELLOW AND RED EMERGENCY SHUTDOWN BUTTONS.

5-7-2 CONTROL PANEL

5-7-3 FUNCTION ACTIVATION INDICATORS 5-8-1 HOUR METER

5-9-2 SAFETY WARNING INDICATORS

5-8-2 WORK LAMP TOGGLE SWITCH

5-9-3 SCREEN TOGGLE SWITCH

5-8-3 FEEDER / MAIN TOGGLE SWITCH

5-9-4 TAIL/SIDE TOGGLE SWITCH

5-8-4 GRID ISOLATOR TOGGLE SWITCH

5-9-5 OVERRIDE BUTTON

5-8-5 GRID UP/DOWN TOGGLE SWITCH

5-9-6 WIRE REMOTE OUTLET

5-9-1 TRACK TOGGLE SWITCH

5-10-1 KEY SWITCH

5-7-3 FUNCTION ACTIVATION INDICATORS Function: Indicates what machine systems are active. Location: Top center of the main control panel. Description: Green lamps illuminate as function toggles are activated. No lamps are active when function switches are off

Special notes: None

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ST356


5-8-1 HOUR METER

Function: Indicates engine accumulated operation time.

Function: Energizes or de-energizes power to hydraulic tipping grid switch circuit.

Location: Top left corner on the main control panel.

Location: Top row of switches, First switch on the left of the main control panel.

Description: 12 volt , Analog meter, hour meter reads to 1/10 of an hour. Special notes: None

Description: Two position, On/Off, 12 volt DC toggle type.

5-8-2 WORK LAMP TOGGLE SWITCH Function: Energizes electric power to work lights. Location: Mid panel, center on the main control panel. Description: Two positions ON/OFF 12 volt DC toggle type.

5-8-3 FEEDER / MAIN TOGGLE SWITCH Function: a)

Manual, Switch in the raised position energizes electric power to the hydraulic solenoid for the main and feeder belt drive circuit to operate.

b)

Off, De-energizes the Main/Feeder solenoid to stop the drive circuit operation.

c)

Special notes: Switch must be on for either the remote or the manual tipping function to operate. Intended use is to lock the tip grid out of operation.

5-8-5 GRID UP/DOWN TOGGLE SWITCH Function: Energizes power to hydraulic tipping grid circuit solenoids for manual operation of the tipping grid. Raise toggle to raise grid, Lower toggle to lower grid.

Special notes: Optional accessory

5-8-4 GRID ISOLATOR TOGGLE SWITCH

Location: Bottom row of switches, First switch on the left of the main control panel. Description: Three position, On/Off/On, 12 volt DC toggle type. Special notes: The Grid Isolator switch must be on before this switch will operate.

Radio, Switch in the lowered position allows the signal from the remote radio to energize electric power to the hydraulic solenoid for the main and feeder belt drive circuit to operate.

Location: Top row of switches, second from the left on the main control panel. Description: Three position, On/Off/On, 12 volt DC toggle type. Special notes: None

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5-8

ST356


5-9-1 TRACK TOGGLE SWITCH

Function: a)

Function: Energizes or de-energizes electrical power to the tail (product) and side conveyors hydraulic motor drive solenoid.

Radio, Switch in the raised position energizes electric power to the remote receiver. Switch must be in the RADIO position for track, main/feeder belt and tipping grid operations to function by the wireless remote.

Location: Top row of switches, Fourth switch from the left on the main control panel.

b) Off, Isolates power to all remote functions. c)

Description: Two position, On/Off, 12 volt DC toggle type.

Wired, Switch in the lowered position allows the signal from the wired remote to energize electric power to the tracking hydraulic solenoids for motion.

Special notes: None

Description: Three position, On/Off/On, 12 volt DC toggle type.

Location: Bottom row of switches, Third location from the left on the main control panel.

Special notes: See: Section 5- -for details remote operations

Description: Push button On/Off, 12 volt DC Push to operate spring loaded return.

5-9-2 SAFETY WARNING INDICATORS Function: Green lamps indicate malfunction or safety circuit problem. Note: Preheat lamp will illuminate while preheating. Location: Top right of the main control panel. Description: Green LED lamps

Special notes: Emergency stop buttons must be in their released position in order for the override to function properly. Also see section 5-4-1 ENGINE START UP

5-9-6 WIRE REMOTE OUTLET Function: Access port for wired track remote

Special notes: None

5-9-5 OVERRIDE BUTTON Function: Overrides the engine safety switches and activates the fuel solenoid allowing engine to start.

Location: Bottom row of switches, second switch on the left of the main control panel.

5-9-4 TAIL/SIDE TOGGLE SWITCH

Location: Lower right corner on the side of the main control panel.

5-9-3 SCREEN TOGGLE SWITCH Function: Energizes or de-energizes electrical power to the screen motor hydraulic drive solenoid.

Description: Multi pin connector with screw on protection cover Special notes: None

Location: Top row of switches, third switch from the left of the main control panel. Description: Two position, On/Off, 12 volt DC toggle type. Special notes: None

Rev. C

06/18/02

5-9

ST356


5-10-1 KEY SWITCH Function: Multi Position. a) OFF b) ON Electrical system energized c) PREHEAT Power to engine glow plugs. d) START Energizes starter circuit. Location: Lower right corner on the face of the main control panel. Description: Keyed ignition switch, Off/On detented, Preheat and start momentary function.

Special notes: Used in conjunction with override button. Also see section 5-4-1 ENGINE START UP

5-10-2 GRID SUB-FRAME OPERATION Function: Tipping grid hydraulics are used to raise and lower the grid sub-frame from the transport position to the operating position and reverse. Location: Grid up and down and Grid Isolator toggle switches are on the Main control panel which is mounted on the right hand side at the mid-chassis area. Description: Grid UP/DOWN toggle switch is used in this instance to electrically control the hydraulic valve for raise and lower functions manually. Special notes: DO NOT USE THE RADIO TRANSMITTER FOR SET-UP FUNCTION. Grid Isolator switch must be on for the grid up and down to function. The Grid up and down switch is a dual-purpose switch depending upon how the grid pins are installed. It is used to set the Grid sub-frame and for Grid tipping functions.

Also see Set-up Section 6-7 for detailed procedure information RAISEING THE GRID SUB-FRAME 1. Remove pins from lower end of the grid sub-frame support arm. 2. Insert the two pins through grid frame ears into grid sub-frame. 3. Using the grid UP/DOWN switch on the main control panel only, move the switch to the UP position. Use caution and jog the switch, as there is a delay in the system. 4. Raising to operate, move the switch to the up position and align the lower holes of the support arm with the lower mount on the hopper frame and insert the pins. 5. Lower the grid frame to the sub-frame and remove the pin attaching the grid frame to the sub-frame. 6. The tipping grid frame is ready for normal operation. LOWERING THE GRID SUB-FRAME 1. Lower grid deck until it is resting on the grid sub-frame. 2. Insert the two grid deck lock pins through grid frame ears into grid sub-frame. 3. Slightly raise the Grid and sub-frame and remove the grid / sub-frame support arm pins.. 4. Move the grid UP/DOWN switch on the main control panel only, to the DOWN position. 5. Lower Grid assembly completely for transport.

Rev. C

06/18/02

5-10

ST356


5-11-1 GRID DECK MANUAL TIPPING FUNCTONS Function: Grid hydraulics are used to raise and lower the Tipping grid deck to discharge unwanted materials. Location: Control is mounted in the Main control panel on the right hand side at the mid-chassis area. Description: Grid UP/DOWN toggle switch electrically controls the hydraulic valve for raise and lower functions. Special notes: Grid Isolator switch must be on for grid to function. Use the grid up and down toggle switch on the control panel for control for manual cycling. Timed cycling is incorporated in remote cycling only.

RAISE To raise the Grid deck of the ST356 (extend the Grid deck hydraulic cylinder): Move the Grid deck hydraulic cylinder control switch to the “UP” position. LOWER To lower the Grid deck of the ST356 (retract the Grid deck hydraulic cylinder): Move the Grid deck hydraulic cylinder control switch to the “DOWN” position. CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE.

5-11-2 GRID DECK REMOTE TIPPING FUNCTIONS Function: ST356s are equipped with a remote Grid operations device that employs a hand held transmitter. Grid remote operation is a timed cyclic operation, used to raise and lower the tipping grid deck to discharge unwanted materials from the loader or a remote location. Location: Hand held transmitter unit location may vary. Generally it may be found in the pocket provided on the main control compartment door located on the right hand side of the machine at the mid-chassis area. The receiver is mounted in the main control panel compartment in the upper left corner of the compartment. Description: Multifunction handheld transmitter has a Grid RAISE/ LOWER button on it that will start the function. The cycle commences at the press of the grid button on the handheld transmitter and if uninterrupted will complete a full cycle of full closed to full open and back to a full closed position. Special notes: Grid Isolator switch must be on for grid to function. Cycle time is adjustable. Cycle speed is not adjustable. Remote batteries are rechargeable, a quick charger is supplied for use in a standard cigarette lighter socket. The receiver does not provide a charging source though it will appear it does. Complete details can be found in the REMOTE OPERATION in this section found on: Pg. 5-24 Standard equipment supplied with new machines 2- rechargeable batteries 1- hand held transmitter w/ capped lock out key 1- non-capped transmitter lock out key 1- remote receiver w/o charger 1- 12 volt portable charger

GENERAL INSTRUCTIONS: START: To raise Grid deck, press the GRID RAISE icon on the remote control. This will start and complete one cycle of opening and closing the Grid deck. STOP: The “STOP” button will stop the cycle at the point where the button was pushed. To restart the cycle, press the start button. The cycle time will be started from “0” and the Grid deck will be held in the open position until the cycle time has lapsed and then return the Grid to the closed position, and cycle times will reset.

Rev. C

06/18/02

5-11

ST356


5-12-1 VIBRATING GRID HYDRAULICS (option), Function: Vibrating Grid hydraulics are used to raise, lower and run the vibrating grid deck. Designed to pre-screen hard to separate materials. Location: Vibration control is mounted in the Main control panel on the right hand side at the midchassis area. Grid tip functions are the same as the non-vibrating grid deck. Description: The Screen switch and Vibrating grid are combined. Positioning the Screen switch to the “on” position, electrically controls the hydraulic valve for Screen and Vibrating grid functions to activate. Special notes: Grid Isolator switch must be on for grid to function. Use the grid up and down toggle switch on the control panel for control for manual cycling. Timed cycling is incorporated in remote cycling only.

RUN / STOP To engage the Vibrating grid of the ST356: 1. Tip grid to ensure all excess material is removed from the deck. 2. Ensure the grid is fully seated in the lowered position. 3. Move the Vibrating grid control handle to the run position.

Rev. C

06/18/02

5-12

ST356


5-13-1 PRODUCT CONVEYOR FOLD HYDRAULICS Function: Product fold hydraulics are used to extend or retract the product conveyor for transport, operations or moving. Location: Control is mounted on the chassis on the rear left hand side of the chassis. Description: 3-bank valve shared with the Main conveyor raise/lower and the Main conveyor / Product conveyor / Screen Angle raise/lower functions. Special notes: Also see: Set-up Section 6-5 for detailed information.

CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE. UNFOLD To unfold the product conveyor of the Nordberg ST356: 1. Remove the transport safety clip from both sides of the product conveyor head section. 2. Move the product conveyor hydraulic cylinder control lever to the “UNFOLD” position. 3. Install hinge-locking pins to lock product conveyor at hinge point. FOLD To fold the product conveyor of the ST356: 1. Remove product conveyor hinge locking pins. 2. Move the product conveyor hydraulic cylinder control lever to the “FOLD” position. 3. Install transport clip to both sides of the product conveyor head section.

Rev. C

Main Conv./Screen Raise Lower



NOTE: Extreme care must be observed in moving the ST356. DO NOT completely FOLD and secure the product conveyor if the machine is to be self-propelled. Ensure there is adequate ground clearance of the conveyor head drum and ground before moving. The product conveyor may be folded and secured to the screen assembly allowing the movement of the ST356 in the folded and secure position providing the Screen is raised at least 10 degrees. DO NOT TRANSPORT OVER THE ROADWAYS WITH SCREEN RAISED. Also, See the loading and unloading section of this manual.

06/18/02

5-13

ST356


5-14-1 PRODUCT CONVEYOR ADJUSTMENT Function: Product conveyor adjustment is provided for stockpiling capacities and to reduce material rollback. Location: Main conveyor/screen angle control is used for this adjustment and is mounted the chassis on the rear left hand side of the chassis. Description: 3-bank valve shared with the Product fold/unfold and the Main conveyor raise/lower functions. Special notes: This is manual function used in conjunction with the screen angle. Also see: Set-up Section 6-5 for detailed information.

Note: The Product conveyor moves with the screen sub-frame. The angle of the Product conveyor relative to the sub-frame is adjustable. For most materials the conveyor should be operated with the pin in the top hole of the product conveyor trestle. TO CHANGE THE PRODUCT CONVEYOR ANGLE 1. Raise the screen sub-frame slightly and remove pin from sub-frame trestle. 2. Lower sub-frame until the product conveyor is horizontal and rests on the supports. 3. Remove the product conveyor trestle pin and adjust sub-frame to achieve the desired pin location on the product conveyor trestle. 4. Raise the screen sub-frame to the desired operation angle and install the screen angle trestle pins to secure. CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE

Rev. C

06/18/02

5-14

ST356


5-15-1 SIDE CONVEYOR FOLD HYDRAULICS Function: Side conveyor fold hydraulics allows the side conveyors to be adjusted for transport, tracking and storage. Location: The side conveyor raise and fold stations are located on the upper framework of the chassis, at the discharge end of the feed hopper (LHS & RHS). Description: RHS 3-bank valve shared with the Hopper leg raise/lower functions. LHS 2-bank valve solely for side conveyor raise/lower and fold/unfold. Special notes: Also see: Set-up Section 6-5 for detailed information.

NOTE: FOLDING THE SIDE CONVEYORS WITHOUT CARE WILL CAUSE DAMAGE TO THE CONVEYORS. UNFOLD To unfold the side conveyor of the ST356: See: SETUP section 6 for instructions for sequence of unfolding and lowering from transport brackets to operation position. 1. Move the side conveyor hydraulic cylinder control lever to the “UNFOLD” position. 2. Ensure side conveyors are fully unfolded before operating. FOLD To fold the side conveyor of the ST356:

Ho p Low per su ppor er Ra t le ise gs

Win Un g Co nve fo yor Fol ld d

Win g Low Conv er eyo Ra r ise

1. Move the side conveyor hydraulic cylinder control lever to the “FOLD” position.

r eyo onv gC Win ise Ra er r eyo Low onv gC Win ld Fo ld fo Un

CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE.

Rev. C

06/18/02

5-15

ST356


5-16-1 SIDE CONVEYOR RAISE HYDRAULICS Function: Side conveyor raise hydraulics allows the side conveyor height to be adjusted for operation, transport, tracking and storage. Location: The side conveyor raise and fold stations are located on the upper framework of the chassis, at the discharge end of the feed hopper (LHS & RHS). Description: RHS 3-bank valve shared with the Hopper leg raise/lower functions. LHS 2-bank valve.

Special notes: Also see: Set-up Section 6-5 for detailed information. See SETUP section 6 for instructions for sequence of folding and raising for transport. RAISE To raise the side conveyor of the ST356 (extend the side conveyor hydraulic cylinder) 1. Move the side conveyor hydraulic cylinder control lever to the “RAISE” position. 2. Move and install the side conveyor trestle pins to the required position. LOWER To lower the side conveyor of the ST356 (retract the side conveyor hydraulic cylinder): 1. Raise the conveyor slightly and remove the side conveyor trestle pins. 2. Replace the side conveyor trestle pins in the desired position. 3. Move the side conveyor hydraulic cylinder control lever to the “LOWER” position.

Hop Low per su ppor er Rai t le se gs

Win Unf g Con old veyo Fo r ld

Win Low g Con veyo er Rai r se


r eyo onv gC Win e is Ra er r eyo Low onv gC Win ld Fo ld fo Un

Rev. C

06/18/02

5-16

ST356


5-17-1 SIDE CONVEYOR OPERATING HYDRAULICS Function: Energizes or de-energizes electrical power to the tail (product) and side conveyors hydraulic motor drive solenoid. Location: Main control enclosure, on the main control, top row of switches, Fourth switch from the left hand side of the panel.

Description: Two position, On/Off, 12 volt DC toggle type. Special notes: Oversize side conveyor has a variable speed control. RUN To engage the product and both side conveyors of the ST356. 1. Move the product/side conveyor hydraulic motor control switch to the “RUN” position. 2. Set Oversize side conveyor speed to a centered position. This control may be adjusted after material flow is determined. TOP DECK SIDE CONVEYOR SPEED CONTROL The Top Deck Side Conveyor speed control knob adjusts the speed of the (top deck) side conveyor only. FASTER To increase the Top Deck Side Conveyor speed of the ST356: Rotate the side conveyor speed control knob counter-clockwise. SLOWER To decrease the Top Deck Side Conveyor speed of the ST356: Rotate the side conveyor speed control knob clockwise. PROCEED TO SCREEN DRIVE OPERATING SECTION 4-14 “RUN” STOP To disengage the tail/side conveyors of the ST356: 1. Allow all conveyor belts to clear material. 2. Move the tail/side conveyor hydraulic motor control switch, located on the main control panel, to the “OFF” position. NOTE: Refer to Preparing for Transport and Preparing for Screening in Section 5 Transporting for proper sequence of operation. CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE. Radio receiver Feeder belt speed control

Oversize side conveyor speed control

Side & Product conveyor run switch

Rev. C

06/18/02

5-17

ST356


5-18-1 SCREEN ANGLE HYDRAULICS Function: Screen angle hydraulics allows the Screen-box to be adjusted for the optimum operating angle for the screen configuration and material feed rate aiding in screening efficiency. Also for transport, tracking and storage. Location: Screen angle control station is located on the left-hand side rear framework of the chassis, at the product conveyor end of the machine. Description: 3-bank valve shared with the product conveyor fold/unfold and main conveyor raise / lower functions.

Special notes: Also see: Set-up Section 6-5 for detailed information. RAISE To raise the angle of the screen box assembly on the ST356 (extend the screen angle hydraulic cylinder): 1. Move the screen hydraulic cylinder control lever to the “RAISE” position. 2. Place the screen angle trestle pins in the desired location. 3. Move the screen hydraulic cylinder control lever to the “LOWER” position, lowering trestle back onto pins. LOWER To lower the angle of the screen box assembly on the ST356 (retract the screen angle hydraulic cylinder): 1. Raise the screen angle slightly and remove the screen angle trestle pins. 2. Replace the screen angle trestle pins in the desired location. 3. Move the screen hydraulic cylinder control lever to the “LOWER” position, lowering trestle back onto pins. CAUTION:

THE TRESTLE PINS MUST BE REMOVED BEFORE CHANGING THE SCREEN ANGLE.

25° 22° Approximate screen angles

20° 171/2°

Screen Angle Raise Lower



Screen / Main trestle

Main Con v./Screen Lower Rai se

Main Conveyor Lower Rai se

Prod uct Conveyor Fold Unfold

15°


Valve bank

MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE. Rev. C

06/18/02

5-18

ST356


5-19-1 SCREEN DRIVE OPERATING HYDRAULICS

Function: Supplies hydraulic fluid flow to the Screen-box motor setting the screen-box into motion. This circuit utilizes an electric switch which energizes or de-energizes electrical power to the screen motor hydraulic drive circuit solenoid. Location: Top row of switches, third switch from the left of the main control panel. Description: Two positions, On/Off, 12 volt DC toggle type. Special notes: None RUN To engage the screen drive of the ST356: 1.

2.

Ensure side and product (tail) conveyors Oversize side are conveyor speed operating. control Using the throttle, increase engine speed to Throttle full operating position.

3.

Move Screen drive hydraulic control switch to the “ON” position.

4.

Check for excessive vibrations the screen-box area.

Side & tail conveyor run switch

Screen run switch outside of

STOP To disengage the screen drive of the ST356: Forward motion

1. Allow screen to empty of material. 2. Move screen drive hydraulic control switch to the “OFF” position. CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE.

Rev. C

06/18/02

5-19

ST356


5-20-1 MAIN CONVEYOR/FEEDER OPERATING HYDRAULICS Function: Supplies hydraulic fluid flow to the Main and Feed conveyor motors setting the conveyors into motion. This circuit utilizes electric switch which energizes or de-energizes electrical power to the Main and Feeder motor hydraulic drive circuit solenoid. a)

Manual, Switch in the raised position energizes electric power to the hydraulic solenoid for the main and feeder belt drive circuit to operate. In this position the belt can not be stopped or started using the remote transmitter.

b) Off, De-energizes the Main/Feeder solenoid to stop the drive circuit operation. c) Radio, Switch in the lowered position allows the signal from the remote transmitter to energize or de-energize electric power to the Main/Feeder hydraulic solenoid allowing the drive circuit to operate or stop. Location: Top row of switches, second from the left on the main control panel. Description: Three positions, On/Off/On, 12 volt DC toggle type. Special notes: Proper conveyor belt tension is required. Stopping a fully loaded belt is not recommended the belt may not restart. When restarting a loaded conveyor follow the “RUN’ procedure. RUN To engage the main conveyor of the ST356: 1. 2. 3. 4. 5.

Engine throttle setting at full operating postion. Ensure Side / product conveyors and screenbox are operating. Set feeder speed control to “0” Move the Main conveyor hydraulic control switch to the “ON” position. Set feeder conveyor speed control for desired material flow. Feeder speed control

FASTER The speed control affects the feeder belt only. To increase the feeder speed of the ST356: Rotate the feeder speed hydraulic motor control knob counter clockwise. SLOWER To decrease the feeder speed of the ST356: Rotate the feeder speed hydraulic motor control knob clockwise.

Throttle Main & Feed conveyor Side & Product conveyor

STOP 1. Ensure Feeder and Main conveyor belts are clear of material. 2. Set feeder speed control to “0” 3. Move Main / feeder conveyor hydraulic control switch to the “OFF” position.

Screen


Rev. C

06/18/02

5-20

ST356


5-21-1 SHREDDER OPERATING HYDRAULICS

(option)

NOTE: The shredder is optional. RAISE To raise the shredder of the ST356 (extend the shredder hydraulic cylinder): 1. Move the shredder hydraulic cylinder control lever to the “RAISE” position. 2. Secure the safety chains from the hopper to the shredder. LOWER To lower the shredder of the ST356 (retract the shredder hydraulic cylinder): 1. Slightly raise the shredder and Disconnect the safety chains pin from the shredder. 2. Move the shredder hydraulic cylinder control lever to the “LOWER” position. RUN To engage the shredder on the ST356: 1. Remove “R” clips from discharge door. 2. Move each shredder hydraulic motor control lever to the “RUN” position. STOP To disengage the shredder on the ST356: Move the shredder hydraulic motor control lever to the “STOP” position. CAUTION: THE SHREDDER SAFETY DEVICES MUST BE DISCONNECTED BEFORE LOWERING THE SHREDDER. MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE.

Rev. C

06/18/02

5-21

ST356


5-22-1 RADIO REMOTE OPERATION

RADIO TRANSMITTER

Tracks may only be operated by the radio remote or wired remote.

Mfg. Hectronic

Hopper jacklegs must be fully retracted before the tracks will operate.

Frequency: 70cm band

The track switch on the main control panel must indicate REMOTE position.

Range: Up to 100m (approx.330 ft.)

Model. Ergo V2

RF output: 10mW

Battery: 9.6V / 350mAh

RADIO TRANSMITTER FUNCTIONS

Operating time: Approx. 7 hrs @ 100% operation

1.

Set-up the machine in accordance with the LOAD / UNLOAD INSTRUCTIONS.

2.

Retract jack legs fully (See: page 5-6 Hopper Jack leg Hydraulics) 3

5

4

3

To activate radio transmitter, insert the key and turn clockwise allowing the key button to pop up activating the remote transmitter. 4

5

5-22-2 Remote Lock Out Key

5-22-3 Indicator Light Green light indicates the remote is active. Red light indicates low battery. No light remote is off or dead battery.

5-22-4 Track Enable / Dis-Able Start/Stop

This initiates a signal between the remote transmitter and the machine receiver, toggling the track system between enable and disable. The machines motion beacon and warning horn will be activated indicating the radio transmitter has enabled the track system. There will be a seven- (7) second delay before functions are engaged.

CAUTION: KEEP PERSONNEL CLEAR OF MACHINE WHILE BEACON AND MOTION ALARM ARE ACTIVE. NOTE: Motion beacon and warning horn will not be activated unless the hopper jacklegs are fully retracted.

Rev. C

06/18/02

5-22

ST356


RADIO TRANSMITTER (continued)

6

6

6

5-23-1 Track Motion Controls.

Straight motion is achieved by depressing both corresponding directional track motion control buttons simultaneously. (A) Button moves the machine straight in the direction of the hopper. (B) Button moves the machine straight in the direction of the product conveyor. The simultaneous release of both track motion buttons will stop the machine motion. While machine is in motion the release of one directional buttons will stop that track, turning the machine in the direction of the stopped track. With the machine at rest depressing only one track motion control button will turn the machine in the direction of the stopped track. Track speed may be regulated by engine speed (See: loading/unloading instructions.) CAUTION: SLEWING THE MACHINE IS STRESSFUL TO THE COMPONENTS AND NOT RECOMMENDED. MOTION MAY BE RAPID, ENSURE THAT ALL PERSONNEL STAND CLEAR OF MACHINE. OPERATOR MUST STAND CLEAR OF MACHINE WHILE IN MOTION OR TURNING. BEWARE OF OBSTICLES IN THE PATH OF TAIL SWING WHEN TURNING.

Rev. C

06/18/02

5-23

ST356


RADIO TRANSMITTER (continued)

8

7 9

7

5-24-1 Grid Cycle Start/Stop.

This function tips the grizzly grid in order to discharge material that may remain on the grid. The function is a timed cycle, (Procedures for setting the time will be found in the service section of this manual.) To start the cycle, depress the Gird start/stop button once. To stop in mid cycle depress the button once. The grid may be restarted after a mid cycle stop by depressing the start stop button once. Note: Stopping the grid in mid cycle will clear the timer cycle, restarting the grid will re-start the timer cycle from zero. This will cause the grid to stay open longer than the normal 3-5 seconds, until the timer cycle is complete. Then the grid will return on the down cycle. DO NOT RE-PRESS BUTTON IF THE GRID APPEARS TO BE TAKING LONGER TO RETURN. This will only reset the timer and delay the cycle function. Use the toggle switch on the main panel to lower the grid before continuing. See Section 6 for timer adjustments. 8

5-24-2 Engine Stop.

Stops engine. Engine can not be re-started from remote control. Main engine control panel key switch must be switched off before restarting engine. Note: Engine stop is not an EMERGENCY STOP Engine stop only works if the radio is on. 9

5-24-3 Feeder Belt Start/Stop For this function to work, the manual / remote MAIN / FEEDER switch on the main control panel must be set to RADIO. This function will stop the MAIN and FEEDER conveyor belts. This function is intended to serve as a manual aid providing the operator a means of keeping the ST356 clear of jams and screen flooding.

Rev. C

06/18/02

5-24

ST356


RADIO TRANSMITTER (continued) 10

5-25-1 Battery

The LED on the transmitter will begin flashing RED when the battery is nearly exhausted. WARNING! : TRANSMITTER THE TRANSMITTER WILL SWITCH TO EMERGENCY STOP POSITION 30 SECONDS AFTER TRANSMITTER WARNING BEGINS… To remove the battery: Switch the transmitter off by turning the key switch to the (0) position. The rechargeable battery is detachable and located on the reverse side of the transmitter. To release the battery, Push the battery slightly forward and lift up and out of the battery compartment.

10

To install the battery; Insert the contact end of the battery in first. Align the battery contact points with the contact pins in the transmitter pushing the battery slightly forward and down into the battery compartment. Specifications; 9.6 volt / 350mAh rechargeable. Fully charged battery operation life averages 7 hours @ 100% operation. Typical charge time: 4hours Useful life approx. 900 charges Options: Extra battery pack. Receiver supplied with machine does not contain integral charging unit. 11

5-25-2 Battery Charger The charging unit provided with the machine is intended to be plugged into an existing 12/24 volt cigarette lighter of the loading machine or service truck.

11 12/24 VOLT CHARGER

Battery loading; Push the battery, contact surface first, into the charger. The GREEN LED flashes slowly during the charging process. The GREEN LED on steady: The battery is fully charged. No harm will come to the battery if it is left in the charger beyond the required charging time. The charger recognizes automatically when the battery is fully charged and regulates the charging amount to maintain a fully charged battery. Note; Never store a charged battery in a toolbox or similar place, where it could be short circuited by metal components. Rev. C

06/18/02

5-25

ST356


5-26-1 RADIO FREQUENCY CHANGE Group A

X1 and X7

Bridge closed Channel

Group B

10POL and 10POL PLUG Frequency

D0

D1

D2

Bridge open D3

MHz

Frequency

Channel

MHz

A1

433.875

ON

ON

ON

ON

433.900

B1

A2

433.925

OFF

ON

ON

ON

433.950

B2

A3

433.975

ON

OFF

ON

ON

434.000

B3

A4

434.025

OFF

OFF

ON

ON

434.050

B4

A5

434.075

ON

ON

OFF

ON

434.100

B5

A6

434.125

OFF

ON

OFF

ON

434.150

B6

A7

434.175

ON

OFF

OFF

ON

434.200

B7

A8

434.225

OFF

OFF

OFF

ON

434.250

B8

A9

434.275

ON

ON

ON

OFF

434.300

B9

A10

434.325

OFF

ON

ON

OFF

434.350

B10

A11

434.375

ON

OFF

ON

OFF

434.400

B11

A12

434.425

OFF

OFF

ON

OFF

434.450

B12

A13

434.475

ON

ON

OFF

OFF

434.500

B13

A14

434.525

OFF

ON

OFF

OFF

434.550

B14

A15

434.575

ON

OFF

OFF

OFF

434.600

B15

A16

434.625

OFF

OFF

OFF

OFF

434.650

B16

Disconnect power supply for transmitter and receiver before changing frequencies. Match the pin or switch positions between transmitter (X1) and receiver (X7) for proper operation. Rev. C

06/18/02

5-26

ST356


5-27-1 WIRED REMOTE

The following instructions assume the ST356 is set-up in the motion configuration. See: LOADING / UNLOADING instructions for this set-up. CAUTION: KEEP PERSONELL CLEAR OF MACHINE WHILE BEACON AND MOTION ALARM ARE ACTIVE.

Track motion controls

1. Retract jack legs fully (See: page 4-5 Hopper Jack legs Hydraulics) 2.

Hopper forward Product conveyor forward

Remote Arm / Dis-arm

Plug wired remote into the outlet provided on the side of the main operation panel.

Remote Emergency Stop

3. Switch the track switch on the main control panel to WIRED. 4. Stretch out remote cord. Ensure there are no knots or damage to this cord. The cord length is 2.5 meters. ( 8 ft.) 5. ARM / DIS-ARM. Arm the remote by moving the arm / disarm switch to the on position. The beacon and motion warning horn will activate. CAUTION: TRACK MOVEMENT IS NOW AVALIABLE. Disarm, move the switch to off. Beacon and horn with stop.

6. TRACK MOTION CONTROLS. Straight motion is achieved by toggling both directional track motion control switches simultaneously. The simultaneous release of both track motion buttons will stop the machine motion. While machine is in motion the release of one directional switches will stop the track, turning the machine in the direction of the stopped track. With the machine at rest toggling only one track motion control switch will turn the machine in the direction of the stopped track. Track speed may be regulated by engine speed (See: loading/unloading instructions.) WARNING: WATCH THAT THE UMBILICAL CONTROL WIRE DOES NOT CONTACT THE TRACK DURING OPERATION. CAUTION: SLEWING THE MACHINE IS STRESSFUL TO THE COMPONENTS AND NOT RECOMMENDED. MOTION MAY BE RAPID, ENSURE THAT ALL PERSONNEL STAND CLEAR OF MACHINE. OPERATOR MUST STAND CLEAR OF MACHINE WHILE IN MOTION OR TURNING. BEWARE OF OBSTICLES IN THE PATH OF TAIL SWING WHEN TURNING. 7. REMOTE EMERGENCY STOP. Shuts engine down. 8. Disconnect the wired remote from control box after machine has been positioned for storage or operation. WARNING: DO NOT MOVE MACHINE WITH SCREEN OR CONVEYORS OPERATING.

Rev. C

06/18/02

5-27

ST356


5-28-1 LOAD/UNLOAD INSTRUCTIONS ST356 – Motion instructions

Carefully read the instructions below before attempting to move this machine. WARNING! Failure to follow these instructions will cause severe damage to the machine. 1. Press and hold in the green MANUAL OVERRIDE button located on the main control panel. 2. Turn key to the start position and hold until warning horn has stopped (approximately 7 seconds) and the engine has started. Continue to press and hold in the override button an additional 3 seconds after engine has started. 3. Set throttle not more than 50% engine speed for folding operations. Note:1 The side conveyor raise and fold stations are located on the upper frame work of the chassis, at the discharge end of the feed hopper (LHS & RHS)

4. Remove the transport pins from side conveyor lifting trestle. (It may be necessary to raise the conveyor slightly to give clearance prior to removing pins.) 5. Operate the "unfold" lever to slowly lift the conveyor head section off the transport bracket ensuring the conveyor frame and belting is clear. 6. Operate the "lower" lever to move the entire side conveyor away from the machine and transport bracket ensuring the conveyor frame and belting is clear of the screen sub-frame. Note: 2

Repeat 4 through 6 on other side of the machine.

Note: 3

The rear control station is located on the LHS of the machine back of the tracks at waist height.

7. At the rear control station, move the Screen "raise" lever to raise the screen & product conveyor assembly until the pin can be placed in the lowest exposed hole in the screen angle trestle (approx. 15 degrees). Lower the screen and product conveyor assembly to rest on the pin and install the “R” clip. 8. At the right hand control station operate the hopper support leg lever to release the positioning pins. Remove the pins and raise the hopper support legs, ensuring they are fully retracted. Replace the pins and “R” clips when closed. 9. At the Engine control panel move the Track radio/wired switch to the radio position. 10. On the hand–held radio transmitter, rotate the RED knob on the top of the handset in a clockwise direction to switch on. Note: 4 When the hand-held radio transmitter battery is fully charged a GREEN flashing light will be seen at the bottom LHS. When the battery is discharged, a RED flashing light will be seen at the bottom LHS.

11. Press the "Start / Stop" button between the track motion control buttons to arm the system. After a 7-second delay the Rotating beacon and motion alarm will activate indicating the remote tracking system is ready for operation. 12. Increase the throttle to a position between 50% and 75%. Engine RPMs may be used to regulate track speed. It is NOT recommended to use full RPM engine speed for loading / unloading to transport. Note: 5

Before tracking the unit, you MUST ensure that all personell are well clear and it is safe to do so.

SAFETY FIRST!

Rev. C

06/18/02

5-28

ST356


ST356 Motion instructions (continued)

ST356 – Motion instructions Carefully read the instructions below before attempting to move this machine. WARNING! Failure to follow these instructions will cause severe damage to the machine. 13. Hand-held radio transmitter – functions - Pressing both forward track direction arrow buttons on the radio control will track the ST356 in a straight line. - Depressing one forward track direction arrow button will steer the ST356 in the direction of the stopped track. The same results will occur when the reverse direction buttons are used. Note: 6 Pressing a forward and opposite reverse track control button will pivot the ST 356 extremely fast and is NOT RECOMMENDED.

14. Carefully track the ST356 onto or off of the transport vehicle with great care, Continually checking ground and overhead clearances.

MACHINE WILL SURGE FORWARD AS THE MIDDLE OF THE TRACKS PASS OVER AN EDGE. 15. When the machine is tracked into its final position, press the RED button on the top of the hand-held radio transmitter. The rotating beacon and motion alarm will stop and the system is disarmed. 16. Reduce the engine rpm to a point not more than half speed and fold the ST356 into the closed transport position by reversing the order of the instructions starting at number 7 following to number 4. Reduce the engine RPMs to idle and turn engine key to "OFF". Stow the hand-held radio transmitter in a safe place, preferably away from the unit.

Rev. C

06/18/02

5-29

ST356



Rev. C

06/18/02

5-30

ST356

Operator's Manual SET-UP Table of contents

SECTION 6 SET-UP SECTION 6 SET-UP.................................................................................................................................... 1 6-2-1 SITE PREPARATION ......................................................................................................................... 2 6-3-1 SCREENING PREPARATION............................................................................................................ 3 Un-Folding ............................................................................................................................................................... 3 Folding ..................................................................................................................................................................... 3 6-3-1 SCREENING PREPARATION (continued) ........................................................................................ 4 Motion / Transport ................................................................................................................................................... 4 Checks and Adjustments .......................................................................................................................................... 4 6-5-1 HOPPER SUPPORT LEGS................................................................................................................ 5 EXTEND.................................................................................................................................................................. 5 RETRACT................................................................................................................................................................ 5 6-6-1 SIDE CONVEYORS............................................................................................................................ 6 UNFOLD.................................................................................................................................................................. 6 FOLD ....................................................................................................................................................................... 7 6-8-1 PRODUCT CONVEYOR..................................................................................................................... 8 UNFOLDING FOR SCREENING OPERATION................................................................................................... 8 FOLDING ................................................................................................................................................................ 9 6-10-1 MAIN CONVEYOR ......................................................................................................................... 10 RAISE/LOWER ..................................................................................................................................................... 10 6-11-1 GRID DECK .................................................................................................................................... 11 SET-UP for operation............................................................................................................................................. 11 LOWER for transport............................................................................................................................................. 11 6-12-1 CATWALK PLATFORMS...................................................................................................................... 12 SET-UP .................................................................................................................................................................. 12 6-13-1 SCREEN ANGLE............................................................................................................................ 13 RAISE .................................................................................................................................................................... 13 LOWER.................................................................................................................................................................. 14

NOTE: THIS MACHINE HAS THREE (3) FUNCTIONING POSITIONS: Operational: Where as the machine is totally unfolded and pinned ready for screening operations. Tracking: Where as the machine is partially folded for safe transport when moving the machine to a new location or loading or unloading from a transport. Folded: Where as the machine is completely folded for storage with all the conveyors in there proper rests with all weight removed from the hydraulic cylinders. Damage may occur if the machine is TRACKED in this position. This page contains links for computer users. Click on desired section to view information.

REV. C

06/18/02

6-1

ST356

Operator's Manual SET-UP

6-2-1 SITE PREPARATION

When the ST356 is delivered, or whenever it must be moved, even if only to a different location at the same site, a number of items must be considered before the move occurs. Site planning includes: • Selecting a firm, level location. • Selecting a location with enough open space around the machine so that it can be safely operated. • Orienting the ST356 for the most efficient loading. • Checking that no hazards to operation are present. The ST356 must be located on a firm and level foundation and the hopper is adequately supported on the hopper support jacklegs. NOTE: Section 4, Operations, contains details on engine startup and shutdown. The engine must be running for all hydraulic operations described in this section. CAUTION: KEEP ALL PERSONNEL AT A SAFE DISTANCE FROM THE NORDBERG ST356 WHEN IT IS BEING RAISED, LOWERED OR MOVED.

REV. C

06/18/02

6-2

ST356


6-3-1 SCREENING PREPARATION

Detailed information regarding the procedures listed below will be found in the section indicated in parentheses.

(X-X-X) Navigation example: (5-2-1) = (section-page-paragraph) 6-3-1 GENERAL SEQUENCE OF OPERATIONS Un-Folding 1. Remove all loose items stored in the hopper or on the main conveyor. 2. Perform engine pre-start check (5-3-1) 3. Start the engine and run at idle. (5-4-1) 4. Set hopper support legs. (EXTEND) 5. Unfold side conveyors. (UNFOLD) 6. Unfold product conveyor. (UNFOLDING FOR SCREENING OPERATION) 7. Unfold catwalks and platform (6-12-1 CATWALK PLATFORMS) 8. Set desired screen and product conveyor angles (6-13 SCREEN ANGLE) 9. Set main conveyor.(RAISE/LOWER) 10. Set up the hopper grid deck and test operation. (SET-UP for operation) 11. Perform the Daily operational check, Refer to Operations Section (5-6-1) Folding 1. Clear machine of all material. 2. Lower Screen and product conveyor. (LOWER) 3. Set product conveyor trestle for transport. (FOLDING) 4. Lower screen fully. (LOWER) 5. Lower main conveyor fully to lock the screen-box. 6. Fold cat-walks (6-12-1 CATWALK PLATFORMS) 7. Fold the product conveyor. (FOLDING) 8. Fold and raise the side conveyors. (FOLD) 9. Lower the grid assembly. (LOWER for transport) 10. Raise the hopper support legs. (RETRACT)

REV. C

06/18/02

6-3

ST356


6-3-1 SCREENING PREPARATION (continued) Motion / Transport The ST356 must be partially folded or unfolded, depending on starting condition, to be moved or loaded for transport. Failure to do so will result in damage to the machine.

READ THE COMPLETE DETAILED MOTION INSTRUCTIONS FOUND IN SECTION 5-19-1 MOTION INSTRUCTIONS. The following is a brief synopsis of the conditions that have to be met before moving the machine. Find and check the radio remote. Understand the function buttons before proceeding. Detail of the remote will be found in Section 5-13-1 1. Unfold the side conveyors to provide 100mm of clearance from the support. 2. Lower the side conveyors to provide 100mm of side clearance from the support. 3. Raise the Main conveyor / screen to the first exposed hole ONLY. 4. Raise the hopper support legs fully. 5. Place the toggle switch on the main control to radio. 6. Increase the throttle to a position between 1/2 and 3/4. Engine RPMs may be used to regulate track speed. 7. Safety first. Slow and easy control motions. Keep personnel away from the moving machine. Watch for tail swing clearances. Watch for over head obstructions. Stand well clear, the life you save may be your own. Checks and Adjustments Make the following checks and adjustments in preparation for screening operations: •

Check to ensure the ST356 is fully assembled, components are resting on their support pins, and clips are installed and the hydraulic rams are under no pressure.

•

Check that main conveyor and hopper are empty of screens or other accessories before start-up.

•

Ensure the hopper support legs are down and set.

•

Check to see if proper screen selection is in the screen box.

•

Check that the entire screen mounting hardware is tight.

•

Perform Daily Pre-Start Check. Start-up instructions. And Daily Operational Checks Refer to Section 5 Operations.

The general nature of material screening would be considered by definition as: EXTREME OPERATING CONDITIONS. Therefore, extra care and concerns should be placed upon air circulation for engine and hydraulic cooling radiators engine air filtration, maintenance scheduling, material buildup around head and tail drum areas. A cleaning and checking routine to fit your particular application will help reduce failures and unnecessary down time. Due to vibrations over time components may become loose, simple routine checks and corrections, such as checking and tightening the band clamps on the engine air intake tubes, may reduce the chances of major damages. NOTE: TURBO CHARGED ENGINES WILL DRAW AIR IN FROM THE SLIGHTEST OPENING AS AIR FILTERS BECOME DIRTY AND RESTRICTED ROUTINE CHECKS OF ALL TUBE CONNECTIONS AND FILTER CONDITIONS ARE REQUIRED. REV. C

06/18/02

6-4

ST356


6-5-1 HOPPER SUPPORT LEGS Function: To support a loaded hopper while in operation. Location: Mounted on the chassis on the front of the hopper. Description: Hydraulically operated support legs raised and lowered by a hydraulic valve mounted on the chassis on the right hand side at the discharge side of the hopper. A 3 bank valve shared with the undersize wing fold and raise functions. Special notes: Must be fully retracted for moving. Electric micro switches on legs will disengage motion function if legs are not fully retracted.

EXTEND To extend the HOPPER SUPPORT jacklegs of the ST356 (extend the hydraulic cylinder): 1. Remove the pins from the two jacklegs. (may be necessary to move the jacklegs slightly to release pins) 2. Remove hopper support jackleg extensions from the under side of the hopper and attach them to the hopper jacklegs.

RETRACT To Retract the HOPPER SUPPORT jacklegs of the ST356 (retract the chassis hydraulic cylinder): 1. Remove the pins from the two jacklegs. (may be necessary to move the jacklegs slightly to release pins)

Ho p Low per s up er por Ra t le ise gs

4. Reinstall the two pins into the jacklegs.

Wi ng Low Con vey er Ra or ise

Wi n Un g C o nve fold yor Fo ld

3. Move the HOPPER hydraulic cylinder control lever to the “LOWER” position until slight pressure is applied to the support legs. DO NOT LIFT THE HOPPER.

2. Move the HOPPER hydraulic cylinder control lever to the “RAISE” position. 3. Reinstall the two pins into the jacklegs. CAUTION: MAKE SURE THAT ALL PERSONNEL ARE CLEAR OF THE MACHINE. DO NOT LEAVE THE HOPPER IN THE RAISED POSITION WITHOUT JACKLEG PINS INSTALLED.

REV. C

06/18/02

6-5

ST356


6-6-1 SIDE CONVEYORS

Ho pp Low er su ppo er Ra rt le ise gs

2. At the FRONT CONTROL STATIONS, raise side conveyor head-section above its transport support slightly by moving the Side conveyor fold/unfold control lever to the “UNFOLD” position.

Win g Low Con vey er or Ra ise

Win U n g Co n fo vey or Fo ld ld

UNFOLD 1. Remove the pins from side conveyor lifting trestles.

3. Lower side conveyor by moving the raise/lower lever to the “LOWER” position. Slight adjustments to the conveyor head section may be required using the fold/unfold control lever to clear the belt from the transport support. 4. Lower conveyor to the horizontal position. 5.

Fully unfold side conveyor by moving the Side conveyor fold/unfold control lever to the “UNFOLD” position.

Head section return roller (tranport position)

Fold ram Lift trestle pins

Side conveyor transport bracket

6. Remove the hold down straps from side conveyor belt and store them in the toolbox. 7. Pin the troughing roller stations in place. 8. Move head section return roller into operating position.

Lift ram

Transport position (open) Operating position (locked)

(Transport height requirements may have required this roller station to be adjusted while in the folded position.) 9. Raise side conveyor to desired operating height by moving the Side conveyor raise/lower lever to the “RAISE” position. 10. Replace the pins into side conveyor lifting trestles.

Head section return roller (transport position)

11. Repeat steps 1. through 8. above for each Side Conveyor. Bolt location for operation positio

CAUTION: MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE.

REV. C

06/18/02

6-6

ST356


6-6-1 SIDE CONVEYORS (continued) FOLD 1. Remove the pins from side conveyor lifting trestles 2. At the FRONT CONTROL STATIONS, Lower the side conveyor by moving the RAISE/LOWER lever to the “LOWER” position. 3. Install the conveyor belt hold down straps.

Return roller (tranport position)

Fold ram Lift trestle pins

Side conveyor transport bracket

Lift ram

4. Move head section return roller into the transport position. (Transport height requirements may have required this roller station to be adjusted while in the folded position.) 5.

Fold the side conveyor to about ¾ fold, by moving the SIDE CONVEYOR FOLD/UNFOLD control lever to the “FOLD” position.

6. Raise the side conveyor by moving the raise/lower lever to the “RAISE” position. 7. STOP, read and understand the NOTE below before proceeding. NOTE: Check the troughing roller stations have opened and are clearing the main conveyor frame. Ensure the belt does not get caught between the support and the head section frame. Lower the conveyor head section onto the transport support. DO NOT rest the side conveyors into the support brackets if the machine is to be tracked or loaded for transportation. See: Motion instructions in OPERATIONS (5-19-1, steps 4 – 8). OR Slight adjustments to the conveyor head section may be required using the FOLD/UNFOLD and the RAISE/LOWER control lever to clear the belt from the transport support if the machine is to be secured for transport or stored. 1.

Repeat steps 1. through 8. above for each Side Conveyor

CAUTION: MAKE SURE ALL PERSONNEL ARE CLEAR OF THE MACHINE

Transport position (open) Operating position (locked)

Head section return roller (transport position) Bolt location for operation position

REV. C

06/18/02

6-7

ST356


6-8-1 PRODUCT CONVEYOR

UNFOLDING FOR SCREENING OPERATION DO NOT RAISE THE SCREEN ANGLE PAST THE FIRST HOLE WITH-OUT UNFOLDING THE PRODUCT CONVEYOR. 1. Remove product conveyor transport safety bracket “R”clips. 2. Remove any belt hold down straps. 3. At the LEFT REAR CONTROL STATION, completely unfold the product conveyor by moving the lever to the “UNFOLD” position.

Anchor pin & "R' clip

4. Install the product conveyor locking pins and clips at the midsection/head section hinge point. Raise the screen / main conveyor angles and set the product conveyor angle to desired setting. See: Section 5-6-1 for details. The Product conveyor angle adjustment works in conjunction with the main conveyor/screen angle hydraulics. The Product conveyor angle may be independently adjusted by presetting the trestle pins prior to raising the screen angle.

Head section

Transport safety bracket

Product conveyor locking pin Product conveyor trestle

Mid section

Tail section

push levers

pull levers

Product conveyor

Hopper

REV. C

06/18/02

6-8

ST356


6-8-1 PRODUCT CONVEYOR (continued) FOLDING CAUTION: IT IS EXTREMELY IMPORTANT THAT THE ST356 BE FREE OF ALL DEBRIS PRIOR TO BEING MOVED ON PUBLIC ROADWAYS. TAKE ALL NECESSARY PRECAUTIONS TO ENSURE THAT NO MATERIAL WILL DISLODGE AND Rear platform handrail CAUSE DAMAGE Head section Product conveyor OR INJURY. locking pin 1. Remove or rotate and stow Product conveyor ladder in the ladder bracket trestle provided on the catwalk platform if Trestle pin fitted. 2. At the LEFT REAR CONTROL STATION lower the MAIN CONVEYOR/ SCREEN until the product conveyor is at rest and the product conveyor trestle pins can be removed.

Mid section

Tail section Screen / Main trestle

3. Remove product conveyor trestle pins from the operation position and continue to lower the main conveyor / screen angle and replace the pins in the product trestle sleeves when the tubes and sleeves are completely collapsed.

Adjusting holes Screen angle trestle pin (storage position)

Main Conv./Scree n Lower Raise

Main Conveyo r Lower Raise

Product Conveyor Fold Unfo ld

4. Lower the main conveyor / screen angle to the: a)

First exposed hole if the machine is to be tracked.

OR Valve bank

b) Lowest point and re-install the pins if the machine is to be stored.

5. Remove the product conveyor midsection/head section locking pins. 6. Fold the product conveyor to a point just before complete closure, by moving the product conveyor fold/unfold control lever to the “FOLD” position. 7. Align the transport safety brackets and completely fold the product conveyor. Install the transport safety bracket “R” clips.

Anchor pin & "R' clip Transport safety bracket

8. Install the belt hold down straps. The ST356 PRODUCT CONVEYOR is now in the STORAGE position. For conveyor position information while TRACKING, See: Section 5-19-1 When tracking the machine to a new location the product conveyor must be pinned at the lowest hole on the product conveyor trestle and the Screen angle trestle must be raised to the first exposed hole and pinned. For transporting the main conveyor must be lowered at this time. See: Section 6-5-1 for details. Fold the screen catwalk platforms (if transporting). See: Section 6-8-1 for details.

REV. C

06/18/02

6-9

ST356


6-10-1 MAIN CONVEYOR

This function provides clearance between the screen-box and the main conveyor. RAISE/LOWER 1. Remove the Main conveyor angle trestle pins. 2. At the LEFT REAR CONTROL STATION raise the Main conveyor to desired position by moving the Main conveyor raise/lower control lever for the desired function position. 3. Install the main conveyor angle trestle pins. NOTE 1:

Main conveyor Trestle pin Main conveyor trestle

Main Conv. / Screen

Transport position. angle trestle Retract the main conveyor ram to the lower point and insert pin. The main conveyor frame will contact the screen-box depressing the screenbox springs slightly. This will hold the Screen-box in place during transport.

Main conveyor lift ram

Screen sub-frame

NOTE 2: Never access the screen from the top when the main conveyor trestle pins are not installed. SAFETY FIRST.

REV. C

06/18/02

6-10

ST356


6-11-1 GRID DECK

SET-UP for operation The following operation requires the two Grid sub-frame supports to be installed together. These are located at each side of the back of the hopper. 1. Remove support pins from lower end of both the grid sub-frame supports. Install the grid deck sub-frame pins into the grid/subShown in the frame locking holes at each side of the operating position hopper. This locks the two components together (grid subframe and grid deck) enabling the use of the grid lift ram to raise the sub-frame into the operating position. 2. Using the grid raise/lower switch on the engine control box only, move the switch to the raise position. 3. Align the holes of the grid supports with the support anchor mount and insert the pin.

Grid deck Grid / sub-frame locking position Sub-frame support anchor mount Grid sub-frame support Grid deck sub-frame locking pin Support pin Grid deck sub-frame Grid lift & tip cylinder

Use caution when toggling the grid raise/lower switch, as there is a delay in the system. 4. Lower the grid/ sub-frame assembly and remove the locking pins. The grid deck will now move independently from the sub-frame. 5. Check the cycle time of the tipping grid using the remote control. If the grid does not move or does not fully cycle the time adjustments need to be corrected. See: 8-13-1 for details. The tipping grid is ready for normal operation.

Grid deck / sub-frame lock pin (pin must be removed for grid tipping)

Grid lift ram

Support pin

Grid sub-frame support Sub-frame support anchor mount

LOWER for transport 1. Install the grid deck / sub-frame lock pins into the both sides of the GRID/SUBFRAME locking holes. This locks the two components together to use the grid lift ram to lower the grid deck assembly to the transport position.

2. Using the grid raise/lower switch on the engine control box only, slightly toggle the switch to the raise position only enough to relieve the pressure off of the sub-frame support anchor mount pins. 3. Remove the support pins. 4. Using the grid raise/lower switch on the engine control box only, toggle the switch to the lower position until the grid/sub-frame assembly is at the lowest point. 5. Replace the support pins into the sub-frame supports for future use.

REV. C

06/18/02

6-11

ST356


6-12-1 CATWALK PLATFORMS

SET-UP 1.

Stored on the main conveyor are the following components; 1- ladder platform, 2- ladder platform handrails, 1- gate, 1- rear platform handrail and ladder.

2.

Attach the ladder platform to the ladder side catwalk.

3.

Attach the 2- low-end catwalk handrails to both side catwalks.

4.

Attach the ladder platform gate by inserting the gate hinge pin into the hinge tube on the ladder platform handrail and secure pin with “R” clip. (figA)

5.

Rear handrail

Un-Folded

Catwalk rear platforms

Unfold the catwalk handrails and fasten securely to the platform with the “U” bolts provided. (fig.B)

A

7. 8. 9.

B

Raise the catwalk into position. Lifting points are provided for additional aid. (fig.C) In position insert the pins into the locking holes at each pivot point. (fig.C) Install the securing bolts through the platform toe kicks and tighten securely.

C

Handrail in folded position Handrail in secured position

Folded

Gate

Remove the locking pins and securing bolts at the catwalk pivot point.(fig.B) Before raising the catwalk, you Ladder platform must ensure the 2 x catwalk support struts (box section) located at underside of the high end of the walkway are pivoted towards the rear of the machine so that they do not interfere with the walkway when it is folded up into position. 6.

Rear Catwalk platform support pocket

Rear Catwalk platform support (folded position)

10. At the rear catwalk platform, lift the platform and align the support with the support pocket provided under the end of the platform. (fig,B) 11. Install the rear handrail and securely fasten them to the stanchions. (fig.A)

Lift point Securing bolt Locking pin Unfolded locking pin hole

REV. C

Handrail securing notches Handrail securing "U" bolt

06/18/02

6-12

ST356


6-13-1 SCREEN ANGLE

RAISE 1. Ensure that both SIDE CONVEYORS are clear of the screen-box. See: 6-4 for details 2. Remove the screen box angle adjusting pins. 3. At the MAIN / PRODUCT/ SCREEN CONTROL STATION raise the Screen Angle by moving the Screen Angle control lever to the “RAISE” position. 4. Position the product conveyor trestle pins in desired holes before raising the screen angle to the desired operation angle. See: 6-5-1 for details 5. Continue raising the Screen Angle to desired operating position. 6. Replace the pins in the screen angle trestle at the desired screen angle. Main Conv./Screen Lower Raise

Main Conveyor Lower Raise

Product Conveyor Fold Unfold

Main / Screen angle trestle


Valve bank

push levers

pull levers

Product conveyor

Hopper

REV. C

06/18/02

6-13

ST356


6-13-1 SCREEN ANGLE (continued) LOWER The assumption is that the machine is in the operating position. IE: side conveyors unfolded and product conveyor unfolded. 1. Slightly raise the Screen Angle trestle and remove the pins. 2. At the MAIN / PRODUCT / SCREEN CONTROL STATION lower the Screen Angle by moving the Screen angle control lever to the “LOWER” position. 3. Lower the Screen angle until the product conveyor rests in the transport position.

a)

The lowest adjusting hole if the machine is to be tracked.

Main Conv./Screen Lower Raise

Replace the pins in the screen angle trestle at :

Main / Screen angle trestle Main Conveyor Lower Raise

5.

Remove the Product conveyor trestle pins. Product Conveyor Fold Unfold

4.


Valve bank

push levers

OR b)

6.

The last hole if the machine is to be stored or transported.

Lower the screen Angle trestle to rest on the pins.

REV. C

pull levers

Product conveyor

Hopper

06/18/02

6-14

ST356

Operator's Manual TRANSPORT Table of contents

SECTION 7 TRANSPORT

SECTION 7 TRANSPORT ........................................................................................................................... 1 7-2-1 Unloading The ST356 ......................................................................................................................... 2 7-2-2 ST356 – Motion instructions ............................................................................................................... 2 7-4-1 Site Preparation .................................................................................................................................. 4 7-5-1 Preparing for Transport....................................................................................................................... 5

Important: A total understanding of the directions contained in the manual is essential for safe operation of this machine. Note: This machine has three (3) functioning positions: Operational: Where as the machine is totally unfolded and pinned ready for screening operations. Tracking: Where as the machine is partially folded for safe transport when moving the machine to a new location or loading or unloading from transport. Folded: Where as the machine is completely folded for storage with all the conveyors in there proper rests with all weight removed from the hydraulic cylinders. Damage may occur if the machine is TRACKED in this position. The unit should be put into the folded position after loading to transport. This page contains links for computer users. Click on desired page number to view information.

REV. C

06/18/02

7-1

ST356

Operator's Manual TRANSPORT

7-2-1 Unloading The ST356

1.

Select and ensure the site is level and properly prepared.

2.

Verify that the hydraulic control levers at both side conveyor and screen angle control stations are in the neutral or stop position.

3.

Unlock the engine compartment door, and verify all hydraulic control switches are in the neutral or off position.

4.

Release securing chains

5.

Check overhead clearances for power wires, doors, etc.

6.

Continue to 7-3-1 ST356 Motion Instructions

7-2-2 ST356 – Motion instructions

Moving the ST356 requires it to be partially unfolded in order to gain sufficient ground clearance to prevent damage to the machine. The Side conveyors must be moved out away from the Main conveyor to allow clearance for the screen angle to be increased, resulting in ground clearance for the Product conveyor head section.

It is assumed that prior to proceeding in this section, the sections pertaining to the Main control panel (OPERATIONS 5-4-1) the Remote transmitter (OPERATIONS 5-22-1) and the Wired remote (OPERATIONS 5-27-1) have been review and are fully understood. Carefully read the instructions below before attempting to move this machine. WARNING! Failure to follow these instructions will cause severe damage to the machine. 1.

Press and hold in the green MANUAL OVERRIDE button located on the main control panel.

2.

Turn key to the start position and hold until warning horn has stopped (approximately 7 seconds) and the engine has started. Continue to press and hold in the override button an additional 3 seconds after engine has started.

3.

Set throttle not more than 50% engine speed for folding operations.

Note:1 The side conveyor raise and fold stations are located on the upper frame work of the chassis, at the discharge end of the feed hopper (LHS & RHS)

4.

Remove the transport pins from side conveyor lifting trestle. (It may be necessary to raise the conveyor slightly to give clearance prior to removing pins.)

5.

Operate the "unfold" lever to slowly lift the conveyor head section off the transport bracket ensuring the conveyor frame and belting is clear.

6.

Operate the "lower" lever to move the entire side conveyor away from the machine and transport bracket ensuring the conveyor frame and belting are clear of the screen sub-frame.

Note: 2

Repeat 4 through 6 on other side of the machine.

Note: 3

The rear control station is located on the LHS of the machine back of the tracks at waist height.

7.

At the rear control station, move the Screen "raise" lever to raise the screen & product conveyor assembly until the pin can be placed in the lowest exposed hole in the screen angle trestle (approx. 15 degrees). Lower the screen and product conveyor assembly to rest on the pin and install the “R” clip.

8.

At the right hand control station operate the hopper support leg lever to release the positioning pins. Remove the pins and raise the hopper support legs, ensuring they are fully retracted. Replace the pins and “R” clips when closed.

Safety FIRST! REV. C

Continued. 06/18/02

7-2

ST356


ST356 – Motion instructions (continued) 9.

At the Engine control panel move the Track radio/wired switch to the radio position.

10. On the hand–held radio transmitter, rotate the RED knob on the top of the handset in a clockwise direction to switch on. Note: 4 When the hand-held radio transmitter battery is fully charged a GREEN flashing light will be seen at the bottom LHS. When the battery is discharged, a RED flashing light will be seen at the bottom LHS.

11. Press the "Start / Stop" button between the track motion control buttons to arm the system. After a 7-second delay the Rotating beacon and motion alarm will activate indicating the remote tracking system is ready for operation. 12. Increase the throttle to a position between 50% and 75%. Engine RPMs may be used to regulate track speed. It is NOT recommended to use full RPM engine speed for loading / unloading to transport. Note: 5

Before tracking the unit, you MUST ensure that all personell are well clear and it is safe to do so.

Hand-held radio transmitter – functions - Pressing both forward track direction arrow buttons on the radio control will track the ST356 in a straight line. - Depressing one forward track direction arrow button will steer the ST356 in the direction of the stopped track. The same results will occur when the reverse direction buttons are used. Note: 6 Pressing a forward and opposite reverse track control button will pivot the ST 356 extremely fast and is NOT RECOMMENDED.

13. Carefully track the ST356 onto or off of the transport vehicle with great care, Continually checking ground and overhead clearances.

MACHINE WILL SURGE FORWARD AS THE MIDDLE OF THE TRACKS PASS OVER AN EDGE. 14. When the machine is tracked into its final position, press the RED button on the top of the hand-held radio transmitter. The rotating beacon and motion alarm will stop and the system is disarmed. 15. Reduce the engine rpm to a point not more than half speed and fold the ST356 into the closed transport position by reversing the order of the instructions starting at number 7 following to number 4. 16. When the final position is achieved press the red button on the top of the radio control. The rotating beacon and motion alarm will stop and the tracking system is disarmed. 17. Reduce the engine RPMs to idle and turn engine key to "OFF". Stow the hand-held radio transmitter in a safe place, preferably away from the unit.

REV. C

06/18/02

7-3

ST356


7-4-1 Site Preparation

WHEN THE ST356 IS DELIVERED, OR WHENEVER IT MUST BE MOVED, EVEN IF ONLY TO A DIFFERENT LOCATION AT THE SAME SITE, A NUMBER OF ITEMS MUST BE CONSIDERED BEFORE THE MOVE OCCURS. Site planning includes: •

Selecting a firm, level location. A firm site is essential, as the ST356 operation weight may exceed 90,000 lbs. (40,800kg). The site must be firm and level in order that the hopper is adequately supported on the hopper support legs. It may be required that steel plates or wooded blocking are placed under the feet of the hopper supports Levelness is critical to the tracking and loading of the conveyor belts.

•

Selecting a location with enough open space around the machine so that it can be safely operated. Easy access to material piles and visibility of other machines and personnel will improve safety and efficiency.

•

Position the ST356 for the most efficient loading. Initial set-up in a good location, close to the material to be processed and easy access to remove processed material, will provide improved production. The mobility of the ST356 is a great advantage, however, as processed material accumulates around the machine, moving the ST356 requires moving the material in order to move the machine.

•

Check that no hazards to operation are present. Check for operating site hazards such as: Over head power lines, Over head conveying equipment, under ground electrical, gas or water systems.

CAUTION: KEEP ALL PERSONNEL AT A SAFE DISTANCE FROM THE ST356 WHEN IT IS BEING RAISED, LOWERED OR MOVED.

REV. C

06/18/02

7-4

ST356


7-5-1 Preparing for Transport

Complete details of functions outlined in the following will be found in section 6 SET-UP. 1. Thoroughly clean the machine of debris. CAUTION: IT IS EXTREMELY IMPORTANT THAT THE ST356 BE FREE OF ALL DEBRIS PRIOR TO BEING MOVED ON PUBLIC ROADWAYS. TAKE ALL NECESSARY PRECAUTIONS TO ENSURE THAT NO MATERIAL WILL DISLODGE AND CAUSE DAMAGE OR INJURY. 2. Remove all debris from the top and bottom screens. 3. Start the engine and run at idle. 4. Lower the shredder-hammermill, if installed, into the operating position. 5. REMOVE THE ACCESS LADDER. If fitted, lower and fold the side walkways including the handrails. Fold handrails against the walkway decking and secure with transport straps. 6.

At the SCREEN ANGLE STATION lower the screen until the product is at rest and the product conveyor trestle pins can be removed.

7. Remove product conveyor trestle pins from the operation position and continue to lower the screen angle and replace the pins in the trestle sleeve when the tube and sleeve is completely collapsed. 8. Remove the main conveyor trestle pins and lower the main conveyor to the lowest point and re-install the pins. 9. Remove the product conveyor midsection/head section locking pins. 10. Fold the product conveyor by moving the product conveyor fold/unfold control lever to the “FOLD” position. Note: This machine has three (3) functioning positions: Operational, Tracking, and Folded 11. When tracking the machine to a new location the Screen angle trestle must be raised to the first exposed hole and pinned. If the machine has been loaded and is being prepared for transport, the screen angle must be lowered to its lowest point and pinned. If fitted, lower and fold the side walkways including the handrails. Fold handrails against the walkway decking and secure with transport straps. Then the side conveyors may be placed into there transport brackets FOLD THE SIDE CONVEYORS a) Remove the safety pins from Side conveyor lifting trestle. b) At 5 bank SIDE/PRODUCT CONVEYOR CONTROL STATION lower the conveyor to the horizontal position by moving the Side conveyor raise/lower lever to the “LOWER” position. c) Install the hold down straps onto the side conveyor belt. d) Partially fold the conveyor by moving the Side conveyor fold/unfold control lever to the “FOLD” position. IMPORTANT: Do not completely fold the side conveyor as it will not clear the side conveyor support. e) Raise the conveyor to the transport position by moving the Side conveyor raise/lower control lever to the “RAISE” position. f)

Replace the trestle pins into side conveyor lifting trestle.

g) Fully fold the conveyor by moving the Side conveyor fold/unfold control lever to the “FOLD” position. IMPORTANT: The side conveyor must be resting SECURELY on the transport support. Repeat steps a. through g. above for the other side conveyor. Use the 2 bank SIDE/PRODUCT CONVEYOR CONTROL STATION located on opposite side of ST356.

REV. C

06/18/02

7-5

ST356



REV. C

06/18/02

7-6

ST356 Operator's Manual MAINTENANCE Table of contents

SECTION 8 MAINTENANCE

SECTION 8 MAINTENANCE.................................................................................................................... 1

8-3-1 MAINTENANCE SCHEDULING ..................................................................................................... 3

8-5-1 FILTERS.......................................................................................................................................... 5

8-5-2 CAPACITIES ................................................................................................................................... 5

8-5-3 LUBRICANTS.................................................................................................................................. 5

8-5-4 SCREEN BEARINGS GREASE...................................................................................................... 5

8-5-4 PILLOW BLOCK BEARINGS.......................................................................................................... 5

8-6-1 ENGINE OIL VISCOSITY................................................................................................................ 6

8-6-2 ENGINE MAINTENANCE ............................................................................................................... 6

8-6-3 CHECK ENGINE OIL LEVEL .......................................................................................................... 6

8-6-4 REPLACE ENGINE OIL AND FILTER............................................................................................ 6

8-7-1 CHECK AIR FILTER RESTRICTION INDICATOR......................................................................... 7

8-7-2 REPLACE AIR FILTER ELEMENT ................................................................................................. 7 Changing the filter elements ..................................................................................................................... 7

8-7-3 CHECK DIESEL FUEL LINES AND FITTINGS .............................................................................. 7

8-7-4 REPLACE FUEL FILTER ELEMENT.............................................................................................. 7

8-8-1 FUEL PRE-FILTER / WATER TRAP .............................................................................................. 8

8-8-2 BLEEDING THE FUEL SYSTEM.................................................................................................... 8

8-8-3 ENGINE COOLING SYSTEM MAINTENANCE............................................................................. 8

8-8-4 CHECK V-BELTS............................................................................................................................ 8

8-8-5 PERFORM ENGINE TUNE UP....................................................................................................... 8

8-8-6 CHECK VALVE CLEARANCE ........................................................................................................ 8

8-8-7 CHECK TIMING BELT .................................................................................................................... 8

8-9-1 SERVICE THE BATTERY............................................................................................................... 9

8-9-2 CHECK HYDRAULIC OIL LINES AND FITTINGS ......................................................................... 9

8-9-3 CHECK HYDRAULIC OIL LEVEL................................................................................................... 9

8-9-4 RETURN FILTER REPLACEMENT................................................................................................ 9

8-10-1 SUCTION FILTER REPLACEMENT........................................................................................... 10

8-10-2 REPLACE THE HYDRAULIC OIL............................................................................................... 10

8-11-1 HYDRAULIC TROUBLESHOOTING .......................................................................................... 11 Pump cavitates ....................................................................................................................................... 11 Pump over-pressurized........................................................................................................................... 11 Pump flow appears inadequate or non-existent ..................................................................................... 11 Moving parts on or connected to the machine slow down...................................................................... 11 Hydraulic pipes burst .............................................................................................................................. 11

REV. C

06/18/02

8-1

ST356 Operator's Manual MAINTENANCE

8-12-1 HOPPER, GRIZZLY BARS AND FEEDER BELT MAINTENANCE ........................................... 12

8-12-2 REMOTE CONTROL FOR GRIZZLY BAR OPERATION .......................................................... 12

8-13-1 GRID DECK ADJUSTMENT FOR UP / DOWN OPERATION ................................................... 13

8-13-2 FEEDER BELT GEAR BOX MAINTENANCE ............................................................................ 13

8-14-1 CONVEYOR COMMON OCCURANCES ................................................................................... 14 Oblique travel.......................................................................................................................................... 14 Belt tracking ............................................................................................................................................ 14

8-15-1 TROUGHED CONVEYOR MAINTENANCE.............................................................................. 15

8-14-2 TROUGHED CONVEYOR BELT OBLIQUE ALIGNMENT......................................................... 15

8-16-1 TROUGHED CONVEYOR BELT TRACKING ALIGNMENT ...................................................... 16

8-17-1 CONVEYOR BELT TENSIONING .............................................................................................. 17

8-18-1 TROUBLESHOOTING CONVEYOR BELTS.............................................................................. 18

8-19-1 SCREEN MAINTENANCE .......................................................................................................... 19

8-20-1 SCREEN BOX SPEED ADJUSTMENT ...................................................................................... 20

8-21-1 THROTTLE SET ......................................................................................................................... 21

8-22-1 SCREEN MESH CHANGE ......................................................................................................... 22 Handling of meshes: ............................................................................................................................... 22 Tools & Equipment required: .................................................................................................................. 22 Changing the meshes:............................................................................................................................ 22

8-23-1 PREPARATION FOR SCREEN CHANGE ................................................................................. 23

8-24-1 MESH REMOVAL – FEED END ................................................................................................. 24 Un-clamping the Screen mesh: .............................................................................................................. 24 Taking the mesh out: .............................................................................................................................. 24

8-25-1 MESH REPLACEMENT - FEED END ........................................................................................ 25

8-26-1 MESH REMOVAL – DISCHARGE END ..................................................................................... 26 Un-clamping the Screen mesh: .............................................................................................................. 26 8-26-1 Mesh removal – DISCHARGE END (continued) ........................................................................ 27 Taking the mesh out: .............................................................................................................................. 27

8-28-1 MESH REPLACEMENT – DISCHARGE END............................................................................ 28 8-28-1 Mesh replacement – DISCHARGE END (continued) ................................................................. 29

8-30-1 HYDRAULIC SCREEN TENSIONING ........................................................................................ 30 8-30-1 Hydraulic Screen Tensioning (continued) ................................................................................... 31

REV. C

8-31-2 SPHERICAL ROLLER BEARING REPLACEMENT ................................................................... 31

06/18/02

8-2

ST356 Operator's Manual MAINTENANCE Properly maintaining the ST356 is your best insurance for operating at peak efficiency through long periods of use. Maintenance consists of routine servicing of the engine, conveyor bearings/seals and screens.

8-3-1 MAINTENANCE SCHEDULING

Routine maintenance for the ST356 is scheduled based on the accumulated number of hours the machine has been operating or a specified elapsed time interval. Using the hour meter as a guide, perform the maintenance specified for that hourly interval shown on the Required Maintenance Schedule chart. The chart indicates the item to be serviced and the frequency with which the maintenance should be performed. Some maintenance procedures are beyond the scope of this manual as they require qualified service personnel. CAUTION: WHEN CARRYING OUT ANY FORM OF MAINTENANCE OR REPAIR ALWAYS ENSURE THAT THE ENGINE IS STOPPED AND THE IGNITION KEY IS REMOVED AND STORED IN A SECURE PLACE.

Required Maintenance Schedule Daily or E V every ten 40 hour 125 hour hrs Engine

Check engine compartment for leaks Check engine oil level (1)

X(2) X X

Clean air filter elements

X

Replace air filter elements or as required

X X

Clean coolant radiator fins

X

Check coolant additive concentration

X

Change coolant

X(5)

Check battery level

X

Check fuel water separator

X

X(2)

Check valve clearance (4)

X(4)

Check engine mounts

X

Check V- belts

X X

Inspect tracks prior to moving per the daily safety inspection found in the track manufacturers operators manual

Inspect Track components Track tension

X X

Drive unit gear oil (Check)

X

Drive unit gear oil (Replace)

REV. C

X

Change fuel filter

Check glowplugs Tracks

2000hr

X(1)

Check air intake clamps and tubes

Check coolant level

R Y 500 hour 1000hr

X

Replace engine oil and filter (2) Check air filter restriction indicator

E 250 hour

X(8)

06/18/02

X

8-3

ST356 Operator's Manual MAINTENANCE Required Maintenance Schedule Daily or E V every ten 40 hour 125 hour hrs Conveyors Check All conveyor belt alignment

R Y 500 hour 1000hr

X

Inspect all conveyor roller stations (6)

X

Check / Adjust all conveyor scrapers

X

X

Inspect all conveyor drive couplings

X

Inspect/ Adjust skirting rubber

X X

Change Feeder gear box oil Screen

2000hr

X

Check All conveyor belt tensions

Check Feeder belt gear box oil level

E 250 hour

X

Check screen balance

X

Check screen tensions

X

Inspect screen-box and sub-frame

X

Inspect drive coupling

X

Grease screen bearings

X(6)

See section 8-19-1 for more details Hydraulics

Check Hydraulic oil level

X

Check Hydraulic oil lines and fittings

X

Replace Hydraulic oil return filters

X (2)(3)

Replace Hydraulic oil suction filters

X

Replace Hydraulic oil

X

Replace Hydraulic tank breather

X

Inspect all tank mounts

X

Check oil coolers

X

Clean oil coolers Misc.

X

Inspect Hopper grid deck

X

(1) During initial break-in of 200 hours, check engine oil level twice daily (2) Replace after the first 50 hours, then at scheduled intervals. (3) Replace every 250 hours for filters without restriction indicators. Filters with restriction indicators replace as indicated or every 500 hours. (4) Or at 1 year interval (5) Or at 2 year interval (6) Use Shell Alvania RA or equivalent (7) Use SKF LGEP2 or Mobilith SHC-220 or equivalent (8) Replace after the first 100 hours, then at scheduled intervals.

REV. C

06/18/02

8-4


8-5-1 FILTERS APPLICATION

HYDRAULIC OIL SUCTION FILTER

N02445789 (Req. 1)

HYDRAULIC OIL RETURN FILTER

N02445790 (Req. 2)

ENGINE OIL

N05502216

(0117 4421 Deutz)

ENGINE FUEL

N05502218

(0118 0597 Deutz)

AIR (PRIMARY)

N05502219

(0118 0867 Deutz)

AIR (SECONDARY)

N05502220

(0118 0872 Deutz)

8-5-2 CAPACITIES TRACK DRIVE UNIT

PART NUMBER

3.6 QUARTS US

3.4 LITERS

FEEDER DRIVE UNIT

(PER GEAR BOX)

1.7 US PINTS

0.8 LITERS

HYDRAULIC OIL CAPACITY

198 US GAL.

752 LITERS

FUEL CAPACITY

75 US GAL

285 LITERS

ENGINE COOLANT CAPACITY

2.6 US GAL

10 LITERS

ENGINE OIL CAPACITY W/ FILTER (DEUTZ BF4M1012)

3.6 U.S. GAL.

9.5 LITERS

8-5-3 LUBRICANTS ENGINE OIL CLASSIFICATION

A.P.I. CF-4, CG-4, or CH-4

ENGINE OIL SAE GRADE

SEE DIAGRAM BELOW

HYDRAULIC OIL TYPE

SHELL TELLUS 32 OR 46

GREASE GENERAL OVERALL

SHELL ALVANIA RA

SCREEN BEARING

MOBILITH SHC-220 SKF LGEP2

TRACK DRIVE

SAE 80W/90 GEAR OIL

FEEDER DRIVE

VG150 GEAR OIL

or

8-5-4 SCREEN BEARINGS GREASE SCREEN BEARINGS

SKF LGEP2

4 STROKES (4 OZ)

40 HOURS (2)

Grease fittings are color coded Red - Grease weekly. Note: Annually remove the bearing caps, clean out the old grease and refill. The bearings should be 30% to 50% full, over filling will cause overheating and bearing failure.

8-5-4 PILLOW BLOCK BEARINGS

Note: The general ST356 applications for these bearings indicates that re-greasing is not necessary. In this application re-greasing will most likely shorten the bearing life. Self-Lube bearing are factory charged with the correct amount of grease and do not require a further grease charge when being fitted. Relubrication is not normally necessary except when operating at extremes of temperature, speed, loading, extended running or where excessive wet or dirty conditions exist. The re-greasing cycle is dependent upon each application. All cast iron units are fitted with a standard re-greasable bearing insert. The housings are provided with a tapped hole to facilitate re-lubrication and supplied with a plastic plug inserted into the tapped hole. All such units are tapped ¼” UNF. To make the unit re-greasable, remove the plastic plug and substitute with a grease nipple. Avoid over-greasing!

REV. C

06/18/02

8-5


8-6-1 ENGINE OIL VISCOSITY

As the viscosity of lubrication oil is greatly influenced by the temperature, the choice of SAE grade should be governed by the ambient temperature at engine site. Optimum operating behavior will be attained if you take as guide the oil viscosity diagram below. Should temperatures temporarily fall below the limits of the SAE grade selected, this will merely affect the starting performance but cause no damage to the engine. Exceeding the application limits should not be over a prolonged period, in order to keep wear down to a minimum. Oil changes dictated by the time of year can be avoided by using multi-grade oils. Multi-grade oils - particularly light-flowing oils also tend to reduce fuel consumption.

8-6-2 ENGINE MAINTENANCE

REFER TO THE DEUTZ OPERATION MANUAL FOR YOUR SPECIFIC ENGINE. CAUTION: WHEN CARRYING OUT ANY FORM OF MAINTENANCE OR REPAIR ALWAYS ENSURE THAT THE ENGINE IS STOPPED AND THE IGNITION KEY IS REMOVED AND STORED IN A SAFE PLACE.

8-6-3 CHECK ENGINE OIL LEVEL

1. Check engine oil level on dipstick daily. 2. Add oil if oil level is below the add mark on dipstick. NOTE: Do not operate engine when oil level is below the add mark. Oil levels anywhere within the crosshatch on dipstick are considered acceptable to operate engine.

8-6-4 REPLACE ENGINE OIL AND FILTER

Replace after first 50 hours, Intervals of 250 hours there after are recommended. Refer to the DEUTZ Operation manual for details.

REV. C

06/18/02

8-6


8-7-1 CHECK AIR FILTER RESTRICTION INDICATOR

The Air Filter Restriction Indicator is located on the air filter assembly. As the air filter becomes dirty (restricted), the sight glass will turn from clear to red, indicating the need to service the air filter. 1. Inspect the Air Filter Restriction Indicator. If sight glass shows red, service the air filter. CAUTION: DO NOT ATTEMPT TO SERVICE THE AIR FILTER WITH THE ENGINE RUNNING.

8-7-2 REPLACE AIR FILTER ELEMENT

The air cleaner should be serviced on an "as required" basis and replaced every 1000 hours. Service is necessary when engine performance is impaired due to a clogged air filter element indicated by one or more of the following conditions:

Air filter Restriction Indicator sight glass turns red.

Lack of power.

Excessive black or gray exhaust smoke.

High fuel consumption. Changing the filter elements

1. Loosen clamps. 2. Remove air cleaner lower housing and primary filter. 3. Pull primary filter out of lower housing. 4. Thoroughly clean all dirt from upper housing. IMPORTANT: USE CARE NOT TO DAMAGE THE SECONDARY FILTER ELEMENT. 5. Clean dust discharge valve slot by squeezing the ends of valve together, Remove caked dust by squeezing the upper portion of the valve. 6. Thoroughly clean all dirt from lower housing. 7. Inspect condition of secondary filter and check that hex nut is secure. IMPORTANT: REPLACE THE SECONDARY ELEMENT EVERY FIFTH PRIMARY FILTER CHANGE OR WHEN DIRTY OR DAMAGED. DO NOT REMOVE THE SECONDARY ELEMENT UNLESS IT IS TO BE REPLACED. DO NOT ATTEMPT TO CLEAN OR REUSE THE SECONDARY ELEMENT. 8. To replace secondary element: Remove the hex nut and secondary element. To prevent dust from entering the intake system, immediately replace secondary element with new element and tighten hex nut securely. 9. Install new primary filter into lower housing. 10. Install housing and secure clamps. 11. Fully depress the Air Filter Restriction Indicator reset button and release to reset the indicator. IMPORTANT: WHENEVER THE AIR CLEANER IS SERVICED, THE AIR FILTER RESTRICTION INDICATOR MUST BE RESET TO ASSURE ACCURATE READINGS.

8-7-3 CHECK DIESEL FUEL LINES AND FITTINGS

Check the diesel fuel lines for signs of bulging, cracking, and abrasion. Check all fittings for signs of leaking. Replace or tighten as necessary.

8-7-4 REPLACE FUEL FILTER ELEMENT

Replace after first 50 hours, then as required, with a routine service not to exceed 1000 operation hour or 1 year. Refer to the DEUTZ Operation manual for details. REV. C

06/18/02

8-7


8-8-1 FUEL PRE-FILTER / WATER TRAP

Check after first 50 hours. Drain, at every engine oil service interval. Clean element, at every 500 hour engine oil service interval. Replace as necessary. Refer to the DEUTZ Operation manual for details.

8-8-2 BLEEDING THE FUEL SYSTEM

Refer to the DEUTZ Operation manual for details. WARNING: KEEP EXPOSED FLAMES AWAY WHEN WORKING ON THE FUEL SYSTEM. NO SMOKING.

8-8-3

ENGINE COOLING SYSTEM MAINTENANCE

Check engine coolant level daily or every 10 hours of operation. Clean engine cooling system EVERY 125 hours. Check / adjust antifreeze and corrosion inhibitor every 500 hours. Change engine coolant every 2 years or 2000 hours. Refer to DEUTZ Operation Manual for adjustment and replacement procedures

8-8-4 CHECK V-BELTS

1. Inspect V-belt for excessive wear or damage. Replace as required. 2. Check tension of V-belt every 50 hr. Refer to DEUTZ Operation Manual for adjustment and replacement procedures.

8-8-5 PERFORM ENGINE TUNE UP

An engine tune up is recommended every 1000 hours or annually. Perform the following services or have your authorized Deutz service dealer perform them for you.

8-8-6 CHECK VALVE CLEARANCE

Adjusting valve clearance is beyond the scope of this manual, but has a maintenance interval . Refer to DEUTZ Operation Manual for interval and adjustment procedures.

8-8-7 CHECK TIMING BELT

Checking the toothed timing belt is beyond the scope of this manual. Refer to DEUTZ Operation Manual for checking and replacing procedures.

REV. C

06/18/02

8-8


8-9-1 SERVICE THE BATTERY

1. Keep battery clean by periodically wiping it with a damp cloth. NOTE: Low maintenance or maintenance free batteries require little service. However electrolyte level should be checked by removing cell plugs. If necessary, add clean, soft water to bring level to bottom of filler neck. 2. Keep all connections clean and tight. Remove any corrosion, and wash terminals with a solution of 1 part baking soda and 4 parts water. Tighten all connections securely. 3. Keep battery fully charged, especially in cold weather. If a battery charger is used, turn charger off before connecting charger to battery. Attach positive battery charger lead to positive battery post. Then attach negative battery charger lead to a good ground. 4. Coat battery terminals and connectors with a mixture of petroleum jelly and baking soda to retard corrosion. OEM Battery specs. MFG. Bosch ZBB 610 47W Cold start performance 680 rated @ 90 Ah. Dimensions: 172mm wide X 345mm long X 230mm high 6 3/4 in. wide X 13 9/16 in. long X 9 1/16in. high CAUTION: BATTERY GAS IS EXPLOSIVE. KEEP SPARKS AND FLAMES AWAY FROM BATTERY. DO NOT ALLOW BATTERY ACID TO COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR POTECTIVE GOGGLES. DO NOT REST TOOLS ON THE BATTERY.

8-9-2 CHECK HYDRAULIC OIL LINES AND FITTINGS

Check the hydraulic oil lines for signs of bulging, cracking, and abrasion. Check all fittings for signs of leaking. Replace or tighten as necessary.

8-9-3 CHECK HYDRAULIC OIL LEVEL

1. Check the level of hydraulic oil on the sight gauge located on the hydraulic oil tank. 2. If level is below the top of the sight gauge, add sufficient hydraulic oil to raise the level to the top of the sight gauge.

8-9-4 RETURN FILTER REPLACEMENT

1. Switch off the engine and remove the starter key. 2. Close the hydraulic oil return shutoff valve. 3. Using a filter wrench, loosen the hydraulic oil return filter. NOTE: Keep a container under the filter to catch draining oil. 4. Remove the hydraulic oil return filter by hand. 5. Lightly lubricate (using new hydraulic oil) the rubber gasket on the new filter. 6. Install the filter by hand, on the screw threads until the gasket makes contact with the base. Then, using the filter wrench, tighten the filter l/2 to 3/4 of a turn (only). 7. Open hydraulic oil return shutoff valve.

REV. C

06/18/02

8-9


8-10-1 SUCTION FILTER REPLACEMENT

1. Switch off the engine and remove the starter key. 2. Close the hydraulic oil suction shutoff valve. 3. Using a filter wrench, loosen the hydraulic oil suction filters. NOTE: Keep a container under the filters to catch draining oil. 4. Remove the hydraulic oil suction filters by hand. 5. Lightly grease (using new hydraulic oil) the rubber gasket on the new filters. 6. Install the filters by hand, on the screw threads until the gasket makes contact with the base. Then, using the filter wrench, tighten the filter l/2 to 3/4 of a turn (only). 7. Open hydraulic oil suction shutoff valves.

8-10-2 REPLACE THE HYDRAULIC OIL

Hydraulic oil change should occur yearly or every 1000 hours in average operating conditions. Shorter intervals may be required if many optional hydraulically powered equipment is installed or operating in high temperatures or Dusty conditions exist. Testing of Hydraulic oil samples taken at 500 hour intervals are a good way to insure the condition of the oil and may increase change intervals and reduce operating costs. Most reputable oil dealers offer this service and will have sample kits available upon request. Note: Use a suitable container to drain the hydraulic oil into taking care not to spill it. Oil is hazardous to the environment. Note: Fill to the approximately one half to three quarters as indicated by the sight glass when chassis is level. When the ST356is resting on the ground (working position) the level will appear less than when chassis is level.

HYDRAULIC ADJUSTMENTS ARE BEYOND THE SCOPE OF THIS OPERATORS MANUAL AND MUST BE PERFORMED BY QUALIFIED METSO MINERALS REPAIR PERSONNEL. WARNING: HYDRAULIC SYSTEMS UNDER PRESSURE ARE VERY DANGEROUS. UNLESS YOU UNDERSTAND HYDRAULIC LAWS AND REQUIRED SAFETY PRECAUTIONS YOU SHOULD NEVER UNDERTAKE HYDRAULIC MAINTENANCE OR REPAIRS.

REV. C

06/18/02

8-10


8-11-1 HYDRAULIC TROUBLESHOOTING

The following information is intended as a guide to help you determine the cause of faults with the hydraulics as indicated by some observed symptom. It is a good idea to observe the sights, sounds and feel of the machine in operation before the need for maintenance arises. This will enable you to notice any changes with the operation of the machine and act accordingly before any component failure occurs. WARNING: HYDRAULIC SYSTEMS UNDER PRESSURE ARE VERY DANGEROUS AND UNLESS YOU KNOW THE HYDRAULIC LAWS AND REQUIRED SAFETY PRECAUTIONS YOU SHOULD NEVER UNDERTAKE HYDRAULIC MAINTENANCE OR REPAIRS. Pump cavitates 1. 2. 3. 4.

Tank outlet gate valve closed. Suction filter blocked. Air in system. Incorrect viscosity of hydraulic oil for ambient temperature.

Pump over-pressurized 1. Relief valve pressures set too high. 2. Blockage in return line to tank. Pump flow appears inadequate or non-existent 1. 2. 3. 4. 5.

Insufficient oil in tank. Pump inlet partially blocked (possibly incorrect filter or filter blockage). Less likely is a kinked input line. Incorrect viscosity of hydraulic oil. Pump parts worn. Where there is no flow, it is probably a broken pump shaft or key.

Moving parts on or connected to the machine slow down 1. 2. 3. 4. 5. 6. 7. 8. 9.

Engine revs have dropped. Lever controls not fully engaged. Pump has lost efficiency. Casing bolts on motors have become loose. Incorrect grade of hydraulic oil used, leading to thinning or over-heating of oil. Air in system. Line restricted or obstructed. Leaking control valve. Wrong relief valve settings.

Hydraulic pipes burst 1. Pipe subjected to excessive pressure. 2. Pipe subjected to excessive heat.

REV. C

06/18/02

8-11


8-12-1 HOPPER, GRIZZLY BARS AND FEEDER BELT MAINTENANCE

1. Ensure that all guards and doors are fitted and secured before operation. 2. Check that the hopper, grizzly bars and feeder belt are free from obstructions or foreign articles. 3. Inspect the hopper, grizzly bars and feeder belt for wear or damage. Replace any worn or damaged parts. 4. Check that all grizzly bar bolts are tight and free from damage. 5. Inspect grizzly bars and cross members for wear and damage. 6. Ensure feeder belt is tracking correctly.

8-12-2 REMOTE CONTROL FOR GRIZZLY BAR OPERATION

1. Hand held remote transmitter. Also see: OPERATIONS 5-10-2 through 5-11-2 a) Depress the start button once to start tip cycle. The grid will raise to the full open position and delay at the open position for 3 to 5 seconds then automatically return to the operating position. Tip cycle is a timed cycle, speed can not be adjusted. b) Depressing the stop button at anytime within the tip cycle will stop the grizzly deck motion. To restart press the start button. NOTE: Stopping the cycle at any point resets the timer. Restarting the cycle starts the timer from “0”. If the cycle was stopped mid way on the raise, it will be held open until the timer releases the cycle and returns the grizzly deck to the operating position. Always allow sufficient time for the grid timer to complete the cycle before depressing the buttons again. 2. Manually operated hydraulic control. To operate the Grid deck of the ST356 the Grid isolator toggle switch, located on the main control panel, must be ‘ON’ for this function to operate. Also See: OPERATIONS 5-8-4 & 5-8-5. a) RAISE Move the Grid deck hydraulic cylinder control switch to the “UP” position. b)

LOWER Move the Grid deck hydraulic cylinder control switch to the “DOWN” position.

Note: when the UP / DOWN switch is released the grid will stop.

Grid isolator switch Grid up / down

REV. C

06/18/02

8-12


8-13-1 GRID DECK ADJUSTMENT FOR UP / DOWN OPERATION

1. Locate the Grid tip control circuit board inside the control panel face cover. 2. With the ST356 running, the Remote Functions activated and the Grid isolator toggle switch on, press the start button on the remote control. 3. When grizzly bars are in the fully raised position, monitor the time it takes the grizzlies to go from fully open to the beginning of the down cycle. The cycle should be approximately 3-5 seconds.

ANTENNA

4. Adjust the “UP” potentiometer in control panel to allow 3-5 seconds of full open time.

Grid up

5. At the end of the down cycle adjust the “DOWN” potentiometer to allow an approximate 2 seconds of over relief when grizzly bars are down.

Grid down

6. This cycling procedure will have to be repeated a few times for accuracy. NOTE: If operating two or more MetsoNordberg conveyor equipped machines and the remotes are operating all grizzly bars, or interference from other sources are encountered, contact your METSONORDBERG DEALER for further assistance.

8-13-2 FEEDER BELT GEAR BOX MAINTENANCE

The oil to be used in the gearbox is VG150 Capacity; 0.8 litres. The first oil change is 50-100 hrs and every 1000 hrs-6 months depending on duty.

REV. C

06/18/02

8-13


8-14-1 CONVEYOR COMMON OCCURANCES

The following is a brief description of conveyor belt problems with possible corrections. The following pages will outline the adjusting procedures for these common problems. Any mis-alignments should be corrected before operating the machine. For further detailed troubleshooting see page 8-18. Oblique travel

Insufficient alignment of pulleys and idlers

Mis-alignment of carrying idlers

Material build-up on head, tail drums and Idlers. Check belt cleaners and replace if necessary.

Wet patches on the pulley side of the belt due to rain or snow (causes friction variations between the belt and drums and Idlers.)

Side influences due to high winds

Oblique joining of the belt Inspection almost always shows minor obliquities in the joint, but seldom results in oblique travel of the entire belt mainly it is limited to the jointed section. Belt tracking

Belt tracking off to one side or diagonally. Many conditions could affect this problem. Carrying idlers have little affect on an empty belt, the head and tail drum have a greater steering affect on an empty belt. Carrying idlers will have a significant affect with a loaded belt as the belt crosses over a mis- adjusted idler. Return roller mis-alignment will affect a loaded or empty belt equally. Loaded and empty conveyors will react different under such conditions. Uneven heating of the belt during sun rise, allow the belt to run in for a period before readjusting. High wind conditions, empty or lightly loaded conveyors with exposed sides are especially vulnerable to wind conditions. Mis-aligned tail drum. The tail drum belt scraper tension is too tight. The conveyor belt has not been loaded evenly Machine is not sufficiently level. Obstructions caught in the wing type tail drum giving and artificial adjustment to the belt. Material buildup on rollers. Gives the roller or idler different circumferences which will direct the belt away from the larger diameter of the roller. Head or tail drum bearing failure.

Conveyor frame is twisted or horizontally racked. Note: The following conveyor belt maintenance section offers many solutions to the different problems encountered.

REV. C

06/18/02

8-14


8-15-1

TROUGHED CONVEYOR MAINTENANCE

1. Check to ensure that all conveyor guards are in place. 2. Check the belt is free from obstructions or foreign articles. 3. Check the condition of the belt. 4. Check that the belt is running straight and that it is correctly tensioned. 5. Check that all return rollers are straight (90° right angle to the frame) 6. Check end drum bearings for wear or damage and replace as necessary. 7. Check end drums for wear or damage and replace as necessary. 8. Check that all rollers are free from material build up, and running freely. 9. Replace any rollers with defective bearings. 10. Clean all debris around the tail drum and keep this area clear. 11. Check the head drum belt scraper and screen feed plate and adjust as required. 12. Check the tail drum belt scraper and return belt scraper and adjust as required. 13. Check for all rubber skirting and adjust as required.

8-14-2 TROUGHED CONVEYOR BELT OBLIQUE ALIGNMENT

Oblique travel caused by insufficient aligning of the rollers may cause a fast deterioration of the conveyor belt. 1. Align all end drums, rollers and return rollers at 90° right angles to the frame. 2. Check that all end drums and rollers are level to each other. Adjustment is made as indicated below by turning the troughed idlers and rollers in the direction of the arrow, until the belt is running straight and centered on the conveyor. 3. Also return rollers may cause oblique belt travel, and therefore they must be aligned at right angles to frame, and after that adjustment can be made. 4. Check conveyor frame folding mechanisms for proper alignment and tightness of fit.

Check tension

Tail drum belt scraper

REV. C

06/18/02

8-15


8-16-1 TROUGHED CONVEYOR BELT TRACKING ALIGNMENT

If the conveyor belt runs off the center line, then the direction of the belt wander determines in which direction the adjusters have to be adjusted. Side conveyors adjusting bolts tend to move during transport. Tail drum alignment may be necessary upon unfolding. Tail drums must be at 90° right angle to the frame and aligned with the head drum for proper operation. To adjust the belt for running off center line, proceed as follows (see figure below): 1. Level the machine. 2. Run the machine to determine the direction of belt wander. 3.

Stop the machine.

4.

Open the access guard door, (if required.)

5. Tail drum bearing bolts should only be snug, to allow bearing to be adjusted. Loosen tail drum bearing bolts if necessary. 6. Tension the adjuster on one side and slacken the adjuster on the other side. 7. Close the guard door. 8. Start the machine. 9. Repeat steps 1 to 8 until the belt runs straight. 10. Tail drum bolts should be only snug after final adjustment is made. 11. Check belt tension. Belt wandering left

Belt wandering right

Head drum

Belt

Tail drum

Adjust tail drum as shown

Adjust tail drum as shown

Tail drum bearing

Adjuster

REV. C

Bearing bolts

06/18/02

8-16


8-17-1 CONVEYOR BELT TENSIONING

Tension should be measured at the middle of the return side of belt along the centerline. Deflection should not be less than about 2½ inches. NOTE: Over-tensioning will cause bearing failure and belt fatigue. Under tensioned belting will cause spillage and head drum slippage.

Bearing bolts

Adjusting bolts Belt tensioning requires that both adjusters be tensioned equally. 1. Tail drum bolts should only be snug, Loosen tail drum bearing bolts slightly if necessary. 2. Adjust both sides of the tail drum equally. 3. Check belt deflection at the middle of the return side of belt along the centerline. Deflection should not be less than about 2½ inches. 4. Snug the tail drum bearing bolts after final adjustment is complete (if necessary). Note: The tail drum bearing bolts are generally left only snug to allow free movement of the bearing on the frame for tension purposes. Tightening of the tail drum bearings to lock the tail drum position, after adjustment, is acceptable.

REV. C

06/18/02

8-17


8-18-1 TROUBLESHOOTING CONVEYOR BELTS PROBLEM

Belt runs off at tail pulley

12

11

14

18

-

-

Entire belt runs off at all points of line

22

14

12

21

4

13

One belt section runs off at all points of line

2

8

1

-

-

-

Belt runs off at head pulley

12

19

18

13

-

-

Belt run to one side throughout entire length at specific idlers

12

13

18

-

-

-

Belt slip

16

18

11

19

-

-

Belt slip on start

16

19

7

-

-

-

Excessive belt stretch

10

7

18

5

6

-

Belt breaks at or behind fasteners; fasteners tear loose

2

20

10

19

17

7

Vulcanized splice separation

10

20

7

17

2

-

1.

Belt bowed – Avoid telescoping belt rolls or storing in damp locations* a new belt should straighten out when “broken in” or it must be replaced.

2.

Belt improperly spliced or wrong fasteners – Use correct fasteners. Re-tighten after running a short while. If improperly spliced remove belt splice and make a new splice.* Set up a regular inspection schedule.

3.

Belt speed to fast – reduce belt speed.

4.

Belt strained on one side – Allow time for new belt to “break in” If belt does not break in properly or is not new, remove strained section and splice in a new piece*.

5.

6.

Belt return scraper tension to tight. - Adjust scraper tension accordingly. Damage by abrasives, acid, chemicals, heat mildew, oil. – Use belt designed for specific condition. For abrasive materials working into cuts and between plies, make spot repairs with cold patch or with permanent repair patch. Seal meatal fasteners or replace with vulcanized step splice. Enclose belt line for protection against rain, snow, or sun.

7.

Excessive wear, including rips, gouges, ruptures and tears

9

21

14

18

6

-

Excessive bottom cover wear

18

11

16

17

19

-

Excessive edge wear, broken edges

22

4

14

6

1

18

Cover swells in spots or streaks

6

-

-

-

-

-

Belt hardens or cracks

6

20

19

15

-

-

Covers become checked or brittle

6

15

-

-

-

-

Longitudinal grooving or cracking of top cover

23

11

18

9

-

-

Longitudinal grooving or cracking of bottom cover

11

18

19

-

-

-

Fabric decay, carcass cracks, soft spots in belt

9

17

5

7

6

-

Ply separation

10

20

8

6

3

-

Drive under belted – Recalculate maximum belt tensions and select correct belt. If carcass is not ridge enough for the load, install belt with proper flexibility when service is lost.

8.

Edge worn or broken – Repair belt edge. Remove badly worn or out of square sections and splice in a new piece.

9.

Excessive impact of material on belt or fasteners – Use correctly designed chutes. Make vulcanized splices. Install impact idlers. Where material is trapped under skirts, adjust skirt boards to minimum clearance.

10.

Probable solutions in order

PROBLEM

Probable solutions in order

Excessive tension – Recalculate and adjust tension. Use vulcanized splice within recommended limits.

11. Frozen idlers – Free up or replace broken idlers. 12. Idlers or pulleys out–of-square with center line of conveyor – Realign pulleys, On folding conveyors check hinge point adjustment. Head and tail drum must be in line. 13. Idlers improperly placed – Relocate idlers to steer belt. 14. Improper loading, spillage – Feed should be centered on the belt. Control flow with feeder, chutes and skirt boards.

15. Improper storage or handling – Weather and sun damage, cover to protect from elements when not in use. 16. Insufficient traction between belt and pulley – Increase belt tension to recommend tolerance. Worn drive lagging. Check belt return scraper tensions. 17. Material between belt and pulley – Adjust skirt boards and scrapers properly. Improve maintenance. 18. Material buildup – Remove accumulation. Adjust / Install cleaning device. Improve housekeeping. 19. Pulley lagging worn – Replace worn lagging. Use grooved lagging for wet conditions. 20. Pulleys too small for belt web – Use larger diameter pulleys. 21. Relative loading velocity too high or to low – Adjust chutes or correct belt speed. Consider use of impact idlers. 22. Side loading – Load in direction of belt travel, or center load on conveyor. 23. Skirts improperly placed – Install skirt boards so that they do not rub against belt.

* Consult belt supplier for additional recommendations and procedures. REV. C

06/18/02

8-18


8-19-1 SCREEN MAINTENANCE

Daily or E V every ten 40 hour 125 hour hrs SCREEN

Check screen balance

X

Check the screen area for obstructions or foreign articles.

X

Check for missing or damaged channel rubber.

X

Check screen tensions

X

Inspect screen for wear, damage and tension.

X

Check all screen bolts and clamps for tightness

X

Check that all screen guards are in place.

X

Inspect all screen chutes for wear or damage and replace as required

X

Lubricate the bearings in accordance with the lubrication schedule. 8-5-4.

X

Check the condition of the screen box springs.

X

Inspect the anti-vibration bushes for wear, excessive movement or damage

X

Check the condition of the outer bearing seals and replace as necessary

X

Inspect all screen supports and the shaft housing for signs of wear or damage.

X

Inspect screen-box and sub-frame

X

Check the screen drive coupling for signs of wear or misalignment

R Y 500 hour 1000hr

2000hr

X

Inspect drive coupling

*

E 250 hour

X

Clean and re-lube screen bearings, check condition

X

* Bearing service should be performed by an authorized Metso minerals service technician. Bearings, screen-box alignment and screen drive repairs are beyond the scope of this Operators manual, contact your local Metso minerals dealer.

REV. C

06/18/02

8-19


8-20-1 SCREEN BOX SPEED ADJUSTMENT

The screen box speed adjustment is a simple process; however, very critical for proper operation. Note: All operating functions are to be performed at set maximum throttle. The screen box speed adjustment is as follows: 1. With the engine off install reflective tape on the screen box shaft end located on the non motor side of the screen box. 2. Install reflective tape on the engine harmonic balance. NOTE: Remove any other reflective markings to ensure accuracy. 3. Start engine and run engine up to full preset stop. 4. Check engine RPMs. at full throttle preset stop. The engine must be running at 2100 rpms under a no load condition. If it is not, STOP and proceed to section 8-19-1 Throttle set and set the engine speed according to the instructions. 5. Engage the screen. Note the reading. 6. Check screen box shaft speed. Note the rpm. 7. Screen speed should be set to 950 ± 25 rpm (warm). NOTE: "Warm" means oil is approximately 50° C or 122° F.. Warm oil will give an accurate reading. Cold oil will tend to run the screen shaft at a higher rpm and hot oil generally a lower rpm will be registered. 8. Check engine rpm. Adjust if necessary to the proper setting of 2100 rpms. See: 8-19-1 Throttle setting. Note the reading. DO NOT EXCEED MAXIMUM ENGINE SPEED OF 2100 RPMs UNDER A NO LOAD CONDITION. 9. Screen shaft speed is set at the Danfoss valve. The screen section is the second section from the bottom. There are 2 set screws with lock nuts, the left hand set screw adjusts the screen speed. Check

Screen valve

shaft rpm with the oil warmed up (50 Screen Switch deg c +). Shaft speed should be 950 rpm. A slight Throttle turn of the screw makes a large difference in shaft speed. Turning the set screw in decreases the screen shaft speed. Turning the screw out increases the speed. 10. Check speed after tightening lock nut, speed can change. Some oil will weep out from under the lock nut when loose. HYDRAULIC ADJUSTMENTS ARE BEYOND THE SCOPE OF THIS OPERATORS MANUAL AND MUST BE PERFORMED BY QUALIFIED METSO MINERALS REPAIR PERSONNEL.

REV. C

06/18/02

8-20


8-21-1 THROTTLE SET

1. Locate engine throttle stop on the engine injection pump. 2. Hold the Allen screw and loosen the nut. 3. Back the screw out to increase engine speed. Turn the screw in to decrease engine speed.

MAXIMUM ENGINE SPEED 2100 RPMS NO LOAD NOTE Engine speed will not increase until the throttle lever is increased. Very slight adjustment will make significant differences in engine speed. Only adjust slightly then recheck engine speed. 4. After the throttle adjustment on the engine injection pump is complete, increase throttle to full. Ensure the throttle arm contacts the throttle stop screw on the injection pump. If the arm does not contact the stop, the throttle control handles, High engine stop plate, will need to be adjusted as follows: a)

Remove handle. Note the position of friction washers for reassemble.

b)

Move the high engine stop plate one hole to increase movement.

c)

Reassemble handle assembly and recheck throttle stop.

d)

Tighten to friction washers.

5. Check the engine rpm and adjust until within specifications. Note the speed. 6. Tighten the throttle stop lock nut. 7. Check the engine rpm at max throttle. Note the rpm.

REV. C

06/18/02

8-21


8-22-1 SCREEN MESH CHANGE Handling of meshes:

Removing & Replacing Top & Bottom Screen meshes from the Nordberg ST356 requires at least 2 people. Screen meshes are heavy and awkward to handle. Wherever possible always use suitable mechanical lifting equipment with a valid test certificate. Always adhere to Health & Safety regulations when lifting manually or mechanically. Take care of hands and fingers when handling meshes. Wire ends can be extremely sharp and there are many pinch points. Work gloves are recommended when handling screen panels. Eye protection should be worn when working under the Screens. Never use Fuel Gas or other cutting equipment on the Nordberg ST356. If replacement Screen meshes require “trimming” because they have been supplied oversize, never cut them when they are inside or on the machine. Tools & Equipment required: 1 - 30mm Deep series ¾” drive impact socket 1 - 200mm (8”) ¾” drive impact extension bar 1 - ¾” drive reversible ratchet or 1 x ¾” T Bar or 1 x ¾” Impact wrench c/w suitable power supply (e.g.: Electric) 1 - 30mm combination spanner / wrench – short series 1 - 30mm combination spanner / wrench – long series

1 - 46mm combination spanner / wrench – long series 2 - Pry Bars approx. 450mm (18”) long 1 - 19mm combination spanner / wrench 1 - 19mm ½” drive socket 1 - ½” drive socket wrench 1- Lump Hammer Gloves

1 - 46mm Deep series ¾” drive impact socket

Safety Glasses

1 - 46mm combination spanner / wrench – short series NOTE: There are 2 methods of Screen mesh tension for the Nordberg ST356. 1) Manual tensioning 2) Hydraulic tensioning The procedure for the removal and installation of meshes is the same for machines equipped with or without Hydraulic Screen tensioning. The only difference is during the tensioning of the Screen meshes. See notes below. Changing the meshes: ITEM 1:1 TO 5:3 COVER THE REMOVAL & REPLACEMENT OF SCREEN MESHES ON THE ST356 FITTED WITH A MANUAL MESH TENSIONING SYSTEM. IF YOUR UNIT HAS HYDRAULIC SCREEN MESH TENSIONING THEN SEE SECTION 6. To 6:17

REV. C

06/18/02

8-22


8-23-1 PREPARATION FOR SCREEN CHANGE 1. Start and run the engine at idle, to carry out the following steps. 2. Unfold both wing conveyors and product conveyor to the operation position. 3. Raise the Main Conveyor to its highest position and lock in place using the Pin and “R” Clip 4. Remove all debris from the Top Deck Mesh and any debris around the Material Distributor Plate located at the end of the Main Conveyor. If Walkways are not fitted then care must be taken when trying to access the Screen from the sides. It is recommended that you work from a ladder that is suitably secured. 5. If the meshes are badly covered with sticky material it is recommended that the Screen Box be run empty for at least 10mins. After this switch off the unit and remove the key. Inspect the meshes and if they are still badly covered then tap the meshes with a hammer loosening the sticky material. Repeat these procedures until you are satisfied that all material is removed. 6. Raise the Screen / Product Conveyor assembly so that the lift-ram securing pins can be removed. Store pins in a safe place.

7. Lower the Screen / Product Conveyor assembly so that the Product Conveyor is in the horizontal position and resting on the chassis member. Lower the assembly enough so that the connecting trestle bears no load and the pins are loose. Note: If replacing Top Deck meshes only, follow steps 1-7 before mesh removal. There is no need to separate the trestle. Allow the Screen / Product Conveyor assembly to be lowered completely ensuring the Screen Sub-Frame assembly is lowered onto the Chassis frame. 8. Remove trestle pins and store in a safe place. 9. Raise the Screen assembly to its lowest pin position, separating the product conveyor trestle assembly, and replace the lift ram securing pins. 10. If your Nordberg ST356 is fitted with Hydraulic Screen tensioning then ensure that the system is working correctly before changing the meshes. 11. Switch off engine and remove the ignition key. Keep ignition key in your pocket at all times when working on the unit. For extra safety, it is advised that all E-Stops are depressed while working on the Screen. 12. Metso Minerals recommends that prior to the removal of the meshes from the Screen, the replacement mesh, replacement Capping rubbers and Cable Ties are on site. 13. Prior to replacement, thoroughly clean down side plates of the Screen Box. 14. Remove all debris at the points where the Screen mesh hooks into the cross beams. 15. Always inspect the condition of Screen Tension Bolts, Screen Sealing Strips and Clamp Plates during mesh replacement. Replace damaged or worn parts accordingly. 16. Replace all damaged Capping rubbers and cable ties 17. Replace any damaged bolts / nuts / washers etc. 18. Replace / repair any damaged or worn Screen Sealing Strips. 19. While the Screen meshes are removed, inspect all Screen cross members, fixings and general Screen structure for damage or wear. Repair / Replace accordingly.

REV. C

06/18/02

8-23


8-24-1 MESH REMOVAL – FEED END

Note: There is no need to remove the Top Deck meshes when removing Bottom Deck meshes and visa-versa. ACCESS NOTE: Top Deck: The top deck feed end clamp plates are accessed by standing on the rear platform. Bottom Deck: Access the underside of the Screen via the Product Conveyor. Eye protection should be worn when working under the Screen. Un-clamping the Screen mesh: 1. There are 2 screen mesh clamps per deck, securing the mesh in place. Each clamp has 3 x M20 bolts c/w long series nuts fitted. Slacken off all M20 Bolts, ensuring that no damage is caused to the threads. Feed end Clamp 2. Remove all M20 nuts and arraignment store in a safe place. Screen clamp 3. Carefully remove M20 Screen tension bolt the M20 bolts ensuring no Channel rubber damage is caused to the threads. It may be required that you knock out the bolts using a heavy piece of timber. Store in a safe place.

M20 Screen Tension Long nut Banded wire mesh hook

4. As you remove the bolts the clamp plates will now be loose. Screen support Carefully lift them out of the rear of the Screen Box and place them Adjustable Screen sealing safely on the rear platform. strip Special note: If the clamp plates on your machine are fitted with the 2 x M30 Hydraulic tension lock studs then these will need to be un-bolted / bolted accordingly, even if there is no actual Hydraulic tension system fitted to your unit. It is not un-common for units to be supplied with the 2 x M30 Hydraulic tension lock studs, with or without Hydraulic tensioning. Adjustable Taking the mesh out: screen sealing strips Center anchor beam 1. Raise the Screen mesh up and forward from the underside releasing it from the center anchor beam. You may need to knock the mesh loose in the area of the center beam using a heavy piece of wood. 2. Screen sealing strips may have to be adjusted prior to screen removal. Channel rubbers 3. When the mesh is free, carefully remove via the rear of the Screen Box, over the rear access platform. Pass the mesh through the hand-railing and onto the Product Conveyor. Take care of hands and fingers when handling meshes. Use an overhead crane where possible and avoid manual lifting. Store the used mesh away from the machine. 4. Remove any damaged channel rubbers.

REV. C

06/18/02

8-24


8-25-1 MESH REPLACEMENT - FEED END

1. Prior to replacement, thoroughly clean down side plates of the Screen Box. 2. Remove all debris at the points where the Screen mesh hooks into the cross beams. 3. Inspect and repair or replace any damaged componentry. 4. In reverse order to the Mesh removal instructions, install the replacement Screen mesh. 5. When fitting the mesh hook over the center anchor beam, ensure that the mesh hook is engaged as far as possible. NOTE: When installing harp wire be sure to align screen profiles with screen supports 6. When installing the clamp plate, fit the center bolt first and slightly tension until the remaining two bolts can be fitted. Repeat the same for all Screen mesh clamps. Ensure that when the bolt is installed it locates and locks inside the welded captive frame. 7. Evenly tighten the Screen mesh tension bolts along the whole width of the mesh. On heavy wired mesh it is recommended that during tensioning the clamp plates are hit with a hammer in the area of the bolt head. This is done from inside the Screen.

welded captive frame clamp plate Screen tension bolt

8. Do not over tension the mesh and always make sure it is fully seated in the hook at the anchor end of the mesh. 9. If the clamp plates on your machine are fitted with the 2 x M30 Hydraulic tension lock studs then these will need to be un-bolted / bolted accordingly, even if there is no actual Hydraulic tension system fitted to your unit. 10. It is not un-common for units to be supplied with the 2 Clamp plate x M30 Hydraulic tension lock studs, with or without Hydraulic tensioning. Special note: It is recommended that upon completion of the Screen mesh change then the Screen Box is run empty for approx. 10mins and the mesh re-tensioned. This should be repeated after 1 hour of normal operation or until you are satisfied the mesh is secure.

Flat washer M30 half nut Manual tension bolts have been removed for picture clarity

M30 lock nut M30 Hydraulic Tensioning stud M30 full nut Screen hook

REV. C

06/18/02

8-25


8-26-1 MESH REMOVAL – DISCHARGE END

Refer to 8-21-1 and follow steps 1 through 5 if not already done. ACCESS NOTE: Top Deck: The top deck discharge end clamp plate bolts are accessed via the Top Deck Side Conveyor discharge chute. Bottom Deck The bottom deck discharge end clamp plate bolts are accessed via the Bottom Deck Side Conveyor Feed Boot Eye protection should be worn when working under the Screen. Un-clamping the Screen mesh: The screen deck discharge end clamp plate bolts on both top and bottom decks are accessed via the Bottom Deck Side Conveyor Feed Boot. 1. There are 2 screen mesh clamps per deck securing the mesh in place. Each clamp has 3 x M20 bolts c/w long series nuts fitted. Slacken off all M20 Bolts, ensuring that no damage is caused to the threads. Hydraulic Screen tension studs

Screen clamps

Top deck discharge end

20mm screen tension long nuts

Screen removal direction

Bottom deck discharge end

2. remove all M20 nuts and store in a safe place. 3. Carefully remove the M20 bolts being careful not to damage the threads. It may be required that you knock out the bolts using a heavy piece of timber. Store in a safe place. Special note: If the clamp plates on your machine are fitted with the 2 x M30 Hydraulic tension lock studs then these will need to be un-bolted / bolted accordingly, even if there is no actual Hydraulic tension system fitted to your unit. 4. As you remove the bolts the clamp plates will now be loose. Carefully lift them out of their position while standing on the Product Conveyor. Place them safely on the Product Conveyor. Eye protection should be worn when working under the Screen.

REV. C

06/18/02

8-26

ST356 Operator's Manual MAINTENANCE 8-26-1 Mesh removal – DISCHARGE END (continued) 5. Fixed to the side plates of the Screen Box are the Screen Sealing strips. To enable the discharge end Screen meshes to be removed there are 2 small Sealing Strips that require slackening. There is one strip

Center anchor beam

Adjustable screen sealing strips

Feed end screen

Discharge end screen

12mm fastners

located either side of the Screen Box and held in place by 2 x M12 x 40 Bolts. Slacken off the holding bolts and pull the strip downwards. This will allow the mesh to be removed from the center beam easily. If Walkways are not fitted then care must be taken when trying to access the Screen from the sides. It is recommended that you work from a ladder that is suitably secured.

Taking the mesh out: 1. TOP DECK As you remove the bolts the clamp plates will now be loose. Raise the Screen mesh up and forward from the underside releasing it from the discharge end beam. You may need to knock the mesh loose in the area of the discharge end beam using a heavy piece of wood. Carefully lift them out of their position while standing inside the Middle product Wing Conveyor feed boot (if bottom deck fitted) or by standing on the Product Conveyor (if bottom deck not fitted). Place them safely on the Product Conveyor. Eye protection should be worn when working under the Screen. 2. BOTTOM DECK When the mesh is free, Raise the Screen mesh up and forward from the underside releasing it from the discharge end beam. You may need to knock the mesh loose in the area of the discharge end beam using a heavy piece of wood. Carefully remove via the rear of the Screen Box, over the rear access platform. Pass the mesh through the hand-railing and onto the Product Conveyor. Take care of hands and fingers when handling meshes. Use an overhead crane where possible and avoid manual lifting. Store the used mesh away from the machine. 3. Remove any damaged Channel Rubbers. Note: If replacing Top Deck meshes only, there is no need to separate the trestle as described in The Preparation For Screen Change section . Allow the Screen / Product Conveyor assembly to be lowered completely ensuring the Screen Sub-Frame assembly is lowered onto the Chassis frame as described in section 8-21-1 items 1-7.

REV. C

06/18/02

8-27


8-28-1 MESH REPLACEMENT – DISCHARGE END

1. Prior to replacement, thoroughly clean down side plates of the Screen Box. 2. Remove all debris at the points where the Screen mesh hooks into the cross beams. 3. Inspect and repair or replace any damaged componentry. 4. In reverse order to the Mesh removal instructions, install the replacement Screen mesh. 5. When fitting the mesh hook over the center anchor beam, ensure that the mesh hook is engaged as far as possible. 6. When installing the clamp plate, fit the center bolt first and slightly tension until the remaining two bolts can be fitted. Repeat the same for all Screen mesh clamps. Ensure that when the bolt is installed it locates and locks inside the welded captive frame.

Discharge end Screen clamp plate Reverse veiw for clarity

M20 long nuts

7. Evenly tighten the Part# N01565002 M20 X 200mm Screen bolts Screen mesh Part# N01530448 tension bolts along the whole width of the mesh. On heavy wired mesh it is recommended that during tensioning the clamp plates are hit with a hammer in the area of the bolt head. This is done from inside the Screen. NOTE: When installing harp wire be sure to align screen profiles with screen supports 8. Fixed to the side plates of the Screen Box are the Screen Sealing strips. These 2 small Sealing Strips require adjusting. There is one strip located either side of the Screen Box and held in place by 2 x M12 x 40 Bolts. Slacken off the holding bolts if necessary and adjust the strip upwards. Adjust sealing strips snug against the screen mesh and re-tighten the 12mm bolts. If Walkways are not fitted then care must be taken when trying to access the Screen from the sides. It is recommended that you work from a ladder that is suitably secured.Do not over tension the mesh and always make sure it is fully seated in the hook at the anchor end of the mesh.

Discharge end Screen Deck

Adjustable screen sealing strips

M30 Hydraulic tensioning stud

M20 long nut

REV. C

12mm fastners Clamp Center anchor beam

06/18/02

8-28

ST356 Operator's Manual MAINTENANCE 8-28-1 Mesh replacement – DISCHARGE END (continued) If the clamp plates on your machine are fitted with the 2 x M30 Hydraulic tension lock studs then these will need to be un-bolted / bolted accordingly, even if there is no actual Hydraulic tension system fitted to your unit. It is not un-common for units to be supplied with the 2 x M30 Hydraulic tension lock studs, with or without Hydraulic tensioning. Screen hook

Screen discharge end

M30 Hydraulic screen tension stud M20 long nut

Clamp plate

Flat washer Special note: It is recommended that upon completion of the Screen mesh change then the Screen Box is run empty for approx. 10mins and the mesh re-tensioned. This should be repeated after 1 hour of normal operation or until you are satisfied the mesh is secure.

NOTE: CHECK LONG NUTS TO SEE IF BOLT THREADS ARE APPROXIMATELY THE SAME LENGTH. IF THEY ARE NOT, CHECK THE SCREEN TO ENSURE THE CLAMPS ARE SEATED INTO SCREEN HOOKS PROPERLY AND EQUALIZE THE BOLTS.

REV. C

06/18/02

8-29


8-30-1 HYDRAULIC SCREEN TENSIONING

Follow the preceding procedures when replacing the meshes For tensioning procedures with the Hydraulic system see below. 1. When installing the clamp plate ensure both M30 Hydraulic tension lock studs are aligned with the corresponding hole. Ensure no damage is caused to the threads. 2. Screw on by hand the M30 full nut and ensure it is hand tight on both studs. 3. Screw on the M30 ½ nut so it is close to the full nut on both studs. 4. Repeat 2 and 3 on both clamp plates. 5. Slide the tension beam over the two studs ensuring the hydraulic jack is in the correct location and secure in place by screwing on the M30 lock-nut (with plastic insert) 6. At this point you will need to start the engine and run at idle speed. 7. Connect the Hydraulic quick release couplings to their corresponding fittings ( 1 x male & 1 x female) 8. Activate the Hydraulic control lever so that the tension beam is pushed away from the screen. This requires 1 person to monitor the Hydraulic Jack and 1 person to activate the control lever. M20 long nut and bolt must be removed before installing the Hydraulic tensioning ram. Long slot Tension beam

Short slot Hydraulic tensioning ram Hydraulic tensioning studs

Note: Feed End control lever located on LHS of rear platform Discharge End control lever located on floor level at the mid-point of the unit on the RHS

REV. C

06/18/02

8-30

ST356 Operator's Manual MAINTENANCE 8-30-1 Hydraulic Screen Tensioning (continued) 9. While tensioning using the Hydraulic Jack, tighten the full nut against the rear tension frame of the Screen. This should be done on either side, ensuring equal tensioning of the mesh along its width. 10. When complete, check the tension using a 46mm spanner / wrench tightening the M30 ½ nut against the M30 full nut. This must be secured tight. 11. Remove the M30 lock-nut (with plastic insert) from both sides. 12. Remove the tension beam and Hydraulic Jack. Store in a safe place. 13. Switch and lock off engine M30 full nut

M30 half nut

M30 lock nut Hydraulic tensioning stud

14. Re-fit M30 lock-nut (with plastic insert) so that it is secured onto the exposed thread. 15. It is recommended that upon completion of the Screen mesh change then the Screen Box is run empty for approx. 10mins and the mesh re-tensioned. This should be repeated after 1 hour of normal operation or until you are satisfied the mesh is secure. Note: Never run the Screen with the Hydraulic tension beam and Jack fitted. NOTE: When installing harp wire be sure to align screen profiles with screen supports. NOTE: Check screen bolts after four hours of running time. Check to see if the screen is tight even if the bolts are tight.

8-31-2 SPHERICAL ROLLER BEARING REPLACEMENT Bearing replacement is beyond the scope of this operators manual and must be performed by qualified repair personnel.

REV. C

06/18/02

8-31



REV. C

06/18/02

8-32

©

CRAWLER TRACK SYSTEMS LTD

OPERATION INSTRUCTION, MAINTENANCE AND SPARE PARTS MANUAL For Model Nos:−

3340−DL−LDN−TBE1

WARNING Do not attempt to operate these crawler track systems unless you have read and understood these instructions.

TECHNICAL MANUAL


TABLE OF CONTENTS MANUFACTURER’S STATEMENT

Page 2

INTRODUCTION

Page 3

UNDERCARRIAGE IDENTIFICATION

Page 4

GENERAL SAFETY AND ACCIDENT PREVENTION

Page 5

DAILY SAFETY CHECKS

Page 6

OPERATING PRECAUTIONS

Page 7

TECHNICAL SPECIFICATION

Page 8

PARTS LIST

Page 9 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15

1. FINAL DRIVE UNIT 2. MOTION CONTROL / BRAKE RELEASE VALVE 3. FINAL DRIVE SPROCKET 4. LOWER ROLLER GROUP 5. IDLER, RECOIL AND TENSIONER 6. TRACK GROUP 7. TRACK REPAIR LINK

MAINTENANCE INFORMATION

Page 16 Page 16 Page 17 Page 17 Page 17 Page 17 Page 18 Page 18 Page 19 Page 20 Page 21 Page 22 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28

1. CORRECT MAINTENANCE PROCEDURES 2. TRACK DRIVE UNIT 2.1 Routine Checks 2.2 Oil Filling 2.3 Oil Draining 3. TRACK GROUP 3.1 Checking Track Tension 3.2 Track Tightening and Slackening 3.3 Removing the Track 3.4 Rejoining the Track 4. COMPONENT WEAR 4.1 Track Shoe Wear 4.2 Track Link Wear 4.3 Internal Pin and Bush Wear 4.4 External Pin and Bush Wear 4.5 Lower Roller Wear 4.6 Front Idler Wear 4.7 Sprocket Wear

- Page 1 STRICKLAND GROUP

CRAWLERTRACKSYSTEMSLTD©

©Copyright Crawler Track Systems Ltd 2000, Cropthorne, Pershore, Worcs, WR10 3JU.

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TECHNICAL MANUAL


MANUFACTURER’S STATEMENT The tracked undercarriage system is designed as a modular unit for integration to a host machine. It is not intended to be cycled, driven or operated in the free standing condition. Crawler Track Systems Ltd will not be held responsible for the attachment method to the host machine and or any failures of the crawler track system relating to these procedures unless approved in writing by Crawler Track Systems Ltd. Crawler Track Systems Ltd reserve the right to alter the design of a track system at anytime. Modification or abuse of the original design may negate manufacturer’s warranty or guarantee which could conflict with health and safety standards and should not be undertaken without prior consultation with the manufacturer. For full warranty cover, any modification or attachment must be approved in writing by Crawler Track Systems Ltd. Help line is available Monday to Friday, 9am to 6pm, for procedures relating to; attachment, safety, operating or maintenance.




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TECHNICAL MANUAL


INTRODUCTION •

The purpose of this spare parts, operating and service manual is to permit customers to properly employ the crawler track system undercarriage on the machines they intend to install it to.

•

Read this manual with care before conducting any maintenance work on undercarriage supplied by Crawler Track Systems Ltd.

•

Continuous improvements to undercarriages produced by Crawler Track Systems Ltd, may result in some of the illustrations in this manual being slightly different from the actual parts used.

•

It is necessary when requesting spare parts, that all serial numbers relating to the undercarriage are quoted.

•

For full technical support contact our Head Office at: Crawler Track Systems Limited The Heath Works Evesham Road Cropthorne, Pershore Worcs. WR10 3JU Tel No: (+44) 0990 872257 Fax No: (+44) 01386 860057 E-mail: [email protected]




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TECHNICAL MANUAL


UNDERCARRIAGE IDENTIFICATION The picture below illustrates the position of the serial numbers on the track systems.

Serial No. Stamp

The six digit serial number of the track system is stamped on each side frame, vertically down the division plate between the drive housing and the main body of the frame.




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GENERAL SAFETY AND ACCIDENT PREVENTION Please ensure all safety regulations, precautions and instructions are adhered to when installing and/or performing maintenance on the track systems.

1. Protective Equipment Always wear protective clothing and footwear as required by job conditions when working around this product. Wear protective glasses when in risk of splintering debris. Use welders gloves, facial/eye protection and other protective clothing appropriate to welding job being performed. Avoid loose clothing.

2. Unauthorised Modifications It is important not to carry out modifications to the track system which could compromise proper operation and safety. Crawler Track Systems Ltd are not responsible for any injury or damage caused by unauthorised modifications.

3. Pressurised Items Avoid welding near pressurised hydraulic pipelines, track tensioners, recoils or other flammable materials. Excessive heating near to pressurised hydraulic pipelines can cause failure, generating a flammable spray with the possibility of severe injuries to nearby persons.

4. Lifting Use a hoist when lifting components which weigh more than 23 Kg (50lbs). Ensure all hooks, chains etc., are in good condition and tested to an adequate safe working load, and be sure hooks are positioned correctly.




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DAILY SAFETY CHECKS The following checks should be made every day before operation. •

Check for loose bolts and nuts on lower rollers, sprockets and track shoes.

•

Check all track links if master pins are correctly located and tight

•

Check for oil leaks from lower rollers, front idlers.

•

Check for oil leaks from track drive gearbox and motor.

•

Check track tension is within given limits (see paragraph 3.1)

•

Check for general damage and wear to all components.

Take corrective action immediately; tighten bolts and nuts to correct torque, replace damaged or worn components etc. Any persistent problem should be reported to the machine manufacturer. DO NOT operate the machine with damaged or defective track system components.




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TECHNICAL MANUAL


OPERATING PRECAUTIONS When travelling up a gradient, the tracks should be driven forward (i.e. idlers first). The machine should be parked on flat level ground. If it is necessary to park the machine on a gradient, the tracks should be solidly blocked. ALWAYS:• Ensure the terrain the machine is working on is firm enough to adequately support the machine. • Ensure the track systems are free from obstructions, including crushed material and fines before moving the machine. • Ensure the tracks are not frozen to the ground before moving the machine. NEVER:• Attempt to track the machine unless any build up of material is removed from around the tracks and components. • Attempt to track the machine unless the tracks are thawed, when frozen to the ground. • Push or tow the machine when unable to free itself.

WARNING Failure to observe the above precautions could result in danger to persons and damage to the machine which may invalidate warranty.




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TECHNICAL SPECIFICATION

B

A

C

D Main Dimensions: A (Pitch) = B (Overall Length) = C (Overall Height) = D (Track Width) = (Alternative widths available.)

3280 mm (Nominal) 4025 mm (Nominal) 777 mm 400 mm

Other Information: Weight per M/C Set = Dynamic Load = Motor Displacement. = Gearbox Ratio = (Alternative ratios available.)

4,500 Kg 30,000 Kg 63 c.c. 122:1

Example of Performance: Pressure Flow Rate Approx. Speed Approx. Grade Ability

= = = =

300 bar 100 l/min 1.4 km/h 32.0° (62.5%) - Page 8 -

STRICKLAND GROUP



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TECHNICAL MANUAL


PARTS LISTS 1. Final Drive Unit

Item No.

Part No.

Description

1

FDM T70C3B122-9

2

BHM 520250065-1

3

HPS B0202540W-5

Track Drive Gearbox c/w Motor Socket Head Capscrews Torque to 575Nm (424lbs/ft) ¼” Stand Off Pipe

4

POL 00280W/90-0

Gear Oil SAE 80W/90

Qty per Assy

Qty per M/C Set

1

2

20

40

1

2

3.4L

6.8L

All part numbers are suitable for both left hand and right hand track frame arrangements.

Track drive units and hydraulic motors are available as complete units only, reconditioned exchange or new.

WARNING It is recommended that the track drive unit is not opened in site conditions. - Page 9 STRICKLAND GROUP



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2. Motion Control / Brake Release Valve

Item No.

Part No.

Description

Qty per Assy

Qty per M/C Set

1

2

FMV OCUAC1449-K

Motion Control / Brake Release Valve Adaptor Plate

1

2

3

FMV 090-06008057-HOS

Hose and Fittings Set

1

2

4

BHM 510150100-0

Bolts

8

16

5

BHM 512175035-3

Bolts

8

16

1

FMV 06008057-2

2

All part numbers are suitable for both left hand and right hand track frame arrangements. Track drive units and hydraulic motors are available as complete units only, reconditioned exchange or new.

WARNING It is recommended that the valve and fittings are not opened in site conditions. - Page 10 STRICKLAND GROUP



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3. Final Drive Sprocket

Item No.

Part No.

Description

1

SPA 171-07709-21

2

BHM 020250045-9

Drive Sprocket Hex Head Bolt Torque to 435Nm (321lbs/ft)

Qty per Assy

Qty per M/C Set

1

2

16

32





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4. Lower Roller Group

Item No.

Part No.

Description

1

LRG 000SC40A-A

2

BHM 016200085-8

3

WFH 019-2

Single Flanged Lower Roller Hex Head Bolt Torque to 314Nm (232lbs/ft) Hardened Washer

Qty per Assy

Qty per M/C Set

1

16

4

64

4

64





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5. Idler, Recoil and Tensioner

Item 2 Item 3 Item 1

Item 4

Item 3 Item No.

Item 5

Item 6 Qty per Assy

Qty per M/C Set

Front Idler

1

2

IDY 073-3-HD

Yoke

1

2

3

TRG 073-3-1834

Recoil

1

2

4

IDM 889-2

Tensioner Grease Fitting

1

2

5

IDM 888-6

Gasket for Above

1

2

6

TLG 080-9

Grease Gun Adaptor

N/A

N/A

7

MMP 073-3-1834

Tensioner Seal Kit

1

2

Part No.

Description

1

IDG 600-0

2


WARNING Do not attempt to dismantle recoil units. Specialised workshop equipment is necessary. - Page 13 STRICKLAND GROUP



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TECHNICAL MANUAL


6. Track Group

ITEM 2

ITEM 3

ITEM 1

Item No.

ITEM 4

Qty per Assy

Qty per M/C Set

1

2

1

98

4

392

TSN 014-1

Track Chain Track Shoe, 400mm Wide Triple Grouser Track Shoe Bolt Torque to 264Nm (358lbs/ft) Track Shoe Nut

4

392

MPG 0032-6

Master Pin with Collars

1

2

Part No.

Description

1

TCA 07249-A

2

TBG 014400-58-0

3

TSB 02250-3

4 5





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7. Track Repair Link Kit

3 Item No.

2

1

4

5

6 Qty per Assy

Qty per M/C Set

N/A

N/A

Left Hand Link

1

1

TSL 006RH-1

Right Hand Link

1

1

3

MBA 052-7

Master Bushing

2

2

4

MPG 0034-0

Master Pin with Collars

2

2

5

TSB 02250-3

Track Shoe Bolt

4

4

6

TSN 014-1

Track Shoe Nut

4

4

Part No.

Description

TRL 015-9

Repair Link Kit; consisting of:

1

TSL 006LH-1

2





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MAINTENANCE INFORMATION 1. Correct Maintenance Procedures ALWAYS:• perform maintenance on a level and solid surface. • ensure the undercarriage is solidly supported if work is necessary under the track systems. • remove any build-up of grease, oil or debris. • repair all damage and replace worn or broken parts immediately. • use only specified lubricants, do not mix different brands or types. • check for oil leaks and damaged hydraulic hoses. • use great care when maintaining the hydraulic system since oil is very hot when the machine has just been working. • dispose of lubricants in the proper manner. Please note that the maintenance intervals specified are for normal working conditions. If the track system is used in severe working conditions then maintenance and safety checks must be performed more frequently.




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2. Track Drive Unit 2.1 Routine Checks The first oil replacement for the gearbox is to be carried out after 100 operating hours. There after replace the oil every 1000 hours or at least once each year. It is good practise to check the oil level every 100 working hours or every month – whichever comes first.

2.2 Oil Filling To fill, track the machine until the gearbox casing is level with a plug positioned at 12 o’clock as shown below. Unscrew the two plugs and fill from the upper hole until oil flows from the lower hole.

Oil fill

Maximum

2.3 Oil Draining To drain, track the machine until a plug is at 6 o’clock position as shown below. Unscrew both plugs and allow all oil to discharge.

Venting

Drain port




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3. Track Group 3.1 Checking Track Tension Stop your machine on solid and level ground and drive 2 metres (minimum) in a forward direction. Measure the sag on the top part of the track on the longest section of unsupported track as shown below.

Carrier Roller or Skid Plate (whichever is fitted)

The sag of the track must be between 5mm and 15mm . If track tension is not within this range, follow adjustment procedure described in paragraph 3.2.




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3.2 Track Tightening and Slackening

ITEM 1

ITEM 2

The grease contained in the track tensioner is pressurised so care must be taken when loosening the grease fitting (Item 2). 1. To tighten the track, loosen the two screws and swing access cover (Item 1) away from access aperture on the side of the track frame. 2. Connect a grease gun to the grease fitting and add grease until the track tension is within the specified values given in paragraph 3.1. 3. Drive 50 metres forwards and 50 metres backwards and repeat the above procedure if the track slackens. 4. To slacken the track, loosen the grease fitting (Item 2), by turning in an anticlockwise direction, using gradual increments until the grease begins to be expelled. Care must be taken not to loosen the grease fitting too quickly. 5. When the correct track tension has been obtained, tighten the grease fitting by turning in a clockwise direction and clean away all trace of extruded grease. If the track fails to slacken after grease fitting has been loosened, DO NOT attempt to remove the tracks or disassemble the track tensioner, or remove the grease fitting from the tensioner. It is possible that running the tracks with the grease fitting loosened may help to expel the grease.

WARNING The following procedure involves working with grease contained at high pressure and must only be carried out by qualified fitters.




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3.3 Removing the Track To uncouple the track group the following procedure must be followed:

1. Jack up the machine and block safely on firm, level ground. 2. Release the tension on the tracks (as described in paragraph 3.2). 3. Locate the master pin. This can be identified by the indentations in each of the end faces. 4. Rotate the track until the pin is in approximate position (as shown above) and place a block under the front of track. This prevents the chain from dropping once the master pin has been removed. 5. The master pin can now be pushed out from the chain, separating the track.

WARNING When removing the master pin, do not use a sledge hammer. This may cause splintering of the metal with the possibility of injury. 6. The track can now be pulled from under the machine.

WARNING Care must be taken when pulling the track chain from under the machine to avoid dislodging the blocks or stands supporting the machine.




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3.4 Rejoining the Track To rejoin the track group, the following procedure must be followed: 1. With the track chain lined up (i.e. with pin holes and the bushing aligned), a dummy pin should be inserted with the collars in position. 2. The track press should then be set up, with the master pin in position. 3. Press the master pin into the chain, pushing the dummy pin through the link.

WARNING A sledge hammer should not be used to insert the master pin. This may cause splintering of the metal with the possibility of injury.




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4. Component Wear 4.1 Track Shoe Wear

tooth height

The most important wear of a track shoe is the relative height of the grouser to the top of the shoe plate. A depth gauge should be used to measure this.

Shoe Part No. TBG 014400-58-0

Wear Percentage

New Shoe mm

25%

25

24.25

50%

75%

100%

22.75

22

mm 23.5




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4.2 Track Link Wear

link height

To measure the wear use a depth gauge and measure the depth from the bottom of the grouser shoe to the running surface.

Link Part No.

New Link mm

Wear Percentage 25%

50%

75%

100%

94.5

94

mm TLS 006LH/RH-1

96

95.5

95




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4.3 Internal Pin and Bush Wear

4 sections of the link assembly Measurement is made of the elongation of the chain pitch. A standard steel tape can be used. To determine the average internal pin and bushing wear measure across a piece of chain comprising of 4 links (5 pins). This track section must not include the master pin, and should be on the upper side of the track and well stretched.

Chain Part No. TCA 07249-A

Wear Percentage

New Chain mm

25%

685.8

686.5

50%

75%

100%

687.5

688

mm 687




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4.4 External Pin and Bush Wear FORWARD DRIVE SIDE WEAR RADIAL WEAR

REVERSE DRIVE SIDE WEAR

outer diameter Wear of the bushes is caused at the point of contact between the bushing and the sprocket tooth. To measure this wear use a small outside calliper. Outside wear of the bushings can be of any of the 3 types shown above. Measurements should be taken in each position and the area where wear is maximum should be considered.

Chain Part No. TCA 07249-A

Wear Percentage

New Bushing mm

25%

50.8

50.6

50%

75%

100%

50.2

50

mm 50.4




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4.5 Bottom Roller Wear

rail diameter rail diameter The tread wear of the roller is the most important wear area and is measured on the roller diameter. The most suitable tool is a large outside calliper. The correct measurement is to take the smallest diameter of either tread on the roller with the highest wear. Due to the difficulty in carrying out this measurement whilst the rollers are fitted to a machine, it is usually sufficient to measure the rollers closest to the idler and the sprocket, as the greatest wear occurs at these two points.

Roller Part No. LRG 000SC40A-A

Wear Percentage

New Roller mm

25%

155

154.5

50%

75%

100%

153.5

153

mm 154




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4.6 Front Idler Wear

rail height Radial tread wear is the most important factor. The simplest method of measuring tread wear is to measure the depth of tread from the centre of the idler.

Idler Part No. IDG 600-0

Wear Percentage

New Idler mm

25%

17

17.25

50%

75%

100%

17.75

18

mm 17.5




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4.7 Sprocket Wear

tooth depth Sprocket wear is very difficult to assess accurately. In fact, under normal working conditions, the wear occurs in such a way that no trace of the original toothing remains as a valid reference for measuring the wear. It is therefore impossible to provide 100% accurate data for wear measurement. As an approximate rule, the sprocket should be replaced when wear has reached the limits shown in the above illustration. As the wear is never uniform, it is necessary to consider the point at which the wear is at a maximum.

Sprocket Part No. SPA 171-07709-21

Wear Percentage

New Teeth mm

25%

34.1

34.3

50%

75%

100%

34.7

34.9

mm 34.5




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ST356 OM Complete

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