Terex Evoquip Bison 120 Operation Manual Download

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10 Troubleshooting

Operations Manual

Bison 120

20-07-2018

Page 10-14

Revision 2.0

Problem

Possible Cause

Procedure

Engine smoke white

Below starting limit temperature

Check

Incorrect valve clearance

Have the engine manufacturer

check

Starting aids

Have the engine manufacturer

check that cold start system is

operating correctly

Fuel injectors defective

Check / have the engine

manufacturer repair as necessary

Fuel quality not as per operation

manual

Check / Clean

Engine smoke black

Air cleaner clogged /

turbocharger

Check / Replace

Air cleaner service switch /

indicator defective

Check

CPD defective (connection line

leaks)

Have the engine manufacturer

check

Charge airline leaking

Have the engine manufacturer

check / Replace

Incorrect valve clearance

Have the engine manufacturer

check

Fuel Injector defective

Check / have the engine

manufacturer repair as necessary

Alternator charging

problem

Alternator drive belts

Check the condition of the drive

belts, if worn or damaged replace

the belts
Check the tension of the drive

belts, adjust the tension if

necessary

Charging circuit

Check the battery cables, wiring

and connections in the charging

circuit. Clean and tighten all

connections. Replace faulty parts

Regulator

Have the engine manufacturer

verify the regulator is operating

correctly, replace if necessary

Alternator

Have the engine manufacturer

verify the alternator is operating

correctly, repair or replace if

necessary

Summary of Contents for Evoquip Bison 120

Page 1: ...Bison 120 Terex 2018 MOBILE CRUSHER Issue Date 20 07 2018 Language English en Revision No 2 0 Original Intructions Operations Manual...

Page 2: ...EvoQuip 200 Coalisland Road Dungannon Co Tyrone BT71 4DR Telephone 44 0 28 8774 0701...

Page 3: ...ason for Change Date 1 0 Introduction of the new Bison 120 manual August 2016 1 1 Start Up Procedure Update Maintenance Updates Greasing Schedule Updates Other General Updates 2 May 2017 2 0 Californi...

Page 4: ...Record of Revisions Operations Manual Bison 120 20 07 2018 Page 2 Revision 2 0 Intentionally Left Blank...

Page 5: ...Ownership 1 6 2 Safety 2 2 1 Safety Warning Symbol 2 2 2 ANSI Hazard Classification System 2 2 3 Property Damage Messages 2 3 4 Positions of Safety Signs on the machine 2 3 2 2 Personal Safety 2 8 1...

Page 6: ...Unit 4 5 2 Crushing System 4 5 a Jaw Crusher 4 5 b Dust Eliminating System Optional 4 5 3 Feed System 4 5 a Vibrating Feeder 4 5 4 Conveying System 4 5 a Extracting Belt 4 5 b Magnetic Belt Optional...

Page 7: ...arting the Engine 6 9 2 Placing the Extraction Belt Into Working Position 6 11 3 Setting the Crusher Discharge Opening 6 12 6 9 Introducing Material to Machine 6 13 6 10 Initial Startup and Running In...

Page 8: ...her Pump Filter 9 17 b Changing Load Sensing Pump Filter 9 18 c Changing The Oil Tank Filter 9 20 d Changing Hydraulic Oil 9 21 9 7 Conveyor Maintenance 9 23 1 Clean and Check the Conveyor Belts 9 23...

Page 9: ...e 9 55 1 Checking components for wear 9 55 a Daily Component Checks 9 55 2 Jaw Liner Maintenance 9 55 a Removal of Moving and Fixed Jaw Liners 9 55 3 Side Jaw Liner Maintenance 9 57 9 12 Drive Belt Ma...

Page 10: ...Terms 12 1 13 Appendix 13 1 Appendix A EC Declaration of Conformity A 1 Appendix B Warranty B 1 Appendix C Schematics C 3 1 Electrical Schematics C 3 a Front Panel CPU Connection C 3 b Front Panel CPU...

Page 11: ...pment 1 3 1 2 Safety Information 1 3 1 Safety Warning Symbol 1 3 2 ANSI Hazard Classification System 1 3 3 California Proposition 65 Warnings 1 4 1 3 Intended Use 1 4 1 4 Prohibited Use 1 4 1 5 Declar...

Page 12: ...machine and the situation conditions prevailing at the time Federal State National and Local laws and safety regulations must be complied with always Compliance may prevent possible danger to persons...

Page 13: ...ty refer to the safety section of the manual Chapter 2 2 ANSI Hazard Classification System This machine contains ANSI type safety signs to assist in hazard recognition and prevention The ANSI hazard c...

Page 14: ...perating instructions the performance of maintenance work as specified and adherence to maintenance intervals are all aspects of proper use Use of this product in any other way is prohibited and contr...

Page 15: ...01 To order additional copies contact your local Evoquip dealer 1 8 Bulletin Distribution and Compliance Safety of product users is of paramount importance to Evoquip Various bulletins are used by Evo...

Page 16: ...d regulations compliance information Questions regarding product modifications Current owner updates such as changes in machine ownership or changes in your contact information See Transfer of Machine...

Page 17: ...3 Work Area Safety 2 9 1 General Work Area Guidelines 2 9 2 Safety Warnings and Labels 2 9 3 Modifications 2 9 4 Transportation Safety 2 10 5 Operation Safety 2 10 6 Hydraulic and Pneumatic Safety 2...

Page 18: ...o alert you to potential personal injury hazards Obey all messages that follow this symbol to avoid possible injury or death Conduct thorough risk assessments and mitigate identified risks in accordan...

Page 19: ...and fitted to the machine to warn of possible dangers and MUST be replaced immediately if they become unreadable or lost If the machine is repaired and parts have been replaced on which safety signs w...

Page 20: ...anual Bison 120 20 07 2018 Page 2 4 Revision 2 0 Item Safety Sign Meaning 3 Risk of hand entrapment 4 Possible stones projection 5 Do not remove casings or safety protection 6 Lifting points 7 Danger...

Page 21: ...20 07 2018 Page 2 5 Revision 2 0 Safety 2 Item Safety Sign Meaning 8 Direction of movement 9 Danger of parts in motion 10 DANGER Moving parts Stop the engine 11 Always wear helmet gloves and working g...

Page 22: ...6 Revision 2 0 Item Safety Sign Meaning 13 Access prohibited to those wearing pacemakers when a magnetic belt has been installed on the machine 14 Anchorage points 15 Battery 16 WARNING Cancer and Re...

Page 23: ...Operations Manual Bison 120 20 07 2018 Page 2 7 Revision 2 0 Safety 2 Figure 2 1 Location of Safety Signs...

Page 24: ...must carry out work on the electrical system Work on the electrical system must be in accordance with electrical engineering rules and regulations Only personnel with special knowledge and experience...

Page 25: ...mpty and cleared of all material beforehand Always check that walkways and handrails are fully secured in place before using Do not smoke or allow smoking near flammable fuels or solvents Use non flam...

Page 26: ...the machine The machine must be loaded and transported only in accordance with the operating instructions For maneuvering the machine observe the prescribed transport position admissible speed and it...

Page 27: ...llers Always use ladders steps and walkways when mounting and dismounting Hole alignment on mechanical supports must be checked and secured with pins provided and in accordance with safety signs Follo...

Page 28: ...must always be worn when working with hydraulic and pneumatic equipment Check for leaks in tanks or tubing with flashlights or other proper equipment Never check for leaks using an open flame to Alway...

Page 29: ...ed for in the regulations the power supply to machines and parts of machines on which inspection maintenance and repair work is carried out must be isolated Before starting any work check the de energ...

Page 30: ...id and stable supports Make sure that any part of the machine raised for any reason is prevented from falling by securing in a safe reliable manner Never work under unsupported equipment For carrying...

Page 31: ...sight or sound of the operator After cleaning examine all fuel lubricant and hydraulic fluid lines for leaks loose connections chafe marks and damage Any defects found must be rectified without delay...

Page 32: ...atory protection as required by Federal State and Local safety and health regulations Carry out welding flame cutting and grinding work on the machine only if this has been expressly authorised as the...

Page 33: ...fire extinguisher mounting brackets and caution must be taken There are hydraulic hoses and pipes on the opposite side of the recommended mounting area When the holes are drilled they are to be thread...

Page 34: ...STAY CLEAR FROM MAGNET The operator must stand out of the exclusion zones while the machine is operating The magnetic field can disturb pacemaker operation if within 3 metres n n WARNING Flying Materi...

Page 35: ...ncy Stop Locations Emergency stops are located at both the left hand side and right hand side of the machine Further emergency stops are located on the control panel and radio control panel 1 DUN03194...

Page 36: ...2 Safety Operations Manual Bison 120 20 07 2018 Page 2 20 Revision 2 0 Intentionally Left Blank...

Page 37: ...Data 3 2 3 1 Machine Specifications 3 2 1 Machine Components Specifications 3 2 a Jaw Crusher 3 2 b Grizzly Feeder with Hopper 3 2 c Power Unit 3 3 d Extracting Belt 3 3 2 Tracks 3 3 3 2 Dimensions 3...

Page 38: ...The technical data given in this section are given as approximations for reference only 3 1 Machine Specifications Weight approximate Complete Machine 11 850 kg 13 06 US Ton 1 Machine Components Speci...

Page 39: ...e Isuzu turbo engine Performance 61kW 83hp 52kW 70hp Operating rpm range 1500 2500 rpm 2000 rpm maximum Plant drive Hydraulic drive Hydraulic drive d Extracting Belt Belt Length 6340 mm 20 10 Belt Wid...

Page 40: ...3 Technical Data Operations Manual Bison 120 20 07 2018 Page 3 4 Revision 2 0 3 2 Dimensions 1 Working Range and Transport Diagrams Figure 3 1 Working Range and Transport Dimensions...

Page 41: ...in decibels 121 dB A Peak C Weighted Instantaneous Sound Pressure Level 103 4 dB C Values determined according to basic standard ISO 3746 ISO 11203 Note Declared single number noise emission values ar...

Page 42: ...3 Technical Data Operations Manual Bison 120 20 07 2018 Page 3 6 Revision 2 0 Intentionally Left Blank...

Page 43: ...Power Unit 4 5 2 Crushing System 4 5 a Jaw Crusher 4 5 b Dust Eliminating System Optional 4 5 3 Feed System 4 5 a Vibrating Feeder 4 5 4 Conveying System 4 5 a Extracting Belt 4 5 b Magnetic Belt Opt...

Page 44: ...ellent product shape and high reduction ratios Vibrating Feeder fitted as standard Easily transported on and off site Magnetic Conveyor Optional Protective hopper sides Optional Dust suppression spray...

Page 45: ...re 4 2 Location of Machine Identification Plate 2 Machine References When using this handbook at all times the right and the left hand references are viewed from the feeder end of the machine When usi...

Page 46: ...4 4 Machine Components Item Description Item Description 1 Undercarriage 10 Service ladder 2 Extraction belt 11 Evacuator belt not applicable 3 Vibrating drawer 12 Open able back door 4 Charging hopp...

Page 47: ...ray system with atomiser nozzles is mounted over the crusher mouth to reduce the amount of dust produced by the machine This is piped from a 200 litre water tank located at the front of the crusher 3...

Page 48: ...ack frame and control systems 8 Guards The Bison 120 is equipped with a range of panels and external hoods which are an integral part of the safety measures taken for the operator s safety Removing th...

Page 49: ...rol system This enables crushers functions to be controlled easily Figure 4 5 Tier 4 Control Panel Item Function 1 Multifunction Display 2 Glow Light 3 Ignition Key 4 Accelerator Potentiometer 5 Extra...

Page 50: ...track enabling lever Item 2 Jaw opening regulation lever Item 3 Vibrating drawer start up switch Item 4 Radio control leds Item 5 Vibrating drawer speed regulator Item 6 Extractor belt opening closing...

Page 51: ...pper Protector 2 Magnetic belt a magnetic belt can be installed to separate out materials containing iron which is thus captured and discharged from the side Figure 4 8 Magnetic Belt 3 Dust eliminatio...

Page 52: ...of high performance primary jaw crushing machines are designed for small and medium scale operators in quarrying demolition recycling mining applications The applications in which it can be used for...

Page 53: ...e Extraction Belt Into Transport Position 5 5 5 3 Loading the Machine for Transport 5 8 1 Prior to Haulage 5 8 2 Tracking Machine onto Trailer 5 9 3 Lifting Machine onto Trailer 5 10 4 Ready for Trans...

Page 54: ...nd pin holes Use a piece of cardboard or wood to search for leaks Do not use hand Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this type of inju...

Page 55: ...site Soft or uneven ground may cause accidents On sloping terrain always adapt your travelling speed to the relevant ground conditions Never change to a lower gear on a slope Always change gear before...

Page 56: ...on Wear personal protective equipment Prior to transportation always check the machine for loose and or damaged components Fasten all loose parts replace missing items or make repairs as found necessa...

Page 57: ...vestigated and rectified immediately by suitably qualified personnel PROCEDURE 1 Observe all safety warnings 2 Ensure that all of the emergency stop buttons have been released 3 Turn the isolator swit...

Page 58: ...e 5 3 Radio Ignition Switch 8 Press button 2 to connect the handset to the reciever Reference Figure 5 3 9 The green LED on the handset will now be flashing slowly and the blue STATUS light on the rec...

Page 59: ...nutes to warm it The number of revolutions will appear at the top of the multifunction display 13 On the radio remote push the extraction belt open close lever Item 1 forward until belt has folded com...

Page 60: ...Check that the travelling dimensions and weight when loaded will be within the regulation limits refer to plant specification and information 3 Make sure suitable ramps are positioned at the end of t...

Page 61: ...brake on and apply wedges to the tyres to avoid any possible slippage during loading unloading In the winter warm the engine and hydraulic system up first before loading unloading using slides When u...

Page 62: ...mize the risk of damaging the machine when lifting Ensure that the lorry has its parking brake on and apply wedges to the tyres to avoid any possible slippage during loading unloading When unloading t...

Page 63: ...e that all loose items are carefully stowed and secured if these are to be transported on the machine 6 Using suitable lifting equipment lift the crusher on to the back of the transporter 7 Secure the...

Page 64: ...transporting this machine you must read and understand the Safety section in this manual NOTICE Before tracking the machine ensure the engine speed is at idle or on slow tracking mode for machines wi...

Page 65: ...nts NOTICE When transporting the machine it is the responsibility of the haulage contractor to secure the machine to the transporter This machine is fitted with transport tie down brackets the bracket...

Page 66: ...st be such as to form an angle of 12 15 with the ground The ramp must be at least 4 times as long as the lorry loading surface The width of the slide must be at least 1 2 times the width of the tracks...

Page 67: ...ion suitable ramps at the end of the transporter 3 Remove the fastenings securing the machine to the transporter Figure 5 13 Transport Tie Down Points 4 Start the engine 5 Ensure the engine speed is a...

Page 68: ...s its parking brake on and apply wedges to the tyres to avoid any possible slippage during loading unloading When unloading the machine the operator must always maintain a safe distance from the machi...

Page 69: ...Measures After Long Term Standstill 6 4 6 6 Pre Operating checks 6 5 1 Checking Engine Oil Level 6 5 2 Checking Diesel Level 6 6 3 Checking Hydraulic Oil Level Check 6 7 4 Checking Track Tension 6 7 6...

Page 70: ...r discharges overspill material vehicle movements and other site related hazards must be anticipated Avoid these risks by carrying out risk assessments before the machine is put into operation Ensure...

Page 71: ...erial or metal from entering the chamber In order to prevent bridging of the crusher no material above the size recommended should be fed into the machine The machine is designed so that when in trans...

Page 72: ...l non operational position The machine must be placed on solid ground capable of carrying the weight of the machine Before detaching the machine from the prime mover it is important that the chosen si...

Page 73: ...hydraulic oil level Check the track tension If any of the above are not satisfactory please follow the procedure outlined in Section 9 to find a solution to rectify the problem before startup 1 Checki...

Page 74: ...d naked flames when working on the fuel system Do not smoke Risk of fire or explosions resulting in serious injuries or death PROCEDURE 1 Observe all safety warnings 2 Position the machine in a flat s...

Page 75: ...outside of the tank Top up hydraulic oil as required through the refill cap Item 2 Figure 6 3 Hydraulic Oil Level 4 Checking Track Tension PROCEDURE 1 Observe all safety warnings 2 Position the machin...

Page 76: ...ving Ensure an adequate distance is keep from the assembly when being raise from the ground Failure in doing so may result in serious injuries Always wear correct personnel protective equipment n n CA...

Page 77: ...lts displayed on the electrical control panel screen should be investigated and rectified immediately by suitably qualified personnel PROCEDURE 1 Observe all safety warnings 2 Ensure that all of the e...

Page 78: ...ll be flashing at a fast speed which means the handset is not connected Figure 6 7 Radio Ignition Switch 8 Press button 2 to connect the handset to the reciever Reference Figure 6 7 9 The green LED on...

Page 79: ...he multifunction display 2 Placing the Extraction Belt Into Working Position n n WARNING Always wear appropriate personnel protective equipment PROCEDURE 1 Observe all safety warnings 2 Start the engi...

Page 80: ...discharge opening NOTICE The size of the crushed aggregates can be regulated by bringing the mobile jaw closer to or moving it further away from the fixed jaw PROCEDURE 1 Observe all safety warnings 2...

Page 81: ...d of the machine to give their shovel loader a better reach into the hopper Item 1 Figure 6 12 Feeding Hopper 2 If you do build a ramp avoid contact with the side end of the machine 3 Initial feed rat...

Page 82: ...period Check for abnormal noises vibration or excessive heat from shaft bearings fluid leaks and so on All control systems must be checked for full function Each day during the initial days of operat...

Page 83: ...andard Operating Procedures 7 2 7 2 Pre Operating Checks 7 3 7 3 Initial Startup 7 4 7 4 Start Up 7 5 7 5 Manoeuvring 7 8 1 Tracking the Machine 7 9 2 Remote Tracking 7 10 3 Remote Tracking with Umbil...

Page 84: ...r example engine manual EvoQuip cannot overemphasize the need to ensure that all safety aspects are checked before starting the machinery Crush hazard from tracking machine Ensure all personnel are cl...

Page 85: ...T continue to operate the machine UNTIL the malfunction is corrected The following items should be checked prior to starting up the machine Ensure the machine is placed on solid ground capable of carr...

Page 86: ...fer to the engine manufacturer s manual for initial start up of the engine 2 Run the machine empty for a short period of time and check for abnormal noises vibration or excessive heat from the shaft b...

Page 87: ...stop buttons have been released 3 Turn the isolator switch to the ON position Item 1 Figure 7 1 Isolator Switch 4 Turn the ignition key Item 1 on the dashboard to ON Figure 7 2 Ignition Switch 5 Check...

Page 88: ...nce Figure 7 3 9 The green LED on the handset will now be flashing slowly and the blue STATUS light on the receiver will be flashing showing a connection If a red LED flashes then either The toggle sw...

Page 89: ...tions Manual Bison 120 20 07 2018 Page 7 7 Revision 2 0 Figure 7 5 Accelerator Potentiometer 12 Keep the engine ticking over on idle for few minutes to warm it The number of revolutions will appear at...

Page 90: ...tow the Machine Failure to observe this warning could result in danger to persons and damage to the machine which may invalidate warranty Ensure that the tracks are free of all obstructions including...

Page 91: ...ding adequate rest When travelling up a gradient the tracks should be driven forward i e idlers first drive sprocket to the rear When travelling down a gradient tracks should be driven sprocket first...

Page 92: ...ace the one in use regularly It is advisable to let the battery run down completely before recharging PROCEDURE 1 Observe all safety warnings 2 Start the engine 3 Use the accelerator potentiometer Ite...

Page 93: ...the tracks press the directional buttons Items 1 4 Figure 7 9 Umbilical Handset Functions The radio handset functions are as follows Position 1 Left Hand Side Track Forward Position 2 Right Hand Side...

Page 94: ...replacement the machine can function by connecting a cable supplied from the radio control console to the central unit PROCEDURE 1 Observe all safety warnings 2 Unroll the supplied connection cable a...

Page 95: ...If you move the lever downwards this will enable the crusher in the opposite direction to that required for work This command is used should the crusher become blocked see instructions further on TO S...

Page 96: ...Figure 7 13 Chamber Start Button 6 On the radio remote press the vibrating drawer start button Item 1 This will start the vibrating drawer The speed of which the drawer feeds the material to the cham...

Page 97: ...rior to this Before stopping the machine ensure that all components are clear of material When the engine of the crusher is stopped it will continue to rotate for approximately 30 seconds under the in...

Page 98: ...7 16 Revision 2 0 5 Turn the ignition key Item 1 of the radio control OFF Figure 7 17 Radio Ignition Switch 6 Turn the ignition key Item 1 on the dashboard to OFF Figure 7 18 Ignition Switch 7 Wait fo...

Page 99: ...to move after materials have been removed dangerous nip points and flying material hazards exist n n CAUTION To comply with health and safety law it is necessary to carry out adequate risk assessment...

Page 100: ...ns to enable safe removal of the material that has created the stall condition The procedure indicated below or any other procedure developed to remove tramp metals or any other material that results...

Page 101: ...tarting at the mid point and working outwards either side in turn Ideally the toggle plate should be heated until it yields The yielding of the toggle plate will reduce or eliminate the pressure on th...

Page 102: ...7 Standard Operating Procedures Operations Manual Bison 120 20 07 2018 Page 7 20 Revision 2 0 Intentioanlly Left Blank...

Page 103: ...e of Content 8 Emergency Operating Procedures 8 2 8 1 Lockout and Tagout 8 2 1 Before Carrying Out Any Work on the Machine 8 2 2 After Carrying out Work on the Machine 8 4 8 2 Emergency Stop 8 5 1 Eme...

Page 104: ...key to anyone else and where more than one person is working on the equipment they must fit their lock also 1 Before Carrying Out Any Work on the Machine NOTICE Depending on the type of machine there...

Page 105: ...solator switch from the OFF position Item 1 to the ON position Item 2 Reference Figure 8 3 Figure 8 3 Isolator Switch 6 Fit the lockout and tagout hasp Item 1 followed by the unique padlock Item 2 on...

Page 106: ...chine to make sure that the power is off 10 Push the stop button again afterward 2 After Carrying out Work on the Machine PROCEDURE 1 Secure the work area by replacing guards and shields removing bloc...

Page 107: ...ime an emergency stop button is used to stop the machine In an emergency situation stop the machine by pressing an emergency stop button on the machine PROCEDURE 1 Press the emergency stop to stop the...

Page 108: ...pper or on the conveyors and platform walkway PROCEDURE 1 Release the emergency stop button s by pulling or twisting 2 Start the machine 8 4 Testing Emergency Stops PROCEDURE 1 Start the engine 2 Push...

Page 109: ...raulic Filters Oil 9 17 a Changing Crusher Pump Filter 9 17 b Changing Load Sensing Pump Filter 9 18 c Changing The Oil Tank Filter 9 20 d Changing Hydraulic Oil 9 21 9 7 Conveyor Maintenance 9 23 1 C...

Page 110: ...e 9 51 1 Changing Gearbox Oil in Tracks 9 52 2 Track Adjustment 9 53 a To Release Track Tension 9 53 b To Increase Track Tension 9 54 9 11 Jaw Crusher Maintenance 9 55 1 Checking components for wear 9...

Page 111: ...under unsupported equipment 9 When working at height make sure you take all necessary precautions in line with local regulations and use approved PPE safety harnesses and work platforms If you are no...

Page 112: ...inery to cool Dangerous nip points exist Keep hands feet and clothing clear of power driven parts and in running nip points Never lubricate clean service or adjust machine while it is moving Securely...

Page 113: ...2 Crusher The best way to keep the crusher in good operating condition is to adopt a planned program of inspection and preventative maintenance It is recommended that a record be kept of the actual o...

Page 114: ...dition Side Sill Condition Undercarrriage Track Tension Reducer Oil Level Check Tightening of roller clamping screws traction wheels etc Hydraulic System Hydraulic Oil Level Hydraulic Oil Filters Pipe...

Page 115: ...used regularly Each grease gun will put out a differing amount Check greasing equipment before use It is important that a strict routine of regular servicing is undertaken from the start of operation...

Page 116: ...9 Maintenance Operations Manual Bison 120 20 07 2018 Page 9 8 Revision 2 0 Figure 9 2 Grease Points Cont...

Page 117: ...rams 2 pumps 7 LEFT TRACK TENSION WHEN REQUIRED 8 CRUSHER CYLINDER PIN EVERY WEEK 4 grams 2 pumps 9 CRUSHER ROLLER 8 HOURS 10 grams 5 pumps 10 CRUSHER ROLLER 8 HOURS 10 grams 5 pumps 11 CRUSHER ROLLER...

Page 118: ...WEEK 4 grams 2 pumps 26 CONVEYOR LEFT CYLINDER PIN EVERY WEEK 4 grams 2 pumps 27 CONVEYOR RIGHT CYLINDER PIN EVERY WEEK 4 grams 2 pumps 28 CONVEYOR RIGHT CYLINDER PIN EVERY WEEK 4 grams 2 pumps GREAS...

Page 119: ...the machine Always use the walkways and platforms provided NOTICE The following table must be used in accordance with the routine maintenance schedules Routine checks replenishments changes of lubrica...

Page 120: ...e oil type MINERAL Thickener type LITHIUM SOAP lithium complex can also be considered if supplier guarantees compatible and approved by Terex Base oil minimum viscosity din 51561 1 40 c 104 f 220 mm2...

Page 121: ...e machine these pumps are powered from the engine The hydraulic system as a whole must be inspected at regular intervals for damage or leaks For best operating results it is recommended that the hydra...

Page 122: ...re no sealing rings between the spool and the body of the directional valve As the sealing characteristics of the fluid depend on its retaining viscosity it is important that the oil selected is capab...

Page 123: ...ion Hazard Fluid escaping under pressure can penetrate skin and result in death or serious injury Relieve pressure before disconnecting hydraulic lines Stay clear of leaks and pin holes Use a piece of...

Page 124: ...nsing pump and the proportional distributor Item 1 New filter element should be fitted at regular intervals see routine maintenance schedule for frequency Figure 9 5 Load Sensing Pump Filter c Tank Oi...

Page 125: ...ump aspiration pipe taps are closed This can cause permanent damage to the pumps It is strongly recommended to change both Suction filter and Return filter elements when the Hydraulic oil is being cha...

Page 126: ...c lines Stay clear of leaks and pin holes Use a piece of cardboard or wood to search for leaks Do not use hand Fluid injected into the skin must be surgically removed within a few hours by a doctor fa...

Page 127: ...Sensing Pump Filter to prevent dirt contaminating the hydraulic oil when the filter is removed 7 Use the spanner from the toolbox to unscrew the filter container Item 2 Figure 9 10 Load Sensing Pump F...

Page 128: ...with this type of injury or gangrene will result NOTICE The filter eliminates dirt and keeps the circuit clean The filter is an importand part of preventing system problems and prolonging its life Ma...

Page 129: ...ay clear of leaks and pin holes Use a piece of cardboard or wood to search for leaks Do not use hand Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar wit...

Page 130: ...e oil tank is cleaned satisfactory replace the drain plug and close the shut off valve 8 Refill the tank through the Fill Cap Item 1 until the oil is between the minimum and maximum marks on the tank...

Page 131: ...is removed If any damage to the belt is found do not operate the machine until it is repaired or replaced entirely by your local Terex dealer n n CAUTION Do not unfasten or remove any guard while the...

Page 132: ...above then carry out the following Adjustments are made as indicated on Figs 1 2 3 by turning drums and carrying idlers in direction of arrow until the belt is running straight and centred on the con...

Page 133: ...htened the life of the belt decreases PROCEDURE 1 Observe all safety warnings 2 Shut down the machine and implement the lockout and tag out procedure 3 Determine which side requires adjustment 4 Loose...

Page 134: ...arge Conveyor PROCEDURE 1 Observe all safety warnings 2 Shut down the machine and implement the lockout and tag out procedure 3 Proceed to the belt adjusters and loosen the lock nuts Item 1 4 Rotate t...

Page 135: ...bject to natural wear and it is therefore important to check them regularly and replace when worn Depending on requirements grids can be different sizes This procedure should only be completed by comp...

Page 136: ...surface where the grids meet the frame of the hopper to ensure new grids mate properly 8 Position new grids on the hopper frame 9 Replace the side carter Item 2 and the Fixing Plate Item 2 on each si...

Page 137: ...masses In the factory vibrating masses are adjusted to 60 of their capacity and this regulation is generally enough to ensure good progress of the material in the different working conditions However...

Page 138: ...6 Loosen the clamping screws Item 1 of the two adjustable masses Item 2 on each vibrator Reference Figure 9 19 Figure 9 19 Vibrating Mass 7 Rotate the 2 adjustable masses equally using the graduated s...

Page 139: ...he skin must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene will result NOTICE The diesel engine is the heart of your machine and a great deal of ca...

Page 140: ...have different equipment Figure 9 20 Tier 4 Engine Overview Item Descriptions 1 Turbocharger 11 Engine Control Lever 2 Exhaust Manifold 12 Oil Filler Cap 3 Starter 13 Crank Pulley 4 Oil Drain Plug 14...

Page 141: ...type of injury or gangrene will result NOTICE Always dispose of filter elements in a safe manner a Changing the Engine Oil Filter NOTICE Change the engine oil when changing the oil filters When instal...

Page 142: ...e oil filter drain plug and drain the oil 1 2 Figure 9 22 Engine Oil Filters Tier 4 6 Remove the center bolt and remove the oil filter case and element Item 2 7 Apply a thin layer of clean engine oil...

Page 143: ...tes after stopping the engine and then measure the oil level When the engine oil level is above the FULL position on the oil level gauge it may cause an engine failure PROCEDURE 1 Observe all safety w...

Page 144: ...e removed d Changing Engine Oil n n WARNING Hot oils can cause serious burns Ensure to wear correct personal protective equipment when carrying out maintenance tasks PROCEDURE 1 Observe all safety war...

Page 145: ...ler cap Item 1 Figure 9 27 Engine Oil Refill Cap Location 6 Open the engine oil filler cap Item 1 Figure 9 28 Engine Oil Filler Cap 1 Figure 9 29 Engine Oil Filter Cap Tier 4 7 Place a suitable contai...

Page 146: ...fit the engine oil filler cap cover plate Item 2 and resecure the side carter Item 1 Reference Figure 9 26 12 Remove the lockout and tag out 13 Start the machine and allow the engine to run for a shor...

Page 147: ...re details on engine air filter maintenance contact your local engine manufacturer PROCEDURE 1 Observe all safety warnings 2 Shut down the machine and implement the lockout and tag out procedure 3 Ope...

Page 148: ...ek medical advice immediately NOTICE For more details of approved engine coolant and coolant levels refer your local engine manufacturer a Checking Engine Coolant Level PROCEDURE 1 Observe all safety...

Page 149: ...and implement the lockout and tag out procedure 3 Place a suitable container under the coolant drain bung Item 1 Figure 9 33 Coolant Inspection Cover 4 Remove the cooling system filler cap slowly rel...

Page 150: ...use a suitable container Used coolant must be disposed of as specified in national and international law Disposal and treatment of the discharged coolant must be conducted in accordance with the spec...

Page 151: ...heater circuits Set the temperature setting and blower speed to MAX Additionally warm up the engine at approx 1 500 rpm or more until the engine coolant temperature gauge stabilizes coolant temperatur...

Page 152: ...an cause a decrease in engine output engine failure engine failure indication or engine stop so perform periodic inspections and maintenance The fuel filter has the function of removing filth or moist...

Page 153: ...d up pressure flow b Draining Water from Fuel System NOTICE Thefuelinjectionpumpandfuelinjectionnozzlesarepreciselymanufactured andtherefore usingthefuel whichcontainswaterordustparticleswillresultine...

Page 154: ...t and drain the fuel 8 Clean the cup install the element and tighten to the filter body with the ring nut 9 Turn the fuel filter lever Item 1 to the open position 10 Remove the lockout and tagout 11 T...

Page 155: ...O rings between the cylinder liners and crankcase are leaking 5 Check whether the drain hole on the coolant pump is blocked If there is a leak renew the seal in the pump or the complete coolant pump...

Page 156: ...eeder plug to remove the air from the fuel filter 5 Repeat Steps 2 through 4 at least 3 times until air does not come out from the air bleeder plug 6 Securely tighten the air bleeder plug and wipe off...

Page 157: ...case Reuse of the element may cause a trouble Make sure to replace it with a new one PROCEDURE 1 Loosen the drain plug Item 6 and air bleeder plug Item 1 to discharge the fuel inside the filter 2 Use...

Page 158: ...to make a mess in the area around when removing the components Also be cautious of fire Clean any foreign matter or dirt at the bottom of inside the element case Reuse of the element may cause a troub...

Page 159: ...in the machine is working on is firm enough to support the machine Ensure that the machine is tracked at least 10 m in either direction on a daily basis doing so minimize risk of track chain seizure E...

Page 160: ...Clean the area around the gearbox drain and refill plugs 5 Remove the filler plug Item 1 allowing air into the gearbox for drainage 6 Remove the drain plug Item 2 and drain the oil to an external cont...

Page 161: ...To establish if the tracks require adjustment move the machine a few metres backwards and forwards on level ground in a straight line This enables the track to adopt its natural degree of tension Mea...

Page 162: ...4 Retighten the grease fitting and replace the cover plate b To Increase Track Tension PROCEDURE 1 Remove the adjuster cover plate Item 1 2 Using the special grease gun adaptor Item 3 attach to a stan...

Page 163: ...ing 2 Jaw Liner Maintenance n n WARNING Crush Hazard Ensure no body parts are between jaw faces at any time Wear personal protection equipment If using hammer for removal of debris in the wedge bolt r...

Page 164: ...wearing plates Figure 9 50 Clamping screws DUN03196 Figure 9 51 Lifting Points 6 Carefully fit suitable dee shackles through the lifting points on the corners of the jaw liners 2 in total and take th...

Page 165: ...type DO NOT USE STEEL NOTICE The side liners protect the frame around the crushing chamber and must be kept tight at all times and replaced before they are worn through to prevent damage to the frame...

Page 166: ...jaw liners 2 in total and take the weight with a crane The shackles should have a safe working load SWL of two 160 Kg 352 lbs and should be to BS3032 1958 or equivalent standard A bow shackle of the s...

Page 167: ...ailure Over tensioning will exert excessive loading on the shaft bearings and can lead to premature failure When replacing a multi belt drive always use a set of matched new belts so that equal force...

Page 168: ...n that is placed on the drive belts Locknuts on the tension screws must be tight whilst running the machine After replacing drive Belts remember to check the tension after 4 hours run in time check ag...

Page 169: ...Measurements NOTICE This machine has high performance drive belts fitted as standard The drive belts consists of 2 sets of 2 The purpose of these drive belts is that they are service free When renewin...

Page 170: ...lso check the grooves for wear Ensure the pulleys are tight on their shafts 2 If replacement of the belts is necessary due to premature failure the cause should be investigated and rectified before fi...

Page 171: ...welding work within a safe environment When completed reconnect the negative battery cable on the batteries and remove the lockout and tag out 2 Battery Removal and Installation n n DANGER Do wear pr...

Page 172: ...top clamps that holds the battery down by removing the bolts at each end of the battery and then followed by the clamp 7 Lift the upper battery straight up and out by holding it at opposite corners A...

Page 173: ...an option The system consists of 4 spraying nozzles The spray nozzles are located over the crusher mouth It is the responsibility of the customer to supply the system with clean water at the manifold...

Page 174: ...arch for leaks Do not use hand Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene will result Switch off the machine a...

Page 175: ...0 Table of Content 10 Troubleshooting 10 2 10 1 General Troubleshooting 10 2 1 General 10 2 2 Vibrating Drawer 10 2 3 Conveyors 10 3 4 Components 10 4 5 Hydraulic 10 5 6 Production 10 7 7 Tracks 10 7...

Page 176: ...parameters and adjust accordingly Chamber block Isolate the machine and remove the blockage Build up in discharge chute Check Replace Broken drive belts Check Replace 2 Vibrating Drawer Fault Cause Co...

Page 177: ...f Machine is not level Ensure machine is on level ground Belts are not aligned Align belts Belts are not being fed evenly material is tending to be fed to one side of the conveyor Ensure conveyor is f...

Page 178: ...ne performance Consult engine manual Low hydraulic oil level Top up hydraulic oil level Return line filter blockage Replace return line filter Pressure filter blockage Replace pressure filter Loose or...

Page 179: ...e Replace relief valve Dirt or chip holding valve partially open Clean around valve Replace valve Control valve relief pressure set too low Set relief pressure to correct level Irregular motion of the...

Page 180: ...eration of solenoid replace if necessary Check for possible sticking spool on valve dismantle clean and replace parts or complete assembly Solenoid operation Check operation of solenoid replace as nec...

Page 181: ...7 Tracks Fault Cause Correct Measure Excessive oil leaking around drive assembly Seal damaged between Motion control block and motor Remove motion control block and replace seals Seal damaged between...

Page 182: ...he valves continue to jam then the oil in the hydraulic system is not being filtered to the required level of cleanliness Motor Fault Swap over the motors on the two tracks If the fault is in the moto...

Page 183: ...p battery Isolator on Turn off isolator Faulty ignition switch terminals Correct connections replace Damaged battery Replace battery Battery goes flat while engine is running Low battery voltage Top u...

Page 184: ...lts to recommended torque Toggle knocking noise Check operation of draw back assembly Crusher slowing under load Drive belts slippage Tension drive belts Engine Check air and fuel filters Excessive ma...

Page 185: ...clean speed sensor electrical connections Check speed sensor for proper installation Fuel injector Check injector electrical connection and clean as necessary Check for injector line leakage have the...

Page 186: ...line blocked coolant heat exchanger Have the engine manufacturer check Fuel injector defective Check have the engine manufacturer replace as necessary Oil filter defective Check Coolant deficiency Che...

Page 187: ...engine manufacturer repair as necessary Air in the fuel system Check Replace Fuel filter fuel pre cleaner soiled Check Fuel quality not as per operation manual Check Clean Engine oil pressure is non...

Page 188: ...e leaks Have the engine manufacturer check Charge airline leaking Have the engine manufacturer check Replace Incorrect valve clearance Have the engine manufacturer check Fuel Injector defective Check...

Page 189: ...ufacturer remove cylinder head and replace head gasket Cylinder liner Have the engine manufacturer with the cylinder head removed check the cylinder liner for cracks replace as necessary Cylinder head...

Page 190: ...peed sensor electrical connections Have the engine manufacturer check sensor for proper installation Fuel injector Check injector electrical connection and clean as necessary Fuel supply Check the fue...

Page 191: ...ns between the engine ECM system display Circuit breakers Check the status of circuit breakers Fuel supply Check the fuel level do not rely on the fuel gauge only add fuel as necessary Check the fuel...

Page 192: ...ent limit value 20 A If this fuse blows the machine stops automatically and the engine turns off The machine cannot be re started until the fuse is restored 2 Buzzer protection fuse air filter blockag...

Page 193: ...wiring start Figure 10 2 CPU Plug Starting from that plug and following the wiring it s possible to find the starter relay glow relay and two fuses named F1 and F2 Figure 10 3 Engine Fuses Labels are...

Page 194: ...located inside the radio control receiver The receiver is positioned behind the machine door that covers the radiator of the engine Figure 10 4 CPU Plug By opening the receiver cover it is possible to...

Page 195: ...of 6 fuses located in the box 12V B 10A that fuse protect the battery of the machine Main fuse 30A that fuse is connected in series with the battery protection fuse it is the main fuse of the board S...

Page 196: ...10 Troubleshooting Operations Manual Bison 120 20 07 2018 Page 10 22 Revision 2 0 Intentionally Left Blank...

Page 197: ...Storage 11 Operations Manual Bison 120 20 07 2018 Page 11 1 Revision 2 0 Table of Content 11 Storage 11 2...

Page 198: ...gainst the equipment delivery note The equipment should be stored in a dry well ventilated area free of excessive dust All openings should be sealed to prevent the ingress of dirt or moisture If the m...

Page 199: ...izontal inclined or vertical device for moving or transporting bulk material packages or objects in a path determined by the design of the device and having points of adding and discharge fixed or sel...

Page 200: ...ns of which the flow of material may be stopped or regulated also a section of a machine equipped with a hinge mechanism for movable service often called a hinge section Grid Aperture The spacing betw...

Page 201: ...context such as prevent injury means to reduce the chances of but does not imply that an injury cannot occur P S I Pounds per square inch Unit of Pressure Conversion 1 Bar 14 5 P S I Rated speed The...

Page 202: ...links of a chain Strut Rigid support used to hold an assembly in place Take up The assembly of the necessary structural and mechanical parts that provides the means to adjust the length of belts cabl...

Page 203: ...If a slightly higher or lower tension does not cure the problem there may be a critical vibration frequency in the system which requires rectification Viewing Apertures Opening holes to view the conv...

Page 204: ...Operations Manual Bison 120 20 07 2018 Page 12 6 Revision 2 0 12 Glossary of Terms Intentionally Left Blank...

Page 205: ...Appendix Operations Manual Bison 120 20 07 2018 Page 13 1 Revision 2 0 13 Appendix Appendix A EC Declaration of Conformity Appendix B Warranty Appendix C Schematics...

Page 206: ...Appendix Operations Manual Bison 120 20 07 2018 Page 13 2 Revision 2 0 Intentionally Left Blank...

Page 207: ...hinery Directive 06 42 EC together with appropriate EN Harmonised Standards and National BS Standards and Specifications A Declaration of Conformity certificate is applicable to each machine The origi...

Page 208: ...Appendix A Operations Manual Bison 120 20 07 2018 Page A 2 Revision 2 0...

Page 209: ...Appendix B Operations Manual Bison 120 20 07 2018 Page B 1 Revision 2 0 Appendix B Warranty The following pages show an example of the warranty information Register the warranty of this machine online...

Page 210: ...e Seller equipment which are not manufactured by Seller are subject to the warranty of their respective manufacturers Normal maintenance adjustments or maintenance wear parts including without limitat...

Page 211: ...NOT LIMITED TO LOST PROFITS LOSS OF PRODUCTION INCREASED OVERHEAD LOSS OF BUSINESS OPPORTUNITY DELAYS IN PRODUCTION COSTS OF REPLACEMENT COMPONENTS AND INCREASED COSTS OF OPERATION THAT MAY ARISE FRO...

Page 212: ...ts are used in the Equipment Accessories assemblies and components included in the Equipment which are not manufactured by Seller are subject to the warranty of their respective manu facturers Normal...

Page 213: ...any kind from personnel other than authorized Seller distributor personnel 9 Stop and Go Warranty Seller does not recognize Stop and Go warranties 10 INCIDENTAL OR CONSEQUENTIAL DAMAGE SELLER SHALL N...

Page 214: ...Appendix B Operations Manual Bison 120 20 07 2018 Page B 6 Revision 2 0 Intentionally Left Blank...

Page 215: ...Page C 1 Revision 2 0 Table of Content Appendix C Schematics C 3 1 Electrical Schematics C 3 a Front Panel CPU Connection C 3 b Front Panel CPU Connection Cont C 4 c Main Wiring C 5 d Relay Box C 6 2...

Page 216: ...Appendix C Operations Manual Bison 120 20 07 2018 Page C 2 Revision 2 0 Intentionally Left Blank...

Page 217: ...Appendix C Operations Manual Bison 120 20 07 2018 Page C 3 Revision 2 0 Appendix C Schematics 1 Electrical Schematics a Front Panel CPU Connection...

Page 218: ...Appendix C Operations Manual Bison 120 20 07 2018 Page C 4 Revision 2 0 b Front Panel CPU Connection Cont...

Page 219: ...Appendix C Operations Manual Bison 120 20 07 2018 Page C 5 Revision 2 0 c Main Wiring...

Page 220: ...Appendix C Operations Manual Bison 120 20 07 2018 Page C 6 Revision 2 0 d Relay Box...

Page 221: ...2018 Page C 7 Revision 2 0 2 Hydraulic Schematics a Crusher hydraulics POS CODE DESCRIPTION QTY POS CODE DESCRIPTION QTY 1 0508021 VARIABLE FLOW PUMP 1 3 0509018 EXCHANGE VALVE 1 2 0509011 SUCTION FI...

Page 222: ...ATOR HYDRAULIC ENGINES 2 11 0509014 OVER CENTRE VALVE 1 4 0508009 HYDRAULIC ENGINE EXTRACTION BELT 1 12 0509015 EXCHANGE VALVE 2nd SPEED 1 5 JM 40 371 JACK FOR JAW ADJUST MENT 1 13 0509012 DELIVERY OI...

Page 223: ......

Page 224: ...200 Coalisland Road Dungannon Co Tyrone BT71 4DR Northern Ireland Tel 44 0 2887 718500 Fax 44 0 2887 747231 E mail EvoQuip terex com Printed in the United Kingdom...

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