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    USER MANUAL 

 

 

 

27

6.

 

TROUBLESHOOTING 

 

Troubleshooting  is  a  series  of  steps  where  faults  may  be  traced.  A 
symptom  of  a  fault  should  be  investigated  immediately  to  determine  the 
severity of the problem and whether it is safe to continue without causing 
further damage. This section describes how to identify symptoms and solve 
specific problems quickly and systematically. 
 

6.1 Dealing with Fault Diagnosis 

 

−

 

confirm the faulty component or function 

−

 

ensure  personal  safety  will  not  be  compromised  if  operation  is      
continued 

−

 

reproduce the fault symptoms 

−

 

systematically forecast possible causes of fault 

−

 

confirm assumed causes 

−

 

use repair method and procedures as shown in the this manual 

 

6.2 Possible Faults 
 

The  REMU  screening  bucket  has  two  basic  systems:  hydraulic  and 
mechanical. 

 
6.3 Hydraulic 
 

Depending  on  the  model  the  REMU  bucket  uses  one  or  two  low  speed, 
high torque hydraulic motors. (The two motor units have the drive shafts 
mechanically  connected  and  are  hydraulically  plumbed  in  parallel.)  Both 
the  single  and  two  motor  versions  are  connected  to  the  auxiliary  service 
ports of the carrier machine. The service ports need to provide the correct 
flow  rate  to  ensure  optimum  performance  of  the  screening  unit.  It  is 
important  that  the  flow  and  pressure  settings  are  set  at  the 
recommendations shown in the specifications section. 
 

 
 

Summary of Contents for REMU

Page 1: ...OPERATORS MANUAL ...

Page 2: ...i Address Ostolantie 4 63700 Ähtäri Finland Herewith we declare that REMU Screening Bucket Model Serial number is in conformity with the relevant provisions of the Machinery Directive 2006 42 EC is in conformity with the provisions of the following other EC Directives And furthermore we declare that the following parts clauses of European harmonised standards have been used SFS EN ISO 12100 SFS EN...

Page 3: ... Pressure Settings 12 2 8 Connection to Carrier 12 2 9 Installation to Carrier 12 2 10 Installation Check List 13 3 Operation 14 3 1 Overview 14 3 2 Safety 14 3 3 Operation Efficiency 15 3 4 Moisture Content 15 3 5 Filling the Bucket 15 3 6 Operating Position 15 3 7 Screening Process 16 3 8 Residue Product 16 3 9 Cleaning the REMU Bucket 17 3 10 When to Clean 17 3 11 How to Clean 17 3 12 Neglect 1...

Page 4: ...28 6 5 1 Rotors Cease to Turn 28 6 5 2 Rotors Turn Slowly 29 6 6 Material Size 29 7 Storage 30 7 1 Storage Preparation 30 7 2 Removing the Bucket from Storage 30 8 Transport 31 8 1 Transport when Mounted on Carrier 31 8 2 Shipped as Stand Alone Bucket 31 9 Specifications 32 9 1 Metric 32 9 2 US Imperial 33 9 3 EX Models Assembly 34 9 4 WL Models Assembly 35 9 5 L Models Assembly 36 9 6 EX and WL M...

Page 5: ...y at the request of the customer to meet the special application needs It should be noted that these modifications totally change the performance and operation characteristics on the Normal standard REMU unit and these characteristics must be fully understood by the user Owners and operators are hereby advised that the use of modified REMU Screening Buckets in applications for which they were not ...

Page 6: ...U Screening Bucket efficiently and economically Your safety and the safety of others depend upon care and judgement in the operation of this attachment A careful operator is good insurance against accident REMU s policy is to continually improve the product design that will provide changes to this REMU screening bucket which may not be included in this manual This publication is based on current i...

Page 7: ...mpt is made to operate the screening bucket in a production environment learn and apply the procedures and rules relative to the work site establish a means of communication in the event of accident or fire complete standard daily checks of the screening unit as well as the carrier machine clear obstacles from work area and be aware of hazards including overhead wires never use diesel or petrol as...

Page 8: ...he bucket and tighten bolts that may have worked loose the Screening Bucket must be operated at a speed that can be correctly controlled do not use the bucket as a battering ram keep work site flat by continually grading to ensure efficiency and safety do not operate the carrier machine in an overloaded condition when loading trucks or hoppers be careful not to hit the truck or hopper with the buc...

Page 9: ... be found in the carrier Operators or Workshop Manual The hydraulic horse power capacity needs to be known to determine if it is able to provide sufficient capacity to operate the screening bucket at its optimum 2 1 Base Installation Requirements The screening bucket requires by directional flow from the carrier An operator controlled directional control valve and plumbing to the boom tip capable ...

Page 10: ...is providing the required flow and pressure Using a serviceable flow meter installed in the delivery lines that the screening unit will be fitted to is the only effective method to determine accurately the carrier s hydraulic performance Please note that some modern construction machinery have flow and pressure sensors that provide readings on a liquid crystal display located in the cab It should ...

Page 11: ...n with the manufacturer or distributor 2 5 Unit Over Speed If a failure occurs due to over speed then the warranty will not apply Note Check the flow rate to the REMU circuit under the following conditions the unit just below maximum relief valve setting the unit under no load condition with other functions of the carrier machine being operated at the same time In all cases the flow rate must not ...

Page 12: ...educing cycle times and reducing excessive strain that can be exerted on the unit 2 9 Installation to Carrier use safety glasses and gloves for protection against injury when installing connecting pins ensure the quick hitch coupling specification of the carrier is to the same dimensions as the pick up on the screening bucket if a quick hitch is installed it is the operator s owner s responsibilit...

Page 13: ...en other functions of the carrier machine are being operated at the same time in the case of Skid Steers Backhoe Loaders Wheel loaders position the bucket so that the bottom of the unit is parallel with the ground with a slight tilt to the front Mark or adjust the auto levelling device to indicate the digging position at low engine R P M operate the screening unit in one direction for approx twent...

Page 14: ...ide rakes will depend on the abrasive quality of the material being screened The size of screened primary product will gradually increase in proportion to the amount of wear of the consumable components The wear rate of the wear parts can be retarded by periodically applying a hard facing in an even manner 3 2 Safety Always check the surroundings before operating the screening unit or carrier The ...

Page 15: ...he plasticity level From this point the material flow through the unit will slow down depending on the type of material Therefore excess moisture content will determine the speed in which the material will be processed through the unit 3 5 Filling the Bucket Operate the carrier in conventional manner to fill the screening bucket to the rollback waterline Except in excavator application where face ...

Page 16: ...to moisture content or material characteristics the material will not screen as expected or if the screening unit begins to stall tilt the unit forward and operate normally until it clears then slowly tilt back to the horizontal position There are a number of reasons why some material placed in the screening unit will not screen Initially it is recommended that a particular load be dumped onto the...

Page 17: ...cess this material through the unit in the normal manner until the build up of material is reduces to a point where the square edges of the rotor shafts are visible 3 12 Neglect If cleaning is not carried out efficiently the bucket operation will be greatly impaired material will build up in the rotors it will cause accelerated wear on the rotor outside diameter surface 3 13 Cleaning Attachment RE...

Page 18: ...ollowed 1 Position the bucket so the rotors are at the bottom and the unit side rake retaining bolts are located at approx waist height 2 Loosen all of side rake retaining nuts 3 Move the rakes fully to the bottom 4 Retighten the side rake nuts in this position 5 Test run the bucket with material to be crushed 6 If the operation of the bucket is impaired in start up configuration then the rakes ne...

Page 19: ...d by replacing the main blades and counter blades 3 18 Changing the Rotors Contact technicalsupport remu fi 3 19 Changing of Side Rakes 1 Ensure that the replacement rakes are correct for the model and the size of product required before proceeding 2 Note In the models that have even number of main blades the counter blades are similar In the models where the number of main blades is odd the count...

Page 20: ...n without loss of efficiency This section provides procedures for safe lubrication and maintenance of the screening bucket Please note all cautions 4 1 Maintenance Schedule The maintenance intervals are determined by the operating hours This manual designates 8 hours for a day 50 hours for a week and 100 hours for two weeks If the screening bucket operates beyond the standard operating hours or wh...

Page 21: ... Maintenance Safety 1 Wear suitable clothing 2 Use the correct tools 3 Use sufficient care while using cleaning fluids 4 Use safety tags or isolate carrier so it cannot be started Do not attempt to inspect or touch the rotors or carry out preventative maintenance while the carrier engine is running and if the screening bucket is not on the ground ...

Page 22: ...ng Pins Grease 2 pumps Multi purpose NLGI No 2 Lithium EP Grease 4 Rotors Inspect condition for wear or damage 5 Side Rakes Inspect condition for wear or damage 6 Cutting Edge Inspect condition for wear or damage 7 Motors and Hoses Inspect for damage and leaks and repair if necessary 8 Chain Case Drain Holes Inspect chain case drain holes are clear and free obstructions Fifty Hours 9 Chain Case Ch...

Page 23: ...wever the mounting pins may not require lubrication because of the installation of a quick hitch Items 4 5 6 A visual inspection is required or each rotor assembly side rake and cutting edge to ensure that each blade rake fin or edge is in a serviceable condition and has not been bent or excessively worn Note The design of the rotors allow them a normal radial movement of about 5mm 3 16 Item 7 A v...

Page 24: ... its service life If chains exceed this deflection dimension they should be adjusted to minimum deflection or replaced with new chains Note Do not use worn out chains as it will wear down the cogwheels Note There is no chain adjustment between rotor shafts It is important that twin motor units have exactly equal adjustment on each of the motor drive chains to load the chains equally To affect adju...

Page 25: ...d from inclement weather 3 If the bucket is still mounted on the carrier ensure the carrier is not in operation and that the starting mechanism is isolated 4 Place welding earth cable on the rotor being hardfaced 5 Apply the same amount of hardfacing to each tip of every blade on the rotor to ensure balance during operation 6 Care must be taken in applying the hardfacing so that it does not exceed...

Page 26: ... and lubricate drive chains Salt water Highly Corrosive Material Before operation Check all inspection plates are in corrosive material in good condition During operation Lubricate every 2 hours After operation Drain chain compartments of water and lubricate drive chains Clean bucket with high pressure fresh water to remove material residue Excessive dust During operation Lubricate every 2 hours R...

Page 27: ...recast possible causes of fault confirm assumed causes use repair method and procedures as shown in the this manual 6 2 Possible Faults The REMU screening bucket has two basic systems hydraulic and mechanical 6 3 Hydraulic Depending on the model the REMU bucket uses one or two low speed high torque hydraulic motors The two motor units have the drive shafts mechanically connected and are hydraulica...

Page 28: ...the problem could be caused by A Incompressible material caught in the rotors Action Check to see if there is material caught in the rotors and remove B Broken drive chain sprocket or shaft Action Turn off the machine and check to see if chains and sprockets are in a serviceable condition by removing inspection cover After replacing chains determine the reason for failure and make the necessary ad...

Page 29: ...in inspection cover and remove drive chain between motor s and try to spin the rotors If rotors are free the motor s require further investigation and or overhaul If the rotors cannot be turned remove the remaining chains between the rotors to determine which rotors cannot be spun separately Remove the drive sprocket from the rotor s that cannot be spun check the bearing and replace it if needed 6...

Page 30: ...gging position 2 Clean the bucket thoroughly 3 Inspect for loose or missing parts and tighten or replace if necessary 4 Lubricate the bucket 5 Ensure hydraulic lines are full of oil and are capped tightly with steel caps 6 Apply rust preventative sealer to all exposed surfaces 7 2 Removing the Bucket from Storage 1 Clean the bucket thoroughly 2 Remove rust preventative sealer from all exposed surf...

Page 31: ...he centre of gravity is known about one third from the rear of the unit depending on the model and adjust slings to compensate B Ensure hydraulic lines are properly capped with steel caps to avoid oil leakage and the ingress of contamination C Position the bucket so that it is transported in the digging position D Position the bucket so that other items will not damage rotors or hydraulic motor s ...

Page 32: ... 3 145 244 140 2340 WL 250 X X X X 30 35 12 19 150 200 2 4 2 9 1 9 3 145 264 140 2440 WL 600 X X X X 38 48 16 24 200 300 5 5 6 4 3 4 5 195 300 187 5260 EX 140 HD X X X X 16 21 150 200 0 9 1 1 0 9 4 128 126 143 1680 EX 180 HD X X X X 21 28 150 200 1 3 1 5 1 4 5 145 151 171 2400 WL 160 HD X X X X 20 25 7 12 150 200 1 8 2 1 1 4 3 145 204 140 2400 WL 170 HD X X X X 25 30 9 14 150 200 2 2 2 7 1 8 3 145...

Page 33: ...9 3 5 2 2 3 57 96 55 5160 WL 250 X X X X 66 77 26 42 40 53 3 1 3 8 2 3 3 57 104 55 5380 WL 600 X X X X 84 108 35 53 53 79 7 2 8 4 4 1 4 77 118 74 11600 EX 140 HD X X X X 35 46 40 53 1 2 1 4 1 1 4 50 50 56 3700 EX 180 HD X X X X 46 62 40 53 1 7 2 0 1 7 5 57 59 67 5290 WL 160 HD X X X X 44 55 15 26 40 53 2 4 2 7 1 7 3 57 80 55 5290 WL 170 HD X X X X 55 66 20 31 40 53 2 9 3 5 2 2 3 57 96 55 5840 WL 2...

Page 34: ...or assembly 7 Cleaning Scraper frame EX180 9 210000003 Main Frame EX80 11 100160080 Shaft Axle drive EX80 140 4 516001012 Main Frame EX140 11 100160140 Shaft Axle drive EX80 140 HD 4 516001022 Main Frame EX180 11 100160180 Shaft Axle drive EX180 4 516001212 Main Frame EX140 HD 11 100200140 Shaft Axle drive EX180 HD 4 516001222 Main Frame EX180 HD 11 100200180 When ordering the parts No 1 3 8 10 an...

Page 35: ...22000003 Main Frame WL160 12 100160160 Shaft Axle drive WL160 4 516001912 Main Frame WL170 12 100160170 Shaft Axle drive WL160HD 4 516001932 Main Frame WL250 12 100160250 Shaft Axle drive WL170 4 516002312 Main Frame WL160HD 12 100200160 Shaft Axle drive WL170HD 4 516002332 Main Frame WL170HD 12 100200170 Shaft Axle drive WL250 4 516002512 Main Frame WL250HD 12 100200250 Shaft Axle drive WL250HD 4...

Page 36: ...r frame L85 10 213000002 Shaft Axle drive L100 4 515001000 Cleaning Scraper frame L100 10 208000003 Shaft Axle drive L150 4 515001700 Cleaning Scraper frame L150 10 215000003 Main Frame L50 12 100160050 Hydraulic motor assembly 7 8 Main Frame L75 12 100160075 Bearing assembly Pull side 5 Main Frame L85 12 100160085 Bearing assembly Free side 6 Main Frame L100 12 100160100 Main Frame L150 12 100160...

Page 37: ... 900000600 Spherical roller bearing 60 110 28 1 16 800751608 Drive shaft end plate thickness 8 mm 1 6 900709010 Seal 70 90 10 2 7 800001645 Drive shaft end bolt M16 x 45 12 9 1 8 800000835 Bearing house end cap bolt M8 x 35 12 9 4 9 800001225 Bearing house bolt DIN 912 M12 x 25 12 9 4 10 800706024 Bushing 60 70 24 1 12 720206019 Double sprocket EX WL 16B or 20B 1 13 800111870 Key 18 11 70 1 15 800...

Page 38: ...000600 Spherical roller bearing 60 110 28 1 16 800751608 Drive shaft end plate thickness 8 mm 1 6 900709010 Seal 70 90 10 2 7 800001645 Drive shaft end bolt M16 x 45 12 9 1 8 800000835 Bearing house end cap bolt M8 x 35 12 9 4 9 800001225 Bearing house bolt DIN 912 M12 x 25 12 9 4 10 800706024 Bushing 60 70 24 1 12 720206019 Double sprocket EX WL 16B or 20B 1 13 800111870 Key 18 11 70 1 15 8007060...

Page 39: ...1 3 900001260 Bearing house end cap free 1 4 900000600 Spherical roller bearing 60 110 28 1 5 800681605 Drive shaft end plate thickness 5 mm 1 6 900709010 Seal 70 90 10 1 7 800001645 Drive shaft end bolt M16 x 45 12 9 1 8 800000835 Bearing house end cap bolt M8 x 35 12 9 4 9 800001225 Bearing house bolt DIN 912 M12 x 25 12 9 4 10 800706024 Bushing 60 70 24 1 ...

Page 40: ...00500 Spherical roller bearing 50 90 23 1 29 800751608 Drive shaft end plate thickness 8 mm 1 21 900608010 Seal 60 80 10 2 30 800001645 Drive shaft end bolt M16 x 45 12 9 1 25 800000835 Bearing house end cap bolt M8 x 35 12 9 4 23 800001225 Bearing house bolt DIN 912 M12 x 25 12 9 3 19 800605019 Bushing 50 60 19 1 28 720165017 Double sprocket L model 16B Z 17 1 27 800091465 Key 14 9 60 1 26 800605...

Page 41: ...900001250 Bearing house end cap L free closed 1 22 900000500 Spherical roller bearing 50 90 23 1 32 800681605 Drive shaft end plate thickness 5 mm 1 21 900608010 Seal 60 80 10 2 30 800001645 Drive shaft end bolt M16 x 45 12 9 1 25 800000835 Bearing house end cap bolt M8 x 35 12 9 4 23 800001225 Bearing house bolt DIN 912 M12 x 25 12 9 3 19 800605019 Bushing 50 60 19 1 ...

Page 42: ...s made by the manufacturer parts made by subcontractors to the extent that these are covered by the subcontractor s warranty labour costs for normal working times excluding weekend and overtime extras 3 The warranty does not comprise parts that wear out normally such as hoses gaskets and chains damages that have occurred due to normal wear standing time or other indirect damages direct or indirect...

Page 43: ... the manufacturer or his representative together with the warranty claim unless some other agreement has been reached 5 The following conditions must be met for the warranty claim to be valid the damage has occurred during circumstances seen as normal the operating and maintenance regulations supplied by the manufacturer have been followed the warranty repairs have been carried out by the seller o...

Page 44: ...USER MANUAL 44 ...

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