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10 Troubleshooting

Operations Manual

Bison 120

20-07-2018

Page 10-2

Revision 2.0

10 Troubleshooting

10.1 General Troubleshooting

(1) General

Fault

Cause

Correct Measure

Machine Stops

Fuel

Top up as necessary

Coolant level

Top up as necessary

High coolant temperature

Clean Radiator / check fan

operation

Hydraulic oil level

Top up as necessary

Packing in crushing chamber

Clear discharge chute

High Hydraulic oil temperature

Clean oil cooler / Replace

Emergency stop depressed

Check all Emergency stops

Fuse Blown

Check Fuses

Crusher stops

Engine Load

Check running 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

Correct Measure

Rock Moves Down

One Side of feeder

Machine not laterally (side-to-

side) level

Level machine

Feeder completely

stopped

Material jam

Remove material jam

Hydraulic motor drive coupling

Replace drive coupling

Hydraulic motor faulty

Replace motor

Rumbling noise from

Vibrator

Weights imbalanced

Balance weights

Bearings are damaged

Replace bearings

Rock moves across

screen too fast

Vibrating drawer speed

Decrease Speed

Rock moves across

screen too slow

Vibrating drawer speed

Increase Speed

Excessive Vibration

Rubber supports damaged

Replace supports

Содержание Evoquip Bison 120

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 223: ......

Страница 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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