Warrior 2100 Operations Manual Revision 3.0 (English)

WARRIOR 2100
OPERATIONS MANUAL
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
Original Instructions
© TEREX GB Ltd
ISSUE DATE: 14-02-2017

LANGUAGE: ENGLISH
REVISION: 3.0
www.powerscreen.com
Email: sales@powerscreen.com
200 Coalisland Road, Dungannon,

Co Tyrone, BT71 4DR, Northern Ireland
Tel: +44 (0) 28 87 718 500
Fax: +44 (0) 28 87 747 231
Serial Number
Year of Construction
Date of Delivery
Dealer Stamp
Notice
Record of Revisions
Record of Revisions
Revision
Number Reason for Change Date
1.0 New style manual for new machine 13-June-2014
1.1 Updates to Maintenance Section 01-Oct-2014

Various general updates
2.0 CAT 4.4 Tier 4 Final update 26-Feb-2015
2.1 Spaleck screenbox maintenance updates. 06-Oct-2015

Troubleshooting updates.
2.2 Triple Shaft, Single Shaft and Spaleck updates. 20-Nov-2015
General Updates
2.3 Various General Updates 02-Mar-2016
2.4 Initial setup: jacking legs updated. 09-May-2016

Warranty update.
Safety Decal update.
3.0 Maintenance Schedule Update 14-02-2017
2WS procedure updated
Tracking Direction Update
Greasing and Lubrication Update
Warranty Update
Other General Updates
Operations Manual Revision 3.0 14-02-2017

Warrior 2100 Page 1
Record of Revisions
Intentionally Left Blank
14-02-2017 Revision 3.0 Operations Manual

Page 2 Warrior 2100
Table of Content
Table of Content
1 Introduction................................................................................................. 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment....................................................................................1-3
1.2 Safety Information...........................................................................................1-3
(1) Safety Alert 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 Declaration of Conformity................................................................................1-4
1.6 Warranty..........................................................................................................1-4
1.7 Copyright.........................................................................................................1-5
1.8 Bulletin Distribution and Compliance..............................................................1-5
1.9 Transfer of Machine Ownership......................................................................1-5
1.10 Contacting the Manufacturer...........................................................................1-6
2 Safety........................................................................................................... 2-2
2.1 General Safety................................................................................................2-2
(3) Property Damage Messages......................................................................2-3
(4) Description of Safety Symbols....................................................................2-3
2.2 Positions of Safety Signs on the Machine.......................................................2-8
2.3 Personal Safety.............................................................................................2-15
(1) Personal Protective Equipment................................................................2-15
2.4 Work Area Safety..........................................................................................2-16
(1) General Work Area Guidelines.................................................................2-16
(2) Safety Warnings and Labels.....................................................................2-16
(a) Modifications........................................................................................2-16
(3) Transportation Safety...............................................................................2-17
(4) Operation Safety.......................................................................................2-18
(5) Hydraulic and Pneumatic Safety..............................................................2-19
(6) Electrical Safety........................................................................................2-20
(7) Maintenance Safety..................................................................................2-21
(8) Gas, Dust, Steam, Smoke........................................................................2-23
(9) Hazardous Substances............................................................................2-23
(10) Noise Levels.............................................................................................2-23
2.5 Emergency Stop Locations...........................................................................2-24
3 Technical Data ............................................................................................ 3-2
3.1 General Information.........................................................................................3-2
(1) Machine Weights........................................................................................3-2
3.2 Machine Component Specifications................................................................3-2
(1) Feeder Unit (A)...........................................................................................3-2

Warrior 2100 Page 1
Table of Content
(a) Warrior Feed Hopper (Standard & Apron)..............................................3-2

(b) Feed Conveyor (Not Apron Feeder).......................................................3-2
(2) Collection Conveyor (B)..............................................................................3-2
(3) Screen Unit (C)...........................................................................................3-2
(4) Side Conveyors (D & E).............................................................................3-3
(5) Tail Conveyor (F)........................................................................................3-3
(6) Power Unit (G)............................................................................................3-3
(a) Tier 3 Engine..........................................................................................3-3
(b) Tier 4 Engine..........................................................................................3-3
(7) Chassis (H).................................................................................................3-3
(a) Warrior 2100 Tracks...............................................................................3-3
3.3 Machine Drawings...........................................................................................3-4
(1) Warrior 2100 Working Dimensions.............................................................3-4
(2) Warrior 2100 Transport Dimensions ..........................................................3-5
(3) Noise Levels...............................................................................................3-6
4 Machine Description................................................................................... 4-2
(1) Identification Plate......................................................................................4-2
(2) Machine References...................................................................................4-3
4.2 Nomenclature and Technical Data..................................................................4-5
4.3 Construction Units...........................................................................................4-6
(1) Feeder Unit (A)...........................................................................................4-6
(a) Feeder (A)..............................................................................................4-8
(3) Screen Unit (C).........................................................................................4-10
(4) Side Conveyors (D&E)............................................................................. 4-11
(5) Tail Conveyor (F)......................................................................................4-12
(6) Power Unit (G)..........................................................................................4-13
4.4 Control and Display Elements.......................................................................4-16
(1) MCU 300 Control Panel............................................................................4-16
(2) Dual Power...............................................................................................4-20
(a) Control Panel Component Identification..............................................4-20
(3) Manual Tracking System..........................................................................4-21
(4) Teleradio Radio Remote Tracking Kit ......................................................4-22
4.5 Telematics.....................................................................................................4-22
4.6 Pictorial Decal Descriptions...........................................................................4-23
(1) Machine Operation Decals.......................................................................4-23
(2) Machine Information Decals.....................................................................4-31
5 Transportation............................................................................................. 5-2
5.1 Prior to Transportation.....................................................................................5-2
5.2 Removing Machine from the Low Loader.......................................................5-3
(1) Remote Control..........................................................................................5-3
(2) Teleradio Remote Control...........................................................................5-5
5.3 Putting the Machine into the Transport Position..............................................5-6
(1) Folding Hopper Discharge Wings...............................................................5-7

Page 2 Warrior 2100
Table of Content
(2) Folding Steps To Transport Position...........................................................5-8

(3) Folding Down Hopper Extensions (If fitted), Lowering Screenbox And ..........
Sliding Back Feeder For Transport.............................................................5-9
(4) Fold Tail Conveyor For Transport.............................................................5-13
(5) Fold in the Side Conveyors......................................................................5-16
5.4 Loading the Machine to the Low Loading Trailer..........................................5-21
(1) Ready for Transport..................................................................................5-22
(2) Prior to Haulage........................................................................................5-22
5.5 Transport Tie Down Points............................................................................5-23
6 Initial Setup and Adjustments................................................................... 6-2
6.1 Initial Inspection...............................................................................................6-2
6.2 Machine Location Considerations...................................................................6-2
6.3 Measures Before Set Up.................................................................................6-3
6.4 Measures After Long Term Standstill...............................................................6-3
6.5 Initial Setup......................................................................................................6-4
(1) Opening Out the Side Conveyors...............................................................6-4
(2) Opening Out the Tail Conveyor.................................................................6-10
(3) Moving The Feeder Into Working Position................................................6-14
(4) Increasing Hopper Angle/ Raising screen................................................6-16
(5) Operating Hopper Extension (if fitted)......................................................6-19
(6) Ladder Setup Instructions.........................................................................6-23
(7) Open Hopper Outlet Wings......................................................................6-25
(8) Warrior 2 Way Split (2WS) Conversion.....................................................6-26
(9) Opening Hopper Rear Door......................................................................6-34
7 Standard Operating Procedures............................................................... 7-2
7.1 Pre-Operating Checks.....................................................................................7-2
7.2 Initial Startup...................................................................................................7-3
7.3 MCU 300 Machine Operation - Tier 4.............................................................7-4
(1) Starting the Engine.....................................................................................7-4
(a) No Faults on the Display Screen...........................................................7-6
(b) Active Fault on the Display screen.......................................................7-10
(c) CAT Fault Indicator Lamps...................................................................7-15
(2) Dual Power Machine Operation................................................................7-17
(3) Diesel Mode Operation.............................................................................7-17
(4) Electric Mode Operation...........................................................................7-18
(a) Pre-run Check......................................................................................7-18
(b) Electric operation.................................................................................7-19
7.4 Normal Operation..........................................................................................7-22
(1) Putting into Operation...............................................................................7-22
7.5 Manoeuvring..................................................................................................7-24
(1) Manoeuvring - General.............................................................................7-24
(a) Undercarriage......................................................................................7-24
(2) Manual Tracking Information....................................................................7-25
(3) Tracking the Machine...............................................................................7-26

Warrior 2100 Page 3
Table of Content
(4) Machine Tracking Directions....................................................................7-27

(5) Manual Tracking Umbilical........................................................................7-28
(a) Manual tracking with the umbilical handset.........................................7-29
(b) Radio Tracking with the Teleradio Remote Control..............................7-30
(c) Fast Tracking ......................................................................................7-31
(d) Fast Tracking - Constant Speed Engine..............................................7-31
7.6 Machine Shutdown........................................................................................7-32
(1) Stopping the Machine...............................................................................7-32
(2) Tier 4 Final Machine Shutdown................................................................7-33
(3) Dual Power Machine Shutdown...............................................................7-35
(a) Diesel Mode.........................................................................................7-35
(b) Electrical Mains Power Mode:..............................................................7-35
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 any Work on the Machine..............................................8-4
8.2 Emergency Stop..............................................................................................8-4
8.3 Restarting after Emergency Stop....................................................................8-6
8.4 Testing Emergency Stops................................................................................8-6
9 Maintenance................................................................................................ 9-4
9.1 Regular Servicing............................................................................................9-4
(1) Daily Checks...............................................................................................9-5
9.2 Non Scheduled Maintenance..........................................................................9-6
(1) Air Cleaner Elements..................................................................................9-6
(2) Tracks.........................................................................................................9-6
(3) Control Systems.........................................................................................9-6
9.3 Maintenance Schedule....................................................................................9-7
9.4 Service Schedule............................................................................................9-9
9.5 Lubrication.....................................................................................................9-12
(1) Lubrication and Routine Servicing............................................................9-12
(a) Machine Lubrication Points..................................................................9-12
(b) Lubricants............................................................................................9-12
(2) Recommended Lubricants........................................................................9-13
(3) Recommended Lubricants for Spaleck Screenbox..................................9-16
(4) Capacities - Fluid......................................................................................9-16
(a) Triple Shaft...........................................................................................9-16
(b) Single Shaft..........................................................................................9-16
9.6 Servicing the Feeder Unit..............................................................................9-17
(1) Clean & Check the Conveyor Belt............................................................9-17
(2) Tensioning the Feeder Conveyor Belt......................................................9-18
(3) Tensioning the Apron Feeder....................................................................9-19
(4) Feeder Conveyor/Apron Feeder Alignment..............................................9-20
(5) Feeder Conveyor undertray cleaning.......................................................9-21
9.7 Servicing Conveyors.....................................................................................9-23
(1) Clean & Check the Conveyor Belts..........................................................9-23

Page 4 Warrior 2100
Table of Content
(2) Tensioning the Conveyor Belts.................................................................9-24

(3) Conveyor Alignment.................................................................................9-25
9.8 Servicing the Tracks......................................................................................9-26
(1) Machine Tracks........................................................................................9-26
(2) Cleaning the Tracks..................................................................................9-26
(3) Measuring Track Tension..........................................................................9-27
(4) Adjusting Track Tension............................................................................9-28
(5) Gearbox Oil Level.....................................................................................9-29
(6) Draining Gearbox Oil................................................................................9-30
9.9 Servicing the Electrical System.....................................................................9-31
(1) Check the Battery.....................................................................................9-31
(2) Battery Removal.......................................................................................9-32
(3) Battery Installation....................................................................................9-32
(4) Changing Fuses.......................................................................................9-33
(5) Proximity Adapter.....................................................................................9-34
9.10 Servicing the Hydraulic System.....................................................................9-35
(1) General.....................................................................................................9-35
(2) Hydraulic Fluid..........................................................................................9-35
(a) Check Hydraulic Oil Level....................................................................9-36
(b) Adding Hydraulic Fluid.........................................................................9-37
(c) Change Hydraulic Oil...........................................................................9-38
(d) Changing Suction Filters......................................................................9-39
(3) Checking the Return Line Filter................................................................9-40
(4) Changing the Return Line Filter................................................................9-41
9.11 Tier 3 Engine Maintenance...........................................................................9-42
(1) Changing Engine Filters & Oil..................................................................9-42
(a) Checking Engine Oil............................................................................9-42
(b) Changing Engine Oil & Filter................................................................9-43
(2) Changing Fuel Filters...............................................................................9-44
(a) Draining the Fuel Filter Water Trap......................................................9-44
(b) Changing Watertrap Filter....................................................................9-45
(c) Changing the Fuel Filters.....................................................................9-46
(1) Changing Engine Oil & Filters .................................................................9-47
(3) Servicing The DEF (Diesel Exhaust Fluid) System..................................9-52
(a) DEF Tank Location...............................................................................9-52
(b) Changing the Pump Main Filter...........................................................9-53
(c) Changing the DEF Tank Filler Screen..................................................9-54
(d) Changing the DEF Manifold Filter........................................................9-56
(e) DEF Tank Flush...................................................................................9-58

Warrior 2100 Page 5
Table of Content
(f) Filling the DEF Tank.............................................................................9-59
9.13 Inspecting the Clean Emissions Module Supports........................................9-61
9.14 Changing Air Filters.......................................................................................9-63
(1) Air Filtration..............................................................................................9-63
(2) Check Both Air Cleaner Elements............................................................9-63
(3) Changing the Air Cleaner Elements.........................................................9-64
9.15 Coolant System.............................................................................................9-65
(a) Topping up Coolant Level....................................................................9-65
9.16 Priming the Fuel System...............................................................................9-66
(1) Electic Fuel Pump Priming.......................................................................9-66
(2) Manual Fuel Pump Priming......................................................................9-67
(3) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines)..............9-68
9.17 Fuel Level and Topup....................................................................................9-70
9.18 Removing the Screenbox..............................................................................9-71
(1) Replacing the Screen...............................................................................9-73
9.19 Screen Unit Maintenance..............................................................................9-74
(1) Daily Maintenance....................................................................................9-74
(2) Weekly Maintenance................................................................................9-76
(3) Snubber Rubber Maintenance..................................................................9-78
(4) Lubrication................................................................................................9-79
(5) Bearing Temperature................................................................................9-81
(6) Screen Tuning Single and Triple Shaft.....................................................9-82
(a) Aspects of Stroke Adjustment..............................................................9-82
(b) Stroke Length.......................................................................................9-85
(c) Stroke Speed.......................................................................................9-87
(d) Stroke Angle.........................................................................................9-88
(7) Checking Screen Drive Belt Tension........................................................9-96
(8) Tensioning the Screen Drive Belt.............................................................9-98
(9) Changing the Bottom Deck Screen Mesh..............................................9-100
(a) Changing Screen Mesh on Triple Shaft.............................................9-100
(10) Changing the Top Deck Screen Mesh (Single & Triple Shaft)................9-103
9.20 Spaleck Screen Unit Maintenance..............................................................9-105
(1) Screening Element.................................................................................9-105
(2) Assembly of the Screening Element.......................................................9-105
(a) Disassembly of the Screening Element.............................................9-106
(b) Servicing the Sieve Base...................................................................9-106
(3) Shaft drive system..................................................................................9-107
(a) Bolted connections.............................................................................9-107
(b) Bearing Temperature.........................................................................9-107
(4) Clamped Screen Mat..............................................................................9-108
(a) Screen Mat Assembly........................................................................9-109
(b) Screen Mat Disassembly................................................................... 9-110
(c) Screen Mat Maintenance................................................................... 9-110
9.21 Collection Conveyor And Diesel Tank Maintenance.................................... 9-111

Page 6 Warrior 2100
Table of Content
10 Troubleshooting........................................................................................ 10-2
10.1 General Troubleshooting...............................................................................10-2
10.2 Conveyors Troubleshooting..........................................................................10-3
10.3 Screen Troubleshooting................................................................................10-4
10.4 Components Troubleshooting.......................................................................10-6
10.5 Hydraulic Troubleshooting.............................................................................10-7
10.6 Production Troubleshooting..........................................................................10-8
10.7 Tracks Troubleshooting.................................................................................10-9
10.8 Electrical Troubleshooting........................................................................... 10-11
10.9 Engine Troubleshooting..............................................................................10-13
10.10 Engine Fault Codes.....................................................................................10-20
10.11 Machine Fault Codes and Descriptions......................................................10-31
11 Storage.......................................................................................................11-2
12 Glossary of Terms.................................................................................... 12-1
Appendix A EC Declaration of Conformity...............................................A-1
Appendix B Warranty.................................................................................B-1
Appendix C..................................................................................................C-3
(1) Hydraulic Drawings.................................................................................... C-3
(2) Tier 4 Schematics...................................................................................... C-5
(3) Dual Power Schematics............................................................................ C-7

Warrior 2100 Page 7
Table of Content

Page 8 Warrior 2100
Introduction 1
Table of Content
1 Introduction................................................................................................. 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment....................................................................................1-3
1.2 Safety Information...........................................................................................1-3
(3) California Proposition 65 Warnings............................................................1-4
1.3 Intended Use...................................................................................................1-4
1.4 Prohibited Use.................................................................................................1-4
1.5 Declaration of Conformity................................................................................1-4
1.6 Warranty..........................................................................................................1-4
1.7 Copyright.........................................................................................................1-5
1.8 Bulletin Distribution and Compliance..............................................................1-5
1.9 Transfer of Machine Ownership......................................................................1-5
1.10 Contacting the Manufacturer...........................................................................1-6

Warrior 2100 Page 1-1
1 Introduction
1 Introduction
1.1 Notes to the Operations Manual

This operations manual contains important information on how to operate the machine safely
and correctly. Read this manual carefully to learn how to operate your machine. Failure to do
so could result in personal injury or equipment damage. Consider this manual a permanent part
of your machine. Keep it with the machine at all times. Included with this manual is a disc which
contains the original language version of this manual which is English.
There is a separate engine manufacturer’s manual which should also be read and understood
prior to any operation or maintenance of the machine.
The following procedure bar indicates the start of a procedure. Any safety warnings related to
the procedure will be highlighted before the procedure.
PROCEDURE
Any results from a step in the procedure will be indicated in italic below that step. The end of a
procedure is indicated with a line under the last step or the last image in a procedure.
Follow all applicable safety regulations and recommendations in this manual as appropriate to
your machine and the situation/conditions prevailing at the time.
Federal, State, National and Local laws and safety regulations must be complied with at all times
to prevent possible danger to person(s) or property from accidents or harmful exposure.
Where supplied as a basic machine only, (with or without optional extras, e.g. drive elements,
etc.), the machine is intended for incorporation into a complete processing machine that is NOT
designed and/or constructed by Terex. In these circumstances, or where supplied as a replacement
machine, Terex will NOT be responsible for addressing environmental issues and/or health and
safety protection measures for the machine installation as a whole and will bear NO responsibility
for ensuring compliance with any regulations and/or statutory requirements that may apply unless
specifically included in the Contract of Sale.
INFORMATION AND ADVICE
If you need any information or advice regarding your machine please contact:
Terex Powerscreen
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8774 0701
E mail: aftersales@powerscreen.com
(1) Units
Within this operations Manual figures shown within brackets ( ) after the Metric unit of measure
are approximate conversions from the actual metric measurement of the item concerned to the
imperial measurement.

Page 1-2 Warrior 2100
Introduction 1
(2) Optional Equipment

Terex machines can include optional equipment and/or special features additional to the
standard specification. These may affect the information given in this operations manual. Refer
to Chapter 4 of the operations manual for extra equipment or variations that can be applicable
to the standard specification. Take note of any variations to the standard procedures and/or
component specifications.
1.2 Safety Information
(1) Safety Alert Symbol
The safety alert symbol is used on safety signs and throughout this manual to alert you to potential
personal injury hazards. Obey all messages that follow this symbol to avoid injury or death.
Conduct thorough risk assessments and mitigate identified risks in accordance to the assessment.
(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and protection
only. All are used as attention-getting devices throughout this manual as well as on ANSI type
decals and labels fixed to the machine.
nn DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
The safety alert symbol is shown with this danger classification.
nn WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
nn CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol is shown with this danger classification
NOTICE
This indicates a message related to property damage. The safety alert symbol is not shown with
this danger classification.
All hazards associated with each procedure will be listed before each procedure as described
above.

1 Introduction
(3) California Proposition 65 Warnings

This equipment contains and/or emits chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
Lead and lead compounds, gasoline, diesel engine exhaust, and used engine oil are chemicals
known to the State of California to cause cancer.
Lead and carbon monoxide are chemicals known to the state of California to cause birth defects.
Lead is a chemical known to the State of California to cause reproductive harm.
1.3 Intended Use

This product and its approved attachments are designed to be used in Material Processing
crushing and screening applications. Compliance with the operating 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 contrary to its intended use.
1.4 Prohibited Use

Operating the machine outside of its recommended range of applications or for any use which
it is not intended, will result in a loss of any guarantee. The manufacturer or supplier cannot be
held liable for any damage or injury resulting from such misuse.
Use of this product in any way other than its intended use is prohibited. The manufacturer will
not be liable for any damage resulting from such use.
1.5 Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery Directive 2006/42/EC together
with appropriate EN Harmonised Standards and National BS Standards and Specifications.
A Declaration of Conformity certificate is applicable to each machine. Refer to Appendix A for
an example of a Declaration of Conformity certificate. The original copy of the certificate is sent
out with the machine.
1.6 Warranty
Refer to Appendix B for an example of the warranty. It is important that it is read and fully
understood.

Introduction 1
1.7 Copyright
The copyright of this operations manual is reserved by Powerscreen.
This operations manual contains information and technical drawings, which may not be copied,
distributed, altered, stored on electronic media, revealed to others or used for the purpose of
competition, either partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice.
Copyright 2017
Terex Powerscreen
200 Coalisland Road
BT71 4DR
Telephone: +44 (0) 28 8774 0701
To order additional copies contact your local Terex dealer.
1.8 Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Terex. Various bulletins are used by Terex
to communicate important safety and product information to dealers and machine owners. The
information contained in bulletins is tied to specific machines using the machine model and serial
numbers. Distribution of bulletins is based on the most current owner on record along with their
associated dealer, so it is important to register your machine and keep your contact information
up to date. To provide for the safety of personnel and the reliable continued operation of your
machine, be sure to comply with actions indicated in all safety and product notices.
1.9 Transfer of Machine Ownership

If you are not the original owner of this machine, provide the model number and PIN number of
your machine. Also include your name and the date of the transfer of ownership. It ensures that
you are the owner on record for this machine, allowing you to receive any applicable notices and
advisories in a timely manner.

1 Introduction
1.10 Contacting the Manufacturer

At times it may be necessary to contact the manufacturer of this machine. When you do, be ready
to supply the model number and PIN number of your machine, along with your name and contact
information. At minimum, the manufacturer should be contacted for any of the following reasons:
• Accident reporting
• Questions regarding product applications and safety
• Standards and 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 Ownership).
Please contact:
Terex Powerscreen
200 Coalisland Road
BT71 4DR
Telephone: +44 (0) 28 8774 0701

Safety 2
Table of Content
2 Safety........................................................................................................... 2-2
2.1 General Safety................................................................................................2-2
(3) Property Damage Messages......................................................................2-3
(4) Description of Safety Symbols....................................................................2-3
2.2 Positions of Safety Signs on the Machine.......................................................2-8
2.3 Personal Safety.............................................................................................2-15
(1) Personal Protective Equipment................................................................2-15
2.4 Work Area Safety..........................................................................................2-16
(1) General Work Area Guidelines.................................................................2-16
(2) Safety Warnings and Labels.....................................................................2-16
(a) Modifications........................................................................................2-16
(3) Transportation Safety...............................................................................2-17
(4) Operation Safety.......................................................................................2-18
(5) Hydraulic and Pneumatic Safety..............................................................2-19
(6) Electrical Safety........................................................................................2-20
(7) Maintenance Safety..................................................................................2-21
(8) Gas, Dust, Steam, Smoke........................................................................2-23
(9) Hazardous Substances............................................................................2-23
(10) Noise Levels.............................................................................................2-23
2.5 Emergency Stop Locations...........................................................................2-24

2 Safety
2 Safety
This safety section covers a wide variety of hazardous situations, (but not necessarily limited
to those described), which may or may not apply to any specific machine installation. They are
given for general guidance only to assist the operator in setting up and maintaining an appropriate
regime for the protection of health and safety. Where the machine is supplied for incorporation
into plant/equipment designed, supplied and located by others, Terex cannot be aware of particular
hazards that may be present or might occur and therefore accept no liability for addressing or
resolving these issues.
2.1 General Safety

The following signs and designations are used in the manual to designate instructions of particular
importance.
(1) Safety Alert Symbol
The safety alert symbol is used on safety signs and throughout this manual to alert you to potential
personal injury hazards. Obey all messages that follow this symbol to avoid injury or death.
Conduct thorough risk assessments and mitigate identified risks in accordance to the assessment.
(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and
protection only. All are used as attention-getting devices throughout this manual as well as on
ANSI type decals and labels fixed to the machine.
nn DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
nn WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
nn CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol is shown with this danger classification

Safety 2
(3) Property Damage Messages

The signal word NOTICE, shown without the safety alert symbol, is used throughout this manual
and on machine labels to address specific practices, or draw attention to supplemental information
that is not related to personal injury.
NOTICE
This indicates information considered important, but not hazard related. This is a message related
to property damage. The safety alert symbol is not shown with this danger classification.
(4) Description of Safety Symbols
Table 2.1 - Description of Safety Symbols

Symbol Description
Electrocution hazard
Electrical shock/ electrocution from conveyor to power line contact.
Stay sufficient distances from electrical power lines.
Entanglement hazard
Entanglement in belt drive or conveyor.
Entanglement hazard
Arm entanglement in belt drive.
Stay clear of conveyor.
Install covers and guards before operation.
Turn machine off and remove the key.
Lockout machine.
Read and understand operations manual before using equipment.

2 Safety
Symbol Description
Injection hazard
Skin injection from high pressure fluid.
Use cardboard or wood to check for leaks.
Crush hazard
Crushed foot from support leg.
Stay clear of support legs and jacks.
Falling material hazard

Struck from falling or flying material.
Stay clear of hopper during operation.
Fall Hazard
Falling from a height.
Do not climb onto the machine.
Use personnel lift to reach high places.
Check tyre pressures prior to transport.
Check wheel nut torque. Recheck wheel nut torque every 150 miles
(200km).
Connect and check braking system.
Crush hazard
Crushing of fingers or hand. Force applied in one direction.

Safety 2
Symbol Description
Keep hands clear of openings.
Hand entanglement in pulley/ winch
Keep hands clear of moving components
Electrocution hazard
Electric shock/ electrocution.
Hearing hazard
Loss or degradation of hearing.
Wear hearing personal protective equipment.
Explosion hazard
Explosion during an operation or service procedure.
Burn hazard
Burns from corrosive material.
Keep open flame away.
Emergency Stop
Press to engage, twist to reset.
Flying Material Hazard

Face struck by flying objects
Wear eye personal protective equipment
Crush Hazard
Crush from overhead impact.

2 Safety
Symbol Description
Stay clear of moving conveyors.
Unauthorized persons prohibited.
Flying Material Hazard

Struck by flying material.
Do not stand on platform while machine is in operation
Do not stand on machine while in operation.
Inhalation Hazard
Inhalation of poisonous/ toxic fumes or dust.
Use dust suppression (water spray) or dust collection (filter) during

operation of this equipment.
Wear respiratory personal protective equipment.
Cutting Hazard
Contact with knives in trommel drum will result in death or serious injury.
Stay clear of sharp knives in trommel drum.
Crush Hazard
Crush from track machine run over.
Stay clear of track machine.
Crush Hazard
Crush from wheel machine run over.

Safety 2
Symbol Description
Stay clear of wheeled machine.
Explosion Hazard
Battery Explosion.
Keep welding sparks away from the battery area.
Burn Hazard
Burn from hot surface or liquid
Stay clear of hot surface or liquid.
Impact Hazard
Impact from spring loaded door.
Stay clear of spring loaded door while opening.

2 Safety
2.2 Positions of Safety Signs on the Machine

Table 2.2 lists the safety signs that are on this machine.
Table 2.2 - Safety Signs

Sign
Item ISO ANSI
1500
1502
1502- IO

Safety 2
Sign
Item ISO ANSI
1503
1504
1504- IO
1507
1507- IO

2 Safety
Sign
Item ISO ANSI
1508
1508- IO
1511
1512

Safety 2
Sign
Item ISO ANSI
1513
1513- IO
1514
1514- IO
1515
1515- IO

2 Safety
Sign
Item ISO ANSI
1518
1518- IO
1520
1520 - IO
1521

Safety 2
Sign
Item ISO ANSI
1522
2
1
1522- IO
1524
1524- IO
1530
1530- IO

2 Safety
Sign
Item ISO ANSI
1531
1531- IO
1532

Safety 2
2.3 Personal Safety

Ascertain from the appropriate authority and observe all statutory and any other regulations that
may apply to the planned location before operating the machine. Operators must be trained in
the correct and safe use of all equipment.
Before operation the operator(s) must:
• Have received specific and adequate training in the task to be carried out.
• Have read and understood the operations manual and the Safety Signs in this manual and
around the machine(s).
• Knows the location and function of controls and safety features such as emergency stop buttons
and safety guards.
• Be aware of all moving parts of the machine.
Any work on and/or with the machine must be executed by trained, reliable and authorised
personnel only. Statutory minimum age limits must be observed.
Work on the electrical system and equipment of the machine must be carried out only by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules and regulations.
Work on the hydraulic system must be carried out only by personnel with special knowledge and
experience of hydraulic equipment.
(1) Personal Protective Equipment

Where possible when working close to engines or machinery, only do so when they are stopped.
If this is not practical, remember to keep tools, test equipment and all other parts of your body
well away from the moving parts. Loose or baggy clothing can get caught in running machinery.
For reasons of safety, long hair must be tied back or otherwise secured, garments must be close
fitting and no jewelry such as rings may be worn. Injury may result from being caught up in the
machinery or from rings catching on moving parts.
Always wear correctly fitting (EN/ANSI approved) protective clothing.
Protective clothing includes: Hard Hat, Safety Glasses, Ear Protection, Dust Mask, Close fitting
Overalls, Steel Toed Boots and a High Visibility Vest.

2 Safety
2.4 Work Area Safety
(1) General Work Area Guidelines

Operators must have received specific training in all operating and service tasks as required for
the safe operation and service of the machine. Operators must know the location and correct
operation of all controls and safety features such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Keep the work area as neat and as clean as practical. Keep your equipment clean and free of
dirt and grease so it can be checked for loose, cracked or broken parts. Replace defective parts
as soon as they are discovered.
The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and plant on which they are fitted can be operated safely and without risk to
health when properly used. However, it cannot be guaranteed that the guards provided will meet
the requirements laid down by individual Inspectors and any additional guard and/or modification
to guarding supplied, which may be required for any reason whatsoever, will be charged as an
addition to the Contract Price.
Walkways should only be used when the machine is turned off, unless to perform specific
maintenance procedures which require the machine to be operational. In this instance, only
suitable trained and authorised personnel equipped with the correct PPE should be allowed
access and the machine must be running empty 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 flammable solvents
for cleaning parts and equipment. Know where fire extinguishers and other fire suppression
equipment are located and learn how to use them.
Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles and
chains for stretch and wear. Never overload hoists, cranes or other lifting devices.
Avoid electrical and static sparks and any open flame while handling, storing, moving or pouring
fuels, electrolytes for batteries, hydraulic fluids or coolants.
(2) Safety Warnings and Labels

You can be injured if you do not obey the safety instructions as indicated on warning signs.
Observe all safety instructions and warnings attached to the equipment.
Ensure that safety instructions and warnings attached to the equipment are always complete and
perfectly legible. Keep warnings and instruction labels clean and up to date.
Replace unreadable or missing labels with new ones before operating the machinery. Make sure
replacement parts include warning or instruction labels where necessary.
(a) Modifications
Never make any modifications, additions or conversions which might affect safety without the
supplier’s approval.
In the event of safety relevant modifications or changes in the behavior of the machinery during
operation, stop the machine and lock out immediately and report the malfunction to the competent
authority/ person.

Safety 2
(3) Transportation Safety

Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know
the overall height to avoid contacting overhead obstructions such as bridges, power lines etc.
The preparations to move equipment by an articulated lorry should be supervised by a minimum of
two persons. Ensure persons transporting the machine adhere to all safety signs and procedures.
Before transportation on public roads, ensure the machine has been properly secured with no loose
material left in or on the machine. Always observe the valid traffic regulations and, if necessary,
ensure beforehand that the machine is in a condition compatible with these regulations.
Extreme caution is required when transporting machinery on 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 reaching a slope.
The machine is remote controlled and may start without notice. Stay clear of the machine. The
machine must be loaded and transported only in accordance with the operating instructions.
For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable
of adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any signalling
and lighting systems are fully functional. Before setting the machine in motion always check that
the accessories have been safely stowed away.
On wheeled machine:
Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport.
Check your tires for:-
• Correct pressure
• Cuts or bulges
• Nails or spikes
• Uneven or excessive wear
• Missing valve caps
Check your wheels for:-
• Damaged rims
• Missing or loose wheel nuts or bolts
• Obvious misalignment
Have cuts or punctures repaired by authorised personnel before adding air. Beware that an over-
inflated tire can explode and cause serious injury or death.

2 Safety
(4) Operation Safety

Before attempting to operate the machine, DO read, fully understand and observe the contents
of this manual. Also any other relevant manual for other equipment incorporated in the machine,
e.g. Engine manual. Study all safety signs on your machine.
It is emphasized that all safety aspects are checked before starting the machinery.
Make sure that you fully understand the operating procedures for the machine before attempting
to start.
Take the necessary precautions to ensure that the machine is used only when in a safe and
reliable state.
Operate the machine only for it’s designed purpose and only if all guarding, protective and safety
orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are
in place and fully functional.
Before starting the engine ensure it is safe to do so. NEVER leave the machine unattended
whilst it is in operation.
Before starting, walk completely around the machine. Make sure no one is under it, on it or close
to it. Let other workers and bystanders know you are starting up and do not start until everyone
is clear of the machine.
Before moving the machine, ensure that everyone is clear from the surrounding area and that the
warning siren and beacon and the tracking umbilical Machine Stop button are operating correctly
Make certain enough ventilation is present to run engines safely. Do not start an engine in an
enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel engines
can kill.
DO NOT allow a build up of solid material or dust in any part of the machine. In the event of
material blockage, any malfunction or operational difficulty, stop the machine immediately and
lockout. Have any defects rectified immediately.
Be alert and watch for pinch points, closing mechanisms, and falling parts when working on or
around any machinery. Keep hands and tools clear. In-running nip points on moving machinery
can cause serious injury or even death. Do not reach into unguarded machinery. Your arm could
be pulled in and amputated. Switch off and lockout the machine before removing any safety
devices or guarding.
Never work or stand beneath machinery or attachments as it is raised or lowered. Never work
or stand beneath machinery as they are being loaded with and/or discharging material. During
operation, do not climb onto, over or under moving conveyor belts and rollers. 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.
Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden stops,
starts or changes in direction. Only use emergency stop buttons or emergency stop lines (if fitted)
in emergency situations or during safety drills.
Never check the tension of ‘V’ belts, drive chains and conveyors when machine is running.
DO check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.
After each day’s operation, always run the machine dry; never leave material in the beltfeeder
on conveyor belts or screenbox. Starting a machine with a full load will cause strain problems in
your machine.

Safety 2
(5) Hydraulic and Pneumatic Safety

Only persons having special knowledge and experience in hydraulic and pneumatic systems
may carry out work on hydraulic and pneumatic equipment. Never disable or alter any hydraulic
circuit or component without consulting with Terex.
Relieve all pressure in the hydraulic system by returning all controls to the neutral position. Turn
off the machine and isolate power supply before any pipes, filter caps, filters or hydraulic fittings
are disconnected or removed. Depressurize all system sections and pressure pipes (hydraulic
system, compressed air system) to be removed in accordance with the specific instructions for
the unit concerned before carrying out any repair work.
Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use an open
flame to check for leaks. Always use a piece of cardboard to check for leaks. Do not use your
hand. Hydraulic fluid under pressure can penetrate the skin causing serious injury. If fluid is
injected under the skin, it must be surgically removed or gangrene will result. Get medical help
immediately if this occurs. Wear personal protective equipment including goggles and gloves.
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Splashed
oil may cause injury and fire. Repair any damage immediately.
Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections
are interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.
Always practice extreme cleanliness servicing hydraulic components.
Do not exceed safe limits. Never set a pressure relief valve to a pressure higher than that set
at the factory.
For questions concerning accumulators, which are pressure-containment vessels, contact your
Terex distributor. Malfunctioning valves or poor maintenance practices can result in build-up of
extremely high hydraulic and/or pneumatic pressures inside the accumulator.

2 Safety
(6) Electrical Safety

The electrical mode of operation on the electric hydraulic machines operates at 380-415 Volts
AC, 50/60Hz.
Work on the electrical system or equipment may only be carried out by a skilled and qualified
electrician or by specially instructed personnel under the control and supervision of such an
electrician and in accordance with applicable electrical engineering rules and regulations.
Use only original fuses with the specified current rating. Switch off the machine immediately if
trouble occurs in the electrical system.
Machines with high voltage electrical equipment must be suitably earth bonded by a qualified
electrician prior to activating the main isolator switch. If machine is electric-hydraulic or direct
electric drive, the ‘mains’ electrical supply to the machine should always be isolated by unplugging/
uncoupling the ‘mains’ power socket. It is recommended that an earth leakage safety switch be
fitted in the supply line to the power point on site. Special care should be taken to ensure that
earth wires are correctly connected.
When working with the machine, maintain a safe distance from overhead electric lines. If work
is to be carried out close to overhead lines, the working equipment must be kept well away from
them. Check out the prescribed safety distances.
If your machine comes into contact with a live wire:
• Warn others against approaching and touching the machine.
• Have the live wire de-energised.
If provided for in the regulations, the power supply to machines and parts of machines, on which
inspection, maintenance and repair work is to be carried out, must be cut off. Before starting
any work, check the de-energised parts for presence of power and ground or short circuit them
in addition to insulating adjacent live parts and elements.
The electrical equipment of the machine is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be rectified
immediately.
Necessary work on live parts and elements must be carried out only in the presence of a second
person, who can cut off the power supply in the case of danger by actuating the emergency
shut off or main power switch. Secure the working area with a red and white safety chain and a
warning sign. Use insulated tools only.
Before starting work on high voltage assemblies and after cutting out the power supply, the feeder
cable must be grounded and components such as capacitors short-circuited with a grounding rod.
Tracked machines are wired with negative earth. Always observe correct polarity.
Always disconnect battery leads before carrying out any maintenance to the electrical system or
servicing the engine. Never short across the starter terminals of a battery as this can cause a
fire and could also damage the electrical system. If welding is to be carried out on the machine,
it is essential that the powerpack is isolated.
The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce
explosive gases. Wear personal protective equipment and avoid contact with the skin, eyes or
clothing.
Diesel engine exhaust emissions contain products of combustion which may be harmful to your
health. Always operate the machine in a well ventilated area and if operating in an enclosed
area, vent the emissions outside. Do not touch any part of the engine or exhaust system. Allow
the engine and exhaust to cool before performing any repair or maintenance.

Safety 2
Never fill the fuel tank with the engine running, while smoking or when near an open flame. Never
overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.
(7) Maintenance Safety

Understand the service procedures before doing work. Keep working area clean and dry. Never
lubricate, clean, service or adjust machinery while it is moving. Keep hands, feet and clothing
clear of power driven parts and in running nip-points. Disengage all power and operate controls
to relieve pressure. Stop the engine, implement the lockout and tag out procedure and allow the
machinery to cool before carrying out any maintenance.
Whenever maintenance or service is being carried out a minimum of two (2) persons should be
present at all times. NEVER WORK ALONE.
Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Remove any build up of grease, oil and debris.
Never attempt repairs or adjustments to the machine while it is running unless specified to do so.
Before carrying out any maintenance, relieve all hydraulic pressure by returning the controls to
the neutral position and secure all hydraulically operated attachments with pins provided.
Disconnect the battery ground cable before making adjustments on electrical systems or welding
on machinery. For the execution of maintenance work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.
Remove only guards or covers that provide access. Wipe away any excess grease and oil.
Never leave guards off or access doors open when unattended. Keep bystanders away if access
doors are open.
When working beneath raised equipment, always use blocks, jack-stands or other rigid 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 out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms. Always use any walkway/platforms provided or a safe
and secure platform approved by the regional safety enforcing authority.
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 not aware of working
at height requirements speak to your manager before starting any work. Keep all handles, steps,
handrails, platforms, landing and ladders free from dirt, oil, snow and ice.
Return idler roller guards should be checked for wear/damage during routine maintenance. The
gap between the guard and the idler roller should not exceed 5 mm. The gap between the idler
roller and the guard must be renewed. Contact your local Terex dealer to obtain an approved
replacement.
Maintenance and Repairs During Operation; Disposal of Parts and Consumables
Observe the adjusting, maintenance and intervals set out in these operating instructions, except
where:
• Warning, horn/light/gauge or indicator calls for immediate action.
• Adverse conditions necessitate more frequent servicing.
Observe information on the replacement of parts and equipment. These activities may be executed
by skilled personnel only.
When the machine is completely shutdown for maintenance and repair work, it must be secured
against inadvertent starting by:

2 Safety
• Switching off the engine and removing the ignition key or isolating the electrical supply as
applicable.
• Implementing the lockout procedure.
• Attaching a warning sign(s) to the machinery in appropriate positions.
Carry out maintenance and repair work only if the machine is positioned on stable and level
ground and has been secured against inadvertent movement and buckling.
Never allow unqualified or untrained personnel to attempt to remove or replace any part of the
machine, or anyone to remove large or heavy components without adequate lifting equipment.
To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes should be carefully attached to lifting tackle and secured. Use only suitable and
technically adequate lifting gear. Never work or stand under suspended loads.
Keep away from the feed hoppers and stockpile conveyor discharge points, where there is risk
of serious injury or death due to the loading and removal of material.
Falling from and/or onto Terex machines can cause injury or even death. Do not climb on the
machine whilst it is in operation. Never use machine parts as a climbing aid.
Beware of moving haulage and loading equipment in the vicinity of the machine.
The fastening of loads and instructing of crane operators should be entrusted to experienced
persons only. The marshaller giving the instructions must be within 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.
Any safety devices removed for setup, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work to ensure full working
order.
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with Terex equipment includes such items as oil, fuel, coolant, filters and batteries,
etc. Use leakproof containers when draining fluids. Do not use food or beverage containers
that may mislead someone into drinking from them. Do not pour waste onto the ground, down
a drain or into any water source. Ensure that all consumables and replaced parts are disposed
of safely and with minimum environmental impact.
Always ensure that any safety fitment such as locking wedges, securing chains, bars or struts
are utilized as indicated in these operating instructions.
Diesel fuel is highly flammable. Never remove the filler cap, or refuel, with the engine running.
Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion
risks. Do not carry out maintenance on the fuel system near naked lights or sources of sparks,
such as welding equipment or whilst smoking.
After maintenance, tighten all bolts, fittings and connections. Install all guards, covers and shields.
Replace or repair any damaged ones. Refill and recharge pressure systems with recommended
fluids. Start the engine and check for leaks. Operate all controls and make sure the machine is
functioning properly. After testing, shut down, check the work you performed. Recheck all fluid
levels before releasing machine for operation.

Safety 2
(8) Gas, Dust, Steam, Smoke

Death, serious injury or delayed lung disease may result from breathing dusts that are generated
when certain hazardous materials are crushed, screened or conveyed with this equipment.
Always operate internal combustion engines and fuel operated heating systems only out of doors
or in a well-ventilated area. Before starting the machine in enclosed areas, make sure that there
is sufficient ventilation.
Observe the regulations in force at the respective site.
Dust found on the machine or produced during work on the machine should be removed by
extraction, not blowing. Dust waste should be dampened, placed in a sealed container and
marked, to ensure safe disposal.
When dusts are generated by the operation of this equipment, use approved respiratory 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 there may be a risk of explosion and fire.
Before carrying out welding, flame cutting and grinding operations, clean the machine and
its surroundings from dust and other flammable substances and make sure the premises are
adequately ventilated as there may be a risk of explosion.
Ensure operators wear a suitable face mask where exposed to possible harmful effects of air
pollution of any kind.
(9) Hazardous Substances

Ensure that correct procedures are formulated to safely handle hazardous materials by correct
identification, labelling, storage, use and disposal.
All hazardous materials must be handled strictly in accordance with the manufacturers instructions
and all applicable regulations observed at all times. Store hazardous materials in restricted
access areas and mark them clearly.
(10) Noise Levels

HEARING HAZARD EXCEEDS 90 dB (A)
May cause loss or degradation of hearing over a period of time.
Always ensure that operators are provided with ear defenders of approved pattern and that these
are worn at all times when the machine is operating.

2 Safety
2.5 Emergency Stop Locations

Emergency stops are located at both the left hand side and right hand side of the machine in the
positions shown. The same positions are true for the opposite side of the machine.
DUN00798
Figure 2.1 - Emergency Stop Locations

Technical Data 3
Table of Content
3 Technical Data ............................................................................................ 3-2
(1) Machine Weights........................................................................................3-2
3.2 Machine Component Specifications................................................................3-2
(1) Feeder Unit (A)...........................................................................................3-2
(a) Warrior Feed Hopper (Standard & Apron)..............................................3-2
(b) Feed Conveyor (Not Apron Feeder).......................................................3-2
(3) Screen Unit (C)...........................................................................................3-2
(4) Side Conveyors (D & E).............................................................................3-3
(5) Tail Conveyor (F)........................................................................................3-3
(6) Power Unit (G)............................................................................................3-3
(a) Tier 3 Engine..........................................................................................3-3
(b) Tier 4 Engine..........................................................................................3-3
(7) Chassis (H).................................................................................................3-3
(a) Warrior 2100 Tracks...............................................................................3-3
3.3 Machine Drawings...........................................................................................3-4
(1) Warrior 2100 Working Dimensions.............................................................3-4
(2) Warrior 2100 Transport Dimensions ..........................................................3-5
(3) Noise Levels...............................................................................................3-6

3 Technical Data
3 Technical Data
3.1 General Information
(1) Machine Weights

Machine................................................Warrior 2100
Type......................................................Mobile screening machine
Total weight (Belt feeder)..........................................34,800 kg*
Total weight (Belt feeder & Single Shaft/Spaleck) 34,300 kg*
Total weight (Apron feeder)......................................37,000 kg*
Total weight (Apron feeder & Single Shaft/Spaleck) 36,500 kg*
Triple Shaft Screen.....................................................7,000 kg
Single Shaft/Spaleck Screen......................................6,500 kg
*The ‘Total weight’ refers to the weight of machine in standard configuration only. Any optional
extras added will have a considerable influence on the overall plant weight.
3.2 Machine Component Specifications
(1) Feeder Unit (A)
(a) Warrior Feed Hopper (Standard & Apron)

Opening size.........................................4.7 m x 2.6 m (Standard)
Feed in height.......................................3.1 m (Back door lowered)
Standard Chassis/Hopper....................3.6m
Chassis Riser/Standard Hopper...........3.8m
(b) Feed Conveyor (Not Apron Feeder)

Belt width..............................................1300 mm (51’’)
Type......................................................4 ply
(2) Collection Conveyor (B)

Belt width..............................................1300 mm (51’’)
(3) Screen Unit (C)

Width....................................................1.55 m (5’1’’)
Length...................................................4.88 m (16’)
Screen Angle (Triple Shaft)...................Fixed 10° (stroke size and angle adjustable)
Screen Angle (Single Shaft).................Variable 10°-18° (stroke size and angle adjustable)
Screen Angle (Spaleck)........................Variable 10°-18° (stroke size and angle adjustable)

Technical Data 3
(4) Side Conveyors (D & E)

Belt width..............................................900 mm (36’’)
(5) Tail Conveyor (F)

Belt width..............................................1400 mm (4’ 7”)
Stockpile Height (3WS)........................4.2 m
Chassis Riser (3WS)............................4.4 m
Degree of incline:
Working Angle......................................Up to 24°
(6) Power Unit (G)
(a) Tier 3 Engine

Tier 3/Stage 3A Caterpillar C4.4 ATAAC 97 kw @ 1800rpm
(b) Tier 4 Engine

Tier 4 Final Caterpillar C4.4 93kw @ 1800rpm
Tier 4 Final Caterpillar C4.4 - Constant Speed 97kw @1800rpm
Refer to engine operation manual supplied with the machine.
(7) Chassis (H)
(a) Warrior 2100 Tracks

Output Torque.......................................26213 - 45,125 Nm
Gradability percentage.........................34.9° (Low speed)
Gearbox ratio........................................166:1
Hydraulic motor....................................up to 85.9 cc/rev
Approximate speed...............................0.8-1.4 Km/hr

3 Technical Data
3.3 Machine Drawings
(1) Warrior 2100 Working Dimensions
DUN00499

Technical Data 3
(2) Warrior 2100 Transport Dimensions
DUN00500

3 Technical Data
(3) Noise Levels

Machine Description 4
Table of Content
4 Machine Description................................................................................... 4-2
(1) Identification Plate......................................................................................4-2
(2) Machine References...................................................................................4-3
4.2 Nomenclature and Technical Data..................................................................4-5
4.3 Construction Units...........................................................................................4-6
(1) Feeder Unit (A)...........................................................................................4-6
(a) Feeder (A)..............................................................................................4-8
(3) Screen Unit (C).........................................................................................4-10
(4) Side Conveyors (D&E)............................................................................. 4-11
(5) Tail Conveyor (F)......................................................................................4-12
(6) Power Unit (G)..........................................................................................4-13
4.4 Control and Display Elements.......................................................................4-16
(1) MCU 300 Control Panel............................................................................4-16
(2) Dual Power...............................................................................................4-20
(a) Control Panel Component Identification..............................................4-20
(3) Manual Tracking System..........................................................................4-21
(4) Teleradio Radio Remote Tracking Kit ......................................................4-22
4.5 Telematics.....................................................................................................4-22
4.6 Pictorial Decal Descriptions...........................................................................4-23
(1) Machine Operation Decals.......................................................................4-23
(2) Machine Information Decals.....................................................................4-30

4 Machine Description
4.1 General Information
(1) Identification Plate

The machine identification plate gives important information about the machine.
1
2
3
4
DUN01719
Figure 4.1 - Identification Plate
1 Machine model
2 Year manufactured
3 Machine mass
4 Serial number
The machine identification plate is located on the outside of the powerunit.
1
DUN00800
Figure 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 using this handbook, at all times the rear of the machine is situated at the feeder end.
4 2
DUN00799
Figure 4.3 - Machine reference from above

3 2
DUN00801
Figure 4.4 - Machine References
1 Left Hand Side

2 Front
3 Right Hand Side
4 Rear

4.2 Nomenclature and Technical Data

The following sections identify the main components of the machine and the term with which they
are referred to in this manual.
4
3
5 2
6
DUN00802
Figure 4.5 - Nomenclature and Technical Data
ID Construction Unit Component

1 Feeder unit Feeder hopper/Feeder conveyor
2 Collection conveyor
3 Screen Unit
4 Mid fines side conveyor
5 Fines side conveyor
6 Tail conveyor
7 Power unit Engine

4.3 Construction Units
(1) Feeder Unit (A)

The feeder unit consists of 2 main components, the hopper and conveyor. The feeder unit can
be seen from Figure 4.6, the hopper can be seen from Figure 4.7, the feeder conveyor can be
seen from Figure 4.8 and the optional apron feeder can be seen from Figure 4.9.
A1 Feeder Unit
Figure 4.6 - Feeder Unit
A2 Feeder Hopper
Figure 4.7 - Feeder Hopper

A3 Belt Feeder Conveyor
Figure 4.8 - Feeder Conveyor
A4 Apron feeder
Figure 4.9 - Apron feeder

(a) Feeder (A)

The hopper is attached to the feeder conveyor which is used to convey loaded material to the
screenbox at a uniform rate and distribution.
The feeder belt is driven by two hydraulic motors with two variable speed gearboxes.
The apron feeder (Optional) is driven by one hydraulic motor and one variable speed gearbox.
DUN00803
Figure 4.10 - Feeder Conveyor

Conveyor Belt Assembly

The conveyor belt assemblies on all machines consists of the components detailed:
9
8
5
4
3
2
6 1 7
Figure 4.11 - Conveyor Belt Assembly
1 Drive drum and motor

2 Tail drum
3 Conveyor belting
4 Side rollers
5 Centre rollers
6 Return rollers
7 Belt scrapers
8 Guarding
9 Viewing apertures
(2) Collection Conveyor (B)

The collection conveyor is attached to the chassis for the purpose of feeding material from the
screen unit to the fines conveyor.
DUN00818
Figure 4.12 - Collection Conveyor

(3) Screen Unit (C)

The screen unit is located at the end of the feeder conveyor where it screens raw material into
different sizes.
Screening action is provided by either a heavy duty, aggressive triple shaft drive mechanism
featuring adjustable speed and stroke angle or a single shaft drive with adjustable screening angle.
Material is fed onto the screen from the hopper by the feed conveyor. A range of mesh sizes are
available and are side tensioned to the top deck and end tensioned to the bottom deck. All are
designed to facilitate easy replacement.
Material is discharged from the screen unit onto the conveyors. Oversize material from the top deck
is discharged to the tail conveyor. Midsize material is discharged to the midsize side conveyor.
Fines material is collected in the collection conveyor and is conveyed to the fines conveyor for
discharge to the fines stockpile.
Figure 4.13 - Screen Unit

(4) Side Conveyors (D&E)

The side conveyors are attached to the machine’s chassis for the purpose of feeding material
from the screen unit to the stockpile.
DUN00805
Figure 4.14 - Side Conveyors

(5) Tail Conveyor (F)

The tail conveyor is attached to the chassis for the purpose of feeding material from the screen
unit to the stockpile.
DUN00806
Figure 4.15 - Tail Conveyor

(6) Power Unit (G)

The power unit is attached at the chassis, under the feeder unit. The power unit is completely
enclosed, sound suppressed and lockable. The power unit is highlighted in Figure 4.16 and
detailed in Figure 4.17.
DUN00807
Figure 4.16 - Location of the Power Unit
DUN00808
Figure 4.17 - Power unit

The control panel (G1) and control valve unit (G2) are situated at the power unit on the right hand
side of the machine.
G1
G2
DUN00809
Figure 4.18 - Control Valves
The control valves (G3, G4 & G5) are situated at the middle of the machine. They can be found
to the right hand and left hand sides respectively, under the screen box.
The tracking control handsets are independent control units. They control the movement of the
tracks.
G3
DUN00529
Figure 4.19 - Left side control levers

G4 G5
DUN00528
Figure 4.20 - Right side control levers
Electric control panel (Panels will vary depending on machine).
1
OK
4 3 2
DUN00079
Figure 4.21 - MCU300 Control Panel (Control panels may vary)

4.4 Control and Display Elements
(1) MCU 300 Control Panel

The main hydraulic control panel, fitted at ground level, has all the controls centrally located. This
allows the operator to quickly and easily optimize production preventing unnecessary downtime.
There is a display screen on the control panel which indicates the current state of the machine.
Familiarize with the control panel. Depending on the engine of the machine, there are three
different control panel options:
Manual Throttle Control Panel
Familiarize with the control panel functions.
5 1
OK
4 3 2 DUN02145
Figure 4.22 - Manual Throttle Control Panel
1 Control Panel Display Screen

2 Ignition Key
3 Preheat Button*
4 Working Panel Light
5 Manual Throttle Lever
*Preheating is normally necessary when ambient temperature is below zero degrees Celsius. If
preheating is necessary hold the pre-heat button for up to one minute (depending on ambient
temperature.

Electric Throttle Control Panel

1
OK
4 3 2
DUN00079
Figure 4.23 - Control Panel

2 Ignition Key
3 Electric Throttle (Engine Speed Switch)
Constant Speed Engine Control Panel
1
OK
4 3 2
DUN02144
Figure 4.24 - Constant Speed Engine Control Panel

2 Ignition Key
3 Track Speed

When the ignition switch is turned to the ON position the home screen is displayed on the control
panel display screen, Reference: Figure 4.25.
Figure 4.25 - Home Screen (No faults)
If there are active faults these will be displayed on the home screen. The total engine run hours
are displayed in the centre of the home screen. The software version is displayed on the bottom
centre of the home screen. The first number states the screen (display) version and the second
number indicates the PLC version, example: v1.1.
Refer to Section 7 for more information on the operation of the MCU 300 Control Panel.
An indicator light on the control panel display screen will illuminate red when a machine fault
occurs. The light or lights which illuminate will depend on the fault, Reference: Table 4.1.

Table 4.1 - Display Screen Fault Codes

Indicator Fault Code Indicates
FC001 Emergency stop engaged
Flashing
Icon
FC002 Low hydraulic oil level
SPN111 Low coolant level
SPN110 High engine temperature
FC005 Air filter element restricted
SPN232 Fuel contamination
SPN100 Low oil pressure
FC008 Remote stop
FC009 Battery Voltage LOW
FC010 Communication loss between

master and display
The control panel also displays an engine fault screen (Figure 4.26) if there is a problem with
the engine.
Figure 4.26 - Engine Fault Screen
Refer to the table in Troubleshooting for a list of the engine fault codes. Refer to the engine
manufacturer’s manual or your local dealer for more information.

(2) Dual Power
(a) Control Panel Component Identification

Figure 4.27 below shows the dual power control panel as used on mobile machines. Control
panels may vary. Table 4.2 identifies each component on the control panel door.
ELECTRIC MODE ELECTRIC MODE

OFF ON E STOP HEALTHY
4 X1
-S1 -H1
X2
3
XB4-BD21 XB4-BVG6
1 2
MOTOR No.1 MOTOR No.1 MOTOR No.2 MOTOR No.2
RUNNING TRIPPED RUNNING TRIPPED
X1 X1 X1 X1
-H2 -H3 -H4 -H5
X2 X2 X2 X2
XB4-BVG3 XB4-BVG4 XB4-BVG3 XB4-BVG4
3 4 5 6
7 -S2
DUN00472
Figure 4.27 - Tier 4 Dual Power Control Panel
Table 4.2 below gives the description of the various switches and lamps on the tier 4 dual power
control panel door.
Table 4.2 - Tier 4 Dual Power Control Panel Door Component Identification
ID Description
1 Electric mode ON/OFF switch
2 Electric mode E-stop healthy
3 Motor No. 1 Running
4 Motor No. 1 Tripped
5 Motor No. 2 Running
6 Motor No. 2 Tripped
7 Main Isolator Switch
8 Emergency Stop

(3) Manual Tracking System

Figure 4.28 below shows the manual tracking umbilical layout.
1 2
3 4
5 6
7 0 I 8
TEREX R
9
DUN00004
Figure 4.28 - Tracking Umbilical Layout
Table 4.3 below gives a description of each button on the tracking umbilical shown above.
Table 4.3 - Tracking Umbilical Layout

ID Description
1 Left Track Forward
2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Unused
6 Unused
7 Stop Tracks
8 Start Tracks

(4) Teleradio Radio Remote Tracking Kit

Figure 4.29 below shows the Teleradio Radio Remote Tracking transmitter layout.
TEREX
DUN01723
Figure 4.29 - Radio Remote Tracking Layout.
Table 4.4 below gives a description of each button on the Radio Remote Tracking transmitter
shown above.
Table 4.4 - Radio Remote Tracking

ID Description
1 Left Track Forward
2 Right Track Forward
3 Left Track Reverse
4 Right Track Reverse
5 Stop Tracks
6 Start Tracks
7 Machine Stop
4.5 Telematics
If a telematics system is included with the Equipment, the telematics system is administered
by a third party and collects a range of operational data about the Equipment including, but not
limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining such data for
warranty, product improvement and customer support purposes. Buyer understands that the
Equipment warranty is conditioned on the proper operation of the telematics system and Buyer
shall not disable, tamper or interfere with the telematics system.
To access telematics system information contact your local dealer.

4.6 Pictorial Decal Descriptions

Pictorial decals have been placed on the machine to ensure that the machine is correctly operated
and maintained. Operations decals describe the operations of levers on the machine. Information
decals give details about how to correctly operate and maintain the machine.
(1) Machine Operation Decals

Each operation decal is placed on the machine beside the corresponding lever or control. The
following tables give short explanations of each operation decal used on the machine. The up
arrow in the decals indicates moving the lever forward or up. The circle in the decals indicates
the neutral position. The down arrow in the decals indicates moving the lever back or down. The
pictorial decals contain an image of a component or of the machine with a shaded component.
This indicates the part of the machine and the operation that the lever controls.
Conveyor orientation may differ, depending on machine option selected.

Auxiliary Control Bank
New Decal Explanation
 Hopper Slide forward
 Hold
 Hopper Slide backward
 Raise Screen Angle
 Hold
o
 Lower Screen Angle
 Raise Jack Up Screen
 Hold
 Lower jack Up Screen
 RHS Hopper Extension Lock
 Hold
 RHS Hopper Extension Unlock

10200306
 LHS Hopper Extension Lock
 Hold
 LHS Hopper Extension Unlock

10200306

Drive Control Bank Warrior 2100 Standard
 Drive Feeder
 Hold
 Drive track motor 1
 Drive Fines Side Conveyor
 Hold
 Drive screen
 Hold
 Drive track motor 2
 Drive Mid Side Conveyor
 Hold
 Drive collection conveyor
 Hold

 Drive Tail Conveyor
 Hold

Main Flow Control Bank Warrior 2100 Standard
Turn flow control valve clockwise

to decrease feeder conveyor
speed.
Turn flow control valve anti-
clockwise to increase feeder
conveyor speed

to decrease fines side conveyor
speed.
clockwise to increase fines side
conveyor speed.

to decrease tail conveyor speed.
clockwise to increase tail
conveyor speed.

LHS Control Lever Decals
 Telescopic Head Section Extend
 Hold
 Telescopic Head Section Retract
 Raise Fold Mid Side Conveyor (Upper)
 Hold
 Lower Fold Mid Side Conveyor (Upper)
 Raise Fold Mid Side Conveyor (Middle)
 Hold
 Lower Fold Mid Side Conveyor (Middle)
 Raise Fold Mid Side Conveyor (Lower)
 Hold
 Lower Fold Mid Side Conveyor (Lower)
 Raise Hopper Extension LH
 Hold
 Lower Hopper Extension LH

LHS Flow Control Valve
Turn flow control valve clockwise to

decrease Mid side conveyor speed.
Turn flow control valve anti-clockwise to
increase Mid side conveyor speed.
Tail Conveyor Control Levers
 Raise Tail Conveyor Angle
 Hold
 Lower Tail Conveyor Angle
 Raise Tail Conveyor Head Section
 Hold
 Lower Tail Conveyor Head Section

RHS Conveyor Control Levers
 Raise Hopper Extension RH
 Hold
 Lower Hopper Extension RH
 Telescopic Head Section Extend
 Hold
 Telescopic Head Section Retract
 Raise Fold Fines Conveyor (Upper)
 Hold
 Lower Fold Fines Conveyor (Upper)
 Raise Fold Fines Conveyor (Middle)
 Hold
 Lower Fold Fines Conveyor (Middle)
 Raise Fold Fines Conveyor (Lower)
 Hold
 Lower Fold Fines Conveyor (Lower)

(2) Machine Information Decals
Decal Explanation
Hydraulic oil
D
Diesel oil
Cold start aid
Ball valve open + closed

Decal Explanation
Engine oil only
Important
Do not over fill hydraulic oil tank.
Important
Check and drain diesel water trap
daily.
Screenbox speed.

Decal Explanation
Important
Machine must be level at all
times.
Air intake area must be kept clear

at all times.
If the fuel supply is interrupted

(e.g. fuel level low, water trap
maintenance or burst hose) the
60 3 mins engine should be primed for 3
minutes before startup by turning
45 15
the ignition key to the on position
as shown.
30
10200282
Greasing screenbox: 22 grease

gun strokes every 50 working
hours. (Applies only to single
shaft screen box machine).

Decal Explanation
2
Important
1. Read Operations Manuals
2. Remove tie down
3
3. Raise screen to full service
angle and pin in place
4. Raise screen discharge end
to full access position and pin in
place
4
10200803
Important
Conveyor Unfolding
2. Fold Out Head Section Midway
3. Fold Middle Lower Section
Fully
4. Fold Lower Section Fully
5. Fold Out Head Section Fully
Important
Folding Conveyor
2. Lower Screenbox into
Transport Position
3. Slide Hopper into Transport
Position and fold in head section
Mid-way.
4. Fold In Lower Section fully
5. Fold In Middle Section fully
6. Fold In Head Section fully

Decal Explanation
2. Lower tail conveyor into pin
10200349 position 1 and secure. Remove
head section securing pin.
3. Raise tail conveyor into pinning
position 5 and secure.
4. Fold head section into transport
position.
5. Secure transport stay using
spring cotter pins.
6. Pin tail conveyor in pinning
6
position 5 as shown. Position
5 for 3 way split configuration.
Pin in position 3 for 2 way split
configuration.
IMPORTANT
2. Set screen angle to working
position and pin in place.
Battery isolator switch

Isolate power and lock out
machine before maintenance is
carried out.

Decal Explanation
Important
2
2. Fold out machine
3. Ensure the screen anchor
system is to be secured in place
prior to operating the screen.
10200804
Use ultra low sulphur fuel only

(Tier 4 Engines)
AdBlue / DEF
Read and fully understand
instructions on refilling urea tank.
Refill using correct fluid. Do not
use water.
10200637

Transportation 5
Table of Content
5 Transportation............................................................................................. 5-2
5.1 Prior to Transportation.....................................................................................5-2
5.2 Removing Machine from the Low Loader.......................................................5-3
(1) Remote Control..........................................................................................5-3
(2) Teleradio Remote Control...........................................................................5-5
5.3 Putting the Machine into the Transport Position..............................................5-6
(1) Folding Hopper Discharge Wings...............................................................5-7
(2) Folding Steps To Transport Position...........................................................5-8
(3) Folding Down Hopper Extensions (If fitted), Lowering Screenbox And ..........
Sliding Back Feeder For Transport......................................................................5-9
(4) Fold Tail Conveyor For Transport.............................................................5-13
(5) Fold in the Side Conveyors......................................................................5-16
5.4 Loading the Machine to the Low Loading Trailer..........................................5-21
(1) Ready for Transport..................................................................................5-22
(2) Prior to Haulage........................................................................................5-22
5.5 Transport Tie Down Points............................................................................5-23

5 Transportation
5 Transportation
5.1 Prior to Transportation
nn CAUTION
Prior to transportation always check the machine for loose or damaged components. Ensure
all loose items are carefully stowed and secured if these are to be transported on the machine.
Check that the travelling dimensions and weight of the machine will be within the regulation limits.
Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know
the overall height to avoid contacting overhead obstructions such as bridges, power lines etc.
The preparations to move equipment by an articulated lorry should be supervised by a minimum of
two persons. Ensure persons transporting the machine adhere to all safety signs and procedures.
Before transportation on public roads, ensure the machine has been properly secured with no loose
material left in or on the machine. Always observe the valid traffic regulations and, if necessary,
ensure beforehand that the machine is in a condition compatible with these regulations.
Extreme caution is required when transporting machinery on 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 reaching a slope.
The machine is remote controlled and may start without notice. Stay clear of the machine. The
machine must be loaded and transported only in accordance with the operating instructions.
For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable
of adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any signalling
and lighting systems are fully functional. Before setting the machine in motion always check that
the accessories have been safely stowed away.
On wheeled machine:
Ensure wheel nuts are torqued between 500 to 550 ft.lb (69 to 76 kg.m) prior to transport. Recheck
the wheel nut torque every 150 miles (200 km).
Connect and check the braking system.
Check your tires for:-
• Correct pressure
• Cuts or bulges
• Nails or spikes
• Uneven or excessive wear
• Missing valve caps
Check your wheels for:-
• Damaged rims
• Missing or loose wheel nuts or bolts
• Obvious misalignment
Have cuts or punctures repaired by authorised personnel before adding air. Beware that an over-
inflated tire can explode and cause serious injury or death.
Transportation 5
5.2 Removing Machine from the Low Loader

A tracked machine will normally be secured to a low loader trailer. If the machine has been
manufactured to connect to special rear bogie, refer to the special instructions to separate the
machine from its bogie.
nn WARNING
The engine stop on tracking remote should only be used in emergencies, the engine should be
shut off at the control panel once manoeuvring has been completed. The engine stop on the
remote control does not result in a control panel reset and so is not the same as the emergency
stops located else where on the machine.
Check that any loose items transported with the machine will not cause a hazard while unloading.
Wear personal protective equipment.
Ensure all personnel are clear from the machine.
NOTICE
Removing the fastenings securing the machine and any loose items from a trailer is the
responsibility of the haulage contractor.
Refer to Chapter 4, for complete specification on radio/remote control units before attempting
the following procedures.
All control levers must be in the neutral (non-operational) position.
(1) Remote Control
PROCEDURE
1. Observe all safety warnings.
2. Prepare the low loading trailer, for removing the machine on tracks.
3. Make sure suitable ramps are positioned at the end of the trailer to unload the machine.
4. Start the machine. (See chapter 7).
5. Ensure that engine is set to idle during unloading process.
»»For constant speed engine, reduce speed of tracks.
6. Ensure all loose parts and items shipped with machine are removed.
7. Ensure all ties are removed from low loader.
8. Activate track circuits by engaging track control hydraulic levers in the power unit (Levers
are identified by decals).
9. Remove the dummy plug (Item 1) and insert the remote control unit plug into it‘s socket at
the rear of the machine.

5 Transportation
Figure 5.1 - Remote Control Unit Connection
10. Move the track levers down, to activate the tracks.

11. Activate the remote control unit by pressing the tracks start button.
12. Operate the track buttons on the remote control unit to move the machine off the low loading
trailer, Reference: Figure 5.3.
DUN00004
Figure 5.2 - Remote Tracking Control Units
13. Press the forward or backward buttons, on the corresponding handset, to move the machine
in the desired direction.
14. Unload the machine slowly off the trailer into a safe position or machine operating position,
15. Move the machine into the required position on the work site.
16. Deactivate the remote control, press the track stop button the handset.
17. Switch off the machine.

Transportation 5
(2) Teleradio Remote Control
PROCEDURE
2. Prepare the low loading trailer, for removing the machine on tracks.
3. Make sure suitable ramps are positioned at the end of the trailer to unload the machine.
5. Ensure that engine is set to idle during unloading process.
»»For constant speed engine, reduce speed of tracks.
6. Ensure all loose parts and items shipped with machine are removed.
7. Ensure all ties are removed from low loader.
8. Activate track circuits by engaging track control hydraulic levers in the power unit (Levers
are identified by decals).
9. To start remote tracking disconnect the manual handset from the machine and press any
button on the transmitter.
»»The LED located in the centre of the control will flash red for a few seconds then turn green. If it
continues to flash red then the battery is low. After the 7 second delay has elapsed the track directional
switches become active.
10. Remove the dummy plug and insert the remote control unit plug into it‘s socket at the rear
of the machine.
11. Turn the transmitter on using the switch on the back.
12. Release the machine stop button (button 7) at the bottom of the transmitter.
13. Hold buttons 5 and 6 until the transmitter beeps indicating the log-in process has begun.
»»The machine siren will sound and there will be a 7 second delay before the tracks can be operated.
TEREX
DUN01723
Figure 5.3 - Teleradio Remote Tracking Transmitter
14. Use buttons 1, 2, 3 and 4 to operate the tracks.

15. Unload the machine slowly off the trailer into a safe position or machine operating position.
17. Press button 5 to disable the tracks. Press button 7 to switch off the machine.

5 Transportation
5.3 Putting the Machine into the Transport Position

Prior to transportation the machine must be put into the transport position.
nn WARNING
Entanglement hazard. Ensure all personnel are clear from the machine.
Ensure all machine components are stopped before putting the machine into the transport position,
Reference: Chapter 7.
nn CAUTION
Fall hazard.
Falling material hazard.
Crush hazard.
NOTICE
The machine must be put into the transport position in the correct order.
PROCEDURE
Observe all safety warnings.
1. Fold the hopper discharge wings.
2. Prepare the ladders for transport.
Start the machine, Reference: Chapter 7.
3. Fold hopper extensions (if fitted). Prepare the screenbox for transport (lower screen angle)
and prepare the feeder for transport (slide back).
4. Prepare the tail conveyor for transport.
5. Prepare the LH side conveyor for transport. Prepare the RH side conveyor for transport.
Refer to the following instructions.

Transportation 5
(1) Folding Hopper Discharge Wings
nn WARNING
Fall hazard. Always use a safe and secure platform when working at a height.
Hazardous nip and crush points.
nn CAUTION
Falling material hazard. For machines fitted with hopper extensions, ensure there is no material
lying on hopper sides before putting them into the working/transport position.
PROCEDURE
2. Ensure the feeder is fully forward in working position.
3. Using the walkway or other suitable working platform remove Wing Plate Wedges (Item 1).
4. Fold wing plates into transport position as shown.
Figure 5.4 - Wedges on Hopper Discharge wings.
Figure 5.5 - Hopper discharge wings folded

5 Transportation
(2) Folding Steps To Transport Position
nn WARNING
Switch off the machine and implement the lockout procedure.
NOTICE
Machine must be on level ground prior mounting.
PROCEDURE
2. Remove the two pins (Item 1) securing the lower section of the steps in the correct position.
DUN00190
Figure 5.6 - Step pins
3. Fold the lower section of the steps upwards, this will simultaneously fold the upper section of
the steps inwards as shown. Secure the steps in position using the pins removed in step 2.
Figure 5.7 - Steps folded/unfolded

Transportation 5
(3) Folding Down Hopper Extensions (If fitted), Lowering Screenbox And
Sliding Back Feeder For Transport.
nn WARNING
nn CAUTION
Falling material hazard. For machines fitted with hopper extensions, ensure there is no material
lying on hopper sides before putting them into the working/transport position.
PROCEDURE
2. Start the machine, Reference: Chapter 7.
3. Identify the hopper control levers located in the power unit and chassis mid points, they will
be clearly marked using decals.
4. Activate the ram (Item 1) which controls the securing pins on the feeder hopper wing plates.
Move the control levers down to retract the pins.
Figure 5.8 - Hopper Rams
5. Activate the folding ram (Item 2) by lowering the lever to fold down the hopper right hand side.
6. Lower the lever to fold down the hopper left hand side.

5 Transportation
DUN00810
Figure 5.9 - Hopper Control Levers
DUN02104
Figure 5.10 - Decals for Feeder Controls

Transportation 5
DUN00811
Figure 5.11 - Left Side Mid Chassis Control Valves
Figure 5.12 - Left side Mid Chassis Decals

5 Transportation
DUN00812
Figure 5.13 - Right Side Mid Chassis Control Valves
Figure 5.14 - Right Side Mid Chassis Control Decals
7. Move the screenbox lever to the down position to lower the screenbox and hopper angle
into the transport position.
8. Move the hopper slide lever to the down position to slide feeder fully into transport position
and pin for transport as shown.

Transportation 5
DUN02054
Figure 5.15 - Hopper and screen in transport position
(4) Fold Tail Conveyor For Transport
nn CAUTION
NOTICE
Take care not to nip the conveyor belt between moving parts.
PROCEDURE
2. Ensure tail conveyor is at the lowest angle.
DUN00821
Figure 5.16 - Tail Conveyor in the lowest angle.

5 Transportation
DUN00813
Figure 5.17 - Tail Conveyor control levers
Figure 5.18 - Tail Conveyor decals
3. Raise the tail conveyor head section to release the pressure off the pins.
4. Remove the pins and stow as shown.

Transportation 5
1 2
DUN00196
Figure 5.19 - Tail conveyor head section locks
5. Raise the tail conveyor angle and pin in transport hole (5th hole from the bottom of the inner
support leg) as shown in Figure 5.20.
DUN00537
Figure 5.20 - Tail conveyor raised for folding
6. Move the head section lever to the down position to fold the tail conveyor top half down.
Figure 5.21 - Tail conveyor folded
7. The tail conveyor can be lowered so that the brace (Item 1) is more accessible.

5 Transportation
8. Fit the tail conveyor brace (Item 1).

9. The tail conveyor must then be returned to its transport position.
(5) Fold in the Side Conveyors
nn WARNING
nn CAUTION
NOTICE
Screenbox and feeder must be in the transport position before the side conveyors can be put
Take care not to nip the conveyor belt between moving parts.
The following procedure is the same for both the left hand side and right hand side conveyors.
Some images in the following procedure are shown for one side conveyor only.
PROCEDURE
2. Start the engine, Reference: Chapter 7.
3. If the conveyor is telescopic, remove pins and fully retract the telescopic section by moving
the lever to the down position.
4. Replace pins in the conveyor telescopic.
5. Refer to Figure 5.22 to Figure 5.25 for control levers location and functions.

Transportation 5
DUN00814

5 Transportation
DUN00811
6. Remove the side conveyor angle pins (Item 1).

Transportation 5
1 DUN00199
Figure 5.26 - Side conveyor angle pins
7. Move the side conveyor head section lever to the up position to raise the side conveyor head
section into a 45° angle.
Figure 5.27 - LHS Head Section at 45 degrees
8. Move the side conveyor lower section lever to the up position to raise the side conveyor
lower section to the vertical position.

5 Transportation
Figure 5.28 - LHS Lower Section at Vertical
9. Move the side conveyor middle section lever to the up position to raise the side conveyor
middle section to 90 degree position.
Figure 5.29 - LHS Middle Section at 90 Degrees
10. Move the side conveyor head section to the up position to lower the side conveyor head
section into the resting position.
11. Insert transport pins and R-clips (Item 1).

Transportation 5
1 DUN00200
Figure 5.30 - Side conveyor folded for transport
12. Repeat for the right hand side conveyor.
5.4 Loading the Machine to the Low Loading Trailer
NOTICE
Securing the machine and any loose items to the low loader trailer is the responsibility of the
haulage contractor.
PROCEDURE
1. Before loading, the machine must be prepared for transportation, refer to putting the machine
2. Check that the travelling dimensions and weight, when loaded, will be within the regulation
limits, refer to machine specification and information.
3. Make sure suitable ramps are positioned at the end of the trailer to load the machine.
4. Ensure all loose items are carefully stowed and secured if these are to be transported on
the machine.
5. Check that any loose items transported with the machine will not cause a hazard while loading.
6. Ensuring that the engine/motors are running at idle load the machine slowly on the trailer,
manoeuvring the machine with the tracks, using the umbilical control or the remote radio
control, if fitted, see moving the machine.
»»For constant speed engine,ensure speed of tracks is reduced.
7. Stop the machine.

5 Transportation
(1) Ready for Transport
nn WARNING
Do not transport this machine without it being properly secured on to the lowloader.
Before transporting this machine you must read and understand the Safety section in this manual.
NOTICE
Before tracking the machine ensure the engine speed is idle.
»»For constant speed engine,ensure speed of tracks is reduced.
The machine should now be ready for transport.
Secure machine with Chain shackles to the Lowloader.
Use securing eyes (Item 1) fitted on the machine undercarriage on either side.
1
TIRC00322
Figure 5.31 - Tracks Secured on Lowloader
(2) Prior to Haulage
PROCEDURE
1. Check for loose parts or debris on the machine.
2. Ensure all pins are secured with ‘R’ pins and Split pins.
3. Ensure persons transporting the machine adhere to all safety signs and procedures.

Transportation 5
5.5 Transport Tie Down Points
NOTICE
When transporting the machine, it is the responsibility of the haulage contractor to safely secure
it to the transporter.
This machine is fitted with transport tie down brackets, the brackets are indicated on the machine
by a safety symbol. Under NO circumstances should these be ever used as a lifting point for the
machine.
OMA00588
Figure 5.32 - Tie Down Points Symbol
1 DUN02055
Figure 5.33 - Tie down points underneath
The machine can also be secured in place using the tie down points on the side of the machine.
The tie down points are located on both sides of the machine.

5 Transportation

Initial Setup and Adjustments 6
Table of Content
6 Initial Setup and Adjustments................................................................... 6-2
6.1 Initial Inspection...............................................................................................6-2
6.2 Machine Location Considerations...................................................................6-2
6.3 Measures Before Set Up.................................................................................6-3
6.4 Measures After Long Term Standstill...............................................................6-3
6.5 Initial Setup......................................................................................................6-4
(1) Opening Out the Side Conveyors...............................................................6-4
(2) Opening Out the Tail Conveyor.................................................................6-10
(3) Moving The Feeder Into Working Position................................................6-14
(4) Increasing Hopper Angle/ Raising screen................................................6-16
(5) Operating Hopper Extension (if fitted)......................................................6-19
(6) Ladder Setup Instructions.........................................................................6-23
(7) Open Hopper Outlet Wings......................................................................6-25
(8) Warrior 2 Way Split (2WS) Conversion.....................................................6-26
(9) Opening Hopper Rear Door......................................................................6-34

6 Initial Setup and Adjustments

NOTICE
Terex recommends that the assembly and installation work of the machine be carried out by the
Terex customer service department. The manufacturer/supplier will not be liable for damage
caused by improper assembly or installation.
The environment in which the machine will operate contains inherent health and safety risks,
which the operator must take steps to avoid.
Dangers from overhead conveyor discharges, overspill material, vehicle movements, etc., as well
as other site related hazards must be anticipated.
Avoid these by carrying out risk assessments before the machine is put into operation to ensure
appropriate exclusion zone measures are put in place and site personnel safety awareness
training has been undertaken.
Refer to the engine manual for initial start up of the engine.
6.1 Initial Inspection

When the machine is delivered, thoroughly check for any damage that might have occurred
during transport. Do not set up the unit until the inspection is complete. Complete any delivery
and start-up forms that were supplied with the equipment. Take note of any damage found, and
photos if possible, and have the driver initial your description of any problem(s).
Check all loose parts, small-parts boxes, and tools against the packing list to ensure all items
shipped are present. Check in and around the machine for any loose items that may have been
shipped inside the machine.
6.2 Machine Location Considerations

Prior to setting up the machine, consideration should be given to a suitable layout to prevent
oversize material or metal from entering the machine. In order to prevent damage of the screen
unit, no material above the size recommended should be fed into the machine.
Position the machine in a safe and level operating position, making sure both tracks are in full
contact with the ground to minimise movement of the Machine. Regularly check the machine is
level and stable.
Pay attention to access from the loading area and to where material is to be deposited.
Ensure the area under the tail drum of the product conveyor is free of large stones etc. Which
may cause damage to the belt.
For dusty conditions some account should be taken of the prevailing wind direction to minimize
the possibility of dust entering the air intake.
When setting up the machine, ensure that enough space is available around the machine to
enable easy set up, servicing and repair work.
Machinery arranged before and after this machine will have to be placed on the site accordingly.

6.3 Measures Before Set Up

We recommend that the assembly/ installation work of the machine be carried out by the Terex
customer service department. The manufacturer/supplier will not be liable for damage caused
by improper assembly/ installation.
PROCEDURE
1. Ensure all guards are fully secured in correct/closed position.
2. Remove all loose items from the belt by untying the securing ropes.
3. Put control valve levers in neutral (non-operational) position.
4. The machine must be placed on solid ground capable of carrying the machine‘s weight.
5. Before detaching the machine from the prime mover, it is important that the chosen site is
level. Level the work site foundation with the loading shovel.
6. Level the machine with a precision spirit level.
7. Do not position the machine above ground level, eg. on blocks etc.
6.4 Measures After Long Term Standstill
NOTICE
Prior to putting into operation perform daily (10 hour) maintenance schedule.
Check tracks before transporting or moving the machine.

6.5 Initial Setup
(1) Opening Out the Side Conveyors
nn WARNING
NOTICE
Ensure belt is fully tensioned before use. All control levers must be in the neutral (non-operational)
position.
Ensure that all transport stays are removed before attempting to move side conveyors.
As part of this process is obstructed from view by the machine it may be beneficial to have a
second person available.
The process is the same for both side conveyors.
Take care not to nip the conveyor belt between moving parts
PROCEDURE
3. Remove transport stays (Item 1) and safety pins from conveyor.
1 DUN00200
Figure 6.1 - Side conveyor transport pins
4. Refer to Figure 6.2 to Figure 6.5 for the control levers locations and functions.

DUN00814

DUN00811
5. Move the conveyor head section into a 45 degree position by placing the head section lever
in the down position.

Figure 6.6 - LHS Head Section at 45 Degrees
6. Move the conveyor middle section into a vertical position by placing the middle\section lever
in the down position.
Figure 6.7 - LHS Middle Section at Vertical
7. Move the conveyor lower section to the required angle by placing the lower section lever in
the down position, Reference: Figure 6.8

Figure 6.8 - LHS Lower Section Unfolded
8. Complete the fold out of the head section.

9. Fit the conveyor safety pins (Item 1) to each of the support legs once the correct conveyor
angle has been set.
1 DUN00199
Figure 6.9 - Conveyor Safety Pins
10. There is an option of telescopic side conveyors on this machine. The fold out procedure
remains the same but the last stage is the adjustment of the telescopic section to the required
position.
11. Remove safety pins (Item 1) before extending or retracting the conveyor. Reference: Figure
6.10.
12. Place lever in the up position to extend telescopic conveyor as shown in Figure 6.10, place
lever in the down position to retract telescopic conveyor.
13. Fit safety pins (Item 1) to telescopic section when desired extension or retraction is reached.
Reference: Figure 6.10.

1
DUN00256
Figure 6.10 - Telescopic head section extended

(2) Opening Out the Tail Conveyor
nn WARNING
Fall hazard.
Lockout and tagout.
NOTICE
Observe ground clearance when unfolding / lowering tail conveyor.
PROCEDURE
Figure 6.11 shows the location of the Tail conveyor controls. Figure 6.12 are the decals showing
the functions of the control levers.
DUN00813
Figure 6.11 - Tail Conveyor control levers

Figure 6.12 - Tail Conveyor decals

3. Remove the tail conveyor angle securing pin (Item 1).
1 DUN00540
Figure 6.13 - Angle securing pins
4. Lower the tail conveyor to allow the operator to access the transport stay from ground level.
5. Move the upper conveyor lever down and release the pressure on the transport stay. Remove
the transport stay. (Item 1).
1
DUN00538
Figure 6.14 - Transport Stay

6. Raise the tail conveyor to allow for enough ground clearance to unfold the top half of the
conveyor.
7. Reinsert the tail conveyor angle securing pin (Item 1).
8. Move the upper conveyor lever to the up position to unfold the top half of the conveyor.
DUN00537
Figure 6.15 - Tail conveyor unfolded
9. Remove the tail conveyor angle securing pin (Item 1).
1 DUN00540
Figure 6.16 - Angle securing pins

10. Lower the tail conveyor to the horizontal position.
DUN00821
Figure 6.17 - Tail conveyor in a horizontal position.
11. Remove the main securing pin from the storage location (Item 2) Reference: Figure 6.18.
1 2
DUN00196
Figure 6.18 - Tail conveyor horizontal
12. Fit the main securing pin to the location shown (Item 1).
13. Raise the tail conveyor to the desired angle and fit the angle securing pin again.

(3) Moving The Feeder Into Working Position
nn WARNING
NOTICE
Ensure that side conveyors have been unfolded before this procedure is started.
PROCEDURE
Figure 6.19 shows the location of the feeder controls. Figure 6.20 are the decals showing the
functions of the control levers.
DUN00530
Figure 6.19 - Feeder Control Levers
DUN02104
Figure 6.20 - Decals for feeder Controls

3. Remove pin securing feeder for transport.
4. Slide hopper forward to working position using the control lever. Reference: Figure 6.21.

DUN00825
Figure 6.21 - Sliding hopper
5. Once the hopper has been moved to its working position return the control lever to its neutral
position.
6. Pin the feeder in its working position using the pin (Item 1).
DUN00826
Figure 6.22 - Feeder pin

(4) Increasing Hopper Angle/ Raising screen
nn WARNING
Do not run the Triple Shaft screenbox above 10 degrees.
Do not use additional perforated holes for the Triple Shaft screenbox, these are for the Single
Shaft and Spaleck Screenbox options only.
NOTICE
Ensure that the screenbox subframe is locked in position at jacking location.
Before running the screenbox, ensure the subframe is fully seated in the chassis at the jack-up
link arm pin.
Ensure that side conveyors have been unfolded before this procedure is started.
There are 3 screenbox options available, ensure the operator is aware of which screenbox option
is on the machine. The correct procedure must be followed for each screenbox option or machine
damage will occur.
Machine damage will occur on the triple shaft screen if it is run at a higher angle than 10°.
For Single Shaft & Spaleck screens ensure the sub frame anchors are fitted and securely fastened.
When changing out the Triple Shaft screen box to a Spaleck or Single Shaft box it is necessary
to replace the proximity switch with the blanking plug adaptor.This gives the screen the ability to
work through its full range of angles.
The screen control levers and functions can be seen from Figure 6.23 and Figure 6.24.
DUN00810
Figure 6.23 - Screen Control Levers

DUN02104
Figure 6.24 - Decals for screen angle Controls.
PROCEDURE
2. The screen anchor system is to be secured in place prior to operating the screen. The screen
sub-frame is to be in its lowest working angle before applying the anchor. Thereafter, the
securing bolt is to be affixed and the assembly tightened to restrain the screen. After initial
tightening the screen angle can be adjusted to the required angle. All further adjustments to
the screen angle can be made without attending to the anchor system.
3. After initial tightening, run the screen for 10 minute and re-tighten at the anchor position.
4. Move the screenbox lever to the up position to raise the screenbox to the working position.
Secure in position using the pins (Item 1).
1
DUN00827
Figure 6.25 - Securing pins
5. The Warrior 2100 Triple Shaft screenbox works at a fixed angle of 10 degrees. Machine
damage will occur if an attempt is made to run the screen at a higher angle and warranty
will be voided. A built in cut-out system prevents the screen from working above 10 degrees.
Figure 6.26 shows the working position of the screenbox
»»IMPORTANT - DO NOT RUN THE TRIPLE SHAFT SCREENBOX ABOVE 10 DEGREES.
»»For Single Shaft and Spaleck plant, the screen can be adjusted within the range of 10 to 18 degrees.

DUN00828
Figure 6.26 - Single shaft screen working positions
6. Figure 6.27 shows the working position (Item 1), the service position (Item 2) of the screenbox
and the Screen mesh change/jackup position (Item 3) for the Triple Shaft screenbox.
»»For the Single Shaft and Spaleck versions these positions are also valid but additional screen angle
positions (Items 4 to 9) will also be included. For a retrofitted Single Shaft or Spaleck screenbox
these additional positions are achieved by removing the partially perforated holes on the jackup legs.
IMPORTANT – THESE ADDITONAL HOLE POSITIONS SHOULD NOT BE USED FOR A

TRIPLESHAFT SCREENBOX
2 1
5 4
7 6
9 8
3
DUN02313
Figure 6.27 - Screen pinning locations

(5) Operating Hopper Extension (if fitted)
nn WARNING
Wear personal protective equipment
Falling material hazard. Ensure there is no material lying on hopper extensions when in transport
position.
NOTICE
Ensure there is no material lying on the extensions before they are unfolded to working position.
PROCEDURE
2. Ensure all transport brackets and stays are removed.
4. Identify the hopper/feeder control levers located in the power unit and chassis midpoint
locations, they will be clearly marked using decals shown.
DUN00810
Figure 6.28 - Hopper Control Levers
DUN02104
Figure 6.29 - Decals for Feeder Controls

DUN02084

DUN00814
5. Raise the lever for the hopper lift left to activate the ram (Item 2) and fold up the hopper left
hand side.
6. Raise the lever for the hopper lift right to fold up the hopper right hand side.
7. Raise the lever for hopper support pin (Item 1) to insert the pin to hold the left hand side
hopper wing plates in position. Repeat for the wing plates on the hopper right hand side.

Figure 6.34 - Hopper wing plates.

(6) Ladder Setup Instructions
nn DANGER
Fall Hazard. Do not climb onto working or moving machinery. Use suitable lifting equipment
when working at a height.
nn WARNING
Hazardous nip and crush points. Keep clear of folding equipment. Wear personal protective
equipment. Switch off, tag out and lock out before working at the machine.
Ensure all nuts, bolts and wedges are inserted correctly before using the walkway.
NOTICE
Machine must be on level ground prior mounting. All control levers must be in the neutral (non-
operational) position.
PROCEDURE
2. Remove the pins (Item 1) securing the lower section of the steps in the transport position.
Figure 6.35 - Step securing pins
3. Fold the lower section of the steps downwards, this will simultaneously fold the upper section
of the steps outwards as shown. Secure the steps in position using the folding pins removed
in step 2.

Figure 6.36 - Steps folded/unfolded.

(7) Open Hopper Outlet Wings
nn DANGER
Fall Hazard. Do not climb onto working or moving machinery. Use suitable lifting equipment
when working at a height.
nn WARNING
PROCEDURE
1. Observe all safety warnings
2. Ensure the feeder is in working position.
3. Fold the hopper extensions out as shown.
4. Secure in place using the supplied wedges (Item 1). Access can be obtained from the walkway
or a suitable access platform.
DUN00217
Figure 6.37 - Hopper outlet wings

(8) Warrior 2 Way Split (2WS) Conversion
nn WARNING
Fall hazard.
Lockout and tagout.
Use suitable lifting equipment capable of lifting the parts in question.
This procedure requires alterations to the hydraulic system. Ensure all safety precautions are
adhered to. All control valves must be in the neutral position, all rams musty be retracted, the
machine must be shut down, locked out and tagged out. Relieve hydraulic system pressure before
starting hydraulic pipe disconnections.
NOTICE
Before removing any part from the machine ensure that the weight of the component is supported
with suitable lifting equipment.
Do not stand under suspended loads.
Secure components for lifting by slinging to installed lifting points.
Ensure that the screenbox has been raised to the mesh maintenance position, as detailed in
Chapter 9 before carrying out this procedure.
PROCEDURE
2. Start the machine. Reference: Chapter 7.
3. Unfold both side conveyors and pin in the lowest working positions.
4. Raise screen/ feeder angle to highest service position and pin in place.
5. Slide the feeder fully forward and pin in working position.
6. Raise screenbox into the mesh maintenance position and pin in place as shown.
DUN00824
Figure 6.38 - Screenbox raised to mesh maintenance position

7. Unfold tail conveyor, lower tail conveyor angle to the lowest position and pin the conveyor
securely in this position. The machine should be set up as is seen in Figure 6.39 before the
conversion.
DUN00822
Figure 6.39 - Machine set up for 2WS conversion
8. Switch off, lockout and tagout.

9. Support the tail conveyor at the locations shown as Item 1 in Figure 6.40 using suitable
lifting equipment.
DUN00823
Figure 6.40 - Lifting points on the tail conveyor
10. Disconnect the highlighted tail conveyor hydraulic lines, Reference: Figure 6.41.

DUN01896
Figure 6.41 - Hydraulic hose connections
11. Support the weight of the tail conveyor right side angle leg. Remove the pin (Item 1) holding
the right side angle leg in position and let the leg rotate down until it rests on ground level.
Repeat this process for the left side angle leg. Reference: Figure 6.41.
12. Remove the pin (Item 1) securing the tail conveyor to the chassis by removing the bolt and
sliding the pin out. This needs to be repeated on the opposite side of the machine. Lift the
tail conveyor away from the machine. Reference: Figure 6.42.
1 DUN00207
Figure 6.42 - Pins securing tail conveyor in place
13. Unbolt the mid side conveyor feedboot and remove it, Reference: Figure 6.43.

DUN00208
Figure 6.43 - Mid side conveyor feedboot
14. Disconnect the highlighted mid side conveyor hydraulic pipes and cap ports shown.
DUN00209
Figure 6.44 - Mid fines side conveyor hydraulic lines.
DUN00210
Figure 6.45 - Mid fines side conveyor hydraulic lines

DUN00211
Figure 6.46 - Mid fines side conveyor hydraulic lines
15. Support the mid side conveyor using suitable lifting equipment at the locations shown (Item
1). Bolt hinge points prior to lift (Item 2).
Figure 6.47 - Lifting points on mid fines side conveyor
16. Unbolt the chassis mounting bracket at the locations highlighted in Figure 6.48 and Figure
6.49.
DUN00213
Figure 6.48 - Chassis mounting bracket connections

DUN00214
Figure 6.49 - Chassis mounting bracket connections
17. Remove the conveyor securing pins from the locations shown in Figure 6.50 and lift the
conveyor free from the machine.
DUN00215
Figure 6.50 - Conveyor securing pins
18. Remove the 3WS skirting extensions (Item 1) from the tail conveyor.
DUN02626
Figure 6.51 - 3WS skirting extensions
19. Fit 2WS skirting extensions (Item 2) and back plate to tail conveyor.

DUN02627
Figure 6.52 - 2WS skirting extensions
20. Relocate the tail conveyor support legs, anchor brackets and angle rams to the position
shown in Figure 6.53.
»»Outer box leg installed with ram on underside without guard.
Figure 6.53 - 2WS support legs, anchor brackets and angle rams
21. Using the original pins, secure the tail conveyor in the 2WS location shown in Figure 6.54
and secure the tail conveyor to the support legs.
Figure 6.54 - Tail conveyor securing pins

22. Once tail conveyor has been installed (not shown), the chassis chute mounting brackets
(Item 1) and chute (Item 2) can be installed as shown.
2 1
1
DUN02628
Figure 6.55 - Chassis Chute
23. 2WS chute angle can be adjusted as required using the mounting brackets.
24. Reconnect the tail conveyor hydraulic lines.

(9) Opening Hopper Rear Door
nn DANGER
Fall Hazard. Do not climb onto working or moving machinery. Use suitable lifting equipment when
working at a height.
nn WARNING
PROCEDURE
1. Observe all safety warnings
2. The hopper rear door can be lowered for crusher feeding.
3. Ensure that the weight of the rear door is supported before removing any bolts.
4. Remove the bolts highlighted.
DUN00218
Figure 6.56 - Hopper rear door closed
5. Slowly allow the rear door to rotate down to a standstill position as shown.
DUN00219
Figure 6.57 - Hopper rear door open

Standard Operating Procedures 7
Table of Content
7 Standard Operating Procedures............................................................... 7-2
7.1 Pre-Operating Checks.....................................................................................7-2
7.2 Initial Startup...................................................................................................7-3
7.3 MCU 300 Machine Operation - Tier 4.............................................................7-4
(1) Starting the Engine.....................................................................................7-4
(a) No Faults on the Display Screen...........................................................7-6
(b) Active Fault on the Display screen.......................................................7-10
(c) CAT Fault Indicator Lamps...................................................................7-15
(2) Dual Power Machine Operation................................................................7-17
(3) Diesel Mode Operation.............................................................................7-17
(4) Electric Mode Operation...........................................................................7-18
(a) Pre-run Check......................................................................................7-18
(b) Electric operation.................................................................................7-19
7.4 Normal Operation..........................................................................................7-22
(1) Putting into Operation...............................................................................7-22
7.5 Manoeuvring..................................................................................................7-24
(1) Manoeuvring - General.............................................................................7-24
(a) Undercarriage......................................................................................7-24
(2) Manual Tracking Information....................................................................7-25
(3) Tracking the Machine...............................................................................7-26
(4) Machine Tracking Directions....................................................................7-27
(5) Manual Tracking Umbilical........................................................................7-28
(a) Manual tracking with the umbilical handset.........................................7-29
(b) Radio Tracking with the Teleradio Remote Control..............................7-30
(c) Fast Tracking ......................................................................................7-31
(d) Fast Tracking - Constant Speed Engine..............................................7-31
7.6 Machine Shutdown........................................................................................7-32
(1) Stopping the Machine...............................................................................7-32
(2) Tier 4 Final Machine Shutdown................................................................7-33
(3) Dual Power Machine Shutdown...............................................................7-35
(a) Diesel Mode.........................................................................................7-35
(b) Electrical Mains Power Mode:..............................................................7-35

7 Standard Operating Procedures
7.1 Pre-Operating Checks

nn DANGER
Do not stand on the maintenance platform whilst the screen and feeder are operating.
nn WARNING
Fall hazard.
Switch off, tag out and lock out machine before carrying out pre-operating checks..
NOTICE
AVOID frequent starting and stopping of the machine unnecessarily as it WILL cause damage
to the machine.
PROCEDURE
1. Ensure the machine is placed on solid level ground capable of carrying the machine‘s weight.
Regularly check the stability of the plant. The chassis should not bounce during operation.
2. Ensure there is adequate space around the machine for operation, material stockpiles,
maintenance and vehicular movement.
3. Ensure all guards are fully secured in correct/closed position.
4. Check that all safety equipment, alarms and interlocks are operative.
5. Remove all loose items from the belt by untying the securing ropes.
6. Ensure all control valve levers are in the neutral (non-operational) position.
7. Check the engine oil level and the fuel level and replenish if necessary.
8. Check the hydraulic oil level and replenish if necessary.
9. Ensure the material being feed into the feeder or screen unit is below the size limitations
recommended by the manufacturer. Do not allow build up of material at feed points.
10. DO NOT allow the engine RPM to run at a speed not suited for the application. Check the
wear parts to ensure speed is suitable for the application and feed rate not excessive.
11. Check setup of the screen unit and adjust as necessary to the required settings.
12. Observe all safety instructions and ensure the correct protective clothing and equipment are
used by operators.
13. Check the oil cooler fan and radiator for any build up of dust/dirt. Check regularly that the oil
cooler fan is running correctly and that dust/dirt has not built up in the fan and radiator unit
(overheating can occur if dust/dirt is allowed to build up). Blow out dust/dirt if necessary.

7.2 Initial Startup
NOTICE
Checks on the machine are crucial during the first week of operation. These checks must be
carried out before operating the machine.
Ensure that there is mesh in the screenbox in all decks when the machine is operational. Should
only one of the decks be needed, then an oversize mesh should be fitted to retain the structure
of the screenbox, as well as to minimise wear.
This section should be read and understood prior to starting the machine. If there are any doubts,
consult your local dealer or Terex Technical Support department.
PROCEDURE
1. Refer 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 bearings.
3. Each day during the initial days of operation check the tension of the conveyor belts.
4. Frequently check the overall stability of the machine, re-position if necessary.
5. Check the machine is level, re-position if necessary.
6. Frequently check the hydraulic oil level in the tank.
7. Frequently check all oil levels.
8. Ensure that the tension of the screen mesh(es) is satisfactory.
9. Frequently check the flow of material over the screen mesh(es) to confirm satisfactory
separation is taking place.
10. Make sure that the screen mesh apertures are free of ‘pegged’ material and that they remain
in good condition.
11. Check the vibrating unit bearing temperatures using a contact thermometer on the end
covers; record the temperature for future reference and fault diagnosis. (Maximum acceptable
temperature is 80 ºC [176°F] .)
12. Ensure that all components of the machine are operating before any material is introduced
to the machine.

7.3 MCU 300 Machine Operation - Tier 4
(1) Starting the Engine
NOTICE
Do not start the engine if any red warning lights or fault symbols are shown on the display screen.
A fault symbol indicates that there is a fault relevant to that indicator which must be fixed before
starting the engine.
Familiarize with the control panel. Depending on the engine of the machine, there are three
different control panel options:
Manual Throttle Control Panel
5 1
OK
4 3 2 DUN02145
Figure 7.1 - Manual Throttle Control Panel

2 Ignition Key
3 Preheat Button*
5 Manual Throttle Lever
*Preheating is normally necessary when ambient temperature is below zero degrees Celsius. If
preheating is necessary hold the pre-heat button for up to one minute (depending on ambient
temperature.

Electric Throttle Control Panel

1
OK
4 3 2
DUN00079

2 Ignition Key
3 Electric Throttle (Engine Speed Switch)
Constant Speed Engine Control Panel
1
OK
4 3 2
DUN02144
Figure 7.3 - Constant Speed Engine Control Panel

2 Ignition Key
3 Track Speed

(a) No Faults on the Display Screen
PROCEDURE
1. Switch the engine speed switch (Item 3) to low, Reference: Figure 7.4.
1
OK
4 3 2
DUN00079
2. Turn the ignition key on the control panel to the “ON” position, Figure 7.5 (Item 2).
3
DUN00001
Figure 7.5 - Ignition Key Positions
»»The home screen will be displayed on the control panel display screen, Reference: Figure 7.6. The
indicator lamps in the centre of the screen will illuminate and extinguish after a few seconds if there
are no faults present. If the indicator lamps do not extinguish. The e-stop healthy and fuel on symbols
only should light up green. Do not start the engine if any other lights are illuminated red or if there
are any other faults shown on the display screen.

Figure 7.6 - Home Screen (No Faults)
»»On Tier 4 machines the wait to start lamp is illuminated briefly on the home screen, Reference: Figure
7.7. The engine can be started after this lamp goes out.
Figure 7.7 - Home Screen (Wait to Start)
3. Turn the key to the crank position, Reference: Figure 7.5 (Item 3).
»»The engine will crank and start after the warning siren has sounded for approximately 7 seconds.
4. To view engine information, press the button under the engine symbol (Item 4), Reference:
Figure 7.8.

2 4
3
DUN00080
Figure 7.8 - Control Panel Display
»»The engine information screen is displayed, Reference: Figure 7.9. Reference Table 7.1 for a
description of each of the symbols.
Figure 7.9 - Engine Information Screen

Table 7.1 - Engine Information Screen Symbols

Symbol Description
Engine Speed
Battery Voltage
Engine Coolant Temperature
Engine Intake Temperature
Fuel rate
Engine Oil Pressures
Engine Boost (or turbo) Pressure
Percentage Engine Load
Engine run hours
When a DM 1 code is present the DM 1 symbol will flash red. Pressing the button will take you
to the Active Fault page
5. To return to the main menu home screen any time press the button under the exit symbol
(Item 2).

(b) Active Fault on the Display screen

A fault symbol will be illuminated red on the home screen when a fault occurs. The symbols
shown will depend on the fault.
NOTICE
Do not start the engine if any red warning lights or fault symbols are shown on the display screen.
The fault symbol indicates that there is a fault relevant to that indicator which must be fixed before
starting the engine.
PROCEDURE
1. Switch the engine speed switch (Item 3) to low, Reference: Figure 7.1.
2. Turn the ignition key to the “ON” position, (Position 2).
»»The main menu is displayed on the control panel screen. A fault symbol around the outer edge of
the home screen is highlighted red and a yellow safety warning symbol is displayed in the bottom left
hand corner of the screen indicating that there is a fault, Reference: Figure 7.107
Figure 7.10 - Home Screen (Active Fault)
3. Press the button under the warning symbol (Item 2) to view the alarm history, Figure 7.11.
Figure 7.11 - Main Menu Active Fault

»»A screen showing the alarm symbol and corresponding fault code is displayed, Reference: Figure
7.12. The engine run hours at which the fault occurred is also displayed. Active alarms will have the
yellow warning symbol displayed beside the fault symbol. If a fault symbol is shown without the yellow
warning symbol, this indicates that the alarm has occurred but it is now inactive.
Figure 7.12 - Active Fault Screen
4. The last 12 faults are stored in the control panel. Press the right direction button (Item 5) on
the panel to scroll through the active faults, Reference: Figure 7.11.
5. To return to the main menu home screen any time press the button under the exit symbol
(Item 2), Reference: Figure 7.11.
6. Determine the cause of the fault(s) and ensure that the problem(s) has been fixed before
continuing. Refer to Troubleshooting for fault code descriptions. If the engine fault screen is
shown (Figure 7.13) there is a problem with the engine. Refer to the table in Troubleshooting
for a list of the engine fault codes. Refer to the engine manufacturer’s manual or your local
dealer for more information.
7. Press the button (Item 2) on the control panel to return to the home screen, Reference:
Figure 7.11.
»»The home screen will be displayed with the fault symbol shown orange indicating that the fault is
cleared, Reference: Figure 7.14.

Figure 7.14 - Home Screen (Fault Cleared)
8. If there is a communication loss fault (FC010), the communication loss fault icon will be
displayed in the centre of the home screen , Reference: Figure 7.15.
Figure 7.15 - Communication Fault
9. Press the button 3 (Reference: Figure 7.11) on the panel to view the machine inputs and
outputs, Reference: Figure 7.16.
»»The controller status screen showing the input and output connections will be displayed, Reference:
Figure 7.16. If there is a communications fault, all of the icons will be shown in grey.
Figure 7.16 - Controller Status Screen

10. If any of the inputs or outputs are illuminated green, there is healthy communication between
the PLC and the display screen. If any of the inputs are grey, the input to the controller is not
active. If any of the outputs are grey, the output to the controller is not active. Ensure that
all connections are correct.
»»Refer to tables below for descriptions of each of the inputs and outputs shown on the controller
status screen.
Table 7.2 - Inputs

Item Description
I0 ESTOP HEALTHY
I1 TRACK REQUEST
I2 LOW SPEED
I3 INTERSPEED
I4 HIGH SPEED
I5 CONV1 START REQ
I6 CONV2 START REQ
I7 JACK LEG SENSORS
I8 AIR FILTER RESTRICTION
I9 START ENGINE
I10 MACHINE STOP
I11 HYD OIL LEVEL
Table 7.3 - Outputs

Item Description
O0 ENGINE CRANK
O1 FUEL SYSTEM
O2 HYD OIL FAN
O3 SIREN/BEACON
O4 TRACKS ENABLE
O5 SPARE
O6 SPARE
O7 SPARE
O8 SPARE
O9 SPARE

Table 7.4 - Expansion Node Inputs

Item Description
I1 FOLDING SENSOR 1
I3 FOLDING SENSOR 2
I5 FOLDING SENSOR 3
I7 SPARE
Table 7.5 - Expansion Node Outputs

Item Description
O2 FOLD1 SOL
O4 FOLD2 SOL
O6 FOLD3 SOL
O8 SPARE
11. Press the button (Item 2) on the control panel to return to the home screen, Reference:
Figure 7.11.
12. Turn the ignition key to the crank position, (Item 3).
»»The engine will crank and start after the warning beeper has sounded for approximately 7 seconds.

(c) CAT Fault Indicator Lamps

The fault indicator lamps in the centre of the home screen will flash when powering up the CAT
ECU on switch on but will switch off again if there are no faults.
If either or both of the indicator lamps are illuminated or flashing while the engine is running, there
is a fault with the engine system which must be dealt with immediately, Reference: Figure 7.17
and Figure 7.18. Refer to the table to determine the fault indicated by the lamps.
NOTICE
All faults must be identified and resolved as soon as possible.
Figure 7.17 - Warning Lamp (Alert Lamp)
Figure 7.18 - Shutdown Lamp (Action Lamp)

Table 7.6 - Indicator Lamps Logic

Warning Shutdown Lamp State Description Engine State
Lamp Lamp
On On Bulb Check When the ignition is turned Key on but engine has
on the EMS shall illuminate yet to be cranked.
each bulb for 2 seconds and
extinguish them afterwards.
Off Off No faults With both lamps off whilst Engine is running with
present engine is running then there no detected faults.
are no currently active warnings
diagnostic’s or events.
On Off Active Should the warning lamp Engine is running
diagnostic illuminate during engine running normally but has one
this indicates that an Active or more faults with the
diagnostic (Electrical fault) is engine management
present. system.
On Flash Derate Should the warning lamp Engine is running
(invoked illuminate and the shutdown but has one or more
by active lamp flash during engine running Active diagnostic
diagnostic) this indicates that an Active events that have
diagnostic (Electrical fault) initiated engine
is present. The diagnostic is derate.
sufficiently serious to invoke
engine derate.
Flash Off Warning Should the warning lamp flash Engine is running
(warning during engine running this normally but has one
only) indicates that one or more of or more monitored
the engine protection strategy engine parameters
warning values have been outside of the
exceeded but not to a level that acceptable range.
will invoke Derate or Shutdown.
Flash Flash Derate Should both the Warning lamp Engine is running but
(warning and and Shutdown lamp flash during one or more of the
derate) engine running this indicates monitored engine
that one, or more, of the engine parameters has
protection strategy values have gone beyond that of
been exceeded beyond the warning only and has
level required to invoke engine now exceeded those
Derate. set for engine derate.
On On Engine Should both the Warning lamp Engine is either
shutdown and Shutdown lamp illuminate shutdown or shutdown
during engine running this is imminent, one
indicates that either: or more monitored
1. One or more of the engine engine parameters
protection strategy shutdown have gone beyond
values has been exceeded. that of warning or
derate and have now
2. A serious Active diagnostic
exceeded those set
has been detected.
for engine shutdown.
Shortly after (time duration to be Or a serious Active
agreed) engine will shutdown. diagnostic has been
detected

(2) Dual Power Machine Operation

4 X1
-S1 -H1
X2
3
XB4-BD21 XB4-BVG6
1 2
X1 X1 X1 X1
-H2 -H3 -H4 -H5
X2 X2 X2 X2
3 4 5 6
7 -S2
DUN00472
(3) Diesel Mode Operation
PROCEDURE
1. Ensure the Electric mode switch (Item 1) is OFF.
2. Switch the isolator switch (Item 7) on the control panel to off.
3. To operate the machine in diesel mode refer to Section “MCU 300 Machine Operation”.

(4) Electric Mode Operation
NOTICE
To operate in electric mode, first make sure that a suitably sized supply cable is connected safely
to the Dual power Control panel isolator Input side.
Ensure that this cable is suitably protected at the supply side with the appropriate protection and
isolating device in strict accordance with local and international regulations.
Supply cable should only be installed by a qualified electrician.
(a) Pre-run Check
NOTICE
Do not leave Motor running while checking the direction. Simply ‘Pulse’ the motor as described.
Failure to follow these directions may result in damage to the motors and/or pumps.
Before the machine can be run normally, the direction of both motors must be checked.
PROCEDURE
1. First, note the required direction of the hydraulic pumps, usually indicated on the pump
housing. If unsure, contact Terex for advice.
2. Ensure all circuit breakers are in the ON position.
3. Ensure all Emergency Stop buttons are released and that it is safe to start the machine.
4. Switch on the Main Panel 3P 160A Isolator switch.
5. Switch the Operating Mode Selector Switch to Electric Mode.
6. Emergency stop healthy lamp should be illuminated.
7. Turn the ignition key to the crank position.
8. Turn off the ignition key.
9. Check Motor 1 is running in the correct direction.
10. If motor 1 is not rotating in correct direction, swap two phases of supply cables.
11. Turn on ignition key, turn to crank position.
12. Wait until both motors are running.
13. Turn off ignition key, verify both motors are running in the correct direction.
14. Do not swap the motor connections in the main control panel as these are tested before
leaving the factory.
15. Once the motors are running in the correct direction the machine can be started as follows.

(b) Electric operation
PROCEDURE
1. To allow the machine to operate in Electric mode, ensure the electric mode switch (Item 1)
is ON.
2. Switch the isolator switch (Item 7) on the control panel to on.

4 X1
-S1 -H1
X2
3
XB4-BD21 XB4-BVG6
1 2
X1 X1 X1 X1
-H2 -H3 -H4 -H5
X2 X2 X2 X2
3 4 5 6
7 -S2
DUN00472
3. Turn the ignition key on the control panel to the “ON” position (Item 2).
3
DUN00001
Figure 7.21 - Ignition Key Positions
»»If all Emergency Stops on machine are OK then “Electric Mode Estop Healthy” Lamp (Item 2) should
illuminate.

»»The electric mode home screen will be displayed on the control panel, Reference: Figure 7.22.
Figure 7.22 - Electric Mode Home Screen
4. Turn the ignition key to the crank position (Item 3).

»»Motor No.1 starts to flash green, when fully running will change to steady green, Reference: Figure 7.23.
Figure 7.23 - Motor 1 Running
»»Then motor No.2 starts to flash green, when fully running will change to steady green, Figure 7.24.
Figure 7.24 - Motor 1 and 2 Running

5. If a motor goes to Fault condition the motor symbol will change to red, Reference: Figure 7.25.
Figure 7.25 - Motor 1 and 2 Fault
6. Switch off the machine and ensure the problem is fixed before restarting

7.4 Normal Operation
(1) Putting into Operation

Refer to Section 4.5 for pictorial decal descriptions.
NOTICE
The machine must be put into operation in the correct order.
The main conveyor will only operate when the screenbox control valve is engaged.
PROCEDURE
2. Start the engine and gradually increase speed to maximum (1800 RPM).
»»In the case of machines fitted with a Constant Speed engine, the engine speed cannot be changed.
The engine will run at a constant RPM.
3. Let the engine run with no load for 3 to 5 minutes.
4. Move the tail conveyor lever to the up position to start the tail conveyor.
5. Move the mid side lever to the up position.
6. Move the fines conveyor lever to the up position to start the fines conveyor.
7. Move the collection lever to the up position to start the collection conveyor.
8. Move the screen lever to the up position to start the screen
9. Move the feeder lever to the up position to start the feeder.
10. To obtain maximum feeder speed, turn the control knob of the variable speed flow control
valve counter clockwise.
DUN00816
Figure 7.26 - Drive control bank

Figure 7.27 - Drive control decal
DUN00817
Variable Control Valves
Figure 7.28 - Variable Speed Flow Control Valves Decals
11. Set the side conveyor speeds on the variable speed control relative to material.
12. Check that all conveyor belts are running in alignment.
13. Turn the control knob of the variable speed flow control valve to level 2.
14. Fill up the feed hopper.
15. Turn the control knob of the correct variable speed flow control valve counter clockwise to
increase conveyor speed.
16. Turn the control knob of the correct variable speed flow control valve clockwise to decrease
conveyor speed.

17. Re-check that all conveyor belts are running in alignment. If an adjustment is necessary
refer to Chapter 9 Maintenance.
18. Check that screenbox is running and is capable of screening.
19. To obtain optimal feeder speed,repeat steps 14 to 16 as required.
7.5 Manoeuvring
(1) Manoeuvring - General
nn DANGER
DO NOT stand on any of the platforms or ladders of the machine whilst it is being manoeuvred.
When manoeuvring your machine to its operating position make sure you stand well clear of the
machine but are in a position to have all-round vision to see any obstacles or dangers that may
lie ahead e.g. Personnel, overhead cables, ditches, unsafe roadways etc.
nn WARNING
Prior to attempting any manoeuvring of the machine the tracks must be free of obstructions,
including screened material and fines. Do not push or tow the Machine. Failure to observe this
warning could result in danger to persons and damage to the machine which may invalidate
warranty.
• Before manoeuvring the machine, ensure the feed hopper and screen are empty, and that all
materials have run off the conveyors. STOP the feeder, screen unit and product conveyors.
• The safety warning horn/siren sounds continuously whilst the machine is being manoeuvred.
• Avoid manoeuvring the machine over extremely uneven ground or damage may occur. Due to
the limited ground clearance, avoid running over isolated objects between the tracks.
(a) Undercarriage
Terex machinery can be moved in one of two different ways depending on the type of machine;
• Bogie
• Tracks
Each type of undercarriage must be properly maintained to ensure a safe, effective working
environment. Track machines are designed for ease of movement around the site and should not
be used on public roads. Haulage equipment, such as a low loader or a roll in bogie, should be
used for this purpose. Non track machines should be transported using the appropriate haulage
equipment.

(2) Manual Tracking Information
nn WARNING
Only a fully qualified and competent electrician must connect the electrical supply to this machine.
The electrical supply to this machine must be carried out in strict accordance with all relevant
local and international electrical safety regulations.
The electrical supply to this machine must have adequate protection for safe disconnection in
the event of either over-current, short circuit or earth leakage faults.
The electrical supply to this machine must be fully tested and inspected by a qualified electrician
in strict accordance with all relevant local and international electrical regulations.
This machine must not, under any circumstances, be operated or tracked unless it is absolutely
safe to do so.
As the Electrical Hydraulic machine must be connected to a three phase 415VAC 50Hz electrical
supply to power the electrical motors that control the hydraulic track pumps, absolute care must
be taken when tracking this machine.
The operator must ensure that strict attention is paid to all relevant health and safety regulations
and guidelines when operating and tracking this machine.
The electrical supply to this machine must be connected via the supplied industrial ‘spring release’
plug with safety tension cord properly attached to facilitate safe disconnection should the cable
come under strain. No other connection method to this machine is acceptable.
When tracking the machine, it must be ensured that the supply cable to the machine is behind
the direction of travel or away from the tracks and the path of travel at all times.

(3) Tracking the Machine
nn DANGER
DO NOT stand on any of the platforms or ladders of the machine whilst it is being manoeuvred.
When tracking your machine to its operating position make sure you stand well clear of the
machine but are in a position to have all-round vision to see any obstacles or dangers that may
lie ahead e.g. Personnel, overhead cables, ditches, unsafe roadways etc.
NOTICE
Before tracking the machine on site ensure that all material has been processed through it and
that no material is left on any belts, in the hopper or the screenbox. Ensure no material has built
up around or on the tracks.
For large tracking manoeuvers or when loading the machine onto a low loader it is necessary to
fold the side conveyor. Never track the machine over long distances with the conveyors in the
working position.
The machine should be tracked at least 10 m in either direction every day to minimise the risk
of chain seizure
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. Do not
manoeuvre the machine on a gradient steeper than 30 degrees.
DUN00019
Figure 7.29 - Tracking Uphill and Downhill
Avoid manoeuvring the machine over extremely uneven ground. Ensure the terrain that the
machine is working on is firm enough to adequately support the machine.
Always park the machine on flat, level ground. If it is necessary to park the machine on a gradient,
the tracks should be solidly blocked.
Move all of the control levers to the neutral positions to stop all machine parts prior to manoeuvring.
Never attempt to track the machine if there is any build up of material around the tracks and drive
sprockets or if the tracks are frozen to the ground.
Stop the machine for 30 minutes after tracking it continuously for 30 minutes, to allow the
components to cool down. Never track the machine constantly for more than 30 minutes without
providing adequate rest.
Ensure no leakage of oil from gearbox, roller and idler before and during tracking.

(4) Machine Tracking Directions
NOTICE
The machine can be tracked using either the umbilical remote tracking unit, the radio tracking unit
or the teleradio tracking unit. Familiarize with the controls before tracking the machine.
Familiarize with the machine tracking directions before tracking the machine.
When tracking the machine, at all times the right and the left hand directions are viewed from
the feeder end of the machine.
2 5 2
3 4
1
1 6
DUN02629
Figure 7.30 - Machine Tracking Directions
The following list identifies the machines directions.

1 Left
2 Right
3 Forward
4 Reverse
5 Right-Hand Side Track
6 Left-Hand Side Track

(5) Manual Tracking Umbilical
NOTICE
When the Radio Control is ENABLED and the Radio Stop button on the Radio Handset is ACTIVE.
Pressing the Radio Stop button at this stage will shut down the machine.
Once the radio control is DISABLED the radio stop button on the radio handset is INACTIVE.
Pressing the radio stop button at this stage will have no effect.
The machine can be tracked using either the umbilical remote tracking unit, the radio tracking
unit or the teleradio radio remote tracking unit.
The umbilical remote control unit cable must be connected to the socket at the rear of the machine.
Figure 7.31 - Manual tracking umbilical socket location

(a) Manual tracking with the umbilical handset
PROCEDURE
1. Ensure engine is running, all conveyors are OFF and the track control valves are engaged.
2. Press the Tracks Start button on the umbilical remote (Item 8).
»»The Led Indicator will illuminate RED. The Siren and Beacon will activate and continue to do so until
the Tracks Stop button (Item 7) is pressed.
1 2
3 4
5 6
7 0 I 8
TEREX R
9
DUN00004
Figure 7.32 - Tracking Umbilical Layout
3. After a period of 10 seconds the LED Indicator will illuminate GREEN.

4. At this stage pressing the various Track direction buttons will engage the respective track
solenoid.
5. To stop the Tracking function, simply press the Tracks Stop button on the Umbilical (Item 7).

(b) Radio Tracking with the Teleradio Remote Control
PROCEDURE
1. Ensure engine is running and all conveyors, feeder etc are OFF.
2. Remove the dummy plug (Item 1) and insert the remote control unit plug into it‘s socket at
the rear of the machine.
Figure 7.33 - Remote Control Unit Connection
3. Turn the transmitter on using the switch on the back and release the machine stop button
(button 7) at the bottom of the transmitter.
4. Hold buttons 5 and 6 until the transmitter beeps indicating the log-in process has begun.
»»The machine siren will sound and there will be a 7 second delay before the tracks can be operated.
TEREX
DUN01723
Figure 7.34 - Teleradio Remote Tracking Transmitter
5. Use buttons 1, 2, 3 and 4 to operate the tracks..

7. Press button 5 to disable the tracks. Press button 7 to switch off the machine.
8. If you have finished with the tracking function, the radio control unit can be disabled by
pressing the radio stop button at the base of the radio handset.

(c) Fast Tracking
Some machines are fitted with two-speed tracking systems.
Both the Umbilical Handset and the Radio Handset have two-step push buttons on the Track
Directions. The first level is the Normal Track speed. The second press level is the Fast Track
Speed.
You cannot slew the machine with Fast Tracks – only both forward or both reverse tracks will
engage the fast track function.
When tracking with the engine speed set to ‘high’, the engine speed will ramp up to 2200 rpm to
further increase the travel speed when the push buttons are pressed to the second level.
(d) Fast Tracking - Constant Speed Engine

Constant Speed machines are fitted with a two-speed tracking system. To engage fast tracking,
turn the central dial (Item 3) to the right. The engine speed will not increase during this process.
Figure 7.35 - Constant Speed Control Panel
You cannot slew the machine with fast tracking engaged – only both tracks going forward or both
tracks reversing together will work with fast tracking engaged.

7.6 Machine Shutdown
NOTICE
When shutting down the machine or carrying out maintenance or adjustment the following
procedure must be followed.
Turning all machine components at once causes a pressure spike in the hydraulic circuit and a
voltage spike in the electrical circuit both of which are detrimental to the machine. A slight pause
between disengaging each component can prevent this spike taking place.
The machine must be running empty of material before the feeder, screenbox and conveyors are
stopped in the correct sequence.
(1) Stopping the Machine
PROCEDURE
1. Disengage each machine component in the correct order using the correct control levers.
2. Turn off the machine components in the following order.
1 Feeder
2 Screen
5 Mid side conveyor
6 Tail conveyor
3. Gradually decrease the engine speed to minimum
4. Let the engine idle with no load for 3 to 5 minutes.
5. Switch off the engine using the correct procedure and remove ignition key.
6. If carrying out maintenance on the machine implement the lockout and tagout procedure,
Reference: Chapter 8.

(2) Tier 4 Final Machine Shutdown
nn WARNING
Do not hit the emergency stop during this process unless completely necessary.
The battery isolator should not be used to close down the control panel during this period.
NOTICE
The system DEF must be purged of DEF fluid on engine shutdown to protect the system
components from damage due to DEF freezing. For this reason it is important that electrical power
is maintained to the engine ECM and aftertreatment system after the ignition has been turned off.
It is therefore important that the machine battery isolator is not turned off until the system purge
has been completed and the battery disconnect light is off. There is a maximum purge time of 20
minutes. The engine ECU records every time the engine is isolated before the wait to disconnect
light has gone out.
PROCEDURE
2. Stop all hydraulic components in the correct sequence.
3. Switch the engine speed switch (Item 3) to low.
5. Turn the ignition key (Item 2) to the off position to stop the engine and remove the key.
1
OK
4 3 2
DUN00079
Figure 7.36 - MCU300 Control Panel
6. Engage an emergency stop on the machine.

7. Before carrying out maintenance on the machine ensure the battery disconnect light is off.

DUN01340
Figure 7.37 - Battery Wait to Disconnect Light
Figure 7.38 - Battery wait to Disconnect Decal
»»When battery disconnect light is ON do not isolate battery. When battery disconnect light is OFF
battery can be isolated.
8. Implement the lockout and tagout procedure, Reference: Chapter 8.

(3) Dual Power Machine Shutdown
(a) Diesel Mode

The diesel mode dual power hydraulics operate as any other diesel machine.
PROCEDURE
1. Disengage each machine component in the correct order using the correct control levers.
2. Turn off the machine components in the following order.
1 Feeder
2 Screen
5 Mid side conveyor
6 Tail conveyor
3. Gradually decrease the engine speed to minimum.
5. Switch off the engine and remove ignition key.
6. If carrying out maintenance on the machine implement the lockout and tagout procedure,
Reference: Chapter 8
(b) Electrical Mains Power Mode:

To shutdown the machine from three phase supply electrics, the sequence of the electrical mode
is as follows:
PROCEDURE
1. Stop all hydraulics.
2. Turn ignition key to off position on operations panel.
3. Turn off main isolator on large electrical panel

Intenionally Left Blank

Emergency Operating Procedures 8
Table 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 any Work on the Machine..............................................8-4
8.2 Emergency Stop..............................................................................................8-4
8.3 Restarting after Emergency Stop....................................................................8-6
8.4 Testing Emergency Stops................................................................................8-6

8 Emergency Operating Procedures
8.1 Lockout and Tagout

This procedure is designed to prevent injuries caused by the unexpected start-up or movement of a
machine. These procedures are to be followed every time a machine is to be cleaned,maintained,
adjusted or repaired. When used as intended, Lockout also protects personnel from energy stored
in devices such as springs, accumulators, batteries, hydraulic systems, etc.
Where the lock out and tagout symbols (Reference: Chapter 2) appear on a safety sign it indicates
that the machine must be switched off and locked out before any work is carried out.
nn WARNING
Never give your 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 can still be several kinds of energy remaining after the
power is turned off. Secondary energy sources are hydraulic (fluid under pressure), pneumatic
(air under pressure), kinetic (force of moving parts) and potential (force contained in weights that
have been raised).
If, the machine will not be used for periods longer than 24 hours, the machine must be locked
out and tagged out until further use is required.
After, key off the isolator switch must remain in the “ON” position for a minimum of 20 seconds
to allow all systems to shut down properly.
PROCEDURE
1. Turn off the engine at the starter panel and remove key.
2. Lock the panel and put the key in a safe place.
3. After 20 seconds, rotate the isolator switch from the “ON” position (Item 1) to the “OFF”
position (Item 2).
1 2
DUN00014
Figure 8.1 - Isolator Switch

4. Fit the lock out hasp (Item 3) and unique padlock (Item 2) on the main power isolator and keep
the key to make sure no one can remove your lock and turn the power back on.
5. Place a Tag (Item 1) on the lock that identifies you (by your name, picture or number) as well
as the date and time you locked it out.
1
1 2
DUN00015
Figure 8.2 - Isolator Switch Off, Locked and Tagged
6. Release stored energy from the system, such as hydraulic fluid under pressure, so that the
machine is in a zero energy state.
7. Try to start or activate the machine to make sure that the power is off. (Don’t forget to push
the stop button again, afterward.)

(2) After Carrying out any Work on the Machine
PROCEDURE
1. Secure the work area by replacing guards and shields, removing blocks, picking up tools and
inspecting the work area.
2. Take your lock and tag off the main power Isolator.
3. If there are no other locks on, turn the main power isolator switch to the ON position
4. Unlock the operator’s control panel.
5. Warn others before starting the machine.
6. Start the machine and proceed with your work.
8.2 Emergency Stop

In an emergency situation only stop the machine by pressing an emergency stop button on the
machine.
nn WARNING
Do not hit an emergency stop button unless it is an emergency. Repeated use of the emergency
stop button could cause damage to the engine. The engine ECU records every time an emergency
stop button is used to stop the machine.
The stop button on the remote radio control, if fitted, is NOT an emergency stop as it may not be
operative at all times.
When an emergency stop has been initiated, the ignition switch stays on. Do not attempt to
restart the engine until it is safe to do so.
PROCEDURE
1. Press any emergency stop to stop the engine and machine, Reference: Figure 8.3 (Emergency
stops are located on both the left hand side and right hand side of the machine.
»»The safety alarm will sound until it is acknowledged and cancelled.
2. Turn the ignition key to the off position as soon as possible, if safe to do so.
3. Remove the ignition key.
4. Set the isolator switch too the off position.
5. When safe, release the emergency stop button(s) by pulling or twisting.

DUN00798
Figure 8.3 - Emergency Stop Locations on both sides of the machine

8.3 Restarting after Emergency Stop
nn WARNING
Ensure that the problem has been solved and all personnel are clear of the machine. Before
restarting, ensure that all guards are correctly fitted and fully functional. Do not restart until it is
safe to do so.
NOTICE
The machine must not be restarted if there is any material in and/or on the machine Ensure there
is no material in and/or on the machine before restarting.
PROCEDURE
1. Release the emergency stop button(s) by pulling or twisting.
2. Restart the machine, Reference: Chapter 7.
8.4 Testing Emergency Stops
PROCEDURE
1. Start the engine.
2. Push in an emergency stop button.
»»The engine will stop, the safety alarm will sound and alarm messages are shown on the display screen..
3. Acknowledge the alarm.
4. Re-set the emergency stop by pulling or twisting, depending on the type fitted.
5. Turn the ignition key to the ‘Off’ position.
6. Turn ignition key to the first position again.
7. Wait for the pre-start warning to complete.
8. Turn ignition key to start the engine again.
9. Repeat the procedure for all other emergency stops.

Maintenance 9
Table of Content
9 Maintenance................................................................................................ 9-4
9.1 Regular Servicing............................................................................................9-4
(1) Daily Checks...............................................................................................9-5
9.2 Non Scheduled Maintenance..........................................................................9-6
(1) Air Cleaner Elements..................................................................................9-6
(2) Tracks.........................................................................................................9-6
(3) Control Systems.........................................................................................9-6
9.3 Maintenance Schedule....................................................................................9-7
9.4 Service Schedule............................................................................................9-9
9.5 Lubrication.....................................................................................................9-12
(1) Lubrication and Routine Servicing............................................................9-12
(a) Machine Lubrication Points..................................................................9-12
(b) Lubricants............................................................................................9-12
(2) Recommended Lubricants........................................................................9-13
(3) Recommended Lubricants for Spaleck Screenbox..................................9-16
(4) Capacities - Fluid......................................................................................9-16
(a) Triple Shaft...........................................................................................9-16
(b) Single Shaft..........................................................................................9-16
9.6 Servicing the Feeder Unit..............................................................................9-17
(1) Clean & Check the Conveyor Belt............................................................9-17
(2) Tensioning the Feeder Conveyor Belt......................................................9-18
(3) Tensioning the Apron Feeder....................................................................9-19
(4) Feeder Conveyor/Apron Feeder Alignment..............................................9-20
(5) Feeder Conveyor undertray cleaning.......................................................9-21
9.7 Servicing Conveyors.....................................................................................9-23
(1) Clean & Check the Conveyor Belts..........................................................9-23
(2) Tensioning the Conveyor Belts.................................................................9-24
(3) Conveyor Alignment.................................................................................9-25
9.8 Servicing the Tracks......................................................................................9-26
(1) Machine Tracks........................................................................................9-26
(2) Cleaning the Tracks..................................................................................9-26
(3) Measuring Track Tension..........................................................................9-27
(4) Adjusting Track Tension............................................................................9-28
(5) Gearbox Oil Level.....................................................................................9-29
(6) Draining Gearbox Oil................................................................................9-30
9.9 Servicing the Electrical System.....................................................................9-31
(1) Check the Battery.....................................................................................9-31
(2) Battery Removal.......................................................................................9-32
(3) Battery Installation....................................................................................9-32
(4) Changing Fuses.......................................................................................9-33
(5) Proximity Adapter.....................................................................................9-34
9.10 Servicing the Hydraulic System.....................................................................9-35
(1) General.....................................................................................................9-35
(2) Hydraulic Fluid..........................................................................................9-35

9 Maintenance
(a) Check Hydraulic Oil Level....................................................................9-36

(b) Adding Hydraulic Fluid.........................................................................9-37
(c) Change Hydraulic Oil...........................................................................9-38
(d) Changing Suction Filters......................................................................9-39
(3) Checking the Return Line Filter................................................................9-40
(4) Changing the Return Line Filter................................................................9-41
(1) Changing Engine Filters & Oil..................................................................9-42
(1) Changing Engine Oil & Filters .................................................................9-47
(3) Servicing The DEF (Diesel Exhaust Fluid) System..................................9-52
(a) DEF Tank Location...............................................................................9-52
(b) Changing the Pump Main Filter...........................................................9-53
(c) Changing the DEF Tank Filler Screen..................................................9-54
(d) Changing the DEF Manifold Filter........................................................9-56
(e) DEF Tank Flush...................................................................................9-58
(f) Filling the DEF Tank.............................................................................9-59
9.13 Inspecting the Clean Emissions Module Supports........................................9-61
9.14 Changing Air Filters.......................................................................................9-63
(1) Air Filtration..............................................................................................9-63
(2) Check Both Air Cleaner Elements............................................................9-63
(3) Changing the Air Cleaner Elements.........................................................9-64
9.15 Coolant System.............................................................................................9-65
(a) Topping up Coolant Level....................................................................9-65
9.16 Priming the Fuel System...............................................................................9-66
(1) Electic Fuel Pump Priming.......................................................................9-66
(2) Manual Fuel Pump Priming......................................................................9-67
(3) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines)..............9-68
9.17 Fuel Level and Topup....................................................................................9-70
9.18 Removing the Screenbox..............................................................................9-71
(1) Replacing the Screen...............................................................................9-73
9.19 Screen Unit Maintenance..............................................................................9-74
(1) Daily Maintenance....................................................................................9-74
(2) Weekly Maintenance................................................................................9-76

Maintenance 9
(3) Snubber Rubber Maintenance..................................................................9-78

(4) Lubrication................................................................................................9-79
(5) Bearing Temperature................................................................................9-81
(6) Screen Tuning Single and Triple Shaft.....................................................9-82
(a) Aspects of Stroke Adjustment..............................................................9-82
(b) Stroke Length.......................................................................................9-85
(c) Stroke Speed.......................................................................................9-87
(d) Stroke Angle.........................................................................................9-88
(7) Checking Screen Drive Belt Tension........................................................9-96
(8) Tensioning the Screen Drive Belt.............................................................9-98
(9) Changing the Bottom Deck Screen Mesh..............................................9-100
(a) Changing Screen Mesh on Triple Shaft.............................................9-100
(10) Changing the Top Deck Screen Mesh (Single & Triple Shaft)................9-103
9.20 Spaleck Screen Unit Maintenance..............................................................9-105
(1) Screening Element.................................................................................9-105
(2) Assembly of the Screening Element.......................................................9-105
(a) Disassembly of the Screening Element.............................................9-106
(b) Servicing the Sieve Base...................................................................9-106
(3) Shaft drive system..................................................................................9-107
(a) Bolted connections.............................................................................9-107
(b) Bearing Temperature.........................................................................9-107
(4) Clamped Screen Mat..............................................................................9-108
(a) Screen Mat Assembly........................................................................9-109
(b) Screen Mat Disassembly................................................................... 9-110
(c) Screen Mat Maintenance................................................................... 9-110
9.21 Collection Conveyor And Diesel Tank Maintenance.................................... 9-111

9 Maintenance
9 Maintenance
Refer to Chapter 2 Safety for relevant safety information before attempting to carry out any
maintenance on the machine.
nn WARNING
Before undertaking any maintenance, repairs or retooling work on the machine, switch off the
machine and implement the lockout and tagout procedure.
Maintenance procedures in the maintenance section of this operations manual are intended to be
carried out by trained operators. You must satisfy yourself that you have received to the correct
training before attempting any procedure in the maintenance section, if you have any doubts do
not attempt any procedure and speak to your manager. More complex machine maintenance
that is not covered in the maintenance section of the operators manual must only be carried out
by fully trained service personnel who have taken part in specific maintenance training provided
by us or our approved dealer, please contact your local dealer for further details.
9.1 Regular Servicing
NOTICE
To deliver the specified quantity of grease to shaft bearings, ascertain the amount the grease gun
will deliver with each ‘pump’. Do not guess or assume an amount! Check the greasing equipment
used regularly.
To prevent contamination of the grease, wipe the grease nipples clean before applying.
It is bad practice to mix oils or greases. The blend can have a lower specification than the
individual oils or greases and can lead to premature bearing failure. USE ONE BRAND ONLY.
Make sure the machine is either level or in operating position when oil checks and changes are
being made.
It is the operators responsibility to ensure that all bearings are greased with the correct quantity
and type of grease/oil at the correct intervals specified.
It is important that a strict routine of regular servicing is undertaken from the start of operation
of the machine
Regular checks on fluids and the lubrication of the machine, in accordance with the schedule,
is essential.
In addition to the lubrication points, the lubrication schedule lists the regular attention required to
the machine hydraulic system.
The engine oil and coolant also require checking regularly.
When power or steam cleaning the machine be aware of the risk of damaging components i.e.,
electrical components , bearings. Water ingress or heat may penetrate or damage seals leading
to premature failure.
of the screenbox, as well as to minimise wear
Remove any buildup of stones, dust, grease, oil, or other debris from the machine.

Maintenance 9
(1) Daily Checks
nn DANGER
DO NOT allow an excavator bucket feeding material into the hopper to pass overhead or near
the machine operator.
nn WARNING
It is imperative that the operator carries out regular and diligent checks before operating the
machine, especially with operational safety in mind.
Always consider what particular safety hazards could occur at specific sites and eliminate them
before commencing work.
NEVER leave the machine unattended whilst it is in operation.
PROCEDURE
2. Visually check and inspect all guards, covers and doors are in position and secure.
3. Check that all equipment and tools that are hazardous to operation are removed from the
immediate site.
4. Perform all actions required in the lubrication schedule requiring a daily check or lubrication,
refer to servicing - lubrication.
5. Make sure all warning and safety signs are clean and visible, see machine specification and
information for their part numbers and positions.
6. Ensure that the screen unit and the feed hopper are empty.
7. Check hydraulic oil level and filter condition indicators.
8. Visually check the hydraulic system for damage or leaks.
9. Check the sub-frame anchor tightness for the Single Shaft and Spaleck arrangements.
10. Check belts for damage, wear and fraying.
11. Clean away dirt and grit from maintenance platforms.
12. On plants fitted with an Apron Feeder, check the return rollers are fully functional and rotating
with the moving apron feeder. Remove any build-up of material around the rollers and ensure
the rollers are clean of debris.

9 Maintenance
9.2 Non Scheduled Maintenance
nn WARNING
Switch off the machine and implement the lockout procedure.
(1) Air Cleaner Elements

The air cleaner element can be seen from Item 1. The life span on air cleaner elements is
dependant on the environment the machine is used in and as such a maintenance schedule can
not be implemented for their replacement. Machines are equipped with an air filter restriction
sensor which will highlight the need for maintenance. It is recommended that air cleaner elements
are replaced and not washed or reused.
Figure 9.1 - Air Cleaner Element
(2) Tracks
The maintenance schedule for the tracks will depend greatly on the amount of travel a machine is
expected to do in its day to day operation and for that reason is not included in the following hourly
schedules. Before any attempt is made to move this machine refer to the Tracks Maintenance
section of this manual.
(3) Control Systems

Ensure that only qualified and trained personnel operate and maintain this equipment.
Always keep control panels closed to avoid water ingress and dust contamination and keep keys
in secure locations.
Regularly check the control system and connections for any damage.
Never adjust any components or settings without authorisation from Terex.

Maintenance 9
9.3 Maintenance Schedule

For further engine maintenance information, refer to the engine manufacturer‘s operation manual
supplied.
General Job 10 Hours 50 Hours

(Daily) (Weekly)
Emergency stop system Check / Repair
Decal either missing or damaged Check / Replace
Diesel level in fuel tank Check / Refill
Material build up Check/ Clean
Electrical defects Check / Repair
Safety guards are in place Check / Replace
Loose parts, nuts, bolts & pins Check / Tighten
Walkways, steps and railings are safe and Check / Tighten loose
secure bolts
Grease Filled Bearings Grease
Battery Electrolyte Level Check
Hydraulic System
Hydraulic oil level Check / Top up
Hydraulic return line filter indicator Check
Hydraulic hoses for leaks Tighten / Replace
Hydraulic cylinders for leaks Tighten / Replace
Hydraulic pumps for leaks Tighten / Replace
Hydraulic motors for leaks Tighten / Replace
Conveyors
Conveyor belts for rips and tears Check / Repair
Belt alignment Check / Align
Direct drive motor coupling (if applicable) Check / Replace
Belt Scraper Check / Adjust /
Replace
Rollers are free moving and unobstructed Check /Free
Skirting rubbers - tension and spillage Check / Adjust /
Replace
Obstruction to drums Check / Remove
Drum bearings Grease
Gearbox bolts Check / Tighten
Feeder Hopper
Skirting rubbers Check / Adjust/
Replace
Feeder gearbox oil Change
Belt cleaners Check / Adjust
Apron feeder return rollers Check / Replace

9 Maintenance
Screenbox Job 10 Hours 50 Hours

(Daily) (Weekly)
Screen mesh - wear Check / Replace
Screen mesh - tension Check / Tighten
Tensioner Sleeve Check / Replace
Bearings Grease
Springs Check / Replace
Rubber cushions Check / Replace
Snubber Rubbers* Check/Adjust
Labyrinth seals (1 gram only) Grease
Parameters (speed & throw) Check / Set
Screen Blanket Check / Replace
Screen Drive Belt Check Adjust /
Replace
Tracks
Tension of tracks Check / Repair
Material build up Clean / Check
Track for oil leaks Check / Tension
Run Machine Forwards and Backwards 10 m Perform
Dual Power Electric Motors
Keep the motor clean and ensure free Inspect / Clean
ventilation airflow
Shaft Seal Check / Replace
Engine
Engine Oil Level Check / Top up
Battery Electrolyte Level Check / Top up
Alternator Belt Check / Adjust /
Replace
Engine Air Cleaner Service Indicator Check
Engine Air Precleaner Check / Clean
Hoses and Clamps Check / Replace
Fuel Tank Water and Watertrap Drain
Fuel Tank Breather / Cap Check / Clean
Fuel System Primary Filter / Water Separator Drain
Cooling System Coolant Level Check
Driven Equipment Check
Hoses and Clamps Inspect / Replace
V-belts Inspect / Adjust /
Replace
*Ensure Snubber Rubbers maintain a 5 mm gap from the screenbox

**After first 50 hours then after every 2000 hours or annually.
Maintenance 9
9.4 Service Schedule

For further engine maintenance information, refer to the engine manufacturer‘s operation manual
supplied.
This machine has the following engine options:
A Tier 3/Stage 3A Caterpillar C4.4 ATAAC
B Tier 4 Constant Speed Caterpillar C4.4
C Tier 4 Final Caterpillar C4.4
The tables below list maintenance schedules. The letters in the engine section represent the
different engine options on this machine.
Hydraulic System Job First Every Every Every Every

100 250 500 1000 2000
Hours Hours Hours Hours Hours
Hydraulic oil Analysis - Check /
Top-up / Replace if
necessary
Replace
Hydraulic relief Check / Adjust
pressures
Hydraulic Return Replace
Filter (1st replace at
100 hours)
Hydraulic Oil Suction Inspect / clean and
Filter change if required
Replace
Conveyors
Feeder gearbox oil Replace
(1st replace at 100
hours)
Tail drum bearings Check / Clean
Drive drum bearings Check / Clean
Guards Check / Replace
Cylinder pivots, Grease
conveyor adjustment
pivots and conveyor
belt tensioners
Tracks
Visual wear on Check
components
Gearbox oil Check / Top up
(1st replace at 100 Replace
hours)

9 Maintenance
Engine Maintenance Job Every Every Every Every Every

250 500 1000 1500 2000
Cooling System Coolant ABC Obtain
Sample (Level 1)
Engine Oil Sample ABC Obtain
Engine Oil and Filter* ABC Change
Engine Valve Lash AB Inspect /
Adjust
Fan Clearance ABC Check
V-Belts AB Inspect /
Adjust /
Replace
Crankcase Breather AB Replace
(Canister)
Cooling System ABC Test / Add
Supplemental Coolant
Additive (SCA)
Engine Air Cleaner ABC Clean /
Element (Dual element) Replace
Engine Air Cleaner ABC Replace
Element (Single Element)
Fuel System Primary ABC Replace
Filter (Water Separator)
Element
Fuel System Secondary ABC Replace
Filter
Fuel Filter (In-Line) C Replace
Radiator ABC Clean
Engine Protective AB Check
Devices
Diesel Exhaust Fluid C Clean /
Filter Replace
Engine Crankcase C Replace
Breather Element
Pump Main Filter C Replace
Tank Header Filter C Replace
Clean Emissions Module C Inspect
Support
Aftercooler Core ABC Inspect
Belt Tensioner ABC Inspect
Belt C Inspect
Exhaust Manifold AB Inspect
Starting Motor ABC Inspect
Turbocharger ABC Inspect

Maintenance 9

250 500 1000 1500 2000
Water Pump ABC Inspect
Alternator AB Inspect
Engine Mounts ABC Inspect
Cooling System Coolant ABC Obtain
Sample (Level 2)
*Due to the severe environment that most machine operate in the engine oil and filter change
should be every 250 hours of service. However if oil sampling and analysis is carried out it is
possible to increase the engine oil and filter change to every 500 hours of service.

3000 4000 6000 10000 12000
Alternator and Fan ABC Inspect /
Belt Adjust /
Replace
Cooling System ABC Change
Coolant (DEAC)
Cooling System ABC Replace
Water Temperature
Regulator
Fuel Injection AB Test /
Nozzles Exchange
Aftercooler Core ABC Clean / Test
Coolant System ABC Add / Change
Coolant (ELC)
Coolant system ABC Change
coolant (ELC)
DEF Manifold Filters C Replace

9 Maintenance
9.5 Lubrication
(1) Lubrication and Routine Servicing
(a) Machine Lubrication Points
nn WARNING
Fall hazard.
Switch off the machine and implement the lockout and tagout procedure.
NOTICE
Do not mix greases. The blend can have a lower specification than an individual grease and can
lead to premature bearing failure.
Regular lubrication of the machine accordance with the Lubrication and Servicing Schedule is
essential.
The locations of the lubrication points are as follows:

• Screen
• Feeder tail drum bearings (Head drum bearings on apron feeder option only)
• Collection conveyor drive and tail bearing grease nipples.
• Track unit gearbox oil levels.
• Side conveyors drive and tail bearing grease nipples.
• Tail conveyor drive and tail bearing grease nipples.
• Feeder unit gearbox oil levels.
• Periodically lubricate hinges, pivot pins, adjusting screws and similar points with oil or grease
to prevent seizure during lengthy spells of inactivity.
(b) Lubricants
Use only unadulterated mineral lubricants. On no account should the lubricant contain uncombined
mineral acids, free alkaline or metal-corroding additives.
The correct lubricants are listed below.

Maintenance 9
(2) Recommended Lubricants
NOTICE
The feeder unit gearbox does NOT use the same type of gear oil as the track gearbox.
Failure to use the appropriate specification of engine oil will reduce the life of your engine. Failure
to use the correct specification of engine will also reduce the life and the effectiveness of your after
treatment system (if fitted). Refer to the engine manufacturer’s manual for additional information
that relates to the lubrication for your engine
Always use lubricants and fluids that meet the international specifications.
Greases outside these specifications are not designed for use in Vibrating Screens e.g. greases
with molybdenum sulphate additives, and should never be used.
Grease cartridges have a general shelf life of approximately 36 months and should be discarded
beyond this point. Consult grease specifications for specific information.
Grease and grease cartridges should always be stored between 0°C and 40°C and in a dry
environment. Grease or grease cartridges should be immediately discarded should any sign of
moisture or other contamination be present. Similarly, this requirement applies to grease guns
or auto greasing systems.
Failure to comply with these recommendations may dramatically reduce screen bearing life and
will void warranty on screen bearings and related components.
The Shell grades are for reference only.
Below is a list of the recommended alternatives suitable for use with your machine. These special
screen greases are lithium base greases of Class 2 with extreme pressure additives. The listed
greases fall under DIN classifications KP2K-20 or KP2K-30.
• Fuchs Renolith EP2
• Mobil Mobilux EP2
• Total Multis EP 2
• Castrol Spheerol EP2
• Shell Retinax EP2
• Maxol Multipurpose EP2
• Texaco Multifak EP2

9 Maintenance
Table 9.1 - Lubricants and Fluids

Volume International Spec Recommended
Fuel 345 L (91.14 US Sulfur free fuel as
Gal) per EN 590 or Ultra
low sulfur fuel as
per ASTM D975
Engine Oil 13.5 L Engine Oil 15W-40 CAT DEO (SAE 15W-40)
Engine Oil (Tier 4) 7L Engine Oil 15W-40 CAT DEO-ULS (SAE 15W-
low SAPS 40)
Coolant 17 L CAT EC-1, ASTM CAT Extended Life Coolant
D4985 or ASTM (ELC) or CAT Diesel Engine
D6210 Antifreeze (DEAC)
Coolant (Tier 4) 16.5 L CAT EC-1, ASTM CAT Extended Life Coolant
D4985 or ASTM (ELC) or CAT Diesel Engine
D6210 Antifreeze (DEAC)
Hydraulic Oil 450 Hydraulic Oil Grade Shell Tellus 46
46
Track Gearbox Oil 4L SAE 80W/90 Shell Spiax
ISO 4406 (20/18/18) S2 G 80W/90
General Grease KP2K-20 Refer to “Recommended
KP2K-30. Lubricants” list
Belt feeder gearbox oil 1.3 ltr (0.34 US SAE 80W/90 Shell Spirax
Gal) S2 G 80W-90
Apron feeder gearbox oil 4 ltr SAE 80W/90 Shell Spirax
S2 G 80W-90
Screen box N/A Industrial Oil 220 Shell Morlina S2 B 220 (4°
(Triple Shaft) to 35°) or Shell Morlina S2
B 150 (-18° to 18°)
Screen box N/A KPHC 2N-20 Mobil Mobilith SHC220
(Single Shaft) KPHC 2N-30. Maxol Heavy Duty
Synthetic 220
**Where ambient temperature is above 30oC

Maintenance 9
Table 9.2 - Hot Climates

Capacity (l) Name Recommended
Hydraulic Oil Shell Tellus S2 M 68
Hydraulic Oil 780
Grade 68
Gear Oil Grade Shell Omala S2 G320
Feeder Gearbox 4/1.3
320
Track Gearbox Gear Oil Grade Shell Omala S2 G320
320
Screen Bearings Gear Oil Grade Shell Morlina 320
320 Synthetic
Engine Oil (Tier 3) 17.4 Engine Oil 15W-40 CAT DEO 15W-40
Engine Oil 15W-40 CAT DEO-ULS
Engine Oil (Tier 4) 17.9
Low SAPS
Where ambient temperatures are +15°C - +50°C.
Table 9.3 - Cold Climate

Capacity (l) Name Recommended
Hydraulic Oil Shell Tellus S4 VX
Hydraulic Oil 780 Grade 32 Cold
Climate
Gear Oil Grade Shell Omala S4 GX 150
Feeder Gearbox 4/1.3
150 Synthetic
Track Gearbox Gear Oil 75W/90 Shell Spirax S6 AXME 75W/90
Screen Bearings Gear Oil Grade Shell Morlina 150
150
Engine Oil (Tier 3) 17.4 Engine Oil 5W-30 Cat DEO Cold Weather SAE 0W-40
Engine Oil 5W-30 Cat DEO Cold Weather SAE 0W-40
Engine Oil (Tier 4) 17.9
Low SAPS
Where ambient temperatures are -20°C - +30°C.

9 Maintenance
(3) Recommended Lubricants for Spaleck Screenbox

The bearings and labyrinth glands are lubricated with ”Renolit H443-HD88“ grease ex works,
which will suffice until the specified lubrication period has elapsed. If there is a long period of time
between delivery of the machine and commissioning, the shaft drive system must be lubricated
beforehand.
Only use Renolit H443-HD88.
The subsequent grease quantities and lubrication periods shown in the table below must be
observed.
Shaft drive system Lubrication per bearing and labyrinth gland Interval
model type Initial Every subsequent 750-900 min-1
8-5800 60 g 20 g 50 hours
The lubrication period should be halved for every 15°C increase in the case of higher surface
temperatures.
The bearings should be washed out and the grease replaced after 5000 hours operating time.
Superfluous grease from the shaft protection tube should be removed if possible.
(4) Capacities - Fluid
(a) Triple Shaft

The engine oil level is checked using a dipstick to ensure correct oil level (See Table 9.1 for details).
Table 9.4 - Triple Shaft Greasing Schedule

AREA FREQUENCY GRAMS OUNCES
All Conveyor Tail Drum Bearings LH/RH 50 HRS 1 0.07
All Conveyor Drive Drum Bearings LH/RH 50 HRS 1 0.07
Screen Oil Seal Labyrinth 50 HRS **
1 Gram = 0.035 Ounce

Each grease gun will put out a differing amount per stroke. Check greasing equipment before use.
**Pump grease into fitting until old grease is forced through labyrinth.
(b) Single Shaft
Table 9.5 - Single Shaft Greasing Schedule

Area Frequency Grams Ounces
All conveyor tail drum bearings LH/RH 50 HRS 1 0.07
All conveyor drive drum bearings LH/RH 50 HRS 1 0.07
Screen bearings LH/RH 10 HRS 6 0.21
1 Gram = 0.035 Ounces

Each grease gun will put out a differing amount per stroke. Check greasing equipment before use.

Maintenance 9
9.6 Servicing the Feeder Unit
(1) Clean & Check the Conveyor Belt
nn WARNING
Fall hazard.
nn CAUTION
Do not unfasten or remove any guard while the machine is running or start the machine while a
guard is unfastened or 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.
PROCEDURE
2. Stop the engine, Reference: Chapter 7.
3. Clean the conveyor belt using a high pressure hose. Ensure that eyes are protected by
wearing safety glasses.
4. Check the belt for cuts, tears, rips or any other physical damage.
5. Close and secure the guard doors in the correct position.

9 Maintenance
(2) Tensioning the Feeder Conveyor Belt
nn WARNING
Fall hazard.
NOTICE
Do not over tension the belt as this will damage the drum bearings.
PROCEDURE
2. Start the feeder conveyor, Reference: Chapter 7.
3. Run the feeder conveyor at desired speed.
4. Tighten the feeder conveyor belt by adjusting both adjusters (Item 1) evenly.
Figure 9.2 - Feeder Conveyor Adjusters
5. This procedure is the same for the apron feeder option.

Maintenance 9
(3) Tensioning the Apron Feeder
nn WARNING
Fall hazard.
NOTICE
PROCEDURE
2. Implement the lockout and tagout procedure.
3. Secondly, assess the current tension in the apron. We design the system to operate with a
maximum. deflection of 1.5%. This can be measured using the feeder frame as a reference
and comparing the offset at the lowest roller with that at the mid-point between the same
roller and the rear sprocket. If this value is less than or equal to 20mm the apron tension
will be sufficient
4. Should additional tension be required, begin to adjust the apron tension bolt at the rear of
the plant working rotating each nut equally and in turn.
5. On a new feeder assembly the springs collection is generally tensioned to a compressed
length of 125 mm to provide the deflection required. This is a good marker point for field
re-tensioning and once reached, the measurement discussed in point 2. above should be
re-checked.
6. Continue to tension until the required deflection measurement is reached.
7. Run the feeder for a short period to observe performance and double check max. deflection
is in reacquired range as per above.
8. Repeat steps above if necessary to successfully re-commission the plant.

9 Maintenance
(4) Feeder Conveyor/Apron Feeder Alignment
nn WARNING
Fall hazard.
nn CAUTION
PROCEDURE
2. Start the feeder conveyor.
3. Turn control knob of the variable speed control valve COUNTER CLOCKWISE to run the
feeder conveyor at maximum speed.
4. Observe the conveyor through the viewing apertures and determine to which side the
conveyor is tracking off.
5. If the conveyor is tracking off to the right side, operate the right side adjuster one turn at a
time until the belt tracks correctly.
6. If the conveyor is tracking off to the left side, operate the left side adjuster one turn at a time
until the belt tracks correctly.
Figure 9.3 - Feeder Conveyor Adjusters
7. This procedure is the same for the apron feeder option, with the adjusters located on the
outside.

Maintenance 9
(5) Feeder Conveyor undertray cleaning
nn WARNING
Fall hazard.
nn CAUTION
NOTICE
Pay attention that the undertray is supported and is not damaged during this maintenance
procedure.
PROCEDURE
3. Ensure both side conveyors are opened fully into the working position,Reference: Chapter 6.
4. Raise the screenbox / feeder angle to the highest service position and pin the screen angle
legs (Item 2).
DUN00835
Figure 9.4 - Screenbox in highest working angle
5. Slide feeder into working position and securely pin in place. This pin position is shown (Item
1), Reference: Figure 9.5.
6. Remove the pins securing the undertray to the feeder by removing the wing bolts (Item 1)
and sliding the pin (Item 2) out.

9 Maintenance
DUN00236 1 2
Figure 9.5 - Undertray pins
7. Slide the feeder backwards towards its transport position. As the feeder is slid back the
undertray will lower to ground level allowing access to clear any build up of material as shown.
DUN00257
Figure 9.6 - Underpan feeder in maintenance position.
8. This process should be reversed to return the feeder undertray to its working position.

Maintenance 9
9.7 Servicing Conveyors
(1) Clean & Check the Conveyor Belts
nn WARNING
Wear personal protective equipment. Ensure that eyes are protected by wearing safety glasses.
Fall hazard.
nn CAUTION
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.
PROCEDURE
2. Stop the machine, Reference: Chapter 7..
3. Implement the lockout and tagout procedure.
4. Open the guard doors where necessary.
5. Clean the conveyor belts using a high pressure hose.
6. Check the belts for cuts, tears, rips or any other physical damage.

9 Maintenance
(2) Tensioning the Conveyor Belts
nn DANGER
Under no circumstances should any adjustment be made on the belt whilst the machine is running.
There is an entanglement hazard and risk of trapping parts of the body.
nn WARNING
Fall hazard.
NOTICE
PROCEDURE
2. Start the conveyor.
3. Tighten the belt by adjusting both belt adjusters evenly, 2 turns at a time until slippage stops.
DUN00237
Figure 9.7 - Conveyor Belt Adjuster

Maintenance 9
(3) Conveyor Alignment
nn WARNING
Fall hazard
NOTICE
PROCEDURE
2. Start the conveyor, Reference: Chapter 7.
3. Observe the conveyor and determine to which side the conveyor is tracking off
4. If the conveyor is tracking off to the right side, operate the right side adjuster one turn at a
time until the belt tracks correctly.
5. If the conveyor is tracking off to the left side, operate the left side adjuster one turn at a time
until the belt tracks correctly.
DUN00237
Figure 9.8 - Conveyor Belt Adjuster

9 Maintenance
9.8 Servicing the Tracks
nn WARNING
Fall hazard.
(1) Machine Tracks
NOTICE
It is essential that the tracks are correctly tensioned at all times. Check track tension regularly.
Moving the machine with incorrectly tensioned tracks can cause severe damage to the
undercarriage components and may invalidate the warranty.
PROCEDURE
1. Keeping the tracks correctly adjusted will increase the service life of the tracks and drive
components.
2. Frequently check for loose bolts, oil leaks, master pins are correctly located and tight, general
wear and damage, correct track tension, etc. to ensure safe working and long life.
3. Always check the tracks prior to manoeuvring the machine.
(2) Cleaning the Tracks
NOTICE
Pay attention to material build up around sprocket, idlers, lower rollers, top chain guides and
chain links. DO NOT attempt to track the machine if material has built up around the tracks as
this will invalidate the warranty.
PROCEDURE
2. On a daily basis the tracks should be hosed down to dislodge any build up of material on
the tracks.

Maintenance 9
(3) Measuring Track Tension
nn WARNING
Prior to attempting any manoeuvring of the machine, the tracks must be free of obstructions,
including crushed material and fines. Do not push or tow the machine. Failure to observe this
warning could result in injury to persons and damage to the machine which may invalidate warranty.
It is important that the track is not tensioned too tightly as this places excessive loads on the
gearbox grease cylinder and idler bearings. It will also lead to accelerated wear and premature
failure.
PROCEDURE
1. Observe all Safety Warnings.
2. Position the machine on solid and level ground and drive 2 metres (2 yards) minimum in a
forward direction, track idler roller leading.
3. Close down the machine and implement the Lockout Procedure.
4. One track at a time, measure the sag on the top part of the track on the longest section of
unsupported track by placing a ‘straight edge’ long enough to reach from the drive sprocket
to the nearest skid plate, as shown.
DUN00018
Figure 9.9 - Measuring Track Tension
5. Measure the maximum amount of track sag from the high point of the track to the bottom of
the ‘straight edge’.
6. Correctly adjusted, the sag should be within the limits set by the supplier as shown in Table 9.4.
Table 9.6 - Track Tension Limits

Identification Sag Value
STRICKLAND 5 MM - 15 MM
7. Depending upon the need to either slacken or tension the track, proceed as follows.

9 Maintenance
(4) Adjusting Track Tension
nn DANGER
Grease coming out of the relief valve under pressure can penetrate the body causing injury or
death; DO NOT watch the relief valve to see if grease is escaping but instead watch the track
adjustment cylinder to verify that the track is being loosened.
nn WARNING
Fall hazard
NOTICE
Do not set track tension too tight.
PROCEDURE
1. Observe all Safety Warnings.
2. Close down the machine and implement the Lockout Procedure.
3. Locate the access aperture on the side of the track frame and remove the cover, where fitted,
to reveal the relief valve inside.
To Release Track Tension [After measurement]:-
4. Loosen the relief valve by turning counter clockwise using gradual increments until the grease
begins to be expelled. Care must be taken not to loosen the relief valve too quickly because
the grease inside is under high pressure.
5. When the correct track tension has been measured, turn the relief valve clockwise to tighten
and then clean away all trace of expelled grease.
6. If the track fails to slacken after the grease fitting has been loosened, do not attempt to remove
the tracks or disassemble the track tensioner, or remove the grease fitting. It is possible that
running the tracks with the grease fitting loosened may help to expel the grease.
To Increase Track Tension [After measurement]:-
7. Connect the grease gun to the grease fitting and add grease until the track tension is within
the specified dimension, see ‘Measuring Track Tension’ and refer to lubricant and fluid
specifications.
Re-check Tension
8. Operate the machine in track mode and drive the machine 50 metres (50 yards) forwards
and 50 metres (50 yards) backwards, check track tension and repeat the above steps if it is
within the specified dimension, see ‘Measuring Track Tension’.
9. If room for manoeuvring the machine is restricted, drive the machine forwards and backwards
several times over a shorter distance.

Maintenance 9
(5) Gearbox Oil Level
nn WARNING
Dispose of oil safely and in a environmentally friendly manner.
NOTICE
Cleanliness is essential when checking, filling or replacing oil in the gearbox. Gearbox operating
life will be dramatically shortened if the oil becomes contaminated. Only use new clean oil in
clean containers and fillers.
The Gearbox should hold approximately 4 litres of oil, which should be filtered through a 10 micron
filter before entering the gearbox.
The gearbox oil should be Oil type SAE80W/90.
Checking and Filling Gearbox Oil
PROCEDURE
1. Move the machine to a level surface and bring the oil drain holes to the position shown.
2
DUN00017
Figure 9.10 - Gearbox Fill position
2. Ensure machine is switched off, locked out and tagged out. Remove ignition key, carry it
with you.
3. Thoroughly clean around both plugs removing all potential contaminants.
4. Remove both plugs.
5. Fill the oil through the upper hole (Item 1) until it runs out through the lower hole (Item 2).
6. Wait a few moments until any trapped air has escaped and then re-check the level.
7. Add more oil if necessary.

9 Maintenance
(6) Draining Gearbox Oil
nn WARNING
Do not move the machine any further until the gearbox oil has been replaced.
Dispose of oil safely and in a environmentally friendly manner.
NOTICE
Do not move the machine any further until the gearbox oil has been replaced.
PROCEDURE
1. Move the machine to a level surface and bring the oil fill (Item 1) and oil drain holes (Item
2) to the position shown.
2
DUN00016
Figure 9.11 - Gearbox Drain Position
with you.
3. Thoroughly clean around both plugs removing all potential contaminants.
4. Remove both plugs and allow the oil to drain. The oil will drain quickly if it is hot, however
care should be taken to avoid burns to the operator.
5. Move the machine to bring the plugs to the fill position shown.
6. Re-fill the oil as per the procedure.

Maintenance 9
9.9 Servicing the Electrical System
nn WARNING
Electrocution hazard.
(1) Check the Battery
NOTICE
In cold weather, distilled water should only be added immediately before starting the engine, to
prevent it freezing.
nn CAUTION
Always disconnect battery leads before carrying out any maintenance to the electrical system.
The battery contains sulphuric acid, electrolyte which can cause severe burns and produce
explosive gases. Avoid contact with the skin, eyes or clothing.
PROCEDURE
2. Ensure that all electrical connections are clean and tight and coat the terminals with petroleum
jelly to protect them from corrosion.
3. Remove the battery filler plugs and check that the electrolyte level is between 6 and 9 mm
(0.25 - 0.37 ins) above the tops of the separators.
4. If necessary, fill up with distilled water.
5. Where batteries have trough fillers, add distilled water to the filling trough until the trough
just begins to fill with water.

9 Maintenance
(2) Battery Removal
nn WARNING
nn CAUTION
Always disconnect battery leads before carrying out any maintenance to the electrical system.
The battery contains sulphuric acid, electrolyte which can cause severe burns and produce
explosive gasses. Avoid contact with the skin, eyes or clothing.

2. Ensure all electrical circuits are switched off.
3. Unlock battery bottom cover.
4. Remove battery box cover.
5. Disconnect the ground (-) lead from the battery.
6. Disconnect the positive (+) lead from the battery.
7. Lift the battery from the machine.
(3) Battery Installation
nn WARNING
PROCEDURE
2. Ensure all electrical circuits are switched off.
3. Lift the battery onto the machine.
4. Connect the positive (+) lead.
5. Connect the ground (-) lead.
6. Replace battery box cover.
7. Lock battery box cover.

Maintenance 9
(4) Changing Fuses
nn WARNING
PROCEDURE
1. Observe all safety warnings. Ensure machine is switched off, locked out and tagged out.
Remove ignition key, carry it with you.
2. For additional protection, disconnect both battery terminals.
3. Unlock fuse box at lock on front of control panel, turning one quarter revolution clockwise.
4. Identify which fuse is to be changed.
5. Grip fuse carefully using needle nose pliers or preferably with plastic fuse removal tweezers.
Figure 9.12 - Plastic Fuse Removal Tweezers
6. Check fuse to see if it is blown, a blown fuse should have a gap in the ampoule.
Figure 9.13 - Blown Fuse
7. Insert new fuse into fusebox.

8. Close fuse box , start machine and test if new fuse corrects original problem.

9 Maintenance
(5) Proximity Adapter

To install the proximity switch adapter, simply remove the proximity switch and connect the plug.
This plug will be coming with all electrical power unit kits and is to be stored in the toolbox when
it’s not required.
Figure 9.14 - Proximity Switch Adapter

Maintenance 9
9.10 Servicing the Hydraulic System
(1) General
nn DANGER
THIS IS A HIGH PRESSURE SYSTEM. Never carry out any maintenance work without ensuring
the hydraulic system is locked out and depressurised. Check the pressure gauges and control
screen, if fitted, to view the current system pressure. Open the bleed valve, if fitted, until all
pressure is relieved then close the valve. Do not amend the hydraulic system. In the event of
any problems these should only be dealt with by suitably experienced and qualified engineers.
nn WARNING
Injection hazard from high pressure fluid. Wear personal protective equipment.
NOTICE
All hydraulic functions are powered by pumps driven by the engine / electric motors.
All relief valve pressures are factory set and should not be adjusted on site.
The hydraulic fluid reservoir together with associated equipment must be maintained in accordance
with the set level and in the schedules and types, see General Routine checks, Specific checks,
Lubrication and Fluid Specifications. Only use a recommended fluid. Specific checks
(2) Hydraulic Fluid
nn DANGER
The air vents in the cap must be kept open to allow the hydraulic system to “breathe”.
Always use the correct grade of oil, otherwise overheating will occur. (Refer this Section, “lubricants
and fluids”)
If the hydraulic system requires filling up on a regular basis, all hydraulic parts and hoses should
be inspected for leaks. Any repairs should be made prior to continued operation of the machine.
ALWAYS practice extreme cleanliness when servicing.
nn WARNING
NOTICE
Check the fluid level on the gauge and top up as necessary.
It is essential when replenishing hydraulic fluid, attending to filters, etc. To apply the greatest
degree of cleanliness as it is most important that contaminants are not allowed to enter the system.
If hydraulic fluid needs to be added, to maintain the correct level, this should be pumped in through
the fill port on the large return filter.

9 Maintenance
(a) Check Hydraulic Oil Level
nn WARNING
PROCEDURE
2. Machine must be on level ground.
3. Always have the hydraulic oil at normal operating temperature.
4. Always have all cylinders retracted (where possible).
5. Check the level indicator (Item 2).
6. The oil level must be between the red and black marks on the gauge.
6
1
5
2
4 3
DUN00096
Figure 9.15 - Hydraulic Oil tank

Maintenance 9
(b) Adding Hydraulic Fluid
nn WARNING
nn CAUTION
Never overfill the hydraulic tank as this will cause leakage from the filler cap.
PROCEDURE
2. Machine must be on level ground.
3. Shutdown the machine and implement lock-out procedure.
4. Clean the area around the filler cap (Item 1).
5. Open the filler cap (Item 1).
6
1
5
2
4 3
DUN00096
Figure 9.16 - Hydraulic Oil tank
6. Fill the tank to midway between red and black marks on the level indicator. (The correct
grade of hydraulic oil, see Section “Lubricants and Fluids.”)

9 Maintenance
(c) Change Hydraulic Oil
nn WARNING
NOTICE
ALWAYS practice extreme cleanliness when servicing.
Before removing the drain plug (Item 3):
• Release any pressure in the hydraulic tank by slowly unscrewing the filler cap (Item 1).
• Ensure a suitable container is placed on the ground to catch the full capacity of oil in the tank.
• Remember to stand on one side to avoid oil which will spill from the drain hole.
Change the suction elements when an oil change is being carried out.
PROCEDURE
3. Always have all cylinders retracted (where possible).
4. Drain the tank by removing the drain plug (Item 3)..
5. Remove the cover plate under the filler cap (Item 1).
6. Discard the gasket.
7. Remove the suction filters (Item 4) by unscrewing them from the suction pipes, Reference:
“Changing Suction Filters”.
8. Flush out the tank with clean hydraulic oil taking extreme care to remove all dirt and foreign
matter.
9. Fit new suction filters (Item 4) to the suction pipes. Reference: “Changing Suction Filters”.
10. Re-fit cover plate to the tank using a new gasket and refit drain plug (Item 3).
11. Change the return line filter element.
12. Refill the tank with clean hydraulic oil to midway between the red and black marks on level
indicator. (Correct grade of hydraulic oil, see Section “Lubricants and Fluids”.)
13. Run the engine to circulate the oil.
14. Operate the hydraulic controls to purge any air from the system.
15. Stop the engine and implement the lock-out and tagout procedure.
16. Fill up the system as required.

Maintenance 9
(d) Changing Suction Filters
nn DANGER
Switch off and lockout. Relieve all hydraulic pressure before working at a machine.
High pressure hydraulic fluid can penetrate the skin causing serious injuries.
PROCEDURE
1. Turn engine off and return all control levers to the neutral position.
2. Open the filler cap (Item 1) to relieve any pressure inside the tank.
1
DUN01674
Figure 9.17 - Hydraulic Tank Inspection Plate & Filler Cap
3. Remove the bolts (Item 2) (Use a 17 mm spanner) holding the inspection plate (Item 3) down.
4. The suction filters are fitted to the inside of the inspection cover. To remove them lift off the
inspection cover.
5. Unscrew the filters (Item 4) from the internal suction pipes (Item 5) and replace with new
filters. Hand tighten the filters.
5
DUN01676
Figure 9.18 - Internal Suction Filters
6. Replace inspection covers and filler cap.

9 Maintenance
(3) Checking the Return Line Filter
nn WARNING
PROCEDURE
2. Always have the engine running at maximum speed.
3. Always have all hydraulic equipment working.
5. Check the return line filter (Item 1) blockage indicator.
6. Change the filter element immediately when the green sector of the blockage indicator goes
to red.
1 DUN00238
Figure 9.19 - Return Line Filter

Maintenance 9
(4) Changing the Return Line Filter
nn DANGER
Burn hazard. Wear personal protective equipment.
Injection Hazard. Hydraulic fluid under pressure can penetrate the skin causing serious injury.
Always use a piece of cardboard to check for leaks. Do not use your hand. If fluid is injected under
the skin, it must be surgically removed or gangrene will result.
PROCEDURE
with you.
3. Ensure all cylinders are closed (where possible).
4. Release any pressure in the hydraulic tanks by slowly unscrewing the filler cap.
5. Clean the outside of the filter housing. (Item 1).
6. Remove the filter by unscrewing the 4 securing nuts and removing cover.
7. Lift out the old element and discard it safely and responsibly.
8. Wash out the filter cap and dry with an air hose. DO NOT USE A RAG.
9. Re-fit new filter ensuring seal ring is in good condition and correctly positioned.
10. Fit cover and fasten 4 securing nuts.
1 DUN00238
Figure 9.20 - Return Line Filter

9 Maintenance
9.11 Tier 3 Engine Maintenance
(1) Changing Engine Filters & Oil

(See the engine Operators Manual for more detailed information regarding the Engine)
nn CAUTION
Hot surfaces. Beware of burns from hot oil.
(a) Checking Engine Oil
PROCEDURE
1. Turn off the engine. Open the engine inspection door (Item 1).
1
DUN01196
Figure 9.21 - Engine Inspection Door
2. Remove dipstick (Item 1, Reference: Figure 9.22) from the engine and clean. Re-insert the
dipstick fully.
1
2
DUN01197
Figure 9.22 - Engine view through inspection door
3. Remove the dipstick again and observe that the oil level is between the minimum and
maximum levels. If the level is below the minimum mark oil has to be added through the
filler cap (Item 2, Reference: Figure 9.22).

Maintenance 9
4. It is important the oil level is not above the maximum level. If this happens some oil must
be removed.
(b) Changing Engine Oil & Filter
PROCEDURE
1. Operate the engine to ensure the oil is warm, this enables the oil to flow more easily, also
when the oil is cool waste particles settle on the bottom of the oil pan and will not drain off.
2. Stop the engine and open the filler cap (Item 2).
3. Remove the drain plug located underneath the engine and drain the oil to an external container
large enough to hold all the oil.
1
DUN01198
Figure 9.23 - Engine Oil Filter
4. When all the oil has drained off replace the drain plug.
5. Loosen the Filter (Item 1) and dispose off properly. Replace the new filter and hand tighten.
6. Refill the engine with oil and dip the engine.

9 Maintenance
(2) Changing Fuel Filters
(a) Draining the Fuel Filter Water Trap
nn WARNING
Lock-out machine.
Diesel fuel is highly flammable.
Do not smoke or carry out maintenance on the fuel system near open flame or sources of sparks,
such as welding equipment, etc.
PROCEDURE
3. Unscrew the drain bung (Item 1, Reference: Figure 9.25) at the bottom of the water trap
(Item 2, Reference: Figure 9.24) and allow the water to drain out into a suitable container.
2 1
DUN01199
Figure 9.24 - Engine Oil Filters
4. Tighten the drain plug when pure diesel starts to come out.
5. Clean up any spilt diesel.

Maintenance 9
1
DUN01201
Figure 9.25 - Water Trap
(b) Changing Watertrap Filter

To change the watertrap filter element (Item 2, Reference: Figure 9.24) follow the procedure
outlined.
PROCEDURE
1. Stop the machine and turn the fuel supply off.
2. Remove the bleed.
3. Remove the filter& watertrap bowl.
4. Remove the watertrap bowl from the filter element.
5. Oil the watertrap bowl.
6. Attach new element to watertrap bowl.
7. Oil top of filter element.
8. Attach the filter element.
9. Prime the fuel system to fill the element and watertrap, and to remove air from the system.
10. Replace the bleed.

9 Maintenance
(c) Changing the Fuel Filters
nn WARNING
Lock-out machine.
NOTICE
Fill up the new fuel filter with diesel. This will make the restart of the machine easier.
PROCEDURE
2. Unscrew the fuel filter (Item 1).
DUN01200
Figure 9.26 - Engine Fuel Filters
3. Fill the new filters with diesel and fit into position.
4. Tighten the new fuel filter and o-ring.

Maintenance 9
9.12 Tier 4 Engine Maintenance
(1) Changing Engine Oil & Filters

(See the engine Operators Manual for more detailed information regarding the Engine)
nn CAUTION
Hot surfaces. Beware of burns from hot oil.
(a) Checking Engine Oil
PROCEDURE
1
DUN01191
Figure 9.27 - Engine Inspection Door
2. Remove dipstick (Item 1, Reference: Figure 9.28) from the engine and clean. Re-insert the
dipstick fully.
DUN01193
Figure 9.28 - Engine Oil Filler Cap & Dipstick

9 Maintenance
3. Remove the dipstick again and observe that the oil level is between the minimum and
maximum levels. If the level is below the minimum mark oil has to be added through the
filler cap (Item 2), Reference: Figure 9.28.
4. It is important the oil level is not above the maximum level. If this happens some oil must
be removed.
(b) Changing Engine Oil & Filter
PROCEDURE
1. Operate the engine to ensure the oil is warm, this enables the oil to flow more easily, also
when the oil is cool waste particles settle on the bottom of the oil pan and will not drain off.
2. Stop the engine and open the filler cap (Item 2).
3. Remove the drain plug located underneath the engine and drain the oil to an external container
large enough to hold all the oil.
1 DUN01194
Figure 9.29 - Engine Oil Filter
4. When all the oil has drained off replace the drain plug.
5. Loosen the Filter (Item 1) and dispose off properly. Replace the new filter and hand tighten.
6. Refill the engine with oil and dip the engine.

Maintenance 9
(2) Changing Fuel Filters
(a) Draining the Fuel Filter Water Trap
nn WARNING
Lock-out machine.
Never remove filler cap or refuel, with the engine running.
Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks.
PROCEDURE
3. Unscrew the drain bung (Item 1, Reference: Figure 9.31) at the bottom of the water trap
(Item 2, Reference: Figure 9.30) and allow the water to drain out into a suitable container.
1
2
DUN01192
Figure 9.30 - Engine Oil Filters
4. Tighten the drain plug when pure diesel starts to come out.
5. Clean up any spilt diesel.

9 Maintenance
1
DUN01201
Figure 9.31 - Water Trap
(b) Changing Watertrap Filter

To change the watertrap filter element (Item 2, Reference: Figure 9.30) follow the procedure
outlined.
PROCEDURE
1. Stop the machine and turn the fuel supply off.
2. Remove the bleed.
3. Remove the filter& watertrap bowl.
4. Remove the watertrap bowl from the filter element.
5. Oil the watertrap bowl.
6. Attach new element to watertrap bowl.
7. Oil top of filter element.
8. Attach the filter element.
9. Prime the fuel system to fill the element and watertrap, and to remove air from the system.
10. Replace the bleed.

Maintenance 9
(c) Changing the Fuel Filters
nn WARNING
Lock-out machine.
Never remove filler cap or refuel, with the engine running.
Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks.
NOTICE
Fill up the new fuel filter with diesel. This will make the restart of the machine easier.
PROCEDURE
2. Unscrew the fuel filters (Item 1).
DUN01195
Figure 9.32 - Engine Fuel Filters
3. Fill the new filters with diesel and fit into position.
4. Tighten the new fuel filter and o-ring.

9 Maintenance
(3) Servicing The DEF (Diesel Exhaust Fluid) System
nn WARNING
Hot Surface Hazard
Beware of hot DEF and surfaces.
DEF is corrosive and therefore must be stored in tanks constructed of approved materials. (Refer
to engine manual for more details)
Care should be taken when dispensing DEF. Spills should be cleaned immediately. All surfaces
should be wiped clean and rinsed with water.
DEF that has been split will crystallize when the water within the liquid evaporates. Split DEF will
attack paint and metal. If DEF is split, wash the area with water immediately.
Caution should be used when dispensing DEF near an engine that has recently been running.
Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe
ammonia vapors. Do not clean up any spills with bleach.
NOTICE
It is recommended that filter elements are not cleaned or reused but replaced with new items.
Do not run the engine with the filter elements removed.
Do not use agricultural grade urea solutions. Do not use any fluids that do not meet ISO 22241-1
requirements in SCR emissions reduction systems. Use of these Fluids can result in numerous
problems including damage to SCR equipment and a reduction in NOx conversion efficiency.
(a) DEF Tank Location
1
DUN01202
Figure 9.33 - Location of the DEF tank - Item 1

Maintenance 9
(b) Changing the Pump Main Filter
nn WARNING
Hot Surface Hazard
NOTICE
PROCEDURE
DUN01318
Figure 9.34 - Pump Main Filter Location - Item 1
1. Ensure that the area around the Diesel Exhaust Fluid (DEF) filter (Item 1) is clean and free
from dirt. The DEF filter threaded cap and the filter element area combined assembly.
Figure 9.35 - Pump Main Filter Parts

9 Maintenance
2. Remove the protective cover (Item 1). Remove the DEF filter assembly and discard the filter
assembly. Reference: Figure 9.35.
3. Install a new DEF filter assembly into DEF pump housing (Item 2).
4. Tighten filter assembly to a torque of 14N m (124lbin). Install the protective cover.
5. Turning on the power will automatically prime the DEF system.
(c) Changing the DEF Tank Filler Screen
nn WARNING
Hot Surface Hazard
NOTICE
PROCEDURE
DUN01327
Figure 9.36 - DEF Tank Remote Filter location
1. Ensure that the area around the DEF filler cap is clean and free from dirt (Item 1).

Maintenance 9
DUN01328
Figure 9.37 - DEF Tank Remote Filter parts
2. Unscrew the filler cap (Item 1).

3. Remove the filter (Item 2) by rotating it and lifting it out. Insert the new one.
»»Depending on the condition of the filter, it can be cleaned in water and dried out using compressed
air. If the filter screen cannot be cleaned or the filter screen is damaged, then the filter screen must
be replaced.
4. Replace the filler cap and screw it in place.

9 Maintenance
(d) Changing the DEF Manifold Filter
nn WARNING
Hot Surface Hazard
NOTICE
If contamination of the Diesel Exhaust Fluid (DEF) is suspected, the DEF tank will need to be
drained and the DEF tank flushed.
PROCEDURE
2
DUN01330
Figure 9.38 - DEF Tank Cover
1. Remove the 2 bolts (Item 1) securing the DEF Tank cover in place and remove the cover
(Item 2).
Figure 9.39 - DEF ManifoldDUN01329

Filter

Maintenance 9
2. Unclip the hoses and the sensor from the top of the DEF Manifold (Item 1), Reference:
Figure 9.40.
3. Remove the 2 screws securing the Manifold to the top of the tank and lift it out.
Figure 9.40 - DEF Manifold Filter
4. Remove the filter (Item 1) and replace with a new one.

5. Insert the Manifold back in to the tank and secure in place with the 2 screws.
6. Reattach all the hoses and the sensor.

9 Maintenance
(e) DEF Tank Flush
nn WARNING
Hot Surface Hazard
NOTICE
If contamination of the Diesel Exhaust Fluid (DEF) is suspected, the DEF tank (2) will need to be
Ensure that the vessel that will be used is large enough to collect the fluid to be drained.
Dispose of the drained fluid in accordance with local regulations.
PROCEDURE
1
DUN01332
Figure 9.41 - DEF Drain Plug
1. Ensure that the purging of the DEF system has been completed.
2. Position a suitable vessel below the drain plug (Item 3). Remove the tank filler cap.
3. Remove the drain plug and allow the fluid to drain.
4. Remove the Manifold (DEF Header) (Item 1) after draining the fluid.

Maintenance 9
5. Install the drain plug (Item 3). Tighten the drain plug to a torque of 6N·m (53lbin). Remove
the vessel used for draining.
6. Reinstall the Manifold in to the tank.
7. Refill the DEF tank.
(f) Filling the DEF Tank
nn WARNING
Hot Surface Hazard
NOTICE
If contamination of the Diesel Exhaust Fluid (DEF) is suspected, the DEF tank will need to be
Before filling the DEF tank, ensure that the DEF lines have been purged. Purging of the DEF
lines will take place, after the engine has stopped. Only after purging the DEF lines should the
DEF tank be filled. For more information on the time taken for purging the DEF lines, refer to the
Engine Operation and Maintenance Manual.
Ensure that the tank is full before starting work.
Do not over fill the tank. The DEF will require room for expansion.

9 Maintenance
PROCEDURE
DUN01333
Figure 9.42 - DEF Tank Filler Cap
1. Ensure that the DEF cap (Item 1) and the surrounding area is clean and free from dirt. Ensure
that all equipment used in filling the tank is clean and free from dirt.
2. Remove the DEF filler cap.
3. Fill the tank with the required amount of DEF. Ensure that dirt is not introduced into the tank
during filling.
4. Reinstall the DEF filler Cap.
5. Visually inpect the DEF tank for any signs of leakage.

Maintenance 9
9.13 Inspecting the Clean Emissions Module Supports
nn WARNING
Hot Surface Hazard
Beware of hot surfaces on and around the engine.
PROCEDURE
DUN01336
Figure 9.43 - Power Unit Inspection Door
1. Open the Power Unit inspection door (Item 1) to gain access to the rear of the Clean Emissions
Module.
Figure 9.44 - Clean Emissions Module Mounts
2. Inspect mounts (Items 2) for wear or damage.

9 Maintenance
1
DUN01191
Figure 9.45 - Power Unit Inspection Door
3. Open the Power Unit inspection door (Item 1) to gain access to the front of the Clean
Emissions Module.
DUN01334
Figure 9.46 - Clean Emissions Module Mount
4. Inspect mounts (Item 1).

5. If wear or damage is found the mounts must be replaced.
»»Contact your local dealer for more information on how to replace these..

Maintenance 9
9.14 Changing Air Filters
(1) Air Filtration

The air required to run the engine is inducted into the engine after passing through a filtration
system. As air passes into the breather system it is initially met by the first filter known as the
precleaner. This removes the heaviest of the dust, some of which escapes through a vent at the
bottom or at the back of the precleaner.
The air then passes through the outer filter which removes more dust and then finally the air
passes through the inner air filter. This filtration system removes virtually all the dust being
inducted into engine.
(2) Check Both Air Cleaner Elements
NOTICE
It is recommended that air cleaner elements are not cleaned or reused but replaced with new items.
Do not run the engine with the cover (Item 3) removed.
PROCEDURE
2. Ensure machine is switched off, locked out and tagged out, Remove the ignition key and
carry it with you.
3. Release the tension clips (Item 4) at side of the outer cover (Item 5).
4. Remove the outer cover.
5. Carefully remove outer filter (Item 3) and inner filter (Item 2).
6. Discard the elements if they are distorted.
7. Hold each element up to the light to check for damage to the paper. The elements should
be discarded if pin pricks of light can be seen or if there are areas of paper that appear thin.
8. Refit new or existing elements as required.
3
5
DUN00101
Figure 9.47 - Air Cleaner Elements

9 Maintenance
(3) Changing the Air Cleaner Elements
NOTICE
It is recommended that air cleaner elements are not cleaned or reused but replaced with new items.
Do not run the engine with the filter cover (Item 3) removed.
If the outer element has not been changed for 500 operating hours, a leak in the induction system
must be suspected. Check that the air cleaning casing and hoses to the engine are not damaged.
Check that all hose connections are airtight.
PROCEDURE
carry it with you
3. Release the tension clips (Item 4) at the side of the cover (Item 5).
4. Remove the cover (Item 5).
5. Carefully remove the outer filter (Item 3), minimizing the amount of dust spilled.
6. Remove the inner element (Item 2).
7. Clean the inside of the air cleaner casing using a damp, lint free cloth.
8. Fit a new inner filter element (Item 2).
9. Fit a new outer filter element (Item 3).
10. Replace the outer cover (Item 5) and fasten the tension clips (Item 4).
3
5
DUN00101
Figure 9.48 - Engine Air Filter

Maintenance 9
9.15 Coolant System

(a) Topping up Coolant Level
Refer to Engine Manual for Fill and Bleed procedures.
DUN02075
Figure 9.49 - Engine Inspection Doors
PROCEDURE
1. Turn off the engine.
2. Carefully open the radiator cap (Item 1) through the hole located on top of the power unit.
3. Fill the radiator with coolant.
4. Check the indicator on the control panel to ensure the indicator is no longer illuminated.

9 Maintenance
9.16 Priming the Fuel System
(1) Electic Fuel Pump Priming
nn WARNING
NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool
for two minutes before cranking again.
If air enters the system, the air must be purged from the fuel system before the engine can be
started.
Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure
is not required.
After the engine has stopped, you must wait for 60 seconds in order to allow to allow the fuel
pressure to be purged from the high pressure fuel lines before any service or repair is performed
on the engine or fuel lines.
PROCEDURE
1. Ensure the fuel system is in working order and that the fuel supply is switched on.
2. Turn the ignition key to the ‘ON’ position (Item 2).
3
DUN00001
Figure 9.50 - Key Positions
3. This allows the electric priming pump to operate. Operate the electric priming pump. The
ECM will stop the pump after 2 minutes.
4. Turn the ignition key to the ‘OFF’ position (Item 1). The fuel system should now be primed
and the engine should be able to start.
5. Turn the ignition key to the crank position (Item 3)

Maintenance 9
6. After the engine has started, operate it at low idle for a minimum of 5 minutes, immediately
after the air has been removed from the fuel system. This will help ensure that the fuel
system is free of air.
7. Ensure that the fuel system is free of leaks.
(2) Manual Fuel Pump Priming
nn WARNING
NOTICE
for two minutes before cranking again.
If air enters the system, the air must be purged from the fuel system before the engine can be
started.
Do not loosen the high pressure fuel line in order to purge air from the fuel system. This procedure
is not required.
After the engine has stopped, you must wait for 60 seconds in order to allow to allow the fuel
pressure to be purged from the high pressure fuel lines before any service or repair is performed
on the engine or fuel lines.
PROCEDURE
1. Ensure the fuel system is in working order and that the fuel supply is switched on.
4
TIRC00592
Figure 9.51 - Fuel Priming Pump
2. Operate the fuel priming pump (Item 2). Count the number of operations of the priming pump.
After 100 depressions of the priming pump, stop.
3. The fuel system should now be primed and the engine should be able to start.
4. Turn the ignition key to the crank position.

9 Maintenance
5. After the engine has started, operate it at low idle for a minimum of 5 minutes, immediately
after the air has been removed from the fuel system. This will help ensure that the fuel
system is free of air.
6. Ensure that the fuel system is free of leaks.
(3) Fuel System Prime (Tier 3 CAT4.4 83KW Mechanical Engines)

If air enters the fuel system, the air must be purged from the fuel system before the engine can
be started. Air can enter the fuel system when the following events occur:
• The fuel tank is empty or the fuel tank has been partially drained.
• The low pressure fuel lines are disconnected.
• A leak exists in the low pressure fuel system.
• The fuel filter is replaced.
nn CAUTION
NEVER leave your product unattended whilst it is in operation.
Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap
or refuel, with the engine running. NEVER add gasoline, petrol or any other fuel mixes to diesel
because of increased fire or explosion risks.
DO NOT smoke while refilling or carrying out maintenance on the fuel system.
DO NOT carry out maintenance on the fuel system near naked lights or sources of sparks, such
as welding equipment.
NOTICE
Unless the cause of the air in fuel has been rectified, it is likely that any replacement fuel injection
pump will have a problem in a short space of time. Ensure that the source of the air leak in the
fuel system has been located and rectified. Ensure that the fuel system has been primed in order
to ensure that there is no trapped air in the fuel system.
The fuel injection pump can be damaged by trapped air.
Air that is present in the fuel can collect in the fuel injection pump. If the hydraulic damping for
the fuel is not effective the movement of the automatic advance piston is uncontrolled. This can
damage the cover plate, the O-ring seal and the fasteners. Investigations have shown that this
can lead to fuel leaks. In extreme cases, the advance piston travel can shear the cover screws.
Problems can occur within a few hours of the start up of the engine, depending on the duty cycle
and the amount of air in the fuel.
for two minutes before cranking the engine again.

Maintenance 9
Use the following procedure to remove air from the fuel system.
PROCEDURE
1. Turn the keyswitch to the RUN position.
2. Leave the keyswitch in the RUN position for three minutes. If a manual purging screw is
installed, the purging screw should be slackened during priming the fuel system.
3. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
4. If necessary, loosen the union nuts (1) on the fuel injection lines at the connection with the
fuel injector until fuel is evident. Stop cranking the engine. Tighten the union nuts (1) to a
torque of 30 N•m (22 lb ft).
Figure 9.52 - Union Nuts
5. Start the engine and run the engine at idle for one minute.
6. Cycle the throttle lever from the low idle position to the high idle position three times. The
cycle time for the throttle lever is one second to six seconds for one complete cycle.
7. In order to purge air from the fuel injection pump on engines with a fixed throttle, the engine
should be run at full load for thirty seconds. The load should then be decreased until the
engine is at high idle. This should be repeated three times. This will assist in removing trapped
air from the fuel injection pump.
8. Check for leaks in the fuel system.

9 Maintenance
9.17 Fuel Level and Topup

nn DANGER
NEVER leave your product unattended whilst it is in operation.
Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap
or refuel, with the engine running. NEVER add gasoline, petrol or any other fuel mixes to diesel
because of increased fire or explosion risks.
DO NOT smoke while refilling or carrying out maintenance on the fuel system.
DO NOT carry out maintenance on the fuel system near naked lights or sources of sparks, such
as welding equipment.
NOTICE
Ultra low sulfur diesel must be used in machines with CAT Tier 4 engines.
The use of fuel additives is not recommended. Additives may not be compatible with the fuel.
Do not fill the tank to overflow or full capacity.
Allow room for expansion and wipe up spilt fuel immediately.
PROCEDURE
2. Check the fuel level gauge / indicator.
3. Clean the area around the filler cap.
4. Remove the filler cap (Item 1) and top up fuel level as required with specified diesel fuel.
Refer to the engine manufacturer’s operation manual.
5. Preferably re-fuel at the end of each day where possible, to reduce overnight water
condensation within the tank.
6. Replace the filler cap and close the door if applicable.
7. If required, switch on the ignition briefly to check the fuel gauge.
1
DUN02078
Figure 9.53 - Diesel Tank

Maintenance 9
9.18 Removing the Screenbox
nn WARNING
Use suitable lifting equipment capable of lifting the parts in question.
NOTICE
Before removing any part from the machine ensure that the weight of the component is supported
with suitable lifting equipment.
Prior to removing the screen, the plant should be in full working position but with the feeder
retracted. The screen should be placed at 10 degrees which is the standard working angle on
the Triple Shaft screen.
Ensure all hoses and motor ports are plugged once disconnected.
When changing out the Triple Shaft screen box to a Spaleck or Single Shaft box it is necessary
to replace the proximity switch with the blanking plug adaptor. This gives the screen the ability to
work through its full range of angles.
Do not stand under suspended loads.
PROCEDURE
1. Disconnect the screen drive and case drain hoses from the screen motor, there are three in
total, Reference: Figure 9.54.
DUN01853
Figure 9.54 - Location of hoses
2. If the screen chain blanket is in place, next remove same (fastened in three locations).
Ensure the folding support is fastened in working position (as per Figure 9.55) the included
lifting eyes are to be used.

9 Maintenance
DUN01854
Figure 9.55 - Chain Blanket on Triple Shaft
3. Retract the snubber assemblies and then remove. (Note that the Spaleck screen does not
use snubbers)
DUN01859
Figure 9.56 - Screen Snubbers on Single Shaft
4. Using the four lifting points and a suitable brace/hoist, remove the screen and lower it to a
suitable surface of keeping.
DUN01856
Figure 9.57 - Lifting Points

Maintenance 9
(1) Replacing the Screen

1. Using the same lifting points on the Spaleck screen and a suitable brace/hoist, fit the screen
and replacement springs to the Warrior 2100 sub-frame. (Note that there two spring sets,
one set for the Triple Shaft screen and a separate set which is used for both Single Shaft
and Spaleck screens.)
»»When changing out the Triple Shaft screen box to a Spaleck or Single Shaft box it is necessary to
replace the proximity switch with the blanking plug adaptor. This gives the screen the ability to work
through its full range of angles.
DUN01877
Figure 9.58 - Spaleck screen
2. Replace the screen chain blanket (if required).

3. Reconnect the screen drive hoses.
4. Adjust the screen speed to the range identified on the screen side (adjustment position 1
Figure 9.59).
4 1
DUN01857
Figure 9.59 - Adjusting screen speed
5. Adjust the screen speed to 910 – 930RPM range (adjustment position 1).
6. Run the screen for 60 minutes before re-checking the screen speed and adjusting if necessary.

9 Maintenance
9.19 Screen Unit Maintenance
nn WARNING
Nip hazard.
Fall Hazard.
(1) Daily Maintenance
nn WARNING
NOTICE
Do not allow breather caps to plug. Clean filter regularly. Running screen with plugged breathers
risks damage to driveshaft seal, case covers and bearings.
When servicing the machine prior to raising the screen into working position, the screen anchor
system is to be un-fastened. Once returned to working position the screen is to be placed in its
lowest working angle before applying the anchor. Thereafter, the securing bolt is to be affixed
and the assembly tightened to restrain the screen. After initial tightening the screen angle can be
adjusted to the required angle.
After initial tightening, run the screen for 10 minute and re-tighten at the anchor position.
Figure 9.60 - Screen Unit

Maintenance 9
Before starting the screen each day, check the following items;
PROCEDURE
1. Check oil level in gear and impulse cases. Unscrew oil level plugs in case covers to see that
oil reaches the holes.
2. Check breather cap on both impulse and gear case covers. Keep dirt build-up away from
breather caps.
3. Check condition of the top discharge lip wear plates. Note excessive wear in your equipment.
Log and replace worn parts as soon as possible.
4. Check screen media for holes or excessive wear.
5. Keep wire cloth taut. Tighten new wire cloth as needed after one or two days of operation.
6. Make sure springs are vertical. If not, remove any rock or dust build-up.
7. Inspect drive assembly for signs of drive-belt stretching or cracking. Note; excessive wear
in your log book and if required replace belt as soon as possible.
8. Make sure all guards are in place and in good condition.
*Note 4 & 5 for mesh/punch plate deck only*
1
2
3
4 5 6
Figure 9.61 - Screen Unit Daily Checks
1 Breather cap clean

2 Oil level correct
3 Screen condition
4 Belt condition
5 Wear plate integrity
6 Springs vertical

9 Maintenance
(2) Weekly Maintenance
NOTICE
For proper operation, centre screen box as follows:
• Measure clearance between snubber housing and snubber plates on screen box at each of the
two snubber locations.
• Clearance measurements at each of the snubbers should come within 5 mm of being identical.
Where difference is greater, adjust snubbers to bring it within spec.
• Loosen jam nut on each snubber adjusting bolt. Turn bolts in or out, as needed, to centre screen
basket between snubbers.
Purpose of final tightening is to force snubbers firmly against snubber plates. As you perform final
tightening, be sure the screen box isn’t pulled off-centre
On a weekly basis it is required to perform the following tasks:
PROCEDURE
1. Make sure screen box is level crossways and cantered in base frame. Adjust snubbers as
necessary. If snubber adjusting screws are turned all the way in and adjustment is no longer
possible, install new snubber rubbers.
2. Make sure springs are vertical. If not, remove any rock or dust build-up.
3. Clean breather cap and area around it. Do not allow dirt or abrasives to enter oil-fill port.
4. Inject grease into oil-seal barrier ring once each week, or as required based on operating
conditions.
5. With hand-operated grease gun, pump about five shots of grease into grease fitting on oil-
seal barrier ring. Use grade 2, high temperature, lithium-base grease. Wipe extruded grease
from oil seal housing.
6. Application of new grease forces old grease, along with dust and moisture, out through the
labyrinth seal. As a result, the seal has a clean, protective grease barrier that is renewed
each week.

Maintenance 9
1
2
3
4 5
Figure 9.62 - Screen Unit Weekly Checks
1 Screenbox level and centred correctly

2 Springs aligned
3 Breather cap clean
4 Grease oil-seal barrier ring
5 Snubbers tight to screenbox
Figure 9.63 - Screen Unit Maintenance
1 Barrier ring
2 Grease fitting
3 Extruded grease
4 Gear case cover
5 Oil-seal housing
6 Oil-seal
7 Grease
8 Gear side of drive shaft

9 Maintenance
(3) Snubber Rubber Maintenance
nn WARNING
Nip hazard.
Fall Hazard.
NOTICE
Snubber Rubbers must have a clearance of 5 mm at all times.
Both Snubber rubber spacing and condition must be checked on a weekly basis.
PROCEDURE
2. Ensure machine is switched off, locked out and tagged out. Remove the ignition key and
carry it with you.
3. There are Snubber Rubbers that require maintenance, located on either side of the screenbox.
4. The Snubber Rubbers must have a clearance of 5 mm from the screenbox. If this clearance
is incorrect it can be adjusted.
5. The four bolts on the snubber rubber frame can be adjusted to allow the snubber rubbers to
move up and down. The sub frame mounts allow the snubber rubbers to move in and out.
6. Adjust these when necessary to allow for optimal performance.

Maintenance 9
(4) Lubrication
nn WARNING
NOTICE
Do not fill above oil-level holes on case covers. Too much oil causes heat buildup and does not
improve lubrication. Too much heat can cause early breakdown of oil, and bearing failure.
Regular oil changes and professional oil sample analyses are among the most important
maintenance practices for your vibrating screen.
Change oil in both cases if you have any of the following conditions:
1 Oil is dirty
2 Warrior operated 500 hours since last oil change
3 Oil sample shows high contaminant levels
Terex recommends a professional oil-sample analysis after every 500 hours of operation. If
contaminant levels exceed any of those listed in the table, change oil in cases and find source
of contamination.
Table 9.7 - Contaminant Levels

Contaminant Acceptable Range (ppm)
Iron 125-150
Chrome 25-30
Aluminium 45-50
Copper 100-125
Silicon 25-30
Water 0
To Change oil, follow the procedure below:
PROCEDURE
1. Remove oil-level plugs from case cover and lay them aside for now.
2. Remove magnetic drain plug from bottom of each case and drain used oil into containers for
recycling. Magnetic plugs help prevent damage to gears and bearings by attracting metal
particles in oil. Look carefully at plugs to see if metal particles are present.
3. When oil has drained completely, clean drain plugs and reinstall them in bottoms of cases.
4. Clean area around breather caps. Be sure fill openings are thoroughly cleaned before oil is
added. Use only clean containers and tools. Do not allow dust, dirt or abrasives to enter case.
5. Add the recommended oil at fill ports. Use only high-quality oil and never mix different brands
of oil. Fill cases up to oil-level holes. Stop when oil reaches holes. Do not add oil with oil
level plugs installed. Doing so may cause you to underfill or overfill.
6. Clean and replace oil-level plugs and breather caps on both cases. Tighten plugs and caps
securely.

9 Maintenance
Figure 9.64 - Oil Plugs
1 Oil level plug

2 Drain plug
Table 9.8 - Lubricant Brand Name & I.S.O. Grade

Lubricant Brand Name & ISO Grade
Ambient Temp 4° to 35°C Ambient Temp - 18° to 18°C
AMOCO Industrial Oil 220 Industrial Oil 150
CHEVRON AW Machine Oil 220 AW Machine Oil 150
EXXON Teresstic 220 Teresstic 150
MOBIL DTE Oil BB DTE Oil Extra Heavy
SHELL Morlina S2 B 220 Morlina S2 B 150
TEXACO Regal R & O 220 Regal R & O 150
If ambient temperature exceeds 95° F, then ISO Grade 320 should be used.
Flushing Oil: Use ISO viscosity grade 46 lubricant.

Maintenance 9
(5) Bearing Temperature

Because shafts are subject to continual stress, it is important to check bearing temperatures
periodically.
Because heat from bearings transfers to the oil, you can get a rough idea of average bearing
operating temperature by monitoring oil temperature. Place a magnetic-type thermometer on
case cover below level of oil-fill plug. During normal operation, temperature of case covers will
average 50° to 80°C.
If oil temperature reaches 90°C or higher, bearings are overheating. Find cause and correct
problem before serious damage occurs.
The most common cause of overheating is excessive lubricating oil. This often occurs when
the screen is new or immediately after changing lubricant. Make sure oil level is correct. Other
causes of overheating include;
1 Wrong type or grade of oil. Always use recommended lubricant.
2 Screen is operated faster than recommended speed. Make sure you have correct number of
plug weights for your screen size and application.
3 Screen Box is not level. Keep screen level crosswise at all times during operation.
Overheating may be a sign that the bearings are beginning to fail. Inspect the bearings for wear.

9 Maintenance
(6) Screen Tuning Single and Triple Shaft
(a) Aspects of Stroke Adjustment

The stroke of a Warrior screen has three aspects. All three are adjustable;
1 Stroke length (amplitude)
2 Stroke speed (frequency)
3 Stroke angle (timing)
Note: Stroke angle relative to gear case.
All are important for getting maximum value from your screening operation. Proper adjustment for
screening conditions you may encounter helps you get the highest output from your equipment.
Generally, coarse material requires a longer, more horizontal stroke and slower speed. For
separating fines, a shorter, more vertical stroke and higher speed are more efficient.
Below are guides to determine optimum settings for your operating conditions. Your actual
measured stroke may vary slightly from the standard due to differences in screen size, type of
material or other factors related to your equipment setup and environment.
The stroke gauge shipped with new Warrior helps you identify stroke length and angle when your
screen is operating. A stroke gauge is a flexible magnetic sheet you can attach to the side plate
of your screen. The gauge has a series of circles, varying in diameter from 5 to 22 mm (3/16 to
7/8 in), with which to determine stroke length. Straight lines on the gauge identify stroke angle.
Figure 9.65 - Available Stroke Angles (Adjustable in 5 degree increments
Table 9.9 - Screen Settings

Settings Length Speed Angle
Scalping Full Slow 35° to 45°
Medium size material Medium Medium 40° to 50°
Fine screening Short Fast 45° to 60°

Maintenance 9
Table 9.10 - Stroke Adjustments (Note: Oval lengths dependant on screen media fitted)
Material Stroke
Length Oval/Weights Speed Angle
(degrees)
Coarse 16 mm    740 Slow 35 to 45
Medium 14.73 mm    785 Med 40 to 50
Fine 13.72 mm    830 Fast 45 to 50
Extra Fine 12.7 mm    875 Very Fast 45 to 60
Figure 9.66 - Vibrating Equipment Gauge
You can move the magnetic sheet anywhere on the screen’s side plates to measure screen action
at that location. Under normal operating conditions, the gauge reads the same from one side of
the screen to the other but may vary from feed end to discharge end. Readings may also vary
due to size of screen, amount of material being screened or other conditions.
The term “stroke length” refers to the maximum distance any point on the screen’s side plate
moves during operation. As the screen vibrates, each point follows an oval-shaped path. The
length of that oval is the stroke length. One way to determine stroke length is to make a dot on
one side plate and use a ruler to measure the long axis of the oval orbit the dot follows during
operation. An easier and more accurate method is to “read” circles on the stroke gauge. Screen
motion causes each circle on the gauge to look like two circles blurred together.
Figure 9.67 - Stroke Length

9 Maintenance
Circles best representing actual length of your screen’s stroke appear to touch at their inner edges
(Oval A). Ignore ovals where circles appear separated (measurement too small) or overlapping
(measurement too big). After identifying the best match, note location of circle and read the
dimension for that circle.
Figure 9.68 - Touching Circles Indicate Stroke Length
A Best match - edges of circles touching

B Measurement too small
C Measurement too big - circles overlapping
D Stroke Angle
An imaginary line drawn through the oval at its greatest length indicates direction of stroke. The
angle formed by that line and the horizontal plane is the stroke angle of your screen. Lines on
upper part of stroke gauge show possible stroke angles. During operation, the sharpest line on
the gauge matches the screen’s stroke angle. Other lines blur more as they deviate from the
true angle.

Maintenance 9
(b) Stroke Length
nn WARNING
Always lock out power source before cleaning, adjusting, performing maintenance or repairs.
Make it impossible for anyone to start the machine while others work in it or on it. Failure to do
so may result in severe personal injury or death.
NOTICE
It is not necessary to remove case cover to change stroke length. For coarse screening or
scalping use a stroke length of approximately 16mm by installing all three plug weights in each
weight disc. For screening finer material, use smaller stroke length of between 12.7-13.72 mm
by removing plugs from discs.
Never operate screen when plug-weight arrangements on gear and impulse sides are not identical.
Weight changes on one side of screen must be matched on opposite side to maintain operational
equilibrium. Operating screen with unbalanced plug-weight arrangement may void warranty.
Stroke length is controlled by the imbalance of six weight discs relative to the weight of the screen
box plus any material in it. Thus alteration of shaft speed will not alter stroke length. Stroke length
can only be changed by changing the degree of imbalance. The vibrating mechanism in the Warrior
has three removable plug weights (plugs) for each of six weight discs. Purpose of the plugs is to
vary length (amplitude) of stroke according to needs of your operation. Figure 9.69 shows gear
& weight-disc assemblies with case cover removed.
Figure 9.69 - Gear and Weight Disc Assemblies

9 Maintenance
To adjust stroke length:
PROCEDURE
1. Remove the belt guard. Do not remove belt or driven sheave.
2. Remove timing cover to access gear-side centre weight disc.
»»An opening has been provided in the single shaft belt drive cover to allow for timing readings to be
made.
Figure 9.70 - Timing Cover Removed
3. Remove inspection plates on remaining two gear-side and three impulse-side weight discs.
Figure 9.71 - Inspection Plates Removed
4. On any weight disc, remove one of two cap screws that hold the plug-retaining strap. Loosen
the other cap screw, but leave it in place to keep retaining strap from falling down behind
case cover.

Maintenance 9
Figure 9.72 - Retaining Straps Loosened
5. Remove or insert plug weights as needed. Configuration must be the same on all discs,
gear side and impulse-side. For easy handling of plugs, use cap screw from retaining strap
as finger knob.
6. Reposition plug-retaining straps and secure with cap screws. Use thread-locking compound
on cap-screw threads. When all discs are adjusted and plug weights secured, replace timing
cover and inspection plates after applying silicone sealer around case cover bolt holes and
in an unbroken bead between holes. Replace belt guard
(c) Stroke Speed
NOTICE
Load on bearings increases dramatically at speeds higher than that necessary for efficient
operation. Operate at the lowest shaft speed that efficiently screens your material, because
doing so extends bearing life.
Do not start or stop Warrior screen slowly! Always start and stop your screen quickly. Start-up
time of 4 to 10 seconds is best.
Stroke speed (also called screen speed or stroke frequency) is the easiest stroke adjustment to
make and may significantly increase screening efficiency. Terex fits each Warrior screen with
an adjustable speed flow control valve. To increase the speed turn the control dial in the anti-
clockwise direction and to decrease the speed turn in the clockwise direction.
Speed control allows you to operate at optimum screening efficiency and lowest operating cost.
Centrifugal forces cause greater bearing load at higher speeds. Bearing life varies inversely with
the cube of load. This means that relatively small increases in rpm can greatly reduce bearing
life, increasing your operating cost.
A screen’s shaft, locking assembly and/or gears can be damaged if screen comes to operating
speed slowly. Possible causes of slow starts are weak motor, worn drive belt, worn sheaves, oil
too thick or worn belt-tensioner.
Under most conditions, fine material screens more effectively with a faster, shorter stroke. Coarse,
heavy material screens better with a slower, longer stroke.

9 Maintenance
(d) Stroke Angle
nn WARNING
Always lock out power source before cleaning, adjusting, performing maintenance or repairs.
Make it impossible for anyone to start the machine while others work in it or on it. Failure to do
so may result in severe personal injury or death.
Keep hands away from gears as you remove key bolt. Gear assembly will sometimes swing
down into neutral position when key bolt is removed. Failure to heed this warning could result in
crushed fingers, hands, or other severe personal injury.
If weight disc has not swung free yet, it will when struck with a hammer.
NOTICE
It is possible to set a screen too flat, causing a decrease in conveying velocity.
Terex ships a timing wrench with each new machine. You can also buy timing wrenches from
Terex distributors.
Before welding, attach grounding clamp to weight disc next to key bolt. This prevents arcing through
bearings or gear teeth. When welding lock washer to key bolt, protect gears from weld spatter.
Do not neglect to bend key-bolt lock washer tab as shown. If key-bolt lock is not used, serious
damage to screen could result and warranty may be void.
Terex normally ships Warrior screens with stroke angle set at 45°, acceptable for most applications.
Stroke angle is adjustable from 30° to 60° in 5° increments, determined by notches on inner edge
of centre drive gear.
Adjusting stroke-angle timing changes rate of material flow across decks. A larger, more vertical
angle moves material across screen more slowly and is usually best for separating fines. A more
horizontal angle moves material faster by thrusting it farther forward with each stroke. Flatter
angles are better for screening coarse material.
With screen timed between 45° and 60°, material is not conveyed as rapidly as when screen is
timed between 30° and 45°. Flatter, less vertical angles decrease bed depth and reduce possibility
of material travelling the length of the deck without falling through the wire cloth.w
The best stroke angle for your equipment is based on several factors;
1 Weight of the material
2 Moisture content
3 Clay content
4 Amount of natural fines
5 the way material shatters (friability)
6 thickness of the bed of material on deck
Priorities for specific jobs influence choice of stroke angle, too. For example, if volume of material
across the screen is more important than efficiency of screening action, a 35° stroke angle can
increase flow across the screen. If more efficient screening action is desired and volume is less
critical, a more vertical stroke of 50° can be used.
Figure 9.65 shows vibrating mechanism from gear side of screen. Case cover is removed for
clarity and each shaft is numbered. The other side of the screen, the impulse side, looks similar
except it has no gears. Shaft No. 1 is always the drive shaft and is at discharge end of screen.

Maintenance 9
Figure 9.73 - Gear-Side Vibrating Mechanism
Power is applied to No. 1 shaft through driven sheave, which turns clockwise as viewed from
gear side of right-hand drive screen. No. 1 gear pulls Nos. 2 and 3. All turn at the same speed.
Because No. 1 and No. 2 gears mesh, No. 2 turns counter to No. 1, while No. 2 drives No. 3 in
same direction as No. 1.
Twice every revolution, weights on all six discs are “in phase”. When in phase, momentum of all
six weights adds together as indicated by the large arrows (positions A and C). Their combined
momentum hurls the screen basket back and forth on long axis in oval motion described by
Figure 9.74.
When weights attached to shaft No. 2 turn 90° past A and C positions, weights are in positions
shown in B or D and are “out of phase.” When weights are out of phase, momentum of weights
on shaft No. 2 is subtracted from momentum of weights on shafts 1 and 3 and causes short axis
of oval stroke.
Figure 9.74 - Screen Basket Travel Diagram
A key bolt locks stroke-angle adjustment on centre weight disc. The bolt holds the disc at a specific
notch on inner edge of gear.
A key-bolt lock washer prevents key bolt from working loose during screen operation. The lock
washer is welded to the key bolt. Then tab end of lock washer is bent into a hole on the gear,
ensuring that key bolt never loosens.
Notches in centre gear are used to time weights and thereby change stroke-angle adjustment.
Figure 9.75 shows key bolt in 45° timing notch.

9 Maintenance
3 2 1
TIRC00158
Figure 9.75 - Shaft and Weight Rotation = Resulting Basket Motion
• Position A - Starting position in cycle*

• All 6 weight discs in phase.
• Weights on all shafts add together.
• Position B - Shafts turned 90°
• No.2 out of phase with No.1 & No.3.
• Weights on shaft No.2 subtract from total of No.1 & No.3.
• Position C - Shafts turned 180°
• All 6 discs in phase again.
• Weights on all shafts add together.
• Position D - Shafts turned 270°
• No.2 out of phase with No.1 & No.3.
• Weights on shaft No.2 subtract from total of No.1 & No.3.
* During operating cycle. The weights are not in this upward position before start-up.

Maintenance 9
Figure 9.76 - Key Bolt in 45° Timing Notch
To change timing angle:
PROCEDURE
1. Lock out power source.
2. Remove timing cover.
Figure 9.77 - Remove Timing Cover
3. Pry up tab on key-bolt lock washer.

9 Maintenance
Figure 9.78 - Key Bolt Lock Washer
4. Loosen key bolt. Keep hands away from gears. Carefully remove key bolt.
Figure 9.79 - Remove Key Bolt
5. Keep hands clear. Loosen counterweight bolts to allow weight disc to slide freely around gear.
Figure 9.80 - Loosen Counterweight Bolts

Maintenance 9
6. Occasionally gear & weight-disc assembly freezes up and does not swing down to rest position
unaided. If that occurs, tap counterweight bolt with hammer to separate counterweight
sections.
7. When disc swings free of gear and comes to rest, remove two counterweight bolts and use
them to bolt timing wrench to disc. Handle toward feed end of screen.
Figure 9.81 - Bolt Timing Wrench to Center Disc
45o
Figure 9.82 - Moving Timing Wrench to Align Notches
8. Terex ships a timing wrench with each new screen. You can also buy timing wrenches from
Terex distributors.
9. Have a co-worker help with this step. Use timing wrench to turn centre weight up toward
feed end of screen. Align notch in weight disc with notch in gear that matches timing angle
you want. Install key-bolt lock washer and key bolt. Remember each notch represents a 5°
change in stroke angle. Turning centre weight clockwise 1/4-turn (90°) aligns notches for a
45° stroke angle. For a steeper stroke angle, turn centre weight less than 90°. For a flatter
stroke angle, turn centre weight more than 90°.

9 Maintenance
10. Check that you have the stroke angle you want. When screen is operating, point of rotation at
which all weights align determines stroke angle. You can check stroke angle without operating
the screen by turning centre weight with timing wrench until all weights are parallel. Stroke
angle is the angle at which an imaginary line through centre of shaft end and the centre plug
hole intersects the horizontal plane. Figure 9.84 shows relative positions of weight discs for
30°, 45° and 60° stroke angles, respectively, when weights are held parallel to each other
with timing wrench. Figure 9.83 shows weight positions at rest with stroke angle set at 45°.
The centre weights are no longer parallel with those on the outer two discs. The exact “at
rest” position varies with the timing angle. Tighten key bolt with extended tab of lock washer
positioned over blank hole in weight disc.
Figure 9.83 - Weight Positions at Rest

Maintenance 9
Figure 9.84 - Relative Positions of Weight Discs
11. Remove timing wrench.

12. Put a general-purpose retaining compound, such as Loctite #242, #243 or equivalent on
two counterweight bolts. Then thread them into place and tighten them. If you have large
counterweights (semicircular), remove the remaining two loosened bolts. Coat threads with
retaining compound and thread them into the weight. Tighten all counterweight bolts.
13. Drive tab on key-bolt lock washer down, locking washer to hole in weight disc. Check tab
carefully for cracks or weakening.
14. Apply silicone sealer around timing port as an oil seal.
15. Replace timing cover. Replace drive belt and belt guard if they were removed.

9 Maintenance
(7) Checking Screen Drive Belt Tension
nn WARNING
Nip hazard.
Fall Hazard.
NOTICE
The recommended amount of slack in the belt is 9mm.
PROCEDURE
carry it with you.
DUN01144
Figure 9.85 - Triple Shaft screen box flywheel cover bolts.
1
DUN01137
Figure 9.86 - Single Shaft screen box flywheel cover
3. Undo the bolts (Item 1) securing the drive side of the screen box flywheel cover and remove
it to get access to the drive belt. There are 9 bolts to be removed.

Maintenance 9
4. Check the tension of the belt by pushing down on it in the center and measuring the deflection
(Item A).
Figure 9.87 - Measuring belt tension
5. Depending on the value of the deflection measurement, the belt may need tensioned.

9 Maintenance
(8) Tensioning the Screen Drive Belt
nn WARNING
Nip hazard.
Fall Hazard.
NOTICE
Do not over tension the belt as this will damage the belt and the belt tensioner.
The recommended amount of slack in the belt is 9mm.
PROCEDURE
2. Ensure machine is switched off, locked out and tagged out. Remove the ignition key and
carry it with you.
3. Undo the bolts (Item 1) securing the drive side of the screen box flywheel cover and remove.
DUN01144
Figure 9.88 - Triple Shaft Screen Box Flywheel Cover
1 DUN01812
Figure 9.89 - Single Shaft Screen Box Flywheel Cover

Maintenance 9
4. Loosen bolts (Item 1) so the pulley mounting plate can slide along the motor mounting plate.
5. Tighten the nuts on the V belt adjuster (Item 1) until the required tension is reached in the V
belts (Item 2). The correct tension is approximately 9 mm of slack.
2
3 1
DUN01145
Figure 9.90 - Screen Box Drive Belt Tensioner
6. Tighten bolts (Items 1) so the pulley mounting plate is fixed and secured.
7. Replace the cover and bolt in position using the bolts.

9 Maintenance
(9) Changing the Bottom Deck Screen Mesh
nn WARNING
nn CAUTION
Only lifting equipment capable of lifting 500 kg or more may be used for this operation.
Tail conveyor must not be used as a platform unless:
• Tail conveyor has been pinned in position.
• Screenbox has been pinned in position.
• Engine lockout procedure has been implemented.
The following instructions should be carried out on both the right and left hand side.
NOTICE
The centre of the mesh tensions first and the appropriate tension is reached when the outside
edges of the mesh are taut. Absolute maximum tension is obtained when the screen tension
bar is parallel with the hook on the screen mesh. This amount of tension is not always required.
Figure 9.91 - Maximum Screen Mesh Tension
Returning the screenbox to the working position is the reverse of this procedure.
(a) Changing Screen Mesh on Triple Shaft
PROCEDURE
3. Raise the screenbox angle and pin to the highest working position on both sides.
4. Lower the tail conveyor to its lowest position. The purpose of this is to allow easier access
to the lower meshes.
5. Remove the pin (Item 1) from the jack-up link arm on both sides.

Maintenance 9
Figure 9.92 - Jack-up Link Arms Pin Removed
6. Raise screenbox into mesh change position.

7. Pin the jack-up link arms in this position and secure pins (Item 1).
Figure 9.93 - Screen Jacked up
8. Implement the shutdown/lockout procedure.

9. Loosen the bolts (A) that hold the screen tension.
10. Remove pins and spring pins (C), 1 off LHS/RHS.
11. Slide back the screen tension bar (B).

9 Maintenance
A C
Figure 9.94 - Screen Tension Bar
12. Push the screen mesh back up until it is free to lift up.
13. Lift up using a prise bar and slide the old mesh out.
14. Check rubber cushions and replace if necessary
15. Clean the screen box to remove any build up of material.
16. Insert new screen mesh ensuring the hooked end of the mesh is in the correct position
around the tension bar.
17. Insert screen tension bar (B) ensuring it is fitted as shown.
18. Replace pins and spring pins (C), 1 off LHS/RHS.
19. Tighten screen tension bolts as required.
20. Lower the screen back into working position.
21. Visually check for vibration in the screen mesh when the screen box is running.

Maintenance 9
(10) Changing the Top Deck Screen Mesh (Single & Triple Shaft)
nn WARNING
nn CAUTION
Only lifting equipment capable of lifting 500 kg or more may be used for this operation.
Tail conveyor must not be used as a platform unless:
• Tail conveyor has been pinned in position.
• Screenbox has been pinned in position.
• Engine lockout procedure has been implemented.
The following instructions should be carried out on both the right and left hand side.
NOTICE
The centre of the mesh tensions first and the appropriate tension is reached when the outside
edges of the mesh are taut. Absolute maximum tension is obtained when the screen tension
bar is parallel with the hook on the screen mesh. This amount of tension is not always required.
Figure 9.95 - Maximum Screen Mesh Tension
PROCEDURE
3. Lower the tail conveyor to its horizontal position as shown. The purpose of this is to allow
easier access to the meshes.

9 Maintenance
DUN00823
Figure 9.96 - Tail conveyor horizontal
4. Implement the shutdown/lockout procedure.

5. Slacken the nuts or remove the quick release pins enough to allow the mesh to be removed
from under the clamps.
6. Replace mesh.
7. Retighten clamps.
8. Refit washers (Item 2), quick release pins (Item 1) and split pins (Item 3), Reference: Figure
9.97.
TIRC00023
Figure 9.97 - Mesh Clamps and Quick Release Pins
9. Return the tail conveyor to its working position.

Maintenance 9
9.20 Spaleck Screen Unit Maintenance
(1) Screening Element
NOTICE
The screening machine should only be used with properly installed and undamaged sieve bases
The manufacturer cannot be held responsible for any damage occurring if this is not observed.
The sieving machine has been fitted out for the individual application which has been agreed and
the manufacturer cannot be held responsible for any damage occurring or poor sieving results if
the product is changed.
nn DANGER
Never carry out modification to the screen lining during operation. Switch off the machine and
implement the lockout and tagout procedure before carrying out any maintenance on the machine.
(2) Assembly of the Screening Element
PROCEDURE
1. Check for any damage of the screening element, screws and spring rings and stop bracket.
2. Lay the screening element (Item 5) in the holder and adjust to ensure that it is centred,
Reference: Figure 9.98.
1 2
8
7
4 3
5
5 DUN01631
Figure 9.98 - Structure of the Sieve Base
3. Move the screening element (Item 5) up to the traverse (Item 3) at the beginning of the
support plate (Item 4), Reference: Figure 9.98.
4. Attend right fit of the slide rail (Item 6). It mustn’t be canted at the beginning of the support
plate (Item 4). It has to fit close to the frontal contact surface, Reference: Figure 9.98.
5. Tighten clamp screw uniformly, until the screen bottom sits tightly on all crossbars of the
machine.
6. Tighten tension nuts.
7. Secure clamp screw against unscrewing.
8. When secure it is urgently necessary:

9 Maintenance
• to clean contact surface of the screening elements.

• that the screening element fits on all places and that it isn’t canted.
• all screws are mounted and tightened sufficiently.
• to clean the screening element from caking.
(a) Disassembly of the Screening Element

Follow the assembly of the screening element procedure in reverse order.
(b) Servicing the Sieve Base

• Check the screening element regularly to ensure that it is firmly fixed in place. (At least once
every 14 days for a single shift production).
• Check the screening element for any defects.
• Keep the sieve base free of caked-on material.
• Inspect the sieve base on an appropriately more regular basis for materials which are difficult
to sieve or which are damp.
• Material which may have become caked-on should be removed immediately.

Maintenance 9
(3) Shaft drive system

Shaft drive systems are strong oscillating drives designed for a long life, used in shaking screens,
shake-out grids, separating grooves, etc. The shaft drive system principally consists of the shaft,
borne on special spherical roller bearings and bearing housings in the side walls of the machine,
and of centrifugal weights located at either end of the shaft.
The circular movement of the sprung vibrating machinery is generated by the centrifugal force of
the rotating centrifugal weights.
(a) Bolted connections

All the bolted connections on the shaft drive system must be checked after the first forty hours
of operation.
Bolts must be tightened to the torque shown in the table below, using a torque spanner:
Thread Size M 12 M 16 M 20 M 24 M 30
Torque (Nm) 86 210 410 710 1450
After the first inspection, the bolts need only be inspected monthly intervals.
NOTICE
The bearing cover screws are cemented in.
(b) Bearing Temperature

Special attention must be initially paid to bearing temperatures in new machines, or when bearings
have been replaced in a shaft drive system. Bearing temperatures of 60°C are normal.
Should the temperature reach or exceed 70°C in constant operation, the cause must be identified,
to prevent bearing failure.
The manufacturer should be consulted in every case of high bearing temperatures.

9 Maintenance
(4) Clamped Screen Mat

The screen mat is fastened using the main components shown in Figure 9.99.
NOTICE
The screening machine should be operated with screen linings that are undamaged and fitted
in accordance with the regulations. If this is not observed, the manufacturer is not liable for
damage that occurs. The screening machine is equipped for the application agreed. In case
of modifications to the product, the manufacturer is not liable for damage that occurs or poor
screening performance.
nn DANGER
Never carry out modification to the screen lining during operation. Switch off the machine and
implement the lockout and tagout procedure before carrying out any maintenance on the machine.
3 2
Figure 9.99 - Screen Mat Construction
1 Basic construction/ side wall of the screening machine

2 Wedge
3 Screen unit
4 Soft hammer
5 Wood board

Maintenance 9
(a) Screen Mat Assembly
NOTICE
Screen mats and clamping strips are fastened using positive locking, additional seal materials
are not necessary. Do not use any hard or sharp objects for driving in the clamping strips. Do
not use oil or grease.
After the first ten hours of operation, a new screen plate must be checked to see it is correctly
clamped.
PROCEDURE
1. Clean the screen mats, clamping strips and screen crossbeams (of the basic and dynamic
frame) and check for damage.
2. Replace defective parts immediately with original replacement parts.
3. Always place screen mats on the screen crossbeams in pairs.
4. Align the screen mats centrally between the side walls so that there is an identical gap on
both sides.
5. Wet the wedges with water before assembly.
6. Fix the wedge in the gap between the two screen mats and drive in.
7. Drive in the wedge cautiously and along the entire length using a rubber hammer.
8. After successful assembly, wedges form a flush finish with the screen mats.

9 Maintenance
(b) Screen Mat Disassembly
PROCEDURE
1. The mats can be pulled out of the clamping by simply pulling them out by hand.
Figure 9.100 - Removing Screen Mats
2. When having pulled out a short part, grab the wedge and pull the mat out of the clamping
completely.
Figure 9.101 - Removing Screen Mats
(c) Screen Mat Maintenance
PROCEDURE
1. Check the screen lining regularly to ensure it is correctly clamped and sitting correctly. (At
least every 14 days for single-shift operation).
2. Check the screen lining for defects.
3. Remove blockages in the screen lining immediately.
4. With products that are sharp and difficult to screen, check for blockages more often.

Maintenance 9
9.21 Collection Conveyor And Diesel Tank Maintenance
nn WARNING
Fall Hazard.
NOTICE
DO NOT move the screen box into the mesh change position while the collection conveyor is
raised to the maintenance position. MACHINE DAMAGE WILL OCCUR.
PROCEDURE
3. Ensure that both side conveyors are open into the full working position.
4. Ensure that the screenbox maintenance arm (Item 1) is fully seated in the chassis and
securely pinned. Reference: Figure 9.102.
Figure 9.102 - Screenbox maintenance arm seated
5. Lower the screenbox angle to the transport position.

6. Shut down, lock out and tagout the machine.
7. Secure the collection lift bracket (Item 1) using the pins provided on left hand side and right
hand side of the machine as shown in Figure 9.103.

9 Maintenance
Figure 9.103 - Collection conveyor lift bracket

9. Raise the screen angle to the highest service position this will simultaneously raise the
collection conveyor to the maintenance position. Pin on both sides (Item 1) to secure the
screen and conveyor at this angle as shown in Figure 9.104.
Figure 9.104 - Collection conveyor in maintenance position
10. Implement the shutdown/lockout procedure before any maintenance is carried out.
11. Reverse this procedure to return the collection conveyor to its working position

Troubleshooting 10
Table of Content
10 Troubleshooting........................................................................................ 10-2
10.1 General Troubleshooting...............................................................................10-2
10.2 Conveyors Troubleshooting..........................................................................10-3
10.3 Screen Troubleshooting................................................................................10-4
10.4 Components Troubleshooting.......................................................................10-6
10.5 Hydraulic Troubleshooting.............................................................................10-7
10.6 Production Troubleshooting..........................................................................10-8
10.7 Tracks Troubleshooting.................................................................................10-9
10.8 Electrical Troubleshooting........................................................................... 10-11
10.9 Engine Troubleshooting..............................................................................10-13
10.10 Engine Fault Codes.....................................................................................10-20
10.11 Machine Fault Codes and Descriptions......................................................10-31

10 Troubleshooting
10 Troubleshooting
NOTICE
The information included in this document is intended for experienced personnel familiar with
this type of equipment. Only trained and competent personnel should perform the work outlined
in this document.
Operation and maintenance of the machine must be done in accordance with the instructions in
the operation manual for the machine.
The diagnostic codes may alert the operator to conditions that may damage the machines
components. Never ignore a Machine fault if one occurs. Always investigate thoroughly or if in
doubt contact your Terex supplier.
10.1 General Troubleshooting

Fault Cause Correct Measure
Fuel Top up as necessary
Coolant level Top up as necessary
Clean Radiator / check fan
High coolant temperature
Machine Stops operation
Hydraulic oil level Top up as necessary
High Hydraulic oil temperature Clean oil cooler / Replace
Emergency stop depressed Check all Emergency stops

Troubleshooting 10
10.2 Conveyors Troubleshooting

Too much load on belt Reduce load on belt
Incorrectly tensioned belt Tension belt
Drive drum turns but belt
Worn belt Replace belt
does not move
Worn drum lagging Replace drum lagging
Rollers cannot rotate freely Clean/check/replace rollers
Material jam Remove material jam
Belt completely stopped
Taperlock is not tight or broken Tighten or replace taperlock
Ensure machine is on level
Machine is not level
ground
Belts are not aligned Align belts
Belts are tracking off
Belts are not being fed evenly,
Ensure conveyor is fed more
material is tending to be fed to
evenly
one side of the conveyor
Tighten or replace as
Conveyor belt is loose
necessary
Material collects under belt
Conveyor belt misaligned Align conveyor belt
Skirting rubbers not adjusted Adjust skirting rubbers
Allow material in drum to be
Feeder conveyor is not Feeder kickout circuit has
processed before re-engaging
moving been activated
control
Bearing lacking lubricant Follow greasing procedure
Rumbling noise from bearing Incorrectly aligned bearing Align bearing
Bearing is damaged Replace bearing
Conveyor belt wedged or Clear obstruction, adjust and
Screeching noise when rubbing against fixed parts align conveyor belt
conveyor is running Belt scraper too tightly placed
Re-adjust belt scraper
against belt

10 Troubleshooting
10.3 Screen Troubleshooting

Drive belt slipping Tighten belt; replace worn belt
Screen Starts Slow (if In cold weather, wheel case oil
Check
applicable) may be too heavy
Motor may be weak Consult licensed electrician
Set it to run at a more shallow
Screen angle too steep
angle
Screen speed too fast Set it to run slower
Screen Spillage Replace screen rubbers or
Worn screen rubbers or curtain
curtain
Reduce stroke length, if
Stroke is too long
possible
Screen decks overflowing Screen is overloaded Decrease feed of material
Screen not laterally (side-to-
Level screen
Rock Moves Down One Side side) level
of screen Feed is introduced to one side
Check in feed conveyor
of the screen only
Screen angle too steep Decrease Screen angle
Rock moves across screen Decrease rpm but stay within
Rpm too high
too fast stroke-speed range
Screen base is not level Level screen
Screen angle too shallow Increase Screen angle
Rock moves across screen
too slow Increase rpm but stay within
Rpm too low
stroke-speed range
Loose or misaligned weights Check counterweight bolts
Remove build up and ensure
Build up of material
build up is regularly removed
Anti-rock stays have not been
Remove anti rock stays
removed
Ensure all meshes,
Meshes are not secure
punchplate, etc are secure
Machine and Screenbox are Ensure machine and
not level screenbox are level
Excessive vibration coil springs, fatigued, sagging
Replace springs
springs bottoming out
Screen shaft is not at correct
Correct screen shaft speed
speed
Bearing failure (excessive
heat,excessive grease, lack of Replace Bearing
oil, or excessive movement)
Co-ordinate feed loading with
Excessive feed overloading tuning of screenbox, adjust
screen angle

Troubleshooting 10

Reduce feed.
Check springs on feed end
Screen ‘‘dead’’ on feed end Screen is overloaded Check plug weight placement,
Increase rpm, but stay within
strke speed range
Wire cloth too heavy Use smaller guage wire
insufficient water spray Spray more water, if possible
Deck Blinds over with clay Clean feed material before
Feed material has too much screening
clay content
Install a balldeck
Leaky gearcase bolt or
Dirty oil spot near gear case Retighten to 305Nm(225lb)
impulse case bolt
hole in wire cloth Replace wire cloth
Product out of specification
Incorrect wire cloth Replace wire cloth
Check oil breather clearance
Condensation in the case or plugging, water entering
Water in the gear case from breather
Leaking Wheel case bolt(in
Retighten to 305Nm(225lb)
wet screening applications)

10 Troubleshooting
10.4 Components Troubleshooting

Obstruction (e.g stone,
Clear obstruction
material build up etc
Check general condition
of machine (eg oil leaks,
Correct problem if possible
excessive heat, hose
blockages etc)
Low engine speed Correct engine speed
Engine performance Consult engine manual
Low hydraulic oil level. Top up hydraulic oil level
Return line filter blockage Replace return line filter
Pre pump filter blockage Replace suction strainer
Machine components Loose or damaged drive Tighten/replace drive
running slowly couplings couplings
Machine is overloaded Check setting parameters
Worn or damaged drive motor Replace motor
Worn or damaged pump Replace pump
Incorrect relief pressure Check and correct relief
settings pressure settings
Pump cavitation, suction line is Check oil level and gate valve
collapsed is open fully (if applicable)
Check flow after pump, after
Flow at pump is not as control valve and after motor.
expected These values should be the
same
Check for power
Faulty switch
Replace switch
Components do not start Check for power
PVG solenoid
Replace solenoid
wiring connection (loose) carry out visual inspection
Place machine on level
Machine is not level
ground
Securing pins not removed Remove securing pins
Machine will not jack to
working position Remove blockage, replace
Blockage along hose
hose if necessary
Incorrect control valve relief Correct control valve relief
pressure pressure

Troubleshooting 10
10.5 Hydraulic Troubleshooting

Low oil level causing cavitation Top up oil level
Blockage at pre pump filter Replace suction strainer
Misalignment between drive Correctly align drive source to
source and pump pump
Drain hydraulic oil and
Incorrect hydraulic oil
replace with correct oil
Hydraulic oil tank breather
Excessively noisy pump Disassemble and clean
clogged
Pressure relief valve stuck in Disassemble, clean or
open position replace the spring nozzle
Drain tank and replace
Contiminated hydraulic oil
hydraulic oil
Damaged pump Replace pump
Obstruction at inlet pipe Remove obstruction
Contaminants in hydraulic oil
hydraulic oil
Worn or sticking relief valve Replace relief valve
Low or erratic pressure Dirt or chip holding valve Clean around valve. Replace
partially open valve
Control valve relief pressure Set relief pressure to correct
set too low level
Check the piping, hose and
Irregular motion of the Air mixed in the cylinder coupling. After checking and
cylinder repair, remove air
Filters blocked Replace
Low oil level Top up hydraulic oil level
Return line element is clogged
Replace return line element
(check blockage indicator)
Damaged suction line Replace suction line pipe
No response from any retighten couplings and
hydraulic system Air mixed from the suction replace the piping as
necessary
Blockage at pre pump filter Remove and clean
Pressure relief valve stuck in
Contact Terex
open position
Check the rotating direction
Rotating direction error
and reconnect
Low oil level Top up oil level
The pump does not start
Check that the pump shaft
Pump seized rotates, fit replacement if
faulty

10 Troubleshooting

Low oil level Top up hydraulic oil level
Incorrect hydraulic oil
hydraulic oil
Machine operating slowly. No Engine performance Consult engine manual
external oil leaks
Loose or damaged taperlocks Tighten / replace taperlock
Worn or damaged drive motor Replace motor
Worn or damaged pump Replace pump
Oil in system becomes Pump running continously Check for symptons of
excessively hot under pressure pressure build up
10.6 Production Troubleshooting

Not enough raw material
Increase feed rate.
delivered to machine
Not enough hauling equipment
Increase removal rate.
for finished product
Low Product Output
Incorrect machine parameter
Change parameter settings
settings
Incorrect or worn liners Replace liners
Incorrect mesh fitted Replace mesh
Incorrect or worn liners Replace liners
Incorrect mesh fitted Replace mesh
Product out of specification
Incorrect machine parameter
Change parameter settings
settings

Troubleshooting 10
10.7 Tracks Troubleshooting

Check parameter setting within the
Parameter settings PLC screen and adjust if necessary
(independly)
Check if the brake is releasing. Fit a
pressure clock to the brake hose. A
Brake jammed
pressure of at least 285 PSI / 20 bar
is required to release the brakes
Different sizes of motors fitted to Check that the same size of motors
tracks have been fitted to both tracks
Incorrect pressure going to the
Try removing the valves and
brake hose caused by a problem
cleaning them thoroughly taking
with the motion control block
care not to damage the external
possibly contamination. If a load
cavity seals.Also check the ports
control valve should jam due to oil-
in the block for dirt etc. If this does
entrained debris then the likelihood
not work replace the valves with
is that it will not open and will not
new ones. Always cross-reference
allow the motor to turn in one
the part numbers on the new valves
direction. This will cause the Host
with the old valve, before fitting .
Machine to ‘crab’ in one direction.
It is critical that the correct valves
Swapping the valves over from
are fitted. Valves should never be
one Track to the other will usually
dismantled as no internal seals or
transfer the problem to the opposite
parts are available.
One track not operating or direction.
operating slower than the Swap the pressure regulator from
other the opposite block to see if the
Brake pressure regulator valve problem is in the brake valve. If
jammed due to debris will stop the the valves continue to jam then the
motor turning on one side oil in the hydraulic system is not
being filtered to the required level of
cleanliness.
Swap over the motors on the two
Motor Fault tracks. If the fault is in the motor,
replace with a new motor
Remove the motor and look into the
gearbox for heat discolouration and/
Faulty brake or fragments of brake disc. If the
fault is in the brakes the complete
gearbox will have to be replaced.
Remove the motor. If there is
hydraulic oil in the gearbox entrance
then the seals are damaged.
While it may be possible to replace
Faulty brake piston seals these seals on-site we strongly
recommended that a replacement
gearbox is fitted and an overhaul of
the damaged gearbox be carried out
off-site.

10 Troubleshooting

Seal damaged between Motion Remove motion control block and
control block and motor replace seals
Excessive oil leaking around Seal damaged between motor and
Remove motor and replace seal
drive assembly gearbox
Seal damage may be caused by Check oil operating temperature
excessive oil temperatures and environmental conditions
Check that the track adjuster grease
valve is tight, has a properly fitted
seal and that there is no grease
leaking past it
Track will not stay tensioned Grease escaping Check around the tensioning
Cylinder for escaping grease. This
will indicate that the seals are
damaged in the tensioning cylinder.
Replace with a new cylinder
immediately
Track group too loose Check track tension
Check alignment of Sprocket Idler
Track group running off Excessive misalignment
and track rollers
Sprocket and / or idler
Excessive component wear Check wear limits
Twisted track frame Check track frame
Track roller leaking oil Damaged or worn seals Replace with a new Track Roller

Troubleshooting 10
10.8 Electrical Troubleshooting

Faulty ignition switch Replace ignition switch
Low engine oil level (warning
Top up oil level
light should be on)
Low engine coolant level
Control panel lights up but Top up coolant level
(warning light should be on)
engine does not start
Emergency stop bottons Check all emergency stop
depressed buttons
Faulty starter motor relay Replace starter motor relay
Faulty starter motor Replace starter motor
Top up electrolyte level
Low battery voltage
Charge up battery
Control panel does not light Fuse blown Replace fuse
up Isolator on turn off isolator
Faulty ignition switch terminals Correct connections/replace
Damaged battery Replace battery
Top up electrolyte level
Low battery voltage
Charge up battery
Battery goes flat while
Faulty Alternator Replace alternator
engine is running
loose fanbelt Adjust tension
Blown fuse Replace fuse
Battery goes flat while Faulty starter motor relay Replace starter motor relay
engine is running Faulty starter motor Replace starter motor
Move remote control to within
Remote control is out of range
100 m of the machine
Batteries are dead Charge or replace batteries
Track radio remote control
does not work Control bank levers are not in Place control levers in the
the correct position correct position
Remote control not
Program receiver box
programmed to receiver box
Control bank levers are not in Control bank levers are not in
Tracks do not operate the correct position the correct position
Fuse blown Replace fuse
Check for power
Faulty switch
Replace switch
Components do not start Check for power
PVG solenoid
Replace solenoid
wiring connection (loose) Carry out visual inspection
7 second delay warning siren Blown fuse Replace fuse
does not operate Siren has been damaged Replace siren

10 Troubleshooting

Move remote control to within
Remote control is out of range
100m of the machine
Tipping grid remote control Batteries are dead Replace batteries
does not work Tipping grid cycle not set Set program
Remote control not
Program receiver box
programmed to receiver box

Troubleshooting 10
10.9 Engine Troubleshooting

Not declutched Check
Battery defective or discharged Check
Incorrect valve clearance Check
Check the display for fault
Diagnostic code code and refer to engine
manual for instructions
Check for battery voltage to
ECM module
ECM
Check that cold start system
Starting aids
is operating correctly
Check that all emergency
Emergency stop switches stops are depressed and
functioning correctly
Remove the starter and
visually inspect the drive
pinion and flywheel for
damage
Starter motor
Check battery voltage to
starter motor and solenoid,
test the operation of both ,
replace as necessary
Engine non-start or difficult Check and clean speed
to start sensor electrical connections
Engine speed
Check speed sensor for
proper installation
Check injector electrical
connection and clean as
necessary
Fuel injector Check for injector line
leakage/ have the engine
manufacturer repair as
necessary
Check the fuel level, do not
rely on the fuel gauge only,
add fuel as necessary
Check the fuel lines for
restrictions, collapsed and
pinched lines, repair / have
Fuel supply the engine manufacturer
Check fuel in the tank for
contamination
Check condition of fuel filters,

10 Troubleshooting

Fuel injection line leaks Check / repair as necessary
Check / have the engine
Fuel injector defective manufacturer Replace as
necessary
Engine starts, but runs
Air in the fuel system Check / Replace
irregularly or fails
Fuel filter / fuel precleaner
Check
soiled
Fuel quality not as per
Check / Clean
operation manual
Oil level too low Top up
Oil level too high Check
Air cleaner clogged /
Check / Replace
turbocharger
Air cleaner service switch /
Check
indicator defective
Charge airline leaking
manufacturer replace
Coolant pump defective Check / Clean
Engine becomes excessively
hot Coolant heat exchanger soiled Check / Clean
Cooling air temperature rise /
Check
heating short circuits
Ventilation line blocked Have the engine
(coolant heat exchanger) manufacturer check
Fuel injector defective manufacturer replace as
necessary
Oil filter defective Check
Coolant deficiency Check / Clean
Check electrical connection to
Electrical connections
engine ECM
Fuel injection line leaks manufacturer repair as
necessary
Engine does not run on all Fuel injector defective manufacturer replace as
cylinders necessary
Check for air inlet restriction,
Air inlet clean/ replace filters as
necessary
Check
soiled

Troubleshooting 10

Engine shut off lever still in
Check
stop position
Check / Replace
turbocharger
Check
indicator defective
CPD defective (connection line Have the engine
leaks) manufacturer check
Check / have engine
Charge airline leaking manufacturer replace as
necessary
Intercooler soiled Check / Clean
Engine output is deficient Cooling air temperature rise / Have the engine
heating short circuits manufacturer check
Have the engine
Incorrect valve clearance
manufacturer check
Fuel injection line leaks manufacturer repair as
necessary
Fuel injector defective manufacturer repair as
necessary
Check
soiled
Check / Clean
operation manual
Oil level too low Top up
Have the engine
Engine oil pressure is non- manufacturer check for
Excessive engine wear
existent or very low excessive crankcase blow by
at the engine breather
Incorrect engine lube Check / Replace
Have the engine
manufacturer check for
excessive crankcase blow by
Engine oil consumption is
excessive Check the turbo for oil leaks,
Turbo charger seal have the engine manufacturer
repair as necessary
Check the engine for oil leaks,
Oil leaks have the engine manufacturer
repair as necessary

10 Troubleshooting

Have the engine
Engine smoke blue manufacturer check for
excessive crankcase blow by
Below starting limit
Check
temperature
Have the engine
manufacturer check
Have the engine
manufacturer check that cold
Starting aids
Engine smoke white start system is operating
correctly
Fuel injectors defective manufacturer repair as
necessary
Check / Clean
operation manual
Check / Replace
turbocharger
Check
indicator defective
CPD defective (connection line Have the engine
leaks) manufacturer check
Engine smoke black Have the engine
Charge airline leaking
manufacturer check / Replace
Have the engine
manufacturer check
Fuel Injector defective manufacturer repair as
necessary

Troubleshooting 10

Check the condition of
the drive belts, if worn or
damaged replace the belts
Alternator drive belts
Check the tension of the drive
belts, adjust the tension if
necessary
Check the battery cables,
wiring and connections in
Charging circuit the charging circuit. Clean
and tighten all connections.
Alternator charging problem
Replace faulty parts
Have the engine
manufacturer verify the
Regulator
regulator is operating
correctly, replace if necessary
Have the engine
manufacturer verify the
Alternator alternator is operating
correctly, repair or replace if
necessary
Check for leaks in the oil
cooler core, if a leak is found
the engine manufacturer
Engine oil cooler core
replace as necessary. Drain
the engine oil and replace
with clean oil and oil filter
Have the engine
manufacturer remove cylinder
Cylinder head gasket
head and replace head
gasket
Have the engine
manufacturer with the cylinder
Coolant in engine oil Cylinder liner head removed check the
cylinder liner for cracks,
Have the engine
Cylinder head cracks in the cylinder head,
if necessary repair or replace
the cylinder head
Have the engine
Cylinder block cracks in the cylinder block,
if necessary repair or replace
the cylinder head
ECM will not communicate
Check and clean electrical
with other systems or Electrical connections
connections
displays

10 Troubleshooting

Check for battery voltage to
ECM module
ECM
Have the engine
manufacturer check that cold
Starting aids
start system is operating
correctly
Have the engine
manufacturer remove the
starter and visually inspect
the drive pinion and flywheel
Starter motor for damage
Check battery voltage to
starter motor and solenoid,
test the operation of both ,
Engine cranks but will not replace as necessary
start
Check and clean speed
sensor electrical connections
Engine speed Have the engine
manufacturer check sensor
for proper installation
Check injector electrical
Fuel injector connection and clean as
necessary
Check the fuel lines for
pinched lines, have the
Fuel supply engine manufacturer repair
and replace as necessary
contamination

Troubleshooting 10

Check for leaks in the oil
cooler core, if a leak is found
have the engine manufacturer
Engine oil cooler core
replace as necessary. Drain
the engine oil and replace
Engine oil in cooling system with clean oil and oil filter
Have the engine
manufacturer remove cylinder
Cylinder head gasket
head and replace head
gasket
Check and clean electrical
Electrical connections connections between the
engine ECM system display
Check the status of circuit
Circuit breakers
breakers
Intermittent engine shutdown Check the fuel lines for
pinched lines, have the
Fuel supply engine manufacturer repair
and replace as necessary
contamination

10 Troubleshooting
10.10 Engine Fault Codes

If there is an engine fault the engine fault screen will be shown on the display (Figure 10.1) when
the alarm button (Item 2) is pressed.
2 4
3
DUN00084
Figure 10.2 - Control Panel Display
The engine fault screen displays the following information:

• The SPN number identifies the specific component which has a fault.
• The number of hours specifies the engine run hours when the fault occurred.
• The FMI number indicates the type of failure that is associated with the component.
• The OC number specifies how many times that particular fault has occurred.
The table gives a list of the fault codes and descriptions of the faults corresponding to the
combination of codes from the engine fault screen. The table can be used to determine what the
active fault is.

Troubleshooting 10
Example:
The table gives a list of the engine fault codes along with a description of the fault.
The J1939 code is made up of two numbers separated by a dash. The first number is the SPN
number. The second number is the FMI number.
The engine fault screen is shown on the display screen. The SPN number is 172 and the FMI
number is 4. The corresponding numbers in Table 10.1 indicate that the engine coolant level is low.
Extract from table:
J1939
Code Description Refer to Procedure
172-4 Engine Air Inlet Temperature : Voltage Below Engine Temperature Sensor
Normal Open or Short Circuit - Test
(Passive Sensors)
The engine fault screen also shows that this fault has occurred twice and the last time it occurred
was when the engine run hours was 6 hours. The yellow warning symbol at the right hand side
of the screen indicates that the fault is currently active.

10 Troubleshooting
Table 10.1 - Engine Fault Codes and Descriptions
J1939
27-3 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Above Normal
27-4 Engine Exhaust Gas Recirculation Valve Position Valve Position Sensor - Test
Sensor : Voltage Below Normal
29-2 Accelerator Pedal Position 2 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
29-2 Accelerator Pedal Position 2 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Analog Throttle Position
Normal (Engines equipped with an analog Sensor Circuit - Test
throttle)
29-3 Accelerator Pedal Position 2 : Voltage Above Digital Throttle Position Sensor
Normal (Engines equipped with a digital throttle) Circuit - Test
29-4 Accelerator Pedal Position 2 : Voltage Below Analog Throttle Position
throttle)
29-4 Accelerator Pedal Position 2 : Voltage Below Digital Throttle Position Sensor
29-8 Accelerator Pedal Position 2 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
51-3 Engine Throttle Position : Voltage Above Normal Valve Position Sensor - Test
51-4 Engine Throttle Position : Voltage Below Normal Valve Position Sensor - Test
91-2 Accelerator Pedal Position 1 : Erratic, Throttle Switch Circuit - Test
Intermittent, or Incorrect (Engines equipped with
a throttle switch)
91-2 Accelerator Pedal Position 1 : Erratic, Intermittent Analog Throttle Position
or Incorrect (Engines equipped with an analog Sensor Circuit - Test
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Analog Throttle Position
throttle)
91-3 Accelerator Pedal Position 1 : Voltage Above Digital Throttle Position Sensor
91-4 Accelerator Pedal Position 1 : Voltage Below Analog Throttle Position
throttle)
91-4 Accelerator Pedal Position 1 : Voltage Below Digital Throttle Position Sensor
91-8 Accelerator Pedal Position 1 : Abnormal Digital Throttle Position Sensor
Frequency, Pulse Width or Period Circuit - Test
97-3 Water In Fuel Indicator : Voltage Above Normal Water in Fuel Sensor - Test
97-15 Water In Fuel Indicator : High - least severe (1) Fuel Contains Water

Troubleshooting 10
J1939
97-16 Water In Fuel Indicator : High - moderate severity Fuel Contains Water
(2)
100-1 Engine Oil Pressure : Low - most severe (3) Oil Pressure Is Low
100-3 Engine Oil Pressure : Voltage Above Normal Engine Pressure Sensor Open
or Short Circuit - Test
100-4 Engine Oil Pressure : Voltage Below Normal Engine Pressure Sensor Open
100-17 Engine Oil Pressure : Low - least severe (1) Oil Pressure Is Low
100-21 Engine Oil Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
102-16 Engine Intake Manifold #1 Pressure : High - Intake Manifold Air Pressure Is
moderate severity (2) High
102-18 Engine Intake Manifold #1 Pressure : Low - Intake Manifold Air Pressure Is
moderate severity (2) Low
105-3 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Above Normal Open or Short Circuit - Test
(Passive Sensors)
105-4 Engine Intake Manifold #1 Temperature : Voltage Engine Temperature Sensor
Below Normal Open or Short Circuit - Test
(Passive Sensors)
105-15 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
least severe (1) Temperature Is High
105-16 Engine Intake Manifold #1 Temperature : High - Intake Manifold Air
moderate severity (2) Temperature Is High
107-15 Engine Air Filter 1 Differential Pressure : High - Inlet Air Is Restricted
least severe (1)
108-3 Barometric Pressure : Voltage Above Normal Engine Pressure Sensor Open
108-4 Barometric Pressure : Voltage Below Normal Engine Pressure Sensor Open
108-13 Barometric Pressure : Calibration Required Sensor Calibration Required -
Test
108-21 Barometric Pressure : Data Drifted Low 5 Volt Sensor Supply Circuit -
Test
110-0 Engine Coolant Temperature : High - most Coolant Temperature Is High
severe (3)
110-3 Engine Coolant Temperature : Voltage Above Engine Temperature Sensor
(Passive Sensors)
110-4 Engine Coolant Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
110-15 Engine Coolant Temperature : High - least Coolant Temperature Is High
severe (1)

10 Troubleshooting
J1939
110-16 Engine Coolant Temperature : High - moderate Coolant Temperature Is High
severity (2)
111-1 Engine Coolant Level : Low - most severe (3) Coolant Level is Low
157-3 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
157-4 Engine Injector Metering Rail #1 Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short Circuit - Test
157-16 Engine Injector Metering Rail #1 Pressure : High Fuel Rail Pressure Problem
- moderate severity (2)
157-18 Engine Injector Metering Rail #1 Pressure : Low - Fuel Rail Pressure Problem
moderate severity (2)
158-2 Keyswitch Battery Potential : Erratic, Intermittent Ignition Keyswitch Circuit and
or Incorrect Battery Supply Circuit - Test
168-2 Battery Potential / Power Input 1 : Erratic, Ignition Keyswitch Circuit and
Intermittent or Incorrect Battery Supply Circuit - Test
168-3 Battery Potential / Power Input 1 : Voltage Above Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
168-4 Battery Potential / Power Input 1 : Voltage Below Ignition Keyswitch Circuit and
Normal Battery Supply Circuit - Test
172-3 Engine Air Inlet Temperature : Voltage Above Engine Temperature Sensor
(Passive Sensors)
172-4 Engine Air Inlet Temperature : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-3 Engine Fuel Temperature 1 : Voltage Above Engine Temperature Sensor
(Passive Sensors)
174-4 Engine Fuel Temperature 1 : Voltage Below Engine Temperature Sensor
(Passive Sensors)
174-15 Engine Fuel Temperature 1 : High - least severe Fuel Temperature Is High
(1)
174-16 Engine Fuel Temperature 1 : High - moderate Fuel Temperature Is High
severity (2)
190-8 Engine Speed : Abnormal Frequency, Pulse Engine Speed/Timing Sensor
Width or Period Circuit - Test
190-15 Engine Speed : High - least severe (1) Engine Overspeeds
411-3 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Above Normal or Short Circuit - Test
411-4 Engine Exhaust Gas Recirculation Differential Engine Pressure Sensor Open
Pressure Sensor : Voltage Below Normal or Short Circuit - Test
411-13 Engine Exhaust Gas Recirculation Differential Sensor Calibration Required -
Pressure Sensor : Calibration Required Test

Troubleshooting 10
J1939
412-3 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Passive Sensors)
412-4 Engine Exhaust Gas Recirculation Temperature: Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Passive Sensors)
412-15 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - least severe (1) Temperature Is High
412-16 Engine Exhaust Gas Recirculation Temperature : NRS Exhaust Gas
High - moderate severity (2) Temperature Is High
558-2 Accelerator Pedal 1 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent or Incorrect Test
626-5 Engine Start Enable Device 1 : Current Below Ether Starting Aid - Test
Normal
626-6 Engine Start Enable Device 1 : Current Above Ether Starting Aid - Test
Normal
630-2 Calibration Memory : Erratic, Intermittent or Flash Programming
Incorrect
631-2 Calibration Module : Erratic, Intermittent or ECM Memory - Test
Incorrect
637-11 Engine Timing Sensor : Other Failure Mode Engine Speed/Timing Sensor
Circuit - Test
651-2 Engine Injector Cylinder #01 : Data Incorrect Injector Data Incorrect- Test
651-5 Engine Injector Cylinder #01 : Current Below Injector Solenoid Circuit - Test
Normal
651-6 Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit - Test
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal

10 Troubleshooting
J1939
Normal
Normal
Normal
676-6 Engine Glow Plug Relay : Current Above Normal Starting Aid (Glow Plug) Relay
Circuit - Test
678-3 ECU 8 Volts DC Supply : Voltage Above Normal Digital Throttle Position Sensor
Circuit - Test
678-4 ECU 8 Volts DC Supply : Voltage Below Normal Digital Throttle Position Sensor
Circuit - Test
723-8 Engine Speed Sensor #2 : Abnormal Frequency, Engine Speed/Timing Sensor
Pulse Width or Period Circuit - Test
1075-5 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Below Normal
1075-6 Engine Electric Lift Pump for Engine Fuel Supply Fuel Pump Relay Circuit - Test
: Current Above Normal
1076-5 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Below Normal
1076-6 Engine Fuel Injection Pump Fuel Control Valve : Solenoid Valve - Test
Current Above Normal
1188-5 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1188-6 Engine Turbocharger 1 Wastegate Drive : Solenoid Valve - Test
1196-9 Anti-theft Component Status States : Abnormal Data Link Circuit - Test
Update Rate
1239-0 Engine Fuel Leakage 1: High - most severe (3) Fuel Rail Pressure Problem
2659-7 Engine Exhaust Gas Recirculation (EGR) Mass NRS Mass Flow Rate Problem
Flow Rate : Not Responding
2791-5 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test
Control : Current Below Normal
Control : Current Above Normal
Control : Not Responding Properly
2882-2 Engine Alternate Rating Select : Erratic, Mode Selection Circuit - Test
Intermittent, or Incorrect
2970-2 Accelerator Pedal 2 Low Idle Switch : Erratic, Idle Validation Switch Circuit -
Intermittent, or Incorrect Test
3241-3 Exhaust Gas Temperature 1 : Voltage Above Engine Temperature Sensor
(Active Sensors)

Troubleshooting 10
J1939
3241-4 Exhaust Gas Temperature 1 : Voltage Below Engine Temperature Sensor
(Active Sensors)
3242-3 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Above Normal Open or Short Circuit - Test
(Active Sensors)
3242-4 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor
Voltage Below Normal Open or Short Circuit - Test
(Active Sensors)
3242-15 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
least severe (1) Temperature Is High
3242-16 Particulate Trap Intake Gas Temperature : High - Diesel Particulate Filter
moderate severity (2) Temperature Is High
3242-18 Particulate Trap Intake Gas Temperature : Low - Diesel Particulate Filter
moderate severity (2) Temperature Is Low
3251-3 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
3251-4 Particulate Trap Differential Pressure : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3251-13 Particulate Trap Differential Pressure : Sensor Calibration Required -
Calibration Required Test
3358-3 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Above Normal or Short Circuit - Test
3358-4 Engine Exhaust Gas Recirculation Inlet Engine Pressure Sensor Open
Pressure: Voltage Below Normal or Short Circuit - Test
3358-13 Engine Exhaust Gas Recirculation Inlet Pressure Sensor Calibration Required -
: Calibration Required Test
3358-21 Engine Exhaust Gas Recirculation Inlet Pressure 5 Volt Sensor Supply Circuit -
: Data Drifted Low Test
3464-5 Engine Throttle Actuator 1 Control Command : Motorized Valve - Test
Not Responding Properly
3473-31 Aftertreatment #1 Failed to Ignite Diesel Particulate Filter
Collects Excessive Soot or
ARD Failed to Ignite
3474-14 Aftertreatment #1 Loss of Combustion : Special ARD Loss of Combustion
Instruction
3474-31 Aftertreatment #1 Loss of Combustion Diesel Particulate Filter
Collects Excessive Soot or
ARD Loss of Combustion
3479-5 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test

10 Troubleshooting
J1939
3479-6 Aftertreatment #1 Fuel Pressure Control : Solenoid Valve - Test
3480-3 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Above Normal or Short Circuit - Test
3480-4 Aftertreatment #1 Fuel Pressure #1 : Voltage Engine Pressure Sensor Open
Below Normal or Short Circuit - Test
3480-15 Aftertreatment #1 Fuel Pressure #1 : High - least ARD Pilot Fuel Pressure Is
severe (1) High
3480-16 Aftertreatment #1 Fuel Pressure #1 : High - ARD Pilot Fuel Pressure Is
moderate severity (2) High
3480-17 Aftertreatment #1 Fuel Pressure #1 : Low - least ARD Pilot Fuel Pressure Is
severe (1) Low
3480-18 Aftertreatment #1 Fuel Pressure #1 : Low - ARD Pilot Fuel Pressure Is
moderate severity (2) Low
3483-11 Aftertreatment #1 Regeneration Status : Other Diesel Particulate Filter
Failure Mode Requires Initial Regeneration
3484-5 Aftertreatment #1 Ignition : Current Below ARD Ignition - Test
Normal
3484-6 Aftertreatment #1 Ignition : Current Above ARD Ignition - Test
Normal
3487-5 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Below Normal
3487-6 Aftertreatment #1 Air Pressure Control : Current Motorized Valve - Test
Above Normal
3487-7 Aftertreatment #1 Air Pressure Control : Not Motorized Valve - Test
Responding Properly
3488-3 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Above Normal
3488-4 Aftertreatment #1 Air Pressure Actuator Position : Valve Position Sensor - Test
Voltage Below Normal
3509-3 Sensor Supply Voltage 1 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3509-4 Sensor Supply Voltage 1 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3510-3 Sensor Supply Voltage 2 : Voltage Above Normal 5 Volt Sensor Supply Circuit -
Test
3510-4 Sensor Supply Voltage 2 : Voltage Below Normal 5 Volt Sensor Supply Circuit -
Test
3556-7 Aftertreatment Fuel Injector #1 : Not Responding ARD Nozzle - Test
Properly
3563-3 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short
3563-4 Engine Intake Manifold #1 Absolute Pressure : Engine Pressure Sensor Open
Voltage Below Normal or Short

Troubleshooting 10
J1939
3563-13 Engine Intake Manifold #1 Absolute Pressure : Sensor Calibration Required -
3563-21 Engine Intake Manifold #1 Absolute Pressure : 5 Volt Sensor Supply Circuit -
Data Drifted Low Test
3609-3 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
Voltage Above Normal or Short
3609-4 Diesel Particulate Filter Intake Pressure 1 : Engine Pressure Sensor Open
3609-13 Diesel Particulate Filter Intake Pressure 1 : Sensor Calibration Required -
3609-15 Diesel Particulate Filter Intake Pressure 1 : High Diesel Particulate Filter Has
Least Severe High Inlet Pressure
3609-17 Diesel Particulate Filter Intake Pressure 1 : Low Diesel Particulate Filter Has
Moderate Severity Low Inlet Pressure
3609-21 Diesel Particulate Filter Intake Pressure 1 : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
3703-31 Particulate Trap Active Regeneration Inhibited Diesel Particulate Filter
Due to Inhibit Switch Collects Excessive Soot or
ARD Is Disabled
Due to Low Exhaust Gas Temperature Collects Excessive Soot or
ARD Temperature Is Low
Due to Temporary System Lockout Collects Excessive Soot
Due to Permanent System Lockout Collects Excessive Soot
3719-0 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
most severe (3) Collects Excessive Soot
3719-16 Particulate Trap #1 Soot Load Percent : High - Diesel Particulate Filter
moderate severity (2) Collects Excessive Soot
3720-15 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
least severe (1) High Ash Load
3720-16 Particulate Trap #1 Ash Load Percent : High - Diesel Particulate Filter Has
moderate severity (2) High Ash Load
3750-31 Diesel Particulate Filter 1 Conditions Not Met for Diesel Particulate Filter
Active Regeneration Collects Excessive Soot or
ARD Is Disabled
3837-3 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
Voltage Above Normal or Short Circuit - Test
3837-4 Aftertreatment 1 Secondary Air Pressure : Engine Pressure Sensor Open
3837-13 Aftertreatment 1 Secondary Air Pressure : Sensor Calibration Required -
3837-17 Aftertreatment 1 Secondary Air Pressure : Low - ARD Combustion Supply Air
least severe Pressure Is Low

10 Troubleshooting
J1939
3837-21 Aftertreatment 1 Secondary Air Pressure : Data 5 Volt Sensor Supply Circuit -
Drifted Low Test
4265-5 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
4265-6 Aftertreatment #1 Transformer Secondary Output ARD Ignition - Test
4301-5 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4301-6 Aftertreatment #1 Fuel Injector #1 Heater Control ARD Nozzle Heater - Test
4783-2 DPF #1 Mean Soot Signal : Erratic, Intermittent, Soot Sensor - Test
or Incorrect
4783-3 DPF #1 Mean Soot Signal : Voltage Above Soot Sensor - Test
Normal
4783-4 DPF #1 Mean Soot Signal : Voltage Below Soot Sensor - Test
Normal
4783-9 DPF #1 Mean Soot Signal : Abnormal Update Soot Sensor - Test
Rate
4783-12 DPF #1 Mean Soot Signal : Failure Soot Sensor - Test
4783-13 DPF #1 Mean Soot Signal : Out of Calibration Soot Sensor - Test
4783-21 DPF #1 Mean Soot Signal : Data Drifted Low Soot Sensor - Test
5423-5 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Below Normal
5423-6 Aftertreatment Regeneration Device Fuel Pump ARD Fuel Supply - Test
Relay : Current Above Normal
5571-0 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve : High - most severe (3)
5576-2 Aftertreatment #1 Identification Number Module : Diesel Particulate Filter
Erratic, Intermittent, or Incorrect Identification Signal - Test
Abnormal Frequency, Pulse Width, or Period Identification Signal - Test
Special Instruction Identification Signal - Test

Troubleshooting 10
10.11 Machine Fault Codes and Descriptions

NOTICE
The fault codes may alert the operator to conditions that may damage the machines components.
Never ignore a Machine fault if one occurs. Always investigate thoroughly or if in doubt contact
your Terex plant supplier.
Table 10.2 - Machine Fault Codes

Fault Description Graphic
1 Emergency Stop Activated
Emergency Stop on the machine has been

activated at ?? Hrs Run
Machine will Shutdown

2 Machine Stop Activated
Machine Stop on the doglead has been

activated at ?? Hrs Run

3 Coolant Level Low - SPN 111
Coolant Level is low, activated at ?? Hrs Run.
4 Engine Temperature - SPN 110
Engine temperature is above normal, activated

at ?? Hrs Run.
Warning only
5 Air Filter Restriction - SPN 107
Air Filter for Engine has become blocked

activated at ?? Hrs Run.
Machine will show this Alarm for 30 Minutes

after which the machine will Shutdown

10 Troubleshooting

6 Fuel Contamination - SPN 97
The water trap is full, activated at ?? Hrs Run.
7 Hydraulic Oil Level Low
Hydraulic Oil Level is low, activated at ?? Hrs

Run.

8 Oil Pressure - SPN 100
Engine oil pressure low, recorded at ?? Hrs

Run.
Engine will not start

9 After treatment Fault - SPN 5246 & 3038
The After treatment is not functioning,

recorded at ?? Hrs Run.
The engine will de-rate

This warning will also appear on the Home
screen when present
10 Battery Voltage
Battery voltage has fallen below the required

level, Alarm recorded at ?? Hrs Run.
Also an indication that the engines alternator

has stopped charging.
11 Comms Fault
MCU Controller has lost CAN Communication

with the MCU Display Screen, Alarm recorded
at ?? Hrs Run.
Engine will not start

Troubleshooting 10

12 DPF Warning - SPN 3719-16
DPF soot level has reached 100%, activated

at ?? Hrs Run.
Engine regen is required

13 DPF Critical Warning - SPN 3719-31
DPF soot level has reached 116%, activated at

?? Hrs Run.
Engine regen is required, engine will shut

down after 30 seconds
14 Emissions System Malfunction - SPN 3038
The engine will de-rate.
If the engine is run in this mode the engine will

go into harbour mode.

10 Troubleshooting

Storage 11
Table of Content
11 Storage.......................................................................................................11-2

11 Storage
11 Storage
On receipt of the machine and the separate lubrication and hydraulic equipment carry out a careful
inspection and immediately report any component damage or loss. Conduct a careful visual check
of the machine and check all the separate loose items against 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 machinery cannot be stored indoors it must be sheeted over and made thoroughly
weatherproof to avoid deterioration.
Contact Terex for advice on any situation wherever storage or inactivity is in excess of that
reasonably to be expected or where a possibly hostile environment exists, as the defects liability
warranty may be affected.

Glossary 12
12 Glossary of Terms
Anti Rock Stay

A strap which is used to stabilise the screen unit whilst in transport.
Antiloosen Fastener
A type of fastener used to secure some doors.
Assemblies
Individual sections of the platform made up of different components parts.
Auxiliary Control Valve
A bank of hydraulic valves which carry out various movement functions throughout the platform.
Belt Scraper
A device fixed or flexible mounted across the width of a belt of a conveyor for removing adherent
material.
Bogie
Undercarriage on chassis to which axles are bolted.
Centre Roller
A roller, which supports the loaded belt.
Transfer Conveyor
A conveyor used to transfer the fines material from underneath the drum onto the incline conveyor.
Control Panel
A panel that is situated in the power unit which is used to start the engine and view the various
warning lights.
Controller
An electromechanical device or assembly of devices for starting, stopping, accelerating, or
decelerating a drive, or serving, to govern in some predetermined manner the power delivered
to the drive.
Conveyor
A horizontal, 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 selective.
Conveyor belt
A belt used to carry materials and transmit the power required to move the load being conveyed.
Conveyor, extendable
A conveyor that may be lengthened or shortened to suit operating needs.
Conveyor, live roller
A series of rollers over which objects are moved by the application of power to all or some of the
rollers. The power transmitting medium is usually belting or chain.
Conveyor, mobile
Conveyor supported on a mobile self propelled structure. These conveyors normally handle bulk
material.

12 Glossary
Conveyor, portable
A transportable conveyor which is not self propelled, usually having supports that provide mobility.
Conveyor, screw
A conveyor screw revolving in a suitably shaped stationary trough or casing fitted hangers, trough
ends, and other auxiliary accessories.
Control Valve
A hydraulic valve, which carries out a movement function on the machine.
Depressurised
To release the pressure from a vessel i.e. a tire, hydraulic system.
Discharge Area
The area where material is dumped from the machine.
Dolly Axle
An axle that can be fitted to king pin, used for towing purpose.
Drive
An assembly of the necessary structural, mechanical, and electrical parts provide the motive
power to change direction.
Drive Drum
The drum that drives the conveyor belt sometimes called the head drum.
Non Drive Drum
The drum that is non-driven in the conveyor belt sometimes called the tail drum.
Drum Lagging
Rubber glued around the drive drum to grip the conveyor belt.
Feed Conveyor
Conveyor used to move the material from the hopper to the main conveyor.
Feedboot
An extended metal surround located at the bottom of the main, tail & side conveyors.
Feeder Unit
Conveyor which feeds the material onto the incline conveyor at an even rate.
Filler Cap
A cap used to seal a tank and is removed in order to fill the tank.
Fines Material
Material that is screened through the lower screen deck and is discharged on to the tail conveyor.
Four Bank
A bank of hydraulic control valves used to control functions of the machine.
Flywheel
A half moon shaped counter weight, which is mounted on the screen unit shaft for the purpose
of counter acting the weight of the eccentric of the screen shaft.
Gate
A device or structure by means 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.

Glossary 12
Grid Aperture
The spacing between the grid bars (typically 100mm) which determines the material size that
enters the feed hopper.
Grid Bar
Bars used on the grid spaced out with equal spacing. Used to roughly screen material.
Grating
A coarse screen made of parallel and crossed bars used to prevent passage of oversized material.
Guard
A covering, barricade, grating, fence, or other form of barrier used to prevent inadvertent physical
contact with operating components such as gears, sprockets, chains, and belts.
Hopper
A box having a funnel shaped bottom, or a bottom reduced in size, narrowed, or necked to receive
material and direct it to a conveyor, feeder, or chute.
Hydraulic Components
A part used in the hydraulic system of the machine i.e. valve, motor etc.
Hydraulic Screen Tension
The assistance of hydraulic rams when tensioning the screen meshes.
Jacking legs
Hydraulic adjustable legs which raise or lower the back of the machine for the purpose of coupling
to the tractor unit.
King Pin
Coupling used for towing by the tractor unit.
Landing Leg
A support leg which lowers from the machine and is used to stabilise it whilst in the working position.
LHS
Left Hand Side, used with reference to the side conveyors.
Lockout
Procedure to be carried out to ensure the machine is safe for maintenance or repairs.
Machine Stop
A stop arising from a sudden and unexpected need, and not as a part of the normal operation.
Main Conveyor
Conveyor used to move the material from the hopper to the screen unit.
Nip Point
A point at which a machine element moving in line meets a rotating element in such a manner
that it is possible to nip, pinch, squeeze, or entrap a person or objects coming into contact with
one or two of the members.
Optimum Speed
The best or most favorable speed to run a conveyor for example.
Oversize material
Material that is larger than the mesh size and runs off the top screen deck.

12 Glossary
Platform
A working space for persons, elevated above the surrounding floor or ground for the operation
of machinery and equipment.
Power unit
An inclosed unit situated under the main conveyor which houses the component parts which
together drive the machine.
Prevent
When used in a context such as prevent access or prevent physical contact, means to impede
or block; when used in a 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 speed, as established by the manufacture or a qualified person, at which safe and satisfactory
service can be expected.
Recommissioning
To prepare the machine for use.
Reject Grid
An arrangement of equally spaced grid bars which is used to separate the large stones before
the material enters the feed hopper.
Remote control
Any system of controls in which the actuator is situated in a remote location.
Retract
Withdraw or fold up conveyor.
Return Roller
A roller, which is used to support the unladened belt on the underside of the conveyor.
RHS
Right Hand Side, used with reference to the side conveyors.
Safety device
A mechanism or an arrangement placed in use for the specific purposes of preventing an unsafe
condition, preventing the continuation of an unsafe condition, warning of an unsafe condition, or
limiting or eliminating the unsafe effects of a possible condition.
Scraper
A device fixed or flexibly mounted across the width of a belt of a conveyor for removing adherent
material.
Screen Drum
Drum which mesh is fitted onto rotates during operation to screen material (Trommel).
Screen Unit
Vibratory unit used to separate by size raw materials.
Should
As used in the context of a provision of this manual, indicates a recommendation, the advisability
of which depends on the facts in a particular situation.

Glossary 12
Shredder Safety Stay

Metal strap which restrains the shredder unit whilst in the raised position.
Shredder Unit
Swinging flail type unit which is located at the discharge end of the feed conveyor and is used
to break down material.
Side Conveyor
Conveyor used to collect the material from the screen unit and move it to the discharge area at
90 degrees to the main machine.
Side Roller
Roller used to create arc on the belt to reduce spillage.
Sound Baffles
Plates used to blank out noise from the power unit.
Spillage
Material that spills over the edge of a conveyor etc.
Spill guard
A stationary device of sufficient strength and capacity to catch, retain, and contain any reasonably
foreseeable spillage from a conveyor passing overhead.
Spreader Plate
Swinging plate located at the discharge end of the main conveyor and is used to spread the
material evenly on the screen unit.
Sprocket
A toothed wheel arranged to fit into the links of a chain.
Strut
Rigid support used to hold an assembly in place.
Swivel Conveyor
Conveyor used to discharge fines material. Swivel through 180° to increase stockpiling capacity.
Tail Conveyor
Conveyor used to collect the fines material from the screen unit and move it to the discharge area.
Take-up
The assembly of the necessary structural and mechanical parts that provides the means to adjust
the length of belts, cables, chains, etc. to compensate for stretch, shrinkage, and wear.
Telescopic Head Section
A section of a conveyor which extends out telescopically into transport position.
Tow pin
A movable or fixed member, used to engage a push or pull.
Tracks
The beams, shapes, or formed section on which trolleys, rollers, shoes, or wheels roll or slide
while propelled.
Transport Bracket
A bracket used to hold an assembly in place whilst in transport.

12 Glossary
Transport Position
The position of the machine when conveyors are folded.
Variable Speed Flow Control
A device which is used to hydraulically vary the speed of the conveyor belt.
Viewing Apertures
Opening holes to view the conveyor belt.
Vulcanized Belt
A conveyor belt that has been joined seamlessly using a special treatment.
Wheel Nut Torque
A measure of pressure applied to tighten a nut.

Appendix
Table of Content
Appendix
Appendix A EC Declaration of Conformity
Appendix B Warranty
Appendix C Schematics

Warrior 2100 Page 1
Appendix

Page 2 Warrior 2100
Appendix A
Appendix A EC Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery 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 original copy of the
certificate is sent out with the machine.
The following page shows an example of a Declaration of Conformity certificate and the information
which should be included in it.
Each item of information on the example is numbered and the list of explanations below refer to
the corresponding numbered items on the example.
1 Full name and address of the manufacturer of the machine.
2 The name of the person authorised to compile the technical file.
3 The address of the person authorised to compile the technical file.
4 The function of the machine.
5 The model or type of the machine.
6 Serial number or pin number of the machine.
7 Commercial name of the machine.
8 Manufacturers declaration of conformity to the Machinery Directive 2006/42/EC.
9 Manufacturers declaration of conformity to the EMC Directive 2004/108/EC.
10 The place where the machine was issued from.
11 The date on which the machine was issued.
12 Identification of the person empowered to sign on behalf of the manufacturer.

Warrior 2100 Page A-1
Appendix A
Example

Page A-2 Warrior 2100
Appendix B
Appendix B Warranty
The following pages show warranty information.

Warrior 2100 Page B-1
Appendix B
NON USA SALES ONLY

LIMITED PRODUCT WARRANTY (NON USA)
Terex GB Ltd. (hereafter referred as “Seller”) warrants its new Equipment, to be free of defects in material or workmanship for a period of (i) 12 months
from the date the Equipment is first placed into service, whether such Equipment is sold, rented or leased or (ii) 2,000 hours of use, whichever first
occurs, provided that in no event shall this warranty extend beyond a period of 24 months from the date of shipment from the factory; provided that
(1) the Buyer or the end-user sends Seller written notice of the defect within sixty (60) days of its discovery and establishes to the Seller’s satisfaction
that: (i) the Equipment has been maintained and operated within the limits of rated and normal usage, and that there have been no alterations to it; and
(ii) the defect did not result in any manner from the intentional or negligent action or inaction by Buyer or the end-user or any of their respective agents
or employees or any person using it and (2) a new machine registration certificate or the commissioning documents have been completed, signed
and delivered to Seller within thirty (30) days of the equipment’s “in-service” date. If requested by Seller, Buyer must return the defective equipment
to Seller’s manufacturing facility, or other location designated by Seller, for inspection, and if Buyer cannot establish that conditions (1) (i) and (1) (ii)
above have been met, then this warranty shall not cover the alleged defect.
Subject to the Buyer establishing that conditions (1)(i) and 1(ii) above have been met, Seller warrants all Critical Components (as defined herein) to be free, under
normal use and service, of any defects in manufacture or materials for a period of: (1) twenty four (24) months from the date of commissioning, (2) 4000 hours of
use, or (3) Thirty Six (36) months the date of shipment from the factory, whichever occurs first. For the purposes of this warranty, Critical Components shall mean:
• Cone machines :- Main frame, Upper frame Countershaft and Housing, Drive pulley Drive Pinion and Gear, Eccentric, Wedge Ring (Excluding Pads)
• Jaw Machines: - Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle Beam, Flywheels.
• Impactor Machines: - Rotor, Main shaft, Crusher Body and Drive Pulley.
• Screen Boxes; - Screen Box Welded Assembly, Screen Box Sub frame, Main Shaft.
Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s sole option, repairing or replacing, with new or remanufactured parts or compo-
nents, any part, which appears to Seller upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the owner.
If requested by Seller, components or parts for which a warranty claim is made shall be returned to Seller at a location designated by Seller. All components and
parts replaced under this limited product warranty become the property of Seller.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM Seller parts are used in the equipment.
Accessories, assemblies and components included in the 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 limitation, friction plates, glass, clutch, proper tightening of bolts,
nuts and brake linings pipe fittings, adding or replacing of fluids, filters, wire rope, belts, screening media, rubber skirting, chute linings and paint, are not covered
by this warranty and are the sole maintenance responsibility of Buyer.
Seller makes no other warranty, express or implied, and makes no warranty of merchantability or fitness for any particular purpose.
No employee or representative is authorised to modify this warranty unless such modification is made in writing and signed by an authorized officer of Seller.
Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including without limitation, disposal or handling of tires, batteries, petro-
chemical items, or any other charges whatsoever, or any liability for direct, indirect, incidental, or consequential damages.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, accident,
sabotage or alteration or repair of the equipment by persons not authorized by Seller shall render this warranty null and void. Seller reserves the right to inspect
the installation of the product and review maintenance procedures to determine if the failure was due to improper maintenance, improper use, abuse, improper
storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by persons not authorized by
Seller.
Parts Warranty:
Seller warrants the parts ordered from the Seller’s parts department to be free of defect in material or workmanship for either (1) a period of 12 months after date
of shipment from the factory or (2) 2000 hrs of use or (3) the balance of the remaining new equipment warranty, whichever occurs first. With respect to parts
ordered from the Seller’s parts department for Equipment that is no longer covered under this limited product warranty due to lapse of time or usage in excess of
4,000 hours of Critical Components, Seller warrants such parts to be free of defect in material or workmanship for a period of either 12 months after date of ship-
ment from the factory or 2000 hrs of use, whichever occurs first.
Telematics.
If a telematics system is included with the Equipment, the telematics system is administered by a third party (“Teleservices Provider) and collects a range of opera-
tional data about the Equipment including, but not limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining such data from the Teleser-
vices Provider for warranty, product improvement and customer support purposes. Buyer understands that the Equipment warranty is conditioned on the proper
operation of the telematics system and Buyer shall not disable, tamper or interfere with the telematics system.
NO TRANSFERABILITY OF WARRANTY:
This warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not assignable or otherwise transferable without the written
agreement of Seller. Please contact your local distributor for additional details if needed.

Page B-2 Warrior 2100
Appendix B
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are NOT covered under the Seller Warranty (the following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Seller distributor.
2. Components which are not manufactured by Seller are not covered by Seller’s warranty. Such components are covered only by the warranty that
is provided by the manufacturer of such components. Such components may include, but are not limited to, chassis, engines, air compressors,
batteries, tires, customer supplied products.
3. Replacement of assemblies: Seller has the option to repair or replace any defective part or assembly. It is Seller’s policy to refuse claims for the
replacement of a complete assembly that is field repairable by the replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance
services and wear parts not covered include, but are not limited to, such items as: seals, gaskets, hoses, friction plates, glass, clutch and brake
linings, filters, wire rope, exterior coatings, proper tightening of bolts, nuts and fittings, adding or replacing of fluids, filter, breathers, belts, nozzles,
adjustments of any kind, services supplies such as hand cleaners, towels and lubricants, inspections, diagnostic time, travel time.
5. Transportation cost and/ or damage: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the
respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use, or use for
transportation of corrosive chemicals.
7. Secondary Failures: Should the owner or operator continue to operate a machine after it has been noted that a failure has occurred, Seller will not
be responsible under the warranty for resultant damage to other parts due to that continued operation.
8. Workmanship of Others: Seller does not accept responsibility for improper installation or labor costs or costs of 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 NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY
KIND, INCLUDING, BUT 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 FROM THE BREACH OF THIS WARRANTY. Customer’s sole remedy shall be limited to (at Seller’s sole option) repair or replacement of the
defective part.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, REPRESENTATIONS AND CONDITIONS, EXPRESS OR IM-
PLIED AND ALL OTHER STATUTORY, CONTRACTUAL, TORTIOUS AND COMMON LAW OBLIGATIONS OR LIABILITY ON SELLER’S PART ARE HEREBY
EXPRESSLY EXCLUDED TO THE MAXIMUM EXTENT PERMITTED BY LAW. THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WAR-
RANTY CONTAINED HEREIN.
Seller neither assumes nor authorizes any other person to assume for Seller any other liability in connection with the sale of Seller’s Equipment. This warranty shall
not apply to any of Seller’s Equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God or sabotage. No
action by any party shall operate to extend or revive this limited warranty without the prior written consent of Seller. In the event that any provision of this warranty
is held unenforceable for any reason, the remaining provisions shall remain in full force and effect.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY SELLER, SELLER’S LIABILITY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT
SELLER’S SOLE OPTION) OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL
SELLER, OR ANY SUBSIDIARY OR DIVISION THEREOF BE LIABLE FOR ANY: (A) LOST PROFITS AND/OR BUSINESS INTERRUPTION (WHETHER
DIRECT OR INDIRECT); AND (B) INDIRECT, INCIDENTAL, CONSEQUENTIAL (WHETHER DIRECT OR INDIRECT) OR OTHER DAMAGES OR LOSSES OF
ANY KIND, RESULTING FROM ANY BREACH OF WARRANTY, REPRESENTATION OR CONDITION, EXPRESS OR IMPLIED, OR ANY OTHER TERMS OF
THIS WARRANTY, OR ANY BREACH OF ANY DUTY OR OBLIGATION IMPOSED BY STATUTE, CONTRACT, TORT OR COMMON LAW OR OTHERWISE
(WHETHER OR NOT CAUSED BY THE NEGLIGENCE OF THE SELLER, ITS EMPLOYEES, AGENTS OR OTHERWISE), INCLUDING, WITHOUT LIMITA-
TION, LOSS OF USE, LOST PROFITS OR REVENUES, LABOUR OR EMPLOYMENT COSTS, LOSS OF USE OF OTHER EQUIPMENT, DOWNTIME OR
HIRE CHARGES, THIRD PARTY REPAIRS, IMPROPER PERFORMANCE OR WORK, LOSS OF SERVICE OF PERSONNEL, LOSS OF CONTRACT OR
OPPORTUNITY AND PENALTIES OF ANY KIND, OR FAILURE OF EQUIPMENT TO COMPLY WITH ANY APPLICABLE LAWS. THE SELLER’S LIABILITY
TO THE BUYER SHALL NOT IN ANY EVENT EXCEED THE PURCHASE PRICE OF THE EQUIPMENT, PROVIDED THAT NOTHING CONTAINED IN THIS
LIMITED PRODUCT WARRANTY SHALL OPERATE TO EXCLUDE THE SELLER’S LIABILITY FOR DEATH OR PERSONAL INJURY.

Appendix B
USA SALES ONLY

LIMITED PRODUCT WARRANTY (USA)
Terex GB Ltd. and Terex USA, LLC (hereafter referred to collectively as “Seller”) warrants its new Equipment, to be free of defects in material or
workmanship for a period of (i) 12 months from the date the Equipment is first placed into service, whether such Equipment is sold, rented or leased
or (ii) 2,000 hours of use, whichever first occurs, provided that in no event shall this warranty extend beyond a period of 24 months from the date of
shipment from the factory; provided that (1) the Buyer or the end-user sends Seller written notice of the defect within sixty (60) days of its discovery
and establishes to the Seller’s satisfaction that: (i) the Equipment has been maintained and operated within the limits of rated and normal usage, and
that there have been no alterations to it; and (ii) the defect did not result in any manner from the intentional or negligent action or inaction by Buyer or
the end-user or any of their respective agents or employees or any person using it and (2) a new machine registration certificate or the commission-
ing documents have been completed, signed and delivered to Seller within thirty (30) days of the equipment’s “in-service” date. If requested by Seller,
Buyer must return the defective equipment to Seller’s manufacturing facility, or other location designated by Seller, for inspection, and if Buyer cannot
establish that conditions (1) (i) and (1) (ii) above have been met, then this warranty shall not cover the alleged defect.
Subject to the Buyer establishing that conditions (1)(i) and 1(ii) above have been met, Seller warrants all Critical Components (as defined herein) to be free, under
normal use and service, of any defects in manufacture or materials for a period of: (1) twenty four (24) months from the date of commissioning, (2) 4000 hours of
use, or (3) Thirty Six (36) months the date of shipment from the factory, whichever occurs first. For the purposes of this warranty, Critical Components shall mean
• Cone machines :- Main frame, Upper frame Countershaft and Housing, Drive pulley Drive Pinion and Gear, Eccentric, Wedge Ring (Excluding Pads)
• Jaw Machines: - Mainframe including Cross Beam, Eccentric Shaft, Jaw Stock, Toggle Beam, Flywheels.
• Impactor Machines: - Rotor, Main shaft, Crusher Body and Drive Pulley.
• Screen Boxes; - Screen Box Welded Assembly, Screen Box Sub frame, Main Shaft.
Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s sole option, repairing or replacing, with new or remanufactured parts or compo-
nents, any part, which appears to Seller upon inspection to have been defective in material or workmanship. Such parts shall be provided at no cost to the owner.
If requested by Seller, components or parts for which a warranty claim is made shall be returned to Seller at a location designated by Seller. All components and
parts replaced under this limited product warranty become the property of Seller.
This warranty shall be null and void if parts (including wear parts) other than genuine OEM Seller parts 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 maintenance, adjustments, or maintenance/wear parts, including without limitation friction plates, glass, clutch and brake linings, filters, wire rope
and paint, are not covered by this warranty and are the sole maintenance responsibility of Buyer.
Seller makes no other warranty, express or implied, and makes no warranty of merchantability or fitness for any particular purpose.
No employee or representative is authorised to modify this warranty unless such modification is made in writing and signed by an authorized officer of Seller.
Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including without limitation, disposal or handling of tires, batteries, petro-
chemical items, or any other charges whatsoever, or any liability for direct, indirect, incidental, or consequential damages.
Improper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts, accident,
sabotage or alteration or repair of the equipment by persons not authorized by Seller shall render this warranty null and void. Seller reserves the right to inspect
the installation of the product and review maintenance procedures to determine if the failure was due to improper maintenance, improper use, abuse, improper
storage, operation beyond rated capacity, operation after discovery of defective or worn parts, or alteration or repair of the equipment by persons not authorized by
Seller.
Parts Warranty:
Seller warrants the parts ordered from the Seller’s parts department to be free of defect in material or workmanship for either (1) a period of 12 months after date
of shipment from the factory or (2) 2000 hrs of use or (3) the balance of the remaining new equipment warranty, whichever occurs first. With respect to parts
ordered from the Seller’s parts department for Equipment that is no longer covered under this limited product warranty due to lapse of time or usage in excess of
4,000 hours of Critical Components, Seller warrants such parts to be free of defect in material or workmanship for a period of either 12 months after date of ship-
ment from the factory or 2000 hrs of use, whichever occurs first.
Telematics.
If a telematics system is included with the Equipment, the telematics system is administered by a third party (“Teleservices Provider) and collects a range of opera-
tional data about the Equipment including, but not limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining such data from the Teleser-
vices Provider for warranty, product improvement and customer support purposes. Buyer understands that the Equipment warranty is conditioned on the proper
operation of the telematics system and Buyer shall not disable, tamper or interfere with the telematics system.
NO TRANSFERABILITY OF WARRANTY:
This warranty is limited to the original purchaser or original end-user if sold to a distributor, and is not assignable or otherwise transferable without the written
agreement of Seller. Please contact your local distributor for additional details if needed.

Appendix B
ITEMS NOT COVERED BY SELLER WARRANTY
The following items are NOT covered under the Seller Warranty (the following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other organization or legal entity that is not an authorized Seller distributor.
2. Components which are not manufactured by Seller are not covered by Seller’s warranty. Such components are covered only by the warranty that
is provided by the manufacturer of such components. Such components may include, but are not limited to, chassis, engines, air compressors,
batteries, tires, customer supplied products.
3. Replacement of assemblies: Seller has the option to repair or replace any defective part or assembly. It is Seller’s policy to refuse claims for the
replacement of a complete assembly that is field repairable by the replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts: Maintenance services and wear parts are excluded from warranty claims. Maintenance
services and wear parts not covered include, but are not limited to, such items as: seals, gaskets, hoses, friction plates, glass, clutch and brake
linings, filters, wire rope, exterior coatings, proper tightening of bolts, nuts and fittings, adding or replacing of fluids, filter, breathers, belts, nozzles,
adjustments of any kind, services supplies such as hand cleaners, towels and lubricants, inspections, diagnostic time, travel time.
5. Transportation cost and/ or damage: Any damage caused by carrier handling is a transportation claim and should be filed immediately with the
respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age, storage, weathering, lack of use, demonstration use, or use for
transportation of corrosive chemicals.
7. Secondary Failures: Should the owner or operator continue to operate a machine after it has been noted that a failure has occurred, Seller will not
be responsible under the warranty for resultant damage to other parts due to that continued operation.
8. Workmanship of Others: Seller does not accept responsibility for improper installation or labor costs or costs of 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 NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF
ANY KIND, INCLUDING, BUT 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 FROM THE BREACH OF THIS WARRANTY. CUSTOMER’S SOLE REMEDY SHALL BE LIMITED TO (AT SELLER’S SOLE OPTION)
REPAIR OR REPLACEMENT OF THE DEFECTIVE PART.
THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) AND ALL OTHER OBLIGATIONS OR LIABILITY ON SELLER’S PART. THERE ARE NO
WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY CONTAINED HEREIN.
Seller neither assumes nor authorizes any other person to assume for Seller any other liability in connection with the sale of Seller’s equipment. This warranty shall
not apply to any of Seller’s equipment or any part thereof which has been subject to misuse, alteration, abuse, negligence, accident, acts of God or sabotage. No
action by any party shall operate to extend or revive this limited warranty without the prior written consent of Seller. In the event that any provision of this warranty
is held unenforceable for any reason, the remaining provisions shall remain in full force and effect.
IN THE EVENT OF ANY BREACH OF THE WARRANTY BY SELLER, SELLER’S LIABILITY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES (AT
SELLER’S SOLE OPTION) OF REPAIR OR REPLACEMENT OF ANY DEFECTIVE EQUIPMENT COVERED BY THE WARRANTY. IN NO EVENT SHALL
SELLER, OR ANY AFFILIATE, SUBSIDIARY OR DIVISION THEREOF BE LIABLE FOR ANY A) LOST PROFITS AND/OR BUSINESS INTERRUPTION
(WHETHER DIRECT OR INDIRECT); AND (B) INDIRECT, INCIDENTAL, CONSEQUENTIAL (WHETHER DIRECT OR INDIRECT) OR OTHER DAMAGES OR
LOSSES OF ANY KIND, RESULTING FROM A BREACH OF WARRANTY INCLUDING, WITHOUT LIMITATION, LABOR COSTS, LOSS OF USE OF OTHER
EQUIPMENT, THIRD PARTY REPAIRS, LOST PROFITS, LOST TIME, TOWING OR HAULING OF EQUIPMENT, RENTAL COSTS, PERSONAL INJURY, EMO-
TIONAL OR MENTAL DISTRESS, IMPROPER PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE OF PERSONNEL, OR FAILURE
OF EQUIPMENT TO COMPLY WITH ANY FEDERAL, STATE OR LOCAL LAWS.

Appendix B
To register the warranty of this machine please visit: http://www.powerscreenwarranty.com.

Depending on the engine fitted to your machine you must also register the engine of your product
via:
Catapillilar
http://www.cat.com/cda/layout?m=37532&x=7&id=3836261
Scania
http://www.scania.co.uk/engines/service/start-up-report/index.aspx
Telematics
If a telematics system is included with the Equipment, the telematics system is administered
by a third party and collects a range of operational data about the Equipment including, but not
limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining such data for
warranty, product improvement and customer support purposes. Buyer understands that the
Equipment warranty is conditioned on the proper operation of the telematics system and Buyer
shall not disable, tamper or interfere with the telematics system.
To access telematics system information visit our website:
http://powerscreen.com/en/pulse/

Appendix C
Table of Content
Appendix C..................................................................................................C-3
(1) Hydraulic Drawings.................................................................................... C-3
(2) Tier 4 Schematics...................................................................................... C-5
(3) Dual Power Schematics............................................................................ C-7

Warrior 2100 Page C-1
Appendix C

Page C-2 Warrior 2100
Appendix C
Appendix C
(1) Hydraulic Drawings

Appendix C

Appendix C
(2) Tier 4 Schematics

Appendix C

F
E
B
D
A
C
For this document and the object represented in that we reserve all rights according to DIN 34.
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
1
1
2
2
-JS
Battery Cable 70mm-B 1/2 Battery Cable 70mm-R
2/2
-JS
CONNECTO
JUMP START
-X1
1/1
3
3
25A
-LF1
-X2 -LF1.2
1/1 AUTO 6mm-R 1/1 AUTO 6mm-R #B+
1/1
/10.F12
only in
11
the E3!
22
drawing
Changing
-LF1.1
0
3
1
2
Revision
1/1
80A
-LF2
-X3 -LF2.2
/2.A2
-X6 -BATT2
12V
1/1 1/1 Battery Cable 16mm-R 1/1 Battery Cable 16mm-R
ECO
2
1
1/1 1/1 1/1

PE - 1
-BATT1
PCB
-LF2.1 AUTO 0.75mm-R

-PE1_1
BATT +
/3.C3 T12V 1/1

1/1
-PE1_2
First Draft
-X4
4
-X7
Revision text
4
1/1 Battery Cable 70mm-R
Battery Cable 70mm-B
-ISO.
1/1
300A
14
-ISO
13
Date
04.01.17
-X11 -X5
5
1/1 1/1
5

M
1/1 -X8
AJC
Name
-X10 1/1
-X13
1/1 Battery Cable 35mm-B
1/1
1/1
1/1
1/1
-X16
-X15
-X14
-X12
User
Proved
Date
6
6
Battery Cable 25mm-R
AUTO 6mm-B
AUTO 6mm-B
Name
AJC
-X9
#138 1/1
#ECU_-VE
#-VE
#301
/3.C1
/10.C5
/10.G12
7
7
/2.A8
-PH
1/1 AUTO 6mm-N
-K12
10/12
PCB
D - 10
CONTACT
-PCBD
Type
ENGINE
PREHEAT
P.-Nr.:
WR2100
/2.E8
-STS
1/1 AUTO 6mm-WR
8
8
-K4
PE - 5
PCB
1/1
CONTACT
-PE5
CONNECTION
STARTER SOLENOID
60552903.0
Description: Electrical Kit
Drawing number
Power Unit Kit CAT C4.4 T4F
9
9
No.
Sheet
Assignment
1
Location +PU
18 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
/10.A11 /1.A7
A -PCB1 /10.A5 A
/10.A10 /10.A10 /10.A10
/1.A4 /10.A11
/3.A1
/3.A9
/7.A2
B +CHAS/9.A6 B
/4.A2
/4.F2
/3.A5
/10.A12
/6.A8 /6.A1
/7.A7
/7.E8
/7.A2
C /7.E8 C
/6.A6
/4.F4 /4.F8
/5.A5
/4.F4
/6.A3
/10.A1
/8.A8
/10.A1
/4.F3
D D
/7.A8 /7.E7
/6.A7
/4.D5
/4.C6 /1.A8
/3.A2
/3.A2 /5.A4
/5.A7
/5.A2
/7.A3 /8.A5
E E
/7.E3
/3.A1
/8.A3 /8.A6
/7.E2
/7.E4
/6.A2
+CHAS/9.A4 /8.A7
/8.E1 /7.E5
/8.E4
/8.A7
/8.A1
/10.A9 /7.E6
/4.C6 /5.A1
/5.A2
/5.F2 60526070
F F
3 Date Name Type WR2100 Description: Electrical Kit Assignment

Changing
2 Power Unit Kit CAT C4.4 T4F
drawing P.-Nr.: Location +PU
1 User AJC
only in
0 First Draft 04.01.17 AJC Drawing number Sheet 2
the E3! Proved 60552903.0 No. 18 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
-8 /2.B8
1/5 AUTO 1mm-B
2/5 AUTO 1mm-U
PE - 4
PCB
1/1
IGN_ON
1
1
-PE4
/2.E2
#-VE Battery Cable 16mm-B

/1.F7
SOCKET
1/1
PE - 2
PCB
3/5 AUTO 0.75mm-GY

-PE2_1
GROUND
EXPANSION NODE
4/5 AUTO 0.75mm-N 1/1
5/5 -PE2_2
AUTO 0.75mm-W
/2.E2
2
2
B-5
5/18
PCB
CAN2_H
-PCBB
/2.E2
1W
Ω 120
B-2
2/18
PCB
CAN2_L
-PCBB
-X17
-R1
4/5
5/5
SOCKET
3
3
PROGRAMMING
+TEL
only in
the E3!
drawing
-TEL1
Changing
1/5 AUTO 0.75mm-R
/1.B4
2/5 AUTO 0.75mm-RBT12V
0
3
1
2
Revision
3/5 AUTO 0.75mm-B
4/5 AUTO 0.75mm-U
ECO
/10.B8
5/5 AUTO 0.75mm-GY#B11
TELEMATICS
/10.B8
#B8
#-VE
#IGN_ON
First Draft
4
Revision text
4
/4.C1
+CHAS/9.F3
/2.B2
Date
AUTO 0.75mm-N
B-9
9/18
PCB
04.01.17
1/2 1/2
IGN_ON
-PCBB
-1 -ESS
5
5
AJC
Name
User
Proved
Date
-S4
-ES2 -3 -ES1 -2
-S5
6
2/2 1/2 2/2 1/2
6
1
2
2/2 1/2 2/2 1/2

+ESTOP2 -W4 BU
+ESTOP2 -W4 BN
+ESTOP1 -W3 BU
+ESTOP1 -W3 BN
Name
AJC
-3 -ES2 -2 -ES1
7
7
ESTOP
ESTOP
-5 -4
CHASSIS
CHASSIS
1/2 1/2
Type
2/2 2/2
P.-Nr.:
-5 -4
WR2100
8
8
ESTOP
ESTOP
-7 -6
CHASSIS
CHASSIS
1/2 1/2
2/2 2/2
60552903.0
-7 -6
Drawing number
/2.B8
9
9
AUTO 0.75mm-B
B-7
7/18
PCB
2/2 2/2
-K2 COIL
-PCBB
No.
-1 -ESS
Sheet
Assignment
3
Location +PU
18 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
BATT +
PCB
/2.B2
A -3
A A
3/12
-PCBA
AUTO 0.75mm-R
13
B 30 B
-S1
ON 15 START 50
#IGN_ON -SP1 #IGN_ON

/3.C4 +CHAS/9.B5
AUTO 1.00mm-RB
AUTO 0.75mm-R
AUTO 0.75mm-R
AUTO 0.75mm-R
GROUND
PCB
/2.F2
C A - 10 C
CAN2_H
PCB
10/12
-PCBA
/2.E2
A - 12
AUTO 0.75mm-R
CAN2_L
PCB
12/12
-PCBA
/2.D2
A - 11
2 1 2 2
-S3 -S2
D SPEED LIGHTS D
11/12
-PCBA
1 2 1 CONTROL 1 ON/OFF
AUTO 0.75mm-R
1W -R3
Ω 120
AUTO 0.75mm-GW
AUTO 0.75mm-B
AUTO 1.00mm-RO
AUTO 0.75mm-RY
AUTO 0.75mm-N
AUTO 0.75mm-W
E E
-HMI.
-PCBA
-PCBA
-PCBA
-PCBA
-PCBA
4/5
2/5
5/5
3/5
1/5
6/12
2/12
5/12
7/12
9/12
5 4 3 2 1
CAN_H
GND
8...32 V DC
N.C
CAN_L
6- A 5-A 7-A 2- A 9- A
/2.B2 /2.D2 /2.C2 /2.C2 /2.C8
PCB PCB PCB PCB PCB
IGN_ON IN 09 IN 03 IN 04 -HMI B12 LINK
F CR0451 F

Changing
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
1
1
/2.F5
-PCBB
10/18
D -1
1/12
10 - B
PCB
PCB
D3 LINK
-PCBD
GROUND
/2.F2
/2.F4
AUTO 1mm-NO
2
2
D-3
3/12
PCB
D1 LINK
-PCBD
/2.E8
-HOC1
-SP2
AUTO 2mm-B HYD OIL 1/2 AUTO 2mm-P
13/18
PCB
B - 13
2/2
FUSE 6
COOLER -PCBB
-HOC1 FAN No.1
3
3
only in
the E3!
drawing
Changing
0
3
1
2
Revision
ECO
First Draft
/2.E9
4
Revision text
4
-HOC2
AUTO 2mm-B HYD OIL 1/2 AUTO 2mm-P
16/18
PCB
2/2
B - 16
FUSE 5
COOLER -PCBB
-HOC2 FAN No.2
Date
04.01.17
5
5
AJC
Name
/2.C8
-H1
-LI -LI
AUTO 0.75mm-B 2/2 1/2 AUTO 0.75mm-GW
1
12/18
PCB
B - 12
User
LIGHT
B9 LINK
-PCBB
Proved
POWER UNIT
Date
6
6
Name
AJC
BEACON
/2.E2
MACHINE
7
7
-BC
-SP3
AUTO 0.75mm-B 1/2

B -1
1/18
PCB
2/2
OUT 03
-PCBB
-BC
Type
P.-Nr.:
WR2100
8
8
AUTO 1.00mm-RN
-H2
-SRN1 -SRN2
AUTO 0.75mm-B +SIREN -W2 BU +SIREN -W2 BN 1/2 1/2
1
2/2 2/2
-SRN2 -SRN1
60552903.0
Drawing number
9
9
No.
Sheet
Assignment
5
Location +PU
18 Sh.
F
E
B
D
A
C
F
E
B
D
A
C
1
1
/2.C8
PCB
13/31
HDP - 13
IGN_ON
-PCBH
/2.E2
PCB
14/31
HDP - 14
GROUND
-PCBH
2
2
AUTO 0.75mm-B
AUTO 0.75mm-R
-B1 -CDS
3
-SP4
3
IFS208 1 1/5 AUTO 0.75mm-R
only in
the E3!
2
drawing
Changing
-CDS
-SP5
3 3/5 AUTO 0.75mm-B

/2.C2
0
3
1
2
-CDS
Revision
4 4/5 AUTO 0.75mm-BW AUTO 0.75mm-BW
PCB
DELAY SENSOR
IN 05
23/31
HDP - 23
CONVEYOR START
ECO
-PCBH
First Draft
4
Revision text
4
+AUX
-B1 -FP1
PK8731 1 1/5 AUTO 0.75mm-R
2
3 3/5 AUTO 0.75mm-B
KICK-OUT 1
4 4/5
Date
FEEDER PRESSURE
04.01.17
5
5
+AUX
AJC
Name
-B2 -FP2
PK8731 1 1/5 AUTO 0.75mm-R
+AUX
2
3 3/5 AUTO 0.75mm-B
/2.C2
User
Proved
KICK-OUT 2
4 4/5 AUTO 0.75mm-SB AUTO 0.75mm-SB

A -8
8/12
PCB
Date
IN 02
FEEDER PRESSURE
-PCBA
6
6
-SP14
Name
AJC
320428
-B2 -HOL
1 1/4 AUTO 0.75mm-R
/2.D2
2 2/4 AUTO 0.75mm-B

3 3/4 AUTO 0.75mm-NW AUTO 0.75mm-NW
7
7
PCB
SENSOR
IN 11
25/31
HDP - 25
-PCBH
HYD OIL LEVEL
Type
P.-Nr.:
WR2100
8
8
-FS
1/2 AUTO 0.75mm-R
/2.C2
-LL2
2/2 AUTO 0.75mm-OB 1/4 AUTO 0.75mm-OB
A-4
4/12
PCB
IN 07
1/4
FUEL SAVE
-PCBA
CONNECTION
-LL1
60552903.0
#HDP13
Drawing number
9
9
/8.C2
No.
Sheet
Assignment
6
Location +PU
18 Sh.
F
E
B
D
A
C
F
E
B
D
A
C
1
1
TRACKS ON SW
/2.C2
-PCBH -TRK
2/31 AUTO 0.75mm-B 10/16 AUTO 1.00mm-RU
PCB
IN 01
PCB
2/16 10/31
HDP - 10
GROUND
2 - HDP
-TRK -PCBH
/2.E2
2
2
/2.B8
-TRK
4/16 AUTO 0.75mm-P
PCB
HDP - 4
4/31
ESTOP
HEALTHY
-PCBH
LTF
/2.E2
-PCBH -TRK
5/31 AUTO 0.75mm-UO 3/16 AUTO 1.0mm-RW
PCB
HDP - 3
PCB
LTF
5/16 3/31
OUT 04
-K7 COIL
5 - HDP
-TRK -PCBH
3
3
/2.E8
only in
the E3!
drawing
Changing
0
3
1
2
Revision
ECO
LTR
-PCBH
8/31 AUTO 0.75mm-UY
PCB
8/16
LTR
First Draft
-K8 COIL
8 - HDP
4
-TRK
Revision text
4
/2.E8
RTF
Date
-PCBH
04.01.17
6/31 AUTO 1.00mm-NS
PCB
5
RTF
6/16
5
-K9 COIL
6 - HDP
-TRK
AJC
Name
/2.F8
TRACKING UMBILICAL
User
Proved
Date
RTR
-PCBH
6
9/31
6
AUTO 1.00mm-NY
PCB
9/16
RTR
Name
AJC
9 - HDP
-K10 COIL
-TRK
/2.F8
FAST
-PCBH
1/31 AUTO 0.75mm-GY
7
7
PCB
1/16
FAST
1- HDP
-K11 COIL
-TRK
/2.D8
/2.C8
Type
P.-Nr.:
-PCBH RADIO -TRK

15/31 AUTO 1.00mm-BP TRACK 16/16 AUTO 1mm-GP
PCB
LINK
PCB
16/31
HDP - 16
15/16
HDP 07
STOP LINK
IGN_ON
15 - HDP
-TRK -PCBH
/2.C8
WR2100
MACHINE REMOTE
8
STOP
8
/2.D2
-PCBH -TRK
7/31 AUTO 1.00mm-BY 12/16 AUTO 1.00mm-WR
PCB
LINK
PCB
IN 10
12/31
HDP - 12
7/16
HDP 15
7 - HDP
-TRK -PCBH
/2.C8
60552903.0
Drawing number
9
9
No.
Sheet
Assignment
7
Location +PU
18 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
A A
-K7 -K8 -K9 -K10 -K11
OUT 10 OUT 06 CONTACT CONTACT CONTACT CONTACT CONTACT
PCB PCB PCB PCB PCB PCB PCB
/2.F2 /2.E3 /2.E8 /2.E8 /2.E8 /2.F8 /2.D8
HDP - 30 C -1 HDP - 17 HDP - 18 HDP - 19 HDP - 20 HDP - 11
-X24
1/6
30/31
20/31
17/31
18/31
19/31
11/31
-PCBH
-PCBH
-PCBH
-PCBH
-PCBH
-PCBH
-LL2
B B
2/4
-LL1
2/4
AUTO 0.75mm-GO
AUTO 0.75mm-GK
AUTO 0.75mm-GN
AUTO 1.00mm-OB
AUTO 0.75mm-RY
AUTO 0.75mm-P
-RTG -X1
1/4 1/4
2/4 2/4
1.00mm-OB AUTO
C #HDP13 3/4 C
/6.C9
4/4
-RTR
-RTF
-CS1
-LTR
-LTF
-cs2
-FT
1/4
1/4
1/4
1/4
1/4
1/4
1/4
LEFT TRACK LEFT TRACK RIGHT TRACK RIGHT TRACK FAST TRACK
CONVEYOR FEED CONVEYOR FORWARD SOL. REVERSE SOL. FORWARD SOL. REVERSE SOL. SOLENOID
-CS1
-LTF
-RTF
2/4
2/4
2/4
2/4
2/4
2/4
-LTR
-RTR
-FT
-cs2
2/4
RUN RUN
AUTO 0.75mm-B
AUTO 0.75mm-B
AUTO 0.75mm-B
AUTO 0.75mm-B
AUTO 0.75mm-B
D D
-SP6
AUTO 0.75mm-B
AUTO 0.75mm-B
-PCBH
-PCBH
21/31
31/31
E E
31- HDP 21- HDP

/2.F2 /2.F2
PCB PCB
GROUND GROUND
F F

Changing
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
SUPPLY
GROUND HEALTHY
PCB PCB
A +PU/2.E2 +PU/2.B8 A
+PU/4.C8
HDP - 27 HDP - 26
27/31
26/31
-PCBH
-PCBH
+AUX
+AUX
#IGN_ON
AUTO 0.75mm-B
AUTO 0.75mm-OB
AUTO 0.75mm-R
B B
-LL1
-LL1
4/4
3/4
-K1.
1/1
-LL2
-LL2
3/4
4/4
30
/9.F7
AUTO 0.75mm-OB
AUTO 0.75mm-B
-K1
87 87a
1/1
-K1._3
-SLL1
-SLL1
C C
3/4
1/4
AUTO 0.75mm-GN
-SLL1.
-SLL1.
3/4
1/4
-SRS -B1
AUTO 0.75mm-OB 1/5 1 IFS208
-SLL1
-SRS 2
3/5
2/4
3
-SRS
-SLL1.
4/5 4
-SLL1.
2/4
D 3 DECK SCREENBOX D
4/4
RAISE LIMIT SWITCH
AUTO 0.75mm-GN
AUTO 0.75mm-B
AUTO 0.75mm-B
60541061
-SLL1
4/4
-SRV
AUTO 0.75mm-NO
1/4
-K1._1
1/1
E 2/4 E
-SRV
86
-K1
/9.F6
85
3 DECK SCREENBOX
1/1
-K1._2
RAISE INHIBIT
SOLENOID
#-VE AUTO 0.75mm-B

+PU/3.C4
-K1
F /9.E6 F
30 87
/9.C5
87a

Changing
drawing P.-Nr.: Location +CHAS
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
XNOX XNOX
POWER IGNITION POWER PREHEAT ELP
RELAY ON TO ECU RELAY RELAY RELAY
-K13 -K5 RELAY -K14
CAN1_L CAN1_H CONTACT CONTACT -K13 COIL -K12 COIL -K14 COIL GROUND CONTACT IGN_ON
A PCB PCB PCB PCB PCB PCB PCB PCB PCB PCB A
/2.D2 /2.D2 /2.A6 /2.F6 /2.A5 /2.A7 /2.A4 /2.A8 /2.A5 /2.B2
B- 8 -PCBB B - 11 D- 6 B-3 D-8 D - 11 D-9 B - 17 D- 2 B - 18
-PCBB
-PCBB
-PCBB
-PCBB
-PCBD
-PCBD
-PCBD
-PCBD
-PCBD
6/12
8/12
11/12
9/12
2/12
8/18
11/18
3/18
17/18
18/18
AUTO 0.75mm-WU
AUTO 0.75mm-W
AUTO 1mm-WP
AUTO 2mm-RB
AUTO 1mm-N
AUTO 1mm-P
0.75mm-R AUTO
AUTO 0.75mm-GY #B11
/3.C4
B B
AUTO 0.75mm-U #B8
/3.C4
/1.F7
TENNECO
XNOX DCU
AUTO 6mm-R
ENGINE
120 Ω
#301
-AFR
-R2 1W ECU
1/2
-XN1
1/31 AUTO 0.75mm-R
-X15:1
-J1
21/31 70/70 AUTO 0.75mm-W AFR SWITCH
-XN1 2/31 -SP7 25/70 (BY OTHERS)
AUTO 6mm-B
AUTO 0.75mm-R -J1
20/31 -J1 7/70 AUTO 1mm-P
C -XN1 C
3/31 AUTO 0.75mm-R 26/70 -J1
-AFR
2/2
-TH1 -J1 8/70 AUTO 1mm-N
-XN1
5/31 AUTO 0.75mm-B -J1
TANK HEADER
4/4 5/70 AUTO 1mm-WP
6/31 AUTO 0.75mm-B -SP8 -J1
UNIT
3/4 18/70 AUTO 0.75mm-WU
7/31 AUTO 0.75mm-B
2/4
1/4
AUTO 0.75mm-GY
AUTO 0.75mm-U
-R5
AUTO 0.75mm-B
D 54/70
D
AUTO 0.75mm-R
-J1
Ω 120
1W
55/70
-XN1
23/31 -SP11 AUTO 0.75mm-U
-J1
-XN1 34/70 -J1
22/31 -SP12 AUTO 0.75mm-GY
-J1 28/70 AUTO 0.75mm-BR
33/70
-XN1 -J1
8/31 AUTO 0.75mm-RY
-J1 4/70 AUTO 2mm-RB
-XN1 15/70
9/31 AUTO 0.75mm-S
-J1 WAIT TO
22/70 ISOLATE
E -XN1
-J1
E
11/31 AUTO 0.75mm-GY
/16.F9
20/70
RED
-XN1 -J1 -WTI -X18
X1
X2
12/31 AUTO 0.75mm-RY
-J1 48/70 AUTO 0.75mm-BP 1/2 1/2 AUTO 0.75mm-BP AUTO 0.75mm-R
21/70 2/2 2/2
-XN1
-H3
-J1
RED
24/31 AUTO 0.75mm-B -X18 -WTI
-J1
12/70 2/70 AUTO 2mm-R
-HL1 -J1
-XN1
13/31 1/2 11/70
HEATED
AUTO 1mm-GP AUTO 0.75mm-GB AUTO 2mm-R
LINE 1
-XN1 36/70
14/31 AUTO 0.75mm-BW 2/2 AUTO 0.75mm-GB
-J1 38/70 AUTO 2mm-R -SP9
/1.A3
3/70 #B+ -LF1.2:1
F -J1
F
-HL2 41/70 AUTO 2mm-R
-XN1
15/31 AUTO 0.75mm-K 1/2 HEATED
LINE 2 57/70 AUTO 2mm-R
-XN1
16/31 AUTO 0.75mm-OB 2/2
-J1
-XN1 -HL3 65/70 AUTO 2mm-B
18/31 2/2
HEATED
AUTO 0.75mm-GW -J1

LINE 3
47/70 AUTO 2mm-B

1/2
-J1
45/70 AUTO 2mm-B
/1.F7
DIVERTER
COOLANT
-XN1 -CDV -J1 -SP10 #ECU_-VE

G G
VALVE
17/31 AUTO 0.75mm-GR -SP14 1/3 35/70 AUTO 2mm-B

-XN1 -J1
19/31 AUTO 0.75mm-OB 3/3 13/70 AUTO 2mm-B
-J1
9/70 AUTO 2mm-B
-XN1
4/31 AUTO 0.75mm-WO
59/70
-J1
H H
I I

Changing 2
drawing M.-Nr.: CAT C4.4 T4F Power Unit Kit CAT C4.4 T4F Location +PU
1 User AJC
only in
the E3! ECO Proved No. 18 Sh.
Revision text Revision Date Name
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
TELEMATICS
-F1
5A
A -TEL2 -TEL3 A
1/5 1/31
1
AUTO 0.75mm-RB
2
AUTO 0.75mm-RB
2/5 AUTO 0.75mm-N 3/31
3/5 AUTO 0.75mm-B -SP13 2/31
6/31
22/31
-MC 23/31
1/4 24/31
2/4 AUTO 0.75mm-U 4/31
3/4 AUTO 0.75mm-Y 5/31
B B
4/5 AUTO 0.75mm-U 7/31
5/5 AUTO 0.75mm-GY 18/31
-BW
1/4
2/4
3/4 AUTO 0.75mm-WO 16/31
4/4 AUTO 0.75mm-BW 17/31
C C
WATER IN
FUEL
-WIF1 -WIF2
1/3 AUTO 0.75mm-GU 1/3
2/3 AUTO 0.75mm-RS 2/3
3/3 AUTO 0.75mm-OB 3/3
D D
FUEL LIFT
PUMP
-FLP1 -FLP2
1/2 AUTO 2mm-G 1/2
2/2 AUTO 2mm-B 2/2
E E

Changing
1 User AJC
only in Drawing number Sheet 11
0 First Draft 04.01.17 AJC
the E3! ECO Proved 60552903.0 No. 18 Sh.
Revision Revision text Date Name
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9
2700MM
A A
-U64 Part No. 60552225/6 -X1#2
-JS#2 -JS#1 1 #129 -JS:1 Red 3 70.00 mm²
1/2 1/1
1 #129 -X1:1 Red 3 70.00 mm² -X1#1
2/2
2 #130 -X6:1 Black 4 70.00 mm² -U65 -X6#2
1 #130 -JS:2 Black 4 70.00 mm²
-BATT2#1 1/1
-BATT1#1
-X6#1
ENGINE JUMP START CONNECTION
TO BATTERY
1/1
1/1
2400MM
B B
480MM
-ISO.#2 -ISO.#1 -U59 Part No. 60552223 -X7#2

1/1
1 #133 -X7:1 Black 6 70.00 mm² 1 #133 -ISO.:1 Black 6 70.00 mm²
1/1
-X7#1
-VE BATTERY TO MAIN ISOLATOR
C C
1400MM
-X4#2 -X4#1 -U60 Part No. 60552221 -X5#2

1/1
1 #132 -X5:1 Red 5 70.00 mm² 1 #132 -X4:1 Red 5 70.00 mm²
1/1
-X5#1
+VE BATTERY TO STARTER +VE STUD
D D
1400MM
-X10#2 -X10#1 -U61 Part No. 60552224 -X11#2

1/1
1 #134 -X11:1 Black 7 70.00 mm² 1 #134 -X10:1 Black 7 70.00 mm²
1/1
-X11#1
MAIN ISOLATOR TO STARTER -VE STUD
E E
300MM
-X12#2 -X12#1 -U62 Part No. 60552222 -X13#2

1/1
1 #135 -X13:1 Black 8 35.00 mm²
1/1
1 #135 -X12:1 Black 8 35.00 mm²
-X13#1
STARTER -VE STUD TO CHASSIS GROUND
600MM
F -X8#2 -X8#1 -U63 Part No. 60552227 -X9#2 F

1/1
1 #137 -X9:1 Red 41 25.00 mm²
1/1
1 #137 -X8:1 Red 41 25.00 mm²
-X9#1
STARTER +VE STUD TO ALTERNATOR CHARGE TERMINAL

Changing
drawing P.-Nr.: Location +BATT
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
WR2100 POWER UNIT LOOM - 60552945
-FT#1
*4/4
-PCBH#2 FAST TRACK
1 #HDP1 -TRK:1 Green-Yellow 50 0.75 mm² -FT#2 SOLENOID
2 #-HDP2 -TRK:2 Black 45 0.75 mm² 1 #HDP11 -PCBH:11 Purple 59 0.75 mm²
A A
3 #HDP3 -TRK:3 Red-White 44 1.00 mm² 2 #HDP21 +PU-SP6:1 Black 27 0.75 mm²
4 #HDP4 -TRK:4 Purple 42 0.75 mm² 3
5 #HDP5 -TRK:5 Blue-Orange 46 0.75 mm² PE
6 #HDP6 -TRK:6 Brown-Grey 48 1.00 mm² 1 2
7 #HDP7 -TRK:7 Black-Yellow 52 1.00 mm²
8 #HDP8 -TRK:8 Blue-Yellow 47 0.75 mm² -RTG#1
*4/4
9 #HDP9 -TRK:9 Brown-Yellow 49 1.00 mm²
10 #HDP10 -TRK:10 Red-Blue 43 1.00 mm² FRONT
11 #HDP11 -FT:1 Purple 59 0.75 mm² VIEW
530mm
12 #HDP12 -TRK:12 White-Red 53 1.00 mm²
13 #HDP13 +PU-SP4:1 Red 56 0.75 mm²
3 4
14 #HDP14 +PU-SP5:1 Black 125 0.75 mm² REMOTE
15 #HDP15 -TRK:15 Black-Purple 51 1.00 mm² FEEDER START/STOP
16 #HDP16 -TRK:16 Green-Pink 54 1.00 mm²
(OPTIONAL)
250mm
17 #HDP17 -LTF:1 Red-Yellow 23 0.75 mm² -RTG#2
18 #HDP18 -LTR:1 Orange-Black24 1.00 mm² 1 #1000299 +PU-LL1:2
19 #HDP19 -RTF:1 Green-Pink 25 0.75 mm² 2 #1000299 +PU-cs2:1
B 20 #HDP20 -RTR:1 Green-Orange26 0.75 mm² 3 #HDP13
B
21 #HDP21 +PU-SP6:1 Black 84 0.75 mm² 4 #HDP31
22 BLANKING PLUG REQUIRED
23 #HDP23 -CDS:4 Black-White 113 0.75 mm²
24 BLANKING PLUG REQUIRED
25 #HDP25 -HOL:3 Brown-White 36 0.75 mm² -SP4#1
26 #HDP26 +PU-LL1:4 Orange-Black616 0.75 mm² #HDP13
27 #HDP27 +PU-LL1:3 Black 620 0.75 mm²
28 BLANKING PLUG REQUIRED Red,Red,Red,Red,Red,Red
29 BLANKING PLUG REQUIRED 57, 56, 124, 608, 609, 613
30 #HDP30 -CS1:1 Green-Brown 21 0.75 mm² 0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²
31 #HDP31 -CS1:2 Black 22 0.75 mm² -SP5#1
#HDP14 -HOL#2
50mm
1 #HDP13 +PU-SP4:1 Red 124 0.75 mm²
Black,Black,Black,Black,Black 2 #HDP14 +PU-SP5:1 Black 150 0.75 mm²
125, 149, 150, 605, 607 3 #HDP25 -PCBH:25 Brown-White 36 0.75 mm²
0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm² 4
C C
*31/31 -SP4 -SP5 HYD. OIL LEVEL
-PCBH#1
300mm 600mm 300mm 650mm 50mm 2300mm 1000mm SENSOR
*4/4
-U78 -HOL#1
-SP6
-SP6#1
#HDP21
90° BEND
*4/4
200mm
Black,Black,Black,Black
550mm
-LTF#1
550mm
28, 30, 27, 84 -LTF#2
0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²
200mm 1 #HDP17
2 #HDP21
-PCBH:17
+PU-SP6:1
Red-Yellow 23
Black 28
0.75 mm²
0.75 mm²
3
D PE D
*4/4
-LTR#1
400mm
-LTR#2
1 #HDP18 -PCBH:18 Orange-Black24 1.00 mm²
2 #HDP21 +PU-SP6:1 Black 30 0.75 mm²
3
PE
100mm Tails *4/4

-RTF#1
-RTF#2
1 #HDP19 -PCBH:19 Green-Pink 25 0.75 mm²

2 #HDP21 -RTR:2 Black 29 0.75 mm²
3
PE
E E
300mm
-LL1#1
*4/4
100mm
*4/4
100mm
-RTR#1
100mm
-LL1#2 LOOM LINK -RTR#2

1 #A7 +PU-FS:2 DT04-4P 0.75 mm² 1 #HDP20 -PCBH:20 Green-Orange26 0.75 mm²
2 #1000299 -RTG:1 DT04-4P -TRK#1 2 #HDP21 -RTF:2 Black 29 0.75 mm²
3 #HDP27 -PCBH:27 DT04-4P 0.75 mm² *16/16 3
4 #HDP26 -PCBH:26 DT04-4P 0.75 mm² PE
TRACKING
UMBILICAL
CONNECTION
-TRK#2
1 #HDP1 -PCBH:1 Green-Yellow 50 0.75 mm²
2 #-HDP2 -PCBH:2 Black 45 0.75 mm²
3 #HDP3 -PCBH:3 Red-White 44 1.00 mm²
4 #HDP4 -PCBH:4 Purple 42 0.75 mm²
5 #HDP5 -PCBH:5 Blue-Orange 46 0.75 mm²
F -B1#1 6 #HDP6 -PCBH:6 Brown-Grey 48 1.00 mm² F
-cs2#1
-CS1#1
*4/4
*4/4
CONVEYOR 1 7 #HDP7 -PCBH:7 Black-Yellow 52 1.00 mm²

*5/5
-C SOLENOID 8 #HDP8 -PCBH:8 Blue-Yellow 47 0.75 mm²
CONVEYOR DELAY DS
# -CS1#2 9 #HDP9 -PCBH:9 Brown-Yellow 49 1.00 mm²
1
SENSOR 1 #HDP30 -PCBH:30 Green-Brown 21 0.75 mm² 10 #HDP10 -PCBH:10 Red-Blue 43 1.00 mm²
-CDS#2 2 #HDP31 -PCBH:31 Black 22 0.75 mm² 11
1 #HDP13 +PU-SP4:1 Red 57 0.75 mm² 3 12 #HDP12 -PCBH:12 White-Red 53 1.00 mm²
2 PE 13
300mm
50mm
3 #HDP14 +PU-SP5:1 Black 149 0.75 mm² 14

4 #HDP23 -PCBH:23 Black-White 113 0.75 mm² 15 #HDP15 -PCBH:15 Black-Purple 51 1.00 mm²
5 16 #HDP16 -PCBH:16 Green-Pink 54 1.00 mm²
-FS#1
*2/2
100mm
G FUELSAVE G
OPTION
-FS#2
1 #HDP13 +PU-SP4:1 Red 613 0.75 mm²
2 #A7 +PU-LL1:1 Orange-Black134 0.75 mm²
250mm
*5/5 2 #1
-FP FEEDER PRESSURE
KICK-OUT 2
-FP2#2
1 #HDP13 +PU-SP4:1 Red 608 0.75 mm²
2
3 #HDP14 +PU-SP5:1 Black 607 0.75 mm²
4 A8 -SP14 Grey-Black 610 0.75 mm²
5
E11512
H H
FEEDER PRESSURE
*5/5
KICK-OUT 1 -FP1#1
-FP1#2
1 #HDP13 +PU-SP4:1 Red 609 0.75 mm²
2
3 #HDP14 +PU-SP5:1 Black 605 0.75 mm²
4 A8 -SP14 Grey-Black 612 0.75 mm²
5
Changing
1 M.-Nr.: CAT C4.4 T4F Power Unit Kit CAT C4.4 T4F Location +AUX
drawing 0 User AJC
1
1 2 3 4 5 6 7 8 9
SCREEN ANGLE SENSOR LOOM - 60552651

A A
B B
-SRS#1
900MM 3800MM
-U113
*5/5
OS75-12.7
0 mm -SLL1.#1
*4/4
-U94
C C
-SRS#2 SCREENBOX SENSOR -SLL1.#2 SCREENBOX LOOM LINK
1 #HDP26 -SLL1.:1 Orange-Black614 0.75 mm² 1 #HDP26 -SRS:1 Orange-Black614 0.75 mm²
2 2 #1000298 -SRV:1 Green-Brown 625 0.75 mm²
3 #HDP27 -SRV:2 Black 617 0.75 mm² 3 #HDP27 -SRV:2 Black 618 0.75 mm²
4 #1000296 -SLL1.:4 Brown-Orange621 0.75 mm² 4 #1000296 -SRS:4 Brown-Orange621 0.75 mm²
800MM
5
D D
SCREENBOX ANGLE
E -SRV#2 SOLENOID E
-SRV#1
*4/4
1 #1000298 -SLL1.:2 Green-Brown 625 0.75 mm²

2 #HDP27 -SRS:3, -SLL1.:3 Black,Black 617, 618 0.75 mm²,0.75 mm²
3
PE
F F
3 Date Name Type WR2100 Description:Electrical Kit Assignment

Changing
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
TELEMETRY HARNESS - 60552946

(OPTIONAL)
A A
-SP13#1
#T_GND
Black,Black,Black,Black,Black,Black
161, 162, 163, 164, 165, 166
0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²,0.75 mm²
B B
500MM -SP13 100MM 100MM
-F1#1
-TEL1#1
*5/5
*31/31
-TEL3#1
-TEL1#2
-TEL3#2
1 T12V +PU-PE1_2:1 Red 157 0.75 mm²

2 #IGN_ON +PU-SP1:1 Red-Black 179 0.75 mm² 1 #T12V1 -F1:2 Brown-White 173 0.75 mm²
C C
3 #-VE +PU-PE2_2:1 Black 178 0.75 mm² 2 #T_GND -SP13 Black 161 0.75 mm²
4 #B11 /3.C4 Blue 176 0.75 mm² 3 #1000293 +CHAS-TEL2:2 Brown 160 0.75 mm²
5 #B8 /3.C4 Green-Yellow177 0.75 mm² 4 #-VE -MC:2 Blue 167 0.75 mm²
5 #1000289 -MC:3 Yellow 168 0.75 mm²
100MM
100MM
6 #T_GND -SP13 Black 163 0.75 mm²
7 #CAN2_H +CHAS-TEL2:4 White-Purple 169 0.75 mm²
16 #1000286 -BW:3 White-Orange172 0.75 mm²
17 #1000285 -BW:4 Black-White 171 0.75 mm²
18 #CAN2_L +CHAS-TEL2:5 Grey-White 170 0.75 mm²
22 #T_GND -SP13 Black 164 0.75 mm²
23 #T_GND -SP13 Black 165 0.75 mm²
D 24 #T_GND -SP13 Black 166 0.75 mm² D
-MC#1
*4/4 -BW#1
*4/4
-MC#2
1 #T_GND -BW:2 Black 174 0.75 mm² -BW#2
E 2 #-VE -TEL3:4 Blue 167 0.75 mm² 1 #T12V1 -F1:2 Red-Black 175 0.75 mm² E
3 #1000289 -TEL3:5 Yellow 168 0.75 mm² 2 #T_GND -MC:1 Black 174 0.75 mm²
4 3 #1000286 -TEL3:16 White-Black 172 0.75 mm²
4 #1000285 -TEL3:17 Black-White 171 0.75 mm²
F F
3 Date Name Type WR2100 Description:Electrical Kit Assignment

Changing
drawing P.-Nr.: Location +TEL
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-SP3#2
PANEL & LOOM KIT - 60552898

#B1
90° BEND - FLEXICON FLT 90 Red-Brown,Red-Brown

87, 20
1.00 mm²,1.00 mm²
300MM 100MM 50MM 800MM 50MM 300MM 200MM 250MM -SP3
A A
-U9
50MM
100MM
150MM
150MM
100MM
50MM
400MM
-LL2#1
*4
-CDV#1
LOOM LINK *3/3
200MM
-LL2#2
*4
B 1 COOLANT B
#A7 -PCBA:4 DT06-4S 0.75 mm² BEACON *2/2
2 #1000299 -X24:1 DT06-4S DIVERTER CONNECTION -BC#1
3 #HDP27 +CHAS-SLL1:3 DT06-4S 0.75 mm² -CDV#2 VALE -BC#2
450MM
4 #HDP26 +CHAS-SLL1:1 DT06-4S 0.75 mm² 1 #HL3-1 -SP14:1 Green-Red 131 0.75 mm² 1 #B1 -SP3:1 Red-Brown 87 1.00 mm²
SCREENBOX 2 2 #-VE_SPLICE -SRN2:2 Black 40 0.75 mm²
-SLL1#1
LOOM 3 #CDV-3 -XN1:19 Orange-Black69 0.75 mm²
LINK
-SLL1#2
-SP7#1 1 #HDP26 -LL2:4 Orange-Black615 0.75 mm²
500MM
50MM
#D6 2 #1000298 +CHAS-K1._3:1 Green-Brown 624 0.75 mm²
3 #HDP27 -LL2:3 Black 619 0.75 mm²
STARTER
300MM
Red,Red,Red,Red,Red,Black,Red,Red 4 #1000296 +CHAS-K1._1:1 Brown-Orange622 0.75 mm²
61, 528, 114, 115, 542, 143, 181, 112 SOLENOID
-STS#1
1/1
150MM
0.75 mm²,6.00 mm²,0.75 mm²,0.75 mm²,6.00 mm²,0.75 mm²,6.00 mm²,1.00 mm² -STS#2
-WIF1#2 -SP8#1 100MM 200MM 1 #PE5 -PE5:1 White-Red 151 6.00 mm²
-ESS#1
*2/2
1 #3134 -WIF2:1 Green-Blue 154 0.75 mm² #301

-SP7
2 #3132 -WIF2:2 Red-Grey 155 0.75 mm²
3 #3135 -WIF2:3 Orange-Black156 0.75 mm² Black,Black,Black,Black,Black,Red,Black TANK HEADER
C -SP8 C
-ESS#2 ESTOP CHASSIS BOX 62, 529, 116, 117, 120, 144, 182 -TH1#2 UNIT
-TH1#1
*4/4
1 #B9 -PCBB:9 Brown 138 0.75 mm² 0.75 mm²,3.00 mm²,0.75 mm²,0.75 mm²,6.00 mm²,0.75 mm²,0.75 mm² 1 #CAN2_L -SP11:1 Blue 67 0.75 mm²
WATER IN 2 #B7 -PCBB:7 Black 137 0.75 mm² 200MM 2 #CAN2_H -SP12:1 Green-Yellow 111 0.75 mm²
FUEL 3 #301 -SP8:1 Black 182 0.75 mm²
50MM 4 #D6 -SP7:1 Red 112 1.00 mm²
*2/2 -FLP1#1
*3/3
1000MM
-WIF1#1 FUEL LIFT
PUMP -HL3#1
-FLP1#2 *2/2
1 #3125 -FLP2:1 Green 89 2.00 mm²
2 #-VE_SPLICE -FLP2:2 Black 88 2.00 mm²
50MM HEATED LINE
+TEL
300MM NO. 3 (RETURN)
-HL3#2
1 #HL3-1 -SP14:1 Green-Red 70 0.75 mm²
2 #HL3-2 -XN1:18 Green-White 71 0.75 mm² -HOC1#1
*2/2
100MM
HYD OIL COOLER
50MM 200MM FAN No.1
100MM
-HOC1#2
D 1 #B13 -PCBB:13 Purple 121 2.00 mm² D
2 #-VE_SPLICE -SP2 Black 10 2.00 mm² 100mm Tails
HEATED LINE
*2/2
-HL1#2 NO.1 -HOC2#1
*2/2
100MM 1 #HL1-1 -XN1:13 Green-Pink 74 1.00 mm²
2 #HL1-2 -XN1:14 Black-White 75 0.75 mm² HYD OIL COOLER
800MM
FAN No.2
400MM
200MM
-HOC2#2
-HL2#1 1 #B16 -PCBB:16 Purple 58 2.00 mm²
*2/2 2 #-VE_SPLICE -SP2 Black 32 2.00 mm²
200MM
W2S -SRN2#1
HEATED LINE *2/2
-WIF2#1 NO.2
100MM *3/3 -HL2#2
1 #HL2-1 -XN1:15 Pink 72 0.75 mm²
550MM
2 #HL2-2 -XN1:16 Orange-Black73 0.75 mm²
100MM
E E
SIREN 60505024
WATER IN
-SRN2#2 CONNECTION
FUEL CON.2
-WIF2#2 1 #B1 -SP3:1 Red-Brown 20 1.00 mm²
1 #3134 -WIF1:1 Green-Blue 154 0.75 mm² 2 #-VE_SPLICE -BC:2 Black 40 0.75 mm²
-FLP2#1 2 #3132 -WIF1:2 Red-Grey 155 0.75 mm²
400MM
*2/2 3 #3135 -WIF1:3 Orange-Black156 0.75 mm²
1
-WTI#1 -LF1#1
*2/2
2
FUEL LIFT
300MM
*70/70
PUMP CON.2
69 68 67 66 65 64 63 62 61 60 59 58
-J1#1
70 57
56
42
43
29 ENGINE ECM -FLP2#2 WAIT TO
-LI#1
28 15
*2/2
AIR FILTER POWER UNIT

14
13 12 11 10 9 8 7 6 5 4 3 2
PLUG 1 #3125 -FLP1:1 Green 89 2.00 mm² -WTI#2 ISOLATE LAMP
-AFR#2 RESTRICTION -LI#2 LIGHT 2 #-VE_SPLICE 1 #3139
*2/2
-AFR#1
-FLP1:2 Black 88 2.00 mm² -J1:48 Black-Purple 119 0.75 mm² 2 1

1 #B18 -PCBB:18 Red 39 0.75 mm² 1 #B12 -PCBB:12 Green-White 83 0.75 mm² 2 #B+ -SP9:1 Red 152 0.75 mm² -LF2 -LF2#1
2 #28 -J1:28 Black-Red 37 0.75 mm² 2 #-VE_SPLICE -SP2 Black 148 0.75 mm² 1 2
F F
-XN1#1
*31/31
-J1#2 -J1#2
1 BLANKING PLUG REQUIRED 36 #B+ -J1:3 Green-Black 123 0.75 mm² XNOX
2 #B+ -SP9:1 Red 103 2.00 mm² 37 BLANKING PLUG REQUIRED -XN1#2 CONNECTOR 200MM
X1
3 #B+ -J1:36 Green-Black 123 0.75 mm² 38 #B+ -SP9:1 Red 105 2.00 mm² 1 #D6 -SP7:1 Red 61 0.75 mm² BLACK SLEEVING
6.00 mm²
4 #D2 -PCBD:2 Red-Black 100 2.00 mm² 39 BLANKING PLUG REQUIRED 2 #D6 -SP7:1 Red 114 0.75 mm² -H3#1
RED *2/2
5 #D8 -PCBD:8 White-Purple 101 1.00 mm² 40 BLANKING PLUG REQUIRED 3 #D6 -SP7:1 Red 115 0.75 mm² -X18#1
RED X2 WAIT TO
6 BLANKING PLUG REQUIRED 41 #B+ -SP9:1 Red 106 2.00 mm² 4 #302 -J1:59 White-Orange68 0.75 mm²
7 #D9 -PCBD:9 Purple 60 1.00 mm² 42 BLANKING PLUG REQUIRED 5 #301 -SP8:1 Black 62 0.75 mm² ISOLATE LAMP
153
Allen Bradley 800F-DOC – 12V lamp holder

8 #D11 -PCBD:11 Brown 11 1.00 mm² 43 BLANKING PLUG REQUIRED 6 #301 -SP8:1 Black 116 0.75 mm²
100MM
Allen Bradley 800FM-P4 – Red lens
9 #ECU_-VE -SP10:1 Black 99 2.00 mm² 44 BLANKING PLUG REQUIRED 7 #301 -SP8:1 Black 117 0.75 mm²
Allen Bradley 800F-ALP – Contact block holder
400MM
Brown
60505272 10 BLANKING PLUG REQUIRED 45 #ECU_-VE -SP10:1 Black 64 2.00 mm² 8 #3116 -J1:15 Red-Yellow 92 0.75 mm²
Allen Bradley 855T-L10 – 12V bulb
1WAY MALE 11 #B+ -SP9:1 Red 104 2.00 mm² 46 BLANKING PLUG REQUIRED 9 #3117 -J1:22 Grey 93 0.75 mm²
ENGINE 12 #3120 -XN1:24 Black 94 0.75 mm² 47 #ECU_-VE -SP10:1 Black 65 2.00 mm² 10 BLANKING PLUG REQUIRED
PREHEAT DEUTSCH
13 #ECU_-VE -SP10:1 Black 98 2.00 mm² 48 #3139 -WTI:1 Black-Purple 119 0.75 mm² 11 #3118 -J1:20 Green-Yellow 95 0.75 mm²
-PCBD:10
TERMINAL
14 BLANKING PLUG REQUIRED 49 BLANKING PLUG REQUIRED 12 #3119 -J1:21 Red-Yellow 96 0.75 mm²
-X20#1
1/1
60505146 15 #3116 -XN1:8 Red-Yellow 92 0.75 mm² 50 BLANKING PLUG REQUIRED 13 #HL1-1 -HL1:1 Green-Pink 74 1.00 mm²
G 16 BLANKING PLUG REQUIRED 51 BLANKING PLUG REQUIRED 14 #HL1-2 -HL1:2 Black-White 75 0.75 mm² G
17 BLANKING PLUG REQUIRED 52 BLANKING PLUG REQUIRED 15 #HL2-1 -HL2:1 Pink 72 0.75 mm²
18 #B17 -PCBB:17 White-Blue 2 0.75 mm² 53 #496
BLANKING PLUG REQUIRED 16 #HL2-2 -HL2:2 Orange-Black73 0.75 mm²
-PH#1
1/1
150mm
19 BLANKING PLUG REQUIRED 54 #D6 -SP7:1 Black 143 0.75 mm² 17 #HL3-1 -SP14:1 Green-Red 130 0.75 mm²
20 #3118 -XN1:11 Green-Yellow 95 0.75 mm² 55 #301 -SP8:1 Red 144 0.75 mm² 18 #HL3-2 -HL3:2 Green-White 71 0.75 mm²
-PH#2
1 #D10
21 #3119 -XN1:12 Red-Yellow 96 0.75 mm² 56 BLANKING PLUG REQUIRED 19 #CDV-3 -CDV:3 Orange-Black69 0.75 mm²
22 #3117 -XN1:9 Grey 93 0.75 mm² 57 #B+ -SP9:1 Red 107 2.00 mm² 20 #B11 -J1:25 Green-Yellow 76 0.75 mm²
PRE-HEAT
6mm-N AUTO
23 BLANKING PLUG REQUIRED 58 BLANKING PLUG REQUIRED 21 #B8 -J1:26 Blue 77 0.75 mm²
LEAD 24 BLANKING PLUG REQUIRED 59 #302 -XN1:4 White-Orange68 0.75 mm² 22 #CAN2_H -SP12:1 Green-Yellow 91 0.75 mm²
60552427
25 #B11 -XN1:20 Green-Yellow 76 0.75 mm² 60 BLANKING PLUG REQUIRED 23 #CAN2_L -SP11:1 Blue 90 0.75 mm²
26 #B8 -XN1:21 Blue 77 0.75 mm² 61 BLANKING PLUG REQUIRED 24 #3120 -J1:12 Black 94 0.75 mm²
27 BLANKING PLUG REQUIRED 62 BLANKING PLUG REQUIRED 25 BLANKING PLUG REQUIRED
-X3#1
1/1
-X2#1
1/1
28 #28 -AFR:2 Black-Red 37 0.75 mm² 63 BLANKING PLUG REQUIRED 26 BLANKING PLUG REQUIRED
29 BLANKING PLUG REQUIRED 64 BLANKING PLUG REQUIRED 27 BLANKING PLUG REQUIRED
30 BLANKING PLUG REQUIRED 65 #ECU_-VE -SP10:1 Black 97 2.00 mm² 28 BLANKING PLUG REQUIRED
31 BLANKING PLUG REQUIRED 66 BLANKING PLUG REQUIRED 29 BLANKING PLUG REQUIRED BATTERY
-X16#1
-X15#1
-X14#1
1/1
1/1
1/1
32 BLANKING PLUG REQUIRED 67 BLANKING PLUG REQUIRED 30 BLANKING PLUG REQUIRED -X2#2 POSITIVES
33 #CAN2_H -SP12:1 Green-Yellow 129 0.75 mm² 68 BLANKING PLUG REQUIRED 31 BLANKING PLUG REQUIRED BATTERY 1 #3138 -LF1.1:1 Red 109 6.00 mm²
H 60536075 NEGATIVES H
34 #CAN2_L -SP11:1 Blue 127 0.75 mm² 69 BLANKING PLUG REQUIRED -X16#2 -X3#2
6.4mm RING
35 #ECU_-VE -SP10:1 Black 63 2.00 mm² 70 #B3 -PCBB:3 White 38 0.75 mm² 1 #ECU_-VE -SP10:1 Black 66 6.00 mm² 1 #136 -LF2.1:1 Red 9 16.00 mm²
-X15#2
-X19#1
1/1
1 #301 -SP8:1 Black 120 6.00 mm²

-X14#2
1 #-VE -PE2_1:1 Black 142 16.00 mm²
Changing
1 M.-Nr.: CAT C4.4 T4F Power Unit Kit CAT C4.4 T4F Location +PU
drawing 0 User AJC
1
1 2 3 4 5 6 7 8 9
A A
500MM
Part No. 60552028 2

1
-SRN1#1
ESTOP SPIDER
+SIREN
-H2#1
-SRN1#2
1 #B1 +SIREN-H2:1 Brown BN 1.00 mm²
-1#1
B 2 #-VE_SPLICE +SIREN-H2:2 Blue BU 1.00 mm² B
*2/2
+ESTOP1
-S4#1
-U1
2100MM -2#1
*2/2
*2/2
C -7#1 C
-ES1#1
*2/2
ESTOP POWER UNIT
NEAR SIDE
+ESTOP1
-ES1#2
1 #B9 +ESTOP1-S4:1 Brown BN 1.00 mm² -3#1
*2/2
2 #IGN_ON +ESTOP1-S4:2 Blue BU 1.00 mm²
*2/2
-6#1
D D
+ESTOP2
-S5#1
-4#1
*2/2
-U2 *2/2
-5#1
5600MM
E E
-ES2#1
*2/2
ESTOP POWER UNIT
OFF SIDE
+ESTOP2
-ES2#2
1 #IGN_ON +ESTOP2-S5:1 Brown BN 1.00 mm²
2 #IGN_ON +ESTOP2-S5:2 Blue BU 1.00 mm²
F F

Changing
1 User AJC
only in
the E3! Proved 60552903.0 No. 18 Sh.
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
1
1
2
2
300MM
-S2
I
LOW
-S3
INT
-HMI
3
3
OK
HIGH
300MM
only in
the E3!
drawing
Changing
-S1
0
3
1
2
Revision
ECO
First Draft
4
Revision text
4
30
-S1
15
50
1
4
5
2
NC
-S3
3
2
-HMI
2
1
NO
-S3
1
2
NO
-S3
300MM
Date
04.01.17
5
5
2
NO
-S2
AJC
Name
2
1
User
+TEL
-TEL1
5
Proved
U9 X74
Date
RHS
2
1
150MM
-8
3
5
6
6
Name
AJC
-A1
LED
N2
VBBs 1
GND 2
CAN2_H 3
CAN2_L 4
A B C D E F P/N1
1 1
A VBBs 1 1 C VBBs 1
1 B VBBs
VBBs 1
2 2 2
2 D GND 2 E GND 2 F GND
VBB1 2
3 3 3 3 3
3
VBB2 3
D GND
7
A GND 4 B GND 4 4 4 E GND F GND
4 C GND 4
GND 4
7
5 5
A GND 5 B GND 5 C GND 5
5
CAN1_H 5
6 6 6
CAN1_L 6
7 7 7 7 7
7
A VBBs 8 B VBBs 8 C VBBs 8 D GND GND F GND

8 8 E 8
Type
P.-Nr.:
WR2100
8
8
60552903.0
Drawing number
9
9
No.
Sheet
Assignment
18
Location +PU
18 Sh.
F
E
B
D
A
C
Appendix C
(3) Dual Power Schematics

Appendix C

F
E
B
D
A
C
1
1
-X1
Battery Cable 70mm-B 1/2 Battery Cable 70mm-R
2/2
-X1
JUMP START
CONNECTOR
2
2
-X2
1/1
30A
-LF1
-X5 -X3
1/1 AUTO 6mm-R 1/1 AUTO 6mm-R -X115:1 #126
1/1
/9.A4
1
-X4
3
3
only in
the E3!
drawing
Changing
80A
-LF2
-X8 -X6
1/1 Battery Cable 16mm-R 1/1 -PCB1 #B+
0
3
1
2
/2.A1
2
1
Revision
1/1 1/1
-X9 -X10 -X7
12V
1/1
ECO
1/1
-X11
50A
-LF3
-X17 -X15
30
87
1/1 AUTO 6mm-N 1/1 AUTO 6mm-N AUTO 6mm-N

1/1 1/1 1/1 1/1 1/1
1
2
ENGINE
-X16
4
-X18 -X14 -X13 -X12
Revision text
4
PREHEAT
FIRSTDRAFT
-K1

-X20
1/1 Battery Cable 70mm-R
-X19
1/1
300A
14
ADD 120 OHM RESISTORS FOR CAN

STARTER SOLENOID WIRE CHANGE
-1
13
-X25 -X23
1/1 1/1
Date
M
15.1.13
11.10.13
29.11.12
1/1
-X148
-X24
5
1/1
5
-X27
1/1 Battery Cable 35mm-B
1/1
1/1
CD
VM
VM
Name
1/1
-X29
-X28
-X26
User
Proved
25mm-R Battery Cable
Date
AUTO 3mm-B
6
6
-X149
#138 1/1
Name
-PCB1
#-VE
#-VE_ECU
/9.A4
/2.A1
7
7
Type WR1800X
M.-Nr.: CAT C4.4 T4
8
8
POWER UNIT
60552463.2
Drawing number
9
9
No.
Sheet
Location
Assignment
1
15 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
#-VE -X28:1
/1.F6
PCB PCB
A /2.C1 /2.D1 A
B-7 B-9
1-967624-1
1-967624-1
7/18
9/18
-X178
-X178
-PCB1
#B+ -X6:1 -X199
/1.B3 B+ (12VDC) GND (-VE) 1/1
/3.F4 A1 HDP-1 /6.E7 -X195:1 #1000116

/9.F1
/5.A5 A2 HDP-2 /6.E2
-X184
-X184
/3.A1 A3 HDP-3 /6.B3
2/2
1/2
/5.F2 A4 HDP-4 /6.B2
B /3.F2 A5 HDP-5 /6.E3

B
/3.F2 A6 HDP-6 /6.E5
2/2
1/2
-X185
-X185
/3.F4 A7 HDP-7 /6.E8
/3.F3 A8 HDP-8 /6.E4
-X202
-X200
-X204
/3.F8 A9 HDP-9 /6.E6
A10 HDP-10
1/2
1/2
1/2
/3.C6 /6.B2
/3.D5 A11 HDP-11 /8.C8
/3.C5 A12 HDP-12 /6.B8
-X31
1/2
1/2
1/2
-X186
-X188
HDP-13 /5.A1
/4.A7 B1 HDP-14 /5.A1 CHASSIS CHASSIS
/2.D4 B2 HDP-15 /6.E8 -X153:1 #IGN_ON -W3 BN ESTOP ESTOP

/3.E1 1
/9.A9 B3 HDP-16 /6.B7 AUTO 1.00mm-OB
C -S4
/9.C9 B4 HDP-17 /8.C3 C
/2.D4 B5 HDP-18 /8.C4 -W3 2BU
/9.A9 B6 HDP-19 /8.C5
-X186
-X188
-X31
/2.A6 B7 HDP-20 /8.C7
2/2
2/2
2/2
/9.A8 B8 HDP-21 /8.E2
/2.A9 B9 HDP-22
/4.E1 B10 HDP-23 /5.A6
-X202
2/2
2/2
2/2
-X200
-X204
/9.A8 B11 HDP-24 AUTO 1mm-GY
/4.A6 B12 HDP-25 /5.A8
/4.A3 B13 HDP-26 /9.A2 AUTO 1.00mm-OB -X155 AUTO 1.00mm-OB AUTO 1.00mm-OB AUTO 1.00mm-OB
AUTO 1.00mm-OB
B14 HDP-27 /9.F2 Splice-1.5
-X201
-X203
-X205
D /4.A2 B15 HDP-28 /7.A3 D
B16 HDP-29 PCB PCB
1/2
1/2
1/2
/4.A5 /2.C1 /2.C1
B17 HDP-30 /7.A2 B-5 B-2
B18 HDP-31 /7.F2
-X32
-X187
1/2
1/2
1/2
-X189
1-967624-1
1-967624-1
C1
5/18
2/18
-X178
-X178
(track ltg) PE3
C2 CHASSIS
-W4 BN
1
CHASSIS
C3 AUTO 1.00mm-OB
(Sw Pwr) PE4 120 Ω ESTOP ESTOP
C4 -R1 1W -S5
C5 (Starter) PE5 -W4 2BU
C6
-X187
-X189
-X32
E 60526041 E
4/5 PROGRAMMING
-X66
2/2
2/2
2/2
SOCKET
AUTO 6mm-WR 5/5
-X201
2/2
2/2
2/2
-X203
-X205
-X66
AUTO 1mm-GY
AUTO 1mm-W
AUTO 1mm-B
AUTO 1mm-U
AUTO 1mm-N
-X43
1/1
F F
STARTER SOLENOID EXPANSION NODE
CONNECTION SOCKET
3 Date Name Type WR1800X Description: Electrical Kit Assignment

Changing
2 ADD 120 OHM RESISTORS FOR CAN 11.10.13 VM POWER UNIT
drawing M.-Nr.: CAT C4.4 T4 Location
1 STARTER SOLENOID WIRE CHANGE 15.1.13 VM User
only in
0 FIRSTDRAFT 29.11.12 CD Drawing number Sheet 2
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
PCB
/2.B1
A -3
A A
1-967622-1
-X177
3/12
AUTO 1mm-R
30 44
B -S1 B
ON 15 START 50
AUTO 1mm-RS #IGN_ON

/9.A1
PCB
/2.B1
1 1 1 A - 10
-S3
2 2 2
C PCB C
1-967622-1
-X177
10/12
/2.C1
A - 12
1-967622-1
-X177
12/12
PCB -S2
/2.C1 -S2
A - 11 2
1-967622-1
-X177
11/12
D D
AUTO 1mm-GW
AUTO 1mm-W
AUTO 1mm-B
AUTO 1mm-N
120 Ω
1W
66
67
-R4
-X153
AUTO 1.00mm-RB
#IGN_ON
AUTO 1.00mm-RG
/2.C5
Splice-1.5
-X181
-X181
-X181
-X181
-X181
1.00mm-RO AUTO
E E
4/5
2/5
5/5
3/5
1/5
1-967622-1
1-967622-1
1-967622-1
1-967622-1
1-967622-1
1-967622-1
-X177
-X177
-X177
-X177
-X177
-X177
5 4 3 2 1
6/12
5/12
8/12
7/12
9/12
1/12
CAN_H
GND
8...32 V DC
N.C
CAN_L
6- A 5-A 8-A 7-A 1- A -P1 9-A

/2.B1 /2.B1 /2.B1 /2.B1 /2.B1 CR0451 /2.B1
PCB PCB PCB PCB PCB PCB
F F

Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
1
1
-X178
10/18
10 - B
1-967624-1
PCB
/2.D1
2
2
/2.D1
-X52
AUTO 1mm-B FUEL PUMP 1/2 AUTO 2mm-P 1-967624-1
15/18
PCB
50
2/2
B - 15
SUPPLY -X178
-X52
3
3
only in
the E3!
drawing
Changing
0
3
1
2
/2.D1
Revision
-X48
AUTO 3mm-B HYD OIL 1/2 AUTO 2mm-P 1-967624-1
ECO
13/18
PCB
2/2
B - 13
28
COOLER -X178
-X48 FAN No.1
4
Revision text
4
FIRSTDRAFT
/2.D1
-X151
1/2
Date
AUTO 3mm-B HYD OIL AUTO 2mm-P 1-967624-1
15.1.13
16/18
PCB
11.10.13
29.11.12
2/2
B - 16
COOLER
261
-X178
-X151
5
5
FAN No.2
CD
VM
VM
Name
User
Proved
Date
6
6
/2.D1
-H1
-X55 -X55
Name
AUTO 1mm-B 2/2 1/2 AUTO 1mm-GW 1-967624-1
1
12/18
PCB
53
B - 12
LIGHT
-X178
POWER UNIT
7
7
Type
BEACON
/2.C1
MACHINE
-X93
1/2 76,77 1-967624-1
B -1
1/18
PCB
2/2
-X178
WR1800X
-X93
M.-Nr.: CAT C4.4 T4
8
8
-H3
1mm-B AUTO
-X96
POWER UNIT
-X95
-W2 BU 1/2 1/2
1.00mm-RN AUTO
2/2 2/2 BN -W2

-X95 -X96
60552463.2
Drawing number
9
9
No.
Sheet
Location
Assignment
4
15 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
A A
PCB PCB PCB PCB PCB

/2.C3 /2.C3 /2.B1 /2.D3 /2.D3
HDP - 13 HDP - 14 A-2 HDP - 23 HDP - 25
-X177
2/12
1-967622-1
23/31
25/31
13/31
14/31
-X74
-X74
-X74
-X74
AUTO,AUTO 1mm-NO,1mm-R
AUTO,AUTO 1mm-SB,1mm-B
AUTO 1mm-SB
1/6 1/6
AUTO 1mm-NW
AUTO 1mm-BW
-X182 -X183
B B
-X176
-X176
-X176
-X169
-X169
-X169
C C
-X72
-X72
-X72
4/5
4/5
4/5
3/5
3/5
3/5
1/5
1/5
1/5
1
1
2
3
2
3
2
3
-X82
2/4
3/4
1/4
PK8731
PK8731
IFS208
-B4
-B3
-B1
1
2
3
320428
-B2
D D
PRESSURE KICK OUT CONVEYOR START HYD OIL LEVEL

DELAY SENSOR SENSOR
-B6
1 PK6521
1/5
E -X191 E
2
2/5 3
AUTO 1.00mm-OB 3/5
4
-X182
4/6
FUELSAVE OPTIONAL
4/6
-X183
F F
-X177
4/12
4- A
/2.B1
PCB 3 Date Name Type WR1800X Description: Electrical Kit Assignment
Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
1
1
TRACKS ON SW
/2.B3
-X74 -X98
2/31 AUTO 1mm-B 10/16 AUTO 1.00mm-RU
PCB
PCB
2/16 10/31
HDP - 10
2 - HDP
-X98 -X74
/2.B3
2
2
/2.B3
-X98
4/16 AUTO 1mm-P
HDP - 4
PCB
4/31
-X74
LTF
/2.B3
-X74 -X98
5/31 AUTO 1mm-UO 3/16 AUTO 1.0mm-RW
HDP - 3
PCB
PCB
5/16 3/31
5 - HDP
-X98 -X74
3
3
/2.B3
only in
the E3!
drawing
Changing
0
3
1
2
Revision
ECO
LTR
-X74
8/31 AUTO 1mm-UY
PCB
8/16
8 - HDP
4
-X98
Revision text
4
FIRSTDRAFT
/2.B3

RTF
Date
-X74
15.1.13
11.10.13
29.11.12
6/31 AUTO 1.00mm-NS
PCB
5
6/16
5
6 - HDP
-X98
CD
VM
VM
Name
/2.B3
TRACKING UMBILICAL
User
Proved
Date
RTR
-X74
6
9/31
6
AUTO 1.00mm-NY
PCB
9/16
Name
9 - HDP
-X98
/2.B3
FAST
7
-X74
7
1/31 AUTO 1mm-GY

PCB
1/16
1- HDP
-X98
/2.C3
Type
/2.B3
-X74 RADIO -X98

15/31 AUTO 1.00mm-BP TRACK 16/16 AUTO 1mm-GP
PCB
PCB
16/31
HDP - 16
15/16 STOP LINK

15 - HDP
-X98 -X74
/2.C3
WR1800X
M.-Nr.: CAT C4.4 T4
MACHINE REMOTE
8
STOP
8
/2.C3
-X74 -X98
7/31 AUTO 1.00mm-BY 12/16 AUTO 1.00mm-WR
PCB
PCB
12/31
HDP - 12
7/16
7 - HDP
-X98 -X74
POWER UNIT
/2.B3
60552463.2
Drawing number
9
9
No.
Sheet
Location
Assignment
6
15 Sh.
F
E
B
D
A
C
1 2 3 4 5 6 7 8 9
A PCB PCB
A
/2.D3 /2.D3
HDP - 30 HDP - 28
30/31
28/31
-X74
-X74
AUTO 1mm-GB
AUTO 1mm-GN
B B
AUTO 1mm-GB
3/4 3/4
C -X164 -X165 C
AUTO 1mm-GB
4/4 4/4
-X164 -X165
-X102
REMOTE FEEDER
HDP26
AUTO 1mm-GN
1/4
START/STOP
1/4
-X164
(FUTURE)
2/4
D D
-X102
2/4
-X164
-X172
1/4
AUTO 1mm-B
-X172
2/4
E E
-X74
31/31
31- HDP
/2.D3
PCB
F F

Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
A A
B B
PCB PCB PCB PCB PCB

/2.C3 /2.C3 /2.C3 /2.C3 /2.C3
HDP - 17 HDP - 18 HDP - 19 HDP - 20 HDP - 11
20/31
17/31
AUTO 1.00mm-OB 18/31
19/31
11/31
-X74
-X74
-X74
-X74
-X74
C C
AUTO 1mm-GO
AUTO 1mm-GK
AUTO 1mm-RY
AUTO 1mm-P
-X107
-X103
-X105
-X106
-X174
1/4
1/4
1/4
1/4
1/4
LEFT TRACK LEFT TRACK RIGHT TRACK RIGHT TRACK FAST TRACK
D FORWARD SOL. REVERSE SOL. FORWARD SOL. REVERSE SOL. SOLENOID D
-X107
2/4
2/4
2/4
2/4
2/4
-X103
-X105
-X106
-X174
AUTO 1.00mm-BU -X104
Splice-2.5
-X74
21/31
E E
21- HDP
/2.C3
PCB
F F

Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
ENGINE
PCB PCB PCB PCB
-R5
ECU /2.D1 /2.C1 /2.C1 /2.C1
B - 11 B-8 B-6 B-3
PCB
Ω 120
/2.D3
1W
/1.B3
/1.F6
HDP - 26 -X117
-X162 50/70
1-967624-1
1-967624-1
1-967624-1
1-967624-1
11/18
8/18
6/18
3/18
-X178
-X178
-X178
-X178
A Splice-1.5 48/70
A
#IGN_ON AUTO 1.00mm-OB
/3.B8 -X117
#-VE_ECU
#126
-X117 AUTO 1mm-GY
26/31
-X74
34/70
52/70
-X3:1
AUTO 1mm-U
HDP26
-X117
/7.D2 -X117
21/70 1.00mm-NR AUTO
-X196
-X193
53/70
1/1 -X117
1/2
-X117
70/70 1mm-W AUTO
30 -X115 55/70
-X192
1/2
Splice-2.5 -X117
-X21
B -K3 -X117 B
AUTO 1.00mm-OB -X116 20/70 1mm-N AUTO
1/1
87 87a 3 DECK S/BOX RAISE Splice-2.5 57/70
-X117 86
LIMIT SWITCH -X117
1/1
-X197
59/70 1.00mm-WU AUTO -K1

-X190 85
-B5
1/5 1 61/70
IFM206
1/1
-X22
-X117
AUTO 1mm-B
AUTO 1.00mm-OB AUTO 1.00mm-OB
COOLANT LEVEL
2 A/3
2/5 -X122
SENSOR
3 -X117
AUTO 1.00mm-OB3/5
-X190 63/70 5/70 1mm-RS AUTO -X119
-X182
4 -X117 Splice-2.5 B/3

C -X122 C
6/6
-X117
-X183
-X112 49/70 1mm-WO AUTO PCB

/2.C1
Splice-2.5 65/70 C/3
5/6
B-4
6/6
-X117 -X122
-X183
-X117
35/70 1mm-GU AUTO
-X182
5/6
1/3
1-967624-1
AUTO 1mm-B
4/18
-X178
-X123
CONTAM.
AUTO 1.00mm-OB
-X120
FUEL
AUTO 1.00mm-OB 67/70 #94
-X117 Splice-2.5
AUTO 1mm-R
2/3
AUTO 1mm-B
-X76
-X123
1/2
-X117
-X175
-X194
4/70
-X113 3/3
1/1
D D
1/4
-X77
#IGN_ON 1/2
Splice-2.5 69/70 -X123
-X117
TEMP SENSOR
86 -X117
1mm-G AUTO
AIR INLET
-K3 17/70
37/70 1/2 AFR SWITCH
85 -X117 -X124
-X117 (BY OTHERS)
2/4
-X175
3/70 -X121 1mm-O AUTO

1/1
-X195
38/70 Splice-2.5 2/2

1mm-WY AUTO -X117 -X124
#28
-X117
-X192
2/70 -X118 1mm-GP AUTO
-X77
TEMP SENSOR
1mm-NO AUTO Splice-2.5 1/4
2/2
2/2
120 Ω -X125
-R3
DPF AIR
1W -X117 E
E 26/70
-X76
2/2
2/2
-X193
2/4
-X125
-X111
-X111
AUTO 1.00mm-OB -X117

14/70 1mm-P AUTO
2/2
1/2
3/4
-X74
27/31
-X125
-X114
-X114
-X114
-X114
AUTO 1.00mm-OB
2/2
1/2
-X150
-X150
2/6
4/6
5/6
1/6
CAN C 1/6
27 - HDP TERMINATION 1 W -R2 DPF SOOT SENSOR -X126
MODULE
Ω 120
DPF ID
/2.D3
PCB CONNECTOR 1mm-K AUTO
F 3/6 F
-X126
3 DECK S/BOX RAISE
INHIBIT SOLENOID
6/6
-X126
#1000116 -X199:1
/2.B4 3
Changing Date Name Type WR1800X Description: Electrical Kit Assignment
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
2400MM
A A
-U64 Part No. 60552225/6 -X2#2
-X1#2 -X1#1 1 70.00 mm² Red -X1:1
1/2 1/1
1 70.00 mm² Red -X2:1 -X2#1
2/2
2 70.00 mm² Black -X9:1 -U65 -X9#2
1 70.00 mm² Black -X1:2
1/1
-X9#1
ENGINE JUMP START CONNECTION
-X10#1
-X11#1
TO BATTERY
1/1
1/1
2100MM
B B
480MM
-X19#2 -X19#1 -U59 Part No. 60552223 -X18#2

1/1
1 70.00 mm² Black -X18:1 1 70.00 mm² Black -X19:1
1/1
-X18#1
-VE BATTERY TO MAIN ISOLATOR
C C
1400MM
-X20#2 -X20#1 -U60 Part No. 60552221 -X23#2

1/1
1 70.00 mm² Red -X23:1 1 70.00 mm² Red -X20:1
1/1
-X23#1
+VE BATTERY TO STARTER +VE STUD
D D
1400MM
-X24#2 -X24#1 -U61 Part No. 60552224 -X25#2

1/1
1 70.00 mm² Black -X25:1 1 70.00 mm² Black -X24:1
1/1
-X25#1
MAIN ISOLATOR TO STARTER -VE STUD
E E
300MM
-X26#2 -X26#1 -U62 Part No. 60552222 -X27#2

1/1
1 35.00 mm² Black -X27:1
1/1
1 35.00 mm² Black -X26:1
-X27#1
STARTER -VE STUD TO CHASSIS GROUND
600MM
F -X148#2 -X148#1 -U63 Part No. 60552227 -X149#2 F

1/1
1 25.00 mm² Red -X149:1
1/1
1 25.00 mm² Red -X148:1
-X149#1
STARTER +VE STUD TO ALTERNATOR CHARGE TERMINAL

Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 12
-X165#1
*4/4
-X165#2
1
2
3 1.00 mm² Black12 -X165:4
-X174#1
4 1.00 mm² Black12 -X165:3
*4/4
FAST TRACK
SOLENOID
1 2 -X174#2
A 1 1.00 mm² BlueGreen -X74:11 A
OPTIONAL REMOTE -X164#1 1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black :(X1)
-X74#2 FEEDER START/STOP *4/4
3
1 1.00 mm² Green-Yellow -X98:1 FRONT PE
2 1.00 mm² Black -X98:2 -X164#2 VIEW
3 1.00 mm² BlackGreen -X98:3 1 1.00 mm²,1.00 mm² RedGrey,TransparentWhite -X176:1, /7.D3
4 1.00 mm² BlueGreen -X98:4 2 1.00 mm² Black :(X1)
3 4
5 1.00 mm² OrangeBlack -X98:5 3 1.00 mm² Black12 -X74:28
6 1.00 mm² Black7 -X98:6 4 1.00 mm² Black12 -X172:1
7 1.00 mm² GreenGrey -X98:7
8 1.00 mm² OrangeWhite -X98:8
9 1.00 mm² Black8 -X98:9 -X183#2
10 1.00 mm² Black10 -X98:10 1 1.00 mm² Black9 -X177:2
100MM
11 1.00 mm²,1.00 mm² BlueGreen,BlueGreen -X174:1, :(X1) 2
-X183#1
12 1.00 mm² Black11 -X98:12
*6/6 3
13 1.00 mm²,1.00 mm² RedGrey,Red -X82:1, -X191:1 4 1.00 mm²,1.00 mm² RedGreen,Black13 -X177:4
-U74
14 1.00 mm²,1.00 mm² Black,Black9 -X176:3, -X191:3 5 1.00 mm² RedGreen -X190:2
300MM
15 1.00 mm² GreenBrown -X98:15 6 1.00 mm² RedGreen -X175:1
16 1.00 mm² VioletWhite -X98:16
17 1.00 mm² Dark blueWhite -X103:1
-U
18 1.00 mm² RedGreen -X105:1
75
-U83
20 1.00 mm² Black1 -X107:1
-U73
21 1.00 mm² BrownWhite -X104:1
22
B 23 1.00 mm² Ligjt brownWhite -X72:4
B
24
25 1.00 mm² RedWhite -X82:3
26 1.00 mm²,1.00 mm² RedGreen,TransparentWhite -X193:1, /9.A2
1.0027mm²,1.00 mm²,1.00 mm² Black,Black,RedGreen :(X1), -X107:2, -X193:2 -X103#2
28 1.00 mm² Black12 -X164:3 1 1.00 mm² Dark blueWhite -X74:17
100
29 LTF SOLENOID 1.00 mm²,1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black,Black,Black-X104:1, -X105:2
100MM
30 1.00 mm² TransparentWhite -X102:1 3
31 1.00 mm² Black -X102:2 PE
*4/4
-X103#1
500mm 550MM 300MM 300MM 50mm 2600MM 200mm
-X105#2
1 1.00 mm² RedGreen -X74:18
LTR SOLENOID 1.00 mm²,1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black,Black -X106:2, -X103:2, -X104:1
-U1 -U68 -U3
-U7 3
PE
*4/4
-X105#1
-X106#2
-U85 1 1.00 mm² VioletWhite -X74:19
RTF SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X105:2, -X107:2
-X74#1 -U4 3
*31/31 PE
*4/4
C -X106#1 C
-X107#2
1 1.00 mm² Black1 -X74:20
RTR SOLENOID 2 1.00 mm²,1.00 mm² Black,Black -X106:2, -X74:27
3
PE
*4/4
-X107#1
450mm
450mm
400mm
D -X98#2 D
1 1.00 mm² Green-Yellow -X74:1
2 1.00 mm² Black -X74:2
3 1.00 mm² BlackGreen -X74:3

4
1.00 mm² BlueGreen -X74:4

5 1.00 mm² OrangeBlack -X74:5
6 1.00 mm² Black7 -X74:6
-U69
-U2
7 1.00 mm² GreenGrey -X74:7

8 1.00 mm² OrangeWhite -X74:8
9 1.00 mm² Black8 -X74:9
10 1.00 mm² Black10 -X74:10
TRACKING -X98#1 11
UMBILICAL CONNECTION *16/16
12 1.00 mm² Black11 -X74:12
13
14
15 1.00 mm² GreenBrown -X74:15
100mm
300mm
1000mm
100mm
100mm
E E
CONVEYOR DELAY
SENSOR
-X172#2
1 1.00 mm² Black12 -X164:4
2 1.00 mm² Black :(X1)
3
-X72#1
*5/5
-B1#1 PE
-U
70
-X72#2
1 1.00 mm² Red -X82:1
2
-X102#1
3 1.00 mm²,1.00 mm² Black,Black -X191:3 CONVEYOR 1 FEED CONVEYOR

*4/4
4 1.00 mm² Ligjt brownWhite -X74:23

SOLENOID SOLENOID
5 -X102#2
-X172#1
*4/4
1 1.00 mm² TransparentWhite -X74:30

2 1.00 mm² Black -X74:31
3
PE
50MM
F F
-U77
-U76
MM300
FUELSAVE
OPTIONAL
700
-X191#1
*5/5
-X191#2
1 1.00 mm² Red -X74:13
250MM

1.00 mm²,1.003 mm²,1.00 mm²,1.00 mm² Black9,Black,Black,Black -X74:14, -X72:3, -X82:2
4
5
-U71
G G
FEED PRESSURE KICK
-X169#2 OUT SWITCH 2
*5/5
1 1.00 mm² RedGrey -X176:1 -X176#1
2 -X176#2
3 1.00 mm² Black -X176:3 1 1.00 mm²,1.00 mm² RedGrey,RedGrey -X164:1, -X169:1
4 1.00 mm²,1.00 mm² Black9,Black9 -X176:4, :(X1)
*5/5
2
5 -X169#1 3 1.00 mm²,1.00 mm² Black,Black -X169:3, -X74:14
4 1.00 mm² Black9 -X169:4
FEED PRESSURE KICK 5
OUT SWITCH 1
HYD. OIL LEVEL

SENSOR
-X82#1
*4/4
-X82#2
1 1.00 mm²,1.00 mm² RedGrey,Red -X74:13, -X72:1
2 1.00 mm² Black -X191:3
3 1.00 mm² RedWhite -X74:25
H 4 H
3 Date Name Type Description: Electrical Kit Assignment

Changing
2 ADD 120 OHM RESISTORS FOR CAN 11.10.13 VM
drawing
M.-Nr.: CATPOWER
C4.4 T4UNIT Location
0 FIRSTDRAFT 29.11.12 CD WR1800X
the E3! Proved No. 15 Sh.
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A A
B B
SCREEN ANGLE SENSOR LOOM
900 3800
-U78 -U79 -U81 -X192#1

*2/2
C C
-X192#2
2 1.00 mm² Black -X175:2
-X190#1
*5/5
-X190#2
3 1.00 mm² Black -X175:2
4
5
D D
800
E E
-U80
F F
*4/4
-X175#3
-X175#4
2 1.00 mm²,1.00 mm² Black,Black -X192:2, -X190:3
3
PE
G G
H H
Changing
2 Date Name Type Description: Electrical Kit Assignment
1 M.-Nr.: POWER UNIT Location
drawing 0 User
only in Highlights of this sheet: Drawing number Sheet 15
3
the E3! ECO Proved - PLC; UNICODE PLC comment with text codes from translation database
No. 15 Sh.
1 - Symbol characteristics (standard / double spaced)
1 2 3 4 5 6 7 8 9 10 11 12
100mm 50MM 250MM 600mm 400 300mm
-U11 -U54 -U15 -U22 -U86 -U33 -U35 -U37

-U87
A A
-U10
-U9
200
600mm
300mm
100MM
-U88
100mm
-X117#2
450mm
1
2 1.00 mm²,1.00 mm² VioletWhite,VioletWhite -X125:1, -X118:1
-U82
B 3 1.00 mm² Orange -X121:1
B
4 1.00 mm² RedGreen :(X1)
5 1.00 mm² Black2 -X119:1
6
-X182#1 7
-U12
400mm
*6/6 8
-U55
-U38
9
10
-U16
-U34
11
POWER UNIT 12 -X93#1
W2S
LIGHT 13 *2/2
14 1.00 mm² Pink -X126:3 BEACON

15 CONNECTION
-X55#2 16
1 1.00 mm² Light brown -X178:12 17 1.00 mm² Green -X124:1
-X55#1
-U56
*2/2
2 1.00 mm² Black -X93:2 -X182#2 18 -X93#2 60505024

1 1.00 mm² Black9 :(X1) 19 1 1.00 mm² Black17 -X178:1
2 20 1.00 mm² Brown -X21:1 1.002mm²,1.00 mm²,1.00 mm² Black,Black,Black :(X1), -X95:2, -X55:2
3 200mm 100mm 100mm 21 1.00 mm² Black18 -X178:6 STARTER
4 1.00 mm² RedGreen -X191:2 22 SOLENOID
5 1.00 mm² RedGreen -X194:1 -U24 -U27 23
-X43#1
1/1
6 1.00 mm² RedGreen -X197:1 -U23 -U26 -U31 24
25
-U17
-X117#1 26 1.00 mm² BlueGreen -X125:3
*70/70
27 -X43#2
C 28 1 6.00 mm² Black11 -PCB1
C
29
-U40
30
31
ENGINE ECU 32
CONNECTOR
800MM
33
34 1.00 mm² Blue -R5.X2:1
35 1.00 mm² Black4 -X123:1
36
37 1.00 mm²,1.00 mm² BlueWhite,BlueWhite -X111:1, -X114:5
800MM
38 1.00 mm²,1.00 mm² RedGrey,RedGrey -X111:2, -X114:4

39 HYD OIL COOLER -X48#1
FAN No.1 *2/2
40 400mm
41
42
43 -X48#2
44 1 2.00 mm²,3.00 mm² BlueGreen,BlueGreen -X178:13, -X151:1 -U36
57
45 3.002mm²,3.00 mm²,3.00 mm² Black,Black,Black -X151:2, :(X1)
-U41
-U
400mm
46
700mm
47
-U18
48 -X162:1 -X151#1
*2/2
49 1.00 mm²,1.00 mm² Black3,RedGreen -X122:C, -X123:3
-U58
50 1.00 mm² Green-Yellow -X178:11 HYD OIL COOLER

51 FAN No.2
AIR INLET
-X124#1
52 -X151#2
*2/2
TEMP SENSOR 53 1 3.00 mm²,2.00 mm² BlueGreen,BlueGreen -X48:1, -X178:16

D 54 3.002mm²,3.00 mm²,3.00 mm² Black,Black,Black :(X1), -X48:2 D
-X124#2 55
1 1.00 mm² Green -X117:17 56
2 1.00 mm² Orange -X121:1 57 W2S -X95#1

58 *2/2
2 1
59 1.00 mm² Black19 -X22:1 -LF1 -LF1#1
AIR FILTER SIREN
150mm
60 1 2
-X76#1
*2/2
RESTRICTION 61 1.00 mm² Black -X117:63

CONNECTION
-U25
-U28
62
-X76#2 63 1.00 mm²,1.00 mm² Black,Black -X117:61, -X117:65 -X95#2 60505024
1 1.00 mm² Red :(X1) 64 1 1.00 mm² Black17 -X178:1
2 1.00 mm² Black6 :(X1) 65 1.00 mm²,1.00 mm² Black,Black -X117:63, -X112:1 2 1.00 mm² Black -X93:2 2 1
1700mm
66 -LF2#1 -LF2#1
-X123#1 W2S -X52#1 67 1.00 mm² Black -X117:69 1 2
*3/3 *2/2 68
1.0069mm²,1.00 mm²,1.00 mm² Black,Black,Black -X117:67, -X112:1, -X113:1
FUEL 70 1.00 mm² White -X178:3 2 1
-U42
CONTAMINATION -LF3 -LF3#1
-U29
SENSOR 2
Fuel Pump Supply 1
-X123#2 -X52#2 60505024
1 1.00 mm² Black4 -X117:35 1 2.00 mm² BlueGreen -X178:15
2 1.00 mm² Black2 -X119:1 2 1.00 mm² Black -X178:10
3 1.00 mm² RedGreen -X117:49
E E
-U43
100mm
400mm
DPF AIR
TEMP. SENSOR
-X125#2
-U
-X125#1 1 1.00 mm²,1.00 mm² VioletWhite,VioletWhite -X117:2, -X118:1
32
400mm
*4/4
100mm
2 1.00 mm² Orange -X121:1
3 1.00 mm² BlueGreen -X117:26
4
-U30
-U19
DPF ID
F -X126#2 MODULE F
-X126#1 1 1.00 mm² VioletWhite -X118:1
*6/6 2
-U44
3 1.00 mm² Pink -X117:14
4
ENGINE 5
PREHEAT 6 1.00 mm² Black2 -X120:1
TERMINAL
60505146
39
-U20
-U
-X12#2
1 6.00 mm² Brown -X13:1
-X12#1
1/1
-X160#1
-X28#1
-X29#1
1/1
1/1
-X8#1
1/1
1/1
-X5#1
-X17#1
1/1
1/1
150mm
-P1:3, :(X1), -X28:1

60505272
3.00 mm²,3.00 mm²,3.00 mm²,3.00 mm²,3.001mm²,3.00 mm²,3.00 mm² Black,Black,Black,Black,Black,Black,Black

G G
1WAY MALE
-X112:1
300MM
DEUTSCH
-X16:1
-X4:1
-X7:1
3.00 mm² Black
6.00 mm² Brown

150mm
6.00 mm² Red
16.00 mm² Red

PRE-HEAT
14
-U
LEAD
-X28#2
-X29#2
60552427
6mm-N AUTO
-X17#2
1
-X5#2
-X8#2
-X122#1
-U21
*3/3 COOLANT LEVEL
1
SENSOR
-X122#2
A 1.00 mm² RedGreen -X162:1 -X114#1
B 1.00 mm²,1.00 mm² Black2,Black2 -X119:1 *6/6
C 1.00 mm² Black3 -X117:49
-X111#1
*2/2 60536075
DPF SOOT 6.4mm RING
H SENSOR CAN C H
-X161#1
1/1
-X114#2 TERMINATION RESISTOR

1 1.00 mm² Red -X116:1 -X111#2
2 1.00 mm² BrownWhite -X113:1 1 1.00 mm² BlueWhite -X117:37
3 2 1.00 mm² RedGrey -X117:38
4 1.00 mm² RedGrey -X117:38
5 1.00 mm² BlueWhite -X117:37
6
W2P
-X150#1
*2/2
-X150#2
1 3
Changing Date Name Type Description: Electrical Kit
WR1800X Assignment
2 -R2.X2:1 2 ADD 120 OHM RESISTORS FOR CAN 11.10.13 VM
drawing
M.-Nr.: CATPOWER
C4.4 T4UNIT Location
DT04-2P 0 FIRSTDRAFT 29.11.12 CD
the E3! Proved No. 15 Sh.
1 2 3 4 5 6 1 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9
A A
500MM
Part No. 60552028 2

1
-X96#1
-X96#2
-H3#1
1 1.00 mm² Brown -H3:1 -W2

2 1.00 mm² Blue -H3:2 -W2
B B
-S5#1
-U48
5500MM
282104-1
C C
Part No. 60552247

ESTOP POWER UNIT *2/2
OFF SIDE -X32#1
-X32#2 282104-1
1 #IGN_ON -S5:1 -W4 1.00 mm²
2 #IGN_ON -S5:2 -W4 1.00 mm²
3
D 4 D
5
-S4#1
-U51
2000MM
282104-1
E E
Part No. 60552265
ESTOP POWER UNIT *2/2
NEAR SIDE -X31#1
-X31#2 282104-1
1 #IGN_ON -S4:1 -W3 1.00 mm²
2 #IGN_ON -S4:2 -W3 1.00 mm²
3
4
F 5
F

Changing
only in
the E3! Proved 60552463.2 No. 15 Sh.
1 2 3 4 5 6 7 8 9
F
E
B
D
A
C
1
1
2
2
300.00
-A1
LED
3
3
N2
VBBs 1
GND 2
only in
CAN2_H 3
the E3!
drawing
CAN2_L 4
Changing
A B C D E F P/N1
1 1
A VBBs 1 1 C VBBs 1
1 B VBBs
VBBs 1
2 2
2 2 D GND 2 E GND 2 F GND
VBB1 2
3 3 3 3
3
3
VBB2 3
A GND 4 4 4 D GND
B GND C GND 4 E GND 4 F GND
4
GND 4
5 5
A GND 5 B GND 5 5
5 C GND
CAN1_H 5
6 6 6
CAN1_L 6
7 7 7 7 7
0
3
1
2
7
A VBBs 8 D GND GND

8 8 B VBBs 8 C VBBs 8 E 8 F GND
Revision
300.00
ECO
4
Revision text
4
FIRSTDRAFT
300.00 300.00
Date
15.1.13
11.10.13
29.11.12
5
5
CD
30
VM
VM
Name
-S2
-S1
15
50
1
4
300.00
300.00
2
-P1
NO
-S3
-S3
3
2
-P1
2
NC
-S3
User
1
2
OK
NO
Proved
-S3
Date
6
-S1
6
2
NO
-S2
Name
7
7
Type WR1800X
M.-Nr.: CAT C4.4 T4
8
8
POWER UNIT
60552463.2
Drawing number
9
9
No.
Sheet
Location
Assignment
14
15 Sh.
F
E
B
D
A
C
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Warrior 2100 Operations Manual Revision 3.0 (English)

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Warrior 2100 Operations Manual Revision 3.0 (English)

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Formatos disponibles

WARRIOR 2100

ISSUE DATE: 14-02-2017

200 Coalisland Road, Dungannon,

1.1 Updates to Maintenance Section 01-Oct-2014

2.1 Spaleck screenbox maintenance updates. 06-Oct-2015

2.4 Initial setup: jacking legs updated. 09-May-2016

Operations Manual Revision 3.0 14-02-2017

Intentionally Left Blank

14-02-2017 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 14-02-2017

(a) Warrior Feed Hopper (Standard & Apron)..............................................3-2

14-02-2017 Revision 3.0 Operations Manual

(2) Folding Steps To Transport Position...........................................................5-8

Operations Manual Revision 3.0 14-02-2017

(4) Machine Tracking Directions....................................................................7-27

14-02-2017 Revision 3.0 Operations Manual

(2) Tensioning the Conveyor Belts.................................................................9-24

Operations Manual Revision 3.0 14-02-2017

14-02-2017 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 14-02-2017

Intentionally Left Blank

14-02-2017 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 14-02-2017

1.1 Notes to the Operations Manual

14-02-2017 Revision 3.0 Operations Manual

(2) Optional Equipment

1.2 Safety Information

(1) Safety Alert Symbol

(2) ANSI Hazard Classification System

Operations Manual Revision 3.0 14-02-2017

(3) California Proposition 65 Warnings

1.3 Intended Use

1.4 Prohibited Use

1.5 Declaration of Conformity

14-02-2017 Revision 3.0 Operations Manual

1.8 Bulletin Distribution and Compliance

1.9 Transfer of Machine Ownership

Operations Manual Revision 3.0 14-02-2017

1.10 Contacting the Manufacturer

14-02-2017 Revision 3.0 Operations Manual

Operations Manual Revision 3.0 14-02-2017

2.1 General Safety

(1) Safety Alert Symbol

(2) ANSI Hazard Classification System

14-02-2017 Revision 3.0 Operations Manual

(3) Property Damage Messages

(4) Description of Safety Symbols

Table 2.1 - Description of Safety Symbols

Stay sufficient distances from electrical power lines.

Stay clear of conveyor.

Install covers and guards before operation.

Turn machine off and remove the key.

Read and understand operations manual before using equipment.

Operations Manual Revision 3.0 14-02-2017

Use cardboard or wood to check for leaks.

Stay clear of support legs and jacks.

Falling material hazard

Stay clear of hopper during operation.

Do not climb onto the machine.

Use personnel lift to reach high places.

Check tyre pressures prior to transport.

Connect and check braking system.

14-02-2017 Revision 3.0 Operations Manual

Hand entanglement in pulley/ winch