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1 Manual Revision History:

28/08/2012 V1.00 Released Manual.

07/01/2013 V1.01 Added Wabasto heater control.

28/03/2014 Updated to new screens.

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Contents

1 Manual Revision History: ............................................................................................ 2


2 Engine Panel Overview ................................................................................................ 5
3 Starting Engine ............................................................................................................ 6
4 Engine Monitoring ....................................................................................................... 7
6. Tier 4 Engine Monitoring ............................................................................................. 9
7. Stopping the Machine ................................................................................................ 10
8. Tracking the Machine ................................................................................................ 11
8.1 Track Control – Wired Handset ........................................................................................ 11
8.2 Track Control – Radio Handset ........................................................................................ 13
8.3 Track Control – Doglead Handset Test .......................................................................... 14
9 Feeder - Control Monitoring ...................................................................................... 16
9.1 Material Height Adjustment ............................................................................................... 17
9.2 Chamber Sensor Overview ................................................................................... 18
9.3 Manual Feeder Speed Adjustment ........................................................................ 19
10 Feeder Parameter Adjustment .................................................................................. 20
11 General Feeder Controls ........................................................................................... 23
12 Starting Crusher......................................................................................................... 24
13 Stopping Crusher....................................................................................................... 25
14 Crusher Parameter Monitoring ................................................................................. 26
15 Closed Side Setting Adjustment ............................................................................... 27
15.1 CCS Calibration .................................................................................................................. 28
15.2 New Liner............................................................................................................................. 28
16 Auxiliary Functions .................................................................................................... 29
17 Error Logging ............................................................................................................. 30
18 Error Alerts ................................................................................................................. 32
19 Service Mode .............................................................................................................. 33
19.1 Access Procedure .............................................................................................................. 33
19.2 Settings and Parameters................................................................................................... 35
19.3 Parameter Adjustment ....................................................................................................... 38
20 Setting The Clock....................................................................................................... 40
21 Heater Control ............................................................................................................ 41
21.1 General.................................................................................................................................. 41
21.2 Operation .............................................................................................................................. 41

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22 Diagnostics ................................................................................................................ 43
22.1 Screen 1 – Radio Handsets .............................................................................................. 43
22.2 Screen 2 – Dog Lead Handset ......................................................................................... 45
22.3 Screen 3 – Valve Block 1 .................................................................................................. 46
22.4 Screen 4 – Valve Block 2 .................................................................................................. 47
22.5 Screen 5 – Sensors ........................................................................................................... 48
22.6 Screen 6 – Feeder Pause Status..................................................................................... 48
22.7 Screen 7 – Lube Flag Status ............................................................................................ 49
22.8 Screen 8 – Lube System Information .............................................................................. 50
22.9 Screen 9 – Lube System Valve Status ........................................................................... 51
22.10 Screen 10 – Clamp Block Valve Status ...................................................................... 51
22.11 Screen 11 – Clamp Block Control................................................................................ 52
22.12 Screen 12 – Scope Screen ........................................................................................... 53
23 Replacing I/O Modules............................................................................................... 55
23.1 Replacing Master I/O Module: .......................................................................................... 55
23.2 Replacing Slave I/O Module ............................................................................................. 56
24 Error Codes ................................................................................................................ 57
24.1 CAT Engine Error Codes .................................................................................................. 57
24.2 Machine Error Codes ......................................................................................................... 59
25 Radio Handsets .......................................................................................................... 63
25.1 Tracking Handset ............................................................................................................... 63
25.2 Feeder Handset .................................................................................................................. 64
25.3 Radio Coding: ..................................................................................................................... 65
25.4 Small Handset Coding Procedure ................................................................................... 67
25.5 FCC / IC Warnings.................................................................................................................. 68
26 Trouble shooting Guides:.......................................................................................... 69
26.1 If Engine won’t start ........................................................................................................... 69
26.2 If display is not working ..................................................................................................... 70
26.3 If machine won’t track ........................................................................................................ 70
26.4 If feeder will not run:........................................................................................................... 71

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2 Engine Panel Overview

The above shows the engine control panel layout, which incorporates the display unit used
for controlling and monitoring machine function, along with the machine key switch. Please
note that reference is made to the “main menu” screen buttons using the following reference
numbers.

Key:-

1. Crusher Start / Stop 11. Display unit


2. Track Speed Enable And Adjust 12. Panel lock
3. Service Mode Access 13. Key switch
4. Language Selection 14. Key switch off position
5. Escape 15. Key switch power only position
6. Engine Information Menu Access 16. Key switch heat position
7. Crusher Function Menu Access 17. Key switch crank position
8. Feeder Function Menu Access
9. Auxiliary Function Menu Access
10. Cursor Controls

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3 Starting Engine

1. Check that all control levers are in the neutral position, and all emergency stops are
released.

2. Make sure that no one is standing within 15m of the machine.

3. Insert the key into the main control ignition switch.

4. Turn the key clockwise to the power position. The display will commence its boot
sequence followed by entry in to the main menu screen.

5. Turn the key clockwise to the heat position, the engine heat lamp will illuminate. Wait
until this lamp goes out before continuing.

6. Turn the key further clockwise to the crank position. The machine alarm will sound to
indicate that the machine is about to start. This will be accompanied by a change of
display to the engine function mode.

7. Hold the key in the crank position for 10 seconds, during which time the alarm will
continue to sound and the display will show time to engine crank. During this time the
engine priming pump will run.

8. Release the key immediately the engine starts.

9. Prior to operating the machine, allow the engine to run for 5 minutes to allow running
temperature to be reached. This will prolong engine life.

10. Pressing the escape key will return the display to the main start-up screen.

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4 Engine Monitoring

1. From the main screen, press the engine information button (Key 6). The display
mode will change to show the important engine parameters as follows :

2. Press the ‘OK’ button to zoom into each parameter in turn.

3. To adjust the engine speed, press and hold the appropriate cursor button (Key 10).
Holding down the “up arrow” key will cause an increase in engine speed, while
holding down the “down arrow” key will cause the engine speed to decrease. The
rate at which engine speed varies depends on how long the key is held. This allows
the desired speed to be reached quickly.

4. Press key 9 to access the Tier 4 Engine Monitoring screen, if the machine is fitted
with a tier 4 engine.

5. Press escape (key 5) to return to the main screen.

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The engine function display also contains 6 automotive-style panel indicators, which alert the
user to the crucial engine warnings and stop conditions:-

Other useful machine operating parameters are continually displayed, including total engine
running hours, total machine crushing hours and total estimated remaining fuel time.

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6. Tier 4 Engine Monitoring

1. From the Engine Monitoring screen, press the Tier4 Engine Monitoring button (Key
9). The display mode will change to show the important Tier 4 engine parameters as
follows:

2. Press key 7 to inhibit DPF regen.

3. Press key 8 to force a manual DPF regen cycle.

The Tier 4 Engine Monitoring display also contains 6 automotive-style panel indicators,
which alert the user to the crucial Tier 4 engine warnings and stop conditions:-

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7. Stopping the Machine

1. Make sure all conveyor belts, feed hopper and crusher are clear of material.

2. Stop the machine in the following sequence :-


 Pan Feeder.
 Crusher.
 Main Conveyor.
 Over-band Magnet Conveyor (where fitted).
 Side Conveyor.

3. Allow the engine to idle for 5 minutes prior to shutting-off. This will allow engine
temperature to cool and prolong engine life.

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8. Tracking the Machine

There are two methods of tracking the machine, either with a wired dog lead handset or
using the optional radio tracking handset. The following sections describe how to enter
tracking mode on the machine using either method.

8.1 Track Control – Wired Handset

1 If the radio handset is being used in track mode, the doglead handset will be ignored.

2 Ensure that the doglead stop button is released and the enable key switch is in the
vertical position.

3 Start the engine. Note that engine speed will be controlled automatically during track
mode.

4 Ensure the crusher is fully stopped. Enter track mode by either using the track mode
button on the display (Key 2) or turn the dog lead handset key switch clockwise. The
siren will sound for 10 seconds prior to machine movement being allowed. The
display will change to show key tracking parameters, including the remaining time
before tracking is allowed.

5 Note the track timer will not count down below 5 seconds if a track direction button is
being pressed.

Note: If the engine is cold, the cold engine symbol will illuminate and tracking
will be disabled until the engine warms up.

6 The main lower conveyor section will automatically move in to the transport position.

7 The tracking speed will default to the slowest setting (snail). This can be changed
using the up and down cursor buttons (key10). The current speed will be indicated by
the large green snail, tortoise or hare symbol, representing slow, intermediate and

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fast track rates respectively. The smaller blue icons, located by the cursor button
indicate the next available allowed speed.

8 Use the four handset buttons to move the associated tracks in the required direction.
The required track will move at the currently set speed for as long as the button is
held. The display will indicate track movement status using arrows, positioned on the
main track icon.

9 Machine track mode can be terminated by pressing the display escape button, or by
turning the handset key switch counter-clockwise. The display will return to the main
machine menu.

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8.2 Track Control – Radio Handset

1. The radio handset will not enter track mode on its own, the display must be used to
enter track mode using key 2.

2. Once in track mode, the machine function is identical to operation with the wired
handset.

3. Use the four handset buttons to move the associated tracks in the required direction.
The required track will move at the currently set speed for as long as the button is
held. The display will indicate track movement status using arrows, positioned on the
main track icon.

4. If the radio handset is being used in track mode, the dog lead handset will be
ignored.

5. To exit track mode, either use the display escape key or switch the radio handset off
using its key switch.

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8.3 Track Control – Doglead Handset Test

If the handset connected is not the new style handset then the following screens are
displayed to test the connected handset.

1. Test the forward left button.

2. Test the forward right button.

3. Test the reverse left button.

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4. Test the reverse right button.

5. Test completed.

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9 Feeder - Control Monitoring

This machine has an auto feeder speed control fitted, that will attempt to maintain a preset
level of material in the feed chamber. The current material level is determined using an
ultrasonic sensor, positioned inside the chamber.

1. Key 1 is used to turn the feeder on or off.

2. Key 2 is used to disable or enable the radio control system.

3. Key 3 turns the pre-screen if fitted on or off. Note: Stopping the pre-screen also
stops the feeder.

4. When key 4 is pressed the screen below is displayed showing the current feeder
pause condition state, as an aid to fault finding:

This screen displays the current feeder pause condition state, as an aid to fault
finding. The user is able to see which processes are preventing the feeder from
running. The feeder control valve will be disabled whenever a ‘cross’ is shown below

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a particular icon. With the above screen example, the feeder is paused due to a
problem with conveyor pressure. The following table explains the meaning for each
icon:-

Status Icon ‘Cross’ Displayed


Crusher Run Cone has not reached operating speed
Feeder Run Feeder has been manually disabled
Crusher Speed Crusher rpm < preset value
Engine Run Engine problem or low rpm
Metal Detect A metallic object has been detected inside the chamber
Lube Temperature Lube oil temperature is too low
Clamp Pressure Main clamp pressure is not OK
Conveyor Pressure Conveyor pressure is not OK
Crusher Pressure Crusher pressure is not OK
Chamber Overflow Chamber full for a certain time
Downstream Input Downstream inhibit is active
Radio Enable Feeder paused by the radio handset
Feeder Current Feeder control valve current fault

9.1 Material Height Adjustment

1. Adjust the desired material level in the feed chamber prior to commencing crushing
operation. The feeder rate will be controlled accordingly to maintain the required feed
height in the feed chamber. This will maximize potential crushing throughput.

2. Use the cursor-up and cursor-down keys to adjust the required material height. The
display will show the current material level as a percentage, along with the
associated bar graph.

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9.2 Chamber Sensor Overview

A good starting point is to set the desired material height to 70 percent. The current material
height in the crushing chamber can be monitored by observing the display, as shown below:-

Desired material height set to 70 percent with no material in the chamber.

Desired material height set to 70 percent with material shown in the chamber. The level is
currently below the desired height, such that the feeder will operate at maximum speed.

Desired material height set to 70 percent with material shown in the chamber. The level in
the chamber is currently above the desired height, such that the feeder will slow or stop in
order to maintain the correct material height.

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9.3 Manual Feeder Speed Adjustment

It is possible to override the automatic feeder speed control system by setting the desired
feeder height to 101 percent.

1. Use the cursor-up and cursor-down keys to set the required material height to 101
percent.

2. Use the cursor-left and cursor-right keys to manually set the maximum allowed
feeder speed.

3. Press escape to return to the main display menu.

4. In certain situations it may be desirable to limit the maximum allowed speed the
feeder can run at. Such as in a chain of machines so as not to overwhelm the next
machine in the chain.

5. In order to limit the maximum feeder speed, either use the left/right arrow keys or the
feeder radio handset. In the example above feeder speed is set to 80 percent but the
actual feeder speed (highlighted in green) is currently below this value. If the auto
feeder system is being used this adjustment will tweak the feeder speed in relation to
the chamber level sensor. If the auto feeder is switched off, the percentage value
shown here is the manually controlled feeder speed.

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10 Feeder Parameter Adjustment

In addition to material height, feeder speed is also governed by the temperature of the lube
oil, the crusher hydraulic drive pressure, conveyor pressure, whether a downstream machine
is connected and the hydraulic oil temperature.

If the crusher drive pressure exceeds a preset maximum value, the feeder speed will be
stopped. Where the feeder has to stop, it will only re-start when the drive pressure drops
below a preset minimum value.

If the conveyor pressure sensor is reading too low (conveyor not running) or too high
(conveyor stalled), the feeder will be disabled.

If a downstream machine requests the feeder on the machine stops, it will do so after a
preset delay. A separate delay controls the feeder restarting after the downstream machine
restarts.

If the hydraulic oil temperature is above its warning point the feeder will derated to run at a
maximum of 50% speed.

1. Key 6 when pressed displays the Crush Pressure settings, the Dynamic Adjust
settings and the Down Stream settings in turn to allow for adjustment.

2. Selection displays the Crush Pressure settings:

- Press Key 7 to select the feeder-off crush pressure adjustment. Use the up and
down cursor buttons to adjust this setting. The cursor keys will revert to
controlling material height following no parameter adjustment activity for four
seconds.

- Press Key 8 to select the feeder-restart crush pressure adjustment. Use the up
and down cursor buttons to adjust this setting.

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3. Selection displays the Dynamic Adjust settings:

- Dynamic adjust is the term used for the crusher pressure at which the Telsmith
cone will start unwinding (opening CSS) to relieve the pressure. Once the
pressure drops back down the CSS will wind back to previous setting.
-
- Press Key 7 to select the Dynamic Adjust Start pressure setting. Use the up and
down cursor buttons to adjust this setting.

- Press Key 8 to select the Dynamic Adjust Start pressure setting. Use the up and
down cursor buttons to adjust this setting.

4. Selection displays the Down Stream Feed settings:

- Press Key 7 to select the downstream feeder-off time adjustment. Use the up and
down cursor buttons to adjust this setting.

- Press Key 8 to select the downstream feeder-restart time adjustment. Use the up
and down cursor buttons to adjust this setting.

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11 General Feeder Controls

1. Press Key 1 to turn the feeder on or off.

2. Press key 2 to enable or disable the remote feeder handset. The icon will change
from green to red when the service is active to indicate that the remote feeder
handset has been disabled.

3. Key 3 turns the pre-screen if fitted on or off.

4. Press key 4 to access the feeder run status flag display. Please refer to the
diagnostics section of this manual for more information.

5. Press escape to return to the main display menu.

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12 Starting Crusher

1. To initiate the crusher start sequence, press the crusher start / stop button (key1)
from the main menu.

The display will enter the crusher start mode. At this point the lubrication pump will
commence pumping lube oil around the cone for 60 seconds.

At the end of this 60 seconds, the control system will check whether the lube oil
parameters are sufficient to allow the cone to rotate. The lube oil parameters consist
of the lube tank temperature, cone return temperature, lube oil pressure, lube flow
rate and lube oil level are all above the minimum set values (refer to service section
for default values).

Each parameter is shown in the box on the right with a tick / cross indicating whether
each parameter is sufficient to allow crushing. In the event that the lube is not at a
high enough temperature to allow crushing, the control system will divert the lube oil
through an engine heat exchanger in order to speed up the warming process. The
engine rpm will increase in order to further speed up this process.

Once the following parameters have been met, the alarm will sound and the cone
allowed to start.

o Lube tank temperature is > 19.0 degrees C


o Cone return temperature is > 12.0 degrees C
o Cone return temperature is < 54.0 degrees C
o Lube Oil Pressure is > 1.4 Bar
o Lube Oil Pressure is < 13.8 Bar
o Lube Oil Flow is > 45.0 Litre Per Minute

The parameters above are adjustable in the service mode, but are not allowed to be
set lower the min values shown above.

Once the cone has started, the red power bar graph display will indicate the current
speed ramp level as a percentage.

The lube oil must also be above a second, higher value in order to allow the feeder to
start.

Note: If the engine is cold, the cold engine symbol will illuminate. To run the
crusher, the engine must be warm.

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2. Press escape to return to the main display menu.

Where one or more lubrication parameters do not meet the crusher start requirements, a red
cross will replace the existing tick icon. This will be accompanied by the wait-to-start
hourglass icon.

3. During this period, press the stop key to abort the crusher start sequence and return
to the main display menu.

13 Stopping Crusher

1. Press the crusher start / stop button (key 1) from the main menu. The display will
enter the crusher stop mode.

2. The red bar graph display will indicate that the crusher is ramping down to a stop
condition.

3. Press escape to exit back to the main menu.

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14 Crusher Parameter Monitoring

1. Press key 7 from the main display screen to view system status while crushing is in
progress.

2. Press key 1 to activate the manual tramp function. This will raise the adjustment ring,
allowing any oversize material to drop through the crusher

3. Press key 2 to access the Closed Side Setting adjustment features.

4. Press key 3 to display the current cone lubrication oil temperatures and flow rate.
Please refer to the diagnostics section of this manual for more information.

5. Press key 4 to display the current cone lubrication status flags. Please refer to the
diagnostics section of this manual for more information.

6. Press key 5 to return to the main display menu.

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15 Closed Side Setting Adjustment

The Closed Side Setting (CCS) is the current gap between the cone and liner.

1. Press key 1 to increase the CSS adjustment by 10mm. The adjustment ring will begin
winding out at high speed until 9.8 mm of travel has been measured, winding speed
will then reduce for the remaining 0.2 mm. The updated CCS will be displayed during
this time

2. Press key 2 to decrease the CSS adjustment by 10mm. The adjustment ring will
begin winding in at high speed until 9.8 mm of travel has been measured, winding
speed will then reduce for the remaining 0.2 mm. The updated CCS will be displayed
during this time.

3. Press and hold key 6 to wind out the adjustment ring at low speed. The updated CCS
will be displayed during this time. Upon releasing the key, adjustment will be halted.

4. Press and hold key 7 to wind in the adjustment ring at low speed. The updated CCS
will be displayed during this time. Upon releasing the key, adjustment will be halted.

5. Press and hold key 8 to wind out the adjustment ring at high speed. The updated
CCS will be displayed during this time. Upon releasing the key, adjustment will be
halted.

6. Press and hold key 9 to wind in the adjustment ring at high speed. The updated CCS
will be displayed during this time. Upon releasing the key, adjustment will be halted.

7. Press key 5 to return to the crusher parameter monitoring display.

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15.1 CCS Calibration

It will be necessary to periodically perform the following steps to re-calibrate the CCS
due to liner wear.

1. Press key 7 to wind in the adjustment ring until both cone and liner are touching.

2. Press key 4 for three seconds to zero the CCS. The liner wear measurement will be
updated to show how much wear has occurred since the last calibration.

15.2 New Liner

1. Press key 3 for three seconds to zero the liner wear measurement when a new liner
is fitted.

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16 Auxiliary Functions

1. Press the auxiliary function button (key 9) from the main menu. The display will
change to display the available options.

2. Press Key 1 to turn the dust suppression water pump on or off. The icon will change
from red to green when the service is active.

3. Press Key 2 to turn the fuelling pump on or off. The icon will change from red to
green when the service is active.

4. Press Key 3 to turn the work lights on or off. The icon will change from red to green
when the service is active.

5. Press Key 4 to access the fault log.

6. Press Key 6 to raise the main conveyor feed boot. This button is momentary acting,
i.e. the service is active only while the button is held.

7. Press Key 7 to lower the main conveyor feed boot. This button is momentary acting,
i.e. the service is active only while the button is held.

8. Press escape Key 5 to exit back to the main menu.

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17 Error Logging

The C38 control system incorporates comprehensive error logging facilities, which allow
errors generated by the engine or crusher control system to be logged, saved to a USB
memory stick and recalled on-screen. All error codes are translated to descriptive text which
is recorded along with a time and date stamp.

1. Press the auxiliary function button (key 9) from the main menu. The display will
change to display the available options.

2. Press key4 to access the fault log display.

An example error log is shown above.

3. Press the up and down cursor buttons (key 10) to scroll through the error display list.

4. Press escape Key 5 to exit back to the auxiliary function screen.

The display is fitted with a rear-mounted type-A USB socket, designed to accept a
memory stick device. Access to this is gained by removing two hex bolts which hold the
cover in place.

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5. Insert the USB memory device into the socket. The display will recognise that the
USB device has been connected.

6. Press key 6 to copy the current error log file to the USB memory device. Note that an
existing file will be overwritten by this action. The resulting text file (error_log.txt) can
be imported into an Excel spreadsheet and manipulated accordingly.

7. Press key 1 to safely eject the USB device.

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18 Error Alerts

The operator will be immediately alerted to the presence of a machine error.

1. Press the OK cursor button to view the next error alert or to exit.

There are two types of error on the machine, those relating to the CAT engine and those
errors relating to the control electronics. See appendix for listing of both types of errors.

Note, if an operator dismisses an error from the display, the error will be re-displayed if the
operator attempts to track or start the cone.

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19 Service Mode

19.1 Access Procedure

1. To enter service mode, press key 3 from the main menu. Note that a four digit
password will be required before service mode access is granted.

2. Use the cursor buttons to select and set the four digit password. The left and right
cursor buttons are used to select the password digit. The up and down cursor buttons
allow the selected digit to be changed.

3. On completion of the password digit entry, press the cursor OK button to enter
service mode.

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4. Press key 1 to access the diagnostic modes. This feature is accessible without
password entry.

5. Press key 2 to set the display real time clock. This feature is accessible without
password entry.

6. Press key 3 to reset the engine maintenance condition. The service icon will be
displayed when engine maintenance is due.

7. Press key 4 to modify those settings related to the lube oil circuit.

8. Press key 6 to modify those settings related to crushing.

9. Press key 7 to modify those settings related to the feeder.

10. Press key 8 to modify those settings related to tracking.

11. Press key 9 to modify those settings related to miscellaneous parameters.

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19.2 Settings and Parameters

The non-volatile machine parameter storage is contained within the Master I/O Module.
Examination and modification of those parameters is performed using the displays service
mode functions. Each non-volatile parameter is grouped according to its function within the
machine, as follows:-

Crusher Parameters
Crusher Maximum PWM Sets maximum cone speed when crushing mA
Crusher Ramp Up Time Time to ramp up to maximum current 0.5 Sec.
Crusher Ramp Down Time Time to ramp up to maximum current 0.5 Sec.
Required Engine Speed to Start
Feeder
Required Crusher Speed to Start
Feeder
Crusher Speed Stall Threshold If crusher speed drops below this value for stall time
then crusher in shutdown
Crusher Speed Stall Time

Feeder Parameters
Crusher Pressure Feeder Disable Cone pressure at which feeder is halted Bar
Crusher Pressure Feeder Restart Cone pressure at which feeder will restart Bar
High Pressure Stop Delay Delay timer related to crusher pressure feeder disable Sec.
High Pressure Restart Delay Delay timer related to crusher pressure feeder restart Sec.
Feeder Min. PWM Sets minimum feeder speed mA
Feeder Max. PWM Sets maximum feeder speed mA
Hydraulic Temperature Feed Hydraulic oil temperature at which feeder speed will
Adjust be limited to 50%
Chamber Full Feeder Disable Sec.
Time
Chamber Full Feeder Restart Sec.
Time
Sensor Distance To Maximum Fill mm
Height
Sensor Distance To Minimum Fill mm
Height

Track Parameters
Snail Track Mode Engine RPM Engine RPM used in snail tracking mode rpm
Snail Track Mode Pump1 PWM Max speed of one track in snail tracking mode mA
Snail Track Mode Pump2 PWM Max speed of one track in snail tracking mode mA
Tortoise Track Mode Engine Engine RPM used in tortoise tracking mode rpm
RPM
Tortoise Track Mode Pump1 Max speed of one track in tortoise tracking mode mA
PWM
Tortoise Track Mode Pump2 Max speed of one track in tortoise tracking mode mA
PWM
Tortoise Track Mode Ramp Up Acceleration time in tortoise tracking mode Sec.
Time
Tortoise Track Mode Ramp Down Deceleration time in tortoise tracking mode Sec.
Time
Hare Track Mode Engine RPM Engine RPM used in hare tracking mode rpm

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Hare Track Mode Pump1 PWM Max speed of one track in hare tracking mode mA
Hare Track Mode Pump2 PWM Max speed of one track in hare tracking mode mA
Hare Track Mode Ramp Up Time Acceleration time in hare tracking mode 0.5 Sec.
Hare Track Mode Ramp Down Deceleration time in hare tracking mode 0.5 Sec.
Time

Miscellaneous Parameters
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Bypass Conveyor Sensor? Allows the conveyor pressure sensor to be YES / NO
bypassed if faulty
Bypass Temperature Sensor? Allows the hydraulic oil temperature sensor to be YES / NO
bypassed if faulty. Feeder speed is limited to 50%
Bypass Crusher Pressure Allows the cone pressure sensor to be bypassed if YES / NO
Sensor? faulty
Bypass Hydraulic Oil Level Allows the hydraulic oil level sensor to be bypassed YES / NO
Sensor? if faulty
Bypass Crusher Speed Sensor?

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Oil Cooler Start Temperature? Temperature at which oil coolers will start Deg. C
Hydraulic Oil Temperature Temperature at which engine will stop Deg. C
System Shutdown?
CSS Sensor Fitted?
Run Relay Control – Feeder The K2 Run Relay in the panel can either be rpm /
Controlled? energised when the engine is running OR feeder
when the feeder is running. Used to link to
other machines in a crushing chain
Select Long Range Ultrasonic
Sensor?
Reduce Power Consumption? Reduces voltage to valve coils
Enable Pre-emptive System Shut Stops crusher before engine overheats
Down?
Pre-screen Fitted? Whether pre-screen fitted
Pre-screen Operating Mode Auto: Starts and stops with feeder.
Manual: Controlled by user.

Lube Parameters
Warm Up RPM RPM Engine is run at during lube warm up cycle rpm
Lube Tank Oil Cooler Start Temp Temperature at which lube oil cooler will start Deg. C
Lube Tank Oil Cooler Shutdown Temperature at which lube oil cooler will stop Deg. C
Temp
Lube Tank Oil Pre-heat activate Temperature at which the lube control circuit will divert Deg. C
Temp lube oil to the engine heat exchanger
Lube Tank Oil Pre-heat de- Temperature at which the lube control circuit will stop Deg. C
activate Temp diverting lube oil to the engine heat exchanger
Cone Return Oil Min. Temp. To Minimum temperature needed to start cone. Deg. C
Start Cone
Cone Return Oil Max. Temp. To Maximum temperature allowed to reach before Deg. C
Run Cone stopping cone.
Cone Return Oil Min. Temp. To Minimum temperature at which feeder is allowed to Deg. C
Start Feeder run.
Lube Min. Pressure To Start Minimum pressure of lube circuit at which cone is Bar

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Cone allowed to run.
Lube Max. Pressure To Run Maximum pressure of lube circuit at which cone is Bar
Cone allowed to run.
Lube min. Flow To Start Cone Minimum flow of lube circuit at which cone is allowed Litres /
to run. min.

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19.3 Parameter Adjustment

Once the required parameter group has been selected, the current settings for that group will
be displayed. The up and down cursor buttons may be used to select the required parameter
for modification. The selection will be highlighted as shown below:-

1. Press the OK cursor button to enable parameter adjustment using the up and down
cursor buttons.

1. Use the up and down cursor buttons to modify the selected parameter value.

2. Press key 2 to set the chosen parameter to the allowed maximum value.

3. Press key 3 to set the chosen parameter to the allowed minimum value.

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4. Press key4 to abort the parameter edit mode and return the cursor button mode to
parameter selection.

5. Press escape to exit back to the main service mode screen.

6. Press the OK cursor button the update the selected parameter. The display will
indicate a successful update as shown below:-

7. Press escape to return to the main service menu,

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20 Setting The Clock

The display is provided with a real time clock which is used primarily for time and date
stamping when logging machine errors. Pressing key2 from within the main service menu
allows the time and date to be set.

1. Use the left and right cursor keys to select the required time or date parameter.

2. Use the up and down cursor keys to adjust the selected field value.

3. Press the OK key to set the new time and date.

4. Press key 6 to toggle the displayed units between metric and imperial.

5. Press key 7 to access the Wabasto heater timer functions.

6. Press the escape key to exit back to the main service level.

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21 Heater Control

21.1 General

Some machine types are fitted with a Webasto oil heater system, which is controlled from
the lube tank module. This allows the heater to be activated prior to machine usage, to bring
the oil up to a suitable operating temperature. Please note that this option forces the lube
module to remain active when the ignition is off, so it is recommended that the battery
isolator is opened if the machine is not in operation for an extended period.

21.2 Operation

The heater system is programmed using the following:

a. Heater On Time (time next to red heat symbol)

b. Heater Off Time (time next to blue heat off symbol)

c. Days of the week system is active.

To program the heater system:

1. Press key 1 to select between the adjustment of heater on and off times. The
associated time display digit is highlighted as shown above.

2. Press key 2 to select the next time digit for adjustment.

3. Press key 3 to select the previous time digit for adjustment.

4. Press key 5 to exit this function and return to the clock setting page.

5. Press key 7 to increment the selected time digit value.

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6. Press key 8 to decrement the selected time digit value.

7. Use the left and right cursor keys (key 10) to select a particular weekday. The
associated weekday abbreviation will be highlighted as shown below.

8. Use the OK cursor key (key 10) to include this day in the timer program. A further
press will exclude this day from the timer program, pretty much like a central heating
controller.

Please note the heater off time is used in conjunction with the Webasto controller itself.
Once the lubrication oil is up to working temperature the Webasto heater will switch off
regardless of heater off time.

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22 Diagnostics

1. Press Key 1 from the main service mode menu.

2. Use the left and right cursor buttons to navigate around the twelve available
diagnostic screen options.

3. Press escape to exit back to the main service mode screen.

22.1 Screen 1 – Radio Handsets

This screen allows the current radio handset functionality to be verified. The status of all
handset controls will be displayed in real time, i.e. a button press on the tracking handset will
cause the corresponding display button to glow. The stop buttons and track-enable key
switch position will be indicated as they are operated.

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The feed control handset button status will be displayed in real-time according to the buttons
pressed. An example is shown below:-

The programmed and received radio handset codes are displayed in the top-right hand of
the display. A green tick will be displayed when the codes match, with a red cross being
displayed at all other times. The following display indicates that no radio code information is
being received.

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22.2 Screen 2 – Dog Lead Handset

This screen allows the current dog-lead handset functionality to be verified. The status of all
handset controls will be displayed in real time, i.e. a button press will cause the
corresponding display button to become visible. The stop button and track-enable key switch
position will be indicated as they are operated.

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22.3 Screen 3 – Valve Block 1

This screen allows the current hydraulic valve status to be viewed in real-time. An active
solenoid status will be indicated by the associated LED indicator icon turning orange. The
main pump proportional solenoid current will be indicated by the associated analogue meter
displays.

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22.4 Screen 4 – Valve Block 2

This screen provides a slightly different view of current valve status, and incorporates the
facility to allow tracking mode selection and non-volatile tracking parameter changes. This
provides the facility to fine-tune machine tracking solenoid currents and ramp times. An
active solenoid status will be indicated by the associated LED indicator icon turning orange.
The main pump and feeder proportional solenoid currents will be indicated by the associated
analogue meter displays.

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22.5 Screen 5 – Sensors

This screen displays general machine sensor information, such as pump pressure and
hydraulic oil temperature, and is updated in real-time.

22.6 Screen 6 – Feeder Pause Status

This screen displays the current feeder pause condition state, as an aid to fault finding. The
user is able to see which processes are preventing the feeder from running. The feeder
control valve will be disabled whenever a ‘cross’ is shown below a particular icon. With the
above screen example, the feeder is paused due to a problem with conveyor pressure. The
following table explains the meaning for each icon:-

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Status Icon ‘Cross’ Displayed
Crusher Run Cone has not reached operating speed
Feeder Run Feeder has been manually disabled
Crusher Speed Crusher rpm < preset value
Engine Run Engine problem or low rpm
Metal Detect A metallic object has been detected inside the chamber
Lube Temperature Lube oil temperature is too low
Clamp Pressure Main clamp pressure is not OK
Conveyor Pressure Conveyor pressure is not OK
Crusher Pressure Crusher pressure is not OK
Chamber Overflow Chamber full for a certain time
Downstream Input Downstream inhibit is active
Radio Enable Feeder paused by the radio handset
Feeder Current Feeder control valve current fault

22.7 Screen 7 – Lube Flag Status

This screen displays the current cone lubrication system flag status, as an aid to fault
finding. The cone will not start whenever a ‘cross’ is shown below a particular icon. The
following table explains the meaning for each icon:-

Status Icon ‘Cross’ Displayed


Lube Oil Level Lube system oil level low
Lube Cone Temperature Lube system cone return temperature below start set point
Lube Tank Temperature Lube system tank temperature below start set point
Lube Pressure Lube system pressure below start set point
Lube Flow Rate Lube system flow rate below start set point

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22.8 Screen 8 – Lube System Information

This screen displays all data relating to the cone lubrication system, including oil
temperatures, flow rate and pressure. In addition the operator can manually control the oil
pump, pre-heat and oil cooler control valves. All key presses are momentary, i.e. the
associated valve is active while the key is held.

1. Press key 1 to manually control the oil pump valve.

2. Press key 2 to manually control the pre-heat valve.

3. Press key 3 to manually control the oil cooler fan valve.

4. Press the escape key to exit back to the main service level.

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22.9 Screen 9 – Lube System Valve Status

This screen displays the current lube system cooling fan and pump control valve status.

22.10 Screen 10 – Clamp Block Valve Status

This screen displays the current clamp block valve status, along with the associated main
clamp and lock cylinder pressures.

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22.11 Screen 11 – Clamp Block Control

This screen allows the manual control of both the main clamp and lock cylinder valves. All
key presses are momentary, i.e. the associated valve is active while the key is held.

1. Press and hold key1 to open the main clamp.

2. Press and hold key2 to close the main clamp.

3. Press and hold key3 to open the lock cylinder.

4. Press and hold key4 to close the lock cylinder.

5. Press the escape key to exit back to the main service level.

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22.12 Screen 12 – Scope Screen

This screen allows for monitoring of the signals from the processes below:

 Engine Oil Pressure


 Engine Speed
 Engine Fuel Temperature
 Engine Fuel Rate
 Fuel Pressure
 Load At Current Speed
 Engine Coolant Temperature
 Intake Manifold Pressure
 Engine Oil Temperature

The buttons on the right are used to select a process by scrolling through the processes with
the up and down arrows as shown in the screen below:

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Once ok is pressed to select a process, the up and down arrows can then be used to adjust
the signal.

A maximum of four processes can be monitored at the same time.

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23 Replacing I/O Modules

In the event that one of the Input/Output modules needs to be replaced, use the following
method:

23.1 Replacing Master I/O Module:

Master I/O Module

1) Unplug all connectors to module


2) Undo 8x screws holding I/O module to side plate of cabinet:
3) Replace I/O module
4) Plug all connectors into module, connectors are polarised by keys but care should be
taken to not deform connector when inserting.

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23.2 Replacing Slave I/O Module

Slave I/O Module

1) Unplug all connectors to module


2) Undo 4x screws holding I/O module to side plate of cabinet:
3) Replace I/O module
4) Plug all connectors into module, connectors are polarised by keys but care should be
taken to not deform connector when inserting.

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24 Error Codes

24.1 CAT Engine Error Codes

Error Code Failure Mode Index Description


1074 short to +batt Retarder Solenoid Current
1074 calibration required Retarder Solenoid Current
626 short to +batt Ether Injection Control Solenoid
626 calibration required Ether Injection Control Solenoid
678 short to ground 8 Volt DC Supply
678 abnormal rate of change 8 Volt DC Supply
620 short to ground 5 Volt Sensor DC Supply
1079 short to ground 5 Volt Sensor DC Supply
620 abnormal rate of change 5 Volt Sensor DC Supply
1079 abnormal rate of change 5 Volt Sensor DC Supply
100 short to ground Engine Oil Pressure
100 abnormal rate of change Engine Oil Pressure
100 signal erratic Engine Oil Pressure
102 short to ground Boost Pressure Sensor
102 abnormal rate of change Boost Pressure Sensor
102 signal erratic Boost Pressure Sensor
108 short to ground Atmospheric Pressure
108 abnormal rate of change Atmospheric Pressure
110 short to ground Engine Coolant Temperature
110 abnormal rate of change Engine Coolant Temperature
91 system fault Throttle Position
91 warning Throttle Position
190 warning Engine Speed
723 grounded/current above normal Secondary Engine Speed
190 below normal Engine Over speed
190 short to ground Engine Over speed
94 abnormal rate of change Fuel Pressure
94 short to ground Fuel Pressure
105 voltage high Intake Manifold Air Temp
105 system fault Intake Manifold Air Temp
164 Injector short Injector Actuation Pressure
164 de-rate Injector Actuation Pressure
164 above normal Injector Actuation Pressure
164 short to +batt Injector Actuation Pressure
637 calibration required Engine Timing
100 calibration required Low Engine Oil Pressure
100 above normal Low Engine Oil Pressure
100 open/short to +batt Low Engine Oil Pressure

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729 open/short to +batt Air Inlet Heater Relay
729 shutdown Air Inlet Heater Relay
168 grounded/current above normal System
168 Injector open circuit System
168 below normal System
630 Injector short Check Programmable Parameters
639 derate J1939 Data Link Communications
110 above normal High Engine Coolant Temperature
110 grounded/current above normal High Engine Coolant Temperature
110 Injector short High Engine Coolant Temperature
111 derate Low Engine Coolant Level
111 grounded/current above normal Low Engine Coolant Level
111 below normal Low Engine Coolant Level
94 grounded/current above normal High Fuel Pressure
94 Injector open circuit High Fuel Pressure
94 below normal High Fuel Pressure
1636 short to ground Low Fuel Pressure
1636 abnormal rate of change Low Fuel Pressure
174 grounded/current above normal High Inlet Air Temperature
174 Injector open circuit High Inlet Air Temperature
174 below normal High Inlet Air Temperature
441 grounded/current above normal High Fuel Temperature
441 Injector open circuit High Fuel Temperature
441 below normal High Fuel Temperature
1836 short to ground High Auxiliary Temperature
1836 abnormal rate of change High Auxiliary Temperature
1837 grounded/current above normal Auxiliary Temperature Sensor
1837 Injector open circuit Auxiliary Temperature Sensor
1837 below normal Auxiliary Temperature Sensor
1835 short to ground High Auxiliary Pressure
1835 abnormal rate of change High Auxiliary Pressure
651 short to +batt Cylinder #1
651 calibration required Cylinder #1
652 short to +batt Cylinder #2
652 calibration required Cylinder #2
653 short to +batt Cylinder #3
653 calibration required Cylinder #3
654 short to +batt Cylinder #4
654 calibration required Cylinder #4
655 short to +batt Cylinder #5
655 calibration required Cylinder #5
656 short to +batt Cylinder #6
656 calibration required Cylinder #6

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24.2 Machine Error Codes

Error Code Title Description


000000 Master I/O Module CAN fault Loss of communications with Master I/O
Module (unit in left hand side of panel.)
Check Fuse F2. Check CAN L / CAN H wiring
from display to I/O Module.
000001 Engine CAN fault Loss of J1939 communications with engine.
Check engine is getting power (Fuse F44 in
relay box), Check +24V on pins 48, 52, 53
and 70 on the CAT ECU connector pin C10.
Check J1939 wiring from panel to CAT ECU
(pins 34 and 50).
000002 Key-off while crusher active Crusher was switched off without correct
ramping down procedure.
000003 E-Stop pressed while crusher active Crusher was emergency-stopped without
correct ramping down procedure.
000101 Emergency Stop activated Emergency Stop is active. Check all e-stop
switches. If none pressed, check fuse-F6 in
panel. If no e-stop present, check +24V on
e-stop return terminal 9 in panel and Pin 70
of CAT ECU connector C10.
000102 Dog lead Handset Stop Request Stop button on dog lead handset has been
pressed.
000103 Track Radio Handset Stop Request Stop button on radio handset had been
pressed.
000104 Small Radio Handset Stop Request Stop button on small radio handset had
been pressed.
000105 Hydraulic Oil Temperature Warning Hydraulic oil temperature has reached
warning point, feeder speed will be
reduced to 50%.
000106 Hydraulic Oil Temperature Error Hydraulic oil temperature has reached
error point, crusher will be halted, engine
will carry on running.
000107 Hydraulic Oil Level Error Hydraulic oil level has is below minimum
switch point, crusher will be halted, engine
will carry on running, can be bypassed in
service mode.
000108 Sensor Error - Chamber Level Disconnected ultrasonic sensor used to
monitor crusher chamber level, can be
bypassed by using manual feeder speed.
000109 Sensor Error - Conveyor Pressure Disconnected pressure transducer used to
monitor conveyor pressure, can be
bypassed in service mode.

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000110 Sensor Error - Crushing Pressure Disconnected pressure transducer used to
monitor crushing pressure. No bypass.

000111 Sensor Error - Temperature Bypass Operator has manually bypassed


temperature sensor. Feeder speed will be
reduced to 50%.
000112 Sensor Error - Conveyor Pressure Operator has manually bypassed pressure
Bypass sensor.
000113 Valve Error - Pump current feedback Incorrect current drawn by proportional
valve operating pump.
If valve is not connected, fault is in Master
I/O Module hardware or wiring.
000114 Valve Error - Pump current feedback Incorrect current drawn by proportional
valve operating pump.
If valve is not connected, fault is in Master
I/O Module hardware or wiring.
000115 Valve Error - feeder current feedback Incorrect current drawn by proportional
valve operating pump. If valve is not
connected, fault is in Slave I/O Module
hardware or wiring.
000116 Slave I/O Module CAN fault Loss of communications with Slave I/O
Module (unit in right hand side of panel.)
Check Fuse F3. Check CAN L / CAN H wiring
from display to I/O Module.
000117 Display CAN fault Loss of communications from display unit.
Note this fault is only visible with service
laptop.
000118 Hydraulic Oil Temperature Sensor Hydraulic oil temperature sensor signal
Disconnected shorted to ground.
000125 Crusher Over Pressure Shutdown Crusher pressure sensor is above preset
value, machine will shut down.
000126 Temperature Sensor Short To Ground Hydraulic oil temperature sensor is shorted
to ground.
000127 Cone Lube Temperature Disconnected Cone lube temperature sensor output has
become disconnected – circuit is open.
000128 Cone Lube Temperature Shorted to Cone lube temperature sensor output is
Ground shorted to ground.
000129 Cone Return Lube Temperature Cone return lube temperature sensor
Disconnected output has become disconnected – circuit
is open.
000130 Cone Return Temperature Shorted to Cone return lube temperature sensor
Ground output is shorted to ground.
000131 Lube Pressure Sensor Disconnected Cone lube pressure sensor has become
disconnected – circuit is open.
000132 Clamp Pressure Sensor Disconnected Cone clamp pressure sensor has become
disconnected – circuit is open.

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000133 Ring Pressure Sensor Disconnected Cone locking ring pressure sensor has
become disconnected – circuit is open.
000134 Cone Stop - Low Cone Lube Cone has stopped due to a low cone lube
Temperature temperature condition.
000135 Cone Stop - High Cone Lube Cone has stopped due to a high cone lube
Temperature temperature condition.
000136 Cone Stop - Low Cone Return Cone has stopped due to a low cone lube
Temperature return temperature condition.
000137 Cone Stop - High Cone Return Cone has stopped due to a high cone lube
Temperature return temperature condition.
000138 Cone Stop - Low Lube Pressure Cone has stopped due to a low cone lube
pressure condition.
000139 Cone Stop - High Lube Pressure Cone has stopped due to a high cone lube
pressure condition.
000140 Cone Stop - Low Lube Flow Cone has stopped due to a low cone lube
flow rate condition.
000141 Cone Stop - High Lube Flow Cone has stopped due to a high cone lube
flow rate condition.
000142 Cone Stop - Low Lube Level Cone has stopped due to a low cone lube
level condition.
000143 Feeder Stop - Metal Detected Feeder has stopped die to metal being
detected.
000148 Low Voltage While Cranking Battery voltage has dropped too low while
engine is cranking.
000149 Lube Tank Module CAN Fault Main I/O module has lost CAN
communication with the lube tank I/O
module.
000150 Clamp Block Module CAN Fault Main I/O module has lost CAN
communication with the clamp valve block
I/O module.
000151 Hydraulic oil cooler fault The control electronics built into the oil
cooler fans is detecting a problem with the
fan. Fan may be jammed or having trouble
turning. Clean any built up dust from
around fan motor
000152 Doglead Pushbutton problem Problem with doglead, short detected to
+24V, check integrity of doglead for shorts.
Tracking disabled.
000154 Charge warning Engine alternator is not charging the
battery. This warning is display if battery
voltage drops below 22V for 60seconds.
Check alternator fuse and drive belt.
000155 Unknown Machine Type Master module is not sure of machine type,
select machine type via panel.
000156 Crusher Stall Crusher speed sensor is detecting less
crusher rpm than required to run machine.

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Check speed sensor, check belts.
000161 Crusher stopping due Engine Fault Crusher is stopping due to a problem with
engine. See engine error
000162 Low Fuel warning Warning machine running low on fuel

Page 62
25 Radio Handsets

25.1 Tracking Handset

This machine comes with an optional two radio controlled handsets. The larger handset is
shown below.

Handset overview:

Key switch – On / Off switch. When not in use keep the key switch turned off to prolong
battery life.

Radio Stop Request – Transmits an engine stop request to the panel. If within range the
machine will stop the engine immediately. Please note this is NOT an emergency stop and
should not be relied upon as such.

Track Forward / Reverse – Used to track the machine once track mode has been selected
on the panel.

Transmitting LED - Will flash continuously when a button is pressed or intermittently if no


buttons are being pressed.

Coding LED – Used when coding a spare handset to the machine, see next section.

Charge Socket – This handset is fitted with a Li-ion rechargeable battery. To charge the
unit, connect the handset to the charging socket fitted to the machine using the adaptor plug
provided. Alternatively the unit can be charged using a 12Vdc charger.

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25.2 Feeder Handset

The smaller handset is used to control the feeder and is shown below:

Handset overview:

Feeder Start – Use this button to start the feeder (all other conditions must be met such as
jaw already running etc)

Feeder Stop – Use this button to stop the feeder. Feeder will not restart until Feeder Start
button pressed.

Feeder Slow Down – Use this button to slow the feeder when in manual speed control
mode on the feeder.

Feeder Slow Down – Use this button to slow the feeder when in manual speed control
mode on the feeder.

Sound Siren – Use this button to sound the siren on the machine, siren will sound whilst
button is held down.

Radio Stop Request – Transmits an engine stop request to the panel. If within range the
machine will stop the engine immediately. Please note this is NOT an emergency stop and
should not be relied upon as such.

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25.3 Radio Coding:

Each radio receiver has its own 11 digit long identifier code.

This code is displayed as a string of 1’s and 0’s on the radio receivers’ sticker.

E.g. Radio Code 11010000111

The code is also displayed on the machine display panel service mode:

Each machine comes with pre-coded handsets but spare / replacement handsets will need
to be coded to match the receiver.

Coding procedure is as follows:

1) Switch on handset with key switch


2) Press down radio stop request button.
3) Hold down the two blue buttons and the red button until coding LED starts to flash.

4) Enter code from left to right using the two yellow track buttons.

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E.g. radio code 00011001010 is entered:

0-0-0-1-1-0-0-1-0-1-0

To enter a 0 use top left yellow button, to enter a 1 press top right yellow button.

As each button is pressed the transmit LED will flash briefly.

Once the code has been entered the coding LED will go out.

To check the handset had been coded correctly, go to the service mode on the display and
look at the transmitted code.

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25.4 Small Handset Coding Procedure

1) Hold down top 3 buttons until coding LED starts to flash.

2) Enter code from left to right using the feeder start / stop buttons.

E.g. radio code 00011001010 is entered:

0-0-0-1-1-0-0-1-0-1-0

To enter a 0 use feeder stop button, to enter a 1 press feeder start button.

As each button is pressed the transmit LED will flash briefly.

Once the code has been entered the coding LED will go out.

To check the handset had been coded correctly, go to the service mode on the display and
look at the transmitted code.

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25.5 FCC / IC Warnings
FCC warning statement:
These radio transmitting devices complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that
may cause undesired operation.
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled
environment. End users must follow the specific operating instructions for satisfying RF exposure
compliance. This transmitter must not be co-located or operating in conjunction with any other
antenna or transmitter.
Changes or modifications not expressly approved by the party responsible for compliance could void
the user's authority to operate the equipment.

Industry Canada warning statement:

English
"Under Industry Canada regulations, this radio transmitter may only operate using an
antenna of a type and maximum (or lesser) gain approved for the transmitter by
Industry Canada.
To reduce potential radio interference to other users, the antenna type and its gain
should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not
more than that necessary for successful communication."
"This device complies with Industry Canada licence-exempt RSS standard(s).
Operation is subject to the following two conditions:
(1) this device may not cause interference, and
(2) this device must accept any interference, including interference that may cause
undesired operation of the device."

French
"Conformément à la réglementation d'Industrie Canada, le présent émetteur radio
peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur)
approuvé pour l'émetteur par Industrie Canada.
Dans le but de réduire les risques de brouillage radioélectrique à l'intention des
autres utilisateurs, il faut choisir le type d'antenne et son gain de sorte que la
puissance isotrope rayonnée équivalente (p.i.r.e.) ne dépasse pas l'intensité
nécessaire à l'établissement d'une communication satisfaisante."
"Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux
appareils
radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes :
(1) l'appareil ne doit pas produire de brouillage, et
(2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, mêmesi le
brouillage est susceptible d'en compromettre le fonctionnement."

Page 68
26 Trouble shooting Guides:

26.1 If Engine won’t start

Checklist:

Are there any active CAT error code shown on the display?

Are the CAT error lamps lit in the engine display screen?

Are any E-stops active?

Is the engine cranking? If not, check whether the K10 Starter Relay is being
energised.

Check Fuse F30.

Check whether getting 24V on starter crank terminal.

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If Cone won’t run

Checklist:

Is the lube oil upto temperature / pressure / flow? Check lube tick list.

Are there any active errors causing the panel to shutdown?

Look at active solenoids on valve block:

Divert1 and Divert 2 should be on along with Crusher Forward.

Pump1 and Pump2 should read ~700mA

26.2 If display is not working

Checklist:

Check Fuse F1

Check wiring from panel to display

If display still not starting up, only action available is to use the dog lead handset to enter
tracking mode and move the machine. Note snail mode only available without display.

26.3 If machine won’t track

Checklist:

Are there any active errors causing the panel to shutdown?

Is the cone running? Track mode is disabled until cone has stopped.

Will the display enter track mode using Key 2?

Will the display enter track mode using the dog lead handset key switch?

When pressing dog lead track buttons are any arrows appearing on tracks? If so the fault is
not with the handset.

Look at active solenoids on valve block.

Divert 1 and Divert2 should on along with directional valves.

Track Direction valve should be on

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Note the proportional valves controlling pump1 and pump2 can be disconnected.
With zero current through these valves the tracks will still operate but at snail speed only.

26.4 If feeder will not run:

Checklist:

Are there any active errors causing the panel to shutdown?

Is the cone running? Feeder is disabled unless cone is running.

Check the tick / cross feeder list in the service mode. Any crosses?

Is the conveyor pressure sensor seeing between 15 and 180Bar? Outside these pressures
the feeder will be disabled. A faulty conveyor pressure sensor can be disabled in the service
mode.

Is the crusher pressure sensor seeing values below the feeder disable setting? Has the
pressure been below the restart setting for longer than the restart delay?

Is a downstream machine stopping the feeder from running? Disconnect downstream


machine to test.

Has a signal from radio handset been received requesting feeder stop? Look at radio
diagnostics screen.

Is the auto feeder control stopping the cone? The auto feeder control will stop the feeder if
the chamber level sensor is seeing a choked chamber for longer than the delay time
(blocked cone). Disable the auto feeder system by setting desired chamber level to 101%.

Page 71