Rev2.

Iss2
ROBOTRAC

OPERATORS MANUAL

Screen2crush, Extec Robotrac.

EXTEC SCREENS & CRUSHERS LTD.
For more screens and crushers like this robotrac
HEARTHCOTE ROADthats featured
Call 00 (1) 773 800SWADLINCOTE,
2842 or DERBYSHIRE
Email james@screen2crush.com
Web www.screen2crush.com
DE11 9DU, ENGLAND
Featured Stock incl. Tel:- +44 (0) 1283 212121
Metso 1213, Metso 1213S,
Fax:- Metso
+44LT1110,
(0) 1283 Crushers
217342
Pegson 1000, Sandvik QJ340, McCloskey Trommels,
BRAND NEW LIPPMANN AND COREX CRUSHERS...........
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 ROBOTRAC
SAFETY INSTRUCTIONS
For safe operation of this machine, the following instructions MUST be followed at ALL
times:-

i) Machine must ONLY be operated by trained personnel.

ii) Different countries and states often have specific legislation relating to the operation of
different types of machinery and their effects on safety and the environment. Therefore, it is
the users responsibility to find out those that apply to their particular circumstances and ensure
that they are complied with.
iii) Always pay attention and concentrate on the job at hand.
iv) Read and follow warnings and labels.
v) Read and understand this manual and all machine aspects.
vi) Familiarise yourself with the surrounding work area.
vii) ONLY operate this machine if guards and safety devices are in position and operative.
viii) ALL personnel in the vicinity of the machine MUST wear suitable safety equipment,
i.e Safety boots, ear protection, eye protection, protective clothing, hard hat, etc.

NEVER:-

i) Run machine without guards in place.

ii) Make adjustments or clean moving parts whilst machine is running.
iii) Reach into the machine to clean, lubricate or adjust without first shutting off power to engine
& removing ignition key.
iv) Operate the machine while under the influence of drink or drugs. (NOTE:- medicines
prescribed by your medical advisor may make you unfit to operate machinery. Always check
before attempting to operate machinery)
v) Allow grease or oil to remain in the area surrounding the machine.
vi) Wear clothing or jewellery that could become entangled in the moving parts of the machine.
vii) Try to clear any blockage whilst any part of the machine is running.
vii) Permit any flame, cigarette, spark or other heat source near fuel tank.
ix) Fill fuel tank while machine is running.
x) Operate this machine on 'sloping' ground.

NOTE:- The above list is not exhaustive, if you are unsure whether anything is unsafe,
stop the machine IMMEDIATELY and contact your supervisor.

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ROBOTRAC
GENERAL MACHINE DIMENSIONS
3216 [10'-7"]

6340 [20'-10"]

11468 [37'-7"]
4482 [14'-8"]

1434 [4'-8"]

3547 [11'-8"]
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 64 65 70 69 69 75 69 71 75 70 71 75 70 72 76 72 72 76 75 75 78 80 80 81

69 72 76 71 74 80 72 75 82 74 75 82 77 77 82 82 82 84

91 91 91 84 84 84

65 69 68 74 72 68 92 92 92 84 84 84

91 91 91 84 84 84

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ROBOTRAC

72 75 77 75 77 80 78 78 82 80 80 82 82 82 84 89 89 89
SOUND LEVELS

67 69 70 71 73 76 72 74 77 75 75 78 78 79 79 80 80 82 81 81 82 81 81 82

7M 1M 1M 7M

LEFT HAND FIGURE - ENGINE ONLY

MIDDLE FIGURE - BELTS RUNNING

RIGHT HAND FIGURE - BELTS & GRID

 ROBOTRAC
PRE-START INSTRUCTIONS
BEFORE starting this machine, it is imperative that the instructions below are followed:-

i) Ensure that this manual is read and understood by the operator. DO NOT attempt
to start the machine until you are aware of ALL aspects of its operation. Any
questions should be referred to your supervisor.
ii) Ensure that all personnel in the vicinity are well clear of the machine and any other
equipment being used in conjuction with your Extec Robotrac.
iii) Check that all ball valves and control levers are in the "Off" positon.
iv) Check levels of:- Fuel, Engine oil, Hydraulic oil and Engine coolant.
v) Drain any water from the fuel pre-filter.
vi) Ensure that all guards and access covers are fitted and secured. (NEVER run the
machine without guards and safety devices working properly.
vii) Check that the throttle is in low idle position.
viii) Familiarise yourself with the location of the emergency stop button and the layout of
the electrical control panel.
ix) Ensure that the checks and pre- start instructions in the engine manufacturers
instruction manual are conmplied with.
x) Remove all tools and equipment from the operational area.
xi) Check that all drums and rollers turn freely. This should be done by hand. (NEVER
attempt to touch drums or rollers while the machine is running.)
xii) Ensure that conveyor skirting rubbers and scrapers are in good condition and working
properly.
xiii) Ensure that the belts and vibrating grid are clear of material.

4 2
1:- Ignition key (ON/OFF)
5 3
2:- Warning lights & R.P.M meter.
3:- Ball valve - (Main conv. ON/OFF)
4:- Ball valve - (Vib. grid ON/OFF)
1 5:- Hopper conveyor stop/start
6:- Webtec control (hopper conv. speed)
7:- Spool valves
8 8:- Throttle
6 9 9:- Umbilical socket - (hard wire drive)
7

Main components on control panel

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 ROBOTRAC
STARTING SEQUENCE

1:- Insert key into the ignition unit

2:- Turn key clockwise to the "ON" position
3:- All lights will flash for several seconds before
going out. The battery light, the oil light and
the on light will remain on.
4:- After waiting for the lights to go out, turn
the key to the "Start" position and hold until
the engine starts.
Throttle at low 5:- Release the key. (It will return to the "ON" position
idle position
and stay there while the engine is running)

6:- The engine will now be running at low idle position.

7:- Battery and oil lights will go out.
8:- Set the throttle to the maximum setting - (fully up)
9:- The engine will now be running at operating speed.

If, for any reason the engine fails to start, turn the key to the "OFF" position and repeat steps 3 to 8.

COLD START:- In low temperatures, the engine should be left running at low idle for 5
minutes before any of the hydraulic functions of the machine are operated. This is to allow the
oil to reach working temperature.

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 ROBOTRAC
STOPPING THE ENGINE
When you wish to stop the engine of the Extec Robotrac, it is recommended that the following
procedure is followed to prevent damage to your machine.

i) Stop feeding material into the vibrating grid of the machine.

ii) Wait until ALL material is fully discharged from the hopper and main conveyor.
iii) Turn off the main conveyor, hopper conveyor and vibrating grid.
iv) Turn the throttle to the low idle position, and allow the engine to run at this speed for 1 or 2
minutes.
v) Turn the key fully anti-clockwise to the "OFF" position.

v) Turn key fully

anti-clockwise

iv) Throttle at low

idle position
iii) Ball vlaves in
"Off" position

STOPPING THE MACHINE IN AN EMERGENCY

In the event of an emergency, the machine can be stopped in the following ways:-

i) Turn the key directly to the "OFF" position.

ii) Press the emergency stop buttons located on the rear of the machine, the vibrating grid
remote control, or on either of the handsets (Hardwire or Remote) for moving the machine.

NOTE:- The machine should be stopped in this

manner only in an emergency. Stopping the machine
in this fashion on a regular basis will cause damage to
the engine and hydraulic system. Extec Screens &
Crushers will not accept any liability for damage caused
to the machine in this fashion.
Emergency stop

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 ROBOTRAC
TRACKING (MOVING) PROCEDURE
BEFORE moving the Extec Robotrac, it is essential that the following checks are carried out:-

i) Ensure that there are NO personnel on the machine.

ii) Check that there are no obstacles such as overhead cables or large rocks in the proposed
route of the machine.
iii) Make sure that the ground which you intend to move the machine across is suitable for
carrying the weight of the machine.
iv) NEVER MOVE THE MACHINE ACROSS EXCESSIVELY SLOPING GROUND.
v) DO NOT move the machine when the vibrating grid is raised or when the power pack is
opened.

To move the machine, start the engine and use either the Remote Control handset or the
Hardwire Drive to move machine. NOTE:- When standing at the power unit facing towards the
main conveyor, hold the handsets with the emergency stop button closest to your body. R.H
buttons operate R.H tracks & vice-versa.

NOTE:- The Remote Handset will be supplied as either yellow or white (Not Both) and must be fully
recharged at regular intervals. PLEASE use the correct instructions for your type of controller.

OR

Yellow Remote Handset. White Remote Handset. Plug in Umbilical socket Hard Wire Handset.
for Hard wire drive..

NOTE:- i) When operating the Yellow Remote Handset, the directional arrows relate to the machines forward
& reverse movement.
ii) When operating the White Remote Handset, the yellow buttons are for forward movement and the
blue ones for reverse.
iii) When operating the Hard Wire Handset, the yellow buttons are for forward movement and the
blue ones for reverse.

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 ROBOTRAC
PREPARING MACHINE FOR OPERATION

Cross Braces

Flares

Securing Bolts

1:- Fold main conveyor into working position, fit 2:- Remove retaining bolts (4 off) from grid flares.
securing bolts, flares and flare cross braces.

3:- Activate lever marked "Grid Flares" 4:- Grid flares in working position.

5:- Re-fit grid flare bolts to lock flares in the 6:- Activate lever marked "Vib Grid" to raise
working position. vibrating grid.

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 ROBOTRAC
PREPARING MACHINE FOR OPERATION

7:- Vibrating grid in fully raised position. 8:- Remove retaining bolts from L.H hopper
door.

Grid Support Signal

Leg Receiver Box

9:- Activate lever marked "Side Doors" to 10:- L.H side door open
open doors on side of hopper.

11:- Insert bolt through holes in box section 12:- Raise grid support legs & secure with
support under each door. bolt provided to set grid angle.

13:- Activate lever marked "Vib Grid" to 14:- Vibrating grid resting on support legs.
lower vibrating grid. NOTE:- several holes are provided in support
12 legs for different grid angles.
 ROBOTRAC
OPERATING THE MACHINE (SCREENING)
When the machine is set up as described in the previous pages, it is now ready to be operated.
When the engine is running, set the throttle to the high position and proceed as follows:-

Ball valve for

Throttle fully vibrating grid
raised

1:- Set throttle to high position 2:- Turn ball valve to turn on vibratin grid

Ball valves for

main conveyor

3:- Start hopper conveyor 4:- Turn two ball valves to turn on main
conveyor
Prior to loading material into machine, ensure that the machine is not rocking or vibrating
excessively. Move machine to more suitable ground if required.

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 ROBOTRAC
LOADING MATERIAL INTO MACHINE:
i) The vibrating grid MUST be running prior to feed material being placed upon it. DO
NOT start the vibrating grid if it is full of material.
ii) It is recommended that the feed material is deposited on the high side of the grid from as
low as height as possible, using the full width of the gird and allowing material to be
loaded evenly onto grid.
iii) Adjust the speed of the hopper conveyor to suit the rate of feed material by turning the
webtec control.
iv) NEVER load material onto grid while it is raised off the grid support legs.

Adjusting hopper
conveyor speed

During operation, the bars on the vibrating grid may become blocked up by feed material. This can
be cleared by using the vibrating grid remote control handset to raise the grid and remove any
blockages. The functions on the remote control for the vibrating grid are as follows:-

i) Yellow button - When this button is pressed, the grid rams will fully open and remain open
for 2/3 seconds before closing fully.
ii) Top Grey button - The grid rams will open as long as this button is pressed.
iii) Bottom Grey button - The grid rams will close as long as this button is pressed.
iv) Red button - This is an emergency stop button ONLY, and will stop the engine and all
hydraulic power. Refer to page 9 for information on stopping the machine.

NOTE:- Quick "stabbing" of the grey buttons will give the grid a shaking action.

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 ROBOTRAC
OPENING THE POWER UNIT
The power unit on the Extec Robotrac can be opened out from the normal position in which it is
situated on the machine. This is a special feature of the Robotrac which allows easy access to the
engine and vibrating grid for manitenance and service..
NOTE:- NEVER TRACK (MOVE) THE MACHINE WHILE THE POWER UNIT IS
OPEN. To open the power unit, follow the steps below:-

1:- Remove safety locking pin. 2:- Activate lever "Power Unit".

3:- Power unit open from normal position. 4:- Panel opened on back of power unit.

After performing any maintenance or checks that require the power unit to be opened, re-fit locking
screws that may have been removed from any panels and clean up any oil that may have been
spilled. To close the power unit, reverse the action of the lever shown above.

REPLACE THE SAFETY LOCKING PIN AFTER CLOSING THE POWER UNIT.

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 ROBOTRAC
MACHINE MAINTENANCE
Maintenance is essential for ensuring the best possible performance from your Extec Robotrac by
reducing the possibility of breakdowns.

WARNING:- THE MACHINE MUST BE SWITCHED OFF AND THE IGNITION KEY
REMOVED BEFORE MAKING ANY ADJUSTMENTS.

ALL adjustments must ONLY be carried out by trained personnel.

Any adjustments to modify the hydraulic system or to set engine speeds should ONLY be carried
out by trained Extec service engineers.

The following DAILY MAINTENANCE SCHEDULE should be carried out.

1:- Check engine oil level 2:- Refill if necessary. (Refer to the engine
manufacturers handbook for engine oil
specification)

3:- Check fuel level & refill if necessary. 4:- Bleed diesel water trap.
(Fuel gauge located on rear of power unit)

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 ROBOTRAC
DAILY MAINTENANCE SCHEDULE - CONT'D

5:- Check engine coolant level & top up if

needed.

Check service indicators on Air Cleaner. Regardless of condition of service indicator, remove
elements from air cleaner as shown below and clean them using compressed air. To change
elements open power unit then open access panel on back of power unit. (NOTE:- Service
indicators are for showing when elements need to be re-placed, not cleaned.)

1:- Loosen clips & remove rear cover 2:- Remove outer element

When removing inner element, remove it as

shown. Don't remove black holder as it is
difficult to replace. Replace elements and
rear cover after cleaning.

3:- Remove inner element

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 ROBOTRAC
DAILY MAINTENANCE SCHEDULE - CONT'D
As well as the previous checks listed, the following should be checked on a daily basis to
prevent damage to your machine:-

i) Condition & adjustment of conveyor belts and scrapers.

ii) Condition of screen meshes.
iii) Hydraulic oil level.
iv) Check machine for possible oil leaks.
v) Clear any obstructions or dust build up from the engine air intake grill.

WEEKLY/ 50 Hrs MAINTENANCE SCHEDULE

The following weekly maintenance must be carried out to ensure the best performance
from your Extec Robotrac..
STOP ENGINE AND REMOVE IGNITION KEY BEFORE CARRYING OUT
ANY MAINTENANCE ON THIS MACHINE.

i) As per daily maintenance schedule.

ii) Check condition of service indicators on hydraulic oil and air filters. If service indicator is red
while the machine is running, replace the elements.
iii) Follow the maintenance schedule in the engine manufacturers handbook.
iv) Inspect and adjust wear rubbers, seals on hopper bin and main conveyor feed boot.
v) Clean out the vibrating grid ensuring that it is free from blockages and material build up.
vi) Clean any build up of material from the return and tracking rollers.
vii) Clean any build up of material out from under the machine, paying particular attention to any
heavy build up around the tracks.
viii) Grease all bearings from central greasing point at rear of hopper. (Use grease type EP2)
ix) Grease bearings on vibrating grid shaft. (Use grease type LGHQ3)
x) Inspect & adjust belt scrapers.
xi) Check tension of tracks & adjust if necessary.

Refer to the instructions and photographs shown in the following pages for information
on carrying out the above checks.

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 ROBOTRAC
CHANGING THE HYDRAULIC RETURN FILTER

"O"-Ring

1:- Open access panel & remove cap from 2:- Rrmove old filter element & replace with new
return filter using spanner provided. one. Ensure that "O"-Ring is fitted before
re-placing filter cap.

INSPECTING WEAR RUBBER

Seal rubber in correct position.

GREASING BEARINGS

Open power unit & grease all points on central Grease bearings in vibrating grid shaft (USE
grease point. (USE GREASE EP2 - 2 strokes GREASE LGHQ3 - 4 strokes each grease point)
each grease point)

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 ROBOTRAC
ADJUSTING BELT SCRAPERS

Loosen bolt on outside of rosta scraper. Use

adjustable spanner to twist rosta forcing scraper
closer to belt.. Re-tighten outside bolt while holding
pressure on rosta to clamp scraper in desired
position. Follow this same procedure for scraper
on hopper conveyor.

ADJUSTING TRACK TENSION

1:- Remove access cover from side of tracks. View on grease point inside access cover.

WARNING:- Grease in the tracks is under

high pressure. 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, instead, watch the track.

2:- Fit grease pipe provided & grease tracks as

required ( USE GREASE TYPE EP2).

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 ROBOTRAC
250 Hrs MAINTENANCE SCHEDULE
Every 250 hrs the following checks should be made to ensure the best performance from
your Extec Robotrac:-

i) Check level of oil in tracks. Top up if necessary using SAE 30W oil
ii) Check level of oil in hopper conveyor gearbox.
iii) Clean out filter breather caps on hydraulic and fuel tanks.
iv) Inspect condition of all rollers.
v) Follow maintenance schedule in engine manufacturers handbook.

FILLING TRACK OIL

To check the track oil level, drive the machine until the oil ports on the track are at the
"9 O'Clock" position as shown in the photographs below.

1:- Remove oil level plug. If oil comes out there is 2:- Remove oil filler plug & fefil (USING OIL
enough oil in tracks. If not, re-fil as shown. TYPE SAE 30W). When oil trickles out of level
plug the oil level is sufficiently full.

FILLING GEARBOX OIL

To check the gearbox oil level, look into the sight

gauge. If oil can be seen, there is enough oil in
the gearbox, if not then remove the filler plug &
FILLER
PLUG top up oil level (See page 23 for oil specification).

SIGHT
GAUGE

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 ROBOTRAC
250 Hrs MAINTENANCE SCHEDULE - CONT'D
CHANGING FILTER BREATHER CAPS

Breather caps are located on top of

fuel and hydraulic tanks. Access is
avaliable through the access panels
BREATHER
on top of the power unit.
FILTER

500 Hrs MAINTENANCE SCHEDULE

Repeat 250 hr service. The hydraulic return filters must be replaced every 500 hours,
regardless of the condition of the service indicators.

1000 Hrs MAINTENANCE SCHEDULE

Every 1000 hours, the 500 hour maintenance schedule must be repeated. It is also
recommended that the hydraulic tanks are drained and cleaned out thoroughly and the
hydraulic oil is replaced.

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 ROBOTRAC
OIL, GREASE & FLUID SPECIFICATION
The following information is provided for use in the service of the Extec Robotrac. Extec
Screens & Crushers Ltd accept NO liability for damage to any part of the machine
caused by using grease, oil or fluid other than those listed below:-

Engine:- 20/20

Coolant:- 50% anti-freeze

Hydraulic Oil:- ISO Grade 46

Gear Box Oil:- GLYGOYLE HE 460 Synthetic Oil

Grease - vibrating grid:- LGHQ 3

Grease - other points:- General use EP2 Lithium based

Diesel Fuel:- Standard diesel fuel (as suitable for climate conditions)

Track Oil:- SAE 30W

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 ROBOTRAC
TRANSPORTING THE EXTEC ROBOTRAC
When you need to transport the Extec Robotrac, ensure that you check the transport regulations in
the country which you are moving the machine through and ensure that they are complied with.
When transporting the Robotrac, the grid flares MUST be folded down. The main conveyor may
be folded back as shown below - remove flares before attempting to fold the conveyor. When the
conveyor is folded for transport, a ratchet strap MUST be used to hold it in place and it is
recommended that a plank of wood is placed on top of the conveyor supports to prevent the top
section hitting or damaging the lower section. See photograph below:-

GRID FLARES MUST

BE FOLDED DOWN

WOODEN
SPACER

RATCHET
STRAP

FLARES
REMOVED

DISCLAIMER:- Extec Screens and Crushers Ltd. accept NO responsibility for any
damage caused to the machine or any other property or person if the machine is
transported contray to these instructions.

BEFORE TRANSPORTING THIS MACHINERY ALL

MEASUREMENTS OF THE MACHINE SHOULD BE CHECKED
TO ENSURE THEY ARE WITHIN THE LEGAL TRANSPORT
DIMENSIONS.

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 ROBOTRAC
TROUBLE SHOOTING GUIDE
The following is a list of some common problems that might occour on your machine. If any of
these problems arise, carry out the checks listed.
PROBLEM SOLUTION
Engine losing power or Check air filter isn't blocked. Check diesel filter & sediment
hard to start. bowl.

Enginewon't start or keeps Check that emergency stops are not pushed in.
shutting off. Check water level in radiator.
Check fuel level.
Check that batteries are charged and terminals are tight.
Check oil pressure, temperature and battery lights on control
panel.

Conveyor belts not moving. Check that there is no build up of material underneath belts.
Check belt tension.

Vibrating grid won't start. Check drive belt tension and belt condition.

Tracks will not operate Check handset is fully charged.

Check main receiver box is switched on.

Remote control operation of Check battery in small handset.

the vibrating grid will not Check main receiver box is switched on.
operate.

Signal receiver box located below L.H.S door.

See pg. 12

ON/OFF
SWITCH

If any problem arises that is not on this list, or if a problem persists after carrying out the
recommended checks, contact Extec service department for further assistance.

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