FM 60C / HYDRO

STATIC SAND
RECOVERY UNIT

Operations Manual Issue Date: 15/05/2017

Language: English (en)
Revision No.: 1.0
Original Instructions

© Terex 2017
Terex Washing Systems,
200 Coalisland Road,
Dungannon, Co. Tyrone,
N. Ireland, BT71 4DR
+44 (0) 28 8771 8709
Email: sales@terex.com
www.terex.com
 FM60
COMPACT / HYDRO

Operations Manual

WARNING WARNING WARNING WARNING WARNING

DO NOT ATTEMPT TO OPERATE THIS PRODUCT UNLESS
YOU HAVE READ AND UNDERSTOOD THESE SAFETY INSTRUCTIONS.
FAILURE TO DO SO WILL INCREASE
THE RISK OF INJURY OR MAY RESULT IN DEATH!
SUBJECT TO CHANGE WITHOUT PRIOR NOTICE!
IMPORTANT SAFETY NOTICE!

Read this manual carefully to learn how to operate and service your machine
correctly. Failure to do so could result in personal injury or equipment damage.

Consider this manual a permanent part of your machine.

Keep a copy of this manual at the operational site.

Follow all applicable safety regulations and recommendations in this manual as

appropriate to your product 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.

See also the separate Operation and Maintenance Manual provided for the diesel
engine if fitted to your product and in particular read and observe the instructions
within the Safety Section of the engine manual

INFORMATION AND ADVICE

If you need any information or advice regarding your Product, contact:-

Northern Ireland:
Terex Washing Systems
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8771 8700
E mail: TWS.sales@terex.com
 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 Ap-
pendix A for an example of a Declaration of
Conformity certificate. The original copy of
the certificate is sent out with the machine.

Noise Level - Hearing Harard

dB (A) Levels

TEREX product machinery are tested ac-

cording to guideline 2000/14/EC.

This machine falls below these values.

‹ WARNING
COperating, servicing and maintaining this equipment can expose you to chemicals including
engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. These chemicals can be emitted from
or contained in other various parts and systems, fluids and some component wear by-products.
To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary,
service your equipment and vehicle in a well-ventilated area and wear gloves or wash your hands
frequently when servicing your equipment or vehicle and after operation. For more information go
to www.P65Warnings. a.gov/ passenger-vehicle.
 Introduction Page 7

The Operator must read and understand all the

WARNING instructions in this manual before operating the
machine.
Owners, Users, and Operators: Terex appreciates your choice of our product for
your application. Our number one priority is user safety which is best achieved by our
joint efforts. We feel that you can make a major contribution to safety if you as the
equipment users and operators:

1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other manuals
supplied with this product.

3. Use Good, Safe Work Practices in a common sense way.

4. Only have trained operators — directed by informed and knowledgeable

supervision — operating this product.

If there is anything in this manual that is not clear or which you believe should be
added, please send your comments to:
Terex Washing Systems
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8771 8700

E mail: TWS.sales@terex.com

The safety alert symbol is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.

Intended use
This product and its approved attachments are designed to perform the following
(state approved function). Use of this product in any other way is prohibited and
contrary to its intended use.
 Introduction Page 8

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.

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.

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 Washing Systems
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8771 8700
E mail: TWS.sales@terex.com

Transfer of Machine Ownership and Contacting Manufacturers

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.
 Contents Page 9

0 Safety 11

1 Technical Information 35

2 General Information 41

3 Design and Function 45

4 Transport 57

5 Set up 65

6 Operating Instructions 93

7 Shut off 105

8 Maintenance 125

9 Troubleshooting 165

10 Storage 189

11 Glossary 191

12 Appendix 199
Contents Page 10
 Safety Page 11

Table of Contents Page

0.1.1 Warnings and symbols 12

0.1.2 Organisational measures 13
0.1.3 Selection and qualification of personnel - Basic responsibilities 15
0.1.4 Safety instructions governing specific operational phases 16
0.1.5 Warning of special dangers 21
0.1.6 Transporting and Recommissioning 25
0.1.7 Machine Safety Decals 27
0.1.8 Position of Emergency Stops (FM 60 COMPACT) 33
0.1.9 Position of Emergency Stops (FM 60 HYDRO) 34
 Safety Page 12

0.1.1 Warnings and symbols

The following signs and designations are used in the manual to designate in-
structions of particular importance:

This is the safety-alert symbol. When you see this symbol on your machine or in
this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury.

indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury. It may
also be used to alert against unsafe practices.

indicates a statement of company policy as the message

Notice relates directly or indirectly to the safety of personnel
and protection of property.
 Safety Page 13

0.1.2 Organisational measures

0.1.2.1 0.1.2.2
Loose or baggy clothing You can be injured if you
can get caught in running do not obey the safety
machinery. instructions as indicated
on warning stickers.
Where possible when
working close to engines Observe all safety in-
or machinery, only do so structions and warnings
when they are stopped. attached to the machine!
If this is not practical, re-
member to keep tools, test See to it that safety in-
equipment and all other structions and warnings
parts of your body well attached to the machine
away from the moving are always complete and
parts. perfectly legible.

For reasons of safety, long Keep warning and instruc-

hair must be tied back tion labels clean.
or otherwise secured,
garments must be close-
fitting and no jewellery Replace unreadable or
- such as rings - may be missing labels with new
worn. Injury may result ones before operating
from being caught up in the machine. Make sure
the machinery or from replacement parts include
rings catching on moving warning or instruction
parts. labels where necessary.

Always wear correctly fit-

ting (EN/ANSI approved)
protective clothing.

Protective clothing in-

cludes Hard Hat, Safety
Glasses, Ear Protection,
Close fitting Overalls,
Steel Toed Boots and a
High Visibility Vest.
 Safety Page 14

0.1.2.3 0.1.2.4
Understand service proce- Never make any modi-
dure before doing work. fications, additions or
Keep area clean and dry. conversions which might
affect safety without the
Never lubricate, clean, supplier’s approval.
service or adjust machine
while it is moving. Keep
In the event of safety-
hands, feet and clothing
relevant modifications or
clear of power driven
parts and in-running nip- changes in the behaviour
points. Disengage all po- of the machine during
wer and operate controls operation, stop the machi-
to relieve pressure. Stop ne and lock out immedi-
the engine. Implement ately and report the mal-
lockout procedure. Allow function to the competent
the machine to cool. authority/person.

Keep all parts in good

condition and properly
installed. Fix damage im-
mediately. Replace worn
and broken parts. Remove
any build up of grease, oil
or debris.

Disconnect battery ground

cable before making
adjustments on electrical
systems or welding on
machine.

For the execution of

maintenance work, tools
and workshop equipment
adapted to the task on
hand are absolutely indis-
pensable.
 Safety Page 15

0.1.3 Selection and qualification

of personnel - Basic responsibilities

0.1.3.3
0.1.3.1 Work on the hydraulic sy-
Any work on and with the stem must be carried out
machine must be executed only by personnel with
by trained, reliable and special knowledge and
authorised personnel only. experience of hydraulic
Statutory minimum age equipment.
limits must be observed.

0.1.3.2
Work on the electrical sy-
stem and equipment of the
machine must be carried
out only by a skilled elec-
trician or by instructed
persons under the super-
vision and guidance of a
skilled electrician and in
accordance with electrical
engineering rules and re-
gulations.
 Safety Page 16

0.1.4 Safety instructions

governing specific operational phases

0.1.4.1 Standard operation

0.1.4.1.1 0.1.4.1.3
Take the necessary pre- In running nip-points can
cautions to ensure that cause serious injury or
the machine is used only even death.
when in a safe and reliab-
le state. Do not reach into an un-
guarded machine.
Operate the machine
only if all protective and Your arm could be pulled
safety-oriented devices, in and amputated.
such as removable safety
devices, emergency shut- Switch off and lockout
off equipment, sound- machine before opening
proofing elements and guard doors.
exhausts, are in place and
fully functional.

0.1.4.1.2
In the event of malfunc-
tions or operational dif-
ficulty stop the machine
immediately and lock out.
Have any defects rectified
immediately.
 Safety Page 17

0.1.4.2 Special work in conjunc-

tion with utilization of
the machine and main-
tenance and repairs du-
ring operation; disposal 0.1.4.2.3
of parts and consumab- Carry out maintenance
les and repair work only if
the machine is positioned
0.1.4.2.1 on stable and level ground
Observe the adjusting, and has been secured
maintenance and intervals against inadvertent move-
set out in these operating ment and buckling.
instructions, except whe-
re: 0.1.4.2.4
Never allow unqualified
A: Warning light/ gau- or untrained personnel
ge or indicator calls for to attempt to remove or
immediate action. replace any part of the
machine, or anyone to re-
B: Adverse conditions
neccessitate more fre- move large or heavy com-
quent servicing. ponents without adequate
lifting tackle.
Observe information on
the replacement of parts To avoid the risk of acci-
and equipment. These dents, individual parts and
activities may be executed large assemblies being
by skilled personnel only. moved for replacement
0.1.4.2.2 purposes should be care-
When the machine is fully attached to lifting
completely shut down for tackle and secured.
maintenance and repair Use only suitable and
work, it must be secured technically adequate lif-
against inadvertent star- ting gear.
ting by:
Never work or stand un-
- Switching off the engi- der suspended loads.
ne and removing the igni-
tion key.
- Implementing the lock- Keep away from the grid
out procedure. and screenbox where
- Attaching a warning there is risk of serious
sign to the control panel injury or death due to the
door. loading and removal of
material.
 Safety Page 18

0.1.4.2.5 0.1.4.2.6
Falling from and/or onto a The fastening of loads and
Terex machine can cause the instructing of crane
injury or even death. operators should be ent-
rusted to experienced per-
Do not climb on the ma- sons only. The marshaller
chine. giving the instructions
Never use machine parts must be within sight or
as a climbing aid. sound of the operator.

For carrying out overhead

assembly work always
use specially designed or 0.1.4.2.7
otherwise safety-oriented After cleaning, examine
ladders and working plat- all fuel, lubricant, and
forms. hydraulic fluid lines for
leaks, loose connections,
Always use any walkway/ chafe marks and damage.
platforms provided or a Any defects found must
safe and secure platform be rectified without delay.
approved by the regional
safety enforcing authority.
0.1.4.2.8
Always use an EN/ANSI Any safety devices remo-
approved safety harness ved for set-up, mainte-
when reaching any points nance or repair purposes
7ft (2m) or more above must be refitted and chec-
the ground level. ked immediately upon
completion of the mainte-
Keep all handles, steps, nance and repair work.
handrails, platforms, lan-
dings and ladders free
from dirt, oil, snow and
ice.
 Safety Page 19

0.1.4.2.9 0.1.4.2.10
Improperly disposing of A shredder or any other
waste can threaten the raised part of the machine
environment and ecology. can fall causing serious
Potentially harmful waste injuries or death.
used with Terex equip-
ment includes such items Always fit the safety sup-
as oil, fuel, coolant, filters port strut provided if any
and batteries. part of the machine (such
as the shredder chamber)
Use leakproof containers must be raised for any
when draining fluids. Do reason.
not use food or beverage
containers that may mis- Never work under unsup-
lead someone into drin- ported equipment.
king from them.
Never work alone.
Do not pour waste onto
the ground, down a drain
or into any water source.

Ensure that all consumab-

les and replaced parts are
disposed of safely and
with minimum enviro-
mental impact.
 Safety Page 20

0.1.4.2.11
Diesel fuel is highly flam-
mable.

Never remove the 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.

Do not smoke or carry out

maintenance on the fuel
system near naked lights
or sources of sparks, such
as welding equipment.

0.1.4.2.12
Using unapproved struc-
tures i.e. walkways\ plat-
forms etc in the vicinity
of a Terex machine is very
dangerous and could lead
to serious injury or even
death through falling and/
or entanglement with the
machine.
Do not use any unautho-
rised structures.
 Safety Page 21

0.1.5 Warning of special dangers

0.1.5.1 Electric energy

0.1.5.1.1 0.1.5.1.4
Use only original fuses Work on the electrical
with the specified current system or equipment may
rating. Switch off the ma- only be carried out by a
chine immediately if trou- skilled electrician or by
ble occurs in the electrical specially instructed per-
system. sonnel under the control
and supervision of such
an electrician and in ac-
0.1.5.1.2 cordance with applicable
When working with the electrical engineering ru-
machine, maintain a safe les.
distance from overhead
electric lines. If work
is to be carried out clo- 0.1.5.1.5
se to overhead lines, lf provided for in the
the working equipment regulations, the power
must be kept well away supply to parts of machi-
from them. Check out nes and plants, on which
the prescribed safety di- inspection, maintenance
stances. and repair work is to be
carried out must be cut
off.
0.1.5.1.3
Before starting any work,
lf your machine comes
check the de-energized
into contact with a live
parts for the the presence
wire:
of power and ground or
short-circuit them in addi-
- Warn others against ap-
tion to insulating adjacent
proaching and touching
live parts and elements.
the machine.

- Have the live wire de-

energized.
 Safety Page 22

0.1.5.1.6 0.1.5.1.8
The electrical equipment Before starting work on
of the machine is to be high-voltage assemblies
inspected and checked at and after cutting out the
regular intervals. Defects power supply, the feeder
such as loose connections cable must be grounded
or scorched or otherwise and components such as
damaged cables must be capacitors short-circuited
rectified immediately. with a grounding rod.

0.1.5.1.7 0.1.5.1.9
Necessary work on live These machines are wired
parts and elements must on negative earth. Always
be carried out only in the observe correct polarity.
presence of a second per-
son, who can cut off the Always disconnect battery
power supply in case of leads before carrying out
danger by actuating the any maintenance to the
emergency shut-off or electrical system.
main power switch. Secu-
re the working area with The battery contains sul-
a red-and-white safety phuric acid, an electrolyte
chain and a warning sign. which can cause severe
Use insulated tools only. burns and produce explo-
sive gases.

Avoid contact with the

skin, eyes or clothing.
 Safety Page 23

0.1.5.2 Gas, dust, steam and

smoke

0.1.5.2.1 0.1.5.2.2
Always operate internal Carry out welding, flame-
combustion engines and cutting and grinding work
fuel operated heating sy- on the machine/plant only
stems only out of doors or if this has been expressly
in a well ventilated area. authorised, as there may
Before starting the machi- be a risk of explosion and
ne in enclosed premises, fire.
make sure that there is
sufficient ventilation.
0.1.5.2.3
Observe the regulations in
Before carrying out
force at the respective site.
welding, flame-cutting
and grinding operations,
Dust found on the ma-
clean the machine and its
chine or produced during
surroundings from dust
work on the machine
and other inflammable
should be removed by ex-
substances and make
traction, not by blowing.
sure that the premises are
adequately ventilated (as
Dust waste should be
there may be a risk of ex-
dampened, placed in
plosion).
a sealed container and
marked, to ensure safe
disposal.
 Safety Page 24

0.1.5.3 Hydraulic and pneumatic

equipment

0.1.5.3.1 0.1.5.3.5
Work on hydraulic equip- Always practice extreme
ment may be carried out cleanliness when ser-
only by persons having vicing hydraulic compon-
special knowledge and ents.
experience in hydraulic
systems.

0.1.5.3.2
0.1.5.3.6
Check all lines, hoses
and screwed connections Hydraulic fluid under
regularly for leaks and pressure can penetrate the
obvious damage. Repair skin causing serious inju-
damage immediately. ry.
Splashed oil may cause
injury and fire. If fluid is injected under
the skin, it must be surgi-
cally removed or gangare-
0.1.5.3.3 ne will result.
Depressurise all system
sections and pressure Always relieve pressure
pipes (hydraulic system,
from the hydraulic system
compressed-air system) to
be removed in accordance before carrying out any
with the specific instruc- kind of maintenance or
tions for the unit concer- adjustment.
ned before carrying out
any repair work. Always use a piece of
cardboard to check for
leaks. Do not use your
0.1.5.3.4
hand.
Hydraulic and com-
pressed-air lines must be
laid and fitted properly. Get medical help immedi-
Ensure that no connec- ately.
tions are interchanged.
The fittings, lengths and
quality of the hoses must
comply with the technical
requirements.
 Safety Page 25

0.1.6 Transporting and Recommissioning

0.1.6.1 0.1.6.5
The machine must be Before setting the ma-
towed, loaded and trans- chine in motion always
ported only in accordance check that the accessories
with the operating in- have been safely stowed
structions. away.

0.1.6.6
0.1.6.2 When travelling on public
Use only appropriate roads, ways and places,
means of transport and always observe the valid
lifting gear of adequate traffic regulations and, if
capacity. necessary, ensure before-
hand that the machine is
in a condition compatible
with these regulations.
0.1.6.3
The recommissioning pro-
cedure must be strictly in 0.1.6.7
accordance with the ope- In conditions of poor
rating instructions visibility and after dark,
always switch on the ligh-
ting system.
0.1.6.4
Before starting work or
travelling with the machi-
ne, check that the braking,
signalling and lighting
systems are fully functio-
nal.
 Safety Page 26

0.1.6.8
When crossing underpas-
ses, bridges and tunnels or
when passing under over-
head lines always make
sure that there is sufficient
clearance.

0.1.6.9
Never travel across slo-
pes; always keep the wor-
king equipment and the
load close to the ground,
especially when travelling
downhill.

0.1.6.10
On sloping terrain, al-
ways adapt your travel-
ling speed to the relevant
ground conditions. Never
change to a lower gear on
a slope. Always change
gear before reaching a
slope.
 Safety Page 27

0.1.7 Machine Safety Decals

The following pages outline the amount and location of each decal on this machine.
Decal reference numbers have been also listed on this and the proceeding page.

Item Sign
ISO ANSI
1500

1502

1502- IO

1503
 Safety Page 28

Item Sign
ISO ANSI
1504

1504- IO

1518

1518- IO

1507

1507- IO
 Safety Page 29

Item Sign
ISO ANSI
1524

1524- IO

1514

1514- IO

1532
 Safety Page 30

Item Sign
ISO ANSI
1523

1512

1513

1513- IO
 Safety Page 31

Item Sign
ISO ANSI
1515

1515- IO

WARNING Cancer and Reproductive Harm -

www.P65Warnings.ca.gov
Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area.
- If in an enclosed area, vent the exhaust to the outside.
- Do not modify or tamper with the exhaust system.
- Do not idle the engine except as necessary.
For more information go to:
www.P65Warnings.ca.gov/diesel 1021008008 0

WARNING Cancer and Reproductive Harm -

www.P65Warnings.ca.gov 1021008009 0
 Safety Page 32

0.1.7.1 Position of warning labels (FM 60 COMPACT)

1502

1512

1518
1515 1503 1507 1512

1514 1524

DUN02758
 Safety Page 33

0.1.8 Position of Emergency Stops (FM 60 COMPACT)

Emergency stops are on both sides of the machine.

DUN02759
 Safety Page 34

0.1.9 Position of Emergency Stops (FM 60 HYDRO)

DUN02760
 Technical Page 35

Table of contents Page

1.1 Dewatering Screen - FM 60 COMPACT 36

1.2 Centrifugal Pump - FM 60 COMPACT 36
1.3 Dewatering Screen - FM 60 COMPACT 36
1.4 General information - FM 60 COMPACT 37
1.5 Cyclone - FM 60 COMPACT 37
1.6 Working Dimensions (FM60 COMPACT) 38
1.7 Working Dimensions (FM60 HYDRO) 39
1.8 Noise levels 40
 Technical Page 36

1.1 Dewatering Screen - FM 60 COMPACT

Vibratory Motors: 3kw (2off)

Weight:1950kg
Fabricated steel design using heavy wall motor beam huckbolted to screen sides.
Screen sides manufactured from 10mm steel plate.
Vibration caused by 2- vibratory motors 3 Kw @ 1500 rpm 400v, 3 phase
Vibration type :- Linear.
Deck stroke :- 3mm .
Conveyed material velocity at 3mm stroke =5.6m/min.
2.5 degree screen working angle.
Screen unit is mounted on four isolation springs approx compressed length = 185mm.
Screen deck comprises of 8 polyurethane panels with 0.5mm openings.

1.2 Centrifugal Pump - FM 60 COMPACT

Size:150/125mm (Rubber lined)

Motor:18.5kw (IP55 enclosure)
Pump casing max working pressure :6 bar
150mm suction port
125mm discharge port
Rubber lined pump casing and impeller
Vee belt drive

1.3 Dewatering Screen - FM 60 COMPACT

Vibratory Motors: 3kw (2off)

Weight:1950kg
Fabricated steel design using heavy wall motor beam huckbolted to screen sides.
Screen sides manufactured from 10mm steel plate.
Vibration caused by 2- vibratory motors 3 Kw @ 960 rpm 400v, 3 phase
Vibration type :- Linear.
 Technical Page 37

1.4 General information - FM 60 COMPACT

Working length overall 5.66m (18ft 16ins)

Working width 2.70m (8ft ins)
Working height overall 6.06m (19ft 9ins)

Total weight 5500kg

Feed height 1.775m (5ft 8ins)
Discharge height 1.3m (4ft 3ins)

1.5 Cyclone - FM 60 COMPACT

Weight: 260kg
Hydrocyclone (1 off)
Fixed spigot discharge
Removable Rubber Lined Inserts
Extended feed box
Underflow collection box
Pressure flange with pressure gauge
Fabricated steel construction
Overall length: 2.754m (9ft)
 Technical Page 38

1.6 Working Dimensions (FM60 COMPACT)

 Technical Page 39

1.7 Working Dimensions (FM60 HYDRO)

 Technical Page 40

1.8 Noise levels

Noise levels for the FM60 (running on empty)

 General Page 41

Table of contents Page

2.1 Introduction 42
2.2 General information 42
2.3 Designated use 43
2.4 Screenable materials 43
2.5 Copyright 44
 General Page 42

2.1 Introduction 2.2 General information

This instruction manual contains The FM60 which you have now
important information on how to received has been manufactured,
operate the machine safely, proper- assembled and tested with the ut-
most care and was built with first
ly and most efficiently. Observing class materials.
these instructions helps to avoid
danger, to reduce repair costs and Close attention has been paid to all
downtimes and to increase the re- details in assembly, running tests
liability and life of the machine. and final inspection.

We are confident that you have

received a machine which will give
The operating instructions must you every satisfaction over a long
always be available wherever the period.
machine is in use.
To be assured of faultless operation
These operating instructions must we would ask you to carefully read
be read and applied by any person the following paragraphs and give
the required time and attention to
in charge of and/ or working on the essential maintenance, cleaning
machine such as: and inspection.

Operation The machine is simple to operate,

including setting up, troubleshoo- adjustments are easy to make and
ting during the course of work, expert assistance is seldom re-
quired, provided that ordinary care
evacuation of production waste,
is exercised in daily use.
care and disposal of fuels and con-
sumables. The machine has been built in
accordance with state-of-the-art
Maintenance standards and recognised safety
(servicing, inspection, repair). rules. It is designed to be reliable,
efficient and safe when used and
maintained in accordance with the
and/ or instructions given in this manual.
Transport Nevertheless, its use may constitu-
Follow all applicable safety regu- te a risk to life and limb of the user
lations for accident prevention and or of third parties, or cause damage
environmental protection. to the machine and to other materi-
al property.
 General Page 43

2.3 Designated use 2.4 Screenable materials

Sand
The material is deposited into the Glass
dewatering screen. Quarry Dust

All light particles, such as silt, float

to the top of the water tank and are
carried of, through weirs, to the
collection tank under the dewate-
ring screen. If you need to process any
Notice material with the FM machine
The dirty water and fine material in which is not on the above list,
the collection tank is then pumped contact your local Terex Dea-
to the cyclone where the fines are ler or Terex Technical Depart-
separated from the dirty water on ment for advice.
the dewatering screen.

Operating the machine beyond it‘s

contractual, will result in a loss of
the guarantee and the manufactu- If you have any doubts about
rer\ supplier cannot be held liable any aspect of the machines ca-
for any damage resulting from pability or servicing procedu-
such use. The risk of such misuse res, you must consult your local
lies entirely with the user. Terex dealer or Terex Technical
Department.
 General Page 44

2.5 Copyright

The copyright of this manual is

reserved by Terex.

This operating manual contains

regulations and technical drawings,
which may not be copied, distri-
buted, 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 1997.

Terex Washing Systems

200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: +44 (0) 28 8771 8700
E mail: TWS.sales@terex.com
 Design and Function Page 45

Table of contents -

Page

3.1 General Information FM 60 COMPACT 46

3.2 Overflow water from rinser FM 60 COMPACT 47
3.3 Features of the recovery unit FM 60 Compact 48
3.4 Advantages of the FM 60 Compact 49
3.5 FM 60 Compact hydrocyclone functionally 50
3.6 Design of screen unit (SU) 52
3.7 Design of centrifugal pump (CP) 54
3.8 Flat Bottom Classifier 55
 Design and Function Page 46

3.1 General Information FM 60

COMPACT

Left and Right hand Front Left

When using this handbook, at all times
the right and the left hand references
are viewed from the area material flow
enters the machine.

Right Rear

Front and Rear

When using this handbook, at all times

the rear of the machine is situated at the
Front
pump end.
Right

Left

Rear
 Design and Function Page 47

3.2 Overflow water from rinser FM 60 COMPACT

J
C D
A
K
F

DUN02761

Sand and water from screenbox enters cyclone

tank through (A) material is pumped at (F) up
hoses (G) to cyclone. material discharges from
bottom of cyclone onto dewatering screen (C) Af-
ter moving along dewatering screen its discharged
onto outlet chute at (D). Fines separated from
the dewatering screen return to the cyclone tank.
Over flow from cyclones (I) returns to tank at (J)
and regulate cyclone tank levels. Over flow from
cyclone tank flows to settling ponds at (K).
 Design and Function Page 48

3.3 Features of the recovery unit FM 60 Compact

The FM 60 Compact is a static sand recovery unit.

It is a combination of already proven technology
coupled with the latest methods of sand / fines
recovery available on the market today. It brings
together on one chassis, centrifugal slurry pump,
hydro cyclone, collection tank and 8x4 dewatering
screen.

It can produce 1 grade of sand at a maximum pro-

duction of approx. 60 T.P.H. It is designed to work
in conjunction with the Terex Washing range.

Features
Underflow rubber lined slurry pump.

(1off) rubber lined hydro cyclone which

classifies at approximately 75 µm.

Self regulating cyclone tank with built in

float system..

High frequency 8x4 dewatering screen

fitted with 500µm polyurethane modular
mats

Cyclone folds down for transport.

150/125 lined pump

 Design and Function Page 49

3.4 Advantages of the FM 60

Compact

Cleans sand by washing and removing

fines.

Removes water following dewatering

operation to 10-15% of residual water.

Low maintenance due to use of

wear and resistant products.

Reduces fines before discharge to

lagoons of waste.

Compact, complete sand/fines

recovery and dewatering in a single
unit.

Major reduction in moisture content

of material. Typically 10 – 15%.
Material is therefore ready for
loading.

Skid mounted.

Output, typically 60 TPH.

Heavy-duty robust construction

ideal for rugged operating
environments.

Cleans sand by washing and

remounting fines.

Removes silt, slimes and clay

below 75 micron.
 Design and Function Page 50

3.5 FM 60 Compact hydrocyclone functionally

The HK Dewatering Cyclone (comprises a feed box with a tangential entry. Below this is a
cone terminating in a spigot fitted with a discharge regulator. Above the feed box is a plate
which supports the vortex finder. The latter projects into the feed box. Above the plate is an
overflow bend providing an outlet. The overflow pipework leads from the outlet to a point
about 2m (6ft) below the discharge regulator.
The sand and water slurry to be treated is introduced at a pressure of between 0.15 to 0.45
bars (5 to 15 ‘ of water) into the feed box through a tangential entry at a consistency suitable
for pumping i.e. around 20% to 35%. In the feed box the rotation imparted by this tangential
entry causes the solids in the slurry to be thrown outwards by centrifugal force, and to pass
downwards under gravity, into the cone and out through the discharge regulator. The material
produced at the discharge regulator is referred to as the underflow and is, in the majority of
cases, the product. The water together with the fine organic matter and clays passes upwards
through the vortex finder and via the overflow bend to waste.
When in operation the overflow pipework acts as a syphon creating a negative pressure in the
Cyclone, this holds the discharge regulator closed (Item 1) unless solids are present when it is
opened by the weight of the solids themselves (Item 2).

1 2

DUN02763

In practice, the underflow comprises the whole of the solids fed with the exception of the silts
and clays. The proportions of water with the underflow depends on the grading of the solids
and in most cases is of the order of 20% by weight, or little more than is required to fill the
voids between the solids. The overflow comprises the greater part of the water in the feed
together with most of the silts and clays.
 Design and Function Page 51

The correct operation of the discharge regulator is dependent on the maintenance of the nega-
tive pressure in the separator created by the syphon effect of the overflow pipework. On
start-up and shut-down the syphon effect is lost for a short time and there is a flow of water
from the discharge regulator. To avoid this flow of water passing to the dewatered material on
the stockpile (or bin) a special water transfer system has been developed and is offered as an
optional.

1
11
2
10
3 9 1 Overflow Tee
2 Pressure Guage
8 3 Feed
4 4 Overflow Pipe
7 5 Non-return Sleeve
6 Discharge Regulator
6
7 Spigot
8 Conical Section
9 Vortex Finder
10 Feed Box
11 Overflow Bend

DUN02764
 Design and Function Page 52

3.6 Design of screen unit (SU)

Qualiy by design

The fabricated main exciter bridge, the

SU
vital component in the transmission of
the vitration from vibrator motor to
screen is stress relieved.

The surfaces mating with the screen

side plates and the motors are
machined to exacting tolerances to
provide a precise fit for long trouble
free life.

Expoxy adhesive is used between all

mating services of the screen frame
eliminating corrosion and uniformly
distributing stresses in these areas.

The side plates of the machine are

fitted with easily replaceable (bolt-in
rubber wear liners affording protection
to structure of the machine to the
structure of the machine ensuring long
service life.

The screen can be fitted with snap-in

modular screen deck panels providing
long lifetime, easy handling and
maintenance with the ability to replace
small areas of localised wear.

Quality control through ISO9002

certification ensures a reliable and
consistent product.
 Design and Function Page 53

3.6 Design of screen unit (SU)

(Continued)

Qualiy by design

Both the linear motion low noise

SU
vibrating screen motors and the robust
geared exciter have been designed
specifically to ensure long life time with
minimum maintenance requirements.

The steel screen frame is

predominantly of bolted construction
avoiding stresses created by welding.

The ease with which adjustment can be

made to the amplitude of vibration,
deck inclination and weir plate ensure
preformance can be optimised quickly
at low cost.

A high solids recovery is achieved

when the screen underflow is kept in
closed losses circuit and the only solid
losses occuring would be the very fine
material exciting from the cyclone
overflow.
 Design and Function Page 54

3.7 Design of centrifugal pump (CP)

Outer casing

Rigid casing designfaciliates ease of

CP
field liner replacement.

Suction Brush Liner

Simple, easy to replace higth quality

rubber bush

Casing liners

Abrasion and corrosion-resistant

rubber liners moulded over steel
reinforcement give maximum wear life.

Impeller

Thick, hydrodynamically efficient

rubber over steel re-inforcing gives
optimum performance.

Bearing and shaft assembly

Fully enclosed, heavy duty shaft

assembly gives long service life and
allows easy removal for clean bench
inspection and maintenance.
 Design and Function Page 55

3.8 Flat Bottom Classifier

The Flat Bottom Classifier (FBC) is a hydraulic sizing device that uses an up flow of water to
classify solids by size and density. By establishing a fluidised ‘teeter bed’ of the feed material
itself, a very sharp separation can be made, by size and density.

1
6

4 3

Each FBC consists of:

1) A cylindrical tank with an overflow launder around the top perimeter and four
equispaced mounting feet around the outside.
2) A density probe mounted at the top of the tank near the overflow launder.
3) A baffled feedwell and impact plate supported on the top frame.
4) A cylindrical water chamber beneath the main tank.
5) A flat base plate separating the main tank from the water chamber. This plate
is fitted with hundreds of water injection nozzles, designed to operate
as non-return valves.
6) One or more valves to discharge classified solids (underflow) from the bottom
of the FBC.
7) An electrical and pneumatic control system which pulses the valves open /
closed to hold the solids level at the desired set point in the tank.
 Design and Function Page 56

Flat Bottom Classifiers operate best on feeds with a high solids content (>40% solids by
weight), similar to the density inside the tank, and so are normally fed from a standard or
dewatering cyclone underflow. Dilute feeds increase the classifier overflow rate, which can
cause unwanted coarse particles to misreport to the overflow.

Typical Feed Rates (t/h)

Lignite/Charcoal Removal Size Classification
Diameter (m) from -250µm Sand at ~500µm

1.2 8 – 10 14 – 22
1.8 20 - 24 30 – 50
3.0 56 – 68 110 – 150
3.5 75 – 91 150 – 200
 Transport Page 57

Table of contents Page

4.1 Safety Information 58

4.2 Containerization 60
 Transport Page 58

4.1 Safety Information

SWITCHOFF TAGOUT AND

DANGER
LOCKOUT PROCEDURE
When carrying out maintenance or
adjustment to the plant the
following procedure must be
followed.
1. Switch off engine.
2. Remove the ignition key.
3. Keep the ignition key on person
during
lockout.
4. Place appropriate maintenance
warning signs (ie. ‘TAG OUT’).
5. NEVER work alone.

PERSONAL PROTECTIVE
WARNING EQUIPMENT
Loose or baggy clothing can get
caught in running machinery.
ALWAYS wear correctly fitting
(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment
includes Hard Hat, Safety Glasses,
Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel
Toed Boots, Industrial Gloves and
High Visibility Vest.
 Transport Page 59

4.1 Safety Information

ENTANGLEMENT
DANGER
HAZARD
In-running nip points can cause
serious injury or even death.
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and
amputated.
SWITCH OFF, LOCKOUT &
TAGOUT machine before opening
or removing guards.

FALLING HAZARD
WARNING

Falling from and/or onto a

Terex machine can cause
serious injury or even death.
DO NOT climb onto the machine
whilst in operation.
ALWAYS use the walkways/platforms
provided or a safe and secure platform
approved by the local regional safety
enforcing authority. ALWAYS use an E.N./
A.N.S.I. approved safety harness when
reaching any points 6ft 6ins (2m) or more
above groundlevel.
 Transport Page 60

4.2 Containerization

The FM60C / HYDRO is a modular plant and is trnasported using containers. Con-
tainers are 40 foot (12.2 m) open top containers. When lifting machine parts, ensure
that you do so at a slow and steady pace. Make sure that parts do not hit the con-
tainer or other parts. Machine parts must be loaded into the containers in the correct
sequence.

DUN02744
 Transport Page 61

Container 1

Using suitable lifting equipment, load the following into container 1:

FM120 - 1.5M CLASSIFIER TOWER SUB

HK125 SEPARATOR ASSEMBLY
HK125_PREMIX
UNDERFLOW BOX FROM SEPARATOR ON PREMIX

DUN02745
 Transport Page 62

Container 2

Using suitable lifting equipment, load the following into container 2:

FM120 - PREMIX COMPACT CHASSIS ASSEMBLY

DOUBLE GRADE SAND PLANT TANK WEIR
FLOAT MANIFOLD WELDED
FM SAND CHUTE ASSEMBLY
8X4 DEWATERING SCREEN COMPLETE (TEMA DECK)

DUN02746
 Transport Page 63

Container 3

Using suitable lifting equipment, load the walkways and stairs into container 3.

DUN02747
Transport Page 64
 Setup Page 65

Table of contents Page

5.1 Safety Information 66

5.2 General information 68
5.3 Dimensions, required space and weight 68
5.4 Measures before set up 68
5.5 Measures after long term standstill 69
5.6 Machine set up 69
5.8 Removing dewatering anti-rock stays 70
5.9 Raising Cyclone unit into working positon (FM 60 COMPACT ) 71
5.10 Fitting the cyclone supply hoses(FM 60 COMPACT) 72
5.11 Fitting the supply pipes (FM 60 COMPACT) 73
5.12 Fitting the cyclone discharge hoses (FM 60 COMPACT) 74
5.13 FM60 Hydro Machine Setup 75
5.14 Hydrocyclone Installation 78
5.15 Pump Setup 79
5.16 Gland Assembly 81
5.17 Dewatering Screen Installation Notes 83
5.18 Removing the walkway from the trailer 87
5.19 Attaching the handrail 88
5.20 Starting the FM 60 89
5.21 Flat Bottom Classifier (FBC) Commissioning Instructions 90
 Setup Page 66

5.1 Safety Information

SKIN INJECTION HAZARD

DANGER

Hydraulic fluid under pressure can

penetrate the skin causing serious
injury.
ALWAYS relieve the pressure from
the hydraulic system before
carrying out any kind of
maintenance or adjustment.
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. Get medical help immediately.

ENTANGLEMENT HAZARD
WARNING

In-running nip points can cause

serious injury or even death.
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and
amputated.

SWITCH OFF, LOCKOUT & TAGOUT

machine before opening or
removing guards.
 Setup Page 67

5.1 Safety Information

FALLING HAZARD
WARNING

Falling from and/or onto a

Terex machine can cause
serious injury or even death.
DO NOT climb onto the machine
whilst in operation.
ALWAYS use the walkways/platforms
provided or a safe and secure platform
approved by the local regional safety
enforcing authority. ALWAYS use an E.N./
A.N.S.I. approved safety harness when
reaching any points 6ft 6ins (2m) or more
above groundlevel.

SWITCHOFF TAGOUT AND

DANGER
LOCKOUT PROCEDURE
When carrying out maintenance or
adjustment to the plant the
following procedure must be
followed.
1. Switch off engine.
2. Remove the ignition key.
3. Keep the ignition key on person
during
lockout.
4. Place appropriate maintenance
warning signs (ie. ‘TAG OUT’).
5. NEVER work alone.
 Setup Page 68

5.2 General information 5.4 Measures before set up

1. Ensure all guards are fully

We recommend that the assembly/ secured in correct/closed position.
installation work of the Machine
be carried out by the Terex custo- 2. Remove all loose items from
mer service department. the inside of the machine.
The manufacturer/ supplier will
not be liable for damage caused by 3. Put all control valve levers
improper assembly/ installation. in neutral (non-operational)
position.

5.3 Dimensions, required space and

weight When setting up the Machine pay
particular attention to the follo-
Dimensions wing points:
Refer to “Technical
Information.” 1. The Machine must be
placed on solid ground ca-
Required space pable of carrying the
Refer to “Technical machine‘s weight.
Information.””
2. Before positioning the Ma-
Weight chine from the prime mover,
Refer to “Technical it is important that the cho-
Information.” sen site is level.
Level the worksite foundati-
on with the loading shovel.

3. Level the Machine with a

precision spirit level.

4. Do not position the machine

above ground level, eg. on
blocks etc.
 Setup Page 69

5.5 Measures after long term 5.6 Machine set up

standstill

Machines arranged before and

No other special actions must be after the Machine will have to be
taken after long term standstill. placed accordingly.

The general arrangement diagram

Prior to putting into operation giving you the basic information
Notice perform daily (10 hour) main- of the Machine including measu-
tenance schedule. rements and weight is provided in
Section 10 “Appendix.”

Before setting up the Machine,

this section and all of the previous
sections must be read, understood
and observed.

Any work on and with the machine

must be executed by reliable, au-
thorised personnel only. Statutory
minimum age limits must be ob-
served.
 Setup Page 70

5.8 Removing dewatering anti-rock

stays

WARNING
Procedure
LOCK-OUT MACHINE.
Refer this Section, Safety information for
relevant Lock-Out procedure.

FALLING HAZARD.
Refer this Section, Safety information for
relevant warning.

WEAR PERSONAL PROTECTIVE

EQUIPMENT.
Refer this section, safety information
for relevant warning.

1. Observe all safety warnings.

2. Remove bolts (A) and anti-

rock stays (B).
BACK A

3. Place bolts (A) and anti-rock B

stays (B) in the toolbox in
order to have them available
for re-use when the machine
is towed on the highway. A

FRONT
 Setup Page 71

5.9 Raising Cyclone unit into working

positon (FM 60 COMPACT )

WARNING
LOCK-OUT MACHINE.
1. Observe all safety warnings. Refer this Section, Safety information for
relevant Lock-Out procedure.

FALLING HAZARD.
Refer this Section, Safety information for
Use suitable lifting equipment relevant warning.
for this operation.
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
2. Using suitable lifting equip- for relevant warning.
ment, secure two chains onto
the upper corners
of the cyclone unit.

Slightly activate the suitable

lifting equipment, to release
the tension from the
retaining pins allowing for
easy removal of the pins.
3. Remove the pins and spring
clips (PS) from the cyclone
assembly jacking legs (LH/
RH).

4. Using the suitable lifting

equipment, extend the cyclo-
nes into their working positi-
on.

5. Refit pins and spring clips

(PS) into cyclone jacking
legs.

6. Remove the chains.

 Setup Page 72

5.10 Fitting the cyclone supply hoses

(FM 60 COMPACT)

Procedure
WARNING
LOCK-OUT MACHINE.
1.Observe all safety warnings. Refer this Section, Safety information for
relevant Lock-Out procedure.

Always use a safe and secure FALLING HAZARD.

Refer this Section, Safety information for
platform. relevant warning.

2.Retrieve hosing from the supply WEAR PERSONAL PROTECTIVE

kit. EQUIPMENT.
Refer this section, safety information
for relevant warning.

Be aware of cyclone supply hoses

when placing them into position.
The supply hose is heavy and
may cause serious injury if allo-
wed to fall.
3.Attach one end of the hosing to
the cylone supply pipe using the
approved clamp.

4.Attach the opposite end of the

hosing to the pump outlet pipe
using the clamp provided.

5.Repeat this procedure for the

sceond cyclone return hose.
 Setup Page 73

5.11 Fitting the supply pipes (FM 60

COMPACT)

Procedure WARNING
LOCK-OUT MACHINE.
Refer this Section, Safety information for
relevant Lock-Out procedure.

1.Observe all safety warnings. FALLING HAZARD.

Refer this Section, Safety information for
relevant warning.
Use suitable lifting equipment
for this operation. WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
2.Retrieve the 10“ rubber lined ho- for relevant warning.
sing from the packing kit.

3. Using suitable lifting equipment,

secure one either
end of the rubber lined hosing.

4.Ensure 10“ hosing clamps are

securley clamped on to the rubber
lined hosing.

5. Using the suitable lifting equip-

ment, lift the hose into position and
attach one end to the static rinser or
respective feeding machine using
the gasket locking nuts
and washers provided.

6. Attach the opposite end of the ho-

sing to the corresponding tank inlet
and attach using the gasket locking
nuts and washers provided.
 Setup Page 74

5.12 Fitting the cyclone discharge

hoses (FM 60 COMPACT)

Procedure WARNING
LOCK-OUT MACHINE.
Refer this Section, Safety information for
relevant Lock-Out procedure.
1.Observe all safety warnings.
FALLING HAZARD.
Refer this Section, Safety information for
Always use a safe and secure relevant warning.
platform.
WEAR PERSONAL PROTECTIVE
2.With the help of another operati- EQUIPMENT.
Refer this section, safety information
ve retrieve the 8 inch cyclone hose. for relevant warning.

3.Attach one end of the hosing

(H1)
to the cyclone discharge pipe
(CD1)
using the clamp provided.

4.Attach the opposite end of the

hose (H2) to the cyclone tank pipe
(P) using the clamp provided.

Be aware of discharge hoses

when placing it into position.
The supply hose may cause se-
rious injury if allowed to fall.
 Setup Page 75

5.13 FM60 Hydro Machine Setup

1. Observe all safety signs.

2. Using suitable lifting equipment, position the

sump tank (Item 1) in a suitable place for opera- 1
tion. The approximate weight of the sump tank is
20000 kg. 4
3. Attach the Double Grade Sand Plant Tank Weir 2
(Item 2).

4. Fit the 4 braces (Item 3) to the chassis.

3
DUN02748
5. Secure the float manifold (Item 4) to the sump
tank.

6. Using suitable lifting equipment, lift the dewa- 5

tering screen (Item 5) onto the sump tank chassis.
The approximate weight of the dewatering screen
is 5000 kg.

7. Secure the dewatering screen in position.

8. Using suitable lifting equipment, lift the com- 6

pact chute (Item 6) into position and secure.
The approximate weight of the chute is 1000 kg.
DUN02749

9. Using suitable lifting equipment, lifting the

sump tank walkways and stairs (Item 7) into
position.
The approximate weight of the sump tank walk-
way is 3000 kg.

10. Secure the walkways and stairs (Item 7) to

the sump tank chassis.
7

DUN02750
 Setup Page 76

11. Using suitable lifting equipment, position the

Pre-Mix Frame (Item 8) in a suitable place for
operation. 11
The approximate weight of the Pre-Mix Frame is
8000 kg. 8 8

12. Attach the dewtaering screen mounting

frames (Item 9) to the Pre-Mix Frame.
9
13. Fit the Dewatering Spraybar (Item 10).
10 9
14. Using suitable lifting equipment, lift the DUN02751
cyclone tower frame (Item 11) into position and
secure. The approximate weight of the Cyclone
Tower Frame is 1000 kg.
13
15. Using suitable lifting equipment, lift the mid
section of the pre mix walkway (Item 12) into
position.

16. Secure the mid section of the pre mix walk-

way (Item 12) in position.

17. Using suitable lifting equipment, lift the top 12

level of the pre mix walkway (Item 13) into posi-
tion. The approximate weight of the walkway is DUN02752
3000 kg.

18. Secure the top level of the pre mix walkway

(Item 13) in position.
14
19. Using suitable lifting equipment, lift the Pre-
Mix Cyclone (Item 14) into position.
15
20. Secure the Pre-Mix Cyclone (Item 14) to the
Pre-Mix Tower frame. The approximate weight
of the Pre-Mix Cyclone is 2000 kg.

21. Using suitable lifting equipment, lift the Cy-

clone Underflow Box (Item 15) into position and DUN02753

secure.
 Setup Page 77

22. Using suitable lifting equipment, lift the

Overflow Catchbox (Item 16) into position and
secure.

23. Using suitable lifting equipment, lift the Pre-

Mix Tower Assembly (Item 17) unto the Sump
16
Tank Chassis (Item 18).
The approximate weight of the Pre-Mix Tower 17
Assembly is 17000 kg. DUN02754

24. Secure he Pre-Mix Tower Assembly (Item 17)

to the Sump Tank Chassis (Item 18).
17
25. Fit the pipework (Item 19) for the plant.

26. Using suitable lifting equipment, lift the Cy-

clone Tower (Item 20) into position on the top of
the plant. The approximate weight of the Cyclone
Tower is 3000 kg.
19 18
27. Secure the Cyclone Tower (Item 20) in posi- DUN02755

tion on the top of the plant.

20

DUN02756
 Setup Page 78

5.14 Hydrocyclone Installation 5.14.1 Setting to Work

No special tools are required for the Cyclo-

ne installation. The Hydrocyclone once correctly installed
is ready to accept feed, the condition of
The Cyclone is rubber lined for abrasion which will be specified by Terex on pur-
and corrosion protection and care must be chase. It should be ensured that the correct
taken to maintain lining integrity during inlet pressure, quantity of feed and consist-
installation. ency of feed are being provided for the
specified duty.
DO NOT WELD OR OXY/ACETYLENE Once the Hydrocyclone is in operation sam-
CUT NEAR THE CYCLONE DURING ples should be taken of feed, overflow and
INSTALLATION. underflow and analysis carried out to ensure
DO NOT USE ANGLE GRINDERS OR satisfactory performance is being achieved.
CUTTING DISCS ON RUBBER LININGS If these results are not satisfactory then
OR LINED STEELWORK. contact Terex immediately for advice before
modifications or changes to the units speci-
Rubber linings are highly flammable and fication are made. Possible faults and action
are easily damaged when subjected to this to take should they occur are shown in the
type of treatment. troubleshooting section.
The external pipe connecting flanges are
also rubber lined to form an integral gasket
surface for sealing purposes. This gasket
face must not be damaged during installati-
on.
The Cyclone is provided with mounting
feet, which are predrilled for mounting
bolts.
The Cyclone is to be lifted into position
and orientated to suit the required pipework
connection locations. The level should be
checked in at least two places at ninety de-
grees to each other. Some minor shimming
may be necessary to ensure mounting feet
sit correctly on supporting steelwork
The Cyclone is of robust construction but is
not designed to take high piping or hydrau-
lic loads. All connecting pipework must be
independently supported to hold the static
weight of the pipe itself and the contained
slurry, plus all hydraulic loads generated by
the pressurised slurry within the pipework.
 Setup Page 79

5.15 Pump Setup

Pipework Access
The suction and delivery pipework must be Lifting equipment capacity and access route-
independently supported, and the pump must from thedelivery point should be checked.
not be used as an anchor to pull the pipes into Access for maintenance, protection from flood-
position. Provision for simple removal ofsuction ing, and ventilation for motor cooling must be
and delivery pipework to facilitate unblocking checked.
and servicing the pump, and dumping solids in
an emergency situation should be Impeller Adjustment Axially
checked. Possible areas which could cause The position of the rotating element must be set
restriction on the suction side should be so that there is a minimum running clearance,
checked. approximately 1mm, between the suction bush
and the impeller , the bearing housing must then
The possibility of thermal expansion in the be locked in position. This clearnace should be
pipework causing undue loads on the pump checked by bolting a dummy flange or stubpipe
should be checked. Check that the pipework to the suction flange this ensures any movement
matches up to the pump without strain. of the rubber lining on connection is allowed
The lining on the Linapump 111r is continued for. Once connected to suction and delivery
out to form gaskets on the suction and lines. The unit should be checked for free
discharge flanges, therefore the use of joint rotation
rings or additional gaskets is not necessary.
Connections to the pump should be made using
flat faced flanges only.

When fitting pumps to rubber lined equipment-

such as valves, hose or lined pipe, a steel gasket
must be used.
 Setup Page 80

5.15 Pump Setup (Continued)

Coupling Alignment The mesh should be relieved and a guard

The pump and motor couplings must be aligned should be fitted in a manner which prevents
in accordance with good enginneering practise accidental contact with the rotating parts of
and axial or radial run out must be less than the drive assembly.
0.05mm total indicated reading on a clock
gauge. With Vee-belt pulleys, the faces of the
couplings must be exactly in line, and the shafts
must be parallel to each other. A check with a
straight edge or string line across the pulley
faces should ahve no visible gap.

Motor Rotation
Before the belts are fitted or the couplings
are connected, the direction of rotation of
the motor must be checked. Incorrect
motor rotation cancause the impeller to
screw off and destroy the pump.

Tension Vee-Belts
When the motors direction of rotation is
correct, fit the Vee-belts and tension them in
accordance with the maker‘s
recommendation. In general, a quarter to a
half twist of the belt will be possible at the
centre of the belt using a finger and a thumb.
Check the tension again after a few hours
running.

Belt Guard
The Belt guard provided with this pump unit is
manufactured with the shaft aperture fully
closed with mesh. On installation of the vee
belt drive and determination of pulley centres,
the shaft guard is offered up and the mesh
relieved locally to allow the shafts to pass
through. Allowance may be required for
movement of shafts when belt tensioning.
 Setup Page 81

5.16 Gland Assembly Sectional Arrangement - D - Gland Assembly

When the pump is first started, ensure thet

the adjusting nuts are finger tight. When the
pump runs, adjust the gland nuts so that there
are approximately 5 drops per minute from
the gland. This should reduce to 1 drop
occasionally, and run satisfactory for up to a
year without further attention in a good
application.

Gland Assembly
Part No. Discription
D01 Gland Housing
D02 Gland Cover
D03 Adjusting Sleeve
D04 Washer
D05 Gland Seal
D06 Adjusting Stud Set (do not
overtighten the adjusting nuts)
D07 Sleeve O-ring
D08 Gland Sleeve
D09 Face Seal
D10 Face O-ring
D11 Wearing Face
D12 Impeller O-ring
D13 Gland Locating Ring (not
shown) only on 100/100
D14 Gland Cover Set Screw
D15 Spacer Ring (not shown)
only on 250/200 and 300/250
 Setup Page 82

D’Gland Adjustment/Commissioning

The gland sealing faces require lubrication by the fluid being pumped. Under no circumstanc-
es may the glad be run dry. Care must be taken to adjust the three nuts equally and not over
tighten the gland, otherwise the face seal will overheat and may result in permanent damage.

- Ensure the pump is electrically isolated and it is safe to work.

- Loosen the 3 adjusting nuts (D06) so the adjusting sleeves (D03) is loose.
- Check for free rotation of the pump shaft. Any stiffness must be investiagated. In particular,
check the impeller is correctly positioned in the casing, there is no interference in the gland
and the shaft passes centrally through it and the belts are not over tight.
- Push in the adjsuting sleev by hand and tighten the 3 adjsuting nuts, keeping the adjusting
sleeve paralle to the shaft until the hard face (D11) just touches the face seal (D09).
- Fill the pump with fluid, and a dribble should come through the gland.
- Tighten the 3 adjusting nuts equally (1 flat in turn) until there is an occasional drip.
- Refit the guards and , when safe, start the pump.
- If necessary, adjsut the 3 nuts (D06) in or out equally to maintain the drip.
- Take time and allow the seal faces to seat. A further small adjustment may be needed.
- Lock the buts and fit the protection strips.

If the gland seal (D05) is not seated properly, water can leak out or air can be sucked in bet-
ween it and the adjusting sleeve (D03).
In newer models of Linapump, the recess in (D03) is removed and the diameter of (D05) was
increased. The new parts are (D03U) and (D05U).
 Setup Page 83

5.17 Dewatering Screen Installation

Notes

LOCKOUT electric power to the

equipment, read ALL Safety Notesbefore 6. The unit should operate at low noise level.
operating the unit and before performing If unusual sounds are observed near the unit, all
any maintenance. bolts and clearances should be checked.

1. Install unit clearances reguired. REMOVE 7. Check the out of balance weights are secure
ALLred shipping braces and allthread ties. and that each end of the motor weights is the
same. Check the guards fit correctly.
2. CLEARANCE: Allow clearances shown on
the General Arrangement Drawings around the 8. LUBRICATION: The motor/s, on the unit,
unit from any fixed equipment, such as skirts, generally is the only item requiring lubrication.
hoppers, pipes, receiving chutes, etc. Note that If additional items require lubrication then it
theunits isolation springs will deflect 25mm to will be listed in the Table of Contents.
75mmvertically underload. There must be
clearance all around the unit, while the unit is 9. MATERIAL FLOW CAPACITY: If
running, with and without material load. maximum capacity or capacity range is not
satisfactory, then contact Terex
3. The unit must be aligned and levelled across International Service Dept.
both width and length of unit before anchoring
and operation. 10. CAUTION When performing maintenance
on the unit, LOCK OUT Control Panel.
4. The feeder should not be overloaded.
11. It is important that all bolts inside and
5. ELECTRICAL CONNECTION: Be sure outside the unit remain tight. Occassionally,
that the motor is connected for the proper as a normal maintenance operation, all bolts
voltage and that the ground wires are properly on the unit should be checked and tightened if
fastened. There must be slack in the electrical necessary. Refer to the TORQUE CHART/S
cable leading from the drive motor/s, and care for proper torque values.
must be taken to prevent cable from contacting
drive covers or stationary steel. If unit was in
storage, then check the motor maintenance
section in this manual for possible motor testing
before energising the motor.
 Setup Page 84

5.17 Dewatering Screen Installation

Notes (Continued)

12. After 24 to 48 hours of initial running time,

check the unit for loose bolts and tighten per FIG. X1
the“TORQUE.CHART/S“ in this manual.

13. SPARE PARTS: Parts should be kept on

hand at all times. See the Spare Parts List/s for
recommendations

5.17.1 Dewatering Screen Unit

Adjustment

The units stroke should be monitored on a

regular basis to ensure that the unit is operating
properly.
The design stroke is normally listed in the basic
data. The stroke should be maintained within
plus or minus 0.5 mm of the listed design stroke.
If the unit is allowed to operate out of this range
for any length of time then SEVERE damage to
the unit is possible.

It is important that the motors

are connected correctly. The motors
must be wired so that they are both int
OPPOSITE DIRECTIONS. See FIG. X1.
Otherwise severe damage to the unit is
possible.
 Setup Page 85

5.17.2 Dewatering Screen Stroke Plate

 Setup Page 86

5.17.2 Dewatering Screen Stroke Plate (Continued)

(Refer to diagram on previous
page)

STROKE PLATE

PLEASE NOTE The following information

only explains how to read a stroke plate,
NOT the stroke requirement of your unit.

The vibration amplitude or stroke of the

pan is the indicator of the units
performance. Check the stoke of the
unit periodically to ensure it is operating
at the intended stroke. The stroke varies
for each unit depending upon its application.

READING THE STROKE PLATE

When the unit is vibrating the stroke appears

as a double image. For Example - FIGURE
“B“ illustrates this double image and shows
intersecting lines at 12mm. (Note the line of
action). A larger stroke will show the
intersecting lines above 12mm and a smaller
stroke will show the intersecting lines below
12mm.

Whenever the unit stroke is found to be either

below or above the Design Stroke, the unit
will not function properly, this under or over
stroking condition can also cause damage to
the unit.
 Setup Page 87

5.18 Removing the walkway from the

trailer

Procedure WARNING
LOCK-OUT MACHINE.
Refer this Section, safety information
1. Observe all safety warning. for relevant Lock-Out procedure.

FALLING HAZARD.
Use suitable lifting equipment Refer this Section, safety information
for relevant warning.
for this operation.
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
2. Remove all straping from the for relevant warning.
trailer.

3. Using suitable lifting equipment,

secure four chains on each corner
of the static frame (W).

4. Remove the walkway (W) from

the trailer.

5. Move the walkway into it‘s cor- W

rect position.Distinguish between
the front and rear of the walkway
to ensure the two holes align cor-
rectly with the FM 60.
B
6. Bolt the walway to the
FM 60 using the two bolts, was-
hers and locknuts supplied.

7. Remove the chains.

8. Attach the walkway braces (B)

and flo flange using bolts, was-
hers and locknuts supplied.
 Setup Page 88

5.19 Attaching the handrail

Procedure
WARNING
LOCK-OUT MACHINE.
Refer this Section, safety information
for relevant Lock-Out procedure.
1. Observe all safety warnings.
FALLING HAZARD.
Refer this Section, safety information
Be aware of handrail when for relevant warning.

placing it into position. The WEAR PERSONAL PROTECTIVE

funnel is heavy and may cau- EQUIPMENT.
Refer this section, safety information
se serious injury if allowed for relevant warning.
to fall.

Always use a safe and secure

platform.

2. With the help of another operative

place the handrail into position.

3. Bolt the handrail to the walkway

using the bolts, washers and loc-
king nuts provided.
 Setup Page 89

5.20 Starting the FM 60

Procedure WARNING
LOCK-OUT MACHINE.
1. Observe all safety warnings. Refer this Section, safety information
for relevant Lock-Out procedure.

2. With the help of a skilled electri- FALLING HAZARD.

cian wire the dewatering screen Refer this Section, safety information
for relevant warning.
vibrating motors to the main elec-
trical supply via the control panel WEAR PERSONAL PROTECTIVE
or isolators. EQUIPMENT.
Refer this section, safety information
for relevant warning.

Refer to the Dewatering

Screen installation notes
ROTATION SECTION
within this chapter for further
information.
3. With the aid of a skilled electri-
can wire the centifugal
powerpack to the main electrical
supply via the control panel or
isolators.

Refer to the Pump Setup Sec-

tion within this chapter for
further information.

3. (FM 60 ONLY) With the aid

of a skilled electrican wire the
hydraulic powerpack to the main
electrical supply via the control
panel isolators.
 Setup Page 90

5.21 Flat Bottom Classifier (FBC) Commissioning Instructions

Consult item specific manuals and operating instructions for control system/flow meter/valve
installation and operation.

Ensure that the structural steel construction is of a good quality and designed for the appropri-
ate FBC loads.

The FBC should be installed level and within 1mm across the top of the weir.

The water injection distribution system must be clean and the water quality good.

Check the installation of the clean water strainer, non-return valves and regulating valves.

Ensure that the pneumatic system has been tested and the air quality good. The air feed regula-
tor in the pneumatic panel should be set at 4 bar and the valve regulator(s) set at 2.5 bar. Once
set, this pressure may need to be adjusted during commissioning.

Ensure that all electrical circuits have been tested and approved.

The discharge valve(s) are fitted on assembly of the FBC and should be checked for alignment
and sealing onto the valve seat(s) once air is available.

Remove any tramp material from the FBC otherwise this will cause damage to the linings and
may cause blockages.

Shut the FBC drain valve.

Ensure inspection points in the distribution chamber are blanked.

Energize the control panel and compressor (air supply).

Set the FBC set point on the control panel to 70%.

Set the control panel to “manual” mode and check discharge valve(s) for alignment and sealing
onto the valve seat(s) using the on/off button.

Set the control panel to “manual” mode and valve(s) to off.

Start the water pump and check for pressure and leaks and for an even water distribution.

Fill the FBC with water and check again for level.
 Setup Page 91

Flat Bottom Classifier (FBC) Commissioning Instructions (Continued)

Adjust the central feed well so that the bottom edge is 100 mm under water.

Adjust the feed well diffuser plate to 50 mm under water.

Calibrate the FBC on the control panel to 0% full of water.

Check the discharge valve(s) for leaks in the underflow. Adjust as necessary to eliminate
downstream leaks. It is important to maintain alignment at this time so if unsure you should
drain the FBC and check.

Start the feed material, if possible at 50% of the nominal capacity.

Observe the overflow weir, when the unit is filled up stop the feed material. Some material
will report to the overflow at this time.

Calibrate the FBC on the control panel to 100% full of material.

Set the PLC set point to “Automatic” mode to enable the valve(s) to operate. The bed level will
drop to 70% at which time the valve operation will cease.

Start the feed material again and gradually increase the feed rate.

The water around the feed well should be “quiet”. If this is not the case lower by about 50 mm.

Check the overflow and underflow. If they are not to specification increase/decrease the injec-
tion water or adjust the set point on the PLC until the correct setting is found.

If during nominal production the valves open more than 3 times per minute reset the stroke
duration. In case of very fine material the frequency may need to be reduced. The valve opera-
tion can be adjusted in the control panel.

Contact Terex for technical questions;

Setup Page 92
 Operation Page 93

Table of contents Page

6.1 Safety information 94

6.2 General information 98
6.3 FM 60 COMPACT / HYDRO Start Sequence 99
6.4 The Flat Bottom Classifier (FBC) Operating Instructions 101
6.5 Emergency Stop 103
6.6 Restart after Emergency Stop 103
6.7 HK Dewatering Cyclone Sand Separator Operation 104
 Operation Page 94

6.1 Safety information

FALLING HAZARD
WARNING

Falling from and/or onto a

Terex machine can cause
serious injury or even death.
DO NOT climb onto the machine
whilst in operation.
ALWAYS use the walkways/platforms
provided or a safe and secure platform
approved by the local regional safety
enforcing authority. ALWAYS use an E.N./
A.N.S.I. approved safety harness when
reaching any points 6ft 6ins (2m) or more
above groundlevel.

SWITCHOFF TAGOUT AND

DANGER
LOCKOUT PROCEDURE
When carrying out maintenance or
adjustment to the plant the
following procedure must be
followed.
1. Switch off engine.
2. Remove the ignition key.
3. Keep the ignition key on person
during
lockout.
4. Place appropriate maintenance
warning signs (ie. ‘TAG OUT’).
5. NEVER work alone.
 Operation Page 95

6.1 Safety information

PERSONAL PROTECTIVE
WARNING EQUIPMENT
Loose or baggy clothing can get
caught in running machinery.
ALWAYS wear correctly fitting
(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment
includes Hard Hat, Safety Glasses,
Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel
Toed Boots, Industrial Gloves and
High Visibility Vest.

ENTANGLEMENT
WARNING
HAZARD
Feet or any other part of the body
can get caught under support legs.

Always wear correctly fitting

(E.N./A.N.S.I. approved) protective
clothing.

Protective clothing includes Hard

Hat, Safety Glasses, Ear Protection,
Close Fitting Overalls, Steel Toed
Boots, Gloves and a High Visibility
Vest.
 Operation Page 96

6.1 Safety information

ELECTRICAL SHOCK
HAZARD

BEWARE OF OVERHEAD
CABLES WHEN FOLDING
MAIN CONVEYOR.

HAZARDOUS VOLTAGE
WILL CAUSE SEVERE
INJURY ORDEATH.

253

WARNING
FALLING MATERIAL
HAZARD
Do not walk near material
discharge areas.

You are at risk of serious head

injury or death.

WEAR A HARD HAT and

EYE PROTECTION at all
times, when working in the
vicinity of the machine.

410

 Operation Page 97

WARNING
Loose or baggy clothing can get
caught in running machinery.

Always wear correctly fitting

(E.N./A.N.S.I. approved)
protective clothing.

Protective clothing includes

Hard Hat, Safety Glasses,
Ear Protection, Close Fitting
Overalls, Steel Toed Boots and
a High Visibility Vest.
 Operation Page 98

6.2 General information

The machine may only be

Operate the machine only if all operated if the safety instruc-
protective and safety-oriented de- tions provided in the previous
vices, such as removable safety chapters have been observed
devices, emergency shut-off equip- and the described procedures
ment, sound-proofing elements and have been performed.
exhausts, are secured in correct
position and fully functional.
KEEP AWAY FROM THE
During operation, all sound baffles DISCHARGE CHUTE, where
must be closed. there is risk of serious injury
or death due to conveyors car-
In the event of malfunctions, stop rying away the processed ma-
the machine/ plant immediately terial and danger from other
and lock out. heavy machinery working in
the area, unless you are a ful-
Have any defects rectified imme- ly-trained operator engaged in
diately. collecting processed material.

ALWAYS WEAR A EN/ANSI

approved HARD HAT AND
FOOTWEAR WITH ADE-
QUATE TOE PROTECTION
when working in the vicinity
of the machine and on the
work site.
 Operation Page 99

6.3 FM 60 COMPACT / HYDRO

Start Sequence WARNING
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Procedure Refer this section, safety information
for relevant warning.

1. Observe all safety warnings.

2. Turn on the power.

3. Turn on the Compressor (HYDRO machine only).

4. Turn on the Fresh water (if applicable).

5. Check Classifier alarms (HYDRO machine only).

6. Start Stockpile Conveyor 1.

7. Start Stockpile Conveyor 2 (HYDRO machine only).

8. Start the dewatering screen.

9. Check the Sump is full (visual check).

8. Check the Classifier is full (visual check on HYDRO machine only)

9. Start slurry pump 1.

10. Start slurry pump 2 (HYDRO machine only).

 Operation Page 100

6.3.1 Control Panel - FM 60 COMPACT

1. Emergency Stop
5 6 10 12
2. Main Isolator
3. Hours run counter
4. Warning lights
5. Pre - Start Siren
6. Screen ON switch
7. Screen OFF switch
10. Pump ON switch
11. Pump OFF switch
12. Run test 7
11
4

FIG 6.3.1
 Operation Page 101

6.4 The Flat Bottom Classifier (FBC) Operating Instructions

1
6

5
2

4 3

The operation of the FBC is controlled by a PLC control system. Please refer to separate
manual for this control.

Slurry enters the FBC through a central feed well (1) which uniformly distributes solids to a
settling chamber (2).

A controlled flow of clean water is injected to a distribution chamber (3) under the settling
chamber. A filter, mag-flow meter, non-return valve and a flow control valve should be fitted
in the water feed system. It is necessary to be able to measure and accurately control the injec-
tion water flow rate as this strongly affects the size (mass) of particles that are lifted out of the
bed. The minimum injection water pressure is 1.5 bar at the inlet flange, and preferably 2.0 to
3.0 bar if coarser cut sizes (higher water flows) are required.

The clean water permeates through the injection nozzles (4) and flows upward through the
settling chamber, discharging over the overflow weir (5).

The interaction between the rising current and the settling solids creates a fluidised bed. The
speed of the rising water column is set to be close to the settling rate of the sand at the desired
 Operation Page 102

d50 cut size. This inhibits the settling of finer sized or lower density material, while allowing
the heavier/coarser particles to pass easily to the bottom of the chamber via the hindered set-
tling process.
A density probe (6) located near the top of the fluidized solids monitors the height and specific
gravity of the slurry and sends this signal to the PLC which in turn activates discharge valve
(7) to open when a set point is reached. FBC’s 2.4m diameter and larger have multiple dis-
charge valves, thus providing even draw down of solids from the base of the tank.

Solids are quickly discharged from the FBC in frequent, discrete pulses via the discharge
valve(s). The on/off nature of the discharge avoids situations which cause valve blockages or
bed channeling behavior (rat-holing) in other classifier types. The pulsing of the bed also as-
sists in removing entrained fines or light particles from the settled bed.

The cut point of the FBC is controlled by both the injection water flow and the classifier bed
level. The injection water flow determines the classification of material close in size to the cut
point, and the bed level determines the fines separation. Higher bed levels cause more fines to
report to the overflow, and vice-versa.

Because of the varying interactions between water flow and bed level, FBC’s should be op-
erated at a starting bed level of 70%, and the injection water flow varied to alter the d50 cut
point. After steady operation is established, the bed level can be varied to fine-tune the opera-
tion.

The compressed air must be dry and filtered (instrument air quality), pressure at least 4 bar.

Clean water inlet pressure 2.4 bar.

 Operation Page 103

6.5 Emergency Stop

WARNING
In case of incident or trouble,
you MUST follow the WARNING
following procedure: LOCK-OUT MACHINE.
Refer this Section, Safety information
for Lock-Out procedure.
1. Engage the nearest emergency
stop. WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
2. Implement the Lockout proce- for relevant warning.
dure.

3. Only when the machine is fully

switched off, should an attempt
be made to solve the problem.

4. Never work alone.

6.6 Restart after Emergency Stop

1. Ensure that the problem has

been solved.

2. Ensure that all personnel are

clear from the machine.

3. Ensure that all guards and

safety devices are correctly
fitted and fully functional.

4. Release all emergency stops.

5. Restart the machine.

 Operation Page 104

6.7 HK Dewatering Cyclone Sand Separator Operation

Once the Cyclone is correctly installed, the feed equipment should be started up on water
only. While this is happening the Cyclone and the water transfer system (if fitted) should be
observed to ensure that once the unit reaches the correct inlet pressure, the discharge regulator
closes and the water transfer box swings into the stockpiling position.
The negative pressure registering on the gauge fitted either at the overflow pipe or at the water
transfer diaphragm housing should be about -0.25 to -0.30 bars (-8 to -10 ft of water).
Should the water transfer box fail to swing up to the stop provided, the connecting rod re-
quires shortening using the adjusting nut at its centre.
It should be ensured that the correct inlet pressure and conditions of feed are being provided
for the specified duty.

6.7.1 Operation

Once the Cyclone is in operation, samples should be taken of feed, overflow and underflow
and analysis carried out to ensure satisfactory performance is being achieved. If these results
are not satisfactory then contact Weir immediately for advice. Under no circumstances should
modifications or changes to the unit’s specification be made. The following table shows pos-
sible faults and actions to take should they occur.

6.7.2 Cyclone Adjustements

No physical adjustment of the Cyclone is possible during operation. Adjustment of Cyclone

configuration (for example feed box extension, vortex finder or spigot change) can only be
done after isolation and shutdown of the Cyclone.
All safety precautions must be taken to avoid start up of the Cyclone feed pump prior to start-
ing any configuration change.
The principal Cyclone adjustments that are available are an increase or decrease of the vac-
uum by opening / closing the vacuum bleed valve fitted to the overflow tee. An increase of
vacuum will give a drier underflow product, a decrease of vacuum will give a wetter under-
flow product.
 Shutoff Page 105

Table of contents Page

7.1 Safety information 106

7.2 Measures prior to long term standstill 111
7.3 FM 60 COMPACT / HYDRO Shut Down Sequence 112
7.4 Removing the cyclone supply hoses (FM 60 COMPACT) 113
7.5 Remove the cyclone discharge hoses 114
7.6 Remove the tank supply hose (FM 60 Compact) 115
7.7 Pump shutdown procedure 116
7.8 Removing handrails (HR) 117
7.9 Removing the ladder (L) 118
7.10 Removing the walkway (WW) from the FM60 119
7.11 Disconnecting the pump assembly from the chains 120
7.12 Removing the cyclone unit for transport 121
7.13 Refitting the dewatering screen anti-rock stays 122
7.14 Removing the FM 60 123
7.15 Pump shutdown procedure 124
 Shutoff Page 106

7.1 Safety information

FALLING HAZARD
WARNING

Falling from and/or onto a

Terex machine can cause
serious injury or even death.
DO NOT climb onto the machine
whilst in operation.
ALWAYS use the walkways/platforms
provided or a safe and secure platform
approved by the local regional safety
enforcing authority. ALWAYS use an E.N./
A.N.S.I. approved safety harness when
reaching any points 6ft 6ins (2m) or more
above groundlevel.

SWITCHOFF TAGOUT AND

DANGER
LOCKOUT PROCEDURE
When carrying out maintenance or
adjustment to the plant the
following procedure must be
followed.
1. Switch off engine.
2. Remove the ignition key.
3. Keep the ignition key on person
during
lockout.
4. Place appropriate maintenance
warning signs (ie. ‘TAG OUT’).
5. NEVER work alone.
 Shutoff Page 107

7.1 Safety information

SKIN INJECTION HAZARD

DANGER

Hydraulic fluid under pressure can

penetrate the skin causing serious
injury.
ALWAYS relieve the pressure from
the hydraulic system before
carrying out any kind of
maintenance or adjustment.
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. Get medical help immediately.

ENTANGLEMENT HAZARD
WARNING

In-running nip points can cause

serious injury or even death.
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and
amputated.

SWITCH OFF, LOCKOUT & TAGOUT

machine before opening or
removing guards.
 Shutoff Page 108

7.1 Safety information

PERSONAL PROTECTIVE
WARNING EQUIPMENT
Loose or baggy clothing can get
caught in running machinery.
ALWAYS wear correctly fitting
(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment
includes Hard Hat, Safety Glasses,
Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel
Toed Boots, Industrial Gloves and
High Visibility Vest.

ENTANGLEMENT
WARNING
HAZARD
Feet or any other part of the body
can get caught under support legs.

Always wear correctly fitting

(E.N./A.N.S.I. approved) protective
clothing.

Protective clothing includes Hard

Hat, Safety Glasses, Ear Protection,
Close Fitting Overalls, Steel Toed
Boots, Gloves and a High Visibility
Vest.
 Shutoff Page 109

7.1 Safety information

HEARING HAZARD

May cause loss or degradation

of hearing over a period of time.

Wear proper hearing personal

protection equipment.

903

WARNING
FALLING MATERIAL
HAZARD
Do not walk near material
discharge areas.

You are at risk of serious head

injury or death.

WEAR A HARD HAT and

EYE PROTECTION at all
times, when working in the
vicinity of the machine.

410

 Shutoff Page 110

Read and understand

operator’s manual and all
safety signs before using or
maintaining machine.

If you do not understand the

information in the manuals
consult your supervisor, the
owner, or the manufacturer.

316
 Shutoff Page 111

7.2 Measures prior to long term

standstill

No special actions must be taken

prior to long term standstill. WARNING
FALLING HAZARD.
Refer this Section, Safety information
for relevant warning.

WEAR PERSONAL PROTECTIVE

EQUIPMENT.
Refer this Section, Safety information
Prior to putting into operation for relevant warning.
Notice perform daily (10 hour) main- LOCK-OUT MACHINE.
tenance schedule. Refer this Section, Safety information
for relevant Lock-Out procedure.
 Shutoff Page 112

7.3 FM 60 COMPACT / HYDRO 5 6 10 12

Shut Down Sequence
Allow the machine to run for
15 minutes after material has
ceased feeding into the cyclo-
ne tank prior to shut off.
7 11
4
Procedure 3

1. Observe all safety warnings.

2. Stop feeding material.

1
3. Allow approximately 15 minutes for 2
material to circulate out of the system 6. Screen ON switch
(no sand should be visible on discharge 7. Screen OFF switch
conveyors). 10. Pump ON switch
11. Pump OFF switch
4. Stop slurry pump 1. 12. Run test
5. Stop Slurry pump 2
(HYDRO machine only)

6. Stop the fresh water pump

(if applicable).

7. Stop the dewatering screen.

8. Stop Stockpile conveyor 1.

9. Stop Stockpile conveyor 2

(HYDRO machine only).

10. Stop the compressor.

11. Turn off the Power.

 Shutoff Page 113

7.4 Removing the cyclone supply

hoses (FM 60 COMPACT)

Procedure
WARNING
FALLING HAZARD.
Refer this Section, Safety information
for relevant warning.

1. Observe all safety warnings. WEAR PERSONAL PROTECTIVE

EQUIPMENT.
Refer this Section, Safety information
2. Unfasten the retaining hose for relevant warning.
clamps (RHC). LOCK-OUT MACHINE.
Refer this Section, Safety information
for relevant Lock-Out procedure.
3.With the help of another opera-
tive remove the hosing (SH + RH)
from the cyclone discharge pipes
and pump system pipes.
RHC
4.Place the hose (SH) and the
clamps (RHC) in a safe place for
reserve. SH

DUN02762
 Shutoff Page 114

7.5 Remove the cyclone discharge

hoses

Procedure
WARNING
FALLING HAZARD.
Refer this Section, Safety information
for relevant warning.

1. Observe all safety warnings. WEAR PERSONAL PROTECTIVE

EQUIPMENT.
Refer this Section, Safety information
2.Unfasten the retaining clamps. for relevant warning.
LOCK-OUT MACHINE.
3.With the help of another operati- Refer this Section, Safety information
for relevant Lock-Out procedure.
ve remove cyclone discharge hose.

4.Place the hose and clamps in a

safe place for reserve.
 Shutoff Page 115

7.6 Remove the tank supply hose

(FM 60 Compact)

WARNING
Procedure FALLING HAZARD.
Refer this Section, Safety information
for relevant warning.

Use suitable lifting equip- WEAR PERSONAL PROTECTIVE

EQUIPMENT.
ment for this operation Refer this Section, Safety information
for relevant warning.
LOCK-OUT MACHINE.
Refer this Section, Safety information
for relevant Lock-Out procedure.
1. Observe all safety warnings.

2.Using a crane, secure two chains

onto the rubberlined supply hose
- one at either end.

3.Unbolt the rubber lined hoses

from the respective feeding and
cyclone tank.

4.Using the crane position the hose

in the desired position.

5.Lower the crane.

6.Remove the chains.

7.Place all brackets, locking nuts

and washers in a safe place for re-
serve.

Always use a safe and secure

platform
 Shutoff Page 116

7.7 Pump shutdown procedure

This depends ultimately on the

system and process flow requirements
but the following procedure is
recommended.

i) Stop the flow of solids into the

sump
ii) Run system on water only to
wash out
the pump and delivery pipeline.
iii) Shut down the pump.

In cold weather, the pump and

auxiliary equipment should be
Notice drained to prevent freezing
damage.
 Shutoff Page 117

7.8 Removing handrails (HR)

Procedure
WARNING
1. Observe all safety warnings. LOCK-OUT MACHINE.
Refer this Section, safety information
for relevant Lock-Out procedure.
Be aware whilst remounting
handrail. The handrail is FALLING HAZARD.
Refer this Section, safety information
heavy and may cause serious for relevant warning.
injury if allowed to fall.
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
2. Always use a safe and secure for relevant warning.
platform.

3. With the aid of another

operative unbolt the handrail
from the walkway.

4. With the aid of another

HR
operative remove the hand-
rails and place in appropriate
position for transport.

5. Place all bolts and fasteners

in a safe place for reuse.
 Shutoff Page 118

7.9 Removing the ladder (L)

Procedure
WARNING
LOCK-OUT MACHINE.
1. Observe all safety warnings. Refer this Section, safety information
for relevant Lock-Out procedure.

Be aware of the ladder whilst FALLING HAZARD.

removal. The ladder is heavy Refer this Section, safety information
for relevant warning.
and may cause serious injury
if alllowed to fall. WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Always use a safe and secure Refer this section, safety information
for relevant warning.
platform.

2. With the help of another

operative unbolt the ladder
hoops and braces and place
them along with the nuts,
bolts and washers on a safe
place for reuse.

3. With the help of another

operative unbolt the ladder
asssembly from the walkway.
L
4. Replace the ladder assembly
assembly in the desired posi-
tion.
 Shutoff Page 119

7.10 Removing the walkway (WW) from

the FM 60

Procedure
WARNING
LOCK-OUT MACHINE.
Refer this Section, safety information
1. Observe all safety warnings. for relevant Lock-Out procedure.

Use suitable lifting equip- FALLING HAZARD.

Refer this Section, safety information
ment for this operation for relevant warning.

WEAR PERSONAL PROTECTIVE

EQUIPMENT.
2. Using a crane secure four Refer this section, safety information
for relevant warning.
chains onto each corner of the
walkway.

3. Unbolt and remove the the

walkway braces and place the
braces and fasteners in a safe
place for reuse.

4. Unbolt the walkway from the

side of the FM 60. WW
5. Using a crane move the walk-
way to the desired position.

6. Lower the crane.

7. Remove the chains.

8. Place the fasteners and compo-

nents in a safe place for reuse.
 Shutoff Page 120

7.11 Disconnecting the pump assembly

from the chains

Procedure
WARNING
LOCK-OUT MACHINE.
1. Observe all safety warnings. Refer this Section, safety information
for relevant Lock-Out procedure.
Use suitable lifting equip-
ment for this operation FALLING HAZARD.
Refer this Section, safety information
for relevant warning.
2. Disconnect the centifrigual WEAR PERSONAL PROTECTIVE
pump inlet hose connecting EQUIPMENT.
to the cyclone tank. Refer this section, safety information
for relevant warning.

3. Remove the cyclone 6 inch

hose assembly.
(REFERENCE: Removing
the Cylone Supply Hose
Section within this Shutoff
Chapter).

4. Using a crane secure the four

chains onto the pump assem-
bly.

5. Disconnect the pump assem-

bly (CP) by removing the
four bolts securing the pump
assembly to the chassis (CH)
assembly.

6. Using a crane move the CP CH

pump assembly to the desi-
red position.

7. Remove the chains.

8. Place the hose assembly

securing bolts and pump as-
sembly bolts in a safe place
for reuse.
 Shutoff Page 121

7.12 Removing the cyclone unit for

transport

Procedure
WARNING
LOCK-OUT MACHINE.
1. Observe all safety warnings. Refer this Section, safety information
for relevant Lock-Out procedure.
Use suitable lifting equip-
ment for this operation FALLING HAZARD.
Refer this Section, safety information
for relevant warning.

WEAR PERSONAL PROTECTIVE

2. Using a crane secure the four EQUIPMENT.
chains onto the two corners Refer this section, safety information
for relevant warning.
of the cyclone assembly.

3. Remove the bolts and faste-

ners securing the cyclone
assembly
to the chassis.

4. Raise the crane to remove

the cyclone assembly.
Place the cyclone in the desi-
red position for transport.

5. Lower the crane.

6. Remove the chains.

 Shutoff Page 122

7.13 Refitting the dewatering screen

anti-rock stays

Procedure
WARNING
LOCK-OUT MACHINE.
Refer this Section, Safety information for
relevant Lock-Out procedure.

FALLING HAZARD.
Refer this Section, Safety information for
relevant warning.
1. Observe all safety warnings.
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
for relevant warning.

2. Refit bolts (A) and anti-rock

stays (B).
BACK A

FRONT
 Shutoff Page 123

7.14 Removing the FM 60

Procedure
WARNING
1. Observe all safety warnings.
LOCK-OUT MACHINE.
Refer this Section, safety information
for relevant Lock-Out procedure.
Use suitable lifting equip-
ment for this operation FALLING HAZARD.
Refer this Section, safety information
for relevant warning.

2. USing a crane, attach four WEAR PERSONAL PROTECTIVE

chains to each of the four EQUIPMENT.
Refer this section, safety information
lifting points on the FM 60. for relevant warning.

3. Raise the crane to remove

the FM 60 from
it‘s up position.

4. Place the FM 60
in the desired position.

5. Lower the crane.

6. Remove the chians.

7. Place all bolts and fasteners

in a safe place for reuse.
 Shutoff Page 124

7.15 Pump shutdown procedure

This depends ultimately on the system and

process flow requirements but the following
procedure is recommended.

i) Stop the flow of solids into the sump

ii) Run system on water only to wash out
the pump and delivery pipeline.
iii) Shut down the pump.

In cold weather, the pump

and auxiliary equipment
Notice should be drained to prevent
freezing damage.
 Maintenance Page 125

Contents
8.1 Safety information 126
8.2 Regular Servicing 130
8.3 General information 131
8.4 Electrical System 133
8.5 Chassis 134
8.6 Control Systems 134
8.7 Pump lubrication and cooling 135
8.8 Pump wear and replacement of parts 135
8.9 Periodic Maintenance Inspection Dewatering unit 136
8.10 Maintenance Schedules 138
8.11 Greasing Schedule 145
8.12 De-watering Deck Assembly Parts Diagram 146
8.13 De-watering Bottom Deck Assembly 147
8.14 Infeed End Panel Assembly (Where Fitted) 148
8.15 Direct Force Dewatering Screen 149
8.16 Electrical Cable Installation Requirements 150
8.17 Out of balance motor Installation 152
8.18 Dewaterer Screen Cleaning / Removal & Fitting of bearings 154
8.19 Dewaterer : Special Instruction for Twin Vibartor Application 155
8.20 Out of Balance Maintenance 156
8.21 Foot Mounted Isolation Springs Assembly 157
8.22 Grade 8.8 Bolt Torque Values 159
8.23 Flat Bottom Classifier Maintenance 160
8.24 Hydrocyclone Maintenance 161
 Maintenance Page 126

8.1 Safety information

ENTANGLEMENT
WARNING
HAZARD
Feet or any other part of the body
can get caught under support legs.

Always wear correctly fitting

(E.N./A.N.S.I. approved) protective
clothing.

Protective clothing includes Hard

Hat, Safety Glasses, Ear Protection,
Close Fitting Overalls, Steel Toed
Boots, Gloves and a High Visibility
Vest.

PERSONAL PROTECTIVE
WARNING EQUIPMENT
Loose or baggy clothing can get
caught in running machinery.
ALWAYS wear correctly fitting
(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment
includes Hard Hat, Safety Glasses,
Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel
Toed Boots, Industrial Gloves and
High Visibility Vest.
 Maintenance Page 127

SKIN INJECTION HAZARD

DANGER

Hydraulic fluid under pressure can

penetrate the skin causing serious
injury.
ALWAYS relieve the pressure from
the hydraulic system before
carrying out any kind of
maintenance or adjustment.
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. Get medical help immediately.

ENTANGLEMENT HAZARD
WARNING

In-running nip points can cause

serious injury or even death.
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and
amputated.

SWITCH OFF, LOCKOUT & TAGOUT

machine before opening or
removing guards.
 Maintenance Page 128

FALLING HAZARD
DANGER

Falling from and/or onto a

Terex machine can cause
serious injury or even death.
DO NOT climb onto the machine
whilst in operation.
ALWAYS use the walkways/platforms
provided or a safe and secure platform
approved by the local regional safety
enforcing authority. ALWAYS use an E.N./
A.N.S.I. approved safety harness when
reaching any points 6ft 6ins (2m) or more
above groundlevel.

SWITCHOFF TAGOUT AND

LOCKOUT PROCEDURE
WARNING
When carrying out maintenance or
adjustment to the plant the
following procedure must be
followed.
1. Switch off engine.
2. Remove the ignition key.
3. Keep the ignition key on person
during
lockout.
4. Place appropriate maintenance
warning signs (ie. ‘TAG OUT’).
5. NEVER work alone.
 Maintenance Page 129

HEARING HAZARD

May cause loss or degradation

WARNING of hearing over a period of time.

Wear proper hearing personal

protection equipment.

903

Read and understand

operator’s manual and all
safety signs before using or
WARNING maintaining machine.

If you do not understand the

information in the manuals
consult your supervisor, the
owner, or the manufacturer.

316
 Maintenance Page 130

8.2 Regular Servicing

Refer to Safety section for relevant safety information before attempting to carry out any
maintenance on the machine.
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.
Before undertaking any maintenance, repairs or retooling work on the machine,
switch off the machine and implement the lockout and tagout procedure.
To deliver the specified quantity of grease to bearings, ascertain the amount
WARNING the grease gun delivers 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 the grease gun.
It is bad practice to mix oils or greases. The blend can have a lower specifica-
tion than the individual oils or greases and can lead to premature bearing fail-
ure. USE ONE BRAND ONLY.
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.
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
 Maintenance Page 131

8.3 General information

When performing maintenance, The machine has been designed to

always observe rules provided in facilitate easy routine maintenance
the safety section. without the removal of any fixed
guards.
Breakdown caused by insufficient
or improper maintenance will cau- All greasing points can be ac-
se high repair costs and long term cessed from the ground level or
standstill. Therefore, regular main- any walkways provided and all belt
tenance is imperative. adjustments can be made without
removing any protective guards.
In addition to several other factors,
the reliability and life of the Ma- If it is necessary to remove any
chine depends on regular and pro- guard doors, all are fitted with
per maintenance. captive nuts and bolts to ensure
that they are replaced before the
The following section contains machine is restarted.
maintenance instructions as well as
maintenance schedules for normal
operating conditions.

When the Machine is opera-

Notice
ted in extreme climatic con-
ditions (e.g. below -5°C or
above 33°C) or in very dusty
conditions for a long period
of time, the maintenance sche-
dules will change.
Ask your local Terex dealer or
Terex Technical Department
for advice.
 Maintenance Page 132

PRACTICE SAFE MAINTENANCE.

Understand service procedure before

doing work. Keep area clean and dry.

Never lubricate, clean, service or

adjust machine 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 lockout procedure.
Allow machine to cool.

Securely support any machine

elements that must be raised for
service work.

Keep all parts in good condition and

properly installed.
Fix damage immediately. Replace
worn or broken parts.

Remove any build up of grease, oil or

debris.
Disconnect battery ground cable
(-) before making adjustments on
electrical systems or welding on
machine.
 Maintenance Page 133

8.4 Electrical System

WARNING
Work on the electrical system
or equipment may only be
carried out by a skilled elec-
trician himself or by specially
instructed personnel under
the control and supervision of
a skilled electrician and in ac-
cordance with the applicable
electrical engineering rules.

WARNING
lf provided for in the regu-
lations, the power supply to
parts of machines and plants,
on which inspection, mainte-
nance and repair work is to be
carried out must be cut off.
Before starting any work,
check the de-energized parts
for the presence of power and
ground or short-circuit them
in addition to insulating adja-
cent live parts and elements.
Cut off any electrical supply
to the machine before any
inspection, maintenance or
repair work is carried out.
 Maintenance Page 134

8.5 Chassis

Check that all bolts and pins are in

place and are secure. WARNING
WEAR PERSONAL PROTECTIVE
EQUIPMENT.
Refer this section, safety information
for relevant warning.

8.6 Control Systems

Ensure that only qualified and trained
ersonnel operate and maintain this equip-
ment.
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 authorization from Terex.
 Maintenance Page 135

8.7 Pump lubrication and cooling

The bearings are grease lubricated and additional grease needs to be added about two grease
gun strokes or 3 grams per week. Do not over grease the bearings. The bearing assemblies
are all test run in the factory to prove that they are correctly assembled and satisfactory. The
bearings are designed to run at high temperatures, maximum 120 degrees, and the grease
has to be compatible with this operating condition. Clean grease must be used. If water gets
into the bearings, the assembly must be stripped, thoroughly dried and regreased, and any seal
failure corrected.
The range of pump 111r pumps are designed to be air cooled and for operation is still air con-
dition up to 37 degrees.

8.8 Pump wear and replacement of parts

To obtain the best service and performance from the pump periodic routine inspections should
be carried out and the pump has been particularly designed for this purpose. It is not possible
to state at what intervals these inspections should be made because the rate of wear varies
onsiderably from one application to the next. However, it is suggested that in the first place
the pump be allowed to run for a period of say, three months, and an examination of the pump
will then give some idea of the length of life which may be expected from the rubber covered
parts.
 Maintenance Page 136

8.9 Periodic Maintenance Inspec-

tion Dewatering unit

PERIODIC MAINTENANCE b. That material is conveying evenly. Refer to

INSPECTIONS SHOULD BE the “Trouble Shooting Guide“ in this
PERFORMED ON THE UNIT TO HELP manual for possible causes if the material is
ENSURE PEAK PERFORMANCE and not conveying properly.
HELP PREVENT PREMATURE DOWN c. Material build-up/obstructions in or around
TIME. Listed below are the inspection items the unit.
to be performed on a periodic basis. d. In the event of material build-up all excess
The periodices stated below are of a general material must
nature and are intended for guidance only, it be cleared in order for the unit to function
is the responsibility of the individual site correctly.
maintenance department to determine the e. Check reading of power absorbsion by the
timings of service items as dictated by the motor is within limits.
actual working environment of each piece of
equipment. During the “Walk Around“ listen for
UNUSUAL noises. The unusual noise can be
1. CHECK STROKE OF UNIT caused by; Broken or loose bolts, broken
The stroke of the unit is a key performance springs or loose bolts or insufficient interface
indicator. Being above or below the design clear-ance with other equipment. Refer to the
stroke will result in an unsatisfactory “Trouble Shooting Guide“ for additional
conveying speed of the product being Possible Causes of noise.
handled.
Stroking above the design stroke will damage Please Note: To achieve proper torque values,
the unit; Stroking below the design stroke before tightening loose bolts, check bolts
will result in a low conveying speed and in for thread damage, replace bolt if damage has
some cases may cause damage to the unit. occured. Refer to Torque table within this
manual for values.
2. DAILY WALKAROUND
During the “Walk Around“, visually inspect
the entire unit, also listen for unusual sounds.
Visually look for the following:

a. That all Safety Devices are in position and

operable. Caution and Warning Stickers are
in place and in clear view.
 Maintenance Page 137

8.9 Periodic Maintenance Inspection De-

watering unit (Continued)

3. WEEKLY MAINTENANCE CHECKS

A) Carry out daily walk round

B) Check integrity of structures and overall unit
construction
C) Check motor is not over heating
D) Check bearings are not over heating
E) Check the integrity of the drive system,
including security and cabling

4. MONTHLY MAINTENANCE CHECKS

A) Carry out weekly maintenance check

B) Check the torque of all main bolts and
fastners

5. ANNUAL MAINTENANCE CHECKS

A) Carry out monthly maintenance check

B) Visually inspect unit body and construction
including:-welding
C) Review spares usage and stock holding

6. FASTNER TIGHTNESS

Check all fastners are tightened to the correct

torque value.

7. LUBRICATION

Items requiring lubrication should be lubricated

at the required frequency with the
correct amount of grease of the appropriate
specification.
 Maintenance Page 138

8.10 Maintenance Schedules

Periodic maintenance inspections must be performed on the machine to help ensure peak
performance and prevent premature down time. This section gives lists of recommended items
to be checked on a periodic basis. When the machine is operated in extreme conditions (for
example below —5°C or above 30°C) or in dusty conditions for a long time, the maintenance
schedules change.
The time periods stated in this section are of a general nature and are intended for guidance
only. It is the responsibility of the individual site maintenance department to determine the
timings of service items as dictated by the actual working environment of each piece of equip-
ment.
Failure to carry out scheduled maintenance or exercise due care invalidates any warranty that
applies.
Ask your local Terex dealer or Terex technical department for advice.

8.10.1 Daily or 10 Hour Maintenance Schedules

Component Object Job Remarks Sign

General Guards Check/replace
Pipelines/Hoses- Check/replace Check hoses and
/Leaks wear areas for
leaks
Bolts and pins Check/fasten/
replace
Moving parts Material build- Remove
up
Moving free Check/ensure
Screen unit Material build- Remove
up
Screen meshes, Check/replace
wear
All Water leaks Repair/replace
components
 Maintenance Page 139

8.10.2 Weekly or 50 Hour Maintenance Schedules (Machine Stopped)

Component Object Job Remarks Sign

Carry out daily
or 10 hour
maintenance
schedule
Slurry Pump Slurry Pump Grease
Bearings
FM 60 Hydro Maintenance
Classifier Water Filter Clean

8.10.3 100 Hour Maintenance Schedules (Machine Stopped)

Component Object Job Remarks Sign

Carry out daily
or 10 hour
maintenance
schedule
Carry out weekly
or 50 hour
maintenance
schedule
FM 60 Hydro Maintenance
Classifier Nozzles Check for wear /
even spray
pattern
Valve Liners Check
 Maintenance Page 140

8.10.4 500 Hour Maintenance Schedules (Machine Stopped)

Component Object Job Remarks Sign

Carry out daily
or 10 hour
maintenance
schedule
Carry out weekly
or 50 hour
maintenance
schedule
Carry out 100
hour
maintenance
schedule
Cyclone Cyclone wear Check
Pump Pump Wear Check
Slurry Pump Pump V-belt Check/ Adjust
Tolerance
Impeller Check/ Adjust
Clearance
Gland Check/ Adjust
Performance
Sump Tank Sump Tank Inspect/ Clean
Protection Plates Inspect
and Rubbers
Float Operation Inspect
FM 60 Hydro Maintenance
Separator Wear Liners Inspect
 Maintenance Page 141

8.10.5 1000 Hour Maintenance Schedules (Machine Stopped)

Component Object Job Remarks Sign

Carry out daily
or 10 hour
maintenance
schedule
Carry out weekly
or 50 hour
maintenance
schedule
Carry out 100
hour
maintenance
schedule
Carry out 500
hour
maintenance
schedule

8.10.6 2000 Hour Maintenance Schedules (Machine Stopped)

Component Object Job Remarks Sign

Carry out daily
or 10 hour
maintenance
schedule
Carry out weekly
or 50 hour
maintenance
schedule
Carry out 100
hour
maintenance
schedule
Carry out 500
hour
maintenance
schedule
Carry out
1000 hour
maintenance
schedule
 Maintenance Page 142

8.10.5 Dewatering Screen Maintenance Checks

Maintenance Daily Weekly Fort- Monthly Checked Action Action

check list for nightly Required taken
dewatering NO YES
screen
Inspect the Y
out of balance
weights for
misalignment.
Inspect the Y
weights for
seating on the
shafts, no move-
ment at all must
be allowed.
Check that the Y
mechanical studs
are tight and
locked. Retorque
every 3 months.
Check the bridge Y
for cracks or
damage.

Check the out- Y

side of the side
plates for any
loose bolts or
nuts.
Check side plates Y
for damage or
cracks.

Where possible Y
check that
beams, stringers
and cleats are
tight. Checks for
cracks or dam-
age.
 Maintenance Page 143

Maintenance Daily Weekly Fort- Monthly Checked Action Action

check list for nightly Required taken
dewatering NO YES
screen
Check Y
suspension
buffers or
springs for
defects.
Clean area Y
around
buffers/springs.
Check that Y
the discharge
lip is in good
condition and
check for loose
bolts.
Check that the Y
back plate bolts
are tight.

Check back Y
plate for
damage and
cracks.
Do a general Y
crack for any
loose rubber on
the screen.
Do a general
check for any
loose panels on
the screen.
Ensure that all guards are replaced and secured. Start the machine.
 Maintenance Page 144

Maintenance Daily Weekly Fort- Monthly Checked Action Action

check list for nightly Required taken
dewatering NO YES
screen
Check that the Y
screen is not
bumping or
touching any
static items
while starting,
running, or
shutting down.
Listen for any Y
extra-ordinary
sounds on the
vibrator motors.
Listen for any Y
noises on
the screen
indicating loose
parts.
Listen for any Y
loose item
noises on the
whole screen.
Listen for any Y
loose bolts on
the vibrator
motor guards.
 Maintenance Page 145

8.11 Greasing Schedule

It is important that a strict routine of regular servicing is undertaken from the start of opera-
tion of the machine. Regular checks on the lubrication of the machine in accordance with the
schedule is essential.
It is to be noted that when greasing, the grease is not too quickly pushed in, as otherwise the
seals could be damaged.
Clean the grease nipples before use.
Make sure that the grease is getting through.

LOCATION FREQUENCY CAPACITY RECOMMENDED

(Hours) (grams) GREASE
Dewatering screen 4800 26 Esso Unirex N3 — If
8x4 screen (50Hz) mixing grease is
Dewatering screen 4100 26 unavoidable use only
8x4 screen (50Hz) Lithium complex
alternatives of
consistency 3
Slurry Pump 50 3 Shell Alvania 3/Mobil
EP2/Caltex LS3

Each grease gun will put out a differing amount per stroke. Check greasing equipment before
use
 Maintenance Page 146

8.12 De-watering Deck Assembly Parts Diagram

PART DESCRIPTION

1 DECK
2 CENTRAL DIVIDER
3 BOLT, WASHER AND SPRING WASHER ASSEMBLY
4 BOLT, WASHER AND SPRING LOCKNUT ASSEMBLY
5 BACK PLATE
6 RUBBER DISCHARGE PLATE
7 BRACE RETAINING ANGLE
8 BRACE
9 BOLT, WASHER, PLAIN NUT AND LOCK NUT ASSEMBLY
10 NUT, COUNTERSUNK, HEADSCREW AND
WASHER ASSEMBLY
11 SIDE LINER
12 BOLT AND WASHER ASSEMBLY
13 SILICON SEAL
 Maintenance Page 147

8.13 De-watering Bottom Deck

Assembly

LOCKOUT electric power to the 8. Replace the rubber discharge plate (6)
equipment, read ALL Safety Notes be- and bolt into position with the bolt as-
fore semblies (12), silicone between mating
operating the unit and before performing surfaces.
any maintenance.
9. Fit ferrules into the centre hole of grids
1. Trough must be empty. before replacing the central divider (2).

2. Remove the bolt assemblies (3) from 10. Fit central divider (2) as shown
the central divider (2). Remove the bolt above, ensuring the bolts (3) & (4) are
assemblies (4) from the back of the unit (5). replaced. Fit braces (8) to brace retaining
Remove bolt assembly (9) from brace (8) channels (7) with bolts (9) and silicone
and brace refering channel (7) then remove seal around the edges of the divider.
central divider (2).
11. Tighten the Self Locking Nuts as per
3. Remove bolt assemblies (12) from the the Torque Chart in this manual.
rubber discharge plate (6), then remove the
rubber discharge plate. 12. Retighten the locknuts after short run

4. Remove countersunk screw assemblies

(10) from the side liner (11) then remove
liners (11) .

5. Remove the bolt assemblies (12) and

remove grids (1).

TO FIT NEW POLYPROPELENE

DECKS:

6. Replace grids (1) and bolt assemblies

(12) silicon seal between each grid (13) as
it is fitted and around the sides of the deck,
once all the grids are in position.

7. Replace side liners (11) and bolt into

position with the bolt assemblies (10) and
silicon seal between the grids and side lin-
ers.
 Maintenance Page 148

8.14 Infeed End Panel Assembly (Where Fitted)

INFEED END PANEL REPLACE-

MENT:

LOCKOUT electric power to the equip-

ment, read ALL Safety Notes before oper-
ating the unit and before performing any
maintenance.

1. Pan trough must be empty.

2. Remove the bolt assemblies (1), then
remove infeed end grid (2) and clamp (3).
3. Replace infeed and grid (2) into the
clamp (3), silicon sealing around the edges.
4. Fit infeed end grid (2) and clamp (3)
assembly to the unit and bolt into position
with a bolt assembly (1).
5. Silicon seal between the clamp and the
unit.
6. Tighten the Self Locking Nuts as per the
Torque Chart in this manual.
7. Retighten the locknuts after short run in
period.
 Maintenance Page 149

8.15 Direct Force Dewatering Screen

PART DESCRIPTION
1 Trough
2 Feed end isolation spring
3 Discharge end isolation spring
4 Rubber discharge Plate
5 Drive motors
6 Wedgewire back plate (Where fitted)
 Maintenance Page 150

8.16 Electrical Cable Installation Requirements

 Maintenance Page 151

8.16 Electrical Cable Installations

Requirements (continued)

CAUTION!
LOCKOUT electric power to the equip- 5. PLEASE NOTE Before welding on
ment, this unit, or its support structure. Discon-
read ALL Safety Notes before operating nect all electrical cables to prevent earthing
the unit and before performing any mainte- through the motor cable.
nance. Make periodic checks of ALL electri-
cal cables to ensure that the cables remain
free hanging from the conveyor Electrical
Device to the Stationary Junction Box.
Check for wear and damage. Ground wire
must be securely and properly fastened.

1. Electrical Devices must be installed and

wired per the instructions on the General
Arrangement Drawings or in this manual.
(Some installation and wiring instructions
maybe vendor supplied).

2. Be sure that the Electrical Cable is

connected for the correct voltage and that
the ground wires are corrctly fastened.

3. The Electrical Device is to be wired to a

Stationary Box located off of the Vibrating
Equipment. See illustration on previous
page.

4. Loop the cable allowing enough slack

for the full movement of the Vibrating
Equipment. The Electrical Cable MUST
NOT at any time come in contact with the
vibrating equipment, stationary steel and
any surface or damage to the cable will
occur. A damaged cable can cause fatal
electrical shock to personnel and damage to
the Electrical Device. PLEASE NOTE On
completion of the wiring operation within
the vibratory motor junction box, the
box should be filled with electrical putty
BICC 562.
 Maintenance Page 152

8.17 Out of balance motor Installation

LOCKOUT electric power to the equipment, read ALL Safety Notes before operating
the unit and before performing any maintenance.

GENERAL

The out of balance motor is thoroughly inspected and tested before leaving and every care
is taken to ensure safe transit to destination. Damage may, however, occur after des-patch
and the motor should be inspected upon receipt and the shaft rotated. Any defects should be
reported immediately A motor not for immediate use should be stored in a dry temperate
atmosphere, free from vibration and protected from dirt. Under these conditions the motor
may be stored for up to two years renew grease after long storage.

INSTALLATION

1. Ensure shaft rotates freely. Check insulation resistance with a“Megger“. Resistance
should not be less than 1 megohm.
2. If the machine has become damp and the insulation resistance is lost, it must be throughly
dried out before commissioning. Recommended drying methods are: stoving in an oven,
heaters around the machine, low voltage current through the windings.
3. The motor is supplied with the out of balance weights or VF unit set to give the antip-ated
unit performance. Ensure that the motor is not overloaded electrically.
4. The maximum ambient temperature at which the motor can be used is 40 degrees.

OUT OF BALANCE ADJUSTMENT

1. The out of balance weights can be

reduced or increased. Also variation to the VF
unit can be made up to a limit but the motor
should not operate at more than the specified
full load current as given on the motor rating
plate. The unit must be operated at high-er
strokes than those recommended.
 Maintenance Page 153

8.17 Out of balance motor Installation

(Continued)

2. When adjusting O/B weights slacken screw in inner weightonly. Adjust inner weight to
required force on percentage scale and retighten screw. Adjust opposite end to the same per-
centage. IT IS IMPORTANT THAT BOTH ENDS ARE THE SAME AND IN LINE - Clamp-
ingscrews MUST always be on the same side of the vibrator. Tighten clamping screws in
accordance with the Torque chart contained in this manual.

3. PLEASE NOTE Flexible cable and a gland should be used from the electrical supply to
the motor.

Installation Guidance Notes:

Mechanical: Inspect vibrator for any physical damage and check that rotor shaft rotates freely.
Remove paint masking stickers from motor mounting holes. All mounting surfaces MUST
be flat and be free of paint, dirt and scale. Fixing bolts should be tightened as recommended
below and tightness checked after initially running the vibrator. Bolts and nuts should not be
reused. Please ensure there is at least 50 mm of clearance between the vibrator and any sur-
rounding static structure.

IMPORTANT - GAPS BETWEEN THE VIBRATOR FOOT AND MATING SURFACES

AND INCORRECT BOLT TIGHTNESS WILL CAUSE BOLT BREAKAGE AND DAMAGE
TO THE VIBRATOR.

BLz 03 -80: Use Grade 8.8 bolts with Grade 8 self locking nuts, torqued to values below. Fig-
ures below apply to lightly oiled threads. Where capscrews are used with locking nuts, Grade
10 nuts must be fitted.
Use plain washers for BLz 03-BLz24. (Not BLz22)

Size Torque (Nm) Size Torque (Nm)

Cap-Screws Setscrews/ Cap-Screws Setscrews/
Bolts Bolts
M5 8 - M 16 310 242
M6 15 11 M 20 580 473
M8 34 27 M 24 950 818
M 10 68 56 M 30 - 1634*
M 12 127 96 M 36 - 2854*
* a torque multiplier is required.
 Maintenance Page 154

8.18 Dewaterer Screen Cleaning /

Removal & Fitting of bearings

1. The stator windings can be cleaned when 7. The race should be pushed into place and
the machine is dismantled, by blowing out held against the shaft shoulder until it
with dry compressed air or hand bellows. contracts sufficiently to grip the shaft.
8. Place the rotor carefully inside the stator
2. Oily deposits on the winding may be bore, sealing bearing housing/stator
removed by a light application of unleaded frame
petrol or white spirit. joint with PBC compound and fit bearing
housings, caps, weights and end co-
3. Before reassembly, the stator windings vers.
should be examined for damaged insulation 9. Use Loctite 221 when refitting bearing
and, if, given a coat of air drying shellac housing and bearing cap fixing screws.
varnish either by brush or spray. 10. Check that the rotor shaft has some end
float.
REMOVAL & FITTING OF BEARINGS

1. Bearings should only be removed when

absolutely necessary.

2. Extractor tools should be used to remove

the outer race, cage and rollers from the
bearing housing and the inner race from the
rotor shaft.

3. If the same bearings are to be used again,

wash them thoroughly in a mixture of petrol
and light machine oil.

4. Replacement bearings must have special

features recommended, contact Terex.

5. When re-fitting bearings, smear inside

recess in housing with grease, lightly pack the
outer race and rollers with grease, forcing
some well into the working parts. Re-fit into
the housing using either a small press or a soft
metal drift and hammer.
6. The inner race of the bearing should be
placed in a bath of clean mineral oil,
heated to a temperature of 80 degrees.
 Maintenance Page 155

8.19 Dewaterer : Special Instruction for Twin Vibartor Application

 Maintenance Page 156

OVERHAUL

8.20 Out of Balance Maintenance Motors should occasionally be completely

stripped and thoroughly cleaned and examined.
LOCKOUT electric power to the equipment, This should be done at the discretion of an
read ALL Safety Notes before operating the experienced maintenance engineer, preferably
unit and before performing any maintenance. at a time when bearing attention or re-lubrica-
tion is necessary.
GENERAL PLEASE NOTE: Where a single out of
balance motor is serviced or over hauled on a
The motor should be kept as clean as possible. conveyor fitted with two of balance motors the
All connections should be adequately cleated motor that has been serviced or over-
and secure. hauled must be run for 1 hour at zero weight,
The terminal base should be adequately cleated prior to being brought back into use.
and secure. The terminal base should be kept
clean in order to prevent tracking. Ensure that
the resilient mounting is secure.

All fixing bolts must be tight and it is

recommended that these be re-tightened
after initially running the motor.
Before running the motor, check that the
eccentric weights are at the correct setting and
that weight claming screws are tight.
During periodic maintenance checks, ensure that
the weights have not slipped from their correct
setting and that the clamping screws are still
tight. See that the end covers are undamaged
and do not foul the rotating weights.
 Maintenance Page 157

8.21 Foot Mounted Isolation Springs Assembly

PART DESCRIPTION PART DESCRIPTION

1 SPRING BRACKET 6 HARDENED STEEL WASHER
2 UPPER SPRING SEAT 7 SELF LOCKING NUT

3 SPRING RETAINER OF SPRING 8 SUPPORT STEEL

SEAT
4 ISOLATION SPRING 9 SHIMS (AS SPECIFIED ON LAY-
OUT DRAWING)
5 SPECIAL HEX HEAD BOLT 10 LOWER SPRING SEAT
 Maintenance Page 158

8.21 Foot Mounted Isolation Springs Assembly (Continued)

REPLACEMENT INSTRUCTIONS

CAUTION
LOCKOUT electric power to the equipment,
read ALL Safety Notes before operating the
unit and before performing any maintenance.

1. Work on one spring at a time.

2. When replacing Spring, raise unit to allow

Spring to clear Spring Retainers, then block
unit securely into position. Install Spring over
Retainer with spring ends ”A”
PERPENDICULAR to FLOW as shown
in insert diagram.

3. Remove blocking and lower unit onto

the Isolation Spring.
 Maintenance Page 159

8.22 Grade 8.8 Bolt Torque Values

Whenever maintenance requires removal of IMPORTANT! Tightening when bolt

high strength bolting, be certain that stand- threads are lubricated.
ard bolts are not substituted. Tighten bolts
using a calibrated torque wrench. When using an Impact Wrench DO NOT
run up nut to the torque value in one op-
All fasteners must be regularly checked to eration cycle of the Impact Wrench. When
ensure tightness to the proper torque value. the threads are lubricated, the nut has less
The following chart offers correct torque resistance and the power of the Impact
values when bolting mild steel to mild steel Wrench will spin the nut faster than when
according to bolt diameter and by turning on dry threads. The faster nut spin speed is
the nut while holding the head of the bolt fast enough to cause a ramming force pow-
with a wrench. If the application demands erful enough to damage the bolt and /or nut.
tightening by the bolt head, increase the
value shown by 20% (multiply by 1.20). Run up nut in separate pulse cycles un-
When bolting cast iron motor feet to mild til contact is made and is snug tight to
steel decrease the value by 20%. the parts being bolted, then tighten to the
Torque Value.

Size Torque (Nm) Size Torque (Nm)

Cap-Screws Setscrews/ Cap-Screws Setscrews/
Bolts Bolts
M5 8 - M 16 310 242
M6 15 11 M 20 580 473
M8 34 27 M 24 950 818
M 10 68 56 M 30 - 1634*
M 12 127 96 M 36 - 2854*
* a torque multiplier is required.
 Maintenance Page 160

8.23 Flat Bottom Classifier Maintenance

Safety Procedures - Rubber Linings

All Flat Bottom Classifiers are rubber lined for abrasion and corrosion protection.

DO NOT WELD OR OXY / ACETYLENE CUT ON OR NEAR THE FBC.

DO NOT USE ANGLE GRINDERS OR CUTTING DISCS ON RUBBER LININGS OR
LINED STEELWORK.

Rubber linings are highly flammable and are easily damaged when subjected to this type of
treatment. Rubber linings burn fiercely and are difficult to extinguish once ignited.

Do not open the control panel during operation.

Do not open the pneumatic control panel during operation.

Check the injection water pressure to the FBC, this should never be more than 2.0 bar at the
water inlet flange.

The FBC should be drained completely in case of frost, the discharge valves need to be left in
the open position.

Maintenance is not possible during operation. This can only be carried out after isolation and
shutdown of the FBC and associated feed pumps and cyclones, as required.

All standard equipment isolation procedures and site safety precautions must be followed to
prevent startup of the pumps and cyclones prior to starting any maintenance.

Do not attempt to lift the classifier if full of slurry or fully sanded up.

Maintenance

Drain the FBC at least once every month and check the nozzles for wear. The spray pattern
should be even.

Clean the water filter weekly.

Check the valve liners monthly.

The internal or wetted area of the FBC uses a lining system of fully cold bonded natural rub-
ber. For relining or repair of the lining, and for all spare parts, please contact Terex.
 Maintenance Page 161

8.24 Hydrocyclone Maintenance

Monitoring the Cyclone for wear is important as damage to the steel housings can occur if the
wear liners are left in service until completely worn through. Terex recommends that an initial
inspection be carried out one month after start up. The initial inspection should not be left for
more than two months. After this initial inspection Terex recommends internal inspections
every two months, until a measure of the rate of wear can be firmly established.
Maintenance of the Cyclone will be limited to monitoring the condition of the wear linings.
This is done by visual inspection, physical measurements, and sample analysis to check on
performance.

8.24.1 Component Replacement

The only maintenance operation on a Cyclone is the replacement of a component when the
liner has worn through.
Components of a Cyclone must only be replaced with genuine rubber components purchased
from Terex. Performance of the Cyclone may be adversely affected by the use on non author-
ized components and any warranty conditions will be invalidated.

8.24.2 Routine Inspection Frequency

The frequency of internal inspection of a Cyclone varies with the wear rate experienced in the
duty. The wear rate in a duty depends on many factors of the feed :–
-Mineral characteristics – hard or abrasive ore, higher wear
-Particle size – large particles, higher wear
-Particle shape and sharpness – flat, sharp particles, higher wear
-Feed pressure – higher pressure, higher wear (square law)
-Feed slurry % solids – high % solids, higher wear.
Terex recommends internal inspections every two months, until a measure of the rate of wear
can be firmly established.
 Maintenance Page 162

8.24.3 Component Wear Life

Wear rate inside a Cyclone varies for different components within the unit and application
conditions. Experience has shown that the ratio of wear life of the components is approxi-
mately:
Component Life Ratio
Overflow Pipe/ Elbow 8
Feed Box 6
Vortex Finder 4
Upper Cone 3
Lower Cone 2
Spigot 1

So for example, if the spigot lasts three months, the feed box is likely to last approximately
twelve months. Whilst this is not exact, and cannot be guaranteed, it is a good general guide-
line.

8.24.4 Safety Procedures

For individual Cyclone maintenance, safety precautions must be taken to ensure that the Cy-
clone is isolated from process flow.

8.24.5 Cyclone Disassembly Procedure

1) Isolate the Cyclone from slurry feed. Note the previously mentioned safety precautions to
avoid personal injury.
2) Refer to the Cyclone assembly drawing for part descriptions. Use the listed part numbers for
re-ordering purposes.
3) Assess the extent of disassembly required to replace the affected component(s), if necessary
remove the Cyclone from the structure to a safe working position for full dismantling.
4) Thoroughly clean the Cyclone. A pressure washer is ideal for this purpose (Care must be
taken not to damage the rubber liners with the high pressure water jet).
5) Any components replaced should be refitted ensuring the correct seating/ positioning of
sealing flanges.
Reassembly of the Cyclone is essentially the reverse of the above disassembly procedure. Some
important items to note are listed below.
 Maintenance Page 163

1. On all bolt assemblies Terex recommend an anti seize lubricant be applied prior to torquing
bolts. Terex recommend Rocol J166 Anti Seize or equivalent.
2. Bolt tightening torques used are:

M10 - 55Nm for all M10 bolts used in the assembly.

M12 - 55Nm for all M12 bolts used in the assembly.
M16 - 75Nm for inlet flange to Cyclone.
M16 – 75Nm for overflow to vortex finder.

8.24.6 Routine Inspection

An inspection of a Cyclone should include:

Before Shutdown – External Check

Visual check of exterior for leaks.
Check that feed pressure gauge is operational, and that the reading is not fluctuating
widely.
While Offline
Check that the Cyclone is isolated, and is not being fed.
Unbolt Spigot. Shine torch up Cyclone to visually check for wear.
Unbolt Overflow pipe and remove vortex finder to visually check for wear.
Measurements
During inspection the internal diameter of the vortex finder and spigot should be
measured and compared with the size fitted initially, as specified on the assembly
drawings.
 Maintenance Page 164

8.24.7 Cyclone Lining Replacement

The Cyclone components have cold bonded rubber liners. Terex recommend that these com-
ponents be replaced when they reach approximately 20% of their original installed thickness.
When a liner becomes too thin the force applied to its surface by the moving slurry may distort
it. This disturbs the slurry flow path and adversely affects Cyclone performance.

Cyclone Lining Thicknesses

Item Original Lining Replace At
(mm) (mm)
Feed Box 10 2
Conical Section 10 2

The internal diameter of the vortex finder and spigot are selected to match the specified duty
cut point, by controlling the volumetric flow rates of the overflow and underflow flow streams.
The ratio of spigot to vortex finder diameters is also important to maintain the design classi-
fication cut point within acceptable limits. When these items wear, resulting in an increase in
internal diameter, this affects the performance of the Cyclone.
To determine when a spigot and/or vortex finder requires replacement is best done by size
analysis of overflow or underflow flow stream samples, to determine if the sample is within
acceptable limits. The size analysis will also show if valuable product is mis-reporting, being
recirculated or being lost to waste.
Terex recommend that when the spigot and vortex finder wear, the increase in internal diam-
eter from that originally fitted be limited to between 5% and 8%. Recommended replacement
diameters.
Wear of rubber liners can have detrimental effects on the hydraulic flow characteristics of the
Cyclone. However, replacement of one worn item may not give the expected change in Cy-
clone performance. The cause of this is usually that a new lining has been paired with a well
worn lining, producing a ‘step’ in the lining which disrupts the slurry flow path. Such steps in
the direction of flow cause eddy currents which can cause accelerated localised wear and mis-
reporting of solids. This must be borne in mind when planning maintenance of these items.
 Troubleshooting Page 165

Contents
9.1 Hydrocyclone faults actions 166
9.2 Fault analysis 168
9.3 Trouble Shooting Guide for Vibratory Motors 184
9.4 Troubleshooting Guide for Direct Force Unit 186
 Troubleshooting Page 166

9.1 Hydrocyclone faults actions

FAULT ACTION
Underflow contains excess water content Fit smaller spigot

Underflow condition is in the form of a rope 1. Reduce solids content of feed

and oversize solids are present in overflow.
2. Fit larger spigot
Rate of flow too low Increase inlet pressure

Rate of flow too high Reduce inlet pressure

Cut too fine 1. Fit larger vortex finder and/or

2. Reduce inlet pressure
3. Increase solids content of feed.
Cut too coarse 1. Fit smaller vortex finder and/or
2. Increase inlet pressure
3. Reduce solids content of feed
 Troubleshooting Page 167

FAULT ACTION
Discharge regulator fails to close when han- Check negative pressure at overflow from
dling water only. Cyclone. If below 0.25 bars (8’) close valve in
line to water transfer system. If pressure still
below 0.25 bars (8’) check for leaks in line
to water transfer system or for fracture in
diaphragm.
Discharge regulator blocks with sand and/or The Cyclone is overloaded and the feed must
sand lost in overflow. be reduced.
Collecting box fails to operate. Check that collecting box swings freely and
evenly by hand. Remove any cause of stiff-
ness.
Check for air leaks as in (1) above.
Adjust length of connecting rod if required.
Discharge from regulator too dry, causing Slightly increase opening of valve in line to
sand to block swivel box. water transfer system.
Water continues to flush from discharge Inspect lining of Cyclone parts for wear or
regulator with loss of vacuum. damage and replace as required.
 Troubleshooting Page 168

9.2 Fault analysis

9.2.1 No Discharge When Pump Runs

When using this procedure ensure that you

THE PUMP MUST NOT BE ALLOWED do not damage the motor starter nor burn
TO RUN IF IT DOES NOT DISCHARGE. out the motor itself by trying too many
If by mischance the pump has been allowed starts in a short period of time. The number
to run for more than a few minutes without of permissible attempts will vary with the
discharge then STOP IT AT ONCE. equipment installed but usually it is safe to
try one start every three to four minutes.
TAKE EXTREME CARE IN
DISMANTLING AFTER SUCH AN OC-
CURENCE DUE TO HIGH TEMPERA-
TURE AND PRESSURE WHICH MAY
BE PRESENT IN THE PUMP CASING.
DO NOT REMOVE THE DRAIN PLUG
UNTIL THE FLUID TEMPERATURE IN
THE PUMP HAS DROPPED.

Air Lock
The commonest cause of failure of a newly
installed pump to discharge when run for
the first time is an air lock in the casing.
Even when a pump is well below water
level, (drawing from a Feed Regulating
Sump for instance), it may retain a large
bubble inside the casing which prevents
the start of pumping. This phenomenon is
far more likely with horizontal undershot
discharge branch arrangements than any
other practical configuration. It is least like-
ly with horizontal overshot arrangements.

If you suspect air lock as the cause of fai-

lure to pump, start and stop pump several
times to drive the air out, a fraction of time.
 Troubleshooting Page 169

9.2 Fault analysis

9.2.1 No Discharge When Pump Runs
(Continued)

Installation Faults

Failure to discharge on start-up can be

caused by installation faults of which the
commonest is inadequate sump capacity.
The result of installing a sump with inade-
quate capacity is to risk repeated air locks
of the pump. This can happen when the
pump reduces the water level, either allo-
wing a vortex to form - which air locks the
pump - or (when water is introduced to the
sump) it entrains so much air that it produ-
ces the same effect.
A small sump can easily prevent any
discharge reaching the end of the pump
discharge line. The only remedy is to ex-
tend the sump capacity. We recommend
sumps of at least one minute‘s pumping
time as a bare minimum. (This recommen-
dation does not apply to feed regulating
sumps in sand plants where greater capaci-
ty is required).
 Troubleshooting Page 170

9.2.2 Brief Discharge only

Air Lock Lack of Delivery Resistance

A pump with a suction lift and partial air A pump which is required to pump with a
lock will often start to pump at a greatly suction lift or with a fair length of suction
reduced rate after each start, then give up pipe, but with practically no resistance on
altogether. the delivery side, (e.g. short, open-ended,
At the discharge end of the pipe this may discharge branch or nozzel), may pump
appear as a brief surge followed by failure. briefly then fail. The reason for this is that
This problem can only be overcome by centrifugal pumps on open discharge need
closer attention to the printing system. positive pressure on the suction eye to pre-
vent gross cavitation. If the installation does
Obstructed Suction not provide sufficient positive pressure on
If the suction line is obstructed either by the suction side the pump will fail.
tramp material or a delaminated suction Usually, the easiest way to overcome this
hose lining, the pump may start well but difficulty is to artifically create resistance
when the discharge rate rises the suction on the delivery side, by extending the pipe
obstruction so throttles the pump that it work or introducing a valve or other resi-
quickly fails by gross cavitation. stance, such as an orifice.

Detection of this sort of condition is diffi- NOTE:

cult, and generally the only certain way of IF A PUMP FAILS TO PUMP
finding out what is happening is the use of THROUGH
a vacuum guage immediately before the A BLOCKAGE SWITCH OFF IMME-
pump suction. An obstructed suction line DIATELY AND READ THESE FAULT
will be indicated by a sudden increase in FINDING NOTES CAREFULLY
vacuum reading immediately before the TO RECTIFY THE SITUATION.
failure. TAKE EXTREME CARE AS THE
PUMP MAY BE FILLED WITH SCAL-
DING STEAM AND SOLIDS AT A
HIGH PRESSURE.
 Troubleshooting Page 171

9.2.3 Pump Water But Not Solids

Air Leaks on Suction Side Rework of the suction line is the only solu-
Badly made joints in the suction line or tion to this problem. If the line is increased
air entrainment will feed into a sump may in diameter it should be brought to the
be insufficient in themselves, to prevent a pump inlet diameter by a specially rolled
pump from pumping water satisfactorily. flanged tapper pipe. It must not be stepped
However, when solids are introduced-parti- down by a mismatch.
cularly, coarse solids-the pump has a more
arduous duty; it has to entrain the solids Electric Motor Wrongly Wired
into the fast moving stream in the suction Most Squirrel Cage Induction motors can
pipe. In effect it has to“dredge“ the solids be wired in two ways: “Star“ or “Delta“. In
into the stream. Even if the solids were al- order to reduce the surge in current when a
ready moving in the right general direction, motor is brought “on line“, some users start
they must be accelerated up to the water their motors in“Star“ because this mode
velocity and thus they act as a suction resi- gives good startling torque and a reduced
stance for the pump. starting surge, and then change to running
The result of the introduction of solids into their motors in “Delta“ mode of powering
an aerated system, which the pump can the motor increases the speed close to syn-
only marginally handle, when pumping wa- chronous speed - which is maximum - and
ter alone, will cause failure. maintains practically a constant speed under
Air leaks can usually be detected as water variations in load.
leaks when the pump is not running; where If a motor is left to run continuously in
water can get out air can get in. Air en- “Star“ it will vary its speed dramically with
trainment with the feed can sometimes be load. Hence, if a mistake has been made in
overcome by the use of baffles in the sump, the wiring of the motor it may well appear
such that the air bubbles have time to rise that the pump pumps water but will not pick
to the surface before being drawn down to up solids, the reason being that on “Star“
the suction. the motor speed drops when the solids load
comes on.
Poor Suction Line To detect this fault the easiest method is
A long suction line, or a line of too small a to check the speed of the motor shaft and
diameter, or a line with a restriction (sud- compare it with the Naeplate rating. There
den step-downs in diameter are the worst) should not be more than a few RPM diffe-
may allow a pump to appear to handle wa- rence between Nameplate RPM rating and
ter adequately, but not allow it to handle actual speed - no matter what load the pump
solids. The reasons for this are explained in is pulling.
above. Correction of this fault is a matter for an
electrician.
 Troubleshooting Page 172

9.2.4 Overloads for Motor Trip Out

Wrong Pump Speed Changed Pipeline System

The power drawn by a centrifugal pump It is not uncommon for a pump speed to be
discharging through a given delivery system calculated on the basis of a pipeline system
is approximately proportional to the cube intended to be used at the time of the nego-
of its speed. If the speed is changed by, say tiations for the purchase of the pump, but to
20% to 1.2 times the original speed, you can be commissioned into service with a very
expect its power demand to rise by the cube different pipeline system. A client may say
of 1.2, i.e. 1.728, or nearly 73% above the “But, it‘s not such a high lift so the pump
original. Even a rise in speed of 10% to 1.1 does not have to work so hard“. Unfortu-
times the original speed, will give rise of nately, at a given pump speed a pump will
33% in power demanded by the pump. pump a larger gallonage through a shorter
pipeline, (or lesser vertical height), and will
The relationship is not exact but is close take more power - not less.
enough for field calculations purposes. When confronted with this situation, the
If a pump is run at the wrong speed it can only thing to do is to calculate the correct
make a very considerable difference to the Head and RPM and make a pulley change.
load drawn from the motor. The affinity rule can be used or the drive
Calculation of the correct pump speed is recalculated.
based on:

1. Gallonage to be pumped;
2. Difference in height between pump and
discharge points;
3. Length, diameter, and inner surface of
pipeline through which pump must deliver;
4. Number of elbows, bends, valves, other
fittings in pipeline;
5. Equipment at end of pipeline such as hy-
drocyclones, pressurised distributors, jets
etc.;
6. Grading, tonnage, and specific gravity of
solids to be pumped;
7. Pump performance curves.
As far as fault finding is concerned, the ac-
tual RPM of a pump should be compared
with the RPM specified. Corrections to pump
speed can be made by pulley changes.
 Troubleshooting Page 173

9.2.4 Overloads for Motor Trip Out

(Continued)

Low voltage Wrongly Set Overload Protection

The power consumed by an electric motor All motor starting equipment has some
is the product of the voltage, amperage and form of overload protection equipment built
power factor for the motor. Without going into the system so that a burnt out motor or
too deeply into the matter, if a pump de- locked-rotor motor does not cause more ex-
mands a certian power from the motor, the tensive damage. If a motor repeatedly drops
motor in turn will demand a corresponding out on overload, and there is no other readily
amperage from the electric supply system. apparent reason, the electrical overload pro-
If, however, the voltage of the electric supp- tection equipment should be checked.
ly system happens to be lower than normal,
then the motor will draw extra amps to meet Mechanical Fault in Pump
the pump‘s power demand. In this way the The pump shaft should be free to turn by
power consumed by the motor, (the product hand. Remove the Vee-belts and check the
of voltage, amperage and power factor) re- pump shaft for freedom to turn. If there is
mains unchanged. no resistance the fault must be in the motor.
If a jarring or resistance can be felt when
KW = LineV x Line A x 1.732 x PF attempting to turn the pump shaft, drop off
1000 the suction pipe and check the clearance bet-
The sort of circumstances where lower than ween the impeller and suction plate, and for
standard voltages might be encountered are: blockages.
1. At the end of a long trailing cable;
2. At the end of an electric supply system If this proves clear, then remove the suction
remote from the nearest transformer substa- bush and look for marks on the surface of the
tion; impeller which might indicate if the impeller
3. In an area where very heavy start-up has been rubbing. If this proves clear rotate
loads can occur, such as near large crusher the shaft again to ascertain if the resistance
stations or long conveyor is still present and if it is then remove the
installations impeller, and inspect the gland side liner. If
there is still no evidence of rubbing, rotate
the shaft by hand again to check that the resi-
stance is still present, than remove the gland
sleeve. If the resistance can still be felt by
hand it can only be the bearings of the pump.
The remedy for the vaults which may be re-
vealed by this step by step approach are:
 Troubleshooting Page 174

9.2.4 Overloads for Motor Trip Out

(Continued)

1. Impeller rubs on suction bush: release 4. Pump entrains the accumulated solids into
bearing housing, set propeller to suction suction pipeline and begins to pump nor-
bush clearance by adjusting position of bea- mally again, increasing throughput through
ring housing until impeller runs free. Tighten sump.
bearing housing. Replace suction pipe. Re- 5. Air entrainment begins to reach pump
align belt drive. suction again and sequence repeats.
2. Impeller rubs on gland half lining; reset 6. Air entrainment can permently reduce
the suction bush clearance. Check for move- slurry throughput and make it appear as if
ment of casing liner. the pump is not working.
3. Seizure in the gland area. Strip and in-
spect. In small installations this surge may be re-
4. Shaft tight in bearings; There is no simple peated at three minute intervals, and in large
field remedy if the pump shaft is found to be installations it may take as long as five minu-
tight in the bearings, the rotating assembly tes for the full cycle to be completed. If the
must be removed and stripped for inspection cycle terminates at stage (3) the pump may
of the bearings and grease seals. explode, if allowed to run blocked.

Air Entrainment
In sump-fed pump systems air entrainment
with the pump feed can produce periodic
overloads on the motor by the following se-
quence of events:

1. Air entrainment with feed gives the pump

a “spongy“ pulp which reduces the pump
throughput and power.
2. Flow through the sump is reduced allo-
wing air in the feed now entering the sump
to escape to surface. Solids, of course, reach
the pump suction.
3. The pump now has a largely de-aired pulp
of far greater percentage solids than inten-
ded, and the power demand rises. At this sta-
ge the pump may choke. This is a dangerous
condition.
 Troubleshooting Page 175

9.2.5 Pump handles Only A Limited

Percentage

Pump Speed Incorrect Cavitation

With increasing solids feed into a pumping If a pump is expected to draw relatively
system three major factors will limit the coarse solids from a sump below the pump
percentage solids handled: centreline, depending on the speed of the
1. Friction resistance increases leaving less pump and its capacity in relation to the gal-
pressure on the delivery side to maintain lonage being handled, it may suffer from
the velocity in the pipeline; cavitation. When this happens, (and the on-
2. Critical (settling) velocity for the pulp in set is often quite sudden and sharp), the to-
the pipeline increases; tal head generated by the pump diminishes
3. Pump performance “drops“ so that the dramatically. As in above, the conditions
total head generated by the pump diminis- for blocking the line are suddenly created,
hes. namely; reduced delivery pressure for
Clearly if the pump speed has been calcula- maintaining flow combined with increased
ted for water only, then increasing tonnages requirement for velocity in the pipeline.
of solids are fed into the system, the combi- Generally, if cavitation is the source of the
nation of factors (1) & (3) above may soon trouble there is ample evidence: audible
produce a situation where the pipeline velo- cavitation“rattle“ in the pump or from the
city is too low to maintain movement of the bearings, sudden reduction in power de-
solids (factor 2). mand, the gland leaks or draws air, and the-
re is a dramatic drop in delivery pressure.
Air Entrainment The solution to the problem is to make the
When the pump can handle water, but fails suction arrangements as smooth as possible
when solids are introduced to the system, without restrictions, and to arrange for the
due to air entrainment. The same fault can feed to come gradually up to load without
sometimes explain why a pump performs sudden surges of solids. If these measures
apparently satisfactorily on pulp up to a do not overcome the problem it may be ne-
certain percentage solids, then “gives up“ cessary to change the suction line to a size
when this is passed. larger and fit a flat topped taper-piece to the
pump suction. If trouble persists, a larger
Poor Suction Line pump will have to be installed. Something
A suction line layout as described in is far effective must be done as the situation is
worse as the percentage solids is increased potentially dangerous.
and can become completely blocked.
 Troubleshooting Page 176

9.2.6 Gland Will Not Seal Adequately

Inadequate Prime
Poor adjustment The ‘snore‘ condition for operating a pump
is very difficult to seal without unaccep-
Type D and P glands, should be tightened table leakage. Under this condition a pump
for reduction of leakage in the same way continuously receives a good proportion of
as standard packed glands in water pumps. air drawn in with the pulp from the sump,
Over tightening should be avoided, especial- in which the level is too low, or the sump
ly on “D“ glands as a drip is always necessa- has inadequate capacity, or both. The sump
ry to lubricate the rubber face seal. should contain a minimum of one minute‘s
pumping time.
Dry Running
The glands will not be dnmaged by a few
seconds running without lubrication and
cooling by water, but if either gland is run
or any length of time without water in the
pump there is danger of melting the rubber
seals. If a Type D gland has been correctly
adjusted this is a fairly remote danger be-
cause without hydraulic pressure to force the
rubber seal against the gland seat, the seal
should run without touching the seat. Ho-
wever, in general terms, do not run a pump
in dry conditions because of the danger of
damaging the gland seals.
Once seals have been damaged in this way
they have to be replaced.
 Troubleshooting Page 177

9.2.7 Excessive Heat in Drive

Slack Vee-belts Inadequate Lubrication of Pump Bea-

The commonest cause for generation of rings
heat in the drive to a newly installed pump The bearings will be charged with grease
is undoubtedly lack of tension in the Vee- before despatch from the factory. Details of
belts. All Vee-belts should be tensioned lubricants are given in this Manual.
periodically, and newly commissioned Addition of grease should be tried if bea-
drives should be tensioned periodically, rings become very hot or noisy. Excess gre-
and newly commissioned drives should be asing should be avoided.
re-tensioned an hour or so after start up.
This fault is easily defected, (pulleys are Motor Runs Hot
the hottest part of the drive), as the belts The usual reason for motors running hot is
will have been slipping. that they are intended to! With Continuous
Maximum Rated motors the temperature
Hot Pump Bearings rises are surprising and are allowed for in
On high speed duties it is to be expected the design of the motor and the selection of
that the bearings will run hotter than on the insulation in it.
low speed duties. Providing the shaft is Generally, heat from the motor can be safe-
free spinning by hand, the heat generated ly ignored provided the amperage drawn
while running under power is probably is lower or equal to the nameplate rating.
immaterial. At 150 Degrees Fahrenheit Many motors are fitted with Thermistors in
(65 degrees celcius) the assembly will be the windings, which sense the temperature
uncomfortable to the hands for more than rise and are wired to operate a cut-out relay
a second or two, but this is not unduly hot if the temperature exceeds a safe limit.
for the bearing assemblies. If the bearing is If a pump is choked when the motor starts
failing the shaft will not run free. the protection must trip out the supply to
the motor.
Bearing troubles in motors are generally
indicated by noise as well as heat, and can
sometimes be detected by use of a long-
stemmed screwdriver. The blade of the
screwdriver is pushed against the bearing
cover and the ear of the investigator pushed
up to the handle. With a limited amount of
experience bearing “rumble“ can quite easi-
ly be detected.
 Troubleshooting Page 178

9.2.8 Pump - Sudden Reduction in

Discharge

Change in Feed Conditions Air leaks on the Suction Pipe

Operators do not always recognise a pump as A pipe which has been steadily wearing
simply one element in a complete system and away from the inside may break through
any change in that system will bear on all the to the open air near a flange, (in a welded
parts of it. For instance, if a screen, rejecting area), at the bottom of the pipe, (where the
plus 6mm material is worn and passes 25mm coarsest solids run). In a suction pipe this
stones, this affects the pump performance. will almost certainly allow air into the pipe
The suction resistance of the larger stones with all the resultant ills described listed in
will cause the suction pressure to reduce and points 1-5:
have less head available for pushing the pulp
through the delivery side piping. 1. Inadequate prime prevents discharge;
At the pump, the larger stones will make a
significant difference to the pump perfor- 2. Air lock allows brief discharge only;
mance, decreasing flow and potentially cau-
sing damage to impeller and linings. 3. Air leaks allowing pumping of water but
In the pipeline, the large stones will probably not
progress by“saltation“, that is, leaping along solids;
the bottom of the pipe. The rest of the pulp is
fully in suspension and has to flow past these 4. Air entrainment limits percentage solids
slow moving obstacles. Overall this means pumped;
the resistance of the pipeline to flow has in-
creased. Thus again reducing flow. 5. Inadequate prime prevents gland from
So a simple fault like a screen cloth with a sealing:
hole in it can cause a sudden reduction in
discharge. If it causes the pipeline to block, Frequently, a pinhole leak will not let
the condition is potentially dangerous. enough air into a pump for any of the five
Other changes in the feed conditions which faults listed to become critical. So ope-
must be investigated are; increased tonnage rators, being human, postpone the repair
of solids, change of grading of solids, change or replacement of the worn pipe. The last
in manner of introduction of solids to pump chapter of the saga occurs surprisingly
system. On this last count, a plant which was quickly and usually on nightshift - when
started up in summer, and is bin-fed via a fault produces a blocked pipeline.
vibrating feeder,
will perform differently in winter, when the
wetter feed “hangs up“ in the feed bin and
collapses down onto the feeder intermittently
in larger dollops.
 Troubleshooting Page 179

9.2.8 Pump - Sudden Reduction in

Discharge (Continued)

Suction Blockage Operators not infrequently attribute the

In dredging applications there is always the pump failure to the gland, instead of to the
danger that the pump suction will be sud- conditions at the end of the suction pipe,
denly submerged in collapsed solids from and this seems the logical explanation to a
the surrounding pit contours. When pum- person standing beside a pump, who heard
ping from a sump the same thing can hap- the air hiss into gland, and then has to con-
pen when solids, which have been clinging tend with the resultant air-lock. However,
precariuosly to the steel sides of the sump, the trouble starts at the end of the suction
subside and momentarily block the pump pipe, the gland collapse occurs afterwards.
suction. In dredging applications the answer is to
If the pump is feeding a fair length of deli- exercise better control over the pit develop-
very piping, it will not be possible for the ment. In sump-fed systems, the feed pulp
long column of pulp in that piping to come can sometimes be directed to flush away
instantly to rest when the suction gets bloc- any build-up of solids on the sides or val-
ked. It will be appreciated that the pulp in leys of the sump. If this is not possible, a
a 200mm pipe, way 300m long, moving at larger capacity take-off box at the base of
3m/sec, has considerable momentum. It just the sump must improve the situation. The
cannot be stopped dead in the same short blocked pipeline situation is potentially
length of time it dangerous.

Tramp Material
The simplest explanations of a fault should
never be overlooked. If the complaint is a
sudden reduction in discharge: drain the
sump and before removing any pipework
or dismantling the pump in any way, have
a look at the take-off box at the base of the
sump. Loose rubber, house bricks, steel off-
cuts have all been found at the outlet to the
pump at one time or another. Plastic gar-
den hose inside the impeller passages was
found to have a dramatic effect on pump
capacity, in an installation which had given
satisfaction for the previous three years.
 Troubleshooting Page 180

9.2.9 Pump - Sudden Increases in

Power Demand

Changed Pump Speed Change in Pipeline System

It has been known for electricans who Clients may alter a discharge pipe layout
have been called in to do maintenance on so the static lift is reduced or the length
a motor to dismount both pump and mo- of pipe shortened, thinking to themselves
tor pulleys, then when reassembling the “the pump won‘t have to work so hard
pumpset, to mistakenly interchange the now“. Actually, in these circumstances the
pulleys. Depending on the pulley ratio this pump pumps a larger gallonage and takes
may have spectacular results. more power not less.

Air Entrainment Low voltage

In sump-fed pump systems air entrainment A new installation near the pumpsite can
can produce cyclic pump overload. This make a significant difference to the volta-
fault can be caused by a change in the ge available, depending on the electric dis-
gallonage fed to sump, or the direction in tribution system in the area. Lower volts
which it is fed to a sump. It can also be mean higher current for the same power
caused by a casual change to the feed type output of the motor.
baffle arrnagement in the sump.
Changed Pump Speed
Damage Inside Pump It has been known for electricans who
If a client has not had occasion to open have been called in to do maintenance on
his pump before he may not realise what a motor to dismount both pump and motor
can happen to the inside of his pump as it pulleys,
wears away day by day. The following list
gives the results of abrasion which will
give an increase in power demand, in or-
der of frequency of occurence.
1. Excessive gap between impeller and
suction bush.
2. Cut or ripped rubber in suction bush or
casing gland rubbing against impeller.
3. Worn out cutwater.
4. Worn out or broken casing liners.
5. Impeller worn through back shroud.
6. Impeller passages worn significantly
wider than intended.
 Troubleshooting Page 181

9.2.10 Pump - Rapid Component

Change in Feed Conditions

If a pump operates satisfactory for some time
Air Entrainment then suddenly begins to wear out components
As an experiment place some sand in an empty in quick succession, look for some change in
milk bottle, fill the bottle to the very top with feed conditions. Extra tonnage, coarser gra-
water, place the palm of one hand over the top ding, higher proportion of crushed material,
and shake the bottle. You will find it difficult to and so on. Sometimes an operator is unaware
move the sand vigorously against your hand. that conditions have changed for the pump.
Now tip out a third of the water, and repeat the A case in point would be a rod mill circuit
test. You will undoubtedly feel the sand in the producing crushed sand minus 5 mm from
air-water froth hitting your palm. a feed which is minus 10 mm. If a pump is
The point of the experiment is to show how used to pump the rod mill discharge to some
much more readily sand can move around in a screening equipment and the screen oversize
froth than it can in water without air bubbles. returns to the mill, a reduction in capacity
Therefore any leaks in the suction side accele- of this screening equipment will make a big
rate abrasion. change in the duty for the pump. However, to
If air entrainment is severe enough to produce the operator, the same tonnage rate through-
an air lock in the presence of solids and water, put is maintained by the circuit, so the pump
the result is an escalation of the abrasion rate. duty is unchanged in his mind. In fact, a
Air entrainment can also cause severe abrasion reduction in screen capacity (for instance,
indirectly. With cyclic changes in pulp density by partial blinding, of the screen cloth) will
due to air, the pump may have to handle, pe- produce an increase in circulating load and a
riodically, far denser pulp than intended. This corresponding increase in pump pulp density.
also is an abrasive accelerator. Another less involved example would be the
pumping of sand from a river deposit. These
Properties of the Solids deposits are notoriously variable, so the pro-
Some solids have worse properties from the portion of crushed sand in relation to natural
point of view of abrasion than others. can vary widely. To the operator however,
1. Sharp edged particles are worse than round sand is sand, and the fact that the pump is
particles, so crushed materials are generally now handling, say 80% crushed material,
worse than natural sands. while three months ago it was 60% natural
2. Course gradings are worse than fines. sand may not appear significant.
3. The specific gravity of the material makes
a difference.
When confronted with a rapid abrasion pro-
blem, always reduce pump speed if possible.
A larger diameter impeller will be rotating
slower at the suction eye of the impeller for a
given head than a smaller pump. So if wear on
the leading edge of the vanes is a problem, a
larger pump would help.
 Troubleshooting Page 182

9.2.10 Pump - Rapid Component -

Continued

If there is a permanent change in feed conditi-

ons which makes component life unsatisfacto-
ry, look into modifiyng the pump.

If there is no suitable pump selection, the

pump duty may have to be split up, and a two
stage pumpset installed. Each pump will run at
about 70% of the speed of a single unit for the
same duty and this speed reduction will make a
very significant change to the abrasion rate.

Shaft Misalignment
After some years of service it occasionally
happens that the saddles on the pedestal which
support the bearing housing get worn and thus
allow the shaft to point downwards. If this
problem is severe enough the eccentricity of
the shaft through the gland will be such that
the gland will not seal properly. A further pro-
blem will be that there will be a misalignment
between the eye of the impeller and the suction
bush, which will detract from pump perfor-
mance. If this happens, the best answer is to
buy a new pedestal. This will almost certainly
be cheaper and quicker than trying to build up
the saddles and then rematching. A temporary
expedient is to pack the saddles with shims,
but inevitably these get lost during impeller
adjustment.
 Troubleshooting Page 183

9.2.11 Mechanical Failure

Broken Shaft Pump Explodes

Practically the only broken shafts in pumps The centrifugal pump - or any other - can
are those where there has been tramp mate- potentially explode by running it with pulp,
rial in the feed, or a bearing has seized, and or water, in the casing but no discharge. An
in each case it is easy to see the cause. example of how this happens is in a pump
drawing pulp from a sump and pumping to
Broken Pedestal or Casing a cyclone or through a rising pipeline. If the
The front bracket of the pump pedestal alt- pump gets a sudden surge of solids, which
hough quite massive to look at can be bro- blocks off the suction, flow will cease. In
ken from the box section of the pedestal by the delivery line the solids will settle in the
the simple expedient or starting the pump rising pipe, but will be unable to enter the
backwards. If this is done the impeller be- casing because the impeller is still spinning
gins to unscrew from the shaft and, as it there.
does so, strikes the suction bush. This is im- We now have a plug in the suction pipe,
movable, being trapped by the flange of the and in the delivery pipe, with a spinning
suction pipework. So something has to give. impeller in between. The pump goes on
Occasionally, with older shafts, the thread absorbing power as the impeller rotates and
in the shaft is stripped instead of the pede- the power raises the fluid temperature. Ulti-
stal being broken. mately, the water will boil and the pressure
We do not recommend attempting to weld generated may be enough to explode the
broken pedestals, alignment problems are pumphead or destroy the rubber.
too difficult. The cheapest and quickest way This is an extremely dangerous situation,
out for a customer is to buy a new pedestal. and if a pumphead feels unusually warm
The running backwards of a pump is an and is not discharging, switch off the po-
electrical problem. It is very simply over- wer, immediately. Under no circumstances
come and no electrician worth his salt will approach the pump until the pumphead
allow this to happen as they are supposed has been relieved of pressure - preferably
to check motor direction of rotation prior to through the suction or discharge pipework
fitting the Vee-belts onto the pulleys. by flushing away the solids plugs. If a pump
is going to explode, there is almost certain-
ly considerable leakage of steam from the
gland.

Important Note: Even if the pump does not

feel hot, take extreme care when dismant-
ling as the pump may be full of scalding
water.

Do not remove the drain plug until certain

the fluid temperature in the pump has redu-
ced. If in doubt carefully clear blockages in
manner described above.
 Troubleshooting Page 184

9.3 Trouble Shooting Guide for Vibratory Motors

MALFUNCTION POSSIBLE CAUSE REMEDY

A) Motor does nor 1. Supply voltage not present. Check main supply to control or
run starter unit on.
Check fuses
2. Motor protection overload Ascertain cause and clear fault relay
relay tripped. tripped before re-setting
3. Incorrect connections to Check connections to vibrating mo-
motor. tor including intermediate terminal
boxes
4. Control or starter unit not Check control/starter unit
functioning correctly.
5. If supply present Check stator winding are not open
circuit
Check motor terminal links in cor-
rect position
Check connections from stator
windings to terminal box are not
open circuit
B) Motor starts but 1. Control/starter unit not Check control or starter unit
fails to continue functioning correctly
2. Supply voltage incorrect Check correct voltage used at con-
trol unit and motor
3. Motor overloaded Check not overloaded electrically
(See C). Check not overloaded me-
chanically (Bearing or rotor seizure)
4. Supply incorrectly con- Check all three phases supply volt-
nected age connected
5. Electrical connections in Check compatibility of motor ter-
motor not suitable to supply minal box and supply. Check brass
voltage links are present
6. Earth faults occurring Check none occurring

7. Motor stator winding open Check for open - circuit

- circuit
8. Short circuit in motor stator Check no short circuits between
windings adjacent turns
 Troubleshooting Page 185

9.3 Trouble Shooting Guide for Vibratory Motors (Continued)

MALFUNCTION POSSIBLE CAUSE REMEDY

C) Motor electrical 1. Fixing bolts loose Check bolts and tighten if necessary
current consumption
in excess of rated full 2. Centrifugal force output Check adequate for this application
load current too great
D) Motor Overheating 1. Ambient temperature Check not too high
2. Motor overloaded Check not overloaded
3. Excessive grease Check grease not excessive in bearings
E) Motor noisy (some 1. Supply voltage incorrect Check supply voltage
noise should be ex- 2. Supply incorrectly con- Check three phases correctly con-
pected) nected nected
3. Bearing failure Check for bearing failure
4. End covers not correctly Check covers are correctly mounted
located and are secure
5. End covers damaged Check for damage as possible fouling
of out of balance weights possible
6. Out of balance wheel Check nuts and tighten if necessary
nuts not secure
F) Motor does not ac- 1. Motor connected in star Check not high voltage on a low volt-
celerate to synchoro- age supply
nous speed 2. Supply voltage low Check supply voltage
3. Supply frequently low Check supply frequency
4. Motor partially seized Check motor not seized
5. Motor overloaded Check motor not overloaded
6. Single phasing Check cable, wire lead and cable con-
nection (motor conduit box is packed
with duxseal and must be repacked
with same)
 Troubleshooting Page 186

9.4 Troubleshooting Guide for Direct Force Unit

Vibratory equipment varies in design because it is custom built

for particular applications, thus some of the POSSIBLE CAUSE
items may not apply.

LOCKOUT electric power to the equipment, read all saftey war-

nings/notes before performing any maintenance.

MALFUNCTION POSSIBLE CAUSE REMEDY

Stroke Increase 1. Motor weights positioned Contact Terex
incorrectly

2. Drive speed increase Check drive speed

Stroke Decrease 1. Motor running slower Check line voltage

2. Overloaded conveyor Adjust feed rate

Material conveying to 1. Isolation spring breakage Replace isolation spring

one side
2. Material build up under pan Clean up
3. Material loaded to one side of Correct loading
conveyor
4. Structural failure Contact Terex
Material not conveying 1. Pan understanding See “conveyor adjustments” to
increase stroke

2. Obstruction in pan Remove obstruction

 Troubleshooting Page 187

9.4 Troubleshooting Guide for Direct Force Unit (Continued)

MALFUNCTION POSSIBLE CAUSE REMEDY

Noise 1. Loose bolts Tighten bolts to proper toque values

per the torque chart/s in this manual
2. Broken or loose spring Replace spring and tighten loose spring
per the torque chart in this manual
3. Hitting stationary object Provide necessary clearance

4. Weld breakage Re - weld

Spring Failure 1. Foreign material build Clean up, replace spring

up under conveyor, sand,
casting,sprue etc.
2. Loose bolts Tighten bolts to proper torque value
per the toque chart in this manual
3. Fatigue or broken Replace spring

Twisting vibration on 1. Both motors moving in Change direction or incorrect motor

pan same direction
Troubleshooting Page 188
 Storage Page 189

10 Storage

10.1 Machine Storage

On receipt of the machine, carry out a careful inspection and immediately report any compo-
nent 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 must be stored in a dry, well-ventilated area free of excessive dust. All open-
ings must 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
weather proof to avoid deterioration.
Contact Terex for advice on any situation where storage or inactivity in a possibly hostile
environment exists, as the warranty is affected.

10.2 Cyclone Storage

Storage of the Cyclone requires special treatment, as detailed below.

Storage of Cyclone must ensure that the linings are protected from mechanical damage which
can affect the erosion / corrosion protection of the unit.
If the Cyclone is stored before installation, a tarpaulin must be used to cover the units to pro-
tect against exposure to UV light, which will damage the rubber linings.
Do not lay the Cyclone directly on the ground, as this may damage connecting flanges and
their gasket surfaces which are an integral part of the rubber linings.
After the Cyclone has been installed and put into service, storage requirements for an extend-
ed shut down period should include a thorough wash down and clean out of all retained slurry
material. A thorough inspection of all wear linings can be undertaken at this time to determine
the need for or timing of any component replacement(s).
Storage Page 190
 Glossary Page 191

The list of terms below, can be found throughout the following manual.

A-Frame
A frame that is mounted at each end of the drum (only on Trommels). Used to ensure drum
is sealed correctly.

Anti Rock Stay

A strap which is used to stabilise the screen unit whilst in transport.

Antiluce Fastener
A type of fastener used to secure some doors.

Assemblies
Individual sections of the machine made up of different components parts.

Auxiliary Control Valve

A bank of hydraulic valves which carry out various movement functions throughout the ma-
chine.

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.

Collection Conveyor
A conveyor used to transfer the fines material from underneath the drum onto the incline con-
veyor.

Control Panel
A panel that is situated in the powerunit 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 .
 Glossary Page 192

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 loading 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 lenghtened 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 roll-
ers. The power transmiting medium is usually belting or chain.

Conveyor, mobile
Conveyor, supported on a structure, and includes, but is not limited to, radial stackers, winged
stackers, reclaiming conveyers, and shipholders. These conveyors normally handle bulk material.

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 tyre, 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 electrial parts provide the motive
power to change direction.

Drive Drum
The drum that drives the conveyor belt sometimes called the head drum.

 Glossary Page 193

Drum
A cyclindrical or polygonal rim type of wheel around which cable, chain, belt, or other lin-
kage may be wrapped. A drum may be drive or driving. The face may be smooth, grooved,
fluted, or flanged.

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 hingesection.

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.
 Glossary Page 194

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 favourable speed to run a conveyor for example.

Oversize material
Material that is larger than the mesh size and runs off the top screen deck.

Platform
A working space for persons, elevated above the surrounding floor or ground for the
operation of machinery and equipment.

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.

Powerunit
An inclosed unit situated under the main conveyor which houses the component parts which
together drive the machine.

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 satisfac-
tory service can be expected.

Return Roller
A roller, which is used to support the unladened belt on the underside of the conveyor.

Grid Aperature
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 course screen made of parallel and crossed bars used to prevent passage of oversized
material.
 Glossary Page 195

Guard
A covering, barricade, grating, fence, or other form of barrier used to prevent inadvertent phy-
sical contact with operating components such as gears, spockets, 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

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.
 Glossary Page 196

Retract
Withdraw or fold up conveyor.

Remote control
Any system of controls in which the actuator is situated in a remote location.

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 un-
safe condition, preventing the continuation of an unsafe condition, warning an unsafe conditi-
on,
or limiting or elimitating 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 ad-
herent material.

Screen Drum
Drum which mesh is fitted onto rotates during operation to screen material (Trommel).

Sound Baffles
Plates used to blank out noise from the powerunit.

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.

Shredder Safety Stay

Metal strap which restrains the shredder unit whilst in the raised position.

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.

Shredder Unit
Swinging flail type unit which is located at the discharge end of the feed conveyor and is used
to break down material.
 Glossary Page 197

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.

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 180o to increase stockpiling capa-
city.

Tail Conveyor
Conveyor used to collect the fines material from the screen unit and move it to the discharge
area.

Tow pin
A movable or fixed member, used to engage a push or pull.

Telescopic Head Section

A section of a conveyor which extends out telescopically into transport position.

Tracks
The beams, shapes, or formed section on which trolleys, rollers, shoes, or wheels roll or slide
while propelled.
 Glossary Page 198

Transport Bracket
A bracket used to hold an assembly in place whilst in transport.

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 tightened a nut.
 Appendix Page 199

Table of contents Page

Appendix A EC Declaration of Conformity 200

Appendix B Warranty 202
Appendix C Schematics 209
 Appendix Page 200

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.
Appendix Page 201
 Appendix Page 202

Appendix B Warranty

The following pages show an example of the warranty information.

Register the warranty of this machine online.
 Appendix Page 203

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 pur-
poses 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 components, 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 of-
ficer of Seller.

Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including without limitation, disposal or handling of tires,
batteries, petrochemical 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 im-
proper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts,
 Appendix Page 204

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 shipment 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 operational data about the Equipment including, but not limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining
such data from the Teleservices Provider for warranty, product improvement and customer support purposes. Buyer understands that the Equip-
ment 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.

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
 Appendix Page 205

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 IMPLIED 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 WARRAN-
TIES 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 WAR-
RANTY. 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, REPRE-
SENTATION 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 LIMITATION, 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 OP-
PORTUNITY 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 NOTH-
ING CONTAINED IN THIS LIMITED PRODUCT WARRANTY SHALL OPERATE TO EXCLUDE THE SELLER’S LIABILITY FOR DEATH OR
PERSONAL INJURY.
 Appendix Page 206

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 main-
tained 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 estab-
lish 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 components, 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 manufacturers. 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 of-
ficer of Seller.

Seller’s obligation under this warranty shall not include duty, taxes, environmental fees, including without limitation, disposal or handling of tires,
batteries, petrochemical 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 im-
proper maintenance, improper use, abuse, improper storage, operation beyond rated capacity, operation after discovery of defective or worn parts,
 Appendix Page 207

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 shipment 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 operational data about the Equipment including, but not limited to, usage, performance and reliability. Buyer consents to Seller’s obtaining
such data from the Teleservices Provider for warranty, product improvement and customer support purposes. Buyer understands that the Equip-
ment 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.

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
 Appendix Page 208

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, EMOTIONAL OR MENTAL DISTRESS, IM-
PROPER 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 Page 209

Appendix C Schematics
Appendix Page 210
 1 2 3 4 5 6 7 8 9 10

A PROJECT INFORMATION: A

600 CLIENT: TEREX GB LIMITED

TITLE: FINESMASTER 60 COMPACT

B B
PROJECT: FM60 50Hz MACHINE

PROJECT NO: 2041

C SUB PROJECT NO: 20410002 C

DRAWING NO: 20410002-2

BUILT BY: K.QUINN

D D

TESTED BY: P.McKENNA

TEST DATE: 17/07/2013

E E
DISPATCH DATE: 17/07/2013

PANEL LOAD KW: 28KW

F PANEL VOLTAGE: 415V 3PHASE F

PANEL FREQUENCY: 50Hz

G G
800

H REV. BY: DATE: REVSION SECTION: REV. H

REV. BY: DATE: REVSION SECTION: REV.

REV. BY: DATE: REVSION SECTION: REV.

I I

REV. BY: DATE: REVSION SECTION: REV.

REV. BY: DATE: REVSION SECTION: REV.

J J
REV. BY: C.MULLAN DATE: 17/07/2013 REVSION SECTION: ALL REV. 2

REV. BY: A.T. DATE: 03/07/2013 REVSION SECTION: ALL REV. 1

K REV. BY: A.T. DATE: 02/07/2013 REVSION SECTION: ALL REV. 0 K

REVISION INFORMATION:

L 250 Axon Power & Control Ltd

347 Pomeroy Road
L

AXON Dungannon
BT70 3DT Northern Ireland
POWER & CONTROL t: +44 (0) 28 8775 8923
M ...a commitment to excellence f: +44 (0) 028 8775 8937 M
www.axon-online..com e: info@axon-online.com
www.axon-online.com
CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 1 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
1 - Cover
PANEL DETAILS CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 1-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A Panel Drawing Index: Panel Cable Colour Code: A

SECTION DESCRIPTION CIRCUITS COLOUR WIRE SIZE

1 COVER Mains Wiring

B 1-1 PANEL DETAILS 1st Phase: Black (L1) Min. 2.5sq mm B

1-2 INDEX 2nd Phase: Black (L2) Min. 2.5sq mm

1-3 EXTERNAL LAYOUT 3rd Phase: Black (L3) Min. 2.5sq mm
1-4 INTERNAL LAYOUT Neutral: Blue (N) Min. 2.5sq mm
C C
Earth: Green & Yellow Min. 2.5sq mm
2 MAINS
2-1 MAINS INCOMING & DISTRIBUTION Motor Wiring

D 2-2 AC CONTROL POWER 1st Phase: Black (U1) Min. 2.5sq mm D

2nd Phase: Black (V1) Min. 2.5sq mm
3 EMERGENCY STOP CONTROLS 3rd Phase: Black (W1) Min. 2.5sq mm
3-1 EMERGENCY STOP CONTROLS Neutral: Blue (N) Min. 2.5sq mm
E 3-2 EMERGENCY STOP FEEDBACK SAFETY CIRCUIT Earth: Green & Yellow Min. 2.5sq mm E

3-3 EMERGENCY STOP PUSHBUTTONS

Control Wiring
4 MANUAL / OFF / SEQUENCE CONTROLS 230VAC Live: Brown Min. 0.75sq mm
F F
4-1 MANUAL / OFF / SEQUENCE 230VAC Neutral: Blue Min. 0.75sq mm
4-2 PRE-START SIREN CIRCUIT 110VAC Live: Red Min. 0.75sq mm
110VAC Neutral: Red Min. 0.75sq mm
5 MOTOR POWER & CONTROL 24VAC Live: Orange Min. 0.75sq mm
G G
5-1 SCREEN MOTOR CONTROLS 24VAC Neutral: Orange Min. 0.75sq mm
5-2 PUMP MOTOR CONTROLS 24VDC +Ve: Grey Min. 0.75sq mm
5-3 EXTERNAL PLANT INTERLOCK 24VDC -Ve: Grey Min. 0.75sq mm
H 12VDC +Ve: Purple Min. 0.75sq mm H
6 TERMINALS 12VDC -Ve: Purple Min. 0.75sq mm
6-1 MAINS & CONTROL TERMINALS Voltfree: Orange Min. 0.75sq mm
Voltfree: Orange Min. 0.75sq mm
I 7 LABELS Thermistors: White Min. 0.75sq mm I

7-1 LABELS ORDER Thermistors: White Min. 0.75sq mm

Current Transformers S1: White Min. 2.5sq mm
Current Transformers S2: White Min. 2.5sq mm
J J
Current Transformers S2 Earth: Green & Yellow Min. 2.5sq mm
Ammeter +: White Min. 2.5sq mm
Ammeter -: White Min. 2.5sq mm

K Earth: Green & Yellow Min. 1.5sq mm K

ELV Controls: Grey (Screened) Min. 0.5sq mm

Notes
L Objects shown surrounded by dotted and dashed lines (- - - - - - - ) are external to this panel L

unless otherwise indicated

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 2 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
1 - Cover
INDEX CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 1-2 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A A

B AXON
B
POWER & CONTROL

347 Pomeroy Road t: 02887758923

Dungannon
Northern Ir eland f : 02887758937

BT70 3DT e: inf o@axon-online.com

C C

D D
5-1PB2 5-2PB2

SCREEN PUMP

E E

5-1PB1 5-2PB1

F F

EMG. STOP RESET PRE-START SIREN MAN / OFF / SEQ MANUAL SEQUENCE
(HEALTHY) (COMPLETE)

G G

3-2BP1 4-2PB1 4-1SW1 4-1LT1 4-1LT2

H H

RGENC
ME

Y
E
I S TO P I

3-3PB1

J J
WARNING
ISOLATOR SUPPLY
BEFORE OPENING COVER

ON
K K
OFF

L L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 3 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
1 - Cover
EXTERNAL LAYOUT CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 1-3 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A A

B B

60 X 80
C C

23 24 A2 A1
33 PE Y2 41

XPS-AC3421

5-1AXFS1

5-2AXFS1
5-1AXFS2
3-1SR1
5-1FS1 5-1FS2 5-2FS1

RE8TA31BUTQ

RE8TA31BUTQ
PWR

C60HD316 C60HD316 C60HD350

RXM4AB2F7

RXM4AB2F7

RXM4AB2F7

RXM4AB2F7
13 23 33 41

CH1

4-1CR1

4-2CR1

4-2CR2
4-1CR2

TBW70.89
4-2TM2
4-2TM1
CH2
OFF OFF OFF OFF OFF OFF OFF OFF OFF 14 24 34 42

D D

5-2HR1
Y43 Y44 34 42
Y1 13 14 34

E E

60 X 80
F F

5-1KM1 5-1KM2 5-2KM1 5-2KM1.1 5-2KM1.2

5-2AXKM1.1 5-2AXKM1.2 2-2FS1 2-2FS2

RE8TA31BUTQ
LADN22 LADN11
C60HC202 C60HC202

5-2AXKM1
5-1AXKM1

5-1AXKM2
G G

LADN20
LADN20

LADN20

5-2TM1
OFF OFF OFF OFF

LC1-D12F7 LC1-D12F7 LC1D25F7 LC1D25F7 LC1-D25F7

5-1FR1 5-1FR2 5-2FR1
LRD14 LRD14 LRD22
60 X 80
H H

I I
60 X 80

J 2-1Q1 MV-PS21-250VA J
OT80F3 2W1
2-2TX1
2W2
2U1

2U2
2V1

2V2
1AW1

1BW1
1AU1

1BU1
1AV1

1BV1

2
3

8
1

1
X2

X3

X4
X1
X1
X1
X1
X1
X1
X1
X1

X1

X1

X1

X1

X1
X1
X1

X2
X2

X3
X3
X3
X3
X3
X3
X3
X3

X4
X4
E

1AU1

1AW1

1BU1

1BW1
1AV1

1BV1

2
1

1
2U1

2W1
2V1

2W2

2U2
2V2

K K

L L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 4 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
1 - Cover
INTERNAL LAYOUT CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 1-4 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A L1 A
/6.B3
L2
/6.B3
L3
END

B B

1AL1
1AL2

1BL1
1BL2
1AL3

1BL3

2L1
2L2
2L3
Black Tri-Rated 2.5mm² Black Tri-Rated 2.5mm² Black Tri-Rated 2.5mm²

C C

/12.B2
/12.B2
/12.B2

/13.B2
/13.B2
/13.B2
/12.B3
/12.B3
/12.B3
D D

SUPPLY TO SCREEN M1 SUPPLY TO SCREEN M2 SUPPLY TO PUMP

400V 3P 400V 3P 400V 3P

E E

F F

G G

H H

I I

J J
/6.J1
E

E
Earth Tri-Rated Earth Tri-Rated 6mm² Earth Tri-Rated 6mm²
K BACKPLATE DOOR K

1 3 5 BOLTED WITH BOLTED WITH

E
2-1Q1 LOCK NUT LOCK NUT
OT80F3
2 4 6
E

L 10mm² 6mm² L
EARTH BAR GLAND PLATE

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 5 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
2 - Mains
MAIN INCOMING & DISTRIBUTION CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 2-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A A

/5.A10
/5.A10
B B

201L1
202L2
Black Tri-Rated 2.5mm²

C 1 3 C
C60HC202
2-2FS1
2A
2 4

D D

203L1 204L2

E E

0 20 380 420

MV-PS21-250VA E
F 2-2TX1 F
Earth Tri-Rated 2.5mm²
0 55 110

2-2WR1
G 2-2WR3 G

Red Tri-Rated 0.75mm²

C60HC202 1 3
H H
2-2FS2
2A
2 4
E

Earth Tri-Rated 2.5mm²

I I

J J
/5.J10 /7.J1

2-2WR2 2-2WR4

K K

L /7.A1 L
/7.K1
CONTROL POWER
PANEL
110V, 50Hz
M CONTROL M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 6 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
2 - Mains
AC CONTROL POWER CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 2-2 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 2-2WR4 2-2WR4 A
/6.L3 /9.A1

B B

C C
3-3WR5
/9.K5
3-3WR6
/9.K6

D 3-1WR1 D
/8.A1
3-2WR6
/8.A10

Red Tri-Rated 0.75mm² Grey Tri-Rated 0.75mm²

E E

A1 A2 Y1 Y2 13 23 33 Y43

3-1SR1 XPSAC3421 110vac

PE 14 24 34 Y44
F F

G G

3-1WR2
/10.A1
COM
H /10.K1 H
E

2-2WR2
Earth Tri-Rated 0.75mm²

I I

3-1WR3

J J
/6.J4 /12.J1 X1

EMG. STOP RESET

/8.B2 (HEALTHY)
K X2 K
2-2WR2 2-2WR2
/6.L3 /9.A1
3-2BP1
XB4 BW36G5
E. STOP
L HEALTHY L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 7 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
3 - Emergency Stop Controls
EMERGENCY STOP CONTROLS CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 3-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 3-1WR1 3-2WR6 A
/7.D5 /7.D5

Grey Tri-Rated 0.75mm²

3-1WR1

B B

/7.K5
3 X1
3-2BP1
XB4 BW36G5 X2
4

C C
3-2WR1

21
5-1KM1
/12.M5
D 22 D
3-2WR2

21
5-1KM2
E /12.M5 E
22

3-2WR3

21
F 5-2KM1 F
/13.M4
22

3-2WR4

G 61 G
5-2AXKM1.1
/13.M6
62

3-2WR5
H H

61
5-2AXKM1.2
/13.M7
62
I I

J J

K K

L L

3-2WR6

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 8 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
3 - Emergency Stop Controls
E. STOP CONTACTORS FEEDBACK SAFETY CIRCUIT CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 3-2 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A A
/7.K10
/7.A10

2-2WR4 2-2WR2
B B

C C

D D

3-3WR1 3-3WR2
E E

X3 X3

3
1
2-2WR4 2-2WR2

F FIELD POS 1 F
1 1

3-3PB1 2 2
XB4 BS8444
X3 X3

2
G G

4
3-3WR1 3-3WR2

3-3WR3 3-3WR4

H H

X3 X3

7
I FIELD POS 2 I

X3 X3

8
6
J J
3-3WR5 3-3WR6
/7.C5

/7.D5

K K

L L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 9 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
3 - Emergency Stop Controls
EMERGENCY STOP PUSHBUTTONS CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 3-3 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 3-1WR2 3-1WR2 A
/7.H6 /12.A4

4-1CR1 11 4-1CR2 11
B /10.M5 /10.M6 B
12 14 12 14

4-1WR3
C /11.A1 C
3-1WR2

D D

PANEL LABEL

1
E M/O/S MAN / OFF / SEQ E

4-1SW1

2
XB4 BG3

F F

4-1WR1 4-1WR2

G G

4-1WR1 4-1WR2

H H

I I

J J
PANEL LABEL PANEL LABEL
X1 X1
A1 A1
MANUAL SEQUENCE

A2 A2
K X2 X2 K
COM COM
/7.H6 /11.K1
4-1LT1 4-1CR1 4-1CR2 4-1LT2
XB4 BVG5 RXM4AB2F7 RXM4AB2F7 XB4 BVG5

L L
4-1CR1 4-1CR2
/10.J5 /10.J6
12 12
11 14 11 14
/10.B8 22 /10.B8 22
21 24 21 24
/14.F3 32 32
31 34 31 34
M 42 42 M
41 44 41 44
RXM4AB2F7 RXM4AB2F7

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 10 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
4 - Manual/Off/Sequence Controls
MANUAL/OFF/SEQENCE CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 4-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 4-1WR3 4-1WR3 A
/10.C10 END
4-2WR7
/12.A4

B 4-1WR3 4-1WR3 B

63 53
C C
5-1AXKM1 5-2AXKM1
/12.M5 /13.M5
64 54

4-2WR6 4-2WR6
D D

E E

F 21 21 F
/11.M2 4-2CR2
4-2CR1 /11.M6
22 24 22 24

G 4-2WR3 4-2WR5 G
/11.K7

15 15
3 X1 4-2CR1 11
4-2PB1 /11.M2 4-2TM1 4-2TM2
/11.M3 /11.M5
H XB4 BW33G5 X2 12 14 16 18 18 16 H
4
4-2WR2 4-2WR3

4-2CR2 11
/11.M6

12 14 4-2WR4 4-2WR5 4-2WR6 4-2WR7

I I

4-2WR1
X2
1

J J
X1
A1 A1 B1 PRE-START SIREN A1 B1 A1
PRE-START SIREN
X2 /11.G2 (COMPLETE)
2

A2 A2 A2 A2
K X2 K
COM COM
/10.K10 /12.K4
4-2CR1 4-2TM1 4-2TM2 4-2CR2 4-2PB1
RXM4AB2F7 RE8TA31BUTQ RE8TA31BUTQ RXM4AB2F7 XB4 BW33G5
PRE-START PRE-START PRE-START PRE-START PRE-START
L RELAY 1 TIMER 1 TIMER 2 RELAY 2 COMPLETE L
4-2CR1 4-2TM1 4-2TM2 4-2CR2
/11.J2 /11.J3 /11.J5 /11.J6
12 16 16 12
11 14 15 18 15 18 11 14
/11.H2 22 /11.H4 /11.H6 /11.I2 22
21 24 21 24
/11.F3 32 /11.F7 32
31 34 31 34
M 42 42 M
41 44 41 44
RXM4AB2F7 RE8TA31BUTQ RE8TA31BUTQ RXM4AB2F7

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 11 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
4 - Manual/Off/Sequence Controls
PRE-START SIREN CIRCUIT CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 4-2 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 4-2WR7 4-2WR7 A

/5.C3
/5.C3
/5.C3

/5.C4
/5.C4
/5.C4
/11.A10 /13.A4
3-1WR2 3-1WR2
PANEL LABEL /10.A10 /13.A4

SCREEN

/12.K9
B B
1

1AL1
1AL2

1BL1
1BL2
1AL3

1BL3
X1
5-1PB1
Black Tri-Rated 2.5mm² Black Tri-Rated 2.5mm² XB4 BW34G5
2 X2

C 5-1WR1 C

13
3-1WR2

/12.K9
5-1KM1
/12.M5
5-1AXFS1 5-1AXFS2 14 3 X1
D 1 3 5 11 21 1 3 5 11 21 5-1PB2 D
C60HD316 C60HD316 5-1WR2
5-1FS1 5-1FS2 XB4 BW33G5
13 4 X2 97 53
16A 16A 97
2 4 6 12 14 22 24 2 4 6 12 14 22 24
21 21
5-1KM2 5-1AXFS1 5-1FR1 5-1AXKM2
/12.E8

5-1FR2
/12.F6

/12.H6

/12.E7
/12.M5 5-1AXFS2 /12.D2 /12.G2 /12.L6
/12.D3 /12.G3
14 98 22 24 98 54
22 24
E 5-1WR3 E

1 3 5 13 21 1 3 5 13 21 5-1WR10
LC1-D12F7 LC1-D12F7
5-1KM1 5-1KM2 11
/12.M5 14 22 /12.M5 14 22 5-1AXFS1
F 2 4 6 2 4 6 /12.D2
F
12 14
1 3 5 95 97 1 3 5 95 97 5-1WR6
LRD14 LRD14
5-1FR1 5-1FR2
7-10A 7-10A
2 4 6 96 98
2 4 6 96 98 95
/12.E9

/12.E8
/12.G6

/12.I6

G 5-1FR1 G
/12.G2
96
5-1WR7
1AW1

1BW1
1AU1

1BU1
1AV1

1BV1

11
Black Tri-Rated 2.5mm² Black Tri-Rated 2.5mm² 5-1AXFS2
H /12.D3 H
12 14
1AW1

1BW1

5-1WR8
1AU1

1BU1
1AV1

1BV1

X1 X1
95
I 5-1FR2 I
/12.G3
96
5-1WR10 5-1WR11
5-1WR9

J J
/7.J4 /13.J1 X1 X1
A1 A1

/12.B6 /12.D6
A2 A2
X2 X2
K K
COM COM
/11.K10 /13.K4
U1 V1 W1 E U1 V1 W1 E 5-1KM1 5-1KM2 5-1PB1 5-1PB2
M M LC1-D12F7 LC1-D12F7 XB4 BW34G5 XB4 BW33G5
3~ 3~ MAIN MAIN TRIP RUN
L L
5-1KM1 5-1AXKM1 5-1KM2 5-1AXKM2
/12.J5 /12.J6
1 2 1 2
53 54 53 54
SCREEN M1 SCREEN M2 /12.F2
3 4 /14.F3
61 62 /12.F3
3 4 /12.E9
63 64
400V 50Hz, 4kW 400V 50Hz, 4kW 5
13
6 /11.C5
14
5
13
6
14
FLC 8.80A FLC 8.80A /12.D5
21 22
/12.E5
21 22
M /8.D2 /8.E2 M
OLC 8.80A OLC 8.80A LC1-D12F7 LADN20 LC1-D12F7 LADN20

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 12 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
5 - Motor Power & Control
SCREEN MOTOR CONTROLS CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 5-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A 4-2WR7 4-2WR7 A

/5.C5
/5.C5
/5.C5
/12.A10 END
3-1WR2 3-1WR2
PANEL LABEL /12.A10 END

PUMP

/13.K8
B 1 B
X1
5-2PB1

2L1
2L2
2L3
XB4 BW34G5
Black Tri-Rated 10mm² 2 X2
5-2WR1

C C

/13.K9
13 3 X1
5-2KM1 5-2PB2
XB4 BW33G5 3-1WR2
/13.M4
14 4 X2
5-2AXFS1
D C60HD350 1 3 5 11 21 D
5-2FS1 5-2WR2
50A 21 97 13
2 4 6 12 14 22 24
5-2AXFS1 5-2FR1 5-2KM1.1
/13.E8
/13.F5

5-2WR2 /13.D2 /13.G3 /13.M6

22 24 98 14
X1

1
E E

ISO AUX
1 3 5 13 21 1 3 5 13 21 1 3 5 13 21 5-2WR10
LC1D25F7 LC1D25F7 LC1-D25F7 X1

2
5-2KM1 5-2KM1.1 5-2KM1.2
/13.M4 /13.M6 /13.M7 5-2WR3
14 22 14 22 14 22
F 2 4 6 2 4 6 2 4 6 F
11
5-2AXFS1
/13.D2
12 14
1 3 5 95 97
LRD22 5-2WR4
G 5-2FR1 G
16-24A 96 98
2 4 6 95 5-2WR10 5-2WR11
/13.E8
/13.H5

5-2FR1
/13.G3
96
2W2

2W2
2U1

2U2
2V2

2V2

H H
Black Tri-Rated 6mm² Black Tri-Rated 6mm²
15
2W1

2W2
2U1

2U2
2V1

2V2

X1 X1 5-2TM1
/13.M6
18 16
I I
5-2WR8
5-2WR5 5-2WR5 5-2WR6
21 21
5-2KM1.2 5-2KM1.1
/13.M7 /13.M6
22 22
J J
5-2WR7 5-2WR9
/12.J3 X1 X1
A1 A1 B1 A1 A1 A1

/13.B5 /13.C5
A2 A2 A2 A2 A2
X2 X2
K K
COM COM
/12.K10 END
W1 V2
5-2KM1 5-2TM1 5-2KM1.1 5-2KM1.2 5-2PB1 5-2PB2 5-2HR1
V1 M W2
3~ LC1D25F7 RE8TA31BUTQ LC1D25F7 LC1-D25F7 XB4 BW34G5 XB4 BW33G5 TBW70.89
U1 U2
MAIN TIMER DELTA STAR TRIP RUN HOUR RUN
E
L L
5-2KM1 5-2AXKM1 5-2TM1 5-2KM1.1 5-2AXKM1.1 5-2KM1.2 5-2AXKM1.2
PUMP 1
/13.J5
2
/13.J6
16 1
/13.J6
2
/13.J7

400V 50Hz, 18.5kW 3 4 /11.C6

53 54
/13.I7
15 18
3 4 /14.G3
53 54 1
3
2
53 54
/13.F2 63 64 /13.F3 61 62 4
FLC 35A 5 6 5 6 /8.G2
71 72
/13.F3
5 6 /8.I2
61 62

M OLC 20.30A /13.D4

13
21
14
22
/13.E9
13
21
14
22
83 84 13 14
M
/8.F2 /13.J7 21 22
/13.J6
LC1D25F7 LADN20 RE8TA31BUTQ LC1D25F7 LADN22 LC1-D25F7 LADN11

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 13 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
5 - Motor Power & Control
PUMP MOTOR CONTROLS CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 5-2 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9 10

A A

B B

C C

D D

E E

Orange Tri-Rated 0.75mm²

53
F 5-1AXKM1 F
/12.L5
4-1CR1 21 54
/10.M5 5-3WR2 5-3WR3

22 24 53
5-2AXKM1.1
G /13.M6 G
54
5-3WR1

X4 X4

2
1

H EXTERNAL PLANT H
INTERLOCK
(VOLT FREE)

I I

J J

K K

L L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 14 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
5 - Motor Power & Control
EXTERNAL PLANT INTERLOCK CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 5-3 REVISION 2
1 2 3 4 5 6 7 8 9 10
 M
L
K
J
I
H
G
F
E
D
C
B
A

1
1

X1 SIZE DESCRIPTION

POWER & CONTROL

AXON
1AU1 4mm² SCREEN M1 (400V)
1AV1 4mm² SCREEN M1 (400V)
1AW1 4mm² SCREEN M1 (400V)

TITLE:
CLIENT:
1BU1 4mm² SCREEN M2 (400V)
1BV1 4mm² SCREEN M2 (400V)

2
2

1BW1 4mm² SCREEN M2 (400V)

2U1 6mm² PUMP (400V)
2V1 6mm² PUMP (400V)

TEREX GB LIMITED
2W1 6mm² PUMP (400V)
2V2 6mm² PUMP (400V)

FINESMASTER 60 COMPACT
2W2 6mm² PUMP (400V)
2U2 6mm² PUMP (400V)
1 4mm² PUMP ISO AUX
2 4mm² PUMP ISO AUX

3
3

X2 SIZE DESCRIPTION
1 4mm² PRE-START SIREN (110V)
2 4mm² PRE-START SIREN (0V)

X3 SIZE DESCRIPTION

SHEET
DETAILS:
PROJECT:
1 4mm² E.STOP FIELD POS.1 CH 1 (110V)
2 4mm² E.STOP FIELD POS.1 CH 1 (110V)

4
4

3 4mm² E.STOP FIELD POS.1 CH 2 (0V)

4 4mm² E.STOP FIELD POS.1 CH 2 (0V)

6 - Terminals
5 4mm² E.STOP FIELD POS.2 CH 1 (110V)
6 4mm² E.STOP FIELD POS.2 CH 1 (110V)

FM60 50Hz MACHINE

7 4mm² E.STOP FIELD POS.2 CH 2 (0V)
8 4mm² E.STOP FIELD POS.2 CH 2 (0V)

MAINS & CONTROL TERMINALS

X4 SIZE DESCRIPTION

5
5

1 4mm² EXTERNAL PLANT INTERLOCK (VOLT FREE)

2 4mm² EXTERNAL PLANT INTERLOCK (VOLT FREE)
TERMINALS

DRAWN NO:
PROJECT NO:

CHECKED BY:
6
6

PMK
2041
20410002-2
DRAWING BY:
APPROVED BY:
7
7

SUB PROJECT NO:

JD
A.T.
20410002

REV BY:
DETAILS:
REVISION

8
8

AS BUILT

C.MULLAN DATE:
17/07/2013
9
9

SHEET

SECTION
15

6-1
OF
16

REVISION

10
10

SHEET(S)

2
M
L
K
J
I
H
G
F
E
D
C
B
A
 1 2 3 4 5 6 7 8 9 10

A A

B B

C C

PANEL LABEL PANEL LABEL

D D
SCREEN SEQUENCE

50X15 50X15
E E

PANEL LABEL

PRE-START SIREN
MAN / OFF / SEQ
(COMPLETE)
F F
50X15 50X15

G PANEL LABEL G

PUMP EMG. STOP RESET

(HEALTHY)

50X15 50X15
H H

PANEL LABEL

I MANUAL I

50X15

J J

K K

L L

M M

CLIENT: PROJECT: PROJECT NO: 2041 SUB PROJECT NO: 20410002 REVISION SHEET 16 OF 16 SHEET(S)
TEREX GB LIMITED FM60 50Hz MACHINE DETAILS: AS BUILT
AXON DRAWN NO: 20410002-2 DRAWING BY: A.T.
POWER & CONTROL
TITLE:
FINESMASTER 60 COMPACT
SHEET
DETAILS:
7 - Labels
LABELS ORDER CHECKED BY: PMK APPROVED BY: JD REV BY: C.MULLAN DATE: 17/07/2013
SECTION 7-1 REVISION 2
1 2 3 4 5 6 7 8 9 10
 1 2 3 4 5 6 7 8 9

A
project: FM120C_2G_CLASSIFIER A

Order:

B
Contents: B
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

C C

D D

E E

F F

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 1
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

-PT4

60X80NS

A A
53 61 71 83

21 A1 A2 -KM.A1D
A1 A2 A1 A2 21 A1 A2 A1 A2 A1 A2 21 A1 A2 21 A1 A2 21 A1 A2
A1 B1 17 A1 B1 17

13 1 3 5 100-FA22 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5
54 62 72 84
1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13 1 3 5 13
-T1
-CB1 -CB2 -CB3 -CB4 -CB7
53
-KM161 71 83
-KM1D -KM1S -T2 53
-KM261 71 83 53 61
-KM2D 71 83 53 61
-KM2S 71 83 53
-KM361 71 83 53
-KM461 71 83 53
-KM761 71 83

ALLEN-BRADLEY ALLEN-BRADLEY
700-FSY 700-FSY

-KM.A1 -KM.A2 -KM.A2D -KM.A2S -KM.A3 -KM.A4 -KM.A7

-1

-2
100-C23KD10 100-C23KD10 100-C12KD10 100-C23KD10 100-C23KD10 100-C12KD10 100-C16KD10 100-C16KD10 100-C16KD10
I 100-FA22 I 100-FA22 100-FA22 100-FA22 I 100-FA31 I 100-FA31 I 100-FA31
O 54 62 72 84 O 54 62 72 84 54 62 72 84 54 62 72 84 O 54 62 72 84 O 54 62 72 84 O 54 62 72 84
1492-SPM3D400 1492-SPM3D500 1492-SPM3D200 1492-SPM3D200 1492-SPM3D160
18 28 A2 18 28 A2
14 14 14 14 14
2 4 6 2 4 6 14 2 4 6 14 2 4 6 14 2 4 6 2 4 6 14 2 4 6 14 2 4 6 14 2 4 6 2 4 6 14 2 4 6 2 4 6 14 2 4 6 2 4 6 14
22 22 22 22 22
-CB.A1 -CB.A2 -CB.A3 -CB.A4 -CB.A7
1 3 5 1 3 5
1 3 5 1 3 5 1 3 5

-OL1 -OL2 -OL3 -OL4 -OL7

193-EEEB 193-EEEB
193-EEEB 193-EEEB 193-EEEB
95 96 97 98 95 96 97 98
95 96 97 98 95 96 97 98 95 96 97 98

2 4 6 2 4 6
2 4 6 2 4 6 2 4 6

-PT6

60X80NS

21 A1 A2 21 A1 A2 21 11 21 11 21 11 21 11 21 11
A1 13 23 33 15 15
13 13 14 24 Y1 Y2
1 3 5 1 3 5 1 3 1 3 1 3
24 14 24 14 24 14 24 14 24 14
1 3 5 13 1 3 5 13 A1 B1 A1 B1
PWR
-CB5 -CB6 22 12 22 12 22 12 22 12 22 12 -CB9 -CB8 -CB 10
53 61 71 83 53 61 71 83
-KM5 -KM6
CH1

CH2
13 23 33 Y43

-L1 -L2 -L3 -PE

-KM.A5 -KM.A6
100-C16KD10 100-C16KD10 14 24 34 Y44 7 8 9 10 11 7 8 9 10 11 7 8 9 10 11 7 8 9 10 11
I 100-FA31 I 100-FA31 I I I
O 54 62 72 84 O 54 62 72 84 Schneider O O O
1492-SPM3D200 1492-SPM3D200 -ESR3 1492-SPM2D060 1492-SPM2D100 1492-SPM2D020
A2 A2
14 14 -ESR3 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6 2 3 4 5 6
2 4 6 14 2 4 6 14 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1
22 2 4 6 22 2 4 6 A1 14 24 34 2 4 2 4 2 4
16 18 16 18
-CB.A5 -CB.A6 A2 PE Y43Y44

B B
1 3 5 1 3 5

-OL5 -OL6

193-EEEB 193-EEEB

95 96 97 98 95 96 97 98

2 4 6 2 4 6

-PT7

60X80NS

-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1
-X1

-X2
-X2
-X2

-X3
-X3
-X3
-X3
-X3
-X3
-X3
-X3

-X4
-X4

-X5
-X5

420
460
440

400
380
480

0
PE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 1 2 3 4 5 6 7 8 1 2 1 2

-Tx1

WV1000P7S8

PE 0 110 0 110

60X80NS

60X80NS
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-PT3

60X80NS

-PT5

-PT2
For this document and the object represented in that we reserve all rights according to DIN 34.

C C

500mm 500mm

EMERGENCY STOP PRESTART CLASSIFIER CONTROL COMPRESSOR SAND CONVEYER NO.1 SAND CONVEYER NO.2 DEWATERING SCREEN
RESET/HEALTHY READY START/RUNNING START/RUNNING START/RUNNING START/RUNNING

-S2 -S4 -PB4A -PB5A -PB6A -PB3A

3 3 3 3 3

D
X1 X1 X1 X1 X1

4 X2
-P3

4 X2 4 X2 4 X2 4 X2
D
XB4BW36G5 XB4BW33G5 XB4BW33G5 XB4BW33G5 XB4BW33G5 XB4BW33G5

MANUAL MODE MANUAL/OFF/AUTO SEQUENCE MODE COMPRESSOR SAND CONVEYER NO.1 SAND CONVEYER NO.2 DEWATERING SCREEN
SELECTED SELECTED STOP/FAULT STOP/FAULT STOP/FAULT STOP/TRIPPED

-PB4B -PB5B -PB6B -PB3B

1 X1 1 X1 1 X1 1 X1

-P1 -S5
1 1
-P2

2 X2 2 X2 2 X2 2 X2

XB4-BW34G5 XB4-BW34G5 XB4-BW34G5 XB4-BW34G5

2 2
XB4BG33

COARSE PUMP FINES SLURRY PUMP

START/RUNNING START/RUNNING

-PB2A -PB1A
3 X1 3 X1

4 X2 4 X2

XB4BW33G5 XB4BW33B5

1000.00mm
COARSE SLURRY PUMP FINES SLURRY PUMP
STOP/FAULT STOP/FAULT

-PB2B -PB1B
1 X1 1 X1

2 X2 2 X2

XB4-BW34G5 XB4BW34B5

1 1.1

-S1

XB4BS84441.2

E E

I ON

O OFF

191mm
F F

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 2
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 F
A

E
B

D
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

OT160EV03P
-Q1

2
2

35-BK
L1
35-BK
L2
35-BK

2 4 6
1 3 5
L3
35-GNYE
PE

3
3

only in
the E3!
drawing
Changing

0
3

1
2

Revision
ECO
FIRST DRAFT
Update Components

4
Revision text
4

slurry pump control modfied

Date
24/1/17
21/2/17

25/11/16
/5.A1 /4.A3

5
5

-L1

/5.A6 /7.A2

BMC
BMC
BMC

Name
/6.A2

/6.A4 /7.A5

/5.A1 /7.A7

User
-L2

Proved
/5.A6 /7.A7

Date
/6.A2 /7.A2

/6.A4 /7.A5

6
6

Name
/5.A1 /7.A8
-L3

/5.A6 /4.A3

/6.A2 /7.A2

/6.A5 /7.A5

/5.D3 /5.D8
-PE

/6.D2 /4.A3
7
7

/6.D5 /8.D6

/7.D8 /4.E2
Type
M.-Nr.:

8
8

Description:

60502852
Drawing number
FM120C 2 GRADE CLASSIFIER

9
9

No.
Sheet
Location
Assignment

3
16 Sh.
F
A

E
B

D
 1 2 3 4 5 6 7 8 9

A A

-L1 /3.C5
-L3 /3.C6
-PE/3.C7
2.5-GNYE
2.5-BK
2.5-BK
8L1
8L3
PE
B B

1492-SPM2D100 1 3
-CB8
10A 2 4
1
2
Duplication announcement onto third party or utilization of his contents are without forbidden to our.
For this document and the object represented in that we reserve all rights according to DIN 34.

C C
460

440

420

400

480 380

0
-Tx1 PE
WV1000P7S8
4

4
3

D D
55

55
0
2.5-RD
2.5-RD
110AC
0VAC

-PE/3.C7

E E
4

4
3

1492-SPM2D060 1 3
1492-SPM2D020 1 3
-CB9
6A 2 4 -CB 10
2A 2 4
0.75-R
0.75-R
6
5

#0VAC
#110VAC

-X2 1 2 3
8 #0VAC
/8.A1
7 #110VAC
/8.A1
F supply to weir calssifier panel F

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 4
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

-L1 /3.C5
-L2 /3.C6
-L3 /3.C6

-L1 /3.C5
-L2 /3.C6
-L3 /3.C6
A A

10-BK
10-BK
10-BK

10-BK
10-BK
10-BK
1L1

2L1
1L2
1L3

2L2
2L3

/16.C2
/16.D6
/15.C2
/15.C6
1 3 5 1 3 5
-CB1 -CB.A1 -CB2 -CB.A2
1492-SPM3D400 189-AL11 1492-SPM3D500 189-AL11
2 4 6 2 4 6
40A 50A
B B
10-BK
10-BK
10-BK

10-BK
10-BK
10-BK
1L1

2L1
1L2
1L3

2L2
2L3
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

100-MCA02 100-MCA02
For this document and the object represented in that we reserve all rights according to DIN 34.

170-PW23 170-PW23
C C
-KM.A1 -KM.A1D -KM.A1S -KM.A2 -KM.A2D -KM.A2S

100-FA22

100-FA22
100-FA22
100-FA22

100-FA22

100-FA22
1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 1 3 5
-KM1 -KM1D -KM1S -KM2 -KM2D -KM2S
100-C23KD10 100-C23KD10 100-C12KD10 100-C23KD10 100-C23KD10 100-C12KD10
2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6

/8.D2
/15.E3

/8.B3
/16.E3
/16.C8
/8.D3

/9.B5
/9.B5
/8.C2

/15.C7

/15.D7
/8.C2
/15.E3

/16.D8
/8.C3
/16.E4
-PE/3.C7

-PE/3.C7
1 3 5 95 97 1 3 5 95 97
D D
-OL1 -OL2
96 98 96 98
2 4 6 2 4 6

4.0-BK
4.0-BK
4.0-BK
193-EEEB 193-EEEB
/15.D2
/15.C5

/16.D2
/16.D5
4.0-BK
4.0-BK
4.0-BK

2.5-GNYE

4.0-GNYE
2U1
2V1
2W1
set to 17.5A set to 21A
4.0-BK
4.0-BK
4.0-BK

4.0-BK
4.0-BK
4.0-BK
1U1
1V1
1W1

1V2
1U2
1W2

PE

2V2
2U2
2W2

PE
-X1 4 5 6 7 11 12 13 14
-X1 1 2 3 -X1 8 9 10

E E

W1 V2 W1 V2
V1 3~ U2 V1 3~ U2
M M
U1 W2 U1 W2

F F
FINES 15KW SLURRY PUMP COARSE 18KW SLURRY PUMP

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 5
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

-L1 /3.C5
-L2 /3.C6
-L3 /3.C7
-L1 /3.C5
-L2 /3.C6
-L3 /3.C6
A A

2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK

4L1
4L2
4L3
3L1
3L2
3L3

/14.D6
/14.E2
/14.D2
/14.D5
1 3 5 1 3 5
-CB3 -CB.A3 -CB4 -CB.A4
1492-SPM3D200 189-AL11 1492-SPM3D200 189-AL11
2 4 6 2 4 6
20A 20A
B B

2.5-BK
2.5-BK
2.5-BK
4L1
4L2
4L3
2.5-BK
2.5-BK
2.5-BK
3L1
3L2
3L3

-KM.A4

100-FA31
1 3 5

61
53

73
83
-KM.A3
100-FA31

1 3 5 -KM4
61
53

73
83
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-KM3 100-C16KD10

54
62
74
84
2 4 6
For this document and the object represented in that we reserve all rights according to DIN 34.

100-C16KD10
54
62
74
84

/14.D8
/8.C4
/9.B6
/10.D7
2 4 6
C
/14.C8
/8.B4
/9.B6
/10.C7

1 3 5 95 97 1 3 5 95 97
-OL3 -OL4
96 98 96 98
D 2 4 6 2 4 6 D
193-EEEB 193-EEEB
/14.D3
/14.D4

-PE/3.C7/14.D3
/14.D5
set to ??A set to ??A
-PE/3.C7
2.5-BK
2.5-BK
2.5-BK

2.5-BK
2.5-BK
2.5-BK
3U1
3V1
3W1

4U1
4V1
4W1
2.5-GNYE
2.5-GNYE

PE

E E
PE

-X1 15 16 17 18 -X1 19 20 21 22

DEWATERING SCREEN M1 DEWATERING SCREEN M2

400V 50Hz 400V 50Hz
4KW 8.1Afla 4KW 8.1Afla

F F

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 6
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

-L1 /3.C5
-L2 /3.C6
-L3 /3.C6

-L1 /3.C5
-L2 /3.C6
-L3 /3.C7

-L2 /3.C6
-L2 /3.C6
-L3 /3.C6
A A

2.5-BK
2.5-BK
2.5-BK

2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK

6L1

7L1
6L2
6L3

7L2
7L3
5L1
5L2
5L3

/11.D3
/11.C7
/13.D2
/13.C6
/12.D3
/12.C6
1 3 5 1 3 5
1 3 5 -CB6 -CB.A6 -CB7 -CB.A7
-CB5 -CB.A5 1492-SPM3D200 189-AL11 1492-SPM3D160 189-AL11
2 4 6 2 4 6
1492-SPM3D200 189-AL11
2 4 6 20A 16A
B B
20A

2.5-BK
2.5-BK
2.5-BK

2.5-BK
2.5-BK
2.5-BK
6L1

7L1
6L2
6L3

7L2
7L3
2.5-BK
2.5-BK
2.5-BK
5L1
5L2
5L3

-KM.A6 -KM.A7

100-FA31

100-FA31
1 3 5 1 3 5

61
53

73
83

61
53

73
83
-KM.A5 -KM6 -KM7
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

100-FA31
1 3 5 100-C16KD10 100-C16KD10
61
53

73
83

54
62
74
84

54
62
74
84
2 4 6 2 4 6
For this document and the object represented in that we reserve all rights according to DIN 34.

-KM5 /11.E2

/13.C8
/8.D4
/9.B7
/10.E7

/11.C8
/8.C4
/9.B7
/10.B7
C 100-C16KD10
54
62
74
84

2 4 6 C
/12.C8
/8.D4
/9.B6
/10.D7

1 3 5 95 97
1 3 5 95 97 -OL6 1 3 5 95 97
-OL5 2 4 6
96 98 -OL7
D 193-EEEB D
96 98 96 98

/13.E2
/13.C5
2 4 6 2 4 6
193-EEEB 193-EEEB
/12.E3
/12.C5

/11.E3
/11.C6
set to 14.8A

-PE/3.C7
set to 14.8A set to ??A

2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK
2.5-BK

2.5-BK
2.5-BK
2.5-BK

7U1
7V1
7W1
5U1
5V1
5W1

6U1
6V1
6W1

2.5-GNYE
2.5-GNYE
2.5-GNYE

PE
E E

-X1 23 24 25 26 -X1 27 28 29 30 -X1 31 32 33 34

SAND CONVEYER NO.1 SAND CONVEYER NO.2 COMPRESSOR

400V 50Hz 400V 50Hz 400VAC 50Hz
7.5KW 14.8Afla 7.5KW 14.8Afla
F F

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 7
0 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC 7 7 #110VAC
/4.F4 /10.A1
-CB 10:2

#0VAC 8 8 #0VAC
A /4.F4 /10.F1 A
-CB 10:4

15

/8.E6
3 X1 22
-S2
XB4BW36G5 X2
/8.E6 4
61
B -KM.A3 B

16
100-FA31
/6.C2 62
61 /5.C9
62
100-FA22
7

-KM.A1
100-FA22
-KM.A2S
62 61

23

27
13

15
/5.C2

8
27
1 1.1
-S1
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

21
XB4BS8444 61 62
/7.C8 A1 Y1 Y2 13 23 33 Y43
2 1.2 100-FA31
For this document and the object represented in that we reserve all rights according to DIN 34.

17

-KM.A4
100-FA31
-KM.A7
C 62 61 -ESR3 C
61 /5.C8 /6.C5
62 Schneider
100-FA22
-KM.A1D XPSAC3421
100-FA22
-KM.A2D
/5.C3 62 61 A2 PE 14 24 34 Y44

24

26
20
18

14
61 /7.C5
62
61 /5.C6 100-FA31
62 -KM.A5 100 -S5:1, -S5:1
#110VAC_S
100-FA22
100-FA31
-KM.A6 /10.A1
-KM.A1S 62
100-FA22
-KM.A2 /7.C3 61 /10.D3 /10.D5
21 21
D /5.C5 62 61 2987969 2987969 D
-K7 -K8

29
24 22 24 22

100
19 25

/3.C7-PE
28 28 #110VAC_S1
/9.A1
11
10

12

13
14
9

X1
5 6 7 8
-S2
-X3 1 2 3 4
XB4BW36G5
X2
E E
LINK IF NOT USED

ES.1 EXTERNAL PLANT E.STOPS

EMG.STOP RESET
ES.4 (HEALTHY)
29 #0VAC_S
/9.E1

ES.2
F F
ES.3

ON MACHINE E.STOPS
3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 8
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC_S1 28 28 28
/8.D9

28
A

28
A

28
28
73

28

28

28

28
-KM.A3 #110VAC_MAN
100-FA31 /10.A1
74 38

28
/9.B4 53 83 /6.C2
21
2987969

33
-KM.A1 -KM.A2 73 73 73
-K5

28
100-FA22 100-FA22 73 -KM.A5 -KM.A6 -KM.A7
24 22 /9.A4 /5.C2 54 /5.C6 84
-KM.A4 100-FA31 100-FA31 100-FA31
/7.C3 74 /7.C5 74 /7.C8 74
100-FA31
74

37
/6.C5 /9.E7
21
B 2987969 B

32

37

37

37

37

37
-K6
24 22
32 32

30
30 /9.E2
11
2987969
-K5 15 /9.D4
14 12 E1ZM10_12-240

37
/9.D8

3 -T3
X1
18 16
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

32
-S4
For this document and the object represented in that we reserve all rights according to DIN 34.

38
XB4BW33G5 /9.E7
X2 11 35 36
/9.D8 4 2987969
C C
-K6 15
14 12 E1ZM10_12-240
-T4
31

18 16

34
31

22
38

37

38
-T3 37
31

/9.C5
A1
A1 -T4 B1

37
18
D B1 D

34
A1 -T3 15 E1ZM10_12-240 X1
16 A2
-K5 E1ZM10_12-240 /9.D4 Set to 15 sec A1
Set to 7 sec A2 -S4
2987969 -K6
/9.E2 A2 XB4BW33G5
2987969
/9.E7 A2 X2
29

29

29

29

29
#0VAC_S 29 29 29 29 29 29 29 29 29 #0VAC_S
/8.F9 /11.F1
-K6
/9.D7

-K5 14
11
/9.D2 12
E 14
/9.C3
24
E
11 21
12 22

22
34
/9.B3 /9.B8
24 2987969
21
22

2987969
-X5 1 2

FEEDER/PLANT
PRESTART SOUNDER

F F

7 Date Name Type Description: Assignment

Changing
6 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
5 Update Components 24/1/17 BMC User
only in Drawing number Sheet 9
4 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC_S
/8.D9

#110VAC_MAN #110VAC_MAN
/9.A9 /11.A1
A A
#110VAC #110VAC
/8.A9 /11.A5

38

38
/10.D5
7

11
2987969
/10.D3 -K8 SEQUENCE MODE
11
2987969 14 12
MANUAL MODE -K7

100
B 14 12

43
B

83
-KM.A7 COMPRESSOR RUNNING
100-FA31
84

50
/7.C8

45

43
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

83
For this document and the object represented in that we reserve all rights according to DIN 34.

-KM.A3 DEWATER M1
100-FA31 /10.E1
C 21 C
/6.C2 84 2987969
-K9

46
24 22 CLASSIFIER READY
83
7

-KM.A4

1
1
| 0 || DEWATER M2
-S5 100-FA31

SEQUENCE MODE
/6.C5 84

2
2
/10.D1
11

MANUAL MODE
2987969 XB4BG33

47
-K9
14 12 -K7 -K8
/10.E4 /10.E4
83
14 14 -KM.A5 SAND CONYEYER 1
D 11 11 100-FA31
D
-K9 -K9A 12 12 84

44
/10.B7 /10.B7 /7.C3
/10.E1 /10.E2 24 24 -K10
21 21
14 14 22 22 /10.F6
40

48
11 11 /8.D8 /8.D8
12 12 2987969 2987969 14
/10.D3 /10.E6 11
24 24 12
21 21 /10.E6 83
22 22 24
/10.C8 21
2987969 2987969 22 -KM.A6 SAND CONYEYER 2
41

100-FA31
2987969 /7.C5 84
41

42
-P3.1

-P1.

-P2.

49
1
42

49

49
E
39

39

E A1
XB4BVG3 XB4BVG5 -K7 A1 11 /10.D2 A1

15
2987969 -T5 B1 OFF DELAY TIMER
A1 A1 2987969 -K8 XB4BVG5
SET 5 MIN
A2 -K9A

-T5
-K9 -K9A -P3 -P1 /10.D4 2987969 A2

18
16
2 /10.D5 A2 /10.D6 14 12 Set to 15 sec
2987969 2987969 -P2 11
A2 A2 2987969

100

/10.E8
-P1._1
-P3.2

/10.D2 /10.D2
-K10
-P2._1

50
8

A1
14 12 #110VAC_PUMP RUN_SIG
-K10 /15.A1
50
8

8
2987969
/10.D6 A2
#0VAC #0VAC
/8.A9 /11.F6

F F
101
102
39
7

-X4 3 4
-X4 1 2
FEEDER RUN
CLASSIFIER READY
3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 10
0 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC 7 7 #110VAC
/10.A9 /12.A5

7
#110VAC_MAN #110VAC_MAN
A /10.A9 /12.A1 A

38
1 X1
-PB4B
XB4-BW34G5 X2
2

7
51
B B

7
51

51

/11.E9
97 21
13 3 X1 -OL7 -CB.A7
-KM7 -PB4A 193-EEEB 189-AL11
98 22
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

100-C16KD10 XB4BW33G5 /7.D8 /7.B8 53

14 4 X2 set to ??A
For this document and the object represented in that we reserve all rights according to DIN 34.

/11.E2 /11.E9
-KM.A7
C 100-FA31
54 C
52

54

54
/7.C8
52
52

13

55
-CB.A7
D 189-AL11 14 D
/7.B8
49

95

54
-OL7
193-EEEB
/7.D8 96
X1 X1
set to ??A
-PB4B RED -PB4A GREEN
XB4-BW34G5 XB4BW33G5
53

-KM7 X2 X2
E
E /11.E3
1 2
A1
3 4 -KM7
/7.C7 100-C16KD10
5 6 A2
/11.E2
13 14
/11.C2

8
100-C16KD10
29

#0VAC_S #0VAC_S #0VAC #0VAC

/9.E9 /12.F1 /10.F9 /12.F5

F TRIPPED RUNNING F

COMPRESSOR
3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 11
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

7
#110VAC 7 #110VAC
/11.A9 /13.A5

A A

7
#110VAC_MAN #110VAC_MAN
/11.A3 /13.A1

38
1 X1
-PB5B
XB4-BW34G5 X2
2

56
B B

7
97 21
56

56
-OL5 -CB.A5

/12.E8
193-EEEB 189-AL11
/7.D2 98 /7.B2 22
13 3 X1 set to 14.8A
-KM5 -PB5A
100-C16KD10 XB4BW33G5 X2
14 4
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

60
/12.E8
For this document and the object represented in that we reserve all rights according to DIN 34.

60
53
57

57

C -KM.A5 C
100-FA31
/7.C2 54
57

13

-CB.A5
189-AL11 14
/7.B2
D D

61
58

60
95
-OL5
193-EEEB
/7.D2 96
X1
set to 14.8A
X1
-PB5A
-PB5B XB4BW33G5
E
E
XB4-BW34G5 X2
59

X2
A1
-KM5

8
100-C16KD10
A2

8
29

#0VAC_S 29 #0VAC_S #0VAC 8 8 8 #0VAC

/11.F3 /13.F1 /11.F9 /13.F5

F F
SAND CONVEYER NO.1

3 Date Name Type Description: Assignment

Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 12
0 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC #110VAC
/12.A9 /14.A4

A A
#110VAC_MAN -PB3B:1 #110VAC_MAN
/12.A3 /14.A1

38

7
1 X1
-PB6B
XB4-BW34G5 X2
2
B B

62

7
97
62

-OL6 21
62

/13.E8
193-EEEB -CB.A6
/7.D5 98
13 3 X1 189-AL11
set to 14.8A 22
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

-PB6A /7.B5
-KM6
For this document and the object represented in that we reserve all rights according to DIN 34.

100-C16KD10 X2
14 /13.E8 4
C 53
C

66

66
XB4BW33G5
-KM.A6
63

63

100-FA31
/7.C5 54
63

13
D D
-CB.A6
189-AL11 14
/7.B5

67
64

66
95
-OL6
E 193-EEEB E
/7.D5 96
X1 X1
set to 14.8A
-PB6B -PB6A
XB4-BW34G5 XB4BW33G5
65

X2 X2
A1
-KM6
100-C16KD10
A2

8
29

8
#0VAC_S #0VAC_S
/12.F3 /14.F1

F /12.F9
#0VAC #0VAC
/14.F5
F

SAND CONVEYER NO.2

3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 13
0 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC #110VAC
/13.A9 /15.A5

A A
#110VAC_MAN
/13.A3

38
1 X1
-PB3B

7
XB4-BW34G5 X2
2

7
68
B
68

B
68

13
-KM3 /14.E8
100-C16KD10 3 X1
14
-PB3A
XB4BW33G5 X2
53
4
69

/14.E8
-KM.A3
100-FA31
54
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

13 /6.C2
For this document and the object represented in that we reserve all rights according to DIN 34.

70

-KM4
C 100-C16KD10
14 C
70

77
72

7
70

95

7
-OL3
13 193-EEEB 53
/6.D2 96
97 21 97 21 -KM.A4
-CB.A3 set to ??A
-OL3 -CB.A3 -OL4 -CB.A4 100-FA31
189-AL11 14 /6.C5 54
/6.B2 193-EEEB 189-AL11 193-EEEB 189-AL11
D 98 22 98 22 D
73

/6.D2 /6.B2 /6.D5 /6.B5

set to ??A set to ??A
71

95

76

76

76

76
13 -OL4
193-EEEB
-CB.A4 /6.D5 96
189-AL11 14 set to ??A
/6.B5
72

74

78
76
E E
X1 X1
74

74

-PB3B -PB3A
XB4-BW34G5 XB4BW33G5
A1 A1
RED X2 GREEN X2
-KM3 -KM4
100-C16KD10 100-C16KD10
A2 A2
29

29

8
#0VAC_S #0VAC_S
/13.F3 /15.F1
F F
#0VAC #0VAC
/13.F9 /15.F5

TRIPPED RUNNING
DEWATERING SCREEN
3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 14
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC #110VAC
/14.A9 /16.A4

A 50 50
A
#110VAC_PUMP RUN_SIG #110VAC_PUMP
-PB2B:1 RUN_SIG
/10.F9 /16.A1

50

/15.E6
1 X1
-PB1B

7
XB4BW34B5 X2
2

79
B B

7
79

79

/15.E7
13 3 X1
-KM1 -PB1A
100-C23KD10 XB4BW33B5 X2
14 /15.E7 4
80

7
83
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

80

-KM.A1
For this document and the object represented in that we reserve all rights according to DIN 34.

100-FA22
/5.C2 84
C 13 97 21
C
-CB.A1 -OL1 -CB.A1
193-EEEB 189-AL11
189-AL11 14 /5.D3 98 /5.B2 22
/5.B2 set to 17.5A
81

84
83

83
95
-OL1
193-EEEB
/5.D3 96
set to 17.5A
53
D D
-KM.A1D
82

100-FA22
/5.C3 54
82

17

-T1
28 18
30 97

83

85
71 71
-KM.A1S -KM.A1D
E
82

E 100-FA22 100-FA22
72 72
82

/5.C5 /5.C3 X1
X1
-PB1B
75

36

XB4BW34B5 -PB1A
A1 A1
X2 XB4BW33B5
A1 -KM1 -KM1D A1
-T1 RED X2
100-C23KD10 100-C23KD10 -KM1S
A2 A2 A2 GREEN
100-C12KD10
A2
29

29

29

29

8
#0VAC_S #0VAC_S
/14.F4 /16.F1
F F
#0VAC #0VAC
/14.F9 /16.F5
TRIPPED RUNNING

FINES 15KW SLURRY PUMP

3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 15
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
 1 2 3 4 5 6 7 8 9

#110VAC
/15.A9

A A
#110VAC_PUMP RUN_SIG
/15.A3

50
1 X1
-PB2B
XB4-BW34G5 X2
2

86

7
86

86

/16.E8
B B

7
3 X1
13 -PB2A
-KM2 XB4BW33G5 X2
/16.E8 4
100-C23KD10
14
87
87

53
-KM.A2
100-FA22
54
Duplication announcement onto third party or utilization of his contents are without forbidden to our.

87

/5.C6
For this document and the object represented in that we reserve all rights according to DIN 34.

95
C 13
C
-CB.A2
189-AL11 14
/5.B6
97
-OL2 21
88

193-EEEB -CB.A2
/5.D7 98
95 189-AL11 53
set to 21A /5.B6 22
-OL2 -KM.A2D
193-EEEB 100-FA22
96 54

94
/5.D7 /5.C7
set to 21A

94
D D
89

96
89

17

-T2
28 18

94

96
90

92

96
X1
89

89

71 71 X1
-PB2A E
E -KM.A2S -KM.A2D -PB2B XB4BW33G5
100-FA22 100-FA22 -HR1
/5.C9 72 /5.C8 72 XB4-BW34G5 X2
Hrs Run
X2 GREEN
A1
RED
91

93

A1 -KM2
-T2 100-C23KD10 A1 A1
A2 A2
-KM2D -KM2S

8
100-C23KD10 100-C12KD10
A2 A2

8
29

29

29

29

#0VAC_S
/15.F4
F F
#0VAC
/15.F9
TRIPPED RUNNING

COARSE 18KW SLURRY PUMP

3 Date Name Type Description: Assignment
Changing
2 slurry pump control modfied 21/2/17 BMC FM120C 2 GRADE CLASSIFIER
drawing M.-Nr.: Location
1 Update Components 24/1/17 BMC User
only in Drawing number Sheet 16
0 FIRST DRAFT 25/11/16 BMC
the E3! Proved 60502852 No. 16 Sh.
Revision ECO Revision text Date Name
1 2 3 4 5 6 7 8 9
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