MODEL GT104

GT104 ®

GLOBAL TRACK

OPERATION & MAINTENANCE MANUAL

A GGR EGAT E AND

M IN IN G GROUP

OM-GT104 9/15
Table of Contents
Section 1: Introduction 7
OVERVIEW 9
PLANT CAPACITY 9
QUICK FACTS 9
SPECIFICATIONS SHEET 10
GETTING TO KNOW YOUR SCREENING PLANT 14
SERIAL PLATE 16
ADDITIONAL INFORMATION 17
INTRODUCTION NOTES 18

Section 2: Safety 19
TRAINING 19
UNDERSTAND SIGNAL WORDS 19
DANGER OR WARNING 19
LOCKOUT/TAGOUT 19
FOLLOW SAFETY INSTRUCTIONS 22
REPLACE SAFETY SIGNS 22
PREVENT BYPASS STARTING 22
HANDLE FUEL SAFELY – AVOID FIRES! 22
PREPARE FOR EMERGENCIES 22
SERVICE ENGINES SAFELY 22
HANDLE STARTING FLUID SAFELY 22
PROTECT AGAINST NOISE 23
WEAR PROTECTIVE CLOTHING 23
INSTALL FAN GUARDS 23
HANDLE CHEMICAL PRODUCTS SAFELY 23
PRACTICE SAFE MAINTENANCE 23
AVOID HIGH PRESSURE FLUIDS 23
SERVICE COOLING SYSTEM SAFELY 24
WORK IN VENTILATED AREA 24
DISPOSE OF WASTE PROPERLY 24
AVOID HEATING NEAR PRESSURIZED FLUID LINES 24
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM 24
REMOVE PAINT BEFORE WELDING OR HEATING 24
AVOID HOT PARTS 25
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM 25
PREVENT BATTERY EXPLOSIONS 25
GT104 Manual III
 Table of Contents
AVOID HARMFUL ASBESTOS DUST 25
PROTECT AGAINST HIGH PRESSURE SPRAY 25
HANDLING BATTERIES SAFELY 26
SAFETY DECALS 27
SAFETY FEATURES 29
SAFETY NOTES 32

Section 3: Setup 33
CONTROL PANEL 33
ENGINE REMOTE (WIRED) 34
ENGINE REMOTE (WIRELESS) 35
STARTING AND MOVING THE MACHINE 36
ENGINE START-UP PROCEDURES 38
TRACKING USING THE MANUAL TRACKING DOGLEAD 39
TRACKING USING THE RADIO REMOTE 39
OPERATING PRECAUTIONS 40
WORKING CONDITIONS 40
SITE SELECTION 41
TRACKING MACHINE SET-UP 42
ACTIVATE TRACKS (WIRED REMOTE) 43
ACTIVATE TRACKS (WIRELESS REMOTE) 44
OPERATING TRACKS 45
ADDITIONAL INFORMATION 46
VALVE LOCATIONS 47
CONTROLS 48
BOTTOM DECK OVERS CONVEYOR 50
FINES SIDE CONVEYOR 52
INTRODUCTION TO CONVENTIONAL SCREENING 54
“K” SERIES SCREEN 55
SCREENING APPLICATION 59
SCREENING EFFICIENCY 61
FACTORS FOR CALCULATING SCREEN AREA 62
CHARTS FOR CALCULATING SCREEN AREA 63
SITE SELECTION AND PREPARATION 64
DIRECTION OF ROTATION 65
CROWN RUBBER 65
SCREEN CLOTH INSTALLATION 66
IV GT104 Manual
Table of Contents
SETUP NOTES 68

Section 4: Operation & Maintenance 69

PRE-OPERATION CHECKS 69
OPERATIONAL CHECKS 71
ENGINE MAINTENANCE SCHEDULE 73
MACHINE MAINTENANCE SCHEDULE 75
FUEL RECOMMENDATIONS 76
REPLACEMENT FILTERS 76
TURNING SCREENING PLANT ON 77
START-UP AND SHUTDOWN 78
OBSERVING SCREEN 79
OPERATION 79
DAILY SHUT-DOWN 79
PRE-OPERATION/OPERATION CHECKLIST 80
SCREEN BOX MAINTENANCE/SERVICE INTERVALS 80
SCREEN ADJUSTMENTS 81
SCREEN MAINTENANCE & LUBRICATION 82
SCREEN TROUBLESHOOTING 85
OVERALL INSPECTION 86
HYDRAULIC MAINTENANCE 86
TRAINING THE BELT 87
BELT TENSION 88
GUARDS 88
BELT CLEANERS 88
BEARINGS 88
HYDRAULIC FILTERS 89
ENGINE FILTERS 90
ENGINE/HYDRAULIC FLUIDS 91
SCREEN CLOTH REPLACEMENT 93
BOTTOM DECK REPLACEMENT 94
TOP DECK COMPONENTS 96
TOP DECK REPLACEMENT 97
MAIN CONTROL PANEL WARNING LIGHTS 98
STORAGE INFORMATION 99
OPERATION AND MAINTENANCE NOTES 101

GT104 Manual V
 Table of Contents

VI GT104 Manual
Table of Contents

Section 5: Warranty 102

STANDARD WARRANTY 102

GT104 Manual VII

 Table of Contents

VIII GT104 Manual

Section 1: Introduction
Introduction Parts
This manual contains safety, setup, operation, The parts section contains drawings of all specific
maintenance, and parts sections. Keep this pieces of the plant. Each drawing contains lines
manual stored in the manual container located with balloons for each sub-part. When calling for
beneath the main control panel of the unit. Keep replacement parts, please provide the service
this manual with the unit at all times. The manual department with the part number that the balloon
should remain with the unit to assist in training, refers to, along with the serial of the machine the
operation, setup, and maintenance procedures. parts are needed for.

Please keep in mind that parts and procedures Disclaimer

in this manual may differ from your exact model. Continuing improvement and advancement
The data used to created this manual are based of AMS products may cause changes to your
on the latest information at the time of publication. equipment which may not be reflected in this
Due to Astec Mobile Screens’ policy of continuous publication.
improvement, features and specifications are
subject to change without notice. All engineering AMS reserves the right to make changes or add
drawings provided in this manual are model improvements to its product at any time, without
specific. Refer to engineering drawings as incurring any obligation to make such changes
needed, they are the best source of model specific on previously manufactured equipment.
information.
Although care has been taken to assure the ac-
Safety curacy of this publication, AMS does not assume
The safety section of this manual is filled with any liability for loss, damage, or injury caused by
procedures that should be followed at all times. errors or omissions.
Take the time to read the safety section of the
manual and obey all safety information presented Contact Astec Mobile Screen
on the unit. Safety is important! Phone (Toll Free).....(800) 545-2125
Fax...........................(815) 626-6430
Operation
Do not attempt to operate this machine without Email
fully reading the manual first. The operation section Parts...... [email protected]
of the manual is arranged in a manner that must Sales..... [email protected]
be followed sequentially. If the description does
not match your unit, or there is a discrepancy in
the data, contact your local Astec Mobile Screens
Dealer for assistance.

Maintenance
Due to the nature of equipment and environmental
variables that may be present, it is imperative to
perform a daily review of your equipment. Pay
close attention to the daily checks outlines in
the Maintenance section of this manual. Failure
to follow maintenance guidelines could result in
premature wear, or damage to equipment.

GT104 Manual 9
 Section 1: Introduction

10 GT104 Manual
Section 1: Introduction

OVERVIEW PLANT CAPACITY

The GT104 provides a rugged, mobile screen- Screening plant can process up to 220 TPH or
ing tool in a highly portable configuration. The more of feed material. Actual tonnage will vary
GT104 was designed to provide contractors and depending on application requirements; feed
producers with a versatile screening plant that material size, material seperation, type of screen
would handle high volumes of material in both used, weight of product and other material con-
scalping and sizing applications. The large load- siderations.
ing hopper with a HD variable speed belt feeder
can withstand heavy loads while metering feed
material to the screen to optimize screening
production and efficiency. The true 4’ wide x 9’
long incline screen can be equipped with an ar-
ray of screen media choices including: standard
woven wire, punch plate, grizzly decks and fin-
ger decks. The oversize discharge conveyor is
impact-resistant to handle oversize material. The
GT104 is a perfect tool for overburden, scalping
ahead of or behind a primary crusher, as well as
screening a wide array of materials from aggre-
gates to recycled materials to organics.

QUICK FACTS
Screen 4’ X 9’ - 1.22m x 2.74m 2 Deck Screen
Loading Hopper Capacity 5.25 Cubic Yards Heaped
Feeder 42” - 1050mm
Underscreen Fines Conveyor 42” - 1050mm
Top Deck Overs Conveyor 42” - 1050mm
Bottom Deck Overs Conveyor 26” - 650mm
Fines Conveyor 26” - 650mm
Fuel Tank Capacity 55 gal - 208L
Hydraulic Tank Capacity 85 gal - 322L
Engine 74HP Kohler

GT104 Manual 11
 Section 1: Introduction

SPECIFICATIONS SHEET

VIBRATING SCREEN UNDERSCREEN CONVEYOR

- 4’ (1.22m) x 9’ (2.74m) top and bottom - One (1) 9’ (2.74m) x 42” (1050mm)
deck fixed conveyor
- 900 RPM adjustable amplitude - Vulcanized belt
- Fixed 15 degree angle
- Top deck has side tensioned screen BOTTOM DECK OVERS CONVEYOR
cloth, bottom deck has end-tensioned
screen cloth - One (1) 25’ (7.62m) x 26” (650mm) fold
- Modular top deck design out design
- Hydraulic variable speed
HOPPER/BELT FEEDER - 10’5” (3.18m) fixed discharge height; 25
degree angle
- 5.25 cubic yard heaped capacity - Chevron belt, vulcanized
- Impact bed
- 13’ (3.96m) x 42” (1050mm) belt feeder FINES CONVEYOR
- Hydraulic variable speed single motor
drive - One (1) 24” (7.32m) x 26” (650mm) fold
- Toughflex grade X cover, vulcanized out design
- Hydraulic variable speed
OVERS CONVEYOR - 11’ (3.35m) fixed discharge height
- Smooth belt, vulcanized, primary belt
- One (1) 14’ (4.27m) x 42” (1050mm) cleaner
fixed conveyor
- Hydraulic variable speed drive CHASSIS
- Staggered impact bed
- Chevron belt, vulcanized - Fabricated I-beam frame
- 8’10” (2.69m) fixed discharge height - Track mount design
- Pendant remote control

12 GT104 Manual
Section 1: Introduction

SPECIFICATIONS SHEET

POWER UNIT OPTIONS AVAILABLE

- Punch plate top deck (flat or crowned)
- Kohler 74HP Tier IV water cooled diesel - Grizzly bars top deck
engine - Tine deck top deck
- 55 gal/ 208L fuel tank - Wireless track remote
- Oil cooler - Ball tray for bottom deck module
- 85 gal/ 322L hydraulic reservoir - Rear loader feed wings
- Engine mounted hydraulic pumps to - HD hydraulic grizzly for hopper
operate all plant functions - Standard steel screen cloth both decks
- NEMA-4 rated instrument panel
- Emergency Stops
Note: Specifications are subject to change without
notice.
STANDARD
Dimension Standard Metric Because AMS may use in its catalog & literature, field pho-
tographs of its products which may have been modified by
Operating Length 35’ 1” 10.7m the owners, products furnished by AMS may not necessari-
ly be as illustrated therein. Also continuous design progress
Operating Width 41’ 12.5m makes it necessary that specifications be subject to change
Travel Length 35’ 1” 10.7m without notice. All sales of the products of AMS are subject
to the provisions of its standard warranty. AMS does not
Travel Width 8’ 2.4m warrant or represent that its products meet any federal,
Operating Height 11’ 8” 3.6m state, or local statutes, codes, ordinances, rules, standards
or other regulations, including OSHA and MSHA, cover-
Feed Height (Front 8’ 7” 2.6m ing safety, pollution, electrical wiring, etc. Compliance with
Feed) these statutes and regulations is the responsibility of the
user and will be dependent upon the area and the use to
Travel Height 10’ 5” 3.2m which the product is put by the user. In some photographs,
Feed Height (Side 10’ 2” 3.1m guards may have been removed for illustrative purposes
only. This equipment should not be operated without all
Feed) guards attached in their normal position. Placement of
Maximum Feed 12” 305mm guards and other safety equipment is often dependent
upon the area and how the product is used. A safety study
Unit Weight 36,000 lbs. 16,329 kg should be made by the user of the application, and, if
required additional guards, warning signs and other safety
devices should be installed by the user, wherever appropri-
ate before operating the products. Rev: 8/2015

GT104 Manual 13
 Section 1: Introduction
TRANSPORTATION DIMENSIONS
[3.2]
10'-5"

[2.4]
8'
35'-1"
[10.7]
25'-2"
[7.7]

14 GT104 Manual
15 GT104 Manual
10'-5"
[3.2]
35'-1"
[10.7]
11'
[3.4]
8'-10"
[2.7]
41'
[12.5]
11'-8"
[3.6]
OPERATION DIMENSIONS
Section 1: Introduction
 Section 1: Introduction

TOP DECK
OVERS CONVEYOR

SCREEN

CHASSIS TRACKS
BELT FEEDER

GETTING TO KNOW YOUR SCREENING PLANT

It is important to get to know the main
components of your screening plant.
The names of these components will be
referenced later in this manual.

16 GT104 Manual
 Section 1: Introduction

BOTTOM DECK
OVERS CONVEYOR

HOPPER WINGS

UNDERSCREEN
CONVEYOR

FINES CONVEYOR

ENGINE
ENCLOSURE FEED HOPPER

GT104 Manual 17
 Section 1: Introduction

Figure 18.1

SERIAL PLATE
Located on both the machine frame (usually Make sure you are aware of where these plates
near the manual container) and screen box are are located on the machine as they will be es-
a serial plate (Figure 18.1) sential is determining proper parts are service
on this machine.
18 GT104 Manual
Section 1: Introduction

ADDITIONAL INFORMATION
Each hydraulic spool valve is labeled with a NOTE: Failure to follow all instructions can
black and white decal. Throughout the manual result in damage to the equipment, serious
we will refer to the action of Pulling or Push- injury, or DEATH. Please note all safety cym-
ing the valve. Pull means to force the valve UP bols that accompany each step.
towards the sky and Push means to force the
valve DOWN towards the ground.

A series of steps must be completed to unfold

the plant before operation can begin. Through-
out the setup and operating sections of this
manual the plant orientation will be referred to
as if you were standing behind the feeder
and facing towards the top deck overs con-
veyor. All “sides” and “direction” of the plant will
be indicated as follows:

Roadside: Your left side. The roadside section

of the plant contains control panel as well as
valves for the feeder and screen box. You can
also find access to the fuel tank and various
grease points.

Curbside: Your right side. The curbside section

of the plant contains access to the fuel tank as
well as various grease points.

Back: The feeder is located in the back of the

machine. Here you will find the wired remote
hookup as well as various grease points.

Front: The front of the plant is where the top

deck overs conveyor is located. Here you will
also find valves for the top deck overs, bottom
deck side, and fines side conveyors as well as
various grease points.

Prior to attempting each step, read the entire

step first. At the beginning of each step a brief
explanation of that step will be given. Following
the brief explanation will be a more detailed de-
scription of how to complete each step. Follow
the steps sequentially. It is important to fold and
unfold the plant in the proper order.

GT104 Manual 19
 Section 1: Introduction

INTRODUCTION NOTES

20 GT104 Manual
Section 2: Safety
TRAINING to the potential for personal injury. Follow
Safety instructions are important! Read all at- recommended precautions and safe operating
tachment and power unit manuals; follow all practices.
safety rules and safety decal information. Re-
placement manuals and safety decals are avail- Indicates a
able from your dealer. Failure to follow instruc- potentially
tions or safety rules can result in serious injury or hazardous
death. If you do not understand any part of this situation which, if not avoided, may result in
manual and need assistance, see your dealer. minor or moderate injury. Caution may also be
used to alert against unsafe practices.
Know your controls and how to stop engine and
attachment quickly in an emergency. Indicates a
potentially
Operators must be instructed in and be capable hazardous
of the safe operation of the equipment, its attach- situation which, if not avoided, could result in
ments, and all controls. death or serious injury.

Do not allow anyone to operate this equipment Indicates an im-

without proper instructions. mediately haz-
ardous situation
Keep hands and body away from pressurized which, if not avoided, will result in death or seri-
lines. Use paper or cardboard, not hands or ous injury. Danger is limited to the most extreme
other body parts to check for leaks. Wear safety situations.
goggles. Hydraulic fluid under pressure can eas-
ily penetrate skin and will cause serious injury or IMPORTANT: Indicates that failure to ob-
death. serve can cause damage to equipment.

Make sure that all operating and service person- NOTE: Indicates helpful information.
nel know that if hydraulic fluid penetrates skin, it
must be surgically removed as soon as possible
by a doctor familiar with this form of injury or gan-
grene, serious injury, or death will result. CON- LOCKOUT/TAGOUT
TACT A PHYSICIAN IMMEDIATELY IF FLUID
ENTERS SKIN OR EYES. DO NOT DELAY. What is the OSHA standard for control of haz-
ardous energy sources?
UNDERSTAND SIGNAL WORDS The OSHA standard for The Control of Hazard-
A signal word DANGER, WARNING OR CAU- ous Energy (Lockout/Tagout), Title 29 Code of
TION is used with the safety alert symbol. DAN- Federal Regulations (CFR) Part 1910.147, ad-
GER identifies the most serious hazards. dresses the practices and procedures necessary
to disable machinery or equipment, thereby pre-
DANGER or WARNING venting the release of hazardous energy while
safety signs are located near specific hazards. employees perform servicing and maintenance
General precautions are listed on CAUTION activities. The standard outlines measures for
safety signs. CAUTION also calls attention to controlling hazardous energies—electrical, me-
safety messages in this manual. chanical, hydraulic, pneumatic, chemical, ther-
mal, and other energy sources.
This is a safety alert symbol.
When you see this symbol on your In addition, 29 CFR 1910.333 sets forth require-
machine or in this manual, be alert ments to protect employees working on electric
circuits and equipment. This section requires
GT104 Manual 21
 Section 2: Safety

workers to use safe work practices, including The standards establish requirements that em-
lockout and tagging procedures. These provi- ployers must follow when employees are ex-
sions apply when employees are exposed to posed to hazardous energy while servicing and
electrical hazards while working on, near, or with maintaining equipment and machinery. Some of
conductors or systems that use electric energy. the most critical requirements from these stan-
dards are outlined below:
Why is controlling hazardous energy sources ■■ Develop, implement, and enforce an energy
important? control program.
Employees servicing or maintaining machines or ■■ Use lockout devices for equipment that can
equipment may be exposed to serious physical be locked out. Tagout devices may be used in
harm or death if hazardous energy is not prop- lieu of lockout devices only if the tagout pro-
erly controlled. Craft workers, machine opera- gram provides employee protection equiva-
tors, and laborers are among the 3 million work- lent to that provided through a lockout pro-
ers who service equipment and face the greatest gram.
risk. Compliance with the lockout/tagout standard ■■ Ensure that new or overhauled equipment is
prevents an estimated 120 fatalities and 50,000 capable of being locked out.
injuries each year. Workers injured on the job ■■ Develop, implement, and enforce an effective
from exposure to hazardous energy lose an av- tagout program if machines or equipment are
erage of 24 workdays for recuperation. not capable of being locked out.
■■ Develop, document, implement, and enforce
How can you protect workers? energy control procedures. [See the note to
The lockout/tagout standard establishes the em- 29 CFR 1910.147(c)(4)(i) for an exception to
ployer’s responsibility to protect employees from the documentation requirements.] Use only
hazardous energy sources on machines and lockout/tagout devices authorized for the par-
equipment during service and maintenance. The ticular equipment or machinery and ensure
standard gives each employer the flexibility to that they are durable, standardized, and sub-
develop an energy control program suited to the stantial.
needs of the particular workplace and the types ■■ Ensure that lockout/tagout devices identify
of machines and equipment being maintained or the individual users.
serviced. This is generally done by affixing the ■■ Establish a policy that permits only the em-
appropriate lockout or tagout devices to energy- ployee who applied a lockout/tagout device
isolating devices and by de-energizing machines to remove it. [See 29 CFR 1910.147(e)(3) for
and equipment. The standard outlines the steps exception.]
required to do this. ■■ Inspect energy control procedures at least
annually.
What do employees need to know? ■■ Provide effective training as mandated for all
Employees need to be trained to ensure that employees covered by the standard.
they know, understand, and follow the applicable ■■ Comply with the additional energy control pro-
provisions of the hazardous energy control pro- visions in OSHA standards when machines
cedures. The training must cover at least three or equipment must be tested or repositioned,
areas: aspects of the employer’s energy control when outside contractors work at the site, in
program; elements of the energy control proce- group lockout situations, and during shift or
dure relevant to the employee’s duties or assign- personnel changes.
ment; and the various requirements of the OSHA
standards related to lockout/tagout.

What must employers do to protect employ-

ees?
22 GT104 Manual
Section 2: Safety

How can you get more information?

OSHA has various publications, standards, tech-
nical assistance, and compliance tools to help
you, and offers extensive assistance through its
many safety and health programs: workplace con-
sultation, voluntary protection programs, grants,
strategic partnerships, state plans, training, and
education. Guidance such as OSHA’s Safety and
Health Management Program Guidelines identify
elements that are critical to the development of a
successful safety and health management sys-
tem. This and other information are available on
OSHA’s website at www.osha.gov.

For a free copy of OSHA publications, send a

self-addressed mailing label to this address:
OSHA Publications Office
P.O. Box 37535
Washington, DC 20013-7535

Or send a request to our fax at (202) 693-2498,

or call us at (202) 693-1888. To file a complaint
by phone, report an emergency, or get OSHA ad-
vice, assistance, or products, contact your near-
est OSHA office under the “U.S. Department of
Labor” listing in your phone book, or call us toll-
free at (800)-321-OSHA
(6742). The teletypewriter (TTY) number is (877)
889-5627

To file a complaint online or obtain more informa-

tion on OSHA federal and state programs, visit
OSHA’s web site. www.osha.gov

GT104 Manual 23
 Section 2: Safety

Read this manual before operating your HANDLE FUEL SAFELY – AVOID FIRES!
equipment. The information presented will Handle fuel with care: it is highly
prepare you to do a better and safer job. flammable. Do not refuel the
Keep this manual handy for ready reference. machine while smoking or when
Require all operators to read this manual near open flame or sparks.
carefully and become acquainted with all
adjustment and operating procedures before Always stop engine before refu-
attempting to operate. Replacement manuals eling machine. Fill fuel tank outdoors. Prevent
can be obtained from your dealer. fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up
FOLLOW SAFETY INSTRUCTIONS spilled fuel.
Carefully read all safety mes-
sages in this manual and on PREPARE FOR EMERGENCIES
your machine safety signs. Keep Be prepared if a fire starts. Keep
safety signs in good condition. a first aid kit and fire extinguish-
Replace missing or damaged er handy.
safety signs. Be sure new equip- Keep emergency numbers for
ment components and repair parts include the doctors, ambulance service,
current safety signs. Replacement safety signs hospital, and fire department
are available from your Astec Mobile Screens near your telephone.
Dealer.
SERVICE ENGINES SAFELY
Learn how to operate the machine and how to Tie long hair behind your head.
use controls properly. Do not let anyone operate Do not wear a necktie, scarf,
without instruction. loose clothing, or necklace when
you work near machine tools
Keep your machine in proper working condition. or moving parts. If these items
Unauthorized modifications to the machine may were to get caught, severe injury
impair the function and/or safety, affect machine or death could result.
life and/or void the warranty.
Remove rings and other jewelry to prevent
If you do not understand any part of this manual electrical shorts and entanglement in moving
and need assistance, contact your Astec Mobile parts.
Screens Dealer.

REPLACE SAFETY SIGNS HANDLE STARTING FLUID SAFELY

Replace missing or damaged safety signs. See Starting fluid is highly flam-
pages 25-26 for a detailed description of safety mable. When handling starting
labels. Contact your Astec Mobile Screens fluid, keep all sparks and flame
Dealer for replacement safety decals. away. Keep starting fluid away
from batteries and cables. To
PREVENT BYPASS STARTING prevent accidental discharge
Avoid possible injury or death when storing the pressurized can, keep the cap
from engine run away. Do not on the container, and store in a cool, protected
start engine by shorting across location. Do not incinerate or puncture a starting
starter terminal. Start engine fluid container.
only from operator’s station.

24 GT104 Manual
Section 2: Safety

PROTECT AGAINST NOISE safely. Then follow procedures and recommend-

Prolonged exposure to loud ed equipment. (See your Astec Mobile Screens
noise can cause impairment or dealer for MSDS’s on chemical products used
loss of hearing. with Astec Mobile Screens equipment)

Wear a suitable hearing protec- PRACTICE SAFE MAINTENANCE

tive device such as earmuffs Understand service procedure
or earplugs to protect against objectionable or before doing work. Keep area
uncomfortable, loud noises. clean and dry.

■■ Never lubricate, service,

WEAR PROTECTIVE CLOTHING or adjust machine while it is
Wear close fitting clothing and moving.
safety equipment appropriate ■■ Keep hands, feet, and clothing from power-
to the job. Operating equipment drive parts.
safely requires the FULL AT- ■■ Disengage all power and operate controls to
TENTION of the operator. Do relieve pressure.
not wear radio or music head- ■■ Lower equipment to the ground.
phones while operating machine. ■■ Stop the engine.
■■ Remove the key, allow machine to cool.
INSTALL FAN GUARDS
Rotating cooling system fans Securely support any machine elements that
can cause serious injury. must be raised for service work.

Keep fan guards in place at all Keep all parts in good condition and properly in-
times during engine operation. stalled. Fix damage immediately. Replace worn
Wear close fitting clothes. Stop or broken parts. Remove any buildup of grease,
the engine and be sure fan is stopped before oil, or debris.
making adjustments or connections, or cleaning
near the front of the engine. On self-propelled equipment, disconnect battery
ground cable (-) before making adjustments on
HANDLE CHEMICAL PRODUCTS SAFELY electrical systems or welding on machine. On
Direct exposure to hazardous towed implements, disconnect wiring harnesses
chemicals can cause serious from tractor before servicing electrical system
injury. Potentially hazardous components or welding on machine.
chemicals used with Astec Mo-
bile Screens equipment include AVOID HIGH PRESSURE FLUIDS
such items as lubricants, cool- Escaping fluid under pressure
ants, paints, and adhesives. A Material Safety can penetrate the skin causing
Data Sheet (MSDS) provides specific details on serious injury or death.
chemical products: physical and health hazards,
safety procedures, and emergency response Avoid the hazard by relieving
techniques. pressure before disconnecting
hydraulic or other lines. Tighten all connections
Check the MSDS before you start any job using before applying pressure.
a hazardous chemical. That way you will know
exactly what the risks are and how to do the job Search for leaks with a piece of cardboard. Pro-

GT104 Manual 25
 Section 2: Safety

tect hands and body from high pressure fluids. can damage the Earth’s atmosphere. Govern-
ment regulations may require a certified air con-
If an accident occurs, seek medical attention im- ditioning service center to recover and recycle
mediately. Any fluid injected in the skin must be used air conditioning refrigerants.
surgically removed within a few hours or gan-
grene may result. Doctors unfamiliar with this Inquire on the proper way to recycle or dispose
type of injury should reference a knowledgeable of waste from your local environmental or recy-
medical source. cling center, or from your Astec Mobile Screens
Dealer.
SERVICE COOLING SYSTEM SAFELY
Explosive release of fluids from AVOID HEATING NEAR PRESSURIZED FLUID
pressurized cooling system can LINES
cause serious burns. Flammable spray can be gen-
erated by heating near pres-
Shut off engine. Only remove surized fluid lines, resulting
filler cap when cool enough to in severe burns to yourself or
touch with bare hands. Slowly bystanders. Do not heat by
loosen cap to “first stop” position to relieve pres- welding soldering, or using a
sure before removing completely. torch near pressurized fluid lines
or other flammable materials. Pressurized lines
WORK IN VENTILATED AREA can be accidentally cut when heat goes beyond
Expel engine exhaust fumes the immediate flame area.
from the area with an exhaust
pipe extension.
DO NOT OPEN HIGH PRESSURE FUEL SYS-
If you do not have an exhaust TEM
pipe extension, open the doors High pressure fluid remaining
to get outside air into the area. in fuel lines can cause serious
injury or death. Do not discon-
nect or attempt repair of fuel
DISPOSE OF WASTE PROPERLY lines, sensors, or any other
Improperly disposing of waste components between the high-
can threaten the environment pressure fuel pump and nozzles on engines
and ecology. Potentially harmful with High Pressure Common Rail (HPCR) fuel
wastes used with Astec Mobile system. Only technicians familiar with this type
Screen equipment include such of system can perform repairs.
items as oil, fuel, coolant, brake
fluid, filters, and batteries. REMOVE PAINT BEFORE WELDING OR
HEATING
Use leak proof containers when draining fluids. Avoid potentially toxic fumes and
Do not use food or beverage containers that dust.
may mislead someone into drinking from them.
Hazardous fumes can be gener-
Do not pour waste onto the ground, down a ated when paint is heated by
drain, or into any water source. welding, soldering, or using a
torch.
Air conditioning refrigerants escaping into the air

26 GT104 Manual
Section 2: Safety

Remove paint before heating: pump and nozzles on engines with High Pres-
■■ Remove paint a minimum of 100 mm (4 in.) sure Common Rail (HPCR) fuel system. Only
from area to be affected by heating. If paint technicians familiar with this type of system can
cannot be removed, wear an approved respi- perform repairs.
rator before heating or welding.
■■ If you sand or grind paint, avoid breathing PREVENT BATTERY EXPLOSIONS
the dust. Wear an approved respirator. Keep sparks, lighted matches,
■■ If you use solvent or paint stripper, remove and open flame away from the
stripper with soap and water before welding. top of battery. Battery vapors
Remove solvent or paint stripper containers can explode. Never check bat-
and other flammable materials from area. tery charge by placing a metal
Allow fumes to disperse at least 15 minutes object across the posts. Use a
before welding or heating. volt meter or hydrometer. Do not charge a frozen
battery; it may explode. Warm battery to 16° C
Do not use chlorinated solvent in areas where (60° F).
welding will take place. Do all work in an area
that is well ventilated to carry toxic fumes and AVOID HARMFUL ASBESTOS DUST
dust away. Dispose of paint and solvent prop- Avoid breathing dust that may
erly. be generated when handling
components containing asbes-
AVOID HOT PARTS tos fibers. Inhaled asbestos
Avoid skin contact with exhaust fibers may cause lung cancer.
manifolds, turbochargers, muf-
flers, and other hot parts. Keep Components in products that may contain as-
flammable materials clear of all bestos fibers are brake pads, brake band and
hot parts. lining assemblies, clutch plates, and some gas-
kets. The asbestos used in these components is
External dry exhaust parts be- usually found in a resin or sealed in some way.
come very hot during operation. Turbochargers Normal handling is not hazardous as long as
may reach temperatures as high as 500°C (932° airborne dust containing asbestos is not gener-
F) under full load, and naturally aspired exhaust ated.
manifolds may reach 600° C (1112° F) under full
load. Avoid creating dust. Never use compressed air
for cleaning. Avoid brushing or grinding material
This may ignite paper, cloth or wooden materi- containing asbestos. When servicing, wear an
als. Parts on engines that have been at full load approved respirator. A special vacuum cleaner
and reduced to no load idle will maintain approx- is recommended to clean asbestos. If not avail-
imately 140° C (302° F) temperatures. able, apply a mist of oil or water on the material
containing asbestos.
DO NOT OPEN HIGH PRESSURE FUEL SYS-
TEM Keep bystanders away from the area.
High pressure fluid remaining in
fuel lines can cause serious inju- PROTECT AGAINST HIGH PRESSURE
ry or death. Do not disconnect or SPRAY
attempt repair of fuel lines, sen- Spray from high pressure nozzles can penetrate
sors, or any other components the skin and cause serious injury. Keep spray
between the high-pressure fuel from contacting hands or body.

GT104 Manual 27
 Section 2: Safety

If an accident occurs, seek medical attention im- WARNING: Battery posts, terminals, and related
mediately. Any fluid injected in the skin must be accessories contain lead and lead compounds,
surgically removed within a few hours or gan- chemicals known to the state of California to
grene may result. Doctors unfamiliar with this cause cancer and reproductive harm. Wash
type of injury should reference a knowledgeable hands after handling.
medical source.

HANDLING BATTERIES SAFELY

CAUTION: Battery vapors can
explode. Keep sparks, lighted
matches, and open flame away
from the top of battery. Use a
flashlight to check battery elec-
trolyte level.

Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer. Always remove grounded (-) battery
clamp first and replace it last.

CAUTION: Sulfuric acid in battery electrolyte

is poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness if
splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well ventilated area.
2. Wearing eye protection and rubber
gloves (CHECK)
3. Avoiding breathing fumes when electro-
lyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.

f you spill acid on yourself:

1. Flush your skin with water.
2. Apply baking soda or lime to help neu-
tralize the acid.
3. Flush your eyes with water for 15-30
minutes. Get medical attention immediately.

If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but
do not exceed 2L (2qt)
3. Get medical attention immediately.

28 GT104 Manual
Section 2: Safety

SAFETY DECALS

DANGER
DANGER
PELIGRO

PELIGRO
DO NOT WALK ON
CONVEYOR
NO CAMINAR
DIESEL FUEL SOBRE LA CINTA
COMBUSTIBLE DIÉSEL D00003-SP
TRANSPORTADORA
D00015-SP

D00003-SP: Diesel Fuel

When refilling the fuel tank, do not smoke. Keep D00015-SP: Do not walk on Conveyor
any ignition sources away from the tank. Do not stand or walk on conveyors at any point.

WARNING
ADVERTENCIA DANGER
MANUAL ENCLOSED/MANUAL ADJUNTO
Read and understand operator’s manual before using this
PELIGRO
machine.

Failure to follow operating instructions could result in personal

injury or damage to equipement.

Lea y comprenda el manual del operador antes de usar esta

máquina.

Si no se siguen las instrucciones de operación podrían provocarse

lesiones personales o daños a los equipos. D00006-R1-SP
D00037-SP

SHIELD IS OFF! / ¡EL ESCUDO NO ESTÁ INSTALADO!

D00006-R1-SP: Manual Enclosure Do not operate without shield in place.
No operar sin que el escudo esté instalado.

Read and understand manual before operat-

ing. If you do not have a manual, contact Astec D00037-SP: Shield if Off
Mobile Screens. Do not operate plant if shield is removed.

WARNING
AVISO
Moving parts can cause injury or death.
Partes que se estan mobiendo pueden
causar grandes accidentes o asta la
muerte.

Do not remove or reach behind guard

while equipment is operating.
No remueva las guardias de seguridar ni
trate de alcansar atras de la guardia de
seguridad cuando este funsionando.
D00012-SP

D00012-SP: Moving Parts D00048 - Lockout Tag Out

Moving parts can cause injury or death. Do not
remove guard while equipment is operating. Follow correct lockout/tagout procedures before
Guards have been designed for easy clean-out. servicing plant.
Make sure conveyor is turned off before clean-
ing and use caution when cleaning.

GT104 Manual 29
 Section 2: Safety

WARNING
ADVERTENCIA

EMERGENCY STOP
D00019-SP
Lock out and/or tag out all energy sources to conveyor system and loading
INTERRUPTOR DE
EMERGENCIA
sytem before performing any work on conveyor or conveyor accessories.
Failure to do so could result in severe injury or death.

Bloquee o etiquete todas las fuentes de alimentación eléctrica del sistema de

la cinta transportadora y el sistema de carga antes de realizar trabajos en la
cinta transportadora o en sus accesorios. De lo contrario, podrían producirse
lesiones graves o la muerte.

D00019-SP: Conveyor Lock Out D00412-B-SP: Emergency Stop

Lock out and/or tag out all energy sources to E-stops are located at convenient locations
conveyor systems and loading system before around the plant in order to quickly shut down
performing any work on conveyor or conveyor power to the plant should the need arise.
accessories. Failure to do so could result in
severe injury or death.

WARNING
!!
ADVERTENCIA
Hot surface.
Do not touch.

caliente. D00418-SP

D00418-SP: Warning Hot Surface

This decal signifies that surface could be ex-
tremely hot. Ensure that machine has been shut
down for an appropriate amount of time to allow
surface to cool off before touching. Failure to
follow these instructions could result in injuries.

30 GT104 Manual
Section 2: Safety

SAFETY FEATURES

In addition to the safety decals placed on the

plant, several other safety features are included.

Lockout Devices
Lockout devices such as the battery disconnect
protect the operator from serious or fatal injury.

Engine Stops
Engine stops quickly shut down power to the
plant should the need arise.

Back-Up Alarm
The alarm sounds to warn all personnel that the
unit is in operation.

GT104 Manual 31
 Section 2: Safety

32 GT104 Manual
Section 2: Safety

Date Trainee Signature Trainer Signature

GT104 Manual 33
 Section 2: Safety
SAFETY NOTES

34 GT104 Manual
Section 3: Setup
REMOTE
BUTTON
INDICATOR LIGHTS ENGINE PANEL

PANEL KEY

DIGITAL DISPLAY ENGINE RPM DOWN

ENGINE RPM UP

IGNITION KEY

CONTROL PANEL
Take a few moments to familiarize yourself with panel located on your machine matches the one
the Control Panel. It is important to review the shown in the image above.
indicator lights on a regular basis to ensure More detailed information can be found in the
the engine is running properly. Verify that the control panel manual.

GT104 Manual 35
 Section 3: Setup
EMERGENCY
STOP

TRACK ON/OFF

RIGHT TRACK

LEFT TRACK

Figure 36.1

Figure 36.2

Figure 36.3
ENGINE REMOTE (WIRED)
Pictured above (Figure 36.1) is the engine re- pass remote adapter is found under the feeder
mote. It is used to track the plant. as shown in Figure 36.3.
NOTE: The engine will not start without the
Picture in Figure 36.2 is the bypass remote remote or bypass remote adapter plugged into
adapter, which allows you to run the machine the receiver. Also, if either are unplugged at
without the remote hooked up. any point in time while the plant is running, the
The plug for both the handheld remote and by- engine will shut down immediately.
36 GT104 Manual
 Section 3: Setup

POWER ON/OFF ENGINE SHUT OFF

RIGHT TRACK

LEFT TRACK

Figure 37.1

ENGINE REMOTE (WIRELESS)

Pictured above (Figure 37.1) is the optional
wireless engine remote. It is used to track the
plant.
GT104 Manual 37
 Section 3: Setup

Figure 38.1

STARTING AND MOVING THE MACHINE TURN BATTERY DISCONNECT TO “ON”

POSITION
NOTE: Please ensure that all personel who will Locate the batter disconnect door on the Curb
be operating this plant have fully read the Quick Side of the plant. Door will be labeled with the
Start Guide and understand it completely before symbol shown in Figure 38.1
attempting to move this machine.

Ensure that the area around the plant is clear Turn battery disconnect to the “ON” (down) posi-
of any people or objects that may be harmed or tion as shown in Figure 38.2.
damaged when the machine is moved.

DANGER: IMPROPER USE OF THIS MA-

CHINE CAN LEAD TO SERIOUS INJURY OR
EVEN DEATH. PLEASE OPERATE WITH
EXTREME CAUTION.
38 GT104 Manual
Section 3: Setup

Figure 39.1 Figure 39.2

Figure 39.3 Figure 39.4

TURN ON THE MACHINE

Located below the feeder will be the control
panel. Open the yellow door to show controls.
(Figure 39.1)

Once inside the box, locate the control panel

shown in Figure 39.2

NOTE: The engine will not start unless the remote

or bypass remote adapter is plugged in.

Locate the ingition key found in Figure 39.3, and

turn the key all the way to the right and hold (Fig-
ure 39.4). Alarm will sound for approximately 10
seconds before engine cranks.
Figure 39.5
Return key to the on position (Figure 39.5) to al-
low engine to continue to run.
GT104 Manual 39
 Section 3: Setup

ENGINE START-UP PROCEDURES

40 GT104 Manual
Section 3: Setup

TRACKING USING THE MANUAL TRACKING DOGLEAD

TRACKING USING THE RADIO REMOTE

GT104 Manual 41
 Section 3: Setup

SPROCKET SPROCKET

Figure 42.1

OPERATING PRECAUTIONS
When traveling up a slope, the tracks should Attempt to track the machine if the tracks are
be driven forward (drive sprocket to the rear). frozen to the ground.
When traveling down a slope, tracks should be Push or tow the macine when unable to free
driven sprocket first. Refer to Figure 42.1 itself.

ALWAYS:
Park the machine on flat, level ground. If it is WORKING CONDITIONS
necessary to park the machine on a slope, the The operating temperature range for track
tracks should be solidly blocked. sysems should be between. -10°C (14°F) to
Ensure the terrain the machine is working +40°C (105°F). Always consult Astec Mobile
on is firm enough to adequetely support the Screens, Inc. when temperatures exceed
machine. above or below this working range, as alter-
Machine should be tracked at least 32 feet nate component specifications will be required.
(10m) in either direction on a daily
basis, to minimize risk of track chain seizure.
Ensure the track systems are free from debris
before moving the machine.
Make certain the tracks are not frozen to the
ground before moving the machine.

FAILURE TO OBSERVE THE ABOVE PRE-

NEVER: CAUTIONS COULD RESULT IN DANGER
Attempt to track the machine if there is buildup TO PERSONNEL AND DAMAGE TO THE
of material around the tracks and drive sprock- TRACK SYSTEMS AND MAY ALSO VOID
ets. THE WARRANTY.
42 GT104 Manual
Section 3: Setup

SITE SELECTION
When selecting a suitable site for operation 2. The plant must be located so ample room
many factors need to be taken into consider- is available. Leave plenty of room around the
ation. Selecting a site without anticipating prob- plant, to facilitate access of loading equipment,
lems could lead to unsatisfactory operation and stacking conveyors and service personnel.
plant relocation could be required. Some things
to consider when selecting a site: 3. Proper drainage is important to allow for run-
off of normal rainfall.
1. Stability of the ground. If the ground is too
soft or unstable, proper leveling and loading 4. You may also want to consider prevailing
may be impossible. wind direction and its effect on the operator or
loading personnel.
GT104 Manual 43
 Section 3: Setup

TRACKING MACHINE SET-UP

NOTICE
Before tracking machine,
ensure valve speed control is
turned all the up to ensure
proper tracking function.

Before you attempt to track the machine, ensure

the valve speed control located on the TOP
DECK OVERS CONVEYOR (figure 44.1) ) valve
is turned all the way up. This valve is tied into
the speed control of the top deck overs
conveyor. Generally, operators adjust the speed
of the conveyors to the optimal level and the
speeds can vary from valve to valve.

Failure to follow these instructions, could result

in the spinning of the machine rather than track-
ing normally.

IMPORTANT: Failure to follow this procedure

could result in damage to equipment and/or
bodily injury. D00434

Figure 44.1

44 GT104 Manual
Section 3: Setup

Figure 45.1

Figure 45.2

ACTIVATE TRACKS (WIRED REMOTE)

Press the REMOTE switch inside the main con- Make sure the area is clear of all personnel and
trol panel as shown in Figure 45.1. that there is sufficient room to maneuver the
Flip the TRACK switch on the remote to the left plant.
“ON” position, as shown by the highlighted box Use the wired remote (Figure 45.2) to move the
in Figure 45.2. plant to the desired spot.
GT104 Manual 45
 Section 3: Setup

Figure 46.1

Figure 46.2
ACTIVATE TRACKS (WIRELESS REMOTE)
Note that the bypass remote adapter must be Figure 46.2.
plugged in for the wireless remoe to work. Make sure the area is clear of all personnel and
Press the REMOTE switch inside the main con- that there is sufficient room to maneuver the
trol panel as shown in Figure 46.1. plant.
Press and hold the Yellow “ON” button to link Use the wireless remote (Figure 46.2) to move
the remote, as shown by the highlighted box in the plant to the desired spot.
46 GT104 Manual
Section 3: Setup

LEFT FEEDER RIGHT

TRACK TRACK
Forward Forward

D00434

Figure 47.1

ROADSIDE CURB SIDE

Reverse SCREEN Reverse

BOX
Figure 47.3
D00423

Figure 47.2

OPERATING TRACKS
Once you have connected the WIRED or WIRE- Make sure the area is clear of all personnel and
LESS remote, you are prepared to track the that there is sufficient room to maneuver the
machine to the desired location. plant.
In order to allow hydraulic flow to the tracks, the Figure 47.1 shows the orientation of the tracks.
TOP DECK OVERS CONVEYOR (Figure 47.1) Right side switch/buttons operate the CURB
and SCREEN/UNDERSCREEN CONVEYOR SIDE, where the left side switch/buttons operate
(Figure 47.2) valves need to be pushed down so the ROAD SIDE. Use the wired remote to move
that OPERATE TRACKS is enabled. the plant to the desired spot.

GT104 Manual 47
 Section 3: Setup

ADDITIONAL INFORMATION
Each hydraulic spool valve is labeled with a Back: The fines conveyor is located at the back
black and white decal. Throughout the manual of the plant.
we will refer to the action of Pulling or Push-
ing the valve. Pull means to force the valve UP Front: The front of the plant is where the feed
towards the sky and Push means to force the bin is located. In this section you can gain ac-
valve DOWN towards the ground. cess to the feed bin conveyor. In addition, you
will find the control lever used to raise and lower
A series of steps must be completed to unfold the top deck conveyor (3 deck only), legs, and
the plant before operation can begin. Through- grizzly.
out the setup and operating sections of this
manual the plant orientation will be referred to
as if you were standing behind the fines con- Prior to attempting each step, read the entire
veyor facing towards the feed bin. All “sides” step first. At the beginning of each step a brief
and “direction” of the plant will be indicated as explanation of that step will be given. Following
follows: the brief explanation will be a more detailed de-
scription of how to complete each step. Follow
Roadside: Your left side. The roadside section the steps sequentially. It is important to fold and
of the plant contains the control lever used to unfold the plant in the proper order.
raise and lower the bottom deck conveyor and
fines conveyor. This side of the plant also con-
tains several grease points is also used to fuel
the plant..

Curbside: Your right side. The curbside section

of the plant contains the engine control panel
and all start/stop functions of the plant used and NOTE: Failure to follow all instructions can
its functions. You will also find access to setup result in damage to the equipment, serious
functions of the middle deck conveyor (3 deck), injury, or DEATH. Please note all safety cym-
top deck conveyor (2 deck) and screen raise/ bols that accompany each step.
lower. This side of the plant also contains sev-
eral grease points and is also used to fuel the
plant.
48 GT104 Manual
Section 3: Setup

VALVE LOCATIONS

GT104 Manual 49
 Section 3: Setup

CONTROLS

The images below display the decals for the near the control panel. Located on the following
plant function controls. pages are the setup valves for the conveyors.
These decals are the main controls located

DECAL DESCRIPTION INSTRUCTION

Screen/Underscreen Conveyor
Screen/ On
Underscreen Hold
Conveyor
+ Engage Tracks
Engage Tracks

D00423

Fines Conveyor On

Hold
Fines Conveyor
Relief, TESTING ONLY

Conveyor speed control

D00424

Bottom Deck Overs Conveyor

On
Hold
Bottom Deck
Overs Conveyor Relief, TESTING ONLY

Conveyor speed control

D00426

Belt Feeder On

Hold
Belt Feeder
Relief, TESTING ONLY

Conveyor speed control

D00433

Top Deck Overs Conveyor On

Top Deck Overs Hold

Conveyor
+ Engage Tracks
Engage Tracks
Conveyor speed control
D00434

50 GT104 Manual
Section 3: Setup

D00428

DECAL DESCRIPTION INSTRUCTION

Raise bottom deck conveyor
Bottom Deck Conveyor
Raise/Lower Hold
Lower bottom deck conveyor

Unfold bottom deck conveyor

Bottom Deck Conveyor
Fold/Unfold Hold

Fold bottom deck conveyor

D00435

DECAL DESCRIPTION INSTRUCTION

Raise fines conveyor
Fines Conveyor
Raise/Lower Hold
Lower fines conveyor

Unfold fines conveyor

Fines Conveyor
Fold/Unfold Hold

Fold fines conveyor

GT104 Manual 51
 Section 3: Setup

Figure 52.1 Figure 52.2

Figure 52.3

BOTTOM DECK OVERS CONVEYOR

Remove the pins on the BOTTOM DECK con-
veyor as shown in Figure 52.1 & Figure 52.2.
Release the bleed out stops shown in Figure
48.3. Once the pins have been removed, locate
the BOTTOM DECK valve. Begin by pulling up
on the HEAD valve to extend the conveyor off of
the transport rest (Figure 52.3). Once it is clear
of the rest, press down on the CONVEYOR valve
to lower the conveyor. Pulling up on the HEAD D00428

valve again will extend the conveyor into the full

operational position (Figure 52.4).

52 GT104 Manual
Section 3: Setup

Figure 53.1 Figure 53.2

Once the conveyor is in the operational position,

it is important that it is secured into it’s place.
To do this, locate the eye bolt shown in Figure
53.1. Swing the bolt into place and tighten the
nut as shown in Figure 53.2.

GT104 Manual 53
 Section 3: Setup

Figure 54.1 Figure 54.2

Figure 54.3

FINES SIDE CONVEYOR

Remove the pins on the FINES conveyor as

shown in Figure 54.1 & Figure 54.2. Release
the cylinder bleed out stop as shown in figure
50.3. Once the pins have been removed and
the stop has been released, locate the FINES
valve. Begin by pulling up on the HEAD valve
to extend the conveyor off of the transport rest
(Figure 54.3). Once it is clear of the rest, press D00435

down on the CONVEYOR valve to lower the

conveyor. Pulling up on the HEAD valve again
will extend the conveyor into the full operational
position (Figure 54.4).

54 GT104 Manual
Section 3: Setup

Figure 55.1 Figure 55.2

Once the conveyor is in the operational position,

it is important that it is secured into it’s place.
To do this, locate the eye bolt shown in Figure
55.1. Swing the bolt into place and tighten the
nut as shown in Figure 55.2.

GT104 Manual 55
 Section 3: Setup

INTRODUCTION TO CONVENTIONAL
SCREENING

Screen orientation is determined by standing at References to the feed end and material flow is
the front of the vibrating screen looking toward shown below.
the direction of travel.

56 GT104 Manual
Section 3: Setup

“K” SERIES SCREEN ing manner from the feed end of the decks to
the discharge end.
A vibrating screen is used to separate material
into different sizes. The inclined vibrating screen has proven to be
the most reliable screen for aggregate separa-
“K” series screens are medium duty screens and tion. The addition of extra counterweights allow
are typically used to size material down to #4 the screen to handle dense, coarse aggregate.
mesh and up to 4” maximum. When properly sized, the inclined vibrating
screen performs relatively maintenance free
This arrangement uses single shaft assembly except for wear from the aggregate being pro-
with counterweight arms that can be adjusted by cessed.
changing speeds and throw. This allows screen
design with reduced investment and installation
costs.

Sorting is done by passing the mixed mate-

rial along a surface having uniform openings.
Those particles small enough to pass through
the openings are called the undersize product.

Vibration is induced by counterweights mounted

on the ends of the shaft. “K” series vibrating
screens can operate between 8 to 35 degrees
from feed end to the discharge end.

The screen cloth is usually formed of woven

wire. Coarse sorting is sometimes done on a
steel plate surface having relatively large holes
either cut or punched in it.

Screen cloths or punched plate surfaces are

held in superimposed frames called decks. “K”
series screens may have one, two, or three
decks.

The undersize from each deck falls to the deck

below it for additional sorting. The decks are
held in a box-like structure called screen box
assembly. The box assembly is mounted on
springs fastened to the base frame. The eccen-
tric shaft, when rotated, makes the screen pan
vibrate.

Each revolution of the powered shaft lifts the

pan assembly and its screening surfaces. At
the same time, it moves the entire assembly in a
circular motion. The vibration and screen angle
causes material on the decks to flow in a bounc-

GT104 Manual 57
 Section 3: Setup

The following is a brief description of the vibrat-

ing screen’s basic parts and their function.

Eccentric Shaft

The eccentric shaft translates

circular motion into screening
action. The shaft revolves on
two roller bearings mounted to
the box sides.

Box Side Assembly

The box sides provide the

framework to support the
screen decks, eccentric shaft
housing, and the spring sus-
pension.

58 GT104 Manual
Section 3: Setup

The following is a brief description of the vibrat-

ing screen’s basic parts and their function.

Counterweight Assembly

The counterweight assembly

permits the addition of weights
to change the screen stroke
and balance.

Counterweights can be added

or removed to change the
stroke. (Contact factory for
more information)

Screen Decks

The screen decks support the

screen cloth. The decks are
crowned to prevent screen sag
and promote optimum screen
efficiency.

GT104 Manual 59
 Section 3: Setup

The following is a brief description of the vibrat-

ing screen’s basic parts and their function.

Clamp bars

The screen cloth clamp bars

hold the screen cloth securely
in place.

Spring Suspension

The spring suspension isolates

vibration from the support-
ing frame or structure. The
suspension features separate
equalizer springs to maintain
proper drive belt tension and
screen alignment.

60 GT104 Manual
Section 3: Setup

SCREENING APPLICATION

Screening is an “art” not a science. There so Stratification must take place before separation.
many variables and conditions involved that it Stratification is affected more by the material
is impossible to select a screen by just using bed depth than any other factor and the depth
a formula. Familiarity and experience with the must be reasonable for the material and separa-
properties of certain materials is necessary in tion size to be made.

NOTICE
order to make the proper selection of a screen
cloth.

Even though a completely theoretical approach

has never been successful, a formula incorpo- Material depth should not exceed four times
rating theory and experience factors is used as the screen cloth opening.
a guide to screen selection.

Experience is needed because formulas do A factor affecting the bed depth is the rate of
not account for excess moisture, clay, wedge travel which is affected by the type of material,
shaped particles, surge loads, or other special stroke, type of motion, rate of feed, slope, etc.
conditions in the feed material. Each of these factors affects the material bed
depth which affects stratification.
Screening efficiency can be improved by using
one or more of the following when allowed in the It is possible to not have deep enough material
process. bed on the screen. Screen efficiency is related
to percent of capacity as shown below.
1. Slotted openings
2. Washing with water
3. Heated decks
4. Ball tray decks
5. More open area in the screen cloth
6. Controlled feed for maintaining the proper
material bed depth.

Stroke RPM is another factor affecting screen

efficiency. When screening a coarser mate-
rial, the screen should be operated at a lower
EFFICIENCY

speed with a higher sroke. For finer material,

the speed should be increased and the stroke
decreased. Refer to the factory on what the
maximum stroke should be compared to RPM.

Every variable involved in the screening process FEED (TPH)

is application dependent and this should be
taken into consideration before screening. Efficiency decreases when the screen is operat-
ed below approximately 75% of the rated capac-
To better understand screening, there are two ity (for free flowing 100# material).
processes taking place: stratification and sepa-
ration.

GT104 Manual 61
 Section 3: Setup

Feed

Screen
Deck

a b c d

a-b Stratification at feed end

b-c Saturation screening
c-d Separation by repeated trails

For very small feed rates, up to point “b”, ef- The rise between “a” and “b” and the location
ficiency actually increases with increased ton- of peak “b”, being at some point along the deck
nage. This happens because a certain bed of rather than at the end of the screen, shows the
oversize material on top of the marginal particles effect stratification taking place.
prevens them from bouncing excessively which
increases their ability to fall through the screen The area “b” to “c” is often referred to as the
openings, and helps to push them through. area of saturation screening in which particles
Beyond the optimum point “b”, efficiency rapidly up to 75% of the aperture size are crowding to
drops off becaue the screen is not large enough get through the deck.
to pass the undersize material.
From “c” to “d”, the process of fit and pass or fit
Stratification also varies with different types and reject takes place.
of material. Generally when screening damp
materials or even when screening fine materi-
als, particularly of lighter density, stratification
is difficult to attain and a relatively thin material
bed depth (no more than four times the screen
cloth opening) from feed to discharge end of the
screen is required.

The chart represents the relative amount of flow

through the screen deck plotted along the deck
length. This graph may also be considered as
the cross section or height of a pile of material
that has passed through the screen deck and
allowed to pile up underneath it after a batch of
material has been screened.

62 GT104 Manual
Section 3: Setup

SCREENING EFFICIENCY

Screening efficiency is the percent of the under-

size in the feed that actually passes through the
surface opening.

The capacity formula (shown to the right) is Efficiency =

based on 92% to 95% screening efficiency. Nor-
mally, 90% to 95% efficiency is an accepted rate % of undersize in feed which actually passes
in most screening operations; however, in some % of undersize in feed (should pass)
instances, even 90% is not always attainable.
Considering the many factors that affect material
classification, it is a difficult task to constantly Capacity Formula
control screening efficiency to an exact percent-
age. Furthermore, multiple deck screens pres- Controlled continuous feeding of proper size
ent separate problems for each deck. material uniformly spread across the screening
surfaces of a well balanced screen is essential
With many factors that govern efficient screen- for maximum vibrating screen production.
ing, it is impractical to expect that a numerical
factor on the capacity formula will automatically Screening capacity and efficiency will be affect-
control this. Industry accepts that 100% ef- ed by the factors listed and additionally by the
ficiency is impossible. It also recognizes there speed, slope, balance of the machine, and the
are screening applications when 90% or even characteristics of the varying materials fed.
80% may be impossible, regardless of screening

NOTICE
area available.

The difficult-to-pass “nearsize” is most often a

controlling factor in determining the problems Controlled continuous feeding of proper
you expect to encounter in attaining a high ef- size material uniformly spread across the
ficiency. Moisture and peculiar particle shapes screening surfaces of a well balanced screen
will compound the problem. is essential for maximum vibrating screen
production.
Material typically remains on a vibrating screen
for only a matter of seconds. Evaluation of
the efficiency of the screen is checked by test-
ing sieves for three to five minutes or longer.
Through material analysis, review of the applica-
tion and testing, an estimate of screen efficiency
can be determined.

To get a reasonable estimate of tons per hour

that can be screened through a square foot of
screen cloth, use the calculations listed on page
33 and 34.

GT104 Manual 63
 Section 3: Setup

FACTORS FOR CALCULATING SCREEN AREA

U
Screen Area (ft2) =
AxBxCxDxExFxGxHxJ
Things to remember in regards to charts:

*Basic operating conditions.

- Feed to screening deck contains 25% oversize and 40% half size.
- Feed is granular free-flowing material
- Material weighs 100 lbs. per cubic foot:
Inclined 18-20 degrees with flow rotation.
Horizontal Screen - 0 degrees
- Objective Screening Efficiency - 95%

U = Undersized Factor Amount in tons per hour of material in feed to screen surface (deck)
that is smaller than a specified aperture.
A = Basic Capacity Factor Predetermined rate of material in tons per hour through a square foot
of a specified opening when feed to deck contains 25% oversize (Fac-
tor B) and 40% halfsize (Factor C)
B = Oversize Factor Actual percent of material in feed to deck that is larger than a speci-
fied aperture (adjusts Factor A to suit conditions.
C = Halfsize Factor Actual percent of material in feed to deck that is one-half the size of a
specified aperture (adjusts Factor A to suit conditions)
D = Deck Location Factor Applies to multiple deck screens. Total screening area is available
to top deck separation. Time delay for material to pass through deck
and leaves less effective area available on next deck. This factor is
expressed in a percent of top deck effective areas.
E = Wet Screening Factor Applies when water is sprayed on the material as it moves down
the screening deck. Generally, about 5-7 gpm of water is used per
ton per hour of solids fed to the screen. A sufficient volume of water
should be supplied so that a portion can be combined with the solids
into a feed box to prepare a slurry feed to the screen. The balance of
water is added through a series of spray bars located over the screen-
ing deck.
F = Material Weight Fac- The bulk density of the material being sieved in pounds per cubic foot
tor divided by 100.

G = Screen Surface Applies when open area of screening surface is less than open area
Open Area Factor shown in Factor A capacity chart. Open area of screen surface being
used. Open area indicated on capacity chart.
H = Shape of Opening Applies when rectangular openings are used. Slotted or oblong open-
Factor ings will pass more material per square foot than square openings.
J = Efficiency Factor Applies when objective screening efficiency is less than 95%

64 GT104 Manual
Section 3: Setup

CHARTS FOR CALCULATING SCREEN AREA

Factor “A” Factor “B” - (% of oversize in feed to deck)

Surface % STPH % Over- 5 10 15 20 25 30 35
Square Open Passing size
Opening Area a sq. ft. Factor B 1.21 1.13 1.08 1.02 1.00 0.96 0.92
4” 75% 7.69
% Over- 40 45 50 55 60 65 70
3 1/2” 77% 7.03 size
3” 74% 6.17 Factor B 0.88 0.84 0.79 0.75 0.70 0.66 0.62
2 3/4” 74% 5.85 % Over- 75 80 85 90 95
2 1/2” 72% 5.52 size
2” 71% 4.90 Factor B 0.58 0.53 0.50 0.46 0.33
1 3/4” 68% 4.51
Factor “C” - (% of halfsize feed into deck)
1 1/2” 69% 4.20
1 1/4” 66% 3.89 % Over- 0 5 10 15 20 25 30
size
1” 64% 3.56
Factor C 0.40 0.45 0.50 0.55 0.60 0.70 0.80
7/8” 63% 3.38
5/8” 59% 2.82 % Over- 35 40 45 50 55 60 65
size
1/2” 54% 2.47
Factor C 0.90 1.00 1.10 1.20 1.30 1.40 1.55
3/8” 51% 2.08
1/4” 46% 1.60 % Over- 70 75 80 85 90 95
size
3/16” 45% 1.27
Factor C 1.70 1.85 2.00 2.20 2.40
1/8” 40% 0.95
3/32” 45% 0.76 Factor “D” - Deck Location
1/16” 37% 0.58 Deck Top Second Third
1/32” 41% 0.39 Factor D 1.00 0.90 0.80
Factor “E” - Factor “F” - Material Weight
Wet Screening Lbs./ 150 125 100 90 80 75
60 70 50 30
Opening Factor E cu. ft.
1/32” 1.00 Factor 1.50 1.25 1.00 0.90 0.80 0.75 0.70 0.60 0.50 0.30
1/16” 1.25 F
1/8” 2.00 Factor “G” Factor “H”
3/16” 2.50 (Screen Surface Open Area) (Shape of Surface Opening)
Factor G = Square..................................1.00
1/4” 2.00 % Open Area of Surface Being Used Short Slot (3-4 times width)..1.15
3/8” 1.75 Long Shot
% Open Area Indicated in Capacity (More than 4 times width).....1.20
1/2” 1.40
3/4” 1.30
1” 1.25 Factor “J” - Efficiency
95% 90% 85% 80% 75% 70%
1.00 1.15 1.35 1.50 1.70 1.90

GT104 Manual 65
 Section 3: Setup

SITE SELECTION AND PREPARATION the v-belt drive. Be sure the drive will not be
blocked by walls, structures, or other objects.
Selecting a site without anticipating problems
could lead to unsatisfactory operation and plant Support Structure Guidelines
relocation could be required. When selecting a
suitable site for operation the following factors The support structure is a steel or concrete
should be taken into consideration: structure located between the screen and its
foundation. The screen base is mounted on top
1. Ground Stability - If the ground is too of this structure.
soft or unstable, proper leveling and loading
may be impossible. Use the following guidelines when designing
2. Ample Room – Leave plenty of room and installing a support structure.
around the screen to facilitate access of the
loading equipment, assembly of screen compo- 1. The support structure must be firmly an-
nents, and service personnel. chored to a solid foundation. It must be strong
3. Proper Drainage – Proper drainage is enough to carry the weight of the screen and its
important to allow for runoff of normal rainfall. material load.
4. Wind Direction – You may also want to 2. The support structure must be capable
consider prevailing wind direction and its effect of withstanding the forces present during nor-
on the operator or loading personnel. mal screen operation and the additional forces
which occur during startup and shutdown. The
Foundation structure must be sufficiently braced to minimize
vibration and swaying.
Do not locate the foundation on sand, unstable 3. Check side-to-side and end-to-end level-
soil, or anywhere where flooding might occur. ness.
Locate the foundation on level, solid rock, or a
compacted aggregate base only.

Where fill of any kind has been used, the foun-

dation must extend through the fill to a solid sub-
surface. The subsurface must be of adequate
load bearing ability to support the combined
weight of the screen and its supporting structure.
When constructing the foundation, consider
these other factors:

1. Allow adequate space beside the screen

for walkways and service platforms. Observe
all federal, state, and local regulations when
designing and constructing walkways or service
platforms.
2. Allow about ten feet of space on one side
of the screen for eccentric shaft removal.
3. Allow space above the screen so it can
be raised when spring replacement is neces-
sary.
4. Allow space at one end for removal and
replacement of screen cloth.
5. Allow adequate space for access to
66 GT104 Manual
Section 3: Setup

DIRECTION OF ROTATION

Jog the motor and check that the screen sheave

rotates in the correct direction. The top of the
screen should move the same direction as the
sheave.

This is the typical direction of the rotation. The

screen can run in a reverse rotation. This is
done when there is a need to increase the mate-
rial retention time on the screen deck to improve
screening efficiency. The feed rate must be
reduced when screening with reverse rotation.

CROWN RUBBER

Check crown rubber to ensure they are in good

condition and seated properly. Also check for
damage and replace if needed.

Crown rubber forms a cushion between the

screen cloth and the supporting metal bars to
protect the screen cloth from damage.

The screen cloth will fail prematurely if the cush-

ion rubber is not installed on the crown bars.

GT104 Manual 67
 Section 3: Setup

SCREEN CLOTH INSTALLATION

Use the following procedure to install screen

cloth:

1. Loosen the clamp bar bolts. This loosens the

clamp bars in the hooked edges of the screen.

2. Slide the screen cloth sections out either end

of the vibrator, whichever end is more conve-
nient. In most cases it may be necessary to
completely remove the clamp bars in order to
take out screen cloth.

3. Install new screen cloth by reversing the

above procedure. Make sure clamp bars en-
gage the hooks along screen edges.

Clamp bars should not extend over a joint be-

tween two lengths of screen mesh or improper
clamping may result.

4. Tighten all clamp bar bolts uniformly to apply

a reasonable tension on the screen. Stretch the
screen tightly enough to prevent fluttering during
operation which will damage the screen, causing
it to wear out. The screen cloth must be cen-
tered to work properly.

68 GT104 Manual
Section 3: Setup

At this point setup is complete and the plant is

ready to be put into production.

Please review the OPERATION section for fur-

ther instructions on how to operate the plant.
GT104 Manual 69
 Section 3: Setup

SETUP NOTES

70 GT104 Manual
 Section 4: Operation &
Maintenance
PRE-OPERATION CHECKS
The screening plant is now ready for operation. Take a few minutes each day to review the
preoperational and operational checklists. Reviewing these each day will help keep your plant
running efficiently and avoid unneccessary downtime in the future.

PRE-OPERATIONAL CHECKS OK ADJUST

1Sheet Metal/Appearance/Paint

2 Engine OK ADJUST
a.Check the engine oil level.
b.Check the engine coolant level.
c.Drain the fuel water separator.
d.Inspect engine drive belts.
e.Check all air filters.
f.Check the fuel level.

3 Hydraulics OK ADJUST
a.Check hydraulic oil level.
b.Check for leaks, loose fittings.
c.Inspect the hydraulic cooler, hoses, and connections.
d.Suction line ball valves open.

4 Electrical OK ADJUST
a.Check battery level.
b.Make sure battery is secure.
c.All terminals tight and secure.
d.Remote system links and functions properly.

5 Tracks OK ADJUST
a.Check for idler oil leaks.
b.Check for loose nuts and bolts on lower rollers.
c.Check for oil leakage on lower rollers.
d.Check for loose nuts and bolts on sprockets.
e.Check for loose nuts and bolts on track drive.
f.Check for oil leakage on track drive.
g.Check for damage to track links, pins and track shoes.
h.Check for loose nuts and bolts on track group.
i.Check for tight or seized track joints on track group.

GT104 Manual 71
 Section 4: Operation & Maintenance

6 Conveyors OK ADJUST
a.Inspect and replace worn flashing.
b.Inspect belts for damage or tears.
c.Check belt cleaner tension.
d.Inspect all bushings and shafts.

7 Screen OK ADJUST
a.Screen cloth properly tensioned.
b.Check for cracks or broken welds.
c.Make sure shipping brackets are removed.
d.Inspect for excessive wear or damage.
e.Check for material build-up.
f.Inspect ag spreader for damage.

8 General OK ADJUST
a.All guards are in place.
b.Decals are in place and legible.
c.Operator’s manual in place.

72 GT104 Manual
Section 4: Operation & Maintenance

OPERATIONAL CHECKS

OPERATIONAL CHECKS
1 Engine OK ADJUST
a.Inspect radiator overflow.

2 Hydraulics OK ADJUST
a.Check hydraulic oil level and temperature.
b.Check for leaks, loose fittings.

3 Electrical OK ADJUST
a.Make sure all emergency stops work.

4 Tracks OK ADJUST
a.Tracks are moving freely.

5 Conveyors OK ADJUST
a.Belts training properly.
b. Check conveyors for material leakage.

6 Screen OK ADJUST
a.Ag Spreader spreading material across width of screen.
b.Listen for any unusual sounds.
c. Look for excess vibration in stucture and handrails.

7 General OK ADJUST
a.List for any unusual sounds or vibrations.
b.Machine is clean of debris.
c.Check feed rate.
d.Watch for excess material build-up under plant.

GT104 Manual 73
 Section 4: Operation & Maintenance

8 Speeds OK ADJUST
a.Belt Feeder - 0-75 FPM
b.Screen - 900 RPM
c.Top Deck Overs Conveyor - 0-350 FPM
d.Bottom Deck Overs Converyor - 0-350 FPM
e.Underscreen Conveyor - 0-350 FPM
f.Fines Side Conveyoy - 0-350 FPM

74 GT104 Manual
Section 4: Operation & Maintenance
ENGINE MAINTENANCE SCHEDULE

ITEM INSTRUCTIONS
When Required
Battery Replace
Battery or Battery Cable Disconnect
Engine Clean
Engine Air Cleaner Element Clean/Replace
Fuel System Prime
Severe Service Application Check
Daily
Alternator Belt Inspect/Adjust/Replace
Cooling System Coolant Level Check
Driven Equipment Check
Engine Air Cleaner Service Indicator Inspect
Engine Air Precleaner Check/Clean
Engine Oil Level Check
Fuel System Primary Filter/Water Separator Drain
Hoses and Clamps Inspect/Replace
V-Belts Inspect/Adjust/Replace
Walk-Around Inspect
Every 50 Hours or Weekly
Fuel Tank Water and Sediment Drain
Every 250 Hours
Cooling System Coolant Sample (Level1) Obtain
Engine Oil Sample Obtain
Engine Oil and Filter Change
Initial 500 Hours
Engine Valve Lash Inspect/Adjust
Every 500 Hours
Fan Clearance Check
V-Belts Inspect/Adjust/Replace
Every 500 Hours or 2 Months
Crankcase Breather (Canister) Replace

GT104 Manual 75
 Section 4: Operation & Maintenance

Every 500 Hours or 1 Year

Battery Electrolyte Level Check
Cooling System Supplemental Coolant Additive (SCA) Test/Add
Engine Air Cleaner Element (Dual Element) Clean/Replace
Engine Air Cleaner Element (Single Element) Replace
Engine Oil and Filter Change
Fuel System Primary Filter/Water Separator Element Replace
Fuel System Secondary Filter Replace
Radiator Clean
Every 1000 Hours
Engine Valve Lash Inspect/Adjust
Every 2000 Hours
Aftercooler Core Inspect
Belt Tensioner Inspect
Exhaust Manifold Inspect
Starting Motor Inspect
Turbocharger Inspect
Water Pump Inspect
Every 2000 Hours or 1 Year
Alternator Inspect
Engine Mounts Inspect
Every Year
Cooling System Coolant Sample (Level 2) Obtain
Every 3000 Hours
Alternator Belt Inspect/Adjust/Replace
Every 3000 Hours or 2 Years
Cooling System Coolant (DEAC) Change
Cooling System Water Temperature Regulator Replace
Every 4000 Hours
Aftercooler Core Clean/Test
Every 6000 Hours or 3 Years
Cooling System Coolant Extender (ELC) Add
Every 12000 Hours or 6 Years
Cooling System Coolant (ELC) Change

76 GT104 Manual
Section 4: Operation & Maintenance
MACHINE MAINTENANCE SCHEDULE
ITEM INSTRUCTIONS
Daily
Screen Box Bearings Grease
Weekly or Every 50 Hours
Conveyor Belt Tension Check/Tighten
Head and Tail Pulley Hubs Check/Tighten
Conveyor Gear Reducers (Oil Levels) Check
Conveyor Scraper Blades Check/Adjust
Track Undercarriage Check
Batteries Inspect
Radiator Inspect/Clean
Oil Cooler Inspect/Clean
Conveyor Bearings Grease
Monthly or Every 200 Hours
Hydraulic Tank Breather Replace
Hydraulic Oil Test
Track Drive Gear Box Oil Level Check
Radiator Hoses Check/Correct
Air Intake Piping Inspect
Fan and Cooling System Check
Every 500 Hours
Conveyor Gear Reducers Oil Change
Track Gear Box Oil Change
Engine Coolant (Antifreeze) Check
Fuel Filter Replace
Engine Oil and Filters Change
Every 1000 Hours
Hydraulic Oil Filters Change
Cooling Fan Belt Tensioner Check/Correct
Serpentine Belt Check/Correct
Every 2000 Hours
Hydraulic Oil and Filters Change
Track Gear Box Oil Change
Cooling System Drain/Flush/Fill

GT104 Manual 77
 Section 4: Operation & Maintenance

FUEL RECOMMENDATIONS

Hydraulic Oil ISO 46

Feeder and Track Gear Box Oil SAE80W/90
Bearing and Track Tensioner Grease NLGI-2 Lithium
CH-4/CI-4 (Suggested: Shell Rotella T6 Fully Synthetic)
Engine Oil
Oil Capacity 3.25 gallons
Fuel Diesel Fuel ASTM D975
Coolant Must Meet ASTM D4985 or D6210
Specifications (Suggested: John Deere Cool-
REPLACEMENT FILTERS Gard II)

ITEM PART #

Hydraulic Filter/Breather C00033

Hydraulic Filter Element C04203
Hydraulic Suction Strainer F00314
Engine Fuel Filter (Primary) C10638
Engine Oil Filter C10643
Engine Air Filter (Primary) C10639
Engine Air Filter (Secondary) C10640

78 GT104 Manual
Section 4: Operation & Maintenance

D00433 D00424 D00423

D00434 D00426

D00428 D00435

TURNING SCREENING PLANT ON

Always do a final walk around the plant before Speed adjustments may be necessary depend-
turning on any of the circuits. Make sure all ing on the application.
personnel are clear of machine and all lockout/
tagout procedures are followed. Once you are It is highly recommended to start the items in the
certain all personnel are out of harm’s way the following order to avoid overloading the convey-
engine can be started. Increase engine speed or belts. The belt feeder should always be the
to 2200 RPM. the last thing turned on.
Fines Conveyor
All circuits can be turned on by pulling up on the Bottom Deck Overs Conveyor
circuit’s valve handle. All conveyors are adjust- Bottom Deck Overs Conveyor
able speed with the exception the fines and de- Screen/Underscreen Conveyor
livery conveyor. These speeds can be adjusted Feeder
by turning the flow control valves up or down.
GT104 Manual 79
 Section 4: Operation & Maintenance

START-UP AND SHUTDOWN 5. Do no overload the screen by feeding too

much material at one time. This will create a
Initial Operation material bed that is too deep. Reduced screen
efficiency, material spillage, and plugging may
The screen should be run empty initially to en- result. Damage to bearings and screen struc-
sure everything is operating properly and there ture may alos occur.
are no misaligned or binding parts. Operate a
new screen empty for two hours.

CAUTION
Before starting the screen, be sure all tools Material flowing Material flowing
and foreign objects have been removed and to left side. to right side.
everyone is clear.

Daily Start-Up

Use the following procedures when starting the

screen for daily use.

1. Perform all maintenance and inspection pro-

cedures.
Material evenly
2. Start the screen and allow it to reach normal distributed.
operating speed. Operate the screen for a few
minutes without material and listen for unusual
noises or other signs of trouble.

NOTICE
If unusual noises or other problems are Bed Depth OK
noticed, stop the screen, lockout power, and
make repairs as required.

3. Start material feed and check that the mate-

rial quickly and evenly flows across the full width
of the screen surface. Bed Depth too Deep

4. Feed material at a steady rate. Avoid surge

loads.

80 GT104 Manual
Section 4: Operation & Maintenance

OBSERVING SCREEN
OPERATION

1. As the screen operates, be

aware of any sudden changes
in the sound, movement, or
material flow that might indicate
trouble.

2. Listen for the sound of

loose parts, such as the rattle Blinding
of loose screen cloth panels or
wire cloth tensioners.

3. Listen for whining or howl-

ing sounds that might indicate
under-greased bearings and
potential bearing failure.

4. Always stop the screen Plugging

if any abnormal noises are
heard, or if any obvious chang-
es in operation is observed.
Identify the problem and make
repairs as necessary.

5. Check if the material is spill-

ing over the sides of the screen
or from around the chutes and
hoppers. Reduce feed rate or
make repairs as required.

6. If there is a sudden drop in

screening action, check that
material is not plugging the
screen cloth or backing up DAILY SHUT-DOWN
inthe discharge chutes.
1. Stop the material feed 3. Lockout power and tag con-
7. If blinding or plugging of the and allow the screen to oper- trols for screen and all related
screen openings occurs fre- ate until all quarry material is equipment (conveyors, etc.)
quently, speed, or stroke may discharged. Be sure no quarry
need to be changed. material is discharged. Be sure 4. Perform all schedule inspec-
no quarry material remains on tion and maintenance proce-
any of the screening surfaces. dures.

2. Stop the screen.

GT104 Manual 81
 Section 4: Operation & Maintenance

PRE-OPERATION/OPERATION CHECKLIST

Check each component of the vibrating screen

to ensure that is is in operational condition. This
NOTICE
This preoperational check should be per-
check should include, but not be limited to the formed any time the screen is moved to a
following: new site, or after an extended time in stor-
age.

PREOPERATIONAL CHECKS OK Adjust OPERATIONAL CHECKS OK Adjust

1.Sheet Metal/Appearance/Paint
1.Check screen cloth for wear, damage,
2.Electrical and tension
a.Electrical connections 2.Visually inspect all fasteners/electrical
b.Wire condition connections.
3. Inspect ag spreader, chutes, & hoppers
3.Lubrication 4. Inspect crown rubber and dams
a.All fittings greased 5. Inspect safety chains and safety decals
6. Secure all pins and clips
4.Screen
a.Cloth installed (all decks) 7. Ensure vibrators running @3600 RPM
b.Cloth tight 8. Check spread of material
9. Make sure screen is level

SCREEN BOX MAINTENANCE/SERVICE INTERVALS

50 250 500 1000 As
Daily Hours Hours Hours Hours Required
Screen Box
Check Screen Cloth for Wear, Damange & Tension X
Visually Inspect all Fasteners &
hydraulic/electric connections X

Inspect Ag Spreader (if present) X

Inspect Chutes and Hoppers X
Change Filters X
Change Oil X

X
Support Springs
Bearing Housting X
Electric Motor X
Secure All Pins and Clips X
Inspect Safety Chains X
Make sure screen is Level (side to side) X
Inspect that all Safety Decals are legible X

82 GT104 Manual
Section 4: Operation & Maintenance

SCREEN ADJUSTMENTS

CHECKING STROKE LENGTH

The stroke length can measured using the fol-

lowing process:

1. Place masking tape on both sides of the

screen near the discharge and feed ends.

2. Start the screen and allow it to reach operat-

ing speed.

3. Lightly touch a pencil or pen to the making

tape. The size of the oval should be the same
WARNING
size as the desired stroke. Check both sides of Never attempt to service or adjust this ma-
the screen. chine until all motion has stopped and power
has been disconnected and locked out.

NOTICE
A weak spring or broken spring can be
detected by checking the corners. Replace
springs as needed.

5. If there is a major difference in oval size from

side to side and end to end, the following condi-
4. If the ovals are less than desired, more coun- tions should be checked and corrected if neces-
terweights should be added. sary:

If they are more than desired, counterweights - Check that the foundation is level
should be removed.
- Check for damage on the support
Be sure to add or subtract weights equally to frame
both counterweight arms.
- Check for weak or broken springs

- Check if counterweights are incorrectly

installed.

- Check for buildup of material on screen.

GT104 Manual 83
 Section 4: Operation & Maintenance

SCREEN MAINTENANCE & LUBRICATION

The following section contains tons maintenance may need to WARNING
instructions for maintaining and be performed more often. Never attempt to service or
lubricating the vibrating screen. adjust this machine until
Failure to perform regular all motion has stopped and
Maintenance intervals shown maintenance may result in power has been disconnect-
are for normal operating condi- screening plant failure or dam- ed and locked out.
tions. If the screen is operated age.
under severe or adverse condi-

1
2

Interval Ref. No. Item Notes

10 hours N/A General Inspection Inspect for loose bolts, set screws.

N/A Screen Cloth Tension Check for wear and proper tightness

1 Bearing Housings Add 3 pumps of lubricant to each bearing

housing
3 Crown Rubber Check for wear and replace as required

N/A V-Belt (if applicable) Check for proper tension

50 hours 2 Support Springs Check screen for level and replace springs as
required.
1000 hours 1 Bearing Housings Purge bearings and Relubricate

As Needed N/A Electric Motor Lubricate Motor Bearings

84 GT104 Manual
Section 4: Operation & Maintenance

General Inspection Generally, you should check the following items:

(10 hours)
1. Make sure all guards are in place and func-
tional.
A walk around inspection should be made on a
daily basis. By taking a few minutes each day to Repair or replace any damaged or missing
inspect the screen, you can spot potential prob- guards or guarding devices.
lems and take care of them before they become
serious. 2. Repair or replace any damaged handrails,
ladders, or walkways.

3. Loosen nuts, bolts, and set screws.

4. Clear away built-up dirt and debris.

Bearing Housings
(10 hours)

The daily addition of lubricant

is necessary because a small
amount of lubricant continu-
ally passes through the seals,
flushing out accumulated dirt.

Bearing Housings

1. Clean grease fitting area

2. Add 3 grease gun strokes of

NLGI-2 grease to each bearing
housing, one on each side of
the screen.

Crown Rubber
(10 hours)

Check for loose, missing, or

damaged crown rubber.
Replace as needed.

GT104 Manual 85
 Section 4: Operation & Maintenance

Screen Cloth Check clamp bar tension. The clamp bars

(10 hours) should be equal distance from the screen
side. The proper amount of clamp bar tension
is required to maintain proper screen service;
Check screen cloth tension to insure proper however, overtightening can cause damage to
screen operation and prevent premature screen screen and not tightening enough can cause
wear.The screen cloth should rest firmly against premature screen wear and inefficient screen-
all rubber cushion strips. Screen should be ing.
tightened just enough to slightly indent the
crown rubber and prevent fluttering. Check the screen cloth for tears, breaks, or ex-
cessive wear, and replace as required.
Check the clamp bar bolts on all decks for tight-
ness. The screen cloth should be tight enough Check screen cloth for material or debris.
to prevent gaps between the screen cloth and
the center support ribs. Always tighten clamp
bar bolts equally.

86 GT104 Manual
Section 4: Operation & Maintenance

SCREEN TROUBLESHOOTING

CAUSE SOLUTION
EFFICIENCY 1. Bed of material is too deep 1. Decrease tonnage rate
SCREENING

2. Screen cloth open area too 2. Increase open area of cloth.

small.
3. Screen cloth is blinded. 3. Clean screen cloth.
4. Screen angle may need to be 4. Decrease angle of screen.
flatter
5. Screen speed too fast. 5. Decrease screen speed.
6. Stroke of screen too low. 6. Decrease screen stroke.
CAUSE SOLUTION
1. Material is too wet for the 1. Reduce feed rate.
SCREEN CLOTH

feed rate.
IS BLINDING

2. Screen speed too fast. 2. Decrease screen speed.

3. Screen angle may need to be 3. Increase angle of screen.
steeper.
4. Spread of material is not even 4. Material needs to be spread
across screen panel. across entire screen panel for
proper screening.
SIDE OR CENTER OF SCREEN

CAUSE SOLUTION
MATERIAL FLOWS TO ONE

1. Material is not centered on 1. Center material on feed con-

feed conveyor veyor.
2. Screening plant may not be 2. Check level of plant.
level.

CAUSE SOLUTION
BREAKING SCREEN CLOTH

1. Wire diameter of screen cloth 1. Increase wire size or de-

is too small for size of material. crease material size.
2. Material impact on screen 2. Install rubber strips across
cloth. width of cloth at impact zone to
protect screen cloth.
3. Improper tension of screen 3. Screen cloth is either too
cloth. loose or too tight (depending on
wire diameter). Make sure an-
chor ends are evenly distributed.
4. Crown rubber on decks are 4. Install new crown rubber on
worn out. deck.
5. Improper weave or crimp of 5. Contact screen manufacturer.
screen panel.
GT104 Manual 87
 Section 4: Operation & Maintenance
OVERALL INSPECTION
A visual inspection of the plant should be done 6. Check battery for corrosion or damage. The
on a daily basis. By inspecting the plant visually battery is located on the outside of the chassis.
each day you may be able to spot and correct To access the battery, remove bolts from cover
potential problems before they become serious. and lift cover off. Make certain battery terminals
are free of corrosion and other debris.
1. Check all grease lines, ensure they are prop-
erly routed, free of rips, punctures and bulges, HYDRAULIC MAINTENANCE
and connected securely.

2. Make sure plant is level. Environmental vari-

ations can cause the plant to become uneven.
Use an accurate level to ensure the plant is
level both front to back and side to side. If the
plant is operated in any matter other than level,
poor performance or damage to the equipment
may occur.

3. Visually inspect all guards. Ensure guards

are properly aligned and tilted at the correct The hydraulic tank fluid level should be visible
angle. Check to make certain guards are free in the sight meter at all times. Do not allow the
from obstructions and are not rubbing belt. hydraulic fluid level to fall below this line. If the
amount does fall below this line, add fluid until
4. Check for loose fittings. Ensure all nuts, visible. Operating the plant with an insufficient
bolts, and other connections are secure. Check level of hydraulic oil can cause premature wear
all pins and clips. When a pin is being used to or damage to equipment.
secure a section, a cotter pin must be used to
protect against vibrations working the pin out of All motors must have a constant supply of
its location. Make sure all pins and clips are in hydraulic oil in order to maintain good running
proper working order and fastened securely. condition. Damage to hydraulic pumps can
occur if hydraulic oil level does not stay within
5. Ensure all hydraulic lines are routed cor- satisfactory levels.
rectly, free of rips, punctures and bulges, and
have solid connections. Use a piece of wood or If adding hydraulic oil, be certain to filter the oil
cardboard as a backstop to pinpoint leaks. before adding it to the hydraulic oil tank. Even
new hydraulic oil contains impurities.

Condensation in the hydraulic tank can occur

during certain operating conditions. Keeping
the tank full will minimize the amount of con-
densation. If excess condensation is detected,
drain hydraulic oil tank and fill will new hydrau-
If hydraulic fluid penetrates skin, it must be lic oil.
surgically removed as soon as possible by
a doctor familiar with this form of injury or At certain times, hydraulic oil will need to be
gangrene, serious injury, or death will re- replaced. Additionally, all hydraulic filters, along
sult. CONTACT A PHYSICIAN IMMEDIATELY with the breather will need to be replaced at
IF FLUID ENTERS SKIN OR EYES. DO NOT certain intervals of operating.
DELAY.
88 GT104 Manual
Section 4: Operation & Maintenance
TRAINING THE BELT conveyor and check for alignment. If necessary,
Although the belt is trained at the factory, many repeat idler adjustments until content with
variations can cause the belt to become mis- alignment.
aligned. The belt should be
running directly down the 2. If adjusting the idlers does not work, an
center of the idlers. Several adjustment to the take-up screws may be
factors can effect the way necessary. The screws are located on either side
the belt tracks, and depend- of the head/tail pulley.
ing on the operating condi-
tions, variations of these This is not the most common cause of a misaligned
factors can occur. belt, but the process can be used as a last resort
to troubleshoot the situation.
Physical variations can
include: alignment of pulleys
(head and tail) and idlers. In
rare cases, the squareness
of the belt splice can cause
serious variations in the con-
veyors path.

Operating variations include: the size of load

and levelness of belt. A loaded belt may also run
differently than an empty belt. In order to prop-
erly train the belt, reduce the number of both Ensure the head pulley is properly aligned with
physical and operating variables. the tail pulley by adjusting the take-up screws. By
increasing the tension on either side of the head/
If the belt needs to be trained use the follow- tail pulley, the belt will shift in that direction.
ing procedures. NOTE: the effects of training
the belt will not be immediate. Allow several
complete rotations of the belt before making
further adjustments.

1. Use an accurate steel square to check the idlers.

Improperly aligned idlers are a common cause of
belt misalignment. Start by adjusting the return
idlers. After adjusting return idlers, if belt is still
straying, adjust several idlers behind the point at
which the belt strays.

Begin the troubleshooting process by performing By decreasing the tension to either side of
this adjustment on the opposite side of the belt the head/tail pulley, the belt will shift in the
that runs off the roller. opposite direction. Keep in mind that the head/
tail pulley must stay parallel with the conveyor
Do not attempt to make extreme adjustments to
frame. If the head/tail pulley is not parallel with
one idler. Instead, make several slight adjustments
the conveyor, the belt will stray. By adjusting
to several idlers. Always allow several rotations to
occur before determining belt alignment. the head pulley you are attempting to create
a parallel line with the conveyor frame.
After idlers have been adjusted, place a load onto

GT104 Manual 89
 Section 4: Operation & Maintenance

After adjusting the take-up screws, run the belt excessively rubbing
and check for proper alignment. Allow several full conveyor.
rotations of the conveyor belt before determining
satisfaction of alignment. If flashing is not
aligned correctly
or needs to be
re-aligned, adjust
accordingly. If
flashing is worn
to the point that it
is not preventing
spillage, replace
flashing with correct
replacement part.
See parts section for specific flashing sizes.

BEARINGS
This plant is equipped with ground level grease
BELT TENSION zerks for all bearing except the screen box bear-
If belt is sagging excessively when a load is ap- ings.All grease zerks can be found by locating
plied, it may be necessary to increase belt ten- the decals shown below. Visually inspect all
sion. Use the take-ups to increase and decrease bearings. A small amount of grease around seal
belt tension. When adjusting belt tension be is normal. Excessive grease or lack of grease
sure that the distance at which the take-ups are around seals may be a sign of bearing tempera-
extended is equal on both sides of head/tail pul- ture problems. See the lubrication chart located
ley. Improperly aligning the head/tail pulley will at the end of this section.
cause the belt to stray. Be certain not to create
to much tension on the belt.
Lube Point
GUARDS
Make sure return idler guards are in proper
place and are not damaged. Guards should be
D00007
tilted at the proper angle and free from obstruc-
tions. Guards should not be rubbing the con-
veyor belt. GREASE DAILY:
BELT CLEANERS 3 GREASE GUN
Located at the head pulley end of the multiple
conveyors is a belt cleaner. Make sure all fas- STROKES EVERY
teners are tight. Tighten if necessary. Inspect the
belt cleaner for excessive wear.
8 HOURS D00351

FLASHING
Check flashing on all conveyors. Flashing is
GREASE WEEKLY:
used to prevent spillage from occurring. 2 GREASE GUN
In order to properly prevent spillage, flashing STROKES EVERY
must be flush with conveyor belt, with a mini-
mum gap. Check to make certain flashing is not 40 HOURS D00352

90 GT104 Manual
Section 4: Operation & Maintenance
HYDRAULIC FILTERS Hydraulic Suction Strainer - F00314
Hydraulic filters will need to be checked and
replaced on a regular basis. Review the follow-
ing images and descriptions along with mainte-
nance schedules for each hydraulic filter.

Hydraulic Filter/Breather - C00033

(filter not shown; this is an in-tank filter and is

replaced when hydraulic oil is replaced)
Replace every 1000 hours

Replace every month or 200 hours.

Hydraulic Filter Element - C04203

Replace every 1000 hours

GT104 Manual 91
 Section 4: Operation & Maintenance
ENGINE FILTERS
Engine filters will need to be checked and re- Engine Air Filter (Primary)
placed on a regular basis. Review the following
images and descriptions along with maintenance
schedules for each hydraulic filter.

Engine Fuel Filter

Inspect Daily
Replace every 500 hours

Engine Air Filter (Secondary)

Replace after initial 250 hours.

Replace every 500 hours.

Engine Oil Filter

Replace every 500 hours

Replace after initial 250 hours.

Replace every 500 hours.

92 GT104 Manual
Section 4: Operation & Maintenance
ENGINE/HYDRAULIC FLUIDS Engine Oil - CH-4/CI-4
Engine filters will need to be checked and re-
placed on a regular basis. Review the following
images and descriptions along with maintenance
schedules for each hydraulic filter.

Hydraulic Oil - ISO 46

Replace every 500 hours

Fuel - Diesel Fuel ASTM D975

Test weekly or every 50 hours

Replace every 1000 hours.

Feeder & Track Gear Box Oil - SAE80W/90

Replace every 500 hours

Replace after initial 500 hours

Replace every 2000 hours after

GT104 Manual 93
 Section 4: Operation & Maintenance
Coolant - Must Meet ASTM D4985 or D6210
Specifications

Check monthly or every 200 hours

Replace after intial 500 hours
Drain/Flush/Fill every 1000 hours after

Bearing & Track Tensioner Grease - NLGI-2

Lithium

Screen Box - Daily/every 8 hours

Conveyors - Weekly/every 40 hours
Tracks check weekly or every 50 hours

94 GT104 Manual
Section 4: Operation & Maintenance

SCREEN CLOTH REPLACEMENT Crown Rubber

(205-005-053)

Tensioning Bar
(104-005-030)

Stationary
Hook End
Figure 95.1

Locknut Take-Up Screw

(H00069) (H01192)

Tensioner
Slide
(205-005-027)

Figure 95.2

GT104 Manual 95
 Section 4: Operation & Maintenance

Figure 96.1

Tension Bar Stationary Hook End

Figure 96.2

NOTE! the correct tension of BOTTOM DECK REPLACEMENT

To replace the bottom deck screen cloth you
the cloth greatly depends on the
will need to do the following:
size of screen cloth being used! 1. Loosen locknut and turn take-up screw so
Thicker screen cloth requires the tension slide moves toward the discharge
higher tension while thinner end of the screen (Figure 96.1).
2. Attach one end of the screen cloth over the
screen cloth requires lower stationary hook end (Figure 96.2).
tension. 3. Attach the opposite end of the cloth over the
tensioning bar (Figure 96.4)
96 GT104 Manual
Section 4: Operation & Maintenance

Figure 97.1

Crown Rubber

Figure 97.1

4. Now that the cloth is hooked on both ends, NOTE! Check screen cloth daily to
turn take-up screw so tension slide moves away
make sure the cloth has remained
from discharge end of the screen (Figure 97.1).
secure and bolts have not
5. Make sure that the cloth is touching the crown loosened up.
rubber (Figure 97.2) and that it is secure. Once
cloth is tightened properly, lock down locknut.

GT104 Manual 97
 Section 4: Operation & Maintenance

Clamp Bar
(104-005-025)
Spherical Washer
(H01244)

Carriage Bolt
Lock Nut (H01261)
(H00077)

Washers
(H00989)
(H00991)

Screen
Crown Cloth
Rubber

Figure 98.1

TOP DECK COMPONENTS

Above you will find a breakdown of the parts on
the top and middle decks (Figure 98.1). Please
familiarize yourself with the parts before attempt-
ing to replace the screen cloth. These parts with
be referenced on the next page.
98 GT104 Manual
Section 4: Operation & Maintenance

TOP DECK REPLACEMENT

To replace the top deck screen cloth you will NOTE! It may be necessary to re-
need to do the following:
1. Remove hardware from clamp bars as shown
torque bolts once all bolts are tight
above on both sides. to ensure all clamps are sealed and
2. Remove clamp bars and screen cloth. screen cloth is tight.
3. Insert new screen cloth and re-insert clamp
bars under the lip.
4. Re-install hardware and tighten the nut lo- NOTE! Check screen cloth daily to
cated on the outside of the screen box.
*Note - You may have to retorque bolts once all make sure the cloth has remained
bolts are tight to ensure all clamps are sealed secure and bolts have not
properly. loosened up.

GT104 Manual 99
 Section 4: Operation & Maintenance

MAIN CONTROL PANEL WARNING LIGHTS 6. Machine Stop Activated Light

This light will only illuminate when a machine
stop has been pressed. This will immediately
shut down the engine.

7. Engine Run Light

This light should illuminate when the key turned
to the “on” position and will remain on at all
times. If it goes out then a machine stop has
been pressed and the engine will shut down im-
mediately. The engine will not start if this light is
not illuminated.

8. Fuel on Light
This light will illuminate when the ignition key is
1. Battery Charging Warning Light turned to the start position to indicate that the
This light should illuminate when the key swtich fuel solenoid circuit has been energized. The
is turned to the “on” position. As soon as the engine will not start if this light is not on. When
engine starts, it should go out. If it fails to illumi- the engine is running this light will remain on.
nate when the key is turned on or if it illuminates
when the engine is running, it indicates that 9. Engine Warning Light
there is a fault in the charging circuit. Stop the The warning lamp provides important operator
engine and have the circuit checked. messages. These messages require timely op-
erator attention. The warning lamp is also used
2. Hydraulic Oil Level Warning Light to delineate diagnostics fault codes.
This light will only illuminate if the hydraulic oil
level is low. The engine will shut down five (5) 10. N/A
seconds after the fault has been detected.
11. LCD Display
3. Fuel Contamination Warning Light Displays engine speed, hours, fuel rate, tem-
See engine manufacturers manual for details. perature oil pressure and engine faults.
This lamp is controlled by the engine ECU.
12. Keypad
4. Engine Stop Light
The stop lamp provides critical operator mes-
sages. These messages require immediate and
decisive operator response. The stop lamp is
also used to flash out diagnostic fault codes.
This lamp is controlled by the engine ECU. See
engine manufacturers manual for details.

5. Remote Stop Light

This light will illuminate when a remote stop has
been pressed. The engine will shut down im-
mediately. The engine will not start if this light is
not illuminated. 13. Ignition Switch
This is used to start and stop the engine when
required.

100 GT104 Manual

Section 4: Operation & Maintenance

STORAGE INFORMATION

When the machine will not be used for a period

of a few months, use the following procedure for
storage to minimize corrosion and deterioration.

General Storage Guidlines Track Storage

• Remove all dirt and debris from all areas in The following guidelines should be followed for
and around the machine track storage on a plant for an extended period
• Lubricate all points as specified in the lubri- of time.
cation section of this manual
• Bearings must be rotated and lubricated ev- Move the plant once a month to keep seals
ery 30 days (they are in storage) to prevent lubricated and functioning properly.
them from drying out
• Clean the outside of the machine and repaint • Store indoors in extremely cold tempera-
any areas where needed. tures.
• Attach a tag to the plant indicating what stor-
age procedures have been done. If indoor storage is not possible, apply diesel or
• To help prevent corrosion, the fuel and hy- similar lubricant to the link joints before winter
draulic tanks should be filled to their proper shutdown. Clean and dispose of over-applied
level. liquid properly.
• Fill the bearing cavities with grease to pre-
vent condensation. If, after winter shutdown, the chain is stiff, use
• Cycle all hydraulic cylinders every three a hammer to break the links loose. Strike the
months plant is in storage hammer on the pin face of the chain.

Extended Period Storage

If the machine will be stored for a period of six

months or longer, follow guidelines below:

These guidelines should be completed once

every three months to lubricate the bearings
and/or to purge condensation and to prevent the
bearings from drying out.

• Lubricate bearings
• Rotate the shaft two revolutions
• Replace breather cap
• Change the fuel filter every year

GT104 Manual 101

 Section 4: Operation & Maintenance

102 GT104 Manual

Section 4: Operation & Maintenance

OPERATION AND MAINTENANCE NOTES

GT104 Manual 103

Section 5: Warranty
STANDARD WARRANTY
Each of Kolberg-Pioneer Inc., Johnson Crushers International, Inc., and Astec Mobile Screens, Inc. (hereinafter referred to
as “KPI-JCI & AMS”) warrants its products to the extent set forth herein (the “Warranty”) to first end-users who purchase the products of
KPI-JCI & AMS for resale, and such Distributors are authorized to extend this same Warranty (and no other) to each purchaser of the
products of KPI-JCI & AMS at the time of sale and to notify each purchaser of the terms and behalf of KPI-JCI & AMS, and any such war-
ranty given by Distributor is not binding on KPI-JCI & AMS. Distributor shall hold KPI-JCI & AMS harmless from any claim, loss and/or
costs (including attorneys’ fees) arising from failure to observe these conditions.
Each of KPI-JCI & AMS warrants, commencing with the date of receipt of the goods by first end-user and for a period of one
(1) year or two thousand (2000) hours of use, whichever comes first, all machinery and parts manufactured by KPI-JCI & AMS to be free
from defects in workmanship and material*. PROVIDED, HOWEVER, that such warranty period shall end thirty-six (36) months after
the date of shipment of the goods by KPI-JCI & AMS to the Distributor. If, within such warranty period, any machinery or parts shall be
proved to the satisfaction of KPI-JCI & AMS to be defective, it shall be replaced or, at the option of KPI-JCI & AMS, repaired at its factory,
providing the defective machinery or parts are returned to KPI’s, JCI’s, or AMS’s manufacturing plant, freight prepaid. At its option, KPI-
JCI & AMS may repair, or arrange to have repaired, any defective machinery or parts at the location of the Distributor, at the yard location
or operating site of the first end-user, or at any other suitable location, at no charge to first end-user and at no charge to Distributor other
than those specified in its Distributor’s Agreement. The right to have defective machinery or parts repaired or replaced shall constitute
Distributor’s and first end-user’s sole and exclusive remedy.
KPI-JCI & AMS may, at its sole discretion, refund the purchase price of the defective machinery or parts in lieu of repairing or
replacing them, providing the defective machinery or parts are returned to KPI’s, JCI’s, or AMS’s manufacturing plant, freight prepaid, and
providing such return is authorized in advance by KPI-JCI & AMS. KPI-JCI & AMS may, at its sole discretion, waive the requirement that
defective machinery or parts be returned to its factory in connection with a warranty claim.
A customer or Distributor who ships equipment to the factory for inspection and possible quotation for repair must agree to the
terms of the repair and quotation within thirty days. If not, the equipment must be moved and shipped from factory at the expense of the
customer or Distributor, otherwise a storage free will be charged equal to $2.50 U.S. per square foot per month or part thereof.
It is KPI-JCI & AMS’s policy that all returns are shipped prepaid, DDP-Yankton, South Dakota USA, Eugene, Oregon USA, or
Sterling, Illinois USA as applicable. All transportation and clearance fees at the origin and destination are the responsibility of the return-
ing party. KPI-JCI & AMS is not responsible for any penalties due to the inappropriate Customs fillings, including ISF. KPI-JCI & AMS
Return Authorization must be completed prior to return, and a preadvice of the return routing must be furnished to KPI-JCI & AMS prior to
making the return goods shipping arrangements.
IMPORTANT NOTICE: New U.S. Customs ISF Enforcement: As of January 26th, 2010, U.S. Customs is imposing a penalty
up to $5,000 for failure to file a proper ISF transmission on ocean shipments coming into the U.S. There are also penalties for failure to
file timely and accurately. If you need assistance in this matter, or with clearing the shipments through U.S. Customs contact KPI-JCI &
AMS.
The obligation of KPI-JCI & AMS under the terms of this Warranty is limited to the described repair or replacement of defective
machinery or parts. With regard to machinery, parts, or accessories which are furnished but not manufactured by KPI-JCI & AMS, the
warranty obligation of the original equipment manufacturer shall be passed through to the customer or Distributor but not otherwise war-
ranted by KPI-JCI & AMS. No warranty shall apply to any used machinery or parts. No warranty shall apply to the products of KPI-JCI &
AMS which, in its opinion, have been adversely affected by the use, on or with its products, of parts, attachments, equipment or lubricants
not manufactured, sold, or authorized by KPI-JCI & AMS.
No warranty shall apply to machinery, parts, or accessories which have been furnished, repaired, or altered by others so as (in
the opinion of KPI-JCI & AMS) to have affected the same adversely. No warranty shall apply to machinery, parts or accessories which (in
the opinion of KPI-JCI & AMS) have been subject to accident, negligence, or improper operation, installation, maintenance, storage, care,
or other-than-normal use during and after the shipment. Any parts or labor furnished by KPI-JCI & AMS, or other expenses incurred, in
anticipation of a warranty claim which is later determined not to be covered by the terms of his Warranty shall be payable to KPI-JCI &
AMS upon receipt of an invoice for such charges.
Each of KPI-JCI & AMS warrants that field services conducted by it in connection with installation or repair of machinery and
pats will be performed in a good workmanlike manner. The obligation and liability of KPI-JCI & AMS in connection with field services shall
be limited to a refund of the amount it charged for such services, if any.
Inasmuch as the work to be performed by the buyer or end-user with the machinery or parts furnished by KPI-JCI & AMS will
vary according to the materials used, local conditions, and the results required and that such variation will continue throughout the use
of such machinery or parts, it is not possible to (and KPI-JCI & AMS does not) warrant or represent that machinery and parts furnished
by it will handle specific materials or will produce specific results from such materials. Any application analysis and resultant equipment
performance expectations are provided as estimates only and are not to be construed in any manner as a production guarantee.
KPI-JCI & AMS is wholly discharged of all liability under the foregoing warranties in the event that purchaser of the machinery
or parts fails to pay for the goods promptly and in accordance with the terms of the purchase agreement.
KPI-JCI & AMS’s liability hereunder is conditioned upon Distributor or fires end-user giving notice in writing to KPI-JCI & AMS of
any alleged defect, and such notice must be given immediately upon the discovery of such alleged defect.
KPI-JCI & AMS does not warrant or represent that any machinery, parts, or accessories furnished by it meet any Federal, state,
or local statutes, codes, ordinances, rules, standard or other regulations covering safety, pollution, noise, electrical wiring, etc.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED (EXCEPT THE
WARRANTY OF TITLE) INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OF FITNESS FOR A PARTICU-
LAR PURPOSE. KPI-JCI & AMS SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES WHATSOEVER WITH
RESPECT TO MACHINERY, PARTS, ACCESSORIES, OR SERVICES MANUFACTURED OR FURNISHED BY IT OR ANY UNDERTAK-
INGS, ACTS OR OMISSIONS RELATING THERETO. UNDER NO CIRCUMSTANCES SHALL KPI-JCI & AMS BE LIABLE FOR ANY
INDIRECT, CONSEQUENTIAL, OR OTHER DAMAGES, EXPENSES, LOSSES OR DELAYS HOWEVER CAUSED, INCLUDING BUT
NOT LIMITED TO LOST PROFITS. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF.
*Provided, however, for Vanguard Plus Series Jaw Crusher unit only, consisting of pitman assembly and crusher base, excluding entire
chassis and mount structure, warranty shall be two (2) years or four thousand (4000) hours of use, whichever comes first.

 2704 W. LeFEVRE ROAD
STERLING, IL 61081

For Parts
Toll free - 800-545-2125 (815-626-6374)
Fax - 815-626-6430
E-mail - [email protected]

For Service
Toll free - 800-545-2125 (815-626-6374)
Fax - 815-626-6430
E-mail - [email protected]