Part 1 I54 Operations Manual REV003

OPERATIONS / MAINTENANCE MANUAL
& SPARE PARTS BOOK

MODEL: I54
MANUAL ISSUE 003
McCloskey International Ltd
47 Moor Road 1 McCloskey Road

Coalisland RR 7
Co. Tyrone Peterborough
N. Ireland Ontario
BT71 4QB Canada
K9J 6X8
tel: +44 (0)28 8774 0926 tel: +1 705 295 4925
fax: +44 (0)28 8774 7242 fax: +1 705 295 4777
mail: [email protected] mail: [email protected]
www.mccloskeyinternational.com
Page 1
REVISIONS I54
REVISION 001 - Crusher bearing grease type changed

REVISION 002 - Greasing info updated
REVISION 003 - Blowbar wear added to maintenance schedule.
Page 2
CONTENTS I54
Page
SECTION 1 INTRODUCTION 1-1
SECTION 2 SAFETY 2-1

2.1 Warning & Symbols 2-1
2.2 Safety Rules – Do’s & Don’ts 2-3
2.3 Description of Machine Parts 2-5
SECTION 3 OPERATIONAL PROCEDURES 3-1

3.1 Starting Machine 3-1
3.1.1 Starting Engine 3-6
3.1.2 Monitoring Engine 3-7
3.1.3 Stopping Engine 3-8
3.1.4 Track Control using Umbilical 3-9
3.1.5 Track Control using Radio Remote 3-10
3.1.6 Feed Control using Radio Remote 3-11
3.2 Machine Set Up Procedure 3-12
3.2.1 Unfold Mail Conveyor 3-12
3.2.2 Unfold Hopper 3-12
3.2.3 Setup Walkway 3-14
3.2.4 Unfold Side Conveyor 3-14
3.2.5 Landing Leg Setup 3-15
3.2.6 Unfold crusher top cover 3-15
3.2.7 Adjust crusher close side setting (CSS) 3-16
3.2.8 Adjust Crusher Maximum Load Setting 3-17
3.2.9 To monitor crushing performance 3-18
3.2.10 To adjust / monitor pan feeder settings 3-19
3.3 Operating Function 3-21

3.3.1 Pre-Start Setup 3-21
3.3.2 Start up Sequence 3-22
3.3.3 Operating Control Valves 3-23
3.3.4 Starting Crusher 3-23
3.3.5 Adjusting Crusher speed 3-24
3.3.6 Operating Auxiliary Functions 3-25
3.4 Emergency Stops 3-25

3.4.1 Stop a Machine in an Emergency 3-25
3.4.2 Re-starting after an Emergency Stop Is Pushed 3-25
3.4.3 Correct use of Emergency Stops 3-25
3.5 Preparing A Machine for Transport 3-26
3.5.1 To Prepare a machine for Transport 3-26
3.5.2 Loading a Machine on a Trailer 3-27
3.5.3 General operating instructions for I54 Impact Crushers 3-30
Page 3
Page
SECTION 4 SPARE PARTS 4-1
4.1 Recommendations Spares 4-1
SECTION 5 MAINTENANCE 5-1

5.1 Safety 5-1
5.2 General 5-1
5.3 Maintenance Schedule 5-2
5.4 Greasing Information 5-5
5.5 Engine Maintenance 5-6
5.6 Track Maintenance 5-8
5.7 Recommended Lubricants 5-8
5.8 Wheel Bogie Maintenance 5.8
5.9 Servicing Terminology 5-9
SECTION 6 SPECIAL PROCEDURES 6-1

6.1 Instructions for Safe Alignment of Conveyor Belt 6-1
6.2 Instructions filter change. 6-2
6.2.1 Air Filter 6-3
6.2.2 Hydraulic Oil Filter 6.4
6.2.3 Engine Oil & Fuel Filter 6-5
6.2.4 Changing hydraulic oil 6-5
6.3 Replacing Impactor Blow bars 6-6
6.3.1 Replacing Impactor Liner Plates 6-6
SECTION 7 FAULT FINDING 7-1

7.1 Fault Finding Table 7-1
SECTION 8 MACHINE TECHNICAL SPECIFICATIONS 8-1

8.1 I54 Technical Specifications 8-1
SECTION 9 TRACKS MANUAL 9-1
SECTION 10 APPENDIX 10-1

10.1 Machine Orientation 10-1
10.2 I54 Elevation Drawing 10-2
10.3 I54 Plan Drawing 10-3
10.4 Bolt Torque Table 10-4
10.5 Electrical part listing 10-5
10.6 Electrical diagrams 10-6
10.7 Parts listing 10-7
10.8 Impactor spare parts listing 10-8
10.9 Impactor operation and maintenance 10-9
10.10 Hydraulic Diagram 10-10
10.11 Sound level Diagram 10-11
10.12 Blowbar Selection Guide 10-12
Page 4
47 Moor Road, 1 McCloskey Road, RR 7,
Coalisland Peterborough,
Co. Tyrone Ontario,
Northern Ireland Canada.
BT714QB K9J 6X8
Tele: (+44)-28-8774-0926 tel: +1 705 295 4925
Fax: (+44)-028-8774-7242 Fax: +1 705 295 4777
Web: www.mccloskeyinternational.com Web: www.mccloskeyinternational.com
Warranty Start-Up Information

IMPORTANT: WARRANTY CANNOT BE ACTIVATED UNTIL THIS FORM IS RECEIVED. PLEASE FILL OUT COMPLETELY AND
RETURN.
Customer Name
Company Name
Address
Phone
Fax
Email
Federal ID# (US customers

only)
Machine Purchased
through
Dealer
Model #
Serial #
Control Panel Serial #
Track Serial # RH LH
Purchase Date
Hour Meter Reading At Time of Control Panel Serial No.

Purchase
Signing Officer
Please Print
Please Sign
Date Day Year

Month
Please Complete This Form And Send It To:

McCloskey International Ltd., McCloskey International Ltd.,
47 Moor Road, 1 McCloskey Road, RR 7,
Coalisland, Peterborough,
Co. Tyrone, Ontario,
Northern Ireland. Canada.
BT71 4QB K9J 6X8
Fax: (+44)-028-8774-7242 fax: +1 705 295 4777
Web: www.mccloskeyinternational.com mail: [email protected]
Page 5
Page 6
INTRODUCTION SECTION 1
Thank you for your purchase of the I54. This manual has been designed to help you properly, safely
operate, and maintain your new machine to ensure years of safe, reliable service and production. Please
ensure that all owners, operators or any other persons working near or on the machine read and understand
this manual. Observing procedures and maintenance schedules as outlined in this manual will help avoid
any dangers, reduce costly repairs and downtime and to increase the reliability of the machine.
The I54 is a machine that has been designed and built to the highest standards using quality materials and
components. McCloskey International has taken the greatest care to insure that you have received a safe,
reliable machine that will provide you with years of production.
The I54 has been designed with the highest regard for safety. Nonetheless any misuse of this machine may
result in serious injury, death, damage to the machine as well as void the manufacturer’s warranty.
This operating manual should always stay with the machine.
Machine’s Designated Use

The I54 is a portable, self-contained crushing plant for crushing materials into various sizes. Typical
materials include rock, concrete, brick and rubble. If you need to crush any other material not listed please
consult with the factory.
McCloskey International cannot be held liable for any damages resulting from misuse.
Contacting McCloskey International Ltd.

If you have any questions regarding your I54, please contact us at the following number:
UK: Canada:
+44 28-8774 0926 +1 705 295 4925
Toll Free: 1 877 TROMMEL
By phoning this number you can reach anyone of the following departments; service, sales, production,
accounting and engineering.
Owner’s Manual Sections

The following briefly outlines each section and its contents.
Warranty
This outlines the manufacturer’s warranty for this machine.
General Information
Technical information and data related to the machine and its components.
Safety
Safety information related to all aspects of the machine including operation, service, hydraulic system,
electrical system, safety stickers and warnings, and transportation.
Operation Procedures
Outlines the basic operating procedures including unloading from transport, on site setup, operation, travel
preparation, transport loading and long-term storage instructions.
Maintenance Procedures
This section covers service schedules and general maintenance checks including; all oil & filter changes,
belt tensioning maintenance, idler maintenance, screen maintenance, brush maintenance and tire pressure
with locknut torque specifications.
Service Parts
This section covers the identification and ordering procedure for common service parts.
Page 7
Problems, Errors and Omissions
We believe this manual will provide you with the necessary information to operate and maintain your
machine for many years of service. If you believe that this manual contains an error, or you encounter a
problem while following guidelines in this manual, or if you believe they may be missing information from
this manual, please contact us so we may rectify any problems immediately.
Copyright
This machine is copyrighted to McCloskey International Ltd. Any information, text, drawings or technical
data cannot be copied distributed, altered, stored on electric media, revealed to others or used for the
purpose of competition.
Page 8
SAFETY SECTION 2
2.1 Warnings and Symbols
Most accidents involving product operation, service and transportation are caused by failure to observe
basic safety rules and precautions. Recognizing all possible safety hazards before acting can often prevent
accidents. A person must always observe each situation for potential hazards. This person must also possess
the required knowledge, skill and equipment required to perform these tasks appropriately. The warnings
printed on the machine and in this publication are NOT inclusive. McCloskey International Ltd cannot
anticipate every possible situation that can be potentially hazardous. For any function performed not
recommended by McCloskey International Ltd, you must satisfy yourself that it is safe for you and
for others. Also, the action must not compromise the safety or function of the product for future use. If in
doubt contact McCloskey International Ltd.for clarification.
Improper operation, service or transportation can result in injury or death. Do not operate this product
unless you have been factory trained. Do not attempt to operate, service or transport the product without
carefully reading and fully understanding the proper safety, operation, service and/or transportation section
of this manual. (See Section 3)
Safety precautions and warnings are provided in this publication and on the product. Failure to observe
these hazards can result in injury or death. Hazards are symbolized by signal words such as Danger,
Warning, Caution and Attention. There are several warning labels printed on the product. The warning
labels are grouped into three categories:
Danger
This indicates an extremely dangerous situation. If proper precautions are not taken, it will result in serious
injury or death.
Warning or Caution
This indicates a hazardous situation. If proper precautions are not taken, it may result in serious injury or
death.
Push Emergency stop switch towards the machine to

completely shut down the engine. For locations see
Section 3.4.1.
When operating any moving part of the machine

ensure hands and feet are clear of all moving parts.
Never approach the tipping grid when the machine is
in operation. Always wear EN/ANSI approved safety
clothing. See Fig 1.
Page 1
Lockout/Tagout machine during any maintenance to
avoid accidental start-up. Located inside the LH
powerunit door beside the oil cooler.
Attention
This indicates a potentially hazardous situation. If proper precautions are not taken, it may result in injury
and or damage to the machine.
Page 2
2.2 SAFETY RULES: THE DO’S AND DON’TS OF A MCCLOSKEY MACHINE
2.2.1 DO NOT:
• Remove obstruction or attempt any maintenance while engine is running.
• Operate machine without reading manuals thoroughly.
• Stand within a 15m (50 ft) radius of the machine when it is in operation.
• Do not increase pressure in system as this may cause damage to pump seal, hoses,
hose fittings and to the actual machine structure.
• Do not start or stop (unless in an emergency) with control levers in the operating
position, as this could stall the engine, shear keys and couplings, blow seals and
cause damage to the actual machine structure.
• Operate machine with guards missing.
• Remove any guards.
• Open inspection doors while machine is operating.
• Block burst hydraulic hoses, pipes or fittings with hands, as hydraulic oil under
pressure will penetrate the skin and cause serious injury.
• Enter loading area while machine is functioning.
• Stand beneath conveyors.
• Stand beneath any head drum.
• Use machine near power lines.
• Touch hot surfaces.
• Wear loose fitting clothing near machine.
Page 3
2.2.2 DO:
• Grease the screen bearings daily (where applicable)
• Change filters and oil regularly
• Grease machine regularly.
• Inspect machine regularly.
• Check conveyor belt alignment before running belt.
• Study all manuals before operating machine.
• Obey all warning labels.
• Replace unreadable or missing labels with new ones before operating this
machine.
• Use a qualified and knowledgeable serviceman.
• Grease ALL exposed hydraulic cylinder rods every 8 weeks to prevent corrosion.
• Always wear correctly fitting (EN/ANSI approved) protective clothing. Protective

clothing includes Hard Hat, Safety Glasses, Ear Protection, Close Fitting Overalls,
Steel Toed Boots a High Visibility Vest and Gloves.
Fig 1
Page 4
2.3 DESCRIPTION OF I54
This section gives the user an insight into location and function of I54 components.
(Refer to Fig. 2)
Fig. 2
1) Hopper – Receives material and channels this onto vibrating pan feeder.
2) Pan Feeder – Consists of a 1354mm wide (53.3inch) heavy duty hardox lined vibrating pan
feeder. Acts as a reserve for raw material and controls the rate at which the material is fed to the
impactor crusher.
3) Grizzly Pre Screen – Consists of a 1354mm wide (53.3inch) heavy duty hardox lined 2
bearing vibrating double deck screenbox. Acts as a highly efficient separator for fines material.
4) Impact Crusher – Consists of a 1200mm (47”) diameter x 1350mm (53”) wide horizontal
impact crusher.
5) Side (Fine Product) Conveyor – A 650mm (26inch) three-ply belt and carries the smallest
screened material from the pan feeder to discharge stockpile.
6) Under crusher Pan Feeder – Consists of a heavy duty hardox lined vibrating pan feeder
mounted under the crusher to convey crusher material onto the main conveyor.
7) Main Conveyor – A 1200mm (48inch) three-ply belt receives material from the jaw crusher
and delivers this to the discharge stockpile.
8) Overband magnet – A 750mm (30”) wide conveyor bet mounted over magnet to lift metal
objects from Main Conveyor and discharge them to the side of machine.
9) Powerunit – Encloses the engine, hydraulic tank and machine operational controls.
NOTE:
THE LEFT AND RIGHT OF THE MACHINE ARE ASSIGNED BY STANDING
AT THE HOPPER END OF THE MACHINE LOOKING TOWARDS THE MAIN
CONVEYOR DISCHARGE.
SEE APPENDIX 10.1 – ORIENTATION FOR DETAILS.
Page 5
Page 6
OPERATIONAL PROCEDURES SECTION 3
3.1 STARTING ENGINE
Operation
Do NOT attempt to start the machine until you have been properly trained by a
McCloskey International technician. Ensure that the operator has read this manual and is
fully aware of its operation. Ensure all precautions are taken so that the machine is only
operated in a safe and reliable manner. Follow all government laws, codes or bylaws
regarding safety matters. Only operate the machine ensuring all safety devices are in
place and working properly, including all guards, safety devices, safety and warning
stickers, emergency shut-off switches, tank caps and exhaust elements. Always operate
internal combustion engine equipped machines out doors, or in properly ventilated area.
Always wear safety boots, glasses and hard hats while operating the machine. Avoid
wearing loose fitting clothing, neckties or scarves.
Machine Setup
Before setting up the machine walk around and check the following:
1. Scan the area around the machine for potential hazards, overhead wires or
structures, hills or slopes, poles or trees etc, address each situation before
continuing. The machine must be set-up on firm level ground for safety, and
maximum performance.
2. Establish a buffer zone around the machine to be kept clear of any personnel or
foreign objects while the machine is in operation.
While setting up the machine check the following:
1. Ensure all safety precautions have been made before starting the machine (see
Machine Pre-Start)
2. Keep all personnel outside the buffer zone while jacking machine and unfolding
radial conveyor.
3. Stabilize the machine from rolling by blocking transport wheels where applicable,
lowering jacking legs and raising the jack axle (if equipped).
4. Level the machine front to back, side to side using secure blocks.
5. Unfold the conveyors in accordance to the operation procedure listed for your
machine. Secure all supports.
Machine Pre-Start
Do NOT attempt to start the machine until you have been properly trained by a
McCloskey International technician. Different countries and states have distinct
legislation relating to the safe operation of machinery. Therefore it is the user’s
responsibility to ensure their operation complies with their laws. Before starting your
McCloskey Crusher walk around and check the following:
1. Check that the machine is in good mechanical condition and that there is no
component damage or loss. Ensure all safety devices, guards, bolts & fittings have
been properly installed and tightened.
2. All conveyors are fully unfolded with supports properly in place.
3. Ensure the feed hopper, conveyor belts, screenbox and grizzly (if equipped) are
free of material.
4. Check for any obstructions that would inhibit the movement of the conveyors.
Page 1
5. Ensure all hydraulic valves are in the neutral position.
6. Ensure all safety pins are in the appropriate position.
7. Know where all emergency stops are located.
8. Ensure the machine is blocked, level and stable. All jacking legs are properly
pinned.
9. Ensure all personnel & equipment is outside the buffer zone.
While Operating
1. Always concentrate and pay attention to the job at hand.

2. At the first sign of malfunction shutdown and lockout the machine (see next
section).
3. Stay clear of all discharge ends of machine components such as tail conveyor,
side conveyors, tipping grid discharge and screenbox. There is risk of serious
injury or death from material discharging from these components.
4. Read and follow all warning labels.
5. Only operate the machine with all guards and safety devices in place.
6. Keep hands and fingers away from moving objects such as the screen, conveyors
& scrapers, conveyor pivot assemblies, and the engine compartment.
7. Do not climb in or on the machine while in operation.
8. Do not fold the conveyor while in operation.
9. Do not transport the machine while in operation.
10. All personnel must be notified prior to the using the remote control.
Lockout/Tagout Procedure
1. Follow proper shut down procedures, (see Machine Shut Down in the Operations
section).
2. Turn the ignition key to the off position and remove the key.
3. Close the control panel door on the engine and lock it using a key.
4. Activate at least one emergency stop button.
5. Isolate the machine by turning off the battery isolator.
6. Lock out the battery isolator switch using a padlock or lock-out tag-out kit and
remove the key.
7. It is suggested that a Maintenance / Repair Tag be secured to the control panel to
notify all personnel that the machine has been immobilized. Only once the
problem has been repaired and inspected, the tag can be removed.
8. Follow proper safety precautions before restarting the machine (see Machine Start
up in this section).
Page 2
Maintenance
Competent personnel must carry out any maintenance or repair performed on the
machine. These actions can only be carried out once the machine is on sturdy and level
ground and is secured against inadvertent movement or buckling. Always assess the
situation for potential hazards before action is taken. Ensure the following safety
precautions are met at all times.
1. Lockout the machine before any action is taken.

2. Never stand or work under a suspended load.
3. Never use machine assemblies or parts as a work area or climbing aid. Only use
proper safety platforms or ladders when working on the machine.
4. When moving large and/or heavy machine assemblies for the purposes of
removing, replacing or performing work, ensure all parts are secured with proper
rigging and all standard rigging practices are followed
5. Always use proper safety harnesses when working more than 7 ft from the
ground.
6. When inflating a tire use an air chuck and hose with enough length to allow you
to stand to one side of the tire. Do not stand in front of a tire being inflated.
7. Sudden tire from rim separation can cause injury or death. A tire should be
separated from a rim using proper equipment by properly trained personal.
8. Never perform maintenance with tools that may cause sparks or provide an
ignition source for the fuel.
9. Only carry out grinding, welding or flame cutting if the manufacturer has
authorized it. There may be risk of explosion and fire.
• Ensure the machine and its surroundings are clear from dust and any other
flammable sources to prevent the risk of an explosion.
• The premises upon which the work will be performed should also be
properly ventilated.
• Do not heat or weld the tire wheel assembly. The heat can cause the
tire/wheel to weaken or explode.
• You must turn the battery isolator switch to the off position. Using your
lockout/tagout procedure. This will help prevent damage to any sensitive
electronics on the machine.
10. Any work to be performed on the electrical system must be carried out by a
qualified electrician in compliance with standard practices and any laws, codes or
bylaws.
• Before any work is performed on the electrical system always disconnect
the battery leads, check all de-energized parts for power and ground or
short circuit them.
• The electrical system must be inspected and checked at regular intervals.
Check for defects such as loose connections, frayed, burned or damaged
cables.
Page 3
11. Any work to be performed on the hydraulic system must be carried out by a
qualified hydraulic specialist in compliance with standard practices and any laws,
codes or bylaws.
• Never use your hands or other body parts to check for hydraulic leaks.
Use a piece of cardboard or paper. Before performing any service or
maintenance work on the hydraulic system ensure it is de-pressurized.
• Any equipment that is raised and lowered hydraulically must be secured in
place before any service work is performed.
• Inspect all lines, hoses, fittings and connections for leaks and any damage.
Any problems should be fixed immediately.
12. Never remove the filler cap or refuel while the engine is running.
13. Keep all safety devices; platforms, work areas and ladders clear from oil, dirt,
snow, ice, water or other medium that may cause harm.
14. All inspection, maintenance, and service schedules must be strictly followed
Page 4
Transportation
Make sure that all of material has been run off the conveyors and the machine has been
properly shut down (see Machine Shut Down in Operations section). Always perform
machine pre-start check starting the machine (see section 3.1.1). Clear the area of all
personnel & obstructions before folding the conveyors. Refer to operation section for
proper procedures for folding the radial conveyor and loading of the machine.
Do NOT move the machine without all transportation fitments securely in place and
safety pins in position.
Ensure that:
1. All travel stays/chains, jacks and tow bars are secured in the travel position.
2. All parts are properly secured, cleaned and free of hardware, rocks, dirt or any
debris that can fall off the machine and cause damage to other motorists.
3. All necessary parts are removed before transport.
4. Check the condition (if applicable) of the wheels and tires for any potential
problems, ie: cuts, excessive rusting, missing rubber, wheel damage, loose or
missing wheel nuts and proper tire inflation. See Wheels and Tires.
5. The brake system has been thoroughly checked and is fully operational.
6. All lights (running, turning and brake) are operational.
The machine must be towed in accordance with all local laws, codes and bylaws. Check
that transportation meets all load capacities. Make note the travel dimensions for your
machine before planning your route (see Weights & Dimensions in the Operations
Section). Take caution when crossing under overhead wires, underpasses, bridges etc. to
ensure enough clearance. Loading and unloading procedure must be followed as outlined
in this manual (see Operational Procedures Section).
Page 5
3.1.1 STARTING ENGINE
1. Check that control levers are in neutral position, and all emergency stops are
released
2. Make sure no one is standing within 15m (50ft) of machine.
3. Refer to (Fig. 3) Insert key in ignition switch (9).
4. Turn key clockwise to Run position (11), The Plus One colour screen will
illuminate and display image as shown in Fig 3.
5. Turn key clockwise again to Crank position (10), the alarm will sound to warn
that machine is about to start, hold for 10 seconds after which engine will crank.
6. Release key after immediately the engine starts.
7. Allow engine to run for 5 mins to allow it to reach running temperature before
operating machine. This will prolong engine life.
Engine Starter Panel
Fig. 3
Key to Fig 3
1 Plus One colour screen 10 Engine crank position

2 Button 1 - Crusher start / stop button. 11 Run position
3 Button 2 - Track speed adjust button. 12 Off position
4 Button 3 - Maintenance / Feedback button 13 Left / Right buttons

5 Button 4 - Language selection button 14 Up / Down buttons
6 Escape (go back) button 15 Button 8 - General information menu
7 OK button. 16 Button 7 - Feeder information menu
8 Panel door keys 17 Button 6 - Crusher information menu
9 Ignition switch 18 Button 5 - Engine information menu
Page 6
3.1.2 MONITORING ENGINE
To monitor engine functions press button 5 on Main Menu. Engine Function Menu will
display as shown in Fig 4 below.
Fig. 4
1. Diesel fuel level in tank displayed as percentage.

2. Diesel fuel pressure displayed as percentage.
3. Diesel fuel consumption measured in L/hr.
4. Diesel fuel supply temperature in engine measured in °c.
5. Cooling water level in engine displayed as percentage.
6. Cooling water temperature in engine measured in °c.
7. Battery voltage.
8. Engine turbo boost pressure measured in KPA.
9. Engine oil pressure measured in KPA.
10. Engine oil temperature measured in °c.
11. Engine load displayed as percentage.
12. Engine RPM
13. Total engine hours.
14. Total crushing hours.
To go back to main menu press ‘ESC’ button.
Page 7
3.1.3 STOPPING ENGINE
1. Make sure all conveyor belts, feed hopper and crusher are clear of all material.
2. Stop the machine in the following sequence.
1. Crusher
2. Pan Feeder & Pre Screen
3. Main Conveyor & Under Crusher pan Feeder
4. Overband Magnet Conveyor (where fitted)
5. Side Conveyor
3. Before stopping the engine, allow engine to run at idle speed for 5 minutes before
turning ignition switch off. This will allow engine temperatures to lower during this time
and will prolong engine life.
Page 8
3.1.4 TRACK CONTROL USING UMBILICAL CORD HANDSET
1. Connect the umbilical handset to the socket on RH side inside control cabinet.
2. Refer to (Fig. 5) showing umbilical handset.
3. Ensure E-stop button (item 1) is released. Twist to unlock.
Fig. 5
4. Start the engine (see 3.1.1). Engine speed will be adjusted automatically.
5. Change switch 2 Fig. 5 from AUX to TRACK to activate handset the siren will
sound. There will be a 10 sec delay before the machine will move.
6. When track sequence is activated (Button 2 on umbilical handset) the main
conveyor lower section will be automatically raised to the transport position.
7. The Snail symbol will appear on control panel Main Menu (see Fig 6 below)
beside button 2 to indicate that tracks are activated in lowest speed setting.
Fig. 6
Page 9
8. To select higher tracking speed press Button 2 on control panel. The symbol with
change to tortoise to indicate medium speed. Pressing again will change to Rabbit
indicating fastest speed. Pressing button again resets back to lowest speed (Snail)
9. To move machine with hopper end moving forward, move both hold switches
(3&4) toward from the E-stop . To move in the opposite direction hold the
switches in the opposite direction.
10. To turn machine use one of the switches above.
11. To stop engine in an emergency, while using umbilical handset, push red button
(Item 1). Please read section 3.4.3 on correct use of Emergency Stop System.
3.1.5 TRACK CONTROL USING RADIO TRANSMITTER HANDSET (OPTION)
1. Refer to Fig. 7 showing radio transmitter handset.

2. Turn on at master On/Off switch (button 1, Fig. 7).
3. Press Standby button to power up handset (button 8, Fig. 7).
4. Note that when radio transmitter is active the umbilical cord handset is inactive.
5. Press track On/Off button to activate track mode, the siren will sound. There will
be a 10 sec delay before the machine will move.
6. The Snail symbol will appear on control panel Main Menu (see Fig. 6) beside
button 2 to indicate that tracks are activated in lowest speed setting.
7. Press track speed selection button (button 9, Fig. 7) to select medium speed if
required; press again to select fastest speed. Press one more time to return to
slowest speed.
8. Press track buttons (buttons 4,5,10,11, Fig. 7) to move machine.
9. When finished moving machine press Track On/Off button to leave track mode.
Fig.7
Key to Fig. 7
1 Master On/Off switch 7 Emergency stop button

2 Increase Feeder speed button 8 Standby On button
3 Decrease Feeder speed button 9 Track speed selection button
4 LH side track forwards button 10 RH side track forwards button
5 LH side track backwards button 11 RH side track backwards button
6 Feeder On/Off button 12 Track On/Off button
Page 10
Page 11
3.1.6 FEEDER CONTROL USING RADIO TRANSMITTER HANDSET (OPTION)
1. Refer to Fig. 7 showing radio transmitter handset.

2. Turn on at master On/Off switch (button 1, Fig. 7).
3. Press Standby button to power up handset (button 8, Fig. 7).
4. Press Feeder On/Off button (button 6, Fig. 7) to activate feeder remote control.
5. Press feeder speed control buttons (button 2&3, Fig. 7) to alter the feeder computer
controlled speed which is being determined by current feed material height and
crusher drive pressure.
6. When finished controlling feeder press Feeder On/Off button to leave Feeder
remote control mode.
Page 12
3.2 MACHINE SET-UP PROCEDURE
MAKE SURE MACHINE IS CLEAR OF

WARNING ALL PERSONELL BEFORE START UP
3.2.1 UNFOLD MAIN CONVEYOR
1. Start engine (See section 3.1.1).

2. Disconnect tail conveyor transport stays (item 1, Fig 9).
Fig. 9
3. The hydraulic control panel shown in Fig 10 is located inside engine control
cabinet see (items 2,3 & 4, Fig. 9).Using lever (item 10, Fig. 10) lift the weight of
the transport bracket see (item 2, Fig. 9) and disconnect.
4. Using control valve (item 10, Fig. 10) raise the main conveyor head section and
lock in place using the pin provided.
5. Using control valve (item 9, Fig. 10) raise or lower the main conveyor to the
desired position.
6. The main conveyor feedboot can be raised or lowered using control valve (item 8,
Fig. 10), however this is also raised or lowered automatically by the track or crush
control system.
Fig. 10
Page 13
3.2.2 UNFOLD HOPPER
7. Raise the Hopper RH and LH sides using the control valves, (item 2 & 3 Fig. 10).
8. Raise the Hopper back using the control valve, (item 1 Fig. 10). Lock in position
using the supplied wedges. 6 off additional M20x65 bolts can be fitted if desired.
Fig. 11
9. Install the Hopper crossbeam, item 1 Fig. 12 using supplied pins (items 2 Fig.12).
Fig.12
10. Lock both Hopper sides in position using the toggle bolts, (item 1, Fig. 13).
Fig. 13
Page 14
3.2.3 SETUP WALKWAY
1. Install the RH and LH removable handrails to the upper walkway platforms. These
are simply dropped into sockets on the walkway.
Fig. 14
3.2.4 UNFOLD SIDE CONVEYOR
1. Before attempting to unfold side conveyor you will first have to unfold the RH
hopper side see 3.2.2, and remove tie strap provided for transport.
2. Using control valve lever (item 4, Fig. 10) lower conveyor to working position.
3. Remove telescopic head (item 2, Fig 15) section pin (item 1, Fig 15) and using
control valve lever (item 5, Fig. 10) extend conveyor to working length.
4. Refit head section pin (item 2, Fig 15) to secure conveyor in extended position.
Fig. 15
Page 15
3.2.5 LANDING LEGS SET UP
1. The crusher must not be operated without sufficient support under the landing
legs. Landing legs have the dual function of supporting the machine chassis as
well as aiding in levelling the machine.
Fig. 16
Remove jacking leg pins (item 1 Fig. 16). Use jacking leg control valve, (items 6&7 Fig.
10), to lower jacking leg. Ensure all limbs are clear of the jacking legs to prevent
crushing.
3.2.6 UNFOLD CRUSHER TOP COVER
1. Hinge crusher top cover (item 1, Fig. 17) into position shown. Do not operate
crusher with cover in transport position as this will restrict the opening height into
the crusher.
Fig. 17
Page 16
3.2.7 ADJUST CRUSHER CLOSED SIDE SETTING
Before operating crusher adjust the close side setting (CSS) to suit application. Impact
Crusher CSS is adjusted by adding or removing shims.
CAUTION:
Do not set the Apron Closed Side Setting below 25mm (1”) recommended minimum.
CAUTION:
Before starting crusher, remember to open the side access door and check to be sure your
adjustment did not result in one or more curtains being to close to the rotor.
1. Using control valve (item 11, Fig. 10), raise the crusher aprons to highest position
so that shims can be added or removed.
2. Refer to Universal 4753 Impact Service Manual for detailed Curtain Setting
procedure.
3. Refer to Universal 4753 Impact Service Manual for table of shim sizes required
for 1st or 2nd curtain setting.
Page 17
3.2.8 ADJUST CRUSHER SPEED SETTING
Crusher Speed Setting should be adjusted to the desired speed after crusher start-up. The
crusher speed can be adjusted between the max. and min. pre-set running speeds by
accessing the menu shown below (Fig.22). After adjustment the Crusher Speed Setting is
automatically stored.
1. Press button 6 on Main Menu to access Crusher Operating Function Menu. The
control panel will display the Crusher Operating Function Menu (Fig. 22) see
below.
2. Press button 3 to increase the Crusher Speed Setting.
3. Press button 4 to decrease the Crusher Speed Setting.
4. Press ‘ESC’ button to return to Main Menu when finished.
Fig. 22
NOTE:
The amount of adjustment available between the pre-set values is displayed as a
percentage as shown in Fig.23.
You can monitor the active crusher speed setting and the amount of adjustment available
from this screen as shown in Fig. 23 below.
Fig 23
Page 18
3.2.9 TO MONITOR CRUSHING PERFORMANCE
To monitor crushing performance during operation Press button 6 on Main Menu to

access Crusher Operating Function Menu. The control panel will display the Crusher
Operating Function Menu (Fig. 24) see below.
Fig. 24
Key to Fig. 24
1. This displays instantaneous engine load as percentage.

2. This displays hydraulic tank temperature in °c.
3. This displays engine rpm.
4. This displays crusher hydraulic drive pressure.
5. This displays crusher running speed.
Press ‘ESC’ button to return to Main Menu when finished.
Page 19
3.2.10 TO ADJUST / MONITOR PAN FEEDER SETTINGS
The Pan Feeder speed is controlled within limits by the crusher hydraulic drive pressure.
The Pre-screen speed is pre-set and fixed. If the crusher drive pressure exceeds the preset
maximum value for a period the feeder will be slowed and eventually stopped. The feeder
will only restart when the drive pressure drops below the restart preset pressure level.
NOTE:
The I54 crusher comes preset from factory with typical settings for the feeder control
pressures.
To adjust or monitor pan feeder settings during operation Press button 7 on the Main
Menu. The control panel will now display the Feeder Operating Function menu (Fig. 25)
see below.
Fig. 25
1. Current Crusher hydraulic drive pressure measured in Bar.

2. Feeder stop crush pressure, press button 5 to select then use up or down arrow
button to adjust this setting.
3. Feeder re-start crush pressure, press button 6 to select then use up or down
arrow button to adjust this setting.
4. Feeder current speed displayed as percentage of maximum available. This is
adjusted by control system based on material height inside jaw chamber and
crusher drive pressure. The amount by which the control system has reduced
the feeder can be further reduced by using up and down arrows.
5. Pre-Screen On-Off
6. Feeder On-Off
NOTE:
If required the Pre-Screen can then be switched on independently by pressing button 1
from the menu above (Fig. 25).
Press ‘ESC’ button to return to Main Menu when finished.
Page 20
3.3 OPERATING FUNCTIONS
MAKE SURE MACHINE IS CLEAR OF

WARNING ALL PERSONELL BEFORE START UP
3.3.1 PRE START UP CHECKS
1. Check crusher bearings have been greased (See Greasing Schedule section 5.4)
4. Check engine oil, (item 1 Fig. 26), Fill if necessary.
5. Check hydraulic oil level, (item 2 Fig. 26), fill if necessary
6. Diesel water separator for water and drain if necessary (item 3 Fig. 26).
7. All control valves must be in the neutral (mid) - position (item 4 fig 26)
Fig. 26
Fig. 27
8. Ensure the electrical isolator switch is turned on (item 1 Fig. 27).

9. Turn the ignition key on the starter panel to the crank position and hold (see
section 10.5). A warning siren will sound for 10 seconds after which the engine
will crank. Once started release the ignition key.
Page 21
3.3.2. START UP SEQUENCE
Engine speed is adjusted automatically by Control Panel. During Crusher smooth start-up
the engine will automatically increase to correct operating speed of 1900rpm. Correct
sequence for starting machine is as follows, see Fig. 28.
1. Under Crusher Pan Feeder & Main Conveyor.

2. Side conveyor.
3. Overband magnet.
4. Crusher.
5. Pan feeder & Pre Screen.
Fig. 28
NOTE:
1. Pan Feeder & Pre Screen will not start until main conveyor is running.
2. Pan Feeder & Pre Screen will not start until crusher is running.
To activate a valve pull it towards you. See Fig. 29.
Note: When crusher startup sequence is activated (Button 1 on panel) the main
conveyor lower section will be automatically lowered to the working position.
Page 22
3.3.3 OPERATING CONTROL VALVES
All control valves operate using levers and each is labelled with their function.
Some control valves in the powerunit are equipped with dials. These dials control the
output flow from the valve which will speed up or slow down the conveyor. See Fig. 29.
Valves (items 2, 3 and 5 Fig.29) have a flow control valve incorporated into the control
valve body. Valves 2 and 3 utilise this to minimise material roll back. Valve 5 speed
control is used to control the maximum material flow to the crusher.
Fig. 29
3.3.4 STARTING CRUSHER
To start impact crusher select button 1 on Main Menu. The following screen will display
(Fig 30). Press ‘OK’ button to start crusher or ‘ESC’ to cancel back to Main Menu.
Fig. 30
Page 23
3.3.5 ADJUSTING CRUSHER SPEED
To adjust crusher speed during operation Press button 6 on Main Menu to access Crusher
Operating Function Menu. The control panel will display the Crusher Operating Function
Menu (Fig. 31) see below.
Fig. 31
1. Press button 3 to increase crusher running speed.

2. Press button 4 to decrease crusher running speed.
3. Crusher running speed is displayed centre of screen.
Page 24
3.3.6 OPERATING AUXILIARY FUNCTIONS
To operate optional equipment auxiliary functions such as water pump, fuel pump or
working lights select button 8 on control panel Main Menu. The following screen will
display (see Fig 31 below).
Fig. 31
Press button 1 - to turn on / off the dust suppression water pump.
Press button 2 - to turn on / off the fuelling pump.
Press button 3 - to turn on / off the working lights.
Page 25
Page 26
3.4 EMERGENCY STOPS
IN THE EVENT OF AN EMERGENCY IT IS IMPORTANT TO KNOW HOW TO
STOP THE MCCLOSKEY I54 QUICKLY. BECOME FAMILIAR WITH LOCATION
AND OPERATION OF ALL EMERGENCY STOPS ON MACHINE. (See Fig. 32).
3.4.1 TO STOP MACHINE IN AN EMERGENCY
If an emergency arises, stop machine quickly, by pressing emergency stop (see Fig. 32).
1. Switch off engine ignition switch.

2. Set all hydraulic control levers to neutral positions.
Fig. 32
3.4.2 RESTARTING AFTER AN EMERGENCY STOP
1. Ensure all control levers are in neutral position.

2. (i) If the emergency stop is of a twist type, simply twist clockwise to reset.
(ii) If emergency stop is of a key type, insert key and turn key clockwise.
3. Start engine (See section 3.1.1).
3.4.3 CORRECT USE OF EMERGENCY STOPS
The McCloskey I54 crusher has safeguards built into the Crusher control system to
minimize cavitation in crusher drive motor during an emergency stop. However due to
the sudden nature of the emergency stop activation it is still possible to damage the
crusher motor if the emergency stop system is used excessively.
DO NOT USE EMERGENCY STOPS UNLESS IT IS AN ACTUAL EMERGENCY.
Page 27
3.5 PREPARING MACHINE FOR TRANSPORT
ENSURE HOPPER, CONVEYORS AND
DANGER SCREENBOX ARE EMPTY AND FREE

FROM MATERIAL
3.5.1 TO PREPARE A MACHINE FOR TRANSPORT
To prepare machine for transport the following sequence should be followed. Use Section
3.2 Machine Setup Procedure as a detailed guide to locate control valves and all locating
pins or bolts that need to be used.
1. Fold crusher top cover to transport position, see 3.2.6.

2. Remove upper walkway pull-out handrails, see 3.2.3.
3. Retract side conveyor head section then fold side conveyor to vertical
position, see 3.2.4.
4. Remove wedge and bolts and fold down hopper back plate, then remove
toggle bolts and fold down hopper RH & LH sides, see 3.2.2.
5. Raise jacking legs, see 3.2.5.
After folding please check that no parts of machine stick up above the powerunit canopy.
The machine is now ready to be put on a trailer.
Page 28
3.5.2 LOADING MACHINE ONTO A TRAILER
LOADING SHOULD ONLY BE
DANGER UNDERTAKEN BY COMPETENT

TRAINED PERSONNEL
The machine should be loaded on a trailer as shown in Fig. 33.

There should be adequate clearance beneath the main conveyor so that it will not come in
contact with the ground but trailers may vary, during loading continually check ground
clearance.
To track the machine see 3.1.3.
During machine loading / unloading operate tracks at lowest speed.
Fig. 33
Fold up the main conveyor head section and fit the transport stay see (item 2, Fig. 9).
Secure the machine to the trailer using suitable equipment.
Check machine is fully folded and sitting level so that it achieves correct overall height;
use Fig. 33 above for guide.
Check that there are no loose parts are on machine that could come detached during
transport and remove if necessary.
Page 29
3.5.3 GENERAL OPERATING INSTRUCTIONS FOR I54 IMPACT CRUSHERS
Following are general rules for operation of impact crushers. These are only guidelines.
The factory should review specific product sizes and capacities and other specific
applications.
Recycle materials
Generally the feed size would be concrete, block, brick or asphalt. It is recommended
that the amount of rebar be limited as much as possible, since large diameter rebar can
cause damage to the crusher. Generally rebar in the ½” diameter range is not a problem.
It is also recommended steel beams and other large steel frameworks be sorted out of the
feed material. These materials will cause damage to the crusher.
The ideal maximum feed size should be 6 inches thick by 18 inches wide by 24 inches
long. This size will feed through the crusher very well and will allow the operation to
maintain a high production rate. Not preparing the material and feeding larger size pieces
will cause bridging and in some extreme cases can cause damage to the machine.
Typically the feed size mentioned above can be broken into a 1 inch nominal product size
at a rate of 175- 300 STPH (short tons per hour – 2000 pounds /ton) depending on the
size preparation and amount of rebar. It is not recommended the product be smaller than
1 inch in this application. If the feed size is smaller approx. 6 inches thick by 12 inches
wide by 18 inches long. The product size can be ¾ inch nominal. The production rate
would need to be reduced by approximately one third or 115-200 STPH.
When crushing primary recycle materials with rebar, it is recommended the hammer
material be a chrome steel alloy. This material is fairly ductile and will limit the breakage
of the hammers while still providing acceptable wear properties. Caution: harder, more
brittle alloys, such as chrome iron, may break and cause rotor damage, hammer failure or
downstream equipment failure from hammer remnants. The I54 impact can have a RPM
range of 375-650. The STPH capacity is nearly the same whether the speed is on the
high or low end of the range. Increasing the speed generates more fines and increases
wear. It is usually recommended in recycle to keep the speed lower for these reasons.
Adjustment of the aprons should be done in order for both aprons to share the crushing.
Typically the lower apron is set at the nominal product size that is required. The primary
apron is set at approximately 2 to 3 times the lower apron setting to start. As the
crushing is taking place the operator should view the aprons and observe the “jumping”
of the aprons. It the top (primary) curtain is bouncing a lot, it should be opened to allow
a larger gap to the rotor circle. If the lower (secondary) curtain is bouncing a lot, the top
(primary) curtain should be closed to allow a smaller gap to the rotor circle.
Quarry run limestone

Generally the feed size for quarry shot limestone should be 27 inches in the maximum
dimension.
Typically the feed size mentioned above can be broken into a 6 inch nominal product size
(85% passing the 6 inch sieve) at a rate of 300-375 STPH depending on the size
preparation.
Page 30
When crushing primary limestone materials, it is recommended the hammer material be
a chrome steel or manganese. These material are ductile and will limit the breakage of
the hammers while still providing acceptable wear properties. Manganese is more tolerant
to the occasional tramp iron event, although it usually does not have the wear
characteristics when grinding occurs between the hammer and the apron liners occurs.
Typically chrome steel alloys are more durable in the grinding areas with less tolerance to
tramp iron. CAUTION: harder more brittle alloys, such as chrome iron alloys should
never be used in this application. Doing so may cause rotor failure, hammer failure, or
downstream equipment failure from hammer remnants. The I54 impact can have a RPM
range of 375-650. The STPH capacity is nearly the same whether the speed is on the
high side or low side. Increasing the speed generates more fines and increases wear.
The speed is generally based on the customer’s product requirement.
apron is set at approximately 2 to 3 times the lower apron setting to start. As the
crushing is taking place the operator should view the aprons and observe the “jumping”
of the aprons. It the top (primary) curtain is bouncing a lot, it should be opened to allow
a larger gap to the rotor circle. If the lower (secondary) curtain is bouncing a lot, the top
If other materials are being crushed other than limestone, capacities will vary depending
on the density of the material. If the density of the crushed material is different than 100
pounds per cubic foot, consult factory for estimated capacities.
Secondary applications
Generally the feed size would be 12 inches or less.
The typical rule of thumb for the I54 impact is a 9:1 reduction of secondary crush
materials. In other words, a 9 inch feed size could be reduced to a 1 inch nominal
product. If the feed size was 4 ½ to 5 inch the product could be ½ inch. It is not
recommended the product size be less than ½ inch. The impact will not reduce materials
smaller than 85% passing ½ inch. As the operator decreases the nominal product size
the capacity will also need to be decreased. For instance making a 1 inch nominal
product (85% passing 1 inch) the capacity in limestone would be in the range of 185
STPH. Making a ½ inch nominal product (85% passing ½ inch) the capacity in limestone
would be in the range of 125 STPH.
When crushing secondary limestone materials with an absence of tramp iron and a feed
size of 8-10 inch, it is recommended the hammer material be a harder more brittle
material than chrome steel. This material is called chrome iron alloy. CAUTION: It is
very critical that the feed material size and the absence of tramp iron must be controlled
by the operator. It is always recommended that metal detector and a magnet be used with
chrome iron alloys. The I54 impact can have a RPM range of 375-650. The STPH
capacity is nearly the same whether the speed is on the high side or low side. Increasing
the speed generates more fines and increases wear. The speed is generally based on the
customer’s product requirement.
Page 31
apron is set at approximately 2 to 3 times the lower apron setting to start. As the crushing
is taking place the operator should view the aprons and observe the “jumping” of the
aprons. It the top (primary) curtain is bouncing a lot, it should be opened to allow a
larger gap to the rotor circle. If the lower (secondary) curtain is bouncing a lot, the top
Hardrock applications
Crushing granites, basalt’s, and similar igneous rocks are not usually recommended due
to the abrasive properties of these materials. The I54 can crush these materials, although
the wear metal costs and maintenance costs can be very high. Generally with these
materials, the feed size would be 12 inches or less.
The typical rule of thumb for the I54 impact is a 9:1 reduction of hardrock materials. In
other words a 9-inch feed size could be reduced to a 1-inch nominal product. Due to the
abrasion and hardness of these materials a product size of less than 1 inch would not be
recommended. At a 1-inch nominal product (85% passing 1 inch) the capacity in this
material would be in the range of 175 STPH.
When crushing hardrock materials with an absence of tramp iron and a feed size of 8-10
inch, it is recommended the hammer material be a harder more brittle material than
chrome steel. This material is called chrome iron. CAUTION: It is very critical that the
feed material size and the absence of tramp iron must be controlled by the operator. In
these materials, it is recommended a sample of the material be sent to the factory for wear
analysis and an estimated wear cost before proceeding.
apron is set at approximately 2 to 3 times the lower apron setting to start. As the crushing
is taking place the operator should view the aprons and observe the “jumping” of the
aprons. It the top (primary) curtain is bouncing a lot, it should be opened to allow a
larger gap to the rotor circle. If the lower (secondary) curtain is bouncing a lot, the top
Page 32
RECOMMENDED SPARE PARTS SECTION 4
During the working life of a McCloskey I54, it may be necessary to replace some parts on
a regular basis due to wear and tear. This section serves as a simple guide as to which
parts are regularly consumed and to those, which may only need replacing once on a very
rare occasion or not at all.
4.1 REGULAR SPARES

We recommend that the following parts are kept in stock for the Annual maintenance of
the McCloskey I54.
PART DESCRIPTION / REFERENCE No. PER ANNUM

NUMBER
501-011-118 Flushing line water filter 2
501-011-058 Hydraulic Tank Air Filter UFI D101 2
501-011-132 RKM 800 5 MICRON ELEMENT (FLUSHING ONLY) 2
501-011-133 RKM 800 10 MICRON ELEMENT BZZ 10R 1O/-NR 2
502-011-021 C13 Engine Air Filter Inner safety element 1

502-011-019 C13 Engine Air Filter Outer As required
502-011-032 C13 Engine Fuel Filter 5
501-011-117 C13 Engine Fuel / Water Separator Element 5
501-011-115 C13 Engine Oil Filter 5
206-231 Pan Feeder / Pre Screen Coupling HRC 150 2

501-008-042 Pan Feeder Coupling insert HRC 150 – Oil resistant 1
501-008-042 Pre Screen Coupling insert HRC 150 – Oil resistant 1
520-005-021 Main Conveyor Belt Scraper 2

501-006-007 Side Conveyor Belt Scraper 2
Page 1
Page 2
MAINTENANCE SECTION 5
BEFORE CARRYING OUT ANY
MAINTENANCE OR ATTEMPT TO
WARNING REMOVE ANY OBSTRUCTION ON
MACHINE ENSURE THAT MACHINE IS
LOCKED OUT
5.1 SAFETY
Fig. 1
5.2 GENERAL
Maintenance of the McCloskey impact crusher is carried out using five schedules: -
Schedule ‘A’ – daily.

Schedule ‘B’ – after first 50 hours.
Schedule ‘C’ – weekly.
Schedule ‘D’ – monthly.
Schedule ‘E’ – 600 HOURS or 3 month
Schedule ‘F’ – annually
IMPORTANT: See Operator Manual for crawler track service intervals
Page 1
5.3 MAINTENANCE SCHEDULES
SCHEDULE ‘A’ DAILY MAINTENANCE
ITEM OPERATION REMARKS

1 Defects Attend to any defects reported by the
operator.
2 Crusher Bearings Check auto greaser for crusher bearings See Section 5.7
has sufficient grease in reservoir and
fill if necessary
3 Pre Screen Bearings Grease screen bearings daily with 1 See Section 5.7
grease gun stroke per side.
3 Electrical System Examine all visible cables and
connections.
4 Hydraulic Power Unit a) Check oil level and replenish. See Section 5.7
b) Visually inspect for leaks, damaged Also Section 3.3.1
hoses and fittings. Replace defective
items.
c) Visually inspect filter indicators
5 Conveyor Belt. a) Visually inspect for cuts, rips and See Section 6. 1
tears. Report to maintenance
manager if necessary.
b) Check alignment, adjust as
necessary.
c) Check tension, adjust as necessary.
6 Guards a) Ensure all guards are securely fitted.
b) Report defective guards to
maintenance manager.
c) Replace defective guards.
7 Fasteners Visually inspect for loose bolts and
screws, tighten if necessary
8 Track maintenance Refer to track manual See section 9
9 Fuel level a) Check fuel level and replenish.

b) Visually inspect for leaks, damaged
items.
10 Engine oil level Check oil level and replenish Section 3.3.1
11 Hoses Visually inspect for leaks, damaged
items.
12 Seals Visually inspect for damaged seals
13 Engine Air filter Change filter if light illuminates
14 Pan Feeder a) Check oil level and replenish. See Section 5.7
b) Visually inspect for leaks.
15 Blowbar Check blowbars daily for wear.
Page 2
Page 3
SCHEDULE ‘B’ MAINTENANCE AFTER FIRST 50 HOURS

1 Schedule ‘A’ Ensure that the work detailed in this
schedule has been carried out.
2 Pan Feeder Change feeder gearbox oil See Section 5.7
3 Return line hydraulic Change filter after the first 50 hours See Section 6.4.1.
filters
4 Diesel pre-filter Drain pre-filter after first 50 hours
SCHEDULE ‘C’ WEEKLY MAINTENANCE OR EVERY 50 HOURS

1 Schedule ‘A’ Ensure that the work detailed in this
schedule has been carried out.
2 Conveyor Belt Scraper a) Remove Material Build Up. See Section 6.1
b) Check adjustment and adjust as
necessary.
c) Replace worn or damaged parts.
3 Greasing of bearings Grease as per recommendations See Section 5.4
4 Bolt tightness Check bolt tightness around screen

box and engine compartment
5 Screen mesh Check condition of screen mesh
6 Rubber cushions Check condition of rubber cushions
when changing mesh.
7 Diesel pre-filter Drain diesel pre-filter
Page 4
SCHEDULE ‘D’ MONTHLY MAINTENANCE OR EVERY 200 HOURS

1 Schedule ‘A’and‘C’ Ensure that the work detailed in
these schedules has been carried
out.
2 Bearings. a) Inspect for loose bolts and See section 5.4
tighten if necessary.
b) Inspect for loose fit on shaft and
any damage, replace if
necessary.
c) Lubricate screen box outer
bearings
3 Hydraulic oil filters Return line oil filters should be Element should be
changed every 1000 hours or when changed frequently in
indicator turns from green to red, excessively dusty
conditions
4 Hydraulic tank Hydraulic tank air filter should be
replaced.
5 Engine air intake pipe a) Check engine air intake pipe for
signs of weakness, holes or
wear.
b) Replace where necessary.
6 Track Refer to track manual for
maintenance details
SCHEDULE ‘E’ ANNUAL MAINTENANCE OR EVERY 500 HOURS

1 Engine oil change Engine oil, oil filter and fuel filter
See section 6.4.2
SCHEDULE ‘F’ ANNUAL MAINTENANCE OR EVERY 2500 HOURS

1 Schedule ‘A’,‘C’ and ‘D’ Ensure that the work detailed in
these schedules has been carried
out.
2 Hydraulic Oil a) Analyze oil sample, check for See section 6.2.4
condition and contamination.
b) Change only as necessary.
3 Under Crusher Pan Apply 16 grease gun strokes or 20 See Section 5.7
Feeder bearings grams per side
Page 5
Page 6
5.4 GREASING INFORMATION
Crusher Bearings
Crusher bearings must be greased daily before the machine is started.
Bearings are greased from central point and require 8 grease gun strokes daily.
Layshaft Bearings
Layshaft bearings must be greased daily before machine is started.
Layshaft bearings are greased from the central grease point located on the walkway.
Layshaft bearings require 2 grease gun strokes daily.
Layshaft Internal Spline

The layshaft internal spline is greased from the central grease point located on the
walkway.
The layshaft internal spline requires 1 grease gun stroke daily.
Conveyor Bearings
Conveyor bearings require 2 grease gun strokes every 40 hours (weekly).
Under Crusher Pan Feeder Bearings

Vibrator units on under Crusher Pan Feeder require 1 grease gun strokes every 40 hours
(weekly).
Screen Bearings
Screen bearings must be greased daily before the machine is started.
Screen bearings require 1.25grams, or 1 grease gun stroke daily before startup.
HYDRAULIC SYSTEM - (IMPORTANT)
IMPORTANT: When changing or topping up hydraulic oil or changing filter elements.

The utmost cleanliness must be observed at all times, as impurities in the oil will destroy
the system.
Check condition of all hydraulic system components weekly.
IMPORTANT: If the performance of the McCloskey machine has decreased i.e.

conveyors or crusher shaft has slowed down, switch off machine immediately, check
hydraulic system before restarting.
Note: If the hydraulic system requires any major repairs contact an agent approved by
McCloskey International Ltd immediately.
Page 7
5.5 ENGINE MAINTENANCE
For engine maintenance refer to the engine manual. Engine servicing should only be
carried out by a qualified Service person.
Maintenance Interval Schedule

The normal oil change is every 500 service hours or 12 months. Be sure to conduct
controlled oil sampling at every 250 service hours or 6 months. The oil change interval
may need to be reduced for some applications based on the controlled oil sampling
results. Verify the proper oil change interval for the engine after satisfactory completion
of the controlled oil sampling.
When Required
Battery - Replace
Engine - Clean
Engine Air Cleaner Element - Clean/Replace
Engine Crankcase Breather - Clean
Daily
Cooling System Coolant Level - Check
Driven Equipment - Check
Engine air Cleaner Service Indicator - Inspect
Engine Oil Level - Check
Walk Around Inspection
Every 50 Service Hours or Weekly

Fuel Water Separator and Filter - Drain
Every 250 Service Hours or 6 Months

Engine Oil Sample - Obtain
Every 250 Service Hours or 1Year

Radiator - Clean
Every 500 Service Hours

Alternator and Fan Belts - Inspect / Adjust / Replace
Battery Electrolyte Level - Check
Cooling System Coolant - Test / Add
Every 500 Service Hours or 6 Months

Engine Protective Devices - Check
Fuel System Secondary Filter - Replace
Fuel Transfer Pump Strainer - Clean
Hoses and Clamps - Inspect/Replace
Every 500 Service Hours or 1 Year

Engine Oil and Filter - Change
Page 8
Engine Valve Lash - Inspect Adjust

Alternator - Inspect
Every 2000 Service Hours or 1 Year

Engine Mounts - Inspect
Fuel Injection Nozzles - Test/Exchange
Every 2000 Service Hours or 2 Years

Cooling System Coolant Extender (ELC) - Add

Cooling System Coolant - Change
Cooling System Water Temperature Regulator - Replace
Starting Motor - Inspect
Water Pump - Inspect

Cooling System Coolant (ELC) - Change
Page 9
5.6 TRACK MAINTENANCE
See Crawler Track Operator / Maintenance Manual.
5.7 RECOMMENDED LUBRICANTS

Pan Feeder Bearings....................................................................................Shell Omala 220
Crusher Bearings……………………………………………...…...........…….. EP2 Grease
Layshaft Bearings…………………………………………………...….Mobilith SHC 220
Pre Screen Bearings…………………………………………………….Mobilith SHC 220
Under Crusher Pan Feeder……………………….…………………..…… Esso Unirex N3
Conveyor Bearings and general purpose grease.................................................EP2 Grease
Engine.......……………………………………………………………...15W/40 Engine oil
Track Gearbox and track adjustment..............……….See Crawler Track Operator Manual
Hydraulic Oil.......................................................................................................ISO VG 68
Cold Weather Operation (Ambient Temp -40C (400 F)
Engine Oil…………………………………..…………………………10W/30 Engine Oil

Hydraulic Oil…………………………………………..……………………….ISO VG 68
Crusher Bearings……………………………………………...……….............EP2 Grease
Layshaft Bearings………………………………………………………...........EP2 Grease
5.8 WHEEL BOGIE MAINTENANCE

Wheel nut torque……………………………………...………800-850Nm (590-627 lbf.ft)
Tyre pressure………………………………………………………………. 9 bar (130 psi)
Tyre size………..………………………………………………………...…. 235/75 R17.5
Tyre load rating…………………………………………………………...……. 143 / 141J
Load capacity per axle……………….......………………….. 10,300 Kgs at rated pressure
Page 10
5.9 SERVICING TERMINOLOGY
Definitions of terms are as follows:-
Check or inspect
Carry out a survey to ensure one or more of the following does not impair the condition
of the item.
• External Damage.
• Insecurity of Attachment.
• Cracks or Fractures.
Check or inspect
Carry out a survey to ensure one or more of the following does not impair the condition
of the item.
• Corrosion, Deterioration or Contamination.

• Distortion.
• Loose or Missing Fasteners.
• Faulty or Broken Locking Devices.
• Chafing, Fraying, Scoring, Wear, Cuts or Tearing.
• Leaks from Pipelines and Hoses.
• Discolouration due to Overheating or Leaking Fluids.
Operate
Ensure that an item or system functions correctly, as far as possible without the use of test
equipment or reference to measurement.
OEM
Original Equipment Manufacturer.
Fit
Correctly attach one item to another.
Remove
Separate completely an item from its support.
Refit
Fit an item, which has previously been removed.
Replace
Remove an item and fit a new or serviced item.
Replenish
Refill a container to a pre-determined level or quantity and where necessary:-
1. Remove caps from filter orifices.
2. Clean orifices.
3. Fill container as directed.
4. Inspect caps and gaskets.
5. Refit caps.
Page 11
Page 12
SPECIAL PROCEDURES SECTION 6
ALL SPECIAL PROCEDURES IN
SECTION 6 SHOULD ONLY BE CARRIED
WARNING OUT BY A QUALIFIED AND COMPETENT
SERVICE PERSON.
BEFORE ATTEMPTING ANY PROCEDURES IN THIS SECTION ENSURE

ENGINE IS SWITCHED OFF AND CANNOT BE RESTARTED BY ANYONE
OTHER THAN THE SERVICE PERSON, ISOLATE THE MACHINE BY
TURNING OFF THE ISOLATOR SWITCH SEE 3.3.1 Fig. 22 AND LOCKOUT
THE MACHINE. THE SERVICE PERSON BEING IN CHARGE OF THE KEYS.
6.1 INSTRUCTIONS FOR SAFE TENSIONING

AND ALIGNMENT OF CONVEYOR BELT
1. Ensure that engine is switched off

and cannot be started by anyone
other than the service person.
2. Turn off the battery isolator switch
(item 1 Fig. 27). Push in one e-stop
(see Fig. 32).
3. Clean build up of material from all
idlers and rollers.
4. Slacken adjuster locking bolt (item
2, Fig. 34)..
5. Turn tensioning bolts (item 1 Fig.
34), alternately and evenly, until belt
feels tight.
Fig. 34
6. Release emergency stops.

7. Check that all unauthorised personnel are clear of machine, restart the engine.
8. Pull the lever to run the conveyor being adjusted (see 3.3.2).
9. If the conveyor belt is running to the right tighten the right hand adjuster.
10. If the conveyor belt is running to the left then tighten the left hand adjuster.
11. Observe the belt to see if it running true to centre, if not repeat procedure ‘9’ or ‘10’
until the belt is centred.
12. Run the machine with belts loaded and unloaded until you are satisfied that the belt
is tensioned and aligned.
13. Tighten Locking bolt.
Page 1
6.2 SERVICING FILTERS
FILTER LOCATION
Fig. 35
1 – Air filter
2 – Primary fuel filter\Water separator
3 – Fuel filter
4 – Hydraulic oil return line filters
5 – Hydraulic oil water filter
6 – Hydraulic pilot line filter
7 – Hydraulic tank air filter
8 – Hydraulic filler cap
9 – Engine oil filter
Page 2
6.2.1 AIR FILTER
1. Turn off engine
2. Remove air filter cap (item 1,

Fig. 36) by loosening clips
(item 2, Fig. 36).
3. The filter elements are shown in

Fig. 37.
4. When removing the filter

element (item 3, Fig. 37) be
careful not to disturb the safety
element (item 4, Fig. 37).
5. Ensure all clips are tight.
6. Reset air filter button (item 3,

Fig. 36).
Fig. 36
Air filter Components
1. Fixed outer housing

2. Cap
3. Outer filter element
4. Safety element
5. Clip
Fig. 37
Page 3
6.2.2 HYDRAULIC FILTER
1. Lock out machine
2. Take off filter cap by removing the 4

bolts (item 1, Fig. 38).
3. Remove Hydraulic filter element

(item 2, Fig. 38).
4. Replace filter element.
5. At all times dirt must be prevented

from entering the tank.
The complete filter housing does not have

to be removed as shown only the cap.
Fig. 38
1. The hydraulic tank filler (item 1, Fig.

39) is mounted on top of hydraulic
tank inside powerunit. This has an
internal strainer (item 2, Fig. 39) to
stop large debris. This strainer should
be kept clear.
2. To remove strainer remove filler cap

and pull out strainer.
Fig. 39
1. The hydraulic tank air filter is

mounted on top of hydraulic tank
inside powerunit. This filter is used to
dry the air entering the hydraulic
system.
2. The crystals inside filter change from
yellow to green to indicate the filter
needs to be replaced.
3. To remove filter pull it vertically out
of its mounting socket.
Fig. 40
Page 4
6.2.3 ENGINE OIL & FUEL FILTER
See Engine Maintenance Section 5
6.2.4 CHANGING HYDRAULIC OIL
1. Drain hydraulic oil through bung on bottom of hydraulic tank.

2. Remove existing return line filters and dispose of.
3. Fit temporary 5 micron return line filters for oil cleansing.
4. Check and replace hydraulic tank air filter / dryer if required.
5. Connect filling pipe direct to filling port on return manifold (item 2, Fig 41).
NOTE: This is highest point on hydraulic system and will ensure that all oil is pre-
filtered through return line filters. Filling through the filling port also ensures that the
main pump suction lines are filled.
6. Temporarily remove test point on pump connector block (item 1, Fig. 41) during
filling process to let out trapped air. This prevents cavitation and damage to
main pump on startup.
7. Fill until oil level reaches full level on tank gauge.
8. Startup up machine and operate all conveyors and feeder for 1 hour to flush
hydraulic system.
NOTE: Do not operate crusher drive during flushing process as excessive backpressure
is caused by 5 micron flushing filters which can damage crusher drive pump and motor.
9. Remove 5 micron flushing filters and store for re-use. (Flushing filters may be
used 5 times).
10. Fit regular 10 micron return line filters.
11. Check and top up hydraulic tank as required.
12. Machine can now be operated as normal.
Fig. 41
Page 5
6.3 REPLACMENT OF CRUSHER BLOW BARS
cabinet see (items 2,3 & 4, Fig. 9).
2. Use control valve (item 13, Fig. 10) to open or close the crusher hood.
See Universal I54 Impact Service Manual for detailed instructions.
6.3.1 REPLACEMENT OF CRUSHER SIDE LINERS
cabinet see (items 2,3 & 4, Fig. 9).
2. Use control valve (item 13, Fig. 10) to open or close the crusher hood.
See Universal 4753 Impact Service Manual for detailed instructions.
Page 6
FAULT FINDING SECTION 7
7.1 FAULT FINDING TABLE
HYDRAULICS CRUSHER BELT HYDRAULIC
HEATING UP. SPEED DOWN. STALLING. OIL FOAMING.
OIL COOLER BLOCKED OR FAN
NOT WORKING
RETURN FILTER CLOGGED

STOP VALVES TURNED OFF

LOW OIL LEVEL IN TANK

HOSE COLLAPSE

BEARING FAILURE

HOSES BLOCKED

LOW PRESSURE TO MOTOR

OIL SYSTEM OBSTRUCTED

BELT SLIPPING ON DRIVE DRUM

AIR IN / ENTERING

SYSTEM
PUMP PRESSURE LOW

PUMP DAMAGE

(PRESSURE TEST)
DAMAGED FITTINGS

MOTOR DAMAGED

HOSES HOLED

OIL THINNING (REPLACE OIL)

ENGINE SLOWING

MOTOR / PUMP KEY HAS

SHEARED
SHEARED COUPLING

Page 7
Page 8
TECHNICAL SPECIFICATION SECTION 8
8.1 I54
TRANSPORT HEIGHT………….…………………………. 3575mm (11’ – 8.8”)
TRANSPORT WIDTH……………………………………… 3000mm (9’ – 10”)
TRANSPORT LENGTH …………………………………… 16330mm (53’ – 7”)
WORKING HEIGHT ………………………………………. 4335mm (14’ – 2.5”)
WORKING LENGTH………………………………………. 16930mm (55’ – 6.6”)
WORKING WIDTH………………………………………… 5135mm (16’ – 10”)
MAIN CONVEYOR DISCHARGE HEIGHT ………….….. 4210mm (13’ – 10”)
SIDE CONVEYOR DISCHARGE HEIGHT …………...…. 2585mm (8’ – 6”)
WEIGHT – TRACK (including overband magnet)…………. 50,000Kgs (110,231 lbs)
CRUSHER SHAFT SPEED………………………………… 530-700 Rpm
CRUSHER ROTOR TIP SPEED…………………………… 34-44m/sec
Page 1
Page 2
TRACK OPERATION MANUAL SECTION 9
OPERATIONS AND
MAINTENANCE
MANUAL
Page 1
Page 2
TRACK MANUAL
Contents
SECTION 9.1
9.1.1 Undercarriage Identification -
9.1.2 General Safety and Accident Prevention -
9.1.3 Daily Safety Checks -
9.1.4 Operating Precautions -
SECTION 9.2
9.2.1 Hydraulic Connections to the Track Drives with A2FE
Fixed Displacement Motors -
9.2.2 Hydraulic Schematic for A2FE Fixed Displ. Motors -
9.2.3 Motion Control / Brake Release Valve for A2FE Fixed
Displacement Motors -
9.2.4 Hydraulic Schematic for Track Drives Fitted with
Motion Control / Brake Release Valves -
SECTION 9.3
9.3.1 Correct Maintenance Procedure -
9.3.2 Checking Track Tension -
9.3.3 Adjustment of Track Tension -
9.3.4 Removing the Track -
9.3.5 Rejoining the Track -
9.3.6 Fitting of Repair Link -
9.3.7 Track Drive Units –
SECTION 9.4
9.4.1 Track Tension -
9.4.2 Loss of Drive -
9.4.3 Leaks and Seizures –
SECTION 9.5
9.5.1 Bolt Torque Table -
Page 3
Page 4
SECTION 9.1 GENERAL INFORMATION
9.1.1 UNDERCARRIAGE IDENTIFICATION
The picture below illustrates the position of the serial numbers on the track
systems.
The six digit serial number of the track system is stamped on each side frame,
vertically down the division plate between the drive housing and the main body of
the frame.
Page 5
9.1.2 GENERAL SAFETY AND ACCIDENT PREVENTION
Please ensure all safety precautions and instructions are adhered to when installing, operating
and/or performing maintenance on the track systems.
1. Protective Equipment
Always wear protective clothing and footwear as
required by job conditions when working around this
product. Wear protective glasses when in risk of
splintering debris. Use welders gloves, facial/eye
protection and other protective clothing appropriate
to welding job being performed. Avoid loose clothing.
2. Unauthorised Modifications
It is important not to carry out modifications to the

track system which could compromise proper
operation and safety. McCloskey International are
not responsible for any injury or damage caused by
unauthorised modifications.
3. Pressurised Items
Avoid welding near pressurised hydraulic pipelines,

track tensioners, track recoils or other flammable
materials. Excessive heating near to pressurised
hydraulic pipelines can cause failure, generating a
flammable spray with the possibility of severe injuries
to nearby persons.
4. Lifting
Use a hoist when lifting components which weigh

more than 23 Kg (50lbs). Ensure all hooks, chains,
slings etc., are in good condition and tested to an
adequate safe working load, and be sure hooks or
slings are positioned correctly.
Page 6
9.1.3 DAILY SAFETY CHECKS
The following checks should be made every day before operation.
. • Check for loose bolts and nuts on lower rollers, sprockets and track shoes.
. • Check all track links if master pins are correctly located and tight
. • Check for oil leaks from lower rollers, front idlers.
. • Check for oil leaks from track drive gearbox and motor.
. • Check track tension is within given limits (see Section 3.2).
. • Check for general damage and wear to all components.
Take corrective action immediately; tighten bolts and nuts to correct torque,
replace
damaged or worn components.
DO NOT operate the machine with damaged or defective track system

components.
Any persistent problem should be reported to the machine manufacturer.
Page 7
9.1.4 OPERATING PRECAUTIONS
When traveling up a gradient, the tracks should be driven forward (i.e. idlers first,
drive sprocket to the rear). When traveling down a gradient, tracks should be
driven sprocket first.
ALWAYS:-
• Park the machine on flat, level ground. If it is necessary to park the machine
on a gradient, the tracks should be solidly blocked.
• Ensure the terrain the machine is working on is firm enough to adequately

support the machine.
• Ensure the machine is tracked at least 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.
• Ensure the tracks are not frozen to the ground before moving the machine.
NEVER:-
• Attempt to track the machine if there is any build up of material around the
tracks and drive sprockets.
• Attempt to track the machine if the tracks are frozen to the ground.
• Push or tow the machine when unable to free itself.
Page 8
SECTION 9.2 HYDRAULIC INSTALLATION
9.2.1 HYDRAULIC CONNECTIONS TO TRACK DRIVES

WITH A2FE FIXED DISPLACEMENT MOTORS
Basic Connections to the Track Drives and Motors
There are four connections to the standard track drive gearbox and fixed
displacement motor, required for normal operation. These are the 2 main flow
ports (A and B), the brake release port (F) and the case drain port (T), the
positions of which are shown below:
Port Functions
Main Flow Ports, A, B - Flow and pressure of hydraulic oil is applied to

these ports, main drive is achieved. Torque and
speed output is dependant on the pressure and
flow applied.
Case Drain Port, T - Allows any excess hydraulic oil to return to tank.
Brake Release Port -With a pressure of between 12 and 50 bar applied to this
port, multi disc parking brake is released, allowing rotation
of the track drive. When no pressure is applied, the
parking brake is locked on.
Page 9
Port Sizes for Fixed Displacement A2FE Motors
The sizes of the main flow ports and the case drain port are dependant on the
motor size. These port sizes for the various motors are given below:
Motor A,B Drain, T

Displ.
M16 x 1.5 x 12
28 / 32cc ½” SAE
deep
45 / 56 / M18 x 1.5 x 12
¾” SAE
63cc deep
M18 x 1.5 x 12
80 / 90cc 1” SAE
deep
M22 x 1.5 x 12
107 / 125cc 1 ¼” SAE
deep
M22 x 1.5 x 12
160 / 180cc 1 ¼” SAE
deep
The brake release port size is dependant on the type of gearbox fitted:
- Lohmann + Stolterfoht gearboxes - Brake release port, F - M12

- Bonfiglioli Trasmital gearboxes - Brake release port, F - ¼” G
Direction of Rotation
When connecting to the track drives, it is important to check that the direction of
rotation corresponds to forward movement of the machine when positioned at the
rear of the machine.
The diagram above shows the direction of rotation of the track drive in relation to
the input flow to the motor. 3DJH
the input flow to the motor.
Page 10
9.2.2 HYDRAULIC SCHEMATIC FOR A2FE
FIXEDDISPLACEMENT MOTORS
Below is a general hydraulic circuit for the track drive gearbox and fixed
displacement motor combination, with no motion control and brake release valve
fitted.
Page 11
9.2.3 MOTION CONTROL / BRAKE RELEASE VALVE
FOR A2FE FIXED DISPLACEMENT MOTORS
Function
This valve is supplied fitted and hosed to the hydraulic motor flange as shown in
the illustrations below.
The valve has two main functions:
- To take a feed from the main pressure line to pressurize the brake release
port with a controlled pressure, releasing the multi disc parking brake
whenever any flow/pressure is applied to the hydraulic motors.
To prevent overrun and cavitation as the machine descends any gradient.
Connections to the Track Drives when Fitted with Motion Control /

Brake Release Valves
This valve is supplied fitted and hosed to the hydraulic motor flange as
shown in the illustrations below.
Three connections are necessary to operate the track drives when supplied
fitted and hosed with the motion control and brake release valve for normal
operation. These are the main flow ports (A and B) and the case drain port.
Page 12
Motion Control / Brake Release Valve Port Sizes
The sizes of the main flow ports and the case drain port when the hydraulic
motors are fitted with the motion control / brake release valves are as follows:
Direction of Rotation
When connecting to the track drives, it is important to check that the direction of
rotation corresponds to forward movement of the machine, when the drives are
positioned at the rear of the machine.
the input flow to the motor / valve.
Page 13
9.2.4 HYDRAULIC SCHEMATIC FOR TRACK DRIVES FITTED WITH
MOTION CONTROL / BRAKE RELEASE VALVES
Below is a general hydraulic circuit for the track drive gearbox and fixed
displacement motor combination, with a motion control and brake release valve
fitted.
Page 14
SECTION 9.3 BASIC MAINTENANCE
9.3.1 CORRECT MAINTENANCE PROCEDURE
ALWAYS:-
• perform maintenance on a level and solid surface.
• ensure the undercarriage is solidly supported if work is necessary under

the track systems.
• remove any build-up of grease, oil or debris.
• repair all damage and replace worn or broken parts immediately.
• check for oil leaks and damaged hydraulic hoses.
• use only specified lubricants, do not mix different brands or types.
• use great care when maintaining the hydraulic system since oil may be
very hot when the machine has just been working.
• use only McCloskey International supplied / approved replacement
parts. Use of unapproved parts will invalidate the warranty.
• dispose of lubricants in the proper manner.
Please note that the maintenance intervals specified are for normal
working conditions. If the track system is used in severe working
conditions then maintenance and safety checks must be performed more
frequently.
Page 15
9.3.2 CHECKING TRACK TENSION
Stop your machine on solid and level ground and drive 2 metres (minimum) in a
forward direction. Measure the sag on the top part of the track on the longest
section of unsupported track as shown below.
The sag of the track must be between 5mm and 15mm .
The above conditions must be fulfilled on a new machine, it must also be

periodically checked and corrected if necessary, by adjusting the valve fitted
to the end of the grease tensioner as described in Section 9.3.
Page 16
9.3.3 ADJUSTMENT OF TRACK TENSION
Crawler track systems use a grease cylinder to keep each track chain in tension.
Screwed into the end of the grease cylinder is a grease fitting, enabling grease to
be pumped into the grease chamber and released from it, tightening and
slackening the track.
The grease contained in the track tensioner is pressurized so care must be taken
when loosening the grease fitting.
TIGHTENING THE TRACKS
1. Loosen the two screws and swing access cover away from access aperture
on the side of the track frame.
2. Ensure the grease fitting and grease gun adaptor are clean, ingress of dirt
into the grease fitting can result in failure. Connect a grease gun to the grease
fitting and add grease until the track tension is within the specified values
given in Section 9.3.2.
3. Drive 50 metres forwards and 50 metres backwards and repeat the above
procedure if the track slackens.
Page 17
SLACKENING THE TRACK
1. Loosen the two screws and swing access cover away from access aperture
on the side of the track frame.
2. Loosen the grease fitting, by turning in an anti-clockwise direction, using

gradual increments until the grease begins to be expelled. Care must be
taken not to loosen the grease fitting too quickly.
3. When the correct track tension has been obtained, tighten the grease fitting
by turning in a clockwise direction and clean away all trace of extruded
grease. Be sure not to over tighten the grease fitting.
If the track fails to slacken after grease fitting has been loosened; DO NOT
attempt to remove the tracks or disassemble the track tensioner, and DO NOT
remove the grease fitting from the tensioner. It is possible that running the tracks
a short distance in both directions with the grease fitting loosened may help to
expel the grease.
Page 18
9.3.4 REMOVING THE TRACK
To uncouple the track group the following procedure must be followed:
1. Jack up the machine and block safely on firm, level ground.

2. Locate the master pin. This can be identified by small circular indentations, or
by an X marked on each of the end faces.
3. Rotate the track until the pin is in approximate position (as shown below) and
place a block under the front of track. This prevents the chain from dropping
once the master pin has been removed.
4. Release the tension on the tracks as described in Section 9.3.3, this should
only be carried out by a qualified fitter.
5.The master pin can now be pressed out from the chain, separating the track.
6. The track can now be pulled from under the machine.
Page 19
9.3.5 REJOINING THE TRACK
To rejoin the track group, the following procedure must be followed, but should
only be carried out by qualified fitters:
1. Position the pin collars into the counter bore of the mating links.
2. Ensure the pin holes and the bushings are aligned and insert a dummy pin.
3. With the master pin in position, set up the track press.
4. Press the master pin fully into the chain links, pushing the dummy pin
through the link.
Page 20
9.3.6 FITTING OF REPAIR LINK
A track repair link kit as shown in Section 9.4.6, consists of:-
1 no. Left hand track link

1 no. Right hand track link
1 no. Master bushing
2 no. Master pin with collars
4 no. Track shoe bolt
4 no. Track shoe nut
the kit is supplied with the master bushing pressed into the left and right
hand links.
To fit a repair link to a track chain, the following procedure should be followed:
1. 1. Position the pin collars into the counter bore of the open mating links.
2. 2. Insert the bushing end of the repair link into the open end of the track
chain.
3. 3. Ensure the pin holes and the bushings are aligned and insert a dummy
pin.
4. 4. With the master pin in position, set up the track press.
5. 5. Press the master pin fully into the chain links, pushing the dummy pin
through the link.
Repeat this procedure for the second join, inserting the dummy pin and pressing
in the second master pin, completing the chain.
Page 21
9.3.7 TRACK DRIVE UNITS
Routine Checks
The first oil replacement for the gearbox is to be carried out after 100 operating
hours. There after replace the oil every 1000 hours or at least once each year.
The oil level should be checked every 100 working hours or every month –
whichever comes first.
Oil Filling
To fill, track the machine until the gearbox casing is level with a plug positioned at
12 o’clock as shown below. Unscrew the two plugs and fill from the upper hole
until oil reaches the level of the lower hole.
Oil Draining
To drain, track the machine until a plug is at 6 o’clock position as shown below.
Unscrew both plugs and allow all oil to discharge into a suitable container.
Dispose of waste oil in a safe and approved way.
Page 22
SECTION 9.4 TROUBLE SHOOTING
9.4.1 TRACK TENSION
Crawler track systems use a grease cylinder to keep the track chains in tension.
Loss of tension in the tracks can result in the sprocket jumping in the track
chain, and also allowing the track chain to run off the idler/sprocket. This can
hinder the tracking ability of the machine and damage many of the components
of the track systems if not resolved quickly.
The tension of the tracks should be checked on a regular basis according to the
parameters set out in Section 9.3 of this manual; General Maintenance. If the
tension of the track is outside these parameters, and the adjustment method
given in paragraph 9.3.3 has no effect, please read below checks that can be
made and possible causes:
Check 1: -With the greaser access plate removed (see Section 3.3),
make a visual inspection of the greaser, looking for any
signs of leaking grease.
Possible - If grease is leaking from the base of the greaser, where it
Cause: screws into the end of the tensioner, either the gasket has
failed and needs replacing, or the greaser is not screwed
in properly and needs tightening.
- If grease is leaking from the end of the greaser where the
grease gun connects to it, the greaser valve has failed and
should be replaced.
Check 2: -When the machine is stationary and blocked, make a

visual inspection of the track below the adjusting end of
the tensioner, looking for any signs of leaking grease.
Also, reach under the frame, feeling the adjusting end of
the tensioner for any grease.
Possible - If grease is leaking from the adjusting end of the
Cause: cylinder, the seals may have failed. This requires the
tensioner to be removed from the tracks frame, to be
either fitted with new seals, or replaced with a complete
new grease tensioner.
Page 23
9.4.2 LOSS OF DRIVE
Crawler track systems are driven using hydraulic motors connected to planetary
drive gearboxes. The hydraulic motors are driven using the hydraulics fitted to
the machine.
Begin by making a visual inspection of the tracks, particularly around the

sprocket, idler and bottom rollers where material / objects can sometimes lodge.
Follow this by inspecting all hoses and connections, ensuring there are no leaks
or blocks. If there are no physical impedances in the tracks and no faults are
found with hoses and connectors, please read below checks that can be made
and possible causes:
Check 1: - Using pressure / flow testing equipment, measure the

values of the flow and pressure being applied to the
hydraulic motors.
Possible - If the values of the flow and pressure passing to the
Cause: hydraulic motors is less than that required to drive the
tracks (see machine manufacturer’s separate publication),
there may be a fault in the machines hydraulic system.
Check 2: - Test the pressure being applied to the brake release port
on the gearbox. In order to release the brake, this should
be fed with a pressure of between 12 and 50 bar.
Possible - If the pressure is below 12 bar, do not attempt to drive
Cause: the tracks. With a pressure below 12 bar, the brake will
not release when driving the tracks is attempted. This can
cause the brakes to seize requiring a replacement unit to
be fitted.
Check 3: If a valve is fitted to the hydraulic motor flange, ensure

there are no visible faults with the valve, and none of the
connections are damaged / leaking.
Possible If there are no visual faults with the valve, and all other
Cause: checks identify any faults, the valve block may need
replacing.
Page 24
9.4.3 LEAKS AND SEIZURES
General Components
Many components fitted to crawler track systems such as rollers and idlers are
lubricated with oil. Regular checks should be made to ensure these components
are not leaking and rotate freely when the tracks are driven. Any items such as
rollers which show signs of leaking, or fail to rotate when the tracks are driven
should be replaced immediately.
Track Chains
Track chains can seize in particular conditions if they remain stationary for
more than a few days, causing kinks in the chain.
This can be prevented by tracking the machine on a daily basis as outlined in

Section 9.3 of this manual, Basic Maintenance. However, should this problem
occur, it may be possible to remedy by applying penetrating fluid to the seized
pin, leaving for several hours, then tracking the machine several meters forward
and back.
If lubricating the pin is unsuccessful, the problem can be resolved by cutting

out the seized link including the pin and bush, replacing it with a complete
repair link (see Section 9.3.6).
If there are several links seized on a single track chain, it may be necessary
to remove the track from the machine and have it repaired at a specialised
track repair shop, or to replace the complete track chain.
Page 25
Page 26
APPENDIX SECTION 10
10.1 ORIENTATION
MACHINE ORIENTATION
Fig. 42
Page 1
10.2 I54 ELEVATION VIEW
Fig. 43
Page 2
10.3 I54 PLAN VIEW
Fig. 44
Page 3
10.4 BOLT TORQUE TABLE
If not otherwise specified, use the following torque settings. Suggested torque for normal
applications (10%), using bolts/nuts without lubricant. Bolts and nuts with lubricant
reduce mean torque by 15%.
Fig. 45
Page 4
Page 5
10.5 CONTROL PANEL WIRING DIAGRAMS
Page 6

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OPERATIONS / MAINTENANCE MANUAL

& SPARE PARTS BOOK

MANUAL ISSUE 003

McCloskey International Ltd

47 Moor Road 1 McCloskey Road

REVISION 001 - Crusher bearing grease type changed

SECTION 1 INTRODUCTION 1-1

SECTION 2 SAFETY 2-1

SECTION 3 OPERATIONAL PROCEDURES 3-1

3.3 Operating Function 3-21

3.4 Emergency Stops 3-25

SECTION 5 MAINTENANCE 5-1

SECTION 6 SPECIAL PROCEDURES 6-1

SECTION 7 FAULT FINDING 7-1

SECTION 8 MACHINE TECHNICAL SPECIFICATIONS 8-1

SECTION 9 TRACKS MANUAL 9-1

SECTION 10 APPENDIX 10-1

Warranty Start-Up Information

Federal ID# (US customers

Hour Meter Reading At Time of Control Panel Serial No.

Date Day Year

Please Complete This Form And Send It To:

This operating manual should always stay with the machine.

Machine’s Designated Use

Contacting McCloskey International Ltd.

Owner’s Manual Sections

Push Emergency stop switch towards the machine to

When operating any moving part of the machine

• Remove obstruction or attempt any maintenance while engine is running.

• Operate machine without reading manuals thoroughly.

• Operate machine with guards missing.

• Remove any guards.

• Open inspection doors while machine is operating.

• Enter loading area while machine is functioning.

• Stand beneath conveyors.

• Stand beneath any head drum.

• Use machine near power lines.

• Touch hot surfaces.

• Wear loose fitting clothing near machine.

• Grease the screen bearings daily (where applicable)

• Change filters and oil regularly

• Grease machine regularly.

• Inspect machine regularly.

• Check conveyor belt alignment before running belt.

• Study all manuals before operating machine.

• Obey all warning labels.

• Always wear correctly fitting (EN/ANSI approved) protective clothing. Protective

SEE APPENDIX 10.1 – ORIENTATION FOR DETAILS.

1. Always concentrate and pay attention to the job at hand.

1. Lockout the machine before any action is taken.

Engine Starter Panel

1 Plus One colour screen 10 Engine crank position

3 Button 2 - Track speed adjust button. 12 Off position

4 Button 3 - Maintenance / Feedback button 13 Left / Right buttons

1. Diesel fuel level in tank displayed as percentage.

To go back to main menu press ‘ESC’ button.

3.1.5 TRACK CONTROL USING RADIO TRANSMITTER HANDSET (OPTION)

1. Refer to Fig. 7 showing radio transmitter handset.