Rev2.

Iss2
TURBOTRAC

OPERATORS MANUAL

EXTEC SCREENS & CRUSHERS LTD

HEARTHCOTE ROAD,
SWADLINCOTE, DERBYSHIRE.
DE11 9DU, ENGLAND.
Tel: +44 (0) 1283 212121
Fax: +44 (0) 1283 217342

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Rev2.Iss2
TURBOTRAC
DECLARATION OF CONFORMITY
DECLARATION DE CONFORMITE
ÜBEREINSTIMMUNGSERKLÄRUNG
DICHIARAZIONE DI CONFORMITA
DECLARACIÓN DE CONFORMIDAD
This is to certify that the machine indicated below conforms to all as parts to:
Nous certfions que la machine definie ci-dessous est conforme dans sa totalite:
Hiermit wird erklärt, daß die untengenannte Maschine in allen Einzelheiten übereinstimmt:
Si dichiara che la macchina sottoindicata e conforme in tutte le sue parti:
Este documento certifica que la máquina indicada más abajo se ajusta a
The directives issued by the council of European Communities. The machine conforms with all
essential health and safety requirements. As laid out in the supply of machinery (safety) Regulations
1992, also the provision and the use of work equipment 1992.
All guarding on machine is in accordance with BS7300 1990.
- Aux Directives du Conseil des Communatee Europeennes:
- Nach den Richtlinien des Europäischen Gemeinschaftsrates:
- Alle Direttive de Consigliodelle Comunita Europee:
- Las directivas emitidas por el Consejo de Comunidades Europeas:
89/392. CEE (91/368/CEE-93/44/CEE-93/68/CEE)
89/622. CEE (98/37/EC.CEE) (92/58/EEC)
E.M.C. 89/336/EEC(91/263/EEC 92/31/EEC.)
-European harmonised standards
- Aux Normes Europeennes Harmonisees
- Und den in Einklang stehenden Europäischen Normen
- Alle Norme europee armonizzate
- Estándares armonizados europeos
EN 292-2
EN 474-1 (EN 474-5)

Manufacturer EXTEC SCREENS & CRUSHERS TYPE TURBOTRAC

Constructeur Hearthcote Road, Swadlincote Modele
Hersteller Derbyshire, England Modell
Costruttore DE11 9DU Tipo
Fabricante Tipo

Serial No:- __________

Numero de chassis
Fahrzeug-Ident-Nr
Matricola
Número de serie
Category MOBILE SCREENING PLANT ENGINE DEUTZ
Categorie Moteur
Erzeugnis Motor
Categoria Motore
Categoría Motor

PRODUCTION MANAGER: ____________________

DATE: ___________________

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Rev2.Iss2
TURBOTRAC
INTRODUCTION
Congratulations on the purchase of your Extec Turbotrac screen.
This machine has been designed and constructed using first class
materials and it will reach you in optimum condition.

Operation of the plant contrary to the instructions contained in this

manual, or modifications to the machine without the agreement of the manufacturer,
will invalidate any undertakings given by the manufacturer attaching to the machine.

The manufacturer will in no way accept any liability should the machine be
misused, abused or operated outside the working parameters specified
by the manufacturers.

Every effort has been taken to ensure the accuracy of this manual,
nevertheless, as operating conditions vary considerably, all performance data contained
herein is indicative only for plant operated in accordance with the conditions set out in
this manual.

It is ESSENTIAL that the operator reads and observes the safety

instructions in this manual. Failure to do so will invalidate any liability the manufacturer
may have.

This manual should be kept at a specific location near the machines site of operation
and be available at all times.

I acknowledge receipt of this operation/safety manual, and fully understand its content
and implications.

Signed ....................

Signed ................... (Extec representative)

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TURBOTRAC
OPERATORS MANUAL - CONTENTS
SAFETY INSTRUCTIONS Page:- 4

MACHINE WORKING DIMENSIONS Page:- 5

MACHINE TRANSPORTATION INFORMATION & DIMENSIONS Page:- 6 - 7

NOISE EMISSIONS Page:- 8

SETTING UP / LOCATION Page:- 9 - 10

PRE - START INSTRUCTIONS Page:- 11

HYDRAULIC CONTROLS Page:- 12

STARTING SEQUENCE Page:- 13

STOPPING THE MACHINE Page:- 14

PREPARING FOR OPERATION Page:- 15 - 18

CLOSING DOWN MACHINE Page:- 19

MAINTENANCE - (DAILY) Page:- 20 - 22

MAINTENANCE - (WEEKLY) Page:- 23 - 26

MAINTENANCE - (EVERY 250 / 500) Page:- 27

MAINTENANCE - (EVERY 1000) Page:-28

TENSIONING & TRACKING CONVEYOR BELTS Page:- 29 - 30

SCREENBOX MESH FITTING & REMOVAL Page:- 30

SCREENBOX DRIVE BELT ADJUSTING Page:- 31

SCREENBOX BEARING REPLACEMENT Page:- 32 - 33

VIBRATING GRID (OPTIONAL) Page:- 34 - 35

HYDRAULIC CIRCUIT / ELECTRICAL DIAGRAM Page:- 36 - 39

TROUBLE SHOOTING GUIDE Page:- 40

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Rev2.Iss2
TURBOTRAC
SAFETY INSTRUCTIONS
For safe operation of this machine, the following instructions MUST
be followed at ALL times:-
i) Machine must ONLY be operated by trained personnel.
ii) Different countries and states often have specific legislation relating to the operation of
different types of machinery and their effects on safety and the environment. Therefore, it is
the users responsibility to find out those that apply to their particular circumstances and
ensure that they are complied with.
iii) Always pay attention and concentrate on the job at hand.
iv) Read and follow warnings and labels.
v) Read and understand this manual and all machine aspects.
vi) Familiarise yourself with the surrounding work area.
vii) ONLY operate this machine if guards and safety devices are in position.
viii) ALL personnel in the vicinity of the machine MUST wear suitable safety equipment,
i.e Safety boots, ear protection, eye protection, protective clothing, hard hat, etc.

NEVER:-

i) Run machine without guards in place.

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

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

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Rev2.Iss2
TURBOTRAC
MACHINE WORKING DIMENSIONS
4330 [14'-2"]

4171 [13'-8 1
4"]
15073 [49'-5"]

17251 [56'-7"]

4330 [14'-2"]
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 Rev2.Iss2
TURBOTRAC
MACHINE TRANSPORTATION DIMENSIONS

* REMOVE TOP CROSSBARS FOR TRANSPORTATION

* *
1082 [3'-7"]

3200 [10'-6"]
451 [1'-6"]
5048 [16'-7"]

8703 [28'-7"]

13481 [44'-3"]

BASIC MACHINE WEIGHT = 22.3 T

2700 [8'-10"]

TRANSPORTATION WIDTH 2590 ( 8' - 6" )

WARNING

IMPORTANT TRANSPORTATION INFORMATION

It is imperative that the top main conveyor crossbars are removed to ensure the
machine folds down to meet the above transportation dimensions.

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Rev2.Iss2
TURBOTRAC
WARNING
IMPORTANT TRANSPORTATION INFORMATION
BEFORE TRANSPORTING THIS MACHINERY ALL MEASUREMENTS OF THE
MACHINE SHOULD BE CHECKED TO ENSURE THEY ARE WITHIN THE LEGAL
TRANSPORT DIMENSIONS.

In some cases extra clearance may be

required when loading on to trailer. This
may be achieved by utilising the centre
jacking leg.

NOTE:- Jacking leg to be used for

transportation only. DONOT use the leg
whilst machine is in operation or tracking
Machines fitted with Vibrating Grid- 1:- Remove 'R' clip & locking pin
FOLD DOWN SIDE FLAIR'S

2:- Re-insert Locking pin & 'R' clip 3:- Use lever for lowering jackleg 4:- Jackleg extended (remember to
raise & store jackleg before tracking
onto trailer)

ENSURE ALL PARTS OF THE MACHINE ARE FOLDED OR CLOSED DOWN

AND LOCKED INTO TRANSPORT POSITION.
ADDITIONALLY ENSURE A CHAIN IS FITTED BETWEEN THE SIDE CONVEYORS
OF THE MACHINE, AS WELL AS A RATCHET STRAP AND THEY ARE BOTH
FULLY SECURE (AS SHOWN BELOW).

Attach Side Conveyor retaining Attach Side Conveyor transportation

chain. straps.
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TURBOTRAC
NOISE EMISSIONS
To comply with the supply of machine (safety) regulations 1992, amended 1994, EXTEC provides
the following information.

The diagram below shows decibel readings taken by Castle GA 101/701 meter - calibrated on the
13.9.94 with all systems running, sited on factory assembly line.

As stated in the Safety Instructions section of this manual, ear protection is compulsory within 10
meters of the machine when the engine and other moving parts of the machine are in operation.

TURBOTRAC with conveyor

running
80 81 82 80 79

7M

85 90 85 80 1M

82 77

1M
87 92 87 82

7M

81 83 83 82

All readings are in decibels

All sizes are approximate

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TURBOTRAC
SETTING UP / LOCATION
The TURBOTRAC is manoeuvred by remote control, use either the remote handset or hard wire drive to
move machine to desired position.

For safety reasons, it is essential to check all around machine for obstacles or personel which may be
endangered by moving your machine.

When loading or unloading your TURBOTRAC on to or from a low loader, accurate control of the unit is
necessary.

Remote Control Hardwire Drive (Umbilical Remote)

When moving the machine, ensure that it is only moved over firm ground suitable for carrying the
weight of the machine, it is ESSENTIAL that both tracks are in contact with firm level ground to
avoid excessive vibration or rocking of the machine. DO NOT MOVE THE MACHINE
ACROSS EXCESSIVELY SLOPING GROUND

Note: Ensure that the electronic recieving unit, located in the power pack, is switched on and the Track
ON / OFF hydraulic lever has been activated.

When operating the remote handset, the directional arrows relate to the machines forward & reverse
movement.The umbilical corded controls yellow buttons are for forward movement and the blue for reverse.
(These correspond to direction indicator stickers on your machine).

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Rev2.Iss2
TURBOTRAC
SETTING UP / LOCATION
Find a level and firm piece of ground (of suitable size and location). Level the machine
by placing a precision spirit level on the main chassis channel under the tail conveyor.

1:- Level machine using precision spirit level

2a:- Jacking legs lever 2b:- Lower Jacking legs 3:- Insert leg lockout pin & retain with 'R'
clip

Lower the Jacking legs to stabilising the machine, taking the weight off the tracks. Ensure
that the legs are level. This may require raising the Jacking legs and removing or adding
hard standing under the feet.

4:- Remove Side Conveyor retaining 5:- Remove Side Conveyor retaining 6:- Remove Side Conveyor
chain. chain. transportation straps.
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Rev2.Iss2
TURBOTRAC
SETTING UP / LOCATION CONTD.

SAFETY
PINS

7:- Remove Tail Conveyor transportation straps. 8:- Remove telescopic arm safety pins.

9:- Replace Main Conveyor top section cross bars.

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

i) Ensure that this manual is read & understood by the operator. Do NOT attempt to start the machine until you
are aware of ALL aspects of its operation. Any questions should be referred to your supervisor.
ii) Remove any temporary sealing.
iii) Check that the machine is in good mechanical condition and that there is no component damage or loss.
Ensure all bolts and fixings are tight and that all guards are in place with all safety devices operated correctly.
NEVER start machine without guards and safety devices operating correctly.
iv) Ensure that hopper, screen and conveyor belts are free of material.
v) Remove all tools and equipment from the operational area. Make sure that ALL personnel are well clear of
the machine, its drives, tracks and auxiliary equipment.
vi) Ensure that the checks and pre-start procedures outlined in the engine manufacturers instruction manual are
complied with.
vii) Check all fluid levels in engine.
viii) Check that all rollers turn freely.This should be done by hand. NEVER attempt to touch rollers whilst
machine is running.
ix) Make sure that skirting rubbers and scrapers are in good condition and working properly.
x) Jacking legs are positioned correctly.
xi) Safety pins are in appropriate positions.
xii) All transit fastenings to conveyor belts undone and securely positioned away from moving parts.
xiii) All personnel are positioned at a safe distance from the moving parts of the machine and away from the
conveyors discharge areas.
xiv) Ensure ALL operating levers are in an off position.

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Rev2.Iss2
TURBOTRAC
HYDRAULIC CONTROLS

1 2 3 4 5 6
9
7 11

13

8 10 12
14

L/H side of Power Pack

1 Main Conveyor drive 12 Not used

2 Screen Box drive 13 Side Conveyor speed control
3 Tail, RH & LH Side Conveyor drives 14 Main Conveyor speed control
4 Shredder drive 15 Jacking legs raise / lower
5 Vibrating Grid drive 16 Grid tipping
6 Hopper Conveyor drive 17 Shredder (if fitted) raise / lower
7 RH/ Side Conveyor fold / unfold 18 L/H Side Conveyor fold / unfold
8 Tail Conveyor fold / unfold 19 Vibrating Grid flairs (if fiited)
9 Tail Conveyor raise / lower 20 Tracks ON / OFF
10 Not used 21 Hopper Conveyor speed
11 Main Conveyor & Screen Box raise / lower 22 Emergency Stop

22
17 19

15

21

16 20
18

R/H side of Power Pack

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Rev2.Iss2
TURBOTRAC
STARTING SEQUENCE
3 2
4
5
1 Throttle
1 6 2 Engine Speed
3 On (Ignition)
4 Battery
5 Water Temperature
6 Low Water Level
8
7 7 Oil Pressure
10 8 Emergency Stop
9 Remote Emergency Stop
9
10 Ignition

Electrical Control Box

3:- Turn key clockwise to No.1 position.

All lights will flash for several sec's. Then the
ON light will remain on and the battery light
and oil light will also remain on.
4:- Turn key fully clockwise the engine
will start.
5:- Release key.
6:- Engine will now run at idle.

1:- Set Throttle lever to idle position 2:- Insert ignition key into
ignition switch

8:- The engine is now running at operating speed.

Note:- In low temperatures the engine should be run at low idle

for 5 minutes.

7:- Pull throttle to maximum

COLD START:- When starting the machine in temperatures of 0º C or below, run all systems at maximum
engine speed for 15 minutes to allow hydraulic oil to reach working temperature. DO NOT feed material into
machine during this time..

NOTE:- The machine MUST be level (see page 10 setting up / location) and set up on firm level ground
before being operated. Failure to comply with this or any other instructions in this manual may cause damage to
the machine and may invalidate any warranty.
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Rev2.Iss2
TURBOTRAC
STOPPING THE MACHINE
To stop the machine, it is ESSENTIAL that the following steps be followed - in order to prevent
damage to the machine:-
i) Stop feeding material into hopper.
ii) Wait for all material to fully discharge from the tail and two side conveyor belts.
iii) Switch off all drive control levers.
iv) Push throttle back to low idle position and allow to run at this speed for 1 minute.
v) Turn key fully counter clockwise.

STOPPING MACHINE IN AN EMERGENCY

THE MACHINE CAN BE STOPPED IN AN EMERGENCY BY PRESSING THE

EMERGENCY STOP BUTTONS LOCATED ON THE ENGINE CANOPY SIDE AND
CHASSIS A'FRAME LEGS.

ENSURE THAT ALL PERSONNEL IN THE VICINITY OF THE MACHINE ARE FULLY AWARE
OF THE LOCATIONS OF THE EMERGENCY STOPS.

PREPARING THE TURBOTRAC FOR OPERATION

SIDE CONVEYOR UNFOLDING PROCEDURE
1:- Ensure side conveyor restraining straps and chains are removed (see page 10).
2:- Start engine as described on page 13

3:- Unfold L.H.CONV. 4:- Conveyor unfolding. 5:- Conveyor working position - release
tracking support rod.
VE V
LECON
R
R.

7:- Locate support rod to lower 8:- Unfold R.H.CONV. Using same 9:- Slot in removable side flairs if
retaining bracket. procedure as for LH provided with machine.
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Rev2.Iss2
TURBOTRAC
TAIL CONVEYOR UNFOLDING PROCEDURE
1:- Ensure tail conveyor transportation straps and telescopic arms safety pins are removed.

2:- Unfold Tail Conveyor halfway and STOP. 3:- Raise Screen and Main Conveyor.

4:- Screenbox & Main Conveyor raised into 5:- Replace safety pins in Screen telescopic legs.
working positions with Tail Conveyor unfolded.

7- Raise Tail Conveyor to working position. 8:- Replace safety pins in Tail Conveyor telescopic
legs.

NOTE:- All pins should be in place or damage may occur whilst

machine is in operation
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Rev2.Iss2
TURBOTRAC
SHREDDER SAFETY
WARNING

Lock out bar

If the Shredder is not being used on a particular application, it must be raised above the flow of
material to avoid damage. When the Shredder has been hydraulically raised, the 'lock out bar'
MUST be placed in position.

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Rev2.Iss2
TURBOTRAC
SCREENING
There are three main variables which effect the screening capacity and efficiency of the Extec TURBOTRAC.

1 & 2) Material Feeding.

3) Screen Angle - Maximum feed rate can be achieved when the optimum screen angle has been
determined, adjust the screen angle with the machine running so that the grading of the material
can be established.
4) Screen Meshes (See page 30 for removal and replacement of screen meshes).

1:- Hopper feed rate control. 2:- Main Conveyor feed rate 3:- Screen angle.
control.
REJECT GRID OPERATION GRID LOADING

1:- Grid tipping. 2:- Adjustment leg stop. 1:- Load from rear.

NOTE:- The Extec TURBOTRAC must always be loaded from the rear of the hopper, this will ensure both
speed and efficiency.

MATERIAL CONTROL

1:- Hopper feeder belt control. 2:- Main Conveyor feed control. 3:- Side Conveyors feed control.
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Rev2.Iss2
TURBOTRAC
REMOTE GRID OPERATION

Remote control hand unit.

i) BY PRESSING THE YELLOW BUTTON ON THE REMOTE CONTROL

A signal is sent to the timer allowing the rams to open fully and remain open for 2/3
seconds then close fully, thus tipping the grid and returning it back to rest.

ii) BY PRESSING THE TOP GREY BUTTON ***

A signal is sent to the unit allowing the rams to open while the button is depressed.

iii) BY PRESSING THE BOTTOM GREY BUTTON ***

A signal is sent to the unit allowing the rams to lower while the button is depressed.

***quick stabbing of these buttons will give the grid a "shaking action"

iv) BY PRESSING THE RED BUTTON (USE ONLY IN EMERGENCY)

A signal is sent to the unit and stops the engine from running, thus stopping all hydraulic power.
" THE RED BUTTON IS ONLY TO BE USED AS AN EMERGENCY STOP, FREQUENT USE WILL CAUSE
DAMAGE TO HYDRAULIC COMPONENTS. "
IMPORTANT
If for any reason, the 10amp fuse on the electronic board fails it must only be replaced by another 10amp fuse.
Incorrect fuse replacement can cause extensive damage to the electronic components.
TIMER ADJUSTMENT SETTING
i) The timer for operation of the grid tipping will have been preset at the factory.
ii) It may be necessary to reset the timer during the working life of the unit, or in different temperatures.

1:- Open hopper door to expose Timer 2:- Operate grid - ensure full stroke of ram 3:- If necessary adjust timer to
Control. & 2/3 sec. delay before return to fully achieve previous operation.
closed grid.
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Rev2.Iss2
TURBOTRAC
CLOSING DOWN THE MACHINE
i) Ensure that all materials have run off the conveyor belts and that the hopper is empty.
ii) Turn off the Vibrating Grid if fitted.------------------------- Hydraulic Control No.5 )
iii) Turn off Hopper Conveyor.------------------------------------- Hydraulic Control No.6 ) (See page 12)
iv) Turn off Shredder if fitted.-------------------------------------- Hydraulic Control No.4 )
v) Turn off Main Conveyor.----------------------------------------- Hydraulic Control No.1 )
vi) Turn off Screenbox.------------------------------------------------ Hydraulic Control No.2 )
vii) Turn off Tail & Side Conveyors.------------------------------- Hydraulic Control No.3 )
viii) Reduce Engine RPM to idle for 1 minute.
ix) Switch off Engine and remove the key.

PREPARING THE MACHINE FOR TRANSPORTATION

i) Ensure that all materials have run off the conveyor belts and that the Hopper is empty.
ii) Folding the Tail & Side Conveyors is a complete reversal of the instructions -Side conveyor unfolding procedure
on page 14 and Tail conveyor unfolding procedure on page 15.

Ensure that :-
i) All belt retention straps have been fitted.
ii) Check and if necessary inflate/de-inflate the tyre pressures (to the tyre manufacturers recommendations).
iii) All loose parts have been secured.

"DO NOT FOLD ANY CONVEYORS UNLESS MOVING PARTS ARE STOPPED".

TRANSPORTING THE MACHINE

DO NOT MOVE THE MACHINE WITHOUT ALL TRANSPORTATION FITMENTS SECURELY IN POSITION
AND SAFETY PINS IN PLACE.

i) Ensure that the Jack legs have been raised, to prevent grounding whilst travelling on to the STEP FRAME trailer.

ii) If required, lower chassis jacking leg for extra clearance over trailer. REMEMBER to raise leg before tracking
machine
iii) Keep the engine revs approx. 1800rpm. This will prevent erratic tracking.

iv) In all conditions, especially wet weather, rubber matting is essential on the ramps and incline of the trailer. This will
prevent skidding and sudden misalignment whilst climbing on to the trailer.
v) When you are happy to proceed manouevring onto the trailer, keep the machine travelling up the ramps and
over the peaks in one full motion. Hesitation at this point may result in loss of control and endanger the safety
of the machine.
vi) When the machine is on the flat bed of the Step Frame trailer any minor corrections to the alignment can be
corrected.
vii) Always check your travelling height before starting your journey, and that the chains are secure.

NOTE:- Incorrect loading will result in uneven weight distribution through the axles and kingpin of your lorry.

Remember, the driver is responsible for his load.

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Rev2.Iss2
TURBOTRAC
MACHINE MAINTENANCE
Maintenance is essential for ensuring the best possible performance from your Extec Turbotrac by reducing
the chances of breakdowns.

WARNING: The machine MUST be switched off and ignition key removed BEFORE making any
adjustments.

All adjustments must ONLY be carried out by trained personnel.

All adjustments to set screen speeds, maximum engine revs or hydraulic system must be carried out by trained
Extec Service Engineers.

It is recommended that the following DAILY MAINTENANCE SCHEDULE is carried out :-

(Refer to the engine

manufacturers handbook for
engine oil specifications.)

1:- Check engine oil level. Refill if necessary.

Use 50% antifreeze.

2:- Check engine coolant level. Refill if necessary.

Use standard diesel oil as

suitable for the operating
climate.

3:- Check diesel fuel level. Refill if necessary.

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Rev2.Iss2
TURBOTRAC
DAILY MAINTENANCE CONTINUED

4:- Drain water from diesel inline water tap. 5- Check hydraulic oil level.

6:- Check condition of conveyor belts and their

tracking.

Refill if necessary with Hydraulic Oil (See oils &

fluid Page 26).

n
sio
Ten ut
n

7:- Check condition of screen mesh and 8:- Check condition of belt scrapers and adjustment.
tension.

NOTE:- The screenbox 'V' belt must be checked at 250hr intervals.

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Rev2.Iss2
TURBOTRAC
REMEMBER TO MAINTAIN YOUR TRACKS.

i) Check your track rollers and idler wheels for possible leakage.

ii) Check the track surface of the track rollers, idler wheels, track shoes and drive sprockets for wear
and loose mounting bolts.

iii) Listen for abnormal noises when the machine is moving slowly.

Note: When abnormal wear exists, noise or leaks are found consult the EXTEC Service Department.

1 Track Roller
3
2 Idle Roller

3 Relief Valve

2 4 Track Surface
4
5 5 Drive Sprocket

6
6 Oil Fill Plug

7 Oil Level Plug

7
8 Oil Drain Plug
1 8 (See page 28 for oil change).

ADJUSTING TRACK TENSION

1:- Remove Access Cover 2:- Fit Grease Pipe provided & View on grease point inside
from side of Tracks. Grease Tracks as required - access cover.
USE GREASE TYPE EP2.

WARNING:- Grease in the tracks is under high pressure. Grease coming out of the relief
valve under pressure can penetrate the body causing injury or DEATH. Do not watch the
relief valve to see if grease is escaping, instead, watch the track.
22
Rev2.Iss2
TURBOTRAC
WEEKLY MAINTENANCE SCHEDULE
The following weekly maintenance must be carried out to ensure the best performance from your Turbotrac Screen :-
STOP MACHINE AND REMOVE IGNITION KEY BEFORE CARRYING OUT ANY
MAINTENANCE ON THIS MACHINE.
1:- As daily checks.
Single filter system

2:- Check hydraulic filter indicators. 3:- Check air filter indicators. If shows Open dust discharge valve.
If shows red whilst machine running - red whilst machine running - change
change filters. elements.

4:- Follow routine maintenance in engine handbook. la mp

p .C
Ty
5:-Inspecting / adjusting belt rubbers -
er
u bb
p .R
Ty

a) HOPPER SIDE SKIRTS - To adjust side skirts open all clamp plates and push wear rubbers down on
to conveyor belt by using a screwdriver or similar tool through the holes provided on top of the
clamps. When adjustment is complete re-tighten all clamps securely.

b) MAIN CONVEYOR - To adjust wear rubbers loosen both clamps, one either side of the feed boot
and pull the wear rubber down to the conveyor belt ensuring a good seal all along the feed boot and
re-tighten the clamps securely.

c) SIDE CONVEYOR -To adjust wear rubbers loosen both clamps, one either side of the feed boot and
pull the wear rubber down to the conveyor belt ensuring a good seal all along the feed boot either
side of the chevron conveyor belt. Re-tighten clamps securely.

d) TAIL CONVEYOR -To adjust wear rubbers loosen the three clamps, one at rear and one either side
of the feed boot. Pull the wear rubbers down to conveyor belt ensuring a good seal is maintained
along the side of the feed boot. This may also be achieved by sliding the feed boot up or down on its
support legs as required, by loosening six nuts and six bolts , one on each leg. Adjust the boot to the
height required and re-tighten the nuts and bolts securely.

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Rev2.Iss2
TURBOTRAC
WEEKLY MAINTENANCE SCHEDULE CONTINUED

If required, adjust head drum scraper

by loosening bolts in rosta springs,
adjusting scraper and re-tightening
bolts. (both sides should be adjusted
simultaneously).

6:- Adjusting belt scraper.

7:- Remove any blockages in screenbox. a) Canopy top and exhaust area.

Ensure areas a,b and c are

cleared of material.

b) Main Conveyor tail drum. c) Return rollers.

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Rev2.Iss2
TURBOTRAC
WEEKLY MAINTENANCE SCHEDULE CONTINUED
GREASING BEARINGS:-

Using suitable equipment, all bearings must be greased every

week. See following chart for details of grease points and types.

WARNING:- NEVER USE GREASE CONTAINING

MOLYBENUM. DOING SO MAY CAUSE DAMAGE TO
MACHINE PARTS AND WILL INVALIDATE ANY WARRANTY.

MAIN CONV.HEAD DRUM BRGS

50 GRAMS GREASE EP2
SCREEN SHAFT BRGS
100 GRAMS GREASE LGHQ3

SHREDDER SHAFT BRGS

50 GRAMS GREASE EP2
VIBRATING GRID SHAFT BRGS
100 GRAMS GREASE LGHQ3

TAIL CONV .HEAD DRUM BRGS

50 GRAMS GREASE EP2

TAIL CONV. TAIL DRUM BRGS

50 GRAMS GREASE EP2

FEED CONV.BRGS
50 GRAMS
GREASE EP2

MAIN CONV.TAIL DRUM BRGS

50 GRAMS GREASE EP2

SIDE CONV.HEAD DRUM BRGS

SIDE CONV.HEAD DRUM BRGS 50 GRAMS GREASE EP2
50 GRAMS GREASE EP2

SIDE CONV.TAIL DRUM BRGS SIDE CONV.TAIL DRUM BRGS

50 GRAMS GREASE EP2 50 GRAMS GREASE EP2

25
 Rev2.Iss2
TURBOTRAC
WEEKLY MAINTENANCE SCHEDULE CONTINUED
MACHINE GREASING POINTS:-

Nipples Nipples

Side / Main / Tail Conveyor & Screen Bearings Side / Main / Tail Conveyor & Screen Bearings
grease points. grease points.

Nipples
ple
Nip

Hopper / Main Conveyor & Shredder Vibrating Grid Bearings

grease points. grease points

OILS AND FLUIDS Manufacturers Equivalent Specifications

Lub / oil and

Grease Points Temperature Viscosity Maxol Esso Castrol Texico Kuwait Petroleum Mobil

Engine See Manufacturers Handbook : : : : : :

: : : : : :
Hydraulic System -10 to +25 degC ISO VG 32 : ) : AWS 32 Rando HD 32 ) : DTE 13m
-5 to +25 degC ISO VG 46 : ) UNIVIS N AWS 46 Rando HD 46 ) Q8 Handel DTE 15m
+5 to +35 degC ISO VG 68 : ) : AWS 68 Rando HD 68 ) range DTE 16m
+10 to +45 degC ISO VG 100 : ) : AWS 100 Rando HD 100 ) : DTE 18m
: : : : : :
Conveyor drive gearbox Temperate SYNTHETIC : : : : : GLYGOYLE HE 460
: : :
Screen & Grid bearings : UNIREX No.3 :
: :
Tracks : EP SAE 80W/90 Gear Oil
:
General Lubrication points EP 2

26
Rev2.Iss2
TURBOTRAC
MAINTENANCE SCHEDULE - EVERY 250 Hrs
Every 250 hours , the following maintenance must be carried out to ensure the best performance and least possible
breakdowns from your machine.
i) Follow maintenance instructions laid out in engine manufacturers handbook.

ii) Inspect condition of conveyor belt and tracking.

iii) Inspect and adjust belt scrapers.

iv) Inspect and adjust wear rubbers.

v) Inspect condition and tension of screen mesh.

vi) Inspect condition of all belt drums.

vii) Check for hydraulic leaks on pipes.

MAINTENANCE SCHEDULE - EVERY 500 Hrs

1:- Follow maintenance instructions laid out in engine manufacturers handbook.
2:- As 250 hour maintenance.

3:- Check hopper conv. gearbox oil. Refill if necessary (See page 26 for oil
specification).

4:- Replace hydraulic return filter.

27
Rev2.Iss2
TURBOTRAC
MAINTENANCE SCHEDULE - EVERY 1000 Hrs

i) Follow maintenance instructions laid out in engine

manufacturers handbook.
ii) As 250 hour maintenance.
iii) Renew hydraulic oil.
iv) Replace suction filters.
v) Replace twist on hydraulic air tank breather.
vi) Change oil in the tracks.

To drain oil from the track motors, drive the machine until either one of the drain plugs is at the bottom of the
motor. Remove drain plug and oil will wash out. Use a suitable container to collect waste oil - disposing of waste oil
must be done in a manner that complies with any relevant legislation.

To re-fill track motors with oil, drive machine until either one of the drain plugs is at the top - (See Photo).
NOTE:- this will only be 1/4 turn of the track motor, DO NOT drive machine any further until oil has been
replaced in tracks. Remove both drain plugs as shown in the photographs below. Fill oil into the top drain plug until
it starts to come out of the other drain plug. Replace both plugs BEFORE driving machine. Each track motor will
have to be done seperately.

Track motor in correct position to re-fill motor Removing level plug.

with oil.

When changing oil in tracks,

use EP90 Gear Oil.

Removing filler plug.

28
Rev2.Iss2
TURBOTRAC
TENSIONING AND TRACKING OF CONVEYOR BELTS
WARNING:- The machine MUST be switched off and ignition key removed BEFORE making any
adjustments.
TENSIONING OF HOPPER CONVEYOR BELT
1:- Tensioning and tracking of hopper conveyor should be done initially with the hopper empty.

g
tin g
jus tin
g. Addjus ltss
Br ers A bo olt
b
ten
fas

2:- Open all access doors. 3:- Slacken off tail drum bearing 4:- With adjusting bolts tension or track
fasteners. the belt.

5:- Re-tighten tail drum bearing fasteners, stand clear of conveyor, start the machine and run the belt for a
few minutes, observing the alignment of the belt.
6:- If after a short time, the belt appears to be in track, stop the belt and switch off the machine. Close and
secure all doors.
7:- If the conveyor is running out of track when the material is on the belt, then slacken off and adjust the
roller carrier angles forward or back to achieve correct tracking.
8:- Start the engine and run the machine with material on the belt, observing the tracking of the belt. If the
belt is still running out of track, repeat No. 7.

TENSIONING OF TAIL CONVEYOR BELT

g.
Br
ers
sten
fa

nd
il e
Ta ard
Gu

1:- Remove tail end guards. 2:- Slacken off tail drum bearing 3:- Slacken off scraper fasteners.
fasteners.

29
Rev2.Iss2
TURBOTRAC
TENSIONING OF TAIL CONVEYOR BELT CONTD.

g.
Br ners
te g
fas tin
jus
Ad bolts
g.
Br ners
te
fas

4:- Slacken off head drum bearing 5:- With adjusting bolts tension or track 6:- With adjusting bolts tension or track
fasteners. the belt. the belt.

7:- Re-tighten bearing fasteners, adjust scraper, close and re-bolt the doors.
8:- Start the machine, run the belt and stand well clear, observing the alignment of the belt. If further adjustment is
required, repeat the above procedure.
TENSIONING OF MAIN & SIDE CONVEYOR BELTS
Remove the safety guards, loosen the tail drum bearing fasteners bolts and follow the same procedure as for the
Tail Conveyor. Re-tighten the bearing fasteners, adjust the scraper and REPLACE SAFETY GUARDS
CORRECTLY.

SCREENBOX MESH FITTING AND REMOVAL

WARNING:- The machine MUST be switched off and ignition key removed BEFORE making any
adjustments.

SCREENBOX MESH FITTING

Ensure caping rubber is in good condition.
Insert mesh into the box on the required level and anchor the end hook into the centre anchor point. Rest the
screen mesh on the cross supports and attach screen clamp on to slider support assembly at the front or back
of the screenbox. Insert T- bolts through clamp and corresponding slots in screenbox, attach looking nuts and
tighten until correct tension is achieved.

In addition to standard type mesh it is possible to fit finger type screens to the screenbox. These fit into the box
on a mounting frame that is attached to the inside walls on the screenbox. In an area where the standard
screen mesh would fit.
Capping
Rubbers
es e n
S c es

M re
M
re h

h
Sc
en

Sc
n M re
ree es e n
S c esh h
M

Removal of screen meshes is a complete reverse procedure of the above.

30
Rev2.Iss2
TURBOTRAC
SCREENBOX DRIVE SHAFT BELT ADJUSTMENT
WARNING:- The machine MUST be switched off and ignition key removed BEFORE making any
adjustments.

1:- Remove safety guard. 2:- Loosen motor mounting plate bolts.

ht
aig
Str g e
ed

3:- Tap motor mtg.plt. to achieve correct belt tension.

4:- Ensure pulleys are aligned.

To ensure the correct speed and balance of the screenbox, the drive belts should be
kept tensioned correctly and changed if worn.

31
Rev2.Iss2
TURBOTRAC
SCREENBOX CONTINUED
BEARING REPLACEMENT
WARNING:- The machine MUST be switched off and ignition key removed BEFORE making
and adjustments.
NOTE:- The bearing replacement can be carried out on site but access to a press and
workshop is desirable. Changing one bearing at a time will retain shaft positioning. If in
doubt please contact Extec Service Department.
1:- Remove safety guard (see page 31).
2:- Slacken adjuster bolts for drive belts (see page 31). (for drive side only)
3:- Remove belts, pulley and counterbalance. (for drive side only)
4:- Remove bearing housing cap and spacer, undo lock tab on star washer. Unscrew locking nut to end
of hreads, knock back the locking sleeve into the bearing, taking care not to damage the threads or
he bearing.
5:- Jack off bearing housing.

Pu
lley

lt
Be L / er
sh
Wa
L/N
ut

ce
lan
/ Ba
C
L/ e
ev
sle

Belts, pulley and counter- balance. Bearing housing spacer fitted drive
side only. Locking sleeve.

6:- Remove grubscrews. 7:- Push out old bearing.

8:- Remove oil seals from housing and cap.

9:- Clean bearing housing and cap thoroughly and refit grubscrews into housing using an appropriate
substance such as "Loctite".
10:- Clean end of shaft thoroughly and inspect bearing surface for damage.
32
Rev2.Iss2
TURBOTRAC
BEARING REPLACEMENT CONTINUED

11:- Replace housing oil 12:- Replace cap oil seals. (Lip 13:- Replace bearings into housings.
seals.(Lip inboard to brg) inboard to brg)

13:- Contd. Bearing in drive housing to

be pressed to full depth. Bearing in
non drive housing to be pressed to
leave a 5mm gap between bearing
and housing shoulder.
14:- Clean faces and apply suitable
gasket sealant

15:- Refit housings. Torque value

600 N m Checking bearing clearance
around bearing.
16:- Set bearing clearance by tightening locking nut and pulling locking sleeve through bearing until
0.003" (0.07 mm) clearance is achieved between both sets of rollers and the outer bearing ring.
17:- Tighten locknut then tap lock washer tab to locate into nut.
18:- Replenish grease in bearing (for grease spec. see p 26) via remote grease point (see below) whilst
slowly rotating shaft until grease is fully entered into rear bearing ring and housing. Pack front
bearing by hand.
19:- Replace bearing cap. (plus spacer - drive side only)
20:- Refit counterbalance taking care to align weight with the location marking, leaving a gap of
approximately 5mm between the weight and the bearing cap.
21:- Refit pulley and drive belts ensuring correct tension and alignment is achieved.
22:- Refit safety guards.
23:- Test run equipment.

Nipple Nipple

Remote grease point for Screen Remote grease point for Screen
non-drive brg. drive brg.
33
Rev2.Iss2
TURBOTRAC
VIBRATING GRID
BEARING REPLACEMENT
WARNING:- The machine MUST be switched off and ignition key removed BEFORE making
and adjustments.
NOTE: The bearing replacement can be carried out on site but access to an appropriate press is
necessary. If in doubt please contact Extec Service Department.

1:- Remove motor. 2:- Remove bolts from motor mounting 3:- Remove motor mounting tube.
tube.

4:- Loosen drive coupling. 5:- Remove drive coupling from shaft. 6:- remove bolts holding bearing cap.

7:- Replace bolts in tapped holes in 8:- Lift bearing cap away. 9:- Loosen locking ring
bearing cap.

34
Rev2.Iss2
TURBOTRAC
BEARING REPLACEMENT CONTINUED

10:- Remove locking ring. 11 & 12:- Remove shaft guard on non - drive side of grid.

13:- Remove bearing cap in same manner 14:- Lift bearing cap away. 15:- Fit bearing cage to drive side.
as drive side.

16:- Place shaft bush over end of grid 17:- Fit ram and adaptor plate. 18:- Fit and tighten all bolts in adaptor
shaft. plate.

19:- Remove short bolts in shaft tube. 20:- Fit long bolts to take weight of grid 21:- Fit bolt through ram rod and bush to
shaft. ensure correct alignment.

35
Rev2.Iss2
TURBOTRAC
BEARING REPLACEMENT CONTINUED

22:- Push grid shaft through to push out 23:- Bearing pushed out. 24:- Clean shaft with emery cloth.
bearing.

25:- Clean with rag and thinners. 26:- Remove bearing, place on new 27:- Fit bearing cage to non - drive side
bearing and locate. of grid.

28:- Build up bearing press adaptor. 29:- Locate bearing press over shaft. 30:- Fit ram as before and fit bolt
through ram rod.

31:- Push new bearing into housing. 32:- Remove bearing tool, push shaft through so it is located biased toward drive side
and refit locking ring.

36
Rev2.Iss2
TURBOTRAC
BEARING REPLACEMENT CONTINUED

33:- Grease, using nipple, until grease 34:- Pack bearing with grease. 35:- Refit bearing cap. Ensure to locate
appears from bearing. seal correctly.

36:- Refit motor drive coupling. 37:- Refit motor mounting tube. 38:- Refit motor. Ensure to align coupling
correctly.

39:- Purge with grease on non - drive 40:- Replace bearing cap. 41:- Replace shaft guard.
side.

42:- Replaced shaft guard. 43:- Ensure to remove shaft centralizing 44:- Fit short or blanking bolts to central
bolts. pipe.
37
 R.H. TAIL TAIL LOWER JACK GRID SHREDDER L.H.SIDE
Rev2.Iss2

OIL COOLER IN SIDE SIDE CONV CONV SCREEN LEGS TIP LIFT CONV
CONV CONV FOLD LIFT BOX
L/H SIDE LIFT
CONV
OIL COOLER IN SIDE
CONV

PRIORITY BYPASS
R/H SIDE
CONV

WEBTEC INLET

TRACK PILOT

MAIN
CONV G/BOX
SCREEN TAIL CONV & GRID OR HOPPER
BOX SIDE CONV SHREDDER CONV
(OPTION)

PRIORITY BYPASS PRIORITY BYPASS

210BAR

WEBTEC INLET WEBTEC INLET

MAIN & SIDE SCREEN BOX TAIL CONV & GRID OR HOPPER
CONV SIDE CONV SHREDDER CONV

38
GRID TIP

200BAR 180BAR 200BAR 200BAR

PILOT
TURBOTRAC

350BAR
TRACK TRACK
MOTOR GEARBOX
63c.c. 83.7:1
HYDRAULIC CIRCUIT

RETURN MANIFOLD

40L
Diesel Engine
60L 60L
OIL RESERVOIR
52L 35L
350BAR
TRACK TRACK
MOTOR GEARBOX
63c.c. 83.7:1

70BAR
Rev2.Iss2
TURBOTRAC
WIRING DIAGRAM

WATER LEVEL EMERGENCY

STOP
REV COUNTER SWITCH
EPL1

TEMP ON

BATT MAIN
BLACK
EARTH
WATER OIL
LEVEL

EMR REMOTE GREEN/WHITE

PLUG 'A'
BLACK/BLUE
1
BROWN/YELLOW
2

3
BROWN
4

5
YELLOW
6
WHITE/BLACK
7

8
HOUR COUNTER

PLUG 'B'

WHITE/RED
1

2
WHITE
3
FUSE
4

5
RELAY
6

L 7
E
SLATE 8
N

3 WAY PLUGS INTO

DUETZ
BATTERY 30 15 50 15 ENGINE LOOM
POSITIVE MAIN
& ALT. KEY SWITCH

39
Rev2.Iss2
TURBOTRAC
TROUBLE SHOOTING GUIDE
Below is a list of some of the common problems that might occur on your machine .if these
problems arise, carry out the checks listed.

PROBLEM SOLUTION

Engine losing power or Check air filter is not blocked.

hard to start. Check diesel filter and sediment bowl.

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

One or all of the conveyor Check belt tension.

belts is/are not moving. Check that there is no build up of material underneath the
conveyors.
Check blockages in hydraulic return and suction filters.

IF ANY PROBLEM PERSISTS AFTER CARRYING OUT THE RECOMMENDED SOLUTION, OR A

PROBLEM ARISES THAT IS NOT ON THIS LIST, CONTACT EXTEC SERVICE DEPARTMENT FOR
FURTHER ASSISTANCE.
40
41
 Extec Screens & Crushers
Hearthcote Rd
Swadlincote
Derbyshire DE11 9DU
England
Tel: +44 (0) 1283 212121
Fax: +44 (0) 1283 217342

Douglas Siebtechnik GmbH

Am Frauenberg 2
36820 Oberaula
Deutschland
Telefon: +49 (0) 6628 9211-0
Telefax: +49 (0) 6628 9211-11

Extec USA, Inc

PO Box 355
Essington
PA, 19029-0355
Tel: +1 610 521 1448
Tel: 1-800-44SCREEN
Fax: +1 610 521 1863

42