Original instructions

Atlas Copco
HCS 3715
Operator’s Manual

PM No. 9852 2834 01

2011-09
 SAFETY INSTRUCTIONS
• Before starting, read all instructions carefully.
• Special attention must be paid
to information alongside this
symbol.
• Only use genuine Atlas Copco parts.
© Copyright 2011, Atlas Copco Powercrusher, Austria
Any unauthorised use or copying of any part thereof is
prohibited.
This applies in particular to trademarks, model
denominations, part numbers and drawings

2 Atlas Copco Powercrusher

4300 St. Valentin, Austria
Contents
1.0 Safety Section - Introduction 9
1.1 The purpose of these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Identification of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.1 Product type and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.2 Product manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.3 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.4 How to identify the right manual for the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.5 Validity of the manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.0 Safety Section - Safety and Environmental Instructions 17

2.1 Safety labels and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.2 General hazard symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.3 Symbols for mandatory actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.4 Symbols for prohibited actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.5 Hazard symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.6 Labels on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.7 Visual and audible signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 User obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.1 Managing work related hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.2 Scheduled safety inspections and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.3 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Product limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.2 Foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.3 Prohibited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.4 Maximum inclination angles during tramming and parking . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.5 Maximum inclination angles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.6 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Hazard zone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5.1 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5.2 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Complementary protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.6.1 Use of Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.6.2 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.6.3 Safe access to machinery and three point support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.6.4 Isolation and energy dissipation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6.5 Fire risk control measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7 Protection against emission hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.7.1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.7.2 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7.3 Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.8 Emergency procedures and methods for unblocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.9 Safety considerations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.10 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10.1 Decommissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10.2 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.10.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.11 Potential product related hazards identified by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.12 Incident reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.0 Technical and Transport 49

3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1.1 Special Considerations For Transport Of The HCS 3715 . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1.2 Machine Preparation for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Atlas Copco Powercrusher 3

4300 St. Valentin, Austria
Contents
3.1.3 Engine Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1.4 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2 Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.2.1 Lowering the Shredder (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.2 Lowering Standard Grid for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2.3 Lowering Vibrating Grid for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2.4 Fold Side Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2.5 Lower Tail Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.6 Lower Screenbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.7 Folding Tail Conveyor End Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2.8 Moving Main Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2.9 Preparing the Maintenance Platform for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.10 Raise Jacking Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.11 Tracking the machine onto and off the transport vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.12 Raise Screenbox for Loading or Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.13 Raise Tail Conveyor for Loading or Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.2.14 Tracking the HCS 3715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.3 Technical Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3.1 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3.2 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.3.3 Transport and Working Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.4 Identification of Main Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.5 Specification of Main Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.5.1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.5.2 Main Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.5.3 Side Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.5.4 Tail Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.5.5 Screen Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.5.6 Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.5.7 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.0 Product Overview 77

4.1 Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2 Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3 Identification and Operation of the HCS 3715 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3.1 Main Control Panel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Hydraulic Controls (HC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4.1 Standard Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4.2 Machine Fitted with Shredder Option and or Vibrating Grid Option . . . . . . . . . . . . . . . . . . . . 84
4.5 Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6 Umbilical and Remote Radio Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6.1 Umbilical Control Movement (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.6.2 Remote Radio Control Movement (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.7 Tipping Grid Radio Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.0 Commissioning and Shut Down 89

5.1 Commissioning & Shutdown Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2.1 Preparation for Machine STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2.2 Engine Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2.3 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2.4 Tracking the HCS 3715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2.5 Moving the HCS 3715 to Chosen Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.3.1 Lower Jacking Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Atlas Copco Powercrusher 4

4300 St. Valentin, Austria
Contents
5.3.2 Preparing the maintenance Platform for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.3 Un-folding Tail Conveyor End Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.3.4 Raise Screenbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3.5 Raise Tail Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.3.6 Unfold Side Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3.7 Raising the Standard Grid for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.3.8 Raising the Vibrating Grid for Operation (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.3.9 Wing Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.3.10 Lowering the Shredder (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.4 Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.4.1 Preparing the machine for transport or for the machine to be moved to a other location . . 112
5.4.2 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

6.0 Operation 115

6.1 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.2 Common Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.2.1 Construction, Demolition and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.2.2 Minerals and Quarrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.3 Operating the HCS 3715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.3.1 Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3.2 Adjusting the Main Conveyor Spreader Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3.3 Adjusting Main Conveyor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3.4 Setting the Tipping Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4 Tipping Grid Radio Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.4.1 Adjustment of Flow Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.4.2 Engine Speed for Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.5 Loading the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.5.1 Avoid damage to equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

7.0 Maintenance 123

7.1 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.2 Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.2.1 Power Unit Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.2.2 Screen Unit, Feed Hopper, Conveyors and General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.2.3 Testing the Emergency stop function and Battery Isolator . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.3 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.3.1 Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.3.2 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.3.3 Checking Fuel Level, Adding Fuel and Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.3.4 Emptying the Fuel Filter Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.3.5 Special Considerations For Maintenance Or Repair with Welding . . . . . . . . . . . . . . . . . . . 133
7.3.6 Shredder Flail Replacement (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.4.1 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.4.2 Hydraulic oil is added as follows: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.4.3 Changing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.4.4 Changing The Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.5 Screen Maintenance/Mesh Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.5.1 Top Deck Mesh Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.5.2 Bottom Deck Mesh Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.5.3 Vibrating Grid Maintenance/Mesh Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.6 Track Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Atlas Copco Powercrusher 5

4300 St. Valentin, Austria
Contents
7.6.1 Checking the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.6.2 Tighten the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.6.3 Loosen the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.6.4 Track Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.6.5 Conveyor Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.6.6 Tracking the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.6.7 Maintenance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.6.8 Hydraulic Oil Requirements for HCS 3715 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.6.9 Lubricants and Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.6.10 Greasing Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.6.11 Grease Nipple Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.6.12 Care of chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

8.0 Trouble Shooting and Warranty 159

8.1 Trouble Shooting Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.2 Trouble Shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3 Commissioning and Engine Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.3.1 Commissioning and Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.4 CAT Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.4.1 CAT C Series Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

9.0 Spare Parts 171

9.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.1.1 Spare Parts illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.1.2 Ordering Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
9.1.3 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 173
9.1.4 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
9.2 Machine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9.2.1 HCS 3715 Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9.2.2 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
9.2.3 Diesel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.2.4 Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
9.2.5 Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.2.6 Bolt in hopper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
9.2.7 Feeder Box Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.2.8 Screen Main Conveyor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.2.9 Feeder Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.2.10 12 FT Tipping Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
9.2.11 14 FT Tipping Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
9.2.12 Screen Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.2.13 Screen complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
9.2.14 Top Deck Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.2.15 Main Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
9.2.16 Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
9.2.17 Tail Conveyor Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
9.2.18 Mid Size Side Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
9.2.19 Over Size Side Conveyo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.2.20 Vib Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9.2.21 Vib Grid Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
9.2.22 Cat Tier III Powerunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9.2.23 Cat Teir III Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.2.24 Shredder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.2.25 CAT Engine Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Atlas Copco Powercrusher 6

4300 St. Valentin, Austria
Contents
10.0 Electrical and Hydraulic 215
10.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
10.2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.2.1 Hydraulic hose kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.2.2 Hydraulic circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.2.3 Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

11.0 OEM Section 245

11.1 Crawler Tracks Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.2 Electrical Control System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.3 Optional Extra’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.4 Material Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Atlas Copco Powercrusher 7

4300 St. Valentin, Austria
 HCS 3715

1.0 Safety Section - Introduction

Atlas Copco Powercrusher 9

4300 St. Valentin, Austria
HCS 3715 Safety

1.1 The purpose of these instructions

The purpose of these instructions is to promote intended safe, proper and optimal use of Atlas Copco
Powercrusher products and to help the user to identify, avoid and prevent hazardous situations and
related consequences.

These instructions must be followed along with any instructions given in local laws and regulations,
any orders given by local authorities and all protective measures specific for the site.

Read and understand the complete manual carefully and follow given instructions strictly. If there is
anything you do not understand, ask your employer or your local Atlas Copco Powercrusher
company office to explain it. All sections of this manual contain information which is vital for your
safety. The manual must be replaced immediately if lost, damaged or unreadable. For replacement
copies, please contact
www.atlascopco.com
and provide the machine serial number, what type of manuals are required eg operators and
language version required.

The instructions set forth in the operator’s and other manuals are to be used as a part of the training
material during orientation. By following these instructions, safe practices will result, maintenance
cost and downtime will be minimised and the reliability and lifetime of the equipment will be optimised.

1.2 Identification of the product

1.2.1 Product type and serial number

The model and serial number of the product are shown on the identification plate.

Atlas Copco Powercrusher 10

4300 St. Valentin, Austria
Safety HCS 3715

1.2.2 Product manufacturer

Country Address Phone- and fax number

Argentina Juncal 2869 Phone: +54 - (0)11 - 47 17 22 00
B1640GRE Martinez Fax: +54 - (0)11 - 47 17 09 88
Buenos Aires
Australia P O Box 6134 Phone: +61 - (0)2 - 9621 9700
Delivery Centre Fax: +61 - (0)2 - 9621 9813
Blacktown NSW 2148
Austria Postfach 108 Phone: + 43- (0)1 -76 01 20
A-1111 Wien Fax: + 43 - (0)1 - 769 56 72
Bolivia P.O. Box 290 Phone: + 591 - (0)3 - 343 68 68
Santa Cruz de la Sierra Fax: + 591 - 0(3) - 343 69 69
Brazil P O Box 12737 Phone: + 55 - (0)11 - 247 88 00
Sao Paulo, SP Fax: + 55 - (0)11 - 55242347
04744-970
Bulgaria 14, Vasil Levski Str., fl. 2 Phone: + 55 - (0) - 29 76 30 98
North Industrial Area Fax: + 55 - (0) - 29 76 30 90
Kazichane
Sofia 1532
Canada 200 Mumford Road Phone: + 1 - 705 - 673 67 11
Walden Industrial Park Fax: + 1 - 705 - 692 31 01
Lively, Ontario P3Y 1L2
Chile Panamericana Norte 5001 - Conchali Phone: + 56 - (0)2 - 442 3600
Santiago, Chile Fax: +56 - (0)2 - 623 44 60
6553935 Conchali
China 1 No 1 Heng Da Road Phone: + 86 - 25 - 85 75 76 00
Nanjing Economic & Technological Fax: + 86 - 25 - 85 75 75 30
Development Zone
Nanjing
Postal code 210038
China 2 No. 12 Kun Ming Hu Street Phone: + 86 - 24 - 25 81 17 19
Shenyang Economic & Technological Fax: + 86 - 24 - 25 81 18 67
Development Zone
CN-Shenyang 110027
CMT S-105 23 Stockholm Phone: + 46 - (0)8 - 743 80 00
International Fax: + 46 - (0)8 - 702 21 29
Colombia A.A. 95310 Phone: +57 - 1 - 291 54 90
Santafé de Bogotá, D.C. Fax: +57 - 1 - 430 6514
Czech Republic Prumyslova 10 Phone: + 420 - (0)2 - 25 43 42 20
Praha 10, Post Code 102 00 Fax: + 420 - (0)2 - 25 43 42 22
Egypt 520 El-Obour Market Phone: + 20 - (0)2 - 610 20 57
Cairo Fax: + 20 - (0)2 - 610 20 56

11 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 Safety

Country Address Phone- and fax number

Finland Tuupakankuja 1 Phone: + 358 - (0)9 - 296 64 42
SF-01740 Vantaa Fax: + 358 - (0)9 - 29 64 21 8
France B.P. 67181 Phone: + 33 - (0)1 - 30 72 32 22
FR-95056 Cergy-Pontoise Cedex Fax: + 33 - (0)1 - 30 72 32 49
Germany Postfach 10 02 25 Phone: + 49 - (0)201 - 217 70
D-46002 Essen Fax: + 49 - (0)201 - 217 74 54
Ghana P O B 10071 Phone: + 233 - 21 77 45 12
Accra North Fax: + 233 - 21 77 61 47
Great Britain P O Box 79 Phone: + 44 – (0)1442 - 22 21 00
Hemel Hempstead Fax: + 44 - (0)1442 - 234467
Herts HP2 7HA
Greece 93, Koropiou - Varis Avenue GR - 194 00 Phone: +30 - (0)210 - 349 96 00
Koropi, Athens Fax: +30 - (0)1 - 345 47 83
Hong Kong P O Box 1516 Phone: + 852 - 24 88 01 03
Shatin Central Post Office Fax: + 852 - 24 88 98 63
New Territories
India Sveanagar Phone: + 91- (0)20 -712 64 16
Bombay Pune Road Fax: + 91 - (0)20 - 712 65 87
Dapodi
Pune 411 012
Indonesia P O Box 7021/JKS CCE Phone: +62 - 780 10 08
Jakarta 12075 Fax: +62 - 780 18 37
Iran PO Box 13145-1311 Phone: +98 - 21 - 669 377 11
Tehran 1345654551 Fax: +98 - 21 - 669 273 14
Ireland Kylemore Road Phone: +353 - (0)1 - 450 5978
Bluebell Fax: +353 - (0)1 - 456 7686
Dublin 12
Italy Casella Postale 77 Phone: + 39 - (0)2 - 61 79 91
IT-20092 Cinisello Fax: + 39 - (0)2 - 66 01 32 99
Balsamo MI
Japan Sumitomo Fudosan Shipa Bldg 4 llF Phone: + 81 - (0)3 - 57 65 78 90
13-4 Shiba 2-chome Fax: + 81 - (0)3 - 57653199
Minato-ku Tokyo 105-0014
Kazakstan Kurmangaliev str 8A Phone: + 7 – (0)327 - 258 85 34
050010 ALMATY Fax: + 7 – (0)327 - 258 85 35
Kenya PO Box 400 90 Phone: + 254 – (0)20 - 660 50 00
Nairobi Fax: + 254 – (0)20 - 82 54 72
Korea C-P.O. Box 8354 Phone: + 82 – (0)2 - 21 89 40 00
Seoul Fax: + 82 – (0)2 - 522 82 39
Malaysia 26 Jalan Anggerik Mokara 31/47 Phone: + 60 – (0)3 - 5123 88 88
Kota Kemuning, Seksyen 31 Fax: + 60 –(0)3 - 51 23 89 49
40460 Shah Alam
Selangor Darul Ehsan

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Country Address Phone- and fax number

Mexico Apartado Postal Box 104 Phone: + 52 – 5 - 626 06 00
Tlalnepantla Fax: + 52 – 5 - 565 62 65
Edo. De Mexico
Marocco P O Box 13 844 Phone: + 212 – 2 - 600 040
20 300 Casablanca Fax: + 212 – 2 - 60 05 22
Mongolia Building BP9, Tavan Erdene (MISHEEL) Phone: + 976 – (0)11 - 99 11 48 16
Center, 2nd Khoroo, Khan Uul District, Fax: + 976 – (0)11 - 11 31 26 13
Chinggis Avenue, Ulaanbaatar, Mongolia
Norway P O Box 334 Phone: + 47 – 64 - 86 03 00
N-1401 Ski Fax: + 47 – 64 - 86 03 30
Peru Apartado 662 Phone: + 51 – (0)1 - 224 86 80
Lima 100 Fax: + 51 – (0)1 - 224 01 53
Philippines P.O. Box 1373 Phone: + 63 – (0)2 - 823 8178-80
1200 Makati City Fax: + 63 – (0)2 - 823 84 59
Poland (Sales) ul. Katowicka 32 Sales
P-40-173 Katowice Phone: + 48 –(0)32 - 209 5774
(Service) ul.Krzywa 3, Fax: + 48 –(0)32 - 209 5776
59-100 Polkowice Service
Phone: + 48 76 8474 935
Portugal Apartado 14P-2790-953 Carnaxide Phone: + 351 – (0)1- 416 85 00
Fax: + 351 – (0)1 - 418 0782 Service
Russia 27 Viatskaya street, building 14 Phone: + 7 – 495 - 933 55 52
127015 Moscow Fax: + 7 – 495 - 933 55 58
Saudi Arabia P O Box 7330 Phone: + 966 – (0)2 - 693 33 57
Jeddah 21462 Fax: + 966 – (0)2 - 693 28 92
Singapore Jurong Point Phone: + 65 – 66 - 68 62 28 11
P O Box 438 Fax: + 65 – 66 - 68 63 60 98
Singapore 639456
South Africa P O Box 14110 Phone: + 27 – (0)11 - 821 90 00
Witfield 1467 Fax: + 27 – (0)11 - 821 92 02
Spain Apartado 24 Phone: + 34 – (9)1 - 627 91 00
E-28820 Coslada Fax: + 34 - (9)1 - 627 9239
Madrid
Sweden S-10523 Stockholm Phone: + 46 - (0)8 - 743 92 30
Fax: + 46 - (0)8 - 743 92 46
Switzerland Büetigenstrasse 80 Phone: + 41 – (0)32 - 374 15 00
CH-2557 Studen/Biel Fax: + 41 –(0)32 – 374 15 15
Taiwan P O Box 14-45, Chungli Phone: + 886 – (0)3 - 479 68 38
Tao Yuen Hsien Fax: + 886 – (0)3 - 479 68 20
Thailand 1696 New Petchburi Road Phone: + 66 – (0)2 - 652 90 06
Bangkapi Fax: + 66 – (0)2 - 652 81 94
Huay Kwang
Bangkok 10320

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HCS 3715 Safety

Country Address Phone- and fax number

Turkey Istasyon Arkasi Phone: + 90 – (0)216 - 581 05 81
81700 Tuzla Fax: + 90 – (0)216 - 581 05 82
Istanbul
Ukraine 9, Moskovskiy Avenue Phone: + 380 – (0)44 499 18 70
Building 3 Fax: + 380 – (0)44 499 18 77
04073 Kiev
USA PO Box 1159 Phone: + 1 – 303 - 287 88 22
Commerce City CO 80022 Fax: + 1 – 303 - 217 28 39
Venezuela Apartado 76111 Phone: + 58 – (0)212 - 256 23 11
Caracas 1071 Fax: + 58 –(0)212 - 257 18 10
Vietnam Nr. 42, Street 37,Thao Dien Ward, District 2, Phone: + 84 - (0)8 - 898 96 38
Ho Chi Minh City Fax: + 84 - (0)8 - 898 96 37
Zambia P O Box 11291 Phone: + 260 – (0)2 - 31 12 81
Chingola Fax: + + 260 – (0)2 - 31 38 77
Zimbabwe P.O. Box CY 935 Phone: + 263 – (0)4 - 62 17 61-5
Causeway Fax: + 263 – (0)4 - 62 17 94

1.2.3 Manuals

Product documentation includes the following manuals:

• The operator's manual includes operating instructions, operator's safety considerations and
maintenance tasks for which an operator would be responsible. It does not include
maintenance procedures that should be performed with less than daily frequency.

• The maintenance manual includes the preventive maintenance schedule and a description of
all scheduled maintenance tasks. It also includes fluid and lubricant specifications and
capacities. It does not include occasional service, breakdown, or repair procedures.

• The parts manual includes part lists and illustrations for spare parts.

The model and serial number are shown on the identification plate (refer to section, “Product type
and serial number” on page 10). Make sure that the model corresponds to the one given on the cover
of this manual.

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1.2.4 How to identify the right manual for the product.

• operator's manual (e.g. Product model)

• maintenance manual (e.g. Product model)

parts manual (e.g. product model + serial number)

1.2.5 Validity of the manuals

This manual, and especially the safety information is valid only, if no unauthorised changes to the
product are made.

Continuing improvement and advancement of product design might have caused changes to your
product which are not included in this publication.

Whenever a question arises regarding your product, or this manual, please consult your local Atlas
Copco Powercrusher company office for the latest available information.

1.3 Copyright notice

This publication is copyright of Altas Copco Powercrusher. It must not be copied, reproduced, or
otherwise made available in full or in part to any third party without Atlas Copco Powercrusher's prior
written consent.

All Rights Reserved.

1.4 Definitions

• Product: Machine, machinery, partly completed machinery, component or tool, including

related services.

• User: The owner, operator or authorised and trained person involved in the transportation,
installation, operation, maintenance and disposal of the product.

• Information for use: The information in this manual, the safety labels and signals on the
product and other related information used separately or in combination to convey information
to the user.

• Harm: Physical injury or damage to health. This is always in relation to people, not to
equipment or property.

• Hazard: Potential source of harm.

• Risk: Combination of a probability of occurrence of harm and the severity of that harm.

• Risk of property damage: Combination of a probability of occurrence of property damage

and the severity of that property damage.

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• Environmental risk: Combination of a probability of occurrence of environmental damage

and the severity of that environmental damage.

• Hazard zone: Any space within and/or around the product in which a person is exposed to a
hazard.

• Intended use of a product: Use of a product in accordance with the information provided in
the instructions for use.

• Reasonably foreseeable misuse: Use of a product in a way that is not intended by the
designer, but which may result from readily predictable human behaviour.

• Prohibited use: Any use which is not intended use, especially use that is specifically
prohibited in the information for use or use which is plainly dangerous.

• Safe working procedures: Practices and methods developed for the users by their employer
for work to be performed. It details how specific risks in the workplace will be managed, taking
into account information for use supplied with the product as well as local acts, laws and
regulations.

• Safeguard: Guard or protective device.

• Guard: Physical barrier, designed as part of the product, to provide protection.

• Protective device: Safeguard other than a guard, which reduces the risk either alone or in
conjunction with a guard; e.g. interlocking device, hold-to-run control, limiting device.

• Emergency stop: Function which is intended to 1) avoid dangerous situations or to reduce

existing hazards to persons and damage to product or work in progress 2) To be initiated by a
single human action.

• Emission value: Numerical value quantifying an emission generated by a product (e.g. noise,
vibration, hazardous substances, radiation).

• Exposure value: Quantifies the exposure of persons to emissions when the product is in use.
Exposure values can be estimated using the emission values.

• Respirator: Approved respiratory protective device.

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 HCS 3715

2.0 Safety Section - Safety and

Environmental Instructions

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2.1 Safety labels and signals

This section includes explanations of safety symbols, signs, signals and labels used on the product
and information for use.

2.1.1 Signal words

The following signal words and symbols are used to identify safety messages in these instructions:

DANGER
The signal word “DANGER” indicates a hazardous situation which, if not avoided, will result in death
or severe injury.

WARNING
The signal word “WARNING” indicates a hazardous situation which, if not avoided, could result in
death or severe injury.

NOTICE
The signal word “NOTICE” indicates a situation which, if not avoided, could result in damage to
property or environment.

2.1.2 General hazard symbol

This general hazard symbol identifies important safety messages in this manual.

When you see this symbol, be alert; your safety is involved. Carefully read and understand the
message that follows, and inform other users.

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2.1.3 Symbols for mandatory actions

Mandatory actions symbols specify actions to be taken to avoid a hazard. Mandatory actions are
indicated by white symbols on a blue background.

Wear Safety Gloves Wear Eye Protection Wear Safety Helmet

Wear Safety Harness Wear Ear Protection Wear Safety Boots

Wear Close Fitting

Read the Manual Wear High Visibility Vest
Overalls

Disconnect Power Switch Off and Lockout

Wear Respirator
Source From Supply Equipment

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HCS 3715 Safety

2.1.4 Symbols for prohibited actions

Prohibited action symbols indicate actions which are prohibited in order to avoid a hazard. Prohibited
actions are indicated by a red circle with a red diagonal line across the circle. The action which is
prohibited will always be in black.

No Climbing No Smoking Do Not Touch

Limited or Restricted
No Open Flames Do Not Weld
Access

Do Not Remove Safety

Guard
2.1.5 Hazard symbols

Hazard symbols are indicated by a yellow triangle with black symbols and black frames.

Crushing Hazard -
Crushing Hazard - Feet Chemical Burn Hazard
Hands

Electrical Shock/
Electrical Hazard Entanglement Hazard
Electrocution Hazard

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Entanglement Hazard Falling Hazard Falling Load Hazard

Hazardous or Poisonous
Flammable Hazard Flying Material Hazard
Material Hazard

Silica or Other Dust

Lifting Hazard Skin Injection Hazard
Hazard

Trip Hazard Magnet Hazard

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2.1.6 Labels on the product

Safety labels communicate the following:

• The severity level of the risk (i.e. signal word ”DANGER” or ”WARNING”)

• The nature of the hazard (i.e. the type of hazard – cutting parts, high pressure, falling objects,
dust, live parts, etc)

• The consequence of interaction with the hazard (i.e. cut, injection, crushing, explosion,
electrocution etc)

• How to avoid the hazard

IMPORTANT! Keep the safety labels clean and visible at all times. Check the condition of
safety labels daily. Safety labels and instructions which have faded, been damaged, been
painted over, come loose or that do not meet the legibility requirements for safe viewing
distance, must be replaced before operating the product.

Replacement of labels -

For replacement labels, please contact:

www.atlascopco.com and provide the machine serial number, label part codes and language
version required.

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23 Atlas Copco Powercrusher

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2.1.7 Visual and audible signals

Sirens and Beacons:

There is one siren and one beacon on the HCS 3715.

When the key is turned to start the HCS 3715 engine, the siren will sound and the beacon will flash
for ten seconds before the engine will crank to start.

When the track controller [umbilical or remote] is switched on and the required control panel button
is pressed to track the machine, the siren will sound and the beacon will flash for seven seconds, in
which time the machine will not be able to be tracked. The siren and beacon will then be on
continuously once the tracking mode is selected.

These visual and audible safety devices should be checked at the start of every working day. For their
location refer to “2.6 Complementary protective measures” on page 34.

2.2 User obligations

WARNING
IGNORING INSTRUCTIONS HAZARD

If you do not understand any information related to your duties in the

operator’s or maintenance manual you MUST make sure that you get
clarification from a person who is well trained with regard to the task
you want to do. When necessary, you or your representative must
contact a Atlas Copco Powercrusher representative to seek
clarification as to how you should do the task.

The safe use of a product depends on, among other things, a combination of the design and
construction measures taken by the manufacturer, the skills of the operators and protective
measures taken by the user. Instructions are an essential and integral part of the product and they
must be always available for users. It is important to pass on the information for use to any
subsequent user of this product. Specify the place of manual on the product.

Altas Copco Powercrusher prohibits the consumption of drugs and/or alcohol or any other substance
likely to impair judgement while using, being in the hazard zone of, or supervising the use of a Atlas
Copco Powercrusher product.

Safety information covers the following: transport, assembly, installation, commissioning, use,
settings, operation, cleaning, troubleshooting, maintenance and disposal of machinery. If you need
more detailed instructions, you must contact your local Atlas Copco Powercrusher company office.

As part of ensuring the safe use of the product, you as the user are responsible for the following:

• Use of Personal Protective Equipment (PPE)

• Scheduled testing and maintenance of safeguards and protective devices

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HCS 3715 Safety

• Provision and use of additional safeguards

• Regular training regarding site safety and safe working procedures

In addition, you must always be familiar with the following:

• Site organisation and supervision

• Workplace safety, including safe working procedures

• Permit-to-work systems

All near-miss incidents and accidents where a Atlas Copco Powercrusher product has been involved
must be reported to your local Atlas Copco Powercrusher company office without a delay. See also
the section, “2.12 Incident reporting” on page 48.

The following safety guidelines apply to each person working with the product or in the vicinity of the
product. Every single person is responsible for his or her own safety and for the safety of his or her
colleagues. In case of violation of any safety guidelines or regulations, everyone has a duty to warn
others and report near misses or any safety violation to the responsible supervisor.

2.2.1 Managing work related hazards

The user must always perform a local risk assessment before every new task, e.g. work phase or
shift. This assessment, also known as a Real Time Hazard Analysis, ensures that the user stops and
thinks about what he or she is going to do before starting to work:

• Identify potential hazards that could impact you, your colleagues, the environment, your
product and/or work method while you are performing the task.

• Assess the risks and implement the actions needed to eliminate or reduce the risks.

Only competent persons may carry out operation and other tasks. The employer must:

• Provide training and orientation

• Validate training methods

• Verify competence and skills

• Monitor and evaluate user performance regularly

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2.2.2 Scheduled safety inspections and preventive maintenance

It is important to thoroughly inspect the product before use to make sure it is safe to operate. Look
for defects and damage before any operation so that any problems can be reported and fixed. For
more information, see the section, “6.3 Operating the HCS 3715” on page 117, in the operator’s
manual.

Scheduled maintenance is an essential procedure to ensure and maintain safety and performance
of the product. Follow the specified instructions for the maintenance and inspection of product. For
more information, see section, “7.2 Maintenance Schedule” on page 125, in Maintenance Manual.

WARNING!

Use of unauthorised parts present an uncontrolled risk and could cause death or
severe injury. The use of unauthorised parts will also invalidate warranty. It is the
user’s responsibility to use only authorised parts as listed in the parts manual.

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2.2.3 Personal protective equipment

Operators and anyone in the vicinity of the product MUST wear approved personal protective
equipment, which includes but is not limited to:

Safety Helmet

Eye-protector

Hearing protectors

Close fitting overall

Safety footwear

Protective gloves

High visibility vest / jacket

Respirator

Do not wear loose clothing or jewellery that can get caught on controls or pulled into moving parts of
the product.

Tie back long hair. Long hair can get entangled, which could cause death or severe injury.

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2.3 Product limitations

2.3.1 Intended use

Refer to “6.2 Common Applications” on page 117.

2.3.2 Foreseeable misuse

The HCS 3715 has been designed with selected components to operate at a optimum level of
performance. The user must never limit or bypass or override any safety aspect of the product (e.g.
removing a guard). Refer to “6.2 Common Applications” on page 117.

2.3.3 Prohibited use

• Use which is not in accordance with intended as described in “2.3.1 Intended use” on page
29.

• Bypassing or overriding a safety device or a safety feature of the machine for any reason.

Use of product without required and approved personal protective equipment.

2.3.4 Maximum inclination angles during tramming and parking

WARNING
TIPPING HAZARD

Never exceed the specifies maximum inclination angles. The maximum

angles are allowed only when the booms are in the tramming position.

The rig must not be trammed or parked on a slope that exceeds the maximum
inclination angles.

This equipment must never be tracked on gradients that are more than:

10 degrees side tilt or 20 degrees front tilt.

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HCS 3715 Safety

2.3.5 Maximum inclination angles during operation

The HCS 3715 is designed for operation on a solid, level surface. It is important that the machine is
placed on solid ground that is capable of carrying the weight of the machine and that the machine is
placed on level ground. An appropriate site must be identified prior to delivery and unloading of the
machine.

2.3.6 Modifications

WARNING
MODIFICATION HAZARD

Unauthorised modifications could lead to death, severe injury or property

damage.

Always contact a Atlas Copco Powercrusher representative in order to get

advance written approval for any modification

All modifications and corrections not authorised in the product manuals or which may affect the
maintenance, operation, safety, and availability of the product need to be approved in writing by the
manufacturer before implementation. Approval requires careful risk assessment taking into
consideration any new risks that the modifications may bring.

Changes and modifications without proper risk assessment, elimination or reduction of risk and
without appropriate safety measures may lead to death, serious personal injuries or damage to
property or environment. Unauthorised modifications will also void the warranty.

If modifications and alterations that affect the maintenance, operation, safety, and usability of the
product are made without the written permission of the manufacturer, the manufacturer is not
responsible for any incidents resulting in death, injury, or property damage brought about by such
modifications and corrections.

If a modification or correction as described above has been implemented without the manufacturing
organisation’s permission, it’s effect on warranty liability will be considered case-by-case. Thus, the
warranty application may be rejected altogether.

Should you consider a modification or alterations necessary, you must contact the organisation that
manufactured and designed the product. No modification is permitted unless you first obtain the
written approval of the manufacturer.

In order to plan and implement the modification you must deliver adequate documentation:
• Product model/type

• Serial number of product

• Description of the modification or correction

• Related blueprints

• Related photos

• And other material if necessary

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31
2.4

HAZARD AREA 20m exclusion zone from any

DO NOT ENTER point of machine for personnel
Material Ejection NOT operating the machine
Area NOT TO SCALE

HAZARD AREA 20m

Hazard zone

DO NOT ENTER
MOVING
MACHINERY ACCESS
AREA ZONE ACCESS ZONE
TO TO CONTROL
5m distance CONTROL LEVERS
from feeder LEVERS HAZARD AREA
DO NOT ENTER
Radius 5m

HAZARD AREA Material Ejection

ACCESS
mechanical hazards, falling loads and ejected materials.

DO NOT ENTER ACCESS ZONE Area

ZONE

4300 St. Valentin, Austria

TO CONTROL

Atlas Copco Powercrusher

TO LEVERS
Material Ejection Area
CONTROL
LEVERS

HAZARD AREA
DO NOT ENTER
Material Ejection Area
Limit access to the equipment and its surrounds by erecting barrier guards to reduce the risk of other
HCS 3715
HCS 3715 Safety

2.5 Safeguarding

2.5.1 Guards

WARNING
TAMPERING HAZARD

Bypassing or overriding of a safeguard or a device could cause death or

severe injury.
Do not make any alterations to protective devices. Make sure that they are in
place and work properly before operating the machine.

x2 (other side)

conveyor tail
x2 (other side)

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2.5.2 Protective devices

Beacon
Siren

ISOLATOR

a. Prior to operation, all safety devices (control devices or guards) temporarily

removed for set-up, maintenance or repair purposes MUST be refitted and
checked immediately upon completion of the maintenance and repair work.

b. To avoid serious personal injury or death, NEVER operate the equipment with
safety devices or guards removed or unsecured.

c. ALWAYS report any defects regarding guards, safety devices or control devices.

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2.6 Complementary protective measures

2.6.1 Use of Emergency stop function

There are four Emergency-Stops on the HCS 3715.

Right
Back

Left

Front

Refer to “7.2.3 Testing the Emergency stop function and Battery Isolator” on page 128.

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2.6.2 Emergency exit

The HCS 3715 is not permitted to operate inside buildings or dwellings. The area surronding the HCS
3715 must always be clear of obsructions eg containers, unnecessary stockpiles etc.

2.6.3 Safe access to machinery and three point support

No climbing on the machine is allowed.

The maintenance platforms should never be used to observe the machine operation.

Three point support is NOT needed on the HCS 3715.

a. Falling from and/or onto this equipment could result in death or serious injury.

b. NEVER climb on the equipment while it is in operation or use equipment parts as

a climbing aid.

c. ALWAYS keep the area around the equipment clear of debris and trip hazards.

d. Beware of moving haulage and loading equipment in the area of the equipment.

e. For carrying out overhead assembly work, ALWAYS use specially designed or
otherwise safety-oriented ladders and working platforms.

f. ONLY use walkways/platforms provided on the equipment. ALWAYS perform

work from an approved, safe and secure platform.

g. When reaching any points 2m (approximately 6 feet) or more above the ground
level, ALWAYS use CE certified safety harness.

h. Keep all handles, steps, handrails, platforms, landing areas, and ladders free from
dirt, oil, snow and ice.

i. This equipment MUST be isolated prior to cleaning.

j. DO NOT direct power washers near or into control boxes and devices.

After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found MUST be repaired
immediately.

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2.6.4 Isolation and energy dissipation

Lockout and Tag Procedure:

Utilise the procedure below whenever the HCS 3715 is being operated under alternate power, or un-
der any condition in which shutting off the engine and removing the ignition key does not completely
cut power to the machine. Under such circumstances, to properly immobilise the HCS 3715:

• Position all hydraulic controls in the neutral position

• Ensure that all supports and slide stops are securely fixed in position

• Switch off machine ignition and remove ignition key

• Turn off Isolator Switch (See Photo Below)

• Lockout the isolator with a padlock and use a Tag to detail the work being done.

• User must retain padlock key on his/her person during immobilisation

ISOLATOR ON ISOLATOR OFF

Note! The above procedure MUST be utilised to safely immobilise the HCS 3715 when it is
under alternate power. Failure to utilise the above procedure may result in damage to
the HCS 3715, serious personal injuries or death.

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Removal of the Lockout and Tag:

Once the work has finished; remove ONLY your lock and tag, as other people may be working on the
machine at the same time.

The machine can only be started when the last lock and tag is removed.

DANGER
IMPACT HAZARD

Before moving the machine, visually check to make sure no one is standing in
the surrounding area.

Note! Refer to Start-up Sequence for Running the Machine, refer to “5.2.2 Engine Start-up
Sequence” on page 92.

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2.6.5 Fire risk control measures

WARNING
FIRE AND EXPLOSION HAZARD

Explosion hazard can exist in addition to the first hazard.

Ignition sources like smoking, open flames, welding work and sparks
together with combustible materials like fuel, can cause fire and if not
avoided, could lead to death or severe injury.

Ignition sources are prohibited in the vicinity of the machine ready for
operation or in operation.

During maintenance appropriate fire prevention and protection measures

must be followed including but not limited to trained personnel, proper fire
extinguishing equipment and agents. Before any maintenance or repairs
requiring ignition sources like welding or flame cutting, a proper risk
assessment must be carried out prior to the start of the work to control the
risk.

Smoking and open fire are prohibited in the vicinity of the product. Access to all fire-fighting
equipment must be granted at all times, especially during maintenance and repair works.

All fire-fighting equipment musto be inspected and serviced regularly according to local regulations.
Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.

Know the various types of fires and the appropriate fire fighting methods. Be aware that various fires
must not be extinguished with water. In most cases special extinguishing agents, dry powders or
deoxygenating are required.

All personnel must be trained regularly in fire-fighting methods in cooperation with local authorities
and rescue organisations. In case of fire, the fire alarm must be activated and all available personnell
must contribute in the fire-fighting according to the predetermined fire plan of the workplace.

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2.7 Protection against emission hazards

2.7.1 Noise

DANGER
NOISE HAZARD

Noise level emitted by the machine exceeds 80 dB(A). Continuous

exposure to noise will cause hearing impairment.

Always wear approved hearing protection.

Ear protection must be worn if you are within 10 meters (approximately 33 feet) of
the machine when the engine and other parts of the machine are running.

The above diagram indicates the measured noise levels at a measured distance; i.e. 3 m
(approximately 12 feet) - 80 dB indicates that at 3 meters the sound measured was 80 decibels. The
readings were measured with all systems running situated on the factory assembly line. The product
and local conditions will affect the noise levels.

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2.7.2 Vibration
WARNING! VIBRATION HAZARD!

Exposure to vibration could cause severe health effects. Follow the maintenance
schedule and keep the machine in good operating condition. Participate in the
health surveillance and training programs offered by your employer.

2.7.3 Dust

DANGER
Breathing dust will cause
death or severe injury.

Always wear approved

respirator.

DANGER
DUST HAZARD

Breathing dust will cause death or severe injury.

Always wear approved respirator.

If machine is equipt with a dust suppression system make sure the dust suppression
system is working properly.
Breathing or inhaling dust particles will cause death or severe injury. Always work with a respirator
approved by the respirator manufacturer for the job you are doing. It is essential that the respirator
that you use protects you from the tiny dust particles which cause silicosis and which may cause
other serious lung diseases. You should not use the product until you are sure your respirator is
working properly. This means the respirator must be checked to make sure that it is clean, that its
filter has been changed, and to otherwise make sure the respirator will protect you in the way it is
meant to.

In any workplace where respirators are necessary to protect the health of the employee, the employer
must establish and implement a written respiratory protection program with worksite-specific
procedures and elements including but not limited to the selection of respirators, proper usage,
maintenance and care, cleaning and disinfecting and training.

Make sure the dust suppression system in your equipment is working properly. If the dust
suppression system is not working properly, stop working immediately.

Regularly clean your working environment properly to minimise the dust level in the air. Always make
sure dust has been cleaned off your boots and clothes when you leave your shift.

Respiratory silica dust is a hazard, which requires special attention. The smallest particles of dust are
the most harmful. They may be so fine that you cannot see them. Remember, you must protect
yourself from the danger of breathing or inhaling dust.

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2.8 Emergency procedures and methods for unblocking

Blockage or Malfunction:

In the event of material blockage, any malfunction or operational difficulty, stop the
equipment and lockout immediately. Repair any defects or hazardous conditions
immediately.

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2.9 Safety considerations for maintenance

Before carrying out any maintenance read and understands the maintenance instructions. Make sure
that you have the skills and authorisation needed before starting any maintenance work. The
maintenance instructions support maintenance personnel performing preventive maintenance for the
product. The maintenance instructions also provide information for maintenance and operating
personnel on scheduled inspections of components and installed equipment.

Make sure all necessary machinery isolations (Refer to “2.9 Safety considerations for maintenance”
on page 42) have been carried out prior to commencing any maintenance work. Before carrying out
any maintenance work make sure that necessary original spare parts or materials are available,
or can be ordered and supplied in time to meet the work schedule. Note all completed maintenance
activities in a maintenance log or maintenance program.

Daily inspections and tasks allowed for operators (which do not require special skills) are in the
Maintenance Chapter refer to “ 7.0 Maintenance” on page 123.

Any tasks not mentioned in this chapter should not be attempted by operators.

• Hydraulic Maintenance

a. Work on hydraulic equipment must be carried out by persons having special

knowledge and experience of hydraulic systems.

WARNING
Splashed oil creates the risk of a fire, which could result in death or serious
injury.

Check all lines, hoses and screwed connections regularly for leaks or other
damage.

Repair damaged lines, hoses, or screwed connections IMMEDIATELY

b. ALWAYS relieve pressure from the hydraulic system before carrying out any kind
of maintenance or adjustment.

c. BEFORE carrying out any repair work, depressurise all system sections and
pressure pipes (i.e. hydraulic system, compressed air system, etc.) requiring
removal, in accordance with the specific instructions for the unit concerned.

d. Hydraulic and compressed air lines MUST be laid and fitted properly. Make sure
that no connections are interchanged. The fittings, lengths and quality of the
hoses MUST comply with the technical requirements.

e. ONLY fit replacement components of a type recommended by the manufacturer.

f. ALWAYS practice extreme cleanliness when servicing hydraulic components

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Battery Maintenance

a. ALWAYS disconnect battery leads before carrying out any maintenance to the
electrical system.

b. Recharge the battery in a well ventilated area.

c. The battery contains sulphuric acid, an electrolyte which can cause severe burns
and produce explosive gases.

d. AVOID contact with the skin, eyes or clothing.

e. Smoking is PROHIBITED when maintaining the battery.

f. ALWAYS wear appropriate personal protective equipment.

DANGER

Hydraulic fluid under pressure can penetrate the skin, which will result in
death or serious injury.

If fluid is injected under the skin, it must be surgically removed or gangrene

will result. GET MEDICAL HELP IMMEDIATELY.

ALWAYS use a piece of cardboard to check for leaks. DO NOT USE YOUR
HAND

Electric maintenance

a. External Considerations and Hazards

When working with the equipment, maintain a safe distance from overhead electric lines. If overhead
cables are in the area, a risk assessment MUST be completed prior to operating the equipment.

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DANGER
Contact with overhead electric lines will cause death or serious injury.

If your equipment comes into contact with a live wire, you MUST:

• Vacate the area;

• Warn others against approaching and touching the equipment;

• Report the incident and have the live wire shut off.

b. Machine - Electrical

1. Work on the electrical system or equipment MUST ONLY be carried out by a

skilled and qualified electrician or by specially instructed personnel under the
control and supervision of such an electrician and in accordance with applicable
electrical engineering rules.
2. Before starting any maintenance or repair work, the power supply to the
equipment MUST be isolated. Check the de-energized parts to make sure they do
not have any power. In addition to insulating any adjacent parts or elements,
ground or short circuit them to avoid the risk of electrical shock.
3. The electrical equipment is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables
MUST be fixed immediately.
4. Use ONLY original fuses with the specified current rating. Switch off the
equipment IMMEDIATELY if trouble occurs in the electrical system.
5. This equipment is wired on a negative earth. ALWAYS observe correct polarity.

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2.10 Environment

2.10.1 Decommissioning

Hazardous Substances:

a. MAKE SURE that correct procedures are formulated to safely handle hazardous
materials in strict accordance with the manufacturer's instructions and all
applicable regulations by correctly identifying, labelling, storing, using and
disposing of the materials.

b. A full list of Hazardous Substances associated with this equipment can be found in
the appendix of this document.

Warning Concerning Crystalline Silica And Similar Particulates:

• The HCS 3715’S operation may produce dust containing crystalline silica or other potentially
harmful particulates. ALWAYS utilise appropriate and properly-fitted and approved Personal
Protective Equipment, (e.g. respirators). Refer to “2.2.3 Personal protective equipment”
on page 28.

• DO NOT linger in areas where dust is produced, blown or otherwise found. NEVER inhale
dust produced by the operation of the HCS 3715.

Note! Inhalation of crystalline silica dust is potentially harmful to human health, and may
result in serious pulmonary disease or other deleterious chronic lung obstruction,
serious personal injuries or death.

2.10.2 Dismantling

Replacement & Removal of Components:

a. ALWAYS observe handling instructions itemised in this manual, the Original

Equipment Manufacturer's manuals, or the spare parts suppliers' instructions.

b. NEVER allow untrained staff to attempt to remove or replace any part of the
equipment.

c. The removal of large or heavy components without adequate lifting equipment is

PROHIBITED.

d. To avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be carefully attached to lifting tackle and
secured. ONLY use suitable and technically adequate lifting gear supplied or
approved by Original Equipment Manufacturer.

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e. NEVER work or stand under suspended loads.

f. KEEP AWAY from the feeder hopper and product conveyor discharge, where
there is risk of serious injury or death from contact with ejected debris.

g. LIMIT ACCESS to the equipment and its surrounds by erecting barrier guards to
reduce the risk of residual mechanical hazards, falling lifted loads, and ejected
materials.

2.10.3 Disposal

This equipment MUST ONLY be disposed at a specialist machine breaker

Handling And Disposal Of Hazardous Components And Materials

A full list of Hazardous Substances associated with this equipment can be found in the appendix of
this document

• The HCS 3715’s battery contains sulphuric acid, which can cause severe burns, and produces
explosive gases. Inspect the machine’s battery regularly, and assure that it is properly
connected and maintained. NEVER allow battery parts to come into contact with unprotected
skin, eyes or clothing, use Personal Protective Equipment, refer to “2.2.3 Personal
protective equipment” on page 28. NEVER attempt maintenance or repair to the HCS
3715’s battery while the battery is connected.

• The HCS 3715 includes an internal combustion engine, which produces exhaust fumes
containing potentially harmful gases and particulates. NEVER operate the machine’s engine
in an area lacking adequate ventilation, whether indoors or outside.

• The HCS 3715 uses a hydraulic oil system to power the components. Refer to the MDS for
information on how to handle hydraulic oil.

• Prior to welding, cutting, or grinding, ALWAYS assure that dust and other flammable
substances are removed from the work site. ALWAYS assure that the area where welding,
cutting or grinding is conducted is properly ventilated. Failure to observe these precautions
may increase the risk of explosion or fire, and may result in serious personal injuries or death.

• Keep flammable materials, chemicals, etc. away from the HCS 3715 at all times.

Special Considerations Concerning Dust Disposal:

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• ALWAYS utilise appropriate and properly-fitted Personal Protective Equipment (e.g.

respirators). Refer to “2.2.3 Personal protective equipment” on page 28.

• Always dispose of dust produced by the operation of the HCS 3715 by applying water,
placing dampened dust in a marked, sealed container, and removing it from the work site.

• NEVER disperse dust by blowing it; doing so may exacerbate dusty conditions in the proximity
of the HCS 3715, and may also cause dust to enter areas where unprotected persons may be
working, creating an increased risk of injury or death.

• ALWAYS assure that dust is removed from clothing, boots, etc. before leaving the work site.

• Liquids such as oil, fuel and battery liquids cause pollution. Follow the local, regional and
national regulations for waste disposal or accidental release to the ennviroment.

• Avoid running the engine at idle if it is not needed. Avoid unnecessary exhaust fumes.

• Observe the law in your country when disposing used machine components.

2.11 Potential product related hazards identified by the user

Operational Safety Considerations:

• Ensure that a copy of all operating instructions, including the Engine Operations Manual, is
kept current and maintained with the HCS 3715 at all times. If the manual is unavailable obtain
a replacement from your local Atlas Copco Powercrusher company office.

• Operators MUST read and understand all operating instructions, and must always work
utilising indicated safety precautions and procedures.

• Operators and anyone in the area of the HCS 3715 must ALWAYS use appropriate Personal
Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 28.

• Operators MUST be familiar with and understand all warnings and labels affixed to the HCS
3715. Failure to do so may result in serious personal injuries or death. If warnings or labels
are damaged or illegible, operators must notify management immediately and urgently obtain
replacements.

• ALWAYS ensure, prior to operation of the HCS 3715, that all safety devices are in place and
operational.

• If in doubt concerning the efficient, proper or safe operation of the HCS 3715, contact your
local Atlas Copco Powercrusher company office.

• Perform tasks only when safety is ensured.

• Contact your supervisor and local Atlas Copco Powercrusher representative.

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2.12 Incident reporting

Product safety issues to be reported are events where a product manufactured by Atlas Copco
Powercrusher has been involved in an accident or near-miss incident. Safety-related feedback, such
as, unauthorised modifications, missing manuals and safety labels, negligence of maintenance or
misuse shall be reported to your local Atlas Copco Powercrusher representative as well.

Reporting is mandatory to ensure safe working conditions for employees, to provide information for
the risk assessment process and to initiate product improvements.

Contact your local Atlas Copco Powercrusher representative to report safety issues, such as those
mentioned above.

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3.0 Technical and Transport

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3.1 Transport

3.1.1 Special Considerations For Transport Of The HCS 3715

Note! The load is the responsibility of the driver.

• Do not attempt to transport the HCS 3715 utilising a vehicle not specified for
hauling at least the listed gross weight of the machine. Failure to use
transportation with sufficient hauling capacity may result in damage to the HCS
3715 and the hauling vehicle, and may result in serious personal injuries or death.
Refer to “3.3 Technical Information” on page 70, for machine transport details. The
dimension of the tracks widths is important to prevent overhang.

• ALWAYS observe applicable local and national regulations concerning the

transportation of heavy equipment. Make sure that all appropriate permits,
licenses and endorsements are obtained and maintained before transporting the
HCS 3715.

• Make sure that the loading/ unloading site is clear of non essential personnel.
Erect barriers around the area and post warning signs where site conditions
warrant this, or performnecessary risk assesments.

• Loading/ unloading must only be carried out on firm flat ground.

3.1.2 Machine Preparation for Transport

WARNING Follow the procedure for preparing the machine for shut down, refer to
“5.4 Shut Down” on page 112.
Before attempting to set-up the machine make sure that the operator has
read and fully understood this and all the preceeding sections in the
manual

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DANGER
WORKING AT HEIGHT HAZARD
Falling may cause injury or death.
Always use a secure platform. Make sure correct procedures are followed for
the tasks that are done at height.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

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3.1.3 Engine Start-up Sequence

The operator must be fully trained in the operation of this equipment. When tracking, the operator
must be in a position to have an all round view of the operation. A additional supervisor should assist
where this is not possible. Make sure the site is clear of non essential persons. Erect barriers around
the area and post warning signs where site conditions warrant this. Make sure the tracking alarm
makes a clear sound.
This equipment must never be tracked on gradients that are more than: 10
degrees left to right or 20 degrees Front to Back. The machine must always be
on flat, solid ground when operating in its normal mode.

a. Make sure all Emergency Stops (refer to “2.9 Safety considerations for
maintenance” on page 42) are released and that the Engine kill switch on the
remote control is also turned off. (Fig4.3).
Right
Engine kill switch
Back

Left

Front

b. Make sure all hydraulic control levers are in the neutral position.

c. Make sure the Engine throttle lever is in the idle position.

Engine throttle lever

Idle position

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d. To start the engine, turn the ignition key to the “on” position, as shown at (B).

PREHEAT
INDICATOR

PREHEAT SWITCH

e. The following warning lights, as shown at (E) will illuminate.

Warning: Do not attempt to start the engine unless the above warning lamps are illuminated.

NOTICE Cold weather starting. Engage and hold the PREHEAT switch on the ON
position for 6 seconds before cranking the engine, if the pre heat indicator
is not shown or is flashing on or off then contact Atlas Copco
Powercrusher.

f. Turn the ignition key to the “Start” position as shown at (C). At this point the “Fuel
on” light will illuminate, as shown at (F) and the start delay safety siren will sound.

g. Hold the key in this position for seven seconds until the engine cranks and runs.

h. Release the ignition key immediately after the engine starts. The ignition key
should return to position D (ON).

Note! As soon as the engine has started the “Oil” light and “Battery” light will go out. Only the
“Fuel on” light and the “Engine Run” light will be illuminated when the engine is running,
as shown at (G). If any other lights illuminate when the engine is running, this indicates
a fault.

To stop the engine return the key to the neutral position, as shown at (A).

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3.1.4 Cold Weather Starting

WARNING Do not use aerosol starting aids, such as ether. The use of aerosols will
result in an explosion and personal injury.

a. Move the throttle lever to the full throttle position

Engine Throttle Lever

Full Throttle Position

b. Engage and hold the PREHEAT switch to the ON position for 6 seconds.

Note! if the pre heat indicator is not shown or is flashing on and off then contact Atlas Copco
Powercrusher.

c. Turn the ignition key to the “Start” position as shown at (C). At this point the “Fuel
on” light will illuminate, as shown at (F) and the start delay safety siren will sound.

d. Hold the key in this position for seven seconds until the engine starts and runs.
NOTICE Do not crank the engine for more than 30 seconds. Allow the electric
starting motor to cool for two minutes before attempting to start the
engine again. Such use could cause damage to the starting motor.

e. Release the ignition key immediately when the engine starts. The ignition key
should return to position D (ON).

Note! As soon as the engine has started the “Oil” light and “Battery” light will go out. Only the
“Fuel on” light and the “Engine Run” light will be illuminated when the engine is running,
as shown at (G). If any other lights illuminate when the engine is running, this indicates
a fault.

f. If the engine does not start repeat steps b. to e.

g. Move the throttle lever to the idle position when the engine is holding steady rpm
and run the engine on idle for over 5 minutes.

h. Operate the engine at low load until all systems reach operating temperature.
Check the guages during the warm-up period.

To stop the engine return the key to the neutral position, as shown at (A).

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3.2 Shut Down

It is recommend to operate the HCS 3715 until all material has been removed from the feeder and
crusher chamber and that the conveyors are not producing a stock pile.

WARNING
FLYING MATERIAL HAZARD

There Is Risk Of Serious Injury Or Death Due To Rejected Material.

Keep away from the Feeder area and the conveyor belts areas, only full trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

CRUSH HAZARD

There is Risk of Serious Injury or Death due to Other Heavy Machinery Working
In The Area.

Keep away from the Feeder area and the conveyor belts areas, only fully trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

a. Stop Feeder Conveyor: Move Hc1 A To Neutral Position

b. Stop Main Conveyor (And Vibrating Grid If Fitted): Move Hc1 B To neutral Position

c. Stop The Screen Box And Tail Conveyor: Move Hc1 C To Neutral Position

d. Stop Side Conveyors: Move Hc1 D To Neutral Position

e. If Shredder Option Is Applicable Stop The Shredder: Move Hc1 X To Neutral

Position

f. Stop Engine

RETURN LEVERS TO NEUTRAL POSITION

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3.2.1 Lowering the Shredder (If Applicable)

a. Re-start Engine If Required (refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Raise the shredder slightly to remove the weight off the locating pin by operating
HC4 B/C. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

b. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Locating Pin From
Shredder Support (If Shredder Is Not In Working/transport Position

Non-working Position Working and transport position

Locating
Pin

c. Restart the engine. Lowering Shredder: Move HC4 B/C (Dependant On Options
Chosen) To The Down Position. Lower The Shredder Fully Until It Rests On The
Diverter Valve. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

3.2.2 Lowering Standard Grid for Transport

a. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Pins From Wing
Plates And Fold Into Transport Position

Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on page 92) and Activate
Auxiliary Controls: Move HC1 D To The Down Position (refer to “4.4 Hydraulic Controls (HC)” on
page 80.)

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b. Using The Tipping Grid Receiver Push The Button Marked “manual Raise” To
Rise The Grid Off The Support Stops.

c. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Pins (Circled In
Picture Below) From Both Sides Of Grid Support Legs

d. Lower Both Grid Support Legs And Re-insert Pins (See Picture Below)

e. Restart the engine. Using The Tipping Grid Receiver Push The Button Marked
“manual Lower” To Lower The Grid Into Transport Position.

3.2.3 Lowering Vibrating Grid for Transport

a. Implement the Lock and Tag Out procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. Using A Secure Platform Remove Pins From Slide Plates And Fold Into Transport
Position (As Shown Below At A). Re-fit Transport Brackets (As Shown Below At B)

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c. Re-start Engine If Required (refer to “5.2.2 Engine Start-up Sequence” on page

92) and Activate Auxiliary Controls: Move HC1 D To The Down Position. Raising
Grid: Move Hc4 B Into The Up Position To Slightly Raise The Vibrating Grid Off
The Support Pins. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

d. Implement the Lock and Tag Out procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36..

e. Using A Secure Platform Remove Pins (Circled In Picture Below) From Both Grid
Support Legs

Working
Position

Transport
Position Only

f. Lowering Vibrating Grid: Move Hc4 B Into Down Position Until The Vibrating Grid
Is In Lowest Position Then Re-insert Pins (As Shown Below).

NOTICE NEVER OPERATE THE VIBRATING GRID IN TRANSPORT POSITION AS

THIS WILL CAUSE DAMAGE TO THE MACHINE AND WILL VOID ALL
WARRANTIES

3.2.4 Fold Side Conveyors

Both side conveyors are folded using the same procedure. The only difference being that a different
control valve is used for each side. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

The LEFT HAND SIDE conveyor is folded using AUXILIARY CONTROL VALVE HC2 A.

The RIGHT HAND SIDE conveyor is folded using AUXILIARY CONTROL VALVE HC3 A.

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a. Re-start Engine If Required (Refer To “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.

b. Use the appropriate HC lever to slightly lift the weight of the locating pin.

c. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Remove locating pin from slide stop.(see next picture).
Re-located slide stop to bottom position and re-insert locating pin.

DANGER
CRUSH HAZARD
Before closing the side conveyors visually check the area around the
machine to make sure there is no one standing in a dangerous position.

d. Re-start Engine If Required and Activate Auxiliary Controls: Move HC1 D To The
Down Position, CLose Side Conveyor Using Appropriate Control Valve As Set Out
In Previous Page.

e. Insert Transport Pin On Each Side Conveyor (See Picture Below)

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3.2.5 Lower Tail Conveyor

a. Re-start Engine (Refer to “5.2.2 Engine Start-up Sequence” on page 92) If

Required and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Slightly raise the tail conveyor to remove the weight of the locating pin by
operating HC3 B Into Pull Position.

.
b. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36) Move Both Slide Stops On Tail Conveyor Support
Down To Bottom Position And Insert locating Pins (See Picture Below)

c. Re-start Engine If Required and Activate Auxiliary Controls: Move HC1 D To The
Down Position. Lower Tail Conveyor Into Transport Position: Move HC3 B Into
Pull Position.

Locating pin

Slide Stop

Tail Conveyor
Working Position

Transport
Position

3.2.6 Lower Screenbox

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Slightly raise the Screenbox to remove the weight of the locating pin.

b. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36)Move Both Slide Stops On Screen Box Support Down
To The Bottom Position And Insert Pins (See Picture Below)

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c. Re-start Engine if required and Activate Auxiliary Controls: Move HC1 D To The
Down Position. Lower Screen Box Into The Transport Position: Move HC2 B Into
Pull Position

Screenbox
Working Positions
Slide Stop
Locating Pin
Transport Position

3.2.7 Folding Tail Conveyor End Section

a. Re-start Engine If Required ( Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move Hc1 D To The Down Position

b. Fold Tail Conveyor End Section: Move Hc3 A Into Pull Position

c. Insert Pin Both Sides Of Tail Conveyor End Section (See Picture Below)

3.2.8 Moving Main Conveyor

The Main Conveyor needs to be moved forward fully to allow the machine to be in the transport
position. To do this the move HC4 B into the UP position.

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3.2.9 Preparing the Maintenance Platform for Transport

a. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36). Remove The Access Ladder

b. Fold Walkway Bases (A) Up Into Transport Position And Lock Into Position With
Spring Loaded Lock (B)

A B

c. Swing The Walkways On The Left And Right Hand Side Of The Machine Into
Transport Position

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d. Insert The Locking Pin One On The Left And Right Hand Side, Into The Walkway
Swing Frame

e. Remove Safety Chain And Slide In Handrail (C) On The Left And Right Hand Side
Of The Machine (As Shown Below).

f. Make sure All The Walkways Are Secure

3.2.10 Raise Jacking Legs

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.

b. Raise Jacking Legs slightly to take weight of the locating pins, by using HC4 A.

c. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36)

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d. Remove Pins From Jacking Legs. Engage Auxiliary Controls: Move HC1 D Into
Down Position.

e. Raise Jacking Legs until fully raised: Move HC4 A Into Up Position.

f. Re-insert Pins From Jacking Legs into holder.

Your Atlas Copco Powercrusher HCS 3715 is now ready for transport.

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3.2.11 Tracking the machine onto and off the transport vehicle

Before loading or unloading the HCS 3715 from transporter the machine will be in the Transport Po-
sition. To load or unload the machine the Screenbox and Tail conveyor need to be raised to avoid
catching the ground or the transporter.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

Note! Engine idle rpm on engine start up is sufficient to track the machine onto or off the
transport vehicle. Any higher engine rpm is not recommended.

3.2.12 Raise Screenbox for Loading or Unloading

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Raise the Screenbox until the lowest working position is available. Operate HC2
B. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

b. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36).Move Both Slide Stops On Screen Box Support Down
To The first working Position And Insert Pins (See Picture Below)

c. Re-start Engine If Required and Activate Auxiliary Controls: Move HC1 D To The
Down Position. Lower Screen Box Onto The locating pin: Operate HC2 B.

Screenbox
Working Positions
Slide Stop
Locating Pin
Transport Position

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3.2.13 Raise Tail Conveyor for Loading or Unloading

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Raise the tail conveyor until the first working position is available, by operating
HC3 B. Refer to “4.4 Hydraulic Controls (HC)” on page 80.

b. Implement the Lock and Tag Out procedure (“2.6.4 Isolation and energy
dissipation” on page 36). Move Both Slide Stops On Tail Conveyor Support
Down To the first working position and Insert locating Pins (See Picture Below)

c. Re-start Engine If Required and Activate Auxiliary Controls: Move HC1 D To The
Down Position. Lower Tail Conveyor Into Transport Position: Operate HC3 B.

Locating pin

Slide Stop

Tail Conveyor
Working Position

Transport
Position

Using Either The Radio Or Remote Control Manoeuvre The Machine ON/OFF The Transporter

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

Note! Engine idle rpm on engine start up is sufficient to track the machine onto or off the
transport vehicle. Any higher engine rpm is not recommended.

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3.2.14 Tracking the HCS 3715

Make sure the engine is switched off before selecting the track remote control option. The track
remote selector located on the Control panel, must be in the neutral position as shown below.

Track remote
Selector

Tracking
lights switch

Note! If the engine is not turned off before choosing track remote option, then the on/off
button on the relevant remote needs to be reset.

Note! Front and rear facing lights are provide to aid machine tracking in low levels of light.

This equipment must never be tracked on gradients that are more than:

10 degrees left to right or 20 degrees Front to Back.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

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Umbilical Remote Control Movement (Standard)

Connect the end of the Umbilical Remote Cable to the socket as shown above.

a. Start the engine (refer to “5.2.2 Engine Start-up Sequence” on page 92).

b. Position Control Valves HC1 B and HC1 C into the DOWN/PULL POSITION.
Refer to“4.4 Hydraulic Controls (HC)” on page 80.

c. Turn the Track Remote Selector to the umbilical remote control symbol.

d. Turn The Switch On The Umbilical Remote Control To The On Position.

e. the siren will sound and the beacon will flash for seven seconds, in which time the
machine will not be able to be tracked. The siren and beacon will then be on
continuously once the tracking mode is selected.

Operation

1. FORWARD: Push both TRACK SWITCHES

2. REVERSE: Pull both TRACK SWITCHES
3. LEFT/RIGHT: Push/Pull combination of TRACK SWITCHES in opposite
directions
4. Disengage Tracks: Move HC1 B and HC1 C into NEUTRAL position.

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Radio Remote Control Movement (OPTION)

Track remote
Selector

REF DESCRIPTION
1 Radio remote receiver (CE /US)
2 Battery Charger Unit 12 V
3 Replacement Battery
4 Remote Transmitter (Mini) (CE / US)

a. Start the engine (refer to “5.2.2 Engine Start-up Sequence” on page 92).

b. Position Control Valves HC1 B and HC1 C into the DOWN/PULL POSITION.
Refer to “4.4 Hydraulic Controls (HC)” on page 80.

c. Turn the Track Remote Selector to the radio remote control symbol.

d. Turn The Switch On The Radio Remote Control To The On Position.

e. the siren will sound and the beacon will flash for seven seconds, in which time the
machine will not be able to be tracked. The siren and beacon will then be on
continuously once the tracking mode is selected.
Operation
1. FORWARD: Push both TRACK FORWARD BUTTONS
2. REVERSE: Pull both TRACK BACKWARD BUTTONS
3. LEFT/RIGHT: Push/Pull combination of TRACK BUTTONS in opposite directions
4. Disengage Tracks: Move HC1 B and HC1 C into NEUTRAL position.
After tracking the machine onto the transport vehicle make sure all temporary sealing and transport
straps or chains are installed. DO NOT secure by tying down over the tracks. Lashing down is the
responsibility of the driver of the low loader.
Before tracking the machine off the transport vehicle make sure all temporary sealing and transport
straps or chains are removed.

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3.3 Technical Information

Machine: Twin Deck Mobile Screening Unit

Type: HCS 3715
Total Weight (std m/c): 28,000Kg (61,800lbs approx)
Total Weight (Vibrating Grid): 28,000Kg (61,800lbs approx)
Transport Width: 3.0m
Transport Length: 15.0m
Transport Height: 3.36m

3.3.1 Standard Features

• 2 bearing screenbox with true 14’ x 5’ (4267x500mm) on the top deck and 12’ x 5
(3650x1500mm) on the bottom deck.

• Increased screening angle built into bottom deck (patent pending)

• Large throw on screenbox

• Unique folding access walkway around screenbox

• Quick release screen section on high impact zone on top deck

• Engine shut down protection system

• 14’ Remote Control Tipping Grid with Bypass Chute

3.3.2 Options

• Radio Controlled Tracks

• Live Vibrating Grid

• Shredder Unit

• CE Approved Wheel Version

• Stockpiling Conveyor Coupling Facility

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3.3.3 Transport and Working Dimensions

Transport

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Working Dimensions:

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3.4 Identification of Main Units

C D

F
G

a. Feeder Unit

b. Main Conveyor

c. Side Conveyor

d. Tail Conveyor

e. Screen Unit

f. Power Unit

g. Tracks

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3.5 Specification of Main Units

3.5.1 Feeder
Reject Grid
Loading Width (Wings Extended): 4945mm (16’3”)
Grid Bar Aperture: 100mm (4”)
Grid Area: 4480mm x 1700mm (14’6”x 5’6”)
Grid Angle: 30°
Radio Transmitter: 75m Range

Vibrating Grid
Loading Width: 4100mm (13’6”)
Grid Bar Aperture: 100mm (4”)
Grid Area: 3300mm x 1690mm (11’ x 5’6”)
Grid Angle: 0 - 15°

Feed Hopper
Capacity: 8m3 (10.4 cubic yards)

Feed Conveyor
Belt Width: 1050mm (42”)
Belt Type: Ep500/3ply 5mm + 1.5mm covers

3.5.2 Main Conveyor

Belt Width: 1050mm (42”)
Belt Type: Ep 500 /3ply 3mm + 1.5mm covers
Degree of Incline(working): 22° - 24°

3.5.3 Side Conveyor

Belt Width: 650mm (26”)
Belt Type: Ep 250 /2ply 3mm + 1.5mm covers, C15 chevron
Degree of Incline(working): 22°

3.5.4 Tail Conveyor

Belt Width: 1200mm (48”)
Belt Type: Ep 400 /3ply 3mm + 1.5mm covers
Degree of Incline(working): 24° - 26°

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3.5.5 Screen Unit

Screenbox
Width: 4267 x 1500 (14’ x 5’) on the top deck
3650 x 1500 (12’ x 5’) on the bottom deck
Type: Twin deck 2 Bearing
Screen Angles: 24° , 30° , 35°

Screen Meshes
Standard:
Top Deck: 40mm mesh
Bottom Deck: 5mm Speed harps

For other available sizes contact your local dealer

3.5.6 Power Unit

Type: Caterpillar C4 Diesel
Power: 74KW (99hp) @ 2200rpm

3.5.7 Tracks
Track Type: low ground pressure twin track undercarriage
Approximate Speed: 1mph/1.6kph

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4.0 Product Overview

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4.1 Product Overview

This section has been designed to familiarise the user with the various controls and functions of the
individual components that make up the HCS 3715.

Please make sure you read this section carefully.

The sections dealing with the various components of the machine will be cross-referred to in other
sections of this Operations and Spares Manual.

4.2 Major Components

C D

a. Feeder Unit - This is where the raw material is initially fed.

b. Main Conveyor - This main conveyor carries the raw material from the feeder to
the screen box.

c. Side Conveyors - These conveyors transport medium and oversize product away
from the screen box.

d. Tail Conveyor - This conveyor is used to transport the smallest material away
from the screen box.

e. Screen Box - This hydraulically driven component is used to screen raw material
into various sizes.

f. Power Unit - The Power Unit Is Lockable. IT Is The Source Of All The Hydraulic
And Electrical Power Used To Power All Functions Of The Machine.

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4.3 Identification and Operation of the HCS 3715 Controls

4.3.1 Main Control Panel:

The Main Control Panel (MCP) is housed in the Power Unit. Red light indicates a fault or warning.
The two Green lights (E & G Below) must be illuminated before the machine will start.

A) Fuel Contamination

B) Pre-Heat

C) E Stop Switch Pressed

D) Hydraulic Oil Level

E) Fuel Solenoid Relay On

F) Air Filter Restriction

G) E Stop Switches Released

H) Engine Coolant Level

I) Water Temperature (Constant Red) or

Water Level (Flashing Red)

J) Engine Oil Pressure

K) Battery Charge

L) Hour Meter

M) Track Switch

N) Worklamp Switch

O) Pre-Heat Switch

P) Ignition Switch

Q) Water Pump (Optional)

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4.4 Hydraulic Controls (HC)

4.4.1 Standard Machine

These valves are housed inside the power unit. Dependant on what options have been selected, up
to 5 valves will be located here. If the SHREDDER option has been selected the fifth valve on the
extreme left hand side will drive the SHREDDER.

HC1 Main Hydraulic Control Valve Unit:

A B C D

Main Hydraulic Control

Valve Unit

UP
UP HC1

Value Position Function

A
Up Drives feed conveyor & B
HC1 A C
tipping grid D
HC1 A Neutral STOP

HC1 A Down No function NEUTRAL

NEUTRAL HC1
Up Drives main conveyor &
HC1 B
optional vibrating grid
Neutral STOP A
HC1 B B
Down Engage left hand track C
HC1 B D
Up Drive screen box & tail
HC1 C
conveyor
DOWN
DOWN HC1
HC1 C Neutral STOP

HC1 C Down Engage right hand track

A
HC1 D Up Drives side conveyors B
C
HC1 D Down Engage auxiliary controls D

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HC2 Auxiliary Hydraulic Control Valves:

These valves, located at the rear of the machine on the left hand side.

Auxillary Hydraulic
Control Valves

PUSH
PUSH
A B
HC 2

HC 2

NEUTRAL
NEUTRAL
A B

HC 2

PULL
PULL

B
Valve Position Function A

HC2 A Push Unfold mid sized side conveyor HC 2

HC2 A Neutral STOP
HC2 A Pull Fold mid sized side conveyor
Push Raises main conveyor and
HC2 B
screen box
HC2 B Neutral STOP
Pull Lowers main conveyor and
HC2 B
screen box

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HC3 Auxiliary Hydraulic Control Valves:

These valves are located at the rear of the machine on the right hand side.

Auxillary Hydraulic
Control Valves

PUSH
PUSH
A B C

HC 3

NEUTRAL
NEUTRAL
HC 3
A B
C

Valve Position Function HC 3

HC3 A Push Unfold Tail Conveyor End Section
PULL
PULL
HC3 A Neutral Stop
HC3 A Pull Fold Tail Conveyor End Section
A B C
HC3 B Push Lowers Tail Conveyor
HC3 B Neutral Stop
HC 3
HC3 B Pull Raises Tail Conveyor
HC3 C Push Unfold Over size Side Conveyor
HC3 C Neutral Stop
HC3 C Pull Fold Over size Side Conveyor

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HC4 Auxiliary Hydraulic Control Valves:

These valve are located behind the power unit on the right hand side of the machine. Dependent on
what options have been selected additional valves will be located here. If the SHREDDER option has
been chosen this valve will control its raising and lowering. If the VIBRATING GRID option has been
chosen this valve will be used to raise and lower it.

Auxillary Hydraulic
Control Valves

UP
UP

HC 4

NEUTRAL
NEUTRAL

HC 4

Valve Position Function HC 4

HC4 A Up Raise Jacking Legs DOWN

DOWN
HC4 A Neutral Neutral
HC4 A Down Lower Jacking Legs
HC4 B Up Slide Main Conveyor Forward
HC4 B Neutral Stop HC 4
HC4 B Down Slide Main Conveyor Backward

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4.4.2 Machine Fitted with Shredder Option and or Vibrating Grid Option

For Machines fitted with a Shredder or Vibrating Grid option the Hydraulic Control Valves HC1 and
HC4 will change while the valves HC2 and HC3 will remain the same as on a standard machine.

a. HC1 Main Hydraulic Control Valve Unit

If the shredder option is selected then an extra control valve is inserted to the control bank HC1. If
the vibrating grid option is selected on its own only four control valves are needed as before but with
one control valve having an extra function.

Valve Position Function

HC1 X UP DRIVE SHREDDER
HC1 X NEUTRAL STOP
HC1 X DOWN NO FUNCTION
HC1 A UP DRIVES FEED CONVEYOR
HC1 A NEUTRAL STOP
HC1 A DOWN NO FUNCTION
HC1 B UP DRIVES MAIN CONVEYOR & VIBRATING GRID
HC1 B NEUTRAL STOP
HC1 B DOWN ENGAGE RIGHT HAND TRACK
HC1 C UP DRIVE SCREEN BOX & TAIL CONVEYOR
HC1 C NEUTRAL STOP
HC1 C DOWN ENGAGE LEFT HAND TRACK
HC1 D UP DRIVES SIDE CONVEYORS
HC1 D NEUTRAL STOP
HC1 D DOWN ENGAGE AUXILIARY CONTROLS

UP

NEUTRAL

DOWN

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b. HC4 Auxiliary Control Valves (Shredder or Vibrating Grid option).

If Either The Shredder Or The Vibrating Grid Option Is Selected Then An Extra Control Valve Will Be
Inserted At Control Bank Hc4.
UP

NEUTRAL

DOWN

SHREDDER OPTION
Valve Position Function
HC4 A UP RAISE JACKING LEGS
HC4 A NEUTRAL STOP
HC4 A DOWN LOWER JACKING LEGS
HC4 B UP SLIDE MAIN CONVEYOR FORWARD
HC4 B NEUTRAL STOP
HC4 B DOWN SLIDE MAIN CONVEYOR BACKWARD
HC4 C UP RAISE SHREDDER
HC4 C NEUTRAL STOP
HC4 C DOWN LOWER SHREDDER
VIBRATING GRID OPTION
Valve Position Function
HC4 A UP RAISE JACKING LEGS
HC4 A NEUTRAL STOP
HC4 A DOWN LOWER JACKING LEGS
HC4 B UP SLIDE MAIN CONVEYOR FORWARD
HC4 B NEUTRAL STOP
HC4 B DOWN SLIDE MAIN CONVEYOR BACKWARD
HC4 C UP RAISE VIBRATING GRID
HC4 C NEUTRAL STOP
HC4 C DOWN LOWER VIBRATING GRID

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c. HC4 Auxiliary Control Valves (Shredder AND Vibrating Grid option)

If both the Shredder and the Vibrating Grid option are selected then two extra control valves will be
inserted at control bank HC4.
UP

NEUTRAL

DOWN

Valve Position Function

HC4 A UP RAISE JACKING LEGS
HC4 A NEUTRAL STOP
HC4 A DOWN LOWER JACKING LEGS
HC4 B UP SLIDE MAIN CONVEYOR FORWARD
HC4 B NEUTRAL STOP
HC4 B DOWN SLIDE MAIN CONVEYOR BACKWARD
HC4 C UP RAISE VIBRATING GRID
HC4 C NEUTRAL STOP
HC4 C DOWN LOWER VIBRATING GRID
HC4 D UP RAISE SHREDDER
HC4 D NEUTRAL STOP
HC4 D DOWN LOWER SHREDDER

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4.5 Flow Control Valves

The controls of these valves are located underneath HC1. They are identified in the photograph as
follows:.

FC1 FC2 FC3

VALVE FUNCTION
FC1 FEEDER CONVEYOR FLOW CONTROL VALVE
RIGHT HAND SIDE CONVEYOR FLOW
FC2
CONTROL VALVE
LEFT HAND SIDE CONVEYOR FLOW
FC3
CONTROL VALVE

4.6 Umbilical and Remote Radio Controls

4.6.1 Umbilical Control Movement (Standard)

Function: The Umbilical Control is used to control the movements of the machine on its tracks.

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4.6.2 Remote Radio Control Movement (Optional)

Function: The radio control is used to control the movements of the machine on its tracks.

4.7 Tipping Grid Radio Control.

Function: The tipping grid control is used to control the tipping grid.

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5.0 Commissioning and Shut Down

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5.1 Commissioning & Shutdown Safety

Please refer to “ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of this
manual for additional information on safe operation, maintenance and repair of the machine. To
make sure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work
on the equipment or making any adjustments. Do not attempt operation, maintenance or repair with
out first consulting all pertinent safety information.

5.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the area of the machine

5.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment. Refer to “2.2.3 Personal

protective equipment” on page 28.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine
• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

5.1.3 When carrying out maintenance or adjustment

• Implement the Lockout and Tag Procedure. Refer to “2.6.4 Isolation and energy
dissipation” on page 36.

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5.2 Commissioning
Read and follow all instructions concerning set up of your HCS 3715. Failure to do so may
result in damage to the machine, may result in serious injury or death and my invalidate
manufacturer’s warranties.

The following instructions assume transport of the HCS 3715 from a low loader-type ve-
hicle in close proximity to the job site; if the machine is transported in a different manner,
contact the manufacturer for additional set up instructions.

It is recommended that set up of the HCS 3715 be carried out by a representative of Atlas
Copco Powercrusher or by trained and authorised representative of the dealer.

5.2.1 Preparation for Machine STARTUP

SURFACE PREPARATION:

The HCS 3715 is designed for operation on a solid, level surface. It is important that the machine is
placed on solid ground that must be capable of carrying the weight of the machine and that the
machine is placed on level ground. An appropriate site must be identified prior to delivery and
unloading of the machine.

This equipment must never be tracked on gradients that are more than:

10 degrees left to right or 20 degrees Front to Back.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

VISUAL INSPECTION:

Before powering up the engine a visual inspection of the HCS 3715 should be performed.
Inspection should Make sure that (1) all safety equipment is installed and functioning
properly; and (2) any loose items delivered with the HCS 3715 have been secured or
removed from the machine.

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5.2.2 Engine Start-up Sequence

The operator must be fully trained in the operation of this equipment. When tracking, the operator
must be in a position to have an all round view of the operation. A additional supervisor should assist
where this is not possible. Make sure the site is clear of non essential persons. Erect barriers around
the area and post warning signs where site conditions warrant this. Make sure the tracking alarm
makes a clear sound.
This equipment must never be tracked on gradients that are more than: 10
degrees left to right or 20 degrees Front to Back. The machine must always be
on flat, solid ground when operating in its normal mode.

a. Make sure all Emergency Stops, refer to “2.6.1 Use of Emergency stop
function” on page 34, are released and that the Engine kill switch on the remote
control is also turned off. (Fig4.3).

Engine Kill Switch Right Back

Left

Front

b. Make sure all hydraulic control levers are in the neutral position. Refer to “4.4
Hydraulic Controls (HC)” on page 80.

c. Make sure the Engine throttle lever is in the idle position.

Engine Throttle Lever

Idle Position

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d. To start the engine, turn the ignition key to the “on” position, as shown at (B).

Preheat engine
switch

Preheat Switch

e. The following warning lights, as shown at (E) will illuminate.

Warning: Do not attempt to start the engine unless the above warning lamps are illuminated.

NOTICE The warning lamps are indicating that monitoring of the engine systems
are currently running. Damage to the engine will result if the engine is
started when the monitoring systems are not operational.

f. Turn the ignition key to the “Start” position as shown at (C). At this point the “Fuel
on” light will illuminate, as shown at (F) and the start delay safety siren will sound.

g. Hold the key in this position for seven seconds until the engine cranks and runs.

h. Release the ignition key immediately after the engine starts. The ignition key
should return to position D (ON).

Note! As soon as the engine has started the “Oil” light and “Battery” light will go out. Only the
“Fuel on” light and the “Engine Run” light will be illuminated when the engine is running,
as shown at (G). If any other lights illuminate when the engine is running, this indicates
a fault.

i. To stop the engine return the key to the neutral position, as shown at (A).

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5.2.3 Cold Weather Starting

WARNING Do not use aerosol starting aids, such as ether. The use of aerosols will
result in an explosion and personal injury.

a. Move the throttle lever to the full throttle position

Engine Throttle Lever

Full throttle position

b. Engage and hold the PREHEAT switch to the ON position for 6 seconds.

Note! if the pre heat indicator is not shown or is flashing on and off then contact Atlas Copco
Powercrusher.

c. Turn the ignition key to the “Start” position as shown at (C). At this point the “Fuel
on” light will illuminate, as shown at (F) and the start delay safety siren will sound.

d. Hold the key in this position for seven seconds until the engine starts and runs.

NOTICE Do not crank the engine for more than 30 seconds. Allow the electric
starting motor to cool for two minutes before attempting to start the
engine again. Such use could cause damage to the starting motor.

e. Release the ignition key immediately when the engine starts. The ignition key
should return to position D (ON).

Note! As soon as the engine has started the “Oil” light and “Battery” light will go out. Only the
“Fuel on” light and the “Engine Run” light will be illuminated when the engine is running,
as shown at (G). If any other lights illuminate when the engine is running, this indicates
a fault.

f. If the engine does not start repeat steps b. to e.

g. Move the throttle lever to the idle position when the engine is holding steady rpm
and run the engine on idle for over 5 minutes.

h. Operate the engine at low load until all systems reach operating temperature.
Check the guages during the warm-up period.

i. To stop the engine return the key to the neutral position, as shown at (A).

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5.2.4 Tracking the HCS 3715

Make sure the engine is switched off before selecting the track remote control option. The track
remote selector located on the Control panel, must be in the neutral position as shown below.

Track remote
selector

Tracking
lights switch

Note! If the engine is not turned off before choosing track remote option, then the on/off
button on the relevant remote needs to be reset.

Note! front and rear facing lights are provide to aid machine tracking in low levels of light.

This equipment must never be tracked on gradients that are more than:

10 degrees left to right or 20 degrees Front to Back.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

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Umbilical Remote Control Movement (Standard)

Connect the end of the Umbilical Remote Cable to the socket as shown above.

a. Start the engine, refer to “5.2.2 Engine Start-up Sequence” on page 92.

b. Position Control Valves HC1 B and HC1 C into the DOWN/PULL POSITION.
Refer to “4.4 Hydraulic Controls (HC)” on page 80.

c. Turn the Track Remote Selector to the umbilical remote control symbol.

d. Turn The Switch On The Umbilical Remote Control To The On Position.

Operation

1. FORWARD: Push both TRACK SWITCHES

2. REVERSE: Pull both TRACK SWITCHES
3. LEFT/RIGHT:Push/Pull combination of TRACK SWITCHES in opposite directions
4. Disengage Tracks: Move HC1 B and HC1 C into NEUTRAL position. Refer to
“4.4 Hydraulic Controls (HC)” on page 80.

Radio Remote Control Movement (Option)

Track remote
selector

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Ref Description
1 Radio Remote Receiver (CE / US)
2 Battery Charger Unit 12V
3 Replacement Battery
4 Remote Transmitter (Mini) (CE / US)

a. Start the engine, refer to “5.2.2 Engine Start-up Sequence” on page 92.

b. Position Control Valves HC1 B and HC1 C into the DOWN/PULL POSITION.
Refer to “4.4 Hydraulic Controls (HC)” on page 80.

c. Turn the Track Remote Selector to the radio remote control symbol.

d. Turn The Switch On The Radio Remote Control To The On Position.

Operation

1. FORWARD: Push both TRACK FORWARD BUTTONS

2. REVERSE: Pull both TRACK BACKWARD BUTTONS
3. LEFT/RIGHT: Push/Pull combination of TRACK BUTTONS in opposite directions
4. Disengage Tracks: Move HC1 B and HC1 C into NEUTRAL position. Refer to
“4.4 Hydraulic Controls (HC)” on page 80.

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5.2.5 Moving the HCS 3715 to Chosen Site

WARNING
Potential tipping hazard

By not using Engine Speed 1 potential damage to transport could occur.

a. Re-start engine if required, refer to “5.2.2 Engine Start-up Sequence” on page

92.

b. Engage Tracks: Move HC1 A and HC1 B into PULL position. Refer to “4.4
Hydraulic Controls (HC)” on page 80.

c. Activate remote radio control unit

d. Using either the remote or radio control manoeuvre the machine to the chosen site

e. Disengage Tracks: Move HC1 A and HC1 B into NEUTRAL position.Refer to “4.4
Hydraulic Controls (HC)” on page 80.

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5.3 Machine Set-up

5.3.1 Lower Jacking Legs

a. Re-start Engine, refer to “5.2.2 Engine Start-up Sequence” on page 92.

b. Engage Auxiliary Controls: Move HC1 D Into Down Position. Refer to “4.4
Hydraulic Controls (HC)” on page 80.

c. Lower Jacking Legs: Move HC4 A Into DOWN Position until jacking legs contacts
the ground, continue lowering the jacking leg until the next locating hole appears.
Align the hole with the feeder body cut out.

Feeder body
cutout

Locating
Holes

d. Implement the Lock and Tag Out procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.)

e. Re-insert Pins From Jacking Legs Once Suitable Height Has Been Selected to
make sure That the Machine Is stable.

f. Raise Jacking rams until the locating pins is taking the weight of the feeder body.

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5.3.2 Preparing the maintenance Platform for Operation

a. Implement the Lock and Tag Out procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. Slide Out Handrail (A) On The Left And Right Hand Side Of The Machine And Attach
Safety Chain (as shown below)

c. Remove The Locking Pin One On The Left And Right Hand Side, From The
Maintenance Platform Swing Frame

d. Swing Maintenance Platform And Hand Rail Assembly On The Left And Right
Hand Side Out Into Working Position

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e. Release Spring Loaded Lock On The Left And Right Hand Sides

f. Fold Maintenance Platform Bases (B) Down Into Working Position

g. Attach Access Ladder Using The Bolts Provided

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5.3.3 Un-folding Tail Conveyor End Section

a. Remove Pin From Both Sides Of Tail Conveyor End Section (See Picture Below).

b. Re-start engine if required (refer to “5.2.2 Engine Start-up Sequence” on page 92)
and activate auxiliary controls: move HC1 D to the down position.

c. Unfold tail conveyor end section: move HC3 a into push position.

NOTICE WARNING:

Make sure the conveyor belt is located correctly on the rollers so that the
belt will operate without catching any guards. Pay particular attention to the
underside of the tail conveyor

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5.3.4 Raise Screenbox

WARNING:

Never Operate The Vibrating Grid In Transport Position As This Will Cause
Damage To The Machine And Will Void All Warranties

a. Re-start engine (Refer to “5.2.2 Engine Start-up Sequence” on page 92) and
activate auxiliary controls: move HC1 D to the down position

b. Raise Screen Box To Desired Working Angle: Move HC2 B Into Push Position.
Travel slightly past the working position to enable the slide stop and locating pin to
engage the hole required.
SCREENBOX

Working positions

Locating pin

Slide stop
Transport position

c. Implement the Lockout and Tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36. Move Both Slide Stops On Screen Box Support Up To
Desired Position And Insert Pins (See Picture Below)

d. Re-start Engine and Activate Auxiliary Controls: Move HC1 D To The Down
Position. Lower the weight of the screenbox onto the locating pin with HC2 B.

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5.3.5 Raise Tail Conveyor

a. Re-start engine if required (Refer to “5.2.2 Engine Start-up Sequence” on page

92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.

b. Raise Tail Conveyor To Desired Working Angle: Move HC3 B Into Push Position.
Travel slightly past the working position to enable the slide stop and locating pin to
engage the hole required.
Locating pin
Slide stop

Tail Conveyor

Working Positions

Transport position

c. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Move Both Slide Stops On Tail Conveyor Support Up
To Desired Position And Insert Pins (See Picture Below)

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d. Re-start Engine and Activate Auxiliary Controls: Move HC1 D To The Down
Position. Lower the weight of the tail conveyor onto the locating pin with HC3 B.

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5.3.6 Unfold Side Conveyors

Both side conveyors are folded using the same procedure. The only difference being that a different
control valve is used for each side..

DANGER
CRUSH HAZARD

BEFORE OPENING THE SIDE CONVEYORS VISUALLY CHECK THE AREA

AROUND THE MACHINE TO MAKE SURE THERE IS NO ONE STANDING IN A
DANGEROUS POSITION.

The LEFT HAND SIDE conveyor is unfolded using AUXILIARY CONTROL VALVE HC2 A.

The RIGHT HAND SIDE conveyor is unfolded using AUXILIARY CONTROL VALVE HC3 C.

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move Hc1 D To The Down Position. Use
the appropriate HC lever to slightly lift the weight of the locating pin

b. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Remove Transport Pin From The Side Conveyor (See
Picture Below)

c. Re-start Engine If Required and Activate Auxiliary Controls: Move HC1 D To The
Down Position. Open Out Side Conveyor Using Appropriate Control Valve As Set
Out In Previous Page. Go past the required hole position to allow the slide stop
and locating pin to be inserted.

d. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Remove Pin From Slide Stop (See Upper Picture
Below).

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e. Re-locate Slide Stop To Top Position And Re-insert Pin (See Lower Picture
Below)

DANGER

Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before moving the machine, visually check to make sure no one is standing
in the surrounding area.

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5.3.7 Raising the Standard Grid for Operation

a. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position

b. Using The Tipping Grid Receiver Push The Button Marked “manual Raise” And
Hold Until Grid Is Slightly Above The Desired Angle

c. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Pins (Circled In
Picture Below) From Both Sides Of Grid Support Legs

d. Raise Both Grid Support Legs To The Desired Level And Re-insert Pins

e. Restart the engine. Using The Tipping Grid Receiver Push The Button Marked
“manual Lower” To Lower The Grid Onto The Support Stops.

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5.3.8 Raising the Vibrating Grid for Operation (If Applicable)

NOTICE WARNING:

Never Operate The Vibrating Grid In Transport Position As This Will Cause
Damage To The Machine And Will Void All Warranties

a. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Pins (Circled In
Picture Below) From Both Grid Support Legs).

b. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92) and Activate Auxiliary Controls: Move HC1 D To The Down Position.
Raising Grid: Move HC4 C Into The Up Position Until Vibrating Grid Is At The
Desired Angle. Travel slightly past the working position to enable the locating pin
to engage the hole required.

c. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Re-insert Pins Into Relevant
Position (As Shown Below)).

Working Positions

Transport Position
Only

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d. Remove Transport Brackets (As Shown Below At B).

A

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5.3.9 Wing Plates

a. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36). Using A Secure Platform Remove Pins From Slide
Plates And Fold Into Transport Position.

5.3.10 Lowering the Shredder (If Applicable)

a. Re-start Engine If Required (refer to “5.2.2 Engine Start-up Sequence” on page

92) and Activate Auxiliary Controls: Move HC1 D To The Down Position. Raise the
shredder slightly to remove the weight off the locating pin by operating HC4 B/C.

b. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36) Using A Secure Platform Remove Locating Pin From
Shredder Support (If Shredder Is Not In Working/transport Position

Working and
Non -working Position Transport Position

Locating
Pin

c. Restart the engine. Lowering Shredder: Move HC4 B/C (Dependant On Options
Chosen) To The Down Position. Lower The Shredder Fully Until It Rests On The
Diverter Valve

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5.4 Shut Down

It is recommend to operate the HCS 3715 until all material has been removed from the feeder and
crusher chamber and that the conveyors are not producing a stock pile.

WARNING
FLYING MATERIAL HAZARD

There Is Risk Of Serious Injury Or Death Due To Rejected Material.

Keep away from the Feeder area and the conveyor belts areas, only full trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

CRUSH HAZARD

There is Risk of Serious Injury or Death due to Other Heavy Machinery Working
In The Area.

Keep away from the Feeder area and the conveyor belts areas, only fully trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

a. Stop Feeder Conveyor: Move Hc1 A To Neutral Position. Refer to “4.4 Hydraulic
Controls (HC)” on page 80.

b. Stop Main Conveyor (And Vibrating Grid If Fitted): Move Hc1 B To neutral Position

c. Stop The Screen Box And Tail Conveyor: Move Hc1 C To Neutral Position

d. Stop Side Conveyors: Move Hc1 D To Neutral Position

e. If Shredder Option Is Applicable Stop The Shredder: Move Hc1 X To Neutral

Position

f. Stop Engine

5.4.1 Preparing the machine for transport or for the machine to be moved to a
other location

Follow the instructions in section “3.1.2 Machine Preparation for Transport” on page 50.

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5.4.2 Emergency Stop

In the event of an accident or any serious problem with the machine you should press the
nearest emergency stop button.

EMERGENCY STOP:

a. Engage the nearest emergency stop.

Back
Right

Left

Front

b. Switch off the engine and remove the ignition key.

c. Implement the lockout and tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

d. Place ALL hydraulic control levers into the NEUTRAL POSITION. Refer to “4.4
Hydraulic Controls (HC)” on page 80.

e. Only when the machine is fully switched off, should an attempt be made to solve
the problem.

RESTART AFTER EMERGENCY STOP:

a. Make sure that the problem has been solved

b. Make sure that all personnel are clear of the machine.

c. Make sure that all safety devices are correctly fitted and fully functional.

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d. Release all emergency stops.Make sure All Control Valves On Hc1 Are In Neutral
Position

e. Re-start Engine (Refer to “5.2.2 Engine Start-up Sequence” on page 92)

f. Start Side Conveyors: Move HC1 D TO UP POSITION

g. Start The Screen Box And Tail Conveyor: Move Hc1 C To Up Position

h. Start Main Conveyor (And Vibrating Grid If Fitted): Move Hc1 B To Up Position

i. Start Feeder Conveyor: Move Hc1 A To Up Position

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6.0 Operation

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6.1 Operation Safety

Please refer to the “ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of
this manual for additional information on safe operation, maintenance and repair of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the
equipment or making any adjustments. Do not attempt operation, maintenance or repair with out
first consulting all pertinent safety information.

6.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the area of the machine

6.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going to
be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing
the task.

• Assess the hazards to determine what scale of control is required (apply

controls to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.

• Do not wear loose or baggy clothing which could become caught in the
moving parts of the machine

• Do not Climb on The Machine – Always use the Access Points and
Platforms or other approved Access Equipment as required

6.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36..

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6.2 Common Applications

The HCS 3715 may not be modified for use in non-aggregate sorting
applications. Unauthorised modification of the machine, or use of the HCS 3715
in applications other than indicated applications, will void all warranties
provided by the manufacturer. the manufacturer assumes no responsibility for
damage to the HCS 3715, or for personal injuries, resulting from use of the HCS
3715 in unauthorised applications. Risks associated with misuse of the HCS
3715 rest exclusively with the end user.

6.2.1 Construction, Demolition and recycling

• Building, Demolition

• Landfill and road planning

6.2.2 Minerals and Quarrying

• Sand, Gravel

• Coal, Limestone

• Granite, Iron Ore

• Soil, Concrete

6.3 Operating the HCS 3715

Before Commencing general operation it is recommended that the following checks are carried out.

• ENGINE OIL LEVEL (refer to engine manual)

• HYDRAULIC OIL LEVEL, refer to “7.4 Hydraulic System” on page 135.

• DIESEL LEVEL, refer to “7.3.3 Checking Fuel Level, Adding Fuel and Draining fuel
tank” on page 131.

• NORMAL DAILY CHECKS, refer to “7.2 Maintenance Schedule” on page 125.

• VISUAL INSPECTION: ensure that there are no loose bolts and no loose guards and
all safety devices such as EMERGENCY STOPS (refer to “2.6.1 Use of
Emergency stop function” on page 34) are fully functional. Inspect the machine
at least once per shift for damaged or defective components. If any damage is
observed, or if the machine exhibits any malfunction or other unexpected
operation, notify management and your maintenance department immediately.

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You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going
to be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing
the task.

• Assess the hazards to determine what scale of control is required (apply

controls to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.

• Do not wear loose or baggy clothing which could become caught in the
moving parts of the machine

• Do not Climb on The Machine – Always use the Access Points and
Platforms or other approved Access Equipment as required

6.3.1 Starting Up

Set up the exclusion zones with safety barriers and appropriate decals (refer to “2.1.6 Labels on
the product” on page 22)

a. Make sure All Control Valves On HC1 Are In Neutral Position. Refer to “4.4
Hydraulic Controls (HC)” on page 80.

b. Re-start Engine If Required (Refer to “5.2.2 Engine Start-up Sequence” on

page 92)

c. If Shredder Option Is Applicable Start The Shredder: Move HC1 X To Up Position

d. Start Side Conveyors: Move HC1 D TO UP POSITION

e. Start The Screen Box And Tail Conveyor: Move HC1 C To Up Position

f. Start Main Conveyor (And Vibrating Grid If Fitted): Move HC1 B To Up Position

g. Start Feeder Conveyor: Move HC1 A To Up Position

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6.3.2 Adjusting the Main Conveyor Spreader Plate

DANGER
Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

a. Implement the Lock and Tag Out procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36)

b. Loosen the bolts on left and right hand side as shown below

Bolts

Spreader
Plate

c. Adjust spreader plate forward or back one hole at a time. Replace and tighten the
bolts

6.3.3 Adjusting Main Conveyor Position

a. Depending on the Angle of the Screenbox the Main Conveyor can be moved
forwards or backwards on the screen. This is to Make sure that maximum
screening area is always achievable.

b. When the Screenbox is at the highest working angle the Main Conveyor needs to
be moved back fully. To do this move HC4 B into the DOWN position.

c. When the Screenbox is at the lowest working angle the Main Conveyor needs to
be moved forward. To do this the move HC4 B into the UP position.

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6.3.4 Setting the Tipping Grid

1 HC1 A must be in the up position to set the tipping grid.

2 Run the machine at full engine speed.
3 To set the grid raise time press the fourth button of the control panel three times,
holding the button pressed on the third time for the required tipping time.
4 To set the grid lowering time press the third button of the control panel three times,
holding the button pressed on the third time for the required lowering time.

6.4 Tipping Grid Radio Control.

Function:
The TIPPING GRID RADIO CONTROL is used to control the TIPPING GRID.

Activation:
In order to activate the TIPPING GRID RADIO CONTROL you need to press the ON button twice on
the REMOTE CONTROL TRANSMITTOR pictured above. The control will automatically de-activate
after two minutes.

Operation:
PUSH BUTTON 1 to start GRID CYCLE.
The GRID will rise into OPEN POSITION- it will remain open for a short period then it will close.
If you need to STOP the GRID CYCLE push BUTTON 2 (push BUTTON 1 to re-start).

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6.4.1 Adjustment of Flow Controls

Control feeder speed and side conveyor speed: using the flow control valves FC1, FC2 and FC3 set
the speeds of the side conveyors and feeder to the desired level based upon the particular
application.

FC1: FEEDER CONVEYOR FLOW CONTROL VALVE

FC2: RIGHT HAND SIDE CONVEYOR FLOW CONTROL VALVE
FC3: LEFT HAND SIDE CONVEYOR FLOW CONTROL VALVE.

FC1 FC2 FC3

Make sure all conveyor belts are running in alignment if this is not the case refer to belt alignment
section of the maintenance section of this manual.

6.4.2 Engine Speed for Machine Operation

Engine throttle
lever

Run position

Make sure the Engine throttle lever is in therun position when operating the machne

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6.5 Loading the feeder

Loading the mobile unit correctly is essential in order to achieve adequate material delivery to the
screenbox.

6.5.1 Avoid damage to equipment

Never use the bucket to force material into the feeder.
Never drop the material from height into the feeder.
Accidental contact between bucket and feeder may cause vibrations that
can damage the feeder.

• Always lower the bucket close to the feeder when loading.

• Always load at regular intervals. Always fill up the feeder before it is empty.

• Adjust the feeder speed if necessary.

• Avoid interruptions, load material at a steady flow.

• Remove the stockpile of screened material before it reaches discharge conveyor

WRONG! Too low into feeder WRONG! Too high up

Fig. 1

WRONG! Bucket in contact with feeder

CORRECT! Load from behind

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7.0 Maintenance

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7.1 Maintenance Safety

Please refer to “ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of this
manual for additional information on safe operation, maintenance and repair of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the
equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first
consulting all pertinent safety information.

7.1.1 Who is at Risk

• Operators, Maintenance Personnel.

• Subcontractors and anybody else in the area of the machine.

7.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.
• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine.

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

7.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

Only Trained and Authorised Personnel are allowed to carry out maintenance

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7.2 Maintenance Schedule

Only Trained and Authorised Personnel are allowed to carry out maintenance

7.2.1 Power Unit Engine

Months 2000 hrs

Every 6 Months
Every 3 Months
Every 250 Hrs

When Needed
Every 12
1000 Hrs
Weekly

500 Hrs
Daily
POWERUNIT - Engine
After First 50 Hours Carry Out Full Service on
Engine and Hydraulic System
Hydraulic Oil - Check Level a
Hydraulic Oil – Replace (Or As Needed) a a
Fuel Tank Mounts a
Return Line Filter - Change a a a
Oil Suction Filters- Change a a
Engine Coolant Level - Check a
Engine Air Pre-Cleaner* a a
Battery Electrolyte Level a
Outer Air Cleaner Elements * a a a a a
Fuel Water Trap* a a a a a
Engine Oil - Check Level a
Engine Oil - Change a a a a
Engine Oil Filter- Change a a a a
Engine Fuel Filter- Change a a a a
V- Belt Tolerance - Inspect a a a
Engine Fuel Injectors - Inspect a
Engine Valve Clearance - Inspect a
Alternator and starter motor - Inspect a
See Engine Manual For Other Maintenance a

* Daily Inspection Required in Severe Enviroments

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7.2.2 Screen Unit, Feed Hopper, Conveyors and General

Months 2000 hrs

Every 6 Months
Every 3 Months
Every 250 Hrs

When Needed
Every 12
1000 Hrs
Weekly

500 Hrs
Daily
Screen Unit
Screen Mesh Tension a
Screen Mesh Wear a a a
Rubber Cushions - Inspect a a a
Screen Tuning - Inspect a a a
Screen Springs - Inspect a a a
Screen Chutes (Liner) * a a a
Screen Chutes (Liner) * a
Screen Bearing - Grease ** a
FEED HOPPER
Skirting Rubbers - Inspect a
Grid Bolts - Inspect a a a
Grid Bars - Inspect a a
CONVEYORS
Belt Tension a
Belt Alignment a
Belt Condition - Inspect a a a
Tail Drum Bearings - Grease ** a
Drive Drum Bearings - Grease ** a
Wear Plates - Inspect * a a a
Scraper Rubber - Inspect * a a a
* Depending On Material
** See information on greasing

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GENERAL
Ram Seals - Inspect a a
Rollers - Inspect a a
Wear rubber- Inspect a
Replace Gearbox oil on new machines 100 Hours
Check tension on track chains, tighteness a a a a
on track bolts & gearbox oil levels
Replace Gearbox oil a a
Apply Grease to exposed cylinder rods a
General guard condition and effectivenesscheck a

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7.2.3 Testing the Emergency stop function and Battery Isolator

There are four Emergency-Stops on the HCS 3715. Check that each Emergency stop is operating
correctly at the start of each day of work when the machine is empty.

Right Back

Left

Front

ISOLATOR

Check that the Isolator when engaged isolats the battery.

If any Emergency stop or isolator fails to work correctly, DO NOT allow the machine to be operational
these faulty items must be repaired before satrt up of machie.

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7.3 Engine maintenance

When you purchased your HCS 3715 you will have been provided with an accompanying Operation
Manual for the engine. Contact your local dealer to arrange replacement if it is not with the
equipment..

WARNING
SAFETY HAZARD
Risk of personnel Injury and or Damage to the Engine.
No Engine Maintenance should be attempted before fully reading and
understanding the accompanying engine Maintenance Manual.

Please refer to the Engine Maintenance Manual in order to carry out the following important areas of
Engine Maintenance.

• Changing The Fuel Filter

• Checking Engine Oil Level

• Changing Engine Oil

• Changing Engine Oil Filter

• Cleaning/Replacing The Air Cleaner

• Cleaning/Replacing The Air Cleaner Elements

7.3.1 Air Cleaner Maintenance

• If the Air Cleaner Restriction Indicator on the control panel (A) is illuminated the air
filter must be cleaned/replaced. Refer to the engine manual for instructions on the
procedures for maintenance

• Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

• When the filter has been cleaned/replaced the restriction indicator must be reset
by pressing the button (B).

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7.3.2 Battery Maintenance

The battery MUST be inspected on a weekly basis.

WARNING
SAFETY HAZARD

Battery contains corrosive chemicals and stored electrical energy.

Before carrying out any maintenance on the battery, stop the Engine,
disconnect the Ground Cable (-), then disconnect the Positive Cable (+).

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.

a. Maintain Water Level. If your battery has removable vent caps, you should
regularly check the water level and add water when it is low. Always use distilled
water to fill the battery in order to prevent chemicals from contaminating the
battery. Be careful not to overfill the vent wells. The fluid should cover the lead
plates in the battery.

b. Keep Terminals Clean. If dirty or corroded, clean the connections with a scraper
and wire brush.

c. Keep Battery case clean. Keep the top of the battery clean of heavy dirt and oil.

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7.3.3 Checking Fuel Level, Adding Fuel and Draining fuel tank

WARNING
FLAMEABLE LIQUID HAZARD

Fuel is flammable and therefore is easily ignited and fires or explosions can
result.

Smoking and Welding is strictly prohibited while refuelling.

Wear the correct Personal Protective Equipment, refer to

“2.2.3 Personal protective equipment” on page 28.

I
Drain Bung

Checking Fuel
The fuel level of the machine can be checked by viewing the indicator “I” as shown above. It is
recommended that the tank should be filled at the end of every working day.

Adding Fuel

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. The tank is filled by removing the filler cap, funnelling in the fuel until the indicator
“I” is at its highest level and replacing the filler cap.

Draining the Fuel Tank

Note! the diesel tank capacity is approx 400 litres.

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. Remove the filler cap, select a suitable container which can store over 400 litres of
fuel and place it under the Drain Bung.

c. Remove the Drain Bung and allow the tank to fully empty.

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d. Perform any required maintenance on the tank and replace the drain bung before
refuelling and replace the filler cap.

7.3.4 Emptying the Fuel Filter Water Trap

The fuel filter water trap (shown above) needs to be drained when warning light, as highlighted is
illuminated.

WARNING
FLAMEABLE LIQUID HAZARD.
Liquid likely to start a fire if exposed to sparks.
Restrict all other activity until liquid is secured in a suitable container, refer to
“2.9 Safety considerations for maintenance” on page 42.

a. Unscrew the drain bung at the bottom of the water trap and allow the water to
drain out.Make sure that the water in drained into a suitable container.

b. Tighten the drain bung when pure diesel starts to come out.

c. Dispose of waste in accordance to environmental statement.

WARNING
CHEMICAL HAZARD
Diesel fuel is a chemical which should not contact your skin.

Wear the correct Personal Protective Equipment, refer to

“2.2.3 Personal protective equipment” on page 28.

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7.3.5 Special Considerations For Maintenance Or Repair with Welding

Before welding;
You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.

• Turn off Isolator Switch (See Photo Below)

• Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

ISOLATOR

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7.3.6 Shredder Flail Replacement (if applicable)

FLAIL

It is recommended that the flails should be replaced after approximately 35% Wear.
a. Make sure that the shredder is pinned in the raise position. Refer to “5.3.10
Lowering the Shredder (If Applicable)” on page 111.

b. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

c. Remove damaged/worn flails using an appropriate wrench.

d. Fit new flails with an appropriate wrench.

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7.4 Hydraulic System

NOTICE It is essential the Hydraulic System is regularly serviced in accordance with
the Maintenance Schedule. When Maintenance is being carried out on the
hydraulics it is essential that extreme care regarding cleanliness is
practiced. Contamination of the hydraulic System will reduce working life
of hydraulic components and will increase the chances of Hydraulic Motor/
Pump Failure

WARNING
SKIN INJECTION HAZARD
Hydraulic fluid at high pressure can penetrate the skin, causing serious allergic
reaction and even death.

Always use a piece of cardboard to inspect for the signs of suspected leaks.
Never use any part of your body.
If fluid is injected into the skin, you must seek medical treatment immediately.

WARNING Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal
protective equipment” on page 28, when performing any adjustment or
maintenance on the Hydraulic System.

7.4.1 Hydraulic Oil

The hydraulic oil level must be checked on a daily basis. This is done by checking the indicator.

If the indicator is below the Lower Black Line, hydraulic oil must be added.

Indicator

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7.4.2 Hydraulic oil is added as follows:

a. All cylinders that can be retracted should be retracted. Make sure that the
machine is on level ground.

b. Implement the Lock out and Tag Procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36) and Wear the correct Personal Protective Equipment
(refer to “2.2.3 Personal protective equipment” on page 28)

Access Lid

Latch

c. Lift open the Access Lid and engage the latch in order to secure the lid in an
upright position. Slowly unscrew Hydraulic Breather Filter (HT3) to release any
build up of pressure in the tank.

d. Make sure that the Return Line Filters (HT4), and the area around the return line
filters, are clean. If there is dust or dirt, use a clean cloth to remove.

e. Unscrew the filter cover bolts and remove the cover of the Return Line Filter
(HT4). Hydraulic oil must be added through the uncovered Return Line Filter, to
make sure the hydraulic oil is filtered on entering the tank.

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f. Fill the tank to the Upper black markings on HT1. Make sure that the correct grade
of Hydraulic Oil has been selected (see Maintenance section)
HT7
HT3 HT4
HT2

HT1

HT8

HT5
HT6

Tank Inspection Plate (HT8) can be

accessed through the Powerunit door.

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7.4.3 Changing the Hydraulic Oil

NOTICE In the event of hydraulic pump or hydraulic motor failure, hydraulic oil and
all hydraulic filters must be renewed in order to avoid contamination of the
hydraulic system.

a. All cylinders that can be retracted should be retracted.

b. Implement the Lock Out and Tag Procedure refer to “2.6.4 Isolation and energy
dissipation” on page 36.

Wear the correct Personal Protective Equipment

(refer to “2.2.3 Personal protective equipment” on page 28)

(The Hydraulic system will drain more efficiently when the Hydraulic Oil is at a normal operating
temperature. It is therefore recommended that the Hydraulic Oil is changed following a period of
operation.)

c. Slowly unscrew the Hydraulic Breather Filter (HT3) to release any build up of
pressure in the tank.

Note! the hydraulic oil tank capacity is approx 630 litres.

It is recommended that the Hydraulic Tank Be flushed out with clean Hydraulic Oil to rid the tank of
all contaminants. Dispose of waste in accordance to environmental statement.

d. Drain the oil into a suitable container by removing the Drain Bung (HT5). Dispose
of waste in accordance to environmental statement.

e. Re-attach the Drain bung (HT5).

f. Remove the Tank Inspection Plate (HT8). [If the tank has no inspection plate fitted
remove the access panel (HT2) and continue with points g - m below.]

g. Unscrew and remove the Suction Filter (HT6)

h. Fit new Suction Filters (HT6)

i. Clean mating surface and re-attach the tank inspection plate (HT8). [Or access
panel (HT2) if required.]

j. Change Return Line Filter (HT4) (see next page).

k. Re-fill the tank with clean Hydraulic Oil between the upper and lower black lines
on HT1. Refer to “7.4.2 Hydraulic oil is added as follows:” on page 136.

l. Re-attach the Hydraulic Breather Filter (HT3).

m. Start the machine and after a short period of operation re-check the hydraulic oil
level, refer to “7.4.1 Hydraulic Oil” on page 135.

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7.4.4 Changing The Return Line Filter

Cover Combined Screw-Washer

Removal Handle

Filter Element

a. Implement the Lock Out and Tag Procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36) and Wear the correct Personal Protective
Equipment (refer to “2.2.3 Personal protective equipment” on page 28).

b. Clean the Return Line Filter Cover and surrounding area.

c. Slowly unscrew the Hydraulic Breather Cap (HT 3) to release any build up of
pressure in the tank.

d. Unscrew the filter cover bolts and remove the cover.

e. Lift out the filter element using the lifting handles.

f. Wash out the filter cover and dry with an air hose.

WARNING
SKIN INJECTION HAZARD
Fluid at high pressure can penetrate the skin, causing serious allergic reaction
and even death.
Wear the correct Personal Protective Equipment, refer to
“2.2.3 Personal protective equipment” on page 28.

If fluid is injected into the skin, you must seek medical treatment immediately.

g. Re-fit the new filter.

h. Replace cover and tighten bolts.

i. Re-attach the Hydraulic Breather Filter OR replace if neccessary (HT3).

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7.5 Screen Maintenance/Mesh Replacement

You must always perform a local risk assessment before starting a task. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are
performing the task.

• Assess the hazards to determine what scale of control is required (apply

controls to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.

• Do not wear loose or baggy clothing which could become caught in the
moving parts of the machine

• Do not Climb on The Machine – Always use the Access Points and
Platforms or other approved Access Equipment as required

Only Trained and Authorised Personnel are allowed to carry out maintenance
Chain (C)

When the SCREEN BOX is set at the desired screening angle

a. Implement the lock out and tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. Adjust the chain (C) to the optimum length. (200mm above Mesh)

After the initial 10 hours of operation the following checks should be carried out;

• Visually check the Screen Meshes for clogging, damage and tension.

• Check and tension the Clamping Bolts (A) where necessary.

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7.5.1 Top Deck Mesh Replacement

Only Trained and Authorised Personnel are allowed to carry out maintenance IT IS
RECOMMENDED THAT THE SCREEN BOX BE RAISED AND PINNED IN ITS
MAINTENANCE ANGLE FOR TOP DECK MESH REPLACEMENT.
(Refer to “5.3.4 Raise Screenbox” on page 103)

SCREENBOX

Maintenance
position

Locating pin

Slide stop

There are 3 mesh sections on the top deck. The same procedure is used for each of them.

a. Implement the lock out and tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

b. Using an appropriate wrench, remove the bolts (A) holding the mesh clamps in
position
Clamping Bolts (A) Rubber Curtain (B)

Chain (C) Cushion Rubbers (D)

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c. Remove the clamps and remove the mesh (B)

d. Clean any excess material from the Screen Box sides and the Cushion Rubbers
(D).

e. Place the new mesh on the screen and centralize it taking care not to let it slip

f. Fix one of the clamps onto the screen, starting with the bottom nut and bolt or
wedge. Do the same on the opposite side. When tightening the remainder of the
nuts and bolts/wedges move from one bolts/wedges to the corresponding bolt/
wedge on the opposite side.

g. Check to make sure mesh function is sufficient that the mesh is tight on

Repeat the Above procedure for the remaining meshes.

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7.5.2 Bottom Deck Mesh Replacement

Only Trained and Authorised Personnel are allowed to carry out maintenance IT IS
RECOMMENDED THAT THE SCREEN BOX BE RAISED AND PINNED IN ITS
MAINTENANCE ANGLE FOR TOP DECK MESH REPLACEMENT.
(Refer to “5.3.4 Raise Screenbox” on page 103)

SCREENBOX

Maintenance
position

Locating pin

Slide stop

Rubber flap (D)

see zoom below

Fixed member (E) (A)

(C)

(B)

There are two mesh sections on the bottom deck. The same procedure is used for each of them.

a. Fully lower the Tail Conveyor in order to obtain the greatest space between the
Screen Box and Tail Conveyor.

b. Implement the lock out and tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

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c. Using an appropriate socket and extension, loosen the tensioning devices (A) on
both sides of the Screen Box body. Remove the locating pin (B) and Remove the
TENSION BAR (C) from the Screen Box.

d. Remove the mesh via the rubber flap (D).

e. Clean any excess material away from the clamping area.

f. Hook the new speed harp over the fixed member (E) and the Tension Bar. Push
the Tension Bar back into position.

g. Tension the mesh by turning the tensioning bolts clockwise. When tensioning,
alternate between the tensioner on both sides ensuring an even Mesh tension.

7.5.3 Vibrating Grid Maintenance/Mesh Replacement

TOP DECK BOLTS - 3 rows per deck

Only Trained and Authorised Personnel are allowed to carry out maintenance Top
Deck Vibrating Grid Replacement

a. Fully lower the Vibrating Grid.

b. Implement the lock out and tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

c. Using an appropriate wrench remove the bolts holding the Top Deck Grid in
position.

d. Remove the Grid using appropriate lifting equipment.

e. Clean any excess material from the vibrating grid.

f. Place new Grid on the top deck and re-bolt.

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Only Trained and Authorised Personnel are allowed to carry out maintenance
Bottom Deck Vibrating Grid Replacement

There are 2 mesh sections on the bottom deck. The same procedure is used for each of them.
a. Fully lower the Vibrating Grid. (Refer to “3.2.3 Lowering Vibrating Grid for
Transport” on page 57)

b. Implement the lock out and tag procedure (refer to “2.6.4 Isolation and energy
dissipation” on page 36)

c. Using an appropriate wrench, remove the bolts (A) holding the mesh clamps in
position.

Bolts A - row for each deck Front Beam

d. Remove the clamps and mesh.

e. Clean any excess material from the vibrating grid sides and cushion rubbers.

f. Hook new mesh over the front beam and re-clamp.

g. Tighten up clamp plates until mesh is fully tensioned.

Repeat the Above procedure for the remaining mesh.

After the initial 10 hours of operation the following checks should be carried out;

• Visually check the SCREEN MESHES for clogging.

• Check and tension the CLAMPING BOLTS (A) where necessary.

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7.6 Track Maintenance

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.

• Make sure the terrain the machine is working on is firm enough to adequately
support the machine.

• Make certain the machine is tracked at least 10m in either direction on a

daily basis to minimise risk of track chain seizure.

• Make sure the track systems are free from debris before moving the machine.

• Make certain the tracks are not frozen to the ground before moving the machine.

NEVER
• Attempt to track the machine if there is any build up of material around the tracks
and drive sprocklets.

• Attempt to track the machine if the tracks are frozen to the ground.

• Push or tow the machine when unable to free itself.

Working Conditions:
If your machine will be working in materials which cause corrosion to carbon steel you must replace
standard tracks with lubricated tracks to avoid seizure of the track joints. Lubricated tracks are
available as an optional extra from new or as a retrofit for customers entering adverse working
conditions.

7.6.1 Checking the Track Tension

Track cover plate Track sag

Track Cover Plate

a. Track the HCS 3715 a minimum of 2 metres in a forward direction on level ground.

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b. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.

c. Measure the sag on the top part of the track on the longest section of unsupported
track as shown.

The sag should be between 5mm and 15mm. IF the measured track sag is above 15mm the tracks
need tightened; and if the track sag is below 5mm the tracks need loosened.

7.6.2 Tighten the Tracks

1. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36. Loosen the two screws and remove the aperture cover
from the side of the track frame.
2. Make sure the grease fitting and grease gun adaptor are clean; ingress of dirt into
the grease fitting can result in failure.
3. Connect a grease gun to the grease fitting and add grease until the track tension
is within the specified values given in the previous section.
4. Drive 50 metres forward and 50 metres backwards and repeat the above
procedure if the track slackens.
5. Replace the aperture cover.

7.6.3 Loosen the Tracks

1. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36. Loosen the two screws and remove the aperture cover
from 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 traces of extruded grease. Be
sure not to overtighten the grease fitting.
4. Replace the aperture cover.

If tracks fail to loosen after the grease fitting has been loosened: DO NOT attempt to
remove the tracks or disassemble the track 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!

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7.6.4 Track Drive Units

The first oil replacement for the gearbox is to be carried out after 100 hrs. Thereafter replace the oil
every 1000 hrs or at least once a year. The oil level should be checked every 250 hrs or every month
– whichever comes first.
a. Oil Filling

• Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and
energy dissipation” on page 36.

• To fill, track the machine until the gearbox casing is level with a plug
positioned at 12 o’clock as shown below.

• Unscrew the 2 plugs and fill from the upper plug until oil reaches the level of
the lower hole.

Oill Fill

Maximum level

b. Oil Draining

• Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and
energy dissipation” on page 36.

• 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 approved way.

Venting

Drain port

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7.6.5 Conveyor Belt Maintenance

WARNING
NIP POINT HAZARD
Conveyor belt tension can only be VISUALLY checked with the conveyor belt
running. Adjustment of conveyor belt tension should only be attempted by
trained and authorised personnel. If you have any concerns regarding
training on the procedure, or the performance of the adjustments themselves,
contact your distributor or the manufacturer. DO NOT attempt to adjust
conveyor belt tension without first undertaking proper instruction and/or
obtaining adequate supervision.

Tensioning the Conveyor Belts

Adjusters on main conveyor Adjusters on tail conveyor

Adjusters on side conveyor Adjusters on feeder conveyor

Before tensioning the belts Make sure that they are free from obstructions and that any excess
material is washed away. If any rips/tears are discovered do not operate the machine until the belt
has been repaired.

1. Implement the LOCKOUT and TAG PROCEDURE, refer to “2.6.4 Isolation and
energy dissipation” on page 36.
2. Remove the appropriate guards.
3. Loosen bearing bolts on both bearings of the idler drum just enough to allow
movement for adjustment.
4. Replace and secure guards.
5. Start the engine and start the conveyor (please refer to operation section).
6. Implement the LOCKOUT and TAG PROCEDURE, refer to “2.6.4 Isolation and
energy dissipation” on page 36.
7. Tighten both belt adjusters evenly until slippage stop.

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8. Implement the LOCKOUT and TAG PROCEDURE, refer to “2.6.4 Isolation and
energy dissipation” on page 36.
9. Remove appropriate guard and re-tighten the bearing bolts.
10. Replace guards and correctly secure in position.

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7.6.6 Tracking the Belts

There are several factors that can have an effect on the tracking of the conveyor belts:
• Misalignment of trough roller sets,

• Misalignment of return rollers

• AND / OR incorrectly adjusted Drum Bearings.

Conveyor plan
Conveyor Plan Conveyor section
Conveyor Section

90 °
X

NOTICE If a conveyor belt is tracking off to the left or right the situation should
be remedied immediately. If action isn’t taken the belt life will be shortened
and through put wont be as efficient due to spillage.

DANGER
WORKING AT HEIGHT HAZARD

Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

Required Action;
1. Implement the Lockout and Tag Procedure “2.6.4 Isolation and energy
dissipation” on page 36.
2. Check alignment of the trough sets and return rollers insuring that they are
mounted at 90 Degrees to the conveyor frame about the central axis.

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3. Run appropriate conveyor and observe the way the belt is tracking.

WARNING
NIP POINT HAZARD

Conveyor belt tracking can only be visually checked with the conveyor belt
running. Adjustment of conveyor belt tracking should only be attempted by
trained and authorised personnel. If you have any concerns regarding training
on the procedure or the performance of the adjustments themselves, contact
your distributor or the manufacturer. DO NOT attempt to adjust conveyor belt
tracking without first undertaking proper instruction and/or obtaining adequate
supervision.

IF THE BELT IS TRACKING TO THE LEFT ADJUST THE LEFT ADJUSTER. IF THE BELT IS
TRACKING TO THE RIGHT ADJUST THE RIGHT ADJUSTER.

4. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.
5. Remove the appropriate conveyor guards.
6. Loosen the appropriate bearing bolts.
7. Re- fit and secure the guard.
8. Restart the machine and run the conveyor.
9. Adjust the idler drum adjuster gradually until the belt is running in alignment.
10. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 36.
11. Remove the guard and re-tighten the bearing bolts.
12. Re- fit and secure the guard.

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7.6.7 Maintenance Data

a. Adjustment Data

Engine Speed: 2200rpm

Screen Shaft: Speed 990 (+/-5 rpm)

b. Fluid Capacities

Engine Coolant: Caterpillar - 16.0 ltr (3.5 gal)

Engine Oil including Filter: Caterpillar - 17.0 ltr (3.7 gal)
Hydraulic Tank: 630ltr (138 gal)
Fuel Tank: 400ltr (88 gal)
Feeder Gearbox Oil: 0.8ltr (0.175 gal)
Track Gearbox Oil (each): 3.0ltr (0.65 gal)

c. Pressures

Hydraulic System: 210bar (3000 psi)

Feeder system: 175bar (2500 psi)
Hydraulic hoses: 215bar (3100 psi)

7.6.8 Hydraulic Oil Requirements for HCS 3715 Machines

• Basic Requirements for the Hydraulic Oil Quality

• viscosity recommended operating range – 12-60 cSt.

• min. viscosity 12 cSt at operating temperature.

• max. viscosity 1000 cSt at starting temperature (Intermittent).

• Cleanliness level - ISO 4406 Class 22/18/13

Unless otherwise mentioned, the factory fill oil is a special hydraulic oil of ISO VG 46 class. The max
allowable operating temperature with this oil type is about +80°C (175°F) and min. allowable starting
temperature is about -20°C(-5°F), which makes it suitable for use all year round in most operating
conditions. Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 46

• BP Energol SHF 46

• Esso Univis N 46

• Shell Tellus Oil T 46

• Mobil DTE 15

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d. Winter Conditions.

In cold climate conditions, when the operating temperature of the oil stays below +60°C (140°F), the
use of a special hydraulic oil of ISO VG 32 class is recommended the max.allowable operating
temperature with this oil type is about +65°C (150°F) and min. allowable starting temperature is about
-30°C (-20°F). Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 32

• BP Energol SHF 32

• Esso Univis N 32

• Mobil DTE 13

• Shell Tellus Oil T 32

e. Summer Conditions.

In hot climate conditions, when the ambient temperature exceeds + 35°C (95°F), the use of a special
hydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature with
this oil type is about +90°C (195°F) and min. allowable starting temperature is about -10°C (14°F).

Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 68

• BP Energol SHF 68

• Mobil DTE 16

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7.6.9 Lubricants and Fluids

Component International Specification Sample

API CD CF Shell Fortisol 15W/40

Engine
CCMC C4 Shell Rimula X 15W/40

Hydraulics - Up to 30°C ISO VG 46 Shell Tellus 46

Hydraulics - Above 30°C ISO VG 68 Shell Tellus 68

Shell safe anti - freeze

BS 6580
Anti - Freeze (Ethylene gylcol based)
ASTM D3306 - 74
Shell save premium anti - freeze

General grease Shell Alvania EP2

Screen bearing grease Shell Retinax EP2

Gearbox SAE 80W/90 (GLS) Shell 80W/90

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HCS 3715 Maintenance

7.6.10 Greasing Schedule

Description Frequency Quantity

1) Feeder Conveyor Tail Drum Bearing (Lh/Rh) 250 Hours 7g

2) Feeder Conveyor Drive Drum Bearing (Rh) 250 Hours 7g

3) Main Conveyor Tail Drum Bearing (Lh/Rh) 250 Hours 7g

4) Main Conveyor Drive Drum Bearing (Lh/Rh) 250 Hours 7g

5) Tail Conveyor Tail Drum Bearing (Lh/Rh) 250 Hours 7g

6) Tail Conveyor Drive Drum Bearing (Lh/Rh) 250 Hours 16g

7) Screen Bearings (Lh/Rh) 40 Hours 7g

8) Lh Side Conveyor Tail Drum Bearings (Lh/Rh) 250 Hours 7g

9) Lh Side Conveyor Drive Drum Bearings (Lh/Rh) 250 Hours 7g

10) Lh Side Conveyor Pivot Boss and Block 250 Hours 7g

11) Rh Side Conveyor Tail Drum Bearings (Lh/Rh) 250 Hours 7g

12) Rh Side Conveyor Drive Drum Bearings (Lh/Rh) 250 Hours 7g

13) Rh Side Conveyor Pivot Boss and Block 250 Hours 7g

14) Vibrating Grid Bearings (Lh/Rh) 40 Hours 16g

15) Apply Grease to Exposed Cylinder Rods When needed

The frequency of the schedule above is recommend for normal working conditions. the frequency
should change if the machine is operating in

• conditions which deviate in temperatures,

• environments with excessive contamination

• excessive operating temperatures

Visually inspect all bearings daily.

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Maintenance HCS 3715

7.6.11 Grease Nipple Locations

Grease Points (1), (2) Grease Points (3), (4) - (LHS)

Grease Points (5), (6) - (LHS) Grease Points (7) - (LHS/RHS)

Grease Points (8),(9),(11),(12) - (LHS/RHS) Grease Points (10), (13) - (LHS/RHS)

Grease Points (14) - (LHS) Grease Points (15) - (RHS)

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HCS 3715 Maintenance

7.6.12 Care of chrome

The following information should be used in order to maximise the life of the Chrome Rods. All
hydraulic rods must be greased to protect against corrosion.A full protective coverage of the chrome
is required.

The grease must be applied at the following stages:

• Assembly

• Before Storage and Transportation

• After Initial Setup

• Every 100 Hours thereafter (the responsibility of the customer)

The greases below are recommended by the manufacturer:

1. Cazar K Adhesive Water Resistant Grease
2. Shell Alvania Grease Wk2

Cleaning

Nitric Solvent (without Chlorate) is recommended in necessary cleaning of Chrome. The use of
anything else may harm or reduce the protection of the chrome.

WARNING
SAFETY HAZARD
Nitric Solvents contains corrosive chemicals.
Do not allow contact with any exposed body parts.
Wear the correct Personal Protective Equipment (Refer to “2.2.3 Personal
protective equipment” on page 28).

Implement the lock out and tag procedure

(Refer to “2.6.4 Isolation and energy dissipation” on page 36) before starting this
operation.

*Only clean the chrome if contaminated

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 HCS 3715

8.0 Trouble Shooting and Warranty

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8.1 Trouble Shooting Safety

Please refer to “ 2.0 Safety Section - Safety and Environmental Instructions” on page 17 of this
manual for additional information on safe operation, maintenance and repair of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the
equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first
consulting all pertinent safety information.

8.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the area of the machine

8.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.
• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required.

8.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 36.

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Trouble Shooting and Warranty HCS 3715

8.2 Trouble Shooting Table

Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

Damaged electrical Cables Repair or replace the cable

Turn the Isolation switch to the

Isolation switch is in the
ON position (make sure it is NOT
Off position
tagged out)

No charge in the battery Replace or recharge the battery

Does NOT crank
Starter or alternator
Repair or replace the part/s
malfunction

Disengage the Emergency Stop

Emergency Stop engaged (make sure there is no problems
first)

Check the fuel tank level re-fill as

No fuel in the engine necessary check the pipes for
leaks repair or replace

Blocked filters:
Air Clean or replace the filters as
Oil necessary.
Starting/Running Fuel

The engine cranks but will NOT The glow plugs or the
Replace or repair as necessary
start or shuts down injectors malfunction

Check for leaks repair as

Oil level low
necessary. Refill engine with oil

Make sure the oils and Fluids are

Extreme - Temperature
correct for the temperature
conditions
conditions

The Battery is NOT fully

Replace or recharge the battery
charged

Check for a blockage in the

High Oil pressure
system

Blocked Filters:
Loose’s power or low RPM Air Clean or replace the filters as
Oil necessary.
Fuel

Over heating see “Over heats quickly”

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Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

Check hydraulic fluid system for

Hydraulic Fluid low leaks repair as necessary. Refill
hydraulic fluid

Check engine for leaks repair if

Engine Oil level Low
necessary. Refill the oil

Check all filters and Fans,

Starting/Running Over heats quickly Blockages
replace and clean as necessary

Check the wiring and the sensor

Sensor malfunction
replace as necessary.

Check the coolant system for

Coolant level low leaks repair if necessary. Refill
coolant level.

The engine is OFF Start the machine

The Remote/Controller See “Remote Controls/Control

Failure Panels”

Motor Ceased Repair or replace as necessary

Make the machine is in track

Does NOT track / or one of the mode (Set the switch to tracks
Tracks does NOT move No hydraulics ON). Check for leaks, or
damaged components repair or
replace as necessary

Solenoid failure Repair or replace

Tracks plates/chain
Replace or repair
damaged
Tracking the Machine
Check the legs for damage
Stabilising legs down repair or replace if necessary. Lift
UP the legs

Slow or NON uniform speed The track tension is low Tighten the tracks

Check for leaks and refill as

Low hydraulic pressure/
necessary. Check hydraulic
flow
system

One of the tracks tension Tighten the Track to the correct

is not correctly set tension
Tracks do NOT move at the
same speed Check the hoses, pumps, valves
Hydraulic system failure and connections for leaks or
damage replace as necessary

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Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

Check the filters, hoses, valves,

pumps for damage. Make sure
Hydraulic system failure
the hydraulic fluid above the
minimum level refill if necessary

The engine is OFF Start the engine

The locating pins or other

locking equipment is still Remove the pins or equipment
Do NOT fold/Do NOT lift up or installed
down The equipment is damage remove the blockage or repair
or blocked. the equipment

Check the valve block, hoses

Lever Failure and lever for damage replace or
repair

Check the hoses, the

Hydraulic Ram Failure connections and the seals, repair
or replace as necessary

The engine is OFF Turn the machine ON

Conveyors/Stabilising Check the filters, hoses, valves,

legs pumps and the motors for
Hydraulic system failure damage. Make sure the
The belt does NOT move
hydraulic fluid above the
minimum level refill if necessary

The belt is too loose Tighten the belt

The belt is blocked or Remove the blockage or align

stuck the bet as necessary

Remove the blockage or repair

Blocked or stuck
as necessary
Fold/Lift slow or at a NON
uniform speed/The belt moves Check the filters, hoses, valves,
slow or at a NON uniform pumps and the motors for
Hydraulic system
speed damage. Make sure the
malfunction
hydraulic fluid above the
minimum level refill if necessary

The belt tension is low Tighten the belt

The belt is slipping The rollers/bars are
Replace or repair as necessary
damaged

The locating pins or

Rocking/moving while in Installed the locating pins or
locking equipment is not
operation. locking equipment
installed

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Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

The bearing are damaged Replace the bearings

Conveyors/ The belt tension is too high Reduce the tension in the belt
maintenance The belt is making too much
platforms noise The belt is scraping
Align the belt as necessary
Stabilising legs against the sides

There is a blockage Remove the blockage

The machine is NOT set

Set the Machine for operation
for operation

No Material on the Feeder Load material on the machine

NO or little material is output
Check the feeder, screen box
Blocked and conveyors for blockages.
Remove the blockage

The screen box is blocked Remove the blockage

The Feeder is full of material
The screen box is OFF See “The screen box”

The conveyor speed is too

Increase the conveyor speed
low

The material slips/moves down The product is too light or

Use a chevron belt
the conveyors slippery

Adjust the angle down as

Conveyor angle is too high
necessary

Move the machine to level

The ground in not level
ground or make the ground level
Loading the Machine
Move the machine to firm ground
The ground is not firm or make the ground more
The Machine is unstable or suitable
rocking from side to side Set the stabilising legs on firm
The Stabilising legs are
level ground to help support the
NOT set correctly
machine

Uneven or excessive
Load the machine correctly
loading

The screen box does NOT Clear the blockage check both
The screen box is blocked/
output material or small output levels and make sure the screen
or OFF
of the material box is ON

The screen box mesh is Replace the mesh or clear the

damaged or blocked blockage

The other conveyors are Make sure the conveyors are set
Only exits from one conveyor
OFF for operation

No smaller product is
N/A
loaded

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Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

The engine is OFF Turn the engine ON

The screen box is off Turn the screen box ON

Does NOT vibrate Check the filters, hoses, valves,

pumps and the motors for
Hydraulic system Failure damage. Make sure the
hydraulic fluid above the
minimum level refill if necessary

The bearings are damaged Replace the bearings

The screen box is

Repair the screen box
damaged
Excessive noise
The screen box is blocked Remove the blockages
The screen box
Check all the springs and
The springs are damaged
replace as necessary

Check the filters, hoses, valves,

pumps and the motors for
Hydraulic system
damage. Make sure the
Malfunction
hydraulic fluid above the
minimum level refill if necessary
Vibrates slow/non uniform
speed Make sure the system is greased
The drive shaft system correctly and inspect the parts for
malfunction damage,. Repair or replace as
necessary

The screen box is blocked Remove the blockage

The machine is OFF Start the machine

The batteries in the remote

Recharge the batteries
are not charged

The remote control is NOT

programmed to the Refer to 5.5.1
machine.
Remote Controls/
Umbilical Controls/ The buttons do NOT work The umbilical cord is not
connect the umbilical connector
Control Panels connected

Check the wires and

components in the control box/
Electrical malfunction
controllers/machine repair or
replace as necessary

The buttons are stuck or Remove the blockage and clean

blocked the buttons

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HCS 3715 Trouble Shooting and Warranty

Event - Issue
Fault - Problem Solution - Action
Location/
Function
sequences

Check the equipment under

The buttons do NOT work Equipment malfunction control (tracks, conveyors,
feeder, etc.)

The remote control is NOT

The remote is not programmed to the Refer to 5.5.1e
communicating with the machine.
machine The batteries are not Replace or recharge the
charged batteries
Remote Controls/
Umbilical Controls/ The machine is OFF Turn On the Machine
Control Panels
The lights are damaged Replace the lights

Check the wires and

The warning lights or the components in the control box
display do NOT work or Electrical malfunction
and machine repair or replace as
intermittent necessary

Check the wires and the sensors

Sensor malfunction for damage replace or repair as
necessary

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8.3 Commissioning and Engine Warranty

8.3.1 Commissioning and Warranty Registration

The Atlas Copco Powercrusher Service Engineer who has been designated to Commission this HCS
3715 will have an electronic version of the Commissioning and Warranty Registration form [CWR].

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HCS 3715 Trouble Shooting and Warranty

8.4 CAT Register Instructions

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Trouble Shooting and Warranty HCS 3715

8.4.1 CAT C Series Warranty Statement

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HCS 3715 Trouble Shooting and Warranty

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 HCS 3715

9.0 Spare Parts

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HCS 3715 Spare Parts

9.1 Spare Parts

9.1.1 Spare Parts illustrations

This manual sets out details of available spares for the HCS 3715 Crushing Machine. The parts list
takes the form of a number of ‘exploded’ illustrations of the various machine assemblies.Components
illustrated have reference numbers, which can be cross-referenced with the corresponding Parts list.

This list includes:

a. Illustration Reference Number

b. Actual Part Number

c. Part Description

d. Quantity of Parts per Unit Assembly

9.1.2 Ordering Procedure:

To ensure correct delivery of your replacement part when ordering please quote:

a. Machine, Model and Serial Number

b. Year of Manufacture

c. Actual Part Number

d. Part Description

e. Illustration Reference Number and Page Number

f. Quantity Required

This information will enable us to supply the part with a minimum of delay.

contact email address

www.atlascopco.com

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Spare Parts HCS 3715

9.1.3 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal

protective equipment” on page 28.
• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine.

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

9.1.4 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.9 Safety considerations for maintenance” on page 42.

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 9.2

174
SPARE PARTS LIST

9.2.1
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021343 0 HOSE CLAMP 2
HCS 3715

2 5730021818 0 TRACK LH 1
3 5730021819 0 TRACK RH 1
4 5730022008 0.02 TRACK FRAME 1
5 5730022009 0 TRACK MOTOR COVER PLATE 2
6 5730022010 0.01 TRACK BOLT IN ASSY 2
7 5730022011 0.01 BOLT ON TRACK PLATE 2
HCS 3715 Tracks
Machine Assemblies

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
 SPARE PARTS LIST
Spare Parts

NO. PART NO. REV. NO. DESCRIPTION QTY 9.2.2

1 5730021749 0 3/8" M/M ADAPTOR 8
2 5730021758 0 1/2" 3/8" M/M ADAPTOR 4
3 5730021761 0 3/4"X2" MM BHD ADAPTOR 4
4 5730021776 0 3/8FX3/8MX3/8M TEE 1
5 5730021778 0 3/8" BSP MALE BUNG 6
6 5730021779 0 MAINTENANCE LIFT LEGS OPTION 1
7 5730021780 0 DOUBLE BANK CONTROL VALVE 1
Chassis

8 5730021781 0 CONTROL VALVE SD5/3-KG3-18L,3-AE 1

9 5730021775 0 20MM SINGLE CLAMP 3
10 5730021835 0 LIGHT 1
11 5730021836 0.02 CHASSIS BACK STEP 1
12 5730021837 0.02 STEP SUPPORT 1
13 5730021838 0.07 CHASSIS 1
14 5730021839 0 HANDRAIL 1
15 5730021877 0 CHASSIS LADDER 1
16 5730021878 0 MAlN CONVEYOR SLIDE SUPPORT 1
17 5730021749 0 MAlN CONVEYOR SLIDE SUPPORT 1

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 176
SPARE PARTS LIST 9.2.3
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730006691 0 FILTER 1
HCS 3715

2 5730008182 0 TANK CAP 1

3 5730020981 0 TANK SIEVE 1
4 5730010266 0 LEVEL GAUGE 1
5 5730020982 0.01 RUBBER MTG 4
6 5730020983 0.04 DIESEL TANK 1
Diesel Tank

7 5730020984 0 DIESEL TANK FRAME 1

8 5730020985 0 DIESEL TANK SPACER 4

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
 Spare Parts

SPARE PARTS LIST 9.2.4

NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730005965 0 2” SUCTION FILTER 90 MICRON 2
2 5730021626 0 3/4” M/M ADAPTOR 1
3 0 350MM TANK INSPECTION PLATE COMPLETE (MP FILTRI) 1
4 5730012463 0 CORK GASKET 1
5 5730020986 0 HYD LEVEL SWITCH 1
6 5730022034 0.05 HYDRAULIC TANK 1
7 5730020988 0 HYDRAULIC TANK LID 1
8 5730013013 0 LEVEL GUAGE 1
9 5730020888 0 RETURN FILTER INSERT 2
10 5730005910 0 RETURN FILTER: 0-MPF184-1A-G1-P10-NB-T 2
Hydraulic tank

11 5730006691 0 TANK AIR BREATHER: 0-SA075G2L03A 1

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 178
SPARE PARTS LIST 9.2.5
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730020999 0 4 BANK SPRAYBAR MAINFOLD 1
2 5730022066 0.07 542 BOLT IN HOPPER 1
HCS 3715

3 5730021629 0 1/8" BSP GREASE NIPPLE 3

4 5730021632 0 1/8"X1 1/4" M/F BHD GREASE ADAPTOR 3
5 5730020959 0 25.4X175 PIN 4
6 5730021625 0 3/8" M/M ADAPTOR 7
7 5730021633 0.01 3/8" M/M/M TEE 2
8 5730021937 0.01 BOLT IN FRONT BEAM 1
9 5730021003 0 COVER PLATE 1
10 5730021000 0 DOOR SUPPORT 5
11 5730021925 0 FEEDER ACCESS DOOR 2
12 5730021926 0 FEEDER ACCESS DOOR 1
Feeder Assembly

13 5730021927 0 FEEDER ACCESS DOOR 1

14 5730008490 0.01 FEEDER ACCESS DOOR 2
15 5730021923 0.03 FEEDER CHASSIS BRACE 1
16 5730021924 0.04 FEEDER CHASSIS BRACE 1
17 5730021921 0 FEEDER CONVEYOR FRONT LH LEG 1
18 5730021922 0 FEEDER CONVEYOR FRONT RH LEG 1
19 5730021919 0 FEEDER CONVEYOR REAR LH LEG 1
20 5730021920 0 FEEDER CONVEYOR REAR RH LEG 1
21 5730022067 0.01 FEEDER EXCESS DOOR 1
22 5730021918 0.08 FEEDER FRAME 1
23 5730021013 0 FEEDER JACK LEG 570 2
24 5730021001 0.01 FEEDER ROLLER MTG COMPLETE 4
25 5730014840 0 FINTEC 542 JACK LEG HOSE KIT 1

4300 St. Valentin, Austria

Atlas Copco Powercrusher
26 5730020998 0 FLOW DIVIDER DFR1205 1
27 5730021936 0 HOPPER OUTLET PLATE 1
28 5730021934 0 HOPPER OUTLET PLATE 1
29 5730017489 0 LEG RAM 2
30 5730020917 0 LIGHT 1
31 5730021935 0 OUTLET RUBBER CLAMP 2
32 5730021939 0.02 OUTLET SIDE GUARD 1
33 5730021938 0.03 OUTLET SIDE GUARD 1
34 5730021941 0 RUBBER CLAMP 2
35 5730021942 0.01 SPILLAGE RUBBER 2
36 5730021940 0.02 SPILLAGE RUBBER 2
37 5730021943 0 START ASSEMBLY 2
38 5730020956 0.01 TRACK LEAD MTG PLATE 1
39 5730021002 0.01 TRANSPORT BRACKET 2
Spare Parts
Spare Parts HCS 3715

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 180
9.2.6
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021023 0 CLAMP PLATE 4
HCS 3715

2 5730021762 0 CLAMP PLATE 1

3 5730022164 0.01 542 BOLT HOPPER 1
4 5730022165 0 542 IMPACT BED 1
5 5730022166 0 HARDOX PLATE 1
6 5730022167 0 HARDOX PLATE 2
7 5730022168 0 HARDOX PLATE 2
Bolt in hopper

8 5730022169 0 HARDOX PLATE 2

9 5730022170 0.01 HARDOX PLATE 2
10 5730022171 0.01 HARDOX PLATE 2
11 5730022172 0 130MM SKIRTING RUBBER 2
12 5730022173 0 130MM SKIRTING RUBBER 1
13 5730022174 0 HARDOX PLATE 2
14 5730022175 0 HARDOX PLATE 2

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Spare Parts
Spare Parts HCS 3715

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 182
9.2.7
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021928 0.03 CRUSHER FEEDER BOX 1
HCS 3715

2 5730021929 0 WING PLATE PIVOT BAR 1

3 5730021930 0.01 CRUSHER FEEDER DOOR 1
4 5730021931 0 CRUSHER FEEDBOX LINER 1
5 5730021932 0 CRUSHER FEEDBOX LINER 1
6 5730021933 0 PLATE 1
Feeder Box Chute

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
 Spare Parts

9.2.8
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730015744 0 SCREEN RAM 1
2 5730020898 0 S146 LINCH PIN AND CHAIN 1
3 5730021840 0 SCREEN SUPPORT SLIDE 1
4 5730021842 0 SCREEN LOWER SUPPORT 1
5 5730021843 0.01 SCREEN UPPER SUPPORT 1
6 5730022080 0 30X150 PIN 1
Screen Main Conveyor Support

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 184
SPARE PARTS LIST SPARE PARTS LIST 9.2.9
NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021040 0 80X65X49.5 COLLAR 2 NO. PART NO. REV. NO. DESCRIPTION QTY
2 5730008414 0 HYDRAULIC MOTOR 1 38 5730022000 0 FEEDER BACK GUARD 1
HCS 3715

3 5730020892 0 GEARBOX 1
39 5730022005 0 FEEDER SIDE GUARD 1
4 5730020895 0 65MM FLANGE BEARING 1
5 5730020897 0 65mm PILLOW BLOCK BEARING 2 40 5730022006 0 FEEDER SIDE GUARD 1
6 5730020901 0 ROSTA TENSIONER 2 41 5730021805 0 TAIL DRUM V SCRAPER 1
7 5730021041 0 TAPER LOCK 4
8 5730020920 0 CENTRE ROLLER 6 42 5730021806 0 DRUM SCRAPER 1
9 5730021405 0 PLAIN RETURN ROLLER 1160 RL 6 43 5730021059 0 V SCRAPER MTG. PLATE 1
10 5730020922 0 DISC RETURN ROLLER 1 44 5730021060 0 V SCRAPER MTG. PLATE 1
11 5730015429 0 20 DEGREE WlNG ROLLER LH 6
12 5730003414 0 20 DEGREE WlNG ROLLER RH 6
Feeder Conveyor

13 5730021828 0 FEEDER 1 050MM EP500/3PLY 1

14 5730020928 0 930 WIDE BELT SCRAPER 1
15 5730021859 0 GEARBOX MTG BRACKET 1
16 5730021860 0 BEARING MTG BRACKET 1
17 5730021861 0 FEED DRIVE DRUM COMPLETE 1
18 5730021862 0 FEEDER CONVEYOR DRIVE DRUM 1
19 5730021863 0 SHAFT 1
20 5730021864 0 FEED TAIL DRUM COMPLETE 1
21 5730021865 0 FEEDER CONVEYOR TAIL DRUM 1
22 5730021866 0 SHAFT 1
23 5730008234 0.01 V-SCRAPER RUBBER 1
24 5730021867 0.01 FEEDER CONVEYOR FRAME 1
25 5730021868 0 SCRAPER MTG 2
26 5730021869 0 SCRAPER MTG 1

4300 St. Valentin, Austria

Atlas Copco Powercrusher
27 5730021870 0 SPILLAGE RUBBER 1
28 5730021044 0 65MM BEARING ADJUSTER PLATE 1
29 5730021871 0 SCRAPER BRACKET 1
30 5730021045 0 65MM BEARING ADJUSTER 2
31 5730021253 0 ADJUSTER BAR 2
32 5730021254 0.01 ADJUSTER BOLT AND CAP 2
33 5730021644 0 V SCRAPER CLAMP 2
34 5730021989 0.01 HEAD DRUM GUARD 1
35 5730021652 0 RETURN ROLLER GUARD 1
36 5730020948 0 UNDERSIDE GUARD 2
37 5730021998 0 FEEDER SIDE GUARD 2
Spare Parts
Spare Parts HCS 3715

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 NO. PART NO. REV. NO. DESCRIPTION QTY

186
1 5730021625 0 3/8" M/M ADAPTOR 4 9.2.10
2 5730021633 0.01 3/8" M/M/M TEE 1
3 5730017490 0 GRID TIPPING RAM 2
4 5730014838 0 FINTEC 542 TIPPING GRID HOSE KIT 1
HCS 3715

5 5730020899 0.01 GRID BUMP STOP 2

6 5730020960 0 30X125 PlN 2
7 5730021645 0 GRID BUMP STOP PLATE 2
8 5730021646 0 WING PLATE LH 1
9 5730021946 0 4" GRID BAR COMPLETE 1
10 5730021647 0.01 WING PLATE RH 1
11 5730021947 0 6" GRID BAR COMPLETE 1
12 5730021648 0 WING PLATE PIVOT BAR 2
13 5730021948 0.03 GRID TIPPING FRAME 1
14 5730021949 0 GRID SUB FRAME 1
15 5730021649 0 GRID SUPPORT LEG 2
16 5730021074 0 RUBBER SUPPORT 6
12 FT Tipping Grid

17 5730021952 0.01 RUBBER 1

18 5730021953 0 RUBBER CLAMP 2
19 5730021650 0 14' GRID HOPPER SIDE 1
20 5730021651 0 14' GRID HOPPER SIDE 1
21 5730021955 0 12' GRID HOPPER CENTRE SECTION 1
22 5730022077 0 GRID BAR MTG. FRAME 2
23 5730022078 0 GRID BAR PIVOT BAR 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 187

4300 St. Valentin, Austria
 188
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.11
1 5730017490 0 GRID TIPPING RAM 2
2 5730020898 0 S146 LINCH PIN AND CHAIN 2
HCS 3715

3 5730020899 0.01 GRID BUMP STOP 2

4 5730020960 0 30X125 PIN 2
5 5730021645 0 GRID BUMP STOP PLATE 2
6 5730021944 0 6" GRID BAR COMPLETE 1
7 5730021945 0 4" GRID BAR COMPLETE 1
8 5730021646 0 WING PLATE LH 1
9 5730021647 0.01 WING PLATE RH 1
10 5730021648 0 WING PLATE PIVOT BAR 2
11 5730021649 0 GRID SUPPORT LEG 2
12 5730021950 0.01 14' GRID SUB FRAME 1
13 5730021951 0.03 14 'GRID TIPPING FRAME 1
14 FT Tipping Grid

14 5730021074 0 RUBBER SUPPORT 6

15 5730021075 0 RUBBER CLAMP 2
16 5730021076 0.01 RUBBER 1
17 5730021650 0 14' GRID HOPPER SIDE 1
18 5730021651 0 14' GRID HOPPER SIDE 1
19 5730021954 0 14' GRID HOPPER CENTRE SECTION 1
20 5730021079 0 GRID PIVOT BAR 2
21 5730021080 0.01 14' GRID BAR MTG FRAME 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 189

4300 St. Valentin, Austria
 SPARE PARTS LIST

190
NO. PART NO. REV. NO. DESCRIPTION QTY 9.2.12
1 5730012476 0 MOTOR RONZIO Z3 WITH UPGRADED CASE DRAIN SEAL 1
2 5730020893 0 ROLLER BEARING 2
3 5730020900 0 SCREEN SPRINGS 8
HCS 3715

4 5730020905 0 TAPER LOCK 1

5 5730020909 0 2517 x 60MM TAPER LOCK 1
6 5730020911 0 HRC 180 COUPLING (TYPE F) 2
7 5730020912 0 HRC 180 COUPLING INSERT 1
8 5730021402 0 END TENSIONER BAR ASSY 2
9 5730020927 0 SPRING COVER 8
10 5730021090 0.01 SCREEN TENSIONER WEDGE KIT 30
Screen Unit

11 5730021097 0 PIPE UNIT 1

12 5730021098 0 SCREEN SHAFT ASSY 1
13 5730021099 0 BEARING HOUSING ASSY 2
14 5730021100 0 BEARING END CAP ASSY 2
15 5730013200 0 BEARING SPACER RING 2
16 5730020935 0 SCREEN FLYWHEEL 2
17 5730020936 0 SCREEN COUNTERWEIGHT 4
18 5730020937 0.01 TENSIONER BRACKET 4
19 5730021642 0 RUBBER CLAMP 1
20 5730021643 0.02 SCREEN DISCHARGE RUBBER 1
21 5730021855 0.01 SCREENBOX DEFLECTOR LINER 1
22 5730021310 0 SCREEN COUNTERWEIGHT 2
23 5730020938 0 KEY LOCKING PLATE 2
24 5730022018 0 14FT TOP DECK FRAME 1
25 5730022019 0 SCREEN SIDE 1
26 5730022020 0 SCREENBOX COMPLETE (3RD GEN) 1
27 5730022021 0 SCREEN SIDE 1
28 5730022022 0 TOP DECK TENSIONER 6

4300 St. Valentin, Austria

29 5730022024 0.01 BOTTOM DECK FRAME 1

Atlas Copco Powercrusher

30 5730022026 0 BEARING HOUSING MTG PLT 2
31 5730022027 0 FRONT SPRING ASSY MTG RHS 1
32 5730022028 0 FRONT SPRING ASSY MTG LHS 1
33 5730022029 0 BACK SPRING ASSY MTG RHS 1
34 5730022030 0 BACK SPRING ASSY MTG LHS 1
35 5730022031 0.01 SCREENBOX DISCHARGE SHUTE 1
36 5730022032 0 BACK DEFLECTOR ASSEMBLY 1
37 5730021653 0 BOTTOM DECK SPILLAGE PLATE 1
38 5730021654 0 BOTTOM DECK SPILLAGE PLATE 1
39 5730021655 0 REAR WALKWAY 2ND EDITION 1
40 5730021656 0 TOR RHS HANDRAIL 1
41 5730021657 0 REAR WALKWAY 1
42 5730020949 0 MOTOR MOUNTING PLATE 1
43 5730008186 0 INSPECTION COVER 1
44 5730022072 0 MTR MTG FRAME 1
45 5730022073 0 SCREEN WEIGHT GUARD 1
46 5730020958 0 DRIVE GUARD FREE SIDE 2ND EDITION 1
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 191

4300 St. Valentin, Austria
 SPARE PARTS LIST SPARE PARTS LIST

192
NO. PART NO. REV. NO. DESCRIPTION QTY NO. PART NO. REV. NO. DESCRIPTION QTY 9.2.13
1 5730021122 0 20X85 PIN 2 45 5730021121 0 WORK LAMP 2
2 5730021782 0 3/4 BSP M/F SWEPT 90 DEGREE 3
3 5730021634 0 3/4 CHECK VALVE ( Z/OCUK10280401) 1 46 5730022017 0 WORK LIGHT BRACKET 1
4 5730021787 0 3/4" M/F /M TEE 3 47 5730022016 0 WORK LIGHT MTG BRACKET 1
HCS 3715

5 5730021626 0 3/4" M/M ADAPTOR 3 48 5730021133 0 WORK LIGHT OPTION 1

6 5730021627 0 3/4" X 1" M/M ADAPTOR 2
7 5730021631 0 3/4"X1 1/2" MM BHD ADAPTOR 4
8 5730021785 0 3/8" BSP MF SWIVEL ADAPTOR 1
9 5730021625 0 3/8" M/M ADAPTOR 1
10 5730021630 0 3/8"X2" MM BHD ADAPTOR 1
11 5730021142 0 BEACON SLIDE BRACKET 1
12 5730022023 0 BOTTOM DECK OUTLET RUBBER 1
13 5730021653 0 BOTTOM DECK SPILLAGE PLATE 1
14 5730021654 0 BOTTOM DECK SPILLAGE PLATE 1
15 5730021884 0.01 CLAMP PLATE 1
Screen complete

16 5730021746 0 CLAMP STRAP 2

17 5730021395 0 FLOW CONTROL 2FB95 G6W 95S 3/4 1
18 5730022013 0.04 LOWER LHS HANDRAIL 1
19 5730021126 0 LOWER LHS SCREEN HANDRAIL 1
20 5730021854 0.05 LOWER LHS WALKWAY 1
21 5730022015 0.04 LOWER RHS SCREEN HANDRAIL 1
22 5730021852 0.06 LOWER PHS SCREEN WALKWAY 1
23 5730022081 0 M16 TAB WASHER 1
24 5730021127 0.02 PULLOUT WALKWAY SUPPORT 2
25 5730011538 0.02 REAR SLIDING HANDRAIL 2
26 5730021657 0 REAR WALKWAY 1
27 5730021655 0 REAR WALKWAY 2ND EDITION 1
28 5730014949 0 RUBBER CLAMP 1
29 5730021642 0 RUBBER CLAMP 1
30 5730021857 0 RUBBER CLAMP 1
31 5730021747 0 RUBBER CLAMP 1250MM 2

4300 St. Valentin, Austria

32 5730021846 0.01 SCREEN BACK RUBBER 1

Atlas Copco Powercrusher

33 5730021643 0.02 SCREEN DISCHARGE RUBBER 1
34 5730022033 0 SCREEN HANGING RUBBER 2
35 5730021844 0.04 SCREEN LADDER 1
36 5730021856 0.03 SCREEN RUBBER 1
37 5730022025 0 SCREEN SUBFRAME ASSY 1
38 5730021123 0.02 SIDE WALKWAY PIVOT MTG 2
39 5730021853 0.03 SIDE WALKWAY PIVOT MTG 2
40 5730021124 0.03 SIDE WALKWAY PIVOT MTG LONG 2
41 5730021656 0 TOP PHS HANDRAIL 1
42 5730021264 0 UPPER FEED BOOT SPILL RUBBER CLAMP 2
43 5730022012 0.02 WALKWAY REAR DOOR 1
44 5730022014 0.02 WALKWAY REAR DOOR 1
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 193

4300 St. Valentin, Austria
 194
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.14
1 5730021832 0 CHUTE LINING 1
2 5730021845 0.02 TOP DECK CHUTE 1
HCS 3715

3 5730021847 0 TOP DECK RUBBER 1

4 5730016558 0 BOTTOM DECK RUBBER 1
5 5730021848 0 CLAMP PLATE 1
6 5730021849 0 CLAMP PLATE 1
7 5730012746 0 CLAMP PLATE 1
8 5730008578 0 TOPDECK CHUTE HARDOX LINER 1
9 5730021850 0.02 CHUTE LIINING 2
10 5730021851 0 TOPDECK CHUTE HARDOX LINER 1
Top Deck Chute

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
 SPARE PARTS LIST SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
Spare Parts

NO. PART NO. REV. NO. DESCRIPTION QTY

1 5730020883 0.01 FEEDBOOT SIDE CLAMP 2 47 5730021153 0.01 HANGING BLANKET BRACKET 1 9.2.15
2 5730021750 0 FEEDBOOT BACK CLAMP 1 48 5730021154 0 CLAMP STRAP 1
3 5730021751 0.02 FEEDBOOT BACK RUBBER 1 49 5730021155 0.02 MAIN CONV HANGING RUBBER 1
4 5730021752 0.02 FEEDBOOT SIDE RUBBER 2 50 5730021876 0.08 MAIN CONVEYOR HEAD SECTION 1
5 5730021753 0.01 80X60X37.5 COLLAR 2 51 5730021879 0.09 MAIN CONVEYOR LOWER SECTION 1
6 5730021754 0 80X60X28.5 COLLAR 2 52 5730021880 0 LOWER SKIRT RUBBER 2
7 5730021624 0 SOMM ID COLLAR 2 53 5730021881 0 UPPER SKIRT RUBBER 2
8 5730021246 0 50MM PIN 2 54 5730021882 0 CURTAIN ANGLE 2
9 5730021626 0 3/4" M/M ADAPTOR 1 55 5730021883 0 CLAMP PLATE 2
10 5730021627 0 3/4" X 1" M/M ADAPTOR 2 56 5730020939 0.01 1250MM SPRAY BAR ASSY 2
11 5730021628 0 1/8" M/M ADAPTOR 4 57 5730021885 0.02 BEACON MTG 1
12 5730021629 0 1/8" BSP GREASE NIPPLE 4 58 5730021202 0.02 ANTI-ROLL CLAMP 7
13 5730021632 0 1/B"X1 1/4" M/F BHD GREASE ADAPTOR 4 59 5730021203 0.01 RUBBER FLAP 6
14 5730021634 0 3/4 CHECK VALVE ( Z/OCUK10280401) 1 60 5730021156 0.01 CLEVLOC BEARING ADJUSTMENT BRACKET 2
Main Conveyor

15 5730021790 0 HYDRAULIC MOTOR 1 61 5730021157 0 MAlN DRUM V-SCRAPER 1

16 5730011668 0 FINTEC 542 MAIN CONVEYOR GREASE PIPE KIT 1 62 5730021886 0.01 MAIN DRUM V-SCRAPPER COMPLETE 1
17 5730004189 0 60MM FLNJGE BEARING FY60TR/VZ3514 2 63 5730020941 0.01 V SCRAPER BRACKET 1
18 5730020896 0 60MM PILLOW BLOCK BEARING SY60TR/VZ3514 2 64 5730020942 0.01 V SCRAPER BRACKET 1
19 5730021810 0 10MM SPRING HOOK 4 65 5730021158 0 V - SCRAPER PLATE 1
20 5730020899 0.01 GRID BUMP STOP 2 66 5730021204 0.01 DUST COVER SUPPORT FRAME 2
21 5730021812 0 DUST COVER 2 67 5730021205 0.01 DUST COVER SUPPORT FRAME 2
22 5730021813 0 DUST COVER 2 68 5730021887 0 MAIN FEEDBOOT 1
23 5730020908 0 2517 x 50MM TAPER LOCK 1 69 5730021888 0 IDLER DRUM BACK GUARD 1
24 5730020909 0 2517 x 60MM TAPER LOCK 1 70 5730021889 0 LHS FEEDBOOT GUARD 1
25 5730020911 0 HRC-180 COUPLING (TYPE F) 2 71 5730021890 0 RHS FEEDBOOT GUARD (2~JD ED) 1
26 5730020912 0 HRC 180 COUPLING INSERT 1 72 5730021891 0 MAIN FEEDBOOT RUBBER 1
27 5730021452 0 BEACON 1 73 5730021207 0 ROLLBACK FLAP BRACKET 15
28 5730020922 0 DISC RETURN ROLLER 2 74 5730021892 0 COMPLETE DUST SUPPRESSION 1
29 5730021822 0 108/20 X 780 C/R 12 75 5730021893 0 COMPLETE ROLLBACK FLAP OPTION 1
30 5730021824 0 108/20 X 220 X 30· LH W/R 5 76 5730021894 0 ROLLBACK FLAPS MJD DUST SUPPRESSION 1
31 5730021825 0 108/20 X 220 X 30" RH W/R 5 77 5730021652 0.02 RETURN ROLLER GUARD 2
32 5730021638 0 108/20 X 220 X 40· LH W/R 7 78 5730020948 0 UNDERSIDE GUARD 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
33 5730021639 0 108/20 X 220 X 40" RH W/R 7 79 5730021993 0 CHEESE GUARD 1
34 5730021829 0 MAIN CONVEYOR BELT 1 80 5730021994 0 MOTOR MOUNTING GUARD 1
35 5730008234 0.02 V SCRAPER RUBBER 1 81 5730021996 0.01 UPPER RHS GUARD 1
36 5730021872 0 MAIN CONVEYOR HEAD DRUM 1 82 5730021997 0.01 UPPER LHS GUARD 1
37 5730016530 0 MAIN CONVEYOR TAIL DRUM 1 83 5730022001 0.01 LOWER PHS GUARD 1
38 5730021873 0.03 HEAD SECTION RHS 1 84 5730022002 0.01 LOWER RHS GUARD 1
39 5730021874 0.02 HEAD SECTION LHS 1 85 5730022003 0.02 LOWER SIDE GUARD CLAMP 1
40 5730021253 0 ADJUSTER BAR 2 86 5730022004 0 UPPER SIDE GUARD CLAMP 2
41 5730021644 0 V-SCRAPER CLAMP 2 87 5730022007 0.01 LOWER SIDE GUARD CLAMP 1
42 5730013665 0.02 MOTOR MOUNTING 1 88 5730022038 0 SCREEN RUBBER MOUNTING PLATE 1
43 5730008244 0.01 SCRAPER 1
44 5730021875 0.01 ADJUSTER END CAP 2
45 5730011434 0.02 RUBBER CURTAIN 2
46 5730021201 0.01 SPREADER PLATE LINER 2

195
HCS 3715
 196
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
89 5730022039 0 SCREEN SPILLAGE RUBBER 2
HCS 3715

90 5730022040 0 CLAMP PLATE 4

91 5730022071 0 MOTOR MOUNT BOTTOM GUARD 1
92 5730020951 0 V-SCRAPER RUBBER CLAMP 2
93 5730022219 0 MAIN CONVEYOR SLIDE BRACKET 1
94 5730021208 0.01 SPREADER PLATE LINER 2
95 5730021187 0.01 LHS SPREADER PLATE NJGLE 1
96 5730021188 0.01 RHS SPREADER PLATE NJGLE 1
97 5730021189 0.01 SPREADER PLATE 1
98 5730021209 0 HARDOX OPTION SPREADER PLATE 1
99 5730021808 0 REMOVER TRANSOME PLATE 1
100 5730020894 0 60mm BEARING ADJUSTER PLATE 2
101 5730021658 0.01 NUT_HEX.PRT 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 197

4300 St. Valentin, Austria
 198
SPARE PARTS LIST SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.16
1 5730021230 0.01 80X60X32.5 COLLAR 2
54 5730022221 0.03 DISC ROLLER GUARD 2
2 5730021214 0.01 80X6DX44.0 COLLAR 2
3 5730021755 0 FEEDBOOT BACK CLAMP 1 55 5730015419 0 FINES FEEDBOOT SIDE GUARDS 4
HCS 3715

4 5730021756 0 RUBBER 1 56 5730021220 0.02 TAIL DRUM SIDE GUARD RH 1

5 5730021757 0 RUBBER 2 57 5730021221 0.02 TAIL DRUM SIDE GUARD LH 1
6 5730021625 0 3/8” M/M ADAPTOR 1
58 5730021222 0.01 TAIL DRUM BACK GUARD 1
7 5730021783 0 ½” X ¾” M/M ADAPTOR 2
8 5730021628 0 1/8” M/M ADAPTOR 4 59 5730020948 0 UNDERSIDE GUARD 2
9 5730021629 0 1/8” BSP GREASE NIPPLE 4 60 5730021236 0 MOTOR MOUNTING BOTTOM GUARD 1
10 5730021632 0 1/8” X 1 1/4" M/F BHD GREASE ADAPTOR 4 61 5730020951 0 V SCRAPER RUBBER CLAMP 2
11 5730020889 0 20MM SINGLE CLAMP 2
62 5730016587 0.03 V SCRAPER RUBBER 1
12 5730020891 0 30mm HOSE CLAMP 5
13 5730002711 0 TAIL B RAM 1 63 5730020894 0 60MM BEARING ADJUSTER PLATE 2
14 5730004189 0 60MM FLANGE BEARING FY60TR/VZ3514 2 64 5730018633 0 HYD MOTOR 2K 395 BAA MTR - 104-1391-006 1
Fines Conveyor

15 5730020896 0 60MM PILLOW BLOCK BEARING SY60TR/VZ3514 2

16 5730020901 0 ROSTA TENSIONER 2
17 5730021815 0 TAPERLOCK 1
18 5730020909 0 2517 x 60MM TAPER LOCk 1
19 5730020911 0 HRC 180 COUPLING (TYPE F) 2
20 5730020912 0 HRC 180 COUPLING INSERT 1
21 5730020923 0 DISC RETURN ROLLER 1310 RL 2
22 5730021823 0 108/20 X 930 C/R 8
23 5730021636 0 108/20 X 220 X 20’LH W/R 6
24 5730021637 0 108/20 X 220 20’ W/R 6
25 5730021638 0 108/20 X 220 X 40’ LH W/R 1
26 5730021639 0 108/20 X 220 X 40’ RH W/R 1
27 5730021640 0 108/20 X 220 X 50’ LH W/R 1
28 5730021641 0 108/20 X 220 X 50’ RH W/R 1
29 5730021830 0 TAIL 1200MM EP400/3PLY 1
30 5730020929 0 1000 WIDE BELT SCRAPER 1
31 5730021216 0 30X85 PIN 2
32 5730008224 0 SCRAPER MTG 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
33 5730020941 0.01 V SCRAPER BRACKET 1
34 5730020942 0.01 V SCRAPER BRACKET 1
35 5730008438 0 FINES CONVEYOR DRIVE DRUM 1
36 5730021217 0 FINES CONVEYOR TAIL DRUM 1
37 5730021218 0.03 BEARING ADJUSTER RH 1
38 5730021895 0.02 BEARING ADJUSTER LH 1
39 5730008249 0 TAIL DRUM SCRAPER PLATE 1
40 5730021898 0.03 FINES UPPER RAM BRACKET 2
41 5730021899 0.02 FINES LOWER RAM BRACKET 1
42 5730021234 0.01 MOTOR MTG ASSY 1
43 5730021235 0.01 COUPLING COVER 1
44 5730008248 0.01 SCRAPER FRAME 1
45 5730021900 0 BEARING ADJUSTER BOLT 2
46 5730021902 0.05 FINES CONVEYOR FEEDBOOT 1
47 5730021903 0 FEEDBOOT RUBBER CLAMP 2
48 5730014210 0.10 FINES CONVEYOR LOWER SECTION 1
49 5730021904 0.01 BLANKING RUBBER 2
50 5730021905 0 DRIVE DRUM GUARD BRACKET 2
51 5730021219 0.01 TAIL DRUM V SCRAPER 1
52 5730014211 0 FINES CONVEYOR UPPER SECTION 1
53 5730021992 0.01 DRIVE DRUM GUARD 1
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 199

4300 St. Valentin, Austria
 200
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.17
1 5730017471 0 TAIL A RAM (100 MM BORE) 1
2 5730020898 0 S146 LINCH PIN AND CHAIN 2
HCS 3715

3 5730021841 0 TAIL CONVEYOR SUPPORT SLIDE 2

4 5730021896 0.01 TAIL CONVEYOR TOP SUPPORT 1
5 5730021897 0 TAIL CONVEYOR LOWER SUPPORT 2
6 5730020960 0 30X125 PlN 2
Tail Conveyor Support

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
 SPARE PARTS LIST SPARE PARTS LIST
Spare Parts

NO. PART NO. REV. NO. DESCRIPTION QTY NO. PART NO. REV. NO. DESCRIPTION QTY
55 5730021912 0.02 STONE GUARD 1
9.2.18
1 5730021243 0.01 80X60X23.5 COLLAR 2
2 5730012747 0 CLAMP PLATE 2 56 5730021913 0.01 STONE GUARD 1
3 5730021759 0 90X10 FEEDBOOT RUBBER 2 57 5730021914 0.01 SIDE CONVEYOR SPRAY BAR ASSY 1
4 5730021760 0 SPILLAGE RUBBER 1 58 5730021915 0 SIDE DRUM V SCRAPER 1
5 5730021624 0 50MM ID COLLAR 5 59 5730021916 0 V-SCRAPPER PLATE 1
6 5730021777 0 60MM ID COLLAR 2 60 5730021263 0 UPPER FEED BOOT SPILL RUBBER CLAMP 2
7 5730021246 0 50MM PIN 2 61 5730021264 0 UPPER FEED BOOT SPILL RUBBER CLAMP 2
62 5730021917 0.02 SIDE CONV FEEDBOOT RUBBER 1
8 5730021625 0 3 8” M/M ADAPTOR 5
63 5730021990 0 SIDE CONVEYOR BREPBY GUARD 1
9 5730021626 0 3 4” M/M ADAPTOR 2
64 5730021991 0.01 650 FULL VIB ROLLER GUARD 1
10 5730021628 0 1 8” M/M ADAPTOR 4
65 5730021995 0 RETURN ROLLER GUARD 1
11 5730021629 0 1 8” BSP GREASE NIPPLE 1
66 5730021999 0 HARTL SIDE CON TAIL DRUM GUARD 1
12 5730021784 0 1 8” BSP 45’ HEAD GREASE NIPPLE 4
67 5730022042 0.01 SIDE CONVEYOR BASE SUPPORT 1
13 5730021786 0 3 8” EXTENSION ADAPTOR 1
68 5730022043 0.04 SIDE CONVEYOR MID SECTION 1
14 5730021630 0 3 8”X2” MM BHD ADAPTOR 3 69 5730022044 0.03 SIDE CONVEYOR HEAD SECTION 1
15 5730021631 0 3 4”X1 1 /2” MM BHD ADAPTOR 2 70 5730022045 0.01 HEAD SECTION COMPLETE 1
16 5730021632 0 1 8”X1 ¼” M F BHD GREASE ADAPTOR 4 71 5730022046 0 PIN COLLAR 2
17 5730021788 0 3 8FX3/8MX3 8M TEE 2 72 5730022047 0 SIDE CONVEYOR INNER SUPPORT STRUT 1
18 5730002385 0 HYDRAULIC MOTOR 1 73 5730022048 0 SIDE CONVEYOR OUTER SUPPORT STRUT 2
19 5730021791 0 12MM DOUBLE HOSE CLAMP 5 74 5730022049 0 SIDE CONVEYOR lNNER SUPPORT STRUT 1
20 5730021792 0 HOSE CLAMP 12MM SINGLE 6
Mid Size Side Conveyor

75 5730022050 0 SIDE CONVEYOR LOWER PIVOT 2

21 5730020891 0 30mm HOSE CLAMP 4 76 5730022051 0 SIDE CONVEYOR UPPER PIVOT BRACKET 2
22 5730017496 0 SIDE A RAM 1 77 5730022053 0 DISC ROLLER MTG. BRACKET 2
23 5730002335 0 RAM 1 78 5730022054 0 CLAMP STRAP 1
24 5730004189 0 60MM FLANGE BEARING FY60TR VZ3514 2 79 5730022055 0 TRANSPORT ARM BRACKET 1
25 5730020896 0 60MM PILLOW BLOCK BEARING SY60TR VZ3514 2 80 5730022056 0 SIDE CONVEYOR TRANSPORT BRACKET 1
26 5730021814 0 DUST COVER 1 81 5730022057 0 542 SIDE CONVEYOR TRANSPORT BRACKET 1
27 5730020907 0 TAPERLOCK 1 82 5730022058 0.02 SIDE CONVEYOR BASE SUPPORT 1
28 5730020909 0 2517 x 60MM TAPER LOCK 1 83 5730022059 0 50 DEG ROLLER BELT COVER 1
29 5730020911 0 HRC 180 COUPLING TYPE F 2 84 5730022060 0 SLIDE STOP 2
30 5730020912 0 HRC 180 COUPLING INSERT 1 85 5730022061 0.01 50MM PIN 1
31 5730021820 0 DISC RETURN ROLLER 0750 3 86 5730022062 0 BOOT SIDE RUBBER 2

4300 St. Valentin, Austria

87 5730022063 0 TAIL DRUM COVER 1

Atlas Copco Powercrusher

32 5730021406 0 650 BELT VIB ROLLER 1
33 5730021821 0 108 20 X 370 C/R 12 88 5730022064 0 SIDE CON FEED BOOT 1
34 5730021636 0 108 20 X 220 X 20”LH W/R 5 89 5730022065 0 RUBBER CLAMP 2
35 5730021637 0 108 20 X 220 20’ W/R 5 90 5730022052 0 MID SECTION RAM MTG 1
36 5730021639 0 108 20 X 220 X 40” RH W/R 1 91 0 BELT TENSION ADJUSTER 2
37 5730021640 0 108 20 X 220 X so· LH W/R 2 92 0 THREAD PROTECTOR 2
38 5730021641 0 108 20 X 220 X 50” RH W/R 2 93 0 SIDE CONVEYOR LOWER SECTION 1
39 5730021826 0 108 20 X 220 X 60” LH W/R 4 94 5730022069 0.01 RETURN ROLLER GUARD 1
40 5730021827 0 108 20 X 220 X 60” RH W/R 4 95 5730022070 0 DISC ROLLER GUARD 1
41 5730021831 0 SIDE 650MM EP250/2PLY C15 1 96 5730022074 0 TAIL DRUM GUARD 1
42 5730021252 0 25.4X125 PIN 1 97 5730022075 0 ROLLER GUARD 1
43 5730020941 0.01 V-SCRAPER BRACKET 1 98 5730022076 0 ROLLER GUARD 1
44 5730021907 0 SIDE CONVEYOR HEAD DRUM 1 99 5730022076 0 SIDE CON RTN ROLLER GUARD 1
45 5730021908 0 SIDE CONVEYOR TAIL DRUM 1 100 5730021286 0 SIDE CONV FEEDBOOT CLAMP 1
46 5730015790 0 SC TENSIONER BOLTS 2 101 5730020894 0 60mm BEARING ADJUSTER PLATE 1
47 5730021255 0.03 RHS HEAD SECTION 1 102 5730021809 0 RUBBER CLAMP 2
103 5730021658 0 NUT HEX.PRT 2
48 5730021256 0.03 LHS HEAD SECTION 1
104 5730022061 0.01 50MM PIN 4
49 5730021257 0 MOTOR MTG ASSY 1
50 5730021258 0 SC MOTOR MTG COVER 1
51 5730021410 0.02 V-SCRAPER RUBBER 1
52 5730021261 0.01 SIDE CONV UPPER PIVOT 1
53 5730021910 0 BELT COVER 5
54 5730021911 0.01 BELT RETAINING BRACKET 1

201
HCS 3715
HCS 3715 Spare Parts

202 Atlas Copco Powercrusher

4300 St. Valentin, Austria
 SPARE PARTS LIST SPARE PARTS LIST
Spare Parts

NO. PART NO. REV. NO. DESCRIPTION QTY NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021243 0.01 80X60X23.5 COLLAR 2 47 5730021914 0.01 SIDE CONVEYOR SPRAY BAR ASSY 1
9.2.19
2 5730012747 0 CLAMP PLATE 2 48 5730021915 0 SIDE DRUM V SCRAPER 1
3 5730021759 0 90X10 FEEDBOOT RUBBER 2 49 5730021916 0 V SCRAPPER PLATE 1
4 5730021760 0 SPILLAGE RUBBER 1 50 5730021263 0 UPPER FEED BOOT SPILL RUBBER CLAMP 2
5 5730021624 0 50MM ID COLLAR 5 51 5730021264 0 UPPER FEED BOOT SPILL RUBBER CLAMP 2
6 5730021246 0 50MM PIN 2 52 5730021990 0 SIDE CONVEYOR BREPBY GUARD 1
7 5730021625 0 3 8” M/M ADAPTOR 5 53 5730021991 0.01 650 FULL VIB ROLLER GUARD 1
8 5730021626 0 3/4” M/M ADAPTOR 2 54 5730021995 0 RETURN ROLLER GUARD 1
9 5730021628 0 1/8” M/M ADAPTOR 4 55 0.02 SUPPORT SECTION COMPLETE 1
10 5730021629 0 1/8” BSP GREASE NIPPLE 1 56 5730022046 0 PIN COLLAR 2
11 5730021786 0 3/8” EXTENSION ADAPTOR 1 57 5730022047 0 SIDE CONVEYOR INNER SUPPORT STRUT 1
12 5730002385 0 HYDRAULIC MOTOR 1 58 5730022048 0 SIDE CONVEYOR OUTER SUPPORT STRUT 2
13 5730021791 0 12MM DOUBLE HOSE CLAMP 5 59 5730022049 0 SIDE CONVEYOR lNNER SUPPORT STRUT 1
14 5730021792 0 HOSE CLAMP 12MM SINGLE 6 60 5730022050 0 SIDE CONVEYOR LOWER PIVOT 2
15 5730020891 0 30mm HOSE CLAMP 4 61 5730022051 0 SIDE CONVEYOR UPPER PIVOT BRACKET 2
16 5730017496 0 SIDE A RAM 1 62 5730022053 0 DISC ROLLER MTG. BRACKET 2
17 5730002335 0 RAM 1 63 5730022054 0 CLAMP STRAP 1
18 5730004189 0 60MM FLANGE BEARING FY60TR/VZ3514 2 64 5730022055 0 TRANSPORT ARM BRACKET 1
Over Size Side Conveyo

19 5730020896 0 60MM PILLOW BLOCK BEARING SY60TR/VZ3514 2 65 5730022056 0 SIDE CONVEYOR TRANSPORT BRACKET 1
20 5730020907 0 TAPERLOCK 1 66 5730022057 0 542 SIDE CONVEYOR TRANSPORT BRACKET 1
21 5730020909 0 2517 x 60MM TAPER LOCK 1 67 0 SIDE CONVEYOR DUST COVER & BRACKETS 1
22 5730020911 0 HRC 180 COUPLING (TYPE F) 2 68 5730022060 0 SLIDE STOP 2
23 5730020912 0 HRC 180 COUPLING INSERT 1 69 5730022061 0.01 50MM PIN 1
24 5730021820 0 DISC RETURN ROLLER 0750 2 70 5730022062 0 BOOT SIDE RUBBER 2
25 5730021406 0 650 BELT VIB ROLLER 1 71 5730022063 0 TAIL DRUM COVER 1
26 0 20’X650MMXØ108MM ROLLER-SET 5 72 5730022064 0 SIDE CON FEED BOOT 1
27 0 40’X650MMXØ108MM ROLLER-SET 1 73 5730022065 0 RUBBER CLAMP 2
28 0 50’X650MMXØ108MM ROLLER-SET 2 74 0 MID SECTION RAMP MTG 1
29 0 60’X650MMXØ108MM ROLLER-SET 4 75 0 BELT TENSION ADJUSTER 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
30 5730021831 0 SIDE 650MM EP250/2PLY C15 1 76 0 THREAD PROTECTOR 2
31 5730021252 0 25.4X125 PIN 1 77 0 SIDE CONVEYOR LOWER SECTION 1
32 5730020941 0.01 V-SCRAPER BRACKET 1 78 0 0 SIZE SIDE CONVEYOR HEAD SECTION 1
33 5730020942 0.01 V-SCRAPER BRACKET 1 79 0 0 SIZE SIDE CONVEYOR MID SECTION 1
34 5730021907 0 SIDE CONVEYOR HEAD DRUM 1 80 0.01 0 SIZE CON MID SECTION COMPLETE 1
35 5730021908 0 SIDE CONVEYOR TAIL DRUM 1 81 5730022070 0 DISC ROLLER GUARD 1
36 5730015790 0 SC TENSIONER BOLTS 2 82 0 MOTOR MOUNTING BOTTOM GUARD 1
37 5730021255 0.03 RHS HEAD SECTION 1 83 5730022074 0 TAIL DRUM GUARD 1
38 5730021256 0.03 LHS HEAD SECTION 1 84 5730022075 0 ROLLER GUARD 1
39 5730021257 0 MOTOR MTG ASSY 1 85 5730022076 0 ROLLER GUARD 1
40 5730021258 0 SC MOTOR MTG COVER 1 86 0 SIDE CON RTN ROLLER GUARD 1
41 5730021410 0.02 V-SCRAPER RUBBER 1 87 5730020894 0 60mm BEARING ADJUSTER PLATE 2
42 5730021261 0.01 SIDE CONV UPPER PIVOT 2 88 5730021809 0 RUBBER CLAMP 2
43 5730021910 0 BELT COVER 2 89 5730021658 0.01 NUT HEX.PRT 4
44 5730021911 0.01 BELT RETAINING BRACKET 1
45 5730021912 0.02 STONE GUARD 1
46 5730021913 0.01 STONE GUARD 1

203
HCS 3715
HCS 3715 Spare Parts

204 Atlas Copco Powercrusher

4300 St. Valentin, Austria
 Spare Parts

SPARE PARTS LIST 9.2.20

NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021395 0 FLOW CONTROL 2FB95-G6W-95S 3/4 1
2 5730002663 0 HYDRAULIC MOTOR (30MM SHAFT) 1
3 5730020889 0 20MM SINGLE CLAMP 3
4 5730020891 0 30mm HOSE CLAMP 1
5 5730017476 0 VIB GRID RAM 2
6 5730013951 0 22320 ROLLER BEARING 2
7 5730010234 0 HOUSING SEAL 4
Vib Grid

8 5730020900 0 SCREEN SPRINGS 8

9 5730020905 0 TAPERLOCK 1
10 5730020909 0 TAPERLOCK 1
11 5730020911 0 HRC 180 COUPLING 2
12 5730020912 0 COUPLING INSERT 1
13 5730020927 0 SPRING COVER 8
14 5730021309 0 20X150 PIN 4
15 5730020959 0 25.4X175 PIN 2
16 5730020935 0 SCREEN FLYWHEEL 2
17 5730020936 0 SCREEN COUNTERWEIGHT 2
18 5730021310 0 SCREEN COUNTERWEIGHT 2
19 5730020938 0 KEY LOCKING PLATE 2
20 5730021957 0.03 VIBRATING GRID BOX COMPLETE 1
21 5730021964 0.02 VIB GRID WING PLATE 1
22 5730021965 0.03 VIB GRID WING PLATE 1
23 5730021313 0.01 4" BOFAR DECK 2
24 5730021314 0 VIB GRID SHAFT 1
25 5730021315 0 BEARING HOUSING ASSY 2
26 5730021316 0 BEARING END CAP ASSY 1

4300 St. Valentin, Austria

Atlas Copco Powercrusher
27 5730021317 0 BEARING SPACER RING 2
28 5730021967 0.01 (542)VIB GRID BASE FRAME 1
29 5730021968 0.05 (540) VIB GRID TIPPING FRAME 1
30 5730021969 0.03 VIB GRID OUTER JACKING LEG 2
31 5730021970 0.01 VIB GRID JACKING LEG 2
32 5730021971 0 PIN 2
33 5730021319 0 TRANSPORT BRACKET 4
34 5730021320 0 DRIVE GUARD 1
35 5730020949 0 MOTOR MOUNTING PLATE 1
36 5730008186 0 INSPECTION COVER 1
37 5730021321 0 VIBRATING GRID WEIGHT GUARD 1
38 5730021326 0 V-GRID RAM COLLAR 4
39 5730020958 0 DRIVE GUARD FREE SIDE 2ND EDI- 1
TION

205
HCS 3715
HCS 3715 Spare Parts

206 Atlas Copco Powercrusher

4300 St. Valentin, Austria
 SPARE PARTS LIST
Spare Parts

NO. PART NO. REV. NO. DESCRIPTION QTY

9.2.21
1 5730021956 0 VIB GRID LH SIDE PLATE 2
2 5730021958 0 VIB GRID FRONT TOP CROSS MEMBER 1
3 5730021959 0.01 VIB GRID BACK TOP CROSS MEMBER 1
4 5730021960 0 BOTTOM DECK CENTER SUPPORT STRUT 1
5 5730021961 0.01 VIB GRID BOTTOM BACK CROSS BEAM 1
6 5730017190 0 VIB GRID BOTTOM DECK CROSS MEMBER 6
7 5730021962 0.01 VIB GRID PIPE UNIT 1
Vib Grid Box

8 5730021963 0.01 VIB GRID SPRING MTG. BRACKET 4

9 5730021318 0 TOP DECK SIDE TENSIONER ASSY 2
10 5730021966 0.03 VIB GRID BOTTOM FRONT CROSS MEMBER 1

4300 St. Valentin, Austria

Atlas Copco Powercrusher
207
HCS 3715
 208
SPARE PARTS LIST SPARE PARTS LIST 9.2.22
NO. PART NO. REV. NO. DESCRIPTION QTY NO. PART NO. REV. NO. DESCRIPTION QTY
1 5730021337 0 LOW PRESSURE BALL VALVE 2 43 5730021366 0.02 MAIN CONVEYOR SUPPORT 1
2 5730010626 0 CONTROL VALVE 4 44 5730021367 0.03 MANIFOLD 1
HCS 3715

3 5730021338 0 DOUBLE BANK CONTROL VALVE 1 45 5730021368 0 EXHAUST HEAT SHIELD 1

4 5730021339 0 TRIPLE BANK CONTROL VALVE 1 46 5730021370 0 TOOL BOX 1
5 5730021340 0 SD5/4 CONTROL VALVE 1 47 5730021858 0 HCS 3715 MAIN CONVEYOR SUPPORT 1
6 5730005552 0 FLOW CONTROL VALVE 2 48 5730021371 0.06 POWERUNIT BASE FRAME 1
7 5730020886 0 FLOW CONTROL VALVE 1 49 5730021372 0 TIER III CAT CROSS MEMBER 1
8 5730010182 0 TRACK SOLENOID 1 50 5730021373 0.02 TIER III CAT CROSS MEMBER 1
9 5730020887 0 GRID SOLENOID 1 51 5730021374 0.01 CONTROL VALVE PLATE 1
10 5730021341 0 1 1/2" FLANGE KIT FCFS106G 1 52 5730021376 0.01 RH (CAT TIER III) POWERUNIT DOOR 1
11 5730021342 0 2” SPLIT FLANGE (SF3006) 1 53 5730021379 0 CAT RADIATOR EXTENSION 1
12 5730020891 0 30mm HOSE CLAMP 2 54 5730021380 0 OIL COOLER ADAPTOR PLATE 1
13 5730021343 0 44.5MM SINGLE HOSE CLAMP 2 55 5730021381 0 TROPICAL COOLER COVER 1
Cat Tier III Powerunit

14 5730021344 0 3/8 M/F TEST POINT 2 56 5730022034 0 HYDRAULIC TANK COMPLETE 1

15 5730021345 0 3/4 M/F TEST POINT 5 57 5730021384 0 AIR CLEANER COVER 1
16 5730017611 0 OIL COOLER 1 58 5730021385 0.02 EXHAUST GUARD 1
17 5730021346 0 TROPICAL OIL COOLER COMPLETE 1 59 5730020186 0 AIRCLEANER SEALING BRACKET 1
18 5730019326 0 LOCKABLE DOOR LOCK 5589/541 2 60 5730021386 0 RADIO CONTROLLED TRACK PANEL MTG PLATE 1
19 5730021347 0 12V HEAVY DUTY BATTERY 1 61 5730022035 0.01 CONTROL VALVE SPACER 1
20 5730021348 0 CONTROL PANEL 1 62 5730022036 0 POWER UNIT CANOPY 1
21 5730020913 0 EMERGENCY STOP 2 63 5730022037 0 COOLANT ACCESS HATCH 6
22 5730020914 0 RADIO CONTROLLED TRACK PANEL 1 64 5730021387 0 MAIN CONVEYOR SUPPORT 1
23 5730021349 0 LOCKABLE ISOLATOR SWITCH 1 65 5730021388 0 HOSE BRACKET 1
24 5730020917 0 LIGHT 1 66 5730021389 0.02 WATER PUMP GUARD 1

4300 St. Valentin, Austria

25 5730021350 0.01 12V WATER PUMP 1 67 5730021390 0 WEIGH SCALE CTRL PANEL MTG 1

Atlas Copco Powercrusher

26 5730021351 0.02 CAT TIER III 4.4 COMPLETE 1 68 5730021391 0.02 COOLANT HEATER MTG PLATE 1
27 5730021352 0 HAND THROTTLE 1 69 5730021807 0 PWR UNIT CANOPY STAY 1
28 5730019780 0 U BOLT 70MM 1 70 5730021381 0 EXHAUST HEAT SHIELD 1
29 5730021353 0 U BOLT 102MM 2 71 5730022034 0 TOOL BOX 1
30 5730021354 0 BRAIDED EXHAUST CENTRE PIECE (TIER 3) 1
31 5730021355 0 TURBO OUTLET PIPE FOR CAT (TIER III) 1
32 5730021356 0 EXHAUST-SILENCER ADAPTOR CAT (TIER III) 1
33 5730021357 0 CAT (TIER III) EJECTOR ADAPTOR 1
34 5730021358 0 EXHAUST SILENCER 1
35 5730021359 0 DUST EJECTOR 1
36 5730021360 0 OUTLET PIPE 1
37 5730021361 0 CAT (TIER III) INDUCTION HOSE 1
38 5730021362 0 AIR CLEANER HOSE 1
39 5730021363 0 AIR CLEANER HOSE 1
40 5730021364 0 TIER III AIR CLEANER HOUSING 1
41 5730019779 0 TIER III AIR CLEANER CHECK VALVE 1
42 5730021365 0.02 HYDRAULIC TANK CANOPY 1
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 209

4300 St. Valentin, Austria
 210
SPARE PARTS LIST
NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.23
1 5730002162 0 23CC TANDEM PUMP CW 1
2 5730002783 0 TANDEM PUMP 1
HCS 3715

6X1AS0365036
3 5730019774 0 CAT 3054 ENGINE MOUNT 4
4 5730019785 0 CAT C4.4 TIER Ill (74.5KW) 1
5 5730016669 0 COUPLING SHAFT 1
6 5730008255 0 COUPLING COLLAR 1
7 5730021392 0 CAT 3054 FLYWHEEL 1
COUPLING
8 5730002578 0 PUMP MTG PLATE 1
9 5730004902 0 FLYWHEEL PLATE 1
Cat Teir III Engine

10 5730004228 0 1" PUMP HUB 1

11 5730008384 0 WATERTRAP 1
12 5730021393 0.01 THROTTLE MOUNTING 1
PLATE
13 5730021394 0 WATER TRAP MTG BRKT 1
14 5730019735 0.01 PUMP SUPPORT 1
BRACKET
16 5730017609 0 OIL FILTER 1
17 5730017594 0 FUEL FILTER 1

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 211

4300 St. Valentin, Austria
 SPARE PARTS LIST

212
NO. PART NO. REV. NO. DESCRIPTION QTY
9.2.24
1 5730016520 0 DF 10/3 DIVERTER VALVE 1
2 5730012475 0 HYDRAULIC MOTOR 1
HCS 3715

3 5730017474 0 SHREDDER LIFT RAM 1

4 5730010828 0 50MM FLANGE BEARING 2
5 5730021399 0 TAPERLOCK 1
6 5730020908 0 TAPERLOCK 1
Shredder

7 5730020911 0 HRC 180 COUPLING 2

8 5730020912 0 COUPLING INSERT 1
9 5730022079 0 25.4X85 PIN 1
10 5730021972 0 SHREDDER BLADES 18
11 5730021973 0 MOTOR MOUNTING 1
12 5730021974 0 SHREDDER STRUT 1
13 5730021975 0 BLANKING PLATE 2
14 5730021976 0.01 SHREDDER 1
15 5730021977 0.01 SHREDDER MTG ASSEMBLY 1
16 5730021978 0.01 SHREDDER BLADE ASSEMBLY 1
17 5730021979 0 SHREDDER SIDE RUBBER 2
18 5730021980 0 RUBBER STRAP 1
19 5730021981 0 RUBBER STRAP 2

4300 St. Valentin, Austria

Atlas Copco Powercrusher
20 5730021982 0 SHREDDER RUBBER CURTAIN 1
21 5730021983 0 lNNER STRUT 1
22 5730021984 0.01 SHREDDER RUBBER CURTAIN 2
23 5730021985 0 SHREDDER OULET RUBBER PLATE 1
24 5730021986 0 SHREDDER OULET RUBBER CLAMP 2
25 5730021987 0 SHREDDER OULET RUBBER PLATE 1
26 5730021988 0 OUTLET PLATE SPACER SHIM 2
27 5730022068 0 FEEDER ADAPTER 1
Spare Parts
Spare Parts HCS 3715

Atlas Copco Powercrusher 213

4300 St. Valentin, Austria
HCS 3715 Spare Parts

9.2.25 CAT Engine Spare Parts

Atlas Copco Powercrusher Number: Qty/Engine Description

5730020919 1 Primary Air Filter 3212411 (C 4.4)

5730020918 1 Secondary Air Filter 3212412 (C 4.4)
5730017609 1 Oil Filter 7W-2326 (C 4.4)
5730017594 1 Engine Fuel Filter 1R-1804 (C 4.4)
5730008384 1 Spin On Fuel Filter 252-6338 (C 4.4)
5730021434 1 Switch Gp Oil 237-4894 (C 4.4)
5730013654 1 Switch Gp Temp 235-8747 (C 4.4)
5730021435 1 Coolant Pump 225-8016 (C 4.4)
5730021436 1 Coolant Pump Kit 247-0144 (C 4.4)
5730013023 1 Fuel Transfer Pump 238-8864 (C 4.4)
5730021437 4 Glow Plugs 232-6662 (C 4.4)
5730021438 1 Start Motor 225-3148 (C 4.4)
5730021439 1 Alternator 225-3141 (C 4.4)
5730009986 1 Vee Belt Set 128-5250 (C 4.4)

214 Atlas Copco Powercrusher

4300 St. Valentin, Austria
 HCS 3715

10.0 Electrical and Hydraulic

Atlas Copco Powercrusher 215

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

10.1 Electrical Schematics

Atlas Copco Powercrusher 216

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

217 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 218

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

219 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 220

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

221 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 222

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

223 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 224

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

225 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

10.2 Hydraulic

10.2.1 Hydraulic hose kits

Atlas Copco Powercrusher 226

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

227 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 228

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

229 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 230

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

231 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 232

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

233 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

10.2.2 Hydraulic circuit diagrams

Standard

Atlas Copco Powercrusher 234

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

Shredder Add On Kit -

235 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Vibrating Grid -

Atlas Copco Powercrusher 236

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

Coupling Kit -

237 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Tropical Pack Option - Hydraulic Cooling Fan -

Atlas Copco Powercrusher 238

4300 St. Valentin, Austria
ELECTRICAL & HYDRAULICS HCS 3715

Main Conveyor Lift Ram Option -

239 Atlas Copco Powercrusher

4300 St. Valentin, Austria
 10.2.3

Track machine
HCS 3715

Screen Box Sub Frame

Right Hand Side Conveyor Oil Cooler

B A

Main Conveyor
Main Conveyor
Tail Conveyor Motor

Lower Ram
Upper Rams
Jacking Leg

Jacking Leg
Upper Ram

Main Conv Slide

To X

To X

Screenbox Motor

Left Hand Side Conveyor

To X
Hydraulic Components

Lower Ram

23cc

From Main
Conveyor Motor
23cc
Manifold(X)

Conveyor motor Engine

middle grade

B A
Tail Raise/Lower B
To X A
To X 36cc
Hydraulic Oil Tank

To X
B/Feeder motor 36cc

4300 St. Valentin, Austria

Atlas Copco Powercrusher
To X To X

To X

Tail Fold

To X
To X

Track
Solenoid
Track L.H.S

Tipping Grid
Tipping Grid
B C
B A D
A

Bulkhead A To X

Conveyor motor
oversize grade

Rear Bulkhead Bulkhead B

To Oil Cooler

Track R.H.S
B
A

To X
Conveyor motor
main

240
ELECTRICAL & HYDRAULICS
 241
Vibrating Grid circuit
ELECTRICAL & HYDRAULICS

Vib Grid Ram

23cc
To X

23cc
Manifold(X)

Engine

B A Vib Grid Ram

To X To Jacking Legs

To X 36cc
B/Feeder motor
To X
To Main Conv Slide
36cc

To Aux Cv

To Jacking Legs

To X

4300 St. Valentin, Austria

Atlas Copco Powercrusher
To Track Solenoid

To Oil Cooler

Vibrating Grid Motor

B
A

To X

Conveyor motor
main
HCS 3715
 Shredder circuit
HCS 3715

23cc

23cc

Manifold(X)
Engine

To Jacking Legs

Shredder Ram

To X To Main Conv Slide

36cc

36cc
To Aux Cv

36cc

To Jacking Legs

To X

4300 St. Valentin, Austria

Atlas Copco Powercrusher
Shredder Motor

To X

242
ELECTRICAL & HYDRAULICS
ELECTRICAL & HYDRAULICS HCS 3715

Manifold(X)

To Main Conv Slide

To Track Solenoid
Engine

36cc

36cc
23cc
23cc

To X

Conveyor motor
A

main
B

243 Atlas Copco Powercrusher

4300 St. Valentin, Austria
HCS 3715 ELECTRICAL & HYDRAULICS

Atlas Copco Powercrusher 244

4300 St. Valentin, Austria
 HCS 3715

11.0 OEM Section

Atlas Copco Powercrusher 245

4300 St. Valentin, Austria
HCS 3715 OEM Manuals

11. OEM Appendices

Please Make sure you read this section carefully. It contains Manuals produced by OEM manufactures,
therefore Atlas Copco Powercrusher has reservations for misprints. The OEM Manuals will be placed in the
following order

11.1 Crawler Tracks Operation Manual

11.2 Electrical Control System Spare Parts

11.3 Optional Extra’s

11.4 Material Data Sheets

Atlas Copco Powercrusher 246

4300 St. Valentin, Austria