Trommall ®

Unit 25, Bay Road,

Mountmellick,

Co. Laois

Ireland

+353 (0) 57 867 9042

Email: sales@trommall.com

www.trommall.com
Contents
1. Introduction ........................................................................................................................ 1
1.1 Notes to the Operations Manual .................................................................................. 1
1.2 Safety Information ....................................................................................................... 2
1.3 Intended Use................................................................................................................ 3
1.4 Prohibited Use ............................................................................................................. 3
1.5 Declaration of Conformity ............................................................................................ 3
1.6 Warranty...................................................................................................................... 3
1.7 Copyright ..................................................................................................................... 4
2. Safety .................................................................................................................................. 5
2.1 General Safety.............................................................................................................. 5
2.2 Positions of Safety Signs on the Machine.................................................................... 10
2.3 Personal Safety .......................................................................................................... 15
2.4 Work Area Safety ....................................................................................................... 15
2.5 Emergency Stop Locations............................................... Error! Bookmark not defined.
3. Technical Data ................................................................................................................... 25
3.1 General information 3500 .......................................................................................... 25
3.2 Machine Component Specifications ........................................................................... 25
3.3 Machine Drawings...................................................................................................... 26
3.4 Noise Levels TrommALL® 3500TR running at 2500 rpm (running empty). ................... 28
4. Machine Description .......................................................................................................... 29
4.1 General Information................................................................................................... 29
4.2 Nomenclature and Technical Data .............................................................................. 31
4.3 Construction Units ..................................................................................................... 32
(1) Screen Unit ................................................................................................................ 32
4.4 Control ....................................................................................................................... 38
4.5 Pictorial Decal Descriptions ........................................................................................ 40
5. Transportation ................................................................................................................... 42
5.1 Prior to Transportation............................................................................................... 42
6. Initial Setup and Adjustments ............................................................................................ 43
6.1 Initial Inspection......................................................................................................... 43
6.2 Machine Location Considerations............................................................................... 43
6.3 Measures before Setup .............................................................................................. 44
6.4 Measures after Long Term Standstill .......................................................................... 44
6.5 Adjusting the screenbox ............................................................................................. 44
7. Standard Operating Procedures ......................................................................................... 46
 Contents

7.1 Pre-Operating Checks ................................................................................................ 46

7.2 Starting the Engine..................................................................................................... 47
7.3 Putting into Operation (Manual) ................................................................................ 48
7.4 Machine Shutdown .................................................................................................... 49
7.5 Tracking ..................................................................................................................... 50
8. Emergency Operating Procedures...................................................................................... 52
8.1 Emergency Stop ......................................................................................................... 53
8.2 Restarting after Emergency Stop ................................................................................ 54
8.3 Testing Emergency Stops ........................................................................................... 54
9. Maintenance ..................................................................................................................... 55
9.1 Regular Servicing ....................................................................................................... 55
9.2 Fuel System ............................................................................................................... 55
9.3 Maintenance Schedules ............................................................................................. 60
9.4 Air Filter ..................................................................................................................... 63
9.5 Servicing the Electrical System ................................................................................... 64
9.6 Servicing Screens ....................................................................................................... 66
10. Hydraulic System ........................................................................................................... 72
10.1 Servicing Conveyors ................................................................................................... 76
10.2 Lubrication................................................................................................................. 79
10.3 Greasing Schedule ..................................................................................................... 80
11. Troubleshooting ............................................................................................................ 81
11.1 Engine Maintenance Schedules .................................................................................. 81
Appendix A Schematics ............................................................................................................. 83
 1.1 Introduction

1. Introduction
1.1 Notes to the Operations Manual
This operations manual contains important information on how to operate the machine safely and
correctly. Read this manual carefully to learn how to operate your machine. Failure to do so could
result in personal injury or equipment damage. Consider this manual a permanent part of your
machine. Keep it with the machine at all times. Included with this manual is a disc which contains
the original language version of this manual which is English.

There is a separate engine manufacturer’s manual which should also be read and understood prior
to any operation or maintenance of the machine.

The following procedure bar indicates the start of a procedure. Any safety warnings related to the
procedure will be highlighted before the procedure.

PROCEDURE
Any results from a step in the procedure will be indicated in italic below that step. The end of a
procedure is indicated with a line under the last step or the last image in a procedure.

Follow all applicable safety regulations and recommendations in this manual as appropriate to
your machine and the situation/conditions prevailing at the time.

Federal, State, National and Local laws and safety regulations must be complied with at all times
to prevent possible danger to person(s) or property from accidents or harmful exposure.

Where supplied as a basic machine only, (with or without optional extras, e.g. drive elements,
etc.), the machine is intended for incorporation into a complete processing machine that is NOT
designed and/or constructed by TrommALL®. In these circumstances, or where supplied as a
replacement machine, TrommALL® will NOT be responsible for addressing environmental issues
and/or health and safety protection measures for the machine installation as a whole and will
bear NO responsibility for ensuring compliance with any regulations and/or statutory
requirements that may apply unless specifically included in the Contract of Sale.

INFORMATION AND ADVICE

If you need any information or advice regarding your machine please contact:

Trommall International Limited ®

Unit 25, Bay Road,

Mountmellick,

Co. Laois

Ireland

+353 (0) 57 867 9042

Email: sales@trommall.com
(1) Units

Within this operations manual figures shown within brackets ( ) after the Metric unit of measure
are approximate conversions from the actual metric measurement of the item concerned to the
imperial measurement.

(2) Optional Equipment

TrommALL® machines can include optional equipment and/or special features additional to the
standard specification. These may affect the information given in this operations manual. Look in
the appendix of this operations manual for any addendum which may relate to additional
equipment or variations to the standard specification. Take note of any variations to the standard
procedures and/or component specifications.

1.2 Safety Information

(1) Safety Warning Symbol

In conjunction with the text which follows it, this safety warning symbol is used as a “safety
warning system” in these operating instructions. The safety warning symbol indicates a risk of
personal injury. Follow all instructions which appear after this safety warning symbol in order to
avoid injury or fatal accidents.

(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and
protection only. All are used as attention-getting devices throughout this manual as well as on
ANSI type decals and labels fixed to the machine.

⚠ DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
safety alert symbol is shown with this danger classification.

⚠ WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
The safety alert symbol is shown with this danger classification.

⚠ CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol is shown with this danger classification.
 1.3 Introduction

NOTICE
This indicates a message related to property damage. The safety alert symbol is not shown with
this danger classification.

All hazards associated with each procedure will be listed before each procedure as described
above.

(3) California Proposition 65 Warnings

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. WASH HANDS AFTER
HANDLING. Diesel engine exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects, and other reproductive harm.

1.3 Intended Use

This product and its approved attachments are designed to be used in Material Processing
crushing and screening applications. Compliance with the operating instructions, the performance
of maintenance work as specified and adherences to maintenance intervals are all aspects of
proper use. Use of this product in any other way is prohibited and contrary to its intended use.

1.4 Prohibited Use

Operating the machine outside of its recommended range of applications or for any use which it
is not intended, will result in a loss of any guarantee. The manufacturer or supplier cannot be held
liable for any damage or injury resulting from such misuse.

Use of this product in any way other than its intended use is prohibited. The manufacturer will not
be liable for any damage resulting from such use.

1.5 Declaration of Conformity

This machine is in conformity with the provisions of the EC Machinery Directive 2006/42/EC
together with appropriate EN Harmonised Standards and National BS Standards and
Specifications.

A Declaration of Incorporation certificate is applicable to each machine. Refer to Appendix A for

an example of a Declaration of Incorporation certificate. The original copy of the certificate is sent
out with the machine.

1.6 Warranty
Refer to Appendix B for an example of the warranty. The original copy of the warranty is sent out
with the machine.
1.7 Copyright
The copyright of this operations manual is reserved by TrommALL®.

This operations manual contains information and technical drawings, which may not be copied,
distributed, altered, stored on electronic media, revealed to others or used for the purpose of
competition, either partially or in its entirety.

The right is reserved to alter any details contained in this manual without notice.

Copyright 2014

TrommALL ®

Unit 25, Bay Road,

Mountmellick,

Co. Laois

Ireland

+353 (0) 57 867 9042

Email: sales@trommall.com

To order additional copies contact your local TrommALL® dealer.

 2.1 Safety

2. Safety
This safety section covers a wide variety of hazardous situations, (but not necessarily limited to
those described), which may or may not apply to any specific machine installation. They are given
for general guidance only to assist the operator in setting up and maintaining an appropriate
regime for the protection of health and safety. Where the machine is supplied for incorporation
into plant/equipment designed, supplied and located by others, TrommALL® cannot be aware of
particular hazards that may be present or might occur and therefore accept no liability for
addressing or resolving these issues.

2.1 General Safety

The following signs and designations are used in the manual to designate instructions of particular
importance.

(1) Safety Warning Symbol

⚠
In conjunction with the text which follows it, this safety warning symbol is used as a “safety
warning system” in these operating instructions. The safety warning symbol indicates a risk of
personal injury. Follow all instructions which appear after this safety warning symbol in order to
avoid injury or fatal accidents.

(2) ANSI Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of severity of the potential
hazard. Signal words used without the safety alert symbol relate to property damage and
protection only. All are used as attention-getting devices throughout this manual as well as on
ANSI type decals and labels fixed to the machine.

⚠ DANGER
This indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
safety alert symbol is shown with this danger classification.

⚠ WARNING
This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
The safety alert symbol is shown with this danger classification.

⚠ CAUTION
This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
The safety alert symbol is shown with this danger classification
 NOTICE
This indicates a message related to property damage. The safety alert symbol is not shown with
this danger classification.

(3) Description of Safety Symbols

Table 2 - Description of Safety Symbols

Symbol Description
Electrocution hazard
Electrical shock/ electrocution from conveyor to power line contact.

Stay sufficient distances from electrical power lines.

Entanglement hazard
Entanglement in belt drive or conveyor.

Entanglement hazard
Arm entanglement in belt drive.

Stay clear of conveyor.

Install covers and guards before operation.

Turn machine off and remove the key.

Lockout machine.

Read and understand operations manual before using equipment.

Injection hazard
Skin injection from high pressure fluid.

Use cardboard or wood to check for leaks.

Crush hazard
Crushed foot from support leg.
 2.1 Safety

Stay clear of support legs and jacks.

Falling material hazard

Struck from falling or flying material.

Stay clear of hopper during operation.

Fall Hazard
Falling from a height.

Do not climb onto the machine.

Use personnel lift to reach high places.

Check tyre pressures prior to transport.

Check wheel nut torque. Recheck wheel nut torque every 150 miles
(200km).

Connect and check braking system.

Crush hazard
Crushing of fingers or hand. Force applied in one direction.

Keep hands clear of openings.

Hand entanglement in pulley/ winch

Keep hands clear of moving components

Electrocution hazard
Electric shock/ electrocution.

Hearing hazard
Loss or degradation of hearing.
Wear hearing personal protective equipment.

Explosion hazard
Explosion during an operation or service procedure.

Burn hazard
Burns from corrosive material.

Keep open flame away.

Emergency Stop
Press to engage, twist to reset.

Flying Material Hazard

Face struck by flying objects

Wear eye personal protective equipment

Crush Hazard
Crush from overhead impact.

Stay clear of moving conveyors.

Unauthorized persons prohibited.

Flying Material Hazard

Struck by flying material.

Do not stand on platform while machine is in operation

Do not stand on machine while in operation.

Inhalation Hazard
Inhalation of poisonous/ toxic fumes or dust.

Use dust suppression (water spray) or dust collection (filter) during

operation of this equipment.
 2.1 Safety

Wear respiratory personal protective equipment.

Cutting Hazard
Contact with knives in trommel drum will result in death or serious
injury.

Stay clear of sharp knives in trommel drum.

Crush Hazard
Crush from track machine run over.

Stay clear of track machine.

Crush Hazard
Crush from wheel machine run over.

Stay clear of wheeled machine.

Explosion Hazard
Battery Explosion.

Keep welding sparks away from the battery area.

Burn Hazard
Burn from hot surface or liquid

Stay clear of hot surface or liquid.

Impact Hazard
Impact from spring loaded door.

Stay clear of spring loaded door while opening.

2.2 Positions of Safety Signs on the Machine
Table 2-1 lists the safety signs that are on this machine. The item number indicates the position of
the safety sign on the machine, Ref: Error! Reference source not found..

Table 2-1 – Safety Signs

Sign
Item
ISO ANSI
315

410
 2.2 Safety

253

905

920
901

316

903
 2.2 Safety

317

354

651
426

907
 2.3 Safety

2.3 Personal Safety

Ascertain from the appropriate authority and observe all statutory and any other regulations that
may apply to the planned location before operating the machine. Operators must be trained in
the correct and safe use of all equipment.

Before operation the operator(s) must:

• Have received specific and adequate training in the task to be carried out.
• Have read and understood the operations manual and the Safety Signs in this manual and
around the machine(s).
• Knows the location and function of controls and safety features such as emergency stop
buttons and safety guards.
• Be aware of all moving parts of the machine.

Any work on and/or with the machine must be executed by trained, reliable and authorised
personnel only. Statutory minimum age limits must be observed.

Work on the electrical system and equipment of the machine must be carried out only by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician and
in accordance with electrical engineering rules and regulations.

Work on the hydraulic system must be carried out only by personnel with special knowledge and
experience of hydraulic equipment.

(1) Personal Protective Equipment

Where possible when working close to engines or machinery, only do so when they are stopped.
If this is not practical, remember to keep tools, test equipment and all other parts of your body
well away from the moving parts. Loose or baggy clothing can get caught in running machinery.

For reasons of safety, long hair must be tied back or otherwise secured, garments must be close
fitting and no jewellery such as rings may be worn. Injury may result from being caught up in the
machinery or from rings catching on moving parts.

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

Protective clothing includes: Hard Hat, Safety Glasses, Ear Protection, Dust Mask, Close fitting
overalls, Steel Toed Boots and a High Visibility Vest.

2.4 Work Area Safety

(1) General Work Area Guidelines

Operators must have received specific training in all operating and service tasks as required for
the safe operation and service of the machine. Operators must know the location and correct
operation of all controls and safety features such as remote stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.

Keep the work area as neat and as clean as practical. Keep your equipment clean and free of dirt
and grease so it can be checked for loose, cracked or broken parts. Replace defective parts as soon
as they are discovered.
The guards provided are designed and manufactured to ensure so far as reasonably practicable
that the machinery and plant on which they are fitted can be operated safely and without risk to
health when properly used. However, it cannot be guaranteed that the guards provided will meet
the requirements laid down by individual Inspectors and any additional guard and/or modification
to guarding supplied, which may be required for any reason whatsoever, will be charged as an
addition to the Contract Price.

Do not smoke or allow smoking near flammable fuels or solvents. Use non-flammable solvents for
cleaning parts and equipment. Know where fire extinguishers and other fire suppression
equipment are located and learn how to use them.

Always use hoisting equipment for heavy loads. Regularly check hooks, cables, shackles and chains
for stretch and wear. Never overload hoists, cranes or other lifting devices.

Avoid electrical and static sparks and any open flame while handling, storing, moving or pouring
fuels, electrolytes for batteries, hydraulic fluids or coolants.

(2) Safety Warnings and Labels

You can be injured if you do not obey the safety instructions as indicated on warning signs.
Observe all safety instructions and warnings attached to the equipment.

Ensure that safety instructions and warnings attached to the equipment are always complete and
perfectly legible. Keep warnings and instruction labels clean and up to date.

Replace unreadable or missing labels with new ones before operating the machinery. Make sure
replacement parts include warning or instruction labels where necessary.

Modifications

Never make any modifications, additions or conversions which might affect safety without the
supplier’s approval.

In the event of safety relevant modifications or changes in the behaviour of the machinery during
operation, stop the machine and lock out immediately and report the malfunction to the
competent authority/ person.
 2.4 Safety

(3) Transportation Safety

Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know the
overall height to avoid contacting overhead obstructions such as bridges, power lines etc.

The preparations to move equipment by an articulated lorry should be supervised by a minimum

of two persons. Ensure persons transporting the machine adhere to all safety signs and
procedures.

Before transportation on public roads, ensure the machine has been properly secured with no
loose material left in or on the machine. Always observe the valid traffic regulations and, if
necessary, ensure beforehand that the machine is in a condition compatible with these
regulations.

Extreme caution is required when transporting machinery on site. Soft or uneven ground may
cause accidents. On sloping terrain, always adapt your travelling speed to the relevant ground
conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope.

For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable of
adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any
signalling and lighting systems are fully functional. Before setting the machine in motion always
check that the accessories have been safely stowed away.
(4) Operation Safety

Before attempting to operate the machine, DO read, fully understand and observe the contents
of this manual. Also any other relevant manual for other equipment incorporated in the machine,
e.g. Engine manual. Study all safety signs on your machine.

It is emphasized that all safety aspects are checked before starting the machinery.

Make sure that you fully understand the operating procedures for the machine before attempting
to start.

Take the necessary precautions to ensure that the machine is used only when in a safe and reliable
state.

Operate the machine only for it’s designed purpose and only if all guarding, protective and safety
orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are in
place and fully functional.

Before starting the engine, ensure it is safe to do so. NEVER leave the machine unattended whilst
it is in operation.

Before starting, walk completely around the machine. Make sure no one is under it, on it or close
to it. Let other workers and bystanders know you are starting up and do not start until everyone
is clear of the machine.

Before moving the machine, ensure that everyone is clear from the surrounding area and that the
warning siren and beacon are operating correctly

Make certain enough ventilation is present to run engines safely. Do not start an engine in an
enclosed space without properly vented exhaust. Exhaust fumes from gasoline or diesel engines
can kill.

DO NOT allow a build-up of solid material or dust in any part of the machine. In the event of
material blockage, any malfunction or operational difficulty, stop the machine immediately and
lockout. Ensure any defects are rectified immediately.

Be alert and watch for pinch points, closing mechanisms, and falling parts when working on or
around any machinery. Keep hands and tools clear. In-running nip points on moving machinery
can cause serious injury or even death. Do not reach into unguarded machinery. Your arm could
be pulled in and amputated. Switch off and lockout the machine before removing any safety
devices or guarding.

Never work or stand beneath machinery or attachments as they are raised or lowered. Never work
or stand beneath machinery as they are being loaded with and/or discharging material. During
operation, do not climb onto, over or under moving conveyor belts and rollers. Always use ladders
and steps when mounting and dismounting.

Hole alignment on mechanical supports must be checked and secured with pins provided and in
accordance with safety signs.

Follow safe operating practices. Operate the machine controls smoothly. Avoid sudden stops,
starts or changes in direction. Only use emergency stop buttons or emergency stop lines (if fitted)
in emergency situations or during safety drills.

Never check the tension of ‘V’ belts, drive chains and conveyors when machine is running.
 2.4 Safety

DO check frequently the stability of the machine. The chassis SHOULD NOT have undue vibration
during operation.

After each day’s operation, always run the machine dry; never leave material in the belt feeder on
conveyor belts or screen box. Starting a machine with a full load will cause strain problems in your
machine.

(5) Hydraulic and Pneumatic Safety

Only persons having special knowledge and experience in hydraulic and pneumatic systems may
carry out work on hydraulic and pneumatic equipment. Never disable or alter any hydraulic circuit
or component without consulting with TrommALL®.

Relieve all pressure in the hydraulic system by returning all controls to the neutral position. Turn
off the machine and isolate power supply before any pipes, filter caps, filters or hydraulic fittings
are disconnected or removed. Depressurize all system sections and pressure pipes (hydraulic
system, compressed air system) to be removed in accordance with the specific instructions for the
unit concerned before carrying out any repair work.

Check for leaks in tanks or tubing with flashlights or other proper equipment. Never use an open
flame to check for leaks. Always use a piece of cardboard to check for leaks. Do not use your hand.
Hydraulic fluid under pressure can penetrate the skin causing serious injury. If fluid is injected
under the skin, it must be surgically removed or gangrene will result. Get medical help
immediately if this occurs. Wear personal protective equipment including goggles and gloves.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Splashed
oil may cause injury and fire. Repair any damage immediately.

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

Always practice extreme cleanliness servicing hydraulic components.

Do not exceed safe limits. Never set a pressure relief valve to a pressure higher than that set at
the factory.

For questions concerning accumulators, which are pressure-containment vessels, contact your
Trommall distributor. Malfunctioning valves or poor maintenance practices can result in build-up
of extremely high hydraulic and/or pneumatic pressures inside the accumulator.

(6) Electrical Safety

The electrical mode of operation on the electric hydraulic machines operates at 380-415 Volts AC,
50/60Hz.

Work on the electrical system or equipment may 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 and regulations.
Use only original fuses with the specified current rating. Switch off the machine immediately if
trouble occurs in the electrical system.

Machines with high voltage electrical equipment must be suitably earth bonded by a qualified
electrician prior to activating the main isolator switch. If machine is electric-hydraulic or direct
electric drive, the ‘mains’ electrical supply to the machine should always be isolated by
unplugging/ uncoupling the ‘mains’ power socket. It is recommended that an earth leakage safety
switch be fitted in the supply line to the power point on site. Special care should be taken to ensure
that earth wires are correctly connected.

When working with the machine, maintain a safe distance from overhead electric lines. If work is
to be carried out close to overhead lines, the working equipment must be kept well away from
them. Check out the prescribed safety distances.

If your machine comes into contact with a live wire:

• Warn others against approaching and touching the machine.

• Have the live wire de-energised.

If provided for in the regulations, the power supply to machines and parts of machines, on which
inspection, maintenance and repair work is to be carried out, must be cut off. Before starting any
work, check the de-energised parts for presence of power and ground or short circuit them in
addition to insulating adjacent live parts and elements.

The electrical equipment of the machine is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables must be rectified
immediately.

Necessary work on live parts and elements must be carried out only in the presence of a second
person, who can cut off the power supply in the case of danger by actuating the emergency shut
off or main power switch. Secure the working area with a red and white safety chain and a warning
sign. Use insulated tools only.

Before starting work on high voltage assemblies and after cutting out the power supply, the feeder
cable must be grounded and components such as capacitors short-circuited with a grounding rod.

Tracked machines are wired with negative earth. Always observe correct polarity.

Always disconnect battery leads before carrying out any maintenance to the electrical system or
servicing the engine. Never short across the starter terminals of a battery as this can cause a fire
and could also damage the electrical system. If welding is to be carried out on the machine, it is
essential that the power-pack is isolated.

The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce
explosive gases. Wear personal protective equipment and avoid contact with the skin, eyes or
clothing.

Diesel engine exhaust emissions contain products of combustion which may be harmful to your
health. Always operate the machine in a well-ventilated area and if operating in an enclosed area,
vent the emissions outside. Do not touch any part of the engine or exhaust system. Allow the
engine and exhaust to cool before performing any repair or maintenance.

Never fill the fuel tank with the engine running, while smoking or when near an open flame. Never
overfill the tank or spill fuel. If fuel is spilled, clean it up immediately.
 2.4 Safety

(7) Maintenance Safety

Understand the service procedures before doing work. Keep working area clean and dry. Never
lubricate, clean, service or adjust machinery while it is moving. Keep hands, feet and clothing clear
of power driven parts and in running nip-points. Disengage all power and operate controls to
relieve pressure. Stop the engine, implement the lockout and tag out procedure and allow the
machinery to cool before carrying out any maintenance.

Whenever maintenance or service is being carried out a minimum of two (2) persons should be
present at all times. NEVER WORK ALONE.

Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage
immediately. Replace worn and broken parts. Remove any build-up of grease, oil and debris.

Never attempt repairs or adjustments to the machine while it is running unless specified to do so.

Before carrying out any maintenance, relieve all hydraulic pressure by returning the controls to
the neutral position and secure all hydraulically operated attachments with pins provided.

Disconnect the battery ground cable before making adjustments on electrical systems or welding
on machinery. For the execution of maintenance work, tools and workshop equipment adapted
to the task on hand are absolutely indispensable.

Remove only guards or covers that provide access. Wipe away any excess grease and oil.

Never leave guards off or access doors open when unattended. Keep bystanders away if access
doors are open.

When working beneath raised equipment, always use blocks, jack-stands or other rigid and stable
supports. Make sure that any part of the machine raised for any reason is prevented from falling
by securing in a safe reliable manner. Never work under unsupported equipment.

For carrying out overhead assembly work always use specially designed or otherwise safety
oriented ladders and working platforms.

Performing work above 2 m (6ft-6”) always use an approved (EN/ANSI) safety harness. Do not use
any unauthorized or unsafe structures or platforms.

Return idler roller guards should be checked for wear/damage during routine maintenance. The
gap between the guard and the idler roller should not exceed 6mm. The gap between the idler
roller and the guard must be renewed. Contact your local TrommALL® dealer to obtain an
approved replacement.

Maintenance and Repairs during Operation; Disposal of Parts and Consumables

Observe the adjusting, maintenance and intervals set out in these operating instructions, except
where:

• Warning, horn/light/gauge or indicator calls for immediate action.

• Adverse conditions necessitate more frequent servicing.

Observe information on the replacement of parts and equipment. These activities may be
executed by skilled personnel only.
When the machine is completely shutdown for maintenance and repair work, it must be secured
against inadvertent starting by:

• Switching off the engine and removing the ignition key or isolating the electrical supply as
applicable.
• Implementing the lockout/tagout procedure.
• Attaching a warning sign(s) to the machinery in appropriate positions.

Carry out maintenance and repair work only if the machine is positioned on stable and level
ground and has been secured against inadvertent movement and buckling.

Never allow unqualified or untrained personnel to attempt to remove or replace any part of the
machine, or anyone to remove large or heavy components without adequate lifting equipment.

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. Use only suitable and
technically adequate lifting gear. Never work or stand under suspended loads.

Keep away from the feed hoppers and stockpile conveyor discharge points, where there is risk of
serious injury or death due to the loading and removal of material.

Falling from and/or onto TrommALL® machines can cause injury or even death. Do not climb on
the machine whilst it is in operation. Never use machine parts as a climbing aid.

Beware of moving haulage and loading equipment in the vicinity of the machine.

Always use an EN/ANSI approved safety harness when reaching any points 2 m (7ft) or more above
the ground level. Keep all handles, steps, handrails, platforms, landing and ladders free from dirt,
oil, snow and ice.

The fastening of loads and instructing of crane operators should be entrusted to experienced
persons only. The marshal giving the instructions must be within sight or sound of the operator.

After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections,
chafe marks and damage. Any defects found must be rectified without delay.

Any safety devices removed for setup, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work to ensure full working
order.

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful
waste used with TrommALL® equipment includes such items as oil, fuel, coolant, filters and
batteries, etc. Use leak-proof containers when draining fluids. Do not use food or beverage
containers that may mislead someone into drinking from them. Do not pour waste onto the
ground, down a drain or into any water source. Ensure that all consumables and replaced parts
are disposed of safely and with minimum environmental impact.

Always ensure that any safety fitment such as locking wedges, securing chains, bars or struts are
utilized as indicated in these operating instructions.

Diesel fuel is highly flammable. Never remove the filler cap, or refuel, with the engine running.

Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion risks.
Do not carry out maintenance on the fuel system near naked lights or sources of sparks, such as
welding equipment or whilst smoking.
 2.4 Safety

After maintenance, tighten all bolts, fittings and connections. Install all guards, covers and shields.

Replace or repair any damaged ones. Refill and recharge pressure systems with recommended
fluids. Start the engine and check for leaks. Operate all controls and make sure the machine is
functioning properly. After testing, shut down, check the work you performed. Recheck all fluid
levels before releasing machine for operation.

(8) Gas, Dust, Steam, Smoke

Death, serious injury or delayed lung disease may result from breathing dusts that are generated
when certain hazardous materials are crushed, screened or conveyed with this equipment.

Always operate internal combustion engines and fuel operated heating systems only out of doors
or in a well-ventilated area. Before starting the machine in enclosed areas, make sure that there
is sufficient ventilation.

Observe the regulations in force at the respective site.

Dust found on the machine or produced during work on the machine should be removed by
extraction, not blowing. Dust waste should be dampened, placed in a sealed container and
marked, to ensure safe disposal.

When dusts are generated by the operation of this equipment, use approved respiratory
protection, as required by Federal, State and Local safety and health regulations.

Carry out welding, flame cutting and grinding work on the machine only if this has been expressly
authorised, as there may be a risk of explosion and fire.

Before carrying out welding, flame cutting and grinding operations clean the machine and its
surroundings from dust and other flammable substances and make sure the premises are
adequately ventilated as there may be a risk of explosion.

Ensure operators wear a suitable face mask where exposed to possible harmful effects of air
pollution of any kind.

(9) Hazardous Substances

Ensure that correct procedures are formulated to safely handle hazardous materials by correct
identification, labelling, storage, use and disposal.

All hazardous materials must be handled strictly in accordance with the manufacturer’s
instructions and all applicable regulations observed at all times. Store hazardous materials in
restricted access areas and mark them clearly.
(10) Noise Levels

HEARING HAZARD EXCEEDS 90 dB (A)

May cause loss or degradation of hearing over a period of time.

Always ensure that operators are provided with ear defenders of approved pattern and that these
are worn at all times when the machine is operating.
 3.1 Technical Data

3. Technical Data
3.1 General information 3500
Machine ............................................. TrommALL

Type ................................................... 3500TR

Engine ................................................ Diesel Hydraulic Yanmar 3TNV88 22kW (29.5hp) @

2500rpm

(1) Machine Weights

Total Machine Weight ...................... 8500kg

(2) Machine Dimensions

Width (transport) ............................... 2.27m

Length (transport) .............................. 6.01m

Length (working) ................................ 11.67m

Height (transport) .............................. 2.85m

Height (working) ……………………………….2.85m

3.2 Machine Component Specifications

(1) Screen Unit

Mesh Sheet

Screening Area ................................... 1.83m x 1.83m

Screening Angle ................................. 16 degrees

(2) Power unit

Engine

Diesel Hydraulic with Yanmar 3TNV88 22kW (29.5hp) @ 2500rpm

3.3 Machine Drawings
(1) General Plan TrommALL® 3500TR Working dimensions
 3.3 Technical Data

(2) General Plan TrommALL® 3500TR transport dimensions(mm)

3.4 Noise Levels TrommALL® 3500TR running at 2500 rpm (running empty).
 4.1 Machine Description

4. Machine Description
4.1 General Information
(1) Identification Plate

The machine identification plate gives important information about the machine, Ref: Figure 4.1

Figure 4.1 - Identification Plate

1
2
3
4

1. Machine model
2. Year manufactured
3. Machine mass
4. Serial number

The machine identification plate is located on the outside of the powerunit.

(2) Machine References

When using this handbook, at all times the right and the left hand references are viewed looking
into the mesh from the front.

When using this handbook, at all times the front of the machine is situated where the large
material falls off and the rear of the machine is situated where the material is poured in

1. Left
2. Front
3. Right
4. Rear
 4.2

4.2 Nomenclature and Technical Data

Construction Unit
Item
1 Screenbox
2 Powerunit
3 Product Conveyor
4 Tail Conveyor
5 Tracks
4.3 Construction Units

(1) Screen Unit

The screen is positioned on the frame.

It oscillates in place on springs by flywheels which are mounted onto the frame.

The screen is driven by a flywheel powered through a hydraulic motor.

The meshes are replaceable by meshes with different sizes of apertures from 5mm - 100mm.

Figure 4.1 – Screenbox

 (1)

(2) Power Unit

The power unit (2) is attached at the Chassis of the machine. Ref: Figure 4..

Figure 4.2 - Power Unit

The TrommALL® 3500TR has one control unit.

1. The control panel

The control panel is situated in the powerunit on the left-hand side of the machine. Which includes
ignition panel with hour meter and warning lights, hand throttle and control valves. Ref: Figure 4..

Figure 4.3 - Control Panel and Control Valve Unit

 2. Hydraulic System

Figure 4.4 - Hydraulic Tank

1. Hydraulic Oil Level Indicator

2. Hydraulic Tank Access Panel
3. Filler Cap
4. Return Line Filter
5. Return Manifold

3. Return Line Filter

Figure 4.5 - Return Line Filter

1. Cover plate
 (1)

2. Filter Housing
3. Filter Element Housing
4. Retaining Bolts
5. Seal ring
6. Filter Element

(3) Product conveyor

The product conveyor, sometimes referred to as the fines’s conveyor, collects the undersized
screened fraction from the material being processed.

Figure 4.6 – Fines conveyor

Belt Design

The Fines conveyor assembly on the 3500TR machines consist of:

1. Fines Conveyor Frame

2. Fines Conveyor Belt
3. Head drum
4. Conveyor Head drum tensioner
5. Hydraulic motor
6. Return roller
7. Skirting guards
8. Tail Drum
9. Tail Drum guard
(4) Tail Conveyor

The tail conveyor, sometimes referred to as the oversize conveyor removes the oversize fraction
from the of the material that cannot pass through the screening media will fall off the end of the
screen box chute and onto the tail conveyor.

Figure 4.7 - Conveyor Belt Assembly

The Fines conveyor assembly on the 3500TR machines consist of:

1. Tail conveyor tail section frame

2. Tail conveyor head section frame
3. Head drum
4. Hydraulic motor
5. Tail conveyor chevron belt
6. Tail conveyor folding cylinder
7. Tail conveyor folding linkage
8. Tail conveyor wing plate
9. Tail Drum
10. Tail drum guard
11. Feed boot

• Belt Performance

All conveyor belts and drum lagging on TrommALL® machines are made to the highest standards
and are tough and durable.

However, these are consumable items and will need to be replaced through normal wear and tear.
Mechanically spliced belts are less effective than vulcanized and have an increased tendency to
 (1)

slip. Also, a belt which has been adjusted to its maximum must be replaced with a new belt. Worn
lagging must also be replaced.

The correct procedure for changing a belt/lagging is to contact your local TrommALL® dealer who
will either carry out the work himself or get it carried out by personnel trained in this field.

To ensure optimum performance and safety, the conveyor must be:

PROCEDURE
1. Cleaned daily or more frequently depending on the application. (For details contact
your local TrommALL® dealer.)
2. Checked for cuts, tears, rips or any other physical damage.
3. Tensioned properly.
4. Kept in alignment.

• Belt Tension

The belt will normally have to be tensioned a number of times during the belts’ lifetime
due to the natural stretching of the belt.

It is very important that the conveyor belt is tensioned evenly and to the correct level, not
too tight and not too loose.

A loose belt can cause slippage, resulting in reduced throughput.

An over-tight belt can damage drum bearings, resulting in increased downtime.

Correct tension is obtained when no slippage occurs during normal use.

See section 10.1 for further details.

• Conveyor Belt Alignment

For safe, proper and efficient operation of the machine, it is important that conveyor belts
are properly aligned.

The belt alignment can be checked without removing any guard by looking through the
viewing apertures.

The conveyor belts are aligned by adjusting the drum adjusters.

Reasons for the conveyor belts not running in alignment:

1. Machine not perfectly levelled

2. Faulty belt tension.
3. Faulty position of the drums.
Refer to Section 10.1 Servicing
 • Belt Slippage

So long as the described maintenance procedures have been properly observed, your
machine should not experience belt slippage.

Slippage occurs when the drum turns and the belt does not move.

Slippage can occur for a number of reasons including:

1. Incorrectly tensioned belts.

2. Worn belts.
3. Ineffective lagging.
4. Too much load on the belt.
5. Rollers cannot rotate freely.
Refer to Section 10.1 Servicing .

(5) Tracks

The tracks on the machine support the chassis and allow the machine to be mobile. The tracks are
hydraulically powered and electronically controlled via the tracking umbilical control.

4.4 Control
(1) Control Valve Unit

The levers of the drive control unit are for the purpose of operating the machine.

Figure 4.8 - Control valve unit

1. CV 1 – Start running conveyors

2. CV 2 – Starting running screenbox.
3. Ignition control panel
 4.4

Note that all control valve levers are labelled on the machine.

Symbols for the levers

In the manual the following symbols are used to show the position (up, neutral, down) of the
levers. Note down function on the control valve units is only applicable to tracked version

Figure 4.9 - Control valve unit

1. Upward
2. Neutral
3. Downward

Control Valve Unit (I2)

Figure 4.10 - Control Valve Unit in Neutral Position

 Figure 4.12 - Control Valve unit in downward position
Figure 4.11 - Control Valve in upward position

Valve Position Function

1 Allows auxiliary controls function
CV 1 A Screen box engaged
a Left track engaged (Tracked Option only)
2 Neutral
CV 2 B Conveyor engaged
b Right Track engaged (Tracked Option only)

4.5 Pictorial Decal Descriptions

Pictorial decals have been placed on the machine to ensure that the machine is correctly operated
and maintained. Operations decals describe the operations of levers on the machine. Information
decals give details about how to correctly operate and maintain the machine.

(1) Machine Operations Decals

Each operation decal is placed on the machine beside the corresponding lever or control. The
following tables give short explanations of each operation decal used on the machine. The up
arrow in the decals indicates moving the lever forward or up. The circle in the decals indicates the
neutral position. The down arrow in the decals indicates moving the lever back or down.
Control Valve Labels (Control Unit)

Decal Description Explanation

Conveyors Engaged
↑

CV 1 Neutral
●

Left Track engaged (Tracked Option

↓ only)

↑ Screenbox Engaged

CV 2 Neutral
●

Right Track engaged (Tracked Option

↓ only)

Fold out conveyor (Straighten for

↑
operation)

● Neutral
Aux

Fold in conveyor (Folds conveyor in for

↓
transport and tracking)

↑ Raise conveyor

Aux ● Neutral

↓ Lower Conveyor

.
5. Transportation
5.1 Prior to Transportation

⚠ CAUTION
Prior to transportation always check the machine for loose or damaged components. Ensure all
loose items are carefully stowed and secured if these are to be transported on the machine.

Check that the travelling dimensions and weight of the machine will be within the regulation
limits.

Before transporting the machine, observe the prescribed transport position, admissible speed and
itinerary. Only use appropriate means of transport and lifting gear of adequate capacity. Know the
overall height to avoid contacting overhead obstructions such as bridges, power lines etc.

The preparations to move equipment by an articulated lorry should be supervised by a minimum

of two persons. Ensure persons transporting the machine adhere to all safety signs and
procedures.

Before transportation on public roads, ensure the machine has been properly secured with no
loose material left in or on the machine. Always observe the valid traffic regulations and, if
necessary, ensure beforehand that the machine is in a condition compatible with these
regulations.

Extreme caution is required when transporting machinery on site. Soft or uneven ground may
cause accidents. On sloping terrain, always adapt your travelling speed to the relevant ground
conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope.

Stay clear of the machine. The machine must be loaded and transported only in accordance with
the operating instructions.

For manoeuvring the machine, observe the prescribed transport position, admissible speed and
itinerary. Use only appropriate means of transport and lifting equipment and where applicable of
adequate capacity. The re-commissioning procedure must be strictly in accordance with the
operating instructions. Before travelling with the machine, check that the braking and any
signalling and lighting systems are fully functional. Before setting the machine in motion always
check that the accessories have been safely stowed away.

For further information please refer to the trailer manual supplied.

6. Initial Setup and Adjustments
NOTICE
TrommALL® recommends that the assembly and installation work of the machine be carried out
by the TrommALL® customer service department. The manufacturer/supplier will not be liable for
damage caused by improper assembly or installation.

The environment in which the machine will operate contains inherent health and safety risks,
which the operator must take steps to avoid.

Dangers from overhead conveyor discharges, overspill material, vehicle movements, etc., as well
as other site related hazards must be anticipated.

Avoid these by carrying out risk assessments before the machine is put into operation to ensure
appropriate exclusion zone measures are put in place and site personnel safety awareness training
has been undertaken.

Refer to the engine manual for initial start-up of the engine.

6.1 Initial Inspection

When the machine is delivered, thoroughly check for any damage that might have occurred during
transport. Do not set up the unit until the inspection is complete. Complete any delivery and start-
up forms that were supplied with the equipment. Take note of any damage found, and photos if
possible, and have the driver initial your description of any problem(s).

Check all loose parts, small-parts boxes, and tools against the packing list to ensure all items
shipped are present. Check in and around the machine for any loose items that may have been
shipped inside the machine.

6.2 Machine Location Considerations

Prior to setting up the machine, consideration should be given to a suitable layout to prevent
oversize material or metal from entering the machine. In order to prevent damage of the screen
unit, no material above the size recommended should be fed into the machine.

Position the machine in a safe and level operating position, making sure both tracks are in full
contact with the ground to minimise movement of the Machine. Regularly check the machine is
level and stable.

Pay attention to access from the loading area and to where material is to be deposited.

For dusty conditions some account should be taken of the prevailing wind direction to minimize
the possibility of dust entering the air intake.

When setting up the machine, ensure that enough space is available around the machine to enable
easy set-up, servicing and repair work.

Machinery arranged before and after this machine will have to be placed on the site accordingly.
6.3 Measures before Setup
We recommend that the assembly/installation work of the machine be carried out by the
TrommALL® customer service department. The manufacturer/supplier will not be liable for
damage caused by improper assembly/installation.

PROCEDURE
1. Ensure all guards are fully secured in correct/closed position.
2. Remove all loose items from the screen by untying the securing ropes.
3. Put control valve levers in neutral (non-operational) position.
4. The machine must be placed on solid ground capable of carrying the machine‘s weight.
5. Before detaching the machine from the prime mover, it is important that the chosen site
is level. Level the work site foundation with the loading shovel.
6. Level the machine with a precision spirit level.
7. Do not position the machine above ground level, e.g. on blocks etc.

6.4 Measures after Long Term Standstill

NOTICE
o Prior to putting the machine into operation perform daily (10 hour) maintenance
schedule.

6.5 Adjusting the screenbox

The screenbox provides the vibration in the TrommALL® 3500TR that allows for the separation of
materials. This vibration (circular motion) is caused by an off centre flywheel and weights on the
screen box shaft that allows this circular motion or “throw” to occur this throw is measured in mm
and the standard throw is set to 8mm in the 3500TR.

The setting of the throw on screen box is done by putting additional weights onto the flywheel.

To alter the throw on the screenbox “throw” weights may added or removed depending on the
application of the machine

• The addition of weights to the flywheel will increase the throw on the screenbox
• The removal of weights will reduce the throw on the on the screenbox

⚠ WARNING
DO NOT exceed 80mm thickness combination of flywheel and weights as shaft bearing tolerance
is set to a maximum of an 8mm throw on the screenbox leaving our facilities.

Ensure same weights are added to both sides of the screenshaft.

Ensure the flywheel is weighted symmetrically i.e. identical weights are on both sides each
flywheel

NOTICE
Consult your TrommALL® dealer before attempting to adjust the screenbox.
 ⚠ DANGER
• Crushing hazard
• Entanglement hazard
• Ensure machine is switched off and keys are removed before any adjustments are made

PROCEDURE

Figure 6.10 - Removing flywheel covers

1. Remove flywheel top and bottom covers (Item 1 and 2; Figure 6.10) with 4 bolts
securing to cover
2. Remove counterbalance flywheel weights (Item 3; Figure 6.10).
3. Once counterbalance weights are removed the motor side cover bracket can be
removed (Item 4; Figure 6.10)
4. Loosen flywheel bolts (Item 1; Figure 6.11) and remove nuts from back
5. Carefully remove weights (Item 2; Figure 6.11) from the nut side first.
6. Adjust weights accordingly and ensure the same weights are applied to either
flywheel (Item 3; Figure 6.11)
7. Reverse procedure to reassemble.
 Fig. 6.11 - Changing flywheel weights

7. Standard Operating Procedures

7.1 Pre-Operating Checks

⚠ DANGER
Keep away from the reject grid, where there is risk of serious injury or death due to rejected
material and danger from other heavy machinery working in the area, unless you are a fully trained
operator engaged in loading the machine.

Keep away from the screens, where there is risk of serious injury or death due to rejected material
and danger from other heavy machinery working in the area, unless you are a fully trained
operator engaged in loading the machine.

⚠ WARNING
The machine may only be operated if the safety instructions provided in the previous chapters
have been observed and the described procedures have been performed.

Always wear an EN/ANSI approved hard hat and footwear with adequate toe protection when
working in the vicinity of the machine and on the work site.
Operate the machine only if all protective and safety devices, such as removable safety devices,
emergency shut-off equipment, sound-proofing elements and exhausts are in place, fully
functional and properly maintained.

During operation, all sound baffles must be closed. In the event the machine malfunctions for any
reason, stop the machine and lock out immediately.

Report the malfunction to the competent authority in charge. DO NOT continue to operate the
machine UNTIL the malfunction is corrected.

7.2 Starting the Engine

⚠ WARNING
o Wear personal protective equipment.

NOTICE
o All control levers must be in the neutral (non-operational) position.
o Do not start engine without the above-mentioned warning lights being illuminated.
o All switches must be in the OFF position.
o If the warning lights fail to extinguish stop the engine and detect the fault before using
the machine.

PROCEDURE
1. Observe all safety warnings.
2. Turn the ignition key to the ON position (item 2), Ref: Figure 7.1

Figure 7.1 - Ignition Key Positions

3. The following warning lights on the control panel will illuminate:

 Figure 7.2 – Ignition panel indication lights

4. Pull the ignition pulley to crank the engine

5. Release ignition pulley immediately after the engine starts.

7.3 Putting into Operation (Manual)

⚠ DANGER
o Entanglement hazard. Stay clear of moving conveyors.
o Fluid injection hazard.
o Explosion/burn hazard.

⚠ WARNING
o Hearing hazard. Wear hearing personal protective equipment.
o Read and understand manual.
o Falling hazard.
o Lock-out machine.

PROCEDURE
1. Observe all safety warnings.
2. Start the engine. (Refer to section 7.2)
3. Adjust engine speed to pre-set limit on throttle.
4. Make sure all panels are down and locked in place.
5. Move the drive lever down (Lever 1 - Position (A)) to start the oscillating screen.

(1) (2)

Figure 7.3 – Control levers operating position

6. Move the conveyor lever into the forward position (B) to start the conveyor
7. Machine is ready for operation.

7.4 Machine Shutdown

⚠ DANGER
o Nip point hazard.
o Fluid injection hazard.

⚠ WARNING
o Wear personal protective equipment.

NOTICE
When shutting down the machine or carrying out maintenance or adjustment the following
procedure must be followed.

Turning all machine components at once causes a pressure spike in the hydraulic circuit and a
voltage spike in the electrical circuit both of which are detrimental to the machine. A slight pause
between disengaging each component can prevent this spike taking place.

The machine must be running empty of material before machine is stopped.

PROCEDURE
1. Observe all safety warnings.
2. Stop the machine by moving Lever 1 and 2 into neutral position
3. Reduce engine speed to idle
4. Turn off ignition and remove key
7.5 Tracking

⚠ DANGER
o Crush hazard. Stay clear of moving machine.

⚠ WARNING
o Read and understand manual.

o Be aware of any persons in the immediate vicinity

NOTICE
The machine can be tracked using either the umbilical remote tracking unit or the radio remote
tracking unit (optional). When using umbilical remote keep cord at full length not to track over it
and give you better sight around the machine.

There is an e-stop on the handset that should be used in the case of emergency.

When plugging the dummy plug out the machine will switch off, you will be able to restart the
machine once the umbilical handset is attached and the e-stop is not activated.

(1) Manual Tracking with the Umbilical Handset

PROCEDURE
1. Plug the umbilical handset into the side of the control panel.

2. Push the control valves CV1 (a) & CV2 (b) backward to “Track” to send hydraulic power to
the track solenoid valve.

Figure 7.4 – Control lever tracking positions

3. Turn the handset on, this will turn on the siren & beacon.
 Figure 7.5 Umbilical Handset

4. Wait 10 seconds and ensure that there are no persons in the immediate vicinity that could
get harmed. Check all sides of the machine.

5. Use the toggle switches on the handset to move the machine. Direction is displayed by
the coloured arrows on the machine.

6. Once the machine has been place in the desired position unplug the umbilical handset
and store in a safe secure place; reattach the dummy plug to restart the machine.

(2) Tracking with the Radio Remote Handset

PROCEDURE
1. To operate Radio Remote, disconnect Tracking Doglead or Blanking Plug from socket on
left side of control panel. Connect the radio remote lead to this socket on the left side of
the control panel.

2. Power on the radio remote control by pressing the remote ON button on the transmitter
handset. NOTE – Transmitter needs to be ON before panel key switch on control panel is
turned to the ON position.

3. Start the Engine as per the Engine start up procedure in previous sections.

4. Push the control valves CV1 (a) & CV2 (b) backward to “Track” to send hydraulic power to
the track solenoid valve.

5. To activate the tracking circuit press the Tracks On/Off button on the transmitter. Note:
At this point the Tracking Safety Siren should sound. There is a safety delay period on the
remote before the Tracks will operate.

Figure 7.6 Radio Remote Handset

 6. The Machine can now be tracked using the forward and reverse controls on the Remote
– before manoeuvring machine, ensure that all personnel are at a safe distance, and that
there is sufficient clearance around the machine to move.

7. Once the machine has been place in the desired position unplug the umbilical handset
and store in a safe secure place; reattach the dummy plug to restart the machine.

8. Emergency Operating Procedures

⚠ WARNING
o Never give your key to anyone else and where more than one person is working on the
equipment, they must fit their lock also

(1) Before carrying out any Work on the Machine

NOTICE
Depending on the type of machine, there may still be several kinds of energy remaining after the
power is turned off. The written lock-out procedure should have a complete list of all these
secondary energy sources. Secondary energy sources may be hydraulic (fluid under pressure),
pneumatic (air under pressure), kinetic (force of moving parts) and/ or potential (force contained
in weights that have been raised).

PROCEDURE
1. Turn off the engine at the starter panel and remove key.
2. Lock the panel and put the key in a safe place.
3. Release stored energy from the system, such as hydraulic fluid under pressure, so that the
machine is in a zero-energy state.
4. Ensure belts aren’t loaded when carrying out maintenance.
5. Try to start or activate the machine to make sure that the power is off. (Don’t forget to
push the stop button again, afterward)

(2) After Carrying out any Work on the Machine

PROCEDURE
1. Secure the work area by replacing guards and shields, removing blocks, picking up tools and
inspecting the work area.

3. If there are no other locks on, turn the main power isolator switch to the ON position

4. Unlock the operator’s control panel.

5. Warn others before starting the machine.

6. Start the machine and proceed with your work.

8.1 Emergency Stop
In an emergency only stop the machine by pressing an emergency stop button on the machine.

⚠ WARNING
When an emergency stop has been initiated, the ignition switch stays on. Do not attempt to restart
the engine until it is safe to do so.

PROCEDURE
1. Press any emergency stop to stop the engine and machine, Item 1 and 2 below. The are
Emergency stops on the opposite side of the machine in the same locations. Ref: Figure
8.1.
2. Turn the ignition key to the off position as soon as possible, if safe to do so.
3. Remove the ignition key.
4. Set the isolator switch to the off position.
5. When safe, release the emergency stop button(s) by pulling or twisting.

Figure 8.1 - Emergency Stop Locations (RHS & LHS)

8.2 Restarting after Emergency Stop

⚠ WARNING
Ensure that the problem has been solved and all personnel are clear of the machine. Before
restarting, ensure that all guards are correctly fitted and fully functional. Do not restart until it is
safe to do so.

NOTICE
The machine must not be restarted if there is any material in and/or on the machine Ensure there
is no material in and/or on the machine before restarting.

PROCEDURE
1. Release the emergency stop button(s) by pulling or twisting.

2. Restart the machine, Ref: Chapter 7.

8.3 Testing Emergency Stops

PROCEDURE
1. Start the engine.
2. Push in an emergency stop button.
3. Re-set the emergency stop by pulling or twisting, depending on the type fitted.
4. Turn the ignition key to the ‘Off’ position.
5. Turn ignition the key to the first position again.
6. Wait for the pre-start warning to complete.
7. Turn ignition key to start the engine again.
8. Repeat the procedure for all other emergency stops.
9. Maintenance
9.1 Regular Servicing

NOTICE
To deliver the specified quantity of grease to shaft bearings, ascertain the amount the grease gun
will deliver with each ‘pump’. Do not guess or assume an amount! Check the greasing equipment
used regularly. To prevent contamination of the grease, wipe the grease nipples clean before
applying the grease gun.

It is bad practice to mix oils or greases. The blend can have a lower specification than the individual
oils or greases and can lead to premature bearing failure. USE ONE BRAND ONLY.

It is the operator’s responsibility to ensure that all bearings are greased with the correct quantity
and type of grease/oil at the correct intervals specified.

It is important that a strict routine of regular servicing is undertaken from the start of operation
of the plant.

Regular checks on fluids and the lubrication of the plant, in accordance with the schedule, is
essential.

In addition to the lubrication points, the lubrication schedule lists the regular attention required
to the plant hydraulic system.

The engine oil and coolant also require checking regularly.

9.2 Fuel System

(1) Check Fuel Level

⚠ DANGER
Explosion / burn hazard.

⚠ WARNING
o Read and understand manual.
o Lock-out machine.
o Wear personal protective equipment.
o Diesel fuel is highly flammable.
o Never remove filler cap or refuel, with the engine running.
o Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion
risks.
o Do not smoke or carry out maintenance on the fuel system near open flame or sources of
sparks, such as welding equipment, etc.
 PROCEDURE
1. Observe all safety warnings.

2. Check the level indicator (Figure 9.1) in early models, newer models will come with fuel gauge
as is seen in (Figure 9.2) to check level ignition must be on.

Figure 9.1 – Diesel Gauge early model

Figure 9.2 – Diesel gauge current model

3. Fill the tank at the end of each day, where possible, to reduce overnight condensation within
the tank.
(2) Adding Fuel

⚠ DANGER
Explosion / burn hazard.

⚠ WARNING
o Read and understand manual.
o Lock-out machine.
o Wear personal protective equipment.
o Never remove filler cap or refuel, with the engine running.
o Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion
risks.
o Do not smoke or carry out maintenance on the fuel system near open flame or sources of
sparks, such as welding equipment, etc.

NOTICE
o DO NOT fill the tank to capacity.
o Monitor gauge on tank side.
o Allow room for expansion and wipe up spilt fuel immediately, otherwise paintwork will be
damaged.
 PROCEDURE
1. Observe all safety warnings.
2. Clean the area around the filler cap.
3. Remove the filler cap, Ref: Figure 9.3

Figure 9.3 – Filler Cap

4. Fill the tank with diesel.

5. Replace the filler cap, Ref: Figure 9.3.

(3) Change Fuel Filter

⚠ DANGER
Explosion / burn hazard.

⚠ WARNING
o Read and understand manual.
o Lock-out machine.
o Wear personal protective equipment.
o Diesel fuel is highly flammable.
o Never remove filler cap or refuel, with the engine running.
o Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion
risks.
o Do not smoke or carry out maintenance on the fuel system near open flame or sources of
sparks, such as welding equipment, etc.

PROCEDURE
 1. Observe all safety warnings.
2. Remove fuel (Item 1) by unscrewing from housing anticlockwise, Ref: Figure 9.2.
3. When fitting the new filter ensure any new seals are fitted and the filter is tightened to
25Nm

Figure 9.2 - Fuel Filter

(4) Changing the Pre filter

⚠ DANGER
Explosion / burn hazard.

⚠ WARNING
o Read and understand manual.
o Lock-out machine.
o Wear personal protective equipment.
o Diesel fuel is highly flammable.
o Never remove filler cap or refuel, with the engine running.
o Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion
risks.
o Do not smoke or carry out maintenance on the fuel system near open flame or sources of
sparks, such as welding equipment, etc.

PROCEDURE
1. Observe all safety warnings.
2. Remove retaining ring (Item 6) by unscrewing from housing, Ref: Figure 9.3.
 Figure 9.3 – Pre-Filter/Water trap

3. Carefully remove filter bowl (Item 4) containing spring (Item 3) and float (Item 5) and
dispose of diesel in the fuel bowl correctly
4. Remove O-ring (Item 2) from lip on fuel bowl and replace with new O-ring
5. Remove filter element (Item 1) from filter housing and replace.
6. Reassemble fuel bowl ensuring spring is inserted correctly and tighten retaining ring.
7. Prime fuel system using lever located on the lift pump

9.3 Maintenance Schedules

(1) Daily (10 Hour) Maintenance Schedule (Machine Stopped)

Object Job Remarks Sign

Visual Check
Guards Check/Replace
Pipelines Check/Replace
Valves Check/Replace
Bolts and Pins Check/Tighten/Replace
Fuel level Check/Fill
oil level Check/Fill
(hydraulic + Engine)
Moving Parts
Material Build Up Remove
Moving Free Check/Ensure

To remove spillage:

PROCEDURE
1. Switch off and lockout machine. Refer to Section 8.
2. Observe all safety warnings.
3. Open or remove any guard doors if necessary.
4. Remove spillage using a trowel or shovel. Ensure that no material is left on the chassis or
underneath the machine.
5. Close/ replace and secure all guard doors.
(2) Daily (10 Hour) Maintenance Schedule (Machine Running)

Object Job Remarks Sign

Power Unit
Return line filter Check/Replace
Suction line filter Check/Replace
Filter Cap Check/Clean
Screen
Mesh Tension Check/Tighten

(3) Weekly (50 Hour) Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Air Filter Check/clean
Torque bolts Check/Tighten

(4) 100 Hour Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Carry out 50 hour
maintenance schedule
All Conveyors
Screen bearings Check/Grease

(5) 250 Hour Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Carry out 50 hour
maintenance schedule
Carry out 100 hour
maintenance schedule
(6) 500 Hour Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Carry out 50 hour
maintenance schedule
Carry out 100 hour
maintenance schedule
Carry out 250 hour
maintenance schedule

(7) 1000 Hour Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Carry out 50 hour
maintenance schedule
Carry out 100 hour
maintenance schedule
Carry out 250 hour
maintenance schedule
Carry out 500 hour
maintenance schedule

(8) 2000 Hour Maintenance Schedule

Object Job Remarks Sign

First
Carry out daily (10 hour)
maintenance schedule
Carry out 50 hour
maintenance schedule
Carry out 100 hour
maintenance schedule
Carry out 250 hour
maintenance schedule
Carry out 500 hour
maintenance schedule
Carry out 1000 hour
maintenance schedule
9.4 Air Filter
(1) Changing the Outer Air Filter Element

⚠ WARNING
o Read and understand manual.
o Lock-out machine.
o Wear personal protective equipment

NOTICE
o Always obey the air cleaner restriction indicator. (Never attempt to clean and reuse an
element).
o During normal service, the outer element (Item 4) will require replacing only when the
restriction indicator is illuminated.
o Do not run the engine with the dust cover (Item 5) removed as this will result in dust
ingression and subsequent engine failure.
o If the outer element has not been changed for 500 operating hours, a leak in the induction
system must be suspected.
o Check that the air cleaner casing and hoses to the engine are not damaged. Check that all
hose connections are airtight.

PROCEDURE
1. Observe all safety warnings.

Figure 9.4 - Air Filter

2. Undo all retaining clips (Item 1), Ref: 9.4.

3. Remove cover (Item 2), Ref: Figure 9..
4. Pull filter element (Item 4) from housing (Item 3), Ref: Figure 9..
5. Clean the inside of the air-cleaner casing using a damp, lint-free cloth, paying particular
attention to the element seals.
6. Re-fit the filter element (Item 4), Ref: Figure 9..
7. Re-fit cover to housing. Ref: Figure 9..
8. Secure cover using the retaining clips on the cover, Ref: Figure 9.
9.5 Servicing the Electrical System
(1) Electrical Safety Instructions

⚠ WARNING
o Switch off the machine immediately if malfunctions occur in the electrical system.
o Before beginning work on any of the machine‘s electrical components, any power supplied
to the machine (whether the battery or a power line) must be cut-off by disconnecting or de-
energizing.
o Before starting any work, check the machine and the electrical parts to be worked on for the
presence of power. Ground or short-circuit the parts to be worked on to prevent the
possibility of an electrocution hazard.
o Before starting any work disconnect any power.
o Insulate any live parts which cannot be de-energized to prevent the possibility of an
electrocution hazard.
o Always use insulated tools when working on the electrical systems.
o The electrical equipment of the machine is to be inspected and checked at regular intervals.
o Defects such as loose connections or scorched or otherwise damaged components must be
rectified immediately.
o Work on the electrical system and equipment of the machine must be carried out by a skilled
electrician or by instructed persons under the supervision and guidance of a skilled electrician
and in accordance with electrical engineering rules and regulations.

NOTICE
Refer to Appendix D for electrical schematics.

(2) Checking the Battery

⚠ WARNING
o Always disconnect battery leads before carrying out any maintenance to the electrical
system.
o The battery leads must be disconnected in the correct sequence.
o The battery contains sulphuric acid, electrolyte which can cause severe burns and produce
explosive gases. Avoid contact with the skin, eyes or clothing.
o Lock-out the machine.
o Wear personal protective equipment.
o Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. Wash hands after
handling.

NOTICE
In cold weather, distilled water should only be added immediately before starting the engine, to
prevent it freezing.
 PROCEDURE
1. Observe all safety warnings.
2. Ensure that all electrical connections are clean and tight and coat the terminals with
petroleum jelly to protect them from corrosion.
3. Remove the battery filler plugs and check that the electrolyte level is between 6 and 9 mm
(0.25 - 0.37 in) above the tops of the separators.
4. If necessary, top up with distilled water.
5. Where batteries (Item 1) have trough fillers, add distilled water to the filling trough until the
trough just begins to fill with water

(3) Battery Removal

⚠ WARNING
o Always disconnect battery leads before carrying out any maintenance to the electrical
system.
o The battery contains sulphuric acid, electrolyte which can cause severe burns and produce
explosive gases. Avoid contact with the skin, eyes or clothing.
o Lock-out the machine.
o Wear personal protective equipment.

PROCEDURE
1. Observe all safety warnings.
2. Ensure all electrical circuits are switched off.
3. Disconnect the ground (- black) lead from the battery.
4. Disconnect the positive (+ red) lead from the battery.
5. Loosen bolts from the battery retaining bracket (Item 2) Ref: Figure 9.5
6. Remove the battery (Item 1) retaining frame, Ref: Figure 9.5

Fig 9.5 – Battery location

(4) Battery installation

⚠ WARNING
o Lock-out machine.
o Wear personal protective equipment.

NOTICE
o When installing the battery the positive (+ red) lead must be connected first.
o These machines are wired negative ground. Always observe correct polarity.

PROCEDURE
1. Observe all safety warnings.
2. Ensure all electrical circuits are switched off.
3. Lift the battery (Item 1) onto the machine, Ref: Figure 9.5.
4. Fit the battery retaining frame.
5. Tighten bolts on the battery retaining bracket (Item 2) Ref: Figure 9.5
6. Connect the positive (+ red) lead.
7. Connect the ground (- black) lead.

9.6 Servicing Screens

(1) Clean and Check the Mesh

⚠ DANGER
o Entanglement hazard.

⚠ WARNING
o Read and understand manual.
o Falling material hazard.
o Hearing hazard.
o Falling hazard.
o Do not remove any guard while the machine is running or start the machine while a guard is
removed.
o If any damage to the mesh is found, do not operate the machine until it is repaired or replaced
entirely by your local TrommALL® dealer.

PROCEDURE
1. Observe all safety warnings.
2. Switch off the engine.
3. Clean the mesh using a high pressure hose. Ensure that eyes are protected by wearing safety
glasses.
4. Check for cuts, tears, rips or any other physical damage.
5. Close and secure the guard doors in the correct position.
(2) Tensioning the bottom deck screen

⚠ DANGER
Entanglement hazard.

⚠ WARNING
o Read and understand manual.
o Falling material hazard.
o Hearing hazard.
o Falling hazard.
o Do not remove any guard while the machine is running or start the machine while a guard is
removed.

NOTICE
o Do not over tension the mesh as this will damage the bearings.

PROCEDURE
1. Observe all safety warnings.
2. Start the screen to be tensioned. (Refer to chapter 7).
3. Run the screen at the desired speed.
4. Tighten the mesh by adjusting mesh tension clamps, until mesh is sufficiently taut, Refer
to Figure 9.6 for locations of mesh clamps.

Figure 9.6 – Tensioning bottom deck mesh

(3) Changing the bottom deck screen mesh

⚠ DANGER
Crushing hazard.

⚠ WARNING
o Wear personal protective equipment.
o Falling hazard.
o Never allow unqualified personnel to attempt to operate, maintain, remove or replace
any part of the machine.
o Do not remove any guard while the machine is running or start the machine while a guard
is removed.
o Never allow anyone to remove large or heavy components without adequate lifting
equipment.

NOTICE
Mesh clamps are left and right handed parts ensure the correct one is in place when replacing
mesh.

PROCEDURE
1. Observe all safety warnings.
2. Loosen bottom deck tensioner bolts on both sides of the screen box. Alternate sides when
removing tension to distribute stress evenly Ref; Figure 9.7

Figure 9.7 – Bottom deck mesh tensioner

 Figure 9.8– Bottom deck tension bar removal

3. Remove the mesh tension bar as seen in Figure 9.8. This may need the impact of a hammer
to loosen as tension bar can become wedged in mesh

Figure 9.9– Bottom deck mesh removal

4. Remove bottom deck mesh by lifting it over the bottom deck chute and pulling it back onto
the tail conveyor as shown in Figure 9.9
5. To install mesh, reverse this procedure.
(4) Tensioning the top deck mesh/punchplate

⚠ DANGER
Crushing hazard.

⚠ WARNING
o Wear personal protective equipment.
o Falling hazard.
o Never allow unqualified personnel to attempt to operate, maintain, remove or replace
any part of the machine.
o Do not remove any guard while the machine is running or start the machine while a guard
is removed.
o Never allow anyone to remove large or heavy components without adequate lifting
equipment.
NOTICE
Mesh clamps are left and right handed parts ensure the correct one is in place when replacing
mesh.

PROCEDURE
1. Observe all safety warnings
2. To tension mesh already installed
3. Tighten the nuts clamping the mesh down gradually with several passes over each nut
shown in figure 9.10
4. Do this on the opposite side to ensure mesh is secure.
5. Repeat procedure for each section on mesh

Figure 9.10 – Tensioning top deck mesh

(5) Tensioning the top deck mesh/punchplate

⚠ DANGER
Crushing hazard.

⚠ WARNING
o Wear personal protective equipment.
o Falling hazard.
o Never allow unqualified personnel to attempt to operate, maintain, remove or replace
any part of the machine.
o Do not remove any guard while the machine is running or start the machine while a guard
is removed.
o Never allow anyone to remove large or heavy components without adequate lifting
equipment.

NOTICE
Mesh clamps are left and right handed parts ensure the correct one is in place when replacing
mesh.

PROCEDURE

Figure 9.11 – Removing top deck mesh clamps

1. Observe all safety warnings

2. Remove nuts (Item 1) and washers (Item 2) From both sides, loosen bolts evenly by
alternating as this will prevent any single nut becoming excessively tight, Ref: Figure 9.11
 3. Pull out bolts from top deck clamp (Item 3), they may be seized over time and may require
some impact to remove, Ref: Figure 9.11
4. Top deck clamp bar (Item 4) should be loose, remove this from either side and top deck
mesh section , Ref: Figure 9.5
5. Remove top deck mesh section (Item 1) , Ref: Figure 9.12

Figure 9.12 – Removing top deck mesh

10. Hydraulic System

⚠ DANGER
Fluid injection hazard.

⚠ WARNING
Lock-out machine.

Wear personal protective equipment.

NOTICE
The air vents in the cap must be kept open to allow the hydraulic system to “breathe”.

Always use the correct grade of oil (Correct grade of hydraulic oil refer to section 9.12.1).

If the hydraulic system requires filling up on a regular basis, all hydraulic parts and hoses should
be inspected for leaks.

Always practice extreme cleanliness when servicing.

(1) Hydraulic Oil

Checking Hydraulic Oil Level

⚠ DANGER
Fluid injection hazard.

⚠ WARNING
Lock-out the machine.

Wear personal protective equipment.

PROCEDURE
1. Observe all safety warnings.

2. The machine must be on level ground.

3. Always have the hydraulic oil at normal operating temperature.

4. Always have all cylinders retracted (where possible).

5. Check the level indicator (Item 1), Ref: Figure 10.13 The oil level must be between the MIN and
MAX marks on the tank.

Figure 10.13 - Hydraulic Tank

 Topping Up Hydraulic Oil Level

⚠ DANGER
Fluid injection hazard.

⚠ WARNING
Wear personal protective equipment.

NOTICE
Never overfill the hydraulic tank as this will cause leakage from the filler cap.

PROCEDURE

1. Observe all safety warnings.

2. Machine must be on level ground.

3. Raise the swivel conveyor belt to its full height and pin securely. (Refer to section 5, “Set up”)

4. Always have all cylinders retracted (where possible).

5. Clean the area around the filler cap (Item 2), Ref: Figure 10.13

6. Open the filler cap (Item 2).

7. Fill the tank to midway between red and black marks on the level indicator. (Correct grade of
hydraulic oil refer to section 10.2)

Changing Hydraulic Oil

⚠ DANGER
Fluid injection hazard.

⚠ WARNING
Lock-out machine.

Wear personal protective equipment.

NOTICE
Before removing the drain plug (Item 1) Ref: Figure 9.10.

a) Release any pressure in the hydraulic tank by slowly unscrewing the filler cap (Item 3).Ref:
Figure 9.13
b) Ensure a suitable container is placed on the ground to catch the full capacity of oil in the tank.
c) Remember to stand on one side to avoid oil which will spill from the drain hole.

Change the suction elements when an oil change is being carried out.

PROCEDURE
6. Observe all safety warnings.
7. Always have the hydraulic oil at normal operating temperature.
8. Always have all cylinders retracted (where possible).
9. Drain the tank by removing the drain plug (Item 1), Ref: Figure 10.114

Figure 10.14 - Hydraulic Tank Bottom

10. Remove the cover plate under the filler cap (Item 2). Discard the gasket.
11. Remove the suction filters by unscrewing them from the suction pipes (Item 4).
12. Flush out the tank with clean hydraulic oil taking extreme care to remove all dirt and foreign
matter.
13. Fit new suction filters to the suction pipes (Item 4).
14. Re-fit cover plate to the tank using a new gasket and refit drain plug (Item 3).
15. Change the return line filter element (refer to this section).
16. Refill the tank with clean hydraulic oil to midway between the red and black marks on level
indicator. (Correct grade of hydraulic oil refer to section 10.2)
17. Run the engine to circulate the oil. Operate the hydraulic controls to purge any air from the
system.
18. Stop the engine and fill up the system as required.

(2) Return Line Filter

Changing Return Line Filter

⚠ DANGER
Fluid injection hazard.
 ⚠ WARNING
Lock-out machine.

Wear personal protective equipment.

PROCEDURE
1. Observe all safety warnings.

2. Release any pressure in the hydraulic tanks by slowly unscrewing the filler cap.

3. Clean the outside of the filter housing (Item 3), Ref: Figure 9.15.

4. Remove the filter by unscrewing the retaining bolts (Item 4), Ref: Figure 9.15.

5. Remove cover plate (Item 1) by unscrewing the 3 retaining bolts (Item 4), Ref: Figure 9.15.

5. Lift out the old element (Item 6) and discard it safely, Ref: Figure 9.15.

6. Wash out the filter cap and dry with an air hose. DO NOT USE A RAG.

7. Re-fit new filter ensuring seal ring (Item 5) is in good condition and correctly positioned, Ref:
Figure 9.15.

Figure 10.15 - Return Line Filter

10.1 Servicing Conveyors

(3) Clean and Check the Conveyor Belts

⚠ DANGER
o Entanglement hazard.
 ⚠ WARNING
o Read and understand manual.
o Falling material hazard.
o Hearing hazard.
o Falling hazard.
o Do not remove any guard while the machine is running or start the machine while a guard is
removed.
o If any damage to the belt is found, do not operate the machine until it is repaired or replaced
entirely by your local TrommALL® dealer.

PROCEDURE
1. Observe all safety warnings.
2. Switch off the engine.
3. Clean the conveyor belt using a high-pressure hose. Ensure that eyes are protected by
wearing safety glasses.
4. Check for cuts, tears, rips or any other physical damage.

(4) Tensioning the Conveyor Belts

⚠ DANGER
Entanglement hazard.

⚠ WARNING
o Read and understand manual.
o Falling material hazard.
o Hearing hazard.
o Falling hazard.
o Do not remove any guard while the machine is running or start the machine while a guard is
removed.

NOTICE
o Do not over tension the belt as this will damage the drum bearings.

PROCEDURE
1. Observe all safety warnings.
2. Start the conveyor to be tensioned. (Refer to chapter 7).
3. Run the conveyor at the desired speed.
4. Tighten the belt by adjusting both belt adjusters evenly, 2 turns at a time until slippage
stops, Refer to for location of conveyor adjusters.
 Fig. 10.1 – Conveyor belt adjusters

(5) Conveyor Belt Alignment

⚠ DANGER
o Entanglement hazard.

⚠ WARNING
o Read and understand manual.
o Falling material hazard.
o Hearing hazard.
o Falling hazard.
o Do not remove any guard while the machine is running or start the machine while a guard is
removed.

PROCEDURE
1. Observe all safety warnings.
2. Start the engine.
3. Start the conveyor to be aligned. (Refer to chapter 7).
4. Observe the conveyor and determine to which side the conveyor is tracking off.
5. If the conveyor is tracking off to the right side, operate the right side adjuster one turn at a
time until the belt tracks correctly.
 Figure 10.2 - RHS Adjustment

6. If the conveyor is tracking off to the left side, operate the left side adjuster one turn at a time
until the belt tracks correctly.

Figure 10.3- LHS Adjustmenteee

10.2 Lubrication
(1) Lubricants and Fluids

NOTICE
Always use lubricants and fluids that meet the above international specifications.

The Shell grades are for reference only.

Component International Spec Sample

Engine Oil ADI CD CF Shell Fortisol 15W / 40
CCMC D4 Shell Rimula 15W / 40
Hydraulics - up to 30°C ISO VG 46 Shell Tellus 46
Hydraulics - above 30°C ISO VG 100 Shell Tellus 100
General Grease Shell Alvania EP2

Capacities – Fluid

Engine oil including filter Min: 3.9 litres

Max: 6.7 litres
Hydraulic tank 250 Litres
 Fuel tank 70 Litres

Adjustment Data

Engine Speed 2500 RPM

Pressures

Hydraulic System 200 Bar

10.3 Greasing Schedule

Grease points on machine

Area Description QTY Frequency No. of strokes

1 Screenbox Bearings 2 50 Hours 4
2 Conveyor Bearings 8 50 Hours 2

Grease points for the screenbox bearings are located on the screenbox on the flywheel covers.
 Troubleshooting

11. Troubleshooting
If any problem arises that is not listed, or if a problem persists after carrying out the recommended
checks, contact TrommALL® Aftersales Service Department for further assistance,

Symptom Possible Cause Solution

Hydraulic System
Return line filter blockage Return line filter element is Replace the return line filter
indicator shows red blocked element

11.1 Engine Maintenance Schedules

(1) Daily (10 Hour) Maintenance Schedule (Machine Stopped)

Object Job Remarks Sign

Engine oil level Check/Top Up
Hydraulic oil level Check/Top Up
Fuel tank level Check/Top Up

(2) Weekly (50 Hour) Maintenance Schedule

Object Job Remarks Sign

After first 50 hours carry out
full service on the engine
Air filter, pre-cleaner Clean out
Battery electrolyte level Check

(3) 250 Hour Maintenance Schedule

Object Job Remarks Sign

Air cleaner elements Check/Replace
Water trap fuel system Empty

(4) 500 Hour Maintenance Schedule

Object Job Remarks Sign

Engine oil Change
Engine oil filter Change
Fuel filter Change
Air cleaner inner element Change
V-Belt tolerance Check/Adjust
Engine speed Check/Tune
Return line filter Change

(5) 1000 Hour Maintenance Schedule

Object Job Remarks Sign
Hydraulic oil Change

(6) 500 Hour Maintenance Schedule

Object Job Remarks Sign

Valve clearance Check
Fuel injectors Check
Alternator and starter motor Check
 Appendix A Schematics

Appendix A Schematics
 1 2 3 4

1 2
3 5
4 7
6 9
A A
8 11
10 13
12 15 Relay E Stop E Stop
14 16
1 2 Schneider Electric ZBE102 Schneider Electric ZBE102
Harting 16 Pin Socket
3
4
5

12V SPDT 30A Relay

E Stop E Stop

Schneider Electric ZBE102 Schneider Electric ZBE102

Fuse Fuse Fuse Fuse Fuse Fuse

15 amp 10 amp 10 amp 10 amp 10 amp 10 amp

1
1
B B
Engine Loom Stop Circuit

+
-

Left Track Forward Right Track Forward GND Vimpex Siren

1 1 1 1
+12 V
Connected to Starter +
2 2 2 2

Female Solenoid Connector Female Solenoid Connector

C C
Left Track Reverse Right Track Reverse
1 1 1 1

2 2 2 2

Female Solenoid Connector Female Solenoid Connector

GND
Title
D D
3500 TR Control Unit Wiring Diagram
Size Number Revision
A4 EK1005
Date: 25/09/2019 Sheet of
File: 3500TR Tracking controls.SchDoc Drawn By:
1 2 3 4
 1 2 3 4

A A

1 2
3 5
4 7
6 9
8 11
10 13
12 15
14 16

Harting 16 Pin Plug

1
2
3
Left Track
E Stop
B B
Track / Aux Switch
1 2 1 2

Schneider Electric ZBE201

1
2
3
Right Track

C C

Title
D D
3500 Umbilical Remote Wiring Diagram
Size Number Revision
A4 100716-01
Date: 25/09/2019 Sheet of
File: 3500 Umbilical Remote.SchDoc Drawn By:
1 2 3 4