Metso Outotec Lokotrack ST3.8 User manual

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Copyright © Metso Outotec.

Table of Contents
1. DRIVING INSTRUCTIONS ................................................................................................................... 1
1.1. SAFETY ...................................................................................................................................... 1
1.2. DRIVING DIRECTIONS .............................................................................................................. 2
1.3. EMERGENCY STOP LOCATIONS ............................................................................................ 3
1.4. REMOTE STOP LOCATION ...................................................................................................... 4
1.5. DRIVE CONTROLS .................................................................................................................... 5
1.5.1. Drive control device ...................................................................................................... 5
1.5.2. Radio control device ..................................................................................................... 6
1.6. PREPARING FOR DRIVING ...................................................................................................... 7
1.6.1. Increasing the ground clearance .................................................................................. 9
1.7. STARTING THE ENGINE ........................................................................................................ 11
1.8. CONNECTING THE CONTROL DEVICE ................................................................................ 12
1.8.1. Connecting the drive control device ........................................................................... 12
1.8.2. Connecting the radio control device ........................................................................... 13
1.9. DRIVING ................................................................................................................................... 14
1.9.1. Driving with drive control device ................................................................................ 14
1.9.2. Driving with radio control device ................................................................................ 16
1.10. STOPPING THE ENGINE ........................................................................................................ 18
1.11. TROUBLESHOOTING .............................................................................................................. 19
1.12. CORRECTIVE ACTIONS ......................................................................................................... 20
1.12.1. Making sure that the main switch is ON .................................................................... 20
1.12.2. Making sure that the emergency stop buttons are not pressed down ........................ 21
1.12.3. Making sure that remote stop button is not pressed down ........................................ 21
1.12.4. Checking if the manual valves are on ....................................................................... 22
1.12.5. Making sure that the battery clamps are attached ..................................................... 22
1.12.6. Charging the battery of Lokotrack unit ....................................................................... 22
1.12.7. Charging the battery of radio control device .............................................................. 23
1.12.8. Jump starting the engine with another machine or vehicle ........................................ 24
1.12.9. Starting the engine with jump starter ......................................................................... 24
1.12.10. Checking the fuel level ............................................................................................... 24
1.12.11. Handling alarms ......................................................................................................... 25
1.12.12. Handling the 'A17: Remote stop active' alarm ........................................................... 27
1.12.13. Handling the emergency stop alarm .......................................................................... 27
1.12.14. Correcting too large inclination angle of the machine ................................................ 27
1.12.15. Checking the hydraulic oil level and possible leaks ................................................... 28
1.12.16. Opening the hydraulic shut-off valve .......................................................................... 29
1.12.17. Recovering from too high hydraulic oil temperature .................................................. 30
1.12.18. Checking if manual controls are active ...................................................................... 31
1.12.19. Checking if process in running ................................................................................... 31

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1. DRIVING INSTRUCTIONS
These driving instructions are valid for Lokotrack ST3.8. The purpose of these instructions is to enable safe
moving of the machine during transportation.
NOTICE: Do not use the machine for screening solely based on these instructions. The
actual instruction manual for the machine is delivered separately.
NOTICE: In these driving instructions, it is assumed that the machine is in the transport
position. If needed, see the actual instruction manual of the machine for
information on how to prepare the machine for transportation.
The illustrations in this instruction may not fully correspond to your machine.
1.1. SAFETY
Because of the size and weight of the machine, pay special attention when moving the machine. It is highly
recommended that a banksman is used when the machine is moved.
DANGER!
GENERAL HAZARD
Will cause death or serious injury.
Read the safety section before working with the machine. Only competent and
trained personnel are allowed to work with the machine.
WARNING!
PERSONAL INJURY HAZARD
Can cause death or serious injury.
Before starting and during track driving the machine, make sure that there
are no persons in the area whose safety may be endangered. Walk around
the machine and make sure that there is nobody on, by or below the machine.
Warn everybody in the vicinity before starting.
WARNING!
CRUSHING HAZARD
Can cause death or serious injury.
Do not drive the machine in locations where there is a risk of squeezing.
Always drive the machine from a safe distance. If possible, drive the machine
from either end of the machine.

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WARNING!
UNEXPECTED MOVEMENT HAZARD
Can cause death or serious injury.
Be extremely cautious when driving in cold temperatures below 0°C (32°F).
The response time of the controls might be longer than usual due to stiff
hydraulic oil.
WARNING!
COLLISION HAZARD
Can cause death or serious injury.
Pay attention to the machine dimensions to avoid power lines, bridges,
branches, and other obstacles.
NOTICE: Make sure the following:
• The process is set to OFF and it will not be started during transportation.
• The driving route is smooth enough.
• Differences in altitude or inclinations do not prevent driving.
• The lighting is appropriate at the site or near the machine.
• The driving surface is not icy or slippery. If needed, sprinkle sand on the
surface.
1.2. DRIVING DIRECTIONS
4
3
2
1
Callout Description Callout Description
1 Forward 3 Left
2 Backward 4 Right

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1.3. EMERGENCY STOP LOCATIONS
DANGER!
GENERAL HAZARD
Will cause death or serious injury.
In a dangerous situation, stop the machine with the emergency stop button,
the key switch of the machine, or with the remote stop button (located on
either the drive control device, radio control device, or track drive radio remote
control). Before starting the machine, make sure you know the location of the
emergency stop buttons.
1
2
3
Callout Description
1 On the left side of the machine
2 On the right side of the machine
3 On the service platform
Figure 2: Locations of emergency stop buttons

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1.4. REMOTE STOP LOCATION
DANGER!
GENERAL HAZARD
Will cause death or serious injury.
In a dangerous situation, stop the machine with the emergency stop button,
the key switch of the machine, or with the remote stop button. Before starting
the machine, make sure you know the location of the emergency stop buttons.
1
2
Callout Description
1 Remote stop button in drive control device
2 Remote stop button in radio control device
Figure 3: Location of remote stop button
NOTICE: To stop the engine with the remote stop button of the drive control device, the
drive control device must be connected.
NOTICE: To stop the engine with the radio control remote stop, the following is required:
• Radio control is on.
• Radio transmitter is on and in the operating range.

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1.5. DRIVE CONTROLS
1.5.1. DRIVE CONTROL DEVICE
WARNING!
UNEXPECTED MOVEMENT HAZARD
Unexpected movement can cause death or serious injury.
• Make sure the cable of the drive control device does not get caught in the
tracks or in any other moving part of the machine during driving.
• The drive control device must be disconnected from the machine
immediately after driving and stored in a safe place when not in use.
• Only lift and hold the drive control device by its handles. Do not pull the
device from the cable or drag or move it otherwise.
1
2
3
4
A
A
B
B
Callout Description Callout Description
1 Drive control lever, left track
A = forward, B = backward
3 Drive control lever, right track
A = forward, B = backward
2 Remote stop button 4 Engine speed and track drive speed
controller
Figure 4: Drive control device
NOTICE: Make sure that the drive control device is stored properly to avoid damages,
dirt, and water.

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1.5.2. RADIO CONTROL DEVICE
A
B
A
B
2
3
4
10
6
9
8
7
1
5
Callout Description Callout Description
1 Status of the radio control device:
• OFF: no light
• ON: green light
• Transmitting ON: green light
blinking
• Low battery: red light blinking
6 Radio control lever, left track A =
forward, B = backward.
2 Grid lifting (UP) (optional)
Grid lowering (DOWN) (optional)
7 Remote stop (push and pull button)
Crushing/screening, hydraulic
operations, and the engine are
stopped
3 Mode selection:
• Track drive (UP)
• Process (DOWN)
8 Track drive mode:
• Increase engine rpm / track
driving speed (UP)
• Decrease engine rpm / track
driving speed (DOWN)
Process:
• Start feed (UP)
• Stop feed (DOWN)
4 Activate grid tilt sequence (UP)
(optional)
Stop process (DOWN)
9 Increase / decrease feed speed
5 Radio control device key: ON/OFF
and horn
10 Radio control lever, right track A =
forward, B = backward.
Figure 5: Radio control device

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NOTICE: Make sure that the radio control device is stored properly to avoid damages,
dirt, and water.
1.6. PREPARING FOR DRIVING
1. Make sure that the process is set to STOP and it will not be started during transportation.
2. Visually inspect that there are no loose parts, and everything is secured in place.
3. Check the inclinations, approach angle, and departure angle of the machine.
5
°
°15
Figure 6: Maximum inclinations
NOTICE: On steep slope, the back end/engine must be on the downhill side.
10°
*4°
Figure 7: Maximum approach and departure angle
* The ground clearance of the screen end (4°) can be increased by lifting the screen. For instructions,
see "Increasing the ground clearance".
NOTICE: Check the current angle of the machine from the spirit levels and
keep checking the angles during track driving.
4. Open the door of main control center.

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Figure 8: Main control panel location (on the right side of the machine)
5
9
8
7
1
3
2
4
6
10
Callout Description
1* Selector switch for track driving speed: SLOW “Turtle” / NORMAL
“Rabbit” (only for machines with Constant Speed Engine (CSE))
2 Work lights ON/OFF: This function is optional.
3* Radio control mode ON/OFF: ON position activates the radio control
mode (and deactivates the drive control device).
4* Manual valves ON/OFF: Activates and deactivates the hydraulic
cylinder functions.
5* Control display: Interface for the user to operate the control system.
6* Emergency stop button: Shuts down all processes including the engine.
7 Process stop: Stops the screening process in sequence.
8 Process start: Starts the screening process in sequence.
9* Engine start and stop: Push button for starting and stopping the engine.
10* Key switch ON/OFF: Turns the control panel ON and OFF
Figure 9: Main control panel
*Relevant for track driving
5. Make sure that the emergency stop buttons are not pressed, and that the remote stop button is not
pressed down.

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1.6.1. INCREASING THE GROUND CLEARANCE
WARNING!
COLLISION HAZARD
Can cause death or serious injury.
Always drive the machine in transport position on flat surfaces. Right after
the increased ground clearance is not needed anymore, lower the screen
back to the transport position and attach the locking pins. Pay attention to
the machine dimensions to avoid power lines, bridges, branches and other
obstacles.
Prerequisites: The machine is positioned on a level ground, with the engine running. To start the engine, see
“Starting the engine”.
The need of increasing ground clearance can vary case-by-case. Increase the ground clearance according
to need but pay attention to how much room there is on top of the machine.
NOTICE: Increasing the ground clearance is allowed to temporary use only.
4
2
1
3
Callout Description
1 Adjustment sleeves
2 Locking pins and clips

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3 Screen angle trestle
4 Screen UP-DOWN
Figure 10: Raising the screen angle
1. From the main control panel, activate the manual valves by pushing the Manual valves ON/OFF
button. An audible start alarm signal sounds and the engine rpm raises to the required lever for using
manual valves. Now you can use the manual valves.
Figure 11: Manual valves ON/OFF push button
2. Using the Screen UP-DOWN control (4), raise the screen angle slightly by moving the screen
angle control to the RAISE position. Raise the screen angle enough to relieve the pressure on the
adjustment sleeves (1) and locking pins (2).
3. Remove the screen box angle adjusting clips and locking pins (2) from the adjustment sleeves (1).
4. Using the Screen UP-DOWN control (4), raise the screen angle by moving the screen angle control to
the RAISE position.
5. Raise the screen angle trestle (3) slightly above the desired operating position.
6. Move the adjustment sleeves (1) to the desired hole and replace the locking pins and clips (2) in the
screen angle trestle (3).
NOTICE: Make sure that both trestles are adjusted equally, failure to do so will damage the
screen box assembly.
7. Using the Screen UP-DOWN control (4), lower the screen angle trestle (3) by moving the Screen UP-
DOWN control (4) to the LOWER position. Lower the screen angle trestle (3) so that it rests securely
on the adjustment sleeves (1) and locking pins (2).
8. Turn the switch for manual valves to OFF position. Otherwise, track driving is not possible.
Figure 12: Manual valves ON/OFF push button

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1.7. STARTING THE ENGINE
WARNING!
EXPLOSION HAZARD
Can cause death or serious injury.
Never use startup spray or similar to help the engine start, because it might
cause a destructive explosion in the induction manifold.
WARNING!
PERSONAL INJURY HAZARD
Can cause death or injury or serious injury.
Before starting the machine, make sure that there are no persons in the area
whose safety may be endangered. Walk around the machine and make sure
that there is nobody on, by or below the machine. Warn everybody in the
vicinity before starting.
For instructions on running-in period of the engine, see the instruction manual of the engine.
1. Make sure that the steps listed in “Preparing for driving” have been done.
2. Locate the main switch and turn it to ON position.
ON
OFF
Figure 13: Main switch in ON position
3. Locate the main control panel.
4. Turn the control panel key switch clockwise to position 1 (ON).
Figure 14: Control panel key switch ON

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a. Wait for 45 seconds. The control system starts up and the display shows ‘Engine starting is
enabled’.
b. If the display shows alarms, see instructions from “Troubleshooting”.
5. Check the fuel level from the Message field (1) of main control panel display. Another way is to tap
Information views (2), and then tap Engine information (3) and check the value (4).
If there is no fuel, or the fuel level is very low, refill. Make sure that no dust or dirt enters the fuel tank
through the refill opening.
1
3
4
2
Figure 15: Fuel level
6. Start the engine by pressing and holding the Engine start/stop button. The machine gives an acoustic
warning signal before it starts. Release the Engine start/stop button when the engine is running.
If the engine does not start, see “Troubleshooting”.
Figure 16: Engine start/stop button
7. Allow the engine to idle until it has warmed up.
8. Check around the engine compartment area for engine oil, fuel, coolant, or hydraulic fluid leaks.
1.8. CONNECTING THE CONTROL DEVICE
Proceed to either of the two sections below depending on the control method you want to use:
• “Connecting the drive control device”
• “Connecting the radio control device”
1.8.1. CONNECTING THE DRIVE CONTROL DEVICE
1. Locate the drive control device.
You can find the drive control device in a tool box (in the middle part the machine), or in the engine
module of the machine.
2. Visually check that the drive control device or the cable is not damaged.

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3. Connect the drive control device cable into either of the cable connecting sockets. There is one at the
front of the machine (1), and the other one at the rear of the machine (2).
2
1
Figure 17: Driving socket location
NOTICE: • If a fault is detected in the connection of the drive control device
plug to the socket, an alarm is displayed on the control panel. To
acknowledge the alarm, disconnect and reconnect the drive control
device plug.
• The drive control device cannot be used if the radio control mode is
switched on.
4. On the main control panel, make sure that the radio control mode ON/OFF switch is in position 0
(OFF).
Figure 18: Radio control switch in position 0 (OFF)
1.8.2. CONNECTING THE RADIO CONTROL DEVICE
NOTICE: Before using the radio control device, check if the local laws and regulations
allow the use of radio signals.
1. Activate the radio control device: On the main control panel, turn the radio control mode ON/OFF
switch to position 1 (ON).

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Figure 19: Radio control position 1 (ON)
1.9. DRIVING
1.9.1. DRIVING WITH DRIVE CONTROL DEVICE
CAUTION!
PROPERTY DAMAGE HAZARD
Can cause moderate injury or property damage.
Be extremely cautious when driving the machine onto a ramp. Make sure that
the ramp is properly positioned, in perfect technical order and can support the
weight of the machine.
To drive the machine straight, move both radio control levers simultaneously to the same direction. When
turning the machine, use only one lever at the time.
Check the directions of radio control levers compared to the directions of the machine from “Driving
directions”.
NOTICE: When turning, avoid driving tracks in opposite directions.
For description of the functions of radio control device, see “Radio control device”.
1. This step is only for machines with Constant Speed Engine (CSE): From the main control panel,
make sure that the track speed selector switch is in the “Slow” (Turtle) position before driving the
machine.
Figure 20: Track speed selector switch SLOW / RABBIT

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With the track speed selector switch, you can select two different track driving speeds: Slow “Turtle”
and Normal “Rabbit”. Use the “Normal” (Rabbit) position only if needed.
• To increase the track driving speed, turn the speed controller on the radio control device to the
“increase” position for 2 seconds
• To decrease the track driving speed, turn the speed controller to the “decrease” position for 2 seconds.
2. From the radio control device ON/OFF switch, turn the key switch clockwise for few seconds to
activate the radio control device. Turn the radio control device ON/OFF switch clockwise once more.
3. Move and release either joystick once to activate track driving.
After an audible start alarm signal, track driving is active and the machine can be driven.
NOTICE: You can change the driving speed by adjusting the engine speed.
4. From the radio control device, select the track drive mode, and then adjust the engine speed to
around 1000 rpm to avoid stalling the engine.
5. To familiarize yourself with the drive controls, and to check that track drive works properly, use the
radio control levers to drive the machine 0.5 m (20 in) straight and stop.
NOTICE: Be aware of the driving conditions. Weather or ground conditions
(firmness of the ground), can affect the traction. If driving on
uneven ground, always note the ground clearance of the machine
and the irregularities of the ground. In bad terrain, the machine
might not move if the engine speed is too low.
Driving speed range Engine speed
Slow driving 850..1200
Normal driving 1200...max
6. Drive the machine to the desired location. Continuously pay attention to the machine and the
surroundings while driving.
NOTICE: After driving with track drive continuously for 30 minutes: Stop
and wait for 30 minutes, to allow the components to cool down
before continuing the track drive.
NOTICE: When track driving longer distances, make sure that you drive the
feed end of the machine ahead.
7. After finishing the driving: On the main control panel, turn the radio control mode ON/OFF switch to
position 0 (OFF).

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Figure 21: Radio control switch in position 0 (OFF)
8. Turn the radio control device ON/OFF switch counterclockwise to position 0 (OFF) to deactivate the
radio control device.
1.9.2. DRIVING WITH RADIO CONTROL DEVICE
CAUTION!
PROPERTY DAMAGE HAZARD
Can cause moderate injury or property damage.
Be extremely cautious when driving the machine onto a ramp. Make sure that
the ramp is properly positioned, in perfect technical order and can support the
weight of the machine.
To drive the machine straight, move both radio control levers simultaneously to the same direction. When
turning the machine, use only one lever at the time.
Check the directions of radio control levers compared to the directions of the machine from “Driving
directions”.
NOTICE: When turning, avoid driving tracks in opposite directions.
For description of the functions of radio control device, see “Radio control device”.
1. This step is only for machines with Constant Speed Engine (CSE): From the main control panel,
make sure that the track speed selector switch is in the “Slow” (Turtle) position before driving the
machine.
Figure 22: Track speed selector switch SLOW / RABBIT