Metso Nordtrack CT85 User manual

Nordtrack CT85(R) / CT100(R)
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DRIVING ,16758&7,21S
For more information and
language versions, see:
metso.com/driving

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Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have
been any such updates or amendments.
The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every
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accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Metso shall not be liable in contract, tort
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Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only.
Copyright © Metso 2023. All rights reserved.
Metso
Address: PO Box 1220
FI-00101, Helsinki, Finland
Telephone: [phone]
Internet: www.metso.com
Status: Valid from product update:
R005
Original size:
A4
Customer: Project Phase: Site No:
Project Name: Customer Document ID:
Replaced by: Replaces: Language:
EN
Document Title:
Driving instructions
Nordtrack CT85(R) / CT100(R)
Equipment No: Item No:
Original instructions Translation of the original instructions
Language: EN
Nordtrack CT85(R) / CT100(R) Driving instructions
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Contents
1.1 Driving instructions.............................................................................................................................. 4
1.1.1 Safety.....................................................................................................................................4
1.1.2 Driving directions................................................................................................................... 5
1.1.3 Emergency stop locations......................................................................................................6
1.1.4 Remote stop location............................................................................................................. 7
1.1.5 Drive controls.........................................................................................................................8
1.1.5.1 Remote control device............................................................................................. 8
1.1.6 Preparing for driving.............................................................................................................10
1.1.6.1 Starting the engine.................................................................................................15
1.1.6.2 Unfolding the conveyor (CT85(R) only)..................................................................19
1.1.6.3 Setting the track driving mode................................................................................21
1.1.6.4 Connecting the remote control device (wireless connection).................................21
1.1.6.5 Connecting the remote control device (wired connection)..................................... 21
1.1.6.6 Unlocking the remote control device......................................................................23
1.1.7 Driving..................................................................................................................................24
1.1.8 Folding the conveyor (CT85(R) only)...................................................................................25
1.1.9 Stopping the engine.............................................................................................................27
1.1.10 Troubleshooting................................................................................................................. 28
1.1.10.1 Pairing the remote control device to the machine (Tier 3)................................... 28
1.1.10.2 Pairing the remote control device to the machine (Tier 4)................................... 30
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1.1 Driving instructions
These driving instructions are valid for Nordtrack CT85(R)/CT100(R) machines. The purpose of these
instructions is to enable safe moving of the machine during transportation.
NOTE: Do not use the machine for screening or crushing solely based on these instructions. The
actual instruction manual for the machine is delivered separately.
NOTE: 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.
1.1.1 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 unit. Only competent and trained personnel are
allowed to work with the unit.
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. Establish a buffer zone of at least 4.5 m (15 feet) around
the machine. 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.
Always drive the machine from a safe distance. Pay attention to the machine dimensions to avoid
power lines, bridges, branches and other obstacles.
1.1.2 Driving directions
4
3
2
1
3
4
2
1
Figure 1. Nordtrack CT85(R) driving directions
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4
3
2
1
3
4
2
1
Figure 2. Nordtrack CT100(R) driving directions
1. Forward 3. Right
2. Backward 4. Left
1.1.3 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 or the radio
control device). Before starting the machine, make sure you know the location of the emergency
stop buttons.
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1
2
Figure 3. Nordtrack CT85(R) and Nordtrack CT100(R) emergency stop locations
To stop the machine quickly in an emergency, pull the yellow emergency pull-cord (1), which runs along both
left and right side of the machine’s center frame.
To restart the machine after an emergency stop, pull the blue emergency stop reset button (2), located on
the left side of the machine where the rear undercarriage joins the conveyor frame.
1.1.4 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 (located on either the drive control device or the radio
control device). Before starting the machine, make sure you know the location of the emergency
stop buttons.
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Figure 4. Location of remote stop button
The remote stop button on the remote control device, if fitted, is not an emergency stop but can be used to
stop the machine.
1.1.5 Drive controls
1.1.5.1 Remote control device
WARNING
UNEXPECTED MOVEMENT HAZARD
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.
You must disconnect the drive control device from the unit immediately after driving and store it in a
safe place when not in use.
Only lift and hold the drive control device by its handles. Do not pull the drive control device from the
cable.
Sleep Mode ON/OFF: The remote control device enters a sleep mode after being inactive for more than 5
minutes. To exit the sleep mode: press the Green lock button (6), or press the Red stop button (7), or
activate one of the track toggles (1, 2, 3).
Power ON/OFF: Hold down the green Lock button (6) for 3 seconds.
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5
15
2
5
6
5
7
3
5
4
Figure 5. Remote control device
1. Left hand track forward/reverse 5. Information LEDs that provide information about
track driving speed and the state of remote control
device.
2. Right hand track forward/reverse 6. Lock/Unlock
Press this button to lock, unlock, or energize the
remote control device.
3. Left and right track together forward/reverse 7. Engine stop request
4. Track driving speed (option)
Press one of the three buttons to set the track
driving speed.
• Snail – Slow
• Tortoise – Medium
• Hare – Fast
1
2
3
4
5
6
Figure 6. Overview of the LEDs of remote control device
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Callout LED Color Mode Description
1 Speed: Hare Green Steady Track driving speed set to
fastest.
2 Speed: Tortoise Green Steady Track driving speed set to
medium.
3 Speed: Snail Green Steady Track driving speed set to
slowest.
4 RF status LED Green Steady Paired with machine and
in range.
Orange Flashing Pairing in progress
Red Steady Not paired with machine
or out of range.
5 Battery
Green
Flashing The battery of remote
control device is
charging.
Steady The battery of remote
control device is charged.
Orange Steady The battery charge is low.
Red Steady The battery is out of
charge.
6 Lock/Unlock Red Flashing The remote control
device is locked.
Green Steady The remote control
device is unlocked.
1.1.6 Preparing for driving
NOTE:
Make sure that
• you are familiar with the machine. Read the safety instructions from the start of this manual.
• the process is set to STOP 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 area is clear of obstructions and personnel. Especially, take into account any low-hanging
wires, trees, or roof bars.
• you inspect the path where the machine will be driven. Avoid track driving on a steep slope.
Make sure that there are no steep hills, valleys, bumps, or holes on the path.
• the driving surface is not icy or slippery. If needed, sprinkle sand on the surface.
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• you inform all personnel about the track driving path,
• you consider the end point of the track driving path. The machine may need to be positioned in a
certain direction. If needed, make sure that there is enough space to turn the machine around.
DANGER
TOXIC GAS HAZARD
Will cause death or serious injury.
If the track driving path includes enclosed space, such as a warehouse or a shipping container,
make sure that the enclosed space has sufficient ventilation during track driving. Exhaust gases
may concentrate to hazardous levels.
1. Visually inspect that there are no loose parts, and everything is secured in place.
2. Check the inclinations, approach angle, and departure angle of the machine.
15 °
5°
Figure 7. Maximum inclinations
11 °11 °
Figure 8. Maximum approach and departure angle
3. On the left-hand side of the machine, locate the main switch and turn it to ON position.
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Figure 9. Main switch
4. Locate the control panel. It is located within or next to the power unit of the machine.
12
Figure 10. Control panel location
1. Control panel location of Nordtrack CT85(R) 2. Control panel location of Nordtrack CT100(R)
Nordtrack CT85(R) / CT100(R) Driving instructions
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9
12
16
15
14
13
1
10
1
11
5 6 7 8
4
1817
2
1
1
3
Figure 11. Control panel (Tier 3 engines)
1. Power: This LED should be lit when the key
switch is turned to ON position. If the LED is
flashing, the fuse that charges the remote control
device has blown.
10. Cranking engine: This LED lights red during
the pre-crank delay before engine starts cranking.
2. Radio signal indicator light
• Green: Receiving valid radio signal
• Red: Radio stop command received
11. Hydraulic oil level sensor: The LED goes red
when the sensor is detecting a low hydraulic oil
level. The LED starts blinking when it goes to its
shutdown condition (no oil seen for 30 seconds).
3. Track driving: The LED goes red when the
operator requests track driving by performing the
unlock sequence on the remote control device.
The LED stays red while the pre-track timer is
counting down. The timer is reset when a track
switch is toggled. The LED will go green when
the machine is ready for track driving.
12. Coolant level sensor: The LED goes red
when the sensor is detecting a low coolant level.
The LED starts blinking when it goes to its
shutdown condition (no coolant seen for 30
seconds).
4. Feeder valve ON/OFF: Not in use for this
model
13. Key switch: OFF position
5. Battery charging (warning): The LED goes red
when the alternator is not charging the battery.
The panel does not shut down under this
condition. This LED is for warning only.
14. Key switch: Power ON position
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6. Oil pressure (warning): The LED goes red
when the sensor is detecting a low engine oil
pressure. The LED starts blinking when it goes to
its shutdown condition, engine has been running
for 20 seconds, and the switch has been closed
for 2 seconds.
15. Key switch: Engine pre-heat position
7. Oil temperature sensor: The LED goes red
when the sensor is detecting a high engine water
temperature. The LED starts blinking when it
goes to its shutdown condition, engine has been
running for 20 seconds, and the switch has been
closed for 2 seconds.
16. Key switch: Crank position
8. Air filter/water in fuel: This LED is lit if either
the air filter pressure switch is activated or the
water in fuel sensor (where fitted) activates. And
it starts blinking when it goes to its shutdown
condition, engine has been running for 20
seconds, and switch has been closed for 90
seconds.
17. Total engine hours
9. Emergency stop: This LED will only be lit if one
or more of the emergency stops have been
pressed. This LED will stay lit until the emergency
stops have been released.
18. Cabinet lock
11
12
1413
1
2
3
4
5
6
7
8
9
10
AB
Figure 12. Control panel (Tier 4 engines)
1. Engine fault warning: Illuminates when an
engine fault is detected.
8. DPF regeneration Inhibited: Illuminates when
the automatic DPF regeneration is disabled.
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2. Coolant level: Illuminates when coolant level is
too low, and flashes when the engine shuts down
as a result of insufficient coolant.
9. Manual DPF regeneration: Press the button (A)
to force-start manual DPF regeneration
3. Engine pre-heat: Illuminates when the engine
pre-heat is active during start-up.
10. Disable automatic DPF regeneration: Press
the button (B) to disable or enable the automatic
DPF regeneration.
4. Track driving: Illuminates orange when track
driving is disabled, and green when track driving
is enabled.
11. Control panel display
5. Total engine hours 12. These 4 buttons are used for selecting
different page-dependent options
6. Diesel Particulate Filter (DPF): illuminates
when a DPF regeneration is required.
13. Direction-pad is used for:
• Navigating through different display pages (left
and right)
• Controlling the engine RPM (up and down)
7. DPF regeneration active: Illuminates during
DPF regeneration
14. OK button used for confirming a given
selection
5. Make sure that the emergency stop buttons are not pressed, and also that the remote stop button is not
pressed down.
6. Proceed to the next section: “Starting the engine”.
1.1.6.1 Starting the engine
CAUTION
EXPLOSION HAZARD
Can cause moderate injury or property damage.
Never use startup spray or any other similar product to help the engine start. Startup sprays and
similar products can cause a destructive explosion in the intake manifold.
WARNING
PERSONAL INJURY HAZARD
Can cause death 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 nearby before starting.
WARNING
PERSONAL INJURY HAZARD
Can cause death or serious injury.
Wear personal protective equipment and clothing such as foot protection, helmet, hearing
protection, dust protective devices, safety glasses or other personal protective clothing and
equipment at all times.
1. Observe all safety warnings.
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2. Set the Throttle knob to idle rpm (Tier 3 engines only).
Figure 13. Throttle knob, (Tier 3 engines only)
3. Check that all control levers are in neutral (OFF) position, and all emergency stops are released.
CAUTION
PROPERTY DAMAGE HAZARD
Can cause moderate injury or property damage.
Make sure that all control levers are in the neutral (OFF) position.
Figure 14. Control levers in neutral (OFF) position
4. Insert the key into the ignition switch of main control panel.
5. Turn the key clockwise to the Power ON position (2).
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1
2
3
4
1. OFF 3. Engine pre-heat
2. Power ON 4. Crank
Figure 15. Ignition key positions
6. Turn the key clockwise to the Engine pre-heat position (3). The Engine pre-heat lamp will illuminate. Wait
until this lamp goes out before continuing.
7. Turn the key clockwise further to the Crank position (4). You will hear an audible start alarm signal to
indicate that the machine is about to start.
8. Hold the key in the Crank position (4) for 10 seconds. During the 10 seconds, the alarm will continue to
sound.
9. Release the key immediately after the engine starts.
10. Before operating the machine, allow the engine to run at idle for 5 minutes to allow the running
temperature to be reached.
11. Check around the engine compartment area for engine oil, fuel, coolant, or hydraulic fluid leaks.
12. If your machine has a Tier 4 engine, prevent DPF regeneration by pushing the Disable automatic DPF
regeneration button (B) on the control panel.
If needed, press the button (A) to force manual DPF regeneration.
AB
Figure 16. DPF regeneration (Tier 4 engines)
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WARNING
FIRE HAZARD
Can cause death or serious injury.
Stay away from the exhaust pipe. Do not place any flammable objects in front of the exhaust pipe.
The exhaust gas is very hot. Note that the exhaust gas can be even hotter during regeneration of
the diesel particulate filter.
13. Adjust the engine rpm if needed. (Track driving can be done at any rpm.)
a) Tier 3 engines: Use the Throttle knob to control engine rpm.
Figure 17. Adjusting the engine rpm (Tier 3 engines)
b) Tier 4 engines: Go to the main page of control panel display. Use the Left and Right arrows (A) to
switch display pages, and the Up and Down arrows (B) to control the engine rpm.
AB
Figure 18. Adjusting the engine rpm (Tier 4 engines)
NOTE:
The engine is programmed to auto-shutdown after 30 minutes of being idle. This safety feature
reduces the engine idle hours, which reduces emissions and extends the engine and component
lifetime.
When the engine is idling or running under 1800 rpm, a timer on the main page of the display shows
the seconds remaining until auto-shutdown. To stop the auto-shutdown timer, increase the engine
rpm.
The auto-shutdown will not occur in track driving mode.
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1.1.6.2 Unfolding the conveyor (CT85(R) only)
To ensure proper weight balance during track driving of CT85(R) stackers, the conveyor must be unfolded
before track driving.
WARNING
GENERAL HAZARD
Can cause death or serious injury.
Make sure that the machine unit stands on an even surface before operation.
WARNING
PERSONAL INJURY HAZARD
Can cause death or serious injury or property damage.
Only trained and competent personnel are allowed to operate, maintain and service the machine. If
operating procedures are unclear, contact Metso for assistance prior to operating.
Stay away from a folding conveyor. Pay attention to obstacles and conveyor belt clearances when
folding and unfolding conveyor.
WARNING
CRUSHING HAZARD
Can cause death or serious injury.
Make sure that there is nobody under the conveyor during the folding of the conveyor.
NOTE:
Check the condition of the fold mechanism, especially check the cotter pin connections (1). Do not
proceed if any damages are found.
2
1
Figure 19. Cotter pin connections and pinch points
1. Cotter pin connections
2. Pinch point
To unfold the conveyor, do the following steps:
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1. Run the engine at idle speed.
2. Make sure that all personnel are away from all the pinch points (2).
2
Figure 20. Pinch point
3. Remove any straps and other obstructions to make sure that the head frame of the conveyor can be
unfolded freely.
4. Unfold the conveyor using the Top fold hydraulic control lever.
Figure 21. Top fold hydraulic control lever
Follow the alignment of conveyor belt while unfolding the conveyor, that is, make sure that the conveyor
belt is not pinched by or tangled in any part of the machine.
5. Make sure that all hydraulic control levers are in neutral (OFF) position.
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