Portafill 4000T User manual

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4000T
USER MANUAL

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Introduction
This document has been created to ensure that the Equipment designed and constructed by
Portafill International Limited, is installed, put into use and operated efficiently and safely.
It is recommended that this manual is read carefully so as to educate on how to operate and service
your machine correctly.
Failure to do so could result in personal injury or damage to the equipment.
A copy of this manual must be kept at the Operational Site for easy reference.
REMEMBER - YOUR MACHINE IS ONLY AS SAFE AS THE OPERATOR!
Hazard control and accident prevention are dependent upon the awareness, concern, prudence,
and proper training of the personnel involved in the operation, transport, maintenance, and
storage of the equipment. Ensure that every operator is properly trained and thoroughly familiar
with all of the controls before operating the machine.
A replacement manual is available from your Authorised Dealer or by contacting Portafill
International Limited directly using the contact details shown at the start of this manual. Please
indicate the complete Model and Serial Number of your product when requesting replacement
manuals.
Whilst every effort has been made to ensure the accuracy of the information contained within this
manual, Portafill International Ltd can assume no responsibility for any errors, omissions, or their
consequences.
Please contact Portafill International Ltd regarding any part of this manual that requires further
clarification.
This Manual is structured by different sections as noted in the Contents Page. These are to help you
familiarize yourself with the Portafill 4000T and, most importantly, with the safe set-up, operating
and maintenance procedures.

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Declaration of Conformity
Declaration Number T 140
The undersigned representing the following supplier:
Portafill International Limited,
29 Farriter Road,
Cabragh,
Dungannon,
Co Tyrone
Northern Ireland
BT70 1TL
Hereby declares that the following equipment:
Model Portafill 4000T
Type Mobile, Diesel-Hydraulic Powered Screening Machine
Serial Number: T 140
Complies with the provisions of the following EC Directives.
2006/42/EC
Machine Safety Directive
2004/108/EC
Electromagnetic Compatibility Directive
2005/95/EC
Low Voltage Directive
Based on the following harmonized standards
BSEN 14121-1:2007
And therefore complies with the essential requirements of those directives.
Name and position of person signing for the manufacturer or authorized representative
Signed by:
Name: Malachy Rafferty
Title: Design Manager
Location: Portafill International Ltd
Date: September 2016

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This machine is designed and engineered by:
Portafill International Limited,
29 Farriter Road, Cabragh,
Dungannon, Co Tyrone,
N. Ireland, BT70 1TL.
http://www.portafill.com
t: [phone]
f: [phone]
e: [email protected]
Copyright Notice
Information in this document is subject to change without notice. The names of companies,
products, people, characters and/or data mentioned herein are fictitious and are in no way
intended to represent any real individual, company, product or event unless otherwise noted.
Complying with all applicable copyright laws is the responsibility of the user. No part of this
document may be reproduced or transmitted in any form or by any means, electronic or
mechanical, for any purpose, without the express written permission of Portafill International Ltd.
If, however, your only means of access is electronic, permission to print one copy is hereby granted.
© 2016 Portafill International. All rights reserved.
NOTE- It is highly recommended that this manual is read carefully so as to educate on how to
operate and service your machine correctly. It is advised that any one operating this machine reads
and understands the Manual.

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SECTION 1 - MACHINE SAFETY .....................................................................................................................................10
1.1 SAFETY INTRODUCTION................................................................................................................................................... 10
1.2 OPERATION .................................................................................................................................................................. 10
1.3 MAINTENANCE.............................................................................................................................................................. 10
1.4 SIGNAL SYMBOL ............................................................................................................................................................ 12
1.5 SIGNAL WORDS............................................................................................................................................................. 12
1.6 SAFETY INSTRUCTIONS AND APPLICATIONS.......................................................................................................................... 12
1.7 SYSTEM LOCK-OUT PROCEDURE ....................................................................................................................................... 12
1.8 GENERAL SAFETY CONSIDERATIONS................................................................................................................................... 13
1.9 SAFETY CONSIDERATIONS DURING OPERATION.................................................................................................................... 13
1.10 SAFETY DURING MAINTENANCE OR SERVICE ..................................................................................................................... 14
1.11 SAFETY WHEN WORKING WITH HAZARDOUS CHEMICALS .................................................................................................... 15
1.12 SAFETY WHEN WORKING WITH BATTERIES ....................................................................................................................... 16
1.13 SAFETY DURING WORK ON ELECTRICAL SYSTEM ................................................................................................................ 16
1.14 SAFETY DURING WORK ON HYDRAULIC SYSTEM ................................................................................................................ 17
1.15 SAFETY DURING TRANSPORT.......................................................................................................................................... 17
1.16 SAFETY DURING MACHINE TRACKING .............................................................................................................................. 18
1.17 REMOTE RADIO PRECAUTIONS ....................................................................................................................................... 18
1.18 MACHINE LAYOUT AND LOCATION OF EMERGENCY STOP..................................................................................................... 19
1.19 INTERLOCK SWITCH...................................................................................................................................................... 19
1.20 MACHINE SAFETY LABELS.............................................................................................................................................. 20
1.21 MACHINE SERIAL PLATE................................................................................................................................................ 22
SECTION 2 - MACHINE FAMILIARISATION AND TECHNICAL INFO. ................................................................................23
2.1 MACHINE SPECIFICATION AND IDENTIFICATION.................................................................................................................... 23
2.2 SPECIFICATION .............................................................................................................................................................. 24
2.3 WORKING DIMENSIONS .................................................................................................................................................. 25
2.4 TRANSPORT DIMENSIONS................................................................................................................................................ 26
2.5 SOUND PRESSURE LEVELS................................................................................................................................................ 27
2.5.1 Conclusions........................................................................................................................................................ 27
SECTION 3 - APPLICATION & FUNCTIONS.....................................................................................................................28
3.1 MATERIAL MACHINE IS CAPABLE OF PROCESSING ................................................................................................................ 29
3.2 OPERATING TECHNIQUES ................................................................................................................................................ 29
3.3 EFFICIENT LOADING OF HOPPER/GRID ............................................................................................................................... 29
3.4 FEEDER SPEED............................................................................................................................................................... 29
3.5 DRUM MESH SELECTION................................................................................................................................................. 29
3.6 SCREEN SPEED .............................................................................................................................................................. 29
SECTION 4 - OPERATION & SET UP...............................................................................................................................30
4.1 ENGINE START UP PROCEDURE......................................................................................................................................... 31
4.2 MACHINE LAYOUT -FRONT /BACK /SIDES ........................................................................................................................ 32
4.3 REMOVING THE MACHINE FROM TRAILER........................................................................................................................... 33
4.4 UNLOADING 4000T ON LOW LOADER TRAILER ................................................................................................................... 34
4.5 LOADING 4000T ON LOW LOADER TRAILER ....................................................................................................................... 34
4.6 USING THE RADIO REMOTE CONTROL................................................................................................................................ 35
4.7 OPERATING INSTRUCTIONS .............................................................................................................................................. 35
4.8 PREPARING MACHINE FOR OPERATION .............................................................................................................................. 36
4.9 SET UP –CONTROL LEVERS FUNCTION .............................................................................................................................. 36
4.10 SET UP –MACHINE WORKING POSITION ......................................................................................................................... 37
4.11 SET UP –CONVEYORS TO WORKING POSITION .................................................................................................................. 38
4.12 OPERATING THE SCREEN ............................................................................................................................................... 42
4.13 LOAD SENSING ON 4000 MODELS.................................................................................................................................. 44
4.14 MOVING THE 4000T ABOUT SITE................................................................................................................................... 45
4.15 SET UP –MACHINE TRANSPORT POSITION ....................................................................................................................... 46

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SECTION 5 - MAINTENANCE.........................................................................................................................................51
5.1 OIL TYPES .................................................................................................................................................................... 52
5.2 MAINTENANCE SCHEDULES.............................................................................................................................................. 52
5.2.1 Maintenance Schedule –Daily 10 Hours........................................................................................................... 52
5.2.2 Maintenance Schedule –Weekly 50 Hours ....................................................................................................... 53
5.2.3 Maintenance Schedule –100 Hours.................................................................................................................. 53
5.2.4 Maintenance Schedule –250 Hours.................................................................................................................. 54
5.2.5 Maintenance Schedule –500 Hours.................................................................................................................. 54
5.2.6 Maintenance Schedule –1000 Hours................................................................................................................ 54
5.2.7 Maintenance Schedule –2000 Hours................................................................................................................ 55
5.3 ENGINE MAINTENANCE................................................................................................................................................... 55
5.4 HYDRAULIC RAM MAINTENANCE ...................................................................................................................................... 55
5.5 HYDRAULIC SYSTEM MAINTENANCE .................................................................................................................................. 56
5.6 HYDRAULIC TANK MAINTENANCE ..................................................................................................................................... 57
5.7 CHECKING AND ADDING HYDRAULIC OIL ............................................................................................................................ 58
5.8 CHANGING HYDRAULIC OIL.............................................................................................................................................. 58
5.9 CHANGING THE RETURN LINE FILTER ................................................................................................................................. 59
5.10 AIR CLEANER MAINTENANCE ......................................................................................................................................... 59
5.11 FUEL SYSTEM.............................................................................................................................................................. 60
5.12 BATTERY ROUTINE CHECKS............................................................................................................................................ 61
5.13 MAIN CONTROL PANEL WARNING LIGHTS........................................................................................................................ 61
5.14 AIR BREATHER RESTRICTION OPTIONS ............................................................................................................................. 62
5.15 TRACK MAINTENANCE .................................................................................................................................................. 62
5.16 TRACKS –GEAR BOX OIL............................................................................................................................................... 64
5.17 TRACKS –FAULT FINDING ............................................................................................................................................. 64
5.18 BEARING GREASING POINTS .......................................................................................................................................... 64
5.19 CONVEYOR BELT MAINTENANCE /ADJUSTMENT ............................................................................................................... 66
5.19.1 Belt Tensioning / Alignment ............................................................................................................................ 66
5.19.2 Wing Conveyor ................................................................................................................................................ 66
5.19.3 Oversize Conveyor ........................................................................................................................................... 67
5.19.4 Feeder Conveyor.............................................................................................................................................. 68
5.19.5 Transfer Conveyor ........................................................................................................................................... 68
5.19.6 Checking for Belt Damage............................................................................................................................... 69
5.20 SCREEN MAINTENANCE /MESH REPLACEMENT................................................................................................................. 69
5.21 MESH REMOVAL /REPLACEMENT................................................................................................................................... 70
5.22 DRUM DRIVE GEAR ALIGNMENT INSTRUCTIONS ................................................................................................................ 70
5.22.1 Drum Guide Wheel Adjustment ...................................................................................................................... 73
5.22.2 Daily Maintenance/ Check before Start Up..................................................................................................... 75
SECTION 6 –ELECTRICAL AND HYDRAULIC SCHEMATICS..............................................................................................76

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1
Section 1 - Machine Safety
1.1 Safety Introduction
Portafill International advises extreme caution
while operating, maintaining and servicing all
components of this machine.
Failure to use adequate safety precautions to
prevent injury or death while performing
operations, maintenance or servicing is the
sole responsibility of the user.
WARNING: Always ensure that all personnel
are clear of the machine when moving,
tracking, maintaining, adjusting or carrying
out setting changes.
Only trained and competent personnel should
operate / maintain / service mobile track
equipment. If operating procedures are
unclear, contact your local distributor for
assistance prior to operating.
Refer to Safety section in the machine’s
operation manual.
1.2 Operation
Factory installed guarding must be in place
before operation. Maintenance and service
may require factory installed guarding to be
removed.
DO NOT OPERATE MACHINERY UNTIL ALL
GUARDING IS REPLACED AND SECURED.
Always read and understand the Operator’s
Manual before Operation / Service /
Maintenance of the machine.
For your protection be aware of all safety
decals positioned around the mobile screen.
These safety decals are positioned in
imminent hazard areas for your safety.
Keep personnel away from all conveyors. DO
NOT STAND OR WALK UNDER ANY
CONVEYORS and beware of loading and
discharge areas. These are extremely
hazardous areas due to falling objects and
moving equipment.
1.3 Maintenance
While maintenance and service functions are
being performed, the Portafill 4000T must be
shut down and secured so that no
unauthorized start-up and operation can
occur. Portafill International advises that the
ignition key be removed prior to any
maintenance or service practices.
Stop all process operations before attempting
adjustments. Remove process material before
adjustment procedures.
This manual is an important part of your
machine and should remain with the machine
when you sell it.

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Reading your operator's manual will help you
and others avoid personal injury or damage to
the machine. Information given in this manual
will provide the operator with the safest and
most effective use of the machine. Knowing
how to operate this machine safely and
correctly will allow you to train others who
may operate this machine.
This manual and safety signs on your machine
may also be available in other languages (see
your authorised dealer to order).
Sections in your operator's manual are placed
in a specific order to help you understand all
the safety messages and learn the controls so
you can operate this machine safely. You can
also use this manual to answer any specific
operating or servicing questions.
RIGHT-HAND and LEFT-HAND sides are
determined by the direction of the material
flow through the machine.
READ THIS OPERATOR’S MANUAL BEFORE ATTEMPTING TO START YOUR MACHINE