Terex Evoquip Bison 120 User manual

Bison 120
© Terex 2018
MOBILE CRUSHER
Issue Date: 20-07-2018
Language: English (en)
Revision No.: 2.0
Original Intructions
Operations Manual

EvoQuip
200 Coalisland Road
Dungannon, Co. Tyrone
BT71 4DR
Telephone: [phone]

Record of Revisions
Operations Manual
Bison 120
20-07-2018
Page 1
Revision 2.0
Record of Revisions
Revision
Number Reason for Change Date
1.0 Introduction of the new Bison 120 manual August 2016
1.1 Start Up Procedure Update
Maintenance Updates
Greasing Schedule Updates
Other General Updates
2 May 2017
2.0 California 65 Proposition updated. Safety Decals added.
Emergency Stop Locations Updated.
Jaw lifting points updated.
20 July 2018

Record of Revisions
Operations Manual
Bison 120
20-07-2018
Page 2
Revision 2.0
Intentionally Left Blank

Table of Content
Operations Manual
Bison 120
20-07-2018
Page 1
Revision 2.0
Table of Content
1 Introduction................................................................................................ 1-2
1.1 Notes to the Operations Manual.....................................................................1-2
(1) Units...........................................................................................................1-2
(2) Optional Equipment ...................................................................................1-3
1.2 Safety Information ..........................................................................................1-3
(1) Safety Warning Symbol .............................................................................1-3
(2) ANSIHazardClassicationSystem ..........................................................1-3
(3) California Proposition 65 Warnings ...........................................................1-4
1.3 Intended Use..................................................................................................1-4
1.4 Prohibited Use................................................................................................1-4
1.5 Declaration of Conformity...............................................................................1-4
1.6 Warranty.........................................................................................................1-4
1.7 Copyright........................................................................................................1-5
1.8 Bulletin Distribution and Compliance..............................................................1-5
1.9 Contacting the Manufacturer..........................................................................1-6
1.10 Transfer of Machine Ownership .....................................................................1-6
2 Safety .......................................................................................................... 2-2
(1) Safety Warning Symbol .............................................................................2-2
(2) ANSIHazardClassicationSystem ..........................................................2-2
(3) Property Damage Messages .....................................................................2-3
(4) Positions of Safety Signs on the machine .................................................2-3
2.2 Personal Safety..............................................................................................2-8
(1) Personal Protective Equipment .................................................................2-8
2.3 Work Area Safety ...........................................................................................2-9
(1) General Work Area Guidelines ..................................................................2-9
(2) Safety Warnings and Labels......................................................................2-9
(3) Modications..............................................................................................2-9
(4) Transportation Safety ..............................................................................2-10
(5) Operation Safety......................................................................................2-10
(6) Hydraulic and Pneumatic Safety .............................................................2-12
(7) Electrical Safety.......................................................................................2-13
(8) Maintenance Safety.................................................................................2-14
(a) Maintenance and Repairs During Operation; Disposal of Parts and
Consumable’s .....................................................................................2-14
(9) Gas, Dust, Steam, Smoke .......................................................................2-16
(10) Hazardous Substances ...........................................................................2-16
(11) Noise Levels ............................................................................................2-16
(12) Fire Hazards ............................................................................................2-17
(13) Exclusion Zones ......................................................................................2-18
(a) Magnet ................................................................................................2-18
2.4 Emergency Stop Locations ..........................................................................2-19

Table of Content
Operations Manual
Bison 120
20-07-2018
Page 2
Revision 2.0
3 Technical Data............................................................................................ 3-2
3.1 MachineSpecications...................................................................................3-2
(1) MachineComponentsSpecications ........................................................3-2
(a) Jaw Crusher..........................................................................................3-2
(b) Grizzly Feeder with Hopper ..................................................................3-2
(c) Power Unit ............................................................................................3-3
(d) Extracting Belt.......................................................................................3-3
(2) Tracks ........................................................................................................3-3
3.2 Dimensions.....................................................................................................3-4
(1) Working Range and Transport Diagrams ..................................................3-4
3.3 Noise Emissions.............................................................................................3-5
3.4 Operating Temperature Range.......................................................................3-5
4 Machine Description.................................................................................. 4-2
4.1 General Information........................................................................................4-2
(1) IdenticationPlate .....................................................................................4-2
(2) Machine References..................................................................................4-3
(3) Machine Components................................................................................4-4
4.2 Systems..........................................................................................................4-5
(1) Power Unit .................................................................................................4-5
(2) Crushing System .......................................................................................4-5
(a) Jaw Crusher..........................................................................................4-5
(b) Dust Eliminating System (Optional) ......................................................4-5
(3) Feed System..............................................................................................4-5
(a) Vibrating Feeder....................................................................................4-5
(4) Conveying System.....................................................................................4-5
(a) Extracting Belt.......................................................................................4-5
(b) Magnetic Belt (Optional) .......................................................................4-5
(5) Twin Track Undercarriage..........................................................................4-6
(6) Maintenance Platform................................................................................4-6
(7) Chassis......................................................................................................4-6
(8) Guards.......................................................................................................4-6
4.3 Control and Display Elements........................................................................4-7
(1) Control Panel.............................................................................................4-7
(2) Radio Control.............................................................................................4-8
4.4 Optional Equipment........................................................................................4-9
4.5 Applications..................................................................................................4-10
5 Transportation............................................................................................ 5-2
5.2 Placing the Machine into the Transport Position ............................................5-4
(1) Placing The Extraction Belt Into Transport Position...................................5-5
5.3 Loading the Machine for Transport.................................................................5-8
(1) Prior to Haulage.........................................................................................5-8
(2) Tracking Machine onto Trailer ...................................................................5-9
(3) Lifting Machine onto Trailer .....................................................................5-10
(4) Ready for Transport.................................................................................5-12
(5) Transport Tie-Down Points ......................................................................5-13

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Operations Manual
Bison 120
20-07-2018
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Revision 2.0
5.4 Removing Machine from the Low Loading Trailer........................................5-14
(1) Tracking the Machine off the Transporter ................................................5-15
(2) Lifting Machine off the Trailer...................................................................5-16
6 Initial Setup and Adjustments .................................................................. 6-2
6.2 Initial Inspection Check ..................................................................................6-3
6.3 Machine Location Considerations ..................................................................6-3
6.4 Measures Before Setup..................................................................................6-4
6.5 Measures After Long-Term Standstill .............................................................6-4
6.6 Pre-Operating checks.....................................................................................6-5
(1) Checking Engine Oil Level ........................................................................6-5
(2) Checking Diesel Level ...............................................................................6-6
(3) Checking Hydraulic Oil Level Check .........................................................6-7
(4) Checking Track Tension.............................................................................6-7
6.7 Setting Up the Machine..................................................................................6-8
6.8 Setup..............................................................................................................6-9
(1) Starting the Engine ....................................................................................6-9
(2) Placing the Extraction Belt Into Working Position.................................... 6-11
(3) Setting the Crusher Discharge Opening..................................................6-12
6.9 Introducing Material to Machine ...................................................................6-13
6.10 Initial Startup and Running In.......................................................................6-14
7 Standard Operating Procedures .............................................................. 7-2
7.2 Pre Operating Checks....................................................................................7-3
7.3 Initial Startup ..................................................................................................7-4
7.4 Start Up ..........................................................................................................7-5
7.5 Manoeuvring...................................................................................................7-8
(1) Tracking the Machine ................................................................................7-9
(2) Remote Tracking......................................................................................7-10
(3) Remote Tracking with Umbilical Cable ....................................................7-12
7.6 Standard Operation via Radio Remote ........................................................7-13
7.7 Shutdown .....................................................................................................7-15
7.9 Stalled Crusher Procedure...........................................................................7-18
8 Emergency Operating Procedures........................................................... 8-2
8.1 Lockout and Tagout ........................................................................................8-2
(1) Before Carrying Out Any Work on the Machine.........................................8-2
(2) After Carrying out Work on the Machine....................................................8-4
8.2 Emergency Stop.............................................................................................8-5
(1) Emergency Stop Locations........................................................................8-5
8.3 Restarting after Emergency Stop ...................................................................8-6
8.4 Testing Emergency Stops...............................................................................8-6

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Operations Manual
Bison 120
20-07-2018
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Revision 2.0
9 Maintenance ............................................................................................... 9-3
9.2 General Information........................................................................................9-4
(1) Diesel Engine ............................................................................................9-5
(2) Crusher......................................................................................................9-5
(3) Vibrating Drawer ........................................................................................9-5
(4) Extraction Belt............................................................................................9-5
9.3 Maintenance Schedule...................................................................................9-6
9.4 Greasing Schedule.........................................................................................9-7
9.5 Lubricants, Oils, and Fluids.......................................................................... 9-11
(1) Lubrication, Quantities, and Levels ......................................................... 9-11
(2) Machine Grease Lubrication....................................................................9-12
(a) Standard Viscosity Option...................................................................9-12
9.6 Hydraulic Maintenance.................................................................................9-13
(1) Hydraulic System Overview.....................................................................9-14
(a) Hydraulic Fluids ..................................................................................9-14
(b) Oil Tank, Pipes & Fittings ....................................................................9-15
(2) Filtration...................................................................................................9-15
(a) Crusher Pump Oil Filter ......................................................................9-15
(b) Load Sensing Pump Oil Filter .............................................................9-16
(c) Tank Oil Filter ......................................................................................9-16
(3) Changing Hydraulic Filters & Oil..............................................................9-17
(a) Changing Crusher Pump Filter ...........................................................9-17
(b) Changing Load Sensing Pump Filter ..................................................9-18
(c) Changing The Oil Tank Filter...............................................................9-20
(d) Changing Hydraulic Oil .......................................................................9-21
9.7 Conveyor Maintenance ................................................................................9-23
(1) Clean and Check the Conveyor Belts......................................................9-23
(2) Belt Tracking............................................................................................9-24
(3) Belt Adjustment on Extraction Belt ..........................................................9-25
(a) Belt Tracking Extraction Belt ...............................................................9-25
(b) Belt Tensioning on Discharge Conveyor .............................................9-26
9.8 Vibrating Drawer and Hopper Maintenance .................................................9-27
(1) Changing Vibrating Drawer Grids............................................................9-27
(2) Adjusting Vibrator Mass Position.............................................................9-29
9.9 Engine Maintenance.....................................................................................9-31
(1) Engine Overview .....................................................................................9-32
(2) Changing Engine Filters and Oil..............................................................9-33
(a) Changing the Engine Oil Filter ............................................................9-33
(b) Changing the Engine Oil Filter (Tier 4 Engine) ...................................9-34
(c) Checking Engine Oil ...........................................................................9-35
(d) Changing Engine Oil ...........................................................................9-36
(e) Changing the Air Cleaner Elements....................................................9-39
(3) Cooling System Maintenance..................................................................9-40
(a) Checking Engine Coolant Level..........................................................9-40
(b) Changing Coolant ...............................................................................9-41
(c) Changing Coolant (Tier 4 Engine).......................................................9-42

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Revision 2.0
(4) Fuel System Maintenance .......................................................................9-44
(a) Changing the Fuel Filter......................................................................9-44
(b) Draining Water from Fuel System .......................................................9-45
(5) Checking for Leaks..................................................................................9-47
(6) Fuel System Maintenance (Tier 4 Engine) ..............................................9-47
(a) Draining Water from Fuel System (Tier 4 Engine) ..............................9-47
(b) Bleeding the Fuel System ...................................................................9-48
(c) Changing the Fuel Filter (Tier 4 Engine) .............................................9-49
(d) Changing the Pre-Fuel Filter...............................................................9-50
9.10 Track Maintenance.......................................................................................9-51
(1) Changing Gearbox Oil in Tracks..............................................................9-52
(2) Track Adjustment .....................................................................................9-53
(a) To Release Track Tension...................................................................9-53
(b) To Increase Track Tension ..................................................................9-54
9.11 Jaw Crusher Maintenance............................................................................9-55
(1) Checking components for wear ...............................................................9-55
(a) Daily Component Checks ...................................................................9-55
(2) Jaw Liner Maintenance............................................................................9-55
(a) Removal of Moving and Fixed Jaw Liners ..........................................9-55
(3) Side Jaw Liner Maintenance ...................................................................9-57
9.12 Drive Belt Maintenance ................................................................................9-59
(1) Alignment.................................................................................................9-59
(2) Adjustment...............................................................................................9-60
(a) Belt Tensioning Measurements ...........................................................9-61
(3) Replacement of Drive Belts .....................................................................9-62
9.13 Electrical Maintenance .................................................................................9-63
(1) Before Welding ........................................................................................9-63
(2) Battery Removal and Installation.............................................................9-63
9.14 Charging Radio Remote Handset Battery....................................................9-65
9.15 Dust Suppression Maintenance ...................................................................9-65
9.16 Hydraulic Ram Maintenance ........................................................................9-66
10 Troubleshooting....................................................................................... 10-2
10.1 General Troubleshooting..............................................................................10-2
(1) General....................................................................................................10-2
(2) Vibrating Drawer ......................................................................................10-2
(3) Conveyors................................................................................................10-3
(4) Components ............................................................................................10-4
(5) Hydraulic..................................................................................................10-5
(6) Production ...............................................................................................10-7
(7) Tracks ......................................................................................................10-7
(8) Electrical ..................................................................................................10-9
(9) Jaw Chamber.........................................................................................10-10
(10) Engine ...................................................................................................10-11
10.2 Machine Fuses...........................................................................................10-18

Table of Content
Operations Manual
Bison 120
20-07-2018
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Revision 2.0
11 Storage ......................................................................................................11-2
12 Glossary of Terms ................................................................................... 12-1
13 Appendix .................................................................................................. 13-1
Appendix A EC Declaration of Conformity..............................................A-1
Appendix B Warranty ................................................................................B-1
Appendix C Schematics............................................................................C-3
(1) Electrical Schematics................................................................................ C-3
(a) Front Panel- CPU Connection ............................................................. C-3
(b) Front Panel- CPU Connection (Cont.) ................................................. C-4
(c) Main Wiring ......................................................................................... C-5
(d) Relay Box............................................................................................. C-6
(2) Hydraulic Schematics ............................................................................... C-7
(a) Crusher hydraulics ............................................................................... C-7