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CONVEYOR SYSTEMSMODELS: TR6540 & TR8042

TR6540/8042 22 3

1. INTRODUCTION / WARRANTY

Thank you for purchasing an EZYSTAK conveyor. This manual is as important as your conveyor and should be read thoroughly before operating your machine.

Safety is always at the forefront at Ezystak. It is recommended that all safety information should be read and followed.

MANUFACTURER:Ezystak Conveyor Sysytems200 Annagher RoadCoalislandCo.TyroneN.IrelandBT71 5DA

T: + 44 (0) 28 8774 8090F: + 44 (0) 28 87746585E: [email protected]

Serial Number: ______________________

Product / Model: ______________________

WARRANTYEzystak Conveyors carries a one year warranty on labour and on all non consumable parts e.g. filters and scrapers. All Ezystak Conveyors are carefully examined and tested before leaving the premises.

Every Ezystak machine must be registered for warranty. Please complete the Warranty Registration Certificate on the next page. One copy should be kept by you the customer and a copy returned to Ezystak Conveyor Systems at the above address .Before warranty can be honoured a Warranty Certificate must be held on file at Ezystak Conveyor Systems.

NOTE:If servicing or repairing any parts that is non factory supplied will invalidate the warranty. It is the sole responsibility of the operator to read, understand and comply with all instructions as stated in this manual.

ENGINE WARRANTY Any engine used in the production of Ezystak Conveyors is covered by it’s own brand warranty e.g Caterpillar or Deutz. It is the sole responsibility of the customer to register your engine with the local dealer e.g Caterpillar or Deutz Dealers. Failure to register could effect the warranty of your engine.

CONTENTS

3. Introduction Warranty4-5. Registration Certificate6. EU Declaration of Conformity7-9. Safety and Operating10. Know your machine11. Power Unit / Engine Control Panel12. Control Panel Description13. Control Valve Bank and Engine Hand Trottle Hydraulic Tank Indicator Conveyor Shut Down14. Conveyor Transit15. Operating the Conveyor16. Starting the Machine17. Machine Shutdown18. Moving the Machine19. Transporting20-23. Maintenance24. Track Maintenance25. Oil filling and Draining26. Hydraulic Schematic Circuit Details27-28. Technical Specifications Optional Extras29. Technical Dimensions

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Registration Certificate

This is a Registration Certificate. Your warranty starts on the day that warranty registration has taken place.

Date:__________________________ Serial Number:______________________

SAFETYHave you located all of the emergency stops? Yes / NoHave you assessed Safe working area? Yes / NoIs the machine set up on level surface? Yes / NoDo you have a proper working dog lead? Yes / NoDo you have a proper working RadioRemote (optional extra)? Yes / NoAny extra options are in place? Yes / NoAll guards are fitted and secure? Yes / NoAre you happy with first test of machine? Yes / NoIf not, why?

POWER UNITCheck oil level and water in diesel tank Yes / No Comments:_______________________________________________________Check Oil Level in hydraulic tank Yes / NoComments:______________________________________________________Are the control valves operating? Yes / NoAny leaks in the hydraulic system? Yes / NoAre all emergency stops are working? Yes / NoControl panel in good working order Yes / No

Any persons who will be operating machine should be fully trained and informed of the workings of the machine Yes / No

CONvEYOR Is the belt tracking? Yes / NoCheck tension of discharge belt Yes / No

Copy to be retained and hard copy to be returned at the above address.Please note: no warranty registration received means no warranty on machine.

Customer Name:

Ezystak Dealer / Distributor:

Customer Contact name:

Contact:

Customer Contact:

Phone Number:

Customer Full Address:

Application:

Engine Registered: Yes / No

Instruction Manual Received: Yes / No

Notes or Comments:

I the undersigned confirm that I have received the Ezystak product and that the operators fully understand the operations of the machine. I was present when all check areas were marked and hereby sign below agreeing to the conditions of the Ezystak warranty:

Signatures:

200 Annagher RoadCoalisland, Co.TyroneN.Ireland. BT71 5DA

T: + 44 (0) 28 8774 8090F: + 44 (0) 28 87746585E: [email protected]

TR6540/8042 66 7

EU DECLARATION OF CONFORMITYDECLARATION No.

We the undersignedEZYSTAK CONVEYORS200 Annagher RoadCoalislandDungannonCo.TyroneN.IrelandBT71 5DA

Declare under our sole responsibility that the following apparatus:

EZYSTAK

Model: _________________________________

Serial Number: __________________________

Is in conformity with the following relevant EC legislation:Machinery Directive 2006/42/EC

Based on the following harmonised standards: EN12100-2:1998. EN ISO 14121-1: 2007, BS EN 982: 1996 + A1: 2008 and therefore complies with the following essential requirements of the Machinery Safety Directive EHSR1.1, EHSR 1.2, EHSR1.3, EHSR 1.4, EHSR 1.5, EHSR 1.6, EHSR 1.7.

We the undersigned, undertake to transmit, in response to a reasoned request by national authorities, relevant information on the machinery by the following method of transmission: Parcel

Name and position of person binding the manufacturer or authorised representative:

Signature:_______________________________

Name: Seamus Mc Grath

Function: Company Director / Quality Controller

Location: Same address as above

Date of issue: ____________________________

SAFETY ANDOPERATING

YOURTR6540 & TR8042

CONVEYORS

WORKING WITh ElECTRICSIt is recommended that any persons working with the electrical operations on the conveyor must work to the standards of European Standard EN 50110 or similar.Before starting the machine always check that all electrical cables and connector’s are in proper working order. Also de-energised parts are checked for presence of power and ground or short circuit them in addition to insulating elements and adjacent live parts.

Use recommended current rating original fuses. If the operator suspects that there is a problem, switch off the machine immediately.Before starting the isolator switch machines with high voltage electrics must be earthed bonded by a qualified electrician.Always risk assess the area where the machine will be working for over head electric cables and other dangerous obstacles. If contact is made with a live wire de-energise and alert all persons about approaching and touching the machine immediately.When cleaning the conveyor DO NOT hose down any electrical enclosures or the electrical motor.

ON SITE ENvIRONMENTRisk assessment should be carried out before, during and after operation of the machine. Ensure appropriate measures are taken for site personnel training in Health & Safety awareness.All hazardous materials must be handled in accordance with the manual instructions.

APPROPRIATE ClOThINGAll persons operating the machine should wear appropriate clothing e.g. hard hat, ear protection andprotective foot wear.

DECAlS FOR SAFETY ON MAChINE

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Safety RecommendationsThe Ezystak Conveyor is designed with safety in mind. All moving parts are covered by guards and shields to prevent accident or injury. If in the event of repair work or servicing to be carried out, these covers will be removed. The guards and shields should be replaced immediately after the work is finished. Any persons working with the machine should be made aware of this.Before servicing or maintenance can be carried out, always isolate energy sources.Ensure the machine can not be started while others carry out work on the machine.Ensure all operators are familiar with the machine, it’s functions and capabilities.Ensure machine is operated and driven on level and stable surfaces.Know the locations and know how to use the emergency stops.

OPERATING CONvEYOR SAFElYRead the operator’s manual carefully taking note of all safety information.DO NOT attempt to adjust the conveyor while it is running, unless it is recommended by trained personnel.Always shut off engine when leaving machine unattended.If the machine vibrates, stop the engine and check immediately for the problem.

ChEMICAl SAFETY Always follow instructions on chemical container.Protective clothing should be worn when using chemical’s (gloves and goggles).Use the appropriate tools when opening a chemical container.Always use a well ventilated area.DO NOT smoke, eat or drink while handling chemicals.Dispose of all waste in line with local and national regulations.

hIGh PRESSURE FlUIDS Check all hoses and lines regularly. Replace when needed. Check all connections and tighten when needed.Always relieve pressure if fluid escapes before disconnecting hydraulic hose or lines.DO NOT use your hands or parts of the body to check for leaks.Always seek medical help if an accident occurs.

OPERATING PERSONNElOnly authorized or trained personnel should carry out any work on the Ezystak conveyor. All instruction should be followed. Ezystak reserve the right not to take responsibility for any injury or damage if the manual is not read and followed.

Plant Management are responsible for:The working area around the machine and the machine itselfAny persons in the area of the equipmentTo assess risk and follow all Heath & Safety Regulations ( local and national)To check that all safety devices are in proper working order

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Know your machine

Please take note of all the different components of the machine

A. hydraulic Folding head Section – This allows the machine to be easily folded for transport

B. hydraulic Folding Tail Section and Feed Boot – The feed boot is where the raw material is fed in to the machine and also allows the machine to be folded for transport

C. Main Conveyor – This main unit carries the raw material from the feedboot to create a stockpile

D. Power Unit – The power unit is the main source of electric and hydraulic power. The unit is detachable and lockable

E. Telescopic Supports head Section – The height can be easily adjusted in order to achieve maximum stockpile heights

F. Telescopic Supports Tail Section – Stability while working and easy to adjust stockpile height

G. Ballast Weight – Allows conveyor to be repositioned while fully elevated

Power UnitThe power unit is attached at the chassis and provides the power output. This contains the control panel, engine throttle, engine, radio remote control, manual tracking doglead, drive control valve bank and also the auxiliary control valve bank. The hydraulic and diesel tanks are placed at either side of the power unit.

ENGINE CONTROl PANElThe control panel is contained in the power unit and starts up the engine

A. Hydraulic Folding Head Section

B. Hydraulic Folding Tail Section and Feed Boot

D. Power Unit

E. Telescopic Supports Head Section

C. Main Conveyor

F. Telescopic Supports Tail Section

G. Ballast Weight

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Control Panel Description

Battery Charging Warning light – This light goes on when the key is turned to the on position. It should go out when the engine starts. If it does not light up when the key is turned to on or when the engine is running there could be a fault in the charging circuit. Stop the machine immediately and check out the circuit

Oil Pressure Warning light – This light should go on when the key is to the on position. When the engine starts it should go out. If there is a problem with the oil pressure the light will go on and the machine will shut down after a few seconds

Engine Temperature Warning – If the coolant system over heats this light will come on. The engine will shut down after a few seconds once this has been detected

Air Intake Pressure Warning – This light will come on if there is a problem with the air breather system. This light will not go out until this has been repaired.

Machine Stop Activated – This lights up when the manual handset stop has been pressed, this shuts down the machine. The light will remain flashing to indicate that the stop has been pressed.

Fuel light – This comes on when the key is in the on position. This indicates that the fuel solenoid circuit has been energized. This light will remain on while the engine is running. The engine will not start if this light is not on.

Engine Pre-heat Indicator light – This lights up when the pre-heat system is in operation during start up.

hour Clock – When the key is to the on position, the engine records the working hours of the machine.

Pre-heat Button – When the pre-heat button is pressed the pre-heat light will come on and the heater circuit is energized. Refer to the engine manual on instruction on pressing the pre-heat button

Ignition Switch – This is used to start and stop the engine.

CONTROl vAlvE BANK AND ENGINE hAND ThROTTlEThe control valves are contained in the power unit. The levers of the drive control unit are for driving the machine. The levers of the auxiliary control unit are for folding / unfolding and lowering / raising the conveyor. The hand throttle has 2 functions, to increase and decrease engine speed. To increase power, pull the lever towards the operator. To decrease push the lever away from the operator.

hYDRAUlIC TANK INDICATOR AND RETURN lINE FIlTERThe indicator is located at the side of the hydraulic tank, the return line filter is located on the top of the hydraulic tank.

ShUT DOWN OF DIESEl / ElECTRIC POWERED CONvEYORObserve all safety warnings. Make sure the conveyor is empty and clear of all materials.Empty the conveyorLower the engine revs by lowering lever / hand throttleStop the main conveyor unit. Stop the engine.

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CONvEYOR IN TRANSIT POSITION1. Observe all safety warnings. Make sure the conveyor is empty and clear of all materials.2. Reduce the engine revs using the hand throttle

3. Turn all control valves to neutral position

4. Remove locking pins from conveyor support legs located at the head and tail sections

FOlDING1. Observe all safety warnings. Make sure the conveyor is empty and clear of all materials2. Reduce the engine revs using the hand throttle3. Remove pins at the tail section. Then lower tail end of conveyor, push 4th lever to the right away from you ( see decal)4. Lower head section by pushing the 1st lever on the left away from you ( see decals)5. When machine is in horizontal position insert pins back in the tail stanchion legs making sure they go all the way through the legs and are properly in place.6. Then fold head section by pulling the 2nd lever towards you (see decal). Always take caution when head section is in vertical balance point when folding and unfolding. Gently ease past balance point then continue to fold head into complete folded position.7. Then fold feedboot section by pulling the 3rd to right lever towards you (see decal), until feedboot is fully folded.8. The conveyor is now in transport position.

OPERATING ThE CONvEYOR

While the conveyor is in operation it is very important to assess risk of the machine, operating personnel and surrounding working area.

Before starting the machine, make sure there is no one in or around it.

Check that all control levers are in neutral position

Before moving check that there is no one in or around the machine

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STARTING ThE MAChINE

Start the engine by turning the key to on position.At this point the control panel lights will start. If any of the lamps, other than the pre-heat lamp, does not light up this indicates that a problem exists. The operator should be aware of the fuel solenoid energizing.

The only lights that will remain on are the battery and oil indicators.If an automatic pre-heat system has been installed the pre-heat light will also light up at this stageDo Not attempt to start engine unless the following warning lamps are illuminated at this pointTurn the key to the start position as seen in diagram C. At this point the fuel on light will come on. The fuel solenoid will energize and the engine will crank.Return the key to the on position immediately after the engine starts. The fuel light will be the only light on while the engine is running. If any other lights come on this indicates a faultTo stop the engine, return the key to the neutral position as seen in diagram A

PREPARING EZYSTAK CONvEYOR FOR OPERATION1. Your Ezystak Conveyor will arrive folded. Before starting the machine or tracking, follow the steps2. Ensure machine is on level ground and is stable enough to support the weight of the machine3. Ensure all guards and shields are in correct position4. Ensure suitable clothing and safety gear is worn5. Check fuel tank for level of fuel6. Check hydraulic oil level7. Put control valve levers into neutral position8. Start the machine (refer to previous section on this, let machine warm up for 10 mins)9. Unfold feedboot by pushing 3rd lever to the right forward (away from you) Ref. Decal10. Unfold conveyor head section by pushing 2nd lever from left forward (see decal). Always take caution at vertical balance point by gently easing the head section downwards to full horizontal position.

11. Start by raising the front of the conveyor main stanchions by pulling 1st lever on left towards yourself (see decal)12. To achieve desired height remove pins from back stanchion legs, then pull down the last lever to the right (see decal). When desired height has been achieved, line up the pin holes and insert the pins back into position. Ensuring to go all the way through the stanchion arms. Ensure lynch pins are in place.13. Now the conveyor is at desired stockpile. Before operating conveyor belt it is recommended to assess risk of any persons or obstruction near the belt or at front of machine where stockpile will begin.14. Now go to the other side of the power unit where the single lever drive bank is located. Raise the single lever to drive the conveyor belt. 15. Check that the conveyor belt is aligned and is running smoothly.16. On first use. Let the conveyor run for 10 minutes before loading the feedboot.17. Adjust engine revs with the hand throttle.

SWITChING OFF ENGINE1. Check that all levers are in neutral position2. Reduce engine revs with hand throttle3. Let the conveyor belt run a few minutes to ensure there is no material left on the belt4. Turn the ignition key to off position to stop the engine. Always remove the key from the machine when it is not is use5. If fitted with radio remote control switch off by using the engine kill switch on the transmitter6. Check that the engine and control panel doors are closed securely. And the machine overall is secure.

EMERGENCY STOPPINGOnly use the emergency stop button for emergencies. The stop button on the radio remote control is not an emergency stop button. When an emergency stop button has been pressed, do not restart the engine until it is safe to do so.Pressing any emergency stop button will stop the engine and machine. Be familiar where all of the stop buttons are located.When an emergency stop button is used the ignition switch key stays onTurn the ignition key to the off position and remove the keyThe emergency stop button will remain on until it is physically disengaged by pulling or twisting (switches vary)Only when the machine is fully switched off and safe should you try to get to the root of the problem

MAChINE ShUTDOWN PROCEDUREThe control panel comes complete with 2 remote machine stops and 1 key switch for normal starting and stopping of the machine. The remote machine stops are located at opposite sides of the power unit.

E-mail: [email protected]: www.edgeinnovate.com

Tel: 028 8774 0525Fax: 028 8774 7244

6.2 Engine Start Up Procedure

STEP 1. To start the Engine turn the ignition key to the “On” position, as shown at (B).

Note: At this point a Test sequence will commence where all the lamps, as shown at (D),will illuminate for 1 - 2 seconds and the Fuel Solenoid will energize. If any of the lamps,other than the Pre-Heat lamp, does not illuminate this indicates that a problem exists.Also the operator should listen for the clicking sound of the Fuel Solenoid as it energizes.

STEP 2. After the test sequence has finished all the lamps, apart from those shown at (E),will go out.

Note: If an Automatic Pre-Heat system has been installed the Pre-Heat light willalso illuminate during the test sequence.

Warning: Do not attempt to start the Engine unless the following warning lamps areilluminated at this stage.

6. PRODUCT OPERATION ISSUE ENG 1 - PAGE 4

(A)Key Switch inThe “Neutral”

Position

(B)Key Switch in

The “On”Position

(C)Key Switch in

The “Start”Position

3. Turn the ignition key to the “Start” position, as shown at (C). At this point the “Fuel On”light will illuminate, as shown at (F), the fuel solenoid will energize and the engine will crank.

4. Return the ignition key to the “On” position immediately after the Engine starts.

Note: As soon as the Engine has started the “Oil” light and “Battery” light will goout. Only the “Fuel On” will be illuminated when the Engine is running, as shownat (G). If any other lights illuminate when the Engine is running this indicates afault.

5. To stop the Engine, return the key to the neutral position, as shown at (A).

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RESTART AFTER EMERGENCY STOP1. Ensure the problem is solved before restarting machine.2. Check that the emergency button is released3. Restart machine in the normal way

MOvING1. Before moving the conveyor, ensure all material has run off the conveyor and the feedboot is empty.

2. Avoid moving the conveyor on unlevel ground. It may cause damage to the conveyor and engine.

3. In cold conditions start up the machine for approximately 10 minutes before moving. When hydraulic oil is cold the machine would tend to steer to the right and track fast forward.

4. Never stand on the conveyor while it is being moved.

SAFE TRACKINGWhen travelling down a gradient, tracks should be driven sprocket first.Going up a gradient, the tracks should driven forward.

Machine should be parked on level ground that is suitable to support the weight of the machine.

Track the machine every day for a short distance. This will reduce the risk of track seizure.

Never track the machine if they are frozen to the ground or attempt to move the machine in any other way.

Always clear the tracks of any surrounding debris. Do not track the machine with out clearing the area.

Do not attempt to move the machine if it is not possible to track it.

TRACKING WITh A DOG lEAD REMOTE CONTROl

Ensure the machine is clear of any obstacles before tracking

• Check that the dog lead is connected to the machine and the machine stop is not pressed• Start the engine• Push the two levers of the drive control up fully• Switch the tracking switch (aux / track) on the handset to the track position. At this point the safety siren will sound. There will be a short delay before the tracks will operate.• You can now use the handset to track the conveyor

Please note that when the remote is not in use, the function controls should be left in neutral position.

Tracking with Radio Remote (Optional Extra)

The radio remote is an independent control unit for the tracks only

• First plug in the Receiver Box connection. The machine will not track if the receiver box is not plugged in. Always unplug the dog lead remote control.• Start the engine / machine• Push the two levers of the drive control up fully• After the remote tracking manual handset has been disconnected from the machine press any button on the transmitter• There will be a short delay and then the transmitter becomes active.

TRANSPORTING1. Before transporting always check that the machine is secure and there are no loose objects or material.2. Always use the appropriate vehicle for hauling the conveyor. Take into consideration the weight and size of the machine and the route when transporting.3. Check local regulations of transporting large machinery i.e. certification.


Tel: 028 8774 0525Fax: 028 8774 7244

5. TRANSIT / SITE MOVEMENT ISSUE ENG 1 - PAGE 13

5.4 Tracking Procedure5.4.2 Via Radio Remote

The remote control is only used to operate the tracks. It performs no otheroperation. The radio remote is an independant control unit which controls themovement of the tracks.

To Track the Machine using the Radio Remote Control the doglead must be first pluggedout and the Receiver Box connection plug plugged in. Once the receiver is plugged in themachine can then be tracked using the transmitter controls.

Start the Engine / Machine.

On the TS65 MODEL :Push the two levers of the drive control up fully.

After the remote tracking manual handset has been disconnected from the machine,press any button on the transmitter.

After the 7 second delay has elapsed the track directional switches become active.

FIGURE 5.4: Radio Remote

Transmitter

Track on / off switch

Right Track Forward

Right Track Reverse

Left & Right Track Reverse

Engine Kill

Left Track Forward

Left Track Reverse

Left & Right Track Forward

Reciever Box

ConnectionPlug

Drive bank levers



Tel: 028 8774 0525Fax: 028 8774 7244

4. PRODUCT FAMILIARISATION ISSUE ENG 1 - PAGE 12

4.3 Construction Units4.3.8 Radio Remote

Radio Remote Control (Optional): This is used to manoeuvre the machine on its tracks.To Track the Machine using the Radio Remote Control the doglead must be first pluggedout and the Receiver Box connection plug plugged in. Once the receiver is plugged in themachine can then be tracked using the transmitter controls.

FIGURE 4.3.8 - Radio Remote

4.3 Construction Units4.3.9 Hydraulic system - Hydraulic Tank Indicator and Return Line Filter:

Hydraulic Tank Indicator and Return Line Filter: The indicator is located at the side of thehydraulic tank, the return line filter is located on the top of hydraulic tank.

A: Hydraulic Oil Level Indicator

B: Filler Cap

C: Return Line Filter

A

BC

FIGURE 4.3.9 - Hydraulic system


Receiver for connecting cable for doglead control

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MAINTENANCE

General maintenance of your conveyor is vital, the conveyor will perform at it’s best when looked after.When working with the conveyor in extreme weather conditions it is important to adapt the maintenance schedule to suit. Only personnel with proper qualifications for servicing and maintenance can perform these tasks. All safety regulations and risk assessment should be followed before these are carried out.Never work under unsupported equipment. It is important to remember that during maintenance a raised part of the machine can fall causing serious injuries or death.When any maintenance is carried ensure all safety aspects are in good working order before returning to work with the machine.

Any hydraulic maintenance should only be carried out by qualified personnel. Always bleed and de-pressurize the machine hydraulic lines before attempting maintenance or repairs. Replace any broken or worn parts.

WeldingOnly welders qualified according to European Standards or similar are permitted to perform welding operations on the machine. Before working on the plant, switch off and isolate battery power.Again assess risk before working on the conveyor.

hydraulicsOnly certified personnel should carry out any maintenance or servicing to the hydraulic system.Always relieve pressure from the hydraulic system before carrying out any kind of maintenance or servicing. NEVER attempt to adjust any hydraulic when the machine is in operation.

Regular Maintenance

The following is a guide line:

Daily• Check engine oil• Check hydraulic oil level• Check belt scrapers and replace if necessary• Check belt alignment• Check all safety guards are in position and secure• Check all safety beacons and sirens are operational

Monthly• Grease all bearings• Check batteries in remote control handset

Quarterly• Check all hydraulic seals and replace as necessary

Annually• Change engine filters• Change in line filters

Never power wash the control panel or emergency stops. Always abide by the Safety Standards (local and national) when carrying out maintenance.

Electric MaintenanceDisconnect battery ground cable before carrying out maintenance on electrics.

Read the following and take noteIt is important to take measures to ensure that the control panels are not exposed to the elements of rain or water and dirt. The control panel lid should be closed at all timesA regular check of the control panel and all the connections is recommendedWhen maintenance or repairs are being carried out on the control panel, ensure it is covered to prevent any rain, water or dirt getting in. Check daily for any damages or worn out parts or switches etc;Always replace any parts with compatible components

BeltsBelts and drum lagging are consumable items and will need to be replaced through general wear and tear.

The belt must be checked regularly for rips, cuts and any damageAlways keep the belt at the proper tensionBelts need to alignedNever overload the beltIf the above is not followed belt slippage could happenConveyor belt should be cleaned from ground height by rotating the belt slightly each time.

Belt AlignmentIt is important that the conveyors belt is in alignment. The belts are aligned by adjusting the drum adjusters.If the belt is not in alignment, the machine may not be level, the belt tension is faulty or the position of the drum is faulty

Belt TensionNaturally the belt will stretch due to wear and tear, so you will have to adjust it a few times. The belt should be tensioned not too tight or not too loose. Loose belts can cause slippage and too tight will cause damage to the drum bearings.

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Tensioning the BeltDo Not attempt to adjust the belt tension without first proper instruction or obtaining adequate supervisionFollow all safety warningsStart the conveyor/ beltTighten the belt by adjusting both belt adjusters evenly. Turn 2 times until slippage stops

Conveyor AlignmentIf a belt is not aligned it will affect the belt working capacity and it’s life spanFollow all safety proceduresStar the conveyorObserve the conveyor through the viewing apertures and determine to which side the conveyor is tracking offDepending on what side is not aligned, adjust with one turn at a time until the belt tracks properly

Power Unit MaintenanceThe engine in your Ezystak Conveyor comes with its own manual. If you have not received this please contact Ezystak.All safety and maintenance information should be read and understood before carrying out maintenance on the powerunit.

Fuel Diesel is a highly flammable fuel. Do not fill the diesel tank to capacity. The fuel level of the machine can be checked by viewing the indicator. We recommend you fill the fuel tank at the end of the day.Check the level indicatorClean around the capRemove the cap and funnel in the fuel until the indicator is at it’s highest level Then replace the capAlways clean any spillage of fuel

hydraulic SystemIt is essential that the hydraulics are regularly serviced. Keep air vents in the cap open to allow the hydraulic system to breathe.

Checking hydraulic Oil levelIt is important that the correct grade of oil is used. If you find that you are filling the hydraulic oil more than usual check all hydraulic parts and pipes for leaks.Before checking the hydraulic oil, ensure it is at normal temperatureWhere possible, have all the cylinders retractedCheck the oil indictor. The oil level must be in the middle of the maximum and minimum marks on the indicator

Filling the hydraulic Oil When filling the hydraulic oil tank always make sure the engine is switched off and fill between the maximum and minimum indicator.. Always follow the safety regulationsNever overfill the hydraulic tank as this will cause leakage from the filler cap and system overheating

Changing hydraulic Oil1. Always assess risk before carrying out work on the Hydraulic oil system2. Ensure oil is at normal operating temperature and cylinders are retracted where possible3. Before removing the drain plug, slowly unscrew the filler cap to release any pressure in the hydraulic tank.4. Ensure you have a suitable container to catch all of the oil. Ensure to clean any spillage.5. Remove the drain plug 6. Remove the cover plate which is under the filler cap. Dispense the gasket7. Remove the suction filters by unscrewing them from the suction pipes8. Using clean oil, flush out the tank removing any dirt. Clean and reuse the suction filters and replace on the suction pipes9. Replace cover plate using a new gasket. Then replace drain plug10. Change the return line filter11. Refill the tank with clean hydraulic oil at the level marked on the indicator12. Run the engine, operate the hydraulic controls which will take any air from the system 13. Stop the engine and check level of oil at the indicator and top up if required

Battery CheckAlways abide by safety regulations when dealing with batteriesAlways wash hands after handling a batteryEnsure to maintain battery level. In cold weather distilled water should only be added immediately before starting the engine, to prevent it freezingAlways keep the terminals and case clean

Removal of BatteryAlways follow safety regulationsEnsure all electrical circuits are switched offDisconnect the earth lead from the batteryDisconnect the positive lead from the batteryRemove the battery from the machine

Installing BatteryAlways follow safety regulationsEnsure all electrical circuits are switched offPut battery into the machineAlways connect the positive lead firstConnect the earth lead

TR6540/8042 2424 25

Track MaintenanceRefer to Tracks Operation Manual for advice and informationIt is important to maintain your tracks on a regular basis.

Always remove any debris and built up oil and greaseReplace any damaged and broken parts

Track TensionWhen checking the tension on the tracks, drive your machine about 2 – 3 metres forward. Measure the sag on the top part of the track on the longest section of unsupported track as shown below

The sag of the track must be between 5mm and 15mm. You must check the track tension on a new machine. DO NOT set track tension too tight.

Adjusting Track TensionCrawler track systems use a grease cylinder to keep each track chain in tension. Screwed into the end of the grease cylinder is grease fitting enabling grease to be pumped into the grease chamber and released from it, tightening and slackening the track1. Take care when loosening the grease fitting as it is pressurised. 2. If the tracks keep becoming slack, check for any leakage on the outer face of grease fitting.3. Check if there is any grease leakage at contact surface between the grease tension and grease fitting. Ensure the tension seal are not damaged.4. Before replacing seals, place a straight edge along the cylinder barrel as shown above to ensure outer sleeve has not swollen from being overlooked.5. To replace seals, simply unscrew grease fitting push or pull out inner cylinder to expose lip seal and inner seal.

Tightening the TracksAt the side of the track frame there is an access cover, unscrew this to gain entryCheck that the grease fitting and grease gun adaptor is clean. Connect a grease gun to the grease fitting and add grease until the track tension is normalDrive the conveyor forward and backward to check if the track is tightened

Slackening the TrackAt the side of the track frame there is an access cover, unscrew this to gain entryLoosen the track fitting, by turning it in a anti-clockwise direction, using small movements until the grease released.Once you have achieved the correct tension, tighten the grease fitting by turning in a clockwise direction. Clean all excess grease.Remember to track the machine for a while forward and backward in order to assess if the tracks are at the right tension. This movement will help the grease work through the tracks.

Track ChainsIt is important to be aware of the conditions that the conveyor tracks are working in. Certain surfaces and environmental surroundings could cause corrosion. Tracks can also seize if they are not moved on a daily basis. To prevent this, track the machine a few meters in both directions.

Oil FillingTo fill the oil, track the machine until the gearbox casing is level with a plug positioned at 12 o’clock (see diagram). Unscrew the two plugs and fill from the upper hole until oil reaches the level of the lower hole

Oil DrainingTo drain the oil, track the machine until the plug is at 6 o’clock position (see diagram). Unscrew both plugs and allow all oil to empty into a container.

Do not fill oil in the track drive without checking oil level inside it. Track systems are supplied with a quantity of oil in track drive. The gearbox life will shorten if oil becomes dirty. Only use new clean oil in clean containers.


Tel: 028 8774 0525Fax: 028 8774 7244

7. MAINTENANCE ISSUE ENG 1 - PAGE 24

7.8 Track Maintenance

7.8.3 Checking the Track Tension

Stop your machine on solid and level ground and drive 2 metres (minimum) in a forwarddirection. Measure the sag on the top part of the track on the longest section ofunsupported track as shown below.

FIGURE 7.8.3: Track Tension

The sag of the track must be between 5mm and 15mm.

The above conditions must be fulfilled on a new machine. This must also be periodicallychecked and corrected if necessary by adding grease to the grease tensioner.

It is important that the track is not tensioned too tightly as this places excessive loadson the gearbox grease cylinder and idler bearings. It will also lead to accelerated wearand premature failure.

DO NOT SET TRACK TENSION TOO TIGHT.

Sag of the trackCarrier roller or skid plate(Whichever is fitted)



Tel: 028 8774 0525Fax: 028 8774 7244



7.8.7 Oil Filling

To fill, track the machine until the gearbox casing is level with a plug positioned at 12o’clock as shown below. Unscrew the two plugs and fill from the upper hole until oil reachesthe level of the lower hole.

7.8.8 Oil Draining

To drain, track the machine until a plug is at 6 o’clock position as shown below. Unscrewboth plugs and allow all oil to discharge into a suitable container. Dispose of waste oil in asafe and approved way.

Grease escaping under high pressure. Grease can penetrate the skin. Ensurecorrect personal protective equipment is worn.

Do not fill oil in the track drive without checking oil level inside it. All track systemsare supplied with a measured quantity of oil in track drive.

Cleanliness is essential when checking, filling or replacing oil inthe gearbox. Gearbox operating life will be dramatically shortened if theoil becomes contaminated. Only use new clean oil in clean containers and fillers.

Dispose of oil safely and in a environmentally friendly manner

Venting

Drain Port

Oil Fill

MaximumLevel



Tel: 028 8774 0525Fax: 028 8774 7244



7.8.7 Oil Filling

To fill, track the machine until the gearbox casing is level with a plug positioned at 12o’clock as shown below. Unscrew the two plugs and fill from the upper hole until oil reachesthe level of the lower hole.

7.8.8 Oil Draining

To drain, track the machine until a plug is at 6 o’clock position as shown below. Unscrewboth plugs and allow all oil to discharge into a suitable container. Dispose of waste oil in asafe and approved way.

Grease escaping under high pressure. Grease can penetrate the skin. Ensurecorrect personal protective equipment is worn.

Do not fill oil in the track drive without checking oil level inside it. All track systemsare supplied with a measured quantity of oil in track drive.

Cleanliness is essential when checking, filling or replacing oil inthe gearbox. Gearbox operating life will be dramatically shortened if theoil becomes contaminated. Only use new clean oil in clean containers and fillers.

Dispose of oil safely and in a environmentally friendly manner

Venting

Drain Port

Oil Fill

MaximumLevel


TR6540/8042 2626 27

hydraulic Circuit Details TEChNICAl

SPECIFICATION• Discharge Height 10.791m / 35.4 Ft• Belt Width 1000mm / 3.3 Ft• Belt Length 19.878mm / 65.2 Ft• Belt Type EP 500 3Ply / Optional• Power Unit Diesel Hydraulic with Cat 2.2c engine• Developing 38kw / 50bhp @ 2200 rpm• Fuel Consumption 5.2 – 6.2 ltr / hr

ADvANTAGES• Minimises transport costs with easy tracking in and out of 40ft container• Can be used for various applications: Top Soil, Sand, Coal, Bark and Crushed Aggregate.• A wide range of heights for output and input and can be used with other crusher and screeners.• Height on front stanchions can be set with out using manual pins by special load holding cylinders• Easy mobility on site• Increased efficiency while operating. And increased stockpile capacity• Reduced fuel costs ie: no need for shovel operator to move materials from under conveyor

OvERAll DIMENSIONS* Machine Width 2260mm / 7.5 Ft* Transport Length 12515mm / 41 Ft* Transport Height 2.580 m / 8.5 Ft

hYDRAUlICS• Hydraulic Motor……………………………….Kasqppa OMV 630

TRACK DATA• Tractive Effort………………………………….14300 daN• Gearbox Ratio…………………………………..134:1• Hydraulic Motor………………………………..Caproni 33cc/ Rev• Approx Speed…………………………………..1.6km / hr (0.95mph)

ENGINE SPECIFICATIONS

Refer to engine manual for these.

TR6540/8042 2828 29

M

TR6540/8042 3030 31

TR6540/8042 3232 33

RL3

RL4

PA

NE

LB

AS

ELA

YO

UT

SD3

Oil

Cooler

Relay

Heater

Relay

X2

F1F2

F3F4

RL1

RL2

F1SW

IGN

ST

FUELS

TOP

F417

3015

50a

19

X3

12345

6789101112

PA

NE

LLID

LAY

OU

T

NEG

NLT

TR6540/8042 3434 35

3M hEAvY DUTY CRAWlER TRACK DATA

• Tracvtive effort - 14300daN• Gearbox ratio - 134:1Hydraulic Motor - Rexroth 32cc / RevApprox. Speed - 1.6 km p/hr (0.9mph)

BatteryType - 12v negative earth

Electric Information3 Phase 380 – 415 Volts (depending on normal national voltage)

Optional Extras• Higher HP Engine• Dual Power (Diesel / Electric Hydraulic)• Full Side skirting or Half side skirting• Hardox hopper liner plates• Rubber hopper liners• Feedboot extension• Dust Covers ( Canvas or Steel)• Spray bar (reduce dust)• Radio remote controlled tracks• Belt scraper upgrade• Chevron belt• 3000mm / 3M heavy duty crawler track • Hydraulic folding head

Standard Features• Full dog lead remote control• Heavy duty head and tail drums• Heavy duty rollers• Cat engine• Impact bars on tail section• Galvanised telescopic legs• Hydraulic folding head section (TR 6036, TR 6542, TR 8042)• 3M Heavy duty crawler track (TR 6036, TR 6542, TR 8042)• Cat 37kw engine ( TR 6036, TR 6542, TR 8042)• Painted with 2 pack epoxy primer and 2 pack high level gloss CE approved

TR8042 Model

3636 37

CONTACT USEZYSTAK CONVEYORS

200 Annagher RoadCoalisland, DungannonCo. Tyrone, N. IrelandBT71 5DA

T: + 44 (0) 28 8774 8090F: + 44 (0) 28 8774 6585E: [email protected]

www.ezystak.com

TR6540 Model

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