McCloskey J45 J45R Mobile Crushing Machine Operations Manual Rev 6.0 2022

Description

McCloskey J45 J45R Mobile Crushing Machine Operations Manual

This is the full operations manual for the McCloskey J45 and J45R mobile crushing machines, issued at Revision 6.0 with an issue date of 01/07/2022. At 366 pages it is the complete factory document set for running, setting up, tracking, folding and servicing these tracked jaw crushers, and it is supplied here as an instant-download PDF. Whether you are commissioning a new machine, training an operator, adjusting the closed side setting, chasing a fault code or planning a 500-hour service, this manual is the reference you keep beside the control panel.

File Details

• Manual type: Operations Manual (Original Instructions)
• Brand: McCloskey International Ltd
• Models covered: J45 and J45R mobile crushing machines
• Language: English (en)
• Page count: 366 pages
• File format: PDF
• Revision: 6.0
• Issue date: 01/07/2022
• Copyright: McCloskey International Ltd 2022

Chapters Covered

• 1. Introduction — Operations Manual Guide, Optional Equipment, Safety Information, ANSI Hazard Classification System, California Proposition 65 Warnings, Machine Designated Use, Machine Storage, Declaration of Conformity, Warranty, Copyright
• 2. Safety — Safety Symbol Classification, Safety Signs on the Machine, Health and Safety Decal Location, Personal Safety and PPE, Work Area Safety, Transportation Safety, Operation Safety, Hydraulic and Pneumatic Safety, Electrical Safety, Maintenance Safety, Gas, Dust, Steam and Smoke, Hazardous Substances, Noise Levels, Restricted Area During Operation, Emergency Stop Locations
• 3. Technical Data — J45 General Information, J45R General Information, Tank Capacities, Main Conveyor, Side Conveyor, Fines Conveyor, Transfer Conveyor, Return Conveyor, Transport Dimensions, Working Dimensions, Crusher Info, General Machine Layout, Machine Measurements, Noise Levels
• 4. Operational Procedures — Prior to Use, Prestart Inspection, Machine Location, Control Panel Overview, Screens Overview, Screen Elements and Layout, Screen Navigation, Main Screen, Engine Screen, Crusher Screen, Feeder Screen, Menus, Control Menus, Settings Menus, Diagnostics Menu, Screen Overlays, Tracking/Radio Overlay, Sensor Settings, Crusher Settings, Feeder Settings, Track Settings, Clock Settings, Display Options, Fitted Options, Software Update, Error Log, CAN Map, Sensor Diagnostics, Cameras Overlay, Error Overlay, Settings Procedures, Unlocking Parameters, Status and Warning Indicators, Machine Status Box, Starting and Stopping the Engine, Changing Engine Speed, Monitoring Engine and Fuel, Exhaust Aftertreatment, DPF Regenerations, DEF Level, Remote Handsets, Tracking Handset, Feeder Handset, Radio Pairing, Error Reporting, Error Codes, Hydraulic Control Levers, Pictorial Decals, Hydraulic Controls, Machine Set Up, Start-Up Procedure, Shut Down Procedure, Lockout and Tag Out, Emergency Stop Procedure
• 5. Transportation — Preparing Machine for Transport, Loading Machine to Transport Trailer
• 6. Maintenance — Regular Servicing, Machine Storage, Fuel System, Unscheduled Maintenance, Maintenance Schedules (Daily/8 Hour, Weekly/50 Hour, 100 Hour, 250 Hour, 500 Hour, 1000 Hour, 2500 Hour), Engine Maintenance Schedules (CAT and Volvo), Lubrication, Servicing Conveyors, Servicing the Tracks, Measuring and Adjusting Track Tension, Gearbox Oil Level, Servicing DEF Tank Filter, Servicing the Hydraulic System, Changing Air Filter Elements, Replacing Crusher Swing Jaw Die, Replacing Crusher Fixed Jaw Die, Replacing Crusher Cheek Plates, Replacing Pitman Wear Plate, Replacing Screen Meshes, Checking if Screen Box is in Tune, Disengage the Recirculation Section
• Glossary — Full A–Z of machine and crushing terminology
• Appendix A — Warranty Registration
• Appendix B — Volvo Engine Fault Codes, Cat Engine Fault Codes, Machine Fault Codes, Schematics

IMAGES PREVIEW

Taken as a whole, this document walks an operator or maintenance technician through the entire life of the machine — from the prestart inspection and correct start-up order through to folding for transport, and from the daily greasing routine through to jaw die replacement and hydraulic oil flushing. The three fault code appendices and the wiring schematic sheets make it a genuine troubleshooting document, not just a glossy start-up booklet.

Technical Data Highlights

The Technical Data chapter gives the working numbers you need before a machine goes on site. The J45 has an estimated operating weight of 43,900 kg (without magnet conveyor), a 636 L diesel tank and a 1,200 L hydraulic tank. Its main conveyor stockpiles at 3,880 mm with a 900 mm plain belt, the side conveyor at 2,500 mm with a 650 mm belt, and transport dimensions are 3,400 mm high, 2,500 mm wide and 14,600 mm long. The J45R is the heavier machine at 56,000 kg and adds fines, transfer and return conveyors on top of the main and side conveyors, with a longer transport length of 15,323 mm and a wider transport width of 3,100 mm. Both machines run the jaw crusher at a 300 RPM shaft speed.

Noise level data is presented as an isometric contour plot from the machine centre line, and the manual carries the warning that the machine exceeds 90 dB(A) at operator positions — hearing protection is mandatory.

Safety and Site Compliance

Section 2 is extensive. It defines the ANSI hazard classification system used throughout the manual (DANGER, WARNING, CAUTION, NOTICE), reproduces the full pictogram decal set with ISO and ANSI variants side by side, and shows the physical location of every safety decal on both the left-hand and right-hand side of the machine using annotated line drawings. Restricted area diagrams specify the exclusion zones around the hopper, the control panel, the magnet conveyor discharge and the belt conveyor discharge. Emergency stop button locations are shown for both sides of the machine. California Proposition 65 warnings for lead compounds and diesel exhaust are also reproduced.

Operation, Control Panel and Handsets

The operational procedures chapter is the biggest in the book. It explains the control panel layout, the key switch positions, the panel lock, and the back-up button inside the cabinet that can start and stop the crusher if the display fails. It then walks through every screen on the display unit — Main, Engine, Crusher and Feeder — with annotated screenshots showing feeder speed, engine speed and load, pump pressure, pilot pressure, toggle pressure, hydraulic oil and coolant temperatures, fuel level and consumption, battery voltage, closed side setting and DEF information. Screen navigation using buttons L1–L8 and R1–R8 is described in detail.

The remote control section covers both the Tracking Handset and the Feeder Handset, including wired (dog lead) and wireless (radio) modes, handset charging, switching on and off, locking and unlocking, the radio pairing procedure with the 60-second countdown, and the FCC and Industry Canada radio compliance statements. The handset LED tables explain what every RF, battery and lock LED state means.

Maintenance and Service Procedures

The maintenance chapter is organised around a full schedule ladder: daily or 8-hour, weekly or 50-hour, every 100 hours, monthly or 250 hours, 500 hours, 1,000 hours and 2,500 hours. Separate CAT and Volvo engine maintenance schedules are provided with their own service intervals, from daily coolant and oil level checks up to 12,000-hour coolant changes. Greasing information lists the exact grease types and gun strokes — for example five strokes of Mobilith SHC 460 to the crusher bearings, two strokes daily to the layshaft bearings, and two strokes every 40 hours to the conveyor bearings. Cold weather lubricant recommendations are also included.

Step-by-step procedures are given for tensioning and aligning conveyor belts, measuring and adjusting track tension (sag tolerance 5–15 mm), checking and filling the track gearbox, changing hydraulic oil with a 5-micron flushing filter cycle, changing the return line filter and hydraulic tank breather filter, servicing the DEF fluid filter, DEF screen filter and DEF manifold filter, and changing air filter elements. The crusher rebuild procedures are covered in full — replacing the swing jaw die, the fixed jaw die, the cheek plates and the Pitman wear plate, with torque values, lifting weight figures and anti-seize requirements specified for each. Screen mesh replacement, screen box tuning checks and the recirculation section disengagement procedure are also detailed.

Fault Codes and Diagnostics

Appendix B is effectively a built-in diagnostic tool. It lists Volvo engine fault codes with SPN, FMI, J1939 fault description and error notes; Cat engine fault codes with failure mode index; and the machine’s own fault code table covering master and slave I/O module CAN faults, engine CAN faults, emergency stop activation, sensor bypasses, hydraulic oil temperature warning and error thresholds, crusher stall, low fuel warning, idle shutdown warnings and more. Each entry explains what the code means and what to check. The appendix closes with the electrical schematics — fuse and relay plate, panel internals, estops, engine loom, valve block, pumps, doglead extension, feeder loom and the fuse/relay cabinet — drawn as proper electrical diagrams with wire colours and connector pin numbering.

What This Manual Enables You to Do

With this McCloskey J45 J45R operations manual on hand you can commission the machine correctly from the prestart inspection onward, set up the hopper, walkways, side conveyor, landing legs and main conveyor in the right order, adjust the closed side setting using the dual wedge system, set the toggle pressure and chamber level, and operate the machine in manual or automatic feeder mode with confidence. You can track the machine safely, fold it into transport position, load it to a trailer and tie it down to the specified points. You can work through every scheduled service interval without guessing at grease types or oil grades, and you can chase an error code through the machine fault table and the engine fault code lists instead of calling out a technician for a simple diagnosis.

Correct procedures and correct specifications matter on a machine of this size. Setting the jaw closed side setting to the wrong value, running the tracks at the wrong tension or skipping the daily greasing on the crusher bearings all lead to premature failure and expensive downtime. This manual gives you the numbers the factory specifies, not a generic guideline.

Instant PDF Delivery

The manual is delivered as an instant-download PDF — there is no physical book to ship and no waiting. Download it after checkout, open it on a laptop, tablet or phone at the machine, and print the pages you need for the workshop. Keep it as a permanent part of your J45 or J45R documentation set.