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Astec Mobile Screens DIRECTFEED 2516T

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Contents
Introduction iv
Safety iv
TRAINING 8
Engine Control Panel 22
Linking the Remote 23
Leveling the Plant 25
Initiate Setup 25
Unfolding Fines Conveyor 25
Main Operating Control Panel 25
Unfolding the Intermediate Conveyor: 28
Unfolding the Intermediate Conveyor: Continued 29
Raising the Screen Box 30
Raise Screen Box to operating angle30
Unfolding the Walkways - Road Side 31
Unfolding the Walkways - Curb Side 34
Positioning the Feeder 37
Raising the Feeder Wings 38
REMOVE TRANSPORT PINS FROM SCREEN 39
Operation 41
Adjusting Conveyor Speeds 43
Screen 44
Moving plant with built in tracks. 45
Quick Facts and tips. 45
Screen Cloth Replacing 47
Preparing For Transport 48
Maintenance 51
Overall Inspection 52
Training the Belt 53
John Deere Break in Service 57
Scheduled Maintenance 58
Lubrication Schedule 60
Parts 63
Warranty 113
Warranty Claim Form 115
Warranty 117

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Astec Mobile Screens DIRECTFEED

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Foreword

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Foreword
Introduction
This manual contains safety, setup, operation, and maintenance sections. This manual should be stored in
the manual container located beneath the main control panel of the unit. Keep this manual with the unit at all
times. The manual should remain with the unit to assist in training, operation, setup and maintenance proce-
dures.
Please keep in mind that parts and procedures in this manual may differ from your exact model. The data
used to create this manual are based on the latest information at the time of publication. Due to Astec Mobile
Screens policy of continuous improvement, features and specifications are subject to change without no-
tice. All engineering drawings provided in this manual are model specific. Refer to engineering drawings as
needed, they are the best source of model specific information.
Safety
The safety section of this manual is filled with procedures that should be followed at all times. Take the time
to read the safety section of the manual and obey all safety information presented on the unit. Safety is impor-
tant!
Operation
Do not attempt to operate this machine without fully reading the manual first. The operation section of the
manual is arranged in a manner that must be followed sequentially. If the description does not match your
unit, or there is a discrepancy in the data, contact your local Astec Mobile Screens Dealer for assistance.
Maintenance
Due to the nature of equipment and environmental variables that may be present, it is imperative to do a daily
review of your equipment. Pay close attention to the daily checks outlined in the Maintenance section of this
manual. Read Appendix A and understand the lubrication and maintenance schedule. Failure to follow mainte-
nance guidelines could result in premature wear, or damage to your equipment.
Parts
The parts section contains drawings of all specific pieces of the plant. Each drawing contains lines with bal-
loons for each sub-part. When calling for replacement parts, please provide the service department with the
part number that the balloon refers to.
Appendix
For more detailed information regarding the on board John Deere Engine, Refer to Appendix B. Appendix B
contains the complete John Deere Engine Manual and should be used as a definitive guide to the safe and effi-
cient operation of your engine. Also included in Appendix B are the complete manuals for the belt cleaners,
attached vibrators, and speed reducers.
Contact Astec Mobile Screens

Phone (Toll Free)......(800) 545-2125
Fax ...........................(815) 626-6430
Email
[email protected]
[email protected]

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Transportation

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Astec Mobile Screens 10 DIRECTFEED

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Contact Information
Astec Mobile Screens

2407 W. LeFevre Avenue
Sterling, IL 61081
Phone: (800) 545-2125
Occupational Safety and Health Administration (OSHA)

200 Constitution Avenue, NW
Washington, DC 20210
Phone: (800) 321-6742
American National Standards Institute (ANSI)

1819 L Street, NW, 6th floor
Washington, DC 20036
Phone: (202) 293-8020
National Electrical Manufacturers Association (NEMA)

1300 North 17th Street
Suite 1752
Rosslyn, Virginia 22209
Phone: (703) 841-3200
Mine Safety and Health Administration (MSHA)

1100 Wilson Boulevard, 21st Floor
Arlington, VA 22209-3939
Phone: (202) 693-9400
John Deere
One John Deere Place
Moline, Illinois 61265
Phone: (309) 765-8000
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Safety

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TRAINING
Safety instructions are important! Read all attachment and power unit manuals; follow all
safety rules and safety decal information. Replacement manuals and safety decals are available
from your dealer. Failure to follow instructions or safety rules can result in serious injury or death. If
you do not understand any part of this manual and need assistance, see your dealer.
Know your controls and how to stop engine and attachment quickly in an emergency.
Operators must be instructed in and be capable of the safe operation of the equipment, its attach-
ments, and all controls.
Do not allow anyone to operate this equipment without proper instructions.
Keep hands and body away from pressurized lines. Use paper or cardboard, not hands or other
body parts to check for leaks. Wear safety goggles. Hydraulic fluid under pressure can easily pen-
etrate skin and will cause serious injury or death.
Make sure that all operating and service personnel know that if hydraulic fluid penetrates skin, it
must be surgically removed as soon as possible by a doctor familiar with this form of injury or gan-
grene, serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID EN-
TERS SKIN OR EYES. DO NOT DELAY.
UNDERSTAND SIGNAL WORDS

A signal word DANGER, WARNING OR CAUTION is used with the safety alert symbol. DANGER
identifies the most serious hazards.
DANGER or WARNING safety signs are located near specific hazards. General precautions are
listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
This is a safety alert symbol. When you see this symbol on your machine or in this
manual, be alert to the potential for personal injury. Follow recommended precautions
and safe operating practices.
Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. Caution
may also be used to alert against unsafe practices.
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Indicates an immediately hazardous situation which, if not

avoided, will result in death or serious injury. Danger is
limited to the most extreme situations.
IMPORTANT: Indicates that failure to observe can cause damage to equipment.
NOTE: Indicates helpful information.

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Lockout/Tagout
What is the OSHA standard for control of hazardous energy sources?
The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of
Federal Regulations (CFR) Part 1910.147, addresses the practices and procedures necessary
to disable machinery or equipment, thereby preventing the release of hazardous energy while
employees perform servicing and maintenance activities. The standard outlines measures for
controlling hazardous energies—electrical, mechanical, hydraulic, pneumatic, chemical, thermal,
and other energy sources.
In addition, 29 CFR 1910.333 sets forth requirements to protect employees working on electric
circuits and equipment. This section requires workers to use safe work practices, including lockout
and tagging procedures. These provisions apply when employees are exposed to electrical
hazards while working on, near, or with conductors or systems that use electric energy.
Why is controlling hazardous energy sources important?

Employees servicing or maintaining machines or equipment may be exposed to serious physical
harm or death if hazardous energy is not properly controlled. Craft workers, machine operators,
and laborers are among the 3 million workers who service equipment and face the greatest risk.
Compliance with the lockout/tagout standard prevents an estimated 120 fatalities and 50,000
injuries each year. Workers injured on the job from exposure to hazardous energy lose an average
of 24 workdays for recuperation.
How can you protect workers?

The lockout/tagout standard establishes the employer’s responsibility to protect employees from
hazardous energy sources on machines and equipment during service and maintenance. The
standard gives each employer the flexibility to develop an energy control program suited to the
needs of the particular workplace and the types of machines and equipment being maintained or
serviced. This is generally done by affixing the appropriate lockout or tagout devices to energy-
isolating devices and by de-energizing machines and equipment. The standard outlines the steps
required to do this.
What do employees need to know?

Employees need to be trained to ensure that they know, understand, and follow the applicable
provisions of the hazardous energy control procedures. The training must cover at least three
areas: aspects of the employer’s energy control program; elements of the energy control
procedure relevant to the employee’s duties or assignment; and the various requirements of the
OSHA standards related to lockout/tagout.
What must employers do to protect employees?

The standards establish requirements that employers must follow when employees are exposed
to hazardous energy while servicing and maintaining equipment and machinery. Some of the most
critical requirements from these standards are outlined below:
■ Develop, implement, and enforce an energy control program.
■ Use lockout devices for equipment that can be locked out. Tagout devices may be used in lieu
of lockout devices only if the tagout program provides employee protection equivalent to that
provided through a lockout program.
■ Ensure that new or overhauled equipment is capable of being locked out.

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■ Develop, implement, and enforce an effective tagout program if machines or equipment are not
capable of being locked out.
■ Develop, document, implement, and enforce energy control procedures. [See the note to 29
CFR 1910.147(c)(4)(i) for an exception to the documentation requirements.] Use only lockout/
tagout devices authorized for the particular equipment or machinery and ensure that they are
durable, standardized, and substantial.
■ Ensure that lockout/tagout devices identify the individual users.
■ Establish a policy that permits only the employee who applied a lockout/tagout device to remove
it. [See 29 CFR 1910.147(e)(3) for exception.]
■ Inspect energy control procedures at least annually.
■ Provide effective training as mandated for all employees covered by the standard.
■ Comply with the additional energy control provisions in OSHA standards when machines or
equipment must be tested or repositioned, when outside contractors work at the site, in group
lockout situations, and during shift or personnel changes.
How can you get more information?

OSHA has various publications, standards, technical assistance, and compliance tools to help you,
and offers extensive assistance through its many safety and health programs: workplace consulta-
tion, voluntary protection programs, grants, strategic partnerships, state plans, training, and educa-
tion. Guidance such as OSHA’s Safety and Health Management Program Guidelines identify ele-
ments that are critical to the development of a successful safety and health management system.
This and other information are available on OSHA’s website at www.osha.gov.
For a free copy of OSHA publications, send a self-addressed mailing label to this address:
OSHA Publications Office
P.O. Box 37535
Washington, DC 20013-7535
Or send a request to our fax at (202) 693-2498, or call us at (202) 693-1888. To file a complaint by
phone, report an emergency, or get OSHA advice, assistance, or products, contact your nearest
OSHA office under the “U.S. Department of Labor” listing in your phone book, or call us toll-free at
(800)-321-OSHA
(6742). The teletypewriter (TTY) number is (877) 889-5627
To file a complaint online or obtain more information on OSHA federal and state programs, visit
OSHA’s web site. www.osha.gov

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Read this manual before operating your equipment. The information presented will prepare
you to do a better and safer job. Keep this manual handy for ready reference. Require all
operators to read this manual carefully and become acquainted with all adjustment and
operating procedures before attempting to operate. Replacement manuals can be obtained
from your dealer.
FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and on your machine safety
signs. Keep safety signs in good condition. Replace missing or damaged safety
signs. Be sure new equipment components and repair parts include the current
safety signs. Replacement safety signs are available from your Astec Mobile
Screens Dealer.
Learn how to operate the machine and how to use controls properly. Do not let
anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to

the machine may impair the function and/or safety, affect machine life and/or void
the warranty.
If you do not understand any part of this manual and need assistance, contact
your Astec Mobile Screens Dealer.
REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See Appendix A for a detailed descrip-
tion of safety label placement. Contact your Astec Mobile Screens Dealer for
replacement safety decals.
PREVENT BYPASS STARTING

Avoid possible injury or death from engine run away. Do not start engine by
shorting across starter terminal. Start engine only from operator’s station.
HANDLE FUEL SAFELY – AVOID FIRES!

Handle fuel with care: it is highly flammable. Do not refuel the machine while
smoking or when near open flame or sparks.
Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent
fires by keeping machine clean of accumulated trash, grease, and debris. Always
clean up spilled fuel.

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PREPARE FOR EMERGENCIES
Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire depart-
ment near your telephone.
SERVICE ENGINES SAFELY

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or
necklace when you work near machine tools or moving parts. If these items were to
get caught, severe injury or death could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in
moving parts.
HANDLE STARTING FLUID SAFELY

Starting fluid is highly flammable. When handling starting fluid, keep all sparks and
flame away. Keep starting fluid away from batteries and cables. To prevent acci-
dental discharge when storing the pressurized can, keep the cap on the container,
and store in a cool, protected location. Do not incinerate or puncture a starting fluid
container.
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect

against objectionable or uncomfortable, loud noises.
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job. Operating
equipment safely requires the FULL ATTENTION of the operator. Do not wear radio
or music headphones while operating machine.
INSTALL FAN GUARDS

Rotating cooling system fans can cause serious injury.
Keep fan guards in place at all times during engine operation. Wear close fitting
clothes. Stop the engine and be sure fan is stopped before making adjustments or
connections, or cleaning near the front of the engine.

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HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause serious injury. Potentially
hazardous chemicals used with Astec Mobile Screens equipment include such
items as lubricants, coolants, paints, and adhesives. A Material Safety Data
Sheet (MSDS) provides specific details on chemical products: physical and
health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way
you will know exactly what the risks are and how to do the job safely. Then fol-
low procedures and recommended equipment. (See your Astec Mobile Screens
dealer for MSDS’s on chemical products used with Astec Mobile Screens equip-
ment)
PRACTICE SAFE MAINTENANCE.

Understand service procedure before doing work. Keep area clean and dry.
■ Never lubricate, service, or adjust machine while it is moving.

■ Keep hands, feet, and clothing from power-drive parts.
■ Disengage all power and operate controls to relieve pressure.
■ Lower equipment to the ground.
■ Stop the engine.
■ Remove the key, allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately.
Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making

adjustments on electrical systems or welding on machine. On towed implements,
disconnect wiring harnesses from tractor before servicing electrical system com-
ponents or welding on machine.
AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the skin causing serious injury or
death.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other

lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.
If an accident occurs, seek medical attention immediately. Any fluid injected in the
skin must be surgically removed within a few hours or gangrene may result. Doc-
tors unfamiliar with this type of injury should reference a knowledgeable medical
source.

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SERVICE COOLING SYSTEM SAFELY
Explosive release of fluids from pressurized cooling system can cause serious
burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare
hands. Slowly loosen cap to “first stop” position to relieve pressure before remov-
ing completely.
WORK IN VENTILATED AREA

Expel engine exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors to get outside air
into the area.
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Poten-
tially harmful wastes used with Astec Mobile Screen equipment include such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leak proof containers when draining fluids. Do not use food or beverage con-
tainers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmo-
sphere. Government regulations may require a certified air conditioning service
center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environ-
mental or recycling center, or from your Astec Mobile Screens Dealer.
AVOID HEATING NEAR PRESSURIZED FLUID LINES

Flammable spray can be generated by heating near pressurized fluid lines, result-
ing in severe burns to yourself or bystanders. Do not heat by welding soldering,
or using a torch near pressurized fluid lines or other flammable materials. Pres-
surized lines can be accidentally cut when heat goes beyond the immediate flame
area.
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM

High pressure fluid remaining in fuel lines can cause serious injury or death. Do
not disconnect or attempt repair of fuel lines, sensors, or any other components
between the high-pressure fuel pump and nozzles on engines with High Pressure
Common Rail (HPCR) fuel system. Only technicians familiar with this type of sys-
tem can perform repairs.

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REMOVE PAINT BEFORE WELDING OR HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering,

or using a torch.
Remove paint before heating:

■ Remove paint a minimum of 100 mm (4 in.) from area to be affected by heat-
ing. If paint cannot be removed, wear an approved respirator before heating
or welding.
■ If you sand or grind paint, avoid breathing the dust. Wear an approved respi-
rator.
■ If you use solvent or paint stripper, remove stripper with soap and water be-
fore welding. Remove solvent or paint stripper containers and other flamma-
ble materials from area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Do not use chlorinated solvent in areas where welding will take place. Do all work
in an area that is well ventilated to carry toxic fumes and dust away. Dispose of
paint and solvent properly.
AVOID HOT PARTS

Avoid skin contact with exhaust manifolds, turbochargers, mufflers, and other hot
parts. Keep flammable materials clear of all hot parts.
External dry exhaust parts become very hot during operation. Turbochargers
may reach temperatures as high as 500°C (932° F) under full load, and naturally
aspired exhaust manifolds may reach 600° C (1112° F) under full load.
This may ignite paper, cloth or wooden materials. Parts on engines that have
been at full load and reduced to no load idle will maintain approximately 140° C
(302° F) temperatures.
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM

High pressure fluid remaining in fuel lines can cause serious injury or death. Do
not disconnect or attempt repair of fuel lines, sensors, or any other components
between the high-pressure fuel pump and nozzles on engines with High Pres-
sure Common Rail (HPCR) fuel system. Only technicians familiar with this type of
system can perform repairs.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and open flame away from the top of battery. Bat-
tery vapors can explode. Never check battery charge by placing a metal object
across the posts. Use a volt meter or hydrometer. Do not charge a frozen battery;
it may explode. Warm battery to 16° C (60° F).

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AVOID HARMFUL ASBESTOS DUST
Avoid breathing dust that may be generated when handling components contain-
ing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brake pads, brake
band and lining assemblies, clutch plates, and some gaskets. The asbestos used
in these components is usually found in a resin or sealed in some way. Normal
handling is not hazardous as long as airborne dust containing asbestos is not
generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or
grinding material containing asbestos. When servicing, wear an approved respira-
tor. A special vacuum cleaner is recommended to clean asbestos. If not available,
apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
PROTECT AGAINST HIGH PRESSURE SPRAY

Spray from high pressure nozzles can penetrate the skin and cause serious injury.
Keep spray from contacting hands or body.
If an accident occurs, seek medical attention immediately. Any fluid injected in the
skin must be surgically removed within a few hours or gangrene may result. Doc-
tors unfamiliar with this type of injury should reference a knowledgeable medical
source.

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HANDLING BATTERIES SAFELY
CAUTION: Battery vapors can explode. Keep sparks, lighted matches, and open flame away from
the top of battery. Use a flashlight to check battery electrolyte level.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrom-
eter. Always remove grounded (-) battery clamp first and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:

1. Filling batteries in a well ventilated area.
2. Wearing eye protection and rubber gloves (CHECK)
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
If you spill acid on yourself:

1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15-30 minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2L (2qt)
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds,
chemicals known to the state of California to cause cancer and reproductive harm. Wash hands
after handling.

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Setup

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Outfitted with a 125 HP Tier III John Deere water cooled diesel engine, the DirectFeed 2516T has a
12 volt battery and engine mounted pumps which operate all plant functions. Additionally, the NEMA-4
rated instrument panel, tachometer, hour meter, voltmeter, oil pressure gauge, oil temperature gauge
and emergency stop come standard on all models.
Productivity will vary depending on application requirements: feed material size, material separations,
type of screens used, weight of product and other material considerations. The feeder system on the Di-
rectFeed 2516T consists of a 10 cubic yard heaped capacity hopper with a 6’ 6” x 16’ top opening.
A series of steps must be completed to unfold the plant before operation can begin. Throughout the
setup and operating sections of this manual the plant orientation will be referred to as if you were
standing behind the oversize conveyor facing towards the feed bin. All “sides” and “direction” of
the plant will be indicated as follows:
Roadside: Your left side. The roadside section of the plant contains the engine control panel and all
start/stop functions of the plant used and its functions. Additionally, the rear section of the roadside
contains the control lever used to setup the intermediate conveyor. This side of the plant also contains
several grease points.
Curb side: Your right Side. The curb side part of the plant gives access to setup functions of the fines
side conveyor, wings setup and feed conveyor set up controls. This side of the plant also contains
several grease points and is also used to fuel the plant.
Back: The over size conveyor is located at the back of the plant.
Front: The front of the plant is where the feed hopper is located.
Additional Information:
Each hydraulic spool valve is labeled with a black and white decal. Each decal is marked with a “push”
and “pull” side. Pull means to force the valve UP towards the sky and Push means to force the valve
DOWN towards the ground.
Prior to attempting each step, read the entire step first. At the beginning of each step a brief expla-
nation of that step will be given. Following the brief explanation will be a more detailed description of
how to complete each step. Follow the steps sequentially. It is important to fold and unfold the plant
in the proper order.
Failure to follow all instructions can result in damage to the equipment,

serious injury or DEATH. Please note all safety symbols that accompany
each step.
TOOLS NEEDED FOR SETUP

■ 3/8” drive ratchet and 9/16” socket
■ 1/2” drive ratchet and 3/4” socket
■ 9/16” wrench and 3/4” wrench
■ Alignment punch

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Front Back
Curb Side Road Side Road Side Curb Side
Curb Side
Overs Screen Fines Feed
Conveyor Box Conveyor Hopper
Bottom Deck & Under Screen Wings, Screen Box,

Fines Conveyors Fines Conveyor Fines Conveyor Feed Conveyor
Grease Points Set-up Controls Set-up Controls
Road Side
Engine Feed Screen Intermediate Overs
Control Panel Hopper Engine Box Conveyor Conveyor
Main Set Up Fines Conveyors Overs Conveyor &

Controls Feeder Head Pulley Grease Points Intermediate Conveyor Under Screen Fines
Grease Point Set-up Controls Conveyor Grease Points

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RED LED
AMBER LED
1. UP: Increase RPM, Scroll Menu Lists
2. DOWN: Decrease RPM, Scroll Menu Lists
3. ENTER: Select Highlighted Menu Item.

Press/Release to Access Main Menu.
Hold to Crank Engine.
Figure 14
6. POWER 5. LEFT: 4. RIGHT:
BUTTON Decrease Increase
Parameter Parameter
Value Value
Engine Control Panel

The diagnostic gauge allows the operator to view many readouts of engine functions and trouble
codes (DTCs). The gauge is linked to the electronic control system and its sensors. This allows the
operator to monitor engine functions and to troubleshoot the engine systems when needed.
Press the menu key to access the various engine functions in sequence. The displays can be se-
lected as either customary English or metric units.
The Following menu of engine parameters can be displayed on the diagnostic gauge window:
■ Engine hours
■ Engine RPM
■ System voltage
■ Percent engine load at the current RPM
■ Coolant temperature
■ Oil pressure
■ Throttle position
■ Intake manifold temperature
■ Current fuel consumption
■ Active service (diagnostic) codes
■ Stored service (diagnostic) codes form the engine
■ Set the units for display.
NOTE: The engine does not need to be running to navigate the diagnostic gauge screens. To access
the diagnostic gauge, press the Power Button.

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Linking the Remote
■ Push the Power button on the Engine Control Panel (lights on receiver will light up)
■ Push the E-Stop in on the remote (Activate E-Stop)
■ Push any of the toggle switches to activate the synchronization sequence. The yellow power
light will begin blinking.
■ After the yellow power light begins blinking, release E-Stop by twisting the knob clockwise.
■ The yellow power light will stop blinking momentarily while the remote syncs with the receiver.
■ After the remote has synced with the receiver, the yellow light will begin blinking again.
If the E-Stop is not released within 10 seconds of activating the startup se-
quence, the remote will power down and the sequence must be restarted.

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Starting the Engine
After Linking Remote as described on page 23 you
are ready to start the engine.
With Control the panel activated, the engine can be

started by pressing and holding the ENTER button, as
shown in Figure 13. The engine can only be started
from the Operation Screen.
NOTE: The H30 protects the engine starter from

damage by limiting the time that the operator can
crank the engine to 15 seconds with a 30 second rest
between cranks. Figure 13
When used with an electronically controlled engine, the engine ECU may be programed to use a
cold start aid (block heater, air intake heater, glow plugs, etc.), a notice will be displayed informing
the user that the engine preheat is taking place and to wait for preheat operation to complete
before attempting to start the engine.
If the ECU COMMUNICATION ERROR is flashing on the H30 screen, the engine will not start.
ENGINE CONTROL
While the engine is running and the H30 is displaying the Operation screen, the UP and DOWN
buttons will increase and decrease the engine speed, respectively. The manner in which the speed
increases and decreases depends on the current Operation Mode: MANUAL RAMP, MANUAL
STEP or AUTO RAMP (MANUAL RAMP is the default Operating Mode.)
ENGINE SHUTDOWN
When the power button is pressed while the engine is running, the engine will shutdown
immediately.
CAUTION: Always follow engine manufacturer recommendations for controlled engine

shutdown prior to pressing the power button.
If operating conditions cause the engine ECU to derate or shutdown the engine, the controller’s red
LED will flash and the engine will derate or shutdown based on the engines ECU’s programing.
NOTE: Stop engine immediately if there are any signs of part failure. Symptoms that may be early
signs of engine problems are:
■ Sudden drop in oil pressure

■ Abnormal coolant temperatures
■ Unusual noise or vibration
■ Sudden loss of power
■ Excessive black exhaust
■ Excessive fuel consumption
■ Excessive oil consumption
■ Fluid leaks

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Leveling the Plant
Level plant prior to operating. Failure to level the plant from both side to side and from front to back
will result in poor performance or damage to equipment.
Main Operating Control Panel

The Main Operating Control Panel is
located on the Road Side of the plant
next to the engine compartment, refer
to Figure 15.
Main Control Panel
Figure 15
Initiate Setup
The Set-Up Functions lever (Figure 15a) is used to initiate the setup process. Prior to attempt-
ing setup of the plant, the setup functions lever must be placed in the ON position (UP). Leave
Set-Up functions lever in the ON position for the duration of the setup process, without this lever
in the ON position, multiple levers will not function.
Setup Functions Lever
Figure 15a
Unfolding Fines Conveyor

It is important to follow the unfolding sequence as outlined below. Failure to follow this sequence
will result in damage to the equipment and/or personal injury. The location of the fines conveyor
set up controls is on the curb side of the plant as shown in (Figure 15b)
Figure 15b
Fines Conveyor
Setup sequence continues on the following page: Setup Controls

DIRECTFEED 2516T
NOTE: The speed at which the conveyors react to the hydraulic controls is directly
related to the speed at which the engine is running. Do not attempt to run the engine
faster than 1100 RPM during the setup process.
To unfold the fines side conveyor:
WHEN RAISING CONVEYOR BEWARE OF

OVERHEAD POWER LINES!
■ Ensure the path of travel is clear from all obstructions and

personnel.
■ Pull the lever in the middle marked Fines Conveyor (MIDDLE)

(Figure 15c) first to raise the middle section to a full upright
position. (Figure 15d & 15e)
Figure 15c
Figure 15d
Main Fines Conveyor Section Transport Pin locations
Figure 15e
■ Before proceeding to unfolding the next section you must remove

the transport pins from the main conveyor section. (Figure 15f)
Figure 15f

DIRECTFEED 2516T
■ With the pins removed, pull on the lever to your left marked Fines
Conveyor (MAIN) (Figure 15g) to extend the Main Section fully
as shown in (Figure 15h) Figure 15g
Figure 15h
■ With Main section fully extended re-pin the conveyor as shown

in (Figure 15i) . It may be necessary to pull and push on the
Fines Conveyor Main Section lever for the pin holes to line up.
Once the pins are reinserted, lower the Fines Conveyor Main
section down to support the conveyor and remove the weight
from the cylinders. There are two holes in each tube to insert
the pin, use the first hole for a taller stock pile, the second
hole appears when the section is all the way down, for a Figure 15i
lower stock pile.
■ With the Middle section fully extended pull on the lever to your
right marked Fines Conveyor (HEAD) (Figure 15j) to extend
the Head Section fully to a straight out position (Figure 15k).
Figure 15j
Figure 15k

DIRECTFEED 2516T
Unfolding the Intermediate Conveyor:
WHEN RAISING CONVEYOR BEWARE OF

OVERHEAD POWER LINES!
Intermediate Conveyor Controls Location Figure 16
■ Ensure the path of travel is clear from

all obstructions and personnel.
■ The Intermediate Overs Conveyor is unfolded in a similar fashion

to the Fines Conveyor
■ Pulling on the second from the right lever marked Bottom Deck Figure 16a
Overs Conveyor (MIDDLE) first will raise the middle section.
■ Continuing to pull this lever will raise the Intermediate conveyor

to a full upright position. (Figure 16a & 16b)
Figure 16b
■ Before proceeding to unfolding the next section you must

remove the transport pins from the main conveyor section.
(Figure 16c)
Figure 16c
Intermediate Conveyor Transport Pin locations

DIRECTFEED 2516T
Unfolding the Intermediate Conveyor: Continued
■ Next pull the second from the left lever marked Bottom Deck
Overs Conveyor (MAIN) to unfold the main section of the
conveyor (Figure 16d).
Figure 16d
■ Once the Main Section is fully extended re-pin to support
the the weight of the conveyor on the pins and not on the
cylinders, as shown in (Figure 16e). It may be necessary to
pull and push on the Main Conveyor Section lever for the
pin holes to line up. There are two holes in each tube to
insert the pin, use the first hole for a taller stock pile,
the second hole appears when the section is all the way
down, for a lower stock pile.
Figure 16e
■ Now pull the lever to the right marked Bottom Deck Overs
Conveyor (HEAD) to unfold the head section. (Figure 16f)
Figure 16f
■ The last step in unfolding the Intermediate Conveyor is to

lower the tail pulley section, this is accomplished by pulling
the lever to the far left. (Figure 16g). The tail section can
be viewed by looking down the Intermediate Conveyor belt
to watch the tail section move down.
Figure 16g
■ The Intermediate Conveyor tail pulley section is shown

lowered into operating position in (Figure 16h). Visually
inspect to insure the tail pulley section is fully lowered.
Intermediate Conveyor tail pulley section
Figure 16h

DIRECTFEED 2516T
WHEN RAISING SCREEN

BOX BEWARE OF
OVERHEAD POWER
LINES!
Controls location for the next three steps

Raising the Screen Box
Raise Screen Box to operating angle:
use the following steps to continue raising the screen box to operating height:
■ Raise the screen box to the desired operating angle by pulling the Screen Box lever. (Figure
17) which will raise the telescoping tubes off the support pins on each side (Figure 17a), when
the screen box is at the desired height, remove and re-insert the support pins on both sides
(Figure 17b) and push the Screen Box lever in to lower screen box support tubes on to the pins
for supporting the weight of the screen box and remove the weight from the cylinders. (Figure
17c)
Figure 17 Figure 17a Figure 17b Figure 17c
■ The operating angle is 15° The angle can be read

from the meter located on the side of the screen box. (Figure 17d)
Figure 17c
■ Before the Feeder can be moved into position, the walkways must be unfolded, this
is the next step in the set-up operation, at this time shut the engine down to prevent
overheating the hydraulic oil as it circulates through the Set-up system.

DIRECTFEED 2516T
Unfolding the Walkways - Road Side
■ Remove the bolt in the hinge point (Figure 21) then remove the
bolt securing the hand rail up right to the top of the had rail (Fig-
ure 21a). Set these fasteners aside for use later in setting up the
walk ways.
Figure 21
■ Remove the bolt securing the hand rail up right to the top of
the had rail (Figure 21a). Again setting the fasteners aside for
later use.
Figure 21a
■ Using the proper rigging lower the pivoting section down into
place (figure 21b)
Figure 21b
■ Insert and tighten the four (4) bolts provided in the support
tube flange (Figure 21c & 21d)
Figure 21c
Figure 21d

DIRECTFEED 2516T
■ Loosen the two (2) bolts securing the removable hand rail section
(figure 21e).
Figure 21e
■ Insert the hand rail section in the pockets in the walkway floor
(Figure 21f)
Figure 21f
■ Bolt the hand rail section to the uprights using the two (2) bolts
from the beginning of this set up. (Figure 21g)
Figure 21g
■ Tighten the bolts in the upright base (Figure 21h)
Figure 21h
■ Use the two (2) bolts removed in step 21 to secure the hinge
points in the operating position (Figure 21i)
Figure 21i

DIRECTFEED 2516T
■ The last step is to bolt the tab on the frame to the tab on the
inner walkway up right (Figure 21j)
■ Failure to perform this last step can result in stress cracking of

welded joints in this area.
Figure 21j
■ Assembled Road Side Walkway (Figure 21k)
Figure 22k

DIRECTFEED 2516T
Unfolding the Walkways - Curb Side
■ Remove the bolts in the hinge points (Figure 22) (The out side
hinge point and the inside hinge point.)
Figure 22
■ Remove the bolt securing the hand rail up right to the top of
the had rail (Figure 21a). Again setting the fasteners aside for
later use.
Figure 22a
■ Using the proper rigging lower the pivoting section down into
place (figure 22b)
Figure 22b
■ Insert and tighten the two (2) carriage bolts provided in the
long support tube flange (Figure 22c & 22d)
Figure 22c
Figure 22d

DIRECTFEED 2516T
■ Loosen the two (2) bolts securing the removable hand rail section
(figure 22e).
Figure 22e
■ Insert the hand rail section in the pockets in the walkway floor
(Figure 22f)
Figure 22f
■ Bolt the hand rail section to the uprights using the two (2) bolts
from the beginning of this set up. (Figure 22g)
Figure 22g
■ Tighten the bolts in the upright base (Figure 22h)
Figure 22h
■ Use the two (2) bolts removed in step 22 to secure the hinge
points in the operating position (Figure 22i)
Figure 22i

DIRECTFEED 2516T
■ The last step is to bolt the tab on the frame to the tab on the
inner walkway up right (Figure 22j)
■ Failure to perform this last step can result in stress cracking of

welded joints in this area.
Figure 22j
■ Assembled Curb Side Walkway (Figure 22l)
Figure 22l

DIRECTFEED 2516T
Positioning the Feeder
• After the screen is in operating position you can position the

feeder for operation, pull the lever marked FEEDER (Figure 18)
Figure 18
• The feeder will move (Figures 18a) into operating position.
Figure 18a
• Final position of the feeder is shown in (Figures 18b) the feeder
automatically stops when it is in position for operation.
Figure 18b

DIRECTFEED 2516T
Raising the Feeder Wings
The next step in setting up the Direct Feed 2516T is to raise the Feeder Wings into position.
■ Locate the lever marked WINGS (Figure 19). Pulling this lever will cause the Feeder Wings
to raise into operating position sequentially. First the Road Side Wing will raise (Figure 19a)
followed by the Curb Side Wing (Figure 19b) and finally the tail gate wing will rise into position
(Figure 19c).
Figure 19 Figure 19a Figure 19b Figure 19c
■ The last step in raising the wings is to insert wedges in special

ears on both wings to secure the tail gate to the wings (Figure
19d) secure the wedges with pins provided.
Figure 19d
■ In some application, such as feeding the DirectScreen 2516T

in-line with a crusher, it is possible to leave the Feeder Tail Gate
down (Figure 19e) simply release the WINGS lever
when the Curb Side wing is up.
Figure 19e
■ This part of the set up is now complete, reset the SETUP/ Fines
Conveyor lever to the neutral position before proceeding to the next
step.
(Figure 19f)
Figure 19f

DIRECTFEED 2516T
IMPORTANT: If the setup valve is not turned OFF, oil will

continue to flow over the relief valve which will heat the
oil to an excessively high temperature. This will result
in severe damage to the hydraulic system.
IMPORTANT:
REMOVE TRANSPORT PINS FROM SCREEN, It is very
important to remove the transport pins from the screen
box before proceeding further, failure to perform this step
will result in severe equipment damage and/ or personal
injury.
■ The transport pins are located at the four (4) spring
mounts for the screen, there are two (2) on each
side of the screen. DO NOT proceed until all four (4)
transport pins have been removed. (Figure 20)
Transport Pin
Figure 20

DIRECTFEED 2516T
OPERATION

DIRECTFEED 2516T
Operation
NOTE: If the setup valve is not set to neutral, oil will continue to flow over the relief valve and
heat the oil to an excessively high temperature. This will result in severe damage to the hy-
draulic system.
Be aware of all personnel around plant. When it has been confirmed that all personnel have cleared
the area, begin the operating process.
If conditions are such that the engine needs to be warmed up, let run idle until necessary temperature is
reached. Once the engine has been thoroughly warmed, increase the engine speed to 2200 RPM.
Item Description
A Engine Control Panel
B Track Enable
C E-Stop
D Circuit Breaker
D
A
Control Panel C
Components
Figure 21

DIRECTFEED 2516T
1 2 3
4 5 6 7
Figure 22
Plant Controls
1. Feeder Belt Speed Control 5. Track Enable/Product Conveyor on/off
2. Bottom Deck Overs Conveyor Speed Control 6. Relief Pressure/Feeder on/off
3. Overs Size Conveyor Speed Control 7. Setup/Fines Conveyor on/off
4. Track Enable/Screen Box Control
Ensure all conveyors are clear of debris and obstructions. It is recommended that the components be
started by pushing the lever for each function down in the following order:
■ Fines Conveyor (7)
■ Product Conveyors (5) (Intermediate Conveyor and Oversize conveyor)
■ Screen (4)
■ Feeder (6)

DIRECTFEED 2516T
Adjusting Conveyor Speeds
• Rotate the BOTTOM DECK OVERS CONVEYOR flow

control lever clockwise until the limit has been reached.
Figure 23
• Rotate the OVERS CONVEYOR flow control lever

counterclockwise until the limit has been reached.
Figure 23a
• Rotate the FEEDER BELT CONTROL to achieve the desired

belt speed for the material being fed to the screen.
Figure 23b
NOTE: The Fines Conveyor flow is one speed continuous. No adjustment is

needed

DIRECTFEED 2516T
Screen
The 2516 double deck screen, a true 5” x 16’ screen, is driven by a 825 RPM vibrating mechanism
mounted on the screen box. Amplitude is adjustable with add on weights.
The oversized material of the screen will be discharged by the conveyor at the rear of the plant. The
material that passes the top deck and is held on the bottom deck, will be discharged on the on-
board stacking conveyor on the road side of the plant.
All material (that has made it through both the top and bottom screens) will be discharged by the
fines conveyor located at the curb side of the plant. The fines conveyor can be set to operate either
as a feeder to an auxiliary conveyor, or set to create a stockpile. For a more detailed explanation of
how to set the fines conveyor to either auxiliary or stockpile positions, refer to the setup section of
this manual.
To determine the proper angle at which to screen your material, first establish what sort of material
will be screened. When determining the screen box angle remember these general rules.
■ Normal screen operating angle is 15°.
■ The angle meter (Figure 23) located on the curb side of the screen box measures the angle of
the screen.
Figure 24
■ To activate the screen motion push down the track

Enable/ Screen Box lever (Figure 24a) the location of
the Main Control Panel as shown on page 41.
Figure 24a

DIRECTFEED 2516T
Moving plant with built in tracks.
Increase engine speed to 2200 RPM.
■ Push the enter button on the Engine control panel to increase engine speed. See (Figure
14 on page 22.
■
CAUTION: MAKE CERTAIN THE FEEDER IS EMPTY PRIOR MOVING THE PLANT. FAILURE TO
MAKE SURE THE FEEDER IS EMPTY MAY CAUSE SEVERE DAMAGE, INJURY OR DEATH!
■ Turn the “enable tracks” switch inside the main control panel to the “ON” position
■ Make sure the area is clear of all personnel and that there is sufficient room to maneuver
the plant.
■ Right Track = Curbside
■ Left Track = Roadside
The LEFT TRACK and RIGHT TRACK functions may be activated while the TRACK mode is enabled.
The TRACK mode is enabled when the following conditions are all true:
■ The Track [ON, OFF] switch is latched in the TRACK ON position
■ No track functions are activated on the transmitter.
■ The TRACK ENABLE receiver input is 6V DC or higher.
The TRACK mode is disabled if any of the following conditions are true:
■ A loss of link occurs
■ A loss of power occurs
■ The TRACK switch is latched to the TRACK OFF position
■ The TRACK ENABLE receiver input goes below 6V DC
Quick Facts and tips.

■ The tracks move independently.
■ There is a slight delay between the time you press the switch to when the track begins
moving. The same is true when you release the switch, there will be a slight delay before
the track actually stops moving.
■ If you stop the engine with the remote e-stop, make certain you turn the key off on the
main control panel. Failure to do so will result in unnecessary draining of the battery.
■ Make sure machinery and surrounding area is clear before operating. Do not activate the
remote system unless it is safe to do so.
■ Turn off the receiver power before working on machinery. Always disconnect the remote
system before doing any maintenance to prevent accidental operation of the machine.

DIRECTFEED 2516T
■ KEEP REMOTE DRY. Do not clean the transmitter / receiver under high pressure. If
water or other liquids get inside the transmitter battery or receiver compartment, imme-
diately dry the unit. Remove the case and let the unit air dry.
■ CLEAN THE REMOTE after operation. Remove any mud, dirt, concrete, etc. from the
unit to prevent clogging of buttons, switches, etc. by using a damp cloth.
■ Disconnect the RADIO receiver before welding on this machine. Failure to disconnect
will result in the destruction of the radio receiver.
LEFT FEED BIN RIGHT Figure 25

TRACK TRACK
Forward Forward
ROADSIDE CURB SIDE
Reverse Reverse

DIRECTFEED 2516T
Screen Cloth Replacement
To replace the screen cloths in the DirectFeed 2516T:
■ Remove nuts, bolts and washer from tension bar.
■ Remove clamp from frame.
■ Remove worn screen.
■ Clear crown rubber edges of debris.
■ Place new screen cloth on deck (with screen hooks facing up).
■ Begin tightening tension clamps. Starting at one point and work your way around plant until all
clamps are snug. Repeat process until all clamps are tight.
■ Ensure screen has even tension on both sides and all bolts are double nutted.
Figure 26

DIRECTFEED 2516T
Preparing for Transport
Prior to transporting unit, perform following checks.
■ Make sure Screen box and feeder are fully lowered.
■ Make sure walkways are folded and all fasteners are tight.
■ Make sure all pins are secure in transport mode
■ Make sure folding conveyors are secured for transport.
■ Make sure all material is discharged from screening plant
■ To prevent debris discharge, clean unit prior to transport.
■ Fold Feed Bin wings down to transport position (Figure 27)
Figure 27

DIRECTFEED 2516T
Operating Notes:

DIRECTFEED 2516T
MAINTENANCE

DIRECTFEED 2516T
Overall Inspection
A visual inspection of the plant should be done on a daily basis. By inspecting the plant visually each
day you may be able to spot and correct potential problems before they become serious.
1. Check all grease lines, ensure they are properly routed, free of rips, punctures and bulges, and
connected securely. See appendix A for a complete greasing schedule.
2. Make sure plant is level. Environmental variations can cause the plant to become uneven. Use an
accurate level to ensure the plant is level both front to back and side to side. If the plant is operated
in any matter other than level, poor performance or damage to the equipment may occur.
3. Visually inspect all guards. Ensure guards are properly aligned and tilted at the correct angle.
Check to make certain guards are free from obstructions and are not rubbing belt.
4. Check for loose fittings. Ensure all nuts, bolts, and

other connections are secure. Check all pins and clips.
When a pin is being used to support a section, a cot-
ter pin must be used to protect against vibrations work-
ing the pin out of its location. Make sure all pins and
clips are in proper working order and fastened securely.
5. Ensure all hydraulic lines are routed correctly, free of

rips, punctures and bulges, and have solid connections.
Use a piece of wood or cardboard as a backstop to pinpoint
leaks.
Figure 28
If hydraulic fluid penetrates skin, it must be

surgically removed as soon as possible by
a doctor familiar with this form of injury or
gangrene, serious injury, or death will result.
CONTACT A PHYSICIAN IMMEDIATELY IF FLUID
ENTERS SKIN OR EYES. DO NOT DELAY.
6. Check battery for corrosion or damage. The battery is located in a plastic bin near the engine. To
access the battery, remove plastic wing nuts from both sides of bin and pull cover off. Make certain
battery terminals are free of corrosion and other debris.

DIRECTFEED 2516T
Hydraulic Maintenance
The hydraulic tank fluid level should be visible in the sight meter at all times. Do not allow the hy-
draulic fluid level to fall below this line. If the amount does fall below this line, add fluid until visible.
Operating the plant with an insufficient level of hydraulic oil can cause premature wear or damage to
equipment.
All motors must have a constant supply of hydraulic oil in order to maintain good running condition.
Damage to hydraulic pumps can occur if hydraulic oil level does not stay within satisfactory levels.
If adding hydraulic oil, be certain to filter the oil before adding it to the hydraulic oil tank. Even new
hydraulic oil contains impurities.
Condensation in the hydraulic tank can occur during certain operating conditions. Keeping the tank
full will minimize the amount of condensation. If excess condensation is detected, drain hydraulic oil
tank and fill will new hydraulic oil.
At certain times, hydraulic oil will need to be replaced. Additionally, the hydraulic oil return filter and
high pressure filter, along with the breather will need to be replaced at certain intervals of operating.
Refer to Appendix A for suitable hydraulic oils and a detailed maintenance schedule.
All Conveyors
Be certain to maintain all safety procedures while working on conveyors. Some maintenance
may require conveyors to be running, such as training the belt. Allow only authorized personnel
to operate the equipment and perform maintenance on the plant.
Training the Belt

Although the belt is trained at the factory, many variations can cause the belt to become misaligned.
The belt should be running directly down the center of the idlers.
Several factors can effect the way the belt tracks, and depending
on the operating conditions, variations of these factors can occur.
Physical variations can include: alignment of pulleys (head and

tail) and idlers. In rare cases, the squareness of the belt splice can
cause serious variations in the conveyors path.
Operating variations include: the size of load and levelness of belt.

A loaded belt may also run differently than an empty belt. In order
to properly train the belt, reduce the number of both physical and
operating variables.
If the belt needs to be trained use the following procedures. NOTE:

the effects of training the belt will not be immediate. Allow
several complete rotations of the belt before making further
adjustments.
1. Use an accurate steel square to check the idlers. Improperly

aligned idlers are a common cause of belt misalignment. Start by
Figure 29

DIRECTFEED 2516T
adjusting the return idlers. (Figure 29) After adjusting return idlers, if belt is still straying, adjust several
idlers behind the point at which the belt strays.
Begin the troubleshooting process by performing this adjustment on the opposite side of the belt that
runs off the roller.
Do not attempt to make extreme adjustments to one idler. Instead, make several slight adjustments to
several idlers. Always allow several rotations to occur before determining belt alignment.
After idlers have been adjusted, place a load onto conveyor and check for alignment. If necessary, repeat
idler adjustments until content with alignment.
2. If adjusting the idlers does not work, an adjustment to the take-up screws may be necessary. The
screws are located on either side of the head/tail pulley, and can be adjusted with a 1 5/8” socket.
This is not the most common cause of a misaligned belt, but the process can be used as a last resort
to troubleshoot the situation.
Ensure the head pulley is properly aligned

with the tail pulley by adjusting the take-up
screws. By increasing the tension on either
side of the head/tail pulley, the belt will shift in
that direction.
By decreasing the tension to either side of

the head/tail pulley, the belt will shift in the
opposite direction. Keep in mind that the
head/tail pulley must stay parallel with the
conveyor frame. If the head/tail pulley is
not parallel with the conveyor, the belt will Figure 30
stray. By adjusting the head pulley you are
attempting to create a parallel line with the
conveyor frame.
After adjusting the take-up screws, run the belt

and check for proper alignment. Allow several
full rotations of the conveyor belt before deter-
mining satisfaction of alignment.
Figure 30a

DIRECTFEED 2516T
Belt Tension
If belt is sagging excessively when a load is ap-
plied, it may be necessary to increase belt ten-
sion. Use the take-ups to increase and decrease
belt tension. When adjusting belt tension be sure
that the distance at which the take-ups are ex-
tended is equal on both sides of head/tail pulley.
Improperly aligning the head/tail pulley will cause
the belt to stray. Be certain not to create to much
tension on the belt.
Guards
Make sure return idler guards are in proper place
and are not damaged. Guards should be tilted
at the proper angle and free from obstructions.
Guards should not be rubbing the conveyor belt. Figure 31
Belt Cleaners
Located at the head pulley end of the side and delivery conveyors are the belt cleaners. Make sure
all fasteners are tight. Tighten if necessary. Inspect the belt cleaner for excessive wear. Allow 3” of
wear on urethane. If blades are worn beyond the wear line, replace as follows.
1. Release tension on mainframe and remove belt cleaner assembly.

2. Use a hammer to remove worn blades from mainframe by pounding downward on bases of worn
blades. Pound new blades onto mainframe after old blades have been removed.
3. Change worn blades with appropriate replacements.
See tension setting decal placed next to belt cleaner for proper tension settings. See the Parts Section
of this manual for replacement part information. Consult the full belt cleaner manual in Appendix C for
more detailed information.
Bearings
Visually inspect bearings on head and tail pulleys.
A small amount of grease around seal is normal.
Excessive grease or lack of grease around seals
may be a sign of bearing temperature problems. For
a detailed description of the greasing schedule, refer
to the lubrication Schedule on page 60.
The plant is equipped with ground level accessible
grease zerks.
Figure 32

DIRECTFEED 2516T
NOTE: When greasing bearings DO NOT over grease! Over greasing will place too much
stress on the seals, causing them to no longer function correctly.
Abnormal bearing temperature may indicate poor lubrication. Normal operating temperatures may range
from cool to touch to too hot to touch, depending on bearing size, speed and surrounding conditions.
Unusually high temperature accompanied by excessive leakage of grease indicates too much grease.
High temperature with no grease showing at the seals, particularly if the bearing is noisy, usually
indicates too little grease.
The bearings have been lubricated at the factory

with No. 2 consistency lithium base grease. This
grease is suitable for normal operation conditions.
Re-lubricate bearings with lithium base grease
or a grease which is compatible with the original
lubricant and that is suitable for ball bearing
service. In unusual or doubtful cases, contact your
local Astec Mobile Screens Dealer.
Flashing
Check Flashing inside of top deck, bottom deck,
feed bin, screen box hoppers, and delivery
conveyor. Flashing is used to prevent spillage
from occurring.
In order to properly prevent spillage, flashing must

be flush with conveyor belt, with a minimum gap. Figure 33
Check to make certain flashing is not excessively
rubbing conveyor.
If flashing is not aligned correctly or needs to be re-aligned, loosen tension brackets (1) by loosening
nut (4) and adjust flashing to proper position.
After realignment, tighten tension bracket nuts. If flashing is worn to the point that it is not preventing
spillage, replace flashing with correct replacement part. See parts section for specific flashing sizes.

DIRECTFEED 2516T
Pillow Block Bearings
High Speed Operation – In the higher speed ranges, too much grease will cause overheating.
The amount of grease that the bearing will take for a particular high speed application can only be
determined by experience. If excess grease in the bearing causes overheating, it will be necessary to
remove grease fitting to permit excess grease to escape. The bearing has been greased at the factory
and is ready to run. When establishing a re-lubrication schedule, note that a small amount of grease
at frequent intervals is preferable to a large amount at infrequent intervals.
JD Engine Break-In Service
Before starting, fill engine with seasonal viscosity grade oil and with coolant meeting specifications. (See DIESEL
ENGINE OIL and DIESEL ENGINE COOLANT SPECIFICATIONS in Fuels, Lubricants, and Coolant Section in
the John Deere Engine Manual.)
• During the first 20 hours, avoid prolonged periods of engine idling or sustained maximum load operation.
Warm-up engine carefully and operate at normal loads. If engine will idle longer than 5 minutes, stop
engine.
• Check oil level daily or every 10 hours during engine break-in period. If oil must be added during this period,
use seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuels, Lubricants, and Coolant section of
the John Deere Engine Manual.)
• Watch oil pressure (F) and coolant temperature (E) closely during break-in period. Also check coolant level
daily or every 10 operational hours and check for leaks.
• Check poly-vee belt for proper alignment and seating in pulley grooves.
• Change engine oil and oil filter after the first 100 hours of use.
After break-in period, change oil and filter every 500 hours/12 months. (See CHANGE ENGINE OIL AND
FILTER in Lubrication and Maintenance/500 Hour Section of the John Deere Engine Manual.) Fill crankcase
with seasonal viscosity grade oil. (See DIESEL ENGINE OIL, in Fuels, Lubricants, and Coolant Section of the
John Deere Manual.)
IMPORTANT: DO NOT operate engine when oil level is below ADD mark on dipstick. Check oil level before
starting engine for the first time.
IMPORTANT: DO NOT fill above the top mark on the dipstick. Oil levels anywhere within crosshatch
(Figure A) are considered to be in the acceptable operating range.
IMPORTANT: DO NOT add makeup oil until the oil level is BELOW the crosshatch marks on the
dipstick.

DIRECTFEED 2516T
Scheduled Maintenance
Daily Checks
In order to maintain your equipment and keep it running at optimal performance, spend a
few minutes each day visually checking the following components. By doing a daily check,
you may find possible problems that need immediate attention or simply components that
are worn but not broken. Worn parts can be replaced at a convenient time such as when the
machine is not in use, keeping your plant running when it has to!
Overall
Take a walk around the plant and ensure all hydraulic lines are routed correctly, are free of
bulges, and are not leaking. Check beneath plant for evidence of leaks, such as puddles or
stains. Check the hydraulic oil tank sight meter. Make sure the hydraulic oil is visible in the
meter. If oil is not visible, fill with new hydraulic oil until level reaches a safe operating level.
While checking the sight meter, ensure that condensation is not present within the reservoir.
Screen Box
Make sure aggregate spreader is properly inserted and that the chain is connected. Inspect
the chutes and hoppers for obstructions or excessive debris. Check screen cloth for wear,
damage and tension. If screen cloth or aggregate has worn through the crown rubber which
supports the screen cloth, replace crown rubber.
Conveyors
On all conveyors connected to your plant, ensure that the belt tension is correct and that
the splice is in proper condition, free of rips or large gaps. Check that belt scrapers are set
to proper tension and are not either excessively rubbing the belt or not tensioned enough to
clear the carryback debris. Ensure all idlers are in the proper position and fastened tightly to
the conveyor frame. Make sure guards are in the proper place and that flashing is not worn
through.

DIRECTFEED 2516T
50 Hour Checks
At 50 hours, you have probably become familiar with your plant, the way it looks, the way it sounds,
and more importantly, the way it runs! After 50 hours of operation, your plant needs a few tune-ups
that will keep it running at it’s peak performance.
The speed reducer located on the feed bin conveyor allows the belt to run at a slow speed while
keeping the torque it needs to pull the product along to the delivery conveyor. After the first 50 hours
of operation, drain, flush and clean out the speed reducer.
Remove drain plug and allow reducers to fully drain. Remember to dispose of old lubricants
properly! After speed reducer is fully drained, flush the interior and refill with High Grade petroleum
based rust oxidation inhibitor. Use only 128 oz.. DO NOT OVERFILL. Do not use EP oils with
slippery additives.
Additionally, replace the hydraulic filter. There is no need to change the hydraulic oil until the
first 500 hours of operation. For proper filter replacement contact Astec Mobile Screens sales
department.
250 Hour Checks

After 250 hours of operation, your machine is well broken in and should need seldom adjustments
and maintenance done. Replace the High pressure hydraulic filter, and the hydraulic return filter.
The filters prevent debris and other contaminants from entering your hydraulic system. If these
contaminants were to breach the filters defenses, severe damage will be done to your machine.
500 Hour Checks

Replace the fuel filter and the primary and secondary air filters in the John Deere engine. After
500 hours of operation change the Hydraulic Oil. After the initial 500 hours, the hydraulic oil need
only be changed every 1000 hours.
While greasing remember to use lithium base grease and DO NOT OVERFILL. Overfilling the
grease lines will cause the seals to fail.

DIRECTFEED 2516T
Lubrication Schedule
Description Interval Type of Lubrication Quantity
Head / Tail Pulley Bearings 50 Hours Lithium Based Grease 3-5 pumps
Screen Box Bearings 8 Hours Lithium Based Grease 3-5 pumps
Change Filter after 50 hours and every 250 hours

Hydraulic Filters after that
Change Fluid after 500 hours and every 1000
Hydraulic Fluid hours after that ISO 46 or equivalent 100 gallons
John Deere Engine Oil Change engine oil & filter after first 100 hours.
Filters Change every 500 hours / 12 months after API - CI-4 Multi-viscosity 15.5 Quarts
Change the primary and secondary fuel filters

John Deere Fuel Filters every 500 hours
Replace the primary element when the filter

Engine Primary Air Filter restriction indicator reads 25 in.(H2O)
Engine Secondary Air Filter Replace only if the primary element had a hole in it.
Drain, Flush, and clean after 100 hours. Drain

Flush, and clean every 2000 hours after intial
Feed Gear Box flushing. NLGI # 2 Grease
Change oil after 100 hours of operation and every 2.1 quarts per
Final Drive 1000 hours after 80W90 Gear Oil side

DIRECTFEED 2516T
PERIODIC MAINTENANCE CHART
DIRECTFEED 2516T SCREENING PLANT
ASTEC MOBILE SCREENS
Daily 50 hrs 250 hrs 500 hrs 1000 hrs As required
Hydraulic Maintenance
Pre-Start
Check hydraulic fluid level - check temperature in operation X
Visually inspect hydraulic fluid X
Inspect hydraulic tank for leaks X
Change hydraulic fluid X
Replace return filter element X
Replace breather X
Make sure setup valve is in neutral position X
Overall Inspection
Pre-Start
Check all grease lines X
Make sure all pins & clips are secure X
Inspect all safety chains X
Make sure plant is level X
Make sure all safety decals are legible X
Check battery for damage and corrosion X
Transporting Screening Plant
Make sure all pins & clips are secure X
Screen Box
Pre-Start
Check screen cloth for wear, damage, and tension X
Visually inspect all fasteners and hydraulic connections X
Inspect ag spreader X
Inspect chutes & hopper X
Grease screen bearings X
When changing screen cloth, inspect the following
Seal strips X
Crown rubber X
Location of dams and wear X
Bolts and Hardware X

DIRECTFEED 2516T
PARTS

DIRECTFEED 2516T

DIRECTFEED 2516T
Parts Ordering
On component assembly and hydraulic schematic drawings, there is a ballooned letter and
a part number identifying the parts. When ordering parts, always supply all of the following
that apply:
 The serial number of the plant

 The ballooned letter that points to the part required
 The description of the part required
 The part number of the part required
Contact Information:
Astec Mobile Screens, Inc.

2704 West LeFevre Road
Sterling, IL 61081
USA
Phone: 1-815-626-6374
1-800-545-2125
Fax: 1-815-626-6430
Visit our website at http://www.astecmobilescreens.com
Questions or comments may be e-mailed to:
Parts Issues: [email protected]

Sales Issues: [email protected]

DIRECTFEED 2516T
APRON FEEDER ASSEMBLY
21
22 12
11
15
15
12
23
11
12 1 20
15
17
11
6
19
4
16 3
5 5
9 7
14
26
6
10 8 6 6 4
24
25 8
6
18
10
1
9 7 5 13
10
8
6 10 8 6
27
6 14 29
5 2
9 5
7 9 5 5 3 7
28
M51025

DIRECTFEED 2516T
APRON FEEDER ASSEMBLY PARTS LIST

M51025
ITEM QTY PART NUMBER DESCRIPTION

1 3 C03735 CYLINDER
2 8 H00010 BOLT
3 12 H00011 BOLT
4 28 H00020 BOLT
5 48 H00049 FLAT WASHER
7 28 H00061 LOCKWASHER
9 28 H00067 NUT
10 36 H00068 NUT
11 6 H00082 NYLOCK
12 6 H00381 BOLT,
13 8 H00401 BOLT
14 8 H00413 BOLT
15 6 M10200PN-04 ROUND
16 1 M51025-A RUBBER SKIRTBOARD
17 1 M51025AFF-48 APRON FEEDER ASSEMBLY
18 1 M51025FF-01 FEEDER FRAME WELDMENT
19 1 M51025FF-02 APRON DISCHARGE GRATE WELD.
20 1 M51025FH-01 FEED HOPPER WELDMENT
21 1 M51025FH-02L HOPPER EXTENSION SIDE WELDMENT(LEFT)
22 1 M51025FH-02R HOPPER EXTENSION SIDE WELDMENT(RIGHT)
23 1 M51025FH-03 EXTENSION, REAR HOPPER WELDMENT
24 2 M51025FR-01 APRON CHAIN SUPPORT
25 1 M51025GR APRON FEEDER GUARD ASSEMBLY
26 1 M51025GR-11 APRON FEEDER GUARD WELD. #11
27 1 M51125BP-01 UPPER BELLY PAN WELDMENT #01
28 1 M51125BP-02 LOWER BELLY PAN WELDMENT #01
29 1 M51125BP-03 BELLY PAN WELDMENT #03

DIRECTFEED 2516T
APRON FEEDER
23
8 2
24 23
19 18 17 21 2
8
4
7
26 14
29 3 12
20 30
22 16
27 9 5
6
15
10
25
3
10
11 7
29
13 15
26 M51025AFF-48
27 20

DIRECTFEED 2516T
APRON FEEDER PARTS LIST

M51025AFF-48

1 1 C06635 APRON CONVEYOR
2 2 C06636 6T., DRIVE SPROCKET
3 2 C06637 SPROCKET, FLAME CUT 6 TOOTH
4 1 C06648 SQUEEZE TORQUE COUPLER
5 1 C07328 GEARBOX
6 1 C07329 MOTOR
7 2 C07337 BRG
8 2 C07414 BRG
9 8 H00011 BOLT
13 8 H00067 NUT
14 12 H00068 NUT
15 2 H00251 SPRING PINS
16 12 H00282 BOLT
19 8 H00470 NUT
20 2 H00575 ACME NUT
21 8 H00654 BOLT
22 1 M51025AFF-01 APRON FEEDER FRAME WELD.
23 2 M51025AFF-X01 KEYSTOCK
24 1 M51025SHFT-TG01 ROUND
26 2 M51025TU-01 TAKE UP WELDMENT
27 2 M51025TU-02 ALL THREAD WELDMENT
29 2 M51025TU-DM01 TUBE
30 1 M51125TA-PL01 PLATE

7
13

10
17
1
3
4
18 5
9
16
DIRECTFEED 2516T
72
1 11
16
6 2 5
19
15 4
15
20 3
6 5
20
APRON FEEDER GUARDS
4 17
3 14
11
1 4 3
8 12
1
20
3
1 4 6 M51025GR
DIRECTFEED
DIRECTFEED 2516T
APRON FEEDER GUARDS PARTS LIST

M51025GR

1 56 H00001 BOLT
5 24 H00066 NUT
6 16 H00379 BOLT
7 1 M51025GR-02 GUARD WELD. #2
8 1 M51025GR-03 GUARD WELD. #3
9 1 M51025GR-04 APRON GUARD WELDMENT #4
10 1 M51025GR-05 GUARD WELD. #5
11 1 M51025GR-06 APRON FEEDER GUARD WELD. #6R
12 1 M51025GR-07 GUARD WELD. #7
15 2 M51025GR-A BELTING
16 2 M51025GR-B BELTING
17 2 M51025GR-C BELTING
18 1 M51025GR-SH02 SHEET

DIRECTFEED 2516T
SCREEN BOX
18
14
13
8
6
5
23
1
9
12
7
17
3
15
19
20
16
12
2
8
11
M51000SB
10
2
22
4
9
23
21

DIRECTFEED 2516T
SCREEN BOX PARTS LIST
M51000SB

1 12 C05641 SPRINGS, COIL
2 8 H00005 BOLT
3 10 H00010 BOLT
4 8 H00011 BOLT
5 18 H00048 FLATWASHER
8 22 H00066 NUT
9 14 H00067 NUT
10 4 H00074 NYLOCK
11 4 H00075 NYLOCK
12 8 H00086 NUT
13 18 H00724 BOLT
14 1 M27800 SCREEN BOX ASSEMBLY
15 1 M51000FW-02 SCREEN BOX FRAME WELDMENT
16 2 M51000FW-08 CLAMP WELD. #8
17 2 M51000FW-09 CLAMP WELD. #9
18 1 M51500CWL-01 CATWALK WELD. (LEFT) #01
19 1 M51500CWL-02 CATWALK WELDMENT (LEFT) #02
20 1 M51500CWR-01 CATWALK WELD. (RIGHT) #01
21 1 M51500CWR-02 CATWALK WELDMENT (RIGHT) #02
22 2 M51500HR-01 CATWALK HANDRAIL WELD. #01
23 2 M51500HR-02 CATWALK HANDRAIL WELD. #02

DIRECTFEED 2516T
UNDER SCREEN FINES CONVEYOR
51
26 31
22
30 10
45
17 27 3
2
1 23
15 6 9
7
41
52
31
50
18
44 36 33
21
22 4
25 9
26 48 12
21 13
14 18
25
43
14 18 39 40
4
23 27
47 37 35
29
34
28 33
8 24
20 42
32 5
16 49
19 26
20 32
22 27 23
19
38 26 22
11 53 20
46
24
20 16 8 28 M51009-48

DIRECTFEED 2516T
UNDER SCREEN FINES CONVEYOR PARTS LIST

ITEM QTY PART NUMBER DESCRIPTION M51009-48
1 1 C00139-0296 BELTING
2 1 C00442 R25 TL RIGID MALE FLANGE
3 1 C00443 R25 TL RIGID FEMALE FLANGE
4 6 C00476 IDLER
5 2 C00527 RETURN
6 1 C01024 BSHG
7 1 C01031 BUSHING
8 2 C01350 BRG
9 2 C01352 BRG
10 1 C03698 MOTOR
11 1 C07102-51243P WING ASSY
12 1 C07103-51268P DRUM ASSY
13 4 H00001 BOLT
14 8 H00011 BOLT
15 4 H00012 BOLT
16 4 H00030 BOLT
25 16 H00066 NUT
26 44 H00067 NUT
27 8 H00068 NUT
28 8 H00069 NUT
29 8 H00381 BOLT
30 12 H00388 BOLT
31 28 H00401 BOLT
32 4 H00413 BOLT
35 4 H00470 NUT
36 4 H00577 BOLT
37 1 M12050-12XFL 12" TAKE UP
38 1 M12050-12XFR 12" TAKE UP
39 1 M51009-01 UNDER SCREEN CONVEYOR WELDMENT
40 1 M51009-BL RUBBER, BEVELED FLASHING
41 1 M51009-BR RUBBER, BEVELED FLASHING
42 1 M51009-D RUBBER
43 1 M51009-PL21L PLATE
44 1 M51009-PL21R PLATE
45 1 M51009-PL22 PLATE
46 1 M51009-PL23L PLATE
47 1 M51009-PL23R PLATE
48 2 M51009-PL24 PLATE
49 1 M51009-PL25 PLATE
50 1 M51009-SQ01 SQ. STOCK
51 1 M51009GR-01 FINES CONV. GUARD WELD.

DIRECTFEED 2516T
UNDER SCREEN FINES CONVEYOR TAKE-UPS
4
RIGHT
1 M12050-12XFR
2
LEFT
1 M12050-12XFL
1

DIRECTFEED 2516T
UNDER SCREEN FINES CONVEYOR TAKE-UPS PARTS LIST

M12050-12XFR
ITEM QTY PART NUMBER DESCRIPTION RIGHT

1 2 H00086 NUT
2 1 M12050-12-02A 12" TAKE UP INNER TUBE
3 1 M12050-12-03 12" TAKE UP ACME ROD ASSEMBLY
4 1 M12050-12JR-01 12" TAKE UP OUTER TUBE
M12050-12XFL
ITEM QTY PART NUMBER DESCRIPTION LEFT

1 2 H00086 NUT
2 1 M12050-12-02A 12" TAKE UP INNER TUBE
4 1 M12050-12JL-01 12" TAKE UP OUTER TUBE

DIRECTFEED 2516T
FINES SIDE CONVEYOR ASSEMBLY
1
10
8
2
9 5 7
M51007-30

DIRECTFEED 2516T
FINES SIDE CONVEYOR ASSEMBLY PARTS LIST

M51007-30

1 1 C00140-0546 BELTING
2 2 C07728 CYLINDER
3 2 H00098 HITCH PIN W/CLIP
4 2 H00339 COTTER PIN
5 2 M10200PN-13 ROUND
6 4 M10200PN-35 PIN #32
7 1 M51007TE FINES SIDE CONVEYOR TAIL END ASSEM.
8 2 M51008-04 SIDE CONVY SUPPORT TUBE, INNER
9 2 M51008-05 SIDE CONVY SUPPORT TUBE, OUTER
10 1 M51107HE FINES SIDE CONVEYOR HEAD END ASSEM.

9A
18 15 5
7
9 37
40 24 21 18 31

29 22 19
20 23 27 17
18 15
5 20 23
1 36
4
38 2 3 30
29 22 19
16 12 28
13
6 13 16
25
19 22 35
27 17
DIRECTFEED 2516T
26 16 39
14 10
82
18 21 24 8
22 19
25
34
28
25 28 13
FINES SIDE CONVEYOR
16 19 22 11
32
22 19
33
M51107HE
DIRECTFEED
DIRECTFEED 2516T
FINES SIDE CONVEYOR PARTS LIST

M51107HE

3 1 C01024 BSHG
4 1 C01028 BUSHING
5 2 C01350 BRG
6 1 C03698 MOTOR
7 1 C07103-32243P DRUM ASSY
8 2 C07334-30 RETURN
9 1 C07338-30 CLEANER
9A 1 C07338-30RB REPLACEMENT BLADE
10 5 C07412P IDLER
11 4 C07718 CYLINDER
12 1 H00009 BOLT
13 36 H00010 BOLT
14 4 H00012 BOLT
15 4 H00029 BOLT
22 45 H00067 NUT
23 8 H00068 NUT
24 4 H00069 NUT
26 4 H00402 BOLT
27 8 H00413 BOLT
28 4 M10200PN-43 ROUND
29 2 M12050-12XH 12" HEAVY DUTY TAKE UP
30 2 M51007-PL21 PLATE
31 1 M51007-PL23 PLATE
32 2 M51007HE-01 RETURN IDLER GUARD
33 1 M51107-01 SIDE CONVEYOR WELD.
36 1 M51107-PL20L PLATE
37 1 M51107-PL20R PLATE
38 1 M51107BRK-PL01 PLATE

DIRECTFEED 2516T
FINES SIDE CONVEYOR TAKE-UP
M12050-12XH-1
FINES SIDE CONVEYOR RETURN IDLER GUARD
2 3
5
3
2
1
4
4 1
4
1 4
7
6
3 2
3 2 1
M51007HE-01

DIRECTFEED 2516T
FINES SIDE CONVEYOR TAKE-UP PARTS LIST

N12050-12XH

1 2 H00086 NUT
3 1 M12050-12X-01 12" HEAVY DUTY TAKE UP OUTER TUBE
4 1 M12050-12XH-01 12" HEAVY DUTY TAKE UP INNER TUBE
FINES SIDE CONVEYOR RETURN IDLER GUARD PARTS LIST
M61007HE-01

3 4 H00065 NUT
4 4 H00380 BOLT
5 1 M51007HE-SH03L SHEET
6 1 M51007HE-SH03R SHEET
7 1 M51007HE-SH04 SHEET

DIRECTFEED 2516T
FINES SIDE CONVEYOR TAIL ASSEMBLY
14
7 5
7
3 5
11 9
15 11 9
11 9
12 10
11 9
5
6 8 7
4
M51007TE
13
5 7

DIRECTFEED 2516T
FINES SIDE CONVEYOR TAIL ASSEMBLY PARTS LIST

M51007TE

1 4 C00473 IDLER
2 2 C01346 BRG
3 1 C07100-32193P WING ASSY
4 1 C07334-30 RETURN
5 29 H00010 BOLT
6 4 H00021 BOLT
11 29 H00067 NUT
12 4 H00068 NUT
13 1 M51007BP BELT PLOW ASSEMBLEY
14 1 M51007HP FINES SIDE CONVEYOR HOPPER ASY

DIRECTFEED 2516T
FINES SIDE CONVEYOR SHOE HOPPER
8
6
4
2 4
4 6
4 1
19
26
6
10
8
4
6
18 8
8
13 4
2 6
4
16
22
25
24
10 4 6 8
11 4 6 8 21
3 12
5
9 4 8 15
7 20
17
23
14
4 6 8
M51007HP

DIRECTFEED 2516T
FINES SIDE CONVEYOR SHOE HOPPER PARTS LIST

M51007HP

1 2 H00001 BOLT
2 5 H00002 BOLT
3 1 H00010 BOLT
8 33 H00066 NUT
9 1 H00067 NUT
10 11 H00724 BOLT
11 5 H00725 BOLT
12 1 M51007-A RUBBER
13 1 M51007-B RUBBER
14 1 M51007-C RUBBER
15 1 M51007-D RUBBER
16 1 M51007-PL05 PLATE
17 1 M51007-PL12 PLATE
18 1 M51007-PL13 PLATE
19 1 M51007-PL17 PLATE
20 1 M51007-PL18 PLATE
21 1 M51007-PL29 PLATE
22 1 M51007HP-01 FINES SHOE HOPPER WELDMENT #01
26 1 M51007HP-GR01 FINES SIDE CONV. GUARD ASSEMBLY

DIRECTFEED 2516T
FINES SIDE CONVEYOR BELT PLOW
1 5
7
6
1 5
2
3
4
1 5
2
3
4
2
3
4
M51007BP

DIRECTFEED 2516T
FINES SIDE CONVEYOR BELT PLOW PARTS LIST

M51007BP

1 6 H00003 BOLT
4 6 H00066 NUT
5 6 H00731 FENDER WASHER
6 1 M51007BP-01 BELT PLOW WELD.
7 1 M51007BP-A RUBBER SKIRTBOARD

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR ASSEMBLY
11
4 9 10
6
M51008-30 7

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR ASSEMBLY PARTS LIST
M51008-30

1 1 C00151-0546C BELTING
2 1 C05989 CYLINDER
3 2 C07728 CYLINDER
4 2 H00098 HITCH PIN W/CLIP
6 4 M10200PN-13 ROUND
7 4 M10200PN-35 PIN #32
8 2 M51008-04 SIDE CONVY SUPPORT TUBE, INNER
9 2 M51008-05 SIDE CONVY SUPPORT TUBE, OUTER
10 1 M51008TE BOTTOM DECK SIDE CONVY, TAIL END
11 1 M51108HE BOTTOM DECK SIDE CONVY, HEAD END

32 21 18
15 25
2
6
1
17 14 3
11 15
4
37
7 21 18
33 23 20

30
28 21 18
5 26 16
19 22
17 14
19 22
20 23
29
5 21 18
12
28 24
12 15
36 27
DIRECTFEED 2516T
94
16 26
8 13 9
35 24
12
27
15 18 21
BOTTOM DECK SIDE CONVEYOR
31
10
21 18
34
M51108HE-a
DIRECTFEED
DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR PARTS LIST
M51108HE

3 1 C01012 BUSHING
4 1 C01028 BUSHING
5 2 C01350 BRG
6 1 C03881 MOTOR
7 1 C07103-32243P DRUM ASSY
8 2 C07334-30 RETURN-B4-CIRRDW-30SB
9 5 C07412P IDLER
10 4 C07718 CYLINDER
11 1 H00009 BOLT
12 35 H00010 BOLT
13 4 H00012 BOLT
14 4 H00028 BOLT
21 44 H00067 NUT
22 8 H00068 NUT
23 4 H00069 NUT
25 4 H00402 BOLT
26 8 H00413 BOLT
27 4 M10200PN-43 ROUND
28 2 M12050-12XH 12" HEAVY DUTY TAKE UP
29 2 M51007-PL21 PLATE
30 1 M51007-PL23 PLATE
31 2 M51007HE-01 RETURN IDLER GUARD
33 1 M51107SHFT-T ROUND

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR TAKE-UP
M12050-12XH-1
BOTTOM DECK SIDE CONVEYOR RETURN IDLER GUARD
2 3
5
3
2
1
4
4 1
4
1 4
7
6
3 2
3 2 1
M51007HE-01

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR TAKE-UP PARTS LIST
N12050-12XH

1 2 H00086 NUT
3 1 M12050-12X-01 12" HEAVY DUTY TAKE UP OUTER TUBE
4 1 M12050-12XH-01 12" HEAVY DUTY TAKE UP INNER TUBE
BOTTOM DECK SIDE CONVEYOR RETURN IDLER GUARD PARTS LIST

M61007HE-01

3 4 H00065 NUT
4 4 H00380 BOLT
5 1 M51007HE-SH03L SHEET
6 1 M51007HE-SH03R SHEET
7 1 M51007HE-SH04 SHEET

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR TAIL ASSEMBLY
15
7 5
11 9
1
5 7
16
13
2
6
8 11 9
12
10
11 5 7 5
9 7
14
4
9 11
M51008TE

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR TAIL ASSEMBLY PARTS LIST

M51008TE

1 4 C00473 IDLER
2 2 C01346 BRG
3 1 C07100-32193P WING ASSY
4 1 C07334-30 RETURN
5 30 H00010 BOLT
6 4 H00021 BOLT
11 30 H00067 NUT
12 4 H00068 NUT
13 1 M51008-06 BOTTOM DECK SIDE CONVY. WELDMENT
14 1 M51008BP BELT PLOW
15 1 M51008HP BOTTOM DECK SIDE CONVY. ASSEMBLY

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR HOPPER
5 4 3
6
12
8
1 3
2 3
M51008HP
2 3
5 4 3
8
6
10
10
5 4 3
3 4 5
5
3
4
3 2
7
9
1 3
11

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR HOPPER PARTS LIST

M51008HP

1 4 H00003 BOLT
2 11 H00004 BOLT
5 15 H00066 NUT
6 2 M51008-B RUBBER
7 1 M51008-D RUBBER
8 2 M51008-PL47 PLATE
9 1 M51008-PL54 PLATE
10 1 M51008-PL57 PLATE
11 1 M51008HP-01 BOTTOM DECK SIDE CONVY. ASSEMBLY
12 1 M51008HP-02 BOTTOM DECK HOPPER SIDE WELDMENT

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR BELT PLOW
1
5
6
1
5
1
5
2
3
4 2
3
4
M51008BP
2
3
4

DIRECTFEED 2516T
BOTTOM DECK SIDE CONVEYOR BELT PLOW PARTS LISTCum ala que
M51008BP

1 6 H00003 BOLT
4 6 H00066 NUT
5 6 H00731 FENDER WASHER
6 1 M51008BP-01 BELT PLOW WELDMENT
7 1 M51008BP-A RUBBER SKIRTBOARD

Curbside
DIRECTFEED 2516T
OVERSIZE CONVEYOR
41
17 20 24 39
14 40
1
21
18 39
47
18
47
31 32 33
43
5
10 14 21
46
45
5
13
20
18
2
29 14
31
25
14
44 21
14 36 8
4
28 6
14 21 25 16 3
18 30 7
25 12 14 31 42
21 30 34 18
11 31
35 31 27 32 33
23
25 19
14 37 6
21 7 33 32 31
18 4
28 3
8
9 15
38
M51111-48P 22 26

DIRECTFEED 2516T
OVERSIZE CONVEYOR PARTS LIST
M51111-48P

1 1 C00170-0340C BELTING
2 12 C00703 IDLER
3 2 C01190 TAPER LOCK BSHG
4 2 C01205 TAPER LOCK BSHG
5 2 C01353 BRG
6 2 C01355 BRG
7 2 C05175 RIGID COUPLING
8 2 C05176 RIGID COUPLING
9 2 C06185 MOTOR
10 1 C07102-51293P WING ASSY
11 1 C07103-51343P DRUM ASSY
12 1 C07333-48 RETURN
13 14 H00003 BOLT
14 82 H00010 BOLT
15 8 H00021 BOLT
16 8 H00026 BOLT
24 3 H00066 NUT
25 56 H00067 NUT
26 8 H00068 NUT
27 8 H00069 NUT
28 2 H00075 NYLOCK
29 4 H00434 BOLT
30 4 H00445 BOLT
33 8 H00470 NUT
34 2 M12050-12XE 12" HEAVY DUTY TAKE UP
35 1 M51011-04 4 8'' RETURN GUARD
36 1 M51011BRK-PL01L PLATE
37 1 M51011BRK-PL01R PLATE
39 1 M51011HP-01 OVER SCREEN CONY. WELDMENT #03
40 1 M51011HP-C RUBBER
41 1 M51011HP-SH01 SHEET
44 1 M51111-01 DIRECT FEED WLEDMENT
45 1 M51111HP-01 FLASHING WELD.
46 1 M51111HP-02 FLASHING WELD.
47 2 M51111HP-PL08 PLATE

DIRECTFEED 2516T
OVERSIZE CONVEYOR TAKE-UP
M12050-12XE
OVERSIZE CONVEYOR RETURN IDLER GUARD
2 3 4 6
3 4
1
1
1
1
4 3 2
4
3
M51011-04

DIRECTFEED 2516T
OVERSIZE CONVEYOR TAKE-UP PARTS LIST
M12050-12XE

1 2 H00086 NUT
3 1 M12050-12XE-01 12" HEAVY DUTY TAKE UP
4 1 M12050-12XE-02 12" HEAVY DUTY TAKE UP INNER TUBE
OVERSIZE CONVEYOR RETURN IDLER GUARD PARTS LIST

M51011-04

1 4 H00001 BOLT
4 4 H00066 NUT
5 1 M51011-SH01L SHEET
6 1 M51011-SH01R SHEET
7 1 M51011-SH02 SHEET

DIRECTFEED 2516T
ENGINE ENCLOSURE
13 10
21
22
15 8
3
6
13 15 17
28
10
4
18 13 8 15
16 17
14 5 15
2
7 9
1
14
26 27
12
15 8
23
11
14 12
20
19
25
18 16 14
17 15 13 24
15 8 M51049EE

DIRECTFEED 2516T
ENGINE ENCLOSURE PARTS LIST
M51049EE

1 2 C03712 VALVE ASSY
2 2 C03713 VALVE ASSY
3 1 C03733 PUMP
4 3 C03736 VALVE
5 2 C05618 VALVE
6 1 C06187-T3 ENGINE
7 4 C07771 ENGINE ISOLATOR BLOCK
8 34 H00001 BOLT
9 4 H00002 BOLT
10 10 H00003 BOLT
11 4 H00010 BOLT
12 4 H00014 BOLT
17 14 H00066 NUT
18 4 H00067 NUT
19 4 H00075 NYLOCK
20 1 M51049-03 ENGINE ENCLOSURE LOUVER DOOR WELD.
21 1 M51049-A RUBBER SKIRTBROAD
22 1 M51049-PL09 PLATE
23 1 M51049DR-01 ENGINE ENCLOSURE DOOR WELD. #01
24 1 M51049DR-02 ENGINE ENCLOSURE DOOR WELD. #02
25 1 M51049EE-01 ENGINE ENCLOSURE WELDMENT
26 1 M51049GR-01 ENGINE ENCLOSURE GUARD WELD.
27 1 M51049LV-02 ENGINE ENCLOSURE LOUVER WELD. #02
28 1 M51080RM-01 RETURN MANIFOLD WELDMENT #01

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HYDRAULIC
SCHEMATIC

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DIRECTFEED 2516T

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Warranty

DIRECTFEED 2516T
STANDARD WARRANTY
Astec Mobile Screens, Inc. (hereinafter referred to as “AMS”) warrants its products to its authorized Distributor, as
specified herein, and Distributor agrees to extend this same warranty (and no other) to each purchaser of the products
of AMS at the time of sale and to notify each purchaser of the terms and conditions of this Warranty. Distributor is not
authorized by AMS to make any other, different, or additional warranty on behalf of AMS, and any such warranty given
by distributor is not binding on AMS. Distributor shall hold AMS harmless from any loss and/or costs (including attorney’s
fees) arising from failure to observe these conditions. AMS extends this same Warranty to those, in addition to its
authorized distributors, who buy the PRODUCTS of AMS directly rather than purchasing from an authorized Distributor.
AMS warrants, commencing with the date of receipt of the goods by first end-user and for a period of twelve (12)
months or two thousand (2000) hours, whichever comes first, all machinery and parts manufactured by AMS to be
free from defects in workmanship and material. If, within such warranty period, any machinery or parts shall be proved
to the satisfaction of AMS to be defective, it shall be replaced or, at the option of AMS, repaired at its factory, F.O.B.
AMS’ manufacturing plant in Sterling, Illinois at no charge (providing the defective machinery or parts are returned to
AMS’ manufacturing plant, IL freight prepaid). At its option, AMS may repair, or arrange to have repaired, any defective
machinery or parts, at the location of the Distributor, at the yard location or operating site of the first end-user, or at any
other suitable location at no charge to the first end-user and at no charge to Distributor other than those specified in its
Distributor Agreement. The right to have defective machinery or parts repaired or replaced shall constitute Distributor’s
and first end-user’s sole and exclusive remedy.
AMS may, at its sole discretion, refund the purchase price or defective machinery or parts in lieu of repairing or
replacing them, providing the defective machinery or parts are returned to AMS manufacturing plant, freight prepaid,
and providing such return is authorized by AMS. AMS may, at its sole discretion, waive the requirement that defective
machinery or parts be returned to its factory in connection with a warranty claim.
The obligation of AMS under the terms of this Warranty is limited to the described repair or replacement of defective
machinery or parts. Labor for warranty repair will be paid under a formula determined by AMS. With regard to machinery,
parts or accessories which are furnished by AMS, but not manufactured by it, the warranty obligation of AMS shall be
limited to and the same as that of its supplier. No warranty shall apply to any used machinery or parts. No warranty shall
apply to the products of AMS which, in its opinion, have been adversely affected by the use, on or with its products, of
parts, attachments, equipment, or lubricants not manufactured, sold or authorized by AMS.
No warranty shall apply to machinery, parts or accessories which have been furnished, repaired or altered by
others so as (in the opinion of AMS) to have affected the same adversely. No warranty shall apply to machinery, parts
or accessories which (in the opinion of AMS) have been subjected to accident, negligence, or improper operation,
installation, maintenance, storage, care or other-than-normal use during and after shipment.
AMS warrants that field services conducted by it in connection with installation or repair of machinery and parts will be
performed in a good workmanlike manner. The obligation and liability of AMS in connection with field services shall be
limited to a refund of the amount it charged for such services, if any.
Inasmuch as the work to be performed by the buyer or end-user with the machinery or parts furnished by AMS will vary
according to the materials used, local conditions, and the results required and that such variation will continue throughout
the use of such machinery or parts, it is not possible to (and AMS does not) warrant or represent that machinery and parts
furnished by it will handle specific materials or will produce specific results from such materials. Any application analysis
and resultant equipment performance expectations are provided as estimates only and are not to be construed in any
manner as a production guarantee.
AMS is wholly discharged of all liability under the foregoing warranties in the event that purchaser of the machinery or
parts fails to pay for the goods promptly and in accordance with the terms of the purchase agreement.
AMS’s liability hereunder is conditioned upon Distributor (or in the event of a direct sale to a first end-user, then first
end-user) giving notice in writing to AMS of any alleged defect, and such notice must be given immediately upon the
discovery of such alleged defect; such notice must be received by AMS not later than 30 days after the expiration of the
warranty period.
AMS does not warrant or represent that any machinery, parts, or accessories furnished by it meet any Federal, State,
or Local statutes, codes, ordinances, rules, standard or other regulations covering safety, pollution, noise, electrical wiring,
etc.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED (EXCEPT THE
WARRANTY OF TITLE) INCLUDING BUT NOT LIMITED TO ANY WARRANTY OR MERCHANTABILITY, AMS SHALL
NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABLITIES WHATSOEVER WITH RESPECT TO MACHINERY,
PARTS, ACCESSORIES, OR SERVICES MANUFACTURED OR FURNISHED BY IT OR ANY UNDERTAKINGS, ACTS
OR OMISSIONS OR OTHER DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER CAUSED. THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.

DIRECTFEED 2516T

DIRECTFEED 2516T

DIRECTFEED 2516T

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What are the main steps to set up the plant?

What are the main steps to set up the plant?

What are some important safety procedures outlined in the manual?

What are some important safety procedures outlined in the manual?

DIRECTFEED

Astec Mobile Screens DIRECTFEED 2516T

Astec Mobile Screens  DIRECTFEED 2516T

Astec Mobile Screens  DIRECTFEED

Astec Mobile Screens  DIRECTFEED 2516T

Contact Astec Mobile Screens

Astec Mobile Screens  DIRECTFEED

Astec Mobile Screens  DIRECTFEED 2516T

Astec Mobile Screens  DIRECTFEED

Astec Mobile Screens  DIRECTFEED 2516T

Astec Mobile Screens 10 DIRECTFEED

Astec Mobile Screens

Occupational Safety and Health Administration (OSHA)

American National Standards Institute (ANSI)

National Electrical Manufacturers Association (NEMA)

Mine Safety and Health Administration (MSHA)

Astec Mobile Screens 11 DIRECTFEED 2516T

Astec Mobile Screens 12 DIRECTFEED

Do not allow anyone to operate this equipment without proper instructions.

UNDERSTAND SIGNAL WORDS

Indicates a potentially hazardous situation which, if not

Indicates an immediately hazardous situation which, if not

NOTE: Indicates helpful information.

Astec Mobile Screens 13 DIRECTFEED 2516T

Why is controlling hazardous energy sources important?

How can you protect workers?

What do employees need to know?

What must employers do to protect employees?

Astec Mobile Screens 14 DIRECTFEED

How can you get more information?

Astec Mobile Screens 15 DIRECTFEED 2516T

FOLLOW SAFETY INSTRUCTIONS

Keep your machine in proper working condition. Unauthorized modifications to

REPLACE SAFETY SIGNS

PREVENT BYPASS STARTING

HANDLE FUEL SAFELY – AVOID FIRES!

Astec Mobile Screens 16 DIRECTFEED

SERVICE ENGINES SAFELY

HANDLE STARTING FLUID SAFELY

PROTECT AGAINST NOISE

Wear a suitable hearing protective device such as earmuffs or earplugs to protect

WEAR PROTECTIVE CLOTHING

INSTALL FAN GUARDS

Astec Mobile Screens 17 DIRECTFEED 2516T

PRACTICE SAFE MAINTENANCE.

■ Never lubricate, service, or adjust machine while it is moving.

On self-propelled equipment, disconnect battery ground cable (-) before making

AVOID HIGH PRESSURE FLUIDS

Avoid the hazard by relieving pressure before disconnecting hydraulic or other

Astec Mobile Screens 18 DIRECTFEED

WORK IN VENTILATED AREA

DISPOSE OF WASTE PROPERLY

AVOID HEATING NEAR PRESSURIZED FLUID LINES

DO NOT OPEN HIGH PRESSURE FUEL SYSTEM

Astec Mobile Screens 19 DIRECTFEED 2516T

Astec Mobile Screens DIRECTFEED 2516T

Astec Mobile Screens DIRECTFEED

Astec Mobile Screens DIRECTFEED 2516T

Astec Mobile Screens DIRECTFEED

Astec Mobile Screens DIRECTFEED 2516T

Astec Mobile Screens DIRECTFEED

Astec Mobile Screens DIRECTFEED 2516T