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ADVANCED CRUSHING TECHNOLOGY

MAXTRAK 1300

PLANT USER MANUAL OPERATION INSTALLATION PARTS MAINTENANCE AND SERVICE

! SAFETY ! This manual contains safety information which the operator should read and follow. Failure to do this will increase the risk of injury or may result in death. AX860-901-8EN-02f 1/396

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IMPORTANT TEREX PEGSON PLANTS CAN INCLUDE OPTIONAL EQUIPMENT AND/OR SPECIAL FEATURES ADDITIONAL TO THE STANDARD SPECIFICATION. THESE MAY AFFECT THE INFORMATION GIVEN IN THIS OPERATORS MANUAL. LOOK IN SECTION 11 - APPENDIX OF THIS MANUAL FOR ANY ADDENDUM WHICH MAY RELATE TO ADDITIONAL EQUIPMENT OR VARIATIONS TO THE STANDARD SPECIFICATION. TAKE NOTE OF ANY VARIATIONS TO THE STANDARD PROCEDURES AND/OR COMPONENT SPECIFICATIONS.

Options EN

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ADVANCED CRUSHING TECHNOLOGY IMPORTANT SAFETY NOTICE! The environment in which the plant will operate contains inherent risks to health and safety which the operator must take steps to guard against. Dangers from overhead conveyor discharges, overspill material, vehicle movements, etc., as well as other site related hazards must be anticipated. Avoid these by carrying out risk assessments before the plant is put into operation to ensure appropriate exclusion zone measures are put in place and site personnel safety awareness training has been undertaken. Follow all applicable safety regulations and recommendations in this manual as appropriate to your plant and the situation/conditions prevailing at the time. Read this manual carefully to learn how to operate and service your plant correctly. Failure to do so could result in personal injury or equipment damage. Consider this manual a permanent part of your plant. Keep it with the plant at all times. Federal, State, National and Local laws and safety regulations must be complied with at all times to prevent possible danger to person(s) or property from accidents or harmful exposure. See also the separate Operation and Maintenance Manual provided for the diesel engine fitted to your plant and in particular read and observe the instructions within the Safety Section of the engine manual.

INFORMATION AND ADVICE If you need any information or advice regarding your Maxtrak, contact:Terex Pegson Limited Mammoth Street Coalville Leicestershire LE67 3GN England Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : [email protected] or your local Distributor :-

Terex Crushing & Screening Inc. 11001 Electron Drive Louisville Kentucky 40299 U.S.A. Telephone : +1 502 267 2314, Fax : +1 502 267 2317 AX860-901-8EN-02f 5/396

ADVANCED CRUSHING TECHNOLOGY EC Conformity This plant is in conformity with the provisions of the EC Machinery Directive 98/37/EC together with appropriate EN Harmonised Standards and National BS Standards and Specifications.

Noise Level HEARING HAZARD EXCEEDS 90 dB (A) May cause loss or degradation of hearing over a period of time. Wear proper hearing personal protective equipment.

Dust Generation INHALATION HAZARD Death, serious injury or delayed lung disease may result from breathing dusts that are generated when certain hazardous materials are crushed, screened or conveyed with this equipment. When dusts are generated by the operation of this equipment, use approved respiratory protection, as required by Federal, State and Local safety and health regulations.

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ADVANCED CRUSHING TECHNOLOGY Units of Measure Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are approximate conversions from the actual metric measurement of the item concerned.

CALIFORNIA

CALIFORNIA

Proposition 65 Warning

Proposition 65 Warning

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.

WARNING: Diesel engine exhaust and some of it’s constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Copyright The copyright of this User Manual is reserved by BL-Pegson Limited. This User Manual contains information and technical drawings, which may not be copied, distributed, altered, stored on electronic media, revealed to others or used for the purpose of competition, either partially or in its entirety. The right is reserved to alter any details contained in this manual without notice. Copyright 2004. Terex Pegson Limited Mammoth Street Coalville Leicestershire LE67 3GN England Telephone:-

+ 44 1530 518600

Fax:-

+ 44 1530 518618

E mail

[email protected]

To order additional copies contact your local Terex Pegson Ltd Dealer.

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1 - Safety 1.1 Warnings and Symbols .................................................................................. 1 - 2 1.2 Organisation Measures .................................................................................. 1 - 2 1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4 1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 4 1.4.1 Standard Operation .................................................................................... 1 - 4 1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and Repairs During Operation; Disposal of Parts and Consumables ................ 1 - 4 1.5 Warning of Special Dangers .......................................................................... 1 - 8 1.5.1 Electric Energy ........................................................................................... 1 - 8 1.5.2 Gas, Dust, Steam, Smoke and Noise ......................................................... 1 - 8 1.5.3 Hydraulic and Pneumatic Equipment ........................................................ 1 - 10 1.5.4 Hazardous Substances ............................................................................ 1 - 10 1.6 Transporting, Manoeuvring and Recommissioning .................................. 1 - 10 1.7 Position of Emergency Stop Buttons ......................................................... 1 - 13 1.8 Safety Signs .................................................................................................. 1 - 14 1.8.1 Location of Safety Signs .......................................................................... 1 - 14 1.8.2 Safety Sign Illustrations............................................................................ 1 - 16 1.8.2 Safety Sign Illustrations, continued ........................................................... 1 - 16

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.1 Warnings and Symbols The following signs and designations are used in the manual to designate instructions of particular importance.

!! This is the safety alert symbol. When you see this symbol on your plant or in this manual, be alert to the potential for personal injury or equipment damage. Follow the recommended precautions and safe operating practices.

! DANGER ! Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

! WARNING ! Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

! CAUTION ! Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe working practices.

! NOTICE ! Indicates a statement of company policy as the message relates directly or indirectly to the safety of personnel and protection of property.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.2 Organisation Measures

1.2.2

1.2.1

You can be injured if you do not obey the safety instructions as indicated on warning stickers.

Ascertain from the appropriate Authority and observe all statutory and any other regulations that may apply to the planned location before operating the Maxtrak Plant. Loose or baggy clothing can get caught in running machinery. Where possible when working close to engines or machinery, only do so when they are stopped. If this is not practical, remember to keep tools, test equipment and all other parts of your body well away from the moving parts. For reasons of safety, long hair must be tied back or otherwise secured, garments must be close fitting and no jewellery such as rings may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts. Always wear correctly fitting (EN/ANSI approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close fitting Overalls, Steel Toed Boots, Industrial Gloves and a High Visibility Vest.

Observe all safety instructions and warnings attached to the plant. See to it that safety instructions and warnings attached to the plant are always complete and perfectly legible. Keep warnings and instruction labels clean. Replace unreadable or missing labels with new ones before operating the plant. Make sure replacement parts include warning or instruction labels where necessary.

1.2.3 Understand service procedure before doing work. Keep area clean and dry. Never lubricate, clean, service or adjust machinery while it is moving. Keep hands, feet and clothing clear of power driven parts and in running nip-points. Disengage all power and operate controls to relieve pressure. Stop the engine. Implement lockout procedure. Allow the machinery to cool. Keep all parts in good condition. Ensure that all parts are properly installed. Fix damage immediately. Replace worn and broken parts. Remove any build up of grease, oil and debris.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Disconnect battery ground cable before making adjustments on electrical systems or welding on plant.

1.3 Selection and Qualification of Personnel Basic Responsibilities

For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable.

1.3.1

1.2.4 Never make any modifications, additions or conversions which might affect safety without the supplier’s approval. In the event of safety relevant modifications or changes in the behaviour of the plant during operation, stop the plant and lock out immediately and report the malfunction to the competent authority/person.

Any work on and/or with the plant must be executed by trained, reliable and authorised personnel only. Statutory minimum age limits must be observed.

1.3.2 Work on electrical system and equipment of the plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

1.3.3 Work on the hydraulic system must be carried out only by personnel with special knowledge and experience of hydraulic equipment.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.4.1.4

1.4 Safety Instructions Governing Specific Operational Phases

Return idler roller guards should be checked for wear/damage during routine maintenance.

1.4.1 Standard Operation 1.4.1.1 Take the necessary precautions to ensure that the plant is used only when in a safe and reliable state. Operate the plant only for it’s designed purpose and only if all guarding, protective and safety orientated devices, emergency shut-off equipment, sound proofing elements and exhausts, are in all place and fully functional. Before starting the engine ensure it is safe to do so.

1.4.1.2

The gap between the guard and the idler roller should not exceed 6mm. The gap between the guard and the conveyor belt should also not exceed 6mm. If these gaps cannot be achieved through adjustment the guard must be renewed. Contact your local BL-Pegson dealer to obtain an approved replacement.

1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and Repairs During Operation; Disposal of Parts and Consumables 1.4.2.1

In the event of material blockage, any malfunction or operational difficulty, stop the plant immediately and lockout. Have any defects rectified immediately.

Observe the adjusting, maintenance and intervals set out in these operating instructions, except where:

1.4.1.3

A : Warning, horn/light/gauge or indicator calls for immediate action.

In-running nip points on moving machinery can cause serious injury or even death. Do not reach into unguarded machinery. Your arm could be pulled in and amputated. Switch off and lockout the plant before removing any safety devices or guarding.

B : Adverse conditions necessitate more frequent servicing. Observe information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.4.2.2

1.4.2.5

When the plant is completely shutdown for maintenance and repair work, it must be secured against inadvertent starting by:

Falling from and/or onto a BL-Pegson plant can cause injury or even death.

•

Switching off the engine and remove the ignition switch/key.

•

Implementing the lockout procedure.

•

Attaching a warning sign(s) to the plant in appropriate positions.

1.4.2.3 Carry out maintenance and repair work only if the plant is positioned on stable and level ground and has been secured against inadvertent movement and buckling.

1.4.2.4 Never allow unqualified or untrained personnel to attempt to remove or replace any part of the plant, or anyone to remove large or heavy components without adequate lifting tackle. To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured. Use only suitable and technically adequate lifting gear. Never work or stand under suspended loads.

Do not climb on the plant whilst it is in operation. Never use plant parts as a climbing aid. Beware of moving haulage and loading equipment in the vicinity of the plant. For carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms. Always use any walkway/platforms provided or a safe and secure platform approved by the regional safety enforcing authority. Always use an EN/ANSI approved safety harness when reaching any points 7ft (2m) or more above the ground level. Keep all handles, steps, handrails, platforms, landing and ladders free from dirt, oil, snow and ice.

1.4.2.6 The fastening of loads and instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of the operator.

Keep away from the feed hopper and product conveyor discharge, where there is risk of serious injury or death due to the loading and removal of material.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.4.2.7

1.4.2.10

After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any defects found must be rectified without delay.

Always ensure that any safety fitment such as locking wedges, securing chains, bars or struts are utilised as indicated in these operating instructions.

1.4.2.8 Any safety devices removed for setup, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work to ensure full working order.

Particularly make sure that any part of the plant raised for any reason is prevented from falling by securing in a safe reliable manner. Never work under unsupported equipment. Never work alone.

1.4.2.11

1.4.2.9 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with BL-Pegson equipment includes such items as oil, fuel, coolant, filters and batteries, etc. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain or into any water source. Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

Diesel fuel is highly flammable. Never remove the filler cap, or refuel, with the engine running. Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion risks. Do not carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment or whilst smoking.

1.4.2.12 Using unapproved structures i.e. walkways/ platforms etc. in the vicinity of a BL-Pegson plant is very dangerous and could lead to serious injury or even death through falling and/or entanglement with the plant. Do not use any unauthorised structures.

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1.5.1.4

1.5 Warning of Special Dangers 1.5.1 Electric Energy 1.5.1.1 Use only original fuses with the specified current rating. Switch off the plant immediately if trouble occurs in the electrical system. Plants with high voltage electrical equipment must be suitably earth bonded by a qualified electrician prior to activating the main isolator switch.

1.5.1.2 When working with the plant, maintain a safe distance from overhead electric lines. If work is to be carried out close to overhead lines, the working equipment must be kept well away from them. Check out the prescribed safety distances.

1.5.1.3 If your plant comes into contact with a live wire: •

Warn others against approaching and touching the plant.

•

Have the live wire de-energized.

Work on the electrical system or equipment may only be carried out by a skilled and qualified electrician or by specially instructed personnel under the control and supervision of such an electrician and in accordance with applicable electrical engineering rules.

1.5.1.5 If provided for in the regulations, the power supply to parts of plants and plants, on which inspection, maintenance and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements.

1.5.1.6 The electrical equipment of the plant is to be inspected and checked at regular intervals. Defects such as loose connections or scorched or otherwise damaged cables must be rectified immediately.

1.5.1.7 Necessary work on live parts and elements must be carried out only in the presence of a second person, who can cut off the power supply in the case of danger by actuating the emergency shut off or main power switch. Secure the working area with a red and white safety chain and a warning sign. Use insulated tools only.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.5.1.8 Before starting work on high voltage assemblies and after cutting out the power supply, the feeder cable must be grounded and components such as capacitors shortcircuited with a grounding rod.

1.5.1.9 These plants are wired on negative earth. Always observe correct polarity. Always disconnect battery leads before carrying out any maintenance to the electrical system. The battery contains sulphuric acid, an electrolyte which can cause severe burns and produce explosive gases.

1.5.2 Gas, Dust, Steam, Smoke and Noise 1.5.2.1 Always operate internal combustion engines and fuel operated heating systems only out of doors or in a well ventilated area. Before starting the plant in enclosed areas, make sure that there is sufficient ventilation. Observe the regulations in force at the respective site. Dust found on the plant or produced during work on the plant should be removed by extraction, not blowing. Dust waste should be dampened, placed in a sealed container and marked, to ensure safe disposal.

Avoid contact with the skin, eyes or clothing.

1.5.2.2 Carry out welding, flame cutting and grinding work on the plant only if this has been expressly authorised, as there may be a risk of explosion and fire.

1.5.2.3 Before carrying out welding, flame cutting and grinding operations, clean the plant and its surroundings from dust and other inflammable substances and make sure the premises are adequately ventilated (as there may be a risk of explosion).

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.5.2.4 Always ensure that the operator(s) are provided with hearing protection of approved pattern and that these are worn at all times when the plant is operating. Ensure operators wear a suitable face mask where exposed to possible harmful effects of air pollution of any kind.

1.5.3 Hydraulic and Pneumatic Equipment 1.5.3.1 Work on hydraulic equipment may be carried out only by persons having special knowledge and experience in hydraulic systems.

1.5.3.2 Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed oil may cause injury and fire.

1.5.3.3 Depressurise all system sections and pressure pipes (hydraulic system, compressed air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work.

1.5.3.4 Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

1.5.3.5 Always practice extreme cleanliness servicing hydraulic components.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.5.3.6 Hydraulic fluid under pressure can penetrate the skin causing serious injury. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately. Always relieve pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. Always use a piece of cardboard to check for leaks. Do not use your hand.

1.5.4 Hazardous Substances

1.6 Transporting, Manoeuvring and Recommissioning 1.6.1 The plant must be towed, loaded and transported only in accordance with the operating instructions.

1.6.2 For towing the plant, observe the prescribed transport position, admissible speed and itinerary.

1.6.3

Ensure that correct procedures are formulated to safely handle hazardous materials by correct identification, labelling, storage, use and disposal, all strictly in accordance with the manufacturers instructions and that all applicable regulations are observed at all times.

Use only appropriate means of transport and lifting gear where applicable of adequate capacity.

1.6.4 The recommissioning procedure must be strictly in accordance with the operating instructions.

1.6.5 Before starting work or travelling with the plant, check that the braking, and any signalling and lighting systems are fully functional.

1.6.6 Before setting the plant in motion always check that the accessories have been safely stowed away.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.6.7

1.6.12

When travelling on public roads, ways and places, always observe the valid traffic regulations and, if necessary, ensure beforehand that the plant is in a condition compatible with these regulations.

Explosive separation of a tyre and rim parts can cause injury or death. Do not attempt to mount a tyre unless you have the proper equipment to perform the job.

1.6.8 In conditions of poor visibility and after dark, always switch on the lighting system of the transporting vehicle..

1.6.9 When crossing underpasses, bridges and tunnels or when passing under overhead lines always make sure that there is sufficient clearance.

1.6.10 Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

Always maintain the correct pressure. Do not inflate the tyre above the recommended pressure. Never weld or heat wheel and tyre assembly. The heat can cause an increase in air pressure resulting in a tyre explosion. Welding can structurally weaken or deform the wheel. When inflating tyres, use a clip-on chuck and extension hose long enough to allow you to stand to one side and not in front or over the assembly. Use safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

1.6.11 On sloping terrain, always adapt your travelling speed to the relevant ground conditions. Never change to a lower gear on a slope. Always change gear before reaching a slope.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.7 Position of Emergency Stop Buttons

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button (Control Panel)

Emergency Stop Button

Figure 1a Emergency Stop Buttons

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1.8 Safety Signs 1.8.1 Location of Safety Signs

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Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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1.8.2 Safety Sign Illustrations

1

2

3

6

7

8

9

10

13

14

15

17

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1.8.2 Safety Sign Illustrations, continued

21

19

27

23

11

20

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Blank page

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2 - Technical Information 2.1 Dimensions and Weights ............................................................................... 2 - 2 2.2 Plant Description ............................................................................................ 2 - 3 2.3 Belt Feeder Conveyor .................................................................................... 2 - 4 2.4 Crusher ........................................................................................................... 2 - 4 2.5 Discharge Conveyor ...................................................................................... 2 - 4 2.6 Standard Powerpack ...................................................................................... 2 - 5 2.7 Controls ........................................................................................................... 2 - 5 2.8 Dustsprays ...................................................................................................... 2 - 5 2.9 Tracks .............................................................................................................. 2 - 5 2.10 Optional Extras * ........................................................................................... 2 - 6

Terex Pegson Limited have designed and built the Maxtrak plant to provide the Buyer with a range of equipment choices to meet a wide variety of individual needs and preferences as selected at the time of initial purchase.

Please note that the asterisk

*

in the text of this User Manual signifies:

Not included in all plants - only appropriate if the item is fitted.

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**

4546 Working

All dimensions are in millimetres (feet/inches)

3782 (12’- 5”)

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3000 (9’- 11”)

2 - Technical Information

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618 Figure 2a Dimensions and Weights

Note: Weights and dimensions are for guidance only and appropriate allowances should be applied when being used for transportation purposes and do not include option feed hopper extension plates.

3197 Feed Height (10’- 6”)

Gross Weight approx. - 45.8 tonne (50.4 US. tons)

(12’- 6”) 3810 Travel Height

the maximum extent when preparing for transportation - Refer to Section 5.2.5

(9’- 2”)

2788 Hopper Width

2.1 Dimensions and Weights

This dimension can only be achieved by lowering the Automax Upper Frame to

(12’- 6”) Overall Travelling Height (Feed Conveyor lowered) - 3810 Overall Working Height (Feed Conveyor raised) - 4830 (15’- 10”) Overall Width - Travelling & Working (Over Tracks) - 3000 (9’-10”)

7669 (25’- 2”)

(11’- 2”)

**

Overall Travelling Length (Feed Conveyor lowered) - 15866 (52’- 1”) Overall Working Length (Feed Conveyor raised) - 15997 (52’- 6”)

(14’- 11”)

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4830 Working Height (15’- 10”)

3407 Disch. Height

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2.2 Plant Description Many of the terms used in this manual may not at first be obvious. Figure 2b identifies the main areas of the plant and the term with which they are referred to in this manual. Discharge Conveyor

Diesel Engine

Crusher Feed Box

Maintenance Platform

Feed Hopper

FRONT

REAR

LEFT HAND SIDE Plant/Automax Control Panel

Maintenance Platform

Automax Crusher

Hydraulic Reservoir

Feeder Conveyor

FRONT

REAR Tracks

RIGHT HAND SIDE Maintenance Platform

Hydraulic Oil Cooler

Tool Box

Figure 2b Plant Terms

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2.3 Belt Feeder Conveyor Type Width Length Drive Unit Lubrication Control Hopper

Shallow troughed plain belt. 1300mm (51”). 5400mm. (17’- 9”) Hydraulic motor with head drum gearbox Oil for drum gearbox and grease for shaft bearings Auto/manual variable speed. Fixed hopper with internal ‘strickle’ gate and full length barge boards with wear pads. Ram to raise and lower for travel and maintenance. Metal detector. Level sensor an optional extra.

Hydraulic Equipment Control Equipment

2.4 Crusher Type Size Liners Adjustment/Controls

Automax roller bearing Cone Crusher. 1300mm. (51”) Manganese mantle and concave. Hydraulic setting adjustment, automatic overload release and unblocking with multi-function keypad and status display screen. (see also 2.7 - Controls). Separate lubricating oil tank with air blast oil cooler. Vee rope drive from engine via hydraulically controlled clutch. High level sensor over the feed box.

Lubrication Drive Control Equipment

2.5 Discharge Conveyor Type Width Drive Lubrication Enclosure Control equipment

Plain troughed belt. 1000mm. (39”) Hydraulic motor. Grease (shaft bearings). Canvas cover. Tail drum movement sensor.

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2.6 Standard Powerpack Type Rating Drives Housing

Caterpillar C12 EPA/CARB Emmissions Regulations compliant, 6 cyl. water cooled diesel engine. 425hp @ 1800 rpm. Hydraulically actuated heavy duty clutch and vee ropes to crusher with vee belts to twin hydraulic pumps. Enclosed canopy with integral fuel tank and battery.

2.7 Controls Automax Crusher Setting, etc. Plant Operation

Plant Set-Up

24 v DC Electro/Hydraulic Panel having numeric keypad and message display on plant chassis. 24 v DC Electric Panel in Control Box with push button controls and fault display, level sensor and metal detector controls. Lever on the plant chassis to raise/lower the feeder conveyor.

2.8 Dustsprays Type Positions Inlet Required supply Frost protection

Clean water multi atomising nozzle spraybars. Crusher feed & discharge and discharge conveyor head. Single point for user’s pressure supply. Up to approx. 7 litres/min (2 US galls) @ 2.8 bar / 42 psi. System drain valves.

2.9 Tracks Type Width Centres Drive Control

190mm (7.5”) pitch heavy duty. 500mm. (20”) 3782mm.(12’- 5”) 2 x Integral Hydraulic motors. Remote handset - dual speed.

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2.10 Optional Extras

*

I)

Autosand (AS) concave in lieu of the standard Medium Coarse (MC).

II)

Belt Weigher with integrator and speed sensing wheel fitted to the discharge conveyor.

III) Hydraulically driven water pump assembly to provide pressurised water supply to the dust suppression sprays. IV)

Low level sensor over feed hopper.

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3 - General Information 3.1 Introduction ..................................................................................................... 3 - 2 3.2 General information ........................................................................................ 3 - 3 3.3 Designated Use .............................................................................................. 3 - 4 3.3.1 Operating Temperature Range ................................................................... 3 - 4 3.4 Crusher Performance ..................................................................................... 3 - 5 3.4.1 Estimated Performance - Automax ............................................................. 3 - 6 3.4.2 Typical Product Analysis - Automax............................................................. 3 - 7 3.4.3 Estimated Performance - Autosand ............................................................ 3 - 8 3.4.4 Typical Product Analysis - Autosand ........................................................... 3 - 9

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3.1 Introduction This instruction manual contains important information on how to operate the Maxtrak 1300 plant safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the plant. These operating instructions must always be available wherever the plant is in use. These operating instructions must be read and applied by any person in charge of and/ or working on the plant such as:Operation Includes manoeuvring, setting up, operation during the course of work, evacuation of production material and waste, care and disposal of fuels and consumables, etc. Maintenance Servicing, inspection and replacement of wearing parts. and/or Transport Follow all applicable laws and safety regulations for accident prevention and environmental protection.

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3.2 General information

! NOTICE !

The Maxtrak 1300 plant has been manufactured, assembled and tested with the utmost care and was built with first class materials. Close attention has been paid to all details in assembly, running tests and final inspection. Terex Pegson is confident that the plant will give every satisfaction over a long period. To be assured of faultless operation the operator should carefully read the following paragraphs and give the required time and attention to essential maintenance, cleaning and inspection.

If high or low ambient temperature conditions apply, specific details need to have been advised at the time of order as special equipment may be necessary. The Caterpillar engine cooling system is protected to -15º C (+ 5º F) with 30% Caterpillar antifreeze concentration when shipped from the factory unless special requirements have been defined.

The plant is easy to operate, adjustments are easy to make and expert assistance is seldom required, provided that ordinary care is exercised in daily use. The plant has been built in accordance with state-of-the-art standards and recognised safety rules. It is designed to be reliable, efficient and safe when used and maintained in accordance with the instructions given in this manual. Nevertheless, it’s use may constitute a risk to life and limb of the user or of third parties, or cause damage to the plant and to other material property.

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3.3 Designated Use The BL-Pegson Maxtrak plant includes the 1300 Automax Cone Crusher designed to maximise throughput and product shape in a wide range of crushing applications. For finer crushing operations the Autosand option is available.

! NOTICE ! It is vitally important that pieces of steel or similar uncrushable objects such as bucket teeth are not allowed to enter the crushing chamber as severe damage and injury may occur. For the above reason a metal detector is fitted to the feeder conveyor. It is imperative that this metal detector is kept operative at all times and that when activated the plant operator removes the offending material before recommencing operation.

Refer to the following information in this Section for guidance regarding the performance of the Automax crusher. Experienced engineers are available at BLPegson to give advice when necessary. If you have any doubts about any aspect of the plant’s capability of servicing procedures, you must consult your local BL-Pegson dealer or Terex Pegson’s technical departments.

3.3.1 Operating Temperature Range The normal operating temperature range of the plant is from -10°C to +40°C (+14°F to +104°F). For use in temperatures outside of this range, contact your local dealer or BLPegson for details. Note: Appropriate oil & coolant to suit the local operating conditions must be used, as specified elsewhere in this manual.

! WARNING ! Operating the plant outside it’s recommended range of applications/operating parameters or for any use for which the equipment is not intended, will result in a loss of any guarantee and the manufacturer/supplier cannot be held liable for any damage or injury resulting from such misuse. The risk of such misuse lies entirely with the user.

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3.4 Crusher Performance In order to obtain the optimum overall crushing performance from the Automax, it is essential to have a continuous and regulated ‘choke’ feed of evenly graded material that is well mixed around the crushing chamber. Typical feed gradings are shown on the product analysis graphs in this section. The level sensing device prior to the crusher will assist in achieving this when used to control the feed. Additionally, all feed material should be of a size that will readily enter the crushing chamber. The gradings and capacities shown in this section are averages base on actual results taken from tests carried out on various materials at different crusher settings. They will vary dependant upon the grading and nature of the feed material. For more specific details please contact Terex Pegson Ltd. Actual performance is dependant upon the particular conditions prevailing at the time such as the nature of the feed material, the control of the Automax feed and the crusher setting, etc.

Performance will be adversely affected if an excessive percentage of fines in the feed causes the packing/caking of material, either to slow the flow of material or cause congealed lumps in the product. Persistent ‘dumping’ (see Glossary) is most undesirable and likely to be caused by operating the machine at too close a setting. Increase the ‘Gap’ setting to avoid damage to the machine. Crusher settings shown in the tabulation are for general guidance only and crusher performance will vary depending upon the conditions prevailing. Capacities shown are for open circuit applications. When operation is required towards the lower end of the setting range. BL-Pegson Ltd should be consulted to verify the application. The power required and product gradings will vary with the feed and product size, capacity and rock characteristics. Usage of wearing parts will depend upon individual crushing conditions and the variable factors which govern wear.

The capacities given are approximate only and based on crushing clean, dry, well graded quarried hard limestone, weighing loose about 1600 kg/f/m3 (100 lbs/cu.ft.) and having a specific gravity of 2.6 - 2.8. Wet sticky feeds will reduce crusher capacities.

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3.4.1 Estimated Performance - Automax

Type of Concave (AUTOMAX)

Maximum Feed Size

Minimum Recommended Setting

STANDARD

220 mm (81/2")

22 mm (7/8")

Figure 3a Maximum Feed Size and Minimum Recommended Settings

Closed Side Setting

Typical Plant Output

mm

inches

M. tph

US. tph

22

7/8"

220-255

240-280

25

1"

235-275

260-300

28

1 /8"

1

250-295

275-325

32

1 /4"

1

260-350

285-390

Figure 3b Estimated Plant Outputs

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PERCENTAGE PASSING

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Figure 3c Typical Product Analysis Curves - Automax

SCREEN MESH SIZE - MM

SCREEN MESH SIZE - INCHES

3.4.2 Typical Product Analysis - Automax

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3.4.3 Estimated Performance - Autosand

Type of Concave (AUTOSAND)

Maximum Feed Size

Minimum Recommended Setting

STANDARD

63 mm (21/2")

13 mm ( /2")

1

Figure 3d Maximum Feed Size and Minimum Recommended Settings

Closed Side Setting

Typical Plant Output

mm

inches

M. tph

US. tph

13

1/2"

165-185

180-200

16

5/8”

180-200

200-220

19

3/4"

195-220

215-240

22

7/8"

210-240

230-260

Figure 3e Estimated Plant Outputs

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PERCENTAGE PASSING

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Figure 3f Typical Product Analysis Curves - Autosand

SCREEN MESH SIZE - MM

SCREEN MESH SIZE - INCHES

3.4.4 Typical Product Analysis - Autosand

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4 - Design and Function 4.1 General Information ........................................................................................ 4 - 2 4.2 Construction Units ......................................................................................... 4 - 3 4.2.1 Automax Crusher ........................................................................................ 4 - 3 4.2.2 Feed Hopper ............................................................................................. 4 - 3 4.2.3 Feed Conveyor .......................................................................................... 4 - 3 4.2.4 Discharge Conveyor .................................................................................. 4 - 3 4.2.5 Chutes ....................................................................................................... 4 - 4 4.2.6 Platforms ................................................................................................... 4 - 4 4.2.7 Power Unit ................................................................................................. 4 - 4 4.2.8 Controls ..................................................................................................... 4 - 4 4.2.9 Chassis ..................................................................................................... 4 - 4 4.2.10 Track Frame............................................................................................. 4 - 5 4.2.11 Guards ..................................................................................................... 4 - 5 4.2.12 Painting ................................................................................................... 4 - 5 4.2.13 Dust Suppression Sprays ......................................................................... 4 - 5 4.2.14 Optional Extras ........................................................................................ 4 - 5 4.2.15 Authorisation for use ................................................................................. 4 - 6 4.2.16 Site Preparation ....................................................................................... 4 - 6 4.2.17 Commissioning ........................................................................................ 4 - 6 4.2.18 Specifications .......................................................................................... 4 - 6

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4.1 General Information The Terex Pegson Maxtrak 1300 Plant has been designed to maximise throughput and product shape in a wide range of quarrying applications, its features include:•

Suitable for aggregate, rail ballast, road-base production or secondary, tertiary and quaternary applications.

•

Unique design giving excellent product shape and high reduction ratios

•

No need for pre-screening on many applications reducing cost and increasing profitability

•

Easily transported on and off site

•

Metal detection fitted as standard

•

Feed hopper and level controls included to ensure choke feed to the crusher with resultant optimum product shape

•

3.5 m (11’- 6”) discharge conveyor material discharge height

•

Hydraulic crusher setting adjustment, overload release and unblocking included as standard

•

Dust suppression sprays

•

Caterpillar water cooled diesel engine with hydraulically controlled clutch

•

Hydraulic rams to assist setting up and packing for transportation

•

Choice of crusher concave (Autosand option)

CRUSHING APPLICATIONS

! WARNING ! This plant is designed for stone crushing applications. It is vitally important that large pieces of steel or similar uncrushable objects are not allowed to enter the crushing chamber as severe damage and injury may occur. The Automax crusher includes automatic hydraulic overload release. However the machine is not designed to accept large pieces of steel or other uncrushable objects such as bucket teeth. The metal detector fitted to the feeder conveyor must be kept operable at all times whilst the plant is in operation and any foreign object removed from the feeder conveyor belt. Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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4.2.3 Feed Conveyor

4.2 Construction Units TEREX PEGSON 1300 MAXTRAK SECONDARY/TERTIARY CRUSHING PLANT WITH DIESEL/HYDRAULIC DRIVE generally as shown on brochure 13MXT 202/1 and comprising:-

4.2.1 Automax Crusher Terex Pegson 1300 Automax Crusher generally as illustrated on leaflet AMB 200/1, and fitted with dedicated system 2 hydraulic controls as standard. The crusher is complete with an oil lubrication system having a chassis mounted tank with air blast cooler. Autosand (AS) concave is available as an option for plants which have not been completed. Advice on the correct concave can be provided by BL-Pegson Sales Department against purchasers specific application data.

4.2.2 Feed Hopper 7.0m³ (8.75yd³) heaped capacity feed hopper fabricated in 10mm (3/8”)thick mild steel plate and fitted with internal crash bar to minimise impact load on the feed conveyor.

1300mm (51”) wide plant mounted shallow troughed belt variable speed conveyor, with hydraulic drive to the head drum having integral reduction gearbox, EP630/4 (or equivalent) belt with 6mm top and 2mm bottom heavy duty covers, and vulcanised belt joint. The conveyor is designed to lower for transportation and lift for crusher maintenance, by means of a hydraulic cylinder. Belt tensioning is maintained by screw adjusters located at the tail drum. Impact rollers are provided immediately below the feed hopper, and barge boards extend from the feed hopper to the conveyor head. A metal detector is included complete with audible warning devices, and is suitable for detecting steel and manganese steel contained in the feed material.

4.2.4 Discharge Conveyor 1000mm (39”) wide plant mounted troughed belt fixed speed conveyor with hydraulic drive to the head drum, EP 500/3 (or equivalent) belt with 5mm top and 1.5mm bottom heavy duty covers, and vulcanised belt joint. The conveyor is of fixed design and belt tensioning is maintained by screw adjusters located at the head drum. Impact rollers are provided immediately below the crusher outlet under the conveyor feed point, and canvas type dust covers are provided over the exposed section of the conveyor.

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4.2.5 Chutes

4.2.8 Controls

Automax feed box fabricated in 6mm mild steel plate. Crusher discharges direct to product conveyor feed boot, which is fabricated in 10mm thick Hardox abrasion resistant plate.

The Automax hydraulic systems control panel and separate start/stop control panel for the crusher, conveyors and oil lubrication system are mounted on the side of the main chassis. Both panels operate from a 24 volt D.C. supply from the diesel engine.

4.2.6 Platforms Provided for inspection and maintenance, allowing access to each side of the crusher and engine, back of engine, and to one side of feed conveyor head section. They are made from steel flooring with steel toe boards, double row handrails and access ladders.

4.2.7 Power Unit Caterpillar C12 EPA/CARB Emmissions Regulations compliant, 6 cylinder, 4 stroke, direct injection, water cooled diesel power pack, with HFO clutch. The engine is rated at 425 BHP (317 kW) nett continuous at 1800 rpm under NTP conditions. Hydraulic power is provided from the engine to drive both conveyors, operate the hydraulic cylinders, and give power to the tracks. It also provides power to the crusher lubrication oil pump and supplies the crusher hydraulic setting and adjustment system. All connecting pipework is provided with steel pipe being used in inaccessible areas.

Also mounted on the chassis are emergency stop buttons and a control lever for lowering and raising the feed conveyor assembly for transport and maintenance. A radio control unit is provided for controlling the tracking function giving a tracking speed of approximately 1km/hour and a ‘creep’ facility for loading, off loading and precise slewing movements. Level sensors over the Automax and, feed conveyor (optional), are designed to automatically maintain an optimum feed condition.

4.2.9 Chassis Fabricated steel frame with supports for the feed conveyor, crusher, product conveyor, power unit, track frame and control systems.

Hydraulic tank is mounted within the main chassis structure, and the system includes air to oil cooling.

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4.2.10 Track Frame

4.2.12 Painting

Heavy duty track frame having 3.8m (12’6”) centres and 500mm (20”) wide tracks.

The plant is finish painted in BL-Pegson Blue RAL 5015.

Total Plant Weight approximately: 5O tonne (55 US tons) Overall track width - 3000mm (9’- 11”) Operating height - 4554mm (14’- 11”) Operating length - 15978mm (52’- 5”) Operating width - 3000mm (9’- 11”) Travel height - 3810mm (12’- 6”) Travel length - 15866mm (52’- 1”) Travel width - 3000mm (9’- 11”) NB. The travel height above can only be achieved if the Automax Upper Frame is first lowered to the maximum extent. Refer to Section 5.2.5.

4.2.13 Dust Suppression Sprays Spray bars with atomiser nozzles are mounted over the crusher mouth and the product conveyor feed and discharge points piped to an inlet manifold for clients pressurised water supply. Buyer to supply pressurised (2.8 bar/42 psi) clean water supply at approximately 7 litres ( 2 US galls) per minute.

4.2.14 Optional Extras

4.2.11 Guards

(These options are only available for plants, which are not already built and are not available for plants already in stock).

Wire mesh or sheet metal guards are provided for all drives, flywheels, pulleys, couplings, wedge belts and belt conveyors.

Autosand concave (no price variation for unfinished plants)

The guards provided are designed and manufactured to ensure so far as reasonably practicable that the machinery and plant on which they are fitted can be operated safely and without risk to health when properly used. However, the Company cannot guarantee that the guards provided will meet the requirements laid down by individual Inspectors and any additional guard and/or modification to guarding supplied, which may be required for any reason whatsoever, will be charged as an addition to the Contract Price.

Beckford belt weigher with integrator and speed sensing wheel fitted to main product conveyor. Hydraulically driven water pump assembly to provide a pressurised water supply to the dust suppression sprays. Level sensor over the feed hopper.

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4.2.15 Authorisation for use This is a requirement of the Environmental Protection Act that the Purchaser must obtain Local Authority authorisation to operate this plant in the U.K.

4.2.16 Site Preparation The buyer shall be responsible for ensuring that a suitably prepared, flat and level site is available for the plant and that the ground is capable of sustaining the working of the equipment. Unit dimensions and loadings can be provided to the buyer for both transportation and operating purposes.

We cannot guarantee that the equipment quoted will meet any specific requirements in respect of noise or vibration levels, dust emissions, or any other factors relevant to health and safety measures or environmental protection needs. However, on receipt of specific information Terex Pegson will endeavour to ascertain the need for additional equipment and, if appropriate, quote extra to contract prices.

4.2.17 Commissioning On arrival of the plant on site BL-Pegson or your local dealer can provide an Engineer if required at extra cost to commission the plant. Feed material, and other essentials to be provided by the buyer in good time for the commissioning being carried out.

4.2.18 Specifications Every endeavour will be made to supply equipment as specified, but we reserve the right, where necessary, to amend specifications without prior notice as we operate a policy of continual product development.

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5 - Transport 5.1 Safety Information .......................................................................................... 5 - 2 5.2 Transportation ................................................................................................ 5 - 5 5.2.1 Manoeuvring .............................................................................................. 5 - 5 5.2.2 Unloading ................................................................................................... 5 - 8 5.2.3 Loading ..................................................................................................... 5 - 9 5.2.4 Lowering the Feed Conveyor ................................................................... 5 - 10 5.2.5 Lowering the Automax Upper Frame ........................................................ 5 - 12 5.3 Remote Control Operation ........................................................................... 5 - 14 5.3.1 Radio Hand Set (where fitted) .................................................................. 5 - 16 5.3.2 Alternative Control Hand Set with Umbilical Cable (where fitted) ............... 5 - 18

HOPPER EXTENSION PLATES WHERE OPTIONAL FEED HOPPER EXTENSION PLATES ARE SUPPLIED, THESE MUST BE REMOVED FIRST WHEN PREPARING THE PLANT FOR TRANSPORTATION. IT IS ESSENTIAL THAT SUITABLE LIFTING EQUIPMENT AND EXPERIENCED PERSONNEL ARE EMPLOYED FOR THIS TASK AND THAT A RISK ASSESSMENT IS CARRIED OUT PRIOR TO THE OPERATION.

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5.1 Safety Information When carrying out maintenance or adjustment to the plant the following procedure must be followed.

LOCKOUT PROCEDURE

LOCKOUT PROCEDURE 1. 2. 3. 4. 5.

Switch off engine. Remove the ignition key. Keep the ignition key on person during lockout. Place appropriate maintenance warning signs (ie. ‘TAG OUT’). NEVER work alone.

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

SKIN INJECTION HAZARD

ALWAYS relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. ALWAYS use a piece of cardboard to check for leaks. DO NOT use your hand. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately.

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Loose or baggy clothing can get caught in running machinery.

PERSONAL PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting (E.N./A.N.S.I. approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close Fitting Overalls, Steel Toed Boots, Industrial Gloves and High Visibility Vest.

Falling from and/or onto a BL-Pegson machine can cause serious injury or even death.

FALLING HAZARD

DO NOT climb onto the machine whilst in operation. ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority. ALWAYS use an E.N./A.N.S.I. approved safety harness when reaching any points 7ft (2m) or more above ground level. In-running nip points can cause serious injury or even death.

ENTANGLEMENT HAZARD

DO NOT reach into an unguarded machine. Your arm could be pulled in and amputated. SWITCH OFF, LOCKOUT & TAGOUT machine before opening or removing guards.

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5.2 Transportation

! DANGER !

5.2.1 Manoeuvring

! WARNING ! Prior to attempting any manoeuvring of the plant the tracks must be free of obstructions, including crushed material and fines. Do not push or tow the plant. Failure to observe this warning could result in serious injury to persons and damage to the plant which may invalidate warranty. •

Before manoeuvring the Maxtrak, ensure the feed hopper and crusher are empty, and that all materials have run off the conveyors. STOP the feeder conveyor, crusher and product conveyor.

•

The plant cannot be manoeuvred in the PLANT mode of operation.

•

The safety warning horn sounds for 10 seconds before selected controls become operative and continuously whilst the plant is being manoeuvred.

When manoeuvring your Maxtrak to its operating position make sure you stand well clear of the plant but are in a position to have allround vision to see any obstacles or hazards that may lie ahead e.g personnel, overhead cables, ditches, unsafe roadways etc. (Refer to Figure 2a Dimensions) •

Make sure that you do not manoeuvre your Maxtrak on a gradient steeper than 30 degrees, damage may occur to the engine and/or plant.

•

Avoid manoeuvring the plant over extremely uneven ground or damage may occur.

•

Initial start up in cold weather may result in a tendency to steer to the right whilst tracking fast forward due to the hydraulic oil being cold. Run the plant for approx. 10 minutes with the conveyor and feeder running prior to manoeuvring the plant.

•

The Maxtrak can be manoeuvred whilst the feeder conveyor is in the working position but refer to Sections 5.2.4 & 5.2.5 when necessary to reduce to the travelling dimensions (Section 2)

•

When transporting the Maxtrak, it is the responsibility of the haulage contractor to safely secure the plant to the transporter.

! DANGER ! DO NOT stand on any of the platforms or ladders of the Maxtrak whilst it is being manoeuvred using the remote control handset.

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To manoeuvre the Maxtrak with the remote control hand set (where fitted):-

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning.

Procedure 1. Observe all safety instructions. 2. Take the Remote Control Hand Set from the Control Box and first become familiar with the functions of all the individual buttons (Figure 5d) before the next step. Forward = Product Conveyor first Reverse = Hopper first 3. To start up the handset transmitter first stand well clear of the plant. Hold the hand set with the stop button nearest to the operator and proceed as follows:• Ensure the stop button is pulled out. • Depress both of the safety buttons (Fig.5d) at the same time for at least 1 second. Release the safety buttons. • The red LED will change to green. • The transmitter is in function status when the green LED comes on. Note: The transmitter has a built in safety function that prevents another function from involuntary cutting-in when the transmitter starts. The transmitter will not start if a button is stuck in the activated position. This is indicated by the red LED coming on.

4. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 5. Turn the OPERATION switch to TRACK (Figure 5a). 6. Press the Horn button for 5 seconds to sound the safety warning horn. This will also ready the tracks for manoeuvring. 7. The radio handset directional buttons (forward, reverse and turn) are double pressure switches with the initial pressure operating the slow speed mode and depressing further operates the higher speed. Press the buttons to manoeuvre the plant in the desired direction (Figure 5d). Employ the ‘Fast’ speed only where safe to do so. Pressing the Stop button at any time will immediately halt the operation and cut out the engine but it is necessary to manually switch off the engine ignition (Section 8.2)

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8. When the Maxtrak is in the correct position, press the Horn button to turn the safety warning horn off and disengage the tracks.

10. To shut down the radio handset transmitter, push in the stop button. Lock out the hand set when finished with to prevent unauthorised use.

9. Turn the OPERATION switch to PLANT and stop the engine (Section 8.2), unless required further.

Figure 5a OPERATION and RADIO REMOTE CONTROL Switches on the Electrical Control Panel

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5.2.2 Unloading The Maxtrak will arrive on site securely fastened to a low loader. It is the responsibility of the haulage contractor to remove the fastenings.

Procedure

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Position easy slope ramps at the end of the transporter to help with unloading of the Maxtrak. 3. Start the engine (Section 7.2.1). Set the engine speed to 1200rpm. 4. Turn the OPERATION switch to TRACK (Figure 5a). Using the remote control hand set, (Section 5.2.1 and 5.3) steer the Maxtrak off the transporter. 5. When the Maxtrak is in the correct position, press the Horn button to turn the safety warning horn off and disengage the tracks. 6. Turn the RADIO REMOTE CONTROL switch to OFF, then shut down the hand set with the hand set stop button. 7. Turn the OPERATION switch to PLANT and stop the engine (Section 8.2), unless required further.

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5.2.3 Loading

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Ensure that both conveyors, feed hopper and crusher are free from stone and dirt.

FALLING HAZARD Refer to Section 5.1, Safety Information for relevant warning.

3. Ensure all loose items are carefully stowed and secured if these are to be transported on the plant. 4. Start the engine (Section 7.2.1). Set the engine speed to 1200rpm. 5. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b). 6. Lower the Automax Upper Frame (Section 5.2.5). ONLY APPLIES IF MINIMUM TRANSPORT HEIGHT REQUIRED.

11. Turn the RADIO REMOTE CONTROL switch to OFF then shut down the hand set with the hand set stop button. 12. Turn the OPERATION switch to PLANT and stop the engine (Section 8.2), unless required further. 13. Securing the Maxtrak to the transporter is the responsibility of the haulage contractor.

7. Lower the feeder conveyor for travelling if not already in this position (Refer to Section 5.2.4 procedure). 8. Position easy slope ramps at the end of the transporter to help with loading of the Maxtrak. 9. Turn the OPERATION switch to TRACK (Figure 5a). Using the remote control hand set (Section 5.2.1 and 5.3), steer the Maxtrak onto the transporter.

! WARNING ! Prior to transportation always check the plant for loose or damaged components. Fasten all loose parts, replace missing items or make repairs as found necessary to ensure that all components are safely secured during transportation.

10. When the Maxtrak is in the correct position, press the Horn button to turn the safety warning horn off and disengage the tracks. BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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5.2.4 Lowering the Feed Conveyor The Maxtrak is designed so that the plant can be prepared for transport without the use of tools. To reduce to the travelling dimensions of the plant the feeder conveyor head is hydraulically lowered from the working position.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning. FALLING HAZARD Refer to Section 5.1, Safety Information for relevant warning.

! WARNING ! Whilst the plant is crushing the conveyor head must always be supported on the locating pins positioned in each of the two telescopic support legs and NOT by the hydraulic ram alone. Procedure 1. Observe all safety warnings. 2. Ensure that the conveyor and feed hopper and Automax feed box are free from stone and dirt. 3. Before lowering the feed conveyor into the travelling position first release the feed box rear plate fastenings and hinge down the plate. 4. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 5. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b).

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6. Operate the hydraulic lever on the chassis side to slightly raise the feeder conveyor so that the locating pins can be withdrawn from both legs of the upper telescopic support leg (Figure 5b).

9. Switch off the engine (Section 8.2) and implement the lockout procedure. 10. Lower the mast(s) supporting the level sensor(s).

7. Operate the hydraulic level again to lower the feeder conveyor to the fullest extent. This action will automatically fold the platform access ladder. 8. Store the locating pins in the places provided on the telescopic legs and stow the security pins to prevent loss.

Upper Telescopic Leg Locating Pin

Feed Box Rear Wall

Lower Telescopic Leg

Hydraulic Lever Figure 5b Feed Conveyor Hydraulic Lever and Locating Pins

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5.2.5 Lowering the Automax Upper Frame

WARNING

(to achieve minimum travel height dimension (Sections 2.1 & 4.2.10)

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

FOR THIS OPERATION THE AUTOMAX MUST NOT BE RUNNING Referring to the separate Automax Control Panel (Section 7.4) for detailed instructions, action as follows;-

Procedure 1. Observe all safety warnings. 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b) but DO NOT press any of the start buttons.

5. Now depress the CLOSE button until the manganese crushing members (mantle and concave) touch. This is indicated by a sudden rise in pressure shown on the gauge near the panel (Figure 5c) and release the button immediately. 6. Continue with the Loading procedure (Section 5.2.3 - step 7).

4. On the Automax hydraulic panel (Figure 5c) switch to MANUAL and depress the OPEN button to raise the Upper Frame approximately 25-38mm. Look into the Automax crushing chamber to check there is no stone lodged in the chamber.

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•

Make the checks prior to starting the plant (Section 7.1.3).

•

Check that all 5 Emergency Stops on the plant are pulled out (Figure 1a).

•

Check that the conveyors and Automax crushing chamber are empty of material.

•

Make sure that you fully understand the operating procedures for the Automax before attempting to start.

Numeric Keypad

OPEN Button

Pressure Gauge

Display

AUTO/MANUAL Switch

TRAMP O/L TEST Button

CLOSE Button

Figure 5c Automax Hydraulic Panel Controls

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5.3 Remote Control Operation

•

For recharging the hand set battery, see Section 5.3.1

•

When the plant is not operating take the opportunity to recharge the internal battery. For convenience a lead is supplied to plug into 12/35 volt DC vehicle cigar lighter point (Section 5.3.1).

•

In the event of the remote radio hand set being inoperable for any reason, the alternative ‘umbilical’ hand set is supplied (Section 5.3.2).

•

If the hand set transmitter does not start when the two safety buttons are depressed at the same time for at least 1 second (Section 5.2.1), check if the stop button is pushed ‘in’, or the battery needing a recharge.

! DANGER ! DO NOT stand on any of the platforms or ladders of the Maxtrak whilst it is being manoeuvered using the remote control handset. When manoeuvring your Maxtrak to it’s operating position make sure you stand well clear of the machine but are in a position to have all-round vision to see any obstacles, dangers that may lie ahead e.g personnel, overhead cables, ditches, unsafe roadways etc. (Refer to Figure 2a for dimensions)

! NOTICE ! The Maxtrak remote control system is supplied to the following:Radio System 2686-0042 •

If the plant moves out of the operating range of the remote control hand set the plant will stop.

•

Operating the stop button on the remote hand set whilst the plant is in TRACK operating mode will stop the engine.

•

To manoeuvre the Maxtrak with the remote hand set, refer to the instructions in Section 5.2.1. BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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PLAN VIEW OF THE PLANT

LED Red/Green

Forward slow or fast, track 1 & 2 Right turn slow, forward track 1 Left turn slow, forward track 2

**Reverse ** Left Turn (travelling forward)

Reverse slow or fast, track 1 & 2

** Right Turn ** (travelling forward) Forward

Not used to Manoeuvre

Right turn slow, reverses track 1 Left turn slow, reverses track 2

Safety Button (Horn) Rotate clockwise, track 1 forward, track 2 reverse (second step)

Safety Button (Feeder On/Off)

Rotate counterclockwise, track 1 reverse, track 2 forward (second step) Stop Button

** Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed Figure 5d Remote Control Hand Set

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5.3.1 Radio Hand Set (where fitted) Features of the 860 System include:•

Unique ID code in each transmitter. The receiver self learns this code, without the need to change DIP switches internally in either component.

•

No need to open transmitter to change frequency (changed from buttons Dealer function). Receiver detects any change automatically.

•

Transmitter can be programmed to work with either 840 or 860 receivers (Dealer function).

•

Enhanced reliability.

Transmitter’s Use NiMh batteries instead of NiCd, which means the following:•

•

•

Input charging voltage is now 12VDC to 35VDC instead of 12/24VDC, no universal adapter required. Battery capacity is changed from 800mA to 2000mA.(Charging time from completely empty battery is now approximately 4 hours). Operating time with fully charged battery is approximately 30 hours.

TRANSMITTER 860TX-PEG

Buttons 1 to 4 = Used for plant directional control Buttons 1 to 9 and 0 = Used for signal frequency programming (factory preset contact Dealer for change) Buttons 9 and 0 = Used to activate the radio hand set transmitter Button 9 = Used to activate the audible warning horn Button 0 = Used to stop / start the plant feeder (where appropriate)

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2 versions of the 860 system transmitter will be supplied, one for European Operations and one for the Rest of the World. The only difference is that the European version will include a black stop button. The Rest of the World transmitter will feature a Red Stop button. Channel 01 (434.650 MHz) through channel 16 (433.900 MHz) available in .050 MHz steps. Refer to Dealer if frequency change needed.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning.

• Battery Recharging

To conserve the battery charge the hand set should be switched off when not in use.

The remote control handset includes a built in chargeable batteries and a charging contact point on the back of the unit (Figure 5k). A 12/35 volt charging lead suitable for plugging into a vehicle cigarette lighter point is supplied. •

Battery charge status is indicated by the LED light in the transmitter; Red - batteries need charging; Green - batteries fully charged. During the charging of the batteries the LED light will be red until changing to green when fully charged. The batteries cannot be overcharged.

•

Fully charged batteries provide about 30 hours continuous running and recharging time takes about 4 hours.

•

The LED light on the hand set changes from green to red when there is about 10% power left in the batteries (1 hour continuous operation remaining) and indicates it is time to recharge. The plant warning horn will also sound when battery recharging is required

Charging point Figure 5d Remote Control Charger Connection

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5.3.2 Alternative Control Hand Set with Umbilical Cable (where fitted) As an alternative to the radio remote control hand set, a hand set with umbilical cable is supplied to manoeuvre the Maxtrak (Figure 5g).

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 5.1, Safety Information for relevant warning.

Connecting and using the Umbilical Control Hand Set

Procedure 1. Observe all safety warnings. 2. Close down the plant (Section 8.2). 3. Locate the connection point (Figure 5f) on the Control Panel. Release the retaining clip and remove the multi pin plug already in situ (only where radio unit fitted). Replace with the umbilical lead plug (Figure 5g) and secure with the retaining clip. 4. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm.. 5. Standing clear of the tracks, turn the OPERATION switch to TRACK but leave the the RADIO REMOTE CONTROL switch at OFF (Figure 5h). 6. Press the Horn button for 5 seconds to sound the safety warning horn. This will also ready the tracks for manoeuvring.

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Figure 5f Umbilical Connection Point

Figure 5g Umbilical Control Hand Set

Figure 5h OPERATION and RADIO REMOTE CONTROL Switches on the Electrical Control Panel

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7. The umbilcal handset (Figure 5i) directional buttons (forward, reverse and turn) are double pressure switches with the initial pressure operating the slow speed mode and depressing further operates the higher speed. Pressing the Stop Button at any time will immediately halt the operation and cut out the engine but it is necessary to manually switch off the engine ignition (Section 8.2).

! DANGER ! Extreme care must be used when manoeuvring the plant with the umbilical control hand set. Stand as far away as possible from the plant. Do not allow the cable of the hand set to sag and become entangled with the tracks.

8. Hold the hand set with the stop button nearest to the operator and proceed as follows. Press the slow speed buttons on the hand set to manoeuvre the plant in the desired direction (Figure 5i). Employ the ‘fast’ speed only where safe to do so. 9. When the Maxtrak is in the correct position, press the Horn button to turn the safety warning horn off and disengage the tracks. 10. On the Control Panel turn the OPERATION switch to PLANT. The safety warning horn will sound for 10 seconds. Stop the engine (Section 8.2), unless required further. 11. Unplug the umbilical cable and replace with the original plug (where radio unit fitted). Store the umbilical hand set unit in the tool box to keep available for future use.

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PLAN VIEW OF THE PLANT

Forward slow or fast, track 1 & 2 Right turn slow, forward track 1 Left turn slow, forward track 2 Reverse slow or fast, track 1 & 2

**Reverse **Left Turn

** Right Turn ** (travelling forward) Forward

(travelling forward) Right turn slow, reverses track 1 Not used

Not used

Safety Button Rotate clockwise, track 1 forward, track 2 (Horn) reverse (second step)

Not used

Left turn slow, reverses track 2

Rotate counterclockwise, track 1 reverse, track 2 forward (second step) Stop Button

**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed Figure 5i Remote Umbilical Control Hand Set

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Blank page

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6 - Set Up 6.1 Safety Information .......................................................................................... 6 - 2 6.2 Setting Up ....................................................................................................... 6 - 4

HOPPER EXTENSION PLATES WHERE OPTIONAL FEED HOPPER EXTENSION PLATES ARE SUPPLIED, THESE WILL HAVE BEEN REMOVED FOR TRANSPORTATION AND WILL REQUIRE FITTING IN ADDITION TO THE SETTING UP PROCESS DESCRIBED. IT IS ESSENTIAL THAT SUITABLE LIFTING EQUIPMENT AND EXPERIENCED PERSONNEL ARE EMPLOYED FOR THIS TASK AND THAT A RISK ASSESSMENT IS CARRIED OUT PRIOR TO THE OPERATION.

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6.1 Safety Information When carrying out maintenance or adjustment to the plant the following procedure must be followed.

LOCKOUT PROCEDURE

LOCKOUT PROCEDURE 1. 2. 3. 4. 5.

Switch off engine. Remove the ignition key. Keep the ignition key on person during lockout. Place appropriate maintenance warning signs (ie. ‘TAG OUT’). NEVER work alone.

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

SKIN INJECTION HAZARD

ALWAYS relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. ALWAYS use a piece of cardboard to check for leaks. DO NOT use your hand. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately.

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Loose or baggy clothing can get caught in running machinery.

PERSONAL PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting (E.N./A.N.S.I. approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close Fitting Overalls, Steel Toed Boots, Industrial Gloves and High Visibility Vest.

Falling from and/or onto a BL-Pegson machine can cause serious injury or even death.

FALLING HAZARD

DO NOT climb onto the machine whilst in operation. ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority. ALWAYS use an E.N./A.N.S.I. approved safety harness when reaching any points 7ft (2m) or more above ground level. In-running nip points can cause serious injury or even death.

ENTANGLEMENT HAZARD

DO NOT reach into an unguarded machine. Your arm could be pulled in and amputated. SWITCH OFF, LOCKOUT & TAGOUT machine before opening or removing guards.

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6.2 Setting Up

WARNING

Plant Location Considerations Prior to setting up your Maxtrak, consideration should be given to a suitable layout to prevent oversize material or tramp metal from entering the plant. In order to prevent bridging of the crusher no material above the size recommended by the BLPegson (Section 3) should be fed into the plant.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 6.1, Safety Information for relevant warning. FALLING HAZARD Refer to Section 6.1, Safety Information for relevant warning.

The Maxtrak is designed so that the plant in transportation mode can be set up and put to work without the use of tools.

Procedure 1. Observe all safety warnings. 2. Position the plant in a safe level operating position making sure both tracks are in full contact with the ground to minimise movement of the Maxtrak. Pay attention to access from the loading area and to where material is to be deposited (Section 5.2.1), and ensure the area under the tail drum is clear of large stones etc which may cause belt damage. 3. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 4. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 6a).

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Figure 6a OPERATION and RADIO REMOTE CONTROL Switches on the Electrical Control Panel

Upper Telescopic Leg Locating Pin

Feed Box Rear Wall

Lower Telescopic Leg

Hydraulic Lever

Figure 6b Feed Conveyor Hydraulic Lever and Locating Pin

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5. Raise the feeder conveyor slightly above the working position by operating the hydraulic lever on the chassis side so that the two locating pins can be inserted through the top pair of holes in the upper telescopic legs. Fit the security pins into the end of each pin (Figure 6b). 6. Operate the hydraulic lever to lower the conveyor until the locating pins rest on the seats in the lower telescopic legs. Make sure the locating pins are resting on their seats on both sides of each leg and not on the pin head on one side only.

! WARNING ! Whilst the plant is crushing the conveyor head must always be supported on the locating pins positioned in each of the two telescopic support legs and NOT by the hydraulic ram alone.

11. Raise the mast(s) supporting the level sensor(s) ensuring restoration at the correct height so that the originally calibrated settings are maintained.

! NOTICE ! IMPORTANT It is very important NOT to run the Automax crusher before the Initial Setting and Calibration procedure has been carried out. The Automax Upper Frame may have been fully lowered to achieve the minimum travel height and serious damage will occur if the machine is started whilst the manganese mantle and concave are touching.

7. Lifting the feeder conveyor head will automatically unfold the platform access ladder. 8. Carry out the Automax Initial Setting and Calibration procedure (Section 7.3.3). See IMPORTANT NOTICE OPPOSITE. 9. Switch off the engine (Section 8.2) and implement the lockout procedure. 10. The rear wall of the feed box needs to be manually lifted and secured with the fixings provided.

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7 - Operating Istructions 7.1 Safety Information .......................................................................................... 7 - 2 7.1.1 Blocked Crusher Procedures ..................................................................... 7 - 4 7.1.2 Safe Operation of the plant ......................................................................... 7 - 5 7.1.3 Checks at Initial Start-Up ............................................................................ 7 - 6 7.2 Plant Start-Up Procedure ............................................................................. 7 - 7 7.2.1 Engine Start-Up .......................................................................................... 7 - 8 7.2.2 Plant Start Up ........................................................................................... 7 - 12 7.2.3 Electric Control Panel Screen Display Data.............................................. 7 - 17 7.2.4 Plant Operating Sequence and Automatic Safeguards ............................. 7 - 18 7.2.5 Fault Indication and Restart ...................................................................... 7 - 19 7.2.6 Metal Detection ........................................................................................ 7 - 20 7.2.7 Feed Conveyor Remote Operation ........................................................... 7 - 21 7.2.8 Crushing Material - Plant and Automax Settings ....................................... 7 - 23 7.2.9 Plant Initial Start Up and Running In ........................................................... 7 - 23 7.2.10 Daily Plant Checks ................................................................................. 7 - 25 7.3 Automax Operation ....................................................................................... 7 - 26 7.3.1 Glossary of Automax Parts ....................................................................... 7 - 28 7.3.2 Glossary of Automax Terms ...................................................................... 7 - 29 7.3.3 Automax Initial Discharge Setting and Calibration ..................................... 7 - 31 7.3.4 Automax Manganese Wear Calibration .................................................... 7 - 32 7.3.5 Guidance for Changing the Manganese Mantle and Concave ................... 7 - 33 7.3.6 Automax Initial Start Up ............................................................................. 7 - 34 7.3.7 Actions during running in ........................................................................... 7 - 35 7.3.8 Automax Adjustment of Discharge Setting ................................................ 7 - 36 7.3.9 Manual Raising/Lowering of the Automax Upper Frame ............................ 7 - 37 7.3.10 Automax Automatic Overload Release/Unblocking and Resetting ........... 7 - 38 7.3.11 Checking Automax Wedge Pressure ...................................................... 7 - 39 7.3.12 Daily Automax Checks ........................................................................... 7 - 40 7.4 Automax Crusher Controls .......................................................................... 7 - 41 7.4.1 Controls Layout ........................................................................................ 7 - 41 7.4.2 Function Keys .......................................................................................... 7 - 42 7.4.3 General Operation .................................................................................... 7 - 43 7.4.4 Manual Operation ..................................................................................... 7 - 52 7.4.5 Setting the Gap ........................................................................................ 7 - 53 7.4.6 Setting New Manganese .......................................................................... 7 - 55 7.4.7 Setting Normal Zero ................................................................................. 7 - 57 7.4.8 Tramp Overload or Test (whilst in Manual) ................................................. 7 - 59 7.4.9 Tramp Overload or Test (whilst in Auto) ..................................................... 7 - 59 7.4.10 ................................................................................................... 7 - 60 Terex Alarms Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618 7.4.11 Alarm List ............................................................................................... 7 - 61 7.4.12 Wedge Lock Option ............................................................................... 7 - 62 7.4.13 Historical Alarms .................................................................................... 7 - 63 7.4.14 Set Time & Date .................................................................................... 7 - 64 AX860-901-8EN-02f 77/396 7.4.15 Set Operating Language ........................................................................ 7 - 66

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7.1 Safety Information When carrying out maintenance or adjustment to the plant the following procedure must be followed.

LOCKOUT PROCEDURE

LOCKOUT PROCEDURE 1. 2. 3. 4. 5.

Switch off engine. Remove the ignition key. Keep the ignition key on person during lockout. Place appropriate maintenance warning signs (ie. ‘TAG OUT’). NEVER work alone.

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

SKIN INJECTION HAZARD

ALWAYS relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. ALWAYS use a piece of cardboard to check for leaks. DO NOT use your hand. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately.

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Loose or baggy clothing can get caught in running machinery.

PERSONAL PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting (E.N./A.N.S.I. approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close Fitting Overalls, Steel Toed Boots, Industrial Gloves and High Visibility Vest.

Falling from and/or onto a BL-Pegson machine can cause serious injury or even death.

FALLING HAZARD

DO NOT climb onto the machine whilst in operation. ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority. ALWAYS use an E.N./A.N.S.I. approved safety harness when reaching any points 7ft (2m) or more above ground level. In-running nip points can cause serious injury or even death.

ENTANGLEMENT HAZARD

DO NOT reach into an unguarded machine. Your arm could be pulled in and amputated. SWITCH OFF, LOCKOUT & TAGOUT machine before opening or removing guards.

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7.1.1 Blocked Crusher Procedures

! WARNING ! Unblocking stalled crushers can be hazardous. Do not undertake without careful risk assessment In order to avoid the Automax cone crusher becoming blocked the machine is equipped with an automatic hydraulic release mechanism to raise the upper frame when excessively high crushing pressure is sensed. The upper frame automatically returns to the original setting when the foreign object should have been released through the machine. However, unduly large uncrushable objects may stall the crusher and become tightly wedged in the crushing chamber. The clearing of blocked crushers should be given considerable thought prior to attempting to unblock a crusher. These procedures should be considered under risk assessment review for the implementation of a procedure of safe working practice for this operation. There is a document entitled ‘Clearing Blocked Crushers’ available from the British Aggregate Construction Materials Industries (BACMI) which gives more details about this and covers in more detail risk assessment areas. Tramp metal is a serious problem when it enters a crusher as this can cause more problems than oversize or hard stone. EVERY EFFORT MUST BE MADE TO REMOVE TRAMP METAL FROM THE FEED MATERIAL

When metal enters any type of crusher it does not shear in the same manner as stone and can become wedged and under considerable pressure. In order to release the tramp metal it is necessary to take the pressure off it and at this time it can be ejected from the machine with catastrophic consequences A cone crusher can become ‘bridged’ when oversize material is fed into it. In the event of this happening the feed conveyor should be stopped immediately. An attempt to clear the machine can be made by raising the upper frame by putting the machine into ‘manual’ and pressing ‘open’. Should this not open sufficiently to allow the stone to drop through then it will be necessary to isolate the machine and remove the rock or break up the stone manually with a hammer and chisel. In the event that the crusher should stall whilst crushing due to an overload or blockage, the crushing chamber will be full of stone and the feed conveyor should be stopped immediately. This should then be released by raising the upper frame as before and letting the material fall through. After the machine has stalled, prior to resetting, the reason why the machine has stopped should be investigated. In the case that a piece of tramp metal is in the machine extreme care should be taken whilst releasing it. To avoid the tramp metal being ejected it may be necessary to fill the opening to the machine with stone whilst the pressure is released. Check the machine for possible damage (particularly the manganese) before resuming operations.

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7.1.2 Safe Operation of the plant

WARNING

! WARNING !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1 Safety Information for relevant warning.

Before attempting to operate the Maxtrak plant. DO read, fully understand and observe the contents of this manual. Also any other relevant manual for other equipment incorporated in the Maxtrak plant, eg. Engine manual.

LOCKOUT PLANT. Refer to Section 7.1, Safety Information for Lockout Procedure.

Terex Pegson Ltd cannot overemphasize the need to ensure that all safety aspects are checked before starting the machinery.

FALLING HAZARD. Refer to Section 7.1 Safety Information for relevant warning.

NEVER leave the plant unattended whilst it is in operation. Make sure that you fully understand the operating procedures for the Automax before attempting to start.

! NOTICE ! DO NOT crush material with the engine below it’s recommended working speed of 1800 rpm to ensure all systems will function correctly.

! NOTICE ! DO NOT allow a build up of solid material or dust in any part of the plant, in particular keep clean the Automax internal frame arms (Section 7.3.12) and the air blast oil cooler (on the lubricating oil tank).

AVOID frequent starting and stopping of your Automax unnecessarily as it WILL be detrimental to the machine.

DO check frequently the stability of the plant. The chassis SHOULD NOT have undue vibration during operation.

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7.1.3 Checks at Initial Start-Up •

•

Inspect the complete plant to check for fluid leaks, loose connections, damage or wear, build up of material, etc. etc.

•

Ensure that the crusher is empty of material.

•

WARNING

Visually check the plant and ensure that all guards and warning signs are in position and that all equipment and tools that are hazardous to operation are removed from the immediate area.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1 Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 7.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 7.1 Safety Information for relevant warning.

Check levels of lubricant and hydraulic oil are satisfactory on :- Automax lubrication tank - Automax hydraulic reservoir

•

Carry out the daily checks and inspections on the Automax crusher and plant (Sections 7.2.9 and 7.3.12)

•

Check the alignment and tension of the vee rope drive daily during the initial days of operation as appropriate

•

•

Avoid overloading the machine by not using small discharge settings during the first few days of operation. Ensure that the machine is running correctly and that the satisfactory feed is maintained at a constant rate (Section 3.4). Irregular and excessive feed rates reduce the efficiency of the Automax.

•

Ensure that the Automax feed is both satisfactory and not segregating in the crushing chamber. Note: This applies to all machine operations subsequent to the running in period.

•

Make sure that the crusher lubrication system is functioning correctly (Section 9.5) and that no leaks are present.

•

Check for leaks in the crusher hydraulic system, both externally and inside the hydraulic panel cabinet.

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7.2 Plant Start-Up Procedure

WARNING

! WARNING ! Terex Pegson Ltd cannot overemphasize the need to ensure that all safety aspects are checked before starting the engine.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

With the engine switched ‘OFF’ •

Ensure that the plant is fully ‘Set Up’ in accordance with Section 6 and ready to operate.

•

Check that the conveyors and Automax crushing chamber are empty of material.

•

Ensure that all guards are in position and secure and that other personnel are clear of the plant.

The plant diesel engine drives the Automax crusher directly through a hydraulically activated clutch and a vee rope drive. Within the engine canopy the engine also powers the twin hydraulic pumps used to drive the remainder of the plant. The control system is 24 volt DC and an engine heat exchanger is used to preheat the Automax crusher lubricating oil. The start-up procedure is in 2 stages carried out in sequence:• •

Engine (Section 7.2.1). Plant (Section 7.2.2).

When the Plant is running the Automax controls can be operated (Section 7.3)

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7.2.1 Engine Start-Up

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Check that all Emergency Stop push buttons are pulled out (Figure 1a) otherwise the engine cannot start. 3. Ensure the engine Isolation Switch (Figure 7a) is turned to the I position. 4. Turn the OPERATION switch to PLANT and the RADIO REMOTE CONTROL switch to ON (Figure 7b). 5. On the engine control panel (Figure 7c) turn on the ignition with the key to the first position and, once the sequence of diagnostic checks is completed, fully turn the key to start the engine. Release the key back to the first position as soon as the engine starts.

! NOTICE !

Figure 7a Isolation Switch

Refer to Figure 7d together with continuation page for details of the engine diagnostic functions. 6. Keep the rpm of the engine to 1200 rpm (view on tachometer) and allow to run for 3-5 minutes before proceeding with preparation for transport (Section 5), setting up the plant (Section 6) or initiating the plant run sequence (Section 7).

! NOTICE ! To avoid damaging the clutch DO NOT increase the engine speed to the operating 1800 RPM until after starting the Crusher (Section 7.2.2)

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Figure 7b OPERATION and RADIO REMOTE CONTROL Switches on the Electrical Control Panel

Maintenance Due Lamp

Diagnostic Lamp

Tachometer

Diagnostic Display

Scroll Switch

US/Metric Switch

Speed Control Fuel Gauge

Ignition Key

Figure 7c Engine Control Panel

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DIAGNOSTIC DISPLAY The main unit has ten warning lamps available for system related diagnostics. These diagnostics can be used for system troubleshooting and diagnostic information. They are located on the main EMS unit in two rows of five:

High Engine Coolant Temperature or Sensor Fault

Low Engine Oil Pressure or Sensor Fault

High Inlet Manifold Temperature or Sensor Fault

Low Fuel Pressure or Sensor Fault

High Fuel Temperature or Sensor Fault

Low Engine Coolant Level or Sensor Fault

Low Battery Voltage or Sensor Fault

Engine Derate

High Auxiliary Temperature or Sensor Fault

High Auxiliary Pressure or Sensor Fault

Figure 7c Caterpillar Engine Diagnostic Panel

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EMS Main Unit LCD Display Beneath the warning lamps is an LCD digital display for engine parameters. Display Scroll Feature Each time the scroll forward switch (Figure 7c) is depressed and held, EMS will page through the engine parameters in the order listed below. When the scroll backward is depressed and held, EMS will page through the engine parameters in reverse order. The abbreviation for the parameter will be displayed. When the scroll switch is released, EMS will display the current ‘real time’ value for that parameter. Abbreviation

Parameter

Spd GA-1 GA-2 GA-3 GA-4 Boost IAirT FuelT AccrP AccrT Fuel Hrs Load

Engine Speed Engine Oil Pressure Coolant Temperature Bateery Voltage Fuel Pressure Boost Pressure Inlet Air Temperature Fuel temperature Auxiliary Pressure Auxiliary Temperature Fuel Rate Engine Hours Engine (Percent) Load

U.S. / Metric Units Either U.S. or Metric (SI) units will be displayed, depending on the position of the U.S. / Metric Switch (Figure 7c).

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7.2.2 Plant Start Up

WARNING

The engine must be started prior to this operation (Section 7.2.1). First check that all emergency stop buttons (Section 1.7) have been disengaged. The display screen on the plant control panel (Figure 7e) will take approximately 10 seconds to carry out a self diagnosis check, then, if a system fault exists, the fault condition will appear on the screen and the warning siren will sound. Refer to Figure 7.2.3 for a list of display messages.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Note: After the 5 second warning ceases, press for the second time within 10 seconds otherwise the warning will be repeated.

! WARNING ! Faults displayed on the electrical control panel screen should be investigated and rectified immediately by suitably qualified personnel BUT FIRST SHUT DOWN THE ENGINE AND IMPLEMENT THE LOCKOUT PROCEDURE (Section 8.2). The panel display screen not only indicates the status of the starting sequence but also identifies any fault condition which will halt the starting procedure. If a fault condition appears refer to Section 7.2.5. Take note of the information on the display screen and operate the controls in the sequence described in the procedure. When any green start button is pressed there is a 5 second warning and then the button has to be pressed a second time to activate the appropriate item.

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Procedure

! NOTICE !

1. Observe all safety warnings. 2. Start the engine (Section 7.2.1)..Set the speed at 1200 rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b). 4. Start the OIL PUMP by pressing the green start button; after 5 seconds warning, press again within 10 seconds. There is now a 5 minute delay before the crusher can be started to allow time for good oil circulation within the Automax crusher before start up of the machine. The display shows the time delay as a time elapsed bar graph. Note: In cold weather, prior to starting the oil pump, preheat the lubricating oil by running the engine which is fitted with a heat exchanger for this purpose.

IMPORTANT It is very important NOT to run the Automax crusher before the Initial Setting and Calibration procedure has been carried out. The Automax Upper Frame may have been fully lowered to achieve the minimum travel height and serious damage will occur if the machine is started whilst the manganese mantle and concave are touching. 6. Before starting the crusher ensure that the engine speed on the tachometer (Figure 7c) is not more than 1200 rpm. Press the crusher start button. Again 5 seconds warning and press again within 10 seconds. With the crusher running the display screen will read WAIT 10 SECONDS, START FEED CONVEYOR.

5. After completion of the oil pump delay the panel display will read START DISCHARGE CONV. Press the discharge conveyor start button. Again 5 seconds warning and second press of the button within 10 seconds to run the conveyor. The display screen should now be reading START CRUSHER.

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7. Adjust the engine speed control to the operating engine speed of 1800 rpm before starting to feed material to the crusher. THE FEED CONVEYOR HAS 2 METHODS OF OPERATION:- AUTO - MANUAL The feed conveyor should be operated in the AUTO mode. Only in exceptional case of auto operation failure should MANUAL operation be used but also manually continuously monitor the feed into the Automax. In AUTO mode the speed of the feed conveyor is regulated automatically by the level sensor mounted over the Automax feed box whereas in MANUAL the conveyor speed has to be regulated from the rotary knob on the control panel (Figure 7e). When operating in manual mode make sure that the crusher sensor control switch (Figure 7e) is also put into the MANUAL position. 8. Ensure the feed conveyor switch is turned to AUTO and then press the start button. Again 5 seconds warning and press again within 10 seconds. See display screen to check conveyor running. Note: Before starting the feed conveyor, check Section 7.2.7 Crushing Material, to ensure that the feed material and the equipment settings are suitable.

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Note: Any fault occurring during plant running stops the relevant items of plant equipment and overwrites the message display with a fault message (Section 7.2.3). Where an optional level sensor is fitted over the feed hopper: After starting the feed conveyor with the level sensor switches in AUTO the feeder will not run unless there is enough material in the feed hopper. This is controlled by presetting the level in the unit MR2. The crusher feed box level sensor switches the feeder off/on via the preset level settings in the unit MR1 (Section 9.12). 9. Once the crushing of material has commenced check that the plant is stable and with no undue vibration. Note: The crusher is mounted on antivibration mountings and any undue vibration is likely to be caused by unsatisfactory support under the tracks Recitify immediately. 10. Ascertain that the product material is to the required specification and adjust the feed material and/or settings if necessary.

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Feed Conveyor Level Sensor Controls (*optional)

Diagnostic Display Screen

Crusher Level Sensor Controls

EMERGENCY STOP

OPERATION PLANT/TRACK RADIO REMOTE CONTROL OFF/ON

FAULT MUTE

FAULT RESET

FEED CONVEYOR CONTROLS AUTO/MANUAL*

CRUSHER CONTROLS AUTO/MANUAL

DISCHARGE CONVEYOR START/STOP

OIL PUMP START/STOP

CRUSHER START/STOP

FEED CONVEYOR MANUAL SPEED CONTROL

FEED CONVEYOR START/STOP

Figure 7e Electric Panel Controls

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7.2.3 Electric Control Panel Screen Display Data When following the the start up procedure (Section 7.2.2), command (C) messages appear on the display screen (Figure 7e) to indicated next action necessary, unless there is a fault (F) message which overrides any message on the screen. Use the reference number as an easy way to identify a fault when contacting Terex Pegson/Dealer’s Service Department. REF No: 1 2 3

TYPE C F F

4

C

5 6 7 8 9 10 11 12 13 17 18 20 26 27 28 29 30 31 33 36 37 38 39 41 42 43 44

C C C C F F C C C F F F F F F F F F F F F F F F F F F

45

F

46

F

47

F

50

F

51 52

F F

DISPLAY MESSAGE WESTBURY CONTROL STYSTEMS LTD TRACK CONTROL MODE WARNING OUT OF SEQUENCE – WARNING WARRANTY INVALID IN THIS MODE START OIL PUMP – PRESS TO SOUND PRESTART ALARM. PRESS AGAIN WITHIN 10 SEC TO START CRUSHER START DELAY – 0 TO 5 MIN START DISCHARGE CONVEYOR WAIT 10 SECS – START FEED CONV PLANT RUNNING CRUSHER BOWL MATERIAL HIGH LEVEL – FEEDER STOPPED MATERIAL HOPPER MATERIAL LOW LEVEL – FEEDER STOPPED PLANT START AVAILABLE – START OIL PUMP. 10 SEC PRESTART ALARM CRUSHER START DELAY – 0 TO 30 SEC CRUSHER START AVAILABLE TRACK UMBILICAL STOP FAULT – CHECK TRACK UMBILICAL STOP BUTTON AND RESET TRACK RADIO STOP FAULT – CHECK TRACK RADIO STOP BUTTONS ETC. EMERGENCY STOP FAULT – CHECK PLANT E/M STOP BUTTONS AND RESET TRACK MOVEMENT C/B FAULT – Q1 OR QUMB – RESET Q1/QUMB CIRCUIT BREAKERS OIL PUMP C/B TRIPPED Q2 – RESET Q2 CIRCUIT BREAKER OIL COOLER C/B TRIPPED Q3 – RESET Q3 CIRCUIT BREAKER OIL HEATER C/B TRIPPED Q4 – RESET Q4 CIRCUIT BREAKER DISCHARGE CONV C/B TRIPPED Q5 – RESET Q5 CIRCUIT BREAKER FEED CONV C/B/ TRIPPED Q6 – RESET Q6 CIRCUIT BREAKER HYD PANEL C/B TRIPPED Q3/Q3A – RESET Q3/Q3A CIRCUIT BREAKER MINIRANGER C/B TRIPPED QMIN – RESET QMIN CIRCUIT BREAKER METAL DETECTOR C/B TRIPPED QMD – RESET QMD CIRCUIT BREAKER CRUSHER C/B TRIPPED QCS – RESET QCS CIRCUIT BREAKER HYDRAULIC PANEL WEDGELOCK FAULT – WEDGELOCK PRESSURE FAULT CRUSHER LUBE OIL TEMPERATURE HIGH – CONTACT BL-PEGSON IMMEDIATELY CRUSHER LUBE OIL LEVEL LOW – CHECK FOR LEAKS AND TOP UP LUBE OIL CRUSHER LUBE OIL FILTER BLOCKAGE – CHANGE LUBE OIL FILTERS CRUSHER LUBE OIL FLOW FAULT – NO LUBE OIL FLOW. CHECK FLOW METER ! METAL DETECTED ON FEED CONV BELT ! REMOVE METAL, RESET METAL DETECTOR & FAULT RESET ON PANEL DISCHARGE CONV TAIL DRUM SPEED FAULT – DISCHARGE CONVEYOR TAIL DRUM STOPPED/SLOW PLC BATTERY LOW – TEL 44-(0) 01530 839829 IMMEDIATELY CRUSHER LUBE HYDRAULIC MOTOR ELECTRONIC FLOW FAULT – NO LUBE OIL FLOW. CHECK ELECTRONIC FLOW FAULT CRUSHER PRESSURE SWITCH FAULT – CHECK PRESSURE SWITCH SETTING HYDRAULIC SYSTEM LOW OIL – CHECK FOR LEAKS & TOP UP HYDRAULIC OIL LEVEL

NOTE: DO NOT REPEAT A RESET OF A CIRCUIT BREAKER IF IT IMMEDIATELY TRIPS OUT AGAIN. HAVE THE REASON INVESTIGATED AND CORRECTED BY A SUITABLY QUALIFIED PERSON Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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7.2.4 Plant Operating Sequence and Automatic Safeguards The plant operating sequence is as follows:I

Oil Pump.

II Discharge Conveyor.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

III Crusher. IV Feed Conveyor. If the discharge conveyor stops the crusher and feed conveyor are automatically stopped. If the discharge conveyor drum rotation sensor detects no rotation the crusher and feed conveyor are automatically stopped. If the crusher stops the feed conveyor is automatically stopped. If the oil pump stops the crusher and feed conveyor are automatically stopped. If the oil flow devices detect no flow or oil pump not running the crusher and feed conveyor are automatically stopped. If the low oil level is detected the crusher and feed conveyor are automatically stopped.

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7.2.5 Fault Indication and Restart System faults cause an alarm to sound and the fault will be shown on the Diagnostic Display Screen (Figure 7e) and the appropriate equipment stopped. The alarm can be silenced by pressing the MUTE button (Figure 7e). The displayed fault must be rectified before the plant can be restarted. If the fault is not corrected and the fault reset button has not been pressed the warning siren will sound again after 5 minutes.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

After the fault has been rectified press the FAULT RESET button (Figure 7e) followed by the appropriate start button(s). Exactly which start button(s) will depend upon where in the sequence the fault occurred. Follow the instructions on the display screen to identify and deal with any faults when they occur. To deal with fault alarms caused by metal detection refer to Section 7.2.6.

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7.2.6 Metal Detection

WARNING

When metal is detected on the conveyor belt the audible alarm will sound (and also the visible red fault light and diagnostic display will indicate) and the Feed Conveyor will stop.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Climb up to the top platform and remove the offending metal from the conveyor and then press the RESET button on the detector control box (Figure 7f). Although the fault will be signalled to the main panel PLC it is only necessary to reset at the metal detector panel (Figure 7f). Restarting the feed conveyor will depend upon which of the following alternative operating modes is being used at the time:

FALLING HAZARD Refer to Section 7.1, Safety Information for relevant warning.

Green ‘POWER ON’ light

Radio Remote Control OFF The feed conveyor is started and stopped with the Electric Panel controls (Figure 7e). After the pressing RESET (Figure 7f), restart the feed conveyor at the panel. Radio Remote Control ON In this mode, where the feed conveyor is being stopped and started remotely with the radio hand set, press RESET (Figure 7f) and then restart the feed conveyor with the start/ stop button of the hand set (Figure 7g).

Red ‘DETECT’ light and ‘RESET’ button

Figure 7f Metal Detector Control Panel

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7.2.7 Feed Conveyor Remote Operation

WARNING

To operate the Feed Conveyor remotely, first switch on the radio hand set and then carry out the plant starting sequence. (Section 7.2.2).

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings. 2. To start up the handset transmitter first stand well clear of the plant. Hold the hand set with the stop button nearest to the operator and proceed as follows:Feed Conveyor stop/start button

• Ensure the stop button is pulled out. • Depress both of the safety buttons (Fig.5b) at the same time for at least 1 second. Release the safety buttons. • The red LED will change to green. • The transmitter is in function status when the green LED comes on. Stop Button

3. Proceed with Plant Start Up (Section 7.2.2) at the Electric Panel Controls (Figure 7e) including starting the Feed Conveyor. Note: The radio remote control of the feed conveyor does not become operative until the Feed Conveyor start button on the main panel is activated.

Figure 7g Feed Conveyor Remote Operation

4. The feed can be turned on and off using the Feed Conveyor On/Off button on the hand set (Figure 7g). Pressing the stop button on the hand set will close down the complete plant. The speed of the feed cannot be adjusted using the hand set. To adjust the speed of the feeder refer to Section 7.2.3.

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7.2.8 Crushing Material - Plant and Automax Settings The crushing performance of the plant is controlled by the particular material being fed into the feed hopper and the settings of various items of equipment within the plant as illustrated below. For optimum crusher performance a continuous ‘choke’ feed into the crusher is most important. Actions A are determined at the time of commissioning and, normally, do not need to be altered, whilst Actions B are usually relevant during daily operation. See the appropriate Sections for detailed instructions. Section 3.4 - Action B for the suitability of the feed material depending upon meeting the criteria specified and also depending upon the crusher installed being an Automax or Autosand.

Feed Material

Feed Hopper Level Sensor (Optional)

Section 9.12 - Action A presetting levels. Action B the plant operator needs to keep above the preset ‘low’ level to ensure a continuous feed. The sensor works in conjunction with the Automax Level Sensor when AUTO selected to control the Feed Conveyor speed.

Metal Detector

Section 9.17 - Action A for sensitivity and setting. Action B for operation when metal is detected (Section 7.2.6).

Automax Level Sensor

Automax Crusher

Product Material

Section 9.12 - Action A for presetting the sensor in conjunction with the Feed Hopper Level Sensor when AUTO selected to control the Feed Conveyor speed Section 7.3 and 7.4 - Action B. for the instructions also covering the monitoring of manganese wear and the unblocking procedure. Section 3.4 - Action B Check the product. The graphs & capacities are a guide only and will vary depending upon the conditions.

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7.2.9 Plant Initial Start Up and Running In

WARNING

Initial Start-Up

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1 Safety Information for relevant warning.

! WARNING ! Observe all safety warnings whilst carrying out inspections and checks. •

LOCKOUT PLANT. Refer to Section 7.1, Safety Information for Lockout Procedure.

Check levels of oils are satisfactory. Refer to the lubrication schedules 9.4.4 and 9.4.5 for details.

•

Refer to engine manual for engine initial start up instructions

•

Run the plant empty for a short period of time and check for abnormal noises, vibration or excessive heat from shaft bearings, fluid leaks, etc. including the feed conveyor gearbox.

Actions During Running-In Period

FALLING HAZARD. Refer to Section 7.1 Safety Information for relevant warning.

•

Each day during the initial days of operation check the tension of the conveyor belts on the feed and discharge conveyors and adjust if necessary. Refer to Section 9.16.3

•

Make sure the conveyor belts are tracking correctly and that the skirt sealing rubbers are correctly adjusted. Refer to Section 9.16.2

•

Check frequently the overall stability of the plant; re-check the level of the plant and move to level position if necessary.

•

Regularly check drive belts (crusher and hydraulic pumps) to ensure correct tension, particularly during the initial 2 weeks of use. Refer to Section 9.15

•

Check the alignment and tension of the vee belt drives daily during the initial days of operation. Refer to Section 9.15

! NOTICE ! Checks on the Maxtrak plant are crucial during the first week of crushing operation. The following section should be read and understood prior to starting the plant. If there are any doubts, contact BL Pegson Ltd. Service Department. Plant •

All control systems should be checked for full function.

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•

Avoid overloading the crusher;

•

Check for any leaks of lubricants, fuel, water or hydraulic fluid and rectify immediately.

•

Check for any overheating of running parts.

•

Make sure that the crusher lubrication system is functioning correctly (fault warnings will show on the diagnostic panel) and that no leaks are present.

•

Check for leaks in the crusher hydraulic system, both externally and inside the hydraulic console.

! WARNING ! Shut down the plant if this occurs and investigate the reason. If necessary, contact Terex Pegson’s Service Department for advice to avoid the possibility of danger or damage. Crusher •

Check the alignment and tension of the vee rope drive daily during the initial days of operation.

•

Avoid overloading the machine by not using small discharge settings during the first few days of operation.

•

Ensure that the machine is running correctly and that the satisfactory feed (Section 3.4) is maintained at a constant rate (Section 7.2.7). Irregular and excessive feed rates reduce the efficiency of the Automax.

•

Ensure that the Automax feed is not segregated in the crushing chamber. Note: This applies to all machine operations subsequent to the running in period.

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7.2.10 Daily Plant Checks

WARNING

! WARNING ! .It is imperative that the operator

carries out regular and diligent checks before operating the plant especially with operational safety in mind including (but not limited to) those listed below. Additionally, the operator should always consider what particular safety hazards could occur at specific operating sites and take steps to eliminate them before commencing work.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1 Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 7.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 7.1 Safety Information for relevant warning.

Daily Checks 1. Check that all guarding is complete and properly secured prior to start up. Also that all warning signs (Section 1.8) are present and readable. 2. Check that all the plant emergency stop buttons are operative (Section 1.7 and 8.3.3). 3. Carry out a general inspection of the plant to ascertain that nothing untoward is out of place or damaged so as to cause a safety hazard. 4. Ascertain any fault messages displayed on the Electrical Control Panel (Section 7.2.3). 5. Check engine clutch bearing oil level (Section 9.19.2) Note: See also Section 7.3.12 for daily Automax checks. Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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7.3 Automax Operation The Automax crusher is a high quality cone crusher featuring:•

Optimum Performance - Advanced crusher geometry. Excellent product shape through attrition crushing. High output capability. Maximum production of high quality material.

•

Low Cost Operation - High capacity with energy efficiency. Low wear costs. Exceptional reliability.

•

Ease of Maintenance - Accessible external hydraulics. Simple assembly and dismantling. Quick manganese changes.

To assist in understanding the Automax hydraulic control functions the following brief explanation is given. The actual step by step procedures are detailed in the following pages under the appropriate section headings. Refer also to the Glossary of Automax Terms (Section 7.3.2) for additional information. With the Automax in normal ‘AUTO’ crushing operation the hydraulic system automatically maintains a pre-selected discharge setting which determines the product from the machine. The setting is maintained by hydraulic pressure and, in the event of uncrushable material entering the machine, the hydraulic overload release is automatically triggered to raise the upper frame to pass the foreign body and then automatically returns to the selected setting.

Selection of the discharge setting is carried out manually with the controls switched into ‘MANUAL’ as are also other additional functions described later. The material product from the Automax is governed by the closed side discharge setting dimension, ie. the minimum gap between the concave and mantle manganese crushing members. See the Glossary of Terms for other ways of referring to the ‘setting’. Changes to the discharge setting are achieved by raising or lowering the Automax upper frame by means of the six externally mounted hydraulic rams. When new manganese is fitted the MANUAL hydraulic controls are used for the panel to record a ‘zero’ point at which the mantle and concave are just touching. The required discharge setting dimension is then manually entered into the panel controls. The hydraulic system can then position the upper frame so that the gap between the mantle and concave equals the entered setting. This procedure is carried out with the machine stationary. During crushing operations the mantle and concave wear under abrasive action of the material being crushed and the gap between the two will increase although the panel display will still show the original gap setting. To restore the actual gap between the two crushing members to the original setting it is necessary to manually reset the ‘zero’ point with the mantle and concave touching. The controls can now compare the new zero point with the original zero point with new manganese. The machine is to be stationary when this procedure is carried out.

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By selecting ‘manganese wear’ on the display screen, the panel will now calculate the amount of wear that has taken place since fitting new manganese. The rate of manganese wear obviously depends upon the physical characteristics of the feed material and other governing factors and will confirm the frequency of re-calibrating the zero point to maintain the desired product and also the need to change the manganese mantle and concave.

Also available on the hydraulic control display are additional read out facilities including crusher motor hours run and number of tramp overload situations (Section 7.4.3)

For guidance on when to change the manganese mantle and concave liners refer to Section 9.7.1.

Additionally, a separate subsidiary hydraulic circuit is employed to apply pressure to the wedge ring and the requirements for this system are also covered later in this manual (Section 9.8).

! NOTICE ! It is most important to change both the liners together when fitting new replacements. At the same time as changing the mantle and concave, take the opportunity of replacing the frame arm and countershaft protection liners.

In addition to these normal machine control functions the system also includes a separate audible alarm and hydraulic system malfunction messages which appear on the display screen (Sections 7.4.10 to 13)

Service schedules in this manual assume reasonable operating conditions apply. Refer to Terex Pegson Limited’s technical department for advice if the operating conditions are other than normal.

Genuine replacement parts obtainable from BL-Pegson are manufactured with the correct material specification and to the original dimensions under strict quality control. Always quote the machine serial number stamped on the machine identity plate when ordering. The hydraulic control system also allows the discharge setting to be altered whilst the machine is running and also a number of other functions as described in the following pages.

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7 - Operating Instructions

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DUMPY

CRUSHING

To identify the terms used in connection with the Automax crusher the illustration below indicates the major parts. Also refer to the Parts List in Section 10 for more detailed identification of individual parts.

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7.3.1 Glossary of Automax Parts

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7.3.2 Glossary of Automax Terms Blocking/Bridging A condition caused by material in the feed being too large to enter the crushing chamber, too dirty or otherwise unsuitable material being unable to pass through the machine. Bouncing Oscillating movement of the Automax upper frame. Choke Feed The feed rate to the machine that enables optimum crushing performance to take place. The condition whereby the feed material completely fills the crushing chamber and the lower section of the feed box. Crushing Chamber The region between the manganese (mantle and concave) where the crushing takes place. Dumping Automatic lifting of the Automax upper frame to allow uncrushable material to pass through the crusher. Manganese (Mang.) The Automax mantle and concave crushing members. Out of Round Uneven wear to the crushing surfaces (mantle and concave), mainly due to badly segregated feeds. Packing/Caking Congealed lumps in the product usually due to an excessive percentage of fines in the feed. Segregated Feed A poorly mixed, uneven distribution particle sizes in the feed. Setting (also referred to as the Closed Side Setting, Discharge Setting or Gap) The distance between the crushing surfaces (mantle and concave) during operation. Tramp Metal Pieces of metal present in the feed material that must be removed in order to prevent damage to the crusher. Wearing Parts Components subject to wear from the stone being crushed. Mainly the mantle and concave, but also any other component subject to stone abrasion, eg. frame arm shields, etc. Well Graded Feed An even distribution of material particle sizes in the feed. Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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•

Make the checks prior to starting the plant (Section 7.1.3).

•

Check that all Emergency Stops on the plant are pulled out (Figure 1a).

•

Check that the conveyors and Automax crushing chamber are empty of material.

•

Make sure that you fully understand the operating procedures for the Automax before attempting to start.

Numeric Keypad

OPEN Button

Pressure Gauge

Display

AUTO/MANUAL Switch

TRAMP O/L TEST Button

CLOSE Button

Figure 7i Automax Hydraulic Panel Controls

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7.3.3 Automax Initial Discharge Setting and Calibration

WARNING

FOR THIS OPERATION THE AUTOMAX MUST NOT BE RUNNING

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Referring to the separate Automax Control Panel (Section 7.4) for detailed instructions, action as follows;-

Procedure 6. Scroll to the New Mang display screen and then press Enter.

1. Observe all safety warnings. 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b). DO NOT press any of the start buttons. 4. On the Automax hydraulic panel (Figure 7i) switch to MANUAL and depress the OPEN button to raise the Upper Frame approximately 25-38mm (1” to 1½”). Look into the Automax crushing chamber to check there is no stone lodged in the chamber. 5. Now depress the CLOSE button until the manganese crushing members (mantle and concave) touch. This is indicated by a sudden rise in pressure shown on the gauge near the panel (Figure 7i) and release the button immediately.

7. Press the F4 key to Zero the display and then press Escape. 8. Scroll to the Set Gap display screen, press Enter and then press Enter again. 9. Key in the required closed side setting (mm) using the number keys, press the Enter and then press Escape. 10. Scroll to the Current Gap display screen. 11. Depress the OPEN button; hold until the Current Gap display shows the gap to be above the Set Gap setting then switch to AUTO. The machine will automatically come down to the required setting.

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7.3.4 Automax Manganese Wear Calibration

WARNING

FOR THIS OPERATION THE AUTOMAX MUST NOT BE RUNNING

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Referring to the separate Automax Control Panel (Section 7.4) for detailed instructions, action as follows;

Procedure 6. Scroll to the Set Zero display screen and then press Enter.

1. Observe all safety warnings 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b). DO NOT press any of the start buttons. 4. On the Automax hydraulic panel (Figure 7i) switch to MANUAL and depress the OPEN button to raise the Upper Frame approximately 25-38mm (1” to 1½”). Look into the Automax crushing chamber to check there is no stone lodged in the chamber. 5. Now depress the CLOSE button until the manganese crushing members (mantle and concave) touch. This is indicated by a sudden rise in pressure shown on the gauge near the panel (Figure 7i).

7. press the F3 key to Zero the display screen and then press Escape. 8. Scroll to the Current Gap screen.

display

9. Depress the OPEN button; hold until the Current Gap display shows the gap to be just above the Set Gap setting then switch to AUTO. The machine will automatically come down to the required setting. Note: After calibration the amount of manganese worn off the crushing members is displayed by scrolling to the Mang Wear display screen.

! NOTICE ! The interval between future calibrations is determined by machine usage and estimated wear of the manganese.

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7.3.5 Guidance for Changing the Manganese Mantle and Concave Both the mantle and concave liners are locked against their mating parts using tapers (angled faces). If these liners are worn too thin they will not be able to hold tight against their mating faces, coming loose and/or slipping relative to their mating part. The mating will be damaged and will need reworking.

When replacing the manganese liners, always fit both a new mantle and a new concave at the same time.

! NOTICE ! Always fit a new manganese mantle and concave as a ‘pair’. It is detrimental to the operation of the machine to do otherwise.

Reworking and machining these large components is expensive and can involve lengthy downtime. It is for this reason that the manganese liners must replaced before the situation described above arises. There is approximately 55-60mm (21/8”- 23/ ”) of wear on the liners, as a pair. 8

Inspect the liners on a daily basis, for possible ‘tramp metal’ damage and also any evidence of an uneven wear pattern developing. The manganese liners must be changed when the hydraulic rams can be fully closed. The pin centre to pin centre distance (Figure 7j) when the rams are fully closed is 774mm (30.5”)..

774 mm (301/2”) minimum

Take note of the ‘wear’ shown on the display (Section 7.4.3).

Figure 7j Minimum Ram Dimension

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7.3.6 Automax Initial Start Up

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

1. Observe all safety warnings 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm.

DANGER

3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b).

SKIN INJECTION HAZARD Refer to Section 7.1, Safety Information for relevant warning

4. Carry out the sequential start procedure (Section 7.2.2) EXCEPT DO NOT START THE FEEDER. Note: The Automax safety interlocks and protection devices are checked with the fault display on the Electrical Control Panel. 5. Check that the overall operation of the lubrication system is satisfactory. 6. Run the Automax empty for a short period and check the machine for unusual noises, vibration, excessive heat, leaks of lubricating oil. 7. Check the hydraulic system for leaks and that the discharge setting is being maintained. 8. Check the travel on the Automax Upper Frame by switching into MANUAL on the Automax Panel (Figure 7i) and depressing the OPEN button. The Upper Frame will travel upwards.

Release the button when the hydraulic cylinders have reached the full extent of their travel and switch to AUTO. Note the pressure on the panel gauge as the machine closes down to it’s discharge setting. This pressure should be in the region of 55 - 82 BAR (800-1200psi). Note: The cone head will rotate with the eccentric while the machine is running empty, but stops when feed is introduced into the crushing chamber and begins to slowly rotate in the opposite direction.

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7.3.7 Actions during running in •

•

Check the alignment and tension of the vee rope drive daily during the initial days of operation. Avoid overloading the machine by not using small discharge settings during the first few days of operation.

•

Ensure that the machine is running correctly with no abnormal noises or leaks evident.

•

Make sure a satisfactory feed (Section 3.4) is maintained at a constant rate to give a ‘choke’ feed (Section 7.3.2 Glossary). Irregular and excessive feed rates reduce the efficiency of the Automax. Ensure that the feed is not segregated in the crushing chamber.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning. FALLING HAZARD Refer to Section 7.1, Safety Information for relevant warning.

Note: This applies to all machine operations subsequent to the running in period. •

Keep a check on the lubrication system to confirm this is operating satisfactorily and that the system safeguards warn of any possible high temperature or low flow (Section 9.5).

•

Check the operation of the hydraulic system (Section 9.6) including the smooth raising and lowering of the upper frame and the correct functioning of the wedge ring (Section 9.8).

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7.3.8 Automax Adjustment of Discharge Setting

WARNING

AUTOMAX RUNNING

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Referring to the separate Automax Control Panel (Section 7.4) for detailed instructions, action as follows;

Procedure 8. Scroll to the Current Gap display screen.

1. Observe all safety warnings. 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b).

9. Depress the OPEN button; hold until the Current Gap display shows the gap to be above the Set Gap setting then switch to AUTO. The machine will automatically come down to the required setting.

4. Carry out the sequential start procedure (Section 7.2.2) EXCEPT DO NOT START THE FEEDER. 5. On the Automax Hydraulic Panel (Figure 7i) switch to MANUAL. 6. Scroll to the Set Gap display screen, press Enter and then press Enter again. 7. Key in the required closed side setting (mm) using the Number keys and then press the Enter and then Escape.

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7.3.9 Manual Raising/Lowering of the Automax Upper Frame

WARNING

AUTOMAX RUNNING

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Provision is made for raising and lowering the Upper Frame when under manual control.

! NOTICE ! DO NOT UNDER ANY CIRCUMSTANCES RUN THE AUTOMAX UNDER MANUAL CONTROL FOR ANY LONGER THAT ABSOLUTELY NECESSARY When under manual control the tramp metal protection (ie. the automatic hydraulic overload release) is not operative and therefore damage to the machine could result. If the machine is left in manual control an audible warning alarm will sound after a short period to warn the operator to switch into auto control.

4. Carry out the sequential start procedure (Section 7.2.2) EXCEPT DO NOT START THE FEEDER. 5. On the Automax Hydraulic Panel (Figure 7i) switch to MANUAL. 6. Depress the OPEN button to raise the Upper Frame to the maximum extent. On release of the button the Upper Frame is retained at this position. 7. On re-selection of AUTO the control automatically resets the discharge setting to that previously specified.

Procedure 1. Observe all safety warnings. 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b).

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7.3.10 Automax Automatic Overload Release/Unblocking and Resetting The control equipment on the Automax crusher automatically monitors the operating conditions of the hydraulic system for tramp metal/packing in the crushing chamber and effects an immediate release. The equipment also resets the discharge setting and also compensates for any tendency for the setting to creep open during normal operation. Normally the hydraulic system clears any tramp metal from the crushing chamber. However, in the event of the tramp metal being too large to be released, severe damage to the machine can occur as the system continues to try and release the object.

! NOTICE ! In order to protect the Automax crusher from the ingress of damaging tramp metal the plant is fitted with a metal detector on the feed conveyor which will sound an alarm and stop the feed. It is essential to remove the offending object before resetting the detector and restarting the feed. Make sure that the metal detector is operative and correctly set for sensitivity (Section 9.17.1) at all times when crushing.

In this event the machine should be switch to manual control, the Upper Frame raised, and the blockage removed manually. Refer to Section 7.1.1. for Blocked Crusher procedures

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7.3.11 Checking Automax Wedge Pressure

WARNING

AUTOMAX NOT RUNNING

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

The pressure on the wedge ring is automatically controlled by the Dumpy Jack hydraulic circuit. However, as the adjustment of the wedge ring is critical for good performance of the Automax crusher it is recommended that this should be checked daily. The pressure gauge near the panel (Figure 7i) gives an accurate indication of whether the Wedge Ring assembly is functioning correctly.

! NOTICE ! The Automax must not be allowed to operate with regular dumping or bouncing of the Upper Frame or damage may result. Possible causes could be crushing at too small a setting, out of round manganese (Section 9.9) or poor Wedge Ring adjustment (Section 9.8).

4. On the Automax Hydraulic Panel (Figure 7i) switch to MANUAL and depress the OPEN button lifting the Upper Frame approximately 20mm (3/4”) above the set point. 5. Switch back to AUTO and observe the pressure reading on the panel pressure gauge (Figure 7i). The pressure should be in the range 55 - 82 BAR (800 - 1200 psi). 6. Whilst the Upper Frame is moving check for smooth movement with no sticking at the start or whilst travelling.

Procedure 1. Observe all safety warnings 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm.

7. If the pressure reading is above or below the range indicated above or the action is not smooth, remedial action is required (Section 9.8).

3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at ON (Figure 7b). DO NOT press any of the start buttons.

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7.3.12 Daily Automax Checks

WARNING

! NOTICE !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 7.1, Safety Information for relevant warning.

Daily attention should always be a matter of routine to ensure maximum efficiency of this vital element of the plant.

DANGER

Before starting the Automax • Look at the manganese liners to check for wear and/or damage. • Check oil level in lubrication tank. • Check oil level in hydraulic tank. • Check oil pressure in hydraulic console. • Check the operation of the lubrication oil heater. • Check Wedge pressure. • Re-calibrate the manganese. • Check for any obstructions in the discharge opening of the Automax. • Check the condition of the vee drive. • Check for loose bolts, leaks, hose connections, etc. • WARNING Ensure the frame arms are free from foreign bodies/stone build up. See the warning sign on the machine (Figure 7k).

SKIN INJECTION HAZARD Refer to Section 7.1, Safety Information for relevant warning

After starting the lub oil pump • Check the oil flow to the crusher and back into the tank (sight glass on top of oil tank in return pipe) and that oil lines do not leak.

After starting the Automax • Set the discharge setting • Listen for any abnormal noise from the crusher. • Check that no bolts have come loose.

During crushing • Listen for any abnormal noise from the crusher. • Check oil pressure at normal running temperature. • Check no leaks in the lubrication system. • Inspect hydraulic system piping, cylinders, etc. for leaks which could cause an alteration in the setting. • Note the crushing pressure.

Figure 7k Frame Arm Warning Sign

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7.4 Automax Crusher Controls The Automax Crusher is equipped with the latest System 2-2000 hydraulic controls having a Unitronics M-90 control module with numeric keypad and status display. The layout, functions and displays are described on the following pages.

7.4.1 Controls Layout

System I I 2000 BL-Pegson a Terex >>

Figure 7l Controls Layout

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7.4.2 Function Keys

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7.4.3 General Operation

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.3 General Operation, continued

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7.4.4 Manual Operation

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7.4.5 Setting the Gap

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7.4.5 Setting the Gap, continued

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7.4.6 Setting New Manganese

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7.4.6 Setting New Manganese, continued

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7.4.7 Setting Normal Zero

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7.4.7 Setting Normal Zero, continued

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7.4.8 Tramp Overload or Test (whilst in Manual)

7.4.9 Tramp Overload or Test (whilst in Auto)

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7.4.10 Alarms

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7.4.11 Alarm List

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7.4.11 Alarm List, continued

7.4.12 Wedge Lock Option

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7.4.13 Historical Alarms

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7.4.14 Set Time & Date

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7.4.14 Set Time & Date, continued

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7.4.15 Set Operating Language

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8 - Shut Off 8.1 Safety Information .......................................................................................... 8 - 2 8.2 Closing Down the Plant ................................................................................. 8 - 4 8.3 Emergency Stopping of the Engine .............................................................. 8 - 8 8.3.1 Emergency Stop Buttons ............................................................................ 8 - 8 8.3.2 Restarting the Plant .................................................................................... 8 - 9 8.3.3 Testing Buttons ......................................................................................... 8 - 10

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8.1 Safety Information

When carrying out maintenance or adjustment to the plant the following procedure must be followed.

LOCKOUT PROCEDURE

LOCKOUT PROCEDURE 1. 2. 3. 4. 5.

Switch off engine. Remove the ignition key. Keep the ignition key on person during lockout. Place appropriate maintenance warning signs (ie. ‘TAG OUT’). NEVER work alone.

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

SKIN INJECTION HAZARD

ALWAYS relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. ALWAYS use a piece of cardboard to check for leaks. DO NOT use your hand. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately.

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Loose or baggy clothing can get caught in running machinery.

PERSONAL PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting (E.N./A.N.S.I. approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close Fitting Overalls, Steel Toed Boots, Industrial Gloves and High Visibility Vest.

Falling from and/or onto a BL-Pegson machine can cause serious injury or even death.

FALLING HAZARD

DO NOT climb onto the machine whilst in operation. ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority. ALWAYS use an E.N./A.N.S.I. approved safety harness when reaching any points 7ft (2m) or more above ground level. In-running nip points can cause serious injury or even death.

ENTANGLEMENT HAZARD

DO NOT reach into an unguarded machine. Your arm could be pulled in and amputated. SWITCH OFF, LOCKOUT & TAGOUT machine before opening or removing guards.

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8.2 Closing Down the Plant Procedure 1. Observe all safety warning 2. On the Electrical Control Panel (Figure 8a), press the red Feed Conveyor stop button to stop the feed and wait until the crusher and both conveyor belts are empty of material before the next step.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 8.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 8.1, Safety Information for Lockout Procedure.

3. Press the red Crusher stop button to stop the crusher and wait until the crusher cone head has stopped spinning before the next step.

! NOTICE ! WARNING. The reason for the delay is so that the oil pump continues to circulate oil to the crusher bearings during the Automax run down time. Failure to obey this instruction will result in reduced bearing life. THE PLANT SHOULD NOT BE SHUT DOWN AT THE END OF A SHIFT BY ONLY SWITCHING OFF THE ENGINE OR BY PRESSING AN EMERGENCY STOP BUTTON. 4. Press the remaining red Discharge Conveyor and Oil Pump stop buttons to stop these items.

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5. Using the speed control, decrease the engine rpm to 1200rpm (Figure 8b) 6. Let the engine idle for 3-5 minutes. 7. Turn the Ignition Key to the off position to shut down the engine. Remove the Ignition Key. Shut and lock the Control Box door. Lockout the Isolation Switch (Figure 8c).If the radio hand set (where fitted) has been in use, shut down by depressing the stop button on the unit. 8. Following the closing down procedure above, it is recommended that at the end of operation for the day the plant is routinely cleaned down and thoroughly examined to check for any damage, breakages, wear, leaks etc. which should be rectified before further operation.

! NOTICE ! Use of high pressure washing equipment is to be avoided where the ingress of water will be detrimental to plant components eg crusher bearings, conveyor bearings, hydraulic tank, electrical equipment etc.

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Feed Conveyor Level Sensor Controls (*optional)

Diagnostic Display Screen

Crusher Level Sensor Controls

EMERGENCY STOP

OPERATION PLANT/TRACK RADIO REMOTE CONTROL OFF/ON

FAULT MUTE

FAULT RESET

FEED CONVEYOR CONTROLS AUTO/MANUAL*

CRUSHER CONTROLS AUTO/MANUAL

DISCHARGE CONVEYOR START/STOP

OIL PUMP START/STOP

CRUSHER START/STOP

FEED CONVEYOR MANUAL SPEED CONTROL

FEED CONVEYOR START/STOP

Figure 8a Electric Panel Controls

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Maintenance Due Lamp

Diagnostic Lamp

Tachometer

Diagnostic Display

US/Metric Switch

Scroll Switch

Fuel Gauge

Speed Control

Ignition Key

Figure 8b Caterpillar Engine Control Panel

Figure 8c Engine Isolation Switch

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8.3 Emergency Stopping of the Engine

WARNING

IN AN EMERGENCY SITUATION, STOP THE ENGINE (AND THE PLANT OPERATION ) USING THE EMERGENCY STOP BUTTONS.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 8.1, Safety Information for relevant warning.

See Section 1, Figure 1a for locations of the Emergency Stop buttons. Note:- The plant should not be restarted if the crusher is full of material (Refer to Section 8.3.2) When the plant has been stopped using an Emergency Stop button, the Engine Ignition Key remains in the ‘on’ position. The switch should be returned to the ‘off’ position as soon as possible to avoid the ignition being left ‘on’.

! WARNING ! When an emergency stop has been initiated, DO NOT attempt to restart the engine until it is safe to do so. 8.3.1 Emergency Stop Buttons Pressing any of the buttons will stop the diesel engine and the button will remain engaged until physically released by pulling or twisting (depending upon the type fitted) the button knob. The engine cannot be started if any of the emergency buttons remain depressed.

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8.3.2 Restarting the Plant

WARNING

! WARNING ! When an emergency stop has been initiated, DO NOT attempt to restart the engine until it is safe to do so.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 8.1, Safety Information for relevant warning.

! NOTICE ! When restarting the plant after the use of an Emergency Stop button it is essential to ensure that the Automax crushing chamber is empty of material. Procedure 1. Observe all safety warnings. 2. Follow the safe start-up procedure (section 7.2) 3. Start the engine (section 7.2.1) 4. Manually raise and lower the Automax Upper Frame by following the procedure in Section 7.3.9. 5. Visually check that material in the crushing chamber has been discharged and that the chamber is empty. Note: In the event of material failing to clear the crushing chamber, repeat the operation above or follow the Blocked Crusher Procedure (Section 7.1.1) as necessary. 6. When safe to do so continue with the Plant Start-Up Procedure (Section 7.2.2). Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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8.3.3 Testing Buttons

WARNING

! WARNING ! Daily, before commencing crushing operations, test each emergency stop button is operative.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 8.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings 2. Follow the safe start-up procedure (section 7.2) 3. Start the engine (section 7.2.1) 4. Test each emergency stop button in turn to cut out the engine and, following the re-setting of the tested button, repeat the process for each of the other emergency stop buttons (Section 1-Figure 1a) and also the stop button on the remote control handset. 5. When safe to do so continue with the Plant Start-Up Procedure (Section 7.2.2).

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9 - Maintenace 9.1 Safety Information .......................................................................................... 9 - 4 9.1.1 Engine Start-Up - Maintenance ................................................................... 9 - 8 9.2 Weights of Automax Crusher Components................................................ 9 - 10 9.3 General Information ...................................................................................... 9 - 11 9.4 Lubricants, Oils, Coolant, etc. ...................................................................... 9 - 13 9.4.1 Service Attention Points ........................................................................... 9 - 13 9.4.2 Regular Servicing ..................................................................................... 9 - 14 9.4.3 Daily, Weekly and Monthly Checks ........................................................... 9 - 15 9.4.4 Automax Crusher Lubrication and Servicing Schedule .............................. 9 - 17 9.4.5 Plant Lubrication and Servicing Schedule ................................................. 9 - 18 9.4.6 Recommended Oil/Grease Types............................................................. 9 - 19 9.5 Automax Crusher - General ......................................................................... 9 - 22 9.5.1 Automax Lubrication Overview ................................................................. 9 - 22 9.5.2 Automax Lubrication Operating Procedure ............................................... 9 - 23 9.5.3 Automax Lubrication System Detailed Description ................................... 9 - 25 9.5.4 Automax Oil Change Intervals ................................................................... 9 - 27 9.5.5 Recommended Automax Oil ..................................................................... 9 - 28 9.5.6 Automax Oil Filter Change Intervals .......................................................... 9 - 29 9.5.7 Automax Oil Filter Replacement ............................................................... 9 - 30 9.5.8 Automax Oil Lubrication System General Maintenance ............................. 9 - 31 9.6 Automax - Hydraulics Overview .................................................................. 9 - 32 9.6.1 Automax Hydraulic System Maintenance Procedure ................................. 9 - 34 9.7 Manganese Change Procedure................................................................... 9 - 35 9.7.1 Guidance for Changing the Manganese Mantle and Concave ................... 9 - 35 9.7.2 Filler Handling .......................................................................................... 9 - 36 9.7.3 Changing the Manganese ........................................................................ 9 - 38 9.8 Wedge Ring Maintenance ............................................................................ 9 - 56 9.8.1 Checking Automax Wedge Pressure ........................................................ 9 - 58 8.8.2 Low Wedge Pressure .............................................................................. 9 - 59 9.8.3 Readjusting Tight Wedge Ring ................................................................. 9 - 60

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9.9 Automax - Out of Round Manganese - Causes and Effects ...................... 9 - 62 9.9.1 Checking Manganese for Out of Round .................................................... 9 - 63 9.10 Automax - Fault finding. ............................................................................ 9 - 66 9.11 Plant - Feed Conveyor ................................................................................ 9 - 76 9.12 Plant - MiniRanger Level Sensors Description ........................................ 9 - 77 9.12.1 Level Sensors - Operation ..................................................................... 9 - 78 9.12.2 Level Sensors - Run Mode ..................................................................... 9 - 79 9.12.3 Level Sensors - Program Mode .............................................................. 9 - 80 9.12.4 Level Sensors - Factory Settings ............................................................ 9 - 81 9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl ..................................... 9 - 82 9.12.6 Level Sensor MR2 Setup Guide - Hopper* ............................................. 9 - 84 9.13 Plant/Automax - Hydraulic Systems ......................................................... 9 - 86 9.13.1 General Description ............................................................................... 9 - 86 9.13.2 Track Drives ........................................................................................... 9 - 88 9.13.3 Feed Conveyor Drive ............................................................................. 9 - 88 9.13.4 Circuit Protection ................................................................................... 9 - 88 9.13.5 Changing the Suction Filter .................................................................... 9 - 90 9.13.6 Changing the Return Filter ...................................................................... 9 - 92 9.12.7 Changing the Tank Breather ................................................................... 9 - 92 9.13.8 Changing the Pressure Filters ................................................................ 9 - 93 9.13.9 Automax Hydraulic System ..................................................................... 9 - 94 9.14 Plant - Electrical System ............................................................................ 9 - 96 9.14.1 General Description ............................................................................... 9 - 96 9.14.2 Operator’s Control Points ....................................................................... 9 - 96 9.14.3 Protection Devices ................................................................................. 9 - 97 9.15 Plant - Crusher and Hydraulic Pump Drive Belts ..................................... 9 - 98 9.15.1 Trouble Shooting - Drive Belts ................................................................ 9 - 99 9.15.2 Replacement and Adjustment of Crusher Drive Belts ............................ 9 - 100 9.15.3 Replacement and Adjustment of Hydraulic Pump Drive Belts ................ 9 - 103 9.15.4 Method of Drive Belt Tensioning ........................................................... 9 - 106

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9.16 Plant - Conveyor Belts ............................................................................. 9 - 108 9.16.1 General Description ............................................................................. 9 - 108 9.16.2 Training of Belts ................................................................................... 9 - 109 9.16.3 Conveyor Belt Tensioning ..................................................................... 9 - 111 9.16.4 Maintenance of Conveyor(s) ................................................................. 9 - 112 9.16.5 Cleaning the Conveyor Belts ................................................................ 9 - 115 9.17 Metal Detector ........................................................................................... 9 - 117 9.17.1 Metal Detector Controls........................................................................ 9 - 118 9.17.2 Metal Detector Indictor Lights (Figure 9am & 9an) ................................ 9 - 120 9.18 Plant - Dust Suppression ......................................................................... 9 - 122 9.19 Plant - Diesel Engine ................................................................................ 9 - 124 9.19.1 Engine - ELC Coolant .......................................................................... 9 - 125 9.19.2 Hydraulic Engine Clutch........................................................................ 9 - 126 9.19.3 Check Fuel Level ................................................................................. 9 - 127 9.19.4 Top Up Fuel Level ................................................................................ 9 - 128 9.20 Plant - Vehicle Tracks ............................................................................... 9 - 130 9.21.1 Measuring Track Tension ...................................................................... 9 - 130 9.20.2 Adjusting Track Tension ........................................................................ 9 - 132 9.20.3 Track Maintenance ............................................................................... 9 - 135 9.20.4 Drive Oil Filling and Draining ................................................................ 9 - 136

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9.1 Safety Information

Loose or baggy clothing can get caught in running machinery.

PERSONAL PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting (E.N./A.N.S.I. approved) personal protective equipment. Personal Protective Equipment includes Hard Hat, Safety Glasses, Hearing Protection, Dust Mask, Close Fitting Overalls, Steel Toed Boots, Industrial Gloves and High Visibility Vest.

When carrying out maintenance or adjustment to the plant the following procedure must be followed.

LOCKOUT PROCEDURE

LOCKOUT PROCEDURE 1. 2. 3. 4. 5. 6.

Switch off engine. Remove the ignition key. Keep the ignition key on person during lockout. Place appropriate maintenance warning signs, (ie. TAG OUT). NEVER work alone. Turn the Isolation Switch to ‘O’ when the plant is not being used (especially while plant is being transported).

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Falling from and/or onto a Terex-Pegson machine can cause serious injury or even death.

FALLING HAZARD

DO NOT climb onto the machine whilst in operation. ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority. ALWAYS use a suitable lifting platform when reaching any points 2m (6’- 6”) or more above ground level.

Hydraulic fluid under pressure can penetrate the skin causing serious injury.

SKIN INJECTION HAZARD

ALWAYS relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment. ALWAYS use a piece of cardboard to check for leaks. DO NOT use your hand. If fluid is injected under the skin, it must be surgically removed or gangrene will result. Get medical help immediately.

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In-running nip points can cause serious injury or even death.

ENTANGLEMENT HAZARD

DO NOT reach into an unguarded machine. Your arm could be pulled in and amputated. SWITCH OFF, LOCKOUT & TAGOUT machine before opening or removing guards.

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WARNING PRIOR TO ANY MAINTENANCE •

The maintence instructions are intended for day to day maintenance to keep the plant in good running order and do not cover major rectifications, repairs or replacements where specialist expertise is required. However, ensure that only suitably competent personnel with the necessary training/experience for the task(s) in hand are employed. A person should never work alone.

•

Observe the safety advice in Sections 1 and 9.1 as appropriate to the task(s) in hand.

•

Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk Assessment for all maintenance operations. Have suitable lifting equipment available for the components involved together with all necessary (and suitable) tools/equipment ready for the task(s) in hand and always secure parts liable to movement before starting work. BL-Pegson’s Service Department is available for advice when required.

•

The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout Procedure (Section 9.1). Display a prominent ‘tag’ at the control station (or other appropriate place) to warn of maintenance work being carried out.

•

Keep clear of moving parts when trying to identify or isolate any unusual noises.

•

Fit dismantled parts in the same location from which they were removed.

•

Ensure that the area surrounding the maintenance site is clear of any obstructions.

•

If arc welding work is involved in any maintenance operation, ensure that the current does not pass through any bearings. FOLLOW THE WARNING INSTRUCTIONS ON THE OPPOSITE PAGE FOR ENGINE PROTECTION. The plant must be fully isolated prior to any welding work.

•

BEFORE WORKING ON THE PLANT, SWITCH OFF, ‘LOCKOUT’ AND ‘TAGOUT’

AFTER EXTENSIVE MAINTENANCE Refer to Sections 7.1.3, 7.2.8 and 7.3.6 and 7.3.7.

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9.1.1 Engine Start-Up - Maintenance Procedure 1. Observe all safety warnings. 2. Check that all Emergency Stop push buttons are pulled out (Figure 1a) otherwise the engine cannot start.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

3. Ensure the engine Isolation Switch is turned to the I position. 4. On the Electrical Control Panel: OPERATION switch = PLANT RADIO REMOTE CONTROL switch = OFF.. 5. On the engine control panel turn on the ignition with the key to the first position and, once the sequence of diagnostic checks is completed, fully turn the key to start the engine. Release the key back to the first position as soon as the engine starts. Engine Isolation Switch

! NOTICE ! Refer to Figure 7d together with continuation page for details of the engine diagnostic functions. 6. Keep the rpm of the engine to 1200 rpm (view on tachometer) and allow to run for 3-5 minutes before proceeding with maintenance.

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OPERATION and RADIO REMOTE CONTROL Switches on the Electrical Control Panel

Maintenance Due Lamp

Diagnostic Lamp

Tachometer

Diagnostic Display

Scroll Switch

US/Metric Switch

Speed Control Fuel Gauge

Ignition Key

Engine Control Panel

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9.2 Weights of Automax Crusher Components Weights of the Automax crusher components, these should be consulted when arranging suitable lifting equipment. Refer to Terex Pegson’s Technical Department for any other weights of individual items or assemblies if not listed. WEIGHTS (APPROXIMATE)

KGS.

LBS.

Complete Automax Crusher

22,000

48,400

Upper Frame Assembly (upperframe with concave)

5,260

11,598

Cone Head Assembly (with bearings, mantle etc.)

2,950

6,505

Eccentric Assembly (with bearings, ring gear etc.)

1,800

3,970

Countershaft Assembly

500

1,103

Concave

760

1,676

Mantle

852

1,879

! WARNING ! All weights given are for guidance only and appropriate allowances should be applied for the sizing of lifting or transporting equipment.

4 x Lifting Points in the Automax Upper Frame Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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9.3 General Information When performing maintenance, always observe rules provided in the safety section. Breakdown caused by insufficient or improper maintenance will cause high repair costs and long term standstill. Therefore, regular maintenance is imperative.

The plant has been designed to facilitate easy routine maintenance, but where necessary to remove any guards make sure that they are replaced before the machine is restarted. Refer to the Spare Parts illustrations (Section 10) to identify the machinery components mentioned in the maintenance procedures.

In addition to several other factors, the reliability and life of the Maxtrak depends on regular and proper maintenance. The following section contains maintenance instructions as well as maintenance schedules for normal operating conditions.

! NOTICE ! When the Maxtrak plant is operated in extreme climatic conditions, e.g. below -15 °C or above 30 °C (5°F or above 86°F) or in very dusty conditions for a longer period of time, the maintenance schedules will change. Ask your local Terex Pegson dealer or Terex Pegson Technical Department for advice.

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! WARNING !

WARNING

PRACTICE SAFE MAINTENANCE Understand service procedures before doing any work. Keep the area clean and dry. Never lubricate, clean, service or adjust machine whilst it is moving. Keep hands, feet and clothing clear of power driven parts and inrunning nip points.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Disengage all the power and operate controls to relieve pressure. Stop the engine. Implement lockout procedure. Allow machinery to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Attend to damage immediately. Replace worn or broken parts. Remove any build up of grease, oil or debris. Disconnect battery ground cable () before making adjustments on electrical systems or welding on machine.

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9.4 Lubricants, Oils, Coolant, etc.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

9.4.1 Service Attention Points Routine checks/replenishment/changes of lubricants, oils, coolant, etc. must be carried out to the plant machinery in accordance with the Lubrication and Servicing Schedule (Section 9.4.4 and 9.4.5) in order to maintain efficiency.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

The locations of the Service Attention Points are as follows:-

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

•

Automax Crusher oil lubrication tank sited within the plant chassis (Figure 9b).

•

Automax Crusher Upper Frame grease nipples x 12.

•

Diesel Engine oil, coolant, (See separate engine manual). Also the fuel (Figure 9ar).

•

Diesel Engine oil lubricated HFO clutch bearing (Section 9.19.2)

•

Track unit gearbox x 2 oil levels (Figures 9au & 9av).

•

Plant hydraulic oil reservoir sited on the forward engine platform .

•

•

Feed Conveyor gearbox within the head drum having oil lubrication (Figure 9ak).

Periodically lubricate hinges, hydraulic cylinder pivot pins and similar linkage points with grease or oil as appropriate.

•

Conveyor head and tailshaft bearing grease nipples located:Feed Conveyor - 1 x headshaft on the platform side and 2 x tailshaft remote nipples on rear of hopper.

! NOTICE ! Failure to carry out scheduled maintenance or exercise due care may invalidate any warranty that might apply.

Discharge Conveyor - 2 x headshaft remote nipples on conveyor LH side and 1 x tailshaft remote nipple on each side of main plant chassis.

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9.4.2 Regular Servicing

WARNING

The Lubrication and Servicing Schedule (Sections 9.4.4 and 9.4.5) lists, in addition to the lubrication points, the attention required to the Automax and Plant hydraulic systems.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Particular attention should be paid to institute a regime of strict adherence from the very start of operations for all aspects of routine servicing and good ‘housekeeping’ in order to keep the your Maxtrak in prime running order.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Keep a accurate record of maintenance work carried out and also log the engine hours operated from the service meter mounted on the engine. Maintenance records can also be used to show compliance with the required maintenance practices and intervals as detailed in this section of the manual. Make sure that frequent checks are made for wear to the manganese mantle and concave (Section 7.3.5) and other wearing surfaces so that replacement can be made before any damage to the core of the Automax is sustained. Regularly check the wedge pressure (Section 7.3.11) to avoid damage to the machine and to obtain the best performance from the Automax.

! NOTICE ! NOTE: Do not overlook the service requirements of the plant diesel engine which are detailed in the separate engine manufacturer’s manual.

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9.4.3 Daily, Weekly and Monthly Checks

WARNING

! WARNING !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

It is imperative that the operator carries out regular and diligent checks before operating the plant especially with operational safety in mind including (but not limited to) those listed below.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Additionally, the operator should always consider what particular safety hazards could occur at specific operating sites and take steps to eliminate them before commencing work. Daily Checks 1. Check that all guarding is complete and properly secured prior to start up. Also that all warning signs (Section 1.8) are present and readable.

6. Look for loose fixings and rectify. Check the security of nuts and bolts on the Automax. Verify there are no leaks of lubricating/hydraulic oil or water.

2. Check that all the plant emergency stop buttons are operative (Section 1.7).

7. Fully raise and lower the Automax Upper Frame several times manually (Section 7.3.9) to help distribute the grease on the wedge ring for smooth operation.

3. Carry out a general inspection of the plant to ascertain that nothing untoward is out of place or damaged so as to cause a safety hazard.

8. Check the Automax Wedge Pressure is satisfactory (Section 7.3.11)

4. Ascertain any fault messages displayed on the Electrical Control Panel (Section 7.2.5).

9. Ensure that the Automax internal frame arms are free of foreign bodies or material build up (Section 7.3.12).

5. Carry out the Automax and Plant daily Lubrication and Servicing Schedule (Sections 9.4.4 & 9.4.5).

10. Recalibrate the manganese wear on the Automax (Section 7.3.4) to compensate for the previous days wear.

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Weekly Checks

WARNING

1. Perform all checks on the daily check list.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

2. Carry out the weekly Lubrication and Servicing Schedule. (Sections 9.4.4 and 9.4.5).

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

3. Note the Automax manganese wear. Arrange renewal when necessary (Section 7.3.4)

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

4. Check the area in and around the Automax for buildup of material; clean out as necessary. 5. Ensure all hydraulic hoses and joints are free from leaks. 6. Check drive belts for damage, wear and fraying.

3. Check the oil level in the Feed Conveyor drive gearbox (Section 9.16.4).

7. Clean away dust, dirt and grit from maintenance platforms and any moving parts.

3. Visually examine the Automax for wear and damage at regular intervals. Renew as necessary.

8. Check conveyor belts for damage and fraying.

4. Inspect crusher drive belts for signs of wear, renew as necessary (Section 9.15).

Monthly/6 Monthly/Annual Checks 1. Perform all checks on the daily and weekly check list

5. Check all drive belts are at the correct tension (Section 9.15).

2. Lubricate and Service to the monthly requirements also attending to the longer interval requirements as necessary (Sections 9.4.4 and 9.4.5).

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~

~

See chart 9.4.6

~

Automax Oil Lubrication Suction Filter (parts list item 2)

Automax Grease Nipples (located around the machine upper frame)

Automax Hydraulic Pressure Filters (parts list items 1 & 2)

See chart 9.4.6

Automax Oil Lubrication Tank (located inside the plant chassis)

Automax Oil Lubrication Pressure Filters (parts list item 10)

Lubricant or Fluid

Description

AX860-901-8EN-02f 169/396 2

12

1

2

275 litres (73 US galls)

Quantity

~

~

~

~

Sight glass upper mark

Level

~

Check wedge pressure

~

Check condition

Check level

Daily

Weekly

Change annually (SEE SECTION 9.13.9)

Add 25 – 50 grams of grease to each nipple if the travel of the upper frame is not smooth (SEE SECTION 9.8)

Replace when changing oil (SEE SECTION 9.5.6)

First change after 100 working hours Thereafter change after every 500 hours (SEE SECTION 9.6.6 & 9.5.7)

First change after 500 working hours Thereafter change after every 1000 hours (SEE SECTIONS 9.5.4 & 9.5.5)

Monthly (165 hrs), 6 Monthly (1000 hrs), Annually (2000 hrs)

Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.

1300 Automax Crusher Schedule

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9.4.4 Automax Crusher Lubrication and Servicing Schedule

Inspect both the complete Automax oil lubrication and Plant hydraulic systems for faults

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D

See chart 9.4.6

~ ~ ~ See chart 9.4.6

See chart 9.4.6

Plant Conveyors Grease Nipples (4 x located on head & tail shaft bearings)

Plant Hydraulic System Reservoir (located on front engine platform)

Plant Hydraulic Suction Filter (located at bottom of hydraulic reservoir)

Plant Hydraulic Return Filter (located on top of hydraulic reservoir)

Plant Hydraulic In-Line Filters x 2 (located one each side of engine inside canopy)

Plant Track Gearboxes x 2 (located each side of plant)

Engine Clutch (accessed when canopy raised and removable panel in engine canopy) Level stick oil wet (approx.)

Fill to level plug

5 litres (1.3 US galls) +/- 10% Approx. 200 cc.

~

~

Check level

~

~

~

~

~

40mm(1½”) below upper sight glass mark

~

~

~

~

~

~

~

360 litres (96 US galls)

~

Fill to centre line of unit

0.8 litres (0.21 US galls)

Daily

~

~

Check condition

Check condition

Check condition

Check level

~

~

Weekly

Check oil level prior to daily start up. Change oil every 1000 working hours. (SEE SECTION 9.19.2)

First oil change after 100 working hours. Thereafter every 1000 hours or at least annually. Check level monthly. (SEE SECTION 9.20.4)

Change filters every 1000 hours or sooner if the tell-tale indicator shows RED (SEE SECTIONS 9.13.5 TO 9.13.8)

Change oil every 2000 hours (SEE SECTION 9.13.1)

Re-grease every 2 weeks (SEE SECTION 9.4.1)

First oil change after 50-100 working hours. Thereafter change after every 2000 hours. Check level monthly. (SEE SECTION 9.16.4)

Monthly (165 hrs), 6 Monthly (1000 hrs), Annually (2000 hrs)

Refer to the separate Engine Operation & Maintenance Manual

See chart 9.4.6

Feed Conveyor Oil Lubricated Gearbox (located in head drum)

Level

Quantity

9 - Maintenance

Caterpillar Engine (fuel, oil, coolant)

Lubricant or Fluid

Description

Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.

Plant Schedule

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9.4.5 Plant Lubrication and Servicing Schedule

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

G F

Automax/Plant Hydraulic System > 30º C (86º F) < 30º C (86º F) Tellus 69 Tellus 46

Omala 220 Omala 150

Shell

Nuto H68 Nuto H46

Spartan EP220 Spartan EP150

Esso

Gulf

Hydrasil 68 Hydrasil 46

EP LUB HD220 EP LUB HD150

Energol HLP-HM68 Energol HLP-HM46

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Energreas LS-EP2

9 - Maintenance

Note: 30°C (86º F), is defined as a daily temperature consistently above 30°C (86º F).

SAE 80w/90 Gear Oil

Beacon EP2

Plant Tracks Gearbox Oil

Alvania EP2

General Multi-Purpose Grease (Grade D grease is suitable)

Mobilux EP2

Plant Tracks Tension

Regulus A2EP

Gear oil with viscosity VG150 with EP additives. Oil temperature always to be below 90º C (194º F) DO NOT MIX OILS OF DIFFERENT MAKET OR TYPE

Plant Conveyor Shaft Bearings

BP

Energol GR-XP220 Energol GR-XP150

Plant Feed Conveyor Drive Gearbox

Chemodex MOLY - BENTONE MP Standard Grade

Mobil DTE26 Mobil DTE25

Mobilgear 630 Mobilgear 629

Mobile

SAE 30 – SAE 40 Oil ISO VG 100 – ISO VG 150 (DO NOT USE SYNTHETIC OIL)

Centraulic PWLC Centraulic PWLB

Centlube F76 Centlube E76

Century

Engine HFO Clutch

D

B A

Automax Oil Lubrication System > 4º C (39º F) < 4º C (39º F)

Automax Upper Frame Grease Nipples

Grade

Equipment

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9.4.6 Recommended Oil/Grease Types

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Lubrication Specifications Oil Specification

Grade A

Grade B

Grade C

Flashpoint: Minimum °C (°F)

199 (390)

204 (399)

216 (421)

Pour Point °C (°F)

-18 (0.4)

-18 (-0.4)

-18 (-0.4)

Kinematic Viscosity at 40°C, mm²/s (104°F, in²/s)

150 (0.232)

220 (0.341)

460 (0.713)

Kinematic Viscosity at 100°C, mm²/s (212°F, in²/s)

15.4 (0.0238)

20.1 (0.0312)

32.9 (0.051)

Viscosity Index

105+

105+

105+

Timken OK lb. Minimum

50

50

50

Extreme Pressure Agent

Yes

Yes

Yes

R & O Agent

Yes

Yes

Yes

Anti Foaming Agent

Yes

Yes

Yes

Copper Strip Corrosion Test Pass

Yes

Yes

Yes

ISO VG

150

220

460

Grease Specification

Grade D

NGLI Grade Number

2

Unworked Penetration at 25°C (77°F)

280

Worked Penetration at 25°C (77°F)

285

Drop Point °C (°F)

185 (365)

ASTM Corrosion Test Pass (14 days)

Yes

Wheel Bearing Test Pass at 135°C (275°F)

Yes

Timken Test lbs. Pass

40/50

Extreme Pressure Agent

Yes

Hydraulic Oil Specification

Grade E

Grade F

Grade G

ISO VG No

32

46

68

Kinematic Viscosity at 40°C mm²/s (104°F, in²/s)

32 (0.049)

46 (0.0713)

68 (0.105)

Kinematic Viscosity at 100°C mm²/s (212°F, in²/s)

5.5 (0.085)

6.5 (0.010)

8.5 (0.013)

Viscosity Index

95+

95+

95+

Rust Inhibitor

Yes

Yes

Yes

Defoament

Yes

Yes

Yes

Anti Scuff

Yes

Yes

Yes

Figure 9a Lubrication Specifications Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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WEDGE RING LUBRICANT FOR CONE CRUSHERS The lubricant grease for BL-Pegson Cone Crushers applied to the grease nipples situated around the upper frame is recommended to be as follows:MOLY - BENTONE M.P. GREASE This is a special non-melt, long life, multi-purpose grease containing molybdenum disulphide. CHEMODEX MOLY-BENTONE M.P. Greases are prepared from specially selected oils solidified with a nonsoap gellant which imparts infusible or non-melt characteristics. The gellant is known as Bentone and is produced by reacting specially selected and refined bentonite with a cationic fatty derivative. The gellant has a micro-lamellar structure which also applies to micronised molybdenum disulphide, so that these two components have a synergistic effect in the compounded grease, giving enhanced stability as well as lubricating value. Chemodex MOLY-BENTONE M.P. GREASES are infusible and have no melting point or drop point show minimum change of consistency with variations in temperature are resistant to mechanical working or shearing in the bearing minimise wear and friction give greater margins of safety in shock and overload conditions are resistant to acids and alkalis and to aqueous solutions of most chemicals are neutral in reaction and suitable for use with all metals and alloys are excellent lubricants for bearings made from plastic materials

Standard Grade Gellant Base Consistency N.L.G.I Penetration at 25 deg. C Temperature Range Drop Point Water Resistance

Bentone No: 3 Medium/Heavy 220/250 -20 deg. C to 200 C None Complete

The Standard Grade is recommended for large. slow speed bearings for slides and splines and to resist shockload conditions.. The molybdenum disulphide content gives greater margin of safety, especially where intervals between lubrication are liable to be prolonged, where there may be occasional overload operations and where temperatures are high. Chemodex MOLY-BENTONE M.P. GREASES are recommended for the lubrication and protection of - stone and ore crushers, conveyor systems, cranes, winches, printing machines, rolling mills and foundry equipment, mechanical stokers, glass works equipment, pumps of all types and marine equipment in general, etc. Chemodex MOLY-BENTONE M.P. GREASES are available in 450 gm and 3 kilo tins, and 12½, 25 and 50 kilo kegs.

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9.5 Automax Crusher General

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

9.5.1 Automax Lubrication Overview The Automax cone crusher is lubricated by oil circulated by hydraulically driven oil pump mounted on the oil tank sited within the plant chassis (Figure 9b) with access being gained from the rear of the chassis.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Filtered oil from the tank is pumped under pressure through external pipework to inlet points on the Automax at the base of the mainshaft from where the oil is distributed internally to the cone head and eccentric roller bearings whilst a second inlet pipe feeds oil to the countershaft assembly bearings. Oil from the bearings lubricates the drive gear and pinion on it’s gravity return to the oil tank to be filtered and re-circulated. After the oil pump has been started the control system delays the crusher start for 5 minutes to allow a good circulation of oil within the Automax and occurs every time the oil pump is started. To prolong the life of the bearings it is also good practice when stopping the crusher to allow the crusher cone head to stop spinning before switching off the oil pump (Section 8.2).

A engine mounted heat exchanger is included to preheat the lubricating oil when necessary and an air blast type cooler is fitted to control the oil temperature whilst the Automax is running. Both of these devices are controlled automatically by thermostats. Lubrication safety devices include monitors for low oil flow, high temperature, low tank level and low oil pressure.

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9.5.2 Automax Lubrication Operating Procedure Once the lubrication pump has been started it does not need to be controlled during the running of the machine and is monitored by the safety electrical interlock safeguards incorporated into the control systems with faults indicated on the Electrical Control Panel Display Screen (Section 7.2.3 & 7.2.5).

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Pressure Gauge

Air Cooler

Cartridge Filters

Float Switch Terminal Box

Oil Filler Cap

Oil Flow Meter

Oil Tank Level Sight Glass

Thermostat

Figure 9b Automax Oil Lubrication Tank

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9.5.3 Automax Lubrication System Detailed Description Function The primary functions of the lubrication system are:- to prevent damage due to metal on metal contact within the bearings. - to dissipate heat generated by the bearings during operation, so acting as a coolant. The bearings can be seriously damaged if any one of the following characteristics are inadequate:• • • •

Viscosity (grade) Quantity (flow) Cleanliness Toughness of the lubricant film (Timken load rating)

Operation Oil is supplied the Automax bearings via a hydraulically driven pump. This oil is filtered clean and pumped under pressure to the main bearings (eccentric and cone head) and via a separate line to the countershaft bearings. It is then piped back to the tank under gravity. An automatic alarm is fitted to the lubrication tank which will sound if there is insufficient pressure or flow to the machine. It is difficult to give a working pressure as this varies significantly under different working conditions so the alarm should be used as an indication of a fault arising.

! NOTICE ! Operating the Automax without the lubrication system safety devices being fully operative will invalidate any warranty in force for the time being. Cold Weather Start-up An engine heat exchanger heats the lubricating oil prior to the Automax operating. This ensures efficient circulation of the oil before the crushing begins. The system is automatically controlled by a thermostat. During cold weather conditions be aware that the commencement of crushing may be delayed whilst the oil reaches a satisfactory temperature Air Blast System This enable the hot oil to be cooled as is circulated through the system and into the machine. This keeps the oil at an optimum working temperature. The system is automatically controlled by a thermostat. Terex Pegson strongly advise against running the Automax empty after initial start-up in cold weather. Even hot oil can be chilled when entering a cold machine and it’s reluctance to return to the tank may result in a slight leak from the machine via the cone head/seal ring and/or mainframe/seal ring. Ideally, once the crusher is started rock should be put through it as soon as possible. BUT THE AUTOMAX MUST NEVER BE STARTED WITH ROCK PRESENT IN THE CRUSHING CHAMBER.

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Air Blast Bypass Valve During initial start-up the viscosity of the oil is very high which results in an increase in pump pressure and a reduction in oilflow through the air blast cooler and into the machine. To overcome this a bypass valve is incorporated in parallel to the cooler. When a predetermined pressure is reached the valve opens allowing oil to pass to the machine without entering the cooler. Once the viscosity is reduced the valve closes and oil passes through the cooler. This is normal on initial start-up with cold oil.

Temperature Monitoring The temperature of the returning oil is monitored to ensure correct operation. One thermostat controls the air-blast cooler fan whilst a second thermostat will stop the machine and will activate an alarm if the oil is too hot, ie. greater than 80°C (176°F). Pressure Relief Valve In order to protect the lubrication system against dead head pressures a relief valve is situated after the pump. This is set (at manufacture) to open at a designated pressure of 3.8 BAR (55psi). It is important that this device is not adjusted or tampered with.

Fluid Level or Float Switch In the event of the lubrication system pipe breaking or a leak occurring the level of the oil tank will drop. To prevent running in this condition the switch will stop the machine and thus prevent damage to the bearings. Oil Feed Flow Indicator and Switch To ensure that sufficient oil is being supplied to the bearings a flow switch is incorporated into the feed side of the lubrication system. In the event of the flow reducing below a set level the switch closes causing warning devices to operate and the machine stop. Continued operation of the Automax with insufficient oil flow will severely damage the bearings.

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9.5.4 Automax Oil Change Intervals

Total Acid Number (TAN) This is the measure of how much the oil has degraded. The TAN increases as the oil degrades. The oil should be changed before it increase 100% above the original value.

The first oil change of the lubricating oil should occur after 500 hours operation. Subsequent oil changes should occurs every 1000 hours, ie once every 5 months working 50 hours per week,

Viscosity Number An engineering/lubrication laboratory is able to identify the viscosity number of an oil which can then be compared to the original value of new oil. If it exceeds a 20% increase at an identical test temperature it is time to change the oil.

Alternatively, Terex Pegson strongly recommend that the oil is tested regularly at monthly intervals by a suitable laboratory and changed when advised to do so. This will provide optimum use of oil as replacement is only made when proved necessary. This will also give an indication on the machines’ condition. This could indicate that the change should be made away from the 1000 hours guideline and will be because of usage and environment effects on the oil life.

Reduction in Additives It is recommended that the oil is changed when the level of additives is reduced by 50% compared to new oil values. It is suggested that any of the above tests could be carried out by a laboratory to establish the optimum time for oil changes. Consultation with your local facility is advisable.

There are several indications that it is time to change the oil in the lubrication system:Concentrations of Wear Metal Elements Increases in certain elements should not exceed the suggested upper limits in parts per million (PPM) as table below.

WEAR METAL Chrome Copper Iron Lead Nickel Silicon (dirt)

TYPICAL CONCENTRATION (PPM) 0-5 0 -15 30 - 50 0 - 20 0-5 10 - 30

UPPER LIMIT (PPM) 10 50 150 50 10 75

Figure 9? Wear Metal Elements

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9.5.5 Recommended Automax Oil The recommended oil is good quality:Summer Grade Winter Grade -

EP220 EP150

Refer to the lubrication chart (Section 9.4.4) for details. Add oil to the tank (Figure 9b) with a recommended lubricant from the list provided in this manual through the filler cap using the level indicator to ensure the correct level is reached. This should be approximately 275 litres (73 US galls).

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Unless consistently cold climates are experienced, ie. below 4ºC (39ºF) it is recommended that EP220 ISO VG oil is used. If difficulties with cold starting are experienced it is recommended that an EP150 VG oil is used but this could be changed back to an EP220 ISO VG as soon as conditions permit. All oils should have extreme pressure (EP) additives. If none of the oil brands specified (Section 9.4.6) are available, ask your supplier to supply an oil that meets the specification for GRADE B in Figure 9a.

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9.5.6 Automax Oil Filter Change Intervals As a general guide it is recommended that the two filter canisters (Section 9.4.4) are changed as follows:The first filter change should be after 100 hours operation. Subsequent filter changes should occur every 500 hours unless the oil filter blocked warning activates between these intervals. It is important the use the correct replacement filter cartridges as too fine a filter element will become blocked prematurely whilst too coarse an element will not filter efficiently enough to protect the machine.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

! NOTICE ! Remember, these filters are very efficient at removing harmful contaminants from the oil and it is more economical to change the filters regularly than the oil. It is also recommended that the suction filters (Section 9.4.4) inside the tank are replaced when the oil is changed. In the event the pressure filters become blocked completely, oil will be supplied to the machine via a relief valve inside the filter top body. This bypasses the filter element and supplies unfiltered oil to the machine. This MUST be avoided and the oil lubrication safety system includes an alarm for this situation.

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9.5.7 Automax Oil Filter Replacement

WARNING

Both filters are to the same specification and operate in parallel. They must be changed at the same time with NEW filters as recommended in Section 9.5.6.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Both filters are non-cleanable elements and must always be replaced with NEW cartridges of the approved pattern.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings. 2. Close down the plant (Section 8.2) and implement the Lockout Procedure. 3. Take steps to collect oil spillage and remove the old filter cartridges by unscrewing counter-clockwise (looking from below) together with the ‘O’ ring seal. Clean the ‘O’ ring seating in the filter body. 4. Lightly oil the new ‘O’ ring on the new filter cartridge and screw onto the filter body taking care not to cross the threads. Hand tighten the cartridge. Note: After recommencing operation of the Automax make sure the seals are oil tight.

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9.5.8 Automax Oil Lubrication System General Maintenance Tank Ensure that the filler/breather cap is clean, in place and tight, at all times. Make sure that the oil tank cover is sealed down and that all bolts are in place and tight. Before carrying out any maintenance on the tank or associated parts, thoroughly clean the area to prevent any containments entering the oil lubrication system.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Air Blast Cooler Clean the cooling matrix to prevent it becoming blocked. Cleaning with an air pressure jet must only be carried out after taking safety precautions. If the dust is oily use a low pressure steam cleaner together with non-caustic detergent. General Frequently check for any leaks developing in the pipework and particularly ensure that the rubber hoses are not being chafed due to the movement of the ‘live’ Automax baseframe. Make sure the flexible hose in the return piping (essential when the Automax is mounted on a ‘live’ baseframe) is in good condition. Attend to the oil and replacement components in accordance with the schedules and advice in this manual using only approved quality materials

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9.6 Automax - Hydraulics Overview The Upper Frame of the Automax is raised and lowered by means of external hydraulic rams to alter the relative position of the concave (in the moveable upper frame) to the mantle (on the fixed position cone head). Six hydraulic cylinders provide control over the machine’s discharge setting through vertical movement of the upper frame. Additionally the system also permits automatic overload release and reset, unblocking of the crushing chamber and monitoring and indication of manganese wear (Section 7.4). The Automax hydraulic system is integrated with the overall plant hydraulic system which drives the tracks, conveyors, etc. and for details of oil replenishment, filter changes, etc. refer to Section 9.13

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

To hold the upper frame firm and steady during crushing a supplementary circuit of hydraulic dumpy jacks is included to activate the wedge ring. The relative position of the upper frame is monitored electrically with a linear transducer. The control of the Automax hydraulics is from the separate panel (Figure 9c) located inside a lockable cabinet with connections by both high pressure hydraulic hoses and screened electric cable for the linear position sensor.

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Numeric Keypad

OPEN Button

Display

AUTO/MANUAL Switch

TRAMP O/L TEST Button

Gauge measuring Wedge Pressure

CLOSE Button

Figure 9c Automax Controls (refer to Sections 7.3 & 7.4 for operating instructions)

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9.6.1 Automax Hydraulic System Maintenance Procedure

! DANGER ! This is a high pressure system and only suitably qualified experienced engineers should tackle any problems that may arise. Maintain in accordance with the reservoir level, filter changes and the schedules and fluid types (Section 9.4.4, 9.4.5 & 9.4.6) ONLY USE A RECOMMENDED FLUID. It is essential when replenishing hydraulic fluid, attending to filters, etc. to apply the greatest degree of cleanliness as it is most important that contaminants are not allowed to enter the system.

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

In addition to the pressure gauge by the control panel (Figure 9c) used when calibrating the manganese, etc., two other pressure gauges are included in the system (Figure 9g) for diagnostic purposes. Faults encountered may be listed in under Section 9.10, Fault Finding, together with possible remedies. Always contact BLPegson’s local dealer or the factory in case of doubt.

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9.7 Manganese Change Procedure

When replacing the manganese liners, always fit both a new mantle and a new concave at the same time.

9.7.1 Guidance for Changing the Manganese Mantle and Concave Both the mantle and concave liners are locked against their mating parts using tapers (angled faces). If these liners are worn too thin they will not be able to hold tight against their mating faces, coming loose and/or slipping relative to their mating part. The mating will be damaged and will need reworking.

! NOTICE ! Always fit a new manganese mantle and concave as a ‘pair’. It is detrimental to the operation of the machine to do otherwise.

Reworking and machining these large components is expensive and can involve lengthy downtime. It is for this reason that the manganese liners must replaced before the situation described above arises. There is approximately 55-60mm (21/8”- 23/ ”) of wear on the liners, as a pair. 8

Inspect the liners on a daily basis, for possible ‘tramp metal’ damage and also any evidence of an uneven wear pattern developing. The manganese liners must be changed when the hydraulic rams can be fully closed. The pin centre to pin centre distance (Figure 9d) when the rams are fully closed is 774mm (30.5”).

774 (301/2”) mm minimum

Take note of the ‘wear’ shown on the display.

Figure 9d Minimum Ram Dimension

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9.7.2 Filler Handling

WARNING

! WARNING !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Use Pegbak for backing filler. It is necessary to carefully read the handling instructions before attempting to use. Follow all the recommended handling procedures and safety precautions. Filler is used as a backing material to fill the void spaces behind the manganese concave and mantle where there is no machined mating surface with the upper frame and cone head respectively. The filler is poured in after the new manganese has been fitted. The Automax cone crusher uses the gunlock type, self tightening concave ring and must use a release agent or thin layer of grease, oil or wax on the concave ring mating surfaces. This is to prevent adhesion between the mating surfaces and to allow the self tightening features to operate properly. Care should be taken to plug all leaks as the filler will fill a very small void. Each pack of Pegbak includes separate filler resin and hardener which are mixed only when required for immediate use.

! WARNING ! BOTH AGENTS ARE TOXIC. ALWAYS WEAR A FACE MASK, RUBBER OR PLASTIC GLOVES, SAFETY GLASSES AND LONG SLEEVED WORK CLOTHING •

! WARNING ! Protect eyes. In case of accidental contact / splashes, flush eyes with plenty of water and consult a doctor. •

Ensure good ventilation of the workplace.

•

When mixing add the hardener to the filler backing resin while agitating.

•

Completely mix the filler backing resin and hardener, continue mixing until all of the filler is one colour, ie. completely mixed.

Packs required Mantle - 3 x 10kg.Tubs Concave - 5 x 10kg.Tubs

Since both agents are toxic, be careful not to allow them to attach onto your skin. If they do attach, wash away with tepid water and soap. Do not use petrol or solvents.

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•

It is necessary to work with both agents at 16-32 °C (60°-90°F). Therefore, in hot weather the container may have to be cooled and warmed in cold weather to within the above temperature range.

•

Both agents can be mixed with the supplied agitating adaptor attached to the top of an electric drill.

•

The filler can be used only once (cannot be reused) and if mixed with the hardener it cannot be stored.

•

Always store both agents at 15-30 °C (59-86°F) and avoid storing in direct sunlight.

•

Never smoke whilst handling these agents.

•

Ensure that application surfaces are dry before pouring. Wet surfaces will result in reduced stength of the filler.

•

Pour the filler immediately after mixing, ie within 10 - 15 minutes at 25°C. Higher temperatures will shorten, and lower temperatures increase, the working time.

•

When making pouring ports with putty, prevent the filler from leaking out.

Filler Hardening Time The filler needs about 12 hours to harden at 20 °C (68°F). In lower temperatures the hardening process takes longer and it may be necessary to heat the mantle and concave etc. in these circumstances.

Low Temperature Mixing Protect the filler resin / hardener from cold weather (< 5°C [41°F] ). Remove the chill from the metal by the use of hot air guns/ blowers. - Do not use an open flame. To ensure the shortest curing time at low temperatures, the filler resin component (LARGER BAG) should be pre-warmed to 25-30°C (77-86°F) before mixing. This is best achieved by applying a hot air blower on the outside of the tin . NB - REMOVE HARDENER FROM TIN BEFORE APPLYING HEAT. ALTERNATIVELY, place the filler resin bag (LARGER BAG) in a bucket of hot water. NB - DO NOT PRE-HEAT THE HARDENER (SMALLER BAG). Thoroughly mix the filler resin and hardener using the included mixing tool or a spiral paddle and pour immediately.

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9.7.3 Changing the Manganese

WARNING

To change the manganese Concave and Mantle Automax crushing members it is necessary to remove the Upper Frame.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

To change the Concave it is necessary to lift off the Automax Upper Frame complete with the concave inside

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Before the Upper Frame can be removed the feed conveyor head must be elevated from the working position to allow access to the crusher and for the feed box to be lifted off (Figure 9e).

9.7.3.1 Gaining access to the Automax Procedure 1. Observe all safety warnings. 2. Ensure that the feed conveyor and Automax feed box are free from stone and dirt. 3. Start the engine (Section 7.2.1). Set the engine speed to 1200rpm. 4. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e). 5. Operate the hydraulic lever on the chassis side to raise the conveyor so that the two locating pins can be inserted through the bottom pair of holes in the upper telescopic legs. Fit the security pins into the end of each pin.

Figure 9e Electric Panel Controls

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6. Operate the hydraulic lever to lower the conveyor until the locating pins rest on the seats in the lower telescopic legs. Make sure the locating pins are resting on their seats on both sides of each leg and not on the pin head on one side only.

! DANGER ! Whilst working on the Automax crusher the conveyor head must always be supported on the locating pins positioned in each of the two telescopic support legs and NOT by the hydraulic ram alone.

Upper Telescopic Leg Locating Pin

7. Switch off the engine (Section 8.2) and implement the lockout procedure. 8. Disconnect the level sensor mast before unbolting and lifting off the Automax feed box.

Feed Box Rear Wall

Lower Telescopic Leg

Hydraulic Lever Figure 9e1 Feed Conveyor Hydraulic Lever and Locating Pin

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9.7.3.2 Removing the Upper Frame

DANGER

Before the Upper Frame can be easily and safely removed it is essential to first ‘release’ the Automax Wedge Ring as follows.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

Procedure

WARNING

1. Observe all safety warnings. 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e).

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

4. On the Automax Hydraulic Panel (figure 9f) select MANUAL and raise the Upper Frame to it’s maximum extent using the OPEN button. 5. Close (turn clockwise) the shut off valve 9B inside the Hydraulic Console (Figure 9g) to isolate the wedge ring hydraulic circuit from the main hydraulic system. 6. Open (turn anticlockwise) the shut off valve 9A inside the Hydraulic Console (Figure 9g) to allow all pressure in the wedge ring circuit to be released thereby removing the loading from the Wedge Ring.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

7. Drop the Upper Frame with the CLOSE button to push the Wedge Ring down and thus free it from the Mainframe to provide clearance needed to lift off the Upper Frame. The wedge pressure indicated on the pressure gauge (Figure 9g) should drop away to 0-28 Bar (0-400 psi) as the wedge ring frees off.

! DANGER ! Ensure the Wedge Ring is free otherwise crane overload and/or sudden violent separation may occur when lifting off (Step 14 below).

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Figure 9f Automax Control Panel Gauge measuring Wedge Pressure

Diagnostic Pressure Gauge only

Valve 9B Automax Control Panel Diagnostic Pressure Gauge only

Valve 9A

Figure 9g Dumpy Jack Circuit Shut Off Valves

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8. With suitable cranage connect lifting tackle to the four lifting eyes in the Upper Frame (Section 4.2 for weights and lifting points) but leave the slings with a small amount of slack.

! DANGER ! Under no circumstances attempt to take the load on the cranage at this stage as a serious overload condition may arise. 9. Using three 5 tonne (5.5 US tons) capacity x 150 mm (6”) stroke hydraulic bottle jacks spaced equidistant around the lower rim of the Upper Frame, extend them equally to take the weight off the clevis pins to aid their removal. 10. Ensure that there is no residual hydraulic pressure in the Upper Frame hydraulic cylinder circuit by pressing the OPEN and CLOSE buttons briefly and in quick succession until the pressure gauge (Figure 9c) on the hydraulic panel reads zero. Follow this procedure to remove the clevis pins with the minimum of effort.

! DANGER ! Do not neglect to ‘Lockout’ to prevent the plant being started whilst maintenance work is being carried out. 12. Remove the top clevis pin from each hydraulic cylinder and pull each cylinder outwards, allowing them to lie flat. Note: The clevis pins should be removed from right to left when facing the machine to avoid disturbing the bearing located against the shoulder inside each lug on the Upper Frame. 13. Remove the linear sensor cover (Figure 9h) and lay to one side. Disconnect the top bolt from the unit. This is essential to avoid damage to the sensor unit. 14. Lift off the Upper Frame assembly from the machine (Refer Section 4.2 for the weight of the complete assembly). Support on wooden blocks on the ground (Figure 9i).

11. Isolate the electrical supply before proceeding further.

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Linear Sensor Unit Cover

Upper Frame

Clevis Pin

Hydraulic Cylinder

Figure 9h Automax Linear Sensor Unit and Hydraulic Cylinders

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9.7.3.3 Changing the Concave

WARNING

The concave ring is held in place in the Upper Frame by a self tightening gun lock arrangement that automatically tightens the manganese steel concave on the concave wedges as the ring stretches under the crushing load.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

The Upper Frame should be supported on wooden blocks so that there is sufficient space for the concave to be driven out. Removing the Concave

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

! WARNING ! When gas cutting through the concave it is essential that breathing apparatus is worn as when the metal is broken through the backing material gives off toxic fumes. Procedure 1. Observe all safety warnings. 2. Following removal of the Upper Frame (Section 9.7.3.2) gas cut through the four lugs as shown (Figure 9i). 3. Drive down and out the old concave with a heavy sledge hammer.

4. Remove the old backing material and dowels (these can be driven out from below) and inspect the lower inside bevelled edge of the Upper Frame seating where the surface has been ground. Remove any nicks or burrs with a file or grinder. Inspect the ground surfaces of the new concave and remove any nicks or burrs in the same manner.

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Figure 9i Gas Cutting the Old Concave

Figure 9j Supporting the New Concave

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Mounting the Concave

WARNING

When supporting the new Concave prior to lowering the Upper Frame on to it, ensure that the supports do not protrude past the sides of the Concave (Figure 9j) and that it is high enough off the ground to allow the Upper Frame to be fully lowered.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Release agent needs to be applied to the internal surface of the Upper Frame where it will be in contact with the backing filler to ease separation when the manganese is next changed.

Procedure 1. Observe all safety warnings. 2. Apply release agent (obtainable from BL-Pegson) to the cleaned inner surface of the Upper Frame. 3. Place the new concave on three wooden blocks (see preamble above) ensuring it is level 4. Lift the upper frame over the concave and turn it so that the concave lugs align with the recesses on the upper frame and gradually lower the upper frame until concave lugs pass through the recesses and stop lowering. 5. Rotate the upper frame to the left so that the concave lugs are located approximately 50mm past the dowel holes.

6. After rotation, equally locate the concave wedges between the concave lugs and upper frame (Figure 9k). An estimate should be made of the correct position for the concave wedges and then tapped in slightly to see how the concave settles. If the position does not look correct with respect to the dowel holes then they should be removed and replaced. Also check to see that the Concave is evenly seated on the machined surfaces at the bottom and there is an equal depth all around at position A (Figure 9l). If there is a gap between the two the Concave must be properly re-seated. Once the position is satisfactory and the Concave is correctly seated, the wedges should be driven fully home.

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7. Insert the dowels into the holes in the upper frame and drive home. Note: If there is a gap between the concave wedge and the dowel pin and this cannot be rectified by moving the wedge position, it may be necessary to tighten the wedges and then weld a piece of steel between the wedge and the dowel pin(s).

! NOTICE ! The concave wedges must be inserted evenly so that the concave ring is centrally located within the Upper Frame. 8. Prepare filler pouring ports with putty by making four weirs around the recesses of the Upper Frame so the filler cannot leak out. 9. After the weirs are completed prepare the filler (Section 9.7.2) and pour the correct quantity of mixed filler into each weir by turns.

! NOTICE ! After mixing, the filler must be poured IMMEDIATELY to ensure complete penetration. 10. Stop pouring when the filler has reached 12-25mm (1/2-1”) below the top of the Concave. The replacement is now complete. Refer to Section 9.7.2 for the filler hardening time.

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RECESS

Figure 9k Plan View of the Upper Frame showing the correct wedge position (1300 has four lugs on the concave)

Figure 9l Sectional view of the concave showing the gap check at A

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4.7.3.4 Replacing the Upper Frame

DANGER

Whilst the Upper Frame is off the machine for the renewal of the manganese wearing parts, take the opportunity of examining the condition of the internal linerplates, frame and countershaft arm shields and replace if necessary.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING

Also, clean out any solidified debris and generally check around the machine for any faults which need to be rectified.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Clean the contact face all around the Wedge Ring and apply a coating of fresh lubricant (MOLY-BENTONE MP Standard Grade grease). Make sure this is not contaminated with dirt or grit prior to replacing the Upper Frame.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings. 2. Using the cranage used to remove the Upper Frame lower over the machine whilst taking care to line up the antirotation stop on the Upper Frame with the guide post. Hold in a suspended position with the crane with a gap between the mantle and concave. 3. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 4. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e). DO NOT press any of the start buttons.

5. On the Automax Hydraulic Panel (Figure 9f) switch to MANUAL and depress the OPEN or CLOSE button (as appropriate). Only one cylinder will respond at any one time and, ‘toggling’ between the buttons, line up and insert each of the six clevis pins in turn. Secure with the washers and split pins. Note: The clevis pins should be inserted from right to left when facing the machine to avoid disturbing the bearing located in it’s required position against the shoulder inside each lug on the Upper Frame. 6. Replace the linear position sensor and replace the cover to the housing.

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7. Detach the cranage and replace the feed ring or box and any chutework. 8. Now take steps to restore the Wedge Ring pressure by returning to the hydraulic console and closing the shut off valve 9A (Figure 9g) to revert to the operating position. 9. Open shut off valve 9B (Figure 9g) to revert to the operating position. 10. Carry out the ‘Initial Discharge Setting and Calibration’ procedure described in Section 7.3.3, following which the Automax is ready to recommence crushing.

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9.7.3.5 Changing the Mantle

WARNING

The operation is carried out with the head left in situ. The internal parts of the Automax are therefore not disturbed or exposed to harmful dust.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

In use all manganese steel will ‘creep’ due to the nature of the material. When creep occurs stress is created in the material which will have to be relieved by suitable cutting of the Mantle. This will be necessary in order to facilitate removal.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Removing the Mantle

! WARNING ! When gas cutting through the concave it is essential that breathing apparatus is worn as when the metal is broken through the backing material gives off toxic fumes. Procedure 1. Observe all safety warnings. 2. With the Upper Frame removed (Section 9.7.3.2) gas cut through the Burning Ring all the way round (Figure 9m). 3. Once the Mantle is cut the Mantle Nut can then be removed by turning CLOCKWISE with the mantle nut wrench (Figure 9n). Ensure that the mantle nut wrench is secure by dropping a suitably sized bolt through the hole in the end of it.

4. Break loose the fit between the Mantle and the Cone Head. This is best achieved by striking the lower section of the circumference with a hammer then levering the Mantle clear of the Cone Head. 5. Insert short blocks of wood between the Mantle and Cone Head in three places around the circumference so as to leave a gap through which lifting chains can be placed. Three equally spaced lifting chains should be passed through this gap and the hooks put round the bottom of the mantle (Figure 9o) and the mantle lifted off.

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6. Remove the old backing material and inspect the Cone Head seating where the surface has been ground. Remove any nicks or burrs with a file or grinder. Inspect the ground surfaces of the new Mantle and remove any nicks or burrs in the same manner.

Figure 9m Gas cutting the Mantle (Showing section through the Cone Head)

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MANTLE NUT WRENCH

SECURITY BOLT

Figure 9n Mantle Nut Wrench securely fitted

Figure 9o Lifting chains correctly fitted Sections through the Automax Cone Head

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Mounting the Mantle

WARNING

Release agent needs to be applied to the Cone Head where it will be in contact with the backing filler to ease separation when the manganese is next changed.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Procedure

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

1. Observe all safety warnings. 2. Apply release agent (obtainable from Terex Pegson) to the unmachined surface all around the Cone Head (Figure 9p). 3. Place the new Mantle and Burning Ring onto the Cone Head and tighten down the Mantle Nut by turning COUNTERCLOCKWISE with the Mantle Nut Wench (Figure 9n). It is sufficient to tighten this by hammer blows without having to replace the Upper Frame and wedge against the Concave. 4. The Mantle Nut was tightened to align the Mantle and seat it firmly on the Cone Head at A (Figure 9q). Now the Mantle Nut and Burning Ring need to be removed so that the filler can be poured. Release the Nut by turning CLOCKWISE with the Mantle Nut Wrench. Note: When the Mantle Nut is removed, grease the threads on the Cone head so any spills when pouring the backing filler can be easily wiped off.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

5. Prepare the filler (Section 9.7.2) and pour the correct quantity of mixed filler at the top of the Mantle making sure it is equally distributed all round.

! NOTICE ! After mixing, the filler must be poured IMMEDIATELY to ensure complete penetration. 6. When the filler reaches 15mm (5/8”) from level B (Figure 9q) stop pouring, fit the Burning Ring and Mantle Nut. First lightly tighten using the Mantle Nut Wrench. Fully tighten by hitting the wrench with a hammer in a COUNTERCLOCKWISE direction. The replacement is now complete. Refer to Section 9.7.2 for the filler hardening time.

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Figure 9p Section through the Cone Head showing where to apply release agent

Figure 9q Section through the Cone Head showing correct filler level

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9.8 Wedge Ring Maintenance

WARNING

! NOTICE !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

The Wedge is fundamental to how the cone crusher functions. It provides damping and guidance to the Upper Frame assembly. Poor machine performance and crusher downtime are often due to an incorrectly maintained Wedge. The condition of the Wedge is assessed by observing the hydraulic pressure required to move the Upper Frame as recorded on the pressure gauge (Figure 9r) When the Upper Frame is moved there should be no noticeable sticking on initial movement or during the travel. If there is any sticking noticed then this should be investigated. On factory assembly the friction pads are greased and it is possible that grease needs to be added through the nipples spaced around the Upper Frame (NB. The minimum amount of Moly Bentone grease should be added to restore smooth travel). In situations where the crusher setting is not changed for long periods it is good practice once a week to work the Upper Frame from the top to bottom of it’s stroke several times to redistribute the grease.

! NOTICE ! Only use Moly Bentone grease (Section 9.4.5) for lubricating the Wedge Ring

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The crusher must not be allowed to operate with regular ‘dumping’ or ‘bouncing’ of the Upper Frame (Section 7.3.2) or damage may result. Possible causes of the are crushing at closed side settings which are too tight, out of round manganese or poor Wedge Ring adjustment.

! NOTICE ! Low wedge pressures are equally as undesirable as high ones. When testing the wedge pressure it should be between 55 and 82 BAR (800 - 1200 psi).

Gauge measuring Wedge Pressure

Automax Hydraulic Panel

Figure 9r Automax Hydraulic Panel and Pressure Gauge

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9.8.1 Checking Automax Wedge Pressure

DANGER

AUTOMAX NOT RUNNING

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

The pressure on the wedge ring is automatically controlled by the Dumpy Jack hydraulic circuit. However, as the adjustment of the wedge ring is critical for good performance of the Automax crusher it is recommended that this should be checked daily. The pressure gauge near the panel (Figure 7h) gives an accurate indication of whether the Wedge Ring assembly is functioning correctly.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

! NOTICE ! The Automax must not be allowed to operate with regular dumping or bouncing of the Upper Frame or damage may result. Possible causes could be crushing at too small a setting, out of round manganese (Section 9.9) or poor Wedge Ring adjustment. Procedure

4. On the Automax Hydraulic Panel (Figure 9f) switch to MANUAL and depress the OPEN button lifting the Upper Frame approximately 20mm (¾”) above the set point. 5. Switch back to AUTO and observe the pressure reading on the pressure gauge (Figure 9r). The pressure should be in the range 55 - 82 BAR (800 - 1200 psi).

1. Observe all safety warnings 2. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm.

6. Whilst the Upper Frame is moving check for smooth movement with no sticking at the start or whilst travelling.

3. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e). DO NOT press any of the start buttons.

7. If the pressure reading is above or below the range indicated above or the action is not smooth, remedial action is required (Section 9.8)

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8.8.2 Low Wedge Pressure

WARNING

If the wedge pressure has been checked and found to be below 55 bar (800psi) then the cause must be investigated and where necessary, the appropriate action taken.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Procedure

DANGER

1. Low or fluctuating dumpy jack circuit pressure. Check circuit is free from leaks, and pressure switches 11A & 11B (Figure 9ab) are functioning correctly.

FLUID INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

2. Wedge ring may not be ‘bedded in’ fully following maintenance or manganese change. Monitor wedge pressure. Work machine at wider setting if excessive bouncing/ dumping is seen (Bouncing, Dumping, see Glossary 7.3.2). 3. Excessive greasing and/or use of wrong type of grease. This can reduce the friction between the wedge and the upper frame and hence limit the wedge pressure.

! NOTICE ! Only use Moly Bentone grease (Section 9.4.5) for lubricating the Wedge Ring.

Monitor the wedge pressure. If no improvement is seen, it may be necessary lift off the upper frame, remove the grease and re-grease, sparingly.

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9.8.3 Readjusting Tight Wedge Ring

DANGER

AUTOMAX NOT RUNNING If the wedge pressure has risen above the prescribed maximum and/or the travel of the Upper Frame is no longer smooth, the Wedge Ring may need adjusting by the following procedure. See Section 9.8.1 for checking the wedge pressure.

Procedure 1. Observe all safety warnings.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

2. Ensure that the feed conveyor and Automax feed box are free from stone and dirt. 3. Start the engine (Section 7.2.1). Set the engine speed at 1200rpm. 4. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e). DO NOT press any of the start buttons. 5. On the Automax Hydraulic Panel (Figure 9f) select MANUAL and raise the Upper Frame to it’s maximum using the OPEN button. 6. Close the shut off valve 9B adjacent to the Automax Hydraulic Panel (Figure 9s) to isolate the wedge ring Dumpy Jack hydraulic circuit from the main hydraulic system.

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7. Open the shut off valve 9A inside the hydraulic console (Figure 9s) to allow all pressure in the Dumpy Jack circuit to be released thereby removing the loading from the Wedge Ring.

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

8. Lower the Upper Frame with the CLOSE button to push the Wedge Ring down and thus free it from the Mainframe. The wedge pressure indicated on the pressure gauge (Figure 9r) should drop away to 0-28 Bar (0-400 psi) as the Wedge Ring frees off.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

9. Close shut off valve 9A (Figure 9s) to revert to the operating position. 10. Open shut off valve 9B (Figure 9s) to revert to the operating position. 11. Depress the OPEN button lifting the Upper Frame approximately 20mm above the set point.

Shut Off Valve 9B

12. Select AUTO control position on switch. The control system will bring the machine down to the required gap position or go through the initial Closed Side Discharge Setting procedure (Section 7.3.3) as necessary.

Diagnostic Pressure Gauge (NOT the gauge referred to in step 8)

Shut Off Valve 9A Figure 9s Dumpy Jack Circuit Valves

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9.9 Automax - Out of Round Manganese - Causes and Effects

F) Increase the wear rate of the manganese, due to the concentrated crushing area. This gets worse as the process is a vicious circle.

When the Mantle and Concave are new both of the wearing surfaces are round. They should remain round throughout their working life, ie. the wear should be consistent and remain round. Should the manganese become out of round then the life of that manganese will be shortened considerably. The causes and effects of this are:-

G) Due to effect of E above the machine will become reluctant to accept a choke feed. The machine will dump as the crushing pressure reaches excessive levels.

Causes: A) Inaccurate manganese manufacture/ fitting. B) Poorly distributed feed material within the hopper and/or segregated feed. C) inconsistent stop/start feed. Effects: D) Produces an uneven load on the Wedge, reducing it’s life and producing a fluctuating wedge pressure.

Prevention: H) Only fit genuine BL-Pegson manganese replacement parts. I) Ensure adequate feed hopper and efficient dead box are maintained to distribute the feed material evenly around the feed opening. J) Adjust the Plant/Automax settings (Section 7.2.7) to ensure the Automax is choke fed at all times. K) Adjust the Plant/Automax settings (Section 7.2.7) to ensure the feed to the Automax is continuous with stop/starting of the feed kept to a minimum.

E) Produces an inaccurate zero set point, resulting in an incorrect closed side setting. This can mean that the machine is crushing at a much lower closed side setting than is indicated on the gap indicator.

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9.9.1 Checking Manganese for Out of Round Check 1 - The Mantle.

DANGER ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all Safety Warnings. 2. Ensure that the feed conveyor and Automax feed box are free from stone and dirt. 3. Close down the plant (Section 8.2) and implement the Lockout Procedure. Note: it is important when checking the Mantle for ‘out of round’ that the Eccentric does not move. Take the drive guard off and watch for any movement of the countershaft. If movement is noted repeat the whole procedure described below, again.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

4. Mark a cross on the top of the Mantle Nut. 5. Mark the Concave opposite one of the lines of the cross. The next steps must be taken with the Automax controls activated but the Automax NOT running. 6. Start the engine (Section 7.2.1). Set the engine speed to 1200rpm.

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7. Continue with the OPERATION switch at PLANT and the RADIO REMOTE CONTROL switch at OFF (Figure 9e). DO NOT press any of the start buttons.

DANGER ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

8. Ensure that everyone is clear of the machine. Put the hydraulic panel into MANUAL and press CLOSE. Release the button the moment the pressure starts to rise and note the figure showing on the gap indicator. Depress the OPEN button to raise the Upper Frame approx. 15-20 mm (5/8” -¾”).

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

9. Close down the plant (Section 8.2) and implement the Lockout Procedure.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

10. Rotate the Cone Head slowly by hand, stopping it when it has gone through 90º whilst doing this watch the vee belts to ensure that the eccentric does not move in the Cone Head. The second mark on the mantle plate should now be lined up with the mark on the Concave.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

11. Repeat steps 6 to 9. 0 12. Repeat the process so that you have four values for the Mantle. If the Mantle is round it should show similar values to Figure 9o.

-1

-1 Typical values Mantle OK.

1 Figure 9t Mantle Check

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Check 2 - The Concave

DANGER

Note: This process is almost identical to the Mantle check. Follow the procedure for the Mantle - Check 1.

ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

HOWEVER, this time the Cone head and Eccentric MUST move as one. To do this the Flywheel should be rotated slowly by hand. The Mantle procedure (previous page) can be followed but rotating the Flywheel not the Cone head. It is useful to have an assistant watch the Cone Head rotate whilst the vee belts are rotated to ensure it is moving. In order to prevent slip between the Eccentric and Cone Head:-

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

A) Ensure slow, gentle movement of the Eccentric, via the vee belts.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

B) Make sure the Concave is well clear of the Mantle when the Eccentric/Cone Head is being rotated. As a final check for any slip between the Eccentric and the Cone Head, repeat the first touch again as the example below:-

0 0

! NOTICE ! If there is a difference of more than 7mm between any two values of the four measured, that piece of manganese must be changed immediately.

-1

-2 Typical values Mantle OK.

1 Figure 9u Concave Check

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9.10 Automax - Fault finding GENERAL

Fault

Possible Cause

Procedure

Machine stops.

Overload through discharge setting too low. Tramp metal fixed in crushing chamber. Packing in crushing chamber. Lubricating oil flow low / temperature high. Build up in discharge chute. Power supply / drive motor failure.

Clear machine adjust setting.

Broken vee belt (s). Discharge setting not maintained.

Hydraulic fluid leakage.

Clear machine adjust setting. Clear discharge chute. Check operation of lubrication system. Clear blockage check chute. Check power supply / drive motor, see manufacturer’s literature Replace belt (s). Check all hydraulic components, couplings, pipes and hoses.

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Fault

Possible Cause

Procedure

Reduction in discharge setting not possible.

Crushing pressure too high Hydraulic system faulty.

Adjust setting.

Manganese out of round. Manganese worn out. Directional control valve inoperative. Relief valve dirty or faulty. Couplings at hydraulic ring- main faulty. Packing in crushing chamber. (excessive ‘fines’ in feed)

Check for internal/ external leaks. Check manganese. Change manganese. Check solenoid. Dislodge dirt from under seat / check valve spring. Investigate and correct. Adjust machine.

Increase in discharge resetting not possible.

Wedge too tight.

Grease and readjust wedge.

Upper frame assembly ‘bounces’.

Manganese out of round. Wedge pressure low / Wedge assembly loose. Adjusting wedge assembly has no apparent effect. Hydraulic cylinder (s) faulty. Manganese out of round.

Check manganese.

Crushing at excessively tight closed side setting. Feed chute incorrectly installed.

Tighten assembly/ repressurise. Check fibre pads worn out or require changing. Investigate and correct. Check feed segregation. Check manganese for out of round, change as necessary. Change setting. Investigate and correct.

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Fault

Possible Cause

Procedure

Erratic movement of hydraulic cylinder(s).

Air in hydraulic system.

Bleed system / check for leaks. Replace.

Hydraulic system filter(s) blocked. Crusher motor stops.

Overcurrent due to voltage drop. Overcurrent due to overload.

Interlock operation.

Check the transformer capacity. Suitable feed amount? Uniform feeding? No packing? Insufficient oil supply? Damaged bearing? Tramp metal? Machine overloaded? Pump motor rotating? Deteriorated pump performance or lack of oil? Return oil temperature too high?

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Fault

Possible Cause

Procedure

Abnormal sound from the crusher.

Damage of the bearing of the countershaft. Damage of the countershaft gear. Loose mantle.

Contact Terex Pegson.

Loose or falling concave.

The particle size of the crushed product is coarse.

Contact Terex Pegson. Inspect conehead/ mantle for damage. Refit as when changing manganese. Adjust the concave wedge. Check the mantle rotating direction. Check the touching surface. Check for partial wear.

Mantle / concave worn out of round.

Check for out of round.

The indicated setting value is different from the actual value. Wedge ring adjustment failure. Partial wear of the mantle and concave.

Measure the actual setting with a lead ball etc. Adjust the wedge ring. Check the feeding chute.

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HYDRAULICS Fault

Possible Cause

Procedure

The pump doesn’t start.

Electrical fault.

Check the thermal relay connection and motor, fuses & connections. Check the rotating direction and reconnect. Refill oil.

Rotating direction error. Insufficient quantity of oil in the tank. Pump seized.

The pump starts but no pressure and discharge occur.

Clogged suction side piping.

Clean the piping and carry out flushing.

Clogged suction side filter. Air mixed from the suction side.

Remove and clean.

Oil viscosity too high. Defective or damaged pump and coupling. Relief valve setting failure. Pump noise.

Check that pump shaft rotates, fit replacement if faulty.

Air mixed from the suction side. Clogged air breather. Sound in the relief valve. High oil viscosity.

Re-tighten the coupling screw. Replace the piping. Check for the specified brand. Check and replace. Contact Terex Pegson.

Clean the piping and carry out flushing. Disassemble and clean. Disassemble. Clean or replace the spring nozzle. Check for the specified brand.

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Fault

Possible Cause

Procedure

Irregular motion of the cylinder.

Air mixed in the cylinder. Check the piping, hose and coupling, after checking and repair, remove air. Filters blocked. Replace.

Downward adjustment possible - system will not build up or maintain pressure.

Unseated unloader valve.

Replace valve.

Solenoid operated vent valve unseated. Directional control valve inoperative.

Replace valve.

Check operation of solenoid, replace if necessary. Check for possible sticking spool on valve, dismantle, clean, replace parts or complete assembly. Dirt in relief valve. Screw the adjuster out a few turns then in again to the original setting. This will dislodge dirt under the ball seat. If no response, remove unit, dismantle and clean, particularly jet. Replace in system. Faulty relief valve. Check valve spring, renew as necessary. External leakages. Make visual inspection. Tighten connections. Renew pipes, hoses or couplings as necessary. Mechanical failure of the Check to see if any crusher. object touches the machine. Insufficient oil quantity. Check the oil level gauge. Refill as necessary. Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Fault

Possible Cause

Procedure

Downward adjustment not possible - high pressure build - up occurs.

One or both quick release couplings faulty.

Inspect, replace as required.

Directional control valve ‘jammed’ half open.

Check operation of valve, dismantle, clean, replace parts or complete valve as necessary. Investigate crusher.

Mechanical blockage on crusher. Upward adjustment not possible.

Directional control valve inoperative.

Solenoid operated vent valve inoperative. One or both quick release couplings faulty. Mechanical blockage on crusher. External leakages.

Oil in system becomes excessively hot.

Check operation of solenoid, replace if necessary. Check for possible sticking spool, dismantle, clean, replace parts or complete valve as necessary. Check operation of solenoid, replace if necessary. Inspect replace as required. Investigate crusher.

Make visual inspection. Tighten connections. Renew pipes, hoses or couplings as necessary. Mechanical failure of the Check to see if any crusher. object touches the machine. Insufficient oil quantity. Check the oil level gauge. Refill as necessary. Pump running Check for symptoms of continuously under pressure build up. pressure

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LUBRICATION SYSTEM

Fault

Possible Cause

The oil cooling efficiency Cooling matrix choked is deteriorating. with dust. Dust depositing at the bottom of the tank. The oil heater cannot be turned off.

The contact type oil temperature gauge doesn’t operate at the preset temperature. Machine stops.

Procedure Disassemble and clean. Clean the tank.

Thermostat failure.

Replace.

Thermostat setting failure.

Correct the setting.

Contact type return oil temperature gauge failure.

Replace.

Setting failure.

Correct the setting.

Lubrication system safety interlocks activated. Oil chilled on entering cold.

Check fault display in Section 7.2.3. Look for oil return to tank. Check oil heater working.

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9.11 Plant - Feed Conveyor The Automax crusher is fed from the feed hopper via the feed conveyor. Feed material can be introduced into the hopper either by overhead loads or continuously via a belt conveyor. During the crushing operation the feed conveyor can be controlled by the level sensors (Section 9.12) over the feed hopper (optional) and/or the Automax feed box. The purpose of the level sensor(s) is to avoid a ‘dribble’ feed to the Automax which is detrimental to the optimum performance of the crusher.

! NOTICE ! The performance of the Automax benefits in all respects from receiving a continuous ‘choke’ feed of material (Section 3.4) and the aim is to achieve this by setting the plant controls (Section 7.2.7) to keep stopping and starting of the feed to a minimum. During crushing operations the level of material in the feed hopper should be maintained at a high level to avoid stopping of the feed conveyor due to lack of material in the hopper. A rotary control on the plant control panel (Figure 7e) is also provided to manually vary the feed rate by regulating the speed of the feed conveyor.

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9.12 Plant - MiniRanger Level Sensors Description The standard Maxtrak includes a level sensor over the Automax feed box to control the feed into the crusher by varying the speed of the feed conveyor. An optional sensor can also be fitted over the feed conveyor hopper where this is practical to the crushing application. The following pages give summaries of the operation and setting-up guides. The MiniRanger units are preset at the factory with settings found to have been generally suitable (Figure 9.12.4) but can be reprogrammed if necessary to suit differing applications and materials.

! NOTICE ! The Automax crusher gives the best performance in all respects when kept ‘choke’ fed as explained in Section 3.4 Unit MR1 - Crusher Bowl This monitors the material level in the Automax crushing chamber and feed box to adjust the speed of the feed conveyor. Unit MR2 - Feed Conveyor (Optional) This monitors the material level in the feed hopper and works in conjunction with the sensor MR1 to provide an addition measure of controlling the feed into the Automax.

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9.12.1 Level Sensors - Operation

WARNING

The MiniRanger Plus is a versatile material level monitoring instrument. Material level measurement is achieved using advance sonic echo ranging techniques. Each unit is complete with an integral multi-function liquid crystal display with four button keypad (Figure 9v) mounted on the Electrical Control Panel Each MiniRanger Plus has two modes of operation: RUN and PROGRAM. When the unit is powered it is programmed to start up in the run mode to detect the distance from the transducer face to the target material in metres.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Optional Sensor

The unit can be placed into the program mode at any time; to alter the number of program parameters in order to better suit the application or user’s preferences. Programming is carried out via the keypad. See Section 9.12.2 for the keypad functions and displays relating to the RUN mode. See Section 9.12.3 for the keypad functions and displays relating to the PROGRAM mode. See Sections 9.12.4 for Factory Presets. See Section 9.12.5 for the simplified Setup Guide for typical mobile crusher bowl level. See Section 9.12.6 for the simplified Setup Guide for typical hopper level (Optional).

Figure 9v MiniRanger Plus Control Panel

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9.12.2 Level Sensors - Run Mode Communication Jack

LCD Keypad LCD Display

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9.12.3 Level Sensors - Program Mode

Communication Jack

LCD Keypad

LCD Display

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9.12.4 Level Sensors - Factory Settings

NB. The Hopper Level Sensor is an optional item.

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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl

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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl, continued

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9.12.6 Level Sensor MR2 Setup Guide - Hopper*

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9.12.6 Level Sensor MR2 Setup Guide - Hopper, continued

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9.13 Plant/Automax Hydraulic Systems

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

9.13.1 General Description One integrated hydraulic system performs the following functions:•

•

WARNING

Automax setting adjustment, overload protection, unblocking and wedge ring pressure. Also driving the crusher lubricating oil circulating system.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Plant hydraulic drives for the conveyors and tracks and also to hydraulically raise and lower the feed conveyor.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

All hydraulic functions are powered by two pumps, one mounted on either side of the diesel within the engine canopy and driven from the engine mainshaft via vee belts. Alternative selection of the PLANT or TRACK switch on the plant control panel (Figures 5a & 6a) ensures the plant cannot be moved whilst operating. The hydraulic fluid reservoir together with associated equipment must be maintained in accordance with the set level (For topping up the reservoir see Section 9.13.6) and in the schedules and types detailed in Section 9.4. ONLY USE A RECOMMENDED FLUID. It is essential when replenishing hydraulic fluid, attending to filters, etc. to apply the greatest degree of cleanliness as it is most important that contaminants are not allowed to enter the system.

! DANGER ! THIS IS A HIGH PRESSURE SYSTEM. Never carry out any maintenance work without ensuring the hydraulic system is locked out and depressurised. Do not tamper with system. In the event of any problems these should only be dealt with by suitably experienced and qualified engineers.

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Each of the two hydraulic pump is an axial piston variable displacement unit feeding a directional control valve.

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

The flows and pressures to each service is limited by the relevant spool as shown below and the pump supplies only the required flow by automatically backing off the swash plate angle thus reducing wasted power and resulting heat generation.

Note:All relief valve pressures are factory set and should not be adjusted on site.

This is achieved by means of a load sensing line from the valve to the pump which measures the pressure required which is then matched by the pump.

Although the maximum flows from each spool is limited as shown, these can be individually adjusted downwards by means of limit screws if desired. Please contact Terex Pegson Ltd.

No: 1 Pump (valve mounted in engine canopy) Service

Spool Type

Max Flow litres/min (US galls/min)

Max Pressure (Bar)

L/H track drive motor

Proportional

100 (26.4)

320

Product Conveyor plus Water Pump (when fitted)

On/Off

100 (26.4)

210

Automax control

On/Off

5 (1.3)

200 180

No: 2 Pump (valve mounted under feed conveyor) Service

Spool Type

Max Flow litres/min (US galls/min)

Max Pressure (Bar)

R/H track drive motor

Proportional

100 (26.4)

320

Feed Conveyor

Proportional

75 (19.8)

180

Feed Conveyor raise/lower

On/Off

25 (6.6)

100

Automax lubrication

On/Off

15 (4.0)

140

Figure 9w Front/Rear Hydraulic Pumps

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9.13.2 Track Drives

9.13.3 Feed Conveyor Drive

Although these valves sections have proportional controls and are theoretically infinitely variable they are electrically limited to two speeds for simplicity.

This valve section is fitted with a proportional solenoid so that the feeder speed can be controlled by level sensor mounted over the Automax feed box.

a) SLOW - For slewing and fine positioning.

9.13.4 Circuit Protection

b) FAST - For straight line running, forward or reverse. Note:- The maximum power take off from one side of the engine is limited to approximately 30 KW, therefore the system is electronically limited such it is only possible to slew (operate one side only) when in the ‘SLOW’ mode. Fine adjustment of the slow speeds is possible. Consult BL-Pegson Ltd. It is recommended that adjustment is not undertaken without BL-Pegson Ltd. consent and under no circumstances should the slow speed be adjusted greater than 0.2mph. Motor mounted counterbalance valves are utilised to prevent the machine over running when moving downhill. This block also incorporates a shuttle valve to release the spring applied track parking brake together with a pressure reducing valve, preset to 60 bar so that the brakes are not over-pressurised.

The system is equipped with the following protection:•

Suction Filter (90μm nominal )

•

Pressure Filter (10μm absolute) in each pump circuit prior to the directional control valves.

•

Return Filter (10μm nominal)

•

Low oil level cut out.

Note:- For Hydraulic Pump Drive Belt adjustment refer to Section 9.15.3.

! NOTICE ! The hydraulic oil filters are fitted with condition indicators to shown when the renewable filter element needs to be changed. These should be checked on a daily basis whilst the plant is running at normal operating temperature (Sections 9.13.5 - 6 & 8). In cold ambient temperatures the filter indicators may show red until the system reaches normal operating temperature.

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9.13.5 Changing the Suction Filter

DANGER

Located at the base of the hydraulic reservoir tank is the hydraulic suction filter. When the dial gauge needle (Figure 9y) enters into the red segment whilst the system is running at normal operating temperature this is an indication that the filter must be replaced immediately . The filter housing has an internal shut off valve to permit work on the system. Make sure the oil has cooled before changing.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Using a hexagon socket key unscrew the bolt A in the centre of the filter housing until it reaches the stop (Figure 9y).

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

4. Take steps to collect spillage of oil (approx. 2 litres) before undoing the six socket head screws on the front of the housing to remove the cover plate. 5. Remove the old filter and clean inside the housing with lint free cloth before fitting a new filter of the approved pattern and specification. 6. Before replacing the cover plate, lightly oil the ‘O’ ring and make sure it is properly seated in the groove. Replace the cover plate and refit the screws to ensure an oil tight seal.

7. Fully screw in the bolt A in the centre of the filter housing.

! NOTICE ! It is important to ensure that the bolt A is fully screwed in before restarting the plant. Damage will occur to the plant if this procedure is not followed.

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Filter Condition Indicator Dial

Removable Cover Plate

Bolt A

! NOTICE ! It is important to ensure that the bolt A is fully screwed in before restarting the plant. Damage will occur to the plant if this procedure is not followed.

Figure 9y Suction Filter

Hydraulic Oil Level & Temperature Gauge

Hydraulic Oil Return Filter and Gauge

Hydraulic Oil Tank

Hydraulic Oil Breather/Filler

Filter Condition Indicator Dial

Figure 7z Hydraulic Oil Tank & Level Indicator

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9.13.6 Changing the Return Filter

DANGER

Located on top of the hydraulic reservoir tank is the hydraulic return filter. When the dial gauge needle (Figure 9z) enters into the red segment whilst the system is running at normal operating temperature this is an indication that the filter must be replaced immediately. Make sure the oil has cooled before changing.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

In the event hydraulic oil needs to be added to maintain the correct level on the gauge (Figure 7z), this should be poured in after removing the cover (see below) but with the filter element left in place. Check the system for leaks if topping up becomes necessary.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Remove the four hexagon head screws on the top of the housing to remove the cover plate together with internal spring. 4. Remove the old filter and clean inside the housing with lint free cloth before fitting a new filter of the approved pattern and specification. Replace the spring which holds the filter in place

9.12.7 Changing the Tank Breather This should be changed after the first 100 hours of operating and thereafter after 500 hours but in dusty atmosphere it is recommended to change more frequently depending upon conditions. Simply unscrew and replace whilst the plant is shut down.

5. Before replacing the cover plate, lightly oil the ‘O’ ring and make sure it is properly seated in the filter housing. Replace the cover plate and refit the screws to ensure an oil tight seal.

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9.13.8 Changing the Pressure Filters

DANGER

Located on each side on the engine within the canopy are the hydraulic pressure filters. When the ‘telltale’ (Figure 9aa) changes from green to red whilst the system is running at normal operating temperature this is an indication that the filter must be replaced immediately. Make sure the oil has cooled before changing.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Unscrew (turn anticlockwise looking from below) the filter bowl using the hexagon ‘nut’ cast into the base. Take steps to contain spillage of oil

Filter condition ‘Telltale’

Filter body

4. Remove the old filter and clean inside the bowl and housing with lint free cloth before fitting into position a new filter and small ‘O’ ring of the approved pattern and specification. 5. Before replacing the bowl, lightly oil the ‘O’ ring and place on it’s seating in the bowl making sure it is properly seated. Screw the bowl into the housing taking care not to ‘cross’ the threads when doing so. Tighten with the ‘nut’ at the base of the bowl to ensure an oil tight seal.

Bowl

‘Nut’ Figure 9aa Pressure Filter

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9.13.9 Automax Hydraulic System

DANGER

The hydraulic control components (with the exception of the position sensor unit on the crusher are housed in the hydraulic control console.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

The System 2 - 2001 enables the Automax to be controlled as described in Section 7.3 & 7.4.

WARNING

In the event of a blockage occurring in the crusher the panel senses an increase in pressure and will automatically raise the crusher upper frame (including the concave) to release material in the crushing chamber. When the crusher is new or a new concave and mantle have been fitted the procedure for setting the Set Zero calibration should be followed (Section 7.3.3). This procedure is necessary to allow all the other functions to take place. By following this procedure the control system then recognizes the position of the concave in relation to the mantle (the two crushing elements) and can then allow the measurements of wear to take place. When the manganese wear procedure has been followed (Section 7.3.4) and as wear on the manganese crushing members (concave and mantle) takes place, the amount of wear is calculated by the control system and can be read off at any time from the Automax console display screen.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

! DANGER ! THIS IS A HIGH PRESSURE SYSTEM. Never carry out any maintenance work without ensuring the hydraulic system is locked out and depressurised. Do not tamper with system. In the event of any problems these should only be dealt with by suitably experienced and qualified engineers.

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ITEM 1 2 3 4 5 6 7 8 9 10 11A 11B 12 13

PART DESCRIPTION PRESSURE FILTER PRESSURE FILTER SOLENOID VALVE DOUBLE PILOT CHECK VALVE UNLOADER VALVE PRESSURE REDUCING VALVE (2) CHECK VALVE PRESSURE RELIEF VALVE NEEDLE VALVE (2) PRESSURE GAUGE (3) PRESSURE SWITCH 35-120 BAR PRESSURE SWITCH 35-120 BAR PRESSURE SWITCH MANIFOLD BLOCK

No:

AUTOMAX HYDRAULIC CONNECTION DETAILS

1

INLET, 4 LPM @ 2700 PSI

2

CONNECT TO WEDGE CIRCUIT

3

CONNECT TO ANNULUS OF GAP SETTING CYLINDERS

4

CONNECT TO FULL BORE OF GAP SETTING CYLINDERS

5

RETURN TO TANK

Figure 9ab Automax Hydraulic Control Circuit

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9.14 Plant - Electrical System

WARNING

9.14.1 General Description Electrical power of DC24 volt for the electrical equipment on the plant is derived from the diesel engine to operate the control systems for the Automax crusher and all the plant items.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Refer to the wiring diagrams in Section 11 Appendix.

9.14.2 Operator’s Control Points Once the diesel engine has been started (Section 7.2.1) the operator controls the electrical equipment from:•

Plant Control Panel (Section 7.2)

•

Automax Control Panel (Section 7.3 & 7.4 )

•

Remote Handset for Tracks (Section 5)

•

Level Sensor(s) Panel(s) (Section 9.12)

•

Metal Detector Panel (Sections 7.2.6 and 9.17)

•

Emergency Stop Buttons (Sections 1.7 and 8.3)

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9.14.3 Protection Devices The plant is fitted with Emergency Stop buttons (Sections 1.7 and 8.3) and, in addition, is equipped with a comprehensive range of protection devices to safeguard the equipment against damage. Should any of the sensing equipment fail in operation, the necessary repairs or replacement should be made immediately. This will restore the safeguard to keep the equipment from harm and maintain any warranty in force for the time being. No attempt should be made to circumvent these protection devices.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

The screen on the Plant Control Panel (Section 7.2.3) displays the appropriate message of any fault occurring.

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9.15 Plant - Crusher and Hydraulic Pump Drive Belts Good alignment of the flywheel and drive pulley is important otherwise the belt flanks will wear quickly. Ensure axis are parallel when viewed from all planes (Figure 9ac).

Shafts are not parallel to one another when seen from above

Shafts are parallel and in alignment but pulleys are not in alignment

Shafts are parallel from above but not from end view

Correct Installation Both shafts and pulleys are parallel and in alignment

Figure 9ac Correct Alignment of Pulley Belts

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9.15.1 Trouble Shooting - Drive Belts Small Cracks on V-Belt side and Base Generally caused by shortage of belt tension but excessive heat and/or chemical fumes can also give same failure. V-Belt Swelling or Softening Caused by excessive contamination by oil, certain cutting fluids or rubber solvent. Whipping During Running Usually caused by incorrect tensioning, principally on long centre drives. If a slightly higher (or lower) tension does not cure the problem there may be a critical vibration frequency in the system which requires redesign or a Banded belt. Consult Terex Pegson Ltd.

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9.15.2 Replacement and Adjustment of Crusher Drive Belts Note: Drive belts should inspected regularly for wear and also to monitor any pattern in the wear if it is occurring (Figure 9ac). The tension of the crusher drive belts is adjusted with the four screws located at each corner of the engine baseframe (Figure 9ad). When replacing the belts the drive should be slackened off sufficiently to remove the old belts and fit the new without stretching them. Only use ‘matched sets’ of belts to ensure equal tension is possible on all the belts.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings. 2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Remove the crusher drive guarding as necessary to gain access to the vee belt drive. 4. Loosen all four locking nuts ‘A’ (Figure 9ad) on the engine baseframe adjusting screws situated beneath the corners of the baseframe. Access can be gained from the platforms along each side of the engine.

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Nut B (4 off)

Nut A (4 off)

Figure 9ad Crusher Drive Belt Tensioning Mechanism RH Side

Deflection Dimension (mm)

Basic Setting Force (kgf)

1.25 x Setting Force (kgf)

See Section 9.15.4 (Step 3)

9.4

12.0

Deflection Dimension (ins)

Basic Setting Force (lbf)

1.25 x Setting Force (lbf)

See Section 9.15.4 (Step 3)

20.73

26.5

Figure 9ae Crusher Drive Belt Tensioning Specifications

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Note: Assuming the drive alignment has been satisfactory, mark, or take a measurement of the existing position of the engine baseframe (in relation to the fixed chassis) at each tension screw. These will serve as alignment reference points when tensioning the drive. 5. Lower the engine baseframe by turning each of the four nuts ‘B’ anticlockwise an equal amount a little at a time. To maintain the engine baseframe as level as possible whilst carrying out this operation only adjust each nut ‘B’ a small amount at a time. 6. If the belts are to be removed, repeat Step 5 to further slacken the belts until it is possible to remove the belts without the need to stretch them. If requiring to tension the belts correctly, follow the method for correctly tensioning each of the belt drives (Section 9.15.4). 7. Check the alignment of the two pulleys is correct (Figure 9ac) making sure that the engine baseframe is level in relation to the fixed chassis. 8. Tighten the four locking nuts ‘A’. 9. Ensure that the drive guarding is replaced and secured before start-up.

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9.15.3 Replacement and Adjustment of Hydraulic Pump Drive Belts

DANGER

Note:- Drive belts should be inspected regularly for wear, correct tension and contamination.

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

The two hydraulic pumps are situated one each side of the engine within the diesel engine canopy

WARNING

The belt tension of both hydraulic pump drives is adjusted by two bolts located on each pump baseplate (Figure 9af).

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings. 2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Remove the diesel engine side access panels.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

4. Loosen the 4 bolts (A) securing the pump bracket to the pump stool. 5. Turn the 2 adjusting screws (B) clockwise to slacken the two drive belts. Continue until it is possible to remove the belts. 6. Remove the two drive belts and re-fit with new belts.

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7. Turn the 2 adjusting screws counter clockwise to tighten the two drive belts. Continue until the belts have reached the correct tension (Section 9.15.4), making sure the pump pulley is aligned with the drive pulley (Figure 9ac). 8. Tighten the 4 bolts (A) to lock the pump bracket to the pump stool. 9. Replace the belt guard and diesel engine side access panels before start-up.

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Hydraulic Pump Drive Belt Guard

Hydraulic Pump

Adjusting Screws (B)

Pump Stool

Bolts (4 off) (A)

Pump Bracket

Figure 9af Hydraulic Pump (LH) Drive Belt Tension Mechanism

Deflection Dimension (mm)

Basic Setting Force (kgf)

1.25 x Setting Force (kgf)

See Section 9.15.4 (Step 3)

6.3

7.9

Deflection Dimension (ins)

Basic Setting Force (lbsf)

1.25 x Setting Force (lbsf)

See Section 9.15.4 (Step 3)

13.9

17.4

Figure 9ag Pump Drive Belt Tensioning Specifications

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9.15.4 Method of Drive Belt Tensioning

WARNING

! WARNING !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Under no circumstances should any check on the belt tension be made whilst the machine is running. There is a risk of trapping parts of the body if this is done.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings. 2. Close down the machine (Section 8.2) and implement the Lockout Procedure. Remove the guards from around the belt.

Crusher/Engine Drive Belts

3. Calculate the deflection distance in mm on a basis of 16mm deflection per 1 metre of belt span (Figure 9ah) (approx. 5/8” per 1 yard)

8 x 4000mm SPC, Part Number 2441-0472 Hydraulic Pump Drive Belts

Centre to Centre Distance metre x 16 = Deflection mm

4 x 2000mm SPB, Part Number 2441-0412

Ce Di ntre sta nc to C en e

tre

Belt Tension Indicator Applied to Mid-Span

16mm Deflection per 1 Metre of Belt Span

( 5/8 ins. Deflection per 1 yar of Belt Span )

Figure 9ah Belt Tensioning Measurements

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4. If a belt tension indicator is available: a) Set the lower marker ring at the deflection distance required on the lower scale. b) Set the upper marker ring against the bottom edge of the top tube.

6. If the measured force falls within the values given, the drive should be satisfactory. A measured force below the lower value indicates under-tensioning. A new drive should be tensioned to the 1.25 x Setting Force value to allow for the normal drop in tension during the running-in period. 7. Replace all guards before start-up.

c) Place the belt tension indicator on top of the belt at the centre of the belt span, and apply a force at right angles to the belt deflecting it to the point where the lower marker ring is level with the top of the adjacent belt. d) Read off the setting force value indicated by the top edge of the upper marker ring.

! NOTICE ! After the drive has been running for 15-20 minutes, the tension should be checked and readjusted to the Basic Setting Force value, if necessary by repeating the above procedure from Step 1.

e ) Compare this value to the lbf value shown in the table: Figure 9ae - Crusher Drive Belt Tensioning Specifications Figure 9ag - Hydraulic Pump Drive Belt Tensioning Specifications 5. If a belt tension indicator is not available: a) Use a spring balance to pull the belt down at the centre of the span. b) When the belt has been pulled down (measure using a rule) by the deflection calculated in Step 3, read off the force from the spring balance.

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9.16 Plant - Conveyor Belts

DANGER

9.16.1 General Description

ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

There are two belt conveyors on the Maxtrak plant. •

•

The Feed Conveyor has a shallow troughed plain belt. Drive is through a head drum mounted oil lubricated gearbox with hydraulic motor. Screw type tensioning of the belt is at the tailshaft. Full length skirt plates are included. A metal detector (Section 9.17) is fitted to stop the conveyor when the detector is triggered. To reduce the height of the plant for transportation the conveyor can be lowered by means of an hydraulic ram (Sections 5.2 and 6.2) and also to elevated (Section 9.7.3.1) to gain access when working on the Automax crusher. To achieve the minimum travelling height it is also necessary to lower the Automax Upper Frame (Section 5.2.5). Grease nipples are provided for lubrication of the shaft bearings. The Discharge Conveyor is a standard troughed plain belt type. The drive is by hydraulic motor at the head end and. Screw tensioning of the belt is at the headshaft. Full length skirt plates are included. A detachable canvas wind cover is included. A movement sensor is fitted at the tail to stop the feed to the Automax in the event of conveyor belt stopping for any reason. The shaft bearings are lubricated the same as the Feed Conveyor.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

! DANGER! Under no circumstances should any adjustment be made on the belt whilst the machine is running. There is a risk of trapping parts of the body if this is done.

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9.16.2 Training of Belts

DANGER

Before starting the conveyors, it is essential to check that:•

Make sure that the Feed Conveyor is in the working position.

•

Wire ropes supporting the Discharge Conveyor head should be correctly tensioned by adjusting with the turnbuckles.

•

•

ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

The head and tail drums are correctly fitted. ie. they are level, and that their axes are square to the centre line of the conveyor.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

All troughing and parallel idlers are correctly fitted with their axles square to the centre line of the conveyor, the side roller lead is in the correct direction (i.e. forward of centre) and all rollers are rotating freely.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

•

In the case of screw-type take up gears, that these are adjusted initially to take up slack from the belt and that equal tension is applied to each side such that the pulley is square to the centre line of the conveyor.

Tracking should be carried out with the belt empty. With very stiff belts, which do not trough well nor make proper contact with the centre idlers roller when empty, it may only be possible to track the return strand when empty and the troughed side when loaded.

•

Where skirt rubbers are fitted they are not bearing down heavily on the belt.

•

There is no obstruction on the conveyor that could cause accident or damage when the conveyor is started.

If the belt tends to run to one side the most likely cause of the trouble will usually be some distance before the point where the running off is apparent, and in the case of troughed strand probably at the second or third idler behind the point where the belt is moving out of its true line.

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Side Roller

Slots for Adjustment

Belt

Side Roller Centre

Slots for Adjustment

Figure 9ai Transom Breakdown The detail of the conveyor idlers actually fitted may vary from the illustration.

Locknut A (2 off)

Clamping Screws

Square/Hex. Ended Adjusting Bar B (2off)

Grease Nipple Belt Tensioning Mechanism

Figure 9aj Conveyor Belt Tensioning Mechanism

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9.16.3 Conveyor Belt Tensioning

DANGER

Both of the conveyors are tensioned at the tailshaft. Tensioning mechanisms are located on either side of the drum(s) (Figure 9aj).

ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Best practice is to tension each side a little at a time and by the same amount until the belt is tensioned. When tensioned, the drum must be square to the conveyor frame.

WARNING

The correct tension is achieved when the drive drum starts the belt and keeps it running when loaded without any slip occurring.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

The tension screws should be kept clean and well oiled.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Loosen locknut A(2 off) and the clamping screws. 4. Tighten or loosen the square or hexagon ended adjusting screw B(2 off) as required. 5. Once correct tension has been achieved, tighten locknut A(2 off). Tighten the clamping screws.

! DANGER ! Under no circumstances should any adjustment be made on the belt whilst the machine is running. There is a risk of trapping parts of the body if this is done.

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9.16.4 Maintenance of Conveyor(s) The following checks should be made regularly in order to keep the conveyor(s) in good working order:

DANGER

•

Observe all safety warnings.

ENTANGLEMENT HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

•

Close down the machine (Section 8.2) and implement the Lockout Procedure

WARNING

•

On the Feed Conveyor inspect the impact idlers and side wearing strips beneath the feed conveyor belt for wear and replace if necessary. Ensure that the plant feed hopper (and check gate) is satisfactory in relation to the conveyor. Also make sure that the belt is kept straight and central at all times.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

•

For the Discharge Conveyor ensure that central feed onto the conveyor belt is maintained at all times and that the belt at the point of feed is kept straight and central at all times.

•

Inspect all skirt plate sealing strips and ensure that they are adjusted close enough to the belt to prevent spillage or material jamming between the seals and the belt, but at the same time not bearing hard on the belt. Replace if worn.

•

Check that the belt generally is running centrally and straight on both the carrying strand and the return strand. If not, refer to Section 9.16.2 Training of Belts.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

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•

Check that there is no evidence of belt slip at the driving drum, as belt slip will cause premature wear on the belt. Check also for undue sag between idlers. Both would indicate lack of belt tension (Section 9.16.3)

•

Check regularly that the idler rollers are rotating freely. If not either free them or replace the idler. Failure to do so will result in belt wear and tracking problems.

•

Check that the belt cleaning equipment is operating correctly and efficiently. In the case of scrapers ensure that they are not choked with a build up of material. Also check that the blades are not bearing on the belt any more than necessary, and that any blades which are unevenly worn or in a condition likely to cause damage to the belt are renewed immediately.

•

Inspect the condition of the conveyor belt regularly and arrange for the earliest possible repair of any damage which may have occurred as this can make a worthwhile extension of the useful life of the belt. Repair a cut or tear in the rubber by cleaning with benzine and plugging with a rubber repair compound.

•

The grease in the head and tail drum bearings need re-greasing every two weeks (Section 9.4.5).

! DANGER ! Do not use clip joints for belt repairs or replacements, as they can be dangerous. Belt repairs/ replacements should be performed by vulcanising only.

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•

•

Follow the lubrication schedule for the oil lubricated gearbox located inside the Feed Conveyor head drum (Section 9.4.5). The gearbox must be filled up to the centre line and two sight glass plugs are provided at 180º (Figure 9ak). To ascertain the required halfway level check that the lower sight glass shows oil whilst the higher sight glass (also used to add oil) is clear. Check the level monthly. Do not mix oils of different maker or type. The oil temperature to be always below 90 º C. In the interests of efficient operation and general safety, it is important that operating conditions are kept as clean as possible and that any spillages are cleaned up regularly and are not allowed to build up.

Hydraulic Motor

Higher Sight Glass

Fill/Level Sight Glasses (1 hidden) Figure 9ak Feed Conveyor Drive Gearbox

! DANGER ! As many inspections as possible should be made whilst the belt is stationary. When this is not possible extreme care should be taken when inspecting the belt whilst it is moving as this creates a risk of trapping parts of the body.

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9.16.5 Cleaning the Conveyor Belts If your machines’ conveyor belts are not properly maintained and skirting rubbers are not kept in proper adjustment, it may be necessary to remove resultant spillage material and / or blockages from the conveyor belts, particularly at the feed section.

! WARNING ! It is important that these procedures are followed when cleaning the conveyor belts. Failure to follow these procedures can result in death or serious injury.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure. FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. The equipment should be switched off and isolated by means of the lockout and tagout procedure prior to the commencement of any work. 2. Use suitable personal protective equipment i.e. eye, foot, hand and head protection etc as may be required or necessary to undertake the task. 3. Gloves to protect the skin against abrasive materials, sharp surfaces, or penetration of the skin should be worn. 4. Goggles should be worn to protect from fragments, particles, or dust that could be ejected into the eyes.

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5. Not only the worker(s) cleaning the belts but also others close by who may be affected, must also wear protective equipment.

! NOTICE ! The conveyor belts can be cleaned using a number of methods. Before commencing, make sure all aforementioned procedures have been followed: • • •

Using a high pressure air hose; Using a water hose; Using a rod with scraper attached, or a brush or shovel.

In the case of a blockage at a drive or tail drum it may be necessary to loosen the tension on the conveyor belt so that the blockage can be removed. See Sections 9.16.2 and 9.16.3 for re-tensioning and realigning the belt after blockage is removed. When work is complete, make sure that all guards are closed / replaced and secured before re-starting the machine.

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9.17 Metal Detector A Metal Detector is fitted to the Feed Conveyor to warn the operator of detected steel on the belt before it enters the Automax crushing chamber possibly causing damage to the machine. The Automax is equipped with hydraulic overload release to activate in the event of uncrushable material being present. However, large foreign objects cannot pass through the machine and must be manually removed from the feed conveyor before entering the crusher.

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Green ‘POWER ON’ light

The electrical system is designed to automatically stop the Feed Conveyor when the detector is triggered. Whilst the detector is switched on the green light on the panel door (Figure 9al) will be illuminated and upon metal being detected the red light will also illuminate. The red light is also the reset button to be pressed when the offending object has been removed. The sensitivity of the detection can be varied to suit the operation as described overleaf.

! NOTICE ! When adjusting the sensitivity of the detector unit it is most important the setting will not allow pieces of steel to enter the Automax which would damage the machine. Red ‘DETECT’ light and ‘RESET’ button Figure 9al Metal Detector Control Panel

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9.17.1 Metal Detector Controls

WARNING

Normally, once the Metal Detector has been set up at the time of plant commissioning there should be no need to alter any of the controls within the control cabinet (Figure 9am) and the panel door should be kept closed to avoid the ingress of dust. However, in the event of subsequent adjustment being necessary the following instructions should be read but any major changes should only be attempted by an engineer conversant with the operation of the Maxtrak plant as a whole.

! NOTICE ! When opening the door of the Metal Detector control panel do not tamper with the terminal blocks or wiring unless the unit is switched off. With the power ‘ON’ the GREEN lamp on the door case will be illuminated. Opening the panel door will reveal the setting controls (Figure 9am). The RED fault light will be extinguished when the sensor is properly connected. Note: The illuminated fault light will also cause the DETECT lamp to be illuminated.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Rotate the SET ZERO control Figure 9am) fully clockwise. If the right hand light illuminates, rotate the SET ZERO control anticlockwise until this light extinguishes and the green light illuminates. This adjustment compensates (or zeros out) any nearby metal in the sensor coil detect area. If this light cannot be illuminated there may be too much metal near the sensor coil. After the above adjustments the detector may have illuminated the DETECT light and the RESET lamp on the detector door. Pressing RESET lamp button will extinguish both lights. The relay function is controlled by the RELAY switch. In the OFF position only the DETECT light and door RESET lamp operate when metal is present in the sensing area. In the LATCH position the relay and above indicators operate but after metal is removed the relay and the indicators remain ‘on’ until either the door RESET button is pressed or the RELAY switch is turned to the ON or OFF position.

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The SENSITIVITY control is a gain adjustment control for the detection of the desired size of material or to allow for smaller pieces of material to be ignored.

FAULT Light

! NOTICE ! Use the sensitivity control very carefully so as not to allow damaging pieces of uncrushable material to enter the Automax crusher.

DETECT Light

SET ZERO indicator lights

RELAY switch

SET ZERO Control

Figure 9am Metal Detector Setting Controls

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9.17.2 Metal Detector Indictor Lights (Figure 9am & 9an) SET ZERO - When the Metal Detector is operating and correctly set, the GREEN light of these three lights is illuminated. If a piece of metal passing across the sensor coil is large enough it will cause the GREEN light to extinguish and the right hand RED light to come on whilst the metal is within the sensing range of the sensor coil. DETECT - This RED light illuminates whenever metal is within the sensing range of the sensor coil. COIL FAULT - This RED light illuminates whenever the sensor is either open circuit, not connected or short circuited. The light also causes the DETECT light to illuminate to prevent operation of the detector until the coil fault is rectified.

SIGNAL LEVEL INDICATOR - This consists of a row of 10 lamps which light in sequence from left to right as the detected signal level increases when metal approaches the sensor. The alarm is triggered when the signal level reaches the right hand lamp which is permanently illuminated. Normally none or perhaps the first 1 or 2 lamps may be flickering on and off.. However, if the detector regularly suffers from false alarms this indicator should be examined since more lamps flickering on and off may indicate the presence of some interference which is either mains or airborne. In this case have a qualified engineer investigate and rectify.

Normally, the Metal Detector control unit should not require any major readjustments after initial commissioning of the plant. After being switched on the GREEN SET ZERO light should illuminate immediately without the need to turn the SET ZERO control. Certain extremely large objects may produce an overload signal causing the unit to indicate continuously even after the object has passed clear of the sensor coil. Depress the RESET button to cancel the indication.

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Signal Level Indicator Lights

Sensitivity Control

Figure 9an Metal Detector Setting Controls

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9.18 Plant - Dust Suppression

WARNING

The Maxtrak plant is fitted with a plain water dust suppression system. The system consists of three spray bars each one having three nozzles. The spray bars are located in the following areas:•

Crusher feed chute.

•

Crusher discharge area.

•

Product conveyor discharge.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

It is the responsibility of the customer to supply the system with clean water. This is supplied at the manifold (Figure 9ao). The total flow requirement for the system is 7 litres/min. This equates to a pressure requirement of 2.8 bar or 42 psi.

FALLING HAZARD. Refer to Section 9.1, Safety Information for relevant warning.

Maintenance All nozzles should be kept free of dirt and blockages. Each nozzle should be checked every time the dust suppression is switched on. Shut-off valves are provided for each spray bar at the manifold. The system can be drained after operation by the drain valves located below the inlet manifold. This is particularly important in winter time when there is the likelihood of the system freezing.

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Water Inlet Point

Crusher Discharge Area

Crusher Feed Chute

Product Conveyor Discharge

Figure 9ao Dust Suppression Manifold

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9.19 Plant - Diesel Engine

WARNING

! NOTICE !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

For the diesel engine powerpack fitted to your Maxtrak to continue to perform safely, efficiently and reliably it is imperative that all the recommendations given in the separate engine manual are strictly followed with regard to:•

Safety

•

Operation

•

Lubrication

•

Maintenance

•

Service

•

Parts

Adhere to the regular maintenance schedules and procedures specified by the manufacturer using the numbers of hours run as displayed on the engine Service Meter.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

The HFO clutch is operative when the engine powered hydraulic system is at operating pressure. Should the hydraulic pressure fall below a preset level, the Feed Conveyor will be stopped to prevent any further material from entering the Automax whilst there is a risk of the clutch slipping due to the low oil pressure. Until the reason for the low pressure has been established and the fault rectified the plant cannot be operated.

All matters relating to the diesel engine can be dealt with directly by your local official engine dealer for the unit fitted without consulting BL-Pegson Limited. The engine is fitted with an HFO hydraulically operated clutch which is electrically actuated from the plant control panel to engage/disengage the crusher drive. The 2 hydraulic pump drives inside the engine canopy are permanently coupled to the engine.

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9.19.1 Engine - ELC Coolant Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this is not available top up with deionized water and adjust mixture concentration in the shop. Under no circumstances use any other coolant as damage will result and any warranty invalidated. Equipment is intended for use in ambient temperatures between -10°C to +40°C (+14°F to +104°F). Appropriate lubricants and coolant must be used as specified within the plant and engine operating and maintenance manuals. For use in temperatures outside the above range consult your Terex Pegson Dealer or BL-Pegson Limited for details prior to commencement of operations. ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH before refilling with ELC coolant. Adhere to the instructions on the external labelling as shown below.

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9.19.2 Hydraulic Engine Clutch

WARNING

The drive from the engine to the Automax crusher is through an HFO hydraulic oil actuated clutch. This totally enclosed unit has the outer driving ring connected to the diesel engine flywheel. The output shaft is supported by a spherical roller bearing, oil lubricated, fitted in a cover flanged to the engine flywheel housing. .

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Check the bearing oil level prior to the daily start up of the plant: as a minimum requirement, level stick must be oil wet. The oil filler/dipstick can be accessed at the rear of the engine housing.

! NOTICE ! Engage the clutch ONLY at engine at idling speed (1200 rpm). At ambient temperature close to or below 0 ºC, keep engine running at idling speed for 5 minutes, at least.

Filler Cap with Dipstick

When changing the oil, drain the old oil by opening the tap located at the bottom of the bearing housing. Make sure this is tightly closed before adding fresh oil of the approved grade - Section 9.4.6 (DO NOT USE SYNTHETIC OIL) filled to the required level. Remove taper plug (41) and through pipe (34) fill the bearing cavity. Turn the shaft by hand until the maximum oil level is indicated on the stick (37). After oil filling, remount the taper plug. See Section 10 parts list to identify reference numbers Check the clutch driving plates annually and it is advisable, every 4000 working hours, to check the condition of the bearings and replace the rotating seals (refer to parts list).

Figure 9ap Clutch Oil Filler

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9.19.3 Check Fuel Level

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Check the fuel level indicator (Figure 9aq)

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

3. Top up fuel level if required (Section 9.19.4). •

Fill the tank at the end of each day, where possible, to reduce overnight condensation within the tank.

! DANGER ! Diesel fuel is highly flammable and is an explosion/ burns hazard. Never remove the filler cap or refuel, with the engine running. Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks. Do Not smoke while refilling or carrying out maintenance on the fuel system.

Fuel Level Gauge

Do Not carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment. Figure 9aq Fuel Level Indicator - Engine Control Panel

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9.19.4 Top Up Fuel Level

WARNING

! NOTICE ! Do Not fill the tank to capacity. Monitor the gauge located on the Control Panel (Figure 9aq). Allow room for expansion and wipe up spilt fuel immediately, otherwise paintwork will be damaged.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning. LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings. 2. Close down the plant (Section 8.2) and implement the lockout procedure. 3. Lift the engine side access panel to reveal the filler cap.(Figure 9ar). Clean the area around the filler cap. 4. Remove the filler cap. 5. Fill the tank will diesel fuel. 6. Replace the cap and refit the engine access panel before start up.

! DANGER ! Diesel fuel is highly flammable and is an explosion/burns hazard.

Figure 9ar Filler Cap

Never remove the filler cap or refuel, with the engine running.

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! DANGER ! Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks. Do Not smoke while refilling or carrying out maintenance on the fuel system. Do Not carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.

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9.20 Plant - Vehicle Tracks

WARNING

! NOTICE !

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

It is essential that the tracks are correctly tensioned at all times. Check track tension regularly (Section 9.21.1).

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

Keeping the track properly adjusted will increase the service life of the track and drive components. When ordering Spare Parts it is essential to quote the plant serial number (with either a / S or /T suffix if included on the identity plate serial number). Frequently check for loose bolts, oil leaks, master pins are correctly located and tight, general wear and damage, correct track tension, etc. to ensure safe working and long life. When travelling on a gradient, the tracks should be driven with the track idler rollers (Figure 9ay) in front (ie. Feed Hopper first).

9.21.1 Measuring Track Tension

! WARNING ! Prior to attempting any manoeuvring of the plant the tracks must be free of obstructions, including crushed material and fines. Do not push or tow the plant. Failure to observe this warning could result in injury to persons and damage to the plant which may invalidate warranty.

Procedure 1. Observe all Safety Warnings. 2. Position the plant on solid and level ground and drive 2 metres (2 yards) minimum in a forward direction, track idler roller leading.

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3. Close down the plant (Section 8.2) and implement the Lockout Procedure. 4. One track at a time, measure the sag on the top part of the track on the longest section of unsupported track by placing a ‘straight edge’ long enough to reach from the drive sprocket to the nearest skid plate. 5. Measure the maximum amount of track sag from the high point of the track grouser to the bottom of the ‘straight edge’ (Figure 9as). Correctly adjusted the sag should be approximately 15 mm (5/8”) but must not be less that 5mm (1/4”).

5 - 15mm (1/4 - 5/8”)

Figure 9as Measuring Track Tension

! WARNING ! Tracking the machine with incorrectly tensioned tracks can cause severe damage to the undercarriage components and may invalidate the warranty. 6. Depending upon the need to either slacken or tension the track(s) proceed as below.

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9.20.2 Adjusting Track Tension

DANGER

! WARNING !

SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

‘GREASE UNDER HIGH PRESSURE’ To Release Track Tension (After measurement - Section 9.20.1):-

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

1. Observe all Safety Warnings. 2. Close down the plant (Section 8.2) and implement the Lockout Procedure.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

3. Locate the access aperture on the side of the track frame and remove the cover (where fitted) to reveal the relief valve inside. 4. Next loosen the relief valve by turning counter clockwise using gradual increments until the grease begins to be expelled. Care must be taken not to loosen the relief valve too quickly because the grease inside is under high pressure. 5. When the correct track tension has been measured (Section 9.20.1), turn the relief valve clockwise to tighten and then clean away all trace of expelled grease.

! DANGER ! Grease coming out of the relief valve under pressure can penetrate the body causing injury or death; do NOT watch the relief valve to see if grease is escaping but instead watch the track adjustment cylinder to verify that the track is being loosened. DO NOT OVER TENSION THE TRACKS (Refer to Section 9.20.1).

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6. Operate the plant in manoeuvring mode (Section 5.2.1) and drive the plant 50 metres (50 yards) forwards and 50 metres (50 yards) backwards, measure the sag and repeat the steps 1 - 4 if the track(s) sag is not enough. If room for manoeuvring the plant is restricted, drive the plant forwards and backwards several times over a shorter distance. If the track fails to slacken after the grease fitting has been loosened, do not attempt to remove the tracks or disassemble the track tensioner, or remove the grease fitting. It is possible that running the tracks with the grease fitting loosened may help to expel the grease.

Track Surface

Idler Roller

Drive Sprocket

Relief Valve Final Drive Unit

Track Roller

Figure 9at Vehicle Track Parts

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To Increase Track Tension (After measurement - Section 9.20.1):-

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, Safety Information for relevant warning

Procedure 1. Observe all Safety Warnings. 2. Close down the plant (Section 8.2) and implement the Lockout Procedure.

WARNING

3. Locate the access aperture on the side of the track frame and remove the cover (where fitted) to reveal the relief valve inside.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

4. Connect the grease gun to the grease fitting and add grease until the track tension is within the specified dimension (Section 9.20.1). See Section 9.4.5. for the grease type and specification.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

5. Operate the plant in manoeuvring mode (Section 5.2.1) and drive the plant 50 metres (50 yards) forwards and 50 metres (50 yards) backwards, measure the sag and repeat the steps 1 - 4 if the track(s) sag is too great. If room for manoeuvring the plant is restricted, drive the plant forwards and backwards several times over a shorter distance.

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9.20.3 Track Maintenance

WARNING

(Figure 9at)

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Maintenance Schedule •

The first drive oil replacement is to be carried out after 100 operating hours of the gearbox.

•

There after replace the drive oil every 1000 hours or at least once per year.

•

Check the drive oil level every 100 working hours.

LOCKOUT PLANT. Refer to Section 9.1, Safety Information for Lockout Procedure.

Daily

Procedure 1. Observe all safety warnings. 2. Close down the machine (Section 8.2) and implement the Lockout Procedure. 3. Check the track rollers and idler wheels for possible leakage. 4. Check the track surface of the track rollers, idler wheels, track shoes and drive sprockets for wear and loose mounting bolts. 5. Clean out any heavy build up of material from around the tracks.

! NOTICE ! To maximise the life of the track, keep it movable and avoid damage, the plant should be moved at least every week, by a distance exceeding four times the track length. It should also be parked on level ground overnight and during periods to of nonusage. This is particularly important when working in adverse conditions.

6. Check the tension of the tracks (Section 9.20.1) and adjust tension if necessary (Section 9.20.2).

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9.20.4 Drive Oil Filling and Draining

WARNING

Oil Filling

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

Procedure 1. Observe all safety warnings.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

2. Close down the plant (Section 8.2) and implement the Lockout Procedure. 3. Make sure the gearbox housing is horizontal. 4. Rotate the gearbox housing so that one plug is at the 12 o’clock position and the other plug is at the 9 o’clock position (Figure 9au). 5. Unscrew the two plugs and fill from the upper hole until the oil flows from the hole located at the 9 o’clock position. See Section 9.4.6 for oil type and specification.

Oil Fill (A)

6. Clean plugs using a clean non-flammable solvent. 7. Apply pipe sealant to the plugs and install. 8. Repeat procedure on the other final drive. Note:- Over filling the final drive will cause the travel motor seal to allow hydraulic oil or water to enter and contaminate the drive.

Oil Level (B)

Figure 9au Tracks - Oil Filling

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Oil Draining

WARNING

Procedure

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, Safety Information for relevant warning.

1. Observe all safety warnings. 2. Close down the plant (Section 8.2) and implement the Lockout Procedure.

LOCKOUT MACHINE. Refer to Section 9.1, Safety Information for Lockout Procedure.

3. Rotate the gearbox housing until a plug is at the 6 o’clock position (Figure 9av). 4. Unscrew both plugs and discharge the oil.

(A)

5. Clean plugs using a clean non-flammable solvent. 6. Apply pipe sealant to the plugs and install. 7. Repeat procedure on the other final drive.

Oil Drain (B)

Figure 9av Tracks - Oil Draining

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Page 9 - 136

Blank Page

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10 - Spare Parts

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Page 10 - 1

10 - Spare Parts 10.1 Automax Crusher Parts .............................................................................. 10 - 3 General Illustration............................................................................................. 10 - 3 Mainframe Assembly......................................................................................... 10 - 4 Upper Frame Assembly .................................................................................... 10 - 6 Hydraulic Cylinder Fixings ................................................................................. 10 - 8 Cone head Assembly ...................................................................................... 10 - 10 Eccentric Assembly......................................................................................... 10 - 12 Countershaft Assembly ................................................................................... 10 - 14 Lubrication Piping Assembly ........................................................................... 10 - 16 Crusher Hydraulic Assembly............................................................................ 10 - 18 Hydraulic Control Panel Assembly ................................................................... 10 - 20 Lubrication Oil Tank Assembly ......................................................................... 10 - 22 10.2 Plant Conveyors ....................................................................................... 10 - 25 Feed Conveyor Parts - sheet 1........................................................................ 10 - 25 Feed Conveyor Parts - sheet 2........................................................................ 10 - 26 Level Sensor - Crusher Unit MR1 .................................................................... 10 - 28 Discharge Conveyor Parts - sheet 1 ................................................................ 10 - 31 Discharge Conveyor Parts - sheet 2 ................................................................ 10 - 32 10.3 Plant Components .................................................................................... 10 - 34 Plant Components - sheet 1 ............................................................................ 10 - 34 Plant Components - sheet 2 ............................................................................ 10 - 35 Plant Components - sheet 3 ............................................................................ 10 - 36 10.4 Plant Tracks .............................................................................................. 10 - 38 10.5 Plant Hydraulic System ............................................................................ 10 - 40 Hydraulic Reservoir ......................................................................................... 10 - 40 Hydraulic System Components ....................................................................... 10 - 42 Hydraulic Components - HFO Hydraulic Clutch Circuit ..................................... 10 - 43 10.6 Electrical Components ............................................................................. 10 - 44 Plant Control Panel ......................................................................................... 10 - 44 Automax Control Panel ................................................................................... 10 - 46 10.7 Warning Signs........................................................................................... 10 - 48 10.7 Hydraulic Engine Clutch .......................................................................... 10 - 50 Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Page 10 - 2

IMPORTANT TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL TEREX PEGSON DISTRIBUTOR TO OBTAIN GENUINE PARTS MANUFACTURED TO ORIGINAL SPECIFICATIONS UNDER STRICT QUALITY CONTROL. ALWAYS QUOTE THE SERIAL NUMBER STAMPED ON THE PLANT/MACHINE IDENTITY PLATE

YOUR LOCAL REPLACEMENT PARTS CONTACT (fill in when known) TEREX PEGSON DISTRIBUTOR............................................................................. CONTACT NAME(S).................................................................................................... ......................................................................................... TELEPHONE NUMBER............................................................................................... FACSIMILE NUMBER................................................................................................. E MAIL ADDRESS....................................................................................................... .......................................................................................................................................... .......................................................................................................................................... ..........................................................................................................................................

REMEMBER! THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 290/396

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10 - Spare Parts

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Page 10 - 3

10.1 Automax Crusher Parts General Illustration

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

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Page 10 - 4

Mainframe Assembly REF

PART NUMBER

DESCRIPTION

1

2500-5004B

WEDGE RING SEAL – 1/2SQ X 8M BOX

1

2

2500-5006B

MAINFRAME SEAL – 3/4SQ X 8M BOX

1

3

307/19

'O' RING (STUB OIL FLINGER)

1

307/18

‘O’ RING (STUB SHAFT)

1

4

603/1372

MAINSHAFT

1

5

603/1530

MAINSHAFT STUB

1

6

603/1532

OIL FLINGER

1

7

603/1531

BEARING CLAMP

1

2230-1121

SCREW

4

2212-7109

LOCKWASHER

4

8

603/1208

MAINFRAME LINER SET

1

9

603/1223

COUNTERSHAFT ARM SHIELD

1

10

603/1443

FRAME ARM SHIELD

3

11

603/1459MCD

WEDGE RING ASSEMBLY

1

603/1457

ANTI-ROTATION POST

1

603/1468

INSERT

12

2147-0101

ADHESIVE – 80 ML

10

2123-2001

MOLYBENTONE GREASE – 0.5 KG

2

603/1298

ANTI-ROTATION STOP PLATE

1

2232-1429

BOLT

2

2215-0022

NUT

2

2211-0016

WASHER

2

603/1302/1

THRUST BLOCK

2

603/165/2

INSERT

2

2147-0051

ADHESIVE – 300 GM

1

2232-1206

BOLT

4

2211-0010

WASHER

4

2210-0019

WASHER

4

15

603/1473MCD

I000 SERIES MAINFRAME ASSEMBLY

1

16

2402-2050

BEARING

6

17

2152-9050

SEAL STRIP – 1 X 1/8 X 48

15

18

603/1373

MAINSHAFT SPACER

1

19

2564-7104

DUMPY JACK

12

603/1465

DUMPY JACK STOOL

12

603/1367

TRANSDUCER COVER

1

12

13

14

20

QUANTITY

2230-1153 SCREW 4 Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 4518618 2211-0007 WASHER 21

2666-9013

22

2690-0020

22/07/04

LINEAR TRANSDUCER UNIT JUNCTION BOX C/W MULTI CORE CABLE AX860-901-8EN-02f 292/396

1 1

Maxtrak 1300

10 - Spare Parts

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Page 10 - 5

21

22 20

1300 Automax - Mainframe Assembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

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Page 10 - 6

Upper Frame Assembly

REF

PART NUMBER

DESCRIPTION

603/1456

FEED RING - AUTOMAX

1

603/1455

FEED RING - AUTOSAND

1

2230-1202

BOLT

4

2210-0019

PLAIN WASHER

4

2211-0010

SPRING WASHER

4

3

320/33

SHOULDERED DOWEL

4

4

603/192

WEDGE

4

5

603/1504MCD

UPPER FRAME - AUTOMAX

1

603/1503MCD

UPPER FRAME - AUTOSAND

1

2402-2050

BEARING

6

2147-0028

LOCTITE - 50ml

1

2530-1135

GREASE NIPPLE

12

2968-4102

GREASE GUN

1

2123-2002

MOLYGREASE CARTRIDGE – 400g

1

603/1416E

CONCAVE - AUTOMAX

1

603/1407E

CONCAVE - AUTOSAND

1

2144-0031

PEGBAK PACK (10KG TUB)

6

2144-0032

RELEASE AGENT

1

1 2

6

7

QUANTITY

22/03/05

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 294/396

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10 - Spare Parts

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Page 10 - 7

- FEED BOX NOT SHOWN FOR CLARITY

1300 Automax - Upper Frame assembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 295/396

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Page 10 - 8

Hydraulic Cylinder Fixings

REF

PART NUMBER

DESCRIPTION

QUANTITY

CYLINDER CLEVIS - UPPER 1

2402-2050

BEARING

6

2

320/25

PIN

6

3

603/1491

SPACER – TOP

12

4

2210-2020

PLAIN WASHER

12

5

2201-0150

SPLIT PIN

12

CYLINDER CLEVIS - LOWER 6

2402-2050

BEARING

6

7

603/1490

PIN

6

8

603/1234

SPACER

12

9

311/10

RUBBER WASHER

12

10

2210-2020

PLAIN WASHER

12

11 22/07/04

2201-0150

SPLIT PIN

24

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Page 10 - 9

1 2 3

5

4

UPPER CLEVIS

10

11 9

6

7

8

LOWER CLEVIS 1300 Automax - Hydraulic Cylinder Fixings Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Page 10 - 10

Cone head Assembly

REF

PART NUMBER

DESCRIPTION

1

2410-0496

BEARING – PARALLEL ROLLER

1

2

2415-9802

BEARING – TAPER ROLLER

1

3

2430-0624

CIRCLIP

1

4

603/1244

BURNING RING

1

5

603/1215

MANTLE NUT PLUG

1

6

603/1229

MANTLE NUT

1

7

603/1508E

MANTLE

1

N/S

2144-0031

PEGBACK PACK (10KG TUB)

3

N/S

2144-0032

RELEASE AGENT

1

603/1236

DISTRIBUTION PLATE

1

2222-0889

SCREW

4

9

603/1313

SNAP RING

1

10

603/1405

COVER PLATE - CONE HEAD

1

2501-1307

'O' RING

1

2230-1220

SCREW

4

2211-0010

WASHER

4

603/1329

OIL FLINGER

1

307/5

'O' RING

1

603/1255MCD

PISTON RING

1

307/3

'O' RING

1

603/108

SLEDGING BAR

1

603/1318

CONE HEAD

1

8

11 12 13 14 22/03/05

QUANTITY

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 298/396

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10 - Spare Parts

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Page 10 - 11

1300 Automax - Cone Head Assembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

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Page 10 - 12

Eccentric Assembly

REF

PART NUMBER

DESCRIPTION

1

2152-9050

SEAL STRIP – 1 X 1/8 X 48”

15

2

2222-6805

SCREW

6

2211-0012

WASHER

6

3

2410-9008

BEARING PAIR – PARALLEL ROLLER

1

4

2415-9801

BEARING – TAPER ROLLER

1

5

2430-0624

CIRCLIP

1

6

302/17

BEVEL GEAR

1

7

323/35

STUD

5

2215-0018

NUT

5

2210-4012

WASHER

5

332/8

KEY

2

2222-6748

SCREW

2

9

605/1256

ECCENTRIC

1

10

603/1339 (MCD)

PISTON RING

1

307/9

'O' RING

1

11

605/1250

ROTARY SEAL RING

1

12

603/1295

BALANCE RING

1

2201-5285

SPRING PIN

1

8

N/S 22/07/04

QUANTITY

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 300/396

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10 - Spare Parts

EN

Page 10 - 13

1

11

10 3

12

7

2

5 9

8 4

6

1300 Automax - Eccentric Assembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 301/396

Maxtrak 1300

10 - Spare Parts

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Page 10 - 14

Countershaft Assembly

REF

PART NUMBER

DESCRIPTION

1

2217-9022

BEARING LOCKNUT

1

2

2230-1221

SCREW

4

2211-0010

WASHER

4

2230-1414

SCREW

8

2211-0016

WASHER

8

4

2415-9003

BEARING

2

5

2443-1801

PULLEY

1

6

2443-8307

TAPER LOCK BUSH

1

7

2450-5001

RINGFEDER

1

8

307/7

'O' RING

1

9

2503-4501

OIL SEAL

1

10

302/25

BEVEL PINION

1

11

331/9

KEY

1

12

603/1442

COUNTERSHAFT HOUSING

1

13

603/1219

SHIM PAIR – 1.5mm THICK

2

603/1501

SHIM PAIR – 0.75mm THICK

603/1343

OIL GUARD

1

2147-4002

SEALANT – 50 ML

1

605/1237

COUNTERSHAFT

1

3

14 15 20/08/04

QUANTITY

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 302/396

Maxtrak 1300

10 - Spare Parts

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Page 10 - 15

1300 Automax - CountershaftAssembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 303/396

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10 - Spare Parts

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Page 10 - 16

Lubrication Piping Assembly REF PART NUMBER 1 2510-3806 2 2510-3007 3 2510-3526 4 2520-6566 5 HOSE 48 6 341/454 7 2510-3899 8 2510-3273 9 2520-3809 10 AX860/126 11 2512-0007 12 2215-0014 13 2211-0008 14 2526-4002 15 2520-6596 16 2520-6597 17 HOSE 49 18 HOSE 52 19 HOSE 47 20 2520-6573 21 2520-6575 22 2500-1023 23 2520-6574 24 2520-6579 25 2510-3589 26 2510-3149 27 2520-6576 28 2340-4007 29 2520-6572 30 2510-3789 31 2581-8129 32 2534-4001 33 2510-3578 34 2510-3595 35 341/452 36 2510-3258 37 2520-2108 38 2340-2004 39 2520-6643 40 2520-6644 41 2520-6645 42 2529-9902 AX860/106/06 – 30/05/03

DESCRIPTION NIPPLE ELBOW REDUCER TAPER NIPPLE HOSE PIPE BACKNUT TEE NIPPLE SUPPORT BRACKET U BOLT NUT WASHER HOSE ELBOW NIPPLE HOSE HOSE HOSE ELBOW REDUCER BONDED SEAL TEE REDUCER REDUCER ELBOW HOSE TAIL JUBILEE HOSE CLIP REDUCER SOCKET OIL TANK HEAT EXCHANGER REDUCER REDUCER PIPE ELBOW HOSE CAP AND LINER CLAMP TAPER NIPPLE ELBOW NIPPLE NYLON HOSE GUARD

QUANTITY 1 1 1 3 1 1 1 1 1 1 1 4 2 1M 1 1 1 1 1 4 2 2 1 1 2 2 2 2 2 1 1 1 1 1 1 2 2 4 1 3 1` 0.8M

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 304/396

1300 Automax Mobile Plant - Lubrication Oil Piping

Page 17

AX860-901-8EN-02f 305/396

Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 18

Crusher Hydraulic Assembly REF

1

PART NUMBER DESCRIPTION QUANTITY HYDRAULIC CYLINDER CIRCUIT (ONLY ONE HALF OF COMPLETE CIRCUIT ILLUSTRATED) 2500-1021 SEAL 2 2500-1023

SEAL

14

2

2520-0120

QUICK RELEASE COUPLING - MALE

2

3

2520-0130

QUICK RELEASE COUPLING - FEMALE

2

4

2520-6027

REDUCER

8

5

2520-6376

TEE ADAPTOR

10

6

2520-6334

ELBOW ADAPTOR

2

7

2520-6125

SWIVEL NUT

12

8

2521-1800

HOSE ASSY - 200

2

9

2521-1806

HOSE ASSY - 500

4

10

2521-1812

HOSE ASSY - 800

2

11

2521-5203

HOSE ASSY - 350

4

12

2521-5210

HOSE ASSY - 700

4

13

2521-5218

HOSE ASSY – 1200

2

14

2521-5221

HOSE ASSY - 1500

2

15

2564-0054

HYDRAULIC CYLINDER

6

16

2554-0002

OVERLOAD VALVE

1

17

2564-0054B

GAITER

6

18

2564-0054A

CYLINDER REPLACEMENT SEAL KIT

6

19

2525-5001

20

HYDRAULIC HOSE – 4600 LG. DUMPY JACK HYDRAULIC CIRCUIT (CIRCUIT NOT ILLUSTRATED) 2564-7104C HOSE ASSY – 334

2

12

21

2564-7104D

HOSE ASSY – 270

1

23

2564-7101D

HOSE ASSY – 4600

1

24

2520-6002

ADAPTOR

4

25

2564-7101F

TEE

1

26

2500-1011

BONDED SEAL

2

27

2564-7101H

QUICK RELEASE COUPLING COMPLETE

1

22

LOOSE ITEMS 28

2147-0024

LOCTITE – 50 ML

1

29 22/03/05

2618-4003

KLAXON

1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

EN

Page 10 - 19

16 1 17

15

18

11 4 12

5

7

3 14

10

9

13

2 8

19

6

1300 Automax - Hydraulic Cylinder Circuit Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

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Page 10 - 20

Hydraulic Control Panel Assembly

REF 1 2 3 4 5 6 7 8 9 10 11A 11B 12 13 14 20/08/04

PART NUMBER 2580-1139 2589-5122 2589-5125 2589-5268 2589-5277 2589-5269 2589-5265 2589-5270 2589-5271 2589-5272 2589-5273 2589-5266 2589-5031 2589-5307 2589-5306 2589-5301 2589-5275 2589-5276

DESCRIPTION PANEL REF L736A PRESSURE FILTER REPLACEABLE FILTER ELEMENT PRESSURE FILTER REPLACEABLE FILTER ELEMENT SOLENOID VALVE DOUBLE PILOT OPERATED CHECK VALVE UNLOADER VALVE PRESSURE REDUCING VALVE CHECK VALVE PRESSURE RELIEF VALVE NEEDLE VALVE BACK MOUNT PRESSURE GAUGE PRESSURE SWITCH PRESSURE SWITCH PRESSURE SWITCH MANIFOLD BLOCK MOUNTING PLATE

QUANTITY 1 1 1 1 1 1 1 2 1 1 2 3 1 1 1 1 1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 308/396

Maxtrak 1300

10 - Spare Parts

EN

10 9 12 2 10 5

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 309/396

1300 Automax - Hydraulic Control Panel Assembly

9

11B

11A

10

1

6A

10

3 4 6B

8 7

14

13

Page 10 - 21

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10 - Spare Parts

EN

Page 10 - 22

Lubrication Oil Tank Assembly

REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18a 19 20 21 22 23 20/08/04

PART NUMBER 2581-8138 2520-3849 2589-1074 2589-1074 2589-2016 2589-2084 2589-2031 2589-2055 2589-2108 2589-2002 2576-4088 2589-2036 2589-2030 2589-2090 2589-2058 2538-7210 2589-2059 2589-2060 2589-2005 2589-2032 2589-1019 2589-2061 AX860/26 2589-2063 AX860/55 2589-2064 2589-2065

DESCRIPTION TANK COMPLETE REF L796 DRAIN PLUG 2” SUCTION FILTER ELEMENT REPLACEABLE FILTER ELEMENT PRESSURE RELIEF VALVE GEAR PUMP FLUID LEVEL GAUGE BELL HOUSING DRIVE COUPLING FILLER/BREATHER CAP HYDRAULIC MOTOR DOUBLE CARTRIDGE FILTER REPLACEABLE FILTER ELEMENT THERMOSTAT 1” BSP CHECK VALVE KOBOLD FLOW METER AIR BLAST COOLER BULLS EYE LEVEL GAUGE THERMOSTAT FLOAT SWITCH PRESSURE GAUGE PRESSURE GAUGE ADAPTOR RESERVOIR AND LIDS ELECTRICAL JUNCTION BOX PROTECTIVE COVER FLEXIBLE MOUNT MOTOR MOUNT PLATE

QUANTITY 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 4 1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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10 - Spare Parts

EN

Page 10 - 23

11

15

20 17 18 10 12 6 9 5 16 14 13 8 19 7 23

22

3 4 2 1

1300 Automax - Lubrication Oil Tank Assembly Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 311/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 24

Blank page

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 312/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 25

10.2 Plant Conveyors Feed Conveyor Parts - sheet 1

REF 1 2

PART NUMBER 2360-0035-15 2366-2006 2366-2006A 2366-2004 3 2389-9143 4 2421-0011 5 2421-2010 6 2473-0002 7 2489-1067 8 2495-3014 9 2495-3015 10 2495-3016 11 2495-3025 12 AX848/62 13 AX857/10 14 AX860/14 15 AX860/37 16 AX860/45 17 AX860/50 18 AX860/64 19 AX860/65 20 AX860/66 21 AX860/67 23 AX860/74 24 AX860/109 25 AX860/110 26 AX860/111 25 AX860/118 27 AX860/122 28 AX860/06/01 29 AX860/109X 30 AX860/143/01 31 AX860/143/02 AX860/113/02 - 30/05/03

DESCRIPTION CONVEYOR BELT METAL DETECTOR COMPLETE SEARCH COIL UNIT ONLY FOR METAL DETECTOR CONTROL BOX ONLY FOR METAL DETECTOR ANTI-VIBRATION PAD BEARING BEARING GEARBOX AND MOTOR ASSEMBLY RUBBER COVERED RETURN ROLLER RUBBER COVERED TROUGHING IDLER BASEPLATE TROUGHING IDLER SPIRAL ROLLER RETURN ROLLER BARGE BOARD INSERT SIDE NIP GUARD HEAD DRUM PICKING PLATFORM FLOORING BELT SUPPORT RETURN ROLLER NIP GUARD HEAD DRUM SUPPORT HEAD DRUM SCRAPER HEAD DRUM NIP GUARD TAIL SCRAPER HEAD DRUM SUPPORT TELESCOPER UNIT TAIL GUARD TAIL DRUM SCRAPER RETURN ROLLER NIP GUARD STICKLE GATES HOPPER TELESCOPER UNIT STRINGER SECTION SPIRAL ROLLER SUPPORT BRACKET

QUANTITY 1 1 1 1 4 2 1 1 10 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SET 1 1 1 2

NB. Fixings are not included with the above parts unless specifically ordered Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 313/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 26

Feed Conveyor Parts - sheet 2

REF PART NUMBER 32 AX860/143/03 33 AX860/145/03 34 AX860/145/04 35 AX860/147/01 36 AX860/15/01 37 AX860/22/01 38 AX860/33/01 39 AX860/34/01 40 AX860/41/01 41 AX860/41/02 42 AX860/41/01X 43 AX860/44/01 44 AX860/46/01 45 AX860/47/01 46 AX860/57/01 47 AX860/57/02 48 AX860/62/01 49 AX860/76/01 50 AX860/76/02 51 AX860/76/03 52 AX860/76/04 53 AX860/77/01 54 AX860/77/03 55 AX860/77/03 56 AX860/77/04 57 AX860/77/05 58 AX860/77/06 59 AX860/77/07 60 AX860/77/08 61 AX860/77/09 62 AX860/77/10 63 AX860/77/11 64 AX860/89/04 65 AX860/89/05 AX860/113/02 - 30/05/03

DESCRIPTION ACCESS COVER PLATE BARGE BOARD TRANSITION PLATE BARGE BOARD TRANSITION PLATE SELF CLOSING SAFETY GATE BARGE BOARD TAIL DRUM PICKING PLATFORM PICKING PLATFORM HANDRAIL SKIRT RUBBERS SKIRT RUBBER SKIRT RUBBERS METAL DETECTOR METAL DETECTOR SUPPORT BRACKET ANTI-FRICTION SUPPORT BRACKET ANTI-FRICTION PAD ANTI-FRICTION SUPPORT PAD PICKING PLATFORM INNER RAIL CLAMP STRIP CLAMP STRIP CLAMP STRIP CLAMP STRIP SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SIDE GUARD SUPPORT PINS SUPPORT PINS

QUANTITY 1 1 1 1 1 1 1 1 1 1 1 1 2 4 2 2 1 6 1 2 2 1 1 1 1 1 1 4 4 2 2 2 1 4

NB. Fixings are not included with the above parts unless specifically ordered Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 314/396

1300 Maxtrak - Feeder Conveyor Parts

Page 27

AX860-901-8EN-02f 315/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 28

Level Sensor - Crusher Unit MR1

REF PART NUMBER 1 2210-0016 2 2215-0013 3 2232-1105 4 2510-3895 5 2512-0004 6 2640-5004 7 Ax860/170/01 8 AX860/172/01 30/05/03 – AX860/171/01

DESCRIPTION PLAIN WASHER NUT BOLT BACKNUT U BOLT LEVEL SENSOR PROBE SENSOR SUPPORT LEVEL SENSOR SUPPORT BRACKET

QUANTITY 1 5 1 1 2 1 1 1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 316/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 29

Level Sensor - Crusher Unit MR 1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 317/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 30

Blank page

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 318/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 31

Discharge Conveyor Parts - sheet 1

REF PART NUMBER 1 2421-0010 2 2421-0014 3 2450-5505 4 2495-3000 5 2495-3001 6 2495-3003 7 2495-3017 8 2495-1130A 9 2576-4075 10 AX789/24 11 AX789/38 12 AX789/24/01 13 AX789/24/01A 14 AX801/16/01 15 AX801/16/02 16 AX815/54 17 AX815/117 18 AX815/12/01 19 AX815/54X 20 AX846/74 21 AX846/75 22 AX846/77 23 AX860/07 24 AX860/10 25 AX860/11 26 AX860/18 27 AX860/99 28 AX860/130 29 AX860/131 30 AX860/132 AX860/129/04 - 30/05/03

DESCRIPTION BEARING BEARING SHRINK DISC TRANSOME TROUGHING IDLER BASEPLATE TROUGHING IDLER SPIRAL ROLLER RUBBER COVERED RETURN ROLLER RETURN ROLLER DRIVE MOTOR HEAD DRUM SCRAPER TORQUE ARM HEAD SCRAPER SUPPORT BRACKET HEAD SCRAPER SUPPORT BRACKET SPRAY BAR SUPPORT SPRAY BAR SUPPORT TELESCOPER UNIT HEAD DRUM SPRAY BAR TELESCOPER UNIT HEAD GUARD SIDE GUARDS HOOP – CANVAS COVER FEED BOOT SIDE GUARD SIDE GUARD TAIL FRAME NIP GUARD RETURN ROLLER NIP GUARD RETURN ROLLER NIP GUARD SUPPORT ROPE

QUANTITY 2 2 1 3 4 4 6 3 1 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 2

NB. Fixings are not included with the above parts unless specifically ordered

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 319/396

Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 32

Discharge Conveyor Parts - sheet 2

REF PART NUMBER 31 AX860/168 32 AX860/161 33 AX869/163 34 AX860/164 35 AX860/07/16 36 AX860/08/01 37 AX860/08/02 38 AX860/08/03 39 AX860/100/01 40 AX860/100/02 41 AX860/100/03 42 AX860/100/04 43 AX860/100/05 44 AX860/100/06 45 AX860/100/07 46 AX860/102/01 47 AX860/103/02 48 AX860/107/01 49 AX860/127/01 50 AX860/127/02 51 AX860/127/04 52 AX860/127/05 53 AX860/128/01 54 AX860/160/01 55 AX860/160/02 56 AX860/19/01 57 AX860/71/01 58 AX860/86/01 59 AX860/86/02 60 AX860/86/03 61 AX860/86/04 62 AX860/164 AX860/129/04 - 30/05/03

DESCRIPTION FEED BOOT RUBBER IMPACT BAR TAIL BEARING SHIM SIDE SKIRT CLAMP HEAD SECTION REMOVEABLE CROSS MEMBER SPIRAL ROLLER SUPPORT BRACKET CLAMP STRIPS CLAMP STRIPS CLAMPSTRIPS CLAMP STRIPS CLAMP STRIPS CLAMP STRIPS CLAMP STRIPS SIDE SKIRT REAR SKIRT SPIRAL ROLLER NIP GUARD CONVEYOR GUARD CONVEYOR GUARD LOCATION BRACKET LOCATION BRACKET RETRUN ROLLER NIP GUARD IMPACT BAR SUPPORT PIVOT BRACKET TAIL DRUM TAIL FRAME SUPPORT STRUT FEED CONVEYOR PIN SUPPORT PIN SUPPORT PIN SUPPORT PIN SIDE SKIRT

QUANTITY 1 4 2 1 2 1 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 2 2 1 2 2 2 2 2 1

NB. Fixings are not included with the above parts unless specifically ordered

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 320/396

1300 Maxtrak - Discharge Conveyor Parts

Page 33

AX860-901-8EN-02f 321/396

Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 34

10.3 Plant Components Plant Components - sheet 1 REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NUMBER 1300_A-MAX 2389-0251 AX848/17 AX848/78/3 AX857/45/01 AX860/16 AX860/21 AX860/28 AX860/49 AX860/58 AX860/78 AX860/95 AX860/113 AX860/04/01 AX860/04/02 AX860/04/03 AX860/04/04

18

AX860/105/01

19

AX860/105/02

20 AX860/115/01 21 AX860/115/02 22 AX860/119/01 23 AX860/119/02 24 AX860/120/01 25 AX860/17/01 26 AX860/17/02 27 AX860/23/01 28 AX860/23/02 AX860/GA - 30/05/03

DESCRIPTION CRUSHER ANTI-VUBRATION MOUNTING HYDRAULIC OIL RESERVOIR SPRAYBAR HYDRAULIC LEVER COVER PLATE CRUSHER FEED BOX ENGINE SUPPORT BEAM FEED BOOT SIDE FILL IN ANGLE LADDER HANDRAIL CRUSHER/ENGINE DRIVE GUARD BUFFER SUPPORT BRACKET CONTROL BOX FEED CONVEYOR CHASSIS FEED CONVEYOR SUPPORT BEAM FEED CONVEYOR PIVOT BRACKET WASHER – ENGINE SUPPORT SELF CLOSING SAFETY GATE – CHASSIS PLATFORM SELF CLOSING SAFETY GATE – CHASSIS PLATFORM DRIVE GUARD RUBBER DRAPE DRIVE GUARD RUBBER DRAPE CRUSHER ENGINE INTERNAL HANDRAIL CRUSHER ENGINE INTERNAL HANDRAIL CRUSHER ENGINE INTERNAL HANDRAIL FEED CONVEYOR SUPPORT TRESTLE FEED CONVEYOR SUPPORT ARM CONE TRANSITION PLATES CONE TRANSITION PLATES

QUANTITY 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 1 1 1 1 1 2 2 2

NB. Fixings are not included with the above parts unless specifically ordered

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 322/396

Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 35

Plant Components - sheet 2 REF PART NUMBER 29 AX860/23/03 30 AX860/26/01 31 AX860/29/01 32 AX860/29/02 33 AX860/30/01 34 AX860/30/02 35 AX860/30/03 36 AX860/30/04 37 AX860/31/01 38 AX860/31/02 39 AX860/32/01 40 AX860/32/02 41 AX860/36/01 42 AX860/38/01 43 AX860/38/02 44 AX860/39/01 45 AX860/40/01 46 AX860/42/01 47 AX860/42/02 48 AX860/51/01 49 AX860/52/01 50 AX860/52/02 51 AX860/53/01 52 AX860/53/02 53 AX860/55/01 54 AX860/56/01 55 AX860/61/01 56 AX860/75/01 57 AX860/81/01 58 AX860/81/02 59 AX860/84/01 AX860/GA - 30/05/03

DESCRIPTION CONE TRANSITION PLATE WASHER LUBRICATION OIL TANK CRUSHER PLATFORM CRUSHER PLATFORM ENGINE PLATFORM ENGINE PLATFROM ENGINE PLATFORM ENGINEPLATFORM PLATFORM SUPPORT BRACKET PLATFORM SUPPORT BRACKET PLATFORM SUPPORT BRACKET PLATFORM SUPPORT BRACKET PICKING PLATFORM LADDER ENGINE PLATFORM HANDRAIL ENGINE PLATFORM HANDRAIL CRUSHER PLATFORM HANDRAIL CRUSHER PLATFORM HANDRAIL ENGINE PLATFORM FLOORING ENGINE PLATFORM FLOORING ENGINE/HYDRAULIC RESERVOIR FLOORING HYDRAULIC RESERVOIR KICKING STRIP ENGINE KICKING STRIP CRUSHER PLATFORM FLOORING CRUSHER PLATFORM FLOORING TANK COVER PLATE OIL LUBRICATION TANK MESH COVER LADDER SUPPORT BRACKET FEED CONVEYOR HYDRAULIC RAM KICKING STRIP FILL-IN PIECE KICKING STRIP FILL-IN PIECE FEED BOOT REAR FILL-IN ANGLE

QUANTITY 4 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

NB. Fixings are not included with the above parts unless specifically ordered

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 36

Plant Components - sheet 3

REF 60 61 62 63 64 65 66 67

PART NUMBER AX860/86/01 AX860/89/01 AX860/89/02 AX860/89/03 AX860/96/01 AX860/123/01 AX860/98/01 2480-0041 AX860/169/01 AX860/169/02 326/17 315/11 68 AX860/129/04 69 AX860/01 AX860/GA - 30/05/03

DESCRIPTION FEED CONVEYOR PIN SUPPORT PIN SUPPORT PIN SUPPORT PIN CONTROL BOX CONTROL BOX CONTROL BOX CATERPILLAR D12 ENGINE ENGINE SUPPORT BRACKET ENGINE SUPPORT BRACKET ENGINE SUPPORT SETSCREW NUT FOR SETSCREW DISCHARGE CONVEYOR TRACK GA

DIAGONALLY HANDED

QUANTITY 2 2 2 2 1 1 1 1 2 2 4 4 1 1

NB. Fixings are not included with the above parts unless specifically ordered

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 324/396

1300 Maxtrak - Plant Components

Page 37

AX860-901-8EN-02f 325/396

Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 38

10.4 Plant Tracks

REF 1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NUMBER 2372-0076 2372-0078 2372-0079 AX818TRAKS04 2372-0088 2372-0077 2372-0080 2372-0081 2372-0032 2372-0033 2372-0034 2372-0035 2372-0064 2372-0065 2372-0084 2372-0085 AX818TRAKS02 AX818TRAKS03 AX818TRAKS01 2372-0027 2372-0018 2372-0019

DESCRIPTION TRACK DRIVE GEARBOX C/W HYDRAULIC MOTOR ADAPTOR BONDED SEAL STAND OFF PIPE GEARBOX DRAIN PLUG GEARBOX BOLTS DRIVE SPROCKET SPROCKET BOLTS TRACK CHAIN –COMPLETE TRACK SHOE TRACK SHOE BOLT TRACK SHOE NUTS IDLER YOKE RECOIL UNIT TENSIONER SEAL KIT GREASER GASKET ADAPTOR ROLLER ROLLER BOLT ROLLER BOLT WASHER

2372-0037 2372-0036

REPAIR LINK - TRACK CHAIN MASTER PIN - TRACK CHAIN

QUANTITY 2 2 2 2 4 40 2 40 2 110 440 440 2 2 2 2 2 2 1 18 72 72

30/05/03

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 326/396

Maxtrak 1300

10 - Spare Parts

EN

14

9

11

10

15

13

12

16

5

6

7

2

8

1

4

3

Tracks Assembly - Maxtrak 1300

Page 10 - 39

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Maxtrak 1300

10 - Spare Parts

EN

Page 10 - 40

10.5 Plant Hydraulic System Hydraulic Reservoir

REF 1 2 3 4 5 5A 6 6a 6b 7

PART NUMBER 2589-2003A 2531-5153 2589-2032A 2531-5060 2531-5151 2538-0053 2531-5155 2531-5150 2538-0054 2520-8002

DESCRIPTION DRAIN SOCKET AND PLUG FLUID LEVEL GAUGE BREATHER FLOAT LEVEL SWITCH RETURN LINE FILTER REPLACEABLE FILTER ELEMENT RETURN LINE FILTER GAUGE SUCTION FILTER REPLACEABLE FILTER ELEMENT SUCTION FILTER GAUGE 2½” SAE 3000 SERIES FLANGE & ADAPTOR INSPECTION COVERS

QUANTITY 1 1 1 1 1 1 1 1 1 1 1 2

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 328/396

Maxtrak 1300

10 - Spare Parts

EN

6 6a 6b

4

7

5

5a

1

3

2

Maxtrak 1300 - Hydraulic Oil Reservoir Assembly

Page 10 - 41

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 329/396

Parts List - 1300 Maxtrak Hydraulic System Components

AX860-901-8EN-02f 330/396

Page 42

Parts List - 1300 Maxtrak Hydraulic Components - HFO Hydraulic Clutch Circuit

AX860-901-8EN-02f 331/396

Page 43

Spare Parts

Maxtrak 1300 Issue EN 02

Page 44

10.6 Electrical Components Plant Control Panel REF

PART NUMBER

1

2683-2148

2 3 4 5

2640-5005 2640-5005 2683-2149 2683-2113 2683-2109 2683-2102 2683-2101 2683-2103 2683-2111 2683-2174 2683-2114 2683-2106 2683-2106A 2683-2107 2683-2107A 2683-2176 2683-2177 2683-2178 2683-2179 2683-2180

6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21 22 23 24 25 30/05/03

2686-0038 2683-2170 2683-2171 2683-2173 2683-2172 2683-2169 2683-2195 2683-2175 2683-2145 2683-2182 2683-2108

DESCRIPTION PLANT CONTROL PANEL DISPLAY SCREEN – NB. WHEN ORDERING QUOTE MODEL DATA ON REVERSE OF UNIT (SEE ILLUSTRATION) TOGETHER WITH PLANT SERIAL NUMBER CRUSHER MINI-RANGER TRANSCEIVER UNIT HOPPER MINI-RANGER TRANSCEIVER UNIT DOOR KEY FEEDER SPEED CONTROL KNOB FEEDER SPEED POTENTIOMETER START/STOP PUSH BUTTONS EMERGENCY STOP BUTTON (PANEL) 2 POSITION STAY PUT SWITCH BLACK PUSH BUTTON COMMUNICATION LEAD HEAVY DUTY RELAY 11 PIN RELAY RELAY BASE 8 PIN RELAY RELAY BASE 20A SINGLE POLE CIRCUIT BREAKER 16A SINGLE POLE CIRCUIT BREAKER 6A SINGLE POLE CIRCUIT BREAKER 4A SINGLE POLE CIRCUIT BREAKER 2A SINGLE POLE CIRCUIT BREAKER TRACK CONTROL KIT – COMPLETE NB. SEE SEPARATE LIST FOR INDIVIDUAL COMPONENTS PLC BASE UNIT PLC INPUT MODULE PLC END CAP PLC OUTPUT MODULE PLC PROCESSOR C/W MEMORY MODULE BATTERY DC/DC POWER CONVERTER ENGINE ANTI-CRANK RELAY FUSE SET TIMER

QUANTITY

1 1 1 1 1 1 4 1 3 OR 4 2 1 2

QUANTITY TO SUIT PANEL

1 1 2 1 1 1 1 1 1 1 1

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 332/396

Maxtrak 1300 Issue EN 02

Spare Parts

Page 45

2 1

3 7

4

8

9 10

1

8 24

14

6 11

5 25

13

12

23 2& 3

24

22

5

15

16

17

20

18

21

19

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 333/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 46

Automax Control Panel

REF

PART NUMBER

DESCRIPTION

QUANTITY

AUTOMAX CONTROL PANEL 1 2 3 4 5 6 7 8 9 10

2695-0082A 2695-0082B 2695-0082C 2695-0082D 2695-0082F 2695-0082G 2695-0082H 2695-0082 I 2695-0082J 2695-0082K 2666-9013

CPU & MODULE 4 POLE PLUG 4 POLE RELAY BASE BLACK PUSH BUTTON YELLOW PUSH BUTTON AUTO/MANUAL SWITCH FUSE HOLDER FUSE LINK VARISTOR DIODE TRANSDUCER (MOUNTED ON CRUSHER)

1 6 6 2 1 1 4 2 4 1 1

860 TRACK CONTROL KIT 2686-0042 COMPONENTS 11

2686-9029

12

2686-9043 2686-9044

13 14 15

2686-9008 2686-9007 2686-9034

UNBILICAL HANDSET WITH CABLE RADIO HANDSET TRANSMITTER – RED STOP BUTTON (USA AND REST OF THE WORLD) RADIO HANDSET TRANSMITTER – BLACK STOP BUTTON (EUROPE) ANTENNA AND CABLE 12/35VDC CHARGER CABLE RECEIVER UNIT C/W CHASSIS SOCKET & CABLE

1 1 1 1 1 1

SUNDRY PLANT ELECTRICAL COMPONENTS 2640-5004 2366-0400 2368-2151 2685-0001 2683-2110 2366-2008 2366-2010 2366-2009 2366-2010

MINI-RANGER TRANSDUCER UNIT PRODUCT CONVEYOR SPEED WHEEL SENSOR ASSEMBLY SPEED WHEEL SENSOR CABLE EMERGENCY STOP PUSH BUTTON STATION AUDIBLE WARNING UNIT METAL DETECTOR PANEL GREEN INDICATOR BULB FOR ABOVE METAL DETECTOR PANEL RED BUTTON BULB FOR ABOVE

1 OR 2 1 1 5 1 1 1 1 1

07/04/04

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 334/396

Maxtrak 1300 Issue EN 02

Spare Parts

Page 47

3

1

10

4 2

7

Commandes du tableau hydraulique Automax 9

8

5

6

14

11

12

15

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 335/396

Maxtrak 1300 Issue EN 02

Spare Parts

Page 48

10.7 Warning Signs REF 1 2 3 6 7 8 9 10 11 13 14 15 17 19 20 21 23 27 30/05/03

PART NUMBER 300/32 300/33 300/34 300/37 300/38 300/39 300/40 300/41 300/42 300/44 300/45 300/46 300/118 300/120 300/175 300/182 300/196 300/224

1

DESCRIPTION DANGER – ENTANGLEMENT HAZARD WARNING– READ MANUAL DANGER – SKIN INJECTION HAZARD IMPORTANT – CHECK FILTERS WARNING – FALLING MATERIAL HAZARD WARNING – STOP AND LOCKOUT WARNING – GUARDS/LABELS IN PLACE WARNING – PRIOR TO TRANSPORT IMPORTANT – DRAIN WATER WARNING – IMPACT HAZARD IMPORTANT – CHECK FRAME ARMS IMPORTANT – CLEVIS PIN DANGER – FLYING MATERIAL HAZARD WARNING – FALLING HAZARD IMPORTANT – HYDRAULIC CLUTCH CAUTION – PRIOR TO TRANSPORT WARNING – HEARING HAZARD HEARING PROTECTION

2

QUANTITY 4 4 4 2 4 4 4 2 1 3 2 2 2 2 1 1 2 2

3

11

6

20

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 336/396

Maxtrak 1300 Issue EN 02

Spare Parts

Page 49

7

8

9

10

13

14

15

19

21

23

17

27

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 337/396

Maxtrak 1300 Issue EN 02

Spare Parts

Page 50

10.7 Hydraulic Engine Clutch The hydraulically actuated clutch fitted to the diesel engine is NOT supplied as part of the Caterpillar diesel power pack. Contact BL-Pegson’s Dealer for all requirements concerning this clutch. REF

DESCRIPTION

REF

DESCRIPTION

1

HOUSING

22

BACKPLATE

2

COVER

23

DRIVING PLATE

3

SCREW

24

CENTRE PLATE

4

BEARING CARRIER

25

SPRING

5

BEARING

26

PRESSURE PLATE

6

SHAFT

27

SCREW

7

SNAP RING

28

KEY

8

SPACER

29

LOCK WASHER

9

COVER

30

LOCK NUT

10

SCREW

31

ROTATING SEAL

11

‘O’ RING

32

ROTATING SEAL

12

LOCK WASHER

33

DRIVING RING

13

SCREW

34

PIPE

14

ROTATING UNION

35

KEY

15

LOCK WASHER

36

TAPER PLUG

16

SCREW

37

LEVEL STICK

17

‘O’ RING

38

NAME PLATE

18

HUB

39

PLATES HUB

19

‘O’ RING

40

SCREW

20

PISTON

41

TAPER PLUG

21

‘O’ RING

42

ELASTIC PIN

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 338/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 51

TRANSFLUID CLUTCH REF HFO 314 - 1 HD BL-Pegson Part Number 2451-1008 - For Spare Parts also advise specification and serial numbers stamped on the identity plate Maxtrak 1300 - Hydraulic Clutch for diesel engine Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 339/396

Spare Parts

Maxtrak 1300 Issue EN 02

Page 52

Blank page

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 340/396

Maxtrak 1300

11 - Appendix

EN

Page 11 - 1

11 - Appendix 11.1 Noise Levels ................................................................................................ 11 - 2

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Maxtrak 1300

11 - Appendix

EN

Page 11 - 2

11.1 Noise Levels Levels shown in the tabulation are for general guidance only and will vary depending upon the conditions prevailing at the time.

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Maxtrak 1300

11 - Appendix

EN

Page 11 - 3

Figures are for engine running with no load on crusher

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

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Maxtrak 1300

11 - Appendix

EN

Page 11 - 4

Blank page

Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 344/396

All Plants - Tier 3, Stage IIIa - ACERT

Addendum to User Manual

Due to the change of engines to comply with requirements of Tier 3/Stage IIIa standards, this plant may have a different engine fitted

Caterpillar C13 engines are replacing the C12 Caterpillar C9 engines have been revised to comply with the standards Caterpillar C6.6 engines are replacing the 3126B engines

AM0013 - EN

E-1 AX860-901-8EN-02f 345/396

Change of Engine Type The change of engines has resulted in the following changes to engine controls and information in the user manual.

Power Output The engine power may have changed slightly. The power of the engine as stated in the manual will not necessarily be correct but the power stated on the plate fixed to the plant is correct.

Engine Speed The engine working speed may have changed slightly. The engine speed stated in the manual will not necessarily be correct but the speed set by the engine controls and display is correct. The engine working speed with no load and speed at full load are now the same.

Engine Monitoring System The engine monitoring system and engine control panel shown and referred to in the user manual will not be correct. The engine information will be displayed on a different type of screen. To operate the engine monitor screen, refer to the appropriate addendum for the controls fitted.

Engine Controls Some engine controls and warning lamps are not as shown and referred to in the manual as they have been repositioned with other plant controls.

Power Plant Spares Some engine electrical controls and power pack spare parts will be different to those referred to in the user manual, therefore please contact Terex Pegson and quote plant and engine serial numbers for assistance.

E-2 AX860-901-8EN-02f 346/396

1000 and 1300 Cone Crushers and Plants

ADDENDUM TO USER MANUAL

Avoiding Damage to Cone Crusher Linings

INTRODUCTION To prolong the life of the cone linings and prevent avoidable damage to the main parts of the cone crusher, please refer to these guidelines.



 AX860-901-8EN-02f 347/396

Avoiding Damage to Cone Crusher Linings FEEDING MATERIAL INTO CONE CRUSHERS The crusher should be fully ‘choke‘ fed with a well mixed and well graded material to give best results. This will also produce even wear on the cone liners, making them last longer.

NOTICE Inspect the liners on a daily basis.

Uneven liner wear can occur when material is ‘trickle’ fed rather than ‘choke’ fed into the crusher. Unusual wear may also be caused by feed material being all one size or the size being heavily segregated.

MAXIMUM CONE SETTINGS Do not operate the crusher with size settings above the maximum.

Maximum Cone Setting Cone Size

mm

Inches

1000

38

1.5

1300

45

1.75

CONE LININGS INSPECTION Inspect the liners on a daily basis. Always check the liners if any non crushable material may have entered the crusher.

RENEWING Renew the cone liners before the adjusting cylinders are working at their minimum. Change the liner at or before the adjusting cylinders reach the dimensions shown in the table.

Minimum Cylinder Dimensions Cone Size

mm

Inches

1000

690

27.25

1300

805

31.75

Do not rely on the minimum dimension shown in the manual, ignore value stated in the diagram. This cannot take into account any features present caused by an unusual wear pattern or damage by non crushable materials Monitor the wear on the crusher liners regularly and renew both the liners before they fail and cause damage to other parts of the crusher.

II AX860-901-8EN-02f 348/396

All Plants with Feed Conveyors

Addendum to User Manual

Oil Specification Change

Plant Feed Conveyor Drive Gearbox

The oil for the feed conveyor gearbox is VG220 with EP additives, not as stated in the existing table the Terex Pegson user manual. An oil such as Shell Omala 220 should be used.

AM0016 - EN

L-1 AX860-901-8EN-02f 349/396

Oil Specification Change

L-2 AX860-901-8EN-02f 350/396

All Plants with Feed Conveyors

Addendum to User Manual Steel Metal Detector and Controls

Steel metal detector An alternative model of steel detector may have been fitted, therefore may not be of the type referred to in the user manual.

Pre-set detector sensitivity The sensitivity of the steel metal detector is now pre-set at the factory. The sensitivity control has been removed from the internal control panel as shown in the diagram.

Pre-set zero set adjustment The zero adjustment control of the steel metal detector is now pre-set at the factory. The zero set adjustment has been removed from the internal control panel as shown in the diagram.

Fault and re-set illuminated button The fault/re-set red illuminated button control remains the same although it may be positioned differently.

Spares requirements The change affects the spare parts for the metal detector, its fixing and electrical controls. Some spare parts will be different to those referred to in the user manual, therefore please contact Terex Pegson and quote plant serial number for assistance.

AM0017 - EN

M-1 AX860-901-8EN-02f 351/396

Metal Detector Controls

M-2 AX860-901-8EN-02f 352/396

All Plants - Cantrak Control

Addendum to User Manual

Plants with Cantrak Engine Monitoring System

AM0020 - EN

C-1 AX860-901-8EN-02f 353/396

Cantrak Engine Monitoring System Introduction The Cantrak Engine Monitor is a graphical instrument clusters to display parameters and alarms. The display has five buttons that change to suit the screen in use. The buttons give to access a graphical menu structure that uses standard and easily-understood icons to indicate the button’s current function. The required engine data and display can display the following formats: Analogue gauges Digital values Historical trend graphs Current and stored alarm messages

C-2 AX860-901-8EN-02f 354/396

All Plants - Cantrak Control Buttons If any button from 1 to 4 is pressed, the display shows a context dependent icon representing the current function of the button. The button icon part of the display will disappear after five seconds of inactivity. This ‘top level’ button icon bar shows the selection options of the Engine Monitor: Pressing button 5 when the menu icons are not being displayed displays a Contrast and Lighting adjustment menu. If held for 3 seconds, the Configuration menu is shown

1

2

3

4

5

Button Icons TRI DISPLAY - shows one large window and two smaller windows. Repeat presses cycle the display through the view options. QUAD DISPLAY - shows data four equal sized windows. Repeat presses cycle the display around three different quad view options.

UNI DISPLAY - shows data using a single window. Repeat presses cycle display through available parameters.

ACTIVE ALARM DISPLAY - shows current active alarm. Holding the key displays Stored Alarms. EXIT from the menu..

AM0020 - EN

C-3 AX860-901-8EN-02f 355/396

Cantrak Engine Monitoring System PAGES - indicates that further pages of information are available by pressing to cycle through options for the screen being viewed. ARROW UP - move up to next item.

ARROW DOWN - move down to next item.

RIGHT ARROW - go to next screen or select option.

RETURN ARROW - go back to previous screen.

ALARM - acknowledge active alarm when an active alarm is being displayed.

CONFIGURE QUAD SCREEN - press button 2 and immediately button 5. The data displayed on a particular window can be selected by repeat pressing the

Button Lock The buttons can be locked so that they cannot be accidentally pressed. Press buttons 1 and 5 simultaneously for one second to switch the button lock on or off. A key symbol is displayed when a button is pressed and they are locked.

1

C-4 AX860-901-8EN-02f 356/396

2

3

4

5

All Plants - Cantrak Control Displays When power is applied, a start-up screen displays for approximately 7 seconds while the display performs a self test. After the start-up screen disappears, the Engine Monitor displays readings on its virtual gauges. The Engine Monitor displays the screen that was last displayed. If data is not available from the engine, it will not be possible to select it. If data becomes unavailable, dashes (- - -) will be shown on the screen.

Tri Display Three windows intended to show the most frequently accessed engine data.

Quad Display Four windows to display available data in digital number format only or as a gauge with numbers also displayed. The windows can be configured to display various available data as listed in the data parameter and icons.

Uni Display A single window to display data in a graph format, together with a numeric data header.

AM0020 - EN

C-5 AX860-901-8EN-02f 357/396

Cantrak Engine Monitoring System Data Parameters and Icons The following data can be displayed

Engine Speed

Oil Pressure

Oil Temperature

Coolant Temperature

Battery volts or amps

Engine Hours

C-6 AX860-901-8EN-02f 358/396

All Plants - Cantrak Control Alarm Messages When a current engine alarm is received, a flashing window appears overlaid over the screen in use and an alarm sound is activated.

If a current alarm message is flashing, press any button to view the message details. The current alarm message will be displayed with a black background, which indicates an unacknowledged alarm.

The alarm can be acknowledged by pressing:

Alarms must be acknowledged before the normal monitoring screen can be displayed. Acknowledged alarm messages are displayed with a grey background.

Alarm messages can also be displayed at any time from the normal monitoring display by pressing button 4 twice.

To return to the monitoring screen press:

AM0020 - EN

C-7 AX860-901-8EN-02f 359/396

Cantrak Engine Monitoring System Configuration Options Screen Brightness and contrast Press button 5 when the normal monitoring screen is being displayed.

Adjust the screen using buttons 1 to 4. Press button 5 to exit 1

Settings Menu Press and hold button 5 for three seconds, when the normal monitoring screen is being displayed.

Scroll to point to SETTINGS and select by pressing:

The following options can then be selected: UNITS - Metric or Imperial LANGUAGE - Select from list BLEEP - Button press sound on or off Set the options for each of these by pressing:

Return to previous screens by pressing:

Exit by pressing:

C-8 AX860-901-8EN-02f 360/396

2

3

4

5

All Plants

Addendum to User Manual

AM0027 - Alternative Track Drive and Gearbox

Introduction An alternative track motor drive and gearbox may be fitted which is different to the type shown in the user manual. For identification, the letter V has been added to the end of the track serial number. Refer to these instruction for servicing if the casing has three plugs and appears as shown on this addendum.

AM0027 - EN

TM-1 AX860-901-8EN-02f 361/396

Alternative Track Drive and Gearbox Servicing Preparation 1. Drive the track to position the motor and gearbox as shown with the drain positioned lowest. 2. The plant should be positioned horizontally side to side. 3. Close down the plant and implement the lockout procedure.

 WARNING

Refer to safety in maintenance section of the user manual for relevant warning and procedure

LOCKOUT PLANT

Gear Oil 4. Type SAE90 API service classification GL-4. 5. Do not mix different types or brands of oil. Oil Level Check and Top up 6. Remove the filling plug. 7. Remove the level plug 8. Check oil level and add oil through the fill hole as required until it begins to overflow through the centre level hole. 6

9. Re-fit the plugs, taking care not to damage the seals.

11 13

Oil Change 10. Place a suitable container in position to collect the old oil, approximately 5.5 litres (1.5 US gal). 11. Remove the filling, level and drain plugs and drain the old oil, looking for metal particles indicating component wear. 12. Re-fit drain plug, taking care not to damage the seal.

FILL

7

LEVEL

11 14 DRAIN

13. Remove the filling plug. 14. Remove the level plug 15. Add new oil until it begins to overflow through the centre level hole. 16. Re-fit the plugs, taking care not to damage the seals.

TM-2 AX860-901-8EN-02f 362/396

1

11

All Plants

Addendum to User Manual AM0030 - Routine InspectionChecks

 WARNING

Refer to safety in maintenance section of the user manual for relevant warning and procedure

LOCKOUT PLANT

Introduction General plant items should be inspected on a weekly basis and at 500 hr intervals for damage in the following areas; 1. Crusher body 2. Wear Parts

3. Flywheel(s) Area to inspect

3

4. Main chassis 5. Feeder 6. Track frames 7. Conveyor frames

AM0030 - EN

RIC-1 AX860-901-8EN-02f 363/396

Routine InspectionChecks

RIC-2 AX860-901-8EN-02f 364/396

Automax

Addendum to User Manual AM0031 Sensor Fitted in Upper Frame Position Cylinders Introduction An different position sensor may be fitted to the Automax crusher. This sensor is fitted into one of the operating hydraulic cylinders which raise and lower the upper frame and concave. The separate position sensor unit is not required.

Operation The operation remains the same.

Renewing Wear Parts When renewing the mantle and concave set, it is not necessary to disconnect the sensor unit when removing the upper frame. The cylinder containing the position sensor is disconnected from the upper frame in the same manner as the other cylinders.

Spare Parts This change affects some spare parts for the controls and hydraulic parts of the Automax. Please contact your local Terex Pegson dealer, Terex Pegson Technical Support Department or Spare Parts Department and quote serial number for assistance.

EN

IPS-1 AX860-901-8EN-02f 365/396

Sensor Fitted in Upper Frame Position Cylinder

IPS-2 AX860-901-8EN-02f 366/396

All Plants

Addendum to User Manual AM0032 Preferred Driving Direction of Tracks Introduction To prolong the life of the track and prevent avoidable damage to the track components, please refer to these guidelines.

Driving Tracked Plants Wherever possible drive the plant with the circular track drive gearbox in the position shown in the diagrams.

This is particularly important if the plant is being driven up an incline.

The track drive gearbox is not fitted in the same position on all plants, relative to the other parts of the plant.

EN

PDD-1 AX860-901-8EN-02f 367/396

Preferred Direction of Travel

PDD-2 AX860-901-8EN-02f 368/396

MANUAL ADDENDUM

All Plants Fuel Transfer Pump Issue 01 ENG

Page 1

OPERATING INSTRUCTIONS FUEL TRANSFER PUMP (for plant diesel engine)

THIS ADDENDUM IS TO BE INSERTED INTO THE BL-PEGSON PLANT USER MANUAL - SECTION 11 BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 369/396

MANUAL ADDENDUM

All Plants Fuel Transfer Pump Issue 01 ENG

Page 2

Optional Fuel Transfer Pump

WARNING

This option is available as originally fitted equipment installed at the time of plant manufacture.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1 of the Plant User Manual-Safety Information for relevant warning.

The pump is for the purpose of transferring diesel engine fuel from a barrel positioned at ground level alongside the plant diesel engine to the engine fuel tank.

LOCKOUT MACHINE. Refer to Section 9.1 of the Plant UserManual-Safety Information for Lockout Procedure.

The pump is permanently mounted in a suitable position on the plant in the vicinity of the engine and is electrically driven from a 24 volt DC supply. The unit is fitted with an integral on/off switch. Also supplied as part of the kit are lengths of plain hose 25mm bore for suction (with strainer) and delivery.

DANGER

The VR050 Series pump is rated at 50 litres per minute, suitable for equipment with tanks between 200 and 500 litres. Duty is continuous up to + 40o C ambient. Self priming up to 3 metres dry. Flow 50 ltrs/min at 3 metres head. Maximum head 10 metres.

Do not use the fuel transfer pump for any other purpose that filling the diesel engine fuel tank on the BL-Pegson plant. Observe the Operating, Service & Safety Instructions on the opposite page and also the general Safety Information given in Section 9.1 of the Plant User Manual.

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 370/396

All Plants Fuel Transfer Pump Issue 01 ENG

MANUAL ADDENDUM

Page 3

Fuel Transfer Pump Operating, Service & Safety Instructions

SAFETY FLASHPOINT BELOW 37o C (99o F)

DO NOT USE A TRGGER NOZZLE FOR DELIVERY INTO THE FUEL TANK FLASHPOINT ABOVE 37o C (99o F)

MAXIMUM DUTY TIME AT 40O C

TEMPERATURE RANGE

INSTALLATION & USE

DO NOT ALLOW THE PUMP TO RUN DRY. SWITCH OFF IMMEDIATELY DELIVERY OF THE FUEL IS COMPLETED.

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 371/396

MANUAL ADDENDUM

All Plants Fuel Transfer Pump Issue 01 ENG

Page 4

Top Up Fuel Level

WARNING

Do Not fill the tank to capacity. Monitor the gauge located on the Engine Control Panel.

WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1 of the Plant User Manual-Safety Information for relevant warning.

Allow room for expansion and wipe up spilt fuel immediately, otherwise paintwork will be damaged.

LOCKOUT MACHINE. Refer to Section 9.1 of the Plant UserManual-Safety Information for Lockout Procedure.

Procedure 1. Observe all safety warnings. 2. Close down the plant (Section 8.2 of the Plant User Manual) and implement the lockout procedure except the engine isolation switch to be at position ‘I’.

DANGER

3. Connect both hoses to the pump and insert the suction hose into the fuel supply. Clean the area around the filler cap. Remove the cap and insert the delivery hose.

Never add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks. Do Not smoke while refilling or carrying out maintenance on the fuel system. Do Not carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.

4. Operate the switch on the pump to fill the fuel tank. Use only in accordance with the instructions on the previous page. 5. Switch off the pump and stow the hoses. Replace the cap and refit the engine access panel before start up. Turn the engine isolation switch to ‘O’.

DANGER

Diesel fuel is highly flammable and is an explosion/burns hazard. Never remove the filler cap or refuel, with the engine running.

Filler Cap

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 372/396

MANUAL ADDENDUM

All Plants Water Pump Issue 01 ENG

Page 1

OPERATING INSTRUCTIONS WATER PUMP (for dust suppression spraybars)

THIS ADDENDUM IS TO BE INSERTED INTO THE BL-PEGSON PLANT USER MANUAL - SECTION 11 BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618 22-Feb-2007

AX860-901-8EN-02f 373/396

MANUAL ADDENDUM

All Plants Water Pump Issue 01 ENG

Page 2

Optional Water Pump This option is available as originally fitted equipment installed at the time of plant manufacture. The pump is to provide a pressurised supply of clean water to the dust suppression spray nozzles included on plants as a standard fitment. For details of typical clean water requirements for the dust suppression system, refer to the Maintenance Section 9 of the plant manual.

DANGER SKIN INJECTION HAZARD Refer to Section 9.1, of the Plant User Manual, Safety Information for relevant warning

WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT. Refer to Section 9.1, of the Plant User Manual, Safety Information for relevant warning

The pump is permanently mounted in a suitable position on the plant near to the water manifold (Figure 1) and is driven from a branch of the engine driven plant hydraulic system.. The inlet is 1/2” BSPT. with hose connector for the user to provide supply suitable piping from the clean water source (eg. bowser near to the plant) as necessary. Initial on/off control of the pump is by means of a 3 way valve lever (Figure 2) mounted on the pump unit. Whilst this valve lever is in the ‘on’ position the screw type valve (Figure 2) can be used to regulate the water supply to the plant inlet manifold. No specific maintenance is required for the pump unit except to check for hydraulic oil leaks when carrying out the normal plant maintenance (Section 9 of the plant manual) Frost precautions must be taken in cold weather to ensure water does not freeze within the system, by opening the water manifold drain valves and detaching the pump inlet feed pipe. BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 374/396

MANUAL ADDENDUM

All Plants Water Pump Issue 01 ENG

Page 3

Manifold Drain Valves

Water Inlet Connection

Figure 1 Water Pump Unit (typical mounting)

Flow Control Valve

3 Way On/Off Valve

Figure 2 Water Pump Valves BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 375/396

All Plants Water Pump Issue 01 ENG

MANUAL ADDENDUM

Page 4

3 Way Valve

Flow Valve

Water Pump

Hydraulic Motor

Coupling Figure 3 Pump Hydraulic Circuit

2575-2008 3 Way Valve

2575-2005 Coupling 2575-2003 Pump

2575-2007 Flow Valve 2575-2004 Hydraulic Motor

Figure 4 Pump Unit Part Numbers

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

AX860-901-8EN-02f 376/396

BW100 INITIAL CALIBRATION SIMPLIFIED GUIDE The Following procedures may be performed when messages E3 and E4 are displayed during routine calibration. The E3 and E4 messages indicate a mechanical problem i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the weigher etc. Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration. Safe working practice should be adopted at all times. Zero Calibration Span Calibration With belt running empty at normal speed with test weights removed

With belt running empty at normal speed with test weights applied

SELECT PARAMETER P377

SELECT P388

INVOKE INITIAL ZERO ENTER “ 1 “

INVOKE INITIAL SPAN ENTER “ 1 ”

CURRENT ZERO COUNT

CURRENT SPAN COUNT= ####

ZERO CALCULATION FREQUENCY COUNT DISPLAYED

SPAN CALCULATION, FREQUNCY COUNT DISPLAYED

ZERO DEVIATION

SPAN DEVIATION= ##

ZERO DEVIATION ACCEPTED INITIAL ZERO COUNT= ####

ZERO DEVIATION ACCEPTED INITIAL ZERO COUNT= ####

PROCEED WITH SPAN CALIBRATION OR AX860-901-8EN-02f 377/396 RETURN TO RUN MODE

RETURN TO RUN MODE

BW100 ROUTINE CALIBRATION SIMPLIFIED GUIDE The Following procedures may be performed on a routine basis as required. Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration. Safe working practice should be adopted at all times. Zero Calibration

Span Calibration

With belt running empty at normal speed with test weights removed

With belt running empty at normal speed with test weights applied

INITIAL SPAN COUNT

ZERO CALIBRATION REQUIRED

FREQUENCY COUNT DISPLAYED DURING CALIBRATION INITIAL ZERO COUNT

FREQUENCY COUNT DISPLAYED DURING CALIBRATION

DEVIATION

NEW SPAN COUNT

DEVIATION NEW ZERO COUNT CALIBRATION COMPLETE RETURN TO RUN MODE PRESS

CALIBRATION COMPLETE REMOVE TEST WEIGHTS PRESS

TO RETURN TO RUN MODE

SPAN REQUIRED

AX860-901-8EN-02f 378/396

TO RETURN TO RUN MODE

Components Manual

2480-0061

.

H

B C

J

E

Section

De scription / Note s

Page

A.

Canopy Encl o s ure :- Lef t Hand Si de

05/01-2

B.

Canopy Encl o s ure :- Ri ght Hand Si de

05/01-3

C

Engi ne Hardware :- Lef t Hand Si de

05/01-4

D

Engi ne Hardware :-Ri ght Hand Si de

05/01-5

E

Bas e :-Lef t Hand Si de

05/01-6

F

Bas e :-Ri ght Hand Si de

05/01-7

G

Ai r Cl eaner Sys t em

05/01-8

H

Exhaus t Sys t em

05/01-10

J

Fus e Box

05/01-11

K

Bat t ery

05/01-12

L

Cont rol Panel

05/01-13

M

Not es / Appendi x

05/01-14

G Engine Service Items

k A

Description

D

B L Pegson Part No

CAT Part No

2481-0564

1R-0762

2481-0565

1R-0771

2481-0566

1R-1808

2481-0567

6I-2509

2481-0055

6I-2510

Qty

Fuel Fi l t er Oi l Fi l t er

F

1

Ai r Fi l t er

BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Main Switchboard Phone :- +44 (0)1530 518600 Main Switchboard Fax :- +44 (0) 1530 518618 Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 E-mail :- [email protected] Website:- www.bl-pegson.com Copyright © 2002 - 2005 BL-Pegson Ltd . All Rights Reserved

AX860-901-8EN-02f 379/396

2480-0061 05/01 - 1

Components Manual

2480-0061

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13

13a

11

1

10

12

2 4 15 & 16

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5

8

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19 6

18

9

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Qty

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1

2

1

3

2

4

1

5

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6

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2

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11

2

12

2

13

1

13a

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14

1

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Components Manual

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26 20 21

7

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27 23

25

28

30

29

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25

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31 36 32 37 44 33 & 34 45

38 41

40

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42

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6

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1

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6

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Components Manual

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ELC 59a

47

48

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48

56

54

55

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50

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53

48 & 61

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Qty

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2

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2 x 25 l tr

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Components Manual

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62 63

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80 & 81

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93 95

91

88 96

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Qty

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1

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1

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1

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1

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1

87

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92

1

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Components Manual

2480-0061

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100 & 101

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Components Manual

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2480-0061

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125

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127 121

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122 - 124

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125 126

127

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120 121

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Components Manual

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Components Manual

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138 & 139

139 & 147

140 148

142 & 143

144

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145 146

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L 2480-0061 05/01 - 13 AX860-901-8EN-02f 391/396

Components Manual

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151 154

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155

156 (120 Ohm)

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L 2480-0061 05/01 - 14 AX860-901-8EN-02f 392/396

12 - Notes

Hours Run / Date

Notes

Page 1

Name

BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618 E-mail : [email protected] Website : www.bl-pegson.com

AX860-901-8EN-02f 393/396

Page 2

Hours Run / Date

12 - Notes

Notes

Name

BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618 E-mail : [email protected] Website : www.bl-pegson.com

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12 - Notes

Hours Run / Date

Notes

Page 3

Name

BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618 E-mail : [email protected] Website : www.bl-pegson.com

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