1300 Maxtrak

1300 Maxtrak 100309 issue 2
1300 Maxtrak
Company Confidential
1300 Maxtrak
Health and Safety aspects,

Contents
Introduction
1
2
3
4
5
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.10
5.3.11
5.4
5.5
6
Application of the Regulations

Personal Protective Equipment
Contractors and Sub-Contractors
Customers, Suppliers & Visitors
Employees
Guidelines
Application of Safety Instruction
Minimum Recommended Requirements
Foot Protection
Leg Protection
Thigh / Torso Protection
Whole Body Protection
Hand Protection
Eye Protection
Respiratory Protection
Hearing Protection
Head Protection
Fall Arrest Protection
Other Protective Equipment
Disciplinary Procedure
Requirement of control measures
Review
Introduction
This Safety Instruction (SI) is issued to assist Employees of BL PEGSON LTD to understand the requirements for the wearing of
Personal Protective Equipment at Work
1/
Application of the Regulations

1.1
1.2
1.3
1.4
2/
The Health and Safety at Work etc Act 1974 (HSWA) requires employers to ensure the health
safety and welfare of their employees and persons not in their employment who may be affected
by work activities.
Regulation 3(1) of the Management of Health and Safety at Work Regulations 1999 requires
employers to identify and assess the risks to health and safety present in the workplace. This
general risk assessment should identify whether there is a risk of injury to persons from working
processes, procedures and practices. Where there is a risk identified, all practical measures shall be
taken to eliminate or reduce so far as is reasonably practicable exposure of the individual to those
risks. There is in effect a hierarchy of control measures and Personal Protective Equipment (PPE)
should always be regarded as the 'last resort'
The Personal Protective Equipment recommended for each group of people will be commensurate
with their experience and knowledge of the risks to which they are being exposed in any particular
working area.
This document details the ways in which BL PEGSON LTD discharges its duties and obligations
to its employees, contractors & sub-contractors, customers, suppliers and visitors under this
requirement.
Personal Protective Equipment
'All equipment designed to be worn or held by a person at work to protect against one or more risks and any addition or accessory
designed to meet this objective'
2.1
Both protective equipment and clothing are within the scope of the definitions and therefore:
2.1.1
For the sake of this Safety Instruction 15/01/01 protective clothing such as overalls (when they
are Proban Treated or Pyrovatec) aprons, protective clothing for adverse weather conditions,
gloves, safety footwear, safety helmets, high visibility waistcoats etc; and
2.1.2
Protective equipment such as eye protectors, hearing protectors, respiratory protectors, face
protectors and safety harnesses
2.1.3
Overalls other than Proban Treated or Pyrovatec will not be regarded as PPE as they are for
welfare purposes and do not provide health and safety protection.
2.2
Selection of appropriate PPE will always be the factor that proves the item to be adequate or not
for example: when working with equipment i.e. hammer and chisel, that produces fragments and
splinters impact protection safety glasses with side protection or wrap-round. When operating
equipment that produces fine grit or offshoot i.e. grinder or cutting disc face mask with safety
glasses or box goggles. When working with hazardous substances or splashes invariably box
goggles should be selected.
2.3
With consideration given to the advice above anyone that feels they have insufficient knowledge
or experience in the selection of appropriate PPE they should consult their supervisor or Health
and Safety Officer for a risk assessment and necessary training.
3/
Contractors and Sub-Contractors
When contractors and sub-contractors are employed to carry out work that comes within the scope of this Safety
Instruction SI 15/01/01 they will be expected to comply in all factors as though they are direct employees of BL-Pegson Ltd.
(See section 5/ Personal Protective Equipment for employees)
4/
Personal protective Equipment for Customers, Suppliers and Visitors

4.1
When customers, suppliers and visitors to BL-Pegson are introduced to production areas they
must be equipped with adequate and appropriate Personal Protective Equipment (PPE).
It shall be the responsibility of the host responsible for the customer, supplier or visitor to ensure that PPE is
readily available prior to any entry to production areas.
4.2
The needs of paragraph 4.1 above may require the host to make pre-visit arrangements for some
customers, suppliers & visitors to provide their own PPE or provide sufficient information as may be necessary
to enable BL-Pegson ltd to obtain the appropriate clothing and or equipment.
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.4
4.5
5/
Adequate and appropriate Personal Protective Equipment for all customers, suppliers and visitors
consists of;
High visibility vest
Safety footwear with internal steel toe cap
Grade 2 impact eye protection
Hearing protection (all customers, suppliers and visitors will be advised to wear the hearing
protection, as, during production hours the background noise levels in production departments is
above the first action level of 85dB(a) whereby hearing protection must be provided.
Hosts escorting suppliers, customers and visitors to production areas who are not in compliance
with the above guidelines will be asked to leave the production area until appropriate remedial
action has been taken.
Persistent failure by an hosts to establish his customers, suppliers and visitors with the above
requirements will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures
against him/her.
Personal Protective Equipment for Employees

5.1
Guidelines With due regard to the section 2.2 of this document, the following guidelines are set out
for PPE to be used by all BL-Pegson personnel when performing tasks in all production,
maintenance and testing areas.
5.1.1
When any employee is travelling through or working in a production, maintenance or test area (as
outlined in section 5.2 of this Safety Instruction), other than his/her normal working area, s/he will
be regarded as a visitor to the area. In these circumstances, as a visitor to an area s/he will be
required to adopt PPE (foot and eye protection) as a minimum basic requirement. Persistent failure
by any employee to conform with the designated requirements, for the use of personal protective
equipment within any production, maintenance or test area will result in the instigation of the BLPegson Ltd progressive disciplinary procedures against him/her.
5.2
5.2.1
5.2.2
5.2.3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
Application of S.I. For the purpose of this Safety Instruction a production, maintenance or testing
area, is anywhere on the Mammoth Street Site inside or outside of buildings, that;
machining, fitting, welding, burning attaching and/or removing, adjusting or testing of units or
components to any item of equipment that goes to make up a crushing or pumping plant; or
any item of equipment used in the production, testing, adjustment or maintenance of crushing or
pumping plant; or
any location other than BL-Pegson Ltd Mammoth Street Site, where BL-Pegson personnel are
involved in the repairs, maintenance, adjusting or testing of any BL-Pegson manufactured plant and
or equipment.
Minimum/Recommended Requirements
Foot Protection - Basic safety footwear protects the feet / lower leg of individuals, assessment has
indicated that the primary protection required at BL-Pegson ltd is Toe Protection (200 joule toecap
protection), Oil and Water Resistant with anti-slip soles with steel mid-sole (100 Newtons
penetration resistance) for protection against penetrating objects.
Safety shoes or Safety Boots shall be worn at all times inside production and maintenance areas.
Leg Protection Gaiters or knee-high boots shall be worn when pouring molten metals.
Thigh Protection Leather apron should be worn when disc cutters and grinders are being operated at or below waist
level.
Nitrile coated or rubber apron should be worn when decanting or using hazardous liquids.
Whole Body Protection Proban overalls (flame retardant coating) should be worn when general welding and grinding
processes are carried out by an individual.
Operators performing high intensity welding processes shall wear Pyrovatec overalls (heavy-duty
cotton with tight knit fabric and flame-retardant coating).
5.3.5
Hand Protection - Gloves giving a level of

Cut and puncture protection gloves should be worn when performing tasks employing sharp
bladed and pointed tools.
Cut and puncture protection gloves should be worn when performing lifting and handling tasks
on items of equipment or materials that may have rough edges or protruding wires etc.
Thermal protection gloves should be worn when processes require the
Handling of hot or cold items of equipment or materials, this is of particular significance in the
handling processes entailed in the use of liquid nitrogen.
Welding gauntlets should be worn when operating profile cutting / burning equipment and
welding.
Rubber or Nitrile coating gauntlets / gloves should be used when working with hazardous
substances.
Nitrile or latex disposable gloves are recommended when working with other non-hazardous
fluids.
5.3.6
Eye Protection - The selection of correct eye protection is the primary consideration for an
individual when performing any task, poor selection is of no benefit to the individual and in some
cases can make a situation worse. The reasoning behind this being that having made their
selection they believe themselves to be protected from any hazard. All eye protection PPE issued
at BL-Pegson Ltd is to EN166 Category 2.
Prescription lenses impact protection glasses all individuals that are required to wear
prescription spectacles will be issued with prescription safety glasses with grade 1 impact lenses
and side shields. There may be occasion where additional protection shall be required for
protection from splashes or dust particles in which case a box goggle shall be worn over the top
of the prescription lens safety glasses.
Impact Protection safety glasses shall be worn by operators at all times when working with the
following items of equipment;
Machine tools (drilling / boring m/c's etc.) [May not be appropriate when reading drawings,
micrometers etc.]
Impact guns/wrenches (of any type), when working in teams, both/all team members shall wear
impact eye protection glasses
Drilling or tapping holes
Hammer of any size
Drift
Spreader
Chisels
Saws / hacksaws
Thread dies
Working in the vicinity of someone welding burning or grinding
Additional protection box goggle or visor shall be worn by operators at all times when using;
Hand held grinder 4" / 9" (angle grinders)
Die grinder
Flap wheel
Bench / pedestal grinder
De-burring / fettling equipment
Air lines for swarf/debris removal
Oxy/acetylene equipment
Initial start-up of plant until such time as integrity of hydraulic system established.
Painting
Rust preventative
Pumps testing
Molten white metal
Decanting any hazardous substance
Tinted glass or Speedglass (electronic polarising action)

Welding
Profile cutter operation
Oxy acetylene burning
Any other situation, not included in this list whereby a potential for eye damage from a working process or procedure is present, should be
assessed by the section Team Leader and or the Health and Safety Manager. Appropriate protection commensurate with the level of risk
assessed should then be applied and this safety instruction amended.
5.3.7
Respiratory Protection - as with eye protection, respiratory safety hazards are extremely difficult
to protect against, as poor selection can lead to individuals feeling they are adequately protected and
yet not receiving any of the protection required for the situation. Dust, Gas and Vapour are specific
hazards and a filter protecting against mist and fume will not necessarily protect against dust
(particulate), similarly a particulate filter will not protect against gas and vapour.
Respiratory protection should only be selected as the last resort. All other sources of to control the
hazard should be considered first e.g. substitution, elimination, separation and engineering controls.
Respiratory Protection - when not in service all respiratory protective equipment must be kept in a
clean dry environment where it can be protected from contaminants. Reusable equipment should be
wiped down with a mild solution of soap and water using a cloth or sponge, dried off and then
stored in a clean dry environment.
Powered air and Airfed Respirators and headtop should be worn when
High intensity welding processes (Particulate filter P(SL) filters must be fitted at the air intake. It is
recommended that in addition Organic gases and vapours with boiling point greater than 65oC;
inorganic gases and vapours and acid gases (A1B1E1) filters, should also be fitted at the air intake.
Paint spraying Plants etc. (Particulate filter P(SL) +Organic Vapour (OV) filters must be fitted at
he air intake.
Compressed Airline Feed Respirator and headtop must be worn when
Grit blasting.
10
Half mask respirators should be worn when

Stick welding (Particulate filter P(SL) It is recommended that in addition organic gases and
vapours with boiling point above 65oC; inorganic gases and vapours (A1B1) filters
should also be applied.
Paint spraying smaller items, short period, (Particulate filter P(SL) +Organic Vapour
Disposable particulate Respirators
Polishing surfaces with die grinder and flap wheels (Particulate filter P(SL))
De-burring / fettling equipment (Particulate filter P(SL))
Any other situation, not included in this list whereby a potential for respiratory damage from a
working process or procedure is present, should be assessed by the section Team Leader and or the
Health and Safety Manager. Appropriate protection commensurate with the level of risk assessed
should then be applied and this safety instruction amended.
5.3.8
Hearing Protection - The Noise at Work Regulations 1989 require hearing protection to be
provided where noise levels are between 85dB(A) and 90dB(A). Where noise levels are in excess
of 90dB(A) hearing protection becomes a mandatory requirement.
Noise level assessments have been carried out across the site and the results illustrate that when
production departments are in normal operation the background level of noise is in excess of
85dB(A). The company has made provision therefore for hearing protection to be available in all
production departments.
Fabrication Department, Quarry Plant Fitting Department and Quarry Plant Assembly
Departments results have indicated that the levels of exposure in these departments are in excess
of 90dB(A) in these departments therefore personal hearing protectors (Variphone) have been
offered to every employee. Being manufactured to suit an individual's ear canal these can be worn
for 8 hours per day with no discomfort and can be attenuated to match each individuals exposure
levels.
For those persons that have declined the offer of the above (Variphone) service a variety of styles
of hearing protection are available and the individuals selection must be worn every time they are
exposed to levels of noise in excess of 90dB(A)
11
Styles available:
Disposable foam Inserts - can be used alongside other PPE easy to use and provide levels of protection that can
exceed some earmuffs. Some come moulded for greater comfort. Must be disposed of after each wearing and
new used each time. For effective operation the insert should be rolled between finger and thumb, the ear canal
should then be opened slightly by lifting the upper part of the ear, using the opposite hand the ear having the
insert applied to. The tightly rolled insert is then pushed into the ear canal and allowed to expand to create an
effective seal.
Corded inserts - a variety of types, foam, some with durable cleanable coatings for extended use, re-usable
moulded plastic. Any insert that is re-usable should be cleaned in a mild solution of soapy water at least each
day. This type of insert is fitted in the same way as described above.
Banded inserts - coated foam inserts and moulded plastic inserts, hang comfortably around the neck and ideal
for intermittent protection needs. To fit effectively the ear canal should be eased open slightly by lifting the
upper part of the ear using the opposite hand to which the ear protector is being applied. The plug or shaped
plastic pod should then be eased into the ear canal until a good seal is formed the ear should then be released.
Ear Muff - 3 basic styles Helmet Mounted, Overhead Band or NeckBand. For the muff to be effective a good
seal must be established between the soft outer part of the muff and the area of the head around the ear. Long
hair, beards and spectacles can impair the seal of the muff and thereby effect the physical performance of the
protection. The earmuff should always be fitted in the vertical position as any other position will seriously
impaired as an effective seal will not be achieved.
When not in service all re-usable hearing protectors must be kept in a clean dry environment where they can be
protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap and water, dried
off and then stored in a clean dry environment.
5.3.9
Head Protection - As a general rule head protection is not required in production or maintenance
areas at BL-Pegson. However when Plants are undergoing display or test programmes in the field
to the front of the site and stone or other material is being run through the machine Safety
Helmets must be worn by operators and onlookers.
12
Safety Helmets are a mandatory requirement for all BL-Pegson personnel when operating, testing, repairing or
adjusting Plant and Machinery at a quarry or demolition / recycling site.
Bump caps are available for all personnel and are recommended for use when working on Plants and Machines
in production and maintenance areas at the Mammoth Street Site.
5.3.10
Fall-arrest Protection - must be worn when working at heights where adequate provision for
guard-rails to prevent falls cannot be established.
Body Harness and attachment systems are available, that can be adjusted to fit the individual.
The attachment system must be connected to a reliable anchorage point. The vertical drop of the
user must be minimised to prevent collision with obstacles and the braking force injuring, tearing
or causing the operator to fall.
Inspections of the equipment must be carried out prior to use to check for wear and damage that
may cause the equipment to fail in operation.
The equipment should be examined every six months in accordance with the Lifting Operations
and Lifting Equipment Regulations 1998.
When not in service all fall arrest protection equipment and attachments must be kept in a clean dry environment
where they can be protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap
and water, dried off and then stored in a clean dry environment.
5.3.11
Other Protective Equipment - Where BL-Pegson personnel are expected to attend quarrying or
other demolition / recycling sites mandatory requirements for Personal Protective Equipment are:
Hard hats / Helmet
Hearing Protectors
Eye Protection
Foot Protection
High Visibility coat or waistcoat
Respiratory Protection P(SL) strongly recommended
13
5.4
Disciplinary Procedure. Persistent failure by any employee to conform with the designated
requirements, for the use of personal protective equipment within any production, maintenance or
test area (as outlined in section 5.2 of this Safety Instruction), will result in the instigation of the
BL-Pegson Ltd progressive disciplinary procedures against him/her.
5.5
Requirement of Control Measures to keep all control measures in a clean condition. The
following is an extract from Regulation 9 of the Control of Substances Hazardous to Health
Regulations 2003.
(5)
Every employer shall ensure that personal protective equipment, including protective clothing, is:
(a)
properly stored in a well-defined place;
(b)
checked at suitable intervals; and
(c)
when discovered to be defective, repaired or replaced before further use.
(6)
Personal protective equipment which may be contaminated by a substance hazardous to health

shall be removed on leaving the working area and kept apart from uncontaminated clothing and
equipment.
(7)
The employer shall ensure that the equipment referred to in paragraph (6) is subsequently
decontaminated and cleaned or, if necessary, destroyed.
14
It is the engineer responsibility to

ensure that all risk assessments and
method statements are in place before
any work is carried out.
15
1300 Maxtrak
16
Starting and Tracking Plant
17
Control Panel and Starting
Battery Isolator Switch

Switch ON isolator switch
On
Off
18
C13 Tier 3 Engine Start Panel with Hycontrol
Engine
Start
Controls.
Hycontrol
display
screen.
PLC
display
screen.
Plant/Track
Controls
All of the controls for starting up the crusher are done from the electrical
panel at the front of the machine.
19
Main Control Panel

Throttle
Switch
Cantrak
Display
Fuel
Gauge
Ignition
Switch
Cat ET
Connector
20
Main Control Panel

Below the Cantrak display there are three indicator .
The C13
engine rpm is
electrically
adjusted by a
rocker
switch.
Maintenance Due
lamp.
Warning (Alert) lamp, the Warning

lamp will flash indicating a fault
code. Count the number of times it
flashes and check the Caterpillar
operation maintenance manual for
the cross reference to give the
possible causes.
The Shut down

(Action) lamp.
When this lamp
is flashing
means the
engine is going
into De-rate.
21
Plant/Track Controls
Plant/Track
Emergency
Stop
Fault Mute
Umbilical/Radio
Automatic/Manual
Fault Reset
22
Plant/Track Controls
Product
Feed Conveyor
Conveyor
Manual Feed Conveyor
Lube Pump
Crusher
Speed Control 23
Engine checks before starting
Engine checks before starting (Daily checks)

1.
2.
3.
4.
5.
6.
7.
8.
Check engine oil level.

Check engine water level, if low check for water leaks.
Check radiator for external blocking dust and debris.
Check air filter service indicator
Check water separator on primary fuel filter and drain if necessary from the
water trap at the bottom of the filter.
Check engine drive belts for correct tension and wear or damage.
Check for oil leaks on engine.
Check all induction pipe work for cracks and loose clamps.
24
Starting Engine and tracking with the 860 Remote Control
LEDs
1
2
Switch selector switch to Remote.

Power up the transmitter by, pulling out the stop
button, then pressing and hold buttons 9 + 0 for 1
second. No 3 LED will go red whilst holding the
buttons then turn green when the buttons are
released, if the LED remains red then the
transmitter needs charging.
With transmitter powered up you can now start
the engine.
Note. If any of the buttons are pressed before the

10 second timer times out, the transmitter will
reset the Tracks to OFF and you will need to press
the Track mode button No 9 to restart the 10
second timer.
Button numbers
25

Throttle Switch
Ignition
Switch
Cantrak
Display
Fault Reset
With the Isolator switch turned ON.

Turn the ignition switch to the first position
and press the fault reset button.
The siren will sound for 10 seconds, then the 3
lights will come ON under the Cantrak (Lamp
test).
Note. If an emergency stop button IN
(including the umbilical stop button) the siren will
not sound).
Allow the PLC to the sequence of self diagnostic
checks (35 seconds).
With the Throttle switch on idle (toward the left),
turn the ignition switch to the second position
and the engine should start with in 3 seconds.
Idle the engine for 3 to 5 minutes.
26
Press button No 9 to put

into track mode, a siren
will sound for 10 seconds
then pause for 1 second the
sound again for the
duration that the machine
is in track mode. You can
now track the machine
using 4 control buttons (No
1 to 4).
When the machine is in
position press No 9 button
the switch out of track
mode.
Before switching the
engine OFF, run it at idle
speed for 3 to 5 minutes.
Tracking Button
Siren
Button
Note. To switch
off the radio
control, first
press IN the
stop button then
pull back OUT.
27
Starting Engine and tracking with the Umbilical Control
Directional
Buttons
To use the Umbilical control. Do not power

up the Remote and select Umbilical control
(as shown in photo).
Press and release No 7 button on the
Umbilical, the siren will sound for 10
seconds then stop for 1 second then sound
again for the duration that the machine is in
Track mode.
Then machine can now be moved using the
4 directional buttons on the Umbilical
Control.
Note. If any of the buttons are pressure
before the 10 second timer times out, the
Umbilical will reset the Tracks to OFF and
you will need to press the Track mode
button No 7 to restart the 10 second timer.
28

Umbilical control unit directional buttons
Umbilical
Emergency stop
Button
29
When the machine is in position, press No 7

button to take the Umbilical out of Track
mode.
Before switching Off the engine, run it at
idle speed for 3 to 5 minutes.
30
Best Practice Loading Procedure
Ensure that the hydraulic pump belts are tight enough otherwise the
machine will not track straight and the chill is out of the hydraulic oil.
The type of trailer determines how the ramps need to be set up.
The higher the trailer the longer the ramps need to be.
Load / unload the machine on level ground
Long shallow ramps enable easier loading
31
Best practice loading procedure

Ensure that the machine is inline with the centre of the trailer and the
ramps are in the centre of the tracks.
Once the machine is centred and up to the ramps lower the engine rpm to
low idle.
The machine will pull one way if the hydraulic oil is less than 5c (<41f) with
high rpm
32
Best practice loading procedure

Track the machine onto the trailer using the fast forwards / reverse button
as the machine will pull straighter than using the slow tracking button.
With the ramps at the correct angle the machine goes gently over centre
ensuring that the machine stops on the trailer and there is no damaged
caused to the tracks.
33
Tracks
Check oil level monthly
6 litres (1.6 US galls) SAE 80w/90 Gear Oil
First oil change at 100 working hours
Change oil thereafter every 1000 hours or Annually
Filler Plug
Level Plug
Drain Plug
34
Track Tension
The tracks are tensioned by pumping EP 2 grease into the track tensioner
grease nipple.
Cover
Grease Nipple
35
Track Tension
Span the tracks with a straight edge between the longest section of
tracks thats unsupported. The tracks should have 15mm (5/8) of sag.
36
Track Tension
If there is less then 5mm of sag in the tracks, it will be necessary to let off
some tension. To do this slowly unscrew the grease nipple until it releases
grease .
The grease nipple is under extreme pressure so never remove it until the
grease has stopped coming out.
Recess for grease extraction
Grease Nipple
37
Setup Plant
38
Setup Plant
Do daily check on engine.

Move machine into position.
Check that the plant is level in both plains, plus both tracks are
fully support across the full length of the tracks.
Check plant stability when running.
Check all guard are in place
plus in good condition
Check that all warning signs
are present and readable
Check all emergency stop are
working (include the umbilical
control emergency stop).
Check for any loose fixings.
Check out general inspection
of the plant t ascertain that
nothing untoward is out of
place or damaged so as to
cause a safety hazard.
39
Feed Conveyor Travel Position
The feed conveyor needs to be raised into the working position as it is lowered
for transport.
Feed
conveyor
40
Feed Conveyor Raise / Lower Hydraulic Control
The feed conveyor is hydraulically raised by the lever on the side of the
chassis which connects directly into the bank valve.
41
Feed Conveyor And Feed Chute
Raise the conveyor in the air to expose the first set of holes and fit the pins.
Swing up the feed chute and secure in place with the four quick release latches.
Travel Brackets
For pins
Working
position
Swing Up
Feed chute
Fit Pins
Hinged
Feed chute
42
Feed Conveyor Pin Positioning
Ensure that the pin head is not touching the conveyor frame.
Pin Head
Conveyor
Frame
43
Cone Material Level Sensor
The Cone material level

sensor needs to be raised
into the working position
as it is lowered for travel.
44
Feed Ring Level Sensor
Position the bottom of the

sensor head so that it
measures 130 centimetres
(51 inch) from the bottom
of the feed ring.
130 cm (51 inches)
Wipe the dust / dirt from the underside of the

sensor on a daily basis.
45
Hycontrol Level Sensor
To view the parameters press the MODE

button it will now display PROG.
Press 1 immediately it will now display

PR.01.
Now use the S and T buttons to select the

required program number.
When on a parameter press the DSP button to

view the value.
To change this value, type in the required value

and then press the ENT button.
It will now display COdE enter 9753 as the

code and press the ENT button.
You can now press the MODE button and it

will display run to place the unit back into
operating mode or use the S and T
buttons to select another parameter to change.
46
Hycontrol Level Sensor
Hycontrol
0.5m (Pr.5)
2.0m
Feed Off
(Pr.3)
1.0m
(Pr.4)
Feed On
85%
(Pr.9)
55% (Pr.10)
47
Hycontrol factory set parameters Level Sensor
Pr.1
Pr.2
Pr.3
Pr.4
Pr.5
Pr.7
Pr.8
Pr.9
Pr.10
Pr.23
Pr.29
Pr.37
Pr.40
Pr.71
=
=
=
=
=
=
=
=
=
=
=
=
=
=
1
2
2.0
1.0
0.5
1
1
85
55
2
30
2
1
-0.5
Defines applications as level Measurement

Program units are metres
Distance from transducer to zero level
Working range, distance from zero level upwards
Blanking zone, echoes can not be processed in this area
Display to show to 1 decimal place
Relay 1 set to normally energized
Relay 1 de-energise point
Relay 1 re-energies point
Relay 1 fail safe
Failsafe time delay (in seconds)
Temperature compensation enabled
Sets measuring range to percentage
extends measurement range to 0.5 metres below zero
Other parameters which can be changed are Pr.06 (Rate of change),

this will change the rate at which the unit works this can be taken up
to a maximum of 6 any higher and the system can become erratic.
Pr.99 returns to Hycontrol factory default settings.
48
Conveyors
Adjust the scrapper on both the feed conveyor

and product conveyor.
Track Feeder Conveyor if required
Track Product conveyor if required.
49
Feed Belt Adjustment

The feed belt is adjusted from the rear end and the belt needs to be kept tight
at all times to prevent the head drum from slipping
Always keep the tail drum square when tensioning the belt otherwise the belt
will get stretched on one side and make belt tracking difficult.
To tension the belt slacken off the locking bolts and lock nut and turn the
adjusting stud anti clockwise.
Locknut
Adjusting
stud
Measuring point
(keep equal on
each side )
Locking
bolts
Adjuster
50
Feed Belt Tracking
DOR
51
Discharge Conveyor Tracking
DOR
52
Belt Direction
R/H
L/H
D.O.R
53
Up And Over Metal Detector
Remove the transport

chain from the top coil.
54
Metal Detector Panel Layout

The green light should be on at all times.
Fault light
Detect light
Detect Lamp
Reset Button
Power Lamp
55
Up And Over Metal Detector
The new detectors are fitted with a coil above the belt as well as the one under
the belt.
The bottom coil is the transmitting coil and the top coil is the receiving coil.
56
Metal Detector
The metal detector is built into the top end of the feed
conveyor under the belt.
Plastic insert
57
Metal Detector Set Up

The set zero indicator needs the green LED to be illuminated. If either of the
two red LEDs are illuminated the set zero adjustment knob needs to be
adjusted until the green light is illuminated. The adjustment compensates
zeros out any near by metal in the sensor coil detect area.
With either of the red LEDs

the detector will not detect
properly.
Relay
control
Set zero
indicator
LED
Set zero
adjustment
58
The sensitivity of the detector can be adjusted

to ignore small pieces of steel that are no
problem to the machine to cut down on the
amount of stoppages.
The sensitivity is adjusted simply by
turning the sensitivity knob.
Use the test block (45mm x 45mm x45mm) to

set up the sensitivity.
59

Using the test block (45mm x 45mm x45mm) to
set up the sensitivity, only adjust to the
minimum setting that will still detect the test
block when it is passed between the coils in the
direction that the conveyor runs.
When the metal test block is passed
between the coils the signal level
indication strip LED`s will move
from the left to the right then trip
(metal detected), the detect LED
(PCB) and the reset button on the
front door will come ON, the feed
conveyor will stop and the PLC will
display 45 METEL DETECTED
ON FEED CON BELT
60
Dust Suppression
A water manifold is situated at the front of the machine that has outlets to 3
dust suppression spray bars.
The inlet water pressure needs to be 2.8 bar (42 psi) to atomise the water
through the nozzles..
61
Spray Bar Location
Crusher feed chute
Discharge conveyor
Crusher discharge
Each nozzle uses approximately 1
litre a minute.
There are filters in the end of the
nozzles that require cleaning if the
water is not clean.
The spray bars can be used
individually or all together.
62
Automax Hydraulic Adjustment
The hydraulic system for adjusting the crusher is situated next to the
adjustment panel.
The outgoing pipes from the hydraulic system connect to the crusher
adjustment cylinders and wedge lock dumpy jacks.
Wedge-ring /
crushing pressure
gauge
System
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
63
Automax Paktronic Control Panel

All of the adjustments for the crusher C.C.S and calibration is done from a
separate panel (Paktronic panel) next to the start up panel.
The C.S.S. of the machine is done on the touch of a button.
64
1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM225
upwards February 2004)
P.S. 1 159 bar (2300psi) Rising

Dump Valve
System Pressure Gauge

(Danfoss Valve)
Adjustment
Solenoid
Stack
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
P.S. 4 103 bar

(1494psi) Falling
Pressure Filters
P.S. 3 138 bar

(2000 psi) Falling
Wedgelock Pressure Gauge
65
1300 Maxtrak
100309 issue 2
AM225
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
186 Bar (2700 PSI)
172 Bar (2500 PSI)

PS3 138 Bar (2000
PSI) Falling
PS4 103 Bar (1494

PSI) Falling
145 Bar (2100 PSI)
166 Bar (2400 PSI)
10 Micron Absolute
90 Micron Nominal
66
Checking Cone Adjustment Pressure

Check wedge lock (dumpy jack)
pressure, should be between
(minimum) 166bar (2400psi) and
(maximum) 172bar (2500psi).
Wedge-ring /
crushing
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
Check the wedge ring pressure,

should be between 55bar (800psi)
and 83bar (1200psi). Select manual
and press close, take the reading
from the wedge-ring/crushing
pressure gauge.
Note. On new machine (machine that just had

new wedge pad fitted) the wedge ring pressure
can be as low as 14bar (200psi), the pressure will
67
increase when the pads bed in
Charging Dumpy Jacks
68
Reducing the C.S.S
69
Set Zero Calibration

As the mantle and concave wear, the crusher needs to be calibrated to ensure that
the setting on the display screen is accurate. Calibration is carried out as follows :
1. Open up machine fully, and check that are no stone in the crushing
chamber.
2.
Put the machine into manual.
2. Ensure the crusher is not running, Press close until the mantle and concave
touch. This is indicated by a rise in pressure on the wedge-ring / crushing
pressure gauge, recheck that there are no stones in the crushing chamber.
3. Scroll down the screen until you get to SET ZERO.
4. Press enter.
5. Press F3 and this will zero the screen. The amount of wear taken off to get it
to zero gets added to the read wear.
6. Press escape and scroll back to current gap /set gap screen.
7. Set the crusher to the required setting (set gap).
70
Manganese Read Wear
1. Ensure the crusher is not running. Put the panel into manual and close the
machine metal to metal.
2. If the display reads a minus figure carry out the set zero calibration.
3. Scroll down to manganese wear and press enter.
4. Providing that the calibrations have been carried out correctly the figure
shown is the combined wear gone off the mantle and concave.
5. Press escape and scroll back to the set gap and select a C.S.S
Note: The wear can only be measured when the manganese is touching.
71
Adjusting The Closed Side Setting
1. Put the machine into manual.

2. Scroll down to the SET GAP.
3. Press enter.
4. Press enter.
5. Select a closed side setting.
6. Press enter.
7. Press escape.
8. Open the machine 5mm above the close side setting entered.
9. Put the machine into auto and the crusher will close itself down to the preselected closed side setting.
72

Test the Tramp Overload System
1.
Select MANUAL, open machine above the SET GAP, select AUTO and
machine will come down to the SET GAP showing wedge-ring pressure of
55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.
2.
Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED
in hirsmann plug) and the wedge-ring pressure will be dumped.
3.
Reset your wedge-ring pressure by repeating step 1
Tramp overload
test button
Wedge-ring/Crushing
Pressure Gauge
Dump Solenoid C
73
1300 Maxtrak Crusher Lubrication System
Check oil level in Lubrication tank

Check for leaks in lubrication system
Lubrication
Oil Level
Sight glass
Check for water leaks

Check for Hydraulic oil leaks
74
Setup Plant
Note. When machine is working it should always be in Auto Mode
75
Operating Plant
76
Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Daily Checks and on start up

Check guards are in good condition plus in place.
Check warning signs are present and readable.
Check the alignment and tension of v-rope.
Check all emergency stops are working.
Check lubrication oil tank level.
Check for any loose fixings.
Do the engine daily checks
Check the metal detector is working correctly.
Fully raise and lower the upper frame several times manually to help distribute
the grease on the wedge ring for smooth operation.
Ensure the crusher internal frame arm shields are free of foreign bodies or
material build up, also check that there is no material in the crushing chamber.
Inspect the liners for possible tramp metal damage and evidence of an uneven
Company
Confidential
developing.
wear pattern
77
Maxtrak
control
for100309 issue 2
Feed Conveyor
Daily Checks and on start up cont.

Check the Metal detector is working correctly.
Check the Wedge lock (Dumpy Jack) pressure should be between (minimum)
166bar (2400psi) and (maximum) 172bar (2500psi).
Check the Wedge ring pressure, should be between 55bar (800psi) and 83bar
(1200psi).
Set Zero (re-calibrate) on manganese.
Check manganese wear.
Check Tramp overload is working.
Set CSS (Close Side Setting) on Crusher.
Carry out the Plant lubrication schedule.
Check that there are no faults displayed on Allen Bradley screen.
Check that there are no leaks on the Lubrication/Hydraulic oil or water
systems.
78
Maxtrak
control
for100309 issue 2
Feed Conveyor

Switch ON isolator switch
On
Off
79
Engine
Start
Controls.
Hycontrol
display
screen.
PLC
display
screen.
Plant/Track
Controls
80
Maxtrak
control
for100309 issue 2
Feed Conveyor
Select Plant on the Plant/Track switch

Select Transmitter on the
Umbilical/Radio switch
Power up the transmitter by, pulling out the stop

button, then pressing and hold buttons 9 + 0 for 1
second. No 3 LED will go red whilst holding the
buttons then turn green when the buttons are
released, if the LED remains red then the
transmitter needs charging.
LED`s
1
2
3
81
Maxtrak
control
for100309 issue 2
Feed Conveyor
Throttle Switch
Ignition Switch
Cantrak
Display
Fault
Reset
With the Isolator switch turned ON.

Turn the ignition switch to the first position
and press the fault reset button.
The siren will sound for 10 seconds, then the 3
lights will come ON under the Cantrak (Lamp
test).
Note. If an emergency stop button IN
(including the umbilical stop button) the siren will
not sound.
Make sure that the Throttle switch on idle
(toward the left).
82
Maxtrak
control
for100309 issue 2
Feed Conveyor
The Allen Bradley PLC will take 35 seconds to do

it self diagnosis check, but the Paktronic takes
longer therefore the Allen Bradley screen will
display fault 39 HYDRAULIC PANEL
WEDGELOCK FAULT, press fault mute to
turn off the siren then press fault reset to
unlatch this fault.
11. Plant start available will now be displays on
the Allen Bradley screen.
Turn the ignition switch to the second position
and the engine should stat within 3 seconds.
Idle the engine for 3 to 5 minutes.
Fault Mute
Company
Confidential
Fault Reset
83
Maxtrak
control
for100309 issue 2
Feed Conveyor
Press the Lub button, the siren will sound for 5

seconds, press it again (within 10 seconds) after the siren
has stopped to start the lub pump, the PLC will not
allow the crusher to be started until the oil pump has
run for 5 minutes plus the Product Conveyor is running.
Press the Product Conveyor button, the siren will
sound for 5 seconds, press it again (within 10 seconds)
after the siren has stopped to start the Product
Conveyor. The Product Conveyor is fitted with a speed
wheel, should the Product Conveyor slow down, the
PLC will automatically stop both the Feed Conveyor
and Crusher
Lub Pump
Product
Conveyor
84
Maxtrak
control
for100309 issue 2
Feed Conveyor
With the Product Conveyor running you can now start

the crusher.
Before starting the crusher check that there is no
material inside the crushing chamber.
With the Engine speed at 1200rpm, press the Crusher
start button, the siren will sound for 5 seconds, press it
again (within 10 seconds) after the siren has stopped to
start the Crusher.
With the clutch engaged increase the engine speed to
1800rpm, allow the Crusher time (10 seconds) to get up
to working speed before starting the Feed Conveyor.
Crusher
Feed
Conveyor
85
Maxtrak
control
for100309 issue 2
Feed Conveyor
With the Crusher running, select Automatic or Manual

Feed Conveyor speed (the Factory recommend Automatic
should be selected to keep the Crusher choke fed).
In Automatic mode you use the Hycontrol PLC and level
sensor to control the Feed Conveyor belt speed/level of
material in Crusher feed hopper.
In Manual mode you use the Pot to control the Feed
Conveyor speed/level of material in Crusher feed hopper.
130 cm (51
inches)
Automatic
Manual
Manual control Pot

for Feed Conveyor
86
Maxtrak
control
for100309 issue 2
Feed Conveyor
Press the Feed Conveyor start button, the siren will

sound for 5 seconds, press it again (with 10 seconds)
after the siren has stopped, the Feed Conveyor will not
start until you press the Feed Conveyor start button
(button No 0) on the transmitter.
With the feed conveyor running the Allen Bradley will
display 8. Plant Running .
You can start and stop the Feed Conveyor on the
remote (transmitter) by pressing button No 0
Feed
Conveyor
Feed
Conveyor
87
Maxtrak
control
for100309 issue 2
Feed Conveyor
With the Plant running

Check the plant is stability (the chassis should not have
undue vibration during operations) on and off load.
Listen for any abnormal noise from the Crusher.
Check for leaks on the Lubrication system.
Check Lubrication filter condition, this will be
displayed on Allen Bradley screen as 43. CRUSHER
LUBE OIL FILTER BLOCKAGE this fault will sound
a siren but will not stop the crusher from running.
Check lubrication oil flow back to tank.
Check and note Lubrication oil pressure to
temperature.
Check for leaks on the water system.
Check the operation of the Lubrication oil heater
(Bowman) if the oil temperature is below 40oC (105oF)
Check for Hydraulic leaks.
Inspection glass
88
Feeding The Crusher
It is essential that the the crusher is choke fed to ensure the machine is is
performing to its best ability. The wear plate should not be visible when the
machine is crushing.
Failure to choke feed the machine will result in low production, poor shape
and a reduction on the material.
In some cases the concave can be worn out of round resulting in premature
manganese changes.
Concave
Wear plate
Mantle
89
Feeding The Crusher
Check that the feed into the crusher is not Segregated (fine material on one side
and coarse on the other.
When segregation takes place in the crushing chamber it means that there are
voids within the coarse material in the crushing chamber resulting in poorer
shape.
The fine material will encourage packing therefore limiting the crusher CSS (for
working at tighter settings.
Coarse
Material
Fine Material
Feeding The Crusher
Check that the CSS is being maintained (current gap should be the same as set
gap) when crushing.
The CSS can be adjusted whilst the crusher is working (on the fly).
Note the Crushing pressure. (the maximum this should be running at is
approximately 138bar (2000psi) to 145bar (2100psi).
Wedge-ring /
crushing
pressure gauge
91
Feeding The Crusher
It is essential that the the crusher is choke fed to ensure the machine is is
performing to its best ability. The wear plate should not be visible when the
machine is crushing.
Failure to choke feed the machine will result in low production, poor shape
and a reduction on the material.
In some cases the concave can be worn out of round resulting in premature
manganese changes.
Concave
Wear plate
Mantle
92
When Plant is running
With the plant running, check the tracking and for spillage on both the
product conveyor and the feed conveyor.
Note. No adjustment should be done to these conveyor when the are
running.
93
Stopping Plant
Run the Feed Hopper empty and stop the Feed conveyor.
Reduce the engine speed 1200rpm.
Stop the Crusher (but keep the lubrication system running until the cone
head stops turning)
Stop the Product conveyor.
When the Cone Head stops turning then stop the lubrication pump.
Run the engine at idle speed (1200rpm) for 3 to 5 minutes then switch of
the engine.
Switch of the remote by pushing in the stop button and pulling it back out.
94
De-rigging Plant
95
De-Rigging Plant
1. Raise the feed conveyor to the highest point and put the pins into the top
holes. Lower the conveyor onto the pins.
2. Clean out the material from the rear half of the feed ring and fold down
hinged door on the feed chute.
3. Raise the feed belt, remove the pins and fit them into the travel brackets.
Lower the feed belt all of the way down.
4. Stop the engine.
5. Lower the miltronics probe into the travel position.
6. Remove all loose stones from the machine.
96
De-rigging machine and preparing it for transport
Check that both the Feed Hopper and Feed Conveyor is empty of material
Run the Product Conveyor to insure there is not material on it.
Raise the Feed Conveyor to the highest point and put the pins into the top
holes. Lower the conveyor onto the pins.
Clean out the material from the rear half of the Feed ring and fold down
hinged door on the feed chute.
Raise the Feed Conveyor, remove the pins and fit them into the travel
brackets. Lower the Feed Conveyor all of the way down.
4. Fit the transport chain to the Metal Detector top coil.
5. Lower the Level probe into the travel position.
6. Remove all loose stones from the machine.
97
Automax Cone Crusher
98
Basic Crusher Layout
ONE PIECE CONCAVE

SUPPORT BOWL /
UPPER FRAME
MANTLE
LINER
MANTLE
NUT
CONCAVE LINER
ECCENTRIC
MAIN SHAFT
SEALING
WEDGE RING
ASSEMBLY
BEARING
ARRANGEMENTS
MAINFRAME
HYDRAULIC
ADJUSTMENT
CYLINDERS
HYDRAULIC
WEDGE
JACKS
LUBRICATION
DRIVE GEARS
COUNTERSHAFT
ASSEMBLY
Direction of
rotation
718 RPM
99
Crusher Motion
100
Manganese Types
The 1300 Automax has only one eccentric throw which is 45mm.
There are two manganese configurations fitted to the Automax :Standard Manganese
Has the largest feed opening capable of accepting 220 mm (8.1/2 inch) down
material. Ideally suited for making 40mm (1 inch) down material.
Autosand Manganese
Designed to accept a feed size from 63mm (2.1/2 inch) to 13mm (1/2 inch).
Used for applications where plenty of fines and small aggregates are required.
101
Manganese Profiles
Automax
Crushing
zones
The longer the crushing zone the

better reduction and shape
Autosand
102
Manganese Profiles
Automax
Autosand
103
Upper Frames
There are two types of upper frames fitted to the crusher to hold the different
profiles of manganese.
The Autosand fit in one support bowl and the Automax in the other.
As the Automax manganese is shallower than the others the difference in the
upper frames are clearly visible.
Automax
Autosand
Upper frame
Upper frame
104
1300 Automax Approximate Capacities
The type of material, feed size and bulk density can effect the capacity of the
machine.
The figures in the table below are only guide lines.
105
1300 Autosand Approximate Capacities
The type of material, feed size and bulk density can effect the capacity of the
machine.
The figures in the table below are only guide lines.
106
1300 Automax 45mm Throw
107
1300 Automax 45mm Throw
Example. With a C.S.S of 19mm

(3/4) 40% of the production (96
to 112 tonnes/hour) will be below
5mm. 90% of the production
(120-140 tonnes /hour) will be
below 24mm.
108
1300 Autosand 45mm Throw
109

The crusher has a stand alone tank for the lubrication oil.
Inline pressure
filters
Lub Air blast cooler
Temperature sensor
Pressure
gauge
Flow meter
Float Switch
Breather /Filler
cap
Temperature
sender
Electrical
junction box
Sight glass
Hydraulic motor
110
111

Pressure Filter 25 Micron Nominal
c/w Bypass and block filter switch
Lubrication Oil
Cooler c/w Bypass
Thermostat 40oC
Lubrication Pressure Gauge
Flow Meter
Hydraulic Motor
125 micron
Breather
Return Oil Sight

Gauge
Lubrication Pump
Oil Level Sight Gauge
Over Temperature switch

set to 80oC
Relief Valve set to 5

Bar @ 23 oC
Float Switch
Suction Filter 90
Micron Nominal
112
1300 Maxtrak fitted with 12.5cc Hydraulic Motor

Calculation. 1 litre of oil into 12.5cc motor = (1000 /12.5 ) 80
rpm.
15 Litres of oil into 12.5cc Motor = 1200rpm.
Hydraulic motor running at 80rpm, Lubrication flow = 80 x 33.7
cc/rev =2696 cc / 1000 = 2.7 Litres per Minute
Hydraulic motor running at 1200rpm, Lubrication flow = 1200 x
33.7 cc/rev = 40440 / 1000 = 40.4 Litres per Minute
Hydraulic Motor = OMM12.5
Lubrication Pump = 33.7cc
113
Lubrication Pump =
33.7cc
Relief Valve set to 5

Bar @ 23 oC
Suction Filter 90
Micron Nominal
114
Cone Lubrication System
The primary function of the

Lubrication system are.
To prevent damage due to
metal on metal contact
within the bearings.
To dissipate heat
generated by the bearing
during operation, so acting
as a coolant.
To reduce friction and
wear with the bearing.
115
Crusher Lubrication System
Feed to countershaft
Return to tank
must fall at a
minimum of 5.
Tank
Feed to main shaft
116
Crusher Lubrication Oil
The crusher runs on two different grades of oil depending on the ambient
temperature.
Ambient temperature above 4C (39 F) use an EP 220 ISO VG.
Ambient temperature below 4C (39 F) use an EP 150 ISO VG.
The tank holds approximately 275 litres (73 US. Gallons) of oil.
117
Crusher Lubrication Oil Level

The oil level should be checked daily
The oil level needs to be maintained at the top of the sight glass (cold oil).
In cold conditions the oil may be pumped into the machine quicker than it is
returned which drops the level in the tank.
A level float is fitted to the tank so that if the oil level drops too low it will
shut down the machine.
Level
float
Sight
glass
118
Lubrication Oil Pump + Motor
The oil pump is is mounted inside the lubrication tank.

An external hydraulic motor is used to drive the pump.
The pump delivers approximately 40 litres of oil / minute (10.6 U.S gallons)
into the crusher at working temperature. The crusher relies on oil flow for
lubrication not pressure.
Lubrication pump
inside the tank
Hydraulic
motor
119
System Pressure
The system pressure will vary depending on the oil temperature.

The pump has a built in relief valve set at 5 Bar (72 PSI). With cold oil the
pressure may get up to 9 Bar(130 PSI).
If the oil pressure is above 5 bar (72 PSI) it means that some of the oil is
going through the relief valve straight back into the tank.
When the oil is up to temperature the pressure will be approximately 2.5
Bar(36 PSI)
Lubrication
system pressure
gauge
120
Pressure Filters
The Lubrication Filter should be checked daily
The oil is pumped from the tank and through two inline pressure filters.
The initial oil and suction filter change needs to be done at 500 hours when
the machine is new.
The oil and suction filter should then be change every 1000 hours there after.
The initial filter change needs to be done at 100 hours when the machine is new
The filters are then changed every 500 hours there after.
Inline pressure
filters
The lubrication oil

tank capacity is 275
litres (73 US galls)
121
Blocked Filter Warning
There is a blocked filter sensor fitted to the to the filter housing.

This will not shut down the machine but it will sound the siren.
There is a bypass valve fitted into the filter housing so the oil will still be
pumped to the crusher but it will be un-filtered
Taking regular oil samples, having them tested and changing the oil when the
analysis instructs to do so will reduce the amount of oil changes.
Blocked
filter sensor
122
Lubrication Air Blast Oil Cooler

The air blast cooler is fitted to cool the oil before it enters the crusher.
It is fitted with a temperature sender unit so that the cooler fan does not start
up until the oil is at 40.6 C (105 F).
Once the fan starts up it will generally continue to run until the machine is
stopped.
The cooler will need to be cleaned out on a regular basis either with an air
line or a pressure washer to prevent the core getting blocked with dust.
Sender unit
Air blast
cooler
123

Crusher Lubrication Oil Flow Switch Setting
(PLC
version 12 onwards from April 2004)
The Kobold flow sensor has 2 cut off points.

When the oil is cold (air-blast cooler not operating) the cut off point is 8 l/min
(2.1 US gal) (3.6 Hz dc volts). When the cooler is running the cut off point is
14.7 l/min (3.9 US gal) (6.4 Hz dc volts)
The electronic sensor is no longer fitted on the lubrication pump when this
flow switch is fitted
124
Lubrication (Bowman) Heat Exchanger

The lubrication oil is below 40oC is passed through a heat exchanger before
it goes into the crusher.
When the oil is cold the water from the engine passes through the heat
exchanger to warm up the oil.
When the oil reaches working temperature (40oC) the solenoid valve closes
on the end of the heat exchanger to stop the water passing through it.
When the solenoid valve closes the air blast cooler starts.
Solenoid
Engine water
pipes
Feed to the
crusher main
shaft
Feed the
from flow
switch
Feed to the
counter shaft
125
Crusher Countershaft Lubrication
The front countershaft bearing has its own feed line.

With the oil at working temperature 2 litre / minute (0.5 US gal) goes to the
bearing.
Feed in
(3/8 BSP)
126
Crusher Lubrication Feed And Return Lines
The lubrication oil is pumped into the crusher from the underside through
the middle of the main shaft.
There is one pipe to return all of the oil back to tank.
Oil return to
the tank
Main shaft
feed in
127
Crusher Lubrication
Although there is only one feed into the main shaft there are two feeds out.
One oil port is situated at the top of the main shaft. There is stationary oil
flinger situated directly below the oil port to help distribute the oil evenly.
The oil from this port lubricates the upper and lower cone head bearings.
Oil port
Upper
bearing
Oil flinger
Lower
bearing
128
Crusher Lubrication
The lower oil port on the shaft lubricates the main shaft bearing pair and
lower bearing.
Oil port
Upper
bearing pair
Lower
bearing
129
Crusher Feed And Return Lubrication Lines
Main shaft
feed in
Oil return to
tank
130
Crusher Lubrication Return Line

A clear union is fitted to the return oil line to inspect the return oil entering
the tank.
The oil flows into s sediment tray before it falls into the bottom of the tank.
Inspection glass
Sediment tray
Tank
131
Crusher Lubrication Tank Oil Drain

Track the machine over some wooden blocks or built up ground to gain
ground clearance for draining the oil.
Try to lean the machine towards the drain plug to remove as much oil
out of the tank as possible.
The drain plug is a 1/2 inch female quick release coupling so a pipe can be
attached to drain the oil.
Filler cap
Drain plug
132
Crusher Lubrication Tank Oil Drain

Pumping the oil out of the tank may be an easier method to remove the oil as
inspection cover needs to be removed to change the suction filter and clean out the
bottom of. the tank.
Always clean the top of the tank before removing the inspection cover.
Also pump or mop out the oil from the sediment tray and clean it as it is not
possible to drain it out.
Inspection
cover
Sediment
tray
133
Crusher Lubrication Over Temperature Sender
The oil temperature sender unit is situated in the tank so that if the oil
exceeds 80 C (176 F) the crusher will automatically shut down.
134
Automax Hydraulic
Adjustment System
135
Automax Paktronic Adjustment Panel

All of the adjustments for the crusher C.C.S and calibration is done from a
separate panel next to the start up panel.
The c.s.s. of the machine is done on the touch of a button.
136
The hydraulic system for adjusting the crusher is situated next to the
adjustment panel.
The outgoing pipes from the hydraulic system connect to the crusher
adjustment cylinders and wedge lock dumpy jacks.
Wedge-ring /
crushing pressure
gauge
System
pressure gauge
Wedge lock
pressure
gauge
137

To adjustment
cylinders (close
C.S.S.)
Solenoid C
Solenoid A
To adjustment
cylinders (open
C.S.S.)
Solenoid B
Tank
Pressure In
To Wedge Ring
Wedgelock shut off valve
(normally open)

(normally closed)
138
1300 Maxtrak
100309 issue 2
1300 Automax Hydraulic Adjustment (Panel
Number
AM225 upwards)

Dump Valve

(Danfoss Valve)
Adjustment
Solenoid
Stack
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
P.S. 4 103 bar

(1494psi) Falling
Pressure Filters
P.S. 3 138 bar

(2000 psi) Falling
139
140
1300 Maxtrak
100309 issue 2
AM225
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
186 Bar (2700 PSI)
172 Bar (2500 PSI)

PS3 138 Bar (2000
PSI) Falling
PS4 103 Bar (1494

PSI) Falling
145 Bar (2100 PSI)
166 Bar (2400 PSI)
10 Micron Absolute
90 Micron Nominal
141
1300 Maxtrak
100309 issue 2
AM224
downwards before February 2004)
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
186 Bar (2700 PSI)
172 Bar (2500 PSI)

PS3 124 Bar (1800
PSI) Falling
PS4 83 Bar (1200

PSI) Falling
145 Bar (2100 PSI)
166 Bar (2400 PSI)
10 Micron Absolute
90 Micron Nominal
142
Automax Adjustment Cylinders

The hydraulic panel operates the six adjustment cylinders which moves the
upper frame up and down which changes the closed side setting of the
machine.
Adjustment
cylinder
Wedge lock
open
Close
143
144
Wedge-ring Dumpy Jacks

The wedge -ring acts like a brake shoe on the inside of the upper-frame to
assist the main hydraulic cylinders in holding the upper-frame in position
whilst it is crushing.
The main hydraulic cylinders cannot hold the upper-frame solely on their own.
Upper-frame
Wedge-ring
Dumpy
jacks (x 12)
145
Wedge-ring
The wedge ring has a series of tapers on the inside of it which match up to the
mainframe. The dumpy jacks push the wedge-ring up which makes it expand
due to the tapers thus pushing the pads hard up to the inside of the upperframe to act like a brake.
Wedge-ring pads
146
Wedge-ring Principle
Expanding
Wedge Ring
Upper Frame
Upper frame
Mainframe
Wedge Ring
Mainframe
Dumpy Jacks
Dumpy Jack Cylinder

147
Closed Side Setting Paktronic Display Screen
The C.S.S. of the machine is displayed on a PLC.

There is a linear transducer that connects from the mainframe to the upper
frame to measure the movement of the upper frame. The transducer sends a 4 to
20 mA signal back t the PLC which converts it into a millimetre display gap.
PLC gap display
Linear Transducer
148
Check wedge lock (dumpy jack)

pressure, should be between
(minimum) 166bar (2400psi) and
(maximum) 172bar (2500psi).
Wedge-ring /
crushing
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
Check the wedge ring pressure,

should be between 55bar (800psi)
and 83bar (1200psi). Select manual
and press close, take the reading
from the wedge-ring/crushing
pressure gauge.
Note. On new machine (machine that just had

new wedge pad fitted) the wedge ring pressure
can be as low as 14bar (200psi), the pressure will
149
increase when the pads bed in
Charging the Dumpy Jacks
150
Reducing the C.S.S
151
Set Zero Calibration

As the mantle and concave wear, the crusher needs to be calibrated to ensure that
the setting on the display screen is accurate. Calibration is carried out as follows :
1. Open up machine fully, and check that are no stone in the crushing
chamber.
2.
Put the machine into manual.
2. Ensure the crusher is not running, Press close until the mantle and concave
touch. This is indicated by a rise in pressure on the wedge-ring / crushing
pressure gauge, recheck that there are no stones in the crushing chamber.
3. Scroll down the screen until you get to SET ZERO.
4. Press enter.
5. Press F3 and this will zero the screen. The amount of wear taken off to get it
to zero gets added to the read wear.
6. Press escape and scroll back to current gap /set gap screen.
7. Set the crusher to the required setting (set gap).
152
Manganese Read Wear
The read wear is the amount of manganese that has worn off the mantle and
concave. There are three indications that the machine needs re-metalling
1. The crushing pressure is too high, preventing you from closing the
machine to the required close side setting.
2. The hydraulic cylinders bottom out restricting the closed side setting.
3. 50mm is the maximum amount of wear to be worn off the manganese.
Wearing more off than this increases the chances of the manganese cracking,
causing damage to the cone head or upper frame.
153
Manganese Read Wear
1. Ensure the crusher is not running. Put the panel into manual and close the
machine metal to metal.
2. If the display reads a minus figure carry out the set zero calibration.
3. Scroll down to manganese wear and press enter.
4. Providing that the calibrations have been carried out correctly the figure
shown is the combined wear gone off the mantle and concave.
5. Press escape and scroll back to the set gap and select a C.S.S
Note: The wear can only be measured when the manganese is touching.
154
Adjusting The Closed Side Setting

2. Scroll down to the SET GAP.
3. Press enter.
4. Press enter.
5. Select a closed side setting.
6. Press enter.
7. Press escape.
8. Open the machine 5mm above the close side setting entered.
9. Put the machine into auto and the crusher will close itself down to the preselected closed side setting.
155

Test the Tramp Overload System
1.
Select MANUAL, open machine above the SET GAP, select AUTO and
machine will come down to the SET GAP showing wedge-ring pressure of
55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.
2.
Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED
in hirsmann plug) and the wedge-ring pressure will be dumped.
3.
Reset your wedge-ring pressure by repeating set 1
Tramp overload
test button
Wedge-ring/Crushing
Pressure Gauge
Dump Solenoid C
156
New Manganese
When the machine is new or when it has been re-metalled the new
manganese calibration needs to be carried out. This is done as follows 1. Ensure the crusher is not running.Put the machine into manual and close
the machine until the mantle and concave touch. This is indicated by a
sudden rise in pressure on the wedge ring / crushing pressure gauge. Ensure
it is metal to metal and no stones are in the crushing chamber.
2. Scroll down the screen using the down arrow until you get to NEW
MANGANESE
3. Press enter
4. Press F4 and it will re-calibrate everything back to zero
5. Press escape.
6. Scroll back up to current gap / set gap display
7. Set new closed side setting
157
Increasing the C.S.S
158
In Working Mode
159
Overload in Automatic
160
Dump Line
There is a check valve in the engine compartment which is connected in the
main suction line. The 3/4 pipe connected to the end of it tees in the full bore
side of the adjustment cylinders. When the crusher dumps it can then draw oil
into the bottom of the cylinders as they are being forced open.
Tees to the
cylinders
161
1300 Maxtrak Pressure Reliefs and Reducers
Adjustment stack
Wedge lock stack
Pressure reducer
145 Bar (2100psi)
Pressure reducer
166 Bar ( 2400psi)
Relief valve172
Bar (2500psi)
162
1300 Maxtrak Paktronic Control Panel
163
Paktronic Electrical Panel

The relays have a built in LED to indicate when they are energised.
The relays also have a button that can be pressed to over ride the relay and
close the contacts.
R1
R2
R3
R4
R5
R7
Relay over-ride
button
Relay
LEDs
Spare fuses
Fuses
164
Maxtrak
100309 issue 2
Paktronic Electrical Drawing 9673 (Panels 1300
AM272
and
after) August 2004
165
1300 Maxtrak
Paktronic Electrical Drawing 9088 (Panels
before100309 issue 2
AM272) August 2004
166
Hydraulic Panel Operation
OPENING THE CRUSHER

When the open button is pressed on the electrical panel, it energises solenoids
B and C. Solenoid B operates the adjustment cylinder stack which diverts oil
to the bottom side of hydraulic cylinders to open the machine. At the same
time solenoid C opens the dump valve which allows the oil in the top side of
the cylinders to be pushed into the tank
CLOSING THE CRUSHER
When the closed button is pressed on the electrical panel, it energises solenoid
A. Solenoid A operates the cylinder adjustment stack in the opposite direction
which diverts oil to the top side of the cylinder which closes the machine. The
oil from the top side of the cylinder has a clear route back to tank
167
Hydraulic Panel Operation
OVERLOAD SITUATION
When the pressure in the hydraulic circuit exceeds 159 bar (2300psi) solenoid
C operates. This opens the dump valve which releases all of the pressure from
the top side of the hydraulic cylinders. The crusher is then forced open by
whatever is in the crushing chamber. As the crusher opens, it draws oil into
the bottom of the cylinders through a one way valve on the suction side of the
hydraulic tank. Once the crusher has opened, it will automatically close itself
back down to the original setting by operating solenoid A.
WORKING SITUATION
When the crusher is working nothing in the hydraulic circuit is being
operated. The pressure within the wedge-lock system and the top side of the
hydraulic cylinders is locked in and held by check valves.
168
Paktronic Panel Operational

There are 6 relays in the Paktronic electrical panel for the crusher
adjustment circuit although the relay numbers go up to 7. Relay 6 no longer
exists.
There are LEDs built into the relay to indicate that they are energised.
Relay 7 should be energised all of the time.
CLOSING THE CRUSHER
When the close button is pressed relays R1 and R2 should energise.
OPENING THE CRUSHER
When the open button is pressed relays R1 , R3 and R4 should energise.
WEDGELOCK CHARGING
When the wedge lock pressure drops below 138 bar (2000 psi) relay R1
should energise.
OVERLOAD
When the crusher dumps and goes into overload relay R4 should energise.
169
Pressure Reliefs And Reducers
Adjustment stack pressure reducer

This reducer limits the manual operating pressure to 145 bar (2100 psi)
within the hydraulic cylinders.
Wedge lock stack reducer

This reducer limits the hydraulic pressure going to the dumpy jacks for the
wedge ring to 166 bar (2400 psi).
Wedge lock stack relief

This relief is set at 172 bar(2500 psi) and it is a back up to the reducer, to
ensure the wedge lock circuit does not over pressurise.
170

System pressure relief
200 bar (2900 psi)
Hydraulic cylinder relief

186 bar (2698 psi)
171
System relief
The system relief is located on the three bank valve in the R/H side of the
engine canopy. It is set at 200 bar (2900 psi) to ensures that sufficient oil
pressure is always available.
Hydraulic cylinder relief

This pressure relief is also set at 186 bar (2698 psi), this is the last line of
relief if a major overload situation should occur. This relief allows the oil
from the top side of the hydraulic cylinder to pass to the bottom side which
allows the machine to open.
172
1300 Maxtrak
100309 issue 2
AM225
upwards)

Dump Valve

(Danfoss Valve)
Adjustment
Solenoid
Stack
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
P.S. 4 103 bar

(1494psi) Falling
Pressure Filters
P.S. 3 138 bar

(2000 psi) Falling
173
Pressure Switches
Pressure switch 1
Pressure switch 1 is set at 159 bar (2300 psi) rising, when the pressure in the
hydraulic cylinders exceeds this the pressure switch changes over and operates
the dump valve C (via the Paktronic PLC) allowing the crusher to open (note,
it is the material in the crushing chamber that pushes it open). 3 seconds after
the dump valve as been operated the Paktronic PLC with de-energize the
dump valve and close the machine down to it original CSS.
Pressure switch 3
Pressure switch 3 is set at 138 bar (2000psi) falling. When the pressure in
the wedge lock circuit drops below 138bar (2000psi) the pressure switch
changes over operating the Danfoss valve (via the Paktronic PLC) to charge
the system back up. Once the pressure exceeds 138 bar (2000psi) the system
will continue to charge for a further 10 seconds.
If the pressure fails to reach 138 bar (2000psi) the machine will shut down
after 3 minutes displaying pump maximum run.
174
Pressure Switches
Pressure switch 4
Pressure switch 4 is set at 103bar (1494psi). If the pressure in the wedge
lock circuit drops below 103bar (1494psi) for more than 30 seconds the
machine will shut down and display wedge lock pressure failure.
175
Other Paktronic Display Functions
Alarms, On the Alarms menu display

the alarm condition along with the time
and date that it occurred.
In the Alarm History will store the last
20 alarms that were activated along with
the time and date.
Transducer Fault @ 18.18 on 12
May 2007. This fault is display
because there is a fault with
transducer circuit. Check the wires
from the Paktronic PLC to the
Positec. The machine will not operate
until the fault has been rectified.
176
Manganese Wear.
Hour Run. The Lubrication Oil

should be changed to the Paktronic
Hours and not the Engine hours.
177

Tramp Metal Count.
Prev = Number of Tramp Overloads in
the previous 30 Hours of Operation.
Hrs = Hours that have expired since the
last 30 hours count.
3 digits to the right of the screen =
Number of Tramp overloads in the Hrs
counted.
Gap Too Large = When machine
overloads when in Automatic but cannot
return to the Set Gap after 30 seconds
(this period is considered too long for
normal operation) the Alarm will be
show. To reset select manual and close
machine down to Set Gap then select
Auto. Confidential
Company
178
Hydr Pump Max Run. When the

machine overloads in Auto and the
hydraulic pump has been running for
over 3 minutes to close the machine
down to Set Gap (this is considered too
long for normal operation), the
hydraulic pump will stop and this alarm
will be displayed. To reset select Manual
mode and close Crusher down to Set
Gap, then select Auto.
In Manual Too Long. When working in
manual there is a time limit of 5
minutes, this is considered too long for
normal operation. To reset select Auto
then Manual.
179
Manual Tramp Latch. A Tramp Metal

Overload has occurred whilst in Manual
mode. The Crusher will remain in its
open position and show the following
alarm. To reset select Auto then Manual
and close machine down to the crusher
Set Gap, then select Auto.
Wedge Press Fail. The press in the
dumpy jacks has drop to the setting of
PS4.
180
Set Operating Language. Press and

hold button F2 for 6 seconds. Select the
required Language and press enter.
Time and date input for

recording pressure over-loads
Hydraulic Oil Low. This fault

should not occur because the
supply comes from the plants
main hydraulic tank.
181
Crusher Closed Side Setting Creeping Open
CAUSES
External leak on adjusting cylinder
Internal leak on adjusting cylinder
Internal leak in the hydraulic panel
182
Crusher Closed Side Setting Creeping Open
DIAGNOSIS
Close the machine metal to metal until it blows through the relief valve at
145bar (2100 psi) on the wedge ring pressure gauge. If the pressure drops
more than 7bar (102psi) in ten minutes there is a leak.
Check the whole of the system for external oil leaks and rectify if necessary.
Re test to see if the pressure still drops.
Disconnect the the two snap connectors and repeat the same process. If the
pressure holds now the leak is within one of the hydraulic cylinders. If the
pressure still drops the leak is within the hydraulic panel.
183
Hydraulic Cylinder Internal Leak Test
Remove the top pipes off five of the

cylinders and plug them with a half inch
BSP plug.
Press close on the machine until 145bar

(2100psi) is achieved. Leave for 10
minutes and note the pressure drop.
Repeat for all six cylinder.
184
Hydraulic Cylinder Internal Leak Test
Relief valve
If a pressure drop occurred on one of the

two cylinders with the relief valves fitted,
the top pipe needs to be piped directly to
the cylinder to determine if the leak is
within the cylinder or the relief valve.
185
Hydraulic Panel Internal Leak

90 percent of internal panel leaks are due to dirty oil.
Remove the pressure reducer and the check valve cartridges. Wash them out
in a cleaning solvent and blow them out with an air line. This may remove any
dirt sat on the valve seats causing the internal leak. If not, trail and error
fitting new parts will be necessary to find the fault.
The check valve sits between the

pressure reducer and manifold
block
186
Relief Valve Setting

If the relief valve is backed off and stripped to remove any contamination it
will need to be re-set.
1. Leave the relief valve backed off when it is re-fitted.
2. Close the machine metal to metal and keep the button pressed. It may be
necessary to screw in the relief valve if the upper frame wont move.
3. Screw in the relief valve until 145bar (2100psi) is achieved on the wedge
ring pressure gauge and secure in place with the lock nut.
Relief valve
Lock nut
187
Wedge-lock Pressure Drop
If the wedge-lock pressure keeps falling and recharging the system, the first
thing to check is the wedge-lock shut off valve is fully closed.
Shut off valve normally closed
188
Wedge-lock Pressure Drop

Open up the upper frame to its maximum to fully expose the dumpy jacks to
check for any oil leaks from either the jacks or the hydraulic pipe work
If no leaks are apparent disconnect the quick release coupling. Put the
machine into auto and open the wedge-lock shut off valve. As soon as the
system starts to build up pressure close the valve. If the pressure still drops the
leak is in the panel. If the pressure holds the leak is within the dumpy jacks.
Quick release coupling
Dumpy jacks
189
Wedge-lock Valve Stack

Remove the pressure reducer, check valve and relief valve. Clean then as
before and re-fit them as contamination is the probable cause.
VALVE SET UP
Fully screw in the pressure reducer and back off the pressure relief valve. Put
the machine into auto and unscrew the wedge-lock shut off valve. When the
pressure drops below 138bar (2000psi)(PS.3) system will build up pressure
again. Shut the wedge-lock valve and slowly screw in the relief valve until
172bar (2500psi) is achieved. You will have to re-charge the system a couple of
time before you can get it set accurately. Repeat for the pressure reducer and
set to 166bar (2400psi)
Pressure reducer
Check valve
Relief valve
190
Wedge-lock Valve Stack
If the wedge-lock circuit continued to drop pressure whilst trying to set up the
valves, again trial fitting of new parts will be necessary to diagnose the fault.
NOTE
Whenever a fault occurs on the hydraulic circuit check and replace

the hydraulic filters if necessary.
The filters should be changed every four months to minimise any

contamination.
191
Upper Frame Bouncing Whilst Crushing

Closed side setting too tight.
Open up the css and run it where the machine is comfortable
Too many fines in the feed material causing packing.
Open the jaw crusher css to reduce the amount of fines produced if the
crusher will accept a larger feed size.
Use the dirt conveyor on the jaw crusher to reduce the fines.
Wedge ring over greased causing low wedge ring pressure.
Run the crusher where it is comfortable and slowly tighten the setting over a
period of time. This will remove some of the grease off the pads.
Alternatively remove the upper frame, remove all of the grease then re grease
with the correct type and amount.
Wedge lock pressure low / internal oil leak.
Investigate and rectify the cause of the problem.
192
Upper Frame Bounding Whilst Crushing
Manganese worn out.

Change the mantle and concave.
Wedge ring pads worn out.
Fit new pads to the wedge ring.
The dumpy jacks have bottomed out causing low wedge ring pressure.
Check that the wedge ring pads are not worn out. If not either remove the
wedge ring stop and reposition the wedge ring or fit packers under the dumpy
jacks. NOTE. THE DUMPY JACKS HAVE A 15MM STROKE.
Manganese out of round.
Carry out out of round check on the manganese. Re metal if necessary.
193
Manganese Out Of Round
CAUSES
Poor manganese.
Incorrectly fitted manganese.
Segregation of feed material.
Continues stop start feed.
Trickle feeding.
194
Manganese Out Of Round Check

Note. Usually its not the mantle that goes go out of round as it is continually
turning so always check the concave first.
The Mantle can you out of round if a there has been a built up of stone
under the crusher causing the head to lock to the eccentric.
Checking the concave
1. Draw an arrow on the mantle
2. Remove the drive guard to gain access to the drive pulley
3. Mark the concave so that each check is done in the same position
4. Slowly turn the pulley so the head and eccentric turn as one. Align
the arrow on the mantle nut to the mark on the concave
5. Start the engine and close the machine metal to metal, ensuring the
pulley doesnt turn. Note the read out on the digital display.
6. Open the machine back up at least 20mm
7. Stop the engine and slowly turn the pulley so the head + eccentric
turns through 90 degrees. Repeat the above procedure until you have
four reading . If at any time the pulley turns whilst closing metal to
metal the whole process needs to be started again
195
Mantle nut
concave
Typical values
Engine
Feed
Conveyor
1
If there is a difference of more than 6mm between any of the four points, the
manganese needs to be changed immediately.
196
Checking the mantle

Repeat the same procedure as before but this time the pulley must be held still
and the cone head rotated. Again if the pulley turns whilst it is being closed
metal to metal the whole procedure needs to be repeated.
The same tolerances apply to the mantle.
197
Welding on Cone Crusher
Welding on Plant
Whenever any welding is done on the machine the battery isolator key must
be turned off, negative battery lead removed and the ECM plugs must
disconnected
Ensure that the current does not pass through any bearings. (Note, always put
the welding earth cable on/beside the unit that is being welded).
198
Caterpillar C13 Engine and

Clutch
199
C13 Engine and Clutch

Always switch off and lock out
when carrying out maintenance,
especially if welding
On
Off
200
Cantrak
display
screen.
Hycontrol
display
screen.
PLC
display
screen.
201
Main Control Panel

Throttle
Switch
Cantrak
Display
Fuel
Gauge
Ignition
Switch
Cat ET
Connector
202
Main Control Panel

Below the Cantrak display there are three indicator .
The C13
engine rpm is
electrically
adjusted by a
rocker
switch.
Maintenance Due
lamp.
Warning (Alert) lamp, the Warning

lamp will flash indicating a fault
code. Count the number of times it
flashes and check the Caterpillar
operation maintenance manual for
the cross reference to give the
possible causes.
The Shut down

(Action) lamp.
When this lamp
is flashing
means the
engine is going
into De-rate.
203
C13 START PANEL
The maintenance due light will illuminate every 250 hours and will stay on until
the reset button is pressed.
Maintenance
Lamp
204
Diagnostic Flash Codes For C11 & C13 Industrial Engine
Flash Code
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
n/a
1387-15
E443 (2)
High Auxiliary Pressure Warning
1387-16
High Auxiliary Pressure Derate
1387-00
High Auxiliary Pressure Shutdown
0441-15
E445 (2)
High Auxiliary Temperature Warning
0441-16
High Auxiliary Temperature Derate
0441-00
High Auxiliary Temperature Shutdown
626-05
626-06
545-05
Ether Start Relay open/short to +batt
2417-05
Ether Injection Control Solenoid open/short to +batt
545-06
Ether Start Relay short to ground
2417-06
Ether Injection Control Solenoid short to ground
205
Flash Code
SPN (1) FMI Code
Diagnostic code or
Event Code
n/a
1835-03
1835-03
Auxiliary Pressure Sensor open/short to +batt
1835-04
1835-04
Auxiliary Pressure Sensor short to ground
1836-03
1836-03
Auxiliary Temperature Sensor open/short to +batt
1836-04
1836-04
Auxiliary Temperature Sensor short to ground
111-02
111-02
Engine Coolant Level Sensor Loss of Signal
174-03
174-03
Fuel Temperature open/short to +batt
174-04
174-04
Fuel Temperature short to ground
678-03
41-03
8 Volt DC Supply short to +batt
678-04
41-04
8 Volt DC Supply short to ground
13
21
Description of Code
206
Flash Code
21
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
620-03
262-03
5 volt Sensor DC Power Supply short to +batt
262-04
5 Volt Sensor DC Power Supply short to ground
100-03
100-03
Engine Oil Pressure open/short to +batt
100-04
100-04
Engine Oil Pressure short to ground
100-10
100-10
Engine Oil Pressure abnormal rate of change
102-03
102-03
Boost Pressure Sensor shor to +batt
102-04
102-04
Boost Pressure Sensor short to ground
102-10
102-10
Boost Pressure Sensor abnormal rate of change
1079-03
620-04
1079-04
24
25
207
Flash Code
SPN (1) FMI Code
Diagnostic code
or Event Code
108-03
274-03
Atmospheric Pressure open/short to +batt
108-04
274-04
Atmospheric Pressure short to ground
110-03
110-03
Engine Coolant Temperature open/short to +batt
110-04
110-04
Engine Coolant Temperature short to ground
28
91-13
91-13
Throttle Position calibration required
32
91-08
91-08
Throttle Position signal abnormal
34
190-08
190-08
Engine Speed signal abnormal
723-08
342-08
Secondary Engine Speed signal abnormal
190-15
E362 (2)
Engine Overspeed Warning
26
27
35
Description of Code
208

Flash Code
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
35
190-00
E362 (2)
Engine Overspeed Shutdown
37
94-03
94-03
Fuel Pressure open/short to +batt
94-04
94-04
Fuel Pressure short to ground
105-03
172-03
Intake Manifold Air Temp open/short to +batt
105-04
172-04
Intake Manifold Air Temp short to ground
42
637-13
261-13
Engine Timing calibration required
46
100-17
E360 (2)
Low Engine Oil Pressure Warning
38
100-18
Low Engine Oil Pressure Derate
100-01
Low Engine Oil Pressure Shutdown
209
Flash Code
51
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
168-00
168-00
System Voltage high
168-01
168-01
System Voltage low
168-02
168-02
System Voltage intermittent/erratic
56
630-02
268-02
Check Programmable Parameters
58
639-09
247-09
J1939 Data Link communications
61
110-15
E361 (2)
High Engine Coolant Temperature Warning
62
110-16
High Engine Coolant Temperature Derate
110-00
High Engine Coolant Temperature Shutdown
111-17
E2143 (2)
Low Engine Coolant Level Warning
210
Flash Code
62
SPN (1) FMI Code
111-18
Diagnostic code or
Event Code
E2143 (2)
111-01
Description of Code
Low Engine Coolant Level Derate

Low Engine Coolant Level Shutdown
63
94-15
E096
High Fuel Pressure Warning
64
1636-15
E539 (2)
High Inlet Air Temperature Warning
1636-00
65
71
174-15
High Inlet Air Temperature Shutdown

E363 (2)
High Fuel Temperature Warning
174-16
High Fuel Temperature Derate
174-00
High Fuel Temperature Shutdown
651-05
001-05
Injector Cylinder 1 open circuit
211
Flash Code
71
72
73
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
651-06
001-06
Injector Cylinder 1 short
651-11
001-11
Injector Cylinder #1 fault
652-05
002-05
652-06
002-06
652-11
002-11
653-05
003-05
653-06
003-06
653-11
003-11
212
Flash Code
74
75
76
SPN (1) FMI Code
Diagnostic code or
Event Code
Description of Code
654-05
004-05
654-06
004-06
654-11
004-11
Injector cylinder #4 fault
655-05
005-05
655-06
005-06
655-11
005-11
656-05
006-05
656-06
006-06
656-11
006-11
213
(1)
Suspect Parameter Number
(2)
Caterpillar Electronic Technician (ET) will display the number 1,2 or 3 after the event code in order to
designate a warning, a derate, or a shutdown
214
C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
On
None
8 Sec
Engine Derate(2)
On
None
4 Sec
Engine Shutdown(3)
On
None
4 Sec
Warn Operator(1)
On
216 Deg F
10 Sec
Engine Derate(2)
On
217 Deg F
10 Sec
Engine Shutdown(3)
On
219 Deg F
10 Sec
Warn Operator(1)
On
2124 RPM
1 Sec
Engine Shutdown(3)
On
2200 RPM
1 Sec
Warn Operator(1)
On
167.0 Deg F
8 Sec
Engine Derate(2)
On
174.2 Deg F
8 Sec
Low Engine Oil Pressure
High Engine Coolant Temperature
Engine Overspeed
High Engine Inlet Air Temperature
215
C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
On
None
10 Sec
Engine Derate(2)
On
None
10 Sec
Engine Shutdown(3)
On
None
10 Sec
Warn Operator(1)
On
194 Deg F
30 Sec
Engine Derate(2)
On
196 Deg F
10 Sec
Engine Shutdown(3)
Off
196 Deg F
10 Sec
On
109.9 PSI
8 Sec
Warn Operator(1)
Off
221 Deg F
4 Sec
Engine Derate(2)
Off
223 Deg F
4 Sec
Engine Shutdown(3)
Off
225 Deg F
4 Sec
Low Coolant Level
High Fuel Temperature
High Fuel Pressure

Warn Operator(1)
High Auxiliary Temperature
216
C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
Off
218 PSI
4 Sec
Engine Derate(2)
Off
218 PSI
3 Sec
Engine Shutdown(3)
Off
218 PSI
3 Sec
High Auxiliary Pressure
217
ENGINE CANOPY
There are two clasps on either side of the engine that need to be undone.
The dip stick is situated at the rear of the engine nearest the hydraulic tank.
The oil should be checked on a daily basis.
Clasps
Gas locking strut, To close

the canopy push in the gas
strut outer cover then pull
down the canopy
Dip stick
218
Thermal Overloads on the C13 Engine

90 Amp for Alternator
15 Amp Ignition Supply
40 Amp customer supply.

This is for the supply
going to the Terex Pegson
panel
15 Amp EMS (ECM) supply

Maintenance reset button Caterpillar ET connection
219
Diesel Filler Cap

The filler cap is accessible without opening the engine canopy.
Always fill the tank through the strainer.
220
Engine Air Filters
An indicator is attached on the outlet pipe to show the condition of the filter.
The filter cleaning / changing intervals are all down to the operating
conditions.
The outer air filter is the only one that should be blown out with an airline,
not the inner.
221
Engine Coolant Level
The coolant level needs to be checked on a daily basis.

It is important that the coolant level is within 30mm(1 3/16) of the top of the
radiator because there is a low level sensor that will stop the engine and flash
the warning light.
Warning light
Level sensor
222
Engine Serial Number
The engine number is on the side of the rocker cover
223
Engine Fuel Filters
There are 2 fuel filters filters fitted to the engine.

The 1st one is a primary filter (14 micron) with a water separator.
The second one is a 2 micron filter.
They both have 250 hour service intervals.
224
ECM Plugs
The ECM is the electronic control module for the engine.

Whenever any welding is done on the machine the battery isolator key must
be turned off, negative battery lead removed and the ECM plugs must
disconnected (Note, always put the welding earth cable on/beside the unit that
is being welded).
The plugs are held in by a bolt and require a 4mm allen key to remove them.
ECM Plugs
4mm Allen key

225
Hydraulically Operated Clutch (HFO)

As the clutch is engaged hydraulically there is no adjustment necessary for
the clutch plates as they wear.
The end bearing on the clutch shaft runs in oil not grease so the oil level
needs to be checked on a daily basis.
The oil is SAE 30 or 40 and requires changing every 1000 hours.
The bearing housing only holds 200 cc (0.05 US Gal) of oil which is indicated
by a notch on the dipstick.
Dipstick
Oil level
226
Conveyors
227
Discharge Conveyor Head Drum Bearings
2 shots of EP2 grease once a week

Grease nipples on grease pipes
228
Skirting Rubbers
Also make the skirt rubbers for the discharge conveyor as long as possible.
Ensure that the feed boot skirt rubber overlaps the first barge board skirt
rubber.
229
Discharge Conveyor Tail Drum Bearings

230
Feed Conveyor Tail Drum Bearings

231
Feed Conveyor Head Drum 1300 Maxtrak 100309 issue 2
The feed conveyor has a small motor connected to a gearbox to achieve

maximum torque from the available oil supply.
The gearbox is lubricated with 0.8 litres (0.21 US galls) of V G 150 gear oil.
The initial oil change is between 50 - 100 hours and 2000 hours there after.
Check the oil level in the feed conveyor gearbox every month, should be half
way up the sight glass at 3 Clock position.
Grease the bearing with two shots of E P 2 grease every week.
Sight glass
Motor
Gearbox
Grease
nipple
232
Skirting Rubbers
Always replace the skirt rubbers once they become worn or damaged.
Always make the skirt rubbers on the feed conveyor in one long piece.
233
Feed Belt Adjustment

The feed belt is adjusted from the rear end and the belt needs to be kept tight
at all times to prevent the head drum from slipping
Always keep the tail drum square when tensioning the belt otherwise the belt
will get stretched on one side and make belt tracking difficult.
To tension the belt slacken off the locking bolts and lock nut and turn the
adjusting stud anti clockwise.
Locknut
Adjusting
stud
Measuring point
(keep equal on
each side )
Locking
bolts
Adjuster
234
Feed Belt Tracking
DOT
235
Beckford Speed Wheel

The speed wheel on the inside of the product conveyor belt.
Belt
speed
Wheel
circumference
Revs per
second
Pulses per
Rev
Time
period
Pulses per
second
125 m/m
80 m/m
628 millimetres
628 millimetres
3.31
2.12
2
2
5 seconds
5 seconds
32
20
236
DOT
237
R/H
L/H
D.O.T
Belt Direction
238
Remote Control Systems
239
840 Remote Control
LED
Red/Green
Remote On
Track Siren
Remote Feeder
Start/Stop
Engine Stop
240
840 Teleradio Remote Control

Battery Isolator position
On
LED
Off
Charging Point
12 v dc Cigarette
Lighter Charger
Battery Isolator
Engine Stop
241
Teleradio 840 New A Type Charger
The new A type chargers are 12 / 24 volts.

The charger clips into the back of the transmitter.
The output voltage from the charger is 9.6 volts.
242
Battery Pack
LED
The LED indicates the battery condition

Green indicates batteries are good
Red indicates batteries are going flat and
will shut the machine down in 1 hour, the
siren will sound when the LED turns red.
12 hours run down time from fully charged
Charge time approx 1.5 hour from flat
243
Teleradio Umbilical Control
The older type umbilical controls are fitted with a 6 or 15 pin plug (Photo is a
15 pin unit).
The function of the buttons are the same as the remote but for tracking only.
244
Teleradio Umbilical Control
The latest type umbilical is fitted with a heavy duty 16 pin plug and socket.
The function buttons remain the same.
245
840 Teleradio, Remote Control Tuning (frequency)

The frequency of the machines is set at random to eliminate interference if
there are 2 machines working together.
The frequency is set by dip switches at the back of the frequency modules.
Open up the transmitter and remove the teleradio frequency module
by removing the two screws.
246

The four dip switches on the radio module in the receiver box are on
the underside, so the cable tie needs cutting to gain access.
The only time these dip switches need to be changed is if interference
is effecting the remote control .
To change the frequency, move the position of the switches ensuring
that both frequency modules are in the same position.
247

Switch positions for operating frequencys-
248
840 Teleradio, Remote Control Tuning. ID Code

For a transmitter to operate with a receiver unit there is also an ID code that
have to match between the 2 units.
The frequency module needs to be removed in the transmitter to gain access.
There are 2 rows of 8 dip switches which are in series in the receiver and
transmitter.
The 2 switches on their own in the receiver should be in the off position.
If any of them are on, it will switch of the transmitter if none of the buttons
are pressed within a certain time period.
249

The new 860 remote control has a white face and red buttons.
The isolator key on the rear has now been removed.
The transmitter can accept 12 to 35 volts DC.
The function buttons operate the same as the 840 unit(including the
umbilical).
LEDs
1
2
3
Button numbers
250
The frequency modules in the transmitter and receiver are not removable so
there is no need to open anything to change the frequency.
1. Press the 9 and 0 buttons for at least 1 second, release 9 but keep 0
depressed.
2. Release 0 and press 8 within 0.3 seconds. The yellow LED(2) lights
continuously and the green LED(3) flashes.
3. Enter the pin number 1 2 3 4 then the yellow LED(2) goes out and the green
LED(3) flashes. This indicates the pin number has been entered correctly.
4. Enter 1 of the 16 channel numbers to set the frequency. Note. For single
digit numbers 0 must be pressed first.
5. The yellow LED flashes 3 times and then the transmitter switches off.
The frequency change has now been accepted.
Note. Each time a button is pressed the yellow LED(1) lights also.
251
CHANNEL NUMBER
FREQUENCY MHz
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
434.650
434.600
434.550
434.500
434.450
434.400
434.350
434.300
434.250
434.200
434.150
434.100
434.050
434.000
433.950
433.900
252
860 Teleradio Receiver Unit

Transmitter signal strength
Power LEDs
E Stop relays
Fault LEDs
4 5 6
8 9 10
1
Function
selector
No. of transmitters programmed
Reset button
Power supply
253
860 Teleradio, Status LEDs In Receiver
Green LED 1- This indicates the strength of signal that the receiver is getting
from the transmitter.
Reset button(2)- This puts the receiver into the learning mode where it will
tune itself into the transmitter.
Yellow LED(3)- When this LED is illuminated it means that the receiver is
powered up.
Yellow LED(4+8)- This flashes when a transmitter is programmed to the
receiver.
Red LED(5+9)- This indicates faults on the receiver.
Green LED(6+10)- This lights up when the receiver locks onto a transmitter
signal.
Selector switch 2
254
255

860 Teleradio, Programming A Transmitter
I D Code
Into A Receiver
1. In the receiver unit turn the function selector switch 2 to the ON position.
2. Press the red reset button. Both sets of green red and yellow LEDs should
illuminate.
3. Release the reset button. The green and red LEDs should go out. The
yellow ones should remain illuminated.
4. Press buttons 9 + 0 simultaneously to power up the transmitter.
5. Press buttons 9 + 0 simultaneously again until the yellow LEDs start to
flash. This indicates the receiver has found the transmitter.
6. On the receiver unit turn the function selector 2 switch to the off position.
7. The receiver is now programmed to the transmitter.
256

860 Teleradio, Erasing A Programmed Transmitter
From A Receiver
1. Turn the function selector switch 2 to the ON position.

2. Press the reset button. The green red and yellow LEDs should light
continuously.
3. Release the reset button. The green and red LEDs should go out. The
yellow ones should remain illuminated.
4. Turn selector switch 2 to the off position.
5. Turn switch 2 to the on position within 2 seconds. The yellow LEDs should
flash. This indicates the receiver has been erased.
6. Turn the function selector switch 2 to the off position.
257
1300
Maxtrak
Programming A Teleradio 860 Transmitter
Into
An 100309
840 issue 2
Receiver
The 840 transmitter is no longer available so all new transmitters are 860s.
The 860 transmitter can be configured to operate as an 840.
If an 840 receiver fails the receiver and transmitter will have to be replaced
because an 840 transmitter will not operate with an 860 receiver.
1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.

2. Release button 9 but continue to hold button 10.
3. Release button 10 and press button 6 within 0.3 seconds. The Yellow LED
should illuminate and the green LED should flash.
4. Enter the safety code 4,9,2,7,6,5. Each button has to be pressed within 5
seconds of each other. The green LED flashes and the yellow one goes out.
5. Enter 0 for 860 mode or 1 for 840 mode. The yellow LED flashes 3 times
and then the transmitter switches itself off.
258
Tuning The Transmitter Into An 840 Receiver

1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.
2. Release button 9 but continue to hold button 10.
3. Release button 10 and press button 5 within 0.3 seconds. The green LED
should flash.
4. Enter the receiver ID code(5 numbers).Example:ID-code 2594 will be 02594
5. Once the code has been entered the yellow LED flashes 3 times and the
transmitter switches off.
Note. If at any time the ID on the receiver was changed the programming will
not work because the ID code will be incorrect for the dip switch position.
259
Tuning The Transmitter Into An 840 Receiver

Remove the frequency module to see the position of the dip switchs.
Compare the position of the switchs to the frequency chart to establish the
frequency and the channel number.
Carry out the frequency change procedure and the 2 units will now function.
CHANNEL NUMBER
FREQUENCY MHz
01
02
03
04
434.650
434.600
434.550
434.500
260
General Maintenance
261
General Maintenance
When the Maxtrak plant is operated in extreme climatic conditions, e.g.

below -15oC (5oF) or above 30oC (86oF) or in very dusty conditions for a
long period of time, the maintenance schedules will change.
Failure to carry out scheduled maintenance or exercise due care may

invalidate any warranty that might apply.
Keep a accurate record of maintenance work carried out to the hours on
the engine.
The Maintenance records can also be used to show compliance with the
required maintenance practices and intervals.
262
Cleaning The Frame Arm Shields
It is essential that the frame arm shields are checked on a daily basis to ensure
that there isnt any material build up.
Failure to do this will result in the seal ring getting damaged or worse still
lifting the cone head.
263
Maintenance Schedule
264
Maintenance Schedule
265
Recommended Oil/Grease Types
266
267
Tracks
Check oil level monthly
6 litres (1.6 US galls) SAE 80w/90 Gear Oil
First oil change at 100 working hours
Change oil thereafter every 1000 hours or Annually
Filler Plug
Level Plug
Drain Plug
268
Track Tension
The tracks are tensioned by pumping EP 2 grease into the track tensioner
grease nipple when required.
Cover
Grease Nipple
269
Track Tension
Span the tracks with a straight edge between the longest section of
tracks thats unsupported. The tracks should have 15mm (5/8) of sag.
270
Track Tension
If there is less then 5mm of sag in the tracks, it will be necessary to let off
some tension. To do this slowly unscrew the grease nipple until it releases
grease .
The grease nipple is under extreme pressure so never remove it until the
grease has stopped coming out.
Recess for grease extraction
Grease Nipple
271
Hydraulic Tank
Check hydraulic oil level weekly
Change the filters (suction, inline, return) every 1000 or sooner if the tell-tale
indicator shows RED
Change the hydraulic oil every 2000 hours, 360 litres (96 US galls)
Use 46 grade hydraulic oil if the ambient temperature is below 86 F (30 C).
Use 68 grade hydraulic oil if the ambient temperature is above 86 F (30 C).
Inspection covers are fitted to the side of the tank to clean it out when the oil is
changed.
Breather
Level float switch/ sight
gauge. Oil level should
be 40mm below top of
Return filter
sight gauge
Inspection
covers
272
Hydraulic Tank Float Switch/Sight Gauge

Dont fill the hydraulic tank above the sight glass because it will throw oil out
through the breather when the it is tracked about with hot oil
If the oil drops down to a low level

the float switch will shut down the
engine to prevent the pumps being
starved of oil and damaging them.
273
Hydraulics
Check the condition of the suction and return filters weekly .
The suction and return filters both have indicators fitted to establish the
condition of the filters.
Unscrewing the shut off valve locks the oil in the hydraulic tank to prevent oil
loss when changing the suction filter element
Filter indicator
Return Filter
Shut Off Valve

Suction Filter
Filter
indicator
274
Hydraulics
Check the condition of the inline filters weekly .

There are two inline pressure filters fitted either side of the engine canopy
Both are fitted with red /green indicators. Red = Blocked. Green = Good.
They will indicate red in cold temperatures when the hydraulic oil is thick
Filter Indicator
Inline Pressure Filter
275
Hydraulics
The two inline pressure filters for the crusher adjustment circuit require
changing every 650 hours (4 months).
Inline pressure filter
Inline pressure filter
(return)
(feed in)
276
Releasing The Wedge-Ring For Greasing
Wedge-ring
pressure
Wedge-lock
pressure

(normally open Valve A )

(normally closed Valve B )
277
Wedge-Ring Greasing
Once the wedge ring has been released the upper frame needs to be positioned
so that the bottom of the upper frame inline with the spacers under the
dumpy jack.
With the upper frame in this position the grease nipples are situated in
between the two wedge ring pads.
Upper-frame
grease nipples
(12 off )
Upper-frame
greasing position
278
Wedge-ring Greasing Procedure
If the upper frame gets tight and doesnt travel smoothly or it requires more
than 1200psi (82 bar)to close it down it will be necessary to grease the wedge
ring.
1. Put the machine into manual
2. Close valve A and open valve B. The pressure should drop to zero on the
wedge lock pressure gauge
3. Open and close the upper frame until there is no pressure registering on
the wedge ring pressure gauge as you press close
4. Position the upper frame so that the bottom of it is inline with the dumpy
jack shelf. In this position the grease nipples are positioned in-between the
wedge ring pads
5. Grease all 12 of the grease nipples with Moly Bentone MP Grease (part
no 2123-2001). Travel the upper frame up and down to spread the grease
6. Close valve B and open valve A. Select a closed side setting and and the
wedge ring circuit will charge up with oil pressure.
279
Wedge-ring Greasing Procedure (cont)
7. Fully open and close the upper frame and check the travel. The ideal
wedge ring pressure is 800 to 1200psi (55 to 83 bar) as you press close.
8. If the travel is not smooth or the pressure is too high, repeat the greasing
procedure.
280
Hydraulic Pump Drive Belts
Check the belt tension weekly and adjust as necessary.

The belt deflection should be kept to approximately 5mm (3/16)at all times
Always look down the belts and square up the pump. The back-nuts enable
you to push the rear end for alignment
Adjusting Bolts
Drive Belts
Pump
Locking Bolts
(4 off)
Back nuts
281
Crusher Drive Belt Adjustment
The belt tension needs to be checked

weekly. Check for damage, wear and
fraying. This can be checked though
the inspection door.
282
Crusher Drive Belt Adjustment

1. Slacken the drive guard support bracket.
2. Back off the 4 bottom nuts on the adjusting studs (nuts A)
3. Tighten the top nuts to raise the engine.
4. Ensure the engine is level by measuring it in each corner and lock in
position with the lower nuts. Tighten the drive guard support bracket.
Nut B
Nut A
Keep the
engine level
Drive guard
support
bracket
Engine adjusting
stud (4 off )
283
Weekly check the condition of both the feed conveyor belt and the
product conveyor belt, check for damage or fraying.
Weekly clean away dust, dirt and grit from the maintenance platforms
and any moving parts.
Weekly check Lubrication oil cooler matrix is clean.
Weekly check the Hydraulic oil cooler matrix is clean.
284
Changing Wear Parts
285
Crusher Wear Parts
Take note of the wear shown on

the Paktronic display. Also check
this to the pin centres when the
machine is closed metal to metal
minimum pin centres should be
774mm. Always fit both a new
mantle and a new concave at the
same time as it is detrimental to the
operation of the machine to do
otherwise.
286
Crusher Wear Parts

The mantle nut has replaceable wear plate bolted to it to pre-long the life of
the nut .
Hit the wear plate on the top and on the sides with a sledge hammer and also
hit the 4 countersunk bolts before trying to undo them. This will free them off
and make them easier to undo.
When a new wear plate is fitted fill the 4 holes full of silicon to make the
removal next time easier.
Wear plate
Mantle nut
287
Crusher Wear Parts
288
Crusher Wear Parts
The mainframe arm supports are fitted with replaceable arm shields to
prevent any wear.
The frame arm shields just drop over the arm support as does the
countershaft arm shield but the countershaft shield locates over a key-way to
prevent it from moving.
The head and eccentric need to be removed from the machine to replace them
so plan to do it when the machine is being re metalled.
Countershaft arm shield
Key
Frame arm shield x 3
289
Crusher Wear Parts
The mainframe also has welded in liner plates fitted all of the way around it.
So provided that all liners and arm shields get replaced before they wear
through no wear should take place on the main frame.
Liner plates
290
Changing The Mantle And Concave

2. Close valve A and open valve B. The pressure should drop to zero on the
wedge lock pressure gauge.
3. Open and close the upper frame until there is no pressure registering on
the wedge ring pressure gauge as you press close. Leave the upper frame
about 5mm (3/16)from being fully open.
Wedge ring
pressure
gauge
Valve A
Wedge lock
pressure
gauge
Valve B
291
Raising The Feed Conveyor
Fully raise the feed conveyor and place the pins in the bottom holes.
Lower down the feed conveyor so that it sits on the pins.
292
Feed Ring
Remove the three retaining bolts from the crusher feed chute and lift off the
crusher feed chute.
There are 2 holes in the top of the feed ring for the lifting point.
293
Linear Transducer
Disconnect the stud from the mainframe that is attached to the linear
transducer.
Push the transducer all of the way down so that the stud cannot foul on the
upper frame when it is lifted off.
294
Changing The Mantle And Concave
Using a set of three leg chains take the weight of the upper frame from the
lifting lugs.
The upper frame weighs 4 ton (4.5 US ton) but use a set of chains of twice that
capacity to allow for drag on the wedge ring.
Lifting lugs x 4
295
Upper Frame Pins
Remove the six split pins and washers from the right hand side of the pins.
Knock out the pins from right to left with a hammer and punch. They have to
be knocked out in this direction because the bearings in the upper frame are
butted against a shoulder and get dislodged if the pins are removed from the
other direction causing premature bearing failure.
Take care when removing the the last pin because the upper frame may move
if there is too much or too little weight on the chains.
296
Upper Frame Removal
Slowly lift off the upper frame ensuring there is equal weight on each chain
and the upper frame is lifting off squarely.
DO NOT FORCE THE UPPER FRAME OFF WITH THE CRANE IF IT IS
TIGHT AS IT WILL CREATE A DANGEROUS SITUATION WHEN IT
COMES FREE.
If the upper frame is tight jack it off from the underside.
297
Releasing The Mantle Nut
As the mantle wears it also spreads which applies a massive amount of

pressure on the mantle nut preventing it from being undone.
To release the pressure of the nut you need to burn through the burning ring
all of the way around, within 20mm (3/4)of the mantle nut. Weaving the cut
will ensure that the pressure is better relieved off the nut.
Mantle
nut
Mantle
Burning
point
298
Unscrewing The Mantle Nut
Clean out the dirt from the square hole in the top of the mantle nut and slide
in the flogging bar.
Using a sledge hammer knock the nut undone.
THE NUT IS LEFT HAND THREAD. ROTATE CLOCKWISE TO LOOSEN.
Flogging
bar
299
Removing The Mantle Nut
Slide a bar through the nut and remove it with the crane.
300
Removing The Mantle
Loosen the mantle by hitting it with a sledge hammer. Using a couple of pry
bars lift up the mantle and drop a chain down the inside. Place the hook back
onto the chain at the top of the mantle.
Alternatively two lifting lugs can be welded to the mantle. Ensure that the
correct type of welding rod is used and a sufficient amount of weld is applied
to hold the weight.
301
Removing The Mantle
As the mantle is lifted off take care not to damage the threads on the cone
head.
302
Removing The Concave
Clean the dirt away from the underside of the three lugs and burn them off.
Cleaning under the lugs eases burning and allows the lug to be cut off in one
attempt.
As with the mantle weaving the torch makes it easier to get a clean cut.
Take care not to damage the wedges when burning off the lugs.
Lug x 3
303
Removing The Concave
Once the lugs have been burnt off the concave can then be knocked out using
a sledge hammer.
304
Preparing The Upper Frame

Lift the upper frame away from the concave and clean the inside where the
concave was fitted.
Remove the worst with a scraper then use either a sanding pad or wire wheel.
Preparing the upper frame in this way will make it easier to remove the
concave next time.
Remove the wedges and dowels and clean them up as necessary.
305
Check the lower seating area where the concave fits for burrs and remove them
with either a sanding disk or grinder depending on the severity.
Smear the inside of the upper frame with release agent where the crusher
backing sits ensuring there is plenty around the three pockets.
A thin smear of grease can be used if release agent is not available.
306
Smear the inside of the upper frame with release agent where the crusher
backing sits ensuring there is plenty around the three pockets.
A thin smear of grease can be used if release agent is not available.
307
Preparing The Concave
Clean up the taper on the concave to remove the anti rusting agent and check
for burrs and dress a necessary.
Taper
308
Preparing The Concave

On flat ground turn the old concave upside down and sit it on 3 pieces of
wood 100mm (4 inch) thick evenly spaced. Sit the new concave on top of the
old one.
If 3 or 4 big blocks are available the concave can be sat directly on top of
them, but ensure the blocks dont stick out beyond the taper.
If the taper on the upperframe looks a little worn a bead of silicon can be put
on the taper to prevent the crusher backing from leaking out.
309
Fitting The Concave
Lift up the upper frame and lower it down onto the new concave.
Guide the upper frame so that the 3 lugs on the concave pass through the 3
pockets in the upper frame.
As soon as the lugs clear the top of the upper frame rotate the upper frame
anti clockwise so that the lugs on the concave are half way between the dowel
hole and pocket.
310
Fitting The Concave
Using a pry bar seat the concave level within the upper frame.
To do this use a tape measure to ensure the distance between the underside of
the lugs and upper frame all the same.
Slide in the three wedges ( from right to left) and the rear edge of the wedge
needs to be about 30 mm (1) before the dowel hole.
If not lift up the upper frame and rotate it. For example if the back of the
wedge has gone beyond the dowel hole the upper frame will need to be
rotated clockwise, or rotate it anti clockwise if the wedge is not near enough
the dowel hole.
311
Fitting The Wedges
Drive in the wedges with a sledge hammer. Ideally with 2 people and a tee
bar.
ALWAYS WEAR SAFETY GLASSES WHEN DOING THIS.
312
Fitting The Wedges
Drive in the wedges so that the back of the wedge just goes beyond the dowel
hole and fit the dowel with anti seize grease.
If the wedge is not tight when it gets to the dowel hole continue to drive it in
until it is tight then weld something to the back of it that butts up to the
dowel.
Dont worry if all three wedges stop in a different position as this is common.
313
Preparing The Cone Head
Clean the whole of the cone head.

Burrs may develop on the bottom of the cone head taper so dress them up
with a sanding disk.
314
Smear the cone head taper with grease.

Smear the rest of the cone head with release agent. If release agent is not
available a thin smear of grease can be used.
Cone head
taper.
315
Smear the rest of the cone head with release agent. If release agent is not
available a thin smear of grease can be used.
A bead of silicon can be placed on the taper to prevent any leakage.
Cone head
Cone head
taper.
316
Preparing The Mantle

Remove the anti rust agent from the mantle taper and any burrs.
317
Lifting The Mantle
The best way to lift up the mantle is to use a set of 3 or4 leg chains and hook
the mantle from the underside.
318
Fitting The Mantle
Lift the mantle and sit it on the cone head.
319
Fitting The Mantle
The mantle will sit on the cone head and trap the hooks. Just Knock out the
hooks with a pry bar.
320
Fitting The Mantle
Re fit the mantle nut and tighten to square up the mantle and squash the
grease on the taper to create a good seal.
Remove the mantle nut and grease the cone head threads.
321
Crusher Backing
Using a drill and a suitable mixing paddle stir up the crusher backing
ensuring to loosen it up in the bottom of the container. Add the hardener and
mix the backing until it is one even colour and texture.
322
Pouring The Backing
Pour the crusher backing between the cone head and mantle until the level is
25mm from the top(1 inch).
DO NOT OVER FILL THE MANLTE AS THIS WILL MAKE IT
DIFFICULT TO BURN ON THE NEXT REMETAL.
Poor any left over backing into one of the concave pockets.
323
Mantle Nut Tightening
Re fit the mantle nut and tighten with the flogging bar in an anti clockwise
direction. Put a chalk mark on the mantle and nut then tighten some more
until the nut has come to a complete stop.
FAILURE TO TIGHTEN THE NUT SUFFICIENTLY WILL RESULT IN
THE NUT COMING LOOSE AND POSSIBLE CONE HEAD DAMAGE.
324
Mantle Nut Tightening
Putting a chalk mark is the best way to judge that the mantle nut has come to
a complete stop.
325
Cylinders Pins And Bearings
Clean up the cylinders and bearings in the upper frame with emery cloth or a
flat wheel. Also clean up the cylinder pins with emery cloth.
326
Wedge Ring Pads
Clean off the wedge ring and brush on a light smear of moly-bentone grease
on the pads and on the wedge ring dust seal.
327
Upper Frame
Clean up the inside of the upper frame where the wedge ring pads run.
Inspect for any burrs and dress accordingly. If the re metals arent very
frequent it may be necessary to clean it with a sanding disk or emery paper to
remove any rust or dust and make it smooth again.
328
Re Fitting The Upper Frame

When re fitting the upper frame ensure that the anti rotation block is inline
with anti rotation stop. Lower the upper frame down slowly until the block
enters the stop otherwise you could rip off one of the stop block fibre pads.
Re fit the cylinder pins with anti seize grease.
329
Pouring The Crusher Backing
Mix the crusher backing one tub at a time and pour it into the 3 pockets of
the upper frame. Fill it up until the backing is about 10mm (3/8) within the
top of the upper frame.
Clean out the stones from the bottom inside lip of the crusher feed chute and
re fit.
Remove the pins from the feed conveyor and lower into the working position.
330
Recharging The Wedgelock Circuit

2. Close valve B and open valve A.
3. Select a css below the actual setting and put the machine into auto. The
upper frame will come down to its setting and then the wedge lock circuit
will charge up with oil pressure.
Wedge ring
pressure
gauge
Valve A
Wedge lock
pressure
gauge
Valve B
331
New Manganese Calibration

When the machine is new or when it has been re-metalled the new
manganese calibration needs to be carried out. This is done as follows 1. Ensure the crusher is not running.Put the machine into manual and close
the machine until the mantle and concave touch. This is indicated by a
sudden rise in pressure on the wedge ring / crushing pressure gauge. Ensure
it is metal to metal and no stones are in the crushing chamber.
2. Scroll down the screen using the down arrow until you get to NEW
MANGANESE.
3. Press enter.
4. Press F4 and it will re-calibrate everything back to zero.
5. Press escape.
6. Scroll back up to current gap / set gap display.
7. Set new closed side setting.
8. The read wear will now be zero.
332
Basic Hydraulic System
333
R/H Side Hydraulic Pump
Two identical pumps are mounted either side of the engine, belt driven from
the engine crankshaft.
This pump supplies oil to the three bank valve.
The oil is drawn through a suction filter into the pump, through an inline
pressure filter and into the three bank valve.
Drive belts
To the 3
bank valve
Pump
Suction
Pressure
Filter
334
Three Bank Valve
The three bank valve is mounted inside the engine Canopy near the pump.
The first section is the feed and return to the valve.
The 1st splice goes to the tracks.
The 2nd splice goes to the product conveyor and HFO clutch. The clutch line
tees into the feed line for the discharge conveyor.
The 3rd splice goes to the crusher adjustment circuit.
To the discharge
conveyor
To the crusher
adjustment
circuit
To the HFO
clutch
To the
R/H track
Feed in
To tank
335
R/H Track
Track cover plate
336
Track Drive
The feed comes in to the Motion Control valve bank and automatically
releases the brake.
The two track motors tee the case drains together before going to tank
The purpose of the cross line check valve is to prevent the machine from
running away on a steep slope or if a pipe bursts
Track feeds
Track Motor
Brake Release
Motor Case Drain
Motion
Control
valve
block
337
Hydraulically Operated Clutch

The feed to the clutch comes through the restrictor valve, then the solenoid
valve and then a relief valve before going to the clutch.
Pressure
switch
Relief
valve
Solenoid
valve
Restrictor
valve
Accumulator
338
H.F.O Clutch Circuit

De energised
With the divertor valve in the off position, the oil comes through the restrictor
valve and dead heads against the divertor valve. The purpose of the orifice
and restrictor valve is to limit the amount of oil flow going through the clutch
circuit.
(334 psi)
(1.3 gal)
(479 psi)
339

Energised
When the divertor valve is energised the spool moves to allow oil to pass
through and go to the clutch. The pressure switch changes over to indicate
good oil pressure and allows the feeder to be started.
The relief valve ensures that 33 bar(479psi) is maintained in the system.
(334 psi)
(1.3 gal)
(479 psi)
340
Product Conveyor Motor
The feed comes in through a check valve and into port B in the motor.
The check valve is fitted to prevent the belt running back if it stops loaded.
The case drain is fitted to prevent any back pressure going to the motor shaft
seal.
Feed Line
(B Port)
Return Line
(A Port)
Check Valve
Case Drain
341
Crusher Hydraulic Adjustment
Pressure in
from the bank
valve
342
L/H Hydraulic Pump

The left hand pump supplies oil to the four bank valve at the back of the
machine.
Pump
case drain
Load
sensing
line
To the
bank
valve
343
Four Bank Valve

The 1st splice goes to the tracks.
The 2nd splice goes to the feed conveyor.
The 3rd splice goes to the feed conveyor raise / lower cylinder.
The 4th splice goes to the lubrication pump motor.
4
Feed in
To tank
344
L/H Track
Track cover plate
345
Feed Conveyor Motor
A check valve is fitted to stop the belt from rolling back when it is stopped
under load either by the milltronics or the metal detector.
Case drain
Return
line
Check
valve
Feed line
346
Feed Conveyor Cylinder
Breather
Single acting cylinder
with a check valve safety
Up
Down
Check valve
Manual operation
347
Hydraulic Motor For Lubrication Pump
Feed
Return
348
Hydraulic System Setup
349
Hydraulic Pump
The hydraulic pump only delivers oil flow on demand, unlike fixed gear
pumps. The standby pressure is set at 30 bar (435psi) and the pump will
deliver a small amount of oil to maintain that pressure. When a function is
operated, the pump detects a pressure drop on the 30 bar (435 psi) and the
swash plate is moved to pump more oil. This happens in a split second. The
system always maintains 30 bar(435psi) more in the pressure line than the
load sensing line.
Case Drain
Load Sensing
Line
Standby
Pressure Relief
30 bar
(435 psi)
Pump Relief Valve

320 bar (4641 psi)
(when test point on
valve bank is used)
350
Hydraulic Pump
When all functions are switched off the pump will de-swash and return to a
low flow maintaining the 30 bar (435psi)stand by pressure.
The pump has its own relief valve set at 320 bar(4641psi). If the pressure
exceeds 320 bar(4641psi), the pump will de-swash, drop to a low flow but
maintain 320 bar(4641psi).
Case Drain
Load Sensing
Line
Standby
Pressure Relief
30 Bar (435psi)
Pump Relief Valve

320 bar (4641 psi)
(when test point on
valve bank is used)
351
Section View - 57 CC/Rev. Full Stroke
Servo Piston
Rotating Kit
Swash plate
Tapered
Roller
Bearing
Tapered
Roller
Bearing
Shaft Seal
Valve Plate
Bias Piston
Piston
352
Swash Plate Operation

Servo Piston
Two piston design.
Bias piston uses system pressure to

hold pump at full stroke.
Servo piston
Three times bias piston area.
The servo piston is the control

piston.
Swash plate
Bias Piston
353
Load Sense Operation Theory
Load Pressure
Control Handle
Valve /Orifice
Flow to
Servo Piston
System Pressure
Pump
354
Load Sensing Circuit

Engine running. No function selected.
M
Port blocked.
0 bar.
CONTROL
Bank valve
VALVE
X PORT
B Port
30 bar (435psi).
BIAS
Remote Port
Stroked to
give 2cc / rev
Bleed Orifice (LB

Control)Plug (LS Control)
M4 Port
L1,L2 Ports
S port
Gain Orifice (Optional)
355

Engine running. Product conveyor selected.
M
55 litres min @ 50 bar (13.2 US gal min @ 725psi)

50 bar (725psi).
CONTROL
Bank
valve
VALVE
X PORT
B Port
80 bar (1160psi).
BIAS
Remote Port
Stroked to
give 31 / rev
Bleed Orifice (LB

M4 Port
L1,L2 Ports
S port
356

Engine running. Tracks selected.
M
90 litres min @ 180 bar (23.7 gal/min @ 2610psi).

180 bar (2610psi).
CONTROL
Bank valve
VALVE
X PORT
B Port
210 bar(3045psi).
BIAS
Remote Port
Stroked to give
50cc / rev
Bleed Orifice (LB

M4 Port
L1,L2 Ports
S port
357

Engine running. Tracks selected + stalled
LOAD
PC SETPOINT
3 litres
min AT
@ 290
bar (1 gal/min
MLS WITH
@ 4205psi)
290 bar(4205psi)
CONTROL
Bank valve
VALVE
X PORT
B Port
320 bar (4640psi).
BIAS
Stroked to give
2cc / rev
Bleed Orifice (LB

M4 Port
L1,L2 Ports
S port
358
Three Bank Valve 2550-9010

The three bank valve has a main relief valve set at 350 bar (5076psi). This is a
last line relief to protect the pump should the pump relief not respond quick
enough. The product conveyor LS relief is set at 210 bar (3046psi)
The hydraulic pressure in the system can be taken from a test point on the
bank valve. On the 4 bank valve when there are two circuits are working at
once, the pressure gauge will only read the highest of the two, not a
combination of the two.
System Test
Point
Product
conveyor relief
210 bar
(3046 psi)
Main
pressure
relief
350 bar
(5076psi)
359
System Test Point

Any pressure registered from the test point is inclusive of the standby
pressure.
So if the pressure registered from the test point was 80 bar(1160psi) with the
product conveyor running the actual pressure in the product conveyor feed
line would be 50 bar (725psi).
System Test
Point
360
HFO Clutch Circuit

Where the HFO clutch line tees into the product conveyor line a 1mm
(0.04)orifice is fitted inside one of the hydraulic fittings to reduce the oil flow.
The needle valve is used to accurately set the oil flow for the clutch
engagement.
With the orifice fitted if somebody unscrews the needle valve too much it
shouldnt stop the product conveyor.
1mm(0.04) orifice
Needle valve
361

De energised
With the divertor valve in the off position, the oil comes through the restrictor
valve and dead heads against the divertor valve. The purpose of the orifice
and restrictor valve is to limit the amount of oil flow going through the clutch
circuit.
(334 psi)
(1.3 gal)
(479 psi)
362

Energised
When the divertor valve is energised the spool moves to allow oil to pass
through and go to the clutch. The pressure switch changes over to indicate
good oil pressure and allows the feeder to be started.
The relief valve ensures that 33 bar(479psi) is maintained in the system.
(334 psi)
(1.3 gal)
(479 psi)
363
3 Bank Valve Reliefs (2550-9010)

The track splice doesnt have a relief valve built into it. The pump will de-swash
or it will relieve through the main bank valve if the pressure gets too high.
The main bank valve relief is set at 350 bar (5076psi)
The product conveyor is set at 210 bar (3045psi)
The crusher adjustment is set to 200 bar (2900psi)
Relief Valve
210 Bar
3045psi
Main Bank
Valve Relief
350 Bar
5076psi
Track
Crusher
adjustment
Product
conveyor
Relief Valve
200 Bar
2900psi
364
4 Bank Valve Reliefs (2550-9046)

No relief fitted to the track splice.
The main bank valve relief is set at 350 bar (5076psi)
The feed conveyor is set at 180 bar (2610psi)
The feed conveyor folds are set at 100 bar (1450psi)
The lubrication motor is set at 140 bar (2030psi)
Feed
conveyor
Track
fold
Lubrication
Feed
motor
conveyor
Main Bank
Valve Relief
(350 Bar)
(5076psi)
180 bar
(2610psi)
100 bar
(1450psi)
140 bar
(2030psi)
365
Approximate Bank Valve Voltages with 24 Vdc supply

Tracks
Earth Pin to Pin 2
Reverse Low Speed 16v
Feed conveyor
Earth Pin to Pin 2
5-10v
Lubrication motor
Earth to Pin1 = 24v
Reverse High Speed 19v

Forwards Low Speed 8v
Forwards High Speed 5v
Track
Feed
conveyor
Lubrication
motor
366
Actuator Pins
Pin 1 is the supply voltage into the actuator.
Pin2 is the variable voltage into the actuator which controls the spool
direction and spool travel for variable oil flow.
None of the pins receive any voltage until a track button is pressed.
Earth.
Pin 1.
Pin 2.
367
Actuator Pins
There are only 2 wires used on the on / off type actuator.
Pin 1 receives 24 volts which moves the lever up which pressurises out of the
bottom port. (as the valve is shown)
Earth.
Pin 1
24 volt
368
Spool Travel with 24 Vdc supply voltage
Max spool
travel
No spool travel
Max spool
travel
Max flow
19 volts
no flow
12 volts
Max flow
5 volts
Lever travels down to

pressurise out of the
bottom port. (as the
valve is mounted)
Lever travels up to
pressurise out of the
top port. (as the
valve is mounted)
369
Full Speed Voltages
Feed conveyor Actuator Requires 25% Of Battery Voltage To

Obtain Full Speed.
Example
24 Volts x 25 % =6 Volts
Track Actuators Require 25 % Or 75 % Of Battery Voltage Depending On
Spool Direction
In the event of a feeder speed control switch failure, a link wire between
the supply voltage and the variable voltage on the Hirschman plug will
give full speed.
370
Actuator Identification
Three types of actuator are fitted to the bank valves. The track and feed
conveyor actuator look the same but are different. The feed conveyor actuator
is more sensitive and can move the spool more gradually for a wider range of
oil flows. The feeder actuator can also be identified by an LED. The track and
feed conveyor work on a variable voltage where as the others are 24 volt on or
off.
The LED should be illuminated green when the feed conveyor is operating.
LED
Motor
circuits
Track
Feed
conveyor
PVEM
PVEH
Lubrication
motor
157B4228
Feed conveyor
Number
157B4088
Track Number
157B4128
371
PVEM/PVEH
+8
+6
+4
+2
-2
-4
P tank: 8 bar
U DC : 24 V
Freq: 0,02 Hz
-6
-8
372
Actuator Operation
Closed loop control of the main spool
Pilot-oil
Electronics
Valves
Electronic sender
unit
Locator pin
373
Actuator Operation
O rings
Locator pin
374
Body Identification
All of the splices in the bank can be identified by the numbers on the bottom.
Track body number 6000
Inlet body number 5111
All other body numbers 6203
All of the end caps are the same.
The only difference between the track body and the other bodies are the relief
valves.
5111
Engraved
numbers
6000
6203
6203
6203
End cap
Inlet
375
Spool Sizes on Four bank Valve 2550-9046

The oil flow through each splice depends on the size of the spool fitted.
The spools should move smoothly in the body.
The spool can be removed by unscrewing the four allen bolts from the
aluminium cover and removing. The spool can then be pulled out. Oil loss can
be reduced by blanking off the feed and return pipes to the bank valve.
Tracks 100 l/min

(26.4 US gal)
Lubrication motor 15
l/min (3.9 US gal)
Feed conveyor 75
l/min (19.8 US gal)
Spool
Removal
Feed conveyor
fold 25 l/min (6.6
US gal)
376
Spool Sizes on Three Bank Valve 2550-9010
Crusher
adjustment
Track
Product
conveyor
Tracks 100 l/min

(26.4 US gal)
Product
conveyor
100
26.3 US gal
Crusher
adjustment
4
1.05 US gal
377
Spool Sizes
The size of the oil groove in the spool determines the oil flow.
The bigger the groove the greater the flow.
The spool size can be identified by the Danfoss number etched into the end of
it.
378
PVG32 Bank Valve Cross Section
The pressure compensator ensures the the valve delivers a constant oil flow
regardless of the working pressure.
Spool
Pressure
compensator
379
Spool Direction
The direction of the spool determines which port is pressure and which is the
return.
Tank
Pressure
Load
sensing
380
Spool Travel Limit Screws

The limit screws are used to restrict the spool movement to control the
amount of oil flow to set up the correct speeds.
Note. When fitting a new Valve block the limited screws are set to give
maximum flow, therefore need to be adjusted to give the correct speed.
If the limit screw is less than 13mm(1 /2) from the tip of the screw to the
valve body, it means that the spool is being restricted (or 8mm from the tip of
the screw to the top of the nut
The arrows below show the top

screw restricts the travel to the
right and the bottom screw
restricts it to the left
8mm (5/16)
13mm (1/2)
381
Hydraulic Schematic Drawing AX860-193-601 issue 6
382
Motion Control Valve
383
Motion Control Valve Working
Track Brakes
= Pressure
= Blue Return
= Case Drain
The pressure comes into

the system and sends a
pressure down to the
brake release which
releases the brake.
It also sends a pilot
pressure across the X-line
check to allow the return
oil to flow back to tank.
384
1300 Final Test Sheet Form 214 Iss 10
385
Electrical System
386
Cantrak
display
screen.
Hycontrol
display
screen.
PLC
display
screen.
387
PLC Fault Screens
388
PLC Fault Screens
389
PLC Fault Screens
390
Allen Bradley Display Screen Language change
Language Screen Selection

Pressing the Down arrow key on any
screen, enters Language selection Menu.
Use the Up and Down arrows to select
the desired language, then press the
Enter key to except the language change.
Press F1 key to escape back to the
normal display screen.
Note. Should the screen be left displaying
the Language Menu Screen, it will
automatically return to the normal display
screen if not touched for 60 seconds.
391
Maxtrak Electrical Panel

Hycontrol
Wiring diagram number

Display
Screen
Contact
blocks
Potentiometer, feed
belt speed control
392
Maxtrak Start Up Panel C13 Tier 3 MK17

Circuit Breaker (MCB)
and identification
Relays and
Identification
Timer
PLC
24 Volt DC
to DC
Converter
Radio
Control
393
Maxtrak PLC C13 Tier 3 MK17

All of the inputs are numbered from 1 to 15. When an input or output is
energised an LED will illuminate below the input / output number.
The inputs appear in order on the electrical drawings.
Expansion D.C
Expansion D.C
Inputs. I:1/0-1/15
Inputs. I:2/0-2/15
Embedded
D.C Inputs.
I:0/0-0/15
Expansion D.C
Outputs.O/12-O/19
Embedded
D.C Outputs.
O/0-O/11
LEDs
394
PLC Lights Maxtrak MK17

If the fault light is flashing on the PLC the display screen usually displays an
emergency stop fault but the engine can be started.
There are a couple of checks to carry our if this is the case.
If the fault light is lit permanently lit a new PLC is required.
Power light should be on

(green)
* fault light should be off *
Run light
should be on
(green)
Comm 0 light should flashing green
395
PLC Processor
To remove the processor push the retaining clip to the left and at the same
time slide the whole of the processor to the left.
Blow out the pins in the PLC and processor to remove any dust then refit.
Retaining clip
396
Maxtrak PLC
Open in plastic cover on the left hand side of the PLC to reveal the run rem
prog switch.
Cover
397
MAXTRAK PLC
Switch on the ignition and let the PLC boot up

Push the switch from the run position to the prog. Wait for 3 seconds and
put back into the run position. The fault light should now be off.
Switch
398
Input Output Locks
If the fault light is still flashing

there are locking clips that hold
the input / output cards together.
They should be pushed fully to the
left to be in the locked position.
If one of the clips unlocks the card
and cards to the right of it will go
dead and the fault light will flash
on the PLC.
Unlock all of the clips, blow out
any dust and lock in position.
The run rem prog procedure will
need to be carried out again.
399
PLC Battery
The PLC has its own battery to ensure that there is always a power supply.
This battery should last 3 or 4 years.
When it does start to go flat the PLC screen will display PLC Battery low.
The replacement battery will have a cable connected to it so that it is plugged
into the spare battery holder and then plugged into the PLC.
Only then can the original battery be removed.
Spare battery
400
Automax Adjustment Panel Electrics
PLC
Relays
Fuses
Spare Fuses
Layout
Diagram
401
Maxtrak 100309 issue 2

Paktronic (Horner) PLC out of Run mode1300
due
to low
supply voltage (5 volts dc)
OK light Lit
Run Light
OFF
Screen 1
NOT USED
402

due
to low
Press the SYSTEM buttons (Up/Down buttons)

simultaneously, this will enter the programme
403

due
to low
Paktronic screen will display

>Set Contract
View OCS Status
Press the down arrow
404

due
to low

Set Contract
>View OCS Status
Press the Enter button.
405

due
to low

>OCS Mode: Idle
Scan-Rate: 0.0 mS
Press down arrow.
406

>OCS Mode: Run
Scan-Rate: 0.0 mS
Press Esc button.
Paktronic is now in Run Mode and the plant can be operated

407
Kobold Sensors
If the Kobold is giving a low flow signal, remove both gears and clean the two
sensors which are fitted to the gear which is fitted opposite the circuit board.
Clean the teeth on both gears.
408
409

1300 Maxtrak

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1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

Health and Safety aspects,

Application of the Regulations

1300 Maxtrak 100309 issue 2

Application of the Regulations

Personal Protective Equipment

1300 Maxtrak 100309 issue 2

Personal protective Equipment for Customers, Suppliers and Visitors

1300 Maxtrak 100309 issue 2

Personal Protective Equipment for Employees

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

Hand Protection - Gloves giving a level of

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

Tinted glass or Speedglass (electronic polarising action)

1300 Maxtrak 100309 issue 2

Half mask respirators should be worn when

1300 Maxtrak 100309 issue 2

Helmets must be worn by operators and onlookers.

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

properly stored in a well-defined place;

checked at suitable intervals; and

when discovered to be defective, repaired or replaced before further use.

Personal protective equipment which may be contaminated by a substance hazardous to health

1300 Maxtrak 100309 issue 2

It is the engineer responsibility to

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

Starting and Tracking Plant

1300 Maxtrak 100309 issue 2

Control Panel and Starting

Battery Isolator Switch

1300 Maxtrak 100309 issue 2

C13 Tier 3 Engine Start Panel with Hycontrol

1300 Maxtrak 100309 issue 2

Main Control Panel

1300 Maxtrak 100309 issue 2

Main Control Panel

Warning (Alert) lamp, the Warning

The Shut down

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

1300 Maxtrak 100309 issue 2

Engine checks before starting

Engine checks before starting (Daily checks)

Check engine oil level.

1300 Maxtrak 100309 issue 2

Starting Engine and tracking with the 860 Remote Control

Switch selector switch to Remote.

Note. If any of the buttons are pressed before the

1300 Maxtrak 100309 issue 2

Starting Engine and tracking with the 860 Remote Control

With the Isolator switch turned ON.

1300 Maxtrak 100309 issue 2

Starting Engine and tracking with the 860 Remote Control

Press button No 9 to put

1300 Maxtrak 100309 issue 2

Starting Engine and tracking with the Umbilical Control

To use the Umbilical control. Do not power