1300 Maxtrak Manual Parts

ADVANCED CRUSHING TECHNOLOGY
MAXTRAK 1300
PLANT USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
! SAFETY !
This manual contains safety information which the operator should read and follow.
Failure to do this will increase the risk of injury or may result in death.
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IMPORTANT
TEREX PEGSON PLANTS CAN INCLUDE
OPTIONAL EQUIPMENT AND/OR SPECIAL
FEATURES ADDITIONAL TO THE
STANDARD SPECIFICATION.
THESE MAY AFFECT THE INFORMATION
GIVEN IN THIS OPERATORS MANUAL.
LOOK IN SECTION 11 - APPENDIX OF THIS
MANUAL FOR ANY ADDENDUM WHICH
MAY RELATE TO ADDITIONAL EQUIPMENT
OR VARIATIONS TO THE STANDARD
SPECIFICATION.
TAKE NOTE OF ANY VARIATIONS TO THE
STANDARD PROCEDURES AND/OR
COMPONENT SPECIFICATIONS.
Options EN
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IMPORTANT SAFETY NOTICE!

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

If you need any information or advice regarding your Maxtrak, contact:-
Terex Pegson Limited

Mammoth Street
Coalville
Leicestershire LE67 3GN
England
Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : sales@bl-pegson.com
or your local Distributor :-
Terex Crushing & Screening Inc.

11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.
Telephone : +1 502 267 2314, Fax : +1 502 267 2317
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EC Conformity
This plant is in conformity with the provisions

of the EC Machinery Directive 98/37/EC
together with appropriate EN Harmonised
Standards and National BS Standards and
Specifications.
Noise Level
HEARING HAZARD
EXCEEDS 90 dB (A)
May cause loss or degradation of hearing

over a period of time.
Wear proper hearing personal protective

equipment.
Dust Generation
INHALATION HAZARD
Death, serious injury or delayed lung disease

may result from breathing dusts that are generated
when certain hazardous materials are crushed,
screened or conveyed with this equipment.
When dusts are generated by the operation of this

equipment, use approved respiratory protection, as
required by Federal, State and Local safety and
health regulations.
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Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are approximate
conversions from the actual metric measurement of the item concerned.
CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Proposition 65 Warning
WARNING: Battery Posts, terminals and
related accessories contain lead and lead WARNING: Diesel engine exhaust and
compounds, chemicals known to the State some of its constituents are known to the
of California to cause cancer and State of California to cause cancer, birth
reproductive harm. defects, and other reproductive harm.
WASH HANDS AFTER HANDLING.
Copyright
The copyright of this User Manual is reserved by BL-Pegson Limited.
This User Manual contains information and technical drawings, which may not be copied, distributed,
altered, stored on electronic media, revealed to others or used for the purpose of competition, either partially
or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright 2004.
Terex Pegson Limited

Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax:- + 44 1530 518618
E mail sales@bl-pegson.com
To order additional copies contact your local Terex Pegson Ltd Dealer.
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Maxtrak 1300
1 - Safety EN
Page 1 - 1
1 - Safety
1.1 Warnings and Symbols .................................................................................. 1 - 2
1.2 Organisation Measures .................................................................................. 1 - 2
1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4
1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 4

1.4.1 Standard Operation .................................................................................... 1 - 4
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ................ 1 - 4
1.5 Warning of Special Dangers .......................................................................... 1 - 8
1.5.1 Electric Energy ........................................................................................... 1 - 8
1.5.2 Gas, Dust, Steam, Smoke and Noise ......................................................... 1 - 8
1.5.3 Hydraulic and Pneumatic Equipment ........................................................ 1 - 10
1.5.4 Hazardous Substances ............................................................................ 1 - 10
1.6 Transporting, Manoeuvring and Recommissioning .................................. 1 - 10
1.7 Position of Emergency Stop Buttons ......................................................... 1 - 13
1.8 Safety Signs .................................................................................................. 1 - 14

1.8.1 Location of Safety Signs .......................................................................... 1 - 14
1.8.2 Safety Sign Illustrations............................................................................ 1 - 16
1.8.2 Safety Sign Illustrations, continued ........................................................... 1 - 16
Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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1.1 Warnings and Symbols
The following signs and designations are used in the manual to designate instructions of particular
importance.
!!
This is the safety alert symbol. When you see this symbol on your plant
or in this manual, be alert to the potential for personal injury or
equipment damage.
Follow the recommended precautions and safe operating practices.
! DANGER !
Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
! WARNING !
Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury.
! CAUTION !
Indicates a potentially hazardous situation which, if not avoided, MAY
result in minor or moderate injury. It may also be used to alert against
unsafe working practices.
! NOTICE !
Indicates a statement of company policy as the message relates directly
or indirectly to the safety of personnel and protection of property.
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1.2 Organisation Measures 1.2.2

You can be injured if you do not obey the
1.2.1 safety instructions as indicated on warning
Ascertain from the appropriate Authority and stickers.
observe all statutory and any other
regulations that may apply to the planned Observe all safety instructions and warnings
location before operating the Maxtrak Plant. attached to the plant.
Loose or baggy clothing can get caught in See to it that safety instructions and
running machinery. warnings attached to the plant are always
complete and perfectly legible.
Where possible when working close to
engines or machinery, only do so when they Keep warnings and instruction labels clean.
are stopped. If this is not practical,
remember to keep tools, test equipment and Replace unreadable or missing labels with
all other parts of your body well away from new ones before operating the plant. Make
the moving parts. sure replacement parts include warning or
instruction labels where necessary.
For reasons of safety, long hair must be tied
back or otherwise secured, garments must 1.2.3
be close fitting and no jewellery such as
Understand service procedure before doing
rings may be worn. Injury may result from
work. Keep area clean and dry.
being caught up in the machinery or from
rings catching on moving parts.
Never lubricate, clean, service or adjust
machinery while it is moving. Keep hands,
Always wear correctly fitting (EN/ANSI
feet and clothing clear of power driven parts
approved) personal protective equipment.
and in running nip-points. Disengage all
power and operate controls to relieve
Personal Protective Equipment includes
pressure. Stop the engine. Implement lockout
Hard Hat, Safety Glasses, Hearing
procedure. Allow the machinery to cool.
Protection, Dust Mask, Close fitting
Overalls, Steel Toed Boots, Industrial Gloves
Keep all parts in good condition. Ensure that
and a High Visibility Vest.
all parts are properly installed. Fix damage
immediately. Replace worn and broken
parts. Remove any build up of grease, oil and
debris.
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Disconnect battery ground cable before 1.3 Selection and

making adjustments on electrical systems or
Qualification of Personnel -
welding on plant.
Basic Responsibilities
For the execution of maintenance work, tools
and workshop equipment adapted to the task 1.3.1
on hand are absolutely indispensable.
Any work on and/or with the plant must be
executed by trained, reliable and authorised
1.2.4 personnel only. Statutory minimum age limits
Never make any modifications, additions or must be observed.
conversions which might affect safety
without the suppliers approval. 1.3.2
Work on electrical system and equipment of
In the event of safety relevant modifications
the plant must be carried out only by a skilled
or changes in the behaviour of the plant
electrician or by instructed persons under the
during operation, stop the plant and lock out
supervision and guidance of a skilled
immediately and report the malfunction to
electrician and in accordance with electrical
the competent authority/person.
engineering rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
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1.4 Safety Instructions 1.4.1.4

Governing Specific Return idler roller guards should be checked
Operational Phases for wear/damage during routine
maintenance.
1.4.1 Standard Operation
The gap between the guard and the idler
1.4.1.1 roller should not exceed 6mm. The gap
between the guard and the conveyor belt
Take the necessary precautions to ensure
should also not exceed 6mm.
that the plant is used only when in a safe and
reliable state.
If these gaps cannot be achieved through
adjustment the guard must be renewed.
Operate the plant only for its designed
Contact your local BL-Pegson dealer to
purpose and only if all guarding, protective
obtain an approved replacement.
and safety orientated devices, emergency
shut-off equipment, sound proofing elements
and exhausts, are in all place and fully
functional.
1.4.2 Special Work In Conjunction
with Utilisation of the Plant and
Before starting the engine ensure it is safe to Maintenance and Repairs During
do so. Operation; Disposal of Parts and
Consumables
1.4.1.2
1.4.2.1
In the event of material blockage, any
Observe the adjusting, maintenance and
malfunction or operational difficulty, stop the
intervals set out in these operating
plant immediately and lockout. Have any
instructions, except where:
defects rectified immediately.
A : Warning, horn/light/gauge or indicator
1.4.1.3 calls for immediate action.
In-running nip points on moving machinery
can cause serious injury or even death. B : Adverse conditions necessitate more
frequent servicing.
Do not reach into unguarded machinery.
Your arm could be pulled in and amputated. Observe information on the replacement of
parts and equipment. These activities may be
Switch off and lockout the plant before executed by skilled personnel only.
removing any safety devices or guarding.
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Page 1 - 6
1.4.2.2 1.4.2.5
When the plant is completely shutdown for Falling from and/or onto a BL-Pegson plant
maintenance and repair work, it must be can cause injury or even death.
secured against inadvertent starting by:
Do not climb on the plant whilst it is in
Switching off the engine and remove the operation. Never use plant parts as a
ignition switch/key. climbing aid.
Implementing the lockout procedure. Beware of moving haulage and loading

equipment in the vicinity of the plant.
Attaching a warning sign(s) to the plant
in appropriate positions. For carrying out overhead assembly work
always use specially designed or otherwise
1.4.2.3 safety-oriented ladders and working
platforms.
Carry out maintenance and repair work only
if the plant is positioned on stable and level Always use any walkway/platforms provided
ground and has been secured against or a safe and secure platform approved by the
inadvertent movement and buckling. regional safety enforcing authority.
1.4.2.4 Always use an EN/ANSI approved safety

harness when reaching any points 7ft (2m)
Never allow unqualified or untrained
or more above the ground level.
personnel to attempt to remove or replace
any part of the plant, or anyone to remove
large or heavy components without adequate Keep all handles, steps, handrails, platforms,
lifting tackle. landing and ladders free from dirt, oil, snow
and ice.
To avoid the risk of accidents, individual
parts and large assemblies being moved for 1.4.2.6
replacement purposes should be carefully The fastening of loads and instructing of
attached to lifting tackle and secured. Use crane operators should be entrusted to
only suitable and technically adequate lifting experienced persons only. The marshaller
gear. giving the instructions must be within sight or
sound of the operator.
Never work or stand under suspended loads.
Keep away from the feed hopper and

product conveyor discharge, where there is
risk of serious injury or death due to the
loading and removal of material.
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1.4.2.7 1.4.2.10
After cleaning, examine all fuel, lubricant, Always ensure that any safety fitment such
and hydraulic fluid lines for leaks, loose as locking wedges, securing chains, bars or
connections, chafe marks and damage. Any struts are utilised as indicated in these
defects found must be rectified without operating instructions.
delay.
Particularly make sure that any part of the
1.4.2.8 plant raised for any reason is prevented from
falling by securing in a safe reliable manner.
Any safety devices removed for setup,
maintenance or repair purposes must be Never work under unsupported equipment.
refitted and checked immediately upon
completion of the maintenance and repair Never work alone.
work to ensure full working order.
1.4.2.11
1.4.2.9
Diesel fuel is highly flammable.
Improperly disposing of waste can threaten
the environment and ecology. Potentially
Never remove the filler cap, or refuel, with
harmful waste used with BL-Pegson
the engine running.
equipment includes such items as oil, fuel,
coolant, filters and batteries, etc.
Never add gasoline or any other fuels mixed
to diesel because of increased fire or
Use leakproof containers when draining
explosion risks.
fluids. Do not use food or beverage
containers that may mislead someone into
Do not carry out maintenance on the fuel
drinking from them.
system near naked lights or sources of
sparks, such as welding equipment or whilst
Do not pour waste onto the ground, down a
smoking.
drain or into any water source.
1.4.2.12
Ensure that all consumables and replaced
parts are disposed of safely and with Using unapproved structures i.e. walkways/
minimum environmental impact. platforms etc. in the vicinity of a BL-Pegson
plant is very dangerous and could lead to
serious injury or even death through falling
and/or entanglement with the plant.
Do not use any unauthorised structures.
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1.5 Warning of Special 1.5.1.4

Dangers Work on the electrical system or equipment
may only be carried out by a skilled and
1.5.1 Electric Energy qualified electrician or by specially instructed
personnel under the control and supervision
1.5.1.1 of such an electrician and in accordance
Use only original fuses with the specified with applicable electrical engineering rules.
current rating. Switch off the plant
immediately if trouble occurs in the electrical 1.5.1.5
system.
If provided for in the regulations, the power
supply to parts of plants and plants, on which
Plants with high voltage electrical equipment inspection, maintenance and repair work is to
must be suitably earth bonded by a qualified be carried out must be cut off. Before
electrician prior to activating the main starting any work, check the de-energized
isolator switch. parts for presence of power and ground or
short circuit them in addition to insulating
1.5.1.2 adjacent live parts and elements.
When working with the plant, maintain a
safe distance from overhead electric lines. If 1.5.1.6
work is to be carried out close to overhead The electrical equipment of the plant is to be
lines, the working equipment must be kept inspected and checked at regular intervals.
well away from them. Check out the Defects such as loose connections or
prescribed safety distances. scorched or otherwise damaged cables must
be rectified immediately.
1.5.1.3
If your plant comes into contact with a live 1.5.1.7
wire: Necessary work on live parts and elements
must be carried out only in the presence of a
Warn others against approaching and second person, who can cut off the power
touching the plant. supply in the case of danger by actuating the
emergency shut off or main power switch.
Have the live wire de-energized. Secure the working area with a red and
white safety chain and a warning sign. Use
insulated tools only.
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1.5.1.8 1.5.2 Gas, Dust, Steam, Smoke and

Noise
Before starting work on high voltage
assemblies and after cutting out the power 1.5.2.1
supply, the feeder cable must be grounded
and components such as capacitors short- Always operate internal combustion engines
circuited with a grounding rod. and fuel operated heating systems only out
of doors or in a well ventilated area. Before
1.5.1.9 starting the plant in enclosed areas, make
sure that there is sufficient ventilation.
These plants are wired on negative earth.
Always observe correct polarity. Observe the regulations in force at the
respective site.
Always disconnect battery leads before
carrying out any maintenance to the Dust found on the plant or produced during
electrical system. work on the plant should be removed by
extraction, not blowing.
The battery contains sulphuric acid, an
electrolyte which can cause severe burns Dust waste should be dampened, placed in a
and produce explosive gases. sealed container and marked, to ensure safe
disposal.
Avoid contact with the skin, eyes or clothing.
1.5.2.2
Carry out welding, flame cutting and grinding
work on the plant only if this has been
expressly authorised, as there may be a risk
of explosion and fire.
1.5.2.3
Before carrying out welding, flame cutting
and grinding operations, clean the plant and
its surroundings from dust and other
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
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1.5.2.4 1.5.3 Hydraulic and Pneumatic

Equipment
Always ensure that the operator(s) are
provided with hearing protection of approved 1.5.3.1
pattern and that these are worn at all times
when the plant is operating. Work on hydraulic equipment may be carried
out only by persons having special
Ensure operators wear a suitable face mask knowledge and experience in hydraulic
where exposed to possible harmful effects of systems.
air pollution of any kind.
1.5.3.2
Check all lines, hoses and screwed
connections regularly for leaks and obvious
damage. Repair damage immediately.
Splashed oil may cause injury and fire.
1.5.3.3
Depressurise all system sections and
pressure pipes (hydraulic system,
compressed air system) to be removed in
accordance with the specific instructions for
the unit concerned before carrying out any
repair work.
1.5.3.4
Hydraulic and compressed air lines must be
laid and fitted properly. Ensure that no
connections are interchanged. The fittings,
lengths and quality of the hoses must comply
with the technical requirements.
1.5.3.5
Always practice extreme cleanliness
servicing hydraulic components.
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1.5.3.6 1.6 Transporting,

Hydraulic fluid under pressure can penetrate Manoeuvring and
the skin causing serious injury. Recommissioning
If fluid is injected under the skin, it must be 1.6.1
surgically removed or gangrene will result.
Get medical help immediately. The plant must be towed, loaded and
transported only in accordance with the
Always relieve pressure from the hydraulic operating instructions.
system before carrying out any kind of
maintenance or adjustment. 1.6.2
For towing the plant, observe the prescribed
Always use a piece of cardboard to check
transport position, admissible speed and
for leaks. Do not use your hand.
itinerary.
1.5.4 Hazardous Substances
1.6.3
Ensure that correct procedures are
Use only appropriate means of transport and
formulated to safely handle hazardous
lifting gear where applicable of adequate
materials by correct identification, labelling,
capacity.
storage, use and disposal, all strictly in
accordance with the manufacturers
instructions and that all applicable regulations 1.6.4
are observed at all times. The recommissioning procedure must be
strictly in accordance with the operating
instructions.
1.6.5
Before starting work or travelling with the
plant, check that the braking, and any
signalling and lighting systems are fully
functional.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.
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1.6.7 1.6.12
When travelling on public roads, ways and Explosive separation of a tyre and rim parts
places, always observe the valid traffic can cause injury or death.
regulations and, if necessary, ensure
beforehand that the plant is in a condition Do not attempt to mount a tyre unless you
compatible with these regulations. have the proper equipment to perform the
job.
1.6.8
Always maintain the correct pressure. Do
In conditions of poor visibility and after dark, not inflate the tyre above the recommended
always switch on the lighting system of the pressure. Never weld or heat wheel and tyre
transporting vehicle.. assembly. The heat can cause an increase in
air pressure resulting in a tyre explosion.
1.6.9 Welding can structurally weaken or deform
the wheel.
When crossing underpasses, bridges and
tunnels or when passing under overhead
lines always make sure that there is When inflating tyres, use a clip-on chuck and
sufficient clearance. extension hose long enough to allow you to
stand to one side and not in front or over the
assembly. Use safety cage if available.
1.6.10
Never travel across slopes; always keep the Check wheels for low pressure, cuts,
working equipment and the load close to the bubbles, damaged rims or missing lug bolts
ground, especially when travelling downhill. and nuts.
1.6.11
On sloping terrain, always adapt your
travelling speed to the relevant ground
conditions. Never change to a lower gear on
a slope. Always change gear before
reaching a slope.
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1.7 Position of Emergency Stop

Buttons
Emergency Stop Button Emergency Stop Button
Emergency Stop Button
Emergency Stop Button Emergency Stop Button

(Control Panel)
Figure 1a Emergency Stop Buttons
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1.8 Safety Signs
1.8.1 Location of Safety Signs Maxtrak 1300
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Figure
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Maxtrak 1300
1 - Safety EN
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Figure 1c Warning Signs - Right Hand Side

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1.8.2 Safety Sign Illustrations
1 2 3 6
7 8 9 10
13 14 15 17
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1.8.2 Safety Sign Illustrations, continued
21 27
19 23
11 20
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2 - Technical Information EN
Page 2 - 1
2 - Technical Information
2.1 Dimensions and Weights ............................................................................... 2 - 2
2.2 Plant Description ............................................................................................ 2 - 3
2.3 Belt Feeder Conveyor .................................................................................... 2 - 4
2.4 Crusher ........................................................................................................... 2 - 4
2.5 Discharge Conveyor ...................................................................................... 2 - 4
2.6 Standard Powerpack ...................................................................................... 2 - 5
2.7 Controls ........................................................................................................... 2 - 5
2.8 Dustsprays ...................................................................................................... 2 - 5
2.9 Tracks .............................................................................................................. 2 - 5
2.10 Optional Extras * ........................................................................................... 2 - 6
Terex Pegson Limited have designed and built the Maxtrak plant to provide the
Buyer with a range of equipment choices to meet a wide variety of individual needs
and preferences as selected at the time of initial purchase.
Please note that the asterisk * in the text of this User Manual signifies:
Not included in all plants - only appropriate if the item is fitted.
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(11- 2)
(10- 6)
(12- 6)
3197 Feed Height

3810 Travel Height
3407 Disch. Height
4546 Working 3782 7669

(14- 11) (12- 5) (25- 2)
2.1 Dimensions and Weights
All dimensions are in millimetres (feet/inches)
Overall Travelling Length (Feed Conveyor lowered) - 15866 (52- 1)

Overall Working Length (Feed Conveyor raised) - 15997 (52- 6)
Overall Travelling Height (Feed Conveyor lowered) - 3810 (12- 6)
** 2788 Hopper Width
Overall Working Height (Feed Conveyor raised) - 4830 (15- 10) (9- 2)
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Overall Width - Travelling & Working (Over Tracks) - 3000 (9-10)
** This dimension can only be achieved by lowering the Automax Upper Frame to
2 - Technical Information
the maximum extent when preparing for transportation - Refer to Section 5.2.5
Gross Weight approx. - 45.8 tonne (50.4 US. tons)

(15- 10)
4830 Working Height
Note: Weights and dimensions are for guidance only and appropriate allowances should be
applied when being used for transportation purposes and do not include option feed hopper
EN
extension plates.
Page 2 - 2
Maxtrak 1300
Figure 2a Dimensions and Weights 3000

(9- 11)
Maxtrak 1300
Page 2 - 3
2.2 Plant Description

Many of the terms used in this manual may not at first be obvious. Figure 2b identifies the main areas
of the plant and the term with which they are referred to in this manual.
Discharge Diesel Crusher Maintenance Feed

Conveyor Engine Feed Box Platform Hopper
FRONT
LEFT HAND SIDE REAR
Plant/Automax Maintenance Automax

Control Panel Platform Crusher
Feeder Hydraulic
Conveyor Reservoir
FRONT
REAR
Tracks
RIGHT HAND SIDE
Maintenance Hydraulic Tool Box

Platform Oil Cooler
Figure 2b Plant Terms
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2.3 Belt Feeder Conveyor

Type Shallow troughed plain belt.
Width 1300mm (51).
Length 5400mm. (17- 9)
Drive Unit Hydraulic motor with head drum gearbox
Lubrication Oil for drum gearbox and grease for shaft bearings
Control Auto/manual variable speed.
Hopper Fixed hopper with internal strickle gate and full length
barge boards with wear pads.
Hydraulic Equipment Ram to raise and lower for travel and maintenance.
Control Equipment Metal detector. Level sensor an optional extra.
2.4 Crusher
Type Automax roller bearing Cone Crusher.
Size 1300mm. (51)
Liners Manganese mantle and concave.
Adjustment/Controls Hydraulic setting adjustment, automatic overload release
and unblocking with multi-function keypad and status
display screen. (see also 2.7 - Controls).
Lubrication Separate lubricating oil tank with air blast oil cooler.
Drive Vee rope drive from engine via hydraulically controlled
clutch.
Control Equipment High level sensor over the feed box.
2.5 Discharge Conveyor

Type Plain troughed belt.
Width 1000mm. (39)
Drive Hydraulic motor.
Lubrication Grease (shaft bearings).
Enclosure Canvas cover.
Control equipment Tail drum movement sensor.
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Maxtrak 1300
Page 2 - 5
2.6 Standard Powerpack

Type Caterpillar C12 EPA/CARB Emmissions Regulations
compliant, 6 cyl. water cooled diesel engine.
Rating 425hp @ 1800 rpm.
Drives Hydraulically actuated heavy duty clutch and vee ropes to
crusher with vee belts to twin hydraulic pumps.
Housing Enclosed canopy with integral fuel tank and battery.
2.7 Controls
Automax Crusher Setting, etc. 24 v DC Electro/Hydraulic Panel having numeric
keypad and message display on plant chassis.
Plant Operation 24 v DC Electric Panel in Control Box with push button
controls and fault display, level sensor and metal
detector controls.
Plant Set-Up Lever on the plant chassis to raise/lower the feeder
conveyor.
2.8 Dustsprays
Type Clean water multi atomising nozzle spraybars.
Positions Crusher feed & discharge and discharge conveyor head.
Inlet Single point for users pressure supply.
Required supply Up to approx. 7 litres/min (2 US galls) @ 2.8 bar / 42 psi.
Frost protection System drain valves.
2.9 Tracks
Type 190mm (7.5) pitch heavy duty.
Width 500mm. (20)
Centres 3782mm.(12- 5)
Drive 2 x Integral Hydraulic motors.
Control Remote handset - dual speed.
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Page 2 - 6
2.10 Optional Extras *

I) Autosand (AS) concave in lieu of the standard Medium Coarse (MC).
II) Belt Weigher with integrator and speed sensing wheel fitted to the discharge conveyor.
III) Hydraulically driven water pump assembly to provide pressurised water supply to the dust
suppression sprays.
IV) Low level sensor over feed hopper.
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3 - General Information EN
Page 3 - 1
3 - General Information
3.1 Introduction ..................................................................................................... 3 - 2
3.2 General information ........................................................................................ 3 - 3
3.3 Designated Use .............................................................................................. 3 - 4

3.3.1 Operating Temperature Range ................................................................... 3 - 4
3.4 Crusher Performance ..................................................................................... 3 - 5
3.4.1 Estimated Performance - Automax ............................................................. 3 - 6
3.4.2 Typical Product Analysis - Automax............................................................. 3 - 7
3.4.3 Estimated Performance - Autosand ............................................................ 3 - 8
3.4.4 Typical Product Analysis - Autosand ........................................................... 3 - 9
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Page 3 - 2
3.1 Introduction
This instruction manual contains important

information on how to operate the Maxtrak
1300 plant safely, properly and most
efficiently. Observing these instructions helps
to avoid danger, to reduce repair costs and
downtimes and to increase the reliability and
life of the plant.
These operating instructions must always be

available wherever the plant is in use.
These operating instructions must be read

and applied by any person in charge of and/
or working on the plant such as:-
Operation
Includes manoeuvring, setting up, operation

during the course of work, evacuation of
production material and waste, care and
disposal of fuels and consumables, etc.
Maintenance
Servicing, inspection and replacement of

wearing parts.
and/or
Transport
Follow all applicable laws and safety

regulations for accident prevention and
environmental protection.
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Page 3 - 3
3.2 General information

! NOTICE !
The Maxtrak 1300 plant has been If high or low ambient temperature
manufactured, assembled and tested with the conditions apply, specific details
utmost care and was built with first class need to have been advised at the
materials. time of order as special equipment
may be necessary.
Close attention has been paid to all details in
assembly, running tests and final inspection.
The Caterpillar engine cooling
Terex Pegson is confident that the plant will system is protected to -15 C (+ 5
give every satisfaction over a long period. F) with 30% Caterpillar antifreeze
concentration when shipped from
To be assured of faultless operation the the factory unless special
operator should carefully read the following requirements have been defined.
paragraphs and give the required time and
attention to essential maintenance, cleaning
and inspection.
The plant is easy to operate, adjustments are

easy to make and expert assistance is
seldom required, provided that ordinary care
is exercised in daily use.
The plant has been built in accordance with

state-of-the-art standards and recognised
safety rules. It is designed to be reliable,
efficient and safe when used and
maintained in accordance with the
instructions given in this manual.
Nevertheless, its use may constitute a risk

to life and limb of the user or of third parties,
or cause damage to the plant and to other
material property.
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Page 3 - 4
3.3 Designated Use Refer to the following information in this

Section for guidance regarding the
The BL-Pegson Maxtrak plant includes the performance of the Automax crusher.
1300 Automax Cone Crusher designed to Experienced engineers are available at BL-
maximise throughput and product shape in a Pegson to give advice when necessary.
wide range of crushing applications. For finer
crushing operations the Autosand option is If you have any doubts about any aspect
available. of the plants capability of servicing
procedures, you must consult your local
BL-Pegson dealer or Terex Pegsons
! NOTICE ! technical departments.
It is vitally important that pieces of 3.3.1 Operating Temperature Range

steel or similar uncrushable
objects such as bucket teeth are The normal operating temperature range of
not allowed to enter the crushing the plant is from -10C to +40C (+14F to
chamber as severe damage and +104F). For use in temperatures outside of
this range, contact your local dealer or BL-
injury may occur.
Pegson for details.
For the above reason a metal detector is
fitted to the feeder conveyor. It is imperative Note: Appropriate oil & coolant to suit the
that this metal detector is kept operative at local operating conditions must be used, as
all times and that when activated the plant specified elsewhere in this manual.
operator removes the offending material
before recommencing operation.
! WARNING !
Operating the plant outside its
recommended range of
applications/operating parameters
or for any use for which the
equipment is not intended, will
result in a loss of any guarantee
and the manufacturer/supplier
cannot be held liable for any
damage or injury resulting from
such misuse. The risk of such
misuse lies entirely with the user.
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Page 3 - 5
3.4 Crusher Performance Performance will be adversely affected if an

excessive percentage of fines in the feed
In order to obtain the optimum overall causes the packing/caking of material, either
crushing performance from the Automax, to slow the flow of material or cause
it is essential to have a continuous and congealed lumps in the product.
regulated choke feed of evenly graded
material that is well mixed around the Persistent dumping (see Glossary) is
crushing chamber. Typical feed gradings most undesirable and likely to be
are shown on the product analysis graphs caused by operating the machine at too
in this section. close a setting. Increase the Gap
setting to avoid damage to the machine.
The level sensing device prior to the
crusher will assist in achieving this when Crusher settings shown in the tabulation are
used to control the feed. Additionally, all for general guidance only and crusher
feed material should be of a size that will performance will vary depending upon the
readily enter the crushing chamber. conditions prevailing.
The gradings and capacities shown in this Capacities shown are for open circuit
section are averages base on actual applications.
results taken from tests carried out on
various materials at different crusher When operation is required towards the
settings. They will vary dependant upon lower end of the setting range. BL-Pegson
the grading and nature of the feed Ltd should be consulted to verify the
material. For more specific details please application.
contact Terex Pegson Ltd.
The power required and product gradings
Actual performance is dependant upon the will vary with the feed and product size,
particular conditions prevailing at the time capacity and rock characteristics.
such as the nature of the feed material,
the control of the Automax feed and the Usage of wearing parts will depend upon
crusher setting, etc. individual crushing conditions and the
variable factors which govern wear.
The capacities given are approximate only
and based on crushing clean, dry, well
graded quarried hard limestone, weighing
loose about 1600 kg/f/m3 (100 lbs/cu.ft.) and
having a specific gravity of 2.6 - 2.8. Wet
sticky feeds will reduce crusher capacities.
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3.4.1 Estimated Performance - Automax
Minimum
Type of Concave Maximum Feed Size Recommended
(AUTOMAX) Setting
STANDARD 220 mm (81/2") 22 mm (7/8")
Figure 3a Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting Typical Plant Output
mm inches M. tph US. tph
22 7/8" 220-255 240-280
25 1" 235-275 260-300
28 1 250-295 275-325
1 /8"
32 1 260-350 285-390
1 /4"
Figure 3b Estimated Plant Outputs
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3.4.2 Typical Product Analysis - Automax
Figure 3c Typical Product Analysis Curves - Automax

SCREEN MESH SIZE - INCHES
SCREEN MESH SIZE - MM
PERCENTAGE PASSING
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3.4.3 Estimated Performance - Autosand
Minimum
Type of Concave Maximum Feed Size Recommended
(AUTOSAND) Setting
STANDARD 63 mm (21/2") 1
13 mm ( /2")
Figure 3d Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting Typical Plant Output
mm inches M. tph US. tph
13 1/2" 165-185 180-200
16 5/8 180-200 200-220
19 3/4" 195-220 215-240
22 7/8" 210-240 230-260
Figure 3e Estimated Plant Outputs
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3.4.4 Typical Product Analysis - Autosand
Figure 3f Typical Product Analysis Curves - Autosand

SCREEN MESH SIZE - INCHES
SCREEN MESH SIZE - MM
PERCENTAGE PASSING
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Blank page
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4 - Design and Function EN
Page 4 - 1
4 - Design and Function
4.1 General Information ........................................................................................ 4 - 2
4.2 Construction Units ......................................................................................... 4 - 3

4.2.1 Automax Crusher ........................................................................................ 4 - 3
4.2.2 Feed Hopper ............................................................................................. 4 - 3
4.2.3 Feed Conveyor .......................................................................................... 4 - 3
4.2.4 Discharge Conveyor .................................................................................. 4 - 3
4.2.5 Chutes ....................................................................................................... 4 - 4
4.2.6 Platforms ................................................................................................... 4 - 4
4.2.7 Power Unit ................................................................................................. 4 - 4
4.2.8 Controls ..................................................................................................... 4 - 4
4.2.9 Chassis ..................................................................................................... 4 - 4
4.2.10 Track Frame............................................................................................. 4 - 5
4.2.11 Guards ..................................................................................................... 4 - 5
4.2.12 Painting ................................................................................................... 4 - 5
4.2.13 Dust Suppression Sprays ......................................................................... 4 - 5
4.2.14 Optional Extras ........................................................................................ 4 - 5
4.2.15 Authorisation for use ................................................................................. 4 - 6
4.2.16 Site Preparation ....................................................................................... 4 - 6
4.2.17 Commissioning ........................................................................................ 4 - 6
4.2.18 Specifications .......................................................................................... 4 - 6
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Page 4 - 2
4.1 General Information
The Terex Pegson Maxtrak 1300 Plant has been designed to maximise throughput and
product shape in a wide range of quarrying applications, its features include:-
Suitable for aggregate, rail ballast, road-base production or secondary, tertiary and quaternary
applications.
Unique design giving excellent product shape and high reduction ratios
No need for pre-screening on many applications reducing cost and increasing profitability
Easily transported on and off site
Metal detection fitted as standard
Feed hopper and level controls included to ensure choke feed to the crusher with resultant optimum
product shape
3.5 m (11- 6) discharge conveyor material discharge height
Hydraulic crusher setting adjustment, overload release and unblocking included as standard
Dust suppression sprays
Caterpillar water cooled diesel engine with hydraulically controlled clutch
Hydraulic rams to assist setting up and packing for transportation
Choice of crusher concave (Autosand option)
CRUSHING APPLICATIONS
! WARNING !
This plant is designed for stone crushing applications. It is vitally important that
large pieces of steel or similar uncrushable objects are not allowed to enter the
crushing chamber as severe damage and injury may occur. The Automax crusher
includes automatic hydraulic overload release. However the machine is not
designed to accept large pieces of steel or other uncrushable objects such as
bucket teeth. The metal detector fitted to the feeder conveyor must be kept
operable at all times whilst the plant is in operation and any foreign object
removed from the feeder conveyor belt.
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Page 4 - 3
4.2 Construction Units 4.2.3 Feed Conveyor

1300mm (51) wide plant mounted shallow
TEREX PEGSON 1300 MAXTRAK troughed belt variable speed conveyor, with
SECONDARY/TERTIARY CRUSHING hydraulic drive to the head drum having
PLANT WITH DIESEL/HYDRAULIC integral reduction gearbox, EP630/4 (or
DRIVE generally as shown on brochure equivalent) belt with 6mm top and 2mm
13MXT 202/1 and comprising:- bottom heavy duty covers, and vulcanised
belt joint. The conveyor is designed to lower
4.2.1 Automax Crusher for transportation and lift for crusher
maintenance, by means of a hydraulic
Terex Pegson 1300 Automax Crusher
cylinder. Belt tensioning is maintained by
generally as illustrated on leaflet AMB 200/1,
screw adjusters located at the tail drum.
and fitted with dedicated system 2 hydraulic
controls as standard. The crusher is
complete with an oil lubrication system Impact rollers are provided immediately
having a chassis mounted tank with air blast below the feed hopper, and barge boards
cooler. extend from the feed hopper to the conveyor
head. A metal detector is included complete
Autosand (AS) concave is available as an with audible warning devices, and is suitable
option for plants which have not been for detecting steel and manganese steel
completed. Advice on the correct concave contained in the feed material.
can be provided by BL-Pegson Sales
Department against purchasers specific 4.2.4 Discharge Conveyor
application data. 1000mm (39) wide plant mounted troughed
belt fixed speed conveyor with hydraulic
4.2.2 Feed Hopper drive to the head drum, EP 500/3 (or
equivalent) belt with 5mm top and 1.5mm
7.0m (8.75yd) heaped capacity feed
bottom heavy duty covers, and vulcanised
hopper fabricated in 10mm (3/8)thick mild
belt joint. The conveyor is of fixed design
steel plate and fitted with internal crash bar
and belt tensioning is maintained by screw
to minimise impact load on the feed
adjusters located at the head drum. Impact
conveyor.
rollers are provided immediately below the
crusher outlet under the conveyor feed point,
and canvas type dust covers are provided
over the exposed section of the conveyor.
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Page 4 - 4
4.2.5 Chutes 4.2.8 Controls

Automax feed box fabricated in 6mm mild The Automax hydraulic systems control
steel plate. Crusher discharges direct to panel and separate start/stop control panel
product conveyor feed boot, which is for the crusher, conveyors and oil lubrication
fabricated in 10mm thick Hardox abrasion system are mounted on the side of the main
resistant plate. chassis. Both panels operate from a 24 volt
D.C. supply from the diesel engine.
4.2.6 Platforms
Also mounted on the chassis are emergency
Provided for inspection and maintenance, stop buttons and a control lever for lowering
allowing access to each side of the crusher and raising the feed conveyor assembly for
and engine, back of engine, and to one side transport and maintenance.
of feed conveyor head section. They are
made from steel flooring with steel toe A radio control unit is provided for controlling
boards, double row handrails and access the tracking function giving a tracking speed
ladders. of approximately 1km/hour and a creep
facility for loading, off loading and precise
4.2.7 Power Unit slewing movements.
Caterpillar C12 EPA/CARB Emmissions
Regulations compliant, 6 cylinder, 4 stroke, Level sensors over the Automax and, feed
direct injection, water cooled diesel power conveyor (optional), are designed to
pack, with HFO clutch. The engine is rated automatically maintain an optimum feed
at 425 BHP (317 kW) nett continuous at condition.
1800 rpm under NTP conditions.
4.2.9 Chassis
Hydraulic power is provided from the engine Fabricated steel frame with supports for the
to drive both conveyors, operate the feed conveyor, crusher, product conveyor,
hydraulic cylinders, and give power to the power unit, track frame and control systems.
tracks. It also provides power to the crusher
lubrication oil pump and supplies the crusher
hydraulic setting and adjustment system. All
connecting pipework is provided with steel
pipe being used in inaccessible areas.
Hydraulic tank is mounted within the main

chassis structure, and the system includes air
to oil cooling.
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Page 4 - 5
4.2.10 Track Frame 4.2.12 Painting

Heavy duty track frame having 3.8m (12- The plant is finish painted in BL-Pegson
6) centres and 500mm (20) wide tracks. Blue RAL 5015.
Total Plant Weight approximately: 4.2.13 Dust Suppression Sprays

5O tonne (55 US tons)
Spray bars with atomiser nozzles are
Overall track width - 3000mm (9- 11) mounted over the crusher mouth and the
Operating height - 4554mm (14- 11) product conveyor feed and discharge points
Operating length - 15978mm (52- 5) piped to an inlet manifold for clients
Operating width - 3000mm (9- 11) pressurised water supply.
Travel height - 3810mm (12- 6)
Travel length - 15866mm (52- 1) Buyer to supply pressurised (2.8 bar/42 psi)
Travel width - 3000mm (9- 11) clean water supply at approximately 7 litres (
2 US galls) per minute.
NB. The travel height above can only be
achieved if the Automax Upper Frame is 4.2.14 Optional Extras
first lowered to the maximum extent. Refer
to Section 5.2.5.
(These options are only available for plants,
which are not already built and are not
4.2.11 Guards available for plants already in stock).
Wire mesh or sheet metal guards are provided
for all drives, flywheels, pulleys, couplings, Autosand concave (no price variation for
wedge belts and belt conveyors. unfinished plants)
The guards provided are designed and Beckford belt weigher with integrator and
manufactured to ensure so far as reasonably speed sensing wheel fitted to main product
practicable that the machinery and plant on conveyor.
which they are fitted can be operated safely
and without risk to health when properly used. Hydraulically driven water pump assembly to
However, the Company cannot guarantee that provide a pressurised water supply to the
the guards provided will meet the requirements dust suppression sprays.
laid down by individual Inspectors and any
additional guard and/or modification to guarding Level sensor over the feed hopper.
supplied, which may be required for any
reason whatsoever, will be charged as an
addition to the Contract Price.
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Page 4 - 6
4.2.15 Authorisation for use We cannot guarantee that the equipment

quoted will meet any specific requirements in
This is a requirement of the Environmental respect of noise or vibration levels, dust
Protection Act that the Purchaser must emissions, or any other factors relevant to
obtain Local Authority authorisation to health and safety measures or environmental
operate this plant in the U.K. protection needs. However, on receipt of
specific information Terex Pegson will
4.2.16 Site Preparation endeavour to ascertain the need for
additional equipment and, if appropriate,
The buyer shall be responsible for ensuring
quote extra to contract prices.
that a suitably prepared, flat and level site is
available for the plant and that the ground is
capable of sustaining the working of the
equipment. Unit dimensions and loadings
can be provided to the buyer for both
transportation and operating purposes.
4.2.17 Commissioning
On arrival of the plant on site BL-Pegson or
your local dealer can provide an Engineer if
required at extra cost to commission the
plant.
Feed material, and other essentials to be

provided by the buyer in good time for the
commissioning being carried out.
4.2.18 Specifications
Every endeavour will be made to supply
equipment as specified, but we reserve the
right, where necessary, to amend
specifications without prior notice as we
operate a policy of continual product
development.
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5 - Transport EN
Page 5 - 1
5 - Transport
5.1 Safety Information .......................................................................................... 5 - 2
5.2 Transportation ................................................................................................ 5 - 5

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

WHERE OPTIONAL FEED HOPPER EXTENSION PLATES ARE SUPPLIED, THESE
MUST BE REMOVED FIRST WHEN PREPARING THE PLANT FOR
TRANSPORTATION. IT IS ESSENTIAL THAT SUITABLE LIFTING EQUIPMENT AND
EXPERIENCED PERSONNEL ARE EMPLOYED FOR THIS TASK AND THAT A RISK
ASSESSMENT IS CARRIED OUT PRIOR TO THE OPERATION.
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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Maxtrak 1300
5 - Transport EN
Page 5 - 2
5.1 Safety Information
When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.
LOCKOUT PROCEDURE
1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs (ie. TAG OUT).
5. NEVER work alone.
Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.
ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.
ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.
If fluid is injected under the skin, it must be

Get medical help immediately.
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5 - Transport EN
Page 5 - 3
Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT
ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.
Falling from and/or onto a FALLING HAZARD

BL-Pegson machine can cause
serious injury or even death.
DO NOT climb onto the machine

whilst in operation.
ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.
ALWAYS use an E.N./A.N.S.I. approved safety

harness when reaching any points 7ft (2m) or
more above ground level.
In-running nip points can cause ENTANGLEMENT

HAZARD
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and amputated.
SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.
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5 - Transport EN
Page 5 - 4
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5 - Transport EN
Page 5 - 5
5.2 Transportation
! DANGER !
5.2.1 Manoeuvring When manoeuvring your Maxtrak
to its operating position make sure
! WARNING ! you stand well clear of the plant
but are in a position to have all-
Prior to attempting any round vision to see any obstacles
manoeuvring of the plant the or hazards that may lie ahead e.g
tracks must be free of personnel, overhead cables,
obstructions, including crushed ditches, unsafe roadways etc.
material and fines. Do not push or (Refer to Figure 2a Dimensions)
tow the plant. Failure to observe
this warning could result in Make sure that you do not manoeuvre
serious injury to persons and your Maxtrak on a gradient steeper than
damage to the plant which may 30 degrees, damage may occur to the
invalidate warranty. engine and/or plant.
Before manoeuvring the Maxtrak, Avoid manoeuvring the plant over

ensure the feed hopper and crusher are extremely uneven ground or damage
empty, and that all materials have run off may occur.
the conveyors. STOP the feeder
conveyor, crusher and product conveyor. Initial start up in cold weather may result
in a tendency to steer to the right whilst
The plant cannot be manoeuvred in the tracking fast forward due to the
PLANT mode of operation. hydraulic oil being cold. Run the plant for
approx. 10 minutes with the conveyor
The safety warning horn sounds for 10 and feeder running prior to manoeuvring
seconds before selected controls become the plant.
operative and continuously whilst the
plant is being manoeuvred. The Maxtrak can be manoeuvred whilst
the feeder conveyor is in the working
position but refer to Sections 5.2.4 &
! DANGER ! 5.2.5 when necessary to reduce to the
travelling dimensions (Section 2)
DO NOT stand on any of the
platforms or ladders of the Maxtrak When transporting the Maxtrak, it is
whilst it is being manoeuvred the responsibility of the haulage
using the remote control handset. contractor to safely secure the plant to
the transporter.
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5 - Transport EN
Page 5 - 6
To manoeuvre the Maxtrak with the

remote control hand set (where
fitted):-
WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Procedure Refer to Section 5.1, Safety
Information for relevant
1. Observe all safety instructions. warning.
2. Take the Remote Control Hand Set from

the Control Box and first become
familiar with the functions of all the 4. Start the engine (Section 7.2.1). Set the
individual buttons (Figure 5d) before the engine speed at 1200rpm.
next step.
Forward = Product Conveyor first 5. Turn the OPERATION switch to
Reverse = Hopper first TRACK (Figure 5a).
3. To start up the handset transmitter first 6. Press the Horn button for 5 seconds to
stand well clear of the plant. Hold the sound the safety warning horn. This will
hand set with the stop button nearest to also ready the tracks for manoeuvring.
the operator and proceed as follows:-
7. The radio handset directional buttons
Ensure the stop button is pulled out. (forward, reverse and turn) are double
Depress both of the safety buttons pressure switches with the initial
(Fig.5d) at the same time for at least pressure operating the slow speed mode
1 second. Release the safety buttons. and depressing further operates the
The red LED will change to green. higher speed. Press the buttons to
The transmitter is in function status manoeuvre the plant in the desired
when the green LED comes on. direction (Figure 5d). Employ the Fast
speed only where safe to do so.
Note: The transmitter has a built in safety
function that prevents another function from Pressing the Stop button at any time will
involuntary cutting-in when the transmitter immediately halt the operation and cut
starts. The transmitter will not start if a out the engine but it is necessary to
button is stuck in the activated position. This manually switch off the engine ignition
is indicated by the red LED coming on. (Section 8.2)
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5 - Transport EN
Page 5 - 7
8. When the Maxtrak is in the correct 10. To shut down the radio handset
position, press the Horn button to turn transmitter, push in the stop button. Lock
the safety warning horn off and out the hand set when finished with to
disengage the tracks. prevent unauthorised use.
9. Turn the OPERATION switch to

PLANT and stop the engine (Section
8.2), unless required further.
Figure 5a OPERATION and RADIO REMOTE CONTROL Switches

on the Electrical Control Panel
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5 - Transport EN
Page 5 - 8
5.2.2 Unloading
The Maxtrak will arrive on site securely
WARNING
fastened to a low loader. It is the WEAR PERSONAL
responsibility of the haulage contractor to PROTECTIVE EQUIPMENT.
remove the fastenings. Refer to Section 5.1, Safety
warning.
Procedure
1. Observe all safety warnings.
2. Position easy slope ramps at the end of

the transporter to help with unloading of
the Maxtrak.
3. Start the engine (Section 7.2.1). Set the

engine speed to 1200rpm.

TRACK (Figure 5a). Using the remote
control hand set, (Section 5.2.1 and 5.3)
steer the Maxtrak off the transporter.
5. When the Maxtrak is in the correct

position, press the Horn button to turn
the safety warning horn off and
disengage the tracks.
6. Turn the RADIO REMOTE

CONTROL switch to OFF, then shut
down the hand set with the hand set stop
button.

8.2), unless required further.
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Maxtrak 1300
5 - Transport EN
Page 5 - 9
5.2.3 Loading
WARNING
Procedure
WEAR PERSONAL
1. Observe all safety warnings. PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
2. Ensure that both conveyors, feed Information for relevant warning.
hopper and crusher are free from
stone and dirt. FALLING HAZARD
3. Ensure all loose items are carefully Information for relevant warning.
stowed and secured if these are to be
transported on the plant.
4. Start the engine (Section 7.2.1). Set the 11. Turn the RADIO REMOTE
engine speed to 1200rpm. CONTROL switch to OFF then shut
down the hand set with the hand set stop
5. Continue with the OPERATION switch button.
at PLANT and the RADIO REMOTE
CONTROL switch at ON (Figure 7b). 12. Turn the OPERATION switch to
6. Lower the Automax Upper Frame 8.2), unless required further.
(Section 5.2.5). ONLY APPLIES IF
MINIMUM TRANSPORT 13. Securing the Maxtrak to the
HEIGHT REQUIRED. transporter is the responsibility of
the haulage contractor.
7. Lower the feeder conveyor for travelling
if not already in this position (Refer to
Section 5.2.4 procedure). ! WARNING !
Prior to transportation always
8. Position easy slope ramps at the end of check the plant for loose or
the transporter to help with loading of the
damaged components.
Maxtrak.
9. Turn the OPERATION switch to Fasten all loose parts, replace

TRACK (Figure 5a). Using the remote missing items or make repairs
control hand set (Section 5.2.1 and 5.3), as found necessary to ensure
steer the Maxtrak onto the transporter. that all components are safely
secured during transportation.
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Maxtrak 1300
5 - Transport EN
Page 5 - 10
5.2.4 Lowering the Feed Conveyor

The Maxtrak is designed so that the plant
WARNING
can be prepared for transport without the
WEAR PERSONAL
use of tools. To reduce to the travelling PROTECTIVE EQUIPMENT.
dimensions of the plant the feeder conveyor Refer to Section 5.1, Safety
head is hydraulically lowered from the Information for relevant warning.
working position.
FALLING HAZARD
! WARNING ! Information for relevant warning.
Whilst the plant is crushing the
conveyor head must always be
supported on the locating pins
positioned in each of the two
telescopic support legs and NOT
by the hydraulic ram alone.
Procedure
2. Ensure that the conveyor and feed

hopper and Automax feed box are free
from stone and dirt.
3. Before lowering the feed conveyor into

the travelling position first release the
feed box rear plate fastenings and hinge
down the plate.

engine speed at 1200rpm.
5. Continue with the OPERATION switch

CONTROL switch at ON (Figure 7b).
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Maxtrak 1300
5 - Transport EN
Page 5 - 11
6. Operate the hydraulic lever on the 9. Switch off the engine (Section 8.2) and
chassis side to slightly raise the feeder implement the lockout procedure.
conveyor so that the locating pins can be
withdrawn from both legs of the upper 10. Lower the mast(s) supporting the level
telescopic support leg (Figure 5b). sensor(s).
7. Operate the hydraulic level again to

lower the feeder conveyor to the fullest
extent. This action will automatically fold
the platform access ladder.
8. Store the locating pins in the places

provided on the telescopic legs and stow
the security pins to prevent loss. Upper Telescopic
Leg
Locating Pin
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 5b Feed Conveyor Hydraulic Lever

and Locating Pins
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Maxtrak 1300
5 - Transport EN
Page 5 - 12
5.2.5 Lowering the Automax Upper

Frame WARNING
(to achieve minimum travel height WEAR PERSONAL
dimension (Sections 2.1 & 4.2.10) PROTECTIVE EQUIPMENT.
FOR THIS OPERATION THE Information for relevant warning.
AUTOMAX MUST NOT BE RUNNING
Referring to the separate Automax

Control Panel (Section 7.4) for
detailed instructions, action as
follows;-
Procedure
1. Observe all safety warnings. 5. Now depress the CLOSE button until
the manganese crushing members
2. Start the engine (Section 7.2.1). Set the (mantle and concave) touch. This is
engine speed at 1200rpm. indicated by a sudden rise in pressure
shown on the gauge near the panel
3. Continue with the OPERATION switch (Figure 5c) and release the button
at PLANT and the RADIO REMOTE immediately.
CONTROL switch at ON (Figure 7b)
but DO NOT press any of the start 6. Continue with the Loading procedure
buttons. (Section 5.2.3 - step 7).
4. On the Automax hydraulic panel (Figure

5c) switch to MANUAL and depress
the OPEN button to raise the Upper
Frame approximately 25-38mm. Look
into the Automax crushing chamber to
check there is no stone lodged in the
chamber.
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5 - Transport EN
Page 5 - 13
Make the checks prior to starting the Check that all 5 Emergency Stops on the
plant (Section 7.1.3). plant are pulled out (Figure 1a).
Check that the conveyors and Automax Make sure that you fully understand the
crushing chamber are empty of material. operating procedures for the Automax
before attempting to start.
Pressure
Numeric Keypad Display Gauge
OPEN Button AUTO/MANUAL TRAMP O/L TEST CLOSE Button

Switch Button
Figure 5c Automax Hydraulic Panel Controls
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Maxtrak 1300
5 - Transport EN
Page 5 - 14
5.3 Remote Control For recharging the hand set battery, see
Section 5.3.1
Operation
When the plant is not operating take the
! DANGER ! opportunity to recharge the internal
battery. For convenience a lead is
DO NOT stand on any of the supplied to plug into 12/35 volt DC
platforms or ladders of the Maxtrak vehicle cigar lighter point (Section 5.3.1).
whilst it is being manoeuvered
using the remote control handset. In the event of the remote radio hand set
being inoperable for any reason, the
When manoeuvring your Maxtrak alternative umbilical hand set is
supplied (Section 5.3.2).
to its operating position make
sure you stand well clear of the
If the hand set transmitter does not start
machine but are in a position to when the two safety buttons are
have all-round vision to see any depressed at the same time for at least 1
obstacles, dangers that may lie second (Section 5.2.1), check if the stop
ahead e.g personnel, overhead button is pushed in, or the battery
cables, ditches, unsafe roadways needing a recharge.
etc.
(Refer to Figure 2a for dimensions)
! NOTICE !
The Maxtrak remote control
system is supplied to the
following:-
Radio System
2686-0042
If the plant moves out of the operating

range of the remote control hand set the
plant will stop.
Operating the stop button on the remote

hand set whilst the plant is in TRACK
operating mode will stop the engine.
To manoeuvre the Maxtrak with the

remote hand set, refer to the instructions
in Section 5.2.1.
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Maxtrak 1300
5 - Transport EN
Page 5 - 15
PLAN VIEW OF THE PLANT
LED Red/Green
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1 **Reverse Forward

**
Left turn slow, forward track 2 ** Left Turn
(travelling forward)
Right Turn **
(travelling forward)
Reverse slow or fast, track 1 & 2 Not used to
Manoeuvre
Right turn slow, reverses track 1
Left turn slow, reverses track 2 Safety Button Safety Button

(Horn) (Feeder On/Off)
Rotate clockwise, track 1 forward, track 2
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
** Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5d Remote Control Hand Set
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Maxtrak 1300
5 - Transport EN
Page 5 - 16
5.3.1 Radio Hand Set (where fitted)

Features of the 860 System include:-
Unique ID code in each transmitter. The

receiver self learns this code, without the
need to change DIP switches internally
in either component.
No need to open transmitter to change

frequency (changed from buttons -
Dealer function). Receiver detects any
change automatically.
Transmitter can be programmed to work

with either 840 or 860 receivers (Dealer
function).
Enhanced reliability.
Transmitters Use NiMh batteries instead of

NiCd, which means the following:-
Input charging voltage is now 12VDC to

35VDC instead of 12/24VDC, no
universal adapter required.
TRANSMITTER 860TX-PEG
Battery capacity is changed from 800mA

to 2000mA.(Charging time from
completely empty battery is now
Buttons 1 to 4 = Used for plant directional
approximately 4 hours). control
Operating time with fully charged battery Buttons 1 to 9 and 0 = Used for signal
is approximately 30 hours. frequency programming (factory preset -
contact Dealer for change)
Buttons 9 and 0 = Used to activate the

radio hand set transmitter
Button 9 = Used to activate the audible

warning horn
Button 0 = Used to stop / start the plant

feeder (where appropriate)
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Maxtrak 1300
5 - Transport EN
Page 5 - 17
2 versions of the 860 system transmitter will

be supplied, one for European Operations
and one for the Rest of the World. The only
WARNING
difference is that the European version will WEAR PERSONAL
include a black stop button. The Rest of the PROTECTIVE EQUIPMENT.
World transmitter will feature a Red Stop Refer to Section 5.1, Safety
button. Channel 01 (434.650 MHz) through Information for relevant warning.
channel 16 (433.900 MHz) available in .050
MHz steps. Refer to Dealer if frequency
change needed.
To conserve the battery charge the hand
Battery Recharging set should be switched off when not in
use.
The remote control handset includes a built
in chargeable batteries and a charging
contact point on the back of the unit (Figure
5k). A 12/35 volt charging lead suitable for
plugging into a vehicle cigarette lighter point
is supplied.
Battery charge status is indicated by the

LED light in the transmitter;
Red - batteries need charging;
Green - batteries fully charged.
During the charging of the batteries the
LED light will be red until changing to
green when fully charged. The batteries
cannot be overcharged.
Fully charged batteries provide about 30

hours continuous running and recharging
time takes about 4 hours.
The LED light on the hand set changes

from green to red when there is about
10% power left in the batteries (1 hour
continuous operation remaining) and
indicates it is time to recharge. The plant
warning horn will also sound when
battery recharging is required Charging point
Figure 5d Remote Control

Charger Connection
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Maxtrak 1300
5 - Transport EN
Page 5 - 18
5.3.2 Alternative Control Hand Set

with Umbilical Cable (where fitted) WARNING
As an alternative to the radio remote control WEAR PERSONAL
hand set, a hand set with umbilical cable is PROTECTIVE EQUIPMENT.
supplied to manoeuvre the Maxtrak (Figure Refer to Section 5.1, Safety
5g). Information for relevant warning.
Connecting and using the Umbilical

Control Hand Set
Procedure
2. Close down the plant (Section 8.2).
3. Locate the connection point (Figure 5f)

on the Control Panel. Release the
retaining clip and remove the multi pin
plug already in situ (only where radio
unit fitted). Replace with the umbilical
lead plug (Figure 5g) and secure with the
retaining clip.

engine speed at 1200rpm..
5. Standing clear of the tracks, turn the

OPERATION switch to TRACK but
leave the the RADIO REMOTE
CONTROL switch at OFF (Figure 5h).
6. Press the Horn button for 5 seconds to

sound the safety warning horn. This will
also ready the tracks for manoeuvring.
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Maxtrak 1300
5 - Transport EN
Page 5 - 19
Figure 5f Umbilical Connection Point
Figure 5g Umbilical Control Hand Set
Figure 5h OPERATION and RADIO REMOTE CONTROL Switches

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Maxtrak 1300
5 - Transport EN
Page 5 - 20
7. The umbilcal handset (Figure 5i)

directional buttons (forward, reverse and ! DANGER !
turn) are double pressure switches with
Extreme care must be used when
the initial pressure operating the slow
speed mode and depressing further
manoeuvring the plant with the
operates the higher speed. umbilical control hand set. Stand
as far away as possible from the
Pressing the Stop Button at any time will plant. Do not allow the cable of the
immediately halt the operation and cut hand set to sag and become
out the engine but it is necessary to entangled with the tracks.
manually switch off the engine ignition
(Section 8.2).
8. Hold the hand set with the stop button

nearest to the operator and proceed as
follows. Press the slow speed buttons on
the hand set to manoeuvre the plant in
the desired direction (Figure 5i). Employ
the fast speed only where safe to do
so.

10. On the Control Panel turn the

OPERATION switch to PLANT. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.
11. Unplug the umbilical cable and replace

with the original plug (where radio unit
fitted). Store the umbilical hand set unit
in the tool box to keep available for
future use.
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Maxtrak 1300
5 - Transport EN
Page 5 - 21
PLAN VIEW OF THE PLANT
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1
Left turn slow, forward track 2 **Reverse Forward **

Reverse slow or fast, track 1 & 2 **Left Turn Right Turn **
(travelling forward) (travelling forward)
Right turn slow, reverses track 1
Not used Not used
Left turn slow, reverses track 2
Safety Button Not used

Rotate clockwise, track 1 forward, track 2
(Horn)
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5i Remote Umbilical Control Hand Set
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Maxtrak 1300
5 - Transport EN
Page 5 - 22
Blank page
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Maxtrak 1300
6 - Set Up EN
Page 6 - 1
6 - Set Up
6.2 Setting Up ....................................................................................................... 6 - 4
HOPPER EXTENSION PLATES

WHERE OPTIONAL FEED HOPPER EXTENSION PLATES ARE SUPPLIED, THESE
WILL HAVE BEEN REMOVED FOR TRANSPORTATION AND WILL REQUIRE FITTING
IN ADDITION TO THE SETTING UP PROCESS DESCRIBED. IT IS ESSENTIAL THAT
SUITABLE LIFTING EQUIPMENT AND EXPERIENCED PERSONNEL ARE EMPLOYED
FOR THIS TASK AND THAT A RISK ASSESSMENT IS CARRIED OUT PRIOR TO THE
OPERATION.
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Maxtrak 1300
6 - Set Up EN
Page 6 - 2

followed.
LOCKOUT PROCEDURE

lockout.

HAZARD
injury.



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Maxtrak 1300
6 - Set Up EN
Page 6 - 3








HAZARD
machine.

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Maxtrak 1300
6 - Set Up EN
Page 6 - 4
6.2 Setting Up
WARNING
Plant Location Considerations
WEAR PERSONAL
Prior to setting up your Maxtrak, Refer to Section 6.1, Safety
consideration should be given to a suitable Information for relevant
layout to prevent oversize material or tramp warning.
metal from entering the plant. In order to FALLING HAZARD
prevent bridging of the crusher no material Refer to Section 6.1, Safety
above the size recommended by the BL- Information for relevant
Pegson (Section 3) should be fed into the warning.
plant.
The Maxtrak is designed so that the plant in

transportation mode can be set up and put to
work without the use of tools.
Procedure
2. Position the plant in a safe level

operating position making sure both
tracks are in full contact with the ground
to minimise movement of the Maxtrak.
Pay attention to access from the loading
area and to where material is to be
deposited (Section 5.2.1), and ensure the
area under the tail drum is clear of large
stones etc which may cause belt
damage.


CONTROL switch at ON (Figure 6a).
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Maxtrak 1300
6 - Set Up EN
Page 6 - 5
Figure 6a OPERATION and RADIO REMOTE CONTROL Switches

Upper Telescopic
Leg
Locating Pin
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 6b Feed Conveyor Hydraulic Lever

and Locating Pin
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Maxtrak 1300
6 - Set Up EN
Page 6 - 6
5. Raise the feeder conveyor slightly above 11. Raise the mast(s) supporting the level
the working position by operating the sensor(s) ensuring restoration at the
hydraulic lever on the chassis side so correct height so that the originally
that the two locating pins can be inserted calibrated settings are maintained.
through the top pair of holes in the upper
telescopic legs. Fit the security pins into
the end of each pin (Figure 6b). ! NOTICE !
IMPORTANT
6. Operate the hydraulic lever to lower the
conveyor until the locating pins rest on
It is very important NOT to run the
the seats in the lower telescopic legs. Automax crusher before the Initial
Make sure the locating pins are resting Setting and Calibration procedure
on their seats on both sides of each leg has been carried out.
and not on the pin head on one side only. The Automax Upper Frame may
have been fully lowered to achieve
the minimum travel height and
! WARNING ! serious damage will occur if the
Whilst the plant is crushing the machine is started whilst the
conveyor head must always be manganese mantle and concave
supported on the locating pins are touching.
positioned in each of the two
telescopic support legs and NOT
by the hydraulic ram alone.
7. Lifting the feeder conveyor head will

automatically unfold the platform access
ladder.
8. Carry out the Automax Initial Setting and

Calibration procedure (Section 7.3.3).
See IMPORTANT NOTICE
OPPOSITE.
9. Switch off the engine (Section 8.2) and

implement the lockout procedure.
10. The rear wall of the feed box needs to

be manually lifted and secured with the
fixings provided.
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Maxtrak 1300
7 - Operating Instructions EN
Page 7 - 1
7 - Operating Istructions

7.1.1 Blocked Crusher Procedures ..................................................................... 7 - 4
7.1.2 Safe Operation of the plant ......................................................................... 7 - 5
7.1.3 Checks at Initial Start-Up ............................................................................ 7 - 6
7.2 Plant Start-Up Procedure ............................................................................. 7 - 7
7.2.1 Engine Start-Up .......................................................................................... 7 - 8
7.2.2 Plant Start Up ........................................................................................... 7 - 12
7.2.3 Electric Control Panel Screen Display Data.............................................. 7 - 17
7.2.4 Plant Operating Sequence and Automatic Safeguards ............................. 7 - 18
7.2.5 Fault Indication and Restart ...................................................................... 7 - 19
7.2.6 Metal Detection ........................................................................................ 7 - 20
7.2.7 Feed Conveyor Remote Operation ........................................................... 7 - 21
7.2.8 Crushing Material - Plant and Automax Settings ....................................... 7 - 23
7.2.9 Plant Initial Start Up and Running In ........................................................... 7 - 23
7.2.10 Daily Plant Checks ................................................................................. 7 - 25
7.3 Automax Operation ....................................................................................... 7 - 26
7.3.1 Glossary of Automax Parts ....................................................................... 7 - 28
7.3.2 Glossary of Automax Terms ...................................................................... 7 - 29
7.3.3 Automax Initial Discharge Setting and Calibration ..................................... 7 - 31
7.3.4 Automax Manganese Wear Calibration .................................................... 7 - 32
7.3.5 Guidance for Changing the Manganese Mantle and Concave ................... 7 - 33
7.3.6 Automax Initial Start Up ............................................................................. 7 - 34
7.3.7 Actions during running in ........................................................................... 7 - 35
7.3.8 Automax Adjustment of Discharge Setting ................................................ 7 - 36
7.3.9 Manual Raising/Lowering of the Automax Upper Frame ............................ 7 - 37
7.3.10 Automax Automatic Overload Release/Unblocking and Resetting ........... 7 - 38
7.3.11 Checking Automax Wedge Pressure ...................................................... 7 - 39
7.3.12 Daily Automax Checks ........................................................................... 7 - 40
7.4 Automax Crusher Controls .......................................................................... 7 - 41
7.4.1 Controls Layout ........................................................................................ 7 - 41
7.4.2 Function Keys .......................................................................................... 7 - 42
7.4.3 General Operation .................................................................................... 7 - 43
7.4.4 Manual Operation ..................................................................................... 7 - 52
7.4.5 Setting the Gap ........................................................................................ 7 - 53
7.4.6 Setting New Manganese .......................................................................... 7 - 55
7.4.7 Setting Normal Zero ................................................................................. 7 - 57
7.4.8 Tramp Overload or Test (whilst in Manual) ................................................. 7 - 59
7.4.9 Tramp Overload or Test (whilst in Auto) ..................................................... 7 - 59
7.4.10
Terex Alarms ...................................................................................................
Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618 7 - 60
7.4.11 Alarm List ............................................................................................... 7 - 61
7.4.12 Wedge Lock Option ............................................................................... 7 - 62
7.4.13 Historical Alarms .................................................................................... 7 - 63
7.4.14 Set Time & Date ....................................................................................
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7.4.15 Set Operating Language ........................................................................ 7 - 66
Maxtrak 1300
Page 7 - 2

followed.
LOCKOUT PROCEDURE

lockout.

HAZARD
injury.



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HAZARD
machine.

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Page 7 - 4
7.1.1 Blocked Crusher Procedures When metal enters any type of crusher it does
not shear in the same manner as stone and can
become wedged and under considerable
! WARNING ! pressure. In order to release the tramp metal it
Unblocking stalled crushers can be is necessary to take the pressure off it and at
hazardous. Do not undertake without this time it can be ejected from the machine
careful risk assessment with catastrophic consequences
In order to avoid the Automax cone crusher A cone crusher can become bridged when
becoming blocked the machine is equipped oversize material is fed into it. In the event of
with an automatic hydraulic release this happening the feed conveyor should be
mechanism to raise the upper frame when stopped immediately. An attempt to clear the
excessively high crushing pressure is machine can be made by raising the upper
sensed. The upper frame automatically frame by putting the machine into manual and
returns to the original setting when the pressing open. Should this not open
foreign object should have been released sufficiently to allow the stone to drop through
through the machine. However, unduly large then it will be necessary to isolate the machine
uncrushable objects may stall the crusher and remove the rock or break up the stone
and become tightly wedged in the crushing manually with a hammer and chisel.
chamber.
In the event that the crusher should stall
The clearing of blocked crushers should be whilst crushing due to an overload or
given considerable thought prior to blockage, the crushing chamber will be full
attempting to unblock a crusher. These of stone and the feed conveyor should be
procedures should be considered under risk stopped immediately. This should then be
assessment review for the implementation of released by raising the upper frame as
a procedure of safe working practice for this before and letting the material fall through.
operation. After the machine has stalled, prior to
resetting, the reason why the machine has
There is a document entitled Clearing stopped should be investigated. In the case
Blocked Crushers available from the British that a piece of tramp metal is in the machine
Aggregate Construction Materials Industries extreme care should be taken whilst
(BACMI) which gives more details about releasing it. To avoid the tramp metal being
this and covers in more detail risk ejected it may be necessary to fill the
assessment areas. Tramp metal is a serious opening to the machine with stone whilst the
problem when it enters a crusher as this can pressure is released.
cause more problems than oversize or hard
stone. Check the machine for possible damage
(particularly the manganese) before
EVERY EFFORT MUST BE MADE TO resuming operations.
REMOVE TRAMP METAL FROM
THE FEED MATERIAL
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Maxtrak 1300
Page 7 - 5
7.1.2 Safe Operation of the plant

WARNING
! WARNING !
WEAR PERSONAL
Before attempting to operate the PROTECTIVE EQUIPMENT.
Maxtrak plant. DO read, fully Refer to Section 7.1 Safety
Information for relevant warning.
understand and observe the
contents of this manual. Also any
LOCKOUT PLANT.
other relevant manual for other
equipment incorporated in the Information for Lockout
Maxtrak plant, eg. Engine manual. Procedure.
Terex Pegson Ltd cannot FALLING HAZARD.

overemphasize the need to ensure Refer to Section 7.1 Safety
that all safety aspects are checked Information for relevant warning.
before starting the machinery.
NEVER leave the plant unattended

whilst it is in operation.
Make sure that you fully ! NOTICE !

understand the operating
procedures for the Automax DO NOT crush material with the
before attempting to start. engine below its recommended
working speed of 1800 rpm to
ensure all systems will function
! NOTICE ! correctly.
DO NOT allow a build up of solid
material or dust in any part of the AVOID frequent starting and
plant, in particular keep clean the stopping of your Automax
Automax internal frame arms unnecessarily as it WILL be
(Section 7.3.12) and the air blast oil detrimental to the machine.
cooler (on the lubricating oil tank).
DO check frequently the stability

of the plant. The chassis SHOULD
NOT have undue vibration during
operation.
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Maxtrak 1300
Page 7 - 6
7.1.3 Checks at Initial Start-Up

Visually check the plant and ensure that
WARNING
all guards and warning signs are in
WEAR PERSONAL
position and that all equipment and tools PROTECTIVE EQUIPMENT.
that are hazardous to operation are Refer to Section 7.1 Safety
removed from the immediate area. Information for relevant warning.
Inspect the complete plant to check for LOCKOUT PLANT.

fluid leaks, loose connections, damage or Refer to Section 7.1, Safety
wear, build up of material, etc. etc. Information for Lockout
Procedure.
Ensure that the crusher is empty of
material. FALLING HAZARD.
Refer to Section 7.1 Safety
Check levels of lubricant and hydraulic Information for relevant warning.
oil are satisfactory on :-
- Automax lubrication tank

- Automax hydraulic reservoir
Ensure that the Automax feed is both
Carry out the daily checks and
satisfactory and not segregating in the
inspections on the Automax crusher and
crushing chamber. Note: This applies to
plant (Sections 7.2.9 and 7.3.12)
all machine operations subsequent to the
running in period.
Check the alignment and tension of the
vee rope drive daily during the initial
Make sure that the crusher lubrication
days of operation as appropriate
system is functioning correctly (Section
9.5) and that no leaks are present.
Avoid overloading the machine by not
using small discharge settings during the
Check for leaks in the crusher hydraulic
first few days of operation.
system, both externally and inside the
hydraulic panel cabinet.
Ensure that the machine is running
correctly and that the satisfactory feed
is maintained at a constant rate (Section
3.4). Irregular and excessive feed rates
reduce the efficiency of the Automax.
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Maxtrak 1300
Page 7 - 7
7.2 Plant Start-Up

Procedure WARNING
WEAR PERSONAL
! WARNING ! Refer to Section 7.1, Safety
Terex Pegson Ltd cannot
warning.
overemphasize the need to ensure
that all safety aspects are checked
before starting the engine.
With the engine switched OFF
Ensure that the plant is fully Set Up in

accordance with Section 6 and ready to
operate.
Check that the conveyors and Automax

crushing chamber are empty of material.
Ensure that all guards are in position and

secure and that other personnel are clear
of the plant.
The plant diesel engine drives the Automax

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

out in sequence:-
Engine (Section 7.2.1).

Plant (Section 7.2.2).
When the Plant is running the Automax

controls can be operated (Section 7.3)
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7.2.1 Engine Start-Up

WARNING
Procedure
WEAR PERSONAL
2. Check that all Emergency Stop push Information for relevant warning.
buttons are pulled out (Figure 1a)
otherwise the engine cannot start.
3. Ensure the engine Isolation Switch

(Figure 7a) is turned to the I position.

PLANT and the RADIO REMOTE
CONTROL switch to ON (Figure 7b).
5. On the engine control panel (Figure 7c)

turn on the ignition with the key to the
first position and, once the sequence of
diagnostic checks is completed, fully turn
the key to start the engine. Release the
key back to the first position as soon as
the engine starts.
! NOTICE ! Figure 7a Isolation Switch
Refer to Figure 7d together with

continuation page for details of the
engine diagnostic functions.
6. Keep the rpm of the engine to 1200 rpm

(view on tachometer) and allow to run
for 3-5 minutes before proceeding with
preparation for transport (Section 5), ! NOTICE !
setting up the plant (Section 6) or To avoid damaging the clutch DO
initiating the plant run sequence
NOT increase the engine speed to
(Section 7).
the operating 1800 RPM until after
starting the Crusher (Section 7.2.2)
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Page 7 - 9
Figure 7b OPERATION and RADIO REMOTE CONTROL

Switches on the Electrical Control Panel
Maintenance Due Lamp Diagnostic Lamp
Tachometer Diagnostic Display
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Figure 7c Engine Control Panel
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Page 7 - 10
DIAGNOSTIC DISPLAY
The main unit has ten warning lamps available for system related diagnostics.
These diagnostics can be used for system troubleshooting and diagnostic information.
They are located on the main EMS unit in two rows of five:
High Engine Coolant Low Engine Oil Pressure

Temperature or Sensor Fault or Sensor Fault
High Inlet Manifold Low Fuel Pressure

Temperature or Sensor Fault or Sensor Fault
High Fuel Temperature Low Engine Coolant Level
or Sensor Fault or Sensor Fault
Low Battery Voltage

Engine Derate
or Sensor Fault
High Auxiliary Temperature High Auxiliary Pressure
or Sensor Fault or Sensor Fault
Figure 7c Caterpillar Engine Diagnostic Panel
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Page 7 - 11
EMS Main Unit
LCD Display
Beneath the warning lamps is an LCD digital display for engine parameters.
Display Scroll Feature
Each time the scroll forward switch (Figure 7c) is depressed and held, EMS will page through the
engine parameters in the order listed below. When the scroll backward is depressed and held, EMS will
page through the engine parameters in reverse order. The abbreviation for the parameter will be
displayed. When the scroll switch is released, EMS will display the current real time value for that
parameter.
Abbreviation Parameter
Spd Engine Speed

GA-1 Engine Oil Pressure
GA-2 Coolant Temperature
GA-3 Bateery Voltage
GA-4 Fuel Pressure
Boost Boost Pressure
IAirT Inlet Air Temperature
FuelT Fuel temperature
AccrP Auxiliary Pressure
AccrT Auxiliary Temperature
Fuel Fuel Rate
Hrs Engine Hours
Load Engine (Percent) Load
U.S. / Metric Units
Either U.S. or Metric (SI) units will be displayed, depending on the position of the U.S. / Metric Switch
(Figure 7c).
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Page 7 - 12
7.2.2 Plant Start Up

The engine must be started prior to this
WARNING
operation (Section 7.2.1). First check that all WEAR PERSONAL
emergency stop buttons (Section 1.7) have PROTECTIVE EQUIPMENT.
been disengaged. Refer to Section 7.1, Safety
The display screen on the plant control panel warning.
(Figure 7e) will take approximately 10
seconds to carry out a self diagnosis check,
then, if a system fault exists, the fault
condition will appear on the screen and the
warning siren will sound. Refer to Figure Note: After the 5 second warning ceases,
7.2.3 for a list of display messages. press for the second time within 10 seconds
otherwise the warning will be repeated.
! WARNING !
Faults displayed on the electrical
control panel screen should be
investigated and rectified
immediately by suitably qualified
personnel BUT FIRST SHUT
DOWN THE ENGINE AND
IMPLEMENT THE LOCKOUT
PROCEDURE (Section 8.2).
The panel display screen not only indicates

the status of the starting sequence but also
identifies any fault condition which will halt
the starting procedure. If a fault condition
appears refer to Section 7.2.5.
Take note of the information on the display

screen and operate the controls in the
sequence described in the procedure. When
any green start button is pressed there is a 5
second warning and then the button has to
be pressed a second time to activate the
appropriate item.
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Procedure ! NOTICE !
1. Observe all safety warnings. IMPORTANT
It is very important NOT to run the
2. Start the engine (Section 7.2.1)..Set the
Automax crusher before the Initial
speed at 1200 rpm.
Setting and Calibration procedure
has been carried out.
at PLANT and the RADIO REMOTE The Automax Upper Frame may
CONTROL switch at ON (Figure 7b). have been fully lowered to achieve
the minimum travel height and
4. Start the OIL PUMP by pressing the serious damage will occur if the
green start button; after 5 seconds machine is started whilst the
warning, press again within 10 seconds. manganese mantle and concave
are touching.
There is now a 5 minute delay before
the crusher can be started to allow time 6. Before starting the crusher ensure that
for good oil circulation within the the engine speed on the tachometer
Automax crusher before start up of the (Figure 7c) is not more than 1200 rpm.
machine. The display shows the time Press the crusher start button. Again 5
delay as a time elapsed bar graph. seconds warning and press again within
10 seconds. With the crusher running the
Note: In cold weather, prior to starting display screen will read WAIT 10
the oil pump, preheat the lubricating oil SECONDS, START FEED
by running the engine which is fitted CONVEYOR.
with a heat exchanger for this purpose.
5. After completion of the oil pump delay

the panel display will read START
DISCHARGE CONV. Press the
discharge conveyor start button. Again 5
seconds warning and second press of
the button within 10 seconds to run the
conveyor. The display screen should
now be reading START CRUSHER.
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Page 7 - 14
7. Adjust the engine speed control to the

operating engine speed of 1800 rpm
before starting to feed material to the
crusher.
THE FEED CONVEYOR HAS 2

METHODS OF OPERATION:-
- AUTO
- MANUAL
The feed conveyor should be

operated in the AUTO mode. Only in
exceptional case of auto operation
failure should MANUAL operation be
used but also manually continuously
monitor the feed into the Automax.
In AUTO mode the speed of the feed

conveyor is regulated automatically by the
level sensor mounted over the Automax
feed box whereas in MANUAL the
conveyor speed has to be regulated from
the rotary knob on the control panel
(Figure 7e).
When operating in manual mode make

sure that the crusher sensor control switch
(Figure 7e) is also put into the MANUAL
position.
8. Ensure the feed conveyor switch is turned

to AUTO and then press the start button.
Again 5 seconds warning and press again
within 10 seconds. See display screen to
check conveyor running.
Note: Before starting the feed

conveyor, check Section 7.2.7 -
Crushing Material, to ensure that
the feed material and the equipment
settings are suitable.
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Note: Any fault occurring during plant

running stops the relevant items of plant
equipment and overwrites the message
display with a fault message (Section
7.2.3).
Where an optional level sensor is

fitted over the feed hopper: After
starting the feed conveyor with the level
sensor switches in AUTO the feeder will
not run unless there is enough material in
the feed hopper. This is controlled by
presetting the level in the unit MR2. The
crusher feed box level sensor switches the
feeder off/on via the preset level settings in
the unit MR1 (Section 9.12).
9. Once the crushing of material has

commenced check that the plant is stable
and with no undue vibration.
Note: The crusher is mounted on anti-

vibration mountings and any undue
vibration is likely to be caused by
unsatisfactory support under the tracks
Recitify immediately.
10. Ascertain that the product material is to

the required specification and adjust the
feed material and/or settings if necessary.
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Page 7 - 16
Diagnostic Display Feed Conveyor Crusher Level

Screen Level Sensor Controls Sensor Controls
(*optional)
EMERGENCY
STOP
OPERATION
PLANT/TRACK
FEED CONVEYOR DISCHARGE CRUSHER FEED CONVEYOR

RADIO REMOTE FAULT CONTROLS CONVEYOR START/STOP MANUAL
CONTROL OFF/ON RESET START/STOP SPEED CONTROL
AUTO/MANUAL*
CRUSHER
FAULT CONTROLS OIL PUMP FEED CONVEYOR
MUTE AUTO/MANUAL START/STOP START/STOP
Figure 7e Electric Panel Controls
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Page 7 - 17
7.2.3 Electric Control Panel Screen Display Data

When following the the start up procedure (Section 7.2.2), command (C) messages appear on the
display screen (Figure 7e) to indicated next action necessary, unless there is a fault (F) message which
overrides any message on the screen. Use the reference number as an easy way to identify a fault
when contacting Terex Pegson/Dealers Service Department.
REF No: TYPE DISPLAY MESSAGE

1 C WESTBURY CONTROL STYSTEMS LTD
2 F TRACK CONTROL MODE
3 F WARNING OUT OF SEQUENCE WARNING WARRANTY INVALID IN THIS MODE
START OIL PUMP PRESS TO SOUND PRESTART ALARM. PRESS AGAIN WITHIN 10 SEC TO
4 C
START
5 C CRUSHER START DELAY 0 TO 5 MIN
6 C START DISCHARGE CONVEYOR
7 C WAIT 10 SECS START FEED CONV
8 C PLANT RUNNING
9 F CRUSHER BOWL MATERIAL HIGH LEVEL FEEDER STOPPED
10 F MATERIAL HOPPER MATERIAL LOW LEVEL FEEDER STOPPED
11 C PLANT START AVAILABLE START OIL PUMP. 10 SEC PRESTART ALARM
12 C CRUSHER START DELAY 0 TO 30 SEC
13 C CRUSHER START AVAILABLE
17 F TRACK UMBILICAL STOP FAULT CHECK TRACK UMBILICAL STOP BUTTON AND RESET
18 F TRACK RADIO STOP FAULT CHECK TRACK RADIO STOP BUTTONS ETC.
20 F EMERGENCY STOP FAULT CHECK PLANT E/M STOP BUTTONS AND RESET
26 F TRACK MOVEMENT C/B FAULT Q1 OR QUMB RESET Q1/QUMB CIRCUIT BREAKERS
27 F OIL PUMP C/B TRIPPED Q2 RESET Q2 CIRCUIT BREAKER
28 F OIL COOLER C/B TRIPPED Q3 RESET Q3 CIRCUIT BREAKER
29 F OIL HEATER C/B TRIPPED Q4 RESET Q4 CIRCUIT BREAKER
30 F DISCHARGE CONV C/B TRIPPED Q5 RESET Q5 CIRCUIT BREAKER
31 F FEED CONV C/B/ TRIPPED Q6 RESET Q6 CIRCUIT BREAKER
33 F HYD PANEL C/B TRIPPED Q3/Q3A RESET Q3/Q3A CIRCUIT BREAKER
36 F MINIRANGER C/B TRIPPED QMIN RESET QMIN CIRCUIT BREAKER
37 F METAL DETECTOR C/B TRIPPED QMD RESET QMD CIRCUIT BREAKER
38 F CRUSHER C/B TRIPPED QCS RESET QCS CIRCUIT BREAKER
39 F HYDRAULIC PANEL WEDGELOCK FAULT WEDGELOCK PRESSURE FAULT
41 F CRUSHER LUBE OIL TEMPERATURE HIGH CONTACT BL-PEGSON IMMEDIATELY
42 F CRUSHER LUBE OIL LEVEL LOW CHECK FOR LEAKS AND TOP UP LUBE OIL
43 F CRUSHER LUBE OIL FILTER BLOCKAGE CHANGE LUBE OIL FILTERS
44 F CRUSHER LUBE OIL FLOW FAULT NO LUBE OIL FLOW. CHECK FLOW METER
! METAL DETECTED ON FEED CONV BELT ! REMOVE METAL, RESET METAL DETECTOR &
45 F
FAULT RESET ON PANEL
DISCHARGE CONV TAIL DRUM SPEED FAULT DISCHARGE CONVEYOR TAIL DRUM
46 F
STOPPED/SLOW
47 F PLC BATTERY LOW TEL 44-(0) 01530 839829 IMMEDIATELY
CRUSHER LUBE HYDRAULIC MOTOR ELECTRONIC FLOW FAULT NO LUBE OIL FLOW.
50 F
CHECK ELECTRONIC FLOW FAULT
51 F CRUSHER PRESSURE SWITCH FAULT CHECK PRESSURE SWITCH SETTING
52 F HYDRAULIC SYSTEM LOW OIL CHECK FOR LEAKS & TOP UP HYDRAULIC OIL LEVEL
NOTE: DO NOT REPEAT A RESET OF A CIRCUIT BREAKER IF IT IMMEDIATELY TRIPS OUT AGAIN.
HAVE THE REASON INVESTIGATED AND CORRECTED BY A SUITABLY QUALIFIED PERSON
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Page 7 - 18
7.2.4 Plant Operating Sequence

and Automatic Safeguards WARNING
The plant operating sequence is as follows:- WEAR PERSONAL
I Oil Pump. Refer to Section 7.1, Safety
warning.
II Discharge Conveyor.
III Crusher.
IV Feed Conveyor.
If the discharge conveyor stops the crusher

and feed conveyor are automatically
stopped.
If the discharge conveyor drum rotation

sensor detects no rotation the crusher and
feed conveyor are automatically stopped.
If the crusher stops the feed conveyor is

automatically stopped.
If the oil pump stops the crusher and feed

conveyor are automatically stopped.
If the oil flow devices detect no flow or oil

pump not running the crusher and feed
conveyor are automatically stopped.
If the low oil level is detected the crusher

and feed conveyor are automatically
stopped.
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Page 7 - 19
7.2.5 Fault Indication and Restart

System faults cause an alarm to sound and
WARNING
the fault will be shown on the Diagnostic WEAR PERSONAL
Display Screen (Figure 7e) and the PROTECTIVE EQUIPMENT.
appropriate equipment stopped. Refer to Section 7.1, Safety
The alarm can be silenced by pressing the warning.
MUTE button (Figure 7e). The displayed fault
must be rectified before the plant can be
restarted. If the fault is not corrected and the
fault reset button has not been pressed the
warning siren will sound again after 5 minutes.
After the fault has been rectified press the

FAULT RESET button (Figure 7e)
followed by the appropriate start button(s).
Exactly which start button(s) will depend
upon where in the sequence the fault
occurred.
Follow the instructions on the display screen

to identify and deal with any faults when
they occur.
To deal with fault alarms caused by metal

detection refer to Section 7.2.6.
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Page 7 - 20
7.2.6 Metal Detection

When metal is detected on the conveyor belt
WARNING
the audible alarm will sound (and also the
WEAR PERSONAL
visible red fault light and diagnostic display PROTECTIVE EQUIPMENT.
will indicate) and the Feed Conveyor will Refer to Section 7.1, Safety
stop. Information for relevant warning.
Climb up to the top platform and remove the FALLING HAZARD

offending metal from the conveyor and then Refer to Section 7.1, Safety
press the RESET button on the detector Information for relevant warning.
control box (Figure 7f).
Although the fault will be signalled to the

main panel PLC it is only necessary to reset Green POWER ON light
at the metal detector panel (Figure 7f).
Restarting the feed conveyor will depend
upon which of the following alternative
operating modes is being used at the time:
Radio Remote Control OFF

The feed conveyor is started and stopped
with the Electric Panel controls (Figure 7e).
After the pressing RESET (Figure 7f),
restart the feed conveyor at the panel.
Radio Remote Control ON

In this mode, where the feed conveyor is
being stopped and started remotely with the
radio hand set, press RESET (Figure 7f) and
then restart the feed conveyor with the start/
stop button of the hand set (Figure 7g).
Red DETECT light and RESET button
Figure 7f Metal Detector Control Panel
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Page 7 - 21
7.2.7 Feed Conveyor Remote

Operation WARNING
To operate the Feed Conveyor remotely, first WEAR PERSONAL
switch on the radio hand set and then carry PROTECTIVE EQUIPMENT.
out the plant starting sequence. (Section Refer to Section 7.1, Safety
7.2.2). Information for relevant warning.
Procedure
2. To start up the handset transmitter first

stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:-
Feed Conveyor
Ensure the stop button is pulled out.
stop/start button
Depress both of the safety buttons
(Fig.5b) at the same time for at least
1 second. Release the safety buttons.
The red LED will change to green.
The transmitter is in function status
when the green LED comes on.
Stop Button
3. Proceed with Plant Start Up (Section
7.2.2) at the Electric Panel Controls Figure 7g Feed Conveyor Remote Operation
(Figure 7e) including starting the Feed
Conveyor.
Note: The radio remote control of the

feed conveyor does not become
operative until the Feed Conveyor start 4. The feed can be turned on and off using
button on the main panel is activated. the Feed Conveyor On/Off button on the
hand set (Figure 7g). Pressing the stop
button on the hand set will close down
the complete plant. The speed of the
feed cannot be adjusted using the hand
set. To adjust the speed of the feeder
refer to Section 7.2.3.
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Page 7 - 22
7.2.8 Crushing Material - Plant and Automax Settings

The crushing performance of the plant is controlled by the particular material being fed into the feed
hopper and the settings of various items of equipment within the plant as illustrated below. For
optimum crusher performance a continuous choke feed into the crusher is most important.
Actions A are determined at the time of commissioning and, normally, do not need to be altered, whilst
Actions B are usually relevant during daily operation. See the appropriate Sections for detailed
instructions.
Section 3.4 - Action B for the suitability of the

feed material depending upon meeting the
Feed Material criteria specified and also depending upon the
crusher installed being an Automax or
Autosand.
Section 9.12 - Action A presetting levels.

Action B the plant operator needs to keep
above the preset low level to ensure a
Feed Hopper Level Sensor continuous feed. The sensor works in
(Optional) conjunction with the Automax Level Sensor
when AUTO selected to control the Feed
Conveyor speed.
Section 9.17 - Action A for sensitivity and

Metal Detector setting. Action B for operation when metal is
detected (Section 7.2.6).
Section 9.12 - Action A for presetting the

sensor in conjunction with the Feed Hopper
Automax Level Sensor Level Sensor when AUTO selected to control
the Feed Conveyor speed
Section 7.3 and 7.4 - Action B. for the

instructions also covering the monitoring of
Automax Crusher manganese wear and the unblocking
procedure.
Section 3.4 - Action B Check the product.

Product Material The graphs & capacities are a guide only and
will vary depending upon the conditions.
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Page 7 - 23
7.2.9 Plant Initial Start Up and

Running In WARNING
Initial Start-Up WEAR PERSONAL
! WARNING ! Information for relevant
warning.
Observe all safety warnings whilst
carrying out inspections and LOCKOUT PLANT.
checks. Information for Lockout
Procedure.
Check levels of oils are satisfactory.
Refer to the lubrication schedules 9.4.4 FALLING HAZARD.
and 9.4.5 for details. Refer to Section 7.1 Safety
Refer to engine manual for engine initial warning.
start up instructions
Run the plant empty for a short period of Each day during the initial days of
time and check for abnormal noises, operation check the tension of the
vibration or excessive heat from shaft conveyor belts on the feed and
bearings, fluid leaks, etc. including the discharge conveyors and adjust if
feed conveyor gearbox. necessary. Refer to Section 9.16.3
Actions During Running-In Period Make sure the conveyor belts are
tracking correctly and that the skirt
sealing rubbers are correctly adjusted.
! NOTICE ! Refer to Section 9.16.2
Checks on the Maxtrak plant are Check frequently the overall stability of
crucial during the first week of the plant; re-check the level of the plant
crushing operation. and move to level position if necessary.
The following section should be
read and understood prior to Regularly check drive belts (crusher and
starting the plant. If there are any hydraulic pumps) to ensure correct
doubts, contact BL Pegson Ltd. tension, particularly during the initial 2
Service Department. weeks of use. Refer to Section 9.15
Plant Check the alignment and tension of the

vee belt drives daily during the initial
All control systems should be checked days of operation. Refer to Section 9.15
for full function.
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Page 7 - 24
Avoid overloading the crusher; Make sure that the crusher lubrication
system is functioning correctly (fault
Check for any leaks of lubricants, fuel, warnings will show on the diagnostic
water or hydraulic fluid and rectify panel) and that no leaks are present.
immediately.
Check for leaks in the crusher hydraulic
Check for any overheating of running system, both externally and inside the
parts. hydraulic console.
! WARNING !
Shut down the plant if this occurs
and investigate the reason. If
necessary, contact Terex Pegsons
Service Department for advice to
avoid the possibility of danger or
damage.
Crusher

days of operation.
Avoid overloading the machine by not

first few days of operation.
Ensure that the machine is running

correctly and that the satisfactory feed
(Section 3.4) is maintained at a constant
rate (Section 7.2.7). Irregular and
excessive feed rates reduce the
efficiency of the Automax.
Ensure that the Automax feed is not

segregated in the crushing chamber.
Note: This applies to all machine
operations subsequent to the running in
period.
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Page 7 - 25
7.2.10 Daily Plant Checks

WARNING
! WARNING ! WEAR PERSONAL
.It is imperative that the operator PROTECTIVE EQUIPMENT.
carries out regular and diligent Information for relevant
checks before operating the plant warning.
especially with operational safety LOCKOUT PLANT.
in mind including (but not limited Refer to Section 7.1, Safety
to) those listed below. Information for Lockout
Procedure.
Additionally, the operator should
always consider what particular FALLING HAZARD.
safety hazards could occur at Information for relevant
specific operating sites and take warning.
steps to eliminate them before
commencing work.
Daily Checks
1. Check that all guarding is complete and

properly secured prior to start up. Also
that all warning signs (Section 1.8) are
present and readable.
2. Check that all the plant emergency stop

buttons are operative (Section 1.7 and
8.3.3).
3. Carry out a general inspection of the plant

to ascertain that nothing untoward is out of
place or damaged so as to cause a safety
hazard.
4. Ascertain any fault messages displayed on

the Electrical Control Panel (Section
7.2.3).
5. Check engine clutch bearing oil level

(Section 9.19.2)
Note: See also Section 7.3.12 for daily

Automax checks.
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Page 7 - 26
7.3 Automax Operation Selection of the discharge setting is carried out

manually with the controls switched into
The Automax crusher is a high quality cone MANUAL as are also other additional
crusher featuring:- functions described later.
Optimum Performance - Advanced The material product from the Automax is

crusher geometry. Excellent product governed by the closed side discharge setting
shape through attrition crushing. High dimension, ie. the minimum gap between the
output capability. Maximum production concave and mantle manganese crushing
of high quality material. members. See the Glossary of Terms for other
ways of referring to the setting. Changes to
the discharge setting are achieved by raising or
Low Cost Operation - High capacity
lowering the Automax upper frame by means
with energy efficiency. Low wear costs.
of the six externally mounted hydraulic rams.
Exceptional reliability.
When new manganese is fitted the MANUAL
Ease of Maintenance - Accessible
hydraulic controls are used for the panel to
external hydraulics. Simple assembly
record a zero point at which the mantle and
and dismantling. Quick manganese
concave are just touching. The required
changes.
discharge setting dimension is then manually
entered into the panel controls. The hydraulic
To assist in understanding the Automax
system can then position the upper frame so
hydraulic control functions the following
that the gap between the mantle and concave
brief explanation is given. The actual step by
equals the entered setting. This procedure is
step procedures are detailed in the following
carried out with the machine stationary.
pages under the appropriate section
headings. Refer also to the Glossary of
Automax Terms (Section 7.3.2) for During crushing operations the mantle and
additional information. concave wear under abrasive action of the
material being crushed and the gap between
With the Automax in normal AUTO the two will increase although the panel display
crushing operation the hydraulic system will still show the original gap setting.
automatically maintains a pre-selected
discharge setting which determines the To restore the actual gap between the two
product from the machine. The setting is crushing members to the original setting it is
maintained by hydraulic pressure and, in the necessary to manually reset the zero point
event of uncrushable material entering the with the mantle and concave touching. The
machine, the hydraulic overload release is controls can now compare the new zero point
automatically triggered to raise the upper with the original zero point with new
frame to pass the foreign body and then manganese. The machine is to be stationary
automatically returns to the selected setting. when this procedure is carried out.
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Page 7 - 27
By selecting manganese wear on the Also available on the hydraulic control

display screen, the panel will now calculate display are additional read out facilities
the amount of wear that has taken place including crusher motor hours run and
since fitting new manganese. The rate of number of tramp overload situations (Section
manganese wear obviously depends upon the 7.4.3)
physical characteristics of the feed material
and other governing factors and will confirm In addition to these normal machine control
the frequency of re-calibrating the zero point functions the system also includes a separate
to maintain the desired product and also the audible alarm and hydraulic system
need to change the manganese mantle and malfunction messages which appear on the
concave. display screen (Sections 7.4.10 to 13)
For guidance on when to change the Additionally, a separate subsidiary hydraulic

manganese mantle and concave liners refer circuit is employed to apply pressure to the
to Section 9.7.1. wedge ring and the requirements for this
system are also covered later in this manual
(Section 9.8).
! NOTICE !
It is most important to change both Service schedules in this manual assume
reasonable operating conditions apply. Refer
the liners together when fitting
to Terex Pegson Limiteds technical
new replacements. department for advice if the operating
conditions are other than normal.
At the same time as changing the mantle and
concave, take the opportunity of replacing
the frame arm and countershaft protection
liners.
Genuine replacement parts obtainable from

BL-Pegson are manufactured with the
correct material specification and to the
original dimensions under strict quality
control. Always quote the machine serial
number stamped on the machine identity
plate when ordering.
The hydraulic control system also allows the

discharge setting to be altered whilst the
machine is running and also a number of
other functions as described in the following
pages.
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To identify the terms used in connection with the Automax crusher the
illustration below indicates the major parts. Also refer to the Parts List in
Section 10 for more detailed identification of individual parts.
CRUSHING
GAP
7.3.1 Glossary of Automax Parts
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7 - Operating Instructions
DUMPY
EN
Maxtrak 1300
Page 7 - 28
Figure 7h Automax Components

Maxtrak 1300
Page 7 - 29
7.3.2 Glossary of Automax Terms

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

An even distribution of material particle sizes in the feed.
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Make the checks prior to starting the Check that all Emergency Stops on the
plant (Section 7.1.3). plant are pulled out (Figure 1a).
Check that the conveyors and Automax Make sure that you fully understand the
crushing chamber are empty of material. operating procedures for the Automax
before attempting to start.
Pressure
Numeric Keypad Display Gauge

Switch Button
Figure 7i Automax Hydraulic Panel Controls
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7.3.3 Automax Initial Discharge

Setting and Calibration WARNING
FOR THIS OPERATION THE WEAR PERSONAL
AUTOMAX MUST NOT BE RUNNING PROTECTIVE EQUIPMENT.
Referring to the separate Automax Information for relevant
Control Panel (Section 7.4) for warning.
follows;-
Procedure
1. Observe all safety warnings. 6. Scroll to the New Mang display screen
and then press Enter.
engine speed at 1200rpm. 7. Press the F4 key to Zero the display and
then press Escape.
at PLANT and the RADIO REMOTE 8. Scroll to the Set Gap display screen,
CONTROL switch at ON (Figure 7b). press Enter and then press Enter again.
DO NOT press any of the start buttons.
9. Key in the required closed side setting
4. On the Automax hydraulic panel (Figure (mm) using the number keys, press the
7i) switch to MANUAL and depress the Enter and then press Escape.
OPEN button to raise the Upper Frame
approximately 25-38mm (1 to 1). 10. Scroll to the Current Gap display
Look into the Automax crushing screen.
chamber to check there is no stone
lodged in the chamber. 11. Depress the OPEN button; hold until the
Current Gap display shows the gap to
5. Now depress the CLOSE button until be above the Set Gap setting then
the manganese crushing members switch to AUTO. The machine will
(mantle and concave) touch. This is automatically come down to the required
indicated by a sudden rise in pressure setting.
shown on the gauge near the panel
(Figure 7i) and release the button
immediately.
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7.3.4 Automax Manganese Wear

Calibration WARNING
FOR THIS OPERATION THE WEAR PERSONAL
AUTOMAX MUST NOT BE RUNNING PROTECTIVE EQUIPMENT.
Referring to the separate Automax Information for relevant
Control Panel (Section 7.4) for warning.
follows;
Procedure
1. Observe all safety warnings 6. Scroll to the Set Zero display screen and
then press Enter.
engine speed at 1200rpm. 7. press the F3 key to Zero the display
screen and then press Escape.
at PLANT and the RADIO REMOTE 8. Scroll to the Current Gap display
CONTROL switch at ON (Figure 7b). screen.
9. Depress the OPEN button; hold until the
4. On the Automax hydraulic panel (Figure Current Gap display shows the gap to
7i) switch to MANUAL and depress the be just above the Set Gap setting then
OPEN button to raise the Upper Frame switch to AUTO. The machine will
approximately 25-38mm (1 to 1). automatically come down to the required
Look into the Automax crushing setting.
chamber to check there is no stone
lodged in the chamber. Note: After calibration the amount of
manganese worn off the crushing
5. Now depress the CLOSE button until members is displayed by scrolling to the
the manganese crushing members Mang Wear display screen.
(mantle and concave) touch. This is
indicated by a sudden rise in pressure
shown on the gauge near the panel ! NOTICE !
(Figure 7i).
The interval between future
calibrations is determined by
machine usage and estimated
wear of the manganese.
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7.3.5 Guidance for Changing the When replacing the manganese liners,
Manganese Mantle and Concave always fit both a new mantle and a new
concave at the same time.
Both the mantle and concave liners are
locked against their mating parts using tapers
(angled faces). If these liners are worn too ! NOTICE !
thin they will not be able to hold tight against
their mating faces, coming loose and/or Always fit a new manganese
slipping relative to their mating part. The mantle and concave as a pair. It is
mating will be damaged and will need detrimental to the operation of the
reworking. machine to do otherwise.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 55-60mm (21/8- 23/

8
) of wear on the liners, as a pair.
Take note of the wear shown on the

display (Section 7.4.3).
Inspect the liners on a daily basis, for

possible tramp metal damage and also any
evidence of an uneven wear pattern
774 mm (301/2) minimum
developing.
The manganese liners must be changed

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance (Figure
7j) when the rams are fully closed is 774mm
(30.5)..
Figure 7j Minimum Ram Dimension
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7.3.6 Automax Initial Start Up

WARNING
Procedure
WEAR PERSONAL
1. Observe all safety warnings PROTECTIVE EQUIPMENT.
2. Start the engine (Section 7.2.1). Set the Information for relevant
warning.

DANGER
SKIN INJECTION HAZARD
CONTROL switch at ON (Figure 7b). Refer to Section 7.1, Safety
4. Carry out the sequential start procedure warning
(Section 7.2.2) EXCEPT DO NOT
START THE FEEDER.
Note: The Automax safety interlocks

and protection devices are checked with
the fault display on the Electrical Control
Panel.
5. Check that the overall operation of the

lubrication system is satisfactory.
6. Run the Automax empty for a short

Release the button when the hydraulic
period and check the machine for
cylinders have reached the full extent of
unusual noises, vibration, excessive heat,
their travel and switch to AUTO. Note
leaks of lubricating oil.
the pressure on the panel gauge as the
machine closes down to its discharge
7. Check the hydraulic system for leaks setting. This pressure should be in the
and that the discharge setting is being region of 55 - 82 BAR (800-1200psi).
maintained.
Note: The cone head will rotate with the
8. Check the travel on the Automax Upper eccentric while the machine is running
Frame by switching into MANUAL on empty, but stops when feed is introduced
the Automax Panel (Figure 7i) and into the crushing chamber and begins to
depressing the OPEN button. The slowly rotate in the opposite direction.
Upper Frame will travel upwards.
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7.3.7 Actions during running in

WARNING
WEAR PERSONAL
days of operation. PROTECTIVE EQUIPMENT.
Avoid overloading the machine by not Information for relevant warning.
first few days of operation. FALLING HAZARD
Ensure that the machine is running Information for relevant warning.
correctly with no abnormal noises or
leaks evident.
Make sure a satisfactory feed (Section

3.4) is maintained at a constant rate to
give a choke feed (Section 7.3.2
Glossary). Irregular and excessive feed
rates reduce the efficiency of the
Automax. Ensure that the feed is not
segregated in the crushing chamber.
Note: This applies to all machine

operations subsequent to the running in
period.
Keep a check on the lubrication system

to confirm this is operating satisfactorily
and that the system safeguards warn of
any possible high temperature or low
flow (Section 9.5).
Check the operation of the hydraulic

system (Section 9.6) including the
smooth raising and lowering of the upper
frame and the correct functioning of the
wedge ring (Section 9.8).
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7.3.8 Automax Adjustment of

Discharge Setting WARNING
AUTOMAX RUNNING WEAR PERSONAL
Referring to the separate Automax Refer to Section 7.1, Safety
Control Panel (Section 7.4) for Information for relevant
detailed instructions, action as warning.
follows;
Procedure
1. Observe all safety warnings. 8. Scroll to the Current Gap display
screen.
engine speed at 1200rpm. 9. Depress the OPEN button; hold until the
Current Gap display shows the gap to
3. Continue with the OPERATION switch be above the Set Gap setting then
at PLANT and the RADIO REMOTE switch to AUTO. The machine will
CONTROL switch at ON (Figure 7b). automatically come down to the required
setting.
4. Carry out the sequential start procedure
(Section 7.2.2) EXCEPT DO NOT
START THE FEEDER.
5. On the Automax Hydraulic Panel (Figure

7i) switch to MANUAL.
6. Scroll to the Set Gap display screen,

press Enter and then press Enter again.
7. Key in the required closed side setting

(mm) using the Number keys and then
press the Enter and then Escape.
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7.3.9 Manual Raising/Lowering of

the Automax Upper Frame WARNING
AUTOMAX RUNNING WEAR PERSONAL
Provision is made for raising and lowering Refer to Section 7.1, Safety
the Upper Frame when under manual Information for relevant
control. warning.
! NOTICE !
DO NOT UNDER ANY
CIRCUMSTANCES RUN THE
AUTOMAX UNDER MANUAL
CONTROL FOR ANY LONGER
4. Carry out the sequential start procedure
THAT ABSOLUTELY NECESSARY (Section 7.2.2) EXCEPT DO NOT
START THE FEEDER.
When under manual control the
tramp metal protection (ie. the 5. On the Automax Hydraulic Panel (Figure
automatic hydraulic overload 7i) switch to MANUAL.
release) is not operative and
therefore damage to the machine 6. Depress the OPEN button to raise the
could result. Upper Frame to the maximum extent.
On release of the button the Upper
If the machine is left in manual control an Frame is retained at this position.
audible warning alarm will sound after a
short period to warn the operator to switch 7. On re-selection of AUTO the control
into auto control. automatically resets the discharge setting
to that previously specified.
Procedure


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7.3.10 Automax Automatic

Overload Release/Unblocking and ! NOTICE !
Resetting In order to protect the Automax
The control equipment on the Automax crusher from the ingress of
crusher automatically monitors the operating damaging tramp metal the plant is
conditions of the hydraulic system for tramp fitted with a metal detector on the
metal/packing in the crushing chamber and feed conveyor which will sound an
effects an immediate release. The equipment alarm and stop the feed.
also resets the discharge setting and also
compensates for any tendency for the setting It is essential to remove the
to creep open during normal operation. offending object before resetting
the detector and restarting the
Normally the hydraulic system clears any feed.
tramp metal from the crushing chamber.
However, in the event of the tramp metal
being too large to be released, severe
Make sure that the metal detector
damage to the machine can occur as the is operative and correctly set for
system continues to try and release the sensitivity (Section 9.17.1) at all
object. times when crushing.
In this event the machine should be switch to

manual control, the Upper Frame raised, and
the blockage removed manually. Refer to
Section 7.1.1. for Blocked Crusher
procedures
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7.3.11 Checking Automax Wedge

Pressure WARNING
AUTOMAX NOT RUNNING WEAR PERSONAL
The pressure on the wedge ring is Refer to Section 7.1, Safety
automatically controlled by the Dumpy Jack Information for relevant
hydraulic circuit. However, as the adjustment warning.
of the wedge ring is critical for good
performance of the Automax crusher it is
recommended that this should be checked
daily. The pressure gauge near the panel
(Figure 7i) gives an accurate indication of
whether the Wedge Ring assembly is
functioning correctly.
4. On the Automax Hydraulic Panel

! NOTICE ! (Figure 7i) switch to MANUAL and
depress the OPEN button lifting the
The Automax must not be allowed Upper Frame approximately 20mm
to operate with regular dumping or (3/4) above the set point.
bouncing of the Upper Frame or
damage may result. Possible 5. Switch back to AUTO and observe the
causes could be crushing at too pressure reading on the panel pressure
small a setting, out of round gauge (Figure 7i). The pressure should
manganese (Section 9.9) or poor be in the range 55 - 82 BAR (800 - 1200
Wedge Ring adjustment (Section psi).
9.8).
6. Whilst the Upper Frame is moving check
for smooth movement with no sticking at
Procedure
the start or whilst travelling.
1. Observe all safety warnings
7. If the pressure reading is above or below
2. Start the engine (Section 7.2.1). Set the the range indicated above or the action is
engine speed at 1200rpm. not smooth, remedial action is required
(Section 9.8).
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7.3.12 Daily Automax Checks

WARNING
! NOTICE ! WEAR PERSONAL
Daily attention should always be a PROTECTIVE EQUIPMENT.
matter of routine to ensure Information for relevant
maximum efficiency of this vital warning.
element of the plant.
DANGER
Before starting the Automax
Look at the manganese liners to check for Refer to Section 7.1, Safety
wear and/or damage. Information for relevant
Check oil level in lubrication tank. warning
Check oil level in hydraulic tank.
Check oil pressure in hydraulic console.
Check the operation of the lubrication oil After starting the lub oil pump
heater.
Check Wedge pressure. Check the oil flow to the crusher and back
Re-calibrate the manganese. into the tank (sight glass on top of oil tank in
Check for any obstructions in the discharge return pipe) and that oil lines do not leak.
opening of the Automax.
Check the condition of the vee drive.
After starting the Automax
Check for loose bolts, leaks, hose
connections, etc. Set the discharge setting
WARNING Ensure the frame arms are Listen for any abnormal noise from the
free from foreign bodies/stone build up. See crusher.
the warning sign on the machine (Figure 7k). Check that no bolts have come loose.
During crushing
Listen for any abnormal noise from the
crusher.
Check oil pressure at normal running
temperature.
Check no leaks in the lubrication system.
Inspect hydraulic system piping, cylinders,
etc. for leaks which could cause an
alteration in the setting.
Note the crushing pressure.
Figure 7k Frame Arm Warning Sign
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7.4 Automax Crusher Controls
The Automax Crusher is equipped with the latest System 2-2000 hydraulic controls having a Unitronics
M-90 control module with numeric keypad and status display. The layout, functions and displays are
described on the following pages.
7.4.1 Controls Layout
System I I 2000
BL-Pegson a Terex >>
Figure 7l Controls Layout
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7.4.2 Function Keys
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7.4.3 General Operation
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7.4.3 General Operation, continued
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7.4.4 Manual Operation
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7.4.5 Setting the Gap
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7.4.5 Setting the Gap, continued
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7.4.6 Setting New Manganese
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7.4.6 Setting New Manganese, continued
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7.4.7 Setting Normal Zero
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7.4.7 Setting Normal Zero, continued
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7.4.8 Tramp Overload or Test (whilst in Manual)
7.4.9 Tramp Overload or Test (whilst in Auto)
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7.4.10 Alarms
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7.4.11 Alarm List
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7.4.11 Alarm List, continued
7.4.12 Wedge Lock Option
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7.4.13 Historical Alarms
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7.4.14 Set Time & Date
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7.4.14 Set Time & Date, continued
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7.4.15 Set Operating Language
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8 - Shut Off EN
Page 8 - 1
8 - Shut Off
8.2 Closing Down the Plant ................................................................................. 8 - 4
8.3 Emergency Stopping of the Engine .............................................................. 8 - 8

8.3.1 Emergency Stop Buttons ............................................................................ 8 - 8
8.3.2 Restarting the Plant .................................................................................... 8 - 9
8.3.3 Testing Buttons ......................................................................................... 8 - 10
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followed.
LOCKOUT PROCEDURE

lockout.

HAZARD
injury.



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HAZARD
machine.

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8.2 Closing Down the Plant

WARNING
Procedure WEAR PERSONAL
1. Observe all safety warning
Information for relevant warning.
2. On the Electrical Control Panel (Figure
8a), press the red Feed Conveyor stop
LOCKOUT MACHINE.
button to stop the feed and wait until
the crusher and both conveyor belts Information for Lockout
are empty of material before the Procedure.
next step.
3. Press the red Crusher stop button to stop

the crusher and wait until the crusher
cone head has stopped spinning
before the next step.
! NOTICE !
WARNING. The reason for the
delay is so that the oil pump
continues to circulate oil to the
crusher bearings during the
Automax run down time. Failure to
obey this instruction will result in
reduced bearing life.
THE PLANT SHOULD NOT BE

SHUT DOWN AT THE END OF A
SHIFT BY ONLY SWITCHING OFF
THE ENGINE OR BY PRESSING
AN EMERGENCY STOP BUTTON.
4. Press the remaining red Discharge

Conveyor and Oil Pump stop buttons to
stop these items.
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Page 8 - 5
5. Using the speed control, decrease the

engine rpm to 1200rpm (Figure 8b)
6. Let the engine idle for 3-5 minutes.
7. Turn the Ignition Key to the off position

to shut down the engine. Remove the
Ignition Key. Shut and lock the Control
Box door. Lockout the Isolation Switch
(Figure 8c).If the radio hand set (where
fitted) has been in use, shut down by
depressing the stop button on the unit.
8. Following the closing down procedure

above, it is recommended that at the end
of operation for the day the plant is
routinely cleaned down and thoroughly
examined to check for any damage,
breakages, wear, leaks etc. which should
be rectified before further operation.
! NOTICE !
Use of high pressure washing
equipment is to be avoided where
the ingress of water will be
detrimental to plant components
eg crusher bearings, conveyor
bearings, hydraulic tank, electrical
equipment etc.
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Page 8 - 6
Diagnostic Display Feed Conveyor Crusher Level

Screen Level Sensor Controls Sensor Controls
(*optional)
EMERGENCY
STOP
OPERATION
PLANT/TRACK
FEED CONVEYOR DISCHARGE CRUSHER FEED CONVEYOR

RADIO REMOTE FAULT CONTROLS CONVEYOR START/STOP MANUAL
CONTROL OFF/ON RESET START/STOP SPEED CONTROL
AUTO/MANUAL*
CRUSHER
FAULT CONTROLS OIL PUMP FEED CONVEYOR
MUTE AUTO/MANUAL START/STOP START/STOP
Figure 8a Electric Panel Controls
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Page 8 - 7
US/Metric Switch Scroll Switch
Fuel Gauge Speed Control
Ignition Key
Figure 8b Caterpillar Engine Control Panel
Figure 8c Engine Isolation Switch
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8.3 Emergency Stopping of

the Engine WARNING
WEAR PERSONAL
IN AN EMERGENCY SITUATION, PROTECTIVE EQUIPMENT.
STOP THE ENGINE (AND THE Refer to Section 8.1, Safety
PLANT OPERATION ) USING THE Information for relevant
EMERGENCY STOP BUTTONS. warning.
See Section 1, Figure 1a for locations of

the Emergency Stop buttons.
Note:- The plant should not be restarted

if the crusher is full of material (Refer to
Section 8.3.2)
When the plant has been stopped using

an Emergency Stop button, the Engine
Ignition Key remains in the on
position. The switch should be returned
to the off position as soon as possible
to avoid the ignition being left on.
! WARNING !
When an emergency stop has
been initiated, DO NOT attempt to
restart the engine until it is safe to
do so.
8.3.1 Emergency Stop Buttons

Pressing any of the buttons will stop the
diesel engine and the button will remain
engaged until physically released by pulling
or twisting (depending upon the type fitted)
the button knob. The engine cannot be
started if any of the emergency buttons
remain depressed.
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8.3.2 Restarting the Plant
! WARNING !
WARNING
WEAR PERSONAL
When an emergency stop has PROTECTIVE EQUIPMENT.
been initiated, DO NOT attempt to Information for relevant
restart the engine until it is safe to warning.
do so.
! NOTICE !
When restarting the plant after the
use of an Emergency Stop button
it is essential to ensure that the
Automax crushing chamber is
empty of material.
Procedure
2. Follow the safe start-up procedure

(section 7.2)
3. Start the engine (section 7.2.1)
4. Manually raise and lower the Automax

Upper Frame by following the procedure
in Section 7.3.9.
5. Visually check that material in the

crushing chamber has been discharged
and that the chamber is empty.
Note: In the event of material failing to

clear the crushing chamber, repeat the
operation above or follow the Blocked
Crusher Procedure (Section 7.1.1) as
necessary.
6. When safe to do so continue with the

Plant Start-Up Procedure (Section
7.2.2).
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8.3.3 Testing Buttons
! WARNING !
WARNING
WEAR PERSONAL
Daily, before commencing PROTECTIVE EQUIPMENT.
crushing operations, test each Information for relevant
emergency stop button is warning.
operative.
Procedure
2. Follow the safe start-up procedure

(section 7.2)
3. Start the engine (section 7.2.1)
4. Test each emergency stop button in turn

to cut out the engine and, following the
re-setting of the tested button, repeat the
process for each of the other emergency
stop buttons (Section 1-Figure 1a) and
also the stop button on the remote
control handset.
5. When safe to do so continue with the

Plant Start-Up Procedure (Section
7.2.2).
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9 - Maintenance EN
Page 9 - 1
9 - Maintenace

9.1.1 Engine Start-Up - Maintenance ................................................................... 9 - 8
9.2 Weights of Automax Crusher Components................................................ 9 - 10
9.3 General Information ...................................................................................... 9 - 11
9.4 Lubricants, Oils, Coolant, etc. ...................................................................... 9 - 13

9.4.1 Service Attention Points ........................................................................... 9 - 13
9.4.2 Regular Servicing ..................................................................................... 9 - 14
9.4.3 Daily, Weekly and Monthly Checks ........................................................... 9 - 15
9.4.4 Automax Crusher Lubrication and Servicing Schedule .............................. 9 - 17
9.4.5 Plant Lubrication and Servicing Schedule ................................................. 9 - 18
9.4.6 Recommended Oil/Grease Types............................................................. 9 - 19
9.5 Automax Crusher - General ......................................................................... 9 - 22
9.5.1 Automax Lubrication Overview ................................................................. 9 - 22
9.5.2 Automax Lubrication Operating Procedure ............................................... 9 - 23
9.5.3 Automax Lubrication System Detailed Description ................................... 9 - 25
9.5.4 Automax Oil Change Intervals ................................................................... 9 - 27
9.5.5 Recommended Automax Oil ..................................................................... 9 - 28
9.5.6 Automax Oil Filter Change Intervals .......................................................... 9 - 29
9.5.7 Automax Oil Filter Replacement ............................................................... 9 - 30
9.5.8 Automax Oil Lubrication System General Maintenance ............................. 9 - 31
9.6 Automax - Hydraulics Overview .................................................................. 9 - 32
9.6.1 Automax Hydraulic System Maintenance Procedure ................................. 9 - 34
9.7 Manganese Change Procedure................................................................... 9 - 35
9.7.1 Guidance for Changing the Manganese Mantle and Concave ................... 9 - 35
9.7.2 Filler Handling .......................................................................................... 9 - 36
9.7.3 Changing the Manganese ........................................................................ 9 - 38
9.8 Wedge Ring Maintenance ............................................................................ 9 - 56
9.8.1 Checking Automax Wedge Pressure ........................................................ 9 - 58
8.8.2 Low Wedge Pressure .............................................................................. 9 - 59
9.8.3 Readjusting Tight Wedge Ring ................................................................. 9 - 60
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9.9 Automax - Out of Round Manganese - Causes and Effects ...................... 9 - 62

9.9.1 Checking Manganese for Out of Round .................................................... 9 - 63
9.10 Automax - Fault finding. ............................................................................ 9 - 66
9.11 Plant - Feed Conveyor ................................................................................ 9 - 76
9.12 Plant - MiniRanger Level Sensors Description ........................................ 9 - 77

9.12.1 Level Sensors - Operation ..................................................................... 9 - 78
9.12.2 Level Sensors - Run Mode ..................................................................... 9 - 79
9.12.3 Level Sensors - Program Mode .............................................................. 9 - 80
9.12.4 Level Sensors - Factory Settings ............................................................ 9 - 81
9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl ..................................... 9 - 82
9.12.6 Level Sensor MR2 Setup Guide - Hopper* ............................................. 9 - 84
9.13 Plant/Automax - Hydraulic Systems ......................................................... 9 - 86
9.13.1 General Description ............................................................................... 9 - 86
9.13.2 Track Drives ........................................................................................... 9 - 88
9.13.3 Feed Conveyor Drive ............................................................................. 9 - 88
9.13.4 Circuit Protection ................................................................................... 9 - 88
9.13.5 Changing the Suction Filter .................................................................... 9 - 90
9.13.6 Changing the Return Filter ...................................................................... 9 - 92
9.12.7 Changing the Tank Breather ................................................................... 9 - 92
9.13.8 Changing the Pressure Filters ................................................................ 9 - 93
9.13.9 Automax Hydraulic System ..................................................................... 9 - 94
9.14 Plant - Electrical System ............................................................................ 9 - 96
9.14.1 General Description ............................................................................... 9 - 96
9.14.2 Operators Control Points ....................................................................... 9 - 96
9.14.3 Protection Devices ................................................................................. 9 - 97
9.15 Plant - Crusher and Hydraulic Pump Drive Belts ..................................... 9 - 98
9.15.1 Trouble Shooting - Drive Belts ................................................................ 9 - 99
9.15.2 Replacement and Adjustment of Crusher Drive Belts ............................ 9 - 100
9.15.3 Replacement and Adjustment of Hydraulic Pump Drive Belts ................ 9 - 103
9.15.4 Method of Drive Belt Tensioning ........................................................... 9 - 106
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Page 9 - 3
9.16 Plant - Conveyor Belts ............................................................................. 9 - 108

9.16.1 General Description ............................................................................. 9 - 108
9.16.2 Training of Belts ................................................................................... 9 - 109
9.16.3 Conveyor Belt Tensioning ..................................................................... 9 - 111
9.16.4 Maintenance of Conveyor(s) ................................................................. 9 - 112
9.16.5 Cleaning the Conveyor Belts ................................................................ 9 - 115
9.17 Metal Detector ........................................................................................... 9 - 117
9.17.1 Metal Detector Controls........................................................................ 9 - 118
9.17.2 Metal Detector Indictor Lights (Figure 9am & 9an) ................................ 9 - 120
9.18 Plant - Dust Suppression ......................................................................... 9 - 122
9.19 Plant - Diesel Engine ................................................................................ 9 - 124

9.19.1 Engine - ELC Coolant .......................................................................... 9 - 125
9.19.2 Hydraulic Engine Clutch........................................................................ 9 - 126
9.19.3 Check Fuel Level ................................................................................. 9 - 127
9.19.4 Top Up Fuel Level ................................................................................ 9 - 128
9.20 Plant - Vehicle Tracks ............................................................................... 9 - 130
9.21.1 Measuring Track Tension ...................................................................... 9 - 130
9.20.2 Adjusting Track Tension ........................................................................ 9 - 132
9.20.3 Track Maintenance ............................................................................... 9 - 135
9.20.4 Drive Oil Filling and Draining ................................................................ 9 - 136
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9 - Maintenance EN
Page 9 - 4




followed.
LOCKOUT PROCEDURE

lockout.
signs, (ie. TAG OUT).
6. Turn the Isolation Switch to O when the
plant is not being used (especially while
plant is being transported).
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9 - Maintenance EN
Page 9 - 5

Terex-Pegson machine can cause


ALWAYS use a suitable lifting platform when

reaching any points 2m (6- 6) or more above
ground level.

HAZARD
injury.



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Maxtrak 1300
9 - Maintenance EN
Page 9 - 6

HAZARD
machine.

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Page 9 - 7
WARNING
PRIOR TO ANY MAINTENANCE
The maintence instructions are intended for day to day maintenance to keep the plant in good
running order and do not cover major rectifications, repairs or replacements where specialist
expertise is required. However, ensure that only suitably competent personnel with the necessary
training/experience for the task(s) in hand are employed. A person should never work alone.
Observe the safety advice in Sections 1 and 9.1 as appropriate to the task(s) in hand.
Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk
Assessment for all maintenance operations. Have suitable lifting equipment available for the
components involved together with all necessary (and suitable) tools/equipment ready for the
task(s) in hand and always secure parts liable to movement before starting work.
BL-Pegsons Service Department is available for advice when required.
The plant should be completely emptied of material i.e. stone. Implement the Lockout Procedure
(Section 9.1). Display a prominent tag at the control station (or other appropriate place) to warn
of maintenance work being carried out.
Keep clear of moving parts when trying to identify or isolate any unusual noises.
Fit dismantled parts in the same location from which they were removed.
Ensure that the area surrounding the maintenance site is clear of any obstructions.
If arc welding work is involved in any maintenance operation, ensure that the current does not pass
through any bearings. FOLLOW THE WARNING INSTRUCTIONS ON THE OPPOSITE
PAGE FOR ENGINE PROTECTION. The plant must be fully isolated prior to any
welding work.
BEFORE WORKING ON THE PLANT, SWITCH OFF, LOCKOUT AND TAGOUT
AFTER EXTENSIVE MAINTENANCE

Refer to Sections 7.1.3, 7.2.8 and 7.3.6 and 7.3.7.
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Page 9 - 8
9.1.1 Engine Start-Up - Maintenance
Procedure
WARNING
WEAR PERSONAL
2. Check that all Emergency Stop push Information for relevant warning.
buttons are pulled out (Figure 1a)
otherwise the engine cannot start.
3. Ensure the engine Isolation Switch is

turned to the I position.
4. On the Electrical Control Panel:

OPERATION switch = PLANT
RADIO REMOTE CONTROL
switch = OFF..
5. On the engine control panel turn on the

ignition with the key to the first position
and, once the sequence of diagnostic
checks is completed, fully turn the key to
start the engine. Release the key back to
the first position as soon as the engine
starts.
Engine Isolation Switch

! NOTICE !
Refer to Figure 7d together with
continuation page for details of the
engine diagnostic functions.
6. Keep the rpm of the engine to 1200 rpm

(view on tachometer) and allow to run
for 3-5 minutes before proceeding with
maintenance.
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Page 9 - 9
OPERATION and RADIO REMOTE CONTROL

Switches on the Electrical Control Panel
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Engine Control Panel
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Page 9 - 10
9.2 Weights of Automax Crusher Components
Weights of the Automax crusher components, these should be consulted when arranging suitable lifting
equipment. Refer to Terex Pegsons Technical Department for any other weights of individual items or
assemblies if not listed.
WEIGHTS (APPROXIMATE) KGS. LBS.
Complete Automax Crusher 22,000 48,400
Upper Frame Assembly (upperframe with concave) 5,260 11,598
Cone Head Assembly (with bearings, mantle etc.) 2,950 6,505
Eccentric Assembly (with bearings, ring gear etc.) 1,800 3,970
Countershaft Assembly 500 1,103
Concave 760 1,676
Mantle 852 1,879
! WARNING !
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment.
4 x Lifting Points in the Automax Upper Frame
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Page 9 - 11
9.3 General Information The plant has been designed to facilitate

easy routine maintenance, but where
When performing maintenance, always necessary to remove any guards make sure
observe rules provided in the safety section. that they are replaced before the machine is
restarted.
Breakdown caused by insufficient or
improper maintenance will cause high repair Refer to the Spare Parts illustrations
costs and long term standstill. Therefore, (Section 10) to identify the machinery
regular maintenance is imperative. components mentioned in the maintenance
procedures.
In addition to several other factors, the
reliability and life of the Maxtrak depends on
regular and proper maintenance.
The following section contains maintenance

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

dealer or Terex Pegson Technical
Department for advice.
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Page 9 - 12
! WARNING ! WARNING
PRACTICE SAFE MAINTENANCE
WEAR PERSONAL
Understand service procedures Refer to Section 9.1, Safety
before doing any work. Keep the Information for relevant warning.
area clean and dry.
LOCKOUT PLANT.
Never lubricate, clean, service or Refer to Section 9.1, Safety
adjust machine whilst it is moving. Information for Lockout
Procedure.
Keep hands, feet and clothing

FALLING HAZARD.
clear of power driven parts and in- Refer to Section 9.1, Safety
running nip points. Information for relevant warning.
Disengage all the power and

operate controls to relieve
pressure. Stop the engine.
Implement lockout procedure.
Allow machinery to cool.
Securely support any machine

elements that must be raised for
service work.
Keep all parts in good condition

and properly installed. Attend to
damage immediately. Replace
worn or broken parts.
Remove any build up of grease, oil

or debris.
Disconnect battery ground cable (-

) before making adjustments on
electrical systems or welding on
machine.
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Page 9 - 13
9.4 Lubricants, Oils, Coolant,

etc. WARNING
WEAR PERSONAL
9.4.1 Service Attention Points PROTECTIVE EQUIPMENT.
Routine checks/replenishment/changes of Information for relevant
lubricants, oils, coolant, etc. must be carried out warning.
to the plant machinery in accordance with the
LOCKOUT PLANT.
Lubrication and Servicing Schedule (Section
9.4.4 and 9.4.5) in order to maintain efficiency. Information for Lockout
Procedure.
The locations of the Service Attention Points
are as follows:- FALLING HAZARD.
Automax Crusher oil lubrication tank sited Information for relevant
within the plant chassis (Figure 9b). warning.
Automax Crusher Upper Frame grease

nipples x 12.
Diesel Engine oil, coolant, (See separate
engine manual). Also the fuel (Figure 9ar).
Diesel Engine oil lubricated HFO clutch
Track unit gearbox x 2 oil levels (Figures
bearing (Section 9.19.2)
9au & 9av).
Plant hydraulic oil reservoir sited on the
Periodically lubricate hinges, hydraulic
forward engine platform .
cylinder pivot pins and similar linkage
Feed Conveyor gearbox within the head points with grease or oil as appropriate.
drum having oil lubrication (Figure 9ak).
Conveyor head and tailshaft bearing ! NOTICE !
grease nipples located:-
Failure to carry out scheduled
Feed Conveyor - 1 x headshaft on the maintenance or exercise due care
platform side and 2 x tailshaft remote may invalidate any warranty that
nipples on rear of hopper.
might apply.
Discharge Conveyor - 2 x headshaft
remote nipples on conveyor LH side and 1
x tailshaft remote nipple on each side of
main plant chassis.
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Page 9 - 14
9.4.2 Regular Servicing

The Lubrication and Servicing Schedule
WARNING
(Sections 9.4.4 and 9.4.5) lists, in addition to WEAR PERSONAL
the lubrication points, the attention required PROTECTIVE EQUIPMENT.
to the Automax and Plant hydraulic systems. Refer to Section 9.1, Safety
Particular attention should be paid to institute warning.
a regime of strict adherence from the very LOCKOUT PLANT.
start of operations for all aspects of routine Refer to Section 9.1, Safety
servicing and good housekeeping in order Information for Lockout
to keep the your Maxtrak in prime running Procedure.
order.
FALLING HAZARD.
Keep a accurate record of maintenance Refer to Section 9.1, Safety
work carried out and also log the engine
warning.
hours operated from the service meter
mounted on the engine.
Maintenance records can also be used to

show compliance with the required
maintenance practices and intervals as
detailed in this section of the manual.
Make sure that frequent checks are made

for wear to the manganese mantle and ! NOTICE !
concave (Section 7.3.5) and other wearing
surfaces so that replacement can be made NOTE: Do not overlook the service
before any damage to the core of the requirements of the plant diesel
Automax is sustained. engine which are detailed in the
separate engine manufacturers
Regularly check the wedge pressure manual.
(Section 7.3.11) to avoid damage to the
machine and to obtain the best performance
from the Automax.
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Page 9 - 15
9.4.3 Daily, Weekly and Monthly

Checks WARNING
It is imperative that the operator Refer to Section 9.1, Safety
carries out regular and diligent warning.
checks before operating the plant
especially with operational safety LOCKOUT PLANT.
in mind including (but not limited
Information for Lockout
to) those listed below. Procedure.
Additionally, the operator should FALLING HAZARD.

always consider what particular Information for relevant
safety hazards could occur at warning.
specific operating sites and take
steps to eliminate them before
commencing work.
Daily Checks
1. Check that all guarding is complete and 6. Look for loose fixings and rectify. Check
properly secured prior to start up. Also the security of nuts and bolts on the
that all warning signs (Section 1.8) are Automax. Verify there are no leaks of
present and readable. lubricating/hydraulic oil or water.
2. Check that all the plant emergency stop 7. Fully raise and lower the Automax Upper
buttons are operative (Section 1.7). Frame several times manually (Section
7.3.9) to help distribute the grease on the
3. Carry out a general inspection of the plant wedge ring for smooth operation.
to ascertain that nothing untoward is out of
place or damaged so as to cause a safety 8. Check the Automax Wedge Pressure is
hazard. satisfactory (Section 7.3.11)
4. Ascertain any fault messages displayed on 9. Ensure that the Automax internal frame
the Electrical Control Panel (Section arms are free of foreign bodies or material
7.2.5). build up (Section 7.3.12).
5. Carry out the Automax and Plant daily 10. Recalibrate the manganese wear on the
Lubrication and Servicing Schedule Automax (Section 7.3.4) to compensate
(Sections 9.4.4 & 9.4.5). for the previous days wear.
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Page 9 - 16
Weekly Checks
1. Perform all checks on the daily check

WARNING
list. WEAR PERSONAL
2. Carry out the weekly Lubrication and
Servicing Schedule. (Sections 9.4.4 and warning.
9.4.5).
LOCKOUT PLANT.
3. Note the Automax manganese wear. Refer to Section 9.1, Safety
Arrange renewal when necessary Information for Lockout
(Section 7.3.4) Procedure.
FALLING HAZARD.
4. Check the area in and around the
Automax for buildup of material; clean Information for relevant
out as necessary. warning.
5. Ensure all hydraulic hoses and joints are

free from leaks.
6. Check drive belts for damage, wear and 3. Check the oil level in the Feed Conveyor
fraying. drive gearbox (Section 9.16.4).
7. Clean away dust, dirt and grit from 3. Visually examine the Automax for wear
maintenance platforms and any moving and damage at regular intervals. Renew
parts. as necessary.
8. Check conveyor belts for damage and 4. Inspect crusher drive belts for signs of
fraying. wear, renew as necessary (Section
9.15).
Monthly/6 Monthly/Annual Checks
5. Check all drive belts are at the correct
1. Perform all checks on the daily and tension (Section 9.15).
weekly check list
2. Lubricate and Service to the monthly

requirements also attending to the longer
interval requirements as necessary
(Sections 9.4.4 and 9.4.5).
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1300 Automax Crusher Schedule
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
Lubricant Monthly (165 hrs),

Description or Quantity Level Daily Weekly 6 Monthly (1000 hrs),
Fluid Annually (2000 hrs)
Automax Oil Lubrication First change after 500 working hours

275 litres
Tank See chart Sight glass Check Thereafter change after every 1000
(73 US
(located inside the plant 9.4.6 upper mark level hours
galls)
chassis) (SEE SECTIONS 9.5.4 & 9.5.5)
Automax Oil Lubrication ~ First change after 100 working hours

Check
Pressure Filters ~ 2 Thereafter change after every 500 hours
condition
(parts list item 10) (SEE SECTION 9.6.6 & 9.5.7)
Automax Oil Lubrication
faults
Replace when changing oil
Suction Filter ~ 1 ~ ~ (SEE SECTION 9.5.6)
(parts list item 2)
9 - Maintenance
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Add 25 50 grams of grease to each
Automax Grease Nipples Check
See chart Inspect both the complete Automax oil nipple if the travel of the upper frame is
(located around the machine 12 ~ wedge
9.4.6 lubrication and Plant hydraulic systems for not smooth
upper frame) pressure
(SEE SECTION 9.8)
9.4.4 Automax Crusher Lubrication and Servicing Schedule
Automax Hydraulic Pressure Change annually

~ 2 ~ ~
Filters (parts list items 1 & 2) (SEE SECTION 9.13.9)
EN
Page 9 - 17
Maxtrak 1300
Plant Schedule
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
Lubricant Monthly (165 hrs),

Description or Quantity Level Daily Weekly 6 Monthly (1000 hrs),
Fluid Annually (2000 hrs)
First oil change after 50-100 working
0.8 litres
Feed Conveyor Oil Lubricated See chart Fill to centre hours. Thereafter change after every
(0.21 US ~ ~
Gearbox (located in head drum) 9.4.6 line of unit 2000 hours. Check level monthly.
galls)
(SEE SECTION 9.16.4)
Plant Conveyors Grease
Re-grease every 2 weeks
Nipples (4 x located on head & D ~ ~ ~
~ (SEE SECTION 9.4.1)
tail shaft bearings)
40mm(1)
Plant Hydraulic System 360 litres
See chart below upper Check Change oil every 2000 hours
Reservoir (located on front (96 US ~
9.4.6 sight glass level (SEE SECTION 9.13.1)
engine platform) galls)
mark
Plant Hydraulic Suction Filter
Check
(located at bottom of hydraulic ~ ~ ~ ~ condition
reservoir)
Change filters every 1000 hours or
9.4.5 Plant Lubrication and Servicing Schedule
Plant Hydraulic Return Filter

Check sooner if the tell-tale indicator
(located on top of hydraulic ~ ~ ~
~ condition shows RED
reservoir)
(SEE SECTIONS 9.13.5 TO 9.13.8)
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9 - Maintenance
Plant Hydraulic In-Line Filters x

Check
2 (located one each side of ~ ~ ~
~ condition
engine inside canopy)
5 litres First oil change after 100 working hours.
Plant Track Gearboxes x 2 See chart (1.3 US Fill to level Thereafter every 1000 hours or at least
(located each side of plant) 9.4.6 galls) plug ~ ~ annually. Check level monthly.
+/- 10% (SEE SECTION 9.20.4)
Engine Clutch (accessed when Level stick Check oil level prior to daily start up.
See chart Approx. Check
canopy raised and removable oil wet ~ Change oil every 1000 working hours.
9.4.6 200 cc. level
panel in engine canopy) (approx.) (SEE SECTION 9.19.2)
Caterpillar Engine
EN
(fuel, oil, coolant) Refer to the separate Engine Operation & Maintenance Manual
Maxtrak 1300
Page 9 - 18
Equipment Grade Century Mobile Shell Esso Gulf BP
Automax Oil
Lubrication System
> 4 C (39 F) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4 C (39 F) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Automax/Plant
Hydraulic System
> 30 C (86 F) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
< 30 C (86 F) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
Automax Upper
Frame Grease Chemodex MOLY - BENTONE MP Standard Grade
Nipples
SAE 30 SAE 40 Oil
Engine HFO Clutch ISO VG 100 ISO VG 150
(DO NOT USE SYNTHETIC OIL)
9.4.6 Recommended Oil/Grease Types
Plant Feed Conveyor Gear oil with viscosity VG150 with EP additives. Oil temperature always to be below 90 C (194 F)
Drive Gearbox DO NOT MIX OILS OF DIFFERENT MAKET OR TYPE
Plant Conveyor
Shaft Bearings D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
9 - Maintenance
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Plant Tracks General Multi-Purpose Grease (Grade D grease is suitable)
Tension
Plant Tracks SAE 80w/90 Gear Oil

Gearbox Oil
Note: <4C (39 F) is defined as a daily temperature consistently below 4C (39 F),
>30C (86 F), is defined as a daily temperature consistently above 30C (86 F).
EN
Page 9 - 19
Maxtrak 1300
Maxtrak 1300
9 - Maintenance EN
Page 9 - 20
Lubrication Specifications
Oil Specification Grade A Grade B Grade C

Flashpoint: Minimum C (F) 199 (390) 204 (399) 216 (421)
Pour Point C (F) -18 (0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40C, mm/s 150 220 460
(104F, in/s) (0.232) (0.341) (0.713)
Kinematic Viscosity at 100C, mm/s 15.4 20.1 32.9
(212F, in/s) (0.0238) (0.0312) (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25C (77F) 280
Worked Penetration at 25C (77F) 285
Drop Point C (F) 185 (365)
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135C (275F) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40C mm/s 32 46 68
(104F, in/s) (0.049) (0.0713) (0.105)
Kinematic Viscosity at 100C mm/s 5.5 6.5 8.5
(212F, in/s) (0.085) (0.010) (0.013)
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes
Figure 9a Lubrication Specifications
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Page 9 - 21
WEDGE RING LUBRICANT FOR CONE CRUSHERS

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

Consistency N.L.G.I No: 3 Medium/Heavy
Penetration at 25 deg. C 220/250
Temperature Range -20 deg. C to 200 C
Drop Point None
Water Resistance Complete
The Standard Grade is recommended for large. slow speed bearings for slides and splines and to resist shock-
load conditions..
The molybdenum disulphide content gives greater margin of safety, especially where intervals between
lubrication are liable to be prolonged, where there may be occasional overload operations and where
temperatures are high.
Chemodex MOLY-BENTONE M.P. GREASES are recommended for the lubrication and protection of - stone
and ore crushers, conveyor systems, cranes, winches, printing machines, rolling mills and foundry equipment,
mechanical stokers, glass works equipment, pumps of all types and marine equipment in general, etc.
Chemodex MOLY-BENTONE M.P. GREASES are available in 450 gm and 3 kilo tins, and 12, 25 and 50 kilo
kegs.
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Page 9 - 22
9.5 Automax Crusher -

General WARNING
WEAR PERSONAL
9.5.1 Automax Lubrication PROTECTIVE EQUIPMENT.
Overview Refer to Section 9.1, Safety
The Automax cone crusher is lubricated by oil warning.
circulated by hydraulically driven oil pump
LOCKOUT MACHINE.
mounted on the oil tank sited within the plant Refer to Section 9.1, Safety
chassis (Figure 9b) with access being gained Information for Lockout
from the rear of the chassis. Procedure.
Filtered oil from the tank is pumped under

pressure through external pipework to inlet points
on the Automax at the base of the mainshaft from
where the oil is distributed internally to the cone
head and eccentric roller bearings whilst a second
inlet pipe feeds oil to the countershaft assembly
bearings.
Oil from the bearings lubricates the drive gear A engine mounted heat exchanger is
and pinion on its gravity return to the oil tank included to preheat the lubricating oil when
to be filtered and re-circulated. necessary and an air blast type cooler is
fitted to control the oil temperature whilst
After the oil pump has been started the control the Automax is running. Both of these
system delays the crusher start for 5 minutes devices are controlled automatically by
to allow a good circulation of oil within the thermostats.
Automax and occurs every time the oil pump is
started. To prolong the life of the bearings it is Lubrication safety devices include monitors for
also good practice when stopping the crusher low oil flow, high temperature, low tank level
to allow the crusher cone head to stop spinning and low oil pressure.
before switching off the oil pump (Section 8.2).
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Page 9 - 23
9.5.2 Automax Lubrication

Operating Procedure
Once the lubrication pump has been started
it does not need to be controlled during the
running of the machine and is monitored by
the safety electrical interlock safeguards
incorporated into the control systems with
faults indicated on the Electrical Control
Panel Display Screen (Section 7.2.3 &
7.2.5).
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Pressure Gauge Air Cooler Oil Filler Cap
Cartridge Filters Oil Flow Meter
Float Switch Oil Tank
Terminal Box Level Sight Glass Thermostat
Figure 9b Automax Oil Lubrication Tank
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9.5.3 Automax Lubrication System

Detailed Description ! NOTICE !
Function Operating the Automax without the
lubrication system safety devices
The primary functions of the lubrication being fully operative will invalidate
system are:- any warranty in force for the time
- to prevent damage due to metal on metal being.
contact within the bearings.
- to dissipate heat generated by the bearings Cold Weather Start-up
during operation, so acting as a coolant. An engine heat exchanger heats the
lubricating oil prior to the Automax operating.
The bearings can be seriously damaged if This ensures efficient circulation of the oil
any one of the following characteristics are before the crushing begins. The system is
inadequate:- automatically controlled by a thermostat.
During cold weather conditions be aware that
Viscosity (grade) the commencement of crushing may be
Quantity (flow) delayed whilst the oil reaches a satisfactory
Cleanliness temperature
Toughness of the lubricant film
(Timken load rating) Air Blast System
This enable the hot oil to be cooled as is
Operation circulated through the system and into the
machine. This keeps the oil at an optimum
Oil is supplied the Automax bearings via a working temperature. The system is
hydraulically driven pump. This oil is filtered automatically controlled by a thermostat.
clean and pumped under pressure to the
main bearings (eccentric and cone head) Terex Pegson strongly advise against
and via a separate line to the countershaft running the Automax empty after initial
bearings. It is then piped back to the tank start-up in cold weather. Even hot oil can be
under gravity. chilled when entering a cold machine and its
reluctance to return to the tank may result in
An automatic alarm is fitted to the lubrication a slight leak from the machine via the cone
tank which will sound if there is insufficient head/seal ring and/or mainframe/seal ring.
pressure or flow to the machine. It is difficult Ideally, once the crusher is started rock
to give a working pressure as this varies should be put through it as soon as possible.
significantly under different working conditions BUT THE AUTOMAX MUST NEVER
so the alarm should be used as an indication of BE STARTED WITH ROCK PRESENT
a fault arising. IN THE CRUSHING CHAMBER.
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Air Blast Bypass Valve Temperature Monitoring

During initial start-up the viscosity of the oil is The temperature of the returning oil is
very high which results in an increase in pump monitored to ensure correct operation. One
pressure and a reduction in oilflow through the thermostat controls the air-blast cooler fan
air blast cooler and into the machine. whilst a second thermostat will stop the
machine and will activate an alarm if the oil is
To overcome this a bypass valve is too hot, ie. greater than 80C (176F).
incorporated in parallel to the cooler. When a
predetermined pressure is reached the valve Pressure Relief Valve
opens allowing oil to pass to the machine In order to protect the lubrication system
without entering the cooler. Once the viscosity against dead head pressures a relief valve is
is reduced the valve closes and oil passes situated after the pump. This is set (at
through the cooler. This is normal on initial manufacture) to open at a designated pressure
start-up with cold oil. of 3.8 BAR (55psi). It is important that this
device is not adjusted or tampered with.
Fluid Level or Float Switch
In the event of the lubrication system pipe
breaking or a leak occurring the level of the oil
tank will drop. To prevent running in this
condition the switch will stop the machine and
thus prevent damage to the bearings.
Oil Feed Flow Indicator and Switch

To ensure that sufficient oil is being supplied to
the bearings a flow switch is incorporated into
the feed side of the lubrication system. In the
event of the flow reducing below a set level
the switch closes causing warning devices to
operate and the machine stop.
Continued operation of the Automax with

insufficient oil flow will severely damage the
bearings.
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9.5.4 Automax Oil Change Intervals Total Acid Number (TAN)

This is the measure of how much the oil has
The first oil change of the lubricating oil degraded. The TAN increases as the oil
should occur after 500 hours operation. degrades. The oil should be changed before
it increase 100% above the original value.
Subsequent oil changes should occurs
every 1000 hours, ie once every 5 months Viscosity Number
working 50 hours per week, An engineering/lubrication laboratory is able
to identify the viscosity number of an oil
Alternatively, Terex Pegson strongly which can then be compared to the original
recommend that the oil is tested regularly at value of new oil. If it exceeds a 20%
monthly intervals by a suitable laboratory and increase at an identical test temperature it is
changed when advised to do so. This will time to change the oil.
provide optimum use of oil as replacement is
only made when proved necessary. This will Reduction in Additives
also give an indication on the machines It is recommended that the oil is changed
condition. This could indicate that the change when the level of additives is reduced by
should be made away from the 1000 hours 50% compared to new oil values.
guideline and will be because of usage and
environment effects on the oil life. It is suggested that any of the above
tests could be carried out by a
There are several indications that it is time to laboratory to establish the optimum time
change the oil in the lubrication system:- for oil changes. Consultation with your
local facility is advisable.
Concentrations of Wear Metal Elements
Increases in certain elements should not
exceed the suggested upper limits in parts
per million (PPM) as table below.
TYPICAL
WEAR METAL CONCENTRATION UPPER LIMIT
(PPM) (PPM)
Chrome 0-5 10
Copper 0 -15 50
Iron 30 - 50 150
Lead 0 - 20 50
Nickel 0-5 10
Silicon (dirt) 10 - 30 75
Figure 9? Wear Metal Elements
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9.5.5 Recommended Automax Oil

The recommended oil is good quality:- WARNING
WEAR PERSONAL
Summer Grade - EP220 PROTECTIVE EQUIPMENT.
Winter Grade - EP150 Refer to Section 9.1, Safety
Refer to the lubrication chart (Section 9.4.4) warning.
for details. LOCKOUT MACHINE.
Add oil to the tank (Figure 9b) with a Information for Lockout
recommended lubricant from the list Procedure.
provided in this manual through the filler cap
using the level indicator to ensure the correct
level is reached. This should be
approximately 275 litres (73 US galls).
Unless consistently cold climates are

experienced, ie. below 4C (39F) it is
recommended that EP220 ISO VG oil is
used. If difficulties with cold starting are
experienced it is recommended that an
EP150 VG oil is used but this could be
changed back to an EP220 ISO VG as soon
as conditions permit.
All oils should have extreme pressure (EP)

additives.
If none of the oil brands specified (Section

9.4.6) are available, ask your supplier to
supply an oil that meets the specification for
GRADE B in Figure 9a.
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9.5.6 Automax Oil Filter Change

Intervals
WARNING
As a general guide it is recommended that WEAR PERSONAL
the two filter canisters (Section 9.4.4) are PROTECTIVE EQUIPMENT.
changed as follows:- Refer to Section 9.1, Safety
The first filter change should be after 100 warning.
hours operation. LOCKOUT MACHINE.
Subsequent filter changes should occur Information for Lockout
every 500 hours unless the oil filter blocked Procedure.
warning activates between these intervals. It
is important the use the correct replacement
filter cartridges as too fine a filter element
will become blocked prematurely whilst too
coarse an element will not filter efficiently
enough to protect the machine.
! NOTICE !
Remember, these filters are very
efficient at removing harmful
contaminants from the oil and it is
more economical to change the
filters regularly than the oil.
It is also recommended that the suction

filters (Section 9.4.4) inside the tank are
replaced when the oil is changed.
In the event the pressure filters become

blocked completely, oil will be supplied to the
machine via a relief valve inside the filter top
body. This bypasses the filter element and
supplies unfiltered oil to the machine. This
MUST be avoided and the oil lubrication
safety system includes an alarm for this
situation.
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9.5.7 Automax Oil Filter

Replacement
WARNING
Both filters are to the same specification and WEAR PERSONAL
operate in parallel. They must be changed at PROTECTIVE EQUIPMENT.
the same time with NEW filters as Refer to Section 9.1, Safety
recommended in Section 9.5.6. Information for relevant
warning.
Both filters are non-cleanable elements and LOCKOUT MACHINE.
must always be replaced with NEW Refer to Section 9.1, Safety
cartridges of the approved pattern. Information for Lockout
Procedure.
Procedure
2. Close down the plant (Section 8.2) and

implement the Lockout Procedure.
3. Take steps to collect oil spillage and

remove the old filter cartridges by
unscrewing counter-clockwise (looking
from below) together with the O ring
seal. Clean the O ring seating in the
filter body.
4. Lightly oil the new O ring on the new

filter cartridge and screw onto the filter
body taking care not to cross the
threads. Hand tighten the cartridge.
Note: After recommencing operation of

the Automax make sure the seals are oil
tight.
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9.5.8 Automax Oil Lubrication

System General Maintenance WARNING
Tank WEAR PERSONAL
Ensure that the filler/breather cap is clean, in Refer to Section 9.1, Safety
place and tight, at all times. Information for relevant
warning.
Make sure that the oil tank cover is sealed LOCKOUT MACHINE.
down and that all bolts are in place and tight. Refer to Section 9.1, Safety
Before carrying out any maintenance on the Procedure.
tank or associated parts, thoroughly clean the
area to prevent any containments entering
the oil lubrication system.
Air Blast Cooler
Clean the cooling matrix to prevent it

becoming blocked. Cleaning with an air
pressure jet must only be carried out after
taking safety precautions. If the dust is oily
use a low pressure steam cleaner together
with non-caustic detergent.
General
Frequently check for any leaks developing in

the pipework and particularly ensure that the
rubber hoses are not being chafed due to the
movement of the live Automax baseframe.
Make sure the flexible hose in the return
piping (essential when the Automax is
mounted on a live baseframe) is in good
condition. Attend to the oil and replacement
components in accordance with the
schedules and advice in this manual using
only approved quality materials
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9.6 Automax - Hydraulics

Overview DANGER
The Upper Frame of the Automax is raised
and lowered by means of external hydraulic Information for relevant
rams to alter the relative position of the warning
concave (in the moveable upper frame) to the
mantle (on the fixed position cone head).
Six hydraulic cylinders provide control over the WARNING

machines discharge setting through vertical WEAR PERSONAL
movement of the upper frame. Additionally the PROTECTIVE EQUIPMENT.
system also permits automatic overload release Refer to Section 9.1, Safety
and reset, unblocking of the crushing chamber Information for relevant
and monitoring and indication of manganese warning.
wear (Section 7.4). LOCKOUT MACHINE.
The Automax hydraulic system is integrated Information for Lockout
with the overall plant hydraulic system which Procedure.
drives the tracks, conveyors, etc. and for
details of oil replenishment, filter changes, etc.
refer to Section 9.13
To hold the upper frame firm and steady during

crushing a supplementary circuit of hydraulic
dumpy jacks is included to activate the wedge
ring.
The relative position of the upper frame is

monitored electrically with a linear transducer.
The control of the Automax hydraulics is from

the separate panel (Figure 9c) located inside a
lockable cabinet with connections by both high
pressure hydraulic hoses and screened electric
cable for the linear position sensor.
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Gauge measuring
Numeric Keypad Display Wedge Pressure

Switch Button
Figure 9c Automax Controls

(refer to Sections 7.3 & 7.4 for operating instructions)
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9.6.1 Automax Hydraulic System

Maintenance Procedure
DANGER
! DANGER ! SKIN INJECTION HAZARD
This is a high pressure system Information for relevant warning
and only suitably qualified
experienced engineers should
tackle any problems that may
arise. WARNING
WEAR PERSONAL
Maintain in accordance with the reservoir PROTECTIVE EQUIPMENT.
level, filter changes and the schedules and Refer to Section 9.1, Safety
fluid types (Section 9.4.4, 9.4.5 & 9.4.6) Information for relevant
ONLY USE A RECOMMENDED FLUID. warning.
LOCKOUT MACHINE.
It is essential when replenishing hydraulic Refer to Section 9.1, Safety
fluid, attending to filters, etc. to apply the Information for Lockout Proce-
greatest degree of cleanliness as it is most dure.
important that contaminants are not allowed
to enter the system.
In addition to the pressure gauge by the

control panel (Figure 9c) used when
calibrating the manganese, etc., two other
pressure gauges are included in the system
(Figure 9g) for diagnostic purposes.
Faults encountered may be listed in under

Section 9.10, Fault Finding, together with
possible remedies. Always contact BL-
Pegsons local dealer or the factory in case
of doubt.
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9.7 Manganese Change When replacing the manganese liners,

always fit both a new mantle and a new
Procedure
concave at the same time.
9.7.1 Guidance for Changing the

Manganese Mantle and Concave ! NOTICE !
Both the mantle and concave liners are Always fit a new manganese
locked against their mating parts using tapers mantle and concave as a pair. It is
(angled faces). If these liners are worn too detrimental to the operation of the
thin they will not be able to hold tight against machine to do otherwise.
their mating faces, coming loose and/or
slipping relative to their mating part. The
mating will be damaged and will need
reworking.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 55-60mm (21/8- 23/

8
) of wear on the liners, as a pair.
Take note of the wear shown on the

display.
774 (301/2) mm minimum
Inspect the liners on a daily basis, for

possible tramp metal damage and also any
evidence of an uneven wear pattern
developing.
The manganese liners must be changed

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance (Figure
9d) when the rams are fully closed is 774mm
(30.5).
Figure 9d Minimum Ram Dimension
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9.7.2 Filler Handling

WARNING
Use Pegbak for backing filler. It is PROTECTIVE EQUIPMENT.
necessary to carefully read the Information for relevant
handling instructions before warning.
attempting to use. Follow all the
recommended handling
procedures and safety
precautions.
Filler is used as a backing material to fill the

! WARNING !
void spaces behind the manganese concave BOTH AGENTS ARE TOXIC.
and mantle where there is no machined ALWAYS WEAR A FACE MASK,
mating surface with the upper frame and RUBBER OR PLASTIC GLOVES,
cone head respectively. The filler is poured
SAFETY GLASSES AND LONG
in after the new manganese has been fitted.
SLEEVED WORK CLOTHING
The Automax cone crusher uses the gunlock Since both agents are toxic, be careful
type, self tightening concave ring and must not to allow them to attach onto your
use a release agent or thin layer of grease, skin. If they do attach, wash away with
oil or wax on the concave ring mating tepid water and soap. Do not use petrol
surfaces. This is to prevent adhesion or solvents.
between the mating surfaces and to allow
the self tightening features to operate
properly. Care should be taken to plug all ! WARNING !
leaks as the filler will fill a very small void.
Protect eyes. In case of accidental
Each pack of Pegbak includes separate filler contact / splashes, flush eyes with
resin and hardener which are mixed only plenty of water and consult a
when required for immediate use. doctor.
Ensure good ventilation of the

Packs required workplace.
Mantle - 3 x 10kg.Tubs When mixing add the hardener to the

Concave - 5 x 10kg.Tubs filler backing resin while agitating.
Completely mix the filler backing resin

and hardener, continue mixing until all of
the filler is one colour, ie. completely
mixed.
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It is necessary to work with both agents Filler Hardening Time

at 16-32 C (60-90F). Therefore, in hot
weather the container may have to be The filler needs about 12 hours to harden at
cooled and warmed in cold weather to 20 C (68F).
within the above temperature range.
In lower temperatures the hardening process
Both agents can be mixed with the takes longer and it may be necessary to heat
supplied agitating adaptor attached to the the mantle and concave etc. in these
top of an electric drill. circumstances.
The filler can be used only once (cannot Low Temperature Mixing
be reused) and if mixed with the
Protect the filler resin / hardener from cold
hardener it cannot be stored.
weather (< 5C [41F] ). Remove the chill
from the metal by the use of hot air guns/
Always store both agents at 15-30 C blowers. - Do not use an open flame. To
(59-86F) and avoid storing in direct ensure the shortest curing time at low
sunlight. temperatures, the filler resin component
(LARGER BAG) should be pre-warmed
Never smoke whilst handling these to 25-30C (77-86F) before mixing. This is
agents. best achieved by applying a hot air blower on
the outside of the tin .
Ensure that application surfaces are dry NB - REMOVE HARDENER FROM TIN
before pouring. Wet surfaces will result BEFORE APPLYING HEAT.
in reduced stength of the filler. ALTERNATIVELY, place the filler resin
bag (LARGER BAG) in a bucket of hot
Pour the filler immediately after mixing, water.
ie within 10 - 15 minutes at 25C. Higher NB - DO NOT PRE-HEAT THE
temperatures will shorten, and lower HARDENER (SMALLER BAG).
temperatures increase, the working time. Thoroughly mix the filler resin and hardener
using the included mixing tool or a spiral
When making pouring ports with putty, paddle and pour immediately.
prevent the filler from leaking out.
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9.7.3 Changing the Manganese

To change the manganese Concave and WARNING
Mantle Automax crushing members it is WEAR PERSONAL
necessary to remove the Upper Frame. PROTECTIVE EQUIPMENT.
To change the Concave it is necessary to lift Information for relevant
off the Automax Upper Frame complete warning.
with the concave inside FALLING HAZARD.
Before the Upper Frame can be removed Information for relevant
warning.
the feed conveyor head must be elevated
from the working position to allow access to
the crusher and for the feed box to be lifted
off (Figure 9e).
9.7.3.1 Gaining access to the

Automax
Procedure
2. Ensure that the feed conveyor and

Automax feed box are free from stone
and dirt.


CONTROL switch at OFF (Figure 9e).
5. Operate the hydraulic lever on the

chassis side to raise the conveyor so that
the two locating pins can be inserted
through the bottom pair of holes in the Figure 9e Electric Panel Controls
upper telescopic legs. Fit the security
pins into the end of each pin.
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6. Operate the hydraulic lever to lower the

conveyor until the locating pins rest on
the seats in the lower telescopic legs.
Make sure the locating pins are resting
on their seats on both sides of each leg
and not on the pin head on one side only.
! DANGER !
Whilst working on the Automax
crusher the conveyor head must
always be supported on the
locating pins positioned in each of
the two telescopic support legs Upper Telescopic
and NOT by the hydraulic ram Leg
alone. Locating Pin
7. Switch off the engine (Section 8.2) and

8. Disconnect the level sensor mast before

unbolting and lifting off the Automax
feed box.
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 9e1 Feed Conveyor Hydraulic
Lever and Locating Pin
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9.7.3.2 Removing the Upper Frame

Before the Upper Frame can be easily and DANGER
safely removed it is essential to first release SKIN INJECTION HAZARD
the Automax Wedge Ring as follows. Refer to Section 9.1, Safety
warning
Procedure
WARNING
2. Start the engine (Section 7.2.1). Set the WEAR PERSONAL
engine speed at 1200rpm. PROTECTIVE EQUIPMENT.
3. Continue with the OPERATION switch Information for relevant
at PLANT and the RADIO REMOTE warning.
CONTROL switch at OFF (Figure 9e).
LOCKOUT PLANT.
4. On the Automax Hydraulic Panel (figure Information for Lockout
9f) select MANUAL and raise the Upper Procedure.
Frame to its maximum extent using the
OPEN button. FALLING HAZARD.
5. Close (turn clockwise) the shut off valve Information for relevant
warning.
9B inside the Hydraulic Console (Figure
9g) to isolate the wedge ring hydraulic
circuit from the main hydraulic system. 7. Drop the Upper Frame with the CLOSE
button to push the Wedge Ring down and
6. Open (turn anticlockwise) the shut off thus free it from the Mainframe to
valve 9A inside the Hydraulic Console provide clearance needed to lift off the
(Figure 9g) to allow all pressure in the Upper Frame. The wedge pressure
wedge ring circuit to be released thereby indicated on the pressure gauge (Figure
removing the loading from the Wedge 9g) should drop away to 0-28 Bar (0-400
Ring. psi) as the wedge ring frees off.
! DANGER !
Ensure the Wedge Ring is free
otherwise crane overload and/or
sudden violent separation may
occur when lifting off (Step 14
below).
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Figure 9f Automax Control Panel
Gauge measuring Diagnostic Pressure

Wedge Pressure Gauge only
Valve 9B
Automax Control Panel

Diagnostic Pressure
Gauge only
Valve 9A
Figure 9g Dumpy Jack Circuit Shut Off Valves
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8. With suitable cranage connect lifting

tackle to the four lifting eyes in the ! DANGER !
Upper Frame (Section 4.2 for weights
Do not neglect to Lockout to
and lifting points) but leave the slings
with a small amount of slack.
prevent the plant being started
whilst maintenance work is being
carried out.
! DANGER !
12. Remove the top clevis pin from each
Under no circumstances attempt hydraulic cylinder and pull each cylinder
to take the load on the cranage at outwards, allowing them to lie flat.
this stage as a serious overload
condition may arise. Note: The clevis pins should be
removed from right to left when
9. Using three 5 tonne (5.5 US tons) facing the machine to avoid
capacity x 150 mm (6) stroke hydraulic disturbing the bearing located
bottle jacks spaced equidistant around against the shoulder inside each lug
the lower rim of the Upper Frame, on the Upper Frame.
extend them equally to take the weight
off the clevis pins to aid their removal. 13. Remove the linear sensor cover (Figure
9h) and lay to one side. Disconnect the
10. Ensure that there is no residual hydraulic top bolt from the unit. This is essential
pressure in the Upper Frame hydraulic to avoid damage to the sensor unit.
cylinder circuit by pressing the OPEN
and CLOSE buttons briefly and in quick 14. Lift off the Upper Frame assembly from
succession until the pressure gauge the machine (Refer Section 4.2 for the
(Figure 9c) on the hydraulic panel reads weight of the complete assembly).
zero. Follow this procedure to remove Support on wooden blocks on the ground
the clevis pins with the minimum of (Figure 9i).
effort.
11. Isolate the electrical supply before

proceeding further.
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Linear Sensor Upper Frame

Unit Cover
Clevis Pin
Hydraulic Cylinder
Figure 9h Automax Linear Sensor Unit and Hydraulic

Cylinders
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9.7.3.3 Changing the Concave

The concave ring is held in place in the WARNING
Upper Frame by a self tightening gun lock WEAR PERSONAL
arrangement that automatically tightens the PROTECTIVE EQUIPMENT.
manganese steel concave on the concave Refer to Section 9.1, Safety
wedges as the ring stretches under the Information for relevant
crushing load. warning.
LOCKOUT PLANT.
The Upper Frame should be supported on Refer to Section 9.1, Safety
wooden blocks so that there is sufficient Information for Lockout
space for the concave to be driven out. Procedure.
Removing the Concave FALLING HAZARD.

! WARNING ! warning.
When gas cutting through the

concave it is essential that
breathing apparatus is worn as
when the metal is broken through
the backing material gives off toxic
fumes.
4. Remove the old backing material and
Procedure dowels (these can be driven out from
below) and inspect the lower inside
1. Observe all safety warnings. bevelled edge of the Upper Frame
seating where the surface has been
2. Following removal of the Upper Frame ground. Remove any nicks or burrs with
(Section 9.7.3.2) gas cut through the four a file or grinder. Inspect the ground
lugs as shown (Figure 9i). surfaces of the new concave and
remove any nicks or burrs in the same
3. Drive down and out the old concave with manner.
a heavy sledge hammer.
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Figure 9i Gas Cutting the Old Concave
Figure 9j Supporting the New Concave
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Mounting the Concave
When supporting the new Concave prior to

WARNING
lowering the Upper Frame on to it, ensure WEAR PERSONAL
that the supports do not protrude past the PROTECTIVE EQUIPMENT.
sides of the Concave (Figure 9j) and that it is Refer to Section 9.1, Safety
high enough off the ground to allow the
warning.
Upper Frame to be fully lowered.
LOCKOUT MACHINE.
Release agent needs to be applied to the Refer to Section 9.1, Safety
internal surface of the Upper Frame where it
Procedure.
will be in contact with the backing filler to
ease separation when the manganese is next
changed.
Procedure
1. Observe all safety warnings. 6. After rotation, equally locate the
concave wedges between the concave
2. Apply release agent (obtainable from lugs and upper frame (Figure 9k).
BL-Pegson) to the cleaned inner surface
of the Upper Frame. An estimate should be made of the
correct position for the concave wedges
3. Place the new concave on three wooden and then tapped in slightly to see how the
blocks (see preamble above) ensuring it concave settles. If the position does not
is level look correct with respect to the dowel
holes then they should be removed and
4. Lift the upper frame over the concave replaced.
and turn it so that the concave lugs align
with the recesses on the upper frame Also check to see that the Concave is
and gradually lower the upper frame until evenly seated on the machined surfaces
concave lugs pass through the recesses at the bottom and there is an equal depth
and stop lowering. all around at position A (Figure 9l). If
there is a gap between the two the
5. Rotate the upper frame to the left so that Concave must be properly re-seated.
the concave lugs are located
approximately 50mm past the dowel Once the position is satisfactory and the
holes. Concave is correctly seated, the wedges
should be driven fully home.
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7. Insert the dowels into the holes in the

upper frame and drive home.
Note: If there is a gap between the

concave wedge and the dowel pin and
this cannot be rectified by moving the
wedge position, it may be necessary to
tighten the wedges and then weld a
piece of steel between the wedge and
the dowel pin(s).
! NOTICE !
The concave wedges must be
inserted evenly so that the
concave ring is centrally located
within the Upper Frame.
8. Prepare filler pouring ports with putty by

making four weirs around the recesses
of the Upper Frame so the filler cannot
leak out.
9. After the weirs are completed prepare

the filler (Section 9.7.2) and pour the
correct quantity of mixed filler into each
weir by turns.
! NOTICE !
After mixing, the filler must be
poured IMMEDIATELY to ensure
complete penetration.
10. Stop pouring when the filler has reached

12-25mm (1/2-1) below the top of the
Concave. The replacement is now
complete. Refer to Section 9.7.2 for the
filler hardening time.
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RECESS
Figure 9k Plan View of the Upper Frame showing the correct wedge position
(1300 has four lugs on the concave)
Figure 9l Sectional view of the concave showing the gap check at A
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4.7.3.4 Replacing the Upper Frame

Whilst the Upper Frame is off the machine DANGER
for the renewal of the manganese wearing SKIN INJECTION HAZARD
parts, take the opportunity of examining the Refer to Section 9.1, Safety
condition of the internal linerplates, frame Information for relevant warning
and countershaft arm shields and replace if
necessary.
Also, clean out any solidified debris and

generally check around the machine for any
WARNING
faults which need to be rectified. WEAR PERSONAL
Clean the contact face all around the Wedge
Ring and apply a coating of fresh lubricant warning.
(MOLY-BENTONE MP Standard Grade
grease). Make sure this is not contaminated LOCKOUT MACHINE.
with dirt or grit prior to replacing the Upper Refer to Section 9.1, Safety
Information for Lockout Proce-
Frame.
dure.
Procedure
(Figure 9f) switch to MANUAL and
2. Using the cranage used to remove the depress the OPEN or CLOSE button
Upper Frame lower over the machine (as appropriate). Only one cylinder will
whilst taking care to line up the anti- respond at any one time and, toggling
rotation stop on the Upper Frame with between the buttons, line up and insert
the guide post. Hold in a suspended each of the six clevis pins in turn. Secure
position with the crane with a gap with the washers and split pins.
between the mantle and concave.
Note: The clevis pins should be
3. Start the engine (Section 7.2.1). Set the inserted from right to left when
engine speed at 1200rpm. facing the machine to avoid
disturbing the bearing located in its
4. Continue with the OPERATION switch required position against the
at PLANT and the RADIO REMOTE shoulder inside each lug on the
CONTROL switch at OFF (Figure 9e). Upper Frame.
6. Replace the linear position sensor and
replace the cover to the housing.
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7. Detach the cranage and replace the feed

ring or box and any chutework.
8. Now take steps to restore the Wedge

Ring pressure by returning to the
hydraulic console and closing the shut off
valve 9A (Figure 9g) to revert to the
operating position.
9. Open shut off valve 9B (Figure 9g) to

revert to the operating position.
10. Carry out the Initial Discharge Setting

and Calibration procedure described in
Section 7.3.3, following which the
Automax is ready to recommence
crushing.
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9.7.3.5 Changing the Mantle

The operation is carried out with the head WARNING
left in situ. The internal parts of the Automax WEAR PERSONAL
are therefore not disturbed or exposed to PROTECTIVE EQUIPMENT.
harmful dust. Refer to Section 9.1, Safety
In use all manganese steel will creep due to warning.
the nature of the material. When creep occurs LOCKOUT MACHINE.
stress is created in the material which will have Refer to Section 9.1, Safety
to be relieved by suitable cutting of the Mantle. Information for Lockout
This will be necessary in order to facilitate Procedure.
removal.
FALLING HAZARD.
Removing the Mantle Refer to Section 9.1, Safety
warning.
! WARNING !
When gas cutting through the
concave it is essential that 4. Break loose the fit between the Mantle
breathing apparatus is worn as and the Cone Head. This is best
when the metal is broken through achieved by striking the lower section of
the backing material gives off toxic the circumference with a hammer then
fumes. levering the Mantle clear of the Cone
Head.
Procedure
5. Insert short blocks of wood between the
1. Observe all safety warnings. Mantle and Cone Head in three places
around the circumference so as to leave
2. With the Upper Frame removed (Section a gap through which lifting chains can be
9.7.3.2) gas cut through the Burning placed. Three equally spaced lifting
Ring all the way round (Figure 9m). chains should be passed through this gap
and the hooks put round the bottom of
3. Once the Mantle is cut the Mantle Nut the mantle (Figure 9o) and the mantle
can then be removed by turning lifted off.
CLOCKWISE with the mantle nut
wrench (Figure 9n). Ensure that the
mantle nut wrench is secure by dropping
a suitably sized bolt through the hole in
the end of it.
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6. Remove the old backing material and

inspect the Cone Head seating where
the surface has been ground. Remove
any nicks or burrs with a file or grinder.
Inspect the ground surfaces of the new
Mantle and remove any nicks or burrs in
the same manner.
Figure 9m Gas cutting the Mantle

(Showing section through the Cone Head)
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MANTLE NUT WRENCH
SECURITY BOLT
Figure 9n Mantle Nut Wrench

securely fitted
Figure 9o Lifting chains correctly fitted
Sections through the Automax Cone Head
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Mounting the Mantle
Release agent needs to be applied to the

WARNING
Cone Head where it will be in contact with WEAR PERSONAL
the backing filler to ease separation when PROTECTIVE EQUIPMENT.
the manganese is next changed. Refer to Section 9.1, Safety
warning.
Procedure LOCKOUT MACHINE.
1. Observe all safety warnings. Information for Lockout
Procedure.
2. Apply release agent (obtainable from
Terex Pegson) to the unmachined FALLING HAZARD.
surface all around the Cone Head Refer to Section 9.1, Safety
(Figure 9p). Information for relevant
warning.
3. Place the new Mantle and Burning Ring
onto the Cone Head and tighten down
the Mantle Nut by turning COUNTER-
CLOCKWISE with the Mantle Nut
Wench (Figure 9n). It is sufficient to 5. Prepare the filler (Section 9.7.2) and
tighten this by hammer blows without pour the correct quantity of mixed filler
having to replace the Upper Frame and at the top of the Mantle making sure it is
wedge against the Concave. equally distributed all round.
4. The Mantle Nut was tightened to align

the Mantle and seat it firmly on the Cone ! NOTICE !
Head at A (Figure 9q). Now the Mantle
After mixing, the filler must be
Nut and Burning Ring need to be
poured IMMEDIATELY to ensure
removed so that the filler can be poured.
Release the Nut by turning complete penetration.
CLOCKWISE with the Mantle Nut
Wrench. 6. When the filler reaches 15mm (5/8)
from level B (Figure 9q) stop pouring, fit
the Burning Ring and Mantle Nut. First
Note: When the Mantle Nut is removed,
lightly tighten using the Mantle Nut
grease the threads on the Cone head so
Wrench. Fully tighten by hitting the
any spills when pouring the backing filler
wrench with a hammer in a COUNTER-
can be easily wiped off.
CLOCKWISE direction. The
replacement is now complete. Refer to
Section 9.7.2 for the filler hardening
time.
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Figure 9p Section through the Cone Head showing where to apply release agent
Figure 9q Section through the Cone Head showing correct filler level
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9.8 Wedge Ring Maintenance

WARNING
The Wedge is fundamental to how Refer to Section 9.1, Safety
the cone crusher functions. It Information for relevant
warning.
provides damping and guidance
to the Upper Frame assembly.
Poor machine performance and

crusher downtime are often due to
an incorrectly maintained Wedge.
The condition of the Wedge is assessed by

observing the hydraulic pressure required to
move the Upper Frame as recorded on the
pressure gauge (Figure 9r)
When the Upper Frame is moved there

should be no noticeable sticking on initial
movement or during the travel. If there is
any sticking noticed then this should be
investigated. On factory assembly the
friction pads are greased and it is possible
that grease needs to be added through the
nipples spaced around the Upper Frame
(NB. The minimum amount of Moly
Bentone grease should be added to restore ! NOTICE !
smooth travel). In situations where the
Only use Moly Bentone grease
crusher setting is not changed for long
periods it is good practice once a week to
(Section 9.4.5) for lubricating the
work the Upper Frame from the top to Wedge Ring
bottom of its stroke several times to
redistribute the grease.
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The crusher must not be allowed to operate

with regular dumping or bouncing of the
Upper Frame (Section 7.3.2) or damage may
result. Possible causes of the are crushing at
closed side settings which are too tight, out
of round manganese or poor Wedge Ring
adjustment.
! NOTICE !
Low wedge pressures are equally
as undesirable as high ones.
When testing the wedge pressure
it should be between 55 and 82
BAR (800 - 1200 psi).
Gauge measuring
Wedge Pressure
Automax Hydraulic Panel
Figure 9r Automax Hydraulic Panel and

Pressure Gauge
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9.8.1 Checking Automax Wedge

Pressure
DANGER
AUTOMAX NOT RUNNING SKIN INJECTION HAZARD
The pressure on the wedge ring is Information for relevant warning
automatically controlled by the Dumpy Jack
hydraulic circuit. However, as the adjustment
of the wedge ring is critical for good
performance of the Automax crusher it is
WARNING
WEAR PERSONAL
recommended that this should be checked PROTECTIVE EQUIPMENT.
daily. The pressure gauge near the panel Refer to Section 9.1, Safety
(Figure 7h) gives an accurate indication of Information for relevant
whether the Wedge Ring assembly is warning.
functioning correctly.
! NOTICE !
The Automax must not be allowed
to operate with regular dumping or
bouncing of the Upper Frame or
(Figure 9f) switch to MANUAL and
damage may result. Possible
depress the OPEN button lifting the
causes could be crushing at too Upper Frame approximately 20mm ()
small a setting, out of round above the set point.
manganese (Section 9.9) or poor
Wedge Ring adjustment. 5. Switch back to AUTO and observe the
pressure reading on the pressure gauge
Procedure (Figure 9r). The pressure should be in
the range 55 - 82 BAR (800 - 1200 psi).
6. Whilst the Upper Frame is moving check
2. Start the engine (Section 7.2.1). Set the for smooth movement with no sticking at
engine speed at 1200rpm. the start or whilst travelling.
3. Continue with the OPERATION switch 7. If the pressure reading is above or below
at PLANT and the RADIO REMOTE the range indicated above or the action is
CONTROL switch at OFF (Figure 9e). not smooth, remedial action is required
DO NOT press any of the start buttons. (Section 9.8)
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8.8.2 Low Wedge Pressure

If the wedge pressure has been checked and WARNING
found to be below 55 bar (800psi) then the WEAR PERSONAL
cause must be investigated and where PROTECTIVE EQUIPMENT.
necessary, the appropriate action taken. Refer to Section 9.1, Safety
warning.
Procedure
1. Low or fluctuating dumpy jack circuit DANGER
pressure.
Check circuit is free from leaks, and FLUID INJECTION HAZARD
pressure switches 11A & 11B (Figure Refer to Section 9.1, Safety
Information for relevant warning
9ab) are functioning correctly.
2. Wedge ring may not be bedded in fully

following maintenance or manganese
change.
Monitor wedge pressure. Work machine
at wider setting if excessive bouncing/
dumping is seen (Bouncing, Dumping,
see Glossary 7.3.2).
3. Excessive greasing and/or use of wrong

type of grease. ! NOTICE !
This can reduce the friction between the
wedge and the upper frame and hence
Only use Moly Bentone grease
limit the wedge pressure. (Section 9.4.5) for lubricating the
Wedge Ring.
Monitor the wedge pressure. If no
improvement is seen, it may be
necessary lift off the upper frame,
remove the grease and re-grease,
sparingly.
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9.8.3 Readjusting Tight Wedge Ring

AUTOMAX NOT RUNNING DANGER
If the wedge pressure has risen above the Refer to Section 9.1, Safety
prescribed maximum and/or the travel of Information for relevant warning
the Upper Frame is no longer smooth, the
Wedge Ring may need adjusting by the
following procedure. See Section 9.8.1 for
checking the wedge pressure.
WARNING
WEAR PERSONAL
1. Observe all safety warnings. warning.
2. Ensure that the feed conveyor and

Automax feed box are free from stone
and dirt.

4. Continue with the OPERATION

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

(Figure 9f) select MANUAL and
raise the Upper Frame to its
maximum using the OPEN button.
6. Close the shut off valve 9B adjacent to

the Automax Hydraulic Panel (Figure
9s) to isolate the wedge ring Dumpy
Jack hydraulic circuit from the main
hydraulic system.
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7. Open the shut off valve 9A inside the

hydraulic console (Figure 9s) to allow all
pressure in the Dumpy Jack circuit to be
DANGER
released thereby removing the loading SKIN INJECTION HAZARD
from the Wedge Ring. Refer to Section 9.1, Safety
8. Lower the Upper Frame with the
CLOSE button to push the Wedge Ring
down and thus free it from the
Mainframe. The wedge pressure
WARNING
WEAR PERSONAL
indicated on the pressure gauge (Figure PROTECTIVE EQUIPMENT.
9r) should drop away to 0-28 Bar (0-400 Refer to Section 9.1, Safety
psi) as the Wedge Ring frees off. Information for relevant
warning.
9. Close shut off valve 9A (Figure 9s) to
10. Open shut off valve 9B (Figure 9s) to

11. Depress the OPEN button lifting the

Upper Frame approximately 20mm
Shut Off Valve 9B
above the set point.
12. Select AUTO control position on switch.

The control system will bring the
machine down to the required gap
position or go through the initial Closed
Side Discharge Setting procedure
(Section 7.3.3) as necessary.
Diagnostic Pressure Gauge

(NOT the gauge referred to in step 8)
Shut Off Valve 9A
Figure 9s Dumpy Jack Circuit Valves
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9.9 Automax - Out of Round F) Increase the wear rate of the

manganese, due to the concentrated
Manganese - Causes and
crushing area. This gets worse as the
Effects process is a vicious circle.
When the Mantle and Concave are new both G) Due to effect of E above the machine
of the wearing surfaces are round. They will become reluctant to accept a choke
should remain round throughout their feed. The machine will dump as the
working life, ie. the wear should be crushing pressure reaches excessive
consistent and remain round. Should the levels.
manganese become out of round then the life
of that manganese will be shortened Prevention:
considerably. The causes and effects of this
are:- H) Only fit genuine BL-Pegson manganese
replacement parts.
Causes:
I) Ensure adequate feed hopper and
A) Inaccurate manganese manufacture/ efficient dead box are maintained to
fitting. distribute the feed material evenly
around the feed opening.
B) Poorly distributed feed material within
the hopper and/or segregated feed. J) Adjust the Plant/Automax settings
(Section 7.2.7) to ensure the Automax is
C) inconsistent stop/start feed. choke fed at all times.
Effects: K) Adjust the Plant/Automax settings

(Section 7.2.7) to ensure the feed to the
D) Produces an uneven load on the Wedge, Automax is continuous with stop/starting
reducing its life and producing a of the feed kept to a minimum.
fluctuating wedge pressure.
E) Produces an inaccurate zero set point,

resulting in an incorrect closed side
setting. This can mean that the machine
is crushing at a much lower closed side
setting than is indicated on the gap
indicator.
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9.9.1 Checking Manganese for Out

of Round
DANGER
Check 1 - The Mantle. ENTANGLEMENT HAZARD.
Procedure
warning.
1. Observe all Safety Warnings.
2. Ensure that the feed conveyor and WARNING

Automax feed box are free from stone WEAR PERSONAL
and dirt. PROTECTIVE EQUIPMENT.
3. Close down the plant (Section 8.2) and Information for relevant
implement the Lockout Procedure. warning.
LOCKOUT MACHINE.
Note: it is important when checking the Refer to Section 9.1, Safety
Mantle for out of round that the Information for Lockout
Eccentric does not move. Take the drive Procedure.
guard off and watch for any movement
of the countershaft. If movement is FALLING HAZARD.
noted repeat the whole procedure Refer to Section 9.1, Safety
described below, again.
warning.
4. Mark a cross on the top of the Mantle

Nut.
5. Mark the Concave opposite one of the

lines of the cross.
The next steps must be taken with

the Automax controls activated but
the Automax NOT running.

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CONTROL switch at OFF (Figure 9e). DANGER
DO NOT press any of the start buttons. ENTANGLEMENT HAZARD.
8. Ensure that everyone is clear of the warning.
machine. Put the hydraulic panel into
MANUAL and press CLOSE. Release
the button the moment the pressure WARNING
starts to rise and note the figure showing WEAR PERSONAL
on the gap indicator. Depress the OPEN PROTECTIVE EQUIPMENT.
button to raise the Upper Frame approx. Refer to Section 9.1, Safety
15-20 mm (5/8 -). Information for relevant
warning.
9. Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the Lockout Procedure. Refer to Section 9.1, Safety
10. Rotate the Cone Head slowly by hand, Procedure.
stopping it when it has gone through 90
whilst doing this watch the vee belts to FALLING HAZARD.
ensure that the eccentric does not move
in the Cone Head. The second mark on
warning.
the mantle plate should now be lined up
with the mark on the Concave.
11. Repeat steps 6 to 9.

0
12. Repeat the process so that you have four
values for the Mantle. If the Mantle is
round it should show similar values to
Figure 9o. -1 -1
Typical values
Mantle OK.
1
Figure 9t Mantle Check
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Check 2 - The Concave
Note: This process is almost identical to the

DANGER
Mantle check. Follow the procedure for the ENTANGLEMENT HAZARD.
Mantle - Check 1. Refer to Section 9.1, Safety
HOWEVER, this time the Cone head and warning.
Eccentric MUST move as one. To do this
the Flywheel should be rotated slowly by
hand. The Mantle procedure (previous page) WARNING
can be followed but rotating the Flywheel not WEAR PERSONAL
the Cone head. It is useful to have an PROTECTIVE EQUIPMENT.
assistant watch the Cone Head rotate whilst Refer to Section 9.1, Safety
the vee belts are rotated to ensure it is Information for relevant
moving. In order to prevent slip between the warning.
Eccentric and Cone Head:- LOCKOUT MACHINE.
A) Ensure slow, gentle movement of the Information for Lockout
Eccentric, via the vee belts. Procedure.
B) Make sure the Concave is well clear of FALLING HAZARD.

the Mantle when the Eccentric/Cone Refer to Section 9.1, Safety
Head is being rotated.
warning.
As a final check for any slip between the

Eccentric and the Cone Head, repeat the
first touch again as the example below:- 0
0
! NOTICE !
If there is a difference of more than
7mm between any two values of -1 -2
the four measured, that piece of
manganese must be changed Typical values
Mantle OK.
immediately.
1
Figure 9u Concave Check
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9.10 Automax - Fault finding
GENERAL
Fault Possible Cause Procedure
Machine stops. Overload through Clear machine adjust

discharge setting too setting.
low.
Tramp metal fixed in Clear machine adjust
crushing chamber. setting.
Packing in crushing Clear discharge chute.
chamber.
Lubricating oil flow low / Check operation of
temperature high. lubrication system.
Build up in discharge Clear blockage check
chute. chute.
Power supply / drive Check power supply /
motor failure. drive motor, see
manufacturers literature
Broken vee belt (s). Replace belt (s).
Discharge setting not Hydraulic fluid leakage. Check all hydraulic

maintained. components, couplings,
pipes and hoses.
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Reduction in discharge Crushing pressure too Adjust setting.

setting not possible. high
Hydraulic system faulty. Check for internal/
external leaks.
Manganese out of Check manganese.
round.
Manganese worn out. Change manganese.
Directional control valve Check solenoid.
inoperative.
Relief valve dirty or Dislodge dirt from under
faulty. seat / check valve
spring.
Couplings at hydraulic Investigate and correct.
ring- main faulty.
Packing in crushing Adjust machine.
chamber. (excessive
fines in feed)
Increase in discharge Wedge too tight. Grease and readjust

resetting not possible. wedge.
Upper frame assembly Manganese out of Check manganese.

bounces. round.
Wedge pressure low / Tighten assembly/
Wedge assembly loose. repressurise.
Adjusting wedge Check fibre pads worn
assembly has no out or require changing.
apparent effect.
Hydraulic cylinder (s) Investigate and correct.
faulty.
Manganese out of Check feed segregation.
round.
Check manganese for
out of round, change as
necessary.
Crushing at excessively Change setting.
tight closed side setting.
Feed chute incorrectly Investigate and correct.
installed.
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Erratic movement of Air in hydraulic system. Bleed system / check for

hydraulic cylinder(s). leaks.
Hydraulic system Replace.
filter(s) blocked.
Crusher motor stops. Overcurrent due to Check the transformer

voltage drop. capacity.
Overcurrent due to Suitable feed amount?
overload. Uniform feeding?
No packing?
Insufficient oil supply?
Damaged bearing?
Tramp metal?
Machine overloaded?
Interlock operation. Pump motor rotating?
Deteriorated pump
performance or lack of
oil?
Return oil temperature
too high?
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Abnormal sound from Damage of the bearing Contact Terex Pegson.

the crusher. of the countershaft.
Damage of the Contact Terex Pegson.
countershaft gear.
Loose mantle. Inspect conehead/
mantle for damage.
Refit as when changing
manganese.
Loose or falling Adjust the concave
concave. wedge.
Check the mantle
rotating direction.
Check the touching
surface.
Check for partial wear.
The particle size of the Mantle / concave worn Check for out of round.
crushed product is out of round.
coarse.
The indicated setting Measure the actual
value is different from setting with a lead ball
the actual value. etc.
Wedge ring adjustment Adjust the wedge ring.
failure.
Partial wear of the Check the feeding
mantle and concave. chute.
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HYDRAULICS
The pump doesnt start. Electrical fault. Check the thermal relay
connection and motor,
fuses & connections.
Rotating direction error. Check the rotating
direction and reconnect.
Insufficient quantity of Refill oil.
oil in the tank.
Pump seized. Check that pump shaft
rotates, fit replacement
if faulty.
The pump starts but no Clogged suction side Clean the piping and
pressure and discharge piping. carry out flushing.
occur.
Clogged suction side Remove and clean.
filter.
Air mixed from the Re-tighten the coupling
suction side. screw.
Replace the piping.
Oil viscosity too high. Check for the specified
brand.
Defective or damaged Check and replace.
pump and coupling.
Relief valve setting Contact Terex Pegson.
failure.
Pump noise. Air mixed from the Clean the piping and
suction side. carry out flushing.
Clogged air breather. Disassemble and clean.
Sound in the relief Disassemble. Clean or
valve. replace the spring
nozzle.
High oil viscosity. Check for the specified
brand.
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Irregular motion of the Air mixed in the cylinder. Check the piping, hose
cylinder. and coupling, after
checking and repair,
remove air.
Filters blocked. Replace.
Downward adjustment Unseated unloader Replace valve.

possible - system will valve.
not build up or maintain
pressure.
Solenoid operated vent Replace valve.
valve unseated.
Directional control valve Check operation of
inoperative. solenoid, replace if
necessary. Check for
possible sticking spool
on valve, dismantle,
clean, replace parts or
complete assembly.
Dirt in relief valve. Screw the adjuster out a
few turns then in again
to the original setting.
This will dislodge dirt
under the ball seat. If no
response, remove unit,
dismantle and clean,
particularly jet.
Replace in system.
Faulty relief valve. Check valve spring,
renew as necessary.
External leakages. Make visual inspection.
Tighten connections.
Renew pipes, hoses or
couplings as necessary.
Mechanical failure of the Check to see if any
crusher. object touches the
machine.
Insufficient oil quantity. Check the oil level
gauge.
Refill as necessary.
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Downward adjustment One or both quick Inspect, replace as

not possible - high release couplings faulty. required.
pressure build - up
occurs.
Directional control valve Check operation of
jammed half open. valve, dismantle, clean,
replace parts or
complete valve as
necessary.
Mechanical blockage on Investigate crusher.
crusher.
Upward adjustment not Directional control valve Check operation of

possible. inoperative. solenoid, replace if
necessary. Check for
possible sticking spool,
dismantle, clean,
replace parts or
complete valve as
necessary.
Solenoid operated vent Check operation of
valve inoperative. solenoid, replace if
necessary.
One or both quick Inspect replace as
release couplings faulty. required.
Mechanical blockage on Investigate crusher.
crusher.
External leakages. Make visual inspection.
Tighten connections.
Renew pipes, hoses or
couplings as necessary.
Mechanical failure of the Check to see if any
crusher. object touches the
machine.
Insufficient oil quantity. Check the oil level
gauge. Refill as
necessary.
Oil in system becomes Pump running Check for symptoms of
excessively hot. continuously under pressure build up.
pressure
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LUBRICATION SYSTEM
The oil cooling efficiency Cooling matrix choked Disassemble and clean.
is deteriorating. with dust.
Dust depositing at the Clean the tank.
bottom of the tank.
The oil heater cannot be Thermostat failure. Replace.

turned off.
Thermostat setting Correct the setting.
failure.
The contact type oil Contact type return oil Replace.

temperature gauge temperature gauge
doesnt operate at the failure.
preset temperature.
Setting failure. Correct the setting.
Machine stops. Lubrication system Check fault display in

safety interlocks Section 7.2.3.
activated.
Oil chilled on entering Look for oil return to
cold. tank. Check oil heater
working.
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9.11 Plant - Feed Conveyor
The Automax crusher is fed from the feed

hopper via the feed conveyor. Feed material
can be introduced into the hopper either by
overhead loads or continuously via a belt
conveyor.
During the crushing operation the feed

conveyor can be controlled by the level
sensors (Section 9.12) over the feed hopper
(optional) and/or the Automax feed box. The
purpose of the level sensor(s) is to avoid a
dribble feed to the Automax which is
detrimental to the optimum performance of
the crusher.
! NOTICE !
The performance of the Automax
benefits in all respects from
receiving a continuous choke
feed of material (Section 3.4) and
the aim is to achieve this by
setting the plant controls (Section
7.2.7) to keep stopping and
starting of the feed to a minimum.
During crushing operations the level of

material in the feed hopper should be
maintained at a high level to avoid stopping
of the feed conveyor due to lack of material
in the hopper.
A rotary control on the plant control panel

(Figure 7e) is also provided to manually vary
the feed rate by regulating the speed of the
feed conveyor.
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9.12 Plant - MiniRanger

Level Sensors Description
The standard Maxtrak includes a level

sensor over the Automax feed box to control
the feed into the crusher by varying the
speed of the feed conveyor. An optional
sensor can also be fitted over the feed
conveyor hopper where this is practical to
the crushing application.
The following pages give summaries of the

operation and setting-up guides.
The MiniRanger units are preset at the factory

with settings found to have been generally
suitable (Figure 9.12.4) but can be
reprogrammed if necessary to suit differing
applications and materials.
! NOTICE !
The Automax crusher gives the
best performance in all respects
when kept choke fed as
explained in Section 3.4
Unit MR1 - Crusher Bowl

This monitors the material level in the
Automax crushing chamber and feed box to
adjust the speed of the feed conveyor.
Unit MR2 - Feed Conveyor (Optional)

This monitors the material level in the feed
hopper and works in conjunction with the
sensor MR1 to provide an addition measure
of controlling the feed into the Automax.
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9.12.1 Level Sensors - Operation

The MiniRanger Plus is a versatile material WARNING
level monitoring instrument. Material level WEAR PERSONAL
measurement is achieved using advance sonic PROTECTIVE EQUIPMENT.
echo ranging techniques. Each unit is complete Refer to Section 9.1, Safety
with an integral multi-function liquid crystal Information for relevant
display with four button keypad (Figure 9v) warning.
mounted on the Electrical Control Panel
Each MiniRanger Plus has two modes of

operation: RUN and PROGRAM. When the
unit is powered it is programmed to start up in Optional Sensor
the run mode to detect the distance from the
transducer face to the target material in
metres.
The unit can be placed into the program mode

at any time; to alter the number of program
parameters in order to better suit the
application or users preferences.
Programming is carried out via the keypad.
See Section 9.12.2 for the keypad functions

and displays relating to the RUN mode.
See Section 9.12.3 for the keypad functions

and displays relating to the PROGRAM mode.
See Sections 9.12.4 for Factory Presets.
See Section 9.12.5 for the simplified Setup

Guide for typical mobile crusher bowl level.
Figure 9v MiniRanger Plus Control Panel
See Section 9.12.6 for the simplified Setup
Guide for typical hopper level (Optional).
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9.12.2 Level Sensors - Run Mode
Communication Jack
LCD Keypad
LCD Display
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9.12.3 Level Sensors - Program Mode
Communication Jack
LCD Keypad
LCD Display
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9.12.4 Level Sensors - Factory Settings
NB. The Hopper Level Sensor is an optional item.
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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl
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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl, continued
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9.12.6 Level Sensor MR2 Setup Guide - Hopper*
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9.12.6 Level Sensor MR2 Setup Guide - Hopper, continued
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9.13 Plant/Automax -
Hydraulic Systems DANGER
9.13.1 General Description Refer to Section 9.1, Safety
One integrated hydraulic system performs warning
the following functions:-
Automax setting adjustment, overload

protection, unblocking and wedge ring WARNING
pressure. Also driving the crusher
WEAR PERSONAL
lubricating oil circulating system. PROTECTIVE EQUIPMENT.
Plant hydraulic drives for the conveyors Information for relevant
and tracks and also to hydraulically raise warning.
and lower the feed conveyor.
LOCKOUT MACHINE.
All hydraulic functions are powered by two Information for Lockout
pumps, one mounted on either side of the Procedure.
diesel within the engine canopy and driven
from the engine mainshaft via vee belts.
Alternative selection of the PLANT or

TRACK switch on the plant control panel
(Figures 5a & 6a) ensures the plant cannot
be moved whilst operating.
! DANGER !
THIS IS A HIGH PRESSURE
The hydraulic fluid reservoir together with SYSTEM.
associated equipment must be maintained in
accordance with the set level (For topping up
Never carry out any maintenance
the reservoir see Section 9.13.6) and in the
schedules and types detailed in Section 9.4. work without ensuring the
ONLY USE A RECOMMENDED FLUID. hydraulic system is locked out and
depressurised.
It is essential when replenishing hydraulic
fluid, attending to filters, etc. to apply the Do not tamper with system. In the
greatest degree of cleanliness as it is most event of any problems these
important that contaminants are not allowed should only be dealt with by
to enter the system. suitably experienced and qualified
engineers.
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Each of the two hydraulic pump is an axial

piston variable displacement unit feeding a
directional control valve.
DANGER
The flows and pressures to each service is Refer to Section 9.1, Safety
limited by the relevant spool as shown below Information for relevant warning
and the pump supplies only the required flow
by automatically backing off the swash plate
angle thus reducing wasted power and
resulting heat generation.
Note:-
This is achieved by means of a load sensing All relief valve pressures are factory set and
line from the valve to the pump which should not be adjusted on site.
measures the pressure required which is
then matched by the pump. Although the maximum flows from each
spool is limited as shown, these can be
individually adjusted downwards by means of
limit screws if desired. Please contact Terex
Pegson Ltd.
No: 1 Pump (valve mounted in engine canopy)

Max Flow
Max Pressure
Service Spool Type litres/min
(Bar)
(US galls/min)
L/H track drive motor Proportional 100 (26.4) 320
Product Conveyor plus Water
On/Off 100 (26.4) 210
Pump (when fitted)
Automax control On/Off 5 (1.3) 200
180
No: 2 Pump (valve mounted under feed conveyor)
Max Flow
Max Pressure
Service Spool Type litres/min
(Bar)
(US galls/min)
R/H track drive motor Proportional 100 (26.4) 320
Feed Conveyor Proportional 75 (19.8) 180
Feed Conveyor raise/lower On/Off 25 (6.6) 100
Automax lubrication On/Off 15 (4.0) 140
Figure 9w Front/Rear Hydraulic Pumps
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9.13.2 Track Drives 9.13.3 Feed Conveyor Drive

Although these valves sections have This valve section is fitted with a
proportional controls and are theoretically proportional solenoid so that the feeder
infinitely variable they are electrically limited speed can be controlled by level sensor
to two speeds for simplicity. mounted over the Automax feed box.
a) SLOW - For slewing and fine 9.13.4 Circuit Protection

positioning.
The system is equipped with the following
b) FAST - For straight line running, forward protection:-
or reverse.
Suction Filter (90m nominal )
Note:- The maximum power take off from
one side of the engine is limited to Pressure Filter (10m absolute) in each
approximately 30 KW, therefore the system pump circuit prior to the directional
is electronically limited such it is only control valves.
possible to slew (operate one side only)
when in the SLOW mode. Return Filter (10m nominal)
Fine adjustment of the slow speeds is Low oil level cut out.
possible. Consult BL-Pegson Ltd.
Note:- For Hydraulic Pump Drive Belt
It is recommended that adjustment is not adjustment refer to Section 9.15.3.
undertaken without BL-Pegson Ltd. consent
and under no circumstances should the slow
speed be adjusted greater than 0.2mph. ! NOTICE !
The hydraulic oil filters are fitted
Motor mounted counterbalance valves are with condition indicators to shown
utilised to prevent the machine over running
when the renewable filter element
when moving downhill.
needs to be changed. These
This block also incorporates a shuttle valve
should be checked on a daily
to release the spring applied track parking basis whilst the plant is running at
brake together with a pressure reducing normal operating temperature
valve, preset to 60 bar so that the brakes are (Sections 9.13.5 - 6 & 8). In cold
not over-pressurised. ambient temperatures the filter
indicators may show red until the
system reaches normal operating
temperature.
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9.13.5 Changing the Suction Filter

Located at the base of the hydraulic DANGER
reservoir tank is the hydraulic suction filter.
When the dial gauge needle (Figure 9y) SKIN INJECTION HAZARD
enters into the red segment whilst the
system is running at normal operating
temperature this is an indication that the
filter must be replaced immediately . The
filter housing has an internal shut off valve to
permit work on the system. Make sure the
WARNING
oil has cooled before changing. WEAR PERSONAL
Procedure Information for relevant
warning.
LOCKOUT MACHINE.
2. Close down the machine (Section 8.2) Information for Lockout
and implement the Lockout Procedure. Procedure.
3. Using a hexagon socket key unscrew the FALLING HAZARD.

bolt A in the centre of the filter housing Refer to Section 9.1, Safety
until it reaches the stop (Figure 9y). Information for relevant
warning.
4. Take steps to collect spillage of oil (approx.
2 litres) before undoing the six socket head
screws on the front of the housing to
remove the cover plate.
5. Remove the old filter and clean inside

the housing with lint free cloth before
fitting a new filter of the approved 7. Fully screw in the bolt A in the
pattern and specification. centre of the filter housing.
6. Before replacing the cover plate, lightly

oil the O ring and make sure it is ! NOTICE !
properly seated in the groove. Replace It is important to ensure that the
the cover plate and refit the screws to
bolt A is fully screwed in before
ensure an oil tight seal.
restarting the plant. Damage will
occur to the plant if this procedure
is not followed.
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Filter Condition Indicator Dial
Removable Cover Plate
Bolt A
! NOTICE !
It is important to ensure that the
bolt A is fully screwed in before
restarting the plant. Damage will
Figure 9y Suction Filter occur to the plant if this procedure
is not followed.
Hydraulic Oil Level & Hydraulic Oil Return Hydraulic Oil

Temperature Gauge Filter and Gauge Breather/Filler
Hydraulic Oil Tank Filter Condition Indicator Dial
Figure 7z Hydraulic Oil Tank & Level Indicator
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9.13.6 Changing the Return Filter

Located on top of the hydraulic reservoir DANGER
tank is the hydraulic return filter. When the
dial gauge needle (Figure 9z) enters into the Refer to Section 9.1, Safety
red segment whilst the system is running Information for relevant warning
at normal operating temperature this is
an indication that the filter must be replaced
immediately. Make sure the oil has
cooled before changing. WARNING
WEAR PERSONAL
In the event hydraulic oil needs to be added
to maintain the correct level on the gauge
(Figure 7z), this should be poured in after Information for relevant
removing the cover (see below) but with the warning.
filter element left in place. Check the system
LOCKOUT MACHINE.
for leaks if topping up becomes necessary.
Procedure Procedure.
1. Observe all safety warnings. FALLING HAZARD.

2. Close down the machine (Section 8.2) Information for relevant
and implement the Lockout Procedure. warning.
3. Remove the four hexagon head screws

on the top of the housing to remove the
cover plate together with internal spring. 9.12.7 Changing the Tank Breather
This should be changed after the first 100
hours of operating and thereafter after 500
the housing with lint free cloth before
hours but in dusty atmosphere it is
fitting a new filter of the approved
recommended to change more frequently
pattern and specification. Replace the
depending upon conditions. Simply unscrew
spring which holds the filter in place
and replace whilst the plant is shut down.
5. Before replacing the cover plate, lightly
oil the O ring and make sure it is
properly seated in the filter housing.
Replace the cover plate and refit the
screws to ensure an oil tight seal.
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9.13.8 Changing the Pressure

Filters DANGER
Located on each side on the engine within the
canopy are the hydraulic pressure filters.
When the telltale (Figure 9aa) changes from
green to red whilst the system is running at
normal operating temperature this is an
indication that the filter must be replaced
immediately. Make sure the oil has cooled
before changing.
WARNING
WEAR PERSONAL
warning.
2. Close down the machine (Section 8.2) LOCKOUT MACHINE.

and implement the Lockout Procedure. Refer to Section 9.1, Safety
Procedure.
3. Unscrew (turn anticlockwise looking
from below) the filter bowl using the
hexagon nut cast into the base. Take
steps to contain spillage of oil
Filter condition Telltale Filter body

the bowl and housing with lint free cloth
before fitting into position a new filter
and small O ring of the approved
pattern and specification.
5. Before replacing the bowl, lightly oil the

O ring and place on its seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
care not to cross the threads when Bowl
doing so. Tighten with the nut at the
base of the bowl to ensure an oil tight
seal.
Nut
Figure 9aa Pressure Filter
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9.13.9 Automax Hydraulic System

The hydraulic control components (with the DANGER
exception of the position sensor unit on the
crusher are housed in the hydraulic control SKIN INJECTION HAZARD
console.
warning
The System 2 - 2001 enables the Automax to
be controlled as described in Section 7.3 &
7.4.
WARNING
In the event of a blockage occurring in the WEAR PERSONAL
crusher the panel senses an increase in PROTECTIVE EQUIPMENT.
pressure and will automatically raise the Refer to Section 9.1, Safety
crusher upper frame (including the concave) Information for relevant
to release material in the crushing chamber. warning.
When the crusher is new or a new concave

and mantle have been fitted the procedure
for setting the Set Zero calibration should be
followed (Section 7.3.3). This procedure is
necessary to allow all the other functions to
take place. By following this procedure the ! DANGER !
control system then recognizes the position THIS IS A HIGH PRESSURE
of the concave in relation to the mantle (the
SYSTEM.
two crushing elements) and can then allow
the measurements of wear to take place.
Never carry out any maintenance
When the manganese wear procedure has work without ensuring the
been followed (Section 7.3.4) and as wear hydraulic system is locked out and
on the manganese crushing members depressurised.
(concave and mantle) takes place, the
amount of wear is calculated by the control Do not tamper with system. In the
system and can be read off at any time from event of any problems these
the Automax console display screen. should only be dealt with by
suitably experienced and qualified
engineers.
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ITEM PART DESCRIPTION

1 PRESSURE FILTER
No: AUTOMAX HYDRAULIC CONNECTION DETAILS
2 PRESSURE FILTER
3 SOLENOID VALVE
4 DOUBLE PILOT CHECK VALVE 1 INLET, 4 LPM @ 2700 PSI
5 UNLOADER VALVE
6 PRESSURE REDUCING VALVE (2) 2 CONNECT TO WEDGE CIRCUIT
7 CHECK VALVE
8 PRESSURE RELIEF VALVE
3 CONNECT TO ANNULUS OF GAP SETTING CYLINDERS
9 NEEDLE VALVE (2)
10 PRESSURE GAUGE (3)
4 CONNECT TO FULL BORE OF GAP SETTING CYLINDERS
11A PRESSURE SWITCH 35-120 BAR
11B PRESSURE SWITCH 35-120 BAR
12 PRESSURE SWITCH 5 RETURN TO TANK
13 MANIFOLD BLOCK
Figure 9ab Automax Hydraulic Control Circuit
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9.14 Plant - Electrical

System WARNING
WEAR PERSONAL
9.14.1 General Description PROTECTIVE EQUIPMENT.
Electrical power of DC24 volt for the Information for relevant
electrical equipment on the plant is derived warning.
from the diesel engine to operate the control
LOCKOUT MACHINE.
systems for the Automax crusher and all the
plant items. Information for Lockout
Procedure.
Refer to the wiring diagrams in Section 11 -
Appendix.
9.14.2 Operators Control Points

Once the diesel engine has been started
(Section 7.2.1) the operator controls the
electrical equipment from:-
Plant Control Panel (Section 7.2)
Automax Control Panel (Section 7.3 &

7.4 )
Remote Handset for Tracks (Section 5)
Level Sensor(s) Panel(s) (Section 9.12)
Metal Detector Panel (Sections 7.2.6

and 9.17)
Emergency Stop Buttons (Sections 1.7

and 8.3)
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9.14.3 Protection Devices

The plant is fitted with Emergency Stop WARNING
buttons (Sections 1.7 and 8.3) and, in WEAR PERSONAL
addition, is equipped with a comprehensive PROTECTIVE EQUIPMENT.
range of protection devices to safeguard the Refer to Section 9.1, Safety
equipment against damage. Should any of Information for relevant
the sensing equipment fail in operation, the warning.
necessary repairs or replacement should be
made immediately. This will restore the
safeguard to keep the equipment from harm
and maintain any warranty in force for the
time being. No attempt should be made to
circumvent these protection devices.
The screen on the Plant Control Panel

(Section 7.2.3) displays the appropriate
message of any fault occurring.
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9.15 Plant - Crusher and Hydraulic Pump Drive Belts
Good alignment of the flywheel and drive pulley is important otherwise the belt flanks will wear quickly.
Ensure axis are parallel when viewed from all planes (Figure 9ac).
Shafts are not parallel

Shafts are parallel
to one another when
from above but not
seen from above
from end view
Shafts are parallel and Correct Installation

in alignment but pulleys
are not in alignment Both shafts and pulleys
are parallel and in
alignment
Figure 9ac Correct Alignment of Pulley Belts
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9.15.1 Trouble Shooting - Drive

Belts
Small Cracks on V-Belt side and Base
Generally caused by shortage of belt tension

but excessive heat and/or chemical fumes
can also give same failure.
V-Belt Swelling or Softening
Caused by excessive contamination by oil,

certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning,

principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires
redesign or a Banded belt. Consult Terex
Pegson Ltd.
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9.15.2 Replacement and

Adjustment of Crusher Drive Belts
WARNING
Note: Drive belts should inspected WEAR PERSONAL
regularly for wear and also to monitor any PROTECTIVE EQUIPMENT.
pattern in the wear if it is occurring Refer to Section 9.1, Safety
(Figure 9ac). Information for relevant
warning.
The tension of the crusher drive belts is
LOCKOUT PLANT.
adjusted with the four screws located at Refer to Section 9.1, Safety
each corner of the engine baseframe Information for Lockout
(Figure 9ad). Procedure.
When replacing the belts the drive should FALLING HAZARD.

be slackened off sufficiently to remove the Refer to Section 9.1, Safety
old belts and fit the new without stretching Information for relevant
warning.
them. Only use matched sets of belts to
ensure equal tension is possible on all the
belts.
Procedure
2. Close down the machine (Section 8.2)

and implement the Lockout Procedure.
3. Remove the crusher drive guarding as

necessary to gain access to the vee belt
drive.
4. Loosen all four locking nuts A (Figure

9ad) on the engine baseframe adjusting
screws situated beneath the corners of
the baseframe. Access can be gained
from the platforms along each side of the
engine.
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Nut B (4 off)
Nut A (4 off)
Figure 9ad Crusher Drive Belt Tensioning Mechanism RH Side
Deflection Dimension Basic Setting Force 1.25 x Setting Force

(mm) (kgf) (kgf)
See Section 9.15.4 (Step 3) 9.4 12.0

(ins) (lbf) (lbf)
See Section 9.15.4 (Step 3) 20.73 26.5
Figure 9ae Crusher Drive Belt Tensioning Specifications
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Note: Assuming the drive alignment has

been satisfactory, mark, or take a
measurement of the existing position of
the engine baseframe (in relation to the
fixed chassis) at each tension screw.
These will serve as alignment reference
points when tensioning the drive.
5. Lower the engine baseframe by turning

each of the four nuts B anticlockwise
an equal amount a little at a time. To
maintain the engine baseframe as level
as possible whilst carrying out this
operation only adjust each nut B a
small amount at a time.
6. If the belts are to be removed, repeat

Step 5 to further slacken the belts until it
is possible to remove the belts without
the need to stretch them.
If requiring to tension the belts

correctly, follow the method for
correctly tensioning each of the belt
drives (Section 9.15.4).
7. Check the alignment of the two pulleys is

correct (Figure 9ac) making sure that the
engine baseframe is level in relation to
the fixed chassis.
8. Tighten the four locking nuts A.
9. Ensure that the drive guarding is

replaced and secured before start-up.
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9.15.3 Replacement and

Adjustment of Hydraulic Pump
Drive Belts
DANGER
Note:- Drive belts should be inspected Refer to Section 9.1, Safety
regularly for wear, correct tension and Information for relevant
contamination. warning
The two hydraulic pumps are situated one

each side of the engine within the diesel
engine canopy
WARNING
WEAR PERSONAL
The belt tension of both hydraulic pump Refer to Section 9.1, Safety
drives is adjusted by two bolts located on Information for relevant
each pump baseplate (Figure 9af). warning.
LOCKOUT PLANT.
Procedure.
2. Close down the machine (Section 8.2) FALLING HAZARD.

and implement the Lockout Procedure. Refer to Section 9.1, Safety
3. Remove the diesel engine side access warning.
panels.
4. Loosen the 4 bolts (A) securing the

pump bracket to the pump stool.
5. Turn the 2 adjusting screws (B)

clockwise to slacken the two drive belts.
Continue until it is possible to remove the
belts.
6. Remove the two drive belts and re-fit

with new belts.
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7. Turn the 2 adjusting screws counter

clockwise to tighten the two drive belts.
Continue until the belts have reached the
correct tension (Section 9.15.4), making
sure the pump pulley is aligned with the
drive pulley (Figure 9ac).
8. Tighten the 4 bolts (A) to lock the pump

bracket to the pump stool.
9. Replace the belt guard and diesel engine

side access panels before start-up.
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Hydraulic Pump Hydraulic Pump

Drive Belt Guard
Adjusting Screws (B)
Pump Stool Bolts (4 off) (A) Pump Bracket
Figure 9af Hydraulic Pump (LH) Drive Belt Tension Mechanism

(mm) (kgf) (kgf)
See Section 9.15.4 (Step 3) 6.3 7.9

(ins) (lbsf) (lbsf)
See Section 9.15.4 (Step 3) 13.9 17.4
Figure 9ag Pump Drive Belt Tensioning Specifications
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9.15.4 Method of Drive Belt

Tensioning
WARNING
Under no circumstances should Refer to Section 9.1, Safety
any check on the belt tension be warning.
made whilst the machine is
running. There is a risk of LOCKOUT PLANT.
trapping parts of the body if this is
done. Procedure.
Procedure FALLING HAZARD.

1. Observe all safety warnings. Information for relevant
warning.
Remove the guards from around the belt. Crusher/Engine Drive Belts
3. Calculate the deflection distance in mm 8 x 4000mm SPC,

on a basis of 16mm deflection per 1 Part Number 2441-0472
metre of belt span (Figure 9ah)
(approx. 5/8 per 1 yard) Hydraulic Pump Drive Belts
Centre to Centre Distance metre x 16 4 x 2000mm SPB,

= Deflection mm Part Number 2441-0412
Ce
Di ntre
sta
nc to C
e en
tre
16mm
( 5/8 ins.
Deflection
Deflection
per 1
per 1
Metre of
yar of
Belt Tension Belt
Belt
Indicator Applied Span
Span )
to Mid-Span
Figure 9ah Belt Tensioning Measurements
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4. If a belt tension indicator is 6. If the measured force falls within the

available: values given, the drive should be
satisfactory. A measured force below the
a) Set the lower marker ring at the lower value indicates under-tensioning. A
deflection distance required on the lower new drive should be tensioned to the
scale. 1.25 x Setting Force value to allow for
the normal drop in tension during the
b) Set the upper marker ring against the running-in period.
bottom edge of the top tube.
7. Replace all guards before start-up.
c) Place the belt tension indicator on top of
the belt at the centre of the belt span,
and apply a force at right angles to the ! NOTICE !
belt deflecting it to the point where the After the drive has been running
lower marker ring is level with the top of
for 15-20 minutes, the tension
the adjacent belt.
should be checked and readjusted
d) Read off the setting force value
to the Basic Setting Force value, if
indicated by the top edge of the upper necessary by repeating the above
marker ring. procedure from Step 1.
e ) Compare this value to the lbf value

shown in the table:
Figure 9ae - Crusher Drive Belt
Tensioning Specifications
Figure 9ag - Hydraulic Pump Drive Belt
Tensioning Specifications
5. If a belt tension indicator is not

available:
a) Use a spring balance to pull the belt

down at the centre of the span.
b) When the belt has been pulled down

(measure using a rule) by the deflection
calculated in Step 3, read off the force
from the spring balance.
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9.16 Plant - Conveyor Belts

DANGER
9.16.1 General Description
ENTANGLEMENT HAZARD.
There are two belt conveyors on the Refer to Section 9.1, Safety
Maxtrak plant. Information for relevant
warning.
The Feed Conveyor has a shallow
troughed plain belt. Drive is through a head
drum mounted oil lubricated gearbox with WARNING
hydraulic motor. Screw type tensioning of
WEAR PERSONAL
the belt is at the tailshaft. Full length skirt PROTECTIVE EQUIPMENT.
plates are included. A metal detector Refer to Section 9.1, Safety
(Section 9.17) is fitted to stop the conveyor Information for relevant
when the detector is triggered. To reduce warning.
the height of the plant for transportation
the conveyor can be lowered by means of LOCKOUT PLANT.
an hydraulic ram (Sections 5.2 and 6.2)
and also to elevated (Section 9.7.3.1) to
Procedure.
gain access when working on the
Automax crusher. To achieve the FALLING HAZARD.
minimum travelling height it is also Refer to Section 9.1, Safety
necessary to lower the Automax Upper Information for relevant
Frame (Section 5.2.5). Grease nipples are warning.
provided for lubrication of the shaft
bearings.
The Discharge Conveyor is a standard

troughed plain belt type. The drive is by
hydraulic motor at the head end and. ! DANGER!
Screw tensioning of the belt is at the
headshaft. Full length skirt plates are
Under no circumstances should
included. A detachable canvas wind cover any adjustment be made on the
is included. A movement sensor is fitted at belt whilst the machine is running.
the tail to stop the feed to the Automax in There is a risk of trapping parts of
the event of conveyor belt stopping for any the body if this is done.
reason. The shaft bearings are lubricated
the same as the Feed Conveyor.
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9.16.2 Training of Belts

Before starting the conveyors, it is essential DANGER
to check that:-
ENTANGLEMENT HAZARD.
Make sure that the Feed Conveyor is in Information for relevant
the working position. warning.
Wire ropes supporting the Discharge

Conveyor head should be correctly WARNING
tensioned by adjusting with the
WEAR PERSONAL
turnbuckles.
The head and tail drums are correctly Information for relevant
fitted. ie. they are level, and that their warning.
axes are square to the centre line of the
conveyor. LOCKOUT PLANT.
All troughing and parallel idlers are Information for Lockout
Procedure.
correctly fitted with their axles square to
the centre line of the conveyor, the side FALLING HAZARD.
roller lead is in the correct direction (i.e. Refer to Section 9.1, Safety
forward of centre) and all rollers are Information for relevant
rotating freely. warning.
In the case of screw-type take up gears, Tracking should be carried out with the belt
that these are adjusted initially to take up empty. With very stiff belts, which do not
slack from the belt and that equal tension trough well nor make proper contact with the
is applied to each side such that the centre idlers roller when empty, it may only
pulley is square to the centre line of the be possible to track the return strand when
conveyor. empty and the troughed side when loaded.
Where skirt rubbers are fitted they are If the belt tends to run to one side the most
not bearing down heavily on the belt. likely cause of the trouble will usually be
some distance before the point where the
There is no obstruction on the conveyor running off is apparent, and in the case of
that could cause accident or damage troughed strand probably at the second or
when the conveyor is started. third idler behind the point where the belt is
moving out of its true line.
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Side Roller
Slots for
Belt Adjustment
Side Roller
Centre
Slots for
Adjustment
Figure 9ai Transom Breakdown

The detail of the conveyor idlers actually fitted may vary from the illustration.
Locknut A (2 off) Clamping Screws
Square/Hex. Grease Nipple

Ended Adjusting
Bar B (2off) Belt Tensioning
Mechanism
Figure 9aj Conveyor Belt Tensioning
Mechanism
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9.16.3 Conveyor Belt Tensioning

Both of the conveyors are tensioned at the DANGER
tailshaft. Tensioning mechanisms are located
on either side of the drum(s) (Figure 9aj). ENTANGLEMENT HAZARD.
Best practice is to tension each side a little at warning.
a time and by the same amount until the belt
is tensioned. When tensioned, the drum must
be square to the conveyor frame. WARNING
The correct tension is achieved when the WEAR PERSONAL
drive drum starts the belt and keeps it PROTECTIVE EQUIPMENT.
running when loaded without any slip
occurring. warning.
The tension screws should be kept clean and LOCKOUT PLANT.

well oiled. Refer to Section 9.1, Safety
Procedure.
Procedure
FALLING HAZARD.
1. Observe all safety warnings. Refer to Section 9.1, Safety
2. Close down the machine (Section 8.2) warning.
3. Loosen locknut A(2 off) and the

clamping screws.
4. Tighten or loosen the square or hexagon

ended adjusting screw B(2 off) as ! DANGER !
required.
Under no circumstances should
any adjustment be made on the
5. Once correct tension has been achieved,
tighten locknut A(2 off). Tighten the belt whilst the machine is running.
clamping screws. There is a risk of trapping parts of
the body if this is done.
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9.16.4 Maintenance of Conveyor(s)

The following checks should be made DANGER
regularly in order to keep the conveyor(s) in ENTANGLEMENT HAZARD.
good working order: Refer to Section 9.1, Safety
Observe all safety warnings. warning.
Close down the machine (Section 8.2)

and implement the Lockout Procedure WARNING
On the Feed Conveyor inspect the WEAR PERSONAL
impact idlers and side wearing strips PROTECTIVE EQUIPMENT.
beneath the feed conveyor belt for wear Refer to Section 9.1, Safety
and replace if necessary. Ensure that the Information for relevant
warning.
plant feed hopper (and check gate) is
satisfactory in relation to the conveyor. LOCKOUT PLANT.
Also make sure that the belt is kept Refer to Section 9.1, Safety
straight and central at all times. Information for Lockout
Procedure.
For the Discharge Conveyor ensure that FALLING HAZARD.
central feed onto the conveyor belt is Refer to Section 9.1, Safety
maintained at all times and that the belt Information for relevant
at the point of feed is kept straight and warning.
central at all times.
Inspect all skirt plate sealing strips and

ensure that they are adjusted close
enough to the belt to prevent spillage or
material jamming between the seals and
the belt, but at the same time not bearing
hard on the belt. Replace if worn.
Check that the belt generally is running

centrally and straight on both the
carrying strand and the return strand. If
not, refer to Section 9.16.2 Training of
Belts.
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Check that there is no evidence of belt

slip at the driving drum, as belt slip will ! DANGER !
cause premature wear on the belt.
Do not use clip joints for belt
Check also for undue sag between
idlers. Both would indicate lack of belt
repairs or replacements, as they
tension (Section 9.16.3) can be dangerous. Belt repairs/
replacements should be
Check regularly that the idler rollers are performed by vulcanising only.
rotating freely. If not either free them or
replace the idler. Failure to do so will
result in belt wear and tracking
problems.
Check that the belt cleaning equipment is

operating correctly and efficiently. In
the case of scrapers ensure that they are
not choked with a build up of material.
Also check that the blades are not
bearing on the belt any more than
necessary, and that any blades which are
unevenly worn or in a condition likely to
cause damage to the belt are renewed
immediately.
Inspect the condition of the conveyor

belt regularly and arrange for the earliest
possible repair of any damage which
may have occurred as this can make a
worthwhile extension of the useful life of
the belt. Repair a cut or tear in the
rubber by cleaning with benzine and
plugging with a rubber repair compound.
The grease in the head and tail drum

bearings need re-greasing every two
weeks (Section 9.4.5).
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Follow the lubrication schedule for the Higher Sight

oil lubricated gearbox located inside the Hydraulic Motor Glass
Feed Conveyor head drum (Section
9.4.5). The gearbox must be filled up to
the centre line and two sight glass plugs
are provided at 180 (Figure 9ak). To
ascertain the required halfway level
check that the lower sight glass shows
oil whilst the higher sight glass (also
used to add oil) is clear. Check the level
monthly. Do not mix oils of different
maker or type. The oil temperature
to be always below 90 C.
In the interests of efficient operation and

general safety, it is important that
operating conditions are kept as clean as
Fill/Level Sight Glasses (1 hidden)
possible and that any spillages are
cleaned up regularly and are not allowed
Figure 9ak Feed Conveyor Drive Gearbox
to build up.
! DANGER !
As many inspections as possible
should be made whilst the belt is
stationary. When this is not
possible extreme care should be
taken when inspecting the belt
whilst it is moving as this creates a
risk of trapping parts of the body.
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9.16.5 Cleaning the Conveyor

Belts WARNING
If your machines conveyor belts are not WEAR PERSONAL
properly maintained and skirting rubbers PROTECTIVE EQUIPMENT.
are not kept in proper adjustment, it may be Refer to Section 9.1, Safety
necessary to remove resultant spillage Information for relevant
warning.
material and / or blockages from the
conveyor belts, particularly at the feed LOCKOUT PLANT.
section. Refer to Section 9.1, Safety
Procedure.
! WARNING ! FALLING HAZARD.
It is important that these Information for relevant
procedures are followed when warning.
cleaning the conveyor belts.
Failure to follow these procedures
can result in death or serious
injury.
Procedure
1. The equipment should be switched off
and isolated by means of the lockout
and tagout procedure prior to the
commencement of any work.
2. Use suitable personal protective

equipment i.e. eye, foot, hand and head
protection etc as may be required or
necessary to undertake the task.
3. Gloves to protect the skin against

abrasive materials, sharp surfaces, or
penetration of the skin should be worn.
4. Goggles should be worn to protect

from fragments, particles, or dust that
could be ejected into the eyes.
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5. Not only the worker(s) cleaning the belts

but also others close by who may be
affected, must also wear protective
equipment.
! NOTICE !
The conveyor belts can be
cleaned using a number of
methods. Before commencing,
make sure all aforementioned
procedures have been followed: -
Using a high pressure air hose;

Using a water hose;
Using a rod with scraper attached, or a
brush or shovel.
In the case of a blockage at a drive or tail

drum it may be necessary to loosen the
tension on the conveyor belt so that the
blockage can be removed. See Sections
9.16.2 and 9.16.3 for re-tensioning and re-
aligning the belt after blockage is removed.
When work is complete, make sure that all

guards are closed / replaced and secured
before re-starting the machine.
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9.17 Metal Detector

WARNING
A Metal Detector is fitted to the Feed
WEAR PERSONAL
Conveyor to warn the operator of detected
steel on the belt before it enters the Automax Refer to Section 9.1, Safety
crushing chamber possibly causing damage Information for relevant
to the machine. The Automax is equipped warning.
with hydraulic overload release to activate in
the event of uncrushable material being
present. However, large foreign objects
cannot pass through the machine and must
be manually removed from the feed Green POWER ON light
conveyor before entering the crusher.
The electrical system is designed to

automatically stop the Feed Conveyor when
the detector is triggered.
Whilst the detector is switched on the green

light on the panel door (Figure 9al) will be
illuminated and upon metal being detected
the red light will also illuminate. The red light
is also the reset button to be pressed when
the offending object has been removed.
The sensitivity of the detection can be varied

to suit the operation as described overleaf.
! NOTICE !
When adjusting the sensitivity of
the detector unit it is most
important the setting will not allow
pieces of steel to enter the
Automax which would damage the
machine.
Red DETECT light and RESET button
Figure 9al Metal Detector Control Panel
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9.17.1 Metal Detector Controls

Normally, once the Metal Detector has been WARNING
set up at the time of plant commissioning WEAR PERSONAL
there should be no need to alter any of the PROTECTIVE EQUIPMENT.
controls within the control cabinet (Figure Refer to Section 9.1, Safety
9am) and the panel door should be kept Information for relevant
closed to avoid the ingress of dust. warning.
However, in the event of subsequent

adjustment being necessary the following
instructions should be read but any major Rotate the SET ZERO control Figure 9am)
changes should only be attempted by an fully clockwise. If the right hand light
engineer conversant with the operation of illuminates, rotate the SET ZERO control
the Maxtrak plant as a whole. anticlockwise until this light extinguishes and
the green light illuminates. This adjustment
compensates (or zeros out) any nearby metal
! NOTICE ! in the sensor coil detect area. If this light
When opening the door of the cannot be illuminated there may be too much
Metal Detector control panel do metal near the sensor coil.
not tamper with the terminal
blocks or wiring unless the unit is After the above adjustments the detector
may have illuminated the DETECT light and
switched off.
the RESET lamp on the detector door.
With the power ON the GREEN lamp on Pressing RESET lamp button will extinguish
the door case will be illuminated. Opening both lights.
the panel door will reveal the setting controls
(Figure 9am). The relay function is controlled by the
RELAY switch. In the OFF position only the
The RED fault light will be extinguished DETECT light and door RESET lamp
when the sensor is properly connected. operate when metal is present in the sensing
Note: The illuminated fault light will also area.
cause the DETECT lamp to be illuminated.
In the LATCH position the relay and above
indicators operate but after metal is removed
the relay and the indicators remain on until
either the door RESET button is pressed or
the RELAY switch is turned to the ON or
OFF position.
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The SENSITIVITY control is a gain

adjustment control for the detection of the ! NOTICE !
desired size of material or to allow for
Use the sensitivity control very
smaller pieces of material to be ignored.
carefully so as not to allow
damaging pieces of uncrushable
material to enter the Automax
crusher.
FAULT Light DETECT Light
SET ZERO
RELAY switch indicator lights
SET ZERO
Control
Figure 9am Metal Detector Setting Controls
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9.17.2 Metal Detector Indictor SIGNAL LEVEL INDICATOR - This

Lights (Figure 9am & 9an) consists of a row of 10 lamps which light in
sequence from left to right as the detected
SET ZERO - When the Metal Detector is signal level increases when metal
operating and correctly set, the GREEN light approaches the sensor. The alarm is
of these three lights is illuminated. If a piece triggered when the signal level reaches the
of metal passing across the sensor coil is right hand lamp which is permanently
large enough it will cause the GREEN light illuminated. Normally none or perhaps the
to extinguish and the right hand RED light to first 1 or 2 lamps may be flickering on and
come on whilst the metal is within the off..
sensing range of the sensor coil.
However, if the detector regularly suffers
DETECT - This RED light illuminates from false alarms this indicator should be
whenever metal is within the sensing range examined since more lamps flickering on and
of the sensor coil. off may indicate the presence of some
interference which is either mains or
COIL FAULT - This RED light illuminates airborne. In this case have a qualified
whenever the sensor is either open circuit, engineer investigate and rectify.
not connected or short circuited. The light
also causes the DETECT light to illuminate
to prevent operation of the detector until the
coil fault is rectified.
Normally, the Metal Detector control unit

should not require any major readjustments
after initial commissioning of the plant. After
being switched on the GREEN SET ZERO
light should illuminate immediately without
the need to turn the SET ZERO control.
Certain extremely large objects may produce

an overload signal causing the unit to indicate
continuously even after the object has
passed clear of the sensor coil. Depress the
RESET button to cancel the indication.
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Signal Level Indicator Lights Sensitivity Control
Figure 9an Metal Detector Setting Controls
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9.18 Plant - Dust

Suppression WARNING
WEAR PERSONAL
The Maxtrak plant is fitted with a plain
water dust suppression system. The system Refer to Section 9.1, Safety
consists of three spray bars each one having Information for relevant
three nozzles. The spray bars are located in warning.
the following areas:-
LOCKOUT PLANT.
Crusher feed chute.
Procedure.
Crusher discharge area.
FALLING HAZARD.
Product conveyor discharge. Refer to Section 9.1, Safety
It is the responsibility of the customer to warning.
supply the system with clean water. This is
supplied at the manifold (Figure 9ao). The
total flow requirement for the system is 7
litres/min. This equates to a pressure
requirement of 2.8 bar or 42 psi.
Maintenance
All nozzles should be kept free of dirt and

blockages. Each nozzle should be checked
every time the dust suppression is switched
on. Shut-off valves are provided for each
spray bar at the manifold.
The system can be drained after operation

by the drain valves located below the inlet
manifold. This is particularly important in
winter time when there is the likelihood of
the system freezing.
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Water
Inlet Point
Crusher Crusher Product

Discharge Feed Conveyor
Area Chute Discharge
Figure 9ao Dust Suppression Manifold
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9.19 Plant - Diesel Engine

WARNING
For the diesel engine powerpack Refer to Section 9.1, Safety
fitted to your Maxtrak to continue Information for relevant
warning.
to perform safely, efficiently and
reliably it is imperative that all the LOCKOUT MACHINE.
recommendations given in the Refer to Section 9.1, Safety
separate engine manual are Procedure.
strictly followed with regard to:-
Safety
Operation
The HFO clutch is operative when the
Lubrication engine powered hydraulic system is at
Maintenance operating pressure. Should the hydraulic
pressure fall below a preset level, the Feed
Service Conveyor will be stopped to prevent any
further material from entering the Automax
Parts whilst there is a risk of the clutch slipping
Adhere to the regular maintenance due to the low oil pressure.
schedules and procedures specified by the
manufacturer using the numbers of hours run Until the reason for the low pressure has
as displayed on the engine Service Meter. been established and the fault rectified the
plant cannot be operated.
All matters relating to the diesel engine can
be dealt with directly by your local official
engine dealer for the unit fitted without
consulting BL-Pegson Limited.
The engine is fitted with an HFO

hydraulically operated clutch which is
electrically actuated from the plant control
panel to engage/disengage the crusher drive.
The 2 hydraulic pump drives inside the
engine canopy are permanently coupled to
the engine.
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9.19.1 Engine - ELC Coolant

Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must
ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this is
not available top up with deionized water and adjust mixture concentration in the shop. Under no
circumstances use any other coolant as damage will result and any warranty invalidated.
Equipment is intended for use in ambient temperatures between -10C to +40C (+14F to +104F).
Appropriate lubricants and coolant must be used as specified within the plant and engine operating and
maintenance manuals.
For use in temperatures outside the above range consult your Terex Pegson Dealer or BL-Pegson
Limited for details prior to commencement of operations.
ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT
THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH
before refilling with ELC coolant.
Adhere to the instructions on the external labelling as shown below.
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9.19.2 Hydraulic Engine Clutch

The drive from the engine to the Automax WARNING
crusher is through an HFO hydraulic oil WEAR PERSONAL
actuated clutch. This totally enclosed unit PROTECTIVE EQUIPMENT.
has the outer driving ring connected to the Refer to Section 9.1, Safety
diesel engine flywheel. The output shaft is Information for relevant
supported by a spherical roller bearing, oil warning.
lubricated, fitted in a cover flanged to the LOCKOUT MACHINE.
engine flywheel housing. . Refer to Section 9.1, Safety
Check the bearing oil level prior to the daily Procedure.
start up of the plant: as a minimum
requirement, level stick must be oil wet. The
oil filler/dipstick can be accessed at the rear
of the engine housing.
! NOTICE !
Engage the clutch ONLY at engine
Filler Cap with Dipstick
at idling speed (1200 rpm). At
ambient temperature close to or
below 0 C, keep engine running at
idling speed for 5 minutes, at least.
When changing the oil, drain the old oil by

opening the tap located at the bottom of the
bearing housing. Make sure this is tightly
closed before adding fresh oil of the
approved grade - Section 9.4.6 (DO NOT
USE SYNTHETIC OIL) filled to the
required level. Remove taper plug (41) and
through pipe (34) fill the bearing cavity. Turn
the shaft by hand until the maximum oil level
is indicated on the stick (37). After oil filling,
remount the taper plug. See Section 10 parts
list to identify reference numbers
Check the clutch driving plates annually and

it is advisable, every 4000 working hours, to
check the condition of the bearings and Figure 9ap Clutch Oil Filler
replace the rotating seals (refer to parts list).
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9.19.3 Check Fuel Level
Procedure
WARNING
WEAR PERSONAL
2. Check the fuel level indicator (Figure Information for relevant
warning.
9aq)
LOCKOUT MACHINE.
3. Top up fuel level if required (Section Refer to Section 9.1, Safety
9.19.4). Information for Lockout
Procedure.
Fill the tank at the end of each day,
where possible, to reduce overnight
condensation within the tank.
! DANGER !
Diesel fuel is highly flammable and
is an explosion/ burns hazard.
Never remove the filler cap or

refuel, with the engine running.
Never add gasoline or any other

fuel mixes to diesel because of
increased fire or explosion risks.
Do Not smoke while refilling or Fuel Level

carrying out maintenance on the Gauge
fuel system.
Do Not carry out maintenance on

the fuel system near naked lights
or sources of sparks, such as
welding equipment.
Figure 9aq Fuel Level Indicator - Engine
Control Panel
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9.19.4 Top Up Fuel Level
! NOTICE !
WARNING
WEAR PERSONAL
Do Not fill the tank to capacity. PROTECTIVE EQUIPMENT.
Monitor the gauge located on the warning.
Control Panel (Figure 9aq). LOCKOUT MACHINE.
Allow room for expansion and Information for Lockout
wipe up spilt fuel immediately, Procedure.
otherwise paintwork will be
damaged.
Procedure

3. Lift the engine side access panel to

reveal the filler cap.(Figure 9ar). Clean
the area around the filler cap.
4. Remove the filler cap.
5. Fill the tank will diesel fuel.
6. Replace the cap and refit the engine

access panel before start up.
! DANGER !
Diesel fuel is highly flammable and
Figure 9ar Filler Cap
is an explosion/burns hazard.
Never remove the filler cap or

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! DANGER !
Never add gasoline or any other
fuel mixes to diesel because of
increased fire or explosion risks.
Do Not smoke while refilling or

carrying out maintenance on the
fuel system.
Do Not carry out maintenance on
the fuel system near naked lights
or sources of sparks, such as
welding equipment.
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9.20 Plant - Vehicle Tracks

WARNING
It is essential that the tracks are Refer to Section 9.1, Safety
correctly tensioned at all times. Information for relevant
warning.
Check track tension regularly
(Section 9.21.1). LOCKOUT PLANT.
Keeping the track properly adjusted will Information for Lockout Proce-
dure.
increase the service life of the track and
drive components.
When ordering Spare Parts it is essential to

quote the plant serial number (with either a /
S or /T suffix if included on the identity plate
serial number).
Frequently check for loose bolts, oil leaks, ! WARNING !

master pins are correctly located and tight,
Prior to attempting any
general wear and damage, correct track
tension, etc. to ensure safe working and long manoeuvring of the plant the
life. tracks must be free of
obstructions, including crushed
When travelling on a gradient, the tracks material and fines. Do not push or
should be driven with the track idler rollers tow the plant. Failure to observe
(Figure 9ay) in front (ie. Feed Hopper first). this warning could result in injury
to persons and damage to the
9.21.1 Measuring Track Tension plant which may invalidate
warranty.
Procedure
1. Observe all Safety Warnings.
2. Position the plant on solid and level

ground and drive 2 metres (2 yards)
minimum in a forward direction, track
idler roller leading.
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Page 9 - 129

4. One track at a time, measure the sag on

the top part of the track on the longest
5 - 15mm
section of unsupported track by placing a (1/4 - 5/8)
straight edge long enough to reach
from the drive sprocket to the nearest
skid plate.
5. Measure the maximum amount of track

sag from the high point of the track
Figure 9as Measuring Track Tension
grouser to the bottom of the straight
edge (Figure 9as). Correctly adjusted
the sag should be approximately 15 mm
(5/8) but must not be less that 5mm
(1/4).
! WARNING !
Tracking the machine with
incorrectly tensioned tracks can
cause severe damage to the
undercarriage components and
may invalidate the warranty.
6. Depending upon the need to either

slacken or tension the track(s) proceed
as below.
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9 - Maintenance EN
Page 9 - 130
9.20.2 Adjusting Track Tension
! WARNING !
DANGER
GREASE UNDER HIGH Refer to Section 9.1, Safety
PRESSURE Information for relevant warning
To Release Track Tension (After

measurement - Section 9.20.1):-
WARNING
Procedure WEAR PERSONAL
1. Observe all Safety Warnings. Refer to Section 9.1, Safety
2. Close down the plant (Section 8.2) and warning.
implement the Lockout Procedure. LOCKOUT PLANT.
3. Locate the access aperture on the side Information for Lockout Proce-
of the track frame and remove the cover dure.
(where fitted) to reveal the relief valve
inside.
4. Next loosen the relief valve by turning

counter clockwise using gradual
increments until the grease begins to be
expelled. Care must be taken not to ! DANGER !
loosen the relief valve too quickly
because the grease inside is under Grease coming out of the relief
high pressure. valve under pressure can
penetrate the body causing injury
5. When the correct track tension has been or death; do NOT watch the relief
measured (Section 9.20.1), turn the relief valve to see if grease is escaping
valve clockwise to tighten and then clean but instead watch the track
away all trace of expelled grease. adjustment cylinder to verify that
the track is being loosened.
DO NOT OVER TENSION THE

TRACKS (Refer to Section 9.20.1).
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9 - Maintenance EN
Page 9 - 131
6. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) forwards and 50
metres (50 yards) backwards, measure
the sag and repeat the steps 1 - 4 if the
track(s) sag is not enough. If room for
manoeuvring the plant is restricted,
drive the plant forwards and backwards
several times over a shorter distance.
If the track fails to slacken after the

grease fitting has been loosened, do not
attempt to remove the tracks or
disassemble the track tensioner, or
remove the grease fitting. It is possible
that running the tracks with the grease
fitting loosened may help to expel the
grease.
Track Surface Idler Roller
Drive Sprocket
Relief
Valve
Final Drive Track Roller
Unit
Figure 9at Vehicle Track Parts
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9 - Maintenance EN
Page 9 - 132
To Increase Track Tension (After

measurement - Section 9.20.1):-
DANGER
Procedure SKIN INJECTION HAZARD
1. Observe all Safety Warnings. Information for relevant warning

WARNING
3. Locate the access aperture on the side WEAR PERSONAL
of the track frame and remove the cover PROTECTIVE EQUIPMENT.
(where fitted) to reveal the relief valve Refer to Section 9.1, Safety
inside. Information for relevant
warning.
4. Connect the grease gun to the grease LOCKOUT PLANT.
fitting and add grease until the track Refer to Section 9.1, Safety
tension is within the specified dimension Information for Lockout
(Section 9.20.1). See Section 9.4.5. for Procedure.
the grease type and specification.
5. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) forwards and 50
metres (50 yards) backwards, measure
the sag and repeat the steps 1 - 4 if the
track(s) sag is too great. If room for
manoeuvring the plant is restricted, drive
the plant forwards and backwards
several times over a shorter distance.
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9 - Maintenance EN
Page 9 - 133
9.20.3 Track Maintenance

(Figure 9at) WARNING
WEAR PERSONAL
Maintenance Schedule PROTECTIVE EQUIPMENT.
The first drive oil replacement is to be Information for relevant
carried out after 100 operating hours of warning.
the gearbox. LOCKOUT PLANT.
There after replace the drive oil every
Procedure.
1000 hours or at least once per year.
Check the drive oil level every 100

working hours.
Daily
Procedure

! NOTICE !
To maximise the life of the track,
3. Check the track rollers and idler wheels keep it movable and avoid
for possible leakage. damage, the plant should be
moved at least every week, by a
4. Check the track surface of the track distance exceeding four times the
rollers, idler wheels, track shoes and
track length. It should also be
drive sprockets for wear and loose
mounting bolts. parked on level ground overnight
and during periods to of non-
5. Clean out any heavy build up of material usage. This is particularly
from around the tracks. important when working in
adverse conditions.
6. Check the tension of the tracks (Section
9.20.1) and adjust tension if necessary
(Section 9.20.2).
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9 - Maintenance EN
Page 9 - 134
9.20.4 Drive Oil Filling and Draining

Oil Filling WARNING
WEAR PERSONAL
Procedure
1. Observe all safety warnings. Information for relevant
warning.
2. Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the Lockout Procedure. Refer to Section 9.1, Safety
Procedure.
3. Make sure the gearbox housing is
horizontal.
4. Rotate the gearbox housing so that one

plug is at the 12 oclock position and the
other plug is at the 9 oclock position
(Figure 9au).
5. Unscrew the two plugs and fill from the

upper hole until the oil flows from the
hole located at the 9 oclock position.
See Section 9.4.6 for oil type and
specification.
Oil Fill (A)
6. Clean plugs using a clean non-flammable
solvent.
7. Apply pipe sealant to the plugs and

install.
8. Repeat procedure on the other final

drive.
Note:- Over filling the final drive will cause

the travel motor seal to allow hydraulic oil or
water to enter and contaminate the drive.
Oil Level (B)
Figure 9au Tracks - Oil Filling
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Maxtrak 1300
9 - Maintenance EN
Page 9 - 135
Oil Draining
Procedure
WARNING
WEAR PERSONAL
2. Close down the plant (Section 8.2) and warning.
LOCKOUT MACHINE.
3. Rotate the gearbox housing until a plug is Information for Lockout
at the 6 oclock position (Figure 9av). Procedure.
4. Unscrew both plugs and discharge the

oil.
(A)
5. Clean plugs using a clean non-flammable
solvent.
6. Apply pipe sealant to the plugs and

install.
7. Repeat procedure on the other final

drive.
Oil Drain (B)
Figure 9av Tracks - Oil Draining
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9 - Maintenance EN
Page 9 - 136
Blank Page
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 1
10 - Spare Parts
10.1 Automax Crusher Parts .............................................................................. 10 - 3

General Illustration............................................................................................. 10 - 3
Mainframe Assembly......................................................................................... 10 - 4
Upper Frame Assembly .................................................................................... 10 - 6
Hydraulic Cylinder Fixings ................................................................................. 10 - 8
Cone head Assembly ...................................................................................... 10 - 10
Eccentric Assembly......................................................................................... 10 - 12
Countershaft Assembly ................................................................................... 10 - 14
Lubrication Piping Assembly ........................................................................... 10 - 16
Crusher Hydraulic Assembly............................................................................ 10 - 18
Hydraulic Control Panel Assembly ................................................................... 10 - 20
Lubrication Oil Tank Assembly ......................................................................... 10 - 22
10.2 Plant Conveyors ....................................................................................... 10 - 25
Feed Conveyor Parts - sheet 1........................................................................ 10 - 25
Feed Conveyor Parts - sheet 2........................................................................ 10 - 26
Level Sensor - Crusher Unit MR1 .................................................................... 10 - 28
Discharge Conveyor Parts - sheet 1 ................................................................ 10 - 31
Discharge Conveyor Parts - sheet 2 ................................................................ 10 - 32
10.3 Plant Components .................................................................................... 10 - 34
Plant Components - sheet 1 ............................................................................ 10 - 34
10.4 Plant Tracks .............................................................................................. 10 - 38
10.5 Plant Hydraulic System ............................................................................ 10 - 40

Hydraulic Reservoir ......................................................................................... 10 - 40
Hydraulic System Components ....................................................................... 10 - 42
Hydraulic Components - HFO Hydraulic Clutch Circuit ..................................... 10 - 43
10.6 Electrical Components ............................................................................. 10 - 44
Plant Control Panel ......................................................................................... 10 - 44
Automax Control Panel ................................................................................... 10 - 46
10.7 Warning Signs........................................................................................... 10 - 48
10.7 Hydraulic Engine Clutch .......................................................................... 10 - 50
AX860-901-8EN-02f 289/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 2
IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
TEREX PEGSON DISTRIBUTOR TO OBTAIN GENUINE PARTS
MANUFACTURED
TO ORIGINAL SPECIFICATIONS UNDER STRICT QUALITY CONTROL.
ALWAYS QUOTE THE SERIAL NUMBER STAMPED ON THE

PLANT/MACHINE IDENTITY PLATE
YOUR LOCAL REPLACEMENT PARTS CONTACT

(fill in when known)
TEREX PEGSON DISTRIBUTOR.............................................................................
CONTACT NAME(S)....................................................................................................
.........................................................................................
TELEPHONE NUMBER...............................................................................................
FACSIMILE NUMBER.................................................................................................
E MAIL ADDRESS.......................................................................................................
..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................
REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 3
10.1 Automax Crusher Parts
General Illustration
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 4
Mainframe Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 2500-5004B WEDGE RING SEAL 1/2SQ X 8M BOX 1
2 2500-5006B MAINFRAME SEAL 3/4SQ X 8M BOX 1
3 307/19 'O' RING (STUB OIL FLINGER) 1
307/18 O RING (STUB SHAFT) 1
4 603/1372 MAINSHAFT 1
5 603/1530 MAINSHAFT STUB 1
6 603/1532 OIL FLINGER 1
7 603/1531 BEARING CLAMP 1
2230-1121 SCREW 4
2212-7109 LOCKWASHER 4
8 603/1208 MAINFRAME LINER SET 1
9 603/1223 COUNTERSHAFT ARM SHIELD 1
10 603/1443 FRAME ARM SHIELD 3
11 603/1459MCD WEDGE RING ASSEMBLY 1
603/1457 ANTI-ROTATION POST 1
12 603/1468 INSERT 12
2147-0101 ADHESIVE 80 ML 10
2123-2001 MOLYBENTONE GREASE 0.5 KG 2
13 603/1298 ANTI-ROTATION STOP PLATE 1
2232-1429 BOLT 2
2215-0022 NUT 2
2211-0016 WASHER 2
14 603/1302/1 THRUST BLOCK 2
603/165/2 INSERT 2
2147-0051 ADHESIVE 300 GM 1
2232-1206 BOLT 4
2211-0010 WASHER 4
2210-0019 WASHER 4
15 603/1473MCD I000 SERIES MAINFRAME ASSEMBLY 1
16 2402-2050 BEARING 6
17 2152-9050 SEAL STRIP 1 X 1/8 X 48 15
18 603/1373 MAINSHAFT SPACER 1
19 2564-7104 DUMPY JACK 12
603/1465 DUMPY JACK STOOL 12
20 603/1367 TRANSDUCER COVER 1
2230-1153 SCREW 4
Terex Pegson Limited, Coalville,
2211-0007 England. Tel : +44 1530 518600, Fax : +44 1530 4518618
WASHER
21 2666-9013 LINEAR TRANSDUCER UNIT 1
JUNCTION BOX C/W MULTI CORE
22 2690-0020 1
CABLE
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 5
21
22
20
1300 Automax - Mainframe Assembly
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 6
Upper Frame Assembly

1 603/1456 FEED RING - AUTOMAX 1
603/1455 FEED RING - AUTOSAND 1
2 2230-1202 BOLT 4
2210-0019 PLAIN WASHER 4
2211-0010 SPRING WASHER 4
3 320/33 SHOULDERED DOWEL 4
4 603/192 WEDGE 4
5 603/1504MCD UPPER FRAME - AUTOMAX 1
603/1503MCD UPPER FRAME - AUTOSAND 1
6 2402-2050 BEARING 6
2147-0028 LOCTITE - 50ml 1
2530-1135 GREASE NIPPLE 12
2968-4102 GREASE GUN 1
2123-2002 MOLYGREASE CARTRIDGE 400g 1
7 603/1416E CONCAVE - AUTOMAX 1
603/1407E CONCAVE - AUTOSAND 1
2144-0031 PEGBAK PACK (10KG TUB) 6
2144-0032 RELEASE AGENT 1
22/03/05
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 7
- FEED BOX NOT SHOWN FOR CLARITY
1300 Automax - Upper Frame assembly
AX860-901-8EN-02f 295/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 8
Hydraulic Cylinder Fixings

CYLINDER CLEVIS - UPPER
1 2402-2050 BEARING 6
2 320/25 PIN 6
3 603/1491 SPACER TOP 12
4 2210-2020 PLAIN WASHER 12
5 2201-0150 SPLIT PIN 12
CYLINDER CLEVIS - LOWER
6 2402-2050 BEARING 6
7 603/1490 PIN 6
8 603/1234 SPACER 12
9 311/10 RUBBER WASHER 12
10 2210-2020 PLAIN WASHER 12
11 2201-0150 SPLIT PIN 24
22/07/04
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 9
1
2
UPPER CLEVIS
10
11
6
7
8
LOWER CLEVIS
1300 Automax - Hydraulic Cylinder Fixings
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 10
Cone head Assembly

1 2410-0496 BEARING PARALLEL ROLLER 1
2 2415-9802 BEARING TAPER ROLLER 1
3 2430-0624 CIRCLIP 1
4 603/1244 BURNING RING 1
5 603/1215 MANTLE NUT PLUG 1
6 603/1229 MANTLE NUT 1
7 603/1508E MANTLE 1
N/S 2144-0031 PEGBACK PACK (10KG TUB) 3
N/S 2144-0032 RELEASE AGENT 1
8 603/1236 DISTRIBUTION PLATE 1
2222-0889 SCREW 4
9 603/1313 SNAP RING 1
10 603/1405 COVER PLATE - CONE HEAD 1
2501-1307 'O' RING 1
2230-1220 SCREW 4
2211-0010 WASHER 4
11 603/1329 OIL FLINGER 1
307/5 'O' RING 1
12 603/1255MCD PISTON RING 1
307/3 'O' RING 1
13 603/108 SLEDGING BAR 1
14 603/1318 CONE HEAD 1
22/03/05
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 11
1300 Automax - Cone Head Assembly
AX860-901-8EN-02f 299/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 12
Eccentric Assembly

1 2152-9050 SEAL STRIP 1 X 1/8 X 48 15
2 2222-6805 SCREW 6
2211-0012 WASHER 6
3 2410-9008 BEARING PAIR PARALLEL ROLLER 1
4 2415-9801 BEARING TAPER ROLLER 1
5 2430-0624 CIRCLIP 1
6 302/17 BEVEL GEAR 1
7 323/35 STUD 5
2215-0018 NUT 5
2210-4012 WASHER 5
8 332/8 KEY 2
2222-6748 SCREW 2
9 605/1256 ECCENTRIC 1
10 603/1339 (MCD) PISTON RING 1
307/9 'O' RING 1
11 605/1250 ROTARY SEAL RING 1
12 603/1295 BALANCE RING 1
N/S 2201-5285 SPRING PIN 1
22/07/04
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 13
11
10
3
12
2 7
9 8
4
1300 Automax - Eccentric Assembly
AX860-901-8EN-02f 301/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 14
Countershaft Assembly

1 2217-9022 BEARING LOCKNUT 1
2 2230-1221 SCREW 4
2211-0010 WASHER 4
3 2230-1414 SCREW 8
2211-0016 WASHER 8
4 2415-9003 BEARING 2
5 2443-1801 PULLEY 1
6 2443-8307 TAPER LOCK BUSH 1
7 2450-5001 RINGFEDER 1
8 307/7 'O' RING 1
9 2503-4501 OIL SEAL 1
10 302/25 BEVEL PINION 1
11 331/9 KEY 1
12 603/1442 COUNTERSHAFT HOUSING 1
13 603/1219 SHIM PAIR 1.5mm THICK 2
603/1501 SHIM PAIR 0.75mm THICK
14 603/1343 OIL GUARD 1
2147-4002 SEALANT 50 ML 1
15 605/1237 COUNTERSHAFT 1
20/08/04
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 15
1300 Automax - CountershaftAssembly
AX860-901-8EN-02f 303/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 16
Lubrication Piping Assembly

1 2510-3806 NIPPLE 1
2 2510-3007 ELBOW 1
3 2510-3526 REDUCER 1
4 2520-6566 TAPER NIPPLE 3
5 HOSE 48 HOSE 1
6 341/454 PIPE 1
7 2510-3899 BACKNUT 1
8 2510-3273 TEE 1
9 2520-3809 NIPPLE 1
10 AX860/126 SUPPORT BRACKET 1
11 2512-0007 U BOLT 1
12 2215-0014 NUT 4
13 2211-0008 WASHER 2
14 2526-4002 HOSE 1M
15 2520-6596 ELBOW 1
16 2520-6597 NIPPLE 1
17 HOSE 49 HOSE 1
18 HOSE 52 HOSE 1
19 HOSE 47 HOSE 1
20 2520-6573 ELBOW 4
21 2520-6575 REDUCER 2
22 2500-1023 BONDED SEAL 2
23 2520-6574 TEE 1
24 2520-6579 REDUCER 1
25 2510-3589 REDUCER 2
26 2510-3149 ELBOW 2
27 2520-6576 HOSE TAIL 2
28 2340-4007 JUBILEE HOSE CLIP 2
29 2520-6572 REDUCER 2
30 2510-3789 SOCKET 1
31 2581-8129 OIL TANK 1
32 2534-4001 HEAT EXCHANGER 1
33 2510-3578 REDUCER 1
34 2510-3595 REDUCER 1
35 341/452 PIPE 1
36 2510-3258 ELBOW 2
37 2520-2108 HOSE CAP AND LINER 2
38 2340-2004 CLAMP 4
39 2520-6643 TAPER NIPPLE 1
40 2520-6644 ELBOW 3
41 2520-6645 NIPPLE 1`
42 2529-9902 NYLON HOSE GUARD 0.8M
AX860/106/06 30/05/03
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AX860-901-8EN-02f 305/396
Page 17
1300 Automax Mobile Plant - Lubrication Oil Piping

Maxtrak 1300
10 - Spare Parts EN
Page 10 - 18
Crusher Hydraulic Assembly

HYDRAULIC CYLINDER CIRCUIT
(ONLY ONE HALF OF COMPLETE CIRCUIT ILLUSTRATED)
1 2500-1021 SEAL 2
2500-1023 SEAL 14
2 2520-0120 QUICK RELEASE COUPLING - MALE 2
3 2520-0130 QUICK RELEASE COUPLING - FEMALE 2
4 2520-6027 REDUCER 8
5 2520-6376 TEE ADAPTOR 10
6 2520-6334 ELBOW ADAPTOR 2
7 2520-6125 SWIVEL NUT 12
8 2521-1800 HOSE ASSY - 200 2
9 2521-1806 HOSE ASSY - 500 4
10 2521-1812 HOSE ASSY - 800 2
11 2521-5203 HOSE ASSY - 350 4
12 2521-5210 HOSE ASSY - 700 4
13 2521-5218 HOSE ASSY 1200 2
14 2521-5221 HOSE ASSY - 1500 2
15 2564-0054 HYDRAULIC CYLINDER 6
16 2554-0002 OVERLOAD VALVE 1
17 2564-0054B GAITER 6
18 2564-0054A CYLINDER REPLACEMENT SEAL KIT 6
19 2525-5001 HYDRAULIC HOSE 4600 LG. 2
DUMPY JACK HYDRAULIC CIRCUIT
(CIRCUIT NOT ILLUSTRATED)
20 2564-7104C HOSE ASSY 334 12
21 2564-7104D HOSE ASSY 270 1
22
23 2564-7101D HOSE ASSY 4600 1
24 2520-6002 ADAPTOR 4
25 2564-7101F TEE 1
26 2500-1011 BONDED SEAL 2
27 2564-7101H QUICK RELEASE COUPLING COMPLETE 1
LOOSE ITEMS
28 2147-0024 LOCTITE 50 ML 1
29 2618-4003 KLAXON 1
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 19
16
1
17
15
18
11
4
12 5
7
3
14
10
9
13
19
1300 Automax - Hydraulic Cylinder Circuit
AX860-901-8EN-02f 307/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 20
Hydraulic Control Panel Assembly

2580-1139 PANEL REF L736A
1 2589-5122 PRESSURE FILTER 1
2589-5125 REPLACEABLE FILTER ELEMENT 1
2 2589-5268 PRESSURE FILTER 1
3 2589-5269 SOLENOID VALVE 1
4 2589-5265 DOUBLE PILOT OPERATED CHECK VALVE 1
5 2589-5270 UNLOADER VALVE 1
6 2589-5271 PRESSURE REDUCING VALVE 2
7 2589-5272 CHECK VALVE 1
8 2589-5273 PRESSURE RELIEF VALVE 1
9 2589-5266 NEEDLE VALVE 2
10 2589-5031 BACK MOUNT PRESSURE GAUGE 3
11A 2589-5307 PRESSURE SWITCH 1
11B 2589-5306 PRESSURE SWITCH 1
12 2589-5301 PRESSURE SWITCH 1
13 2589-5275 MANIFOLD BLOCK 1
14 2589-5276 MOUNTING PLATE 1
20/08/04
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 21
1300 Automax - Hydraulic Control Panel Assembly

11B
11A
13
10
1
9
14
6A
8
7
6B
3
4
10
10
9
12
2
10
5
AX860-901-8EN-02f 309/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 22
Lubrication Oil Tank Assembly

2581-8138 TANK COMPLETE REF L796
1 2520-3849 DRAIN PLUG 1
2 2589-1074 2 SUCTION FILTER ELEMENT 1
3 2589-2016 PRESSURE RELIEF VALVE 1
4 2589-2084 GEAR PUMP 1
5 2589-2031 FLUID LEVEL GAUGE 1
6 2589-2055 BELL HOUSING 1
7 2589-2108 DRIVE COUPLING 1
8 2589-2002 FILLER/BREATHER CAP 1
9 2576-4088 HYDRAULIC MOTOR 1
10 2589-2036 DOUBLE CARTRIDGE FILTER 1
11 2589-2090 THERMOSTAT 1
12 2589-2058 1 BSP CHECK VALVE 1
13 2538-7210 KOBOLD FLOW METER 1
14 2589-2059 AIR BLAST COOLER 1
15 2589-2060 BULLS EYE LEVEL GAUGE 1
16 2589-2005 THERMOSTAT 1
17 2589-2032 FLOAT SWITCH 1
18 2589-1019 PRESSURE GAUGE 1
18a 2589-2061 PRESSURE GAUGE ADAPTOR 1
19 AX860/26 RESERVOIR AND LIDS 1
20 2589-2063 ELECTRICAL JUNCTION BOX 1
21 AX860/55 PROTECTIVE COVER 1
22 2589-2064 FLEXIBLE MOUNT 4
23 2589-2065 MOTOR MOUNT PLATE 1
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 23
11 15
20 17 18 10 12 6 9 5 16 14 13 8 19
7
23
22
3
4
2
1
1300 Automax - Lubrication Oil Tank Assembly
AX860-901-8EN-02f 311/396
Maxtrak
1300
Spare Parts Issue EN 02
Page 24
Blank page
AX860-901-8EN-02f 312/396
Maxtrak
1300
Page 25
10.2 Plant Conveyors
Feed Conveyor Parts - sheet 1

1 2360-0035-15 CONVEYOR BELT 1
2 2366-2006 METAL DETECTOR COMPLETE 1
2366-2006A SEARCH COIL UNIT ONLY FOR METAL DETECTOR 1
2366-2004 CONTROL BOX ONLY FOR METAL DETECTOR 1
3 2389-9143 ANTI-VIBRATION PAD 4
4 2421-0011 BEARING 2
5 2421-2010 BEARING 1
6 2473-0002 GEARBOX AND MOTOR ASSEMBLY 1
7 2489-1067 RUBBER COVERED RETURN ROLLER 10
8 2495-3014 RUBBER COVERED TROUGHING IDLER 1
9 2495-3015 BASEPLATE TROUGHING IDLER 1
10 2495-3016 SPIRAL ROLLER 1
11 2495-3025 RETURN ROLLER 1
12 AX848/62 BARGE BOARD INSERT 2
13 AX857/10 SIDE NIP GUARD 2
14 AX860/14 HEAD DRUM 1
15 AX860/37 PICKING PLATFORM FLOORING 1
16 AX860/45 BELT SUPPORT 1
17 AX860/50 RETURN ROLLER NIP GUARD 1
18 AX860/64 HEAD DRUM SUPPORT 1
19 AX860/65 HEAD DRUM SCRAPER 1
20 AX860/66 HEAD DRUM NIP GUARD 1
21 AX860/67 TAIL SCRAPER 1
23 AX860/74 HEAD DRUM SUPPORT 1
24 AX860/109 TELESCOPER UNIT 1
25 AX860/110 TAIL GUARD 1
26 AX860/111 TAIL DRUM SCRAPER 1
27 AX860/122 STICKLE GATES 1 SET
28 AX860/06/01 HOPPER 1
29 AX860/109X TELESCOPER UNIT 1
30 AX860/143/01 STRINGER SECTION 1
31 AX860/143/02 SPIRAL ROLLER SUPPORT BRACKET 2
AX860/113/02 - 30/05/03
NB. Fixings are not included with the above parts unless specifically ordered
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Maxtrak
1300
Page 26
Feed Conveyor Parts - sheet 2

32 AX860/143/03 ACCESS COVER PLATE 1
33 AX860/145/03 BARGE BOARD TRANSITION PLATE 1
34 AX860/145/04 BARGE BOARD TRANSITION PLATE 1
35 AX860/147/01 SELF CLOSING SAFETY GATE 1
36 AX860/15/01 BARGE BOARD 1
37 AX860/22/01 TAIL DRUM 1
38 AX860/33/01 PICKING PLATFORM 1
39 AX860/34/01 PICKING PLATFORM HANDRAIL 1
40 AX860/41/01 SKIRT RUBBERS 1
41 AX860/41/02 SKIRT RUBBER 1
42 AX860/41/01X SKIRT RUBBERS 1
43 AX860/44/01 METAL DETECTOR 1
44 AX860/46/01 METAL DETECTOR SUPPORT BRACKET 2
45 AX860/47/01 ANTI-FRICTION SUPPORT BRACKET 4
46 AX860/57/01 ANTI-FRICTION PAD 2
47 AX860/57/02 ANTI-FRICTION SUPPORT PAD 2
48 AX860/62/01 PICKING PLATFORM INNER RAIL 1
49 AX860/76/01 CLAMP STRIP 6
53 AX860/77/01 SIDE GUARD 1
64 AX860/89/04 SUPPORT PINS 1
65 AX860/89/05 SUPPORT PINS 4
AX860/113/02 - 30/05/03
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Page 27
1300 Maxtrak - Feeder Conveyor Parts

Maxtrak
1300
Page 28
Level Sensor - Crusher Unit MR1

1 2210-0016 PLAIN WASHER 1
2 2215-0013 NUT 5
3 2232-1105 BOLT 1
4 2510-3895 BACKNUT 1
5 2512-0004 U BOLT 2
6 2640-5004 LEVEL SENSOR PROBE 1
7 Ax860/170/01 SENSOR SUPPORT 1
8 AX860/172/01 LEVEL SENSOR SUPPORT BRACKET 1
30/05/03 AX860/171/01
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1300
Page 29
Level Sensor - Crusher Unit MR 1
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Maxtrak
1300
Page 30
Blank page
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Maxtrak
1300
Page 31
Discharge Conveyor Parts - sheet 1

1 2421-0010 BEARING 2
2 2421-0014 BEARING 2
3 2450-5505 SHRINK DISC 1
4 2495-3000 TRANSOME TROUGHING IDLER 3
5 2495-3001 BASEPLATE TROUGHING IDLER 4
6 2495-3003 SPIRAL ROLLER 4
7 2495-3017 RUBBER COVERED RETURN ROLLER 6
8 2495-1130A RETURN ROLLER 3
9 2576-4075 DRIVE MOTOR 1
10 AX789/24 HEAD DRUM SCRAPER 1
11 AX789/38 TORQUE ARM 1
12 AX789/24/01 HEAD SCRAPER SUPPORT BRACKET 1
13 AX789/24/01A HEAD SCRAPER SUPPORT BRACKET 1
14 AX801/16/01 SPRAY BAR SUPPORT 1
15 AX801/16/02 SPRAY BAR SUPPORT 1
16 AX815/54 TELESCOPER UNIT 1
17 AX815/117 HEAD DRUM 1
18 AX815/12/01 SPRAY BAR 1
19 AX815/54X TELESCOPER UNIT 1
20 AX846/74 HEAD GUARD 1
21 AX846/75 SIDE GUARDS 1
22 AX846/77 HOOP CANVAS COVER 5
23 AX860/07 FEED BOOT 1
24 AX860/10 SIDE GUARD 1
25 AX860/11 SIDE GUARD 1
26 AX860/18 TAIL FRAME 1
27 AX860/99 NIP GUARD 1
30 AX860/132 SUPPORT ROPE 2
AX860/129/04 - 30/05/03
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 32
Discharge Conveyor Parts - sheet 2

31 AX860/168 FEED BOOT RUBBER 1
32 AX860/161 IMPACT BAR 4
33 AX869/163 TAIL BEARING SHIM 2
34 AX860/164 SIDE SKIRT 1
35 AX860/07/16 CLAMP 2
36 AX860/08/01 HEAD SECTION 1
37 AX860/08/02 REMOVEABLE CROSS MEMBER 2
38 AX860/08/03 SPIRAL ROLLER SUPPORT BRACKET 2
39 AX860/100/01 CLAMP STRIPS 2
41 AX860/100/03 CLAMPSTRIPS 2
46 AX860/102/01 SIDE SKIRT 2
47 AX860/103/02 REAR SKIRT 1
48 AX860/107/01 SPIRAL ROLLER NIP GUARD 1
49 AX860/127/01 CONVEYOR GUARD 1
50 AX860/127/02 CONVEYOR GUARD 1
51 AX860/127/04 LOCATION BRACKET 1
52 AX860/127/05 LOCATION BRACKET 1
53 AX860/128/01 RETRUN ROLLER NIP GUARD 1
54 AX860/160/01 IMPACT BAR SUPPORT 2
55 AX860/160/02 PIVOT BRACKET 2
56 AX860/19/01 TAIL DRUM 1
57 AX860/71/01 TAIL FRAME SUPPORT STRUT 2
58 AX860/86/01 FEED CONVEYOR PIN 2
59 AX860/86/02 SUPPORT PIN 2
62 AX860/164 SIDE SKIRT 1
AX860/129/04 - 30/05/03
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Page 33
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 34
10.3 Plant Components
Plant Components - sheet 1

1 1300_A-MAX CRUSHER 1
2 2389-0251 ANTI-VUBRATION MOUNTING 4
3 AX848/17 HYDRAULIC OIL RESERVOIR 1
4 AX848/78/3 SPRAYBAR 1
5 AX857/45/01 HYDRAULIC LEVER COVER PLATE 1
6 AX860/16 CRUSHER FEED BOX 1
7 AX860/21 ENGINE SUPPORT BEAM 1
8 AX860/28 FEED BOOT SIDE FILL IN ANGLE 1
9 AX860/49 LADDER HANDRAIL 1
10 AX860/58 CRUSHER/ENGINE DRIVE GUARD 1
11 AX860/78 BUFFER SUPPORT BRACKET 1
12 AX860/95 CONTROL BOX 1
13 AX860/113 FEED CONVEYOR 1
14 AX860/04/01 CHASSIS 1
15 AX860/04/02 FEED CONVEYOR SUPPORT BEAM 1
16 AX860/04/03 FEED CONVEYOR PIVOT BRACKET 2
17 AX860/04/04 WASHER ENGINE SUPPORT 4
SELF CLOSING SAFETY GATE CHASSIS
18 AX860/105/01 1
PLATFORM
SELF CLOSING SAFETY GATE CHASSIS
19 AX860/105/02 1
PLATFORM
20 AX860/115/01 DRIVE GUARD RUBBER DRAPE 1
21 AX860/115/02 DRIVE GUARD RUBBER DRAPE 1
22 AX860/119/01 CRUSHER ENGINE INTERNAL HANDRAIL 1
25 AX860/17/01 FEED CONVEYOR SUPPORT TRESTLE 1
26 AX860/17/02 FEED CONVEYOR SUPPORT ARM 2
27 AX860/23/01 CONE TRANSITION PLATES 2
28 AX860/23/02 CONE TRANSITION PLATES 2
AX860/GA - 30/05/03
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 35

29 AX860/23/03 CONE TRANSITION PLATE WASHER 4
30 AX860/26/01 LUBRICATION OIL TANK 1
31 AX860/29/01 CRUSHER PLATFORM 1
32 AX860/29/02 CRUSHER PLATFORM 1
33 AX860/30/01 ENGINE PLATFORM 1
34 AX860/30/02 ENGINE PLATFROM 1
35 AX860/30/03 ENGINE PLATFORM 1
36 AX860/30/04 ENGINEPLATFORM 1
37 AX860/31/01 PLATFORM SUPPORT BRACKET 2
41 AX860/36/01 PICKING PLATFORM LADDER 1
42 AX860/38/01 ENGINE PLATFORM HANDRAIL 1
43 AX860/38/02 ENGINE PLATFORM HANDRAIL 1
44 AX860/39/01 CRUSHER PLATFORM HANDRAIL 1
45 AX860/40/01 CRUSHER PLATFORM HANDRAIL 1
46 AX860/42/01 ENGINE PLATFORM FLOORING 1
47 AX860/42/02 ENGINE PLATFORM FLOORING 1
48 AX860/51/01 ENGINE/HYDRAULIC RESERVOIR FLOORING 2
49 AX860/52/01 HYDRAULIC RESERVOIR KICKING STRIP 1
50 AX860/52/02 ENGINE KICKING STRIP 1
51 AX860/53/01 CRUSHER PLATFORM FLOORING 1
52 AX860/53/02 CRUSHER PLATFORM FLOORING 1
53 AX860/55/01 TANK COVER PLATE 1
54 AX860/56/01 OIL LUBRICATION TANK MESH COVER 1
55 AX860/61/01 LADDER SUPPORT BRACKET 1
56 AX860/75/01 FEED CONVEYOR HYDRAULIC RAM 1
57 AX860/81/01 KICKING STRIP FILL-IN PIECE 1
58 AX860/81/02 KICKING STRIP FILL-IN PIECE 1
59 AX860/84/01 FEED BOOT REAR FILL-IN ANGLE 1
AX860/GA - 30/05/03
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 36

60 AX860/86/01 FEED CONVEYOR PIN 2
64 AX860/96/01 CONTROL BOX 1
67 2480-0041 CATERPILLAR D12 ENGINE 1
AX860/169/01 ENGINE SUPPORT BRACKET DIAGONALLY 2
AX860/169/02 ENGINE SUPPORT BRACKET HANDED 2
326/17 ENGINE SUPPORT SETSCREW 4
315/11 NUT FOR SETSCREW 4
68 AX860/129/04 DISCHARGE CONVEYOR 1
69 AX860/01 TRACK GA 1
AX860/GA - 30/05/03
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1300 Maxtrak - Plant Components
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 38
10.4 Plant Tracks

1 2372-0076 TRACK DRIVE GEARBOX C/W HYDRAULIC MOTOR 2
2372-0078 ADAPTOR 2
2372-0079 BONDED SEAL 2
AX818TRAKS04 STAND OFF PIPE 2
2372-0088 GEARBOX DRAIN PLUG 4
2 2372-0077 GEARBOX BOLTS 40
3 2372-0080 DRIVE SPROCKET 2
4 2372-0081 SPROCKET BOLTS 40
5 2372-0032 TRACK CHAIN COMPLETE 2
6 2372-0033 TRACK SHOE 110
7 2372-0034 TRACK SHOE BOLT 440
8 2372-0035 TRACK SHOE NUTS 440
9 2372-0064 IDLER 2
10 2372-0065 YOKE 2
11 2372-0084 RECOIL UNIT 2
2372-0085 TENSIONER SEAL KIT 2
12 AX818TRAKS02 GREASER 2
13 AX818TRAKS03 GASKET 2
AX818TRAKS01 ADAPTOR 1
14 2372-0027 ROLLER 18
15 2372-0018 ROLLER BOLT 72
16 2372-0019 ROLLER BOLT WASHER 72
2372-0037 REPAIR LINK - TRACK CHAIN

2372-0036 MASTER PIN - TRACK CHAIN
30/05/03
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 39
Tracks Assembly - Maxtrak 1300

3
4
1
8
2
7
6
16
12
13
15
14
10
11
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Maxtrak 1300
10 - Spare Parts EN
Page 10 - 40
10.5 Plant Hydraulic System
Hydraulic Reservoir

1 DRAIN SOCKET AND PLUG 1
2 2589-2003A FLUID LEVEL GAUGE 1
3 2531-5153 BREATHER 1
4 2589-2032A FLOAT LEVEL SWITCH 1
5 2531-5060 RETURN LINE FILTER 1
5A 2538-0053 RETURN LINE FILTER GAUGE 1
6 2531-5155 SUCTION FILTER 1
6a 2538-0054 SUCTION FILTER GAUGE 1
6b 2520-8002 2 SAE 3000 SERIES FLANGE & ADAPTOR 1
7 INSPECTION COVERS 2
AX860-901-8EN-02f 328/396
Maxtrak 1300
10 - Spare Parts EN
Page 10 - 41
Maxtrak 1300 - Hydraulic Oil Reservoir Assembly

2
3
1
5
7
4 5a
6 6a 6b
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Parts List - 1300 Maxtrak Page 42
Hydraulic System Components
AX860-901-8EN-02f 330/396
Parts List - 1300 Maxtrak Page 43
Hydraulic Components - HFO Hydraulic Clutch Circuit
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Maxtrak
1300
Page 44
10.6 Electrical Components
Plant Control Panel

PLANT CONTROL PANEL
DISPLAY SCREEN
NB. WHEN ORDERING QUOTE MODEL DATA ON
1 2683-2148 1
REVERSE OF UNIT (SEE ILLUSTRATION)
TOGETHER WITH PLANT SERIAL NUMBER
2 2640-5005 CRUSHER MINI-RANGER TRANSCEIVER UNIT 1
3 2640-5005 HOPPER MINI-RANGER TRANSCEIVER UNIT 1
4 2683-2149 DOOR KEY 1
5 2683-2113 FEEDER SPEED CONTROL KNOB 1
2683-2109 FEEDER SPEED POTENTIOMETER 1
6 2683-2102 START/STOP PUSH BUTTONS 4
7 2683-2101 EMERGENCY STOP BUTTON (PANEL) 1
8 2683-2103 2 POSITION STAY PUT SWITCH 3 OR 4
9 2683-2111 BLACK PUSH BUTTON 2
10 2683-2174 COMMUNICATION LEAD 1
11 2683-2114 HEAVY DUTY RELAY 2
12 2683-2106 11 PIN RELAY
2683-2106A RELAY BASE
13 2683-2107 8 PIN RELAY
2683-2107A RELAY BASE QUANTITY
14 2683-2176 20A SINGLE POLE CIRCUIT BREAKER TO SUIT
2683-2177 16A SINGLE POLE CIRCUIT BREAKER PANEL
2683-2178 6A SINGLE POLE CIRCUIT BREAKER
TRACK CONTROL KIT COMPLETE
15 2686-0038 NB. SEE SEPARATE LIST FOR INDIVIDUAL 1
COMPONENTS
16 2683-2170 PLC BASE UNIT 1
17 2683-2171 PLC INPUT MODULE 2
18 2683-2173 PLC END CAP 1
19 2683-2172 PLC OUTPUT MODULE 1
20 2683-2169 PLC PROCESSOR C/W MEMORY MODULE 1
21 2683-2195 BATTERY 1
22 2683-2175 DC/DC POWER CONVERTER 1
23 2683-2145 ENGINE ANTI-CRANK RELAY 1
24 2683-2182 FUSE SET 1
25 2683-2108 TIMER 1
30/05/03
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Maxtrak
1300
Page 45
8 9 8 6 5
10 1 24 14 11 25 13 12
23
2&
3
24
22
5
15
16 17
20 18
21 19
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Maxtrak
1300
Page 46
Automax Control Panel
AUTOMAX CONTROL PANEL
1 2695-0082A CPU & MODULE 1

2 2695-0082B 4 POLE PLUG 6
3 2695-0082C 4 POLE RELAY BASE 6
4 2695-0082D BLACK PUSH BUTTON 2
5 2695-0082F YELLOW PUSH BUTTON 1
6 2695-0082G AUTO/MANUAL SWITCH 1
7 2695-0082H FUSE HOLDER 4
8 2695-0082 I FUSE LINK 2
9 2695-0082J VARISTOR 4
10 2695-0082K DIODE 1
2666-9013 TRANSDUCER (MOUNTED ON CRUSHER) 1
860 TRACK CONTROL KIT 2686-0042 COMPONENTS
11 2686-9029 UNBILICAL HANDSET WITH CABLE 1

RADIO HANDSET TRANSMITTER RED STOP
12 2686-9043 1
BUTTON (USA AND REST OF THE WORLD)
RADIO HANDSET TRANSMITTER BLACK STOP
2686-9044 1
BUTTON (EUROPE)
13 2686-9008 ANTENNA AND CABLE 1
14 2686-9007 12/35VDC CHARGER CABLE 1
15 2686-9034 RECEIVER UNIT C/W CHASSIS SOCKET & CABLE 1
SUNDRY PLANT ELECTRICAL COMPONENTS
2640-5004 MINI-RANGER TRANSDUCER UNIT 1 OR 2

PRODUCT CONVEYOR SPEED WHEEL SENSOR
2366-0400 1
ASSEMBLY
2368-2151 SPEED WHEEL SENSOR CABLE 1
2685-0001 EMERGENCY STOP PUSH BUTTON STATION 5
2683-2110 AUDIBLE WARNING UNIT 1
2366-2008 METAL DETECTOR PANEL GREEN INDICATOR 1
2366-2010 BULB FOR ABOVE 1
2366-2009 METAL DETECTOR PANEL RED BUTTON 1
2366-2010 BULB FOR ABOVE 1
07/04/04
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Maxtrak
1300
Page 47
3 1 10
4
2
Commandes du tableau hydraulique

Automax
9 8 5 6
14
11
12 15
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Maxtrak
1300
Page 48
10.7 Warning Signs

1 300/32 DANGER ENTANGLEMENT HAZARD 4
2 300/33 WARNING READ MANUAL 4
3 300/34 DANGER SKIN INJECTION HAZARD 4
6 300/37 IMPORTANT CHECK FILTERS 2
7 300/38 WARNING FALLING MATERIAL HAZARD 4
8 300/39 WARNING STOP AND LOCKOUT 4
9 300/40 WARNING GUARDS/LABELS IN PLACE 4
10 300/41 WARNING PRIOR TO TRANSPORT 2
11 300/42 IMPORTANT DRAIN WATER 1
13 300/44 WARNING IMPACT HAZARD 3
14 300/45 IMPORTANT CHECK FRAME ARMS 2
15 300/46 IMPORTANT CLEVIS PIN 2
17 300/118 DANGER FLYING MATERIAL HAZARD 2
19 300/120 WARNING FALLING HAZARD 2
20 300/175 IMPORTANT HYDRAULIC CLUTCH 1
21 300/182 CAUTION PRIOR TO TRANSPORT 1
23 300/196 WARNING HEARING HAZARD 2
27 300/224 HEARING PROTECTION 2
30/05/03
1 2 3 6
11 20
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Maxtrak
1300
Page 49
7 8 9 10
13 14 15 17
19 21 23 27
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Maxtrak
1300
Page 50
10.7 Hydraulic Engine Clutch
The hydraulically actuated clutch fitted to the diesel engine is NOT supplied as
part of the Caterpillar diesel power pack. Contact BL-Pegsons Dealer for all
requirements concerning this clutch.
REF DESCRIPTION REF DESCRIPTION

1 HOUSING 22 BACKPLATE
2 COVER 23 DRIVING PLATE
3 SCREW 24 CENTRE PLATE
4 BEARING CARRIER 25 SPRING
5 BEARING 26 PRESSURE PLATE
6 SHAFT 27 SCREW
7 SNAP RING 28 KEY
8 SPACER 29 LOCK WASHER
9 COVER 30 LOCK NUT
10 SCREW 31 ROTATING SEAL
11 O RING 32 ROTATING SEAL
12 LOCK WASHER 33 DRIVING RING
13 SCREW 34 PIPE
14 ROTATING UNION 35 KEY
15 LOCK WASHER 36 TAPER PLUG
16 SCREW 37 LEVEL STICK
17 O RING 38 NAME PLATE
18 HUB 39 PLATES HUB
19 O RING 40 SCREW
20 PISTON 41 TAPER PLUG
21 O RING 42 ELASTIC PIN
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Maxtrak
1300
Page 51
TRANSFLUID CLUTCH REF HFO 314 - 1 HD
BL-Pegson Part Number 2451-1008 - For Spare Parts also advise

specification and serial numbers stamped on the identity plate
Maxtrak 1300 - Hydraulic Clutch for diesel engine
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Maxtrak
1300
Page 52
Blank page
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Maxtrak 1300
11 - Appendix EN
Page 11 - 1
11 - Appendix
11.1 Noise Levels ................................................................................................ 11 - 2
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Maxtrak 1300
11 - Appendix EN
Page 11 - 2
11.1 Noise Levels
Levels shown in the tabulation are for

general guidance only and will vary
depending upon the conditions prevail-
ing at the time.
AX860-901-8EN-02f 342/396
Maxtrak 1300
11 - Appendix EN
Page 11 - 3
Figures are for engine running with no load on crusher
AX860-901-8EN-02f 343/396
Maxtrak 1300
11 - Appendix EN
Page 11 - 4
Blank page
AX860-901-8EN-02f 344/396
All Plants - Tier 3, Stage IIIa - ACERT
Addendum to User Manual
Due to the change of engines to comply with requirements

of Tier 3/Stage IIIa standards, this plant may have a different
engine fitted
Caterpillar C13 engines are replacing the C12

Caterpillar C9 engines have been revised to comply with the standards
Caterpillar C6.6 engines are replacing the 3126B engines
AM0013 - EN E-1
AX860-901-8EN-02f 345/396
Change of Engine Type
The change of engines has resulted in the following changes to engine controls
and information in the user manual.
Power Output
The engine power may have changed slightly.
The power of the engine as stated in the manual will not necessarily be correct but the power stated on the
plate fixed to the plant is correct.
Engine Speed
The engine working speed may have changed slightly.
The engine speed stated in the manual will not necessarily be correct but the speed set by the engine controls
and display is correct.
The engine working speed with no load and speed at full load are now the same.
Engine Monitoring System

The engine monitoring system and engine control panel shown and referred to in the user manual will not be
correct.
The engine information will be displayed on a different type of screen.
To operate the engine monitor screen, refer to the appropriate addendum for the controls fitted.
Engine Controls
Some engine controls and warning lamps are not as shown and referred to in the manual as they have been
repositioned with other plant controls.
Power Plant Spares

Some engine electrical controls and power pack spare parts will be different to those referred to in the user
manual, therefore please contact Terex Pegson and quote plant and engine serial numbers for assistance.
E-2
AX860-901-8EN-02f 346/396
1000 and 1300 Cone Crushers and Plants
ADDENDUM TO USER MANUAL
Avoiding Damage to Cone Crusher Linings
INTRODUCTION
To prolong the life of the cone linings and prevent avoidable damage to the main parts of the cone crusher,
please refer to these guidelines.

AX860-901-8EN-02f 347/396
Avoiding Damage to Cone Crusher Linings
FEEDING MATERIAL INTO CONE

CRUSHERS NOTICE
The crusher should be fully choke fed with a Inspect the liners on a daily basis.
well mixed and well graded material to give best
results. This will also produce even wear on the
cone liners, making them last longer.
Uneven liner wear can occur when material
is trickle fed rather than choke fed into the
crusher. Unusual wear may also be caused by feed
material being all one size or the size being heavily
segregated.
MAXIMUM CONE SETTINGS

Maximum Cone Setting
Do not operate the crusher with size settings above Cone Size mm Inches
the maximum.
1000 38 1.5
1300 45 1.75
CONE LININGS
INSPECTION
Inspect the liners on a daily basis.
Always check the liners if any non crushable
material may have entered the crusher.
RENEWING
Minimum Cylinder Dimensions
Renew the cone liners before the adjusting
cylinders are working at their minimum. Cone Size mm Inches
1000 690 27.25
Change the liner at or before the adjusting
cylinders reach the dimensions shown in the table. 1300 805 31.75
Do not rely on the minimum dimension shown

in the manual, ignore value stated in the
diagram. This cannot take into account any
features present caused by an unusual wear
pattern or damage by non crushable materials
Monitor the wear on the crusher liners regularly
and renew both the liners before they fail and cause
damage to other parts of the crusher.
II
AX860-901-8EN-02f 348/396
All Plants with Feed Conveyors
Oil Specification Change
Plant Feed Conveyor Drive Gearbox

The oil for the feed conveyor gearbox is VG220 with EP additives,
not as stated in the existing table the Terex Pegson user manual.
An oil such as Shell Omala 220 should be used.
AM0016 - EN L-1
AX860-901-8EN-02f 349/396
Oil Specification Change
L-2
AX860-901-8EN-02f 350/396
All Plants with Feed Conveyors
Steel Metal Detector and Controls
Steel metal detector

An alternative model of steel detector may have
been fitted, therefore may not be of the type
referred to in the user manual.
Pre-set detector sensitivity
The sensitivity of the steel metal detector is now
pre-set at the factory.
The sensitivity control has been removed from the
internal control panel as shown in the diagram.
Pre-set zero set adjustment
The zero adjustment control of the steel metal
detector is now pre-set at the factory.
The zero set adjustment has been removed from
the internal control panel as shown in the diagram.
Fault and re-set illuminated button
The fault/re-set red illuminated button control
remains the same although it may be positioned
differently.
Spares requirements
The change affects the spare parts for the metal
detector, its fixing and electrical controls.
Some spare parts will be different to those referred
to in the user manual, therefore please contact
Terex Pegson and quote plant serial number for
assistance.
AM0017 - EN M-1
AX860-901-8EN-02f 351/396
Metal Detector Controls
M-2
AX860-901-8EN-02f 352/396
All Plants - Cantrak Control
Plants with Cantrak Engine Monitoring System
AM0020 - EN C-1
AX860-901-8EN-02f 353/396
Cantrak Engine Monitoring System
Introduction
The Cantrak Engine Monitor is a graphical
instrument clusters to display parameters and
alarms.
The display has five buttons that change to suit
the screen in use. The buttons give to access a
graphical menu structure that uses standard and
easily-understood icons to indicate the buttons
current function.
The required engine data and display can display
the following formats:
Analogue gauges
Digital values
Historical trend graphs
Current and stored alarm messages
C-2
AX860-901-8EN-02f 354/396
Buttons
If any button from 1 to 4 is pressed, the display
shows a context dependent icon representing the
current function of the button.
The button icon part of the display will disappear
after five seconds of inactivity.
This top level button icon bar shows the selection
options of the Engine Monitor:
1 2 3 4 5
Pressing button 5 when the menu icons are not
being displayed displays a Contrast and Lighting
adjustment menu. If held for 3 seconds, the
Configuration menu is shown
Button Icons
TRI DISPLAY - shows one large window and two
smaller windows. Repeat presses cycle the
display through the view options.
QUAD DISPLAY - shows data four equal sized

windows. Repeat presses cycle the display
around three different quad view options.
UNI DISPLAY - shows data using a single

window. Repeat presses cycle display through
available parameters.
ACTIVE ALARM DISPLAY - shows current

active alarm. Holding the key displays Stored
Alarms.
EXIT from the menu..
AM0020 - EN C-3
AX860-901-8EN-02f 355/396
PAGES - indicates that further pages of

information are available by pressing to cycle
through options for the screen being viewed.
ARROW UP - move up to next item.
ARROW DOWN - move down to next item.
RIGHT ARROW - go to next screen or select

option.
RETURN ARROW - go back to previous screen.
ALARM - acknowledge active alarm when an

active alarm is being displayed.
CONFIGURE QUAD SCREEN - press button 2

and immediately button 5. The data displayed
on a particular window can be selected by
repeat pressing the
Button Lock
The buttons can be locked so that they cannot be
accidentally pressed.
Press buttons 1 and 5 simultaneously for one
second to switch the button lock on or off.
A key symbol is displayed when a button is pressed
and they are locked.
1 2 3 4 5
C-4
AX860-901-8EN-02f 356/396
Displays
When power is applied, a start-up screen displays
for approximately 7 seconds while the display
performs a self test.
After the start-up screen disappears, the Engine
Monitor displays readings on its virtual gauges.
The Engine Monitor displays the screen that was
last displayed.
If data is not available from the engine, it will not
be possible to select it.
If data becomes unavailable, dashes (- - -) will be
shown on the screen.
Tri Display
Three windows intended to show the most
frequently accessed engine data.
Quad Display
Four windows to display available data in digital
number format only or as a gauge with numbers
also displayed.
The windows can be configured to display various
available data as listed in the data parameter
and icons.
Uni Display
A single window to display data in a graph format,
together with a numeric data header.
AM0020 - EN C-5
AX860-901-8EN-02f 357/396
Data Parameters and Icons

The following data can be displayed
Engine Speed
Oil Pressure
Oil Temperature
Coolant Temperature
Battery volts or amps
Engine Hours
C-6
AX860-901-8EN-02f 358/396
Alarm Messages
When a current engine alarm is received, a flashing
window appears overlaid over the screen in use
and an alarm sound is activated.
If a current alarm message is flashing, press any

button to view the message details.
The current alarm message will be displayed
with a black background, which indicates an
unacknowledged alarm.
The alarm can be acknowledged by pressing:
Alarms must be acknowledged before the normal

monitoring screen can be displayed.
Acknowledged alarm messages are displayed with
a grey background.
Alarm messages can also be displayed at any time

from the normal monitoring display by pressing
button 4 twice.
To return to the monitoring screen press:
AM0020 - EN C-7
AX860-901-8EN-02f 359/396
Configuration Options
Screen Brightness and contrast
Press button 5 when the normal monitoring screen
is being displayed.
Adjust the screen using buttons 1 to 4.

Press button 5 to exit
1 2 3 4 5
Settings Menu
Press and hold button 5 for three seconds, when the
normal monitoring screen is being displayed.
Scroll to point to SETTINGS and select by

pressing:
The following options can then be selected:

UNITS - Metric or Imperial
LANGUAGE - Select from list
BLEEP - Button press sound on or off
Set the options for each of these by pressing:
Return to previous screens by pressing:
Exit by pressing:
C-8
AX860-901-8EN-02f 360/396
All Plants
AM0027 - Alternative Track Drive and Gearbox
Introduction
An alternative track motor drive and gearbox may
be fitted which is different to the type shown in
the user manual.
For identification, the letter V has been added to
the end of the track serial number.
Refer to these instruction for servicing if the casing
has three plugs and appears as shown on this
addendum.
AM0027 - EN TM-1
AX860-901-8EN-02f 361/396
Alternative Track Drive and Gearbox
Servicing
Preparation
1. Drive the track to position the motor and
gearbox as shown with the drain positioned
lowest.
2. The plant should be positioned horizontally side
to side.
3. Close down the plant and implement the
lockout procedure.
WARNING
Refer to safety in maintenance section of
the user manual for relevant warning and
procedure
LOCKOUT
Gear Oil PLANT
4. Type SAE90 API service classification GL-4.
5. Do not mix different types or brands of oil.
Oil Level Check and Top up

6. Remove the filling plug.
7. Remove the level plug
8. Check oil level and add oil through the fill hole
as required until it begins to overflow through
the centre level hole.
9. Re-fit the plugs, taking care not to damage the 6 11 13
seals.
Oil Change
10. Place a suitable container in position to collect
the old oil, approximately 5.5 litres (1.5 USgal).
FILL
11. Remove the filling, level and drain plugs and 7 LEVEL
drain the old oil, looking for metal particles
indicating component wear. 11
12. Re-fit drain plug, taking care not to damage the 14

seal. DRAIN
13. Remove the filling plug.
14. Remove the level plug
15. Add new oil until it begins to overflow through 1 11
the centre level hole.
16. Re-fit the plugs, taking care not to damage the
seals.
TM-2
AX860-901-8EN-02f 362/396
All Plants
AM0030 - Routine InspectionChecks
WARNING
Refer to safety in maintenance section of
the user manual for relevant warning and
procedure
LOCKOUT
PLANT
Introduction
General plant items should be inspected on a
weekly basis and at 500 hr intervals for damage
in the following areas;
1. Crusher body
2. Wear Parts
3. Flywheel(s) Area to inspect

3
4. Main chassis
5. Feeder
6. Track frames
7. Conveyor frames
AM0030 - EN RIC-1
AX860-901-8EN-02f 363/396
Routine InspectionChecks
RIC-2
AX860-901-8EN-02f 364/396
Automax
AM0031 Sensor Fitted in Upper Frame Position Cylinders
Introduction
An different position sensor may be fitted to the
Automax crusher.
This sensor is fitted into one of the operating
hydraulic cylinders which raise and lower the
upper frame and concave.
The separate position sensor unit is not required.
Operation
The operation remains the same.
Renewing Wear Parts

When renewing the mantle and concave set, it
is not necessary to disconnect the sensor unit
when removing the upper frame.
The cylinder containing the position sensor is
disconnected from the upper frame in the same
manner as the other cylinders.
Spare Parts
This change affects some spare parts for the
controls and hydraulic parts of the Automax.
Please contact your local Terex Pegson dealer,
Terex Pegson Technical Support Department
or Spare Parts Department and quote serial
number for assistance.
EN
IPS-1
AX860-901-8EN-02f 365/396
Sensor Fitted in Upper Frame Position Cylinder
IPS-2
AX860-901-8EN-02f 366/396
All Plants
AM0032 Preferred Driving Direction of Tracks
Introduction
To prolong the life of the track and prevent
avoidable damage to the track components,
please refer to these guidelines.
Driving Tracked Plants

Wherever possible drive the plant with the circular
track drive gearbox in the position shown in the
diagrams.
This is particularly important if the plant is being

driven up an incline.
The track drive gearbox is not fitted in the same

position on all plants, relative to the other parts
of the plant.
EN
PDD-1
AX860-901-8EN-02f 367/396
Preferred Direction of Travel
PDD-2
AX860-901-8EN-02f 368/396
All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 1
OPERATING INSTRUCTIONS
FUEL TRANSFER PUMP

(for plant diesel engine)
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
AX860-901-8EN-02f 369/396
All Plants
Fuel Transfer Pump
Page 2
Optional Fuel Transfer Pump

This option is available as originally fitted
WARNING
equipment installed at the time of plant WEAR PERSONAL
manufacture. PROTECTIVE EQUIPMENT.
Refer to Section 9.1 of the Plant
User Manual-Safety Information
The pump is for the purpose of transferring for relevant warning.
diesel engine fuel from a barrel positioned at
LOCKOUT MACHINE.
ground level alongside the plant diesel Refer to Section 9.1 of the Plant
engine to the engine fuel tank. UserManual-Safety Information
for Lockout Procedure.
The pump is permanently mounted in a
suitable position on the plant in the vicinity
of the engine and is electrically driven from
a 24 volt DC supply. The unit is fitted with
an integral on/off switch.
Also supplied as part of the kit are lengths Do not use the fuel transfer
of plain hose 25mm bore for suction (with pump for any other purpose
strainer) and delivery. DANGER that filling the diesel engine
fuel tank on the BL-Pegson
The VR050 Series pump is rated at 50 plant.
litres per minute, suitable for equipment with
tanks between 200 and 500 litres. Duty is Observe the Operating,
continuous up to + 40o C ambient. Self Service & Safety Instructions
priming up to 3 metres dry. Flow 50 ltrs/min on the opposite page and also
at 3 metres head. Maximum head 10 the general Safety Information
metres. given in Section 9.1 of the
Plant User Manual.
AX860-901-8EN-02f 370/396
All Plants
Fuel Transfer Pump
Page 3
Fuel Transfer Pump Operating, Service & Safety Instructions
SAFETY
FLASHPOINT BELOW
37o C (99o F)
DO NOT USE A TRGGER NOZZLE

FOR DELIVERY INTO THE FUEL
TANK
FLASHPOINT ABOVE
37o C (99o F)
MAXIMUM DUTY TIME AT 40O C TEMPERATURE RANGE
INSTALLATION & USE
DO NOT ALLOW THE PUMP

TO RUN DRY. SWITCH OFF
IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.
AX860-901-8EN-02f 371/396
All Plants
Fuel Transfer Pump
Page 4
Top Up Fuel Level

Do Not fill the tank to capacity.
WARNING
Monitor the gauge located on WEAR PERSONAL
the Engine Control Panel. PROTECTIVE EQUIPMENT.
Refer to Section 9.1 of the Plant
User Manual-Safety Information
Allow room for expansion and for relevant warning.
wipe up spilt fuel immediately,
LOCKOUT MACHINE.
otherwise paintwork will be Refer to Section 9.1 of the Plant
damaged. UserManual-Safety Information
for Lockout Procedure.
Procedure
1. Observe all safety warnings. Never add gasoline or any

other fuel mixes to diesel
2. Close down the plant (Section 8.2 of DANGER because of increased fire or
the Plant User Manual) and implement explosion risks.
the lockout procedure except the engine
isolation switch to be at position I. Do Not smoke while refilling
or carrying out maintenance on
3. Connect both hoses to the pump and the fuel system.
insert the suction hose into the fuel supply. Do Not carry out maintenance
Clean the area around the filler cap. on the fuel system near naked
Remove the cap and insert the delivery lights or sources of sparks,
hose. such as welding equipment.
4. Operate the switch on the pump to fill

the fuel tank. Use only in accordance with
the instructions on the previous page.
5. Switch off the pump and stow the

hoses. Replace the cap and refit the
engine access panel before start up.
Turn the engine isolation switch to O.
Diesel fuel is highly flammable

and is an explosion/burns
DANGER hazard.
Never remove the filler cap or Filler Cap
AX860-901-8EN-02f 372/396
All Plants
Water Pump
Page 1
OPERATING INSTRUCTIONS
WATER PUMP
(for dust suppression spraybars)
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
22-Feb-2007
AX860-901-8EN-02f 373/396
All Plants
Water Pump
Page 2
Optional Water Pump

This option is available as originally fitted
DANGER
equipment installed at the time of plant SKIN INJECTION HAZARD
manufacture. Refer to Section 9.1, of the Plant
User Manual, Safety Information
for relevant warning
The pump is to provide a pressurised
supply of clean water to the dust
suppression spray nozzles included on WARNING
plants as a standard fitment. For details of WEAR PERSONAL
typical clean water requirements for the Refer to Section 9.1, of the Plant
dust suppression system, refer to the User Manual, Safety Information
Maintenance Section 9 of the plant manual. for relevant warning
The pump is permanently mounted in a

suitable position on the plant near to the
water manifold (Figure 1) and is driven
from a branch of the engine driven plant
hydraulic system..
The inlet is 1/2 BSPT. with hose connector

for the user to provide supply suitable
piping from the clean water source (eg.
bowser near to the plant) as necessary.
Initial on/off control of the pump is by

means of a 3 way valve lever (Figure 2)
mounted on the pump unit. Whilst this valve
lever is in the on position the screw type
valve (Figure 2) can be used to regulate the
water supply to the plant inlet manifold.
No specific maintenance is required for the

pump unit except to check for hydraulic oil
leaks when carrying out the normal plant
maintenance (Section 9 of the plant manual)
Frost precautions must be taken in cold
weather to ensure water does not freeze
within the system, by opening the water
manifold drain valves and detaching the
pump inlet feed pipe.
AX860-901-8EN-02f 374/396
All Plants
Water Pump
Page 3
Manifold Drain
Valves
Water Inlet
Connection
Figure 1 Water Pump Unit

(typical mounting)
Flow
Control Valve
3 Way
On/Off Valve
Figure 2 Water Pump Valves
AX860-901-8EN-02f 375/396
All Plants
Water Pump
Page 4
3 Way Valve
Flow Valve
Water Pump
Hydraulic Motor
Coupling
Figure 3 Pump Hydraulic Circuit
2575-2008 3 Way Valve 2575-2005 Coupling
2575-2003 Pump
2575-2007 Flow Valve
2575-2004 Hydraulic Motor
Figure 4 Pump Unit Part Numbers
AX860-901-8EN-02f 376/396
BW100 INITIAL CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed when messages E3 and E4 are displayed during routine calibration.
The E3 and E4 messages indicate a mechanical problem
i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the weigher etc.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration. Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied
SELECT SELECT P388

PARAMETER
P377
INVOKE INITIAL ZERO INVOKE INITIAL SPAN

ENTER 1 ENTER 1
CURRENT ZERO COUNT CURRENT SPAN COUNT= ####
ZERO CALCULATION SPAN CALCULATION,

FREQUENCY COUNT FREQUNCY COUNT DISPLAYED
DISPLAYED
ZERO DEVIATION SPAN DEVIATION= ##
ZERO DEVIATION ACCEPTED ZERO DEVIATION ACCEPTED

INITIAL ZERO COUNT= #### INITIAL ZERO COUNT= ####
PROCEED WITH
SPAN CALIBRATION OR
AX860-901-8EN-02f 377/396
RETURN TO RUN MODE RETURN TO RUN MODE
BW100 ROUTINE CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed on a routine basis as required.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration.
Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied
ZERO CALIBRATION REQUIRED INITIAL SPAN COUNT
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION
INITIAL ZERO COUNT
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION DEVIATION
NEW SPAN COUNT

DEVIATION
NEW ZERO COUNT CALIBRATION COMPLETE REMOVE TEST WEIGHTS

CALIBRATION COMPLETE
RETURN TO RUN MODE PRESS TO RETURN TO RUN MODE
TO RETURN
PRESS
TO RUN MODE
SPAN REQUIRED
AX860-901-8EN-02f 378/396
Components Manual .
2480-0061
Section De scription / Note s Page
A. Canopy Encl o s ure :- Lef t Hand Si de 05/01-2
B. Canopy Encl o s ure :- Ri ght Hand Si de 05/01-3

H
C Engi ne Hardware :- Lef t Hand Si de 05/01-4
D Engi ne Hardware :-Ri ght Hand Si de 05/01-5
J E Bas e :-Lef t Hand Si de 05/01-6

B C F Bas e :-Ri ght Hand Si de 05/01-7
G Ai r Cl eaner Sys t em 05/01-8

E H Exhaus t Sys t em 05/01-10
J Fus e Box 05/01-11
K Bat t ery 05/01-12
L Cont rol Panel 05/01-13
M Not es / Appendi x 05/01-14
G
Engine Service Items
k B L Pegson
Description CAT Part No Qty
Part No
A D
2481-0564 1R-0762
Fuel Fi l t er
2481-0565 1R-0771
Oi l Fi l t er 2481-0566 1R-1808 1
F
2481-0567 6I-2509
Ai r Fi l t er
2481-0055 6I-2510
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom.
Main Switchboard Phone :- +44 (0)1530 518600 Main Switchboard Fax :- +44 (0) 1530 518618
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651
E-mail :- sales@bl-pegson.com Website:- www.bl-pegson.com
2480-0061 05/01 - 1
Copyright 2002 - 2005 BL-Pegson Ltd . All Rights Reserved
AX860-901-8EN-02f 379/396
Components Manual
.
2480-0061
13 13a Item Qty

11 10
1 1
2 1
3 2
1 12 4 1
2 5 1
6 1
4
7 2
15 8 2
7 &
5 9 1
16
10 1
8 11 2
14 12 2
13 1
13a 1
19
18 14 1
6
15 1
9
16 1
17 1
18 1
19 1
A
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Components Manual
.
2480-0061
26
20
21
7
8 Item Qty
20 1
22
27 21 1
23 22 1
24
23 1
29 24 1
25 28 30
25 1
26 1
27 2
28 1
29 1
30 1
B
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Components Manual .
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36
32
37 Item Qty
44 31 1
33 & 34 32 6
33 1
45 34 1
35 1
36 1
38
37 1
38 6
41
39 1
40 1
40 43 41 1
42 1
43 1
42 44 1
45 1
C
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Components Manual .
2480-0061
ELC 59a
47 48 46 48 56 54 55
Item Qty
46 1
47 1
48 1
49 1
57
50 2
59 51 1
49 50 58 52 1
53 1
60 54 1
55 1
56 1
57 1
58 1
59 1
2 x 25
59a
l tr
60 1
48 51 52 53 48 & 61
61 1
D
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Components Manual
.
2480-0061
59
Item Qty
67
62 1
63 1
70
64 1
66 65 2
62
66 1
63 67 1
68 1
69 2
70 1
71 1
72 1
73 5
64
65
68
73
71
69
72
E
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Components Manual
.
2480-0061
Item Qty
74 1
77 75 4
76 1
77 1
78 1
74 76
77 78
75 75
F
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Components Manual .
2480-0061
Item Qty
79 79 1
82 80 1
83 92
81 1
82 1
80 & 81 87 83 1
84 84 1
85 1
88
85 86 1
87 1
88 1
89 1
86 90 89 91 90 1
91 2
93 92 1
85 94 95 93 1
91 94 2
95 4
97 92 88
96 1
96
97 1
G
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Components Manual
.
2480-0061
95 94 95
101 100 101
56
93
Item Qty
98 1
95 98
99 1
94
100 2
101 8
99
100 & 101
G
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.
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105
Item Qty
111 102 1
103 2
102 109 104 1
105 1
106 108
106 1
107 1
108 1
110 109 1
103 107
110 1
111 2
104 112 1
113 1
114 1
115 2
116 1
110
113
114 - 116
H
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Components Manual .
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118
126 Item Qty
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119 118 1
120 119 1
127
120 2
121
121 1
122 1
123 1
128 129
124 2
125 1
122 - 124
126 1
127 1
128 1
125 118 132 131 129 1

130
130 1
126
117 133 131 1
120 132 2
127
133 1
121
J
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136 2
137 4
135
137
134
136
K
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Components Manual .
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138 1
140
139 3
148 140 3
141 1
142 1
143 1
142 & 143
144 1
145 1
144 146 1
147 1
148 1
141
145 149 1
146
127
149
L
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Components Manual
.
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154
152 Item Qty
151 1
155 153
152 3
153 1
154 1
155 1
156 156 1
(120 157 1
Ohm)
157
L
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12 - Notes Page 1
Hours Run / Date Notes Name
BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618
E-mail : sales@bl-pegson.com Website : www.bl-pegson.com
AX860-901-8EN-02f 393/396
Page 2 12 - Notes
AX860-901-8EN-02f 394/396
12 - Notes Page 3
AX860-901-8EN-02f 395/396
AX860-901-8EN-02f 396/396

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ADVANCED CRUSHING TECHNOLOGY

PLANT USER MANUAL

IMPORTANT SAFETY NOTICE!

INFORMATION AND ADVICE

Terex Pegson Limited

or your local Distributor :-

Terex Crushing & Screening Inc.

Telephone : +1 502 267 2314, Fax : +1 502 267 2317

This plant is in conformity with the provisions

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung disease

When dusts are generated by the operation of this

The copyright of this User Manual is reserved by BL-Pegson Limited.

Terex Pegson Limited

Telephone:- + 44 1530 518600

Fax:- + 44 1530 518618

1.1 Warnings and Symbols .................................................................................. 1 - 2

1.2 Organisation Measures .................................................................................. 1 - 2

1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4

1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 4

1.7 Position of Emergency Stop Buttons ......................................................... 1 - 13

1.8 Safety Signs .................................................................................................. 1 - 14

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

1.2 Organisation Measures 1.2.2

Disconnect battery ground cable before 1.3 Selection and

1.4 Safety Instructions 1.4.1.4

Implementing the lockout procedure. Beware of moving haulage and loading

1.4.2.4 Always use an EN/ANSI approved safety

Keep away from the feed hopper and

Do not use any unauthorised structures.

1.5 Warning of Special 1.5.1.4

1.5.1.8 1.5.2 Gas, Dust, Steam, Smoke and

1.5.2.4 1.5.3 Hydraulic and Pneumatic

1.5.3.6 1.6 Transporting,

1.7 Position of Emergency Stop

Emergency Stop Button Emergency Stop Button

Emergency Stop Button

Emergency Stop Button Emergency Stop Button

Figure 1a Emergency Stop Buttons

Figure 1c Warning Signs - Right Hand Side

1.8.2 Safety Sign Illustrations

1.8.2 Safety Sign Illustrations, continued

2.1 Dimensions and Weights ............................................................................... 2 - 2

2.2 Plant Description ............................................................................................ 2 - 3

2.3 Belt Feeder Conveyor .................................................................................... 2 - 4

2.4 Crusher ........................................................................................................... 2 - 4

2.5 Discharge Conveyor ...................................................................................... 2 - 4

2.6 Standard Powerpack ...................................................................................... 2 - 5

2.7 Controls ........................................................................................................... 2 - 5

2.8 Dustsprays ...................................................................................................... 2 - 5

2.9 Tracks .............................................................................................................. 2 - 5

2.10 Optional Extras * ........................................................................................... 2 - 6

3197 Feed Height

3407 Disch. Height

4546 Working 3782 7669

All dimensions are in millimetres (feet/inches)

Overall Travelling Length (Feed Conveyor lowered) - 15866 (52- 1)

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

Figure 2a Dimensions and Weights 3000

2.2 Plant Description

Discharge Diesel Crusher Maintenance Feed

LEFT HAND SIDE REAR