1000SR Plant Manual 2004 (U) PDF

Powerscreen of Florida.
5125 N. Frontage Road,

1000SR Lakeland, FL 33810
Tel: (863) 687-7153
Fax: (863) 680-1289
Web: www.powerscreenfla.com
CRUSHING AND SCREENING PLANT
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.
AX868-901-8EN-01c 1/412
Powerscreen of Florida - 5125 N. Frontage Rd., Lakeland, FL, 33810 Page 2 of 412
Ph : 863-687-7153 / Web : www.powerscreenfla.com
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 1000SR contact:-
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire LE67 3GN
England
Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : sales@bl-pegson.com
or
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
WARNING: Diesel engine exhaust and
related accessories contain lead and lead
some of it’s constituents are known to the
compounds, chemicals known to the State
State of California to cause cancer, birth
of California to cause cancer and
defects, and other reproductive harm.
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.
BL-Pegson Limited Telephone:- + 44 1530 518600

Mammoth Street
Coalville Fax:- + 44 1530 518618
Leicestershire
LE67 3GN E mail sales@bl-pegson.com
England
To order additional copies contact your local BL-Pegson Ltd Dealer.
1000SR
Safety Issue EN 01
Page 1
Contents
1.1 Warnings and Symbols ....................................................................................... 2
1.2 Organisation Measures ....................................................................................... 3
1.3 Selection and Qualification of Personnel - Basic Responsibilities .................. 4
1.4 Safety Instructions Governing Specific Operational Phases ........................... 5

1.4.1 Standard Operation ......................................................................................... 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ..................... 5
1.5 Warning of Special Dangers ............................................................................... 8
1.5.1 Electric Energy ................................................................................................ 8
1.5.2 Gas, Dust, Steam, Smoke and Noise .............................................................. 9
1.5.3 Hydraulic and Pneumatic Equipment ............................................................. 10
1.5.4. Hazardous Substances ................................................................................ 10
1.6 Transporting, Manoeuvring and Recommissioning ....................................... 11
1.7 Position of Emergency Stop Buttons .............................................................. 13
1.8 Plant Warning Signs .......................................................................................... 14

1.8.1 Location of Warning Signs, Left Hand side of plant ....................................... 14
1.8.2 Safety Sign Illustrations................................................................................. 16
Safety Sign Illustrations, continued ......................................................................... 17
Safety Sign Illustrations, continued ......................................................................... 18
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
1000SR
Safety Issue EN 01
Page 2
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.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
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.
Indicates a statement of company policy as the message relates directly or indirectly to the
safety of personnel and protection of property.
1000SR
Safety Issue EN 01
Page 3
1.2 Organisation Measures Observe all safety instructions and warnings

attached to the plant.
1.2.1
See to it that safety instructions and
Ascertain from the appropriate Authority warnings attached to the plant are always
and observe all statutory and any other complete and perfectly legible.
regulations that may apply to the planned
location before operating the plant. Keep warnings and instruction labels clean.
Loose or baggy clothing can get caught in Replace unreadable or missing labels with
running machinery. new ones before operating the plant. Make
sure replacement parts include warning or
Where possible when working close to instruction labels where necessary.
engines or machinery, only do so when they
are stopped. If this is not practical, 1.2.3
remember to keep tools, test equipment
and all other parts of your body well away Understand service procedure before doing
from the moving parts. work. Keep area clean and dry.
For reasons of safety, long hair must be tied Never lubricate, clean, service or adjust
back or otherwise secured, garments must machinery while it is moving. Keep hands,
be close fitting and no jewellery such as feet and clothing clear of power driven
rings may be worn. Injury may result from parts and in running nip-points. Disengage
being caught up in the machinery or from all power and operate controls to relieve
rings catching on moving parts. pressure. Stop the engine. Implement
lockout procedure. Allow the machinery to
Always wear correctly fitting (EN/ANSI cool.
approved) personal protective equipment.
Keep all parts in good condition. Ensure
Personal Protective Equipment includes that all parts are properly installed. Fix
Hard Hat, Safety Glasses, Hearing damage immediately. Replace worn and
Protection, Dust Mask, Close fitting broken parts. Remove any build up of
Overalls, Steel Toed Boots, Industrial grease, oil and debris.
Gloves and a High Visibility Vest.
Disconnect battery ground cable before
1.2.2 making adjustments on electrical systems or
welding on plant.
You can be injured if you do not obey the
safety instructions as indicated on warning
stickers.
1000SR
Safety Issue EN 01
Page 4
For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted to Qualification of Personnel -
the task on hand are absolutely
Basic Responsibilities
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must be
Never make any modifications, additions or
executed by trained, reliable and authorised
conversions which might affect safety
personnel only. Statutory minimum age
without the supplier’s approval.
limits must be observed.
In the event of safety relevant modifications
1.3.2
or changes in the behaviour of the plant
during operation, stop the plant and lock Work on electrical system and equipment of
out immediately and report the malfunction the plant must be carried out only by a
to the competent authority/person. skilled electrician or by instructed persons
under the supervision and guidance of a
skilled electrician and in accordance with
electrical engineering rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
1000SR
Safety Issue EN 01
Page 5
1.4 Safety Instructions 1.4.2 Special Work In Conjunction

Governing Specific with Utilisation of the Plant and
Maintenance and Repairs During
Operational Phases
Operation; Disposal of Parts and
Consumables
1.4.1 Standard Operation
1.4.2.1
1.4.1.1
Observe the adjusting, maintenance and
Take the necessary precautions to ensure
intervals set out in these operating
that the plant is used only when in a safe
instructions, except where:
and reliable state.
A : Warning, horn/light/gauge or indicator
Operate the plant only for it’s designed
calls for immediate action.
purpose and only if all guarding, protective
and safety orientated devices, emergency
B : Adverse conditions necessitate more
shut-off equipment, sound proofing
frequent servicing.
elements and exhausts, are in all place and
fully functional.
Observe information on the replacement of
parts and equipment. These activities may
Before starting the engine ensure it is safe to
be executed by skilled personnel only.
do so.
1.4.2.2
1.4.1.2
When the plant is completely shutdown for
In the event of material blockage, any
maintenance and repair work, it must be
malfunction or operational difficulty, stop
secured against inadvertent starting by:
the plant immediately and lockout. Have
any defects rectified immediately.
• Switching off the engine and remove the
ignition switch/key.
1.4.1.3
In-running nip points on moving machinery • Implementing the lockout procedure.
can cause serious injury or even death.
• Attaching a warning sign(s) to the plant
Do not reach into unguarded machinery. in appropriate positions.
Your arm could be pulled in and amputated.
Switch off and lockout the plant before

removing any safety devices or guarding.
1000SR
Safety Issue EN 01
Page 6
1.4.2.3 For carrying out overhead assembly work

always use specially designed or otherwise
Carry out maintenance and repair work safety-oriented ladders and working
only if the plant is positioned on stable and platforms.
level ground and has been secured against
inadvertent movement and buckling. Always use any walkway/platforms
provided or a safe and secure platform
1.4.2.4 approved by the regional safety enforcing
Never allow unqualified or untrained authority.
personnel to attempt to remove or replace
any part of the plant, or anyone to remove Always use an EN/ANSI approved safety
large or heavy components without harness when reaching any points 7ft (2m)
adequate lifting tackle. or more above the ground level.
To avoid the risk of accidents, individual Keep all handles, steps, handrails,
parts and large assemblies being moved for platforms, landing and ladders free from
replacement purposes should be carefully dirt, oil, snow and ice.
attached to lifting tackle and secured. Use
only suitable and technically adequate lifting 1.4.2.6
gear. The fastening of loads and instructing of
crane operators should be entrusted to
Never work or stand under suspended experienced persons only. The marshaller
loads. giving the instructions must be within sight
or sound of the operator.
Keep away from the feed hopper and
product conveyor discharge, where there is 1.4.2.7
risk of serious injury or death due to the
loading and removal of material. After cleaning, examine all fuel, lubricant,
and hydraulic fluid lines for leaks, loose
1.4.2.5 connections, chafe marks and damage. Any
defects found must be rectified without
Falling from and/or onto a BL-Pegson plant delay.
can cause injury or even death.
1.4.2.8
Do not climb on the plant whilst it is in
operation. Never use plant parts as a Any safety devices removed for set-up,
climbing aid. maintenance or repair purposes must be
refitted and checked immediately upon
Beware of moving haulage and loading completion of the maintenance and repair
equipment in the vicinity of the plant. work to ensure full working order.
1000SR
Safety Issue EN 01
Page 7
1.4.2.9 1.4.2.11
Improperly disposing of waste can threaten Diesel fuel is highly flammable.
the environment and ecology. Potentially
harmful waste used with BL-Pegson Never remove the filler cap, or refuel, with
equipment includes such items as oil, fuel, the engine running.
coolant, filters and batteries, etc.
Never add gasoline or any other fuels
Use leakproof containers when draining mixed to diesel because of increased fire or
fluids. Do not use food or beverage explosion risks.
containers that may mislead someone into
drinking from them. Do not carry out maintenance on the fuel
system near naked lights or sources of
Do not pour waste onto the ground, down sparks, such as welding equipment or whilst
a drain or into any water source. smoking.
Ensure that all consumables and replaced 1.4.2.12

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
1.4.2.10 plant is very dangerous and could lead to
serious injury or even death through falling
Always ensure that any safety fitment such and/or entanglement with the plant.
as locking wedges, securing chains, bars or
struts are utilised as indicated in these Do not use any unauthorised structures.
operating instructions.
Particularly make sure that any part of the

plant raised for any reason is prevented
from falling by securing in a safe reliable
manner.
Never work under unsupported

equipment.
Never work alone.
1000SR
Safety Issue EN 01
Page 8
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
1.5.1.1 instructed personnel under the control and
supervision of such an electrician and in
Use only original fuses with the specified accordance with applicable electrical
current rating. Switch off the plant engineering rules.
immediately if trouble occurs in the
electrical system. 1.5.1.5
Plants with high voltage electrical equipment If provided for in the regulations, the power
must be suitably earth bonded by a supply to parts of plants and plants, on
qualified electrician prior to activating the which inspection, maintenance and repair
main isolator switch. work is to be carried out must be cut off.
Before starting any work, check the de-
1.5.1.2 energized parts for presence of power and
ground or short circuit them in addition to
When working with the plant, maintain a insulating adjacent live parts and elements.
safe distance from overhead electric lines. If
work is to be carried out close to overhead 1.5.1.6
lines, the working equipment must be kept
well away from them. Check out the The electrical equipment of the plant is to
prescribed safety distances. be inspected and checked at regular
intervals. Defects such as loose connections
1.5.1.3 or scorched or otherwise damaged cables
must be rectified immediately.
If your plant comes into contact with a live
wire:
• Warn others against approaching and

touching the plant.
• Have the live wire de-energized.
1000SR
Safety Issue EN 01
Page 9
1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

Noise
Necessary work on live parts and elements
must be carried out only in the presence of 1.5.2.1
a second person, who can cut off the
power supply in the case of danger by Always operate internal combustion engines
actuating the emergency shut off or main and fuel operated heating systems only out
power switch. Secure the working area of doors or in a well ventilated area. Before
with a red and white safety chain and a starting the plant in enclosed areas, make
warning sign. Use insulated tools only. sure that there is sufficient ventilation.
1.5.1.8 Observe the regulations in force at the

respective site.
Before starting work on high voltage
assemblies and after cutting out the power Dust found on the plant or produced during
supply, the feeder cable must be grounded work on the plant should be removed by
and components such as capacitors short- extraction, not blowing.
circuited with a grounding rod.
Dust waste should be dampened, placed in
1.5.1.9 a sealed container and marked, to ensure
safe disposal.
These plants are wired on negative earth.
Always observe correct polarity. 1.5.2.2
Always disconnect battery leads before Carry out welding, flame cutting and
carrying out any maintenance to the grinding work on the plant only if this has
electrical system. been expressly authorised, as there may be
a risk of explosion and fire.
The battery contains sulphuric acid, an
electrolyte which can cause severe burns 1.5.2.3
and produce explosive gases.
Before carrying out welding, flame cutting
Avoid contact with the skin, eyes or and grinding operations, clean the plant and
clothing. its surroundings from dust and other
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
1000SR
Safety Issue EN 01
Page 10
1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with hearing protection of laid and fitted properly. Ensure that no
approved pattern and that these are worn at connections are interchanged. The fittings,
all times when the plant is operating. lengths and quality of the hoses must
comply with the technical requirements.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects 1.5.3.5
of air pollution of any kind.
Always practice extreme cleanliness
1.5.3 Hydraulic and Pneumatic servicing hydraulic components.
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can
Work on hydraulic equipment may be penetrate the skin causing serious injury.
carried out only by persons having special
knowledge and experience in hydraulic If fluid is injected under the skin, it must be
systems. surgically removed or gangrene will result.
Get medical help immediately.
1.5.3.2
Always relieve pressure from the hydraulic
Check all lines, hoses and screwed system before carrying out any kind of
connections regularly for leaks and obvious maintenance or adjustment.
damage. Repair damage immediately.
Splashed oil may cause injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4. Hazardous Substances
pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification, labelling,
for the unit concerned before carrying out storage, use and disposal, all strictly in
any repair work. accordance with the manufacturers
instructions and that all applicable
regulations are observed at all times.
1000SR
Safety Issue EN 01
Page 11
1.6 Transporting, 1.6.7

Manoeuvring and When travelling on public roads, ways and
Recommissioning places, always observe the valid traffic
regulations and, if necessary, ensure
1.6.1 beforehand that the plant is in a condition
compatible with these regulations.
The plant must be towed, loaded and
transported only in accordance with the
1.6.8
operating instructions.
In conditions of poor visibility and after
1.6.2 dark, always switch on the lighting system
of the transporting vehicle..
For towing the plant, observe the
prescribed transport position, admissible
1.6.9
speed and itinerary.
When crossing underpasses, bridges and
1.6.3 tunnels or when passing under overhead
lines always make sure that there is
Use only appropriate means of transport
sufficient clearance.
and lifting gear where applicable of
adequate capacity.
1.6.10
1.6.4 Never travel across slopes; always keep
the working equipment and the load close
The recommissioning procedure must be
to the ground, especially when travelling
strictly in accordance with the operating
downhill.
instructions.
1.6.11
1.6.5
On sloping terrain, always adapt your
Before starting work or travelling with the
travelling speed to the relevant ground
plant, check that the braking, and any
conditions. Never change to a lower gear
signalling and lighting systems are fully
on a slope. Always change gear before
functional.
reaching a slope.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.
1000SR
Safety Issue EN 01
Page 12
1.6.12
Explosive separation of a tyre and rim parts
can cause injury or death.
Do not attempt to mount a tyre unless you

have the proper equipment to perform the
job.
Always maintain the correct pressure. Do

not inflate the tyre above the recommended
pressure. Never weld or heat wheel and
tyre assembly. The heat can cause an
increase in air pressure resulting in a tyre
explosion. Welding can structurally weaken
or deform the wheel.
When inflating tyres, use a clip-on chuck

and extension hose long enough to allow
you to stand to one side and not in front or
over the assembly. Use safety cage if
available.
Check wheels for low pressure, cuts,

bubbles, damaged rims or missing lug bolts
and nuts.
1000SR
Safety Issue EN 01
Page 13
1.7 Position of Emergency Stop Buttons
Emergency Stop Button

(Metal Detector Control Panel)
Emergency Stop Button

Emergency Stop Button (Chassis Side)
(Screen) Emergency Stop Button
(Control Panel)
Emergency Stop Button Emergency Stop Button

(Chassis Side) (Control Panel)
Figure 1a Emergency Stop Buttons
1.8 Plant Warning Signs
1.8.1 Location of Warning Signs, Left Hand side of plant
KEY TO SIGN REFERENCE

NUMBERS ON NEXT PAGES
Location of Warning Signs, Right Hand side of plant
KEY TO SIGN REFERENCE

NUMBERS ON NEXT PAGES
1000SR
Safety Issue EN 01
Page 16
1.8.2 Safety Sign Illustrations
1 2 3
8
6 7
9 11 13
1000SR
Safety Issue EN 01
Page 17
Safety Sign Illustrations, continued
14 15 17
20
19 21
22 23 30
1000SR
Safety Issue EN 01
Page 18
Safety Sign Illustrations, continued
Upper and Lower Transfer Conveyors, each:-
2x
4x
Recirculating and Stockpile Conveyors, each:-
2x
4x
1000SR
Technical Information Issue EN 01
Page 1
Contents
2.1 Dimensions .......................................................................................................... 2
2.2 Plant Description ................................................................................................. 3
2.3 Belt Feeder Conveyor .........................................................................................4
2.4 Crusher ................................................................................................................ 4
2.5 Automax rushed Product Conveyor .................................................................. 4
2.6 Tracks ................................................................................................................... 5
2.7 Engine Powerpack .............................................................................................. 5
2.8 Dust Suppression Sprays .................................................................................. 5
2.9 Sizing Screen ....................................................................................................... 5
2.10 Fines Conveyor ................................................................................................. 6
2.11 Upper and Lower Side Transfer Conveyors .................................................... 6
2.12 Re-Circulating/Stockpile Conveyors ............................................................... 6
AUTOMAX / AUTOSAND - EXPLANATORY NOTE
The BL-Pegson ‘Automax’ cone crusher is incorporated into the 1000SR plant.
The name ‘Automax’ is used throughout this manual when referring to the
crusher but the instructions apply equally to the alternative ‘Autosand’ version of
the machine, except for the variations relevant to the feed material and the
product (Refer to Section 3) together with appropriate changes to the Spare Parts
(Section 10).
CENTRE LINE
OF GRAVITY
2.1 Dimensions
2934 (9’- 8”)
2779 (9’- 1”)

FEED HEIGHT
554 (1’- 10”)
DISCHARGE HEIGHT
1400 CLEARANCE - TRAVELLING POSITION

1133 (4’- 7”)
(3’- 9”)
4830 (15’- 10”) 3800 (12’- 6”) 8205 (26’- 11”)
Figure 2a Dimensions MM (feet/inches)
Overall Travel Length including spray bars 17193mm (56’- 5”)
Overall Travel Width: 3100mm (10’- 2”)
Travel Height (Excluding Transport Trailer): 3446mm (11’- 4”)

Technical Information
NB. ADD 150mm (6”) to height if the feed conveyor barge

board extensions (Figure 5h) are retained in position,
Powerscreen of Florida - 5125 N. Frontage Rd., Lakeland, FL, 33810

Overall Track Width: 2794mm (9’- 2”)
4753 (15’- 7”) OPERATING HEIGHT
Working Height: 4753mm (15’- 7”)
Gross Weight approx. 38 tonnes (42 US tons) 432
(1’- 5”)
1000SR
Page 2
2794 (9’- 2”)

Issue EN 01
Note: Weights and dimensions are for guidance only and appropriate OVER TRACKS
allowances should be applied when being used for transportation purposes.
Page 28 of 412
1000SR
Page 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.
Automax Product Diesel Engine Feeder

On Plant Conveyor Power Pack Conveyor
Metal Detector
Control Box
FRONT REAR
Top Deck Side Bottom Deck Side Control Box Maintenance

Transfer Conveyor Transfer Conveyor Platform
LEFT HAND SIDE
Feed Hopper
Fines Conveyor
REAR FRONT
Tracks Sizing Screen
Automax Crusher Re-circulating Conveyor

(Or Stockpile option)
RIGHT HAND SIDE

Figure 2b Plant Terms
1000SR
Page 4
2.3 Belt Feeder Conveyor

Type ............................. EP 500/3 Shallow troughed plain belt. 5mm (0.2”) and 1.5mm (0.06”)
rubber covers. Vulcanised joint
Width ........................... 1000mm (39”).
Length .......................... 5400mm (17’-9”).
Drive Unit ..................... Hydraulic motor with head drum reduction gearbox
Lubrication ................... Grease for shaft bearings - oil for drive gearbox
Control ......................... Auto/manual variable speed.
Hopper ........................ Fixed hopper with rear feed facility and internal ‘strickle’ gate and full
length barge boards.
Hydraulic Equipment ..... Cylinders 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 .............................. 1000mm (39”).
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 ........ Level sensor over the feed box.
2.5 Automax Crushed Product Conveyor

Type ............................. EP500/3 troughed belt. 5mm (0.2”) and 1.5mm (0.06”) rubber covers.
Vulcanised joint
Width ........................... 800mm (31”).
Drive ............................ Hydraulic motor.
Lubrication ................... Grease for shaft bearings.
Enclosure ..................... Canvas cover.
Control equipment ........ Tail drum movement sensor.
1000SR
2 - Technical Information Issue EN 01
Page 5
2.6 Tracks
Type ............................. 160mm (6in) pitch heavy duty
Width ........................... 400mm (15.8in)
Centres ........................ 3800mm (12’- 6”)
Drive ............................ Hydraulic integral motors
Control ......................... Remote radio handset-dual speed
2.7 Engine Powerpack

Type ............................. Caterpillar C9 EU/EC Emmission Regulations compliant 6 cyl. water
cooled diesel
Rating ........................... 257kW (345hp) @ 1800 rpm
Drives .......................... Hydraulically actuated heavy duty clutch to crusher through vee belts
Vee belts to twin hydraulic pumps plus engine mounted pump.
Housing ........................ Totally enclosed canopy with integral fuel tank and battery
2.8 Dust Suppression Sprays

Type ............................. Clean water multi atomising nozzles
Positions ....................... Crusher feed and discharge and fines conveyor discharge
Inlet .............................. Single point
Required supply ............ Up to approx. 23 litres/min (6 US gall/min) @ 2.8bar (42psi)
Frost protection ............ System drain valves
2.9 Sizing Screen

Type ............................. Vibrating two deck - 4 bearing type
Top deck mesh ............. 45mm (1.8in) square aperture (with intial impact section) fitted as standard
Bottom deck mesh ........ 22mm (0.87in) square aperature fitted as standard
Width ........................... 1525mm (5’- 0”)
Length .......................... 3350mm (11’- 0”)
Drive ............................ Hydraulic motor
Control ......................... Fixed speed
Lubrication ................... Grease lubricated shaft bearings
1000SR
Page 6
2.10 Fines Conveyor

Type ............................. Roply EP400/2 Plain troughed belt. 5mm (0.2”) and 1.5mm (0.06”) rubber
covers. Vulcanised joint
Width ........................... 1400mm (55in)
Lubrication ................... Grease for shaft bearings
Enclosure ..................... Canvas cover.
2.11 Upper and Lower Side Transfer Conveyors

Type ............................. Roply EP500/3 Plain flat belt.5mm (0.2”) and 1.5mm (0.06”) rubber
covers. Vulcanised joint
Width ........................... 500mm (20in)
2.12 Re-Circulating/Stockpile Conveyors

Type ............................. Roply EP325/2 Chevron type troughed belt. 3mm (0.12”) and 1mm
(0.04”) rubber covers and 35mm (1.38”) high cleats. Vulcanised joint.
Width ........................... 500mm (20in)
1000SR
3 - General Information Issue EN 01
Page 1
Contents
3.1 Introduction .......................................................................................................... 2
3.2 General information ............................................................................................. 3
3.3 Designated Use ................................................................................................... 4

3.3.1 Operating Temperature Range ........................................................................ 4
3.4 Plant Features ...................................................................................................... 5
3.5 Plant Performance ............................................................................................... 6
3.6 Crusher Performance .......................................................................................... 7

3.6.1 Estimated Performance - Automax with long throw eccentric ........................... 8
3.6.2 Typical Product Analysis - Automax with long throw eccentric ........................... 9
3.6.3 Estimated Performance - Automax with short throw eccentric ....................... 10
3.6.4 Typical Product Analysis - Automax with short throw eccentric....................... 11
3.6.5 Estimated Performance - Autosand with long throw eccentric ....................... 12
3.6.6 Typical Product Analysis - Autosand with long throw eccentric....................... 13
3.6.7 Estimated Performance - Autosand with short throw eccentric ...................... 14
3.6.8 Typical Product Analysis - Autosand with short throw eccentric ..................... 15
1000SR
Page 2
3.1 Introduction
This instruction manual contains important

information on how to operate the 1000SR
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.
1000SR
Page 3
3.2 General information If high or low ambient

temperature conditions apply,
The1000SR plant has been manufactured, specific details need to have
assembled and tested with the utmost care been advised at the time of
and was built with first class materials. order as special equipment
may be necessary.
Close attention has been paid to all details
in assembly, running tests and final The Caterpillar engine cooling
inspection. system is protected to -15 ºC
with 30% Caterpillar
BL-Pegson is confident that the plant will antifreeze concentration when
give every satisfaction over a long period. shipped from the factory
unless special requirements
To be assured of faultless operation the have been defined.
operator should carefully read the following
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, it’s use may constitute a risk

to life and limb of the user or of third
parties, or cause damage to the plant and to
other material property.
1000SR
Page 4
3.3 Designated Use Experienced engineers are available at BL-

Pegson to give advice when necessary.
The BL-Pegson 1000SR plant includes the
1000 Automax Cone Crusher designed to If you have any doubts about any
maximise throughput and product shape in a aspect of the plant’s capability or
wide range of crushing applications. For finer servicing procedures, you must consult
crushing operations the Autosand option is your local BL-Pegson dealer or BL-
available. Pegson’s technical department.
It is vitally important that pieces The 1000SR Plant has been designed to
of steel or similar uncrushable give a controlled product size whilst
objects such as bucket teeth are maximising throughput and product shape.
not allowed to enter the crushing Applications include: quarry, demolition and
chamber as severe damage and recycling.
injury may occur.
In addition to the tremendous advantages
For the above reason a metal detector is arising from the mobility of a tracked unit,
fitted to the feeder. It is imperative that this the standard design and specification is
metal detector is kept operative at all times intended to give the plant operator a wide
and that when activated the plant operator choice of operating configurations. These
removes the offending material before are described in the guidance notes on plant
recommencing operation. performance (Section 3.4).
Operating the plant outside it’s Additional choices are available to the
recommended range of buyer to select additional equipment from
applications/operating the range of optional extras (Section 4).
parameters or for any use for
which the equipment is not 3.3.1 Operating Temperature Range
intended, will result in a loss of The normal operating temperature range of
any guarantee and the the plant is from -10°C to +40°C (+14°F
manufacturer/supplier cannot be to +104°F). For use in temperatures
held liable for any damage or outside of this range, contact your local
injury resulting from such dealer or BL-Pegson for details.
misuse. The risk of such misuse
lies entirely with the user.. Note: Appropriate oil & coolant to suit the
local operating conditions must be used, as
Refer to the following information in this specified elsewhere in this manual.
Section for guidance regarding the
performance of the Automax crusher.
1000SR
Page 5
3.4 Plant Features included to vary the angle of the screen

whereby screening may be improved.
The 1000SR is a self contained diesel
driven tracked crushing plant incorporating Re-circulating Conveyor
the Automax cone crusher.. The inclusion of Provided to return rejects from the screen
a plant mounted double deck vibrating back to the cone crusher for recrushing,
screen allows for oversize material to be facility is also included to suspend from
recirculated for recrushing and for sized end the plant and turn at 90o to form a
products. Together with the various stockpile.
crushing configurations available for the
Automax, the plant design allows the Side Transfer Conveyor(s)
operator to work the plant in a wide variety A conveyor is supplied to transfer rejected
of different operations as described below. material from the screen top deck to the re-
circulating conveyor. Another similar transfer
BL-Pegson 1000 Automax Crusher. conveyor (optional extra) is available to
Generally as illustrated on leaflet AMB 200/ handle material from the bottom deck (if
1, and fitted with long throw eccentric, fitted) for recirculating or stockpiling.
medium coarse (MC) concave and
dedicated system hydraulic controls as Fines Conveyor
standard. The crusher is complete with an This is sited immediately below the sizing
oil lubrication system having a chassis screen and, in the normal arrangement of a
mounted tank with air blast cooler. top deck only being fitted to the screen,
discharges the one screened all-in product
Extra coarse (XC), coarse (C) and onto a ground stockpile or to other equipment
Autosand (AS) concaves and a short throw for further processing.
eccentric are all available as options to the
above for plants which have not been Stockpile Conveyor (optional extra)
completed. Advice on the correct A conveyor similar to the re-circulating
combination of concave and eccentric can conveyor suspended from the opposite side of
be provided by the sales department against the plant for a sized material coming off the
purchasers specific application data. bottom deck screen mesh (when fitted).
Double Deck Sizing Screen

The standard supply is for the top deck
to be fitted with a 45mm (c 13/4”)
aperture wire mesh and the bottom deck
left open. Different meshes (optional
extras) can be supplied to suit customer
requirements. Additionally, facility is
1000SR
Page 6
3.5 Plant Performance If you have any doubts about

any aspect of the plant’s
The overall maximum plant capacity can be capability or servicing
governed by the nature of the feed material, procedures, you must consult
the screen mesh size(s) fitted, the Automax your local BL-Pegson dealer or
crusher configuration and settings, the BL-Pegsons technical
conveyor capacities, etc., etc. or a department
combination of all these type of factors.
If high or low ambient
When selecting the crusher settings (Section temperature conditions apply
3.6), it is best practice to keep the amount and/or any other unusual
of oversize material recirculating back to the situation(s) may occur, either
crusher to a maximum of 20 percent of the during operation or otherwise,
original feed. The mesh apertures on the refer to BL-Pegson for advice
screen are also a governing factor. In any as to the suitability of the
case, material flows must be kept within plant. Full details are required
the handling capability of the system. for an assessment, as plant
performance could be affected.
Selecting the size of mesh apertures fitted
to the sizing screen must not be detrimental The Caterpillar engine cooling
to the screen for reasons of wear or system is protected to -15º C
screening efficiency and must provide an (+5º F) with 30% (Caterpillar
acceptable balance of material flows from antifreeze concentration when
the screen. shipped from the factory
unless special requirements
Estimates of performance are given as a have been defined.
guide only due to the wide variety and
variable nature of the numerous factors that
can be involved. In respect of specific
applications seek prior advice from BL-
Pegson’s technical department
Operating the plant outside it’s

recommended range of applications and
operating parameters, will result in a loss of
guarantee and the manufacturer/supplier
cannot be held liable for any damage
resulting from such use. The risk of such
misuse lies entirely with the user.
1000SR
Page 7
3.6 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 BL-Pegson Ltd.
The power required and product gradings
Performance is dependant upon the throw will vary with the feed and product size,
of the eccentric built into the Automax capacity and rock characteristics.
and also the type of concave fitted to the
machine. Sections 3.4.1 to 3.4.8 cover Usage of wearing parts will depend upon
the various options. 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.
1000SR
Page 8
3.6.1 Estimated Performance - Automax with long throw eccentric
Minimum
Type of Concave Maximum Feed Size Recommended
Setting
Med. Coarse (MC) 160 mm (61/4") 3

19 mm ( /4")
Coarse (C) 175 mm (67/8") 3

19 mm ( /4")
Extra Coarse (XC) 195 mm (73/4") 7

22 mm ( /8")
Figure 3a Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting Typical Plant Output
mm inches M. tph US. tph
19 3/4" 125 - 145 135 - 160
22 7/8" 140 - 180 155 - 195
25 1" 145 - 195 160 - 215
28 1 155 - 205 170 - 225

1 /8 "
32 1 160 - 220 175 - 240

1 /4 "
Figure 3b Estimated Plant Outputs
1000SR
Page 9
3.6.2 Typical Product Analysis - Automax with long throw eccentric
Figure 3c Typical Product Analysis Curves - Long Throw Eccentric Automax

SCREEN MESH SIZE - INCHES
SCREEN MESH SIZE - MM
PERCENTAGE PASSING
1000SR
Page 10
3.6.3 Estimated Performance - Automax with short throw eccentric
Minimum
Setting
Med. Coarse (MC) 160 mm (61/4") 5

16 mm ( /8")
Coarse (C) 175 mm (67/8") 5

16 mm ( /8")
Extra Coarse (XC) 195 mm (73/4") 3

19 mm ( /4")
Figure 3d Maximum Feed Size and Minimum Recommended Settings
16 5/8" 90 - 110 100 - 120
19 3/4" 105 - 120 115 - 130
22 7/8" 115 - 150 125 - 165
25 1" 120 - 160 130 - 175
28 1 130 - 170 140 - 185

1 /8 "
32 1 135 - 180 150 - 200

1 /4 "
Figure 3e Estimated Plant Outputs
1000SR
Page 11
3.6.4 Typical Product Analysis - Automax with short throw eccentric
Figure 3f Typical Product Analysis Curves - Short Throw Eccentric Automax

PERCENTAGE PASSING
1000SR
Page 12
3.6.5 Estimated Performance - Autosand with long throw eccentric
Minimum
Setting
Sand (AS) 63 mm (21/2") 1

13 mm ( /2")
Figure 3g Maximum Feed Size and Minimum Recommended Settings
13 1/2" 85 - 120 95 - 130
16 5/8" 95 -130 105 - 140
19 3/4" 100 - 150 110 - 165
Figure 3h Estimated Plant Outputs
1000SR
Page 13
3.6.6 Typical Product Analysis - Autosand with long throw eccentric
Figure 3i Typical Product Analysis Curves - Long Throw Eccentric Autosand

PERCENTAGE PASSING
1000SR
Page 14
3.6.7 Estimated Performance - Autosand with short throw eccentric
Minimum
Setting
Sand (AS) 63 mm (21/2") 1

13 mm ( /2")
Figure 3j Maximum Feed Size and Minimum Recommended Settings
13 1/2" 70 - 100 75 - 110
16 5/8" 80 - 110 90 - 120
19 3/4" 85 - 125 95 - 135
Figure 3k Estimated Plant Outputs
1000SR
Page 15
3.6.8 Typical Product Analysis - Autosand with short throw eccentric
Figure 3l Typical Product Analysis Curves - Short Throw Eccentric Autosand

PERCENTAGE PASSING
1000SR
Page 16
Blank page
1000SR
Design and Function Issue EN 01
Page 1
Contents
4.1 General Information ............................................................................................. 2
4.2 Construction Units .............................................................................................. 3

4.2.1 Automax Crusher ............................................................................................ 3
4.2.2 Feed Hopper .................................................................................................. 3
4.2.3 Feed Conveyor ............................................................................................... 3
4.2.4 Automax Crushed Product Conveyor ............................................................... 3
4.2.5 Sizing Screen.................................................................................................. 4
4.2.6 Fines Conveyor ............................................................................................... 4
4.2.7 Upper Side Transfer Conveyor ........................................................................ 4
4.2.8 Lower Side Transfer Conveyor ........................................................................ 4
4.2.9 Re-Circulating Conveyor ................................................................................. 4
4.2.10 Stockpiling Conveyor (optional extra) ............................................................ 5
4.2.11 Belt Scrapers ................................................................................................ 5
4.2.12 Track Frame.................................................................................................. 5
4.2.13 Plant Chutework ............................................................................................ 5
4.2.14 Dust Suppression ......................................................................................... 5
4.2.15 Platforms ...................................................................................................... 5
4.2.16 Power-Pack .................................................................................................. 5
4.2.17 Controls ........................................................................................................ 6
4.2.18 Chassis ........................................................................................................ 6
4.2.19 Guards .......................................................................................................... 6
4.2.20 Painting ........................................................................................................ 6
4.2.21 Optional Extras ............................................................................................. 6
4.2.22 Authorisation ................................................................................................. 7
4.2.23 Site Preparation ............................................................................................ 7
4.2.24 Commissioning ............................................................................................. 7
1000SR
Page 2
4.1 General Information

The BL-Pegson 1000SR Plant has been designed to maximise throughput and product
shape in a wide range of quarrying applications, its features include:-
• Unique design giving excellent product shape and high reduction ratios
• Hydraulic crusher setting adjustment, overload release and unblocking included as standard
• Choice of crusher concave (including Autosand option) and eccentric throw available
• No need for pre-screening on many applications reducing cost and increasing profitability
• Rapid set up time and easily transported on and off site
• Metal detection fitted as standard
• Feed level controls for feed hopper (optional) and crusher included to ensure choke feed to the
crusher with resultant optimum product shape
• Fully skirted product conveyor from beneath the Automax and discharging onto the sizing screen
• Double deck vibrating sizing screen 1500 x 3350mm (5ft x 11ft) with simple access for screen
maintenance
• Re-circulating conveyor to return material from top deck of the screen for re-working,
alternatively this conveyor can be slewed to enable oversize material to be stockpiled
• Optional side conveyor from lower sizing screen to a freestanding stockpiling conveyor
• Dust suppression sprays
• Caterpillar emmission compliant water cooled diesel engine with hydraulically controlled clutch
• Hydraulic rams to assist setting up and packing for transportation
• Heavy duty tracks with remote radio control
CRUSHING APPLICATIONS
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.
1000SR
Page 3
4.2 Construction Units drum having integral reduction gearbox,

EP500/3 (or equivalent) belt with 5mm
BL-PEGSON 1000SR SECONDARY/
(0.2”) top and 1.5mm (0.06”) bottom
TERTIARY CRUSHING PLANT
heavy duty covers, and vulcanised belt
WITH DIESEL/HYDRAULIC DRIVE
joint. The conveyor is designed to lower
generally as shown on brochure 1000SR-
for transportation and lift for crusher
2003/4 and comprising:-
maintenance, by means of hydraulic
cylinders. Belt tensioning is maintained by
screw adjusters located at the tail drum.
4.2.1 Automax Crusher
Impact rollers are provided immediately
BL-Pegson 1000 Automax Crusher below the feed hopper, and barge boards
generally as illustrated on leaflet AMB 200/ extend from the feed hopper to the
1, and fitted with long throw eccentric, conveyor head. A metal detector is
medium coarse (MC) concave and included complete with audible warning
dedicated system 2 hydraulic controls as devices, and is suitable for detecting steel
standard. The crusher is complete with an and manganese steel contained in the feed
oil lubrication system having a chassis material.
mounted tank with air blast cooler.
Extra coarse (XC), coarse (C) and 4.2.4 Automax Crushed Product
Autosand (AS) concaves and a short throw Conveyor
eccentric are all available as options to the
800mm (31in) wide plant mounted
above for plants which have not been
troughed belt conveyor carrying the product
completed. Advice on the correct
from beneath the impactor and discharging
combination of concave and eccentric can
on to the sizing screen.
be provided by the sales department against
purchasers specific application data. Belt:- EP500/3 with 5mm (0.2”) top and
1.5mm (0.06”) bottom heavy duty rubber
covers. A vulcanised joint is included.
4.2.2 Feed Hopper Feedboot:- Fabricated in mild steel plate

with abrasion resistant steel liners, access
4.0m³ nominal capacity feed hopper door and fully skirted wear resistant rubber
fabricated in 10mm (0.4”) thick mild steel sealing strips along the entire conveyor
plate and fitted with internal crash bars to length.
minimise impact load on the feed conveyor.
Impact Idlers:-Provided beneath the belt
below the Automax outlet.
4.2.3 Feed Conveyor
1000mm (39”) wide, plant mounted
shallow troughed belt variable speed
conveyor, with hydraulic drive to the head
1000SR
Page 4
Covers:- Canvas type removable dust 4.2.7 Upper Side Transfer Conveyor
covers are fitted at the head end. 500mm (20in) wide conveyor to transfer
material from the top deck of the screen to
the re-circulating conveyor.
4.2.5 Sizing Screen Belt:- Roply EP400/2 with 5mm (0.2”) top
1525 x 3350mm (5ft x 11ft) inclined and 1.5mm (0.06”) bottom rubber covers.
double deck vibrating screen mounted A vulcanised joint is included.
beneath the impactor product conveyor.
The screen is complete with hydraulic
drive, with wire meshes on the top deck to
4.2.8 Lower Side Transfer Conveyor
separate at 40mm (45mm square
aperture) and bottom deck (whereat 500mm (20in) wide conveyor to transfer
20mm (22mm square aperture) fitted as material from the bottom deck of the screen
standard. to an optional plant mounted stockpiling
conveyor..
Different meshes can be supplied to suit
customer requirements, see optional Belt:- Roply EP400/2 with 5mm (0.2”) top
extras. These are only supplied against and 1.5mm (0.06”) bottom rubber covers.
specific order. A vulcanised joint is included.
4.2.6 Fines Conveyor 4.2.9 Re-Circulating Conveyor

1400mm (55in) wide fines conveyor 500mm (20in) wide conveyor to return
mounted beneath the screen giving a material transferred from the top deck of
discharge height of approximately the screen, back to the impactor for
2900mm (9’- 6”) to the top of the head re-crushing. This conveyor includes a
drum. slewing facility to enable oversize material
to be stockpiled at the side of the plant.
Belt:- Roply EP400/2 with 5mm (0.2”) Belt:- Roply EP315/2 with 3mm (0.12”)
top and 1.5mm (0.06) bottom rubber top and 1mm (0.04”) bottom rubber
covers. A vulcanised joint is included. covers, 35mm (1.38”) high cleats and a
vulcanised joint.
1000SR
Page 5
4.2.10 Stockpiling Conveyor 4.2.13 Plant Chutework

(optional extra) Fabricated chutework is provided at the
500mm (20in) wide conveyor to return material transfer points having renewable
material transferred from the bottom deck liner plates on the impact surfaces.
of the screen to the side of the plant.
Belt:- Roply EP315/2 with 3mm (0.12”)
top and 1mm (0.04”) bottom rubber 4.2.14 Dust Suppression
covers, 35mm (1.38”) high cleats and a
vulcanised joint. Dust suppression spray nozzles are fitted at
the Automax feed and dicharge and also at
the head of the fines conveyor, piped to a
central inlet manifold.
4.2.11 Belt Scrapers
Torsion type belt scrapers with
polyurethane blades are fitted as standard 4.2.15 Platforms
and are suitable for most applications.
Special scrapers can be fitted at extra cost Provided for inspection and maintenance,
but only on machines that are built to a allowing access to each side of the crusher
specific order. Dealer/Customer to specify and engine, back of engine, and to one side
type if different from standard. of feed conveyor head section. They are
made from steel flooring with steel toe
boards, double row handrails and access
ladders.
4.2.12 Track Frame
Heavy duty track frame having 3.8m (12’-
6”) longitudinal centres with 400mm(1’- 4”) 4.2.16 Power-Pack
wide tracks fitted as standard.
Caterpillar C9 EU/EC Emmissions
Total Plant Weight - approx. 38 tonnes (42 Regulations compliant, 6 cylinder, 4 stroke,
US tons). direct injection, water cooled diesel power
Overall Track Width - 2..79m (9’- 2”). pack, with HFO clutch. The engine is rated
Plant Operating Height - 4.75m (15’- 7”) at 345 BHP (257 kW) nett continuous at
Plant Transport Height - 3.45m (11’- 4”) 1800 rpm under NTP conditions.
Plant Transport Width - 3.10m (10’- 2”)
Plant Transport Length - 17.19m (56’- 5”) Hydraulic power is provided from the
engine to drive the tracks, feeder conveyor,
NB. Transport height excluded trailer. all on-plant conveyors and the sizing screen.
All necessary pipework is provided with
steel pipe run to inaccessible areas.
1000SR
Page 6
4.2.17 Controls 4.2.19 Guards

The Automax/Plant hydraulic systems Wire mesh or sheet metal guards are
control panel, and separate set up control provided for all drives, pulleys, couplings,
panel for the screen and conveyors are wedge belts and belt conveyors.
mounted on the side of the main chassis.
Both panels operate from a 24 volt D.C. The guards provided are designed and
supply from the diesel engine. manufactured to ensure so far as reasonably
practicable that the machinery and plant on
A radio control unit is provided for which they are fitted can be operated safely
controlling the tracking function giving a and without risk to health when properly
tracking speed of approximately 1km/hour used. However, the company cannot
and a ‘creep’ facility for loading, off loading guarantee that the guards provided will
and precise slewing movements. This also meet the requirements laid down by
provides stop and start control for the feed individual inspectors and any additional
conveyor from a remote position. An guard and/or modification to guarding
alternative umbilical control unit is also supplied, which may be required for any
provided for use in case of remote control reason whatsoever, will be charged as an
unit failure. additional contract price.
Level sensors over the Automax and, feed
conveyor (optional), are designed to
automatically maintain an optimum feed 4.2.20 Painting
condition. The plant is finish painted in blue RAL5015.
Emergency stop buttons are provided on
each side of the plant.
4.2.21 Optional Extras
Standard optional extras, which can be
added to plants not already built for stock:-
4.2.18 Chassis
Fabricated steel frame of welded Beckford or Siemens belt weigher.
construction with supports for the Automax Hydraulically driven water pump.
crusher, on-plant conveyors, sizing screen,
power unit and track frame. Electronic Refuelling pump kit
500 mm (20”) wide stockpiling
conveyor for the lower transfer
conveyor.
Alternative sizes of screen meshes.
1000SR
Page 7
4.2.22 Authorisation specifications without prior notice as we

This is a requirement of the Environmental operate a policy of continual product
Protection Act that the Purchaser must development.
obtain Local Authority authorisation to BL-Pegson cannot guarantee that the
operate this plant in the United Kingdom or equipment specified will meet any specific
as may be required elsewhere to comply requirements in respect of noise or vibration
with local regulatory controls. levels, dust emission, or any other factors
relevant to health and safety measures or
environmental protection needs. However,
on receipt of specific information BL-
4.2.23 Site Preparation pegson will endeavour to ascertain the need
The buyer shall be responsible for ensuring for additional equipment and, if appropriate,
that a suitably prepared, flat and level site is quote extra to contract prices.
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.
4.2.24 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.
4.2.25 Specification Amendments

Every endeavour will be made to supply
equipment as specified, but we reserve the
right, where necessary, to amend
1000SR
Page 8
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1000SR
Transport Issue EN 01
Page 1
Contents
5.1 Safety Information ............................................................................................... 2
5.2 Transportation ..................................................................................................... 5

5.2.1 Manoeuvring ................................................................................................... 6
5.2.2 Unloading ...................................................................................................... 11
5.2.3 Loading - from re-circulating mode ................................................................ 12
5.2.4 Loading - from conveyor stockpiling mode..................................................... 18
5.2.5 Conveyor Weights ......................................................................................... 18
5.3 Remote Control Hand Set ................................................................................. 19
5.3.1 Radio Hand Set (where fitted) ....................................................................... 19
5.3.2 Alternative Control Hand Set with Umbilical Cable (where fitted) .................... 22
1000SR
Page 2
5.1 Safety Information
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.
1000SR
Page 3
In-running nip points can cause ENTANGLEMENT

HAZARD
DO NOT reach into an unguarded
machine.
SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.
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

surgically removed or gangrene will result.
1000SR
Page 4
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.
1000SR
Page 5
5.2 Transportation When manoeuvring your

1000SR to it’s operating
Prior to attempting any position make sure you stand
manoeuvring of the plant the well clear of the plant but are
tracks must be free of in a position to have all-round
obstructions, including crushed vision to see any obstacles or
material and fines. Do not push hazards that may lie ahead e.g
or tow the plant. Failure to personnel, overhead cables,
observe this warning could ditches, unsafe roadways etc.
result in serious injury to (Refer to Figure 2a
persons and damage to the plant Dimensions)
which may invalidate warranty.
• Make sure that you do not manoeuvre
Particular care must be taken your 1000SR on a gradient steeper than
when manoeuvring the plant 10 degrees in transportation mode (5
with the re-circulating and/or degrees maximum in operating
stockpile conveyors in their mode) or damage may occur to the
operating positions to avoid engine and/or plant.
damaging the tail drum
section(s) on uneven ground. • Avoid manoeuvring the plant over uneven
ground or damage may occur.
• Before manoeuvring the plant, ensure
the feed hopper and crusher are empty • Control valves mounted on the engine and
and shut down the plant (Section 8). beneath the feeder are NOT to be used
to manoeuvre the plant. They are for use
• The plant cannot be manoeuvred in the by BL-Pegson Service Engineers only.
PLANT mode of operation.
• Initial start up in cold weather may
• The safety warning horn sounds result in a tendency to steer to the right
continuously whilst the plant is being whilst tracking fast forward due to the
manoeuvred. hydraulic oil being cold. Run the plant
for approx. 10 minutes with the
DO NOT stand on any of the conveyor and feeder running prior to
platforms or ladders of the manoeuvring the plant.
plant whilst it is being
manoeuvred using the remote • When transporting the 1000SR, it is
control handset. the responsibility of the haulage
contractor to safely secure the plant
to the transporter.
1000SR
Page 6
5.2.1 Manoeuvring
To manoeuvre the 1000SR with the
WARNING
remote radio hand set (where WEAR PERSONAL
fitted):- PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
Information for relevant
The plant is manoeuvred using the remote warning.
hand held radio transmitter control unit (Fig
5b). This hand set also has the facility to
switch the plant feeder on and off whilst the
plant is in the crushing mode.
Procedure Note: The transmitter has a built in safety

function that prevents another function from
involuntary cutting-in when the transmitter
1. Observe all safety instructions.
starts. The transmitter will not start if a
button is stuck in the activated position.
2. Check that all Emergency Stop push
This is indicated by the red LED coming on.
buttons are pulled out (Figure 1a)
otherwise the engine cannot start.
5. Ensure the engine Isolation Switch
(Figure 5a) is turned to the I position.
3. Take the Remote Control Hand Set
from the Control Box and first become
familiar with the functions of all the
individual buttons (Figure 5b) before the
next step.
Forward = Product Conveyor first
Reverse = Hopper first
4. To start up the handset transmitter first

stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:-
• Ensure the stop button is pulled out.
• Depress both of the safety buttons
(Fig.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 Figure 5a Isolation Switch
when the green LED comes on.
1000SR
Page 7
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
Rotate clockwise, track 1 forward, track 2 (Horn) (Feeder On/Off)
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
For more information on the Radio Hand Set see Section 5.3 of this manual.
Figure 5b Remote Control Hand Set
1000SR
Page 8
Plant Control Panel Engine Control Panel
Figure 5c Control Box
Variable Function buttons

Radio Mode button (current functions shown on screen above) Escape button
Figure 5d Selection Screen Display
1000SR
Page 9
6. On the engine control panel (Figure 5c),

insert the engine Ignition Key and turn WARNING
only to the first position. The pre-start
WEAR PERSONAL
audible warning will sound for 10 PROTECTIVE EQUIPMENT.
seconds during the SYSTEM START Refer to Section 5.1, Safety
DELAY before the initial screen display Information for relevant warning.
appears on the Control Panel (Figure
5d).
7. Press the F1-RADIO MODE then

F6-TRACK MODE buttons for the
LEDs to illuminate to confirm active
status.
8. Fully turn the Ignition Key to start the

engine. Release the key to the first
position when engine running. Keep the
engine speed at 1200 rpm
9. Press the hand set Horn button for 5

seconds to sound the safety warning
horn. This will also ready the tracks for
manoeuvring.
10. The radio handset directional buttons

(forward, reverse and turn) are double
pressure switches with the initial
pressure operating the slow speed
mode and depressing further operates
the higher speed. Press the buttons to
manoeuvre the plant in the desired
direction (Figure 5b). Employ the ‘Fast’
speed only where safe to do so.
Pressing the Stop button at any time will

immediately halt the operation and cut
out the engine but it is necessary to
manually switch off the engine ignition
(Section 8.2).
1000SR
Page 10
11. When the plant is in the desired

position, press the Horn button to turn WARNING
the safety warning horn ‘OFF’ and
WEAR PERSONAL
disengage the tracks. PROTECTIVE EQUIPMENT.
12. If not required further, switch off the Information for relevant warning.
engine ignition. To shut down the radio
handset transmitter, push in the stop
button. Lock out the hand set when
finished with to prevent unauthorised
use.
1000SR
Page 11
5.2.2 Unloading
The 1000SR 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. Information for relevant warning.
Once the plant is unloaded and crushing

operations are to follow, it is necessary to
prepare the plant by following the Set Up
procedures (Section 6).
Procedure
1. Observe all safety warnings.
2. Position easy slope ramps at the end of

the transporter to help with unloading of
the plant.
When manoeuvring the

1000SR on or off a transport
trailer or at a sharp change in
gradient, make sure that the
overhanging screen support
structure does not foul on the
ground. The maximum
clearance is 550mm (22”).
3. Manoeuvre the plant off the transporter

and into the desired position (Section
5.2.1). Refer to Section 6 for the Set
Up procedures.
1000SR
Page 12
5.2.3 Loading - from re-circulating

mode WARNING
If the 1000SR has been in crushing WEAR PERSONAL
operation it must be suitably prepared prior PROTECTIVE EQUIPMENT.
Refer to Section 5.1 Safety
to transportation. This mainly involves Information for relevant warning.
repositioning the conveyors from the way
they operate and, very importantly, FALLING HAZARD.
securing all equipment to prevent movement Refer to Section 5.1 Safety
during transportation. Information for relevant warning.
Procedure
Prior to transportation always
1. Observe all safety warnings. check the plant for loose or
damaged components.
2. Ensure that all the conveyors, feed
hopper and crusher are free from stone Fasten all loose parts, replace
and dirt. missing items or make repairs
as found necessary to ensure
3. Bolt the 2 (or 4) off anti-rock stays at that all components are safely
the screen spring mountings on both secured during transportation.
sides of the machine (Figure 5e).
In step 5, it is most important
4. Unbolt and remove the discharge chutes to check that the locking pins
from both transfer conveyors. (Figure 5f) on both Side
Transfer Conveyors are fully
5. Manually slide each Side Transfer inserted into their respective
Conveyor into it’s travelling position by holes to ensure the conveyors
pulling out the spring loaded locking pin. do not break free during
Retract the conveyors into the plant until transportation.
the locking pins can be fully inserted into
the holes provided and also that both
hinged travel straps are secured to the
brackets with the safety pins (Figure 5f).
continued overleaf......
1000SR
Page 13
Detachable transport stay
Figure 5e Screen Anti-Rock Stays

Travel Straps
Spring loaded
Locking Pins
Figure 5f Transfer Conveyor travelling positions
1000SR
Page 14
6. Locate the control box and raise the

cover to reveal the control panel and WARNING
engine control panel (Figure 7b).
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
7. Start the engine (Section 7.2.1). Keep Refer to Section 5.1 Safety
the engine speed at 1200rpm, Information for relevant warning.
8. At the control panel (Figure 5d) press FALLING HAZARD.

the F4-SET UP button for the LED to Refer to Section 5.1 Safety
illuminate to confirm active status with Information for relevant warning.
the message ‘PROCEED TO SET UP
STATION’. This is situated on the
opposite side of the plant (Figure 5g).
Note: The controls for all services are a

two handed operation and will only
operate if the FUNCTION ENABLE
button is pressed and held whilst
pressing any of the Set Up buttons. The
audible warning will sound whenever
the enable button is pressed.
9. Pressing and holding the enable button,

press the RECIRC CONVEYOR
RAISE button sufficient to disengage
the support bar (Figure 5h) and lift the
head of the conveyor away from the re-
circ. chute.

press the FEED CONVEYOR RAISE
button briefly to take the weight off the
locating pins in the telescopic legs
(Figure 5h). Ensure controls cannot be
operated whilst carrying out next step.
continued overleaf......
1000SR
Page 15
Function Enable Button
Recirc Chute
(Support Brace removed)
Figure 5g Set Up Control Station

Locating Bar (hidden)
Triangular Barge Board
Barge Board
Extensions
Transport Stay
Brackets
Chute Support Brace (fitted)
Feeder Telescopic
Support Leg Pin
Automax Feed Box

Back Plate Figure 5h Recirc Conveyor Head
1000SR
Page 16
11. Manually lower the backplate of the

Automax feed box (Figure 7h). On the WARNING
Feed Conveyor telescopic support legs
WEAR PERSONAL
remove both locating pins and place in PROTECTIVE EQUIPMENT.
the adjacent carriers and secure with Refer to Section 5.1 Safety
the spring clips. Information for relevant warning.
At this time, unbolt and remove the FALLING HAZARD.

triangular barge board extension plate Refer to Section 5.1 Safety
Information for relevant warning.
below the re-circulating chute. Also the
barge board extensions on both sides of
the feeder if minimum transport
dimensions are desired.
Detach the bottom end only of the chute

support brace (Figure 5h).

press the RE-CIRC CHUTE LOWER
button until the chute is fully lowered.

press the FEED CONVEYOR
LOWER button until the feeder is fully
lowered. Transport Stays

press the RE-CIRC CONVEYOR
LOWER button until the securing pin
can be located through the eye of the
hinged transport stay (Figure 5i).
15. Secure the re-circulating chute with the

transport stay to the support brace
bracket (Figure 5i).
It is most important both the

conveyor and chute are
secured by the transport stays
Figure 5i Re-circulating Conveyor
for safety and stability reasons. and ChuteTransport Stays
1000SR
Page 17
Prior to transporting the

1000SR ensure that the weight WARNING
of the screen is lowered onto
WEAR PERSONAL
the support pins (Figure 5j). To PROTECTIVE EQUIPMENT.
do this make sure the pin on Refer to Section 5.1 Safety
each side is in place and Information for relevant warning.
operate the SCREEN LOWER
button. This ensures the load is FALLING HAZARD.
taken on the pins rather than Refer to Section 5.1 Safety
the internal hydraulic rams.
Only lower the Automax Feed

Box level sensor mast if it is
required to achieve the
minimum height dimension.
Hydraulic rams inside support leg
15. Position easy slope ramps at the end of
the transporter to help with loading of
the plant.
When loading the 1000SR on

or off a transport trailer or at a
sharp change in gradient,
make sure that the
Pin
overhanging screen support
structure does not foul on the
ground. The maximum
clearance is 550mm (22”).
Figure 5j Screen Support Pins
16. Manoeuvre the plant onto the
transporter and shut down and
implement the lockout procedure.
(Section 8.2).
17. Securing the plant to the transporter

is the responsibility of the haulage
contractor.
1000SR
Page 18
5.2.4 Loading - from conveyor

stockpiling mode WARNING
Dismounting on-plant conveyor(s) WEAR PERSONAL
from the stockpiling mode PROTECTIVE EQUIPMENT.
involves the use of suitable Information for relevant warning.
craneage and slinging expertise in
addition to the employment of
skilled erection engineers to
carry out the task of both
mounting and dismounting.
Undertake only in these
circumstances, making sure a
Risk Assessment exercise is
carried out prior to
commencing the work.
The procedure is generally the

reverse of that described in Set
Up, Section 6.2.2
5.2.5 Conveyor Weights

Recirculating Conveyor - c1320kg.
(1.46 US. tons)
Stockpile Conveyor - c1160kg.

(1.28 US. tons)
1000SR
Page 19
5.3 Remote Control Hand Set
5.3.1 Radio Hand Set (where fitted)

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

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

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

work with either 840 or 860 receivers
(Dealer function).
• Enhanced reliability.
Transmitter’s Use NiMh batteries instead of

NiCd, which means the following:- TRANSMITTER 860TX-PEG
• Input charging voltage is now 12VDC

to 35VDC instead of 12/24VDC, no
Buttons 1 to 4 = Used for plant directional
universal adapter required.
control
• Battery capacity is changed from Buttons 1 to 9 and 0 = Used for signal

800mA to 2000mA.(Charging time frequency programming (factory preset -
from completely empty battery is now contact Dealer for change)
approximately 4 hours).
Buttons 9 and 0 = Used to activate the
radio hand set transmitter
• Operating time with fully charged
battery is approximately 30 hours. Button 9 = Used to activate the audible
warning horn
Button 0 = Used to stop / start the plant

feeder (where appropriate)
1000SR
Page 20
2 versions of the 860 system transmitter will

be supplied, one for European Operations WARNING
and one for the Rest of the World. The only
WEAR PERSONAL
difference is that the European version will PROTECTIVE EQUIPMENT.
include a black stop button. The Rest of the Refer to Section 5.1, Safety
World transmitter will feature a Red Stop Information for relevant warning.
button. Channel 01 (434.650 MHz)
through channel 16 (433.900 MHz)
available in .050 MHz steps. Refer to
Dealer if frequency change needed.
Battery Recharging
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 Charging point
continuous operation remaining) and
indicates it is time to recharge. The plant
warning horn will also sound when Figure 5k Remote Control
battery recharging is required. Charger Connection
1000SR
Page 21
• To conserve the battery charge the hand

set should be switched off when not in WARNING
use.
WEAR PERSONAL
1000SR
Page 22
5.3.2 Alternative Control Hand Set

with Umbilical Cable (where fitted) WARNING
An alternative hand set with umbilical cable WEAR PERSONAL
is provided to manoeuvre the 1000SR plant PROTECTIVE EQUIPMENT.
(Figure 5l). This hand set is located in the Information for relevant warning.
Control Box.
Connecting and using the

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

5m) on the Control Panel. Release the
retaining clip and remove the multi pin
plug in situ (only where radio unit
fitted). Replace with the umbilcal lead Figure 5l Umbilical Control Hand Set
plug and secure with the retaining clip
(Figure 5m).
4. Ensure the engine Isolation Key (Figure

5a) is turned to the I position.
5. On the engine control panel (Figure 7b),

insert the engine Ignition Key and turn
only to the first position. Wait 8/10
seconds until the initial screen display to
appear on the Control Panel (Figure
7d).
6. Standing clear of the tracks, press

the TRACK MODE button.
Figure 5m Umbilical Connection Point
1000SR
Page 23
7. Fully turn the Ignition Key to start the

engine. Release the key to the first WARNING
position when engine running. Keep the
WEAR PERSONAL
engine speed at 1200 rpm. PROTECTIVE EQUIPMENT.
8. Press the Horn button for 5 seconds to Information for relevant warning.
sound the safety warning horn. This will
also ready the tracks for manoeuvring.
9. The umbilical handset directional

buttons (forward, reverse and turn) are fitted). Store the umbilical hand set unit
double pressure switches with the initial in the tool box to keep available for
pressure operating the slow speed future use,
mode and depressing further operates
the higher speed. Extreme care must be used
when manoeuvring the plant
Pressing the Stop button at any time will with the umbilical control hand
immediately halt the operation and cut set. Stand as far away as
out the engine but it is necessary to possible from the plant. Do not
manually switch off the engine ignition allow the cable of the hand set
(Section 8.2) (and disengage the manual to sag and become entangled
clutch if applicable). with the tracks.
10. 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 5n).
Employ the ‘Fast’ speed only where
safe to do so.
11. When the plant is in the correct

position, press the Horn button to turn
the safety warning horn ‘OFF’ and
disengage the tracks. Shut down the
plant with the hand set stop button. Turn
off the engine ignition.
12. Unplug the umbilical cable and replace

with the original plug (where radio unit
1000SR
Page 24
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 5n Remote Umbilical Control Hand Set
1000SR
Set Up Issue EN 01
Page 1
Contents
6.2 Setting Up ............................................................................................................ 5

6.2.1 Set Up - Re-circulating Mode .......................................................................... 5
6.2.2 Set Up - Transfer Conveyors .......................................................................... 11
6.2.3 Set Up - Conveyor(s) mounted in Stockpiling mode .......................................12
6.2.4 Conveyor Weights ......................................................................................... 13
1000SR
Set Up Issue EN 01
Page 2







1000SR
Set Up Issue EN 01
Page 3

HAZARD
machine.


HAZARD
injury.



1000SR
Set Up Issue EN 01
Page 4

followed.
LOCKOUT PROCEDURE

lockout.
1000SR
Set Up Issue EN 01
Page 5
6.2 Setting Up
WARNING
Plant Location Considerations WEAR PERSONAL
Prior to setting up your 1000SR, Refer to Section 6.1 Safety
consideration should be given to a suitable Information for relevant warning.
layout to prevent oversize material or tramp
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 BL-Pegson
should be fed into the plant.
Position the plant in a safe and level operating

position making sure both tracks are in full
contact with the ground to minimise
movement of the plant. 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 free
of large stones etc. which may cause belt
damage.
Procedure
Transport Stays
6.2.1 Set Up - Re-circulating Mode

2. Remove the pin from the hinged transport

stay on the re-circulating conveyor and
also the pin securing the recirc chute
transport stay (Figure 6a).

cover to reveal the control panel and
engine control panel (Figure 6c).
Figure 6a Re-circulating Conveyor
continued overleaf.......... and Chute Transport Stays
1000SR
Set Up Issue EN 01
Page 6
4. Start the engine (Section 7.2.1) but it is

not necessary to switch on the Radio WARNING
Remote Hand Set. Keep the engine
WEAR PERSONAL
speed at 1200rpm. PROTECTIVE EQUIPMENT.
5. At the control panel (Figure 6d) press Information for relevant warning.
the F4-SET UP button for the LED to
illuminate to confirm active status with FALLING HAZARD.
the message ‘PROCEED TO SET UP Refer to Section 6.1 Safety
STATION’. This is situated on the Information for relevant warning.
opposite side of the plant (Figure 6b).

button is pressed and held whilst
pressing any of the Set Up buttons. The Function Enable Button
audible warning will sound whenever
the enable button is pressed.

press the button RE-CIRCULATING
CONVEYOR RAISE until the
conveyor is at maximum height.

press the button FEED CONVEYOR
RAISE enough for the support pins
(Figure 6f) to be inserted.

press the button RECIRC CHUTE
RAISE until the chute is fully raised.
Ensure the controls cannot be operated
whilst carrying out the next step.
Figure 6b Set Up Control Station
continued overleaf..........
1000SR
Set Up Issue EN 01
Page 7
Plant Control Panel Engine Control Panel
Figure 6c Control Box

Radio Mode button (current functions shown on screen above) Escape button
Figure 6d Selection Screen Display
1000SR
Set Up Issue EN 01
Page 8
9. Locate the re-circulating chute support

brace to the bracket on the feeder WARNING
support and secure with the safety clips.
WEAR PERSONAL
Bolt on the triangular barge board PROTECTIVE EQUIPMENT.
extension plate (below the re-circulating Refer to Section 6.1 Safety
chute) and manually raise the Automax Information for relevant warning.
Feed box backplate and secure. Insert
the locating pins in the telescopic feeder FALLING HAZARD.
support legs and fit the security clips. Refer to Section 6.1 Safety
Refit the barge board extensions to both
sides of the feeder if these have been
removed to achieve minimum travel
dimensions.

press the FEED CONVEYOR
LOWER button until the conveyor is
resting on the locating pins.

press the RE-CIRCULATING
CONVEYOR LOWER button until the
support bar at the conveyor head
locates fully into the gussets on the feed
chute but with the wire rope is still taut.
12. Switch off the engine (Section 8.2) and

implement the lockout procedure .
13. Remove the travel strap and slide the

upper transfer conveyor into it’s
working position by pulling out the
spring loaded locking pin. Push the
transfer conveyor towards the re-
circulating conveyor to allow the locking
pin to locate into the second hole from
Figure 6e Recirc Conveyor Tail
the end. Ensure the locking pin is fully
inserted into the hole..
continued overleaf..........
1000SR
Set Up Issue EN 01
Page 9
Recirc Chute
(Support Brace removed)
Locating Bar (hidden)

Triangular Barge Board
Barge Board
Extensions
Transport Stay
Brackets
Chute Support Brace (fitted)
Feeder Telescopic
Support Leg Pin
Automax Feed Box Figure 6f Recirc Conveyor Head

Back Plate
1000SR
Set Up Issue EN 01
Page 10
14. Hang the discharge chute (complete

with rubber curtain) (Figure 6e) for WARNING
upper transfer conveyor onto the
WEAR PERSONAL
mounting bolts and tighten. PROTECTIVE EQUIPMENT.
15. Position the lower transfer conveyor to Information for relevant warning.
suit the operating configuration, either
for material stockpiling or for re- FALLING HAZARD.
circulating (Section 6.2.2) Arrange the Refer to Section 6.1 Safety
chutework to suit. Information for relevant warning.
17. Remove the 2 (or 4) anti-rock stays at

the screen spring mountings on both
sides of the machine (Figure 6g).
Detachable transport stay
Prior to operating the 1000SR

ensure that the weight of the
screen is lowered onto the
support pins (Figure 6h). To do
this make sure the pin on each
side is in place and operate the
SCREEN LOWER button.
This ensures the load is taken
on the pins rather than the
internal hydraulic rams.
Figure 6g Screen Anti-Rock Stays
Hydraulic rams inside support leg
Pin
Figure 6h Screen Support Pin

(left hand side only shown)
1000SR
Set Up Issue EN 01
Page 11
6.2.2 Set Up - Transfer Conveyors

Provision is included for two transfer
WARNING
conveyors taking material discharging from WEAR PERSONAL
the upper and lower screen decks. Both are PROTECTIVE EQUIPMENT.
mounted on sliding frames for repositioning Information for relevant warning.
in either transport or operating modes.
FALLING HAZARD.
The upper conveyor receives the oversize Refer to Section 6.1 Safety
material from the top deck of the screen Information for relevant warning.
and discharges into the feed boot of the
recirculating conveyor for recrushing. The
conveyor slides across from the transport
position for an efficient material transfer
(Figure 6e) and is locked in position with a
spring loaded pin. A secondary pin location Spring loaded
Travel Straps Locking Pins
hole is provided for when the recirculating
conveyor is used for stockpiling (Section
6.2.3).
The optional lower transfer conveyor takes

material from the bottom deck of the screen
and can be used in 2 alternative positions.
Positioning to discharge to the same side of
the plant as the upper transfer conveyor it
will pass material to the recirculating
conveyor. Alternatively, by removing the
complete conveyor (weight approx.325kg.)
and turning round, it will discharge to the
opposite side of the plant where the
material can be stockpiled via the optional
stockpile conveyor (Section 6.2.3). In a
similar fashoin to the upper conveyor, a
spring loaded pin is provided for accurate
and secure location of the conveyor.
Figure 6i Transfer Conveyor travelling positions
1000SR
Set Up Issue EN 01
Page 12
6.2.3 Set Up - Conveyor(s) mounted Before repositioning the re-circulating

in Stockpiling mode conveyor, retract the upper side transfer
conveyor, first removing the discharge chute
Fitting plant mounted conveyor(s) and also fully lower the return chute. In
to stockpile material involves order to reposition the re-circulating
the use of suitable craneage and conveyor it is first necessary support the
slinging expertise in addition to conveyor with suitable lifting equipment and
the employment of skilled appropriate length slings using both the
erection engineers to carry out upper and lower lifting points (Figure 6k).
the task of both mounting and Operate the CONVEYOR LOWER
dismounting. Undertake only in control (Section 6.2.1) to fully extend the
these circumstances, making wire rope hydraulic cylinder. Disconnect the
sure a Risk Assessment conveyor at the upper stay, pivot point and
exercise is carried out prior to at the quick release hydraulic couplings so
commencing the work. that the unit can be lifted clear of the plant.
The plant design includes the facility to
Using the separate bracket kit supplied,
alternatively use the plant mounted re-
bolt to the plant structure (Figure 6j).
circulating conveyor as a stockpile
Position the conveyor at right angles to the
conveyor. This involves lifting the conveyor
plant and drop the tail locating bar into the
off the plant and remounting the tail end at
brackets. Operate the CONVEYOR
right angles whilst the head is suspended
RAISE control (Section 6.2.1) so that the
with the same wire rope system used when
tie bar (supplied as part of the separate kit
re-circulating. This conveyor takes material
of parts) can be secured in position. Do not
from the upper side transfer conveyor but,
operate the plant without this tie bar being
additionally if required, also from the lower
fitted. Do not press CONVEYOR RAISE/
transfer conveyor.
LOWER buttons once the tie bar is fitted as
damage will result. When the conveyor is
Additionally, a similar conveyor is available
fully supported off the plant and all security
as an optional extra which can be mounted
pins are in place, disconnect the lifting gear
in the same fashion on the opposite side of
slings.
the plant to form a stockpile for material
discharging from the lower side transfer
Reconnect the hydraulic hoses at the quick
conveyor. This conveyor assembly requires
release couplings. Pull out the upper (or
transporting separately from site to site.
lower) side transfer conveyor and refit the
chutework. Test for correct running, belt
Setting up the plant mounted stockpile
tracking, etc. before crushing operations.
conveyor(s) is an operation carried out
once the plant is in the operating position.
The optional stockpile conveyor is supplied
The plant should not be moved with the
with a kit of parts to fit in a similar fashion.
conveyor(s) suspended out from the plant.
1000SR
Set Up Issue EN 01
Page 13
Detachable Brackets for

mounting the conveyor
tail
Security Bolts - must be

fitted before operation
Figure 6j Stockpile Conveyor Tail Mounting
Cranage lifting slings Wire Rope Support with

hydraulic cylinder
Tie Bar (hidden on far side)

- must be fitted before
operation
6.2.4 Conveyor Weights

Recirculating Conveyor - c1320kg.
(1.46 US. tons)
Stockpile Conveyor - c1160kg.

(1.28 US. tons)
Figure 6k Positioning the Conveyor for Stockpiling
1000SR
Set Up Issue EN 01
Page 14
Blank page
1000SR
Operating Instructions Issue EN 01
Page 1
Contents
7.1 Safety Information ............................................................................................................ 2
7.1.1 Blocked Crusher Procedures ..................................................................................... 4
7.1.2 Safe Operation of the plant ......................................................................................... 5
7.1.3 Checks at Initial Start-Up ............................................................................................ 6
7.2 Plant Operation ................................................................................................................ 7
7.2.1 Engine Start ................................................................................................................ 8
7.2.2 Plant Start (except Feed Conveyor) .......................................................................... 13
7.2.3 Feed Conveyor Controls ........................................................................................... 15
7.2.4 Plant Control Panel ................................................................................................... 16
7.2.5 PLC Screen Command Messages ........................................................................... 18
7.2.6 Plant Operating Sequence and Automatic Safeguards ............................................ 19
7.2.7 Fault Indication and Restart ...................................................................................... 20
7.2.8 Preparations prior to using Automax controls ........................................................... 20
7.2.9 Automax/Plant Alarm Messages List ........................................................................ 21
7.2.10 Metal Detection ....................................................................................................... 23
7.2.11 Feed Conveyor Remote Operation ......................................................................... 23
7.2.12 Crushing Material - Plant and Automax Settings ..................................................... 24
7.2.13 Plant Initial Start Up and Running In ........................................................................ 25
7.2.14 Daily Plant Checks ................................................................................................. 27
7.3 Automax Operation ........................................................................................................ 28
7.3.1 Glossary of Automax Parts ....................................................................................... 31
7.3.2 Glossary of Automax Terms ..................................................................................... 31
7.3.3 Daily Automax Checks.............................................................................................. 32
7.3.4 Actions during running in ........................................................................................... 34
7.3.5 Automax Automatic Overload Release/Unblocking and Resetting ........................... 35
7.4 Automax Management ................................................................................................... 36
7.4.1 Automax Initial Discharge Setting and Calibration .................................................... 36
7.4.2 Automax Manganese Wear Calibration .................................................................... 38
7.4.3 Automax Discharge Setting Adjustment ................................................................... 40
7.4.4 Manual Raising/Lowering of the Automax Upper Frame ........................................... 42
7.4.5 Checking Automax Wedge Pressure ....................................................................... 44
7.4.6 Automax/Plant Data Screens .................................................................................. 46
7.5 Feed Conveyor Management ....................................................................................... 48
7.5.1 Automatic Mode ........................................................................................................ 48
7.5.2 Manual Mode ............................................................................................................. 49
7.6 Level Sensor Management ........................................................................................... 50
7.6.1 Level Sensor Control ................................................................................................ 50
7.6.2 Hopper Level Sensor (Optional)................................................................................ 51
1000SR
Page 2

followed.
LOCKOUT PROCEDURE

lockout.
signs (ie. ‘TAG OUT’).

HAZARD
injury.



1000SR
Page 3





whilst it is in operation.



HAZARD
machine.

1000SR
Page 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
Unblocking stalled crushers become wedged and under considerable
can be hazardous. Do not pressure. In order to release the tramp metal it
undertake without careful risk is necessary to take the pressure off it and at
assessment this time it can be ejected from the machine
with catastrophic consequences
In order to avoid the Automax cone crusher
becoming blocked the machine is equipped A cone crusher can become ‘bridged’ when
with an automatic hydraulic release oversize material is fed into it. In the event of
mechanism to raise the upper frame when this happening the feed conveyor should be
excessively high crushing pressure is stopped immediately. An attempt to clear the
sensed. The upper frame automatically machine can be made by raising the upper
returns to the original setting when the frame by putting the machine into ‘manual’
foreign object should have been released and pressing ‘open’. Should this not open
through the machine. However, unduly large sufficiently to allow the stone to drop through
uncrushable objects may stall the crusher then it will be necessary to isolate the machine
and become tightly wedged in the crushing and remove the rock or break up the stone
chamber. manually with a hammer and chisel.
The clearing of blocked crushers should be In the event that the crusher should stall
given considerable thought prior to whilst crushing due to an overload or
attempting to unblock a crusher. These blockage, the crushing chamber will be full
procedures should be considered under risk of stone and the feed conveyor should be
assessment review for the implementation of stopped immediately. This should then be
a procedure of safe working practice for released by raising the upper frame as
this operation. before and letting the material fall through.
After the machine has stalled, prior to
There is a document entitled ‘Clearing
resetting, the reason why the machine has
Blocked Crushers’ available from the
stopped should be investigated. In the case
British Aggregate Construction Materials
that a piece of tramp metal is in the machine
Industries (BACMI) which gives more
extreme care should be taken whilst
details about this and covers in more detail
releasing it. To avoid the tramp metal being
risk assessment areas. Tramp metal is a
ejected it may be necessary to fill the
serious problem when it enters a crusher as
opening to the machine with stone whilst the
this can cause more problems than oversize
pressure is released.
or hard stone.
Check the machine for possible damage
EVERY EFFORT MUST BE MADE TO
(particularly the manganese) before
REMOVE TRAMP METAL FROM
resuming operations.
THE FEED MATERIAL
1000SR
Page 5
7.1.2 Safe Operation of the plant

Before attempting to operate
WARNING
the 1000SR plant. DO read, WEAR PERSONAL
fully understand and observe PROTECTIVE EQUIPMENT.
the contents of this manual. Information for relevant warning.
Also any other relevant
manual for other equipment
LOCKOUT PLANT.
incorporated in the plant, eg.
Engine manual. Information for Lockout
Procedure.
BL-Pegson Ltd cannot
overemphasize the need to FALLING HAZARD.
ensure that all safety aspects Refer to Section 7.1 Safety
are checked before starting
the machinery.
NEVER leave the plant

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

stability of the plant. The
chassis SHOULD NOT have
undue vibration during
operation.
1000SR
Page 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 Information for relevant warning.
removed from the immediate area.
LOCKOUT PLANT.
• Inspect the complete plant to check for
fluid leaks, loose connections, damage Information for Lockout
or wear, build up of material, etc. etc. Procedure.
• Ensure that the crusher is empty of FALLING HAZARD.

material. Refer to Section 7.1 Safety
• Check levels of lubricant and hydraulic
oil are satisfactory on :-
- Automax lubrication tank

• Ensure that the Automax feed is both
- Automax hydraulic reservoir
satisfactory and not segregating in the
crushing chamber. Note: This applies to
• Carry out daily checks and inspections
all machine operations subsequent to
on the Plant (Section 7.2.14) and the
the running in period.
Automax crusher (7.3.3).
• Make sure that the crusher lubrication
• Check the alignment and tension of the
system is functioning correctly (Section
vee rope drive daily during the initial
9.5) and that no leaks are present.
days of operation as appropriate
• Check for leaks in the crusher hydraulic
• Avoid overloading the machine by not
system, both externally and inside the
using small discharge settings during the
hydraulic console.
first few days of operation.
• Ensure that the machine is running

correctly and that the satisfactory feed
is maintained at a constant rate (Section
7.2.3). Irregular and excessive feed
rates reduce the efficiency of the
Automax.
1000SR
Page 7
7.2 Plant Operation

WARNING
BL Pegson Ltd cannot WEAR PERSONAL
overemphasize the need to PROTECTIVE EQUIPMENT.
ensure that all safety aspects Refer to Section 7.1, Safety
are checked before starting Information for relevant
the engine. warning.
With the engine switched ‘OFF’
• Ensure that the plant is fully ‘Set Up’ in

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

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

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

crusher directly through a hydraulically
activated clutch and a vee rope drive. Within
the engine canopy the engine also powers the
three 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).
1000SR
Page 8
7.2.1 Engine Start

When operating the 1000SR in PLANT
WARNING
MODE the plant operator has the facility WEAR PERSONAL
to use the Radio Hand Set to switch the PROTECTIVE EQUIPMENT.
Feeder ‘on’ and ‘off’ remotely. For this Information for relevant warning.
purpose the Radio Hand Set must be
switched on prior to starting the engine in
the manner described below.
Procedure
button is stuck in the activated position.
This is indicated by the red LED coming on.
2. Check that all Emergency Stop push (Figure 7a) is turned to the I position.
buttons are pulled out (Figure 1a)
3. Take the Remote Control Hand Set

from the Control Box. See Figure 5b
for the button functions.

hand set with the stop button nearest to

(Fig.7i) at the same time for at least 1
Figure 7a Isolation Switch
• The transmitter is in function status
when the green LED comes on.
Note: The transmitter has a built in safety

function that prevents another function from
involuntary cutting-in when the transmitter
starts. The transmitter will not start if a
1000SR
Page 9
6. On the engine control panel (Figure 7b), 8. Fully turn the Ignition Key to start the
insert the engine Ignition Key and turn engine. Release the key to the first
only to the first position. The pre-start position when engine running. Keep the
audible warning will sound for 10 engine speed at 1200 rpm.
seconds during the SYSTEM START
DELAY before the initial screen display To avoid damaging the clutch
appears on the Control Panel (Figures DO NOT increase the engine
7d & 7e). speed to the operating 1800
RPM until after starting the
7. Press the F1-RADIO MODE >> F5- Crusher (Section 7.2.2).
PLANT MODE buttons for the LEDs
to illuminate to confirm active status.
Maintenance Due Lamp Diagnostic Lamp
Tachometer Diagnostic Display
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Figure 7b Engine Control Panel
1000SR
Page 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
1000SR
Page 11
Engine Diagnostic Functions - EMS Main Unit, continued
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 7b).
1000SR
Page 12
Figure 7d Mode Selection Screen and Automax Pressure Gauge
Figure 7e Plant Mode Screen
Figure 7f Plant Mode Screen continued
1000SR
Page 13
7.2.2 Plant Start (except Feed

Conveyor) WARNING
Prior to commencing the start WEAR PERSONAL
procedure ensure all personnel PROTECTIVE EQUIPMENT.
are clear of the plant. Information for relevant
warning.
From the Mode Selection screen (Figure
7d) select F5-PLANT MODE for the Plant
Mode screen to be displayed. The system
can now be operated in the normal
sequence as described below.
Operation of each button sounds the pre

start alarm for 3 seconds and flashes the The OUT OF SEQUENCE
associated LED before running the item. facility button is NEVER to be
The LED will then show continuous used in normal operation and,
illumination to confirm the item is enabled. when pressed, the message
‘warranty invalid’ will be
Start the conveyors and screen in sequence displayed.
left to right on the screen. The oil pump can
be started independent of this sequence.
Procedure
2. Press the button F-3 CONVS to start

the transfer conveyor(s) and the
recirculating conveyor.
3. Press the button F4-SCREEN &

FINES to start the vibrating screen and
fines conveyor.
3. Press the button F5-PROD CONV. to

start the on plant conveyor taking the
continued on next page.................
1000SR
Page 14
crushed product from the Automax to

the screen. WARNING
WEAR PERSONAL
4. Press the button F6-OIL PUMP to PROTECTIVE EQUIPMENT.
start the Automax oil lubrication pump. Refer to Section 7.1, Safety
The oil pump can be started at any time warning.
if required as there is now a 5 minute
delay before the crusher can be started.
This allows time for good oil circulation
within the Automax crusher before start
up of the machine. The display shows
the time delay as a time elapsed bar. If
the pump has been stopped less the 10
minutes the delay is reduced to 30
seconds.
Note: In cold weather, prior to starting

the oil pump, preheat the lubricating oil
by running the engine which is fitted with
a heat exchanger for this purpose.
5. Press the button F7-MORE >> to

continue. Ignore ALL CONVS and
OIL PUMP as these are used to stop
these items.
6. Press the button F5-CRUSHR to start

the Automax crusher..
7. Increase the engine speed control

(Figure 7b) to the operating engine
speed of 1800 rpm before starting to
feed material to the crusher.
8. Read Section 7.2.3 before starting the

feed conveyor with the button
F6-FEEDER (Figure 7f).
1000SR
Page 15
7.2.3 Feed Conveyor Controls

THE FEED CONVEYOR HAS TWO DANGER
METHODS OF OPERATION:- ENTANGLEMENT HAZARD.
- AUTO Information for relevant warning.
- MANUAL
The feed conveyor should be operated in

the AUTO mode where the feed rate to the support under the tracks. Rectify
crusher is regulated automatically by the immediately.
level sensor mounted over the Automax
feed box, whereas in MANUAL the • Ensure that the feed conveyor maintains
conveyor speed has to be regulated from a ‘choke’ feed (Section 7.3.2) to the
the Control Panel (Section 7.5). crusher which, as far as possible, is
continuous and avoids stopping and
Either when operating in starting the feed conveyor during
AUTO mode or when manually crushing operations. A degree of
started, there is NO audible or adjustment is available to the operator
visual indication prior to the both in AUTO and MANUAL modes
feed conveyor starting to run. (Sections 7.5 and 7.6).
Before starting the feed • Ascertain that the product material is to

conveyor, check Section 7.2.12 the required specification and adjust the
Crushing Material, to ensure feed material (Section 3.6) and/or the
that the feed material and the Automax settings (Section 7.4.3) if
equipment settings are necessary.
suitable.
• Any fault occurring during plant running
• Where an optional level sensor is fitted stops the relevant items of plant
over the feed hopper the feed conveyor equipment and overwrites the message
will not start in AUTO mode if there is display with a fault alarm message
insufficient material in the feed hopper. (Section 7.2.9).
• Once the crushing of material has • Only in the exceptional case of AUTO
commenced check that the plant is operation failure should MANUAL
stable and with no undue vibration. The operation be used but in this event there
crusher is mounted on anti-vibration must be continuous manual monitoring
mountings and any undue vibration is of the feed into the Automax.
likely to be caused by unsatisfactory
1000SR
Page 16
7.2.4 Plant Control Panel

The PLC control unit has an LCD screen displaying messages and data selected via soft touch
buttons. Start the engine (Section 7.2.2) when operating the controls to avoid draining the battery.
Button F1 is selected when using the the remote radio handset. The screen display and the button
functions change depending on the operation being carried out. F8-Escape returns the display to a
previous screens as appropriate. When starting to run any of the equipment there is 3 second audible
warning and the LED will flash after the button is pressed. Thereafter the LED shines continuously to
indicate the active status of the selected item. During crushing operations information is displayed as
shown on the screen illustration below (Figure 7g). Access to view other information screens is
available by pressing F2 or F7-ADJUST. as described later.
CURRENT WEAR is the record, at the

most recent recalibration, of the SET GAP indicates the crusher setting
amount of manganese wear since the that has been selected by the operator
fitting of a new mantle and concave to obtain the desired material product
CURRENT GAP shown indicates position

of the Upper Frame above the zero point
LEVEL of material in
the Automax feed box
FEED RATE expressed

as % of maximum
Display showing the current

FEEDER STOP/START shows the
functions of the push buttons
settings of the automatic control
level sensor over the Automax
(or for the optional hopper sensor) Line where messages appear
Figure 7g Crusher and Feeder Control Screen

(illustrated in plant operating mode)
1000SR
Page 17
Adjust Mode plant for transportation - Section 5.
Select for Automax crusher operating Plant Mode

requirements - Section 7.
This is the mode in which the plant normally
Input the settings required prior to the operates and is selected for starting and
commencement of crushing. See Section 3 running the plant for crushing operations -
for guidance on Automax settings. Section 7.
Press the button below F2 or F7-ADJUST Track Mode

to access the Adjustment Mode Screen
Menu which is available at any time. It Selection enables the plant to be
allows change to the adjustable parameters manoeuvred on it’s tracks using the hand
relevant to the feed conveyor and Automax held remote control unit. - Section 5.
crusher and also for viewing certain
recorded data. Configuration Mode
Feed Conveyor - Section 7.5 The Configuration Mode is used by BL-

Automax Crusher - Section 7.4 Pegson to set the basic non adjustable
parameters at the time of manufacture and
Out of Sequence Mode is not available to the operator.
Used only in certain maintenance situations

where appropriate and safety prompted -
Section 9.
The OUT OF SEQUENCE

facility button is NEVER to be
used in normal operation and,
when pressed, the message
‘warranty invalid’ will be
displayed.
Set Up Mode
Select this mode when readying the plant

for operation from the condition in which
the plant is transported - Section 6 and also
the reverse operation when preparing the
1000SR
Page 18
7.2.5 PLC Screen Command Messages

When following the the start up procedure (Section 7.2.2), command messages appear on the
display screen (Figure 7e) to indicated next action necessary, unless there is a fault message which
overrides any message on the screen.
REF No: COMMAND MESSAGE DISPLAY

A SYSTEM START DELAY
B TRACKING MODE – ENSURE RADIO ON
C OUT OF SEQUENCE – WARRANTY INVALID
D PLANT START AVAILABLE
E START OIL PUMP
F CRUSHER START DELAY
G CRUSHER START AVAILABLE
H START DISCHARGE CONVEYOR
I START FEED CONVEYOR
J FEED CONVEYOR – RADIO STOP/START
K PLANT RUNNING
L CRUSHER BOWL – MATERIAL HIGH LEVEL
M FEED CONVEYOR – MATERIAL LOW LEVEL
N WARNING – CHANGE MANGANESE
O DANGER – REPLACE MANGANESE
1000SR
Page 19
7.2.6 Plant Operating Sequence If the oil pump stops the crusher and feed
and Automatic Safeguards conveyor are automatically stopped.
The plant operating sequence is as follows:- If the oil flow devices detect no flow or oil
pump not running the crusher and feed
I Transfer Conveyor(s) and Recirculating conveyor are automatically stopped.
Conveyor (plus optional Stockpile
conveyor if fitted). If the low oil level is detected the crusher
and feed conveyor are automatically
II Vibrating Screen and Fines Conveyor. stopped.
III Automax Discharge Conveyor (OPC). If any of the faults shown on the alarm list
(Figure 7.2.9) are detected by the sensors
IV Oil Lubrication Pump. Note: This can
the audible alarm will sound and the fault
be started first if required as there will
displayed on the screen. Depending upon
be a 5 minute delay before the crusher
the nature of the fault, some or all of the
can be started to ensure a good internal
equipment will be stopped.
flow of oil in the Automax. The 5 minute
delay is automatically reduced to 30
seconds if the crusher has been
operating within the last 10 minutes.
V Automax Crusher.
VI Feed Conveyor.
If the discharge conveyor stops the crusher

and feed conveyor are automatically
stopped.
If the discharge conveyor under the

Automax slows or stops, the speed wheel
sensor running on the conveyor belt will
detect this fault and automatically halt the
feed to the crusher.
If the crusher stops, the feed conveyor is

automatically stopped.
1000SR
Page 20
7.2.7 Fault Indication and Restart 7.2.8 Preparations prior to using

Automax controls
System faults cause an alarm to sound and
the fault will be shown on the Diagnostic • Observe all safety warnings.
Display Screen (Figure 7e) and the
appropriate equipment stopped. • Make the checks prior to starting the
plant (Section 7.1.3).
The alarm can be silenced by pressing the
button F3-ACKN ALARM but do not do • Check that the conveyors and Automax
this before reading the fault message on the crushing chamber are empty of material.
screen as the suggested remedial action
(second line) disappears once the button is • Check that all the Emergency Stops on
pressed. the plant (Figure 1a) are pulled out .
The displayed fault must be rectified before • Make sure that you fully understand the
the plant can be restarted. If the fault is not operating procedures for the Automax
corrected and the fault reset button has not (Section 7.3) before attempting to start.
been pressed the warning siren will sound
again after 5 minutes. • Ensure all personnel are clear of the
plant.
Follow the instructions on the display
screen to identify and deal with any faults • Start the plant diesel engine (Section
when they occur. Use the reference number 7.2.1) to provide hydraulic pressure.
as an easy way to identify a fault when
contacting BL-Pegson/Dealer’s Service
Department.
To deal with fault alarms caused by metal

detection refer to Section 7.2.10.
1000SR
Page 21
7.2.9 Automax/Plant Alarm Messages List
REF No: FAULT MESSAGE DISPLAY

1 EMERGENCY STOP FAULT – Check E/Stop Buttons, Twist to Reset
2 RADIO STOP FAULT – Check TRACK Radio & Umbilical buttons
3 HYDRAULIC OIL LOW – Check for Leaks & Top Up Hydraulic Oil
4 HYDRAULIC OIL COOLER CB TRIPPED Q2 – Reset Circuit Breaker Q2
5 LUBE OIL COOLER CB TRIPPED Q3 - Reset Circuit Breaker Q3
6 EMERGENCY STOP RELAY CB TRIPPED Q4 - Reset Circuit Breaker Q4
7 RADIO/TRACK CB TRIPPED Q6 OR Q7 - Reset Circuit Breaker Q6 or Q7
8 PLC I/O CB TRIPPED Q10 - Reset Circuit Breaker Q10
9 METAL DETECTOR CB TRIPPED Q11 OR Q12 - Reset Circuit Breaker Q11 or Q12
10 WEDGELOCK PRESSURE FAULT -
11 CRUSHER LUBE OIL HIGH TEMPERATURE – Contact BL-Pegson Ltd IMMEDIATELY
12 CRUSHER LUBE OIL LEVEL LOW – Check for Leaks & Top Up Lube Oil Level
13 CRUSHER LUBE OIL FILTER BLOCKAGE – Change Lube Oil Filters
14 CRUSHER LUBE OIL FLOW FAULT – No Lube Oil Flow – Check for Leaks
15 CRUSHER LUBE OIL LOW TEMPERATURE – Check Temperature Sensor
16 METAL DETECTED ON FEED CONVEYOR BELT – Remove METAL & Reset Metal Detector
17 DISCHARGE CONVEYOR UNDERSPEED – Check Discharge Conveyor – Stopped or Slow
18 CRUSHER HFO CLUTCH PRESSURE FAULT- Check Pressure Switch Setting
19
20 HYDRAULIC PUMP MAX RUN – Check Hydraulic System
21 TRAMP METAL OVERLOAD – Over Pressure Detected
22 GAP TOO LARGE – Check for Material Obstruction
23 IN MANUAL MODE TOO LONG – Select Automatic Mode to Reset
25 MANUAL TRAMP LATCH – Manual Tramp Overload Activated
26 TRANSDUCER FAULT – Check Supply/Connections/Short Circuits
27 CAN BLOCK ERROR – Check Supply/Connections/Short Circuits
28 CAN BUS ERROR – Check Supply/Connections/Short Circuits
29 OUTPUT ERROR – VALVE FAULT – Check last
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
1000SR
Page 22
7.2.10 Metal Detection

When metal is detected on the conveyor
WARNING
belt the audible alarm will sound (and also WEAR PERSONAL
the visible red fault light and diagnostic PROTECTIVE EQUIPMENT.
display will indicate) and the Feed Information for relevant warning.
Conveyor will stop.
FALLING HAZARD
Climb up to the top platform and remove Refer to Section 7.1, Safety
the offending metal from the conveyor and Information for relevant warning.
then press the RESET button on the
detector control box (Figure 7h).
Although the fault will be signalled to the Green ‘POWER ON’ light
main panel PLC it is only necessary to reset
at the metal detector panel. 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 7f).
After the pressing RESET (Figure 7h),
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 7h)
for automatic start of the feed conveyor if
the hand set (Figure 7i) is still enabled..
Red ‘DETECT’ light and ‘RESET’ button
Figure 7h Metal Detector Control Panel
1000SR
Page 23
7.2.11 Feed Conveyor Remote

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

hand set with the stop button nearest to Feed Conveyor
stop/start button

(Fig.5b) at the same time for at least 1
Stop Button
• The transmitter is in function status
when the green LED comes on. Figure 7i Feed Conveyor Remote Operation
3. Proceed with Plant Start Up (Section

7.2.2) at the Electric Panel Controls stop button on the hand set will close
(Figure 7e and 7f) including starting the down the complete plant. The speed of
Feed Conveyor. the feed cannot be adjusted using the
hand set. Speed adjustment is only
Note: The radio remote control of the possible when operating the feed
feed conveyor does not become conveyor in MANUAL (Section 7.5.2).
operative until the Feed Conveyor start
button on the main panel is activated.
4. The feed can be turned on and off using

the Feed Conveyor On/Off button on
the hand set (Figure 7i). Pressing the
1000SR
Page 24
7.2.12 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 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 3.6 - Action B for the suitability of
the feed material depending upon meeting the
Feed Material criteria specified and also depending upon the
Automax eccentric throw (long or short) and
the type of concave fitted.
Section 9.13 - 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 9.18 - Action A for sensitivity and

Metal Detector setting. Action B for operation when metal
is detected (Section 7.2.10).
Section 9.13 - 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 cover the monitoring of
Automax Crusher manganese wear and the unblocking
procedure.
Section 3.6 - Action B Check the product

Product Material The graphs & capacities are a guide only and
will vary depending upon the conditions.
1000SR
Page 25
7.2.13 Plant Initial Start Up and

Running In WARNING
Initial Start-Up WEAR PERSONAL
Observe all safety warnings
whilst carrying out inspections warning.
and checks.
LOCKOUT PLANT.
• Check levels of oils are satisfactory. Information for Lockout
Refer to the lubrication schedules 9.4.4 Procedure.
and 9.4.5 for details.
FALLING HAZARD.
• Refer to engine manual for engine initial Refer to Section 7.1 Safety
start up instructions
warning.
• Run the plant empty for a short period

of time and check for abnormal noises,
vibration or excessive heat from shaft
bearings, fluid leaks, etc. including the conveyor belts on the feed and
feed conveyor gearbox. discharge conveyors and adjust if
necessary. Refer to Section 9.17.3
Actions During Running-In Period
• Make sure the conveyor belts are
Checks on the 1000SR plant are tracking correctly and that the skirt
crucial during the first week of sealing rubbers are correctly adjusted.
crushing operation. Refer to Section 9.17.2
The following section should be
read and understood prior to • Check frequently the overall stability of
starting the plant. If there are the plant; re-check the level of the plant
any doubts, contact BL Pegson and move to level position if necessary.
Ltd. Service Department.
• Regularly check drive belts (crusher and
Plant hydraulic pumps) to ensure correct
tension, particularly during the initial 2
• All control systems should be checked weeks of use. Refer to Section 9.16.
for full function.
• Each day during the initial days of vee belt drives daily during the initial
operation check the tension of the days of operation. Refer to Section
9.16
1000SR
Page 26
• Avoid overloading the crusher;

WARNING
• Check for any leaks of lubricants, fuel,
WEAR PERSONAL
water or hydraulic fluid and rectify PROTECTIVE EQUIPMENT.
immediately. Refer to Section 7.1 Safety
• Check for any overheating of running warning.
parts. LOCKOUT PLANT.
Shut down the plant if this Information for Lockout
occurs and investigate the Procedure.
reason. If necessary, contact
FALLING HAZARD.
BL-Pegson’s Service Refer to Section 7.1 Safety
Department for advice to avoid Information for relevant
the possibility of danger or warning.
damage.
Crusher
• Make sure that the crusher lubrication
system is functioning correctly (fault
warnings will show on the diagnostic
vee rope drive daily during the initial
panel) and that no leaks are present.
days of operation.
• Check for leaks in the crusher hydraulic
• Avoid overloading the machine by not
system, both externally and inside the
using small discharge settings during
hydraulic console.
the first few days of operation.

correctly and that the satisfactory
feed (Section 3.6) is maintained at a
constant rate (Section 7.5). 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 27
7.2.14 Daily Plant Checks

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

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

buttons are operative (Section 1.7 and
8.3.1).
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 alarm messages

displayed on the Electrical Control Panel
(Section 7.2.9).
5. Check engine clutch bearing oil level

(Section 9.20.2)
Note: See also Section 7.3.3 for daily

Automax checks.
1000SR
Page 28
7.3 Automax Operation

WARNING
The Automax crusher is a high quality cone WEAR PERSONAL
crusher featuring:- PROTECTIVE EQUIPMENT.
• Optimum Performance - Advanced Information for relevant
crusher geometry. Excellent product warning.
shape through attrition crushing. High
output capability. Maximum production
of high quality material.
• Low Cost Operation - High capacity Selection of the discharge setting is carried out
with energy efficiency. Low wear costs. manually with the controls switched into
Exceptional reliability. ‘MANUAL’ as are also other additional
functions described later.
• Ease of Maintenance - Accessible
external hydraulics. Simple assembly The material product from the Automax is
and dismantling. Quick manganese governed by the closed side discharge setting
changes. dimension, ie. the minimum gap between the
concave and mantle manganese crushing
To assist in understanding the Automax members. See the Glossary of Terms for other
hydraulic control functions the following ways of referring to the ‘setting’. Changes to
brief explanation is given. The actual step the discharge setting are achieved by raising or
by step procedures are detailed in the lowering the Automax upper frame by means
following pages under the appropriate of the six externally mounted hydraulic rams.
section headings. Refer also to the Glossary
of Automax Terms (Section 7.3.2) for When new manganese is fitted the MANUAL
additional information. hydraulic controls are used for the panel to
record a ‘zero’ point at which the mantle and
With the Automax in normal ‘AUTO’ concave are just touching. The required
crushing operation the hydraulic system discharge setting dimension is then manually
automatically maintains a pre-selected entered into the panel controls. The hydraulic
discharge setting which determines the system can then position the upper frame so
product from the machine. The setting is that the gap between the mantle and concave
maintained by hydraulic pressure and, in the equals the entered setting. This procedure is
event of uncrushable material entering the carried out with the machine stationary.
machine, the hydraulic overload release is
automatically triggered to raise the upper During crushing operations the mantle and
frame to pass the foreign body and then concave wear under abrasive action of the
automatically returns to the selected setting. material being crushed and the gap between
1000SR
Page 29
the two will increase although the panel original dimensions under strict quality
display will still show the original gap setting. control. Always quote the machine serial
number stamped on the machine identity
To restore the actual gap between the two plate when ordering.
crushing members to the original setting it is
necessary to manually reset the ‘zero’ point The hydraulic control system also allows the
with the mantle and concave touching. The discharge setting to be altered whilst the
controls can now compare the new zero point machine is running and also a number of
with the original zero point with new other functions as described in the following
manganese. The machine is to be stationary pages.
when this procedure is carried out.
Other information available on screen are
Once the recalibration has been carried out an alarm history, Automax lubrication
the panel now displays the amount of wear system monitor, and a ‘zero’ help screen
(Section 7.4.2) that has taken place since
fitting new manganese. The rate of In addition to these normal machine control
manganese wear obviously depends upon functions the system also includes a
the physical characteristics of the feed separate audible alarm and hydraulic system
material and other governing factors and malfunction messages which appear on the
will confirm the frequency of re-calibrating display screen (Sections 7.2.9)
the zero point to maintain the desired
product and also the need to change the Additionally, a separate subsidiary hydraulic
manganese mantle and concave. circuit is employed to apply pressure to the
wedge ring and the requirements for this
For guidance on when to change the system are also covered later in this manual
manganese mantle and concave liners refer (Section 9.8).
to Section 9.7.1.
Service schedules in this manual assume
It is most important to change reasonable operating conditions apply.
both the liners together when Refer tp BL-Pegson Limited’s technical
fitting 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
1000SR
Page 30
7.3.1 Glossary of Automax Parts

GAP
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
Figure 7j Automax Components

CRUSHING
DUMPY
identification of individual parts.
1000SR
Page 31
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 The distance between the crushing surfaces (mantle and
Closed Side Setting, concave) during operation.
Discharge Setting or Gap)
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.
1000SR
Page 32
7.3.3 Daily Automax Checks

Daily attention should always
WARNING
be a matter of routine to WEAR PERSONAL
ensure maximum efficiency of PROTECTIVE EQUIPMENT.
this vital element of the plant. Information for relevant
warning.
Before starting the Automax
• Look at the manganese liners to check

DANGER
for wear and/or damage. SKIN INJECTION HAZARD
• 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 heater.
• Check Wedge pressure.
• Recalibrate the manganese.
• Check for any obstructions in the

discharge opening of the Automax.
• Check the condition of the vee drive.
• Check for loose bolts, leaks, hose

connections, etc.
• IMPORTANT Ensure the frame arms Figure 7k Frame Arm Important Sign
are free from foreign bodies/stone
build up. See the warning sign on the
machine (Figure 7k).
1000SR
Page 33
After starting the lube oil pump

WARNING
• Check the oil flow to the crusher and
WEAR PERSONAL
back into the tank (sight glass on top PROTECTIVE EQUIPMENT.
of oil tank in return pipe) and that oil Refer to Section 7.1, Safety
lines do not leak. Information for relevant
warning.
DANGER
SKIN INJECTION HAZARD
After starting the Automax Refer to Section 7.1, Safety
• Set the discharge setting. warning
• Listen for any abnormal noise from the

crusher.
• Check that no bolts have come loose.
During crushing
• Listen for any abnormal noise from the
crusher.
• Check oil pressure at normal running

temperature.
• Check no leaks in the lubrication

system.
• Inspect hydraulic system piping, cylinders,

etc. for leaks which could cause an alteration
in the setting.
• Note the crushing pressure.
1000SR
Page 34
7.3.4 Actions during running in

WARNING
vee rope drive daily during the initial WEAR PERSONAL
days of operation. PROTECTIVE EQUIPMENT.
• Avoid overloading the machine by not warning.
using small discharge settings during the
first few days of operation.

correctly with no abnormal noises or
leaks evident.
• Make sure a satisfactory feed (Section

3.6) 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).
1000SR
Page 35
7.3.5 Automax Automatic Overload In order to protect the

Release/Unblocking and Resetting Automax crusher from the
ingress of damaging tramp
The control equipment on the Automax metal the plant is fitted with a
crusher automatically monitors the operating metal detector on the feed
conditions of the hydraulic system for tramp conveyor which will sound an
metal/packing in the crushing chamber and alarm and stop the feed.
effects an immediate release. The
equipment also resets the discharge setting It is essential to remove the
and also compensates for any tendency for offending object before
the setting to creep open during normal resetting the detector and
operation. restarting the feed.
Normally the hydraulic system clears any Make sure that the metal
tramp metal from the crushing chamber. detector is operative and
However, in the event of the tramp metal correctly set for sensitivity
being too large to be released, severe (Section 9.18.1) at all times
damage to the machine can occur as the when crushing.
system continues to try and release the
object.
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
1000SR
Page 36
7.4 Automax Management

WARNING
7.4.1 Automax Initial Discharge WEAR PERSONAL
Setting and Calibration PROTECTIVE EQUIPMENT.
FOR THIS OPERATION THE Information for relevant warning.
AUTOMAX MUST NOT BE
RUNNING (but engine started to
provide hydraulic pressure).
Starting with new manganese liners, a ‘zero’

point is established with ‘metal to metal’
3. Press F4-SET GAP.
contact between the mantle and concave.
From this ‘zero’ point the desired gap
4. Press F4-MANUAL MODE.
setting is measured.
The function buttons are identified F1 to
F8. With each operation of a button the
information displayed on the screen alters. A
Changes to the button functions can be seen
in the captions along the bottom of the
screen
21
Procedure
63 61 62
6. Press F5-OPEN to increase the current
3
gap figure A shown on the screen to
25-38mm. Pressing F6-CLOSE button
release immediately a sudden in
pressure shows on the gauge (Figure
7d) indicating ‘metal to metal’ contact
between the mantle and concave and
2 then press F2-NEW MANG.
2. Press F2-ADJUST
1000SR
Page 37
7. Press F2-NEW ONLY and then

F4-NEW YES followed by pressing A
F8-ESC.
8. Check the Set Gap figure shown on the

screen is the default setting of 25mm. If B
21
a change from this setting is required,
press F4-SET GAP but if 25mm is the
setting required, go to step 10.
B 10
10. Press F5-OPEN until the Current Gap

figure A (mm) shown on the screen is
reading in excess of the Set Gap figure
B (mm). Then press F8-ESC.
26
11. Press F3-AUTO.
A
B
92 91 91 14
9. Increase or decrease the Set Gap figure

B shown on the screen by pressing F4
or F5 until the desired setting is
indicated. Press F2-SET GAP then
F8-ESC.
12. This screen will now show the Automax
It is important that the setting to have automatically closed to a
selected gap setting is within Current Gap A + / - 1mm of the Set
the range shown for the type of Gap B. Press F8-ESC and F8-ESC
concave fitted as detailed in again to return to the Crusher and
Sections 3.6.1 to 3.6.8. Feeder Control Screen shown in step 2.
1000SR
Page 38
7.4.2 Automax Manganese Wear

Calibration WARNING
FOR THIS OPERATION THE AUTOMAX WEAR PERSONAL
MUST NOT BE RUNNING (but engine PROTECTIVE EQUIPMENT.
started to provide hydraulic pressure).
This procedure is necessary to determine the

amount of wear that has taken place on the
manganese mantle and concave since the last
calibration.
From the time of fitting new manganese liners
(Section 7.4.1), repeating the manual ‘metal to 4. Press F4-MANUAL MODE.
metal’ contact procedure will establish a new
‘zero’ point. The PLC will calculate the total 5. Press F2-SET GAP.
amount of wear that has taken place and display
it on the screen.
A
Routinely recalibrate on a regular
basis to establish the amount of
liner wear. Refer to Section 9.7.1 for
guidance on replacing the
manganese mantle and concave. 21
Procedure

63 61 62
6. Press F5-OPEN to increase the current

gap figure A shown on the screen to
3
25-38mm. Pressing F6-CLOSE button
release immediately a sudden increase
in pressure shows on the gauge (Figure
7d) indicating ‘metal to metal’ contact
between the mantle and concave and
2 then press F3-WEAR ZERO.
2. Press F2-ADJUST
1000SR
Page 39
7. Press F2-ZERO and then F4-ZERO

YES followed by pressing F8-ESC.
B
21

9. Press F3-AUTO.
C
14
D
10. This screen will now show the amount

of manganese wear at C and D. Press
F8-ESC and F8-ESC again to return to
the Crusher and Feeder Control Screen
shown in step 2.
1000SR
Page 40
7.4.3 Automax Discharge Setting

Adjustment WARNING
AUTOMAX RUNNING WEAR PERSONAL
This procedure is carried out if a change to
the crushed product size is required or if the
amount of screened oversize material being
recirculated requires to be adjusted.
Always keep within the parameters shown
in Section 3.6 for the Eccentric Throw and
Concave type fitted to the Automax.
Procedure
26
72 71 71
2 7. Increase or decrease the Set Gap figure

B shown on the screen by pressing F4
2. Press F7-ADJUST. or F5 until the desired setting is
indicated. Press F2-SET GAP then
3. Press F4-SET GAP. F8-ESC.
4. Press F4-MANUAL MODE. It is important that the

selected gap setting is within
5. Press F2-SET GAP. the range shown for the type of
concave fitted as detailed in
6. Press F4-SET GAP Sections 3.6.1 to 3.6.8.
1000SR
Page 41
B
21

9. Press F3-AUTO.
A
B
14

setting to have automatically closed to a
Current Gap A + / - 1mm of the new
Set Gap figure B. Press F8-ESC and
F8-ESC again to return to the Crusher
and Feeder Control Screen shown in
step 2.
1000SR
Page 42
7.4.4 Manual Raising/Lowering of

the Automax Upper Frame WARNING
AUTOMAX RUNNING WEAR PERSONAL
The raising and lowering the Upper Frame
is made when under manual control.
DO NOT UNDER ANY

CIRCUMSTANCES RUN
THE AUTOMAX UNDER 2. Press F7-ADJUST
MANUAL CONTROL FOR
ANY LONGER THAT 3. Press F4-SET GAP.
ABSOLUTELY NECESSARY
4. Press F4-MANUAL MODE.
When under manual control the
tramp metal protection (ie. the 5. Press F2-SET GAP.
automatic hydraulic overload
release) is not operative and
therefore damage to the A
machine could result.
If the machine is left in manual control an

alarm will be activated to warn the operator
to switch into auto control. 21
Procedure

61 62
6. Press F5-OPEN to raise the Upper

Frame to the maximum extent where it
6 will remain. Press F8-ESC.
7. Press F3-AUTO for automatic return to

the selected Gap Setting.
1000SR
Page 43
A
B
14

setting to have automatically closed to a
Current Gap A + / - 1mm of the Set
Gap B. Press F8-ESC and F8-ESC
again to return to the Crusher and
Feeder Control Screen shown in step 2.
1000SR
Page 44
7.4.5 Checking Automax Wedge

Pressure WARNING
AUTOMAX NOT RUNNING (but engine WEAR PERSONAL
started (Section 7.2.1) to provide PROTECTIVE EQUIPMENT.
hydraulic pressure).
The pressure on the wedge ring is automatically

controlled by the Dumpy Jack hydraulic circuit.
However, as the adjustment of the wedge ring is
critical for good performance of the Automax
crusher it is recommended that this should be
checked daily. The pressure gauge near the panel
(Figure 7d) gives an accurate indication of
whether the Wedge Ring assembly is functioning
correctly. 3. Press F4-SET GAP.
The Automax must not be allowed to 4. Press F4-MANUAL MODE.

operate with regular dumping or
bouncing of the Upper Frame or 5. Press F2-SET GAP.
damage may result. Possible causes
could be crushing at too small a
setting, out of round manganese A
(Section 9.9) or poor Wedge Ring
adjustment.
Procedure
21
1. Observe all safety warnings
3
6
6. Press F5-OPEN to raise the Upper
Frame approximately 19mm above the
set point Press F8-ESC.
2
2. Press F2-ADJUST
1000SR
Page 45
13
7. Press F3-AUTO MODE and observe

the pressure reading on the pressure
gauge (Figure 7d). The pressure should
be in the range 55 - 82 BAR (800 -
1200 psi).
Whilst the Upper Frame is moving

check for smooth movement with no
sticking at the start or whilst travelling.
If the pressure reading is above or

below the range indicated above or the
action is not smooth, remedial action is
required (Section 9.8).
Press F8-ESC and F8-ESC again to

return to the Crusher and Feeder
Control Screen.
1000SR
Page 46
7.4.6 Automax/Plant Data Screens

These data screens are available to the
operator by first pressing F2/F7-ADJUST
and then the required item. F7-MORE >>
displays more menus and F2 << MORE
returns to the previous screen. Press
F8-ESC and F8-ESC again to return to the
original screen.
TRAMP TEST - Daily check that the

automatic overload ‘dump’ facility on the
Automax is operative. The pressure gauge
should drop to zero.
F2-ADJUST > F4-SET GAP > F5-TRAMP
TEST .
LUBE - This is a visual display only giving

data relating to the Automax oil lubrication
system.
F2-ADJUST > F3-LUBE.
ZERO HELP - Access this screen for a

quick reference of the procedure for setting
‘zero’.
F2-ADJUST > F4-SET GAP > F6-ZERO
HELP.
1000SR
Page 47
HISTORY - Select to access the screen to

display the current data log for the Automax.
F2-ADJUST > F4-SET GAP > F7-HISTORY.
ALARM LOG - Access this display for

the alarm log record. Scroll F4-NEXT or
F5-PREV to show a possible total of 20
alarms; date and time stamped.
F2-ADJUST > F7-MORE > F3-ALARM
LOG.
CAT ENGINE - Current status data

relating to the plant diesel engine is shown.
F2-ADJUST > F7-MORE > F4-CAT
ENGINE.
LANGUAGE - Programmed alternatives can be

selected to change the language displayed.
F2-ADJUST > F7-MORE > F5-LANGUAGE.
1000SR
Page 48
7.5 Feed Conveyor Management

WARNING
7.5.1 Automatic Mode WEAR PERSONAL
Normal operation of the 1000SR is in the Refer to Section 7.1, Safety
automatic mode. The system is designed to Information for relevant warning.
automatically control the feed of material
and provide the recommended continuous
‘choke’ feed (see glossary Section 7.3.2)
to the Automax.
3. Press F2-FEEDER
A high level sensor over the Automax feed
box detects the level of feed material. When Mode status. If MANUAL shown, Press
the material reaches the upper level the feed F8-ESC and select F6-LEVEL MODE
conveyor will stop but will automatically >>F2 AUTO >> F8-ESC >> F2-
restart when the low level setting is reached. FEEDER.
The preset levels are displayed on the
control screen (Figure 7g) with status Sensor shows ENABLED if device fitted.
shown ENABLED.
Alteration to the factory settings should only

be made after operating experience 11
indicates the need and a careful assessment 85 55

has been made as to the extent of change.
Procedure
4. F2 to F5 Auto Mode buttons with
factory settings shown above. Use
buttons to alter as necessary and press
F8-ESC and F8-ESC again.
Optional Feed Hopper Sensor

6
An optional extra sensor over the feed
hopper can be supplied - see Section 7.6.2.
2
2. Press F7-ADJUST.
1000SR
Page 49
7.5.2 Manual Mode

In certain instances the plant can be
WARNING
switched from the automatically regulated WEAR PERSONAL
feed to the Automax to mode where the PROTECTIVE EQUIPMENT.
speed of the feed conveyor is manually Information for relevant warning.
adjusted. In this manual mode the level
sensor(s) are shown DISABLED.
When operating in manual care must be

taken to ensure an excessive feed rate does
not cause material to overflow the Automax
feed box or an low rate to deprive the
crusher of sufficient material to form a
‘choke’ feed (see glossary 7.3.2). 11
85 55
Procedure

4. F6 and F7 Manual Mode buttons with
feed rate shown above. Use buttons to
increase or decrease the speed.
Press F8 - ESC >> F8 - ESC.
Mode status. If AUTO shown, press F8 -

ESC >> F6 - LEVEL MODE >> F3 -
2 MANUAL >> F8 - ESC >> F2 - FEEDER
Sensor shown as DISABLED.

2. Press F7 - ADJUST.
3. Press F2 - FEEDER
1000SR
Page 50
7.6 Level Sensor Management

7.6.1 Level Sensor Control
WARNING
WEAR PERSONAL
The feed of material into the Automax can PROTECTIVE EQUIPMENT.
be switched from the automatic regulation Refer to Section 7.1, Safety
to manual regulation.
The level sensor fitted as standard over the

crusher and also the optional extra sensor
for mounting over the feed hopper can both
be switched between automatic and manual
modes.
3. Press F6-LEVEL MODE.
indicates the need and a careful assessment
Do not operate the plant in the

manual mode unless the plant
operator is in attendance at all
times.
4. Select F2/F3 or F6/F7 as required. The
screen will show if the sensor is Enabled
Procedure or Disabled and also if in Auto or
Manual mode. Pressing F8-ESC will
1. Observe all safety warnings. revert to previous screens.
2
2. Press F7-ADJUST.
1000SR
Page 51
7.6.2 Hopper Level Sensor (Optional)

WARNING
This optional extra is recommended where WEAR PERSONAL
the site operation may not be able to PROTECTIVE EQUIPMENT.
maintain an adequate material feed into the Refer to Section 7.1, Safety
plant feed hopper thereby depriving the Information for relevant warning.
Automax of the required ‘choke’ feed and
leading to increased running costs.
Where fitted, the optional level sensor 3. Press F5-HOPPER LEVEL

mounted over the feed hopper can be
adjusted from the standard factory settings.

indicates the need and a careful assessment

The sensor will stop the feed conveyor

when material in the hopper reaches the low 4. Adjust F3 to F6 as required for hopper
level setting and restart at the high level material low level stop and restart. To
setting. The sensor can also be separately programme for a high level stop press
programmed to automatically stop/start an F7 for MORE>>. Pressing F8-ESC
off plant supply conveyor, see step 5. will revert to previous screens.
Procedure
1. Observe all safety warnings. 8
5. Adjust F3 to F6 as required for hopper

material high level stop and restart. To
programme for a low level stop press
F2 for <<MORE. Pressing F8-ESC
2. Press F7-ADJUST. 2 will revert to previous screens.
1000SR
Page 52
Blank page
1000SR
Shut Off Issue EN 01
Page 1
Contents
8.2 Closing Down the Plant ...................................................................................... 4
8.3 Emergency Stopping of the Engine ................................................................... 8

8.3.1 Emergency Stop Buttons ................................................................................. 8
8.3.2 Restarting the Plant ......................................................................................... 9
8.3.3 Testing Buttons .............................................................................................. 10
1000SR
Page 2








HAZARD
machine.

1000SR
Page 3

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
signs (ie. ‘TAG OUT’).
1000SR
Page 4
8.2 Closing Down the Plant

WARNING
The closing down procedure must be WEAR PERSONAL
carried out in the reverse order to that for PROTECTIVE EQUIPMENT.
starting the plant. After stopping the feeder, Refer to Section 8.1, Safety
keep the remainder of the plant running until Information for relevant warning.
the screen and conveyors (particularly the
re-circulating) are clear of material. This LOCKOUT MACHINE.
may take several minutes to complete. Refer to Section 8.1, Safety
Information for Lockout Proce-
dure.
On pressing a panel control button the LED
will extinguish to show that item is now
inactive.
Procedure
2. On the Control Panel (Figure 8a), press

the FEEDER button to stop the feeder.
DO NOT proceed to the next step
until the screen and all conveyors
are clear of material.
3. Press CRUSHER to stop the Automax

and wait until the crusher cone head
has stopped spinning before the
next step.
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.
1000SR
Page 5
Figure 8a Plant Mode Screen
1000SR
Page 6
THE PLANT SHOULD NOT

BE SHUT DOWN AT THE WARNING
END OF A SHIFT BY ONLY
WEAR PERSONAL
SWITCHING OFF THE PROTECTIVE EQUIPMENT.
ENGINE OR BY PRESSING Refer to Section 8.1, Safety
AN EMERGENCY STOP Information for relevant warning.
BUTTON.
LOCKOUT MACHINE.
4. Press the buttons for OIL PUMP and Refer to Section 8.1, Safety
ALL CONVS to stop all the remainder Information for Lockout Proce-
dure.
of the machinery (including the screen).
5. Using the engine speed control, de-

crease 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 Use of high pressure washing
Ignition Key. Shut and lock the Control equipment is to be avoided
Box door. Lockout the Isolation Switch where the ingress of water will
(Figure 8c).If the radio hand set (where be detrimental to plant compo-
fitted) has been in use, shut down by nents eg crusher bearings,
depressing the stop button on the unit. conveyor bearings, hydraulic
tank, electrical equipment etc.
8. Following the closing down procedure
above, it is recommended that at the Do not use the emergency stop
end of operation for the day the plant is buttons for routinely stopping
routinely cleaned down and thoroughly the plant.
examined to check for any damage,
breakages, wear, leaks etc. which
should be rectified before further opera-
tion.
1000SR
Page 7
US/Metric Switch Scroll Switch
Fuel Gauge Speed Control
Ignition Key
Figure 8b Caterpillar Engine Control Panel
Figure 8c Engine Isolation Switch
1000SR
Page 8
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
warning.
EMERGENCY STOP BUTTONS.
See Section 1, Figure 1a for locations of

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

started 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 Ignition
Key stays switched ‘on’ and should be
returned to off position as soon as
possible to avoid the ignition being left
‘on’.
When an emergency stop has

been initiated, DO NOT at-
tempt 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.
1000SR
Page 9
8.3.2 Restarting the Plant

When an emergency stop has
WARNING
been initiated, DO NOT at- WEAR PERSONAL
tempt to restart the engine
until it is safe to do so. Information for relevant
warning.
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 proce-
dure in Section 7.4.4.
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).
1000SR
Page 10
8.3.3 Testing Buttons

Daily, before commencing
WARNING
crushing operations, test each WEAR PERSONAL
emergency stop button is
operative. Information for relevant
warning.
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
resetting of the tested button, repeat the
process for each of the other emer-
gency stop buttons (Section 1-Figure
1a) and also the stop button on the
remote handset.
5. When safe to do so continue with the

Plant Start-Up Procedure (Section
7.2.2).
1000SR
Maintenance Issue EN 01
Page 1
Contents

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

9.4.1 Service Attention Points ................................................................................ 13
9.4.2 Regular Servicing .......................................................................................... 14
9.4.3 Daily, Weekly and Monthly Checks ................................................................ 15
9.4.4 Automax Crusher Lubrication and Servicing Schedule ................................... 17
9.4.5 Plant Lubrication and Servicing Schedule ...................................................... 18
9.4.6 Recommended Oil/Grease Types.................................................................. 19
9.5 Automax Crusher - General .............................................................................. 22
9.5.1 Automax Lubrication Overview ...................................................................... 22
9.5.2 Automax Lubrication Operating Procedure .................................................... 23
9.5.3 Automax Lubrication System Detailed Description ........................................ 25
9.5.4 Automax Oil Change Intervals ........................................................................ 27
9.5.5 Automax Recommended Oil .......................................................................... 28
9.5.6 Automax Oil Filter Change Intervals ............................................................... 29
9.5.7 Automax Oil Filter Replacement .................................................................... 30
9.5.8 Automax Oil Lubrication System General Maintenance .................................. 31
9.6 Automax - Hydraulics Overview ....................................................................... 32
9.6.1 Automax Hydraulic System Maintenance Procedure ...................................... 34
9.7 Automax - Manganese Change Procedure ..................................................... 35
9.7.1 Guidance for Changing the Manganese Mantle and Concave ........................ 35
9.7.2 Filler Handling ............................................................................................... 36
9.7.3 Changing the Manganese ............................................................................. 38
9.8 Automax - Wedge Ring Maintenance ............................................................... 56
9.8.1 Checking Automax Wedge Pressure ............................................................. 58
8.8.2 Low Wedge Pressure ................................................................................... 59
9.8.3 Readjusting Tight Wedge Ring ...................................................................... 60
17/01/05
1000SR
Page 2
9.9 Automax - Out of Round Manganese - Causes and Effects ...........................62

9.9.1 Checking Manganese for Out of Round ......................................................... 63
9.10 Automax - Fault finding. ................................................................................. 66
9.11 Sizing Screen ................................................................................................... 76

9.11.1 Screen Lower / Raise .................................................................................. 77
9.11.2 Re-Tuning Screen Unit ................................................................................. 80
9.11.3 Changing the impact screen mesh ............................................................... 82
9.11.4 Changing the screen sizing meshes - manual tensioning .............................83
9.11.5 Changing the screen sizing meshes - hydraulic tensioning (optional) ............84
9.12 Plant - Feed Conveyor..................................................................................... 86
9.13 Plant - MiniRanger Level Sensors Description ............................................. 87
9.14 Plant/Automax - Hydraulic Systems .............................................................. 88

9.14.1 General Description .................................................................................... 88
9.14.2 Track Drives ................................................................................................ 90
9.14.3 Feed Conveyor Drive .................................................................................. 90
9.14.4 Circuit Protection ........................................................................................ 90
9.14.5 Changing the Suction Filter ......................................................................... 92
9.14.6 Changing the Return Filter ........................................................................... 94
9.14.7 Changing the Tank Breather ........................................................................ 94
9.14.8 Changing the Pressure Filters ..................................................................... 95
9.14.9 Automax Hydraulic System .......................................................................... 96
9.15 Plant - Electrical System Description ............................................................. 98
9.15.1 General Description .................................................................................... 98
9.15.2 Protection Devices ...................................................................................... 99
9.16 Plant - Crusher and Hydraulic Pump Drive Belts ........................................100
9.16.1 Trouble Shooting - Drive Belts ................................................................... 101
9.16.2 Replacement and Adjustment of Crusher Drive Belts ................................. 102
9.16.3 Replacement and Adjustment of Hydraulic Pump Drive Belts ..................... 105
9.16.4 Method of Drive Belt Tensioning ................................................................ 108
1000SR
Page 3
9.17 Plant - Conveyor Belts .................................................................................. 110

9.17.1 General Description .................................................................................. 110
9.17.2 Training of Belts ........................................................................................ 111
9.17.3 Conveyor Belt Tensioning .......................................................................... 113
9.17.4 Maintenance of Conveyor(s) ...................................................................... 114
9.17.5 Cleaning the Conveyor Belts ..................................................................... 117
9.18 Metal Detector ................................................................................................ 119
9.18.1 Metal Detector Controls............................................................................. 120
9.18.2 Metal Detector Indictor Lights (Figure 9au & 9av) ...................................... 122
9.19 Plant - Dust Suppression .............................................................................. 124
9.20 Plant - Diesel Engine ..................................................................................... 126

9.20.1 Engine - ELC Coolant ............................................................................... 127
9.20.2 Hydraulic Engine Clutch............................................................................. 128
9.20.3 Check Fuel Level ...................................................................................... 129
9.20.4 Top Up Fuel Level ..................................................................................... 130
9.21 Plant - Vehicle Tracks .................................................................................... 132
9.21.1 Measuring Track Tension ........................................................................... 132
9.21.2 Adjusting Track Tension ............................................................................. 134
9.21.3 Track Maintenance .................................................................................... 137
9.21.4 Drive Oil Filling and Draining ..................................................................... 138
1000SR
Page 4




followed.
LOCKOUT PROCEDURE

lockout.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).
1000SR
Page 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.



1000SR
Page 6

HAZARD
machine.

1000SR
Page 7
WARNING
PRIOR TO ANY MAINTENANCE
• The maintenance 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 formal risk
assessment for all maintenance operations. Have suitable lifting equipment available for the
components involved together with all necessary (and suitable) tools/equipment ready for the
task(s) in hand and always secure parts liable to movement before starting work.
BL-Pegson’s Service Department is available for advice when required.
• The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout
Procedure (Section 9.1). Display a prominent ‘tag’ at the control station (or other appropriate
place) to warn of maintenance work being carried out.
• Keep clear of moving parts when trying to identify or isolate any unusual noises.
• Fit dismantled parts in the same location from which they were removed.
• Ensure that the area surrounding the maintenance site is clear of any obstructions.
If arc welding work is involved in any maintenance operation, ensure that the current does not
pass through any bearings. FOLLOW THE WARNING INSTRUCTIONS ON THE
OPPOSITE PAGE FOR ENGINE PROTECTION. The plant must be fully isolated
prior to any welding work.
• BEFORE WORKING ON THE PLANT, SWITCH OFF, ‘LOCKOUT’ AND ‘TAGOUT’
AFTER EXTENSIVE MAINTENANCE

Refer to Sections 7.1.3, 7.2.8, 7.2.12, 7.2.13 and 7.3.4.
1000SR
Page 8
9.1.1 Engine Start

Operating the 1000SR in ADJUST MODE
WARNING
will require the engine to be running to WEAR PERSONAL
provide hydraulic pressure for some PROTECTIVE EQUIPMENT.
maintenance operations. Only run the Information for relevant warning.
engine in these circumstance and always
ensure the Lockout Procedure has been
carried for maintenance operations where
the engine is not required to be running.
Procedure
2. Check that all Emergency Stop push

buttons are pulled out (Section 1.7)

(Figure 9a) is turned to the I position.
4. On the engine control panel (Figure 9b),

turn on the ignition with the key to the
first position and, once the sequence of Figure 9a Isolation Switch
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.
Refer to Figure 7c together

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

rpm (view on tachometer) and allow to
run for 3-5 minutes before proceeding
with maintenance.
1000SR
Page 9
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Figure 9b Engine Control Panel
1000SR
Page 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 BL-Pegson’s Technical Department for any other weights of individual
items or assemblies if not listed.
Component Weights (approximate) kgs (lbs)
Complete Automax Crusher 11,226 ( 24,700 )

Cone Head Assembly (with bearings, mantle etc.) 1,322 ( 2,900 )
Eccentric Assembly (with bearings, ring gear etc.) 1,042 ( 2,300 )
Upper Frame Assembly (upperframe with concave) 2,875 ( 6,300 )
Countershaft Assembly 454 ( 1,000 )
Concave 435 ( 960 )
Mantle 330 ( 725 )
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment
Figure 9c Lifting Points for the Automax Upper Frame
1000SR
Page 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 1000SR depends
on regular and proper maintenance.
The following section contains maintenance

instructions as well as maintenance
schedules for normal operating conditions.
When the 1000SR plant is

operated in extreme climatic
conditions (e.g. below
minus 15°C or above 30°C) or
in very dusty conditions for a
longer period of time, the
maintenance schedules will
change.
Ask your local BL-Pegson

dealer or BL-Pegson Technical
Department for advice.
1000SR
Page 12
PRACTICE SAFE
MAINTENANCE WARNING
WEAR PERSONAL
Understand service procedures PROTECTIVE EQUIPMENT.
before doing any work. Keep Refer to Section 9.1, Safety
the area clean and dry. Information for relevant warning.
Never lubricate, clean, service LOCKOUT PLANT.

or adjust machine whilst it is Refer to Section 9.1, Safety
moving. Information for Lockout
Procedure.
Keep hands, feet and clothing
FALLING HAZARD.
clear of power driven parts and Refer to Section 9.1, Safety
in-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.
1000SR
Page 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 warning.
out to the plant machinery in accordance with LOCKOUT PLANT.
the Lubrication and Servicing Schedule Refer to Section 9.1, Safety
(Section 9.4.4 and 9.4.5) in order to maintain Information for Lockout
efficiency. Procedure.
FALLING HAZARD.
The locations of the Service Attention
Points are as follows:- Information for relevant
warning.
• Automax Crusher oil lubrication tank sited
within the plant chassis (Figure 9e).
• Automax Crusher Upper Frame grease • Re-circulating Conveyor and 2 x
nipples x 12 (Figure 9l). Transfer Conveyor head and tailshaft
bearing grease nipples.
• Diesel Engine oil, coolant, (See separate
engine manual). Also the fuel (Figure 9az). • Screen vibrating unit bearing 4 x grease
nipples.
• Diesel Engine oil lubricated HFO clutch
bearing (Figure 9ax) • Track unit gearbox x 2 oil levels (Figures
9bc & 9bd).
• Plant hydraulic oil reservoir sited on the
forward engine platform . • Periodically lubricate hinges, cylinder pivot
pins, tensioning screws and similar points
• Feed Conveyor gearbox within the head with oil or grease (as appropriate) to
drum having oil lubrication (Figure 9as). prevent seizure during lengthy spells of
inactivity. Keep the runners for the side
• Feed Conveyor -1 x headshaft on the
transfer conveyors well lubricated with
platform side and 2 x tailshaft remote
grease.
nipples on rear of hopper.
• Crushed Product Conveyor head and
tailshaft bearing grease nipples located Failure to carry out scheduled
on the bearing housings (tailshaft piped maintenance or exercise due
to grease points on plant chassis sides). care may invalidate any
warranty that might apply.
1000SR
Page 14
9.4.2 Regular Servicing

The Lubrication and Servicing Schedule
WARNING
(Sections 9.4.4 and 9.4.5) lists, in addition WEAR PERSONAL
to the lubrication points, the attention PROTECTIVE EQUIPMENT.
required to the Automax and Plant Information for relevant
hydraulic systems. warning.
LOCKOUT PLANT.
Particular attention should be paid to
institute a regime of strict adherence from Information for Lockout
the very start of operations for all aspects of Procedure.
routine servicing and good ‘housekeeping’
in order to keep the your 1000SR in prime FALLING HAZARD.
running order. Refer to Section 9.1, Safety
warning.
Keep a accurate record of maintenance
work carried out and also log the engine
hours operated from the service meter
mounted on the engine.
Maintenance records can also be used to

NOTE: Do not overlook the
show compliance with the required
service requirements of the
maintenance practices and intervals as
plant diesel engine which are
detailed in this section of the manual.
detailed in the separate engine
manufacturer’s manual.
Make sure that frequent checks are made
for wear to the manganese mantle and
concave (Section 7.4.2) and other wearing
surfaces so that replacement can be made
before any damage to the core of the
Automax is sustained.
Regularly check the wedge pressure

(Section 7.4.5) to avoid damage to the
machine and to obtain the best performance
from the Automax.
1000SR
Page 15
9.4.3 Daily, Weekly and Monthly

Checks WARNING
It is imperative that the operator
WEAR PERSONAL
carries out regular and diligent PROTECTIVE EQUIPMENT.
checks before operating the Refer to Section 9.1, Safety
plant especially with operational Information for relevant
safety in mind including (but not warning.
limited to) those listed below. LOCKOUT PLANT.
Additionally, the operator should Information for Lockout
always consider what particular Procedure.
safety hazards could occur at FALLING HAZARD.
specific operating sites and take Refer to Section 9.1, Safety
steps to eliminate them before Information for relevant
warning.
commencing work.
Daily Checks
6. Look for loose fixings and rectify. Check
1. Check that all guarding is complete and the security of nuts and bolts on the
properly secured prior to start up. Also Automax. Verify there are no leaks of
that all warning signs (Section 1.8) are lubricating/hydraulic oil or water.
present and readable.
7. Fully raise and lower the Automax
2. Check that all the plant emergency stop Upper Frame several times manually
buttons are operative (Section 1.7). (Section 7.4.4) to help distribute the
grease on the wedge ring for smooth
3. Carry out a general inspection of the operation.
plant to ascertain that nothing
untoward is out of place or damaged so 8. Check the Automax Wedge Pressure is
as to cause a safety hazard. satisfactory (Section 7.4.5)
4. Ascertain any fault messages displayed 9. Ensure that the Automax internal frame
on the Electrical Control Panel (Section arms are free of foreign bodies or
7.2.9). material build up (Section 7.3.3).
5. Carry out the Automax and Plant daily 10. Re-calibrate the manganese wear on the
Lubrication and Servicing Schedule Automax (Section 7.4.2) to compensate
(Sections 9.4.4 & 9.4.5). for the previous days wear.
1000SR
Page 16
Weekly Checks
WARNING
1. Perform all checks on the daily check
list. WEAR PERSONAL
2. Carry out the weekly Lubrication and Refer to Section 9.1, Safety
Servicing Schedule. (Sections 9.4.4 and
warning.
9.4.5).
LOCKOUT PLANT.
3. Note the Automax manganese wear.
Information for Lockout
Arrange renewal when necessary Procedure.
(Section 7.4.2)
FALLING HAZARD.
4. Check the area in and around the
Automax for buildup of material; clean warning.
out as necessary.
5. Ensure all hydraulic hoses and joints

are free from leaks.
3. Check the oil level in the Feed
6. Check drive belts for damage, wear Conveyor drive gearbox (Section
and fraying. 9.17.4).
7. Clean away dust, dirt and grit from 4. Visually examine the Automax for wear
maintenance platforms and any and damage at regular intervals. Renew
moving parts. as necessary.
8. Check conveyor belts for damage and 5. Inspect crusher drive belts for signs of
fraying. wear, renew as necessary (Section
9.16).
Monthly/6 Monthly/Annual Checks
6. Check all drive belts are at the correct
1. Perform all checks on the daily and
tension (Section 9.16).
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).
1000 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

Tank See chart 223 litres Sight glass Check Thereafter change after every 1000
(located inside the plant 9.4.6 (59 US galls) upper mark level hours
chassis) (SEE SECTIONS 9.5.4 & 9.5.5)
First change after 100 working hours

Automax Oil Lubrication ~ Check Thereafter change after every 500
Pressure Filters ~ 2
condition hours
(parts list item 10)
(SEE SECTION 9.5.6 & 9.5.7)
Automax Oil Lubrication

Replace when changing oil
for faults
Suction Filter ~ 1 ~ ~ (SEE SECTION 9.5.6)
(parts list item 2)
Maintenance
Add 25-50 grams of grease to each

Automax Grease Nipples Check
See chart nipple if the travel of the upper frame
(located around the machine 12 wedge
9.4.6 ~ is not smooth
Inspect both the complete Automax oil
lubrication and Plant hydraulic systems
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 9.14.9)
14/01/04
1000SR
Page 17
Issue EN 01
Page 173 of 412

1000SR Lubrication Schedule
Frequency of Lubrication: X = Change
O = Check, top-up or clean as necessary
R = Re-grease
Schedule based on a 40 hour operating week. Adjust schedule to suit actual operating hours
No of 2
Description Lubricant Quantity Daily Weekly Monthly Other
Locations Weekly
Sizing Screen Inner & Outer Shaft

4 D 12g (0.4oz) each ~ ~ R ~ ~
Bearings
Fill to centre line O Check level monthly

Feed Conveyor Oil Lubricated See table
1 approx. 1.7 litres X First oil change after 50–100 working hours
Gearbox (located in head drum) 9.4.6
(0.45 US galls.) X Thereafter change every 2000 hours.
Conveyor Head & Tail Shaft Bearings

23 D ~ ~ ~ R ~ ~
Plus 4 x Stockpile Conveyor (if fitted)
See table 360 litres X 2000hrs

1 Hydraulic Reservoir O
9.4.6 (95 US gal) (Annually)
In-line Hydraulic Filters inside engine
2 ~ ~ ~ O ~ ~ X 1000hrs
canopy
9.4.5 Plant Lubrication and Servicing Schedule
(6 months)
Hydraulic Suction Filters at bottom of Sooner if
2 ~ ~ ~ O ~ ~
the hydraulic reservoir indicator
Maintenance
shows
Hydraulic Return Filter on top of the RED
1 ~ ~ ~ O ~ ~
hydraulic reservoir

See table Approx. 200cc O Check oil level daily prior to start-up
1 Engine Hydraulic HFO Clutch bearing
9.4.6 Level stick oil wet X Change oil every 1000 working hours

See table Approx. 5 litres X 2000hrs
2 Track Gearbox ~ ~ ~ O
9.4.6 (1.3 US gal) ±10% (Annually)
Caterpillar Diesel Engine

1 Refer to the separate Engine Operation & Maintenance Manual
(Fuel, oil, coolant)
06/01/04
1000SR
Page 18
Issue EN 01
Page 174 of 412

1000SR Oil and Grease Lubricants
Equipment Grade Century Mobile Shell Esso Gulf BP

Automax
Oil Lubrication System
> 4º C (39°F) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4º C (39°F) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Automax
Upper Frame Grease Chemodex MOLY - BENTONE MP Standard Grade
Nipples
Automax/Plant
Hydraulic System
<30ºC (<86°F) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
>30ºC (>86°F) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
Sizing Screen
9.4.6 Recommended Oil/Grease Types
Bearing Grease Nipples H ~ ~ Retinax EP2 ~ ~

Plant Feed Conveyor Gear oil with viscosity ISO VG150 with EP additives. Oil temperature always to be below 90º C
Drive Gearbox DO NOT MIX OILS OF DIFFERENT MAKES OR TYPE
Plant
Conveyor Shaft Bearings D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
Maintenance
Plant
Track Tensioners D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
Plant

Track Gearboxes SAE 80W/90 Gear Oil
Diesel Engine

HFO Clutch SAE 30 – SAE 40 Oil (DO NOT USE SYNTHETIC OIL)
Note: <4°C (<39°F) is defined as a daily temperature consistently below 4°C (39°F).
>30°C (>86°F) is defined as a daily temperature consistently above 30°C (86°F).
Diesel Engine Powerpack
Refer to Engine Operation and Maintenance Manual for Lubricating Oil, Coolant and Fuel.
1000SR
Page 19
Issue EN 01
Page 175 of 412

1000SR
Page 20
Lubrication Specifications
Oil Specification Grade A Grade B Grade C
Flashpoint: Minimum °C (ºF) 199 (390.2) 204 (399.2) 216 (420.8)
Pour Point °C (ºF) -18 (-0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s (104ºF, in²/s) 150 (0.232) 220 (0.341) 460 (0.713)
Kinematic Viscosity at 100°C, mm²/s (212ºF, in²/s) 15.4 (0.0238) 20.1 (0.0312) 32.9 (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R&O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D Grade H

NGLI Grade Number 2
Unworked Penetration at 25°C (77ºF) 280
Worked Penetration at 25°C (77ºF) 285
Drop Point °C (ºF) 185 (365)
ASTM Corrosion Test Pass (14 Days) Yes
Wheel Bearing Test Pass at 135°C (275ºF) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade F Grade G

ISO VG No 46 68
Kinematic Viscosity at 40°C, mm²/s (104ºF, in²/s) 46 (0.0713) 68 (0.105)
Kinematic Viscosity at 100°C, mm²/s (212ºF, in²/s) 6.5 (0.010) 8.5 (0.013)
Viscosity Index 95+ 95+
Rust Inhibitor Yes Yes
Defoament Yes Yes
Anti Scuff Yes Yes
Figure 9d Lubrication Specifications
1000SR
Page 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 12½, 25 and 50 kilo
kegs.
1000SR
Page 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 warning.
oil circulated by hydraulically driven oil LOCKOUT PLANT.
pump mounted on the oil tank sited within Refer to Section 9.1, Safety
the plant chassis (Figure 9e) with access Information for Lockout
being gained 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 A engine mounted heat exchanger is
gear and pinion on it’s gravity return to the included to preheat the lubricating oil when
oil tank 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 the Automax is running. Both of these
control system delays the crusher start for 5 devices are controlled automatically by
minutes to allow a good circulation of oil thermostats.
within the Automax and occurs every time
the oil pump is started. To prolong the life Lubrication safety devices include monitors for
of the bearings it is also good practice when low oil flow, high temperature, low tank level
stopping the crusher to allow the crusher and low oil pressure.
cone head to stop spinning before switching
off the oil pump (Section 8.2).
1000SR
Page 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 7.2.7 &
7.2.9).
1000SR
Page 24
Pressure Gauge
Cartridge Filters Air Cooler Oil Flow Meter
Pressure Gauge Oil Filler Cap
Float Switch
Oil Tank
Terminal Box Level Sight Glass Thermostat
Figure 9e Automax Oil Lubrication Tank
1000SR
Page 25
9.5.3 Automax Lubrication System Operating the Automax

Detailed Description without the lubrication system
safety devices being fully
Function operative will invalidate any
warranty in force for the time
The primary functions of the lubrication
being.
system are:-
- to prevent damage due to metal on metal Cold Weather Start-up
contact within the bearings. An engine heat exchanger heats the
- to dissipate heat generated by the lubricating oil prior to the Automax operating.
bearings during operation, so acting as a This ensures efficient circulation of the oil
coolant. before the crushing begins. The system is
automatically controlled by a thermostat.
The bearings can be seriously damaged if
During cold weather conditions be aware that
any one of the following characteristics are
the commencement of crushing may be
inadequate:-
delayed whilst the oil reaches a satisfactory
temperature
• Viscosity (grade)
• Quantity (flow)
Air Blast System
• Cleanliness
This enables the hot oil to be cooled as is
• Toughness of the lubricant film
circulated through the system and into the
(Timken load rating)
machine. This keeps the oil at an optimum
working temperature. The system is
Operation
automatically controlled by a thermostat.
Oil is supplied the Automax bearings via a
BL-Pegson strongly advise against running
hydraulically driven pump. This oil is filtered
the Automax empty after initial start-up in
clean and pumped under pressure to the
cold weather. Even hot oil can be chilled
main bearings (eccentric and cone head)
when entering a cold machine and it’s
and via a separate line to the countershaft
reluctance to return to the tank may result in
bearings. It is then piped back to the tank
a slight leak from the machine via the cone
under gravity.
head/seal ring and/or mainframe/seal ring.
Ideally, once the crusher is started rock
An automatic alarm is fitted to the lubrication
should be put through it as soon as
tank which will sound if there is insufficient
possible. BUT THE AUTOMAX MUST
pressure or flow to the machine. It is difficult
NEVER BE STARTED WITH ROCK
to give a working pressure as this varies
PRESENT IN THE CRUSHING
significantly under different working conditions
CHAMBER.
so the alarm should be used as an indication of
a fault arising.
1000SR
Page 26
Air Blast Bypass Valve machine and will activate an alarm if the oil is
During initial start-up the viscosity of the oil is too hot, ie. greater than 80°C.
very high which results in an increase in pump
pressure and a reduction in oil flow through Pressure Relief Valve
the air blast cooler and into the machine. In order to protect the lubrication system
against dead head pressures a relief valve is
To overcome this a bypass valve is situated after the pump. This is set (at
incorporated in parallel to the cooler. When a manufacture) to open at a designated pressure
predetermined pressure is reached the valve of 3.8 BAR (55psi). It is important that this
opens allowing oil to pass to the machine device is not adjusted or tampered with.
without entering the cooler. Once the viscosity
is reduced the valve closes and oil passes
through the cooler. This is normal on initial
start-up with cold oil.
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.
Temperature Monitoring
The temperature of the returning oil is
monitored to ensure correct operation. One
thermostat controls the air-blast cooler fan
whilst a second thermostat will stop the
1000SR
Page 27
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, BL-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
increase at an identical test temperature it is
and changed when advised to do so. This
time to change the oil.
will provide optimum use of oil as
replacement is only made when proved Reduction in Additives
necessary. This will also give an indication It is recommended that the oil is changed
on the machines’ condition. This could when the level of additives is reduced by
indicate that the change should be made 50% compared to new oil values.
away from the 1000 hours guideline and
will be because of usage and environment It is suggested that any of the above
effects on the oil life. tests could be carried out by a
laboratory to establish the optimum
There are several indications that it is time time for oil changes. Consultation with
to change the oil in the lubrication system:- 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
Wear Metal Elements
1000SR
Page 28
9.5.5 Automax Recommended Oil

The recommended oil is good quality:-
WARNING
WEAR PERSONAL
Summer Grade - EP220 PROTECTIVE EQUIPMENT.
Winter Grade - EP150 Information for relevant
warning.
Refer to the lubrication chart (Section
LOCKOUT PLANT.
9.4.4) for details. Refer to Section 9.1, Safety
Add oil to the tank (Figure 9e) with a Procedure.
recommended lubricant from the list
provided in this manual through the filler cap
using the level indicator to ensure the
correct level is reached. This should be
approximately 223 litres (59 US galls.).
Unless consistently cold climates are

experienced, ie. below 4º C (39º F) 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 9d.
1000SR
Page 29
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:- Information for relevant
warning.
The first filter change should be after
LOCKOUT PLANT.
100 hours operation. Refer to Section 9.1, Safety
Subsequent filter changes should occur Procedure.
every 500 hours unless the oil filter blocked
warning activates between these intervals. It
is important the use the correct replacement
filter cartridges as too fine a filter element
will become blocked prematurely whilst too
coarse an element will not filter efficiently
enough to protect the machine.
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.
1000SR
Page 30
9.5.7 Automax Oil Filter

Replacement WARNING
Both filters (Figure 9e) are to the same WEAR PERSONAL
specification and operate in parallel. They PROTECTIVE EQUIPMENT.
must be changed at the same time with Information for relevant
NEW filters as recommended in Section warning.
9.5.6.
LOCKOUT PLANT.
Both filters are non-cleanable elements and Information for Lockout
must always be replaced with NEW Procedure.
cartridges of the approved pattern.
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.
1000SR
Page 31
9.5.8 Automax Oil Lubrication

System General Maintenance WARNING
Tank WEAR PERSONAL
Ensure that the filler/breather cap is clean, in
place and tight, at all times. warning.
LOCKOUT PLANT.
Make sure that the oil tank cover is sealed Refer to Section 9.1, Safety
down and that all bolts are in place and Information for Lockout
tight. Procedure.
Before carrying out any maintenance on the

tank or associated parts, thoroughly clean
the area to prevent any contaminents
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
1000SR
Page 32
9.6 Automax - Hydraulics

Overview DANGER
The Upper Frame of the Automax is raised Refer to Section 9.1, Safety
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).
WARNING
Six hydraulic cylinders provide control over
WEAR PERSONAL
the machine’s discharge setting through PROTECTIVE EQUIPMENT.
vertical movement of the upper frame. Refer to Section 9.1, Safety
Additionally the system also permits automatic Information for relevant
overload release and reset, unblocking of the warning.
crushing chamber and monitoring and LOCKOUT PLANT.
indication of manganese wear (Section 7.4). Refer to Section 9.1, Safety
Procedure.
The Automax hydraulic system is integrated
with the overall plant hydraulic system which
drives the tracks, conveyors, etc. and for
details of oil replenishment, filter changes, etc.
refer to Section 9.14
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 panel (Figure 9f) located inside a lockable
cabinet with connections by both high
pressure hydraulic hoses and screened electric
cable for the linear position sensor.
1000SR
Page 33
Gauge measuring
Wedge Pressure
Figure 9f Adjustment Mode Menu Screen and Automax Pressure Gauge
1000SR
Page 34
9.6.1 Automax Hydraulic System

Maintenance Procedure DANGER
This is a high pressure system SKIN INJECTION HAZARD
and only suitably qualified Refer to Section 9.1, Safety
experienced engineers should Information for relevant warning
DANGER
tackle any problems that may
arise.
Maintain in accordance with the reservoir WARNING

level, filter changes and the schedules and WEAR PERSONAL
fluid types (Section 9.4.4, 9.4.5 & 9.4.6) PROTECTIVE EQUIPMENT.
ONLY USE A RECOMMENDED Refer to Section 9.1, Safety
FLUID.
warning.
It is essential when replenishing hydraulic LOCKOUT PLANT.

fluid, attending to filters, etc. to apply the
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 on the

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

Section 9.10, Fault Finding, together with
possible remedies. Always contact BL-
Pegson’s local dealer or the factory in case
of doubt.
1000SR
Page 35
9.7 Automax - Manganese When replacing the manganese liners,

Change Procedure always fit both a new mantle and a new
concave at the same time.
9.7.1 Guidance for Changing the
Manganese Mantle and Concave Always fit a new manganese
Both the mantle and concave liners are mantle and concave as a ‘pair’.
locked against their mating parts using It is detrimental to the
tapers (angled faces). If these liners are operation of the machine to do
worn too thin they will not be able to hold otherwise.
tight against 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 45-50mm (13/4” -

2”) of wear on the liners, as a pair.
Take note of the ‘wear’ shown on the

display.
680 mm (26 /4”) minimum
Inspect the liners on a daily basis, for

possible ‘tramp metal’ damage and also any
evidence of an uneven wear pattern
3
developing.
The manganese liners must be changed

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance
(Figure 9g) when the rams are fully closed
is 680mm (263/4”).
Figure 9g Minimum Ram Dimension
1000SR
Page 36
9.7.2 Filler Handling

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

filler backing resin while agitating.
Mantle - 2 x 10kg.Tubs
Concave - 2 x 10kg.Tubs • Completely mix the filler backing resin
and hardener, continue mixing until all of
the filler is one colour, ie. completely
mixed.
1000SR
Page 37
• It is necessary to work with both agents Filler Hardening Time

at 16-32 °C (60°-90°F). Therefore, in
hot weather the container may have to The filler needs about 12 hours to harden at
be cooled and warmed in cold weather 20 °C (68°F).
to within the above temperature range.
• Both agents can be mixed with the In lower temperatures the hardening
supplied agitating adaptor attached to process takes longer and it may be
the top of an electric drill. necessary to heat the mantle and concave
etc. in these circumstances.
• The filler can be used only once (cannot
be reused) and if mixed with the
hardener it cannot be stored.
Low Temperature Mixing
• Always store both agents at 15-30 °C Protect the filler resin / hardener from cold
(59-86°F) and avoid storing in direct weather (< 5°C [41°F] ). Remove the chill
sunlight. from the metal by the use of hot air guns/
blowers. - Do not use an open flame. To
• Never smoke whilst handling these ensure the shortest curing time at low
agents. temperatures, the filler resin component
(LARGER BAG) should be pre-warmed
• Ensure that application surfaces are dry to 25-30°C (77-86°F) before mixing. This
before pouring. Wet surfaces will result is best achieved by applying a hot air
in reduced stength of the filler. blower on the outside of the tin .
NB - REMOVE HARDENER FROM
• Pour the filler immediately after mixing, TIN BEFORE APPLYING HEAT.
ie within 10 - 15 minutes at 25°C. ALTERNATIVELY, place the filler resin
Higher temperatures will shorten, and bag (LARGER BAG) in a bucket of hot
lower temperatures increase, the water.
working time. NB - DO NOT PRE-HEAT THE
HARDENER (SMALLER BAG).
• When making pouring ports with putty, Thoroughly mix the filler resin and hardener
prevent the filler from leaking out. using the included mixing tool or a spiral
paddle and pour immediately.
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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 warning.
off the Automax Upper Frame complete FALLING HAZARD.
with the concave inside Refer to Section 9.1, Safety
Before the Upper Frame can be removed 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. Function Enable Button
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.
3. Start the engine (Section 7.2.1). Keep

the engine speed at 1200rpm,
4. At the control panel (Figure 7d) press

the F4-SET UP button for the LED to
Feed Conveyor Raise/Lower Buttons
illuminate to confirm active status with
the message ‘PROCEED TO SET UP
STATION’. This is situated on the
opposite side of the plant (Figure 5h). Figure 9h Set Up Control Station

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Page 39

button is pressed and held whilst WARNING
pressing any of the Set Up buttons. The WEAR PERSONAL
audible warning will sound whenever PROTECTIVE EQUIPMENT.
the enable button is pressed. Refer to Section 9.1, Safety
5. Pressing and holding the enable button, warning.
press the FEED CONVEYOR RAISE FALLING HAZARD.
button to raise the conveyor so that the Refer to Section 9.1, Safety
two locating pins (Figure 9i) can be Information for relevant
warning.
inserted through the bottom pair of
holes in the upper telescopic legs. Fit
the security pins into the end of each Upper Telescopic
pin. Leg
Locating Pin
6. Press the FEED CONVEYOR
LOWER button 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.
Whilst working on the

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

8. Disconnect the level sensor mast before

unbolting and lifting off the Automax Lower Telescopic Leg
feed box.
Figure 9i Feed Conveyor Support and

Locating Pins
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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
Information for relevant warning
Procedure
1. Observe all safety warning..

WARNING
WEAR PERSONAL
2. Start the engine (Section 9.1.1). Keep PROTECTIVE EQUIPMENT.
at 1200 rpm. DO NOT run any of the Refer to Section 9.1, Safety
machinery. Information for relevant warning.
3. At the control panel (Figure 7d) press LOCKOUT PLANT.

the ADJUST button for the LED to Refer to Section 9.1, Safety
illuminate to confirm active status. Procedure.
4. Operate the function buttons in turn F4, FALLING HAZARD.

repeat F4 and then F2. On the Refer to Section 9.1, Safety
Adjustment Mode Menu screen now
displayed (Figure 9j) press the F5-OPEN
button to raise the Upper Frame to it’s
maximum extent.
Ring down and thus free it from the
5. Close (turn clockwise) the shut off valve Mainframe to provide clearance needed
9B inside the Hydraulic Console (Figure to lift off the Upper Frame. The wedge
9k) to isolate the wedge ring hydraulic pressure indicated on the pressure
circuit from the main hydraulic system. gauge (Figure 9k) should drop away to
0-28 Bar (0-400 psi) as the wedge ring
6. Open (turn anticlockwise) the shut off frees off.
valve 9A inside the Hydraulic Console
(Figure 9k) to allow all pressure in the Ensure the Wedge Ring is free
wedge ring circuit to be released otherwise crane overload and/
thereby removing the loading from the or sudden violent separation
Wedge Ring. may occur when lifting off
(Step 14 below).
7. Drop the Upper Frame with the
F6-CLOSE button to push the Wedge continued on the next page.........
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Page 41

(current functions shown on screen above)
Figure 9j Adjustment Mode Menu Screen Display
Diagnostic Pressure
Gauge measuring Gauge only
Wedge Pressure
Valve 9B
Diagnostic Pressure
Gauge only
Valve 9A
Figure 9k Wedge Jack Circuit Shut Off Valves
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8. With suitable cranage connect lifting

tackle to the three lifting eyes in the
Upper Frame (Section 9.2 for weights
DANGER
and lifting points) but leave the slings SKIN INJECTION HAZARD
with a small amount of slack. Information for relevant warning
Under no circumstances
attempt to take the load on the
cranage at this stage as a
serious overload condition may
WARNING
arise. WEAR PERSONAL
9. Using three 5 tonne capacity x 150 mm Information for relevant
stroke hydraulic bottle jacks spaced warning.
equidistant around the lower rim of the
LOCKOUT PLANT.
Upper Frame, extend them equally to Refer to Section 9.1, Safety
take the weight off the clevis pins to aid Information for Lockout Proce-
their removal. dure.
10. Ensure that there is no residual hydraulic

pressure in the Upper Frame hydraulic
cylinder circuit by pressing the F5-
Note: The clevis pins should be
OPEN and F6-CLOSE buttons briefly
removed from right to left when
and in quick succession until the
facing the machine to avoid
pressure gauge (Figure 9k) on the
disturbing the bearing located
hydraulic panel reads zero. Follow this
against the shoulder inside each lug
procedure to remove the clevis pins
on the Upper Frame.
with the minimum of effort.
13. Remove the linear sensor cover (Figure
9l) and lay to one side. Disconnect the
top bolt from the unit. This is essential
to avoid damage to the sensor unit.
Do not neglect to ‘Lockout’ to
prevent the plant being started
14. Lift off the Upper Frame assembly from
whilst maintenance work is
the machine (Refer Section 4.2 for the
being carried out.
weight of the complete assembly).
Support on wooden blocks on the
12. Remove the top clevis pin from each
ground (Figure 9m).
hydraulic cylinder and pull each cylinder
outwards, allowing them to lie flat.
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Page 43
Linear Sensor Upper Frame

Unit Cover
Clevis Pin
Grease Nipple x 12
Hydraulic Cylinder
Figure 9l 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.
FALLING HAZARD.
Removing the Concave Refer to Section 9.1, Safety
When gas cutting through the warning.
concave it is essential that
breathing apparatus is worn as
when the metal is broken
through the backing material
gives off toxic fumes.
ground. Remove any nicks or burrs with

Procedure a file or grinder. Inspect the ground
surfaces of the new concave and
remove any nicks or burrs in the same
1. Observe all safety warnings. manner.
2. Following removal of the Upper Frame

(Section 9.7.3.2) gas cut through the
three lugs as shown (Figure 9m).
3. Drive down and out the old concave

with a heavy sledge hammer.
4. Remove the old backing material and

dowels (these can be driven out from
below) and inspect the lower inside
bevelled edge of the Upper Frame
seating where the surface has been
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Page 45
Figure 9m Gas Cutting the Old Concave
Figure 9n Supporting the New Concave
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Page 46
Mounting the Concave

WARNING
When supporting the new Concave prior to
WEAR PERSONAL
lowering the Upper Frame on to it, ensure PROTECTIVE EQUIPMENT.
that the supports do not protrude past the Refer to Section 9.1, Safety
sides of the Concave (Figure 9n) and that it Information for relevant
is high enough off the ground to allow the warning.
Upper Frame to be fully lowered. LOCKOUT PLANT.
Release agent needs to be applied to the Information for Lockout
internal surface of the Upper Frame where Procedure.
it will be in contact with the backing filler to
ease separation when the manganese is next
changed.
Procedure
6. After rotation, equally locate the
concave wedges between the concave
lugs and upper frame (Figure 9o).
An estimate should be made of the
2. Apply release agent (obtainable from correct position for the concave
BL-Pegson) to the cleaned inner wedges and then tapped in slightly to
surface of the Upper Frame. see how the concave settles. If the
position does not look correct with
3. Place the new concave on three respect to the dowel holes then they
wooden blocks (see preamble above) should be removed and replaced.
ensuring it is level
Also check to see that the Concave is
4. Lift the upper frame over the concave evenly seated on the machined surfaces
and turn it so that the concave lugs align at the bottom and there is an equal
with the recesses on the upper frame depth all around at position A (Figure
and gradually lower the upper frame 9p). If there is a gap between the two
until concave lugs pass through the the Concave must be properly re-
recesses and stop lowering. seated.
5. Rotate the upper frame to the left so Once the position is satisfactory and the
that the concave lugs are located Concave is correctly seated, the
approximately 50mm (2”) past the wedges should be driven fully home.
dowel holes.
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Page 47
7. Insert the dowels into the holes in the

upper frame and drive home. WARNING
WEAR PERSONAL
Note: If there is a gap between the PROTECTIVE EQUIPMENT.
concave wedge and the dowel pin and Refer to Section 9.1, Safety
this cannot be rectified by moving the Information for relevant
wedge position, it may be necessary to warning.
tighten the wedges and then weld a LOCKOUT PLANT.
piece of steel between the wedge and Refer to Section 9.1, Safety
the dowel pin(s). Information for Lockout Proce-
dure.
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 three 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.
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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Page 48
RECESS
Figure 9o Plan View of the Upper Frame showing the correct wedge position
Figure 9p Sectional view of the concave showing the gap check at A
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Page 49
9.7.3.4 Replacing the Upper Frame

In order the reconnect the six DANGER
hydraulic cylinders to the SKIN INJECTION HAZARD
Upper Frame (Step 6 following) Refer to Section 9.1, Safety
the engine must be running to Information for relevant warning
provide hydraulic pressure.
ENSURE the risk assessment

for this procedure covers the WARNING
necessity for very effective WEAR PERSONAL
communication between any PROTECTIVE EQUIPMENT.
personnel involved in the task, Refer to Section 9.1, Safety
taking into account the visual Information for relevant
warning.
restrictions between the
Automax control panel and the LOCKOUT PLANT.
crusher and also engine noise. Refer to Section 9.1, Safety
dure.
Whilst the Upper Frame is off the machine
for the renewal of the manganese wearing
parts, take the opportunity of examining the 2. Using the cranage used to remove the
condition of the internal linerplates, frame Upper Frame, lower over the machine
and countershaft arm shields and replace if whilst taking care to line up the anti-
necessary. rotation stop on the Upper Frame with
the guide post. Hold in a suspended
Also, clean out any solidified debris and position with the crane with a gap
generally check around the machine for any between the mantle and concave..
faults which need to be rectified.
3. Start the engine (Section 9.1.1). Set the
Clean the contact face all around the engine speed to 1200rpm. DO NOT
Wedge Ring and apply a coating of fresh run any of the machinery.
lubricant (MOLY-BENTONE MP
Standard Grade grease). Make sure this is 4. At the control panel (Figure 7d) press
not contaminated with dirt or grit prior to the F2-ADJUST button for the LED to
replacing the Upper Frame. illuminate to confirm active status.
5. Operate the function buttons in turn F4,

Procedure repeat F4 and F2. On the Adjustment
Mode Menu screen now displayed
1. Observe all safety warnings. (Figure 9j).
continued overleaf.................
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Page 50
6. Press the F5-OPEN or F6-CLOSE

button (as appropriate). Only one
cylinder will respond at any one time
DANGER
and, ‘toggling’ between the buttons, line SKIN INJECTION HAZARD
up and insert each of the six clevis pins Information for relevant warning
in turn. Secure with the washers and
split pins.
Note: The clevis pins should be

inserted from right to left when
WARNING
facing the machine to avoid WEAR PERSONAL
disturbing the bearing located in it’s
required position against the Information for relevant
shoulder inside each lug on the warning.
Upper Frame.
LOCKOUT PLANT.
7. Close down the plant (Section 8.2) and Information for Lockout Proce-
implement the Lockout Procedure. dure.
8. Replace the linear position sensor and

replace the cover to the housing.
9. Detach the cranage and replace the

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

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

revert to the operating position.
12. Carry out the ‘Initial Discharge Setting

and Calibration’ procedure described in
Section 7.4.1, following which the
Automax is ready to recommence
crushing.
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Page 51
9.7.3.5 Changing the Mantle

The operation is carried out with the head
WARNING
left in situ. The internal parts of the WEAR PERSONAL
Automax are therefore not disturbed or PROTECTIVE EQUIPMENT.
exposed to harmful dust. Information for relevant
warning.
In use all manganese steel will ‘creep’ due to
LOCKOUT PLANT.
the nature of the material. When creep occurs Refer to Section 9.1, Safety
stress is created in the material which will have Information for Lockout
to be relieved by suitable cutting of the Procedure.
Mantle. This will be necessary in order to
facilitate removal. FALLING HAZARD.
Removing the Mantle
warning.
When gas cutting through the

concave it is essential that
breathing apparatus is worn as
when the metal is broken
through the backing material
gives off toxic fumes. 4. Break loose the fit between the Mantle
and the Cone Head. This is best
Procedure achieved by striking the lower section of
the circumference with a hammer then
levering the Mantle clear of the Cone
1. Observe all safety warnings. Head.
2. With the Upper Frame removed 5. Insert short blocks of wood between
(Section 9.7.3.2) gas cut round the the Mantle and Cone Head in three
mantle within 20-30mm (3/4” - 1 1/4”) places around the circumference so as
from the top (Figure 9q). to leave a gap through which lifting
chains can be placed. Three equally
3. Once the Mantle is cut the Mantle Nut spaced lifting chains should be passed
can then be removed by turning through this gap and the hooks put
CLOCKWISE with the mantle nut round the bottom of the mantle (Figure
wrench (Figure 9r). Ensure that the 9s) and the mantle lifted off.
mantle nut wrench is secure by
dropping a suitably sized bolt through
the hole in the end of it.
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Page 52
6. Remove the old backing material and

inspect the Cone Head seating where WARNING
the surface has been ground. Remove
WEAR PERSONAL
any nicks or burrs with a file or PROTECTIVE EQUIPMENT.
grinder. Inspect the ground surfaces of Refer to Section 9.1, Safety
the new Mantle and remove any nicks Information for relevant
or burrs in the same manner. warning.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
warning.
Figure 9q Gas cutting the Mantle
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Page 53
MANTLE NUT WRENCH
SECURITY BOLT
Figure 9r Mantle Nut Wrench

securely fitted
Figure 9s Lifting chains correctly fitted
Sections through the Automax Cone Head
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Page 54
Mounting the Mantle

WARNING
Release agent needs to be applied to the
WEAR PERSONAL
Cone Head where it will be in contact with PROTECTIVE EQUIPMENT.
the backing filler to ease separation when Refer to Section 9.1, Safety
the manganese is next changed. Information for relevant
warning.
Procedure LOCKOUT PLANT.

Procedure.
FALLING HAZARD.
2. Apply release agent (obtainable from Refer to Section 9.1, Safety
BL-Pegson) to the unmachined surface Information for relevant
all around the Cone Head (Figure 9t). warning.
3. Place the new Mantle onto the Cone

Head and tighten down the Mantle Nut
by turning COUNTER-CLOCKWISE
with the Mantle Nut Wench (Figure 9r). 5. Prepare the filler (Section 9.7.2) and
It is sufficient to tighten this by hammer pour the correct quantity of mixed filler
blows without having to replace the at the top of the Mantle making sure it is
Upper Frame and wedge against the equally distributed all round.
Concave.
After mixing, the filler must be
4. The Mantle Nut was tightened to align poured IMMEDIATELY to
the Mantle and seat it firmly on the ensure complete penetration.
Cone Head at A (Figure 9u). Now the
Mantle Nut needs to be released so that 6. When the filler reaches 15mm (5/8”)
the filler can be poured. Release the from level B (Figure 9q) stop pouring,
Nut by turning CLOCKWISE with the fit the Mantle Nut and first lightly tighten
Mantle Nut Wrench. using the Mantle Nut Wrench. Fully
tighten by hitting the wrench with a
Note: When the Mantle Nut is hammer in a COUNTER-
removed, grease the threads on the CLOCKWISE direction. The
Cone head so any spills when pouring replacement is now complete. Refer to
the backing filler can be easily wiped Section 9.7.2 for the filler hardening
off. time.
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Page 55
Figure 9t Section through the Cone Head showing where to apply release agent
Figure 9u Section through the Cone Head showing correct filler level
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Page 56
9.8 Automax - Wedge Ring may result. Possible causes of the are
Maintenance crushing at closed side settings which are
too tight, out of round manganese or poor
The Wedge is fundamental to Wedge Ring adjustment.
how the cone crusher
functions. It provides damping Low wedge pressures are
and guidance to the Upper equally as undesirable as high
Frame assembly. ones. When testing the wedge
pressure it should be between
Poor machine performance and 55 and 82 BAR (800 - 1200
crusher downtime are often psi).
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 9w)
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
Only use Moly Bentone
(NB. The minimum amount of Moly
grease (Section 9.4.5) for
Bentone grease should be added to
lubricating the Wedge Ring
restore smooth travel). In situations where
the crusher setting is not changed for long
periods it is good practice once a week to
work the Upper Frame from the top to
bottom of it’s stroke several times to
redistribute the grease.
The crusher must not be allowed to operate

with regular dumping (Section 7.3.2) or
bouncing of the Upper Frame or damage
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Page 57

(current functions shown on screen above)
Figure 9v Adjustment Mode Menu Screen Display
Diagnostic Pressure
Gauge measuring Gauge only
Wedge Pressure
Valve 9B
Diagnostic Pressure
Gauge only
Valve 9A
Figure 9w Wedge Jack Circuit Shut Off Valves
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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 WARNING
good performance of the Automax crusher WEAR PERSONAL
it is recommended that this should be Refer to Section 9.1, Safety
checked daily. The pressure gauge near Information for relevant
the panel (Figure 9w) gives an accurate warning.
indication of whether the Wedge Ring
assembly is functioning correctly.
The Automax must not be

allowed to operate with regular 4. Operate the function buttons in turn F4,
dumping or bouncing of the repeat F4 and F2. On the Adjustment
Upper Frame or damage may Mode Menu screen now displayed
result. Possible causes could (Figure 9v) press the F5-OPEN button to
be crushing at too small a raise the Upper Frame to approximately
setting, out of round 20mm (3/4”) above the set point.
manganese (Section 9.9) or
poor Wedge Ring adjustment. 5. Press F8-ESC and then F3-AUTO
MODE and observe the pressure
reading on the pressure gauge (Figure
Procedure 9w). The pressure should be in the
range 55 - 82 BAR (800 - 1200 psi).
6. Whilst the Upper Frame is moving
2. Start the engine (Section 9.1.1). Keep check for smooth movement with no
the engine speed to 1200rpm. DO sticking at the start or whilst travelling.
NOT run any of the machinery.
7. If the pressure reading is above or
3. At the control panel (Figure 5d) press below the range indicated above or the
the F2-ADJUST button for the LED to action is not smooth, remedial action is
illuminate to confirm active status. required (Section 9.8.2).
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Page 59
8.8.2 Low Wedge Pressure

If the wedge pressure has been checked
DANGER
and found to be below 55 bar (800psi) then SKIN INJECTION HAZARD
the cause must be investigated and where Refer to Section 9.1, Safety
necessary, the appropriate action taken. Information for relevant warning
Procedure WARNING
WEAR PERSONAL
1. Low or fluctuating dumpy jack circuit Information for relevant
pressure. warning.
Check circuit is free from leaks, and
pressure switch 11 (Figure 9aj) is
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.
This can reduce the friction between the
wedge and the upper frame and hence
limit the wedge pressure.
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 WARNING
for checking the wedge pressure. WEAR PERSONAL
Procedure warning.
2. Ensure that the feed conveyor and

Automax feed box are free from stone
and dirt.

the engine speed to 1200rpm. DO

the F2-ADJUST button for the LED to
illuminate to confirm active status.
5. Operate the function buttons in turn F4,

repeat F4 and F2. On the Adjustment
Mode Menu screen now displayed press
the F5-OPEN button to raise the Upper
Frame to it’s maximum extent.
6. Close the shut off valve 9B adjacent

to the Automax Hydraulic Panel
(Figure 9x) to isolate the wedge ring
Dumpy Jack hydraulic circuit from the
main hydraulic system.
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Page 61
7. Open the shut off valve 9A inside the

hydraulic console (Figure 9x) to allow DANGER
all pressure in the Dumpy Jack circuit to
be released thereby removing the
loading from the Wedge Ring. Information for relevant warning
8. Lower the Upper Frame with the

F-6CLOSE button to push the Wedge
Ring down and thus free it from the
WARNING
WEAR PERSONAL
Mainframe. The wedge pressure PROTECTIVE EQUIPMENT.
indicated on the pressure gauge (Figure Refer to Section 9.1, Safety
9w) should drop away to 0-28 Bar (0- Information for relevant
400 psi) as the Wedge Ring frees off. warning.
9. Close shut off valve 9A (Figure 9x) to

10. Open shut off valve 9B (Figure 9x) to

11. Press the F5-OPEN button to raise the Shut Off Valve 9B
Upper Frame to approximately 20mm
(3/4”) above the set point.
12. Press F8-ESC and then F3-AUTO

MODE for the control system will bring
the machine down to the required gap
position or go through the initial Closed
Side Discharge Setting procedure
(Section 7.4.1) as necessary.
Diagnostic Pressure Gauge

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

Manganese - Causes and manganese, due to the concentrated
crushing area. This gets worse as the
Effects
process is a vicious circle.
When the Mantle and Concave are new
G) Due to effect of E above the machine
both of the wearing surfaces are round.
will become reluctant to accept a
They should remain round throughout their
choke feed. The machine will dump
working life, ie. the wear should be
as the crushing pressure reaches
consistent and remain round. Should the
excessive 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
J) Adjust the plant settings (Section 7.2.12)
feed.
to ensure the Automax is choke fed at
all times.
C) inconsistent stop/start feed.
K) Adjust the plant settings (Section 7.2.12)
Effects:
to ensure the feed to the Automax is
continuous with stop/starting of the feed
D) Produces an uneven load on the
kept to a minimum.
Wedge, reducing it’s life and
producing a 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.
1000SR
Page 63
9.9.1 Checking Manganese for Out

of Round DANGER
Check 1 - The Mantle. ENTANGLEMENT HAZARD.
Procedure warning.
1. Observe all Safety Warnings. WARNING

2. Ensure that the feed conveyor and WEAR PERSONAL
Automax feed box are free from stone PROTECTIVE EQUIPMENT.
and dirt. Information for relevant
warning.
LOCKOUT PLANT.
implement the Lockout Procedure. Refer to Section 9.1, Safety
Note: it is important when checking the Procedure.
Mantle for ‘out of round’ that the
Eccentric does not move. Take the FALLING HAZARD.
drive guard off and watch for any Refer to Section 9.1, Safety
movement of the countershaft. If warning.
movement is noted repeat the whole
procedure described below, again.
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.

the engine speed to 1200rpm. DO
............continued on next page
1000SR
Page 64

the F2-ADJUST button for the LED to
illuminate to confirm active status.
DANGER
ENTANGLEMENT HAZARD.
8. Operate the function buttons in turn F4, Information for relevant
repeat F4 and then F2.to display the warning.
Adjustment Mode Menu screen (Fig. 9v).
9. Ensure that everyone is clear of the WARNING

machine. Press F6-CLOSE. Release WEAR PERSONAL
the button the moment the pressure PROTECTIVE EQUIPMENT.
starts to rise and note the figure showing Refer to Section 9.1, Safety
on the gap indicator. Press F5-OPEN Information for relevant
warning.
button to raise the Upper Frame
approximately 15 -20mm (5/8”- 3/4”). LOCKOUT PLANT.
10. Close down the plant (Section 8.2) and Procedure.
FALLING HAZARD.
11. Rotate the Cone Head slowly by hand, Refer to Section 9.1, Safety
stopping it when it has gone through 90º Information for relevant
whilst doing this watch the vee belts to warning.
ensure that the eccentric does not move
in the Cone Head. The second mark on
the mantle plate should now be lined up
with the mark on the Concave. 0
12. Repeat steps 6 to 10.
13. Repeat the process so that you have -1 -1

four values for the Mantle. If the Mantle
is round it should show similar values to Typical values
Figure 9o. Mantle OK.
Figure 9y Mantle Check
1000SR
Page 65
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. Information for relevant
warning.
HOWEVER, this time the Cone head and
Eccentric MUST move as one. To do this
the Flywheel should be rotated slowly by WARNING
hand. The Mantle procedure (previous WEAR PERSONAL
page) can be followed but rotating the PROTECTIVE EQUIPMENT.
Flywheel not the Cone head. It is useful to Refer to Section 9.1, Safety
have an assistant watch the Cone Head Information for relevant
rotate whilst the vee belts are rotated to warning.
ensure it is moving. In order to prevent slip LOCKOUT PLANT.
between the Eccentric and Cone Head:- Refer to Section 9.1, Safety
Procedure.
A) Ensure slow, gentle movement of the
Eccentric, via the vee belts.
FALLING HAZARD.
B) Make sure the Concave is well clear Information for relevant
of the Mantle when the Eccentric/ warning.
Cone Head is being rotated.
As a final check for any slip between the 0

Eccentric and the Cone Head, repeat the 0
first touch again as the example below:-
If there is a difference of more

than 7mm (c.1/4”) between any -1 -2
two values of the four
measured, that piece of Typical values
manganese must be changed Mantle OK.
immediately.
1
Figure 9z Concave Check
1000SR
Page 66
9.10 Automax - Fault finding.
Fault. Possible Cause. Procedure.
GENERAL.
Machine stops. Overload through discharge Clear machine

setting too low. adjust setting.
Tramp metal fixed in crushing Clear machine

chamber. adjust setting.
Packing in crushing chamber. Clear discharge

chute.
Lubricating oil flow low / Check operation of

temperature high. lubrication system.
Build up in discharge chute. Clear blockage check

chute.
Power supply / drive motor Check power supply /

failure. drive motor, see
manufacturer’s
literature
Broken vee belt (s) Replace belt (s).
Discharge setting not Hydraulic fluid leakage. Check all hydraulic

maintained. components, couplings,
pipes and hoses.
1000SR
Page 67
.
Fault Possible Cause Procedure
Reduction in discharge Crushing pressure too high Adjust setting.

setting not possible.
Hydraulic system faulty Check for internal/
external leaks.
Manganese out of round Check manganese.
Manganese worn out. Change manganese.
Directional control valve Check solenoid.

inoperative.
Relief valve dirty or faulty. Dislodge dirt from

under seat / check
valve spring.
Couplings at hydraulic ring- Investigate and

main faulty. correct.
Packing in crushing chamber. Adjust machine.

(excessives ‘fines’ in feed
Increase in discharge Wedge too tight Grease and

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

‘bounces’.
Wedge pressure low / Tighten assembly/

Wedge assembly loose. repressurise
Adjusting wedge assembly has Check fibre pads

no apparent effect. worn out or require
changing.
1000SR
Page 68
Hydraulic cylinder (s) faulty. Investigate and

correct.
Manganese out of round. Check feed

segregatoin.
Check manganese
for out of round,
change as
necessary.
Crushing at excessively tight Change setting.

closed side setting.
Feed chute incorrectly installed. Investigate and

correct.
Erratic movement of Air in hydraulic system. Bleed system / check

hydraulic cylinder(s). for leaks.
Hydraulic system filter (s) Replace.

blocked.
Crusher motor stops. Overcurrent due to voltage drop. Check the

transformer capacity.
Overcurrent due to overload. Suitable feed

amount ?
Uniform feeding ?
No packing ?
Insufficent oil supply?
Damaged bearing ?
Tramp metal ?
Machine overloaded?
1000SR
Page 69
Interlock operation. Pump motor rotating?

Deteriorated pump
performance or lack
of oil ?
Return oil temperature
too high?
Abnormal sound from Damage of the bearing of the Contact BL-Pegson

the crusher. countershaft.
Damage of the countershaft gear. Contact BL-Pegson
Loose mantle. Inspect conehead/

mantle for damage.
Refit as when changing
manganese.
Loose or falling concave. Adjust the concave

wedge.
Check the mantle

rotating direction.
Check the touching

surface.
Check for partial wear.
The particle size of Mantle / concave worn out of Check for out of round.
the crushed product is round.
coarse.
The indicated setting value is Measure the actual
different from the actual value. setting with a lead ball
etc.
1000SR
Page 70
Wedge ring adjustment failure. Adjust the wedge ring.
Partial wear of the mantle and Check the feeding

concave. chute.
HYDRAULICS.
The pump doesn’t start. Electrical fault Check the thermal relay
connection and motor,
fuses & connections.
Rotating direction error. Check the rotating

direction and
reconnect.
Insufficent quantity of oil in the Refill oil.

tank.
Pump siezed. Check that pump shaft

rotates, fit replacement
if faulty.
The pump starts but no Clogged suction side piping. Clean the piping and
pressure and discharge carry out flushing.
occur.
Clogged suction side filter. Remove and clean.
Air mixed from the suction side. Re-tighten the coupling

screw.
Replace the piping.
Oil viscosity too high. Check for the specified

brand.
1000SR
Page 71
Defective or damaged Check and replace.

pump and coupling.
Relief valve setting failure. Contact BL-Pegson.
Pump noise. Air mixed from the suction Clean the piping and
side. carry out flushing.
Clogged air breather. Disassemble and

clean.
Sound in the relief valve. Disassemble. Clean or

replace the spring
nozzle.
High oil viscosity. Check for the specified

brand.
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 valve. Replace valve

possible - system
will not build up or
maintain pressure. Solenoid operated vent valve Replace valve.
unseated.
1000SR
Page 72
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.
Insufficent oil quantity. Check the oil level

gauge.
Refill as necessary.
1000SR
Page 73
Downward adjustment One or both quick release Inspect, replace as

not possible - high 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 valve Check operation of

inoperative. solenoid, replace if
necessary.
One or both quick release Inspect replace as

couplings faulty. required.
Mechanical blockage on Investigate crusher.

crusher.
1000SR
Page 74
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.
Insufficent oil quantity. Check the oil level gauge.

Refill as necessary.
Oil in system becomes Pump running continuously Check for symtoms of

excessively hot. under pressure. pressure build up.
LUBRICATION SYSTEM.
The oil cooling effiency Cooling matrix choked with Disassemble and
is deteriorating. dust clean.
Dust depositing at the bottom Clean the tank.

of the tank.
Abnormal sound from the High oil viscosity. The sound becomes low
as the oil pump. oil temperature rises.
The gear is damaged. Dissasemble and clean

or replace.
The oil heater cannot Thermostat failure. Replace.

be turned off.
Thermostat setting failure. Correct the setting.
1000SR
Page 75
The contact type oil Contact type return oil Replace.

temperature gauge temperature gauge failure.
doesn’t operate at the
preset temperature. Setting failure. Correct the setting.
Machine stops Lubrication system safety Check fault display in

interlocks activated Section 7.2.3
Oil chilled on entering cold Look for oil return to

tank. Check oil heater
working.
1000SR
Page 76
9.11 Sizing Screen

WARNING
The sizing screen box is spring mounted on WEAR PERSONAL
an incline, an eccentric shaft providing the PROTECTIVE EQUIPMENT.
screening action, driven by a hydraulic Refer to Section 9.1, Safety
motor, pulleys and vee-belt. The eccentric Information for relevant warning.
shaft has a balance flywheel at each side to
balance the shaft and reduce the movement LOCKOUT PLANT.
transmitted to the rubber mounted bearing Refer to Section 9.1, Safety
blocks. The flywheel counter balance can Information for Lockout
Procedure.
be tuned by the addition or removal of
weights to compensate for the varying FALLING HAZARD.
weight of the screen box if different meshes Refer to Section 9.1, Safety
are fitted. Information for relevant warning.
A short impact screen mesh is fitted below

the conveyor discharge point with the
remainder of the top deck fitted with the
mesh having an aperture to pass the desired Regularly check the screen to make sure
material size. Unless otherwise stipulated at that the screen can vibrate freely without
the time of order the screen is fitted with a fouling against the adjacent conveyors or
45mm (1 3/4”) woven wire mesh. chutework and that hardened material is
not allowed to build up and affect the
Whilst the standard build does not include a performance of the machine. Also check
bottom deck mesh, the screen includes the to ensure that the hydraulic and vee belt
facility to fit a mesh of suitable aperture. drives are operating efficiently.
The normal operating incline of the screen is
25 degrees although this can be adjusted to
23 or 21 degrees if the application is
suitable.
The sizing screen must, in addition to the

scheduled lubrication requirements (Section
9.4), be regularly inspected for any wear,
damage or breakage, with the mesh(es),
mainframe and support springs being paid
particular attention. Make sure the screen
meshes are correctly tensioned to avoid
flexing. Rectify faults immediately.
1000SR
Page 77
9.11.1 Screen Lower / Raise

For transportation and normal screening
WARNING
operations the screen remains at an angle of WEAR PERSONAL
25 degrees. The screen, together with the PROTECTIVE EQUIPMENT.
fines conveyor, can be lowered from this Information for relevant warning.
position for maintenance purposes by using
the hydraulic rams situated inside the
LOCKOUT PLANT.
telescopic suspension units (Figure 9ab).
Use this facility only when the plant is on Procedure.
level hard standing which will provide solid
support. Once the conveyor support leg is FALLING HAZARD.
solidly grounded the screen/fines conveyor Refer to Section 9.1, Safety
link pins can be removed so that the screen
can be raised. In this manner, maintenance
works can be more easily undertaken on
both the screen and fines conveyor.
When the screen is in the

raised position it is essential
for it to be supported with both
locating pins securely fastened
in place with their spring clips
(Figure 9ab)).
Lowering the Screen
Procedure

cover to reveal the control panel and
engine control panel (Figure 7d).
3. Start the engine (Section 7.2.1) but it is

not necessary to switch on the Radio
Remote Hand Set. Keep the engine continued overleaf............
speed at 1200rpm.
1000SR
Page 78

the F4-SET UP button for the LED to WARNING
illuminate to confirm active status with
WEAR PERSONAL
the message ‘PROCEED TO SET UP PROTECTIVE EQUIPMENT.
STATION’. This is situated on the Refer to Section 9.1, Safety
opposite side of the plant (Figure 9aa). Information for relevant warning.
Note: The controls for all services are a LOCKOUT PLANT.

two handed operation and will only Refer to Section 9.1, Safety
operate if the ‘enable’ button is pressed Information for Lockout
and held whilst pressing any of the Set Procedure.
Up buttons. The audible warning will
FALLING HAZARD.
sound whenever the ‘enable’ button is Refer to Section 9.1, Safety
pressed. Information for relevant warning.
5. Pressing and holding the ‘enable’

button, press the button SCREEN
RAISE very briefly to take the weight
off both screen support locking pins.
After removing their spring clips, extract
the pins. (Figure 9ab).The operate the ‘Enable’ Button
SCREEN LOWER button until the
fines conveyor support leg is solidly
grounded.
6. Disconnect the screen from the fines

conveyor by removing the link pins
(Figure 9ab).
Note: ‘Toggle’ between the SCREEN

RAISE and SCREEN LOWER buttons
to remove the weight off the links and
allow the pins to be extracted.
7. Operate the SCREEN RAISE to the

limit of the hydraulic rams so that both
locating pins can be securely fastened in
place with their spring clips. Operate
the SCREEN LOWER button so that
the pins take the weight of the screen. Figure 9aa Set Up Control Station
1000SR
Page 79
Raising the Screen Each linking bar between the

screen frame and the fines
Carry out the actions described in steps 6 conveyor has an additional
and 7 opposite in REVERSE order. locating hole which can be used
to lower the angle of the
Prior to operating the 1000SR ensure that conveyor in relation to the
the weight of the screen is lowered onto the screen by 2 degrees. This may
support pins (Figure 9ab). To do this make be of benefit if roll-back of
sure the pin on each side is in place and material occurs on the conveyor.
operate the SCREEN LOWER button.
This ensures the load is taken on the pins
rather than the internal hydraulic rams.
Fines Conveyor Sizing Screen Screen Telescopic Suspension Units
Fines Conveyor Support Leg Screen Support Pins
Screen/Fines Conveyor Link Pins Set Up Control Station
Figure 9ab Screen/Fines Conveyor Lowered
1000SR
Page 80
9.11.2 Re-Tuning Screen Unit

Re-tune the sizing screen only
WARNING
when the weight of the screen WEAR PERSONAL
has altered if fitting a new or PROTECTIVE EQUIPMENT.
different screen, or if it is Information for relevant warning.
causing vibration in the sub-
frame of the plant. DO NOT
LOCKOUT PLANT.
OPERATE THE PLANT IF
VIBRATION IS PRESENT IN Information for Lockout
THE SUB FRAME.. Procedure.
FALLING HAZARD.
Procedure
2. Operate the plant normally until the

sizing screen and conveyors are empty
of material.
3. Lower the screen together the fines

conveyor (Section 9.11.1).
4. Stop the plant and implement the

lockout procedure (Section 8.2).
5. Remove the flywheel access panels on

both side of the plant.
6. Add or remove weights as deemed

necessary. Always fit identical weights
in the same positions on both flywheels
on the shaft.
7. Re-fit the flywheel access panels.
8. Ready the plant for operation by raising

the screen together with the fines
conveyor, taking care to lower the
1000SR
Page 81
weight of the screen assembly onto the

locking pins (Section 9.11.1). WARNING
WEAR PERSONAL
9. Start the plant (Section 7) including the PROTECTIVE EQUIPMENT.
sizing screen. Refer to Section 9.1, Safety
10. Check for vibration in the sub frame.
LOCKOUT PLANT.
11. If vibration is detected, repeat proce- Refer to Section 9.1, Safety
dure from 3. Information for Lockout
Procedure.
12. If vibration is not present in the sub
FALLING HAZARD.
frame, the plant may be operated. Refer to Section 9.1, Safety
Screen Box
Flywheel
Balance Weights
Figure 9ac Screen Balance Weights

(shown with flywheel guard removed)
1000SR
Page 82
9.11.3 Changing the impact screen

mesh WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.

LOCKOUT PLANT.
2. Operate the plant normally until the Information for Lockout
sizing screen and conveyors are empty Procedure.
of material.
FALLING HAZARD.
3. Lower the screen together the fines Refer to Section 9.1, Safety

5. Release the side tensioning strips by

slackening the 4 x nuts and bolts on
each side until the mesh can be re-
moved from under the clamp plates..
6. Fit replacement mesh and tension it

sufficiently so it will not move or flex
during operation.

the screen together with the fines
conveyor, taking care to then lower the
weight of the screen assembly onto the
locking pins before operation of the
plant or transportation (Section 9.11.1).
1000SR
Page 83
9.11.4 Changing the screen sizing

meshes - manual tensioning WARNING
WEAR PERSONAL

LOCKOUT PLANT.
2. Operate the plant normally until the Information for Lockout
sizing screen and conveyors are empty Procedure.
of material.
FALLING HAZARD.
3. Lower the screen together with the Refer to Section 9.1, Safety
fines conveyor (Section 9.11.1).

lockout procedure (Section 8.2). weight of the screen assembly onto the
locking pins before operation of the
5. Slacken the tensioning screws on each plant or transportation (Section 9.11.1).
side sufficiently to pull the tension bar
from the sizing mesh (Figure 9ad), Retaining Pin & Spring Clip
enabling the mesh to be removed from
the screen hooks at each end.. Tension Bar Tensioning Screws
6. Check the mesh support cushions and

replace if necessary. Also clean out any
build up of material in the screen box.
7. Hook the new mesh over the cross bar

at the far end. Re-insert the tension bar
to locate within the mesh hook.
8. Tighten the tensioning screws on each

side sufficiently to enable the spring
clips and retaining pins to be refitted
behind tension bar (Figure 9ad).

the screen together with the fines Figure 9ad Screen Tensioner
conveyor, taking care to then lower the
1000SR
Page 84
9.11.5 Changing the screen sizing

meshes - hydraulic tensioning
(optional)
DANGER
Where this equipment has been included in Refer to Section 9.1, Safety
the order specification, tensioning of the Information for relevant warning
screen mesh is assisted by two detachable
hydraulic cylinders (Figure 9ae). On each
side of the screen are quick release
couplings to which the hydraulic ram hoses WARNING
are attached. The cylinders are mounted on WEAR PERSONAL
the brackets on the screen box with the PROTECTIVE EQUIPMENT.
piston clevis pin locating in the hole at each Refer to Section 9.1, Safety
end of the screen tension bar (Figure 9ad) in Information for relevant warning.
order to retract or tension as required.
LOCKOUT PLANT.
Quick release couplings connect the Refer to Section 9.1, Safety
cylinders to a separate hand pump supplied Procedure.
for the purpose.
FALLING HAZARD.
Procedure
2. Operate the plant normally until the

sizing screen and conveyors are empty
of material.
3. Lower the screen together the fines


5. Remove both screen tension cylinders

from their storage point then position
and secure with pins and spring clips.
Connect the hoses to the quick release
couplings and hand pump. Figure 9ae Screen Tensioner
1000SR
Page 85
6. Operate the hydraulic hand pump

(optional item) to extend the tension
cylinders sufficiently to enable the spring
DANGER
clips and retaining pins (Figure 9ad) to SKIN INJECTION HAZARD
be removed from behind the tension bar. Information for relevant warning
7. Retract the cylinders sufficiently to pull

the tension bar from the sizing mesh,
enabling mesh to be removed from the
screen hooks at each end.
WARNING
WEAR PERSONAL
8. Remove screen tension bar
(Figure 9ad), also the spring clips and Information for relevant warning.
pins that connect tensioning bar to
cylinders.
LOCKOUT PLANT.
Remove main screen mesh. Refer to Section 9.1, Safety
9. Check all mesh support cushions and Procedure.
replace if necessary. Clean any build up
of material in the screen box. FALLING HAZARD.
10. Locate lower hook of the replacement
screen mesh around the lower bar.
Insert the tensioning bar through slots
into the upper hook of screen. Refit the
pins and spring clips to connect cylin-
ders to the tensioning bar. 13. Raise the screen together the fines
conveyor into the working position
11. Operate the hand pump to extend the (Section 9.11.1).
tension cylinders sufficiently to enable
The screen box may need
the spring clips and retaining pins to be
re-tuning after fitting
refitted behind tensioning bar.
replacement screen meshes
(Section 9.11.2).
12. Remove the spring clips and pins to
release cylinders at both sides.
Disconnect the hydraulic hoses at the
quick coupling points. Place cylinders in
their storage point.
1000SR
Page 86
9.12 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 9.13) 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.
The performance of the

Automax benefits in all
respects from receiving a
continuous ‘choke’ feed of
material (Section 3.6) and the
aim is to achieve this by
setting the plant controls
(Section 7.5 & 7.6) 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.
1000SR
Page 87
9.13 Plant - MiniRanger

Level Sensors Description
The standard 1000SR 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 (Sections 7.5 & 7.6) but can be
reprogrammed if necessary to suit differing
applications and materials.
The Automax crusher gives

the best performance in all
respects when kept ‘choke’ fed
as explained in Section 3.6
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.
1000SR
Page 88
9.14 Plant/Automax -
Hydraulic Systems DANGER
9.14.1 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 warning.
and tracks and also to hydraulically
LOCKOUT PLANT.
raise and lower the feed conveyor. Refer to Section 9.1, Safety
All hydraulic functions are powered by two Procedure.
pumps, one mounted on either side of the
diesel within the engine canopy and driven
from the engine mainshaft via vee belts. A
third pump is mounted on the engine power
take-off.
Alternative selection of the PLANT MODE

THIS IS A HIGH PRESSURE
or TRACK MODE on the plant control
SYSTEM.
panel ensures the plant cannot be moved
whilst operating. DANGER
Never carry out any
maintenance work without
The hydraulic fluid reservoir together with
ensuring the hydraulic system is
associated equipment must be maintained in
locked out and depressurised.
accordance with the set level (For topping
up the reservoir see Section 9.14.6) and in
Do not tamper with system. In
the schedules and types detailed in Section
the event of any problems
9.4. ONLY USE A RECOMMENDED
these should only be dealt with
FLUID.
by suitably experienced and
qualified engineers
It is essential when replenishing hydraulic
fluid, attending to filters, etc. to apply the
greatest degree of cleanliness as it is most
1000SR
Page 89
important that contaminants are not This is achieved by means of a load sensing
allowed to enter the system. line from the valve to the pump which
measures the pressure required which is
Each of the hydraulic pumps is an axial then matched by the pump.
piston variable displacement unit feeding a
directional control valve. Note:-
All relief valve pressures are factory set and
The flows and pressures to each service is should not be adjusted on site.
limited by the relevant spool as shown
below and the pump supplies only the Although the maximum flows from each
required flow by automatically backing off spool is limited as shown, these can be
the swash plate angle thus reducing wasted individually adjusted downwards by means
power and resulting heat generation. of limit screws if desired. Please contact
BL-Pegson Ltd.
Max. flow litres/min Max. Pressure

Service Spool Type
(US galls) Bar
Pump No. 1
L/H Track drive motor Proportional 100 (26.4) 350
Crushed product conveyor On/Off 65 (17.2) 210
2 x Transfer conveyors On/Off 25 (6.6) 180
Automax control On/Off 4 (1) 180
200
Pump No. 2
R/H Track drive motor Proportional 100 (26.4) 350
Feed conveyor On/Off 40 (10.6) 180
Re-circulating/Stockpile
On/Off 40 (10.6) 210
conveyor
Automax lubrication On/Off 10 (2.6) 140
Engine Power Take-Off Pump
Screen & Fines conveyor On/Off 70 (18.5) 230
Feeder conveyor Raise/Lower On/Off 10 (2.6) 175
Screen Raise/Lower On/Off 10 (2.6) 175
Re-Circ. conveyor Raise/Lower On/Off 10 (2.6) 175
Feed chute Raise/Lower On/Off 10 (2.6) 175
14/01/04
1000SR
Page 90
9.14.2 Track Drives 9.14.3 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 9.14.4 Circuit Protection

positioning.
The system is equipped with the following
b) FAST - For straight line running, protection:-
forward or reverse.
• Suction Filter (90µm nominal)
Note:- The maximum power take off from
one side of the engine is limited to • Pressure Filter (10µm 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)
• Return Filter (10µm nominal)
when in the ‘SLOW’ mode.
• Low oil level cut out.
Fine adjustment of the slow speeds is
possible. Consult BL-Pegson Ltd.
Note:- For Hydraulic Pump Drive Belt
adjustment refer to Section 9.15.3.
It is recommended that adjustment is not
undertaken without BL-Pegson Ltd.
consent and under no circumstances should
the slow speed be adjusted greater than
The hydraulic oil filters are fitted
0.2m/s.
with condition indicators to shown
when the renewable filter element
Motor mounted counterbalance valves are
needs to be changed. These
utilised to prevent the machine over running
should be checked on a daily
when moving downhill.
basis whilst the plant is running at
normal operating temperature
This block also incorporates a shuttle valve
(Sections 9.13.6 - 7 & 9). In cold
to release the spring applied track parking
ambient temperatures the filter
brake together with a pressure reducing
indicators may show red until the
valve, preset to 60 bar (870 psi.) so that
system reaches normal operating
the brakes are not over-pressurised.
temperature.
1000SR
Page 91
Figure
Powerscreen 9af Plant
of Florida - 5125 Hydraulic Circuit
N. Frontage Rd., Diagram
Lakeland, FL, 33810 Page 247 of 412
1000SR
Page 92
9.14.5 Changing the Suction Filter

Located at the base of the hydraulic reservoir DANGER
tank are the two hydraulic suction filters. SKIN INJECTION HAZARD
When the dial gauge needle (Figure 9ag) Refer to Section 9.1, Safety
enters into the red segment whilst the Information for relevant warning
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
WARNING
permit work on the system. Make sure the WEAR PERSONAL
oil has cooled before changing the filter.
warning.
Procedure
LOCKOUT MACHINE.
1. Observe all safety warnings. Information for Lockout Proce-
dure.
2. Close down the machine (Section 8.2)
and implement the Lockout Procedure. FALLING HAZARD.
3. Unscrew the black plastic nut in the warning.
centre of the filter housing anticlockwise
until it reaches the stop (Figure 9ag).
4. Take steps to collect spillage of oil -

approx. 2 litres (2 US quarts) - before
undoing the six socket head screws on
the front of the housing to remove the
cover plate. 7. Fully screw in the black plastic nut
in the centre of the filter housing.
5. Remove the old filter and clean inside the
housing with lint free cloth before fitting a It is important to ensure that
new filter of the approved pattern and the black knob is fully screwed
specification. in before starting the plant.
Damage will occur to the plant
6. Before replacing the cover plate, lightly if this procedure is not
oil the ‘O’ ring and make sure it is followed.
properly seated in the groove. Replace
the cover plate and refit the screws to
ensure an oil tight seal.
1000SR
Page 93
Filter Condition Indicator Dial
Black Knob
Removable Cover Plate
It is important to ensure that

the black knob is fully screwed
in before starting the plant.
Damage will occur to the plant
if this procedure is not
Figure 9ag Suction Filter
followed.
Hydraulic Oil Return Hydraulic Oil

Hydraulic Oil Level Filter and Gauge Breather/Filler
Hydraulic Oil Tank Filter Condition Indicator Dial
Figure 9ah Hydraulic Oil Tank & Level Indicator
1000SR
Page 94
9.14.6 Changing the Return Filter

Located on top of the hydraulic reservoir DANGER
tank is the hydraulic return filter. When the SKIN INJECTION HAZARD
dial gauge needle (Figure 9ah) enters into Refer to Section 9.1, Safety
the red segment whilst the system is Information for relevant warning
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
In the event hydraulic oil needs to be added PROTECTIVE EQUIPMENT.
to maintain the correct level on the gauge Information for relevant
(Figure 9ah), this should be poured in after warning.
removing the cover (see below) but with the
LOCKOUT PLANT.
filter element left in place. Check the system Refer to Section 9.1, Safety
for leaks if topping up becomes necessary. Information for Lockout Proce-
dure.
Procedure FALLING HAZARD.

1. Observe all safety warnings. warning.

and implement the Lockout Procedure.
3. Remove the four hexagon head screws

on the top of the housing to remove the
cover plate together with internal spring. 9.14.7 Changing the Tank Breather
This breather (Figure 9ah) should be
4. Remove the old filter and clean inside changed after the first 100 hours of
the housing with lint free cloth before operating and thereafter after 500 hours but
fitting a new filter of the approved in dusty atmosphere it is recommended to
pattern and specification. Replace the change more frequently depending upon
spring which holds the filter in place conditions. Simply unscrew and replace
whilst the plant is shut down (Section 8.2).
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.
1000SR
Page 95
9.14.8 Changing the Pressure

Filters DANGER
Located on each side on the engine within the SKIN INJECTION HAZARD
canopy are the hydraulic pressure filters. Refer to Section 9.1, Safety
When the ‘telltale’ (Figure 9ai) changes from Information for relevant warning
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 WARNING
before changing.. WEAR PERSONAL
Procedure Information for relevant
warning.
LOCKOUT PLANT.
1. Observe all safety warnings. Refer to Section 9.1, Safety
dure.
3. Unscrew (turn anticlockwise looking Filter condition ‘Telltale’ Filter body

from below) the filter bowl using the
hexagon ‘nut’ cast into the base. Take
steps to contain spillage of oil
4. Remove the old filter and clean inside

the bowl and housing with lint free cloth
before fitting into position a new filter
and small ‘O’ ring of the approved
pattern and specification.
Bowl
5. Before replacing the bowl, lightly oil the
‘O’ ring and place on it’s seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
care not to ‘cross’ the threads when
doing so. Tighten with the ‘nut’ at the
base of the bowl to ensure an oil tight ‘Nut’
seal. Figure 9ai Pressure Filter
1000SR
Page 96
9.14.9 Automax Hydraulic System

The hydraulic control components (with the DANGER
exception of the position sensor unit on the SKIN INJECTION HAZARD
crusher are housed in the hydraulic control Refer to Section 9.1, Safety
console. Information for relevant
warning
The system incorporated in the 1000SR

enables the Automax to be controlled as
described in Section 7.3 & 7.4. WARNING
WEAR PERSONAL
In the event of a blockage occurring in the PROTECTIVE EQUIPMENT.
crusher the panel senses an increase in Refer to Section 9.1, Safety
pressure and will automatically raise the Information for relevant
warning.
crusher upper frame (including the concave)
to release material in the crushing chamber.
When the crusher is new or a new concave

and mantle have been fitted the procedure
for initial calibration procedure should be THIS IS A HIGH PRESSURE
followed (Section 7.4.1). This procedure is SYSTEM.
necessary to allow all the other functions to DANGER
take place. By following this procedure the Never carry out any
control system then recognizes the position maintenance work without
of the concave in relation to the mantle (the ensuring the hydraulic system is
two crushing elements) and can then allow locked out and depressurised.
the measurements of wear to take place.
Do not tamper with system. In
When the manganese wear procedure has the event of any problems
been followed (Section 7.4.2) and as wear these should only be dealt with
on the manganese crushing members by suitably experienced and
(concave and mantle) takes place, the qualified engineers
amount of wear is calculated by the control
system and can be read off at any time from
the Automax console display screen
1000SR
Page 97
WEDGE AND GAP CYLINDERS SHOWN FOR REFERENCE ONLY

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 9aj Automax Hydraulic Control Circuit
1000SR
Page 98
9.15 Plant - Electrical

System Description WARNING
WEAR PERSONAL
9.15.1 General Description PROTECTIVE EQUIPMENT.
For the plant electrical circuit diagram Information for relevant
and also for the diesel engine, see the warning.
Appendix section 11 of this manual. LOCKOUT PLANT.
The plant electrical equipment is a self Information for Lockout
contained system receiving a 24 volt DC Procedure.
supply when the diesel engine is running.
Depending upon the model of plant and the

equipment fitted, various types of control,
monitoring, sequencing, electrical
safeguards and fault detection devices are
built into the system including a multi station
emergency stop circuit. Refer to the specific
wiring diagram supplied in this manual for regular intervals check the tightness of the
details. Any work on the plant electrics electrical components on the plant and look
should only be undertaken by a qualified for any damage to the electrical wiring.
electrician familiar with this type of system.
Emergency stop equipment
Wiring diagram(s) for the diesel engine are and all other safety systems
separate from the plant diagram(s). (including the audible warning
siren) must be operative at all
Circuit protection fuses or circuit breakers times whilst the plant is
fitted depend upon the plant model. The running or being manoeuvred.
replacement of a protection device after The safety devices must be
failure must not exceed the rating shown in checked as fully operational at
the wiring diagram otherwise any warranty each daily start and must not
may be invalidated. A repeat of the failure have been tampered with or
must be investigated and the problem disabled in any way.
rectified by a competent person.
Always keep the electrical cabinets and

control boxes shut during operation to
prevent the ingress of dust and damp. At
1000SR
Page 99
9.15.2 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 Information for relevant
equipment against damage. Should any of warning.
the sensing equipment fail in operation, the
necessary repairs or replacement should be
made immediately. This will restore the
safeguard to keep the equipment from harm
and maintain any warranty in force for the
time being. No attempt should be made to
circumvent these protection devices.
The screen on the Plant Control Panel

(Section 7.2.9) displays the appropriate
message of any fault occurring.
1000SR
Page 100
9.16 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 9ak).
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 9ak Correct Alignment of Pulley Belts
1000SR
Page 101
9.16.1 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 BL
Pegson Ltd.
1000SR
Page 102
9.16.2 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 9ak). 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 9al). Procedure.
FALLING HAZARD.
When replacing the belts the drive should Refer to Section 9.1, Safety
be slackened off sufficiently to remove Information for relevant
the old belts and fit the new without warning.
stretching them. Only use ‘matched sets’
of belts to ensure equal tension is
possible on all the belts.
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

9al) 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.
continued overleaf......................
1000SR
Page 103
Nut B (4 off)
Nut A (4 off)
Figure 9al Crusher Drive Belt Tensioning Mechanism RH Side
Deflection Dimension - mm Basic Setting Force - kgf 1.25 x Setting Force - kgf
(inches) (lbf) (lbf)
See Section 9.16.4 (Step 3) 9.4 (20.73) 12.0 (26.5)
14/01/04
Figure 9am Crusher Drive Belt Tensioning Specifications
1000SR
Page 104
Note: Assuming the drive alignment has

been satisfactory, mark, or take a WARNING
measurement of the existing position of
the engine baseframe (in relation to the WEAR PERSONAL
fixed chassis) at each tension screw. PROTECTIVE EQUIPMENT.
These will serve as alignment reference Refer to Section 9.1, Safety
points when tensioning the drive. warning.
5. Lower the engine baseframe by turning LOCKOUT PLANT.

each of the four nuts ‘B’ anticlockwise
an equal amount a little at a time. To Procedure.
maintain the engine baseframe as level
as possible whilst carrying out this FALLING HAZARD.
operation only adjust each nut ‘B’ a Information for relevant
small amount at a time. warning.
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 9.16.4).
7. Check the alignment of the two pulleys

is correct (Figure 9ak) 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.
1000SR
Page 105
9.16.3 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
warning
contamination.
The two hydraulic pumps are situated one

each side of the engine within the diesel
WARNING
engine canopy 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 9an). warning.
LOCKOUT PLANT.
Procedure Information for Lockout
Procedure.
FALLING HAZARD.
warning.
3. Remove the diesel engine side access

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.
continued overleaf.................
1000SR
Page 106
7. Turn the 2 adjusting screws counter

clockwise to tighten the two drive belts.
Continue until the belts have reached
DANGER
the correct tension (Section 9.16.4), SKIN INJECTION HAZARD
making sure the pump pulley is aligned Information for relevant
with the drive pulley (Figure 9ak). warning
8. Tighten the 4 bolts (A) to lock the pump

bracket to the pump stool. WARNING
9. Replace the belt guard and diesel engine WEAR PERSONAL
side access panels before start-up. PROTECTIVE EQUIPMENT.
warning.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
warning.
1000SR
Page 107
Hydraulic Pump Hydraulic Pump

Drive Belt Guard
Adjusting Screws (B)
Pump Stool Bolts (4 off) (A) Pump Bracket
Figure 9an Hydraulic Pump (LH) Drive Belt Tension Mechanism
Deflection Dimension- mm Basic Setting Force - kgf 1.25 x Setting Force - kgf
(inches) (lbf) (lbf)
See Section 9.16.4 (Step 3) 6.3 (13.9) 7.9 (17.4)
14/01/04
Figure 9ao Pump Drive Belt Tensioning Specifications
1000SR
Page 108
9.16.4 Method of Drive Belt

Tensioning WARNING
Under no circumstances
WEAR PERSONAL
should any check on the belt PROTECTIVE EQUIPMENT.
tension be made whilst the Refer to Section 9.1, Safety
machine is running. There is a Information for relevant
risk of trapping parts of the warning.
body if this is done. LOCKOUT PLANT.
Procedure Procedure.
FALLING HAZARD.
1. Observe all safety warnings. Information for relevant
warning.
and implement the Lockout Procedure. Crusher/Engine Drive Belts
Remove the guards from around the
belt. 8 x 3550mm SPC,
Part Number 2441-0470
3. Calculate the deflection distance in mm
on a basis of 16mm deflection per 1 Hydraulic Pump Drive Belts
metre (0.6” per 1 yard) of belt span
(Figure 9ap). 4 x 2000mm SPB,
Part Number 2441-0412
Centre to Centre Distance metre x 16
(yard x 0.6”) = Deflection.
Ce
Di ntre
sta
nc to C
e en
tre
16mm
Deflection per 1 Metre of
Belt Span (0.6” per yard)
Belt Tension Indicator

Applied to Mid-Span
Figure 9ap Belt Tensioning Measurements
1000SR
Page 109
4. If a belt tension indicator is

available: WARNING
a) Set the lower marker ring at the WEAR PERSONAL
deflection distance required on the PROTECTIVE EQUIPMENT.
lower scale. Refer to Section 9.1, Safety
warning.
b) Set the upper marker ring against the
bottom edge of the top tube. LOCKOUT PLANT.
c) Place the belt tension indicator on top Procedure.
of the belt at the centre of the belt
span, and apply a force at right angles FALLING HAZARD.
to the belt deflecting it to the point
where the lower marker ring is level warning.
with the top of the adjacent belt.
d) Read off the setting force value

indicated by the top edge of the upper
marker ring.
e) Compare this value to the lbf value

shown in the table: 6. If the measured force falls within the
Figure 9am - Crusher Drive Belt values given, the drive should be
Tensioning Specifications satisfactory. A measured force below
Figure 9ao - Hydraulic Pump Drive Belt the lower value indicates under-
Tensioning Specifications tensioning. A new drive should be
tensioned to the 1.25 x Setting Force
5. If a belt tension indicator is not value to allow for the normal drop in
available: tension during the running-in period.
a) Use a spring balance to pull the belt 7. Replace all guards before start-up.
down at the centre of the span.
After the drive has been
b) When the belt has been pulled down running for 15-20 minutes, the
(measure using a rule) by the tension should be checked and
deflection calculated in Step 3, read off readjusted to the Basic Setting
the force from the spring balance. Force value, if necessary by
repeating the above procedure
from Step 1.
1000SR
Page 110
9.17 Plant - Conveyor Belts

DANGER
9.17.1 General Description
ENTANGLEMENT HAZARD.
There are several belt conveyors on the Refer to Section 9.1, Safety
1000 SR plant.
warning.
• The Feed Conveyor has a shallow

troughed plain belt. Drive is through a
head drum mounted oil lubricated
WARNING
gearbox with hydraulic motor. Screw type WEAR PERSONAL
tensioning of the belt is at the tailshaft. Full PROTECTIVE EQUIPMENT.
length skirt plates are included. A metal Refer to Section 9.1, Safety
detector (Section 9.18) is fitted to stop Information for relevant
warning.
the conveyor when the detector is
triggered. To reduce the height of the plant LOCKOUT PLANT.
for transportation the conveyor can be Refer to Section 9.1, Safety
lowered by means of an hydraulic ram Procedure.
(Sections 5.2 and 6.2) and also to
elevated (Section 9.7) to gain access FALLING HAZARD.
when working on the Automax crusher. Refer to Section 9.1, Safety
Grease nipples are provided for warning.
lubrication of the shaft bearings.
• The remaider of the belt conveyors on

the plant are fixed speed and comprise
plain troughed conveyors for the
crushed product and fines material, Under no circumstances should
plain flat belts for the two transfer any adjustment be made on the
conveyors and chevron type belts for DANGER belt whilst the machine is
the recirculating and optional stockpile running. There is a risk of
conveyors. All are driven by hydraulic trapping parts of the body if
motors and have screw tensioning of the this is done.
belt. Grease lubrication points are
provided for the shaft bearings and full
length skirt plates with rubber wearing
strips are fitted. Canvas wind covers
are provided over the exposed parts of
the crushed product and fines
conveyors.
1000SR
Page 111
9.17.2 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
warning.
the working position.
• Wire ropes supporting the Re-

circulating and optional Stockpile
WARNING
conveyor heads should be correctly WEAR PERSONAL
tensioned by adjusting with the PROTECTIVE EQUIPMENT.
turnbuckles. Refer to Section 9.1, Safety
• The head and tail drums are correctly warning.
fitted. ie. they are level, and that their LOCKOUT PLANT.
axes are square to the centre line of the Refer to Section 9.1, Safety
conveyor. Information for Lockout
Procedure.
• All troughing and parallel idlers are FALLING HAZARD.

correctly fitted with their axles square Refer to Section 9.1, Safety
to the centre line of the conveyor, the Information for relevant
warning.
side roller lead is in the correct
direction (i.e. forward of centre) and
all rollers are rotating freely. Tracking should be carried out with the belt
empty. With very stiff belts, which do not
• In the case of screw-type take up trough well nor make proper contact with
gears, that these are adjusted initially the centre idlers roller when empty, it may
to take up slack from the belt and that only be possible to track the return strand
equal tension is applied to each side when empty and the troughed side when
such that the pulley is square to the loaded.
centre line of the conveyor.
If the belt tends to run to one side the most
• Where skirt rubbers are fitted they are likely cause of the trouble will usually be
not bearing down heavily on the belt. some distance before the point where the
running off is apparent, and in the case of
• There is no obstruction on the troughed strand probably at the second or
conveyor that could cause accident or third idler behind the point where the belt is
damage when the conveyor is started. moving out of its true line.
1000SR
Page 112
Side Roller
Slots for
Belt Adjust-
Side Roller
Centre
Slots for
Adjust-
Figure 9aq Transom Breakdown

The detail of the conveyor idlers actually fitted may vary from the illustration.
Locknut A Clamping Screws Locknut A Clamping Screws
Belt Tensioning
Adjusting Screw B Adjusting Screw B Clamping Screws
Mechanism
Figure 9ar Conveyor Belt Tensioning Mechanisms
Adjusting Screw (C)
1000SR
Page 113
9.17.3 Conveyor Belt Tensioning

Conveyors are screw tensioned. Tensioning DANGER
mechanisms are located on either side of ENTANGLEMENT HAZARD.
the drum(s) (Figure 9ar). Refer to Section 9.1, Safety
warning.
Best practice is to tension each side a little
at a time and by the same amount until the
belt is tensioned. When tensioned, the drum
must be square to the conveyor frame.
WARNING
WEAR PERSONAL
The correct tension is achieved when the PROTECTIVE EQUIPMENT.
drive drum starts the belt and keeps it Refer to Section 9.1, Safety
running when loaded without any slip Information for relevant
occurring. warning.
LOCKOUT PLANT.
The tension screws should be kept clean Refer to Section 9.1, Safety
and well greased. Information for Lockout
Procedure.
FALLING HAZARD.
Procedure
warning.

3. Loosen locknuts A and the clamping

screws on both sides of the conveyor . Under no circumstances should
any adjustment be made on the
4. Tighten or loosen the square or hexagon DANGER belt whilst the machine is
ended adjusting screws B as required. running. There is a risk of
trapping parts of the body if
5. Once correct tension has been this is done.
achieved, tighten locknut A. Tighten the
clamping screws.
1000SR
Page 114
9.17.4 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
warning.
• Observe all safety warnings.
• Close down the machine (Section 8.2)

and implement the Lockout Procedure
WARNING
WEAR PERSONAL
• On the Feed Conveyor inspect the PROTECTIVE EQUIPMENT.
impact idlers and side wearing strips Refer to Section 9.1, Safety
beneath the feed conveyor belt for wear Information for relevant
and replace if necessary. Ensure that the warning.
plant feed hopper (and check gate) is LOCKOUT PLANT.
satisfactory in relation to the conveyor. Refer to Section 9.1, Safety
Also make sure that the belt is kept Information for Lockout
Procedure.
straight and central at all times.
FALLING HAZARD.
• Inspect all skirt plate sealing strips and Refer to Section 9.1, Safety
ensure that they are adjusted close Information for relevant
warning.
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 9.17.2 Training of
Belts.
• Check that there is no evidence of belt

slip at the driving drum, as belt slip will
cause premature wear on the belt.
Check also for undue sag between
idlers. Both would indicate lack of belt
tension (Section 9.17.3)
1000SR
Page 115
• Check regularly that the idler rollers are

rotating freely. If not either free them or
replace the idler. Failure to do so will
DANGER
result in belt wear and tracking ENTANGLEMENT HAZARD.
problems. Information for relevant warning.
• Check that the belt cleaning equipment

is operating correctly and efficiently. In
the case of scrapers ensure that they are WARNING
not choked with a build up of material.
Also check that the blades are not WEAR PERSONAL
bearing on the belt any more than PROTECTIVE EQUIPMENT.
necessary, and that any blades which
are unevenly worn or in a condition
likely to cause damage to the belt are
LOCKOUT PLANT.
renewed immediately.
• Inspect the condition of the conveyor Procedure.
belt regularly and arrange for the earliest
FALLING HAZARD.
possible repair of any damage which
may have occurred as this can make a Information for relevant warning.
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
Clip joints can be dangerous
• The grease in the head and tail drum
and should not be used. Belt
bearings need re-greasing every two
DANGER repairs/replacements should be
weeks (Section 9.4.5).
performed by vulcanising only.
• Follow the lubrication schedule for the
oil lubricated gearbox located inside the
Feed Conveyor head drum (Section
9.4.5). The gearbox must be filled up to
the centre line and two sight glass plugs
are provided at 180º (Figure 9as) to fill
or drain and also to ascertain the
1000SR
Page 116
required halfway level. Check the level

monthly. Do not mix oils of different
maker or type. The oil temperature
DANGER
to be always below 90º C (194º F). ENTANGLEMENT HAZARD.
• In the interests of efficient operation and
general safety, it is important that
operating conditions are kept as clean
as possible and that any spillages are WARNING
cleaned up regularly and are not
allowed to build up. WEAR PERSONAL
As many inspections as
possible should be made whilst
DANGER the belt is stationary. When
this is not possible extreme LOCKOUT PLANT.
care should be taken when Information for Lockout
inspecting the belt whilst it is Procedure.
moving as this creates a risk of
FALLING HAZARD.
trapping parts of the body.
Hydraulic Motor Conveyor Head Drum
Fill/Drain/Level Plugs (1 hidden)
Figure 9as Feed Conveyor Drive Gearbox
1000SR
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9.17.5 Cleaning the Conveyor Belts

If your machines’ conveyor belts are not DANGER
properly maintained and skirting rubbers are ENTANGLEMENT HAZARD.
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
section.
WARNING
It is important that these WEAR PERSONAL
procedures are followed when PROTECTIVE EQUIPMENT.
cleaning the conveyor belts. Refer to Section 9.1, Safety
Failure to follow these Information for relevant warning.
procedures can result in death
or serious injury. LOCKOUT PLANT.
Procedure.
Procedure
FALLING HAZARD.
1. The equipment should be switched off Information for relevant warning.
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 WARNING
be affected, must also wear protective
equipment. WEAR PERSONAL
The conveyor belts can be Refer to Section 9.1, Safety
cleaned using a number of
methods. Before commencing,
make sure all aforementioned LOCKOUT PLANT.
procedures have been
followed: - Procedure.
• Using a high pressure air hose; FALLING HAZARD.

• 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
9.17.2 and 9.17.3 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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9.18 Metal Detector

WARNING
A Metal Detector is fitted to the Feed WEAR PERSONAL
Conveyor to warn the operator of detected PROTECTIVE EQUIPMENT.
steel on the belt before it enters the Refer to Section 9.1, Safety
Automax crushing chamber possibly Information for relevant
warning.
causing damage to the machine. The
Automax is equipped with hydraulic
overload release to activate in the event of
uncrushable material being present.
However, large foreign objects cannot pass Green ‘POWER ON’ light
through the machine and must be manually
removed from the feed 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 9at) 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.
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 9at Metal Detector Control Panel
1000SR
Page 120
9.18.1 Metal Detector Controls

Normally, once the Metal Detector has
WARNING
been set up at the time of plant WEAR PERSONAL
commissioning there should be no need to PROTECTIVE EQUIPMENT.
alter any of the controls within the control Information for relevant
cabinet (Figure 9au) and the panel door warning.
should be kept closed to avoid the ingress
of dust.
However, in the event of subsequent light cannot be illuminated there may be too
adjustment being necessary the following much metal near the sensor coil.
instructions should be read but any major
changes should only be attempted by an After the above adjustments the detector
engineer conversant with the operation of may have illuminated the DETECT light and
the 1000 SR plant as a whole. the RESET lamp on the detector door.
Pressing RESET lamp button will extinguish
When opening the door of the both lights.
Metal Detector control panel
do not tamper with the terminal The relay function is controlled by the
blocks or wiring unless the unit RELAY switch. In the OFF position only
is switched off. the DETECT light and door RESET lamp
operate when metal is present in the sensing
With the power ‘ON’ the GREEN lamp on area.
the door case will be illuminated. Opening
the panel door will reveal the setting In the LATCH position the relay and above
controls (Figure 9au). indicators operate but after metal is
removed the relay and the indicators remain
The RED fault light will be extinguished ‘on’ until either the door RESET button is
when the sensor is properly connected. pressed or the RELAY switch is turned to
Note: The illuminated fault light will also the ON or OFF position.
cause the DETECT lamp to be illuminated.
Rotate the SET ZERO control Figure 9au)

fully clockwise. If the right hand light
illuminates, rotate the SET ZERO control
anticlockwise until this light extinguishes and
the green light illuminates. This adjustment
compensates (or zeros out) any nearby
metal in the sensor coil detect area. If this
1000SR
Page 121
The SENSITIVITY control is a gain Use the sensitivity control very

adjustment control for the detection of the carefully so as not to allow
desired size of material or to allow for damaging pieces of
smaller pieces of material to be ignored. uncrushable material to enter
the Automax crusher.
FAULT Light DETECT Light
SET ZERO
RELAY switch indicator lights
SET ZERO
Control
Figure 9au Metal Detector Setting Controls
1000SR
Page 122
9.18.2 Metal Detector Indictor signal level increases when metal

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

consists of a row of 10 lamps which light in
sequence from left to right as the detected
1000SR
Page 123
Signal Level Indicator Lights Sensitivity Control
Figure 9av Metal Detector Setting Controls
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9.19 Plant - Dust Suppression

WARNING
The 1000SR plant is fitted with a plain
water dust suppression system. The system WEAR PERSONAL
consists of three spray bars each one having PROTECTIVE EQUIPMENT.
three nozzles. The spray bars are located in Information for relevant
the following areas:- warning.
LOCKOUT PLANT.
• Crusher feed chute.
• Crusher discharge area. Procedure.
FALLING HAZARD.
• Product conveyor discharge.
It is the responsibility of the customer to warning.
supply the system with clean water. This is
supplied at the manifold (Figure 9aw). The
total flow requirement for the system is 23
litres/min (6 US galls/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 9aw Dust Suppression Manifold
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9.20 Plant - Diesel Engine

WARNING
For the diesel engine WEAR PERSONAL
powerpack fitted to your 1000 PROTECTIVE EQUIPMENT.
SR to continue to perform Refer to Section 9.1, Safety
safely, efficiently and reliably Information for relevant
it is imperative that all the warning.
recommendations given in the LOCKOUT PLANT.
separate engine manual are Refer to Section 9.1, Safety
strictly followed with regard
Procedure.
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
• Parts further material from entering the Automax
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 Until the reason for the low pressure has
run as displayed on the engine Service been established and the fault rectified the
Meter. 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 hydraulic pump drives inside the
engine canopy are permanently coupled to
the engine.
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9.20.1 Engine - ELC Coolant

Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must
ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this
is not available top up with deionized water and adjust mixture concentration in the shop. Under no
circumstances use any other coolant as damage will result and any warranty invalidated.
Equipment is intended for use in ambient temperatures between -10°C to +40°C (+14°F to
+104°F). Appropriate lubricants and coolant must be used as specified within the plant and engine
operating and maintenance manuals.
For use in temperatures outside the above range consult your Terex Pegson Dealer or BL-Pegson
Limited for details prior to commencement of operations.
ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT
THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH
before refilling with ELC coolant.
Adhere to the instructions on the external labelling as shown below.
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9.20.2 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 Information for relevant
diesel engine flywheel. The output shaft is warning.
supported by a spherical roller bearing, oil
LOCKOUT PLANT.
lubricated, fitted in a cover flanged to the Refer to Section 9.1, Safety
engine flywheel housing. Information for Lockout
Procedure.
Check the bearing oil level prior to the daily
start up of the plant: as a minimum
requirement, level stick must be oil wet. The
oil filler/dipstick can be accessed at the rear
of the engine housing
Engage the clutch ONLY at

engine at idling speed (1200
rpm). At ambient temperature Filler Cap with Dipstick
close to or below 0º C (32º F),
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, Figure 9ax Clutch Oil Filler
to check the condition of the bearings and
replace the rotating seals (refer to parts list).
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9.20.3 Check Fuel Level

WARNING
Procedure WEAR PERSONAL
LOCKOUT PLANT.
2. Check the fuel level indicator (Figure Refer to Section 9.1, Safety
9ay) Information for Lockout
Procedure.
3. Top up fuel level if required (Section
9.20.4).
• Fill the tank at the end of each day,

where possible, to reduce overnight
condensation within the tank.
Diesel fuel is highly flammable

and is an explosion/burns
DANGER 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 Fuel Level
explosion risks. Gauge
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. Figure 9ay Fuel Level Indicator - Engine
Control Panel
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9.20.4 Top Up Fuel Level

Do Not fill the tank to
WARNING
capacity. WEAR PERSONAL
Monitor the gauge located on
the Control Panel (Figure 9ay). warning.
LOCKOUT PLANT.
Allow room for expansion and Refer to Section 9.1, Safety
wipe up spilt fuel immediately, Information for Lockout
otherwise paintwork will be Procedure.
damaged.
Procedure

3. Lift the engine side access flap door to

reveal the filler cap.(Figure 9az). 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.

and is an explosion/burns Figure 9az Filler Cap
DANGER hazard.
Never remove the filler cap or

AX868-901-8EN-01c 286/412
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Page 131
Never add gasoline or any

other fuel mixes to diesel WARNING
DANGER because of increased fire or
WEAR PERSONAL
explosion risks. PROTECTIVE EQUIPMENT.
Do Not smoke while refilling Information for relevant
or carrying out maintenance on warning.
the fuel system. LOCKOUT PLANT.
Do Not carry out maintenance Refer to Section 9.1, Safety
on the fuel system near naked Information for Lockout
Procedure.
lights or sources of sparks,
such as welding equipment.
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9.21 Plant - Vehicle Tracks

WARNING
It is essential that the tracks WEAR PERSONAL
are correctly tensioned at all PROTECTIVE EQUIPMENT.
times. Check track tension Refer to Section 9.1, Safety
regularly (Section 9.21.1). Information for relevant
warning.
Keeping the track properly adjusted will LOCKOUT PLANT.
increase the service life of the track and Refer to Section 9.1, Safety
drive components. Information for Lockout
Procedure.
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). Prior to attempting any
manoeuvring of the plant the
Frequently check for loose bolts, oil leaks, tracks must be free of
master pins are correctly located and tight, obstructions, including crushed
general wear and damage, correct track material and fines. Do not push
tension, etc. to ensure safe working and or tow the plant. Failure to
long life. observe this warning could
result in injury to persons and
When travelling on a gradient, the tracks damage to the plant which may
should be driven with the track idler rollers invalidate warranty.
(Figure 9ay) in front (ie. Feed Hopper first).
9.21.1 Measuring Track Tension
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 133

implement the Lockout Procedure. WARNING
WEAR PERSONAL
4. One track at a time, measure the sag on PROTECTIVE EQUIPMENT.
the top part of the track on the longest Refer to Section 9.1, Safety
section of unsupported track by placing Information for relevant
a ‘straight edge’ long enough to reach warning.
from the drive sprocket to the nearest LOCKOUT PLANT.
skid plate. Refer to Section 9.1, Safety
5. Measure the maximum amount of track Procedure.
sag from the high point of the track
grouser to the bottom of the ‘straight
edge’ (Figure 9ba). Correctly adjusted
the sag should be approximately 15 mm
(5/8”) but must not be less that 5mm
(1/4”).
Tracking the machine with

incorrectly tensioned tracks
can cause severe damage to
the undercarriage components
and may invalidate the
warranty. 5 - 15mm
(1/4 - 5/8”)
6. Depending upon the need to either
slacken or tension the track(s) proceed
as below.
continued....................... Figure 9ba Measuring Track Tension
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9.21.2 Adjusting Track Tension

‘GREASE UNDER HIGH DANGER
PRESSURE’ SKIN INJECTION HAZARD
To Release Track Tension (After Information for relevant
warning
measurement - Section 9.21.1):-
Procedure WARNING
WEAR PERSONAL
1. Observe all Safety Warnings. PROTECTIVE EQUIPMENT.
2. Close down the plant (Section 8.2) and warning.
LOCKOUT PLANT.
3. Locate the access aperture on the side Information for Lockout
of the track frame and remove the Procedure.
cover (where fitted) to reveal the relief
valve inside.
4. Next loosen the relief valve by turning

counter clockwise using gradual
increments until the grease begins to be
expelled. Care must be taken not to Grease coming out of the relief
loosen the relief valve too quickly valve under pressure can
because the grease inside is under penetrate the body causing
high pressure. injury or death; do NOT watch
the relief valve to see if grease
5. When the correct track tension has is escaping but instead watch
been measured (Section 9.21.1), turn the track adjustment cylinder
the relief valve clockwise to tighten and to verify that the track is being
then clean away all trace of expelled loosened.
grease.
DO NOT OVER TENSION
6. Operate the plant in manoeuvring mode THE TRACKS (Refer to
(Section 5.2.1) and drive the plant 50 Section 9.21.1).
metres (50 yards) forwards and 50
metres (50 yards) backwards, measure
the sag and repeat the steps 1 - 4 if the
AX868-901-8EN-01c 290/412
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Page 135
track(s) sag is not enough. If room for

manoeuvring the plant is restricted,
drive the plant forwards and backwards
DANGER
several times over a shorter distance. SKIN INJECTION HAZARD
If the track fails to slacken after the warning
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
WARNING
WEAR PERSONAL
that running the tracks with the grease
fitting loosened may help to expel the Refer to Section 9.1, Safety
grease. Information for relevant
warning.
LOCKOUT PLANT.
Procedure.
Track Surface Idler Roller
Drive Sprocket
Relief
Valve
Final Drive Track Roller
Unit
Figure 9bb Vehicle Track Parts
AX868-901-8EN-01c 291/412
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Page 136
To Increase Track Tension (After

measurement - Section 9.21.1):- DANGER
Procedure Refer to Section 9.1, Safety
warning
1. Observe all Safety Warnings.

WARNING
WEAR PERSONAL
3. Locate the access aperture on the side Information for relevant
of the track frame and remove the warning.
cover (where fitted) to reveal the relief LOCKOUT PLANT.
valve inside. Refer to Section 9.1, Safety
4. Connect the grease gun to the grease Procedure.
fitting and add grease until the track
tension is within the specified dimension
(Section 9.21.1). See Section 9.4.5. for
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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9.21.3 Track Maintenance

(Figure 9bb)
WARNING
WEAR PERSONAL
Maintenance Schedule PROTECTIVE EQUIPMENT.
• The first drive oil replacement is to be warning.
carried out after 100 operating hours
LOCKOUT PLANT.
of the gearbox. Refer to Section 9.1, Safety
• 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
To maximise the life of the
1. Observe all safety warnings. track, keep it movable and
avoid damage, the plant should
2. Close down the machine (Section 8.2) be moved at least every week,
and implement the Lockout Procedure. by a distance exceeding four
times the track length. It
3. Check the track rollers and idler wheels should also be parked on level
for possible leakage. ground overnight and during
periods of non-usage. This is
4. Check the track surface of the track particularly important when
rollers, idler wheels, track shoes and working in adverse conditions.
drive sprockets for wear and loose
mounting bolts.
5. Clean out any heavy build up of

material from around the tracks.
6. Check the tension of the tracks

(Section 9.21.1) and adjust tension if
necessary (Section 9.21.2).
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9.21.4 Drive Oil Filling and Draining

Oil Filling
WARNING
WEAR PERSONAL
Procedure Information for relevant
warning.
LOCKOUT PLANT.
2. Close down the plant (Section 8.2) and Procedure.
3. Make sure the gearbox housing is

horizontal.
the travel motor seal to allow hydraulic oil
4. Rotate the gearbox housing so that or water to enter and contaminate the drive.
one plug is at the 12 o’clock position
and the other plug is at the 9 o’clock
position (Figure 9bc).
5. Unscrew the two plugs and fill from the

upper hole until the oil flows from the
Oil Fill (A)
hole located at the 9 o’clock position.
See Section 9.4.6 for oil type and
specification.
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.
Oil Level (B)
Note:- Over filling the final drive will cause
Figure 9bc Tracks - Oil Filling
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Page 139
Oil Draining
WARNING
WEAR PERSONAL
LOCKOUT PLANT.
2. Close down the plant (Section 8.2) and Refer to Section 9.1, Safety
implement the Lockout Procedure. Information for Lockout
Procedure.
3. Rotate the gearbox housing until a plug
is at the 6 o’clock position (Figure 9bd).
(A)
4. Unscrew both plugs and discharge the
oil.
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 9bd Tracks - Oil Draining
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Blank page
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Spare Parts Issue EN 01
Page 1
Contents
10.1 Automax Crusher Parts..................................................................................... 5

General Illustration .................................................................................................... 5
Mainframe Assembly ............................................................................................... 6
Upper Frame Assembly ........................................................................................... 8
Hydraulic Cylinder Fixings ...................................................................................... 10
Cone head Assembly ............................................................................................. 12
Eccentric Assembly ............................................................................................... 14
Countershaft Assembly .......................................................................................... 16
Lubrication Piping Assembly .................................................................................. 18
Crusher Hydraulic Assembly .................................................................................. 20
Hydraulic Control Panel .......................................................................................... 22
Lubrication Oil Tank Assembly ............................................................................... 24
10.2 Vibrating Screen .............................................................................................. 26
Screen Box Assembly ............................................................................................ 26
Screen Box Assembly, continued ........................................................................... 28
Screen Shaft & Drive Assembly ............................................................................. 30
Screen Shaft & Drive Assembly, continued ............................................................. 32
10.3 Plant Conveyors .............................................................................................. 34
Feed Conveyor ...................................................................................................... 34
Crushed Product Conveyor ................................................................................... 36
Lower Transfer Conveyor ....................................................................................... 38
Upper Transfer Conveyor ....................................................................................... 40
Fines Conveyor ...................................................................................................... 42
Recirculating Conveyor .......................................................................................... 44
Stockpile Conveyor - Optional Item ........................................................................ 46
10.4 Plant Components ........................................................................................... 48
Plant General Assembly ......................................................................................... 48
Feed Conveyor Supports ....................................................................................... 50
Recirculating Feed Chute ....................................................................................... 52
Feed Hopper with Barge Boards ........................................................................... 54
Feed Conveyor Platform Assembly ........................................................................ 56
Level Sensor - Crusher Unit MR1 ........................................................................... 58
Screen/Conveyor Support Frame Assembly ........................................................... 60
Recirculating/Stockpile Conveyor Mounting Parts ................................................... 62
Plant Chassis Parts ............................................................................................... 64
19/11/04
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Page 2
10.5 Plant Tracks ..................................................................................................... 66
10.6 Plant Hydraulic System ................................................................................... 68

Hydraulic Reservoir ................................................................................................ 68
Hydraulic System ................................................................................................... 70
Hydraulic Components - HFO Hydraulic Clutch Circuit ............................................ 71
10.7 Electrical Components .................................................................................... 72
10.8 Warning Signs.................................................................................................. 74
10.9 Hydraulic Engine Clutch ................................................................................. 76
AX868-901-8EN-01c 298/412
1000SR
Page 3
IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
BL-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)
BL-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.
AX868-901-8EN-01c 299/412
1000SR
Page 4
ONLY FIT GENUINE TEREX PEGSON P

ONLY AR
PAR TS
ARTS
ONLY FIT GENUINE TEREX PEGSON P

ONLY AR
PAR TS
ARTS
AX868-901-8EN-01c 300/412
1000SR
Page 5
10.1 Automax Crusher Parts
General Illustration
1000 Automax Crusher
AX868-901-8EN-01c 301/412
Spare Parts - Model 1000 SR Page 6
Mainframe Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 2500-5004B WEDGE RING SEAL – 8M 1
2 2500-5006B MAINFRAME SEAL – 8M 1
3 307/17 'O' RING (STUB OIL FLINGER) 1
4 603/903 MAINSHAFT 1
5 603/9142 STUB SHAFT 1
6 603/9144 OIL FLINGER 1
7 603/9143 BEARING CLAMP 1
307/16 ‘O’ RING 1
2222-6687 CAP SCREW 4
8 603/9126 MAINFRAME LINER SET 1
9 603/923 COUNTERSHAFTARM SHIELD 1
10 603/9125 FRAME ARM SHIELD 3
11 603/9088MCD WEDGE RING ASSEMBLY 1
603/9034 ANTI-ROTATION POST 1
12 603/9141 INSERT 10
2147-0101 ADHESIVE – 80 ML 10
2123-2001 MOLYBENTONE GREASE – 0.5 KG 1
13 603/1014 ANTI-ROTATION STOP PLATE 1
2232-1353 BOLT 2
2215-0020 NUT 2
2211-0014 WASHER 2
14 603/1022/1 THRUST BLOCK 2
603/1022/2 INSERT 2
2147-0051 ADHESIVE – 300 GM 1
2232-1204 BOLT 4
2211-0010 WASHER 4
2210-0019 WASHER 4
15 603/9092FMCD MAINFRAME ASSEMBLY 1
16 2402-2040 BEARING 6
17 2152-9050 TUFNOL STRIP 11
18 603/6007 MAINSHAFT SPACER 1
19 2564-7102 DUMPY JACK 12
20 603/1367 TRANSDUCER COVER 1
2230-1121 SCREW 4
2211-0007 WASHER 4
21 2666-9013 LINEAR TRANSDUCER UNIT 1
2232-1092 BOLT 2
2211-0007 WASHER 2
315-10 NUT 2
JUNCTION BOX C/W MULTI CORE
22 2690-0020 1
CABLE
18/08/04
AX868-901-8EN-01c 302/412
21
22
20
Mainframe Assemblyl - Automax 1000

AX868-901-8EN-01c 303/412
Upper Frame Assembly

1 AX857/06/04
603-9091 FEED
FEEDBOX (NOT SHOWN)
RING 1
2 2230-1222 SCREW 3
2210-0019 WASHER 3
2211-0010 WASHER 3
3 320/33 SHOULDED DOWEL 3
4 603/9090 WEDGE 3
5 603/9089 * UPPER FRAME (MEDIUM COARSE) 1
UPPER FRAME (EXTRA COARSE,
603/9083 * 1
COARSE AND AUTOSAND)
6 2402-2040 BEARING 6
2147-0028 LOCTITE – 50 ML 1
2530-1135 GREASE NIPPLE 12
2968-4102 GREASE GUN 1
2123-2002 MOLY-BENTONE GREASE CARTRIDGE 1
300/252 GREASING INSTRUCTION PLATE 1
7 603/9053E * CONCAVE (EXTRA COARSE) 1
603/9107E * CONCAVE (COARSE) 1
603/9052E * CONCAVE (MEDIUM COARSE) 1
603/9071E * CONCAVE (AUTOSAND) 1
2144-0001 PEGBAK PACK - 1 TIN A/ 1 TIN B (5 KG) 3
2144-0002 RELEASE AGENT 1
* ALTERNATIVE PARTS, DEPENDING UPON WHICH CONCAVE FITTED
18/08/04
AX868-901-8EN-01c 304/412
- FEED
- FEED BOX
BOX NOT
NOT SHOWN
SHOWN FOR
FOR CLARITY
CLARITY
1000 Automax - Upper Frame assembly

AX868-901-8EN-01c 305/412
Hydraulic Cylinder Fixings

1 603/9100 PIN 12
2 2210-2017 WASHER 24
3 311/9 WASHER 24
4 2201-0148 SPLIT PIN 24
5 603/934 SPACER 24
6 2402-2040 BEARING 6
AX868-901-8EN-01c 306/412
5 3
4
2
1000 Automax - Hydraulic Cylinder Fixings

AX868-901-8EN-01c 307/412
Cone head Assembly

1 2410-9006 BEARING 1
2 2415-9900 BEARING 1
3 2430-0584 CIRCLIP 1
4 603/915 MANTLE NUT PLUG 1
5 603/929 MANTLE NUT 1
6 603/9106E MANTLE 1
2144-0001 PEGBACK PACK - 1 TIN A/1TIN B (5KG) 5
2144-0002 RELEASE AGENT 1
7 603/1040 SNAP RING 1
8 603/6020 COVER PLATE CONE HEAD 1
2501-1250 'O' RING 1
2230-1220 SCREW 4
2211-0010 WASHER 4
9 603/1039 OIL FLINGER 1
307/4 'O' RING 1
10 603/955MCD CONE HEAD PISTON RING ASSEMBLY 1
307/1 'O' RING 1
11 603/1051 SLEDGING BAR 1
12 603/9082 CONE HEAD 1000 SERIES 1
13 603/936 WEAR PLATE/DISTRIBUTION PLATE 1
2226-0889 SCREW 4
16/10/03
AX868-901-8EN-01c 308/412
1000 Automax - Cone Head Assembly

AX868-901-8EN-01c 309/412
Eccentric Assembly

1 2152-9050 TUFNOL STRIP 11
2 2222-6753 CAPSCREW 4
3 2410-9007 BEARING PAIR 1
4 2415-9901 BEARING 1
5 2430-0584 CIRCLIP 1
6 302/15 BEVEL GEAR 1
7 323/37 STUD 5
2215-0016 NUT 5
603/9115 LOCKWASHER 5
8 332/2 KEY 2
2222-6748 CAPSCREW 2
9 603/6008* ECCENTRIC (LONG THROW) 1
603/1120* ECCENTRIC (SHORT THROW) 1
10 603/9079MCD PISTON RING (ROTARY SEAL) 1
307/2 'O' RING 1
11 603/9006* ROTARY SEAL RING (LONG THROW) 1
603/9094* ROTARY SEAL RING (SHORT THROW) 1
* ALTERNATIVE PARTS, DEPENDING UPON WHICH ECCENTRIC THROW FITTED
16/10/03
AX868-901-8EN-01c 310/412
1000 Automax - Eccentric Assembly

AX868-901-8EN-01c 311/412
Countershaft Assembly

1 2217-9007 BEARING LOCKNUT 1
2 2230-1356 SCREW 6
2211-0014 WASHER 6
3 2230-1122 SCREW 6
2211-0007 WASHER 6
4 2415-9002 BEARING 2
5 1787
2443-1774 PULLEY 1
6 2443-8365 TAPER LOCK BUSH 1
7 2450-5002 RINGFEDER 1
8 307/6 'O' RING 1
9 2503-3153 OIL SEAL 1
10 302/26 BEVEL PINION 1
11 2432-1404 KEY 1
12 603/9004 COUNTERSHAFT HOUSING 1
13 603/9022 SHIM PAIR – 1.5 THK 3
603/9109 SHIM PAIR – 0.8 THK 1
14 603/9019 OIL GUARD 1000 1
2147-4002 SEALANT – 50 ML 1
15 605/909 COUNTERSHAFT 1
16/10/03
AX868-901-8EN-01c 312/412
1000 Automax - CountershaftAssembly

AX868-901-8EN-01c 313/412
Lubrication Piping Assembly
AX868-901-8EN-01c 314/412
1000SR Automax - Lubrication Oil Piping

AX868-901-8EN-01c 315/412
Crusher Hydraulic Assembly

HYDRAULIC CYLINDER CIRCUIT
(ONLY ONE HALF OF COMPLETE CIRCUIT ILLUSTRATED)
1 2500-1021 SEAL 16
2 2520-0120 QUICK RELEASE COUPLING - MALE 2
3 2520-0130 QUICK RELEASE COUPLING - FEMALE 2
4 2520-6026 REDUCER 12
5 2520-6376 TEE ADAPTOR 10
6 2520-6334 ELBOW ADAPTOR 2
7 2520-6125 REDUCER 12
8 2521-1800 HOSE ASSY - 200 2
9 2521-1810 HOSE ASSY - 700 2
10 2521-1824 HOSE ASSY - 275 4
11 2521-5202 HOSE ASSY - 300 4
12 2521-5208 HOSE ASSY - 600 4
13 2521-5216 HOSE ASSY – 1000 2
14 2521-5220 HOSE ASSY - 1400 2
15 2564-0040 HYDRAULIC CYLINDER 6
16 2554-0003 OVERLOAD VALVE 1
17 2564----35 GAITER 6
18 2564-9310 CYLINDER SEAL KIT 6
19 2525-5001 HYDRAULIC HOSE – 4600 LG. 2
DUMPY JACK HYDRAULIC CIRCUIT
(CIRCUIT NOT ILLUSTRATED)
20 2564-7101A HOSE ASSY – 190 11
21 2564-7101B HOSE ASSY – 120 1
22 2564-7101C HOSE ASSY – 250 1
23 2564-7101/D HOSE ASSY – 4600 1
24 2520-6002 ADAPTOR 3
25 2564-7101F TEE 1
26 2500-1011 BONDED SEAL 1
27 2564-7101H QUICK RELEASE COUPLING COMPLETE 1
LOOSE ITEMS
28 2147-0024 LOCTITE – 50 ML 1
29 2618-4003 KLAXON 1
18/08/04
AX868-901-8EN-01c 316/412
16
1
17
15
18
11
4
12 5
7
3
14
10
9
13
19
1000 Automax - Hydraulic Cylinder Circuit

AX868-901-8EN-01c 317/412
Hydraulic Control Panel

PANEL REF L883
1 2589-5122 PRESSURE FILTER 1
2589-5125 REPLACEABLE FILTER ELEMENT 1
2 2589-5268 PRESSURE FILTER 1
3 2589-5240 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
11 2589-5302 PRESSURE SWITCH 1
12 2589-5301 PRESSURE SWITCH 1
13 2589-5275 MANIFOLD BLOCK 1
14 TBA MOUNTING PLATE 1
20/08/04
AX868-901-8EN-01c 318/412
5 10 2 12 9 10 14
3 8
4 7
6 6
13
10
10 9
11
1000SR Automax - Hydraulic Control Panel

AX868-901-8EN-01c 319/412
Lubrication Oil Tank Assembly

TANK REF L884
1 2510-3849 DRAIN PLUG 1
2 2589-1074 2” SUCTION FILTER ELEMENT 1
3 2589-2016 PRESSURE RELIEF VALVE 1
4 TBA 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
12 2589-2058 1” BSP CHECK VALVE 1
13 2538-7210 KOBOLD FLOW METER 1
14 2589-2059 AIR BLAST COOLER 1
2589-2089 COOLER FAN MOTOR ASSEMBLY ONLY 1
15 2589-2060 BULLS EYE LEVEL GAUGE 1
16 TBA TEMPERATURE SENSOR 1
17 TBA PROGRAMMABLE FLOAT SWITCH 1
18 2589-1019 PRESSURE GAUGE 1
18a 2589-2061 PRESSURE GAUGE ADAPTOR 1
19 TBA RESERVOIR AND LIDS 1
20 2580-2063 ELECTRICAL JUNCTION BOX 1
21
22 2589-2064 FLEXIBLE MOUNT 4
23 2589-2065 MOTOR MOUNT PLATE 1
20/08/04
AX868-901-8EN-01c 320/412
15
20 17 18 10 12 6 9 5 16 14 13 8 19
7
23
22
1000SR Automax - Lubrication Oil Tank Assembly

AX868-901-8EN-01c 321/412
10.2 Vibrating Screen
Screen Box Assembly

1 AX862/55/4 SUB FRAME 1
2 2371-2032 SCREEN BOX 1
3 2371-2033 CAMBER BAR RUBBER – 1545 LONG 8
2371-3034 CAMBER BAR RUBBER – 395 LONG 6
4 2371-2037 TENSIONER 6
5-7 2371-2038 BOLT, NUT AND WASHER EACH X 12
8 2371-2039 CAMBER BAR 3
9 2371-2040 RETAINING PIN 6
10 2371-2041 SPRING PIN 6
14 2371-2043 TOP DECK CLAMP PLATE 2
15 2371-2044 SPRING 4
16 2371-2045 TRANSPORT STAY 4
17 2371-2046 BOLT, NUT, WASHER 2
TOP DECK SIDE TENSIONED WIRE
48 2371-2002 1
MESH 44MM APERTURE
TOP DECK END TENSIONED WIRE
49 2371-2004 1
MESH 22 MM APERTURE
50 AX862/202/2 FLYWHEEL GUARD 1
AX862/182/2 UNDER GUARD 1
57 AX802/202/1 MOTOR GUARD 1
18/11/03
AX868-901-8EN-01c 322/412
48 - SIDE TENSIONED MESH

(NOT SHOWN)
11 - 14
50 - 56
1
2
57 - 63
15 - 17
49 - END TENSIONED MESH

(NOT SHOWN)
4 - 10
1000SR - Screen Box Assembly

AX868-901-8EN-01c 323/412
Screen Box Assembly, continued

1 2371-2051 FRONT RUBBER FLAP 1
2 2371-2052 FRONT RUBBER STRAP 3
4 2371-2054 SCREEN BOX BACK RUBBER FLAP 1
5 2371-2055 SCREEN BOX BACK RUBBER UPPER 1
7 2371-2056 SIDE RUBBER 2
8 2371-2057 SIDE RUBBER CLAMP 6
15 2371-2058 BOTTOM DECK CAMBER BAR 4
16 2371-2033 CAMBER BAR RUBBER – 1545 LONG 4
17 2371-2059 BOLT 8
18 2371-2060 NUT 8
19 2371-2061 WASHER 16
BOTTOM DECK END TENSIONED WIRE
22 2371-2004 2
MESH, 22 MM APERTURE
18/11/03
AX868-901-8EN-01c 324/412
4-6
15 - 19
7-9
22 - BOTTOM DECK MESHES

(NOT SHOWN)
1-3
1000SR - Screen Box Assembly

AX868-901-8EN-01c 325/412
Screen Shaft & Drive Assembly
PART
REF DESCRIPTION QUANTITY
NUMBER
1 2371-2062 FLYWHEEL 2
2 2371-2063 TAPERLOCK CENTRE 2
3 2371-2064 HALF FLYWHEEL 2
5 2371-2065 COUNTER WEIGHT 2
2371-2066 COUNTER WEIGHT 2
7 2371-2071 BEARING – COMPLETE 2
8 2371-2072 PLUMMER BLOCK HOUSING 2
10 2371-2074 BEARING 2
11 2371-2075 SLEEVE & NUT 2
12 2371-2076 LOCATING RING 2
13 2371-2077 PLUMMER BLOCK HOUSING SEAL 2
14 2371-2078 ADAPTOR 2
15 2371-2079 SEAL 1
16 2371-2080 OUTER BEARING GREASE PIPE 2
17 2371-2081 ADAPTOR 2
18 2371-2079 SEAL 2
19 2371-2082 INNER BEARING GREASE PIPE 2
20 2371-2083 SCREEN SHAFT 1
21 2371-2084 PIPE UNIT 1
25 2371-2085 FLANGE BEARING HOUSING 2
26 2371-2086 BOLT, NUT 24
27 2371-2087 HARDENED WASHER 48
28 2371-2088 SPRING WASHER 24
29 2371-2089 BEARING 2
30 2371-2090 SLEEVE & NUT 2
18/11/03
AX868-901-8EN-01c 326/412
1000SR - Screen Shaft & Drive Assembly

AX868-901-8EN-01c 327/412
Screen Shaft & Drive Assembly, continued
PART
REF DESCRIPTION QUANTITY
NUMBER
31 2371-2091 LOCATING RING 2
32 2371-2092 BEARING HOUSING CAP 2
33 2371-2093 HOUSING CAP BOLTS 8
34 2371-2094 HOUSING LIP SEAL 4
35 2371-2095 FLANGE BEARING GASKET 2
36 2371-2096 GASKET SEALER 1
37 2371-2097 HYDRAULIC MOTOR MOUNTING BRKT. 1
38 2371-2098 BACKING PLATE 2
39 2371-2061 WASHER 4
40 2371-2060 NUT 4
41 2371-2099 HYDRAULIC MOTOR 1
42 2371-2100 COUNTERSUNK BOLT 4
43 2371-2101 NUT 4
44 2371-2102 WASHER 4
45 2371-2103 SPRING W ASHER 4
48 2371-2104 MOTOR ADAPTOR COMPLETE 2
49 2371-2105 SEAL 2
50 2371-2106 ADAPTOR 2
51 2371-2107 SEAL 1
52 2371-2108 ADAPTOR 1
53 2371-2109 HYDRAULIC HOSE 1
54 2371-2110 SCREEN MOTOR PULLEY 1
56 2371-2112 VEE BELT 2
57 2371-2113 SCREEN SHAFT PULLEY 1
58 2371-2114 KEY – SCREEN SHAFT 1
67 2371-2118 RUBBER BEARING MOUNT 1

18/11/03
AX868-901-8EN-01c 328/412
1000SR - Screen Shaft & Drive Assembly

AX868-901-8EN-01c 329/412
10.3 Plant Conveyors
Feed Conveyor
AX868-901-8EN-01c 330/412
NB. Fixings are not included with the above parts unless specifically ordered
1000SR - Feed Conveyor

AX868-901-8EN-01c 331/412
Crushed Product Conveyor
NB. Fixings are not included with the above332/412

AX868-901-8EN-01c parts unless specifically ordered
NOTE
Feed Boot AX868/35 with welded in liner plates includes:-
2 x AX857/69/1 Liner Plate - centre.
2 x AX857/69/2 Liner Plate - rear.
2 x AX857/69/3 Liner Plate - front
1000SR - Product Conveyor

AX868-901-8EN-01c 333/412
Lower Transfer Conveyor
AX868-901-8EN-01c 334/412
360
1000SR Lower Transfer Conveyor

AX868-901-8EN-01c 335/412
Upper Transfer Conveyor
AX868-901-8EN-01c 336/412
360
1000SR - Upper Transfer Conveyor

AX868-901-8EN-01c 337/412
Fines Conveyor
NB. Fixings are not included with the above 338/412

1000SR - Fines Conveyor

AX868-901-8EN-01c 339/412
Recirculating Conveyor
NB. Fixings are not included with the above340/412

1320
1000SR - Recirculating Conveyor
AX868-901-8EN-01c 341/412
Stockpile Conveyor - Optional Item
AX868-901-8EN-01c 342/412
1160
1000SR - Stockpile Conveyor - Optional Item

AX868-901-8EN-01c 343/412
10.4 Plant Components

Plant General Assembly
AX868-901-8EN-01c 344/412
Plant General Assembly - 1000SR

AX868-901-8EN-01c 345/412
Feed Conveyor Supports
AX868-901-8EN-01c 346/412
1000SR - Feed Conveyor Supports

AX868-901-8EN-01c 347/412
Recirculating Feed Chute
AX868-901-8EN-01c 348/412
1000SR - Recirculating Feed Chute

AX868-901-8EN-01c 349/412
Feed Hopper with Barge Boards
AX868-901-8EN-01c 350/412
1000SR - Feed Hopper with Barge Boards

AX868-901-8EN-01c 351/412
Feed Conveyor Platform Assembly
AX868-901-8EN-01c 352/412
1000SR - Feed Conveyor Platform

AX868-901-8EN-01c 353/412
Level Sensor - Crusher Unit MR1

1 3RG6113-3GF00 LEVEL SENSOR PROBE 1
2 AX868/20 AUTOMAX FEED BOX 1
3 AX868/120/01 SENSOR SUPPORT MAST 1
4 AX868/171 SENSOR GUARD 1
AX868-170-601 - 17/02/04
AX868-901-8EN-01c 354/412
Automax Feed Box
1000SR - Level Sensor - Crusher Unit MR1

AX868-901-8EN-01c 355/412
Screen/Conveyor Support Frame Assembly
AX868-901-8EN-01c 356/412
1000 SR - Screen/Conveyor Support Frame Assembly

AX868-901-8EN-01c 357/412
Recirculating/Stockpile Conveyor Mounting Parts
AX868-901-8EN-01c 358/412
1000 SR - Recirculating/Stockpile Conveyor Mounting Parts

AX868-901-8EN-01c 359/412
Plant Chassis Parts
NB. Fixings are not included with the above parts

AX868-901-8EN-01c unless specifically ordered
360/412
1000SR - Plant Chassis Parts

AX868-901-8EN-01c 361/412
10.5 Plant Tracks

1 2372-0110 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 2372-0107 GEARBOX BOLTS 32
3 2372-0111 DRIVE SPROCKET 2
4 2372-0109 SPROCKET BOLTS 40
5 2372-0112 TRACK CHAIN –COMPLETE 2
6 2372-0007 TRACK SHOE 112
7 2372-0008 TRACK SHOE BOLT 448
8 2372-0009 TRACK SHOE NUTS 448
9 2372-0073 IDLER 2
10 2372-0074 YOKE 2
11 2372-0072 RECOIL UNIT 2
2372-0075 TENSIONER SEAL KIT 2
12 AX818TRAKS02 GREASER 2
13 AX818TRAKS03 GASKET 2
AX818TRAKS01 ADAPTOR 1
14 2372-0017 ROLLER 16
15 2372-0018 ROLLER BOLT 64
16 2372-0019 ROLLER BOLT WASHER 64
2372-0010 REPAIR LINK - TRACK CHAIN

2372-0011 MASTER PIN - TRACK CHAIN
22/07/03
AX868-901-8EN-01c 362/412
4
1
8
2
7
6
16
12
13
15
14
10
11
1000SR - Tracks Assembly

AX868-901-8EN-01c 363/412
10.6 Plant Hydraulic System
Hydraulic Reservoir

TANK REF L885
1 TBA DRAIN SOCKET 1
2 2589-2105 FLUID LEVEL GAUGE WITH LEVEL SWITCH 1
3 2531-1000 BREATHER 1
4 2531-5252 RETURN LINE FILTER 1
4A 2538-0053 RETURN LINE FILTER GAUGE 1
5 TBA INSPECTION COVERS 2
6 2531-5154 SUCTION FILTER 2
TBA ‘O’ RING KIT 2
6A 2538-0054 SUCTION FILTER GAUGE 1
6B TBA 2½” SAE 3000 SERIES FLANGE & ADAPTOR 1
6B TBA 2½” SAE 3000 SERIES FLANGE & ADAPTOR 1
06/01/04
AX868-901-8EN-01c 364/412
6
6a 4
5 3 6b 4a 1 2
1000SR - Hydraulic Oil Reservoir Assembly

AX868-901-8EN-01c 365/412
Hydraulic System
AX868-901-8EN-01c 366/412
Hydraulic Components - HFO Hydraulic Clutch Circuit
AX868-901-8EN-01c 367/412
10.7 Electrical Components

PARTS IN MAIN CONTROL PANEL
1 2683-2217 PLC 1000SR (R360PLC)
2 2683-2218 PLC CONNECTOR FOR R360
3 2683-2219 LOAD DUMP MODULE
4 2683-2220 TEXT DISPLAY 1000SR REAL TIME CLOCK
5 2683-2221 CAN MODULE IP20. NODE 1
6 2683-2222 CONNECTOR FOR CAN MODULE IP20
7 2683-2223 DANFOSS CONNECTOR
8 2683-2224 DC/DC CONVERTOR
9 2683-2225 CR2011 SWAGED NODE 4 & 3
10 2683-2226 CR2013 SWAGED NODES 5 / 6 / 7 & 8
11 2683-2107 10A 8 PIN RELAT 24V DC
2883-2107A 8 PIN RELAY BASE
12 2683-2114 HEAVY DUTY PANEL SUPPLY RELAY
13 2683-2155 CAN PLC EMERGENCY STOP RELAY
14 2683-2106 10A 11 PIN 3 POLE RELAY 24V DC
2683-2106A 11 PIN RELAY BASE
15 2683-2227 Q1 / 2 & 3 CIRCUIT BREAKER 2 AMP
16 2683-2228 Q4 CIRCUIT BREAKER 1 AMP
17 2683-2229 Q5 & 9 CIRCUIT BREAKER 4 AMP
18 2683-2230 Q6 / 10 & 12 CIRCUIT BREAKER 2 AMP
19 2683-2231 Q 7 / 8 & 11 CIRCUIT BREAKER 6 AMP
20 2683-2232 CIRCUIT BREAKER AUXILLARY CONTACT
EMERGENCY STOP BUTTON WITH N/C
21 2683-2193
BLOCK
OPERATORS SET UP STATION
22 2683-2157 OPERATORS SET UP STATION ASSEMBLY
PARTS ON PLANT
23 2685-0001 PLANT EMERGENCY STOP STATION ASSY
24 2683-2110 AUDIBLE WARNING UNIT
25 2683-2233 HYDRAULIC OIL LEVEL SENSOR
26 2683-2234 LUBE TANK OIL LEVEL SENSOR
27 2683-2235 LUBE TANK TEMPERATURE SENSOR
28 2683-2236 PS1 PRESSURE SENSOR
29 2683-2237 PS2 PRESSURE SENSOR
30 2683-2238 CRUSHER HFO PRESSURE SENSOR
31 2683-2251 CRUSHER BOWL LEVEL SENSOR
RADIO / UMBILICAL CONTROL
32 2686-9034 RECEIVER UNIT INCLUDING CABLES
33 2686-9008 ANTENNA
34 2686-9007 CHARGER UNIT
35 2686-9029 UMBILCAL SYSTEM
HAND SET TRANSMITTER – RED STOP
36 2686-0043
BUTTON (USA AND REST OF WORLD)
HAND SET TRANSMITTER – BLACK STOP
37 2686-0044
BUTTON (EUROPE)
Mk V02 – 20/02/04
AX868-901-8EN-01c 368/412
AX868-901-8EN-01c 369/412
1000SR
Page 74
10.8 Warning Signs
300/32 300/33 300/34 300/37
300/42
300/38 300/39 300/40
300/44 300/45 300/46 300/118
AX868-901-8EN-01c 370/412
1000SR
Page 75
300/175
300119 300120 300/182
300/224
300/189 300/196 300/252
AX868-198-001
AX868-203-001 AX868-206-001
300/284
AX868-901-8EN-01c 371/412
10.9 Hydraulic Engine Clutch
The hydraulically actuated clutch fitted to the diesel engine is NOT supplied as
part of the Caterpillar diesel power pack. Contact BL-Pegson’s Dealer for all
requirements concerning this clutch.
REF DESCRIPTION REF DESCRIPTION

1 HOUSING 22 BACKPLATE
2 COVER 23 DRIVING PLATE
3 SCREW 24 CENTRE PLATE
4 BEARING CARRIER 25 SPRING
5 BEARING 26 PRESSURE PLATE
6 SHAFT 27 SCREW
7 SNAP RING 28 KEY
8 SPACER 29 LOCK WASHER
9 COVER 30 LOCK NUT
10 SCREW 31 ROTATING SEAL
11 ‘O’ RING 32 ROTATING SEAL
12 LOCK WASHER 33 DRIVING RING
13 SCREW 34 PIPE
14 ROTATING UNION 35 KEY
15 LOCK WASHER 36 TAPER PLUG
16 SCREW 37 LEVEL STICK
17 ‘O’ RING 38 NAME PLATE
18 HUB 39 PLATES HUB
19 ‘O’ RING 40 SCREW
20 PISTON 41 TAPER PLUG
21 ‘O’ RING 42 ELASTIC PIN
AX868-901-8EN-01c 372/412
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
1000SR - Hydraulic Clutch for diesel engine

AX868-901-8EN-01c 373/412
1000SR
Page 78
Blank page
AX868-901-8EN-01c 374/412
1000SR
Appendix Issue EN 01
Page 1
Contents
11.1 Noise Levels ....................................................................................................... 2
AX868-901-8EN-01c 375/412
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.
AX868-901-8EN-01c 376/412
Figures are for engine running with no load on crusher
AX868-901-8EN-01c 377/412
AX868-901-8EN-01c 378/412
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
AX868-901-8EN-01c 379/412
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
AX868-901-8EN-01c 380/412
All Plants - Messenger Control
Caterpillar Messenger Display
INTRODUCTION
The engine fitted on this plant may not have the engine monitoring system shown and referred to in the Terex
Pegson User Manual but has the Caterpillar Messenger system.
Messenger is an electronic monitoring system with real-time visual display of engine operating conditions,
historical data and diagnostic information.
If applicable, also refer to ‘Messenger Display’ in Features and Controls in the Operation Section of the
Caterpillar Operation and Maintenance Manual for the engine.
AM0014 - EN M-1
AX868-901-8EN-01c 381/412
Caterpillar Messenger Engine Monitoring System
Operation
The operator button functions are:
1
1. Previous button
Return to previous level and screen display
2
2. Scroll Up / Left button
Scroll display to view different menus and use to set up display settings.
3. Scroll Down / Right button

3
Scroll display to view different menus and use to set up display settings.
4. OK button
4
Confirm selection on the display / continue to next screen
Performance Display
The displays available are:
Engine speed
Coolant temperature
Totals Display
Cumulative totals displays available are:
Service hours engine has accumulated
Total time system in use
M-2
AX868-901-8EN-01c 382/412
All Plants - Messenger Control
Settings Display
System options available are:
Language used on display screen
Units shown on display
Adjust screen contrast
Adjust screen back light
Identification numbers available are:
Equipment identification number
Product identification number
Service Display
Service events display is:
View logged events, errors or alarms
System parameters are:
Battery voltage
Engine speed
Coolant temperature
Boost pressure
Self Test
Perform a self test, similar to when the start switch
is turned to the ON position
Monitoring information displays are:
Software part number
ECM (Electrical Control Module) part number
Software release date
Software description
AM0014 - EN M-3
AX868-901-8EN-01c 383/412
Caterpillar Messenger Engine Monitoring System
Engine information displays are:

ECM serial number
Software part number
Software release date
Software description
Engine serial number
Tattle tale
(To display maximum values reached during
operation).
Full tattle tale read-out
Engine coolant
Tachometer
Spare Parts
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.
M-4
AX868-901-8EN-01c 384/412
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.
AM0012 - EN
AX868-901-8EN-01c 385/412
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
AX868-901-8EN-01c 386/412
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
AX868-901-8EN-01c 387/412
Oil Specification Change
L-2
AX868-901-8EN-01c 388/412
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
AX868-901-8EN-01c 389/412
Metal Detector Controls
M-2
AX868-901-8EN-01c 390/412
All Plants - Cantrak Control
Plants with Cantrak Engine Monitoring System
AM0020 - EN C-1
AX868-901-8EN-01c 391/412
Cantrak Engine Monitoring System
Introduction
The Cantrak Engine Monitor is a graphical
instrument clusters to display parameters and
alarms.
The display has five buttons that change to suit
the screen in use. The buttons give to access a
graphical menu structure that uses standard and
easily-understood icons to indicate the button’s
current function.
The required engine data and display can display
the following formats:
Analogue gauges
Digital values
Historical trend graphs
Current and stored alarm messages
C-2
AX868-901-8EN-01c 392/412
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
AX868-901-8EN-01c 393/412
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
AX868-901-8EN-01c 394/412
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
AX868-901-8EN-01c 395/412
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
AX868-901-8EN-01c 396/412
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
AX868-901-8EN-01c 397/412
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
AX868-901-8EN-01c 398/412
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
AX868-901-8EN-01c 399/412
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.
AX868-901-8EN-01c 400/412
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.
AX868-901-8EN-01c 401/412
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’.

and is an explosion/burns
DANGER hazard.
Never remove the filler cap or Filler Cap
AX868-901-8EN-01c 402/412
All Plants
Water Pumps
Page 1
OPERATING INSTRUCTIONS
WATER PUMP
2575-2002 or 2575-2009
(for dust suppression spraybars)
TYPICAL INSTALLATION
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
AX868-901-8EN-01c 403/412
All Plants
Water Pumps
Page 2
Optional Water Pump

This option is available as originally fitted
DANGER
equipment installed at the time of plant SKIN INJECTION HAZARD
manufacture. Two models are available: Refer to Section 9.1, of the Plant
User Manual, Safety Information
for relevant warning
• 25 litres/minute nominal (6.6 US galls)
to suplly the plant spraybars only.
WARNING
• 65 litres/minute nominal (17 US galls) to WEAR PERSONAL
supply the plant spraybars plus
Refer to Section 9.1, of the Plant
additional capacity for the operator’s User Manual, Safety Information
off plant needs. for relevant warning
The pump is to provide a pressurised

supply of clean water to the dust
suppression spray nozzles included on
plants as a standard fitment. For details of The supply for external equipment can be
typical clean water requirements for the taken off one of the drain valves on the
dust suppression system, refer to the spraybar manifold.
Maintenance Section 9 of the plant manual.
No specific maintenance is required for the
The pump is permanently mounted in a pump unit except to check for hydraulic oil
suitable position on the plant near to the leaks when carrying out the normal plant
water manifold (Figure 1) and is driven maintenance (Section 9 of the plant manual)
from a branch of the engine driven plant Frost precautions must be taken in cold
hydraulic system.. weather to ensure water does not freeze
within the system, by opening the water
The inlet is with hose connector for the user manifold drain valves and detaching the
to provide supply suitable piping from the pump inlet feed pipe.
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.
AX868-901-8EN-01c 404/412
All Plants
Water Pumps
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
AX868-901-8EN-01c 405/412
All Plants
Water Pumps
Page 4
Hydraulic Oil Water
3 Way Valve
Flow Valve
Hydraulic Motor Water Pump
Coupling
Figure 3 Pump Hydraulic Oil/Water Circuits
2575-2008 3 Way Valve 2575-2005 Coupling

25 l/min Pump 2575-2003
2575-2007 Flow Valve
65 l/min Pump 2575-2010
2575-2004 Hydraulic Motor
Figure 4 Pump Unit Part Numbers
AX868-901-8EN-01c 406/412
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
AX868-901-8EN-01c 407/412
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
AX868-901-8EN-01c 408/412
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
AX868-901-8EN-01c 409/412
Page 2 12 - Notes
AX868-901-8EN-01c 410/412
12 - Notes Page 3
AX868-901-8EN-01c 411/412
AX868-901-8EN-01c 412/412

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Powerscreen of Florida.

5125 N. Frontage Road,

CRUSHING AND SCREENING PLANT

PLANT USER MANUAL

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

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

This plant is in conformity with the

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.

BL-Pegson Limited Telephone:- + 44 1530 518600

1.1 Warnings and Symbols ....................................................................................... 2

1.2 Organisation Measures ....................................................................................... 3

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

1.4 Safety Instructions Governing Specific Operational Phases ........................... 5

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

1.8 Plant Warning Signs .......................................................................................... 14

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

1.2 Organisation Measures Observe all safety instructions and warnings

For the execution of maintenance work, 1.3 Selection and

1.4 Safety Instructions 1.4.2 Special Work In Conjunction

Switch off and lockout the plant before

1.4.2.3 For carrying out overhead assembly work

Ensure that all consumables and replaced 1.4.2.12

Particularly make sure that any part of the

Never work under unsupported

Never work alone.

1.5 Warning of Special 1.5.1.4

• Warn others against approaching and

• Have the live wire de-energized.

1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

1.5.1.8 Observe the regulations in force at the

1.6 Transporting, 1.6.7

Do not attempt to mount a tyre unless you

Always maintain the correct pressure. Do

When inflating tyres, use a clip-on chuck

Check wheels for low pressure, cuts,

1.7 Position of Emergency Stop Buttons

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button Emergency Stop Button

Figure 1a Emergency Stop Buttons

1.8.1 Location of Warning Signs, Left Hand side of plant

KEY TO SIGN REFERENCE

KEY TO SIGN REFERENCE

1.8.2 Safety Sign Illustrations

Safety Sign Illustrations, continued

Safety Sign Illustrations, continued

Upper and Lower Transfer Conveyors, each:-

Recirculating and Stockpile Conveyors, each:-

2.1 Dimensions .......................................................................................................... 2

2.2 Plant Description ................................................................................................. 3

2.3 Belt Feeder Conveyor .........................................................................................4

2.4 Crusher ................................................................................................................ 4

2.5 Automax rushed Product Conveyor .................................................................. 4

2.6 Tracks ................................................................................................................... 5

2.7 Engine Powerpack .............................................................................................. 5

2.8 Dust Suppression Sprays .................................................................................. 5

2.9 Sizing Screen ....................................................................................................... 5