1000 Maxtrak Plant User Manual 2008 L PDF

ADVANCED CRUSHING TECHNOLOGY
MAXTRAK 1000
PLANT USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
! SAFETY !
This manual contains safety information which the operator should read and
follow. Failure to do this will increase the risk of injury or may result in death.
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IMPORTANT
TEREX PEGSON PLANTS CAN INCLUDE
OPTIONAL EQUIPMENT AND/OR SPECIAL
FEATURES ADDITIONAL TO THE
STANDARD SPECIFICATION.
THESE MAY AFFECT THE INFORMATION
GIVEN IN THIS OPERATORS MANUAL.
LOOK IN SECTION 11 - APPENDIX OF THIS
MANUAL FOR ANY ADDENDUM WHICH
MAY RELATE TO ADDITIONAL EQUIPMENT
OR VARIATIONS TO THE STANDARD
SPECIFICATION.
TAKE NOTE OF ANY VARIATIONS TO THE
STANDARD PROCEDURES AND/OR
COMPONENT SPECIFICATIONS.
Options EN
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IMPORTANT SAFETY NOTICE!
The environment in which the plant will operate contains inherent risks to health and
safety which the operator must take steps to guard against. Dangers from overhead
conveyor discharges, overspill material, vehicle movements, etc., as well as other site
related hazards must be anticipated. Avoid these by carrying out risk assessments before
the plant is put into operation to ensure appropriate exclusion zone measures are put in
place and site personnel safety awareness training has been undertaken.
Follow all applicable safety regulations and recommendations in this manual as

appropriate to your plant and the situation/conditions prevailing at the time.
Read this manual carefully to learn how to operate and service your plant correctly.
Failure to do so could result in personal injury or equipment damage.
Consider this manual a permanent part of your plant. Keep it with the plant at all times.
Federal, State, National and Local laws and safety regulations must be complied with at all
times to prevent possible danger to person(s) or property from accidents or harmful
exposure.
See also the separate Operation and Maintenance Manual provided for the diesel engine
fitted to your plant and in particular read and observe the instructions within the Safety
Section of the engine manual.
INFORMATION AND ADVICE

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

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

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

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

over a period of time.
Wear proper hearing personal protective

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

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

equipment, use approved respiratory protection, as
required by Federal, State and Local safety and
health regulations.
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Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are approximate
conversions from the actual metric measurement of the item concerned.
CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Proposition 65 Warning
WARNING: Battery Posts, terminals and
related accessories contain lead and lead WARNING: Diesel engine exhaust and
compounds, chemicals known to the State some of it’s constituents are known to the
of California to cause cancer and State of California to cause cancer, birth
reproductive harm. defects, and other reproductive harm.
WASH HANDS AFTER HANDLING.
Copyright
The copyright of this User Manual is reserved by Terex Pegson Limited.
This User Manual contains information and technical drawings, which may not be copied, distributed,
altered, stored on electronic media, revealed to others or used for the purpose of competition, either partially
or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright 2004.
Terex Pegson Limited Telephone:- + 44 1530 518600

Mammoth Street
Coalville Fax:- + 44 1530 518618
Leicestershire
LE67 3GN E mail sales@bl-pegson.com
England
AUTOMAX/AUTOSAND - EXPLANATORY NOTE

The Terex Pegson ‘Automax’ cone crusher is incorporated into the Maxtrak 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).
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Page 1 - 1
1 - Safety
1.1 Warnings and Symbols .................................................................................. 1 - 2
1.2 Organisation Measures .................................................................................. 1 - 3
1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4
1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 5

1.4.1 Standard Operation .................................................................................... 1 - 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ................ 1 - 5
1.5 Warning of Special Dangers .......................................................................... 1 - 8
1.5.1 Electric Energy ........................................................................................... 1 - 8
1.5.2 Gas, Dust, Steam, Smoke and Noise ......................................................... 1 - 9
1.5.3 Hydraulic and Pneumatic Equipment ........................................................ 1 - 10
1.5.4 Hazardous Substances ............................................................................ 1 - 11
1.6 Transporting, Manoeuvring and Recommissioning .................................. 1 - 11
1.7 Position of Emergency Stop Buttons ......................................................... 1 - 13
1.8 Safety Signs .................................................................................................. 1 - 14

1.8.1 Location of Safety Signs .......................................................................... 1 - 14
1.8.2 Safety Sign Illustrations............................................................................ 1 - 16
1.8.2 Safety Sign Illustrations, continued ........................................................... 1 - 17
Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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1.1 Warnings and Symbols
The following signs and designations are used in the manual to designate instructions of particular
importance.
!!
This is the safety alert symbol. When you see this symbol on your plant
or in this manual, be alert to the potential for personal injury or
equipment damage.
Follow the recommended precautions and safe operating practices.
! DANGER !
Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
! WARNING !
Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury.
! CAUTION !
Indicates a potentially hazardous situation which, if not avoided, MAY
result in minor or moderate injury. It may also be used to alert against
unsafe working practices.
! NOTICE !
Indicates a statement of company policy as the message relates directly
or indirectly to the safety of personnel and protection of property.
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1.2 Organisation Measures See to it that safety instructions and

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

attached to the plant.
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1.2.4 1.3 Selection and

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

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

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

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

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

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

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

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

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

(Control Panel)
Figure 1a Emergency Stop Buttons
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1.8 Safety Signs
1.8.1 Location of Safety Signs
Figure 1b Warning Signs - Left Hand Side

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Figure 1c Warning Signs - Right Hand Side
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1.8.2 Safety Sign Illustrations
1 2 3 6
7 8 9 10
13 14 15 17
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1.8.2 Safety Sign Illustrations, continued
21 27
19 23
11 20
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Blank page
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Page 2 - 1
2 - Technical Information
2.1 Dimensions and Weights ............................................................................... 2 - 2
2.2 Plant Description ............................................................................................ 2 - 3
2.3 Belt Feeder Conveyor .................................................................................... 2 - 4
2.4 Crusher ........................................................................................................... 2 - 4
2.5 Discharge Conveyor ...................................................................................... 2 - 4
2.6 Standard Powerpack ...................................................................................... 2 - 5
2.7 Controls ........................................................................................................... 2 - 5
2.8 Dustsprays ...................................................................................................... 2 - 5
2.9 Tracks .............................................................................................................. 2 - 5
2.10 Optional Extras * ........................................................................................... 2 - 6
Terex Pegson Limited have designed and built the Maxtrak plant to provide the
Buyer with a range of equipment choices to meet a wide variety of individual
needs and preferences as selected at the time of initial purchase.
Please note that the asterisk * in the text of this User Manual signifies:
Not included in all plants - only appropriate if the item is fitted.
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3229 (10’- 7”)
Discharge Height
2779 (9’- 1”)

3446 (11’- 4”)Travel Height
3990 (13’- 1”) 3800 (12’ -6”)

2.1 Dimensions and Weights
All dimensions are in millimetres (feet/inches)
Overall Travelling Length (Feed Conveyor lowered) - 15095 mm (49’- 6”) Hopper Width
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Overall Working Length (Feed Conveyor raised) - 15173 mm (49’- 9”)
Overall Travelling Height (Feed Conveyor lowered) - 3446 mm (11’- 4”)
Overall Working Height (Feed Conveyor raised) - 3914 mm (12’- 10”)
2 - Technical Information
Overall Width - Travelling & Working (Over Tracks) - 2800 mm (9’- 2”)
Gross Weight approx. - 31.3 tonnes (34.4 US tons)
Note: Weights and dimensions are for guidance only and appropriate allowances should be
3914 (12’- 10”)
applied when being used for transportation purposes.

Working Height
EN
1000
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Figure 2a Dimensions and Weights 2800 (9’- 2”)

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2.2 Plant Description

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

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

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

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

Type Shallow troughed plain belt.
Width 1000mm (39”).
Length 5400mm (17’-9”).
Drive Unit Hydraulic motor with head drum oil lubricated gearbox
Control Auto/manual variable speed.
Hopper Fixed hopper with rear feed facility and internal ‘strickle’
gate and full length barge boards with wear pads.
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 High level sensor over the feed box.
2.5 Discharge Conveyor

Type Plain troughed belt.
Width 800mm (32”).
Drive Hydraulic motor.
Lubrication Grease (shaft bearings).
Enclosure Canvas cover.
Control equipment Tail drum movement sensor.
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2.6 Standard Powerpack

Type Caterpillar C9 EU/EC Emmission Regulations
compliant, 6 cyl. water cooled diesel engine.
Rating 335hp @ 1800 rpm.
Drives Hydraulically actuated heavy duty clutch and vee ropes
to crusher and vee belts to twin hydraulic pumps.
Housing Enclosed canopy with integral fuel tank and battery.
2.7 Controls
Automax Crusher Setting, etc. 24 v DC Electro/Hydraulic Panel having numeric
keypad and message display on plant chassis.
Plant Operation 24 v DC Electric Panel in Control Box with push button
controls and fault display, level sensor and metal
detector controls.
Plant Set-Up Lever on the plant chassis to raise/lower the feeder
conveyor.
2.8 Dustsprays
Type Clean water multi atomising nozzle spraybars.
Positions Crusher feed & discharge and discharge conveyor head.
Inlet Single point for user’s pressure supply.
Required supply Up to approx. 7 litres/min @ 2.8 bar (2 US galls @ 42
psi.
Frost protection System drain valves.
2.9 Tracks
Type 160mm (6.3”) pitch heavy duty.
Width 400mm (16””).
Centres 3800mm (12’-6”).
Drive Hydraulic integral motors.
Control Remote handset - dual speed.
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2.10 Optional Extras *

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

3.3.1 Operating Temperature Range ................................................................... 3 - 4
3.4 Crusher Performance ..................................................................................... 3 - 5
3.4.1 Estimated Performance - Automax with long throw eccentric ...................... 3 - 6
3.4.2 Typical Product Analysis - Automax with long throw eccentric ...................... 3 - 7
3.4.3 Estimated Performance - Automax with short throw eccentric .................... 3 - 8
3.4.4 Typical Product Analysis - Automax with short throw eccentric .................... 3 - 9
3.4.5 Estimated Performance - Autosand with long throw eccentric .................. 3 - 10
3.4.6 Typical Product Analysis - Autosand with long throw eccentric .................. 3 - 11
3.4.7 Estimated Performance - Autosand with short throw eccentric ................. 3 - 12
3.4.8 Typical Product Analysis - Autosand with short throw eccentric ................. 3 - 13
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3.1 Introduction
This instruction manual contains important

information on how to operate the Maxtrak
1000 plant safely, properly and most
efficiently. Observing these instructions helps
to avoid danger, to reduce repair costs and
downtimes and to increase the reliability and
life of the plant.
These operating instructions must always be

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

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

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

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

regulations for accident prevention and
environmental protection.
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3.2 General information

! NOTICE !
The Maxtrak 1000 plant has been If high or low ambient temperature
manufactured, assembled and tested with the conditions apply, specific details
utmost care and was built with first class need to have been advised at the
materials. time of order as special equipment
may be necessary.
Close attention has been paid to all details in
assembly, running tests and final inspection.
The Caterpillar engine cooling
Terex Pegson is confident that the plant will system is protected to -15 ºC with
give every satisfaction over a long period. 30% Caterpillar antifreeze
concentration when shipped from
To be assured of faultless operation the the factory unless special
operator should carefully read the following requirements have been defined.
paragraphs and give the required time and
attention to essential maintenance, cleaning
and inspection.
The plant is easy to operate, adjustments are

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

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

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

Section for guidance regarding the
The Terex Pegson Maxtrak plant includes the performance of the Automax crusher.
1000 Automax Cone Crusher designed to Experienced engineers are available at BL-
maximise throughput and product shape in a Pegson to give advice when necessary.
wide range of crushing applications. For finer
crushing operations the Autosand option is If you have any doubts about any aspect
available. of the plant’s capability or servicing
procedures, you must consult your local
BL-Pegson dealer or BL-Pegson’s
! NOTICE ! technical departments
It is vitally important that pieces of 3.3.1 Operating Temperature Range

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

and based on crushing clean, dry, well
In order to obtain the optimum overall graded quarried hard limestone, weighing
crushing performance from the Automax, loose about 1600 kg/f/m3 (100 lbs/cu.ft.) and
it is essential to have a continuous and having a specific gravity of 2.6 - 2.8. Wet
regulated ‘choke’ feed of evenly graded sticky feeds will reduce crusher capacities.
material that is well mixed around the
crushing chamber. Typical feed gradings Performance will be adversely affected if an
are shown on the product analysis graphs excessive percentage of fines in the feed
in this section. causes the packing/caking of material, either
to slow the flow of material or cause
The level sensing device prior to the congealed lumps in the product.
crusher will assist in achieving this when
used to control the feed. Additionally, all Persistent ‘dumping’ (see Glossary) is
feed material should be of a size that will most undesirable and likely to be
readily enter the crushing chamber. caused by operating the machine at too
close a setting. Increase the ‘Gap’
The gradings and capacities shown in this setting to avoid damage to the machine.
section are averages base on actual
results taken from tests carried out on Crusher settings shown in the tabulation are
various materials at different crusher for general guidance only and crusher
settings. They will vary dependant upon performance will vary depending upon the
the grading and nature of the feed conditions prevailing.
material. For more specific details please
contact BL-Pegson Ltd. Capacities shown are for open circuit
applications.
Performance is dependant upon the throw
of the eccentric built into the Automax and When operation is required towards the
also the type of concave fitted to the lower end of the setting range. Terex
machine. Sections 3.4.1 to 3.4.8 cover the Pegson Ltd should be consulted to verify the
various options. application.
Note: The power required and product gradings

Terex Pegson’s Technical Department will vary with the feed and product size,
can confirm the specification of the capacity and rock characteristics.
machine as originally built but bear in
mind this may have been subsequently Usage of wearing parts will depend upon
changed. individual crushing conditions and the
variable factors which govern wear.
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3.4.1 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
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3.4.2 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
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3.4.3 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
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3.4.4 Typical Product Analysis - Automax with short throw eccentric
Figure 3f Typical Product Analysis Curves - Short Throw Eccentric Automax

PERCENTAGE PASSING
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3.4.5 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
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3.4.6 Typical Product Analysis - Autosand with long throw eccentric
Figure 3i Typical Product Analysis Curves - Long Throw Eccentric Autosand

PERCENTAGE PASSING
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3.4.7 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
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3.4.8 Typical Product Analysis - Autosand with short throw eccentric
Figure 3l Typical Product Analysis Curves - Short Throw Eccentric Autosand

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

4.2.1 Automax Crusher ........................................................................................ 4 - 3
4.2.2 Feed Hopper ............................................................................................. 4 - 3
4.2.3 Feed Conveyor .......................................................................................... 4 - 3
4.2.4 Discharge Conveyor .................................................................................. 4 - 3
4.2.5 Chutes ....................................................................................................... 4 - 4
4.2.6 Platforms ................................................................................................... 4 - 4
4.2.7 Power Unit ................................................................................................. 4 - 4
4.2.8 Controls ..................................................................................................... 4 - 4
4.2.9 Chassis ..................................................................................................... 4 - 4
4.2.10 Track Frame............................................................................................. 4 - 5
4.2.11 Guards ..................................................................................................... 4 - 5
4.2.12 Painting ................................................................................................... 4 - 5
4.2.13 Dust Suppression Sprays ......................................................................... 4 - 5
4.2.14 Optional Extras ........................................................................................ 4 - 5
4.2.15 Authorisation ............................................................................................ 4 - 6
4.2.16 Site Preparation ....................................................................................... 4 - 6
4.2.17 Commissioning ........................................................................................ 4 - 6
4.2.18 Specifications .......................................................................................... 4 - 6
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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4.1 General Information
The Terex Pegson Maxtrak 1000 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
• No need for pre-screening on many applications reducing cost and increasing profitability
• Easily transported on and off site
• Metal detection fitted as standard
• Feed hopper and level controls included to ensure choke feed to the crusher with resultant optimum
product shape
• 3.2 m (10’-7”) discharge conveyor material discharge height
• Hydraulic crusher setting adjustment, overload release and unblocking included as standard
• Dust suppression sprays
• Caterpillar water cooled diesel engine with hydraulically controlled clutch
• Hydraulic rams to assist setting up and packing for transportation
• Choice of crusher concave (including Autosand option) and eccentric throw available
CRUSHING APPLICATIONS
! WARNING !
This plant is designed for stone crushing applications. It is vitally important that
large pieces of steel or similar uncrushable objects are not allowed to enter the
crushing chamber as severe damage and injury may occur. The Automax
crusher includes automatic hydraulic overload release. However the machine is
not designed to accept large pieces of steel or other uncrushable objects such
as bucket teeth. The metal detector fitted to the feeder conveyor must be kept
operable at all times whilst the plant is in operation and any foreign object
removed from the feeder conveyor belt.
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4.2 Construction Units 4.2.3 Feed Conveyor

1000mm (39”) wide plant mounted shallow
TEREX PEGSON 1000 MAXTRAK troughed belt variable speed conveyor, with
SECONDARY/TERTIARY CRUSHING hydraulic drive to the head drum having
PLANT WITH DIESEL/HYDRAULIC integral reduction gearbox, EP500/3 (or
DRIVE generally as shown on brochure MT equivalent) belt with 5mm (0.2”) top and
200/1 and comprising:- 1.5mm (0.06”) bottom heavy duty covers,
and vulcanised belt joint. The conveyor is
4.2.1 Automax Crusher designed to lower for transportation and lift
for crusher maintenance, by means of
Terex Pegson 1000 Automax Crusher
hydraulic cylinders. Belt tensioning is
generally as illustrated on leaflet AMB 200/1,
maintained by screw adjusters located at the
and fitted with long throw eccentric, medium
tail drum.
coarse (MC) concave and dedicated system
2 hydraulic controls as standard. The
crusher is complete with an oil lubrication Impact rollers are provided immediately
system having a chassis mounted tank with below the feed hopper, and barge boards
air blast cooler. extend from the feed hopper to the conveyor
head. A metal detector is included complete
Extra coarse (XC), coarse (C) and Autosand with audible warning devices, and is suitable
(AS) concaves and a short throw eccentric for detecting steel and manganese steel
are all available as options to the above for contained in the feed material.
plants which have not been completed.
Advice on the correct combination of 4.2.4 Discharge Conveyor
concave and eccentric can be provided by 800mm (32”) wide plant mounted troughed
the sales department against purchasers belt fixed speed conveyor with hydraulic
specific application data. drive to the head drum, EP 500/3 (or
equivalent) belt with 5mm top (0.2”) and
4.2.2 Feed Hopper 1.5mm (0.06”) bottom heavy duty covers,
and vulcanised belt joint. The conveyor is of
7.0m³ (8.75yd³) heaped capacity feed
fixed design and belt tensioning is maintained
hopper fabricated in 10mm (3/8”) thick mild
by screw adjusters located at the tail drum.
steel plate and fitted with internal crash bars
Impact rollers are provided immediately
to minimise impact load on the feed
below the crusher outlet under the conveyor
conveyor.
feed point, and canvas type dust covers are
provided over the exposed section of the
conveyor.
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4.2.5 Chutes 4.2.8 Controls

Automax feed box fabricated in 6mm (1/4”) The Automax hydraulic systems control
mild steel plate. Crusher discharges direct to panel, and separate start/stop control panel
product conveyor feed boot, which is for the crusher conveyors, and oil lubrication
fabricated in 10mm (3/8”) thick Hardox. system are mounted on the side of the main
chassis. Both panels operate from a 24 volt
4.2.6 Platforms D.C. supply from the diesel engine.
Provided for inspection and maintenance, Also mounted on the chassis are emergency
allowing access to each side of the crusher stop buttons and a control lever for lowering
and engine, back of engine, and to one side and raising the feed conveyor assembly for
of feed conveyor head section. They are transport and maintenance.
made from steel flooring with steel toe
boards, double row handrails and access A radio control unit is provided for controlling
ladders. the tracking function giving a tracking speed
of approximately 1km/hour and a ‘creep’
4.2.7 Power Unit facility for loading, off loading and precise
slewing movements. This also provides stop
Caterpillar C9 EU/EC Emmissions
and start control for the feed conveyor from
Regulations compliant, 6 cylinder, 4 stroke,
a remote position. An alternative unbilical
direct injection, water cooled diesel power
control unit is also provided for use in case
pack, with HFO clutch. The engine is rated
of remote control unit failure.
at 335 BHP (248 kW) nett continuous at
1800 rpm under NTP conditions.
Level sensors over the Automax and, feed
conveyor (optional), are designed to
Hydraulic power is provided from the engine
automatically maintain an optimum feed
to drive both conveyors, operate the
condition.
hydraulic cylinders, and give power to the
tracks. It also provides power to the crusher
lubrication oil pump and supplies the crusher 4.2.9 Chassis
hydraulic setting and adjustment system. All Fabricated steel frame with supports for the
connecting pipework is provided with steel feed conveyor, crusher, product conveyor,
pipe being used in inaccessible areas. power unit, track frame and control systems.
Hydraulic tank is mounted within the main

chassis structure, and the system includes air
to oil cooling.
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Page 4 - 5
4.2.10 Track Frame 4.2.13 Dust Suppression Sprays

Heavy duty track frame having 3.8m long Spray bars with atomiser nozzles are
(12’- 6”) centres and 400mm (1’- 4”) wide mounted over the crusher mouth and the
tracks. product conveyor feed and discharge points
piped to an inlet manifold for clients
Total Plant Weight pressurised water supply.
31.300 kgs (34.4 US tons)
Overall track width - 2800mm (9’- 2”) Buyer to supply pressurised at 2.8 bar (42
Operating height - 3914 mm (12’- 10”) psi) clean water supply at approximately 7
Operating length - 15173 mm (49’- 9”) litres (2 US galls.) per minute.
Operating width - 2800 mm (9’- 2”)
Travel height - 3446 mm (11’- 4”) 4.2.14 Optional Extras
Travel length - 15095 mm (49’- 6”)
Travel width - 2800 mm (9#- 2”) (These options are only available for plants,
which are not already built and are not
4.2.11 Guards available for plants already in stock)
Wire mesh or sheet metal guards are provided Automax extra coarse concave (no price
for all drives, flywheels, pulleys, couplings, variation for unfinished plants)
wedge belts and belt conveyors.
Automax coarse concave (no price variation
The guards provided are designed and for unfinished plants)
manufactured to ensure so far as reasonably
practicable that the machinery and plant on Autosand concave (no price variation for
which they are fitted can be operated safely unfinished plants)
and without risk to health when properly used.
However, the Company cannot guarantee that Short throw eccentric (no price variation for
the guards provided will meet the requirements unfinished plants)
laid down by individual Inspectors and any
additional guard and/or modification to guarding Beckford belt weigher with integrator and
supplied, which may be required for any
speed sensing wheel fitted to main product
reason whatsoever, will be charged as an
conveyor.
addition to the Contract Price.
Hydraulically driven water pump assembly to
4.2.12 Painting
provide a pressurised water supply to the
The plant is finish painted in BL-Pegson dust suppression sprays.
Blue RAL 5015.
Level sensor over the feed hopper.
Feed Hopper Extension Plates.
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4.2.15 Authorisation 4.2.18 Specifications

This is a requirement of the Environmental Every endeavour will be made to supply
Protection Act that the Purchaser must equipment as specified, but we reserve the
obtain Local Authority authorisation to right, where necessary, to amend
operate this plant in the U.K. specifications without prior notice as we
operate a policy of continual product
4.2.16 Site Preparation development.
The buyer shall be responsible for ensuring We cannot guarantee that the equipment
that a suitably prepared, flat and level site is quoted will meet any specific requirements in
available for the plant and that the ground is respect of noise or vibration levels, dust
capable of sustaining the working of the emissions, or any other factors relevant to
equipment. Unit dimensions and loadings health and safety measures or environmental
can be provided to the buyer for both protection needs. However, on receipt of
transportation and operating purposes. specific information Terex Pegson will
endeavour to ascertain the need for
4.2.17 Commissioning additional equipment and, if appropriate,
quote extra to contract prices.
On arrival of the plant on site Terex 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.
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1000
5 - Transport EN
Page 5 - 1
5 - Transport
5.1 Safety Information .......................................................................................... 5 - 2
5.2 Transportation ................................................................................................ 5 - 5

5.2.1 Manoeuvring .............................................................................................. 5 - 5
5.2.2 Unloading ................................................................................................... 5 - 8
5.2.3 Loading ..................................................................................................... 5 - 9
5.2.4 Lowering the Feed Conveyor ................................................................... 5 - 10
5.3 Remote Control Operation ........................................................................... 5 - 12
5.3.1 Radio Hand Set (where fitted) .................................................................. 5 - 14
5.3.2 Alternative Control Hand Set with Umbilical Cable (where fitted) ............... 5 - 16
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5 - Transport EN
Page 5 - 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

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

whilst it is 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.
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1000
5 - Transport EN
Page 5 - 3
In-running nip points can cause ENTANGLEMENT

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

before opening or removing guards.
Hydraulic fluid under pressure can SKIN INJECTION

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

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

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

Get medical help immediately.
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5 - Transport EN
Page 5 - 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.
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1000
5 - Transport EN
Page 5 - 5
5.2 Transportation
! DANGER !
5.2.1 Manoeuvring When manoeuvring your Maxtrak
to its operating position make sure
! WARNING ! you stand well clear of the plant
but are in a position to have all-
Prior to attempting any round vision to see any obstacles
manoeuvring of the plant the or hazards that may lie ahead e.g
tracks must be free of personnel, overhead cables,
obstructions, including crushed ditches, unsafe roadways etc.
material and fines. Do not push or (Refer to Figure 2a Dimensions).
tow the plant. Failure to observe
this warning could result in • Make sure that you do not manoeuvre
serious injury to persons and your Maxtrak on a gradient steeper than
damage to the plant which may 30 degrees, damage may occur to the
invalidate warranty. engine and/or plant.
• Before manoeuvring the Maxtrak, • Avoid manoeuvring the plant over

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

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

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

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

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

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

engine speed at 1200rpm.

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

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

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

PLANT and stop the engine (Section
8.2), unless required further.
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5.2.3 Loading
Procedure
WARNING
WEAR PERSONAL
1. Observe all safety warnings. PROTECTIVE EQUIPMENT.
2. Ensure that both conveyors, feed hopper
and crusher are free from stone and dirt.
FALLING HAZARD
3. Ensure all loose items are carefully Refer to Section 5.1, Safety
stowed and secured if these are to be Information for relevant warning.
transported on the plant.

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

at PLANT and the RADIO REMOTE
CONTROL switch at ON (Figure 7b). 10. Turn the RADIO REMOTE
CONTROL switch to OFF then shut
6. Lower the feeder conveyor for travelling down the hand set with the hand set stop
if not already in this position (Refer to button.
Section 5.2.4 procedure).
7. Position easy slope ramps at the end of PLANT and Stop the engine (Section
the transporter to help with loading of the 8.2), unless required further.
Maxtrak.
12. Securing the Maxtrak to the
8. Turn the OPERATION switch to transporter is the responsibility of
TRACK (Figure 5a). Using the remote the haulage contractor.
control hand set (Section 5.2.1 and 5.3),
steer the Maxtrak on to the transporter.
! WARNING !
9. When the Maxtrak is in the correct Prior to transportation always
position, press the Horn button to turn check the plant for loose or
the safety warning horn off and damaged components.
Fasten all loose parts, replace
missing items or make repairs
as found necessary to ensure
that all components are safely
secured during transportation.
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5.2.4 Lowering the Feed Conveyor

The Maxtrak is designed so that the plant
WARNING
can be prepared for transport without the WEAR PERSONAL
use of tools. To reduce to the travelling PROTECTIVE EQUIPMENT.
dimensions of the plant the feeder conveyor Refer to Section 5.1, Safety
head is hydraulically lowered from the Information for relevant warning.
working position.
FALLING HAZARD
! WARNING ! Information for relevant warning.
Whilst the plant is crushing the

conveyor head must always be
supported on the locating pins
positioned in each of the two
telescopic support legs and NOT
by the hydraulic ram alone.
Procedure
2. Ensure that the conveyor and feed

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

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


CONTROL switch at ON (Figure 7b)..
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6. Operate the hydraulic lever on the

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

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

provided on the telescopic legs and stow
the security pins to prevent loss. Upper Telescopic
Leg
9. Switch off the engine (Section 8.2) and Locating Pin
implement the lockout procedure.
10. Lower the mast(s) supporting the level

sensor(s).
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 5b Feed Conveyor Hydraulic Lever

and Locating Pins
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5.3 Remote Control • To manoeuvre the Maxtrak with the

remote hand set, refer to the instructions
Operation
in Section 5.2.1.
! DANGER ! • For recharging the hand set battery, see

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

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

hand set whilst the plant is in TRACK
operating mode will stop the engine, but
the engine ignition switch needs to be
turned off manually.
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PLAN VIEW OF THE PLANT
LED Red/Green
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1

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

(Horn) (Feeder On/Off)
Rotate clockwise, track 1 forward, track 2
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5c Remote Control Hand Set
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Page 5 - 14
5.3.1 Radio Hand Set (where fitted)

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

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

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

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

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

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

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

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

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

feeder (where appropriate)
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2 versions of the 860 system transmitter will

be supplied, one for European Operations
and one for the Rest of the World. The only
WARNING
difference is that the European version will WEAR PERSONAL
include a black stop button. The Rest of the PROTECTIVE EQUIPMENT.
World transmitter will feature a Red Stop
button. Channel 01 (434.650 MHz) through
channel 16 (433.900 MHz) available in .050
MHz steps. Refer to Dealer if frequency
change needed. • To conserve the battery charge the hand
set should be switched off when not in
Battery Recharging use.
The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
5d). A 12/35 volt charging lead suitable for
plugging into a vehicle cigarette lighter point
is supplied.
• Battery charge status is indicated by the

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

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

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

Charger Connection
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5.3.2 Alternative Control Hand Set

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

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

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

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

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

sound the safety warning horn. This will
also ready the tracks for manoeuvring.
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Figure 5e Umbilical Connection Point
Figure 5f Umbilical Control Hand Set
Figure 5g OPERATION and RADIO REMOTE CONTROL Switches

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Page 5 - 18
7. The umbilcal handset (Figure 5h)

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

nearest to the operator and proceed as
follows. Press the slow speed buttons on
the hand set to manoeuvre the plant in
the desired direction (Figure 5h). Employ
the ‘fast’ speed only where safe to do
so.
9. When the Maxtrak is in the correct

position, press the Horn button to turn
the safety warning horn off and
10. On the Control Panel turn the

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

with the original plug (where radio unit
fitted). Store the umbilical hand set unit
in the tool box to keep available for
future use.
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PLAN VIEW OF THE PLANT
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1
Left turn slow, forward track 2 **Reverse 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 5h Remote Umbilical Control Hand Set
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6 - Set Up
6.2 Setting Up ....................................................................................................... 6 - 5
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BL-Pegson machine can cause



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6 - Set Up EN
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HAZARD
machine.


HAZARD
injury.



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6 - Set Up EN
Page 6 - 4

followed.
LOCKOUT PROCEDURE

lockout.
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Page 6 - 5
6.2 Setting Up
WARNING
Plant Location Considerations
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Prior to setting up your Maxtrak, 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 the Terex Information for relevant warning.
Pegson (Section 3) should be fed into the
plant.
The Maxtrak is designed so that the plant in

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

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


CONTROL switch at ON (Figure 6a).
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Page 6 - 6
5. Raise the feeder conveyor into the

working position by operating the
hydraulic lever on the chassis side so
that the two locating pins can be inserted
through the top pair of holes in the upper
telescopic legs. Fit the security pins into
the end of each pin (Figure 6b).
6. Operate the hydraulic lever to lower the

conveyor until the locating pins rest on
the seats in the lower telescopic legs.
Make sure the locating pins are resting
on their seats on both sides of each leg
and not on the pin head on one side only.
! WARNING !
Whilst the plant is crushing the
conveyor head must always be
supported on the locating pins
positioned in each of the two
telescopic support legs and NOT
by the hydraulic ram alone.
7. Lifting the feeder conveyor head will

automatically unfold the platform access
ladder.
8. Switch off the engine (Section 8.2) and

9. The rear wall of the feed box needs to

be manually lifted and secured with the
fixings provided.
10. Raise the masts supporting the level

sensor(s) making ensuring restoration at
the correct height so that the originally
calibrated settings are maintained.
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Page 6 - 7
Figure 6a OPERATION and RADIO REMOTE CONTROL Switches

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

and Locating Pin
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Blank Page
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Page 7 - 1
7 - Operating Instructions

7.1.1 Blocked Crusher Procedures ..................................................................... 7 - 4
7.1.2 Safe Operation of the plant ......................................................................... 7 - 5
7.1.3 Checks at Initial Start-Up ............................................................................ 7 - 6
7.2 Plant Start-Up Procedure ............................................................................. 7 - 7
7.2.1 Engine Start-Up .......................................................................................... 7 - 8
7.2.2 Plant Start Up ........................................................................................... 7 - 12
7.2.3 Electric Control Panel Screen Display Data.............................................. 7 - 17
7.2.4 Plant Operating Sequence and Automatic Safeguards ............................. 7 - 18
7.2.5 Fault Indication and Restart ...................................................................... 7 - 19
7.2.6 Metal Detection ........................................................................................ 7 - 20
7.2.7 Feed Conveyor Remote Operation ........................................................... 7 - 21
7.2.8 Crushing Material - Plant and Automax Settings ....................................... 7 - 22
7.2.9 Plant Initial Start Up and Running In ........................................................... 7 - 23
7.2.10 Daily Plant Checks ................................................................................. 7 - 25
7.3 Automax Operation ....................................................................................... 7 - 26
7.3.1 Glossary of Automax Parts ....................................................................... 7 - 28
7.3.2 Glossary of Automax Terms ...................................................................... 7 - 29
7.3.3 Automax Initial Discharge Setting and Calibration ..................................... 7 - 31
7.3.4 Automax Manganese Wear Calibration .................................................... 7 - 32
7.3.5 Guidance for Changing the Manganese Mantle and Concave ................... 7 - 33
7.3.6 Automax Initial Start Up ............................................................................. 7 - 34
7.3.7 Actions during running in ........................................................................... 7 - 35
7.3.8 Automax Adjustment of Discharge Setting ................................................ 7 - 36
7.3.9 Manual Raising/Lowering of the Automax Upper Frame ............................ 7 - 37
7.3.10 Automax Automatic Overload Release/Unblocking and Resetting ........... 7 - 38
7.3.11 Checking Automax Wedge Pressure ...................................................... 7 - 39
7.3.11 Checking Automax Wedge Pressure ...................................................... 7 - 39
7.3.12 Daily Automax Checks ........................................................................... 7 - 40
7.4 Automax Crusher Controls .......................................................................... 7 - 41
7.4.1 Controls Layout ........................................................................................ 7 - 41
7.4.2 Function Keys .......................................................................................... 7 - 42
7.4.3 General Operation .................................................................................... 7 - 43
7.4.4 Manual Operation ..................................................................................... 7 - 52
7.4.5 Setting the Gap ........................................................................................ 7 - 53
7.4.6 Setting New Manganese .......................................................................... 7 - 55
7.4.7 Setting Normal Zero ................................................................................. 7 - 57
7.4.8 Tramp Overload or Test (whilst in Manual) ................................................. 7 - 59
7.4.9 Tramp Overload or Test (whilst in Auto) ..................................................... 7 - 59
7.4.10 Alarms ................................................................................................... 7 - 60
7.4.11 Alarm List ............................................................................................... 7 - 61
7.4.12 Wedge Lock Option ...............................................................................
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7.4.13 Historical Alarms .................................................................................... 7 - 63
Maxtrak
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Page 7 - 2

followed.
LOCKOUT PROCEDURE

lockout.
signs (ie. ‘TAG OUT’).

HAZARD
injury.



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HAZARD
machine.

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

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

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

whilst it is in operation. ! NOTICE !
Make sure that you fully DO NOT crush material with the
understand the operating engine below it’s recommended
procedures for the Automax working speed of 1800 rpm to
before attempting to start ensure all systems will function
correctly.
! NOTICE ! AVOID frequent starting and
DO NOT allow a build up of solid stopping of your Automax
material or dust in any part of the unnecessarily as it WILL be
plant, in particular keep clean the detrimental to the machine.
Automax internal frame arms
(Section 7.3.12) 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.
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7.1.3 Checks at Initial Start-Up

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

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

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

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

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

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

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

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

out in sequence:-
• Engine (Section 7.2.1).

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

controls can be operated (Section 7.3)
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7.2.1 Engine Start-Up
Procedure
WARNING
WEAR PERSONAL
2. Check that all Emergency Stop push
buttons are pulled out (Figure 1a)
otherwise the engine cannot start.
3. Ensure the engine Isolation Switch

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

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

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

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

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

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

The engine must be started prior to this
WARNING
operation (Section 7.2.1). First check that all WEAR PERSONAL
5 emergency stop buttons (Section 1.7) have PROTECTIVE EQUIPMENT.
been disengaged. Refer to Section 7.1, Safety
The display screen on the plant control panel
(Figure 7e) will take approximately 10
seconds to carry out a self diagnosis check,
then, if a system fault exists, the fault
condition will appear on the screen and the
warning siren will sound. Refer to Figure
7.2.3 for a list of display messages. ! WARNING !
Faults displayed on the electrical
The panel display screen not only indicates
control panel screen should be
the status of the starting sequence but also
identifies any fault condition which will halt
investigated and rectified
the starting procedure. If a fault condition immediately by suitably qualified
appears refer to Section 7.2.5. personnel BUT FIRST SHUT
DOWN THE ENGINE AND
Take note of the information on the display IMPLEMENT THE LOCKOUT
screen and operate the controls in the PROCEDURE (Section 8.2).
sequence described in the procedure. When
any green start button is pressed there is a 5
second warning and then the button has to
be pressed a second time to activate the
appropriate item.
Note: After the 5 second warning ceases,

press for the second time within 10 seconds
otherwise the warning will be repeated.
Procedure

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CONTROL switch at ON (Figure 7b).
4. Start the OIL PUMP by press the green

start button; after 5 second warning
press again within 10 seconds.
There is now a 5 minute delay before

the crusher can be started to allow time
for good oil circulation within the
Automax crusher before start up of the
machine. The display shows the time
delay as a time elapsed bar graph.
Note: In cold weather, prior to starting

the oil pump, preheat the lubricating oil
by running the engine which is fitted
with a heat exchanger for this purpose.
5. After completion of the oil pump delay

the panel display will read START
DISCHARGE CONV. Press the
discharge conveyor start button. Again 5
second warning and second press of the
button within 10 seconds to run the
conveyor. The display screen should
now be reading START CRUSHER.
6. Before starting the crusher ensure that

the engine speed on the tachometer
(Figure 7c) is not more than 1200 rpm.
Press the crusher start button. Again 5
second warning and press again within
10 seconds. With the crusher running the
display screen will read WAIT 10
SECONDS, START FEED
CONVEYOR.
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7. Adjust the engine throttle to the

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

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

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

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

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

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

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

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

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

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

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

the required specification and adjust the
feed material and/or settings if necessary.
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Deutsch
English
Español
Français
Diagnostic Display Português Feed Conveyor Crusher Level
Screen Level Sensor Controls Sensor Controls
(*optional)
1 - Select
2 - Press
3 - Press
EMERGENCY
STOP
OPERATION
PLANT/TRACK
FEED CONVEYOR DISCHARGE CRUSHER FEED CONVEYOR

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

When following the the start up procedure (Section 7.2.2), command (C) messages appear on the
display screen (Figure 7e) to indicated next action necessary, unless there is a fault (F) message which
overrides any message on the screen. Use the reference number as an easy way to identify a fault
when contacting Terex Pegson/Dealer’s Service Department.
REF No: TYPE DISPLAY MESSAGE
1 C WESTBURY CONTROL STYSTEMS LTD
2 F TRACK CONTROL MODE
3 F WARNING OUT OF SEQUENCE – WARNING WARRANTY INVALID IN THIS MODE
START OIL PUMP – PRESS TO SOUND PRESTART ALARM. PRESS AGAIN WITHIN 10 SEC TO
4 C
START
5 C CRUSHER START DELAY – 0 TO 5 MIN
6 C START DISCHARGE CONVEYOR
7 C WAIT 10 SECS – START FEED CONV
8 C PLANT RUNNING
9 F CRUSHER BOWL MATERIAL HIGH LEVEL – FEEDER STOPPED
10 F MATERIAL HOPPER MATERIAL LOW LEVEL – FEEDER STOPPED
11 C PLANT START AVAILABLE – START OIL PUMP. 10 SEC PRESTART ALARM
12 C CRUSHER START DELAY – 0 TO 30 SEC
13 C CRUSHER START AVAILABLE
17 F TRACK UMBILICAL STOP FAULT – CHECK TRACK UMBILICAL STOP BUTTON AND RESET
18 F TRACK RADIO STOP FAULT – CHECK TRACK RADIO STOP BUTTONS ETC.
20 F EMERGENCY STOP FAULT – CHECK PLANT E/M STOP BUTTONS AND RESET
26 F TRACK MOVEMENT C/B FAULT – Q1 OR QUMB – RESET Q1/QUMB CIRCUIT BREAKERS
27 F OIL PUMP C/B TRIPPED Q2 – RESET Q2 CIRCUIT BREAKER
28 F OIL COOLER C/B TRIPPED Q3 – RESET Q3 CIRCUIT BREAKER
29 F OIL HEATER C/B TRIPPED Q4 – RESET Q4 CIRCUIT BREAKER
30 F DISCHARGE CONV C/B TRIPPED Q5 – RESET Q5 CIRCUIT BREAKER
31 F FEED CONV C/B/ TRIPPED Q6 – RESET Q6 CIRCUIT BREAKER
33 F HYD PANEL C/B TRIPPED Q3/Q3A – RESET Q3/Q3A CIRCUIT BREAKER
36 F MINIRANGER C/B TRIPPED QMIN – RESET QMIN CIRCUIT BREAKER
37 F METAL DETECTOR C/B TRIPPED QMD – RESET QMD CIRCUIT BREAKER
38 F CRUSHER C/B TRIPPED QCS – RESET QCS CIRCUIT BREAKER
39 F HYDRAULIC PANEL WEDGELOCK FAULT – WEDGELOCK PRESSURE FAULT
41 F CRUSHER LUBE OIL TEMPERATURE HIGH – CONTACT BL-PEGSON IMMEDIATELY
42 F CRUSHER LUBE OIL LEVEL LOW – CHECK FOR LEAKS AND TOP UP LUBE OIL
43 F CRUSHER LUBE OIL FILTER BLOCKAGE – CHANGE LUBE OIL FILTERS
44 F CRUSHER LUBE OIL FLOW FAULT – NO LUBE OIL FLOW. CHECK FLOW METER
! METAL DETECTED ON FEED CONV BELT ! REMOVE METAL, RESET METAL DETECTOR &
45 F
FAULT RESET ON PANEL
DISCHARGE CONV TAIL DRUM SPEED FAULT – DISCHARGE CONVEYOR TAIL DRUM
46 F
STOPPED/SLOW
47 F PLC BATTERY LOW – TEL 44-(0) 01530 839829 IMMEDIATELY
CRUSHER LUBE HYDRAULIC MOTOR ELECTRONIC FLOW FAULT – NO LUBE OIL FLOW.
50 F
CHECK ELECTRONIC FLOW FAULT
51 F CRUSHER PRESSURE SWITCH FAULT – CHECK PRESSURE SWITCH SETTING
52 F HYDRAULIC SYSTEM LOW OIL – CHECK FOR LEAKS & TOP UP HYDRAULIC OIL LEVEL
NOTE: DO NOT REPEAT A RESET OF A CIRCUIT BREAKER IF IT IMMEDIATELY TRIPS OUT AGAIN.
HAVE THE REASON INVESTIGATED AND CORRECTED BY A SUITABLY QUALIFIED PERSON
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7.2.4 Plant Operating Sequence

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

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

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

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

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

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

and feed conveyor are automatically
stopped.
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7.2.5 Fault Indication and Restart

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

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

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

detection refer to Section 7.2.6.
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7.2.6 Metal Detection

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

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

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

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

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

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

stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:-
• Ensure the stop button is pulled out. Feed Conveyor

• Depress both of the safety buttons stop/start button
(Fig.5c) at the same time for at least
1 second. Release the safety buttons.
• The red LED will change to green.
• The transmitter is in function status
when the green LED comes on.
Stop Button
3. Proceed with Plant Start Up (Section
7.2.2) at the Electric Panel Controls Figure 7g Feed Conveyor Remote Operation
(Figure 7e) including starting the Feed
Conveyor.
Note: The radio remote control of the

feed conveyor does not become
operative until the Feed Conveyor start
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 7g). Pressing the stop
button on the hand set will close down
the complete plant. The speed of the
feed cannot be adjusted using the hand
set. To adjust the speed of the feeder
refer to Section 7.2.2.
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7.2.8 Crushing Material - Plant and Automax Settings

The crushing performance of the plant is controlled by the particular material being fed into the feed
hopper and the settings of various items of equipment within the plant as illustrated below. For optimum
crusher performance a continuous ‘choke’ feed is most important.
Actions A are determined at the time of commissioning and, normally, do not need to be altered, whilst
Actions B are usually relevant during daily operation. See the appropriate Sections for detailed
instructions.
Section 3.4 - Action B for the suitability of the
feed material depending upon meeting the
Feed Material criteria specified and also depending upon the
Automax eccentric throw (long or short) and
the type of concave fitted.
Section 9.12 - Action A presetting levels.

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

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

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

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

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

Running In WARNING
Initial Start-Up WEAR PERSONAL
! WARNING ! Information for relevant warning.
Observe all safety warnings whilst

LOCKOUT PLANT.
carrying out inspections and Refer to Section 7.1, Safety
checks. Information for Lockout
Procedure.
• Check levels of oils are satisfactory.
Refer to the lubrication schedules 9.4.4 FALLING HAZARD.
and 9.4.5 for details. Refer to Section 7.1 Safety
• Refer to engine manual for engine initial
start up instructions
• Run the plant empty for a short period of

time and check for abnormal noises,
• Each day during the initial days of
vibration or excessive heat from shaft
operation check the tension of the
bearings, fluid leaks, etc. including the
conveyor belts on the feed and
feed conveyor gearbox.
discharge conveyors and adjust if
necessary. Refer to Section 9.16.3
Actions During Running-In Period
• Make sure the conveyor belts are
! NOTICE ! tracking correctly and that the skirt
sealing rubbers are correctly adjusted.
Checks on the Maxtrak plant are Refer to Section 9.16.2
crucial during the first week of
crushing operation. • Check frequently the overall stability of
The following section should be the plant; re-check the level of the plant
read and understood prior to and move to level position if necessary.
starting the plant. If there are any
• Regularly check drive belts (crusher and
doubts, contact Terex Pegson Ltd.
hydraulic pumps) to ensure correct
Service Department. tension, particularly during the initial 2
weeks of use. Refer to Section 9.15.
Plant
• Check the alignment and tension of the
• All control systems should be checked
vee belt drives daily during the initial
for full function.
days of operation. Refer to Section 915
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• Avoid overloading the crusher; • Make sure that the crusher lubrication
system is functioning correctly (fault
• Check for any leaks of lubricants, fuel, warnings will show on the diagnostic
water or hydraulic fluid and rectify panel) and that no leaks are present.
immediately.
• Check for leaks in the crusher hydraulic
• Check for any overheating of running system, both externally and inside the
parts. hydraulic console.
! WARNING !
Shut down the plant if this occurs
and investigate the reason. If
necessary, contact Terex Pegson’s
Service Department for advice to
avoid the possibility of danger or
damage.
Crusher

vee rope drive daily during the initial
days of operation.
• Avoid overloading the machine by not

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

correctly and that the satisfactory feed
(Section 3.4) is maintained at a constant
rate (Section 7.2.8). Irregular and
excessive feed rates reduce the
efficiency of the Automax.
• Ensure that the Automax feed is not

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

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

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

buttons are operative (Section 1.7 and
8.3.2).
3. Carry out a general inspection of the plant

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

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

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

Automax checks.
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7.3 Automax Operation Selection of the discharge setting is carried out

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

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

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

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

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

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

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7.3.2 Glossary of Automax Terms

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

An even distribution of material particle sizes in the feed.
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• Make the checks prior to starting the • Check that all 5 Emergency Stops on the
plant (Section 7.1.3). plant are pulled out (Figure 1a).
• Check that the conveyors and Automax • Make sure that you fully understand the
crushing chamber are empty of material. operating procedures for the Automax
before attempting to start.
Pressure
Numeric Keypad Display Gauge
OPEN Button AUTO/MANUAL TRAMP O/L TEST CLOSE Button

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

Setting and Calibration WARNING
FOR THIS OPERATION THE WEAR PERSONAL
AUTOMAX MUST NOT BE RUNNING PROTECTIVE EQUIPMENT.
Referring to the separate Automax Information for relevant warning.
Control Panel (Section 7.4) for
detailed instructions, action as
follows;-
Procedure
7. Press the F4 key to Zero the display and
1. Observe all safety warnings. then press Escape.
2. Start the engine (Section 7.2.1). Set the 8. Scroll to the Set Gap display screen,
engine speed at 1200rpm. press Enter and then press Enter again.
3. Continue with the OPERATION switch 9. Key in the required closed side setting
in PLANT and the RADIO REMOTE (mm) using the number keys, press the
CONTROL at ON (Figure 7b). DO Enter and then press Escape.
NOT press any of the start buttons.
10. Scroll to the Current Gap display
4. On the Automax hydraulic panel (Figure screen.
7i) switch to MANUAL and depress the
OPEN button to raise the Upper Frame 11. Depress the OPEN button; hold until the
approximately 25-38mm (1” - 1½”). Current Gap display shows the gap to
Look into the Automax crushing be above the Set Gap setting then
chamber to check there is no stone switch to AUTO. The machine will
lodged in the chamber. automatically come down to the required
setting.
5. Now depress the CLOSE button until
the manganese crushing members
(mantle and concave) touch. This is
indicated by a sudden rise in pressure
shown on the gauge near the panel
(Figure 7i) and release the button
immediately
6. Scroll to the New Mang display screen

and then press Enter.
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7.3.4 Automax Manganese Wear

Calibration WARNING
FOR THIS OPERATION THE WEAR PERSONAL
AUTOMAX MUST NOT BE RUNNING PROTECTIVE EQUIPMENT.
Referring to the separate Automax Information for relevant warning.
Control Panel (Section 7.4) for
follows;
Procedure
6. Scroll to the Set Zero display screen and
1. Observe all safety warnings then press Enter.
2. Start the engine (Section 7.2.1). Set the 7. Press the F3 key to Zero the display
engine speed at 1200rpm. screen and then press Escape.
3. Continue with the OPERATION switch 8. Scroll to the Current Gap display
at PLANT and the RADIO REMOTE screen.
CONTROL at ON (Figure 7b). DO
NOT press any of the start buttons. 9. Depress the OPEN button; hold until the
Current Gap display shows the gap to
4. On the Automax hydraulic panel (Figure be just above the Set Gap setting then
7i) switch to MANUAL and depress the switch to AUTO. The machine will
OPEN button to raise the Upper Frame automatically come down to the required
approximately 25 - 30mm (1” - 1½”). setting.
Look into the Automax crushing
chamber to check there is no stone Note: After calibration the amount of
lodged in the chamber. manganese worn off the crushing
members is displayed by scrolling to the
5. Now depress the CLOSE button until Mang Wear display screen.
the manganese crushing members
(mantle and concave) touch. This is
indicated by a sudden rise in pressure ! NOTICE !
shown on the gauge near the panel
The interval between future
(Figure 7i).
calibrations is determined by
machine usage and estimated
wear of the manganese.
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7.3.5 Guidance for Changing the When replacing the manganese liners,
Manganese Mantle and Concave always fit both a new mantle and a new
concave at the same time.
Both the mantle and concave liners are
locked against their mating parts using tapers
(angled faces). If these liners are worn too ! NOTICE !
thin they will not be able to hold tight against
their mating faces, coming loose and/or Always fit a new manganese
slipping relative to their mating part. The mantle and concave as a ‘pair’. It is
mating will be damaged and will need detrimental to the operation of the
reworking. machine to do otherwise.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 45-50mm (1¾” - 2”)

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

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

possible ‘tramp metal’ damage and also any
evidence of an uneven wear pattern
680 mm (26¾”) minimum
developing.
The manganese liners must be changed

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance (Figure
7j) when the rams are fully closed is 680mm
(26¾”).
Figure 7j Minimum Ram Dimension
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7.3.6 Automax Initial Start Up
Procedure
WARNING
WEAR PERSONAL
1. Observe all safety warnings PROTECTIVE EQUIPMENT.
3. Continue with the OPERATION switch DANGER

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

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

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

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

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

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

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

Discharge Setting WARNING
AUTOMAX RUNNING WEAR PERSONAL
Referring to the separate Automax Refer to Section 7.1, Safety
Control Panel (Section 7.4) for Information for relevant warning.
follows:-
Procedure
8. Scroll to the Current Gap display
2. Start the engine (Section 7.2.1). Set the screen.
speed at 1200rpm.
9. Depress the OPEN button; hold until
3. Continue with the OPERATION switch the Current Gap display shows the
at PLANT and the RADIO REMOTE gap to be above the Set Gap setting
CONTROL switch at ON (Figure 7b). then switch to AUTO. The machine
will automatically come down to the
4. Carry out the sequential start procedure required setting.
(Section 7.2.2) EXCEPT DO NOT
START THE FEEDER.
5. On the Automax Hydraulic Panel (Figure

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

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

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

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

speed at 1200rpm.

CONTROL switch at ON (Figure 7b).
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7.3.10 Automax Automatic

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

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

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

! NOTICE ! 7i) switch to MANUAL and depress the
OPEN button lifting the Upper Frame
The Automax must not be allowed approximately 19mm
to operate with regular dumping or above the set point.
bouncing of the Upper Frame or
damage may result. Possible 5. Switch back to AUTO and observe the
causes could be crushing at too pressure reading on the panel pressure
small a setting, out of round gauge (Figure 7i). The pressure should
manganese (Section 9.9) or poor be in the range 55 - 82 BAR (800 - 1200
Wedge Ring adjustment. psi).
6. Whilst the Upper Frame is moving check

Procedure for smooth movement with no sticking at
1. Observe all safety warnings the start or whilst travelling.
2. Start the engine (Section 7.2.1). Set the 7. If the pressure reading is above or below
engine speed at 1200rpm. the range indicated above or the action is
not smooth, remedial action is required
3. Continue with the OPERATION switch (Section 9.8).
in PLANT and the RADIO REMOTE
CONTROL at ON (Figure 7b). DO
NOT press any of the start buttons.
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7.3.12 Daily Automax Checks

WARNING
! NOTICE ! WEAR PERSONAL
Daily attention should always be a Refer to Section 7.1, Safety
matter of routine to ensure Information for relevant warning.
maximum efficiency of this vital
element of the plant.
Before starting the Automax

DANGER
SKIN INJECTION HAZARD
• Look at the manganese liners to check Refer to Section 7.1, Safety
for wear and/or damage. Information for relevant warning
• Check oil level in lubrication tank
• Check oil level in hydraulic tank.
• Check oil pressure in hydraulic console.
• Check the operation of the lubrication After starting the lube oil pump
oil heater.
• Check Wedge pressure. • Check the oil flow to the crusher and back
• Re-calibrate the manganese. into the tank (sight glass on top of
• Check for any obstructions in the oil tank in return pipe) and that oil
discharge opening of the Automax. lines do not leak.
• Check the condition of the vee drive.
• Check for loose bolts, leaks, hose
After starting the Automax
connections, etc.
• IMPORTANT Ensure the frame arms • Set the discharge setting
are free from foreign bodies/stone • Listen for any abnormal noise from the
build up. See the warning sign on the crusher.
machine (Figure 7k). • Check that no bolts have come loose.
During crushing
• Listen for any abnormal noise from the
crusher.
• Check oil pressure at normal running
temperature.
• Check no leaks in the lubrication system.
• Inspect hydraulic system piping, cylinders,
etc. for leaks which could cause an
alteration in the setting.
• Note the crushing pressure.
Figure 7k Frame Arm Important Sign
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7.4 Automax Crusher Controls
The Automax Crusher is equipped with the latest System 2-2000 hydraulic controls having a Unitronics
M-90 control module with numeric keypad and status display. The layout, functions and displays are
described on the following pages.
7.4.1 Controls Layout
System I I 2000
BL-Pegson a Terex >>
Figure 7k Controls Layout
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7.4.2 Function Keys
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7.4.3 General Operation
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7.4.3 General Operation, continued
Tryk
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7.4.4 Manual Operation
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7.4.5 Setting the Gap
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7.4.5 Setting the Gap, continued
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7.4.6 Setting New Manganese
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7.4.6 Setting New Manganese, continued
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7.4.7 Setting Normal Zero
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7.4.7 Setting Normal Zero, continued
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7.4.8 Tramp Overload or Test (whilst in Manual)
7.4.9 Tramp Overload or Test (whilst in Auto)
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7.4.10 Alarms
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7.4.11 Alarm List
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7.4.11 Alarm List, continued
7.4.12 Wedge Lock Option
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7.4.13 Historical Alarms
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7.4.14 Set Time & Date
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7.4.14 Set Time & Date, continued
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7.4.15 Set Operating Language
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8 - Shut Off EN
Page 8 - 1
8 - Shut Off
8.2 Closing Down the Plant ................................................................................. 8 - 5
8.3 Emergency Stopping of the Engine .............................................................. 8 - 9

8.3.1 Emergency Stop Buttons ............................................................................ 8 - 9
8.3.2 Restarting the Plant .................................................................................. 8 - 10
8.3.3 Testing Buttons ......................................................................................... 8 - 10
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HAZARD
machine.


HAZARD
injury.



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followed.
LOCKOUT PROCEDURE

lockout.
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8.2 Closing Down the Plant

WARNING
Procedure WEAR PERSONAL
1. Observe all safety warning Refer to Section 8.1, Safety
2. On the Electrical Control Panel (Figure
8a), press the red Feed Conveyor stop LOCKOUT MACHINE.
button to stop the feed and wait until Refer to Section 8.1, Safety
the crusher and both conveyor belts Information for Lockout Proce-
are empty of material before the dure.
next step.
3. Press the red Crusher stop button to stop

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

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

Conveyor and Oil Pump stop buttons to
stop these items.
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5. Using the hand throttle, decrease the

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

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

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

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

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

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

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

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

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

Pressing any of the buttons will stop the
diesel engine and the button will remain
engaged until physically released by pulling
or twisting (depending upon the type fitted)
the button knob. The engine cannot be
started if any of the emergency buttons
remain depressed.
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8.3.2 Restarting the Plant

WARNING
When an emergency stop has Refer to Section 8.1, Safety
been initiated, DO NOT attempt to Information for relevant
restart the engine until it is safe to warning.
do so.
! NOTICE ! 8.3.3 Testing Buttons

When restarting the plant after the
use of an Emergency Stop button ! WARNING !
it is essential to ensure that the
Daily, before commencing
Automax crushing chamber is
crushing operations, test each
empty of material.
emergency stop button is
operative.
Procedure
1. Observe all safety warnings. Procedure
1. Observe all safety warnings
2. Follow the safe start-up procedure
(section 7.2)
2. Follow the safe start-up procedure
(section 7.2)
3. Start the engine (section 7.2.1)
3. Start the engine (section 7.2.1)
4. Manually raise and lower the Automax
Upper Frame by following the procedure
in Section 7.3.9. 4. Test each emergency stop button in turn
to cut out the engine and, following the
resetting of the tested button, repeat the
5. Visually check that material in the
process for each of the other emergency
crushing chamber has been discharged
stop buttons (Section 1-Figure 1a) and
and that the chamber is empty.
also the stop button on the remote
handset.
Note: In the event of material failing to
clear the crushing chamber, repeat the
5. When safe to do so continue with the
operation above or follow the Blocked
Plant Start-Up Procedure (Section
Crusher Procedure (Section 7.1.1) as
7.2.2).
necessary.
6. When safe to do so continue with the

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

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

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

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

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

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

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

lockout.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).
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Terex-Pegson machine can cause

whilst in operation.

ALWAYS use a suitable lifting platform when

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

HAZARD
injury.



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HAZARD
machine.

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

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

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

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

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

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

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

Switches on the Electrical Control Panel
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Engine Control Panel
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9.2 Weights of Automax Crusher Components
Weights of the Automax crusher components, these should be consulted when arranging suitable lifting
equipment. Refer to Terex Pegson’s Technical Department for any other weights of individual items or
assemblies if not listed.
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 )
! WARNING !
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment.
Lifting Points for the Automax Upper Frame
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9.3 General Information The plant has been designed to facilitate

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

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

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

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

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

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

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

or debris.
Disconnect battery ground cable (-

) before making adjustments on
electrical systems or welding on
machine.
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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 warning.
lubricants, oils, coolant, etc. must be carried out
to the plant machinery in accordance with the
LOCKOUT PLANT.
Lubrication and Servicing Schedule (Section
9.4.4 and 9.4.5) in order to maintain efficiency. Information for Lockout
Procedure.
The locations of the Service Attention Points
are as follows:- FALLING HAZARD.
• Automax Crusher oil lubrication tank sited Information for relevant warning.
within the plant chassis (Figure 9b).
• Automax Crusher Upper Frame grease
nipples x 12. .
• Diesel Engine oil, coolant, (See separate • Track unit gearbox x 2 oil levels (Figures
engine manual). Also the fuel (Figure 9ar). 9au & 9av).
• Diesel Engine oil lubricated HFO clutch • Periodically lubricate hinges, hydraulic
bearing (Section 9.19.2) cylinder pivot pins and similar linkage
points with grease or oil as appropriate.
• Plant hydraulic oil reservoir sited on the
forward engine platform .
• Feed Conveyor gearbox within the head
! NOTICE !
drum having oil lubrication (Figure 9ak). Failure to carry out scheduled
• Conveyor head and tailshaft bearing maintenance or exercise due care
grease nipples located:- may invalidate any warranty that
might apply.
Feed Conveyor - 1 x headshaft on the
platform side and 2 x tailshaft remote
nipples on rear of hopper.
Discharge Conveyor - 2 x headshaft
remote nipples on conveyor LH side and 1
x tailshaft remote nipple on each side of
main plant chassis.
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9.4.2 Regular Servicing

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

show compliance with the required
maintenance practices and intervals as
detailed in this section of the manual.
! NOTICE !
Make sure that frequent checks are made NOTE: Do not overlook the service
for wear to the manganese mantle and
requirements of the plant diesel
concave (Section 7.3.5) and other wearing
engine which are detailed in the
surfaces so that replacement can be made
before any damage to the core of the separate engine manufacturer’s
Automax is sustained. manual.
Regularly check the wedge pressure

(Section 7.3.11) to avoid damage to the
machine and to obtain the best performance
from the Automax.
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9.4.3 Daily, Weekly and Monthly

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

always consider what particular Refer to Section 9.1, Safety
safety hazards could occur at
warning.
specific operating sites and take
steps to eliminate them before
commencing work.
Daily Checks 6. Look for loose fixings and rectify. Check

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

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

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

requirements also attending to the longer
interval requirements as necessary
(Sections 9.4.4 and 9.4.5).
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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
Suction Filter ~ 1 ~ ~ (SEE SECTION 9.5.6)
(parts list item 2)
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
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upper frame)
9.4.6 ~ pressure
is not smooth
(SEE SECTION 9.8)
Automax Hydraulic Pressure Change annually

9.4.4 Automax Crusher Lubrication and Servicing Schedule
~ 2 ~ ~
Filters (parts list items 1 & 2) (SEE SECTION 9.13.9)
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1000 Maxtrak Plant Schedule
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
Lubricant Monthly (165 hrs),

Description or Quantity Level Daily Weekly 6 Monthly (1000 hrs),
Fluid Annually (2000 hrs)
First oil change after 50-100 working
Feed Conveyor Oil Lubricated See chart 1.7 litres Fill to centre hours. Thereafter change after every
Gearbox (located in head drum) 9.4.6 (0.45 US galls) line of unit ~ ~ 2000 hours. Check level monthly.
(SEE SECTION 9.16.4)
Plant Conveyors Grease
Re-grease every 2 weeks
Nipples (4 x located on head & D ~ ~ ~
~ (SEE SECTION 9.4.1)
tail shaft bearings)
40mm (1½”)
Plant Hydraulic System
See chart 360 litres below upper Check Change oil every 2000 hours
Reservoir (located on front ~
9.4.6 (96 US galls) sight glass level (SEE SECTION 9.13.1)
engine platform)
mark
Plant Hydraulic Suction Filter
Check
(located at bottom of hydraulic ~ ~ ~ ~ condition
reservoir)
Change filters every 1000 hours or
Plant Hydraulic Return Filter
9.4.5 Plant Lubrication and Servicing Schedule
Check sooner if the tell-tale indicator

(located on top of hydraulic ~ ~ ~
~ condition shows RED
reservoir)
(SEE SECTIONS 9.13.5 TO 9.13.8)
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Plant Hydraulic In-Line Filters x
9 - Maintenance
Check
2 (located one each side of ~ ~ ~
~ condition
engine inside housing)
First oil change after 100 working
5 litres
Plant Track Gearboxes x 2 See chart Fill to level hours. Thereafter every 1000 hours or
(1.3 US galls) ~ ~
(located each side of plant) 9.4.6 plug at least annually. Check level monthly.
+/- 10%
(SEE SECTION 9.20.4)
Level stick Check oil level prior to daily start up.
Engine Clutch (accessed at See chart Approx. 200 Check
oil wet ~ Change oil every 1000 working hours.
rear of engine housing) 9.4.6 cc. level
(approx.) (SEE SECTION 9.19.2)
Caterpillar Engine
(fuel, oil, coolant) Refer to the separate Engine Operation & Maintenance Manual
EN
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Page 9 - 18
Equipment Grade Century Mobile Shell Esso Gulf BP
Automax Oil
Lubrication System
> 4º C (39º F) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4º C (39º F) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Automax/Plant
Hydraulic System
> 30º C (86º F) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
< 30º C (86º F) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
Automax Upper
Frame Grease Chemodex MOLY - BENTONE MP Standard Grade
Nipples
SAE 30 – SAE 40 Oil
Engine HFO Clutch ISO VG 100 – ISO VG 150
(DO NOT USE SYNTHETIC OIL)
9.4.6 Recommended Oil/Grease Types
Plant Feed Conveyor Gear oil with viscosity VG150 with EP additives. Oil temperature always to be below 90º C
Drive Gearbox DO NOT MIX OILS OF DIFFERENT MAKET OR TYPE
Plant Conveyor
Shaft Bearings D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
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Plant Tracks General Multi-Purpose Grease (Grade D grease is suitable)
Tension
Plant Tracks SAE 80w/90 Gear Oil

Gearbox Oil
16/07/03
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)
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Lubrication Specifications
Oil Specification Grade A Grade B Grade C
Flashpoint: Minimum °C (°F) 199 (390) 204 (399) 216 (421)
Pour Point °C (°F) -18 (0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s 150 220 460
(104°F, in²/s) (0.232) (0.341) (0.713)
Kinematic Viscosity at 100°C, mm²/s 15.4 20.1 32.9
(212°F, in²/s) (0.0238) (0.0312) (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25°C (77°F) 280
Worked Penetration at 25°C (77°F) 285
Drop Point °C (°F) 185 (365)
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135°C (275°F) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40°C mm²/s 32 46 68
(104°F, in²/s) (0.049) (0.0713) (0.105)
Kinematic Viscosity at 100°C mm²/s 5.5 6.5 8.5
(212°F, in²/s) (0.085) (0.010) (0.013)
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes
Figure 9a Lubrication Specifications
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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.
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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 pump LOCKOUT PLANT.
mounted on the oil tank sited within the plant Refer to Section 9.1, Safety
chassis (Figure 9b) with access being gained Information for Lockout Proce-
from the rear of the chassis. dure.
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 A engine mounted heat exchanger is
bearings. included to preheat the lubricating oil when
necessary and an air blast type cooler is
Oil from the bearings lubricates the drive fitted to control the oil temperature whilst
gear and pinion on it’s gravity return to the the Automax is running. Both of these
oil tank to be filtered and re-circulated. devices are controlled automatically by
thermostats.
After the oil pump has been started the
control system delays the crusher start for 5 Lubrication safety devices include monitors for
minutes to allow a good circulation of oil low oil flow, high temperature, low tank level
within the Automax and occurs every time and low oil pressure.
the oil pump is started. To prolong the life of
the bearings it is also good practice when
stopping the crusher to allow the crusher
cone head to stop spinning before switching
off the oil pump (Section 8.2).
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9.5.2 Automax Lubrication

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

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

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

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

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

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

The recommended oil is good quality:-
WARNING
WEAR PERSONAL
Summer Grade - EP220 PROTECTIVE EQUIPMENT.
Winter Grade - EP150 Refer to Section 9.1, Safety
warning.
Refer to the lubrication chart (Section 9.4.4)
for details. LOCKOUT PLANT.
Add oil to the tank (Figure 9b) with a Information for Lockout Proce-
dure.
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 4ºC it is
recommended that EP220 ISO VG oil is
used. If difficulties with cold starting are
experienced it is recommended that an
EP150 VG oil is used but this could be
changed back to an EP220 ISO VG as soon
as conditions permit.
All oils should have extreme pressure (EP)

additives.
If none of the oil brands specified (Section

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

Intervals WARNING
As a general guide it is recommended that WEAR PERSONAL
the two filter canisters (Section 9.4.4) are PROTECTIVE EQUIPMENT.
changed as follows:- Refer to Section 9.1, Safety
warning.
The first filter change should be after 100
hours operation. LOCKOUT PLANT.
Subsequent filter changes should occur Information for Lockout Proce-
dure.
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.
! NOTICE !
Remember, these filters are very
efficient at removing harmful
contaminants from the oil and it is
more economical to change the
filters regularly than the oil.
It is also recommended that the suction

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

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

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

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

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

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

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

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

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

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

Overview DANGER
The Upper Frame of the Automax is raised Refer to Section 9.1, Safety
and lowered by means of external hydraulic Information for relevant warning
rams to alter the relative position of the
concave (in the moveable upper frame) to the
mantle (on the fixed position cone head).
Six hydraulic cylinders provide control over the

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

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

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

the separate panel (Figure 9c) located inside a
lockable cabinet with connections by both high
pressure hydraulic hoses and screened electric
cable for the linear position sensor.
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Gauge measuring
Numeric Keypad Display Wedge Pressure
OPEN Button AUTO/MANUAL TRAMP O/L TEST CLOSE Button

Switch Button
Figure 9c Automax Controls

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

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

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

Section 9.10, Fault Finding, together with
possible remedies. Always contact Terex
Pegson’s local dealer or the factory in case
of doubt.
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9.7 Manganese Change

! NOTICE !
Procedure
Always fit a new manganese
9.7.1 Guidance for Changing the mantle and concave as a ‘pair’. It is
Manganese Mantle and Concave detrimental to the operation of the
machine to do otherwise.
Both the mantle and concave liners are
locked against their mating parts using tapers
(angled faces). If these liners are worn too
thin they will not be able to hold tight against
their mating faces, coming loose and/or
slipping relative to their mating part. The
mating will be damaged and will need
reworking.
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 (1¾” - 2”)

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

display.
680 mm (26¾”) minimum
Inspect the liners on a daily basis, for

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

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance (Figure
9d) when the rams are fully closed is 680mm
(26¾”).
When replacing the manganese liners, Figure 9d Minimum Ram Dimension

always fit both a new mantle and a new
concave at the same time.
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9.7.2 Filler Handling

WARNING
Use Pegbak for backing filler. It is Refer to Section 9.1, Safety
necessary to carefully read the Information for relevant
handling instructions before warning.
attempting to use. Follow all the
recommended handling
procedures and safety
precautions. ! WARNING !
BOTH AGENTS ARE TOXIC.
Filler is used as a backing material to fill the
ALWAYS WEAR A FACE MASK,
void spaces behind the manganese concave
and mantle where there is no machined
RUBBER OR PLASTIC GLOVES,
mating surface with the upper frame and SAFETY GLASSES AND LONG
cone head respectively. The filler is poured SLEEVED WORK CLOTHING
in after the new manganese has been fitted.
• Since both agents are toxic, be careful
The Automax cone crusher uses the gunlock not to allow them to attach onto your
type, self tightening concave ring and must skin. If they do attach, wash away with
use a release agent or thin layer of grease, tepid water and soap. Do not use petrol
oil or wax on the concave ring mating or solvents.
surfaces. This is to prevent adhesion
between the mating surfaces and to allow
the self tightening features to operate
! WARNING !
properly. Care should be taken to plug all Protect eyes. In case of accidental
leaks as the filler will fill a very small void. contact / splashes, flush eyes with
plenty of water and consult a
Each pack of Pegbak includes separate filler doctor.
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.
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• 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 be The filler needs about 12 hours to harden at
cooled and warmed in cold weather to 20 °C (68°F).
within the above temperature range.
In lower temperatures the hardening process
• Both agents can be mixed with the takes longer and it may be necessary to heat
supplied agitating adaptor attached to the the mantle and concave etc. in these
top of an electric drill. circumstances.
• The filler can be used only once (cannot Low Temperature Mixing
be reused) and if mixed with the
Protect the filler resin / hardener from cold
hardener it cannot be stored.
weather (< 5°C [41°F] ). Remove the chill
from the metal by the use of hot air guns/
• Always store both agents at 15-30 °C blowers. - Do not use an open flame. To
(59-86°F) and avoid storing in direct ensure the shortest curing time at low
sunlight. temperatures, the filler resin component
(LARGER BAG) should be pre-warmed
• Never smoke whilst handling these to 25-30°C (77-86°F) before mixing. This is
agents. best achieved by applying a hot air blower on
the outside of the tin .
• Ensure that application surfaces are dry NB - REMOVE HARDENER FROM TIN
before pouring. Wet surfaces will result BEFORE APPLYING HEAT.
in reduced stength of the filler. ALTERNATIVELY, place the filler resin
bag (LARGER BAG) in a bucket of hot
• Pour the filler immediately after mixing, water.
ie within 10 - 15 minutes at 25°C. Higher NB - DO NOT PRE-HEAT THE
temperatures will shorten, and lower HARDENER (SMALLER BAG).
temperatures increase, the working time. Thoroughly mix the filler resin and hardener
using the included mixing tool or a spiral
• When making pouring ports with putty, paddle and pour immediately.
prevent the filler from leaking out.
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9.7.3 Changing the Manganese

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

Automax
Procedure
2. Ensure that the feed conveyor and

Automax feed box are free from stone
and dirt.

CONTROL switch to OFF (Figure 9e).

engine speed to 1200rpm. DO NOT
press any of the start buttons.
5. Operate the hydraulic lever on the

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

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

8. Disconnect the level sensor mast before

unbolting and lifting off the Automax
feed box.
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 9e1 Feed Conveyor Hydraulic

Lever and Locating Pin
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9.7.3.2 Removing the Upper Frame

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

Wedge Pressure Gauge only
Valve 9B
Automax Control Panel

Diagnostic Pressure
Gauge only
Valve 9A
Figure 9g Wedge Jack Circuit Shut Off Valves
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8. With suitable cranage connect lifting 12. Remove the top clevis pin from each
tackle to the three lifting eyes in the hydraulic cylinder and pull each cylinder
Upper Frame (Section 9.2 for weights outwards, allowing them to lie flat.
and lifting points) but leave the slings
with a small amount of slack. Note: The clevis pins should be
removed from right to left when
facing the machine to avoid
! DANGER ! disturbing the bearing located
against the shoulder inside each lug
Under no circumstances attempt
on the Upper Frame.
to take the load on the cranage at
this stage as a serious overload 13. Remove the linear sensor cover (Figure
condition may arise. 9h) and lay to one side. Disconnect the
top bolt from the unit. This is essential
9. Using three 5 tonne capacity x 150 mm to avoid damage to the sensor unit.
(5.5 US tons x 6”) stroke hydraulic bottle
jacks spaced equidistant around the
14. Lift off the Upper Frame assembly from
lower rim of the Upper Frame, extend
the machine (Refer Section 9.2 for the
them equally to take the weight off the
weight of the complete assembly).
clevis pins to aid their removal.
Support on wooden blocks on the ground
(Figure 9i).
10. Ensure that there is no residual hydraulic
pressure in the Upper Frame hydraulic
cylinder circuit by pressing the OPEN
and CLOSE buttons briefly and in quick
succession until the pressure gauge
(Figure 9c) on the hydraulic panel reads
zero. Follow this procedure to remove
the clevis pins with the minimum of
effort.

! DANGER !
Do not neglect to ‘Lockout’ to
prevent the plant being started
whilst maintenance work is being
carried out.
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Linear Sensor Upper Frame

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

Cylinders
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9.7.3.3 Changing the Concave

The concave ring is held in place in the
WARNING
Upper Frame by a self tightening gun lock
WEAR PERSONAL
arrangement that automatically tightens the PROTECTIVE EQUIPMENT.
manganese steel concave on the concave Refer to Section 9.1, Safety
wedges as the ring stretches under the Information for relevant
crushing load. warning.
The Upper Frame should be supported on LOCKOUT PLANT.

wooden blocks so that there is sufficient Refer to Section 9.1, Safety
space for the concave to be driven out.
Procedure.
Removing the Concave FALLING HAZARD.

! WARNING ! warning.
When gas cutting through the

concave it is essential that
breathing apparatus is worn as
when the metal is broken through
the backing material gives off toxic
fumes.
Procedure
1. Observe all safety warnings. ground. Remove any nicks or burrs with
a file or grinder. Inspect the ground
2. Following removal of the Upper Frame surfaces of the new concave and
(Section 9.7.3.2) gas cut through the remove any nicks or burrs in the same
three lugs as shown (Figure 9i). manner.
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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Figure 9i Gas Cutting the Old Concave
Figure 9j Supporting the New Concave
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Mounting the Concave
When supporting the new Concave prior to

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

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

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

making 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.
! NOTICE !
After mixing, the filler must be
poured IMMEDIATELY to ensure
complete penetration.
10. Stop pouring when the filler has reached

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

DANGER
! WARNING ! SKIN INJECTION HAZARD
In order the re-connect the six Refer to Section 9.1, Safety
hydraulic cylinders to the Upper
Frame (Step 5 following) the
engine must be running to provide
hydraulic pressure.
WARNING
ENSURE the risk assessment for WEAR PERSONAL
this procedure covers the PROTECTIVE EQUIPMENT.
necessity for very effective Refer to Section 9.1, Safety
communication between any warning.
personnel involved in the task,
LOCKOUT PLANT.
taking into account the visual
restrictions between the Automax Information for Lockout Proce-
control panel and the crusher and dure.
also engine noise.
Whilst the Upper Frame is off the machine

for the renewal of the manganese wearing
Procedure
parts, take the opportunity of examining the
condition of the internal linerplates, frame 1. Observe all safety warnings.
and countershaft arm shields and replace if
necessary. 2. Using the cranage used to remove the
Upper Frame, lower over the machine
Also, clean out any solidified debris and whilst taking care to line up the anti-
generally check around the machine for any rotation stop on the Upper Frame with
faults which need to be rectified. the guide post. Hold in a suspended
position with the crane with a gap
Clean the contact face all around the Wedge between the mantle and concave.
Ring and apply a coating of fresh lubricant
(MOLY-BENTONE MP Standard Grade 3. Turn the OPERATION switch to
grease). Make sure this is not contaminated PLANT and the RADIO REMOTE
with dirt or grit prior to replacing the Upper CONTROL switch to OFF (Figure 9e).
Frame.
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9f) switch to MANUAL and press the
OPEN or CLOSE button (as
appropriate). Only one cylinder will
respond at any one time and, ‘toggling’
between the buttons, line up and insert
each of the six clevis pins in turn. Secure
with the washers and split pins.
Note: The clevis pins should be

inserted from right to left when
facing the machine to avoid
disturbing the bearing located in it’s
required position against the
shoulder inside each lug on the
Upper Frame.

7. Replace the linear position sensor and

replace the cover to the housing.
8. Detach the cranage and replace the feed

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

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

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

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

The operation is carried out with the head
WARNING
left in situ. The internal parts of the Automax WEAR PERSONAL
are therefore not disturbed or exposed to PROTECTIVE EQUIPMENT.
harmful dust. Refer to Section 9.1, Safety
In use all manganese steel will ‘creep’ due to warning.
the nature of the material. When creep occurs LOCKOUT PLANT.
stress is created in the material which will have Refer to Section 9.1, Safety
to be relieved by suitable cutting of the Mantle. Information for Lockout Proce-
This will be necessary in order to facilitate dure.
removal.
FALLING HAZARD.
Removing the Mantle Refer to Section 9.1, Safety
warning.
! WARNING !
When gas cutting through the
concave it is essential that
breathing apparatus is worn as
when the metal is broken through
the backing material gives off toxic
fumes. 4. Break loose the fit between the Mantle
and the Cone Head. This is best
achieved by striking the lower section of
Procedure the circumference with a hammer then
1. Observe all safety warnings. levering the Mantle clear of the Cone
Head.
2. With the Upper Frame removed (Section
9.7.3.2) gas cut round the mantle within 5. Insert short blocks of wood between the
20-30mm (¾” -1¼”) from the top Mantle and Cone Head in three places
(Figure 9m). around the circumference so as to leave
a gap through which lifting chains can be
3. Once the Mantle is cut the Mantle Nut placed. Three equally spaced lifting
can then be removed by turning chains should be passed through this gap
CLOCKWISE with the mantle nut and the hooks put round the bottom of
wrench (Figure 9n). Ensure that the the mantle (Figure 9o) and the mantle
mantle nut wrench is secure by dropping lifted off.
a suitably sized bolt through the hole in
the end of it.
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6. Remove the old backing material and

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

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

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

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

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

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

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

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

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

Pressure Gauge
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9.8.1 Checking Automax Wedge

Pressure DANGER
AUTOMAX NOT RUNNING SKIN INJECTION HAZARD
The pressure on the wedge ring is Information for relevant warning
automatically controlled by the Dumpy Jack
hydraulic circuit. However, as the adjustment
of the wedge ring is critical for good
performance of the Automax crusher it is
WARNING
WEAR PERSONAL
recommended that this should be checked PROTECTIVE EQUIPMENT.
daily. The pressure gauge near the panel Refer to Section 9.1, Safety
(Figure 9r) gives an accurate indication of Information for relevant
whether the Wedge Ring assembly is warning.
functioning correctly.
! NOTICE !
The Automax must not be allowed
to operate with regular dumping or 4. On the Automax Hydraulic Panel
bouncing of the Upper Frame or (Figure 9r) switch to MANUAL and
depress the OPEN button lifting the
damage may result. Possible
Upper Frame approximately 20mm
causes could be crushing at too (¾”) above the set point.
small a setting, out of round
manganese (Section 9.9) or poor 5. Switch back to AUTO and observe the
Wedge Ring adjustment. pressure reading on the pressure gauge
(Figure 9r). The pressure should be in
Procedure the range 55 - 82 BAR (800 - 1200 psi).
1. Observe all safety warnings 6. Whilst the Upper Frame is moving check
for smooth movement with no sticking at
2. Turn the OPERATION switch to the start or whilst travelling.
CONTROL switch to OFF (Figure 9e). 7. If the pressure reading is above or below
the range indicated above or the action is
3. Start the engine (Section 9.1.1). Set the not smooth, remedial action is required
engine speed to 1200rpm. DO NOT (Section 9.8.2).
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8.8.2 Low Wedge Pressure

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

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

type of grease.
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.
! NOTICE !
Only use Moly Bentone grease
(Section 9.4.5) for lubricating the
Wedge Ring.
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9.8.3 Readjusting Tight Wedge Ring

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

Automax feed box are free from stone
and dirt.


engine speed to 1200rpm..DO NOT
5. On the Automax Hydraulic Panel

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

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

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

CLOSE button to push the Wedge Ring
down and thus free it from the
Mainframe. The wedge pressure
indicated on the pressure gauge (Figure
9r) should drop away to 0-28 Bar (0-400
psi) as the Wedge Ring frees off.
9. Close shut off valve 9A (Figure 9s) to

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

11. Depress the OPEN button lifting the

Upper Frame approximately 20mm
above the set point.
12. Select AUTO control position on switch.

The control system will bring the
machine down to the required gap
position or go through the initial Closed
Shut Off Valve 9B
Side Discharge Setting procedure
(Section 7.3.3) as necessary.
Diagnostic Pressure Gauge

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

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

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

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

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

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

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

the Automax controls activated but
the Automax NOT running.

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8. Ensure that everyone is clear of the

machine. Put the hydraulic panel into
MANUAL and press CLOSE. Release
the button the moment the pressure
starts to rise and note the figure showing
on the gap indicator. Depress the OPEN
button to raise the Upper Frame
approximately 15 -20mm (5/8” - 3/4”).

10. Rotate the Cone Head slowly by hand,

stopping it when it has gone through 90º
whilst doing this watch the vee belts to
ensure that the eccentric does not move
in the Cone Head. The second mark on
the mantle plate should now be lined up
with the mark on the Concave.
11. Repeat steps 6 to 9.
12. Repeat the process so that you have four

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

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

the Mantle when the Eccentric/Cone Refer to Section 9.1, Safety
Head is being rotated. Information for relevant
warning.
As a final check for any slip between the
Eccentric and the Cone Head, repeat the
first touch again as the example below:- 0
0
! NOTICE !
If there is a difference of more than
7mm (¼”) between any two values -1 -2
of the four measured, that piece of
manganese must be changed Typical values
immediately. Mantle OK.
Figure 9u Concave Check
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9.10 Automax - Fault finding
GENERAL
Fault Possible Cause Procedure
Machine stops. Overload through Clear machine adjust

discharge setting too setting.
low.
Tramp metal fixed in Clear machine adjust
crushing chamber. setting.
Packing in crushing Clear discharge chute.
chamber.
Lubricating oil flow low / Check operation of
temperature high. lubrication system.
Build up in discharge Clear blockage check
chute. chute.
Power supply / drive Check power supply /
motor failure. drive motor, see
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.
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Reduction in discharge Crushing pressure too Adjust setting.

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

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

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

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

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

the crusher. of the countershaft.
Damage of the Contact Terex Pegson.
countershaft gear.
Loose mantle. Inspect conehead/
mantle for damage.
Refit as when changing
manganese.
Loose or falling Adjust the concave
concave. wedge.
Check the mantle
rotating direction.
Check the touching
surface.
Check for partial wear.
The particle size of the Mantle / concave worn Check for out of round.
crushed product is out of round.
coarse.
The indicated setting Measure the actual
value is different from setting with a lead ball
the actual value. etc.
Wedge ring adjustment Adjust the wedge ring.
failure.
Partial wear of the Check the feeding
mantle and concave. chute.
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HYDRAULICS
The pump doesn’t start. Electrical fault. Check the thermal relay
connection and motor,
fuses & connections.
Rotating direction error. Check the rotating
direction and reconnect.
Insufficient quantity of Refill oil.
oil in the tank.
Pump seized. Check that pump shaft
rotates, fit replacement
if faulty.
The pump starts but no Clogged suction side Clean the piping and
pressure and discharge piping. carry out flushing.
occur.
Clogged suction side Remove and clean.
filter.
Air mixed from the Re-tighten the coupling
suction side. screw.
Replace the piping.
Oil viscosity too high. Check for the specified
brand.
Defective or damaged Check and replace.
pump and coupling.
Relief valve setting Contact Terex Pegson.
failure.
Pump noise. Air mixed from the Clean the piping and
suction side. carry out flushing.
Clogged air breather. Disassemble and clean.
Sound in the relief Disassemble. Clean or
valve. replace the spring
nozzle.
High oil viscosity. Check for the specified
brand.
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Irregular motion of the Air mixed in the cylinder. Check the piping, hose
cylinder. and coupling, after
checking and repair,
remove air.
Filters blocked. Replace.
Downward adjustment Unseated unloader Replace valve.

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

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

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

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

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

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

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

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

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

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

Level Sensors Description
The standard Maxtrak includes a level

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

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

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

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

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

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

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

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

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

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

Guide for typical mobile crusher bowl level.
Figure 9v MiniRanger Plus Control Panel
See Section 9.12.6 for the simplified Setup
Guide for typical hopper level (Optional).
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9.12.2 Level Sensors - Run Mode
Communication Jack
LCD Keypad
LCD Display
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9.12.3 Level Sensors - Program Mode
Communication Jack
LCD Keypad
LCD Display
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9.12.4 Level Sensors - Factory Settings
Measurements are shown in centimeters - 2.54 centimeters = 1 inch
NB. The Hopper Level Sensor is an optional item.
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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl
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9.12.5 Level Sensor MR1 Setup Guide - Crusher Bowl, continued
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9.12.6 Level Sensor MR2 Setup Guide - Hopper *
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9.12.6 Level Sensor MR2 Setup Guide - Hopper, continued
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9.13 Plant/Automax -
Hydraulic Systems DANGER
9.13.1 General Description Refer to Section 9.1, Safety
One integrated hydraulic system performs
the following functions:-
• Automax setting adjustment, overload

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

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

piston variable displacement unit feeding a All relief valve pressures are factory set and
directional control valve. should not be adjusted on site.
The flows and pressures to each service is Although the maximum flows from each
limited by the relevant spool as shown below spool is limited as shown, these can be
and the pump supplies only the required flow individually adjusted downwards by means of
by automatically backing off the swash plate limit screws if desired. Please contact Terex
angle thus reducing wasted power and Pegson Ltd.
resulting heat generation.
This is achieved by means of a load sensing

line from the valve to the pump which
measures the pressure required which is
then matched by the pump.
No: 1 Pump (valve mounted in engine canopy)

Max Flow
Max Pressure
Service Spool Type litres/min
Bar
(US galls)
L/H track drive motor Proportional 100 (26.4) 320
Product Conveyor plus Water
On/Off 100 (26.4) 210
Pump (when fitted)
Automax control On/Off 4 (1) 200
180
No: 2 Pump (valve mounted under feed conveyor)
Max Flow
Max Pressure
Service Spool Type litres/min
Bar
(US galls)
R/H track drive motor Proportional 100 (26.4) 320
Feed Conveyor Proportional 75 (19.8) 180
Feed Conveyor raise/lower On/Off 25 (6.6) 100
Automax lubrication On/Off 10 (2.6) 140
16/07/03
Note – 1 Bar = 14.5 pounds per square inch / 1 pound per square inch = 0.069 Bar
Figure 9w Front/Rear Hydraulic Pumps
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9.13.2 Track Drives 9.13.3 Feed Conveyor Drive

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

positioning.
The system is equipped with the following
b) FAST - For straight line running, forward protection:-
or reverse.
• Suction Filter (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)
when in the ‘SLOW’ mode. • Return Filter (10μm nominal)
Fine adjustment of the slow speeds is • Low oil level cut out.
possible. Consult BL-Pegson Ltd.
Note:- For Hydraulic Pump Drive Belt
It is recommended that adjustment is not adjustment refer to Section 9.15.3.
undertaken without BL-Pegson Ltd. consent
and under no circumstances should the slow
speed be adjusted greater than 0.2m/s.
Motor mounted counterbalance valves are ! NOTICE !

utilised to prevent the machine over running The hydraulic oil filters are fitted
when moving downhill.
with condition indicators to shown
when the renewable filter element
This block also incorporates a shuttle valve
needs to be changed. These
to release the spring applied track parking
brake together with a pressure reducing should be checked on a daily
valve, preset to 60 bar so that the brakes are basis whilst the plant is running at
not over-pressurised. normal operating temperature
(Sections 9.13.5 - 6 & 8). In cold
ambient temperatures the filter
indicators may show red until the
system reaches normal operating
temperature.
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Figure 9x Plant Hydraulic Circuit Diagram

THIS DIAGRAM IS REPRODUCED TO A LARGER SCALE IN SECTION 10
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9.13.5 Changing the Suction Filter

Located at the base of the hydraulic DANGER
reservoir tank is the hydraulic suction filter. SKIN INJECTION HAZARD
When the dial gauge needle (Figure 9y) 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.
Procedure Information for relevant
warning.
1. Observe all safety warnings. LOCKOUT PLANT.
2. Close down the machine (Section 8.2) Information for Lockout Proce-
and implement the Lockout Procedure. dure.
3. Using a hexagon socket key unscrew the FALLING HAZARD.

bolt A in the centre of the filter housing Refer to Section 9.1, Safety
until it reaches the stop (Figure 9y). Information for relevant
warning.
4. Take steps to collect spillage of oil
(approx. 2 litres / 1/2 US gall) before
undoing the six socket head screws on
the front of the housing to remove the
7. Fully screw in the bolt A in the
cover plate.
centre of the filter housing.
5. Remove the old filter and clean inside
the housing with lint free cloth before ! NOTICE !
fitting a new filter of the approved
pattern and specification. It is important to ensure that the
bolt A is fully screwed in before
6. Before replacing the cover plate, lightly restarting the plant. Damage will
oil the ‘O’ ring and make sure it is occur to the plant if this procedure
properly seated in the groove. Replace is not followed.
the cover plate and refit the screws to
ensure an oil tight seal.
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Filter Condition Indicator Dial
Removable Cover Plate
Bolt A
! NOTICE !
It is important to ensure that the
bolt A is fully screwed in before
restarting the plant. Damage will
Figure 9y Suction Filter occur to the plant if this procedure
is not followed.
Hydraulic Oil Level & Hydraulic Oil Return Hydraulic Oil

Temperature Gauge Filter and Gauge Breather/Filler
Hydraulic Oil Tank Filter Condition Indicator Dial
Figure 9z Hydraulic Oil Tank & Level Indicator
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9.13.6 Changing the Return Filter

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

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

on the top of the housing to remove the
cover plate together with internal spring.
4. Remove the old filter and clean inside 9.13.7 Changing the Tank Breather
the housing with lint free cloth before
fitting a new filter of the approved This should be changed after the first 100
pattern and specification. Replace the hours of operating and thereafter after 500
spring which holds the filter in place hours but in dusty atmosphere it is
recommended to change more frequently
5. Before replacing the cover plate, lightly depending upon conditions. Simply unscrew
oil the ‘O’ ring and make sure it is and replace whilst the plant is shut down
properly seated in the filter housing. (Section 8.2).
Replace the cover plate and refit the
screws to ensure an oil tight seal.
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9.13.8 Changing the Pressure

Filters DANGER
Located on each side on the engine within the SKIN INJECTION HAZARD
canopy are the hydraulic pressure filters. Refer to Section 9.1, Safety
When the ‘telltale’ (Figure 9aa) 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
before changing..
WARNING
WEAR PERSONAL
1. Observe all safety warnings. warning.
2. Close down the machine (Section 8.2) LOCKOUT PLANT.

and implement the Lockout Procedure.
dure.
3. Unscrew (turn anticlockwise looking
from below) the filter bowl using the
hexagon ‘nut’ cast into the base. Take
steps to contain spillage of oil Filter condition ‘Telltale’ Filter body
4. Remove the old filter and clean inside

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

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

The hydraulic control components (with the DANGER
exception of the position sensor unit on the SKIN INJECTION HAZARD
crusher are housed in the hydraulic control Refer to Section 9.1, Safety
console. Information for relevant warning
The System 2 - 2000 enables the Automax to

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

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

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

System WARNING
WEAR PERSONAL
9.14.1 General Description PROTECTIVE EQUIPMENT.
Electrical power of DC24 volt for the Information for relevant
electrical equipment on the plant is derived warning.
from the diesel engine to operate the control
LOCKOUT PLANT.
systems for the Automax crusher and all the Refer to Section 9.1, Safety
plant items. Information for Lockout Proce-
dure.
Refer to the wiring diagrams in Section 11 -
Appendix.
9.14.2 Operator’s Control Points

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

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

and 9.17)
• Emergency Stop Buttons (Sections 1.7

and 8.3)
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9.14.3 Protection Devices

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

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

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

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

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

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

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

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

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

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

3. Remove the crusher drive guarding as

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

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

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

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

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

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

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

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

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

replaced and secured before start-up.
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9.15.3 Replacement and

Adjustment of Hydraulic Pump
Drive Belts
DANGER
Note:- Drive belts should be inspected Refer to Section 9.1, Safety
regularly for wear, correct tension and Information for relevant 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 PROTECTIVE EQUIPMENT.
drives is adjusted by two bolts located on Refer to Section 9.1, Safety
each pump baseplate (Figure 9af).
LOCKOUT PLANT.
Procedure.
2. Close down the machine (Section 8.2) FALLING HAZARD.

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

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

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

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

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

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

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

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

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

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

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

1. Observe all safety warnings. Information for relevant warning.
2. Close down the machine (Section 8.2)

Remove the guards from around the belt. Crusher/Engine Drive Belts
3. Calculate the deflection distance in mm 8 x 3550mm SPC,

on a basis of 16mm deflection per 1 Part Number 2441-0470
metre (0.6” per 1 yard) of belt span
(Figure 9ah). Hydraulic Pump Drive Belts
Centre to Centre Distance metre x 16 4 x 2000mm SPB,

(yard x 0.6”) = Deflection Part Number 2441-0412
Ce
nt
re
to
Ce
nt
re
16mm 0.6 ins.
Deflection Deflection
per 1 per 1 Yard
Metre of of Belt
Belt Span
Span
Belt Tension Indicator
Applied to Mid-Span
Figure 9ah Belt Tensioning Measurements
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4. If a belt tension indicator is 6. If the measured force falls within the

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

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

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

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

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

DANGER
9.16.1 General Description
ENTANGLEMENT HAZARD.
There are two belt conveyors on the Refer to Section 9.1, Safety
Maxtrak plant. Information for relevant warning.
• The Feed Conveyor has a shallow

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

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

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

Conveyor head should be correctly WARNING
tensioned by adjusting with the
turnbuckles. WEAR PERSONAL
• The head and tail drums are correctly
fitted. ie. they are level, and that their warning.
axes are square to the centre line of the
conveyor. LOCKOUT PLANT.
• All troughing and parallel idlers are Information for Lockout
correctly fitted with their axles square to Procedure.
the centre line of the conveyor, the side FALLING HAZARD.
roller lead is in the correct direction (i.e. Refer to Section 9.1, Safety
forward of centre) and all rollers are Information for relevant warning.
rotating freely.
• In the case of screw-type take up gears,

that these are adjusted initially to take up Tracking should be carried out with the belt
slack from the belt and that equal tension empty. With very stiff belts, which do not
is applied to each side such that the trough well nor make proper contact with the
pulley is square to the centre line of the centre idlers roller when empty, it may only
conveyor. be possible to track the return strand when
empty and the troughed side when loaded.
• Where skirt rubbers are fitted they are
not bearing down heavily on the belt. If the belt tends to run to one side the most
likely cause of the trouble will usually be
• There is no obstruction on the conveyor some distance before the point where the
that could cause accident or damage running off is apparent, and in the case of
when the conveyor is started. troughed strand probably at the second or
third idler behind the point where the belt is
moving out of its true line.
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Side Roller
and Spindle
Slots for
Adjustment
Belt
of
Travel
Transom
Side Roller and Centre Roller

Spindle and Spindle
Slots for Adjustment

of Transom
Figure 9ai Transom Breakdown

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

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

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

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

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

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

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

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

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

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

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

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

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

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

oil lubricated gearbox located inside the
Feed Conveyor head drum (Section
9.4.5). The gearbox must be filled up to
the centre line and two sight glass plugs
are provided at 180º (Figure 9ak) to fill
or drain and also to ascertain the
required halfway level. Check the level
monthly. Do not mix oils of different
maker or type. The oil temperature
to be always below 90º C.
• In the interests of efficient operation and

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

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

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

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

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

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

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

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

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

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

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

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

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

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

adjustment being necessary the following
instructions should be read but any major After the above adjustments the detector
changes should only be attempted by an may have illuminated the DETECT light and
engineer conversant with the operation of the RESET lamp on the detector door.
the Maxtrak plant as a whole. Pressing RESET lamp button will extinguish
both lights.
! NOTICE ! The relay function is controlled by the

RELAY switch. In the OFF position only the
When opening the door of the
DETECT light and door RESET lamp
Metal Detector control panel do operate when metal is present in the sensing
not tamper with the terminal area.
blocks or wiring unless the unit is
switched off. In the LATCH position the relay and above
indicators operate but after metal is removed
With the power ‘ON’ the GREEN lamp on the relay and the indicators remain ‘on’ until
the door case will be illuminated. Opening either the door RESET button is pressed or
the panel door will reveal the setting controls the RELAY switch is turned to the ON or
(Figure 9am). OFF position.
The RED fault light will be extinguished

when the sensor is properly connected.
Note: The illuminated fault light will also
cause the DETECT lamp to be illuminated.
Rotate the SET ZERO control Figure 9am)

fully clockwise. If the right hand light
illuminates, rotate the SET ZERO control
anticlockwise until this light extinguishes and
the green light illuminates. This adjustment
compensates (or zeros out) any nearby metal
in the sensor coil detect area. If this light
cannot be illuminated there may be too much
metal near the sensor coil.
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The SENSITIVITY control is a gain

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

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

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

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

WARNING
The Maxtrak 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 Refer to Section 9.1, Safety
the following areas:-
warning.
• Crusher feed chute. LOCKOUT PLANT.

• Crusher discharge area. Information for Lockout
Procedure.
• Product conveyor discharge. FALLING HAZARD.
It is the responsibility of the customer to Information for relevant
supply the system with clean water. This is warning.
supplied at the manifold (Figure 9ao). The
total flow requirement for the system is 7
litres/min.(2 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 9ao Dust Suppression Manifold
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9.19 Plant - Diesel Engine

WARNING
For the diesel engine powerpack Refer to Section 9.1, Safety
fitted to your Maxtrak to continue Information for relevant
warning.
to perform safely, efficiently and
reliably it is imperative that all the LOCKOUT PLANT.
recommendations given in the
separate engine manual are dure.
strictly followed with regard to:-
• Safety
• Operation The HFO clutch is operative when the
engine powered hydraulic system is at
• Lubrication operating pressure. Should the hydraulic
pressure fall below a preset level, the Feed
• Maintenance Conveyor will be stopped to prevent any
• Service further material from entering the Automax
whilst there is a risk of the clutch slipping
• Parts due to the low oil pressure.
Adhere to the regular maintenance
Until the reason for the low pressure has
schedules and procedures specified by the
been established and the fault rectified the
manufacturer using the numbers of hours run
plant cannot be operated.
as displayed on the engine Service Meter.
All matters relating to the diesel engine can

be dealt with directly by your local official
engine dealer for the unit fitted without
consulting Terex Pegson Limited.
The engine is fitted with an HFO

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

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

The drive from the engine to the Automax
WARNING
crusher is through an HFO hydraulic oil WEAR PERSONAL
actuated clutch. This totally enclosed unit PROTECTIVE EQUIPMENT.
has the outer driving ring connected to the Refer to Section 9.1, Safety
diesel engine flywheel. The output shaft is Information for relevant
supported by a spherical roller bearing, oil warning.
lubricated, fitted in a cover flanged to the LOCKOUT PLANT.
engine flywheel housing. Refer to Section 9.1, Safety
Check the bearing oil level prior to the daily dure.
start up of the plant: as a minimum
requirement, level stick must be oil wet. The
oil filler/dipstick can be accessed at the rear
of the engine housing.
! NOTICE !
Engage the clutch ONLY at engine
at idling speed (1200 rpm). At Filler Cap with Dipstick
ambient temperature close to or
below 0 ºC (32 ºF), keep engine
running at idling speed for 5
minutes, at least.
When changing the oil, drain the old oil by

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

it is advisable, every 4000 working hours, to Figure 9ap Clutch Oil Filler
check the condition of the bearings and
replace the rotating seals (refer to parts list).
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9.19.3 Check Fuel Level
Procedure
2. Check the fuel level indicator (Figure

9aq)
3. Top up fuel level if required (Section

9.19.4).
• Fill the tank at the end of each day,

where possible, to reduce overnight
condensation within the tank.
! DANGER !
Diesel fuel is highly flammable and
is an explosion/burns hazard.
Never remove the filler cap or

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

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

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

the fuel system near naked lights
or sources of sparks, such as
welding equipment.
Figure 9aq Fuel Level Indicator - Engine

Control Panel
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9.19.4 Top Up Fuel Level

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

3. Lift the engine side access flap door to

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

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

refuel, with the engine running.
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! DANGER !
fuel mixes to diesel because of
increased fire or explosion risks.
Do Not smoke while refilling or

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

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

quote the plant serial number (with either a /
S or /T suffix if included on the identity plate
serial number).
! WARNING !
Prior to attempting any
Frequently check for loose bolts, oil leaks, manoeuvring of the plant the
master pins are correctly located and tight, tracks must be free of
general wear and damage, correct track obstructions, including crushed
tension, etc. to ensure safe working and long
material and fines. Do not push or
life.
tow the plant. Failure to observe
When travelling on a gradient, the tracks this warning could result in injury
should be driven with the track idler rollers to persons and damage to the
(Figure 9ay) in front (ie. Feed Hopper first). plant which may invalidate
warranty.
9.21.1 Measuring Track Tension
Procedure
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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4. One track at a time, measure the sag on

the top part of the track on the longest
section of unsupported track by placing a
‘straight edge’ long enough to reach
from the drive sprocket to the nearest
skid plate.
5. Measure the maximum amount of track

sag from the high point of the track
grouser to the bottom of the ‘straight
edge’ (Figure 9as). Correctly adjusted
the sag should be approximately 15 mm
(5/8”) but must not be less that 5mm
(1/4”).
! WARNING !
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:
Figure 9as Measuring Track Tension
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9.20.2 Adjusting Track Tension

DANGER
! WARNING ! SKIN INJECTION HAZARD
‘GREASE UNDER HIGH Refer to Section 9.1, Safety
PRESSURE’
To Release Track Tension (After

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

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

TRACKS (Refer to Section 9.20.1).
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6. Operate the plant in manoeuvring mode If the track fails to slacken after the
(Section 5.2.1) and drive the plant 50 grease fitting has been loosened, do not
metres (50 yards) forwards and 50 attempt to remove the tracks or
metres (50 yards) backwards, measure disassemble the track tensioner, or
the sag and repeat the steps 1 - 4 if remove the grease fitting. It is possible
thetrack(s) sag is not enough. If room that running the tracks with the grease
for manoeuvring the plant is restricted, fitting loosened may help to expel the
drive the plant forwards and backwards grease.
several times over a shorter distance.
Track Surface Idler Roller
Drive Sprocket
Relief
Valve
Final Drive Track Roller
Unit
Figure 9at Vehicle Track Parts
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To Increase Track Tension (After

measurement - Section 9.20.1):- DANGER

WARNING
3. Locate the access aperture on the side WEAR PERSONAL
of the track frame and remove the cover PROTECTIVE EQUIPMENT.
(where fitted) to reveal the relief valve Refer to Section 9.1, Safety
inside. Information for relevant
warning.
4. Connect the grease gun to the grease LOCKOUT PLANT.
fitting and add grease until the track Refer to Section 9.1, Safety
tension is within the specified dimension Information for Lockout Proce-
(Section 9.20.1). See Section 9.4.5. for dure.
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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9.20.3 Track Maintenance

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

working hours.
Daily
Procedure
1. Observe all safety warnings. ! NOTICE !
2. Close down the machine (Section 8.2) To maximise the life of the track,
and implement the Lockout Procedure. keep it movable and avoid
damage, the plant should be
3. Check the track rollers and idler wheels moved at least every week, by a
for possible leakage. distance exceeding four times the
track length. It should also be
4. Check the track surface of the track parked on level ground overnight
rollers, idler wheels, track shoes and and during periods to of non-
drive sprockets for wear and loose usage. This is particularly
mounting bolts. important when working in
adverse conditions.
5. Clean out any heavy build up of material
from around the tracks.
6. Check the tension of the tracks (Section

9.20.1) and adjust tension if necessary
(Section 9.20.2).
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9.20.4 Drive Oil Filling and Draining

Oil Filling
WARNING
WEAR PERSONAL
warning.
2. Close down the plant (Section 8.2) and LOCKOUT PLANT.

implement the Lockout Procedure. Refer to Section 9.1, Safety
dure.
3. Make sure the gearbox housing is
horizontal.
4. Rotate the gearbox housing so that one

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

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

install.
8. Repeat procedure on the other final

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

the travel motor seal to allow hydraulic oil or
water to enter and contaminate the drive.
Oil Level (B)
Figure 9au Tracks - Oil Filling
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Oil Draining
WARNING
1. Observe all safety warnings. Refer to Section 9.1, Safety
2. Close down the plant (Section 8.2) and warning.
LOCKOUT PLANT.
3. Rotate the gearbox housing until a plug is Information for Lockout Proce-
at the 6 o’clock position (Figure 9av). dure.
4. Unscrew both plugs and discharge the

oil.
5. Clean plugs using a clean non-flammable

solvent.
(A)
6. Apply pipe sealant to the plugs and
install.
7. Repeat procedure on the other final

drive.
Oil Drain (B)
Figure 9av Tracks - Oil Draining
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Blank page
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Page 10 - 1
10 - Spare Parts
10.1 Automax Crusher Parts .............................................................................. 10 - 3

General Illustration............................................................................................. 10 - 3
Mainframe Assembly......................................................................................... 10 - 4
Upper Frame Assembly .................................................................................... 10 - 6
Hydraulic Cylinder Fixings ................................................................................. 10 - 8
Cone head Assembly ...................................................................................... 10 - 10
Eccentric Assembly......................................................................................... 10 - 12
Countershaft Assembly ................................................................................... 10 - 14
Lubrication Piping Assembly ........................................................................... 10 - 16
Crusher Hydraulic Assembly............................................................................ 10 - 18
Hydraulic Control Panel Assembly ................................................................... 10 - 20
Lubrication Oil Tank Assembly ......................................................................... 10 - 22
10.2 Plant Conveyors ....................................................................................... 10 - 24
Feed Conveyor Parts - sheet 1........................................................................ 10 - 24
Level Sensor - Crusher Unit MR1 .................................................................... 10 - 28
Discharge Conveyor Parts - sheet 1 ................................................................ 10 - 31
Discharge Conveyor Parts - sheet 2 ................................................................ 10 - 32
10.3 Plant Components .................................................................................... 10 - 34
Plant Components - sheet 1 ............................................................................ 10 - 34
10.4 Plant Tracks .............................................................................................. 10 - 38
10.5 Plant Hydraulic System ............................................................................ 10 - 40

Hydraulic Reservoir ......................................................................................... 10 - 40
Hydraulic Components .................................................................................... 10 - 42
Hydraulic Hoses .............................................................................................. 10 - 44
Hydraulic Hoses, continued ............................................................................. 10 - 46
10.6 Electrical Components ............................................................................. 10 - 48
Plant Control Panel ......................................................................................... 10 - 48
Automax Control Panel ................................................................................... 10 - 50
10.7 Warning Signs........................................................................................... 10 - 52
10.8 Hydraulic Engine Clutch .......................................................................... 10 - 54

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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)
TERX PEGSON DISTRIBUTOR.............................................................................
CONTACT NAME(S)..........................................................................................
.........................................................................................
TELEPHONE NUMBER.....................................................................................
FACSIMILE NUMBER........................................................................................
E MAIL ADDRESS.............................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.
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10.1 Automax Crusher Parts
General Illustration
1000 Automax Crusher
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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 W ASHER 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 W ASHER 4
2210-0019 W ASHER 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 W ASHER 4
21 2666-9013 LINEAR TRANSDUCER UNIT 1
2232-1092 BOLT 2
2211-0007 W ASHER 2
315-10 NUT 2
JUNCTION BOX C/W MULTI CORE
22 2690-0020 1
CABLE
18/08/04
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21
22
20
1000 Automax - Mainframe Assembly
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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
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Page 10 - 7
- FEED BOX NOT SHOWN FOR CLARITY
1000 Automax - Upper Frame assembly
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Page 10 - 8
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
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5 3
6
4
2
1000 Automax - Hydraulic Cylinder Fixings
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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
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1000 Automax - Cone Head Assembly
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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
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1000 Automax - Eccentric Assembly
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Page 10 - 14
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 (+ KEY 2432-1404) 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
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1000 Automax - CountershaftAssembly
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Page 10 - 16
Lubrication Piping Assembly

1 2510-3067 BEND 1
2 2510-3526 REDUCTION SOCKET 1
3 2520-6566 TAPER NIPPLE 1
4 2520-6580 ELBOW 2
5 HOSE 48 HOSE 1
6 341/439 PIPE 1
7 2510-3898 BACKNUT 1
8 2510-3114 ELBOW 1
9 2520-6570 NIPPLE 1
10 AX857/27 SUPPORT BRACKET 1
11 2512-0007 U BOLT 1
12 2215-0014 NUT 4
13 2211-0008 WASHER 2
14 HOSE 52 HOSE 1
15 2510-3147 ELBOW 1
16 2520-6571 NIPPLE 1
17 HOSE 49 HOSE 1
18 2520-6572 NIPPLE 1
19 HOSE 47 HOSE 1
20 2520-6573 ELBOW 3
21 2520-6575 REDUCER 2
22 2500-1023 BONDED SEAL 2
23 2520-6574 TEE 1
24 2520-6579 REDUCER 1
25 2510-3589 REDUCER 2
26 2510-3149 ELBOW 2
27 2520-6576 HOSE TAIL 2
28 2340-4007 JUBILEE HOSE CLIP 2
29 2520-6572 REDUCER 2
30 2510-3789 SOCKET 1
31 2581-8125 OIL TANK 1
32 2534-4001 HEAT EXCHANGER 1
33 2520-6577 NIPPLE 4
34 2520-6578 BEND 1
35 HOSE 64 HOSE 1
36 2510-3790 SOCKET 2
37 WEBER 1
38 PIPE 1
39 2520-6581 PLUG 1
40 2529-9904 HOSE GUARD 1 METRE
Revised 22/07/03
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1000 Automax Mobile Plant - Lubrication Oil Piping
Page 17
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10 - Spare Parts EN
Page 10 - 18
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
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Page 10 - 19
16
1
17
15
18
11
4
12 5
7
3
14
10
9
13
19
1000 Automax - Hydraulic Cylinder Circuit
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Hydraulic Control Panel Assembly

2580-1137 PANEL REF L736
1 2589-5122 PRESSURE FILTER 1
2589-5125 REPLACEABLE FILTER ELEMENT 1
2 2589-5268 PRESSURE FILTER 1
3 2589-5269 SOLENOID VALVE 1
4 2589-5265 DOUBLE PILOT OPERATED CHECK VALVE 1
5 2589-5270 UNLOADER VALVE 1
6 2589-5271 PRESSURE REDUCING VALVE 2
7 2589-5272 CHECK VALVE 1
8 2589-5273 PRESSURE RELIEF VALVE 1
9 2589-5266 NEEDLE VALVE 2
10 2589-5031 BACK MOUNT PRESSURE GAUGE 3
11A 2589-5302 PRESSURE SWITCH 1
11B 2589-5303 PRESSURE SWITCH 1
12 2589-5301 PRESSURE SWITCH 1
13 2589-5275 MANIFOLD BLOCK 1
14 2589-5276 MOUNTING PLATE 1
20/08/04
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Page 10 - 21
1000 Automax - Hydraulic Control Panel Assembly

11B
11A
13
10
1
9
14
6A
8
7
6B
3
4
10
10
9
12
2
10
5
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Lubrication Oil Tank Assembly

2581-8139 TANK REF L732
1 2510-3844 DRAIN PLUG 1
2 2589-1074 2” SUCTION FILTER ELEMENT 1
3 2589-2016 PRESSURE RELIEF VALVE 1
4 2589-2054 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 2576-4086 HYDRAULIC MOTOR 1
10 2589-2036 PRESSURE FILTER UNIT 1
2589-2045 TWIN FILTER HEAD 1
2589-2046 PRESSURE SWITCH 1
11 2589-2090 THERMOSTAT 1
12 2589-2058 1” BSP CHECK VALVE 1
13 2538-7210 KOBOLD FLOW METER 1
14 2589-2059 AIR BLAST COOLER COMPLETE 1
2589-2089 COOLER FAN AND MOTOR UNIT ONLY 1
15 2589-2060 BULLS EYE LEVEL GAUGE 1
16 2589-2005 THERMOSTAT 1
17 2589-2032 FLOAT SWITCH 1
18 2589-1019 PRESSURE GAUGE 1
18a 2589-2061 PRESSURE GAUGE ADAPTOR 1
19 2589-2062 RESERVOIR AND LIDS 1
20 2589-2063 ELECTRICAL JUNCTION BOX 1
21
22 2589-2064 FLEXIBLE MOUNT 4
23 2589-2065 MOTOR MOUNT PLATE 1
20/08/04
AX857-901-8EN-02f 314/390
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1000
10 - Spare Parts EN
Page 10 - 23
11 15
20 17 18 10 12 6 9 5 16 14 13 8 19
7
23
22
3
4
2
1
1000 Automax - Lubrication Oil Tank Assembly
AX857-901-8EN-02f 315/390
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1000
10 - Spare Parts EN
Page 10 - 24
10.2 Plant Conveyors
Feed Conveyor Parts - sheet 1

1 2473-0001 MOTOR & GEARBOX 1
2 2421-2008S HEAD DRUM BEARING 1
3 AX848/113(01) HEAD DRUM 1
4 AX848/57/1 GEARBOX SUPPORT 1
5 AX848/58/1 BEARING SUPPORT 1
6 AX848/77/1 HEAD DRUM NIP GUARD 1
7 AX848/77/2 HEAD DRUM NIP GUARD SUPPORT ANGLE 2
8 AX848/77/3 HEAD DRUM NIP GUARD SUPPORT ANGLE 2
9 AX848/36/1 BELT SCRAPER FRAME 1
10 AX848/36/2 BELT SCRAPER CLAMP STRIP 1
11 AX607/3/46 TENSIONING ELEMENT 2
12 AX868/104 SCRAPER BLADE 1
13 2495-3012 MULTI TROUGH IDLER 1
14 AX857/2/1 CONVEYOR STRINGER SECTION 1
15 AX857/2/2 DISC ROLLER SUPPORT BRACKET 2
16 2495-1196 RETURN DISC IDLER 1
17 AX848/73/1 RETURN DISC IDLER BASKET GUARD 1
18 AX848/61/1 BARGE BOARD 1
19 AX848/61/2 BARGE BOARD 1
20 AX848/65/1 CENTRAL BELT SUPPORT 2
21 AX848/65/2 CENTRAL BELT SUPPORT STIFFENER 2
22 AX848/66 BELT SUPPORT BRACKET 4
23 AX848/65/05 BELT SUPPORT SIDE WEDGE 8
24 AX848/65/03 SIDE BELT SUPPORT 2
25 AX848/65/04 SIDE BELT SUPPORT STIFFENER 2
26 2366-2005 METAL DETECTOR SENSOR AND CONTROL BOX 1
2366-2004 METAL DETECTOR CONTROL BOX ONLY 1
27 AX848/63 METAL DETECTOR BRACKET 2
28 AX848/62/01 HDPE BARGE BOARD INSERT 2
29 AX848/62/02 HDPE CLAMP FLAT 2
AX857/22/06 - 22/07/03
NB. Fixings are not included with the above parts unless specifically ordered
AX857-901-8EN-02f 316/390
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10 - Spare Parts EN
Page 10 - 25

30 AX848/64/1 BARGE BOARD WING PLATE 1
31 AX848/64/2 BARGE BOARD WING PLATE 1
32 2489-1062 RUBBER COVERED CENTRE ROLLER 10
33 AX857/3/1 HOPPER 1
34 AX857/49/01 STRICKLE GATE MOUNTING PLATE 1
35 AX857/49/02 STRICKLE GATE – RH OUTER 1
36 AX857/49/03 STRICKLE GATE – LH OUTER 1
37 AX857/49/04 STRICKLE GATE – CENTRE 1
38 AX857/49/05 STRICKLE GATE HINGE PIN 1
43 AX848/70/1 HDPE SIDE SUPPORT WEAR PAD 2
44 AX848/70/2 HDPE SIDE SUPPORT WEAR PAD 2
45 2495-1130A RETURN IDLER 1
46 AX857/09/01 MID SECTION NIP GUARD 1
47 AX857/10/01 SIDE RETURN NIP GUARD 2
48 2495-3011 MULTI TROUGH IMPACT IDLER BASE PLATE 1
49 AX848/33 TAIL DRUM 1
50 2421-0011S TAIL DRUM BEARING 2
GREASE PIPES FOR BEARINGS (KIT FOR 2
2530-2013 1
BEARINGS)
51 AX818/110/1 TELESCOPER UNIT LH 1
52 AX818/110/1X TELESCOPER UNIT RH 1
53 AX848/34/3 FEED PLOUGH SCRAPER BLADE 1
54 AX868/105/01 TAIL DRUM GUARD SCRAPER BLADE 1
55 AX848/34/1 FEED SCRAPER PLOUGH 1
56 AX848/34/2 FEED SCRAPER PLOUGH CLAMP STRIP 2
57 AX848/79/2 FEED SCRAPER SUPPORT LINK 2
58 AX848/79/1 FEED TAIL DRUM SCRAPER 1
59 AX857/90/01 TAIL DRUM GUARD 1
65 AX857/12/01 UPPER PLATFORM STRUCTURE 1
66 AX857/26/01 UPPER PLATFORM HANDRAIL 1
AX857/22/06 - 22/07/03
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67 AX857/13/01 UPPER PLATFORM OPEN MESH 1
68 2389-9143 RUBBER BUFFER 4
69 2360-0050/14 CONVEYOR BELT 1
70 AX857/21/01 RUBBER SIDE SKIRT 2
71 AX857/21/02 RUBBER REAR SKIRT 1
72 AX857/18/01 CLAMP STRIP - HOPPER SIDE 6
73 AX857/18/02 CLAMP STRIP - HOPPER REAR 1
74 AX857/18/03 CLAMP STRIP BARGE BOARD - LOWER 2
75 AX857/18/04 CLAMP STRIP BARGE BOARD – UPPER 2
76 AX848/106/01 UPPER PLATFORM INNER RAIL 1
77 AX857/20 FEED CONVEYOR SIDE GUARDS 1 SET
78 AX857/35/01 HOPPER EXTENSION SIDEPLATE 1
HOPPER EXTENSION SIDEPLATE (OPPOSITE
79 AX858/35/02 1
HAND)
80 AX857/35/03 HOPPER EXTENSION BACKPLATE 1
NB. THE EXTENSION PLATES - ITEMS 78-80 ARE AN OPTIONAL EXTRA
AX857/22/06 - 22/07/03
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1000
10 - Spare Parts EN
Page 10 - 27
1000 Maxtrak - Feeder Conveyor Parts
AX857-901-8EN-02f 319/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 28
Level Sensor - Crusher Unit MR1

1 2210-0016 PLAIN WASHER 1
2 2215-0013 NUT 5
3 2232-1105 BOLT 1
4 2510-3895 BACKNUT 1
5 2512-0004 U BOLT 2
6 2640-5004 LEVEL SENSOR PROBE 1
7 Ax860/170/01 SENSOR SUPPORT 1
8 AX860/172/01 LEVEL SENSOR SUPPORT BRACKET 1
30/05/03 – AX860/171/01
AX857-901-8EN-02f 320/390
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1000
10 - Spare Parts EN
Page 10 - 29
Automax Feed Box
Level Sensor - Crusher Unit MR 1
AX857-901-8EN-02f 321/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 30
Blank page
AX857-901-8EN-02f 322/390
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1000
10 - Spare Parts EN
Page 10 - 31
Discharge Conveyor Parts - sheet 1

1 2421-0010S BEARING 4
2530-2012 GREASE PIPES (KITFOR 4 BEARINGS) 1
2 2450-5503 SHRINK DISC 1
3 2495-1129 RETURN IDLER 2
4 2495-1159 RETURN IDLER 6
5 2495-3004 ANGLE TROUGHING SET 2
6 2495-3005 ANGLE TROUGH SET 4
7 2495-3026 SPIRAL ROLLER 4
8 2576-4073 HYDRAULIC MOTOR 1
9 AX607/3/46 TENSIONING ELEMENT 2
10 AX801/16/01 SPRAY BAR SUPPORT 1
11 AX801/16/02 SPRAY BAR SUPPORT 1
12 AX818/07 HEAD DRUM 1
13 AX818/34 SCRAPER FRAME 1
14 AX818/156 DUST COVER SUPPORT 7
15 AX818/110/01 TELESCOPER – RH 1
16 AX818/110/01X TELESCOPER – LH 1
17 AX818/34/01 SCRAPER BLADE FRAME 1
18 AX818/34/02 SCRAPER BLADE 1
19 AX818/34/03 BRACKET 1
20 AX818/73/01 ROSTER UNIT SUPPORT 1
21 AX818/73/01A ROSTER UNIT SUPPORT 1
22 AX818/74/01 TORQUE ARM 1
23 AX857-117-501 FEED BOOT 1
AX857/69/01 FEED BOOT LINER PLATE – CENTRE 2
AX857/69/02 FEED BOOT LINER PLATE – REAR 2
AX857/69/03 FEED BOOT LINER PLATE – FRONT 2
24 AX848/39 GUARD IN CHASSIS 1
25 AX848/40 BARGE BOARD 2
26 AX848.41 MID SECTION GUARD 1
27 AX848/51 TAIL STRUT 2
28 AX848/100 FEED BOOT RUBBER SUPPORT ANGLE 1
29 AX848/56/01 PIN (PRODUCT CONVEYOR TO CHASSIS) 2
30 AX848/56/02 PIN (CONVEYOR TAIL TO CROSS BEAM) 2
AX857/51/04 – 16/07/04
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10 - Spare Parts EN
Page 10 - 32
Discharge Conveyor Parts - sheet 2

31 AX848/56/03 PIN (CONVEYOR TAIL TO STRUT) 2
32 AX848/56/04 PIN (STRUT TO BRACKET) 2
33 AX848/71/01 CLAMP STRIP 2
39 AX848/88/01 SIDE SKIRT 2
40 AX848/88/02 SIDE SKIRT 2
41 AX857/50 STRINGER SECTION 1
42 AX857/52 TAIL FRAME 1
43 AX857/53 TAIL DRUM 1
44 AX857/55 NIP GUARD 1
45 AX857/56 HEAD GUARD 1
46 AX857/64 RETURN ROLLER NIP GUARD 2
47 AX857/65 SHRINK DISC GUARD 1
48 AX857/79 TAIL BEARING SHIM 2
49 AX857/50/03 SPIRAL ROLLER SUPPORT BRACKET 2
50 AX857/51/24 CONVEYOR BELT 1
51 AX857/57/01 SPIRAL ROLLER NIP GUARD 1
52 AX857/61/01 RETURN ROLLER NIP GUARD 1
AX857/51/03 – 22/07/03
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1000 Maxtrak - Discharge Conveyor Parts
Page 33
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 34
10.3 Plant Components
Plant Components - sheet 1

1 AX857/01/01 CHASSIS 1
2 AX848/49 ENGINE/HYD. TANK OPEN MESH PLATFORM 2
3 AX857/17/01 ENGINE PLATFORM FRAME 1
7 AX848/98/01 ENGINE PLATFORM HANDRAIL 1
8 AX848/98/02 ENGINE PLATFORM HANDRAIL 1
9 AX848/48/01 ENGINE OPEN MESH PLATFORM 1
10 AX848/48/02 ENGINE OPEN MESH PLATFORM 1
11 AX848/47/01 ENGINE PLATFORM SUPPORT 1
12 AX848/47/02 ENGINE PLATFORM SUPPORT 1
13 AX848/37/01 PLATFORM KICKING STRIP - HYD TANK 1
14 AX848/37/02 PLATFORM KICKING STRIP – ENGINE 1
15 AX857/15 ENGINE SUPPORT BEAM 1
16 AX848/43/01 LOWER PLATFORM SUPPORT 2
17 AX848/43/02 LOWER PLATFORM SUPPORT 2
18 2443-1787 AUTOMAX VEE PULLEY 1
19 2443-1708 ENGINE VEE PULLEY 1
20 2443-8334 ENGINE PULLEY TAPER LOCK BUSH 1
21 2441-0470 VEE BELTS 8
22 AX848/59/01 DRIVE GUARD LOWER PANEL 1
23 AX848/59/02 DRIVE GUARD LOWER PANEL 1
24 AX848/59/03 DRIVE GUARD UPPER PANEL 1
25 AX848/59/04 DRIVE GUARD INSPECTION COVER 1
26 AX848/59/05 DRIVE GUARD SUPPORT ANGLE 2
27 AX848/59/06 DRIVE GUARD SUPPORT ANGLE 2
28 603/9001 1000 AUTOMAX CRUSHER 1
29 AX848/78/02 SPRAY BAR 1
30 ‘U’ BOLT 2
Revised 23/07/03
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1000
10 - Spare Parts EN
Page 10 - 35

31 SPRAY BAR NOZZLES 3
32 AX857/06/01 CRUSHER FEED BOX 1
33 AX857/06/02 CRUSHER FEED BOX DOOR 1
34 2294-0009 ANTILUCE FITTINGS 4
35 AX848/86 SAFETY BAR 2
36 AX848/42/01 LOWER SUPPORT FRAME 1
37 AX848/42/02 LOWER SUPPORT FRAME 1
38 AX848/30 UPPER PLATFORM SHIPS LADDER BRACKET 1
39 AX848/44/02 LOWER PLATFORM OPEN MESH LADDER SIDE 1
40 AX848/44/01 LOWER P’FORM OPEN MESH NON LADDER SIDE 1
41 AX848/84/01 LOWER PLATFORM HAND RAIL LADDER SIDE 1
42 AX848/83/01 LOWER PLATFORM H’RAIL NON LADDER SIDE 1
43 2389-0250 ANTI-VIBRATION MOUNTINGS 4
44 AX848/18/01 ADAPTOR PLATE 4
45 AX857/11 UPPER PLATFORM SHIPS LADDER 1
46 AX848/26 UPPER PLATFORM LADDER HANDRAILING 1
47 AX848/96/01 MESH LUBRICATION TANK COVER 1
48 2592-2004 OIL COOLER 1
49 AX857/16/01 PIN – LOWER TRESTLE/CHASSIS 2
50 AX857/16/02 PIN – LOWER TRESTLE/UPPER TRESTLE 2
51 AX848/80/01 PIN – UPPER TRESTLE/FEED CONVEYOR 4
52 AX857/04/01 LOWER TRESTLE 1
53 AX857/04/02 UPPER TRESTLE 2
54 AX857/01/02 TRESTLE SUPPORT BEAM 1
55 AX857/01/03 FEED CONVEYOR SUPPORT BRACKET 2
56 AX857/05/01 HYDRAULIC CYLINDER 1
57 AX848/16/01 ENGINE ADJUSTMENT BRACKET 2
58 AX848/16/02 ENGINE ADJUSTMENT BRACKET 2
59 2480-0044 FINNINGS/CATERPILLAR ENGINE POWER PACK 1
60 2451-1008 ENGINE HYDRAULIC CLUTCH 1
61 AX848/17 HYDRAULIC TANK 1
Revised 23/07/03
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10 - Spare Parts EN
Page 10 - 36

62 AX848/171 LEVEL SENSOR SUPPORT 1
63 2512-4029 STAUFF CLAMP 2
64 AX848/01 CROSS BEAM ASSEMBLY 1
65 AX857/51 DISCHARGE CONVEYOR ASSEMBLY 1
66 AX857/22 FEED CONVEYOR ASSEMBLY 1
67 AX857/07/01 LUBRICATION TANK PROTECTION PLATE 1
68 AX857/24/01 RUBBER DRAPE DRIVE GUARD 2
69 2389-1001 RUBBER BUFFER 6
70 AX857/47/02 SAFETY GATE – LH 1
71 AX857/47/01 SAFETY GATE – RH 1
Revised 23/07/03
AX857-901-8EN-02f 328/390
Page 37
1000 Maxtrak - Plant Components
AX857-901-8EN-02f 329/390
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1000
10 - Spare Parts EN
Page 10 - 38
10.4 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
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1000
10 - Spare Parts EN
Page 10 - 39
Tracks Assembly - Maxtrak 1000

3
4
1
8
2
7
6
16
12
13
15
14
10
11
AX857-901-8EN-02f 331/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 40
10.5 Plant Hydraulic System
Hydraulic Reservoir

1 2552-6561 QUICK RELEASE COUPLING 1
2 2589-2003 FLUID LEVEL GAUGE 1
3 2531-1000 BREATHER 1
4 2105
2589-2032A FLOAT LEVEL SWITCH 1
5 2531-5060 RETURN LINE FILTER 1
5a 2538-0053 RETURN LINE FILTER GAUGE 1
6 2531-5155 SUCTION FILTER 1
2580-8009 ‘O’ RING KIT 1
6a 2538-0054 SUCTION FILTER GAUGE 1
6b 2520-8002 2½” SAE 3000 SERIES FLANGE & ADAPTOR 1
7 2580-8005 INSPECTION COVERS 2
Revised 22/07/03
AX857-901-8EN-02f 332/390
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1000
10 - Spare Parts EN
Page 10 - 41
Maxtrak 1000 - Hydraulic Oil Reservoir Assembly

2
3
1
5
7
4 5a
6 6a 6b
AX857-901-8EN-02f 333/390
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1000
10 - Spare Parts EN
Page 10 - 42
Hydraulic Components
70 2573-6001 PUMP - HYDRAULIC 2
71 2550-9010 VALVE – HYDRAULIC, 3 WAY 1
72 2550-9011 VALVE – HYDRAULIC, 4 WAY 1
73 2531-5057 FILTER ASSEMBLY 2
74 2592-2004 AIR BLAST COOLER COMPLETE 1
2592-9006 COOLER FAN AND MOTOR UNIT ONLY 1
2592-9005 COOLER RADIATOR ONLY 1
75 2553-2013 TEST POINT 2
76 2550-9003 MOTION CONTROL BLOCK 2
77 2579-0018 CHECK VALVE (FEED CONVEYOR) 1
78 2579-0020 CHECK VALVE (PRODUCT CONVEYOR) 1
81 2576-4073 MOTOR – HYDRAULIC 1
82 2473-0001 GEARBOX & MOTOR ASSEMBLY 1
83 MOTOR – HYDRAULIC (SEE SECTION 10.4) 2
84 AX857/05 CYLINDER – HYDRAULIC 1
85 AX848/17 HYDRAULIC OIL RESERVOIR (SEE SECTION 10.5) 1
95 2550-9004 TRANSFER PLATE 2
ENGINE HYDRAULIC CLUTCH CIRCUIT PARTS

1 2553-2018 CONTROL VALVE 1
2 2553-2019 RELIEF VALVE 1
3 2589-5300 PRESSURE SWITCH 1
4 2553-2013 TEST POINT 1
5 2553-2020 RESTRICTOR 1
6 2553-2023 RESTRICTOR 1
AX857/29-22/07/03
1
6 5
4
AX857-901-8EN-02f 334/390
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Page 43
Maxtrak 1000 - Hydraulic System Components

Maxtrak
1000
10 - Spare Parts EN
Page 10 - 44
Hydraulic Hoses
Hose Number Tag
Hose ref Description x 1-off each Description

Fitting ref BL-Pegson Pt qty
No
HOSE 1 3/4R2AT-ST/STx700mm E/S/MB32/FB32 2"BSP M/F swept 2520- 1
6598
HOSE 2 3/4R2AT-ST/STx760mm AFS306 2"SAE 3000Series clamp half + O ring 2340- 2pr
2003
HOSE 3 3/8R2AT-ST/STx620mm AFS303 1"SAE 3000Series clamp half + O ring 2340- 2pr
2002
HOSE 4 3/4R2AT-ST/90Sx7000mm V12L/04 NONE* 0*
HOSE 5 3/4R2AT-ST/90Sx7000mm FFC-G12F 1/2"BSP Flat faced carrier 2552- 2
6556
HOSE 6 3/8R2AT-ST/90Sx7030mm T/MB06/FB06/MB 3/8BSP Tee Female on the run 1
06 2520-6599
HOSE 7 3/4R9R-Metric Male/90Sx1890mm P/MB06 NONE* 0*
HOSE 8 3/4R9R-Metric Male/90Sx1900mm P/MB08 1/2BSP Plug 2520- 4
6581
HOSE 9 3/4R9R-Metric Male/90Sx2100mm P/MB12 3/4BSP Plug 2520- 1
6600
HOSE 10 3/4R2AT-ST/90Sx5000mm MB24 1.1/2BSP M/M 2520- 1
6601
HOSE 11 1/4R2AT-3/8FemaleNut/90SJICx2600mm MB12/MBT16 3/4BSP-1"BSPT M/M 2520- 0
6577
HOSE 12 3/4R9R-ST Flange/90Sx710mm T/FB24 1.1/2BSP Female Tee 2520- 1
6586
HOSE 13 3/4R9R-90 Flange/STx800mm MB20/MB24 1.1/4BSP-1.1/2BSP M/M 2520- 1
6040
HOSE 14 1/4R2AT ST/7/16JIC90Sx900mm MB32/MBT32 2"BSP-2"BSPT M/M 2520- 2
6570
HOSE 15 3/4R9R ST/90Sx950mm B92-12 3/4ELBOW M/F Black Iron 2510- 2
3149
HOSE 16 1/2R2AT JICST/JIC90Sx2000mm MB12/MBT08 3/4BSP-1/2BSPT M/M 2520- 1
6572
HOSE 17 1/2R2AT JICST/STBSPx5700mm MB12/MBT12 3/4BSP-3/4BSPT M/M 2520- 1
6566
HOSE 18 3/4R9R Metric Male/90Sx900mm 109-1A Hose clip for 3/4 Hose 2340- 2
4008
HOSE 19 3/4R2AT Metric Male/90Sx900mm B241-3212 2"BSP-3/4BSP R-Bush 2510- 2
3589
HOSE 20 3/8R2AT ST/90Sx950mm 100B-1212 3/4BSPT-3/4 Hose tail 2520- 1
6576
AX857-901-8EN-02f 336/390
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10 - Spare Parts EN
Page 10 - 45
Hose Number Tag
Hose ref. Description x 1-off each Fitting ref. Description BL-Pegson qty
Pt. No:
HOSE 21 3/4R9R ST/90Sx1350mm [ARM] 100B-0812 1/2BSPT-3/4 Hose tail 2520- 1
6649
HOSE 22 3/4R9R ST/90Sx1350mm [ARM] MB04/FFB06 1/4BSPMale-3/8BSPFemale Fix 2520- 1
6602
HOSE 23 3/8R2AT ST/90Sx260mm B270-12 3/4 Socket 2510- 0
3879
HOSE 24 1/4R2AT ST/90Sx620mm B245-1208 1/2BSP-3/4BSP R-NIP 2510- 12
3629
HOSE 25 3/8R2AT ST/90Sx260mm 342-02 Bonded Seal 1/8 2500- 2
1008
1011
1015
HOSE 28 3/4R9R Metric Male/STx1100mm [ARM] 342-08 Bonded Seal 1/2 2500- 20
1018
HOSE 29 3/4R9R Metric Male/STx1290mm [ARM] 342-12 Bonded Seal 3/4 2500- 25
1021
HOSE 30 1/4R2AT ST/90Sx620mm 342-16 Bonded Seal 1" 2500- 5
1023
HOSE 31 3/8R2AT ST/90Sx260mm 342-20 Bonded Seal 1.1/4 2500- 5
1025
HOSE 32 3/8R2AT ST/90Sx260mm MB04 1/4BSP M/M 2520- 1
6584
HOSE 33 NONE* MB06 3/8BSP M/M 2520- 4
6571
HOSE 34 NONE* MB08 1/2BSP M/M 2520- 2
6604
HOSE 35 3/4R2AT ST/90Sx6200mm MB12 3/4BSP M/M 2520- 15
6585
HOSE 36 3/4R2AT ST/90Sx6200mm MB02/MB04 1/8BSP-1/4BSP M/M 2520- 2
6635
HOSE 37 3/8R2AT ST/STx5000mm MB04/MB06 1/4BSP-3/8BSP M/M 2520- 4
6605
HOSE 38 3/8R2AT ST/STx4850mm MB06/MB08 3/8BSP-1/2BSP M/M 2520- 8
6606
HOSE 39 NONE* MB06/MB12 3/8BSP-3/4BSP M/M 2520- 1
6579
AX857-901-8EN-02f 337/390
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10 - Spare Parts EN
Page 10 - 46
Hydraulic Hoses, continued
Hose Number Tag
Pt. No:
HOSE 40 NONE* MB08/MB12 1/2BSP-3/4BSP M/M 2520- 12
6026
HOSE 41 NONE* MB12/MB16 3/4BSP-1"BSP M/M 2520- 4
6575
HOSE 42 NONE* MB12/MB20 3/4BSP-1.1/4BSP M/M 2520- 3
6034
HOSE 43 3/8R2AT ST/90Sx1500mm E/S/MB24/FB24 1.1/2BSP M/F SWEPT 90 2520- 1
6607
HOSE 44 3/8R2AT ST/90Sx1500mm E/S/3/MB12/FB12 3/4BSP M/F SWEPT 45 2520- 0
6578
HOSE 45 3/8R2AT ST/90Sx1800mm MB06/FB06 3/8 BSP M/F 2520- 2
6608
HOSE 46 3/8R2AT ST/90Sx1800mm MB08/FB08 1/2 BSP M/F 0
HOSE 47 3/4R2AT ST/STx5300mm MB12/FB12 3/4 BSP M/F 2520- 3
6609
HOSE 48 3/4R2AT ST/STx4100mm T/MB12/FB12/MB 3/4BSP Tee Female on run 4
12 2520-6574
HOSE 49 3/8R2AT ST/STx3400mm E/MB06/FB06 3/8BSP M/F Block Elbow 90 2520- 4
6596
HOSE 50 3/4R2AT ST/90Sx1800mm E/MB08/FB08 1/2BSP M/F Block Elbow 90 2520- 2
6650
HOSE 51 1/2R2AT ST/90Sx3000mm E/MB12/FB12 3/4BSP M/F Block Elbow 90 2520- 3
6580
HOSE 52 NONE* E/S/MB04/FB04 1/4BSP M/F SWEPT 90 2620- 2
6612
HOSE 53 2R1AT ST/45x1600mm c/w AZEB/32x1M E/S/MB06/FB06 3/8BSP M/F SWEPT 90 2520- 1
6563
HOSE 54 3/4R2AT Metric Male/STx5000mm E/S/MB12/FB12 3/4BSP M/F SWEPT 90 2520- 15
6573
HOSE 55 3/8R2AT ST/STx4630mm
HOSE 56 1.1/2R1AT Flange90S/STx650mm BH/MB06 3/8BSP BULKHEAD 2520- 1
6285
HOSE 57 2R1AT 1.1/2Female Nut/2STx3400mm BH/MB12 3/4BSP BULKHEAD 2520- 2
6291
HOSE 58 1.1/2R1AT Flange90S/STx1200mm MB06/MM18 3/8BSP-18mm M/M 2520- 2
6614
HOSE 59 3/4R2AT ST/STx4500mm MJ04/MU04 7/16JIC-7/16SAE M/M 2520- 2
AX857-901-8EN-02f 338/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 47
Hose Number Tag
Pt. No:
HOSE 60 3/4R2AT ST/90Sx2700mm MJ10/MU10 7/8JIC-7/8SAE M/M 2520- 1
6616
HOSE 61 3/4R2AT ST/90Sx5300mm E/MJ10/FJ10 7/8JIC M/F Elbow 2520- 1
6617
HOSE 62 1/4R2AT ST/STx5300mm T/MJ10/MJ10/MU1 7/8 Male Tee 2520- 1
0 6618
HOSE 63 3/4R2AT ST/90Sx5000mm MB04/MM12 NONE* 0*
HOSE 64 NONE* BJ-12 3/4BSP Banjo 2520- 4
6619
HOSE 65 NONE* T/MB24 1.1/2 Male Tee 2520- 1
6620
Hydraulic Clutch Hoses

Hose ref Description x 1-off each Fitting ref Description BL- Qt
Pegson Pt No y
2527-1054 3/8R2AT x ST/ST x 5500mm Z21B/12 Tee M/F Run, M Branch 3/4BSP 1
2520-6404
2527-1038 3/8R2AT x ST/90 x 1900mm 2B/12-6 BSP 3/8M-3/4F SWIV NUT 2
2520-6124
2527-1051 3/8R2AT x ST/90 x 600mm Bonded seal 3/8BSP 12
2500-1015
2527-1040 3/8R2AT x ST/90 x 2400mm Bonded seal 1/4BSP 3
2500-1011
3/8 M/M Nipple 7
2520-6003
E/S/MB06/FB0 3/8BSP M/F Elbow swept 90 1
6 2520-6563
Adaptor M18x1.5F-3/8BSPM 1
2520-6564
BH/MB06 3/8BSP Bulkhead 2
2520-6285
Locknut 3/8BSP 2
2520--6297
3/8 M/F Swivel nut adaptor 2
2520-6102
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1000
10 - Spare Parts EN
Page 10 - 48
10.6 Electrical Components
Plant Control Panel

PLANT CONTROL PANEL
DISPLAY SCREEN –
NB. WHEN ORDERING QUOTE MODEL DATA ON
1 2683-2148 1
REVERSE OF UNIT (SEE ILLUSTRATION)
TOGETHER WITH PLANT SERIAL NUMBER
2 2640-5005 CRUSHER MINI-RANGER TRANSCEIVER UNIT 1
3 2640-5005 HOPPER MINI-RANGER TRANSCEIVER UNIT 1
4 2683-2149 DOOR KEY 1
5 2683-2113 FEEDER SPEED CONTROL KNOB 1
2683-2109 FEEDER SPEED POTENTIOMETER 1
6 2683-2102 START/STOP PUSH BUTTONS 4
7 2683-2101 EMERGENCY STOP BUTTON (PANEL) 1
8 2683-2103 2 POSITION STAY PUT SWITCH 3 OR 4
9 2683-2111 BLACK PUSH BUTTON 2
10 2683-2174 COMMUNICATION LEAD 1
11 2683-2114 HEAVY DUTY RELAY 2
12 2683-2106 11 PIN RELAY
2683-2106A RELAY BASE
13 2683-2107 8 PIN RELAY
2683-2107A RELAY BASE QUANTITY
14 2683-2176 20A SINGLE POLE CIRCUIT BREAKER TO SUIT
2683-2177 16A SINGLE POLE CIRCUIT BREAKER PANEL
2683-2178 6A SINGLE POLE CIRCUIT BREAKER
TRACK CONTROL KIT – COMPLETE
15 2686-0038 NB. SEE SEPARATE LIST FOR INDIVIDUAL 1
COMPONENTS
16 2683-2170 PLC BASE UNIT 1
17 2683-2171 PLC INPUT MODULE 2
18 2683-2173 PLC END CAP 1
19 2683-2172 PLC OUTPUT MODULE 1
20 2683-2169 PLC PROCESSOR C/W MEMORY MODULE 1
21 2683-2195 BATTERY 1
22 2683-2175 DC/DC POWER CONVERTER 1
23 2683-2145 ENGINE ANTI-CRANK RELAY 1
24 2683-2182 FUSE SET 1
25 2683-2108 TIMER 1
30/05/03
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Maxtrak
1000
10 - Spare Parts EN
Page 10 - 49
8 9 8 6 5
10 1 24 14 11 25 13 12
23
2&
3
24
22
5
15
16 17
20 18
21 19
AX857-901-8EN-02f 341/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 50
Automax Control Panel
AUTOMAX CONTROL PANEL
1 2695-0082A CPU & MODULE 1

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

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

PRODUCT CONVEYOR SPEED WHEEL SENSOR
2366-0400 1
ASSEMBLY
2368-2151 SPEED WHEEL SENSOR CABLE 1
2685-0001 EMERGENCY STOP PUSH BUTTON STATION 5
2683-2110 AUDIBLE WARNING UNIT 1
2366-2008 METAL DETECTOR PANEL GREEN INDICATOR 1
2366-2010 BULB FOR ABOVE 1
2366-2009 METAL DETECTOR PANEL RED BUTTON 1
2366-2010 BULB FOR ABOVE 1
07/04/04
AX857-901-8EN-02f 342/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 51
3 1 10
4
2
Commandes du tableau hydraulique Automax
9 8 5 6
14
11
12 15
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Maxtrak
1000
10 - Spare Parts EN
Page 10 - 52
10.7 Warning Signs

1 300/32 DANGER – ENTANGLEMENT HAZARD 4
2 300/33 WARNING– READ MANUAL 4
3 300/34 DANGER – SKIN INJECTION HAZARD 4
6 300/37 IMPORTANT – CHECK FILTERS 2
7 300/38 WARNING – FALLING MATERIAL HAZARD 4
8 300/39 WARNING – STOP AND LOCKOUT 4
9 300/40 WARNING – GUARDS/LABELS IN PLACE 4
10 300/41 WARNING – PRIOR TO TRANSPORT 2
11 300/42 IMPORTANT – DRAIN WATER 1
13 300/44 WARNING – IMPACT HAZARD 3
14 300/45 IMPORTANT – CHECK FRAME ARMS 2
15 300/46 IMPORTANT – CLEVIS PIN 2
17 300/118 DANGER – FLYING MATERIAL HAZARD 2
19 300/120 WARNING – FALLING HAZARD 2
20 300/175 IMPORTANT – HYDRAULIC CLUTCH 1
21 300/182 CAUTION – PRIOR TO TRANSPORT 1
23 300/196 WARNING – HEARING HAZARD 2
27 300/224 HEARING PROTECTION 2
30/05/03
1 2 3 6
11 20
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Maxtrak
1000
10 - Spare Parts EN
Page 10 - 53
7 8 9 10
13 14 15 17
19 21 23 27
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Maxtrak
1000
10 - Spare Parts EN
Page 10 - 54
10.8 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
AX857-901-8EN-02f 346/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 55
TRANSFLUID CLUTCH REF HFO 314 - 1 HD
Terex Pegson Part Number 2451-1008 - For Spare Parts also advise
specification and serial numbers stamped on the identity plate
Maxtrak 1000 - Hydraulic Clutch for diesel engine
AX857-901-8EN-02f 347/390
Maxtrak
1000
10 - Spare Parts EN
Page 10 - 56
Blank page
AX857-901-8EN-02f 348/390
Maxtrak
1000
11 - Appendix EN
Page 11 - 1
11 - Appendix
11.1 Noise Levels ................................................................................................ 11 - 2
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Maxtrak
1000
11 - Appendix EN
Page 11 - 2
11.1 Noise Levels
Levels shown in the tabulation are for

general guidance only and will vary
depending upon the conditions prevail-
ing at the time.
AX857-901-8EN-02f 350/390
Maxtrak
1000
11 - Appendix EN
Page 11 - 3
Figures are for engine running with no load on crusher
AX857-901-8EN-02f 351/390
Maxtrak
1000
11 - Appendix EN
Page 11 - 4
Blank page
AX857-901-8EN-02f 352/390
All Plants - Tier 3, Stage IIIa - ACERT
Addendum to User Manual
AM0013 Engine Change
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
AX857-901-8EN-02f 353/390
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
AX857-901-8EN-02f 354/390
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
AX857-901-8EN-02f 355/390
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
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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
AX857-901-8EN-02f 357/390
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
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1000 and 1300 Cone Crushers and Plants
ADDENDUM TO USER MANUAL
AM0012 - 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
AX857-901-8EN-02f 359/390
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.
VI
AX857-901-8EN-02f 360/390
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
AX857-901-8EN-02f 361/390
Oil Specification Change
L-2
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All Plants - Cantrak Control
AM0020 Plants with Cantrak Engine Monitoring System
AM0020 - EN C-1
AX857-901-8EN-02f 363/390
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
AX857-901-8EN-02f 364/390
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
AX857-901-8EN-02f 365/390
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
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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
AX857-901-8EN-02f 367/390
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
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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
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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
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Automax
AM0031 Sensor Fitted in Upper Frame Position Cylinders
Introduction
An different position sensor may be fitted to the
Automax crusher.
This sensor is fitted into one of the operating
hydraulic cylinders which raise and lower the
upper frame and concave.
The separate position sensor unit is not required.
Operation
The operation remains the same.
Renewing Wear Parts

When renewing the mantle and concave set, it
is not necessary to disconnect the sensor unit
when removing the upper frame.
The cylinder containing the position sensor is
disconnected from the upper frame in the same
manner as the other cylinders.
Spare Parts
This change affects some spare parts for the
controls and hydraulic parts of the Automax.
Please contact your local Terex Pegson dealer,
Terex Pegson Technical Support Department
or Spare Parts Department and quote serial
number for assistance.
EN
IPS-1
AX857-901-8EN-02f 371/390
Sensor Fitted in Upper Frame Position Cylinder
IPS-2
AX857-901-8EN-02f 372/390
All Plants
AM0032 Preferred Driving Direction of Tracks
Introduction
To prolong the life of the track and prevent
avoidable damage to the track components,
please refer to these guidelines.
Driving Tracked Plants

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

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

position on all plants, relative to the other parts
of the plant.
EN
PDD-1
AX857-901-8EN-02f 373/390
Preferred Direction of Travel
PDD-2
AX857-901-8EN-02f 374/390
All Plants
Fuel Transfer Pump
MANUAL ADDENDUM 01EN
Page 1
OPERATING INSTRUCTIONS
FUEL TRANSFER PUMP

2573-7002
(for plant diesel engine)
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618
E-mail : sales@bl-pegson.com Website : www.bl-pegson.com
220305
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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
The pump is for the purpose of transferring User Manual-Safety Information
diesel engine fuel from a barrel positioned at for relevant warning.
ground level alongside the plant diesel engine
to the engine fuel tank. LOCKOUT MACHINE.
The pump is permanently mounted in a UserManual-Safety Information
suitable position on the plant in the vicinity of for Lockout Procedure.
the engine and is electrically driven from a
24v DC supply. The unit is fitted with an
integral on/off switch.
Also supplied as part of the kit are lengths of
plain hose 25mm bore for suction (with
strainer) and delivery.
! DANGER !
The VR050 Series pump is rated at 50 litres
Do not use the fuel transfer pump
per minute, suitable for equipment with tanks
between 200 and 500 litres. Duty is for any other purpose that filling
continuous up to + 40o C ambient. Self the diesel engine fuel tank on the
priming up to 3 metres dry. Flow 50 l/m at BL-Pegson plant.
3m head. Maximum head 10m.
Observe the Operating, Service &
Safety Instructions on the
opposite page and also the
general Safety Information given in
Section 9.1 of the Plant User
Manual.
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All Plants
Fuel Transfer Pump
Page 3
Fuel Transfer Pump Operating, Service & Safety Instructions
SAFETY
FLASHPOINT BELOW
37oC (99oF)
DO NOT USE A TRGGER NOZ-

ZLE FOR DELIVERY INTO THE
FUEL TANK
FLASHPOINT ABOVE
37oC (99oF)
MAXIMUM DUTY TIME AT 40ºC TEMPERATURE RANGE
INSTALLATION & USE
DO NOT ALLOW THE PUMP

TO RUN DRY. SWITCH OFF
IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.
220305
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All Plants
Fuel Transfer Pump
Page 4
Top Up Fuel Level

! WARNING !
Do Not fill the tank to capacity. PROTECTIVE EQUIPMENT.
Monitor the gauge located on the
User Manual-Safety Information
Engine Control Panel. for relevant warning.
Allow room for expansion and wipe LOCKOUT MACHINE.

up spilt fuel immediately, otherwise Refer to Section 9.1 of the Plant
UserManual-Safety Information
paintwork will be damaged.
for Lockout Procedure.
Procedure
! DANGER !
2. Close down the plant (Section 8.2 of the fuel mixes to diesel because of
Plant User Manual) and implement the increased fire or explosion risks.
lockout procedure except the engine
isolation switch to be at position ‘I’.
Do Not smoke while refilling or
3. Connect both hoses to the pump and insert carrying out maintenance on the
the suction hose into the fuel supply. Clean fuel system.
the area around the filler cap. Remove the Do Not carry out maintenance on
cap and insert the delivery hose. the fuel system near naked lights
4. Operate the switch on the pump to fill the or sources of sparks, such as
fuel tank. Use only in accordance with the welding equipment.
instructions on the previous page.
5. Switch off the pump and stow the hoses.
Replace the cap and refit the engine
access panel before start up. Turn the
engine isolation switch to ‘O’.
! DANGER !
Diesel fuel is highly flammable and
Never remove the filler cap or refuel,
with the engine running.
Filler Cap
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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
220305
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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.
220305
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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
220305
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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
220305
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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
AX857-901-8EN-02f 383/390
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
AX857-901-8EN-02f 384/390
General Routine Inspection All Plant
Issue EN 02
Checks
Page 1
Introduction
General plant items should be inspected on

a weekly basis and at 500 hr intervals for
damage in the following areas;
• Crusher body
• Wear Parts
• Flywheel(s)
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• Main chassis
• Feeder
• Track frames
• Conveyor frames
TEREX-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
10 04 2007
AX857-901-8EN-02f 385/390
AX857-901-8EN-02f 386/390
12 - Notes Page 1
Hours Run / Date Notes Name
AX857-901-8EN-02f 387/390
Page 2 12 - Notes
AX857-901-8EN-02f 388/390
12 - Notes Page 3
AX857-901-8EN-02f 389/390
AX857-901-8EN-02f 390/390

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ADVANCED CRUSHING TECHNOLOGY

PLANT USER MANUAL

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

Terex Pegson Limited

Terex Crushing & Screening Inc

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

This plant is in conformity with the provisions

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung disease

When dusts are generated by the operation of this

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

Terex Pegson Limited Telephone:- + 44 1530 518600

AUTOMAX/AUTOSAND - EXPLANATORY NOTE

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

1.2 Organisation Measures .................................................................................. 1 - 3

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

1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 5

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

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

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

1.2 Organisation Measures See to it that safety instructions and

Observe all safety instructions and warnings

1.2.4 1.3 Selection and

1.4 Safety Instructions 1.4.1.4

• Implementing the lockout procedure. Beware of moving haulage and loading

1.4.2.4 Always use an EN/ANSI approved safety

Keep away from the feed hopper and

Do not use any unauthorised structures.

1.5 Warning of Special 1.5.1.4

1.5.1.8 1.5.2 Gas, Dust, Steam, Smoke and

1.5.2.4 1.5.3 Hydraulic and Pneumatic

1.5.3.6 1.6 Transporting,

1.7 Position of Emergency Stop Buttons

Emergency Stop Button Emergency Stop Button

Emergency Stop Button

Emergency Stop Button Emergency Stop Button

Figure 1a Emergency Stop Buttons

Figure 1b Warning Signs - Left Hand Side

1.8.2 Safety Sign Illustrations

1.8.2 Safety Sign Illustrations, continued

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

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

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

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

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

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

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

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

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

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

2779 (9’- 1”)

3990 (13’- 1”) 3800 (12’ -6”)

All dimensions are in millimetres (feet/inches)

Gross Weight approx. - 31.3 tonnes (34.4 US tons)

applied when being used for transportation purposes.

Figure 2a Dimensions and Weights 2800 (9’- 2”)

2.2 Plant Description

Discharge Diesel Crusher Maintenance Feed

LEFT HAND SIDE

Plant/Automax Maintenance Automax