1000 Maxtrak Plant User Manual 2008 (L)

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
compounds, chemicals known to the State
of California to cause cancer and
reproductive harm.
WASH HANDS AFTER HANDLING.
WARNING: Diesel engine exhaust and

some of its constituents are known to the
State of California to cause cancer, birth
defects, and other reproductive harm.
Copyright
The copyright of this User Manual is reserved by 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
Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:-
+ 44 1530 518600
Fax:-
+ 44 1530 518618
E mail
sales@bl-pegson.com
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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Page 1 - 2
1.1 Warnings and Symbols

The following signs and designations are used in the manual to designate instructions of particular
importance.
!!
This is the safety alert symbol. When you see this symbol on your plant
or in this manual, be alert to the potential for personal injury or
equipment damage.
Follow the recommended precautions and safe operating practices.
! 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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Page 1 - 3
1.2 Organisation Measures

1.2.1
Ascertain from the appropriate Authority and
observe all statutory and any other
regulations that may apply to the planned
location before operating the Maxtrak Plant.
Loose or baggy clothing can get caught in
running machinery.
See to it that safety instructions and

warnings attached to the plant are always
complete and perfectly legible.
Keep warnings and instruction labels clean.
Replace unreadable or missing labels with
new ones before operating the plant. Make
sure replacement parts include warning or
instruction labels where necessary.
1.2.3
Where possible when working close to
engines or machinery, only do so when they
are stopped. If this is not practical,
remember to keep tools, test equipment and
all other parts of your body well away from
the moving parts.
For reasons of safety, long hair must be tied
back or otherwise secured, garments must
be close fitting and no jewellery such as
rings may be worn. Injury may result from
being caught up in the machinery or from
rings catching on moving parts.
Always wear correctly fitting (EN/ANSI
approved) personal protective equipment.
Understand service procedure before doing

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

Hard Hat, Safety Glasses, Hearing
Protection, Dust Mask, Close fitting
Overalls, Steel Toed Boots, Industrial Gloves
and a High Visibility Vest.
Disconnect battery ground cable before

making adjustments on electrical systems or
welding on plant.
1.2.2
For the execution of maintenance work, tools

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
Never make any modifications, additions or
conversions which might affect safety
without the suppliers approval.
1.3 Selection and

Qualification of Personnel Basic Responsibilities
1.3.1
In the event of safety relevant modifications

or changes in the behaviour of the plant
during operation, stop the plant and lock out
immediately and report the malfunction to
the competent authority/person.
Any work on and/or with the plant must be

executed by trained, reliable and authorised
personnel only. Statutory minimum age limits
must be observed.
1.3.2
Work on electrical system and equipment of
the plant must be carried out only by a skilled
electrician or by instructed persons under the
supervision and guidance of a skilled
electrician and in accordance with electrical
engineering rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
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1.4.1.4
1.4 Safety Instructions

Governing Specific
Operational Phases
Return idler roller guards should be checked

for wear/damage during routine
maintenance.
1.4.1 Standard Operation

1.4.1.1
Take the necessary precautions to ensure
that the plant is used only when in a safe and
reliable state.
Operate the plant only for its designed
purpose and only if all guarding, protective
and safety orientated devices, emergency
shut-off equipment, sound proofing elements
and exhausts, are in all place and fully
functional.
Before starting the engine ensure it is safe to
do so.
1.4.1.2
The gap between the guard and the idler

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

with Utilisation of the Plant and
Maintenance and Repairs During
Operation; Disposal of Parts and
Consumables
1.4.2.1
In the event of material blockage, any

malfunction or operational difficulty, stop the
plant immediately and lockout. Have any
defects rectified immediately.
Observe the adjusting, maintenance and

intervals set out in these operating
instructions, except where:
1.4.1.3
A : Warning, horn/light/gauge or indicator

calls for immediate action.
In-running nip points on moving machinery

can cause serious injury or even death.
Do not reach into unguarded machinery.
Your arm could be pulled in and amputated.
Switch off and lockout the plant before
removing any safety devices or guarding.
B : Adverse conditions necessitate more

frequent servicing.
Observe information on the replacement of
parts and equipment. These activities may be
executed by skilled personnel only.
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1.4.2.2
1.4.2.5
When the plant is completely shutdown for

maintenance and repair work, it must be
secured against inadvertent starting by:
Falling from and/or onto a BL-Pegson plant

can cause injury or even death.
Switching off the engine and remove the

ignition switch/key.
Implementing the lockout procedure.
Attaching a warning sign(s) to the plant

in appropriate positions.
1.4.2.3
Carry out maintenance and repair work only
if the plant is positioned on stable and level
ground and has been secured against
inadvertent movement and buckling.
1.4.2.4
Never allow unqualified or untrained
personnel to attempt to remove or replace
any part of the plant, or anyone to remove
large or heavy components without adequate
lifting tackle.
To avoid the risk of accidents, individual
parts and large assemblies being moved for
replacement purposes should be carefully
attached to lifting tackle and secured. Use
only suitable and technically adequate lifting
gear.
Never work or stand under suspended loads.
Do not climb on the plant whilst it is in

operation. Never use plant parts as a
climbing aid.
Beware of moving haulage and loading
equipment in the vicinity of the plant.
For carrying out overhead assembly work
always use specially designed or otherwise
safety-oriented ladders and working
platforms.
Always use any walkway/platforms provided
or a safe and secure platform approved by the
regional safety enforcing authority.
Always use an EN/ANSI approved safety
harness when reaching any points 7ft (2m)
or more above the ground level.
Keep all handles, steps, handrails, platforms,
landing and ladders free from dirt, oil, snow
and ice.
1.4.2.6
The fastening of loads and instructing of
crane operators should be entrusted to
experienced persons only. The marshaller
giving the instructions must be within sight or
sound of the operator.
Keep away from the feed hopper and

product conveyor discharge, where there is
risk of serious injury or death due to the
loading and removal of material.
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1.4.2.7
1.4.2.10
After cleaning, examine all fuel, lubricant,

and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any
defects found must be rectified without
delay.
Always ensure that any safety fitment such

as locking wedges, securing chains, bars or
struts are utilised as indicated in these
operating instructions.
1.4.2.8
Any safety devices removed for setup,
maintenance or repair purposes must be
refitted and checked immediately upon
completion of the maintenance and repair
work to ensure full working order.
Particularly make sure that any part of the

plant raised for any reason is prevented from
falling by securing in a safe reliable manner.
Never work under unsupported equipment.
Never work alone.
1.4.2.11
1.4.2.9
Improperly disposing of waste can threaten
the environment and ecology. Potentially
harmful waste used with BL-Pegson
equipment includes such items as oil, fuel,
coolant, filters and batteries, etc.
Use leakproof containers when draining
fluids. Do not use food or beverage
containers that may mislead someone into
drinking from them.
Do not pour waste onto the ground, down a
drain or into any water source.
Ensure that all consumables and replaced
parts are disposed of safely and with
minimum environmental impact.
Diesel fuel is highly flammable.

Never remove the filler cap, or refuel, with
the engine running.
Never add gasoline or any other fuels mixed
to diesel because of increased fire or
explosion risks.
Do not carry out maintenance on the fuel
system near naked lights or sources of
sparks, such as welding equipment or whilst
smoking.
1.4.2.12
Using unapproved structures i.e. walkways/
platforms etc. in the vicinity of a BL-Pegson
plant is very dangerous and could lead to
serious injury or even death through falling
and/or entanglement with the plant.
Do not use any unauthorised structures.
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1.5.1.4
1.5 Warning of Special

Dangers
1.5.1 Electric Energy
1.5.1.1
Use only original fuses with the specified
current rating. Switch off the plant
immediately if trouble occurs in the electrical
system.
Plants with high voltage electrical equipment
must be suitably earth bonded by a qualified
electrician prior to activating the main
isolator switch.
1.5.1.2
When working with the plant, maintain a
safe distance from overhead electric lines. If
work is to be carried out close to overhead
lines, the working equipment must be kept
well away from them. Check out the
prescribed safety distances.
1.5.1.3
If your plant comes into contact with a live
wire:
Warn others against approaching and

touching the plant.
Have the live wire de-energized.
Work on the electrical system or equipment

may only be carried out by a skilled and
qualified electrician or by specially instructed
personnel under the control and supervision
of such an electrician and in accordance
with applicable electrical engineering rules.
1.5.1.5
If provided for in the regulations, the power
supply to parts of plants and plants, on which
inspection, maintenance and repair work is to
be carried out must be cut off. Before
starting any work, check the de-energized
parts for presence of power and ground or
short circuit them in addition to insulating
adjacent live parts and elements.
1.5.1.6
The electrical equipment of the plant is to be
inspected and checked at regular intervals.
Defects such as loose connections or
scorched or otherwise damaged cables must
be rectified immediately.
1.5.1.7
Necessary work on live parts and elements
must be carried out only in the presence of a
second person, who can cut off the power
supply in the case of danger by actuating the
emergency shut off or main power switch.
Secure the working area with a red and
white safety chain and a warning sign. Use
insulated tools only.
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1.5.1.8
Before starting work on high voltage
assemblies and after cutting out the power
supply, the feeder cable must be grounded
and components such as capacitors shortcircuited with a grounding rod.
1.5.1.9
These plants are wired on negative earth.
Always observe correct polarity.
Always disconnect battery leads before
carrying out any maintenance to the
electrical system.
The battery contains sulphuric acid, an
electrolyte which can cause severe burns
and produce explosive gases.
1.5.2 Gas, Dust, Steam, Smoke and

Noise
1.5.2.1
Always operate internal combustion engines
and fuel operated heating systems only out
of doors or in a well ventilated area. Before
starting the plant in enclosed areas, make
sure that there is sufficient ventilation.
Observe the regulations in force at the
respective site.
Dust found on the plant or produced during
work on the plant should be removed by
extraction, not blowing.
Dust waste should be dampened, placed in a
sealed container and marked, to ensure safe
disposal.
Avoid contact with the skin, eyes or clothing.
1.5.2.2
Carry out welding, flame cutting and grinding
work on the plant only if this has been
expressly authorised, as there may be a risk
of explosion and fire.
1.5.2.3
Before carrying out welding, flame cutting
and grinding operations, clean the plant and
its surroundings from dust and other
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
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1.5.2.4
Always ensure that the operator(s) are
provided with hearing protection of approved
pattern and that these are worn at all times
when the plant is operating.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects of
air pollution of any kind.
1.5.3 Hydraulic and Pneumatic

Equipment
1.5.3.1
Work on hydraulic equipment may be carried
out only by persons having special
knowledge and experience in hydraulic
systems.
1.5.3.2
Check all lines, hoses and screwed
connections regularly for leaks and obvious
damage. Repair damage immediately.
Splashed oil may cause injury and fire.
1.5.3.3
Depressurise all system sections and
pressure pipes (hydraulic system,
compressed air system) to be removed in
accordance with the specific instructions for
the unit concerned before carrying out any
repair work.
1.5.3.4
Hydraulic and compressed air lines must be
laid and fitted properly. Ensure that no
connections are interchanged. The fittings,
lengths and quality of the hoses must comply
with the technical requirements.
1.5.3.5
Always practice extreme cleanliness
servicing hydraulic components.
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1.5.3.6
Hydraulic fluid under pressure can penetrate
the skin causing serious injury.
If fluid is injected under the skin, it must be
surgically removed or gangrene will result.
Get medical help immediately.
Always relieve pressure from the hydraulic
system before carrying out any kind of
maintenance or adjustment.
Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.4 Hazardous Substances
1.6 Transporting,
Manoeuvring and
Recommissioning
1.6.1
The plant must be towed, loaded and
transported only in accordance with the
operating instructions.
1.6.2
For towing the plant, observe the prescribed
transport position, admissible speed and
itinerary.
1.6.3
Ensure that correct procedures are

formulated to safely handle hazardous
materials by correct identification, labelling,
storage, use and disposal, all strictly in
accordance with the manufacturers
instructions and that all applicable regulations
are observed at all times.
Use only appropriate means of transport and

lifting gear where applicable of adequate
capacity.
1.6.4
The recommissioning procedure must be
strictly in accordance with the operating
instructions.
1.6.5
Before starting work or travelling with the
plant, check that the braking, and any
signalling and lighting systems are fully
functional.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.
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1.6.7
1.6.12
When travelling on public roads, ways and

places, always observe the valid traffic
regulations and, if necessary, ensure
beforehand that the plant is in a condition
compatible with these regulations.
Explosive separation of a tyre and rim parts

can cause injury or death.
Do not attempt to mount a tyre unless you
have the proper equipment to perform the
job.
1.6.8
In conditions of poor visibility and after dark,
always switch on the lighting system of the
transporting vehicle..
1.6.9
When crossing underpasses, bridges and
tunnels or when passing under overhead
lines always make sure that there is
sufficient clearance.
1.6.10
Never travel across slopes; always keep the
working equipment and the load close to the
ground, especially when travelling downhill.
Always maintain the correct pressure. Do

not inflate the tyre above the recommended
pressure. Never weld or heat wheel and tyre
assembly. The heat can cause an increase in
air pressure resulting in a tyre explosion.
Welding can structurally weaken or deform
the wheel.
When inflating tyres, use a clip-on chuck and
extension hose long enough to allow you to
stand to one side and not in front or over the
assembly. Use safety cage if available.
Check wheels for low pressure, cuts,
bubbles, damaged rims or missing lug bolts
and nuts.
1.6.11
On sloping terrain, always adapt your
travelling speed to the relevant ground
conditions. Never change to a lower gear on
a slope. Always change gear before
reaching a slope.
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1.7 Position of Emergency Stop Buttons
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
10
13
14
15
17
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1.8.2 Safety Sign Illustrations, continued
21
19
27
23
11
20
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2 - Technical Information
Maxtrak
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Page 2 - 1
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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All dimensions are in millimetres (feet/inches)
3800 (12 -6)
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2779 (9- 1)
Figure 2a Dimensions and Weights
Note: Weights and dimensions are for guidance only and appropriate allowances should be
applied when being used for transportation purposes.
2800 (9- 2)
2.1 Dimensions and Weights
Gross Weight approx. - 31.3 tonnes (34.4 US tons)
Hopper Width
3229 (10- 7)
Discharge Height
Overall Travelling Length (Feed Conveyor lowered) - 15095 mm (49- 6)

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)
Overall Width - Travelling & Working (Over Tracks) - 2800 mm (9- 2)
3990 (13- 1)
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3914 (12- 10)

Working Height
3446 (11- 4)Travel Height
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2.2 Plant Description

Many of the terms used in this manual may not at first be obvious. Figure 2b identifies the main areas
of the plant and the term with which they are referred to in this manual.
Discharge
Conveyor
Diesel
Engine
Crusher
Feed Box
Maintenance
Platform
FRONT
Feed
Hopper
REAR
LEFT HAND SIDE
Plant/Automax
Control Panel
Maintenance
Platform
Automax
Crusher
Hydraulic
Reservoir
REAR
FRONT
RIGHT HAND SIDE

Maintenance
Platform
Hydraulic
Oil Cooler
Tool Box
Figure 2b Plant Terms
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2.3 Belt Feeder Conveyor

Type
Width
Length
Drive Unit
Control
Hopper
Shallow troughed plain belt.

1000mm (39).
5400mm (17-9).
Hydraulic motor with head drum oil lubricated gearbox
Auto/manual variable speed.
Fixed hopper with rear feed facility and internal strickle
gate and full length barge boards with wear pads.
Cylinders to raise and lower for travel and maintenance.
Metal detector. Level sensor an optional extra.
Hydraulic Equipment
Control Equipment
2.4 Crusher
Type
Size
Liners
Adjustment/Controls
Automax roller bearing Cone Crusher.

1000mm (39).
Manganese mantle and concave.
Hydraulic setting adjustment, automatic overload release
and unblocking with multi-function keypad and status
display screen. (see also 2.7 - Controls).
Separate lubricating oil tank with air blast oil cooler.
Vee rope drive from engine via hydraulically controlled
clutch.
High level sensor over the feed box.
Lubrication
Drive
Control Equipment
2.5 Discharge Conveyor

Type
Width
Drive
Lubrication
Enclosure
Control equipment
Plain troughed belt.

800mm (32).
Hydraulic motor.
Grease (shaft bearings).
Canvas cover.
Tail drum movement sensor.
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Maxtrak
1000
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Page 2 - 5
2.6 Standard Powerpack

Type
Rating
Drives
Housing
Caterpillar C9 EU/EC Emmission Regulations

compliant, 6 cyl. water cooled diesel engine.
335hp @ 1800 rpm.
Hydraulically actuated heavy duty clutch and vee ropes
to crusher and vee belts to twin hydraulic pumps.
Enclosed canopy with integral fuel tank and battery.
2.7 Controls
Automax Crusher Setting, etc.
Plant Operation
Plant Set-Up
24 v DC Electro/Hydraulic Panel having numeric

keypad and message display on plant chassis.
24 v DC Electric Panel in Control Box with push button
controls and fault display, level sensor and metal
detector controls.
Lever on the plant chassis to raise/lower the feeder
conveyor.
2.8 Dustsprays
Type
Positions
Inlet
Required supply
Frost protection
Clean water multi atomising nozzle spraybars.

Crusher feed & discharge and discharge conveyor head.
Single point for users pressure supply.
Up to approx. 7 litres/min @ 2.8 bar (2 US galls @ 42
psi.
System drain valves.
2.9 Tracks
Type
Width
Centres
Drive
Control
160mm (6.3) pitch heavy duty.

400mm (16).
3800mm (12-6).
Hydraulic integral motors.
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
Maxtrak
1000
EN
Page 3 - 1
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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Page 3 - 3
3.2 General information
! NOTICE !
The Maxtrak 1000 plant has been

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

conditions apply, specific details
need to have been advised at the
time of order as special equipment
may be necessary.
The Caterpillar engine cooling
system is protected to -15 C with
30% Caterpillar antifreeze
concentration when shipped from
the factory unless special
requirements have been defined.
The plant is easy to operate, adjustments are

easy to make and expert assistance is
seldom required, provided that ordinary care
is exercised in daily use.
The plant has been built in accordance with
state-of-the-art standards and recognised
safety rules. It is designed to be reliable,
efficient and safe when used and
maintained in accordance with the
instructions given in this manual.
Nevertheless, its use may constitute a risk
to life and limb of the user or of third parties,
or cause damage to the plant and to other
material property.
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1000
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Page 3 - 4
3.3 Designated Use

The Terex Pegson Maxtrak plant includes the
1000 Automax Cone Crusher designed to
maximise throughput and product shape in a
wide range of crushing applications. For finer
crushing operations the Autosand option is
available.
! NOTICE !
It is vitally important that pieces of
steel or similar uncrushable
objects such as bucket teeth are
not allowed to enter the crushing
chamber as severe damage and
injury may occur.
For the above reason a metal detector is
fitted to the feeder. It is imperative that this
metal detector is kept operative at all times
and that when activated the plant operator
removes the offending material before
recommencing operation.
Refer to the following information in this

Section for guidance regarding the
performance of the Automax crusher.
Experienced engineers are available at BLPegson to give advice when necessary.
If you have any doubts about any aspect
of the plants capability or servicing
procedures, you must consult your local
BL-Pegson dealer or BL-Pegsons
technical departments
3.3.1 Operating Temperature Range

The normal operating temperature range of
the plant is from -10C to +40C (+14F to
+104F). For use in temperatures outside of
this range, contact your local dealer or Terex
Pegson for details.
Note: Appropriate oil & coolant to suit the
local operating conditions must be used, as
specified elsewhere in this manual.
! NOTICE !
Operating the plant outside its
recommended range of
applications/operating parameters
or for any use for which the
equipment is not intended, will
result in a loss of any guarantee
and the manufacturer/supplier
cannot be held liable for any
damage or injury resulting from
such misuse. The risk of such
misuse lies entirely with the user.
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1000
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Page 3 - 5
3.4 Crusher Performance

In order to obtain the optimum overall
crushing performance from the Automax,
it is essential to have a continuous and
regulated choke feed of evenly graded
material that is well mixed around the
crushing chamber. Typical feed gradings
are shown on the product analysis graphs
in this section.
The level sensing device prior to the
crusher will assist in achieving this when
used to control the feed. Additionally, all
feed material should be of a size that will
readily enter the crushing chamber.
The gradings and capacities shown in this
section are averages base on actual
results taken from tests carried out on
various materials at different crusher
settings. They will vary dependant upon
the grading and nature of the feed
material. For more specific details please
contact BL-Pegson Ltd.
Performance is dependant upon the throw
of the eccentric built into the Automax and
also the type of concave fitted to the
machine. Sections 3.4.1 to 3.4.8 cover the
various options.
Note:
Terex Pegsons Technical Department
can confirm the specification of the
machine as originally built but bear in
mind this may have been subsequently
changed.
The capacities given are approximate only

and based on crushing clean, dry, well
graded quarried hard limestone, weighing
loose about 1600 kg/f/m3 (100 lbs/cu.ft.) and
having a specific gravity of 2.6 - 2.8. Wet
sticky feeds will reduce crusher capacities.
Performance will be adversely affected if an
excessive percentage of fines in the feed
causes the packing/caking of material, either
to slow the flow of material or cause
congealed lumps in the product.
Persistent dumping (see Glossary) is
most undesirable and likely to be
caused by operating the machine at too
close a setting. Increase the Gap
setting to avoid damage to the machine.
Crusher settings shown in the tabulation are
for general guidance only and crusher
performance will vary depending upon the
conditions prevailing.
Capacities shown are for open circuit
applications.
When operation is required towards the
lower end of the setting range. Terex
Pegson Ltd should be consulted to verify the
application.
The power required and product gradings
will vary with the feed and product size,
capacity and rock characteristics.
Usage of wearing parts will depend upon
individual crushing conditions and the
variable factors which govern wear.
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1000
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Page 3 - 6
3.4.1 Estimated Performance - Automax with long throw eccentric
Type of Concave
Maximum Feed Size
Minimum
Recommended
Setting
Med. Coarse (MC)
160 mm (61/4")
19 mm ( /4")
Coarse (C)
175 mm (67/8")
19 mm ( /4")
Extra Coarse (XC)
195 mm (73/4")
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 /8 "
155 - 205
170 - 225
32
1 /4 "
160 - 220
175 - 240
Figure 3b Estimated Plant Outputs
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1000
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PERCENTAGE PASSING
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Figure 3c Typical Product Analysis Curves - Long Throw Eccentric Automax
SCREEN MESH SIZE - MM
SCREEN MESH SIZE - INCHES
3.4.2 Typical Product Analysis - Automax with long throw eccentric
Maxtrak
1000
EN
Page 3 - 8
3.4.3 Estimated Performance - Automax with short throw eccentric
Type of Concave
Maximum Feed Size
Minimum
Recommended
Setting
Med. Coarse (MC)
160 mm (61/4")
16 mm ( /8")
Coarse (C)
175 mm (67/8")
16 mm ( /8")
Extra Coarse (XC)
195 mm (73/4")
19 mm ( /4")
Figure 3d Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting
mm
inches
M. tph
US. tph
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 /8 "
130 - 170
140 - 185
32
1 /4 "
135 - 180
150 - 200
Figure 3e Estimated Plant Outputs

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Maxtrak
1000
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Page 3 - 9
PERCENTAGE PASSING
AX857-901-8EN-02f 41/390
Figure 3f Typical Product Analysis Curves - Short Throw Eccentric Automax
3.4.4 Typical Product Analysis - Automax with short throw eccentric
Maxtrak
1000
EN
Page 3 - 10
3.4.5 Estimated Performance - Autosand with long throw eccentric
Type of Concave
Maximum Feed Size
Minimum
Recommended
Setting
Sand (AS)
63 mm (21/2")
13 mm ( /2")
Figure 3g Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting
mm
inches
M. tph
US. tph
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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Maxtrak
1000
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Page 3 - 11
PERCENTAGE PASSING
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Figure 3i Typical Product Analysis Curves - Long Throw Eccentric Autosand
3.4.6 Typical Product Analysis - Autosand with long throw eccentric
Maxtrak
1000
EN
Page 3 - 12
3.4.7 Estimated Performance - Autosand with short throw eccentric
Type of Concave
Maximum Feed Size
Minimum
Recommended
Setting
Sand (AS)
63 mm (21/2")
13 mm ( /2")
Figure 3j Maximum Feed Size and Minimum Recommended Settings
Closed Side Setting
mm
inches
M. tph
US. tph
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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Maxtrak
1000
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Page 3 - 13
PERCENTAGE PASSING
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Figure 3l Typical Product Analysis Curves - Short Throw Eccentric Autosand
3.4.8 Typical Product Analysis - Autosand with short throw eccentric
Maxtrak
1000
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Page 3 - 14
Blank page
AX857-901-8EN-02f 46/390
4 - Design and Function
Maxtrak
1000
EN
Page 4 - 1

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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Maxtrak
1000
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Page 4 - 2
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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Maxtrak
1000
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Page 4 - 3
4.2.3 Feed Conveyor
4.2 Construction Units

TEREX PEGSON 1000 MAXTRAK
SECONDARY/TERTIARY CRUSHING
PLANT WITH DIESEL/HYDRAULIC
DRIVE generally as shown on brochure MT
200/1 and comprising:-
4.2.1 Automax Crusher

Terex Pegson 1000 Automax Crusher
generally as illustrated on leaflet AMB 200/1,
and fitted with long throw eccentric, medium
coarse (MC) concave and dedicated system
2 hydraulic controls as standard. The
crusher is complete with an oil lubrication
system having a chassis mounted tank with
air blast cooler.
Extra coarse (XC), coarse (C) and Autosand
(AS) concaves and a short throw eccentric
are all available as options to the above for
plants which have not been completed.
Advice on the correct combination of
concave and eccentric can be provided by
the sales department against purchasers
specific application data.
4.2.2 Feed Hopper

7.0m (8.75yd) heaped capacity feed
hopper fabricated in 10mm (3/8) thick mild
steel plate and fitted with internal crash bars
to minimise impact load on the feed
conveyor.
1000mm (39) wide plant mounted shallow

troughed belt variable speed conveyor, with
hydraulic drive to the head drum having
integral reduction gearbox, EP500/3 (or
equivalent) belt with 5mm (0.2) top and
1.5mm (0.06) bottom heavy duty covers,
and vulcanised belt joint. The conveyor is
designed to lower for transportation and lift
for crusher maintenance, by means of
hydraulic cylinders. Belt tensioning is
maintained by screw adjusters located at the
tail drum.
Impact rollers are provided immediately
below the feed hopper, and barge boards
extend from the feed hopper to the conveyor
head. A metal detector is included complete
with audible warning devices, and is suitable
for detecting steel and manganese steel
contained in the feed material.
4.2.4 Discharge Conveyor

800mm (32) wide plant mounted troughed
belt fixed speed conveyor with hydraulic
drive to the head drum, EP 500/3 (or
equivalent) belt with 5mm top (0.2) and
1.5mm (0.06) bottom heavy duty covers,
and vulcanised belt joint. The conveyor is of
fixed design and belt tensioning is maintained
by screw adjusters located at the tail drum.
Impact rollers are provided immediately
below the crusher outlet under the conveyor
feed point, and canvas type dust covers are
provided over the exposed section of the
conveyor.
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Maxtrak
1000
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Page 4 - 4
4.2.5 Chutes
4.2.8 Controls
Automax feed box fabricated in 6mm (1/4)

mild steel plate. Crusher discharges direct to
product conveyor feed boot, which is
fabricated in 10mm (3/8) thick Hardox.
The Automax hydraulic systems control

panel, and separate start/stop control panel
for the crusher conveyors, and oil lubrication
system are mounted on the side of the main
chassis. Both panels operate from a 24 volt
D.C. supply from the diesel engine.
4.2.6 Platforms
Provided for inspection and maintenance,
allowing access to each side of the crusher
and engine, back of engine, and to one side
of feed conveyor head section. They are
made from steel flooring with steel toe
boards, double row handrails and access
ladders.
4.2.7 Power Unit

Caterpillar C9 EU/EC Emmissions
Regulations compliant, 6 cylinder, 4 stroke,
direct injection, water cooled diesel power
pack, with HFO clutch. The engine is rated
at 335 BHP (248 kW) nett continuous at
1800 rpm under NTP conditions.
Hydraulic power is provided from the engine
to drive both conveyors, operate the
hydraulic cylinders, and give power to the
tracks. It also provides power to the crusher
lubrication oil pump and supplies the crusher
hydraulic setting and adjustment system. All
connecting pipework is provided with steel
pipe being used in inaccessible areas.
Also mounted on the chassis are emergency

stop buttons and a control lever for lowering
and raising the feed conveyor assembly for
transport and maintenance.
A radio control unit is provided for controlling
the tracking function giving a tracking speed
of approximately 1km/hour and a creep
facility for loading, off loading and precise
slewing movements. This also provides stop
and start control for the feed conveyor from
a remote position. An alternative unbilical
control unit is also provided for use in case
of remote control unit failure.
Level sensors over the Automax and, feed
conveyor (optional), are designed to
automatically maintain an optimum feed
condition.
4.2.9 Chassis
Fabricated steel frame with supports for the
feed conveyor, crusher, product conveyor,
power unit, track frame and control systems.
Hydraulic tank is mounted within the main

chassis structure, and the system includes air
to oil cooling.
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Maxtrak
1000
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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

(12- 6) centres and 400mm (1- 4) wide
tracks.
Spray bars with atomiser nozzles are

mounted over the crusher mouth and the
product conveyor feed and discharge points
piped to an inlet manifold for clients
pressurised water supply.
Total Plant Weight

31.300 kgs (34.4 US tons)
Overall track width - 2800mm (9- 2)
Operating height - 3914 mm (12- 10)
Operating length - 15173 mm (49- 9)
Operating width - 2800 mm (9- 2)
Travel height - 3446 mm (11- 4)
Travel length - 15095 mm (49- 6)
Travel width - 2800 mm (9#- 2)
4.2.11 Guards
Wire mesh or sheet metal guards are provided
for all drives, flywheels, pulleys, couplings,
wedge belts and belt conveyors.
The guards provided are designed and
manufactured to ensure so far as reasonably
practicable that the machinery and plant on
which they are fitted can be operated safely
and without risk to health when properly used.
However, the Company cannot guarantee that
the guards provided will meet the requirements
laid down by individual Inspectors and any
additional guard and/or modification to guarding
supplied, which may be required for any
reason whatsoever, will be charged as an
addition to the Contract Price.
4.2.12 Painting
The plant is finish painted in BL-Pegson
Blue RAL 5015.
Buyer to supply pressurised at 2.8 bar (42

psi) clean water supply at approximately 7
litres (2 US galls.) per minute.
4.2.14 Optional Extras

(These options are only available for plants,
which are not already built and are not
available for plants already in stock)
Automax extra coarse concave (no price
variation for unfinished plants)
Automax coarse concave (no price variation
for unfinished plants)
Autosand concave (no price variation for
unfinished plants)
Short throw eccentric (no price variation for
unfinished plants)
Beckford belt weigher with integrator and

speed sensing wheel fitted to main product
conveyor.
Hydraulically driven water pump assembly to
provide a pressurised water supply to the
dust suppression sprays.
Level sensor over the feed hopper.
Feed Hopper Extension Plates.
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Maxtrak
1000
EN
Page 4 - 6
4.2.15 Authorisation
4.2.18 Specifications
This is a requirement of the Environmental

Protection Act that the Purchaser must
obtain Local Authority authorisation to
operate this plant in the U.K.
Every endeavour will be made to supply

equipment as specified, but we reserve the
right, where necessary, to amend
specifications without prior notice as we
operate a policy of continual product
development.
4.2.16 Site Preparation

The buyer shall be responsible for ensuring
that a suitably prepared, flat and level site is
available for the plant and that the ground is
capable of sustaining the working of the
equipment. Unit dimensions and loadings
can be provided to the buyer for both
transportation and operating purposes.
4.2.17 Commissioning
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.
We cannot guarantee that the equipment

quoted will meet any specific requirements in
respect of noise or vibration levels, dust
emissions, or any other factors relevant to
health and safety measures or environmental
protection needs. However, on receipt of
specific information Terex Pegson will
endeavour to ascertain the need for
additional equipment and, if appropriate,
quote extra to contract prices.
Feed material, and other essentials to be

provided by the buyer in good time for the
commissioning being carried out.
AX857-901-8EN-02f 52/390
5 - Transport
Maxtrak
1000
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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Maxtrak
1000
5 - Transport
EN
Page 5 - 2
5.1 Safety Information

Loose or baggy clothing can get
caught in running machinery.
PERSONAL
PROTECTIVE EQUIPMENT
ALWAYS wear correctly fitting

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

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

whilst it is in operation.
ALWAYS use the walkways/platforms provided
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.
AX857-901-8EN-02f 54/390
5 - Transport
Maxtrak
1000
EN
Page 5 - 3
In-running nip points can cause

ENTANGLEMENT
HAZARD
DO NOT reach into an unguarded

machine.
SWITCH OFF, LOCKOUT & TAGOUT machine
before opening or removing guards.
Hydraulic fluid under pressure can

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

the hydraulic system before
carrying out any kind of
ALWAYS use a piece of cardboard to check for
leaks. DO NOT use your hand.
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Page 5 - 4
When carrying out maintenance or

adjustment to the plant the
following procedure must be
followed.
LOCKOUT PROCEDURE
LOCKOUT PROCEDURE
1.
2.
3.
4.
5.
Switch off engine.

Remove the ignition key.
Keep the ignition key on person during
lockout.
Place appropriate maintenance warning
signs, (ie. TAG OUT).
NEVER work alone.
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1000
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Page 5 - 5
5.2 Transportation
! DANGER !
5.2.1 Manoeuvring
! WARNING !
Prior to attempting any
manoeuvring of the plant the
tracks must be free of
obstructions, including crushed
material and fines. Do not push or
tow the plant. Failure to observe
this warning could result in
serious injury to persons and
damage to the plant which may
invalidate warranty.
Before manoeuvring the Maxtrak,

ensure the feed hopper and crusher are
empty, and that all materials have run off
the conveyors. STOP the feeder
conveyor, crusher and product conveyor.
The plant cannot be manoeuvred in the

PLANT mode of operation.
The safety warning horn sounds for 10

seconds before selected controls become
operative and continuously whilst the
plant is being manoeuvred.
When manoeuvring your Maxtrak

to its operating position make sure
you stand well clear of the plant
but are in a position to have allround vision to see any obstacles
or hazards that may lie ahead e.g
personnel, overhead cables,
ditches, unsafe roadways etc.
(Refer to Figure 2a Dimensions).
Make sure that you do not manoeuvre

your Maxtrak on a gradient steeper than
30 degrees, damage may occur to the
engine and/or plant.
Avoid manoeuvring the plant over

extremely uneven ground or damage
may occur.
Initial start up in cold weather may result

in a tendency to steer to the right whilst
tracking fast forward due to the
hydraulic oil being cold. Run the plant for
approx. 10 minutes with the conveyor
and feeder running prior to manoeuvring
the plant.
The Maxtrak can be manoeuvred whilst

the feeder conveyor is in the working
position but refer to Section 5.2.4 when
necessary to reduce to the travelling
dimensions (Section 2)
When transporting the Maxtrak, it is

the responsibility of the haulage
contractor to safely secure the plant to
the transporter.
! DANGER !
DO NOT stand on any of the
platforms or ladders of the Maxtrak
whilst it is being manoeuvred
using the remote control handset.
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1000
5 - Transport
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Page 5 - 6
To manoeuvre the Maxtrak with the

remote radio hand set (where fitted):-
WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
Information for relevant warning.
Procedure
1. Observe all safety instructions.
2. Take the Remote Control Hand Set from
the Control Box and first become
familiar with the functions of all the
individual buttons (Figure 5c) before the
next step.
Forward = Product Conveyor first
Reverse = Hopper first
3. To start up the handset transmitter first
stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows: Ensure the stop button is pulled out.
Depress both of the safety buttons
(Fig.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.
Note: The transmitter has a built in safety
function that prevents another function from
involuntary cutting-in when the transmitter
starts. The transmitter will not start if a
button is stuck in the activated position. This
is indicated by the red LED coming on.
4. Start the engine (Section 7.2.1). Set the

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

position, press the Horn button to turn
the safety warning horn off and
disengage the tracks.
10. To shut down the radio handset

transmitter, push in the stop button. Lock
out the hand set when finished with to
prevent unauthorised use.

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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1000
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Page 5 - 8
5.2.2 Unloading
The Maxtrak will arrive on site securely
fastened to a low loader. It is the
responsibility of the haulage contractor to
remove the fastenings.
WARNING
WEAR PERSONAL
Procedure
1. Observe all safety warnings.
2. Position easy slope ramps at the end of
the transporter to help with unloading of
the Maxtrak.
TRACK (Figure 5a). Using the remote
control hand set (Section 5.2.1 and 5.3),
steer the Maxtrak off the transporter .
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
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Maxtrak
1000
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Page 5 - 9
5.2.3 Loading
WARNING
Procedure
WEAR PERSONAL

2. Ensure that both conveyors, feed hopper
and crusher are free from stone and dirt.
FALLING HAZARD
3. Ensure all loose items are carefully

stowed and secured if these are to be
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).
6. Lower the feeder conveyor for travelling
if not already in this position (Refer to
Section 5.2.4 procedure).
7. Position easy slope ramps at the end of
the transporter to help with loading of the
Maxtrak.
TRACK (Figure 5a). Using the remote
control hand set (Section 5.2.1 and 5.3),
steer the Maxtrak on to the transporter.
10. 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
12. Securing the Maxtrak to the
transporter is the responsibility of
the haulage contractor.
! WARNING !
Prior to transportation always
check the plant for loose or
damaged components.
Fasten all loose parts, replace
missing items or make repairs
as found necessary to ensure
that all components are safely
secured during transportation.
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1000
5 - Transport
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Page 5 - 10
5.2.4 Lowering the Feed Conveyor

The Maxtrak is designed so that the plant
can be prepared for transport without the
use of tools. To reduce to the travelling
dimensions of the plant the feeder conveyor
head is hydraulically lowered from the
working position.
WARNING
WEAR PERSONAL
FALLING HAZARD
! 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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1000
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Page 5 - 11
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.
9. Switch off the engine (Section 8.2) and
implement the lockout procedure.
Upper Telescopic
Leg
Locating Pin
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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1000
5 - Transport
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Page 5 - 12
5.3 Remote Control

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

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

Section 5.3.1
When the plant is not operating take the

opportunity to recharge the internal
battery. For convenience a lead is
supplied to plug into 12/35 volt DC
vehicle cigar lighter point (Section 5.3.1).
In the event of the remote radio hand set

being inoperable for any reason, the
alternative umbilical hand set is
supplied (Section 5.3.2).
If the hand set transmitter does not start

when the two safety buttons are
depressed at the same time for at least 1
second (Section 5.2.1), check if the stop
button is pushed in, or the battery
needing a recharge.
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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Page 5 - 13
PLAN VIEW OF THE PLANT
LED Red/Green
Forward slow or fast, track 1 & 2

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

Right turn slow, reverses track 1
Left turn slow, reverses track 2
Safety Button
(Horn)
Safety Button
(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.
Transmitters Use NiMh batteries instead of

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

35VDC instead of 12/24VDC, no
universal adapter required.
Battery capacity is changed from 800mA
to 2000mA.(Charging time from
completely empty battery is now
approximately 4 hours).
Operating time with fully charged battery
is approximately 30 hours.
TRANSMITTER 860TX-PEG
Buttons 1 to 4 = Used for plant directional

control
Buttons 1 to 9 and 0 = Used for signal
frequency programming (factory preset contact Dealer for change)
Buttons 9 and 0 = Used to activate the
radio hand set transmitter
Button 9 = Used to activate the audible
warning horn
Button 0 = Used to stop / start the plant
feeder (where appropriate)
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Maxtrak
1000
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Page 5 - 15
2 versions of the 860 system transmitter will

be supplied, one for European Operations
and one for the Rest of the World. The only
difference is that the European version will
include a black stop button. The Rest of the
World transmitter will feature a Red Stop
button. Channel 01 (434.650 MHz) through
channel 16 (433.900 MHz) available in .050
MHz steps. Refer to Dealer if frequency
change needed.
Battery Recharging
WARNING
WEAR PERSONAL
To conserve the battery charge the hand

set should be switched off when not in
use.
The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
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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1000
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EN
Page 5 - 16
5.3.2 Alternative Control Hand Set

with Umbilical Cable (where fitted)
WARNING
As an alternative to the radio remote control

hand set, a hand set with umbilical cable is
supplied to manoeuvre the Maxtrak (Figure
5e).
WEAR PERSONAL
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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5 - Transport
Page 5 - 17
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
turn) are double pressure switches with
the initial pressure operating the slow
speed mode and depressing further
operates the higher speed.
Pressing the Stop Button at any time will
immediately halt the operation and cut
out the engine but it is necessary to
manually switch off the engine ignition
(Section 8.2).
! DANGER !
Extreme care must be used when
manoeuvring the plant with the
umbilical control hand set. Stand
as far away as possible from the
plant. Do not allow the cable of the
hand set to sag and become
entangled with the tracks.
8. Hold the hand set with the stop button

nearest to the operator and proceed as
follows. Press the slow speed buttons on
the hand set to manoeuvre the plant in
the desired direction (Figure 5h). Employ
the fast speed only where safe to do
so.
10. On the Control Panel turn the
OPERATION switch to PLANT. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.
11. Unplug the umbilical cable and replace
with the original plug (where radio unit
fitted). Store the umbilical hand set unit
in the tool box to keep available for
future use.
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5 - Transport
Page 5 - 19
PLAN VIEW OF THE PLANT
Forward slow or fast, track 1 & 2

Right turn slow, forward track 1
Left turn slow, forward track 2
Reverse slow or fast, track 1 & 2
**Reverse
**Left Turn
**
Right Turn **
Forward
Right turn slow, reverses track 1
Not used
Not used
Safety Button
Rotate clockwise, track 1 forward, track 2
(Horn)
reverse (second step)
Not used
Left turn slow, reverses track 2
Rotate counterclockwise, track 1 reverse,

track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5h Remote Umbilical Control Hand Set
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Page 5 - 20
Blank page
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6 - Set Up
Maxtrak
1000
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Page 6 - 1
6 - Set Up
6.2 Setting Up ....................................................................................................... 6 - 5
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6 - Set Up
Page 6 - 2

PERSONAL


BL-Pegson machine can cause
FALLING HAZARD

AX857-901-8EN-02f 74/390
6 - Set Up
Maxtrak
1000
EN
Page 6 - 3

ENTANGLEMENT
HAZARD

machine.

injury.
SKIN INJECTION
HAZARD

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Maxtrak
1000
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6 - Set Up
Page 6 - 4

followed.
LOCKOUT PROCEDURE
LOCKOUT PROCEDURE
1.
2.
3.
4.
5.
Switch off engine.

lockout.
NEVER work alone.
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6 - Set Up
Maxtrak
1000
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Page 6 - 5
6.2 Setting Up
WARNING
Plant Location Considerations

Prior to setting up your Maxtrak,
consideration should be given to a suitable
layout to prevent oversize material or tramp
metal from entering the plant. In order to
prevent bridging of the crusher no material
above the size recommended by the Terex
Pegson (Section 3) should be fed into the
plant.
WEAR PERSONAL
FALLING HAZARD
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.
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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6 - Set Up
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
AX857-901-8EN-02f 79/390
6 - Set Up
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1000
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Page 6 - 8
Blank Page
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7 - Operating Instructions
Maxtrak
1000
EN
Page 7 - 1
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 ...............................................................................
7 - 62
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7.4.13 Historical Alarms .................................................................................... 7 - 63
Maxtrak
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Page 7 - 2

followed.
LOCKOUT PROCEDURE
LOCKOUT PROCEDURE
1.
2.
3.
4.
5.
Switch off engine.

lockout.
signs (ie. TAG OUT).
NEVER work alone.

injury.
SKIN INJECTION
HAZARD

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Page 7 - 3

PERSONAL


FALLING HAZARD

ENTANGLEMENT
HAZARD

machine.
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Page 7 - 4
7.1.1 Blocked Crusher Procedures
! WARNING !
Unblocking stalled crushers can be
hazardous. Do not undertake without
careful risk assessment.
In order to avoid the Automax cone crusher
becoming blocked the machine is equipped
with an automatic hydraulic release
mechanism to raise the upper frame when
excessively high crushing pressure is
sensed. The upper frame automatically
returns to the original setting when the
foreign object should have been released
through the machine. However, unduly large
uncrushable objects may stall the crusher
and become tightly wedged in the crushing
chamber.
The clearing of blocked crushers should be
given considerable thought prior to
attempting to unblock a crusher. These
procedures should be considered under risk
assessment review for the implementation of
a procedure of safe working practice for this
operation.
There is a document entitled Clearing
Blocked Crushers available from the British
Aggregate Construction Materials Industries
(BACMI) which gives more details about
this and covers in more detail risk
assessment areas. Tramp metal is a serious
problem when it enters a crusher as this can
cause more problems than oversize or hard
stone.
EVERY EFFORT MUST BE MADE TO
REMOVE TRAMP METAL FROM
THE FEED MATERIAL
When metal enters any type of crusher it does

not shear in the same manner as stone and can
become wedged and under considerable
pressure. In order to release the tramp metal it
is necessary to take the pressure off it and at
this time it can be ejected from the machine
with catastrophic consequences
A cone crusher can become bridged when
oversize material is fed into it. In the event of
this happening the feed conveyor should be
stopped immediately. An attempt to clear the
machine can be made by raising the upper
frame by putting the machine into manual and
pressing open. Should this not open
sufficiently to allow the stone to drop through
then it will be necessary to isolate the machine
and remove the rock or break up the stone
manually with a hammer and chisel.
In the event that the crusher should stall
whilst crushing due to an overload or
blockage, the crushing chamber will be full
of stone and the feed conveyor should be
stopped immediately. This should then be
released by raising the upper frame as
before and letting the material fall through.
After the machine has stalled, prior to
resetting, the reason why the machine has
stopped should be investigated. In the case
that a piece of tramp metal is in the machine
extreme care should be taken whilst
releasing it. To avoid the tramp metal being
ejected it may be necessary to fill the
opening to the machine with stone whilst the
pressure is released.
Check the machine for possible damage
(particularly the manganese) before
resuming operations.
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7.1.2 Safe Operation of the plant
WARNING
! WARNING !
WEAR PERSONAL
Refer to Section 7.1 Safety
Before attempting to operate the

Maxtrak plant. DO read, fully
understand and observe the
contents of this manual. Also any
other relevant manual for other
equipment incorporated in the
Maxtrak plant, eg. Engine manual.
LOCKOUT PLANT.
Information for Lockout
Procedure.
FALLING HAZARD.
Terex Pegson Ltd cannot

overemphasize the need to ensure
that all safety aspects are checked
before starting the machinery.
NEVER leave the plant unattended
! NOTICE !
DO NOT crush material with the
engine below its recommended
working speed of 1800 rpm to
ensure all systems will function
correctly.
Make sure that you fully

understand the operating
procedures for the Automax
before attempting to start
! NOTICE !
DO NOT allow a build up of solid
material or dust in any part of the
plant, in particular keep clean the
Automax internal frame arms
(Section 7.3.12) and the air blast oil
cooler (on the lubricating oil tank).
AVOID frequent starting and

stopping of your Automax
unnecessarily as it WILL be
detrimental to the machine.
DO check frequently the stability

of the plant. The chassis SHOULD
NOT have undue vibration during
operation.
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7.1.3 Checks at Initial Start-Up
Inspect the complete plant to check for

fluid leaks, loose connections, damage or
wear, build up of material, etc. etc.
Ensure that the crusher is empty of

material.
WARNING
Visually check the plant and ensure that

all guards and warning signs are in
position and that all equipment and tools
that are hazardous to operation are
removed from the immediate area.
WEAR PERSONAL
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
Check levels of lubricant and hydraulic

oil are satisfactory on :- Automax lubrication tank
- Automax hydraulic reservoir
Check the alignment and tension of the

vee rope drive daily during the initial
days of operation as appropriate
Ensure that the Automax feed is both

satisfactory and not segregating in the
crushing chamber. Note: This applies to
all machine operations subsequent to the
running in period.
Avoid overloading the machine by not

using small discharge settings during the
first few days of operation.
Make sure that the crusher lubrication

system is functioning correctly (Section
9.5) and that no leaks are present.
Check for leaks in the crusher hydraulic

system, both externally and inside the
hydraulic console.
Carry out the daily checks and

inspections on the Automax crusher and
plant (Sections 7.2.9 and 7.3.12)
Ensure that the machine is running

correctly and that the satisfactory feed
is maintained at a constant rate (Section
3.4). Irregular and excessive feed rates
reduce the efficiency of the Automax.
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7.2 Plant Start-Up

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

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

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

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

crusher directly through a hydraulically
activated clutch and a vee rope drive. Within
the engine canopy the engine also powers the
twin hydraulic pumps used to drive the
remainder of the plant. The control system is
24 volt DC and an engine heat exchanger is
used to preheat the Automax crusher
lubricating oil.
The start-up procedure is in 2 stages carried
out in sequence:
Engine (Section 7.2.1).

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

controls can be operated (Section 7.3)
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7.2.1 Engine Start-Up
WARNING
Procedure
WEAR PERSONAL

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

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

Temperature or Sensor Fault
Low Engine Oil Pressure

or Sensor Fault
High Inlet Manifold

Temperature or Sensor Fault
Low Fuel Pressure

or Sensor Fault
High Fuel Temperature

or Sensor Fault
Low Engine Coolant Level

or Sensor Fault
Low Battery Voltage

or Sensor Fault
Engine Derate
High Auxiliary Temperature

or Sensor Fault
High Auxiliary Pressure

or Sensor Fault
Figure 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
GA-1
GA-2
GA-3
GA-4
Boost
IAirT
FuelT
AccrP
AccrT
Fuel
Hrs
Load
Engine Speed
Engine Oil Pressure
Coolant Temperature
Bateery Voltage
Fuel Pressure
Boost Pressure
Inlet Air Temperature
Fuel temperature
Auxiliary Pressure
Auxiliary Temperature
Fuel Rate
Engine Hours
Engine (Percent) Load
U.S. / Metric Units

Either U.S. or Metric (SI) units will be displayed, depending on the position of the U.S. / Metric Switch
(Figure 7c).
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7.2.2 Plant Start Up
WARNING
The engine must be started prior to this

operation (Section 7.2.1). First check that all
5 emergency stop buttons (Section 1.7) have
been disengaged.
WEAR PERSONAL
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.
The panel display screen not only indicates
the status of the starting sequence but also
identifies any fault condition which will halt
the starting procedure. If a fault condition
appears refer to Section 7.2.5.
Take note of the information on the display
screen and operate the controls in the
sequence described in the procedure. When
any green start button is pressed there is a 5
second warning and then the button has to
be pressed a second time to activate the
appropriate item.
! WARNING !
Faults displayed on the electrical
control panel screen should be
investigated and rectified
immediately by suitably qualified
personnel BUT FIRST SHUT
DOWN THE ENGINE AND
IMPLEMENT THE LOCKOUT
PROCEDURE (Section 8.2).
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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Page 7 - 13

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 antivibration mountings and any undue
vibration is likely to be caused by
unsatisfactory support under the tracks
Recitify immediately.
10. Ascertain that the product material is to
the required specification and adjust the
feed material and/or settings if necessary.
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Page 7 - 16
Deutsch
English
Espaol
Franais
Portugus
Diagnostic Display
Screen
Feed Conveyor
Level Sensor Controls
(*optional)
Crusher Level
Sensor Controls
1 - Select
2 - Press
3 - Press
EMERGENCY
STOP
OPERATION
PLANT/TRACK
RADIO REMOTE
CONTROL OFF/ON
FAULT
MUTE
FAULT
RESET
FEED CONVEYOR
CONTROLS
AUTO/MANUAL*
CRUSHER
CONTROLS
AUTO/MANUAL
DISCHARGE
CONVEYOR
START/STOP
CRUSHER
START/STOP
OIL PUMP
START/STOP
FEED CONVEYOR
MANUAL
SPEED CONTROL
FEED CONVEYOR
START/STOP
Figure 7e Electric Panel Controls
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7.2.3 Electric Control Panel Screen Display Data

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

and Automatic Safeguards
The plant operating sequence is as follows:I
Oil Pump.
WARNING
WEAR PERSONAL
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
the fault will be shown on the Diagnostic
Display Screen (Figure 7e) and the
appropriate equipment stopped.
WARNING
WEAR PERSONAL
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
WARNING
When metal is detected on the conveyor belt

the audible alarm will sound (and also the
visible red fault light and diagnostic display
will indicate) and the Feed Conveyor will
stop.
WEAR PERSONAL
Climb up to the top platform and remove the

offending metal from the conveyor and then
press the RESET button on the detector
control box (Figure 7f).
Although the fault will be signalled to the
main panel PLC it is only necessary to reset
at the metal detector panel (Figure 7f).
Restarting the feed conveyor will depend
upon which of the following alternative
operating modes is being used at the time:
FALLING HAZARD
Green POWER ON light
Radio Remote Control OFF

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

Operation
WARNING
To operate the Feed Conveyor remotely, first

switch on the radio hand set and then carry
out the plant starting sequence. (Section
7.2.2).
WEAR PERSONAL
Procedure
2. To start up the handset transmitter first
stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:Feed Conveyor
stop/start button
Ensure the stop button is pulled out.

Depress both of the safety buttons
(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 7e) including starting the Feed
Conveyor.
Figure 7g Feed Conveyor Remote Operation
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
criteria specified and also depending upon the
Automax eccentric throw (long or short) and
the type of concave fitted.
Feed Material
Feed Hopper Level Sensor

(Optional)
Metal Detector
Automax Level Sensor
Automax Crusher
Product Material
Section 9.12 - Action A presetting levels.

Action B the plant operator needs to keep
above the preset low level to ensure a
continuous feed. The sensor works in
conjunction with the Automax Level Sensor
when AUTO selected to control the Feed
Conveyor speed.
Section 9.17 - Action A for sensitivity and
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
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
manganese wear and the unblocking
procedure.
Section 3.4 - Action B Check the product
The graphs & capacities are a guide only and
will vary depending upon the conditions.
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7.2.9 Plant Initial Start Up and

Running In
WARNING
Initial Start-Up
WEAR PERSONAL
! WARNING !
Observe all safety warnings whilst
carrying out inspections and
checks.
LOCKOUT PLANT.
Procedure.
Check levels of oils are satisfactory.

Refer to the lubrication schedules 9.4.4
and 9.4.5 for details.
Refer to engine manual for engine initial

start up instructions
Run the plant empty for a short period of

time and check for abnormal noises,
vibration or excessive heat from shaft
bearings, fluid leaks, etc. including the
feed conveyor gearbox.
FALLING HAZARD.
Each day during the initial days of

operation check the tension of the
conveyor belts on the feed and
discharge conveyors and adjust if
necessary. Refer to Section 9.16.3
Make sure the conveyor belts are

tracking correctly and that the skirt
sealing rubbers are correctly adjusted.
Refer to Section 9.16.2
Check frequently the overall stability of

the plant; re-check the level of the plant
and move to level position if necessary.
Regularly check drive belts (crusher and

hydraulic pumps) to ensure correct
tension, particularly during the initial 2
weeks of use. Refer to Section 9.15.

vee belt drives daily during the initial
days of operation. Refer to Section 915
Actions During Running-In Period
! NOTICE !
Checks on the Maxtrak plant are
crucial during the first week of
crushing operation.
The following section should be
read and understood prior to
starting the plant. If there are any
doubts, contact Terex Pegson Ltd.
Service Department.
Plant
All control systems should be checked

for full function.
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Page 7 - 24
Avoid overloading the crusher;
Check for any leaks of lubricants, fuel,

water or hydraulic fluid and rectify
immediately.
Check for any overheating of running

parts.
Make sure that the crusher lubrication

system is functioning correctly (fault
warnings will show on the diagnostic
panel) and that no leaks are present.
Check for leaks in the crusher hydraulic

system, both externally and inside the
hydraulic console.
! WARNING !
Shut down the plant if this occurs
and investigate the reason. If
necessary, contact Terex Pegsons
Service Department for advice to
avoid the possibility of danger or
damage.
Crusher

days of operation.


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
! WARNING !
It is imperative that the operator
carries out regular and diligent
checks before operating the plant
especially with operational safety
in mind including (but not limited
to) those listed below.
Additionally, the operator should
always consider what particular
safety hazards could occur at
specific operating sites and take
steps to eliminate them before
commencing work.
WEAR PERSONAL
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
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

The Automax crusher is a high quality cone
crusher featuring:
Optimum Performance - Advanced

crusher geometry. Excellent product
shape through attrition crushing. High
output capability. Maximum production
of high quality material.
Low Cost Operation - High capacity

with energy efficiency. Low wear costs.
Exceptional reliability.
Ease of Maintenance - Accessible

external hydraulics. Simple assembly
and dismantling. Quick manganese
changes.
To assist in understanding the Automax

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

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

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

display are additional read out facilities
including crusher motor hours run and
number of tramp overload situations (Section
7.4.3)
For guidance on when to change the

manganese mantle and concave liners refer
to Section 9.7.1.
Additionally, a separate subsidiary hydraulic

circuit is employed to apply pressure to the
wedge ring and the requirements for this
system are also covered later in this manual
(Section 9.8).
! NOTICE !
It is most important to change both
the liners together when fitting
new replacements.
At the same time as changing the mantle and
concave, take the opportunity of replacing
the frame arm and countershaft protection
liners.
In addition to these normal machine control

functions the system also includes a separate
audible alarm and hydraulic system
malfunction messages which appear on the
display screen (Sections 7.4.10 to 13)
Service schedules in this manual assume

reasonable operating conditions apply. Refer
tp Terex Pegson Limiteds technical
department for advice if the operating
conditions are other than normal.
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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DUMPY
Figure 7h Automax Components
CRUSHING CHAMBER
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.
GAP
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7.3.1 Glossary of Automax Parts
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7.3.2 Glossary of Automax Terms

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

plant (Section 7.1.3).
Check that all 5 Emergency Stops on the

plant are pulled out (Figure 1a).
Check that the conveyors and Automax

crushing chamber are empty of material.
Make sure that you fully understand the

operating procedures for the Automax
before attempting to start.
Numeric Keypad
OPEN Button
Pressure
Gauge
Display
AUTO/MANUAL
Switch
TRAMP O/L TEST

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

Setting and Calibration
WARNING
FOR THIS OPERATION THE

AUTOMAX MUST NOT BE RUNNING
WEAR PERSONAL
Referring to the separate Automax

Control Panel (Section 7.4) for
detailed instructions, action as
follows;-
Procedure
7. Press the F4 key to Zero the display and

then press Escape.

8. Scroll to the Set Gap display screen,

press Enter and then press Enter again.

in PLANT and the RADIO REMOTE
CONTROL at ON (Figure 7b). DO
NOT press any of the start buttons.
9. Key in the required closed side setting

(mm) using the number keys, press the
Enter and then press Escape.
4. On the Automax hydraulic panel (Figure

7i) switch to MANUAL and depress the
OPEN button to raise the Upper Frame
approximately 25-38mm (1 - 1).
Look into the Automax crushing
chamber to check there is no stone
lodged in the chamber.
10. Scroll to the Current Gap display

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

AUTOMAX MUST NOT BE RUNNING
WEAR PERSONAL

follows;
Procedure
1. Observe all safety warnings
6. Scroll to the Set Zero display screen and

then press Enter.

7. Press the F3 key to Zero the display

screen and then press Escape.

8. Scroll to the Current Gap

screen.
4. On the Automax hydraulic panel (Figure

OPEN button to raise the Upper Frame
approximately 25 - 30mm (1 - 1).
Look into the Automax crushing
chamber to check there is no stone
lodged in the chamber.
5. Now depress the CLOSE button until
the manganese crushing members
(mantle and concave) touch. This is
indicated by a sudden rise in pressure
shown on the gauge near the panel
(Figure 7i).
display
9. Depress the OPEN button; hold until the

Current Gap display shows the gap to
be just above the Set Gap setting then
switch to AUTO. The machine will
automatically come down to the required
setting.
Note: After calibration the amount of
manganese worn off the crushing
members is displayed by scrolling to the
Mang Wear display screen.
! NOTICE !
The interval between future
calibrations is determined by
machine usage and estimated
wear of the manganese.
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7.3.5 Guidance for Changing the

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

always fit both a new mantle and a new
concave at the same time.
! NOTICE !
Always fit a new manganese
mantle and concave as a pair. It is
detrimental to the operation of the
machine to do otherwise.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 45-50mm (1 - 2)
of wear on the liners, as a pair.
Inspect the liners on a daily basis, for

possible tramp metal damage and also any
evidence of an uneven wear pattern
developing.
The manganese liners must be changed
when the hydraulic rams can be fully closed.
The pin centre to pin centre distance (Figure
7j) when the rams are fully closed is 680mm
(26).
680 mm (26) minimum
Take note of the wear shown on the

display (Section 7.4.3).
Figure 7j Minimum Ram Dimension
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7.3.6 Automax Initial Start Up
WARNING
Procedure
WEAR PERSONAL

DANGER

SKIN INJECTION HAZARD

Information for relevant warning
4. Carry out the sequential start procedure

(Section 7.2.2) EXCEPT DO NOT
START THE FEEDER.
Note: The Automax safety interlocks
and protection devices are checked with
the fault display on the Electrical Control
Panel.
5. Check that the overall operation of the
lubrication system is satisfactory.
6. Run the Automax empty for a short
period and check the machine for
unusual noises, vibration, excessive heat,
leaks of lubricating oil.
7. Check the hydraulic system for leaks
and that the discharge setting is being
maintained.
8. Check the travel on the Automax Upper

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

days of operation.

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

3.4) is maintained at a constant rate to
give a choke feed (Section 7.3.2
Glossary). Irregular and excessive feed
rates reduce the efficiency of the
Automax. Ensure that the feed is not
segregated in the crushing chamber.
WARNING
WEAR PERSONAL
FALLING HAZARD
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

follows:-
Procedure
speed at 1200rpm.
START THE FEEDER.
8. Scroll to the Current Gap display

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

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

START THE FEEDER.
7i) switch to MANUAL.
6. Depress the OPEN button to raise the
Upper Frame to the maximum extent.
On release of the button the Upper
Frame is retained at this position.
7. On re-selection of AUTO the control
automatically resets the discharge setting
to that previously specified.
Procedure
speed at 1200rpm.
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7.3.10 Automax Automatic

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

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

Pressure
WARNING
AUTOMAX NOT RUNNING
WEAR PERSONAL
The pressure on the wedge ring is

automatically controlled by the Dumpy Jack
hydraulic circuit. However, as the adjustment
of the wedge ring is critical for good
performance of the Automax crusher it is
recommended that this should be checked
daily. The pressure gauge near the panel
(Figure 7h) gives an accurate indication of
whether the Wedge Ring assembly is
functioning correctly.
! NOTICE !
The Automax must not be allowed
to operate with regular dumping or
bouncing of the Upper Frame or
damage may result. Possible
causes could be crushing at too
small a setting, out of round
manganese (Section 9.9) or poor
Wedge Ring adjustment.

OPEN button lifting the Upper Frame
approximately 19mm
above the set point.
5. Switch back to AUTO and observe the
pressure reading on the panel pressure
gauge (Figure 7i). The pressure should
be in the range 55 - 82 BAR (800 - 1200
psi).
6. Whilst the Upper Frame is moving check
for smooth movement with no sticking at
the start or whilst travelling.
Procedure
in PLANT and the RADIO REMOTE
7. If the pressure reading is above or below

the range indicated above or the action is
not smooth, remedial action is required
(Section 9.8).
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7.3.12 Daily Automax Checks
WARNING
! NOTICE !
WEAR PERSONAL
Daily attention should always be a

matter of routine to ensure
maximum efficiency of this vital
element of the plant.
DANGER
Before starting the Automax

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

After starting the lube oil pump

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

Set the discharge setting
Listen for any abnormal noise from the
crusher.
Check that no bolts have come loose.
During crushing
Listen for any abnormal noise from the
crusher.
Check oil pressure at normal running
temperature.
Check no leaks in the lubrication system.
Inspect hydraulic system piping, cylinders,
etc. for leaks which could cause an
alteration in
the setting.
Note the crushing pressure.
Figure 7k Frame Arm 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
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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PERSONAL


FALLING HAZARD

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ENTANGLEMENT
HAZARD

machine.

injury.
SKIN INJECTION
HAZARD

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followed.
LOCKOUT PROCEDURE
LOCKOUT PROCEDURE
1.
2.
3.
4.
5.
Switch off engine.

lockout.
NEVER work alone.
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8.2 Closing Down the Plant

Procedure
WARNING
1. Observe all safety warning
WEAR PERSONAL
2. On the Electrical Control Panel (Figure

8a), press the red Feed Conveyor stop
button to stop the feed and wait until
the crusher and both conveyor belts
are empty of material before the
next step.
LOCKOUT MACHINE.
Information for Lockout Procedure.
3. Press the red Crusher stop button to stop

the crusher and wait until the crusher
cone head has stopped spinning
before the next step.
! NOTICE !
WARNING. The reason for the
delay is so that the oil pump
continues to circulate oil to the
crusher bearings during the
Automax run down time. Failure to
obey this instruction will result in
reduced bearing life.
THE PLANT SHOULD NOT BE
SHUT DOWN AT THE END OF A
SHIFT BY ONLY SWITCHING OFF
THE ENGINE OR BY PRESSING
AN EMERGENCY STOP BUTTON.
4. Press the remaining red Discharge
Conveyor and Oil Pump stop buttons to
stop these items.
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5. Using the 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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Feed Conveyor
Level Sensor Controls
(*optional)
Diagnostic Display
Screen
Crusher Level
Sensor Controls
EMERGENCY
STOP
OPERATION
PLANT/TRACK
RADIO REMOTE
CONTROL OFF/ON
FAULT
MUTE
FAULT
RESET
FEED CONVEYOR
CONTROLS
AUTO/MANUAL*
CRUSHER
CONTROLS
AUTO/MANUAL
DISCHARGE
CONVEYOR
START/STOP
OIL PUMP
START/STOP
CRUSHER
START/STOP
FEED CONVEYOR
MANUAL
SPEED CONTROL
FEED CONVEYOR
START/STOP
Figure 8a Electric Panel Controls
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Diagnostic Lamp
Tachometer
Diagnostic Display
US/Metric Switch
Scroll Switch
Fuel Gauge
Speed Control
Ignition Key
Figure 8b Caterpillar Engine Control Panel
Figure 8c Engine Isolation Switch
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8.3 Emergency Stopping of

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

the Emergency Stop buttons.
Note:- The plant should not be restarted
if the crusher is full of material (Refer to
Section 8.3.2)
When the plant has been stopped using
an Emergency Stop button, the 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 - Shut Off
Page 8 - 10
8.3.2 Restarting the Plant
WARNING
! WARNING !
WEAR PERSONAL
warning.
When an emergency stop has

been initiated, DO NOT attempt to
restart the engine until it is safe to
do so.
! NOTICE !
8.3.3 Testing Buttons
When restarting the plant after the

use of an Emergency Stop button
it is essential to ensure that the
Automax crushing chamber is
empty of material.
Procedure
! WARNING !
Daily, before commencing
crushing operations, test each
emergency stop button is
operative.
Procedure

2. Follow the safe start-up procedure
(section 7.2)
3. Start the engine (section 7.2.1)
4. Manually raise and lower the Automax
Upper Frame by following the procedure
in Section 7.3.9.
5. Visually check that material in the
crushing chamber has been discharged
and that the chamber is empty.
Note: In the event of material failing to
clear the crushing chamber, repeat the
operation above or follow the Blocked
Crusher Procedure (Section 7.1.1) as
necessary.

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

Plant Start-Up Procedure (Section
7.2.2).
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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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Page 9 - 2
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 Operators Control Points ....................................................................... 9 - 96
9.14.3 Protection Devices ................................................................................. 9 - 97
9.15 Plant - Crusher and Hydraulic Pump Drive Belts ..................................... 9 - 98
9.15.1 Trouble Shooting - Drive Belts ................................................................ 9 - 99
9.15.2 Replacement and Adjustment of Crusher Drive Belts ............................ 9 - 100
9.15.3 Replacement and Adjustment of Hydraulic Pump Drive Belts ................ 9 - 103
9.15.4 Method of Drive Belt Tensioning ........................................................... 9 - 106
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Page 9 - 3
9.16 Plant - Conveyor Belts ............................................................................. 9 - 108

9.16.1 General Description ............................................................................. 9 - 108
9.16.2 Training of Belts ................................................................................... 9 - 109
9.16.3 Conveyor Belt Tensioning ..................................................................... 9 - 111
9.16.4 Maintenance of Conveyor(s) ................................................................. 9 - 112
9.16.5 Cleaning the Conveyor Belts ................................................................ 9 - 115
9.17 Metal Detector ........................................................................................... 9 - 117
9.17.1 Metal Detector Controls........................................................................ 9 - 118
9.17.2 Metal Detector Indictor Lights (Figure 9am & 9an) ................................ 9 - 120
9.18 Plant - Dust Suppression ......................................................................... 9 - 122
9.19 Plant - Diesel Engine ................................................................................ 9 - 124
9.19.1 Engine - ELC Coolant .......................................................................... 9 - 125
9.19.2 Hydraulic Engine Clutch........................................................................ 9 - 126
9.19.3 Check Fuel Level ................................................................................. 9 - 127
9.19.4 Top Up Fuel Level ................................................................................ 9 - 128
9.20 Plant - Vehicle Tracks ............................................................................... 9 - 130
9.21.1 Measuring Track Tension ...................................................................... 9 - 130
9.20.2 Adjusting Track Tension ........................................................................ 9 - 132
9.20.3 Track Maintenance ............................................................................... 9 - 135
9.20.4 Drive Oil Filling and Draining ................................................................ 9 - 136
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Page 9 - 4

PERSONAL


followed.
LOCKOUT PROCEDURE
LOCKOUT PROCEDURE
1.
2.
3.
4.
5.
6.
Switch off engine.

lockout.
NEVER work alone.
Turn the Isolation Switch to O when the
plant is not being used (especially while
plant is being transported).
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Page 9 - 5

Terex-Pegson machine can cause
FALLING HAZARD

whilst in operation.
ALWAYS use a suitable lifting platform when
reaching any points 2m (6- 6) or more above
ground level.

injury.
SKIN INJECTION
HAZARD

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Page 9 - 6

ENTANGLEMENT
HAZARD

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

Refer to Sections 7.1.3, 7.2.8 and 7.3.6 and 7.3.7.
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9.1.1 Engine Start-Up - Maintenance

Procedure
2. Check that all Emergency Stop push
buttons are pulled out (Figure 1a)
otherwise the engine cannot start.
WARNING
WEAR PERSONAL
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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Page 9 - 9
OPERATION and RADIO REMOTE CONTROL

Switches on the Electrical Control Panel
Diagnostic Lamp
Tachometer
Diagnostic Display
Scroll Switch
US/Metric Switch
Speed Control
Fuel Gauge
Ignition Key
Engine Control Panel
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Page 9 - 10
9.2 Weights of Automax Crusher Components

Weights of the Automax crusher components, these should be consulted when arranging suitable lifting
equipment. Refer to Terex Pegsons Technical Department for any other weights of individual items or
assemblies if not listed.
Component Weights (approximate)
Complete Automax Crusher
Cone Head Assembly (with bearings, mantle etc.)
Eccentric Assembly (with bearings, ring gear etc.)
Upper Frame Assembly (upperframe with concave)
Countershaft Assembly
Concave
Mantle
kgs
11,226
1,322
1,042
2,875
454
435
330
(lbs)
( 24,700 )
( 2,900 )
( 2,300 )
( 6,300 )
( 1,000 )
( 960 )
( 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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Page 9 - 11
9.3 General Information

When performing maintenance, always
observe rules provided in the safety section.
Breakdown caused by insufficient or
improper maintenance will cause high repair
costs and long term standstill. Therefore,
regular maintenance is imperative.
The plant has been designed to facilitate

easy routine maintenance, but where
necessary to remove any guards make sure
that they are replaced before the machine is
restarted.
Refer to the Spare Parts illustrations
(Section 10) to identify the machinery
components mentioned in the maintenance
procedures.
In addition to several other factors, the

reliability and life of the Maxtrak depends on
regular and proper maintenance.
The following section contains maintenance
instructions as well as maintenance
schedules for normal operating conditions.
! NOTICE !
When the Maxtrak plant is
operated in extreme climatic
conditions e.g. below -15C or
above 30C (below 5F or above
86F) or in very dusty conditions
for a longer period of time, the
maintenance schedules will
change.
Ask your local Terex Pegson
dealer or Terex Pegson Technical
Department for advice.
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Page 9 - 12
! WARNING !
WARNING
PRACTICE SAFE MAINTENANCE

Understand service procedures
before doing any work. Keep the
area clean and dry.
WEAR PERSONAL
Never lubricate, clean, service or

adjust machine whilst it is moving.
LOCKOUT PLANT.
Procedure.
Keep hands, feet and clothing

clear of power driven parts and inrunning nip points.
FALLING HAZARD.
Disengage all the power and

operate controls to relieve
pressure. Stop the engine.
Implement lockout procedure.
Allow machinery to cool.
Securely support any machine
elements that must be raised for
service work.
Keep all parts in good condition
and properly installed. Attend to
damage immediately. Replace
worn or broken parts.
Remove any build up of grease, oil
or debris.
Disconnect battery ground cable () before making adjustments on
electrical systems or welding on
machine.
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Page 9 - 13
9.4 Lubricants, Oils, Coolant,

etc.
WARNING
WEAR PERSONAL
9.4.1 Service Attention Points

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

are as follows:-
FALLING HAZARD.
Automax Crusher oil lubrication tank sited

within the plant chassis (Figure 9b).
Automax Crusher Upper Frame grease

nipples x 12. .
Diesel Engine oil, coolant, (See separate

engine manual). Also the fuel (Figure 9ar).
Track unit gearbox x 2 oil levels (Figures

9au & 9av).
Diesel Engine oil lubricated HFO clutch

bearing (Section 9.19.2)
Plant hydraulic oil reservoir sited on the

forward engine platform .
Periodically lubricate hinges, hydraulic

cylinder pivot pins and similar linkage
points with grease or oil as appropriate.
Feed Conveyor gearbox within the head

drum having oil lubrication (Figure 9ak).
Conveyor head and tailshaft bearing

grease nipples located:-
! NOTICE !
Failure to carry out scheduled
maintenance or exercise due care
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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Page 9 - 14
9.4.2 Regular Servicing
WARNING
The Lubrication and Servicing Schedule

(Sections 9.4.4 and 9.4.5) lists, in addition to
the lubrication points, the attention required
to the Automax and Plant hydraulic systems.
WEAR PERSONAL
Particular attention should be paid to institute

a regime of strict adherence from the very
start of operations for all aspects of routine
servicing and good housekeeping in order
to keep the your Maxtrak in prime running
order.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
Keep a accurate record of maintenance

work carried out and also log the engine
hours operated from the service meter
mounted on the engine.
Maintenance records can also be used to
show compliance with the required
maintenance practices and intervals as
detailed in this section of the manual.
Make sure that frequent checks are made
for wear to the manganese mantle and
concave (Section 7.3.5) and other wearing
surfaces so that replacement can be made
before any damage to the core of the
Automax is sustained.
! NOTICE !
NOTE: Do not overlook the service
requirements of the plant diesel
engine which are detailed in the
separate engine manufacturers
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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Page 9 - 15
9.4.3 Daily, Weekly and Monthly

Checks
WARNING
! WARNING !
WEAR PERSONAL
warning.
It is imperative that the operator

carries out regular and diligent
checks before operating the plant
especially with operational safety
in mind including (but not limited
to) those listed below.
LOCKOUT PLANT.
Procedure.
Additionally, the operator should

always consider what particular
safety hazards could occur at
specific operating sites and take
steps to eliminate them before
commencing work.
Daily Checks
1. Check that all guarding is complete and
properly secured prior to start up. Also
that all warning signs (Section 1.8) are
present and readable.
2. Check that all the plant emergency stop
buttons are operative (Section 1.7).
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
7.2.5).
5. Carry out the Automax and Plant daily
Lubrication and Servicing Schedule
(Sections 9.4.4 & 9.4.5).
FALLING HAZARD.
warning.
6. Look for loose fixings and rectify. Check

the security of nuts and bolts on the
Automax. Verify there are no leaks of
lubricating/hydraulic oil or water.
7. Fully raise and lower the Automax Upper
Frame several times manually (Section
7.3.9) to help distribute the grease on the
wedge ring for smooth operation.
8. Check the Automax Wedge Pressure is
satisfactory (Section 7.3.11)
9. Ensure that the Automax internal frame
arms are free of foreign bodies or material
build up (Section 7.3.12).
10. Re-calibrate the manganese wear on the
Automax (Section 7.3.4) to compensate
for the previous days wear.
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Page 9 - 16
Weekly Checks
WARNING
1. Perform all checks on the daily check

list.
WEAR PERSONAL
warning.
2. Carry out the weekly Lubrication and

Servicing Schedule. (Sections 9.4.4 and
9.4.5).
LOCKOUT PLANT.
Procedure.
3. Note the Automax manganese wear.

Arrange renewal when necessary
(Section 7.3.4)
FALLING HAZARD.
4. Check the area in and around the

Automax for buildup of material; clean
out as necessary.
5. Ensure all hydraulic hoses and joints are
free from leaks.
6. Check drive belts for damage, wear and
fraying.
7. Clean away dust, dirt and grit from
maintenance platforms and any moving
parts.
8. Check conveyor belts for damage and
fraying.
Monthly/6 Monthly/Annual Checks
1. Perform all checks on the daily and
weekly check list
3. Check the oil level in the Feed Conveyor

drive gearbox (Section 9.16.4).
4. Visually examine the Automax for wear
and damage at regular intervals. Renew
as necessary.
5. Inspect crusher drive belts for signs of
wear, renew as necessary (Section
9.15).
6. Check all drive belts are at the correct
tension (Section 9.15).
2. Lubricate and Service to the monthly

requirements also attending to the longer
interval requirements as necessary
(Sections 9.4.4 and 9.4.5).
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See chart
9.4.6
Automax Oil Lubrication

Suction Filter
(parts list item 2)
Automax Grease Nipples

(located around the machine
upper frame)
Automax Hydraulic Pressure

Filters (parts list items 1 & 2)
16/07/03
See chart
9.4.6

Tank
(located inside the plant
chassis)

Pressure Filters
(parts list item 10)
Lubricant
or
Fluid
Description
12
223 litres
(59 US galls)
Quantity
Sight glass
upper mark
Level
Check
wedge
pressure
Check
condition
Check
level
Daily
Weekly
Change annually
(SEE SECTION 9.13.9)
Add 25-50 grams of grease to each

nipple if the travel of the upper frame
is not smooth
(SEE SECTION 9.8)
Replace when changing oil

(SEE SECTION 9.5.6)
First change after 100 working hours

Thereafter change after every 500
hours
(SEE SECTION 9.5.6 & 9.5.7)
First change after 500 working hours

Thereafter change after every 1000
hours
(SEE SECTIONS 9.5.4 & 9.5.5)
Monthly (165 hrs),

6 Monthly (1000 hrs),
Annually (2000 hrs)
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
1000 Automax Crusher Schedule
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9.4.4 Automax Crusher Lubrication and Servicing Schedule
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~
See chart
9.4.6
See chart
9.4.6
Plant Hydraulic In-Line Filters x

2 (located one each side of
engine inside housing)
Plant Track Gearboxes x 2

(located each side of plant)
Engine Clutch (accessed at

rear of engine housing)
16/07/03
Check
level
Level stick
oil wet
(approx.)
Approx. 200
cc.
Fill to level
plug
5 litres
(1.3 US galls)
+/- 10%
40mm (1)
below upper
sight glass
mark
Daily
Fill to centre
line of unit
Level
360 litres
(96 US galls)
1.7 litres
(0.45 US galls)
Quantity
Check
condition
Check
condition
Check
condition
Check
level
Weekly
Check oil level prior to daily start up.

Change oil every 1000 working hours.
First oil change after 100 working

hours. Thereafter every 1000 hours or
at least annually. Check level monthly.
Change filters every 1000 hours or

sooner if the tell-tale indicator
shows RED
(SEE SECTIONS 9.13.5 TO 9.13.8)
Change oil every 2000 hours

Re-grease every 2 weeks

(SEE SECTION 9.4.1)
First oil change after 50-100 working

hours. Thereafter change after every
2000 hours. Check level monthly.
Monthly (165 hrs),

6 Monthly (1000 hrs),
Annually (2000 hrs)
Refer to the separate Engine Operation & Maintenance Manual
Plant Hydraulic Return Filter

(located on top of hydraulic
reservoir)
Caterpillar Engine
(fuel, oil, coolant)
Plant Hydraulic Suction Filter

(located at bottom of hydraulic
reservoir)
Plant Conveyors Grease

Nipples (4 x located on head &
tail shaft bearings)
See chart
9.4.6
See chart
9.4.6
Feed Conveyor Oil Lubricated

Gearbox (located in head drum)
Plant Hydraulic System

Reservoir (located on front
engine platform)
Lubricant
or
Fluid
Description
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
1000 Maxtrak Plant Schedule
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Page 9 - 18
9.4.5 Plant Lubrication and Servicing Schedule
G
F
Automax/Plant
Hydraulic System
> 30 C (86 F)
< 30 C (86 F)
Tellus 69
Tellus 46
Omala 220
Omala 150
Shell
Nuto H68
Nuto H46
Spartan EP220
Spartan EP150
Esso
Gulf
Hydrasil 68
Hydrasil 46
EP LUB HD220
EP LUB HD150
Energol HLP-HM68
Energol HLP-HM46
AX857-901-8EN-02f 175/390
Gulfcrown EP2
Energreas LS-EP2
9.4.6 Recommended Oil/Grease Types
Note:
<4C (39 F) is defined as a daily temperature consistently below 4C (39 F), >30C (86 F) is defined as a daily temperature consistently above 30C (86 F)
16/07/03
SAE 80w/90 Gear Oil
Beacon EP2
Plant Tracks
Gearbox Oil
Alvania EP2
General Multi-Purpose Grease (Grade D grease is suitable)
Mobilux EP2
Plant Tracks
Tension
Regulus A2EP
Gear oil with viscosity VG150 with EP additives. Oil temperature always to be below 90 C
DO NOT MIX OILS OF DIFFERENT MAKET OR TYPE
Plant Conveyor
Shaft Bearings
BP
Energol GR-XP220
Energol GR-XP150
Plant Feed Conveyor

Drive Gearbox
Chemodex MOLY - BENTONE MP Standard Grade
Mobil DTE26
Mobil DTE25
Mobilgear 630
Mobilgear 629
Mobile
SAE 30 SAE 40 Oil

ISO VG 100 ISO VG 150
(DO NOT USE SYNTHETIC OIL)
Centraulic PWLC
Centraulic PWLB
Centlube F76
Centlube E76
Century
Engine HFO Clutch
B
A
Automax Oil
Lubrication System
> 4 C (39 F)
< 4 C (39 F)
Automax Upper
Frame Grease
Nipples
Grade
Equipment
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9 - Maintenance
Page 9 - 20
Lubrication Specifications
Oil Specification
Grade A
Grade B
Grade C
Flashpoint: Minimum C (F)
199 (390)
204 (399)
216 (421)
Pour Point C (F)
-18 (0.4)
-18 (-0.4)
-18 (-0.4)
Kinematic Viscosity at 40C, mm/s

(104F, in/s)
150
(0.232)
220
(0.341)
460
(0.713)
Kinematic Viscosity at 100C, mm/s

(212F, in/s)
15.4
(0.0238)
20.1
(0.0312)
32.9
(0.051)
Viscosity Index
105+
105+
105+
Timken OK lb. Minimum
50
50
50
Extreme Pressure Agent
Yes
Yes
Yes
R & O Agent
Yes
Yes
Yes
Anti Foaming Agent
Yes
Yes
Yes
Copper Strip Corrosion Test Pass
Yes
Yes
Yes
ISO VG
150
220
460
Grease Specification
Grade D
NGLI Grade Number
Unworked Penetration at 25C (77F)
280
Worked Penetration at 25C (77F)
285
Drop Point C (F)
185 (365)
ASTM Corrosion Test Pass (14 days)
Yes
Wheel Bearing Test Pass at 135C (275F)
Yes
Timken Test lbs. Pass
40/50
Extreme Pressure Agent
Yes
Hydraulic Oil Specification
Grade E
Grade F
Grade G
ISO VG No
32
46
68
Kinematic Viscosity at 40C mm/s

(104F, in/s)
32
(0.049)
46
(0.0713)
68
(0.105)
Kinematic Viscosity at 100C mm/s

(212F, in/s)
5.5
(0.085)
6.5
(0.010)
8.5
(0.013)
Viscosity Index
95+
95+
95+
Rust Inhibitor
Yes
Yes
Yes
Defoament
Yes
Yes
Yes
Anti Scuff
Yes
Yes
Yes
Figure 9a Lubrication Specifications
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WEDGE RING LUBRICANT FOR CONE CRUSHERS

The lubricant grease for BL-Pegson Cone Crushers applied to the grease nipples situated around the upper
frame is recommended to be as follows:MOLY - BENTONE M.P. GREASE
This is a special non-melt, long life, multi-purpose grease containing molybdenum disulphide.
CHEMODEX MOLY-BENTONE M.P. Greases are prepared from specially selected oils solidified with a nonsoap gellant which imparts infusible or non-melt characteristics. The gellant is known as Bentone and is
produced by reacting specially selected and refined bentonite with a cationic fatty derivative.
The gellant has a micro-lamellar structure which also applies to micronised molybdenum disulphide, so that
these two components have a synergistic effect in the compounded grease, giving enhanced stability as well as
lubricating value.
Chemodex MOLY-BENTONE M.P. GREASES are infusible and have no melting point or drop point
show minimum change of consistency with variations in temperature
are resistant to mechanical working or shearing in the bearing
minimise wear and friction
give greater margins of safety in shock and overload conditions
are resistant to acids and alkalis and to aqueous solutions of most chemicals
are neutral in reaction and suitable for use with all metals and alloys
are excellent lubricants for bearings made from plastic materials
Standard Grade
Gellant Base
Consistency N.L.G.I
Penetration at 25 deg. C
Temperature Range
Drop Point
Water Resistance
Bentone
No: 3 Medium/Heavy
220/250
-20 deg. C to 200 C
None
Complete
The Standard Grade is recommended for large. slow speed bearings for slides and splines and to resist shockload conditions..
The molybdenum disulphide content gives greater margin of safety, especially where intervals between
lubrication are liable to be prolonged, where there may be occasional overload operations and where
temperatures are high.
Chemodex MOLY-BENTONE M.P. GREASES are recommended for the lubrication and protection of - stone
and ore crushers, conveyor systems, cranes, winches, printing machines, rolling mills and foundry equipment,
mechanical stokers, glass works equipment, pumps of all types and marine equipment in general, etc.
Chemodex MOLY-BENTONE M.P. GREASES are available in 450 gm and 3 kilo tins, and 12, 25 and 50 kilo
kegs.
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9.5 Automax Crusher General
WARNING
WEAR PERSONAL
warning.
9.5.1 Automax Lubrication

Overview
The Automax cone crusher is lubricated by
oil circulated by hydraulically driven oil pump
mounted on the oil tank sited within the plant
chassis (Figure 9b) with access being gained
from the rear of the chassis.
Filtered oil from the tank is pumped under
pressure through external pipework to inlet
points on the Automax at the base of the
mainshaft from where the oil is distributed
internally to the cone head and eccentric
roller bearings whilst a second inlet pipe
feeds oil to the countershaft assembly
bearings.
Oil from the bearings lubricates the drive
gear and pinion on its gravity return to the
oil tank to be filtered and re-circulated.
After the oil pump has been started the
control system delays the crusher start for 5
minutes to allow a good circulation of oil
within the Automax and occurs every time
the oil pump is started. To prolong the life of
the bearings it is also good practice when
stopping the crusher to allow the crusher
cone head to stop spinning before switching
off the oil pump (Section 8.2).
LOCKOUT PLANT.
A engine mounted heat exchanger is

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

Operating Procedure
Once the lubrication pump has been started
it does not need to be controlled during the
running of the machine and is monitored by
the safety electrical interlock safeguards
incorporated into the control systems with
faults indicated on the Electrical Control
Panel Display Screen (Section 7.2.3 &
7.2.5).
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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
Function
The primary functions of the lubrication
system are:- to prevent damage due to metal on metal
contact within the bearings.
- to dissipate heat generated by the bearings
during operation, so acting as a coolant.
The bearings can be seriously damaged if
any one of the following characteristics are
inadequate:
Viscosity (grade)
Quantity (flow)
Cleanliness
Toughness of the lubricant film
(Timken load rating)
Operation
Oil is supplied the Automax bearings via a
hydraulically driven pump. This oil is filtered
clean and pumped under pressure to the
main bearings (eccentric and cone head)
and via a separate line to the countershaft
bearings. It is then piped back to the tank
under gravity.
An automatic alarm is fitted to the lubrication
tank which will sound if there is insufficient
pressure or flow to the machine. It is difficult
to give a working pressure as this varies
significantly under different working conditions
so the alarm should be used as an indication of
a fault arising.
! NOTICE !
Operating the Automax without the
lubrication system safety devices
being fully operative will invalidate
any warranty in force for the time
being.
Cold Weather Start-up
An engine heat exchanger heats the
lubricating oil prior to the Automax operating.
This ensures efficient circulation of the oil
before the crushing begins. The system is
automatically controlled by a thermostat.
During cold weather conditions be aware that
the commencement of crushing may be
delayed whilst the oil reaches a satisfactory
temperature
Air Blast System
This enables the hot oil to be cooled as is
circulated through the system and into the
machine. This keeps the oil at an optimum
working temperature. The system is
automatically controlled by a thermostat.
Terex Pegson strongly advise against
running the Automax empty after initial
start-up in cold weather. Even hot oil can be
chilled when entering a cold machine and its
reluctance to return to the tank may result in
a slight leak from the machine via the cone
head/seal ring and/or mainframe/seal ring.
Ideally, once the crusher is started rock
should be put through it as soon as possible.
BUT THE AUTOMAX MUST NEVER
BE STARTED WITH ROCK PRESENT
IN THE CRUSHING CHAMBER.
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Air Blast Bypass Valve

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

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

The first oil change of the lubricating oil
should occur after 500 hours operation.
Subsequent oil changes should occurs
every 1000 hours, ie once every 5 months
working 50 hours per week,
Alternatively, Terex Pegson strongly
recommend that the oil is tested regularly at
monthly intervals by a suitable laboratory and
changed when advised to do so. This will
provide optimum use of oil as replacement is
only made when proved necessary. This will
also give an indication on the machines
condition. This could indicate that the change
should be made away from the 1000 hours
guideline and will be because of usage and
environment effects on the oil life.
There are several indications that it is time to
change the oil in the lubrication system:-
Total Acid Number (TAN)

This is the measure of how much the oil has
degraded. The TAN increases as the oil
degrades. The oil should be changed before
it increase 100% above the original value.
Viscosity Number
An engineering/lubrication laboratory is able
to identify the viscosity number of an oil
which can then be compared to the original
value of new oil. If it exceeds a 20%
increase at an identical test temperature it is
time to change the oil.
Reduction in Additives
It is recommended that the oil is changed
when the level of additives is reduced by
50% compared to new oil values.
It is suggested that any of the above
tests could be carried out by a
laboratory to establish the optimum
time for oil changes. Consultation with
your local facility is advisable.
Concentrations of Wear Metal Elements

Increases in certain elements should not
exceed the suggested upper limits in parts per
million (PPM) as table below.
WEAR METAL
Chrome
Copper
Iron
Lead
Nickel
Silicon (dirt)
TYPICAL
CONCENTRATION
(PPM)
0-5
0 -15
30 - 50
0 - 20
0-5
10 - 30
UPPER LIMIT
(PPM)
10
50
150
50
10
75
Figure 9? Wear Metal Elements
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9.5.5 Recommended Automax Oil

The recommended oil is good quality:Summer Grade Winter Grade -
EP220
EP150
Refer to the lubrication chart (Section 9.4.4)

for details.
Add oil to the tank (Figure 9b) with a
recommended lubricant from the list
provided in this manual through the filler cap
using the level indicator to ensure the correct
level is reached. This should be
approximately 223 litres (59 US galls).
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Unless consistently cold climates are

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

Intervals
As a general guide it is recommended that
the two filter canisters (Section 9.4.4) are
changed as follows:The first filter change should be after 100
hours operation.
Subsequent filter changes should occur
every 500 hours unless the oil filter blocked
warning activates between these intervals. It
is important the use the correct replacement
filter cartridges as too fine a filter element
will become blocked prematurely whilst too
coarse an element will not filter efficiently
enough to protect the machine.
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
! NOTICE !
Remember, these filters are very
efficient at removing harmful
contaminants from the oil and it is
more economical to change the
filters regularly than the oil.
It is also recommended that the suction
filters (Section 9.4.4) inside the tank are
replaced when the oil is changed.
In the event the pressure filters become
blocked completely, oil will be supplied to the
machine via a relief valve inside the filter top
body. This bypasses the filter element and
supplies unfiltered oil to the machine. This
MUST be avoided and the oil lubrication
safety system includes an alarm for this
situation.
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9.5.7 Automax Oil Filter

Replacement
WARNING
Both filters are to the same specification and

operate in parallel. They must be changed at
the same time with NEW filters as
recommended in Section 9.5.6.
WEAR PERSONAL
warning.
Both filters are non-cleanable elements and

must always be replaced with NEW
cartridges of the approved pattern.
LOCKOUT PLANT.
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
Tank
Ensure that the filler/breather cap is clean, in
place and tight, at all times.
Make sure that the oil tank cover is sealed
down and that all bolts are in place and tight.
Before carrying out any maintenance on the
tank or associated parts, thoroughly clean the
area to prevent any containments entering
the oil lubrication system.
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Air Blast Cooler

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

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

crushing a supplementary circuit of hydraulic
dumpy jacks is included to activate the wedge
ring.
The relative position of the upper frame is
monitored electrically with a linear transducer.
The control of the Automax hydraulics is from
the separate panel (Figure 9c) located inside a
lockable cabinet with connections by both high
pressure hydraulic hoses and screened electric
cable for the linear position sensor.
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Numeric Keypad
OPEN Button
Display
AUTO/MANUAL
Switch
TRAMP O/L TEST

Button
Gauge measuring
Wedge Pressure
CLOSE Button
Figure 9c Automax Controls

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

Maintenance Procedure
! DANGER !
This is a high pressure system
and only suitably qualified
experienced engineers should
tackle any problems that may
arise.
Maintain in accordance with the reservoir
level, filter changes and the schedules and
fluid types (Section 9.4.4, 9.4.5 & 9.4.6)
ONLY USE A RECOMMENDED FLUID.
It is essential when replenishing hydraulic
fluid, attending to filters, etc. to apply the
greatest degree of cleanliness as it is most
important that contaminants are not allowed
to enter the system.
DANGER
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
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
Pegsons local dealer or the factory in case
of doubt.
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9.7 Manganese Change

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

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 45-50mm (1 - 2)
of wear on the liners, as a pair.
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
(26).
When replacing the manganese liners,
always fit both a new mantle and a new
concave at the same time.
680 mm (26) minimum
Take note of the wear shown on the

display.
Figure 9d Minimum Ram Dimension
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9.7.2 Filler Handling
WARNING
! WARNING !
WEAR PERSONAL
warning.
Use Pegbak for backing filler. It is

necessary to carefully read the
handling instructions before
attempting to use. Follow all the
recommended handling
procedures and safety
precautions.
Filler is used as a backing material to fill the
void spaces behind the manganese concave
and mantle where there is no machined
mating surface with the upper frame and
cone head respectively. The filler is poured
in after the new manganese has been fitted.
The Automax cone crusher uses the gunlock
type, self tightening concave ring and must
use a release agent or thin layer of grease,
oil or wax on the concave ring mating
surfaces. This is to prevent adhesion
between the mating surfaces and to allow
the self tightening features to operate
properly. Care should be taken to plug all
leaks as the filler will fill a very small void.
Each pack of Pegbak includes separate filler
resin and hardener which are mixed only
when required for immediate use.
Packs required
Mantle - 2 x 10kg.Tubs
Concave - 2 x 10kg.Tubs
! WARNING !
BOTH AGENTS ARE TOXIC.
ALWAYS WEAR A FACE MASK,
RUBBER OR PLASTIC GLOVES,
SAFETY GLASSES AND LONG
SLEEVED WORK CLOTHING
Since both agents are toxic, be careful

not to allow them to attach onto your
skin. If they do attach, wash away with
tepid water and soap. Do not use petrol
or solvents.
! WARNING !
Protect eyes. In case of accidental
contact / splashes, flush eyes with
plenty of water and consult a
doctor.
Ensure good ventilation of the

workplace.
When mixing add the hardener to the

filler backing resin while agitating.
Completely mix the filler backing resin

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

at 16-32 C (60-90F). Therefore, in hot
weather the container may have to be
cooled and warmed in cold weather to
within the above temperature range.
Both agents can be mixed with the

supplied agitating adaptor attached to the
top of an electric drill.
The filler can be used only once (cannot

be reused) and if mixed with the
hardener it cannot be stored.
Always store both agents at 15-30 C

(59-86F) and avoid storing in direct
sunlight.
Never smoke whilst handling these

agents.
Ensure that application surfaces are dry

before pouring. Wet surfaces will result
in reduced stength of the filler.
Pour the filler immediately after mixing,

ie within 10 - 15 minutes at 25C. Higher
temperatures will shorten, and lower
temperatures increase, the working time.
When making pouring ports with putty,

prevent the filler from leaking out.
Filler Hardening Time

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

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

Mantle Automax crushing members it is
necessary to remove the Upper Frame.
WEAR PERSONAL
warning.
To change the Concave it is necessary to lift

off the Automax Upper Frame complete
with the concave inside
FALLING HAZARD.
warning.
Before the Upper Frame can be removed

the feed conveyor head must be elevated
from the working position to allow access to
the crusher and for the feed box to be lifted
off.
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
pins into the end of each pin.
Figure 9e Electric Panel Controls
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6. Operate the hydraulic lever to lower the

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

8. Disconnect the level sensor mast before
unbolting and lifting off the Automax
feed box.
Feed Box Rear Wall
Lower Telescopic
Leg
Hydraulic Lever
Figure 9e1 Feed Conveyor Hydraulic
Lever and Locating Pin
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9.7.3.2 Removing the Upper Frame
DANGER
Before the Upper Frame can be easily and

safely removed it is essential to first release
the Automax Wedge Ring as follows.

Procedure
WARNING

WEAR PERSONAL

LOCKOUT PLANT.
Procedure.
4. On the Automax Hydraulic Panel (figure

9f) select MANUAL and raise the Upper
Frame to its maximum extent using the
OPEN button.
5. Close (turn clockwise) the shut off valve
9B inside the Hydraulic Console (Figure
9g) to isolate the wedge ring hydraulic
circuit from the main hydraulic system.
6. Open (turn anticlockwise) the shut off
valve 9A inside the Hydraulic Console
(Figure 9g) to allow all pressure in the
wedge ring circuit to be released thereby
removing the loading from the Wedge
Ring.
7. Drop the Upper Frame with the CLOSE
button to push the Wedge Ring down and
thus free it from the Mainframe to
provide clearance needed to lift off the
FALLING HAZARD.
warning.
Upper Frame. The wedge pressure

indicated on the pressure gauge (Figure
9g) should drop away to 0-28 Bar (0-400
psi) as the wedge ring frees off.
! DANGER !
Ensure the Wedge Ring is free
otherwise crane overload and/or
sudden violent separation may
occur when lifting off (Step 14
below).
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Figure 9f Automax Control Panel

Gauge measuring
Wedge Pressure
Diagnostic Pressure
Gauge only
Valve 9B
Automax Control Panel
Diagnostic Pressure
Gauge only
Valve 9A
Figure 9g Wedge Jack Circuit Shut Off Valves
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8. With suitable cranage connect lifting

tackle to the three lifting eyes in the
Upper Frame (Section 9.2 for weights
and lifting points) but leave the slings
with a small amount of slack.
! DANGER !
Under no circumstances attempt
to take the load on the cranage at
this stage as a serious overload
condition may arise.
9. Using three 5 tonne capacity x 150 mm
(5.5 US tons x 6) stroke hydraulic bottle
jacks spaced equidistant around the
lower rim of the Upper Frame, extend
them equally to take the weight off the
clevis pins to aid their removal.
10. Ensure that there is no residual hydraulic
pressure in the Upper Frame hydraulic
cylinder circuit by pressing the OPEN
and CLOSE buttons briefly and in quick
succession until the pressure gauge
(Figure 9c) on the hydraulic panel reads
zero. Follow this procedure to remove
the clevis pins with the minimum of
effort.
12. Remove the top clevis pin from each

hydraulic cylinder and pull each cylinder
outwards, allowing them to lie flat.
Note: The clevis pins should be
removed from right to left when
facing the machine to avoid
disturbing the bearing located
against the shoulder inside each lug
on the Upper Frame.
13. Remove the linear sensor cover (Figure
9h) and lay to one side. Disconnect the
top bolt from the unit. This is essential
to avoid damage to the sensor unit.
14. Lift off the Upper Frame assembly from
the machine (Refer Section 9.2 for the
weight of the complete assembly).
Support on wooden blocks on the ground
(Figure 9i).

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

Cylinders
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9.7.3.3 Changing the Concave
WARNING
The concave ring is held in place in the

Upper Frame by a self tightening gun lock
arrangement that automatically tightens the
manganese steel concave on the concave
wedges as the ring stretches under the
crushing load.
WEAR PERSONAL
warning.
The Upper Frame should be supported on

wooden blocks so that there is sufficient
space for the concave to be driven out.
LOCKOUT PLANT.
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
2. Following removal of the Upper Frame
(Section 9.7.3.2) gas cut through the
three lugs as shown (Figure 9i).
ground. Remove any nicks or burrs with

a file or grinder. Inspect the ground
surfaces of the new concave and
remove any nicks or burrs in the same
manner.
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
WARNING
When supporting the new Concave prior to

lowering the Upper Frame on to it, ensure
that the supports do not protrude past the
sides of the Concave (Figure 9j) and that it is
high enough off the ground to allow the
Upper Frame to be fully lowered.
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Release agent needs to be applied to the

internal surface of the Upper Frame where it
will be in contact with the backing filler to
ease separation when the manganese is next
changed.
Procedure
6. After rotation, equally locate the
concave wedges between the concave
lugs and upper frame (Figure 9k).

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

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

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

In order the re-connect the six

hydraulic cylinders to the Upper
Frame (Step 5 following) the
engine must be running to provide
hydraulic pressure.
WARNING
ENSURE the risk assessment for

this procedure covers the
necessity for very effective
communication between any
personnel involved in the task,
taking into account the visual
restrictions between the Automax
control panel and the crusher and
also engine noise.
Whilst the Upper Frame is off the machine
for the renewal of the manganese wearing
parts, take the opportunity of examining the
condition of the internal linerplates, frame
and countershaft arm shields and replace if
necessary.
Also, clean out any solidified debris and
generally check around the machine for any
faults which need to be rectified.
Clean the contact face all around the Wedge
Ring and apply a coating of fresh lubricant
(MOLY-BENTONE MP Standard Grade
grease). Make sure this is not contaminated
with dirt or grit prior to replacing the Upper
Frame.
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Procedure
2. Using the cranage used to remove the
Upper Frame, lower over the machine
whilst taking care to line up the antirotation stop on the Upper Frame with
the guide post. Hold in a suspended
position with the crane with a gap
between the mantle and concave.
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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 its
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
WARNING
The operation is carried out with the head

left in situ. The internal parts of the Automax
are therefore not disturbed or exposed to
harmful dust.
WEAR PERSONAL
warning.
In use all manganese steel will creep due to

the nature of the material. When creep occurs
stress is created in the material which will have
to be relieved by suitable cutting of the Mantle.
This will be necessary in order to facilitate
removal.
LOCKOUT PLANT.
FALLING HAZARD.
warning.
Removing the Mantle
! WARNING !
When gas cutting through the
concave it is essential that
breathing apparatus is worn as
when the metal is broken through
the backing material gives off toxic
fumes.
Procedure
2. With the Upper Frame removed (Section
9.7.3.2) gas cut round the mantle within
20-30mm ( -1) from the top
(Figure 9m).
3. Once the Mantle is cut the Mantle Nut
can then be removed by turning
CLOCKWISE with the mantle nut
wrench (Figure 9n). Ensure that the
mantle nut wrench is secure by dropping
a suitably sized bolt through the hole in
the end of it.
4. Break loose the fit between the Mantle

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

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

securely fitted
Figure 9o Lifting chains correctly fitted

Sections through the Automax Cone Head
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Mounting the Mantle
WARNING
Release agent needs to be applied to the

Cone Head where it will be in contact with
the backing filler to ease separation when
the manganese is next changed.
WEAR PERSONAL
warning.
Procedure
LOCKOUT PLANT.

2. Apply release agent (obtainable from
BL-Pegson) to the unmachined surface
all around the Cone Head (Figure 9p).
3. Place the new Mantle onto the Cone
Head and tighten down the Mantle Nut
by turning COUNTER-CLOCKWISE
with the Mantle Nut Wench (Figure 9n).
It is sufficient to tighten this by hammer
blows without having to replace the
Upper Frame and wedge against the
Concave.
4. The Mantle Nut was tightened to align
the Mantle and seat it firmly on the Cone
Head at A (Figure 9q). Now the Mantle
Nut needs to be released so that the filler
can be poured. Release the Nut by
turning CLOCKWISE with the Mantle
Nut Wrench.
Note: When the Mantle Nut is removed,
grease the threads on the Cone head so
any spills when pouring the backing filler
can be easily wiped off.
FALLING HAZARD.
warning.
5. Prepare the filler (Section 9.7.2) and

pour the correct quantity of mixed filler
at the top of the Mantle making sure it is
equally distributed all round.
! NOTICE !
After mixing, the filler must be
poured IMMEDIATELY to ensure
complete penetration.
6. When the filler reaches 15mm from level
B (Figure 9q) stop pouring, fit the Mantle
Nut and first lightly tighten using the
Mantle Nut Wrench. Fully tighten by
hitting the wrench with a hammer in a
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
! NOTICE !
The Wedge is fundamental to how
the cone crusher functions. It
provides damping and guidance
to the Upper Frame assembly.
WARNING
WEAR PERSONAL
warning.
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 its 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
bouncing of the Upper Frame or damage
may result. Possible causes of the are
crushing at closed side settings which are too
tight, out of round manganese or poor Wedge
Ring adjustment.
! NOTICE !
Low wedge pressures are equally
as undesirable as high ones.
When testing the wedge pressure
it should be between 55 and 82
BAR (800 - 1200 psi).
Gauge measuring
Wedge Pressure
Automax Hydraulic Panel
Figure 9r Automax Hydraulic Panel and

Pressure Gauge
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9.8.1 Checking Automax Wedge

Pressure
DANGER
AUTOMAX NOT RUNNING

The pressure on the wedge ring is

automatically controlled by the Dumpy Jack
hydraulic circuit. However, as the adjustment
of the wedge ring is critical for good
performance of the Automax crusher it is
recommended that this should be checked
daily. The pressure gauge near the panel
(Figure 9r) gives an accurate indication of
whether the Wedge Ring assembly is
functioning correctly.
WARNING
WEAR PERSONAL
warning.
! NOTICE !
The Automax must not be allowed
to operate with regular dumping or
bouncing of the Upper Frame or
damage may result. Possible
causes could be crushing at too
small a setting, out of round
manganese (Section 9.9) or poor
Wedge Ring adjustment.
Procedure
4. On the Automax Hydraulic Panel

(Figure 9r) switch to MANUAL and
depress the OPEN button lifting the
Upper Frame approximately 20mm
() above the set point.
5. Switch back to AUTO and observe the
pressure reading on the pressure gauge
(Figure 9r). The pressure should be in
the range 55 - 82 BAR (800 - 1200 psi).
6. Whilst the Upper Frame is moving check
for smooth movement with no sticking at
the start or whilst travelling.
7. If the pressure reading is above or below
the range indicated above or the action is
not smooth, remedial action is required
(Section 9.8.2).
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8.8.2 Low Wedge Pressure

If the wedge pressure has been checked and
found to be below 55 bar (800psi) then the
cause must be investigated and where
necessary, the appropriate action taken.
Procedure
1. Low or fluctuating dumpy jack circuit
pressure.
Check circuit is free from leaks, and
pressure switches 11A & 11B (Figure
9ab) are functioning correctly.
WARNING
WEAR PERSONAL
warning.
DANGER
FLUID INJECTION HAZARD
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
If the wedge pressure has risen above the
prescribed maximum and/or the travel of
the Upper Frame is no longer smooth, the
Wedge Ring may need adjusting by the
following procedure. See Section 9.8.1 for
checking the wedge pressure.
Procedure
DANGER
WARNING
WEAR PERSONAL
warning.

and dirt.
engine speed to 1200rpm..DO NOT
5. On the Automax Hydraulic Panel
(Figure 9r) select MANUAL and
raise the Upper Frame to its
maximum using the OPEN button.
6. Close the shut off valve 9B adjacent to
the Automax Hydraulic Panel (Figure
9s) to isolate the wedge ring Dumpy
Jack hydraulic circuit from the main
hydraulic system.
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
Side Discharge Setting procedure
(Section 7.3.3) as necessary.
Shut Off Valve 9B
Diagnostic Pressure Gauge

(NOT the gauge referred to in step 8)
Shut Off Valve 9A

Figure 9s Dumpy Jack Circuit Valves
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9.9 Automax - Out of Round

Manganese - Causes and
Effects
F) Increase the wear rate of the

manganese, due to the concentrated
crushing area. This gets worse as the
process is a vicious circle.
When the Mantle and Concave are new both

of the wearing surfaces are round. They
should remain round throughout their
working life, ie. the wear should be
consistent and remain round. Should the
manganese become out of round then the life
of that manganese will be shortened
considerably. The causes and effects of this
are:-
G) Due to effect of E above the machine

will become reluctant to accept a choke
feed. The machine will dump as the
crushing pressure reaches excessive
levels.
Causes:
A) Inaccurate manganese manufacture/
fitting.
B) Poorly distributed feed material within
the hopper and/or segregated feed.
C) inconsistent stop/start feed.
Effects:
D) Produces an uneven load on the Wedge,
reducing its life and producing a
fluctuating wedge pressure.
Prevention:
H) Only fit genuine BL-Pegson manganese
replacement parts.
I) Ensure adequate feed hopper and
efficient dead box are maintained to
distribute the feed material evenly
around the feed opening.
J) Adjust the plant settings (Section 7.2.7)
to ensure the Automax is choke fed at all
times.
K) Adjust the plant settings (Section 7.2.7)
to ensure the feed to the Automax is
continuous with stop/starting of the feed
kept to a minimum.
E) Produces an inaccurate zero set point,

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

of Round
Check 1 - The Mantle.
DANGER
ENTANGLEMENT HAZARD.
Procedure
1. Observe all Safety Warnings.
and dirt.
Note: it is important when checking the
Mantle for out of round that the
Eccentric does not move. Take the drive
guard off and watch for any movement
of the countershaft. If movement is
noted repeat the whole procedure
described below, again.
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
FALLING HAZARD.
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 90
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
round it should show similar values to
Figure 9o.
-1
-1
Typical values
Mantle OK.
1
Figure 9t Mantle Check
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Check 2 - The Concave
DANGER
Note: This process is almost identical to the

Mantle check. Follow the procedure for the
Mantle - Check 1.
HOWEVER, this time the Cone head and

Eccentric MUST move as one. To do this
the Flywheel should be rotated slowly by
hand. The Mantle procedure (previous page)
can be followed but rotating the Flywheel not
the Cone head. It is useful to have an
assistant watch the Cone Head rotate whilst
the vee belts are rotated to ensure it is
moving. In order to prevent slip between the
Eccentric and Cone Head:-
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
A) Ensure slow, gentle movement of the

Eccentric, via the vee belts.
FALLING HAZARD.
warning.
B) Make sure the Concave is well clear of

the Mantle when the Eccentric/Cone
Head is being rotated.
As a final check for any slip between the
Eccentric and the Cone Head, repeat the
first touch again as the example below:-
0
0
! NOTICE !
If there is a difference of more than
7mm () between any two values
of the four measured, that piece of
manganese must be changed
immediately.
-1
-2
Typical values
Mantle OK.
1
Figure 9u Concave Check
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9.10 Automax - Fault finding

GENERAL
Fault
Possible Cause
Procedure
Machine stops.
Overload through
discharge setting too
low.
Tramp metal fixed in
crushing chamber.
Packing in crushing
chamber.
Lubricating oil flow low /
temperature high.
Build up in discharge
chute.
Power supply / drive
motor failure.
Clear machine adjust

setting.
Broken vee belt (s).

Discharge setting not
maintained.
Hydraulic fluid leakage.
Clear machine adjust

setting.
Clear discharge chute.
Check operation of
lubrication system.
Clear blockage check
chute.
Check power supply /
drive motor, see
manufacturers literature
Replace belt (s).
Check all hydraulic
components, couplings,
pipes and hoses.
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Fault
Possible Cause
Procedure
Reduction in discharge
setting not possible.
Crushing pressure too

high
Hydraulic system faulty.
Adjust setting.
Manganese out of
round.
Manganese worn out.
Directional control valve
inoperative.
Relief valve dirty or
faulty.
Couplings at hydraulic
ring- main faulty.
Packing in crushing
chamber. (excessive
fines in feed)
Check for internal/

external leaks.
Check manganese.
Change manganese.
Check solenoid.
Dislodge dirt from under
seat / check valve
spring.
Investigate and correct.
Adjust machine.
Increase in discharge
resetting not possible.
Wedge too tight.
Grease and readjust

wedge.
Upper frame assembly

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

leaks.
Replace.
Hydraulic system
filter(s) blocked.
Crusher motor stops.
Overcurrent due to
voltage drop.
Overcurrent due to
overload.
Interlock operation.
Check the transformer

capacity.
Suitable feed amount?
Uniform feeding?
No packing?
Insufficient oil supply?
Damaged bearing?
Tramp metal?
Machine overloaded?
Pump motor rotating?
Deteriorated pump
performance or lack of
oil?
Return oil temperature
too high?
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Fault
Possible Cause
Procedure
Abnormal sound from

the crusher.
Damage of the bearing

of the countershaft.
Damage of the
countershaft gear.
Loose mantle.
Contact Terex Pegson.
Loose or falling
concave.
The particle size of the

crushed product is
coarse.

Inspect conehead/
mantle for damage.
Refit as when changing
manganese.
Adjust the concave
wedge.
Check the mantle
rotating direction.
Check the touching
surface.
Check for partial wear.
Mantle / concave worn

out of round.
Check for out of round.
The indicated setting

value is different from
the actual value.
Wedge ring adjustment
failure.
Partial wear of the
mantle and concave.
Measure the actual

setting with a lead ball
etc.
Adjust the wedge ring.
Check the feeding
chute.
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HYDRAULICS
Fault
Possible Cause
Procedure
The pump doesnt start.
Electrical fault.
Check the thermal relay

connection and motor,
fuses & connections.
Check the rotating
direction and reconnect.
Refill oil.
Rotating direction error.

Insufficient quantity of
oil in the tank.
Pump seized.
The pump starts but no

pressure and discharge
occur.
Clogged suction side

piping.
Clean the piping and

carry out flushing.
Clogged suction side

filter.
Air mixed from the
suction side.
Remove and clean.
Oil viscosity too high.

Defective or damaged
pump and coupling.
Relief valve setting
failure.
Pump noise.
Check that pump shaft

rotates, fit replacement
if faulty.
Air mixed from the

suction side.
Clogged air breather.
Sound in the relief
valve.
High oil viscosity.
Re-tighten the coupling

screw.
Replace the piping.
Check for the specified
brand.
Check and replace.
Clean the piping and

carry out flushing.
Disassemble and clean.
Disassemble. Clean or
replace the spring
nozzle.
Check for the specified
brand.
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Fault
Possible Cause
Procedure
Irregular motion of the

cylinder.
Air mixed in the cylinder. Check the piping, hose

and coupling, after
checking and repair,
remove air.
Filters blocked.
Replace.
Downward adjustment
possible - system will
not build up or maintain
pressure.
Unseated unloader
valve.
Replace valve.
Solenoid operated vent

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

release couplings faulty.
Inspect, replace as
required.

jammed half open.
Check operation of
valve, dismantle, clean,
replace parts or
complete valve as
necessary.
Investigate crusher.
Mechanical blockage on
crusher.
Upward adjustment not
possible.

inoperative.
Solenoid operated vent

valve inoperative.
One or both quick
release couplings faulty.
Mechanical blockage on
crusher.
External leakages.
Oil in system becomes

excessively hot.
Check operation of
necessary. Check for
possible sticking spool,
dismantle, clean,
replace parts or
complete valve as
necessary.
Check operation of
necessary.
Inspect replace as
required.
Investigate crusher.
Make visual inspection.

Tighten connections.
Renew pipes, hoses or
couplings as necessary.
Mechanical failure of the Check to see if any
crusher.
object touches the
machine.
Insufficient oil quantity.
Check the oil level
gauge. Refill as
necessary.
Pump running
Check for symptoms of
continuously under
pressure build up.
pressure
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LUBRICATION SYSTEM
Fault
Possible Cause
The oil cooling efficiency Cooling matrix choked

is deteriorating.
with dust.
Dust depositing at the
bottom of the tank.
The oil heater cannot be
turned off.
The contact type oil

temperature gauge
doesnt operate at the
preset temperature.
Machine stops.
Procedure
Disassemble and clean.
Clean the tank.
Thermostat failure.
Replace.
Thermostat setting
failure.
Correct the setting.
Contact type return oil

temperature gauge
failure.
Replace.
Setting failure.
Correct the setting.
Lubrication system
safety interlocks
activated.
Oil chilled on entering
cold.
Check fault display in

Section 7.2.3.
Look for oil return to
tank. Check oil heater
working.
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9.11 Plant - Feed Conveyor

The Automax crusher is fed from the feed
hopper via the feed conveyor. Feed material
can be introduced into the hopper either by
overhead loads or continuously via a belt
conveyor.
During the crushing operation the feed
conveyor can be controlled by the level
sensors (Section 9.12) over the feed hopper
(optional) and/or the Automax feed box. The
purpose of the level sensor(s) is to avoid a
dribble feed to the Automax which is
detrimental to the optimum performance of
the crusher.
! NOTICE !
The performance of the Automax
benefits in all respects from
receiving a continuous choke
feed of material (Section 3.4) and
the aim is to achieve this by
setting the plant controls (Section
7.2.7) to keep stopping and
starting of the feed to a minimum.
During crushing operations the level of
material in the feed hopper should be
maintained at a high level to avoid stopping
of the feed conveyor due to lack of material
in the hopper.
A rotary control on the plant control panel
(Figure 7e) is also provided to manually vary
the feed rate by regulating the speed of the
feed conveyor.
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9.12 Plant - MiniRanger

Level Sensors Description
The standard Maxtrak includes a level
sensor over the Automax feed box to control
the feed into the crusher by varying the
speed of the feed conveyor. An optional
sensor can also be fitted over the feed
conveyor hopper where this is practical to
the crushing application.
The following pages give summaries of the
operation and setting-up guides.
The MiniRanger units are preset at the factory
with settings found to have been generally
suitable (Figure 9.12.4) but can be
reprogrammed if necessary to suit differing
applications and materials.
! NOTICE !
The Automax crusher gives the
best performance in all respects
when kept choke fed as
explained in Section 3.4
Unit MR1 - Crusher Bowl
This monitors the material level in the
Automax crushing chamber and feed box to
adjust the speed of the feed conveyor.
Unit MR2 - Feed Conveyor (Optional)
This monitors the material level in the feed
hopper and works in conjunction with the
sensor MR1 to provide an addition measure
of controlling the feed into the Automax.
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9.12.1 Level Sensors - Operation
WARNING
The MiniRanger Plus is a versatile material

level monitoring instrument. Material level
measurement is achieved using advance sonic
echo ranging techniques. Each unit is complete
with an integral multi-function liquid crystal
display with four button keypad (Figure 9v)
mounted on the Electrical Control Panel
Each MiniRanger Plus has two modes of
operation: RUN and PROGRAM. When the
unit is powered it is programmed to start up in
the run mode to detect the distance from the
transducer face to the target material in
metres.
WEAR PERSONAL
warning.
Optional Sensor
The unit can be placed into the program mode

at any time; to alter the number of program
parameters in order to better suit the
application or users preferences.
Programming is carried out via the keypad.
See Section 9.12.2 for the keypad functions
and displays relating to the RUN mode.
See Section 9.12.3 for the keypad functions
and displays relating to the PROGRAM mode.
See Sections 9.12.4 for Factory Presets.
See Section 9.12.5 for the simplified Setup
Guide for typical mobile crusher bowl level.
Figure 9v MiniRanger Plus Control Panel
See Section 9.12.6 for the simplified Setup

Guide for typical hopper level (Optional).
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9.12.2 Level Sensors - Run Mode

Communication Jack
LCD Keypad
LCD Display
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9.12.3 Level Sensors - Program Mode
Communication Jack
LCD Keypad
LCD Display
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9.12.4 Level Sensors - Factory Settings
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

One integrated hydraulic system performs

the following functions:
Automax setting adjustment, overload

protection, unblocking and wedge ring
pressure. Also driving the crusher
lubricating oil circulating system.
WARNING
WEAR PERSONAL
warning.
Plant hydraulic drives for the conveyors

and tracks and also to hydraulically raise
and lower the feed conveyor.
LOCKOUT PLANT.
All hydraulic functions are powered by two

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

piston variable displacement unit feeding a
directional control valve.
Note:All relief valve pressures are factory set and

should not be adjusted on site.
The flows and pressures to each service is

limited by the relevant spool as shown below
and the pump supplies only the required flow
by automatically backing off the swash plate
angle thus reducing wasted power and
resulting heat generation.
Although the maximum flows from each

spool is limited as shown, these can be
individually adjusted downwards by means of
limit screws if desired. Please contact Terex
Pegson Ltd.
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)

Service
Spool Type
Max Flow
litres/min
(US galls)
Max Pressure
Bar
L/H track drive motor
Proportional
100 (26.4)
320
Product Conveyor plus Water

Pump (when fitted)
On/Off
100 (26.4)
210
Automax control
On/Off
4 (1)
200
180
No: 2 Pump (valve mounted under feed conveyor)

Service
Spool Type
Max Flow
litres/min
(US galls)
Max Pressure
Bar
R/H track drive motor
Proportional
100 (26.4)
320
Feed Conveyor
Proportional
75 (19.8)
180
Feed Conveyor raise/lower
On/Off
25 (6.6)
100
Automax lubrication
On/Off
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

proportional controls and are theoretically
infinitely variable they are electrically limited
to two speeds for simplicity.
This valve section is fitted with a

proportional solenoid so that the feeder
speed can be controlled by level sensor
mounted over the Automax feed box.
a) SLOW - For slewing and fine

positioning.
9.13.4 Circuit Protection
b) FAST - For straight line running, forward

or reverse.
Note:- The maximum power take off from
one side of the engine is limited to
approximately 30 KW, therefore the system
is electronically limited such it is only
possible to slew (operate one side only)
when in the SLOW mode.
Fine adjustment of the slow speeds is
possible. Consult BL-Pegson Ltd.
It is recommended that adjustment is not
undertaken without BL-Pegson Ltd. consent
and under no circumstances should the slow
speed be adjusted greater than 0.2m/s.
Motor mounted counterbalance valves are
utilised to prevent the machine over running
when moving downhill.
This block also incorporates a shuttle valve
to release the spring applied track parking
brake together with a pressure reducing
valve, preset to 60 bar so that the brakes are
not over-pressurised.
The system is equipped with the following

protection:
Suction Filter (90m nominal )
Pressure Filter (10m absolute) in each

pump circuit prior to the directional
control valves.
Return Filter (10m nominal)
Low oil level cut out.
Note:- For Hydraulic Pump Drive Belt

adjustment refer to Section 9.15.3.
! NOTICE !
The hydraulic oil filters are fitted
with condition indicators to shown
when the renewable filter element
needs to be changed. These
should be checked on a daily
basis whilst the plant is running at
normal operating temperature
(Sections 9.13.5 - 6 & 8). In cold
ambient temperatures the filter
indicators may show red until the
system reaches normal operating
temperature.
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Figure 9x Plant Hydraulic Circuit Diagram
THIS DIAGRAM IS REPRODUCED TO A LARGER SCALE IN SECTION 10
Page 9 - 87
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9.13.5 Changing the Suction Filter
DANGER
Located at the base of the hydraulic

reservoir tank is the hydraulic suction filter.
When the dial gauge needle (Figure 9y)
enters into the red segment whilst the
system is running at normal operating
temperature this is an indication that the
filter must be replaced immediately . The
filter housing has an internal shut off valve to
permit work on the system. Make sure the
oil has cooled before changing.

WARNING
WEAR PERSONAL
warning.
Procedure
LOCKOUT PLANT.
2. Close down the machine (Section 8.2)

and implement the Lockout Procedure.
3. Using a hexagon socket key unscrew the
bolt A in the centre of the filter housing
until it reaches the stop (Figure 9y).
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
cover plate.
5. Remove the old filter and clean inside
the housing with lint free cloth before
fitting a new filter of the approved
pattern and specification.
6. Before replacing the cover plate, lightly
oil the O ring and make sure it is
properly seated in the groove. Replace
the cover plate and refit the screws to
ensure an oil tight seal.
FALLING HAZARD.
warning.
7. Fully screw in the bolt A in the

centre of the filter housing.
! NOTICE !
It is important to ensure that the
bolt A is fully screwed in before
restarting the plant. Damage will
occur to the plant if this procedure
is not followed.
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Filter Condition Indicator Dial
Removable Cover Plate
Bolt A
! NOTICE !
It is important to ensure that the
bolt A is fully screwed in before
restarting the plant. Damage will
occur to the plant if this procedure
is not followed.
Figure 9y Suction Filter
Hydraulic Oil Level &

Temperature Gauge
Hydraulic Oil Return

Filter and Gauge
Hydraulic Oil Tank
Hydraulic Oil
Breather/Filler
Filter Condition Indicator Dial
Figure 9z Hydraulic Oil Tank & Level Indicator
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9.13.6 Changing the Return Filter
DANGER
Located on top of the hydraulic reservoir

tank is the hydraulic return filter. When the
dial gauge needle (Figure 9y) enters into the
red segment whilst the system is running
at normal operating temperature this is
an indication that the filter must be replaced
immediately. Make sure the oil has
cooled before changing.

WARNING
WEAR PERSONAL
warning.
In the event hydraulic oil needs to be added

to maintain the correct level on the gauge
(Figure 9z), this should be poured in after
removing the cover (see below) but with the
filter element left in place. Check the system
for leaks if topping up becomes necessary.
LOCKOUT PLANT.
Procedure
FALLING HAZARD.
warning.

3. Remove the four hexagon head screws
on the top of the housing to remove the
cover plate together with internal spring.
the housing with lint free cloth before
fitting a new filter of the approved
pattern and specification. Replace the
spring which holds the filter in place
5. Before replacing the cover plate, lightly
oil the O ring and make sure it is
properly seated in the filter housing.
Replace the cover plate and refit the
screws to ensure an oil tight seal.
9.13.7 Changing the Tank Breather

This should be changed after the first 100
hours of operating and thereafter after 500
hours but in dusty atmosphere it is
recommended to change more frequently
depending upon conditions. Simply unscrew
and replace whilst the plant is shut down
(Section 8.2).
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9.13.8 Changing the Pressure

Filters
DANGER
Located on each side on the engine within the

canopy are the hydraulic pressure filters.
When the telltale (Figure 9aa) changes from
green to red whilst the system is running at
normal operating temperature this is an
indication that the filter must be replaced
immediately. Make sure the oil has cooled
before changing..

WARNING
WEAR PERSONAL
warning.
Procedure
LOCKOUT PLANT.

3. Unscrew (turn anticlockwise looking
from below) the filter bowl using the
hexagon nut cast into the base. Take
steps to contain spillage of oil
Filter condition Telltale
Filter body

the bowl and housing with lint free cloth
before fitting into position a new filter
and small O ring of the approved
pattern and specification.
5. Before replacing the bowl, lightly oil the
O ring and place on its seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
care not to cross the threads when
doing so. Tighten with the nut at the
base of the bowl to ensure an oil tight
seal.
Bowl
Nut
Figure 9aa Pressure Filter
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9.13.9 Automax Hydraulic System
DANGER
The hydraulic control components (with the

exception of the position sensor unit on the
crusher are housed in the hydraulic control
console.

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

crusher the panel senses an increase in
pressure and will automatically raise the
crusher upper frame (including the concave)
to release material in the crushing chamber.
When the crusher is new or a new concave
and mantle have been fitted the procedure
for setting the Set Zero calibration should be
followed (Section 7.3.3). This procedure is
necessary to allow all the other functions to
take place. By following this procedure the
control system then recognizes the position
of the concave in relation to the mantle (the
two crushing elements) and can then allow
the measurements of wear to take place.
When the manganese wear procedure has
been followed (Section 7.3.4) and as wear
on the manganese crushing members
(concave and mantle) takes place, the
amount of wear is calculated by the control
system and can be read off at any time from
the Automax console display screen.
WEAR PERSONAL
warning.
! DANGER !
THIS IS A HIGH PRESSURE
SYSTEM.
Never carry out any maintenance
work without ensuring the
hydraulic system is locked out and
depressurised.
Do not tamper with system. In the
event of any problems these
should only be dealt with by
suitably experienced and qualified
engineers.
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ITEM
1
2
3
4
5
6
7
8
9
10
11A
11B
12
13
PART DESCRIPTION
PRESSURE FILTER
PRESSURE FILTER
SOLENOID VALVE
DOUBLE PILOT CHECK VALVE
UNLOADER VALVE
PRESSURE REDUCING VALVE (2)
CHECK VALVE
PRESSURE RELIEF VALVE
NEEDLE VALVE (2)
PRESSURE GAUGE (3)
PRESSURE SWITCH 35-120 BAR
PRESSURE SWITCH 35-120 BAR
PRESSURE SWITCH
MANIFOLD BLOCK
No:
AUTOMAX HYDRAULIC CONNECTION DETAILS
INLET, 4 LPM @ 2700 PSI
CONNECT TO WEDGE CIRCUIT
CONNECT TO ANNULUS OF GAP SETTING CYLINDERS
CONNECT TO FULL BORE OF GAP SETTING CYLINDERS
RETURN TO TANK
Figure 9ab Automax Hydraulic Control Circuit
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9.14 Plant - Electrical

System
WARNING

Electrical power of DC24 volt for the
electrical equipment on the plant is derived
from the diesel engine to operate the control
systems for the Automax crusher and all the
plant items.
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Refer to the wiring diagrams in Section 11 Appendix.
9.14.2 Operators Control Points

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

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

and 9.17)
Emergency Stop Buttons (Sections 1.7

and 8.3)
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9.14.3 Protection Devices

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

(Section 7.2.3) displays the appropriate
message of any fault occurring.
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9.15 Plant - Crusher and Hydraulic Pump Drive Belts

Good alignment of the flywheel and drive pulley is important otherwise the belt flanks will wear quickly.
Ensure axis are parallel when viewed from all planes (Figure 9ac).
Shafts are not parallel

to one another when
seen from above
Shafts are parallel and

in alignment but pulleys
are not in alignment
Shafts are parallel

from above but not
from end view
Correct Installation
Both shafts and pulleys
are parallel and in
alignment
Figure 9ac Correct Alignment of Pulley Belts

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9.15.1 Trouble Shooting - Drive

Belts
Small Cracks on V-Belt side and Base
Generally caused by shortage of belt tension
but excessive heat and/or chemical fumes
can also give same failure.
V-Belt Swelling or Softening
Caused by excessive contamination by oil,
certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning,
principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires
redesign or a Banded belt. Consult Terex
Pegson Ltd.
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9.15.2 Replacement and

Adjustment of Crusher Drive Belts
Note: Drive belts should inspected
regularly for wear and also to monitor any
pattern in the wear if it is occurring
(Figure 9ac).
WARNING
WEAR PERSONAL
warning.
The tension of the crusher drive belts is

adjusted with the four screws located at
each corner of the engine baseframe
(Figure 9ad).
LOCKOUT PLANT.
Procedure.
When replacing the belts the drive should

be slackened off sufficiently to remove the
old belts and fit the new without stretching
them. Only use matched sets of belts to
ensure equal tension is possible on all the
belts.
FALLING HAZARD.
warning.
Procedure
3. Remove the crusher drive guarding as
necessary to gain access to the vee belt
drive.
4. Loosen all four locking nuts A (Figure
9ad) on the engine baseframe adjusting
screws situated beneath the corners of
the baseframe. Access can be gained
from the platforms along each side of the
engine.
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Nut B (4 off)
Nut A (4 off)
Figure 9ad Crusher Drive Belt Tensioning Mechanism RH Side
Deflection Dimension
(mm)
Basic Setting Force

(kgf)
1.25 x Setting Force

(kgf)
See Section 9.15.4 (Step 3)
9.4
12.0
(ins)
Basic Setting Force

(lbf)

(lbf)
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
Note:- Drive belts should be inspected
regularly for wear, correct tension and
contamination.
The two hydraulic pumps are situated one
each side of the engine within the diesel
engine canopy
The belt tension of both hydraulic pump
drives is adjusted by two bolts located on
each pump baseplate (Figure 9af).
DANGER
WARNING
WEAR PERSONAL
LOCKOUT PLANT.
Procedure.
Procedure
FALLING HAZARD.
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
Drive Belt Guard
Hydraulic Pump
Adjusting Screws (B)
Pump Stool
Bolts (4 off) (A)
Pump Bracket
Figure 9af Hydraulic Pump (LH) Drive Belt Tension Mechanism
(mm)
Basic Setting Force

(kgf)

(kgf)
6.3
7.9
(ins)
Basic Setting Force

(lbsf)

(lbsf)
13.9
17.4
Figure 9ag Pump Drive Belt Tensioning Specifications
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9.15.4 Method of Drive Belt

Tensioning
WARNING
! WARNING !
WEAR PERSONAL
warning.
Under no circumstances should

any check on the belt tension be
made whilst the machine is
running. There is a risk of
trapping parts of the body if this is
done.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
Procedure
Remove the guards from around the belt.
Crusher/Engine Drive Belts
3. Calculate the deflection distance in mm

on a basis of 16mm deflection per 1
metre (0.6 per 1 yard) of belt span
(Figure 9ah).
8 x 3550mm SPC,
Part Number 2441-0470
Hydraulic Pump Drive Belts
Centre to Centre Distance metre x 16

(yard x 0.6) = Deflection
4 x 2000mm SPB,
Part Number 2441-0412
Ce
nt
re
to
Ce
nt
Belt Tension Indicator

Applied to Mid-Span
re
16mm
Deflection
per 1
Metre of
Belt
Span
0.6 ins.
Deflection
per 1 Yard
of Belt
Span
Figure 9ah Belt Tensioning Measurements
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4. If a belt tension indicator is

available:
a) Set the lower marker ring at the
deflection distance required on the lower
scale.
b) Set the upper marker ring against the
bottom edge of the top tube.
6. If the measured force falls within the

values given, the drive should be
satisfactory. A measured force below the
lower value indicates under-tensioning. A
new drive should be tensioned to the
1.25 x Setting Force value to allow for
the normal drop in tension during the
running-in period.
7. Replace all guards before start-up.
c) Place the belt tension indicator on top of

the belt at the centre of the belt span,
and apply a force at right angles to the
belt deflecting it to the point where the
lower marker ring is level with the top of
the adjacent belt.
d) Read off the setting force value
indicated by the top edge of the upper
marker ring.
! NOTICE !
After the drive has been running
for 15-20 minutes, the tension
should be checked and readjusted
to the Basic Setting Force value, if
necessary by repeating the above
procedure from Step 1.
e ) Compare this value to the lbf value

shown in the table:
Figure 9ae - Crusher Drive Belt
Tensioning Specifications
Figure 9ag - Hydraulic Pump Drive Belt
Tensioning Specifications
5. If a belt tension indicator is not
available:
a) Use a spring balance to pull the belt
down at the centre of the span.
b) When the belt has been pulled down
(measure using a rule) by the deflection
calculated in Step 3, read off the force
from the spring balance.
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9.16 Plant - Conveyor Belts
DANGER
There are two belt conveyors on the

Maxtrak plant.
The Feed Conveyor has a shallow

troughed plain belt. Drive is through a head
drum mounted oil lubricated gearbox with
hydraulic motor. Screw type tensioning of
the belt is at the tailshaft. Full length skirt
plates are included. A metal detector
(Section 9.17) is fitted to stop the conveyor
when the detector is triggered. To reduce
the height of the plant for transportation
the conveyor can be lowered by means of
an hydraulic ram (Sections 5.2 and 6.2)
and also to elevated (Section 9.7.3.1) to
gain access when working on the
Automax crusher. Grease nipples are
provided for lubrication of the shaft
bearings.
The Discharge Conveyor is a standard
troughed plain belt type. The drive is by
hydraulic motor at the head end and.
Screw tensioning of the belt is at the
tailshaft. Full length skirt plates are
included. A detachable canvas wind cover
is included. A movement sensor is fitted at
the tail to stop the feed to the Automax in
the event of conveyor belt stopping for any
reason. The shaft bearings are lubricated
the same as the Feed Conveyor.
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
! DANGER !
any adjustment be made on the
belt whilst the machine is running.
There is a risk of trapping parts of
the body if this is done.
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9.16.2 Training of Belts
DANGER
Before starting the conveyors, it is essential

to check that:
Make sure that the Feed Conveyor is in

the working position.
Wire ropes supporting the Discharge

Conveyor head should be correctly
tensioned by adjusting with the
turnbuckles.
WARNING
WEAR PERSONAL
warning.
The head and tail drums are correctly

fitted. ie. they are level, and that their
axes are square to the centre line of the
conveyor.
LOCKOUT PLANT.
Procedure.
All troughing and parallel idlers are

correctly fitted with their axles square to
the centre line of the conveyor, the side
roller lead is in the correct direction (i.e.
forward of centre) and all rollers are
rotating freely.
In the case of screw-type take up gears,
that these are adjusted initially to take up
slack from the belt and that equal tension
is applied to each side such that the
pulley is square to the centre line of the
conveyor.
Where skirt rubbers are fitted they are
not bearing down heavily on the belt.
There is no obstruction on the conveyor
that could cause accident or damage
when the conveyor is started.
FALLING HAZARD.
Tracking should be carried out with the belt

empty. With very stiff belts, which do not
trough well nor make proper contact with the
centre idlers roller when empty, it may only
be possible to track the return strand when
empty and the troughed side when loaded.
If the belt tends to run to one side the most
likely cause of the trouble will usually be
some distance before the point where the
running off is apparent, and in the case of
troughed strand probably at the second or
third idler behind the point where the belt is
moving out of its true line.
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Side Roller
and Spindle
Slots for
Adjustment
of
Transom
Belt
Travel
Side Roller and

Spindle
Centre Roller
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.
Ended Adjusting
Bar B (2off)
Grease Nipple
Belt Tensioning
Mechanism
Figure 9aj Conveyor Belt Tensioning

Mechanism
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9.16.3 Conveyor Belt Tensioning
DANGER
Both of the conveyors are tensioned at the

tailshaft. Tensioning mechanisms are located
on either side of the drum(s) (Figure 9aj).
ENTANGLEMENT
HAZARD.
warning.
Best practice is to tension each side a little at

a time and by the same amount until the belt
is tensioned. When tensioned, the drum must
be square to the conveyor frame.
WARNING
The correct tension is achieved when the

drive drum starts the belt and keeps it
running when loaded without any slip
occurring.
WEAR PERSONAL
warning.
The tension screws should be kept clean and

well oiled.
LOCKOUT PLANT.
Procedure.
Procedure
FALLING HAZARD.
warning.

3. Loosen locknut A(2 off) and the
clamping screws.
4. Tighten or loosen the square or hexagon
ended adjusting screw B(2 off) as
required.
5. Once correct tension has been achieved,
tighten locknut A(2 off). Tighten the
clamping screws.
! DANGER !
any adjustment be made on the
belt whilst the machine is running.
There is a risk of trapping parts of
the body if this is done.
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9.16.4 Maintenance of Conveyor(s)

The following checks should be made
regularly in order to keep the conveyor(s) in
good working order:
Observe all safety warnings.
Close down the machine (Section 8.2)

and implement the Lockout Procedure
On the Feed Conveyor inspect the

impact idlers and side wearing strips
beneath the feed conveyor belt for wear
and replace if necessary. Ensure that the
plant feed hopper (and check gate) is
satisfactory in relation to the conveyor.
Also make sure that the belt is kept
straight and central at all times.
For the Discharge Conveyor ensure that

central feed onto the conveyor belt is
maintained at all times and that the belt
at the point of feed is kept straight and
central at all times.
Inspect all skirt plate sealing strips and

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

centrally and straight on both the
carrying strand and the return strand. If
not, refer to Section 9.16.2 Training of
Belts.
DANGER
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
warning.
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Check that there is no evidence of belt

slip at the driving drum, as belt slip will
cause premature wear on the belt.
Check also for undue sag between
idlers. Both would indicate lack of belt
tension (Section 9.16.3)
Check regularly that the idler rollers are

rotating freely. If not either free them or
replace the idler. Failure to do so will
result in belt wear and tracking
problems.
Check that the belt cleaning equipment is

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

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

bearings need re-greasing every two
weeks (Section 9.4.5).
! DANGER !
Do not use clip joints for belt
repairs or replacements, as they
can be dangerous. Belt repairs/
replacements should be
performed by vulcanising only.
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Follow the lubrication schedule for the

oil lubricated gearbox located inside the
Feed Conveyor head drum (Section
9.4.5). The gearbox must be filled up to
the centre line and two sight glass plugs
are provided at 180 (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 90 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
whilst it is moving as this creates a
risk of trapping parts of the body.
Hydraulic Motor
Conveyor Head Drum
Fill/Drain/Level Plugs (1 hidden)

Figure 9ak Feed Conveyor Drive Gearbox
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9.16.5 Cleaning the Conveyor

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

equipment i.e. eye, foot, hand and head
protection etc as may be required or
necessary to undertake the task.
3. Gloves to protect the skin against
abrasive materials, sharp surfaces, or
penetration of the skin should be worn.
4. Goggles should be worn to protect
from fragments, particles, or dust that
could be ejected into the eyes.
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5. Not only the worker(s) cleaning the belts

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

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

drum it may be necessary to loosen the
tension on the conveyor belt so that the
blockage can be removed. See Sections
9.16.2 and 9.16.3 for re-tensioning and realigning the belt after blockage is removed.
When work is complete, make sure that all
guards are closed / replaced and secured
before re-starting the machine.
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9.17 Metal Detector
WARNING
A Metal Detector is fitted to the Feed

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

automatically stop the Feed Conveyor when
the detector is triggered.
Whilst the detector is switched on the green
light on the panel door (Figure 9al) will be
illuminated and upon metal being detected
the red light will also illuminate. The red light
is also the reset button to be pressed when
the offending object has been removed.
The sensitivity of the detection can be varied
to suit the operation as described overleaf.
! NOTICE !
When adjusting the sensitivity of
the detector unit it is most
important the setting will not allow
pieces of steel to enter the
Automax which would damage the
machine.
Red DETECT light and RESET button
Figure 9al Metal Detector Control Panel
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9.17.1 Metal Detector Controls
WARNING
Normally, once the Metal Detector has been

set up at the time of plant commissioning
there should be no need to alter any of the
controls within the control cabinet (Figure
9am) and the panel door should be kept
closed to avoid the ingress of dust.
However, in the event of subsequent
adjustment being necessary the following
instructions should be read but any major
changes should only be attempted by an
engineer conversant with the operation of
the Maxtrak plant as a whole.
! NOTICE !
When opening the door of the
Metal Detector control panel do
not tamper with the terminal
blocks or wiring unless the unit is
switched off.
With the power ON the GREEN lamp on
the door case will be illuminated. Opening
the panel door will reveal the setting controls
(Figure 9am).
WEAR PERSONAL
warning.
After the above adjustments the detector

may have illuminated the DETECT light and
the RESET lamp on the detector door.
Pressing RESET lamp button will extinguish
both lights.
The relay function is controlled by the
RELAY switch. In the OFF position only the
DETECT light and door RESET lamp
operate when metal is present in the sensing
area.
In the LATCH position the relay and above
indicators operate but after metal is removed
the relay and the indicators remain on until
either the door RESET button is pressed or
the RELAY switch is turned to the ON or
OFF position.
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
desired size of material or to allow for
smaller pieces of material to be ignored.
FAULT Light
! NOTICE !
Use the sensitivity control very
carefully so as not to allow
damaging pieces of uncrushable
material to enter the Automax
crusher.
DETECT Light
SET ZERO
indicator lights
RELAY switch
SET ZERO
Control
Figure 9am Metal Detector Setting Controls
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9.17.2 Metal Detector Indictor

Lights (Figure 9am & 9an)
SET ZERO - When the Metal Detector is
operating and correctly set, the GREEN light
of these three lights is illuminated. If a piece
of metal passing across the sensor coil is
large enough it will cause the GREEN light
to extinguish and the right hand RED light to
come on whilst the metal is within the
sensing range of the sensor coil.
DETECT - This RED light illuminates
whenever metal is within the sensing range
of the sensor coil.
COIL FAULT - This RED light illuminates
whenever the sensor is either open circuit,
not connected or short circuited. The light
also causes the DETECT light to illuminate
to prevent operation of the detector until the
coil fault is rectified.
SIGNAL LEVEL INDICATOR - This

consists of a row of 10 lamps which light in
sequence from left to right as the detected
signal level increases when metal
approaches the sensor. The alarm is
triggered when the signal level reaches the
right hand lamp which is permanently
illuminated. Normally none or perhaps the
first 1 or 2 lamps may be flickering on and
off..
However, if the detector regularly suffers
from false alarms this indicator should be
examined since more lamps flickering on and
off may indicate the presence of some
interference which is either mains or
airborne. In this case have a qualified
engineer investigate and rectify.
Normally, the Metal Detector control unit

should not require any major readjustments
after initial commissioning of the plant. After
being switched on the GREEN SET ZERO
light should illuminate immediately without
the need to turn the SET ZERO control.
Certain extremely large objects may produce
an overload signal causing the unit to indicate
continuously even after the object has
passed clear of the sensor coil. Depress the
RESET button to cancel the indication.
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Signal Level Indicator Lights
Sensitivity Control
Figure 9an Metal Detector Setting Controls
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9.18 Plant - Dust Suppression

The Maxtrak plant is fitted with a plain
water dust suppression system. The system
consists of three spray bars each one having
three nozzles. The spray bars are located in
the following areas:
Crusher feed chute.
Crusher discharge area.
Product conveyor discharge.
WARNING
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Procedure.
It is the responsibility of the customer to

supply the system with clean water. This is
supplied at the manifold (Figure 9ao). The
total flow requirement for the system is 7
litres/min.(2 US galls/min.) This equates to a
pressure requirement of 2.8 bar or 42 psi.
FALLING HAZARD.
warning.
Maintenance
All nozzles should be kept free of dirt and
blockages. Each nozzle should be checked
every time the dust suppression is switched
on. Shut-off valves are provided for each
spray bar at the manifold.
The system can be drained after operation
by the drain valves located below the inlet
manifold. This is particularly important in
winter time when there is the likelihood of
the system freezing.
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Water
Inlet Point
Crusher
Discharge
Area
Crusher
Feed
Chute
Product
Conveyor
Discharge
Figure 9ao Dust Suppression Manifold
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9.19 Plant - Diesel Engine
WARNING
! NOTICE !
WEAR PERSONAL
warning.
For the diesel engine powerpack

fitted to your Maxtrak to continue
to perform safely, efficiently and
reliably it is imperative that all the
recommendations given in the
separate engine manual are
strictly followed with regard to:
Safety
Operation
Lubrication
Maintenance
Service
Parts
LOCKOUT PLANT.
The HFO clutch is operative when the

engine powered hydraulic system is at
operating pressure. Should the hydraulic
pressure fall below a preset level, the Feed
Conveyor will be stopped to prevent any
further material from entering the Automax
whilst there is a risk of the clutch slipping
due to the low oil pressure.
Adhere to the regular maintenance

schedules and procedures specified by the
manufacturer using the numbers of hours run
as displayed on the engine Service Meter.
Until the reason for the low pressure has

been established and the fault rectified the
plant cannot be operated.
All matters relating to the diesel engine can

be dealt with directly by your local official
engine dealer for the unit fitted without
consulting 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 -10C to +40C (+14F to +104F).
Appropriate lubricants and coolant must be used as specified within the plant and engine operating and
maintenance manuals.
For use in temperatures outside the above range consult your Terex Pegson Dealer or 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
WARNING
The drive from the engine to the Automax

crusher is through an HFO hydraulic oil
actuated clutch. This totally enclosed unit
has the outer driving ring connected to the
diesel engine flywheel. The output shaft is
supported by a spherical roller bearing, oil
lubricated, fitted in a cover flanged to the
engine flywheel housing.
WEAR PERSONAL
warning.
LOCKOUT PLANT.
Check the bearing oil level prior to the daily

start up of the plant: as a minimum
requirement, level stick must be oil wet. The
oil filler/dipstick can be accessed at the rear
of the engine housing.
! NOTICE !
Engage the clutch ONLY at engine
at idling speed (1200 rpm). At
ambient temperature close to or
below 0 C (32 F), keep engine
running at idling speed for 5
minutes, at least.
Filler Cap with Dipstick
When changing the oil, drain the old oil by

opening the tap located at the bottom of the
bearing housing. Make sure this is tightly
closed before adding fresh oil of the
approved grade - Section 9.4.6 (DO NOT
USE SYNTHETIC OIL) filled to the
required level. Remove taper plug (41) and
through pipe (34) fill the bearing cavity. Turn
the shaft by hand until the maximum oil level
is indicated on the stick (37). After oil filling,
remount the taper plug. See Section 10 parts
list to identify reference numbers.
Check the clutch driving plates annually and
it is advisable, every 4000 working hours, to
check the condition of the bearings and
replace the rotating seals (refer to parts list).
Figure 9ap Clutch Oil Filler
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9.19.3 Check Fuel Level

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

the fuel system near naked lights
or sources of sparks, such as
welding equipment.
Figure 9aq Fuel Level Indicator - Engine
Control Panel
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9.19.4 Top Up Fuel Level
WARNING
! NOTICE !
Do Not fill the tank to capacity.
Monitor the gauge located on the
Control Panel (Figure 9aq).
Allow room for expansion and
wipe up spilt fuel immediately,
otherwise paintwork will be
damaged.
WEAR PERSONAL
warning.
LOCKOUT PLANT.
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 !
Figure 9ar Filler Cap
Never remove the filler cap or

refuel, with the engine running.
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! DANGER !
fuel system.
welding equipment.
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9.20 Plant - Vehicle Tracks
WARNING
! NOTICE !
WEAR PERSONAL
warning.
It is essential that the tracks are

correctly tensioned at all times.
Check track tension regularly
(Section 9.21.1).
LOCKOUT PLANT.
Keeping the track properly adjusted will

increase the service life of the track and
drive components.
When ordering Spare Parts it is essential to
quote the plant serial number (with either a /
S or /T suffix if included on the identity plate
serial number).
Frequently check for loose bolts, oil leaks,
master pins are correctly located and tight,
general wear and damage, correct track
tension, etc. to ensure safe working and long
life.
When travelling on a gradient, the tracks
should be driven with the track idler rollers
(Figure 9ay) in front (ie. Feed Hopper first).
! WARNING !
Prior to attempting any
manoeuvring of the plant the
tracks must be free of
obstructions, including crushed
material and fines. Do not push or
tow the plant. Failure to observe
this warning could result in injury
to persons and damage to the
plant which may invalidate
warranty.
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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Page 9 - 129

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 !

GREASE UNDER HIGH

PRESSURE
To Release Track Tension (After
measurement - Section 9.20.1):-
WARNING
Procedure
WEAR PERSONAL
warning.

LOCKOUT PLANT.
3. Locate the access aperture on the side

of the track frame and remove the cover
(where fitted) to reveal the relief valve
inside.
4. Next loosen the relief valve by turning
counter clockwise using gradual
increments until the grease begins to be
expelled. Care must be taken not to
loosen the relief valve too quickly
because the grease inside is under
high pressure.
5. When the correct track tension has been
measured (Section 9.20.1), turn the relief
valve clockwise to tighten and then clean
away all trace of expelled grease.
! DANGER !
Grease coming out of the relief
valve under pressure can
penetrate the body causing injury
or death; do NOT watch the relief
valve to see if grease is escaping
but instead watch the track
adjustment cylinder to verify that
the track is being loosened.
DO NOT OVER TENSION THE
TRACKS (Refer to Section 9.20.1).
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Page 9 - 131
6. Operate the plant in manoeuvring mode

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

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

measurement - Section 9.20.1):-
DANGER
Procedure
WARNING
3. Locate the access aperture on the side

of the track frame and remove the cover
(where fitted) to reveal the relief valve
inside.
WEAR PERSONAL
warning.
4. Connect the grease gun to the grease

fitting and add grease until the track
tension is within the specified dimension
(Section 9.20.1). See Section 9.4.5. for
the grease type and specification.
LOCKOUT PLANT.
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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Page 9 - 133
9.20.3 Track Maintenance
WARNING
(Figure 9at)
WEAR PERSONAL
warning.
Maintenance Schedule
The first drive oil replacement is to be

carried out after 100 operating hours of
the gearbox.
There after replace the drive oil every

1000 hours or at least once per year.
Check the drive oil level every 100

working hours.
LOCKOUT PLANT.
Daily
Procedure
! NOTICE !

3. Check the track rollers and idler wheels
for possible leakage.
4. Check the track surface of the track
rollers, idler wheels, track shoes and
drive sprockets for wear and loose
mounting bolts.
5. Clean out any heavy build up of material
from around the tracks.
To maximise the life of the track,

keep it movable and avoid
damage, the plant should be
moved at least every week, by a
distance exceeding four times the
track length. It should also be
parked on level ground overnight
and during periods to of nonusage. This is particularly
important when working in
adverse conditions.
6. Check the tension of the tracks (Section

9.20.1) and adjust tension if necessary
(Section 9.20.2).
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9.20.4 Drive Oil Filling and Draining
WARNING
Oil Filling
WEAR PERSONAL
warning.
Procedure
LOCKOUT PLANT.

3. Make sure the gearbox housing is
horizontal.
4. Rotate the gearbox housing so that one
plug is at the 12 oclock position and the
other plug is at the 9 oclock position
(Figure 9au).
5. Unscrew the two plugs and fill from the
upper hole until the oil flows from the
hole located at the 9 oclock position.
See Section 9.4.6 for oil type and
specification.
Oil Fill (A)
6. Clean plugs using a clean non-flammable

solvent.
7. Apply pipe sealant to the plugs and
install.
8. Repeat procedure on the other final
drive.
Note:- Over filling the final drive will cause
the travel motor seal to allow hydraulic oil or
water to enter and contaminate the drive.
Oil Level (B)
Figure 9au Tracks - Oil Filling
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Page 9 - 135
Oil Draining
WARNING
Procedure
WEAR PERSONAL
warning.

LOCKOUT PLANT.
3. Rotate the gearbox housing until a plug is

at the 6 oclock position (Figure 9av).
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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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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10 - Spare Parts
Page 10 - 2
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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Page 10 - 3
10.1 Automax Crusher Parts

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

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Upper Frame Assembly
REF
PART NUMBER
DESCRIPTION
AX857/06/04
603-9091
FEED
(NOT SHOWN)
FEEDBOX
RING
2230-1222
SCREW
2210-0019
WASHER
2211-0010
WASHER
320/33
SHOULDED DOWEL
603/9090
WEDGE
603/9089 *
2402-2040
UPPER FRAME (MEDIUM COARSE)

UPPER FRAME (EXTRA COARSE,
COARSE AND AUTOSAND)
BEARING
2147-0028
LOCTITE 50 ML
2530-1135
GREASE NIPPLE
12
2968-4102
GREASE GUN
2123-2002
MOLY-BENTONE GREASE CARTRIDGE
300/252
GREASING INSTRUCTION PLATE
603/9053E *
CONCAVE (EXTRA COARSE)
603/9107E *
CONCAVE (COARSE)
603/9052E *
CONCAVE (MEDIUM COARSE)
603/9071E *
CONCAVE (AUTOSAND)
2144-0001
PEGBAK PACK - 1 TIN A/ 1 TIN B (5 KG)
2144-0002
RELEASE AGENT
603/9083 *
6
QUANTITY
1
6
* 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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Hydraulic Cylinder Fixings
REF
PART NUMBER
DESCRIPTION
QUANTITY
603/9100
PIN
12
2210-2017
WASHER
24
311/9
WASHER
24
2201-0148
SPLIT PIN
24
603/934
SPACER
24
2402-2040
BEARING
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10 - Spare Parts
Page 10 - 9
6
5
4
4
2
1000 Automax - Hydraulic Cylinder Fixings

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Page 10 - 10
Cone head Assembly

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

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Eccentric Assembly
REF
PART NUMBER
DESCRIPTION
QUANTITY
2152-9050
TUFNOL STRIP
11
2222-6753
CAPSCREW
2410-9007
BEARING PAIR
2415-9901
BEARING
2430-0584
CIRCLIP
302/15
BEVEL GEAR
323/37
STUD
2215-0016
NUT
603/9115
LOCKWASHER
332/2
KEY
2222-6748
CAPSCREW
603/6008*
ECCENTRIC (LONG THROW)
603/1120*
ECCENTRIC (SHORT THROW)
603/9079MCD
PISTON RING (ROTARY SEAL)
307/2
'O' RING
603/9006*
ROTARY SEAL RING (LONG THROW)
603/9094*
ROTARY SEAL RING (SHORT THROW)
8
9
10
11
* 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
REF
PART NUMBER
DESCRIPTION
2217-9007
BEARING LOCKNUT
2230-1356
SCREW
2211-0014
WASHER
2230-1122
SCREW
2211-0007
WASHER
2415-9002
BEARING
1787
2443-1774
PULLEY
2443-8365
TAPER LOCK BUSH (+ KEY 2432-1404)
2450-5002
RINGFEDER
307/6
'O' RING
2503-3153
OIL SEAL
10
302/26
BEVEL PINION
11
2432-1404
KEY
12
603/9004
COUNTERSHAFT HOUSING
13
603/9022
SHIM PAIR 1.5 THK
603/9109
SHIM PAIR 0.8 THK
603/9019
OIL GUARD 1000
2147-4002
SEALANT 50 ML
605/909
COUNTERSHAFT
14
15
16/10/03
QUANTITY
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1000 Automax - CountershaftAssembly

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Lubrication Piping Assembly

REF
PART NUMBER
1
2510-3067
2
2510-3526
3
2520-6566
4
2520-6580
5
HOSE 48
6
341/439
7
2510-3898
8
2510-3114
9
2520-6570
10
AX857/27
11
2512-0007
12
2215-0014
13
2211-0008
14
HOSE 52
15
2510-3147
16
2520-6571
17
HOSE 49
18
2520-6572
19
HOSE 47
20
2520-6573
21
2520-6575
22
2500-1023
23
2520-6574
24
2520-6579
25
2510-3589
26
2510-3149
27
2520-6576
28
2340-4007
29
2520-6572
30
2510-3789
31
2581-8125
32
2534-4001
33
2520-6577
34
2520-6578
35
HOSE 64
36
2510-3790
37
38
39
2520-6581
40
2529-9904
Revised 22/07/03
DESCRIPTION
BEND
REDUCTION SOCKET
TAPER NIPPLE
ELBOW
HOSE
PIPE
BACKNUT
ELBOW
NIPPLE
SUPPORT BRACKET
U BOLT
NUT
WASHER
HOSE
ELBOW
NIPPLE
HOSE
NIPPLE
HOSE
ELBOW
REDUCER
BONDED SEAL
TEE
REDUCER
REDUCER
ELBOW
HOSE TAIL
JUBILEE HOSE CLIP
REDUCER
SOCKET
OIL TANK
HEAT EXCHANGER
NIPPLE
BEND
HOSE
SOCKET
WEBER
PIPE
PLUG
HOSE GUARD
QUANTITY
1
1
1
2
1
1
1
1
1
1
1
4
2
1
1
1
1
1
1
3
2
2
1
1
2
2
2
2
2
1
1
1
4
1
1
2
1
1
1
1 METRE
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1000 Automax Mobile Plant - Lubrication Oil Piping
Page 17
AX857-901-8EN-02f 309/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 18
Crusher Hydraulic Assembly

REF
PART NUMBER DESCRIPTION

QUANTITY
HYDRAULIC CYLINDER CIRCUIT
(ONLY ONE HALF OF COMPLETE CIRCUIT ILLUSTRATED)
2500-1021
SEAL
16
2520-0120
QUICK RELEASE COUPLING - MALE
2520-0130
QUICK RELEASE COUPLING - FEMALE
2520-6026
REDUCER
12
2520-6376
TEE ADAPTOR
10
2520-6334
ELBOW ADAPTOR
2520-6125
REDUCER
12
2521-1800
HOSE ASSY - 200
2521-1810
HOSE ASSY - 700
10
2521-1824
HOSE ASSY - 275
11
2521-5202
HOSE ASSY - 300
12
2521-5208
HOSE ASSY - 600
13
2521-5216
HOSE ASSY 1000
14
2521-5220
HOSE ASSY - 1400
15
2564-0040
HYDRAULIC CYLINDER
16
2554-0003
OVERLOAD VALVE
17
2564----35
GAITER
18
2564-9310
CYLINDER SEAL KIT
19
2525-5001
20
HYDRAULIC HOSE 4600 LG.

DUMPY JACK HYDRAULIC CIRCUIT
(CIRCUIT NOT ILLUSTRATED)
2564-7101A
HOSE ASSY 190
11
21
2564-7101B
HOSE ASSY 120
22
2564-7101C
HOSE ASSY 250
23
2564-7101/D
HOSE ASSY 4600
24
2520-6002
ADAPTOR
25
2564-7101F
TEE
26
2500-1011
BONDED SEAL
27
2564-7101H
QUICK RELEASE COUPLING COMPLETE
LOOSE ITEMS
28
2147-0024
LOCTITE 50 ML
29
18/08/04
2618-4003
KLAXON
AX857-901-8EN-02f 310/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 19
16
1
17
15
18
11
4
12
3
14
10
13
2
8
19
1000 Automax - Hydraulic Cylinder Circuit
AX857-901-8EN-02f 311/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 20
Hydraulic Control Panel Assembly
REF
1
2
3
4
5
6
7
8
9
10
11A
11B
12
13
14
20/08/04
PART NUMBER
2580-1137
2589-5122
2589-5125
2589-5268
2589-5277
2589-5269
2589-5265
2589-5270
2589-5271
2589-5272
2589-5273
2589-5266
2589-5031
2589-5302
2589-5303
2589-5301
2589-5275
2589-5276
DESCRIPTION
PANEL REF L736
PRESSURE FILTER
REPLACEABLE FILTER ELEMENT
PRESSURE FILTER
SOLENOID VALVE
DOUBLE PILOT OPERATED CHECK VALVE
UNLOADER VALVE
PRESSURE REDUCING VALVE
CHECK VALVE
NEEDLE VALVE
BACK MOUNT PRESSURE GAUGE
PRESSURE SWITCH
PRESSURE SWITCH
PRESSURE SWITCH
MANIFOLD BLOCK
MOUNTING PLATE
QUANTITY
1
1
1
1
1
1
1
2
1
1
2
3
1
1
1
1
1
AX857-901-8EN-02f 312/390
Maxtrak
1000
EN
10 - Spare Parts
10
9
12
2
10
5
AX857-901-8EN-02f 313/390
1000 Automax - Hydraulic Control Panel Assembly
11B
11A
10
6A
10
3
4
6B
8
7
14
13
Page 10 - 21
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 22
Lubrication Oil Tank Assembly
REF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18a
19
20
21
22
23
20/08/04
PART NUMBER
2581-8139
2510-3844
2589-1074
2589-1074
2589-2016
2589-2054
2589-2031
2589-2055
2589-2108
2589-2002
2576-4086
2589-2036
2589-2030
2589-2045
2589-2046
2589-2090
2589-2058
2538-7210
2589-2059
2589-2089
2589-2060
2589-2005
2589-2032
2589-1019
2589-2061
2589-2062
2589-2063
DESCRIPTION
TANK REF L732
DRAIN PLUG
2 SUCTION FILTER ELEMENT
GEAR PUMP
FLUID LEVEL GAUGE
BELL HOUSING
DRIVE COUPLING
FILLER/BREATHER CAP
HYDRAULIC MOTOR
PRESSURE FILTER UNIT
TWIN FILTER HEAD
PRESSURE SWITCH
THERMOSTAT
1 BSP CHECK VALVE
KOBOLD FLOW METER
AIR BLAST COOLER COMPLETE
COOLER FAN AND MOTOR UNIT ONLY
BULLS EYE LEVEL GAUGE
THERMOSTAT
FLOAT SWITCH
PRESSURE GAUGE
PRESSURE GAUGE ADAPTOR
RESERVOIR AND LIDS
ELECTRICAL JUNCTION BOX
2589-2064
2589-2065
FLEXIBLE MOUNT
MOTOR MOUNT PLATE
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
AX857-901-8EN-02f 314/390
Maxtrak
1000
EN
10 - Spare Parts
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
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 24
10.2 Plant Conveyors

Feed Conveyor Parts - sheet 1
REF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
PART NUMBER
2473-0001
2421-2008S
AX848/113(01)
AX848/57/1
AX848/58/1
AX848/77/1
AX848/77/2
AX848/77/3
AX848/36/1
AX848/36/2
AX607/3/46
AX868/104
2495-3012
AX857/2/1
AX857/2/2
2495-1196
AX848/73/1
AX848/61/1
AX848/61/2
AX848/65/1
AX848/65/2
AX848/66
AX848/65/05
AX848/65/03
AX848/65/04
2366-2005
2366-2004
27
AX848/63
28
AX848/62/01
29
AX848/62/02
AX857/22/06 - 22/07/03
DESCRIPTION
MOTOR & GEARBOX
HEAD DRUM BEARING
HEAD DRUM
GEARBOX SUPPORT
BEARING SUPPORT
HEAD DRUM NIP GUARD
HEAD DRUM NIP GUARD SUPPORT ANGLE
HEAD DRUM NIP GUARD SUPPORT ANGLE
BELT SCRAPER FRAME
BELT SCRAPER CLAMP STRIP
TENSIONING ELEMENT
SCRAPER BLADE
MULTI TROUGH IDLER
CONVEYOR STRINGER SECTION
DISC ROLLER SUPPORT BRACKET
RETURN DISC IDLER
RETURN DISC IDLER BASKET GUARD
BARGE BOARD
BARGE BOARD
CENTRAL BELT SUPPORT
CENTRAL BELT SUPPORT STIFFENER
BELT SUPPORT BRACKET
BELT SUPPORT SIDE WEDGE
SIDE BELT SUPPORT
SIDE BELT SUPPORT STIFFENER
METAL DETECTOR SENSOR AND CONTROL BOX
METAL DETECTOR CONTROL BOX ONLY
METAL DETECTOR BRACKET
HDPE BARGE BOARD INSERT
HDPE CLAMP FLAT
QUANTITY
1
1
1
1
1
1
2
2
1
1
2
1
1
1
2
1
1
1
1
2
2
4
8
2
2
1
1
2
2
2
NB. Fixings are not included with the above parts unless specifically ordered
AX857-901-8EN-02f 316/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 25
REF
30
31
32
33
34
35
36
37
38
43
44
45
46
47
48
49
50
PART NUMBER
AX848/64/1
AX848/64/2
2489-1062
AX857/3/1
AX857/49/01
AX857/49/02
AX857/49/03
AX857/49/04
AX857/49/05
AX848/70/1
AX848/70/2
2495-1130A
AX857/09/01
AX857/10/01
2495-3011
AX848/33
2421-0011S
2530-2013
51
AX818/110/1
52
AX818/110/1X
53
AX848/34/3
54
AX868/105/01
55
AX848/34/1
56
AX848/34/2
57
AX848/79/2
58
AX848/79/1
59
AX857/90/01
65
AX857/12/01
66
AX857/26/01
AX857/22/06 - 22/07/03
DESCRIPTION
BARGE BOARD WING PLATE
BARGE BOARD WING PLATE
RUBBER COVERED CENTRE ROLLER
HOPPER
STRICKLE GATE MOUNTING PLATE
STRICKLE GATE RH OUTER
STRICKLE GATE LH OUTER
STRICKLE GATE CENTRE
STRICKLE GATE HINGE PIN
HDPE SIDE SUPPORT WEAR PAD
HDPE SIDE SUPPORT WEAR PAD
RETURN IDLER
MID SECTION NIP GUARD
SIDE RETURN NIP GUARD
MULTI TROUGH IMPACT IDLER BASE PLATE
TAIL DRUM
TAIL DRUM BEARING
GREASE PIPES FOR BEARINGS (KIT FOR 2
BEARINGS)
TELESCOPER UNIT LH
TELESCOPER UNIT RH
FEED PLOUGH SCRAPER BLADE
TAIL DRUM GUARD SCRAPER BLADE
FEED SCRAPER PLOUGH
FEED SCRAPER PLOUGH CLAMP STRIP
FEED SCRAPER SUPPORT LINK
FEED TAIL DRUM SCRAPER
TAIL DRUM GUARD
UPPER PLATFORM STRUCTURE
UPPER PLATFORM HANDRAIL
QUANTITY
1
1
10
1
1
1
1
1
1
2
2
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
AX857-901-8EN-02f 317/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 26
REF
67
68
69
70
71
72
73
74
75
76
77
78
PART NUMBER
AX857/13/01
2389-9143
2360-0050/14
AX857/21/01
AX857/21/02
AX857/18/01
AX857/18/02
AX857/18/03
AX857/18/04
AX848/106/01
AX857/20
AX857/35/01
DESCRIPTION
QUANTITY
UPPER PLATFORM OPEN MESH
1
RUBBER BUFFER
4
CONVEYOR BELT
1
RUBBER SIDE SKIRT
2
RUBBER REAR SKIRT
1
CLAMP STRIP - HOPPER SIDE
6
CLAMP STRIP - HOPPER REAR
1
CLAMP STRIP BARGE BOARD - LOWER
2
CLAMP STRIP BARGE BOARD UPPER
2
UPPER PLATFORM INNER RAIL
1
FEED CONVEYOR SIDE GUARDS
1 SET
HOPPER EXTENSION SIDEPLATE
1
HOPPER EXTENSION SIDEPLATE (OPPOSITE
1
79
AX858/35/02
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
AX857-901-8EN-02f 318/390
10 - Spare Parts
Maxtrak
1000
EN
1000 Maxtrak - Feeder Conveyor Parts
Page 10 - 27
AX857-901-8EN-02f 319/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 28
Level Sensor - Crusher Unit MR1
REF
PART NUMBER
1
2210-0016
2
2215-0013
3
2232-1105
4
2510-3895
5
2512-0004
6
2640-5004
7
Ax860/170/01
8
AX860/172/01
30/05/03 AX860/171/01
DESCRIPTION
PLAIN WASHER
NUT
BOLT
BACKNUT
U BOLT
LEVEL SENSOR PROBE
SENSOR SUPPORT
LEVEL SENSOR SUPPORT BRACKET
QUANTITY
1
5
1
1
2
1
1
1
AX857-901-8EN-02f 320/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 29
Automax Feed Box
Level Sensor - Crusher Unit MR 1
AX857-901-8EN-02f 321/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 30
Blank page
AX857-901-8EN-02f 322/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 31
Discharge Conveyor Parts - sheet 1
REF
1
PART NUMBER
2421-0010S
2530-2012
2
2450-5503
3
2495-1129
4
2495-1159
5
2495-3004
6
2495-3005
7
2495-3026
8
2576-4073
9
AX607/3/46
10
AX801/16/01
11
AX801/16/02
12
AX818/07
13
AX818/34
14
AX818/156
15
AX818/110/01
16
AX818/110/01X
17
AX818/34/01
18
AX818/34/02
19
AX818/34/03
20
AX818/73/01
21
AX818/73/01A
22
AX818/74/01
23
AX857-117-501
AX857/69/01
AX857/69/02
AX857/69/03
24
AX848/39
25
AX848/40
26
AX848.41
27
AX848/51
28
AX848/100
29
AX848/56/01
30
AX848/56/02
AX857/51/04 16/07/04
DESCRIPTION
BEARING
GREASE PIPES (KITFOR 4 BEARINGS)
SHRINK DISC
RETURN IDLER
RETURN IDLER
ANGLE TROUGHING SET
ANGLE TROUGH SET
SPIRAL ROLLER
HYDRAULIC MOTOR
TENSIONING ELEMENT
SPRAY BAR SUPPORT
SPRAY BAR SUPPORT
HEAD DRUM
SCRAPER FRAME
DUST COVER SUPPORT
TELESCOPER RH
TELESCOPER LH
SCRAPER BLADE FRAME
SCRAPER BLADE
BRACKET
ROSTER UNIT SUPPORT
ROSTER UNIT SUPPORT
TORQUE ARM
FEED BOOT
FEED BOOT LINER PLATE CENTRE
FEED BOOT LINER PLATE REAR
FEED BOOT LINER PLATE FRONT
GUARD IN CHASSIS
BARGE BOARD
MID SECTION GUARD
TAIL STRUT
FEED BOOT RUBBER SUPPORT ANGLE
PIN (PRODUCT CONVEYOR TO CHASSIS)
PIN (CONVEYOR TAIL TO CROSS BEAM)
QUANTITY
4
1
1
2
6
2
4
4
1
2
1
1
1
1
7
1
1
1
1
1
1
1
1
1
2
2
2
1
2
1
2
1
2
2
AX857-901-8EN-02f 323/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 32
Discharge Conveyor Parts - sheet 2
REF
PART NUMBER
31
AX848/56/03
32
AX848/56/04
33
AX848/71/01
34
AX848/71/02
35
AX848/71/03
36
AX848/71/04
37
AX848/71/05
38
AX848/71/06
39
AX848/88/01
40
AX848/88/02
41
AX857/50
42
AX857/52
43
AX857/53
44
AX857/55
45
AX857/56
46
AX857/64
47
AX857/65
48
AX857/79
49
AX857/50/03
50
AX857/51/24
51
AX857/57/01
52
AX857/61/01
AX857/51/03 22/07/03
DESCRIPTION
PIN (CONVEYOR TAIL TO STRUT)
PIN (STRUT TO BRACKET)
CLAMP STRIP
CLAMP STRIP
CLAMP STRIP
CLAMP STRIP
CLAMP STRIP
CLAMP STRIP
SIDE SKIRT
SIDE SKIRT
STRINGER SECTION
TAIL FRAME
TAIL DRUM
NIP GUARD
HEAD GUARD
RETURN ROLLER NIP GUARD
SHRINK DISC GUARD
TAIL BEARING SHIM
SPIRAL ROLLER SUPPORT BRACKET
CONVEYOR BELT
SPIRAL ROLLER NIP GUARD
RETURN ROLLER NIP GUARD
QUANTITY
2
2
2
4
2
2
2
2
2
2
1
1
1
1
1
2
1
2
2
1
1
1
AX857-901-8EN-02f 324/390
1000 Maxtrak - Discharge Conveyor Parts
Page 33
AX857-901-8EN-02f 325/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 34
10.3 Plant Components

Plant Components - sheet 1
REF
PART NUMBER
1
AX857/01/01
2
AX848/49
3
AX857/17/01
4
AX857/17/02
5
AX857/17/03
6
AX857/17/04
7
AX848/98/01
8
AX848/98/02
9
AX848/48/01
10
AX848/48/02
11
AX848/47/01
12
AX848/47/02
13
AX848/37/01
14
AX848/37/02
15
AX857/15
16
AX848/43/01
17
AX848/43/02
18
2443-1787
19
2443-1708
20
2443-8334
21
2441-0470
22
AX848/59/01
23
AX848/59/02
24
AX848/59/03
25
AX848/59/04
26
AX848/59/05
27
AX848/59/06
28
603/9001
29
AX848/78/02
30
Revised 23/07/03
DESCRIPTION
CHASSIS
ENGINE/HYD. TANK OPEN MESH PLATFORM
ENGINE PLATFORM FRAME
ENGINE PLATFORM HANDRAIL
ENGINE PLATFORM HANDRAIL
ENGINE OPEN MESH PLATFORM
ENGINE OPEN MESH PLATFORM
ENGINE PLATFORM SUPPORT
ENGINE PLATFORM SUPPORT
PLATFORM KICKING STRIP - HYD TANK
PLATFORM KICKING STRIP ENGINE
ENGINE SUPPORT BEAM
LOWER PLATFORM SUPPORT
LOWER PLATFORM SUPPORT
AUTOMAX VEE PULLEY
ENGINE VEE PULLEY
ENGINE PULLEY TAPER LOCK BUSH
VEE BELTS
DRIVE GUARD LOWER PANEL
DRIVE GUARD LOWER PANEL
DRIVE GUARD UPPER PANEL
DRIVE GUARD INSPECTION COVER
DRIVE GUARD SUPPORT ANGLE
DRIVE GUARD SUPPORT ANGLE
1000 AUTOMAX CRUSHER
SPRAY BAR
U BOLT
QUANTITY
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
8
1
1
1
1
2
2
1
1
2
AX857-901-8EN-02f 326/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 35
REF
PART NUMBER
31
32
AX857/06/01
33
AX857/06/02
34
2294-0009
35
AX848/86
36
AX848/42/01
37
AX848/42/02
38
AX848/30
39
AX848/44/02
40
AX848/44/01
41
AX848/84/01
42
AX848/83/01
43
2389-0250
44
AX848/18/01
45
AX857/11
46
AX848/26
47
AX848/96/01
48
2592-2004
49
AX857/16/01
50
AX857/16/02
51
AX848/80/01
52
AX857/04/01
53
AX857/04/02
54
AX857/01/02
55
AX857/01/03
56
AX857/05/01
57
AX848/16/01
58
AX848/16/02
59
2480-0044
60
2451-1008
61
AX848/17
Revised 23/07/03
DESCRIPTION
SPRAY BAR NOZZLES
CRUSHER FEED BOX
CRUSHER FEED BOX DOOR
ANTILUCE FITTINGS
SAFETY BAR
LOWER SUPPORT FRAME
LOWER SUPPORT FRAME
UPPER PLATFORM SHIPS LADDER BRACKET
LOWER PLATFORM OPEN MESH LADDER SIDE
LOWER PFORM OPEN MESH NON LADDER SIDE
LOWER PLATFORM HAND RAIL LADDER SIDE
LOWER PLATFORM HRAIL NON LADDER SIDE
ANTI-VIBRATION MOUNTINGS
ADAPTOR PLATE
UPPER PLATFORM SHIPS LADDER
UPPER PLATFORM LADDER HANDRAILING
MESH LUBRICATION TANK COVER
OIL COOLER
PIN LOWER TRESTLE/CHASSIS
PIN LOWER TRESTLE/UPPER TRESTLE
PIN UPPER TRESTLE/FEED CONVEYOR
LOWER TRESTLE
UPPER TRESTLE
TRESTLE SUPPORT BEAM
FEED CONVEYOR SUPPORT BRACKET
HYDRAULIC CYLINDER
ENGINE ADJUSTMENT BRACKET
ENGINE ADJUSTMENT BRACKET
FINNINGS/CATERPILLAR ENGINE POWER PACK
ENGINE HYDRAULIC CLUTCH
HYDRAULIC TANK
QUANTITY
3
1
1
4
2
1
1
1
1
1
1
1
4
4
1
1
1
1
2
2
4
1
2
1
2
1
2
2
1
1
1
AX857-901-8EN-02f 327/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 36
REF
PART NUMBER
62
AX848/171
63
2512-4029
64
AX848/01
65
AX857/51
66
AX857/22
67
AX857/07/01
68
AX857/24/01
69
2389-1001
70
AX857/47/02
71
AX857/47/01
Revised 23/07/03
DESCRIPTION
LEVEL SENSOR SUPPORT
STAUFF CLAMP
CROSS BEAM ASSEMBLY
DISCHARGE CONVEYOR ASSEMBLY
FEED CONVEYOR ASSEMBLY
LUBRICATION TANK PROTECTION PLATE
RUBBER DRAPE DRIVE GUARD
RUBBER BUFFER
SAFETY GATE LH
SAFETY GATE RH
QUANTITY
1
2
1
1
1
1
2
6
1
1
AX857-901-8EN-02f 328/390
1000 Maxtrak - Plant Components
Page 37
AX857-901-8EN-02f 329/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 38
10.4 Plant Tracks
REF
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART NUMBER
2372-0110
2372-0078
2372-0079
AX818TRAKS04
2372-0088
2372-0107
2372-0111
2372-0109
2372-0112
2372-0007
2372-0008
2372-0009
2372-0073
2372-0074
2372-0072
2372-0075
AX818TRAKS02
AX818TRAKS03
AX818TRAKS01
2372-0017
2372-0018
2372-0019
DESCRIPTION
TRACK DRIVE GEARBOX C/W HYDRAULIC MOTOR
ADAPTOR
BONDED SEAL
STAND OFF PIPE
GEARBOX DRAIN PLUG
GEARBOX BOLTS
DRIVE SPROCKET
SPROCKET BOLTS
TRACK CHAIN COMPLETE
TRACK SHOE
TRACK SHOE BOLT
TRACK SHOE NUTS
IDLER
YOKE
RECOIL UNIT
TENSIONER SEAL KIT
GREASER
GASKET
ADAPTOR
ROLLER
ROLLER BOLT
ROLLER BOLT WASHER
2372-0010
2372-0011
REPAIR LINK - TRACK CHAIN

MASTER PIN - TRACK CHAIN
QUANTITY
2
2
2
2
4
32
2
40
2
112
448
448
2
2
2
2
2
2
1
16
64
64
22/07/03
AX857-901-8EN-02f 330/390
Maxtrak
1000
EN
10 - Spare Parts
14
11
10
15
13
12
16
Tracks Assembly - Maxtrak 1000
Page 10 - 39
AX857-901-8EN-02f 331/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 40
10.5 Plant Hydraulic System

Hydraulic Reservoir
REF
1
2
3
4
5
PART NUMBER
2552-6561
2589-2003
2531-1000
2105
2589-2032A
2531-5060
2531-5151
5a
2538-0053
6
2531-5155
2531-5150
2580-8009
6a
2538-0054
6b
2520-8002
7
2580-8005
Revised 22/07/03
DESCRIPTION
QUICK RELEASE COUPLING
FLUID LEVEL GAUGE
BREATHER
FLOAT LEVEL SWITCH
RETURN LINE FILTER
RETURN LINE FILTER GAUGE
SUCTION FILTER
O RING KIT
SUCTION FILTER GAUGE
2 SAE 3000 SERIES FLANGE & ADAPTOR
INSPECTION COVERS
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
1
2
AX857-901-8EN-02f 332/390
10 - Spare Parts
Maxtrak
1000
EN
6 6a 6b
5a
Maxtrak 1000 - Hydraulic Oil Reservoir Assembly
Page 10 - 41
AX857-901-8EN-02f 333/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 42
Hydraulic Components
REF
70
71
72
73
74
75
76
77
78
81
82
83
84
85
95
PART NUMBER
2573-6001
2550-9010
2550-9011
2531-5057
2531-5152
2592-2004
2592-9006
2592-9005
2553-2013
2550-9003
2579-0018
2579-0020
2576-4073
2473-0001
AX857/05
AX848/17
2550-9004
1
2553-2018
2
2553-2019
3
2589-5300
4
2553-2013
5
2553-2020
6
2553-2023
AX857/29-22/07/03
DESCRIPTION
PUMP - HYDRAULIC
VALVE HYDRAULIC, 3 WAY
VALVE HYDRAULIC, 4 WAY
FILTER ASSEMBLY
AIR BLAST COOLER COMPLETE
COOLER FAN AND MOTOR UNIT ONLY
COOLER RADIATOR ONLY
TEST POINT
MOTION CONTROL BLOCK
CHECK VALVE (FEED CONVEYOR)
CHECK VALVE (PRODUCT CONVEYOR)
MOTOR HYDRAULIC
GEARBOX & MOTOR ASSEMBLY
MOTOR HYDRAULIC (SEE SECTION 10.4)
CYLINDER HYDRAULIC
HYDRAULIC OIL RESERVOIR (SEE SECTION 10.5)
TRANSFER PLATE
QUANTITY
2
1
1
2
2
1
1
1
2
2
1
1
1
1
2
1
1
2
ENGINE HYDRAULIC CLUTCH CIRCUIT PARTS

CONTROL VALVE
RELIEF VALVE
PRESSURE SWITCH
TEST POINT
RESTRICTOR
RESTRICTOR
1
1
1
1
1
1
3
6
1
4
AX857-901-8EN-02f 334/390
Maxtrak 1000 - Hydraulic System Components
Page 43
AX857-901-8EN-02f 335/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 44
Hydraulic Hoses
Hose Number Tag
BL-Pegson Pt
Description
No
25202"BSP M/F swept
HOSE 1 3/4R2AT-ST/STx700mm
E/S/MB32/FB32
6598
2"SAE 3000Series clamp half + O ring 2340HOSE 2 3/4R2AT-ST/STx760mm
AFS306
2003
1"SAE 3000Series clamp half + O ring 2340HOSE 3 3/8R2AT-ST/STx620mm
AFS303
2002
HOSE 4 3/4R2AT-ST/90Sx7000mm
V12L/04
NONE*
25521/2"BSP Flat faced carrier
FFC-G12F
6556
T/MB06/FB06/MB 3/8BSP Tee Female on the run
2520-6599
06
HOSE 7 3/4R9R-Metric Male/90Sx1890mm
P/MB06
NONE*
25201/2BSP Plug
P/MB08
6581
25203/4BSP Plug
P/MB12
6600
25201.1/2BSP M/M
MB24
6601
25203/4BSP-1"BSPT M/M
HOSE 11 1/4R2AT-3/8FemaleNut/90SJICx2600mm MB12/MBT16
6577
25201.1/2BSP Female Tee
HOSE 12 3/4R9R-ST Flange/90Sx710mm
T/FB24
6586
25201.1/4BSP-1.1/2BSP M/M
HOSE 13 3/4R9R-90 Flange/STx800mm
MB20/MB24
6040
25202"BSP-2"BSPT M/M
HOSE 14 1/4R2AT ST/7/16JIC90Sx900mm
MB32/MBT32
6570
25103/4ELBOW M/F Black Iron
HOSE 15 3/4R9R ST/90Sx950mm
B92-12
3149
25203/4BSP-1/2BSPT M/M
HOSE 16 1/2R2AT JICST/JIC90Sx2000mm
MB12/MBT08
6572
25203/4BSP-3/4BSPT M/M
HOSE 17 1/2R2AT JICST/STBSPx5700mm
MB12/MBT12
6566
2340Hose clip for 3/4 Hose
HOSE 18 3/4R9R Metric Male/90Sx900mm
109-1A
4008
25102"BSP-3/4BSP R-Bush
HOSE 19 3/4R2AT Metric Male/90Sx900mm
B241-3212
3589
25203/4BSPT-3/4 Hose tail
HOSE 20 3/8R2AT ST/90Sx950mm
100B-1212
6576
Hose ref
Description x 1-off each
Fitting ref
AX857-901-8EN-02f 336/390
qty
1
2pr
2pr
0*
2
1
0*
4
1
1
0
1
1
2
2
1
1
2
2
1
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 45
Hose Number Tag
Hose ref.
Fitting ref.
HOSE 21 3/4R9R ST/90Sx1350mm [ARM]
100B-0812
HOSE 22 3/4R9R ST/90Sx1350mm [ARM]
MB04/FFB06
B270-12
B245-1208
342-02
342-04
342-06
HOSE 28 3/4R9R Metric Male/STx1100mm [ARM]
342-08
HOSE 29 3/4R9R Metric Male/STx1290mm [ARM]
342-12
342-16
342-20
MB04
HOSE 33 NONE*
MB06
HOSE 34 NONE*
MB08
MB12
MB02/MB04
HOSE 37 3/8R2AT ST/STx5000mm
MB04/MB06
MB06/MB08
HOSE 39 NONE*
MB06/MB12
Description
BL-Pegson
qty
Pt. No:
1/2BSPT-3/4 Hose tail
25201
6649
1/4BSPMale-3/8BSPFemale Fix 25201
6602
3/4 Socket
25100
3879
1/2BSP-3/4BSP R-NIP
2510- 12
3629
Bonded Seal 1/8
25002
1008
2500Bonded Seal 1/4
8
1011
Bonded Seal 3/8
25005
1015
Bonded Seal 1/2
250020
1018
Bonded Seal 3/4
250025
1021
Bonded Seal 1"
25005
1023
Bonded Seal 1.1/4
25005
1025
1/4BSP M/M
25201
6584
3/8BSP M/M
25204
6571
1/2BSP M/M
25202
6604
3/4BSP M/M
252015
6585
1/8BSP-1/4BSP M/M
25202
6635
1/4BSP-3/8BSP M/M
25204
6605
25203/8BSP-1/2BSP M/M
8
6606
3/8BSP-3/4BSP M/M
25201
6579
AX857-901-8EN-02f 337/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 46
Hydraulic Hoses, continued

Hose Number Tag
Hose ref.
BL-Pegson
Description
Pt. No:
25201/2BSP-3/4BSP M/M
MB08/MB12
6026
25203/4BSP-1"BSP M/M
MB12/MB16
6575
25203/4BSP-1.1/4BSP M/M
MB12/MB20
6034
25201.1/2BSP M/F SWEPT 90
E/S/MB24/FB24
6607
E/S/3/MB12/FB12
25203/4BSP M/F SWEPT 45
6578
25203/8 BSP M/F
MB06/FB06
6608
MB08/FB08
1/2 BSP M/F
25203/4 BSP M/F
MB12/FB12
6609
T/MB12/FB12/MB 3/4BSP Tee Female on run
2520-6574
12
25203/8BSP M/F Block Elbow 90
E/MB06/FB06
6596
E/MB08/FB08
6650
E/MB12/FB12
6580
E/S/MB04/FB04
6612
E/S/MB06/FB06
6563
E/S/MB12/FB12
6573
Fitting ref.
HOSE 40 NONE*
HOSE 41 NONE*
HOSE 42 NONE*
HOSE 52 NONE*
HOSE 53 2R1AT ST/45x1600mm c/w AZEB/32x1M
HOSE 54 3/4R2AT Metric Male/STx5000mm
HOSE 56 1.1/2R1AT Flange90S/STx650mm
BH/MB06
HOSE 57 2R1AT 1.1/2Female Nut/2STx3400mm
BH/MB12
HOSE 58 1.1/2R1AT Flange90S/STx1200mm
MB06/MM18
MJ04/MU04
3/8BSP BULKHEAD
6285
3/4BSP BULKHEAD
6291
3/8BSP-18mm M/M
6614
7/16JIC-7/16SAE M/M
12
4
3
1
0
2
0
3
4
4
2
3
2
1
15
2520-
2520-
2520-
2520-
AX857-901-8EN-02f 338/390
qty
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 47
Hose Number Tag
Hose ref.
Description
Pt. No:
7/8JIC-7/8SAE M/M
MJ10/MU10
6616
7/8JIC M/F Elbow
E/MJ10/FJ10
6617
T/MJ10/MJ10/MU1 7/8 Male Tee
6618
0
MB04/MM12
NONE*
3/4BSP Banjo
BJ-12
6619
1.1/2 Male Tee
T/MB24
6620
Fitting ref.

HOSE 64 NONE*
HOSE 65 NONE*
BL-Pegson
qty
2520-
2520-
2520-
1
0*
2520-
2520-
Description
BLPegson Pt No
Z21B/12
Tee M/F Run, M Branch 3/4BSP
2520-6404
2B/12-6
BSP 3/8M-3/4F SWIV NUT
2520-6124
Bonded seal 3/8BSP
2500-1015
Bonded seal 1/4BSP
2500-1011
3/8 M/M Nipple
2520-6003
E/S/MB06/FB0 3/8BSP M/F Elbow swept 90
6
2520-6563
Adaptor M18x1.5F-3/8BSPM
2520-6564
BH/MB06
3/8BSP Bulkhead
2520-6285
Locknut 3/8BSP
2520--6297
3/8 M/F Swivel nut adaptor
2520-6102
Qt
y
1
Hydraulic Clutch Hoses

Hose ref
2527-1054
3/8R2AT x ST/ST x 5500mm
2527-1038
3/8R2AT x ST/90 x 1900mm
2527-1051
3/8R2AT x ST/90 x 600mm
2527-1040
3/8R2AT x ST/90 x 2400mm
Fitting ref
AX857-901-8EN-02f 339/390
2
12
3
7
1
1
2
2
2
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 48
10.6 Electrical Components

Plant Control Panel
REF
PART NUMBER
2683-2148
2
3
4
5
2640-5005
2640-5005
2683-2149
2683-2113
2683-2109
2683-2102
2683-2101
2683-2103
2683-2111
2683-2174
2683-2114
2683-2106
2683-2106A
2683-2107
2683-2107A
2683-2176
2683-2177
2683-2178
2683-2179
2683-2180
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
30/05/03
2686-0038
2683-2170
2683-2171
2683-2173
2683-2172
2683-2169
2683-2195
2683-2175
2683-2145
2683-2182
2683-2108
DESCRIPTION
PLANT CONTROL PANEL
DISPLAY SCREEN
NB. WHEN ORDERING QUOTE MODEL DATA ON
REVERSE OF UNIT (SEE ILLUSTRATION)
TOGETHER WITH PLANT SERIAL NUMBER
CRUSHER MINI-RANGER TRANSCEIVER UNIT
HOPPER MINI-RANGER TRANSCEIVER UNIT
DOOR KEY
FEEDER SPEED CONTROL KNOB
FEEDER SPEED POTENTIOMETER
START/STOP PUSH BUTTONS
EMERGENCY STOP BUTTON (PANEL)
2 POSITION STAY PUT SWITCH
BLACK PUSH BUTTON
COMMUNICATION LEAD
HEAVY DUTY RELAY
11 PIN RELAY
RELAY BASE
8 PIN RELAY
RELAY BASE
20A SINGLE POLE CIRCUIT BREAKER
TRACK CONTROL KIT COMPLETE
NB. SEE SEPARATE LIST FOR INDIVIDUAL
COMPONENTS
PLC BASE UNIT
PLC INPUT MODULE
PLC END CAP
PLC OUTPUT MODULE
PLC PROCESSOR C/W MEMORY MODULE
BATTERY
DC/DC POWER CONVERTER
ENGINE ANTI-CRANK RELAY
FUSE SET
TIMER
QUANTITY
1
1
1
1
1
1
4
1
3 OR 4
2
1
2
QUANTITY
TO SUIT
PANEL
1
1
2
1
1
1
1
1
1
1
1
AX857-901-8EN-02f 340/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 49
2
1
3
7
9
10
8
24
14
6
11
5
25
13
12
23
2&
3
24
22
15
16
17
20
18
21
19
AX857-901-8EN-02f 341/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 50
Automax Control Panel
REF
PART NUMBER
DESCRIPTION
QUANTITY
AUTOMAX CONTROL PANEL

1
2
3
4
5
6
7
8
9
10
2695-0082A
2695-0082B
2695-0082C
2695-0082D
2695-0082F
2695-0082G
2695-0082H
2695-0082 I
2695-0082J
2695-0082K
2666-9013
CPU & MODULE

4 POLE PLUG
4 POLE RELAY BASE
BLACK PUSH BUTTON
YELLOW PUSH BUTTON
AUTO/MANUAL SWITCH
FUSE HOLDER
FUSE LINK
VARISTOR
DIODE
TRANSDUCER (MOUNTED ON CRUSHER)
1
6
6
2
1
1
4
2
4
1
1
860 TRACK CONTROL KIT 2686-0042 COMPONENTS

11
2686-9029
12
2686-9043
2686-9044
13
14
15
2686-9008
2686-9007
2686-9034
UNBILICAL HANDSET WITH CABLE

RADIO HANDSET TRANSMITTER RED STOP
BUTTON (USA AND REST OF THE WORLD)
RADIO HANDSET TRANSMITTER BLACK STOP
BUTTON (EUROPE)
ANTENNA AND CABLE
12/35VDC CHARGER CABLE
RECEIVER UNIT C/W CHASSIS SOCKET & CABLE
1
1
1
1
1
1
SUNDRY PLANT ELECTRICAL COMPONENTS

2640-5004
2366-0400
2368-2151
2685-0001
2683-2110
2366-2008
2366-2010
2366-2009
2366-2010
MINI-RANGER TRANSDUCER UNIT

PRODUCT CONVEYOR SPEED WHEEL SENSOR
ASSEMBLY
SPEED WHEEL SENSOR CABLE
EMERGENCY STOP PUSH BUTTON STATION
AUDIBLE WARNING UNIT
METAL DETECTOR PANEL GREEN INDICATOR
BULB FOR ABOVE
METAL DETECTOR PANEL RED BUTTON
BULB FOR ABOVE
1 OR 2
1
1
5
1
1
1
1
1
07/04/04
AX857-901-8EN-02f 342/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 51
10
4
2
Commandes du tableau hydraulique Automax

9
14
11
12
15
AX857-901-8EN-02f 343/390
Maxtrak
1000
EN
10 - Spare Parts
Page 10 - 52
10.7 Warning Signs

REF
1
2
3
6
7
8
9
10
11
13
14
15
17
19
20
21
23
27
30/05/03
PART NUMBER
300/32
300/33
300/34
300/37
300/38
300/39
300/40
300/41
300/42
300/44
300/45
300/46
300/118
300/120
300/175
300/182
300/196
300/224
DESCRIPTION
DANGER ENTANGLEMENT HAZARD
WARNING READ MANUAL
DANGER SKIN INJECTION HAZARD
IMPORTANT CHECK FILTERS
WARNING FALLING MATERIAL HAZARD
WARNING STOP AND LOCKOUT
WARNING GUARDS/LABELS IN PLACE
WARNING PRIOR TO TRANSPORT
IMPORTANT DRAIN WATER
WARNING IMPACT HAZARD
IMPORTANT CHECK FRAME ARMS
IMPORTANT CLEVIS PIN
DANGER FLYING MATERIAL HAZARD
WARNING FALLING HAZARD
IMPORTANT HYDRAULIC CLUTCH
CAUTION PRIOR TO TRANSPORT
WARNING HEARING HAZARD
HEARING PROTECTION
QUANTITY
4
4
4
2
4
4
4
2
1
3
2
2
2
2
1
1
2
2
11
20
AX857-901-8EN-02f 344/390
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 53
10
13
14
15
19
21
23
17
27
AX857-901-8EN-02f 345/390
Maxtrak
1000
EN
10 - Spare Parts
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-Pegsons Dealer for all
requirements concerning this clutch.
REF
DESCRIPTION
REF
DESCRIPTION
HOUSING
22
BACKPLATE
COVER
23
DRIVING PLATE
SCREW
24
CENTRE PLATE
BEARING CARRIER
25
SPRING
BEARING
26
PRESSURE PLATE
SHAFT
27
SCREW
SNAP RING
28
KEY
SPACER
29
LOCK WASHER
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
10 - Spare Parts
Maxtrak
1000
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
10 - Spare Parts
Maxtrak
1000
EN
Page 10 - 56
Blank page
AX857-901-8EN-02f 348/390
11 - Appendix
Maxtrak
1000
EN
Page 11 - 1
11 - Appendix
11.1 Noise Levels ................................................................................................ 11 - 2
AX857-901-8EN-02f 349/390
11 - Appendix
Maxtrak
1000
EN
Page 11 - 2
11.1 Noise Levels

Levels shown in the tabulation are for
general guidance only and will vary
depending upon the conditions prevailing at the time.
AX857-901-8EN-02f 350/390
11 - Appendix
Maxtrak
1000
EN
Page 11 - 3
Figures are for engine running with no load on crusher
AX857-901-8EN-02f 351/390
11 - Appendix
Maxtrak
1000
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. Previous button
2. Scroll Up / Left button
Return to previous level and screen display
Scroll display to view different menus and use to set up display settings.
3. Scroll Down / Right button

Scroll display to view different menus and use to set up display settings.
4. OK button
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
AX857-901-8EN-02f 356/390
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
AX857-901-8EN-02f 358/390
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
The crusher should be fully choke fed with a
well mixed and well graded material to give best
results. This will also produce even wear on the
cone liners, making them last longer.
NOTICE
Inspect the liners on a daily basis.
Uneven liner wear can occur when material

is trickle fed rather than choke fed into the
crusher. Unusual wear may also be caused by feed
material being all one size or the size being heavily
segregated.
MAXIMUM CONE SETTINGS

Do not operate the crusher with size settings above
the maximum.
Maximum Cone Setting

Cone Size
mm
Inches
1000
38
1.5
1300
45
1.75
CONE LININGS
INSPECTION
Inspect the liners on a daily basis.
Always check the liners if any non crushable
material may have entered the crusher.
RENEWING
Renew the cone liners before the adjusting
cylinders are working at their minimum.
Change the liner at or before the adjusting
cylinders reach the dimensions shown in the table.
Minimum Cylinder Dimensions

Cone Size
mm
Inches
1000
690
27.25
1300
805
31.75
Do not rely on the minimum dimension shown

in the manual, ignore value stated in the
diagram. This cannot take into account any
features present caused by an unusual wear
pattern or damage by non crushable materials
Monitor the wear on the crusher liners regularly
and renew both the liners before they fail and cause
damage to other parts of the crusher.
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
AX857-901-8EN-02f 362/390
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 buttons
current function.
The required engine data and display can display
the following formats:
Analogue gauges
Digital values
Historical trend graphs
Current and stored alarm messages
C-2
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:
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.
C-4
AX857-901-8EN-02f 366/390

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
AX857-901-8EN-02f 368/390

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
AX857-901-8EN-02f 369/390

Configuration Options
Screen Brightness and contrast
Press button 5 when the normal monitoring screen
is being displayed.
Adjust the screen using buttons 1 to 4.

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

pressing:
The following options can then be selected:

UNITS - Metric or Imperial
LANGUAGE - Select from list
BLEEP - Button press sound on or off
Set the options for each of these by pressing:
Return to previous screens by pressing:
Exit by pressing:
C-8
AX857-901-8EN-02f 370/390
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
MANUAL ADDENDUM
All Plants
Fuel Transfer Pump
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
AX857-901-8EN-02f 375/390
MANUAL ADDENDUM
All Plants
Fuel Transfer Pump
01EN
Page 2
Optional Fuel Transfer Pump
! WARNING !
This option is available as originally fitted

equipment installed at the time of plant
manufacture.
WEAR PERSONAL
Refer to Section 9.1 of the Plant
User Manual-Safety Information
for relevant warning.
The pump is for the purpose of transferring

diesel engine fuel from a barrel positioned at
ground level alongside the plant diesel engine
to the engine fuel tank.
LOCKOUT MACHINE.
UserManual-Safety Information
for Lockout Procedure.
The pump is permanently mounted in a

suitable position on the plant in the vicinity of
the engine and is electrically driven from a
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

per minute, suitable for equipment with tanks
between 200 and 500 litres. Duty is
continuous up to + 40o C ambient. Self
priming up to 3 metres dry. Flow 50 l/m at
3m head. Maximum head 10m.
Do not use the fuel transfer pump

for any other purpose that filling
the diesel engine fuel tank on the
BL-Pegson plant.
Observe the Operating, Service &
Safety Instructions on the
opposite page and also the
general Safety Information given in
Section 9.1 of the Plant User
Manual.
220305
AX857-901-8EN-02f 376/390
All Plants
Fuel Transfer Pump
01EN
MANUAL ADDENDUM
Page 3
Fuel Transfer Pump Operating, Service & Safety Instructions
SAFETY
FLASHPOINT BELOW
37oC (99oF)
DO NOT USE A TRGGER NOZZLE FOR DELIVERY INTO THE

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

TO RUN DRY. SWITCH OFF
IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.
220305
AX857-901-8EN-02f 377/390
MANUAL ADDENDUM
All Plants
Fuel Transfer Pump
01EN
Page 4
Top Up Fuel Level
! WARNING !
! NOTICE !
Do Not fill the tank to capacity.
Monitor the gauge located on the
Engine Control Panel.
WEAR PERSONAL
User Manual-Safety Information
for relevant warning.
Allow room for expansion and wipe

up spilt fuel immediately, otherwise
paintwork will be damaged.
LOCKOUT MACHINE.
UserManual-Safety Information
for Lockout Procedure.
Procedure
! DANGER !

2. Close down the plant (Section 8.2 of the

Plant User Manual) and implement the
lockout procedure except the engine
isolation switch to be at position I.

fuel system.
welding equipment.
3. Connect both hoses to the pump and insert

the suction hose into the fuel supply. Clean
the area around the filler cap. Remove the
cap and insert the delivery hose.
4. Operate the switch on the pump to fill the
fuel tank. Use only in accordance with the
instructions on the previous page.
5. Switch off the pump and stow the hoses.
Replace the cap and refit the engine
access panel before start up. Turn the
engine isolation switch to O.
! DANGER !
Never remove the filler cap or refuel,
with the engine running.
Filler Cap
220305
AX857-901-8EN-02f 378/390
MANUAL ADDENDUM
All Plants
Water Pumps
02EN
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
AX857-901-8EN-02f 379/390
MANUAL ADDENDUM
All Plants
Water Pumps
02EN
Page 2
Optional Water Pump
! DANGER !
This option is available as originally fitted

equipment installed at the time of plant
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 !
WEAR PERSONAL
Refer to Section 9.1, of the Plant
User Manual, Safety Information
for relevant warning
65 litres/minute nominal (17 US galls) to

supply the plant spraybars plus
additional capacity for the operators
off plant needs.
The pump is to provide a pressurised

supply of clean water to the dust
suppression spray nozzles included on
plants as a standard fitment. For details of
typical clean water requirements for the
dust suppression system, refer to the
Maintenance Section 9 of the plant manual.
The supply for external equipment can be

taken off one of the drain valves on the
spraybar manifold.
No specific maintenance is required for the
pump unit except to check for hydraulic oil
leaks when carrying out the normal plant
maintenance (Section 9 of the plant manual)
Frost precautions must be taken in cold
weather to ensure water does not freeze
within the system, by opening the water
manifold drain valves and detaching the
pump inlet feed pipe.
The pump is permanently mounted in a

suitable position on the plant near to the
water manifold (Figure 1) and is driven
from a branch of the engine driven plant
hydraulic system..
The inlet is with hose connector for the user
to provide supply suitable piping from the
clean water source (eg. bowser near to the
plant) as necessary.
Initial on/off control of the pump is by
means of a 3 way valve lever (Figure 2)
mounted on the pump unit. Whilst this valve
lever is in the on position the screw type
valve (Figure 2) can be used to regulate the
water supply to the plant inlet manifold.
220305
AX857-901-8EN-02f 380/390
MANUAL ADDENDUM
All Plants
Water Pumps
02EN
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
AX857-901-8EN-02f 381/390
MANUAL ADDENDUM
All Plants
Water Pumps
02EN
Page 4
Hydraulic Oil
Water
3 Way Valve
Flow Valve
Water Pump
Hydraulic Motor
Coupling
Figure 3 Pump Hydraulic Oil/Water Circuits
2575-2008 3 Way Valve
2575-2005 Coupling
2575-2007 Flow Valve

2575-2004 Hydraulic Motor
25 l/min Pump 2575-2003

65 l/min Pump 2575-2010
Figure 4 Pump Unit Part Numbers
220305
AX857-901-8EN-02f 382/390
BW100 INITIAL CALIBRATION SIMPLIFIED GUIDE

The Following procedures may be performed when messages E3 and E4 are displayed during routine calibration.
The E3 and E4 messages indicate a mechanical problem
i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the weigher etc.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration. Safe working practice should be adopted at all times.
Zero Calibration
Span Calibration
With belt running empty at normal speed with test weights removed
With belt running empty at normal speed with test weights applied
SELECT
PARAMETER
P377
SELECT P388
INVOKE INITIAL ZERO

ENTER 1
INVOKE INITIAL SPAN

ENTER 1
CURRENT ZERO COUNT
CURRENT SPAN COUNT= ####
ZERO CALCULATION
FREQUENCY COUNT
DISPLAYED
SPAN CALCULATION,
FREQUNCY COUNT DISPLAYED
ZERO DEVIATION
SPAN DEVIATION= ##
ZERO DEVIATION ACCEPTED

INITIAL ZERO COUNT= ####
ZERO DEVIATION ACCEPTED

INITIAL ZERO COUNT= ####
PROCEED WITH
SPAN CALIBRATION OR
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
INITIAL SPAN COUNT
ZERO CALIBRATION REQUIRED
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION
INITIAL ZERO COUNT
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION
DEVIATION
NEW SPAN COUNT
DEVIATION
NEW ZERO COUNT
CALIBRATION COMPLETE
RETURN TO RUN MODE
PRESS
CALIBRATION COMPLETE REMOVE TEST WEIGHTS

PRESS
TO RETURN
TO RUN MODE
SPAN REQUIRED
AX857-901-8EN-02f 384/390
TO RETURN TO RUN MODE
General Routine Inspection

Checks
All Plant
Issue EN 02
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)
Area to inspect
Main chassis
Feeder
Track frames
Conveyor frames
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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
Hours Run / Date
Notes
Page 1
Name
AX857-901-8EN-02f 387/390
Page 2
Hours Run / Date
12 - Notes
Notes
Name
AX857-901-8EN-02f 388/390
12 - Notes
Hours Run / Date
Notes
Page 3
Name
AX857-901-8EN-02f 389/390
AX857-901-8EN-02f 390/390

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ADVANCED CRUSHING TECHNOLOGY

PLANT USER MANUAL

ADVANCED CRUSHING TECHNOLOGY

INFORMATION AND ADVICE

ADVANCED CRUSHING TECHNOLOGY

ADVANCED CRUSHING TECHNOLOGY

WARNING: Battery Posts, terminals and

WARNING: Diesel engine exhaust and

AUTOMAX/AUTOSAND - EXPLANATORY NOTE

1.1 Warnings and Symbols

1.2 Organisation Measures

See to it that safety instructions and

Understand service procedure before doing

Personal Protective Equipment includes

Disconnect battery ground cable before

For the execution of maintenance work, tools

You can be injured if you do not obey the

1.3 Selection and

In the event of safety relevant modifications

Any work on and/or with the plant must be

1.4 Safety Instructions

Return idler roller guards should be checked

1.4.1 Standard Operation

The gap between the guard and the idler

1.4.2 Special Work In Conjunction

In the event of material blockage, any

Observe the adjusting, maintenance and

A : Warning, horn/light/gauge or indicator

In-running nip points on moving machinery

B : Adverse conditions necessitate more

When the plant is completely shutdown for

Falling from and/or onto a BL-Pegson plant

Switching off the engine and remove the

Implementing the lockout procedure.

Attaching a warning sign(s) to the plant

Do not climb on the plant whilst it is in

Keep away from the feed hopper and

After cleaning, examine all fuel, lubricant,

Always ensure that any safety fitment such

Particularly make sure that any part of the

Diesel fuel is highly flammable.

1.5 Warning of Special

Warn others against approaching and

Have the live wire de-energized.

Work on the electrical system or equipment

1.5.2 Gas, Dust, Steam, Smoke and

Avoid contact with the skin, eyes or clothing.

1.5.3 Hydraulic and Pneumatic

1.5.4 Hazardous Substances

Ensure that correct procedures are

Use only appropriate means of transport and

When travelling on public roads, ways and

Explosive separation of a tyre and rim parts

Always maintain the correct pressure. Do

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

1.8 Safety Signs

Figure 1b Warning Signs - Left Hand Side

Figure 1c Warning Signs - Right Hand Side