Ptrak650 PDF

ADVANCED CRUSHING TECHNOLOGY
PREMIERTRAK 1100 x 650

PREMIERTRAK 26 x 44
PLANT USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
This manual contains safety information which the

operator should read and follow. Failure to do this will
Safety 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.
Consider this manual a permanent part of your plant. Keep it with the plant at all
times.
Follow all applicable safety regulations and recommendations in this manual as

appropriate to your plant and the situation/conditions prevailing at the time.
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 Premiertrak contact:-
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire LE67 3GN
England
Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : [email protected]
or
Terex Crushing & Screening Inc
11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.
Telephone : +1 502 267 2314, Fax : +1 502 267 2317
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EC Conformity
This plant is in conformity with the

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

over a period of time.
Wear proper hearing personal protective

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

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

equipment, use approved respiratory protection,
as required by Federal, State and Local safety and
health regulations.
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Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are
approximate conversions from the actual metric measurement of the item concerned.
CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Proposition 65 Warning
WARNING: Battery Posts, terminals and
WARNING: Diesel engine exhaust and
related accessories contain lead and lead
some of it’s constituents are known to the
compounds, chemicals known to the State
State of California to cause cancer, birth
of California to cause cancer and
defects, and other reproductive harm.
reproductive harm.
WASH HANDS AFTER HANDLING.
Copyright
The copyright of this User Manual is reserved by BL-Pegson Limited.
This User Manual contains information and technical drawings, which may not be copied, distributed,
altered, stored on electronic media, revealed to others or used for the purpose of competition, either
partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright
2004.
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax:- + 44 1530 518618
E mail [email protected]
To order additional copies contact your local BL-Pegson Ltd Dealer.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 1
Contents
1.1 Warnings and Symbols ....................................................................................... 2
1.2 Organisation Measures ....................................................................................... 3
1.3 Selection and Qualification of Personnel - Basic Responsibilties .................. 4
1.4 Safety Instructions Governing Specific Operational Phases ........................... 5

1.4.1 Standard Operation ......................................................................................... 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ..................... 5
1.5 Warning of Special Dangers ............................................................................... 8
1.5.1 Electric Energy ................................................................................................ 8
1.5.2 Gas, Dust, Steam, Smoke and Noise .............................................................. 9
1.5.3 Hydraulic and Pneumatic Equipment ............................................................. 10
1.5.4.Hazardous Substances ................................................................................. 10
1.6 Transporting, Manoevering and Recommissioning ....................................... 11
1.7 Position of Emergency Stop Buttons .............................................................. 13
1.8 Plant Warning Signs- locations and illustrations ............................................ 15
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 2
1.1 Warnings and Symbols
The following signs and designations are used in the manual to designate instructions of
particular importance.
This is the safety alert symbol. When you see this symbol on your plant or in this
manual, be alert to the potential for personal injury or equipment damage.
Follow the recommended precautions and safe operating practices.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentiallly hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe working practices.
Indicates a statement of company policy as the message relates directly or indirectly

to the safety of personnel and protection of property.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 3
1.2 Organisation Measures Observe all safety instructions and warnings

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

making adjustments on electrical systems or
You can be injured if you do not obey the welding on plant.
safety instructions as indicated on warning
stickers.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 4
For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted to Qualification of Personnel -
the task on hand are absolutely
Basic Responsibilties
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must be
Never make any modifications, additions or
executed by trained, reliable and authorised
conversions which might affect safety
personnel only. Statutory minimum age
without the supplier’s approval.
limits must be observed.
In the event of safety relevant modifications
1.3.2
or changes in the behaviour of the plant
during operation, stop the plant and lock Work on electrical system and equipment of
out immediately and report the malfunction the plant must be carried out only by a
to the competent authority/person. skilled electrician or by instructed persons
under the supervision and guidance of a
skilled electrician and in accordance with
electrical engineering rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 5
1.4 Safety Instructions 1.4.2 Special Work In Conjunction

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

removing any safety devices or guarding.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 6
1.4.2.3 For carrying out overhead assembly work

always use specially designed or otherwise
Carry out maintenance and repair work safety-oriented ladders and working
only if the plant is positioned on stable and platforms.
level ground and has been secured against
inadvertent movement and buckling. Always use any walkway/platforms
provided or a safe and secure platform
1.4.2.4 approved by the regional safety enforcing
Never allow unqualified or untrained authority.
personnel to attempt to remove or replace
any part of the plant, or anyone to remove Always use an EN/ANSI approved safety
large or heavy components without harness when reaching any points 7ft (2m)
adequate lifting tackle. or more above the ground level.
To avoid the risk of accidents, individual Keep all handles, steps, handrails,
parts and large assemblies being moved for platforms, landing and ladders free from
replacement purposes should be carefully dirt, oil, snow and ice.
attached to lifting tackle and secured. Use
only suitable and technically adequate lifting 1.4.2.6
gear. The fastening of loads and instructing of
crane operators should be entrusted to
Never work or stand under suspended experienced persons only. The marshaller
loads. giving the instructions must be within sight
or sound of the operator.
Keep away from the feed hopper, all belt
conveyor and the magnetic separator 1.4.2.7
discharges, where there is risk of serious
injury or death due to the loading and After cleaning, examine all fuel, lubricant,
removal of material. and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any
1.4.2.5 defects found must be rectified without
delay.
Falling from and/or onto a BL-Pegson plant
can cause injury or even death. 1.4.2.8
Do not climb on the plant. Never use plant Any safety devices removed for set-up,
parts as a climbing aid. maintenance or repair purposes must be
refitted and checked immediately upon
Beware of moving haulage and loading completion of the maintenance and repair
equipment in the vicinity of the plant. work to ensure full working order.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 7
1.4.2.9 1.4.2.11
Improperly disposing of waste can threaten Diesel fuel is highly flammable.
the environment and ecology. Potentially
harmful waste used with BL-Pegson Never remove the filler cap, or refuel, with
equipment includes such items as oil, fuel, the engine running.
coolant, filters and batteries, etc.
Never add gasoline or any other fuels
Use leakproof containers when draining mixed to diesel because of increased fire or
fluids. Do not use food or beverage explosion risks.
containers that may mislead someone into
drinking from them. Do not smoke or carry out maintenance on
the fuel system near naked lights or sources
Do not pour waste onto the ground, down of sparks, such as welding equipment.
a drain or into any water source.
1.4.2.12
Ensure that all consumables and replaced
Using unapproved structures i.e. walkways/
parts are disposed of safely and with
platforms etc in the vicinity of a BL-Pegson
minimum environmental impact.
plant is very dangerous and could lead to
1.4.2.10 serious injury or even death through falling
and/or entanglement with the plant.
Always ensure that any safety fitment such
as locking wedges, securing chains, bars or Do not use any unauthorised structures.
struts are utilised as indicated in these
operating instructions.
Particularly make sure that any part of the

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

equipment.
Never work alone.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 8
1.5 Warning of Special 1.5.1.4

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

touching the plant.
• Have the live wire de-energized.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 9
1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

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

respective site.
Before starting work on high voltage
assemblies and after cutting out the power Dust found on the plant or produced during
supply, the feeder cable must be grounded work on the plant should be removed by
and components such as capacitors short- extraction, not blowing.
circuited with a grounding rod.
Dust waste should be dampened, placed in
1.5.1.9 a sealed container and marked, to ensure
safe disposal.
These plants are wired on negative earth.
Always observe correct polarity. 1.5.2.2
Always disconnect battery leads before Carry out welding, flame cutting and
carrying out any maintenance to the grinding work on the plant only if this has
electrical system. been expressly authorised, as there may be
a risk of explosion and fire.
The battery contains sulphuric acid, an
electrolyte which can cause severe burns 1.5.2.3
and produce explosive gases.
Before carrying out welding, flame cutting
Avoid contact with the skin, eyes or and grinding operations, clean the plant and
clothing. its surroundings from dust and other
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 10
1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with ear defenders of approved laid and fitted properly. Ensure that no
pattern and that these are worn at all times connections are interchanged. The fittings,
when the plant is operating. lengths and quality of the hoses must
comply with the technical requirements.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects 1.5.3.5
of air polution of any kind.
Always practice extreme cleanliness
1.5.3 Hydraulic and Pneumatic servicing hydraulic components.
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can
Work on hydraulic equipment may be penetrate the skin causing serious injury.
carried out only by persons having special
knowledge and experience in hydraulic If fluid is injected under the skin, it must be
systems. surgically removed or gangrene will
result.Get medical help immediately.
1.5.3.2
Always relieve pressure from the hydraulic
Check all lines, hoses and screwed system before carrying out any kind of
connections regularly for leaks and obvious maintenance or adjustment.
damage. Repair damage immediately.
Splashed oil may cause injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4.Hazardous Substances
pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification, labelling,
for the unit concerned before carrying out storage, use and disposal, all strictly in
any repair work. accordance with the manufacturers
instructions and that all applicable
regulations are observed at all times.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 11
1.6 Transporting, 1.6.7

Manoevering and When travelling on public roads, ways and
Recommissioning places, always observe the valid traffic
regulations and, if necessary, ensure
1.6.1 beforehand that the plant is in a condition
compatible with these regulations.
The plant must be loaded and transported
only in accordance with the operating
1.6.8
instructions.
In conditions of poor visibility and after
1.6.2 dark, always switch on the lighting system
of the transporting vehicle..
For manoevering the plant, observe the
prescribed transport position, admissible
1.6.9
speed and itinerary.
When crossing underpasses, bridges and
1.6.3 tunnels or when passing under overhead
lines always make sure that there is
Use only appropriate means of transport
sufficient clearance.
and lifting gear where applicable of
adequate capacity.
1.6.10
1.6.4 Never travel across slopes; always keep
the working equipment and the load close
The recommissioning procedure must be
to the ground, especially when travelling
strictly in accordance with the operating
downhill.
instructions.
1.6.11
1.6.5
On sloping terrain, always adapt your
Before starting work or travelling with the
travelling speed to the relevant ground
plant, check that the braking, and any
conditions. Never change to a lower gear
signalling and lighting systems are fully
on a slope. Always change gear before
functional.
reaching a slope.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 12
1.6.12
Explosive separation of a tyre and rim parts
can cause injury or death.
Do not attempt to mount a tyre unless you

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

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

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

bubbles, damaged rims or missing lug bolts
and nuts.
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 13
1.7 Position of Emergency

Emergency Stop Button
Stop Buttons (Maintenance Platform)

(Chassis Side)

(Feeder/Conveyor Control Box)
(Control Panel)

(Maintenance Platform)

(Chassis Side)
Figure 1a Emergency Stop Buttons
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1.8 Plant Warning Signs
Premiertrak
1.8.1 Location of Warning Signs. 1100 x 650 (26 x 44)
Left Hand side of plant
Safety Issue EN 07
Page 14
* Hydraulic Cusher only
Figure 1b Warning Signs

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Location of Warning Signs, Right
Premiertrak
Hand side of plant
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 15
* Hydraulic Crusher only
Figure 1c Warning Signs

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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 16
1.8.2 Safety Sign Illustrations
1 2 3 4
5 6 7 8
11
9 12 13
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 17
Safety Sign Illustrations, continued
20
17 19
21
25
27
22 23
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 18
Blank Page
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Premiertrak
1100 x 650 (26 x 44)
Technical Information Issue EN 07
Page 1
Contents
2.1 Dimensions .......................................................................................................... 2
2.2 Plant Description ................................................................................................. 3
2.3 Feeder................................................................................................................... 4
2.4 Crusher ................................................................................................................ 4
2.5 Product Conveyor ............................................................................................... 4
2.6 Tracks ................................................................................................................... 4
2.7 Standard Powerpack ........................................................................................... 5
2.8 Dustsprays ........................................................................................................... 5
2.9 Dirt Conveyor * .................................................................................................... 5
2.10 Magnetic Separator * ......................................................................................... 5
2.11 Manual Folding Hopper * .................................................................................. 6
2.12 Feed Hopper Liner Plates * ............................................................................... 6
2.13 Belt Weigher * .................................................................................................... 6
2.14 Water Pump *...................................................................................................... 6
2.15 Anti-vandal Guards * ......................................................................................... 6
2.16 Manual Clutch * .................................................................................................. 6

PLEASE NOTE
BL-Pegson Limited have designed and built the Premiertrak 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.
AX815-901-8EN-07b 27/318
13436
(44’- 1”)
2.1 Dimensions
3225
4116 (13’- 6”)

(10’- 7”)
Feed Hopper Raised

3235 3880 6060
10’- 7”) (12’- 9”) (19’- 11”)
ALL DIMENSIONS ARE IN MILLIMETRES (FT./INS.)

2420 (7’-11”)
Overall Travel Length - 14000mm (45’- 11”)
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Overall Travel Width - 2800mm (9’- 2”)
Overall Travel Height (Excluding Transport Trailer) 3400mm (11’- 2”)
Technical Information
Operating Width (Dirt Conveyor lowered) - 4040mm (13’- 3”)

Operating Height (Hopper Raised) 4200mm (13’- 9”)
Gross Weight approx 45.4 tonnes (49.9 US tons)

2125 (7’ - 0”)
2800 (9’- 2”)

Refer to the plant identity plate for weights relating to the
4040 (13’- 3”!)
Page 2
Premiertrak with rear bogie
Premiertrak
Issue EN 07
Figure 2a Dimensions
1100 x 650 (26 x 44)
Viewed from the rear of the Premiertrak

Premiertrak
1100 x 650 (26 x 44)
Page 3
2.2 Plant Description
Many of the terms used in this manual may not at first be obvious. Figure 2b identifies the main
areas of the plant and the term with which they are referred to in this manual.
Dirt Conveyor (Head drum guard and

Diesel side skirt plates removed)
FRONT Engine
REAR
Magnetic Overband
Seperator
Engine Maintenance
Platform LEFT Tool Box
Control Box Crusher Maintenance
Platform
Feed Hopper
Side Plate FRONT
Feeder
REAR Jaw Crusher
Product Conveyor
Maintenance
RIGHT Tracks
Platform Figure 2b Plant Terms
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Premiertrak
1100 x 650 (26 x 44)
Page 4
2.3 Feeder
Type Spring mounted vibrating pan

Width 1060mm (32”)
Length 4200mm (13’-9”)
Unit Twin shaft oil lubricated
Grizzly Stepped cartridge type, bars pre set at nom. 50mm (2”)
spaces
Drive Hydraulic motor
Control Variable speed
Hopper Hydraulic folding (to reduce height when transporting)
2.4 Crusher
Type Single toggle jaw

Feed Gape 650mm (26”)
Feed Width 1100mm (44”)
Adjustment Shims – hydraulically assisted
Lubrication Greased spherical roller bearings
Drive Vee belts from engine
Control Engine clutch
2.5 Product Conveyor
Type Plain troughed belt

Width 1000mm (40”)
Lubrication Grease
Control Fixed speed
Skirts Full length
2.6 Tracks
Type 190mm (7.5”) pitch heavy duty

Width 500mm (1’-8”)
Centre 3880 mm (12’-9”)
Drive Hydraulic integral motors
Control Remote handset – dual speed
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Page 5
2.7 Standard Powerpack
Type Caterpillar C9 EU/EC Emmission Regulations

compliant 6 cyl. water cooled diesel
Rating 230hp @ 1600 rpm
Drives Hydraulically activated clutch to engage the crusher
Vee belts to twin hydraulic pumps
Housing Canopy enclosure with integral fuel tank and battery
2.8 Dustsprays
Type Clean water multi atomising nozzles

Positions Crusher feed & discharge and product conveyor
discharge
Inlet Single point
Required supply Approx. 7 litres/min (2 US galls/min)@ 2.8 bar / 42 psi.
Frost protection System drain valves
2.9 Dirt Conveyor *

Type Plain troughed belt, hydraulically folded for transport
by engine driven pump.
Width 600 mm (24”)
Lubrication Grease
Control Fixed speed
Skirts Full length
2.10 Magnetic Separator *

Type Suspended self cleaning crossbelt overband
Magnet Permanent - 450 gauss @ 250mm (10”)
Width 750 mm (30”)
Centres 1700 mm (5’-7”)
Control Preset variable
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2.11 Manual Folding Hopper *

Type Manually folding sides and rear plates in lieu of hydraulic
operation.
2.12 Feed Hopper Liner Plates *

Type Mild steel
2.13 Belt Weigher *

Type Single idler load sensor type including flow rate and
totalizer displays on chasis mounted control box
2.14 Water Pump *

Type Hydraulically driven to provide pressurised water
supply for the dust suppression sprays.
2.15 Anti-vandal Guards *

Type Lockable covers over control stations
2.16 Manual Clutch *

Type Lever operated twin disc clutch in lieu of hydraulically
actuated clutch.
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3 - General Information Issue EN 07
Page 1
Contents
3.1 Introduction .......................................................................................................... 2
3.2 General information ............................................................................................. 2
3.3 Designated Use ................................................................................................... 3

3.3.1 Operating Temperature Range ........................................................................ 3
3.4 Crusher Capacity ................................................................................................. 3
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3.1 Introduction 3.2 General information
This instruction manual contains important The Plant which you have now received has
information on how to operate the Plant been manufactured, assembled and tested
safely, properly and most efficiently. with the utmost care and was built with first
class materials.
Observing these instructions and exercising
Common Sense helps to avoid danger, to Close attention has been paid to all details
reduce repair costs and downtimes and to in assembly, running tests and final
increase the reliability and life of the plant. inspection.
Failure to do so may invalidate any
warranties in force. We are confident that you have received a
plant which will give you every satisfaction
The operating instructions must always be over a long period.
available wherever the plant is in use.
To be assured of faultless operation we
These operating instructions must be read would ask you to carefully read the
and applied by any person in charge of and/ following paragraphs and give the required
or working on the plant such as:- time and attention to essential maintenance,
cleaning and inspection.
Operation
The plant is simple to operate, adjustments
Includes manoeuvring, setting up, operation are easy to make and expert assistance is
during the course of work, evacuation of seldom required, provided that ordinary
production material and waste, care and care is exercised in daily use.
disposal of fuels and consumables, etc.
The plant has been built in accordance with
Maintenance state-of-the-art standards and recognised
safety rules. It is designed to be reliable,
Servicing, inspection and repair efficient and safe when used and
maintained in accordance with the
and/or instructions given in this manual.
Transport Nevertheless, it’s use may constitute a risk

to life and limb of the user or of third
Follow all applicable laws and safety parties, or cause damage to the plant and to
regulations for accident prevention and other material property.
environmental protection.
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Page 3
3.3 Designated Use The crusher must not be operated at a

discharge opening less than 75mm without
The Plant has been designed exclusively as prior consultation with BL-Pegson
a self-contained mobile unit for crushing Limited, the only exception to this being
materials in a wide range of quarry, for crushing bricks and demolition materials
demolition and recycling applications within only. Operating the crusher below this
the parameters set out and described within setting may result in extensive damage.
this manual.
The percentage of oversize output from the
3.3.1 Operating Temperature Range crusher, for a given discharge opening, will
depend largely on the quality and character
The normal operating temperature range of of the feed material. Figure 3b shows an
the plant is from -10°C to +40°C (+14°F estimated analysis of the product for
to +104°F). For use in temperatures different discharge openings.
outside of this range, contact your local
dealer or BL-Pegson for details. Note:- The crusher has been designed to
work with feed materials having a 10%
Note: Appropriate oil & coolant to suit the fines value not exceeding 390kN.
local operating conditions must be used, as
specified elsewhere in this manual. Product gradings are typical only and will
vary depending on material characteristics.
3.4 Crusher Capacity
In order to obtain the optimum output from

the crusher, it’s feed should be continuous
and regulated. Additionally, all feed should
be of a size that will readily enter the
crusher chamber and, in order to avoid
packing of the discharge opening and
excessive wear of the plant jaws, undersize
material should be removed from the feed
prior to entry to the crusher.
*
The discharge rates given (Figure 3a) are *

based on crushing clean, dry limestone
weighing approximately 1600Kg/m3 ,
(100lbs/cuft.), loose and having a specific
gravity of 2.6. Wet feed material reduces
the crusher discharge rate. * Demolition materials only
Figure 3a Crusher Capacity
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Page 4
Operating the plant outside it’s material in the feed must be limited to a size
recommended range of applications and that will not cause damage to the crusher.
operating parameters, will result in a loss of
guarantee and the manufacturer/supplier If you have any doubts about
cannot be held liable for any damage any aspect of the plant’s
resulting from such use. The risk of such capability or servicing
misuse lies entirely with the user. procedures, you must consult
your local BL-Pegson dealer or
When the optional dirt conveyor is fitted, BL-Pegson technical
material passing through the feeder grizzly department.
bars will be extracted from the crusher feed
material to by-pass the crusher (coarse
material) and discharge to the dirt conveyor
(fines material).
The optional magnetic overband separator,

where fitted, is intended to extract ferrous
materials from the crushed product but this
Figure 3b Product Analysis
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1100 x 650 (26 x 44)
Design and Function Issue EN 07
Page 1
Contents
4.1 General Information ............................................................................................. 2
4.2 Construction Units .............................................................................................. 3

4.2.1 Single Toggle Jaw Crusher .............................................................................. 3
4.2.2 Vibrating Grizzly Feeder .................................................................................. 3
4.2.3 Track Frame.................................................................................................... 3
4.2.4 On-Plant Product Conveyor ............................................................................. 4
4.2.5 Magnet ............................................................................................................ 4
4.2.6 Plant Chutework .............................................................................................. 4
4.2.7 Maintenance Platforms .................................................................................... 4
4.2.8 Standard Power-Pack ..................................................................................... 4
4.2.9. Dirt Conveyor ................................................................................................. 5
4.2.10 Controls ........................................................................................................ 5
4.2.11 Chassis ......................................................................................................... 5
4.2.12 Guards .......................................................................................................... 5
4.2.13 Painting ........................................................................................................ 5
4.2.15 Optional Extras * ........................................................................................... 5
4.2.16 Optional Exclusions *..................................................................................... 6
4.2.17 Specifications ............................................................................................... 6
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4.1 General Information
The BL-Pegson Premiertrak Plant has been designed for a wide range of quarry and
recycling applications, its features include:-
• Rapid set up time
• Easily transported on and off site
• Well proven high performance 1100x650mm (26” x 44”) ‘M’ series single toggle roller bearing
jaw crusher
• Fully skirted product conveyor with hydraulic tail lift
• Folding Hopper
• Stepped cartridge type grizzly section, pre set at 50mm (2”) aperture
• Two way dirt chute
• Facility to remove scalpings
• Heavy duty chassis and track frame
• Remote control
• Dust suppression sprays
• Caterpillar water cooled diesel engine
• Optional dirt conveyor and magnetic separator
• CE Approved
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Page 3
4.2 Construction Units Grizzly Section:- A stepped cartridge type

grizzly section with tapered finger type bars
BL-Pegson 1100 x 650 Premiertrak at nom.50mm (2”) spaces (at mid point
Recycling /Crushing plant with Diesel/ along bar). A renewable feeder discharge
Hydraulic drive. lip is also included.
4.2.1 Single Toggle Jaw Crusher Drive:- Hydraulic motor mounted on

vibrating unit.
BL-Pegson 1100 x 650mm (26” x 44”)
‘M’ Series Single Toggle Roller Bearing Control:- Variable speed is achieved via a
Jaw Crusher including:- rotary control located on the Feeder/
Conveyor control panel. Facility is also
Lubrication:- Eccentric shaft spherical included to stop/start the feeder from the
roller bearings are lubricated by grease. remote control handset.
Setting Adjustment:- Hydraulically Hopper:- Hydraulic folding feed hopper

assisted and pre-set in the factory at 75mm. fabricated in 15mm (0.6”) thick abrasion
resistant steel plate suitable braced with
Drive:- Through vee belts from the diesel steel sections. An optional manual folding
engine with screw tension adjustment of the hopper is available.
engine baseframe.
4.2.3 Track Frame
4.2.2 Vibrating Grizzly Feeder Heavy duty size nine track frame having
190mm (7.5”) pitch chain and 3880mm
BL-Pegson 1060 wide x 4200mm long (12’-9”) longitudinal centres with 500mm
(42” x 13’-9”) Vibrating Grizzly Feeder, (20”) wide tracks fitted as standard.
including:-
Total plant weight approximately -
Vibrating Unit:- Heavy duty mechanical 45.4 tonnes (49.9 US. tons).
type with twin counter rotating shafts with
oil lubricated bearings and gears. Overall Track width - 2800mm (9’- 2”).
Pan:- 12mm (0.5”) thick abrasion resisting Plant overall height - 4200mm (13’ 9”)
steel bottom and side plates. (hopper raised).
Plant travel height with hopper folded -

3400mm (11’- 2”) (plus low loader height).
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4.2.4 On-Plant Product Conveyor 4.2.6 Plant Chutework

1000mm (39”) wide plant mounted Crusher Feed Chute:- Fabricated in
troughed belt conveyor, 3225mm (10’-7”) 12mm (0.5”) mild steel plate sides with
discharge height, with hydraulic lift tail 25mm (1.0”) thick wear resistant bottom
section. and including integral safety grid.
Belt:- EP 500/3 with 5mm (0.2”) top and Grizzly Fines Chutes:- A hand operated
1.5mm (0.06”) bottom heavy duty rubber two way dirt chute is provided to
covers to BS490 and DIN 22102. discharge to the on-plant product
Maximum stretch over life of belt conveyor or the optional dirt conveyor
running in normal working conditions (when fitted) as required.
will be no greater than 1%. A vulcanised
joint is include.
Drive:- Hydraulic motor drive via 4.2.7 Maintenance Platforms

coupling to drive drum at pre-set speed.
Steel grid platforms are provided each
Feedboot:- Fabricated in mild steel plate side of the feeder fitted with double row
with abrasion resistant steel liners at feed handrails having safety bar and access
point, fully skirted wear resistant rubber ladder. Platforms are also included to
sealing strips along the entire conveyor gain access to the rear of the crusher and
length. to the power-pack.
Adjustment:- Belt tensioning to be

maintained and adjustment at the head 4.2.8 Standard Power-Pack
drum. Caterpillar C9 EU/EC Emmissions
Regulation Compliant 6 cylinder, 4 stroke,
Covers:- Canvas type removable dust direct injection, emission compliant water
covers are fitted at the head end. cooled diesel power-pack, 230HP
continuous rated 1600 rpm under NTP
conditions designed to drive the crusher via
a hydraulically actuated clutch.
4.2.5 Magnet
Overband magnetic separator with Hydraulic transmissions powered from the
permanent magnet, suspended over the engine are provided to drive the tracks,
main on-plant product conveyor and feeder, product conveyor, hydraulic rams
complete with hydraulic drive. and, where fitted, the optional dirt conveyor
and/or the overband magnetic separator.
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4.2.9. Dirt Conveyor 4.2.12 Guards

Plant mounted 600 mm (24”) wide side Wire mesh or sheet metal guards are
discharge dirt conveyor with hydraulic flding provided for all drives, flywheels, pulleys,
facility giving a discharge height of couplings, gears and vee belts. The guards
2125mm (7’-0”) from the top of the head provided are designed and manufactured to
drum. The conveyor is hydraulically driven ensure so far as reasonably practicable that
from the head drum and is mounted on the the machinery and plant on which they are
left hand side viewed from the feed end. 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
4.2.10 Controls requirements laid down by individual
inspectors and any additional guard and/or
Controls are fitted on the plant for the
modification to guarding supplied, which
feeder (on/off and speed), conveyors etc.
may be required for any reason whatsoever,
with engine and master controls sited in a
will be charged as an additional contract
lockable box mounted below the engine.
price.
A remote control unit is provided for the
tracking function giving a tracking speed of
approximately 0.96kmh (0.62mph) a
4.2.13 Painting
“creep” facility for loading, off loading and
precise slewing movements. There is also a The plant is finish painted in RAL 5015
stop and start control for the vibrating blue.
grizzly feeder from a remote position.
Emergency stop buttons are provided on

each side of the plant.
4.2.15 Optional Extras *
Available at the time of initial purchase:-
4.2.11 Chassis
• Manual folding feed hopper in lieu of
Fabricated steel frame of welded hydraulic folding..
construction with supports for the feeder,
crusher, on-plant conveyor, power unit, • Mild steel liner plates for feed hopper.
track frame and where fitted, the dirt
conveyor and/or overband magnetic • Water pump, hydraulically driven, to
separator. provide pressurised water supply for
the dust suppression sprays.
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• Single idler belt weigher with integrator

and speed sensing wheel fitted to main
product conveyor.
• Anti-vandal guards.
• manual twin disc clutch in lieu of hy-

draulically actuated clutch..
4.2.16 Optional Exclusions *

Available at time of initial purchase:-
• Dirt Conveyor.
• Overband Magnetic Separator.
4.2.17 Specifications
Every endeavour will be made to supply
equipment as specified, but we reserve the
right, where necessary, to amend
specifications without prior notice as we
operate a policy of continuous product
development.
BL-Pegson cannot guarantee that the

equipment specified will meet any specific
requirements in respect of noise or vibration
levels, dust emission, or any other factors
relevant to health and safety measures or
environmental protection needs.
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1100 x 650 (26 x 44)
Transport Issue EN 07
Page 1
Contents
5.1 Safety Information ............................................................................................... 2
5.2 Transportation ..................................................................................................... 4

5.2.1 Manoeuvring - General .................................................................................... 4
5.2.2 Manoeuvring with the remote RADIO control hand set
(where fitted) ................................................................................................... 6
5.2.3 Radio Hand Set (where fitted) ....................................................................... 10
5.2.4 Manoeuvring with the remote UMBILICAL control hand set
(where fitted) ................................................................................................. 12
5.2.5 Unloading ...................................................................................................... 16
5.2.6 Loading ........................................................................................................ 17
5.3 Folding Hopper Plates ...................................................................................... 20
5.3.1 Hydraulic Folding Hopper - lowering for transport . ......................................... 20
5.3.2 Manual Folding Hopper * - lowering for transport .......................................... 22
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Page 2
5.1 Safety Information

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

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

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

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

whilst in operation.
ALWAYS use the walkways/platforms provided

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

harness when reaching any points 7ft (2m) or
more above ground level.
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.
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Page 3
Hydraulic fluid under pressure can SKIN INJECTION

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

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

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

surgically removed or gangrene will result.
Get medical help immediately.
When carrying out maintenance or LOCKOUT PROCEDURE

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

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
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5.2 Transportation
WARNING
5.2.1 Manoeuvring - General WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
Information for relevant 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 danger to persons and
damage to the plant which may
invalidate warranty.
• Before manoeuvring the Plant, ensure

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

PLANT mode of operation.
• DO NOT manoeuvre the Premietrak

whilst the crusher running.
• The safety warning horn sounds

continuously whilst the plant is being
manoeuvred.
DO NOT stand on any of the

platforms or ladders of the
Plant whilst it is being
manoeuvred using the remote
control handset.
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Page 5
When manoeuvring the Plant

to its operating position make WARNING
sure you stand well clear of the
WEAR PERSONAL
plant but are in a position to PROTECTIVE EQUIPMENT.
have all-round vision to see Refer to Section 5.1, Safety
any obstacles, dangers that Information for relevant warning.
may lie ahead e.g personnel,
overhead cables, ditches,
unsafe roadways etc. (Refer
to Figure 2a Dimensions)
• Make sure that you do not manoeuvre

the Plant on a gradiant 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.
• Control valves mounted on the engine

and beneath the feeder are NOT to be
used to manoeuvre the Plant. They are
for use by BL-Pegson Service
Engineers only.
• 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.
• When transporting the Plant, it is the

responsibility of the haulage
contractor to safely secure the plant
to the transporter.
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5.2.2 Manoeuvring with the remote

RADIO control hand set WARNING
(where fitted)
WEAR PERSONAL
The plant is manoeuvred using the remote PROTECTIVE EQUIPMENT.
hand held radio transmitter control unit (Fig Information for relevant warning.
5a). This hand set also has the facility to
switch the plant feeder on and off whilst the
Plant is in the crushing mode.
Procedure
Note: The transmitter has a built in safety
function that prevents another function from
1. Observe all safety instructions. involuntary cutting-in when the transmitter
starts. The transmitter will not start if a
2. Take the Remote Control Hand Set button is stuck in the activated position.
from the Control Box and first become This is indicated by the red LED coming on.
familiar with the functions of all the
individual buttons (Figure 5a) before the 4. Start the engine (Section 7.2.1).
next step. Increase the engine speed to 1600rpm.
Forward = Product Conveyor first
Reverse = Hopper first 5. Before manoeuvring the Plant ensure
the tail section of the product conveyor
3. To start up the handset transmitter first is fully raised.
stand well clear of the plant. Hold the To raise the tail section:-
hand set with the stop button nearest to On the Control Panel located within the
the operator and proceed as follows:- Control Box (Figure 5b), turn the Tail
Lift switch to ‘Ï’ and raise the tail
• Ensure the stop button is pulled out. section.
• Depress both of the safety buttons
(Fig.5a) at the same time for at least 1 6. On the Control Panel, turn the
second. Release the safety buttons. Operation switch to ‘TRACK’.
• The red LED will change to green.
• The transmitter is in function status 7. Press the Horn button for 5 seconds to
when the green LED comes on. sound the safety warning horn. This will
also ready the tracks for manoeuvring.
continued overleaf..............
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Page 7
PLAN VIEW OF THE PLANT
LED Red/Green
Forward slow or fast, track 1 & 2

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

Safety Button Safety Button
Left turn slow, reverses track 2 (Horn) (Feeder On/Off)
Rotate clockwise, track 1 forward, track 2

reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
For more information on the Radio Hand Set see Section 7 of this manual.
Figure 5a Remote RADIO Control Hand Set
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Page 8
8. The radio handset directional buttons

(forward, reverse and turn) are double WARNING
pressure switches with the initial
WEAR PERSONAL
pressure operating the slow speed PROTECTIVE EQUIPMENT.
mode and depressing further operates Refer to Section 5.1, Safety
the higher speed. Press the buttons to Information for relevant warning.
manoeuvre the plant in the desired
direction (Figure 5a). 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) (and disengage the manual
clutch if applicable.
9. When the Plant is in the correct

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

transmitter, push in the stop button.
Lock out the hand set when finished
with to prevent unauthorised use.
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Operation Feeder Remote Dirt Conveyor Tail Lift - Product

Plant/Track Off/On Lower/Raise * Conveyor Lower/Raise
Figure 5b Control Panel
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5.2.3 Radio Hand Set (where fitted)

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

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

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

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

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

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

control
800mA to 2000mA.(Charging time
from completely empty battery is now Buttons 1 to 9 and 0 = Used for signal
approximately 4 hours). frequency programming (factory preset -
contact Dealer for change)
• Operating time with fully charged
Buttons 9 and 0 = Used to activate the
battery is approximately 30 hours.
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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Page 11
2 versions of the 860 system transmitter will

be supplied, one for European Operations WARNING
and one for the Rest of the World. The only
WEAR PERSONAL
difference is that the European version will PROTECTIVE EQUIPMENT.
include a black stop button. The Rest of the Refer to Section 5.1, Safety
World transmitter will feature a Red Stop Information for relevant warning.
button. Channel 01 (434.650 MHz)
through channel 16 (433.900 MHz)
available in .050 MHz steps. Refer to
Dealer if frequency change needed. • To conserve the battery charge the hand
set should be switched off when not in
Battery Recharging use..
The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
5c). 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 Charging point
indicates it is time to recharge. The plant
warning horn will also sound when Figure 5c Remote Control
battery recharging is required Charger Connection
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5.2.4 Manoeuvring with the remote

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

Umbilical Control Hand Set
Procedure
1. Observe all safety warnings.
2. Close down the plant (Section 8.2).
3. Locate the connection point (Figure 5d)

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 5e) and secure with
the retaining clip.

Operation switch to ‘PLANT’ and the
Feeder Remote switch to ‘OFF’
(Figure 5b).
5. Start the engine (Section 7.2). Increase

the engine speed to 1600rpm.
6. Standing clear of the tracks, turn the

Operation switch to ‘TRACKS’.
continued overleaf...............
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Premiertrak
1100 x 650 (26 x 44)
Page 13
Figure 5d Umbilical Connection
Figure 5e Umbilical Control Hand Set
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Premiertrak
1100 x 650 (26 x 44)
Page 14
PLAN VIEW OF THE PLANT
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1
Left turn slow, forward track 2 **Reverse Forward **

Reverse slow or fast, track 1 & 2 **Left Turn Right Turn **
(travelling forward) (travelling forward)
Right turn slow, reverses track 1
Not used Not used
Left turn slow, reverses track 2
Safety Button Not used
Rotate clockwise, track 1 forward, track 2
(Horn)
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5f Remote Umbilical Control Hand Set
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Page 15
7. Press the Horn button for 5 seconds to 12. Unplug the umbilical cable and replace
sound the safety warning horn. This will with the original plug (where radio unit
also ready the tracks for manoeuvring. fitted). Store the umbilical hand set unit
in the tool box to keep available for
8. The umbilcal handset directional buttons future use.
(forward, reverse and turn) are double
pressure switches with the initial Extreme care must be used
pressure operating the slow speed when manoeuvring the plant
mode and depressing further operates with the umbilical control hand
the higher speed. set. Stand as far away as
possible from the plant. Do not
Pressing the Stop button at any time will allow the cable of the hand set
immediately halt the operation and cut to sag and become entangled
out the engine but it is necessary to with the tracks.
manually switch off the engine ignition
(Section 8.2) (and disengage the manual
clutch if applicable).
9. 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 5f).
Employ the ‘Fast’ speed only where
safe to do so.
10. When the Plant is in the correct

position, press the Horn button to turn
the safety warning horn ‘OFF’ and
disengage the tracks.

Operation switch to ‘PLANT’. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.
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Premiertrak
1100 x 650 (26 x 44)
Page 16
5.2.5 Unloading
The Premiertrak will arrive on site securely
WARNING
fastened to a low loader. It is the WEAR PERSONAL
responsibility of the haulage contractor to PROTECTIVE EQUIPMENT.
remove the fastenings. Information for relevant warning.
Procedure
2. Position easy slope ramps at the end of

the transporter to help with unloading of
the Premiertrak.
3. Locate the control box and raise the

spring loaded cover to reveal the
control panel and engine control panel
(Figure 7b).
4. Follow the instructions for manoeuvring

the Premiertrak (Section 5.2.1).
5. Using the remote control hand set, steer

the Premiertrak off the transporter
(Section 5.2.1).
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Premiertrak
1100 x 650 (26 x 44)
Page 17
5.2.6 Loading
Before loading onto a low height trailer, the
WARNING
Plant must be prepared for transportation. WEAR PERSONAL
Refer to Section 2.1 for the travel PROTECTIVE EQUIPMENT.
Refer to Section 5.1 Safety
dimensions. This includes raising the Information for relevant warning.
product conveyor tail and the dirt conveyor
(where fitted) and lowering the feed hopper. FALLING HAZARD.
Additionally, where the Premiertrak is Information for relevant warning.
supplied with the rear running gear bogie
system, the maximum permissable highway
axle loadings may require the dirt conveyor
and magnetic separator (if fitted) to be
removed.
Only experienced engineers

using suitable tools and lifting
equipment should remove
these items.
Procedure
2. Ensure that both conveyors, feed

hopper and crusher are free from stone
and dirt.
3. Lower the safety grid (Figure 6d) on the

crusher feed chute.First support the grid
with suitable lifting equipment before
unbolting and removing the two
supports to allow the grid to fold flat. Figure 5g Front Ladder Folded for
Transportation
4. On the left hand side of the Premiertrak
raise the bottom section of the front
ladder and secure (Figure 5g).
continued overleaf.............
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Premiertrak
1100 x 650 (26 x 44)
Page 18
5. Remove the dirt conveyor head drum

guard, side plates (Figure 5h) and the WARNING
rear handrails on the feeder
WEAR PERSONAL
maintenance platforms on both sides of PROTECTIVE EQUIPMENT.
the plant . This is necessary before Refer to Section 5.1 Safety
folding the dirt conveyor for transport. Information for relevant warning.
6. Ensure all loose items are carefully FALLING HAZARD.

stowed and secured if these are to be Refer to Section 5.1 Safety
transported on the plant. Information for relevant warning.

cover to reveal the control panel and
engine control panel (Figure 5b).
8. Start the engine (Section 7.2.1).

Increase the engine speed to 1600rpm.
9. Turn the Operation switch to ‘PLANT’,

the safety warning horn will sound for
10 seconds.
10. Turn the Tail Lift switch to ‘Ï’ and fully

raise the tail section of the product
conveyor into the travelling position.
11. Turn the Dirt Conveyor switch to‘Ï’

and fold the dirt conveyor fully in the
travelling position. Secure with the
transportation safety chain (Figure Figure 5h Dirt Conveyor Head Drum
5i) Guard and Side Plates
During folding of the dirt

conveyor ensure that the
hydraulic hoses and conveyor
belt do not foul any part of the
structure.
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Page 19
12. Lower the hopper plates into the

travelling position (Section 5.3).
Dirt Conveyor Safety
13. Position easy slope ramps at the end of Chain
the transporter to help with loading of
the Premiertrak.
14. Turn the Operation switch to

‘TRACK’. Using the remote control
hand set, steer the Premiertrak onto the
transporter (Section 5.2.1).
15. When the plant is loaded shut down the

remote control hand set using stop
button on the unit (figure 5a or 5f).
16. Switch off the engine (Section 8.2).
17. Securing the Premiertrak to the Dirt Conveyor

transporter is the responsibility of
the haulage contractor. Figure 5i Dirt Conveyor Safety Chain
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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Premiertrak
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Page 20
5.3 Folding Hopper Plates

WARNING
Road transportation regulations WEAR PERSONAL
may require that the hopper PROTECTIVE EQUIPMENT.
plates be lowered for road Refer to Section 5.1 Safety
transportation. Information for relevant warning.
When the hopper side plates are FALLING HAZARD.

lowered into the travelling Refer to Section 5.1 Safety
position, one of the hopper sides
plates will fold on top of the
folded dirt conveyor. The dirt
conveyour head drum guard and
side plates and also the rear
feeder maintenance platforms
(Figure 5j) must be removed
before the hopper side plates
are folded into the travelling
postion.
Procedure
5.3.1 Hydraulic Folding Hopper -

lowering for transport
2. Using lifting equipment support the

Figure 5j Dirt Conveyor Folded Hopper Lowered
hopper tie bar. Remove the locking
wedges and lift off the tie bar (Figure5k).
3. Remove the bolts securing the end plate

to the side plates.
4. Remove the four hopper side plate

wedges (two for each side plate (Figures
5l and 5m).
Figure 5k Hopper Tie Bar
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Page 21
4. Start the engine (Section 7.2). Increase

the engine speed to 1600rpm.
5. Using the two hydraulic operating levers

located inside the rear of the chassis
(Figure 5n), lower the hopper side
plates and end plate into the travelling
position.
Figure 5l Hopper Side Plate Locking Wedge
6. Close down the plant and implement the

Lock Out procedure (Section 8.2).
Hopper Locking Wedge
7. Store the locking wedges in the tool
box and secure the tie bar to the plant.
Figure 5m Hopper Raised - Wedge Location
Figure 5n Hopper Hydraulic Control Levers
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Page 22
5.3.2 Manual Folding Hopper

lowering for transport
* WARNING
WEAR PERSONAL
Do Not attempt to undo any PROTECTIVE EQUIPMENT.
fastenings holding the manual Refer to Section 5.1 Safety
folding hopper side plates or
end plate until securely held by
lifting equipment to prevent LOCKOUT PLANT.
any movement. Information for Lockout
Procedure.
Procedure
FALLING HAZARD.
1. Observe all safety warnings. Information for relevant warning.
2. Using lifting equipment support the

hopper tie bar. Remove the locking
wedges and lift off the tie bar (Figure
5k).
3. Using lifting equipment support the end

plate.
4. Remove the bolts securing the end plate

to the side plates. Lower the end plate
into the travelling position.
5. Using lifting equipment support one of

the side plates.
6. Remove the locking wedges (Figures 5l

and 5m) holding the side plate in
position. Lower the side plate into the
travelling position.
7. Repeat Steps 5 & 6 for the other side

plate.
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Page 23
8. Secure the folding hopper plates to the

chassis with the chains provided (Figure
5o).
Transport Chain
9. Store the locking wedges in the tool
box and secure the tie bar to the plant.
Figure 5o Hopper Plate Chain
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Page 24
Blank page
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 1
Contents
6.2 Setting Up ............................................................................................................ 4

6.2.1 Manoeuvring ................................................................................................... 4
6.2.2 Unloading ........................................................................................................ 5
6.2.3 Setting Up ....................................................................................................... 6
6.3 Folding Hpper Plates ......................................................................................... 10
6.3.1 Hydraulic Folding Hopper .............................................................................. 10
6.3.2 Manual Folding Hopper * ............................................................................... 12
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Premiertrak
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Set Up Issue EN 07
Page 2








HAZARD
machine.

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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 3

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 4
6.2 Setting Up unsafe roadways etc. (Refer

to Figure 2a Dimensions)
6.2.1 Manoeuvring
• Make sure that you do not manoeuvre
Prior to attempting any the Plant on a gradiant steeper than 30
manoeuvring of the plant the degrees, damage may occur to the
tracks must be free of engine and/or plant.
obstructions, including crushed
material and fines. Do not push • Avoid manoeuvring the plant over
or tow the plant. Failure to extremely uneven ground or damage
observe this warning could may occur.
result in danger to persons and
damage to the plant which may • Control valves mounted on the engine
invalidate warranty. and beneath the feeder are NOT to be
used to manoeuvre the Plant. They are
• The plant cannot be manoeuvred in the for use by BL-Pegson Service
PLANT mode of operation. Engineers only.
• DO NOT manoeuvre the Premietrak • Initial start up in cold weather may

whilst the crusher running. result in a tendency to steer to the right
whilst tracking fast forward due to the
• The safety warning horn sounds hydraulic oil being cold. Run the plant
continuously whilst the plant is being for approx. 10 minutes with the
manoeuvred. conveyor and feeder running prior to
manoeuvring the plant.
DO NOT stand on any of the
platforms or ladders of the • When transporting the Plant, it is the
Plant whilst it is being responsibility of the haulage
manoeuvred using the remote contractor to safely secure the plant
control handset. to the transporter.
When manoeuvring the Plant

to its operating position make
sure you stand well clear of the
plant 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,
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 5
6.2.2 Unloading
The Plant will arrive on site securely
WARNING
fastened to a low loader. It is the WEAR PERSONAL
responsibility of the haulage contractor to PROTECTIVE EQUIPMENT.
remove the fastenings. Information for relevant warning.
Procedure
2. Position easy slope ramps at the end of

the transporter to help with unloading of
the Plant.

spring loaded cover to reveal the
control panel and engine control panel.

5. Turn the Operation switch to ‘TRACK’

(Figure 6b). Using the remote control
hand set, steer the Plant off the
transporter (Section 5.2.1).
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 6
6.2.3 Setting Up
Plant Location Considerations
WARNING
WEAR PERSONAL
The environment in which the PROTECTIVE EQUIPMENT.
plant will operate contains
Information for relevant
inherent risks to health and warning.
safety which the operator must
LOCKOUT PLANT.
take steps to guard against.
Dangers from overhead Information for Lockout
conveyor discharges, overspill Procedure.
material, vehicle movements,
etc., as well as other site FALLING HAZARD.
related hazards must be Refer to Section 6.1 Safety
anticipated. Avoid these by
warning.
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.
Prior to setting up the Plant, 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 manufacturer
should be fed into the plant.
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 Plant. Pay attention to
access from the loading area and to where
material is to be deposited (Section 5.2.1).
Ensure the area under the tail drum is free
of large stones etc which may cause belt
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 7
damage and sufficient clearance is present

for the tail drum to be lowered from the WARNING
travelling position. damage and sufficient
WEAR PERSONAL
clearance is present for the tail drum to be PROTECTIVE EQUIPMENT.
lowered from the travelling position. Refer to Section 6.1 Safety
warning.
Procedure
LOCKOUT PLANT.
1. Observe all safety instructions. Information for Lockout
Procedure.
2. Raise the feed hopper plates into the
FALLING HAZARD.
working position (Section 6.3.1 or 2). Refer to Section 6.1 Safety
3. Remove the dirt conveyor warning.
transportation safety chain (Figure 6a).
4. Turn the Operation switch

to’PLANT’(Figure 6b).
Dirt Conveyor Safety
5. Start the engine (Section 7.2). Increase Chain
the engine speed to 1600 rpm.
6. Lower the dirt conveyor fully by turning

the dirt conveyor switch to ‘Ð’ (Figure
6b).
During lowering of the dirt

conveyor ensure that the
hydraulic hoses and conveyor
belt do not foul any part of the
structure. Do not operate the
plant with the dirt conveyor
folded.
Dirt Conveyor
7. Lower the product conveyor tail section

Figure 6a Dirt Conveyor Safety Chain
by turning the Tail Lift switch to ‘Ð’
(Figure 6b).
continued overleaf...................
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 8
8. Switch off the engine (Section 8.2) and

lockout. WARNING
WEAR PERSONAL
9. Replace and secure the dirt conveyor PROTECTIVE EQUIPMENT.
head drum guard and side plates Refer to Section 6.1 Safety
(Figure 6c). Information for relevant
warning.
10. For the maintenance platforms fit the LOCKOUT PLANT.
rear handrails into position and make Refer to Section 6.1, Safety
sure the spring tension on each gate Information for Lockout
across the access gap is correctly Procedure.
adjusted to be self closing.
FALLING HAZARD.
11. Raise the safety grid on the crusher feed Information for relevant
chute with suitable lifting equipment and warning.
then bolt the two supports to the chute
and to the grid. Always operate the
plant with the safety grid supports
bolted in place (Figure 6d).
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 9
Operation Feeder Remote Dirt Conveyor Tail Lift - Product

Plant/Track Off/On Lower/Raise * Conveyor Lower/Raise
Figure 6b Control Panel
Figure 6d Safety Grid

(in plant operating position)
Figure 6c Dirt Conveyor Head Drum

Guard and Side Skirts
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Premiertrak
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Set Up Issue EN 07
Page 10
6.3 Folding Hpper Plates

WARNING
6.3.1 Hydraulic Folding Hopper WEAR PERSONAL
Raising the Hydraulic Folding
Hopper Plates into the Working Information for relevant warning.
Position
LOCKOUT PLANT.
Procedure Refer to Section 6.1, Safety
Information for Lockout
Procedure.
FALLING HAZARD.
2. Remove the locking wedges from the
tool box (Figure 6f).

4. Locate the two hydraulic control levers

inside the rear of the plant chassis
(Figure 6e). One lever will raise both
hopper side plates and the other lever
the hopper back plate into their working
positions.
5. Raise the side plates into position.
6. Raise the back plate into position .
7. Turn off the ignition to stop the engine

and implement the Lock Out
procedure.
10. Lock the sideplates into place using

using the four locking wedges (Figure 6f
-two wedges for each side plate). Figure 6e Hopper Hydraulic Control
Levers
Attach the locking wedge chains to the
plant. Bolt the end plate to the side
plates.
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 11
11. Using lifting equipment locate the tie bar

(Figure 6g) in position above the side WARNING
plates and lock into place using the
WEAR PERSONAL
attached wedges. PROTECTIVE EQUIPMENT.
LOCKOUT PLANT.
Procedure.
FALLING HAZARD.
Figure 6f Hopper Side Plate Locking

Wedge x 4
Figure 6g Hopper Tie Bar
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Premiertrak
1100 x 650 (26 x 44)
Set Up Issue EN 07
Page 12
6.3.2 Manual Folding Hopper * WARNING

Do Not attempt to undo any WEAR PERSONAL
fastenings holding the manual Refer to Section 6.1 Safety
folding hopper side plates or Information for relevant warning.
end plate until securely held by
lifting equipment to prevent LOCKOUT PLANT.
any movement. Refer to Section 6.1, Safety
Raising the Manual Folding Procedure.
Hopper Plates into the Working
Position FALLING HAZARD.
Procedure
2. Open the tool box and remove the side 7. Using lifting equipment locate the tie bar
plate locking wedges (Figure 6g). in position above the side plates and
lock into place using the attached
3. Remove the chains securing the folding wedges (Figure 6g).
hopper plates to the chassis. Store the
chains in the toolbox.
4. Using lifting equipment, raise one side

plate into position and lock into place
using the locking wedges (Figure 6f) -
two wedges for each side plate). Attach
the locking wedge chains to plant.
5. Repeat Steps 4 for the other side plate.
6. Using lifting equipment, raise the end

plate into position. Bolt the end plate to
the side plates.
Figure 6g Hopper Plate Chains
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Premiertrak
1100 x 650 (26x44)
Operating Instructions Issue EN 07
Page 1
Contents

7.1.1 Blocked Crusher Situation ............................................................................... 4
7.1.2 Stalled Crusher Procedure (1) ......................................................................... 5
7.1.3 Stalled Crusher Procedure (2) ......................................................................... 6
7.2 Safe Start-Up Procedure ..................................................................................... 7
7.2.1 Engine Start-Up .............................................................................................. 8
7.2.2 Crusher Engagement
(manual or hydraulically* activated) ............................................................... 13
7.2.3 Feeder/Conveyor Start-Up ............................................................................ 14
7.2.4 Safe Operation of the Plant ........................................................................... 16
7.2.5 Checks Prior to Initial Daily Start ................................................................... 16
7.2.6 Initial Start Up and Running In ........................................................................ 17
7.3 Feeder Remote Stop/Start ................................................................................ 20
7.3.1 Radio Remote Operation (where fitted) ......................................................... 20
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HAZARD
machine.

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1100 x 650 (26x44)
Page 3

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
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Page 4
7.1.1 Blocked Crusher Situation

It is the responsibility of the Owner, End
WARNING
User and/or Safety Officer of the Plant to WEAR PERSONAL
provide a safe means of dealing with PROTECTIVE EQUIPMENT.
oversize material and construct a safe Information for relevant
procedure for unblocking a stalled machine warning.
which is full of material.
LOCKOUT PLANT.
To comply with British Health and Safety Information for Lockout
Law it is necessary to conduct an adequate Procedure.
risk assessment of the procedures for
unblocking a blocked crusher. FALLING HAZARD.
Should an oversize piece of material be fed
warning.
to a jaw crusher and cause the feed opening
to be bridged the recommended procedure
for removing this is to use a hydraulic arm.
When a hydraulic arm is used no pressure
should be put on the rock when the crusher
is STATIONARY as this will cause assessment where there is every indication
premature failure of the bearings. A crane that they can be worked safely.
and hook can be used although EXTREME
caution must be exercised to ensure that the Once this has been decided it should be
crane is not overloaded by trying to lift a incorporated into a permit to work
jammed rock. procedure to be issued by the manager.
This system should cover things such as
The following methods SHOULD notification to the manager, isolation,
NOT be attempted.:- methods of removal of excess stone, safe
positions for personnel.
The use of wedges. TURN TO NEXT PAGE FOR STALLED

CRUSHER PROCEDURES.
Using mobile plant to drag stones out of the
crusher or feeder.
Under most arrangements pinch bars and

hand hammers cannot be used safely. Their
use should be limited to situations under risk
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Page 5
7.1.2 Stalled Crusher Procedure (1)

In the situation where an oversize piece of
WARNING
WEAR PERSONAL
material causes the crusher to stall, it is PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety Informa-
possible the pressure will be sustained on tion for relevant warning.
the moving swing jaw. This pressure will
need to be released under controlled LOCKOUT PLANT.
conditions to enable safe removal of the Refer to Section 7.1, Safety
material that has created the stall condition Information for Lockout
FALLING HAZARD.
BEFORE ANY ATTEMPT TO
CARRY OUT THE Information for relevant warning.
PROCEDURES TO CLEAR
THE STALLED CONDITION
OF THE CRUSHER THE 3. Carefully ascertain if this has allowed
MACHINE MUST BE some possible movement of the toggle
ISOLATED FROM ALL beam/plate which has released the
SOURCES OF SUPPLY AND pressure on the blocking material.
THE SAFETY GRID AT THE
MOUTH OF THE CRUSHER 4. If the procedure is sucessful and the
MUST BE SECURELY blocking material removed, retighten the
FASTENED IN PLACE. locking wedges before recommencing
operation.
In certain circumstances it may be possible
to release the pressure on the moving swing
jaw by slackening off the toggle beam
locking wedges which may allow the toggle
beam to be raised sufficiently to allow the 2 1
jaw to fall back by a small amount
Procedure
3
1. Observe all safety warnings. Toggle Beam
2. Release each clamping wedge locking

nut (1) (Figure 7). Then turn each
locking nut (2) to move both locking Mainframe
wedges (3) towards the machine side
walls leaving the toggle beam free to
move.
Figure 7 Toggle Beam Locking Wedge
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Page 6
7.1.3 Stalled Crusher Procedure (2)

If the previous procedure fails to provided
WARNING
WEAR PERSONAL
sufficient means of releasing the pressure on PROTECTIVE EQUIPMENT.
the toggle plate to enable the stalling Information for relevant warning.
blockage to be removed, more radical LOCKOUT PLANT.
means may be required. This could incur Refer to Section 9.1, Safety
the cutting through of the toggle plate (from Information for Lockout
above the plate) with the aid of a thermic FALLING HAZARD.
lance or other similar cutting device. A new Refer to Section 9.1, Safety
toggle plate will be required to be fitted Information for relevant warning.
before crushing operations can be re-

commenced (Section 9.7.3).
CUTTING THROUGH THE IMPORTANT

TOGGLE PLATE WILL The above, or any other procedure
CAUSE THE RELEASE OF developed to remove tramp metals, or any
STORED ENERGY IN THE other material that results in the stalling of the
MOVING JAW WHICH WILL crusher should be incorporated into a permit
SWING VIOLENTLY BACK to work procedure. This procedure should be
TOWARDS THE OPERATOR maintained under the control of the competent
PERFORMING THE person appointed by the management.
CUTTING OPERATION.
The system should cover all factors of safety
including notification to the manager, isolation
Procedure
of systems and locking out procedures,
methods of removal, safe positions for
1. Observe all safety warnings. persons and any other precautions as may be
deemed necessary.
2. Before the cutting operation is
commenced adequate and appropriate Should any futher information be required with
provision MUST be made to support regard to the clearing of blocked crushers,
the weight of the jawstock to control reference can be made to the :-
the release of the stored energy in order
to prevent the violent swinging British Aggregate Construction Materials
movement of the jawstock. Industries (BACMI) document ‘Clearing
Blocked Crushers’.
3. Cut the toggle plate across its line,
observing any movement prior to the This document provides recommended
final separation. procedures and advice on risk assessment
and permit to work.
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Page 7
7.2 Safe Start-Up Procedure • Check that all guards are in position and
secure and that all personnel are clear
BL Pegson Ltd cannot over- of the plant.
emphasize the need to ensure
that all safety aspects are • Ensure that (where fitted) the anti-
checked before starting the vandal engine radiator cover is secured
engine. in the fully raised position before
attempting to start the engine.
Whilst the engine is running
and the Operation switch is
turned from ‘TRACK’ to
‘PLANT’ mode the safety
warning horn will sound for 10
seconds. When the horn has
stopped the conveyor(s) and/or
feeder can be started.
With the engine switched ‘OFF’
• Ensure the full length of both vehicle

tracks are in contact with a firm level
surface.
• Check that the crushing chamber and

feed hopper are empty.
• Measure the crusher discharge

opening and adjust if necessary.
(Section 9.9)
• Check that all Emergency Stops are

pulled out (Figure 1a).
• Manual clutch only. Ensure the

engine clutch is disengaged (lever
fully away from the engine) and the
throttle is set to the lowest position,
screwed fully in (Figures 7d and 7f).
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7.2.1 Engine Start-Up

WARNING
Procedure WEAR PERSONAL
1. Observe all safety warnings warning.
2. Ensure the engine Isolation Switch

(Figure 7a) is turned to the I position.
3. Locate the Control Box and raise the

cover to reveal the control panel and
engine control panel (Figure 7b).
4. Turn the Operation switch, located on

the Control Panel to ‘PLANT’ and the
Feeder Remote switch ‘ON’ (Figure
7c).
5. On the engine control panel (Figure 7d)

set the speed control switch in the
DOWN position then turn on the
ignition with the key to the first position
and, once the sequence of diagnostic Figure 7a Isolation Switch
checks is completed, fully turn the key
to start the engine. Release the key
back to the first position as soon as the
engine starts.
Refer to Figure 7e together with

continuation page for details of the
engine diagnostic functions. To avoid damaging the clutch
DO NOT increase the engine
6. Check the engine speed is at 1200 rpm speed to the operating 1600
(view on tachometer) and allow to run RPM until after starting the
for 3-5 minutes before proceeding with Crusher (Section 7.2.2)
preparation for transport (Section 5),
setting up the plant (Section 6) or
initiating the plant run sequence
(Section 7).
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Control Panel Umbilical Handset Connection Point Engine Control Panel
Figure 7b Control Box
Crusher Off/On * Tail Lift

(Hydraulic clutch only) Product Conveyor
Lower/Raise
Operation Feeder Remote Dirt Conveyor *

Plant/Track Off/On Lower/Raise
Figure 7c Control Panel
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Maintenance Due Lamp Diagnostic Lamp
Tachometer Diagnostic Display
Scroll Switch
Fuel Gauge Speed Control
Ignition Key
Figure 7d Engine Control Panel
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DIAGNOSTIC DISPLAY
The main unit has ten warning lamps available for system related diagnostics.
These diagnostics can be used for system troubleshooting and diagnostic information.
They are located on the main EMS unit in two rows of five:
High Engine Coolant Low Engine Oil Pressure
Temperature or Sensor Fault or Sensor Fault
High Inlet Manifold Low Fuel Pressure

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

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

GA-1 Engine Oil Pressure
GA-2 Coolant Temperature
GA-3 Bateery Voltage
GA-4 Fuel Pressure
Boost Boost Pressure
IAirT Inlet Air Temperature
FuelT Fuel temperature
AccrP Auxiliary Pressure
AccrT Auxiliary Temperature
Fuel Fuel Rate
Hrs Engine Hours
Load Engine (Percent) Load
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7.2.2 Crusher Engagement

(manual or hydraulically* WARNING
activated)
WEAR PERSONAL
Procedure Information for relevant
warning.
With the engine speed set at 1200rpm :-
2. Manual Clutch only. Slowly engage

the clutch by moving the clutch lever
towards the engine unit, this will start
the crusher (Figure 7f).
Hydraulic Clutch only. On the

Feeder/Conveyor Control Box (Figure
7g) located on the left hand side of the
Plant, press the ‘GREEN’ Product
Conveyor button to start the conveyor
(fixed speed) and the magnetic
overband separator (Th e speed of the
separator can be altered, refer to
section 9.17). Note that the Crusher Figure 7f Clutch Lever
(manual clutch)
cannot be started until the Product
Conveyor is running.
On the Control Panel (Figure 7c) press 4. Check the plant is stable with no
the ‘GREEN’ Crusher button to excessive vibration.
operate the hydraulic clutch on the
engine. A warning horn will sound for
10 seconds before the clutch engages.
3. Using the speed control, increase the

engine speed to 1600 rpm, view on
tachometer (engine speed 1600 rpm
under crushing load). This is the
crusher and engine’s optimum speed.
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7.2.3 Feeder/Conveyor Start-Up

The control valves mounted on
WARNING
the engine and beneath the WEAR PERSONAL
feeder are NOT to be used in PROTECTIVE EQUIPMENT.
any circumstances to operate Information for relevant
the feeder or conveyors. warning.
The operation switch on the

control panel has to be in
‘PLANT’ mode for the feeder
and conveyors to work (Figure material to be crushed so as to maintain
7c). The safety warning horn an even regular flow through the crusher
will sound for 10 seconds when (Section 7.2.7).
the Operation switch is turned To adjust the speed of the feeder turn
from ‘TRACK’ to ‘PLANT’ the Feeder Speed Control knob and
mode. adjust to the required setting.
The feeder can be switched ON and OFF

remotely (Section 7.4). However the
Procedure speed cannot be adjusted from the remote
control handset.
2. Manual Clutch only. On the Feeder/

Conveyor Control Box press the
‘GREEN’ Product Conveyor button
NOTE FOR HYDRAULIC *
to start the conveyor (fixed speed) CLUTCH:
and the magnetic separator (The
speed of the separator can be altered, Should the Pressure Fault Light on the
refer to Section 9.17). control box (Figure 7g) remain
illuminated the feeder cannot be
3. Press the ‘GREEN’ Dirt Conveyor started. This red warning light indicates
button to start the dirt conveyor insufficient pressure for the hydraulic
(fixed speed). engine clutch to operate under crushing
loads. Investigate the cause and rectify.
4. Press the ‘GREEN’ Feeder button to
start the feeder.
The speed of the feeder will need
adjusting depending on the type of
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Page 15
Emergency Stop Feeder Speed

Button Control
Low Hydraulic Oil

Pressure Warning
Light *
(hydraulic clutch
only)
Crusher Stop
Button
*
(hydraulic clutch
only)
Dirt Conveyor On/ Product Conveyor Feeder On/Off

Off Buttons* On/Off Buttons Buttons
Figure 7g Feeder/Conveyor Control Box
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7.2.4 Safe Operation of the Plant 7.2.5 Checks Prior to Initial Daily
Start
NEVER leave the Plant
unattended whilst it is in Plant
operation.
• Visually check the plant and ensure that
Do check regularly that the oil all guards and warning signs (Section 1)
cooler fan (located on the are in position and that all equipment
Engine Maintenance Platform) and tools that are hazardous to
is running correctly and that operation are removed from the
dust/dirt has not built up in the immediate site.
fan and radiator unit (over
heating can occur if dust/dirt is • Manual Clutch only. Ensure that the
allowed to build up). Blow out jaw crusher clutch on the diesel
dust/dirt if necessary. engine is disengaged.
DO NOT allow a build up of • Ensure that the jaw crusher and the
material at the feed on points grizzly feeder hopper are empty.
to enter either the product
conveyor or dirt conveyor. • Check discharge opening with
calipers and adjust as necessary, to
DO check frequently the the required settings (Section 9.5).
stability of the Plant. The
chassis SHOULD NOT bounce • Check the oil cooler fan and radiator
during operation. unit (located on the Engine
Mainenance Platform) for any build
DO NOT run the engine below up of dust/dirt. Blow out dust/dirt if
its recommended working necessary.
speed of 1600 RPM when
crushing, and DO NOT slip the Crusher should be fed by an
engine clutch. excavator such that the bucket
does not pass over or near to
AVOID frequent starting and the operator.
stopping of the Plant
unnecessarily as it WILL
cause damage to the plant.
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Page 17
7.2.6 Initial Start Up and Running 2. Check frequently the overall stability of
In the plant; re-check the level of the plant
and re-level if necessary.
Initial Start-Up
3. Manual Clutch only. After several
• Check the vibrating unit oil level and days use re-check clutch engagement
hydraulic oil level (Figure 7h & 7i). torque as described in engine manual.
• Refer to engine manual for engine Crusher
initial start up.
1. Regularly check drive belts (crusher and
• Run the plant empty for a short hydraulic pumps) to ensure correct
period of time and check for tension, particularly during the initial 2
abnormal noises, vibration or weeks of use (Section 9.15).
excessive heat from the shaft
bearings. 2. Check the alignment and tension of the
vee belt drive daily during the initial
• Check the direction of rotation of the days of operation (Section 9.15).
crusher flywheels is correct, ie. over
the top of the flywheels towards the 3. Check the shaft bearing temperature
feeder. daily using a contact thermometer
and record for future reference and
Actions During Running-In Period fault diagnosis. The maximum
acceptable working temperature is
Checks on the Plant are crucial
80°C.
during the first week of
operation. 4. Avoid overloading the crusher;
The following section should be restrict loading to 50% and 75% of
read and understood prior to full capacty during the first and
starting the Plant. If there are second days of operation respectively.
any doubts, contact BL Pegson
Ltd. Service Department. 5. Ensure that all drives are running
before any feed is introduced to the
Plant
plant and that the feed is maintained
at a constant rate, irregular and
1. Each day during the initial days of
excessive feed rates reduce the
operation check the tension of the
efficiency of the plant.
conveyor belts on the main product
conveyor and dirt conveyor (if fitted).
6. Ensure that all undersize feed (smaller
than the discharge setting) and
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Hydraulic Oil Hydraulic Oil Return

Breather/Filler Filter and Gauge
Hydraulic Oil Level Hydraulic Oil Tank
Figure 7h Hydraulic Oil Tank & Level Indicator
Oil Filler Plug
Oil Level
Signt Glass
Oil Drain Plug
Figure 7i Feeder Vibrating Unit
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Page 19
oversize feed (greater that 80% of the

feed opening) is removed prior to
introduction into the crusher.
Feeder
1. Frequently check the oil levels in the

vibrating unit end covers and the
hydraulic oil level in the tank (Figure
7h &7i).
2. After first 8 hours of operation,

change the oil in the vibrating unit
end covers
3. Check the vibrating unit bearing

temperatures using a contact
thermometer on the end covers;
record for future reference and fault
diagnosis. (Maximum acceptable
temperature is 80ºC [176° F] ).
4. Ensure that the vibrating unit is

operating before any feed is
introduced to the plant.
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7.3 Feeder Remote Stop/Start

WARNING
7.3.1 Radio Remote Operation WEAR PERSONAL
(where fitted) PROTECTIVE EQUIPMENT.
To operate the feeder remotely the Information for relevant warning.
conveyors and feeder must first be switched
on manually and the feeder speed set
manually (Section 7.2.3).
Procedure
1. Observe all safety instructions.

Feed Conveyor
2. Take the Remote Control Hand Set stop/start button
from the Control Box and first become
familiar with the functions of all the
individual buttons (Figure 5b) before the
next step.
3. To start up the handset transmitter first Stop Button

stand well clear of the plant. Hold the
hand set with the stop button nearest to Figure 7k Feeder Remote Operation
the operator and proceed as follows:- (RADIO)
• Ensure the stop button is pulled out.

• Depress both of the safety buttons
(Fig.7?) at the same time for at least 1 4. Put the Plant into full operation (Sections
second. Release the safety buttons. 7.2.1, 7.2.2 & 7.2.3).
• The red LED will change to green.
• The transmitter is in function status 5. The feeder can be turned on and off
when the green LED comes on. using the Feeder On/Off button on the
hand set. The speed of the feeder
Note: The transmitter has a built in safety cannot be adjusted using the hand set.
function that prevents another function from To adjust the speed of the feeder refer
involuntary cutting-in when the transmitter to Section 7.2.3.
starts. The transmitter will not start if a
button is stuck in the activated position.
This is indicated by the red LED coming on.
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Shut Off Issue EN 07
Page 1
Contents
8.2 Closing Down the Plant ...................................................................................... 4
8.3 Emergency Stopping of the Engine ................................................................... 7

8.3.1 Emergency Stop Buttons ................................................................................. 7
8.3.2 Testing Buttons ................................................................................................ 7
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HAZARD
machine.

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HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
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Page 4
8.2 Closing Down the Plant

WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
Information for relevnat
1. Observe all safety warnings. warning.
LOCKOUT MACHINE.
2. Ensure that the feeder and crusher are Refer to Section 8.1, Safety
empty, and that all materials have run Information for Lockout
Procedure.
off the conveyor(s).
3. On the Feeder/Conveyor Control Box

(Figure 8a) located on the left hand
side on the Plant, press the ‘RED’ 10. Turn the Ignition Key to the off position
Feeder button to Stop the feeder. to shut down the engine. Remove the
Ignition Key. Shut and lock the Control
4. Hydraulic Clutch only. Press the Box door. Lockout the Isolation Switch
Crusher ‘OFF’ button to disengage (Figure 8c).If the radio hand set (where
the hydraulic clutch drive to the fitted) has been in use, shut down by
crusher. depressing the stop button on the unit. .
5. Press the ‘RED’ Dirt Conveyor 11. Following the closing down proceedure
button to Stop the dirt conveyor. above, it is recommended that at the
end of operation for the day the plant is
6. Press the ‘RED’ Product Conveyor routinely cleaned down and thoroughly
button to Stop the the product con- examined to check for any damage,
veyor and also the magnetic overband breakages, wear, leaks etc which
separator. should be rectified before further opera-
tion.
7. Using the speed control, decrease the
engine rpm to 1200rpm (Figure 8d). Use of high pressure washing
equipment is to be avoided
8. Manual Clutch only. Disengage the where the ingress of water will
engine clutch by slowly moving the be detrimental to plant com-
clutch lever (Figure 8b) away from the ponents eg. crusher bearings,
engine unit (this will disengage the conveyour bearings, hydraulic
crusher). tank, electrical equipment etc.
9. Let the engine idle for 3-5 minutes.
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Emergency Stop Feeder Speed

Button Control
Low Hydraulic Oil

Pressure Warning
Light *
(hydraulic clutch
only)
Crusher Stop
Button
*
(hydraulic clutch
only)
Dirt Conveyor On/ Product Conveyor Feeder On/Off

*
Off Buttons On/Off Buttons Buttons
Figure 8a Feeder/Conveyor Control Box
Figure 8b Clutch Lever Figure 8c Engine Isolation Switch

(manual clutch)
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Maintenance Due Lamp Diagnostic Lamp
Tachometer Diagnostic Display
Scroll Switch
Speed Control
Fuel Gauge
Ignition Key
Figure 8d Engine Control Panel
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8.3 Emergency Stopping of

the Engine WARNING
WEAR PERSONAL
Refer to Section 8.2 PROTECTIVE EQUIPMENT.
IN AN EMERGENCY STOP SITUA- Information for relevnat warning.
TION, STOP THE ENGINE (AND
PLANT OPERATION ) USING THE
EMERGENCY STOP BUTTONS.
(Figures 1a) 8.3.2 Testing Buttons
Note:- The Plant should not be re- Daily, before commencing

started if the crusher is full of material. crushing operations, test each
emergency stop button is
When the Plant has been stopped using operative.
the emergency stop button the Ignition
Switch stays ‘on’. Immediately turn the Procedure
key to the off position.
If the emergency stop button is then 1. Observe all safety warnings

released whilst the Ignition Switch is in
‘on’ position’ the safety warning horn 2. Follow the safe start-up procedure
will sound for 10 seconds before the (section 7.2)
engine can be restarted. (Section 7.2).
3. Start the engine (section 7.2.1)
When an emergency stop has
been intiated, DO NOT at- 4. Test each emergency stop button in turn
tempt to restart the engine to cut out the engine and, following the
until it is safe to do so. resetting of the tested button, repeat the
process for each of the other emer-
gency stop buttons (Section 1.7) and
8.3.1 Emergency Stop Buttons
also the stop button on the remote
Pressing any of the buttons will stop the control handset.
diesel engine and the button will remain
engaged until physically released by The emergency stop button on the main
pulling or twisting (depending upon the control panel can be tested during the
type fitted) the button knob. The engine 10 second warning prior to engine start
cannot be started if any of the emergency in which case the sound will cease if the
buttons remain depressed button is operative.
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Blank page
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Maintenance 1100x650 (26x44)
Issue EN 07
Safety Information
Page 1
Contents

Maintenance Hazards and Procedures .................................................................... 4
Diesel Engine Welding Precautions ......................................................................... 6
General Maintenance Safety Precautions ................................................................. 7
MAINTENANCE - SPECIFIC TO MODEL
9A.0 Maintenance Description .................................................................................. 3
9A.1 Weights of Components ................................................................................... 3
9A.2 General Information .......................................................................................... 4
9A.3 Plant - Lubrication and Servicing .................................................................... 6

9A.3.1 Lubrication Points ......................................................................................... 6
9A.3.2 Regular Servicing ......................................................................................... 7
9A.3.3 Lubrication and Servicing Schedule .............................................................. 8
9A.3.4 Crusher Lubrication in High Ambient Temperatures ....................................... 9
9A.3.5 Importance of Correct Grease ..................................................................... 10
9A.3.6 Lubricant and Oil Types............................................................................... 11
9A.3.7 Lubrication & Oil Specifications .................................................................. 12
9A.4 Crusher - Adjustment of Discharge Opening ................................................ 13
9A.4.1 Adjustment.................................................................................................. 14
9A.5 Crusher - Fitting of Tension Rod Assembly .................................................. 16
9A.6 Crusher - Toggle Plate Replacement ............................................................. 18

9A.6.1 Tension Rod Removal ................................................................................. 18
9A.6.2 Toggle Plate Removal ................................................................................. 20
9A.6.3 Fitting New Toggle Plate ............................................................................. 22
9A.7 Crusher - Fitting New Toggle Seat ................................................................. 23
9A.8 Crusher - Manganese Replacement .............................................................. 24

9A.8.1 Changing the Swing Jaw ............................................................................ 24
9A.8.2 Changing the Fixed Jaw ............................................................................. 26
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Page 2
9A.9 Crusher - Changing of Cheek Plates ............................................................. 29

9A.9.1 Removal ..................................................................................................... 29
9A.9.2 Fitment ....................................................................................................... 31
9A.10 Crusher - Fitting and Removing Flywheel Locking Mechanism .............. 32
9A.10.1 Loosening the Ringfeder ........................................................................... 32
9A.10.2 Tightening the Ringfeder ........................................................................... 33
9A.11 Feeder - Operation ......................................................................................... 34
9A.11.1 Feeder Maintenance ................................................................................. 35
9A.12 Plant - Hydraulic System Description .......................................................... 36
9A.12.1 General Description .................................................................................. 36
9A.12.2 Track Drives ............................................................................................. 38
9A.12.3 Feeder Drive ............................................................................................ 38
9A.12.4 Circuit Protection ...................................................................................... 38
MAINTENANCE - GENERAL ALL MODELS
9B.0 Maintenance Description ................................................................................. 3
9B.1 Plant Hydraulic System .................................................................................... 4

9B.1.1 Changing the Suction Filter ........................................................................... 4
9B.1.2 Changing the Return Filter ............................................................................ 6
9B.1.3 Changing the Tank Breather .......................................................................... 7
9B.1.4 Changing then Hydraulic Pressure Filters ...................................................... 8
9B.2 Plant - Electrical System ................................................................................. 10
9B.3 Plant - V Belt Drives ........................................................................................ 12

9B.3.1 V Belt Drives - General ............................................................................... 12
9B.3.2 V Belt Drives - Alignment ............................................................................ 13
9B.3.3 V Belt Drives - Adjustment .......................................................................... 14
9B.3.4 V Belt Drives - Replacement ....................................................................... 15
9B.3.5 Method of Drive Belt Tensioning .................................................................. 16
9B.3.6 Trouble Shooting - Drive Belts ..................................................................... 19
9B.4 Plant - Conveyors ........................................................................................... 20
9B.4.1 Training of Belts .......................................................................................... 20
9B.4.2 Conveyor Belt Tensioning ............................................................................ 22
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Safety Information
Page 3
9B.4.3 Maintenance of Conveyor(s) ....................................................................... 24

9B.4.4 Cleaning the Conveyor Belts ....................................................................... 26
9B.5 Plant - Overband Magnet (where fitted) ......................................................... 28
9B.6 Plant - Dust Suppression ............................................................................... 30
9B.7 Plant - Diesel Engine ....................................................................................... 32

9B.7.1 Engine - General Information ....................................................................... 32
9B.7.2 Engine - ELC Coolant ................................................................................. 33
9B.7.3 Engine - Check Fuel Level .......................................................................... 34
9B.7.4 Engine - Top Up Fuel Level ......................................................................... 35
9B.8 Engine Power Transmission .......................................................................... 36
9B.8.1 Transmission Types - fitted to models ......................................................... 36
9B.8.2 Hydraulic Clutch - Grease Lubricated Bearing ............................................. 38
9B.8.3 Hydraulic Clutch - Oil Lubricated Bearing .................................................... 40
9B.8.3.1 Hydraulic Clutch Trouble Shooting ............................................................................... 42
9B.8.4 Manual Clutch ............................................................................................. 43
9B.8.4.1 Manual Clutch - Adjustment ........................................................................................ 45
9B.8.4.2 Manual Clutch - Max/Min Adjustment Values .............................................................. 45
9B.8.5 Fluid Coupling ............................................................................................ 46
9B.8.5.1 Fluid Coupling Description ........................................................................................... 46
9B.8.5.2 Fluid Coupling - Features ............................................................................................. 48
9B.8.5.3 Fluid Coupling - Maintenance ....................................................................................... 50
9B.8.5.4 Fluid Coupling - Trouble Shooting ................................................................................. 52
9B.8 Plant - Vehicle Tracks ..................................................................................... 54
9B.8.1 Measuring Track Tension ............................................................................ 54
9B.8.2 Adjusting Track Tension .............................................................................. 56
9B.8.3 Track Maintenance ..................................................................................... 59
9B.8.4 Drive Oil Filling and Draining ...................................................................... 60
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Issue EN 07
Safety Information
Page 4
Maintenance Hazards and Procedures

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
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Issue EN 07
Safety Information
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HAZARD
machine.

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Issue EN 07
Safety Information
Page 6
Diesel Engine Welding Precautions
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Issue EN 07
Safety Information
Page 7
General Maintenance Safety Precautions
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 9.0 as appropriate to the task(s) in hand.
• Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk
Assessment for all maintenance operations. Have suitable lifting equipment available for the
components involved together with all necessary (and suitable) tools/equipment ready for the
task(s) in hand and always secure parts liable to movement before starting work.
BL-Pegson’s Service Department is available for advice when required.
• The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout
Procedure (Section 9.0). 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 INSTRUCTIONS OPPOSITE 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 Section 7,‘Checks Prior to Initial Daily Start Up’ and ‘Initial Start Up and Running In’.
AX815-901-8EN-07b 113/318
Premiertrak
Issue EN 07
Safety Information
Page 8
Blank page
AX815-901-8EN-07b 114/318
Premiertrak
Maintenance 1100 x 650
Issue EN 07
Specific to Model
Page 1
Contents
9A.0 Maintenance Description .................................................................................. 3
9A.1 Weights of Components ................................................................................... 3
9A.2 General Information .......................................................................................... 4
9A.3 Plant - Lubrication and Servicing .................................................................... 6

9A.3.1 Lubrication Points ..................................................................................................... 6
9A.3.2 Regular Servicing ..................................................................................................... 7
9A.3.3 Lubrication and Servicing Schedule ......................................................................... 8
9A.3.4 Crusher Lubrication in High Ambient Temperatures ................................................. 9
9A.3.5 Importance of Correct Grease ................................................................................ 10
9A.3.6 Lubricant and Oil Types .......................................................................................... 11
9A.3.7 Lubrication & Oil Specifications .............................................................................. 12
9A.4 Crusher - Adjustment of Discharge Opening ................................................ 13
9A.4.1 Adjustment .............................................................................................................. 14
9A.5 Crusher - Fitting of Tension Rod Assembly .................................................. 16
9A.6 Crusher - Toggle Plate Replacement .............................................................18

9A.6.1 Tension Rod Removal ............................................................................................ 18
9A.6.2 Toggle Plate Removal ............................................................................................. 20
9A.6.3 Fitting New Toggle Plate ......................................................................................... 22
9A.7 Crusher - Fitting New Toggle Seat .................................................................23
9A.8 Crusher - Manganese Replacement ..............................................................24

9A.8.1 Changing the Swing Jaw ........................................................................................ 24
9A.8.2 Changing the Fixed Jaw ......................................................................................... 26
9A.9 Crusher - Changing of Cheek Plates .............................................................29
9A.9.1 Removal ................................................................................................................. 29
9A.9.2 Fitment ................................................................................................................... 31
9A.10 Crusher - Fitting and Removing Flywheel Locking Mechanism .............. 32
9A.10.1 Loosening the Ringfeder ....................................................................................... 32
9A.10.2 Tightening the Ringfeder ....................................................................................... 33
AX815-901-8EN-07b 115/318
Premiertrak
Issue EN 07
Specific to Model
Page 2
9A.11 Feeder - Operation ......................................................................................... 34

9A.11.1 Feeder Maintenance ............................................................................................. 35
9A.12 Plant - Hydraulic System Description .......................................................... 36
9A.12.1 General Description .............................................................................................. 36
9A.12.2 Track Drives ......................................................................................................... 38
9A.12.3 Feeder Drive ......................................................................................................... 38
9A.12.4 Circuit Protection .................................................................................................. 38
AX815-901-8EN-07b 116/318
Premiertrak
Issue EN 07
Specific to Model
Page 3
9A.0 Maintenance Description
The Maintenance Section is divided into two parts.
9A - Specific instructions for the particular model or type of plant.

9B - General instructions for equipment for all models or types of plant.
9A.1 Weights of Components
Weights of crusher and feeder assemblies, these should be consulted when arranging suitable lifting
equiptment.
Component kg lbs.
Complete Jaw Crusher 16 300 35,925
Swing Jaw Assembly Including Flywheels 8 564 18,875
Swing Jaw Assembly Excluding Flywheels 5 964 13,145
Swing Jaw Manganese 794 1,750
Fixed Jaw Manganese 710 1,565
Cheek Plate - upper (each) 135 298
Cheek Plate - lower (each) 86 190
Toggle Plate 172 380
Feeder Including Vibrating Unit 3 900 8,595
Vibrating Motor Unit 884 1,948
Total Weight of Plant approx 45.4 tonnes (49.9 US tons)
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment
AX815-901-8EN-07b 117/318
Premiertrak
1100 x 650
Maintenance Issue EN 07
Page 4
9A.2 General Information The plant has been designed to facilitate

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

instructions as well as mainteenance
schedules for normal operating conditions.
When the Plant is operated in

extreme climatic conditions
e.g. below -15° C (5° F) or
above 30° C (86° F), or in very
dusty conditions for a longer
period of time, the
maintenance schedules will
change.
Ask your local BL-Pegson

dealer or BL-Pegson Technical
Department for advice.
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1100 x 650
Page 5
PRACTICE SAFE
MAINTENANCE
Understand sevice procedure

before doing any work. Keep
area clean and dry.
Never lubricate, clean, service

or adjust machine whilst it is
moving.
Keep hands, feet and clothing

clear of power driven parts and
in-running nip points.
Disengage all the power and

operate controls to relieve
presure. 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 6
9A.3 Plant - Lubrication and

Servicing WARNING
WEAR PERSONAL
9A.3.1 Lubrication Points PROTECTIVE EQUIPMENT.
Regular lubrication of the plant machinery in Information for relevant warning.
accordance with the Lubrication and Servicing
Schedule (Section 9.4.3) is essential. LOCKOUT PLANT.
The locations of the lubrication points are as Information for Lockout
follows:- Procedure.
FALLING HAZARD.
• Crusher jawstock bearing grease
nipples (2) situated on the back of the Information for relevant warning.
crusher jawstock behind the crusher
and accessed by lifting off the rear
guard panel. SEE NOTICE It is the operators
OPPOSITE. responsibility to ensure that all
bearings are greased with the
• Crusher mainframe bearing grease
correct quantity and quality of
nipples (2) on the crusher bearing caps
grease at the correct intervals
accessed fron the back of the crusher.
specified above.
SEE NOTICE OPPOSITE.
• Feeder vibrating unit bearing oil baths It is bad practice to mix
on both sides of the feeder vibrating unit greases. The blend can have a
(Section 9.12 and Figure 9n). lower specification than the
individual greases. USE ONE
• On-plant conveyor head and tailshaft BRAND ONLY.
bearing grease nipples located:-
Headshaft - 2 nipples on the left hand To deliver the specified
side of the conveyor beneath the quantity of grease (Section 9.4)
magnetic separator. to each of the four CRUSHER
ECCENTRIC SHAFT
Tailshaft - 1 nipple each side of the main BEARINGS, ascertain the
plant chassis below the feeder. amount your grease gun will
deliver with each ‘pump’.
• Track unit gearbox (2) oil levels (Section
9.20).
DO NOT ASSUME! CHECK THE
continued on the next page opposite....... GREASING EQUIPMENT USED ON A
REGULAR BASIS.
AX815-901-8EN-07b 120/318
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Page 7
• Optional dirt conveyor head and

tailshaft bearing housing grease nipples WARNING
located:-
WEAR PERSONAL
Headshaft - 1 on each bearing housing. PROTECTIVE EQUIPMENT.
Tailshaft - 2 on one side of the main Information for relevant
chassis below the feeder. warning.
LOCKOUT PLANT.
• Optional overband magnetic separator Refer to Section 9.1, Safety
head and tailshaft bearing housing Information for Lockout
grease nipples. Procedure.
The belt magnet assembly is FALLING HAZARD.

very powerful and permanently Refer to Section 9.1, Safety
charged. The strong magnetic Information for relevant
warning.
field produced could affect
heart pacemakers, watches,
credit cards, mobile phones
etc. The operator has the sole
responsibility to keep anyone
at risk clear of the machine.
Do not overlook the service
• HFO hydraulic clutch grease lubricated requirements of the plant
bearing. diesel engine and the optional
manually operated Twin Disc
• Periodically lubricate hinges, cylinder clutch which are detailed in the
pivot pins and similar points with oil to separate manufacturer’s
prevent seizure during lengthy spells of manuals.
inactivity.
9A.3.2 Regular Servicing

The Lubrication and Servicing Schedule
(Section 9.4) lists, in addition to the
lubrication points, the attention required to
the hydraulic system (Section 9.13).
Particular attention should be paid to
institute a regime of strict adherence from
the start of operations for all aspects of
routine maintenance.
AX815-901-8EN-07b 121/318
1100 x 650 (26 x 44) Premiertrak Lubrication Schedule
Frequency of Lubrication: X = Change
O = Check, top up or clean as necessary
R = Re-grease
Schedule based on a 40 hour operating week. Adjust schedule to suit actual operating hours.
No of 6 Monthly
Description Lubricant Quantity Daily Weekly 2 Weekly Monthly
Locations (1000 hrs)
85 grams each
2 Jawstock grease nipple D ~ R ~ ~ ~
(3 ounces each)
Mainframe bearing cap 85 grams each
2 D ~ R ~ ~ ~
grease nipple (3 ounces each)
To middle of sight
Feeder drive side filler Refer to X(200
1 glass 2.1 litres O ~ ~ ~
plug Lub. Types (c.4½ US pints) hours)
To middle of sight
Feeder non-drive side Refer to X (200
1 glass 1.7 litres O ~ ~ ~
filler plug Lub. Types (c.3½ US pints) hours)
Product conveyor head

4 and tail shaft bearing D ~ ~ ~ R ~ ~
grease nipples
Dirt conveyor head and
4 tail shaft bearing grease D ~ ~ ~ R ~ ~
9A.3.3 Lubrication and Servicing Schedule
nipples
Magnetic Separator
4 head and tail shaft D ~ ~ ~ R ~ ~
bearing grease nipples
Maintenance
Refer to 360 litres X
AX815-901-8EN-07b 122/318
1 Hydraulic reservoir ~ O ~ ~
Lub. Types (96 US gallons) (Annually)
In-line hydraulic filters
2 ~ ~ O ~ ~ ~ X
inside engine canopy
change at
Hydraulic suction filter at 1000 hrs
1 ~ ~ ~ O ~ ~
bottom of hyd reservoir or sooner
if indicator
Hydraulic return filter on shows RED
1 ~ ~ ~ O ~ ~
top of hyd reservoir
approx. 5 litres X After 100 hours
Refer to Sec X
2 Plant Tracks (1.3 US gallons) ~ (Hours worked by tracks)
9.20 (Annually)
±10% Check Drive oil levels every 2 weeks
O After 100 initial hours operation
HFO Hydraulic Clutch Refer to X Purge old grease and replace at 3000
1 R 35 grams (c.1¼ ounce) thereafter at
Page 8
Bearing Lub. types hours operation intervals
1100 x 650
Premiertrak
Issue EN 07
500 hour intervals

08/10/03
NB. Refer to the separate engine manual for the lubrication schedules & specifications for the plant diesel engine.
Premiertrak
1100 x 650
Page 9
9A.3.4 Crusher Lubrication in High Ambient Temperatures
HIGH AMBIENT TEMPERATURES
Where the machine is working for extended periods in

ambient temperatures in excess of
35 degrees C (95o F)
the greasing of the jaw crusher eccentric shaft bearings
must be increased in frequency and the quantity revised
to the following:
Model 1100 x 650 (26 x44)
19 - 20 grams (¾ ounce) each bearing (4 per machine)

every 8 hours of operation.
It is most important to use the correct grease.

See overleaf for the recommended grease specification.
Contact BL-Pegson’s Technical Department for advice if in doubt.
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1100 x 650
Page 10
9A.3.5 Importance of Correct Grease
THE IMPORTANCE OF THE USING THE

CORRECT GREASE SPECIFICATION
The grease specification for the jaw crusher eccentric
shaft bearings must conform to the specification below.
It is bad practice to mix greases. The blend can have a

lower specification than an individual grease and can
lead to premature bearing failure. BL-Pegson Ltd use
Fuchs Renolit EP2 grease during machine assembly.
Use ONLY a NLGI No: 2 grease with lithium or lithium complex soap
containing extreme pressure additives and having a base oil viscosity of
220 Cst at 40 degrees C. (104oF) / 17 Cst at 100 degrees C (212oF).
suitable for an operating range of minus 20 to plus 120 degrees C
manufactured to:
DIN Classification DIN 51 825......KP 2 K-20

ISO Classification ISO 6743-9....L-XBCEB 2
Do not use grease that contains Molybdenum Disulphide
For operation in high temperature conditions the greasing
frequency and grease quantity must be as shown on the
previous page.
Contact BL-Pegson’s Technical Department for advice if in doubt.
AX815-901-8EN-07b 124/318
Premiertrak Lubricants, Oils & Fuel Types
Equipment Grade Century Mobile Shell Esso Gulf BP

M Series Jaw Crusher
Shaft Bearings Grease D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
(all temperatures)
Hydraulic Pump Oil E Centraulic PWLA Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLPP-HM32
Vibrating Feeder
Oil Bath Lubrication
> 15º C (59ºF) C Centlube H76 Mobilgear 634 Omala 680 Spartan EP460 EP LUB HD460 Energol GR-XP460
4º C (39ºF) to 15º C (59ºF) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4º C (39ºF) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP HD MULTI H Energol GR-XP150
Conveyors & Magnet
9A.3.6 Lubricant and Oil Types
Shaft Bearings Grease D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
(all temperatures)
Plant Hydraulic System
< 30º C (86ºF) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
> 30º C (86ºF) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
08/10/03
Note: < 4º C (39ºF) is defined as a daily ambient temperature consistently below 4º C (39ºF). > 15º C (59ºF) is defined as a dail
ambient temperature above 15º C (59ºF). > 30º C (86ºF) is defined as a daily ambient temperature above 30º C (86ºF).
Maintenance
AX815-901-8EN-07b 125/318
Vehicle Tracks
Track Tension - General Multi-Purpose Grease - (Grade D Grease is Suitable)
Track Gearboxes - SAE 80w/90 Gear Oil
Diesel Engine
Lubricating Oil
Coolant Refer to Engine Operation & Maintenance Manual
Fuel
Hydraulic Clutch
Grease for bearing Castrol Spheerol EPL2
Page 11
1100 x 650
Shell Albida LX
Premiertrak
Issue EN 07
Kluber Centoplex 2EP

FAG Arcanol L135V
Premiertrak
Issue EN 07
Specific to Model
Page 12
9A.3.7 Lubrication & Oil Specifications
Oil Specification Grade A Grade B Grade C

Flashpoint: Minimum °C (°F) 199 (390) 204 (399) 216 (421)
Pour Point °C (°F) -18 (0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s 150 220 460
(104°F, in²/s) (0.232) (0.341) (0.713)
Kinematic Viscosity at 100°C, mm²/s 15.4 20.1 32.9
(212°F, in²/s) (0.0238) (0.0312) (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25°C (77°F) 280
Worked Penetration at 25°C (77°F) 285
Drop Point °C (°F) 185 (365)
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135°C (275°F) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40°C mm²/s 32 46 68
(104°F, in²/s) (0.049) (0.0713) (0.105)
Kinematic Viscosity at 100°C mm²/s 5.5 6.5 8.5
(212°F, in²/s) (0.085) (0.010) (0.013)
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes
AX815-901-8EN-07b 126/318
Premiertrak
1100 x 650
Page 13
9A.4 Crusher - Adjustment

of Discharge Opening DANGER
FLUID INJECTION HAZARD
Measurement Refer to Section 9.1, Safety
The discharge opening is the distance warning
between the fixed and moving jaw plates at
the bottom of the crushing chamber and
regulates the size of the product material. WARNING
The opening is measured from the top of
WEAR PERSONAL
the tooth on one jaw plate to the PROTECTIVE EQUIPMENT.
corresponding root between two teeth on Refer to Section 9.1, Safety
the other jaw plate - see Figure 9a. Information for relevant
warning.
The opening should be measured when the LOCKOUT MACHINE.
eccentric shaft is at its highest point, and the Refer to Section 9.1, Safety
measurement should be made at a point of Information for Lockout
Procedure.
shortest distance between the two jaw
plates.
Adjustment
Adjustment to the crusher discharge

opening is made by inserting or removing Discharge Root Swing Jaw
steel shims behind the toggle beam and Opening
accessed from the back of the
crusher.Various shim thicknesses are
supplied (some in the crusher and several
spare), not only to enable the product size
to be varied, but also to compensate for
wear on the manganese jaws so as to
maintain the crushed material product size.
Tip Fixed Jaw
To assist the process of making setting

Figure 9a Discharge Opening
adjustments the crusher is fitted with a hand Measurement
operated hydraulic ram system which is also
used when changing the toggleplate.
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1100 x 650
Page 14
9A.4.1 Adjustment
DANGER
warning
2. Run the plant until the crushing chamber

is empty; close down the plant (Section WARNING
8.2) and implement the Lockout WEAR PERSONAL
Procedure. PROTECTIVE EQUIPMENT.
3. Before starting work on the adjusting Information for relevant
warning.
mechanism it is very important to
thoroughly clean down the area on top LOCKOUT MACHINE.
of the rear cross beam and spacing
shims to prevent debris from falling into Procedure.
the shim slot whilst carrying out the
adjusting procedure.
4. Check the servicability of the hydraulic

handpump unit.
5. Release each clamping wedge locking 1

2
nut (1)(Figure 9b). Then turn each
locking nut (2) to move both locking
wedges (3) towards the machine side
walls leaving the toggle beam free to
move forward. 3
Toggle Beam
6. Measure and note the compressed
length of the tension rod spring.
7. Unscrew the locking nuts and release

Mainframe
the compression on the tension rod
spring (Figure 9d).
8. Before operating the pump ensure the Figure 9b Toggle Beam Locking Wedge
pressure relief valve knob is fully
tightened. Push the valve lever ‘X’ of
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1100 x 650
Page 15
the hydraulic handpump unit Pressure Relief Handpump

(Figure 9c) forward of the central Valve Knob
position and operate the handpump to
move the toggle beam forward and so
permit insertion/removal of spacing
shims as necessary.
Always lift the spacing shims

by the lifting eyes provided.
Never allow hands inside the
shim slot whilst changing the
shims as accidental closure
would result in serious injury.
9. Pull the valve lever ‘X’ of the hydraulic

handpump unit backward of the central
position and operate the handpump to
clamp the shims between the toggle
beam and the main frame crossbeam.
10. Reset both toggle beam locking wedges

Valve Lever ‘W’ Valve Lever ‘X’
by tightening nuts (1) and locking with
nuts (2)
Figure 9c Hydraulic Handpump Unit
11. Compress the tension rod spring to the

length noted (Step 6). Do Not over
compress the spring.
12. Run the crusher empty. If ‘knocking’ is

heard from the toggle plate, stop the
plant and lockout. Increase the
compression on the tension rod spring
slightly. Repeat Step 11 until the crusher
runs smoothly. Do Not over compress
the spring.
13. Return the valve lever ‘X’ of the

hydraulic handpump unit to the central
position.
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Page 16
9A.5 Crusher - Fitting of

Tension Rod Assembly WARNING
WEAR PERSONAL
(Figure 9d) PROTECTIVE EQUIPMENT.
Removal of the tension rod assembly will be Information for relevant
warning.
necessary when replacing the toggle plate.
LOCKOUT MACHINE.
Procedure.
Procedure

knocking is experienced on the toggle
2. Close down the plant (Section 8.2) and
plate.
implement the Lockout Procedure.
It is important that the spring
3. Pass the threaded end of the bare
is correctly adjusted. If it is too
tension rod through the the bracket
tight the spring or tension rod
from the jawstock side. The brackets
may break. If it is too loose
are screwed to the underside of the
the toggle plate will knock or
crossbeam and should be checked
drop out. It is important to
regularly for tightness.
check that the U shaped
Tension Rod Guard is fitted
4. Install the clevis end of the tension rod
correctly and is secure.
between the cast eyes at the bottom of
the jawstock. Secure the pin at each
7. Operate the crusher and check the
side with the washer and pin.
locknuts for tightness. Ensure that the
crusher runs without the toggle plate
5. Check that the washers are in good
knocking.
condition and fitted correctly, replacing
if necessary.
For the removal of the tension rod assembly
see Section 9A.6.
6. Assemble the spring, cap, washer and
two locknuts on the tension rod.
Tighten the nuts until the spring is
compressed by 20mm (c. 3/4”).
They should then be tightened until no
AX815-901-8EN-07b 130/318
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Page 17
Locknuts
Spring Cap
Bracket
Tension Rod Guard with Pin

Spring
Rubber Washer
Tension Rod
Bearing
Split Pin
Plain
Washer
Spacer
Pin
Figure 9d Tension Rod Assembly
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Page 18
9A.6 Crusher - Toggle Plate

Replacement DANGER
This will need replacing due to wear or Refer to Section 9.1, Safety
breakage due to uncrushable feed. The Information for relevant
toggle plate must be installed from beneath warning
the crusher. A hoist suspended from a
spreader bar positioned at the top-rear of
the crusher is the most convenient method WARNING
of lifting and lowering the toggle plate.
WEAR PERSONAL
9A.6.1 Tension Rod Removal Refer to Section 9.1, Safety
warning.
Procedure LOCKOUT MACHINE.
1. Observe all safety warnings. Procedure.
2. Run the crusher until completely empty.

Close down the plant (refer to Section
8.2) and implement the Lockout
Procedure.
3. Attach suitable support cables to the

toggle plate (Figure 9f).
4. Remove the tension rod assembly

(Figure 9d).
a Remove the two locknuts, washer,

spring cap and spring.
b Remove the split pin with washer.
c Remove the pin from the tension rod
bush through the cast eyes of the Figure 9e Tension Rod Location
jawstock. The tension rod at the clevis
end will then drop free - BE
PREPARED FOR THIS.
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Page 19
d Pull the bare tension rod through the

bracket from the jawstock side.
Under no circumstances should

the rod be burnt or cut through
whilst it is still tensioned.
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1100 x 650
Page 20
9A.6.2 Toggle Plate Removal

(Figure 9f & 9g) DANGER
In order to remove the toggle plate it is first Refer to Section 9.1, Safety
necessary to take the weight of the Information for relevant
warning
jawstock off the toggle plate.
Procedure WARNING
WEAR PERSONAL
1. Observe all safety warnings. Refer to Section 9.1, Safety
warning.
Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the Lockout Procedure. Refer to Section 9.1, Safety
Procedure.
3. Take the hydraulic cylinder from the
toolbox on the plant and attach by the
quick release hose couplings to the
hydraulic handpump unit.
4. Mount the hydraulic cylinder on the lug

of the crusher body (Figure 9g) so that
the ram will engage in the recess in the Toggle Beam
Toggle Plate
back of the jawstock.
5. Push the valve lever ‘W’ forward of the

central position. Operate the handpump
to locate the ram in the recess of the
jawstock and move the jawstock
forward. If the toggle plate is not
broken allow it to become free and be
lowered from the crusher. Jawstock Seat
6. Provide temporary blocking at the Figure 9f Toggle Plate Assembly

lower jawstock edge to prevent
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Premiertrak
1100 x 650
Page 21
accidental movement.
In addition use a chain pull lift to
secure the free jaw.
It is imperative that Part 6 is

adhered to.
Nobody is to enter the gap
between the jawstock and the
crossbeam.
Failure to do so may cause
injury or death.
7. Remove slings or chains from broken

Detachable Hydraulic Cylinder
toggle plate.
Figure 9g Hydraulic Cylinder Location
Handpump
Jawstock
Toggle Beam
Port K
Port A Port L 74 Port C
72 72
Port B Port D
Cross Beam
Valve 151
N
E F M
G H
Y
W X Handpump 150
Valve Lever ‘W’ Valve Lever ‘X’
Figure 9h Hydraulic Hand Pump and Circuit Diagram
AX815-901-8EN-07b 135/318
Premiertrak
1100 x 650
Page 22
9A.6.3 Fitting New Toggle Plate

DANGER
Procedure FLUID INJECTION HAZARD
warning
2. Run the crusher unitl completely empty.

Close down the plant (Section 8.2) and WARNING
implement the Lockout Procedure. WEAR PERSONAL
3. Position new toggle plate beneath the Refer to Section 9.1, Safety
crusher. Information for relevant
warning.
4. Hoist or jack the new toggle plate into LOCKOUT MACHINE.

position and remove the blocking from Refer to Section 9.1, Safety
the jawstock. Procedure.
5. Pull the valve lever ‘W’ backward of

the central position and operate the the
handpump and allow the jawstock to
return under its own weight. The toggle NOTE: The detachable hydraulic
plate must locate between the two cylinder must be removed before
retainers and the toggle beam. crusher start up.
6. When the jawstock has returned, Finally:
support the hydraulic cylinder and
operate the handpump to retract the 9. Fit the tension rod assembly (Section
cylinder ram from the jawstock. 9.6).
7. Return the valve lever ‘W’ to the central 10. Check the discharge opening and adjust
position and relieve the pressure. as necessary (Section 9.5).
8. Detach the hydraulic cylinder from the

crusher body and disconnect the
hydraulic hoses. Replace the hydraulic
cylinder in the toolbox.
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9A.7 Crusher - Fitting New

Toggle Seat WARNING
WEAR PERSONAL
warning.
1. Observe all safety warnings. LOCKOUT MACHINE.

2. Run the crusher until completely empty. Procedure.
Close down the machine (Section 8.2)
and implement the Lockout Procedure.
3. Remove the toggle plate (Section

9. Fit toggle plate (Section 9.7).
9A.6.1)
10. Fit tension rod assembly (Section 9.6).
4. Inspect the canvas apron (Figure 9i).
Replace the apron if it is worn.
Note : Toggle seat faces operate dry
and must not be lubricated.
5. Using an oxy-acetylene cutting torch,
cut the toggle seat in half lengthways.
There is a groove in the toggle seat
recess to minimise damage to the
jawstock. The toggle seat can then be
removed.
6. Inspect the recess for rough spots.

Remove any rough spots with a file and
smooth with emery.
Canvas Apron
7. Fit the dowel of the new toggle seat
into the hole in the jawstock and press
the toggle seat home. It is important
that the toggle seat fits tightly.
8. Make several indents on the jawstock

adjacent to one side of the seat with a
centre punch to secure it in place.
Figure 9i Canvas Apron
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9A.8 Crusher - Manganese

Replacement WARNING
WEAR PERSONAL
9A.8.1 Changing the Swing Jaw PROTECTIVE EQUIPMENT.
warning.
Procedure LOCKOUT MACHINE.
1. Observe all safety warnings Procedure.

Close down the plant (Section 8.2) and
implement the Lockout Procedure. Lifting hooks are availible from
Lifting Gear Supplies Ltd,
3. Remove the swing jaw wedge nuts, Leicester.
washers and fabreeka washers. England.
Tel : +(44) 0116 262 8023
4. Retract bolts and remove the two Fax : +(44) 0116 251 8864
wedges.
5. Tip the top of the jaw forward and

insert a lifting hook of a similar type
shown in Figure 9j.
Lifting
Extreme care must be taken
Hook
when moving the jaw forward.
After moving the jaw forward
wedge in place prior to locating
the hook in the back of the jaw.
Jaw
6. Lift out the jaw and place it on blocks
Face
with the wearing side face down.
Slot
Remember - The manganese can be
rotated through 180°, the worn area of
the manganese then being at the top of Figure 9j Lifting Hook
the crusher.
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DO NOT wear the manganese below

the bottom of the grooves. Any wear
below this level will result in the
support block at the base of the
manganese being worn.
Continued crushing with heavily worn

manganese increases crushing forces
and power consumption. This may limit
the minimum closed side setting on
hard materials.
7. Insert lifting hook in the back of the jaw

(refer to Figure 9j).
8. Hoist the jaw into position and locate

onto the centering key at the bottom of
ALTERNATIVE METHOD
the jawstock.
OF LIFTING JAW PLATES
9. Fit the wedge and the bolts.
Jaw plates supplied with 2 lifting holes
10. Fit the washers, fabreeka washers and require the use of suitable ‘D’ shackles
nuts - TIGHTEN SECURELY. through both holes for lifting purposes in
place of the lifting hook method shown in
After fitting the jaws operate Figure 9g.
the crusher for 15 minutes.
Stop the crusher and check the Weight of jawplate = approx. 710kg
bolt tightness. Continue to (1562lbs).
check the nuts at the beginning
of each shift.
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9A.8.2 Changing the Fixed Jaw

The fixed jaw is held into position by two
WARNING
fixed jaw wedges. When changing the fixed WEAR PERSONAL
jaw it will be necessary to undo and remove PROTECTIVE EQUIPMENT.
the four wedge bolts holding the jaw Information for relevant
wedges in place. warning.
LOCKOUT MACHINE.
Removal of the Fixed Jaw Refer to Section 9.1, Safety
Procedure.
Procedure
!. Observe all safety warnings.

implement the Lockout procedure.
3. Remove the jaw wedge nuts, washers,

and fabreeka washers (Figure 9k). ALTERNATIVE METHOD
OF LIFTING JAW PLATES
4. Withdraw the bolts and remove the
wedges. Jaw plates supplied with 2 lifting holes
require the use of suitable ‘D’ shackles
5. Tip the top of the jaw forward and through both holes for lifting purposes in
insert a lifting hook of the type shown in place of the lifting hook method shown in
Figure 9j into the back of the jaw. Figure 9g.
Extreme care must be taken Weight of jawplate = approx. 710kg

when moving the jaw forward. (1562lbs).
After moving the jaw forward
wedge in place prior to locating
the hook in the back of the jaw.
10. Lift out the jaw and place it on blocks

with the wearing side face down.
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Remember - The manganese can be

rotated through 180°, the worn area of
the manganese then being at the top of
the crusher.
DO NOT wear the manganese below

the bottom of the grooves. Any wear
below this level will result in the
support block at the base of the
manganese being worn.
Continued crushing with heavily worn

manganese increases crushing forces
and power consumption. This may limit
the minimum closed side setting on
hard materials.
Mainframe
Nut
Washer
Wedge
Fabreeka
Washer
Washer Manganese
Wedge Bolt Wedge Bolt
Figure 9k Fixed Jaw Wedge and Bolt Assembly
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Replacement of the Fixed Jaw
11. Insert the lifting hook into the slot at the

back of the new jaw (Figure 9j).
12. Hoist the jaw into position and locate

onto the Jaw Support at the bottom of
the Front wall.
13. Fit the wedges and bolts.
14. Fit the washers, fabreeka washers and

nuts. TIGHTEN SECURELY.
After fitting the jaws operate

the crusher for 15 minutes.
Stop the crusher and check the
bolt tightness. Continue to
check the nuts at the beginning
of each shift.
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9A.9 Crusher - Changing of

Cheek Plates WARNING
WEAR PERSONAL
Cheek plates should be inspected regularly PROTECTIVE EQUIPMENT.
for wear and all cheek plate bolts checked Refer to Section 9.1, Safety
for tightness. Information for relevant
warning.
Note : Cheek plates are not reversible. LOCKOUT MACHINE.

There are four cheek plates, two on each Procedure.
side of the machine; the upper plate is
retained at three fixing points. The cheek
plates are not interchangable.
9A.9.1 Removal
Lift and lower cheekplates with a crane.
DO NOT ATTEMPT TO MOVE BY
HAND.
Procedure
1. Observe all safety procedures.

3. Remove necessary guards to gain

access.
4. Remove the upper fixing nut, bolt and

washer from the cheek plate and
machine frame and loosen the remaining
fixing bolt(s) - (Figure 9l).
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5. Insert a lifting hook in the bolt recess in

the cheek plate with the lifting
equipment.
6. Take the weight of the cheek plate with

the crane.
7. Remove the remaining fixing nuts, bolts

and washers from the cheek plate then
lift it clear of the machine.
Cheek Plate
Cheek Mainframe
Plate
Locking
Pin
Philidas
Nut
Figure 9l Cheek Plate Fixing and Bolt Assembly
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9A.9.2 Fitment
When fitting both cheek plates on one side,
WARNING
always fit the lower plate first. WEAR PERSONAL
Lift and lower cheekplates with a crane.
DO NOT ATTEMPT TO INSTALL BY warning.
HAND.
LOCKOUT MACHINE.
Procedure
Procedure.

3. Insert a lifting hook in the upper fixing

bolt recess in the cheek plate; lower the
cheek plate into the machine, align the
lower bolt holes in the cheek plate and
the machine side.
4. Insert the lower fixing bolt, washer and

nut, but do not tighten.
5. Remove the lifting hook from the upper

bolt recess in the cheek plate and fit and
tighten the upper fixing nut, bolt and
washer, tighten the remaining fixing
bolts.
6. Replace any guards removed to gain

access.
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9A.10 Crusher - Fitting and

Removing Flywheel WARNING
Locking Mechanism WEAR PERSONAL
These Ringfeder locking mechanisms are Refer to Section 9.1, Safety
used to secure the drive side and non drive warning.
side flywheels on the crusher to the
LOCKOUT MACHINE.
eccentric shaft. Should they need to be
loosened to reposition the flywheel, the Information for Lockout
following procedure should be followed. Procedure.
9A.10.1 Loosening the Ringfeder
Procedure
Removal
2. Loosen locking screws a turn at a time

and in diametrically opposite sequence.
3. Now the loosened connection (between

the shaft and the flywheel) can be
readjusted or dis-assembled. Tightening
If necessary, the front and rear thrust ring

are to be dis-assembled as shown in Figure
9m. The removal threads are located on the
silver capped screws. These should be
removed and three of the black headed
Figure 9m Front/Rear Thrust Ring
screws used to push the assembly apart.
There are only 3 - 5 threads on the removal
holes and are therefore not suitable for high
torques. These threads should only be
used for the removal/dis-assembly of
the ringfeder.
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9A.10.2 Tightening the Ringfeder

Once the flywheel is aligned properly
WARNING
(arrow on flywheel cap and flywheel line WEAR PERSONAL
up) the Ringfeder can be tightened up. PROTECTIVE EQUIPMENT.
When doing this on the drive side it should Information for relevant
always be done whilst the drive belts are warning.
slack because it may result in the flywheel
LOCKOUT MACHINE.
being tightened at an angle. In addition to Refer to Section 9.1, Safety
this on both sides a piece of square bar Information for Lockout
should be secured by the threaded holes on Procedure.
the eccectric shaft and used like a press to
push the flywheel in to also ensure that it is
square (refer to Section 9.15 for details of
how to slacken the belts).
Procedure
2. Tighten locking screws lightly and align

hub.
3. Tighten screws evenly in diametrically

opposite sequence and do this in two or
three stages up to the indicated
tightening torque of 190 Nm.
4. Re-check tightening torque by applying

it to all screws all the way around.
When the screws have reached the
correct torque the assembly is
complete.
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9A.11 Feeder - Operation

WARNING
The vibrating feeder must, in addition to the WEAR PERSONAL
scheduled lubrication requirements (Section PROTECTIVE EQUIPMENT.
9A.3), be regularly inspected for any wear, Refer to Section 9.1, Safety
damage or breakage with the mainframe Information for relevant
and support springs being paid particular warning.
attention. Rectify faults immediately. LOCKOUT PLANT.
Make sure that the feeder can vibrate Information for Lockout
Procedure.
freely without fouling against the adjacent
hopper or chutework and that hardened FALLING HAZARD.
material inside the pan is not allowed to Refer to Section 9.1, Safety
build up and affect the performance of the Information for relevant
machine. Also check to ensure that the warning.
hydraulic drive is operating efficiently.
The variable speed control is situated on
the Feeder/Conveyor control box.
Periodically check the condition of the

grizzly bars for both wear and build up of
material and recitify if necessary.
When the plant is supplied without the

optional dirt conveyor all the material
passing through the grizzly bars will by-
pass the crusher and discharge onto the
product conveyor.
The two-way chute is only relevant when

the optional dirt conveyor is fitted so that
there is then a choice of either extracting
the ‘grizzly fines’ material via the dirt
convyor or by-passing the crusher onto
the product convyor.
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9A.11.1 Feeder Maintenance

• Frequently check the oil levels in the
WARNING
vibrating unit end covers (Figure 9n). WEAR PERSONAL
• After first 8 hours of operation, change
the oil in the vibrating unit end covers warning.
LOCKOUT PLANT.
• Check the vibrating unit bearing
temperatures using a contact Information for Lockout
thermometer on the end covers; record Procedure.
for future reference and fault diagnosis.
(Maximum acceptable temperature is FALLING HAZARD.
80ºC [176° F] ). Refer to Section 9.1, Safety
warning.
• Ensure that the vibrating unit is
operating before any feed is introduced
to the plant.
Oil Filler Plug
Oil Level
Signt Glass
Oil Drain Plug
Figure 9n Feeder Vibrating Unit
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9A.12 Plant - Hydraulic

System Description DANGER
SKIN INJECTION HAZARD
9A.12.1 General Description Refer to Section 9.1, Safety
Information for relevant warning
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 V belts.
WARNING
Alternative selection of the PLANT or WEAR PERSONAL
TRACK switch on the plant control panel PROTECTIVE EQUIPMENT.
ensures the plant cannot be moved whilst Information for relevant
operating. warning.
LOCKOUT PLANT.
The hydraulic fluid reservoir together with Refer to Section 9.1, Safety
associated equipment must be maintained in Information for Lockout Proce-
accordance with the set level (For topping dure.
up the reservoir see Section 9 - Changing
the Return Filter) and in the schedules and
types detailed in Section 9 - Lubrication
and Servicing. ONLY USE A
RECOMMENDED FLUID.
It is essential when replenishing hydraulic THIS IS A HIGH PRESSURE

fluid, attending to filters, etc. to apply the SYSTEM.
greatest degree of cleanliness as it is most DANGER
important that contaminants are not Never carry out any
allowed to enter the system. maintenance work without
ensuring the hydraulic system is
All hydraulic functions are powered by two locked out and depressurised.
pumps,one mounted either side of the diesel
engine and driven from the main crankshaft Do not tamper with system. In
pulley via two SPB belts. the event of any problems
these should only be dealt with
Each pump is an axial piston variable by suitably experienced and
displacement unit capable of up to 95 qualified engineers
litres/min at 320 bar and each feeds a
directional control valve.
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The flows and pressures to each service is Note:-

limited by the relevant spool as shown All relief valve pressures are factory set and
below and the pump supplies only the should not be adjusted on site.
required flow by automatically backing off
the swash plate angle thus reducing wasted
power and resulting heat generation.
This is achieved by means of a load sensing

line from the valve to the pump which
measures the pressure required which is
then matched by the pump.
Front Pump
Max Flow
Max Pressure
Service Spool Type litres/min.
(Bar)
(US galls/min)
L/H track drive motor Proportional 90 (24) 320
Product conveyor plus Magnet and Water 65
On/Off 210
Pump (when fitted) (17)
Crusher Hydraulic Release or Hydraulic 10
Adjust systems (when fitted)
On/Off NOT APPLICABLE
(2.7)
75
Rear Pump
Max Flow
Max Pressure
Service Spool Type litres/min.
(Bar)
(US galls/min)
R/H track drive motor Proportional 90 (24) 320
Feeder Proportional 65 (17) 180
Dirt Conveyor On/Off 180
25
Dirt Conveyor Fold On/Off 100
(6.5)
Tail Lift On/Off 100
20/04/04
Figure 9o Front/Rear Hydraulic Pumps
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Although the maximum flows from each brake together with a pressure reducing
spool is limited as shown, these can be valve, pre set to 60 bar so that the brakes
individually adjusted downwards by means are not overpressurized.
of limit screws if desired. Please contact
BL-Pegson Ltd. 9A.12.3 Feeder Drive
9A.12.2 Track Drives This valve section is fitted with a

proportional solenoid so that the feeder
Although these valves sections have speed can be controlled by means of a
proportional controls and are theoretically chasis mounted control box potentiometer.
infinitely variable they are electrically limited
to two speeds for simplicity. 9A.12.4 Circuit Protection
a) SLOW - For slewing and fine The system is equiped with the following
positioning. protection:-
b) FAST - For straight line running, • Suction Filter (90 µm nominal)

forward or reverse.
• Pressure Filter (10 µm absolute) in
Note:- The maximum power take off from each pump circuit prior to the
one side of the engine is limited to directional control valves.
approximately 30 KW, therefore the system
• Return Filter (10 µm nominal)
is electronically limited such it is only
possible to slew (operate one side only)
• Low oil level cut out.
when in the ‘SLOW’ mode.
Note:- For Hydraulic Pump Drive Belt
Fine adjustment of the slow speeds is
adjustment refer to Section -
possible. Consult BL-Pegson Ltd.
The hydraulic oil filters are fitted
It is recommended that adjustment is not
with condition indicators to shown
undertaken without BL-Pegson Ltd.
when the renewable filter element
consent and under no circumstances should
needs to be changed. These
the slow speed be adjusted greater than
should be checked on a daily
0.2metres per second.
basis whilst the plant is running at
normal operating temperature. In
Motor mounted counterbalance valves are
cold ambient temperatures the
utilised to prevent the machine over running
filter indicators may show red until
when moving downhill.
the system reaches normal
This block also incorporates a shuttle valve operating temperature.
to release the spring applied track parking
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Figure 9p Hydraulic Circuit Diagram
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Issue EN 07
Specific to Model
Page 40
Blank page
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9B - Maintenance General
General - All Models
Page 1
Contents
9B.0 Maintenance Description ................................................................................. 3
9B.1 Plant Hydraulic System .................................................................................... 4

9B.1.1 Changing the Suction Filter ...................................................................................... 4
9B.1.2 Changing the Return Filter ....................................................................................... 6
9B.1.3 Changing the Tank Breather ..................................................................................... 7
9B.1.4 Changing then Hydraulic Pressure Filters ................................................................ 8
9B.2 Plant - Electrical System ................................................................................. 10
9B.3 Plant - V Belt Drives ........................................................................................ 12

9B.3.1 V Belt Drives - General ........................................................................................... 12
9B.3.2 V Belt Drives - Alignment ........................................................................................ 13
9B.3.3 V Belt Drives - Adjustment ..................................................................................... 14
9B.3.4 V Belt Drives - Replacement .................................................................................. 15
9B.3.5 Method of Drive Belt Tensioning ............................................................................. 16
9B.3.6 Trouble Shooting - Drive Belts ................................................................................ 19
9B.4 Plant - Conveyors ........................................................................................... 20

9B.4.1 Training of Belts ...................................................................................................... 20
9B.4.2 Conveyor Belt Tensioning ....................................................................................... 22
9B.4.3 Maintenance of Conveyor(s) .................................................................................. 24
9B.4.4 Cleaning the Conveyor Belts .................................................................................. 26
9B.5 Plant - Overband Magnet (where fitted) ......................................................... 28
9B.6 Plant - Dust Suppression ............................................................................... 30
9B.7 Plant - Diesel Engine ....................................................................................... 32

9B.7.1 Engine - General Information .................................................................................. 32
9B.7.2 Engine - ELC Coolant ............................................................................................. 33
9B.7.3 Engine - Check Fuel Level ..................................................................................... 34
9B.7.4 Engine - Top Up Fuel Level ..................................................................................... 35
04/11/04
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Page 2
9B.8 Engine Power Transmission .......................................................................... 36

9B.8.1 Transmission Types - fitted to models ................................................................... 36
9B.8.2 Hydraulic Clutch - Grease Lubricated Bearing ....................................................... 38
9B.8.3 Hydraulic Clutch - Oil Lubricated Bearing............................................................... 40
9B.8.3.1 Hydraulic Clutch Trouble Shooting ............................................................................... 42
9B.8.4 Manual Clutch ......................................................................................................... 43
9B.8.4.1 Manual Clutch - Adjustment ........................................................................................ 45
9B.8.4.2 Manual Clutch - Max/Min Adjustment Values .............................................................. 45
9B.8.5 Fluid Coupling ......................................................................................................... 46
9B.8.5.1 Fluid Coupling Description ........................................................................................... 46
9B.8.5.2 Fluid Coupling - Features ............................................................................................. 48
9B.8.5.3 Fluid Coupling - Maintenance ....................................................................................... 50
9B.8.5.4 Fluid Coupling - Trouble Shooting ................................................................................. 52
9B.8 Plant - Vehicle Tracks ..................................................................................... 54

9B.8.1 Measuring Track Tension ........................................................................................ 54
9B.8.2 Adjusting Track Tension .......................................................................................... 56
9B.8.3 Track Maintenance ................................................................................................. 59
9B.8.4 Drive Oil Filling and Draining .................................................................................. 60
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Page 3
9B.0 Maintenance Description
The Maintenance Section is divided into two parts.
9A - Specific instructions for the particular model or type of plant.
9B - General instructions for equipment for all models or types of plant.
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Page 4
9B.1 Plant Hydraulic System

DANGER
9B.1.1 Changing the Suction Filter
Located at the base of the hydraulic Refer to Section 9.1, Safety
reservoir tank is the hydraulic suction filter.
When the dial gauge needle (pictured
opposite page) enters into the red segment
whilst the system is running at normal
operating temperature this is an WARNING
indication that the filter must be replaced WEAR PERSONAL
immediately. The filter housing has an PROTECTIVE EQUIPMENT.
internal shut off valve to permit work on the Refer to Section 9.1, Safety
system. Make sure the oil has cooled warning.
LOCKOUT MACHINE.
Information for Lockout Proce-
dure.
before changing.
2. Close down the machine (Section 8.2)

3. Using a hexagon socket key unscrew

the bolt A (or black knob) in the centre
of the filter housing until it reaches the
stop.
4. Take steps to collect spillage of oil

approx. 2 litres (0.53 US galls) 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.
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Page 5
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.
7. Fully screw in the bolt A (or black

knob) in the centre of the filter
housing.
It is important to ensure that

the bolt in the centre of the
housing is fully screwed in
before starting the plant.
Damage will occur to the plant
Dial Gauge
Bolt A
Black Knob
Alternative Suction Filter
Suction Filter
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Page 6
9B.1.2 Changing the Return Filter

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

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.
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Page 7
9B.1.3 Changing the Tank

Breather WARNING
This Breather should be changed after the WEAR PERSONAL
first 100 hours of operating and thereafter PROTECTIVE EQUIPMENT.
after 500 hours but in dusty atmosphere it is Information for relevant
recommended to change more frequently warning.
depending upon conditions. Simply unscrew
LOCKOUT PLANT.
and replace whilst the plant is shut down Refer to Section 9.1, Safety
(Section 8.2). Information for Lockout Proce-
dure.
Hydraulic Oil Return

Tank Breather/Filler Filter and Gauge
Hydraulic Oil Level Hydraulic Oil Tank
Hydraulic Oil Tank & Level Indicator (typical)
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Page 8
9B.1.4 Changing then Hydraulic

Pressure Filters DANGER
Located on each side on the engine within the SKIN INJECTION HAZARD
canopy are the hydraulic pressure filters. Refer to Section 9.1, Safety
When the ‘telltale’ (pictured opposite page) Information for relevant warning
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 WARNING
the oil has cooled before changing.. WEAR PERSONAL
warning.
LOCKOUT PLANT.
dure.
3. Unscrew (turn anticlockwise looking

from below) the filter bowl using the
hexagon ‘nut’ cast into the base. Take
steps to contain spillage of oil

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

‘O’ ring and place on it’s seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
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.
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Page 9
Filter condition ‘Telltale’ Filter body
‘Nut’ Bowl
Hydraulic Pressure Filter
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Page 10
9B.2 Plant - Electrical

System WARNING
WEAR PERSONAL
For the plant electrical circuit diagram PROTECTIVE EQUIPMENT.
and also for the diesel engine, see the Refer to Section 9.1, Safety
Appendix section 11 of this manual. Information for relevant
warning.
The plant electrical equipment is a self LOCKOUT MACHINE.

contained system receiving a 24 volt Refer to Section 9.1, Safety
DC supply when the diesel engine is dure.
running.
Depending upon the model of plant and

the equipment fitted, various types of
control, monitoring, sequencing,
electrical safeguards and fault detection
devices are built into the system
including a multi station emergency
stop circuit. Refer to the specific wiring
diagram supplied in this manual for
details. Any work on the plant electrics
should only be undertaken by a
qualified electrician familiar with this
type of system.
Wiring diagram(s) for the diesel engine

are separate from the plant diagram(s).
Circuit protection fuses or circuit

breakers fitted depend upon the plant
model. The replacement of a
protection device after failure must not
exceed the rating shown in the wiring
diagram otherwise any warranty may
be invalidated. A repeat of the failure
must be investigated and the problem
rectified by a competent person.
AX815-901-8EN-07b 164/318
Page 11
Always keep the electrical cabinets and

control boxes shut during operation to
prevent the ingress of dust and damp.
At regular intervals check the tightness
of the electrical components on the
plant and look for any damage to the
electrical wiring.
Emergency stop equipment

and all other safety systems
(including the audible warning
siren) must be operative at all
times whilst the plant is
running or being manoeuvred.
The safety devices must be
checked as fully operational at
each daily start and must not
have been tampered with or
disabled in any way.
AX815-901-8EN-07b 165/318
Page 12
9B.3 Plant - V Belt Drives

WARNING
9B.3.1 V Belt Drives - General
WEAR PERSONAL
Do not inspect or carry out PROTECTIVE EQUIPMENT.
work on belt drives before Information for relevant
closing down the plant and warning.
implementing the Lockout
LOCKOUT MACHINE.
Procedure. Never operate the Refer to Section 9.1, Safety
plant without effective drive Information for Lockout Proce-
guarding in place. dure.
• The modern V belt drive is a highly

efficient power transmission medium,
but optimum performance will not be
achieved without correct tensioning and • When replacing a multi belt drive
alignment (pictured opposite page). always use a set of ‘matched’ new
belts so that equal force can be applied
• V belt drives are used on the plant to all the belts.
between the plant diesel engine and the
crusher and also to drive the hydraulic • Ensure that any ventilation provided in
pumps mounted inside the engine the drive guarding is kept clear to avoid
canopy. over heating. Ensure contaminating
material does not come into contact
• Drive belts should inspected regularly with the drive elements.
for wear and also to monitor any
pattern in the wear if it is occuring.
• Insufficient belt tension will cause

slippage leading to loss of drive
efficiency, heat generation and belt
failure. Over tensioning will exert
excessive loading on the shaft bearings
and can lead to premature failure.
• Tensioning of the belts is by means of 2

or more adjusting screws for each
drive. Section 9 - Method of Drive belt
Tensioning - describes the method to
achieve the correct tension.
AX815-901-8EN-07b 166/318
Page 13
9B.3.2 V Belt Drives - Alignment

Good alignment of the drive pulleys is important otherwise the belt flanks will wear quickly. Ensure
axis are parallel when viewed from all planes.
Shafts are not parallel

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

in alignment but pulleys
are not in alignment Both shafts and pulleys
are parallel and in
alignment
Correct Alignment of Pulley Belts
AX815-901-8EN-07b 167/318
Page 14
9B.3.3 V Belt Drives - Adjustment

Belt adjustment is by means of adjusting
WARNING
screws to increase or decrease the distance
WEAR PERSONAL
between the shaft centres. Locknuts on the PROTECTIVE EQUIPMENT.
tension screws must be tight whilst running Refer to Section 9.1, Safety
the plant. Information for relevant warning.
Drives tensioned horizontally have a sliding LOCKOUT PLANT.

baseframe with four clamping bolts which Refer to Section 9.1, Safety
must be tight whilst running the plant. Information for Lockout
Procedure.
Drives tensioned vertically have the moving FALLING HAZARD.
baseframe mounted on four adjusting screws Refer to Section 9.1, Safety
which must have the locknuts tight whilst Information for relevant warning.
running the plant.
Adjust each screw only to a limited extent at

a time and by equal amounts to ease the 6. Undo locknuts on the tension screws to
movement of the baseframe. allow the baseframe to be moved in the
required direction.
Procedure 7. Either by turning a nut on the screw or

the screw itself (depending on the type),
tension or slacken the drive belts as
1. Observe all safety warnings. required. Make an equal amount of
adjustment to each screw.
and implement the Lockout Procedure. 8. To establish correct belt tension use the
method described in Section 9 - Method
3 Remove guarding as necessary to gain of Drive Belt Tensioning
access to the V drive and tensioning
elements. 9. Use the marks or measurements made in
step 3 to ensure that the correct pulley
4. Mark or measure the existing position alignment (Figure) has been restored.
(assuming correct alignment) of the
moving frame at each tension screw. 10.Tighten all locknuts and/or clamping bolts.
5. Loosen the 4 clamping bolts securing the 11. Ensure that all the drive guarding is
moving baseframe (horizontal drives). replaced and secured before start up.
AX815-901-8EN-07b 168/318
Page 15
9B.3.4 V Belt Drives - Replacement

The V belts must be of the same type, size,
WARNING
and number to those originally fitted and
WEAR PERSONAL
specified by BL-Pegson Ltd. PROTECTIVE EQUIPMENT.
Before fitting new belts, check the pulley Information for relevant warning.
grooves are free from score marks or sharp
edges. Also the grooves for wear. Ensure LOCKOUT PLANT.
the pulleys are tight on their shafts. Refer to Section 9.1, Safety
If replacement of the belts is necessary due Procedure.
to premature failure, the cause should be FALLING HAZARD.
investigated (Section 9 - Trouble Shooting - Refer to Section 9.1, Safety
Drive belts) and rectified before fitted new Information for relevant warning.
belts.
The drive centre distance must be reduced

prior to installation so that new belts can be
fitted without the use of force.
Under no circumstance must belts be prised

into the grooves as belts and pulley grooves
can be damaged by using sharp tools to
stretch the belts over the pulley rim.
The procedure for fitting new belts is the

generally the same as described for belt
adjustment except it is necessary to slacken
off the drive enough to remove the old belts
and fit the new without damage (see
above). It may also be necessay to remove
more of the guarding to gain access.
AX815-901-8EN-07b 169/318
Page 16
9B.3.5 Method of Drive Belt

Tensioning WARNING
Under no circumstances
WEAR PERSONAL
should any check on the belt PROTECTIVE EQUIPMENT.
tension be made whilst the Refer to Section 9.1, Safety
machine is running. There is a Information for relevant warning.
risk of trapping parts of the
body if this is done. LOCKOUT PLANT.
Procedure Procedure.
FALLING HAZARD.
1. Observe all safety warnings. Information for relevant warning.

Remove the guards from around the
belt.
3. Calculate the deflection distance in mm

on a basis of 16mm deflection per 1
metre of belt span (0.6” per 1 yard)
(Figure).
Centre to Centre Distance (m or yd) x

16 or 0.6 = Deflection (mm or ins.).
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.
continued.................
AX815-901-8EN-07b 170/318
Page 17
Ce
nt
re
to
Ce
nt
re
Di
sta
nc
e
16mm
Deflection per
1 Metre of Belt
Span
(0.6” per 1 yd.)
Belt Tension Indi-
cator Applied to
Mid-Span
V Belt Tensioning Measurements
SETTING FORCE TO DEFLECT BELT 16MM PER METRE OF SPAN
BELT SECTION SMALL PULLEY BASIC SETTING 1.25 X SETTING

DIAMETER (MM) FORCES FORCES
KILOGRAMS (KGF) KILOGRAMS (KGF)
112 – 160 4.0 5.1

170 – 224 5.1 6.3
SPB 236 – 355 6.3 7.9
OVER 355 6.6 7.9
224 – 250 7.1 8.9
SPC 265 – 355 9.4 12
OVER 375 12 15
V Belt Setting Forces
AX815-901-8EN-07b 171/318
Page 18
c) Place the belt tension indicator on top

of the belt at the centre of the belt span, WARNING
and apply a force at right angles to the
belt deflecting it to the point where the WEAR PERSONAL
lower marker ring is level with the top PROTECTIVE EQUIPMENT.
of the adjacent belt. Refer to Section 9.1, Safety
d) Read off the setting force value

indicated by the top edge of the upper LOCKOUT PLANT.
marker ring.
Procedure.
e) Compare this value to the lbf value
shown in the table (previous page). FALLING HAZARD.
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 After the drive has been
claculated in Step 3, read off the force running for 15-20 minutes, the
from the spring balance. tension should be checked and
re-adjusted to the Basic
6. If the measured force falls within the Setting Force value, if
values given, the drive should be necessary by repeating the
satisfactory. A measured force below above procedure from Step 1.
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.
AX815-901-8EN-07b 172/318
Page 19
9B.3.6 Trouble Shooting - Drive

Belts WARNING
Small Cracks on V-Belt side and WEAR PERSONAL
Base PROTECTIVE EQUIPMENT.
Generally caused by shortage of belt warning.
tension but excessive heat and/or chemical
LOCKOUT MACHINE.
fumes can also give same failure. Refer to Section 9.1, Safety
V-Belt Swelling or Softening dure.
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
rectification. Consult BL Pegson Ltd.
AX815-901-8EN-07b 173/318
Page 20
9B.4 Plant - Conveyors

DANGER
9B.4.1 Training of Belts
NIP POINT HAZARD.
Before starting the conveyor, it is essential Refer to Section 9.1, Safety
to check that:-
• The conveyor is straight and correctly

levelled.
WARNING
• The head and tail drums are correctly WEAR PERSONAL
fitted. i.e. they are level, and that their PROTECTIVE EQUIPMENT.
axes are square to the centre line of the Refer to Section 9.1, Safety
conveyor.
warning.
• All troughing and parallel idlers are

correctly fitted with their axles square to
the centre line of the conveyor, the side only be possible to track the return strand
roller lead is in the correct direction (i.e. when empty and the troughed side when
forward of centre) and all rollers are loaded.
rotating freely.
If the belt tends to run to one side the most
• In the case of screw-type take up likely cause of the trouble will usually be
gears, that these are adjusted initially to some distance before the point where the
take up slack from the belt and that running off is apparent, and in the case of
equal tension is applied to each side troughed strand probably at the second or
such that the pulley is square to the third idler behind the point where the belt is
centre line of the conveyor. moving out of its true line.
• Where skirt rubbers are fitted they are Under no circumstances should
not bearing down heavily on the belt. any adjustment be made on the
belt whilst the machine is
• There is no obstruction on the conveyor running. There is a risk of
that could cause accident or damage trapping parts of the body if
when the conveyor is started. this is done.
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
AX815-901-8EN-07b 174/318
Page 21
Side Roller and

Spindle
Slots for
Adjustment
Belt Travel of Transome
Side Roller and

Spindle
Centre Roller
and Spindle
Slots for
Adjustment
of Transome
Typical Troughing Idler
The detail of the conveyor idlers actually fitted may vary from the illustration.
AX815-901-8EN-07b 175/318
Page 22
9B.4.2 Conveyor Belt Tensioning

Conveyor belts are tensioned by a pair of
WARNING
screw type mechanisms located on either
WEAR PERSONAL
side of the conveyor. PROTECTIVE EQUIPMENT.
Best practice is to tension each side a little Information for relevant warning.
at a time and by the same amount until the
belt is tensioned. When tensioned, the drum LOCKOUT PLANT.
must be square to the conveyor frame. Refer to Section 9.1, Safety
The correct tension is achieved when the Procedure.
drive drum starts the belt and keeps it FALLING HAZARD.
running when loaded without any slip Refer to Section 9.1, Safety
occuring. Information for relevant warning.
The tension screws should be kept clean

and well oiled.
See Section 9 - Training of Belts - for

advice on the training of conveyor belts.
Under no circumstances should

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. Figure - Tensioning mechanism
Procedure

3. Loosen any screws used to clamp the

tensioning mechanism or securing a Figure - Sliding Bearing
sliding bearing.
AX815-901-8EN-07b 176/318
Page 23
4. Loosen the screw tensioner locknuts.
5. Either by turning a nut on the screw or

the screw itself (depending on the type),
tension or slacken the belt as required.
Make an equal amount of adjustment to
each screw.
6. Once correct tension has been

achieved, tighten the locknuts and
clamping nuts.
AX815-901-8EN-07b 177/318
Page 24
9B.4.3 Maintenance of
Conveyor(s) DANGER
The following checks should be made NIP POINT HAZARD.
regularly in order to keep the conveyor(s) in Refer to Section 9.1, Safety
good working order: Information for relevant warning.
• Observe all safety warnings.
• Close down the machine (Section 8.2) WARNING

and implement the Lockout Procedure. WEAR PERSONAL
• Ensure that central feed onto the Refer to Section 9.1, Safety
conveyor belt is maintained at all times Information for relevant
warning.
and that the belt at the point of feed is
kept straight and central at all times. LOCKOUT MACHINE.
• Inspect the skirt plate sealing strips and dure.
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.
• 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 - Training of
Belts.
• Inspect the condition of the conveyor

belt regularly and arrange for the earliest Clip joints can be dangerous
possible repair of any damage which and should not be used. Belt
may have occurred as this can make a DANGER repairs/replacements should be
worthwhile extension of the useful life of performed by vulcanising only.
the belt. Repair a cut or tear in the
rubber by cleaning with benzine and
plugging with a rubber repair
compound.
AX815-901-8EN-07b 178/318
Page 25
• Check that there is no evidence of belt • Where the plant includes a slow speed
slip at the driving drum, as belt slip will conveyor with an oil lubricated
cause premature wear on the belt. reduction gearbox inside the head drum,
Check also for undue sag between refer to the lubrication schedules and
idlers. Both would indicate lack of belt specific filling instructions given herein.
tension (Section 9 - Conveyor Belt
Tensioning) • In the interests of efficient operation and
general safety, it is important that
• Check regularly that the idler rollers are operating conditions are kept as clean
rotating freely. If not either free them or as possible and that any spillages are
replace the idler. Failure to do so will cleaned up regularly and are not
result in belt wear and tracking allowed to build up.
problems.
As many inspections as
• Check that the belt cleaning equipment possible should be made whilst
is operating correctly and efficiently. In the belt is stationary. When
the case of scrapers ensure that they are this is not possible extreme
not choked with a build up of material. care should be taken when
Also check that the blades are not inspecting the belt whilst it is
bearing on the belt any more than moving as this creates a risk of
necessary, and that any blades which trapping parts of the body.
are unevenly worn or in a condition
likely to cause damage to the belt are
renewed immediately.
• Lubricate the product conveyor tail

section pivots (where fitted) and dirt
conveyor (optional) pivots.
• The grease in the head and tail drum

bearings of the product conveyor and
dirt conveyor (optional) need re-
greasing bi-monthly (Section 9.4A).
Note:- The grease nipples for the product

conveyor and dirt conveyor (optional) tail
drum are remote and located either side of
the Plant chassis below the maintenance
platforms.
AX815-901-8EN-07b 179/318
Page 26
9B.4.4 Cleaning the Conveyor Belts

If your machines’ conveyor belts are not
WARNING
properly maintained and skirting rubbers are
WEAR PERSONAL
not kept in proper adjustment, it may be PROTECTIVE EQUIPMENT.
necessary to remove resultant spillage Refer to Section 9.1, Safety
material and / or blockages from the Information for relevant warning.
conveyor belts, particularly at the feed
section. LOCKOUT PLANT.
It is important that these Information for Lockout
Procedure.
procedures are followed when
cleaning the conveyor belts. FALLING HAZARD.
Failure to follow these Refer to Section 9.1, Safety
procedures can result in death Information for relevant warning.
or serious injury.
Procedure
1. The equipment should be switched off

and isolated by means of the lockout and
tagout procedure prior to the
commencement of any work.
2. Use suitable personal protective

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

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

fragments, particles, or dust that could be
ejected into the eyes.
AX815-901-8EN-07b 180/318
Page 27
5. Not only the worker(s) cleaning the

belts but also others close by who may
be affected, must also wear protective
equipment.
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
for re-tensioning and re-aligning the belt
after blockage is removed.
When work is complete, make sure that

all guards are closed / replaced and
secured before re-starting the machine.
AX815-901-8EN-07b 181/318
Page 28
9B.5 Plant - Overband Magnetic Belt

Magnet (where fitted)
The self cleaning suspended magnet utilises

a two pulley design. The tail pulley has
approximately 150 mm (6”) of take up
available for both belt stretch and tracking
purposes. To track the belt, the tail pulley
should be moved in a direction to tighten
the belt on the side opposite to the
direction in which the belt wanders.
The belt magnet assembly is

very powerful and permanently
charged. The strong magnetic
field produced could affect
heart pacemakers, watches,
credit cards, mobile phones
etc. The operator has the sole
responsibility to keep anyone
at risk clear of the machine.
Shedder Plate
Start-Up of Self Cleaning Magnet
Magnetic Belt
1. Be sure the magnet frame is visibly
square and has not been damaged or
twisted.
2. Check belt alignment.
3. Momentarily energise the belt drive and

check that the belt is tracking properly
and is not wandering laterally. Never
start the belt drive and allow it to
run continuously until the belt is
properly “trained”. If the belt
wanders, note the direction and adjust
as follows:
AX815-901-8EN-07b 182/318
Page 29
Maintenance
• Belt tracking should be checked

DANGER
frequently and adjusted as necessary. NIP POINT HAZARD.
Tighten the side of the belt to which you Information for relevant warning.
want the belt to move.
• When tracking or tensioning the belt

take care not to over-tension as this will
cause the shaft bearings to fail
WARNING
WEAR PERSONAL
• Regularly check the hydraulic motor PROTECTIVE EQUIPMENT.
mounting bolts for tightness and that Information for relevant
both halves of the coupling between the warning.
motor and the drive shaft are in
LOCKOUT MACHINE.
alignment. Refer to Section 9.1, Safety
• Lubricate bearings on a schedule dure.
consistent with other equipment in use
with your product.
• The speed of the belt on the magnetic

overband seperator is pre-set at the
factory but can be altered by turning the
adjusting screw located in the hydraulic
line.
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.
AX815-901-8EN-07b 183/318
Page 30
9B.6 Plant - Dust Suppression

WARNING
The plant is fitted with a plain water dust
suppression system. The system consists of WEAR PERSONAL
spray bars each fitted with atomiser nozzles. PROTECTIVE EQUIPMENT.
The spray bars are usually located in the Information for relevant warning.
following areas:-
LOCKOUT PLANT.
• Crusher feed chute (not for Impact
Crushers). Information for Lockout
Procedure.
• Crusher discharge area.
FALLING HAZARD.
• Product conveyor discharge. Information for relevant warning.
It is the responsibility of the customer to

supply the system with clean water. This is
supplied at the manifold (pictured opposite
page). The total flow requirement for the
system is 7 litres/min (2 US gallls/min). This
equates to a pressure requirement of 2.8 bar
or 42 psi.
Maintenance
All nozzles should be kept free of dirt and

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

the drain valves located below the inlet
manifold. This is particularly important in
winter time when there is the likelihood of the
system freezing.
AX815-901-8EN-07b 184/318
Page 31
Water Inlet Shut Off Valves
Drain Valves
Typical Dust Suppression Manifold
AX815-901-8EN-07b 185/318
Page 32
9B.7 Plant - Diesel Engine

WARNING
9B.7.1 Engine - General Information WEAR PERSONAL
For the diesel engine powerpack
fitted to the Plant to continue to Information for relevant
perform safely, efficiently and warning.
reliably it is imperative that all LOCKOUT MACHINE.
the recommendations given in Refer to Section 9.1, Safety
the separate engine manual are Information for Lockout Proce-
strictly followed with regard to:- dure.
• Safety
• Operation
• Lubrication
• Maintenance
• Service
• Parts
Adhere to the regular maintenance
schedules and procedures specified by the
manufacturer.
The diesel engine powerpack incorporates

a Caterpillar engine but the external housing
and some of the associated ancillary engine
components are not necessarily of CAT
origin.
For after sales and warranty matters, first

contact your local Terex Pegson dealer for
assistance
See Section 9B.8 for the maintenance

requirements for the type of clutch fitted.
AX815-901-8EN-07b 186/318
Page 33
9B.7.2 Engine - ELC Coolant

Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must
ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this
is not available top up with deionized water and adjust mixture concentration in the shop. Under no
circumstances use any other coolant as damage will result and any warranty invalidated.
Equipment is intended for use in ambient temperatures between -10°C to +40°C (+14°F to
+104°F). Appropriate lubricants and coolant must be used as specified within the plant and engine
operating and maintenance manuals.
For use in temperatures outside the above range consult your Terex Pegson Dealer or BL-Pegson
Limited for details prior to commencement of operations.
ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT
THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH
before refilling with ELC coolant.
Adhere to the instructions on the external labelling as shown below.
AX815-901-8EN-07b 187/318
Page 34
9B.7.3 Engine - Check Fuel Level

WARNING
WEAR PERSONAL
warning.
LOCKOUT MACHINE.
2. Check the fuel level indicator (pictured Information for Lockout Proce-
right). dure.
3. Top up fuel level if required.
• Fill the tank at the end of each day,

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

and is an explosion/burns
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 Indicator
(on Engine Control Panel)
Do Not carry out maintenance
on the fuel system near naked
lights or sources of sparks,
such as welding equipment.
AX815-901-8EN-07b 188/318
Page 35
9B.7.4 Engine - Top Up Fuel Level

Do Not fill the tank to
WARNING
capacity. WEAR PERSONAL
Monitor the gauge located on
the Control Panel (Figure). warning.
LOCKOUT MACHINE.
Allow room for expansion and Refer to Section 9.1, Safety
wipe up spilt fuel immediately, Information for Lockout Proce-
otherwise paintwork will be dure.
damaged.
Procedure
Never add gasoline or any
1. Observe all safety warnings. because of increased fire or
explosion risks.
implement the lockout procedure. Do Not smoke while refilling
3. Remove the engine side access panel on the fuel system.
the side nearest to the crusher to reveal Do Not carry out maintenance
the filler cap.(pictured right). Clean the on the fuel system near naked
area around the filler cap. lights or sources of sparks,
such as welding equipment.
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.
Diesel fuel is highly

flammableand is an explosion/
burns hazard.
Never remove the filler cap or

refuel, with the engine running. Filler Cap (typical)
AX815-901-8EN-07b 189/318
Page 36
9B.8 Engine Power

Transmission
9B.8.1 Transmission Types - fitted

to models
The diesel engine power take off to the
crusher is through various types of clutch
or fluid coupling mounted on the engine
output shaft. These disconnect the drive
from the engine to the crusher during the
starting and stopping procedures.
Detailed instructions for the engagement

and dis-engagement of each type are given
elsewhere in this manual.
Different types of clutch or coupling are

used to suit the specific requirements for the
model of plant (or option fitted) and the
general maintenance procedure for each
type is detailed in the following pages.
The list on the opposite page identifies the

particular type of clutch or coupling which
fitted to a specific model as standard.
NB. Where available as an option, some

plants can be fitted with the manually
operated Twin Disc clutch as an alternative
to the standard unit. Where fitted this will
be obvious from manual lever method of
engaging the crusher drive.
AX815-901-8EN-07b 190/318
Page 37
HYDRAULIC CLUTCH WITH GREASE

LUBRICATED OUTPUT SHAFT
BEARING - Section 9B.8.2
900 x 600 (24 x 36) Metrotrak.

900 x 600 Eurotrak.
1100 x 650 Premiertrak.
HYDRAULIC CLUTCH WITH OIL

LUBRICATED OUTPUT SHAFT
BEARING - Section 9B.8.3
1100 x 800 Premiertrak.

1000 Maxtrak.
1300 Maxtrak.
1000SR.
TWIN DISC MANUAL CLUTCH WITH

GREASE LUBRICATED OUTPUT
SHAFT BEARING - Section 9B.8.4
428 Trakpactor
4242SR Tracked Impactor
FLUID COUPLING - Section 9B.8.5
1412 Trakpactor.
AX815-901-8EN-07b 191/318
Page 38
9B.8.2 Hydraulic Clutch - Grease

Lubricated Bearing WARNING
WEAR PERSONAL
These units are OIL POWER TAKE PROTECTIVE EQUIPMENT.
OFFS with clutches composed by two or Refer to Section 9.1, Safety
three discs having the outer driving ring warning.
connected to the engine flywheel. The
output shaft is supported by a spherical LOCKOUT MACHINE.
roller bearing, grease or oil lubricated, Information for Lockout Proce-
fitted in a cover flanged to the engine dure.
flywheel housing.
Engage the clutch with engine at idling

speed (1200 rpm).
Bearing Carrier 4 Grease Nipple 11
Too high a belt tension may reduce
drastically the life of bearing.
At ambient temperature close to or below

0°C (32°F), keep the engine running at
idling speed (1200 rpm) for 5 minutes at
least before engagement.
At first start up, run power take off with

engaged clutch and engine at half of max
speed for not less than 10 minutes.
Check the clutch driving plates annually and

it is advisable, every 3000 working hours,
to check the condition of the bearings and
replace the rotating seals (refer to parts list)
Grease lubricated bearing

Clutch Housing 1
The clutch output shaft bearing off is
supplied already greased. After the first 100 Overflow Plug 36
hours of operation the grease level should
be checked. Removing the overflow plug Clutch
- Bearing
36, insert a screw driver into the cavity and Grease Lubrication Point
AX815-901-8EN-07b 192/318
Page 39
check if the grease is present. If necessary

add grease through the grease nipple 11.
For the next maintenance cycle see Section
9 - Lubrication Schedule.
Do not overgrease the bearing

carrier 4. The main bearing
may overheat and grease exit
from the seals.
Every 500 working hours add 35 g (37 cc)

of grease through the grease nipple 11
(pictured previous page). Remove the
overflow plug 36 to insure that the grease is
not overfilled.
After 3000 working hours it is

recommended to purge the old grease. The
old grease should be replaced if the unit has
not been used for more than 6 month. The
bearing, not the bearing cavity, should be
packed with approximately 122g (130cc)
of new grease and the cover remounted.
Remove the overflow plug 36 to control for
overfilling. Grease should then be added
through the greaser 11. To refill, to the
proper level (approximately 50%), a
completely empty bearing cavity will require
approximately 128g (137cc) of grease. 100
hours of operation after purging, the grease
level should be checked as described.
AX815-901-8EN-07b 193/318
Page 40
9B.8.3 Hydraulic Clutch - Oil

Lubricated Bearing WARNING
WEAR PERSONAL
These units are OIL POWER TAKE PROTECTIVE EQUIPMENT.
OFFS with clutches composed by two or Refer to Section 9.1, Safety
three discs having the outer driving ring warning.
connected to the engine flywheel. The
output shaft is supported by a spherical LOCKOUT MACHINE.
roller bearing, grease or oil lubricated, Information for Lockout Proce-
fitted in a cover flanged to the engine dure.
flywheel housing.
Engage the clutch with engine at idling

speed (1200 rpm).
Too high a belt tension may reduce

drastically the life of bearing.
At ambient temperature close to or below Clutch Housing 1

0°C (32°F), keep the engine running at
idling speed (1200 rpm) for 5 minutes at
least before engagement.
At first start up, run power take off with

engaged clutch and engine at half of max
speed for not less than 10 minutes.
Check the clutch driving plates annually and

it is advisable, every 3000 working hours,
to check the condition of the bearings and
replace the rotating seals (refer to parts list).
Taper Plug 41
Oil lubricated bearing
Bearing Carrier 4
Check the bearing oil level prior to the daily
start up of the plant: as a minimum Oil Filler 34 with
requirement, level stick must be oil wet. Level Stick 37
Clutch Bearing
Oil Lubrication Point
AX815-901-8EN-07b 194/318
Page 41
Change the oil every 1000 hours (or at 6

months whichever is the sooner) and refill
with fresh oil.
When changing the oil drain the old oil by

opening the tap located at the bottom of the
bearing housing 4. Make sure this is tightly
closed before adding fresh oil of the
approved grade.
Fill the bearing and bearing cavity with oil

(Section 9 - Lubricant Types). Remove
taper plug 41 and through pipe 34 fill the
bearing cavity (pictured previous page).
Turn the shaft by hand until maximum oil
level is indicated on the stick 37. After oil
filling remount the taper plug.
AX815-901-8EN-07b 195/318
Page 42
9B.8.3.1 Hydraulic Clutch Trouble Shooting
REMEDY CAUSE REMEDY

CHECK PLATES WEARING
DRIVING PLATES CHECK DRIVEN MACHINE
CHECK ENGINE SPEED
CLUTCH SLIP AND OR CHECK PRESSURE FEEDING
OVERHEATING LOW OIL PRESSURE SYSTEM
CHECK ROTARY UNION
CHECK POSSIBLE LOSS
GREASE MISSING ADD GREASE. IF OLD GREASE
BLACK COLOUR, CHECK BEARING
CONDITION
RADIAL LOAD TOO HIGH REDUCE VEE BELT TENSION
SLIPPING PLATES CHECK OIL PRESSURE
NOISE AND/OR OVERHEATING BEARING FAILURE
OUTPUT BEARING CARRIER MISALIGNMENT
TORSIONAL VIBRATION
TOOTH WEAR ON DRIVING RING CONTACT BL-PEGSON IF PLANT
AND/OR CLUTCH PLATES UNDER WARRANTY
OIL LEAKAGE AT CLUTCH SIDE ‘O’ RING(S) WORN OR DAMAGED
RESIDUAL PRESSURE OVER O CHECK DISENGAGEMENT
INCOMPLETE CLUTCH BAR PRESSURE
DISENGEMENT (DRAG ON LOAD ENGINE RPM NOT AT MINIMUM REDUCED TO IDLING SPEED
OR SMOKE FROM CLUTCH) DIRT BETWEEN INTERNAL AND CLEAN OUT DIRT. CHECK
EXTERNAL TEETH OF PLATES HOUSING APERTURE COVERS IN
PLACE WITH GASKETS.
AX815-901-8EN-07b 196/318
Page 43
9B.8.4 Manual Clutch

IMPORTANT -TWIN DISC MANUAL
WARNING
CLUTCH INSTRUCTIONS WEAR PERSONAL
Refer to instructions overleaf regarding
the engine clutch adjustment check to be warning.
made at the time of initial commissioning
LOCKOUT MACHINE.
at new and the essential regular Refer to Section 9.1, Safety
maintenance of the clutch thereafter. Information for Lockout Proce-
dure.
New clutch plates have a ‘wear in’ period and
the clutch may require several adjustments
until new plates are ‘worn in’.
A newly fitted power take off must have it’s

clutch adjustment checked at the following
intervals:-
• After installation
• After 4 hours operation.
• After 10 hours operation.
• At the end of each working day for
approximately 1 week.
• Once a week.
After ‘wear in’, clutch adjustments should

be made on a weekly basis.
AX815-901-8EN-07b 197/318
Page 44
9B.8.4.1 Manual Clutch - Adjustment
AX815-901-8EN-07b 198/318
Page 45
9B.8.4.2 Manual Clutch - Max/Min Adjustment Values
AX815-901-8EN-07b 199/318
Page 46
9B.8.5 Fluid Coupling

9B.8.5.1 Fluid Coupling Description DANGER
SKIN INJECTION HAZARD
The 21 KPTO fluid coupling (pictured
opposite page) fitted to the engine is a drain Information for relevant warning
type coupling. If ‘drained’ it works as a
disconnected clutch. If progressively filled,
it operates as a ‘soft’ starter.
When the CRUSHER start is operated it

WARNING
electrically activates the pump inside the WEAR PERSONAL
fluid coupling and engages the drive from
the engine to the crusher. Information for relevant
warning.
When the CRUSHER stop is activated it
LOCKOUT MACHINE.
disconnects the electric supply and thus Refer to Section 9.0, Safety
allows the unit to drain. Information for Lockout Proce-
dure.
In the course of normal operation the fluid
coupling operates automatically and no
action is required to the unit.
Maintenance of the unit is required, eg.

changing the fluid, attending to the filter THIS IS A HIGH PRESSURE
assembly, etc. SYSTEM.
DANGER
Maintain in accordance with the reservoir Do not tamper with the unit. In
level and the schedules and fluid types the event of anything other
detailed in Section 9A. ONLY USE A than minor problems, these
RECOMMENDED FLUID. should only be dealt with by
suitably experienced and
It is essential when replenishing hydraulic
qualified engineers.
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..
AX815-901-8EN-07b 200/318
Page 47
Breather Cap
Pressure Gauge
Temperature Gauge
Filter
Solenoid Valve
Oil Level
Sight Glass
Figure - Engine Fluid Coupling
AX815-901-8EN-07b 201/318
Page 48
9B.8.5.2 Fluid Coupling - Features
The KPT Fluid Coupling is a drain type

WARNING
fluid coupling. when oil is drained out it WEAR PERSONAL
works as a disconnected clutch and PROTECTIVE EQUIPMENT.
when progressively oil filled it works as
a soft starter. warning.
LOCKOUT MACHINE.
The fluid coupling is a totally enclosed
unit incorporating a feed pump to Information for Lockout Proce-
provide an oil flow to fill the coupling dure.
from the integral oil reservoir. The oil
pump operates continuously whilst the
plant diesel engine is running. To start
the crusher an electrically operated
valve is actuated to fill the coupling and
thus engage the drive between the
engine and the crusher.
To stop the crusher the valve is de-

activated to divert the oil back to the
integral oil tank. In this manner the fluid
is drained out of the coupling while the
oil flow continues to ensure tank
cooling and bearing lubrication.
The coupling fluid is cooled through the

diesel engine jacket water with a preset
maximum temperature level which must
not be changed from the factory setting
of 95 o C.(203 o F).
The temperature gauge is coupled with

a switch to activate a high temperature
fault message on the Electrical Control
Panel display screen and automatically
stop the feeder.
AX815-901-8EN-07b 202/318
Page 49
Oil is cleaned by a replaceable filter.

The pressure gauge is coupled with a
switch to activate a filter blocked fault
message on the Electrical Control
Panel display screen. The filter
cartridge must be changed immediately
as the oil flow will be unfiltered.
AX815-901-8EN-07b 203/318
Page 50
9B.8.5.3 Fluid Coupling - Maintenance
Before carrying out any WARNING

maintenance on the fluid WEAR PERSONAL
coupling close down the plant PROTECTIVE EQUIPMENT.
(Section 8.2) and implement Refer to Section 9.0, Safety
the Lock Out procedure. warning.
Change the hydraulic oil in the unit after the LOCKOUT MACHINE.
first 100 working hours together with the oil Information for Lockout Proce-
cartridge filter. Thereafter change the oil after dure.
every 4000 working hours and change the oil
filter cartridge when the pressure is 1.7 bar
over the rated value.
The correct oil level is the blue line on the

level indicator. First fill the KPT unit, then Check periodically, possibly every 1000
start the engine to run the pump to fully fill hours, that the pump chain be of correct
the heat exchanger. Then check the oil level length. Hang 20kg (44lbs) weight to stretch
again with the engine stationary. chain. Maximum chain length = 1556mm
(61 1/4”).
Whilst the plant is under
warranty the following work Check, periodically, the condition of the
must only be carried out by the elastic coupling.
manufacturer otherwise the
warranty will be invalidated. Do not make any modification
without the approval of the
It is recommended that only a manufacturer so as not to
trained engineer is used for invalidate any warranty in
any subsequent work on this force for the time being.
fluid coupling.
The rotating seals (items 46 & 58 in Section

10 Parts List) need to be changed in the
event of significant oil leakage. Only fit seals
supplied by the coupling manufacturer.
Keep the cooler system clean.
AX815-901-8EN-07b 204/318
Page 51
Fluid Coupling Hydraulic Circuit Diagram
AX815-901-8EN-07b 205/318
Page 52
9B.8.5.4 Fluid Coupling - Trouble Shooting
The fluid coupling is a complex WARNING

piece of machinery fully WEAR PERSONAL
installed and tested during the PROTECTIVE EQUIPMENT.
plant manufacture. Only a Refer to Section 9.0, Safety
skilled engineer fully warning.
conversant with the coupling
should attempt any rectification LOCKOUT MACHINE.
work other than making the Information for Lockout Proce-
following checks. dure.
Unit fails to operate
1. Check the coupling output shaft turns

freely with the engine shut down.
2. Check the solenoid valve is operating.
3. Check the oil level is up to the blue line

(Figure).
4. Check the oil pressure is satisfactory.
5. Check the temperature alarm switch is

working correctly.
Unit operates at reduced output

speed
1. Carry out the checks above.
2. Check engine high idle speed with fluid

coupling disengaged.
3. Check that the crusher shaft turns freely.
AX815-901-8EN-07b 206/318
Page 53
Oil Loss
1. Check all pipe connections.
2. Check seals for leakage.
3. Check engine flywheel housing.
4 Check for leakage into engine coolant.
If vapour comes from the breather, wait

until the oil temperature reaches more
than 55-60 ºC (130-140 ºF). If oil comes
out of the breather, refer to the
manufacturer.
High oil pressure
1. Check filter and replace if necessary.
2 Check pressure gauge is correctly set.
3. Check oil tubes not obstructed.
AX815-901-8EN-07b 207/318
Page 54
9B.8 Plant - Vehicle Tracks

WARNING
It is essential that the tracks WEAR PERSONAL
are correctly tensioned at all PROTECTIVE EQUIPMENT.
times. Check track tension Refer to Section 9.1, Safety
regularly (Section 9B.8.1). Information for relevant
warning.
Keeping the track properly adjusted will LOCKOUT PLANT.
increase the service life of the track and Refer to Section 9.1, Safety
drive components. Information for Lockout Proce-
dure.
When ordering Spare Parts it is essential to

quote the plant serial number (with either a /
S or /T suffix if included on the identity
plate serial number). Prior to attempting any
manoeuvring of the plant the
Frequently check for loose bolts, oil leaks, tracks must be free of
master pins are correctly located and tight, obstructions, including crushed
general wear and damage, correct track material and fines. Do not push
tension, etc. to ensure safe working and or tow the plant. Failure to
long life. observe this warning could
result in injury to persons and
When travelling on a gradient, the tracks damage to the plant which may
should be driven with the track idler rollers invalidate warranty.
(Figure) in front (ie. Feed Hopper first).
9B.8.1 Measuring Track Tension
Procedure
1. Observe all Safety Warnings.
2. Position the plant on solid and level

ground and drive 2 metres (2 yards)
minimum in a forward direction, track
idler roller leading.
AX815-901-8EN-07b 208/318
Page 55

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

incorrectly tensioned tracks
can cause severe damage to
the undercarriage components
and may invalidate the 5 - 15mm
(1/4 - 5/8”)
warranty.
6. Depending upon the need to either

slacken or tension the track(s) proceed
as below.
Measuring Track Tension
continued.......................
AX815-901-8EN-07b 209/318
Page 56
9B.8.2 Adjusting Track Tension

‘GREASE UNDER HIGH DANGER
PRESSURE’ SKIN INJECTION HAZARD
To Release Track Tension (After Information for relevant warning
measurement - Section 9B.8.1):-
Procedure WARNING
WEAR PERSONAL
1. Observe all Safety Warnings. PROTECTIVE EQUIPMENT.
2. Close down the plant (Section 8.2) and warning.
LOCKOUT PLANT.
3. Locate the access aperture on the side Information for Lockout Proce-
of the track frame and remove the dure.
cover (where fitted) to reveal the relief
valve inside.
4. Next loosen the relief valve by turning

counter clockwise using gradual
increments until the grease begins to be
expelled. Care must be taken not to Grease coming out of the relief
loosen the relief valve too quickly valve under pressure can
because the grease inside is under penetrate the body causing
high pressure. injury or death; do NOT watch
the relief valve to see if grease
5. When the correct track tension has is escaping but instead watch
been measured (Section 9B.8.1), turn the track adjustment cylinder
the relief valve clockwise to tighten and to verify that the track is being
then clean away all trace of expelled loosened.
grease.
DO NOT OVER TENSION
6. Operate the plant in manoeuvring mode THE TRACKS (Refer to
(Section 5.2.1) and drive the plant 50 Section 9B.8.1).
metres (50 yards) forwards and 50
metres (50 yards) backwards, measure
the sag and repeat the steps 1 - 4 if the
AX815-901-8EN-07b 210/318
Page 57
track(s) sag is not enough. If room for

manoeuvring the plant is restricted,
drive the plant forwards and backwards
DANGER
several times over a shorter distance. SKIN INJECTION HAZARD
If the track fails to slacken after the
grease fitting has been loosened, do not
attempt to remove the tracks or
disassemble the track tensioner, or
remove the grease fitting. It is possible
WARNING
WEAR PERSONAL
that running the tracks with the grease
fitting loosened may help to expel the Refer to Section 9.1, Safety
grease. Information for relevant
warning.
LOCKOUT PLANT.
dure.
Track Surface Idler Roller
Drive Sprocket
Relief
Valve
Final Drive Track Roller
Unit
Vehicle Track Parts
AX815-901-8EN-07b 211/318
Page 58
To Increase Track Tension (After

measurement - Section 9B.8.1):- DANGER
Procedure Information for relevant warning
1. Observe all Safety Warnings.

WARNING
WEAR PERSONAL
3. Locate the access aperture on the side Information for relevant
of the track frame and remove the warning.
cover (where fitted) to reveal the relief LOCKOUT MACHINE.
valve inside. Refer to Section 9.1, Safety
4. Connect the grease gun to the grease dure.
fitting and add grease until the track
tension is within the specified dimension
(Section 9B.8.1 - Measuring Track
Tension). See Section 9A.3.8-
Lubricant Types - for the grease type
and specification.
5. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) forwards and 50
metres (50 yards) backwards, measure
the sag and repeat the steps 1 - 4 if the
track(s) sag is too great. If room for
manoeuvring the plant is restricted,
drive the plant forwards and backwards
several times over a shorter distance.
AX815-901-8EN-07b 212/318
Page 59
9B.8.3 Track Maintenance

Maintenance Schedule
WARNING
WEAR PERSONAL
• The first drive oil replacement is to be PROTECTIVE EQUIPMENT.
carried out after 100 operating hours of
the gearbox. warning.
LOCKOUT MACHINE.
• There after replace the drive oil every Refer to Section 9.1, Safety
1000 hours or at least once per year. Information for Lockout Proce-
dure.
• Check the drive oil level every 100
working hours.
Procedure
To maximise the life of the

Daily track, keep it movable and
avoid damage, the plant should
1. Observe all safety warnings. be moved at least every week,
by a distance exceeding four
2. Close down the machine (Section 8.2) times the track length. It
and implement the Lockout Procedure. should also be parked on level
ground overnight and during
3. Check the track rollers and idler wheels periods to of non-usage. This
for possible leakage. is particularly important when
working in adverse conditions.
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.
6. Check the tension of the tracks (Section

- Measuring Track Tension) and adjust
tension if necessary (Section 9B.8.1 -
Adjusting Track Tension).
AX815-901-8EN-07b 213/318
Page 60
9B.8.4 Drive Oil Filling and Draining

Oil Filling
WARNING
WEAR PERSONAL
warning.
LOCKOUT MACHINE.
2. Close down the plant (Section 8.2) and dure.
3. Make sure the gearbox housing is

horizontal.
4. Rotate the gearbox housing so that one

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

upper hole until the oil flows from the
Oil Fill (A)
hole located at the 9 o’clock position.
See Section 9A.3.8 for oil type and
specification.
6. Clean plugs using a clean non-

flammable solvent.
7. Apply pipe sealant to the plugs and

install.
8. Repeat procedure on the other final

drive.
Oil Level (B)
Note:- Over filling the final drive will cause
the travel motor seal to allow hydraulic oil
or water to enter and contaminate the drive. Tracks - Oil Filling
AX815-901-8EN-07b 214/318
Page 61
Oil Draining
WARNING
WEAR PERSONAL
1. Observe all safety warnings. warning.
LOCKOUT MACHINE.
2. Close down the plant (Section 8.2) and Refer to Section 9.1, Safety
implement the Lockout Procedure. Information for Lockout Proce-
dure.
3. Rotate the gearbox housing until a plug
is at the 6 o’clock position (pictured
right). (A)
4. Unscrew both plugs and discharge the

oil.
5. Clean plugs using a clean non-

flammable solvent.
6. Apply pipe sealant to the plugs and

install.
7. Repeat procedure on the other final

drive.
Oil Drain (B)
Figure - Oil Draining
AX815-901-8EN-07b 215/318
Page 62
Blank Page
AX815-901-8EN-07b 216/318
Premiertrak
1100 x 650
Spare Parts Issue EN 07
Page 1
Contents
10.1 Jaw Crusher Parts ............................................................................................. 3

Jaw Crusher Unit - Premiertrak 1100 x 650 ......................................................................... 3
Jaw Crusher - Mainframe Assembly ................................................................................... 4
Jaw Crusher - Swing Jaw Assembly ................................................................................... 6
Jaw Crusher - Eccentric Shaft Assembly ............................................................................ 8
Jaw Crusher - Toggle Plate Assembly ............................................................................... 10
Jaw Crusher - Tension Rod Assembly .............................................................................. 12
Jaw Crusher - Hand Pump Hose Assembly ...................................................................... 14
Jaw Crusher - Hand Pump Assembly ............................................................................... 16
10.2 Feeder Parts ..................................................................................................... 18
4200 x 1060 Grizzly Feeder - Mainframe Assembly .......................................................... 18
4200 x 1060 One Piece Grizzly Section 50mm Spacing Assembly .................................. 20
4200 x 1060 Grizzly Feeder - Vibrating Unit Assembly ...................................................... 22
4200 x 1060 Grizzly Feeder - Vibrating Unit Shaft Assembly ............................................. 24
10.3 Conveyor Parts ................................................................................................ 28
Product Conveyor - Conveyor Frame Parts Assembly ..................................................... 28
Product Conveyor - Conveyor Mechanical Parts Assembly .............................................. 30
Dirt Conveyor - Conveyor Frame Parts Assembly ............................................................ 32
Dirt Conveyor - Conveyor Mechanical Parts Assembly ..................................................... 34
10.4 Overband Magnetic Separator ........................................................................ 36
10.5 Plant Component Parts .................................................................................. 38

Plant Guards Assembly ..................................................................................................... 38
Plant Rubber Seals Assembly ........................................................................................... 40
Plant Platforms Assembly ................................................................................................. 42
Plant Feed Hopper Assembly ............................................................................................ 44
10.6 Track Parts ....................................................................................................... 46
‘S’ Mark Tracks .................................................................................................................. 46
‘T’ Mark Tracks .................................................................................................................. 48
10.7 Hydraulic Parts ................................................................................................ 50
Hydraulic System Components ......................................................................................... 50
Hydraulic Parts - HFO Clutch ............................................................................................ 52
Hydraulic Oil Reservoir ...................................................................................................... 54
10.8 Electrical Parts ................................................................................................. 56
10.9 Warning Labels ................................................................................................ 58
10.10 Hydraulic Engine Clutch ............................................................................... 60
AX815-901-8EN-07b 217/318
Premiertrak
1100 x 650
Page 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)
BL-PEGSON DISTRIBUTOR.............................................................................
CONTACT NAME(S)..........................................................................................
.........................................................................................
TELEPHONE NUMBER.....................................................................................
FACSIMILE NUMBER........................................................................................
E MAIL ADDRESS.............................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.
AX815-901-8EN-07b 218/318
Premiertrak
1100 x 650
Page 3
10.1 Jaw Crusher Parts
Jaw Crusher Unit - Premiertrak 1100 x 650
AX815-901-8EN-07b 219/318
Premiertrak
1100 x 650
Page 4
Jaw Crusher - Mainframe Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 600/2080SF MAINFRAME 1
2 600/2011E FIXED JAW 1
3 600/2021M FIXED JAW WEDGE 2
4 325/28 JAW WEDGE BOLT 4
5 2217-0015 LOCKNUT 4
6 310/23 WASHER 8
7 311/11 FIBRE WASHER 4
N/S 2960-0026 SPANNER ( NOT SHOWN. ) 1
8 600/2014 CHEEK PLATE UPPER LH. 1
9 600/2016 CHEEK PLATE LOWER LH. 1
N/S 600/2015 CHEEK PLATE UPPER RH. 1
N/S 600/2017 CHEEK PLATE LOWER RH. 1
10 2232-1356 BOLT 10
11 2217-0011 LOCKNUT 10
12 2210-0023 WASHER 10
13 323/22 ROTABOLT 4
14 2217-0049 LOCKNUT 4
15 2210-2020 WASHER 4
16 2530-1044 GREASE NIPPLE 2
17 2520-6221 BUSH 2
12/05/03
AX815-901-8EN-07b 220/318
Premiertrak
1100 x 650
Page 5
Mainframe Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 221/318
Premiertrak
1100 x 650
Page 6
Jaw Crusher - Swing Jaw Assembly

1 600/2006 JAWSTOCK 1
2 600/2012E SWING JAW 1
3 600/2022M SWING JAW WEDGE 2
4 325/27 BOLT 4
310/16 WASHER 8
311/5 FIBRE WASHER 4
2217-0015 LOCKNUT 4
5 600/2008 JAWSTOCK GUARD 1
6 2232-1353 BOLT 3
2211-0014 WASHER 3
2215-0020 NUT 3
7 600/2029 APRON 1
8 600/2030 APRON CLAMP 1
9 2230-1153 SCREW 6
2211-0008 WASHER 6
10 2530-1044 GREASE NIPPLE 2
11 2520-6221 BUSH 2
12/05/03
AX815-901-8EN-07b 222/318
Premiertrak
1100 x 650
Page 7
Swing Jaw Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 223/318
Premiertrak
1100 x 650
Page 8
Jaw Crusher - Eccentric Shaft Assembly

1 600/2054 ECCENTRIC SHAFT 1
600/2089 SHAFT ASSEMBLY SHIM 1
2 600/2047 SPACER 2
3 2416-1543 BEARING 2
4 2430-0640 CIRCLIP 2
5 600/2060 SPACER 2
6 600/2061 SPACER 2
2201-5215 SPRING PIN 2
7 2416-4517 BEARING 2
8 2400-7182 BEARING SLEEVE 2
9 2430-0640 CIRCLIP 1
10 2503-5112 V-RING SEAL 2
11 303/79 FLYWHEEL GROOVED 1
12 318/6 SLIT BUSH 2
13 2450-5003 LOCK RING 2
14 600/2050 FLYWHEEL END CAP 2
15 600/745 LOCK WASHER 2
16 2230-1358 SCREW 4
17 303/78 FLYWHEEL PLAIN 1
N/S 600-2084 FLYWHEEL BALANCE WEIGHT 2
N/S 600-2085 FLYWHEEL BALANCE WEIGHT 2
12/05/03
Crusher/Engine Drive Belts
8 x 6700mm SPC,
Part Number 2441-0483
AX815-901-8EN-07b 224/318
Premiertrak
1100 x 650
Page 9
Eccentric Shaft Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 225/318
Premiertrak
1100 x 650
Page 10
Jaw Crusher - Toggle Plate Assembly

1 600/2009 TOGGLE SEAT 1
2 600/2025 TOGGLE PLATE 1
3 600/2013 TOGGLE BEAM 1
600/742 CROSS BEAM KEY 1
2226-0816 SCREW 3
600/732 TOGGLE PLATE RETAINER 2
2232-1281 BOLT 4
2212-7113 LOCKWASHER 4
4 600/2108/1 7.5 MM SHIM 2
600/2108/2 7.5MM SHIM 1
600/2109/1 11MM SHIM 2
600/2109/2 11MM SHIM 2
600/2110/1 14MM SHIM 2
600/2110/2 14MM SHIM 2
5 600/2041 SHIM PAD 1
6 600/2097 LOCKING WEDGE 2
7 600/2098 STUD 2
8 2215-0222 NUT 6
9 2212-6015 WASHER 4
10 600/737 RAILKO PAD 2
2147-0101 ADHESIVE 1
11 600/2019 LOCKING BRACKET (LH) 1
2232-1433 BOLT 2
2210-2014 WASHER 2
2217-0013 NUT 2
12 600/2020 LOCKING BRACKET (RH) 1
2232-1433 BOLT 2
2210-2014 WASHER 2
2217-0013 NUT 2
2960-0022 SPANNER 1
12/05/03
AX815-901-8EN-07b 226/318
Premiertrak
1100 x 650
Page 11
Toggle Plate Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 227/318
Premiertrak
1100 x 650
Page 12
Jaw Crusher - Tension Rod Assembly

1 600/2076 TENSION ROD 1
2215-0024 NUT 2
2210-2016 WASHER 2
2 600/2043 TENSION SPRING BRACKET 1
2230-1226 SCREW 4
2211-0010 WASHER 4
3 4448D-84 TENSION ROD SPRING 1
4 600/2045 SPRING CAP 1
5 2210-2017 WASHER 2
6 311/9 WASHER 2
7 600/1058 SPACER 2
8 2402-2040 BEARING 1
9 320/23 PIN 1
2201-0148 SPLIT PIN 2
10 2960-0024 SPANNER 1
11 2210-7194 SCREW 1
N/S 600/3093 TENSION ROD GUARD. 1
12/05/03
AX815-901-8EN-07b 228/318
Premiertrak
1100 x 650
Page 13
Tension Rod Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 229/318
Premiertrak
1100 x 650
Page 14
Jaw Crusher - Hand Pump Hose Assembly

1 2527-1003 HOSE ASSEMBLY 1
9 2564-2004 HYDRAULIC CYLINDER 1
600/2055 CLEVIS 1
10 2520-3004 COUPLING 2
11 2520-3005 ELBOW 2
13 2520-3002 MALE TEE 2
14 2520-3003 FEMALE UNION 2
15 2520-3001 MALE ADAPTOR 18
16 2500-1015 SEAL 18
17 2210-0017 WASHER 10
18 320/29 PIN 5
19 2201-0124 SPLIT PIN 10
20 2512-5012 HOSE CLAMP 2
12/05/03
AX815-901-8EN-07b 230/318
Premiertrak
1100 x 650
Page 15
Hand Pump Hose Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 231/318
Premiertrak
1100 x 650
Page 16
Jaw Crusher - Hand Pump Assembly
REF PART NUMBER DESCRITION QUANTITY

1 2571-1970 HAND PUMP 1
2232-1094 BOLT 4
2211-0007 WASHER 4
2215-0013 NUT 4
2 2553-1101 VALVE 1
2232-1078 BOLT 3
2211-0006 WASHER 3
2215-0012 NUT 3
3 600/1044 BRACKET 1
2230-1220 SCREW 2
2211-0010 WASHER 2
12/05/03
AX815-901-8EN-07b 232/318
Premiertrak
1100 x 650
Page 17
Hand Pump Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 233/318
Premiertrak
1100 x 650
Page 18
10.2 Feeder Parts
4200 x 1060 Grizzly Feeder - Mainframe Assembly

1 620/437 MAINFRAME 1
2 620/439 PAN LINER(REAR) 1
3 620/440 PAN LINER(FRONT) 1
2226-0895 SCREW 24
2210-0021 WASHER 24
2217-0009 NUT 24
4 620/441 RH SIDE LINER 2
5 620/441 LH SIDE LINER 2
6 620/442 RH SIDE LINER 1
7 620/442 LH SIDE LINER 1
2226-0818 SCREW 26
2210-0017 WASHER 26
2217-0005 NUT 26
8 620/438 DISCHARGE LIP 1
2226-0856 SCREW 8
2210-0019 WASHER 8
2217-0007 NUT 8
9 620/444 CLAMP STRIP 2
10 620/445 RUBBER SKIRT 2
2226-0856 SCREW 8
2210-0019 WASHER 8
2217-0007 NUT 8
11 84AV13 SPRING 4
12 301/13 SPRING 8
12/05/03
AX815-901-8EN-07b 234/318
Premiertrak
1100 x 650
Page 19
Feeder Mainframe Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 235/318
Premiertrak
1100 x 650
Page 20
4200 x 1060 One Piece Grizzly Section 50mm Spacing Assembly

1 620/443 GRIZZLY SECTION – STANDARD 50MM NOM GAP 1
2 620/446 BAR PLATE 2
3 2232-1207 BOLT 6
4 2232-1219 BOLT 6
5 2217-0007 NUT 12
6 2212-2005 WASHER 24
12/05/03
AX815-901-8EN-07b 236/318
Premiertrak
1100 x 650
Page 21
Grizzly Section Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 237/318
Premiertrak
1100 x 650
Page 22
4200 x 1060 Grizzly Feeder - Vibrating Unit Assembly

1 629/150 UNIT HOUSING 1
2 629/151 COVER PLATE 1
3 629/47 END COVER (GEAR) 1
4 629/160 END COVER (DRIVE) 1
5 2510-3860 PLUG 2
6 2230-1122 SCREW 48
7 2211-0007 WASHER 48
8 2236-4278 BOLT AND NUT 20
9 2212-2006 WASHER 20
10 2215-0018 NUT 20
11 2230-1150 SCREW 24
12 2211-0008 WASHER 24
13 2538-5152 OIL LEVEL GLASS 2
14 2510-9848 MAGNETIC PLUG 2
2510-4574 REDUCING BUSH 2
15 2531-1021 BREATHER 1
LOCTITE GASKET COMPOUND
2141-0027 2
(FOR SEALING END PLATES AND COVER PLATES)
12/05/03
AX815-901-8EN-07b 238/318
Premiertrak
1100 x 650
Page 23
Feeder Vibrating Unit Housing - Premiertrak 1100 x 650
AX815-901-8EN-07b 239/318
Premiertrak
1100 x 650
Page 24
4200 x 1060 Grizzly Feeder - Vibrating Unit Shaft Assembly

1 629/154 DRIVEN SHAFT 1
2 629/155 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 BOLT 32
5 629/153 BEARING HOUSING 4
6 629/157 BEARING SPACER 2
7 2416-1909 BEARING 4
8 629/159 LOCKING RING 4
9 629/162 ‘O’ RING INNER 4
10 629/163 ‘O’ RING OUTER 4
11 629/156 BEARING CAP 4
2510-3864 PLUG 4
12 2232-1279 BOLT 40
13 2217-0009 NUT 40
14 310/28 WASHER 1
15 2212-8014 LOCKWASHER 1
16 2217-7014 LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 3
19 325/20 SCREW 6
20 18HS50 KEY (SPUR GEAR) 2
21 18HS54 DRIVE GEAR 2
23 2222-0157 BOLT 2
2217-0004 NUT 2
2210-0016 WASHER 2
24 2576-4074 HYDRAULIC MOTOR 1
25 629/253 MOTOR COUPLING 1
331/58 KEY 1
26 2577-0001 ADAPTOR PLATE 1
27 326/11 BOLT 4
2217-0005 NUT 4
2210-0017 WASHER 4
12/05/03
AX815-901-8EN-07b 240/318
Premiertrak
1100 x 650
Page 25
Feeder Driveside Shaft Assembly - Premiertrak 1100 x 650
Note:- There is also a third hose coming off the motor which is not illustrated which is the
return to tank for the motor.
AX815-901-8EN-07b 241/318
Premiertrak
1100 x 650
Page 26
4200 x 1060 Grizzly Feeder - Vibrating Unit Shaft Assembly(cont’)

1 629/154 DRIVEN SHAFT 1
2 629/155 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 BOLT 32
5 629/153 BEARING HOUSING 4
7 2416-1909 BEARING 4
8 629/159 LOCKING RING 4
9 629/162 ‘O’ RING INNER 4
10 629/163 ‘O’ RING OUTER 4
11 629/156 BEARING CAP 4
2510-3864 PLUG 4
12 2232-1279 BOLT 40
13 2217-0009 NUT 40
14 310/28 WASHER 1
15 2212-8014 LOCKWASHER 1
16 2217-7014 LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 3
19 325/20 SCREW 6
20 18HS50 KEY (SPUR GEAR) 2
21 18HS54 DRIVE GEAR 2
23 2222-0157 BOLT 2
2217-0004 NUT 2
2210-0016 WASHER 2
25 629/253 MOTOR COUPLING 1
331/58 KEY 1
26 2577-0001 ADAPTOR PLATE 1
27 326/11 BOLT 4
2217-0005 NUT 4
2210-0017 WASHER 4
12/05/03
AX815-901-8EN-07b 242/318
Premiertrak
1100 x 650
Page 27
Feeder Non Driveside Shaft Assembly- Premiertrak 1100 x 650
AX815-901-8EN-07b 243/318
Premiertrak
1100 x 650
Page 28
10.3 Conveyor Parts
Product Conveyor - Conveyor Frame Parts Assembly

1 AX815-219-501 TAIL FRAME 1
AX815-221-501 TAIL FRAME PIVOT BRACKETS 2
2 AX789/27 PIVOT 2
3 AX789/37/1 GUARD ANGLE LH 1
AX789/37/2 GUARD ANGLE RH 1
4 AX789/53 PIVOT 2
5 AX815/135/1 HEAD FRAME 1
Ax815/135/2 REMOVABLE CROSS MEMBER 1
6 AX789/24/1 SCRAPER BRACKET RH 1
AX815/171 HEAD DRUM NIP GUARD 1
7 AX789/24/1A SCRAPER BRACKET LH 1
8 AX789/24/3 BELT SCRAPER CARRIER 1
9 AX789/24/2 BELT SCRAPER CLAMP 1
10 AX846/77 WIND COVER SUPPORT 4
11 AX815/193/1 HEAD GUARD LH 1
12 AX815/193/2 HEAD GUARD RH 1
13 AX789//35/1 SKIRT CLAMP 2
14 SIDE GUARD LH (NOW PART OF ITEM 11) 1
15 SIDE GUARD RH (NOW PART OF ITEM 12) 1
16 AX789/35/2 SKIRT CLAMP 2
17 AX789/43/1 SIDE GUARD LH (no magnet fitted) 1
AX789/35/5 SKIRT CLAMP (no magnet fitted) 1
17 AX815/77/1 DEFLECTOR BRACKET (magnet fitted) 1
AX815/189/2 SHEDDER PLATE BRACKET (magnet fitted) 1
AX815/189/1 SHEDDER PLATE (magnet fitted) 1
AX815/71 SHEDDER PLATE BACKING STRIP 1
18 AX789/43/2 SIDE GUARD RH 1
21 AX789/28/2 SIDE GUARD LH 1
23 AX789/28/3 SIDE GUARD LH 1
26 AX815/173 FEED BOOT - COMPLETE 1
27 AX815/174/1 FEED BOOT GUARD RH 1
28 AX815/174/2 FEED BOOT GUARD LH 1
29 AX789/22 LINER 2
30 AX815/154/2 NIP GUARD – HEAD SPIRAL RETURN ROLLER 1
AX815/167 NIP GUARD – SPIRAL RETURN ROLLERS 2
31 AX860/128 NIP GUARD – PLAIN 1
32 AX789/50 WIRE ROPE ASSEMBLY 2
33BL-Pegson
AX789/30/1 CYLINDER PIVOT PINS 4
Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
34 AX801/16 SPRAY BAR BRACKETS 1 PAIR
35 AX846/76 CANVAS WIND COVER 1
18/03/04
NB. Fixings are not included with the above parts unless specifically ordered
AX815-901-8EN-07b 244/318
Premiertrak
1100 x 650
Page 29
Product Conveyor - Conveyor FRame Parts - Premiertrak 1100 x 650
NOTE; Part No: 35 - Canvas Wind

Cover not shown
AX815-901-8EN-07b 245/318
Premiertrak
1100 x 650
Page 30
Product Conveyor - Conveyor Mechanical Parts Assembly

1 AX815/172 TAIL DRUM 1
2 2421-0011S TAILSHAFT BEARING 2
GREASE PIPES FOR TAILSHAFT BEARINGS (PART
2530-2010 1
OF KIT ONLY)
3 2495-3013 IMPACT IDLER SET COMPLETE 1
3A 2489-1065 SEPARATE OUTER ROLLER FOR ITEM 3 2
3B 2489-3004 FIXING CLAMP WITH FIXINGS FOR ITEM 3A 2
3C 2489-1066 SEPARATE CENTRE ROLLER FOR ITEM 3 1
3D 2489-1064 SEPARATE BASEPLATE FOR ITEM 3 1
4 AX607/513/3 IMPACT BAR 6
AX815/116 IMPACT BAR 3
TROUGHING IDLER SET COMPLETE (NO
5 2495-3009 5
TRANSOME)
5B 2489-3004 FIXING CLAMP WITH BOLTS FOR 5A 10
5D SEPARATE BASEPLATE FOR ITEM 5 5
TROUGHING IDLER SET COMPLETE (WITH
6 2495-3008 3
TRANSOME)
6B 2489-3004 FIXING CLAMP WITH BOLTS FOR 6A 6
6D SEPARATE BASEPLATE FOR ITEM 6 3
7 2495-3003 SPIRAL RETURN ROLLER 4
8 2495-1130A PLAIN RETURN ROLLER 1
9 AX815/54/1 TELESCOPER UNIT LH 1
AX815/54/1X TELESCOPER UNIT RH 1
10 AX607/3/46 TENSIONING ELEMENT 2
11 AX815/117 HEAD DRUM 1
13 AX789/38 TORQUE ARM 1
14 AX789/24/4 BELT SCRAPER BLADE 1
15 2421-0014S HEADSHAFT BEARING 2
GREASE PIPES FOR HEADHAFT BEARINGS (PART
2530-2010 1
OF KIT ONLY)
16 2450-5505 SHRINK DISC COUPLING 1
AX862/92 COUPLING GUARD 1
17 2360-0050 CONVEYOR BELT(21 METRES) 1
18/03/04
AX815-901-8EN-07b 246/318
Premiertrak
1100 x 650
Page 31
Product Conveyor - Conveyor Mechanica Parts - Premiertrak 1100 x 650

5/6B
5/6A
5/6C
5/6D
5/6B
5/6A
AX815-901-8EN-07b 247/318
Premiertrak
1100 x 650
Page 32
Dirt Conveyor - Conveyor Frame Parts Assembly

1 AX815/81 TAIL FRAME 1
2 AX789/7/1 FEED BOOT 1
3 AX789/7/2 SUPPORT RH 1
4 AX789/7/2A SUPPORT LH 1
5 AX789/7/7 SUPPORT RH 1
6 AX789/7/7A SUPPORT LH 1
7 AX789/30/1 PIVOT PIN – LOWER 2
AX789/30/3 PIVOT PIN – UPPER 2
8 AX789/32 HEAD FRAME 1
9 AX815/75 SIDE SKIRT 1
10 AX815/75 SIDE SKIRT 1
11 AX789/45/1 HEAD GUARD 1
AX842/107/1 SKIRT RUBBER 1
AX842/107/2 CLAMP PLATE 1
12 AX789/39/3 SCRAPER BLADE CLAMP 1
13 AX789/39/1 SCRAPER BLADE FRAME 1
14 AX815/91/1 TENSIONER SUPPORT LH 1
15 AX815/91/2 TENSIONER SUPPORT RH 1
16 AX789/30/2 PIVOT 2
17 AX815/6 NIP GUARD 1
18 AX789/7/4 SIDE SKIRT CLAMP 2
19 AX789/7/5 REAR SKIRT CLAMP 1
20 AX862/120 NIP GUARD 1
21 AX862/244 BLADE & CLAMP FOR TAIL SECTION 2
22 AX815/82/1 COUPLING GUARD 1
23 AX815/76/1 CLAMP 1
24 AX815/76/2 CLAMP 1
25 AX815/76/3 CLAMP 1
26 AX815/76/4 CLAMP 1
27 AX815-213-501 FEED BOOT SIDE GUARD LH (NOT SHOWN) 1
28 AX815-215-501 FEED BOOT SIDE GUARD RH (NOT SHOWN) 1
18/03/04
AX815-901-8EN-07b 248/318
Premiertrak
1100 x 650
Page 33
Dirt Conveyor - Conveyor Frame Parts Assembly - Premiertrak 1100 x 650
AX815-901-8EN-07b 249/318
Premiertrak
1100 x 650
Page 34
Dirt Conveyor - Conveyor Mechanical Parts Assembly

2 AX815/90 MOTOR TORQUE ARM 1
3 2450-5503 SHRINK DISC COUPLING 1
4 2421-0010S TAILSHAFT BEARING 2
REMOTE GREASING KIT FOR BOTH TAILSHAFT
2530-2009 1
BEARINGS
5 AX789/13 TAIL DRUM 1
AX833/15 CYLINDER PROTECTION COVER 2
7 AX815/92 HEAD DRUM 1
8 2421-0010S HEADSHAFT BEARING 2
9 AX789/39/2 BELT SCRAPER BLADE 1
10 AX607/3/46 TENSIONING ELEMENT 2
11 AX818/110/1 TELESCOPER LH 1
AX818/110/1X TELESCOPER RH 1
12 AX815/31 TROUGHING IDLER 5
12B 2489-3001 & 2 CLAMP WITH BOLT FOR ITEM 12A 10
12D 2489-3003 FIXING CLAMP FOR ITEM 12C 10
13 AX607/658/3 RETURN IDLER 1
14 AX789/7/3 RUBBER SKIRT(SIDE) 2
15 AX789/7/6 RUBER SKIRT(REAR) 1
16 2360-0062 CONVEYOR BELT(8.20 METERS) 1
12/05/03
AX815-901-8EN-07b 250/318
Premiertrak
1100 x 650
Page 35
Dirt Conveyor - Conveyor Mechanical Parts Assembly - Premiertrak 26 x 44

12A
12B
12D
12C
12A
12B
AX815-901-8EN-07b 251/318
Premiertrak
1100 x 650
Page 36
10.4 Overband Magnetic Separator

AX815/186 MAGNETIC SEPARATOR – COMPLETE UNIT 1
STANDARD LEFT HAND SIDE DISCHARGE
AX846/126 MAGNETIC SEPARATOR – COMPLETE UNIT 1
OPPOSITE RIGHT HAND SIDE DISCHARGE
1 FRAME 1
2 MAGNET 1
3 HYDRAULIC MOTOR 1
4 DRIVE PULLEY 1
5 NON-DRIVE PULLEY 1
6 BEARING 4
7 BEAING CAP 3
8 BEARING BACK PLATE 2
9 BEARING TAKE-UP PLATE 2
10 BEARING SPACER PLATE 2
11 SIDE PLATE LEFT HAND 1
12 SIDE PLATE RIGHT HAND 1
13 BELT 1
14 EYENUT 4
15 MOTOR MOUNTING PLATE 1
16 COUPLING ASSEMBLY 1
18/03/04
AX815-901-8EN-07b 252/318
Premiertrak
1100 x 650
Page 37
14
15
5 8
10
3 16
4 12
11
13
Overband Magnetic Separator- Premiertrak 1100 x 650
AX815-901-8EN-07b 253/318
Premiertrak
1100 x 650
Page 38
10.5 Plant Component Parts
Plant Guards Assembly

1 AX815/160/1 CRUSHER DRIVE GUARD 1
2 AX815/160/2 LARGE REMOVABLE ACCESS PANEL 1
3 AX815/160/3 SMALL REMOVABLE ACCESS PANEL 1
4 AX815/16/1 CRUSHER FLYWHEEL GUARD 1
5 AX815/16/2 REMOVABLE ACCESS PANEL 1
6 AX815/17/1 TOOL BOX 1
7 AX815/17/2 TOOLBOX DOOR 1
8 2301-0001 LOCK ASSEMBLY FOR TOOLBOX DOOR 1
9 2563-0001 TOOLBOX DOOR GAS STRUTS 2
10 AX815/18/1 CONTROL BOX 1
11 AX815/18/2 CONTROL BOX DOOR 1
12 2301-0001 LOCK ASSEMBLY FOR TOOL DOOR 1
13 2563-0001 CONTROL BOX LID GAS STRUTS 2
14 AX789/77 CRUSHER REAR HEAD GUARD 1
15 AX815/21 CRUSHER REAR DOOR 1
16 AX815/58/1 FEED CHUTE SAFETY GRID 1
17 AX815/8/1 STOOL FOR SAFETY GRID 2
18 AX815/19/1 DIRT CONVEYOR MESH GUARD 1
19 AX815/19/2 DIRT CONVEYOR UNDER GUARD 1
20 AX815/19/2 DIRT CONVEYOR TAIL COVER PLATE 1
12/05/03
NOTE: REFER TO CONVEYOR FRAME PARTS FOR CONVEYOR GUARDS
AX815-901-8EN-07b 254/318
Premiertrak
1100 x 650
Page 39
20 2 1 3
18
19
14 16
5 4
17
15
10,11,12,13 6,7,8,9
Plant Guards Assembly - 1100 x 650 Premiertrak
AX815-901-8EN-07b 255/318
Premiertrak
1100 x 650
Page 40
Plant Rubber Seals Assembly

1 AX815/101 BOTTOM OF DIRT CHUTE SKIRT RUBBER 1
2 AX815/102 PRODUCT CONVEYOR TAIL DRUM RUBBER 1
3 AX815/103 FEED BOOT BACK RUBBER 1
4 AX815/104 CRUSHER BODY SIDE RUBBER 2
BOTTOM OF CRUSHER RUBBER – PRODUCT
5 AX815/105 2
CONVEYOR FEED BOOT
PRODUCT CONVEYOR SKIRT RUBBER – HEAD
6 AX815/106 1
END – MAGNET DISCHARGE SIDE (when fitted)
PRODUCT CONVEYOR SKIRT RUBBER – HEAD
7 AX815/107 1
END – NON MAGNET SIDE
PRODUCT CONVEYOR SKIRT RUBBER – MID
8 AX815/108 2
SECTION
PRODUCT CONVEYOR SKIRT RUBBER – MAGNET
9 AX815/109 1
SECTION OPPOSITE DISCHARGE
10 AX815/113 CRUSHER JAWSTOCK SKIRT RUBBER 1
PRODUCT CONVEYOR SKIRT RUBBER – FEED
11 AX815/114 2
BOOT SIDE
12 AX815/75 DIRT CONVEYOR SIDE SKIRT RUBBER 2
13 AX801/11/3 FEED CHUTE RUBBER SEAL 2
14 AX789/7/3 DIRT CONVEYOR FEED BOOT SKIRT RUBBER 2
15 AX789/7/6 DIRT CONVEYOR FEED BOOT SKIRT RUBBER 1
16 AX842/107/1 DIRT CONVEYOR HEAD SKIRT RUBBER 2
AX815RUB – 09/10/03
AX815-901-8EN-07b 256/318
Premiertrak
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Page 41
6&7
8
15
14
10
11
5
12
1, 2 & 3
13
16
Plant Component Parts - Rubber Seals Assembly - 1100 x 650 Premiertrak
AX815-901-8EN-07b 257/318
Premiertrak
1100 x 650
Page 42
Plant Platforms Assembly
REF PART NUMBER DESCRITION QUANTITY

FEEDER MAINTENANCE PLATFORMS
1 AX789/51/1 OPEN MESH FLOORING PANEL - RH SIDE 1
2 AX789/51/2 OPEN MESH FLOORING PANEL - LH SIDE 1
3 AX815/148/1 FIXED HANDRAIL - RH SIDE 1
4 AX815/148/2 FIXED HANDRAIL - LH SIDE 1
5 AX815/69/1 REMOVABLE HANDRAIL - RH SIDE 1
6 AX815/147/1 SELF CLOSING GATE - RH SIDE 1
7 AX815/69/1A REMOVABLE HANDRAIL - LH SIDE 1
8 AX815/147/2 SELF CLOSING SAFETY GATE - LH SIDE 1
9 AX789/49/2 ACCESS LADDER - RH SIDE 1
10 AX789/49/2A ACCESS LADDER - LH SIDE 1
CRUSHER PLATFORM
11 AX789/16/2 OPEN MESH FLOORING PANEL - INNER 1
12 AX789/16/3 OPEN MESH FLOORING PANEL - CENTRE 1
13 AX789/16/4 OPEN MESH FLOORING PANEL - OUTER 1
14 AX818/180 HAND GRIP RAIL - ENGINE 1
15 AX862/156 HAND GRIP RAIL - FLYWHEEL GUARD 1
16 AX815/159 SELF CLOSING SAFETY GATE 1
17 AX815/13 ACCESS LADDER 1
ENGINE PLATFORM
18 AX789/16/1 OPEN MESH FLOORING PANEL 2
19 AX818/180 HAND GRIP RAIL - ENGINE 1
20 AX815/158 SELF CLOSING SAFETY GATE 1
21 AX815/14/1 ACCESS LADDER - UPPER SECTION 1
22 AX815/14/2 ACCESS LADDER - LOWER SECTION 1
NB. WHEN ORDERING OPEN MESH FLOORING PANELS SPECIFY SUPPLY TO BE

COMPLETE WITH FIXING CLIPS AND FASTENERS.
AX 815 - 12/05/03
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Premiertrak
1100 x 650
Page 43
4, 7 & 8 (3, 5 & 6 on the opposite side

of the plant)
2 (1 on the opposite side

of the plant)
10 (9 on the opposite side

of the plant)
14 15
20 19
16
18
11
17
21 & 22
Plant Component Parts - Platforms Assembly - 1100 x 650 Premiertrak
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Premiertrak
1100 x 650
Page 44
Plant Feed Hopper Assembly

1 AX804/1/1 FEED HOPPER - HYDRAULIC FOLDING 1
HOPPER SIDEPLATE HINGE PIN -
2 AX789/47/1 4
COMPLETE
HOPPER BACKPLATE HINGE PIN -
3 AX789/47/2 2
COMPLETE
4A AX842/102/1 & 1X HOPPER SIDEPLATE LOCKING WEDGE 2 PAIRS
4B AX842/102/2 LOCKING U BRACKET 4
4C 2230-1241 SCREW 4
4D 2210-0019 WASHER 4
6 AX804/1/3 HOPPER TIE BAR 1
7 AX804/1/4 TIE BAR WEDGES 2
8 AX815/35/1 HOPPER HYDRAULIC CYLINDER LH 2
AX815/35/2 HOPPER HYDRAULIC CYLINDER RH 1
AX815/198/1 HOPPER CYLINDER GUARD 3
9 AX789/82 HOPPER CYLINDER CONNECTING PINS 6
10 AX842/102/2 LOCKING BRACKET 4
11 2230-1241 SCREW 4
18/03/04
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Premiertrak
1100 x 650
Page 45
3
6
8 7
1
2
4A
4B
4C & 4D 9
Plant Feed Hopper Assembly - 1100 x 650 Premiertrak
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Premiertrak
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Page 46
10.6 Track Parts
‘S’ Mark Tracks

Before ordering track parts it is essential tolook for the identifying ‘S’ suffix to
the plant serial number on the plant identity plate, eg. QMXXXXXXS. If suffixed
‘T’ refer to the part numbers on the following pages.

1 2372-0076 TRACK DRIVE GEARBOX C/W HYDRAULIC MOTOR 2
2372-0078 ADAPTOR 2
2372-0079 BONDED SEAL 2
AX818TRAKS04 STAND OFF PIPE 2
2372-0088 GEARBOX DRAIN PLUG 4
2 2372-0077 GEARBOX BOLTS 40
3 2372-0080 DRIVE SPROCKET 2
4 2372-0081 SPROCKET BOLTS 48
5 2372-0032 TRACK CHAIN –COMPLETE 2
6 2372-0033 TRACK SHOE 110
7 2372-0034 TRACK SHOE BOLT 440
8 2372-0035 TRACK SHOE NUTS 440
9 2372-0064 IDLER 2
10 2372-0065 YOKE 2
11 2372-0084 RECOIL UNIT 2
2372-0085 TENSIONER SEAL KIT 2
12 AX818TRAKS02 GREASER 2
13 AX818TRAKS03 GASKET 2
AX818TRAKS01 ADAPTOR 1
14 2372-0027 ROLLER 18
15 2372-0018 ROLLER BOLT 72
16 2372-0019 ROLLER BOLT WASHER 72
2372-0037 REPAIR LINK - TRACK CHAIN

2372-0036 MASTER PIN - TRACK CHAIN
‘S’ - 18/03/04
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Premiertrak
1100 x 650
Page 47
Tracks Assembly - Premiertrak 1100 x 650

3
4
1
8
2
7
6
16
12
13
15
14
10
11
AX815-901-8EN-07b 263/318
Premiertrak
1100 x 650
Page 48
‘T’ Mark Tracks

Before ordering track parts it is essential tolook for the identifying ‘T’ suffix to
the plant serial number on the plant identity plate, eg. QMXXXXXXT. If suffixed
‘S’ refer to the part numbers on the previous pages.

1 2372-1037 TRACK DRIVE GEARBOX C/W HYDRAULIC MOTOR 2
2372-1041 ADAPTOR 2
2372-1012 BONDED SEAL 2
AX818TRAKS04 STAND OFF PIPE 2
2372-1059 GEARBOX DRAIN PLUG 4
2 2372-1040 GEARBOX BOLT 48
2372-1010 SPRING WASHER 48
3 2372-1042 DRIVE SPROCKET 2
4 2372-1043 SPROCKET BOLT 48
2212-0012 SPRING WASHER 48
5 2372-1045 TRACK CHAIN –COMPLETE 2
6 2372-1047 TRACK SHOE 108
7 2372-1048 TRACK SHOE BOLT 432
8 2372-1049 TRACK SHOE NUT 432
9 2372-1061 IDLER 2
10 2372-1062 YOKE 2
11 2372-1063 RECOIL UNIT 2
2372-1064 TENSIONER 2
2372-1065 TENSIONER SEAL KIT 2
12 2372-1024 GREASER 2
13 2372-1025 GASKET 2
AX818TRAKS01 ADAPTOR 1
14 2372-1052 ROLLER 18
15 2372-1053 ROLLER BOLT 72
16 2372-1054 ROLLER BOLT WASHER 72
2372-1056 REPAIR LINK - TRACK CHAIN

2372-1046 MASTER PIN - TRACK CHAIN
‘T’ – 18/03/04
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Premiertrak
1100 x 650
Page 49
Tracks Assembly - Premiertrak 1100 x 650

3
4
1
8
2
7
6
16
12
13
15
14
10
11
AX815-901-8EN-07b 265/318
Premiertrak
1100 x 650
Page 50
10.7 Hydraulic Parts
Hydraulic System Components

A AX815/3 OIL RESERVOIR 1
B 2550-9009 PVG32-2 VALVE (2 BANK) 1
C 2550-9002 PVG32-7 VALVE (7 BANK) 1
D 2550-9003 MOTION CONTROL VALVES - TRACK 2
2550-9004 TRANSFER PLATE FOR 2550-9003 2
E 2531-5057 FILTER 2
E 2531-5152 REPLACEMENT FILTER ELEMENT 2
F 2552-0024 MAGNET CONTROL FLOW ASSEMBLY 1
G 2553-3010 SINGLE C/N BALANCE VALVE 2
H 2579-0020 CHECK VALVE 1
I 2520-8002 2.5SAE 1
J 2553-2013 TEST POINTS 2
THERMOSTAT NOW IN ITEM A – HYDRAULIC OIL
K
RESERVOIR
L 2576-4075 PRODUCT CONVEYOR MOTOR 1
M 2573-6001 HYDRAULIC PUMP 2
N AX815/35/1 FOLDING HOPPER RAM LH 2
N AX815/35/2 FOLDING HOPPER RAM RH 1
O 2564-5015 DIRT CONVEYOR RAM 2
P 2576-4078 DIRT CONVEYOR MOTOR 1
Q 2576-4074 FEEDER MOTOR 1
2441-0412 HYDRAULIC PUMP DRIVE BELT 2
08/04/04
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Premiertrak
1100 x 650
Page 51
Hydraulic Circuit Diagram - Premiertrak 1100 x 650

O
F
G
B
P
H
Q
J
D
D
CRUSHER HYDRAULIC CIRCUIT

K
NOT SHOWN
E
E
M
M
A
AX815-901-8EN-07b 267/318
Premiertrak
1100 x 650
Page 52
Hydraulic Parts - HFO Clutch

2553-2018 3 WAY VALVE 1
2553-2019 RELIEF VALVE 1
2589-5300 PRESSURE SWITCH 1
2553-2013 TEST POINT 1
2553-2020 RESTRICTOR 1
2553-2023 RESTRICTOR 1
07/08/03
AX815-901-8EN-07b 268/318
Premiertrak
1100 x 650
Page 53
HFO Hydraulic Clutch Schematic Diagram
AX815-901-8EN-07b 269/318
Premiertrak
1100 x 650
Page 54
Hydraulic Oil Reservoir

AX815/3 OIL RESERVOIR L586 - COMPLETE
1 2552-6561 FLAT FACE QUICK RELEASE COUPLING 1
2 2589-2105 FLUID LEVEL GAUGE WITH LEVEL SWITCH 1
3 2531-1000 BREATHER 1
4 2579-0009 RETURN LINE FILTER 1
N/S 2531-5151 FILTER ELEMENT 1
4a 2538-0053 RETURN LINE FILTER GAUGE 1
5 INSPECTION COVERS 2
6 2531-5155 SUCTION FILTER 1
N/S 2531-5150 FILTER ELEMENT 1
6a 2538-0054 SUCTION FILTER GAUGE 1
6b 2520-8002 FLANGED ADAPTOR 1
08/04/04
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Premiertrak
1100 x 650
Page 55
4a 6a
6, 6b
3 4
5 6, 6a, 6b
Hydraulic Oil Reservoir - Premiertrak 1100 x 650
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Premiertrak
1100 x 650
Page 56
10.8 Electrical Parts

1 2683-2100 FUSE SET - 2*3A, 2*5A, 2*10A & 2*16A 1
2 2683-2101 EM/STOP TWIST TO RELEASE PUSH 2
BUTTON WITH CONTACT BLOCKS
(CONTROL PANEL)
3 2683-2103 2 POSITION STAYPUT SWITCH WITH 1
CONTACT BLOCK 2 N/O, 2 N/C
2 POSITION STAYPUT SWITCH WITH 1
CONTACT BLOCK 3 N/O
4 2683-2104 3 POSITION SPRING RETURN SWITCH 2
WITH CONTACT BLOCKS
5 2685-0001 1 HOLE EMERGENCY STOP 3
ENCLOSURE (ON PLANT)
6 2683-2107 & 7A 10 AMP 8 PIN 2 POLE MINI RELAY 24V 8
DC
7 2683-2108 TIMER 2
8 2683-2109 FEEDER SPEED CONTROL 1
POTENTIOMETER
2386-2113 KNOB FOR POTENTIOMETER 1
9 2683-2110 AUDIBLE WARNING UNIT 24V DC 1
10 2683-2114 HEAVY DUTY RELAY 2
11 2683-2117 GREEN START BUTTON COMPLETE 3
12 2683-2118 RED STOP BUTTON COMPLETE 3
13 2683-2102 STOP/START PUSH BUTTON 1
14 2683-2121 INDICATOR LAMP WITH LED 1
15 2686-0042 TELERADIO CONTROL (WHERE FITTED 1
COMPLETE KIT INCLUSIVE OF ITEMS 15
TO 20 BELOW
16 2686-9034 TELERADIO RECEIVER UNIT ONLY 1
(CONTROL PANEL COMPONENT)
17 2686-9043 RADIO HAND SET TRANSMITTER – RED 1
STOP BUTTON (USA & REST OF THE
WORLD)
18 2686-9044 RADIO HAND SET TRANSMITTER – 1
BLACK STOP BUTTON (EUROPE)
19 2686-9008 TELERADIO ANTENNA ONLY WITH 1
CABLE
20 2686-9007 12/35VDC CHARGER CABLE 1
21 2683-9029 TELERADIO UMBILICAL HAND SET 1
ONLY
N/S 2593-2004 HYDRAULIC OIL AIR BLAST COOLER 1
N/S 2666-0001 PRESSURE SWITCH (OPTIONAL ITEM) 1
AX815 – Mk 23 - 08/04/04
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Premiertrak
1100 x 650
Page 57
7 6 10 1 (5 A & 15A)
CONTROL
PANEL
(INTERNAL)
15
21
16
17
&
18 20
2 2 14 8
4 3 13 11 12
Electrical Parts - Premiertrak 1100 x 650
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Premiertrak
1100 x 650
Page 58
10.9 Warning Labels

300/32 DANGER – NIP POINT HAZARD 4
300/33 WARNING – READ MANUAL 2
300/34 DANGER – SKIN INJECTION HAZARD 3
300/35 DANGER – DRAWBACK ROD GUARD 1
300/36 IMPORTANT – CHECK FEEDER OIL LEVEL 2
300/37 IMPORTANT – CHECK HYDRAULIC FILTERS 2
300/38 WARNING – FALLING MATERIAL 3
300/39 WARNING – STOP & LOCKOUT 3
300/40 WARNING – GUARDS/LABELS IN PLACE 5
300/42 IMPORTANT – DRAIN WATER 1
300/43 WARNING – STRONG MAGNETIC HAZARD 2
300/44 WARNING – SPRING LOADED DOOR 2
300/118 DANGER – MAINTENANCE PLATFORM 2
300/120 WARNING – FALLING FROM PLANT 2
300/175 IMPORTANT – CLUTCH ENGAGEMENT SPEED 1
300/182 CAUTION –SECURE FOR TRANSPORT 1
300/189 WARNING – CRUSHING/SHEARING HAZARD 2
300/196 WARNING – HEARING HAZARD 2
300/213 IMPORTANT – FIT EQUAL SHIMS 2
300/224 EAR DEFENDER SIGN 2
AX815-901-8EN-07b 274/318
Premiertrak
1100 x 650
Page 59
300/32 300/33 300/34 300/35 300/36
300/42
300/37 300/38 300/39 300/40
300/175
300/43 300/44 300/118 300/120
300/224
300/213
300/182 300/189 300/196
AX815-901-8EN-07b 275/318
Premiertrak
1100 x 650
Page 60
10.10 Hydraulic Engine Clutch
The hydraulically actuated clutch fitted to the diesel engine is NOT supplied as
part of the Caterpillar diesel power pack. Contact BL-Pegson’s Dealer for all
requirements concerning this clutch.
REF DESCRIPTION REF DESCRIPTION

1 HOUSING 23 DRIVING PLATE
2 COVER 24 CENTRE PLATE
3 SCREW 25 SPRING
4 BEARING CARRIER 26 PRESSURE PLATE
5 BEARING 27 SCREW
6 SHAFT 28 KEY
7 SNAP RING 29 LOCK WASHER
8 SPACER 30 LOCK NUT
9 COVER 31 BALL BEARING
10 SCREW 32 SNAP RING
11 GREASER 33 DRIVING RING
12 LOCK WASHER 34 FLYWHEEL ADAPTOR
13 SCREW 35 KEY
14 ROTARY UNION 36 TAPER PLUG
15 LOCK WASHER 37 ELEASTIC PIN
16 SCREW 38 SPLINED HUB
17 O RING 39 BACKPLATE
18 HUB 40 SCREW
19 O RING 41 SPACER
20 PISTON 42 SCREW
21 O RING 43 LOCK WASHER
22 HUB AND BACKPLATE
AX815-901-8EN-07b 276/318
Premiertrak
1100 x 650
Page 61
TRANSFLUID CLUTCH REF HFO 314 - 1
BL-Pegson Part Number 2451-1007 - For Spare Parts also advise

specification and serial numbers stamped on the identity plate
Hydraulic Clutch for diesel engine - 1100 x 650 Premiertrak
AX815-901-8EN-07b 277/318
Premiertrak
1100 x 650
Page 62
Blank Page
AX815-901-8EN-07b 278/318
Premiertrak
1100 x 650 (26 x 44)
Appendix Issue EN 07
Page 1
Contents
11.1 Noise Assessment ............................................................................................. 2
AX815-901-8EN-07b 279/318
Premiertrak
1100 x 650 (26 x 44)
Page 2
11.1 Noise Assessment
Levels shown in the tabulation are for general guidance only and will vary depending upon the
conditions prevailing at the time.
20
20m
15m
19
10m
18
1100 x 650 Premtrak
5m
17
10
11
9
12
8
20m
15m
10m
10m
15m
20m
5m
5m
Noise Assessment
31
30
21
24
15
14
13
22
23
16
7
1
29
2
6
Flow
5
4
3
25
5m
All at 1m
26
10m
15m
27
RA:06/01/05
20m
28
AX815-901-8EN-07b 280/318
Noise Assessment 1100 x 650 Premtrak
Measurement Point Reading in Decibel (dB(A) Sound Pressure Level (SPL)dB(A) Sound Power Level (S
87.5 dB(A) 109.5 dB
1 91.9 9.19
2 91.6 9.16
3 91.2 9.12
4 91.1 9.11 -22.0
5 89.9 8.99
6 91.9 9.19
7 89.1 8.91
8 88.0 8.8
9 87.6 8.76
10 87.2 8.72
11 88.3 8.83
12 95.5 9.55
13 91.6 9.16
14 86.9 8.69
15 85.0 8.5
16 85.8 8.58
Figures are for engine running with no load on crusher
17 84.1 8.41
18 80.5 8.05
19 76.5 7.65
Appendix
20 74.0 7.4
21 85.8 8.58
AX815-901-8EN-07b 281/318
22 82.8 8.28
23 80.3 8.03
24 77.3 7.73
25 82.3 8.23
26 80.5 8.05
27 78.1 7.81
28 77.8 7.78
29 94.6 9.46
30 98.0 9.8
31 99.4 9.94
Date 26/03/2003 Assessor A.John Moore Signed

Page 3
Premiertrak
Issue EN 07
1100 x 650 (26 x 44)
Premiertrak
1100 x 650 (26 x 44)
Page 8
Blank page
AX815-901-8EN-07b 282/318
All Plants - Tier 3, Stage IIIa - ACERT
Addendum to User Manual
Due to the change of engines to comply with requirements

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

Caterpillar C9 engines have been revised to comply with the standards
Caterpillar C6.6 engines are replacing the 3126B engines
AM0013 - EN E-1
AX815-901-8EN-07b 283/318
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
AX815-901-8EN-07b 284/318
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
AX815-901-8EN-07b 285/318
Caterpillar Messenger Engine Monitoring System
Operation
The operator button functions are:
1
1. Previous button
Return to previous level and screen display
2
2. Scroll Up / Left button
Scroll display to view different menus and use to set up display settings.
3. Scroll Down / Right button

3
Scroll display to view different menus and use to set up display settings.
4. OK button
4
Confirm selection on the display / continue to next screen
Performance Display
The displays available are:
Engine speed
Coolant temperature
Totals Display
Cumulative totals displays available are:
Service hours engine has accumulated
Total time system in use
M-2
AX815-901-8EN-07b 286/318
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
AX815-901-8EN-07b 287/318
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
AX815-901-8EN-07b 288/318
All Plants - Cantrak Control
Plants with Cantrak Engine Monitoring System
AM0020 - EN C-1
AX815-901-8EN-07b 289/318
Cantrak Engine Monitoring System
Introduction
The Cantrak Engine Monitor is a graphical
instrument clusters to display parameters and
alarms.
The display has five buttons that change to suit
the screen in use. The buttons give to access a
graphical menu structure that uses standard and
easily-understood icons to indicate the button’s
current function.
The required engine data and display can display
the following formats:
Analogue gauges
Digital values
Historical trend graphs
Current and stored alarm messages
C-2
AX815-901-8EN-07b 290/318
Buttons
If any button from 1 to 4 is pressed, the display
shows a context dependent icon representing the
current function of the button.
The button icon part of the display will disappear
after five seconds of inactivity.
This ‘top level’ button icon bar shows the selection
options of the Engine Monitor:
1 2 3 4 5
Pressing button 5 when the menu icons are not
being displayed displays a Contrast and Lighting
adjustment menu. If held for 3 seconds, the
Configuration menu is shown
Button Icons
TRI DISPLAY - shows one large window and two
smaller windows. Repeat presses cycle the
display through the view options.
QUAD DISPLAY - shows data four equal sized

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

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

active alarm. Holding the key displays Stored
Alarms.
EXIT from the menu..
AM0020 - EN C-3
AX815-901-8EN-07b 291/318
PAGES - indicates that further pages of

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

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

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

and immediately button 5. The data displayed
on a particular window can be selected by
repeat pressing the
Button Lock
The buttons can be locked so that they cannot be
accidentally pressed.
Press buttons 1 and 5 simultaneously for one
second to switch the button lock on or off.
A key symbol is displayed when a button is pressed
and they are locked.
1 2 3 4 5
C-4
AX815-901-8EN-07b 292/318
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
AX815-901-8EN-07b 293/318
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
AX815-901-8EN-07b 294/318
Alarm Messages
When a current engine alarm is received, a flashing
window appears overlaid over the screen in use
and an alarm sound is activated.
If a current alarm message is flashing, press any

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

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

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

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

pressing:
The following options can then be selected:

UNITS - Metric or Imperial
LANGUAGE - Select from list
BLEEP - Button press sound on or off
Set the options for each of these by pressing:
Return to previous screens by pressing:
Exit by pressing:
C-8
AX815-901-8EN-07b 296/318
Premiertrak
Deflector Plate
MANUAL ADDENDUM Issue EN 01
Page 1
OPERATING INSTRUCTIONS
HYDRAULIC DEFLECTOR PLATE

AX866/16
(for Premiertrak)
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
AX815-901-8EN-07b 297/318
Premiertrak
Deflector Plate
Page 2
Crusher Discharge Deflector Plate

A hydraulically adjustable deflector plate is WARNING
fitted below the crusher. The primary WEAR PERSONAL
purpose of the deflector is to protect the PROTECTIVE EQUIPMENT.
conveyor belt against damage likely to be Refer to Section 7.1, Safety
caused when excessively long foreign
objects are allowed to enter the crusher.
When looking down into the crusher feed
opening the deflector plate should normally DO NOT attempt to remove a
be positioned to effectively prevent material blockage whilst the crusher or
falling directly onto the conveyor belt. product conveyor are running.
Always stop BOTH items.
The hydraulic raise/lower facility (Figure) is
to provide assistance in the event this
extraneous material forms a blockage This hydraulically operated
underneath the crusher. In this situation, Deflector Plate is designed to
stop the feeder, wait until the crusher assist the operator in the event
empties and then stop the crusher and this type of unsuitable material
product conveyor (Section 8.2); leave the enters the crusher, but it is
engine running. recommended that the material
put into the plant feed hopper
Assess the blockage by looking into the is monitored to avoid the
crusher discharge area. The blockage might situation occuring in the first
be cleared from the crusher discharge area place.
by dropping the divertor plate to the fullest
extent using the LOWER button.
Deflector Plate Raise/Lower buttons
Otherwise, operate the divertor plate with
the RAISE/LOWER hydraulic ram controls
to manipulate and exert pressure on the
blocking material until it can obviously pass
up the conveyor without causing any further
problem. Take care not to damage the
conveyor belting whilst doing this.
Before restarting operation, reduce the

engine speed to 1200rpm and then follow
the procedures in Section 7.2.1 to start the
product conveyor, crusher and feeder. Figure - Deflector Plate Controls
AX815-901-8EN-07b 298/318
Premiertrak
Deflector Plate
Page 3
Replacement Parts
AX815-901-8EN-07b 299/318
Premiertrak
Deflector Plate
Page 4
Blank page
AX815-901-8EN-07b 300/318
All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 1
FUEL TRANSFER PUMP

(for plant diesel engine)

AX815-901-8EN-07b 301/318
All Plants
Fuel Transfer Pump
Page 2
Optional Fuel Transfer Pump

This option is available as originally fitted
WARNING
equipment installed at the time of plant WEAR PERSONAL
manufacture. PROTECTIVE EQUIPMENT.
Refer to Section 9.1 of the Plant
User Manual-Safety Information
The pump is for the purpose of transferring for relevant warning.
diesel engine fuel from a barrel positioned at
LOCKOUT MACHINE.
ground level alongside the plant diesel Refer to Section 9.1 of the Plant
engine to the engine fuel tank. UserManual-Safety Information
for Lockout Procedure.
The pump is permanently mounted in a
suitable position on the plant in the vicinity
of the engine and is electrically driven from
a 24 volt DC supply. The unit is fitted with
an integral on/off switch.
Also supplied as part of the kit are lengths Do not use the fuel transfer
of plain hose 25mm bore for suction (with pump for any other purpose
strainer) and delivery. DANGER that filling the diesel engine
fuel tank on the BL-Pegson
The VR050 Series pump is rated at 50 plant.
litres per minute, suitable for equipment with
tanks between 200 and 500 litres. Duty is Observe the Operating,
continuous up to + 40o C ambient. Self Service & Safety Instructions
priming up to 3 metres dry. Flow 50 ltrs/min on the opposite page and also
at 3 metres head. Maximum head 10 the general Safety Information
metres. given in Section 9.1 of the
Plant User Manual.
AX815-901-8EN-07b 302/318
All Plants
Fuel Transfer Pump
Page 3
Fuel Transfer Pump Operating, Service & Safety Instructions
SAFETY
FLASHPOINT BELOW
37o C (99o F)
DO NOT USE A TRGGER NOZZLE

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

TO RUN DRY. SWITCH OFF
IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.
AX815-901-8EN-07b 303/318
All Plants
Fuel Transfer Pump
Page 4
Top Up Fuel Level

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

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

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

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

and is an explosion/burns
DANGER hazard.
Never remove the filler cap or Filler Cap
refuel, with the engine running.
AX815-901-8EN-07b 304/318
All Plants
Water Pumps
Page 1
WATER PUMP
2575-2002 or 2575-2009
(for dust suppression spraybars)
TYPICAL INSTALLATION

AX815-901-8EN-07b 305/318
All Plants
Water Pumps
Page 2
Optional Water Pump

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

supply of clean water to the dust
suppression spray nozzles included on
plants as a standard fitment. For details of The supply for external equipment can be
typical clean water requirements for the taken off one of the drain valves on the
dust suppression system, refer to the spraybar manifold.
Maintenance Section 9 of the plant manual.
No specific maintenance is required for the
The pump is permanently mounted in a pump unit except to check for hydraulic oil
suitable position on the plant near to the leaks when carrying out the normal plant
water manifold (Figure 1) and is driven maintenance (Section 9 of the plant manual)
from a branch of the engine driven plant Frost precautions must be taken in cold
hydraulic system.. weather to ensure water does not freeze
within the system, by opening the water
The inlet is with hose connector for the user manifold drain valves and detaching the
to provide supply suitable piping from the pump inlet feed pipe.
clean water source (eg. bowser near to the
plant) as necessary.
Initial on/off control of the pump is by

means of a 3 way valve lever (Figure 2)
mounted on the pump unit. Whilst this valve
lever is in the ‘on’ position the screw type
valve (Figure 2) can be used to regulate the
water supply to the plant inlet manifold.
AX815-901-8EN-07b 306/318
All Plants
Water Pumps
Page 3
Manifold Drain
Valves
Water Inlet
Connection
Figure 1 Water Pump Unit

(typical mounting)
Flow
Control Valve
3 Way
On/Off Valve
Figure 2 Water Pump Valves
AX815-901-8EN-07b 307/318
All Plants
Water Pumps
Page 4
Hydraulic Oil Water
3 Way Valve
Flow Valve
Hydraulic Motor Water Pump
Coupling
Figure 3 Pump Hydraulic Oil/Water Circuits
2575-2008 3 Way Valve 2575-2005 Coupling

25 l/min Pump 2575-2003
2575-2007 Flow Valve
65 l/min Pump 2575-2010
2575-2004 Hydraulic Motor
Figure 4 Pump Unit Part Numbers
AX815-901-8EN-07b 308/318
MANUAL ADDENDUM
INFRA-RED REMOTE CONTROL
FOR FEEDER
THIS MANUAL ADDENDUM IS TO BE INSERTED INTO

THE PLANT OPERATORS MANUAL
THESE INSTRUCTIONS REPLACE THE RADIO REMOTE
CONTROL FEEDER INSTRUCTIONS
AX815-901-8EN-07b 309/318
Infra-red feeder
Issue 01 UK/US Infra-red feeder control
Page 2
INFRA-RED Remote Feeder

Operation (where fitted) WARNING
This method of remotely stopping and WEAR PERSONAL
starting the feeder is only supplied with PROTECTIVE EQUIPMENT
plants not equipped with radio controlled Refer to Safety
Information in Manual for
remote feeder control.
relevant warning.
The operating range is dependant upon
conditions but has a range of up to
30metres (98feet). Transmiter Lens
L.E.D.
Procedure
1. Observe all safety instructions.
2. Take the infra-red control from the

1 Start
control box and first become familiar
with the functions of the individual
buttons.
3. Turn the Feeder Remote switch on the

plant to the ON position. (Section 7 0 Stop
of manual)
4. To operate the feeder remotely the

engine must be started, conveyors and
feeder must be switched on and the
speed of the feeder set. (Section 7 of
manual)
Infra-red feeder remote
5. Point the transmitter lens of the infra- control operation
red control unit at the receiver
mounted above the engine. Operate
the 1 button to start the feeder and the
0 button to stop the feeder.
BL-Pegson Limited, Coalville, England. Tel.: +44 (0)1530 518600 Fax: +44 (0)1530 518618
Website: www.bl-pegson.com E-mail: [email protected]
AX815-901-8EN-07b 310/318
Infra-red feeder
Infra-red feeder control Issue 01 UK/US
Page 3
General Information Infra-red control

Do not use the transmitter and/or receiver Technical Data
for any other purpose than for which they
are supplied or in conjunction with any Transmitter
other equipment.
Supply Voltage: 1 x 9v Alkaline battery,
Ensure that the operating position is in line type 6AM6, 6F22, PP3.
of sight of the receiver and within range Transmission type: PPM Infra-red. 3 x
and that the area surrounding the Lens type transmitters.
machinery is clear.
Operating temperature: -20°C to 60°C
Pressing the relevant button will light the (-4°F to 140°F).
red L.E.D. indicator. On releasing the
Housing: IP55 Sealed.
button, the L.E.D. should remain on for
0.5 to 1 second. Switch type: Tactile sealed.
Avoid knocking or dropping the infra-red Receiver

control, keep it clean (especially the lens),
dry, and store in a dry place when not in Code: 9 + 10.
use. Clean both the handset and receiver Matching transmitters: Any transmitter
with a damp cloth only and ensure all with codes 9 + 10.
screws and connections remain tight.
Supply voltage: 12V DC only.
Relay type: K4BC12.
Relay Contacts rating: 16A 240V AC.
Supply current standby: (12V) - <20mA.
Supply Current Active: (12V) - <80mA.
Operating temperature: -10°C to 60°C
(14°F to 140°F).
Storage temperature: -20°C to 60°C
(-4°F to 140°F).
Relay No1: N/O configuration - Function
On/Off.
Relay No2: C/O configuration - Not used.
AX815-901-8EN-07b 311/318
Infra-red feeder
Issue 01 UK/US Infra-red feeder control
Page 10
Troubleshooting
Check that infra-red lenses of the
transmitter and/or receiver are clean.
Ensure that transmitter is in range of the
receiver and in line of sight.
If the red L.E.D. is not lighting or flashing,
change the battery.
If the L.E.D. is working correctly, check
the receiver relay operation. There should
be a sharp click when the relay operates.
If the relays are working correctly the
problem may be in the plant wiring and
requiring the services of a qualified
electrician.
For a fault where the output chatters
intermittently, check for electro-
mechanical interference from contactors,
solenoids, motors, etc. Employ a qualified
electrician to solve this type of problem.
AX815-901-8EN-07b 312/318
BW100 INITIAL CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed when messages E3 and E4 are displayed during routine calibration.
The E3 and E4 messages indicate a mechanical problem
i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the weigher etc.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration. Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied
SELECT SELECT P388

PARAMETER
P377
INVOKE INITIAL ZERO INVOKE INITIAL SPAN

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

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

INITIAL ZERO COUNT= #### INITIAL ZERO COUNT= ####
PROCEED WITH
SPAN CALIBRATION OR
AX815-901-8EN-07b 313/318
RETURN TO RUN MODE RETURN TO RUN MODE
BW100 ROUTINE CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed on a routine basis as required.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration.
Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied
ZERO CALIBRATION REQUIRED INITIAL SPAN COUNT
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION
INITIAL ZERO COUNT
FREQUENCY COUNT DISPLAYED

DURING CALIBRATION DEVIATION
NEW SPAN COUNT

DEVIATION
NEW ZERO COUNT CALIBRATION COMPLETE REMOVE TEST WEIGHTS

CALIBRATION COMPLETE
RETURN TO RUN MODE PRESS TO RETURN TO RUN MODE
TO RETURN
PRESS
TO RUN MODE
SPAN REQUIRED
AX815-901-8EN-07b 314/318
12 - Notes Page 1
Hours Run / Date Notes Name
BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618
E-mail : [email protected] Website : www.bl-pegson.com
AX815-901-8EN-07b 315/318
Page 2 12 - Notes
AX815-901-8EN-07b 316/318
12 - Notes Page 3
AX815-901-8EN-07b 317/318
AX815-901-8EN-07b 318/318

Ptrak650 PDF

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ADVANCED CRUSHING TECHNOLOGY

PREMIERTRAK 1100 x 650

PLANT USER MANUAL

This manual contains safety information which the

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

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

This plant is in conformity with the

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung disease

When dusts are generated by the operation of this

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

Telephone:- + 44 1530 518600

Fax:- + 44 1530 518618

To order additional copies contact your local BL-Pegson Ltd Dealer.

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

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

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

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

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

1.8 Plant Warning Signs- locations and illustrations ............................................ 15

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

Indicates a statement of company policy as the message relates directly or indirectly

1.2 Organisation Measures Observe all safety instructions and warnings

1.2.2 Disconnect battery ground cable before

For the execution of maintenance work, 1.3 Selection and

1.4 Safety Instructions 1.4.2 Special Work In Conjunction

Switch off and lockout the plant before

1.4.2.3 For carrying out overhead assembly work

Particularly make sure that any part of the

Never work under unsupported

Never work alone.

1.5 Warning of Special 1.5.1.4

• Warn others against approaching and

• Have the live wire de-energized.

1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

1.5.1.8 Observe the regulations in force at the

1.6 Transporting, 1.6.7

Do not attempt to mount a tyre unless you

Always maintain the correct pressure. Do

When inflating tyres, use a clip-on chuck

Check wheels for low pressure, cuts,

1.7 Position of Emergency

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button

Figure 1a Emergency Stop Buttons

* Hydraulic Cusher only

Figure 1b Warning Signs

* Hydraulic Crusher only

Figure 1c Warning Signs

1.8.2 Safety Sign Illustrations

Safety Sign Illustrations, continued

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

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

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

2.5 Product Conveyor ............................................................................................... 4

2.6 Tracks ................................................................................................................... 4

2.7 Standard Powerpack ........................................................................................... 5

2.8 Dustsprays ........................................................................................................... 5

2.9 Dirt Conveyor * .................................................................................................... 5

2.10 Magnetic Separator * ......................................................................................... 5

2.11 Manual Folding Hopper * .................................................................................. 6

2.12 Feed Hopper Liner Plates * ............................................................................... 6

2.13 Belt Weigher * .................................................................................................... 6

2.14 Water Pump *...................................................................................................... 6

2.15 Anti-vandal Guards * ......................................................................................... 6

2.16 Manual Clutch * .................................................................................................. 6

4116 (13’- 6”)

Feed Hopper Raised

ALL DIMENSIONS ARE IN MILLIMETRES (FT./INS.)

Overall Travel Length - 14000mm (45’- 11”)

Operating Width (Dirt Conveyor lowered) - 4040mm (13’- 3”)