1000 Maxtrak Plant User Manual 2008 (L)

ADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGY

MAXTRAK 1000

PLANT USER MANUAL

OPERATIONINSTALLATION

PARTSMAINTENANCE AND SERVICE

! SAFETY !This manual contains safety information which the operator should read andfollow. Failure to do this will increase the risk of injury or may result in death.

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IMPORTANTTEREX PEGSON PLANTS CAN INCLUDE

OPTIONAL EQUIPMENT AND/OR SPECIALFEATURES ADDITIONAL TO THE

STANDARD SPECIFICATION.

THESE MAY AFFECT THE INFORMATIONGIVEN IN THIS OPERATORS MANUAL.

LOOK IN SECTION 11 - APPENDIX OF THISMANUAL FOR ANY ADDENDUM WHICH

MAY RELATE TO ADDITIONAL EQUIPMENTOR VARIATIONS TO THE STANDARD

SPECIFICATION.

TAKE NOTE OF ANY VARIATIONS TO THESTANDARD PROCEDURES AND/OR

COMPONENT SPECIFICATIONS.

Options EN

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ADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYIMPORTANT SAFETY NOTICE!The environment in which the plant will operate contains inherent risks to health andsafety which the operator must take steps to guard against. Dangers from overheadconveyor discharges, overspill material, vehicle movements, etc., as well as other siterelated hazards must be anticipated. Avoid these by carrying out risk assessments beforethe plant is put into operation to ensure appropriate exclusion zone measures are put inplace and site personnel safety awareness training has been undertaken.

Follow all applicable safety regulations and recommendations in this manual asappropriate to your plant and the situation/conditions prevailing at the time.

Read this manual carefully to learn how to operate and service your plant correctly.Failure to do so could result in personal injury or equipment damage.

Consider this manual a permanent part of your plant. Keep it with the plant at all times.

Federal, State, National and Local laws and safety regulations must be complied with at alltimes to prevent possible danger to person(s) or property from accidents or harmfulexposure.

See also the separate Operation and Maintenance Manual provided for the diesel enginefitted to your plant and in particular read and observe the instructions within the SafetySection of the engine manual.

INFORMATION AND ADVICEIf you need any information or advice regarding your Maxtrak, contact:-

Terex Pegson LimitedMammoth StreetCoalvilleLeicestershire LE67 3GNEngland

Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : [email protected]:

Terex Crushing & Screening Inc11001 Electron DriveLouisvilleKentucky 40299

U.S.A.

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

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ADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYEC Conformity

This plant is in conformity with the provisionsof the EC Machinery Directive 98/37/ECtogether with appropriate EN HarmonisedStandards and National BS Standards andSpecifications.

Noise Level

HEARING HAZARDEXCEEDS 90 dB (A)

May cause loss or degradation of hearingover a period of time.

Wear proper hearing personal protectiveequipment.

Dust Generation

INHALATION HAZARD

Death, serious injury or delayed lung diseasemay result from breathing dusts that are generatedwhen certain hazardous materials are crushed,screened or conveyed with this equipment.

When dusts are generated by the operation of thisequipment, use approved respiratory protection, asrequired by Federal, State and Local safety andhealth regulations.

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ADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGYADVANCED CRUSHING TECHNOLOGY

The Terex Pegson Automax cone crusher is incorporated into the Maxtrak plant. Thename Automax is used throughout this manual when referring to the crusher but theinstructions apply equally to the alternative Autosand version of the machine, except forthe variations relevant to the feed material and the product (Refer to Section 3) togetherwith appropriate changes to the Spare Parts (Section 10).

AUTOMAX/AUTOSAND - EXPLANATORY NOTE

Copyright

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

This User Manual contains information and technical drawings, which may not be copied, distributed,altered, stored on electronic media, revealed to others or used for the purpose of competition, either partiallyor in its entirety.

The right is reserved to alter any details contained in this manual without notice. Copyright 2004.

Terex Pegson LimitedMammoth StreetCoalvilleLeicestershireLE67 3GNEngland

CALIFORNIA

Proposition 65 Warning

WARNING: Battery Posts, terminals andrelated accessories contain lead and leadcompounds, chemicals known to the Stateof California to cause cancer andreproductive harm.WASH HANDS AFTER HANDLING.

CALIFORNIA

Proposition 65 Warning

WARNING: Diesel engine exhaust andsome of its constituents are known to theState of California to cause cancer, birthdefects, and other reproductive harm.

Units of Measure

Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are approximateconversions from the actual metric measurement of the item concerned.

Telephone:- + 44 1530 518600

Fax:- + 44 1530 518618

E mail [email protected]

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Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

1 - Safety ENPage 1 - 1

1 - Safety

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

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

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

1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 51.4.1 Standard Operation .................................................................................... 1 - 51.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and

Repairs During Operation; Disposal of Parts and Consumables ................ 1 - 5

1.5 Warning of Special Dangers .......................................................................... 1 - 81.5.1 Electric Energy ........................................................................................... 1 - 81.5.2 Gas, Dust, Steam, Smoke and Noise ......................................................... 1 - 91.5.3 Hydraulic and Pneumatic Equipment ........................................................ 1 - 101.5.4 Hazardous Substances ............................................................................ 1 - 11

1.6 Transporting, Manoeuvring and Recommissioning .................................. 1 - 11

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

1.8 Safety Signs .................................................................................................. 1 - 141.8.1 Location of Safety Signs .......................................................................... 1 - 141.8.2 Safety Sign Illustrations............................................................................ 1 - 161.8.2 Safety Sign Illustrations, continued ........................................................... 1 - 17

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1.1 Warnings and Symbols

The following signs and designations are used in the manual to designate instructions of particularimportance.

! !This is the safety alert symbol. When you see this symbol on your plantor in this manual, be alert to the potential for personal injury orequipment damage.

Follow the recommended precautions and safe operating practices.

! DANGER !Indicates an imminently hazardous situation which, if not avoided, WILLresult in death or serious injury.

! WARNING !Indicates a potentially hazardous situation which, if not avoided, COULDresult in death or serious injury.

! CAUTION !Indicates a potentially hazardous situation which, if not avoided, MAYresult in minor or moderate injury. It may also be used to alert againstunsafe working practices.

! NOTICE !Indicates a statement of company policy as the message relates directlyor indirectly to the safety of personnel and protection of property.

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1.2 Organisation Measures

1.2.1

Ascertain from the appropriate Authority andobserve all statutory and any otherregulations that may apply to the plannedlocation before operating the Maxtrak Plant.

Loose or baggy clothing can get caught inrunning machinery.

Where possible when working close toengines or machinery, only do so when theyare stopped. If this is not practical,remember to keep tools, test equipment andall other parts of your body well away fromthe moving parts.

For reasons of safety, long hair must be tiedback or otherwise secured, garments mustbe close fitting and no jewellery such asrings may be worn. Injury may result frombeing caught up in the machinery or fromrings catching on moving parts.

Always wear correctly fitting (EN/ANSIapproved) personal protective equipment.

Personal Protective Equipment includesHard Hat, Safety Glasses, HearingProtection, Dust Mask, Close fittingOveralls, Steel Toed Boots, Industrial Glovesand a High Visibility Vest.

1.2.2

You can be injured if you do not obey thesafety instructions as indicated on warningstickers.

Observe all safety instructions and warningsattached to the plant.

See to it that safety instructions andwarnings attached to the plant are alwayscomplete and perfectly legible.

Keep warnings and instruction labels clean.

Replace unreadable or missing labels withnew ones before operating the plant. Makesure replacement parts include warning orinstruction labels where necessary.

1.2.3

Understand service procedure before doingwork. Keep area clean and dry.

Never lubricate, clean, service or adjustmachinery while it is moving. Keep hands,feet and clothing clear of power driven partsand in running nip-points. Disengage allpower and operate controls to relievepressure. Stop the engine. Implement lockoutprocedure. Allow the machinery to cool.

Keep all parts in good condition. Ensure thatall parts are properly installed. Fix damageimmediately. Replace worn and brokenparts. Remove any build up of grease, oil anddebris.

Disconnect battery ground cable beforemaking adjustments on electrical systems orwelding on plant.

For the execution of maintenance work, toolsand workshop equipment adapted to the taskon hand are absolutely indispensable.

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1.2.4

Never make any modifications, additions orconversions which might affect safetywithout the suppliers approval.

In the event of safety relevant modificationsor changes in the behaviour of the plantduring operation, stop the plant and lock outimmediately and report the malfunction tothe competent authority/person.

1.3 Selection andQualification of Personnel -Basic Responsibilities

1.3.1

Any work on and/or with the plant must beexecuted by trained, reliable and authorisedpersonnel only. Statutory minimum age limitsmust be observed.

1.3.2

Work on electrical system and equipment ofthe plant must be carried out only by a skilledelectrician or by instructed persons under thesupervision and guidance of a skilledelectrician and in accordance with electricalengineering rules and regulations.

1.3.3

Work on the hydraulic system must becarried out only by personnel with specialknowledge and experience of hydraulicequipment.

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1.4 Safety InstructionsGoverning SpecificOperational Phases

1.4.1 Standard Operation

1.4.1.1

Take the necessary precautions to ensurethat the plant is used only when in a safe andreliable state.

Operate the plant only for its designedpurpose and only if all guarding, protectiveand safety orientated devices, emergencyshut-off equipment, sound proofing elementsand exhausts, are in all place and fullyfunctional.

Before starting the engine ensure it is safe todo so.

1.4.1.2

In the event of material blockage, anymalfunction or operational difficulty, stop theplant immediately and lockout. Have anydefects rectified immediately.

1.4.1.3

In-running nip points on moving machinerycan cause serious injury or even death.

Do not reach into unguarded machinery.Your arm could be pulled in and amputated.

Switch off and lockout the plant beforeremoving any safety devices or guarding.

1.4.1.4

Return idler roller guards should be checkedfor wear/damage during routinemaintenance.

The gap between the guard and the idlerroller should not exceed 6mm. The gapbetween the guard and the conveyor beltshould also not exceed 6mm.

If these gaps cannot be achieved throughadjustment the guard must be renewed.Contact your local BL-Pegson dealer toobtain an approved replacement.

1.4.2 Special Work In Conjunctionwith Utilisation of the Plant andMaintenance and Repairs DuringOperation; Disposal of Parts andConsumables

1.4.2.1

Observe the adjusting, maintenance andintervals set out in these operatinginstructions, except where:

A : Warning, horn/light/gauge or indicatorcalls for immediate action.

B : Adverse conditions necessitate morefrequent servicing.

Observe information on the replacement ofparts and equipment. These activities may beexecuted by skilled personnel only.

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1.4.2.2

When the plant is completely shutdown formaintenance and repair work, it must besecured against inadvertent starting by:

Switching off the engine and remove theignition switch/key.

Implementing the lockout procedure.

Attaching a warning sign(s) to the plantin appropriate positions.

1.4.2.3

Carry out maintenance and repair work onlyif the plant is positioned on stable and levelground and has been secured againstinadvertent movement and buckling.

1.4.2.4

Never allow unqualified or untrainedpersonnel to attempt to remove or replaceany part of the plant, or anyone to removelarge or heavy components without adequatelifting tackle.

To avoid the risk of accidents, individualparts and large assemblies being moved forreplacement purposes should be carefullyattached to lifting tackle and secured. Useonly suitable and technically adequate liftinggear.

Never work or stand under suspended loads.

Keep away from the feed hopper andproduct conveyor discharge, where there isrisk of serious injury or death due to theloading and removal of material.

1.4.2.5

Falling from and/or onto a BL-Pegson plantcan cause injury or even death.

Do not climb on the plant whilst it is inoperation. Never use plant parts as aclimbing aid.

Beware of moving haulage and loadingequipment in the vicinity of the plant.

For carrying out overhead assembly workalways use specially designed or otherwisesafety-oriented ladders and workingplatforms.

Always use any walkway/platforms providedor a safe and secure platform approved by theregional safety enforcing authority.

Always use an EN/ANSI approved safetyharness when reaching any points 7ft (2m)or more above the ground level.

Keep all handles, steps, handrails, platforms,landing and ladders free from dirt, oil, snowand ice.

1.4.2.6

The fastening of loads and instructing ofcrane operators should be entrusted toexperienced persons only. The marshallergiving the instructions must be within sight orsound of the operator.

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1.4.2.7

After cleaning, examine all fuel, lubricant,and hydraulic fluid lines for leaks, looseconnections, chafe marks and damage. Anydefects found must be rectified withoutdelay.

1.4.2.8

Any safety devices removed for setup,maintenance or repair purposes must berefitted and checked immediately uponcompletion of the maintenance and repairwork to ensure full working order.

1.4.2.9

Improperly disposing of waste can threatenthe environment and ecology. Potentiallyharmful waste used with BL-Pegsonequipment includes such items as oil, fuel,coolant, filters and batteries, etc.

Use leakproof containers when drainingfluids. Do not use food or beveragecontainers that may mislead someone intodrinking from them.

Do not pour waste onto the ground, down adrain or into any water source.

Ensure that all consumables and replacedparts are disposed of safely and withminimum environmental impact.

1.4.2.10

Always ensure that any safety fitment suchas locking wedges, securing chains, bars orstruts are utilised as indicated in theseoperating instructions.

Particularly make sure that any part of theplant raised for any reason is prevented fromfalling by securing in a safe reliable manner.

Never work under unsupported equipment.

Never work alone.

1.4.2.11

Diesel fuel is highly flammable.

Never remove the filler cap, or refuel, withthe engine running.

Never add gasoline or any other fuels mixedto diesel because of increased fire orexplosion risks.

Do not carry out maintenance on the fuelsystem near naked lights or sources ofsparks, such as welding equipment or whilstsmoking.

1.4.2.12

Using unapproved structures i.e. walkways/platforms etc. in the vicinity of a BL-Pegsonplant is very dangerous and could lead toserious injury or even death through fallingand/or entanglement with the plant.

Do not use any unauthorised structures.

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1.5 Warning of SpecialDangers

1.5.1 Electric Energy

1.5.1.1

Use only original fuses with the specifiedcurrent rating. Switch off the plantimmediately if trouble occurs in the electricalsystem.

Plants with high voltage electrical equipmentmust be suitably earth bonded by a qualifiedelectrician prior to activating the mainisolator switch.

1.5.1.2

When working with the plant, maintain asafe distance from overhead electric lines. Ifwork is to be carried out close to overheadlines, the working equipment must be keptwell away from them. Check out theprescribed safety distances.

1.5.1.3

If your plant comes into contact with a livewire:

Warn others against approaching andtouching the plant.

Have the live wire de-energized.

1.5.1.4

Work on the electrical system or equipmentmay only be carried out by a skilled andqualified electrician or by specially instructedpersonnel under the control and supervisionof such an electrician and in accordancewith applicable electrical engineering rules.

1.5.1.5

If provided for in the regulations, the powersupply to parts of plants and plants, on whichinspection, maintenance and repair work is tobe carried out must be cut off. Beforestarting any work, check the de-energizedparts for presence of power and ground orshort circuit them in addition to insulatingadjacent live parts and elements.

1.5.1.6

The electrical equipment of the plant is to beinspected and checked at regular intervals.Defects such as loose connections orscorched or otherwise damaged cables mustbe rectified immediately.

1.5.1.7

Necessary work on live parts and elementsmust be carried out only in the presence of asecond person, who can cut off the powersupply in the case of danger by actuating theemergency shut off or main power switch.Secure the working area with a red andwhite safety chain and a warning sign. Useinsulated tools only.

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1.5.1.8

Before starting work on high voltageassemblies and after cutting out the powersupply, the feeder cable must be groundedand components such as capacitors short-circuited with a grounding rod.

1.5.1.9

These plants are wired on negative earth.Always observe correct polarity.

Always disconnect battery leads beforecarrying out any maintenance to theelectrical system.

The battery contains sulphuric acid, anelectrolyte which can cause severe burnsand produce explosive gases.

Avoid contact with the skin, eyes or clothing.

1.5.2 Gas, Dust, Steam, Smoke andNoise

1.5.2.1

Always operate internal combustion enginesand fuel operated heating systems only outof doors or in a well ventilated area. Beforestarting the plant in enclosed areas, makesure that there is sufficient ventilation.

Observe the regulations in force at therespective site.

Dust found on the plant or produced duringwork on the plant should be removed byextraction, not blowing.

Dust waste should be dampened, placed in asealed container and marked, to ensure safedisposal.

1.5.2.2

Carry out welding, flame cutting and grindingwork on the plant only if this has beenexpressly authorised, as there may be a riskof explosion and fire.

1.5.2.3

Before carrying out welding, flame cuttingand grinding operations, clean the plant andits surroundings from dust and otherinflammable substances and make sure thepremises are adequately ventilated (as theremay be a risk of explosion).

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1.5.2.4

Always ensure that the operator(s) areprovided with hearing protection of approvedpattern and that these are worn at all timeswhen the plant is operating.

Ensure operators wear a suitable face maskwhere exposed to possible harmful effects ofair pollution of any kind.

1.5.3 Hydraulic and PneumaticEquipment

1.5.3.1

Work on hydraulic equipment may be carriedout only by persons having specialknowledge and experience in hydraulicsystems.

1.5.3.2

Check all lines, hoses and screwedconnections regularly for leaks and obviousdamage. Repair damage immediately.Splashed oil may cause injury and fire.

1.5.3.3

Depressurise all system sections andpressure pipes (hydraulic system,compressed air system) to be removed inaccordance with the specific instructions forthe unit concerned before carrying out anyrepair work.

1.5.3.4

Hydraulic and compressed air lines must belaid and fitted properly. Ensure that noconnections are interchanged. The fittings,lengths and quality of the hoses must complywith the technical requirements.

1.5.3.5

Always practice extreme cleanlinessservicing hydraulic components.

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1.5.3.6

Hydraulic fluid under pressure can penetratethe skin causing serious injury.

If fluid is injected under the skin, it must besurgically removed or gangrene will result.Get medical help immediately.

Always relieve pressure from the hydraulicsystem before carrying out any kind ofmaintenance or adjustment.

Always use a piece of cardboard to checkfor leaks. Do not use your hand.

1.5.4 Hazardous Substances

Ensure that correct procedures areformulated to safely handle hazardousmaterials by correct identification, labelling,storage, use and disposal, all strictly inaccordance with the manufacturersinstructions and that all applicable regulationsare observed at all times.

1.6 Transporting,Manoeuvring andRecommissioning

1.6.1

The plant must be towed, loaded andtransported only in accordance with theoperating instructions.

1.6.2

For towing the plant, observe the prescribedtransport position, admissible speed anditinerary.

1.6.3

Use only appropriate means of transport andlifting gear where applicable of adequatecapacity.

1.6.4

The recommissioning procedure must bestrictly in accordance with the operatinginstructions.

1.6.5

Before starting work or travelling with theplant, check that the braking, and anysignalling and lighting systems are fullyfunctional.

1.6.6

Before setting the plant in motion alwayscheck that the accessories have been safelystowed away.

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1.6.7

When travelling on public roads, ways andplaces, always observe the valid trafficregulations and, if necessary, ensurebeforehand that the plant is in a conditioncompatible with these regulations.

1.6.8

In conditions of poor visibility and after dark,always switch on the lighting system of thetransporting vehicle..

1.6.9

When crossing underpasses, bridges andtunnels or when passing under overheadlines always make sure that there issufficient clearance.

1.6.10

Never travel across slopes; always keep theworking equipment and the load close to theground, especially when travelling downhill.

1.6.11

On sloping terrain, always adapt yourtravelling speed to the relevant groundconditions. Never change to a lower gear ona slope. Always change gear beforereaching a slope.

1.6.12

Explosive separation of a tyre and rim partscan cause injury or death.

Do not attempt to mount a tyre unless youhave the proper equipment to perform thejob.

Always maintain the correct pressure. Donot inflate the tyre above the recommendedpressure. Never weld or heat wheel and tyreassembly. The heat can cause an increase inair pressure resulting in a tyre explosion.Welding can structurally weaken or deformthe wheel.

When inflating tyres, use a clip-on chuck andextension hose long enough to allow you tostand to one side and not in front or over theassembly. Use safety cage if available.

Check wheels for low pressure, cuts,bubbles, damaged rims or missing lug boltsand nuts.

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Figure 1a Emergency Stop Buttons

Emergency Stop Button(Control Panel)

Emergency Stop Button




1.7 Position of Emergency Stop Buttons

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Figure 1b Warning Signs - Left Hand Side

1.8 Safety Signs1.8.1 Location of Safety Signs

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Figure 1c Warning Signs - Right Hand SideAX857-901-8EN-02f 23/390

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6321

1714

10

15

987

13

1.8.2 Safety Sign Illustrations

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19 232127

11 20

1.8.2 Safety Sign Illustrations, continued

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Blank page

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2 - Technical Information ENPage 2 - 1

Terex Pegson Limited have designed and built the Maxtrak plant to provide theBuyer 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.

2 - Technical Information

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

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

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

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

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

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

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

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

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

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

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2779 (9- 1)

3800

(12

-6)

3990

(13

- 1)

3914 (12- 10)

2800

(9-

2)

Ove

rall

Trav

ellin

g Le

ngth

(Fee

d C

onve

yor l

ower

ed) -

150

95 m

m (4

9- 6

)O

vera

ll W

orki

ng L

engt

h (F

eed

Con

veyo

r rai

sed)

- 15

173

mm

(49

- 9)

Ove

rall

Trav

ellin

g H

eigh

t (Fe

ed C

onve

yor l

ower

ed) -

344

6 m

m (1

1- 4

)O

vera

ll W

orki

ng H

eigh

t (Fe

ed C

onve

yor r

aise

d) -

3914

mm

(12

- 10

)O

vera

ll W

idth

- Tr

avel

ling

& W

orki

ng (O

ver T

rack

s) -

2800

mm

(9-

2)

Gro

ss W

eigh

t app

rox.

- 31

.3 to

nnes

(34.

4 U

S to

ns)

Not

e: W

eigh

ts a

nd d

imen

sion

s ar

e fo

r gui

danc

e on

ly a

nd a

ppro

pria

te a

llow

ance

s sh

ould

be

appl

ied

whe

n be

ing

used

for t

rans

porta

tion

purp

oses

.

Figu

re 2

a D

imen

sion

s an

d W

eigh

ts

2.1 Dimensions and Weights

All

dim

ensi

ons

are

in m

illim

etre

s (fe

et/in

ches

)

3446 (11- 4)Travel Height

3229 (10- 7)Discharge Height

3914 (12- 10)

Hop

per W

idth

Working Height

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FeedHopper

DieselEngine

Figure 2b Plant Terms

DischargeConveyor

CrusherFeed Box

Plant/AutomaxControl Panel

MaintenancePlatform

AutomaxCrusher

MaintenancePlatform

REAR

MaintenancePlatform

FRONTREAR

RIGHT HAND SIDE

Tool Box

HydraulicReservoir

HydraulicOil Cooler

2.2 Plant DescriptionMany of the terms used in this manual may not at first be obvious. Figure 2b identifies the main areasof the plant and the term with which they are referred to in this manual.

FRONT

LEFT HAND SIDE

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2.3 Belt Feeder ConveyorType Shallow troughed plain belt.Width 1000mm (39).Length 5400mm (17-9).Drive Unit Hydraulic motor with head drum oil lubricated gearboxControl Auto/manual variable speed.Hopper Fixed hopper with rear feed facility and internal strickle

gate and full length barge boards with wear pads.Hydraulic Equipment Cylinders to raise and lower for travel and maintenance.Control Equipment Metal detector. Level sensor an optional extra.

2.4 CrusherType Automax roller bearing Cone Crusher.Size 1000mm (39).Liners Manganese mantle and concave.Adjustment/Controls Hydraulic setting adjustment, automatic overload release

and unblocking with multi-function keypad and statusdisplay screen. (see also 2.7 - Controls).

Lubrication Separate lubricating oil tank with air blast oil cooler.Drive Vee rope drive from engine via hydraulically controlled

clutch.Control Equipment High level sensor over the feed box.

2.5 Discharge ConveyorType Plain troughed belt.Width 800mm (32).Drive Hydraulic motor.Lubrication Grease (shaft bearings).Enclosure Canvas cover.Control equipment Tail drum movement sensor.

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2.6 Standard PowerpackType Caterpillar C9 EU/EC Emmission Regulations

compliant, 6 cyl. water cooled diesel engine.Rating 335hp @ 1800 rpm.Drives Hydraulically actuated heavy duty clutch and vee ropes

to crusher and vee belts to twin hydraulic pumps.Housing Enclosed canopy with integral fuel tank and battery.

2.7 ControlsAutomax Crusher Setting, etc. 24 v DC Electro/Hydraulic Panel having numeric

keypad and message display on plant chassis.Plant Operation 24 v DC Electric Panel in Control Box with push button

controls and fault display, level sensor and metaldetector controls.

Plant Set-Up Lever on the plant chassis to raise/lower the feederconveyor.

2.8 DustspraysType Clean water multi atomising nozzle spraybars.Positions Crusher feed & discharge and discharge conveyor head.Inlet Single point for users pressure supply.Required supply Up to approx. 7 litres/min @ 2.8 bar (2 US galls @ 42

psi.Frost protection System drain valves.

2.9 TracksType 160mm (6.3) pitch heavy duty.Width 400mm (16).Centres 3800mm (12-6).Drive Hydraulic integral motors.Control Remote handset - dual speed.

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2.10 Optional Extras *I) Automax Extra Coarse (XC) concave in lieu of the standard Medium Coarse (MC).

II) Autosand (AS) concave in lieu of the standard Medium Coarse (MC).

III) Short throw eccentric in lieu of the standard long throw eccentric.

IV) Belt Weigher with integrator and speed sensing wheel fitted to the product conveyor.

V) Hydraulically driven water pump assembly to provide pressurised water supply to the dustsuppression sprays.

VI) Low level sensor over feed hopper.

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3 - General Information ENPage 3 - 1

3 - General Information

3.1 Introduction.....................................................................................................3 - 2

3.2 General information ........................................................................................ 3 - 3

3.3 Designated Use .............................................................................................. 3 - 43.3.1 Operating Temperature Range ................................................................... 3 - 4

3.4 Crusher Performance ..................................................................................... 3 - 53.4.1 Estimated Performance - Automax with long throw eccentric ...................... 3 - 63.4.2 Typical Product Analysis - Automax with long throw eccentric ...................... 3 - 73.4.3 Estimated Performance - Automax with short throw eccentric .................... 3 - 83.4.4 Typical Product Analysis - Automax with short throw eccentric .................... 3 - 93.4.5 Estimated Performance - Autosand with long throw eccentric ..................3 - 103.4.6 Typical Product Analysis - Autosand with long throw eccentric .................. 3 - 113.4.7 Estimated Performance - Autosand with short throw eccentric .................3 - 123.4.8 Typical Product Analysis - Autosand with short throw eccentric .................3 - 13

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3.1 Introduction

This instruction manual contains importantinformation on how to operate the Maxtrak1000 plant safely, properly and mostefficiently. Observing these instructions helpsto avoid danger, to reduce repair costs anddowntimes and to increase the reliability andlife of the plant.

These operating instructions must always beavailable wherever the plant is in use.

These operating instructions must be readand applied by any person in charge of and/or working on the plant such as:-

Operation

Includes manoeuvring, setting up, operationduring the course of work, evacuation ofproduction material and waste, care anddisposal of fuels and consumables, etc.

Maintenance

Servicing, inspection and replacement ofwearing parts.

and/or

Transport

Follow all applicable laws and safetyregulations for accident prevention andenvironmental protection.

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3.2 General information

The Maxtrak 1000 plant has beenmanufactured, assembled and tested with theutmost care and was built with first classmaterials.

Close attention has been paid to all details inassembly, running tests and final inspection.

Terex Pegson is confident that the plant willgive every satisfaction over a long period.

To be assured of faultless operation theoperator should carefully read the followingparagraphs and give the required time andattention to essential maintenance, cleaningand inspection.

The plant is easy to operate, adjustments areeasy to make and expert assistance isseldom required, provided that ordinary careis exercised in daily use.

The plant has been built in accordance withstate-of-the-art standards and recognisedsafety rules. It is designed to be reliable,efficient and safe when used andmaintained in accordance with theinstructions given in this manual.

Nevertheless, its use may constitute a riskto life and limb of the user or of third parties,or cause damage to the plant and to othermaterial property.

! NOTICE !If high or low ambient temperatureconditions apply, specific detailsneed to have been advised at thetime of order as special equipmentmay be necessary.

The Caterpillar engine coolingsystem is protected to -15 C with30% Caterpillar antifreezeconcentration when shipped fromthe factory unless specialrequirements have been defined.

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3.3 Designated Use

The Terex Pegson Maxtrak plant includes the1000 Automax Cone Crusher designed tomaximise throughput and product shape in awide range of crushing applications. For finercrushing operations the Autosand option isavailable.

! NOTICE !It is vitally important that pieces ofsteel or similar uncrushableobjects such as bucket teeth arenot allowed to enter the crushingchamber as severe damage andinjury may occur.

For the above reason a metal detector isfitted to the feeder. It is imperative that thismetal detector is kept operative at all timesand that when activated the plant operatorremoves the offending material beforerecommencing operation.

! NOTICE !Operating the plant outside itsrecommended range ofapplications/operating parametersor for any use for which theequipment is not intended, willresult in a loss of any guaranteeand the manufacturer/suppliercannot be held liable for anydamage or injury resulting fromsuch misuse. The risk of suchmisuse lies entirely with the user.

Refer to the following information in thisSection for guidance regarding theperformance of the Automax crusher.Experienced engineers are available at BL-Pegson to give advice when necessary.

If you have any doubts about any aspectof the plants capability or servicingprocedures, you must consult your localBL-Pegson dealer or BL-Pegsonstechnical departments

3.3.1 Operating Temperature Range

The normal operating temperature range ofthe plant is from -10C to +40C (+14F to+104F). For use in temperatures outside ofthis range, contact your local dealer or TerexPegson for details.

Note: Appropriate oil & coolant to suit thelocal operating conditions must be used, asspecified elsewhere in this manual.

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3.4 Crusher Performance

In order to obtain the optimum overallcrushing performance from the Automax,it is essential to have a continuous andregulated choke feed of evenly gradedmaterial that is well mixed around thecrushing chamber. Typical feed gradingsare shown on the product analysis graphsin this section.

The level sensing device prior to thecrusher will assist in achieving this whenused to control the feed. Additionally, allfeed material should be of a size that willreadily enter the crushing chamber.

The gradings and capacities shown in thissection are averages base on actualresults taken from tests carried out onvarious materials at different crushersettings. They will vary dependant uponthe grading and nature of the feedmaterial. For more specific details pleasecontact BL-Pegson Ltd.

Performance is dependant upon the throwof the eccentric built into the Automax andalso the type of concave fitted to themachine. Sections 3.4.1 to 3.4.8 cover thevarious options.

Note:Terex Pegsons Technical Departmentcan confirm the specification of themachine as originally built but bear inmind this may have been subsequentlychanged.

The capacities given are approximate onlyand based on crushing clean, dry, wellgraded quarried hard limestone, weighingloose about 1600 kg/f/m3 (100 lbs/cu.ft.) andhaving a specific gravity of 2.6 - 2.8. Wetsticky feeds will reduce crusher capacities.

Performance will be adversely affected if anexcessive percentage of fines in the feedcauses the packing/caking of material, eitherto slow the flow of material or causecongealed lumps in the product.

Persistent dumping (see Glossary) ismost undesirable and likely to becaused by operating the machine at tooclose a setting. Increase the Gapsetting to avoid damage to the machine.

Crusher settings shown in the tabulation arefor general guidance only and crusherperformance will vary depending upon theconditions prevailing.

Capacities shown are for open circuitapplications.

When operation is required towards thelower end of the setting range. TerexPegson Ltd should be consulted to verify theapplication.

The power required and product gradingswill vary with the feed and product size,capacity and rock characteristics.

Usage of wearing parts will depend uponindividual crushing conditions and thevariable factors which govern wear.

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3.4.1 Estimated Performance - Automax with long throw eccentric

Closed Side Setting Typical Plant Output

mm inches M. tph US. tph

19 3/4" 125 - 145 135 - 160

22 7/8" 140 - 180 155 - 195

25 1" 145 - 195 160 - 215

28 11/8" 155 - 205 170 - 225

32 11/4" 160 - 220 175 - 240

Type of Concave Maximum Feed SizeMinimum

RecommendedSetting

Med. Coarse (MC) 160 mm (61/4") 19 mm (3/4")

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

Extra Coarse (XC) 195 mm (73/4") 22 mm (7/8")

Figure 3a Maximum Feed Size and Minimum Recommended Settings

Figure 3b Estimated Plant Outputs

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Figu

re 3

c Ty

pica

l Pro

duct

Ana

lysi

s C

urve

s - L

ong

Thro

w E

ccen

tric

Aut

omax

SCR

EEN

MES

H S

IZE

- IN

CH

ES

SCR

EEN

MES

H S

IZE

- MM

PERCENTAGE PASSING

3.4.2 Typical Product Analysis - Automax with long throw eccentric

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3.4.3 Estimated Performance - Automax with short throw eccentric


RecommendedSetting

Med. Coarse (MC) 160 mm (61/4") 16 mm (5/8")

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

Extra Coarse (XC) 195 mm (73/4") 19 mm (3/4")

Figure 3d Maximum Feed Size and Minimum Recommended Settings

Figure 3e Estimated Plant Outputs



16 5/8" 90 - 110 100 - 120

19 3/4" 105 - 120 115 - 130

22 7/8" 115 - 150 125 - 165

25 1" 120 - 160 130 - 175

28 11/8" 130 - 170 140 - 185

32 11/4" 135 - 180 150 - 200

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3.4.4 Typical Product Analysis - Automax with short throw eccentric

SCR

EEN

MES

H S

IZE

- IN

CH

ES

SCR

EEN

MES

H S

IZE

- MM

PERCENTAGE PASSING

Figu

re 3

f Typ

ical

Pro

duct

Ana

lysi

s C

urve

s - S

hort

Thr

ow E

ccen

tric

Aut

omax

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3.4.5 Estimated Performance - Autosand with long throw eccentric


RecommendedSetting

Sand (AS) 63 mm (21/2") 13 mm (1/2")



13 1/2" 85 - 120 95 - 130

16 5/8" 95 -130 105 - 140

19 3/4" 100 - 150 110 - 165

Figure 3g Maximum Feed Size and Minimum Recommended Settings

Figure 3h Estimated Plant Outputs

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3.4.6 Typical Product Analysis - Autosand with long throw eccentric

SCR

EEN

MES

H S

IZE

- IN

CH

ES

SCR

EEN

MES

H S

IZE

- MM

PERCENTAGE PASSING

Figu

re 3

i Typ

ical

Pro

duct

Ana

lysi

s C

urve

s - L

ong

Thro

w E

ccen

tric

Aut

osan

d

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3.4.7 Estimated Performance - Autosand with short throw eccentric


RecommendedSetting

Sand (AS) 63 mm (21/2") 13 mm (1/2")



13 1/2" 70 - 100 75 - 110

16 5/8" 80 - 110 90 - 120

19 3/4" 85 - 125 95 - 135

Figure 3j Maximum Feed Size and Minimum Recommended Settings

Figure 3k Estimated Plant Outputs

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3.4.8 Typical Product Analysis - Autosand with short throw eccentric

SCR

EEN

MES

H S

IZE

- IN

CH

ES

SCR

EEN

MES

H S

IZE

- MM

Figu

re 3

l Typ

ical

Pro

duct

Ana

lysi

s C

urve

s - S

hort

Thr

ow E

ccen

tric

Aut

osan

d

PERCENTAGE PASSING

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Blank page

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BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618

4 - Design and Function ENPage 4 - 1

4 - Design and Function

4.1 General Information ........................................................................................ 4 - 2

4.2 Construction Units .........................................................................................4 - 34.2.1 Automax Crusher ........................................................................................ 4 - 34.2.2 Feed Hopper ............................................................................................. 4 - 34.2.3 Feed Conveyor .......................................................................................... 4 - 34.2.4 Discharge Conveyor .................................................................................. 4 - 34.2.5 Chutes ....................................................................................................... 4 - 44.2.6 Platforms ................................................................................................... 4 - 44.2.7 Power Unit ................................................................................................. 4 - 44.2.8 Controls ..................................................................................................... 4 - 44.2.9 Chassis ..................................................................................................... 4 - 44.2.10 Track Frame............................................................................................. 4 - 54.2.11 Guards ..................................................................................................... 4 - 54.2.12 Painting ................................................................................................... 4 - 54.2.13 Dust Suppression Sprays ......................................................................... 4 - 54.2.14 Optional Extras ........................................................................................ 4 - 54.2.15 Authorisation ............................................................................................ 4 - 64.2.16 Site Preparation ....................................................................................... 4 - 64.2.17 Commissioning ........................................................................................ 4 - 64.2.18 Specifications .......................................................................................... 4 - 6

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4.1 General Information

The Terex Pegson Maxtrak 1000 Plant has been designed to maximise throughput andproduct shape in a wide range of quarrying applications, its features include:-

Unique design giving excellent product shape and high reduction ratios

No need for pre-screening on many applications reducing cost and increasing profitability

Easily transported on and off site

Metal detection fitted as standard

Feed hopper and level controls included to ensure choke feed to the crusher with resultant optimumproduct shape

3.2 m (10-7) discharge conveyor material discharge height

Hydraulic crusher setting adjustment, overload release and unblocking included as standard

Dust suppression sprays

Caterpillar water cooled diesel engine with hydraulically controlled clutch

Hydraulic rams to assist setting up and packing for transportation

Choice of crusher concave (including Autosand option) and eccentric throw available

CRUSHING APPLICATIONS

! WARNING !This plant is designed for stone crushing applications. It is vitally important thatlarge pieces of steel or similar uncrushable objects are not allowed to enter thecrushing chamber as severe damage and injury may occur. The Automaxcrusher includes automatic hydraulic overload release. However the machine isnot designed to accept large pieces of steel or other uncrushable objects suchas bucket teeth. The metal detector fitted to the feeder conveyor must be keptoperable at all times whilst the plant is in operation and any foreign objectremoved from the feeder conveyor belt.

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4.2 Construction Units

TEREX PEGSON 1000 MAXTRAKSECONDARY/TERTIARY CRUSHINGPLANT WITH DIESEL/HYDRAULICDRIVE generally as shown on brochure MT200/1 and comprising:-

4.2.1 Automax Crusher

Terex Pegson 1000 Automax Crushergenerally as illustrated on leaflet AMB 200/1,and fitted with long throw eccentric, mediumcoarse (MC) concave and dedicated system2 hydraulic controls as standard. Thecrusher is complete with an oil lubricationsystem having a chassis mounted tank withair blast cooler.

Extra coarse (XC), coarse (C) and Autosand(AS) concaves and a short throw eccentricare all available as options to the above forplants which have not been completed.Advice on the correct combination ofconcave and eccentric can be provided bythe sales department against purchasersspecific application data.

4.2.2 Feed Hopper

7.0m (8.75yd) heaped capacity feedhopper fabricated in 10mm (3/8) thick mildsteel plate and fitted with internal crash barsto minimise impact load on the feedconveyor.

4.2.3 Feed Conveyor

1000mm (39) wide plant mounted shallowtroughed belt variable speed conveyor, withhydraulic drive to the head drum havingintegral reduction gearbox, EP500/3 (orequivalent) belt with 5mm (0.2) top and1.5mm (0.06) bottom heavy duty covers,and vulcanised belt joint. The conveyor isdesigned to lower for transportation and liftfor crusher maintenance, by means ofhydraulic cylinders. Belt tensioning ismaintained by screw adjusters located at thetail drum.

Impact rollers are provided immediatelybelow the feed hopper, and barge boardsextend from the feed hopper to the conveyorhead. A metal detector is included completewith audible warning devices, and is suitablefor detecting steel and manganese steelcontained in the feed material.

4.2.4 Discharge Conveyor

800mm (32) wide plant mounted troughedbelt fixed speed conveyor with hydraulicdrive to the head drum, EP 500/3 (orequivalent) belt with 5mm top (0.2) and1.5mm (0.06) bottom heavy duty covers,and vulcanised belt joint. The conveyor is offixed design and belt tensioning is maintainedby screw adjusters located at the tail drum.Impact rollers are provided immediatelybelow the crusher outlet under the conveyorfeed point, and canvas type dust covers areprovided over the exposed section of theconveyor.

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4.2.5 Chutes

Automax feed box fabricated in 6mm (1/4)mild steel plate. Crusher discharges direct toproduct conveyor feed boot, which isfabricated in 10mm (3/8) thick Hardox.

4.2.6 Platforms

Provided for inspection and maintenance,allowing access to each side of the crusherand engine, back of engine, and to one sideof feed conveyor head section. They aremade from steel flooring with steel toeboards, double row handrails and accessladders.

4.2.7 Power Unit

Caterpillar C9 EU/EC EmmissionsRegulations compliant, 6 cylinder, 4 stroke,direct injection, water cooled diesel powerpack, with HFO clutch. The engine is ratedat 335 BHP (248 kW) nett continuous at1800 rpm under NTP conditions.

Hydraulic power is provided from the engineto drive both conveyors, operate thehydraulic cylinders, and give power to thetracks. It also provides power to the crusherlubrication oil pump and supplies the crusherhydraulic setting and adjustment system. Allconnecting pipework is provided with steelpipe being used in inaccessible areas.

Hydraulic tank is mounted within the mainchassis structure, and the system includes airto oil cooling.

4.2.8 Controls

The Automax hydraulic systems controlpanel, and separate start/stop control panelfor the crusher conveyors, and oil lubricationsystem are mounted on the side of the mainchassis. Both panels operate from a 24 voltD.C. supply from the diesel engine.

Also mounted on the chassis are emergencystop buttons and a control lever for loweringand raising the feed conveyor assembly fortransport and maintenance.

A radio control unit is provided for controllingthe tracking function giving a tracking speedof approximately 1km/hour and a creepfacility for loading, off loading and preciseslewing movements. This also provides stopand start control for the feed conveyor froma remote position. An alternative unbilicalcontrol unit is also provided for use in caseof remote control unit failure.

Level sensors over the Automax and, feedconveyor (optional), are designed toautomatically maintain an optimum feedcondition.

4.2.9 Chassis

Fabricated steel frame with supports for thefeed conveyor, crusher, product conveyor,power unit, track frame and control systems.

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4.2.10 Track Frame

Heavy duty track frame having 3.8m long(12- 6) centres and 400mm (1- 4) widetracks.

Total Plant Weight31.300 kgs (34.4 US tons)Overall track width - 2800mm (9- 2)Operating height - 3914 mm (12- 10)Operating length - 15173 mm (49- 9)Operating width - 2800 mm (9- 2)Travel height - 3446 mm (11- 4)Travel length - 15095 mm (49- 6)Travel width - 2800 mm (9#- 2)

4.2.11 Guards

Wire mesh or sheet metal guards are providedfor all drives, flywheels, pulleys, couplings,wedge belts and belt conveyors.

The guards provided are designed andmanufactured to ensure so far as reasonablypracticable that the machinery and plant onwhich they are fitted can be operated safelyand without risk to health when properly used.However, the Company cannot guarantee thatthe guards provided will meet the requirementslaid down by individual Inspectors and anyadditional guard and/or modification to guardingsupplied, which may be required for anyreason whatsoever, will be charged as anaddition to the Contract Price.

4.2.12 Painting

The plant is finish painted in BL-PegsonBlue RAL 5015.

4.2.13 Dust Suppression Sprays

Spray bars with atomiser nozzles aremounted over the crusher mouth and theproduct conveyor feed and discharge pointspiped to an inlet manifold for clientspressurised water supply.

Buyer to supply pressurised at 2.8 bar (42psi) clean water supply at approximately 7litres (2 US galls.) per minute.

4.2.14 Optional Extras

(These options are only available for plants,which are not already built and are notavailable for plants already in stock)

Automax extra coarse concave (no pricevariation for unfinished plants)

Automax coarse concave (no price variationfor unfinished plants)

Autosand concave (no price variation forunfinished plants)

Short throw eccentric (no price variation forunfinished plants)

Beckford belt weigher with integrator andspeed sensing wheel fitted to main productconveyor.

Hydraulically driven water pump assembly toprovide a pressurised water supply to thedust suppression sprays.

Level sensor over the feed hopper.

Feed Hopper Extension Plates.

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4.2.15 Authorisation

This is a requirement of the EnvironmentalProtection Act that the Purchaser mustobtain Local Authority authorisation tooperate this plant in the U.K.

4.2.16 Site Preparation

The buyer shall be responsible for ensuringthat a suitably prepared, flat and level site isavailable for the plant and that the ground iscapable of sustaining the working of theequipment. Unit dimensions and loadingscan be provided to the buyer for bothtransportation and operating purposes.

4.2.17 Commissioning

On arrival of the plant on site Terex Pegsonor your local dealer can provide an Engineerif required at extra cost to commission theplant.

Feed material, and other essentials to beprovided by the buyer in good time for thecommissioning being carried out.

4.2.18 Specifications

Every endeavour will be made to supplyequipment as specified, but we reserve theright, where necessary, to amendspecifications without prior notice as weoperate a policy of continual productdevelopment.

We cannot guarantee that the equipmentquoted will meet any specific requirements inrespect of noise or vibration levels, dustemissions, or any other factors relevant tohealth and safety measures or environmentalprotection needs. However, on receipt ofspecific information Terex Pegson willendeavour to ascertain the need foradditional equipment and, if appropriate,quote extra to contract prices.

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5 - Transport ENPage 5 - 1

5 - Transport

5.1 Safety Information .......................................................................................... 5 - 2

5.2 Transportation ................................................................................................ 5 - 55.2.1 Manoeuvring .............................................................................................. 5 - 55.2.2 Unloading................................................................................................... 5 - 85.2.3 Loading ..................................................................................................... 5 - 95.2.4 Lowering the Feed Conveyor ................................................................... 5 - 10

5.3 Remote Control Operation ........................................................................... 5 - 125.3.1 Radio Hand Set (where fitted) .................................................................. 5 - 145.3.2 Alternative Control Hand Set with Umbilical Cable (where fitted) ............... 5 - 16

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5.1 Safety Information

PERSONALPROTECTIVE EQUIPMENT

Loose or baggy clothing can getcaught in running machinery.

ALWAYS wear correctly fitting(E.N./A.N.S.I. approved) personalprotective equipment.

Personal Protective Equipment includes HardHat, Safety Glasses, Hearing Protection, DustMask, Close Fitting Overalls, Steel Toed Boots,Industrial Gloves and High Visibility Vest.

FALLING HAZARDFalling from and/or onto aTerex Pegson machine can causeserious injury or even death.

DO NOT climb onto the machinewhilst it is in operation.

ALWAYS use the walkways/platforms providedor a safe and secure platform approved by thelocal regional safety enforcing authority.

ALWAYS use an E.N./A.N.S.I. approved safetyharness when reaching any points 7ft (2m) ormore above ground level.

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ENTANGLEMENTHAZARD

In-running nip points can causeserious injury or even death.

DO NOT reach into an unguardedmachine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machinebefore opening or removing guards.

SKIN INJECTIONHAZARD

Hydraulic fluid under pressure canpenetrate the skin causing seriousinjury.

ALWAYS relieve the pressure fromthe hydraulic system beforecarrying out any kind ofmaintenance or adjustment.

ALWAYS use a piece of cardboard to check forleaks. DO NOT use your hand.

If fluid is injected under the skin, it must besurgically removed or gangrene will result.

Get medical help immediately.

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LOCKOUT PROCEDUREWhen carrying out maintenance oradjustment to the plant thefollowing procedure must befollowed.

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

5.2.1 Manoeuvring

! WARNING !Prior to attempting anymanoeuvring of the plant thetracks must be free ofobstructions, including crushedmaterial and fines. Do not push ortow the plant. Failure to observethis warning could result inserious injury to persons anddamage to the plant which mayinvalidate warranty.

Before manoeuvring the Maxtrak,ensure the feed hopper and crusher areempty, and that all materials have run offthe conveyors. STOP the feederconveyor, crusher and product conveyor.

The plant cannot be manoeuvred in thePLANT mode of operation.

The safety warning horn sounds for 10seconds before selected controls becomeoperative and continuously whilst theplant is being manoeuvred.

! DANGER !DO NOT stand on any of theplatforms or ladders of the Maxtrakwhilst it is being manoeuvredusing the remote control handset.

! DANGER !When manoeuvring your Maxtrakto its operating position make sureyou stand well clear of the plantbut are in a position to have all-round vision to see any obstaclesor hazards that may lie ahead e.gpersonnel, overhead cables,ditches, unsafe roadways etc.(Refer to Figure 2a Dimensions).

Make sure that you do not manoeuvreyour Maxtrak on a gradient steeper than30 degrees, damage may occur to theengine and/or plant.

Avoid manoeuvring the plant overextremely uneven ground or damagemay occur.

Initial start up in cold weather may resultin a tendency to steer to the right whilsttracking fast forward due to thehydraulic oil being cold. Run the plant forapprox. 10 minutes with the conveyorand feeder running prior to manoeuvringthe plant.

The Maxtrak can be manoeuvred whilstthe feeder conveyor is in the workingposition but refer to Section 5.2.4 whennecessary to reduce to the travellingdimensions (Section 2)

When transporting the Maxtrak, it isthe responsibility of the haulagecontractor to safely secure the plant tothe transporter.

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WARNINGWEAR PERSONALPROTECTIVE EQUIPMENT.Refer to Section 5.1, SafetyInformation for relevant warning.

To manoeuvre the Maxtrak with theremote radio hand set (where fitted):-

Procedure

1. Observe all safety instructions.

2. Take the Remote Control Hand Set fromthe Control Box and first becomefamiliar with the functions of all theindividual buttons (Figure 5c) before thenext step.Forward = Product Conveyor firstReverse = Hopper first

3. To start up the handset transmitter firststand well clear of the plant. Hold thehand set with the stop button nearest tothe operator and proceed as follows:-

Ensure the stop button is pulled out. Depress both of the safety buttons(Fig.5c) at the same time for at least1 second. Release the safety buttons. The red LED will change to green. The transmitter is in function statuswhen the green LED comes on.

Note: The transmitter has a built in safetyfunction that prevents another function frominvoluntary cutting-in when the transmitterstarts. The transmitter will not start if abutton is stuck in the activated position. Thisis indicated by the red LED coming on.

4. Start the engine (Section 7.2.1). Set theengine speed at 1200rpm.

5. Turn the OPERATION switch toTRACK (Figure 5a).

6. Press the Horn button for 5 seconds tosound the safety warning horn. This willalso ready the tracks for manoeuvring.

7. The radio handset directional buttons(forward, reverse and turn) are doublepressure switches with the initialpressure operating the slow speed modeand depressing further operates thehigher speed. Press the buttons tomanoeuvre the plant in the desireddirection (Figure 5c). Employ the Fastspeed only where safe to do so.

Pressing the Stop button at any time willimmediately halt the operation and cutout the engine but it is necessary tomanually switch off the engine ignition(Section 8.2)

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Figure 5a OPERATION and RADIO REMOTE CONTROL Switcheson the Electrical Control Panel

8. When the Maxtrak is in the correctposition, press the Horn button to turnthe safety warning horn off anddisengage the tracks.

9. Turn the OPERATION switch toPLANT and stop the engine (Section8.2), unless required further.

10. To shut down the radio handsettransmitter, push in the stop button. Lockout the hand set when finished with toprevent unauthorised use.

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5.2.2 Unloading

The Maxtrak will arrive on site securelyfastened to a low loader. It is theresponsibility of the haulage contractor toremove the fastenings.

Procedure

1. Observe all safety warnings.

2. Position easy slope ramps at the end ofthe transporter to help with unloading ofthe Maxtrak.


4. Turn the OPERATION switch toTRACK (Figure 5a). Using the remotecontrol hand set (Section 5.2.1 and 5.3),steer the Maxtrak off the transporter .


6. Turn the RADIO REMOTECONTROL switch to OFF, then shutdown the hand set with the hand set stopbutton.

7. Turn the OPERATION switch toPLANT and stop the engine (Section8.2), unless required further.

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FALLING HAZARDRefer to Section 5.1, SafetyInformation for relevant warning.

5.2.3 Loading

Procedure


2. Ensure that both conveyors, feed hopperand crusher are free from stone and dirt.

3. Ensure all loose items are carefullystowed and secured if these are to betransported on the plant.

4. Start the engine (Section 7.2.1). Set theengine speed to 1200rpm.

5. Continue with the OPERATION switchat PLANT and the RADIO REMOTECONTROL switch at ON (Figure 7b).

6. Lower the feeder conveyor for travellingif not already in this position (Refer toSection 5.2.4 procedure).

7. Position easy slope ramps at the end ofthe transporter to help with loading of theMaxtrak.

8. Turn the OPERATION switch toTRACK (Figure 5a). Using the remotecontrol hand set (Section 5.2.1 and 5.3),steer the Maxtrak on to the transporter.


10. Turn the RADIO REMOTECONTROL switch to OFF then shutdown the hand set with the hand set stopbutton.

11. Turn the OPERATION switch toPLANT and Stop the engine (Section8.2), unless required further.

12. Securing the Maxtrak to thetransporter is the responsibility ofthe haulage contractor.

! WARNING !Prior to transportation alwayscheck the plant for loose ordamaged components.

Fasten all loose parts, replacemissing items or make repairsas found necessary to ensurethat all components are safelysecured during transportation.

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FALLING HAZARDRefer to Section 5.1, SafetyInformation for relevant warning.

5.2.4 Lowering the Feed Conveyor

The Maxtrak is designed so that the plantcan be prepared for transport without theuse of tools. To reduce to the travellingdimensions of the plant the feeder conveyorhead is hydraulically lowered from theworking position.

! WARNING !Whilst the plant is crushing theconveyor head must always besupported on the locating pinspositioned in each of the twotelescopic support legs and NOTby the hydraulic ram alone.

Procedure


2. Ensure that the conveyor and feedhopper and Automax feed box are freefrom stone and dirt.

3. Before lowering the feed conveyor intothe travelling position first release thefeed box rear plate fastenings and hingedown the plate.


5. Continue with the OPERATION switchat PLANT and the RADIO REMOTECONTROL switch at ON (Figure 7b)..

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Figure 5b Feed Conveyor Hydraulic Leverand Locating Pins

Locating Pin

Hydraulic Lever

Upper TelescopicLeg

Lower TelescopicLeg

Feed Box Rear Wall

6. Operate the hydraulic lever on thechassis side to slightly raise the feederconveyor so that the locating pins can bewithdrawn from both legs of the uppertelescopic support leg (Figure 5b).

7. Operate the hydraulic level again tolower the feeder conveyor to the fullestextent. This action will automatically foldthe platform access ladder.

8. Store the locating pins in the placesprovided on the telescopic legs and stowthe security pins to prevent loss.

9. Switch off the engine (Section 8.2) andimplement the lockout procedure.

10. Lower the mast(s) supporting the levelsensor(s).

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5.3 Remote ControlOperation

! DANGER !DO NOT stand on any of theplatforms or ladders of the Maxtrakwhilst it is being manoeuveredusing the remote control handset.

When manoeuvring your Maxtrakto its operating position makesure you stand well clear of themachine but are in a position tohave all-round vision to see anyobstacles, dangers that may lieahead e.g personnel, overheadcables, ditches, unsafe roadwaysetc.(Refer to Figure 2a for dimensions)

! NOTICE !The Maxtrak remote controlsystem is supplied to thefollowing:-

Radio System2686-0042

If the plant moves out of the operatingrange of the remote control hand set theplant will stop.

Operating the stop button on the remotehand set whilst the plant is in TRACKoperating mode will stop the engine, butthe engine ignition switch needs to beturned off manually.

To manoeuvre the Maxtrak with theremote hand set, refer to the instructionsin Section 5.2.1.

For recharging the hand set battery, seeSection 5.3.1

When the plant is not operating take theopportunity to recharge the internalbattery. For convenience a lead issupplied to plug into 12/35 volt DCvehicle cigar lighter point (Section 5.3.1).

In the event of the remote radio hand setbeing inoperable for any reason, thealternative umbilical hand set issupplied (Section 5.3.2).

If the hand set transmitter does not startwhen the two safety buttons aredepressed at the same time for at least 1second (Section 5.2.1), check if the stopbutton is pushed in, or the batteryneeding a recharge.

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Figure 5c Remote Control Hand Set

**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed

PLAN VIEW OF THE PLANT

Rotate counterclockwise, track 1 reverse,track 2 forward (second step)

Forward slow or fast, track 1 & 2

Right turn slow, forward track 1

Left turn slow, forward track 2

Reverse slow or fast, track 1 & 2

Right turn slow, reverses track 1

Left turn slow, reverses track 2

Rotate clockwise, track 1 forward, track 2reverse (second step)

Left Turn(travelling forward)

Right Turn(travelling forward)

Safety Button(Feeder On/Off)

Stop Button

Forward

LED Red/Green

Reverse

Safety Button(Horn)

********

Not used toManoeuvre

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TRANSMITTER 860TX-PEG

Buttons 1 to 4 = Used for plant directionalcontrol

Buttons 1 to 9 and 0 = Used for signalfrequency programming (factory preset -contact Dealer for change)

Buttons 9 and 0 = Used to activate theradio hand set transmitter

Button 9 = Used to activate the audiblewarning horn

Button 0 = Used to stop / start the plantfeeder (where appropriate)

5.3.1 Radio Hand Set (where fitted)

Features of the 860 System include:-

Unique ID code in each transmitter. Thereceiver self learns this code, without theneed to change DIP switches internallyin either component.

No need to open transmitter to changefrequency (changed from buttons -Dealer function). Receiver detects anychange automatically.

Transmitter can be programmed to workwith either 840 or 860 receivers (Dealerfunction).

Enhanced reliability.

Transmitters Use NiMh batteries instead ofNiCd, which means the following:-

Input charging voltage is now 12VDC to35VDC instead of 12/24VDC, nouniversal adapter required.

Battery capacity is changed from 800mAto 2000mA.(Charging time fromcompletely empty battery is nowapproximately 4 hours).

Operating time with fully charged batteryis approximately 30 hours.

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Figure 5d Remote ControlCharger Connection

Charging point


2 versions of the 860 system transmitter willbe supplied, one for European Operationsand one for the Rest of the World. The onlydifference is that the European version willinclude a black stop button. The Rest of theWorld transmitter will feature a Red Stopbutton. Channel 01 (434.650 MHz) throughchannel 16 (433.900 MHz) available in .050MHz steps. Refer to Dealer if frequencychange needed.

Battery Recharging

The remote control handset includes a builtin chargeable batteries and a chargingcontact point on the back of the unit (Figure5d). A 12/35 volt charging lead suitable forplugging into a vehicle cigarette lighter pointis supplied.

Battery charge status is indicated by theLED light in the transmitter;Red - batteries need charging;Green - batteries fully charged.During the charging of the batteries theLED light will be red until changing togreen when fully charged. The batteriescannot be overcharged.

Fully charged batteries provide about 30hours continuous running and rechargingtime takes about 4 hours.

The LED light on the hand set changesfrom green to red when there is about10% power left in the batteries (1 hourcontinuous operation remaining) andindicates it is time to recharge. The plantwarning horn will also sound whenbattery recharging is required

To conserve the battery charge the handset should be switched off when not inuse.

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5.3.2 Alternative Control Hand Setwith Umbilical Cable (where fitted)

As an alternative to the radio remote controlhand set, a hand set with umbilical cable issupplied to manoeuvre the Maxtrak (Figure5e).

Connecting and using the UmbilicalControl Hand Set

Procedure


2. Close down the plant (Section 8.2).

3. Locate the connection point (Figure 5e)on the Control Panel. Release theretaining clip and remove the multi pinplug already in situ. (only where radiounit fitted) Replace with the umbilicallead plug (Figure 5f) and secure with theretaining clip.

4. Start the engine (Section 7.2.1). Set theengine speed at 1200rpm..

5. Standing clear of the tracks, turn theOPERATION switch to TRACK butleave the the RADIO REMOTECONTROL switch at OFF (Figure 5g).

6. Press the Horn button for 5 seconds tosound the safety warning horn. This willalso ready the tracks for manoeuvring.

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Figure 5f Umbilical Control Hand Set

Figure 5e Umbilical Connection Point

Figure 5g OPERATION and RADIO REMOTE CONTROL Switcheson the Electrical Control Panel

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7. The umbilcal handset (Figure 5h)directional buttons (forward, reverse andturn) are double pressure switches withthe initial pressure operating the slowspeed mode and depressing furtheroperates the higher speed.

Pressing the Stop Button at any time willimmediately halt the operation and cutout the engine but it is necessary tomanually switch off the engine ignition(Section 8.2).

8. Hold the hand set with the stop buttonnearest to the operator and proceed asfollows. Press the slow speed buttons onthe hand set to manoeuvre the plant inthe desired direction (Figure 5h). Employthe fast speed only where safe to doso.


10. On the Control Panel turn theOPERATION switch to PLANT. Thesafety warning horn will sound for 10seconds. Stop the engine (Section 8.2),unless required further.

11. Unplug the umbilical cable and replacewith the original plug (where radio unitfitted). Store the umbilical hand set unitin the tool box to keep available forfuture use.

! DANGER !Extreme care must be used whenmanoeuvring the plant with theumbilical control hand set. Standas far away as possible from theplant. Do not allow the cable of thehand set to sag and becomeentangled with the tracks.

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Figure 5h Remote Umbilical Control Hand Set

PLAN VIEW OF THE PLANT

**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed

Rotate counterclockwise, track 1 reverse,track 2 forward (second step)

Forward slow or fast, track 1 & 2

Right turn slow, forward track 1

Left turn slow, forward track 2

Reverse slow or fast, track 1 & 2

Right turn slow, reverses track 1

Left turn slow, reverses track 2

Rotate clockwise, track 1 forward, track 2reverse (second step)

Left Turn(travelling forward)

Right Turn(travelling forward)

Stop Button

ForwardReverse

Safety Button(Horn)

Not usedNot used

Documents

1000 Maxtrak Plant User Manual 2008 (L)