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1300 Maxtrak
Company Confidential
1300 Maxtrak
Company Confidential
Company Confidential
Introduction
This Safety Instruction (SI) is issued to assist Employees of BL PEGSON LTD to understand the requirements for the wearing of
Personal Protective Equipment at Work
1/
1.2
1.3
1.4
2/
The Health and Safety at Work etc Act 1974 (HSWA) requires employers to ensure the health
safety and welfare of their employees and persons not in their employment who may be affected
by work activities.
Regulation 3(1) of the Management of Health and Safety at Work Regulations 1999 requires
employers to identify and assess the risks to health and safety present in the workplace. This
general risk assessment should identify whether there is a risk of injury to persons from working
processes, procedures and practices. Where there is a risk identified, all practical measures shall be
taken to eliminate or reduce so far as is reasonably practicable exposure of the individual to those
risks. There is in effect a hierarchy of control measures and Personal Protective Equipment (PPE)
should always be regarded as the 'last resort'
The Personal Protective Equipment recommended for each group of people will be commensurate
with their experience and knowledge of the risks to which they are being exposed in any particular
working area.
This document details the ways in which BL PEGSON LTD discharges its duties and obligations
to its employees, contractors & sub-contractors, customers, suppliers and visitors under this
requirement.
'All equipment designed to be worn or held by a person at work to protect against one or more risks and any addition or accessory
designed to meet this objective'
2.1
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Both protective equipment and clothing are within the scope of the definitions and therefore:
2.1.1
For the sake of this Safety Instruction 15/01/01 protective clothing such as overalls (when they
are Proban Treated or Pyrovatec) aprons, protective clothing for adverse weather conditions,
gloves, safety footwear, safety helmets, high visibility waistcoats etc; and
2.1.2
Protective equipment such as eye protectors, hearing protectors, respiratory protectors, face
protectors and safety harnesses
2.1.3
Overalls other than Proban Treated or Pyrovatec will not be regarded as PPE as they are for
welfare purposes and do not provide health and safety protection.
2.2
Selection of appropriate PPE will always be the factor that proves the item to be adequate or not
for example: when working with equipment i.e. hammer and chisel, that produces fragments and
splinters impact protection safety glasses with side protection or wrap-round. When operating
equipment that produces fine grit or offshoot i.e. grinder or cutting disc face mask with safety
glasses or box goggles. When working with hazardous substances or splashes invariably box
goggles should be selected.
2.3
With consideration given to the advice above anyone that feels they have insufficient knowledge
or experience in the selection of appropriate PPE they should consult their supervisor or Health
and Safety Officer for a risk assessment and necessary training.
3/
Contractors and Sub-Contractors
When contractors and sub-contractors are employed to carry out work that comes within the scope of this Safety
Instruction SI 15/01/01 they will be expected to comply in all factors as though they are direct employees of BL-Pegson Ltd.
(See section 5/ Personal Protective Equipment for employees)
4/
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4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.4
4.5
5/
Adequate and appropriate Personal Protective Equipment for all customers, suppliers and visitors
consists of;
High visibility vest
Safety footwear with internal steel toe cap
Grade 2 impact eye protection
Hearing protection (all customers, suppliers and visitors will be advised to wear the hearing
protection, as, during production hours the background noise levels in production departments is
above the first action level of 85dB(a) whereby hearing protection must be provided.
Hosts escorting suppliers, customers and visitors to production areas who are not in compliance
with the above guidelines will be asked to leave the production area until appropriate remedial
action has been taken.
Persistent failure by an hosts to establish his customers, suppliers and visitors with the above
requirements will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures
against him/her.
Guidelines With due regard to the section 2.2 of this document, the following guidelines are set out
for PPE to be used by all BL-Pegson personnel when performing tasks in all production,
maintenance and testing areas.
5.1.1
When any employee is travelling through or working in a production, maintenance or test area (as
outlined in section 5.2 of this Safety Instruction), other than his/her normal working area, s/he will
be regarded as a visitor to the area. In these circumstances, as a visitor to an area s/he will be
required to adopt PPE (foot and eye protection) as a minimum basic requirement. Persistent failure
by any employee to conform with the designated requirements, for the use of personal protective
equipment within any production, maintenance or test area will result in the instigation of the BLPegson Ltd progressive disciplinary procedures against him/her.
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5.2
5.2.1
5.2.2
5.2.3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
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Application of S.I. For the purpose of this Safety Instruction a production, maintenance or testing
area, is anywhere on the Mammoth Street Site inside or outside of buildings, that;
machining, fitting, welding, burning attaching and/or removing, adjusting or testing of units or
components to any item of equipment that goes to make up a crushing or pumping plant; or
any item of equipment used in the production, testing, adjustment or maintenance of crushing or
pumping plant; or
any location other than BL-Pegson Ltd Mammoth Street Site, where BL-Pegson personnel are
involved in the repairs, maintenance, adjusting or testing of any BL-Pegson manufactured plant and
or equipment.
Minimum/Recommended Requirements
Foot Protection - Basic safety footwear protects the feet / lower leg of individuals, assessment has
indicated that the primary protection required at BL-Pegson ltd is Toe Protection (200 joule toecap
protection), Oil and Water Resistant with anti-slip soles with steel mid-sole (100 Newtons
penetration resistance) for protection against penetrating objects.
Safety shoes or Safety Boots shall be worn at all times inside production and maintenance areas.
Leg Protection Gaiters or knee-high boots shall be worn when pouring molten metals.
Thigh Protection Leather apron should be worn when disc cutters and grinders are being operated at or below waist
level.
Nitrile coated or rubber apron should be worn when decanting or using hazardous liquids.
Whole Body Protection Proban overalls (flame retardant coating) should be worn when general welding and grinding
processes are carried out by an individual.
Operators performing high intensity welding processes shall wear Pyrovatec overalls (heavy-duty
cotton with tight knit fabric and flame-retardant coating).
5.3.5
5.3.6
Eye Protection - The selection of correct eye protection is the primary consideration for an
individual when performing any task, poor selection is of no benefit to the individual and in some
cases can make a situation worse. The reasoning behind this being that having made their
selection they believe themselves to be protected from any hazard. All eye protection PPE issued
at BL-Pegson Ltd is to EN166 Category 2.
Prescription lenses impact protection glasses all individuals that are required to wear
prescription spectacles will be issued with prescription safety glasses with grade 1 impact lenses
and side shields. There may be occasion where additional protection shall be required for
protection from splashes or dust particles in which case a box goggle shall be worn over the top
of the prescription lens safety glasses.
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Impact Protection safety glasses shall be worn by operators at all times when working with the
following items of equipment;
Machine tools (drilling / boring m/c's etc.) [May not be appropriate when reading drawings,
micrometers etc.]
Impact guns/wrenches (of any type), when working in teams, both/all team members shall wear
impact eye protection glasses
Drilling or tapping holes
Hammer of any size
Drift
Spreader
Chisels
Saws / hacksaws
Thread dies
Working in the vicinity of someone welding burning or grinding
Additional protection box goggle or visor shall be worn by operators at all times when using;
Hand held grinder 4" / 9" (angle grinders)
Die grinder
Flap wheel
Bench / pedestal grinder
De-burring / fettling equipment
Air lines for swarf/debris removal
Oxy/acetylene equipment
Initial start-up of plant until such time as integrity of hydraulic system established.
Painting
Rust preventative
Pumps testing
Molten white metal
Decanting any hazardous substance
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Respiratory Protection - as with eye protection, respiratory safety hazards are extremely difficult
to protect against, as poor selection can lead to individuals feeling they are adequately protected and
yet not receiving any of the protection required for the situation. Dust, Gas and Vapour are specific
hazards and a filter protecting against mist and fume will not necessarily protect against dust
(particulate), similarly a particulate filter will not protect against gas and vapour.
Respiratory protection should only be selected as the last resort. All other sources of to control the
hazard should be considered first e.g. substitution, elimination, separation and engineering controls.
Respiratory Protection - when not in service all respiratory protective equipment must be kept in a
clean dry environment where it can be protected from contaminants. Reusable equipment should be
wiped down with a mild solution of soap and water using a cloth or sponge, dried off and then
stored in a clean dry environment.
Powered air and Airfed Respirators and headtop should be worn when
High intensity welding processes (Particulate filter P(SL) filters must be fitted at the air intake. It is
recommended that in addition Organic gases and vapours with boiling point greater than 65oC;
inorganic gases and vapours and acid gases (A1B1E1) filters, should also be fitted at the air intake.
Paint spraying Plants etc. (Particulate filter P(SL) +Organic Vapour (OV) filters must be fitted at
he air intake.
Compressed Airline Feed Respirator and headtop must be worn when
Grit blasting.
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Hearing Protection - The Noise at Work Regulations 1989 require hearing protection to be
provided where noise levels are between 85dB(A) and 90dB(A). Where noise levels are in excess
of 90dB(A) hearing protection becomes a mandatory requirement.
Noise level assessments have been carried out across the site and the results illustrate that when
production departments are in normal operation the background level of noise is in excess of
85dB(A). The company has made provision therefore for hearing protection to be available in all
production departments.
Fabrication Department, Quarry Plant Fitting Department and Quarry Plant Assembly
Departments results have indicated that the levels of exposure in these departments are in excess
of 90dB(A) in these departments therefore personal hearing protectors (Variphone) have been
offered to every employee. Being manufactured to suit an individual's ear canal these can be worn
for 8 hours per day with no discomfort and can be attenuated to match each individuals exposure
levels.
For those persons that have declined the offer of the above (Variphone) service a variety of styles
of hearing protection are available and the individuals selection must be worn every time they are
exposed to levels of noise in excess of 90dB(A)
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Styles available:
Disposable foam Inserts - can be used alongside other PPE easy to use and provide levels of protection that can
exceed some earmuffs. Some come moulded for greater comfort. Must be disposed of after each wearing and
new used each time. For effective operation the insert should be rolled between finger and thumb, the ear canal
should then be opened slightly by lifting the upper part of the ear, using the opposite hand the ear having the
insert applied to. The tightly rolled insert is then pushed into the ear canal and allowed to expand to create an
effective seal.
Corded inserts - a variety of types, foam, some with durable cleanable coatings for extended use, re-usable
moulded plastic. Any insert that is re-usable should be cleaned in a mild solution of soapy water at least each
day. This type of insert is fitted in the same way as described above.
Banded inserts - coated foam inserts and moulded plastic inserts, hang comfortably around the neck and ideal
for intermittent protection needs. To fit effectively the ear canal should be eased open slightly by lifting the
upper part of the ear using the opposite hand to which the ear protector is being applied. The plug or shaped
plastic pod should then be eased into the ear canal until a good seal is formed the ear should then be released.
Ear Muff - 3 basic styles Helmet Mounted, Overhead Band or NeckBand. For the muff to be effective a good
seal must be established between the soft outer part of the muff and the area of the head around the ear. Long
hair, beards and spectacles can impair the seal of the muff and thereby effect the physical performance of the
protection. The earmuff should always be fitted in the vertical position as any other position will seriously
impaired as an effective seal will not be achieved.
When not in service all re-usable hearing protectors must be kept in a clean dry environment where they can be
protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap and water, dried
off and then stored in a clean dry environment.
5.3.9
Head Protection - As a general rule head protection is not required in production or maintenance
areas at BL-Pegson. However when Plants are undergoing display or test programmes in the field
to the front of the site and stone or other material is being run through the machine Safety
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Safety Helmets are a mandatory requirement for all BL-Pegson personnel when operating, testing, repairing or
adjusting Plant and Machinery at a quarry or demolition / recycling site.
Bump caps are available for all personnel and are recommended for use when working on Plants and Machines
in production and maintenance areas at the Mammoth Street Site.
5.3.10
Fall-arrest Protection - must be worn when working at heights where adequate provision for
guard-rails to prevent falls cannot be established.
Body Harness and attachment systems are available, that can be adjusted to fit the individual.
The attachment system must be connected to a reliable anchorage point. The vertical drop of the
user must be minimised to prevent collision with obstacles and the braking force injuring, tearing
or causing the operator to fall.
Inspections of the equipment must be carried out prior to use to check for wear and damage that
may cause the equipment to fail in operation.
The equipment should be examined every six months in accordance with the Lifting Operations
and Lifting Equipment Regulations 1998.
When not in service all fall arrest protection equipment and attachments must be kept in a clean dry environment
where they can be protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap
and water, dried off and then stored in a clean dry environment.
5.3.11
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Other Protective Equipment - Where BL-Pegson personnel are expected to attend quarrying or
other demolition / recycling sites mandatory requirements for Personal Protective Equipment are:
Hard hats / Helmet
Hearing Protectors
Eye Protection
Foot Protection
High Visibility coat or waistcoat
Respiratory Protection P(SL) strongly recommended
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5.4
Disciplinary Procedure. Persistent failure by any employee to conform with the designated
requirements, for the use of personal protective equipment within any production, maintenance or
test area (as outlined in section 5.2 of this Safety Instruction), will result in the instigation of the
BL-Pegson Ltd progressive disciplinary procedures against him/her.
5.5
Requirement of Control Measures to keep all control measures in a clean condition. The
following is an extract from Regulation 9 of the Control of Substances Hazardous to Health
Regulations 2003.
(5)
Every employer shall ensure that personal protective equipment, including protective clothing, is:
(a)
(b)
(c)
(6)
(7)
The employer shall ensure that the equipment referred to in paragraph (6) is subsequently
decontaminated and cleaned or, if necessary, destroyed.
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1300 Maxtrak
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On
Off
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Engine
Start
Controls.
Hycontrol
display
screen.
PLC
display
screen.
Plant/Track
Controls
All of the controls for starting up the crusher are done from the electrical
panel at the front of the machine.
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Cantrak
Display
Fuel
Gauge
Ignition
Switch
Cat ET
Connector
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Maintenance Due
lamp.
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Plant/Track Controls
Plant/Track
Emergency
Stop
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Fault Mute
Umbilical/Radio
Automatic/Manual
Fault Reset
22
Plant/Track Controls
Product
Feed Conveyor
Conveyor
Manual Feed Conveyor
Lube Pump
Crusher
Speed Control 23
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LEDs
1
2
25
Ignition
Switch
Cantrak
Display
Fault Reset
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Tracking Button
Siren
Button
Note. To switch
off the radio
control, first
press IN the
stop button then
pull back OUT.
27
Directional
Buttons
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Umbilical
Emergency stop
Button
29
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Ensure that the hydraulic pump belts are tight enough otherwise the
machine will not track straight and the chill is out of the hydraulic oil.
The type of trailer determines how the ramps need to be set up.
The higher the trailer the longer the ramps need to be.
Load / unload the machine on level ground
Long shallow ramps enable easier loading
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Tracks
Check oil level monthly
6 litres (1.6 US galls) SAE 80w/90 Gear Oil
First oil change at 100 working hours
Change oil thereafter every 1000 hours or Annually
Filler Plug
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Level Plug
Drain Plug
34
Track Tension
The tracks are tensioned by pumping EP 2 grease into the track tensioner
grease nipple.
Cover
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Grease Nipple
35
Track Tension
Span the tracks with a straight edge between the longest section of
tracks thats unsupported. The tracks should have 15mm (5/8) of sag.
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Track Tension
If there is less then 5mm of sag in the tracks, it will be necessary to let off
some tension. To do this slowly unscrew the grease nipple until it releases
grease .
The grease nipple is under extreme pressure so never remove it until the
grease has stopped coming out.
Recess for grease extraction
Grease Nipple
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Setup Plant
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Setup Plant
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The feed conveyor needs to be raised into the working position as it is lowered
for transport.
Feed
conveyor
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The feed conveyor is hydraulically raised by the lever on the side of the
chassis which connects directly into the bank valve.
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Raise the conveyor in the air to expose the first set of holes and fit the pins.
Swing up the feed chute and secure in place with the four quick release latches.
Travel Brackets
For pins
Working
position
Swing Up
Feed chute
Fit Pins
Hinged
Feed chute
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Ensure that the pin head is not touching the conveyor frame.
Pin Head
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Conveyor
Frame
43
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45
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Hycontrol
0.5m (Pr.5)
2.0m
Feed Off
(Pr.3)
1.0m
(Pr.4)
Feed On
85%
(Pr.9)
55% (Pr.10)
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Pr.1
Pr.2
Pr.3
Pr.4
Pr.5
Pr.7
Pr.8
Pr.9
Pr.10
Pr.23
Pr.29
Pr.37
Pr.40
Pr.71
=
=
=
=
=
=
=
=
=
=
=
=
=
=
1
2
2.0
1.0
0.5
1
1
85
55
2
30
2
1
-0.5
48
Conveyors
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Locknut
Adjusting
stud
Measuring point
(keep equal on
each side )
Locking
bolts
Adjuster
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DOR
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DOR
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Belt Direction
R/H
L/H
D.O.R
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Detect light
Detect Lamp
Reset Button
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Power Lamp
55
The new detectors are fitted with a coil above the belt as well as the one under
the belt.
The bottom coil is the transmitting coil and the top coil is the receiving coil.
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Metal Detector
The metal detector is built into the top end of the feed
conveyor under the belt.
Plastic insert
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Relay
control
Set zero
indicator
LED
Set zero
adjustment
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59
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Dust Suppression
A water manifold is situated at the front of the machine that has outlets to 3
dust suppression spray bars.
The inlet water pressure needs to be 2.8 bar (42 psi) to atomise the water
through the nozzles..
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Discharge conveyor
Crusher discharge
Each nozzle uses approximately 1
litre a minute.
There are filters in the end of the
nozzles that require cleaning if the
water is not clean.
The spray bars can be used
individually or all together.
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The hydraulic system for adjusting the crusher is situated next to the
adjustment panel.
The outgoing pipes from the hydraulic system connect to the crusher
adjustment cylinders and wedge lock dumpy jacks.
Wedge-ring /
crushing pressure
gauge
System
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
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1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM225
upwards February 2004)
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
Pressure Filters
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1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM225
upwards February 2004)
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
10 Micron Absolute
90 Micron Nominal
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Wedge-ring /
crushing
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
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2. Ensure the crusher is not running, Press close until the mantle and concave
touch. This is indicated by a rise in pressure on the wedge-ring / crushing
pressure gauge, recheck that there are no stones in the crushing chamber.
3. Scroll down the screen until you get to SET ZERO.
4. Press enter.
5. Press F3 and this will zero the screen. The amount of wear taken off to get it
to zero gets added to the read wear.
6. Press escape and scroll back to current gap /set gap screen.
7. Set the crusher to the required setting (set gap).
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1. Ensure the crusher is not running. Put the panel into manual and close the
machine metal to metal.
2. If the display reads a minus figure carry out the set zero calibration.
3. Scroll down to manganese wear and press enter.
4. Providing that the calibrations have been carried out correctly the figure
shown is the combined wear gone off the mantle and concave.
5. Press escape and scroll back to the set gap and select a C.S.S
Note: The wear can only be measured when the manganese is touching.
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Select MANUAL, open machine above the SET GAP, select AUTO and
machine will come down to the SET GAP showing wedge-ring pressure of
55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.
2.
Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED
in hirsmann plug) and the wedge-ring pressure will be dumped.
3.
Tramp overload
test button
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Wedge-ring/Crushing
Pressure Gauge
Dump Solenoid C
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Lubrication
Oil Level
Sight glass
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Setup Plant
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Operating Plant
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
On
Off
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Engine
Start
Controls.
Hycontrol
display
screen.
PLC
display
screen.
Plant/Track
Controls
All of the controls for starting up the crusher are done from the electrical
panel at the front of the machine.
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
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LED`s
1
2
3
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Throttle Switch
Ignition Switch
Cantrak
Display
Fault
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Reset
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Fault Mute
Company
Confidential
Fault Reset
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Lub Pump
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Product
Conveyor
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Crusher
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Feed
Conveyor
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
130 cm (51
inches)
Automatic
Manual
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Feed
Conveyor
Feed
Conveyor
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Maxtrak
Starting and Operating plant using remote 1300
control
for100309 issue 2
Feed Conveyor
Inspection glass
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It is essential that the the crusher is choke fed to ensure the machine is is
performing to its best ability. The wear plate should not be visible when the
machine is crushing.
Failure to choke feed the machine will result in low production, poor shape
and a reduction on the material.
In some cases the concave can be worn out of round resulting in premature
manganese changes.
Concave
Wear plate
Mantle
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Check that the feed into the crusher is not Segregated (fine material on one side
and coarse on the other.
When segregation takes place in the crushing chamber it means that there are
voids within the coarse material in the crushing chamber resulting in poorer
shape.
The fine material will encourage packing therefore limiting the crusher CSS (for
working at tighter settings.
Coarse
Material
Fine Material
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Check that the CSS is being maintained (current gap should be the same as set
gap) when crushing.
The CSS can be adjusted whilst the crusher is working (on the fly).
Note the Crushing pressure. (the maximum this should be running at is
approximately 138bar (2000psi) to 145bar (2100psi).
Wedge-ring /
crushing
pressure gauge
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It is essential that the the crusher is choke fed to ensure the machine is is
performing to its best ability. The wear plate should not be visible when the
machine is crushing.
Failure to choke feed the machine will result in low production, poor shape
and a reduction on the material.
In some cases the concave can be worn out of round resulting in premature
manganese changes.
Concave
Wear plate
Mantle
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With the plant running, check the tracking and for spillage on both the
product conveyor and the feed conveyor.
Note. No adjustment should be done to these conveyor when the are
running.
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Stopping Plant
Run the Feed Hopper empty and stop the Feed conveyor.
Reduce the engine speed 1200rpm.
Stop the Crusher (but keep the lubrication system running until the cone
head stops turning)
Stop the Product conveyor.
When the Cone Head stops turning then stop the lubrication pump.
Run the engine at idle speed (1200rpm) for 3 to 5 minutes then switch of
the engine.
Switch of the remote by pushing in the stop button and pulling it back out.
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De-rigging Plant
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De-Rigging Plant
1. Raise the feed conveyor to the highest point and put the pins into the top
holes. Lower the conveyor onto the pins.
2. Clean out the material from the rear half of the feed ring and fold down
hinged door on the feed chute.
3. Raise the feed belt, remove the pins and fit them into the travel brackets.
Lower the feed belt all of the way down.
4. Stop the engine.
5. Lower the miltronics probe into the travel position.
6. Remove all loose stones from the machine.
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Check that both the Feed Hopper and Feed Conveyor is empty of material
Run the Product Conveyor to insure there is not material on it.
Raise the Feed Conveyor to the highest point and put the pins into the top
holes. Lower the conveyor onto the pins.
Clean out the material from the rear half of the Feed ring and fold down
hinged door on the feed chute.
Raise the Feed Conveyor, remove the pins and fit them into the travel
brackets. Lower the Feed Conveyor all of the way down.
4. Fit the transport chain to the Metal Detector top coil.
5. Lower the Level probe into the travel position.
6. Remove all loose stones from the machine.
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MANTLE
LINER
MANTLE
NUT
CONCAVE LINER
ECCENTRIC
MAIN SHAFT
SEALING
WEDGE RING
ASSEMBLY
BEARING
ARRANGEMENTS
MAINFRAME
HYDRAULIC
ADJUSTMENT
CYLINDERS
HYDRAULIC
WEDGE
JACKS
LUBRICATION
DRIVE GEARS
COUNTERSHAFT
ASSEMBLY
Direction of
rotation
718 RPM
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Crusher Motion
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100
Manganese Types
The 1300 Automax has only one eccentric throw which is 45mm.
There are two manganese configurations fitted to the Automax :Standard Manganese
Has the largest feed opening capable of accepting 220 mm (8.1/2 inch) down
material. Ideally suited for making 40mm (1 inch) down material.
Autosand Manganese
Designed to accept a feed size from 63mm (2.1/2 inch) to 13mm (1/2 inch).
Used for applications where plenty of fines and small aggregates are required.
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Manganese Profiles
Automax
Crushing
zones
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102
Manganese Profiles
Automax
Autosand
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Upper Frames
There are two types of upper frames fitted to the crusher to hold the different
profiles of manganese.
The Autosand fit in one support bowl and the Automax in the other.
As the Automax manganese is shallower than the others the difference in the
upper frames are clearly visible.
Automax
Autosand
Upper frame
Upper frame
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The type of material, feed size and bulk density can effect the capacity of the
machine.
The figures in the table below are only guide lines.
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105
The type of material, feed size and bulk density can effect the capacity of the
machine.
The figures in the table below are only guide lines.
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Temperature sensor
Pressure
gauge
Flow meter
Float Switch
Breather /Filler
cap
Temperature
sender
Electrical
junction box
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Sight glass
Hydraulic motor
110
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111
Flow Meter
Hydraulic Motor
125 micron
Breather
Lubrication Pump
Oil Level Sight Gauge
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113
Lubrication Pump =
33.7cc
Suction Filter 90
Micron Nominal
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115
Feed to countershaft
Return to tank
must fall at a
minimum of 5.
Tank
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116
The crusher runs on two different grades of oil depending on the ambient
temperature.
Ambient temperature above 4C (39 F) use an EP 220 ISO VG.
The tank holds approximately 275 litres (73 US. Gallons) of oil.
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Level
float
Sight
glass
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System Pressure
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Pressure Filters
The Lubrication Filter should be checked daily
The oil is pumped from the tank and through two inline pressure filters.
The initial oil and suction filter change needs to be done at 500 hours when
the machine is new.
The oil and suction filter should then be change every 1000 hours there after.
The initial filter change needs to be done at 100 hours when the machine is new
The filters are then changed every 500 hours there after.
Inline pressure
filters
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Blocked
filter sensor
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Sender unit
Air blast
cooler
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123
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124
Solenoid
Engine water
pipes
Feed to the
crusher main
shaft
Feed the
from flow
switch
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Feed to the
counter shaft
125
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126
The lubrication oil is pumped into the crusher from the underside through
the middle of the main shaft.
There is one pipe to return all of the oil back to tank.
Oil return to
the tank
Main shaft
feed in
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Crusher Lubrication
Although there is only one feed into the main shaft there are two feeds out.
One oil port is situated at the top of the main shaft. There is stationary oil
flinger situated directly below the oil port to help distribute the oil evenly.
The oil from this port lubricates the upper and lower cone head bearings.
Oil port
Upper
bearing
Oil flinger
Lower
bearing
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Crusher Lubrication
The lower oil port on the shaft lubricates the main shaft bearing pair and
lower bearing.
Oil port
Upper
bearing pair
Lower
bearing
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Main shaft
feed in
Oil return to
tank
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Inspection glass
Sediment tray
Tank
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Drain plug
132
Sediment
tray
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133
The oil temperature sender unit is situated in the tank so that if the oil
exceeds 80 C (176 F) the crusher will automatically shut down.
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Automax Hydraulic
Adjustment System
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The hydraulic system for adjusting the crusher is situated next to the
adjustment panel.
The outgoing pipes from the hydraulic system connect to the crusher
adjustment cylinders and wedge lock dumpy jacks.
Wedge-ring /
crushing pressure
gauge
System
pressure gauge
Wedge lock
pressure
gauge
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Solenoid C
Solenoid A
To adjustment
cylinders (open
C.S.S.)
Solenoid B
Tank
Pressure In
To Wedge Ring
Wedgelock shut off valve
(normally open)
Company Confidential
1300 Maxtrak
100309 issue 2
1300 Automax Hydraulic Adjustment (Panel
Number
AM225 upwards)
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
Pressure Filters
139
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140
1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM225
upwards February 2004)
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
10 Micron Absolute
90 Micron Nominal
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1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM224
downwards before February 2004)
PS1 159 Bar (2300
PSI) Raising
10 Micron Nominal
10 Micron Absolute
90 Micron Nominal
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Wedge lock
open
Close
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Wedge-ring
The wedge ring has a series of tapers on the inside of it which match up to the
mainframe. The dumpy jacks push the wedge-ring up which makes it expand
due to the tapers thus pushing the pads hard up to the inside of the upperframe to act like a brake.
Wedge-ring pads
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Wedge-ring Principle
Expanding
Wedge Ring
Upper Frame
Upper frame
Mainframe
Wedge Ring
Mainframe
Dumpy Jacks
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Linear Transducer
148
Wedge-ring /
crushing
pressure gauge
Wedge lock
pressure (Dumpy
Jacks) gauge
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2. Ensure the crusher is not running, Press close until the mantle and concave
touch. This is indicated by a rise in pressure on the wedge-ring / crushing
pressure gauge, recheck that there are no stones in the crushing chamber.
3. Scroll down the screen until you get to SET ZERO.
4. Press enter.
5. Press F3 and this will zero the screen. The amount of wear taken off to get it
to zero gets added to the read wear.
6. Press escape and scroll back to current gap /set gap screen.
7. Set the crusher to the required setting (set gap).
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The read wear is the amount of manganese that has worn off the mantle and
concave. There are three indications that the machine needs re-metalling
1. The crushing pressure is too high, preventing you from closing the
machine to the required close side setting.
2. The hydraulic cylinders bottom out restricting the closed side setting.
3. 50mm is the maximum amount of wear to be worn off the manganese.
Wearing more off than this increases the chances of the manganese cracking,
causing damage to the cone head or upper frame.
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1. Ensure the crusher is not running. Put the panel into manual and close the
machine metal to metal.
2. If the display reads a minus figure carry out the set zero calibration.
3. Scroll down to manganese wear and press enter.
4. Providing that the calibrations have been carried out correctly the figure
shown is the combined wear gone off the mantle and concave.
5. Press escape and scroll back to the set gap and select a C.S.S
Note: The wear can only be measured when the manganese is touching.
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Select MANUAL, open machine above the SET GAP, select AUTO and
machine will come down to the SET GAP showing wedge-ring pressure of
55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.
2.
Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED
in hirsmann plug) and the wedge-ring pressure will be dumped.
3.
Tramp overload
test button
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Wedge-ring/Crushing
Pressure Gauge
Dump Solenoid C
156
New Manganese
When the machine is new or when it has been re-metalled the new
manganese calibration needs to be carried out. This is done as follows 1. Ensure the crusher is not running.Put the machine into manual and close
the machine until the mantle and concave touch. This is indicated by a
sudden rise in pressure on the wedge ring / crushing pressure gauge. Ensure
it is metal to metal and no stones are in the crushing chamber.
2. Scroll down the screen using the down arrow until you get to NEW
MANGANESE
3. Press enter
4. Press F4 and it will re-calibrate everything back to zero
5. Press escape.
6. Scroll back up to current gap / set gap display
7. Set new closed side setting
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In Working Mode
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Overload in Automatic
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Dump Line
There is a check valve in the engine compartment which is connected in the
main suction line. The 3/4 pipe connected to the end of it tees in the full bore
side of the adjustment cylinders. When the crusher dumps it can then draw oil
into the bottom of the cylinders as they are being forced open.
Tees to the
cylinders
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Adjustment stack
Pressure reducer
145 Bar (2100psi)
Pressure reducer
166 Bar ( 2400psi)
Relief valve172
Bar (2500psi)
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R1
R2
R3
R4
R5
R7
Relay over-ride
button
Relay
LEDs
Spare fuses
Fuses
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164
Maxtrak
100309 issue 2
Paktronic Electrical Drawing 9673 (Panels 1300
AM272
and
after) August 2004
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1300 Maxtrak
Paktronic Electrical Drawing 9088 (Panels
before100309 issue 2
AM272) August 2004
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OVERLOAD SITUATION
When the pressure in the hydraulic circuit exceeds 159 bar (2300psi) solenoid
C operates. This opens the dump valve which releases all of the pressure from
the top side of the hydraulic cylinders. The crusher is then forced open by
whatever is in the crushing chamber. As the crusher opens, it draws oil into
the bottom of the cylinders through a one way valve on the suction side of the
hydraulic tank. Once the crusher has opened, it will automatically close itself
back down to the original setting by operating solenoid A.
WORKING SITUATION
When the crusher is working nothing in the hydraulic circuit is being
operated. The pressure within the wedge-lock system and the top side of the
hydraulic cylinders is locked in and held by check valves.
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169
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System relief
The system relief is located on the three bank valve in the R/H side of the
engine canopy. It is set at 200 bar (2900 psi) to ensures that sufficient oil
pressure is always available.
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1300 Maxtrak
100309 issue 2
1300 Automax Pressure Switches (Panel Number
AM225
upwards)
Wedgering/Crushing
Pressure Gauge
Wedgering
Valve Stack
Pressure Filters
173
Pressure Switches
Pressure switch 1
Pressure switch 1 is set at 159 bar (2300 psi) rising, when the pressure in the
hydraulic cylinders exceeds this the pressure switch changes over and operates
the dump valve C (via the Paktronic PLC) allowing the crusher to open (note,
it is the material in the crushing chamber that pushes it open). 3 seconds after
the dump valve as been operated the Paktronic PLC with de-energize the
dump valve and close the machine down to it original CSS.
Pressure switch 3
Pressure switch 3 is set at 138 bar (2000psi) falling. When the pressure in
the wedge lock circuit drops below 138bar (2000psi) the pressure switch
changes over operating the Danfoss valve (via the Paktronic PLC) to charge
the system back up. Once the pressure exceeds 138 bar (2000psi) the system
will continue to charge for a further 10 seconds.
If the pressure fails to reach 138 bar (2000psi) the machine will shut down
after 3 minutes displaying pump maximum run.
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Pressure Switches
Pressure switch 4
Pressure switch 4 is set at 103bar (1494psi). If the pressure in the wedge
lock circuit drops below 103bar (1494psi) for more than 30 seconds the
machine will shut down and display wedge lock pressure failure.
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176
Manganese Wear.
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178
179
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181
CAUSES
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DIAGNOSIS
Close the machine metal to metal until it blows through the relief valve at
145bar (2100 psi) on the wedge ring pressure gauge. If the pressure drops
more than 7bar (102psi) in ten minutes there is a leak.
Check the whole of the system for external oil leaks and rectify if necessary.
Re test to see if the pressure still drops.
Disconnect the the two snap connectors and repeat the same process. If the
pressure holds now the leak is within one of the hydraulic cylinders. If the
pressure still drops the leak is within the hydraulic panel.
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Relief valve
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Relief valve
Lock nut
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If the wedge-lock pressure keeps falling and recharging the system, the first
thing to check is the wedge-lock shut off valve is fully closed.
Shut off valve normally closed
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Dumpy jacks
189
190
If the wedge-lock circuit continued to drop pressure whilst trying to set up the
valves, again trial fitting of new parts will be necessary to diagnose the fault.
NOTE
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192
193
CAUSES
Poor manganese.
Incorrectly fitted manganese.
Segregation of feed material.
Continues stop start feed.
Trickle feeding.
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Mantle nut
concave
Typical values
Engine
Feed
Conveyor
1
If there is a difference of more than 6mm between any of the four points, the
manganese needs to be changed immediately.
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Welding on Plant
Whenever any welding is done on the machine the battery isolator key must
be turned off, negative battery lead removed and the ECM plugs must
disconnected
Ensure that the current does not pass through any bearings. (Note, always put
the welding earth cable on/beside the unit that is being welded).
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On
Off
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Cantrak
display
screen.
Hycontrol
display
screen.
PLC
display
screen.
All of the controls for starting up the crusher are done from the electrical
panel at the front of the machine.
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Cantrak
Display
Fuel
Gauge
Ignition
Switch
Cat ET
Connector
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Maintenance Due
lamp.
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The maintenance due light will illuminate every 250 hours and will stay on until
the reset button is pressed.
Maintenance
Lamp
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204
Flash Code
Diagnostic code or
Event Code
Description of Code
n/a
1387-15
E443 (2)
1387-16
1387-00
0441-15
E445 (2)
0441-16
0441-00
626-05
626-06
Company Confidential
545-05
2417-05
545-06
2417-06
205
Flash Code
Diagnostic code or
Event Code
n/a
1835-03
1835-03
1835-04
1835-04
1836-03
1836-03
1836-04
1836-04
111-02
111-02
174-03
174-03
174-04
174-04
678-03
41-03
678-04
41-04
13
21
Company Confidential
Description of Code
206
Flash Code
21
Diagnostic code or
Event Code
Description of Code
620-03
262-03
262-04
100-03
100-03
100-04
100-04
100-10
100-10
102-03
102-03
102-04
102-04
102-10
102-10
1079-03
620-04
1079-04
24
25
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207
Flash Code
Diagnostic code
or Event Code
108-03
274-03
108-04
274-04
110-03
110-03
110-04
110-04
28
91-13
91-13
32
91-08
91-08
34
190-08
190-08
723-08
342-08
190-15
E362 (2)
26
27
35
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Description of Code
208
Diagnostic code or
Event Code
Description of Code
35
190-00
E362 (2)
37
94-03
94-03
94-04
94-04
105-03
172-03
105-04
172-04
42
637-13
261-13
46
100-17
E360 (2)
38
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100-18
100-01
209
Flash Code
51
Diagnostic code or
Event Code
Description of Code
168-00
168-00
168-01
168-01
168-02
168-02
56
630-02
268-02
58
639-09
247-09
61
110-15
E361 (2)
62
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110-16
110-00
111-17
E2143 (2)
210
Flash Code
62
111-18
Diagnostic code or
Event Code
E2143 (2)
111-01
Description of Code
63
94-15
E096
64
1636-15
E539 (2)
1636-00
65
71
Company Confidential
174-15
174-16
174-00
651-05
001-05
211
Flash Code
71
72
73
Company Confidential
Diagnostic code or
Event Code
Description of Code
651-06
001-06
651-11
001-11
652-05
002-05
652-06
002-06
652-11
002-11
653-05
003-05
653-06
003-06
653-11
003-11
212
Flash Code
74
75
76
Diagnostic code or
Event Code
Description of Code
654-05
004-05
654-06
004-06
654-11
004-11
655-05
005-05
655-06
005-06
655-11
005-11
656-05
006-05
656-06
006-06
656-11
006-11
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(1)
(2)
Caterpillar Electronic Technician (ET) will display the number 1,2 or 3 after the event code in order to
designate a warning, a derate, or a shutdown
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C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
On
None
8 Sec
Engine Derate(2)
On
None
4 Sec
Engine Shutdown(3)
On
None
4 Sec
Warn Operator(1)
On
216 Deg F
10 Sec
Engine Derate(2)
On
217 Deg F
10 Sec
Engine Shutdown(3)
On
219 Deg F
10 Sec
Warn Operator(1)
On
2124 RPM
1 Sec
Engine Shutdown(3)
On
2200 RPM
1 Sec
Warn Operator(1)
On
167.0 Deg F
8 Sec
Engine Derate(2)
On
174.2 Deg F
8 Sec
Engine Overspeed
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C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
On
None
10 Sec
Engine Derate(2)
On
None
10 Sec
Engine Shutdown(3)
On
None
10 Sec
Warn Operator(1)
On
194 Deg F
30 Sec
Engine Derate(2)
On
196 Deg F
10 Sec
Engine Shutdown(3)
Off
196 Deg F
10 Sec
On
109.9 PSI
8 Sec
Warn Operator(1)
Off
221 Deg F
4 Sec
Engine Derate(2)
Off
223 Deg F
4 Sec
Engine Shutdown(3)
Off
225 Deg F
4 Sec
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C13 Monitoring
Description
State
Trip Point
Delay Time
Warn Operator(1)
Off
218 PSI
4 Sec
Engine Derate(2)
Off
218 PSI
3 Sec
Engine Shutdown(3)
Off
218 PSI
3 Sec
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ENGINE CANOPY
There are two clasps on either side of the engine that need to be undone.
The dip stick is situated at the rear of the engine nearest the hydraulic tank.
The oil should be checked on a daily basis.
Clasps
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Dip stick
218
219
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220
An indicator is attached on the outlet pipe to show the condition of the filter.
The filter cleaning / changing intervals are all down to the operating
conditions.
The outer air filter is the only one that should be blown out with an airline,
not the inner.
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Level sensor
222
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ECM Plugs
ECM Plugs
225
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Oil level
226
Conveyors
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Skirting Rubbers
Also make the skirt rubbers for the discharge conveyor as long as possible.
Ensure that the feed boot skirt rubber overlaps the first barge board skirt
rubber.
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Motor
Gearbox
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Grease
nipple
232
Skirting Rubbers
Always replace the skirt rubbers once they become worn or damaged.
Always make the skirt rubbers on the feed conveyor in one long piece.
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Locknut
Adjusting
stud
Measuring point
(keep equal on
each side )
Locking
bolts
Adjuster
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DOT
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235
Belt
speed
Wheel
circumference
Revs per
second
Pulses per
Rev
Time
period
Pulses per
second
125 m/m
80 m/m
628 millimetres
628 millimetres
3.31
2.12
2
2
5 seconds
5 seconds
32
20
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DOT
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R/H
L/H
D.O.T
Belt Direction
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LED
Red/Green
Remote On
Track Siren
Remote Feeder
Start/Stop
Engine Stop
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240
LED
Off
Charging Point
12 v dc Cigarette
Lighter Charger
Battery Isolator
Engine Stop
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Battery Pack
LED
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243
The older type umbilical controls are fitted with a 6 or 15 pin plug (Photo is a
15 pin unit).
The function of the buttons are the same as the remote but for tracking only.
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The latest type umbilical is fitted with a heavy duty 16 pin plug and socket.
The function buttons remain the same.
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Button numbers
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The frequency modules in the transmitter and receiver are not removable so
there is no need to open anything to change the frequency.
1. Press the 9 and 0 buttons for at least 1 second, release 9 but keep 0
depressed.
2. Release 0 and press 8 within 0.3 seconds. The yellow LED(2) lights
continuously and the green LED(3) flashes.
3. Enter the pin number 1 2 3 4 then the yellow LED(2) goes out and the green
LED(3) flashes. This indicates the pin number has been entered correctly.
4. Enter 1 of the 16 channel numbers to set the frequency. Note. For single
digit numbers 0 must be pressed first.
5. The yellow LED flashes 3 times and then the transmitter switches off.
The frequency change has now been accepted.
Note. Each time a button is pressed the yellow LED(1) lights also.
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CHANNEL NUMBER
FREQUENCY MHz
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
434.650
434.600
434.550
434.500
434.450
434.400
434.350
434.300
434.250
434.200
434.150
434.100
434.050
434.000
433.950
433.900
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252
Power LEDs
E Stop relays
Fault LEDs
4 5 6
8 9 10
1
Function
selector
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Reset button
Power supply
253
Green LED 1- This indicates the strength of signal that the receiver is getting
from the transmitter.
Reset button(2)- This puts the receiver into the learning mode where it will
tune itself into the transmitter.
Yellow LED(3)- When this LED is illuminated it means that the receiver is
powered up.
Yellow LED(4+8)- This flashes when a transmitter is programmed to the
receiver.
Red LED(5+9)- This indicates faults on the receiver.
Green LED(6+10)- This lights up when the receiver locks onto a transmitter
signal.
Selector switch 2
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1. In the receiver unit turn the function selector switch 2 to the ON position.
2. Press the red reset button. Both sets of green red and yellow LEDs should
illuminate.
3. Release the reset button. The green and red LEDs should go out. The
yellow ones should remain illuminated.
4. Press buttons 9 + 0 simultaneously to power up the transmitter.
5. Press buttons 9 + 0 simultaneously again until the yellow LEDs start to
flash. This indicates the receiver has found the transmitter.
6. On the receiver unit turn the function selector 2 switch to the off position.
7. The receiver is now programmed to the transmitter.
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257
1300
Maxtrak
Programming A Teleradio 860 Transmitter
Into
An 100309
840 issue 2
Receiver
The 840 transmitter is no longer available so all new transmitters are 860s.
The 860 transmitter can be configured to operate as an 840.
If an 840 receiver fails the receiver and transmitter will have to be replaced
because an 840 transmitter will not operate with an 860 receiver.
258
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FREQUENCY MHz
01
02
03
04
434.650
434.600
434.550
434.500
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General Maintenance
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General Maintenance
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262
It is essential that the frame arm shields are checked on a daily basis to ensure
that there isnt any material build up.
Failure to do this will result in the seal ring getting damaged or worse still
lifting the cone head.
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Maintenance Schedule
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264
Maintenance Schedule
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Tracks
Check oil level monthly
6 litres (1.6 US galls) SAE 80w/90 Gear Oil
First oil change at 100 working hours
Change oil thereafter every 1000 hours or Annually
Filler Plug
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Level Plug
Drain Plug
268
Track Tension
The tracks are tensioned by pumping EP 2 grease into the track tensioner
grease nipple when required.
Cover
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Grease Nipple
269
Track Tension
Span the tracks with a straight edge between the longest section of
tracks thats unsupported. The tracks should have 15mm (5/8) of sag.
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270
Track Tension
If there is less then 5mm of sag in the tracks, it will be necessary to let off
some tension. To do this slowly unscrew the grease nipple until it releases
grease .
The grease nipple is under extreme pressure so never remove it until the
grease has stopped coming out.
Recess for grease extraction
Grease Nipple
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271
Hydraulic Tank
Check hydraulic oil level weekly
Change the filters (suction, inline, return) every 1000 or sooner if the tell-tale
indicator shows RED
Change the hydraulic oil every 2000 hours, 360 litres (96 US galls)
Use 46 grade hydraulic oil if the ambient temperature is below 86 F (30 C).
Use 68 grade hydraulic oil if the ambient temperature is above 86 F (30 C).
Inspection covers are fitted to the side of the tank to clean it out when the oil is
changed.
Breather
Level float switch/ sight
gauge. Oil level should
be 40mm below top of
Return filter
sight gauge
Inspection
covers
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Hydraulics
Check the condition of the suction and return filters weekly .
The suction and return filters both have indicators fitted to establish the
condition of the filters.
Unscrewing the shut off valve locks the oil in the hydraulic tank to prevent oil
loss when changing the suction filter element
Filter indicator
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Return Filter
Filter
indicator
274
Hydraulics
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275
Hydraulics
The two inline pressure filters for the crusher adjustment circuit require
changing every 650 hours (4 months).
Inline pressure filter
(return)
(feed in)
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276
Wedge-ring
pressure
Wedge-lock
pressure
Wedge-Ring Greasing
Once the wedge ring has been released the upper frame needs to be positioned
so that the bottom of the upper frame inline with the spacers under the
dumpy jack.
With the upper frame in this position the grease nipples are situated in
between the two wedge ring pads.
Upper-frame
grease nipples
(12 off )
Upper-frame
greasing position
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If the upper frame gets tight and doesnt travel smoothly or it requires more
than 1200psi (82 bar)to close it down it will be necessary to grease the wedge
ring.
1. Put the machine into manual
2. Close valve A and open valve B. The pressure should drop to zero on the
wedge lock pressure gauge
3. Open and close the upper frame until there is no pressure registering on
the wedge ring pressure gauge as you press close
4. Position the upper frame so that the bottom of it is inline with the dumpy
jack shelf. In this position the grease nipples are positioned in-between the
wedge ring pads
5. Grease all 12 of the grease nipples with Moly Bentone MP Grease (part
no 2123-2001). Travel the upper frame up and down to spread the grease
6. Close valve B and open valve A. Select a closed side setting and and the
wedge ring circuit will charge up with oil pressure.
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7. Fully open and close the upper frame and check the travel. The ideal
wedge ring pressure is 800 to 1200psi (55 to 83 bar) as you press close.
8. If the travel is not smooth or the pressure is too high, repeat the greasing
procedure.
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Drive Belts
Pump
Locking Bolts
(4 off)
Back nuts
281
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282
Keep the
engine level
Drive guard
support
bracket
Engine adjusting
stud (4 off )
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Weekly check the condition of both the feed conveyor belt and the
product conveyor belt, check for damage or fraying.
Weekly clean away dust, dirt and grit from the maintenance platforms
and any moving parts.
Weekly check Lubrication oil cooler matrix is clean.
Weekly check the Hydraulic oil cooler matrix is clean.
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Wear plate
Mantle nut
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The mainframe arm supports are fitted with replaceable arm shields to
prevent any wear.
The frame arm shields just drop over the arm support as does the
countershaft arm shield but the countershaft shield locates over a key-way to
prevent it from moving.
The head and eccentric need to be removed from the machine to replace them
so plan to do it when the machine is being re metalled.
Countershaft arm shield
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Key
289
The mainframe also has welded in liner plates fitted all of the way around it.
So provided that all liners and arm shields get replaced before they wear
through no wear should take place on the main frame.
Liner plates
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Wedge lock
pressure
gauge
Valve B
291
Fully raise the feed conveyor and place the pins in the bottom holes.
Lower down the feed conveyor so that it sits on the pins.
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Feed Ring
Remove the three retaining bolts from the crusher feed chute and lift off the
crusher feed chute.
There are 2 holes in the top of the feed ring for the lifting point.
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Linear Transducer
Disconnect the stud from the mainframe that is attached to the linear
transducer.
Push the transducer all of the way down so that the stud cannot foul on the
upper frame when it is lifted off.
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Using a set of three leg chains take the weight of the upper frame from the
lifting lugs.
The upper frame weighs 4 ton (4.5 US ton) but use a set of chains of twice that
capacity to allow for drag on the wedge ring.
Lifting lugs x 4
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Remove the six split pins and washers from the right hand side of the pins.
Knock out the pins from right to left with a hammer and punch. They have to
be knocked out in this direction because the bearings in the upper frame are
butted against a shoulder and get dislodged if the pins are removed from the
other direction causing premature bearing failure.
Take care when removing the the last pin because the upper frame may move
if there is too much or too little weight on the chains.
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Slowly lift off the upper frame ensuring there is equal weight on each chain
and the upper frame is lifting off squarely.
DO NOT FORCE THE UPPER FRAME OFF WITH THE CRANE IF IT IS
TIGHT AS IT WILL CREATE A DANGEROUS SITUATION WHEN IT
COMES FREE.
If the upper frame is tight jack it off from the underside.
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Mantle
nut
Mantle
Burning
point
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Clean out the dirt from the square hole in the top of the mantle nut and slide
in the flogging bar.
Using a sledge hammer knock the nut undone.
THE NUT IS LEFT HAND THREAD. ROTATE CLOCKWISE TO LOOSEN.
Flogging
bar
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Slide a bar through the nut and remove it with the crane.
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Loosen the mantle by hitting it with a sledge hammer. Using a couple of pry
bars lift up the mantle and drop a chain down the inside. Place the hook back
onto the chain at the top of the mantle.
Alternatively two lifting lugs can be welded to the mantle. Ensure that the
correct type of welding rod is used and a sufficient amount of weld is applied
to hold the weight.
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As the mantle is lifted off take care not to damage the threads on the cone
head.
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Clean the dirt away from the underside of the three lugs and burn them off.
Cleaning under the lugs eases burning and allows the lug to be cut off in one
attempt.
As with the mantle weaving the torch makes it easier to get a clean cut.
Take care not to damage the wedges when burning off the lugs.
Lug x 3
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Once the lugs have been burnt off the concave can then be knocked out using
a sledge hammer.
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Check the lower seating area where the concave fits for burrs and remove them
with either a sanding disk or grinder depending on the severity.
Smear the inside of the upper frame with release agent where the crusher
backing sits ensuring there is plenty around the three pockets.
A thin smear of grease can be used if release agent is not available.
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Smear the inside of the upper frame with release agent where the crusher
backing sits ensuring there is plenty around the three pockets.
A thin smear of grease can be used if release agent is not available.
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Clean up the taper on the concave to remove the anti rusting agent and check
for burrs and dress a necessary.
Taper
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Lift up the upper frame and lower it down onto the new concave.
Guide the upper frame so that the 3 lugs on the concave pass through the 3
pockets in the upper frame.
As soon as the lugs clear the top of the upper frame rotate the upper frame
anti clockwise so that the lugs on the concave are half way between the dowel
hole and pocket.
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Using a pry bar seat the concave level within the upper frame.
To do this use a tape measure to ensure the distance between the underside of
the lugs and upper frame all the same.
Slide in the three wedges ( from right to left) and the rear edge of the wedge
needs to be about 30 mm (1) before the dowel hole.
If not lift up the upper frame and rotate it. For example if the back of the
wedge has gone beyond the dowel hole the upper frame will need to be
rotated clockwise, or rotate it anti clockwise if the wedge is not near enough
the dowel hole.
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Drive in the wedges with a sledge hammer. Ideally with 2 people and a tee
bar.
ALWAYS WEAR SAFETY GLASSES WHEN DOING THIS.
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Drive in the wedges so that the back of the wedge just goes beyond the dowel
hole and fit the dowel with anti seize grease.
If the wedge is not tight when it gets to the dowel hole continue to drive it in
until it is tight then weld something to the back of it that butts up to the
dowel.
Dont worry if all three wedges stop in a different position as this is common.
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Cone head
taper.
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Smear the rest of the cone head with release agent. If release agent is not
available a thin smear of grease can be used.
A bead of silicon can be placed on the taper to prevent any leakage.
Cone head
Cone head
taper.
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The best way to lift up the mantle is to use a set of 3 or4 leg chains and hook
the mantle from the underside.
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The mantle will sit on the cone head and trap the hooks. Just Knock out the
hooks with a pry bar.
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Re fit the mantle nut and tighten to square up the mantle and squash the
grease on the taper to create a good seal.
Remove the mantle nut and grease the cone head threads.
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Crusher Backing
Using a drill and a suitable mixing paddle stir up the crusher backing
ensuring to loosen it up in the bottom of the container. Add the hardener and
mix the backing until it is one even colour and texture.
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Pour the crusher backing between the cone head and mantle until the level is
25mm from the top(1 inch).
DO NOT OVER FILL THE MANLTE AS THIS WILL MAKE IT
DIFFICULT TO BURN ON THE NEXT REMETAL.
Poor any left over backing into one of the concave pockets.
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Re fit the mantle nut and tighten with the flogging bar in an anti clockwise
direction. Put a chalk mark on the mantle and nut then tighten some more
until the nut has come to a complete stop.
FAILURE TO TIGHTEN THE NUT SUFFICIENTLY WILL RESULT IN
THE NUT COMING LOOSE AND POSSIBLE CONE HEAD DAMAGE.
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Putting a chalk mark is the best way to judge that the mantle nut has come to
a complete stop.
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Clean up the cylinders and bearings in the upper frame with emery cloth or a
flat wheel. Also clean up the cylinder pins with emery cloth.
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Clean off the wedge ring and brush on a light smear of moly-bentone grease
on the pads and on the wedge ring dust seal.
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Upper Frame
Clean up the inside of the upper frame where the wedge ring pads run.
Inspect for any burrs and dress accordingly. If the re metals arent very
frequent it may be necessary to clean it with a sanding disk or emery paper to
remove any rust or dust and make it smooth again.
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Mix the crusher backing one tub at a time and pour it into the 3 pockets of
the upper frame. Fill it up until the backing is about 10mm (3/8) within the
top of the upper frame.
Clean out the stones from the bottom inside lip of the crusher feed chute and
re fit.
Remove the pins from the feed conveyor and lower into the working position.
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3. Select a css below the actual setting and put the machine into auto. The
upper frame will come down to its setting and then the wedge lock circuit
will charge up with oil pressure.
Wedge ring
pressure
gauge
Valve A
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Wedge lock
pressure
gauge
Valve B
331
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333
Two identical pumps are mounted either side of the engine, belt driven from
the engine crankshaft.
This pump supplies oil to the three bank valve.
The oil is drawn through a suction filter into the pump, through an inline
pressure filter and into the three bank valve.
Drive belts
To the 3
bank valve
Pump
Suction
Pressure
Filter
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The three bank valve is mounted inside the engine Canopy near the pump.
The first section is the feed and return to the valve.
The 1st splice goes to the tracks.
The 2nd splice goes to the product conveyor and HFO clutch. The clutch line
tees into the feed line for the discharge conveyor.
The 3rd splice goes to the crusher adjustment circuit.
To the discharge
conveyor
To the crusher
adjustment
circuit
To the HFO
clutch
To the
R/H track
Feed in
To tank
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R/H Track
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336
Track Drive
The feed comes in to the Motion Control valve bank and automatically
releases the brake.
The two track motors tee the case drains together before going to tank
The purpose of the cross line check valve is to prevent the machine from
running away on a steep slope or if a pipe bursts
Track feeds
Track Motor
Brake Release
Motion
Control
valve
block
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337
Pressure
switch
Relief
valve
Solenoid
valve
Restrictor
valve
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Accumulator
338
(1.3 gal)
(479 psi)
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(1.3 gal)
(479 psi)
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340
The feed comes in through a check valve and into port B in the motor.
The check valve is fitted to prevent the belt running back if it stops loaded.
The case drain is fitted to prevent any back pressure going to the motor shaft
seal.
Feed Line
(B Port)
Return Line
(A Port)
Check Valve
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Case Drain
341
Pressure in
from the bank
valve
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342
Load
sensing
line
To the
bank
valve
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343
Feed in
To tank
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L/H Track
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345
A check valve is fitted to stop the belt from rolling back when it is stopped
under load either by the milltronics or the metal detector.
Case drain
Return
line
Check
valve
Feed line
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346
Breather
Single acting cylinder
with a check valve safety
Up
Down
Check valve
Manual operation
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Feed
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Return
348
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349
Hydraulic Pump
The hydraulic pump only delivers oil flow on demand, unlike fixed gear
pumps. The standby pressure is set at 30 bar (435psi) and the pump will
deliver a small amount of oil to maintain that pressure. When a function is
operated, the pump detects a pressure drop on the 30 bar (435 psi) and the
swash plate is moved to pump more oil. This happens in a split second. The
system always maintains 30 bar(435psi) more in the pressure line than the
load sensing line.
Case Drain
Load Sensing
Line
Standby
Pressure Relief
30 bar
(435 psi)
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Hydraulic Pump
When all functions are switched off the pump will de-swash and return to a
low flow maintaining the 30 bar (435psi)stand by pressure.
The pump has its own relief valve set at 320 bar(4641psi). If the pressure
exceeds 320 bar(4641psi), the pump will de-swash, drop to a low flow but
maintain 320 bar(4641psi).
Case Drain
Load Sensing
Line
Standby
Pressure Relief
30 Bar (435psi)
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Servo Piston
Rotating Kit
Swash plate
Tapered
Roller
Bearing
Tapered
Roller
Bearing
Shaft Seal
Valve Plate
Bias Piston
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Piston
352
Servo piston
Swash plate
Bias Piston
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353
Load Pressure
Control Handle
Valve /Orifice
Flow to
Servo Piston
System Pressure
Pump
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354
Port blocked.
0 bar.
CONTROL
Bank valve
VALVE
X PORT
B Port
30 bar (435psi).
BIAS
Remote Port
Stroked to
give 2cc / rev
M4 Port
L1,L2 Ports
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S port
Gain Orifice (Optional)
355
CONTROL
Bank
valve
VALVE
X PORT
B Port
80 bar (1160psi).
BIAS
Remote Port
Stroked to
give 31 / rev
M4 Port
L1,L2 Ports
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S port
Gain Orifice (Optional)
356
CONTROL
Bank valve
VALVE
X PORT
B Port
210 bar(3045psi).
BIAS
Remote Port
Stroked to give
50cc / rev
M4 Port
L1,L2 Ports
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S port
Gain Orifice (Optional)
357
@ 4205psi)
290 bar(4205psi)
CONTROL
Bank valve
VALVE
X PORT
B Port
BIAS
Stroked to give
2cc / rev
M4 Port
L1,L2 Ports
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S port
Gain Orifice (Optional)
358
Product
conveyor relief
210 bar
(3046 psi)
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Main
pressure
relief
350 bar
(5076psi)
359
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360
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Needle valve
361
(1.3 gal)
(479 psi)
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362
(1.3 gal)
(479 psi)
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363
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Track
Crusher
adjustment
Product
conveyor
Relief Valve
200 Bar
2900psi
364
Main Bank
Valve Relief
(350 Bar)
(5076psi)
180 bar
(2610psi)
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100 bar
(1450psi)
140 bar
(2030psi)
365
Feed conveyor
Earth Pin to Pin 2
5-10v
Lubrication motor
Earth to Pin1 = 24v
Track
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Feed
conveyor
Lubrication
motor
366
Actuator Pins
Pin 1 is the supply voltage into the actuator.
Pin2 is the variable voltage into the actuator which controls the spool
direction and spool travel for variable oil flow.
None of the pins receive any voltage until a track button is pressed.
Earth.
Pin 1.
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Pin 2.
367
Actuator Pins
There are only 2 wires used on the on / off type actuator.
Pin 1 receives 24 volts which moves the lever up which pressurises out of the
bottom port. (as the valve is shown)
Earth.
Pin 1
24 volt
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368
Max spool
travel
No spool travel
Max spool
travel
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Max flow
19 volts
no flow
12 volts
Max flow
5 volts
Lever travels up to
pressurise out of the
top port. (as the
valve is mounted)
369
370
Actuator Identification
Three types of actuator are fitted to the bank valves. The track and feed
conveyor actuator look the same but are different. The feed conveyor actuator
is more sensitive and can move the spool more gradually for a wider range of
oil flows. The feeder actuator can also be identified by an LED. The track and
feed conveyor work on a variable voltage where as the others are 24 volt on or
off.
The LED should be illuminated green when the feed conveyor is operating.
LED
Motor
circuits
Track
Feed
conveyor
PVEM
PVEH
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Lubrication
motor
157B4228
Feed conveyor
Number
157B4088
Track Number
157B4128
371
PVEM/PVEH
+8
+6
+4
+2
-2
-4
P tank: 8 bar
U DC : 24 V
Freq: 0,02 Hz
-6
-8
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372
Actuator Operation
Closed loop control of the main spool
Pilot-oil
Electronics
Valves
Electronic sender
unit
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Locator pin
373
Actuator Operation
O rings
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Locator pin
374
Body Identification
All of the splices in the bank can be identified by the numbers on the bottom.
Track body number 6000
Inlet body number 5111
All other body numbers 6203
All of the end caps are the same.
The only difference between the track body and the other bodies are the relief
valves.
5111
Engraved
numbers
6000
6203
6203
6203
End cap
Inlet
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375
Lubrication motor 15
l/min (3.9 US gal)
Feed conveyor 75
l/min (19.8 US gal)
Spool
Removal
Company Confidential
Feed conveyor
fold 25 l/min (6.6
US gal)
376
Crusher
adjustment
Track
Product
conveyor
Product
conveyor
100
26.3 US gal
Crusher
adjustment
4
1.05 US gal
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Spool Sizes
The size of the oil groove in the spool determines the oil flow.
The bigger the groove the greater the flow.
The spool size can be identified by the Danfoss number etched into the end of
it.
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The pressure compensator ensures the the valve delivers a constant oil flow
regardless of the working pressure.
Spool
Pressure
compensator
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379
Spool Direction
The direction of the spool determines which port is pressure and which is the
return.
Tank
Pressure
Load
sensing
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8mm (5/16)
13mm (1/2)
381
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383
Track Brakes
= Pressure
= Blue Return
= Case Drain
384
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Electrical System
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Cantrak
display
screen.
Hycontrol
display
screen.
PLC
display
screen.
All of the controls for starting up the crusher are done from the electrical
panel at the front of the machine.
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Contact
blocks
Potentiometer, feed
belt speed control
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392
Relays and
Identification
Timer
PLC
24 Volt DC
to DC
Converter
Radio
Control
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393
Expansion D.C
Outputs.O/12-O/19
Embedded
D.C Outputs.
O/0-O/11
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LEDs
394
Run light
should be on
(green)
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395
PLC Processor
To remove the processor push the retaining clip to the left and at the same
time slide the whole of the processor to the left.
Blow out the pins in the PLC and processor to remove any dust then refit.
Retaining clip
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396
Maxtrak PLC
Open in plastic cover on the left hand side of the PLC to reveal the run rem
prog switch.
Cover
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397
MAXTRAK PLC
Switch
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398
399
PLC Battery
The PLC has its own battery to ensure that there is always a power supply.
This battery should last 3 or 4 years.
When it does start to go flat the PLC screen will display PLC Battery low.
The replacement battery will have a cable connected to it so that it is plugged
into the spare battery holder and then plugged into the PLC.
Only then can the original battery be removed.
Spare battery
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400
PLC
Relays
Fuses
Spare Fuses
Layout
Diagram
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401
OK light Lit
Run Light
OFF
Screen 1
NOT USED
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407
Kobold Sensors
If the Kobold is giving a low flow signal, remove both gears and clean the two
sensors which are fitted to the gear which is fitted opposite the circuit board.
Clean the teeth on both gears.
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