ADVANCED CRUSHING TECHNOLOGY

428 TRAKPACTOR

PLANT USER MANUAL

OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
Safety. This manual contains safety information which the
operator should read and follow. Failure to do this will
increase the risk of injury or may result in death.

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 IMPORTANT
TEREX PEGSON PLANTS CAN INCLUDE
OPTIONAL EQUIPMENT AND/OR SPECIAL
FEATURES ADDITIONAL TO THE
STANDARD SPECIFICATION.
THESE MAY AFFECT THE INFORMATION
GIVEN IN THIS OPERATORS MANUAL.
LOOK IN SECTION 11 - APPENDIX OF THIS
MANUAL FOR ANY ADDENDUM WHICH
MAY RELATE TO ADDITIONAL EQUIPMENT
OR VARIATIONS TO THE STANDARD
SPECIFICATION.
TAKE NOTE OF ANY VARIATIONS TO THE
STANDARD PROCEDURES AND/OR
COMPONENT SPECIFICATIONS.

Options EN

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IMPORTANT SAFETY NOTICE!

The environment in which the plant will operate can contain risks to health and safety
which the operator must take steps to identify and guard against. Dangers from overhead
conveyor discharges, overspill material, vehicle movements, etc., as well as other site
related hazards must be anticipated. Avoid these dangers by carrying out risk
assessments before the plant is put into operation to ensure appropriate measures are
implemented and site personnel safety awareness training has been undertaken.

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.

Follow all applicable safety regulations and recommendations in this manual as

appropriate to your plant and the situation/conditions prevailing at the time.

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

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

INFORMATION AND ADVICE

If you need any information or advice regarding your 428 Trakpactor contact:-

BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire LE67 3GN
England

Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : sales@bl-pegson.com

or

Terex Crushing & Screening Inc

11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.

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

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EC Conformity

This plant is in conformity with the

provisions of the EC Machinery Directive
98/37/EC together with appropriate EN
Harmonised Standards and National BS
Standards and Specifications.

Noise Level

HEARING HAZARD
EXCEEDS 90 dB (A)

May cause loss or degradation of hearing

over a period of time.

Wear proper hearing personal protective

equipment.

Dust Generation

INHALATION HAZARD

Death, serious injury or delayed lung disease

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

When dusts are generated by the operation of this

equipment, use approved respiratory protection,
as required by Federal, State and Local safety and
health regulations.

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Units of Measure

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

CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Proposition 65 Warning
WARNING: Battery Posts, terminals and
WARNING: Diesel engine exhaust and
related accessories contain lead and lead
some of it’s constituents are known to the
compounds, chemicals known to the State
State of California to cause cancer, birth
of California to cause cancer and
defects, and other reproductive harm.
reproductive harm.
WASH HANDS AFTER HANDLING.

Copyright

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

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

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

BL-Pegson Limited Telephone:- + 44 1530 518600

Mammoth Street
Coalville Fax:- + 44 1530 518618
Leicestershire
LE67 3GN E mail sales@bl-pegson.com
England
To order additional copies contact your local BL-Pegson Ltd Dealer.

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Page 1

Contents

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

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

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

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

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

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

1.8 Plant Warning Signs .......................................................................................... 14

1.8.1 Location of Warning Signs. Left Hand side of plant ....................................... 14
1.8.2 Location of Warning Signs - ENTANGLEMENT HAZARD .............................16
1.8.3 Safety Sign Illustrations................................................................................. 18

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
15/12/04

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1.1 Warnings and Symbols

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

This is the safety alert symbol. When you see this symbol on your plant or in this
manual, be alert to the potential for personal injury or equipment damage.

Follow the recommended precautions and safe operating practices.

Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe working practices.

Indicates a statement of company policy as the message relates directly or indirectly to the
safety of personnel and protection of property.

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1.2 Organisation Measures Observe all safety instructions and warnings

attached to the plant.
1.2.1
See to it that safety instructions and
Ascertain from the appropriate Authority warnings attached to the plant are always
and observe all statutory and any other complete and perfectly legible.
regulations that may apply to the planned
location before operating the Trakpactor. Keep warnings and instruction labels clean.

Loose or baggy clothing can get caught in Replace unreadable or missing labels with
running machinery. new ones before operating the plant. Make
sure replacement parts include warning or
Where possible when working close to instruction labels where necessary.
engines or machinery, only do so when they
are stopped. If this is not practical, 1.2.3
remember to keep tools, test equipment
and all other parts of your body well away Understand service procedure before doing
from the moving parts. work. Keep area clean and dry.

For reasons of safety, long hair must be tied Never lubricate, clean, service or adjust
back or otherwise secured, garments must machinery while it is moving. Keep hands,
be close fitting and no jewellery such as feet and clothing clear of power driven
rings may be worn. Injury may result from parts and in running nip-points. Disengage
being caught up in the machinery or from all power and operate controls to relieve
rings catching on moving parts. pressure. Stop the engine. Implement
lockout procedure. Allow the machinery to
Always wear correctly fitting (EN/ANSI cool.
approved) personal protective equipment.
Keep all parts in good condition. Ensure
Personal Protective Equipment includes that all parts are properly installed. Fix
Hard Hat, Safety Glasses, Hearing damage immediately. Replace worn and
Protection, Dust Mask, Close fitting broken parts. Remove any build up of
Overalls, Steel Toed Boots, Industrial grease, oil and debris.
Gloves and a High Visibility Vest.
Disconnect battery ground cable before
1.2.2 making adjustments on electrical systems or
welding on plant.
You can be injured if you do not obey the
safety instructions as indicated on warning
stickers.

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For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted to Qualification of Personnel -
the task on hand are absolutely
Basic Responsibilities
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must be
Never make any modifications, additions or
executed by trained, reliable and authorised
conversions which might affect safety
personnel only. Statutory minimum age
without the supplier’s approval.
limits must be observed.
In the event of safety relevant modifications
1.3.2
or changes in the behaviour of the plant
during operation, stop the plant and lock Work on electrical system and equipment of
out immediately and report the malfunction the plant must be carried out only by a
to the competent authority/person. skilled electrician or by instructed persons
under the supervision and guidance of a
skilled electrician and in accordance with
electrical engineering rules and regulations.

1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.

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1.4 Safety Instructions 1.4.2 Special Work In Conjunction

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

Switch off and lockout the plant before

removing any safety devices or guarding.

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1.4.2.3 For carrying out overhead assembly work

always use specially designed or otherwise
Carry out maintenance and repair work safety-oriented ladders and working
only if the plant is positioned on stable and platforms.
level ground and has been secured against
inadvertent movement and buckling. Always use any walkway/platforms
provided or a safe and secure platform
1.4.2.4 approved by the regional safety enforcing
Never allow unqualified or untrained authority.
personnel to attempt to remove or replace
any part of the plant, or anyone to remove Always use a suitable lifting platform before
large or heavy components without attempting any work 2 metres (6’- 6”) or
adequate lifting tackle. more above the ground level.

To avoid the risk of accidents, individual Keep all handles, steps, handrails,
parts and large assemblies being moved for platforms, landing and ladders free from
replacement purposes should be carefully dirt, oil, snow and ice.
attached to lifting tackle and secured. Use
only suitable and technically adequate lifting 1.4.2.6
gear. The fastening of loads and instructing of
crane operators should be entrusted to
Never work or stand under suspended experienced persons only. The marshaller
loads. giving the instructions must be within sight
or sound of the operator.
Keep away from the feed hopper and
product conveyor discharge, where there is 1.4.2.7
risk of serious injury or death due to the
loading and removal of material. After cleaning, examine all fuel, lubricant,
and hydraulic fluid lines for leaks, loose
1.4.2.5 connections, chafe marks and damage. Any
defects found must be rectified without
Falling from and/or onto a BL-Pegson plant delay.
can cause injury or even death.
1.4.2.8
Do not climb on the plant whilst it is in
operation. Never use plant parts as a Any safety devices removed for set-up,
climbing aid. maintenance or repair purposes must be
refitted and checked immediately upon
Beware of moving haulage and loading completion of the maintenance and repair
equipment in the vicinity of the plant. work to ensure full working order.

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1.4.2.9 1.4.2.11
Improperly disposing of waste can threaten Diesel fuel is highly flammable.
the environment and ecology. Potentially
harmful waste used with BL-Pegson Never remove the filler cap, or refuel, with
equipment includes such items as oil, fuel, the engine running.
coolant, filters and batteries, etc.
Never add gasoline or any other fuels
Use leakproof containers when draining mixed to diesel because of increased fire or
fluids. Do not use food or beverage explosion risks.
containers that may mislead someone into
drinking from them. Do not carry out maintenance on the fuel
system near naked lights or sources of
Do not pour waste onto the ground, down sparks, such as welding equipment or whilst
a drain or into any water source. smoking.

Ensure that all consumables and replaced 1.4.2.12

parts are disposed of safely and with
Using unapproved structures i.e. walkways/
minimum environmental impact.
platforms etc. in the vicinity of a BL-Pegson
1.4.2.10 plant is very dangerous and could lead to
serious injury or even death through falling
Always ensure that any safety fitment such and/or entanglement with the plant.
as locking wedges, securing chains, bars or
struts are utilised as indicated in these Do not use any unauthorised structures.
operating instructions.

Particularly make sure that any part of the

plant raised for any reason is prevented
from falling by securing in a safe reliable
manner.

Never work under unsupported

equipment.

Never work alone.

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1.5 Warning of Special 1.5.1.4

Dangers Work on the electrical system or equipment
may only be carried out by a skilled and
1.5.1 Electric Energy qualified electrician or by specially
1.5.1.1 instructed personnel under the control and
supervision of such an electrician and in
Use only original fuses with the specified accordance with applicable electrical
current rating. Switch off the plant engineering rules.
immediately if trouble occurs in the
electrical system. 1.5.1.5

Plants with high voltage electrical equipment If provided for in the regulations, the power
must be suitably earth bonded by a supply to parts of plants and plants, on
qualified electrician prior to activating the which inspection, maintenance and repair
main isolator switch. work is to be carried out must be cut off.
Before starting any work, check the de-
1.5.1.2 energized parts for presence of power and
ground or short circuit them in addition to
When working with the plant, maintain a insulating adjacent live parts and elements.
safe distance from overhead electric lines. If
work is to be carried out close to overhead 1.5.1.6
lines, the working equipment must be kept
well away from them. Check out the The electrical equipment of the plant is to
prescribed safety distances. be inspected and checked at regular
intervals. Defects such as loose connections
1.5.1.3 or scorched or otherwise damaged cables
must be rectified immediately.
If your plant comes into contact with a live
wire:

• Warn others against approaching and

touching the plant.

• Have the live wire de-energized.

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1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

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

1.5.1.8 Observe the regulations in force at the

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

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1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with hearing protection of laid and fitted properly. Ensure that no
approved pattern and that these are worn at connections are interchanged. The fittings,
all times when the plant is operating. lengths and quality of the hoses must
comply with the technical requirements.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects 1.5.3.5
of air pollution of any kind.
Always practice extreme cleanliness
1.5.3 Hydraulic and Pneumatic servicing hydraulic components.
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can
Work on hydraulic equipment may be penetrate the skin causing serious injury.
carried out only by persons having special
knowledge and experience in hydraulic If fluid is injected under the skin, it must be
systems. surgically removed or gangrene will result.
Get medical help immediately.
1.5.3.2
Always relieve pressure from the hydraulic
Check all lines, hoses and screwed system before carrying out any kind of
connections regularly for leaks and obvious maintenance or adjustment.
damage. Repair damage immediately.
Splashed oil may cause injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4. Hazardous Substances
pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification, labelling,
for the unit concerned before carrying out storage, use and disposal, all strictly in
any repair work. accordance with the manufacturers
instructions and that all applicable
regulations are observed at all times.

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1.6 Transporting, 1.6.7

Manoeuvring and When travelling on public roads, ways and
Recommissioning places, always observe the valid traffic
regulations and, if necessary, ensure
1.6.1 beforehand that the plant is in a condition
compatible with these regulations.
The plant must be towed, loaded and
transported only in accordance with the
1.6.8
operating instructions.
In conditions of poor visibility and after
1.6.2 dark, always switch on the lighting system
of the transporting vehicle..
For towing the plant, observe the
prescribed transport position, admissible
1.6.9
speed and itinerary.
When crossing underpasses, bridges and
1.6.3 tunnels or when passing under overhead
lines always make sure that there is
Use only appropriate means of transport
sufficient clearance.
and lifting gear where applicable of
adequate capacity.
1.6.10
1.6.4 Never travel across slopes; always keep
the working equipment and the load close
The recommissioning procedure must be
to the ground, especially when travelling
strictly in accordance with the operating
downhill.
instructions.
1.6.11
1.6.5
On sloping terrain, always adapt your
Before starting work or travelling with the
travelling speed to the relevant ground
plant, check that the braking, and any
conditions. Never change to a lower gear
signalling and lighting systems are fully
on a slope. Always change gear before
functional.
reaching a slope.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.

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1.6.12
Explosive separation of a tyre and rim parts
can cause injury or death.

Do not attempt to mount a tyre unless you

have the proper equipment to perform the
job.

Always maintain the correct pressure. Do

not inflate the tyre above the recommended
pressure. Never weld or heat wheel and
tyre assembly. The heat can cause an
increase in air pressure resulting in a tyre
explosion. Welding can structurally weaken
or deform the wheel.

When inflating tyres, use a clip-on chuck

and extension hose long enough to allow
you to stand to one side and not in front or
over the assembly. Use safety cage if
available.

Check wheels for low pressure, cuts,

bubbles, damaged rims or missing lug bolts
and nuts.

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1.7 Position of Emergency Stop Buttons & Isolation Switch

Emergency Stop Button

(Control Panel) Lockable
Isolation Switch
(Diesel Engine)

Emergency Stop Button

(Chassis Side)

Emergency Stop Button

(Chassis Side)

Figure 1a - Emergency Stop Buttons & Isolation Switch

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

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1.8 Plant Warning Signs

1.8.1 Location of Warning Signs.

Left Hand side of plant

Figure 1b Warning Labels - Left Hand Side

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Location of Warning Signs, Right
Hand side of plant

Figure 1c Warning Labels - Right Hand Side

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1.8.2 Location of Warning Signs - ENTANGLEMENT HAZARD

Safety Decal: 300/268 ‘Danger - Entanglement Hazard for Crusher & Panel’

Decal Location - 428 Trakpactor:

Control Panel, 428 Trakpactor

Impactor non-drive side, 428 Trakpactor

Impactor drive side, 428 Trakpactor

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Safety Decal: 300/269 ‘Danger - Entanglement Hazard for Inspection Door’

Decal Location - 428 Trakpactor:

Inspection door both sides of impactor,

428 Trakpactor

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1.8.3 Safety Sign Illustrations

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1 2 3 5

6 7 8 9

11

12 13 16

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Safety Sign Illustrations, continued

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17 19 21 23

27
29

28

31

32

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Blank Page

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Page 1

Contents

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

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

2.3 Feeder................................................................................................................... 4

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

2.5 Product Conveyor ............................................................................................... 5

2.6 Tracks ................................................................................................................... 5

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

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

2.9 Dirt Conveyor ....................................................................................................... 6

2.10 Magnetic Separator ........................................................................................... 6

2.11 Belt Weigher (optional) ...................................................................................... 6

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
15/12/04

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 2.1 Dimensions
3280
(10’ -9”)

2320 (7’- 7”)

3075 3300 7200

(10’- 1”) (10’- 10”) (23’- 7”)
CENTRE OF GRAVITY

ALL DIMENSIONS ARE IN MILLIMETRES (FEET/INCHES)

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Overall Length - 14092mm (46’- 3”)

Overall Height (Excluding Transport Trailer) 3440mm (11’- 4”)

2 - Technical Information

Overall Width (Dirt Conveyor Folded) 2800mm (9’- 2”)

3440
(11’- 4”)
2060

Gross Weight approx. 33.4 tonnes (36.74 US tons)

(6’- 9”)

Note: Weights and dimensions are for guidance only and

428

appropriate allowances should be applied when being used for 2700

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
Page 2
Trakpactor

(8’- 10”)
Issue EN 02

transportation purposes.
Figure 2a Dimensions Viewed from the rear of the Trakpactor
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2.2 Plant Description

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

FRONT

REAR
Magnetic Overband
Separator

Tracks
LEFT HAND SIDE

Dirt Conveyor (Head drum guard and

side skirt plates are removed for
Feeder transport)
Product Conveyor

FRONT

REAR
Engine Maintenance
Platform

Control Box
Maintenance
Platform RIGHT HAND SIDE Figure 2b Plant Terms

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2.3 Feeder

Type Spring mounted vibrating pan

Width 1080mm (43”)
Length 3800mm (12’- 6”)
Unit Twin shaft oil lubricated
Grizzly Stepped fixed bars preset at nom. 50mm (2”) spaces (at
discharge end) Renewable tips at discharge end.
Underscreen Blank mat fitted as standard (wire mesh an optional
fitting)
Drive Hydraulic motor
Control Variable speed
Hopper Heavy duty fixed type

2.4 Crusher

Type Fixed blow bar impact crusher

Feed Opening 42”x 28” (1067mm x 711mm)
Liners Fully lined internally with renewable abrasion resistant
steel
Adjustment Manual adjustment of impact faces - front and rear
aprons - with overload compression springs on rear
apron
Rotor Four reversible/replaceable fixed blow bars running in
two heavy duty self aligning spherical roller bearings
Lubrication Greased roller bearings, inner and outer labyrinth seals
Drive Vee belts from engine
Crusher Speed Nom. 504 or 630 rpm - Two engine pulleys are
provided - one fitted and the other supplied loose.
Stock build plants are fitted with the higher speed pulley
to suit general applications. Refer to 4.2.1 also
Control Engine clutch
Blow Bars Cast high manganese steel hammers are fitted as
standard suitable for recycling applications with feed
sizes up to 400mm and including some small quantity of
steel reinforcing bar. They are secured with locking
plates and can be turned when worn: For alternative
applications and feed size, please consult BL-Pegson’s
Sales Department

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Maintenance Hydraulic case opening

Optional fitting Lower swing beam/ grinding path, having overload
compression spring, available for certain quarry applications
subject to confirmation of suitability by BL - Pegsons Sales
Department

2.5 Product Conveyor

Type Steel reinforced troughed belt

Width 1000mm (40”)
Lubrication Grease
Drive Hydraulic motor
Control Fixed speed
Skirts Full length

2.6 Tracks

Type 160mm (6.3”) pitch heavy duty

Width 400mm (16”) - 500 mm wide optional
Centre 3300mm (10’- 10”)
Drive Hydraulic integral motors
Control Remote handset-dual speed

2.7 Standard Powerpack

Type Caterpillar C9 EU/EC Emmission Regulations compliant 6

cyl. water cooled diesel
Rating 300hp @ 1800 rpm
Drives Manual clutch to crusher through vee drive
Vee belts to twin hydraulic pumps
Housing Totally enclosed canopy with integral fuel tank and battery

2.8 Dustsprays

Type Clean water multi atomising nozzles

Positions Crusher discharge and product conveyor discharge
Inlet Single point
Required supply Up to approx. 7 litres/min (2 US galls) @ 2.8 bar (42psi)
Frost protection System drain valves

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2.9 Dirt Conveyor

Type Plain troughed belt, hydraulically folded for transport by

engine driven pump. Extended conveyor optional.
Width 600 mm (24”)
Lubrication Grease
Drive Hydraulic motor
Control Fixed speed
Skirts/Hood Full length (removable for transport)

2.10 Magnetic Separator

Type Suspended self cleaning crossbelt overband

Magnet Permanent
Width 750 mm (30”)
Centres 1680 mm (66”)
Drive Hydraulic motor
Control Preset variable

2.11 Belt Weigher (optional)

Type Single idler load sensor type including flow rate and
totalizer displays on chassis mounted control box

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Contents

3.1 Introduction .......................................................................................................... 2

3.2 General information ............................................................................................. 2

3.3 Designated Use ................................................................................................... 3

3.3.1 Operating Temperature Range ........................................................................ 3
3.4 Crusher Capacity ................................................................................................. 4
3.4.1 Impactor Settings ............................................................................................ 5
3.4.2 Estimated Product Analysis ............................................................................ 6

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3.1 Introduction 3.2 General information

This instruction manual contains important The Trakpactor which you have now
information on how to operate the received has been manufactured, assembled
Trakpactor safely, properly and most and tested with the utmost care and was
efficiently. built with first class materials.

Observing these instructions and exercising Close attention has been paid to all details
Common Sense helps to avoid danger, to in assembly, running tests and final
reduce repair costs and downtimes and to inspection.
increase the reliability and life of the plant.
Failure to do so may invalidate any We are confident that you have received a
warranties in force. plant which will give you every satisfaction
over a long period.
The operating instructions must always be
available wherever the plant is in use. To be assured of faultless operation we
would ask you to carefully read the
These operating instructions must be read following paragraphs and give the required
and applied by any person in charge of and/ time and attention to essential maintenance,
or working on the plant such as:- cleaning and inspection.

Operation The plant is simple to operate, adjustments

are easy to make and expert assistance is
Includes manoeuvring, setting up, operation seldom required, provided that ordinary
during the course of work, evacuation of care is exercised in daily use.
production material and waste, care and
disposal of fuels and consumables, etc. The plant has been built in accordance with
state-of-the-art standards and recognised
Maintenance safety rules. It is designed to be reliable,
efficient and safe when used and
Servicing, inspection and repair maintained in accordance with the
instructions given in this manual.
and/or

Transport

Follow all applicable laws and safety

regulations for accident prevention and
environmental protection.

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3.3 Designated Use The magnetic overband separator is

intended to extract ferrous materials from
IMPORTANT NOTICE the crushed product but this material in the
feed must be limited to a size that will not
This plant is designed for both cause damage to the crusher.
demolition and quarrying applications.
When fitted with manganese steel blow 3.3.1 Operating Temperature Range
bars the crusher will tolerate small
The normal operating temperature range of
quantities of steel reinforcing bar in the
the plant is from -10°C to +40°C (+14°F
feed. However, the machine is not
to +104°F). For use in temperatures
designed to accept large pieces of steel
outside of this range, contact your local
or other uncrushable objects and the
dealer or BL-Pegson for details.
feed material should be assessed /
inspected for suitability prior to use. It
Note: Appropriate oil & coolant to suit the
is vitally important that large pieces of
local operating conditions must be used, as
steel or similar uncrushable objects are
specified elsewhere in this manual.
not allowed to enter the crushing
chamber as severe damage and injury
may occur. When High Chromium steel
bars are fitted, NO steel should be
allowed to enter the crushing chamber
and the machine should only be used on
quarry applications or clean materials
such as asphalt.

Operating the plant outside it’s

recommended range of applications and If you have any doubts about
operating parameters, will result in a loss of any aspect of the plant’s
guarantee and the manufacturer/supplier capability or servicing
cannot be held liable for any damage procedures, you must consult
resulting from such use. The risk of such your local BL-Pegson dealer or
misuse lies entirely with the user. BL-Pegsons technical
department
Material passing through the feeder grizzly
bars can be disposed of onto the dirt
conveyor or reclaimed totally or in part to
bypass the crusher and join the crushed
product.

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3.4 Crusher Capacity The crusher in the standard

plant has a rotor speed of
In order to obtain the optimum output from 630rpm and is fitted with 2 long
the crusher, it’s feed should be continuous x 2 short ‘High Manganese’
and regulated. Additionally, all feed should blow bars. This may have been
be of a size that will readily enter the altered to specific order.
crusher chamber and undersize material
should be removed from the feed prior to The very variable nature of
entry to the crusher. feed material and crushing
applications may require
Product curves shown overleaf are typical consideration of alternative
only, based on average limestone, and configurations in order to
indicate the product gradings from the achieve optimum performance.
Impactor only. Any natural fines in the feed
material which bypass the Impactor are not Refer to the Addendum ‘428
taken into account. Curves will vary Impact Crusher - Guide to
dependant on nature, type and grading of Efficient Operation’ in Section
the material being processed. Capacity 11 of this manual for details.
shown is based on feed material weighing
loose, approximately 1.6t/m3 (100lbs/ft)
and indicates the throughput of the plant.
For suitability of particular applications,
please consult your local dealer or
BL-Pegson Ltd.

Technical Information for Impact Crusher – standard configuration

Refer to the Addendum ‘428 Impact Crusher – Guide to Efficient Operation’ in Section 11
for alternative types of blow bar and rotor speed
Feed Rotor Rotor Blow Bar
Opening Diameter Speed Configuration
1067 x 711mm 1060mm 630rpm 2 x long
(28”x42”) (42”) 2 x short
Maximum Feed Size

‘High Manganese’ Blow Bars - 700mm [28”] diagonal length or 400mm [16”] cube

Estimated Capacity – 150 – 250 mtph (165 – 275 US tph)

011204 - 428

Figure 3a Crusher Capacity

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3.4.1 Impactor Settings

Figure 3b Impactor Setting Gaps

Settings mm (ins.)
Adjustment Setting Ratio Setting Ratio
Minimum Maximum

Upper Impact 60
Apron ~
175
Dimension 'A' (2 1/2”) (7”) Keep ratio of settings
(Upper Impact Apron
to Lower Impact Apron)
between
Lower Impact 30
Apron
85 2 : 1 and 2.5 : 1

Dimension 'B' Keep ratio of settings

(1 3/8”) (3 3/8”)
(Lower Impact Apron
to Swing Beam)
Swing Beam between
Liner/Rails 1 : 1 and 2 : 1 20 63 ~
Dimension 'C' (7/8”) 2 1/2”)
(optional item)

Figure 3c Impactor Min and Max settings

NOTES:
1) The Swing Beam (Grinding Path) should be set 0 – 5mm (0 – 0.2”) smaller than the
desired maximum product size.
2) When the optional Swing Beam is NOT fitted, set the Lower Impact Apron at 0 – 5mm
(0 – 0.2”) smaller than the desired maximum product size.
3) Whilst conforming with the Setting Ratios in the table make sure the settings ‘A’, ‘B’ or
‘C’ do not fall outside the minimum and maximum dimensions shown.
4) All settings are subject to the suitability of the feed material.

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3.4.2 Estimated Product Analysis

Material Sizes

Estimated Product Envelope

with Grinding Path Fitted

Estimated Product Envelope

with Grinding Path Excluded
Percentage Passing %

Typical
Feed
Grading

Figure 3d Product Analysis

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Contents

4.1 General Information ............................................................................................. 2

4.2 Construction Units .............................................................................................. 3

4.2.1 Impact Crusher ................................................................................................ 3
4.2.2 Vibrating Grizzly Feeder .................................................................................. 4
4.2.3 Track Frame.................................................................................................... 4
4.2.4 On-Plant Product Conveyor ............................................................................. 4
4.2.5 Dirt Conveyor .................................................................................................. 5
2.2.6 Overband magnetic separator ......................................................................... 5
4.2.7 Plant Chutework .............................................................................................. 5
4.2.8 Operators Maintenance Platforms ................................................................... 5
4.2.9 Standard Power-Pack ..................................................................................... 6
4.2.10 Controls ........................................................................................................ 6
4.2.11 Chassis ......................................................................................................... 6
4.2.12 Guards .......................................................................................................... 6
4.2.13 Painting ........................................................................................................ 6
4.2.14 Dust Suppression Sprays .............................................................................. 6
4.2.15 Optional Extras ............................................................................................. 7

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4.1 General Information

The BL-Pegson Trakpactor Plant has been designed for a wide range of quarry and
recycling applications, its features include:-

• Rapid set up time

• Easily transported on and off site

• 428 Impact Crusher, feed opening 42”x28” (1067mm x 711mm)

• Fully skirted product conveyor

• Two step self cleaning grizzly with under screen (blank mat fitted as standard - mesh optional
fitting)

• Facility to direct “grizzly fines” to dirt conveyor and/or bypass crusher

• Heavy duty chassis and track frame

• Remote control

• Dust suppression sprays

• Caterpillar water cooled diesel engine

• Dirt conveyor and magnetic separator fitted as standard

• CE Approved

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4.2 Construction Units Impact Aprons:- Fitted in the front and

rear positions and lined with wear resistant
BL-Pegson 1067mm x 711mm (42” x impact plates, some of which are
28”) Trakpactor Recycling Plant with interchangeable. The setting is made
Diesel/Hydraulic Drive. manually by adjusting rods from the back of
the machine.
4.2.1 Impact Crusher
Drive:- Through vee belts direct from the
The BL-Pegson 428 fixed blow bar Impact diesel engine with screw tension adjustment.
Crusher has a feed opening of 1067mm x
711mm (42" x 28") Engine Pulleys:- Two are provided, one is
supplied fitted and the other is supplied
The features of the machine are as follows:- loose. Machines built for stock are fitted
with the higher speed pulley as standard to
Crusher Frame:- Fabricated from steel suit general applications. The slower speed
plate and rolled steel sections to form a pulley will only be fitted against a specific
rugged construction which is fully lined with order prior to the plant being completed.
replaceable liner plates. Use with appropriate blow bars (see Blow
Bars above).
Rotor:- Running in two heavy duty self
aligning spherical roller bearings and fitted Impactor speeds:-
with four reversible and replaceable fixed
hammers. Slow - 504 rpm nominal - 224 mm
(8.8”) pitch circle diameter engine
Blow Bars:- Two full size and two half size pulley.
standard manganese steel blow bars are
fitted as standard and are suitable for Fast - 630 rpm nominal - 280 mm
material recycling applications. They are (11”) pitch circle diameter engine pulley.
secured with locking plates and can be
turned when worn. An optional lower swing beam/grinding path
Blow bars are available in alternative with overload compression springs is
materials for crushing applications other available for certain quarry applications.
than materials for recycling. Please See optional extras (Section 4.2.15) for
consult the Addendum in Section 11 - 428 details.
Impact Crusher, ‘Guide to Efficient
Operation’.

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4.2.2 Vibrating Grizzly Feeder Hopper:- Fixed feed hopper fabricated in

8 mm (0.3”) abrasion resistant steel plate
BL-Pegson 1080 wide x 3800mm long suitable braced with steel sections.
(43” x 12’-6”) Vibrating Grizzly Feeder,
including:- 4.2.3 Track Frame
Vibrating Unit:- Heavy duty mechanical Heavy duty size nine track frame having
type with twin counter rotating shafts with 160mm (6.3”) pitch chain and 3.3m (10’-
oil lubricated bearings and gears. 10”) longitudinal centres with 400mm (16”)
wide tracks fitted as standard.
Pan:- 12mm (0.5”) thick abrasion resisting
steel bottom plate is included in the welded Total plant weight approximately 33.4 tonne
construction. (36.74 U.S. tons)

Grizzly Section:- Double section of fixed Overall Track width 2700mm (8’- 10”)
welded tapered finger type bars at 50mm
(2”) spaces (at discharge end) fabricated in Plant transport height 3440 (11’- 4”)”
20mm (0.8”) thick abrasion resistant steel.
Renewable tips are included on the bars
nearest the crusher.
4.2.4 On-Plant Product Conveyor
Underdeck:- Supplied with a removable
1000mm (40”) wide plant mounted
blank rubber mat fitted to allow all grizzly
troughed belt conveyor, 3280mm (10’-9”)
fines to be directed on to the main product
discharge height, having a fixed tail section.
conveyor. An optional wire mesh having
apertures to pass 20 mm material can be
Belt:- Ripstop EP500/3 with 10mm top
supplied; the screened fines would then
and 3mm bottom heavy duty rubber covers.
discharge to the plant mounted dirt
A vulcanised joint is included.
conveyor and the oversize onto the main
product conveyor.
Drive:- Hydraulic motor drive via coupling
to drive drum at preset speed.
Drive:- Hydraulic motor mounted on the
vibrating unit.
Feedboot:- Fabricated in mild steel plate
with abrasion resistant steel liners, access
Control:- Variable speed is achieved via a
door in one side, and fully skirted wear
rotary control located on the Feeder/
resistant rubber sealing strips along the
Conveyor control box. Facility is also
entire conveyor length.
included to stop/start the feeder from the
remote control handset (but not to vary the
speed).

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Impact Cradle:-This is provided beneath 4.2.7 Plant Chutework

the belt below the impactor outlet.
Impactor Feed Chute:-Fabricated in mild
Adjustment:- Belt tensioning to be steel plate with full width single strand chain
maintained and adjustment at the head curtain and rubber curtain. Liners are fitted
drum. at wear points.

Covers:- Canvas type removable dust Grizzly Fines/Bypass Chute:- Fabricated

covers are fitted at the head end. in mild steel plate, is provided with a two-
way flap door. Material passing over the
4.2.5 Dirt Conveyor blank rubber mat (or optional underscreen)
and through the end section of the feeder
600 mm (24”) wide side discharge grizzly bars is discharged to the main
troughed belt conveyor with hydraulic product conveyor via the by-pass chute.
folding facility and having a discharge height Material passing through the under screen
of 2060mm (6’-9”). (when fitted) is discharged to the side dirt
conveyor and the flap door will also allow a
Belt:- EP500 with 3.5mm top and 1.5mm portion of the material to be diverted to the
bottom rubber covers. A vulcanised joint is main product conveyor.
included.
4.2.8 Operators Maintenance
Drive:- Hydraulic motor drive via coupling Platforms
to drive drum at preset speed.
A steel grid platform is provided on one
Adjustment:-Belt tensioning to be side of the plant fitted with double row
maintained and adjusted at the head drum4. handrails and access ladder. Platforms are
also included to gain access to the rear of
2.2.6 Overband magnetic the crusher and to the power-pack.
separator
DANGER! NOT TO BE USED WHILST
Self cleaning type with permanent magnet, THE CRUSHER ROTOR IS SPINNING.
over the on-plant product conveyor with
discharge of ferrous metal to the side of the
plant. Driven by hydraulic motor with
preset speed.

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4.2.9 Standard Power-Pack 4.2.11 Chassis

Caterpillar C9 EU/EC Emmission Fabricated steel frame of welded
Regulations compliant 6 cylinder, 4 stroke construction with supports for the feeder,
direct injection, emission compliant water crusher, on-plant conveyors, power unit,
cooled diesel power-pack in an steel track frame and the overband magnetic
canopy, 300 HP continous rated at 1800 separator.
rpm under NTP conditions driving the
crusher via a manually operated Twin Disc 4.2.12 Guards
clutch.
Wire mesh or sheet metal guards are
Twin hydrostatic drives are provided for the provided for all drives, flywheels, pulleys,
crusher, tracks and also to operate the couplings, gears and vee belts. The guards
hydraulic rams. These also power the provided are designed and manufactured to
magnetic separator, conveyors and feeder ensure so far as reasonably practicable that
motors via a solenoid operated directional the machinery and plant on which they are
control valves. All necessary pipe work is fitted can be operated safely and without
to DIN standard 20022 and is provided risk to health when properly used.
with steel pipe run to inaccessible areas.
4.2.13 Painting
4.2.10 Controls The plant is finish painted in RAL 5015
Controls are fitted on the plant for the blue.
feeder (on/off and speed), conveyors etc.
4.2.14 Dust Suppression Sprays
with engine and master controls sited in a
lockable box mounted below the engine. Spray bars with atomiser nozzles are
mounted over the product conveyor feed
A control unit is provided for the tracking and discharge points piped to a single inlet
function giving a tracking speed of manifold for clients pressurised clean water
approximately 0.62mph a “creep” facility supply.
for loading, off loading and precise slewing
movements. This also provides stop and
start control for the vibrating grizzly feeder
from a remote position.

Emergency stop buttons are provided on

each side of the plant.

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4.2.15 Optional Extras

Standard optional extras which can be
added to plants:-

- Hydraulic water pump assembly for dust

suppression.

- Refuelling pump kit.

- Belt weigher.

- Anti-vandal guards

- Wire meshes for feeder underscreen to

separate scalpings at 10, 20, 30, 40 or
50mm (0.39, 0.79, 1.25, 1.5 or 2in).

- Lower swing beam/Grinding path (not

suitable for recycling applications) fitted in
the lower position and lined with wear
resistant impact plates on the upper section,
and reversible manganese impact bars on
the lower section.

-The setting is made as described above.

The lower swing beam assembly is an
optional part of the machine and is omitted
from the standard build. When fitted,
greater control on product size is achieved,
together with improved product shape.

BL-Pegson’s Sales Department can advise

whether the lower swing beam is required
following receipt of full application details
prior to the machine being built.

- High chrome blow bars (not suitable for

recycling applications) or Martensitic steel.

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Blank Page

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Contents

5.1 Safety Information ............................................................................................... 2

5.2 Transportation ..................................................................................................... 4

5.2.1 Manoeuvring ................................................................................................... 4
5.2.2 Unloading ........................................................................................................ 9
5.2.3 Loading ........................................................................................................ 10

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5.1 Safety Information

Loose or baggy clothing can get PERSONAL
caught in running machinery. PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.

Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.

Falling from and/or onto a FALLING HAZARD

Terex-Pegson machine can cause
serious injury or even death.

DO NOT climb onto the machine

whilst in operation.

ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.

ALWAYS use a suitable lifting platform when

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

In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.

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Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.

ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.

ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be

surgically removed or gangrene will result.

Get medical help immediately.

When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.

LOCKOUT PROCEDURE

1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).

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5.2 Transportation DO NOT stand on any of

the platforms or ladders of
5.2.1 Manoeuvring the Trakpactor whilst it is
being manoeuvred using the
(Refer to Section 7.3) remote control handset.

Prior to attempting any Ensure all personnel are

manoeuvring of the plant clear of the plant before
the tracks must be free of manoeuvring.
obstructions, including
crushed material and fines. When manoeuvring your
Do not push or tow the Trakpactor to its operating
plant. Failure to observe position make sure you
this warning could result in stand well clear of the plant
serious injury to persons but are in a position to have
and damage to the plant all-round vision to see any
which may invalidate obstacles or hazards that
warranty. may lie ahead e.g
personnel, overhead cables,
• Before manoeuvring the Trakpactor, ditches, unsafe roadways
ensure the feed hopper and crusher etc. (Refer to Figure 2a
are empty, and that all materials Dimensions)
have run off the conveyors. STOP
the feeder, dirt conveyor, product • Make sure that you do not
conveyor and disengage the clutch. manoeuvre your Trakapctor on a
gradiant (fore and aft directions)
• The plant cannot be manoeuvred in steeper than 30 degrees, damage
the PLANT mode of operation. may occur to the engine and/or
plant.
• DO NOT manoeuvre the
Trakpactor whilst the crusher • Avoid manoeuvring the plant over
running. extremely uneven ground or damage
may occur.
• The safety warning horn sounds
continuously whilst the plant is • Control valves mounted on the
being manoeuvred. engine and beneath the feeder are
NOT to be used to manoeuvre the
Trakpactor. They are for use by
BL-Pegson Service Engineers only.

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• Initial start up in cold weather may

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

• When transporting the

Trakpactor, it is the
responsibility of the haulage
contractor to safely secure the
plant to the transporter.

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Page 6

To manoeuvre the Trakpactor with

the radio remote control hand set WARNING
(Where fitted)
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
The plant is manoeuvred using the remote Refer to Section 5.1, Safety
hand held radio transmitter control unit (Fig Information for relevant
5b). This hand set also has the facility to warning.
switch the plant feeder on and off whilst the
plant is in the crushing mode. Note: The transmitter has a built in safety
function that prevents another function from
involuntary cutting-in when the transmitter
Procedure
starts. The transmitter will not start if a
button is stuck in the activated position.
This is indicated by the red LED coming on.
1. Observe all safety instructions.
4. Start the engine (Section 7.2). Increase
2. Take the Remote Control Hand Set the engine speed to 1800rpm.
from the Control Box and first become
familiar with the functions of all the 5. On the Control Panel located within the
individual buttons (Figure 5b) before the Control Box (Figure 5a), turn the
next step. Operation switch to ‘TRACK’.
Forward = Product Conveyor first
Reverse = Hopper first 6. Press the Horn button for 5 seconds to
sound the safety warning horn. This will
3. To start up the handset transmitter first also ready the tracks for manoeuvring.
stand well clear of the plant. Hold the
hand set with the stop button nearest to 7. The radio handset directional buttons
the operator and proceed as follows:- (forward, reverse and turn) are double
pressure switches with the initial
• Ensure the stop button is pulled out. pressure operating the slow speed
• Depress both of the safety buttons mode and depressing further operates
(Fig.5b) at the same time for at least 1 the higher speed. Press one button at a
second. Release the safety buttons. time to manoeuvre the plant in the
• The red LED will change to green. desired direction (Figure 5b). Employ
• The transmitter is in function status the ‘Fast’ speed only where safe to do
when the green LED comes on. so.

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Pressing the Stop button at any time will 9. On the Control Panel turn the
immediately halt the operation and cut Operation switch to ‘PLANT’. The
out the engine but it is necessary to safety warning horn will sound for 10
manually switch off the engine ignition seconds. Stop the engine (Section 8.2),
(Section 8.2) (and disengage the manual unless required further.
clutch).
10. To shut down the radio handset
8. When the Trakpactor is in the correct transmitter, push in the stop button.
position, press the Horn button to turn Lock out the hand set when finished
the safety warning horn ‘OFF’ and with to prevent unauthorised use.
disengage the tracks.

Operation Feeder Remote Dirt Conveyor Pump On

Plant/Track/Pump Off/On Lower/Raise Button

Figure 5a Control Panel

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PLAN VIEW OF THE PLANT

LED Red/Green

SELECT AND PRESS BUTTON(S) TO MOVE

Forward slow or fast, track 1 & 2

Right turn slow, forward track 1 **Reverse Forward

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

Left turn slow, reverses track 2 Safety Button Safety Button

(Horn) (Feeder On/Off)
Rotate clockwise, track 1 forward, track 2
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)

RELEASE BUTTON(S) TO STOP MOVEMENT Stop Button

**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
For more information on the Radio Hand Set see Section 7 of this manual.

Figure 5b Remote Control Hand Set

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5.2.2 Unloading
WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
Information for relevant
The Trakpactor will arrive on site securely warning.
fastened to a low loader. It is the
responsibility of the haulage contractor to
remove the fastenings.

1. Observe all safety warnings.

2. Position easy slope ramps at the end of

the transporter to help with unloading of
the Trakpactor.

3. Locate the control box and raise the

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

4. Before attempting to start the engine,

check that the engine air cleaner is in
situ as this may have been removed to
reduce the overall plant height for
travelling. Refit if necessary.

5. Start the engine (Section 7.2). Increase

the engine speed to 1800rpm.

6. Turn the Operation switch to ‘TRACK’

(Figure 5a). Using the remote control
hand set, steer the Trakpactor off the
transporter (Section 5.2.1 and Section
7.3).

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5.2.3 Loading
Before transportation, the Trakpactor must
WARNING
be prepared as described below. Refer to WEAR PERSONAL
Section 2.1 for minimum travel dimensions. PROTECTIVE EQUIPMENT.
Refer to Section 5.1 Safety
Information for relevant
Procedure warning.
FALLING HAZARD.
Refer to Section 5.1 Safety
1. Observe all safety warnings. Information for relevant
warning.
2. Ensure that both conveyors, feed
hopper and crusher are free from stone
and dirt.

3. On the right hand side of the Trakpactor

raise the bottom section of the front
ladder and secure with the bolts (Figure
5c).

4. Remove the dirt conveyor head drum

guard (Figure 5d). This is necessary
before folding the conveyor for
transport.

5. Ensure all loose items are carefully

stowed and secured if these are to be
transported on the plant.

6. Locate the control box and raise the

cover to reveal the control panel and
engine control panel.

7. Start the engine (Section 7.2). Increase

Figure 5c Front Ladder (shown
the engine speed to 1800rpm. unfolded)

8. Turn the Operation switch to ‘PLANT’,

the safety warning horn will sound for
15 seconds. Turn the Dirt Conveyor

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switch to ‘Ï’ and fold the dirt conveyor

fully in to the travelling position. Secure WARNING
with the transportation safety chain
WEAR PERSONAL
(Figure 5e) PROTECTIVE EQUIPMENT.
Refer to Section 5.1 Safety
During folding of the dirt Information for relevant
conveyor ensure that the warning.
hydraulic hoses and conveyor FALLING HAZARD.
belt do not foul any part of the Refer to Section 5.1 Safety
structure. Information for relevant
warning.

9. Position easy slope ramps at the end of

the transporter to help with loading of
the Trakpactor.

10. Turn the Operation switch to

‘TRACK’. Using the remote control
hand set, steer the Trakpactor onto the
transporter (Section 5.2.1 and Section Prior to transportation always
7.3). check the plant for loose or
damaged components.
11. When the plant is loaded shut down the
remote control hand set using stop Fasten all loose parts, replace
button. missing items or make repairs
as found necessary to ensure
12. Switch off the engine (Section 8.2). that all components are safely
secured during transportation.
13. In order to reduce the overall plant
height to the minimum it is necessary to
detach the engine air cleaner (refer to
section 2.1 for dimensions)

14. Securing the Trakpactor to the

transporter is the responsibility of
the haulage contractor.

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Dirt Conveyor Head Drum

Guard

Figure 5d Dirt Conveyor

Dirt Conveyor Safety

Chain

Dirt Conveyor

Figure 5e Dirt Conveyor Safety Chain

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Figure 5f Dirt Conveyor Folded and

Secured with Chain

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Blank Page

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Page 1

Contents

6.1 Safety Information ............................................................................................... 2

6.2 Setting Up ............................................................................................................ 5

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6.1 Safety Information

Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.

Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.

Falling from and/or onto a FALLING HAZARD

Terex-Pegson machine can cause
serious injury or even death.

DO NOT climb onto the machine

whilst in operation.

ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.

ALWAYS use a suitable lifting platform when

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

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In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.

Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.

ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.

ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be

surgically removed or gangrene will result.

Get medical help immediately.

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When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.

LOCKOUT PROCEDURE

1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).

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6.2 Setting Up
WARNING
Plant Location Considerations WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Prior to setting up your Trakpactor, Refer to Section 6.1 Safety
consideration should be given to a suitable Information for relevant
layout to prevent oversize material or tramp warning.
metal from entering the plant. In order to LOCKOUT PLANT.
prevent bridging of the crusher no material Refer to Section 6.1, Safety
above the size recommended by the Information for Lockout
Procedure.
manufacturer should be fed into the plant.
FALLING HAZARD.
Refer to Section 6.1 Safety
Procedure
Information for relevant
warning.
1. Observe all safety instructions.

2. Position the plant in a safe, level

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

3. Remove the dirt conveyor

transportation safety chain (Figure 6a).

4. Before attempting to start the engine,

check that the engine air cleaner is in
situ as this may have been removed to
reduce the overall plant height for
travelling. Refit if necessary.

5. Start the engine (Section 7.2). Increase

the engine speed to 1800rpm.

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6. Keep the Operation switch at 8. Switch off the engine (Section 8.2) and
’PLANT’ (Figure 6b). lockout.

7. Lower the dirt conveyor fully by turning 9. Replace and secure the dirt conveyor
the dirt conveyor switch to ‘Ð’ (Figure head drum guard and side skirts.
6b).

During lowering of the dirt

conveyor ensure that the
hydraulic hoses and conveyor
belt do not foul any part of the
structure. Do not operate the
plant with the dirt conveyor
folded

Dirt Conveyor Safety

Chain

Dirt Conveyor

Figure 6a Dirt Conveyor Safety Chain

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Operation Feeder Remote Dirt Conveyor Pump On

Plant/Track/Pump Off/On Lower/Raise Button

Figure 6b Control Panel

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Blank Page

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7 - Operating Instructions Issue EN 02
Page 1

Contents

7.1 Safety Information ............................................................................................... 2

7.1.1 Blocked Crusher Procedures .......................................................................... 5
7.2 Safe Start-Up Procedure ..................................................................................... 6
7.2.1 Engine Start-Up .............................................................................................. 7
7.2.2 Crusher Engagement .................................................................................... 12
7.2.3 Feeder/Conveyor Start-Up ............................................................................ 13
7.2.4 Safe Operation of the Plant ........................................................................... 15
7.2.5 Checks Prior to Initial Daily Start ................................................................... 15
7.2.6 Initial Start Up and Running In ........................................................................ 16
7.3 Radio Remote Control Operation (Where fitted) ............................................. 19
7.3.1 Radio Remote Control Hand Set (Where Fitted) ............................................ 20
7.3.2 Radio Feeder Remote Operation (Where fitted) ............................................ 21
7.3.3 Radio Hand Set (where fitted) ....................................................................... 22
7.4 Alternative Control Hand Set with Umbilical Cable (where fitted) .................. 24

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Page 2

7.1 Safety Information

Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.

Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.

Falling from and/or onto a FALLING HAZARD

Terex-Pegson machine can cause
serious injury or even death.

DO NOT climb onto the machine

whilst in operation.

ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.

ALWAYS use a suitable lifting platform when

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

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Page 3

In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.

Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.

ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.

ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be

surgically removed or gangrene will result.

Get medical help immediately.

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Page 4

When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.

LOCKOUT PROCEDURE

1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).

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Page 5

7.1.1 Blocked Crusher Procedures In the case of a stalled crusher it should

always be treated as possibly being jammed
It is the responsibility of the Owner, End with tramp metal. A safe system of work
User and/or Safety Officer of the should be devised for approaching this
Trakpactor to provide a safe means of situation due to the potential dangers of
dealing with oversize material and construct tramp metal being released. Due care and
a safe procedure for unblocking a stalled attention should be given to where the
machine which is full of material. released tramp metal will fall to avoid any
injury to personnel. Once this has been
To comply with British Health and Safety
decided it should be incorporated into a
Law it is necessary to conduct an adequate
permit to work procedure to be issued by
risk assessment of the procedures for
the manager. This system should cover
unblocking a blocked crusher.
things such as notification to the manager,
isolation, methods of removal of excess
Should an oversize piece of material be fed
stone, safe positions for personnel. Should
to a crusher and cause the feed opening to
any further information be required with
be bridged the recommended procedure for
regard to the clearance of blocked crushers
removing this is to open the crusher (as
then reference can be made to the British
described in Section 9.5) if the bridged
Aggregate Construction Materials
material is not accessible otherwise. Only
Industries (BACMI) document “ Clearing
open the crusher slowly with caution and
Blocked Crushers “. This document
with all personnel well clear. A crane and
provides recommended procedures and
hook can be used although EXTREME
advice on risk assessment.
caution must be exercised to ensure that the
crane is not overloaded by trying to lift a
jammed rock.

The following methods SHOULD NOT be

attempted.:-

The use of wedges.

Using mobile plant to drag stones out of the

crusher or feeder.

Under most arrangements pinch bars and

hand hammers cannot be used safely. Their
use should be limited to situations under risk
assessment where there is every indication
that they can be worked safely.

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7.2 Safe Start-Up Procedure • Ensure the engine clutch is disengaged

(lever fully towards the crusher drive
BL Pegson Ltd. cannot guard) (Figures 7f).
overemphasise the need to
ensure that all safety aspects • Check that all guards are in position and
are checked before starting secure and that all personnel are clear
the engine. of the plant.

Whilst the engine is running

and the Operation switch is
turned from ‘TRACK’ to
‘PLANT’ mode the safety
warning horn will sound for 10
seconds. When the horn has
stopped the conveyor(s) and/or
feeder can be started.

With the engine switched ‘OFF’

• Ensure the full length of both vehicle

tracks are in contact with a firm, level
surface.

• Check that the size of the engine pulley

is correct for the crushing application
(refer to section 4.2.1 for correct pulley
size for crushing duty and section 9.11.3
if change required)

• Check that the crushing chamber and

feed hopper are empty.

• Measure the crusher settings and adjust

if necessary. (Section 9.6)

• Check that the Emergency Stops are

pulled out (Figure 1a).

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7.2.1 Engine Start-Up

WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety
Information for relevant
1. Observe all safety warnings warning.

2. Ensure the engine Isolation Switch

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

3. Locate the Control Box and raise the

cover to reveal the control panel and
engine control panel (Figure 7b).

4. Turn the Operation Switch, located on

the Control Panel to ‘PLANT’ and the
Remote switch to ‘ON’ (Figure 7c).

5. On the engine control panel (Figure 7d)

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

Refer to Figure 7e together with

continuation page for details of the
engine diagnostic functions.
To avoid damaging the clutch
DO NOT increase the engine
6. Check the engine speed is at 1200 rpm
speed to the operating 1800
(view on tachometer) and allow to run
rpm until after starting the
for 3-5 minutes before proceeding with
crusher (Section 7.2.2)
preparation for transport (Section 5),
setting up the plant (Section 6) or
initiating the plant run sequence
(Section 7).

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Control Panel Umbilical Handset Connection Point Engine Control Panel

Figure 7b Control Box

Emergency Stop
Button

Operation Feeder Remote Dirt Conveyor Pump On

Figure 7c Control Panel

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Maintenance Due Lamp Diagnostic Lamp

Tachometer Diagnostic Display

Scroll Switch

Fuel Gauge Speed Control

Ignition Key

Figure 7d Engine Control Panel

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DIAGNOSTIC DISPLAY
The main unit has ten warning lamps available for system related diagnostics.
These diagnostics can be used for system troubleshooting and diagnostic information.
They are located on the main EMS unit in two rows of five:
High Engine Coolant Low Engine Oil Pressure
Temperature or Sensor Fault or Sensor Fault

High Inlet Manifold Low Fuel Pressure

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

Low Battery Voltage

Engine Derate
or Sensor Fault
High Auxiliary Temperature High Auxiliary Pressure
or Sensor Fault or Sensor Fault

Figure 7e Caterpillar Engine Diagnostic Panel

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Engine Diagnostic Functions - EMS Main Unit, continued

LCD Display

Beneath the warning lamps is an LCD digital display for engine parameters.

Display Scroll Feature

Each time the scroll forward switch (Figure 7d) is depressed and held, EMS will page through the
engine parameters in the order listed below. When the scroll backward is depressed and held, EMS
will page through the engine parameters in reverse order. The abbreviation for the parameter will be
displayed. When the scroll switch is released, EMS will display the current ‘real time’ value for that
parameter.

Abbreviation Parameter

Spd Engine Speed

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

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7.2.2 Crusher Engagement

WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety
Information for relevant
With the engine speed set at 1200rpm :- warning.

1. Observe all Safety Warnings.

Crusher Drive Guard
2. Slowly engage the clutch by pulling the
clutch lever away from the crusher drive
guard, this will start the crusher (Figure
7f).

3. Using the hand throttle increase the

engine speed to 1800 rpm, view on
tachometer (NB.engine speed 1800
rpm required under crushing load).

4. Check the plant is stable with no

excessive vibration. If necessary,
reposition the plant on firm, level area
with full length of both tracks in contact
with the ground.

Figure 7f Clutch Lever

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7.2.3 Feeder/Conveyor Start-Up

The control valves mounted on
WARNING
the engine and beneath the WEAR PERSONAL
feeder are NOT to be used in PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety
any circumstances to operate Information for relevant
the feeder or conveyors. warning.

The operation switch on the

control panel has to be in
‘PLANT’ mode for the feeder
and conveyors to work (Figure 5. Press the ‘GREEN’ Feeder button to
7c). The safety warning horn start the feeder.
will sound for 10 seconds when The speed of the feeder will need
the Operation switch is turned adjusting depending on the type of
from ‘TRACK’ to ‘PLANT’ material to be crushed so as to maintain
mode. an even regular flow through the crusher
.
To adjust the speed of the feeder turn
Procedure the Feeder Speed Control knob and
adjust to the required setting.
1. Observe all safety warnings.
The feeder can be switched ON and OFF
2. With the engine speed at 1800 rpm remotely (Section 7.3.2). However the
(engine speed 1800 rpm required under speed cannot be adjusted from the remote
crushing load) continue at the control control handset.
panel (Figure 7g).

3. Press the ‘GREEN’ Product Conveyor

button to start the product conveyor
(fixed speed) and the magnetic
overband separator.

(The speed of the magnetic overband

separator can be altered, refer to
Section 9.13)

4. Press the ‘GREEN’ Dirt Conveyor

(optional) button to start the dirt
conveyor (fixed speed).

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Emergency Stop
Button

Feeder On/Off
Buttons

Hydraulic Oil
Pressure Warning
Light

Feeder Speed
Control

Dirt Conveyor On/ * Product Conveyor

Off Buttons On/Off Buttons

Figure 7g Feeder/Conveyor Controls

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7.2.4 Safe Operation of the Plant 7.2.5 Checks Prior to Initial Daily
Start
NEVER leave your Trakpactor
unattended whilst it is in Plant
operation.
• Visually check the plant and ensure that
Do check regularly that the oil all guards and warning signs (Section 1)
cooler fan (located on the are in position and that all equipment
Engine Maintenance Platform) and tools that are hazardous to
is running correctly and that operation are removed from the
dust/dirt has not built up in the immediate site.
fan and radiator unit (over
heating can occur if dust/dirt is • Ensure that the impact crusher clutch on
allowed to build up). Blow out the diesel engine is disengaged.
dust/dirt if necessary.
• Ensure that the impact crusher and the
DO NOT allow a build up of grizzly feeder hopper are empty.
material at the feed on points
to enter either the product • Check setup of the impact crusher and
conveyor or dirt conveyor. adjust as necessary to the required
settings (refer to Sections 3.4 and 9.6).
DO check frequently the
stability of the Trakpactor. The • Check the oil cooler fan and radiator
chassis SHOULD NOT bounce unit (located on the Engine Maintenance
during operation. Platform) for any build up of dust/dirt.
Blow out dust/dirt if necessary.
DO NOT allow the engine
RPM to drop below it’s • Before putting the plant into operation
operating speed, and DO NOT check that all emergency stop buttons
slip the engine clutch. are operative. (refer to Section 8.3)

AVOID frequent starting and The plant should be fed by an

stopping of your Trakpactor excavator such that the bucket
unnecessarily as it WILL does not pass over or near to
cause damage to the plant. personnel.

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DO NOT STAND ON THE Actions During Running-In Period

UPPER MAINTENANCE
PLATFORM WHILST THE Checks on the Trakpactor are
IMPACT CRUSHER AND crucial during the first week of
FEEDER ARE OPERATING. operation.
The following section should be
Other than when operating the read and understood prior to
engine clutch, the impact starting the Trakpactor. If
crusher and grizzly feeder must there are any doubts, contact
be stationary and disabled at BL Pegson Ltd. Service
the engine control panel. Department.

Discontinue loading the feed Plant

hopper when the operator is
attending to the controls on the 1. Each day during the initial days of
feeder/conveyor box. operation check the tension of the
conveyor belts on the main product
conveyor and dirt conveyor..
7.2.6 Initial Start Up and Running
In 2. Check frequently the overall stability of
the plant; re-check the level of the plant
Initial Start-Up and re-level if necessary.

• Check the vibrating unit oil level and 3. After several days use re-check clutch
hydraulic oil level (Figure 7h & 7i). engagement torque as described in
Section 9.15.
• Refer to engine manual for engine initial
start up. Crusher

• Run the plant empty for a short period 1. Regularly check drive belts (crusher and
of time and check for abnormal noises, hydraulic pumps) to ensure correct
vibration or excessive heat from the tension, particularly during the initial 2
shaft bearings. weeks of use (Section 9.11).

2. Check the alignment and tension of the

vee belt drive daily during the initial
days of operation (Section 9.11).

3. Check the shaft bearing temperature

daily using a contact thermometer and

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Hydraulic Oil Return Hydraulic Oil

Filter and Gauge Breather/Filler

Hydraulic Oil Level Hydraulic Oil Tank

Figure 7h Hydraulic Oil Tank & Level Indicator

Oil Filler Plug

Oil Level
Sight Glass

Oil Drain Plug

Figure 7i Feeder Vibrating Unit

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record for future reference and fault

diagnosis. The maximum acceptable
working temperature is 80°C (176ºF).

4. Avoid overloading the crusher; restrict

loading to 50% and 75% of full
capacity during the first and second
days of operation respectively.

5. Ensure that all drives are running before

any feed is introduced to the plant and
that the feed is maintained at a constant
rate, irregular and excessive feed rates
reduce the efficiency of the plant.

Feeder

1. Frequently check the oil levels in the

vibrating unit end covers and the
hydraulic oil level in the tank (Figure 7h
& 7i).

2. After first 8 hours of operation, change

the oil in the vibrating unit end covers

3. Check the vibrating unit bearing

temperatures using a contact
thermometer on the end covers; record
for future reference and fault diagnosis.
(Maximum acceptable temperature is
80ºC [176ºF] ).

4. Ensure that the vibrating unit is

operating before any feed is introduced
to the plant fee hopper.

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7.3 Radio Remote Control • To manoeuvre the Trakpactor with the

Operation (Where fitted) remote hand set, refer to the instructions
in Section 5.2.1.
DO NOT stand on any of the
platforms or ladders of the • To use the remote hand set to switch
Trakpactor whilst it is being the feeder on/off during crushing
manoeuvered using the remote operations refer to Section 7.3.2
control handset.
• For recharging the hand set battery, see
When manoeuvring your Section 7.3.3
Trakpactor to it’s operating
position make sure you stand • When the plant is not operating take the
well clear of the machine but opportunity to recharge the internal
are in a position to have all- battery. For convenience a lead is
round vision to see any supplied to plug into 12/35 volt DC
obstacles, dangers that may lie vehicle cigar lighter point
ahead e.g. personnel, overhead
cables, ditches, unsafe • In the event of the remote radio hand
roadways etc. set being inoperable for any reason, the
(Refer to Figure 2a for alternative ‘umbilical’ hand set is
dimensions) supplied (Section 7.3.4).

The Trakpactor remote control • If the hand set transmitter does not start
system is supplied to the when the two safety buttons are
following:- depressed at the same time for at least
1 second (Section 5.2.1), check if the
Radio System/Umbilical handset. stop button is pushed ‘in’, or the battery
needing a recharge.
• If the plant moves out of the operating
range of the remote control hand set the
plant will stop.

• Operating the stop button on the remote

hand set whilst the plant is in either
TRACK or PLANT (Feeder Remote
switch ‘on’) operating mode will stop
the engine.

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7.3.1 Radio Remote Control Hand

Set (Where Fitted) WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Procedure Refer to Section 7.1, Safety
Information for relevant
warning.
(Figures 5b & 7e)

To operate the hand set:- LED

1. Remove the remote control hand set

from the Control Box (Figure 7b).

2. Ensure that the three Emergency Stops

on the plant and the stop button on the Track Directional
hand set are pulled out (Figures 1a and Control Buttons
7j).

3. Start the engine (Section 7.2). Not used to

Manoeuvre
4. Refer to Section 5.2.1 if the plant is to
manouvered to a new position.
Refer to Section 7.3.2 if the feeder is to 2 x Safety Buttons
be operated remotely. (also Horn & Feeder
Remote Control)

Stop Button

Figure 7j Remote Control Hand Set

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7.3.2 Radio Feeder Remote

Operation (Where fitted) WARNING
To operate the feeder remotely the WEAR PERSONAL
conveyors and feeder must first be switched PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety
on manually and the feeder speed set Information for relevant
manually (Section 7.2.3). warning.

Procedure

1. Observe all safety warnings.

2. Remove the Radio Remote Hand Set

from the Control Box (Figure 7b).
Feed Conveyor
3. Ensure that the Emergency Stops on the stop/start button
plant and the stop button on the hand
set are pulled out (Figures 1a and 7k).

4. Follow the procedures in Sections 7.2.1

to 7.2.4.
Stop Button
5. Stop and start the Feeder by pressing
the hand set button (Figure7k). Figure 7k Remote Control Hand Set

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7.3.3 Radio Hand Set (where fitted)

Features of the 860 System include:-

• Unique ID code in each transmitter. The

receiver self learns this code, without
the need to change DIP switches
internally in either component.

• No need to open transmitter to change

frequency (changed from buttons -
Dealer function). Receiver detects any
change automatically.

• Transmitter can be programmed to

work with either 840 or 860 receivers
(Dealer function).

• Enhanced reliability.

Transmitter’s Use NiMh batteries instead of

NiCd, which means the following:-

• Input charging voltage is now 12VDC TRANSMITTER 860TX-PEG

to 35VDC instead of 12/24VDC, no
universal adapter required.

• Battery capacity is changed from Buttons 1 to 4 = Used for plant directional

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

Button 9 = Used to activate the audible

warning horn

Button 0 = Used to stop / start the plant

feeder (where appropriate)

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2 versions of the 860 system transmitter will

be supplied, one for European Operations WARNING
and one for the Rest of the World. The only
WEAR PERSONAL
difference is that the European version will PROTECTIVE EQUIPMENT.
include a black stop button. The Rest of the Refer to Section 7.1, Safety
World transmitter will feature a Red Stop Information for relevant warning.
button. Channel 01 (434.650 MHz)
through channel 16 (433.900 MHz)
available in .050 MHz steps. Refer to
Dealer if frequency change needed. • To conserve the battery charge the hand
set should be switched off when not in
Battery Recharging use..

The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
7l). A 12/35 volt charging lead suitable for
plugging into a vehicle cigarette lighter point
is supplied.

• Battery charge status is indicated by the

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

• Fully charged batteries provide about

30 hours continuous running and
recharging time takes about 4 hours.

• The LED light on the hand set changes

from green to red when there is about
10% power left in the batteries (1 hour
continuous operation remaining) and Charging point
indicates it is time to recharge. The plant
warning horn will also sound when Figure 7l Remote Control
battery recharging is required Charger Connection

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7.4 Alternative Control Hand

Set with Umbilical Cable WARNING
(where fitted) WEAR PERSONAL
PROTECTIVE EQUIPMENT.
As an alternative to the radio remote Refer to Section 7.1, Safety
Information for relevant warning.
control hand set, a hand set with umbilical
cable is supplied to manoeuvre the
Trakpactor (Figure 7m)

Connecting and using the

Umbilical Control Hand Set

Procedure

1. Observe all safety warnings.

2. Close down the plant (Section 8.2).

3. Locate the connection point on the

Control Panel. Release the retaining clip
and remove the multi pin plug already in
situ (only where radio unit fitted).
Replace with the umbilical lead plug
(Figure 7m) and secure with the
retaining clip.

4. On the Control Panel turn the

Operation switch to ‘PLANT’ and the
Feeder Remote switch to ‘OFF’
(Figure 7c).

5. Start the engine (Section 7.2). Increase

the engine speed to 1800rpm.

6. Standing clear of the tracks, turn the

Operation switch to ‘TRACKS’. Figure 7m Umbilical Control Hand Set

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7. Press the Horn button for 5 seconds to fitted). Store the umbilical hand set unit
sound the safety warning horn. This will in the tool box to keep available for
also ready the tracks for manoeuvring. future use.

8. The umbilcal handset directional buttons Extreme care must be used

(forward, reverse and turn) are double when manoeuvring the plant
pressure switches with the initial with the umbilical control hand
pressure operating the slow speed set. Stand as far away as
mode and depressing further operates possible from the plant. Do not
the higher speed. allow the cable of the hand set
to sag and become entangled
Pressing the Stop button at any time will with the tracks.
immediately halt the operation and cut
out the engine but it is necessary to
manually switch off the engine ignition
(Section 8.2) (and disengage the manual
clutch if applicable).

9. Hold the hand set with the stop button

nearest to the operator and proceed as
follows. Press the slow speed buttons
on the hand set to manoeuvre the plant
in the desired direction (Figure 7n).
Employ the ‘Fast’ speed only where
safe to do so.

10. When the Trakpactor is in the correct

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

11. On the Control Panel turn the

Operation switch to ‘PLANT’. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.

12. Unplug the umbilical cable and replace

with the original plug (where radio unit

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PLAN VIEW OF THE PLANT

SELECT AND PRESS BUTTON(S) TO MOVE

Forward slow or fast, track 1 & 2

**Reverse
Right turn slow, forward track 1
Forward **
Left turn slow, forward track 2

Reverse slow or fast, track 1 & 2

**Left Turn Right Turn **
(forward travel) (forward travel)

Right turn slow, reverses track 1 Not used Not used

Left turn slow, reverses track 2

Safety Button Not used
(Horn)
Rotate clockwise, track 1 forward, track 2
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
RELEASE BUTTON(S) TO STOP MOVEMENT

**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 7n Remote Umbilical Control Hand Set

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Contents

8.1 Safety Information ............................................................................................... 2

8.2 Closing Down the Plant ...................................................................................... 5

8.3 Emergency Stopping of the Engine ................................................................... 8

8.3.1 Emergency Stop Buttons ................................................................................. 8
8.3.2 Testing Buttons ................................................................................................ 8

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8.1 Safety Information

Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.

Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.

Falling from and/or onto a FALLING HAZARD

Terex-Pegson machine can cause
serious injury or even death.

DO NOT climb onto the machine

whilst in operation.

ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.

ALWAYS use a suitable lifting platform when

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

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In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.

Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.

ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.

ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be

surgically removed or gangrene will result.

Get medical help immediately.

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When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.

LOCKOUT PROCEDURE

1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).

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8.2 Closing Down the Plant

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 8.1, Safety
1. Observe all safety warnings. Information for relevant warning.

2. Ensure that the feeder and crusher are LOCKOUT MACHINE.

empty, and that all materials have run off Refer to Section 8.1, Safety
the conveyor(s). Information for Lockout
Procedure.

3. On the Control Panel (Figure 8a), press

the ‘RED’ Feeder button to Stop the
feeder.
fitted) has been in use, shut down by
4. Press the ‘RED’ Dirt Conveyor button depressing the stop button on the unit.
to Stop the dirt conveyor.
10. Following the closing down procedure
5. Press the ‘RED’ Product Conveyor above, it is recommended that at the
button to Stop the the product con- end of operation for the day the plant
veyor and also the magnetic overband is routinely cleaned down and thor-
separator. oughly examined to check for any
damage, breakages, wear, leaks etc.
6. Using the speed control, decrease the which should be rectified before
engine rpm to 1200rpm (Figure 8b & further operation.
8d).
Use of high pressure washing
7. Disengage the engine clutch by slowly equipment is to be avoided
moving the clutch lever (Figure 8c) where the ingress of water will
towards the crusher drive guard (this be detrimental to plant compo-
will disengage the crusher). nents eg crusher bearings,
conveyor bearings, hydraulic
8. Let the engine idle for 3-5 minutes. tank, electrical equipment etc.
9. Turn the Ignition Key to the off position Do not use the emergency stop
to shut down the engine. Remove the buttons for routinely stopping
Ignition Key. Shut and lock the Control the plant.
Box door. Lockout the Isolation Switch
(Figure 8c).If the radio hand set (where

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Emergency Stop
Button

Feeder On/Off
Buttons

Hydraulic Oil
Pressure Warning
Light

Feeder Speed
Control
Dirt Conveyor On/ * Product Conveyor
Off Buttons On/Off Buttons

Figure 8a Feeder/Conveyor Controls

Figure 8b Clutch Lever Figure 8c Engine Isolation Switch

(manual clutch)

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Maintenance Due Lamp Diagnostic Lamp

Tachometer Diagnostic Display

Scroll Switch

Fuel Gauge Speed Control

Ignition Key

Figure 8d Engine Control Panel

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8.3 Emergency Stopping of 8.3.1 Emergency Stop Buttons

the Engine Pressing any of the buttons will stop the
diesel engine and the button will remain
IN AN EMERGENCY STOP SITUA- engaged until physically released by pulling
TION, STOP THE ENGINE (AND or twisting (depending upon the type fitted)
PLANT OPERATION ) USING THE the button knob. The engine cannot be
EMERGENCY STOP BUTTONS. started if any of the emergency buttons
remain depressed
(See Section 1, Figure 1a, for locations
of all the emergency stop buttons). 8.3.2 Testing Buttons

When the plant has been stopped using Daily, before commencing
the emergency stop button the Ignition crushing operations, test each
Switch stays ‘on’. Immediately turn the emergency stop button is
key to the off position. operative.

When an emergency stop has

been initiated, DO NOT at- Procedure
tempt to restart the engine
until it is safe to do so.
1. Observe all safety warnings
In the event of an emergency
stop operation leaving material 2. Follow the safe start-up procedure
in the Impact Crusher, this (section 7.2)
MUST be cleared prior to
restarting. Refer to Section 3. Start the engine (section 7.2.1)
7.1.1 for Blocked Crusher
Procedure. 4. Test each emergency stop button in turn
to cut out the engine and, following the
Before restart (Section 7.2.1 to 7.2.3) resetting of the tested button, repeat the
ensure the engine clutch is manually process for each of the other emer-
disengaged. Delay starting the feeder gency stop buttons (Section 1.7) and
until material left of the conveyors and also the stop button on the remote
screen has cleared. control handset (Figure 5b).

If the emergency stop button is then The emergency stop button on the main
released whilst the Ignition Switch is in control panel can be tested during the
‘on’ position’ the safety warning horn 10 second warning prior to engine start
will sound for 10 seconds before the in which case the sound will cease if the
engine can be restarted. (Section 7.2). button is operative.

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Page 1

Contents

9.1 Safety Information ............................................................................................... 3

9.2 Weights of Components ..................................................................................... 7

9.3 General Information ............................................................................................. 8

9.4 Plant - Lubrication and Servicing ..................................................................... 10

9.4.1 Lubrication Points ......................................................................................... 10
9.4.2 Regular Servicing .......................................................................................... 11
9.4.3 Daily, Weekly and Monthly Checks ................................................................ 12
9.4.4 Lubrication and Servicing Schedule .............................................................. 14
9.5 Crusher - Opening and Closing ........................................................................ 18
9.5.1 Safety Cutout Switch ..................................................................................... 19
9.5.2 Opening the Crusher ..................................................................................... 20
9.5.3 Closing the Crusher ....................................................................................... 22
9.6 Crusher - Adjustment ........................................................................................ 24
9.6.1 Entanglement Hazard for Inspection Door ...................................................... 25
9.6.2 Adjusting the Front Impact Apron ................................................................... 26
9.6.3 Adjusting the Rear Impact Apron ................................................................... 28
9.6.4 Adjusting the Swing Arm (where fitted) .......................................................... 30
9.7 Crusher - Replacement of Wear Parts ............................................................. 32
9.7.1 Replacing worn Blow Bars ............................................................................ 33
9.7.2 Replacing the Impact Plates of the Front and Rear Impact Aprons .................38
9.7.3 Replacing the Side Wall Liner Plates ............................................................. 41
9.7.4 Replacing the Bottom Inlet Beam ................................................................... 42
9.7.5 Replacing the Retractable Beam ................................................................... 44
9.8 Feeder - Operation ............................................................................................. 47
9.8.1 Removing the Underscreen Mesh or Blanking Mat .........................................48
9.9 Plant - Hydraulic System Description .............................................................. 50
9.9.1 General Description ...................................................................................... 50
9.9.2 Track Drives .................................................................................................. 51
9.9.3 Feeder Drive ................................................................................................. 51
9.9.4 Circuit Protection .......................................................................................... 51

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9.9.5 Changing the Suction Filter ........................................................................... 52

9.9.6 Changing the Return Filter ............................................................................. 54
9.9.7 Changing the Tank Breather .......................................................................... 55
9.9.8 Changing the Pressure Filters ....................................................................... 56
9.10 Plant - Electrical System Description ............................................................. 57

9.11 Plant - Crusher and Hydraulic Pump Drive Belts .......................................... 58

9.11.1 Replacement of Crusher Drive Belts ............................................................ 59
9.11.2 Adjustment of Crusher Drive Belts ............................................................... 60
9.11.3 Changing the engine pulley ......................................................................... 63
9.11.4 Replacement and Adjustment of Hydraulic Pump Drive Belts ....................... 64
9.11.5 Method of Drive Belt Tensioning .................................................................. 67
9.11.6 Trouble Shooting - Drive Belts ..................................................................... 70
9.12 Plant - Conveyor Belts .................................................................................... 71
9.12.1 Training of Belts .......................................................................................... 71
9.12.2 Conveyor Belt Tensioning ............................................................................ 73
9.12.3 Maintenance of Conveyor(s) ........................................................................ 75
9.12.4 Cleaning the Conveyor Belts ....................................................................... 77
9.13 Plant - Overband Magnetic Separator ............................................................ 79

9.14 Plant - Dust Suppression ................................................................................ 81

9.15 Plant - Diesel Engine ....................................................................................... 82

9.15.1 Manual Clutch Adjustment ........................................................................... 84
9.15.2 Clutch Maintenance ..................................................................................... 85
9.15.3 Engine - ELC Coolant ................................................................................. 86
9.15.4 Check Fuel Level ........................................................................................ 87
9.15.5 Top Up Fuel Level ....................................................................................... 88
9.16 Plant - Vehicle Tracks ...................................................................................... 90
9.16.1 Measuring Track Tension ............................................................................. 90
9.16.2 Adjusting Track Tension ............................................................................... 92
9.16.3 Track Maintenance ...................................................................................... 95
9.16.4 Drive Oil Filling and Draining ....................................................................... 96

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9.1 Safety Information

Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT

ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.

Personal Protective Equipment includes Hard

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.

Falling from and/or onto a FALLING HAZARD

Terex-Pegson machine can cause
serious injury or even death.

DO NOT climb onto the machine

whilst in operation.

ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.

ALWAYS use a suitable lifting platform when

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

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In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.

Your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.

Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.

ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.

ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be

surgically removed or gangrene will result.

Get medical help immediately.

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When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.

LOCKOUT PROCEDURE

1. Switch off engine.

2. Remove the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).

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WARNING
PRIOR TO ANY MAINTENANCE
• The maintence instructions are intended for day to day maintenance to keep the plant in good
running order and do not cover major rectifications, repairs or replacements where specialist
expertise is required. However, ensure that only suitably competent personnel with the necessary
training/experience for the task(s) in hand are employed. A person should never work alone.

• Observe the safety advice in Sections 1 and 9.1 as appropriate to the task(s) in hand.

• Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk
Assessment for all maintenance operations. Have suitable lifting equipment available for the
components involved together with all necessary (and suitable) tools/equipment ready for the
task(s) in hand and always secure parts liable to movement before starting work.
BL-Pegson’s Service Department is available for advice when required.

• The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout
Procedure (Section 9.1). Display a prominent ‘tag’ at the control station (or other appropriate
place) to warn of maintenance work being carried out.

• Keep clear of moving parts when trying to identify or isolate any unusual noises.

• Fit dismantled parts in the same location from which they were removed.

• Ensure that the area surrounding the maintenance site is clear of any obstructions.

• If arc welding work is involved in any maintenance operation, ensure that the current does not
pass through any bearings.
The plant must be fully isolated prior to any welding work.

• BEFORE WORKING ON THE PLANT, SWITCH OFF, ‘LOCKOUT’ AND ‘TAGOUT’

AFTER EXTENSIVE MAINTENANCE

Refer to Section 7.2.5 ‘Checks Prior to Initial Daily Start Up’ and 7.2.7 ‘Initial Start Up and
Running In’.

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9.2 Weights of Components

Weights of crusher and feeder assemblies, these should be consulted when arranging suitable lifting
equipment.

Component
Weight – (kg) Weight - (lb)
Rotor Shaft Assembly 3204 7065
Rotor 1250 2756
Rotor Shaft 339 748
Bearing Housing 101.3 223
Bearing 41.5 91.5
Inner Labyrinth 25.5 56.2
Outer Labyrinth 4.22 9.31
Outer Labyrinth 126 278
Blow Bar 214 472
Crusher (complete) 10690 23520

NOTE: FOR INDIVIDUAL WEIGHTS OF THE IMPACT CRUSHER LINER PLATES PLEASE REFER TO
THE PARTS LISTS IN SECTION 10

All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment.

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9.3 General Information The plant has been designed to facilitate

easy routine maintenance, but where
When performing maintenance, always necessary to remove any guards make sure
observe rules provided in the safety that they are replaced before the machine is
Section. restarted.

Breakdown caused by insufficient or Refer to the Spare Parts illustrations

improper maintenance will cause high repair (Section 10) to identify the machinery
costs and long term standstill. Therefore, components mentioned in the maintenance
regular maintenance is imperative. procedures.

In addition to several other factors, the

reliability and life of the Trakpactor depends
on regular and proper maintenance.

The following Section contains maintenance

instructions as well as maintenance
schedules for normal operating conditions.

When the Trakpactor is

operated in extreme climatic
conditions, e.g. below -10°C or
above 40°C (+14° to + 104°F)
or in very dusty conditions for
a longer period of time, the
maintenance schedules will
change.

Ask your local BL-Pegson

dealer or BL-Pegson Technical
Department for advice.

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PRACTICE SAFE
MAINTENANCE

Understand service procedure

before doing any work. Keep
area clean and dry.

Never lubricate, clean, service

or adjust machine whilst it is
moving.

Keep hands, feet and clothing

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

Disengage all the power and

operate controls to relieve
pressure. Stop the engine.
Implement lockout procedure.
Allow machinery to cool.

Securely support any machine

elements that must be raised
for service work.

Keep all parts in good

condition and properly
installed. Attend to damage
immediately. Replace worn or
broken parts.

Remove any build up of

grease, oil or debris.

Disconnect battery ground

cable (-) before making
adjustments on electrical
systems or welding on
machine.

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9.4 Plant - Lubrication and

Servicing WARNING
WEAR PERSONAL
9.4.1 Lubrication Points PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Regular lubrication of the plant machinery in Information for relevant warning.
accordance with the Lubrication and Servicing
Schedule (Section 9.4.4) is essential. LOCKOUT PLANT.
Refer to Section 9.1, Safety
The locations of the lubrication points are as Information for Lockout
follows:- Procedure.

FALLING HAZARD.
• Crusher rotor shaft bearing housing
Refer to Section 9.1, Safety
grease nipples (5) Information for relevant warning.
• Feeder vibrating unit bearing oil baths
on both sides of the feeder vibrating unit
(Section 7.2.6 and Figure7i).
• On-plant product conveyor head and
tailshaft bearing grease nipples located
on the bearing housings (tailshaft piped
to grease points on plant chassis sides).
• Track unit gearbox (2) oil levels (Section
9.16..3).
The overband magnet
• Dirt conveyor head and tailshaft bearing assembly is very powerful and
housing grease nipples (tailshaft piped permanently charged. The
to grease points on plant chassis sides). strong magnetic field produced
• Overband magnetic separator head and could affect heart
tailshaft bearing housing grease nipples pacemakers,watches, credit
(tailshaft piped to grease points on the cards, mobile phones etc. The
plant chassis sides). operator has the sole
responsibility to keep anyone
• Periodically lubricate hinges, cylinder at risk clear of the machine.
pivot pins and similar points with oil to
prevent seizure during lengthy spells of
inactivity.

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9.4.2 Regular Servicing

The Lubrication and Servicing Schedule
WARNING
(Section 9.4.4) lists, in addition to the WEAR PERSONAL
lubrication points, the attention required to PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
the hydraulic system (Section 9.9). Information for relevant warning.
Particular attention should be paid to
institute a regime of strict adherence from
LOCKOUT PLANT.
the start of operations for all aspects of
Refer to Section 9.1, Safety
routine maintenance. Information for Lockout
Procedure.
Keep a detailed Maintenance Log of all
work carried out, recording faults FALLING HAZARD.
experienced and actions taken, details of Refer to Section 9.1, Safety
Information for relevant warning.
routine maintenance, personnel name(s),
method statements, parts fitted,
consumeables used, dates, hours run, etc.
etc. Also note any extended periods when
the plant is inactive and steps taken for
protection whilst the plant is laid up.

NOTE: Do not overlook the service

requirements of the plant diesel engine
which are detailed in the engine
manufacturer’s manual. Also attend to
the service requirements of the clutch
as detailed (Section

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9.4.3 Daily, Weekly and Monthly

Checks WARNING
It is imperative that the
WEAR PERSONAL
operator carries out regular PROTECTIVE EQUIPMENT.
and diligent checks before Refer to Section 9.1, Safety
operating the plant especially Information for relevant warning.
with operational safety in mind
including (but not limited to) LOCKOUT PLANT.
those listed below. Refer to Section 9.1, Safety
Information for Lockout
Additionally, the operator Procedure.
should always consider what
FALLING HAZARD.
particular safety hazards could Refer to Section 9.1, Safety
occur at specific operating Information for relevant warning.
sites and take steps to
eliminate them before
commencing work. 6. Check the crusher shaft bearing
temperatures using a contact
Daily Checks thermometer and record for future
reference and fault diagnosis. The
1. Check that all guarding is complete and maximum acceptable working
properly secured prior to start up. Also temperature is 80°C (176°F)
that all warning signs (Section 1.8) are
present and readable. Weekly Checks

2. Check that all the plant emergency stop 1. Perform all checks on the daily check
buttons are operative (Section 1.7) list.

3. Carry out a general inspection of the 2. Lubricate to the weekly schedule.

plant to ascertain that nothing untoward (Section 9.4.4)
is out of place or damaged so as to
cause a safety hazard. 3. Check the area around the rotary
impactor for build-up of material; clean
4. Carry out daily lubrication schedule out as necessary.
(Section 9.4.4).
4. Ensure all hydraulic hoses and joints
5. Attend to Track Maintenance (Section are free from leaks.
9.16.3).
5. Lubricate the crusher rotor bearings.

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6. Check drive belts for damage, wear

and fraying. WARNING
7. Check crusher rotor, blow bars etc. for WEAR PERSONAL
security and wear/damage. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant warning.
8. Check crusher setting.

9. Clean away dust, dirt and grit from LOCKOUT PLANT.

Refer to Section 9.1, Safety
maintenance platforms and any moving
Information for Lockout
parts. Procedure.

10. Check side wall liners for wear damage FALLING HAZARD.
and security. Refer to Section 9.1, Safety
Information for relevant warning.
11. Check both aprons and, if fitted, the
swing beam adjusters for security wear
and damage.

12. Check conveyor belts for damage and

6. Check all drive belts are at the correct
fraying.
tension.
Monthly Checks
7. Clean oil strainers and filters. Inspect
for metal chips or flakes indicating
1. Perform all checks on the daily and
excessive bearing pressure or bearing
weekly check list
failure.
2. Lubricate to the monthly schedule
(Section 9.4.4)

3. Visually examine the rotary impactor,

liners and aprons for wear and damage.
Renew as necessary.

4. Inspect crusher drive belts for signs of

wear, renew as necessary.

5. Inspect both crusher aprons and, if

fitted, the swing beam adjustment
mechanisms for wear and damage.
Renew as necessary.
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 428 Trakpactor Lubrication Schedule
Frequency of Lubrication: X = Change
O = Check, top up or clean as necessary
R = Re-grease
Schedule based on a 40 hour operating week. Adjust schedule to suit actual operating hours.
No of 2 Bi-
Description Lubricant Quantity Daily Weekly Monthly Other
Locations Weekly Monthly
Crusher Shaft Bearing 30g (1oz)
2 D R
grease nipples each

Labyrinth Lid (left and 5g (0.2oz)

3 D R
right) each
Crusher Door Ram
4 D R
Bearing grease nipples
Multi-
Nuts of Lower Apron 3g (0.1oz)
- purpose R
adjusting assy each
grease

Feeder Drive side filler To middle of X(200

1 See chart O
plug sight glass hours)

Feeder Non-drive side To middle of X (200

1 See chart O
filler plug sight glass hours)
9.4.4 Lubrication and Servicing Schedule

On-Plant Conveyor Head

4 & Tail Shaft bearing D R
grease nipples
Dirt Conveyor Head and
4 Tail Shaft bearing grease D R

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nipples
9 - Maintenance

360 litres X
1 Hydraulic Reservoir See chart O
(96US galls) (annually)
In-line Hyd Filters (inside
2 - O X
engine canopy)
1000 hrs
Hyd Suction Filter (bottom sooner if
1 - O
of hydraulic reservoir) indicator
shows
Hyd Return Filter (top of RED
1 - O
hydraulic reservoir)
approx 5 litres
X
428

2 Tracks See chart (1.3 US galls) O

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(annually)
±10%
Page 14
Trakpactor

Issue EN 02

27/11/03
NB. Refer to the separate engine & clutch manuals for the lubrication schedules & specifications for those items.
Where the Optional Magnetic Separator is fitted, regrease the head and tailshaft bearings same as the Plant Conveyors.
 428 Trakpactor Lubricants, Oils & Fuel Types
Equipment Grade Century Mobile Shell Esso Gulf BP
428 Impact Crusher
Shaft bearings (grease) D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
All temperatures
Vibrating Feeder
Oil Bath Lubrication
>15ºC (59ºF) C Centlube H76 Mobilgear 634 Omala 680 Spartan EP460 EP LUB HD460 Energol GR-XP460
4ºC to 15ºC (39º-59ºF) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4ºC (39ºF) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP HD MULTI H Energol GR-XP150
Conveyors & Magnet
Shaft Bearings Grease D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
(all temperatures)
Plant Hydraulic System
<30ºC (86ºF) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
>30ºC (86ºF) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68

Track Tension D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2

Track Gearboxes SAE 80W/90 Gear Oil

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9 - Maintenance

27/11/03

Note: >15°C (59º F) is defined as a daily temperature consistently ABOVE 15°C (59º F)
< 4°C (39°F) is defined as a daily temperature consistently BELOW 4°C (39°F)
>30°C (86°F) is defined as a daily temperature consistently ABOVE 30°C (86°F)

Diesel Engine
Lubricating Oil
Coolant Refer to the Caterpillar Engine Operation & Maintenance Manual
428

Fuel

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
Engine Clutch Refer to the Twin Disc Clutch Operation and Maintenance Manual
Page 15
Trakpactor

Issue EN 02
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Lubrication Specifications

Oil Specification Grade A Grade B Grade C

Flashpoint: Minimum °C (°F) 199 (390) 204 (399) 216 (421)
Pour Point °C (°F) -18 (0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s 150 220 460
(104°F, in²/s) (0.232) (0.341) (0.713)
Kinematic Viscosity at 100°C, mm²/s 15.4 20.1 32.9
(212°F, in²/s) (0.0238) (0.0312) (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25°C (77°F) 280
Worked Penetration at 25°C (77°F) 285
Drop Point °C (°F) 185 (365)
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135°C (275°F) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40°C mm²/s 32 46 68
(104°F, in²/s) (0.049) (0.0713) (0.105)

Kinematic Viscosity at 100°C mm²/s 5.5 6.5 8.5

(212°F, in²/s) (0.085) (0.010) (0.013)
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes

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Crusher Shaft Bearing Grease

Nipples & Labyrinth Lid
* Front Adjusting Spindles

Crusher Door Ram

Bearing Grease Nipple

Nuts of Apron Adjusting

Assembly

Crusher Door Ram

Bearing Grease Nipple

* Adjusting Assembly of
Swing Arm (where
*Lubricate with molybdenum disulphide spray fitted)

Figure 9 Crusher Lubrication Points

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9.5 Crusher - Opening and Both sets of bolts must NOT

Closing be undone at the same time
and it is essential that when
Access to the inside of the Impact Crusher requiring to change from one
body is gained by first releasing some of the opening mode to the other that
swivelling eye bolts on the crusher body the crusher body should be
and then operating the hydraulic rams to completely closed off (Section
open the pivotted upper frame of the 9.5.3) before attempting to
crusher. reopen (Section 9.5.2) into the
other mode.
The crusher upper frame opens in two
modes depending upon the servicing All maintenance on the impact crusher must
required for the machine. By releasing only only be carried out when the plant lockout
the internal swivelling eye bolts (‘A’ in procedure has been carried out and the
Figure 9a) the rotor is accessed whereas by crusher rotor is stationary.
only releasing the outer eye bolts (‘B’ in
Figure 9a) only the top of the body is raised
for access to the impact aprons area.

Swivelling Eye Bolts ‘A’ Swivelling Eye Bolts ‘B’

(5 each side) (6 each side)

Figure 9a Swivelling Eye Bolts

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9.5.1 Safety Cutout Switch

Before opening the crusher, the following safety check must be carried out

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9.5.2 Opening the Crusher

Before atempting to open the
WARNING
crusherbody make sure that all WEAR PERSONAL
tools and personnel are PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
evacuated from the Information for relevant
maintenance platform. warning.
LOCKOUT MACHINE.
Procedure Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.
1. Observe all safety warnings.

2. Run the crusher until completely empty.

Close down the plant (Section 8.2) and
implement the lockout procedure.

A safety cut-out switch on the

crusher body prevents the
engine being turned over or
started whilst the crusher body
is open .

3. Secure both of the Front Apron

Adjusting Mechanisms (Figure 9g) with
the chains (D) to the protective caps
(A) to hold the mechanisms in place
when the crusher body is open. Failure
to do this will result in damage to
the plant.

4. Depending upon the access required,

loosen the swivelling eye bolts ‘A’ or
‘B’on the crusher flange and rotate
them through 180º Ensure that only
one set of bolts ‘A’ OR ‘B’ (Figure
9a) have been released before
attempting to open the crusher
body, ie. NOT both sets of bolts
undone at the same time.

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5. On the main Control Panel turn the 8. Using the two locking pins provided
Plant/Track/Pump operation switch to always lock the crusher door in the
the ‘PUMP’ position. open position. (Figure 9c).

6. Next (after replacing the engine isolation 9. Turn the engine ignition switch to
key) turn the engine ignition switch to position ‘O’ and implement the lockout
position ‘I’. (although the engine procedure.
ignition has to be ‘on’ the engine
does not require to be started and
cannot not be cranked over). The
warning horn will sound but this is Hydraulic Valve Lever
irrelevant to this operation.

7. To operate the hydraulic rams press

(and keep depressed) the button
marked ‘PUMP’ and at the same time
operate the control lever on the
hydraulic valve on the maintenance
platform. Avoid prolonged use of the
pump to avoid draining the engine
battery.

Locking Pin Location

Locking Pin

Figure 9c Locking Pin & Crusher Open-Locking Pin Location

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9.5.3 Closing the Crusher

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
1. Observe all safety warnings. warning.
LOCKOUT MACHINE.
2. Remove the two locking pins from the Refer to Section 9.1, Safety
crusher door and keep safe for future Information for Lockout Proce-
use. dure.

Before attempting to close the

crusher body make sure that
all the opened swivelling eye
bolts are folded back from the
mainframe flange and that all
tools and personnel are
evacuated from the
maintenance platform.

3. Reverse the lockout procedure and turn

the engine ignition switch to position ‘I’
(although the engine ignition has to
be ‘on’ the engine does not require
to be started and cannot be cranked
over.) The warning horn will sound but
his is irrelevant to this operation.

4. On the main control panel turn the

Plant/Track/Pump operation switch to
the ‘PUMP’ position.

5. To operate the hydraulic rams press

(and keep depressed) the button
marked ‘PUMP’ and at the same time
operate the control lever on the
hydraulic valve on the maintenance
platform. Avoid prolonged use of the
pump to avoid draining the battery.

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6. Turn the engine ignition switch to the

‘O’ position and implement the lockout WARNING
procedure.
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
7. Rotate the swivelling eye bolts through Refer to Section 9.1, Safety
180º and thoroughly tighten. Information for relevant
warning.
8. Detach the chains (D) from the LOCKOUT MACHINE.
Protection caps (A) on the Front Apron Refer to Section 9.1, Safety
Adjusting mechanisms (Figure 9g). It is Information for Lockout Proce-
essential these chains are detached dure.
before operating the crusher in
order to allow movement of the
Front Apron.

After blow bars, apron liners or

swing arm rails have changed,
the gap settings MUST be
checked, and adjusted if
necessary, to within the
permissable limits (Sections
3.4 and 9.6) before attempting
to start the crusher otherwise
serious damage could occur if
the rotor is not free to turn.

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9.6 Crusher - Adjustment It is most important that settings between

the rotor blow bars and the front and rear
Adjustments are required to the impact aprons and also the swing beam (optional),
crusher to enable the product size to be if fitted, do not exceed the minimum or
varied and to compensate for wear on the maximum dimensions given in Figure 3b and
aprons, swingbeam (where fitted) and blow that ratios are maintained between the front
bars. Refer to Section 3.4, Figure 3c for the and rear apron settings and between the rear
setting gaps. apron and the swing beam (if fitted) otherwise
any warranty may be invalidated.

Front Impact Apron Adjustment

Mechanism

Front Impact Apron

Rear Impact Apron

Adjustment Mechanism
Rear Impact Apron

Retractable Beam

Swing Beam Adjustment

Mechanism

Bottom Inlet Beam

Rotor Protection Cap

Blow Bars Swing Beam Rails

Axial Lock & Securing Pin

Figure 9d Impact Crusher Parts

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9.6.1 Entanglement Hazard for Inspection Door

Keep doors (Figure 9f) closed, latched and bolted except when performing
maintenance.

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9.6.2 Adjusting the Front Impact

Apron WARNING
After any maintenance and WEAR PERSONAL
before starting the crusher, PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
ensure the rotor can turn
Information for relevant
without any impedance. Check warning.
the distance between the ‘long’
LOCKOUT MACHINE.
blow bars (Section 9.7.1) and Refer to Section 9.1, Safety
impact plates and if necessary Information for Lockout Proce-
adjust the impact aprons and dure.
swing arm

See Section 3.4.1 Impactor Settings

Procedure

1. Observe all safety warnings.

2. Run the crusher until completely empty.

Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Only when the rotor shaft is stationary

open the upper inspection doors on the
side of the crusher (Figure 9f).
Figure 9f Upper Inspection Door

Do NOT in any circumstances

open the Upper Inspection
Doors whilst the crusher is Each blow bar must be in
running. contact with the lower seat
engaging surfaces of the rotor
4. Measure the smallest gap between when measuring the gap. If the
each blow bar and the lowest wear blow bar is not in contact with
plate of the Front apron. the lower seat engaging
surfaces, the gap MUST be
increased by 10mm (3/8”) to
compensate for the lifting of
the blow bars under centrifugal
force

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5. Loosen the locknut with protective

sleeve (A) a few turns (Figure 9g). WARNING
Repeat this step for the other adjusting
WEAR PERSONAL
mechanism. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
6. To increase the gap, between the Information for relevant
blow bar and apron, tighten (turn warning.
clockwise) both adjusting nuts (B) LOCKOUT MACHINE.
(Figure 9g) in turn a little at a time and Refer to Section 9.1, Safety
by an equal amount. Information for Lockout Proce-
dure.
7. To decrease the gap, between the
blow bar and apron loosen (turn anti-
clockwise) both adjusting nuts (B) 8. When the gap is correct, tighten the
(Figure 9g) in turn by a little at a time locknut with protection cap (A) and
and by an equal amount. lock against the adjusting nut (B).
Repeat this step for the other adjusting
Ensure the adjusting nut (B) mechanism.
always sits on the guiding
sleeve and disc springs (C). 9. Close the inspection doors and secure
with the locking clip..

Locknut with Protection Cap (A)

Adjusting Nut (B)

Disc Springs (C)

Chain (D) - shown

fixed
Chain (D) - shown loose

Figure 9g Front Impact Apron Adjustment

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9.6.3 Adjusting the Rear Impact

Apron WARNING
After any maintenance and WEAR PERSONAL
before starting the crusher, PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
ensure the rotor can turn
Information for relevant
without any impedance. Check warning.
the distance between the ‘long’
LOCKOUT MACHINE.
blow bars (Refer to Section Refer to Section 9.1, Safety
9.7.1) and impact plates and if Information for Lockout Proce-
necessary adjust the impact dure.
aprons and swing arm

See Section 3.4.1 Impactor Settings

Procedure

1. Observe all safety warnings.

2. Run the crusher until completely empty.

Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Open the upper inspection doors on the

side of the crusher (Figure 9f).

4. Measure the smallest gap between

each blow bar and the lowest wear
plate of the rear apron.

The blow bar must be in contact

with the lower seat engaging
surfaces of the rotor when
measuring the gap. If the blow
bar is not in contact with the
lower seat engaging surfaces,
the gap MUST be increased by
10 mm (3/8”) to compensate for
the lifting of the blow bars under
centrifugal force

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5. On one of the Rear Impact Apron

Adjusting mechanisms (Figure 9h) undo WARNING
the set screws (A) and remove the keep
WEAR PERSONAL
plate (B). Repeat this step for the other PROTECTIVE EQUIPMENT.
adjusting mechanism. Refer to Section 9.1, Safety
Information for relevant
6. To increase the gap, between the warning.
blow bar and the rear apron, tighten LOCKOUT MACHINE.
(turn clockwise) both adjusting sleeves Refer to Section 9.1, Safety
(C) each in turn a little at a time and by Information for Lockout Proce-
dure.
equal amounts.

7. To decrease the gap between the

8. When the gap is correct, replace both
blow bar and the rear apron, loosen
keep plates and secure with the 2 set
(turn anti-clockwise) both adjusting
screws in each keep plate.
sleeves (C) each in turn a little at a time
and by equal amounts.
9. Close the inspection doors and secure
with the locking clip.

Set Screws (A) Keep Plate (B) Adjusting Sleeve (C)

Figure 9h Rear Impact Apron Adjustment

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9.6.4 Adjusting the Swing Arm

(where fitted) WARNING
After any maintenance and WEAR PERSONAL
before starting the crusher, PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
ensure the rotor can turn
Information for relevant
without any impedance. Check warning.
the distance between the ‘long’
LOCKOUT MACHINE.
blow bars (Refer to Section Refer to Section 9.1, Safety
9.7.1) and impact plates and if Information for Lockout Proce-
necessary adjust the impact dure.
aprons and swing arm

See Section 3.4.1 Impactor Settings

Procedure

1. Observe all safety warnings.

2. Run the crusher until completely empty.

Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Lift out the platform between the

crusher and engine canopy, to increase
access to the swing beam adjusting
mechanism.

4. Measure the smallest gap between Figure 9i Swing Arm and Blow bar
each blow bar and the swing beam
rails. (Figure 9i).

The blow bar must be in

contact with the lower seat
engaging surfaces of the rotor
when measuring the gap. If the increased by 10mm (3/8”) to
blow bar is not in contact with compensate for the lifting of
the lower seat engaging the blow bars under centrifugal
surfaces, the gap MUST be force

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5. On the swing arm adjusting mechanism

(similar to Figure 9h) undo the set WARNING
screws (A) and remove the keep plate
WEAR PERSONAL
(B). PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
6. To increase the gap, between the Information for relevant
blow bar and the swing arm rail, tighten warning.
(turn clockwise) the adjusting sleeve LOCKOUT MACHINE.
(C). Refer to Section 9.1, Safety
Information for Lockout Proce-
7. To decrease the gap between the dure.
blow bar and the swing arm rail, loosen
(turn anti-clockwise) the adjusting
sleeve (C).

8. When the gap is correct, replace the

keep plate and secure with the 2 set
screws.

9. Close the inspection doors and secure

with the locking clips

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9.7 Crusher - Replacement All maintenance on the impact crusher must

of Wear Parts only be carried out when the plant lockout
procedure has been carried out and the
Use only genuine BL-Pegson replacement crusher rotor is stationary.
wear parts. Check daily for wear on all
parts affected particularly where the When replacing wear parts check there is
material being crushed is known to be no build up of material within the crusher,
abrasive. It is important that designed eg. between the impact aprons, swing beam
replaceable wearing parts are renewed (if fitted) and the crusher side walls, and
before the underlying machine is subjected clear as necessary. Always make sure that
to wear. the seating of a wear part is clean and the
part is properly ‘bedded’ in position.
One working day after fitting new
replacement wear parts always check the
fixing bolts for tightness.

Front Apron Adjustment Mechanism

Body Side Liner Plates

Rear Apron Adjustment
Mechanism

Front Apron
Liner Plates

Rear Apron Liner

Plates
Rotor Protection
Caps

Blow Bars Swing Beam

Rails Swing Beam (Grinding Path)
Adjustment Mechanism

Figure 9j Impact Crusher Parts

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9.7.1 Replacing worn Blow Bars

The crusher must be fitted the
WARNING
matched pairs of blow bars WEAR PERSONAL
fitted diametrically opposite to PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
each other. The maximum Information for relevant
weight difference between the warning.
two Blow Bars supplied as a
LOCKOUT MACHINE.
pair is 0.47 kg. Refer to Section 9.1, Safety
Information for Lockout Proce-
ONLY REPLACE/TURN dure.
BLOW BARS AS MATCHED
OPPOSITE PAIRS TO
MAINTAIN THE CORRECT
ROTOR BALANCE

Of the two pairs of blow bars Before replacing the blow bars,
fitted to the rotor, one pair is the impact aprons and swing
shorter (ie. having a smaller beam should be set fully open.
projection from the rotor (Fully Open - maximum gap
periphery) than the other pair. between blow bar and impact
apron/swing beam).
Reverse the wearing face of a
pair of blow bars through 180° After any maintenance and
when the original face is worn before starting the crusher,
but maintain the one pair ‘long’ ensure the rotor can turn
and one pair ‘short’ blow bar without any impedance. Check
configuration on the rotor by the distance between the ‘long’
fitted appropriate new blow bar blow bar and impact plates
when necessary. and, if necessary, adjust the
impact aprons and swing arm
(Section 9.6) in accordance
with data set out in Sections
3.3 (Designated Use) and 3.4
(Crusher Capacity).

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Removal of each Blow Bar

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
1. Observe all safety warnings. Information for relevant
warning.
2. Run the crusher until completely empty. LOCKOUT MACHINE.
Close down the plant (Section 8.2) and Refer to Section 9.1, Safety
implement the lockout procedure. Information for Lockout Proce-
dure.
3. Open the crusher (Section 9.5.2)

4. To remove the two axial locks - remove

the split pins, withdraw the securing pins
and remove the axial locks. (Figure
9k). To prevent the rotor from turning
whilst the blow bar is removed, lock
the rotor into position using the
rotor lock (Figure 9l) Insert the pin
end of the rotor lock into the hole in the
rotor just vacated by the axial lock and
secure the lock to the crusher body by
the adjacent swivelling eye bolt (Figure 9l
& 9m).

5. Clean out the debris between the blow

bar and rotor recess.
support the weight with suitable slings
6. Using the hydraulic blow bar extraction and lifting gear. Extension bars are
tool provided mount the tool as shown included with the extraction tool to be
(Figure 9m) on the drive guard side of inserted, when necessary, when the limit
the crusher. Using the quick release of travel is reached.
hose couplings connect to the crusher
ram operating valve on the platform 8. Retract the piston in the extraction tool
by moving the operating lever in the
7. In the same manner of operation as reverse direction and remove the tool
when opening the crusher body, push from the rotor.
out the blow bar with the extraction
tool. As the blow bar is extracted continued on the next page.........

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Split Pin

Axial Lock &

Securing Pin

Blow Bar

Figure 9k Impact Crusher - Blow Bar and Axial Lock

Figure 9l Rotor Lock

(fit where indicated)

Figure 9m Removing the Blow Bar

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Fitting of Blow Bars

WARNING
ONLY REPLACE/TURN
WEAR PERSONAL
BLOW BARS AS MATCHED PROTECTIVE EQUIPMENT.
OPPOSITE PAIRS TO Refer to Section 9.1, Safety
MAINTAIN THE CORRECT Information for relevant
ROTOR BALANCE warning.
LOCKOUT MACHINE.
Every time a blow bar is Refer to Section 9.1, Safety
rotated or replaced, check the Information for Lockout Proce-
4 rotor protection caps for dure.
wear and damage. If
necessary replace all 4 rotor
protection caps. Do not replace
individual rotor protection
caps. NEVER work with worn
or damaged rotor protection
caps.

9. Using suitable lifting equipment support

the blow bar in the middle.

10. Slide the blow bar halfway into the

rotor.

11. Reposition the lifting equipment and

support the blow bar at its end.

12. Slide the blow bar into position.

13. Remove to rotor lock.

14. Fit the both axial locks and axial

securing pins. Fit new split pins.

15. Rotate the rotor and repeat Steps 4 to

14 for the other diametrically opposite
Blow Bar MAKING SURE THAT
IT IS THE OTHER BLOW BAR
OF THE MATCHING PAIR.

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After any maintenance and

before starting the crusher, WARNING
ensure the rotor can turn
WEAR PERSONAL
without any impedance. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
16. Close the crusher (Section 9.5.2). Information for relevant
warning.
17. Check the distance between the ‘long’ LOCKOUT MACHINE.
blow bars and impact plates and if Refer to Section 9.1, Safety
necessary adjust the impact aprons and Information for Lockout Proce-
swing arm (Section 9.6). dure.

18. When the blow bar changing process is

complete disconnect the extraction tool
and reconnect the crusher door ram
hoses to the valve unit on the platform.

Run the crusher empty for 30

minutes to allow the blow bars
to bed into position and also
check that the crusher is
running smoothly.

Never open the inspection

doors while the crusher is in
operation.

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9.7.2 Replacing the Impact Plates

of the Front and Rear Impact WARNING
Aprons
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Procedure Refer to Section 9.1, Safety
Information for relevant
warning.
LOCKOUT MACHINE.
1. Observe all the safety warnings. Refer to Section 9.1, Safety
Information for Lockout Proce-
2. Run the crusher until completely empty. dure.
Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Remove the appropriate access panels

(Figures 9o & 9p) on the outside of the 9. Close the crusher (Section 9.5.3).
crusher using suitable lifting equipment.
10. Refit the access panels.
4. Open the crusher (Section 9.5.2).
11. Check the distance between the blow
5. Remove the worn impact plates. bars and impact plates and if necessary
adjust the impact aprons and swing
6. Clean the seats of the impact plates. beam (Section 9.6).

7. Fit new impact plates. Strike the bolt After any maintenance and
heads repeatedly during tightening to before starting the crusher,
ensure the bolts are seated correctly in ensure the rotor can turn
the bores of the of impact plates. To without any impedance.
help prevent the special countersunk
bolts from turning when the nuts are
tightened, a suitable chisel or screw
driver can be pushed between the bore
and the bevelled part of the bolts head.

8. Tighten the nuts to the specified torque

(Figure 9n).

Only use NEW Philidas

locking nuts when fitting new
liner plates.

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Figure 9n Front & Rear Impact Plate Bolts - Tightening Torques

Access Panels

Figure 9o Front Impact Apron Access Panels and Wear Plates

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Wear Plates
Access Panels

Figure 9p Rear Impact Apron Access Panels and Wear Plates

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9.7.3 Replacing the Side Wall Liner

Plates WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
warning.
1. Observe all the safety warnings.
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
2. Run the crusher until completely empty. Information for Lockout Proce-
Close down the plant (Section 8.2) and dure.
implement the lockout procedure.

3. Open the crusher (Section 9.5.1)

4. Remove one of the axial locks from the

top Blow Bar. (Figure 9k )
In the main wear area, the
5. Secure the rotor lock into the place liner plates can be rotated or
where the axial lock seats and bolt the interchanged to achieve
rotor lock to the side of the crusher optimal utilisation of the liner
body. (Figure 9l & 9m) plates.

6. Clean out any debris from the liner The bottom inlet beam is
plates. located on two side wall liner
plates A6984/9/2 (Figure 9r).
7. All the side wall liner plates are bolted DO NOT attempt to remove
into position from the outside of the the side wall liner plates
crusher. To remove/replace any of the A6984/9/2, without first
side wall liner plates, support the liner removing the bottom inlet
from the inside of the crusher whilst beam A6984/9/23 (Section 10)
removing/fitting the bolt.

Side Liner Tightening Torque

420Nm (310lbf ft).

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9.7.4 Replacing the Bottom Inlet

Beam WARNING
Removal of the Bottom Inlet Beam WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Procedure Information for relevant
warning.
LOCKOUT MACHINE.
1. Observe all the safety warnings. Refer to Section 9.1, Safety
Information for Lockout Proce-
2. Run the crusher until completely empty. dure.
Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Remove the rubber panels on either

side of the crusher.

4. Undo the three bolt protection caps on

the front access door.

5. Loosen the three toggle bolts and rotate

them through 180º.

6. Using suitable lifting equipment support

the front access door.

7. Standing clear of the access door, prise

open the door, using the lifting
equipment to take the weight of the
door. Lower the door until it is fully
open.

DO NOT enter the area

between the front access door
of the crusher and the crusher
feed chute whilst opening/
closing the access door.

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8. Remove the lifting equipment.

WARNING
9. Screw two M20 eye bolts into the two
WEAR PERSONAL
tapped holes of the bottom inlet beam. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
10. Using suitable lifting equipment lift out Information for relevant
the beam using the eye bolts. warning.
LOCKOUT MACHINE.
Fitment of the Bottom Inlet Beam Refer to Section 9.1, Safety
Information for Lockout Proce-
11. Screw two M20 eye bolts into the two dure.
tapped holes of the new bottom inlet
beam.

12. Using suitable lifting equipment position

the beam onto the two side wall liner
plates and slide the beam into position.

13. Using suitable lifting equipment, close

the access door.

DO NOT enter the area

between the front access door
of the crusher and the crusher
feed chute whilst opening/
closing the access door.

14. Rotate the three toggle bolts through

180º and fully tighten.

15. Refit the three bolt protection caps.

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9.7.5 Replacing the Retractable

Beam WARNING
Removal of Retractable Beam WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Procedure Information for relevant
warning.
LOCKOUT MACHINE.
1. Observe all the safety warnings. Refer to Section 9.1, Safety
Information for Lockout Proce-
2. Run the crusher until completely empty. dure.
Close down the plant (Section 8.2) and
implement the lockout procedure.

3. Remove the retractable beam access

covers on either side of the crusher
(Figure 9q).

4. Using a heavy hammer or beetle, drive

out the retractable beam, supporting the
beam with suitable lifting equipment.

When driving out the

retractable beam splinters may
be produced. Where protective
clothing and safety glasses.

To aid removal of the beam the

front wall can be opened
(Figure 9s). A cantilever bar
can then be used to assist with
the driving out procedure.

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Figure 9q Access Cover - Retractable

Beam

Retractable
Beam

Bottom Inlet
Beam

Figure 9s Front Wall Open

Figure 9r Retractable Beam Detail

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Fitting of Retractable Beam

WARNING
The retractable beam can be
WEAR PERSONAL
rotated through 180° if the v- PROTECTIVE EQUIPMENT.
grooves are in good condition. Refer to Section 9.1, Safety
DO NOT rotate the beam if Information for relevant
the v-grooves are worn. warning.
LOCKOUT MACHINE.
Whenever the retractable Refer to Section 9.1, Safety
beam is rotated or replaced, Information for Lockout Proce-
the bottom intake armouring dure.
should be checked and
replaced if necessary.

5. Using suitable lifting equipment support

the beam.

6. Using a hammer or beetle drive the

beam into position.

When driving in the retractable

beam splinters may be
produced. Wear protective
clothing and safety glasses.

7. Close the front wall of the machine.

8. Replace the retractable beam covers on

either side of the crusher.

After any maintenance and

before starting the crusher,
ensure the rotor can turn
without any impedance.

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9.8 Feeder - Operation

WARNING
The vibrating feeder must, in addition to the WEAR PERSONAL
scheduled lubrication requirements (Section PROTECTIVE EQUIPMENT.
9.4), be regularly inspected for any wear, Refer to Section 9.1, Safety
damage or breakage with the mainframe Information for relevant warning.
and support springs being paid particular
attention. Rectify faults immediately. LOCKOUT PLANT.
Refer to Section 9.1, Safety
After first 8 hours of operation, change the Information for Lockout
Procedure.
oil in the vibrating unit end covers.
FALLING HAZARD.
Drive side-approx. 2.1 litres (4.5 US pints) Refer to Section 9.1, Safety
Non-drive side-approx.1.7 litres (3.5 US Information for relevant warning.
pints).

Make sure that the feeder can vibrate

freely without fouling against the adjacent
hopper or chutework and that hardened
material inside the pan is not allowed to
build up and affect the performance of the If a wire mesh underscreen is fitted (an
machine. Also check to ensure that the alternative option to the blanking mat) the
hydraulic drive is operating efficiently. material rejected will bypass the crusher
The variable speed control is situated on whilst the material passing through the
the Feeder/Conveyor control box. mesh will discharge onto the dirt
conveyor.
Periodically check the condition of the
blanking mat or mesh panel beneath the A two-way hand operated flap door can
grizzly bars for both wear and build up of be positioned so that a portion of the
material and recitify if necessary. undersize can be directed to the bypass
chute.
The plant is supplied with the feeder
Frequently check the oil levels in the
fitted with a blanking mat; all the material
passing through the grizzly bars will vibrating unit end covers (Figure 7i).
bypass the crusher and discharge onto
the product conveyor.

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9.8.1 Removing the Underscreen

Mesh or Blanking Mat WARNING
The plant feeder can be fitted with wire WEAR PERSONAL
underscreen to discharge material to the dirt PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
conveyor or may initially be fitted with a Information for relevant warning.
blanking mat which directs all material passing
through the grizzly bars on to the on-plant
LOCKOUT PLANT.
product conveyor. If required to alter the
Refer to Section 9.1, Safety
configuration either to change from one to the Information for Lockout
other or to remove altogether, follow the Procedure.
procedure below.
FALLING HAZARD.
Refer to Section 9.1, Safety
Procedure Information for relevant warning.

1. Observe all safety warnings.

2. Run the plant until the feeder and

crusher are completely empty. Close
down the plant (Section 8.2) and
implement the Lockout Procedure.

3. Lower the mesh access panel at the

rear of the dirt chute (Figure 9t).

4. Slacken the 2 clamping screws located

in the slots each side of the feeder
(Figure 9u).

5. Loosen the locking nuts on the 3 screws

located underneath the feeder
sufficiently to disengage the hooked Figure 9t Mesh/Mat Access Panel
ends of the panel.

6. With the hooked rod tool provided,

reach through the grizzly bars from
above to lift and slide the panel out.

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7. When replacing a panel carry out the

procedure in reverse order making sure
that the panel is sufficiently tensioned
but take care not to over tighten
otherwise the panel may be damaged.

Clamping Screw

Figure 9u Feeder Clamping Screw

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9.9 Plant - Hydraulic System

Description DANGER
SKIN INJECTION HAZARD
(Figure 9v & Hydraulic circuit diagram Refer to Section 9.1, Safety
in Section 10) Information for relevant warning

9.9.1 General Description

All hydraulic functions are powered by two
pumps, one mounted either side of the The flows and pressures to each service is
diesel engine and driven from the main limited by the relevant spool as shown
crankshaft pulley via two SPB belts. below and the pump supplies only the
required flow by automatically backing off
Each pump is an axial piston variable the swash plate angle thus reducing wasted
displacement unit capable of up to95 litres/ power and resulting heat generation.
min. at 320 bar and each feeds a directional
control valve.

Front Pump
Max Flow
Max Pressure
Service Spool Type Litres/min
(Bar)
(US galls/min)
L/H track drive motor Proportional 65 (17) 320
Product conveyor plus Magnet
On/Off 100 (26.4) 210
and Water Pump (when fitted)
Rear Pump
Max Flow
Max Pressure
Service Spool Type Litres/min
(Bar)
(US galls/min)
R/H track drive motor Proportional 65 (17) 320
Feeder Proportional 0 - 65 (17) 180
Dirt Conveyor On/Off 25 (6.5) 180
Dirt Conveyor Fold On/Off 25 (6.5) 100
22/10/04
Figure 9v Front/Rear Hydraulic Pumps

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This is achieved by means of a load sensing It is recommended that adjustment is not

line from the valve to the pump which undertaken without BL-Pegson Ltd.
measures the pressure required which is consent and under no circumstances should
then matched by the pump. the slow speed be adjusted greater than
0.4kph (0.2mph).
Note:-
All relief valve pressures are factory set and Motor mounted motion control valves are
should not be adjusted on site. utilised to prevent the machine over running
when moving downhill.
Although the maximum flows from each
spool is limited as shown, these can be This block also incorporates a shuttle valve
individually adjusted downwards by means to release the spring applied track parking
of limit screws if desired. Please contact brake together with a pressure reducing
BL-Pegson Ltd. valve, pre set to 60 bar so that the brakes
are not overpressurised.
9.9.2 Track Drives
9.9.3 Feeder Drive
Although these valves Sections have
proportional controls and are theoretically This valve Section is fitted with a
infinitely variable they are electrically limited proportional solenoid so that the feeder
to two speeds for simplicity. speed can be controlled by means of a
chassis mounted control box potentiometer.
a) SLOW - For slewing and fine
positioning. 9.9.4 Circuit Protection

b) FAST - For straight line running, The system is equipped with the following
forward or reverse. protection:-

Note:- The maximum power take off from • Suction Filter (90µm nominal)
one side of the engine is limited to
• Pressure Filter (10µm absolute) in each
approximately 30 kW, therefore the system
pump circuit prior to the directional
is electronically limited such it is only
control valves.
possible to slew (operate one side only)
when in the ‘SLOW’ mode.
• Return Filter (10µm nominal)
Fine adjustment of the slow speeds is
• Low oil level cut out.
possible. Consult BL-Pegson Ltd.
Note:- For Hydraulic Pump Drive Belt
adjustment refer to Section 9.11.4.

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9.9.5 Changing the Suction Filter

Located at the base of the hydraulic DANGER
reservoir tank is the hydraulic suction filter. SKIN INJECTION HAZARD
When the dial gauge needle (Figure 9w) Refer to Section 9.1, Safety
enters into the red segment whilst the Information for relevant warning
system is running at normal operating
temperature this is an indication that the
filter must be replaced immediately . The
filter housing has an internal shut off valve to WARNING
permit work on the system. Make sure WEAR PERSONAL
the oil has cooled before changing. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
Procedure warning.
LOCKOUT MACHINE.
1. Observe all safety warnings. Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.
2. Close down the plant (Section 8.2) and
implement the Lockout Procedure.

3. Unscrew the black plastic knob in the

centre of the filter housing anticlockwise
until it reaches the stop (Figure 9w). 7. Fully screw in the bolt A in the
centre of the filter housing.
4. Take steps to collect spillage of oil
(approx. 2 litres / 1/2 US gall) before
undoing the six socket head screws on
the front of the housing to remove the
cover plate. It is important to ensure that
the black knob is fully screwed
5. Remove the old filter and clean inside in before restarting the plant.
the housing with lint free cloth before Damage will occur to the plant
fitting a new filter of the approved if this procedure is not
pattern and specification. followed.

6. Before replacing the cover plate, lightly

oil the ‘O’ ring and make sure it is
properly seated in the groove. Replace
the cover plate and refit the screws to
ensure an oil tight seal.

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Filter Condition Indicator Dial

It is important to ensure that

the black knob is fully screwed
in before restarting the plant.
Damage will occur to the plant
if this procedure is not
followed.
Black Knob Removable Cover Plate

Hydraulic Oil Return Hydraulic Oil

Filter and Gauge Breather/Filler

Hydraulic Oil Level Hydraulic Oil Tank

Figure 9w Suction Filter, Hydraulic Oil Tank & Level Indicator

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9.9.6 Changing the Return Filter

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

Procedure FALLING HAZARD.

Refer to Section 9.1, Safety
Information for relevant
1. Observe all safety warnings. warning.

2. Close down the machine (Section 8.2)

and implement the Lockout Procedure.

3. Remove the four hexagon head screws

on the top of the housing to remove the
cover plate together with internal spring.

4. Remove the old filter and clean inside

the housing with lint free cloth before
fitting a new filter of the approved
pattern and specification. Replace the
spring which holds the filter in place

5. Before replacing the cover plate, lightly

oil the ‘O’ ring and make sure it is
properly seated in the filter housing.
Replace the cover plate and refit the
screws to ensure an oil tight seal.

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9.9.7 Changing the Tank Breather

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

FALLING HAZARD.
Refer to Section 9.1, Safety
Information for relevant
warning.

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9.9.8 Changing the Pressure

Filters DANGER
Located on each side on the engine within the SKIN INJECTION HAZARD
canopy are the hydraulic pressure filters. Refer to Section 9.1, Safety
When the ‘telltale’ (Figure 9x) changes from Information for relevant warning
green to red whilst the system is running at
normal operating temperature this is an
indication that the filter must be replaced
immediately. Make sure the oil has cooled WARNING
before changing.. WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Procedure Information for relevant
warning.
LOCKOUT PLANT.
1. Observe all safety warnings. Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.
2. Close down the machine (Section 8.2)
and implement the Lockout Procedure.

3. Unscrew (turn anticlockwise looking Filter condition ‘Telltale’ Filter body

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

4. Remove the old filter and clean inside

the bowl and housing with lint free cloth
before fitting into position a new filter
and small ‘O’ ring of the approved
pattern and specification.
Bowl
5. Before replacing the bowl, lightly oil the
‘O’ ring and place on it’s seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
care not to ‘cross’ the threads when
doing so. Tighten with the ‘nut’ at the
base of the bowl to ensure an oil tight ‘Nut’
seal. Figure 9x Pressure Filter

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9.10 Plant - Electrical

System Description WARNING
WEAR PERSONAL
For the electrical circuit diagram see PROTECTIVE EQUIPMENT.
Appendix Section of the manual Refer to Section 9.1, Safety
Information for relevant
warning.
Electrical power of DC24 volt for the
electrical equipment on the plant is derived LOCKOUT MACHINE.
from the diesel engine to operate the control Refer to Section 9.1, Safety
Information for Lockout Proce-
systems for the crusher and all the plant dure.
items.

The electrical system on the Trakpactor

provides protection against incorrect
operation, such as low oil level in the
hydraulic tank cutting out the motor. In
addition to this, parts of the hydraulic
system are controlled by electrical contacts
operating solenoid valves.

The plant is fitted with Emergency Stop

buttons (Sections 1.7 and 8.3) and, in
addition, is equipped with a comprehensive
range of protection devices to safeguard the
equipment against damage. Should any of
the sensing equipment fail in operation, the
necessary repairs or replacement should be
made immediately. This will restore the
safeguard to keep the equipment from harm
and maintain any warranty in force for the
time being. No attempt should be made to
circumvent these protection devices.

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9.11 Plant - Crusher and Hydraulic Pump Drive Belts

Good alignment of both pulleys is important otherwise the belt flanks will wear quickly. Ensure axis
are parallel when viewed from all planes (Figure 9z).

Shafts are not parallel

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

Shafts are parallel and Correct Installation

in alignment but pulleys
are not in alignment Both shafts and pulleys
are parallel and in
alignment

Figure 9z Correct Alignment of Pulley Belts

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9.11.1 Replacement of Crusher

Drive Belts WARNING
Note: Drive belts should inspected WEAR PERSONAL
regularly for wear and also to monitor any PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
pattern in the wear if it is occurring (Figure Information for relevant
9z). warning.
LOCKOUT MACHINE.
Procedure Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.
1. Observe all safety warnings.

2. Close down the plant (Section 8.2) and

implement the Lockout Procedure.
10. Tighten and tension the belts to the
3. Open the hinged ends of the crusher
correct specification (Section 9.11.2)
drive guard and also the underside
ensuring the engine pulley is in correct
panel by removing the securing hex. hd.
alignment with the crusher pulley (Figure
set screws. (captive nuts inside guard).
9z).
4. On the engine base frame, loosen nuts
11. Ensure the crusher drive guarding is fully
A (Figure 9aa) - 4 off
replaced and secured before start-up.
5. Unscrew nut B a few turns. Repeat this
step for the other adjusting screw,
turning the nut an equivalent amount.

6. Tighten nut C. Repeat this step for the

other adjusting screw.

7. Slacken the belts until it is possible to

remove the belts without the need to
stretch them (Section 9.11.2).

8. Remove the belts.

9. Reposition the new belts in place by

threading through the guard, utilising the
underside access to assist this process.

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9.11.2 Adjustment of Crusher Drive

Belts WARNING
The tension of the crusher drive belts is WEAR PERSONAL
adjusted with the two screws one located PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
on either side of the engine sliding base Information for relevant
(Figure 9aa). warning.
LOCKOUT MACHINE.
Slackening of Drive Belts Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.
Procedure

1. Observe all safety warnings.

2. Close down the plant(Section 8.2) and

implement the Lockout Procedure.

3. Open the crusher drive guard panels as

necessary to gain access to the vee belt
drive. (refer to Section 9.11.1 step 3)

4. Loosen nuts (A) (4 off) Figure 9aa.

5. Unscrew nut (B) a few turns. Repeat

this step for the other adjusting screw,
turning the nut an equivalent amount.

6. Tighten nut (C). Repeat this step for the

other adjusting screw.

7. If the belts are to be removed,

repeat Steps 5 and 6 to further slacken
the belts until it is possible to remove
the belts without the need to stretch
them.

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If the tension is being adjusted,

repeat Steps 5 and 6 to further slacken
the belts, ensuring the engine pulley is in
correct alignment with the crusher pulley
(Figure 9z).

When the belts have reached the

correct tension (Figure 9ae, Section
19.11.5), tighten nuts (A) 4 off.

8. Ensure the crusher drive guarding is fully

replaced and secured before start-up.

B C A (4)

Figure 9aa Crusher Drive Belt Tensioning Mechanism LH Side

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Tightening of the Drive Belts

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
1. Observe all safety warnings. warning.
LOCKOUT MACHINE.
2. Close down the plant(Section 8.2) and Refer to Section 9.1, Safety
implement the Lockout Procedure. Information for Lockout Proce-
dure.
3. Open the access panels from the
crusher drive and flywheel guard as
necessary. To gain access to the vee
belt drive (refer to Section 9.11.1 step
3)
9. When the belt has reached the correct
tension (Figure 9ae, Section 9.11.5),
4. Loosen nuts (A) (4 off) Figure 9aa.
tighten nuts (A) 4 off.
5. Unscrew nut (C) a few turns. Repeat
10. Ensure the crusher drive guarding is
this step for the other adjusting screw,
replaced and secured before start-up.
turning the nut an equivalent amount.

6. Tighten nut (B). Repeat this step for the

other adjusting screw.

7. Repeat steps 5 and 6 to further tighten

the belts, ensuring the engine pulley is in
correct alignment with the crusher
flywheel (Figure 9z).

Deflection Pulley Size (pcd) Basic Setting Force 1.25 Setting Force
Dimension (mm) mm (ins) kgf (lbf) kgf (lbf)

See Section 9.11.5 224 (8.82”) 7.1 (15.62) 8.9 (19.58)

(Step 3) 280 (11.02”) 9.4 (20.68) 12.0 (26.40)
27/11/03

Figure 9ab Crusher Pulley Belt Tensioning Specifications

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9.11.3 Changing the engine pulley

When changing the plant crushing
WARNING
application from recycling duties to quarry WEAR PERSONAL
operation or vice versa, the engine pulley PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
needs to be changed to alter the crusher Information for relevant
speed. warning.
LOCKOUT MACHINE.
Plant are supplied with an engine pulley Refer to Section 9.1, Safety
sized to suit each type of crushing Information for Lockout Proce-
application, one fitted and one loose dure.

Before commencing a new crushing

operation check if it necessary to change
the pulley. This can most easily be done by
measuring the size of the loose pulley. Refer
to Section 4.2.1 for the appropriate pulley 5. Tighten the crusher drive belts (Section
size for each type of crushing operation. 9.11.2)

Under no circumstances fit pulleys of a

different size unless authorised by BL-
Pegson Limited.

Procedure

1. Observe all safety warnings

2. Close down the plant (Section 8.2) and

implement the lockout procedure.

3. Slacken the crusher drive belts (Section

9.11.2)

4. Change over the engine pulley keeping

the taper locking bush on the engine
shaft. Ensure that the new pulley is in
the same alignment as the original pulley
(Figure 9z) and firmly secure with the
taper locking socket screws.

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9.11.4 Replacement and

Adjustment of Hydraulic Pump
Drive Belts
DANGER
SKIN INJECTION HAZARD
Note:- Drive belts should be inspected Refer to Section 9.1, Safety
regularly for wear, correct tension and Information for relevant warning
contamination.

The tension of the hydraulic pump drive

belts is adjusted by two bolts located WARNING
beneath the hydraulic pump. WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Replacement of Drive Belts Refer to Section 9.1, Safety
Information for relevant
warning.
(Figures 9ac & 9ad)
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
Procedure Information for Lockout Proce-
dure.

1. Observe all safety warnings.

2. Close down the plant (Section 8.2) and

implement the Lockout Procedure.
belts. Continue until the belts have
3. Remove the diesel engine access reached the correct tension (Figure 9ae,
covers. Section 9.11.5), making sure the pump
pulley is aligned with the drive pulley.
4. Loosen the 4 bolts (A) securing the
pump bracket to the pump stool. 8. Tighten the 4 bolts (A) to lock the pump
bracket to the pump stool.
5. Turn the 2 adjusting screws (B)
clockwise to slacken the two drive 9. Replace the diesel engine access covers
belts. Continue until it is possible to before start-up.
remove the belts.

6. Remove the two drive belts and refit

with new belts.

7. Turn the 2 adjusting screws

anticlockwise to tighten the two drive

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Adjustment of Drive Belts

(Figures 9ac & 9ad)

DANGER
SKIN INJECTION HAZARD
Refer to Section 9.1, Safety
Information for relevant warning
Procedure

1. Observe all safety warnings. WARNING

2. Close down the plant (Section 8.2) and WEAR PERSONAL
implement the Lockout Procedure. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
3. Remove the diesel engine side access warning.
covers.
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
4. Loosen the 4 bolts (A) securing the Information for Lockout Proce-
pump bracket to the pump stool. dure.

5. If the drive belts need to be

slackened, turn the 2 adjusting screws
(B) clockwise. Continue to turn the
adjusting screws equal amounts until the
drive belts have reached the correct 7. Replace the diesel engine side access
tension (Figure 9ae, Section 9.11.4), covers before start-up.
making sure the pump pulley is aligned
with the drive pulley.

If the drive belts need to be

tightened, turn the 2 adjusting screws
(B) anticlockwise. Continue to turn the
adjusting screws equal amounts until the
drive belts have reached the correct
tension
(Figure 9ae, Section 9.11.5), making
sure the pump pulley is aligned with the
drive pulley.

6. Tighten the 4 bolts (A) to lock the pump

bracket to the pump stool.

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Pump Bracket

Bolts (4 off) (A)

Pump Stool
Adjusting Screws (B)

Figure 9ac Hydraulic Pump Drive Belt Tension Mechanism

Deflection Dimension Basic Setting Force 1.25 x Setting Force

mm / inches kgf (lbf) kgf (lbf)
See Section 9.11.5 (Step 3) 6.3 (13.95) 7.9 (17.4)
27/11/03

Figure 9ad Hydraulic Pump Drive Belts Tensioning Specifications

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9.11.5 Method of Drive Belt

Tensioning
WARNING
Under no circumstances WEAR PERSONAL
should any check on the belt PROTECTIVE EQUIPMENT.
tension be made whilst the Refer to Section 9.1, Safety
machine is running. There is a Information for relevant
risk of trapping parts of the warning.
body if this is done. LOCKOUT MACHINE.
Refer to Section 9.1, Safety
Information for Lockout Proce-
Procedure dure.

1. Observe all safety warnings.

2. Close down the plant (Section 8.2) and Crusher/Engine Drive Belts
implement the Lockout Procedure.
Remove the guards from around the 6 x 7500mm SPC,
belt. Part Number 2441-0482

3. Calculate the deflection distance in Hydraulic Pump Drive Belts

inches on a basis of 16mm (0.625”)
4 x 2000mm SPB,
deflection per 1 metre (1 yard) of belt
Part Number 2441-0412
span (Figure 9ae).

Centre to Centre Distance - metres

(yards) x 16mm (0.625”) = Deflection
in mm (ins).

eg a centre distance of 2 metres (72”)

would be calculated as:

2 x 16mm = 32mm (0.625” = 11/4”)

4. If a belt tension indicator is

available:

a) Set the lower marker ring at the

deflection distance required on the
lower scale. continued next page..................

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b) Set the upper marker ring against the

bottom edge of the top tube. WARNING
WEAR PERSONAL
c) Place the belt tension indicator on top PROTECTIVE EQUIPMENT.
of the belt at the centre of the belt span, Refer to Section 9.1, Safety
and apply a force at right angles to the Information for relevant
belt deflecting it to the point where the warning.
lower marker ring is level with the top LOCKOUT MACHINE.
of the adjacent belt. Refer to Section 9.1, Safety
Information for Lockout Proce-
d) Read off the setting force value dure.
indicated by the top edge of the upper
marker ring.

e) Compare this value to the lbf value

shown in the table:
Figure 9ab - Crusher Drive Belt 7. Replace all guards before start-up.
Tensioning Specifications
Figure 9ad - Hydraulic Pump Drive Belt After the drive has been
Tensioning Specifications running for 15-20 minutes, the
tension should be checked and
5. If a belt tension indicator is not readjusted to the Basic Setting
available: Force value, if necessary by
repeating the above procedure
a) Use a spring balance to pull the belt from Step 1.
down at the centre of the span.

b) When the belt has been pulled down

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

6. If the measured force falls within the

values given, the drive should be
satisfactory. A measured force below
the lower value indicates under-
tensioning. A new drive should be
tensioned to the 1.25 x Setting Force
value to allow for the normal drop in
tension during the running-in period.

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Ce
nt
re
to
Ce
nt
re
Di
sta
nc
e

16mm
Deflection
per 1 metre
(0.625in per
Belt Tension Indi- 1 yard) of
cator Applied to Belt Span
Mid-Span

Figure 9ae Belt Tensioning Measurements

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9.11.6 Trouble Shooting - Drive

Belts WARNING
Small Cracks on V-Belt side and WEAR PERSONAL
Base PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
Generally caused by shortage of belt warning.
tension but excessive heat and/or chemical
LOCKOUT MACHINE.
fumes can also give same failure. Refer to Section 9.1, Safety
Information for Lockout Proce-
V-Belt Swelling or Softening dure.

Caused by excessive contamination by oil,

certain cutting fluids or rubber solvent.

Whipping During Running

Usually caused by incorrect tensioning,

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

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9.12 Plant - Conveyor Belts

DANGER
9.12.1 Training of Belts
ENTANGLEMENT HAZARD.
Before starting the conveyor, it is essential Refer to Section 9.1, Safety
Information for relevant warning.
to check that:-

• The conveyor is straight and correctly

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

• All troughing and parallel idlers are

correctly fitted with their axles square to
the centre line of the conveyor, the side Tracking should be carried out with the belt
roller lead is in the correct direction (i.e. empty. With very stiff belts, which do not
forward of centre) and all rollers are trough well nor make proper contact with
rotating freely. the centre idlers roller when empty, it may
only be possible to track the return strand
• In the case of screw-type take up when empty and the troughed side when
gears, that these are adjusted initially to loaded.
take up slack from the belt and that
equal tension is applied to each side If the belt tends to run to one side the most
such that the pulley is square to the likely cause of the trouble will usually be
centre line of the conveyor. some distance before the point where the
running off is apparent, and in the case of
• Where skirt rubbers are fitted they are troughed strand probably at the second or
not bearing down heavily on the belt. third idler behind the point where the belt is
moving out of its true line.
• There is no obstruction on the conveyor
that could cause accident or damage Under no circumstances should
when the conveyor is started. any adjustment be made on the
belt whilst the machine is
running. There is a risk of
trapping parts of the body if
this is done.

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Side Roller and

Spindle

Slots for
Adjustment
Belt Travel of Transome

Side Roller and

Spindle
Centre Roller
and Spindle

Slots for
Adjustment
of Transome

Figure 9af Transome Breakdown

NB. The fixings for the side roller spindles may vary slightly from those shown
in the above typical illustration. The centre roller may be fastened with nuts
or clips.

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9.12.2 Conveyor Belt Tensioning

Both the product conveyor and the dirt
WARNING
conveyor are tensioned on the conveyor WEAR PERSONAL
head drum.. Tensioning mechanisms are PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
located on either side of the drum (Figure Information for relevant
9ag). warning.
LOCKOUT MACHINE.
Best practice is to tension each side a little Refer to Section 9.1, Safety
at a time and by the same amount until the Information for Lockout Proce-
belt is tensioned. When tensioned, the drum dure.
must be square to the conveyor frame.

The correct tension is achieved when the

drive drum starts the belt and keeps it
running when loaded without any slip Belt Tensioning
Mechanism
occurring.

The tension screws should be kept clean

and well oiled.

Tightening the Conveyor Belt

(Figure 9ag)

Procedure

1. Observe all safety warnings.

Locknut A (2 off) Square/Hex.
2. Close down the plant (Section 8.2) and Ended Adjusting
implement the Lockout Procedure. Bar B (2off)

3. Loosen locknut A(2 off). Figure 9ag Conveyor Belt Tensioning

Mechanism
4. Tighten square or hexagon ended
adjusting screw B(2 off).

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5. Once correct tension has been

achieved, tighten locknut A(2 off). WARNING
WEAR PERSONAL
Under no circumstances should PROTECTIVE EQUIPMENT.
any adjustment be made on the Refer to Section 9.1, Safety
belt whilst the machine is Information for relevant
running. There is a risk of warning.
trapping parts of the body if LOCKOUT MACHINE.
this is done. Refer to Section 9.1, Safety
Information for Lockout Proce-
Slackening the Conveyor Belt dure.

(Figure 9ag)

Procedure

1. Observe all safety warnings.

2. Close down the plant (Section 8.2) and

implement the Lockout Procedure.

3. Loosen locknut A(2 off).

4. Slacken square or hexagon ended

adjusting screw B(2 off).

5. Once correct tension has been

achieved, tighten locknut A(2 off).

Under no circumstances should

any adjustment be made on the
belt whilst the machine is
running. There is a risk of
trapping parts of the body if
this is done.

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9.12.3 Maintenance of Conveyor(s)

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

• Close down the plant(Section 8.2) and

implement the Lockout Procedure. WARNING
WEAR PERSONAL
• Ensure that central feed onto the PROTECTIVE EQUIPMENT.
conveyor belt is maintained at all times Refer to Section 9.1, Safety
and that the belt at the point of feed is Information for relevant
warning.
kept straight and central at all times.
LOCKOUT MACHINE.
• Inspect the skirt plate sealing strips and Refer to Section 9.1, Safety
Information for Lockout Proce-
ensure that they are adjusted close dure.
enough to the belt to prevent spillage or
material jamming between the seals and
the belt, but at the same time not
bearing hard on the belt.

• Check that the belt generally is running

centrally and straight on both the
carrying strand and the return strand. If
not, refer to Section 9.12.1 Training of
Belts.

• Inspect the condition of the conveyor

belt regularly and arrange for the earliest Do not use clip joints for belt
possible repair of any damage which repairs or replacements, as
may have occurred as this can make a they can be dangerous. Belt
worthwhile extension of the useful life of repairs/replacements should be
the belt. Repair a cut or tear in the performed by vulcanising only.
rubber by cleaning with benzine and
plugging with a rubber repair
compound.

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• Check that there is no evidence of belt • In the interests of efficient operation and
slip at the driving drum, as belt slip will general safety, it is important that
cause premature wear on the belt. operating conditions are kept as clean
Check also for undue sag between as possible and that any spillages are
idlers. Both would indicate lack of belt cleaned up regularly and are not
tension (Section 9.12.2) allowed to build up.

• Check regularly that the idler rollers are As many inspections as

rotating freely. If not either free them or possible should be made whilst
replace the idler. Failure to do so will the belt is stationary. When
result in belt wear and tracking this is not possible extreme
problems. care should be taken when
inspecting the belt whilst it is
• Check that the belt cleaning equipment moving as this creates a risk of
is operating correctly and efficiently. In trapping parts of the body.
the case of scrapers ensure that they are
not choked with a build up of material.
Also check that the blades are not
bearing on the belt any more than
necessary, and that any blades which
are unevenly worn or in a condition
likely to cause damage to the belt are
renewed immediately.

• Lubricate the dirt conveyor pivots.

• The grease in the head and tail drum

bearings of the product conveyor and
dirt conveyor need re-greasing
bimonthly (Section 9.4).

Note:- The grease nipples for the product

conveyor and dirt conveyor tail drum are
remote and located either side of the
Trakpactor chassis.

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9.12.4 Cleaning the Conveyor Belts

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

Procedure

1. The equipment should be switched off

and isolated by means of the lockout and
tagout procedure prior to the
commencement of any work.

2. Use suitable personal protective

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

3. Gloves to protect the skin against

abrasive materials, sharp surfaces, or
penetration of the skin should be worn.

4. Goggles should be worn to protect from

fragments, particles, or dust that could be
ejected into the eyes.

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5. Not only the worker(s) cleaning the

belts but also others close by who may WARNING
be affected, must also wear protective
equipment. WEAR PERSONAL
PROTECTIVE EQUIPMENT.
The conveyor belts can be Refer to Section 9.1, Safety
Information for relevant warning.
cleaned using a number of
methods. Before commencing,
make sure all aforementioned LOCKOUT PLANT.
Refer to Section 9.1, Safety
procedures have been
Information for Lockout
followed: - Procedure.

• Using a high pressure air hose; FALLING HAZARD.

Refer to Section 9.1, Safety
• Using a water hose;
Information for relevant warning.
• Using a rod with scraper attached, or a
brush or shovel.

In the case of a blockage at a drive or tail

drum it may be necessary to loosen the
tension on the conveyor belt so that the
blockage can be removed. See Sections
9.12.1 and 9.12.2 for re-tensioning and re-
aligning the belt after blockage is removed.

When work is complete, make sure that all

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

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9.13 Plant - Overband Magnetic Separator

Magnetic Separator

The self cleaning suspended magnet utilises

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

The belt magnet assembly is

very powerful and permanently
charged. The strong magnetic
field produced could affect
heart pacemakers, watches,
credit cards, mobile phones
etc. The operator has the sole
responsibility to keep anyone
at risk clear of the machine.
Shedder Plate
Start-Up of Self Cleaning Magnetic
Separator Figure 9ah MagneticSeparator

1. Be sure the magnet frame is visibly

square and has not been damaged or
twisted.

2. Check belt alignment.

3. Momentarily energise the belt drive and

check that the belt is tracking properly
and is not wandering laterally. Never
start the belt drive and allow it to
run continuously until the belt is
properly “trained”. If the belt
wanders, note the direction and adjust
as follows:

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Maintenance

• Belt tracking should be checked

DANGER
frequently and adjusted as necessary. ENTANGLEMENT HAZARD.
Refer to Section 9.1, Safety
Tighten the side of the belt to which you Information for relevant warning.
want the belt to move.

• Lubricate bearings on a schedule

consistent with other equipment in use
with your product.
WARNING
WEAR PERSONAL
• The speed of the belt on the magnetic PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
overband separator is preset at the Information for relevant
factory but can be altered by turning the warning.
adjusting screw located in the hydraulic
LOCKOUT MACHINE.
line. Refer to Section 9.1, Safety
Information for Lockout Proce-
As many inspections as dure.
possible should be made whilst
the belt is stationary. When
this is not possible extreme
care should be taken when
inspecting the belt whilst it is
moving as this creates a risk of
trapping parts of the body.

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9.14 Plant - Dust

Suppression Water Inlet

The Trakpactor plant is fitted with a plain

water dust suppression system. The system
consists of two spray bars each one having
three nozzles. The spray bars are located
in the following areas:-

• Crusher discharge area.

• Product conveyor discharge.

It is the responsibility of the customer to

supply the system with clean water. This is
supplied at the manifold (Figure 9ai). The
total flow requirement for the system is 7
litres/min (2 US galls). This equates to a
pressure requirement of 2.8 bar (42 psi).

Maintenance

All nozzles should be kept free of dirt and

blockages. Each nozzle should be checked Product Crusher
every time the dust suppression is switched Conveyor Discharge
on. Shut-off valves are provided for each Discharge Area
spray bar at the manifold.
Figure 9ai Dust Suppression Manifold
The system can be drained after operation
by the drain valves located below the inlet
manifold. This is particularly important in
winter time when there is the likelihood of Do not spray water into the
the system freezing. crusher as this will increase
the wear.

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9.15 Plant - Diesel Engine

WARNING
For the diesel engine WEAR PERSONAL
powerpack fitted to your PROTECTIVE EQUIPMENT.
Trakpactor to continue to Refer to Section 9.1, Safety
perform safely, efficiently and Information for relevant
reliably it is imperative that all warning.
the recommendations given in LOCKOUT MACHINE.
the separate engine manual Refer to Section 9.1, Safety
Information for Lockout Proce-
are strictly followed with
dure.
regard to:-

• Safety
• Operation
• Lubrication
• Maintenance
• Service For the Twin Disc mechanically
operated clutch refer to the instruction
• Parts plate on the clutch (or separate
manufacturers manual) for the correct
Adhere to the regular maintenance
adjustment and lubrication information.
schedules and procedures specified by the
Also Section 9.15.1.
manufacturer

The diesel engine powerpack incorporates

a Caterpillar engine but the external housing
and some of the associated ancillary engine
components are not necessarily of CAT
origin.

For after sales and warranty matters, first

contact your local Terex Pegson dealer for
assistance.

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9.15.1 Manual Clutch Adjustment

IMPORTANT -TWIN DISC MANUAL
CLUTCH INSTRUCTIONS

Refer to the Appendix (Section 11) for

instructions regarding the engine clutch
adjustment check to be made at the time
of initial commissioning at new and the
essential regular maintenance of the
clutch thereafter.

New clutch plates have a ‘wear in’ period and

the clutch may require several adjustments
until new plates are ‘worn in’.

A newly fitted power take off must have it’s

clutch adjustment checked at the following
intervals:-

• After installation
• After 4 hours operation.
• After 10 hours operation.
• At the end of each working day for
approximately 1 week.
• Once a week.

After ‘wear in’, clutch adjustments should

be made on a weekly basis.

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9.15.2 Clutch Maintenance

Adhere to the manufacturers separate
WARNING
manual, particularly in respect of the WEAR PERSONAL
adjustment (9.15.1) and for lubricating the PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
output shaft bearing (Figure 9aj). Information for relevant
warning.
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.

Bearing Grease Nipple

Figure 9aj Clutch Bearing Lubricator

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9.15.3 Engine - ELC Coolant

Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must
ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this
is not available top up with deionized water and adjust mixture concentration in the shop. Under no
circumstances use any other coolant as damage will result and any warranty invalidated.

Equipment is intended for use in ambient temperatures between -10°C to +40°C (+14°F to
+104°F). Appropriate lubricants and coolant must be used as specified within the plant and engine
operating and maintenance manuals.

For use in temperatures outside the above range consult your Terex Pegson Dealer or BL-Pegson
Limited for details prior to commencement of operations.

ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT
THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH
before refilling with ELC coolant.

Adhere to the instructions on the external labelling as shown below.

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9.15.4 Check Fuel Level

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
1. Observe all safety warnings. warning.
LOCKOUT MACHINE.
2. Check the fuel level indicator (Figure Refer to Section 9.1, Safety
9ak) Information for Lockout Proce-
dure.
3. Top up fuel level if required (Section
9.15.2).

• Fill the tank at the end of each day,

where possible, to reduce overnight
condensation within the tank.

Diesel fuel is highly flammable

and is an explosion/burns
hazard.

NEVER remove the filler cap

or refuel, with the engine
running.

NEVER add gasoline or any

other fuel mixes to diesel
Fuel Level
because of increased fire or
explosion risks.

DO NOT smoke while refilling

or carrying out maintenance on
the fuel system.

DO NOT carry out Figure 9ak Fuel Level Indicator - Engine

maintenance on the fuel Control Panel
system near naked lights or
sources of sparks, such as
welding equipment.

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9.15.5 Top Up Fuel Level

DO NOT fill the tank to
WARNING
capacity. WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Monitor the gauge located on
Information for relevant
the Control Panel (Figure 9ak). warning.
LOCKOUT MACHINE.
Allow room for expansion and Refer to Section 9.1, Safety
wipe up spilt fuel immediately, Information for Lockout Proce-
otherwise paintwork will be dure.
damaged.

Procedure

1. Observe all safety warnings.

2. Close down the plant (Section 8.2) and

implement the lockout procedure.

3. Remove the engine side access panel on

the side nearest to the crusher to reveal
the filler cap. (Figure 9al). Clean the
area around the filler cap.

4. Remove the filler cap.

5. Fill the tank will diesel fuel.

6. Replace the cap and refit the engine

access panel before start up.

Diesel fuel is highly flammable

and is an explosion/burns
hazard. Figure 9al Filler Cap

NEVER remove the filler cap

or refuel, with the engine
running.

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NEVER add gasoline or any

other fuel mixes to diesel WARNING
because of increased fire or
WEAR PERSONAL
explosion risks. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
DO NOT smoke while refilling Information for relevant
or carrying out maintenance on warning.
the fuel system. LOCKOUT MACHINE.
Refer to Section 9.1, Safety
DO NOT carry out Information for Lockout Proce-
dure.
maintenance on the fuel
system near naked lights or
sources of sparks, such as
welding equipment.

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9.16 Plant - Vehicle Tracks

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

When ordering Spare Parts it is essential

to quote the plant serial number with
either a /S or /T suffix.

Frequently check for loose bolts, oil leaks, Prior to attempting any
master pins are correctly located and tight, manoeuvring of the plant the
general wear and damage, correct track tracks must be free of
tension, etc. to ensure safe working and obstructions, including crushed
long life. material and fines. Do not push
or tow the plant. Failure to
When travelling on a gradient, the tracks observe this warning could
should be driven with the track idler rollers result in injury to persons and
(Figure 9an) in front. damage to the plant which may
invalidate warranty.

Procedure

9.16.1 Measuring Track Tension

1. Observe all Safety Warnings.

2. Position the plant on solid and level

ground and drive 2 metres (2 yards)
minimum in a forward direction, track
idler roller leading.

3. Close down the plant (Section 8.2) and

implement the Lockout Procedure.

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4. One track at a time, measure the sag on

the top part of the track on the longest WARNING
section of unsupported track by placing
WEAR PERSONAL
a ‘straight edge’ long enough to reach PROTECTIVE EQUIPMENT.
from the drive sprocket to the nearest Refer to Section 9.1, Safety
skid plate. Information for relevant
warning.
5. Measure the maximum amount of track LOCKOUT MACHINE.
sag from the high point of the track Refer to Section 9.1, Safety
grouser to the bottom of the ‘straight Information for Lockout Proce-
dure.
edge’ (Figure 9am). Correctly adjusted
the sag must be a maximum of 15mm
(5/8”) but must not be less that 5mm
(1/4”).

Tracking the machine with

incorrectly tensioned tracks
can cause severe damage to
the undercarriage components 5 - 15mm
and may invalidate the (1/4 - 5/8”)
warrant.

6. Depending upon the need to either

slacken or tension the track(s) proceed
as below. Figure 9am Measuring Track Tension

continued...........

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9.16.2 Adjusting Track Tension

‘GREASE UNDER HIGH DANGER
PRESSURE’ SKIN INJECTION HAZARD
Refer to Section 9.1, Safety
To Release Track Tension (After Information for relevant warning
measurement - Section 9.16.1):-

Procedure WARNING
WEAR PERSONAL
1. Observe all Safety Warnings. PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
2. Close down the plant (Section 8.2) and Information for relevant
warning.
implement the Lockout Procedure.
LOCKOUT MACHINE.
3. Locate the access aperture on the side Refer to Section 9.1, Safety
Information for Lockout Proce-
of the track frame and remove the dure.
cover (where fitted) to reveal the relief
valve inside.

4. Next loosen the relief valve by turning

anti-clockwise using gradual increments
until the grease begins to be expelled.
Care must be taken not to loosen
Grease coming out of the relief
the relief valve too quickly because
valve under pressure can
the grease inside is under high
penetrate the body causing
pressure.
injury or death; do NOT watch
the relief valve to see if grease
5. When the correct track tension has
is escaping but instead watch
been measured (Section 9.16.1), turn
the track adjustment cylinder
the relief valve clockwise to tighten and
to verify that the track is being
then clean away all trace of expelled
loosened.
grease.
DO NOT OVER TENSION
6. Operate the plant in manoeuvring mode
THE TRACKS (Refer to
(Section 5.2.1) and drive the plant 50
Section 9.16.1).
metres (50 yards) forwards and 50
metres backwards, measure the sag
and repeat the steps 1 - 4 if the

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Page 93

track(s) sag is not enough. If room for

manoeuvring the plant is restricted,
drive the plant forwards and backwards
DANGER
several times over a shorter distance. SKIN INJECTION HAZARD
Refer to Section 9.1, Safety
Information for relevant warning
If the track fails to slacken after the
grease fitting has been loosened, do not
attempt to remove the tracks or
disassemble the track tensioner, or
remove the grease fitting. It is possible
WARNING
that running the tracks with the grease WEAR PERSONAL
PROTECTIVE EQUIPMENT.
fitting loosened may help to expel the
Refer to Section 9.1, Safety
grease. Information for relevant
warning.
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
Information for Lockout Proce-
dure.

Track Surface Idler Roller

Skid plate
Drive Sprocket

Relief Valve
(inside access aperture)
Final Drive Track Roller
Unit

Figure 9an Vehicle Track Parts

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To Increase Track Tension (After

measurement - Section 9.16.1):- DANGER
SKIN INJECTION HAZARD
Procedure Refer to Section 9.1, Safety
Information for relevant warning

1. Observe all Safety Warnings.

2. Close down the plant (Section 8.2) and

implement the Lockout Procedure.
WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
3. Locate the access aperture on the side Refer to Section 9.1, Safety
of the track frame and remove the Information for relevant
cover (where fitted) to reveal the relief warning.
valve inside. LOCKOUT MACHINE.
Refer to Section 9.1, Safety
4. Connect the grease gun to the grease Information for Lockout Proce-
fitting and add grease until the track dure.
tension is within the specified dimension
(Section 9.16.1). See Section 9.4.4. for
the grease type and specification.

5. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) forwards and 50
metres backwards, measure the sag
and repeat the steps 1 - 4 if the
track(s) sag is too great. If room for
manoeuvring the plant is restricted,
drive the plant forwards and backwards
several times over a shorter distance.

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9.16.3 Track Maintenance

(Figure 9an)
WARNING
WEAR PERSONAL
Maintenance Schedule PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
Information for relevant
• The first drive oil replacement is to be warning.
carried out after 100 operating hours of
LOCKOUT MACHINE.
the gearbox. Refer to Section 9.1, Safety
Information for Lockout Proce-
• There after replace the drive oil every dure.
1000 hours or at least once per year.

• Check the drive oil level every 100

working hours.

Daily

Procedure

1. Observe all safety warnings. To maximise the life of the

track, keep it movable and
2. Close down the machine (Section 8.2) avoid damage, the plant should
and implement the Lockout Procedure. be moved at least every week,
by a distance exceeding four
3. Check the track rollers and idler wheels times the track length. It
for possible leakage. should also be parked on level
ground overnight and during
4. Check the track surface of the track periods to of non-usage. This
rollers, idler wheels, track shoes and is particularly important when
drive sprockets for wear and loose working in adverse conditions.
mounting bolts.

5. Clean out any heavy build up of material

from around the tracks.

6. Check the tension of the tracks (Section

9.16.1) and adjust tension if necessary
(Section 9.16.2).

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9.16.4 Drive Oil Filling and Draining

Oil Filling
WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Procedure Refer to Section 9.1, Safety
Information for relevant
warning.
1. Observe all safety warnings.
LOCKOUT MACHINE.
Refer to Section 9.1, Safety
2. Close down the plant (Section 8.2) and Information for Lockout Proce-
implement the Lockout Procedure. dure.

3. Make sure the gearbox housing is

horizontal.

4. Rotate the gearbox housing so that one Note:- Over filling the final drive will cause
plug is at the 12 o’clock position and the travel motor seal to allow hydraulic oil
the other plug is at the 9 o’clock or water to enter and contaminate the drive.
position (Figure 9ao).

5. Unscrew the two plugs and fill from the

upper hole until the oil flows from the
hole located at the 9 o’clock position.
Oil Fill (A)
See Section 9.4.4 for oil type and
specification.

6. Clean plugs using a clean non-

flammable solvent.

7. Apply pipe sealant to the plugs and

install.

8. Repeat procedure on the other final

drive.
Oil Level (B)

Figure 9ao Tracks - Oil Filling

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Oil Draining
WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 9.1, Safety
1. Observe all safety warnings. Information for relevant
warning.
2. Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the Lockout Procedure. Refer to Section 9.1, Safety
Information for Lockout Proce-
3. Rotate the gearbox housing until a plug dure.
is at the 6 o’clock position (Figure 9ap).

4. Unscrew both plugs and discharge the (A)

oil.

5. Clean plugs using a clean non-

flammable solvent.

6. Apply pipe sealant to the plugs and

install.

7. Repeat procedure on the other final

drive.

Oil Drain (B)

Figure 9ap Tracks - Oil Draining

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Blank page

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Spare Parts Issue EN 02
Page 1

Contents

10.1 Impact Crusher Parts ........................................................................................ 5

Impact Crusher - Blow bar Assembly ........................................................................ 6
Impact Crusher - Rotor Shaft Assembly .................................................................... 8
Impact Crusher - Mainframe Liner Plates................................................................ 10
Impact Crusher - Front Impact Apron Liner Plates ................................................... 12
Impact Crusher - Rear Impact Apron Liner Plates ................................................... 14
Impact Crusher - Grinding path - Swing Beam Liners ............................................. 16
Impact Crusher - Front Apron Adjustment Mechanism ............................................ 18
Impact Crusher - Rear Apron Adjustment Mechanism ............................................. 20
Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism................... 22
10.2 Feeder Parts ..................................................................................................... 24
Grizzly Feeder - Mainframe assembly .................................................................... 24
Grizzly Feeder - Vibrating Unit Assembly................................................................ 26
Grizzly Feeder - Driveside Shaft Assembly ............................................................. 28
Grizzly Feeder - Non Driveside Shaft Assembly ..................................................... 30
10.3 Conveyor Parts ................................................................................................ 33
Product Conveyor - Conveyor Parts Assembly - sheet 1 .........................................33
Product Conveyor - Conveyor Parts Assembly - sheet 2 .........................................34
Product Conveyor - Conveyor Parts Assembly - sheet 3 .........................................36
Product Conveyor with Magnetic Separator fitted ................................................... 38
Dirt Conveyor - Conveyor Parts Assembly - sheet 1 ............................................... 40
Dirt Conveyor - Conveyor Parts Assembly - sheet 2 ............................................... 42
10.4 Overband Magnetic Separator ........................................................................ 44

10.5 Plant Component Parts ................................................................................... 46

Plant General Arrangement .................................................................................... 46
Plant Guards Assembly .......................................................................................... 48
Plant Platforms Assembly ...................................................................................... 50
10.6 Plant Tracks ..................................................................................................... 52

continued............................

BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
15/12/04

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Spare Parts Issue EN 02
Page 2

10.7 Hydraulic System ............................................................................................ 54

Hydraulic Hoses ..................................................................................................... 54
Hydraulic Hoses, continued .................................................................................... 55
Hydraulic Hoses for Impact Crusher Door Rams..................................................... 56
Hydraulic Oil Reservoir Components ..................................................................... 56
Hydraulic System Components - sheet 1 ................................................................ 58
Hydraulic System Components - sheet 2 ................................................................ 60
Hydraulic System Components - sheet 3 ................................................................ 62
10.8 Electrical System ............................................................................................. 64
Electrical Components .......................................................................................... 64
10.9 Safety Signs (with part numbers) ................................................................... 66

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Spare Parts Issue EN 02
Page 3

Blank page

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Spare Parts Issue EN 02
Page 4

IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
BL-PEGSON DISTRIBUTOR TO OBTAIN GENUINE PARTS MANUFACTURED
TO ORIGINAL SPECIFICATIONS UNDER STRICT QUALITY CONTROL.

ALWAYS QUOTE THE SERIAL NUMBER STAMPED ON THE

PLANT/MACHINE IDENTITY PLATE

YOUR LOCAL REPLACEMENT PARTS CONTACT

(fill in when known)

BL-PEGSON DISTRIBUTOR.............................................................................

CONTACT NAME(S)..........................................................................................

.........................................................................................

TELEPHONE NUMBER.....................................................................................

FACSIMILE NUMBER........................................................................................

E MAIL ADDRESS.............................................................................................

...........................................................................................................................

...........................................................................................................................

...........................................................................................................................

REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.

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Spare Parts Issue EN 02
Page 5

10.1 Impact Crusher Parts

14 11 12 13

10

3 4 5 15 6 16

1 Feed Opening 9 Rear Apron Adjustment

2 Shaft 10 Rear Apron
3 Rotor 11 Front Apron Liner Plates
4 Rotor Protection Cap 12 Front Apron Adjustment
5 Blow Bars (Hammers) 13 Front Apron
6 Swing Beam (Grinding Path) 14 Crusher Mainframe
7 Swing Beam Liner Plates 15 Swing Beam Rails
8 Rear Apron Liners Plates 16 Swing Beam Adjustment

Impact Crusher - 428 Trakpactor

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Spare Parts - 428 Trakpactor Page 6

Impact Crusher - Blow bar Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/93 ROTOR SHAFT 1
2 A6984/76H CAST ROTOR 1
3 IM 020 4228 AXIAL SECURING PLATE 8
4 A6984/80 STD. HIGH Mg. BLOW BAR (LONG) 2
4A A6984/79 STD. HIGH Mg. BLOW BAR (SHORT) 2
5 IM 024 4228 ROTOR PROTECTION CAP 16
6 A6984/23/117 PIN – AXIAL SECURE PLATE 8
2201-0165 SPLIT PIN 8
A6984/23/8 WASHER 8
7 2450-5108 RINGFEDDER 2
N/S 2971-2002 HYDRAULIC HAMMER EXTRACTION TOOL 1
N/S 2527-1048 HOSE ASSY 2
N/S 2520-6557 3/8 M COUPLING THESE PARTS ARE 3
N/S 2520-6558 3/8 F/M COUPLING FOR THE 3
EXTRACTION TOOL
N/S 2520-6003 3/8 M/M ADAPTOR 10
N/S 2500-1015 BONDED SEAL 10
A6984/96 – 23/11/04

REF PART NUMBER DESCRIPTION QUANTITY

ALTERNATIVE HIGH CHROME / HIGH MANGANESE BLOW BARS

OF 2 x LONG / 2 x SHORT CONFIGURATION SHOWN BELOW
BUT CAN BE 4 LONG HIGH CHROME BARS

4 A6984/83 HIGH CHROME BLOW BAR (LONG) 2

4A A6984/79 HIGH MANGANESE BLOW BAR (SHORT) 2

ALTERNATIVE MARTENSITIC / HIGH MANGANESE BLOW BARS

OF 2 x LONG / 2 x SHORT CONFIGURATION SHOWN BELOW
BUT CAN BE 4 LONG MARTENSITIC BARS

4 A6984/121 MARTENSITIC BLOW BAR (LONG) 2

4A A6984/79 HIGH MANGANESE BLOW BAR (SHORT) 2

IMPORTANT
BEFORE FITTING BLOW BARS OF ALTERNATIVE TYPES OF STEEL, READ THE
ADDENDUM ‘428 IMPACT CRUSHER – GUIDE TO EFFICIENT OPERATION’
OR CONSULT YOUR TEREX PEGSON DEALER

01/12/04

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4A
3
6

7
4

4
5
2

1
4A
4

4
3

5
5
3

428 Impact Crusher - Blow bar Assembly

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Spare Parts - 428 Trakpactor Page 8

Impact Crusher - Rotor Shaft Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/93 ROTOR SHAFT 1
2 A6984/5 BEARING HOUSING 2
3 A6984/94 SPACING COLLAR 1
4 A6984/7 OUTER LABYRINTH – FIXED 2
5 A6984/8 OUTER LABYRINTH – FLOATING 1
6 A6984/97 SHAFT END DISC 1
7 A6984/52 BEARING HOUSING COVER PLATE 1
8 IM 027D 4228 INNER LABYRINTH – 125 BORE 1
9 IM 027F 4228 INNER LABYRINTH – 160 BORE 2
10 A6984/76P CAST ROTOR 1
11 A6984/81 ROTOR END CAP 2
12 2416-0417 BEARING – SPHERICAL ROLLER 2
13 2430-1101 CIRCLIP – EXTERNAL ? 150 1
14 AX846/113 PULLEY 1
15 2450-8060 PULLEY LOCKING BUSH 1
16 2450-5108 RINGFEDDER 2
17 2510-3861 PLUG – RECESSED 4
18 2530-1008 GREASE NIPPLE 5
19 2222-0187 SCR – HEX SKT – CAP HD. 6
2211-0008 WASHER - SPRING 6
20 2222-0188 SCR - HEX SKT - CAP HD. 18
2211-0008 WASHER - SPRING 18
21 2226-0795 SCR - CSK HD. 12
22 2226-0584 SCREW - CSK HD. 2
23 2222-0356 SCR - HEX SKT - CAP HD. 8
2210-0023 WASHER - PLAIN 8
2217-0011 NUT - HEX 8
N/S A6984/50/1 ROTOR LOCK THESE ITEMS ARE 1
N/S A6984/50/2 ROTOR LOCK LH & RH HANDED 1
A6984/96 – 23/11/04

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17

15
6

22
14

8
3

20
4
2
18

12
4

21
9
11

16

10
1

16
11

20
21

9
2
18

12
19

23
7

13
17

428 Impact Crusher - Rotor Shaft Assembly

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Impact Crusher - Mainframe Liner Plates

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/9/1 LINER PLATE – 9.8 kg. EACH 2
2 A6984/9/2 LINER PLATE – 6.4 kg. EACH 2
3 A6984/9/3 LINER PLATE – 9.7 kg. EACH 2
4 A6984/9/4 LINER PLATE – 6.2 kg. EACH 68
5 A6984/9/5 LINER PLATE – 6.2 kg. EACH 4
6 A6984/9/6 LINER PLATE – 8.4 kg. EACH 2
7 A6984/9/7 LINER PLATE – 9.5 kg. EACH 2
8 A6984/9/8 LINER PLATE – 10.5 kg. EACH 12
9 A6984/9/9 LINER PLATE – 11.2 kg. EACH 2
10 A6984/9/10 LINER PLATE – 11.3 kg. EACH 3
11 A6984/9/11 LINER PLATE – 30. 8 kg. EACH 6
12 A6984/9/148 LINER PLATE – 39 kg. EACH 2
13 A6984/9/13 LINER PLATE – 28.2 kg. EACH 2
14 A6984/9/14 LINER PLATE – 5.6 kg. EACH 2
15 A6984/9/15 LINER PLATE – 6 kg. EACH 2
16 A6984/9/16 LINER PLATE – 5.6 kg. EACH 2
17 A6984/9/17 LINER PLATE – 29 kg. EACH 4
18 A6984/9/18 LINER PLATE – 11 kg. EACH 4
19 A6984/9/19 LINER PLATE – 13 kg. EACH 2
20 A6984/9/20 LINER PLATE – 5.2 kg. EACH 2
21 A6984/9/21 LINER PLATE – 5.2 kg. EACH 2
22 A6984/9/22 LINER PLATE – 5 kg. EACH 2
23 A6984/9/23 LINER PLATE – 102 kg. 1
24 A6984/9/29 LINER PLATE – 6 kg. EACH 2
25
26 2222-0297 SCREW 56
27 2230-1285 SCREW 177
28 2230-1287 SCREW 28
29
30 2232-1281 BOLT 20
31
32 2211-0012 WASHER-SPRING 281
A6984/19_02mod – 23/11/04

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428 Impact Crusher - Mainframe Liner Plates

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Spare Parts - 428 Trakpactor Page 12

Impact Crusher - Front Impact Apron Liner Plates

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/106 FRONT IMPACT APRON 1
2 A6984/9/25 LINER PLATE 2
3 A6984/9/26 LINER PLATE 4
4 A6984/9/28 LINER PLATE 4
5 A6984/102 LINER PLATE 2
6 A6984/103 LINER PLATE 2
7 A6984/25/1 SCREW 20
8 A6984/25/2 SCREW 8
9 A6984/25/3 SCREW 4
10
11
12 2210-0021 WASHER – PLAIN – FORM A 20 4
13 2210-0023 WASHER – PLAIN – FORM A 24 28
14
15 2217-0009 NUT – HEX – PHILIDAS MKV M20 4
16 2217-0011 NUT – HEX – PHILIDAS MKV M24 28
17
18 2220-0206 SCREW 4
19
20 2220-06 KEY – 36x20x200 SQ END. 12
A6984/109_01 – 26/09/03

ITEM PART NO: DESCRIPTION QTY WEIGHT

1 A6984/106 FRONT IMPACT APRON 1 685 kg.
2 A6984/9/25 LINER PLATE 2 19.8 kg. each
3 A6984/9/26 LINER PLATE 4 43 kg. each
4 A6984/9/28 LINER PLATE 4 47.2 kg. each
5 A6984/102 LINER PLATE 2 84 kg. each
6 A6984/103 LINER PLATE 2 56 kg. each
A6984/109_01 – 26/09/03

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Pivot Pin A6984/150 with

2 x A6984/149 aluminium bronze Bushes

428 Impact Crusher - Front Impact Apron Liner Plates

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Impact Crusher - Rear Impact Apron Liner Plates

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/107 REAR IMPACT APRON 1
2 A6984/9/24 LINER PLATE 4
3 A6984/9/28 LINER PLATE 4
4 A6984/25/1 SCREW 8
5
6
7 2220-0206 SCREW 4
8 2222-0313 SCREW 8
9
10 2210-0023 WASHER – PLAIN – FORM A 24 8
11 2211-0012 WASHER – SPRING -SQ SECT. 20 8
12
13 2217-0011 NUT – HEX 8
14
15 2432-0577 KEY 4
A6984/110_01 – 26/09/03

ITEM PART NO: DESCRIPTION QTY WEIGHT

1 A6984/107 REAR IMPACT APRON 1 435 kgs
2 A6984/9/24 LINER PLATE 4 24.2 kgs each
3 A6984/9/28 LINER PLATE 4 47.2 kgs each
A6984/110_01 – 26/09/03

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Spare Parts - 428 Trakpactor Page 15

Pivot Pin A6984/150 with

2 x A6984/149 aluminium bronze Bushes

428 Impact Crusher - Rear Impact Apron Liner Plates

AX846-901-8EN-02a 217/300
Spare Parts - 428 Trakpactor Page 16

Impact Crusher - Grinding path - Swing Beam Liners

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/43/1 SWING BEAM 1
2 A6984/43/2 SHEAR BLOCK 1
3 A6984/23/13 SWING BEAM CONNECTING PIN 1
4 A6984/23/14 SWING BEAM CONNECTING PIN WASHER 1
5 A6984/25/4 SCREW 4
6 A6984/26 SWING BEAM PIVOT BAR 1
7 A6984/51 SWING BEAM LOCATING SLEEVE 2
8 A6984/62 LINER PLATE 1
9 A6984/132 SWING BEAM RAIL 6
10
11
12 2201-0182 PIN – SPLIT COTTER 1
13
14 2210-0023 WASHER 4
15
16 2217-0011 NUT 4
17
18 2432-0577 KEY 36 x 20 x 200 SQ END 2
CHAIN CURTAIN FOR FINES CHUTE – NOT ILLUSTRATED
A6984/145 CHAIN MOUNTING PLATE 2
A6984/146 CHAIN SPACER 1
A6984/147 CLAMP STRIP 1
AX864/119 RUBBER FOR CHAIN CURTAIN 1
2321-1102 CHAIN – 2 LINKS LONG 2
2321-1103 CHAIN – 3 LINKS LONG 2
2321-1104 CHAIN – 6 LINKS LONG 2
2321-1105 CHAIN – 7 LINKS LONG 7
2232-1214 BOLT 13
A6984/42_00 – 23/11/04

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Spare Parts - 428 Trakpactor Page 17

428 Impact Crusher - Grinding Path - Swing Beam Liners

AX846-901-8EN-02a 219/300
Spare Parts - 428 Trakpactor Page 18

Impact Crusher - Front Apron Adjustment Mechanism

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/12 ADJUSTING ROD 1
2 A6984/37 ADJUSTING BOLT SLEEVE 4
3 2436-9144 DISC SPRING 4
4 2215-0024 ADJUSTING NUT 1
LOCKNUT (WITH PROTECTIVE SLEEVE
5 A6984/84 1
AND CHAIN)
A6984/35_00 – 26/-9/03

NB. THERE ARE 2 OF THE ABOVE MECHANISMS ON THE 428 IMPACTOR

AX846-901-8EN-02a 220/300
Spare Parts - 428 Trakpactor Page 19

428Impact Crusher - Front Apron Adjustment Mechanism

AX846-901-8EN-02a 221/300
Spare Parts - 428 Trakpactor Page 20

Impact Crusher - Rear Apron Adjustment Mechanism

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/11/1 ADJUSTING ROD 1
2 A6984/38 FABRICATED SEAT-REAR 1
3 2436-9131 DISC SPRING 2
4 IA6984/71 THRUST WASHER 1
5 A6984/10 SLEEVE 1
6 A6984/13 SPRING CAP 1
7 A6984/141 KEEP PLATE 1
8 2210-0016 WASHER 2
9 2211-0007 SPRING WASHER 2
10 2232-1099 BOLT 2
11 A6984/136 HOLLOW PLUG 1
12 A6984/11/2 END CAP 1
13 2211-0006 SPRING WASHER 2
14 2222-0118 CAPSCREW 2
15 A6984/143 PROTECTION CAP WITH CHAIN 2
16 2215-0018 NUT 2
17 2210-0021 WASHER 2
18 IM 029H 4228 SPRING 1
19 A6984/40 TENSION ROD 2
20 A6984/41 SPRING SUPPORT 1
A6984/36_06 – 01/12/04

NB. THERE ARE 2 OF THE ABOVE MECHANISMS ON THE 428 IMPACTOR

AX846-901-8EN-02a 222/300
Spare Parts - 428 Trakpactor Page 21

428 Impact Crusher - Rear Impact Apron Adjustment

AX846-901-8EN-02a 223/300
Spare Parts - 428 Trakpactor Page 22

Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism

REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/47/1 SWING BEAM - ADJUSTING ROD 1
2 2215-0018 NUT 4
3 2210-0021 WASHER 4
4 2436-9131 DISC SPRING 4
5 A6984/71 THRUST WASHER 1
6 A6984/10 SLEEVE 1
7 A6984/13 SPRING CAP 1
8 A6984/86 KEEP PLATE 1
9 2210-0016 WASHER - PLAIN 2
10 2211-0007 WASHER - SPRING 2
11 2230-1153 SCREW 2
12 2510-3836 HOLLOW PLUG 1
13 A6984/47/2 END CAP 1
14 2211-0006 WASHER - SPRING` 2
15 2222-0118 CAPSCREW 2
16 A6984/39 PROTECTION CAP 2
17 IM.030H.4228 SPRING 1
18 A6984/49 TENSION ROD 2
19 A6984/48 SPRING SUPPORT 1
A6984/46_04 – 26/09/03

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Spare Parts - 428 Trakpactor Page 23

428 Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism

AX846-901-8EN-02a 225/300
Spare Parts - 428 Trakpactor Page 24

10.2 Feeder Parts

Grizzly Feeder - Mainframe assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 620/541 MAINFRAME 1
2 301/13 SPRING (FEED END) 4
301/13 SPRING (DISCHARGE END) 4
3 620/514 MESH TENSIONER 1
4 2215-3018 NUT 8
2211-0021 WASHER 8
2210-0012 WASHER 8
5 2230-1290 SCREW 2
2210-0021 WASHER 2
2211-0012 SPRING WASHER 2
6 620/515 MESH SUPPORT 1
7 2236-4203 BOLT WITH NUT 4
2212-2005 WASHER 4
8 2315/0005 SCREEN CAPPING RUBBER 1.2M
9 620/516 TENSIONED RUBBER MAT 1
10 432/1 TENSIONED WIRE MESH 10MM 1
432/2 TENSIONED WIRE MESH 20MM 1
432/3 TENSIONED WIRE MESH 30MM 1
432/4 TENSIONED WIRE MESH 40MM 1
432/5 TENSIONED WIRE MESH 50MM 1
04/11/03

AX846-901-8EN-02a 226/300
Spare Parts - 428 Trakpactor Page 25

Feerder Mainframe Assembly - 428 Trakpactor

AX846-901-8EN-02a 227/300
Spare Parts - 428 Trakpactor Page 26

Grizzly Feeder - Vibrating Unit Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 629/269 UNIT HOUSING 1
2 629/151 COVER PLATE 1
3 629/47 END COVER (GEAR) 1
4 629/160 END COVER (DRIVE) 1
5 2510-3864 PLUG 2
6 2230-1122 SCREW 48
7 2211-0007 WASHER 48
8 2236-4278 BOLT WITH NUT 20
9 2212-2006 WASHER 20
10 NUT (SUPPLIED WITH ITEM 8) 20
11 2230-1152 SCREW 20
2230-1153 SCREW (FOUR CORNER SCREWS) 4
12 2211-0017 WASHER 24
13 2538-5152 OIL LEVEL GLASS 2
14 2510-9848 MAGNETIC PLUG 2
2510-4574 REDUCING BUSH 2
15 2531-1021 BREATHER 1
LOCTITE GASKET COMPOUND
2141-0027 160ML (FOR SEALING END PLATES 1
AND COVER PLATES
23/11/04

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Spare Parts - 428 Trakpactor Page 27

Feeder Vibrating Unit Housing - 428 Trakpactor

AX846-901-8EN-02a 229/300
Spare Parts - 428 Trakpactor Page 28

Grizzly Feeder - Driveside Shaft Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 629/154 DRIVEN SHAFT 1
2 629/155 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 BOLT 16
5 629/153 BEARING HOUSING 2
6 629/157 BEARING SPACER 2
7 2416-1909 BEARING 2
8 629/159 LOCKING RING 2
9 629/162 ‘O’ RING INNER 2
10 629/163 ‘O’ RING OUTER 2
11 629/156 BEARING CAP 2
12 2232-1279 BOLT 20
13 2217-0009 NUT 20
14 310/28 WASHER 1
15 2212-8014 LOCKWASHER 1
16 2217-7014 LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 1
19 325/20 SCREW 2
20 2576-4087 HYDRAULIC MOTOR 1
21 629/174 MOTOR COUPLING 1
22 326/11 BOLT 4
2217-0005 NUT 4
2210-0017 WASHER 4
04/11/03

SEE SECTION 10.2.4 FOR THE DRIVESIDE SHAFT COMPONENTS.

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Spare Parts - 428 Trakpactor Page 29

Feeder Driveside Shaft Assembly - 428 Trakpactor

AX846-901-8EN-02a 231/300
Spare Parts - 428 Trakpactor Page 30

Grizzly Feeder - Non Driveside Shaft Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 325/45 BOLT 16
2 629/153 BEARING HOUSING 2
3 2416-1909 BEARING 2
4 629/159 LOCKING RING 2
5 629/162 ‘O’ RING INNER 2
6 629/163 ‘O’ RING OUTER 2
7 629/156 BEARING CAP 2
2510-3864 PLUG 2
8 2232-1279 BOLT 20
9 2217-0009 NUT 20
10 18HS39 RETAINING WASHER 2
11 325/20 SCREW 4
12 18HS50 KEY (SPUR GEAR) 2
13 18HS54 DRIVE GEAR 2
14 629/158 BEARING SPACER 2
04/11/03

SEE SECTION 10.2.3 FOR THE DRIVESIDE SHAFT COMPONENTS.

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Spare Parts - 428 Trakpactor Page 31

Feeder Non Driveside Shaft Assembly- 428 Trakpactor

AX846-901-8EN-02a 233/300
Spare Parts - 428 Trakpactor Page 32

Blank page

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Spare Parts - 428 Trakpactor Page 33

10.3 Conveyor Parts

Product Conveyor - Conveyor Parts Assembly - sheet 1

REF PART NUMBER DESCRIPTION QUANTITY

1 AX789/117 HEAD DRUM 1
2 2421-0014S PLUMMER BLOCK BEARING 2
REMOTE GREASE PIPING (PART OF KIT FOR
2530-2008 1
HEADSHAFT BEARINGS ONLY)
3 2450-5505 SHRINK DISC COUPLING 1
AX862/92 COUPLING GUARD 1
4 AX789/38 TORQUE ARM 1
5 2476-4075 HYDRAULIC MOTOR 1
6 AX789/24/4 BELT SCRAPER 1
7 AX789/24/2 BELT SCRAPER CLAMP 1
8 AX789/24/3 BELT SCRAPER BRACKET 1
9 AX789/24/1 ROSTA UNIT SUPPORT LH 1
10 AX789/24/1A ROSTA UNIT SUPPORT RH 1
11 AX607/3/46 ROSTA TENSIONING UNIT 2
12 AX815/54/1 TELESCOPER UNIT 1
13 AX846/118/1 CONVEYOR STRINGER FRAME 1
14 AX846/118/2 REMOVABLE ROLLER X MEMBER 1
15 AX815/142 CONVEYOR RETURN IDLER BRACKET 2
16 AX846/119 SPIRAL ROLLER NIP GUARD 1
17 AX815/167 SPIRAL ROLLER NIP GUARD 2
18 AX860/99 HEAD DRUM NIP GUARD 1
19 2495-1130A RETURN IDLER 1
20 AX860/128 PLAIN ROLLER NIP GUARD 1
21 2495-3001 MULTI TROUGH IDLER SET COMPLETE 4
22 AX846/14/2 CONVEYOR PIN (HEAD TO CHASSIS) 2
23 AX846/74/1 CONVEYOR HEAD GUARD 1
24 AX846/74/2 CONVEYOR HEAD GUARD 1
25 AX846/75/1 CONVEYOR UPPER GUARD 1
26 AX846/75/2 CONVEYOR UPPER GUARD 1
27 AX843/39/1 CONVEYOR MIDDLE GUARD 1
28 AX843/39/2 CONVEYOR MIDDLE GUARD 1
29 AX843/40/1 CONVEYOR LOWER GUARD 1
30 AX843/40/2 CONVEYOR LOWER GUARD 1
31 AX846/77 WIND COVER SUPPORT 4
CANVAS WIND COVER (NOT APPLICABLE
32 AX846/10 FOR PLANT FITTED WITH MAGNETIC 1
SEPARATOR - SEE SEPARATE PAGE
33 AX843/22 SUPPORT WIRE ROPE 2
34 2495-3000 MULTI TROUGH IDLER SET COMPLETE 3
AX846/121 iss. 02mod sht 1 – 01/12/04

NB. Fixings are not included with the above parts unless specifically ordered
AX846-901-8EN-02a 235/300
Spare Parts - 428 Trakpactor Page 34

Product Conveyor - Conveyor Parts Assembly - sheet 2

PART
REF DESCRIPTION QUANTITY
NUMBER
34A 2489-1055 SEPARATE OUTER ROLLER FOR ITEM 34 6
34B 2489-3005 CLAMP WITH FIXINGS FOR ITEM 34A 6
SEPARATE CENTRE ROLLER FOR ITEM
34C 2489-1056 3
34
34D SEPARATE BASEPLATE FOR ITEM 34 3
35 AX843/45/1 GUARD INSIDE CHASSIS 1
36 AX843/45/2 GUARD INSIDE CHASSIS 1
37 AX843/45/3 GUARD MOUNTING BRACKET 4
38 AX843/47/1 CLAMPING STRIP 2
39 AX843/47/2 CLAMPING STRIP 2
40 AX843/47/3 CLAMPING STRIP 2
41 AX843/47/4 CLAMPING STRIP 2
42 AX843/47/5 CLAMPING STRIP 2
43 AX843/47/6 CLAMPING STRIP 2
44 AX843/47/7 CLAMPING STRIP 2
45 AX843/18 IMPACT BAR CRADLE FRAME 1
46 AX846/38 IMPACT BAR, 620 MM LONG 6
47 AX843/62 RUBBER CURTAIN 1
48 AX843/55/1 RUBBER CURTAIN SUPPORT BRACKET 1
49 AX843/55/2 RUBBER CURTAIN CLAMPING STRIP 1
50 AX846/4 TAIL CONVEYOR FRAME 1
51 AX846/14/1 PIN, (TAIL TO CHASSIS) 2
52 AX846/14/3 PIN, TAIL (TO STRUT) 2
53 AX846/15 TAIL STRUT 2
54 AX846/14/4 PIN, (STRUT TO TAIL) 2
55 AX843/15/1 SCRAPER BLADE FRAME 1
56 AX843/15/2 SCRAPER BLADE 1
57 AX843/15/3 SCRAPER BLADE CLAMP 2
58 2495-3003 SPIRAL RETURN ROLLER 4
MULTI TROUGH IMPACT IDLER
59 2495-3002 1
COMPLETE
59A 2489-1057 SEPARATE OUTER ROLLER FOR ITEM 59 2
59B 2489-3005 CLAMP WITH FIXINGS FOR ITEM 59A 2
SEPARATE CENTRE ROLLER FOR ITEM
59C 2489-1058 1
59
59D SEPARATE BASEPLATE FOR ITEM 59 1
60 2421-0011S PLUMMER BLOCK BEARING 2
AX846/121 iss 02 sht 2 - 041203

NB. Fixings are not included with the above parts unless specifically ordered
AX846-901-8EN-02a 236/300
 Spare Parts - 428 Trakpactor

AX846-901-8EN-02a 237/300
SEE NEXT PAGE FOR
TAIL SECTION OF
CONVEYOR
Page 35

NOTE: WHEN A MAGNETIC SEPARATOR IS FITTED OVER THE CONVEYOR THERE ARE SOME VARIATIONS TO THE

Product Conveyor Head Section - Conveyor Parts Assembly - 428 Trakpactor

CONVEYOR PARTS LIST. REFER TO A LATER PAGE FOR THE APPROPRIATE PARTS LIST.
Spare Parts - 428 Trakpactor Page 36

Product Conveyor - Conveyor Parts Assembly - sheet 3

PART
REF DESCRIPTION QUANTITY
NUMBER
REMOTE GREASE PIPING (PART OF KIT
2530-2008 1
FOR TAILSHAFT BEARINGS ONLY)
61 AX843/7 TAIL DRUM 1
62 AX846/36 IMPACT BAR, 1240 MM LONG 2
63 AX846/37 IMPACT BAR, 1130 MM LONG 4
64 AX846/41/1 FEED BOOT 1
65 AX846/41/2 FEED BOOT REAR CLAMPING STRIP 1
66 AX846/41/3 FEED BOOT FRONT CLAMPING STRIP 2
67 AX846/41/4 FEED BOOT SIDE CLAMPING STRIP 2
68 AX843/13/1 FEED BOOT LINER PLATE 1
69 AX843/13/2 FEED BOOT LINER PLATE 1
70 AX843/13/3 FEED BOOT LINER PLATE 8
71 AX843/13/4 FEED BOOT LINER PLATE 1
72 AX843/13/5 FEED BOOT LINER PLATE 1
73 AX843/13/6 FEED BOOT LINER PLATE 1
74 AX843/13/7 FEED BOOT LINER PLATE 1
75 AX843/13/8 FEED BOOT LINER PLATE 2
76 AX843/13/9 FEED BOOT LINER PLATE 2
77 AX843/30/1 FEED BOOT CLAMP PLATE 2
78 AX843/30/2 FEED BOOT CLAMP PLATE 2
79 AX843/30/3 FEED BOOT CLAMP PLATE 2
80 AX843/30/4 FEED BOOT CLAMP PLATE 1
81 AX843/30/5 FEED BOOT CLAMP PLATE 1
82 AX843/30/6 FEED BOOT CLAMP PLATE 1
83 AX843/30/7 FEED BOOT CLAMP PLATE 1
84 AX846/80 FEED BOOT CLAMP PLATE 1
85 2360-0052 CONVEYOR BELT (2360-0152 FOR CONTI BELT) 1
86 AX846/30/1 SKIRT RUBBER TOP CONVEYOR 2
87 AX846/30/3 SKIRT RUBBER LOWER CONVEYOR 2
88 AX846/81/1 SKIRT RUBBER FEED BOOT 2
89 AX846/81/2 SKIRT RUBBER FEED BOOT 1
90 AX846/33 RUBBER DUST STRIP 1
91 AX846/41/5 BOLT ON SPACER 2
92 AX843/13/10 FEED BOOT LINER 2
93 AX815/54/1X TELESCOPER UNIT 1
94 AX846/120 BEARING SHIM 4
AX846/121 iss 02 sht 3 - 041203

NB. Fixings are not included with the above parts unless specifically ordered
AX846-901-8EN-02a 238/300
Spare Parts - 428 Trakpactor Page 37

FOR HEAD SECTION OF

SEE PREVIOUS PAGE

CONVEYOR

Product Conveyor Tail Section - Conveyor Parts Assembly - 428 Trakpactor

AX846-901-8EN-02a 239/300
Spare Parts - 428 Trakpactor Page 38

Product Conveyor with Magnetic Separator fitted

PART
REF DESCRIPTION QUANTITY
NUMBER
1 AX846/126 MAGNETIC SEPARATOR 1
2 AX818/62/1 'D' SHACKLE 2
3 AX818/62/2 'D' SHACKLES AND CHAIN 4
4 AX818/121 BACKING STRIP 1
5 AX818/33/1 SHEDDER PLATE 1
6 AX818/33/2 SHEDDER PLATE BRACKET 1
7 AX843/56/1 DEFLECTOR BRACKET 1
8 AX843/56/2 DEFLECTOR BRACKET CLAMP PLATE 1
9 AX846/76 CANVAS WIND COVER 1
10 AX846/30/2 UPPER SKIRT (MAGNET) 1
AX846/25 iss 04 – 01/12/04

NB. Fixings are not included with the above parts unless specifically ordered

AX846-901-8EN-02a 240/300
Spare Parts - 428 Trakpactor Page 39

Product Conveyor with Magnetic Separator fitted - 428 Trakpactor

AX846-901-8EN-02a 241/300
Spare Parts - 428 Trakpactor Page 40

Dirt Conveyor - Conveyor Parts Assembly - sheet 1

REF PART NUMBER DESCRIPTION QUANTITY

1 2360-0062 CONVEYOR BELT 1
2 2421-0010S BEARING 2
REMOTE GREASING KIT FOR BOTH
2530-2007 1
TAILSHAFT BEARINGS
3 2450-5503 SHRINK DISC 1
4 2564-5015 HYDRAULIC CYLINDER 2
5 2576-4078 HYDRAULIC MOTOR 1
6 AX607/3/46 TENSIONING ELEMENT 2
7 AX607/658/3 RETURN IDLER 1
8 AX789/13 TAIL DRUM 1
9 AX789/30/2 PIVOT PIN 2
10 AX789/30/3 PIVOT PIN 4
11 AX789/32 HEAD FRAME 1
12 AX789/39/01 SCRAPER BLADE FRAME 1
13 AX789/39/2 SCRAPER BLADE 1
14 AX789/39/3 SCAPER BLADE CLAMP STRIP 1
15 AX789/45/1 HEAD COVER 1
16 AX815/6 NIP GUARD 1
17 AX815/31 TROUGHING IDLER 5
18 AX815/81 TAIL FRAME 1
19 AX815/82/1 COUPLING GUARD RH 1
20 AX815/90 TORQUE ARM 1
21 AX815/91/1 ROSTA UNIT SUPPORT LH 1
22 AX815/91/2 ROSTA UNIT SUPPORT RH 1
23 AX815/92 HEAD DRUM 1
24 AX815/120 HEAD DRUM NIP GUARD 1
25 AX818/110/1 TELESCOPER 1
26 AX818/110/1X TELESCOPER 1
27 AX833/15 CYLINDER PROTECTION COVER 2
28 AX862/244/1 POLYURETHANE BLADE 2
29 AX862/244/2 CLAMP 2
30 AX842/107/1 HEAD COVER SKIRT RUBBER 2
31 AX842/107/2 HEAD COVER CLAMP PLATE 2
AX846/07 iss 02 – 01/12/04

NB. Fixings are not included with the above parts unless specifically ordered
AX846-901-8EN-02a 242/300
Spare Parts - 428 Trakpactor Page 41

Dirt Conveyor - Conveyor Parts Assembly - 428 Trakpactor

AX846-901-8EN-02a 243/300
Spare Parts - 428 Trakpactor Page 42

Dirt Conveyor - Conveyor Parts Assembly - sheet 2

REF PART NUMBER DESCRIPTION QUANTITY

ASSEMBLY OF 600MM WIDE DIRT
1 AX846/7 1
CONVEYOR
2
3
4 AX846/5/1 FEED BOOT 1
5 AX846/5/2 FEED BOOT CLAMP 2
6 AX846/5/3 FEED BOOT CLAMP 2
7 AX846/5/4 FEED BOOT CLAMP 1
8 AX846/32/1 SIDE SKIRT 2
9 AX846/32/2 REAR SKIRT 1
10
11
12 AX843/21 DIRT CONVEYOR SUPPORT 1
13
14
15 AX815/75 SKIRT RUBBER 2
16 AX815/76/1 CLAMP PLATE 1
17 AX815/76/2 CLAMP PLATE 1
18 AX815/76/3 CLAMP PLATE 1
19 AX815/76/4 CLAMP PLATE 1
20
AX846/42 iss 05 – 04/12/03

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Spare Parts - 428 Trakpactor Page 43

Dirt Conveyor - Conveyor Parts Assembly, continued - 428 Trakpactor

AX846-901-8EN-02a 245/300
Spare Parts - 428 Trakpactor Page 44

10.4 Overband Magnetic Separator

REF PART NUMBER DESCRIPTION QUANTITY

AX846/126 MAGNETIC SEPARATOR - COMPLETE UNIT
1 FRAME 1
2 MAGNET 1
3 HYDRAULIC MOTOR 1
4 DRIVE PULLEY 1
5 NON-DRIVE PULLEY 1
6 BEARING 4
7 BEAING CAP 3
8 BEARING BACK PLATE 2
9 BEARING TAKE-UP PLATE 2
10 BEARING SPACER PLATE 2
11 SIDE PLATE LEFT HAND 1
12 SIDE PLATE RIGHT HAND 1
13 BELT 1
14 EYENUT 4
15 MOTOR MOUNTING PLATE 1
16 COUPLING ASSEMBLY 1
05/12/03

NB. Fixings are not included with the above parts unless specifically ordered

AX846-901-8EN-02a 246/300
Spare Parts - 428 Trakpactor Page 45

14

15

5 8

10
3 16

4 12
11

13

Overband Magnetic Separator- 428 Trakpactor

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Spare Parts - 428 Trakpactor Page 46

10.5 Plant Component Parts

Plant General Arrangement

REF PART NUMBER DESCRIPTION QUANTITY

1 AX846/121 PRODUCT CONVEYOR ASSEMBLY 1
2 AX846/1 PLANT CHASSIS 1
3 2480-0054 CATERPILLAR ENGINE POWER PACK 1
4 A6984 42 x 48 IMPACT CRUSHER 1
5 AX846/72 FEED HOPPER ASSEMBLY 1
6 AX846/24 FEED HOPPER LINER PLATES 1 SET
7 620/B52/428T 3800 x 1080 VIBRATING GRIZZLY FEEDER 1
8 AX843/52 VGF MOTOR GUARD 1
9 AX846/42 SIDE DIRT CONVEYOR ASSEMBLY 1
10 AX846/13 CROSS BEAM ASSEMBLY 1
11 AX846/27 WALKWAYS AND LADDERS ASSEMBLY 1
12 AX815-217-501 CONTROL CABINET LESS INNER PANEL 1
AX815-217-003 CONTROL CABINET INNER PANEL 1
AX815-217-502 CONTROL CABINET DOOR 1
AX815-249-001 PLASTIC HINGE 1
2301-0005 COMPRESSION LOCKING LATCH 1
2563-0013 GAS STRUT 2
13 AX843MAG OVERBAND MAGNETIC SEPARATOR 1
ASSEMBLY
14 AX846-L675 HYDRAULIC OIL RESERVOIR 1
15 2592-2006 AIR BLAST OIL COOLER 1
16 AX846/92 OIL COOLER GUARD 1
17 AX846/106/1 CRUSHER DRIVE GUARD 1
18 2443-1700 ENGINE PULLEY – 280 PCD 1
18 2443-1673 ENGINE PULLEY – 224 PCD 1
19 2443-8337 TAPER LOCK BUSH 1
20 AX846/113 CRUSHER PULLEY 1
21 2450-8060 PULLEY BUSH 1
22 2441-0482 DRIVE VEE BELTS 6
23 AX846/3 FINES CHUTE WITH CLAMP STRIPS 1
AX846/35 CHUTE/FEEDER RUBBER CURTAIN 1
24 AX846/6/1 CHUTE BY-PASS DOOR 1
25 AX846/6/2 BY-PASS DOOR HANDLE 1
26 2424-5021 BY-PASS DOOR SPINDLE BEARING 2
27 AX843/43/1 CHAIN CURTAIN FRAME 1
28 2321-1107 CHAIN FOR CHAIN CURTAIN 13
29 AX843/61 RUBBER CURTAIN 1
30 AX843/43/2 RUBBER CHAIN CURTAIN CLAMP PLATE 1
31 AX846/128/1 CRUSHER FEED CHUTE 1
32 AX846/128/2 WEAR PLATE 1
AX846/128/3 CLAMP PLATES 1 SET
AX862/248/1 FEED CHUTE LID PIN 1
33 AX846/16 DEFLECTOR PLATE ASSEMBLY 1
34 AX843/58 SIDE RUBBER CURTAIN 2
35 AX846/70 SIDE RUBBER CURTAIN 2
36 AX846-133-501 TOOL BOX 1
AX846-133-502 TOOL BOX DOOR ASSEMBLY 1
2301-0005 COMPRESSION LOCKING LATCH 1
AX815-253-001 PLASTIC HINGE 1
AX846-133-CHAIN CHAIN ASSEMBLY 2
AX846GA_mod_01/12/04

NB. Fixings are not included with the above parts unless specifically ordered
AX846-901-8EN-02a 248/300
Spare Parts - 428 Trakpactor Page 47

Plant General Assembly - 428 Trakpactor

AX846-901-8EN-02a 249/300
Spare Parts - 428 Trakpactor Page 48

Plant Guards Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 AX846/101/1 TUNNEL THIRD SECTION – LH SIDE 1
2 AX846/101/2 TUNNEL THIRD SECTION – RH SIDE 1
3 AX846/99/1 TUNNEL SECOND SECTION 1
4 AX846/96/1 BARGE BOARD SIDE GUARD – RH SIDE 1
5 AX846/96/2 BARGE BOARD SIDE GUARD – LH SIDE 1
6 AX846/98/1 PRODUCT CONVEYOR TUNNEL – FIRST 1
SECTION – RH SIDE
7 AX846/98/2 PRODUCT CONVEYOR TUNNEL – FIRST 1
SECTION – LH SIDE
8 AX846/90/1 PRODUCT CONVEYOR SIDE GUARD – RH 1
9 AX846/90/2 PRODUCT CONVEYOR SIDE GUARD – LH 1
10 AX846/87/1 PRODUCT CONVEYOR TAIL DRUM GUARD – 1
LH SIDE
11 AX846/87/2 PRODUCT CONVEYOR TAIL DRUM GUARD – 1
RH SIDE
12 AX846/105/1 DIRT CONVEYOR TAIL SECTION SIDE GUARD 1
13 AX846/92 COOLER GUARD 1
14 AX846/106/1 MAIN DRIVE GUARD 1
15 AX846/93 TUNNEL INSPECTION GUARD 1
16 AX846/102 TUNNEL TOP PLATE FIRST SECTION 1
17 AX846/103 TUNNEL TOP PLATE SECOND SECTION 1
18 AX846/104 TUNNEL TOP PLATE FINAL SECTION 1
19 AX846/95 VALVE GUARD 1
20 AX846/86 DIRT CONVEYOR ROLLER GUARD – 1 1
21 AX846/88 DIRT CONVEYOR ROLLER GUARD – 2 1
22
23 AX846/18 IMPACTOR BULK HEAD GUARD 1
24 AX846-132-601 TOOL BOX (SEE PREVIOUS PAGE ITEM 36) 1
25 AX846/100/1 TUNNEL SECOND SECTION-NON DRIVE SIDE 1
26 AX846/114/1 DIRT CONVEYOR TAIL DRUM GUARD 1
27 AX846/91/1 DIRT CONVEYOR REAR GUARD 1
28 AX846/101/3 CLAMP STRIP 2
29 AX846/99/2 COVER 1
30 AX846/99/3 CLAMP 5
31 AX846/98/3 BRACKET 1 2
32 AX846/98/4 BRACKET 2 2
33 AX846/98/5 CLAMP 4
34 AX846/98/6 BRACKET 3 2
35 AX846/98/7 BRACKET 4 2
36 AX846/98/8 WASHER 12
37 AX846/105/2 BRACKET 2
38 AX846/106/2 COVER PLATE 1
39 AX846/106/3 REAR BRACKET 1
40 AX846/106/4 FRONT BRACKET 1
41 AX846/106/5 GRILL 1
42 AX843/63 HAND RAIL 1
43 AX846/100/2 COVER 1
44 AX846/100/3 CLAMP 5
45 AX846/114/2 CLAMP 1
46 AX846/91/2 CLAMP 1
47
48 AX815-228-601 CONTROL BOX 1
(SEE PREVIOUS PAGE ITEM 12)
AX846/108 iss 02 – 01/12/04

AX846-901-8EN-02a
NB. Fixings are not included with the above250/300
parts unless specifically ordered
Spare Parts - 428 Trakpactor Page 49

Plant Guards Assembly - 428 Trakpactor

AX846-901-8EN-02a 251/300
Spare Parts - 428 Trakpactor Page 50

Plant Platforms Assembly

REF PART NUMBER DESCRIPTION QUANTITY

1 AX843/23 LOWER PLATFORM 1
2 AX843/33 LOWER PLATFORM OPEN MESH 1
3 AX843/35 LOWER PLATFORM HANDRAIL 1 1
4 AX843/36 LOWER PLATFORM HANDRAIL 2 1
5 AX843/42 LOWER PLATFORM ACCESS LADDER 1
6 AX843/25 LOWERPLATFORM SUPPORT 1 1
7 AX843/27 LOWERPLATFORM SUPPORT 2 1
8 AX843/29 STAIRS 1
9 AX843/32 STAIR SUPPORT 1
10 AX843/28/1 UPPER PLATFORM 1
11 AX843/28/2 UPPER PLATFORM SPACER 1
12 AX843/34 UPPER PLATFORM OPEN MESH 1
13 AX843/37 UPPER PLATFORM HANDRAIL 1
14 AX843/49 CRUSHER PLATFORM OPEN MESH 1
15 AX843/53/1 CRUSHER PLATFORM FILL IN - FIXED 1
16
17
18 AX846/48 VALVE LEVER GUARD 1
19 AX846/18 HOSE COVER 1
20 AX846/130 ENGINE PLATFORM OPEN MESH (2 OFF
PANELS 1
21 AX843/41/1 ENGINE PLATFORM LADDER - UPPER 1
AX843/41/2 ENGINE PLATFORM LADDER – LOWER 1
22 AX818/180 ENGINE HANDRAIL 1
23 AX843/63 CRUSHER PLATFORM HANDRAIL - DRIVE 1
GUARD
24 AX846/115 PLATFORM SAFETY GATE 1
25 AX846/116 PLATFORM SAFETY GATE 1
AX843/27mod – 01/12/04

NB. Fixings are not included with the above parts unless specifically ordered

AX846-901-8EN-02a 252/300
Spare Parts - 428 Trakpactor Page 51

Plant Platforms Assembly - 428 Trakpactor

AX846-901-8EN-02a 253/300
Spare Parts - 428 Trakpactor Page 52

10.6 Plant Tracks

REF PART NUMBER DESCRIPTION QUANTITY

CRAWLER TRACK AX846TRAK/A/1

1 2372-0132 TRACK DRIVE GEARBOX c/w HYDRAULIC MOTOR 2

2372-0088 GEARBOX DRAIN PLUG 4
2 2372- GEARBOX CAPSCREWS 52
3 2372- DRIVE SPROCKET 2
4 2372- SPROCKET BOLTS 40
5 2372-0006 TRACK CHAIN –COMPLETE 2
6 2372-0007 TRACK SHOE – 400MM WIDE 98
2372-0104 TRACK SHOE – 500MM WIDE 98
7 2372-0008 TRACK SHOE BOLT 392
8 2372-0009 TRACK SHOE NUTS 392
9 2372-0012 IDLER 2
10 2372-0013 YOKE 2
11 2372-0014 RECOIL UNIT 2
2372-0103 TENSIONER SEAL KIT 2
12 AX818TRAKS02 GREASER 2
13 AX818TRAKS03 GASKET 2
AX818TRAKS01 ADAPTOR 1
14 2372-0017 ROLLER 16
15 2372-0018 ROLLER BOLT 64
16 2372-0019 ROLLER BOLT WASHER 64

2372-0010 REPAIR LINK - TRACK CHAIN

2372-0011 MASTER PIN - TRACK CHAIN
428-S-01/12/04

AX846-901-8EN-02a 254/300
Spare Parts - 428 Trakpactor Page 53

4
1

8
2

7
6

16
12
13

15
14
10
11

Plant Tracks Assembly - 428 Trakpactor

AX846-901-8EN-02a 255/300
Spare Parts - 428 Trakpactor Page 54

10.7 Hydraulic System

Hydraulic Hoses

Hose Number Tag

DESCRIPTION X 1 OFF EACH

HOSE
HOSE FITTING LENGTH
REF
1 R1AT-24 1.1/2ST / 2" 3000 90 FLANGE 1660
2 R1AT-24 1.1/2ST / 2" 3000 90 FLANGE 600
3 R1AT-32 1.1/2ST / 2.1/2"Series 3000 90 Flange 470
4 R9R-12 ST / 90S 360
5 R9R-12 ST / 1" 3000 ST FLANGE 970
6 R9R-12 90S / 1" 3000 ST FLANGE 830
7 R2AT-04 1/4BSP ST / 7/16JIC ST 1270
8 R9R-12 36/25/12 MALE / 3/4 90S 865
9 R9R-12 36/25/12 FEMALE / 3/4 90S 1680
10 R2AT-12 36/25/12 MALE / 3/4 90S 850
11 R2AT-06 ST / 90S 630
12 R2AT-12 36/25/12 MALE / 3/4 90ST 3800
13 R9R-12 36/25/12 MALE / 3/4 45DEG 1480-ARM
14 R9R-12 36/25/12 MALE / 3/4 45DEG 1480-ARM
15 R2AT-06 ST / 90S 1800
16 R2AT-06 ST / 90S 1700
17 R2AT-04 3/8STF / 7/16JIC 90S 1800
18 R9R-12 ST / 45DEG 2480-ARM
19 R9R-12 ST / 45DEG 2480-ARM
20 R9R-12 36/25/12 MALE / 3/4 90S 2360
21 R9R-12 36/25/12 MALE / 3/4 90S 2410
22 R2AT-08 7/8JIC ST / 7/8JIC 90S 2120
23 R2AT-08 1/2 ST / 7/8JIC ST 5100
24-29
30 R2AT-06 ST / 90S 3600
31 R2AT-06 ST / 90S 1900
32
33 R2AT-12 ST / 90S 4100
34 R2AT-12 ST / 90S 6610
35 R2AT-12 ST / ST 2090
AX846HOSEC9/1 – 01/12/04

AX846-901-8EN-02a 256/300
Spare Parts - 428 Trakpactor Page 55

Hydraulic Hoses, continued

DESCRIPTION X 1 OFF EACH

HOSE
HOSE FITTING LENGTH
REF
36 R2AT-08 ST / ST 4000
37 R2AT-08 ST / ST 4000
38 R2AT-12 ST / ST 900
39 R2AT-12 ST / ST 820
40 R2AT-06 ST / ST 930
41 R2AT-06 ST / ST 700
42 R2AT-06 ST / 45 700
43 R2AT-06 ST / 45 900
44 R2AT-12 ST / 90S 1050
45 R2AT-12 ST / 90S 1070
46 R2AT-12 ST / 90S 3000
47 R2AT-06 ST / 90S 6540
48 R2AT-06 ST / ST 700
49 R2AT-12 ST / 90S 3000
50 R2AT-08 ST / ST 2600
51 R2AT-06 ST / 45 1850
52 R2AT-06 ST / 45 1850
53 R2AT-06 ST / 45 1490
54 R2AT-06 ST / 45 1490
55 R2AT-12 ST / ST 1000
56 R2AT-12 ST / 90S 2000
57 R2AT-12 ST / ST 1050
58 R2AT-04 90DEG /45DEG 580
59 R2AT-04 90DEG /45DEG 810
AX846HOSEC9/1 – 01/12/04

AX846-901-8EN-02a 257/300
Spare Parts - 428 Trakpactor Page 56

Hydraulic Hoses for Impact Crusher Door Rams

Hose Number Tag

DESCRIPTION X 1 OFF EACH

HOSE
HOSE FITTING LENGTH
REF
428 IMPACT CRUSHER DOOR RAM HOSES
1
2
3
4
5 R2AT-06 ST / ST 1170
6 R2AT-06 ST / ST 1170
7 R2AT-06 ST / ST 1170
8 R2AT-06 ST / ST 1170
9 R2AT-06 ST / ST 4000
10 R2AT-06 ST / ST 4000
11 R2AT-06 ST / ST 6680
12 R2AT-06 ST / 90S 2200
13 R2AT-08 ST / 90S 1660
AX846HYDAUXHC9 – Iss. 00 - 121203

Hydraulic Oil Reservoir Components

REF PART NUMBER DESCRIPTION QUANTITY

1
2 2589-2105 FLUID LEVEL GAUGE & SWITCH 1
3 2531-1000 BREATHER 1
4 2531-5060 RETURN LINE FILTER 1
2531-5151 FILTER ELEMENT 1
4a 2538-0053 RETURN LINE FILTER GAUGE 1
5 INSPECTION COVERS 2
6 2531-5154 SUCTION FILTER 1
2531-5150 FILTER ELEMENT 1
6a 2538-0054 SUCTION FILTER GAUGE 1
6b 2520-8002 FLANGED ADAPTOR 1
L675 iss 01 – 01/12/04

AX846-901-8EN-02a 258/300
Spare Parts - 428 Trakpactor Page 57

Hydraulic Oil Reservoir Components - 428 Trakpactor

AX846-901-8EN-02a 259/300
Spare Parts - 428 Trakpactor Page 58

Hydraulic System Components - sheet 1

REF PART NUMBER DESCRIPTION QUANTITY

70 2573-6001 HYDRAULIC PUMP – IN ENGINE CANOPY 2
71 2550-9009 VALVE, HYDRAULIC, 2-WAY 1
72 2550-9005 VALVE, HYDRAULIC, 4-WAY 1
73 2531-5057 FILTER ASSY – IN ENGINE CANOPY 2
2531-5152 ELEMENT, FILTER 2
74 2592-2006 COOLER 1
75 2553-2013 TEST POINT 2
76
77 2579-0018 CHECK VALVE 2
78 2553-3010 VALVE, COUNTER BALANCE 1
79 2552-0024 FLOW CONTROL 1
80 2650-9001 HYDRAULIC MOTOR – MAG. SEPARATOR 1
81 2576-4075 HYDRAULIC MOTOR – PRODUCT CONV. 1
82 2576-4002 HYDRAULIC MOTOR – FEEDER 1
83 0000-0000 HYDRAULIC MOTOR – TRACKS 2
84 2564-5015 CYLINDER, HYDRAULIC 2
85 AX843/6 HYDRAULIC OIL TANK 1
2531-5150 ELEMENT, SUCTION FILTER 1
2531-5151 ELEMENT, RETURN FILTER 1
86 2550-5001 VALVE, DIVERTER DE20-3A-24G 1
87 2552-6555 COUPLING, FLAT FACE FFC-12M 2
88 2552-6556 COUPLING, FLAT FACE FFC- 12F 2
89 2552-6557 COUPLING, FLAT FACE FFC- 38M 1
90 2552-6558 COUPLING, FLAT FACE FFC- 38F 1
91 2520-6559 TEE, T/MB24/FFB8 1
92 2573-9002 PUMP/MOTOR UNIT 1
93 2553-2021 VALVE, HYDRAULIC 1
94 2535-0001 VALVE, CHECK, PO 2
95
96 2564-5026 CYLINDER, IMPACTOR 2
97 2576-4078 HYDRAULIC MOTOR – DIRT CONVEYOR 1
AX846/45 Iss 02mod – 01/12/04

AX846-901-8EN-02a 260/300
Spare Parts - 428 Trakpactor Page 59

Hydraulic System Components SHEET 1- 428 Trakpactor

AX846-901-8EN-02a 261/300
Spare Parts - 428 Trakpactor Page 60

Hydraulic System Components - sheet 2

REF PART NUMBER DESCRIPTION QUANTITY

70 2573-6001 HYDRAULIC PUMP – IN ENGINE CANOPY 2
71 2550-9009 VALVE, HYDRAULIC, 2-WAY 1
72 2550-9005 VALVE, HYDRAULIC, 4-WAY 1
73 2531-5057 FILTER ASSY – IN ENGINE CANOPY 2
2531-5152 ELEMENT, FILTER 2
74 2592-2004 COOLER 1
75 2553-2013 TEST POINT 2
76 2550-9003 MOTION CONTROL BLOCK, OIL CONTROL 2
77 2579-0018 CHECK VALVE 2
78 2553-3010 VALVE, COUNTER BALANCE 1
79 2552-0024 FLOW CONTROL 1
80 2650-9001 HYDRAULIC MOTOR – MAG. SEPARATOR 1
81 2576-4075 HYDRAULIC MOTOR – PRODUCT CONV. 1
82 2576-4002 HYDRAULIC MOTOR – FEEDER 1
83 0000-0000 HYDRAULIC MOTOR – TRACKS 2
84 2564-5015 CYLINDER, HYDRAULIC 2
85 AX843/6 HYDRAULIC OIL TANK 1
2531-5150 ELEMENT, SUCTION FILTER 1
2531-5151 ELEMENT, RETURN FILTER 1
86 2550-5001 VALVE, DIVERTER DE20-3A-24G 1
87 2552-6555 COUPLING, FLAT FACE FFC-12M 2
88 2552-6556 COUPLING, FLAT FACE FFC- 12F 2
89 2552-6557 COUPLING, FLAT FACE FFC- 38M 1
90 2552-6558 COUPLING, FLAT FACE FFC- 38F 1
91 2520-6559 TEE, T/MB24/FFB8 1
92 2573-9002 PUMP/MOTOR UNIT 1
93 2553-2021 VALVE, HYDRAULIC 1
94 2535-0001 VALVE, CHECK, PO 2
95
96 2564-5026 CYLINDER, IMPACTOR 2
97 2576-4078 HYDRAULIC MOTOR – DIRT CONVEYOR 1
AX846/45 Iss 02mod – 04/12/03

AX846-901-8EN-02a 262/300
Spare Parts - 428 Trakpactor Page 61

Hydraulic System Components SHEET 2- 428 Trakpactor

AX846-901-8EN-02a 263/300
Spare Parts - 428 Trakpactor Page 62

Hydraulic System Components - sheet 3

REF PART NUMBER DESCRIPTION QUANTITY

70 2573-6001 HYDRAULIC PUMP – IN ENGINE CANOPY 2
71 2550-9009 VALVE, HYDRAULIC, 2-WAY 1
72 2550-9005 VALVE, HYDRAULIC, 4-WAY 1
73 2531-5057 FILTER ASSY – IN ENGINE CANOPY 2
2531-5152 ELEMENT, FILTER 2
74 2592-2004 COOLER 1
75 2553-2013 TEST POINT 2
76 2550-9003 MOTION CONTROL BLOCK, OIL CONTROL 2
77 2579-0018 CHECK VALVE 2
78 2553-3010 VALVE, COUNTER BALANCE 1
79 2552-0024 FLOW CONTROL 1
80 2650-9001 HYDRAULIC MOTOR – MAG. SEPARATOR 1
81 2576-4075 HYDRAULIC MOTOR – PRODUCT CONV. 1
82 2576-4002 HYDRAULIC MOTOR – FEEDER 1
83 0000-0000 HYDRAULIC MOTOR – TRACKS 2
84 2564-5015 CYLINDER, HYDRAULIC 2
85 AX843/6 HYDRAULIC OIL TANK 1
2531-5150 ELEMENT, SUCTION FILTER 1
2531-5151 ELEMENT, RETURN FILTER 1
86 2550-5001 VALVE, DIVERTER DE20-3A-24G 1
87 2552-6555 COUPLING, FLAT FACE FFC-12M 2
88 2552-6556 COUPLING, FLAT FACE FFC- 12F 2
89 2552-6557 COUPLING, FLAT FACE FFC- 38M 1
90 2552-6558 COUPLING, FLAT FACE FFC- 38F 1
91 2520-6559 TEE, T/MB24/FFB8 1
92 2573-9002 PUMP/MOTOR UNIT 1
93 2553-2021 VALVE, HYDRAULIC 1
94 2535-0001 VALVE, CHECK, PO 2
95
96 2564-5026 CYLINDER, IMPACTOR 2
97 2576-4078 HYDRAULIC MOTOR – DIRT CONVEYOR 1
AX846/45 Iss 02mod – 04/12/03

AX846-901-8EN-02a 264/300
Spare Parts - 428 Trakpactor Page 63

Hydraulic System Components - 428 Trakpactor

AX846-901-8EN-02a 265/300
Spare Parts - 428 Trakpactor Page 64

10.8 Electrical System

Electrical Components

REF PART NUMBER DESCRIPTION QUANTITY

1 2683-2100 FUSE SET COMP 2*3A 2*5A 2*10A 2*16A 1
E/M STOP TWIST TO RELEASE PUSH
2 2683-2101 2
BUTTON WITH CONTACT BLOCKS
2 POSITION REMOTE CONTROL OFF/ON
3 2683-2103 1
SWITCH
3 POSITION SPRING RETURN SWITCH
4 2683-2104 1
WITH CONTACT BLOCKS
5 2683-2106 10 AMP 11 PIN 2 POLE MINI RELAY 24V DC
2683-2106A 11 PIN RELAY BASE
2683-2107 10 AMP 8 PIN 2 POLE MINI RELAY 24V DC
2683-2107A 8 PIN RELAY BASE
6 2683-2121 INDICATOR LAMP 1
7 2683-2108 15 SECOND PRE-START TIMER 24V DC 1
FEEDER SPEED CONTROL
8 2683-2109 1
POTENTIOMETER
2683-2113 FEEDER SPEED CONTROL KNOB 1
9 2683-2114 HEAVY DUTY E/M STOP RELAY 1
2683-2114 HEAVY DUTY PANEL SUPPLY RELAY 1
3 POSITION STAYPUT SWITCH WITH
10 2683-2146 1
CONTACT BLOCKS
11 2683-2145 ANTI-CRANK RELAY 1
12 2683-2102 STOP/START BUTTON COMPLETE 1
13 2683-2111 BLACK PUSH BUTTON 1
TELERADIO CONTROL (WHERE FITTED
14 2686-0042 COMPLETE KIT INCLUSIVE OF ITEMS 15 1
TO 20 BELOW
TELERADIO RECEIVER UNIT ONLY
15 2686-9034 1
(CONTROL PANEL COMPONENT)
RADIO HAND SET TRANSMITTER – RED
16 2686-0043 STOP BUTTON (USA & REST OF THE 1
WORLD)
RADIO HAND SET TRANSMITTER – BLACK
17 2686-0044 1
STOP BUTTON (EUROPE)
18 2686-9008 TELERADIO ANTENNA ONLY WITH CABLE 1
19 2686-9007 12/35VDC CHARGER CABLE 1
20 2683-9029 TELERADIO UMBILICAL HAND SET ONLY 1
21 2683-2135 IMPACTOR DOOR LIMIT SWITCH 1
REMOTE INFRA-RED HANDSET (WHERE
22 2686-0040 1
FITTED)
23 2685-0001 EMERGENCY STOP STATION ASSEMBLY 1
24 2683-2110 AUDIBLE WARNING UNIT 24V DC 1
Mk 16 – 01/12/04

NB. SEE THE HYDRAULIC SYSTEM FOR THE HYDRAULIC VALVE SOLENOIDS.
AX846-901-8EN-02a 266/300
Spare Parts - 428 Trakpactor Page 65

7 5 9 11 9 1

2
14

10 3 4 13 6 12

19
20
15 16 & 17 Electrical Items - 428 Trakpactor

AX846-901-8EN-02a 267/300
Spare Parts - 428 Trakpactor Page 66

10.9 Safety Signs (with part numbers)

Note: For positions of these Warning Signs refer to Section 1.8, Figures 1b & 1c

300/32 300/33 300/34

300/36

300/37 300/38 300/39 300/40

300/42

300/43 300/44 300/52

AX846-901-8EN-02a 268/300
Spare Parts - 428 Trakpactor Page 67

300/118 300/120 300/182 300/196

300/224
300/269

300/268

300/284

300/354
AX846-901-8EN-02a 269/300
 Trakpactor
428
Spare Parts Issue EN 02
Page 68

Blank page

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

AX846-901-8EN-02a 270/300
 Trakpactor
428
Appendix Issue EN 02
Page 1

Contents

11.1 Noise Level Assessment ................................................................................... 2

11.2 Manual Engine Clutch ....................................................................................... 4

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

AX846-901-8EN-02a 271/300
11.1 Noise Level Assessment Page 2

Noise levels measured on one

occasion for the Trakpactor plant
(running empty; ie. not crushing)
recorded as shown on the site
layout

Layout - Noise Recording Poitions

AX846-901-8EN-02a 272/300
 Page 3

Measured Noise Levels

AX846-901-8EN-02a 273/300
 Trakpactor
428
Appendix Issue EN 02
Page 4

11.2 Manual Engine Clutch

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

AX846-901-8EN-02a 274/300
 Trakpactor
428
Appendix Issue EN 02
Page 5

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

AX846-901-8EN-02a 275/300
 Trakpactor
428
Appendix Issue EN 02
Page 8

Blank page

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

AX846-901-8EN-02a 276/300
 All Plants - Tier 3, Stage IIIa - ACERT

Addendum to User Manual

Due to the change of engines to comply with requirements

of Tier 3/Stage IIIa standards, this plant may have a different
engine fitted

Caterpillar C13 engines are replacing the C12

Caterpillar C9 engines have been revised to comply with the standards
Caterpillar C6.6 engines are replacing the 3126B engines

AM0013 - EN E-1
AX846-901-8EN-02a 277/300
Change of Engine Type

The change of engines has resulted in the following changes to engine controls
and information in the user manual.

Power Output
The engine power may have changed slightly.
The power of the engine as stated in the manual will not necessarily be correct but the power stated on the
plate fixed to the plant is correct.

Engine Speed
The engine working speed may have changed slightly.
The engine speed stated in the manual will not necessarily be correct but the speed set by the engine controls
and display is correct.
The engine working speed with no load and speed at full load are now the same.

Engine Monitoring System

The engine monitoring system and engine control panel shown and referred to in the user manual will not be
correct.
The engine information will be displayed on a different type of screen.
To operate the engine monitor screen, refer to the appropriate addendum for the controls fitted.

Engine Controls
Some engine controls and warning lamps are not as shown and referred to in the manual as they have been
repositioned with other plant controls.

Power Plant Spares

Some engine electrical controls and power pack spare parts will be different to those referred to in the user
manual, therefore please contact Terex Pegson and quote plant and engine serial numbers for assistance.

E-2
AX846-901-8EN-02a 278/300
 All Plants - Messenger Control

Addendum to User Manual

Caterpillar Messenger Display

INTRODUCTION
The engine fitted on this plant may not have the engine monitoring system shown and referred to in the Terex
Pegson User Manual but has the Caterpillar Messenger system.
Messenger is an electronic monitoring system with real-time visual display of engine operating conditions,
historical data and diagnostic information.
If applicable, also refer to ‘Messenger Display’ in Features and Controls in the Operation Section of the
Caterpillar Operation and Maintenance Manual for the engine.

AM0014 - EN M-1
AX846-901-8EN-02a 279/300
Caterpillar Messenger Engine Monitoring System

Operation
The operator button functions are:

1
1. Previous button
Return to previous level and screen display

2
2. Scroll Up / Left button
Scroll display to view different menus and use to set up display settings.

3. Scroll Down / Right button

3
Scroll display to view different menus and use to set up display settings.

4. OK button
4
Confirm selection on the display / continue to next screen

Performance Display
The displays available are:
Engine speed
Coolant temperature

Totals Display
Cumulative totals displays available are:
Service hours engine has accumulated
Total time system in use

M-2
AX846-901-8EN-02a 280/300
 All Plants - Messenger Control

Settings Display
System options available are:
Language used on display screen
Units shown on display
Adjust screen contrast
Adjust screen back light
Identification numbers available are:
Equipment identification number
Product identification number

Service Display
Service events display is:
View logged events, errors or alarms
System parameters are:
Battery voltage
Engine speed
Coolant temperature
Boost pressure
Self Test
Perform a self test, similar to when the start switch
is turned to the ON position
Monitoring information displays are:
Software part number
ECM (Electrical Control Module) part number
Software release date
Software description

AM0014 - EN M-3
AX846-901-8EN-02a 281/300
Caterpillar Messenger Engine Monitoring System

Engine information displays are:

ECM serial number
Software part number
Software release date
Software description
Engine serial number
Tattle tale
(To display maximum values reached during
operation).
Full tattle tale read-out
Engine coolant
Tachometer

Spare Parts
Some engine electrical controls and power pack
spare parts will be different to those referred to in
the user manual, therefore please contact Terex
Pegson and quote plant and engine serial numbers
for assistance.

M-4
AX846-901-8EN-02a 282/300
 All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 1

OPERATING INSTRUCTIONS

FUEL TRANSFER PUMP

(for plant diesel engine)

THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11

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

AX846-901-8EN-02a 283/300
 All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 2

Optional Fuel Transfer Pump

This option is available as originally fitted
WARNING
equipment installed at the time of plant WEAR PERSONAL
manufacture. PROTECTIVE EQUIPMENT.
Refer to Section 9.1 of the Plant
User Manual-Safety Information
The pump is for the purpose of transferring for relevant warning.
diesel engine fuel from a barrel positioned at
LOCKOUT MACHINE.
ground level alongside the plant diesel Refer to Section 9.1 of the Plant
engine to the engine fuel tank. UserManual-Safety Information
for Lockout Procedure.
The pump is permanently mounted in a
suitable position on the plant in the vicinity
of the engine and is electrically driven from
a 24 volt DC supply. The unit is fitted with
an integral on/off switch.

Also supplied as part of the kit are lengths Do not use the fuel transfer
of plain hose 25mm bore for suction (with pump for any other purpose
strainer) and delivery. DANGER that filling the diesel engine
fuel tank on the BL-Pegson
The VR050 Series pump is rated at 50 plant.
litres per minute, suitable for equipment with
tanks between 200 and 500 litres. Duty is Observe the Operating,
continuous up to + 40o C ambient. Self Service & Safety Instructions
priming up to 3 metres dry. Flow 50 ltrs/min on the opposite page and also
at 3 metres head. Maximum head 10 the general Safety Information
metres. given in Section 9.1 of the
Plant User Manual.

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

AX846-901-8EN-02a 284/300
 All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 3

Fuel Transfer Pump Operating, Service & Safety Instructions

SAFETY

FLASHPOINT BELOW
37o C (99o F)

DO NOT USE A TRGGER NOZZLE

FOR DELIVERY INTO THE FUEL
TANK

FLASHPOINT ABOVE
37o C (99o F)

MAXIMUM DUTY TIME AT 40O C TEMPERATURE RANGE

INSTALLATION & USE

DO NOT ALLOW THE PUMP

TO RUN DRY. SWITCH OFF
IMMEDIATELY DELIVERY OF
THE FUEL IS COMPLETED.

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

AX846-901-8EN-02a 285/300
 All Plants
Fuel Transfer Pump
MANUAL ADDENDUM Issue 01 ENG
Page 4

Top Up Fuel Level

Do Not fill the tank to capacity.
WARNING
Monitor the gauge located on WEAR PERSONAL
the Engine Control Panel. PROTECTIVE EQUIPMENT.
Refer to Section 9.1 of the Plant
User Manual-Safety Information
Allow room for expansion and for relevant warning.
wipe up spilt fuel immediately,
LOCKOUT MACHINE.
otherwise paintwork will be Refer to Section 9.1 of the Plant
damaged. UserManual-Safety Information
for Lockout Procedure.

Procedure

1. Observe all safety warnings. Never add gasoline or any

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

4. Operate the switch on the pump to fill

the fuel tank. Use only in accordance with
the instructions on the previous page.

5. Switch off the pump and stow the

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

Diesel fuel is highly flammable

and is an explosion/burns
DANGER hazard.
Never remove the filler cap or Filler Cap
refuel, with the engine running.

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

AX846-901-8EN-02a 286/300
 All Plants
Water Pumps
MANUAL ADDENDUM Issue 02 ENG
Page 1

OPERATING INSTRUCTIONS

WATER PUMP
2575-2002 or 2575-2009
(for dust suppression spraybars)

TYPICAL INSTALLATION

THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11

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

AX846-901-8EN-02a 287/300
 All Plants
Water Pumps
MANUAL ADDENDUM Issue 02 ENG
Page 2

Optional Water Pump

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

The pump is to provide a pressurised

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

Initial on/off control of the pump is by

means of a 3 way valve lever (Figure 2)
mounted on the pump unit. Whilst this valve
lever is in the ‘on’ position the screw type
valve (Figure 2) can be used to regulate the
water supply to the plant inlet manifold.

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

AX846-901-8EN-02a 288/300
 All Plants
Water Pumps
MANUAL ADDENDUM Issue 02 ENG
Page 3

Manifold Drain
Valves

Water Inlet
Connection

Figure 1 Water Pump Unit

(typical mounting)

Flow
Control Valve

3 Way
On/Off Valve

Figure 2 Water Pump Valves

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

AX846-901-8EN-02a 289/300
 All Plants
Water Pumps
MANUAL ADDENDUM Issue 02 ENG
Page 4

Hydraulic Oil Water

3 Way Valve

Flow Valve

Hydraulic Motor Water Pump

Coupling

Figure 3 Pump Hydraulic Oil/Water Circuits

2575-2008 3 Way Valve 2575-2005 Coupling

25 l/min Pump 2575-2003
2575-2007 Flow Valve
65 l/min Pump 2575-2010
2575-2004 Hydraulic Motor

Figure 4 Pump Unit Part Numbers

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

AX846-901-8EN-02a 290/300
 BW100 INITIAL CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed when messages E3 and E4 are displayed during routine calibration.
The E3 and E4 messages indicate a mechanical problem
i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the weigher etc.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration. Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied

SELECT SELECT P388

PARAMETER
P377

INVOKE INITIAL ZERO INVOKE INITIAL SPAN

ENTER “ 1 “ ENTER “ 1 ”

CURRENT ZERO COUNT CURRENT SPAN COUNT= ####

ZERO CALCULATION SPAN CALCULATION,

FREQUENCY COUNT FREQUNCY COUNT DISPLAYED
DISPLAYED

ZERO DEVIATION SPAN DEVIATION= ##

ZERO DEVIATION ACCEPTED ZERO DEVIATION ACCEPTED

INITIAL ZERO COUNT= #### INITIAL ZERO COUNT= ####

PROCEED WITH
SPAN CALIBRATION OR
AX846-901-8EN-02a 291/300 RETURN TO RUN MODE
RETURN TO RUN MODE
 BW100 ROUTINE CALIBRATION SIMPLIFIED GUIDE
The Following procedures may be performed on a routine basis as required.

Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration.
Safe working practice should be adopted at all times.
Zero Calibration Span Calibration
With belt running empty at normal speed with test weights removed With belt running empty at normal speed with test weights applied

ZERO CALIBRATION REQUIRED INITIAL SPAN COUNT

FREQUENCY COUNT DISPLAYED

DURING CALIBRATION
INITIAL ZERO COUNT

FREQUENCY COUNT DISPLAYED

DURING CALIBRATION DEVIATION

NEW SPAN COUNT

DEVIATION

NEW ZERO COUNT CALIBRATION COMPLETE REMOVE TEST WEIGHTS

CALIBRATION COMPLETE
RETURN TO RUN MODE PRESS TO RETURN TO RUN MODE
TO RETURN
PRESS
TO RUN MODE

SPAN REQUIRED
AX846-901-8EN-02a 292/300
 MANUAL ADDENDUM
OPERATING INSTRUCTIONS
INFRA-RED REMOTE CONTROL
FOR FEEDER

THIS MANUAL ADDENDUM IS TO BE INSERTED INTO

THE PLANT OPERATORS MANUAL
THESE INSTRUCTIONS REPLACE THE RADIO REMOTE
CONTROL FEEDER INSTRUCTIONS

AX846-901-8EN-02a 293/300
 Infra-red feeder
Issue 01 UK/US Infra-red feeder control
Page 2

INFRA-RED Remote Feeder

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

1. Observe all safety instructions.

2. Take the infra-red control from the

‘1’ Start
control box and first become familiar
with the functions of the individual
buttons.

3. Turn the Feeder Remote switch on the

plant to the ‘ON’ position. (Section 7 ‘0’ Stop
of manual)

4. To operate the feeder remotely the

engine must be started, conveyors and
feeder must be switched on and the
speed of the feeder set. (Section 7 of
manual)
Infra-red feeder remote
5. Point the transmitter lens of the infra- control operation
red control unit at the receiver
mounted above the engine. Operate
the ‘1’ button to start the feeder and the
‘0’ button to stop the feeder.

BL-Pegson Limited, Coalville, England. Tel.: +44 (0)1530 518600 Fax: +44 (0)1530 518618
Website: www.bl-pegson.com E-mail: sales@bl-pegson.com

AX846-901-8EN-02a 294/300
 Infra-red feeder
Infra-red feeder control Issue 01 UK/US
Page 3

General Information Infra-red control

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

Avoid knocking or dropping the infra-red Receiver

control, keep it clean (especially the lens),
dry, and store in a dry place when not in Code: 9 + 10.
use. Clean both the handset and receiver Matching transmitters: Any transmitter
with a damp cloth only and ensure all with codes 9 + 10.
screws and connections remain tight.
Supply voltage: 12V DC only.
Relay type: K4BC12.
Relay Contacts rating: 16A 240V AC.
Supply current standby: (12V) - <20mA.
Supply Current Active: (12V) - <80mA.
Operating temperature: -10°C to 60°C
(14°F to 140°F).
Storage temperature: -20°C to 60°C
(-4°F to 140°F).
Relay No1: N/O configuration - Function
On/Off.
Relay No2: C/O configuration - Not used.

BL-Pegson Limited, Coalville, England. Tel.: +44 (0)1530 518600 Fax: +44 (0)1530 518618
Website: www.bl-pegson.com E-mail: sales@bl-pegson.com

AX846-901-8EN-02a 295/300
 Infra-red feeder
Issue 01 UK/US Infra-red feeder control
Page 10

Troubleshooting
Check that infra-red lenses of the
transmitter and/or receiver are clean.
Ensure that transmitter is in range of the
receiver and in line of sight.
If the red L.E.D. is not lighting or flashing,
change the battery.
If the L.E.D. is working correctly, check
the receiver relay operation. There should
be a sharp click when the relay operates.
If the relays are working correctly the
problem may be in the plant wiring and
requiring the services of a qualified
electrician.
For a fault where the output ‘chatters’
intermittently, check for electro-
mechanical interference from contactors,
solenoids, motors, etc. Employ a qualified
electrician to solve this type of problem.

BL-Pegson Limited, Coalville, England. Tel.: +44 (0)1530 518600 Fax: +44 (0)1530 518618
Website: www.bl-pegson.com E-mail: sales@bl-pegson.com

AX846-901-8EN-02a 296/300
 Trakpactor
428
Notes Issue EN 02
Page 1

Hours Run / Date Notes Name

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

AX846-901-8EN-02a 297/300
 Trakpactor
428
Notes Issue EN 02
Page 2

Hours Run / Date Notes Name

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

AX846-901-8EN-02a 298/300
 Trakpactor
428
Notes Issue EN 02
Page 3

Hours Run / Date Notes Name

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

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AX846-901-8EN-02a 300/300