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00 EN02 428 Trakpactor User Manual

1. c 9 L 9 um 2 S3HONI L332 SANLAWITIIW NI SNOISN3MWIG T JO JHLNIO i 01 01 41 01 0021 0066 8106 e e e e e e 9 c gt 5 l m TEREX PEGSON 2 1 Dimensions AX846 901 8EN 02a 30 300 Trakpactor TEREX 428 2 Technical Information Issue EN 02 PEGSON Page 3 2 2 Plant Description Many of the terms used in this manual may not at first be obvious Figure 2b identifies the main areas of the plant and the term with which they are referred to in this manual Diesel Impact Crusher Engine Feed Hopper Magnetic Overband Separator Tracks LEFT HAND SIDE Dirt Conveyor Head drum guard and side skirt plates are removed for Feader transport Product Conveyor Engine Maintenance Platform Control Box Maintenance Platform RIGHT HAND SIDE Figure 2b Plant Terms BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 31 300 Trakpactor TEREX 428 2 Technical Informa
2. 5 3 4 2 Estimated Product Analysis rnrn rnrn nennen 6 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 35 300 TEREX PEGSON 3 1 Introduction This instruction manual contains important information on how to operate the Trakpactor safely properly and most efficiently Observing these instructions and exercising Common Sense helps to avoid danger to reduce repair costs and downtimes and to increase the reliability and life of the plant Failure to do so may invalidate any warranties in force The operating instructions must always be available wherever the plant is in use These operating instructions must be read and applied by any person in charge of and or working on the plant such as Operation Includes manoeuvring setting up operation during the course of work evacuation of production material and waste care and disposal of fuels and consumables etc Maintenance Servicing inspection and repair and or Transport Follow all applicable laws and safety regulations for accident prevention and environmental protection Trakpactor 428 3 General Information Issue EN 02 Page 2 3 2 General information The Trakpactor which you have now received has been manufactured assembled and tested with the utmost care and was built with first class materials
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4. 44 9 8 mee 47 9 8 1 Removing the Underscreen Mesh or Blanking Mat 48 9 9 Plant Hydraulic System Description 2 4 00000 50 9 9 1 General Description T 50 9 9 2 Track lt gt EE 51 9 9 3 Feeder 2 51 9 9 4 Circuit PrOteECtON 51 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 105 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 9 9 5 Changing the Suction 5522 55558 2225089242 08 2 o 1 m 52 54 9 9 7 Changing the Tank Breather a eo aA aa RR ennenen 55 9 9 8 Changing the Pressure 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 2 2 2202 59 9 11 2 Adjustment of Crusher Drive Belts 2
5. meon s mum screw 11 20 meon 2 SPRNGWASER 0200 s ess 1 _ 7 zseaxs sorwmwur 2 00 SCREEN CAPPING RUBBER s TENSIONED RUBBER WAT 1 _ ________ TENSIONED WIRE MeSH tom 01 06 uz TENSONEDWREMESHENM 1 _ es reNsoONEDWREMESHSNM 1 ex TENSONEDWREMESHANM 1 eus rewsomepwmEMEsHsNM 1 04 11 03 5 AX846 901 8EN 02a 226 300 Spare Parts 428 Trakpactor Page 26 Grizzly Feeder Vibrating Unit Assembly REF PARTNUMBER DESCRIPTION a fems 3 5 4 ese 1 s moss fee 1 20 s paon sw s 7 ponor 1 4 wenn T 2 zoms SCREW FOUR CORNER SCREWS 4 x assests 200200 M NN 1 GASKET COMPOUND 2141 0027 160ML FOR SEALING END PLATES AND COVER PLATES 23 11 04 AX846 901 8EN 02a 228 300 Spare Parts 428 Trakpactor Page 27 Feeder Vibrating Unit Housing 428 Trakpactor Spare Parts 428 Trakpactor Page 28 Grizzly Feeder Driveside Shaft Assembly 0 2 15 mus
6. sem 1 eee BLADE CLAMP 2495 3003 SPIRALRETURNROLLER RETURN ROLLER o MULTI TROUGH IMPACT IDLER 2495 3002 COMPLETE 59 2489 1057 1057 SEPARATE OUTER ROLLER FOR 59 OUTER ROLLER FOR SEPARATE OUTER ROLLER FOR ITEM 59 59 598 2489 3005 3005 CLAMP WITH FIXINGS FORITEM 59A WITH FIXINGS FOR ITEM 59A RES 2489 1058 SERAISATE CENTRE ROLLER FOR ITEM geram i 2421 00115 PLUMMER BLOCK BEARING AX846 121 iss 02 sht 2 041203 NB Fixings not included with the above parts unless specifically ordered AX846 901 8EN 02a 236 300 35 428 Trakpactor Spare Parts 20 58 LCL OV8XV 5 900 00 181 SLYVd AHL 1 1 OL 151 SLYVd AHL OL SNOLLVINVA SINOS GALLIA SI YOLVAVdsAS V NSHM 1 NOILOAS TIVL 39Vd LX3N 33S 9 9 NOILIAS gt N LI gt 2 o 9 lt o t gt gt LI c o gt gt 5 Spare Parts 428 Trakpactor Page 36 Product Conveyor Conveyor Parts Assembly sheet 3 Tae FOR TAILSHAFT BEARINGS ONLY 61
7. 7 8 9 4 Plant Lubrication and Servicing 10 9 4 1 11 18 18 10 94 2 Reg lar 11 9 4 3 Daily Weekly and Monthly Checks 2 4 12 9 4 4 Lubrication and Servicing Schedule 14 9 5 Crusher Opening and 18 9 5 7 Safety CULOHESWIBGD 19 9 5 2 Opening the Crusher Fe n 20 9 5 3 Closing the 22 9 6 Crusher Adjustment ee 24 9 6 1 Entanglement Hazard for Inspection 25 9 6 2 Adjusting the Front Impact Apron uel Rn caen Gne 26 9 6 3 Adjusting the Rear Impact Apron 28 9 6 4 Adjusting the Swing Arm where fitted 2 30 9 7 Crusher Replacement of Wear Parts 32 9 7 1 Replacing wore 92 9 7 2 Replacing the Impact Plates the Front and Rear Impact Aprons 38 9 7 3 Replacing the Side Wall Liner Plates cerca 41 9 7 4 Replacing the Bottom Inlet 42 9 7 5 Replacing the Retractable
8. Spare Parts 428 Trakpactor Page 48 Plant Guards Assembly REF _ PART NUMBER DESCRIPTION QUANTITY 1 mee eue em SECTION RH SIDE SECTION LH SIDE 8 846 901 PRODUCT CONVEYOR SIDE GUARD RH_ 1 9 AX846 90 72 PRODUCT CONVEYOR SIDE GUARD LH_ 1 10 1 846 87 1 PRODUCT CONVEYOR TAIL DRUM GUARD LH SIDE AX846 87 2 PRODUCT CONVEYOR TAIL DRUM GUARD RH SIDE 846 102 22 846 132 601 TOOL BOX SEE PREVIOUS 38 1 26 8464148 DIRT CONVEYOR TAIL DRUM GUARD 1 BRACKET BRACKET Lo AX815 228 601 CONTROL BOX SEE PREVIOUS PAGE ITEM 12 AX846 108 iss 02 01 12 04 NB Fixings are not included fl9th Ebove2paRPunless specifically ordered Spare Parts 428 Trakpactor Page 49 Dr Xy XO 10 wo li UN I N Smee NA gt MESE A G TANKS 3 Spare Parts 428 Trakpactor Page 50 Plant Platforms Assembly 6 __ AX843 25 LOWERPLATFORMSUPPORT1 8 AXe4320 STAIRS 9 __ 43 32 ____ STAIRSUPPORT 1 p _17 846 48 VALVE LEVER GUARD 1 AX846 18 HOSE COVER 1 20 AX846 130 ENGINE PLATFORM OPEN MESH 2 OFF PANELS AX843 41 1 ENGINE PLATFORM LADDER UPPER 843 41 2 ENGINE PLATFORM LADDER LOWER AX818 180 ENGIN
9. TALDRUM sit 00001017 e 3 FEED BOOT FRONT CLAMPING STRIP sana 1 wes wbsooTUMERRUTE 67 3 eto poor carats e FEED BOOT CLAMP PLATE to reosoorcuee unt 3 L sem ser ROSSER TOP conveyor 2 se esa 0 7 AX846 121 iss 02 sht 3 041203 NB Fixings are not included with the above parts unless specifically ordered 37 428 Trakpactor Spare Parts 20 SS LCL OV8XV 2 1 NOI L23S HOA3ANOO JO NOILO3S QV3H 403 39 Vd SNOIAAYd 33S 3 3 NOILJAS NO M3IA 13 N LI 9 lt o t gt gt o LI gt gt o 5 75 Spare Parts 428 Trakpactor Page 38 Product Conveyor with Magnetic Separator fitted 6 AWMBG32 SHEDDERPLATEBRACKET __ DEFLECTOR BRACKET CLAP PLATE s mear CANVASWINDCOVER 846 25 155 04 01 12 04 NB Fixings are not included with the above parts unless specifically ordered
10. 7 1 1 Blocked Crusher Procedures It is the responsibility of the Owner End User and or Safety Officer of the Trakpactor to provide a safe means of dealing with oversize material and construct a safe procedure for unblocking a stalled machine which is full of material To comply with British Health and Safety Law it is necessary to conduct an adequate risk assessment of the procedures for unblocking a blocked crusher Should an oversize piece of material be fed to a crusher and cause the feed opening to be bridged the recommended procedure for removing this is to open the crusher as described in Section 9 5 if the bridged material is not accessible otherwise Only open the crusher slowly with caution and with all personnel well clear A crane and hook can be used although EXTREME 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 Trakpactor 428 7 Operating Instructions Issue EN 02 Page 5 In the case ofa stalled crusher it should always be treated as possibly being jammed with tramp metal A safe system of work should be devise
11. Contents General 2 4 2 Construction 3 420 Impact 3 4 2 2 Vibrating Grizzly Feeder ttem 4 E 4 4 2 4 On Plant Product Conveyor 4 5 2 2 6 Overband magnetic 5 5 4 2 Plant 5 4 2 8 Operators Maintenance 5 6 4 210 CONi serenon ee ee 6 LAC Ed EE 6 4 2 12 6 6 4 2 14 Dust Suppression Sprays 6 2 det eta bade 7 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 41 300 Trakpactor TEREX 428 4 Design and Function Issue EN 02 Page 2 PEGSON 4 1 General Information The BL Pegson Trakpactor Plant has been designed for a wide range of quarry and recycling applications its features include
12. S9INH d1H 9 43 61 243 61 pue uoneJedo 26101 UIML eui 1242Y 9 24 1342Y 00 Buneouqn 4 98 2 06 Ajuejsisuoo e se peuyep s 4 98 2 0 lt 4 66 2 7 MO 138 nueisisuoo e se s 4 62 22 gt 4 69 0 91 e peugep 4 566 0 91 lt 91oN 1299 06 M08 AVS UMOIDJIND dazy 99 ISeJp H ISeAp H 89H 69 50191 IIdoIN Neus ONN 50191 ScALC 99 2 UMOIDJIND uooeeg dazy H ILIAW 09v OH ueueds 05 elewo 629 973 2 ueueds 024 029 9 4 2 ueueds 089 94H 2 uooeeg daz
13. 02 244 300 Spare Parts 428 Trakpactor Page 43 AX842 42 155 05 VIEW ON ARROW nc lt gt T 27 15 VIEW ON REAR OF PLANT ice d 885 Dirt Conveyor Conveyor Parts Assembly continued 428 Trakpactor Spare Parts 428 Trakpactor Page 44 10 4 Overband Magnetic Separator REF PARTNUMBER DESCRIPTION 2 QUANTITY ______ 46 126 ____ MAGNETIC SEPARATOR COMPLETE UNIT 17410 __________ BEARING BEARING BACK PLATE 7 9 BEARING TAKE UP PLATE P P gt 14 15 MOTORMOUNTINGPLATE 16 COUPLING ASSEMBLY 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 Overband Magnetic Separator 428 Trakpactor Spare Parts 428 Trakpactor Page 46 10 5 Plant Component Parts Plant General Arrangement PART NUMBER QUANTIT 846 121 1 AX846 1 2480 0054 CATERPILLAR ENGINE POWER PACK 6984 846 72 846 24 7 620 B52 428T 843 52 846 42 846 13 846 27 815 217 501 815 217 003 815 217 502 815 249 001 2301 0005 2563 0013 AX843MAG OVERBAND MAGNETIC SEPA
14. 44 1530 518618 AX846 901 8EN 02a 16 300 TEREX PEGSON 1 5 1 7 Necessary work on live parts and elements must be carried out only in the presence of a second person who cut off the power supply in the case of danger by actuating the emergency shut off or main power switch Secure the working area with a red and white safety chain anda warning sign Use insulated tools only 1 5 1 8 Before starting work on high voltage assemblies and after cutting out the power supply the feeder cable must be grounded and components such as capacitors short circuited with a grounding rod 1 5 1 9 These plants are wired on negative earth Always observe correct polarity Always disconnect battery leads before carrying out any maintenance to the electrical system The battery contains sulphuric acid an electrolyte which can cause severe burns and produce explosive gases Avoid contact with the skin eyes or clothing Trakpactor 428 Issue 2 Page 9 1 5 2 Gas Dust Steam Smoke and Noise 1 5 2 1 Always operate internal combustion engines and fuel operated heating systems only out of doors or in a well ventilated area Before starting the plant in enclosed areas make sure that there is sufficient ventilation Observe the regulations in force at the respective site Dust found on the plant or produced during work on the plant should be removed by extraction not blowing Dust waste shou
15. AX846 901 8EN 02a 240 300 Spare Parts 428 Trakpactor Page 39 AX846 25 iss 03 ee SS 8 Product Conveyor with Magnetic Separator fitted 428 Trakpactor Spare Parts 428 Trakpactor Page 40 Dirt Conveyor Conveyor Parts Assembly sheet 1 paer nman escano uaa eonen 2 2421 00105 BEARING i 2450 5503 SHRINKDISC s mmas WORARGWONOR 5 ners reson eenen 3 Lema moms 10 0 0100 rescore 1 mess vanes provecvoncoven 2 2 m meas ooo sese WEOGNERSERTRUER 2 Ls rewcowncuwe E 2 846 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 N 2 5 Spare Parts 428 Trakpactor Page 42 Dirt Conveyor Conveyor Parts Assembly sheet 2 PART NUMBER DESCRIPTION QUANTITY ASSEMBLY OF 600MM WIDE DIRT 000 CONVEYOR 846 5 1 FEED BOOT 1 AX846 5 2 FEED BOOT CLAMP AX846 5 3 FEED BOOT CLAMP AX846 5 4 FEED BOOT CLAMP 846 32 1 SIDE SKIRT AX846 32 2 REAR SKIRT AX815 76 2 CLAMP PLATE 1 AX815 76 3 CLAMP PLATE AX815 76 4 CLAMP PLATE 846 42 15 05 04 12 03 846 901 8
16. SKIN INJECTION HAZARD Refer to Section 9 1 Safety 27 VY nformation for relevant warning N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 198 300 PEGSON 9 16 3 Track Maintenance Figure 9an Maintenance Schedule first drive oil replacement is to be carried out after 100 operating hours of the gearbox There after replace the drive oil every 1000 hours or at least once per year e Check the drive oil level every 100 working hours Daily Procedure 1 Observe all safety warnings 2 Close down the machine Section 8 2 and implement the Lockout Procedure 3 Check the track rollers and idler wheels for possible leakage 4 Check the track surface of the track rollers idler wheels track shoes and drive sprockets for wear and loose mounting bolts 5 Clean out any heavy build up of material from around the tracks 6 Check the tension of the tracks Section 9 16 1 and adjust tension if necessary Section 9 16 2 Trakpactor 428 9 Maintenance Issue EN 02 Page 95 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Ref
17. 428 Trakpactor Page 67 DANGER FLYING MATERIAL HAZARD Platform is for maintenance only You could be hit in the face or body by flying material Do not use platform when plant is working 300 118 300 224 300 224 PRIOR TO TRANSPORT 1 Fasten all loose items securely 2 Check the plant for loose or damaged parts FALLING HAZARD Do not climb onto moving or working You could fall and be seriously injured parts are safely secured SWITCH OFF LOCKOUT AND during transport TAGOUT machine Always use suitable lifting platform before attempting any maintenance work above 2 metres 6 6 make repairs as found 300 120 300 182 3 Replace missing parts or necessary to ensure that all HEARING HAZARD EXCEEDS 90 dB A May cause loss or degradation of hearing over a period of time Wear proper hearing personal protective equipment 200196 300 196 A DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop Safety Cutout Switch Before opening the crusher the following safety check must be undertaken Run feeder and crusher empty of all mate
18. 160mm 6 3 pitch chain and 3 3m 10 10 longitudinal centres with 400mm 167 wide tracks fitted as standard Total plant weight approximately 33 4 tonne 36 74 U S tons Overall Track width 2700mm 8 10 Plant transport height 3440 11 4 4 2 4 On Plant Product Conveyor 1000mm 40 wide plant mounted troughed belt conveyor 3280mm 107 9 discharge height having a fixed tail section Belt Ripstop EP500 3 with 10mm top and 3mm bottom heavy duty rubber covers A vulcanised joint is included Drive Hydraulic motor drive via coupling to drive drum at preset speed Feedboot Fabricated in mild steel plate with abrasion resistant steel liners access door in one side and fully skirted wear resistant rubber sealing strips along the entire conveyor length BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 44 300 TEREX PEGSON Impact Cradle This is provided beneath the belt below the impactor outlet Adjustment Belt tensioning to be maintained and adjustment at the head drum Covers Canvas type removable dust covers are fitted at the head end 4 2 5 Dirt Conveyor 600 mm 247 wide side discharge troughed belt conveyor with hydraulic folding facility and having a discharge height of 2060mm 6 9 Belt EP500 with 3 5mm top and 1 5mm bottom rubber covers A vulcanised joint is included Drive Hydraul
19. 55 Hydraulic Hoses for Impact Crusher Door 56 Hydraulic Oil Reservoir Components 2 55 56 Hydraulic System Components sheet 1 2 222 1 121 2 1 6 rana 58 Hydraulic System Components sheet 2 55 60 Hydraulic System Components sheet 3 62 10 8 Electrical 64 Electrical aii 64 10 9 Safety Signs with part 66 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 846 901 8 02 204 300 Trakpactor TEREX 428 Spare Parts Issue EN 02 Page 3 PEGSON Blank page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 205 300 Trakpactor TEREX 428 Spare Parts Issue EN 02 Page 4 PEGSON 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 A
20. BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 158 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 55 PEGSON 9 9 7 Changing the Tank Breather DANGER The breather should be changed after the 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 22 Information for relevant warning depending upon conditions Simply unscrew and replace whilst the plant is shut down Section 8 2 WARN 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 159 300 PEGSON 9 9 8 Changing the Pressure Filters Located on each side on the engine within the canopy are the hydraulic pressure filters When the telltale Figure 9x changes from green to red whilst the system is running at normal operating temperature this is an indication that the filter must be replaced immediately Make sure the oil has cooled before changing Procedure 1 Observe all safety warnings 2 Close
21. Fax 44 1530 518618 AX846 901 8EN 02a 45 300 TEREX PEGSON 4 2 9 Standard Power Pack Caterpillar C9 EU EC Emmission Regulations compliant 6 cylinder 4 stroke direct injection emission compliant water cooled diesel power pack in an steel canopy 300 HP continous rated at 1800 rpm under NTP conditions driving the crusher via a manually operated Twin Disc clutch Twin hydrostatic drives are provided for the crusher tracks and also to operate the hydraulic rams These also power the magnetic separator conveyors and feeder motors via a solenoid operated directional control valves All necessary pipe work is to DIN standard 20022 and is provided with steel pipe run to inaccessible areas 4 2 10 Controls Controls are fitted on the plant for the feeder on off and speed conveyors etc with engine and master controls sited ina lockable box mounted below the engine A control unit is provided for the tracking function giving a tracking speed of approximately 0 62mph creep facility 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 Trakpactor 428 4 Design and Function Issue EN 02 Page 6 4 2 11 Chassis Fabricated steel frame of welded construction with supports for the feeder crusher on plant conveyors power unit track
22. Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 9 4 Plant Lubrication and Servicing N WARN 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 ofthe lubrication points are as Information for Lockout follows Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning e Crusher rotor shaft bearing housing grease nipples 5 Feeder vibrating unit bearing oil baths on both sides ofthe feeder vibrating unit Section 7 2 6 and Figure71 e On plant product conveyor head and tailshaft bearing grease nipples located on the bearing housings tailshaft piped to grease points on plant chassis sides e Track unit gearbox 2 oil levels Section 9 16 3 The overband magnet e Dirt conveyor head and tailshaft bearing N assembly is very ica ful and housing grease nipples tailshaft piped Permanently charged The to grease points on plant chassis sides strong magnetic field produced e 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
23. e Rapid setup time Easily transported on and off site 428 Impact Crusher feed opening 42 x28 1067mm x 711mm e Fully skirted product conveyor Two step selfcleaning 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 e Remote control e Dust suppression sprays e Caterpillar water cooled diesel engine Dirtconveyor and magnetic separator fitted as standard e CE Approved BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 42 300 TEREX PEGSON 4 2 Construction Units BL Pegson 1067mm x 711mm 42 x 28 Trakpactor Recycling Plant with Diesel Hydraulic Drive 4 2 1 Impact Crusher The BL Pegson 428 fixed blow bar Impact Crusher has a feed opening of 1067mm x 711mm 42 x 28 The features of the machine are as follows Crusher Frame Fabricated from steel plate and rolled steel sections to form a rugged construction which is fully lined with replaceable liner plates Rotor Running in two heavy duty self aligning spherical roller bearings and fitted with four reversible and replaceable fixed hammers Blow Bars Two full size and two half size standard manganese steel blow bars are fitted as standard and are suitable for material recycling applications They are secured with locking
24. 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 machine Also check to ensure that the hydraulic drive is operating efficiently The variable speed control is situated on the Feeder Conveyor control box Periodically check the condition ofthe blanking mat or mesh panel beneath the grizzly bars for both wear and build up of material and recitify if necessary The plant is supplied with the feeder fitted with a blanking mat all the material passing through the grizzly bars will bypass the crusher and discharge onto the product conveyor Trakpactor 428 9 Maintenance Issue EN 02 Page 47 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUTPLANT Refer to Section 9 1 Safety Information for Lockout Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning Ifa wire mesh underscreen is fitted an alternative option to the blanking mat the material rejected will bypass the crusher whilst the material passing through the mesh will discharge onto the dirt conveyor A two way hand operated flap door can be positioned so that a portion ofthe undersize can be directed to the bypass chute Frequently check the oil levels in the vibrating unit end covers Figure 71 BL Pegson Limited Coalville Engl
25. 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 N beam is rotated or replaced Information for Lockout Proce DANGER the bottom intake armouring mue should be checked and replaced if necessary 5 Using suitable lifting equipment support the beam 6 Using a hammer or beetle drive beam into position When driving in the retractable beam splinters may be CAUTION produced Wear protective clothing and safety glasses 7 Closethe front wall ofthe machine 8 Replace the retractable beam covers on either side ofthe crusher After any maintenance and before starting the crusher warning ensure the rotor can turn without any impedance BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 150 300 PEGSON 9 8 Feeder Operation The vibrating feeder must in addition to the scheduled lubrication requirements Section 9 4 be regularly inspected for any wear damage or breakage with the mainframe and support springs being paid particular attention Rectify faults immediately After first 8 hours of operation change the oil in the vibrating unit end covers Drive side approx 2 1 litres 4 5 US pints Non drive side approx 1 7 litres 3 5 US pints Make sure that the feeder can vibrate
26. 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 A 9 When the belt has reached the correct tension Figure Section 9 11 5 4 L ts A 4 off Fi oosen nuts A 4 off Figure 9aa lishiet nuts CA 5 Unscrew nut C a few turns Repeat this step for the other adjusting screw turning the nut an equivalent amount 10 Ensure the crusher drive guarding is replaced and secured before start up 6 Tighten nut B Repeat this step for the other adjusting screw 7 Repeatsteps 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 ins kgf Ibf kgf Ibf 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 166 300 PEGSON 9 11 3 Changing the engine pulley When changing the plant crushing application from recycling duties to quarry operation or vice versa the engine pulley needs to be changed to alter the crusher speed Plant
27. must be suitably earth bonded by a qualified electrician prior to activating the main isolator switch 1 5 1 2 When working with the plant maintain a safe distance from overhead electric lines If work is to be carried out close to overhead lines the working equipment must be kept well away from them Check out the prescribed safety distances 1 5 1 3 If your plant comes into contact with a live wire e Warn others against approaching and touching the plant Have the live wire de energized Trakpactor 428 Issue ENO2 Page 8 1 5 1 4 Work on the electrical system or equipment may only be carried out by a skilled and qualified electrician or by specially instructed personnel under the control and supervision of such an electrician and in accordance with applicable electrical engineering rules 1 5 1 5 If provided for in the regulations the power supply to parts of plants and plants on which inspection maintenance and repair work is to be carried out must be cut off Before starting any work check the de energized parts for presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements 1 5 1 6 The electrical equipment ofthe plant is to be inspected and checked at regular intervals Defects such as loose connections or scorched or otherwise damaged cables must be rectified immediately BL Pegson Limited Coalville England Tel 44 1530 518600 Fax
28. specification Oil Fill A 6 Clean plugs using clean non flammable solvent 7 Apply pipe sealantto the plugs and install 8 Repeat procedure on the other final drive Oil Level B Figure 9ao Tracks Oil Filling BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 200 300 PEGSON Oil Draining Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 and implement the Lockout Procedure 3 Rotate the gearbox housing until a plug is at the 6 o clock position Figure 4 Unscrew both plugs and discharge the oil 5 Clean plugs using a clean non flammable solvent 6 Apply pipe sealant to the plugs and install 7 Repeat procedure on the other final drive Trakpactor 428 9 Maintenance Issue EN 02 Page 97 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Oil Drain B Figure Tracks Oil Draining BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 201 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON pn Blank page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 202 300 Tr
29. the Feeder Speed Control knob and adjust to the required setting 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 83 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 14 PEGSON Emergency Stop Button Feeder On Off Buttons Hydraulic Oil Pressure Warning Light ENSURE ALL ARE FITTED 4 WARNING LABELS ARE gt N Feeder Speed Control Dirt Conveyor On Product Conveyor Off Buttons On Off Buttons Figure 7g Feeder Conveyor Controls BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 84 300 TEREX PEGSON 7 2 4 Safe Operation of the Plant NEVER leave your Trakpactor unattended whilst it is in WARNING Operation Do check regularly that the oil cooler fan locat
30. this will start the crusher Figure 7f 3 Usingthe hand throttle increase the engine speed to 1800 rpm view on tachometer NB engine speed 1800 rpm required under crushing load 4 Checkthe 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 82 300 TEREX PEGSON 7 2 3 Feeder Conveyor Start Up The control valves mounted on the engine and beneath the Notice feeder are NOT to be used in any circumstances to operate the feeder or conveyors The operation switch on the control panel has to be in PLANT mode for the feeder and conveyors to work Figure 7c The safety warning horn will sound for 10 seconds when the Operation switch is turned from TRACK to PLANT mode Procedure 1 Observe all safety warnings Trakpactor 428 7 Operating Instructions Issue EN 02 Page 13 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 7 1 Safety Information for relevant warning 5 Press the GREEN Feeder button to start the feeder The speed of the feeder will need adjusting depending on the type of material to be crushed so as to maintain an even regular flow through the crusher To adjust the speed of the feeder turn
31. 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 e 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 e Check that the crushing chamber and feed hopper are empty Measure the crusher settings and adjust if necessary Section 9 6 e Check that the Emergency Stops are pulled out Figure 1a BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 76 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 7 PEGSON 7 2 1 Engine Start Up WARNING WEAR PERSONAL 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 Figure 7c 5 the engine control panel Figure 7d turn on the ignition with the key to the first position and once the sequence of d
32. 4 0 4 60 9 11 3 Changing the engine pulley 53 23 2 22 295 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 COnVBVOF Bells iaeia 71 9 12 1 EET 71 9 12 2 Conveyor Belt TENSIONING d Rd EU RdE 73 9 12 3 Maintenance Of 75 9 12 4 Cleaning Conveyor Belts usce 9 13 Plant Overband Magnetic 79 9 14 Plant Dust Suppression 81 9 15 Plant Diesel Engine 82 9 15 1 Manual Clutch Adjustment m T 84 9 15 2 Clutch iaeia 85 9 15 3 Engine ELC Coolant 86 9 15 4 Check Fuel Level 87 9 15 5 Top Up 88 9 16 Plant Vehicle 90 9 16 1 Measuring Track Tension desesesesesesesenaseseceneceeessieentuseeesacusdeusseasseusecu
33. 6 000 4 od 8 Nu 1234 3 SELECT PARAMETER P377 INVOKE INITIAL ZERO ENTER 1 CURRENT ZERO COUNT ZERO CALCULATION FREQUENCY COUNT DISPLAYED ZERO DEVIATION ZERO DEVIATION ACCEPTED INITIAL ZERO COUNT PROCEED WITH Span Calibration With belt running empty at normal speed with test weights applied 0 388 HHHH 5 388 HHHH SP HH 3d HHHH A SE 1234 PAN CALIBRATION E 98 901 8 08529 885 RETURN TO RUN MO SELECT P388 INVOKE INITIAL SPAN ENTER 1 CURRENT SPAN SPAN CALCULATION FREQUNCY COUNT DISPLAYED SPAN DEVIATION ZERO DEVIATION ACCEPTED INITIAL ZERO COUNT 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 0 E 3 56 E 544 ZERO CALIBRATION REQUIRED 38 2 INITIAL SPA
34. 9 1 5 3 Hydraulic and Pneumatic Equipment 10 1 5 4 Hazardous Substances Me m 10 1 6 Transporting Manoeuvring Recommissioning 11 1 7 Position of Emergency Stop Buttons 2222 13 1 8 Plant Warning Sigis 14 1 8 1 Location of Warning Signs Left Hand side of plant 14 1 8 2 Location of Warning Signs ENTANGLEMENT 16 1 8 Satety 18 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 9 300 Trakpactor TEREX 428 Issue ENO2 Page 2 PEGSON 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 N 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 gt DANGER Indicates a potentially hazardous situation which if not avoided could result in death or serious injury gt WARNING Indicates a potentially hazardous situation which if not avoided may result in minor moderate injury It may
35. BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 175 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Page 72 Side Roller and Spindle Slots for Adjustment 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 176 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Page 73 9 12 2 Conveyor Belt Tensioning Both the product conveyor and the dirt conveyor are tensioned on the conveyor head drum Tensioning mechanisms are located on either side of the drum Figure Best practice is to tension each side a little at a time and by the same amount until the belt is tensioned When tensioned the drum must be square to the conveyor frame The correct tension is achieved when the drive drum starts the belt and keeps it running when loaded without any slip occurring The tension screws should be kept clean and well oiled Tightening the Conveyor Belt Figure 9ag Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 and
36. Base Generally caused by shortage of belt tension but excessive heat and or chemical fumes can also give same failure V Belt Swelling or Softening Caused by excessive contamination by oil certain cutting fluids or rubber solvent Whipping During Running Usually caused by incorrect tensioning principally on long centre drives Ifa 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 9 Maintenance Trakpactor 428 Issue EN 02 Page 70 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 174 300 TEREX PEGSON 9 12 Plant Conveyor Belts 9 12 1 Training of Belts Before starting the conveyor it is essential to check that e The conveyor is straight and correctly levelled e The head and tail drums are correctly fitted i e they are level and that their axes are square to the centre line of the conveyor e All troughing and parallel idlers are correctly fitted with their axles square to the centre line of the conveyor the side roller lead is in the correct direction i e forward of centre and all rollers are
37. Clean both the handset and receiver with a damp cloth only and ensure all screws and connections remain tight Infra red control Technical Data Transmitter Supply Voltage 1 x 9v Alkaline battery type 6AM6 6F22 PP3 Transmission type PPM Infra red 3 x Lens type transmitters Operating temperature 20 C to 60 C 4 F to 140 F Housing IP55 Sealed Switch type Tactile sealed Receiver Code 9 10 Matching transmitters Any transmitter with codes 9 10 Supply voltage 12V DC only Relay type KABC12 Relay Contacts rating 16A 240V AC Supply current standby 12V lt 20mA Supply Current Active 12V 80mA Operating temperature 10 C to 60 14 F to 140 F Storage temperature 20 C to 60 4 F to 140 F Relay 1 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 50 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
38. Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 33 300 Trakpactor TEREX 428 2 Technical Information issue 02 6 PEGSON 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 34 300 Trakpactor TEREX 428 3 General Information Issue EN 02 Page 1 PEGSON Contents S 2 3 2 General information 2 3 3 Designated 1 ee 3 3 3 1 Operating Temperature Range annn nnnneeennn nnn 3 34 Crusher eee ee eee ee eee 4
39. PLANT Refer to Section 9 1 Safety Information for Lockout Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 115 300 PEGSON 9 4 3 Daily Weekly and Monthly Checks It is imperative that the operator carries out regular wanNNG and diligent checks before operating the plant especially with operational safety in mind including but not limited to those listed below Additionally the operator should always consider what particular safety hazards could occur at specific operating sites and take steps to eliminate them before commencing work Daily Checks 1 Check that all guarding is complete and properly secured prior to start up Also that all warning signs Section 1 8 are present and readable Check that all the plant emergency stop buttons are operative Section 1 7 Carry out a general inspection of the plant to ascertain that nothing untoward is out of place or damaged so as to cause a safety hazard Carry out daily lubrication schedule Section 9 4 4 Attend to Track Maintenance Section 9 16 3 9 Maintenance Trakpactor 428 Issue EN 02 Page 12 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT PLANT Refer to Section 9 1 Safety Information f
40. Radio Hand Set where fitted nere retten dne vati oq sa 22 7 4 Alternative Control Set with Umbilical Cable where fitted 24 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 71 300 TEREX PEGSON 7 1 Safety Information Loose or baggy clothing can get caught in running machinery WARNING 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 N Terex Pegson machine can cause serious injury or even death WARNING 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 plattorm when reaching any points 2m 6 6 or more above ground level Trakpactor 428 7 Operating Instructions Issue EN 02 Page 2 PERSONAL PROTECTIVE EQUIPMENT ca Se Pars FALLING HAZARD BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 72 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON aaa serious injury or even
41. SHORT ALTERNATIVE MARTENSITIC HIGH MANGANESE BLOW BARS OF 2 x LONG 2 x SHORT CONFIGURATION SHOWN BELOW BUT CAN BE 4 LONG MARTENSITIC BARS 6984 121 MARTENSITIC BLOW BAR LONG 6984 79 HIGH MANGANESE BLOW SHORT 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 AX846 901 8EN 02a 208 300 Spare Parts 428 Trakpactor Page 7 428 Impact Crusher Blow bar Assembly AX846 901 8EN 02a 209 300 Spare Parts 428 Trakpactor Page 8 Impact Crusher Rotor Shaft Assembly REF PART NUMBER DESCRIPTION QUANTITY 7 10 11 2 13 1 2 22100023 WASHER PLAN O 22170011 NUT MEX ____ N S THESE ITEMS ARE A6984 96 23 11 04 AX846 901 8EN 02a 210 300 9 Spare Parts 428 Trakpactor E E 1 xx il 1 all 4 4 1 j a NN Gasca ci SSH gt 57 ANS SS 8 H Ze dl 122 PR 223 2 S DN 7 H SS T CD D 2 24 gt o lt o gt c 1 gt o 5 gt o N Spare Parts 428 Trakpactor Page 10
42. Safety 27 YP information for relevant warning WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 7 Fully screw in the bolt A in the centre of the filter housing 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 CAUTION 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 156 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON dana Filter Condition Indicator Dial Itisimportant to ensure that the black knob is fully screwed Notice before restarting the plant Damage will occur to the plant ifthis 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 amp Level Indicator BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 157 300 PEGSON 9 9 6 Changing the Return Filter Located on top of the hydraulic reservoir tank is the hydraulic return filter When the dial gauge needle Figure 9w enters into the red segment whilst the system is running at normal operating temperature this is an indication th
43. Section 9 1 Safety Information for relevant warning waRNIGG ensure the rotor can turn without any impedance Check the distance between the LOCKOUT MACHINE blow bars Refer to Section 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 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 with the lower seat engaging Notice 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 The blow bar must be in contact BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 132 300 Trakpactor 9 t 428 Maintenance Issue EN 02 of the Rear Impact Apron Adjusting mechanisms Figure 9h undo the set screws A and remove the keep plate B Repeat this step for the other adjusting mechanism Toincrease the gap between t
44. ____ 1 faroa O J 3 _ w sss otrucR 10 ress RETANNGWASER o wsm _ 2 770 MVDRAUICMOTOR m mm 04 11 03 N 5 11 14 1 41 1 11 14 SEE SECTION 10 2 4 FOR THE DRIVESIDE SHAFT COMPONENTS AX846 901 8EN 02a 230 300 Spare Parts 428 Trakpactor Page 29 Feeder Driveside Shaft Assembly 428 Trakpactor Spare Parts 428 Trakpactor Page 30 Grizzly Feeder Non Driveside Shaft Assembly REF PARTNUMBER DESCRIPTION 3 meis 2 4 ewe ______ gt _ s ewe gt s ewe ornoo gt 1 ewe gt mese mu o 2 mee 20 s mmo RETMNNGWASER 010200 sm sew 40 7742 2 _ 1 20 4 ese semmosecR 2001 0200 04 11 03 SEE SECTION 10 2 3 FOR THE DRIVESIDE SHAFT COMPONENTS AX846 901 8EN 02a 232 300 Spare Parts 428 Trakpactor Page 31 Feeder Non Driveside Shaft Assembly 428 Trakpactor Spare Parts 428 Trakpactor Page 32 Blank page AX846 901 8EN 02a 234 300 Spare Parts 428 Trakpactor Page 33 10 3 Conveyor Parts Product Conveyor Conveyor Parts Assembly sheet 1 REF PARTNUMBER DESCRIPTION QUANTITY PLU
45. approximately 4 hours frequency programming factory preset contact Dealer for change e Operating time with fully charged battery D approximately 30 hours Buttons 9 and 0 Used to activate the radio hand set transmitter Button 9 Used to activate the audible warning horn Button 0 Used to stop start the plant feeder where appropriate BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 92 300 PEGSON 2 versions of the 860 system transmitter will be supplied one for European Operations and one for the Rest of the World The only difference is that the European version will include a black stop button The Rest of the World transmitter will feature a Red Stop button Channel 01 434 650 MHz through channel 16 433 900 MHz available in 050 MHz steps Refer to Dealer if frequency change needed Battery Recharging The remote control handset includes a built in chargeable batteries and a charging contact point on the back of the unit Figure A 12 35 volt charging lead suitable for plugging into a vehicle cigarette lighter point is supplied Battery charge status is indicated by 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 cha
46. carrying out maintenance or OCKOUT PROCEDURE LOCKOUT PROCEDURE 1 Switch off engine 2 Remove the ignition key 3 Keep the ignition key on person during lockout Place appropriate maintenance warning signs ie TAG OUT NEVER work alone Turn the Isolation Switch to O when the plant is not being used especially while plant is being transported BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 100 300 Trakpactor TEREX 428 PEGSON Issue EN 02 Page 5 8 2 Closing Down the Plant WARNING 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 Onthe Control Panel Figure 8a press the RED Feeder button to Stop the feeder fitted has been in use shut down by depressing the stop button on the unit 4 Press the RED Dirt Conveyor button to Stop the dirt conveyor 10 Following the closing down procedure 5 Press the Product Conveyor above it is recommended that at the button to Stop the the product cons 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
47. coolant life and protection do NOT mix with conventional coolants Supplemental Coolant Additive SCA poor quality water 9 Change out Cat ELC at 12 000 hours 600 000 miles 1 000 000 kilometers or 6 years whichever comes first GATERPILLAR 2 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 190 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 87 9 15 4 Check Fuel Level WARNING PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant 1 Observe safety warnings warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 2 Check the fuel level indicator Figure 3 Top up fuel level if required Section 9 15 2 e 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 DANGER hazard D 48 CATERPILLAR NEVER remove the filler cap or refuel with the engine running NEVER add gasoline or any other fuel mixes to diesel because of increased fire or explosion risks Fuel Level 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 wel
48. damage breakages wear leaks etc 6 Using the speed control decrease the which should be rectified before engine rpm to 1200rpm Figure 8b amp 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 ete 9 Turn the Ignition Key to the off position to shut down the engine Remove the Ignition Key Shut and lock the Control Box door Lockout the Isolation Switch Figure 8c Ifthe radio hand set where Do not use the emergency stop buttons for routinely stopping the plant BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 101 300 Trakpactor TEREX 428 Issue EN 02 Page 6 PEGSON Emergency Stop Button Feeder On Off Buttons Hydraulic Oil Pressure Warning Light gt N 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 90
49. death In running nip points cause ENTANGLEMENT DANGER DO NOT reach into an unguarded machine Your arm could be pulled in and amputated SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards Hydraulic fluid under pressure can SKIN INJECTION penetrate the skin causing serious HAZARD injury DANGER ALWAYS relieve the pressure from the hydraulic system before carrying out any 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 73 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON Pid adjustment to the plant the following procedure must be WARNING followed When carrying out maintenance OCKOUT PROCEDURE LOCKOUT PROCEDURE 1 Switch off engine 2 Remove the ignition key 3 Keep the ignition key on person during lockout Place appropriate maintenance warning signs ie TAG OUT NEVER work alone Turn the Isolation Switch to O when the plant is not being used especially while plant is being transported BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 74 300 TEREX PEGSON
50. down the machine Section 8 2 and implement the Lockout Procedure 3 Unscrew turn anticlockwise looking from below the filter bowl using 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 ofthe approved pattern and specification 5 Beforereplacing 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 ofthe bowl to ensure an oil tight seal BL Pegson Limited Coalville England Tel 9 Maintenance Trakpactor 428 Issue EN 02 Page 56 N DANGER SKININJECTION HAZARD Refer to Section 9 1 Safety 2 Information for relevant warning N 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 Filter condition Telltale Filter body Bowl PARES ene ot 2 Nut Figure 9x Pressure Filter 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 160 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON ies 9 10 Plant Electrical System Description N WARNING WEAR PERSONAL Fo
51. elements and exhausts are in all place and fully functional Before starting the engine ensure it is safe to do so 1 4 1 2 In the event of material blockage any malfunction or operational difficulty stop the plant immediately and lockout Have any defects rectified immediately 1 4 1 3 In running nip points on moving machinery can cause serious injury or even death Do not reach into unguarded machinery Your arm could be pulled in and amputated Switch off and lockout the plant before removing any safety devices or guarding Trakpactor 428 Issue 2 Page 5 1 4 2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and Repairs During Operation Disposal of Parts and Consumables 1 4 2 1 Observe the adjusting maintenance and intervals set out in these operating instructions except where A Warning horn light gauge or indicator calls for immediate action Adverse conditions necessitate more frequent servicing Observe information on the replacement of parts and equipment These activities may be executed by skilled personnel only 1 4 2 2 When the plant is completely shutdown for maintenance and repair work it must be secured against inadvertent starting by Switching offthe engine and remove the ignition switch key Implementing the lockout procedure e Attaching a warning sign s to the plant in appropriate positions BL Pegson Limited Coalville E
52. implement the Lockout Procedure 3 Loosen locknut A 2 off 4 Tighten square or hexagon ended adjusting screw B 2 off N WARNING WEAR PERSONAL gt PROTECTIVE EQUIPMENT 4 Refer to Section 9 1 Safety Ss Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Belt Tensioning Mechanism Locknut 2 off Square Hex Ended Adjusting Bar B 2off Figure 9ag Conveyor Belt Tensioning Mechanism BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 177 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 5 Once correct tension has been achieved tighten locknut A 2 off WAR 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 on Figure 9ag Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 and implement the Lockout Procedure 3 Loosen locknut 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 cir
53. placed into service A newly fitted power take off s must have its clutch adjustment checked at the following intervals 1 After installation 2 After 4 hours operation 3 After 10 hours operation 4 At the end of each working day for approx 1 week 5 Once a week New clutch plates have a wear in period and the clutch may require several adjustments until the new plates are worn in After wear in clutch adjustments should be made on a weekly basis Heavy duty applications rock crushers etc which have frequent engagements and relatively long periods of clutch slip will require more frequent re adjustments than light duty applications In order to determine if clutch adjustment is required operating shaft torque should be measured as shown over If this force is found to be at or below the MINIMUM shown the clutch should be adjusted until the MAXIMUM force for your model is required to engage the clutch NOTE Do not adjust the clutch to tight Forces above MAXIMUM can cause clutch component failure See over for torque ratings BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 274 300 Trakpactor TEREX 428 PEGSON Appendix Issue EN 02 Page 5 USE SPRING SCALE AT HAND LEVER LENGTH SHOWN IN THE CHART AND MEASURE POUNDS OF PULL REQUIRED TO ENGAGE THE CLUTCH The chart shows the MINIMUM and MAXIMUM values for clutch adjustm
54. platforms provided or a safe and secure platform approved by the local regional safety enforcing authority ALWAYS use a suitable lifting plattorm when reaching any points 2m 6 6 or more above ground level Trakpactor 428 Issue EN 02 Page 2 PERSONAL PROTECTIVE EQUIPMENT ca Se 4 b FALLING HAZARD BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 98 300 Trakpactor TEREX 428 Issue EN 02 PEGSON coal serious injury or even death In running nip points cause ENTANGLEMENT DANGER DO NOT reach into an unguarded machine Your arm could be pulled in and amputated SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards Hydraulic fluid under pressure can SKIN INJECTION penetrate the skin causing serious HAZARD injury DANGER ALWAYS relieve the pressure from the hydraulic system before carrying out any 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 99 300 Trakpactor TEREX 428 Issue EN 02 PEGSON Hia adjustment to the plant the following procedure must be WARNING followed When
55. rotating freely e Inthe case of screw type take up gears that these are adjusted initially to take up slack from the belt and that equal tension 15 applied to each side such that the pulley is square to the centre line of the conveyor e Where skirt rubbers are fitted they are not bearing down heavily on the belt e There is no obstruction on the conveyor that could cause accident or damage when the conveyor is started Trakpactor 428 9 Maintenance Issue EN 02 Page 71 DANGER ENTANGLEMENT HAZARD Refer to Section 9 1 Safety NA Information for relevant warning WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning Tracking should be carried out with the belt empty With very stiffbelts which do not trough well nor make proper contact with the centre idlers roller when empty it may only be possible to track the return strand when empty and the troughed side when loaded Ifthe belt tends to run to one side most likely cause of the trouble will usually be some distance before the point where the running off is apparent and in the case of troughed strand probably at the second or third idler behind the point where the belt is moving out of its true line Under no circumstances should any adjustment be made on the DANGER belt whilst the machine is running There is a risk of trapping parts of the body if this is done
56. sides operator has the sole responsibility to keep anyone e Periodically lubricate hinges cylinder at risiccl ar af ihe machine pivot pins and similar points with oil to prevent seizure during lengthy spells of inactivity BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 114 300 PEGSON 9 4 2 Regular Servicing The Lubrication and Servicing Schedule Section 9 4 4 lists in addition to the lubrication points the attention required to the hydraulic system Section 9 9 Particular attention should be paid to institute a regime of strict adherence from the start of operations for all aspects of routine maintenance Keep a detailed Maintenance Log of all work carried out recording faults experienced and actions taken details of 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 9 Maintenance Trakpactor 428 Issue EN 02 Page 11 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT
57. tension and contamination The tension of the hydraulic pump drive belts is adjusted by two bolts located beneath the hydraulic pump Replacement of Drive Belts Figures amp 9 Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 and implement the Lockout Procedure 3 Remove the diesel engine access covers 4 Loosen the 4 bolts A securing the pump bracket to the pump stool 5 Turn the 2 adjusting screws clockwise to slacken the two drive belts Continue until it is possible to 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 Trakpactor 428 9 Maintenance Issue EN 02 Page 64 DANGER SKIN INJECTION HAZARD Refer to Section 9 1 Safety 27 YP information for relevant warning WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure belts Continue until the belts have reached the correct tension Figure 9ae Section 9 11 5 making sure the pump pulley is aligned with the drive pulley Tighten the 4 bolts A to lock the pump bracket to the pump stool Replace the diesel engine access covers before start up BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618
58. wear correctly fitting 2 2 YV E N A N S I approved personal protective equipment 4 Personal Protective Equipment includes Hat Safety Glasses Hearing Protection Dust Mask Close Fitting Overalls Steel Toed Boots Industrial Gloves and High Visibility Vest Terex Pegson machine can cause serious injury or even death Falling from and or onto FALLING HAZARD WARNING DO NOT climb onto the machine whilst 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 plattorm when reaching any points 2m 6 6 or more above ground level serious injury or even death In running nip points cause ENTANGLEMENT DANGER DO NOT reach into an unguarded machine Your arm could be pulled in and amputated SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 50 300 Trakpactor TEREX 428 5 Transport EN 02 PEGSON ps Hydraulic fluid under pressure can SKIN INJECTION penetrate the skin causing serious HAZARD injury DANGER ALWAYS relieve the pressure from the hydraulic system before carrying out any of maintenance or adjustment ALWAYS use a piece of cardboard to check for leaks DO NOT use your hand If fluid is inj
59. when inspecting the belt whilst it is e 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 ina condition likely to cause damage to the belt are renewed immediately e 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 180 300 PEGSON 9 12 4 Cleaning the Conveyor Belts If your machines conveyor belts are not properly maintained and skirting rubbers are not kept in proper adjustment it may be necessary to remove resultant spillage material and or blockages from the conveyor belts particularly at the feed section It is important that these procedures are followed when DANGER Cleaning the conveyor belts Failure to follow these procedures can result in death or serious injury Procedure 1 The equipment should be switched off and isolat
60. which might affect safety without the supplier s approval In the event of safety relevant modifications or changes in the behaviour of the plant during operation stop the plant and lock out immediately and report the malfunction to the competent authority person Trakpactor 428 Issue ENO2 Page 4 1 3 Selection and Qualification of Personnel Basic Responsibilities 1 3 1 Any work on and or with the plant must be executed by trained reliable and authorised personnel only Statutory minimum age limits must be observed 1 3 2 Work on electrical system and equipment of the plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance ofa 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 12 300 TEREX PEGSON 1 4 Safety Instructions Governing Specific Operational Phases 1 4 1 Standard Operation 1 4 1 1 Take the necessary precautions to ensure that the plant is used only when in a safe and reliable state Operate the plant only for it s designed purpose and only if all guarding protective and safety orientated devices emergency shut off equipment sound proofing
61. 1 8EN 02a 102 300 Trakpactor TEREX 428 Issue EN 02 Page 7 PEGSON Maintenance Due Lamp Diagnostic Lamp Tachometer Diagnostic Display s Scroll Switch Speed Control Fuel Gauge Ignition Key ges Figure 8d Engine Control Panel BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 103 300 TEREX PEGSON 8 3 Emergency Stopping of the Engine IN AN EMERGENCY STOP SITUA TION STOP THE ENGINE AND PLANT OPERATION USING THE EMERGENCY STOP BUTTONS See Section 1 Figure for locations of all the emergency stop buttons When the plant has been stopped using the emergency stop button the Ignition Switch stays Immediately turn the key to the off position When an emergency stop has N been initiated DO NOT at warning tempt to restart the engine until it is safe to do so In the event of an emergency stop operation leaving material in the Impact Crusher this MUST be cleared prior to restarting Refer to Section 7 1 1 for Blocked Crusher Procedure Before restart Section 7 2 1 to 7 2 3 ensure the engine clutch is manually disengaged Delay starting the feeder until material left of the conveyors and screen has cleared If the emergency stop button is then released whilst the Ignition Switch is in on position the safety warning horn will sound for 10 seconds before the engine c
62. 132 DESCRIPTION QUANTITY 1 SWING BEAM SHEAR BLOCK SWING BEAM CONNECTING PIN SWING BEAM CONNECTING PIN WASHER SCREW SWING BEAM PIVOT BAR SWING BEAM LOCATING SLEEVE LINER PLATE SWING BEAM RAIL 2201 0182 PIN SPLIT COTTER 14 15 16 2210 0023 WASHER 2217 0011 18 2432 0577 20 200 50 CHAIN CURTAIN FOR FINES CHUTE ILLUSTRATED A6984 145 CHAIN MOUNTING PLATE A6984 146 CHAIN SPACER A6984 147 CLAMP STRIP AX864 119 RUBBER FOR CHAIN CURTAIN 2321 1102 CHAIN 2 LINKS LONG 2321 1103 CHAIN 3 LINKS LONG 2321 1104 CHAIN 6 LINKS LONG 2321 1105 CHAIN 7 LINKS LONG 2232 1214 BOLT 6984 42 00 23 11 04 RE 2 5 BE NECEN AX846 901 8EN 02a 218 300 17 Spare Parts 428 Trakpactor 00 SS Zv v869 V V V NOILO3S dz 4 1 428 Impact Crusher Grinding Path Swing Beam Liners 3341 929 WN 922 OL 1 Spare Parts 428 Trakpactor Page 18 Impact Crusher Front Apron Adjustment Mechanism REF PART NUMBER DESCRIPTION QUANTITY A6984 12 ADJUSTING ROD A6984 37 ADJUSTING BOLT SLEEVE 3 2436 9144 DISC SPRING 4 2215 0024 ADJUSTING NUT LOCKNUT WITH PRO
63. 2 Series 3000 90 Flange 4 60 ST 1 3000 ST FLANGE 905 1 3000 ST FLANGE 1 4BSP ST 7 16 ST 36 25 12 MALE 3 4 90S 36 25 12 FEMALE 3 4 90 36 25 12 MALE 3 4 905 36 25 12 MALE 3 4 90ST 36 25 12 MALE 3 4 45DEG 36 25 12 MALE 3 4 45DEG 3 85 7 16JIC 905 36 25 12 MALE 3 4 90S 36 25 12 MALE 3 4 90S 7 8JIC ST 7 8JIC 905 1 2 ST 7IBJIC ST R2AT 06 ST 90S 1900 R2AT 12 ST 90S 4100 R2AT 12 ST 90S 6610 R2AT 12 ST ST 2090 AX846HOSEC9 1 01 12 04 2 2 2 2 NM um EN 8 to 2 NUN NN NN 20 EM 22 29 7 10 11 12 13 14 15 16 17 18 19 0 1 2 3 30 31 32 33 34 35 AX846 901 8EN 02a 256 300 Spare Parts 428 Trakpactor Page 55 Hydraulic Hoses continued DESCRIPTION X 1 OFF EACH R2AT 08 R2AT 08 846 9 01 12 04 4 4 4 4 4 4 4 4 4 4 36 37 38 39 0 1 2 3 4 5 6 7 8 9 50 51 52 53 54 55 56 57 58 59 FITTING ST ST ST ST ST ST ST ST ST ST ST ST ST 45 ST 45 ST 90S ST 90S ST 90S ST 90S ST ST ST 90S ST ST ST 45 ST 45 ST 45 ST 45 ST ST ST 90S ST ST 90DEG 45DEG 90DEG 45DEG AX846 901 8EN 02a 257 300 N N N Spare Parts 428 Trakpactor Page 56 Hydraulic Hoses for Impact Crusher Door Rams Hose Number Tag DESCRIPTION X 1 OF
64. 30 518600 Fax 44 1530 518618 AX846 901 8EN 02a 155 300 PEGSON 9 9 5 Changing the Suction Filter Located at the base of the hydraulic reservoir tank is the hydraulic suction filter When the dial gauge needle Figure 9w enters into the red segment whilst the system is running at normal operating temperature this is an indication that the filter must be replaced immediately The filter housing has an internal shut off valve to permit work on the system Make sure the oil has cooled before changing Procedure 1 Observe all safety warnings 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 4 Take steps to collect spillage of oil approx 2 litres 2 US gall before undoing the six socket head screws on the front of the housing to remove the cover plate 5 Remove the old filter and clean inside the housing with lint free cloth before fitting a new filter of the approved pattern and specification 6 Before replacing the cover plate lightly oil the 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 BL Pegson Limited Coalville England Tel Trakpactor 428 9 Maintenance Issue EN 02 Page 52 DANGER SKIN INJECTION HAZARD Refer to Section 9 1
65. 300 Location of Warning Signs Right Hand side of plant 000 28 29 19 5 2 3 82 Warning Labels Right Hand Side Figure 1 AX846 901 8EN 02a 23 300 1 8 2 Location of Warning Signs ENTANGLEMENT HAZARD Safety Decal 300 268 Danger Entanglement Hazard for Crusher amp Panel Decal Location 428 Trakpactor Control Panel 428 Trakpactor A DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop Safety Cutout Switch Before opening the crusher the following safety check must be undertaken Run feeder and crusher empty of all material Close down the plant and impiement the Lockout Procedure Refer to User Manual Check safety cutout switch and wiring for any signs of physical damage Secure chains to protective caps of upper apron adjusters Release outer swivel eye bolts Turn Ignition Key to first position and then select pump mode Depress pump button and using manual lever open crusher until there is approximately 25mm 1 between top of upper frame and main body Select plant mode on control panel Ensure everyone is clear of the machine and all emergency stops are released Attemp
66. 4 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 124 300 TEREX PEGSON Onthe main Control Panel turn the Plant Track Pump operation switch to the PUMP position Next after replacing the engine isolation key turn the engine ignition switch to position although the engine 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 irrelevant to this operation 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 Trakpactor 428 9 Maintenance Issue EN 02 Page 21 Using the two locking pins provided always lock the crusher door in the open position Figure 9c the engine ignition switch to position and implement the lockout procedure Hydraulic Valve Lever Locking Pin Location Figure 9c Locking Pin amp Crusher Open Locking Pin Location BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 125 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 2 9 5 3 Closing the Crusher WARNING PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for rel
67. 5 Nm 535 Ibf ft 2 gt a SECTION 4 VLU UREN SINS CESSIT X NUN NN LI GJ Pivot Pin A6984 150 with 2 x A6984 149 aluminium bronze Bushes 428 Impact Crusher Front Impact Apron Liner Plates Spare Parts 428 Trakpactor Page 14 Impact Crusher Rear Impact Apron Liner Plates REF PARTNUMBER 4 zo sew 2210 0028 WASHER PLAN FORWA2 8 _ WASHER SPRING sasEcT 20 e LLL zo o Ww LC A6984 110 01 26 09 03 ITEM PART NO DESCRIPTION WEIGHT 6984 107 REAR IMPACT APRON 435 kgs A6984 9 24 LINER PLATE 24 2 kgs each A6984 9 28 LINER PLATE 47 2 kgs each A6984 110_01 26 09 03 AX846 901 8EN 02a 216 300 Spare Parts 428 Trakpactor Page 15 A6984 110 iss 01 4 535 TORQUE TO 685 Nm 505 Ibf ft TORQUE TO 725 Nm SECTION Pivot Pin A6984 150 with 2x A6984 149 aluminium bronze Bushes 428 Impact Crusher Rear Impact Apron Liner Plates Spare Parts 428 Trakpactor Page 16 Impact Crusher Grinding path Swing Beam Liners PART NUMBER 6984 43 1 6984 43 2 6984 23 13 6984 23 14 6984 25 4 6984 26 7 6984 51 6984 62 6984
68. 530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 146 300 PEGSON 8 Remove the lifting equipment 9 Screw two M20 eye bolts into the two tapped holes of the bottom inlet beam 10 Using suitable lifting equipment lift out the beam using the eye bolts Fitment of the Bottom Inlet Beam 11 Screw two M20 eye bolts into the two 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 DANGER of the crusher and the crusher feed chute whilst opening closing the access door 14 Rotate the three toggle bolts through 180 and fully tighten 15 Refit the three bolt protection caps 9 Maintenance Trakpactor 428 Issue EN 02 Page 43 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 147 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 9 7 5 Replacing the Retractable WARNING Beam Removal of Retractable Beam WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Inf
69. 8 but must not be less that 5mm 1 4 Tracking the machine with N incorrectly tensioned tracks can cause severe damage to the undercarriage components and may invalidate the warrant WARNING 6 Depending upon the need to either slacken or tension the track s proceed as below Figure 9am Measuring Track Tension continued BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 195 300 PEGSON 9 16 2 Adjusting Track Tension N GREASE UNDER HIGH PRESSURE DANGER To Release Track Tension After measurement Section 9 16 1 Procedure 1 Observe all Safety Warnings 2 Close down the plant Section 8 2 and implement the Lockout Procedure 3 Locate the access aperture on the side of the track frame and remove the cover where fitted to reveal the relief valve inside 4 Next loosen the relief valve by turning anti clockwise using gradual increments until the grease begins to be expelled Care must be taken not to loosen the relief valve too quickly because the grease inside is under high pressure 5 When the correct track tension has been measured Section 9 16 1 turn the relief valve clockwise to tighten and then clean away all trace of expelled grease 6 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
70. ATERIAL HAZARD Do not walk near material discharge areas You are at risk of serious head injury or death WEAR A HARD HAT and EYE PROTECTION at all times when working in the vicinity of machine 300 38 STRONG MAGNETIC HAZARD STAY CLEAR OF MAGNET Strong magnetic field produced by magnet will have serious adverse effect on heart pacemakers which could result in death 300 43 DANGER SKIN INJECTION HAZARD Use a piece of cardboard to check for hydraulic hose leaks DO NOT USE YOUR HAND If fluid is injected under the skin it can cause gangrene Get medical help immediately 300 34 STOP AND LOCKOUT PLANT BEFORE MAINTENANCE 300 39 IMPACT HAZARD Do not allow spring loaded door to be opened unrestrained You could suffer a facial injury 300 44 AX846 901 8EN 02a 268 300 IMPORTANT CHECK FEEDER OIL LEVEL DAILY CHANGE EVERY 200 HOURS FILL TO CENTRE OF SIGHT GLASS REFER TO OPERATOR S MANUAL FOR CORRECT GRADES OF OIL 300 36 Ensure all guards are fitted and all warning labels are complete and legible before operating plant Refer to Operator s manual for location of warning labels 300 40 300 40 Ay DANGER ENTANGLEMENT HAZARD Rotating parts DO NOT enter while rotor is turning Death or serious injury will result SWITCH OFF LOCKOUT amp TAGOUT machine before inspection or maintenance 309 2 300 52 5 are Parts
71. AX846 901 8EN 02a 168 300 TEREX PEGSON Adjustment of Drive Belts Figures amp Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 and implement the Lockout Procedure 3 Remove the diesel engine side access covers 4 Loosen the 4 bolts A securing the pump bracket to the pump stool 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 tension Figure 9ae Section 9 11 4 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 tolock the pump bracket to the pump stool Trakpactor 428 9 Maintenance Issue EN 02 Page 65 N DANGER SKIN INJECTION HAZARD Refer to Section 9 1 Safety 27 YP information for relevant warning WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 7 Replace the diesel engine side access covers before start up BL P
72. Close attention has been paid to all details in assembly running tests and final inspection We are confident that you have received a plant which will give you every satisfaction over a long period To be assured of faultless operation we would ask you to carefully read the following paragraphs and give the required time and attention to essential maintenance cleaning and inspection The plant is simple to operate adjustments are easy to make and expert assistance is seldom required provided that ordinary care is exercised in daily use The plant has been built in accordance with state of the art standards and recognised safety rules It is designed to be reliable efficient and safe when used and maintained in accordance with the instructions given in this manual BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 36 300 TEREX PEGSON 3 3 Designated Use IMPORTANT NOTICE This plant is designed for both demolition and quarrying applications When fitted with manganese steel blow bars the crusher will tolerate small quantities of steel reinforcing bar in the feed However the machine is not designed to accept large pieces of steel or other uncrushable objects and the feed material should be assessed inspected for suitability prior to use It is vitally important that large pieces of steel or similar uncrushable objects are not allowed to enter the crushin
73. E HANDRAIL 23 AX843 63 CRUSHER PLATFORM HANDRAIL DRIVE GUARD AX846 115 PLATFORM SAFETY GATE 1 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 AX846 27 iss O2MOD Ll BN 11011 07 o Xil 1 1 1 i i 1 qi stu si tg ce SIDE ELEVATION a Mc COL 31707 Z Plant Platforms Assembly 428 Trakpactor Spare Parts 428 Trakpactor Page 52 10 6 Plant Tracks REF PART NUMBER DESCRIPTION QUANTITY ___ 2372 0088 GEARBOXDRAINPLUG 4 2372 0007 TRACKSHOE 400MMWIDE 98 TRACK SHOE 500MM WIDE 98 2372 0008 TRACK SHOE BOLT 10 11 2 12 13 14 15 16 eae ee KENNEN 2372 0010 REPAIR LINK TRACK 2372 0011 MASTER PIN TRACK ________ ______ 428 S 01 12 04 846 901 8 02 254 300 Spare Parts 428 Trakpactor Page 53 lt x gt 3 NX WS Nee 9 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 R1AT 24 1 1 2ST 2 3000 90 FLANGE 1660 R1AT 24 1 1 2ST 2 3000 90 FLANGE R1AT 32 1 1 2ST 2 1
74. F EACH 428 IMPACT CRUSHER DOOR RAM HOSES s sts s 1 s ss AX846HYDAUXHC9 Iss 00 121203 Hydraulic Oil Reservoir Components REF PARTNUMBER pESCRIPTION QUANTITY 3 oza FLUDLEVELGAUGEASwitcH 1 3 ferem 3 4 zsstso RETURNUNEFLTER messi 1 lt 2596 0059 RETURNLINEFILTERGAUGE 3 s _ _______ 22 s essa __ mss 506 0054 SUCTONFLTERGAUGE 1 e 25208002 FLANGEDADAPTOR 1 L675 iss 01 01 12 04 AX846 901 8EN 02a 258 300 Spare Parts 428 Trakpactor Page 57 L675 iss 01 Hydraulic Oil Reservoir Components 428 Trakpactor Spare Parts 428 Trakpactor Page 58 Hydraulic System Components sheet 1 sf i z 4 5 7 z 3 779 254596 CYUNDER MPACIOR 006 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 Spare Parts 428 Trakpactor Page 60 Hydraulic System Components sheet 2 REF PARTNUMBER pESCRIPTION QUANTITY 7 i 2 __ 77 568 5005 CYUNDER MPACTOR 0 846 45 155 02 04 12 03 846 901 8 02 262 300 Spare Par
75. HED notice OPPOSITE PAIRS MAINTAIN THE CORRECT ROTOR BALANCE Every time a blow bar is N rotated or replaced check the waRNNG 4rotor protection caps for 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 Fitthe 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 ITIS THE OTHER BLOW BAR OF THE MATCHING PAIR Trakpactor 428 9 Maintenance Issue EN 02 Page 36 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 140 300 PEGSON After any maintenance and N before starting the crusher WARNING ensure the rotor can turn without any impedance 16 Close the crusher Section 9 5 2 17 Check the distance between the long blow ba
76. Impact Crusher Mainframe Liner Plates REF PARTNUMBER DESCRIPTION QUANTITY z z 7 Rp eec RI A6984 19 02mod 23 11 04 1 3 AX846 901 8EN 02a 212 300 11 428 Trakpactor Spare Parts 6L V869V 341 OLE ANOYOL 51108 30165 9 582 56 5 CEYLEXOL p 428 Impact Crusher Mainframe Liner Plates Spare Parts 428 Trakpactor Page 12 Impact Crusher Front Impact Apron Liner Plates REF PARTNUMBER QUANTITY 2112 22 20 2 5 8 2247 0011 NUT HEX PHILIDAS a 1220006 1040 9 A6984 109_01 26 09 03 ITEM PART NO DESCRIPTION WEIGHT A6984 106 FRONT IMPACT APRON 685 kg 6984 9 25 LINER PLATE 19 8 kg each 6 984 103 LINER PLATE 2 __ 56 kg A6984 109_01 26 09 03 AX846 901 8EN 02a 214 300 Spare Parts 428 Trakpactor Page 13 A6984 109 iss 01 TORQUE TO 725 Nm 535 Ibf ft TORQUE 725 535 Ibf ft TORQUE TO 725 Nm 535 Ibf ft TORQUE TO 420 Nm 310 Ibf ft 92956 TORQUE 725 Nm 535 Ibf ft 2 0 4209 TORQUE 72
77. LSO CATER FOR YOUR SERVICE REQUIREMENTS WITH TRAINED SERVICE ENGINEERS BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 206 300 Trakpactor TEREX 428 Spare Parts Issue EN 02 Page 5 PEGSON 10 1 Impact Crusher Parts o Feed Opening 9 Rear Apron Adjustment Shaft 10 Rear Apron Rotor 11 Front Apron Liner Plates Rotor Protection Cap 12 Front Apron Adjustment Blow Bars Hammers 13 Front Apron Swing Beam Grinding Path 14 Crusher Mainframe Swing Beam Liner Plates 15 Swing Beam Rails Rear Apron Liners Plates 16 Swing Beam Adjustment Impact Crusher 428 Trakpactor BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 207 300 Spare Parts 428 Trakpactor Page 6 Impact Crusher Blow bar Assembly A6984 93 ROTOR SHAFT 1 N S 2527 1048 2220 8831 THESE PARTS N S 2520 6558 FOR THE EXTRACTION TOOL 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 6984 83 HIGH CHROME BLOW BAR LONG A6984 79 HIGH MANGANESE BLOW BAR
78. MMER BLOCK BEARING REMOTE GREASE PIPING PART OF KIT FOR HEADSHAFT BEARINGS ONLY 7 2 3 4 18 6 7 18 19 0 22 CONVEYOR PIN HEAD TO CHASSIS 2 CONVEYORHEADGUARD a 4 2 25 axen cowvEvoRUPPERGUARD 26 axess CONVEYORUPPERGUMRD 1 _ aeon CONVEYORMDDLEGUARD 1 _ 28 aeaoe CONVEYORMDDLEGUARD r _ CONVEVORLOWERGUARO 2 CONVEYORLOWERGUARD r _ ___ CANVAS WIND COVER NOT APPLICABLE 32 AX846 10 FOR PLANT FITTED WITH MAGNETIC 1 SEPARATOR SEE SEPARATE PAGE AX843 22 SUPPORT WIRE ROPE 2495 3000 MULTI TROUGH IDLER SET COMPLETE 846 121 iss 02mod sht 1 01 12 04 5 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 NUMBER DESCRIPTION QUANTITY 2489 1055 1055 SEPARATE OUTER ROLLER FOR ITEM 34 2489 3005 CLAMP WITH FIXINGS FOR ITEM 34A CLAMP WITH FIXINGS FOR ITEM 34A FIXINGS FOR ITEM 34 3e ree o GUARD INSIDE CHASSIS CLAMPING STRIP mense renn owens e 1 se nese esa
79. N COUNT n HHHH u cp FREQUENCY COUNT DISPLAYED 4 ot 3 8 DURING CALIBRATION 988 INITIAL ZERO COUNT z FREQUENCY COUNT DISPLAYED Sd 99 2 DURING CALIBRATION 54 DEVIATION 000 Sf od 5 8 NEW SPAN COUNT DEVIATION HHHH NEW ZERO COUNT CALIBRATION COMPLETE REMOVE TEST WEIGHTS CALIBRATION COMPLETE 9 RETURN TO RUN MODE PRESS TO RETURN RUN MODE TO RETURN 1 E PRESS gt lg 34 E Sr 88 SPAN REQUIRED 5 8 AX846 901 8EN 02a 292 300 5 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 50 2 INFRA RED Remote Feeder Operation where fitted This method of remotely stopping and starting the feeder is only supplied with plants not equipped with radio controlled remote feeder control The operating range is dependant upon conditions but has a range of up to 30metres 98 feet Procedure 1 Observe all safety instructions 2 Take the infra red control from the control box and first become familiar with the functions of the individual buttons 3 Turn the Feeder Remote switch on the pla
80. N WAR N DANGER 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 193 300 PEGSON 9 16 Plant Vehicle Tracks It is essential that the tracks are correctly tensioned at all warning times Check track tension regularly Keeping the track properly adjusted will increase the service life of the track and drive components When ordering Spare Parts it is essential to quote the plant serial number with either a S or T suffix Frequently check for loose bolts oil leaks master pins are correctly located and tight general wear and damage correct track tension etc to ensure safe working and long life When travelling on a gradient the tracks should be driven with the track idler rollers Figure 9an in front Procedure 9 16 1 Measuring Track Tension 1 Observeall 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 le
81. ON 4 2 2 Vibrating Grizzly Feeder BL Pegson 1080 wide x 3800mm long 43 x 127 6 Vibrating Grizzly Feeder including Vibrating Unit Heavy duty mechanical type with twin counter rotating shafts with oil lubricated bearings and gears Pan 12mm 0 5 thick abrasion resisting steel bottom plate is included in the welded construction Grizzly Section Double section of fixed welded tapered finger type bars at 50mm 2 spaces at discharge end fabricated in 20mm 0 8 thick abrasion resistant steel Renewable tips are included on the bars nearest the crusher Underdeck Supplied with a removable blank rubber mat fitted to allow all grizzly fines to be directed on to the main product conveyor An optional wire mesh having apertures to pass 20 mm material can be supplied the screened fines would then discharge to the plant mounted dirt conveyor and the oversize onto the main product conveyor Drive Hydraulic motor mounted on the vibrating unit Control Variable speed is achieved via a rotary control located on the Feeder Conveyor control box Facility is also included to stop start the feeder from the remote control handset but not to vary the speed Trakpactor 428 4 Design and Function Issue EN 02 Page 4 Hopper Fixed feed hopper fabricated in 8 mm 0 3 abrasion resistant steel plate suitable braced with steel sections 4 2 3 Track Frame Heavy duty size nine track frame having
82. Plates Access Panels Figure 9p Rear Impact Apron Access Panels and Wear Plates BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 144 300 PEGSON 9 7 3 Replacing the Side Wall Liner Plates Procedure Observe all the safety warnings crusher until completely empty Close down the plant Section 8 2 and implement the lockout procedure Open crusher Section 9 5 1 Remove one of the axial locks from the top Blow Bar Figure 9k Secure the rotor lock into the place where the axial lock seats and bolt the rotor lock to the side of the crusher body Figure 91 amp 9m Clean out any debris from the liner plates the side wall liner plates are bolted into position from the outside of the crusher To remove replace any of the side wall liner plates support the liner from the inside of the crusher whilst removing fitting the bolt Side Liner Tightening Torque 420Nm 310151 ft Trakpactor 428 9 Maintenance Issue EN 02 Page 41 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure In the main wear area the liner plates can be rotated or Notice interchanged to achieve optimal utilisation of the liner plates The bottom inlet beam is locat
83. RATOR ASSEMBLY AX846 L675 2592 2006 AX846 92 AX846 106 1 2443 1700 2443 1673 2443 8337 AX846 113 2450 8060 2441 0482 AX846 3 AX846 35 AX846 6 1 AX846 6 2 2424 5021 843 43 1 2321 1107 13 843 61 843 43 2 846 128 1 846 128 2 846 128 3 862 248 1 FEED CE 1 33 __ 846 6 DEFLECTOR PLATE ASSEMBLY 1 34 843588 ______ SIDERUBBERCURTAIN 2 35 __ 846 70 ______ SIDERUBBERCURTAIN 2 36 __ 846 133 501 TOOLBOX 1 846 133 502 TOOL DOOR ASSEMBLY 1 2301 0005 COMPRESSION LOCKING LATCH 1 AX815253 0001 PLASTIC HINGE 1 AX846 133 CHAIN CHAIN ASSEMBLY CE 70 AX846GA_mod_01 12 04 C m 4 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0 4 REF 6 8 __9 10 M C RENNES EE NE 14 15 16 a 18 18 19 20 21 22 29 NEN 24 25 26 28 25 30 32 NE mm 31 1 1 1 NB Fixings are not included with the above parts unless specifically ordered AX846 901 8EN 02a 248 300 47 Spare Parts 428 Trakpactor AX846GA issue 02 VIEW ON 3 J DAL E il j V PES rmn ai MT AAL UTES
84. REFER TO OPERATOR S MANUAL FOR CORRECT GRADES OF OIL 30037 IMPORTANT DRAIN WATER FROM MANIFOLD AT NIGHT IN COLD WEATHER Read and understand operator s manual and all safety signs before using or maintaining machine If you do not understand the information in the manuals consult your supervisor the owner or the manufacturer FALLING MATERIAL HAZARD Do not walk near material discharge areas You are at risk of serious head injury or death WEAR A HARD HAT and EYE PROTECTION at times when working in the vicinity of machine STRONG MAGNETIC HAZARD STAY CLEAR OF MAGNET Strong magnetic field produced by magnet will have serious adverse effect on heart pacemakers which could result in death Safety DANGER SKIN INJECTION HAZARD Use a piece of cardboard to check for hydraulic hose leaks DO NOT USE YOUR HAND If fluid is injected under the skin it can cause gangrene Get medical help immediately uid STOP AND LOCKOUT PLANT BEFORE MAINTENANCE IMPACT HAZARD Do not allow spring loaded door to be opened unrestrained You could suffer a facial injury IMPORTANT Trakpactor 428 Issue 2 Page 18 CHECK FEEDER OIL LEVEL DAILY CHANGE OIL EVERY 200 HOURS FILL TO CENTRE OF SIGHT GLASS REFER TO OPERATOR S MANUAL FOR CORRECT GRADES OF OIL Ensure all guards are fitted and all warning labels are complete and legible before operating plant Refer to Ope
85. ROTECTIVE EQUIPMENT fitting loosened may help to expel the grease Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Track Surface Idler Roller Drive Sprocket Skid plate Relief Valve inside access aperture Final Drive Track Roller Unit Figure 9an Vehicle Track Parts BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 197 300 PEGSON To Increase Track Tension After measurement Section 9 16 1 Procedure Observe Safety Warnings Close down the plant Section 8 2 and implement the Lockout Procedure Locate the access aperture on the side of the track frame and remove the cover where fitted to reveal the relief valve inside Connect the grease gun to the grease fitting and add grease until the track tension is within the specified dimension Section 9 16 1 See Section 9 4 4 for the grease type and specification 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 ifthe track s sag is too great Ifroom for manoeuvring the plant is restricted drive the plant forwards and backwards several times over a shorter distance Trakpactor 428 9 Maintenance Issue EN 02 Page 94 DANGER
86. TECTIVE SLEEVE 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 Spare Parts 428 Trakpactor Page 20 Impact Crusher Rear Apron Adjustment Mechanism REF PARTNUMBER pESCRIPTION 6 Wer T 5 A6984 36_06 01 12 04 NB THERE ARE 2 OF THE ABOVE MECHANISMS ON THE 428 IMPACTOR AX846 901 8EN 02a 222 300 21 428 Trakpactor Spare Parts ls N 177 22742 428 Impact Crusher Rear Impact Apron Adjustment Spare Parts 428 Trakpactor Page 22 Impact Crusher Grinding Path Swing Beam Adjustment Mechanism REF PARTNUMBER 6 7 2 5 A6984 46_04 26 09 03 AX846 901 8EN 02a 224 300 23 428 Trakpactor Spare Parts 8 252 ds LS Se zi 428 Impact Crusher Grinding Path Swing Beam Adjustment Mechanism Spare Parts 428 Trakpactor Page 24 10 2 Feeder Parts Grizzly Feeder Mainframe assembly REF PARTNUMBER DESCRIPTION sw SPRING OISCHARGEEND 4 4 mess wr
87. TED 14 2686 0042 COMPLETE KIT INCLUSIVE OF ITEMS 15 TO 20 BELOW os mee RADIO HAND SET TRANSMITTER RED 16 2686 0043 STOP BUTTON USA amp REST OF THE WORLD REMOTE INFRA RED HANDSET WHERE i 1 16 01 12 04 SEE THE HYDRAULIC SYSTEM FOR THE HYDRAULIC VALVE SOLENOIDS AX846 901 8EN 02a 266 300 5 are Parts 428 Trakpactor Page 65 ENSURE ALL GUARDS ARE FITTED AND ALL WARNING LABELS ARE COMPLETE AND LEGIBLE BEFORE 20 Electrical Items 428 Trakpactor Spare Parts 428 Trakpactor 10 9 Safety Signs with part numbers Page 66 Note For positions of these Warning Signs refer to Section 1 8 Figures 1b amp 1c DANGER ENTANGLEMENT HAZARD Do not reach into unguarded machine you can be pulled Death or serious injury will result Keep all guards in place SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards 300 32 IMPORTANT CHECK CONDITION OF FILTERS ON A REGULAR BASIS CHANGE ELEMENTS WHEN INDICATORS SHOW RED CHECK OIL LEVEL WEEKLY REFER TO OPERATOR S MANUAL FOR CORRECT GRADES OF OIL 300 37 IMPORTANT DRAIN WATER FROM MANIFOLD AT NIGHT IN COLD WEATHER 300 42 Read and understand operator s manual and all safety signs before using or maintaining machine If you do not understand the information in the manuals consult your supervisor the owner or the manufacturer 300 33 FALLING M
88. TEREX PEGSON ADVANCED CRUSHING TECHNOLOGY 428 TRAKPACTOR PLANT USER MANUAL OPERATION ds INSTALLATION PARTS THE QUEEN S AWARDS MAINTENANCE AND SERVICE 41215429 2002 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 AX846 901 8EN 02a 1 300 AX846 901 8EN 02a 2 300 TEREX PEGSON 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 AX846 901 8EN 02a 3 300 AX846 901 8EN 02a 4 300 d E TEREX PEGSON 9 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 awa
89. 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 TEREX 2 PEGSON Issue EN 02 Hours Run Date BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 297 300 Trakpactor 428 TEREX 2 PEGSON Issue EN 02 Hours Run Date BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 298 300 Trakpactor 428 TEREX 2 PEGSON Issue EN 02 Hours Run Date BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 299 300 AX846 901 8EN 02a 300 300
90. actor TEREX 9 Maintenance es 02 PEGSON Page 7 9 2 Weights of Components Weights of crusher and feeder assemblies these should be consulted when arranging suitable lifting equipment 1 Weight kg NOTE FORINDIVIDUAL WEIGHTS OF THE IMPACT CRUSHER LINER PLATES PLEASE REFER TO THE PARTS LISTS IN SECTION 10 weights given are for guidance only and appropriate allowances should be applied for the sizing of lifting or transporting equipment WARNING BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 111 300 TEREX PEGSON 9 3 General Information When performing maintenance always observe rules provided in the safety Section Breakdown caused by insufficient or improper maintenance will cause high repair costs and long term standstill Therefore regular maintenance is imperative 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 N operated in extreme climatic Conditions e g below 10 C or above 40 C 7 14 to 104 F or in very dusty conditions for longer period of time the maintenance schedules will change Ask your local BL Pegson dealer or BL Pegson Technical Department for advice Trakpac
91. ading 3 Close down the plant Section 8 2 and implement the Lockout Procedure 9 Maintenance Trakpactor 428 Issue EN 02 Page 90 WARNING WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Prior to attempting any manoeuvring of the plant the tracks must be free of obstructions including crushed material and fines Do not push or tow the plant Failure to observe this warning could result in injury to persons and damage to the plant which may invalidate warranty BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 194 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 91 4 One track at a time measure the sag on the top part of the track on the longest WAR N 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 amaximum of 15mm 5
92. akpactor TEREX 428 Spare Parts Issue EN 02 Page 1 PEGSON Contents 10 1 Impact Crusher Parts Rn rure 5 Impact Crusher Blow bar Assembly 6 Impact Crusher Rotor Shaft Assembly Ee Bere 422 225425244 4444444244 8 Impact Crusher Mainframe Liner 4 1 1 10 Impact Crusher Front Impact Apron Liner 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 P rtS m E 24 Grizzly Feeder Mainframe assembly 24 Grizzly Feeder Vibrating Unit e enses 26 Grizzly Feeder Driveside Shaft Assembly 2 28 Grizzly Feeder Non Driv
93. also be used to alert against unsafe working practices gt CAUTION Indicates a statement of company policy as the message relates directly or indirectly to the safety of personnel and protection of property gt NOTICE BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 10 300 TEREX PEGSON 1 2 Organisation Measures 1 2 1 Ascertain from the appropriate Authority and observe all statutory and any other regulations that may apply to the planned location before operating the Trakpactor Loose or baggy clothing can get caught in running machinery Where possible when working close to engines or machinery only do so when they are stopped If this is not practical remember to keep tools test equipment and all other parts of your body well away from the moving parts For reasons of safety long hair must be tied back or otherwise secured garments must be close fitting and no jewellery such as rings may be worn Injury may result from being caught up in the machinery or from rings catching on moving parts Always wear correctly fitting EN ANSI approved personal protective equipment Personal Protective Equipment includes Hard Hat Safety Glasses Hearing Protection Dust Mask Close fitting Overalls Steel Toed Boots Industrial Gloves and a High Visibility Vest 1 2 2 You can be injured if you do not obey the safety instructions as indicate
94. an be restarted Section 7 2 Trakpactor 428 Issue EN 02 Page 8 8 3 1 Emergency Stop Buttons Pressing any of the buttons will stop the diesel engine and the button will remain engaged until physically released by pulling or twisting depending upon the type fitted the button knob The engine cannot be started if any of the emergency buttons remain depressed 8 3 2 Testing Buttons Daily before commencing N crushing operations test each emergency stop button is operative Procedure 1 Observeall safety warnings WARNING 2 Follow the safe start up procedure section 7 2 3 Startthe engine section 7 2 1 4 Testeach emergency stop button in turn to cut out the engine and following the resetting ofthe tested button repeat the process for each of the other emer gency stop buttons Section 1 7 and also the stop button on the remote control handset Figure 5b The emergency stop button on the main control panel can be tested during the 10 second warning prior to engine start in which case the sound will cease ifthe button is operative BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 104 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 1 PEGSON Contents Safety Inf rmation 3 9 2 Weights of Components aos ce ese 7 9 3 General Information
95. and Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 151 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 9 8 1 Removing the Underscreen Mesh or Blanking Mat WARN WEAR PERSONAL gt PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety S Information for relevant warning LOCKOUT PLANT Refer to Section 9 1 Safety Information for Lockout Procedure The plant feeder can be fitted with wire underscreen to discharge material to the dirt conveyor or may initially be fitted witha blanking mat which directs all material passing et through the grizzly bars on to the on plant product conveyor If required to alter the configuration either to change from one to the other orto remove altogether follow the procedure below K FALLING HAZARD Refer to Section 9 1 Safety 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 5 Loosen the locking nuts on the 3 screws located underneath the feeder sufficiently to disengage the hooked ends of the panel Figure 9t Mesh Mat Access Panel 6 With the hooked rod tool provided reach through the grizzly bar
96. and repeat the steps 1 4 ifthe Trakpactor 428 9 Maintenance Issue EN 02 Page 92 DANGER SKIN INJECTION HAZARD Refer to Section 9 1 Safety 22 Information for relevant warning N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Grease coming out of the relief valve under pressure can WARNING penetrate the body causing injury or death do NOT watch the relief valve to see if grease is escaping but instead watch the track adjustment cylinder to verify that the track is being loosened DO NOT OVER TENSION THE TRACKS Refer to Section 9 16 1 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 196 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 93 PEGSON track s sag is not enough If room for manoeuvring the plant is restricted drive the plant forwards and backwards several times over a shorter distance Refer to Section 9 1 Safety Information for relevant warning If the track fails to slacken after the P 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 DANGER SKIN INJECTION HAZARD WARNING that running the tracks with the grease WEAR EE P
97. are supplied with an engine pulley sized to suit each type of crushing application one fitted and one loose 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 size for each type of crushing operation Under no circumstances fit pulleys ofa 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 Trakpactor 428 9 Maintenance Issue EN 02 Page 63 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 5 Tighten the crusher drive belts Section 9 11 2 BL Pegson Limited Coalville England 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 167 300 PEGSON 9 11 4 Replacement and Adjustment of Hydraulic Pump Drive Belts Note Drive belts should be inspected regularly for wear correct
98. asured on one occasion for the Trakpactor plant running empty ie not crushing recorded as shown on the site layout 17 4 SCALE 428 Trakpactor c 9 2 lt 42 All at im 06 01 07 Layout Noise Recording Poitions 3 ri SP 1MS 19497 punos 7 68 1 5 punos 1ojoedye1 827 9J00 N JOSsessy 55955 aSION 2001 8101 986 CLL 164 9 8 998 164 608 6 28 0 88 071 281 5 58 678 198 998 488 9 6 066 916 466 816 0706 016 68 168 890 6 8 996 0786 20 90 81 O CO t 10 O CN NNN QN sf lO OM OD 5 2 gt 2 5 AX846 901 8EN 02a 273 300 Trakpactor TEREX 428 Appendix Issue EN 02 Page 4 PEGSON 11 2 Manual Engine Clutch Marine amp Industrial Transmissions Ltd Queenborough Shipyard Queenborough Kent 11 5EE Tel 44 0 1795 580808 Fax 44 0 1795 580900 email Ukmitgroup aoi com ey 1509002 Tate POWER TAKE OFF CLUTCH ADJUSTMENTS All new and replacement power take off units must have the clutch adjustment checked before being
99. at the filter must be replaced immediately Make sure the oil has cooled before changing In the event hydraulic oil needs to be added to maintain the correct level on the gauge Figure 9w this should be poured in after removing the cover see below but with the filter element left in place Check the system for leaks if topping up becomes necessary Procedure 1 Observe all safety warnings 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 Trakpactor 428 9 Maintenance Issue EN 02 Page 54 DANGER SKIN INJECTION HAZARD Refer to Section 9 1 Safety 27 YP information for relevant warning 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
100. ath 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 Safety Cutout Switch Before opening the crusher the following safety check must be undertaken Run feeder and crusher empty of all material Close down the plant and implement the Lockout Procedure Refer to 00 224 Check safety cutout switch and wiring for any signs of physical damage Secure chains to protective caps of upper apron adjusters Release outer swivel eye bolts Tum Ignition Key to first position and then select pump mode Depress pump button and using manual lever open crusher until there is approximately 25mm 17 between top of upper frame and main body Select plant mode on control panel Ensure everyone is clear of the machine and all emergency stops are released Attempt to start the engine No cranking of the engine should occur If the engine attempts to start lockout the machine and contact your dealer to investigate the problem Do not attempt to run until the fault has been corrected Implement the Lockout Procedure and refer to the user manual before proceeding with maintenance moving rotor or flying material Entry by authorized trained personnel only L
101. ation check that all emergency stop buttons are operative refer to Section 8 3 The plant should be fed by an excavator such that the bucket DANGER does not pass over or near to personnel BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 85 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 16 PEGSON DO NOT STAND ON THE Actions During Running In Period A N UPPER MAINTENANCE DANGER PLATFORM WHILST THE Checks on the Trakpactor are IMPACT CRUSHER AND crucial during the first week of FEEDER ARE OPERATING NOTICE 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 Afterseveral days use re check clutch hydraulic oil level Fig
102. ay 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 0013 1 AX846 901 8EN 02a 277 300 Change of Engine 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 diff
103. before carrying out any repair work Trakpactor 428 Issue ENO2 Page 10 1 5 3 4 Hydraulic and compressed air lines must be laid and fitted properly Ensure that no connections are interchanged The fittings lengths and quality ofthe hoses must comply with the technical requirements 1 5 3 5 Always practice extreme cleanliness servicing hydraulic components 1 5 3 6 Hydraulic fluid under pressure can penetrate the skin causing serious injury If fluid is injected under the skin it must be surgically removed or gangrene will result Get medical help immediately Alwaysrelieve pressure from the hydraulic system before carrying out any kind of maintenance or adjustment Always use a piece of cardboard to check for leaks Do not use your hand 1 5 4 Hazardous Substances Ensure that correct procedures are formulated to safely handle hazardous materials by correct identification labelling storage use and disposal all strictly in accordance with the manufacturers instructions and that all applicable regulations are observed at all times BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 18 300 Trakpactor TEREX 428 Issue ENO2 PEGSON P 1 6 Transporting 1 6 7 Manoeuvri ng 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 p
104. cceeceecnneoece 90 9 16 2 Adjusting Track 92 9 16 3 Track Maintenance 95 Ol Filling and Draining 96 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 106 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 3 PEGSON 9 1 Safety Information caught in running machinery PROTECTIVE EQUIPMENT WARNING ALWAYS wear correctly fitting al YV E N A N S I approved personal protective equipment Y Personal Protective Equipment includes Hard Hat Safety Glasses Hearing Protection Dust Loose baggy clothing can get PERSONAL Mask Close Fitting Overalls Steel Toed Boots Industrial Gloves and High Visibility Vest Terex Pegson machine can cause serious injury or even death Falling from and or onto a FALLING HAZARD WARNING DO NOT climb onto the machine whilst 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 107 300 TEREX 428 9 Maintenance Issue EN 02 PEGSON ey s
105. crease the gap between the blow bar and apron tighten turn clockwise both adjusting nuts B Figure 9g in turn a little at a time and by an equal amount To decrease the gap between the blow bar and apron loosen turn anti clockwise both adjusting nuts B Figure 9g in turn by a little at a time and by an equal amount Ensure the adjusting nut B always sits on the guiding notice Sleeve and disc springs C Adjusting Nut B Chain D shown loose Trakpactor 428 9 Maintenance Issue EN 02 Page 27 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure When the gap is correct tighten the locknut with protection cap A and lock against the adjusting nut B Repeat this step for the other adjusting mechanism Closethe inspection doors and secure with the locking clip Locknut with Protection Cap A Disc Springs C Chain D shown fixed Figure 9g Front Impact Apron Adjustment BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 131 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 28 9 6 3 Adjusting the Rear Impact Apron WA R N After any maintenance WEAR PERSONAL N before starting the crusher PROTECTIVE EQUIPMENT Refer to
106. crew nut few turns Repeat this step for the other adjusting screw turning the nut an equivalent amount 6 Tighten nut Repeat this step for the other adjusting screw 7 Ifthe 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 164 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Page 61 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 97 When the belts have reached the correct tension Figure Section 19 11 5 tighten nuts A 4 off 8 Ensure the crusher drive guarding is fully replaced and secured before start up B 4 Figure Crusher Drive Belt Tensioning Mechanism LH Side BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 165 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 62 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
107. cumstances should any adjustment be made DANGER belt whilst the machine is running There is a risk of trapping parts of the body if this is done BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 178 300 TEREX PEGSON 9 12 3 Maintenance of Conveyor s The following checks should be made regularly in order to keep the conveyor s in good working order e Observe all safety warnings e Close down the plant Section 8 2 and implement the Lockout Procedure Ensure that central feed onto the conveyor belt is maintained at all times and that the belt at the point of feed is kept straight and central at all times e Inspect the skirt plate sealing strips and ensure that they are adjusted close enough to the belt to prevent spillage or material jamming between the seals and the belt but at the same time not bearing hard on the belt e 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 e Inspect the condition of the conveyor belt regularly and arrange for the earliest possible repair of any damage which may have occurred as this can make a worthwhile extension of the useful life of the belt Repair a cut or tear in the rubber by cleaning with benzine and plugging with a rubber repair compound Trakpactor 428 9 Mainte
108. d Procedure Figures 5b amp 7e To operate the hand set 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 hand set are pulled out Figures 1a and 7 3 Start the engine Section 7 2 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 be operated remotely 7 Operating Instructions Trakpactor 428 Issue EN 02 Page 20 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 7 1 Safety Information for relevant warning LED 6 Track Directional Control Buttons Not used to 4Manoeuvre Vl 0 2 x Safety Buttons also Horn amp Feeder Remote Control Stop Button Figure 7j Remote Control Hand Set BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 90 300 TEREX PEGSON 7 3 2 Radio Feeder Remote Operation Where fitted To operate the feeder remotely the conveyors and feeder must first be switched on manually and the feeder speed set manually Section 7 2 3 Procedure 1 Observe all safety warnings 2 Remove the Radio Remote Hand Set from the Control Box Figure 7b 3 Ensure that the Emergency Stops on the plant and the stop button on the hand set are pulled out Figures 1 and 7k 4 Follow the procedures in S
109. d Procedure Using a high pressure air hose FALLINGHAZARD 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 ofa 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 182 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 9 13 Plant Overband Magnetic Separator Magnetic Separator The self cleaning suspended magnet utilises atwo 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 N very powerful and permanently warning 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 Shedde
110. d for approaching this situation due to the potential dangers of tramp metal being released Due care and attention should be given to where the released tramp metal will fall to avoid any injury to personnel Once this has been decided it should be incorporated into a permit to work procedure to be issued by the manager This system should cover things such as notification to the manager isolation methods of removal of excess stone safe positions for personnel Should any further information be required with regard to the clearance of blocked crushers then reference can be made to the British Aggregate Construction Materials Industries BACMI document Clearing Blocked Crushers This document provides recommended procedures and advice on risk assessment BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 75 300 TEREX 428 7 Operating Instructions Issue EN 02 Page 6 PEGSON 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 WARNING ensure that all safety aspects e 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
111. d 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 do not fall outside the minimum and maximum dimensions shown 4 All settings are subject to the suitability of the feed material BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 39 300 Trakpactor TEREX 428 3 General Information Issue EN 02 Page 6 PEGSON 3 4 2 Estimated Product Analysis Percentage Passing Material Sizes 05 Sieve Series 5 2 100 Estimated Product Envelope 90 with Grinding Path Fitted 1 e 5 200 100 T No 30 No 16 80 Estimated Product Envelope 2 with Grinding Path Excluded me 2 7 E J 443 EA 1 Feed 10 LL AA s Oe CAUMAR AIRE E 2 85888 Figure 3d Product Analysis BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 40 300 Trakpactor TEREX 428 4 Design and Function Issue EN 02 Page 1 PEGSON
112. d on warning stickers Trakpactor 428 Issue 2 Page 3 Observe all safety instructions and warnings attached to the plant See to it that safety instructions and warnings attached to the plant are always complete and perfectly legible Keep warnings and instruction labels clean Replace unreadable or missing labels with new ones before operating the plant Make sure replacement parts include warning or instruction labels where necessary 1 2 3 Understand service procedure before doing work Keep area clean and dry Never lubricate clean service or adjust machinery while it is moving Keep hands feet and clothing clear of power driven parts and in running nip points Disengage all power and operate controls to relieve pressure Stop the engine Implement lockout procedure Allow the machinery to cool Keep all parts in good condition Ensure that all parts are properly installed Fix damage immediately Replace worn and broken parts Remove any build up of grease oil and debris Disconnect battery ground cable before making adjustments on electrical systems or welding on plant BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 11 300 TEREX PEGSON For the execution of maintenance work tools and workshop equipment adapted to the task on hand are absolutely indispensable 1 2 4 Never make any modifications additions or conversions
113. ding equipment BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 191 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 88 9 15 5 Top Up Fuel Level WARN DO fill the tank to N capacity WEAR PERSONAL NOTICE PROTECTIVE EQUIPMENT Refer to Section 9 1 Safe Monitor the gauge located on y the Control Panel Figure 9ak wanting 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 DANGER hazard Figure 9al Filler Cap NEVER remove the filler cap or refuel with the engine running BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 192 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 89 NEVER add gasoline or any N other fuel mixes to diesel
114. dure Liftoutthe platform between the crusher and engine canopy to increase access to the swing beam adjusting mechanism Measure the smallest gap between each blow bar and the swing beam rails Figure 91 The blow bar must bein contact with the lower seat NoTice 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 BL Pegson Limited Coalville England Tel Trakpactor 428 9 Maintenance Issue EN 02 Page 30 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Figure 9i Swing Arm and Blow bar increased by 10mm 3 8 to compensate for the lifting of the blow bars under centrifugal force 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 134 300 PEGSON Onthe swing arm adjusting mechanism similar to Figure 9h undo the set screws A and remove the keep plate B Toincrease the gap between the blow bar and the swing arm rail tighten turn clockwise the adjusting sleeve C To decrease the gap between blow bar and the swing arm rail loosen turn anti clockwise the adjusting sleeve C When the gap is correct replace the keep plate and secure with the 2 set screws Close the inspection do
115. e Refer to the Addendum 428 Impact Crusher Guide to Efficient Operation in Section 11 of this manual for details Technical Information for Impact Crusher standard configuration Refer to the Addendum 428 Impact Crusher Guide to Efficient Operation in Section 11 p 1 for alternative Feed Opening 1067 x 711mm 28 42 42 Maximum Feed Size Blow Bar Configuration 2 x long 2 x short 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 38 300 Trakpactor TEREX 428 3 General Information Issue EN 02 Page 5 PEGSON 3 4 1 Impactor Settings Figure 3b Impactor Setting Gaps Setting Ratio elinge ins Setting Ratio Minimum Maximum Upper Impact 60 Apron 2 1 2 Keep ratio of settings Upper Impact Apron to Lower Impact Apron between Lower Impact 30 2 1 2 5 1 Dimension Keep ratio of settings Lower Impact Apron to Swing Beam Swing Beam between Liner Rails 1 1 42 1 20 63 Dimension 7 8 2 1 2 optional item 1 3 8 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 desire
116. e 9 10 Dirt Conveyor Lower Raise Button Trakpactor 428 5 Transport EN 02 Page 7 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 To shut down the radio handset transmitter push in the stop button Lock out the hand set when finished with to prevent unauthorised use Pump On Figure 5a Control Panel BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 55 300 Trakpactor TEREX 428 5 Transport Issue EN 02 PEGSON ae PLAN VIEW OF THE PLANT MC 2 pact LED Red Green SELECT AND PRESS BUTTON S TO MOVE Forward slow or fast track 1 amp 2 gt Right turn slow forward track 1 Reverse lt Left turn slow forward track 2 Left Turn forward travel Reverse slow or fast track 1 amp 2 gt Right turn slow reverses track 1 lt Left turn slow reverses track 2 Safety Button Horn gt Rotate clockwise track 1 forward track 2 reverse second step lt 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 Forward Right Turn forward travel Safety Button Feeder On O
117. e following procedure must be WARNING followed When carrying out maintenance or OCKOUT PROCEDURE LOCKOUT PROCEDURE 1 Switch off engine 2 Remove the ignition key 3 Keep the ignition key on person during lockout Place appropriate maintenance warning signs ie TAG OUT NEVER work alone Turn the Isolation Switch to O when the plant is not being used especially while plant is being transported BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 66 300 Trakpactor TEREX 428 Issue EN 02 PEGSON Page 5 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 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 T for Lockout manufacturer should be fed into the plant FALLING HAZARD Procedure Refer to Section 6 1 Safety Information for relevant warning 1 Observe all safety instructions 2 Position the plant 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 ar
118. e feeder dirt conveyor product conveyor and disengage the clutch The plant cannot be manoeuvred in the PLANT mode of operation DO NOT manoeuvre the Trakpactor whilst the crusher running The safety warning horn sounds continuously whilst the plant is being manoeuvred manoeuvring When manoeuvring your Trakpactor to its operating position make sure you stand well clear of the plant but are in a position to have all round vision to see any obstacles or hazards that may lie ahead e g personnel overhead cables ditches unsafe roadways etc Refer to Figure 2a Dimensions Make sure that you do not manoeuvre your Trakapctor on a gradiant fore and aft directions steeper than 30 degrees damage may occur to the engine and or plant Avoid manoeuvring the plant over extremely uneven ground or damage may occur Control valves mounted on the engine and beneath the feeder are NOT to be used to manoeuvre the Trakpactor They are for use by BL Pegson Service Engineers only BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 52 300 Trakpactor TEREX 428 5 Transport EN 02 Page 5 PEGSON 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 e When
119. e transmitter has a built in safety function that prevents another function from involuntary cutting in when the transmitter starts The transmitter will not start ifa button is stuck in the activated position This is indicated by the red LED coming on 4 Start the engine Section 7 2 Increase the engine speed to 1800rpm 5 On Control Panel located within the Control Box Figure 5a turn the Operation switch to TRACK 6 Press the Horn button for 5 seconds to sound the safety warning horn This will also ready the tracks for manoeuvring 7 The radio handset directional buttons forward reverse and turn are double pressure switches with the initial pressure operating the slow speed mode and depressing further operates the higher speed Press one button time to manoeuvre the plant in the desired direction Figure 5b Employ the Fast speed only where safe to do SO BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 54 300 TEREX PEGSON Pressing the Stop button at any time will immediately halt the operation and cut out the engine but it is necessary to manually switch off the engine ignition Section 8 2 and disengage the manual clutch When the Trakpactor is in the correct position press the Horn button to turn the safety warning horn OFF and disengage the tracks Operation Plant Track Pump Off On Feeder Remot
120. ea 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 67 300 Trakpactor TEREX 428 Issue EN 02 Page 6 PEGSON 6 Keep the Operation switch at 8 Switch off the engine Section 8 2 and Figure 6b lockout 7 Lower the dirt conveyor fully by turning 9 Replace and secure the dirt conveyor the dirt conveyor switch to W Figure head drum guard and side skirts 6b During lowering of the dirt N conveyor ensure that the Notice 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 68 300 Trakpactor TEREX 428 Issue EN 02 PEGSON Page 7 Operation Feeder Remote Dirt Conveyor Pump On P
121. ected under the skin it must be surgically removed or gangrene will result Get medical help immediately adjustment to the plant the following procedure must be WARNING followed When carrying out maintenance PROCEDURE LOCKOUT PROCEDURE Switch off engine Remove the ignition key Keep the ignition key on person during lockout Place appropriate maintenance warning signs ie TAG OUT NEVER work alone Turn the Isolation Switch to O when the plant is not being used especially while plant is being transported BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 51 300 Trakpactor TEREX 428 5 Transport Issue EN 02 Page 4 PEGSON DO NOT stand on any of the platforms or ladders of 5 2 1 Manoeuvring DANGER the Trakpactor whilst it is being manoeuvred using the remote control handset 5 2 Transportation Refer to Section 7 3 Prior to attempting any N manoeuvring of the plant wanne the tracks must be free of Ensure all personnel are clear of the plant before obstructions including crushed material and fines Do not push or tow the plant Failure to observe this warning could result in serious injury to persons and damage to the plant which may invalidate warranty Before manoeuvring the Trakpactor ensure the feed hopper and crusher are empty and that all materials have run off the conveyors STOP th
122. ections 7 2 1 to 7 2 4 5 Stop and start the Feeder by pressing the hand set button Figure7k Trakpactor 428 7 Operating Instructions Issue EN 02 Page 21 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 7 1 Safety Information for relevant warning Feed Conveyor stop start button Stop Button Figure 7k Remote Control Hand Set BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 91 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON 22 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 e Noneed 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 e Enhanced reliability Transmitter s Use NiMh batteries instead of NiCd which means the following e 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 800mA to 2000mA Charging time control from comp letely empty battery is now Buttons 1 to 9 and 0 Used for signal
123. ed the notice Engine Maintenance Platform is running correctly and that dust dirt has not built up in the fan and radiator unit over heating can occur if dust dirt is allowed to build up Blow out dust dirt if necessary DO NOT allow a build up of material at the feed on points to enter either the product conveyor or dirt conveyor DO check frequently the stability of the Trakpactor The chassis SHOULD NOT bounce during operation DO NOT allow the engine RPM to drop below it s operating speed and DO NOT slip the engine clutch AVOID frequent starting and stopping of your Trakpactor unnecessarily as it WILL cause damage to the plant Trakpactor 428 7 Operating Instructions Issue EN 02 Page 15 7 2 5 Checks Prior to Initial Daily Start Plant e Visually check the plant and ensure that all guards and warning signs Section 1 are in position and that all equipment and tools that are hazardous to operation are removed from the immediate site e Ensure that the impact crusher clutch on the diesel engine is disengaged Ensure that the impact crusher and the grizzly feeder hopper are empty e Check setup of the impact crusher and adjust as necessary to the required settings refer to Sections 3 4 and 9 6 e Check the oil cooler fan and radiator unit located on the Engine Maintenance Platform for any build up of dust dirt Blow out dust dirt ifnecessary e Before putting the plant into oper
124. ed 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 Trakpactor 428 9 Maintenance Issue EN 02 Page 77 N 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 Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 181 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 78 PEGSON 5 Not only the worker s cleaning belts but also others close by who may N WA R N be affected must also wear protective equipment WEAR PERSONAL PROTECTIVE EQUIPMENT The conveyor belts can be Referto Section 9 1 Safety Information for relevant warning cleaned using a number of Notice methods Before commencing make sure all aforementioned 2 procedures have been 2 47 Information for Lockout followe
125. ed on two side wall liner DANGER Plates A6984 9 2 Figure 9r DO NOT attempt to remove the side wall liner plates A6984 9 2 without first removing the bottom inlet beam A6984 9 23 Section 10 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 145 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON E 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 Refer to Section 9 1 Safety Information for Lockout 2 Run the crusher until completely empty dure Close down the plant Section 8 2 and implement the lockout procedure 1 Observe all the safety warnings 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 180 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 BANGER of the crusher and the crusher feed chute whilst opening closing the access door BL Pegson Limited Coalville England Tel 44 1
126. egson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 169 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 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 Ibf kgf Ibf 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 170 300 PEGSON 9 11 5 Method of Drive Belt Tensioning Under no circumstances should any check on the belt tension be made whilst the machine is running There is a risk of trapping parts of the body if this is done Procedure 1 Observe all safety warnings WARNING 2 Close down the plant Section 8 2 and implement the Lockout Procedure Remove the guards from around the belt 3 Calculate the deflection distance in inches on a basis of 16mm 0 625 deflection per metre 1 yard of belt span Figure 9ae Centre to Centre Distance metres yards x 16mm 0 625 Deflection inmm ins eg acentre distance of 2 metres 72 would be calculated as 2x l mm 32mm 0 625 1 4 Ifa belt tension indicator is available a Set the low
127. egson dealer or BL Pegsons technical department BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 37 300 TEREX PEGSON 3 4 Crusher Capacity In order to obtain the optimum output from the crusher it s feed should be continuous and regulated Additionally all feed should be ofa size that will readily enter the crusher chamber and undersize material should be removed from the feed prior to entry to the crusher Product curves shown overleaf are typical only based on average limestone and indicate the product gradings from the Impactor only Any natural fines in the feed material which bypass the Impactor are not taken into account Curves will vary dependant on nature type and grading of the material being processed Capacity shown is based on feed material weighing loose approximately 1 6t m 100Ibs ft and indicates the throughput ofthe plant For suitability of particular applications please consult your local dealer or BL Pegson Ltd 3 General Information AN NOTICE Trakpactor 428 Issue EN 02 Page 4 The crusher in the standard plant has a rotor speed of 630rpm and is fitted with 2 long x 2 short High Manganese blow bars This may have been altered to specific order The very variable nature of feed material and crushing applications may require consideration of alternative configurations in order to achieve optimum performanc
128. enance Issue EN 02 PEGSON 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 Attention Filled with ELC Extended Life Coolant Mileage or Hours Date Filled Top up or refill with Cat ELC or a coolant that meets Cat EC 1 specification If this is not available top with deionized water and adjust mixture concentration in the shop Add Cat ELC Extender after 6 000 hours 300 000 miles or 500 000 kilometers achieve optimum
129. ent checking OPERATING SHAFT TORQUE HAND LEVER EFFORT HAND LEVER CLUTCH POUNDS FEET POUNDS LENGTH A MODEL MIN MAX MIN MAX INCHES C 106 66 86 58 76 13 6 C 107 55 86 58 76 13 6 C 108 71 94 63 83 13 6 C 110 88 117 78 103 13 5 SP 111 108 142 95 125 13 6 SP 311 171 227 130 21 3 32 211 134 177 118 156 13 6 SP 114 218 289 123 163 21 3 5 214 218 289 123 163 21 3 SP 314 218 289 123 163 213 18 214 240 320 135 180 21 3 32 314 240 320 135 180 21 3 B 118 247 325 139 183 213 8 218 247 325 139 183 21 3 32 218 514 576 225 297 27 3 5 318 514 675 226 297 27 3 182 318 569 751 22200472 227 39 7 121 695 913 210 276 39 7 EH 221 695 913 hs 210 276 39 7 SP 321 513 675 il 155 204 39 7 321 513 675 155 204 39 7 224 731 955 221 292 39 7 most Dru AERE rere These clutch models no longer in production This information applies to power take offs reduction gears and pump drive units built by Twin Disc Incorporated BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 275 300 Trakpactor TEREX 428 Appendix Issue EN 02 Page 8 PEGSON 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 ACERT Addendum to User Manual Due to the change of engines to comply with requirements of Tier 3 Stage Illa standards this plant m
130. er marker ring at the deflection distance required on the lower scale 9 Maintenance Trakpactor 428 Issue EN 02 Page 67 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Crusher Engine Drive Belts 6 7500mm SPC Part Number 2441 0482 Hydraulic Pump Drive Belts 4 2000mm SPB Part Number 2441 0412 continued next page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 171 300 PEGSON b d e a b Set the upper marker ring against the bottom edge of the top tube Place the belt tension indicator on top of the belt at the centre of the belt span and apply a force at right angles to the belt deflecting it to the point where the lower marker ring is level with the top of the adjacent belt Read off the setting force value indicated by the top edge of the upper marker ring Compare this value to the lbf value shownin the table Figure 9ab Crusher Drive Belt Tensioning Specifications Figure 9ad Hydraulic Pump Drive Belt Tensioning Specifications If a belt tension indicator is not available Usea spring balance to pull the belt down at the centre ofthe span When the belt has been pulled down measure using a rule by the deflecti
131. er to Section 9 1 Safety Information for Lockout Proce dure To maximise the life of the N track keep it movable and avoid damage the plant should be moved at least every week by a distance exceeding four times the track length It should also be parked on level ground overnight and during periods to of non usage This is particularly important when working in adverse conditions BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 199 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 96 9 16 4 Drive Oil Filling and Draining Oil Filling N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT 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 See Section 9 4 4 for oil type and
132. ere off 11 Ensure the crusher drive guarding is fully 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 163 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 2 9 11 2 Adjustment of Crusher Drive Belts N WARNING The tension of the crusher drive belts is WEAR PERSONAL adjusted with the two screws one located PROTECTIVE EQUIPMENT Zr Refer to Section 9 1 Safety on either side ofthe engine sliding base Information for relevant Figure 9aa warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Procedure Slackening of Drive Belts 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 Uns
133. erent to those referred to in the user manual therefore please contact Terex Pegson and quote plant and engine serial numbers for assistance E 2 m TEREX PEGSON AX846 901 8EN 02a 278 300 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 0014 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 lt i gt 2 Scroll Up Left button Scroll display to view different menus and use to set up display settings 3 Scroll Down Right button Scroll display to view different menus and use to set up display settings O 4 OK button Confirm selection on the display continue to next screen Performance Display The displays available are Engine speed Coolant temperature T
134. erious injury or even death In running nip points cause ENTANGLEMENT DANGER DO NOT reach into an unguarded machine Your arm could be pulled in and amputated SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards Hydraulic fluid under pressure can SKIN INJECTION penetrate the skin causing serious HAZARD injury DANGER ALWAYS relieve the pressure from the hydraulic system before carrying out 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 108 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 5 When carrying out maintenance or OCKOUT PROCEDURE adjustment to the plant the following procedure must be WARNING followed LOCKOUT PROCEDURE Switch off engine Remove the ignition key Keep the ignition key on person during lockout Place appropriate maintenance warning signs ie TAG OUT NEVER work alone Turn the Isolation Switch to O when the plant is not being used especially while plant is being transported Welding on a Machine Unit equipped with the Electronic Engine Before welding on a machine unit equipped with an e
135. eside Shaft Assembly 2 2 2 22 30 10 3 Conveyor ura mec 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 38 Dirt Conveyor Conveyor Parts Assembly sheet 1 40 Dirt Conveyor Conveyor Parts Assembly sheet 2 42 10 4 Overband Magnetic 44 10 5 Plant Component 46 Plant General Arrangement atc ce bcati d ix dai 46 Plant Guards 5561101 T ai 48 Plant 50 10 6 PLANE TACKS pe 52 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 203 300 Trakpactor TEREX 428 Spare Parts Issue EN 02 Page 2 PEGSON 10 7 Hydraulic System eee 54 lab ieri HOSES PENES 54 Fiydrauli Hoses CODD BE
136. evant 1 Observe 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 N 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 WARNING 3 Reverse the lockout procedure and turn the engine ignition switch to position although the engine ignition has to be on the engine does not require to bestarted and cannot be cranked over The warning horn will sound but his is irrelevant to this operation 4 Onthemain 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 126 300 PEGSON Turnthe engine ignition switch to the position and implement the lockout procedure Rotate the swivelling eye bolts through 180 and thoroughly tighten Detach the chains D from the Protection caps A on the Fro
137. fely and with minimum environmental impact 1 4 2 10 Always ensure that any safety fitment such as locking wedges securing chains bars or struts are utilised as indicated in these operating instructions Particularly make sure that any part of the plant raised for any reason is prevented from falling by securing in a safe reliable manner Never work under unsupported equipment Never work alone Trakpactor 428 Issue 2 Page 7 1 4 2 11 Diesel fuel is highly flammable Never remove the filler cap or refuel with the enginerunning Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion risks Do notcarry out maintenance on the fuel system near naked lights or sources of sparks such as welding equipment or whilst smoking 1 4 2 12 Using unapproved structures i e walkways platforms etc in the vicinity ofa BL Pegson plant is very dangerous and could lead to serious injury or even death through falling and or entanglement with the plant Do not use any unauthorised structures BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 15 300 TEREX PEGSON 1 5 Warning of Special Dangers 1 5 1 Electric Energy 1 5 1 1 Use only original fuses with the specified current rating Switch off the plant immediately if trouble occurs in the electrical system Plants with high voltage electrical equipment
138. ff For more information on the Radio Hand Set see Section 7 of this manual Figure 5b Remote Control Hand Set BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 56 300 Trakpactor TEREX 428 5 Transport EN 02 Page 9 PEGSON 5 2 2 Unloading WARNING PROTECTIVE EQUIPMENT Refer to Section 5 1 Safety Information for relevant warning The Trakpactor will arrive on site securely 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 ifnecessary 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 57 300 Trakpactor TEREX 5 Transport ec 02 PEGSON Page 10 5 2 3 Loading Before transpo
139. fication 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 mm s 32 46 68 104 F in s 0 049 0 0713 0 105 Kinematic Viscosity at 100 C mm s 5 5 6 5 8 5 212 F in 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON and Crusher Shaft Bearing Grease 2 Front Adjusting Spindles Nipples amp Labyrinth Lid 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 121 300 TEREX PEGSON 9 5 Crusher Opening and Closing Access to the inside of the Impact Crusher body is gained by first releasing some of the swivelling eye bolts on the crushe
140. frame and the overband magnetic separator 4 2 12 Guards Wire mesh or sheet metal guards are provided for all drives flywheels pulleys couplings gears and vee belts The guards provided are designed and manufactured to ensure so far as reasonably practicable that the machinery and plant on which they are fitted can be operated safely and without risk to health when properly used 4 2 13 Painting The plant is finish painted in RAL 5015 blue 4 2 14 Dust Suppression Sprays Spray bars with atomiser nozzles are mounted over the product conveyor feed and discharge points piped to a single inlet manifold for clients pressurised clean water supply BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 46 300 TEREX 4 Design and Function PEGSON 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 i
141. g 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 operating parameters will result in a loss of guarantee and the manufacturer supplier cannot be held liable for any damage resulting from such use The risk of such misuse lies entirely with the user 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 Trakpactor 428 3 General Information lssue EN 02 Page 3 The magnetic overband separator is intended to extract ferrous materials from the crushed product but this material in the feed must be limited to a size that will not cause damage to the crusher 3 3 1 Operating Temperature Range The normal operating temperature range of the plant is from 10 C to 40 C 14 F to 104 For use in temperatures outside ofthis range contact your local dealer or BL Pegson for details Note Appropriate oil amp coolant to suit the local operating conditions must be used as specified elsewhere in this manual If you have any doubts about any aspect of the plant s warning Capability or servicing procedures you must consult your local BL P
142. 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 e 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 e Keepclearof moving parts when trying to identify or isolate any unusual noises Fit dismantled parts in the same location from which they were removed e Ensure that the area surrounding the maintenance site is clear of any obstructions e 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 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 110 300 Trakp
143. he blow bar and the rear apron tighten turn clockwise both adjusting sleeves C each in turn a little at a time and by equal amounts To decrease the gap between the blow bar and the rear apron loosen turn anti clockwise both adjusting sleeves C each in turn a little at a time and by equal amounts Set Screws A Keep Plate B WARNING WEAR PERSONAL PROTECTIVEEQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 8 When the gap is correct replace both keep plates and secure with the 2 set screws in each keep plate 9 Close the inspection doors and secure with the locking clip Adjusting Sleeve C Figure 9h Rear Impact Apron Adjustment BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 133 300 PEGSON 9 6 4 Adjusting the Swing Arm where fitted After any maintenance and A N before starting the crusher warninc ensure the rotor can turn without any impedance Check the distance between the long blow bars Refer to Section 9 7 1 and impact plates and if necessary adjust the impact aprons and swing arm See Section 3 4 1 Impactor Settings Procedure Observe all safety warnings Run the crusher until completely empty Close down the plant Section 8 2 and implement the lockout proce
144. hilst warning 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 line BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 184 300 TEREX PEGSON 9 14 Plant Dust Suppression 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 e 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 nozzles should be kept free of dirt and blockages Each nozzle should be checked every time the dust suppression 1s switched on Shut off valves are provided for each spray bar at the manifold The system can be drained after operation by the drain valves located below the inlet manifold This is particularly important in winter time when there is the likelihood of the system freezing Trakpactor 428 9 Maintenance Issue EN 02 Page 81 Water Inlet Product Crusher Conveyor Discharge Discharge Area Figure 9ai Dust Supp
145. hould be set fully open Fully Open maximum gap between blow bar and impact apron swing beam After any maintenance and before starting the crusher ensure the rotor can turn without any impedance Check the distance between the long blow bar and impact plates 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 137 300 PEGSON Removal of each Blow Bar Procedure Observe all safety warnings Run crusher until completely empty Close down the plant Section 8 2 and implement the lockout procedure Open the crusher Section 9 5 2 Toremove 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 91 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 91 amp 9m Clean out the debris between the blow bar and rotor recess Using the hydraulic blow bar extraction tool provided mount the tool as shown Figure 9m on the drive guard side of the crusher Us
146. iagnostic checks is completed fully turn the key to start the engine Release the key back to the first position as soon as the engine starts Refer to Figure 7e together with continuation page for details of the NOTICE engine diagnostic functions Figure 7a Isolation Switch To avoid damaging the clutch DO NOT increase the engine Notice Speed to the operating 1800 rpm until after starting the crusher Section 7 2 2 6 Checkthe engine speed is at 1200 rpm view on tachometer and allow to run for 3 5 minutes before proceeding with preparation for transport Section 5 setting up the plant Section 6 or initiating the plant run sequence Section 7 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 77 300 Trakpactor TEREX 428 PEGSON 7 Operating Instructions Issue EN 02 Page 8 E3 999 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 78 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 9 PEGSON Maintenance Due Lamp Diagnostic Lamp Tachometer e Diagnostic Display e Scroll Switch N Fuel Gauge Speed Contr
147. ic motor drive via coupling to drive drum at preset speed Adjustment Belt tensioning to be maintained and adjusted at the head drum4 2 2 6 Overband magnetic separator Self cleaning type with permanent magnet over the on plant product conveyor with discharge of ferrous metal to the side of the plant Driven by hydraulic motor with preset speed Trakpactor 428 4 Design and Function Issue EN 02 Page 5 4 2 7 Plant Chutework Impactor Feed Chute Fabricated in mild steel plate with full width single strand chain curtain and rubber curtain Liners are fitted at wear points Grizzly Fines Bypass Chute Fabricated in mild steel plate is provided with a two way flap door Material passing over the blank rubber mat or optional underscreen and through the end section of the feeder grizzly bars is discharged to the main product conveyor via the by pass chute Material passing through the under screen when fitted is discharged to the side dirt conveyor and the flap door will also allow a portion ofthe material to be diverted to the main product conveyor 4 2 8 Operators Maintenance Platforms A steel grid platform is provided on one side ofthe plant fitted with double row handrails and access ladder Platforms are also included to gain access to the rear of the crusher and to the power pack DANGER NOT TO BE USED WHILST THE CRUSHER ROTOR IS SPINNING BL Pegson Limited Coalville England Tel 44 1530 518600
148. ine 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 plattorm when reaching any points 2m 6 6 or more above ground level Trakpactor 428 Issue EN 02 Page 2 PERSONAL PROTECTIVE EQUIPMENT ca Se FALLING HAZARD BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 64 300 Trakpactor TEREX 428 Issue EN 02 PEGSON Page 3 serious injury or even death In running nip points cause ENTANGLEMENT DANGER DO NOT reach into an unguarded machine Your arm could be pulled in and amputated SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards Hydraulic fluid under pressure can SKIN INJECTION penetrate the skin causing serious HAZARD injury DANGER ALWAYS relieve the pressure from the hydraulic system before carrying out any 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 65 300 Trakpactor TEREX 428 Issue EN 02 PEGSON adjustment to the plant th
149. ing the quick release hose couplings connect to the crusher ram operating valve on the platform Inthe same manner of operation as when opening the crusher body push out the blow bar with the extraction tool As the blow bar is extracted Trakpactor 428 9 Maintenance Issue EN 02 Page 34 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure support the weight with suitable slings and lifting gear Extension bars are included with the extraction tool to be inserted when necessary when the limit of travel is reached Retract the piston in the extraction tool by moving the operating lever in the reverse direction and remove the tool from the rotor continued on the next page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 138 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Split Pin Axial Lock amp Securing Pin Blow Bar Figure 9k Impact Crusher Blow Bar and Axial Lock Figure 91 Rotor Lock fit where indicated Figure 9m Removing the Blow Bar BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 139 300 PEGSON Fitting of Blow Bars ONLY REPLACE TURN BLOW BARS AS MATC
150. is important otherwise the belt flanks will wear quickly Ensure axis are parallel when viewed from all planes Figure 97 Shafts are not parallel to one another when seen from above Shafts are parallel from above but not 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 162 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON 9 11 1 Replacement of Crusher Drive Belts N WARNING Note Drive belts should inspected WEAR PERSONAL regularly for wear and also to monitor any PROTECTIVE EQUIPMENT mu Refer to Section 9 1 Safety pattern in the wear ifit is occurring Figure dt 97 warning LOCKOUT MACHINE 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 correct specification Section 9 11 2 ensuring the engine pulley is in correct alignment with the crusher pulley Figure 97 3 Open the hinged ends of the crusher drive guard and also the underside panel by removing the securing hex hd set screws captive nuts inside guard 4 Onthe engine base frame loosen nuts Fi
151. lant Track Pump Off On Lower Raise Button Figure 6b Control Panel TRACK PLANT PUMP BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 69 300 Trakpactor TEREX 428 Issue EN 02 Page 8 PEGSON Blank Page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 70 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 1 PEGSON Contents 2 A V Blocked Crusher Procedures 5 7 2 Safe Start Up Procedure 6 recusa Engine Start Up Pt R R 7 7 2 2 Crusher 12 7 2 3 Feeder Conveyor Start Up o 13 7 2 4 Safe Operation of the Plant 15 7 2 5 Checks Prior to Initial Daily 15 7 2 0 initial Start Upang RUNDING uou Roses s eu aem Siue enne 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
152. lant is in a condition the plantmustbstowedlloadedand compatible with these regulations transported only in accordance with the i 1 6 8 operating instructions In conditions of poor visibility and after 1 6 2 dark always switch on the lighting system For towing the plant observe the VOICI prescribed transport position admissible 1 6 9 speed and itinerary When crossing underpasses bridges and 1 6 3 tunnels or when passing under overhead Use only appropriate means of transport 2 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 to the ground especially when travelling downhill The recommissioning procedure must be strictly in accordance with the operating instructions 165 1 6 11 On sloping terrain always adapt your travelling speed to the relevant ground conditions Never change to a lower gear on a slope Always change gear before reaching a slope Before starting work or travelling with the plant check that the braking and any signalling and lighting systems are fully functional 1 6 6 Before setting the plant in motion always check that the accessories have been safely stowed away BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 19 300 Trakpactor TEREX 428 Issue ENO2 PEGSON npa 1 6 12 Explosive sepa
153. ld be dampened placed in a sealed container and marked to ensure safe disposal 1 5 2 2 Carry out welding flame cutting and grinding work on the plant only if this has been expressly authorised as there may be arisk of explosion and fire 1 5 2 3 Before carrying out welding flame cutting and grinding operations clean the plant and its surroundings from dust and other inflammable substances and make sure the premises are adequately ventilated as there may bea risk ofexplosion BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 17 300 TEREX PEGSON 1 5 2 4 Always ensure that the operator s are provided with hearing protection of approved pattern and that these are worn at all times when the plant is operating Ensure operators wear a suitable face mask where exposed to possible harmful effects of air pollution of any kind 1 5 3 Hydraulic and Pneumatic Equipment 1 5 3 1 Work on hydraulic equipment may be carried out only by persons having special knowledge and experience in hydraulic systems 1 5 3 2 Check all lines hoses and screwed connections regularly for leaks and obvious damage Repair damage immediately Splashed oil may cause injury and fire 1 5 3 3 Depressurise all system sections and pressure pipes hydraulic system compressed air system to be removed in accordance with the specific instructions for the unit concerned
154. lectronic engine the following precautions should be observed Turn the Engine Control Switch to the OFF position Disconnect the NEGATIVE battery cable at the battery Ifa battery disconnection switch is provided open the switch Disconnect multi pin connectors from the Electronic Control Module ECM located on side of engine Connect the welder ground cable directly to the member to be welded Place the ground cable clamp as close as possible to the weld to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Do not use electrical components the ECM or Electrics Ground Stud for grounding the welder Protect wiring from the welding debris or splatter BL Pegso Use standard welding techniques to weld the materials together 0518618 0000224 AX846 901 8EN 02a 109 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 6 PEGSON N WARNING N PRIOR TO ANY MAINTENANCE Themaintence 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
155. ment 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 Atthe end of each working day for approximately 1 week e Once a week After wear in clutch adjustments should be made on a weekly basis Trakpactor 428 Issue EN 02 Page 84 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 188 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 85 9 15 2 Clutch Maintenance Adhere to the manufacturers separate WA R N 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 Figu 18 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 189 300 Trakpactor TEREX 428 9 Maint
156. 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 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 94 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 Page 25 PEGSON 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 N when manoeuvring the plant pressure switches with the initial DANGER 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 offthe engi
157. nance Issue EN 02 Page 75 DANGER ENTANGLEMENT HAZARD Refer to Section 9 1 Safety NA Information for relevant warning WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Do not use clip joints for belt repairs or replacements as DANGER they can be dangerous Belt repairs replacements should be performed by vulcanising only BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 179 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 76 PEGSON e Check that there is no evidence of belt Inthe 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 N possible should be made whilst replace the idler Failure to do so will DANGER the beltis stationary When result in belt wear and tracking this is not possible extreme problems care should be taken
158. nd resulting heat generation Service Spool Type Max Flow Litres min US galls min Max Pressure Bar L H track drive motor Proportional 65 17 320 Product conveyor plus Magnet and Water Pump when fitted On Off 100 26 4 210 Rear Pump Service Spool Type Max Flow Litres min US galls min Max Pressure Bar 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 22 10 04 On Off 25 6 5 Figure 9v Front Rear Hydraulic Pumps 100 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 154 300 TEREX PEGSON This is achieved by means of a load sensing line from the valve to the pump which measures the pressure required which is then matched by the pump Note All relief valve pressures are factory set and should not be adjusted on site Although the maximum flows from each spool is limited as shown these can be individually adjusted downwards by means of limit screws if desired Please contact BL Pegson Ltd 9 9 2 Track Drives Although these valves Sections have proportional controls and are theoretically infinitely variable they are electrically limited to two speeds for simplicity a SLOW For slewing and fine positioning b FAST For straight line
159. ndards 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 ofthis equipment use approved respiratory protection as required by Federal State and Local safety and health regulations AX846 901 8EN 02a 6 300 ij TEREX Units of Measure Within this User Manual figures shown within brackets after the Metric unit of measure approximate conversions from the actual metric measurement of the item concerned CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning WARNING Battery Posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm WASH HANDS AFTER HANDLING WARNING Diesel engine exhaust and some of it s constituents are known to the State of California to cause cancer birth defects and other reproductive harm Copyright The copyright of this User Manual is reserved by BL Pegson Limited This User Manual contains information and technical drawing
160. ne 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 setto 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 95 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON 2 FORWARD PLAN VIEW OF THE PLANT MC P pact SELECT AND PRESS BUTTON S TO MOVE Forward slow or fast track 1 amp 2 gt Right turn slow forward track 1 dee Reverse Left turn slow forward track 2 lt forward travel Forward Right Reverse slow or fast track 1 amp 2 forward travel Right turn slow reverses track 1 Not used Not used CCOCOCOCOCO 9000 Left turn slow reverses track 2 Safety Butt n Horn Not used Rotate clockwise t
161. ngland Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 13 300 TEREX PEGSON 1 4 2 3 Carry out maintenance and repair work only if the plant is positioned on stable and level ground and has been secured against inadvertent movement and buckling 1 4 2 4 Never allow unqualified or untrained personnel to attempt to remove or replace any part of the plant or anyone to remove large or heavy components without adequate lifting tackle To avoid the risk of accidents individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting tackle and secured Use only suitable and technically adequate lifting gear Never work or stand under suspended loads Keep away from the feed hopper and product conveyor discharge where there is risk of serious injury or death due to the loading and removal of material 1 4 2 5 Falling from and or onto a BL Pegson plant can cause injury or even death Do not climb on the plant whilst it is in operation Never use plant parts as a climbing aid Beware of moving haulage and loading equipment in the vicinity of the plant Trakpactor 428 Issue 2 Page 6 For carrying out overhead assembly work always use specially designed or otherwise safety oriented ladders and working platforms Always use any walkway platforms provided or a safe and secure platform approved by the regional safety enforcing autho
162. not exceed the minimum or maximum dimensions given in Figure 3b and that ratios are maintained between the front and rear apron settings and between the rear apron and the swing beam if fitted otherwise any watranty may be invalidated Front Impact Apron Adjustment Mechanism Rear Impact Apron Adjustment Mechanism Swing Beam Adjustment Mechanism Swing Beam Rails Axial Lock amp Securing Pin Figure 9d Impact Crusher Parts BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 128 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON nae 9 6 1 Entanglement Hazard for Inspection Door Keep doors Figure 9f closed latched and bolted except when performing maintenance DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop 300 269 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 129 300 Trakpactor TEREX 428 n 9 Maintenance Issue EN 02 PEGSON Page 26 9 6 2 Adjusting the Front Impact Apron A WARNING After any maintenance and WEAR PERSONAL before starting the c
163. ns 2 2 2 F cdi js 3 4 cece 4 2 5 2 4 cs ts cee eee a eet 5 2 5 2 7 Standard 5 2 8 5 qme c T 5 2 3 Dirt COR 77 6 2 10 Magnetic SeparalOF se ce a csc cscs ce tit ttt 6 2 11 Belt Weigher optional 6 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 29 300 Joyoedyes y 169 ez ainbi4 _ 0 8 sesodund 9055 10 pesn eq pjnous ejeudoudde 11 11 pue 10 suoisueuuip pue 930N Trakpactor 428 Issue EN 02 suo SN 96 56984401 xoudde 65046 2060 97 Z 6 JOASAUOD 11 4 3440 7 LL
164. ns Issue EN 02 Page 11 PEGSON 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 Inlet Air Temperature FuelT Fuel temperature AccrP Auxiliary Pressure AccrT Auxiliary Temperature Fuel Fuel Rate Hrs Engine Hours Load Engine Percent Load BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 81 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON in 7 2 2 Crusher Engagement WARNING WEAR PERSONAL f Refer to Section 7 1 Safety Information for relevant warning With the engine speed set at 1200rpm 1 Observeall Safety Warnings Crusher Drive Guard 2 Slowly engage the clutch by pulling the clutch lever away from the crusher drive guard
165. nt Apron Adjusting mechanisms Figure 9g It is essential these chains are detached before operating the crusher in order to allow movement of the Front Apron After blow bars apron liners or N swing arm rails have changed notice 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 9 Maintenance Trakpactor 428 Issue EN 02 Page 23 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 127 300 TEREX PEGSON 9 6 Crusher Adjustment Adjustments are required to the impact crusher to enable the product size to be varied and to compensate for wear on the aprons swingbeam where fitted and blow bars Refer to Section 3 4 Figure 3c for the setting gaps Front Impact Apron Rear Impact Apron Retractable Beam Bottom Inlet Beam Rotor Protection Ca Blow Bars Trakpactor 428 9 Maintenance Issue EN 02 Page 24 It is most important that settings between the rotor blow bars and the front and rear aprons and also the swing beam optional if fitted do
166. nt to the ON position Section 7 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 5 Point the transmitter lens of the infra 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 WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Safety Information in Manual for D relevant warning Lens 1 Start 0 Stop Infra red feeder remote control operation 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 5 Infra red feeder control Infra red feeder Issue 01 UK US Page 3 General Information Do not use the transmitter and or receiver for any other purpose than for which they are supplied or in conjunction with any other equipment Ensure that the operating position is in line of sight of the receiver and within range and that the area surrounding the machinery is clear Pressing the relevant button will light the red L E D indicator On releasing the button the L E D should remain on for 0 5 to 1 second Avoid knocking or dropping the infra red control keep it clean especially the lens dry and store in a dry place when not in use
167. ockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop 300 268 PRIOR TO TRANSPORT 1 Fasten all loose items securely 2 Check the plant for loose or damaged parts 3 Replace missing parts or make repairs as found necessary to ensure that all parts are safely secured during transport 4 Ensure safety chain or locking device is fitted to folding conveyor and all additional conveyors screens 5 Ensure the plant is correctly folded to suit the transport height regulations applicable 300 954 ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop 300 269 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 27 300 Trakpactor TEREX 428 Issue ENO2 PEGSON ana Blank Page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 28 300 Trakpactor TEREX 428 2 Technical Information Issue EN 02 Page 1 PEGSON Contents 21 Dimensi
168. of full capacity during the first and second days of operation respectively 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 amp 71 After first 8 hours of operation change the oil in the vibrating unit end covers 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 80 C 176 F Ensure that the vibrating unit is operating before any feed is introduced to the plant fee hopper BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 88 300 TEREX PEGSON 7 3 Radio Remote Control Operation Where fitted DO NOT stand on any of the N platforms or ladders of the DANGER whilst it is being manoeuvered using the remote control handset When manoeuvring your Trakpactor to it s operating position make sure you stand well clear of the machine but are in a position to have all round vision to see any obstacles dangers that may lie ahead e g personnel overhead cables ditches unsafe roadways etc Refer to Figure 2a for dimensi
169. ol Ignition Key a Figure 7d Engine Control Panel BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 79 300 TEREX 428 7 Operating Instructions Issue EN 02 PEGSON EMS Main Unit Battery Intet Manifold Voltage Temperature Auxiliary Engine Coolant Fuel Temperature Temperature Temperature RPM SERV ODEN 29 Pressure Engine Engine Oil Derate Pressure Engine Coolant LCD Digital Level Display Fuel Pressure 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 gt Low Battery Voltage or Sensor Fault Engine D High Auxiliary Temperature High Auxiliary Pressure or Sensor Fault or Sensor Fault Figure 7e Caterpillar Engine Diagnostic Panel BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 80 300 Trakpactor TEREX 428 7 Operating Instructio
170. on Figure 1 Water Pump Unit typical mounting Flow Control 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 TEREX Water Pumps MANUAL ADDENDUM Issue 02 ENG Page 4 PEGSON Hydraulic Oil Water 3 Way Valve Flow Valve Hydraulic Motor Water Pump AX868 180 601 Coupling Figure 3 Pump Hydraulic Oil Water Circuits 2575 2008 3 Way Valve 2575 2005 Coupling 25 l min Pump 2575 2003 29 9200 Fow Valve 65 l min Pump 2575 2010 X 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 BWI00 INITIAL CALIBRATION SIMPLIFIED GUIDE 45 Following procedures may be performed when messages and 4 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 With belt running empty at normal speed with test weights removed 0 2971 11 HHHH HHHH oo
171. on Also Section 9 15 1 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 186 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON ines Welding on Machine Unit equipped with the Electronic Engine Before welding on a machine unit equipped with an electronic engine the following precautions should be observed Turn the Engine Control Switch to the OFF position Disconnect the NEGATIVE battery cable at the battery battery disconnection switch is provided open the switch Disconnect multi pin connectors from the Electronic Control Module ECM located on side of engine Connect the welder ground cable directly to the member to be welded Place the ground cable clamp as close as possible to the weld to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Do not use electrical components the ECM or Electrics Ground Stud for grounding the welder Protect wiring from the welding debris or splatter Use standard welding techniques to weld the materials together 0000224E BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 187 300 TEREX 9 Maintenance PEGSON 9 15 1 Manual Clutch Adjustment IMPORTANT TWIN DISC MANUAL CLUTCH INSTRUCTIONS Refer to the Appendix Section 11 for instructions regarding the engine clutch adjust
172. on Liner Plates Rotor Protection Caps Blow Bars Rear Apron Adjustment Mechanism Rear Apron Liner Plates Swing Beam Swing Beam Grinding Path Adjustment Mechanism Figure 9j Impact Crusher Parts BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 136 300 PEGSON 9 7 1 Replacing worn Blow Bars A NOTICE The crusher must be fitted the matched pairs of blow bars fitted diametrically opposite to each other The maximum weight difference between the two Blow Bars supplied as a pair is 0 47 kg ONLY REPLACE TURN BLOW BARS AS MATCHED OPPOSITE PAIRS TO MAINTAIN THE CORRECT ROTOR BALANCE Of the two pairs of blow bars fitted to the rotor one pair is shorter ie having a smaller projection from the rotor periphery than the other pair Reverse the wearing face of a pair of blow bars through 180 when the original face is worn but maintain the one pair long and one pair short blow bar configuration on the rotor by fitted appropriate new blow bar when necessary 9 Maintenance Trakpactor 428 Issue EN 02 Page 33 WARNING WARNING WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure Before replacing the blow bars the impact aprons and swing beam s
173. on calculated in Step 3 read offthe force from the spring balance Ifthe 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 BL Pegson Limited Coalville England Tel 9 Maintenance Trakpactor 428 Issue EN 02 Page 68 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 7 Replace all guards before start up A NOTICE After the drive has been running for 15 20 minutes the tension should be checked and readjusted to the Basic Setting Force value if necessary by repeating the above procedure from Step 1 44 1530 518600 Fax 44 1530 518618 846 901 8 02 172 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Page 69 16mm Deflection per 1 metre 0 625in per Belt Tension Irdi 1 yard of cator Applied to Belt S Mid Span Figure Belt Tensioning Measurements BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 173 300 PEGSON 9 11 6 Trouble Shooting Drive Belts Small Cracks on V Belt side and
174. ons The Trakpactor remote control N system is supplied to the Notice Polowing Radio System Umbilical handset Ifthe plant moves out ofthe operating range ofthe 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 Trakpactor 428 7 Operating Instructions Issue EN 02 Page 19 To manoeuvre the Trakpactor with the remote hand set refer to the instructions in Section 5 2 1 To use the remote hand set to switch the feeder on off during crushing operations refer to Section 7 3 2 For recharging the hand set battery see Section 7 3 3 When the plant is not operating take the opportunity to recharge the internal battery For convenience a lead is supplied to plug into 12 35 volt DC vehicle cigar lighter point In the event of the remote radio hand set being inoperable for any reason the alternative umbilical hand set is supplied Section 7 3 4 If the hand set transmitter does not start when the two safety buttons are depressed at the same time for at least 1 second Section 5 2 1 check if the stop button is pushed in or the battery needing a recharge BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 89 300 PEGSON 7 3 1 Radio Remote Control Hand Set Where Fitte
175. ons and feed size please consult BL Pegson s Sales Department BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 32 300 TEREX PEGSON Maintenance Optional fitting 2 5 Product Conveyor Type Width Lubrication Drive Control Skirts 2 6 Tracks Type Width Centre Drive Control 2 7 Standard Powerpack Type Rating Drives Housing 2 8 Dustsprays Type Positions Inlet Required supply Frost protection 2 Technical Information Trakpactor 428 Issue EN 02 Page 5 Hydraulic case opening Lower swing beam grinding path having overload compression spring available for certain quarry applications subject to confirmation of suitability by BL Pegsons Sales Department Steel reinforced troughed belt 1000mm 40 Grease Hydraulic motor Fixed speed Fulllength 160mm 6 3 pitch heavy duty 400mm 16 500 mm wide optional 3300mm 10 10 Hydraulic integral motors Remote handset dual speed Caterpillar C9 EU EC Emmission Regulations compliant 6 cyl water cooled diesel 300hp 1800 rpm Manual clutch to crusher through vee drive Vee belts to twin hydraulic pumps Totally enclosed canopy with integral fuel tank and battery Clean water multi atomising nozzles Crusher discharge and product conveyor discharge Single point Up to approx 7 litres min 2 US galls 2 8 bar 42psi System drain valves BL Pegson
176. oom for expansion and wipe up spilt fuel immediately otherwise paintwork will be damaged Procedure 1 Observe all safety warnings 2 Close down the plant Section 8 2 of the Plant User Manual and implement the lockout procedure except the engine isolation switch to be at position 3 Connect both hoses to the pump and insert the suction hose into the fuel supply Clean the area around the filler cap Remove the cap and insert the delivery hose 4 Operate the switch on the pump to fill the fuel tank Use only in accordance with the instructions on the previous page 5 Switch off the pump and stow the hoses Replace the cap and refit the engine access panel before start up Turn the engine isolation switch to Diesel fuel is highly flammable andis an explosion burns DANGER hazard Never remove the filler cap or refuel with the engine running BL Pegson Limited Coalville England Tel All Plants Fuel Transfer Pump BL PEGSON MANUAL ADDENDUM Issue 01 ENG Page 4 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 ofthe Plant User Manual Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 ofthe Plant UserManual Safety Information for Lockout Procedure Never add gasoline or any other fuel mixes to diesel DANGER because of increased fire or explosion risks Do Not smoke while refilling or carrying out maintenance on the fuel sys
177. or Lockout Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning 6 Check the crusher shaft bearing temperatures using a contact thermometer and record for future reference and fault diagnosis The maximum acceptable working temperature is 80 C 176 F Weekly Checks 1 Perform all checks on the daily check list Lubricate to the weekly schedule Section 9 4 4 Check the area around the rotary impactor for build up of material clean out as necessary Ensure all hydraulic hoses and joints are free from leaks Lubricate the crusher rotor bearings BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 116 300 TEREX PEGSON Check drive belts for damage wear and fraying Check crusher rotor blow bars etc for security and wear damage Check crusher setting Clean away dust dirt and grit from maintenance platforms and any moving parts 10 Check side wall liners for wear damage and security 11 Check both aprons and if fitted the swing beam adjusters for security wear and damage 12 Check conveyor belts for damage and fraying Monthly Checks 1 Perform all checks on the daily and weekly check list 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 f
178. or 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 9 Maintenance Trakpactor 428 Issue EN 02 Page 13 N 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 Procedure FALLING HAZARD Refer to Section 9 1 Safety Information for relevant warning Check all drive belts are at the correct tension Clean oil strainers and filters Inspect for metal chips or flakes indicating excessive bearing pressure or bearing failure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 117 300 Trakpactor 428 Issue EN 02 c PEGSON Schedule icing 9 4 4 Lubrication and Serv 9 991 se pue peau pay si jeuondo 99 2194M BSOU 10 9 104 sjenueui 9 y 1949Y qas SMOUS Joyeolpul JI SJU 0001 pieeM AjujuoIN 8166 Sn 1 soul 6
179. ormation for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout 2 Run the crusher until completely empty dure Close down the plant Section 8 2 and implement the lockout procedure 1 Observe all the safety warnings 3 Remove the retractable beam access covers on either side of the crusher Figure 9q 4 Usinga heavy hammer or beetle drive out the retractable beam supporting the beam with suitable lifting equipment When driving out the N retractable beam splinters may caution be produced Where protective clothing and safety glasses To aid removal of the beam the front wall can be opened notice Figure 9s A cantilever bar can then be used to assist with the driving out procedure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 148 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON ipe Figure 9q Access Cover Retractable Beam Retractable Beam Bottom Inlet Beam Figure 9s Front Wall Open Figure 9r Retractable Beam Detail BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 149 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Fitting of Retractable Beam N WARNING The retractable beam can be rotated through 180 if the v 1 WARNING grooves are
180. ors and secure with the locking clips Trakpactor 428 9 Maintenance Issue EN 02 Page 31 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 135 300 TEREX PEGSON 9 7 Crusher Replacement of Wear Parts Use only genuine BL Pegson replacement wear parts Check daily for wear on all parts affected particularly where the material being crushed is known to be abrasive It is important that designed replaceable wearing parts are renewed before the underlying machine is subjected to wear One working day after fitting new replacement wear parts always check the fixing bolts for tightness Trakpactor 428 9 Maintenance Issue EN 02 Page 32 All maintenance on the impact crusher must only be carried out when the plant lockout procedure has been carried out and the crusher rotor is stationary When replacing wear parts check there is no build up of material within the crusher eg between the impact aprons swing beam 1f fitted and the crusher side walls and clear as necessary Always make sure that the seating of a wear part is clean and the part is properly bedded in position Front Apron Adjustment Mechanism Body Side Liner Plates Front Apr
181. otals Display Cumulative totals displays available are Service hours engine has accumulated Total time system in use M 2 m TEREX PEGSON AX846 901 8EN 02a 280 300 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 0014 EN 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 numbe
182. plates and can be turned when worn Blow bars are available in alternative materials for crushing applications other than materials for recycling Please consult the Addendum in Section 11 428 Impact Crusher Guide to Efficient Operation Trakpactor 428 4 Design and Function Issue EN 02 Page 3 Impact Aprons Fitted in the front and rear positions and lined with wear resistant impact plates some of which are interchangeable The setting is made manually by adjusting rods from the back of the machine Drive Through vee belts direct from the diesel engine with screw tension adjustment Engine Pulleys Two are provided one is supplied fitted and the other is supplied loose Machines built for stock are fitted with the higher speed pulley as standard to suit general applications The slower speed pulley will only be fitted against a specific order prior to the plant being completed Use with appropriate blow bars see Blow Bars above Impactor speeds Slow 504 rpm nominal 224 mm 8 87 pitch circle diameter engine pulley Fast 630 rpm nominal 280 mm 11 pitch circle diameter engine pulley An optional lower swing beam grinding path with overload compression springs is available for certain quarry applications See optional extras Section 4 2 15 for details BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 43 300 TEREX PEGS
183. pump for any other purpose DANGER that filling the diesel engine fuel tank on the BL Pegson The 050 Series pump is rated at 50 plant litres per minute suitable for equipment with tanks between 200 and 500 litres Duty is continuous up to 40 C ambient Self priming up to 3 metres dry Flow 50 Itrs min on the opposite page and also at3 metres head Maximum head 10 the general Safety Information metres given in Section 9 1 of the Plant User Manual Observe the Operating Service amp Safety Instructions BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 284 300 All Plants Fuel Transfer Pump BL PEGSON MANUAL ADDENDUM Issue 01 ENG A Terex Company Page 3 Fuel Transfer Pump Operating Service amp Safety Instructions SAFETY FLASHPOINT BELOW 37 99 DO NOT USE A TRGGER NOZZLE FOR DELIVERY INTO THE FUEL TANK FLASHPOINT ABOVE 37 99 MAXIMUM DUTY TIME AT 40 C TEMPERATURE RANGE Model x VRO50 VR100 VR100 12 6 3m 6m H Head DO NOT ALLOW THE PUMP TO RUN DRY SWITCH OFF IMMEDIATELY DELIVERY OF THE FUEL IS COMPLETED LE BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 285 300 A Terex Company Top Up Fuel Level Do Not fill the tank to capacity Monitor the gauge located on NOTICE the Engine Control Panel Allow r
184. r Head Drum Guard Figure 5d Dirt Conveyor Dirt Conveyor Safety Chain Dirt Conveyor Figure 5e Dirt Conveyor Safety Chain BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 60 300 Trakpactor TEREX 428 5 Transport EN 02 Figure 5f Dirt Conveyor Folded and Secured with Chain BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 61 300 Trakpactor TEREX 428 5 Transport Issue EN 02 PEGSON Page 14 Blank Page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 62 300 Trakpactor TEREX 428 Issue EN 02 PEGSON Page 1 Contents Safety ee eee 2 6 2 Setting UP 5 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 63 300 TEREX PEGSON 6 1 Safety Information Loose or baggy clothing can get caught in running machinery WARNING 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 N Terex Pegson machine can cause serious injury or even death WARNING DO NOT climb onto the mach
185. r Plat Start Up of Self Cleaning Magnetic Separator Figure 9ah MagneticSeparator 1 Besure 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 183 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 80 Maintenance DANGER e Belt tracking should be checked frequently and adjusted as necessary Refer to Section 9 1 Safety Tighten the side of the belt to which you Wo Information for relevant warning want the belt to move e Lubricate bearings on a schedule consistent with other equipment in use N WA R N with your product WEAR PERSONAL The speed of the belt on the magnetic PROTEC TIVEEQUIFMENI band totis presetatthe Refer to Section 9 1 Safety Information for relevant factory but can be altered by turning the 7 warning adjusting screw located in the hydraulic LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce As many inspections as dure possible should be made w
186. r body and then operating the hydraulic rams to open the pivotted upper frame of the crusher The crusher upper frame opens in two modes depending upon the servicing required for the machine By releasing only the internal swivelling eye bolts in Figure 9a the rotor is accessed whereas by only releasing the outer eye bolts in Figure 9a only the top of the body is raised for access to the impact aprons area Swivelling Eye Bolts A 5 each side Sle ee 9 Maintenance ems Trakpactor 428 Issue EN 02 Page 18 Both sets of bolts must NOT be undone at the same time and it is essential that when requiring to change from one opening mode to the other that the crusher body should be completely closed off Section 9 5 3 before attempting to reopen Section 9 5 2 into the other mode WARNING All maintenance on the impact crusher must only be carried out when the plant lockout procedure has been carried out and the crusher rotor is stationary Swivelling Eye Bolts B 6 each side e oleo A q Figure 9a Swivelling Eye Bolts BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 122 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON a 9 5 1 Safety Cuto
187. r 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 forthe electrical equipment on the plant is derived LOCKOUT MACHINE from the diesel engine to operate the control Information for Lockout Proce systems for the crusher and all the plant 12 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 161 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 Page 58 PEGSON 9 11 Plant Crusher and Hydraulic Pump Drive Belts Good alignment of both pulleys
188. rack 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 pressure buttons 1st pressure slow speed 2nd pressure fast speed Figure 7n Remote Umbilical Control Hand Set BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 96 300 Trakpactor TEREX 428 Issue EN 02 Page 1 PEGSON Contents 8 1 Safety Inf rmation 2 8 2 Closing Down the Plant 5 8 3 Emergency Stopping of the 8 8 3 1 Emergency Stop 2 8 8 3 2 16 00 8 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 97 300 TEREX PEGSON 8 1 Safety Information Loose or baggy clothing can get caught in running machinery WARNING 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 N Terex Pegson machine can cause serious injury or even death WARNING DO NOT climb onto the machine whilst in operation ALWAYS use the walkways
189. ration ofa 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 20 300 Trakpactor TEREX 428 Issue ENO2 1 7 Position of Emergency Stop Buttons amp Isolation Switch Emergency Stop Button Control Panel Lockable Isolation Switch Diesel Engine Emergency Stop Button Chassis Side 413 Emergency Stop Button Chassis Side Figure 1a Emergency Stop Buttons amp Isolation Switch BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 21 300 1 8 Plant Warning Signs 1 8 1 Location of Warning Signs Left Hand side of plant ing Labels Left Hand Side Figure 1b Warn AX846 901 8EN 02a 22
190. rator s manual for location of warning labels Ay DANGER ENTANGLEMENT HAZARD Rotating parts DO NOT enter while rotor is turning Death or serious injury will result SWITCH OFF LOCKOUT amp TAGOUT machine before inspection or maintenance 309 2 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 26 300 Safety Sign Illustrations continued Trakpactor TEREX 428 1 Safety Issue ENO2 PEGSON Page 19 PRIOR TO TRANSPORT 1 Fasten all loose items securely 2 Check the plant for loose or damaged parts FALLING HAZARD HEARING HAZARD Do not climb onto moving or working machi 3 Platform is for maintenance only You fall and be seriously You could be hit in the face or injured parts are safely secured May cause loss or degradation body by flying material SWITCH OFF LOCKOUT AND during transport of hearing over a period of TAGOUT machine dine Always use suitable lifting platform 5 before attempting any maintenance Wear proper hearing personal protective equipment FLYING MATERIAL HAZARD 3 Replace missing parts or make repairs as found necessary to ensure that all EXCEEDS 90 dB A Do not use platform when plant is working work above 2 metres 6 6 200 118 200 120 300 196 17 19 21 23 A DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with User Manual INHALATION HAZARD De
191. raulic system The inlet is with hose connector for the user to provide supply suitable piping from the clean water source eg bowser near to the plant as necessary Initial on off control of the pump is by means of a3 way valve lever Figure 2 mounted on the pump unit Whilst this valve leveris inthe on position the screw type valve Figure 2 can be used to regulate the water supply to the plant inlet manifold MANUAL ADDENDUM All Plants Water Pumps Issue 02 ENG Page 2 DANGER SKIN INJECTION HAZARD Refer to Section 9 1 of the Plant User Manual Safety Information for relevant warning WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 of the Plant User Manual Safety Information for relevant warning The supply for external equipment can be taken off one of the drain valves on the spraybar manifold No specific maintenance is required for the pump unit except to check for hydraulic oil leaks when carrying out the normal plant maintenance Section 9 of the plant manual Frost precautions must be taken in cold weather to ensure water does not freeze within the system by opening the water manifold drain valves and detaching the pump inlet feed pipe BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 288 300 All Plants TEREX Water Pumps MANUAL ADDENDUM Issue 02 ENG PEGSON Manifold Drain Valves Water Inlet Connecti
192. reness 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 amp Screening Inc 11001 Electron Drive Louisville Kentucky 40299 U S A Telephone 1 502 267 2314 Fax 1 502 267 2317 AX846 901 8EN 02a 5 300 EC Conformity This plantis in conformity with the provisions ofthe EC Machinery Directive 98 37 EC together with appropriate EN Harmonised Sta
193. ression Manifold Do not spray water into the crusher as this will increase NOTICE the wear BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 185 300 PEGSON 9 15 Plant Diesel Engine NOTICE For the diesel engine powerpack fitted to your Trakpactor to continue to perform safely efficiently and reliably it is imperative that all the recommendations given in the separate engine manual are strictly followed with regard to Safety Operation e Lubrication Maintenance e Service e Parts Adhere to the regular maintenance schedules and procedures specified by the manufacturer The diesel engine powerpack incorporates a Caterpillar engine but the external housing and some ofthe 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 BL Pegson Limited Coalville England Tel 9 Maintenance Trakpactor 428 Issue EN 02 Page 82 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure For the Twin Disc mechanically operated clutch refer to the instruction plate on the clutch or separate manufacturers manual for the correct adjustment and lubrication informati
194. rged batteries provide about 30 hours continuous running and recharging time takes about 4 hours e The LED light on hand set changes from green to red when there is about 10 power left in the batteries 1 hour continuous operation remaining and indicates it is time to recharge The plant warning horn will also sound when battery recharging is required Trakpactor 428 7 Operating Instructions Issue EN 02 Page 23 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 7 1 Safety Information for relevant warning Toconserve the battery charge the hand set should be switched off when not in use Charging point Figure 7 Remote Control Charger Connection BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 93 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 7 4 Alternative Control Hand Set with Umbilical Cable N WARNING where fitted WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 7 1 Safety Information for relevant warning As an alternative to the radio remote 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
195. rial Close down the plant and implement the Lockout Procedure Refer to User Manual Check safety cutout switch and wiring for any signs of physical damage Secure chains to protective caps of upper apron adjusters Release outer swivel eye bolts Turn Ignition Key to first position and then select pump mode Depress pump button and using manual lever open crusher until there is DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop 300 269 approximately 25mm 1 between top of upper frame and main body L Select plant mode on control panel Ensure everyone is clear of the machine and all emergency stops are released Attempt to start the engine No cranking of the engine should occur If the engine attempts to start lockout the machine and contact your dealer to investigate the problem Do not attempt to run until the fault has been corrected Implement the Lockout Procedure and refer to the user manual before proceeding with maintenance 300 268 300 268 INHALATION HAZARD PRIOR TO TRANSPORT 1 Fasten all loose items securely Death serious injury or delayed lung disease may result from breathing dust
196. rity Always use a suitable lifting platform before attempting any work 2 metres 6 6 or more above the ground level Keep all handles steps handrails platforms landing and ladders free from dirt snow and ice 1 4 2 6 The fastening of loads and instructing of crane operators should be entrusted to experienced persons only The marshaller giving the instructions must be within sight or sound of the operator 1 4 2 7 After cleaning examine all fuel lubricant and hydraulic fluid lines for leaks loose connections chafe marks and damage Any defects found must be rectified without delay 1 4 2 8 Any safety devices removed for set up maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work to ensure full working order BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 14 300 TEREX PEGSON 1 4 2 9 Improperly disposing of waste can threaten the environment and ecology Potentially harmful waste used with BL Pegson equipment includes such items as oil fuel coolant filters and batteries etc Use leakproof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source Ensure that all consumables and replaced parts are disposed of sa
197. rs for assistance M 4 m TEREX PEGSON AX846 901 8EN 02a 282 300 All Plants Fuel Transfer Pump od BL PEGSON 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 BL PEGSON A Terex Company Optional Fuel Transfer Pump This option is available as originally fitted equipment installed at the time of plant manufacture The pump is for the purpose of transferring diesel engine fuel from a barrel positioned at ground level alongside the plant diesel engine to the engine fuel tank MANUAL ADDENDUM All Plants Fuel Transfer Pump Issue 01 ENG Page 2 N WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 of the Plant User Manual Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 of the Plant UserManual Safety Information for Lockout Procedure The pump is permanently mounted 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 of plain hose 25mm bore for suction with strainer and delivery Do not use the fuel transfer
198. rs and impact plates and if necessary adjust the impact aprons and swing arm Section 9 6 18 When the blow bar changing process is complete disconnect the extraction tool andreconnect the crusher door ram hoses to the valve unit on the platform Run the crusher empty for 30 minutes to allow the blow bars notice to bed into position and also check that the crusher is running smoothly Never open the inspection doors while the crusher is in WARNING operation 9 Maintenance Trakpactor 428 Issue EN 02 Page 37 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 141 300 PEGSON 9 7 2 Replacing the Impact Plates of the Front and Rear Impact Aprons Procedure 1 Observe all the safety warnings 2 Run the crusher until completely empty Close down the plant Section 8 2 and implement the lockout procedure 3 Remove the appropriate access panels Figures 90 amp 9p on the outside of the crusher using suitable lifting equipment 4 Open the crusher Section 9 5 2 5 Remove the worn impact plates 6 Clean the seats of the impact plates 7 Fitnew impact plates Strike the bolt heads repeatedly during tightening to ensure the bolt
199. rtation the Trakpactor must be prepared as described below Refer to Section 2 1 for minimum travel dimensions 4 S 1 Observeall safety warnings ik 2 Ensure that both conveyors feed hopper and crusher are free from stone and dirt 3 Ontheright hand side ofthe Trakpactor raise the bottom section ofthe 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 Startthe engine Section 7 2 Increase the engine speed to 1800rpm 8 Turn the Operation switch to PLANT the safety warning horn will sound for 15 seconds Turn the Dirt Conveyor WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 5 1 Safety Information for relevant warning FALLING HAZARD Refer to Section 5 1 Safety Information for relevant warning Figure 5c Front Ladder shown unfolded BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 58 300 PEGSON switch to and fold the dirt conveyor fully in to the travelling position Secure with the transportation safety chain Figure 5e During folding of the dirt conve
200. running forward or reverse Note The maximum power take off from one side ofthe engine is limited to approximately 30 kW therefore the system is electronically limited such it is only possible to slew operate one side only when in the SLOW mode Fine adjustment ofthe slow speeds is possible Consult BL Pegson Ltd Trakpactor 428 9 Maintenance Issue EN 02 Page 51 Itis recommended that adjustment is not undertaken without BL Pegson Ltd consent and under no circumstances should the slow speed be adjusted greater than 0 4kph 0 2mph Motor mounted motion control valves are utilised to prevent the machine over running when moving downhill This block also incorporates a shuttle valve to release the spring applied track parking brake together with a pressure reducing valve pre set to 60 bar so that the brakes are not overpressurised 9 9 3 Feeder Drive This valve Section is fitted with a proportional solenoid so that the feeder speed can be controlled by means ofa chassis mounted control box potentiometer 9 9 4 Circuit Protection The system is equipped with the following protection Suction Filter 904m nominal e Pressure Filter 10m absolute in each pump circuit prior to the directional control valves Return Filter 10um nominal e Lowoil level cut out Note For Hydraulic Pump Drive Belt adjustment refer to Section 9 11 4 BL Pegson Limited Coalville England Tel 44 15
201. rusher 2 WARNING ensure the rotor can turn Information for relevant without any impedance Check the distance between the long blow bars Section 9 7 1 and iy 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 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 warning Doors whilst the crusher is running Each blow bar must be in contact with the lower seat NoTice 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 10mm 3 8 to compensate for the lifting of the blow bars under centrifugal force 4 Measure the smallest gap between each blow bar and the lowest wear plate of the Front apron BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 130 300 PEGSON Loosen the locknut with protective sleeve A a few turns Figure 9g Repeat this step for the other adjusting mechanism To in
202. s 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 300 284 300 284 2 Check the plant for loose or damaged parts 3 Replace missing parts or make repairs as found necessary to ensure that all parts are safely secured during transport 4 Ensure safety chain or locking device is fitted to folding conveyor and all additional conveyors screens 5 Ensure the plant is correctly folded to suit the transport height regulations applicable 300 354 300 354 AX846 901 8EN 02a 269 300 300 269 Trakpactor TEREX 428 Spare Parts Issue EN 02 PEGSON Page 68 Blank page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 270 300 Trakpactor TEREX 428 Appendix Issue EN 02 Page 1 PEGSON Contents 11 1 Noise Level 2 11 2 Manual Engine ere E ERE x 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 me
203. s 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 Email sales bl pegson com England To order additional copies contact your local BL Pegson Ltd Dealer AX846 901 8EN 02a 7 300 AX846 901 8EN 02a 8 300 Trakpactor TEREX 428 1 Safety Issue 2 Page 1 PEGSON Contents 1 1 Warnings and Symbols ei 2 1 2 Organisation 3 1 3 Selection and Qualification of Personnel Basic Responsibilities 4 1 4 Safety Instructions Governing Specific Operational Phases 5 145 tStandard 5 1 4 2 Special Work Conjunction with Utilisation of the Plant and Maintenance and Repairs During Operation Disposal of Parts and Consumables 5 1 5 Warning OF Special Dangers inre eben eu cues EE ea ceca 8 1 5 1 ENergy KC 8 1 5 2 Gas Dust Steam Smoke and
204. s 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 Trakpactor 428 Issue EN 02 Page 7 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 47 300 Trakpactor TEREX 428 4 Design and Function Issue EN 02 Page 8 PEGSON Blank Page BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 48 300 Trakpactor TEREX 428 5 Transport EN 02 Page 1 PEGSON Contents 5 1 Safety oils a 2 9 2 ile EEDE 4 UU 4 2 2 2 Unloading ete RT 9 SRM 1 012 10 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 15 12 04 AX846 901 8EN 02a 49 300 Trakpactor TEREX 428 5 Transport Issue EN 02 PEGSON a 5 1 Safety Information Loose or baggy clothing can get PERSONAL caught in running machinery PROTECTIVE EQUIPMENT WARNING ALWAYS
205. s are seated correctly in the bores of the of impact plates To 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 NOTICE liner plates BL Pegson Limited Coalville England Tel Trakpactor 428 9 Maintenance Issue EN 02 Page 38 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 9 1 Safety Information for relevant warning LOCKOUT MACHINE Refer to Section 9 1 Safety Information for Lockout Proce dure 9 Close the crusher Section 9 5 3 10 Refitthe access panels 11 Check the distance between the blow bars and impact plates and if necessary adjust the impact aprons and swing beam Section 9 6 After any maintenance and before starting the crusher warning ensure the rotor can turn without any impedance 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 142 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Access Panels Figure Front Impact Apron Access Panels and Wear Plates BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 143 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Wear
206. s from above to lift and slide the panel out BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 152 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 49 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 153 300 TEREX PEGSON 9 9 Plant Hydraulic System Description Figure 9v amp Hydraulic circuit diagram in Section 10 9 9 1 General Description All hydraulic functions are powered by two pumps one mounted either side ofthe diesel engine and driven from the main crankshaft pulley via two SPB belts Each pump is an axial piston variable displacement unit capable of up 1095 litres min at 320 bar and each feeds a directiona control valve Front Pump 9 Maintenance 1 Trakpactor 428 Issue EN 02 Page 50 DANGER SKIN INJECTION HAZARD Refer to Section 9 1 Safety 27 YP information for relevant warning The flows and pressures to each service is limited by the relevant spool as shown below and the pump supplies only the required flow by automatically backing off the swash plate angle thus reducing wasted power a
207. t start the engine Impactor non d rive side 428 Trakpactor No cranking of the engine should occur If the engine attempts to start lockout the machine and contact your dealer to investigate the problem Do not attempt to run until the fault has been corrected Implement the Lockout Procedure and refer to the user manual before proceeding with maintenance Impactor drive side 428 Trakpactor AX846 901 8EN 02a 24 300 Safety Decal 300 269 Danger Entanglement Hazard for Inspection Door Decal Location 428 Trakpactor DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and bolted except when performing maintenance Open door only to perform maintenance after rotor comes to a complete stop Inspection door both sides of impactor 428 Trakpactor AX846 901 8EN 02a 25 300 1 8 3 Safety Sign Illustrations TEREX PEGSON DANGER ENTANGLEMENT HAZARD Do not reach into unguarded machine you can be pulled in Death or serious injury will result Keep all guards in place SWITCH OFF LOCKOUT amp TAGOUT machine before opening or removing guards IMPORTANT CHECK CONDITION OF FILTERS ON A REGULAR BASIS CHANGE ELEMENTS WHEN INDICATORS SHOW RED CHECK OIL LEVEL WEEKLY
208. tem Do Not carry out maintenance on the fuel system near naked lights or sources of sparks such as welding equipment Filler Cap 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 286 300 All Plants rPum TEREX MANUAL ADDENDUM 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 PEGSON Optional Water Pump This option is available as originally fitted equipment installed at the time of plant manufacture Two models are available 25 litres minute nominal 6 6 US galls to suplly the plant spraybars only e 65 litres minute nominal 17 US galls to supply the plant spraybars plus additional capacity for the operator s off plant needs The pump is to provide a pressurised supply of clean water to the dust suppression spray nozzles included on plants as a standard fitment For details of typical clean water requirements for the dust suppression system refer to the Maintenance Section 9 of the plant manual The pump is permanently mounted suitable position on the plant near to the water manifold Figure 1 and is driven from a branch of the engine driven plant hyd
209. tion issue 02 4 PEGSON 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 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 selfaligning 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 applicati
210. tor 428 9 Maintenance Issue EN 02 Page 8 The plant has been designed to facilitate easy routine maintenance but where necessary to remove any guards make sure that they are replaced before the machine is restarted Referto the Spare Parts illustrations Section 10 to identify the machinery components mentioned in the maintenance procedures BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 112 300 TEREX 9 Maintenance PEGSON WARNING 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 Trakpactor 428 Issue EN 02 Page 9 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 113 300
211. transporting the Trakpactor it is the responsibility of the haulage contractor to safely secure the plant to the transporter BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 53 300 PEGSON To manoeuvre the Trakpactor with the radio remote control hand set Where fitted The plant is manoeuvred using the remote hand held radio transmitter control unit Fig 5b This hand set also has the facility to switch the plant feeder on and off whilst the plant is in the crushing mode Procedure 1 Observe all safety instructions 2 Take the Remote Control Hand Set from the Control Box and first become familiar with the functions of all the individual buttons Figure 5b before the next step Forward Product Conveyor first Reverse Hopper first 3 To startup the handset transmitter first stand well clear of the plant Hold the hand set with the stop button nearest to the operator and proceed as follows Ensure the stop button is pulled out Depress both of the safety buttons Fig 5b at the same time for at least 1 second Release the safety buttons The red LED will change to green The transmitter is in function status when the green LED comes on Trakpactor 428 5 Transport Issue EN 02 Page 6 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 5 1 Safety Information for relevant warning Note Th
212. ts 428 Trakpactor Page 61 Hydraulic System Components SHEET 2 428 Trakpactor Spare Parts 428 Trakpactor Page 62 Hydraulic System Components sheet 3 REF PARTNUMBER DESCRIPTION QUANTITY ELEMENT ITER 2 mm NE s 2568 5005 CYUNDER MPACTOR 0 AX846 45 Iss 02mod 04 12 03 AX846 901 8EN 02a 264 300 63 428 Trakpactor Spare Parts 20 SS 145 Gy 9V8XV 10980 330 Or vsldAH 4000 YOLIYANI Hydraulic System Components 428 Trakpactor Spare Parts 428 Trakpactor Page 64 10 8 Electrical System Electrical Components REF PART NUMBER DESCRIPTION QUANTITY 2683 2100 FUSE SET COMP 2 3A 2 5A 2 10A 2 16A E M STOP TWIST TO RELEASE PUSH BUTTON WITH CONTACT BLOCKS 2 POSITION REMOTE CONTROL OFF ON 3 POSITION SPRING RETURN SWITCH 19882105 WITH CONTACT BLOCKS 2683 2106 10 11 PIN 2 POLE MINI RELAY 24vDC 12683 2106 11 PIN RELAY BASE By 2683 2107 10 AMP 8 PIN 2 POLE MINI RELAY 24VDC 12683 2107 PIN RELAY BASE 6 2683 2121 INDICATOR LAMP 2683 2108 15 SECOND PRE START TIMER 24V DC FEEDER SPEED CONTROL _ 258529 2683 2113 FEEDER SPEED CONTROL KNOB 9 26 24 DUTYEMSTOPRELAY 1 HEAVY DUTY PANEL SUPPLY RELAY 1 i BLACK PUSH BUTTON ow mem TELERADIO CONTROL WHERE FIT
213. ure 7h amp 71 engagement torque as described in Section 9 15 e Refer to engine manual for engine initial start up Crusher Run the plant empty fora short period 1 Regularly check drive belts crusher and oftime 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 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 86 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON ines Hydraulic Oil Return Hydraulic Oil Filter and Gauge Breather Filler Hydraulic Oil Level Hydraulic Oil Tank Figure 7h Hydraulic Oil Tank amp Level Indicator Oil Filler Plug Oil Level Sight Glass Oil Drain Plug Figure 7i Feeder Vibrating Unit BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 87 300 Trakpactor TEREX 428 7 Operating Instructions Issue EN 02 PEGSON record for future reference and fault diagnosis The maximum acceptable working temperature is 80 C 176 F Avoid overloading the crusher restrict loading to 50 and 75
214. user manual before proceeding with maintenance 300 268 BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 123 300 Trakpactor TEREX 428 PEGSON 9 Maintenance Issue EN 02 Page 20 9 5 2 Opening the Crusher N WARNING Before atempting to open the crusherbody make sure that all WEAR PERSONAL warninc tools and personnel are 1 efer to Section 9 1 Safety Information for relevant maintenance platform warning LOCKOUT MACHINE 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 notice 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 swivelling eye bolts or the crusher flange and rotate them through 180 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 BL Pegson Limited Coalville England Tel 4
215. ut Switch Before opening the crusher the following safety check must be carried out DANGER ENTANGLEMENT HAZARD DEATH OR SERIOUS INJURY will result from contact with moving rotor or flying material Entry by authorized trained personnel only Lockout tagout equipment prior to entry Keep doors closed latched and Y bolted except when performing maintenance Open door a only to perform maintenance after rotor comes to a 1 complete stop Safety Cutout Switch Before opening the crusher the following safety check must be undertaken e Run feeder and crusher empty of all material Close down the plant and impiement the Lockout Procedure Refer to User Manual Check safety cutout switch and wiring for any signs of physical damage Secure chains to protective caps of upper apron adjusters Release outer swivel eye boits Turn Ignition Key to first position and then select pump mode Depress pump button and using manual lever open crusher until there is approximately 25mm 1 between top of upper frame and main body Select plant mode on control panel Ensure everyone is clear of the machine and all emergency stops are released Attempt to start the engine No cranking of the engine should occur If the engine attempts to start lockout the machine and contact your dealer to investigate the problem Do not attempt to run until the fault has been corrected Implement the Lockout Procedure and refer to the
216. y sed 9 510 sjue2uqn3 82 d 2 0 11 LC SoxoqJeoc uoisue 4698 2 0 lt 498 2006 gt 14 14 eseoJc sBuueeg yeys 9 2 4066 gt 065 6 2061 04 Dov 4669 lt uoneouqn seJnjeJeduJej eseoJ6 yeys pedu 87 jueuidinb3 44 1530 518618 44 1530 518600 Fax 5 x o c x ted Coalvi imi BL Pegson L AX846 901 8EN 02a 119 300 Trakpactor TEREX 428 9 Maintenance Issue EN 02 PEGSON Page 16 Lubrication Specifications AX846 901 8EN 02a 120 300 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 mm s 150 220 460 104 F in s 0 232 0 341 0 713 Kinematic Viscosity at 100 C mm s 15 4 20 1 32 9 212 F in s 0 0238 0 0312 0 051 Viscosity Index 105 105 105 Timken OK Ib Minimum 50 50 50 Extreme Pressure Agent Yes Yes Yes R amp 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 Speci
217. yor ensure that the notice hydraulic hoses and conveyor 10 11 12 13 14 belt do not foul any part of the structure Position easy slope ramps at the end of the transporter to help with loading of the Trakpactor Turn the Operation switch to TRACK Using the remote control hand set steer the Trakpactor onto the transporter Section 5 2 1 and Section 7 3 When plant is loaded shut down the remote control hand set using stop button Switch off the engine Section 8 2 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 Securing the Trakpactor to the transporter is the responsibility of the haulage contractor WARNING Trakpactor 428 5 Transport EN 02 Page 11 WARNING WEAR PERSONAL PROTECTIVE EQUIPMENT Refer to Section 5 1 Safety Information for relevant warning FALLING HAZARD Refer to Section 5 1 Safety Information for relevant warning Prior to transportation always check the plant loose or damaged components Fasten all loose parts replace missing items or make repairs as found necessary to ensure that all components are safely secured during transportation BL Pegson Limited Coalville England Tel 44 1530 518600 Fax 44 1530 518618 AX846 901 8EN 02a 59 300 Trakpactor TEREX 428 5 Transport Issue EN 02 Dirt Conveyo

00 EN02 428 Trakpactor User Manual

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