to our PDF user manual.

PEGSON METROTRAK M.A.

PEGSON METROTRAK H.A.

USER MANUAL

OPERATION

SET-UP

TRANSPORT

SERVICING

LUBRICATION

WEAR PARTS

n 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. This user manual is part of the plant and must always be available wherever the plant is in use and kept with it at all times.

AX893-901-8 EN -01f

Pegson Metrotrak/Eurotrak ~ 1/270

EN - English

◄ EN - To display the language required, select the language bookmark icon.

◄ FR - Pour afficher la langue exigée, choisir l’icône de signet de langue.

◄ ES - Para demostrar el idioma necesario, seleccione el icono de señalador de idioma.

◄ DE - Um die erforderliche Sprache darzustellen, wählen Sie das

Sprachenlesezeichenabbild aus.

◄ IT - Per mostrare la lingua richiesta, di scegliere l’icona di segnalibro di lingua.

◄ NL - Om de noodzakelijke taal te tonen, selecteer de taalbladwijzerbeeld.

◄ PT - Para exibir a linguagem necessária, seleciona o marcador de linguagem de ícone de livro.

◄ BR PT - Para exibir a linguagem necessária, seleciona o marcador de linguagem de ícone de livro.

◄ RU - Чтобы показывать требуемый язык, выберите языковое изображение закладки.

◄ CS - Vyberte ikonu záložky jazyka, který chcete zobrazit.

◄ HU - A kívánt nyelv megjelenítéséhez kattintson a nyelv könyvjelzőikonjára.

◄ PL - Aby wyświetlić żądany język, wybierz ikonę zakładki języka.

◄ RO - Pentru a afişa limba dorită, selectaţi pictograma limbii corespunzătoare.


Pegson Metrotrak M.A. + Metrotrak H.A.

EN - English

01

EN

Introduction

Introduction to User Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -01-2

Safety Warnings and Symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -01-3

Designated Use of Plant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -01-4

Additional Information and features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -01-5

AM0009 fuel Transfer Pumps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AM0009-1

AM0010 M.C.S. Belt Weigher BW100 - - - - - - - - - - - - - - - - - - - - - - - - - - - - AM0010-1

AM0011 Water Pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AM0011-1

02

EN

Safety Notices and Hazards

Safety Notices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -02-2

Safety Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -02-6

Organisation Measures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -02-7

Selection and Qualification of Personnel - Basic Responsibilities- - - - - - - - - - - - - -02-8

Safety Instructions Governing Specific Operational Phases- - - - - - - - - - - - - - - - - -02-9

Warning of Special Dangers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -02-12

Safety Signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -02-16

03

EN

General Information

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-2

EC Conformity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-2

Units of Measure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-3

Copyright - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-3

Operating Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-4

Information and Advice - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -03-4

04

EN

Plant Specification and Information

Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-2

Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-3

Plant Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-3

Standard fittings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-4

Optional Extra Fittings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-6

Crusher Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-7

Location of Safety Signs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -04-9

EN

Pegson Metrotrak/Eurotrak ~ 3/270 i

User Manual Contents

10

EN

Preparing to Move the Plant

Initial Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10-2

Preparing for Loading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10-3

11

EN

Unload and Load Plant - Transport Trailer

Unloading from Trailer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11-2

Loading on to Trailer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11-3

12

EN

Moving the Plant

Moving the plant on the tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-2

Initial Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-2

Preparing Umbilical Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-3

Preparing Radio Control [if fitted] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-4

Manoeuvring the Plant- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-6 finish Manoeuvring the Plant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12-10

13

EN

Engine Starting and Controls

Engine Start-Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-2

Cantrak Engine Monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-6

Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-6

Displays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-9

Data Parameters and Icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-10

Alarm Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-11

Configuration Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-12

Engine Warning Lamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13-13

14

EN

‘860’ Radio Remote Control

Operation [if fitted] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14-2

Battery Recharging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14-3

15

EN

Engine Stop

Switching off engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15-2

16

EN

Emergency Stop

Emergency Stopping the Plant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16-2

Re-Setting Emergency Stops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16-3

Testing Emergency Stops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16-4

17

EN

Preparing to Crush

Plant Location Considerations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17-2

Setting Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17-3

18

EN

Loading the Plant Hopper

Correct Loading of Hopper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18-2 ii



20

EN

Plant Operation

Crusher Models - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20-2

Plant Starting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20-3

21

EN

Plant Operation - Adjusting and Setting

Discharge Opening - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -21-2

Adjusting Discharge Opening H.A. [Hydraulic Adjust model only] - - - - - - - - - - - - - - - - -21-4

Adjusting Discharge Opening M.A. [Manual Adjust Model only] - - - - - - - - - - - - - - - - - -21-6

22

EN

Plant Operation - Clearing Blockage

Clear Assist System H.A. [Hydraulic Adjust model only] - - - - - - - - - - - - - - - - - - - - - - - -22-2

Blocked Crusher H.A. [Hydraulic Adjust model only] - - - - - - - - - - - - - - - - - - - - - - - - - -22-3

Clearing Blocked Crusher M.A. [Manual Adjust model only] - - - - - - - - - - - - - - - - - - - - -22-6

23

EN

Operation - Plant Alarms

Plant Diagnostic Lamp- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23-2

24

EN

Daily Plant Checks

Checks Prior to Daily Start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24-2

25

EN

Dust Suppression System

Dust Suppression System [if fitted] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25-2

26

EN

Re-fuelling

Check fuel Level and fill Up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26-2

27

EN

feeder Stop and Start

[‘860’ Radio Remote]

Radio Remote Control - Feeder Stop & Start, [if fitted] - - - - - - - - - - - - - - - - - - - - - -27-2

31

EN

Preparing to finish Crushing

Normal Closing Down the Plant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -31-2

32

EN

Clearing Blocked Jaw Crushers

Blocked Jaw Crusher- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32-2

33

EN

Initial Checks - Running In

Initial Start-Up- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33-2

Actions During Running-In Period - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33-3

34

EN

Jaw Crusher Checks

Jaw Crushers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34-2

Wear Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34-2

Jaw faces - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34-2

Routine Inspection Checks- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -34-4

EN

Pegson Metrotrak/Eurotrak ~ 5/270 iii


40

EN

Servicing Safety and Precautions

Servicing Safety Information- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -40-2

41

EN

Servicing - Lubrication and Checks

Lubrication Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41-2

Lubrication and Hydraulic System Schedule - - - - - - - - - - - - - - - - - - - - - - - - - - - -41-4

Hydraulic Jaw Adjustment Check [H.A. model only] - - - - - - - - - - - - - - - - - - - - - - - - -41-8

Toggle Plate Springs Check [H.A. model only] - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41-9

Ambient Temperature Variations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -41-10

42

EN

Pegson Lubricant and Fluid Specifications

Lubricant Oil Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -42-2

Grease Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -42-4

Hydraulic Fluid Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -42-6

43

EN

Servicing Vibrating Hopper feeder

Vibrating Hopper feeder - Servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -43-2

44

EN

Servicing Jaw Crusher

Jaw Crusher Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44-2

45

EN

Servicing Vee Belts

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-2

Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-3

Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-4

Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-7

Drive Belt Tensioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-8 fault finding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45-10

46

EN

Servicing Conveyors

Training of Belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46-2

Conveyor Belt Tensioning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46-3

Inspection of Conveyors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46-5

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46-7

Cleaning Conveyor Belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -46-8 iv



47

EN

Servicing of Tracks

Plant Tracks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47-2

Adjusting Track Tension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47-4

Drive Oil Draining & filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47-6

48

EN

Servicing Clutches

Engine Power Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48-2

A - Hydraulic Clutch - Grease Lubricated Bearing- - - - - - - - - - - - - - - - - - - - - - - - -48-2

B - Hydraulic Clutch - Oil Lubricated Bearing [Transfluid] - - - - - - - - - - - - - - - - - - - - -48-4

Hydraulic Clutch Operation [Types A and B] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48-5

C - Manual Clutch [TwinDisc] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48-6

D - fluid Coupling [Transfluid] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48-8

49

EN

Servicing Magnetic Separator

Magnetic Separator - General [if fitted] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49-2

Inspection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49-2

Servicing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49-3

50

EN

Servicing Electrical System

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -50-2

Battery Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -50-3

51

EN

Servicing Hydraulic System

General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-2

Hydraulic fluid Level - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-3

Suction filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-4

Return filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-6

Tank Breather- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-7

Pressure filters [if fitted] - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51-8

EN

Pegson Metrotrak/Eurotrak ~ 7/270 v


60

EN

Replacing Worn Jaws

Jaw Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60-2 vi


01

EN

Introduction

Pegson Plant

EN


01-1

Introduction to the Plant

Introduction to User Manual

1. This instruction manual contains important information on how to operate the plant safely, properly and most efficiently.

2. To be assured of faultless operation we would ask you to carefully read the manual and give the required time and attention to essential maintenance, cleaning and inspection.

3. Observing these instructions and exercising common sense helps to avoid danger, to reduce repair costs and down time and to increase the reliability and life of the plant. failure to do so may invalidate any warranties in force.

4. This manual is part of the plant and must always be available wherever the plant is in use and kept with it at all times.

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

Operation

6. Includes manoeuvring, setting up, operation during the course of work, evacuation of production material and waste, care and disposal of fuels and consumable items, etc.

Servicing

7. Servicing, lubrication, inspection and adjustments.

Transport

8. follow all applicable laws and safety regulations for accident prevention and environmental protection.

01-2


Pegson Plant

Safety Warnings and Symbols

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

n

This is the safety alert symbol. When you see this symbol on the plant or in this manual be alert to the potential for personal injury or equipment damage. follow the recommended precautions and safe operating practices.

02

n

CAUTION

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

n

DANGER

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

NOTICE

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

n

WARNING

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

EN 01-3



Designated Use of Plant

10. Pegson tracked crusher plants are designed exclusively as a self-contained mobile unit for crushing materials in a wide range of quarry applications, within the parameters set out and described within this manual. It is also possible for some models to be used in demolition and recycling applications.

11. A Pegson tracked crusher plant is intended to be used only in above ground open air environments. Use of the plant in any other way is contrary to its intended use.

n

WARNING

This plant is designed for stone crushing applications. It is vitally important that large pieces of steel or similar uncrushable objects are not allowed to enter the crushing chamber as severe damage and injury may occur. The plant is not designed to accept large pieces of steel or other uncrushable objects such as bucket teeth from a loading shovel.

12. Operating the plant outside it’s recommended range of applications and operating parameters shown 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.

03

NOTICE

If you have any doubts about any aspect of the plant’s capability or servicing procedures, you must consult your local

Powerscreen® dealer or Powerscreen®

Technical Support.

01-4


Pegson Plant

Additional Information and features

PEGSON PLANTS CAN VARy IN SPECIfICATION.

The plant may have several changes such as:

OPTIONAL EQUIPMENT

SPECIAL fEATURES

ADDITIONAL fEATURES OR INfORMATION

MODIfICATIONS

THESE CHANGES MAy AffECT THE INfORMATION GIVEN IN THIS MANUAL.

CHECK fOR ANy ADDENDUM OR BULLETIN WHICH IS INCLUDED IN THIS

SECTION TO SUPPORT THESE VARIATIONS.

TAKE NOTE Of ANy VARIATIONS AS THEy MAy AffECT PROCEDURES.

EN


01-5


01-6


Pegson plants

Addendum to User Manual

Operating Instructions

AM0009 fuel Transfer Pumps

[EN]

Introduction and Specification

1. This is available as originally fitted equipment installed at the time of plant manufacture.

2. The pump is for the purpose of transferring diesel fuel from a fuel container positioned at ground level alongside the plant fuel tank.

3. The pump is permanently mounted in a suitable position on the plant in the vicinity of the engine and is electrically driven from a 24v DC supply.

The unit is fitted with an integral on/off switch.

4. Also supplied as part of the kit are lengths of plain hose 25mm (1in) bore for suction [with strainer] and delivery.

5. The 2573-7002 pump is suitable for equipment with diesel fuel tanks between 200 and 500 litres (53 and 132 US gallons) . Flow is 50 l/min

(13.2 US gal/min)

6. The 2573-7014 pump is suitable for equipment with diesel fuel tanks between 500 and 1000 litres (132 and 264 US gallons) . Flow is 100 l/ min (26.4 US gal/min)

7. Duty is continuous up to 40°C (104°f) ambient, self priming dry up to 3m (9.8 ft) head.

Maximum head 10m (32.8 ft) .

EN n DANGER

Do not use the fuel transfer pump for any other purpose than filling the diesel fuel tank on a Pegson plant.

Observe the safety instructions in these instructions plus safety and information given in the re-fuelling section of the plant user manual.

AM0009-1


fuel Transfer Pump

[if fitted]

SAfETy

1. DO NOT USE A TRIGGER NOZZLE fOR

DELIVERy INTO THE fUEL TANK.

1

2. fLASHPOINT BELOW 37°C (99°f)

PETROL

GASOLINE

BENZINE

2

3. fLASHPOINT ABOVE 37°C (99°f)

DIESEL

GAS OIL fUEL OIL

3

AM0009-2


INSTALLATION & USE

4. CONTINUOUS DUTy AT 40°C (104°f) 4

Pegson plants

5. TEMPERATURE RANGE

5

6. DO NOT ALLOW THE PUMP TO RUN DRy.

6

7. SWITCH Off IMMEDIATELy DELIVERy Of

THE fUEL IS COMPLETED.

EN


7

AM0009-3

fuel Transfer Pump

[if fitted]

Top Up With fuel

1. Check the fuel gauge on the plant.

2. Observe all safety warnings.

3. follow the instructions to re-fuel in the plant user manual

4. Connect both hoses to the pump and insert the suction hose into the fuel supply.

5. Remove the filler cap and insert the delivery hose into the plant fuel tank.

6. Operate the switch on the pump to top up the fuel tank. Use only in accordance with the introduction and specification.

7. When re-fuelling is complete, switch off the pump and stow the hoses.

8. Replace the filler cap.

9. If the plant is to be operated, refer to engine starting in the user manual to start up.

10. If the plant is not being used, set the isolation switch to the ‘0’ position.

NOTICE

Do Not fill the tank to overflow or full capacity.

Allow room for expansion and wipe up spilt fuel immediately.

n DANGER

Diesel fuel is highly flammable and is an explosion/burns hazard. NEVER remove the filler cap or re-fuel, with the engine running.

NEVER add petrol, gasoline or any other fuel mixes to diesel because of increased fire or explosion risks.

DO NOT smoke while refilling or carrying out maintenance on the fuel system. DO

NOT carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.

AM0009-4


Addendum to User Manual

AM0010 M.C.S. Belt Weigher BW100

[EN]

Pegson Plants

EN


AM0010-1

BW100 Belt Weigher

[if fitted]

ROUTINE CALIBRATION SIMPLIfIED GUIDE

1. The Following procedures may be performed on a routine basis as required.

2. Important: The belt should be stopped and secured prior to suspending or removing the test weights for span calibration.

3. Safe working practice should be adopted at all times.

Zero Calibration

4. With belt running empty at normal speed with test weights removed.

5. ZERO CALIBRATION REQUIRED.

5

6. INITIAL ZERO COUNT.

6

7. fREQUENCy COUNT DISPLAyED DURING

CALIBRATION.

8. DEVIATION.

7

8

9

9. NEW ZERO COUNT CALIBRATION

COMPLETE - RETURN TO RUN MODE.

10. PRESS TO RETURN TO RUN MODE.

10

11

11. SPAN REQUIRED.

AM0010-2


Span Calibration

12. With belt running empty at normal speed with test weights applied.

13. INITIAL SPAN COUNT.

14. fREQUENCy COUNT DISPLAyED DURING

CALIBRATION.

13

14

15. DEVIATION.

15

16. NEW SPAN COUNT.

17. CALIBRATION COMPLETE - REMOVE TEST WEIGHTS

18. PRESS TO RETURN TO RUN MODE.

16

18

Pegson Plants

EN


AM0010-3

BW100 Belt Weigher

[if fitted]

INITIAL CALIBRATION SIMPLIfIED GUIDE

1. The following procedures may be performed when messages E3 and E4 are displayed during routine calibration.

2. 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.

3. 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

4. With belt running empty at normal speed with test weights removed.

5. SELECT PARAMETER P377.

5

6. INVOKE INITIAL ZERO ENTER “ 1 “.

6

7. CURRENT ZERO COUNT.

7

8. ZERO CALCULATION fREQUENCy COUNT

DISPLAyED.

9. ZERO DEVIATION.

10. ZERO DEVIATION ACCEPTED - INITIAL

ZERO COUNT= ####.

8

9

10

11. PROCEED WITH SPAN CALIBRATION OR

RETURN TO RUN MODE.

AM0010-4

11


Span Calibration

12. With belt running empty at normal speed with test weights applied.

13. SELECT P388 .

13

14. INVOKE INITIAL SPAN ENTER “ 1 “.

14

15. CURRENT SPAN COUNT= ####.

16. SPAN CALCULATION - fREQUENCy COUNT

DISPLAyED.

17. SPAN DEVIATION= ##.

18. ZERO DEVIATION ACCEPTED - INITIAL

ZERO COUNT= ####.

15

18

19. RETURN TO RUN MODE.

EN

19


16

17

Pegson Plants

AM0010-5

BW100 Belt Weigher

[if fitted]

AM0010-6


Pegson plants

Addendum To User Manual

AM0011 Water Pump

[EN]

2575-2002 for dust suppression system

2575-2009 for dust suppression system plus additional requirements

TyPICAL INSTALLATION SHOWN

Optional Water Pump [If fitted]

1. This option is available as originally fitted equipment installed at the time of plant manufacture.

2. Two models are available:

2575-2002: 25 l/min nominal (6.6 US gall/min) to supply the plant spray bars only.

2575-2009: 65 l/min nominal (17 US gall/ min) to supply the plant spray bars, plus additional capacity for requirements additional to the plant.

3. The pump is to provide a pressurised supply of clean water to the dust suppression spray nozzles included on plants. for details of clean water requirements for the dust suppression system, refer to the plant user manual.

4. The pump is permanently mounted in a suitable position on the plant near to the water system inlet and is driven by the plant hydraulic system.

EN


AM0011-1

Water Pump

[if fitted]

Controls

1. The water inlet is a hose connector for the provision of suitable supply piping from a clean water container close to the plant.

n DANGER

Refer to Safety Notices Section for relevent warning and procedure

SKIN INJECTION

HAZARD

1

2. Initial on and off control of the pump is by means of a three position valve lever.

3. Whilst valve lever 2 is in the on position the screw type valve can be used to regulate the supply to the plant water system.

2

3

AM0011-2


Pegson plants

4. If the higher capacity pump is fitted, the supply to the additional equipment can be taken off one of the drain valves.

4

Servicing

5. No specific maintenance is required for the pump unit except to check for hydraulic oil leaks when carrying out the normal plant checks.

4

Protection from freezing

6. Precautions must be taken in cold weather to ensure water does not freeze within the system, by opening the water manifold drain valves and draining the system.

7. Detach the pump water inlet feed pipe and any additional equipment supply also.

NOTICE

Drain water from system when not in use, if there is a possibility of freezing.

Pump Hydraulic and Water Circuits

A. Hydraulic fluid

B. Water

C. Three Position Valve

D. flow Control Valve

E. Hydraulic Motor f. Water Pump

EN


AM0011-3

Water Pump

[if fitted]

AM0011-4


02

EN

Safety Notices and Hazards

Pegson plants

EN


02-1

Safety Hazards

Safety Notices

n

DANGER

ENTANGLEMENT HAZARD

In-running nip points can cause serious injury or even death.

DO NOT reach into an unguarded plant.

your arm could be pulled in and amputated.

SWITCH OFF, LOCKOUT and TAGOUT machine before opening or removing guards.

n

DANGER

SKIN INJECTION HAZARD

Hydraulic fluid under high pressure can penetrate the skin causing serious injury.

Always relieve the pressure from the hydraulic system before carrying out any kind of maintenance or adjustment.

ALWAyS use a piece of cardboard to check for leaks. DO NOT use your hand.

If fluid is injected under the skin, it must be surgically removed or gangrene may result.

Get medical help immediately.

02-2


Pegson plants

n

WARNING

PERSONAL PROTECTIVE

EQUIPMENT

Loose or baggy clothing can be caught in running machinery.

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.

EN

n

WARNING

fALLING HAZARD

Falling from and/or onto a plant can cause serious injury or even death.

DO NOT climb onto the plant whilst it is in operation.

ALWAYS use the walkways/platforms provided or a safe and secure platform approved by the local regional safety enforcing authority.

ALWAyS use a suitable lifting platform before attempting any maintenance work above 2m (6ft 6in) .


02-3

Safety Hazards

n

WARNING

LOCKOUT PROCEDURE

When carrying out maintenance or adjustment to the plant the following lockout procedure must be followed.

1. Switch off engine or motor.

2. Remove ignition or isolation key.

3. Keep keys on person during lockout.

4. Turn the battery or isolation switch to ‘0’ when the plant is not being used, especially when mobile plant is being transported.

5. Place appropriate maintenance warning signs

[i.e. TAGOUT]

6. NEVER work alone.

1

0

02-4

n

WARNING

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.


n

WARNING

DUST GENERATION INHALATION

HAZARD

Death, serious injury or delayed lung disease may result from breathing dusts that are generated when certain hazardous materials are crushed, screened or conveyed with this equipment.

When dusts are generated by the operation of this equipment, use approved respiratory protection, as required by National, Federal,

State and Local safety and health regulations.

Pegson plants

EN

n

DANGER

fLyING MATERIAL HAZARD ON

MAINTENANCE PLATfORMS

Platforms are for maintenance access only.

There is a danger of being hit by flying material.

Do not use platforms when the plant is working.


02-5

Safety Hazards

Safety Information

Important Safety Notices

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

2. follow all applicable safety regulations and recommendations in this manual as appropriate to your plant and the situation/conditions prevailing at the time.

3. 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.

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

5. See also the separate Operation and Maintenance Manual provided for the diesel engine when fitted and supplied as a complete Pegson plant. In particular read and observe the instructions within the Safety

Section of the engine manual.

6. This safety section covers a wide variety hazardous situations, but not necessarily limited to those described, which may or may not apply to any specific plant use or installation. They are given for general guidance only to assist the operator in setting up and maintaining an appropriate regime for the protection of health and safety.

7. Where the crusher is supplied for incorporation into plant/equipment designed, supplied and located by others, or as a replacement crusher only, Powerscreen® cannot be aware of particular hazards that may be present or might occur and therefore accept no liability for addressing or resolving these issues.

8. For further U.K. information also refer to: n

>

http://www.hse.gov.uk/quarries/crushing.htm

02-6


Pegson plants

Organisation Measures

9. Ascertain from the appropriate Authority and observe all statutory and any other regulations that may apply to the planned location before operating the plant.

10. Loose or baggy clothing can get caught in running machinery.

11. 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.

12. 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.

13. Always wear correctly fitting [EN/A.N.S.I. approved] protective clothing.

14. Protective clothing includes hard hat, safety glasses, ear protection, dust mask, close fitting overalls, steel toed boots and a high visibility vest.

15. you can be injured if you do not obey the safety instructions as indicated on warning signs.

16. Observe all safety instructions and warnings attached to the plant.

17. Keep warnings and instruction labels clean to ensure safety instructions and warnings attached to the plant are always complete and perfectly legible.

18. Replace unreadable or missing labels with new ones before operating the plant. Make sure replacement parts include warning or instruction labels where necessary.

19. Understand service procedure before doing work. Keep areas clean and dry.

20. 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.

21. 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.

22. Disconnect battery ground cable before making adjustments on electrical systems or welding on plant.

23. Never make any modifications, additions or conversions, which might affect safety without the supplier’s approval.

24. 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.

EN


02-7

Safety Hazards

Selection and Qualification of Personnel - Basic Responsibilities

1. Trained, reliable and authorised personnel only must execute any work on and/or with the plant. Statutory minimum age limits must be observed.

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 of a skilled electrician and in accordance with electrical engineering rules and regulations.

3. Only personnel with special knowledge and experience of hydraulic equipment must carry out work on the hydraulic system.

02-8


Pegson plants

Safety Instructions Governing Specific Operational Phases

Standard Operation Special Work In Conjunction with

Utilisation of the Plant

4. Take the necessary precautions to ensure that the plant is used only when in a safe and reliable state.

Maintenance and Repairs During Operation;

Disposal of Parts and Consumable items

5. 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 elements and exhausts, are in all place and fully functional.

Warning horn/light/gauge or indicator calls for immediate action.

6. Before starting the engine ensure it is safe to do so.

12. Observe the adjusting, maintenance and intervals set out in these operating instructions, except where:

7. In the event of material blockage, any malfunction or operational difficulty, stop the plant immediately and lockout. Have any defects rectified immediately.

Adverse conditions necessitate more frequent servicing.

13. Observe information on the replacement of parts and equipment. These activities may be executed by skilled personnel only.

8. In-running nip points on moving machinery can cause serious injury or even death.

14. When the plant is completely shutdown for maintenance and repair work, it must be secured against inadvertent starting by:

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

Switching off the engine and remove the ignition key.

10. Switch off and lockout the plant before removing, for adjustment purposes, any safety devices or guarding.

11. NEVER leave the plant unattended whilst it is in operation.

Implementing the lockout procedure.

Attaching warning signs to the plant in appropriate positions.

EN


02-9

Safety Hazards

15. 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.

16. 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 equipment.

17. To avoid the risk of accidents, individual parts and large assemblies being moved for replacement purposes should be carefully attached to lifting equipment and secured. Use only suitable and technically adequate lifting equipment.

18. Never work or stand under suspended loads.

19. Keep away from the feed hopper. There is risk of serious injury or death due to the loading of material.

20. Keep away from underneath the product conveyor and the conveyor discharge area.

There is risk of serious injury or death due to the material falling from the conveyor.

21. Falling from and/or onto a Pegson plant can cause injury or even death.

22. Do not climb on the plant. Never use plant parts as a climbing aid.

23. Beware of moving haulage and loading equipment in the vicinity of the plant.

24. for carrying out overhead assembly work always use specially designed or otherwise safety-oriented ladders and working platforms.

25. Always use any walkway/platforms provided or a safe and secure platform approved by the regional safety enforcing authority.

26. Always use an EN/A.N.S.I. approved safety harness when reaching any points 2m (7ft) or more above the ground level.

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

28. The fastening of loads and instructing of crane operators should be entrusted to experienced persons only. The person marshalling and giving the instructions must be within sight or sound of the operator.

29. 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.

30. Any safety devices removed for setting up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work to ensure full working order.

31. Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Pegson equipment includes such items as oil, fuel, coolant, filters and batteries, etc.

32. Use leak proof trays and sealed containers for drained fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

33. Do not pour waste onto the ground, down a drain or into any water source.

34. Ensure that all consumable items and replaced parts are disposed of safely and with minimum environmental impact.

02-10


35. Always ensure that any safety fitment such as locking wedges, securing chains, bars or struts are utilised as indicated in these operating instructions.

36. Particularly make sure that any part of the plant raised for any reason is prevented from falling by securing in a safe reliable manner.

37. Never work under unsupported equipment.

38. Never work alone.

39. Diesel fuel is highly flammable.

40. Never remove the filler cap, or refuel, with the engine running.

41. Never add gasoline or any other fuels mixed to diesel because of increased fire or explosion risks.

42. Do not smoke or carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.

43. Use of non-approved structures like walkways or platforms etc. in the vicinity of a Pegson plant is very dangerous and could lead to serious injury or even death through falling and/or entanglement with the plant.

44. Do not use any unauthorised structures.

Pegson plants

EN


02-11

Safety Hazards

Warning of Special Dangers

Electric Energy

1. Use only original fuses with the specified current rating. Switch off the plant immediately if trouble occurs in the electrical system.

2. Plants with high voltage electrical equipment must be suitably earth bonded by a qualified electrician prior to activating the main isolator switch.

3. 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.

4. If your plant comes into contact with a live wire:

Warn others against approaching and touching the plant.

Have the live wire de-energised.

5. 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.

6. 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-energised parts for presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements.

7. The electrical equipment of the 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.

8. Necessary work on live parts and elements must be carried out only in the presence of a second person, who can 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 and a warning sign. Use insulated tools only.

9. 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.

10. Tracked plants are wired with negative earth.

Always observe correct polarity.

11. Always disconnect battery leads before carrying out any maintenance to the electrical system.

12. If welding is to be carried out on the plant it is essential that the power pack is isolated, refer to servicing safety & precautions.

13. The batteries contain sulphuric acid, an electrolyte which can cause severe burns and produce explosive gases.

14. Avoid contact with the skin, eyes or clothing.

02-12


Gas, Dust, Steam, Smoke and Noise

15. Always operate internal combustion engines and fuel operated heating systems only out of doors or in a well-ventilated area.

16. Before starting the plant in enclosed areas, make sure that there is sufficient ventilation.

17. Observe the regulations in force at the respective site.

18. Dust found on the plant or produced during work on the plant should be removed by extraction, not blowing.

19. Dust waste should be dampened, placed in a sealed container and marked, to ensure safe disposal.

20. Carry out welding, flame cutting and grinding work on the plant only if this has been expressly authorised, as there may be a risk of explosion and fire.

21. Before carrying out welding, flame cutting and grinding operations, clean the plant and its surroundings from dust and other flammable substances and make sure the premises are adequately ventilated as there may be a risk of explosion.

22. Always ensure that operators are provided with ear defenders of approved pattern and that these are worn at all times when the plant is operating.

23. Ensure operators wear a suitable face mask where exposed to possible harmful effects of air pollution of any kind.

Pegson plants

Hydraulic and Pneumatic Equipment

24. Only persons having special knowledge and experience in hydraulic systems may carry out work on hydraulic equipment.

25. Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately.

Splashed oil may cause injury and fire.

26. 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 before carrying out any repair work.

27. Hydraulic and compressed air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements.

28. Always practice extreme cleanliness servicing hydraulic components.

29. Hydraulic fluid under pressure can penetrate the skin causing serious injury.

30. Always use a piece of cardboard to check for leaks. Do not use your hand.

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

32. Get medical help immediately.

33. Always relieve pressure from the hydraulic system before carrying out any kind of maintenance or adjustment.

EN


02-13

Safety Hazards

Hazardous Substances

1. Ensure that correct procedures are formulated to safely handle hazardous materials by correct identification, labelling, storage, use and disposal.

2. All hazardous materials must be handled strictly in accordance with the manufacturers instructions and all applicable regulations observed at all times.

02-14


Transporting, Manoeuvring and Re - commissioning

3. The plant is remote controlled and may start without notice. Stay clear of the plant.

4. The plant must be loaded and transported only in accordance with the operating instructions.

5. For manoeuvring the plant, observe the prescribed transport position, admissible speed and itinerary.

6. Use only appropriate means of transport and lifting equipment where applicable of adequate capacity.

7. The re-commissioning procedure must be strictly in accordance with the operating instructions.

8. Before travelling with the plant, check that the braking and any signalling and lighting systems are fully functional.

9. Before setting the plant in motion always check that the accessories have been safely stowed away.

10. When travelling on public roads, ways and places, always observe the valid traffic regulations and, if necessary, ensure beforehand that the plant is in a condition compatible with these regulations.

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

12. When crossing underpasses, bridges and tunnels or when passing under overhead lines always make sure that there is sufficient clearance.

13. Never travel across slopes; always keep the working equipment and the load close to the ground, especially when travelling downhill.

14. 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.

Pegson plants

EN


02-15

Safety Hazards

Safety Signs

Location

1. Refer to plant specification and information for the identification and positions of safety signs on the plant.

Maintenance

2. Replace any missing or damaged safety signs.

3. Keep operator safety in mind at all times.

4. Keep safety signs clean using mild soap and water only. Do not use solvent based cleaners because they may damage the safety signs.

04

02-16


Pegson plants

Illustrations

3000032-ISO >

3000033-ISO >

3000034-ISO >

EN

3000035-ISO >


02-17

Safety Hazards

3000038-ISO >

3000039-ISO >

3000040-ISO >

02-18

3000043-ISO >


3000118-ISO >

Pegson plants

3000120-ISO >

3000189-ISO >

EN

3000196-ISO >


02-19

Safety Hazards

3000269-ISO >

3000284-ISO >

3000355-ISO >

02-20

3000386-ISO >


3000819-ISO >

Pegson plants

3000820-ISO >

EN

3000821-ISO >


02-21

Safety Hazards

3000822-ISO >

3000823-ISO >

02-22

3000834-ISO >


3000835-ISO >

Pegson plants

EN

3000836-ISO >


02-23

Safety Hazards

3000837-ISO >

02-24

3000838-ISO >




3000838-ISO

Pegson plants

3000839-ISO >

EN

3000840-ISO >


02-25

Safety Hazards

3000848-ISO >

3000848-ISO

02-26

3000850-ISO >




3000850-ISO

Pegson plants

3000862-ISO >

3

3000862-ISO

EN


02-27

Safety Hazards

3000866-ISO >

3000866-ISO

02-28


03

EN

General Information

Pegson plants

EN


03-1

General Information

General

1. The plant has been manufactured with quality materials and assembled and tested with care.

2. Close attention has been paid in assembly, tests and final inspection.

3. We are confident that the plant will give you every satisfaction over a long period.

4. The plant is simple to operate and adjust.

Expert assistance is seldom required, provided that ordinary care is exercised in daily use.

5. The plant has been built in accordance with current standards and recognised safety rules.

6. It is designed to be reliable, efficient and safe when used and maintained in accordance with the instructions given in this manual.

7. When the plant is new and first commissioned, refer to initial checks - running in.

33

EC Conformity

8. This plant is in conformity with the provisions of the current EC Machinery Directive.

2006/42/EC

03-2


Units of Measure

9. Metric ISO units are used within this manual.

Threads and fasteners

10. Metric threads and fasteners are used throughout the plant normally.

11. Where a standard component is used on the plant, the thread and fastener system on that component may not be metric.

Copyright

12. The copyright of this user manual is reserved by Terex ®. The right is reserved to alter any details contained in this manual without notice.

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

Pegson plants

EN


03-3

General Information

Operating Temperature

1. The normal operating temperature range of the plant is -12°C to +40°C (+10.4°f to

+104°f) . Refer to the engine operation manual also. for use in temperatures outside of this range, contact your Powerscreen® dealer or

Powerscreen® technical support department for details.

2. Appropriate oils, lubricants & coolant to suit the local operating environment and conditions must be used, as specified in the manual.

Information and Advice

3. If you need information or advice regarding your plant or wish to order additional copies of this manual, contact your local Powerscreen® dealer or Powerscreen® technical support.

Powerscreen® International Ltd.

200 Coalisland Road

Dungannon

Co. Tyrone

Northern Ireland

BT71 4DR

+44 [0] 28 8774 0701 www.powerscreen.com

03-4



04

EN

Plant Specification and Information

EN


04-1

Specification and Plant Information

Dimensions

Working Dimensions

All dimensions are in millimetres.

A 3400mm

B 2030mm

C 2400mm

D 400mm

E 13120mm f 3200mm

G 3023mm

H 3300mm

J 6798mm

K 2897mm

Feed Hopper Raised or Fixed Hopper Fitted A

B

E

F

G H

Transport Dimensions

Overall Length: 12220mm

Overall Width: 2500mm with dirt conveyor up

Overall Height [Excluding Transport Trailer] :

3200mm with hopper folded down or 3400mm if alternative fixed hopper is fitted

04-2


J

C

D

K


Weight

The weight is dependant on options and type of crusher fitted, therefore refer to plate fixed to plant.

Plant Description

Recycling/Crushing plant with Diesel/Hydraulic drives. Refer to the diagrams to identify the main areas of the plant and the term with which they are referred to in this manual.

PLEASE NOTE

The plant has been designed and built to provide a range of equipment choices to meet a wide variety of individual needs and preferences as selected at the time of initial purchase.

9 fRONT

3

1 Engine Power pack

2 Maintenance Platform

3 Optional Magnetic Over band Separator

4 Engine Maintenance Platform

5 Control Box

6 Optional Dirt Conveyor

4

1

8

2

5

11

7 feed Hopper

8 Jaw Crusher

9 Product Conveyor

10 Vibrating feeder

11 Tracks

6

REAR

7

10

EN


04-3


Standard fittings

Hopper and feeder

1. Hydraulic folding hopper sides and manually operated end plate, fabricated in abrasion resistant steel plate. A hopper fixed in the raised position can be fitted optionally.

2. Spring mounted vibrating grille feeder, driven by a heavy duty vibrating mechanical unit with twin eccentric rotating shafts.

3. Drive is by hydraulic motor mounted on vibrating unit with variable speed control. An optional radio remote control to stop and start the feeder may be supplied.

4. feeder grille is a double section of welded tapered finger type bars, fabricated in abrasion resistant steel.

Product Conveyor

11. Plain troughed belt EP500/3 to BS490 and

DIN22102. Belt includes a vulcanised joint.

Hydraulic motor drive via coupling to drive drum at pre-set speed. Canvas type removable dust covers are fitted at the head end.

Tracks

12. Heavy-duty track pitch chain tracks driven by integral hydraulic motors and gearboxes with dual speed control by umbilical control, [or radio remote control, if fitted].

Under screen

5. The under screen has a removable mesh, used in conjunction with the optional dirt conveyor. If the material is able to be screened, it allows the extraction of smaller fines onto the dirt conveyor with the coarser material discharging onto the product conveyor.

6. By removing the mesh entirely all the fines are directed to the dirt conveyor.

7. A rubber blanking mat will be fitted where the plant does not have the dirt conveyor fitted.

Crusher

8. Single toggle jaw crusher with feed gape of

600mm (24in) and width of 900mm (36in) , operated by eccentric shaft driven by vee belts and pulleys from the engine.

9. The MA model discharge setting has manual adjustment by shims, with manual hydraulic assistance.

10. The HA model has discharge setting adjustment by hydraulically operated wedges.

Power Pack

13. Water-cooled diesel engine driving the crusher via an hydraulically operated mechanical clutch and hydraulic pumps.

14. The hydraulic pumps drive the tracks, feeder, product conveyor and other items.

15. Engine is enclosed with integral hydraulic fluid tank and batteries.

04-4


Maintenance Platforms

16. A steel grid maintenance platform is provided on one side of the feeder fitted with double row handrails and access ladder. Maintenance platforms are also provided to gain access to the rear of the crusher and to the power pack


Controls

17. Controls are fitted on the plant for setting up and preparing the plant for transport, adjusting crusher settings, vibrating feeder and conveyors. Engine and plant controls are in a lockable box.

18. An umbilical control unit is provided for operating the tracks to move the plant.

19. Emergency stop buttons are provided on each side of the plant and on the umbilical control.

Guards

20. 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. However, the company cannot guarantee that the guards provided will meet the requirements laid down by individual inspectors.

Specifications

21. Every endeavour will be made to supply equipment as specified, but we reserve the right, where necessary, to amend specifications without prior notice as we operate a policy of continual product development.

22. It cannot be guaranteed that the equipment specified will meet any specific requirements in respect of noise or vibration levels, dust emission, or any other factors relevant to health and safety measures or environmental protection needs.

EN 04-5



Optional Extra Fittings

Dust suppression sprays

23. Spray bars with multi-atomising nozzles are mounted over the crusher mouth, the product conveyor feed and discharge points.

Dirt Conveyor

24. The side discharge dirt conveyor with a hydraulic folding facility for transportation. Belt is plain troughed and bearings are grease lubricated.

25. The fixed speed conveyor is hydraulically driven from the head drum. It is mounted on the left hand side viewed from the feed end.

Radio Remote control

26. A remote radio control and receiver can be fitted for operating the tracks to move the plant.

This radio control also provides stop and start control for the vibrating feeder from a remote position.

Magnetic Separator

27. Self-cleaning cross belt over band magnetic separator with permanent magnet, suspended over the product conveyor. Hydraulic motor drive, pre-set variable control.

Belt Weigher

28. An optional material load sensor fitted to main product conveyor, with flow rate and totalizer displays on a chassis mounted control box.

Water Pump

29. A hydraulically driven pump and controls to provide a pressurised water supply for the dust suppression sprays.

fuel transfer Pump

30. Fuel transfer pump, electrically driven from the engine 24v supply.

further options

31. For all other available extras and option details, contact Powerscreen®.

04-6


Crusher Capacity

1. In order to obtain the optimum output from the crusher, it’s feed should be continuous and regulated. Additionally, all feed should be of a size that will readily enter the crusher chamber and, in order to avoid packing of the discharge opening and excessive wear of the plant jaws, under size material should be removed from the feed prior to entry to the crusher.


2 3

A* - B* - C - D - E- f

M.A. Model

Setting Typical Output mm tonnes/hour

A* 40 60-70

B* 50 70-90

C 63 85-110

D 75 90-115

E 100 120-140 f 125 145-175

H.A. Model

Settings for New Jaws

Open Closed

[at rest] [working]

Minimum B

85mm 50mm

Maximum

160mm 120mm

*Re-cycling Materials

Minimum A*

*75mm *40mm

2. The discharge rates given are based on crushing clean, dry limestone weighing approximately 1600kg/m³ (100lbs/ft³) loose and having a specific gravity of 2.6. Wet feed material reduces the crusher discharge rate.

3. Crusher discharge settings marked * are for re-cycling operations only. The crusher must not be operated at a discharge opening less than shown for quarry applications without prior consultation with Powerscreen®.

4. The only exception to this being for crushing bricks and demolition materials. Operating the crusher below this setting may result in extensive damage.

EN

NOTICE

DO NOT feed non crushable material larger than the closed jaw gap setting.

04-7



5. The percentage of oversize output from the crusher, for a given discharge opening, will depend largely on the quality and character of the feed material.

6. The graph shows an estimated analysis of the product for different discharge openings.

Note:- The crusher has been designed to work with feed materials having a 10% fines value not exceeding 390kN (87675 lbf) .

7. Product gradings are typical only and will vary depending on material characteristics.

8. When the optional dirt conveyor is fitted, material passing through the vibrating feeder bars will by-pass the crusher. The coarser material discharges to the product conveyor and finer material to the dirt conveyor.

9. The optional magnetic over band separator, where fitted, 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.

(INCH)

04-8

SCREEN MESH SIZE mm

PRODUCT ANALySIS


Location of Safety Signs


Item Part No [ISO]

1 3000032-ISO

2 3000033-ISO

3 3000034-ISO

4 3000035-ISO

7 3000038-ISO

8 3000039-ISO

9 3000040-ISO

11 3000043-ISO

12 3000118-ISO

13 3000120-ISO

15 3000196-ISO

16 3000284-ISO

17 3000355-ISO

19 3000820-ISO

20 3000823-ISO

24 3000840-ISO

EN


04-9


04-10



10

EN

Preparing to Move the Plant

EN


10-1

Preparing to Move Plant

Initial Preparation

Before moving the plant it must be cleared of any material.


2. Refer to Preparing to finish crushing to make sure the feed hopper and crusher are empty and that all materials have run off all of the conveyors.

3. Clear the tracks of any obstructions and remove any crushed or fine material and dirt.

31 n WARNING

Prior to attempting any manoeuvring of the plant the tracks must be free of obstructions, including crushed material and fine material. Do not push or tow the plant.

failure to observe this warning could result in danger to persons and damage to the plant which may also invalidate warranty.

4. If the plant is only being moved using the tracks to a new working position follow instructions in moving the plant.

12

10-2


Preparing for Loading

5. Before loading, the plant must be prepared for transportation, refer to initial preparation.


6. Refer to specification and plant information for travel dimensions.


04 n WARNING

Refer to Safety Notices Section for relevant warning and procedure fALLING

HAZARD

LOCK OUT

PLANT

8. fold up the maintenance platform ladder to the raised position.

8

9. Remove the dirt conveyor head drum guard.

This is necessary before folding the conveyor for transport.

9

10. Ensure all loose items are carefully stowed and secured if these are to be transported on the plant.

10

EN 10-3



Lowering Hopper for Transport

[Not applicable if a fixed hopper is fitted]

1. Using suitable lifting equipment to hold the end plate, remove the corner wedges securing the end plate to the side plates and lower the end plate.

1 n WARNING

DO NOT attempt to undo any fasteners holding the manual folding hopper end plate until it is securely held by lifting equipment to prevent any movement.

2. Start the engine, see engine starting.

3. Set engine speed to low.

4. Set the mode switch to plant operation.

13

3 n/min

5. Remove the four hopper side plate wedges.

6. Use the hydraulic valve lever at the rear of the plant to lower the hopper sides.

6

5

10-4


7. Unfasten the clips securing the chains and hopper locking wedges and place them in the toolbox.


folding Dirt Conveyor for Transport

[If fitted]

8. Use the hydraulic valve lever at the rear of the plant to raise and fold the dirt conveyor into the transport position.

8

9. Secure the folded dirt conveyor for transportation.

NOTICE

During folding of the dirt conveyor ensure that the hydraulic hoses and conveyor belt are not entangled with any part of the plant.

9

EN


10-5


final Preparation

10. Refer to unloading and loading to manoeuvre the plant and load on to the transporting trailer.

11 12 n WARNING

Prior to transportation always check the plant for loose or damaged components.

Fasten all loose parts, replace missing items or make repairs as found necessary to ensure that all components are safely secured during transportation.

11 Stop the engine, unless required further, refer to engine stop.

15

NOTICE

To obtain the minimum transport height, remove the engine air inlet filter. Fit the transportation cap in its place.

Pegson Metrotrak/Eurotrak

10-6


Pegson plants

11

EN

Unload and Load Plant - Transport Trailer

EN


11-1

Unload & Load - Transport Trailer

Unloading from Trailer

1. If the plant has been manufactured to connect to a special rear bogie, refer to the special instructions to separate the plant from its bogie.

2. Removing the fastenings securing the plant and any loose items to a trailer is the responsibility of the haulage contractor.

3. A tracked plant will normally be secured to a transport trailer.


5. Make sure suitable ramps are positioned at the end of the trailer to unload the plant.

6. Check that any loose items transported with the plant will not cause a hazard while unloading.

01

NOTICE

On some plants, the air inlet filter may have been removed to obtain the minimum transport height, remove transportation cap and fit the air filter.

Store the transport cap in the toolbox.


8. Set the engine at the slowest speed, if applicable. Some plants have automatic engine speed control.

9. Unload the plant slowly off the trailer into a safe position or plant operating position, manoeuvring the plant with the tracks. Use the umbilical control or the remote radio control, if fitted, see moving the plant.

13

8

n/min

12

10. Stop the engine, see engine stop, unless required further.

11-2

15


Loading on to Trailer

11. Before loading, the plant must be prepared for transport, refer to preparing to move plant.

12. Check that the travelling dimensions and weight, when loaded, will be within the regulation limits, refer to plant specification and information and plate fixed to the plant.


14. Ensure all loose items are carefully stowed and secured if these are to be transported on the plant.

15. Make sure suitable ramps are positioned at the end of the trailer to load the plant.

04


17. Set the engine at the slowest speed, if applicable. Some plants have automatic engine speed control.

13

17

n/min

18. Load the plant slowly on the trailer, manoeuvring the plant with the tracks, using the umbilical control or the remote radio control, if fitted, see moving the plant.

12

19. Stop the engine, see engine stop, unless required further.

15

EN


Pegson plants

11-3

Unload & Load - Transport Trailer

NOTICE

To obtain the minimum transport height on some plants it is necessary to remove the engine air inlet filter. If necessary, remove it when the engine has been stopped. fit the transport cap in its place.

18. Securing the plant and any loose items to the transport trailer is the responsibility of the haulage contractor.

n CAUTION

Ensure that all components are safely secured for transport. fasten all loose parts, replace missing items or make repairs as found necessary.

Prior to transport always check the plant for loose or damaged components.

11-4


Pegson plants with ‘860’ controls

12

EN

Moving the Plant

EN


12-1

Moving the Plant

Moving the plant on the tracks

1. The plant is manoeuvred with the tracks using the umbilical control or the radio remote control, if fitted.

2. Prepare the plant for moving, see preparing to move the plant.

10

Initial Preparation



5. Set operation mode to track.

13

10

12-2



Preparing Umbilical Control

6. The umbilical control is the default track control on some plants and does not have to be selected. De-select the radio remote control, if fitted, to activate the umbilical control. Refer to preparing to move plant - setting to track mode.

10

7. If an umbilical option is shown, set track control to umbilical, referring to icon and appropriate function button, as plants vary.

7 f3

8. Take the umbilical control from the control box

9. Stand well clear of the plant.

f4

8

10. Hold the control with the stop button nearest to the operator

11. Press the horn button to sound the safety warning horn. The missing beep or break in the alarm after five seconds indicates that the tracks are ready for use. The alarm will continue to sound.

12. To move the plant, refer to manoeuvring the plant.

EN

-->


11

10

12-3

Moving the Plant

Preparing Radio Control

[if fitted]

1. Take the radio remote control from the control box

1

2. Hold the radio remote control with the stop button nearest to the operator and switch it on by pulling out the stop button.

3. Press both of the safety buttons at the same time for at least 1 second and a red light will illuminate. Release the safety buttons.

4. The red light will change colour to green when it is ready for use.

12-4


4

2

3

+

3

+

5. Set track control mode to radio, referring to icon and appropriate control, as plants vary.

5


f3 f1 f4

6. Press the horn button to sound the alarm. The missing beep or break in the alarm after five seconds indicates that the tracks are ready for use. The alarm will continue to sound.

6

7. To move the plant, refer to manoeuvring the plant.

-->

8. The radio control has a safety function that prevents any action from involuntary cutting-in when it is switched on.

9. The radio control will not start if a button is pressed or stuck prior to the missing beep in the pre-start warning.

10. Keep the internal re-chargable battery fully charged, see radio remote control.

14

EN


12-5

Moving the Plant

Manoeuvring the Plant

1. The plant cannot be manoeuvred when mode is set to plant or 0.

2. The alarm sounds continuously whilst the plant is being manoeuvred.

n WARNING

Prior to manoeuvring the plant, the tracks must be free of obstructions, including crushed material and fines. The tracks must be correctly tensioned before moving.

Do not push or tow the plant. failure to observe this warning could result in danger to persons and damage to the plant which may invalidate warranty.

n DANGER

DO NOT stand on any of the maintenance platforms or ladders of the plant whilst it is being manoeuvred.

Ensure all personnel are clear of the plant before manoeuvring.

When manoeuvring the plant make sure you stand well clear of the plant but are in a position to have all-round vision to see any obstacles or dangers that may lie ahead such as personnel, overhead cables, ditches, unsafe roadways etc.

12-6


3. To prolong the life of the track and prevent avoidable damage to the track components, wherever possible drive the plant with the circular track drive gearbox in the position shown in the diagrams.

4. This is particularly important if the plant is being driven up an incline.

5. Do not manoeuvre the plant on a gradient [fore and aft directions] steeper than 30°, as damage may occur to the engine and/or plant.


6. The track drive gearbox is not fitted in the same position on all plants, relative to the other parts of the plant.

7. Avoid manoeuvring the plant over extremely uneven ground or damage may occur.

8. Control valves mounted on the engine and beneath the feeder are NOT to be used to manoeuvre the plant. They are for use by

Powerscreen® service engineers only.

9. 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 about 10 minutes with the conveyor and feeder running to warm the oil, prior to manoeuvring the plant.

10. Stand well clear of the plant.

EN


12-7

Moving the Plant

11. Some plants can be driven with different engine speeds which provides two speed ranges. Select range to suit requirements, the slow speed in high range is equal to the fast speed in slow range.

12. Only use the faster speed where safe to do so. Use the slower speed for more accurate manoeuvring.

13. The directional control buttons are double pressure switches. The initial pressure 1 operating the slow speed mode and second pressure 2 operates the faster speed.

n DANGER

Extreme care must be used when manoeuvring the plant with the umbilical control. Stand as far away as possible from the plant. Do not allow the cable of the hand set to sag and become entangled with the tracks.

11 f5

PRESS BUTTON TO MOVE

13

RELEASE BUTTON TO STOP MOVEMENT

14. Press the buttons to manoeuvre the plant in the desired direction.

15. Release the buttons to stop movement.

NOTICES

If the plant is being moved using the radio remote control and moves out of the operating range of the radio or the battery becomes discharged, the engine and plant will stop.

Pressing the stop button on the radio or umbilical control will immediately halt the operation and cut out the engine but it is necessary to manually switch off the engine ignition.

12-8


16. Refer to direction control diagram.

17. The controls will stop operating if the track control has not been used for a period of time.

18. The engine speed will vary with the use of the track controls.

PLAN VIEW Of THE PLANT

Forward = Product Conveyor first

16


LEfT fORWARD

RIGHT

Reverse = Hopper first

EN

LEfT forward slow 1 or fast 2 [tracks A & B forward]

Right turn slow [forward track A]

Left turn slow [forward track B]

Reverse slow 1 or fast 2 [tracks A & B reverse]

Right turn slow [reverse track A]

Left turn slow [reverse track B]

Rotate clockwise [track A forward & B reverse]

Rotate counter-clockwise [track A reverse & B forward]


REVERSE

RIGHT

12-9

Moving the Plant finish Manoeuvring the Plant

1. When the plant is in the correct position, press the horn button to disengage the tracks which will turn the safety warning horn off.

1

2. Set track operation mode off by esc, exit, ‘0’ or plant, depending on the type of controls fitted.

2

ESC f1 f1

0

3. If crushing is to commence, see preparing to crush.

17

4. If not required further, switch off the engine, see engine stop.

15

5. If not required further, switch off the radio remote control, push in the stop button. This will also conserve the battery charge.

5

12-10


Pegson Plants with:

[Cantrak + Caterpillar 6.6 Engine]

13

EN


[Cantrak + Caterpillar 6.6]

EN


13-1


n

WARNING

Ensure that all safety aspects are checked before starting the engine.

Whilst the engine is running and the operation mode is changed from ‘Track’ to

'0' to ‘Plant’ the safety alarm will sound for

10 seconds. When the alarm has stopped the plant operation can be started.

Engine Start-Up


NOTICE

If the air inlet filter has been removed to obtain the minimum transport height, remove transportation cap and fit the air filter. Store the transportation cap in the toolbox.

2. Turn the battery switch on to the ‘1’ position.

2

3. Make sure no emergency stop buttons are pressed in, including the umbilical control and, if active, the radio control stop button. Re-set all emergency stops by pulling or twisting out, depending on type fitted.

3

13-2


1

0

Pegson Plants with:


4. The plant and engine controls are located in the control box.

5. Set the operation mode switch to 0.

6. Set product conveyor switch to 0

7. Set the crusher or impactor switch to 0.

8. Set dirt conveyor switch to 0, if fitted.

9. Set any other plant controls off to 0.

EN


13-3


10. Set the engine to its slowest speed.

11. Turn on the ignition with the key to the first position only.

10

n/min

11

12. The Cantrak engine monitoring display screen will be switched on.

13. Pre-start audible warning will start.

13

12

14. The warning lamp, stop lamp and pre-heat glow plug will light together then go off. This is to check the bulbs are operational.

15. If the amber warning or red stop lamps flash or light continuously, refer to the engine manual for more information displayed by the warning and stop lamps.

13-4

14


Pegson Plants with:


16. Wait until the pre-heat glow plug lamp goes off and turn ignition key to the start position until the engine is running.

16

17. Release the key back to the first position as soon as the engine starts.

18. Allow the engine to reach normal operating temperature by running it for three to five minutes.

17

NOTICE

DO NOT increase the engine from idling speed to operation speed until after engaging the clutch and starting the crusher, to avoid damage to the clutch.

EN


13-5


Cantrak Engine Monitor

Introduction

1. The Cantrak Engine Monitor is a graphical instrument clusters to display parameters and alarms.

2. The display has five buttons that change to suit the screen in use. The buttons give to access a graphical menu structure that uses standard and easily-understood icons to indicate the button’s current function.

3. The required engine data and display can display the following formats:

Analogue gauges

Digital values

Historical trend graphs

Current and stored alarm messages

2

1

Buttons

4. If any button from 1 to 4 is pressed, the display shows a context dependent icon representing the current function of the button.

5. The button icon part of the display will disappear after five seconds of inactivity.

6. This ‘top level’ button icon bar shows the selection options of the engine monitor:

4

7. Pressing button 5 briefly when the menu icons are not being displayed displays a contrast and lighting adjustment menu. If held for 3 seconds, the Configuration menu is shown.

13-6


7

Pegson Plants with:


Top Level Button Icons

8. Tri display - shows one large window and two smaller windows. Repeat presses cycle the display through the view options.

8

9. Quad display - shows data four equal sized windows. Repeat presses cycle the display around three different quad view options.

9

10. Uni display - shows data using a single window. Repeat presses cycle display through available parameters.

10

11. Active alarm display - shows current active alarm. Holding the key displays stored alarms.

11

12. Single brief press to exit from the menu.

12

EN


13-7


Other Button Icons

13. Pages - indicates that further pages of information are available by pressing to cycle through options for the screen being viewed.

14. Arrow up - move up to next item.

13

14

15. Arrow down - move down to next item.

15

16. Right arrow - go to next screen or select option.

16

17. Return arrow - go back to previous screen.

18. Alarm - acknowledge active alarm when an active alarm is being displayed.

17

18

Button Lock

19. The buttons can be locked so that they cannot be accidentally pressed.

20. Press buttons 1 and 5 simultaneously for one second to switch the button lock on or off.

21. A key symbol is displayed when a button is pressed and they are locked.

20

13-8


Pegson Plants with:


Displays

1. When power is applied, a start-up screen displays for approximately 7 seconds while the display performs a self test.

2. After the start-up screen disappears, the Engine

Monitor displays readings on its virtual gauges.

3. The Engine Monitor displays the screen that was last displayed.

4. If data is not available from the engine, it will not be possible to select it.

5. If data becomes unavailable, dashes [- - -] will be shown on the screen.

Tri Display

6. Three windows intended to show the most frequently accessed engine data.

6

Quad Display

7. four windows to display available data in digital number format only or as a gauge with numbers also displayed.

8. The windows can be configured to display various available data as listed in the data parameter and icons.

9. Configure quad screen - press.

9

10. The data displayed on a particular window can be selected by repeat pressing the appropriate button.

10

Uni Display

11. A single window to display data in a graph format, together with a numeric data header.

EN

11


13-9


Data Parameters and Icons

1. The following data can be displayed

2. Engine Speed

3. Oil Pressure

4. Oil Temperature

5. Coolant Temperature

6. Battery volts or amps

7. Engine Hours

2

5

6

3

4

7

13-10


Pegson Plants with:


Alarm Messages

8. When a current engine alarm is received, a flashing window appears overlaid over the screen in use and an alarm sound is activated.

8

9. If a current alarm message is flashing, press any button to view the message details.

10. The current alarm message will be displayed with a black background, which indicates an unacknowledged alarm.

11. The alarm can be acknowledged by pressing:

11

12. Alarms must be acknowledged before the normal monitoring screen can be displayed.

13. Acknowledged alarm messages are displayed with a grey background.

14. Alarm messages can also be displayed at any time from the normal monitoring display by pressing button twice.

14

15. To return to the monitoring screen press:

EN

15


13-11


Configuration Options

Screen Brightness and contrast

1. Press button 5 briefly when the normal monitoring screen is being displayed, not when the menu icons are displayed. Do not hold down button.

2. Adjust the screen using buttons 1 to 4.

3. Press button 5 to exit

Settings Menu

4. Press and hold button 5 for 3 seconds, when the normal monitoring screen is being displayed.

2

5. Scroll to point to settings and select by pressing:

5

6. The following options can then be selected:

7. Units - metric or imperial

8. Language - select from list

9. Bleep - button press sound on or off

10. Set the options for each of these by pressing:

10

11. Return to previous screens by pressing:

12. To return to the monitoring screen press:

13-12

11

12


4

1

3

Pegson Plants with:


Engine Warning Lamps

1. Engine alarms will also make amber warning and diagnostic lamp flash or illuminate continuously.

1

2. A red stop lamp may also flash or illuminate continiously.

2

3. Refer to the operation section of the engine manual for information of these lamps.

3

EN


13-13


13-14



14

EN

‘860’ Radio Remote Control

EN


14-1

Radio Remote Control

[if fitted]

Operation

[if fitted]

1. To switch on the control, pull the stop button out.

2. To enable the radio remote control to be used, press both of the safety buttons at the same time for at least 1 second and a red light will illuminate. Release the safety buttons and it will change to green.

3. To switch off the control, push in the stop button when the plant is not set to radio mode or is not operating.

4. To conserve the battery charge the hand set should be switched off when not in use.

5. Store the control in a dry, secure place when not being used to prevent damage and unauthorised use.

2

+

+

1

14-2


Battery Recharging

6. The radio remote control has a built in NiMH battery and charging unit.

7. Battery charge status is indicated by the light in the transmitter:

Red - battery needs charging

Green - battery charged

8. The light on the hand set changes from green to red when there is about 3% power left in the battery, approximately 1 hour continuous operation remaining, and indicates it requires recharging.

9. The input charging point on the rear of the control can accept a charging voltage from either 12VDC or 24VDC systems.


7

9

10. A charging cable is supplied, suitable for plugging into a vehicle auxiliary or cigarette lighter point. Some plants have a 24V socket on the control panel.

11. Battery capacity is 2000mAh.

12. Charging time from completely empty battery is approximately 4 hours.

13. Operating time with fully charged battery is approximately 30 hours.

14. During the charging of the batteries the light will be red until changing to green when fully charged. The battery cannot be overcharged.

15. The plant warning horn will also sound when battery recharging is required.

EN


14-3

Radio Remote Control

[if fitted]

Battery Replacement

1. The radio remote control contains rechargable batteries which are unable to be replaced, therefore the radio control should be recycled.

2. Contact your local Powerscreen® dealer or

Powerscreen® technical support department for advice on recycling the radio remote control.

03

Battery Recycling

3. Do not dispose of the radio remote control or any old batteries with normal waste that may to go to landfill.

3

4. All batteries shall be disposed of correctly to be recycled at an approved treatment facility.

4

14-4


15

EN

Engine Stop

Pegson plants

EN


15-1

Engine Stop

Switching off engine

NOTICE

For normal closing down the plant, DO

NOT use the emergency stop buttons [or, if fitted, radio remote control stop buttons] or by switching off the engine ignition to close down the plant. Always follow the correct preparation sequence.


2. Follow instructions to prepare to finish crushing or finish manoevring in moving the plant.

31 12

NOTICE

The feeder, crusher and conveyors must be stopped in sequence and emptied before the next section is stopped.

15-2


3. Plants with automatic engine speed control set the engine speed to its slowest speed when all plant components are switched off. Check the engine is running at its slowest speed.

3

n/min

Pegson plants

4. Switch plant controls off if necessary by esc, exit or ‘0’, depending on the type of controls fitted.

ESC f8 f1

4

f1

0

5. On plants with manual engine speed control, set the engine at its slowest speed.

5

n/min

6. Let the engine idle with no load for 3 to 5 minutes.

7. Turn the ignition key to '0' to stop the engine then remove the key.

8. Set the the battery disconnect switch to ‘0’ and lockout.

7

8

1

0

EN 15-3


Engine Stop

9. If the radio remote control, if fitted, has been in use switch off by depressing the stop button.

n

WARNING

Refer to Safety Notices Section for relevant warning and procedure

LOCKOUT

PLANT

9

15-4


16

EN

Emergency Stop

Pegson plants

EN


16-1

Emergency Stop

Emergency Stopping the Plant

IN AN EMERGENCY ONLY, STOP THE

ENGINE AND PLANT OPERATION

By USING AN EMERGENCy STOP

BUTTON

1

1. Pressing any of the emergency stops on the plant or umbilical control will stop the engine and plant.

1

1 n WARNING

The stop button on the remote radio control, if fitted, is NOT an emergency stop as it may not be operative at all times.

2. When the plant has been stopped using an emergency stop button the ignition switch stays on.

3. Emergency stop activation and alarm messages are shown on plants with a display, refer to plant alarms.

23

STOP

3

4. The safety alarm will sound until it is acknowledged and cancelled.

!

f1

4 f2

16-2


5. Turn the key off the 0 position as soon as possible and remove the key.

5

6. Set the battery disconnect switch off to the ‘0’ position.

6

1

0

Pegson plants

n WARNING

When an emergency stop has been initiated, DO NOT attempt to restart the engine until it is safe to do so.

NOTICE

The plant should not be re-started if the crusher is full of material.

Re-Setting Emergency Stops

7. The button will remain engaged until physically released by pulling or twisting, depending upon the type fitted.

8. The engine cannot be started if any of the emergency stops remain depressed.

EN


16-3

Emergency Stop

Testing Emergency Stops



n WARNING

Daily, before commencing crushing operations, test each emergency stop button is operative.

13

3. Push in an emergency stop on the plant or umbilical control and the engine will stop.

3

4. Alarm messages are shown on plants with a display.

5. The safety alarm will sound.

5

6. Acknowledge the alarm.

!

f1

7. Re-set the emergency stop by pulling or twisting, depending on the type fitted.

8. Turn the key off the 0 position.

9. Turn ignition key to the first position again.

10. Wait for the pre-start warning to complete.

11. Turn ignition key to start the engine again.

9

11

12. Repeat the process for all other emergency stops.

16-4


6 f2


17

EN

Preparing to Crush

EN


17-1

Preparing to Crush

Plant Location Considerations

Prior to setting up the plant, consideration should be given to a suitable layout to prevent oversize material or metal from entering the plant. In order to prevent bridging of the crusher no material above the size recommended should be fed into the plant.

Position the plant in a safe, level, operating position making sure both tracks are in full contact with the ground to minimise movement of the Plant. Regularly check the plant is level and stable.

Pay attention to access from the loading area and to where material is to be deposited.

Ensure the area under the tail drum of the product conveyor is free of large stones etc. which may cause damage to the belt.

n DANGER

The environment in which the plant will operate contains inherent health and safety risks, which the operator must take steps to avoid.

Dangers from overhead conveyor discharges, overspill material, vehicle movements, etc., as well as other site related hazards must be anticipated.

Avoid these by carrying out risk assessments before the plant is put into operation to ensure appropriate exclusion zone measures are put in place and site personnel safety awareness training has been undertaken.

17-2



Setting Up

1. Observe all safety instructions.


3. Leave the engine set at its slowest speed.

NOTICE

If the air inlet filter has been removed to obtain the minimum transport height, remove transportation cap and fit the air filter. Store the transportation cap in the toolbox.

13

3 n/min

4. Release the dirt conveyor, if fitted, from the transportation securing system.

5. Unfold the maintenance platform ladder down and secure.

5

EN


17-3

Preparing to Crush

6. Use the hydraulic valve lever at the rear of the plant to fully unfold and lower the dirt conveyor into the working position.

6

NOTICE

During lowering of the dirt conveyor ensure that the hydraulic hoses and conveyor belt are not entangled with any part of the plant.

Raising Hopper for Crushing

[Not applicable if a fixed hopper is fitted] n WARNING


HAZARD

7. Take the hopper locking wedges from the toolbox and attach the side plate and corner wedges to the plant ready for use, using the clips and chains.

7

8. Use the hydraulic valve lever at the rear of the plant to fully raise both hopper side plates at the same time.

8

17-4


9. Lock the side plates into position using two locking wedges each side.


9

10. Using suitable lifting equipment, raise the hopper end plate and secure to the side plates using corner locking wedges.

10 n WARNING

DO NOT attempt to fit any fasteners holding the manual folding hopper end plate until it is securely held by lifting equipment to prevent any movement.

EN


17-5

Preparing to Crush

final Preparation

11. Stop the engine, refer to engine stop.

12. Lock out the plant.

15 n WARNING


LOCK OUT

PLANT

13. If a dirt conveyor is fitted, fit the head drum guard.

13

17-6


Pegson plants with vibrating feeder

18

EN

Loading the Plant Hopper

EN


18-1

Loading the Hopper

Correct Loading of Hopper

1. Observe all safety warnings and notices.

2. Make sure all personnel are clear of the plant as described in plant location considerations, refer to preparing to crush.

17

3. Material for crushing must be within the sizes specified in the crusher capacity of the plant, refer to specification and plant information.

04

4. Material for crushing must be fed into the rear part of the plant hopper on to the base plate designed for loading.

5. This method will allow feed material to pass over the feeder bars gradually to allow them to function correctly.

4

6. The feed bucket should pass as close as possible to the hopper top edge, just clearing the sides or end of the hopper.

7. Empty the bucket to drop material the minimum height into the hopper base plate.

8. Do not drop material on to the feeder bars as they are not designed for impact of material from a great height.

6

18-2


8

8

Pegson plants with vibrating feeder

9. Load material into the hopper at a rate the feeder and crusher can work efficiently.

10. Set the feeder speed such that material is fed evenly and does not build up, refer to crusher operation.

11. Do not feed excess material into the hopper.

20

EN


18-3

Loading the Hopper

18-4



20

EN

Plant Operation

EN


20-1

Plant Operation

Crusher Models

M.A. model - Manual Adjust Crusher

Shims clamped with a spring are used to provide different crusher discharge setting.

H.A. model - Hydraulic Adjust Crusher

Pressurised hydraulic rams are used to lock the crusher discharge setting under normal crushing conditions.

The crusher hydraulics provide a quick and easy operation when adjustment to the crusher discharge setting is required, either to compensate for wear on the jaws or to alter the product required.

n WARNINGS

The M.A. model discharge setting has manual adjustment by shims, with assistance from a manual hydraulic system.

The H.A. model has discharge setting operated by a plant hydraulic adjust and locking wedge system.

The operation of the plant should be fully understood prior to starting it.

NOTICE

DO NOT feed non crushable material larger than the closed jaw discharge setting.

20-2


Plant Starting

Before Starting

1. Ensure the full length of both tracks are in contact with a firm and level surface.

2. Check that the crushing chamber and feed hopper are empty.

3. Measure the crusher discharge opening and adjust if necessary.

4. Check that all guards are in position and secure.

5. Make sure all personnel are clear of the plant.


n WARNING

Ensure that all safety aspects are checked before starting the engine.

Product Conveyor and Magnetic Separator [if fitted]


7. Start the engine, refer to engine starting.


13

8 n/min

9. Set the mode switch to plant operation.

10. Set product conveyor switch to 1 to start the conveyor and, if fitted, the magnetic separator will also start.

11. A pre-start delay and an audible warning will sound before movement takes place.

EN 20-3


Plant Operation

Crusher


13. Check the product conveyor is operating.

14. Make sure the engine speed switch is set to low.

14 n/min

NOTICE

To avoid damage to the clutch, DO NOT increase the engine speed until after the crusher is running

15. Set the crusher switch to 1 to engage the clutch and drive the crusher.


17. When the clutch is fully engaged, the engine speed switch can be set to the working speed.

18. If there is a problem with the clutch hydraulic system, it will be indicated by a fault warning.

Dirt Conveyor Operation [if fitted]


20 Visually confirm that the dirt conveyor [if fitted] has been lowered outward into its working position.

21. Check the product conveyor and crusher are operating.

22. Set the dirt conveyor switch to 1.


20-4


feeder


25. Check the product conveyor, crusher and dirt conveyor, if fitted, are operating.

26. The feeder controls are positioned separately to the other controls.


27. Set the feeder switch to 1.

28. The speed of the feeder will need adjusting, depending upon the type of material to be crushed, to maintain an even regular flow through the crusher. Use the feeder Speed control knob to adjust to the required feed rate.

27

28

29. The feeder can be switched on and off remotely with the radio remote control, if fitted and selected, but the speed can only be adjusted by the feeder control on the plant.

29

NOTICE

The control valves mounted on the engine and beneath the feeder are NOT to be used in any circumstances to operate the feeder or conveyors. Manual over rides, where fitted to valves, are for test and fault finding only and are not to be used to operate any function of the plant while working.

EN 20-5


Plant Operation

finishing Plant Start Up

30. Check that all items are running satisfactorily.

31. Ensure the plant is stable and without undue vibration. If necessary, reposition the plant on firm, level area with the full length of both tracks in contact with the ground.

32. Check all other aspects of the plant are ready for the introduction of material.

20-6



21

EN

Plant Operation - Adjusting and Setting

EN


21-1

Operation - Adjusting and Setting

[All Models]

Discharge Opening

n WARNING


LOCKOUT

PLANT

Measurement

1. The discharge opening is the distance between the fixed and moving jaw plates at the bottom of the crushing chamber and regulates the size of the product material. The opening is measured from the top of the tooth on one jaw plate to the corresponding root between two teeth on the other jaw plate.

1

2. The opening should be measured when the eccentric shaft is at its highest point. The measurement should be made at a point of shortest distance between the two jaw plates, when the jaw is closed.

21-2



EN


21-3


[H.A. models only]

Adjusting Discharge Opening H.A.

[Hydraulic Adjust model only]


4. Ensure the crusher is completely empty of material.

5. Measure the discharge opening.

6. Start the engine, refer to engine starting.

13


8. Set all switches to 0 position.

7

n/min

9. Set the mode switch to plant operation but DO

NOT start the crusher.

10. Use the jaw adjustment switch to increase or decrease the discharge opening.

21-4


Pegson Metrotrak H.A.

11. There will be a slight delay, for the locking mechanism to operate before the jaw moves.

12. There will also be a slight delay after setting the discharge opening, for the locking mechanism to operate, ready for crushing.

13. An audible warning will sound while the adjustment is made.

14. Do not set the jaw discharge opening less than the minimum in the rest position as given in the crusher specification.

04

NOTICE fully open and close the jaw every week to keep the adjustment and locking systems operational.

EN


21-5


[M.A. models only]

Adjusting Discharge Opening M.A.

[Manual Adjust Model only]


2. Ensure the crusher is completely empty of material.

3. Measure the discharge opening.

4. Run the plant until the crushing chamber is empty.

5. Close down the plant and implement the lockout procedure.

n WARNING


LOCKOUT

PLANT

6. Thoroughly clean down the area on top of the rear cross beam and spacing shims to prevent debris from falling into the shim slot whilst carrying out the adjusting procedure.

7. Remove any dirt or burrs that may prevent the shims seating correctly.

8. Release the toggle beam locking wedges by unlocking and slackening the nuts.

9. Measure and note the compressed length of the tension rod spring.

8

8

21-6


Pegson Metrotrak M.A.

10. Slacken the locking nuts to release the compression on the spring but do not remove the nuts.

11. Adjustment to the crusher discharge opening is made by inserting or removing steel shims that are accessed from the back of the crusher.

Shims of various thickness are supplied, some in the crusher and several spare.

10 n WARNING

Always lift the spacing shims by the lifting loops provided. Never allow hands inside the shim slot whilst changing the shims as accidental closure would result in serious injury.

EN


21-7


[M.A. models only]

12. To assist the process of making setting adjustments, a hand operated hydraulic ram system is fitted.

13. Close the pressure relief valve.

12

13 21

14. Push the valve lever forward of the central position and operate the hand pump to move the toggle beam forward to permit insertion or removal of shims as necessary.

15. Pull the valve lever backward of the central position and operate the hand pump to clamp the shims between the toggle beam and the main frame crossbeam.

16. Reset both the toggle beam locking mechanisms by tightening the clamping and locking nuts.

17. Compress the tension rod spring to the length previously noted. Do not over compress the spring.

18. Run the crusher empty. If ‘knocking’ is heard from toggle plate movement, stop the plant and lockout.

19. Increase the compression on the tension rod spring slightly. Repeat this until the crusher runs smoothly but do not over compress the spring.

20. Return the valve lever to the central position.

21. Open the pressure relief valve.

21-8


14 15 20


22

EN

Plant Operation - Clearing Blockage

EN


22-1

Operation - Clearing Blockage

[H.A. models only]

Clear Assist System H.A.

[Hydraulic Adjust model only]

1. If the blockage has not been released by opening the jaw, operate the clear assist system for 5 seconds maximum.

2. Check again if this has allowed some possible movement of the jaw which has released the pressure on the blocking material.

3. If the blockage has cleared, start up the product conveyor to clear the material.

4. If the blockage has not cleared, try the clear assist system again. If the blockage has not cleared after 3 attempts, the blockage must be cleared by another method.

5. If the procedure is not successful, refer to separate section on clearing blocked jaw crushers.

32

22-2



Blocked Crusher H.A.

[Hydraulic Adjust model only] n WARNING


LOCKOUT

PLANT

Blocked H.A. Crusher Procedure

6. If an oversize piece of material has caused the crusher to become blocked, it is possible the pressure will be sustained on the moving jaw.

This pressure will need to be released under controlled conditions to enable safe removal of the material.

n WARNING

Before any attempt to carry out the procedures to clear the crusher, the plant must be stopped and locked out. The safety grid at the mouth of the crusher must be securely fastened in place.

7. In certain circumstances it may be possible to release the pressure on the moving swing jaw by using the clear assist system.


9. Stop the plant and engine, refer to engine stop.

10. Lockout the plant.

11. Check that the material causing the blockage is made of crushable material.

15

EN 22-3



[H.A. models only]

12. Start the engine, refer to engine starting, but

DO NOT start the crusher.

13

13. Use the jaw adjustment switch to open the jaw fully to release blocking material.

14. Refer also to adjusting discharge opening H.A..

15. Ascertain if this has allowed some movement of the jaw which has released the pressure on the blocking material.

16. If the blockage has cleared, start up the product conveyor to clear the material.

17. If the jaw will not move and open to release the blockage using the jaw adjustment switch, use the clear assist system.

22-4



EN


22-5


[M.A. models only]

Clearing Blocked Crusher M.A.

[Manual Adjust model only] n WARNING


LOCKOUT

PLANT

1. In the situation where an oversize piece of material causes the crusher to stall, it is possible the pressure will be sustained on the moving jaw. This pressure will need to be released under controlled conditions to enable safe removal of the material that has created the stall condition.

n WARNING

Before any attempt to carry out the procedures to clear the stalled crusher it must be locked out and the safety grid at the mouth of the crusher must be securely fastened in place.

2. In certain circumstances it may be possible to release the pressure on the moving jaw by slackening off the toggle beam locking wedges which may allow the toggle beam to be raised sufficiently to allow the jaw to fall back by a small amount.


4. Release the toggle beam locking wedges by unlocking and slackening the nuts.

5. Carefully ascertain if this has allowed some possible movement of the toggle beam, which has released the pressure on the blocking material.

6. If the procedure is successful and the blocking material removed, re-tighten the locking wedges before recommencing operation

4

4

7. If the procedure is not successful, refer to separate section on clearing blocked jaw crushers.

22-6

32



23

EN

Operation - Plant Alarms

EN


23-1

Operation - Alarms

Plant Diagnostic Lamp

The plant diagnostic lamp will flash to indicate the following faults.

fault No. and Description Action

1 Emergency stop fault. Check all emergency stop buttons.

2 Radio stop fault. Check the radio remote control is not selected and stop button pressed in.

3 Hydraulic fluid level low. Check for leaks, rectify if necessary and top up.

4 Product conveyor speed low. Check for a slipping belt [If a speed wheel is fitted].

5 Clutch operating pressure low. #

6 Jaw cylinder pressure low.

[Hydraulic adjust model only]. #

7 function selected but not running. Check non running functions are turned off to 0.

8 - - -

9 - - -

10 - - -

11 C.A.N. block error. #

12 C.A.N. bus error. #

13 - - -

# = Contact your local Powerscreen® dealer or

Powerscreen® Technical Support department for advice.

03 n WARNING

Alarm messages without a suggested rectification or to rectify faults which require repairs or replacements of parts where specialist tools or expertise is required, contact your local Powerscreen® dealer or Powerscreen® Technical

Support.

23-2

NOTICE

A fault must be rectified before crushing operations can be resumed.


24

EN

Daily Plant Checks

Pegson plants

EN


24-1

Daily Plant Checks

Checks Prior to Daily Start

n WARNINGS

It is imperative that the operator carries out regular and diligent checks before operating the plant, especially with operational safety in mind.

Always consider what particular safety hazards could occur at specific sites and eliminate them before commencing work.

While it may not be the operator’s responsibility to perform servicing or mechanical maintenance, the operator must be thoroughly familiar with the plant and its proper care since their own safety is involved.

Plant


2. Visually check and inspect all guards, covers and doors are in position and secure.

3. Check that all equipment and tools that are hazardous to operation are removed from the immediate site.

4. Perform all actions required in the lubrication schedule requiring a daily check or lubrication, refer to servicing - lubrication.

41 n DANGER

DO NOT allow an excavator bucket feeding material into the hopper to pass overhead or near the plant operator.

n WARNING

NEVER leave the plant unattended whilst it is in operation.

24-2


Pegson plants

NOTICES

Check frequently the stability of the plant.

The chassis SHOULD NOT bounce during operation.

DO NOT run the engine below its recommended working speed when crushing.

Check regularly that all cooler fans are running correctly and that dust/dirt has not built up in the fan and radiator or heat exchanger element. Overheating can occur if dust/dirt is allowed to build up.

Clean out dust/dirt if necessary.

Avoid frequent starting and stopping of the plant unnecessarily, as it will cause damage to the plant and excessive wear.

5. Make sure all warning and safety signs are clean and visible, see plant specification and information for their positions.

6. Ensure that the crusher and the feed hopper are empty.

04

7. Check hydraulic oil level and filter condition indicators.

8. Visually check the hydraulic system for damage or leaks.

51 n DANGER


SKIN INJECTION

HAZARD

EN 24-3


Daily Plant Checks

Engine


2. Refer to the engine manual for the daily checks required such as oil level and filters.

3. Check fuel level.

4. Check the hydraulic fluid filter condition indicators, if fitted.

5. Check coolant level when cold and top up as necessary, refer to engine manual and servicing

- lubrication.

26

51

41

6. Some plants are fitted with a coolant header tank for filling and topping up.

7. Some plants are fitted with an expansion bottle for topping up. If the expansion bottle is empty, first fill through the radiator filler then top up via the expansion bottle.

n WARNING


HAZARD

24-4


Pegson plants

Tracks



10. Check the track rollers and idler wheels for possible leakage.

11. Check the surface of the track, rollers, idler wheels, track shoes and drive sprockets for wear and loose mounting bolts.

12. Clean out any heavy build up of material from around the tracks.

n WARNING


LOCKOUT

PLANT

13. Check the tension of the tracks, refer to servicing of tracks.

14. Check the track frames for any damage

47

EN


24-5

Daily Plant Checks

Conveyors


16. Check that all conveyor rollers are free to rotate.

17. Remove any build up of material on the plant chassis or framework below conveyors.

NOTICE

DO NOT allow a build up of material at the feed on points to any conveyor.

Other Plant Checks

18. General plant items should be inspected on a weekly basis and at 500 hour intervals for damage in the following areas:

Main chassis.

feeder.

Track frames.

Conveyor frames.

24-6


25

EN


Pegson plants

EN


25-1

Dust Suppression

[if fitted]


[if fitted]

1. The plant dust suppression is a plain water spray system with one inlet feeding separate circuits. The customer or user should provide the clean pressurised water supply.

2. The layout of the valves and pipe work varies on different type of plant.

3. Each circuit consists of spray bars each fitted with atomiser nozzles.

4. These are normally located in the following areas:-

Crusher or impactor discharge area.

Product conveyor discharge.

Crusher feed,.

Dirt conveyor, [not all plants].

5 The total flow requirement for the system is

25litres/min (6.6USgall/min) at a pressure of

2.8bar (42lbf/in²) .

25-2


6. The system requires a clean pressurised plain water supply to the connection point.

7. Shut-off valves are provided for each spray bar circuit.

8. The water can be drained from the system using the drain valves located below the inlet.

This is particularly important when there is the likelihood of the system freezing.

6

6

7

8

7

Pegson plants

7

8

9. All nozzles should be kept free of dirt and blockages.

10. Each nozzle should be checked every time the dust suppression is switched on.

NOTICE

Drain water from system when not in use, if there is a possibility of freezing.

EN 25-3


Dust Suppression

[if fitted]

25-4


26

EN

Re-fuelling

Pegson plants

EN


26-1

Re-fuelling

Check fuel Level and fill Up

fuel Sight Glass

1. Some plants have a fuel sight glass for checking the tank level.

2. Check level and fill up with fuel, refer to fuel filling.

2 n DANGER

Diesel fuel is highly flammable and is an explosion/burns hazard.

NEVER remove the filler cap or refuel, with the engine running.

NEVER add gasoline, petrol or any other fuel mixes to diesel because of increased fire or explosion risks.

DO NOT smoke while refilling or carrying out maintenance on the fuel system.

DO NOT carry out maintenance on the fuel system near naked lights or sources of sparks, such as welding equipment.

26-2


Pegson plants

fuel Gauge

3. Some plants have an electric fuel gauge.


5. Turn the battery switch to the ‘1’ position.

5

1

0

6. Turn ignition to the ‘1’ position.

7. Check the fuel level gauge.

8. Turn ignition switch to ‘0’.

6 fuel filling

9. Clean the area around the fuel filler cap. On some plants the filler is located behind a door or panel. Some plants have an external fuel tank fitted with filler.

10. Remove the filler cap and fill up with fuel as required with specified diesel fuel. Refer to the engine manufacturer’s operation manual.

10

NOTICES

Do Not fill the tank to overflow or full capacity.

Allow room for expansion and wipe up spilt fuel immediately.

EN 26-3


Re-fuelling

11. Preferably re-fuel at the end of each day where possible, to reduce overnight water condensation within the tank.

12. Replace the filler cap and close the door if applicable.

13. On plants fitted with an electric fuel gauge, switch on the ignition briefly to check the level, if required.

14. When finished, turn ignition switch to ‘0’ and remove key then turn the battery switch to ‘0’.

14 fuel Transfer Pump

15. Some plants are fitted with an electrically operated pump, refer to addendum AM0009.

01 - AM0009

1

0

26-4


27

EN

feeder Stop and Start [‘860’

Radio Remote]

Pegson plants

EN


27-1

'860' Radio Remote feeder Stop & Start

[if fitted]

Radio Remote Control - Feeder Stop & Start,

[if fitted]

1. Observe all safety instructions.

2. Set up the plant for operation in plant mode.

Refer to specific plant controls.

17

3. Activate the radio remote control, refer to radio remote ‘860’.

4. Start the engine. Refer to specific plant and engine controls.

5. Prepare the plant for crushing. Refer to specific plant controls.

14

13

17

6. Switch on the conveyors, impactor or crusher and feeder at the plant controls. Refer to specific plant controls.

20

7. Set the desired feeder speed at the plant controls or set to automatic, depending upon the specific controls fitted to the plant.

20

8. The feeder speed on some plants can also be controlled with the radio, refer to feeder speed adjust ‘860’, if applicable.

28

9. Press the button to start and stop the feeder.

Alternative icons are used on some plant controls.

9

27-2



31

EN


EN


31-1


Normal Closing Down the Plant

1. To finish crushing each section of the plant must be emptied in sequence before being stopped.

NOTICE

For normal closing down the plant, DO

NOT use any emergency stop buttons, or radio control stop button if fitted, or by switching off the engine ignition. Always follow the correct closing down sequence to avoid premature failure or damage to plant components.

Always close down in the following sequence.

2. Wait until the feeder is empty of material then stop the feeder. Set the feeder off to 0 or, if fitted and being used, press the button on the radio remote control. Wait until the feeder has stopped before stopping the next item.

2

3. Wait until the dirt conveyor is empty of material then stop the dirt conveyor, if fitted. Set the dirt conveyor off to 0. Dirt conveyors are not fitted to all plants. Wait until the conveyor has stopped before stopping the next item

4. Set the engine to the slowest speed.

4

n/min

31-2


5. When the crusher is empty, set the crusher off to 0 to disengage the clutch. Wait until the crusher has stopped completely before stopping the next item.


6. After all materials have run off the product conveyor, set the product conveyor off to 0 to stop the conveyor and other equipment. Wait until the conveyor has stopped before stopping the next item.

7. Stop the engine as described in engine stop.

15

8. It is recommended that at the end of operation for the day the plant is routinely cleaned down and thoroughly examined to check for any damage, breakages, wear, leaks etcetera which should be rectified before further operation.

NOTICE

Use of high pressure washing equipment is to be avoided where the ingress of water will be detrimental to plant components. For example: crusher bearings, conveyor bearings, hydraulic tank, electrical equipment etcetera.

EN


31-3


31-4


Pegson Jaw Plants

32

EN


EN


32-1


Blocked Jaw Crusher

1. It is the responsibility of the owner, user and/ or safety officer of the plant to provide a safe means of dealing with oversize material and construct a safe procedure for unblocking a stalled crusher which is full of material.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD

2. It will probably be necessary to conduct an adequate and appropriate risk assessment of the procedures for unblocking a blocked crusher to comply with local health and safety laws. Make sure you comply with any local laws applicable to such procedures.

3. Should an oversize piece of material be fed to a jaw crusher and cause the feed opening to be bridged the recommended procedure for removing this is to use a hydraulic arm.

When a hydraulic arm is used no pressure should be put on the rock when the crusher is STATIONARy as this will cause premature failure of the bearings.

4. 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.

n WARNING

Unblocking stalled crushers can be hazardous. Do not undertake without careful risk assessment.

n WARNING

The following methods of unblocking a crusher SHOULD NOT be attempted:-

DO NOT use wedges

DO NOT use mobile plant to drag stones out of the crusher or feeder

32-2


5. 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.

6. 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.

7. If the previous procedure fails to enable the stalling blockage to be removed, more complex methods may be required for which special training is required.

8. In the event of any problems these should only be dealt with by suitably experienced and qualified engineers.

9. For advice, contact your local Powerscreen® dealer or Powerscreen® technical support.

03

Pegson Jaw Plants

EN


32-3


32-4


Pegson Jaw Plants

33

EN

Initial Checks - Running In

EN


33-1

Initial Checks

Initial Start-Up

1. Check the oil levels in the vibrating unit oil baths.

43

1 15

2. Check the hydraulic oil level in the tank.

51

2 8

3. Refer to engine manual for initial start up of engine.

4. Run the plant empty for a short period of time and check for abnormal noises, vibration or excessive heat from the shaft bearings.

03

NOTICE

Checks on the plant are crucial during the first week of operation.

This section should be read and understood prior to starting the plant. If there are any doubts, consult your local

Powerscreen® dealer or Powerscreen® technical support.

33-2


Actions During Running-In Period

Plant

5. Each day during the initial days of operation check the tension of the conveyor belts: product conveyor, and dirt conveyor if one is fitted.

6. Frequently check the overall stability of the plant, re-position if necessary.

7. Check the plant is level, re-position if necessary.

46

Pegson Jaw Plants

8. Frequently check the hydraulic fluid level in the tank.

51

Crusher

9. On hydraulic jaw plants, regularly check the crusher slider pads for wear.

10. Check the alignment and tension of the vee belt drive daily during the initial days of operation.

11. Check the shaft bearing temperature daily using a contact thermometer and record for future reference and fault diagnosis. The maximum acceptable working temperature is

80°C (176°f) .

12. Avoid overloading the crusher; restrict loading to 50% of full capacity on the first few days and increase gradually to full capacity when the crusher has been operating 60 hours.

13. 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.

45

EN 33-3


Initial Checks

14. Check all liner fixings daily whilst liners settle in, when the plant is new or if the liners have been disturbed. This should be checked daily until no adjustment is required.

15. Ensure that all under size feed [smaller than the discharge setting] and oversize feed

[greater that 80% of the feed opening] is removed prior to introduction into the crusher.

16. If the crusher has not been run for some time, re-grease all the crusher bearings then run empty for approximately 2 hours.

feeder

17. Frequently check the oil levels in the vibrating unit oil baths.

18. After first 8 hours of operation, change the oil in the vibrating unit oil baths, see servicing vibrating feeder.

19. Check the vibrating unit bearing temperatures using a contact thermometer on the oil baths; record for future reference and fault diagnosis.

Maximum acceptable temperature is 80°C

(176°f) .

20. Ensure that the vibrating feeder unit is operating before any material is introduced to the plant.

43

33-4


34

EN

Jaw Crusher Checks

Pegson Jaw Plants

EN


34-1

Jaw Checks

Jaw Crushers

1. Check discharge opening with callipers and adjust as necessary, to the required settings.

2. Check the jaw and side cheek securing nuts daily.

3. In high ambient temperatures, grease the jaw eccentric shaft, see servicing - lubrication.

21

41

Wear Checks

Jaw faces

4. Monitor the wear on the jaw liners from new and turn or renew them when 95% worn.

5. Monitor and check the wear of the jaw liners regularly.

6. DO NOT allow the jaw liners to wear below the bottom of the grooves. Any wear below this will result in the support block at the base being worn.

7. Continued crushing with heavily worn jaws increases the crushing forces and power consumption. This may limit the minimum setting on hard materials.

60

8. The jaws are double ended can be turned to use the other end, if one end has become worn.

The worn area then being at the top of the crusher.

Toggle Plate and Seats

9. The toggle seats and toggle plate should be checked for wear as this can effect the operation of the spring system and in extreme cases cause the mechanism to fail [the greater the wear the closer the spring bracket gets to the jaw – collision could occur].

60

34-2


10. If inspection reveals the toggle plate and seats are worn then replacement is required. Do not modify the jaws or spring system to effect additional clearance as this may adversely effect the structural integrity of components leading to failure and loss of any warranty.

11. Specialist training and experience are required for this work, contact your local Powerscreen® dealer or Powerscreen® technical support for advice.

03

HR - Hydraulic Release Jaw Crushers

Toggle Beam Slider Pads

12. In applications where the crusher is subjected to frequent overload release situations, wear on the slider pads may be accelerated.

13. Regularly check to make sure there is no rocking movement of the toggle beam. View through the chassis shim aperture guards whilst the crusher is running.

14. Excessive wear or damaged pads could result in movement of the toggle beam or cylinders in normal operation, which will result in further machine damage.

15. If the slider pads are worn, these should be replaced as soon as possible to prevent failure during crushing.

Pegson Jaw Plants

16. Specialist training and experience are required for this work, contact your local Powerscreen® dealer or Powerscreen® technical support for advice.

03

EN


34-3

Jaw Checks

Routine Inspection Checks

Crushers should be inspected on a weekly basis and at 500 hour intervals for damage in the following areas:

1. Crusher body.

2. Wear Parts.

3. flywheel[s] Area to inspect.

3

34-4


Pegson plants

40

EN

Servicing Safety and Precautions

EN


40-1

Servicing Safety & Precautions

Servicing Safety Information

03 n WARNING

PRIOR TO ANy MAINTENANCE

The servicing instructions are intended for day to day checks and servicing to keep the plant in good running order. for all other maintenance issues, repairs or replacements of parts where specialist tools or expertise is required, contact your local Powerscreen® dealer or

Powerscreen® technical support.

General Information

1. When performing servicing, always observe rules provided in the safety section.

2. Breakdown caused by insufficient or improper servicing will cause high repair costs and long term standstill. Therefore, regular servicing is imperative.

3. The reliability and life of the plant depends on regular and proper servicing.

4. The servicing instructions and schedules are for normal operating conditions.

5. for servicing where it is necessary to remove any guards, make sure that they are replaced before the machine is restarted.

40-2

03

NOTICE

When the plant is operated in extreme climatic conditions: below -15°C (5°f) or above 30°C (86°f) or in very dusty conditions for a longer period of time, the servicing schedules will change.

Contact your local Powerscreen® dealer or Powerscreen® technical support department for advice.


Servicing Safety Precautions

6. Make sure that only suitably competent personnel with the necessary training/ experience for the task[s] in hand are employed.

7. A person should never work alone.

8. Observe the advice in the Safety Sections as appropriate to any task[s] undertaken.

9. Read the appropriate manual relevant to the operation in hand.

10. Carry out a risk assessment for all servicing operations.

11. 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.

Pegson plants

12. Powerscreen® technical support department is available for advice when required.

13. The plant should be completely emptied of all material.

03

EN


40-3


n WARNING


LOCKOUT

PLANT

14. Implement the lockout procedure and display a prominent ‘tag’ at the control station or other appropriate place to warn of work being carried out.

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

16. fit dismantled parts in the same location from which they were removed.

17. Ensure that the area surrounding the servicing site is clear of any obstructions.

02 14

40-4


Pegson plants

Welding on a plant fitted with an electronic controlled engine n WARNING


LOCKOUT

PLANT

1. BEFORE WORKING ON THE PLANT, SWITCH

OFF, ‘LOCKOUT’ AND ‘TAG OUT’ 02

1

NOTICES

Before welding on a plant fitted with an electronic engine, these precautions shall be followed.

Refer also to welding instruction label inside the engine canopy.

2. Turn the battery disconnect switch off to the ‘0’ position and lockout.

2

1

0

3. Disconnect the battery ground negative [-] battery cable at the battery and at the battery disconnect switch.

EN


40-5


4. Connect the welder ground cable clamp directly to the member to be welded as close as possible to the weld.

5. If arc-welding work is involved in any servicing operation, make sure that the current does not pass through any bearings, hydraulic components, electrical components and ground straps.

6. Do not use electrical components, the electronics control module or electrical ground stud for grounding the welder.

7. Protect any wiring and electrical or hydraulic components from welding debris or splatter.

8. Disconnect engine management system as described in the welding instruction label inside the engine canopy.

9. Use standard welding techniques to weld the materials together.

40-6


After Extensive Maintenance

Refer to initial checks - running in.

Pegson plants

33 n WARNING

PRACTICE SAfE MAINTENANCE

Understand service procedure before doing any work. Keep areas 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 plant or 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, negative, [-] at the battery and the battery disconnect switch before making adjustments on electrical systems or welding.

EN


40-7


40-8



41

EN

Servicing - Lubrication and Checks

EN


41-1

Servicing - Lubrication

Lubrication Requirements

Regular Servicing

1. It is important that a strict routine of regular servicing is undertaken from the start of operation of the plant.

2. Regular checks on fluids and the lubrication of the plant, in accordance with the schedule, is essential.

3. In addition to the lubrication points, the lubrication schedule lists the regular attention required to the plant hydraulic system.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD

41-2



NOTICES

To deliver the specified quantity of grease to each of the four crusher eccentric shaft bearings, ascertain the amount the grease gun will deliver with each ‘pump’. Do not guess or assume an amount ! Check the greasing equipment used regularly.

Type ‘D’ grease used during manufacture is fuchs Renolit EP2.

DO NOT use grease that contains molybdenum disulphide [MoS

2

].

To prevent contamination of the grease, wipe the grease nipples clean before applying the grease gun.

4. Refer to Pegson lubricant and fluid specifications for all oil or grease and hydraulic fluid requirements.

42

NOTICE

DO NOT MIX OILS Of DIffERENT

MAKES OR TyPES

EN


41-3


Lubrication and Hydraulic System Schedule

1. All hours stated are working hours for the component concerned.

2. This schedule is based on the plant operating 8 hours a day and 40 hours a week.

Monthly = 160 hours

Annually = 2000 hours

3. Adjust schedule to suit actual operating hours

4. Refer also to servicing jaw crushers.

Eccentric Jaw shaft

Locations 4

Standard Lubrication:

Below 35°C (95°f) D

Quantity 72g (2.5 oz) each

Re-grease Weekly

High Ambient Lubrication:

Above 35°C (95°f) D

Quantity 17g (0.6 oz) each

Re-grease Daily

44

41-4


5. feeder vibrating oil baths on both sides. Refer to servicing vibrating feeder.


43

Vibrating Hopper feed Oil Bath

Locations 2

Lubricant:

Below 4°C (39°f) A

4°C (39°f) to 15°C (59°f) B

Above 15°C (59°f) C

Quantity:

Drive side 2.1 litres (4.5 US pints)

Non drive 1.7 litres (3.5 US pints)

Check sight glass and top up Every day

Change oil Every 200 hours

6. Product conveyor head and tail shaft bearing grease nipples located each side of the conveyor. Refer to servicing conveyors.

Product Conveyor Shafts

Locations 4

Lubricant D

Re-grease Every 2 weeks

46

7. Dirt conveyor, if fitted, head and tail shaft bearings, two being on one side of the chassis below the feeder. Refer to servicing conveyors.

46

Dirt Conveyor Shafts

[If fitted]

Locations 4

Lubricant D


EN


41-5


8. Magnetic separator, if fitted. Refer to servicing magnetic separator.

Magnetic Separator

[If fitted]

Locations 4

Lubricant D


49 n WARNING

The belt magnet assembly is very powerful and permanently charged. The strong magnetic field produced could affect heart pacemakers, watches, credit cards, mobile phones etc. The operator has the sole responsibility to keep anyone at risk clear of the plant.

Persons with medical implants which may be affected by the magnetic field should keep a minimum of 3m (10ft) away

9. Track gearbox, refer to servicing tracks

47

Track gearbox

Locations 2

Lubricant:

Type A gearbox K

Type B gearbox Q

Approximate Quantity [±10%] 5 litres (1.3 US gal)

Change oil After first 100 hours

Check and top up Every 100 hours

Change oil Every 1000 hours

Change oil Annually

[Hours worked by Tracks]

10. Clutch bearing, also refer to servicing clutch.

Type A clutch is fitted to this plant.

48

Clutch Bearing

Lubricant P

Check and top up At initial 100 hours

Re-grease Every 500 hours

Purge old grease and replace Every 3000 hours

Approximate quantity 128g (4.5 oz)

[Bearing carrier 50% full]

41-6


11. The engine also requires servicing which is detailed in the separate engine manufacturer’s manual.

Engine

Lubricating oil and filters See engine manual

Fuel and filters See engine manual

Coolant:

Also see engine manual E.L.C.*

Coolant Extender:

Also see engine manual E.L.C.* Extender

*E.L.C. = Extended Life Coolant


12. Periodically lubricate hinges, cylinder pivot pins and similar points with oil or grease to prevent seizure during lengthy spells of inactivity.

13. Hydraulic system and filters, also refer also to servicing hydraulic system.

51

Hydraulic Reservoir

Quantity 360 litres (96 US gallons)

Fluid:

Temperature Below 30°C (86°f) f

Temperature Above 30°C (86°f) G

Check and top up Every week

Change fluid 2000 hours

Change fluid Annually

Suction filter and Return filter

Check Each week

Renew When indicator shows red

Renew Every 1000 hours

Track Tension

Track Tension D, E or H

EN

47


41-7

Servicing - Checks

[H.A. models only]

Hydraulic Jaw Adjustment Check

[H.A. model only]

1. To keep the jaw adjustment and locking system working correctly, it is preferable not to leave the system in a fixed position for long periods.

2. To check the operation, fully open and close the jaw each week to keep the adjustment and locking systems operational.

21

41-8



Toggle Plate Springs Check

[H.A. model only]

3. As the toggle plate and locations wear the preloading springs may require adjusting.

4. Every month check the dimension of the protruding collar is correct as shown.

5. If adjustment is necessary slackening the lock nut.

6. Adjust the nut to obtain the correct dimension.

7. Lock the nuts to secure the setting.

10.5mm

(0.4in)

4

5

7 6

EN


41-9


Ambient Temperature Variations

1. The type of lubrication oil and hydraulic fluids in the following parts of the plant are dependent upon the ambient operating temperature.

2. Temperatures shown are defined as a daily ambient temperatures which are consistently below the figure stated or a daily ambient temperatures which are consistently above the figure stated.

NOTICE

Jaw Crusher Lubrication in High Ambient

Temperatures

Where the plant is working for extended periods in ambient temperatures in excess of 35°C (95°f) , the greasing of the four jaw crusher eccentric shaft bearings must be increased in frequency and the quantity revised as shown in the schedule.

Low or High Ambient Temperatures


Powerscreen® Technical Support department for advice if in doubt.

03

41-10


Pegson plant

42

EN

Pegson Lubricant and Fluid Specifications

EN


42-1

Lubricant & Fluid Specifications

Lubricant Oil Specifications

Oil Specification Grade A

ISO VG150 EP

Flashpoint: Minimum 199°C (390°f)

Pour Point -18°C (-0.4°f)

Kinematic Viscosity at:

40°C, mm²/s (104°F, in²/s) 150 (0.232)

100°C, mm²/s (212°F, in²/s) 15.4 (0.0238)

Viscosity Index 105+

Timken OK lb. Minimum 50

Extreme Pressure Agent yes

R & O Agent yes

Anti foaming Agent yes

Copper Strip Corrosion Test Pass yes

Suppliers

Shell Omala 150

Century Centlube E76

Mobil Mobilgear 629

Esso Spartan EP150

Gulf EP LUB MULTI H

BP Energol GR-XP150

Oil Specification Grade B

ISO VG220 EP




40°C, mm²/s (104°F, in²/s) 220 (0.341)

100°C, mm²/s (212°F, in²/s) 20.1 (0.0312)




R & O Agent yes



Suppliers

Shell Omala 220

Century Centlube f76

Mobil Mobilgear 630

Esso Spartan EP220

Gulf EP LUB HD220

BP Energol GR-XP220

Oil Specification Grade C

ISO VG460 EP




40°C, mm²/s (104°F, in²/s) 460 (0.713)

100°C, mm²/s (212°F, in²/s) 32.9 (0.051)




R & O Agent yes



Suppliers

Shell Omala 680

Century Centlube H76

Mobil Mobilgear 634

Esso Spartan EP460

Gulf EP LUB HD460

BP Energol GR-XP460

42-2


Pegson plant

Oil Specification Grade K

Specification API GL-5

Gear oil SAE 80w/90

Oil Specification Grade R

Shell Omala 100

BP Energol GR-XP 100

Oil Specification Grade L

ISO VG150 with EP additives

Oil Specification Grade S

Shell Omala 68

BP Energol GR-XP 68

Oil Specification Grade N

SAE 30 - SAE 40

ISO VG 100 - ISO VG 150

[DO NOT use synthetic oil]

Oil Specification Grade T

Viscosity Index 195

Viscosity at 50°C (122°f) 5.3

Texaco Rando HD-CZ 68

Oil Specification Grade Q


Gear Oil SAE 90

EN

Oil Specification Grade X


Gear oil SAE 85w/140

42-3



Grease Specifications

Check the grease to be used is to the correct specification, do not assume a general reference or name used by a supplier will conform to the required specification.

Grease Specification Grade D

NLGI Grade Number 2

DIN Classification DIN 51 825 KP 2 K-20

ISO Classification ISO 6743-9 L-XBCEB-2

Unworked Penetration at 25°C (77°f) 280

Worked Penetration at 25°C (77°f) 285

Drop Point 185°C (365°f)

ASTM Corrosion Test Pass [14 days] yes

Wheel Bearing Test Pass at 135°C (275°f) yes

Timken Test [lb] Pass 40/50


NOTICE

GRADE D

DO NOT use grease that contains molybdenum disulphide [MoS

2

].

Use ONLy a grease with lithium or lithium complex soap containing extreme pressure additives and having a base oil viscosity of 220 Cst at 40°C (104°f) /

17 Cst at 100°C (212°f) suitable for an operating range of -20 to +120°C (-4 to

248°f) .

Grease Specification Grade P

NLGI 2

Soap base Lithium

Temperature Range -20 to +120°C

(-4 to 248°f)

Viscosity <150cSt - 40°C (104°f)

Speed factor >200.000

Duty Heavy

Castrol Spheerol EPL2

Shell Albida LX

Kluber Centoplex 2EP fAG Arcanol L135V

42-4


Pegson plant

Grease Specification Grade H

Shell Retinax EP2

Grease Specification Grade M

NLGI Grade Number 3 Medium/Heavy Duty

Penetration at 25°C (77°f) 220/250

Temperature Range -20 to 200°C (-4 to 392°f)

Drop Point None

Water Resistance Complete

Chemodex Moly-Bentone MP

NOTICE

GRADE M

For cone crusher wedge rings, this grease

MUST be used

Grease Specification Grade U

General Purpose grease containing Molybdenum

Disulphide [MoS

2

]

Grease Specification Grade W

NLGI Grade Number 3

DIN Classification K3K-30

Thickening Agent Lithium soap

Drop Point 182°C (360°f) minimum

Worked Penetration 220-250

Temperature Range -30 to +125°C (-22 to 257°f)

EN

NOTICE

It is bad practice to mix greases. The blend can have a lower specification than the individual greases and can lead to premature bearing failure. USE ONE

BRAND ONLy.

It is the operators responsibility to ensure that all bearings are greased with the correct quantity and type of grease at the correct intervals specified.

42-5



Hydraulic Fluid Specifications

Hydraulic Fluid Specification Grade E

ISO VG 32


40°C mm²/s (104°F, in²/s) 32 (0.049)

100°C mm²/s (212°F, in²/s) 5.5 (0.085)

Viscosity Index 95+

Rust Inhibitor yes

De-foament yes

Anti Scuff yes

Suppliers

Shell Hydra 37 or Tellus 37

Mobil DTE24

Century Centraulic PWLA

Esso Nuto H32

Gulf Hydrasil 32

BP Energol HLPP-HM32

Hydraulic Fluid Specification Grade G

ISO VG 68


40°C mm²/s (104°F, in²/s) 68 (0.105)

100°C mm²/s (212°F, in²/s) 8.5 (0.013)

Viscosity Index 95+

Rust Inhibitor yes

De-foament yes

Anti Scuff yes

Suppliers


Mobil DTE26

Century Centraulic PWLC

Esso Nuto H68

Gulf Hydrasil 68


Hydraulic Fluid Specification Grade F

ISO VG 46


40°C mm²/s (104°F, in²/s) 46 (0.0713)

100°C mm²/s (212°F, in²/s) 6.5 (0.010)

Viscosity Index 95+

Rust Inhibitor yes

De-foament yes

Anti Scuff yes

Suppliers


Mobil DTE25

Century Centraulic PWLB

Esso Nuto H46

Gulf Hydrasil 46


Hydraulic Fluid Specification Grade J

ISO HM 32

Shell Tellus 32

Mobil DTE 24

Esso Nuto H32

BP Energol HLP-32

Hydraulic Fluid Specification Grade V

Shell Donax TD

42-6


Pegson plants with Vibrating Hopper feeder

43

EN


EN


43-1


Vibrating Hopper feeder - Servicing

1. After the initial 8 hours of operation, renew the oil in the feed hopper vibrating unit oil baths.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD

2. Unscrew the plug to drain oil from each oil bath.

Re-fit plug to seal.

3

4

3. Fill each oil bath with suitable oil, see servicing - lubrication plus lubricant and fluid specifications.

4. Oil should be level with the line on sight glass.

41 42

43-2


2

Pegson plants with Vibrating Hopper feeder

5. Always check the oil level before starting the plant.

6. The vibrating feeder must be regularly inspected for any wear, damage or breakage with the mainframe and support springs being paid particular attention. Rectify any faults immediately.

7. Make sure that the feeder can vibrate freely without fouling against the adjacent hopper or chute work and that any hardened material inside the pan is not allowed to build up and affect the performance of the plant.

8. Check to ensure that the hydraulic drive is operating efficiently.

9. Check the condition of the bars for both wear and build up of material and rectify if necessary.

10. Check the vibrating unit bearing temperatures using a contact thermometer on the end covers; record for future reference and fault diagnosis.

Maximum acceptable temperature is 80ºC

(176°f) .

11. Check the security of all fasteners on the vibrating feeder and any bolted sections of the feeder bars.

EN


43-3


43-4


44

EN


Pegson Plants

EN


44-1


Jaw Crusher Lubrication

n WARNING


LOCKOUT PLANT

1. The lubrication of the eccentric shaft and jaw bearings varies in frequency and amount of grease depending on the ambient temperature.

It is important that the crusher eccentric shaft is greased at the correct intervals, refer to servicing - lubrication.

41

2. Use the correct grease only, not a mixture, refer to lubricant and fluid specifications.

42


Powerscreen® Technical Support department for advice if in doubt.

03

4. Access to the eccentric shaft is from the maintenance platform.

5. Lubricate the jaw bearing at the grease nipples.

6. Lubricate the shaft bearings at the grease nipples.

44-2


45

EN

Servicing Vee Belts

Pegson plants

EN


45-1

Servicing Vee Belts

General

n DANGER


ENTANGLEMENT

HAZARD

1. The Vee belt drive is a highly efficient power transmission medium, but optimum performance will not be achieved without correct tensioning and alignment.

2. Vee belt drives are used on the plant between the engine and the crusher and also to drive the hydraulic pumps on some plants.

3. Drive belts should be inspected regularly for wear and also to monitor any pattern in the wear if it is occurring.

4. Insufficient belt tension will cause slippage leading to loss of drive efficiency, heat generation and belt failure.

5. Over tensioning will exert excessive loading on the shaft bearings and can lead to premature failure.

6. When replacing a multi-belt drive always use a set of ‘matched’ new belts so that equal force can be applied to all the belts.

7. Ensure that any ventilation provided in the drive guarding is kept clear to avoid overheating.

8. Do not allow contaminating material to come into contact with the drive elements.

n WARNING


LOCKOUT

PLANT n WARNING

Do not inspect or carry out work on belt drives before closing down the plant and implementing the Lockout Procedure.

Never operate the plant without effective drive guarding in place.

45-2


Alignment

9. It is important to align the pulleys, otherwise the belt flanks will wear quickly.

10. Ensure axis are parallel when viewed from all planes.

A - Correct installation, both shafts and pulleys are parallel and in alignment.

B - Incorrect, shafts are parallel from above but not from end view.

C - Incorrect, shafts are parallel and in alignment but pulleys are not in alignment.

D - Incorrect, shafts are not parallel to one another when seen from above.

Pegson plants

EN


45-3

Servicing Vee Belts

Adjustment

n DANGER


ENTANGLEMENT

HAZARD

1. Belt adjustment is by means of adjusting screws to increase or decrease the distance between the shaft centres. Locknuts on the tension screws must be tight whilst running the plant.

2. Drives tensioned horizontally have a sliding base frame with four clamping bolts which must be tight whilst running the plant.

3. Drives tensioned vertically have the moving power pack base frame mounted on four adjusting screws which must have all the locknuts tight whilst running the plant.

4. Some plants with vertical tensioning have a hydraulic assisted system, refer to hydraulic assisted belt tensioning.

5. Adjust each screw only to a limited extent at a time and by equal amounts to ease the movement of the base frame.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD

45-4


Pegson plants

Manual Adjustment


7. Close down the plant and implement the

Lockout Procedure.

8. Remove guarding as necessary to gain access to the Vee belt drive and tensioning elements.

9. Mark or measure the existing position, assuming correct alignment, of the moving frame at each tension screw.

10. Loosen the clamping bolts securing the moving base frame [horizontal drives].

11. Undo locknuts on the tension screws to allow the base frame to be moved in the required direction.

12. On the Pegson XH250, XH320 and XH320SR the two adjusters are positioned as shown and do not have locknuts.

13. Either by turning a nut on the screw or the screw itself, depending on the type, tension or slacken the drive belts as required. Make an equal amount of adjustment to each screw.

02

12

14. To establish correct belt tension, use the method described in ‘drive belt tensioning’.

15. Use the marks or measurements made before adjustment to ensure that the correct pulley alignment has been restored.

16. Tighten all locknuts and/or clamping bolts.

17. Ensure that all the drive guarding is replaced and secured before start the plant.

~> n DANGER

Under no circumstances should any check on the belt tension be made whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

EN 45-5


Servicing Vee Belts

Vertical Belt Adjustment - Hydraulic Assisted, [only fitted to some plants]



3. Remove guarding as necessary to gain access to the Vee belt drive and tensioning elements.

4. Mark or measure the existing position of the moving frame at each tension screw, assuming the frame is correctly aligned.

02

5. The hand operated hydraulic pump and controls are positioned under the engine and frame.

5

6. Set hydraulic direction control to up.

7. Open each of the three valves in turn and operate the pump to raise each cylinder and take the weight of the engine and frame off the nuts.

8. The centre valve operates two cylinders at the belt end.

9. Release the appropriate locking nuts on the support studs to enable the frame to be raised to tighten the belts or lower to slacken.

10. Set the hydraulic direction control as required to raise or lower.

11. Open each of the three valve in turn and operate the pump to move the frame a little at a time and keep it level.

12. Close all valves when in the final level position to maintain the position.

13. When the belts are tensioned correctly, tighten all the locking nuts.

7

9

8

6 10

11 12

7

11

13

45-6


Replacement

14. The Vee belts must be of the same type, size, and number to those originally fitted and specified.

15. Before fitting new belts, check the pulley grooves are free from score marks or sharp edges. Also check the grooves for wear. Ensure the pulleys are tight on their shafts.

16. If replacement of the belts is necessary due to premature failure, the cause should be investigated and rectified before fitted new belts. Refer to servicing vee belts, fault finding.

17. The drive centre distance must be reduced prior to installation so that new belts can be fitted without the use of force.

18. Under no circumstance must belts be prised into the grooves as belts and pulley grooves can be damaged by using sharp tools to stretch the belts over the pulley rim.

19. The procedure for fitting new belts is generally the same as described for belt adjustment except it is necessary to slacken off the drive enough to remove the old belts and fit the new without damage. It may also be necessary to remove more of the guarding to gain access.

~>

Pegson plants

EN


45-7

Servicing Vee Belts

Drive Belt Tension


2. Close down the machine and implement the

Lockout Procedure.

3. Remove the guards from around the belt.

4. Calculate the deflection distance in mm (or inches) on a basis of 16mm (0.6in) deflection per 1 metre (1 yard) of belt span.

METRIC: Centre to Centre Distance in metres x 16 = Deflection in mm.

n DANGER


ENTANGLEMENT

HAZARD

5. If a belt tension indicator is available: a. Set the lower marker ring at the deflection distance required on the lower scale.

b. Set the upper marker ring against the bottom edge of the top tube.

c. 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.

d. Read off the setting force value indicated by the top edge of the upper marker ring.

e. Compare this value to the value shown in the table.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD n DANGER

Under no circumstances should any check on the belt tension be made whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

45-8


Pegson plants

6. If a belt tension indicator is not available: a. Use a spring balance to pull the belt down at the centre of the span.

b. When the belt has been pulled down

[measure using a rule] by the deflection calculated in step 4, read off the force from the spring balance.

7. If the measured force falls within the values given, the drive should be satisfactory.

A measured force below the lower value indicates under-tensioning. Some new drive belts are tensioned to the x1.25 Setting Force value to allow for the normal drop in tension during the running-in period. This is not recommended for all belts.

8. Replace all guards before start-up.

Belt Tensioning Measurements

A - 16mm deflection per metre (0.6in per 3ft) .

B - Belt tension indicator applied to mid-span.

C - Centre to centre distance.

[x1] BASIC SETTING FORCES

SPB BELT SECTION

Small Pulley Diameter:

112 to 160mm (4.4 to 6.3in) 4.0kgf (8.8lbf)

170 to 224mm (6.7 to 8.8in) 5.1kgf (11.2lbf)

236 to 355mm (9.3 to 14.0in) 6.3kgf (13.9lbf)

Over 355mm (14in) 6.6kgf (14.6lbf)

SPC BELT SECTION


224 to 250mm (8.8 to 9.8in) 7.1kgf (15.7lbf)

265 to 355mm (10.4 to 14in) 9.4kgf (20.7lbf)

Over 375mm (14.8in) 12kgf (26.5lbf)

[x1.25] BASIC SETTING FORCES

If recommended for new belts

SPB BELT SECTION


112 to 160mm (4.4 to 6.3in) 5.1kgf (11.2lbf)

170 to 224mm (6.7 to 8.8in) 6.3kgf (13.9lbf)

236 to 355mm (9.3 to 14.0in) 7.9kgf (17.4lbf)

Over 355mm (14in) 8.3kgf (18.3lbf)

SPC BELT SECTION


224 to 250mm (8.8 to 9.8in) 8.9kgf (19.6lbf)

265 to 355mm (10.4 to 14in) 11.8kgf (26lbf)

Over 375mm (14.8in) 15kgf (33.1lbf)

EN

NOTICE

After the drive has been running for 15 to

20 minutes, the plant should be stopped and the tension checked. If necessary, readjusted to the basic setting force value by repeating the above procedure from step

1.

45-9


Servicing Vee Belts fault finding

Small Cracks on V-belt side and Base

Generally caused by shortage of belt tension but excessive heat and/or chemical fumes can also give same failure.

Vee 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. If a slightly higher [or lower] tension does not cure the problem there may be a critical vibration frequency in the system which requires rectification.

Consult your local Powerscreen® dealer or

Powerscreen® Technical Support department.

03

45-10


46

EN

Servicing Conveyors

Pegson plants

EN


46-1

Servicing Conveyors

Magnetic Separator

[if fitted]

1. The self cleaning suspended magnet utilises a two pulley design. The tail pulley has adjustment available to take up belt stretch and for tracking purposes.

n WARNING

The belt magnet assembly is very powerful and permanently charged. The strong magnetic field produced could affect heart pacemakers, watches, credit cards, mobile phones etc. The operator has the sole responsibility to keep anyone at risk clear of the machine.


46-2


Pegson plants

Training of Belts

2. Before starting the conveyor, it is essential to check the following.

3. The conveyor is straight and correctly levelled.

4. 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.

5. All trough type 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 rotating freely.

6. In the case of screw-type take up gears, that these are adjusted initially to take up slack from the belt and that equal tension is applied to each side such that the pulley is square to the centre line of the conveyor.

7. Where skirt rubbers are fitted they are not bearing down heavily on the belt.

8. There is no obstruction on the conveyor that could cause accident or damage when the conveyor is started.

9. Tracking should be carried out with the belt empty. With very stiff belts, which do not trough well nor make proper contact with the centre idlers roller when empty, it may only be possible to track the return strand when empty and the troughed side when loaded.

10. If the belt tends to run to one side the 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.

n DANGER


ENTANGLEMENT

HAZARD n WARNING


LOCKOUT

PLANT

EN n DANGER

Under no circumstances should any adjustment be made on the belt whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

46-3


Servicing Conveyors

Conveyor Belt Tensioning

1. Conveyor belts are tensioned by a pair of screw type mechanisms located on either side of the conveyor.

2. 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.

3. The correct tension is achieved when the drive drum starts the belt and keeps it running when loaded without any slip occuring.

4. The tension adjusting screws should be kept clean and well oiled.

n DANGER


ENTANGLEMENT

HAZARD n WARNING


LOCKOUT

PLANT



n DANGER

Under no circumstances should any adjustment be made on the belt whilst the machine is running. There is an entanglement hazard and risk of trapping parts of the body.

46-4


7. Loosen any screws used to clamp the tensioning mechanism or securing a sliding bearing.

8. Loosen the screw tension lock nuts. where fitted.

7

Pegson plants

8

9

9. Either by turning a nut on the screw or the screw itself, depending on the type, tension or slacken the belt as required. Make an equal amount of adjustment to each screw.

7

9 8

8

9

7

7

9

10. Once correct tension has been achieved, tighten the lock nuts and clamping nuts.

EN


7

46-5

Servicing Conveyors

Inspection of Conveyors

1. The following checks should be made regularly in order to keep the conveyors in good working order:



4. 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.

5. 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.

n DANGER


ENTANGLEMENT

HAZARD n WARNING


LOCKOUT

PLANT

6. Check that the belt generally is running centrally and straight on both the carrying strand and the return strand. If not, refer to training of belts.

7. 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 thoroughly and plugging with a rubber repair compound.

<~ n DANGER

Clip joints can be dangerous and should not be used. Belt repairs/replacements should be performed by vulcanising only.

8. Check that there is no evidence of belt slip at the driving drum, as belt slip will cause premature wear on the belt. Check also for undue sag between idlers. Both would indicate lack of belt tension, refer to conveyor belt tensioning.

<~

46-6


Pegson plants

9. Check regularly that the idler rollers are rotating freely. If not either free them or replace the idler. failure to do so will result in belt wear and tracking problems.

10. Check that the belt cleaning equipment is operating correctly and efficiently. In the case of scrapers ensure that they are not choked with a build up of material. Also check that the blades are not bearing on the belt any more than necessary, and that any blades which are unevenly worn or in a condition likely to cause damage to the belt are renewed immediately.

11. In the interests of efficient operation and general safety, it is important that operating conditions are kept as clean as possible and that any spillages are cleaned up regularly and are not allowed to build up.

12. Some conveyors are fitted with low friction strips under the belt. If the strips are fitted, check if they are worn down. Slide them out and turn them over for further use or renew as neccessary.

EN

12 n DANGER

As many inspections as possible should be made whilst the belt is stationary.

When this is not possible extreme care should be taken when inspecting the belt whilst it is moving as there is an entanglement hazard and risk of trapping parts of the body.

46-7


Servicing Conveyors

Lubrication

1. Lubricate the product conveyor tail section pivots, where fitted and dirt conveyor, if fitted, pivots.

2. Refer to the plant specific schedule in servicing

- lubrication.

3. Refer to lubricant and fluid specifications for the correct lubricants.

41

42

4. Grease the head and tail drum bearings of the conveyors as specified in the servicing - lubrication schedule.

4

5. The grease nipples for some conveyors are place in more convenient positions remotely from the bearing.

5

5

6. Where the plant does not have a vibrating feeder but includes a feed conveyor with an oil lubricated speed reduction gearbox inside the head drum, refer to the plant specific schedule in Servicing - Lubrication.

Maximum gearbox oil temperature 90°C (194°f) .

46-8


6

6

4

Pegson plants

Cleaning Conveyor Belts

n DANGER


ENTANGLEMENT

HAZARD

7. If the conveyor belts are not properly maintained and skirting rubbers are not kept in correct adjustment, it may be necessary to remove resultant spillage material and / or blockages from the conveyor belts, particularly at the feed section.

8. The plant should be switched off and isolated by means of the lockout and tag out procedure prior to the commencement of any work.

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

10. Gloves to protect the skin against abrasive materials, sharp surfaces, or penetration of the skin should be worn.

11. Goggles should be worn to protect eyes from fragments, particles and dust.

12. Not only the workers cleaning the belts but also others close by who may be affected, must also wear protective equipment.

13. Before commencing, make sure all procedures mentioned previously have been followed.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD n WARNING

It is important that these procedures are followed when cleaning the conveyor belts. failure to follow these procedures can result in death or serious injury.

EN 46-9


Servicing Conveyors

14. The conveyor belts can be cleaned using a number of methods, a water hose; a rod with scraper attached, or a brush or shovel.

15. In the case of a blockage at a drive or tail drum it may be necessary to loosen the tension on the conveyor belt so that the blockage can be removed. Re-tension and re-align the belt after blockage is removed.

16. When work is complete, make sure that all guards are closed or replaced and secured before re-starting the plant.

46-10


47

EN

Servicing of Tracks

Pegson plants

EN


47-1

Servicing of Tracks

Plant Tracks

Keeping the track correctly adjusted will increase the service life of the track and drive components.

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.

n WARNING


LOCKOUT

PLANT

NOTICE

To maximise the life of the 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.

It is essential that the tracks are correctly tensioned at all times. Check track tension regularly.

Moving the plant with incorrectly tensioned tracks can cause severe damage to the undercarriage components and may invalidate the warranty.

47-2


Pegson plants

Measuring Track Tension

1. Observe all Safety Warnings.

2. Position the plant on solid and level ground and drive 2 metres (2 yards) minimum in a forward direction, track idler roller leading.

n WARNING

Prior to attempting any manoeuvring of the plant the tracks must be free of obstructions, including crushed material and fines. Do not push or tow the plant. failure to observe this warning could result in injury to persons and damage to the plant which may invalidate warranty.


Lockout Procedure.

4. One track at a time, measure the sag on the top part of the track on the longest section of unsupported track by placing a ‘straight edge’ long enough to reach from the drive sprocket to the nearest skid plate.

5. Measure the maximum amount of track sag from the high point of the track to the bottom of the ‘straight edge’. Correctly adjusted, the sag should be approximately 15mm (0.63in) but must not be less that 5mm (0.2in) .

4 5

6. Depending upon the need to either slacken or tension the track, proceed as follows.

-->

EN


47-3

Servicing of Tracks

Adjusting Track Tension

1. Observe all Safety Warnings.


Lockout Procedure.

n DANGER


SKIN INJECTION

HAZARD n WARNING


LOCKOUT

PLANT n WARNING

‘GREASE UNDER HIGH PRESSURE’

3. Locate the access aperture on the side of the track frame and remove the cover, where fitted, to reveal the relief valve inside.

3

47-4


Pegson plants

To Release Track Tension [After measurement] :-

4. Loosen the relief valve by turning counter 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.

n DANGER

Grease coming out of the relief valve under pressure can 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.

5. When the correct track tension has been measured, turn the relief valve clockwise to tighten and then clean away all trace of expelled grease.

6. If the track fails to slacken after the grease fitting has been loosened, do not attempt to remove the tracks or disassemble the track tension system, or remove the grease fitting. It is possible that running the tracks with the grease fitting loosened may help to expel the grease.

4

5

7

To Increase Track Tension [After measurement] :-

7. Connect the grease gun to the grease fitting and add grease until the track tension is within the specified dimension, see ‘Measuring

Track Tension’ and refer to lubricant and fluid specifications.

42

Re-check Tension

8. Operate the plant in track mode and drive the plant 50 metres (50 yards) forwards and 50 metres (50 yards) backwards, check track tension and repeat the above steps if it is within the specified dimension, see ‘Measuring Track

Tension’.

9. If room for manoeuvring the plant is restricted, drive the plant forwards and backwards several times over a shorter distance.

DO NOT SET TRACK TENSION TOO

TIGHT.

EN


47-5

Servicing of Tracks

Drive Oil Draining & filling

Alternative track motor drive and gearbox may be fitted. Refer to illustrations to identify if type A,

B, C or D is fitted.

Type A

Refer to these instruction for servicing if the casing has two plugs and appears as shown.


2. Rotate the gearbox housing until one of the plugs is at the lowest point.

3. Unscrew both plugs

4. Discharge the oil into a container for correct disposal.

2

5. To refill, rotate the gearbox housing so that one plug is at the top position and the other plug is as shown.

6. Fill through upper hole until the oil flows from lower hole. Use only the correct oil, refer to servicing - lubrication.

41

6

7. Clean plugs using a clean non-flammable solvent.

8. Apply thread sealant to the plugs and refit.

9. Repeat procedure on the other side.

Note:- Over filling the final drive will cause the travel motor seal to allow hydraulic fluid or water to enter and contaminate the drive

5

6

47-6


Pegson plants

Type B

For identification, the letter V has been added to the end of the track serial number.

Refer to these instruction for servicing if the casing has three plugs and appears as shown.


11. Drive the track to position the motor and gearbox as shown with the drain positioned lowest.

12. The plant should be positioned horizontally side to side.


14. Place a suitable container in position to collect the old oil.

15. Remove the filling, level and drain plugs and drain the old oil, looking for metal particles indicating component wear.

16. Re-fit drain plug, taking care not to damage the seal.

17. Add new oil until it begins to overflow through the centre level hole.

15 20

FILL

LEVEL

15 17 20

DRAIN

11 15 16

18. Use only the correct oil, refer to servicing - lubrication.

19. Do not mix different types or brands of oil.

20. Re-fit level and fill plugs, taking care not to damage the seals.

41

EN


47-7

Servicing of Tracks

Type C and D

1. Refer to these instruction for servicing if the casing has two plugs and appears as shown.


3. Drive the track to position the motor and gearbox with a plug at the lowest point for drainage.

4. The plant should be positioned horizontally side to side.

5. Place a suitable container in position to collect the old oil.

6. Remove the filling plug.

7. Remove the drain plug and drain the old oil, looking for metal particles indicating component wear.

3 7 8

6 10 11

8. Clean and re-fit the drain plug, taking care not to damage the seal.

9. Use only the correct type and quantity oil suitable for the type of gearbox and ambient temperature, refer to servicing - lubrication.

10. Add new oil until it is level with the filling hole.

11. Clean and re-fit level and fill plug, taking care not to damage the seal.

12. Repeat procedure on the other side.

41

47-8


48

EN

Servicing Clutches

[Clutch Types A, B, C, D]

Pegson plants

EN


48-1

Servicing Clutches

Engine Power Transmission

Types of Transmission fitted

Different types of clutch or coupling are used to suit the specific requirements for the model of plant [or option fitted]. The engine power take off to the crusher is through a clutch or fluid coupling mounted on the engine output shaft. These disconnect the crusher form the engine during the starting and stopping operation.

A - Hydraulic clutch with grease lubricated output shaft bearing.

B - Hydraulic clutch with oil lubricated output shaft bearing [Transfluid] .

C - Manual clutch with grease lubricated output shaft bearing [Twindisc] .

D - fluid coupling [Transfluid] .

n WARNING


LOCKOUT

PLANT

A - Hydraulic Clutch - Grease Lubricated Bearing

1. The output shaft is supported by a spherical roller bearing, grease lubricated, fitted in a cover flanged to the engine flywheel housing.

2. Refer to servicing - lubrication.

41

48-2


3. If necessary add recommended grease through the grease nipple, see lubricant and fluid specifications.

42

4. For the next maintenance cycle see servicing - lubrication.

41

11

Pegson plants

3 5 10

6 9

NOTICE

Do not over grease the bearing carrier

[12]. The main bearing may overheat and grease exit from the seals.

5. Add grease through the grease nipple at the recommended intervals, refer to servicing - lubrication.

6. Remove the overflow plug to ensure that it is not overfilled [Transfluid only].

7. Check the clutch driving plates annually and it is advisable, every 3000 working hours, to check the condition of the bearings and replace the rotating seals.

8. Purge the old grease at the recommended intervals. The grease should also be replaced if the unit has not been used for more than 6 months.

9. Remove the overflow plug to ensure that it is not overfilled [Transfluid only].

10. Grease should then be added through the grease nipple.

41

3 5 10

6 9

11

11. Refill bearing carrier with correct amount and type of grease, refer to servicing - lubrication

12. After 100 hours of operation after purging, the grease level should be checked.

41

EN


48-3

Servicing Clutches

B - Hydraulic Clutch - Oil Lubricated Bearing

[Transfluid] n WARNING


LOCKOUT PLANT

1. The output shaft is supported by a spherical roller bearing, oil lubricated, fitted in a cover flanged to the engine flywheel housing.

2. Check the bearing oil level prior to the daily start up of the plant: as a minimum requirement, level stick must be oil wet.

3. Renew the oil at intervals shown in the plant lubrication schedule of servicing - lubrication.

4. Drain the old oil by opening the tap located at the bottom of the bearing housing. Make sure this is closed before adding fresh oil.

5. Check the clutch driving plates annually and it is advisable, every 3000 working hours, to check the condition of the bearings and replace the rotating seals.

6. Remove the plug.

6 9

41

4

2 7

7. fill the bearing cavity through pipe with the correct oil, see lubricant and fluid specifications.

8. Turn the shaft until maximum oil level is indicated on the stick.

9. After filling refit the plug.

42

48-4


Hydraulic Clutch Operation

[Types A and B]

Types A and B

10. The hydraulically operated clutch is a minimum maintenance unit.

11. The clutch is operative when the plant hydraulic system is at operating pressure. Should the hydraulic pressure fall below a preset level, a low pressure warning will be indicated and the feeder will stop. This prevents any further material entering the crusher whilst there is a risk of the clutch slipping due to low hydraulic fluid pressure. Establish the reason for the fall in pressure and contact your local

Powerscreen® dealer to rectify.

03

Pegson plants

EN


48-5

Servicing Clutches

C - Manual Clutch

[TwinDisc]

1. Refer to the clutch adjustment check to be made at the time of initial commissioning when new and the essential regular maintenance of the clutch thereafter.

2. New clutch plates have a ‘wear in’ period and the clutch may require several adjustments until new plates are ‘worn in’.

3. A manual clutch must have an adjustment check at the following intervals:-

• At commissioning.

• After 4 hours operation.

• After 10 hours operation.

• At the end of each working day for approximately 1 week.

• Once a week after ‘wear in’.

n WARNING


LOCKOUT

PLANT

48-6


Pegson plants

Clutch Adjustment Check

4. In order to determine if clutch adjustment is required, operating shaft torque should be measured as shown.

5. If this force is found to be at or below the

‘MINIMUM’ shown, the clutch should be adjusted until the ‘MAXIMUM’ force is required to engage he clutch.

4

USE SPRING SCALE AT HAND LEVER LENGTH ‘A’

SHOWN AND MEASURE THE PULL REQUIRED TO

ENGAGE THE CLUTCH

NOTE: Do not adjust the clutch too tight as forces above ‘MAXIMUM’ can cause clutch component failure. Please contact your local

Powerscreen® dealer or Powerscreen®

Technical Support department.

03

Pegson 428 Trakpactor and Pegson 4242SR

IBF-314 clutch shaft torque 325 to 434Nm (240 to

320lbf ft) Pull of 61 to 82kgf (135 to 180lbf) at lever length ‘A’ of 541mm (21.3in)

6. Lubricate the output shaft at the grease nipple, refer to the plant lubrication schedule in servicing - lubrication.

41

7. Grease the operating lever shaft.

8. Refer to information plate on clutch housing.

6

8

EN 48-7


Servicing Clutches

D - fluid Coupling

[Transfluid]

Description

1. The fluid coupling is a drain type coupling..

When the crusher stop is activated it electrically disconnects the fluid supply and thus allows the unit to drain. When ‘drained’ it disconnects the crusher from the engine.

2. When the crusher start is operated it electrically activates the fluid pump inside the coupling. As it is progressively filled it operates as a ‘soft’ engagement to drive the crusher.

3. In the course of normal operation the fluid coupling operates automatically and no action is required to the unit.

4. The coupling fluid is cooled through the engine cooling system with a preset maximum temperature level. The temperature is monitored and a high temperature fault will be indicated and automatically stop the feeder.

5. Fluid is cleaned by a replaceable filter. The filter blocked fault will be indicated when the filter cartridge must be changed immediately or the fluid flow will be unfiltered.

03 n DANGER

THIS IS A HIGH PRESSURE SySTEM.

Do not tamper with the unit. In the event of anything other than minor problems, these should only be dealt with by suitably experienced and qualified engineers.

Please contact your local Powerscreen® dealer or Powerscreen® Technical

Support department.

48-8


Servicing

Pegson plants

n WARNING


LOCKOUT

PLANT n WARNING

Before carrying out any servicing on the fluid coupling close down the plant and implement the lockout procedure.

1. Change the hydraulic fluid and the cartridge filter after the first 100 working hours. Only use a recommended fluid and filter.

2. Thereafter change the fluid at the recommended working hour intervals and change the oil filter cartridge when indicated.

3. Fill the unit to the correct level, the line on the indicator. Start the engine to run the pump to fully fill the heat exchanger. Then check the fluid level again with the engine stationary.

4. It is essential when replenishing hydraulic fluid, attending to filters, etc. to apply the greatest degree of cleanliness as it is most important that contaminants are not allowed to enter the system.

EN

1

3

NOTICE

Do not make any modification without the approval of the manufacturer

48-9


Servicing Clutches

fault finding

If you are unfamiliar with the fluid coupling, contact your local Powerscreen® dealer or


Unit fails to operate

1. Check the fluid level is up to the level line.

2. Check the fluid pressure is satisfactory.

3. Check if the temperature alarm has operated.

Unit operates at reduced output speed

4. Carry out the checks above.

5. Check engine high idle speed with fluid coupling disengaged.

6. Check that the crusher shaft turns freely.

03

NOTICE

The fluid coupling is a complex unit.

Any rectification work should only be undertaken by a skilled engineer fully conversant with the coupling.

fluid Loss

7. Check all pipe connections.

8. Check seals for leakage.

9. Check engine flywheel housing.

10. Check for leakage into engine coolant.

11. If vapour comes from the breather, wait until the fluid temperature reaches more than 55ºC

(130ºF) . If fluid comes out of the breather, contact your local Powerscreen® dealer or


High fluid pressure

12. Check filter and replace if necessary.

13. Check the tubes are not obstructed.

03

48-10


49

EN


Pegson plants

EN


49-1


[if fitted]

Magnetic Separator - General

[if fitted]

The self cleaning suspended magnet utilises a two pulley design. The tail pulley has adjustment available to take up belt stretch and for tracking purposes.

n WARNING

The belt magnet assembly is very powerful and permanently charged. The strong magnetic field produced could affect heart pacemakers, watches, credit cards, mobile phones etc. The operator has the sole responsibility to keep anyone at risk clear of the machine.


Inspection

1. Be sure the magnet frame is visibly square and has not been damaged or twisted.

2. Check belt alignment.

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


ENTANGLEMENT

HAZARD

49-2


Pegson plants

Servicing

4. Belt tracking should be checked frequently and adjusted as necessary. 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. Tighten the side of the belt to which you want the belt to move.

5. When tracking or tensioning the belt take care not to over-tension as this will cause the shaft bearings to fail.

4

7

6. Regularly check the hydraulic motor mounting bolts for tightness and that both halves of the coupling between the motor and the drive shaft are in alignment.

6

7

7. Lubricate bearings consistent with schedule in servicing - lubrication using suitable grease.

41

7

8. Refer to lubricant and fluid specifications.

EN

42 n DANGER

As many inspections as possible should be made whilst the belt is stationary.

When this is not possible extreme care should be taken when inspecting the belt whilst it is moving as this creates an entanglement hazard and risk of trapping parts of the body.

49-3



[if fitted]

49-4


50

EN


Pegson plants

EN


50-1


General

1. The plant electrical equipment is a self contained 24V DC system operated via automotive batteries which are recharged when the engine is running.

2. Depending upon the model of plant and the equipment fitted, various types of control, monitoring, sequencing, electrical safeguards and fault detection devices are built into the system including a multi station emergency stop circuit.

3. Any work on the plant electrical system shall only be undertaken by a qualified electrician, familiar with this type of system.

4. Circuit protection fuses or circuit breakers fitted depend upon the plant model. The replacement of a protection device after failure must not exceed the rating of the original otherwise damage to components may occur and any warranty invalidated. A repeat of the failure must be investigated and the problem rectified by a competent person.

5. Always keep the electrical cabinets and control boxes closed during the crushing operation to prevent the ingress of dust and damp.

6. At regular intervals check the tightness of the electrical components on the plant and look for any damage to the electrical wiring.

n DANGER

Emergency stop equipment and all other safety systems, including the audible warning siren, must be operative at all times whilst the plant is running or being manoeuvred.

The safety devices must be checked as fully operational at each daily start and must not have been tampered with or disabled in any way.

7. Refer to emergency stop section.

50-2

16


Battery Replacement

Safe Handling of Automotive Batteries

8. The plant contains 2 automotive type batteries which are replacable.

9. Battery Posts, terminals and related accessories contain lead and lead compounds.

10. Handle batteries carefully and keep them level as they contain sulphuric acid, an electrolyte which can cause severe burns and produce explosive gases.

11. Avoid contact with the skin, eyes or clothing.

12. Wash hands thoroughly after handling.

Pegson plants

EN


50-3


Automotive Battery Replacement

13. Batteries should only be replaced by a competent person.

14. Stop the plant and remove the ignition key.

15. Set the battery disconnect switch to ‘0’ and lockout.

16. Two batteries are used for the plant electrical system, located near or within the engine powerpack.

17. Remove fasteners and guard, cover or floor panel to gain access to the batteries.

15

14

1

0

18. On some plants it is necessary for a suitable working platform to be used.

n WARNING


LOCKOUT

PLANT fALLING

HAZARD

19. The plant has a negative [-] chassis connection.

20. Disconnect the cable at the negative [-] battery terminal first.

21. Disconnect the positive [+] plant feed cable at the battery terminal.

22. Disconnect the battery linking cable.

50-4


23. Release the batteries from the securing clamps and remove batteries.

24. Replacement batteries must be of the same type and capacity as the original ones fitted.


Powerscreen® technical support department for advice if in doubt.

03

Pegson plants

Battery Recycling

26. Do not dispose of any old batteries with normal waste that may to go to landfill.

26

27. All batteries shall be disposed of correctly to be recycled at an approved treatment facility.

27

EN


50-5


50-6


51

EN


Pegson plants

EN


51-1


General

n DANGER


All hydraulic functions are powered by pumps driven by the engine.

Note:- All relief valve pressures are factory set and should not be adjusted.

The hydraulic fluid reservoir together with associated equipment must be maintained in accordance with the set level and in the schedules and types, refer to:

Daily plant checks

Lubrication - checks - specifications.

24

41 42

SKIN INJECTION

HAZARD

ONLy USE A RECOMMENDED fLUID.

n DANGER

THIS IS A HIGH PRESSURE SySTEM.

Never carry out any maintenance work without ensuring the hydraulic system is locked out and depressurised. Check the pressure gauges and control screen, if fitted, to view the current system pressure.

Open the bleed valve, if fitted, until all pressure is relieved then close the valve.

Do not amend the hydraulic system. In the event of any problems these should only be dealt with by suitably experienced and qualified engineers.

51-2


Hydraulic fluid Level

1. Check the fluid level on the gauge and top up as necessary.

2. Maximum approximately 40mm (1.5in) below upper mark.

3. It is essential when replenishing hydraulic fluid, attending to filters, etc. to apply the greatest degree of cleanliness as it is most important that contaminants are not allowed to enter the system.

4. If hydraulic fluid needs to be added to maintain the correct level, this should be poured in after removing the return filter cover but with the filter element left in place.

Pegson plants

n WARNING


LOCKOUT

PLANT

2

1

4

EN


51-3


Suction filter

n DANGER


SKIN INJECTION

HAZARD

1. Locate the hydraulic suction filter and gauge within the engine canopy.


3. The filter housing has an internal shut off valve to permit the filter to be changed.

4. Close down the machine and implement the lockout procedure.

5. Make sure the oil has cooled before changing a filter.

n WARNING


LOCKOUT

PLANT

1

NOTICE

The hydraulic fluid filters have condition indicators to show when the filter element needs to be renewed.

When the gauge changes from green to red whilst the system is running at normal operating temperature the filter must be renewed.

In cold ambient temperatures the filter indicators may show an incorrect red condition until the system reaches normal operating temperature.

51-4


Pegson plants

6. Depending on which type is fitted, unscrew the centre bolt or turn shut off valve in the centre of the filter housing until it reaches the stop.

7. Place container below filter to collect spillage of fluid.

8. Remove screws and the cover plate.

9. Remove filter and clean inside the housing and cover plate with lint free cloth.

6

10. Fit new filter of the approved pattern and specification.

11. Lightly smear the ‘O’ ring with fluid and make sure it is properly seated in the groove.

12. Replace the cover plate and screws evenly to ensure a good seal.

13. Depending on which type is fitted, fully screw in the centre bolt or shut off valve in the centre of the filter housing.

NOTICE

It is important to ensure that the bolt or knob in the centre of the housing is fully screwed in before starting the plant, otherwise damage will occur to the plant.

EN


51-5


Return filter

n DANGER


SKIN INJECTION

HAZARD

1. Locate the hydraulic return filter and gauge within the engine canopy.



4. Make sure the fluid has cooled before changing a filter.

n WARNING


LOCKOUT

PLANT

1

5. Remove the screws and remove the cover plate together with internal spring.

6. Remove the old filter and clean inside the housing and cover with lint free cloth.

7. Fitting new filter of the approved pattern and specification.

8. Replace the spring which holds the filter in place.

9. Lightly smear the ‘O’ ring with fluid and make sure it is properly seated in the groove.

10. Replace the cover plate and screws evenly to ensure a good seal.

51-6

5


Tank Breather

11. The breather is also a filter and should be changed after the first 100 hours of operating and thereafter after 1000 hours but in dusty atmosphere it is recommended to change more frequently depending upon conditions.



14. Unscrew and renew the breather whilst the plant is shut down.

15. Clean breather cap every 200 hours.

14

Pegson plants

EN


51-7


Pressure filters

[if fitted]

1. Locate the hydraulic pressure filters within the engine canopy. Not fitted to all systems.

2. Check the filter condition indicator.



5. Make sure the fluid has cooled before changing filter.

6. Place container below filter to collect spillage of fluid.

7. Unscrew the filter bowl, turn anti-clockwise looking from below.

8. Remove the old filter and clean inside the bowl and housing with lint free cloth.

9. Fit new filter and small ‘O’ ring of the approved pattern and specification.

10. Lightly smear the ‘O’ ring with fluid and place on it’s seating in the bowl making sure it is properly seated.

11. Replace and secure bowl to ensure a good seal, taking care as it has a fine thread.

n WARNING


LOCKOUT

PLANT

2

7

51-8


60

EN

Replacing Worn Jaws

Pegson Jaw Plants

EN


60-1

Wear Parts - Replacing Jaws

Jaw Replacement

n WARNING

Refer to Safety Notices Section for relevant warning and procedure.

LOCKOUT

PLANT

1. Observe all safety warnings

2. Run the crusher until completely empty.


02 n DANGER

Only use lifting equipment suitable for the work to be carried out.

For fixed jaw only:

4. Remove any flexible or rigid covers or guards to gain access to the jaw securing nuts.

5. To gain access to the jaw securing nuts on some models, it is necessary to release and lower the dirt bypass chute.

6. Use lifting equipment to support the dirt bypass chute, then remove securing bolts on each side.

7. Raise and move the chute slightly forward, then lower the chute to rest on the plant chassis.

60-2


Pegson Jaw Plants

All jaws:

8. Remove the securing nuts, steel and ‘Fabreeka’ washers.

9. Remove the bolts and jaw clamping wedges.

9 9

8

8 9

9 n WARNING

As the fixed jaw is mounted vertically, secure it while removing the nuts, washers, bolts and wedges.

8

8

10. Tip the top of the jaw forward slightly and fit the lifting shackles to the jaw, inserting each shackle bolt from the front face of the jaw.

10

11. Note: Some jaws have a slot in the back as an alternative method of lifting.

11

EN


60-3

Wear Parts - Replacing Jaws

12. Lift out the jaw and place it on blocks with the wearing side face down if it is only part worn and is to be re-fitted. Refer to component manual for weights.

13. fit the lifting shackles or hooks into the lifting points at the other end of a jaw to be re-fitted or the replacement jaw, inserting each shackle bolt from the front face of the jaw.

14. Hoist the jaw into position and locate onto the centring key at the bottom of the jaw.

15. After locating the jaw in position, tip the top of the jaw forward slightly and wedge it securely in place, then remove the lifting shackles or hook.

16. Move jaw back into position and secure with the jaw wedges, bolts, washers, ‘Fabreeka’ washers and nuts - TIGHTEN SECURELy.

n DANGER

Take extreme care when moving the jaw forward. Wedge jaw securely in place prior to fitting the shackles into the jaw lifting points or using hooks.

Fixed jaw only:

17. Re-fit any guards or covers removed to gain access.

18. If applicable, raise and locate the dirt bypass chute, using lifting equipment, on to the location mountings and secure with the bolts.

NOTICE

After fitting the jaws operate the crusher for 15 minutes. Stop the crusher and check the nut tightness. Continue to check the nuts before operation each day.

60-4


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