1300 Maxtrak

1300 Maxtrak 100309 issue 2

1

1300 MaxtrakCompany Confidential

2Company Confidential


1300 Maxtrak1300 Maxtrak



Health and Safety aspects,

Contents

Introduction

1 Application of the Regulations2 Personal Protective Equipment3 Contractors and Sub-Contractors4 Customers, Suppliers & Visitors5 Employees5.1 Guidelines5.2 Application of Safety Instruction5.3 Minimum Recommended Requirements5.3.1 Foot Protection5.3.2 Leg Protection5.3.3 Thigh / Torso Protection5.3.4 Whole Body Protection5.3.5 Hand Protection5.3.6 Eye Protection5.3.7 Respiratory Protection5.3.8 Hearing Protection5.3.9 Head Protection5.3.10 Fall Arrest Protection5.3.11 Other Protective Equipment5.4 Disciplinary Procedure5.5 Requirement of control measures6 Review



IntroductionThis Safety Instruction (SI) is issued to assist Employees of BL PEGSON LTD to understand the requirements for the wearing of Personal Protective Equipment at Work

1/ Application of the Regulations

1.1 The Health and Safety at Work etc Act 1974 (HSWA) requires employers to ensure the health safety and welfare of their employees and persons not in their employment who may be affected by work activities.

1.2 Regulation 3(1) of the Management of Health and Safety at Work Regulations 1999 requires employers to identify and assess the risks to health and safety present in the workplace. This general risk assessment should identify whether there is a risk of injury to persons from working processes, procedures and practices. Where there is a risk identified, all practical measures shall be taken to eliminate or reduce so far as is reasonably practicable exposure of the individual to those risks. There is in effect a hierarchy of control measures and Personal Protective Equipment (PPE) should always be regarded as the 'last resort'

1.3 The Personal Protective Equipment recommended for each group of people will be commensurate with their experience and knowledge of the risks to which they are being exposed in any particular working area.

1.4 This document details the ways in which BL PEGSON LTD discharges its duties and obligations to its employees, contractors & sub-contractors, customers, suppliers and visitors under this requirement.

2/ Personal Protective Equipment

'All equipment designed to be worn or held by a person at work to protect against one or more risks and any addition or accessory designed to meet this objective'

2.1 Both protective equipment and clothing are within the scope of the definitions and therefore:



2.1.1 For the sake of this Safety Instruction 15/01/01 protective clothing such as overalls (when they are Proban Treated or Pyrovatec) aprons, protective clothing for adverse weather conditions, gloves, safety footwear, safety helmets, high visibility waistcoats etc; and

2.1.2 Protective equipment such as eye protectors, hearing protectors, respiratory protectors, face protectors and safety harnesses

2.1.3 Overalls other than Proban Treated or Pyrovatec will not be regarded as PPE as they are for welfare purposes and do not provide health and safety protection.

2.2 Selection of appropriate PPE will always be the factor that proves the item to be adequate or not for example: when working with equipment i.e. hammer and chisel, that produces fragments and splinters impact protection safety glasses with side protection or wrap-round. When operating equipment that produces fine grit or offshoot i.e. grinder or cutting disc face mask with safety glasses or box goggles. When working with hazardous substances or splashes invariably box goggles should be selected.

2.3 With consideration given to the advice above anyone that feels they have insufficient knowledge or experience in the selection of appropriate PPE they should consult their supervisor or Health and Safety Officer for a risk assessment and necessary training.

3/ Contractors and Sub-ContractorsWhen contractors and sub-contractors are employed to carry out work that comes within the scope of this Safety

Instruction SI 15/01/01 they will be expected to comply in all factors as though they are direct employees of BL-Pegson Ltd. (See section 5/ Personal Protective Equipment for employees)

4/ Personal protective Equipment for Customers, Suppliers and Visitors

4.1 When customers, suppliers and visitors to BL-Pegson are introduced to production areas they must be equipped with adequate and appropriate Personal Protective Equipment (PPE).It shall be the responsibility of the host responsible for the customer, supplier or visitor to ensure that PPE is readily available prior to any entry to production areas.4.2 The needs of paragraph 4.1 above may require the host to make pre-visit arrangements for some customers, suppliers & visitors to provide their own PPE or provide sufficient information as may be necessary to enable BL-Pegson ltd to obtain the appropriate clothing and or equipment.



4.3 Adequate and appropriate Personal Protective Equipment for all customers, suppliers and visitors consists of;

4.3.1 High visibility vest4.3.2 Safety footwear with internal steel toe cap4.3.3 Grade 2 impact eye protection4.3.4 Hearing protection (all customers, suppliers and visitors will be advised to wear the hearing

protection, as, during production hours the background noise levels in production departments is above the first action level of 85dB(a) whereby hearing protection must be provided.

4.4 Hosts escorting suppliers, customers and visitors to production areas who are not in compliance with the above guidelines will be asked to leave the production area until appropriate remedial action has been taken.

4.5 Persistent failure by an hosts to establish his customers, suppliers and visitors with the above requirements will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures against him/her.

5/ Personal Protective Equipment for Employees

5.1 Guidelines With due regard to the section 2.2 of this document, the following guidelines are set out for PPE to be used by all BL-Pegson personnel when performing tasks in all production, maintenance and testing areas.

5.1.1 When any employee is travelling through or working in a production, maintenance or test area (as outlined in section 5.2 of this Safety Instruction), other than his/her normal working area, s/he will be regarded as a visitor to the area. In these circumstances, as a visitor to an area s/he will be required to adopt PPE (foot and eye protection) as a minimum basic requirement. Persistent failure by any employee to conform with the designated requirements, for the use of personal protective equipment within any production, maintenance or test area will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures against him/her.



5.2 Application of S.I. For the purpose of this Safety Instruction a production, maintenance or testing area, is anywhere on the Mammoth Street Site inside or outside of buildings, that;

5.2.1 machining, fitting, welding, burning attaching and/or removing, adjusting or testing of units or components to any item of equipment that goes to make up a crushing or pumping plant; or

5.2.2 any item of equipment used in the production, testing, adjustment or maintenance of crushing or pumping plant; or

5.2.3 any location other than BL-Pegson Ltd Mammoth Street Site, where BL-Pegson personnel are involved in the repairs, maintenance, adjusting or testing of any BL-Pegson manufactured plant and or equipment.

5.3 Minimum/Recommended Requirements5.3.1 Foot Protection - Basic safety footwear protects the feet / lower leg of individuals, assessment has

indicated that the primary protection required at BL-Pegson ltd is Toe Protection (200 joule toecap protection), Oil and Water Resistant with anti-slip soles with steel mid-sole (100 Newtonspenetration resistance) for protection against penetrating objects. Safety shoes or Safety Boots shall be worn at all times inside production and maintenance areas.

5.3.2 Leg Protection -Gaiters or knee-high boots shall be worn when pouring molten metals.

5.3.3 Thigh Protection -Leather apron should be worn when disc cutters and grinders are being operated at or below waist level.Nitrile coated or rubber apron should be worn when decanting or using hazardous liquids.

5.3.4 Whole Body Protection -Proban overalls (flame retardant coating) should be worn when general welding and grinding processes are carried out by an individual. Operators performing high intensity welding processes shall wear Pyrovatec overalls (heavy-duty cotton with tight knit fabric and flame-retardant coating).



5.3.5 Hand Protection - Gloves giving a level of Cut and puncture protection gloves should be worn when performing tasks employing sharp bladed and pointed tools. Cut and puncture protection gloves should be worn when performing lifting and handling tasks on items of equipment or materials that may have rough edges or protruding wires etc. Thermal protection gloves should be worn when processes require the Handling of hot or cold items of equipment or materials, this is of particular significance in the handling processes entailed in the use of liquid nitrogen. Welding gauntlets should be worn when operating profile cutting / burning equipment and welding.Rubber or Nitrile coating gauntlets / gloves should be used when working with hazardous substances.Nitrile or latex disposable gloves are recommended when working with other non-hazardous fluids.

5.3.6 Eye Protection - The selection of correct eye protection is the primary consideration for an individual when performing any task, poor selection is of no benefit to the individual and in some cases can make a situation worse. The reasoning behind this being that having made their selection they believe themselves to be protected from any hazard. All eye protection PPE issued at BL-Pegson Ltd is to EN166 Category 2.Prescription lenses impact protection glasses all individuals that are required to wear prescription spectacles will be issued with prescription safety glasses with grade 1 impact lenses and side shields. There may be occasion where additional protection shall be required for protection from splashes or dust particles in which case a box goggle shall be worn over the top of the prescription lens safety glasses.



Impact Protection safety glasses shall be worn by operators at all times when working with the following items of equipment;Machine tools (drilling / boring m/c's etc.) [May not be appropriate when reading drawings, micrometers etc.]Impact guns/wrenches (of any type), when working in teams, both/all team members shall wear impact eye protection glassesDrilling or tapping holesHammer of any sizeDriftSpreaderChiselsSaws / hacksawsThread diesWorking in the vicinity of someone welding burning or grindingAdditional protection box goggle or visor shall be worn by operators at all times when using;Hand held grinder 4" / 9" (angle grinders)Die grinderFlap wheelBench / pedestal grinderDe-burring / fettling equipmentAir lines for swarf/debris removalOxy/acetylene equipmentInitial start-up of plant until such time as integrity of hydraulic system established.PaintingRust preventativePumps testingMolten white metalDecanting any hazardous substance



Tinted glass or Speedglass (electronic polarising action)WeldingProfile cutter operationOxy acetylene burning

Any other situation, not included in this list whereby a potential for eye damage from a working process or procedure is present, should be assessed by the section Team Leader and or the Health and Safety Manager. Appropriate protection commensurate with the level of risk assessed should then be applied and this safety instruction amended.

5.3.7 Respiratory Protection - as with eye protection, respiratory safety hazards are extremely difficult to protect against, as poor selection can lead to individuals feeling they are adequately protected and yet not receiving any of the protection required for the situation. Dust, Gas and Vapour are specific hazards and a filter protecting against mist and fume will not necessarily protect against dust (particulate), similarly a particulate filter will not protect against gas and vapour.Respiratory protection should only be selected as the last resort. All other sources of to control the hazard should be considered first e.g. substitution, elimination, separation and engineering controls.Respiratory Protection - when not in service all respiratory protective equipment must be kept in a clean dry environment where it can be protected from contaminants. Reusable equipment should be wiped down with a mild solution of soap and water using a cloth or sponge, dried off and then stored in a clean dry environment.

Powered air and Airfed Respirators and headtop should be worn whenHigh intensity welding processes (Particulate filter P(SL) filters must be fitted at the air intake. It is recommended that in addition Organic gases and vapours with boiling point greater than 65oC; inorganic gases and vapours and acid gases (A1B1E1) filters, should also be fitted at the air intake.Paint spraying Plants etc. (Particulate filter P(SL) +Organic Vapour (OV) filters must be fitted at

t he air intake.Compressed Airline Feed Respirator and headtop must be worn whenGrit blasting.



Half mask respirators should be worn whenStick welding (Particulate filter P(SL) It is recommended that in addition organic gases and vapours with boiling point above 65oC; inorganic gases and vapours (A1B1) filters should also be applied.Paint spraying smaller items, short period, (Particulate filter P(SL) +Organic VapourDisposable particulate RespiratorsPolishing surfaces with die grinder and flap wheels (Particulate filter P(SL))De-burring / fettling equipment (Particulate filter P(SL))Any other situation, not included in this list whereby a potential for respiratory damage from a working process or procedure is present, should be assessed by the section Team Leader and or the Health and Safety Manager. Appropriate protection commensurate with the level of risk assessed should then be applied and this safety instruction amended.

5.3.8 Hearing Protection - The Noise at Work Regulations 1989 require hearing protection to be provided where noise levels are between 85dB(A) and 90dB(A). Where noise levels are in excess of 90dB(A) hearing protection becomes a mandatory requirement. Noise level assessments have been carried out across the site and the results illustrate that when production departments are in normal operation the background level of noise is in excess of 85dB(A). The company has made provision therefore for hearing protection to be available in all production departments.Fabrication Department, Quarry Plant Fitting Department and Quarry Plant Assembly Departments results have indicated that the levels of exposure in these departments are in excess of 90dB(A) in these departments therefore personal hearing protectors (Variphone) have been offered to every employee. Being manufactured to suit an individual's ear canal these can be worn for 8 hours per day with no discomfort and can be attenuated to match each individuals exposure levels.

For those persons that have declined the offer of the above (Variphone) service a variety of styles of hearing protection are available and the individuals selection must be worn every time they are exposed to levels of noise in excess of 90dB(A)



Styles available:Disposable foam Inserts - can be used alongside other PPE easy to use and provide levels of protection that can exceed some earmuffs. Some come moulded for greater comfort. Must be disposed of after each wearing and new used each time. For effective operation the insert should be rolled between finger and thumb, the ear canal should then be opened slightly by lifting the upper part of the ear, using the opposite hand the ear having the insert applied to. The tightly rolled insert is then pushed into the ear canal and allowed to expand to create an effective seal.

Corded inserts - a variety of types, foam, some with durable cleanable coatings for extended use, re-usable moulded plastic. Any insert that is re-usable should be cleaned in a mild solution of soapy water at least each day. This type of insert is fitted in the same way as described above. Banded inserts - coated foam inserts and moulded plastic inserts, hang comfortably around the neck and ideal for intermittent protection needs. To fit effectively the ear canal should be eased open slightly by lifting the upper part of the ear using the opposite hand to which the ear protector is being applied. The plug or shaped plastic pod should then be eased into the ear canal until a good seal is formed the ear should then be released.Ear Muff - 3 basic styles Helmet Mounted, Overhead Band or NeckBand. For the muff to be effective a good seal must be established between the soft outer part of the muff and the area of the head around the ear. Long hair, beards and spectacles can impair the seal of the muff and thereby effect the physical performance of the protection. The earmuff should always be fitted in the vertical position as any other position will seriously impaired as an effective seal will not be achieved. When not in service all re-usable hearing protectors must be kept in a clean dry environment where they can be protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap and water, dried off and then stored in a clean dry environment.

5.3.9 Head Protection - As a general rule head protection is not required in production or maintenance areas at BL-Pegson. However when Plants are undergoing display or test programmes in the field to the front of the site and stone or other material is being run through the machine Safety

Helmets must be worn by operators and onlookers.



Safety Helmets are a mandatory requirement for all BL-Pegson personnel when operating, testing, repairing or adjusting Plant and Machinery at a quarry or demolition / recycling site.

Bump caps are available for all personnel and are recommended for use when working on Plants and Machines in production and maintenance areas at the Mammoth Street Site.

5.3.10 Fall-arrest Protection - must be worn when working at heights where adequate provision for guard-rails to prevent falls cannot be established. Body Harness and attachment systems are available, that can be adjusted to fit the individual. The attachment system must be connected to a reliable anchorage point. The vertical drop of the user must be minimised to prevent collision with obstacles and the braking force injuring, tearing or causing the operator to fall.Inspections of the equipment must be carried out prior to use to check for wear and damage that may cause the equipment to fail in operation.The equipment should be examined every six months in accordance with the Lifting Operations and Lifting Equipment Regulations 1998.

When not in service all fall arrest protection equipment and attachments must be kept in a clean dry environment where they can be protected from contaminants. Reusable equipment should be cleaned in a mild solution of soap and water, dried off and then stored in a clean dry environment.

5.3.11 Other Protective Equipment - Where BL-Pegson personnel are expected to attend quarrying or other demolition / recycling sites mandatory requirements for Personal Protective Equipment are:Hard hats / HelmetHearing ProtectorsEye ProtectionFoot ProtectionHigh Visibility coat or waistcoatRespiratory Protection P(SL) strongly recommended



5.4 Disciplinary Procedure. Persistent failure by any employee to conform with the designated requirements, for the use of personal protective equipment within any production, maintenance or test area (as outlined in section 5.2 of this Safety Instruction), will result in the instigation of the BL-Pegson Ltd progressive disciplinary procedures against him/her.

5.5 Requirement of Control Measures to keep all control measures in a clean condition. The following is an extract from Regulation 9 of the Control of Substances Hazardous to Health Regulations 2003.

(5) Every employer shall ensure that personal protective equipment, including protective clothing, is:

(a) properly stored in a well-defined place;

(b) checked at suitable intervals; and

(c) when discovered to be defective, repaired or replaced before further use.

(6) Personal protective equipment which may be contaminated by a substance hazardous to health shall be removed on leaving the working area and kept apart from uncontaminated clothing and equipment.

(7) The employer shall ensure that the equipment referred to in paragraph (6) is subsequently decontaminated and cleaned or, if necessary, destroyed.



It is the engineer responsibility to ensure that all risk assessments and method statements are in place before any work is carried out.



13001300 MaxtrakMaxtrak



Starting and Tracking Plant


1300 Maxtrak 100309 issue 2Control Panel and Starting

Battery Isolator Switch

Off

On

Switch ON isolator switch


1300 Maxtrak 100309 issue 2C13 Tier 3 Engine Start Panel with Hycontrol

PLC display screen.

Hycontrol display screen.

Engine Start

Controls.

Plant/Track Controls

All of the controls for starting up the crusher are done from the electrical panel at the front of the machine.


1300 Maxtrak 100309 issue 2Main Control Panel

CantrakDisplay Fuel

Gauge

Cat ETConnector

Throttle Switch

Ignition Switch



Below the Cantrak display there are three indicator .

Maintenance Due lamp. Warning (Alert) lamp, the Warning

lamp will flash indicating a fault code. Count the number of times it flashes and check the Caterpillar operation maintenance manual for the cross reference to give the possible causes.

The Shut down (Action) lamp. When this lamp is flashing means the engine is going into De-rate.

The C13 engine rpm is

electrically adjusted by a

rocker switch.




Emergency Stop

Plant/Track

Umbilical/Radio

Fault Mute

Fault Reset

Automatic/Manual




Lube Pump

Product Conveyor

Crusher

Feed ConveyorManual Feed Conveyor

Speed Control



Engine checks before starting

Engine checks before starting (Daily checks)

1. Check engine oil level.2. Check engine water level, if low check for water leaks.3. Check radiator for external blocking dust and debris.4. Check air filter service indicator5. Check water separator on primary fuel filter and drain if necessary from the

water trap at the bottom of the filter.6. Check engine drive belts for correct tension and wear or damage.7. Check for oil leaks on engine.8. Check all induction pipe work for cracks and loose clamps.


1300 Maxtrak 100309 issue 2Starting Engine and tracking with the 860 Remote Control

LED’s123

Button numbers

• Switch selector switch to Remote.• Power up the transmitter by, pulling out the stop

button, then pressing and hold buttons 9 + 0 for 1 second. No 3 LED will go red whilst holding the buttons then turn green when the buttons are released, if the LED remains red then the transmitter needs charging.

• With transmitter powered up you can now start the engine.

• Note. If any of the buttons are pressed before the 10 second timer times out, the transmitter will reset the Tracks to OFF and you will need to press the Track mode button No 9 to restart the 10 second timer.



CantrakDisplay

Throttle Switch

Ignition Switch

•With the Isolator switch turned ON.•Turn the “ignition switch” to the first position and press the “fault reset button”.•The siren will sound for 10 seconds, then the 3 lights will come ON under the Cantrak (Lamp test).•Note. If an “emergency stop button” IN (including the umbilical stop button) the siren will not sound).•Allow the PLC to the sequence of self diagnostic checks (35 seconds).•With the Throttle switch on idle (toward the left), turn the “ignition switch” to the second position and the engine should start with in 3 seconds.•Idle the engine for 3 to 5 minutes.

Fault Reset



Siren Button

Tracking Button•Press button No 9 to put into track mode, a siren will sound for 10 seconds then pause for 1 second the sound again for the duration that the machine is in track mode. You can now track the machine using 4 control buttons (No 1 to 4).•When the machine is in position press No 9 button the switch out of track mode.•Before switching the engine OFF, run it at idle speed for 3 to 5 minutes.

Note. To switch off the radio control, first press IN the

stop button then pull back OUT.


1300 Maxtrak 100309 issue 2Starting Engine and tracking with the Umbilical Control

Directional Buttons

• To use the Umbilical control. Do not power up the Remote and select Umbilical control (as shown in photo).

• Press and release No 7 button on the Umbilical, the siren will sound for 10 seconds then stop for 1 second then sound again for the duration that the machine is in Track mode.

• Then machine can now be moved using the 4 directional buttons on the Umbilical Control.

• Note. If any of the buttons are pressure before the 10 second timer times out, the Umbilical will reset the Tracks to OFF and you will need to press the Track mode button No 7 to restart the 10 second timer.



Umbilical control unit directional buttons

Umbilical Emergency stop

Button



• When the machine is in position, press No 7 button to take the Umbilical out of Track mode.

• Before switching Off the engine, run it at idle speed for 3 to 5 minutes.



Best Practice Loading Procedure

Ensure that the hydraulic pump belts are tight enough otherwise the machine will not track straight and the chill is out of the hydraulic oil.

The type of trailer determines how the ramps need to be set up.

The higher the trailer the longer the ramps need to be. Load / unload the machine on level ground

Long shallow ramps enable easier loading



Best practice loading procedure

Ensure that the machine is inline with the centre of the trailer and the ramps are in the centre of the tracks.

Once the machine is centred and up to the ramps lower the engine rpm to low idle.

The machine will pull one way if the hydraulic oil is less than 5ºc (<41ºf) with high rpm



Best practice loading procedure

Track the machine onto the trailer using the fast forwards / reverse button as the machine will pull straighter than using the slow tracking button.

With the ramps at the correct angle the machine goes gently over centre ensuring that the machine stops on the trailer and there is no damaged

caused to the tracks.



Tracks

Check oil level monthly6 litres (1.6 US galls) SAE 80w/90 Gear Oil

Change oil thereafter every 1000 hours or AnnuallyFirst oil change at 100 working hours

Level PlugFiller Plug Drain Plug



Track Tension

The tracks are tensioned by pumping EP 2 grease into the track tensioner grease nipple.

Grease NippleCover



Track Tension

Span the tracks with a straight edge between the longest section of tracks that’s unsupported. The tracks should have 15mm (5/8”) of sag.



Track Tension

If there is less then 5mm of sag in the tracks, it will be necessary to let off some tension. To do this slowly unscrew the grease nipple until it releases

grease .

The grease nipple is under extreme pressure so never remove it until the grease has stopped coming out.

Recess for grease extraction

Grease Nipple



Setup Plant



• Do daily check on engine.• Move machine into position.• Check that the plant is level in both plains, plus both tracks are

fully support across the full length of the tracks.• Check plant stability when running.

Setup Plant

• Check all guard are in place plus in good condition

• Check that all warning signs are present and readable

• Check all emergency stop are working (include the umbilical control emergency stop).

• Check for any loose fixings.• Check out general inspection

of the plant t ascertain that nothing untoward is out of place or damaged so as to cause a safety hazard.


1300 Maxtrak 100309 issue 2Feed Conveyor Travel Position

The feed conveyor needs to be raised into the working position as it is lowered for transport.

Feed conveyor



Feed Conveyor Raise / Lower Hydraulic Control

The feed conveyor is hydraulically raised by the lever on the side of the chassis which connects directly into the bank valve.


1300 Maxtrak 100309 issue 2Feed Conveyor And Feed Chute

Raise the conveyor in the air to expose the first set of holes and fit the pins.

Swing up the feed chute and secure in place with the four quick release latches.

Hinged Feed chute

Travel Brackets For pins

Working position

Swing Up Feed chute Fit Pins



Feed Conveyor Pin Positioning

Ensure that the pin head is not touching the conveyor frame.

Pin Head Conveyor Frame


1300 Maxtrak 100309 issue 2Cone Material Level Sensor

The Cone material level sensor needs to be raised into the working position as it is lowered for travel.



Feed Ring Level Sensor

Position the bottom of the sensor head so that it

measures 130 centimetres (51 inch) from the bottom

of the feed ring.

130 cm (51 inches)

Wipe the dust / dirt from the underside of the sensor on a daily basis.



Hycontrol Level Sensor

• To view the parameters press the “MODE”button it will now display “PROG”.

• Press “1” immediately it will now display “PR.01”.

• Now use the “ ” and “ ” buttons to select the required program number.

• When on a parameter press the “DSP” button to view the value.

• To change this value, type in the required value and then press the “ENT” button.

• It will now display “COdE” enter 9753 as the code and press the “ENT” button.

• You can now press the “MODE” button and it will display “run” to place the unit back into operating mode or use the “ ” and “ ”buttons to select another parameter to change.



Hycontrol Level Sensor

2.0m

(Pr.3)

1.0m

(Pr.4)

0.5m (Pr.5)

55% (Pr.10)

85%

(Pr.9)

Feed On

Feed Off

Hycontrol


1300 Maxtrak 100309 issue 2Hycontrol factory set parameters Level Sensor

Pr.1 = 1 Defines applications as level Measurement Pr.2 = 2 Program units are metres Pr.3 = 2.0 Distance from transducer to zero levelPr.4 = 1.0 Working range, distance from zero level upwardsPr.5 = 0.5 Blanking zone, echoes can not be processed in this areaPr.7 = 1 Display to show to 1 decimal placePr.8 = 1 Relay 1 set to normally energizedPr.9 = 85 Relay 1 de-energise point

Pr.10 = 55 Relay 1 re-energies pointPr.23 = 2 Relay 1 fail safePr.29 = 30 Failsafe time delay (in seconds)Pr.37 = 2 Temperature compensation enabled Pr.40 = 1 Sets measuring range to percentage Pr.71 = -0.5 extends measurement range to 0.5 metres below zero

Other parameters which can be changed are Pr.06 (Rate of change), this will change the rate at which the unit works this can be taken up to a maximum of 6 any higher and the system can become erratic.

Pr.99 returns to Hycontrol factory default settings.



Conveyors

• Adjust the scrapper on both the feed conveyor and product conveyor.

• Track Feeder Conveyor if required• Track Product conveyor if required.



Feed Belt Adjustment

The feed belt is adjusted from the rear end and the belt needs to be kept tight at all times to prevent the head drum from slipping

Always keep the tail drum square when tensioning the belt otherwise the belt will get stretched on one side and make belt tracking difficult.

To tension the belt slacken off the locking bolts and lock nut and turn the adjusting stud anti clockwise.

Locknut

Locking bolts

Adjuster

Measuring point (keep equal on

each side )Adjusting

stud



Feed Belt Tracking

DOR



Discharge Conveyor Tracking

DOR




D.O.R

L/H

Belt DirectionR/H



Up And Over Metal Detector

Remove the transport chain from the top coil.


1300 Maxtrak 100309 issue 2Metal Detector Panel Layout

The green light should be on at all times.

Detect light Fault light

Power LampDetect Lamp Reset Button



Up And Over Metal Detector

The new detectors are fitted with a coil above the belt as well as the one under the belt.

The bottom coil is the transmitting coil and the top coil is the receiving coil.



Metal Detector

The metal detector is built into the top end of the feed conveyor under the belt.

Plastic insert



Metal Detector Set Up

Set zero indicator

LED

Set zero adjustment

Relay control

The set zero indicator needs the green LED to be illuminated. If either of the two red LED’s are illuminated the set zero adjustment knob needs to be

adjusted until the green light is illuminated. The adjustment compensates “zeros” out any near by metal in the sensor coil detect area.

With either of the red LED’s the detector will not detect

properly.


1300 Maxtrak 100309 issue 2Metal Detector Set Up

The sensitivity of the detector can be adjusted to ignore small pieces of steel that are no

problem to the machine to cut down on the amount of stoppages.

The sensitivity is adjusted simply by turning the sensitivity knob.

Use the test block (45mm x 45mm x45mm) to set up the sensitivity.


1300 Maxtrak 100309 issue 2Metal Detector Set Up

Using the test block (45mm x 45mm x45mm) to set up the sensitivity, only adjust to the

minimum setting that will still detect the test block when it is passed between the coils in the

direction that the conveyor runs.

When the metal test block is passed between the coils the signal level indication strip LED`s will move from the left to the right then trip (metal detected), the detect LED

(PCB) and the reset button on the front door will come ON, the feed

conveyor will stop and the PLC will display “45 METEL DETECTED

ON FEED CON BELT”


1300 Maxtrak 100309 issue 2Dust Suppression

A water manifold is situated at the front of the machine that has outlets to 3 dust suppression spray bars.

The inlet water pressure needs to be 2.8 bar (42 psi) to atomise the water through the nozzles..


1300 Maxtrak 100309 issue 2Spray Bar Location

Crusher dischargeCrusher feed chute

Each nozzle uses approximately 1 litre a minute. Discharge conveyor

There are filters in the end of the nozzles that require cleaning if the

water is not clean.The spray bars can be used individually or all together.



Automax Hydraulic Adjustment

The hydraulic system for adjusting the crusher is situated next to the adjustment panel.

The outgoing pipes from the hydraulic system connect to the crusher adjustment cylinders and wedge lock dumpy jacks.

System pressure gauge

Wedge-ring / crushing pressure gauge

Wedge lock pressure (Dumpy Jacks) gauge



Automax Paktronic Control Panel

All of the adjustments for the crusher C.C.S and calibration is done from a separate panel (Paktronic panel) next to the start up panel.

The C.S.S. of the machine is done on the touch of a button.


1300 Maxtrak 100309 issue 21300 Automax Pressure Switches (Panel Number AM225 upwards February 2004)

P.S. 4 103 bar (1494psi) Falling

P.S. 3 138 bar (2000 psi) Falling

Adjustment Solenoid Stack

Pressure Filters

Wedgering Valve Stack

System Pressure Gauge (Danfoss Valve)

P.S. 1 159 bar (2300psi) Rising

Dump Valve

Wedgering/Crushing Pressure Gauge

Wedgelock Pressure Gauge



PS1 159 Bar (2300 PSI) Raising

PS3 138 Bar (2000 PSI) Falling

PS4 103 Bar (1494 PSI) Falling 166 Bar (2400 PSI)

145 Bar (2100 PSI)

172 Bar (2500 PSI)

186 Bar (2700 PSI)

10 Micron Absolute

10 Micron Nominal

90 Micron Nominal

1300 Automax Pressure Switches (Panel Number AM225 upwards February 2004)


1300 Maxtrak 100309 issue 2Checking Cone Adjustment Pressure

•Check wedge lock (dumpy jack) pressure, should be between

(minimum) 166bar (2400psi) and (maximum) 172bar (2500psi).

•Check the wedge ring pressure, should be between 55bar (800psi)

and 83bar (1200psi). Select manual and press close, take the reading

from the wedge-ring/crushing pressure gauge.



Note. On new machine (machine that just had new wedge pad fitted) the wedge ring pressure can be as low as 14bar (200psi), the pressure will increase when the pads bed in


1300 Maxtrak 100309 issue 2Charging Dumpy Jacks


1300 Maxtrak 100309 issue 2Reducing the C.S.S



Set Zero Calibration

As the mantle and concave wear, the crusher needs to be calibrated to ensure that the setting on the display screen is accurate. Calibration is carried out as follows :

1. Open up machine fully, and check that are no stone in the crushing chamber.

2. Put the machine into manual.

2. Ensure the crusher is not running, Press close until the mantle and concave touch. This is indicated by a rise in pressure on the wedge-ring / crushing pressure gauge, recheck that there are no stones in the crushing chamber.

3. Scroll down the screen until you get to SET ZERO.

4. Press enter.

5. Press F3 and this will zero the screen. The amount of wear taken off to get it to zero gets added to the read wear.

6. Press escape and scroll back to current gap /set gap screen.

7. Set the crusher to the required setting (set gap).



Manganese Read Wear

1. Ensure the crusher is not running. Put the panel into manual and close the machine metal to metal.

2. If the display reads a minus figure carry out the set zero calibration.

3. Scroll down to manganese wear and press enter.

4. Providing that the calibrations have been carried out correctly the figure shown is the combined wear gone off the mantle and concave.

5. Press escape and scroll back to the set gap and select a C.S.S

Note: The wear can only be measured when the manganese is touching.



Adjusting The Closed Side Setting


2. Scroll down to the SET GAP.

3. Press enter.

4. Press enter.

5. Select a closed side setting.

6. Press enter.

7. Press escape.

8. Open the machine 5mm above the close side setting entered.

9. Put the machine into auto and the crusher will close itself down to the pre-selected closed side setting.



Automax Paktronic Control Panel Test the Tramp Overload System

1. Select MANUAL, open machine above the SET GAP, select AUTO and machine will come down to the SET GAP showing wedge-ring pressure of 55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.

2. Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED in hirsmann plug) and the wedge-ring pressure will be dumped.

3. Reset your wedge-ring pressure by repeating step 1

Tramp overload test button

Wedge-ring/Crushing Pressure Gauge

Dump Solenoid C



1300 Maxtrak Crusher Lubrication System

•Check oil level in Lubrication tank

•Check for leaks in lubrication system

Lubrication Oil Level

Sight glass

Check for water leaks

Check for Hydraulic oil leaks


1300 Maxtrak 100309 issue 2Setup Plant

Note. When machine is working it should always be in Auto Mode



Operating Plant



Daily Checks and on start up

•Check guards are in good condition plus in place.

•Check warning signs are present and readable.

•Check the alignment and tension of v-rope.

•Check all emergency stops are working.

•Check lubrication oil tank level.

•Check for any loose fixings.

•Do the engine daily checks

•Check the metal detector is working correctly.

•Fully raise and lower the upper frame several times manually to help distribute the grease on the wedge ring for smooth operation.

•Ensure the crusher internal frame arm shields are free of foreign bodies or material build up, also check that there is no material in the crushing chamber.

•Inspect the liners for possible tramp metal damage and evidence of an uneven wear pattern developing.

Starting and Operating plant using remote control for Feed Conveyor


1300 Maxtrak 100309 issue 2Starting and Operating plant using remote control for Feed Conveyor

Daily Checks and on start up cont.

•Check the Metal detector is working correctly.

•Check the Wedge lock (Dumpy Jack) pressure should be between (minimum) 166bar (2400psi) and (maximum) 172bar (2500psi).

•Check the Wedge ring pressure, should be between 55bar (800psi) and 83bar (1200psi).

•Set Zero (re-calibrate) on manganese.

•Check manganese wear.

•Check Tramp overload is working.

•Set CSS (Close Side Setting) on Crusher.

•Carry out the Plant lubrication schedule.

•Check that there are no faults displayed on Allen Bradley screen.

•Check that there are no leaks on the Lubrication/Hydraulic oil or water systems.




Off

On

Switch ON isolator switch



PLC display screen.


Engine Start

Controls.





•Select Plant on the Plant/Track switch

• Select Transmitter on the Umbilical/Radio switch

• Power up the transmitter by, pulling out the stop button, then pressing and hold buttons 9 + 0 for 1 second. No 3 LED will go red whilst holding the buttons then turn green when the buttons are released, if the LED remains red then the transmitter needs charging.

LED`s123



CantrakDisplay

Throttle Switch

Ignition Switch

•With the Isolator switch turned ON.•Turn the “ignition switch” to the first position and press the “fault reset button”.•The siren will sound for 10 seconds, then the 3 lights will come ON under the Cantrak (Lamp test).•Note. If an “emergency stop button” IN (including the umbilical stop button) the siren will not sound.•Make sure that the Throttle switch on idle (toward the left).

Fault Reset



•The Allen Bradley PLC will take 35 seconds to do it self diagnosis check, but the Paktronic takes longer therefore the Allen Bradley screen will display fault “39 HYDRAULIC PANEL WEDGELOCK FAULT”, press “fault mute” to turn off the siren then press “fault reset” to unlatch this fault.•“11. Plant start available” will now be displays on the Allen Bradley screen.•Turn the “ignition switch to the second position and the engine should stat within 3 seconds.•Idle the engine for 3 to 5 minutes.

Fault Mute Fault Reset



•Press the Lub button, the siren will sound for 5 seconds, press it again (within 10 seconds) after the siren has stopped to start the lub pump, the PLC will not allow the crusher to be started until the oil pump has run for 5 minutes plus the Product Conveyor is running.

• Press the Product Conveyor button, the siren will sound for 5 seconds, press it again (within 10 seconds) after the siren has stopped to start the Product Conveyor. The Product Conveyor is fitted with a speed wheel, should the Product Conveyor slow down, the PLC will automatically stop both the Feed Conveyor and Crusher

Lub PumpProduct

Conveyor



•With the Product Conveyor running you can now start the crusher.•Before starting the crusher check that there is no material inside the crushing chamber. •With the Engine speed at 1200rpm, press the Crusher start button, the siren will sound for 5 seconds, press it again (within 10 seconds) after the siren has stopped to start the Crusher.•With the clutch engaged increase the engine speed to 1800rpm, allow the Crusher time (10 seconds) to get up to working speed before starting the Feed Conveyor.

CrusherFeed

Conveyor



•With the Crusher running, select Automatic or Manual Feed Conveyor speed (the Factory recommend Automatic should be selected to keep the Crusher choke fed).•In Automatic mode you use the Hycontrol PLC and level sensor to control the Feed Conveyor belt speed/level of material in Crusher feed hopper.•In Manual mode you use the Pot to control the Feed Conveyor speed/level of material in Crusher feed hopper.

Automatic Manual control Pot for Feed Conveyor

130 cm (51 inches)

Manual



•Press the Feed Conveyor start button, the siren will sound for 5 seconds, press it again (with 10 seconds) after the siren has stopped, the Feed Conveyor will not start until you press the Feed Conveyor start button (button No 0) on the transmitter.•With the feed conveyor running the Allen Bradley will display “8. Plant Running” .•You can start and stop the Feed Conveyor on the remote (transmitter) by pressing button No 0

Feed Conveyor

Feed Conveyor



With the Plant running•Check the plant is stability (the chassis should not have undue vibration during operations) on and off load.•Listen for any abnormal noise from the Crusher.•Check for leaks on the Lubrication system.•Check Lubrication filter condition, this will be displayed on Allen Bradley screen as “43. CRUSHER LUBE OIL FILTER BLOCKAGE” this fault will sound a siren but will not stop the crusher from running.•Check lubrication oil flow back to tank.•Check and note Lubrication oil pressure to temperature.•Check for leaks on the water system.•Check the operation of the Lubrication oil heater (Bowman) if the oil temperature is below 40oC (105oF)•Check for Hydraulic leaks.

Inspection glass


1300 Maxtrak 100309 issue 2Feeding The Crusher

Wear plate

Mantle

Concave

•It is essential that the the crusher is choke fed to ensure the machine is is performing to its best ability. The wear plate should not be visible when the machine is crushing.

•Failure to choke feed the machine will result in low production, poor shape and a reduction on the material.•In some cases the concave can be worn out of round resulting in premature manganese changes.

Company Confidential


•Check that the feed into the crusher is not Segregated (fine material on one side and coarse on the other.

•When segregation takes place in the crushing chamber it means that there are voids within the coarse material in the crushing chamber resulting in poorer shape.

•The fine material will encourage packing therefore limiting the crusher CSS (for working at tighter settings.

Fine Material

Coarse Material



•Check that the CSS is being maintained (current gap should be the same as set gap) when crushing.

•The CSS can be adjusted whilst the crusher is working (on the fly).

•Note the Crushing pressure. (the maximum this should be running at is approximately 138bar (2000psi) to 145bar (2100psi).




Wear plate

Mantle

Concave

•It is essential that the the crusher is choke fed to ensure the machine is is performing to its best ability. The wear plate should not be visible when the machine is crushing.

•Failure to choke feed the machine will result in low production, poor shape and a reduction on the material.•In some cases the concave can be worn out of round resulting in premature manganese changes.


1300 Maxtrak 100309 issue 2When Plant is running

•With the plant running, check the tracking and for spillage on both the product conveyor and the feed conveyor.

•Note. No adjustment should be done to these conveyor when the are running.


1300 Maxtrak 100309 issue 2Stopping Plant

•Run the Feed Hopper empty and stop the Feed conveyor.•Reduce the engine speed 1200rpm.•Stop the Crusher (but keep the lubrication system running until the cone head stops turning)•Stop the Product conveyor.•When the Cone Head stops turning then stop the lubrication pump.•Run the engine at idle speed (1200rpm) for 3 to 5 minutes then switch of the engine.•Switch of the remote by pushing in the stop button and pulling it back out.



De-rigging Plant



De-Rigging Plant

1. Raise the feed conveyor to the highest point and put the pins into the top holes. Lower the conveyor onto the pins.

2. Clean out the material from the rear half of the feed ring and fold down hinged door on the feed chute.

3. Raise the feed belt, remove the pins and fit them into the travel brackets. Lower the feed belt all of the way down.

4. Stop the engine.

5. Lower the miltronics probe into the travel position.

6. Remove all loose stones from the machine.


1300 Maxtrak 100309 issue 2De-rigging machine and preparing it for transport

•Check that both the Feed Hopper and Feed Conveyor is empty of material

•Run the Product Conveyor to insure there is not material on it.

•Raise the Feed Conveyor to the highest point and put the pins into the top holes. Lower the conveyor onto the pins.

•Clean out the material from the rear half of the Feed ring and fold down hinged door on the feed chute.

•Raise the Feed Conveyor, remove the pins and fit them into the travel brackets. Lower the Feed Conveyor all of the way down.

•4. Fit the transport chain to the Metal Detector top coil.

•5. Lower the Level probe into the travel position.

•6. Remove all loose stones from the machine.



Automax Cone Crusher


1300 Maxtrak 100309 issue 2Basic Crusher Layout

ONE PIECE CONCAVE SUPPORT BOWL / UPPER FRAME

MANTLE LINER

MAIN SHAFT

BEARING ARRANGEMENTS

HYDRAULIC ADJUSTMENT CYLINDERS

LUBRICATION COUNTERSHAFT ASSEMBLYDRIVE GEARS

WEDGE RING ASSEMBLY

SEALING

ECCENTRIC

CONCAVE LINER

HYDRAULIC WEDGE JACKS

MANTLE NUT

MAINFRAME

Direction of rotation

718 RPM


1300 Maxtrak 100309 issue 2Crusher Motion



Manganese Types

The 1300 Automax has only one eccentric throw which is 45mm.

There are two manganese configurations fitted to the Automax :-

Standard Manganese

Has the largest feed opening capable of accepting 220 mm (8.1/2 inch) down material. Ideally suited for making 40mm (1½ inch) down material.

Autosand Manganese

Designed to accept a feed size from 63mm (2.1/2 inch) to 13mm (1/2 inch). Used for applications where plenty of fines and small aggregates are required.


1300 Maxtrak 100309 issue 2Manganese Profiles

Automax

Crushing zones

Autosand

The longer the crushing zone the better reduction and shape



Manganese Profiles

Automax

Autosand



Upper Frames

There are two types of upper frames fitted to the crusher to hold the different profiles of manganese.

The Autosand fit in one support bowl and the Automax in the other.

As the Automax manganese is shallower than the others the difference in the upper frames are clearly visible.

Automax Autosand

Upper frameUpper frame


1300 Maxtrak 100309 issue 21300 Automax Approximate Capacities

The type of material, feed size and bulk density can effect the capacity of the machine.

The figures in the table below are only guide lines.


1300 Maxtrak 100309 issue 21300 Autosand Approximate Capacities

The type of material, feed size and bulk density can effect the capacity of the machine.

The figures in the table below are only guide lines.



1300 Automax 45mm Throw



1300 Automax 45mm Throw

Example. With a C.S.S of 19mm (3/4”) 40% of the production (96 to 112 tonnes/hour) will be below 5mm. 90% of the production (120-140 tonnes /hour) will be below 24mm.



1300 Autosand 45mm Throw




The crusher has a stand alone tank for the lubrication oil.

Lub Air blast coolerInline pressure filters

Temperature sender

Electrical junction box

Pressure gauge

Sight glass

Hydraulic motor

Breather /Filler cap

Flow meterFloat Switch

Temperature sensor







Lubrication Pump

Lubrication Pressure Gauge

125 micron Breather

Relief Valve set to 5 Bar @ 23 oC

Oil Level Sight Gauge

Flow Meter

Hydraulic Motor

Return Oil Sight Gauge

Float Switch

Over Temperature switch set to 80oC

Suction Filter 90 Micron Nominal

Lubrication Oil Cooler c/w Bypass

Pressure Filter 25 Micron Nominal c/w Bypass and block filter switch

Thermostat 40oC



1300 Maxtrak fitted with 12.5cc Hydraulic Motor

Lubrication Pump = 33.7cc

Hydraulic Motor = OMM12.5

Calculation. 1 litre of oil into 12.5cc motor = (1000 /12.5 ) 80rpm.

15 Litres of oil into 12.5cc Motor = 1200rpm.

Hydraulic motor running at 80rpm, Lubrication flow = 80 x 33.7 cc/rev =2696 cc / 1000 = 2.7 Litres per Minute

Hydraulic motor running at 1200rpm, Lubrication flow = 1200 x 33.7 cc/rev = 40440 / 1000 = 40.4 Litres per Minute



Lubrication Pump = 33.7cc

Relief Valve set to 5 Bar @ 23 oC

Suction Filter 90 Micron Nominal



Cone Lubrication System

The primary function of the Lubrication system are.

•To prevent damage due to metal on metal contact within the bearings.

•To dissipate heat generated by the bearing during operation, so acting as a coolant.

•To reduce friction and wear with the bearing.


1300 Maxtrak 100309 issue 2Crusher Lubrication System

Feed to countershaft

Feed to main shaft

Return to tank must fall at a

minimum of 5°.

Tank


1300 Maxtrak 100309 issue 2Crusher Lubrication Oil

The crusher runs on two different grades of oil depending on the ambient temperature.

Ambient temperature above 4°C (39 °F) use an EP 220 ISO VG.

Ambient temperature below 4°C (39 °F) use an EP 150 ISO VG.

The tank holds approximately 275 litres (73 US. Gallons) of oil.


1300 Maxtrak 100309 issue 2Crusher Lubrication Oil Level

The oil level should be checked daily

The oil level needs to be maintained at the top of the sight glass (cold oil).

In cold conditions the oil may be pumped into the machine quicker than it is returned which drops the level in the tank.

A level float is fitted to the tank so that if the oil level drops too low it will shut down the machine.

Level float

Sight glass


1300 Maxtrak 100309 issue 2Lubrication Oil Pump + Motor

The oil pump is is mounted inside the lubrication tank.

An external hydraulic motor is used to drive the pump.

The pump delivers approximately 40 litres of oil / minute (10.6 U.S gallons) into the crusher at working temperature. The crusher relies on oil flow for

lubrication not pressure.

Lubrication pump inside the tank

Hydraulic motor


1300 Maxtrak 100309 issue 2System Pressure

The system pressure will vary depending on the oil temperature.

The pump has a built in relief valve set at 5 Bar (72 PSI). With cold oil the pressure may get up to 9 Bar(130 PSI).

If the oil pressure is above 5 bar (72 PSI) it means that some of the oil is going through the relief valve straight back into the tank.

When the oil is up to temperature the pressure will be approximately 2.5 Bar(36 PSI)

Lubrication system pressure

gauge

Lubrication system pressure



Pressure Filters

The Lubrication Filter should be checked dailyThe oil is pumped from the tank and through two inline pressure filters.

The initial oil and suction filter change needs to be done at 500 hours when the machine is new.

The oil and suction filter should then be change every 1000 hours there after.

The initial filter change needs to be done at 100 hours when the machine is new

The filters are then changed every 500 hours there after.

The lubrication oil tank capacity is 275 litres (73 US galls)

Inline pressure filters



Blocked Filter Warning

There is a blocked filter sensor fitted to the to the filter housing.

This will not shut down the machine but it will sound the siren.

There is a bypass valve fitted into the filter housing so the oil will still be pumped to the crusher but it will be un-filtered

Taking regular oil samples, having them tested and changing the oil when the analysis instructs to do so will reduce the amount of oil changes.

Blocked filter sensor



Lubrication Air Blast Oil Cooler

The air blast cooler is fitted to cool the oil before it enters the crusher.

It is fitted with a temperature sender unit so that the cooler fan does not start up until the oil is at 40.6 °C (105 °F).

Once the fan starts up it will generally continue to run until the machine is stopped.

The cooler will need to be cleaned out on a regular basis either with an air line or a pressure washer to prevent the core getting blocked with dust.

Sender unit

Air blast cooler


1300 Maxtrak 100309 issue 2Crusher Lubrication Oil Flow Switch Setting (PLC version 12 onwards from April 2004)

The Kobold flow sensor has 2 cut off points.

When the oil is cold (air-blast cooler not operating) the cut off point is 8 l/min (2.1 US gal) (3.6 Hz dc volts). When the cooler is running the cut off point is

14.7 l/min (3.9 US gal) (6.4 Hz dc volts)

The electronic sensor is no longer fitted on the lubrication pump when this flow switch is fitted



Lubrication (Bowman) Heat Exchanger

Feed the from flow

switch

Feed to the crusher main

shaft

Feed to the counter shaft

The lubrication oil is below 40oC is passed through a heat exchanger before it goes into the crusher.

When the oil is cold the water from the engine passes through the heat exchanger to warm up the oil.

When the oil reaches working temperature (40oC) the solenoid valve closes on the end of the heat exchanger to stop the water passing through it.

Engine water pipes

When the solenoid valve closes the air blast cooler starts.

Solenoid



Crusher Countershaft Lubrication

The front countershaft bearing has its own feed line.

With the oil at working temperature 2 litre / minute (0.5 US gal) goes to the bearing.

Feed in

(3/8 BSP)



Crusher Lubrication Feed And Return Lines

The lubrication oil is pumped into the crusher from the underside through the middle of the main shaft.

There is one pipe to return all of the oil back to tank.

Main shaft feed in

Oil return to the tank



Crusher Lubrication

Although there is only one feed into the main shaft there are two feeds out.

One oil port is situated at the top of the main shaft. There is stationary oil flinger situated directly below the oil port to help distribute the oil evenly.

The oil from this port lubricates the upper and lower cone head bearings.

Oil port

Upper bearing

Oil flinger

Lower bearing


1300 Maxtrak 100309 issue 2Crusher Lubrication

The lower oil port on the shaft lubricates the main shaft bearing pair and lower bearing.

Oil port

Upper bearing pair

Lower bearing



Crusher Feed And Return Lubrication Lines

Main shaft feed in

Oil return to tank



Crusher Lubrication Return Line

A clear union is fitted to the return oil line to inspect the return oil entering the tank.

The oil flows into s sediment tray before it falls into the bottom of the tank.

Inspection glass Sediment tray

Tank



Crusher Lubrication Tank Oil Drain

Track the machine over some wooden blocks or built up ground to gain ground clearance for draining the oil.

Try to lean the machine towards the drain plug to remove as much oil out of the tank as possible.

The drain plug is a 1/2 inch female quick release coupling so a pipe can be attached to drain the oil.

Filler cap Drain plug


1300 Maxtrak 100309 issue 2Crusher Lubrication Tank Oil Drain

Pumping the oil out of the tank may be an easier method to remove the oil as inspection cover needs to be removed to change the suction filter and clean out the

bottom of the tank..Always clean the top of the tank before removing the inspection cover.

Also pump or mop out the oil from the sediment tray and clean it as it is not possible to drain it out.

Inspection cover

Sediment tray



Crusher Lubrication Over Temperature Sender

The oil temperature sender unit is situated in the tank so that if the oil exceeds 80 °C (176 °F) the crusher will automatically shut down.



Automax Hydraulic Adjustment System



Automax Paktronic Adjustment Panel

All of the adjustments for the crusher C.C.S and calibration is done from a separate panel next to the start up panel.

The c.s.s. of the machine is done on the touch of a button.




The hydraulic system for adjusting the crusher is situated next to the adjustment panel.

The outgoing pipes from the hydraulic system connect to the crusher adjustment cylinders and wedge lock dumpy jacks.

System pressure gauge


Wedge lock pressure gauge




To adjustment cylinders (open C.S.S.)

To adjustment cylinders (close C.S.S.)

Solenoid A

Solenoid B

Solenoid C

Tank

Pressure In

To Wedge Ring

Wedgelock shut off valve (normally closed)

Wedgelock shut off valve (normally open)


1300 Maxtrak 100309 issue 21300 Automax Hydraulic Adjustment (Panel Number AM225 upwards)





Pressure Filters




Dump Valve









145 Bar (2100 PSI)

172 Bar (2500 PSI)

186 Bar (2700 PSI)

10 Micron Absolute

10 Micron Nominal

90 Micron Nominal

1300 Automax Pressure Switches (Panel Number AM225 upwards February 2004)






1300 Automax Pressure Switches (Panel Number AM224 downwards before February 2004)

145 Bar (2100 PSI)

172 Bar (2500 PSI)

186 Bar (2700 PSI)

10 Micron Absolute

10 Micron Nominal

90 Micron Nominal



Automax Adjustment Cylinders

The hydraulic panel operates the six adjustment cylinders which moves the upper frame up and down which changes the closed side setting of the

machine.Adjustment

cylinderopen

Close

Wedge lock





Wedge-ring Dumpy Jacks

The wedge -ring acts like a brake shoe on the inside of the upper-frame to assist the main hydraulic cylinders in holding the upper-frame in position

whilst it is crushing.The main hydraulic cylinders cannot hold the upper-frame solely on their own.

Upper-frameWedge-ring

Dumpy jacks (x 12)


1300 Maxtrak 100309 issue 2Wedge-ring

The wedge ring has a series of tapers on the inside of it which match up to the mainframe. The dumpy jacks push the wedge-ring up which makes it expand

due to the tapers thus pushing the pads hard up to the inside of the upper-frame to act like a brake.

Wedge-ring pads


1300 Maxtrak 100309 issue 2Wedge-ring Principle

Wedge Ring

Upper Frame

Dumpy Jack Cylinder

Mainframe

Dumpy Jacks

Expanding Wedge Ring

Upper frame

Mainframe


1300 Maxtrak 100309 issue 2Closed Side Setting Paktronic Display Screen

The C.S.S. of the machine is displayed on a PLC. There is a linear transducer that connects from the mainframe to the upper

frame to measure the movement of the upper frame. The transducer sends a 4 to 20 mA signal back t the PLC which converts it into a millimetre display gap.

PLC gap display Linear Transducer



•Check wedge lock (dumpy jack) pressure, should be between

(minimum) 166bar (2400psi) and (maximum) 172bar (2500psi).

•Check the wedge ring pressure, should be between 55bar (800psi)

and 83bar (1200psi). Select manual and press close, take the reading

from the wedge-ring/crushing pressure gauge.



Note. On new machine (machine that just had new wedge pad fitted) the wedge ring pressure can be as low as 14bar (200psi), the pressure will increase when the pads bed in



Charging the Dumpy Jacks



Reducing the C.S.S



Set Zero Calibration

As the mantle and concave wear, the crusher needs to be calibrated to ensure that the setting on the display screen is accurate. Calibration is carried out as follows :

1. Open up machine fully, and check that are no stone in the crushing chamber.


2. Ensure the crusher is not running, Press close until the mantle and concave touch. This is indicated by a rise in pressure on the wedge-ring / crushing pressure gauge, recheck that there are no stones in the crushing chamber.

3. Scroll down the screen until you get to SET ZERO.

4. Press enter.

5. Press F3 and this will zero the screen. The amount of wear taken off to get it to zero gets added to the read wear.

6. Press escape and scroll back to current gap /set gap screen.

7. Set the crusher to the required setting (set gap).



Manganese Read Wear

The read wear is the amount of manganese that has worn off the mantle and concave. There are three indications that the machine needs re-metalling

1. The crushing pressure is too high, preventing you from closing the machine to the required close side setting.

2. The hydraulic cylinders bottom out restricting the closed side setting.

3. 50mm is the maximum amount of wear to be worn off the manganese. Wearing more off than this increases the chances of the manganese cracking, causing damage to the cone head or upper frame.



Manganese Read Wear

1. Ensure the crusher is not running. Put the panel into manual and close the machine metal to metal.

2. If the display reads a minus figure carry out the set zero calibration.

3. Scroll down to manganese wear and press enter.

4. Providing that the calibrations have been carried out correctly the figure shown is the combined wear gone off the mantle and concave.

5. Press escape and scroll back to the set gap and select a C.S.S

Note: The wear can only be measured when the manganese is touching.



Adjusting The Closed Side Setting


2. Scroll down to the SET GAP.

3. Press enter.

4. Press enter.

5. Select a closed side setting.

6. Press enter.

7. Press escape.

8. Open the machine 5mm above the close side setting entered.

9. Put the machine into auto and the crusher will close itself down to the pre-selected closed side setting.



Automax Paktronic Control Panel Test the Tramp Overload System

1. Select MANUAL, open machine above the SET GAP, select AUTO and machine will come down to the SET GAP showing wedge-ring pressure of 55bar ( 800) to 83bar (1200psi) on your wedge-ring/crushing pressure gauge.

2. Press the TRAMP O/L TEST button, dumpty solenoid (C) will energize (LED in hirsmann plug) and the wedge-ring pressure will be dumped.

3. Reset your wedge-ring pressure by repeating set 1

Tramp overload test button

Wedge-ring/Crushing Pressure Gauge

Dump Solenoid C



New Manganese

When the machine is new or when it has been re-metalled the new manganese calibration needs to be carried out. This is done as follows -

1. Ensure the crusher is not running.Put the machine into manual and close the machine until the mantle and concave touch. This is indicated by a sudden rise in pressure on the wedge ring / crushing pressure gauge. Ensure it is metal to metal and no stones are in the crushing chamber.

2. Scroll down the screen using the down arrow until you get to NEW MANGANESE

3. Press enter

4. Press F4 and it will re-calibrate everything back to zero

5. Press escape.

6. Scroll back up to current gap / set gap display

7. Set new closed side setting



Increasing the C.S.S



In Working Mode



Overload in Automatic



Dump Line

There is a check valve in the engine compartment which is connected in the main suction line. The 3/4 pipe connected to the end of it tee’s in the full bore

side of the adjustment cylinders. When the crusher dumps it can then draw oil into the bottom of the cylinders as they are being forced open.

Tee’s to the cylinders



1300 Maxtrak Pressure Reliefs and Reducers

Relief valve172 Bar (2500psi)

Pressure reducer 145 Bar (2100psi)

Pressure reducer 166 Bar ( 2400psi)

Adjustment stack Wedge lock stack



1300 Maxtrak Paktronic Control Panel


1300 Maxtrak 100309 issue 2Paktronic Electrical Panel

The relays have a built in LED to indicate when they are energised.

The relays also have a button that can be pressed to over ride the relay and close the contacts.

R1

Relay LED’s

Relay over-ride buttonR2 R3 R4 R5 R7

Spare fuses

Fuses


1300 Maxtrak 100309 issue 2Paktronic Electrical Drawing 9673 (Panels AM272 and after) August 2004


1300 Maxtrak 100309 issue 2Paktronic Electrical Drawing 9088 (Panels before AM272) August 2004



Hydraulic Panel Operation

OPENING THE CRUSHER

When the open button is pressed on the electrical panel, it energises solenoids B and C. Solenoid B operates the adjustment cylinder stack which diverts oil to the bottom side of hydraulic cylinders to open the machine. At the same time solenoid C opens the dump valve which allows the oil in the top side of the cylinders to be pushed into the tank

CLOSING THE CRUSHER

When the closed button is pressed on the electrical panel, it energises solenoid A. Solenoid A operates the cylinder adjustment stack in the opposite direction which diverts oil to the top side of the cylinder which closes the machine. The oil from the top side of the cylinder has a clear route back to tank



Hydraulic Panel Operation

OVERLOAD SITUATION

When the pressure in the hydraulic circuit exceeds 159 bar (2300psi) solenoid C operates. This opens the dump valve which releases all of the pressure from the top side of the hydraulic cylinders. The crusher is then forced open by whatever is in the crushing chamber. As the crusher opens, it draws oil into the bottom of the cylinders through a one way valve on the suction side of the hydraulic tank. Once the crusher has opened, it will automatically close itself back down to the original setting by operating solenoid A.

WORKING SITUATION

When the crusher is working nothing in the hydraulic circuit is being operated. The pressure within the wedge-lock system and the top side of the hydraulic cylinders is locked in and held by check valves.



Paktronic Panel Operational

There are 6 relays in the Paktronic electrical panel for the crusher adjustment circuit although the relay numbers go up to 7. Relay 6 no longer exists.

Relay 7 should be energised all of the time.There are LED’s built into the relay to indicate that they are energised.

CLOSING THE CRUSHERWhen the close button is pressed relays R1 and R2 should energise.

OPENING THE CRUSHER

When the open button is pressed relays R1 , R3 and R4 should energise.

WEDGELOCK CHARGING

When the wedge lock pressure drops below 138 bar (2000 psi) relay R1 should energise.

OVERLOAD

When the crusher dumps and goes into overload relay R4 should energise.



Pressure Reliefs And Reducers

Adjustment stack pressure reducer

This reducer limits the manual operating pressure to 145 bar (2100 psi) within the hydraulic cylinders.

Wedge lock stack reducer

This reducer limits the hydraulic pressure going to the dumpy jacks for the wedge ring to 166 bar (2400 psi).

Wedge lock stack relief

This relief is set at 172 bar(2500 psi) and it is a back up to the reducer, to ensure the wedge lock circuit does not over pressurise.




System pressure relief 200 bar (2900 psi)

Hydraulic cylinder relief 186 bar (2698 psi)




System relief

The system relief is located on the three bank valve in the R/H side of the engine canopy. It is set at 200 bar (2900 psi) to ensures that sufficient oil pressure is always available.

Hydraulic cylinder relief

This pressure relief is also set at 186 bar (2698 psi), this is the last line of relief if a major overload situation should occur. This relief allows the oil from the top side of the hydraulic cylinder to pass to the bottom side which allows the machine to open.


1300 Maxtrak 100309 issue 21300 Automax Pressure Switches (Panel Number AM225 upwards)




Pressure Filters




Dump Valve





Pressure Switches

Pressure switch 1

Pressure switch 1 is set at 159 bar (2300 psi) rising, when the pressure in the hydraulic cylinders exceeds this the pressure switch changes over and operates the dump valve C (via the Paktronic PLC) allowing the crusher to open (note, it is the material in the crushing chamber that pushes it open). 3 seconds after the dump valve as been operated the Paktronic PLC with de-energize the dump valve and close the machine down to it original CSS.

Pressure switch 3Pressure switch 3 is set at 138 bar (2000psi) falling. When the pressure in the wedge lock circuit drops below 138bar (2000psi) the pressure switch changes over operating the Danfoss valve (via the Paktronic PLC) to charge the system back up. Once the pressure exceeds 138 bar (2000psi) the system will continue to charge for a further 10 seconds.

If the pressure fails to reach 138 bar (2000psi) the machine will shut down after 3 minutes displaying ‘pump maximum run’.



Pressure Switches

Pressure switch 4Pressure switch 4 is set at 103bar (1494psi). If the pressure in the wedge lock circuit drops below 103bar (1494psi) for more than 30 seconds the machine will shut down and display ‘wedge lock pressure failure’.



Other Paktronic Display Functions

•Alarms, On the Alarms menu display the alarm condition along with the time and date that it occurred.

•In the Alarm History will store the last 20 alarms that were activated along with the time and date.

•Transducer Fault @ 18.18 on 12 May 2007. This fault is display because there is a fault with transducer circuit. Check the wires from the Paktronic PLC to the Positec. The machine will not operate until the fault has been rectified.




•Manganese Wear.

•Hour Run. The Lubrication Oil should be changed to the Paktronic Hours and not the Engine hours.




•Tramp Metal Count.

•Prev = Number of Tramp Overloads in the previous 30 Hours of Operation.

•Hrs = Hours that have expired since the last 30 hours count.

•3 digits to the right of the screen = Number of Tramp overloads in the Hrs counted.

•Gap Too Large = When machine overloads when in Automatic but cannot return to the Set Gap after 30 seconds (this period is considered too long for normal operation) the Alarm will be show. To reset select manual and close machine down to Set Gap then select Auto.




•Hydr Pump Max Run. When the machine overloads in Auto and the hydraulic pump has been running for over 3 minutes to close the machine down to Set Gap (this is considered too long for normal operation), the hydraulic pump will stop and this alarm will be displayed. To reset select Manual mode and close Crusher down to Set Gap, then select Auto.

•In Manual Too Long. When working in manual there is a time limit of 5 minutes, this is considered too long for normal operation. To reset select Auto then Manual.




•Manual Tramp Latch. A Tramp Metal Overload has occurred whilst in Manual mode. The Crusher will remain in its open position and show the following alarm. To reset select Auto then Manual and close machine down to the crusher Set Gap, then select Auto.

•Wedge Press Fail. The press in the dumpy jacks has drop to the setting of PS4.




•Set Operating Language. Press and hold button F2 for 6 seconds. Select the required Language and press enter.

•Time and date input for recording pressure over-loads

•Hydraulic Oil Low. This fault should not occur because the supply comes from the plants main hydraulic tank.



Crusher Closed Side Setting Creeping Open

CAUSES

External leak on adjusting cylinder

Internal leak on adjusting cylinder

Internal leak in the hydraulic panel



Crusher Closed Side Setting Creeping Open

DIAGNOSIS

Close the machine metal to metal until it blows through the relief valve at 145bar (2100 psi) on the wedge ring pressure gauge. If the pressure drops

more than 7bar (102psi) in ten minutes there is a leak.

Check the whole of the system for external oil leaks and rectify if necessary.

Re test to see if the pressure still drops.

Disconnect the the two snap connectors and repeat the same process. If the pressure holds now the leak is within one of the hydraulic cylinders. If the

pressure still drops the leak is within the hydraulic panel.



Hydraulic Cylinder Internal Leak Test

Remove the top pipes off five of the cylinders and plug them with a half inch

BSP plug.

Press close on the machine until 145bar (2100psi) is achieved. Leave for 10

minutes and note the pressure drop.

Repeat for all six cylinder.



Hydraulic Cylinder Internal Leak Test

If a pressure drop occurred on one of the two cylinders with the relief valves fitted, the top pipe needs to be piped directly to

the cylinder to determine if the leak is within the cylinder or the relief valve.

Relief valve



Hydraulic Panel Internal Leak

90 percent of internal panel leaks are due to dirty oil.

Remove the pressure reducer and the check valve cartridges. Wash them out in a cleaning solvent and blow them out with an air line. This may remove any

dirt sat on the valve seats causing the internal leak. If not, trail and error fitting new parts will be necessary to find the fault.

The check valve sits between the pressure reducer and manifold

block



Relief Valve Setting

If the relief valve is backed off and stripped to remove any contamination it will need to be re-set.

1. Leave the relief valve backed off when it is re-fitted.2. Close the machine metal to metal and keep the button pressed. It may be necessary to screw in the relief valve if the upper frame won’t move. 3. Screw in the relief valve until 145bar (2100psi) is achieved on the wedge ring pressure gauge and secure in place with the lock nut.

Relief valve

Lock nut



Wedge-lock Pressure Drop

If the wedge-lock pressure keeps falling and recharging the system, the firstthing to check is the wedge-lock shut off valve is fully closed.

Shut off valve normally closed



Wedge-lock Pressure Drop

Quick release coupling

Open up the upper frame to its maximum to fully expose the dumpy jacks to check for any oil leaks from either the jacks or the hydraulic pipe workIf no leaks are apparent disconnect the quick release coupling. Put the

machine into auto and open the wedge-lock shut off valve. As soon as the system starts to build up pressure close the valve. If the pressure still drops the

leak is in the panel. If the pressure holds the leak is within the dumpy jacks.

Dumpy jacks



Wedge-lock Valve Stack

Remove the pressure reducer, check valve and relief valve. Clean then as before and re-fit them as contamination is the probable cause.

Fully screw in the pressure reducer and back off the pressure relief valve. Put the machine into auto and unscrew the wedge-lock shut off valve. When the pressure drops below 138bar (2000psi)(PS.3) system will build up pressure again. Shut the wedge-lock valve and slowly screw in the relief valve until

172bar (2500psi) is achieved. You will have to re-charge the system a couple of time before you can get it set accurately. Repeat for the pressure reducer and

set to 166bar (2400psi)

VALVE SET UP

Pressure reducer

Check valve

Relief valve



Wedge-lock Valve Stack

If the wedge-lock circuit continued to drop pressure whilst trying to set up the valves, again trial fitting of new parts will be necessary to diagnose the fault.

NOTE Whenever a fault occurs on the hydraulic circuit check and replace the hydraulic filters if necessary.

The filters should be changed every four months to minimise any contamination.



Upper Frame Bouncing Whilst Crushing

Closed side setting too tight.Open up the css and run it where the machine is comfortable

Too many fines in the feed material causing packing. Open the jaw crusher css to reduce the amount of fines produced if the

crusher will accept a larger feed size.Use the dirt conveyor on the jaw crusher to reduce the fines.Wedge ring over greased causing low wedge ring pressure.

Run the crusher where it is comfortable and slowly tighten the setting over a period of time. This will remove some of the grease off the pads.

Alternatively remove the upper frame, remove all of the grease then re grease with the correct type and amount.

Wedge lock pressure low / internal oil leak.

Investigate and rectify the cause of the problem.



Upper Frame Bounding Whilst Crushing

Manganese worn out.Change the mantle and concave.

Wedge ring pads worn out.Fit new pads to the wedge ring.

The dumpy jacks have bottomed out causing low wedge ring pressure.Check that the wedge ring pads are not worn out. If not either remove the

wedge ring stop and reposition the wedge ring or fit packers under the dumpy jacks. NOTE. THE DUMPY JACKS HAVE A 15MM STROKE.

Manganese out of round.

Carry out ‘out of round check’ on the manganese. Re metal if necessary.



Manganese Out Of Round

CAUSES

Poor manganese.

Incorrectly fitted manganese.

Segregation of feed material.

Continues stop start feed.

Trickle feeding.



Manganese Out Of Round Check

Note. Usually its not the mantle that goes go out of round as it is continually turning so always check the concave first.

The Mantle can you out of round if a there has been a built up of stone under the crusher causing the head to lock to the eccentric.

1. Draw an arrow on the mantle 2. Remove the drive guard to gain access to the drive pulley

Checking the concave

3. Mark the concave so that each check is done in the same position4. Slowly turn the pulley so the head and eccentric turn as one. Align the arrow on the mantle nut to the mark on the concave 5. Start the engine and close the machine metal to metal, ensuring the pulley doesn’t turn. Note the read out on the digital display.

7. Stop the engine and slowly turn the pulley so the head + eccentric turns through 90 degrees. Repeat the above procedure until you have four reading . If at any time the pulley turns whilst closing metal to metal the whole process needs to be started again

6. Open the machine back up at least 20mm




Mantle nut

x

concave

2

0 Typical values

2 Feed ConveyorEngine

1

If there is a difference of more than 6mm between any of the four points, the manganese needs to be changed immediately.




Checking the mantle

Repeat the same procedure as before but this time the pulley must be held still and the cone head rotated. Again if the pulley turns whilst it is being closed metal to metal the whole procedure needs to be repeated.

The same tolerances apply to the mantle.



Welding on Cone Crusher

Welding on Plant

Whenever any welding is done on the machine the battery isolator key must be turned off, negative battery lead removed and the ECM plugs must disconnected

Ensure that the current does not pass through any bearings. (Note, always put the welding earth cable on/beside the unit that is being welded).



Caterpillar C13 Engine and Clutch


1300 Maxtrak 100309 issue 2C13 Engine and Clutch


Off

On

Always switch off and lock out when carrying out maintenance,

especially if welding



PLC display screen.


Cantrak display screen.




CantrakDisplay Fuel

Gauge

Cat ETConnector

Throttle Switch

Ignition Switch



Below the Cantrak display there are three indicator .

Maintenance Due lamp. Warning (Alert) lamp, the Warning

lamp will flash indicating a fault code. Count the number of times it flashes and check the Caterpillar operation maintenance manual for the cross reference to give the possible causes.

The Shut down (Action) lamp. When this lamp is flashing means the engine is going into De-rate.

The C13 engine rpm is

electrically adjusted by a

rocker switch.



C13 START PANEL

The maintenance due light will illuminate every 250 hours and will stay on until the reset button is pressed.

Maintenance Lamp


1300 Maxtrak 100309 issue 2Diagnostic Flash Codes For C11 & C13 Industrial Engine

Flash Code SPN (1) FMI Code Diagnostic code or Event Code

Description of Code

1387-15 High Auxiliary Pressure Warning

1387-16 High Auxiliary Pressure Derate

1387-00 High Auxiliary Pressure Shutdown

0441-15 High Auxiliary Temperature Warning

0441-16 High Auxiliary Temperature Derate

0441-00 High Auxiliary Temperature Shutdown

545-05 Ether Start Relay open/short to +batt

2417-05 Ether Injection Control Solenoid open/short to +batt

545-06 Ether Start Relay short to ground

2417-06 Ether Injection Control Solenoid short to ground

626-06

626-05

E445 (2)

E443 (2)n/a




Description of Code

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

111-02 111-02 Engine Coolant Level Sensor Loss of Signal

174-03 174-03 Fuel Temperature open/short to +batt13

174-04 174-04 Fuel Temperature short to ground

678-03 41-03 8 Volt DC Supply short to +batt21

678-04 41-04 8 Volt DC Supply short to ground

n/a




Description of Code

620-03

1079-03

262-03 5 volt Sensor DC Power Supply short to +batt

620-04

1079-04

262-04 5 Volt Sensor DC Power Supply short to ground

100-03 100-03 Engine Oil Pressure open/short to +batt

100-04 100-04 Engine Oil Pressure short to ground

100-10 100-10 Engine Oil Pressure abnormal rate of change

102-03 102-03 Boost Pressure Sensor shor to +batt

102-04 102-04 Boost Pressure Sensor short to ground

102-10 102-10 Boost Pressure Sensor abnormal rate of change

25

24

21




Description of Code

108-03 274-03 Atmospheric Pressure open/short to +batt

108-04 274-04 Atmospheric Pressure short to ground

110-03 110-03 Engine Coolant Temperature open/short to +batt

110-04 110-04 Engine Coolant Temperature short to ground

28 91-13 91-13 Throttle Position calibration required

32 91-08 91-08 Throttle Position signal abnormal

190-08 190-08 Engine Speed signal abnormal

723-08 342-08 Secondary Engine Speed signal abnormal

34

35 190-15 E362 (2) Engine Overspeed Warning

27

26




Description of Code

35 190-00 E362 (2) Engine Overspeed Shutdown

94-03 94-03 Fuel Pressure open/short to +batt

94-04 94-04 Fuel Pressure short to ground

105-03 172-03 Intake Manifold Air Temp open/short to +batt

105-04 172-04 Intake Manifold Air Temp short to ground

42 637-13 261-13 Engine Timing calibration required

100-17 Low Engine Oil Pressure Warning

100-18 Low Engine Oil Pressure Derate

100-01 Low Engine Oil Pressure Shutdown

E360 (2)46

38

37




Description of Code

168-00 168-00 System Voltage high

168-01 168-01 System Voltage low

168-02 168-02 System Voltage intermittent/erratic

56 630-02 268-02 Check Programmable Parameters

58 639-09 247-09 J1939 Data Link communications

110-15 High Engine Coolant Temperature Warning

110-16 High Engine Coolant Temperature Derate

110-00 High Engine Coolant Temperature Shutdown

62 111-17 E2143 (2) Low Engine Coolant Level Warning

E361 (2)61

51




Description of Code

111-18 Low Engine Coolant Level Derate

111-01 Low Engine Coolant Level Shutdown

63 94-15 E096 High Fuel Pressure Warning

1636-15 High Inlet Air Temperature Warning

1636-00 High Inlet Air Temperature Shutdown

174-15 High Fuel Temperature Warning

174-16 High Fuel Temperature Derate

65

174-00 High Fuel Temperature Shutdown

651-05 001-05 Injector Cylinder 1 open circuit

E363 (2)

71

E539 (2)64

E2143 (2)62




Description of Code

651-06 001-06 Injector Cylinder 1 short

651-11 001-11 Injector Cylinder #1 fault







73

72

71




Description of Code



654-11 004-11 Injector cylinder #4 fault







76

75

74



(1) Suspect Parameter Number

(2) Caterpillar Electronic Technician (ET) will display the number 1,2 or 3 after the event code in order to designate a warning, a derate, or a shutdown


1300 Maxtrak 100309 issue 2C13 Monitoring

Description State Trip Point Delay Time

Low Engine Oil Pressure

Warn Operator(1) On None 8 Sec

Engine Derate(2) On None 4 Sec

Engine Shutdown(3) On None 4 Sec

High Engine Coolant Temperature

Warn Operator(1) On 216 Deg F 10 Sec

Engine Derate(2) On 217 Deg F 10 Sec

Engine Shutdown(3) On 219 Deg F 10 Sec

Engine Overspeed

Warn Operator(1) On 2124 RPM 1 Sec

Engine Shutdown(3) On 2200 RPM 1 Sec

High Engine Inlet Air Temperature

Warn Operator(1) On 167.0 Deg F 8 Sec

Engine Derate(2) On 174.2 Deg F 8 Sec




Low Coolant Level

Warn Operator(1) On None 10 Sec

Engine Derate(2) On None 10 Sec

Engine Shutdown(3) On None 10 Sec

High Fuel Temperature

Warn Operator(1) On 194 Deg F 30 Sec

Engine Derate(2) On 196 Deg F 10 Sec

Engine Shutdown(3) Off 196 Deg F 10 Sec

High Fuel Pressure

Warn Operator(1) On 109.9 PSI 8 Sec

High Auxiliary Temperature

Warn Operator(1) Off 221 Deg F 4 Sec

Engine Derate(2) Off 223 Deg F 4 Sec

Engine Shutdown(3) Off 225 Deg F 4 Sec




High Auxiliary Pressure

Warn Operator(1) Off 218 PSI 4 Sec

Engine Derate(2) Off 218 PSI 3 Sec

Engine Shutdown(3) Off 218 PSI 3 Sec



ENGINE CANOPY

There are two clasps on either side of the engine that need to be undone.

The dip stick is situated at the rear of the engine nearest the hydraulic tank.

The oil should be checked on a daily basis.

Clasps

Gas locking strut, To close the canopy push in the gas strut outer cover then pull

down the canopy

Dip stick



40 Amp customer supply. This is for the supply going to the Terex Pegson panel

Caterpillar ET connectionMaintenance reset button

15 Amp EMS (ECM) supply

Thermal Overloads on the C13 Engine

90 Amp for Alternator

15 Amp Ignition Supply



Diesel Filler Cap

The filler cap is accessible without opening the engine canopy. Always fill the tank through the strainer.


1300 Maxtrak 100309 issue 2Engine Air Filters

An indicator is attached on the outlet pipe to show the condition of the filter.

The filter cleaning / changing intervals are all down to the operating conditions.

The outer air filter is the only one that should be blown out with an airline, not the inner.


1300 Maxtrak 100309 issue 2Engine Coolant Level

The coolant level needs to be checked on a daily basis.

It is important that the coolant level is within 30mm(1 3/16”) of the top of the radiator because there is a low level sensor that will stop the engine and flash

the warning light.

Level sensorWarning light


1300 Maxtrak 100309 issue 2Engine Serial Number

The engine number is on the side of the rocker cover


1300 Maxtrak 100309 issue 2Engine Fuel Filters

There are 2 fuel filters filters fitted to the engine.

The 1st one is a primary filter (14 micron) with a water separator.

The second one is a 2 micron filter.

They both have 250 hour service intervals.


1300 Maxtrak 100309 issue 2ECM Plugs

The ECM is the electronic control module for the engine.

Whenever any welding is done on the machine the battery isolator key must be turned off, negative battery lead removed and the ECM plugs must

disconnected (Note, always put the welding earth cable on/beside the unit that is being welded).

The plugs are held in by a bolt and require a 4mm allen key to remove them.

ECM Plugs

4mm Allen key



Hydraulically Operated Clutch (HFO)

As the clutch is engaged hydraulically there is no adjustment necessary for the clutch plates as they wear.

The end bearing on the clutch shaft runs in oil not grease so the oil level needs to be checked on a daily basis.

The oil is SAE 30 or 40 and requires changing every 1000 hours.The bearing housing only holds 200 cc (0.05 US Gal) of oil which is indicated

by a notch on the dipstick.

DipstickOil level



Conveyors



Discharge Conveyor Head Drum Bearings

2 shots of EP2 grease once a week

Grease nipples on grease pipes



Skirting Rubbers

Also make the skirt rubbers for the discharge conveyor as long as possible.Ensure that the feed boot skirt rubber overlaps the first barge board skirt

rubber.



Discharge Conveyor Tail Drum Bearings





Feed Conveyor Tail Drum Bearings




1300 Maxtrak 100309 issue 2Feed Conveyor Head Drum

The feed conveyor has a small motor connected to a gearbox to achieve maximum torque from the available oil supply.

The gearbox is lubricated with 0.8 litres (0.21 US galls) of V G 150 gear oil.The initial oil change is between 50 - 100 hours and 2000 hours there after.

Check the oil level in the feed conveyor gearbox every month, should be half way up the sight glass at 3 °Clock position.

Grease the bearing with two shots of E P 2 grease every week.

Sight glass

Motor

Gearbox Grease nipple



Skirting Rubbers

Always replace the skirt rubbers once they become worn or damaged.

Always make the skirt rubbers on the feed conveyor in one long piece.



Feed Belt Adjustment

The feed belt is adjusted from the rear end and the belt needs to be kept tight at all times to prevent the head drum from slipping

Always keep the tail drum square when tensioning the belt otherwise the belt will get stretched on one side and make belt tracking difficult.

To tension the belt slacken off the locking bolts and lock nut and turn the adjusting stud anti clockwise.

Locknut

Locking bolts

Adjuster

Measuring point (keep equal on

each side )Adjusting

stud



Feed Belt Tracking

DOT



Beckford Speed Wheel

The speed wheel on the inside of the product conveyor belt.

Beltspeed

Wheelcircumference

Revs persecond

Pulses perRev

Timeperiod

Pulses persecond

125 m/m 628 millimetres 3.31 2 5 seconds 3280 m/m 628 millimetres 2.12 2 5 seconds 20




DOT




L/H

Belt Direction

D.O.T

R/H



Remote Control Systems


1300 Maxtrak 100309 issue 2840 Remote Control

LED Red/Green

Remote OnTrack SirenRemote Feeder Start/StopEngine Stop



840 Teleradio Remote Control

Battery Isolator positionLED On Off

Engine Stop

Battery Isolator

Charging Point

12 v dc Cigarette Lighter Charger



Teleradio 840 New A Type Charger

The new A type chargers are 12 / 24 volts.

The charger clips into the back of the transmitter.

The output voltage from the charger is 9.6 volts.




LED Battery Pack

• The LED indicates the battery condition

• Green indicates batteries are good

• Red indicates batteries are going flat and will shut the machine down in 1 hour, the siren will sound when the LED turns red.

• 12 hours run down time from fully charged

• Charge time approx 1.5 hour from flat



Teleradio Umbilical Control

The older type umbilical controls are fitted with a 6 or 15 pin plug (Photo is a 15 pin unit).

The function of the buttons are the same as the remote but for tracking only.



Teleradio Umbilical Control

The latest type umbilical is fitted with a heavy duty 16 pin plug and socket.

The function buttons remain the same.



840 Teleradio, Remote Control Tuning (frequency)

The frequency of the machines is set at random to eliminate interference if there are 2 machines working together.

The frequency is set by dip switches at the back of the frequency modules.

Open up the transmitter and remove the teleradio frequency module by removing the two screws.




The four dip switches on the radio module in the receiver box are on the underside, so the cable tie needs cutting to gain access.

The only time these dip switches need to be changed is if interference is effecting the remote control .

To change the frequency, move the position of the switches ensuring that both frequency modules are in the same position.




Switch positions for operating frequency’s-



840 Teleradio, Remote Control Tuning. ID Code

For a transmitter to operate with a receiver unit there is also an ‘ID code that have to match between the 2 units.

The frequency module needs to be removed in the transmitter to gain access.

There are 2 rows of 8 dip switches which are in series in the receiver and transmitter.

The 2 switches on their own in the receiver should be in the off position. If any of them are on, it will switch of the transmitter if none of the buttons

are pressed within a certain time period.




The new 860 remote control has a white face and red buttons.

The isolator key on the rear has now been removed.

The transmitter can accept 12 to 35 volts DC.

The function buttons operate the same as the 840 unit(including the umbilical).

LED’s123

Button numbers




The frequency modules in the transmitter and receiver are not removable so there is no need to open anything to change the frequency.

1. Press the 9 and 0 buttons for at least 1 second, release 9 but keep 0 depressed.

2. Release 0 and press 8 within 0.3 seconds. The yellow LED(2) lights continuously and the green LED(3) flashes.

3. Enter the pin number 1 2 3 4 then the yellow LED(2) goes out and the green LED(3) flashes. This indicates the pin number has been entered correctly.

4. Enter 1 of the 16 channel numbers to set the frequency. Note. For single digit numbers 0 must be pressed first.

5. The yellow LED flashes 3 times and then the transmitter switches off.

The frequency change has now been accepted.

Note. Each time a button is pressed the yellow LED(1) lights also.




CHANNEL NUMBER FREQUENCY MHz01 434.65002 434.60003 434.55004 434.50005 434.45006 434.40007 434.35008 434.30009 434.25010 434.20011 434.15012 434.10013 434.05014 434.00015 433.95016 433.900



860 Teleradio Receiver Unit

Transmitter signal strength

Reset button

E Stop relays

Power supply

Power LED’s

4 5 6 8 9 10

No. of transmitters programmed

Fault LED’s

Function selector

12

3



860 Teleradio, Status LED’s In Receiver

Green LED 1- This indicates the strength of signal that the receiver is getting from the transmitter.

Reset button(2)- This puts the receiver into ‘the learning mode’ where it will tune itself into the transmitter.

Yellow LED(3)- When this LED is illuminated it means that the receiver is powered up.

Yellow LED(4+8)- This flashes when a transmitter is programmed to the receiver.

Red LED(5+9)- This indicates faults on the receiver.

Green LED(6+10)- This lights up when the receiver locks onto a transmitter signal.

Selector switch 2




1300 Maxtrak 100309 issue 2860 Teleradio, Programming A Transmitter I D Code Into A Receiver

1. In the receiver unit turn the function selector switch 2 to the ON position.

2. Press the red reset button. Both sets of green red and yellow LED’s should illuminate.

3. Release the reset button. The green and red LED’s should go out. The yellow ones should remain illuminated.

4. Press buttons 9 + 0 simultaneously to power up the transmitter.

5. Press buttons 9 + 0 simultaneously again until the yellow LED’s start to flash. This indicates the receiver has found the transmitter.

6. On the receiver unit turn the function selector 2 switch to the off position.

7. The receiver is now programmed to the transmitter.


1300 Maxtrak 100309 issue 2860 Teleradio, Erasing A Programmed Transmitter From A Receiver

1. Turn the function selector switch 2 to the ON position.

2. Press the reset button. The green red and yellow LED’s should light continuously.

3. Release the reset button. The green and red LED’s should go out. The yellow ones should remain illuminated.

4. Turn selector switch 2 to the off position.

5. Turn switch 2 to the on position within 2 seconds. The yellow LED’s should flash. This indicates the receiver has been erased.

6. Turn the function selector switch 2 to the off position.


1300 Maxtrak 100309 issue 2Programming A Teleradio 860 Transmitter Into An 840 Receiver

The 840 transmitter is no longer available so all new transmitters are 860’s.

The 860 transmitter can be configured to operate as an 840.

If an 840 receiver fails the receiver and transmitter will have to be replaced because an 840 transmitter will not operate with an 860 receiver.

1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.

2. Release button 9 but continue to hold button 10.

3. Release button 10 and press button 6 within 0.3 seconds. The Yellow LED should illuminate and the green LED should flash.

4. Enter the safety code 4,9,2,7,6,5. Each button has to be pressed within 5 seconds of each other. The green LED flashes and the yellow one goes out.

5. Enter 0 for 860 mode or 1 for 840 mode. The yellow LED flashes 3 times and then the transmitter switches itself off.


1300 Maxtrak 100309 issue 2Tuning The Transmitter Into An 840 Receiver

1. Switch on the transmitter by pressing buttons 9 + 0 for at least 1 second.

2. Release button 9 but continue to hold button 10.

3. Release button 10 and press button 5 within 0.3 seconds. The green LED should flash.

4. Enter the receiver ID code(5 numbers).Example:ID-code 2594 will be 02594

5. Once the code has been entered the yellow LED flashes 3 times and the transmitter switches off.

Note. If at any time the ID on the receiver was changed the programming will not work because the ID code will be incorrect for the dip switch position.



Tuning The Transmitter Into An 840 Receiver

Remove the frequency module to see the position of the dip switch’s.

Compare the position of the switch’s to the frequency chart to establish the frequency and the channel number.

Carry out the frequency change procedure and the 2 units will now function.

CHANNEL NUMBER FREQUENCY MHz01 434.65002 434.60003 434.55004 434.500



General Maintenance


1300 Maxtrak 100309 issue 2General Maintenance

When the Maxtrak plant is operated in extreme climatic conditions, e.g. below -15oC (5oF) or above 30oC (86oF) or in very dusty conditions for a long period of time, the maintenance schedules will change.

Failure to carry out scheduled maintenance or exercise due care may invalidate any warranty that might apply.

Keep a accurate record of maintenance work carried out to the hours on the engine.

The Maintenance records can also be used to show compliance with the required maintenance practices and intervals.


1300 Maxtrak 100309 issue 2Cleaning The Frame Arm Shields

It is essential that the frame arm shields are checked on a daily basis to ensure that there isn’t any material build up.

Failure to do this will result in the seal ring getting damaged or worse still lifting the cone head.



Maintenance Schedule



Maintenance Schedule



Recommended Oil/Grease Types





Tracks

Check oil level monthly6 litres (1.6 US galls) SAE 80w/90 Gear Oil

Change oil thereafter every 1000 hours or AnnuallyFirst oil change at 100 working hours

Level PlugFiller Plug Drain Plug



Track Tension

The tracks are tensioned by pumping EP 2 grease into the track tensioner grease nipple when required.

Grease NippleCover



Track Tension

Span the tracks with a straight edge between the longest section of tracks that’s unsupported. The tracks should have 15mm (5/8”) of sag.



Track Tension

If there is less then 5mm of sag in the tracks, it will be necessary to let off some tension. To do this slowly unscrew the grease nipple until it releases

grease .

The grease nipple is under extreme pressure so never remove it until the grease has stopped coming out.

Recess for grease extraction

Grease Nipple



Hydraulic Tank

Check hydraulic oil level weeklyChange the filters (suction, inline, return) every 1000 or sooner if the tell-tale

indicator shows REDChange the hydraulic oil every 2000 hours, 360 litres (96 US galls)

Use 46 grade hydraulic oil if the ambient temperature is below 86º F (30º C).

Breather

Return filter

Level float switch/ sight gauge. Oil level should be 40mm below top of sight gauge

Inspection covers

Inspection covers are fitted to the side of the tank to clean it out when the oil is changed.

Use 68 grade hydraulic oil if the ambient temperature is above 86º F (30º C).



Hydraulic Tank Float Switch/Sight Gauge

Don’t fill the hydraulic tank above the sight glass because it will throw oil out through the breather when the it is tracked about with hot oil

If the oil drops down to a low level the float switch will shut down the engine to prevent the pumps being starved of oil and damaging them.



Hydraulics

Check the condition of the suction and return filters weekly .

The suction and return filters both have indicators fitted to establish the condition of the filters.

Unscrewing the shut off valve locks the oil in the hydraulic tank to prevent oil loss when changing the suction filter element

Return FilterFilter indicator Suction Filter

Filter indicator

Shut Off Valve



Hydraulics

Check the condition of the inline filters weekly .

There are two inline pressure filters fitted either side of the engine canopyBoth are fitted with red /green indicators. Red = Blocked. Green = Good. They will indicate red in cold temperatures when the hydraulic oil is thick

Inline Pressure FilterFilter Indicator



Hydraulics

The two inline pressure filters for the crusher adjustment circuit require changing every 650 hours (4 months).

Inline pressure filter

(feed in)

Inline pressure filter

(return)



Releasing The Wedge-Ring For Greasing

Wedge-ring pressure

Wedge-lock pressure

Wedgelock shut off valve (normally closed Valve B )

Wedgelock shut off valve (normally open Valve A )



Wedge-Ring Greasing

Once the wedge ring has been released the upper frame needs to be positioned so that the bottom of the upper frame inline with the spacers under the

dumpy jack.

Upper-frame grease nipples (12 off )

With the upper frame in this position the grease nipples are situated in between the two wedge ring pads.

Upper-frame greasing position



Wedge-ring Greasing Procedure

If the upper frame gets tight and doesn’t travel smoothly or it requires more than 1200psi (82 bar)to close it down it will be necessary to grease the wedge ring. 1. Put the machine into manual

2. Close valve A and open valve B. The pressure should drop to zero on the wedge lock pressure gauge

3. Open and close the upper frame until there is no pressure registering on the wedge ring pressure gauge as you press close 4. Position the upper frame so that the bottom of it is inline with the dumpy jack shelf. In this position the grease nipples are positioned in-between the wedge ring pads

5. Grease all 12 of the grease nipples with “Moly Bentone MP Grease” (part no 2123-2001). Travel the upper frame up and down to spread the grease

6. Close valve B and open valve A. Select a closed side setting and and the wedge ring circuit will charge up with oil pressure.



Wedge-ring Greasing Procedure (cont)

7. Fully open and close the upper frame and check the travel. The ideal wedge ring pressure is 800 to 1200psi (55 to 83 bar) as you press close.

8. If the travel is not smooth or the pressure is too high, repeat the greasing procedure.



Hydraulic Pump Drive Belts

Check the belt tension weekly and adjust as necessary.

The belt deflection should be kept to approximately 5mm (3/16)at all times

Always look down the belts and square up the pump. The back-nuts enable you to push the rear end for alignment

Drive Belts PumpAdjusting Bolts Locking Bolts (4 off)

Back nuts



Crusher Drive Belt Adjustment

The belt tension needs to be checked weekly. Check for damage, wear and fraying. This can be checked though the inspection door.



Crusher Drive Belt Adjustment

1. Slacken the drive guard support bracket.2. Back off the 4 bottom nuts on the adjusting studs (nuts A)

3. Tighten the top nuts to raise the engine.4. Ensure the engine is level by measuring it in each corner and lock in position with the lower nuts. Tighten the drive guard support bracket.

Drive guard support bracket

Engine adjusting stud (4 off )

Keep the engine levelNut A

Nut B



•Weekly check the condition of both the feed conveyor belt and the product conveyor belt, check for damage or fraying.

•Weekly clean away dust, dirt and grit from the maintenance platforms and any moving parts.

•Weekly check Lubrication oil cooler matrix is clean.

•Weekly check the Hydraulic oil cooler matrix is clean.



Changing Wear Parts



Crusher Wear Parts

Take note of the “wear” shown on the Paktronic display. Also check this to the pin centres when the machine is closed metal to metal minimum pin centres should be 774mm. Always fit both a new

mantle and a new concave at the same time as it is detrimental to the

operation of the machine to do otherwise.



Crusher Wear Parts

The mantle nut has replaceable wear plate bolted to it to pre-long the life of the nut .

Hit the wear plate on the top and on the sides with a sledge hammer and also hit the 4 countersunk bolts before trying to undo them. This will free them off

and make them easier to undo.

When a new wear plate is fitted fill the 4 holes full of silicon to make the removal next time easier.

Wear plate

Mantle nut


1300 Maxtrak 100309 issue 2Crusher Wear Parts



The mainframe arm supports are fitted with replaceable arm shields to prevent any wear.

The frame arm shields just drop over the arm support as does thecountershaft arm shield but the countershaft shield locates over a key-way to

prevent it from moving.The head and eccentric need to be removed from the machine to replace them

so plan to do it when the machine is being re metalled.

Countershaft arm shield Key Frame arm shield x 3



The mainframe also has welded in liner plates fitted all of the way around it.

So provided that all liners and arm shields get replaced before they wear through no wear should take place on the main frame.

Liner plates



Changing The Mantle And Concave


2. Close valve A and open valve B. The pressure should drop to zero on the wedge lock pressure gauge.

3. Open and close the upper frame until there is no pressure registering on the wedge ring pressure gauge as you press close. Leave the upper frame about 5mm (3/16)from being fully open.

Wedge ring pressure

gauge

Valve A Valve B

Wedge lock pressure

gauge


1300 Maxtrak 100309 issue 2Raising The Feed Conveyor

Fully raise the feed conveyor and place the pins in the bottom holes.

Lower down the feed conveyor so that it sits on the pins.


1300 Maxtrak 100309 issue 2Feed Ring

Remove the three retaining bolts from the crusher feed chute and lift off the crusher feed chute.

There are 2 holes in the top of the feed ring for the lifting point.


1300 Maxtrak 100309 issue 2Linear Transducer

Disconnect the stud from the mainframe that is attached to the linear transducer.

Push the transducer all of the way down so that the stud cannot foul on the upper frame when it is lifted off.


1300 Maxtrak 100309 issue 2Changing The Mantle And Concave

Using a set of three leg chains take the weight of the upper frame from the lifting lugs.

The upper frame weighs 4 ton (4.5 US ton) but use a set of chains of twice that capacity to allow for drag on the wedge ring.

Lifting lugs x 4


1300 Maxtrak 100309 issue 2Upper Frame Pins

Remove the six split pins and washers from the right hand side of the pins.Knock out the pins from right to left with a hammer and punch. They have to be knocked out in this direction because the bearings in the upper frame are butted against a shoulder and get dislodged if the pins are removed from the

other direction causing premature bearing failure.Take care when removing the the last pin because the upper frame may move

if there is too much or too little weight on the chains.


1300 Maxtrak 100309 issue 2Upper Frame Removal

Slowly lift off the upper frame ensuring there is equal weight on each chain and the upper frame is lifting off squarely.

DO NOT FORCE THE UPPER FRAME OFF WITH THE CRANE IF IT IS TIGHT AS IT WILL CREATE A DANGEROUS SITUATION WHEN IT

COMES FREE.If the upper frame is tight jack it off from the underside.


1300 Maxtrak 100309 issue 2Releasing The Mantle Nut

As the mantle wears it also spreads which applies a massive amount of pressure on the mantle nut preventing it from being undone.

Mantle nut

Mantle

To release the pressure of the nut you need to burn through the burning ring all of the way around, within 20mm (3/4”)of the mantle nut. Weaving the cut

will ensure that the pressure is better relieved off the nut.

Burning point


1300 Maxtrak 100309 issue 2Unscrewing The Mantle Nut

Clean out the dirt from the square hole in the top of the mantle nut and slide in the flogging bar.

Using a sledge hammer knock the nut undone.THE NUT IS LEFT HAND THREAD. ROTATE CLOCKWISE TO LOOSEN.

Flogging bar


1300 Maxtrak 100309 issue 2Removing The Mantle Nut

Slide a bar through the nut and remove it with the crane.


1300 Maxtrak 100309 issue 2Removing The Mantle

Loosen the mantle by hitting it with a sledge hammer. Using a couple of pry bars lift up the mantle and drop a chain down the inside. Place the hook back

onto the chain at the top of the mantle.Alternatively two lifting lugs can be welded to the mantle. Ensure that the

correct type of welding rod is used and a sufficient amount of weld is applied to hold the weight.


1300 Maxtrak 100309 issue 2Removing The Mantle

As the mantle is lifted off take care not to damage the threads on the cone head.


1300 Maxtrak 100309 issue 2Removing The Concave

Clean the dirt away from the underside of the three lugs and burn them off.Cleaning under the lugs eases burning and allows the lug to be cut off in one

attempt.As with the mantle weaving the torch makes it easier to get a clean cut.

Take care not to damage the wedges when burning off the lugs.

Lug x 3


1300 Maxtrak 100309 issue 2Removing The Concave

Once the lugs have been burnt off the concave can then be knocked out using a sledge hammer.



Preparing The Upper Frame

Lift the upper frame away from the concave and clean the inside where the concave was fitted.

Remove the worst with a scraper then use either a sanding pad or wire wheel.

Preparing the upper frame in this way will make it easier to remove the concave next time.

Remove the wedges and dowels and clean them up as necessary.


1300 Maxtrak 100309 issue 2Preparing The Upper Frame

Check the lower seating area where the concave fits for burrs and remove them with either a sanding disk or grinder depending on the severity.

Smear the inside of the upper frame with release agent where the crusher backing sits ensuring there is plenty around the three pockets.

A thin smear of grease can be used if release agent is not available.


1300 Maxtrak 100309 issue 2Preparing The Upper Frame

Smear the inside of the upper frame with release agent where the crusher backing sits ensuring there is plenty around the three pockets.

A thin smear of grease can be used if release agent is not available.


1300 Maxtrak 100309 issue 2Preparing The Concave

Clean up the taper on the concave to remove the anti rusting agent and check for burrs and dress a necessary.

Taper



Preparing The Concave

On flat ground turn the old concave upside down and sit it on 3 pieces of wood 100mm (4 inch) thick evenly spaced. Sit the new concave on top of the

old one.

If 3 or 4 big blocks are available the concave can be sat directly on top of them, but ensure the blocks don’t stick out beyond the taper.

If the taper on the upperframe looks a little worn a bead of silicon can be put on the taper to prevent the crusher backing from leaking out.


1300 Maxtrak 100309 issue 2Fitting The Concave

Lift up the upper frame and lower it down onto the new concave.Guide the upper frame so that the 3 lugs on the concave pass through the 3

pockets in the upper frame.

As soon as the lugs clear the top of the upper frame rotate the upper frame anti clockwise so that the lugs on the concave are half way between the dowel

hole and pocket.


1300 Maxtrak 100309 issue 2Fitting The Concave

Using a pry bar seat the concave level within the upper frame.To do this use a tape measure to ensure the distance between the underside of

the lugs and upper frame all the same.Slide in the three wedges ( from right to left) and the rear edge of the wedge

needs to be about 30 mm (1¼) before the dowel hole. If not lift up the upper frame and rotate it. For example if the back of the

wedge has gone beyond the dowel hole the upper frame will need to be rotated clockwise, or rotate it anti clockwise if the wedge is not near enough

the dowel hole.


1300 Maxtrak 100309 issue 2Fitting The Wedges

Drive in the wedges with a sledge hammer. Ideally with 2 people and a tee bar.

ALWAYS WEAR SAFETY GLASSES WHEN DOING THIS.


1300 Maxtrak 100309 issue 2Fitting The Wedges

Drive in the wedges so that the back of the wedge just goes beyond the dowel hole and fit the dowel with anti seize grease.

If the wedge is not tight when it gets to the dowel hole continue to drive it in until it is tight then weld something to the back of it that butts up to the

dowel.

Don’t worry if all three wedges stop in a different position as this is common.


1300 Maxtrak 100309 issue 2Preparing The Cone Head

Clean the whole of the cone head.Burrs may develop on the bottom of the cone head taper so dress them up

with a sanding disk.



Smear the cone head taper with grease.

Smear the rest of the cone head with release agent. If release agent is not available a thin smear of grease can be used.

Cone head taper.



Smear the rest of the cone head with release agent. If release agent is not available a thin smear of grease can be used.

A bead of silicon can be placed on the taper to prevent any leakage.

Cone head taper.

Cone head



Preparing The Mantle

Remove the anti rust agent from the mantle taper and any burrs.


1300 Maxtrak 100309 issue 2Lifting The Mantle

The best way to lift up the mantle is to use a set of 3 or4 leg chains and hook the mantle from the underside.


1300 Maxtrak 100309 issue 2Fitting The Mantle

Lift the mantle and sit it on the cone head.



The mantle will sit on the cone head and trap the hooks. Just Knock out the hooks with a pry bar.



Re fit the mantle nut and tighten to square up the mantle and squash the grease on the taper to create a good seal.

Remove the mantle nut and grease the cone head threads.


1300 Maxtrak 100309 issue 2Crusher Backing

Using a drill and a suitable mixing paddle stir up the crusher backing ensuring to loosen it up in the bottom of the container. Add the hardener and

mix the backing until it is one even colour and texture.


1300 Maxtrak 100309 issue 2Pouring The Backing

Pour the crusher backing between the cone head and mantle until the level is 25mm from the top(1 inch).

Poor any left over backing into one of the concave pockets.

DO NOT OVER FILL THE MANLTE AS THIS WILL MAKE IT DIFFICULT TO BURN ON THE NEXT REMETAL.


1300 Maxtrak 100309 issue 2Mantle Nut Tightening

Re fit the mantle nut and tighten with the flogging bar in an anti clockwise direction. Put a chalk mark on the mantle and nut then tighten some more

until the nut has come to a complete stop.FAILURE TO TIGHTEN THE NUT SUFFICIENTLY WILL RESULT IN THE NUT COMING LOOSE AND POSSIBLE CONE HEAD DAMAGE.


1300 Maxtrak 100309 issue 2Mantle Nut Tightening

Putting a chalk mark is the best way to judge that the mantle nut has come to a complete stop.


1300 Maxtrak 100309 issue 2Cylinders Pins And Bearings

Clean up the cylinders and bearings in the upper frame with emery cloth or a flat wheel. Also clean up the cylinder pins with emery cloth.


1300 Maxtrak 100309 issue 2Wedge Ring Pads

Clean off the wedge ring and brush on a light smear of moly-bentone grease on the pads and on the wedge ring dust seal.


1300 Maxtrak 100309 issue 2Upper Frame

Clean up the inside of the upper frame where the wedge ring pads run. Inspect for any burrs and dress accordingly. If the re metals aren’t very

frequent it may be necessary to clean it with a sanding disk or emery paper to remove any rust or dust and make it smooth again.


1300 Maxtrak 100309 issue 2Re Fitting The Upper Frame

When re fitting the upper frame ensure that the anti rotation block is inline with anti rotation stop. Lower the upper frame down slowly until the block enters the stop otherwise you could rip off one of the stop block fibre pads.

Re fit the cylinder pins with anti seize grease.


1300 Maxtrak 100309 issue 2Pouring The Crusher Backing

Mix the crusher backing one tub at a time and pour it into the 3 pockets of the upper frame. Fill it up until the backing is about 10mm (3/8”) within the

top of the upper frame.

Clean out the stones from the bottom inside lip of the crusher feed chute and re fit.

Remove the pins from the feed conveyor and lower into the working position.


1300 Maxtrak 100309 issue 2Recharging The Wedgelock Circuit


2. Close valve B and open valve A.

3. Select a css below the actual setting and put the machine into auto. The upper frame will come down to its setting and then the wedge lock circuit will charge up with oil pressure.

Wedge ring pressure

gauge

Valve A Valve B

Wedge lock pressure

gauge


1300 Maxtrak 100309 issue 2New Manganese Calibration

When the machine is new or when it has been re-metalled the new manganese calibration needs to be carried out. This is done as follows -

1. Ensure the crusher is not running.Put the machine into manual and close the machine until the mantle and concave touch. This is indicated by a sudden rise in pressure on the wedge ring / crushing pressure gauge. Ensure it is metal to metal and no stones are in the crushing chamber.

2. Scroll down the screen using the down arrow until you get to NEW MANGANESE.

3. Press enter.

4. Press F4 and it will re-calibrate everything back to zero.

5. Press escape.

6. Scroll back up to current gap / set gap display.

7. Set new closed side setting.

8. The read wear will now be zero.



Basic Hydraulic System


1300 Maxtrak 100309 issue 2R/H Side Hydraulic Pump

Two identical pumps are mounted either side of the engine, belt driven from the engine crankshaft.

This pump supplies oil to the three bank valve.

To the 3 bank valve

The oil is drawn through a suction filter into the pump, through an inline pressure filter and into the three bank valve.

Drive belts

Pump

Suction

Pressure Filter


1300 Maxtrak 100309 issue 2Three Bank Valve

The three bank valve is mounted inside the engine Canopy near the pump.The first section is the feed and return to the valve.

The 1st splice goes to the tracks.The 2nd splice goes to the product conveyor and HFO clutch. The clutch line

tee’s into the feed line for the discharge conveyor.

The 3rd splice goes to the crusher adjustment circuit.

To the HFO clutch

To the crusher adjustment circuit

To the discharge conveyor

To the R/H track

Feed in

To tank


1300 Maxtrak 100309 issue 2R/H Track

Track cover plate


1300 Maxtrak 100309 issue 2Track Drive

The feed comes in to the Motion Control valve bank and automatically releases the brake.

The two track motors tee the case drains together before going to tank The purpose of the cross line check valve is to prevent the machine from

running away on a steep slope or if a pipe bursts

Motor Case DrainBrake ReleaseTrack MotorTrack feeds

Motion Control

valve block



Hydraulically Operated Clutch

The feed to the clutch comes through the restrictor valve, then the solenoid valve and then a relief valve before going to the clutch.

Relief valve

Solenoid valve

Restrictor valve

Pressure switch

Accumulator



H.F.O Clutch Circuit

De energised

With the divertor valve in the off position, the oil comes through the restrictor valve and dead heads against the divertor valve. The purpose of the orifice

and restrictor valve is to limit the amount of oil flow going through the clutch circuit.

(1.3 gal)

(334 psi)

(479 psi)




Energised

When the divertor valve is energised the spool moves to allow oil to pass through and go to the clutch. The pressure switch changes over to indicate

good oil pressure and allows the feeder to be started.

The relief valve ensures that 33 bar(479psi) is maintained in the system.

(1.3 gal)

(334 psi)

(479 psi)


1300 Maxtrak 100309 issue 2Product Conveyor Motor

The feed comes in through a check valve and into port B in the motor.

The check valve is fitted to prevent the belt running back if it stops loaded.

The case drain is fitted to prevent any back pressure going to the motor shaft seal.

Return Line (A Port)

Feed Line (B Port)

Check Valve Case Drain


1300 Maxtrak 100309 issue 2Crusher Hydraulic Adjustment

Pressure in from the bank valve



L/H Hydraulic Pump

The left hand pump supplies oil to the four bank valve at the back of the machine.

Pump case drain

Load sensing line

To the bank valve



Four Bank Valve

The 1st splice goes to the tracks.The 2nd splice goes to the feed conveyor.

The 3rd splice goes to the feed conveyor raise / lower cylinder.

The 4th splice goes to the lubrication pump motor.

4

Feed in

To tank

3 12


1300 Maxtrak 100309 issue 2L/H Track

Track cover plate


1300 Maxtrak 100309 issue 2Feed Conveyor Motor

A check valve is fitted to stop the belt from rolling back when it is stopped under load either by the milltronics or the metal detector.

Feed line

Return line

Case drain

Check valve


1300 Maxtrak 100309 issue 2Feed Conveyor Cylinder

Up Down Check valve

BreatherSingle acting cylinder with a check valve safety

Manual operation



Hydraulic Motor For Lubrication Pump

Feed Return



Hydraulic System Setup


1300 Maxtrak 100309 issue 2Hydraulic Pump

Pump Relief Valve 320 bar (4641 psi) (when test point on valve bank is used)

Standby Pressure Relief

30 bar

(435 psi)

Load Sensing Line

The hydraulic pump only delivers oil flow on demand, unlike fixed gear pumps. The standby pressure is set at 30 bar (435psi) and the pump will

deliver a small amount of oil to maintain that pressure. When a function is operated, the pump detects a pressure drop on the 30 bar (435 psi) and the swash plate is moved to pump more oil. This happens in a split second. The system always maintains 30 bar(435psi) more in the pressure line than the

load sensing line. Case Drain


1300 Maxtrak 100309 issue 2Hydraulic Pump

When all functions are switched off the pump will de-swash and return to a low flow maintaining the 30 bar (435psi)stand by pressure.

The pump has its own relief valve set at 320 bar(4641psi). If the pressure exceeds 320 bar(4641psi), the pump will de-swash, drop to a low flow but

maintain 320 bar(4641psi).

Standby Pressure Relief 30 Bar (435psi)

Load Sensing Line

Case Drain

Pump Relief Valve 320 bar (4641 psi) (when test point on valve bank is used)



Section View - 57 CC/Rev. Full Stroke

Tapered Roller Bearing

Swash plate

Bias Piston

Rotating Kit

Valve Plate

Piston

Servo Piston

Shaft Seal

Tapered Roller Bearing



Swash Plate Operation

• Two piston design.

• Bias piston uses system pressure to hold pump at full stroke.

• Servo piston• Three times bias piston area.• The servo piston is the control

piston.

Servo Piston

Bias Piston

Swash plate



Load Sense Operation Theory

Control Handle

Valve /Orifice

System Pressure

Load Pressure

Pump

Flow to Servo Piston



CONTROLVALVE

BIAS

X PORT

M4 Port

B Port

Remote Port

S portL1,L2 Ports

Bleed Orifice (LBControl)Plug (LS Control)

Gain Orifice (Optional)

Load Sensing Circuit

Engine running. No function selected.

Stroked to give 2cc / rev

M Port blocked.

0 bar.

30 bar (435psi).

Bank valve

.



CONTROLVALVE

BIAS

X PORT

M4 Port

B Port

Remote Port

S portL1,L2 Ports



.


Engine running. Product conveyor selected.

55 litres min @ 50 bar (13.2 US gal min @ 725psi)M

Stroked to give 31 / rev

50 bar (725psi).

80 bar (1160psi).

Bank valve



CONTROLVALVE

BIAS

X PORT

M4 Port

B Port

Remote Port

S portL1,L2 Ports





Engine running. Tracks selected.

90 litres min @ 180 bar (23.7 gal/min @ 2610psi).M

180 bar (2610psi).

210 bar(3045psi).

Bank valve



LS WITH LOAD AT PC SETPOINT

CONTROLVALVE

BIAS

X PORT

M4 Port

B Port

S portL1,L2 PortsGain Orifice (Optional)



Engine running. Tracks selected + stalled


3 litres min @ 290 bar (1 gal/min @ 4205psi)M

290 bar(4205psi)

320 bar (4640psi).

Bank valve

.



Three Bank Valve 2550-9010

The three bank valve has a main relief valve set at 350 bar (5076psi). This is a last line relief to protect the pump should the pump relief not respond quick

enough. The product conveyor LS relief is set at 210 bar (3046psi)The hydraulic pressure in the system can be taken from a test point on the bank valve. On the 4 bank valve when there are two circuits are working at

once, the pressure gauge will only read the highest of the two, not a combination of the two.

System Test Point

Main pressure

relief 350 bar

(5076psi)Product conveyor relief

210 bar (3046 psi)



System Test Point

Any pressure registered from the test point is inclusive of the standby pressure.

So if the pressure registered from the test point was 80 bar(1160psi) with the product conveyor running the actual pressure in the product conveyor feed

line would be 50 bar (725psi).

System Test Point


1300 Maxtrak 100309 issue 2HFO Clutch Circuit

Where the HFO clutch line tee’s into the product conveyor line a 1mm (0.04”)orifice is fitted inside one of the hydraulic fittings to reduce the oil flow.

The needle valve is used to accurately set the oil flow for the clutch engagement.

With the orifice fitted if somebody unscrews the needle valve too much it shouldn’t stop the product conveyor.

1mm(0.04”) orifice Needle valve




De energised

With the divertor valve in the off position, the oil comes through the restrictor valve and dead heads against the divertor valve. The purpose of the orifice

and restrictor valve is to limit the amount of oil flow going through the clutch circuit.

(1.3 gal)

(334 psi)

(479 psi)




Energised

When the divertor valve is energised the spool moves to allow oil to pass through and go to the clutch. The pressure switch changes over to indicate

good oil pressure and allows the feeder to be started.

The relief valve ensures that 33 bar(479psi) is maintained in the system.

(1.3 gal)

(334 psi)

(479 psi)



3 Bank Valve Reliefs (2550-9010)

The track splice doesn’t have a relief valve built into it. The pump will de-swash or it will relieve through the main bank valve if the pressure gets too high.

The main bank valve relief is set at 350 bar (5076psi)The product conveyor is set at 210 bar (3045psi)

Relief Valve 210 Bar

Main Bank Valve Relief

350 Bar Relief Valve 200 Bar

Product conveyor

TrackCrusher

adjustment

The crusher adjustment is set to 200 bar (2900psi)

5076psi

3045psi

2900psi



4 Bank Valve Reliefs (2550-9046)

No relief fitted to the track splice.

The main bank valve relief is set at 350 bar (5076psi)The feed conveyor is set at 180 bar (2610psi)

The feed conveyor folds are set at 100 bar (1450psi)

The lubrication motor is set at 140 bar (2030psi)

Track

Feed conveyor

Feed conveyor

foldLubrication

motor

Main Bank Valve Relief

(350 Bar) (5076psi)

100 bar (1450psi)

180 bar (2610psi)

140 bar (2030psi)



Approximate Bank Valve Voltages with 24 Vdc supply

Lubrication motor Earth Pin to Pin 2

Reverse Low Speed 16v

Forwards High Speed 5v

Tracks Feed conveyorEarth Pin to Pin 2

5-10v

Reverse High Speed 19vForwards Low Speed 8v

Earth to Pin1 = 24v

Feed conveyor

Track Lubrication motor



Actuator Pins

Pin 1 is the supply voltage into the actuator.Pin2 is the variable voltage into the actuator which controls the spool

direction and spool travel for variable oil flow.

None of the pins receive any voltage until a track button is pressed.

Pin 1. Pin 2.Earth.



Actuator Pins

There are only 2 wires used on the on / off type actuator.

Pin 1 receives 24 volts which moves the lever up which pressurises out of the bottom port. (as the valve is shown)

Earth.

Pin 1 24 volt


1300 Maxtrak 100309 issue 2Spool Travel with 24 Vdc supply voltage

12 volts

19 volts

Lever travels down to pressurise out of the bottom port. (as the valve is mounted)

Lever travels up to pressurise out of the

top port. (as the valve is mounted)

Max spool travel Max flow

No spool travel no flow

Max spool travel Max flow 5 volts



Full Speed Voltages

•Feed conveyor Actuator Requires 25% Of Battery Voltage To Obtain Full Speed.

•Example

24 Volts x 25 % =6 Volts

•Track Actuators Require 25 % Or 75 % Of Battery Voltage Depending On Spool Direction



•In the event of a feeder speed control switch failure, a link wire between the supply voltage and the variable voltage on the Hirschman plug will

give full speed.



Actuator Identification

Three types of actuator are fitted to the bank valves. The track and feed conveyor actuator look the same but are different. The feed conveyor actuator is more sensitive and can move the spool more gradually for a wider range of oil flows. The feeder actuator can also be identified by an LED. The track and feed conveyor work on a variable voltage where as the others are 24 volt on or

off. The LED should be illuminated green when the feed conveyor is operating.

Track Number 157B4128

Feed conveyor Number

157B4088

Motor circuits

157B4228Feed conveyorTrack Lubrication

motor

LED

PVEM PVEH


1300 Maxtrak 100309 issue 2PVEM/PVEH

Ptank: 8 barUDC: 24 VFreq: 0,02 Hz

+8

+6

+4

+2

0

-2

-4

-6

-8



Actuator Operation

Electronics

Pilot-oil

Closed loop control of the main spool

Electronic sender unit

Valves Locator pin



Actuator Operation

Locator pinO rings



Body Identification

All of the splices in the bank can be identified by the numbers on the bottom.

Track body number 6000Inlet body number 5111All other body numbers 6203

All of the end caps are the same.

The only difference between the track body and the other bodies are the relief valves.

Engraved numbers End cap

5111 6000 6203 6203 6203

Inlet



Spool Sizes on Four bank Valve 2550-9046

The oil flow through each splice depends on the size of the spool fitted.

The spools should move smoothly in the body.The spool can be removed by unscrewing the four allen bolts from the

aluminium cover and removing. The spool can then be pulled out. Oil loss can be reduced by blanking off the feed and return pipes to the bank valve.

Tracks 100 l/min (26.4 US gal)

Lubrication motor 15 l/min (3.9 US gal)

Feed conveyor 75 l/min (19.8 US gal)

Feed conveyor fold 25 l/min (6.6

US gal)•Spool

Removal



Spool Sizes on Three Bank Valve 2550-9010

Product conveyor

TrackCrusher

adjustment

Tracks 100 l/min (26.4 US gal)

Product conveyor

100

Crusher adjustment

4

26.3 US gal

1.05 US gal


1300 Maxtrak 100309 issue 2Spool Sizes

The size of the oil groove in the spool determines the oil flow.

The bigger the groove the greater the flow.

The spool size can be identified by the Danfoss number etched into the end of it.



PVG32 Bank Valve Cross Section

The pressure compensator ensures the the valve delivers a constant oil flow regardless of the working pressure.

Spool

Pressure compensator


1300 Maxtrak 100309 issue 2Spool Direction

The direction of the spool determines which port is pressure and which is the return.

Tank Pressure

Load sensing


1300 Maxtrak 100309 issue 2Spool Travel Limit Screws

The limit screws are used to restrict the spool movement to control the amount of oil flow to set up the correct speeds.Note. When fitting a new Valve block the limited screws are set to give maximum flow, therefore need to be adjusted to give the correct speed.

If the limit screw is less than 13mm(1 /2”) from the tip of the screw to the valve body, it means that the spool is being restricted (or 8mm from the tip of the screw to the top of the nut

The arrows below show the top screw restricts the travel to the

right and the bottom screw restricts it to the left

8mm (5/16”)

13mm (1/2”)


1300 Maxtrak 100309 issue 2Hydraulic Schematic Drawing AX860-193-601 issue 6



Motion Control Valve



Motion Control Valve Working

Track Brakes = Pressure

= Blue Return

= Case Drain

The pressure comes into the system and sends a pressure down to the brake release which releases the brake.

It also sends a pilot pressure across the X-line check to allow the return oil to flow back to tank.



1300 Final Test Sheet Form 214 Iss 10



Electrical System



PLC display screen.


Cantrak display screen.




PLC Fault Screens



PLC Fault Screens



PLC Fault Screens



Allen Bradley Display Screen Language change

Language Screen Selection

Pressing the “Down” arrow key on any screen, enters Language selection Menu.

Use the “Up and Down” arrows to select the desired language, then press the

“Enter” key to except the language change.

Press “F1” key to escape back to the normal display screen.

Note. Should the screen be left displaying the Language Menu Screen, it will

automatically return to the normal display screen if not touched for 60 seconds.



Maxtrak Electrical Panel

Wiring diagram number

Display Screen

Hycontrol

Contact blocks

Potentiometer, feed belt speed control



Maxtrak Start Up Panel C13 Tier 3 MK17

P L C

24 Volt DC to DC Converter

Radio Control

Relays and Identification

Timer

Circuit Breaker (MCB) and identification



Maxtrak PLC C13 Tier 3 MK17

All of the inputs are numbered from 1 to 15. When an input or output is energised an LED will illuminate below the input / output number.

The inputs appear in order on the electrical drawings.

Embedded D.C Outputs. O/0-O/11

Embedded D.C Inputs. I:0/0-0/15

Expansion D.C Inputs. I:1/0-1/15

Expansion D.C Inputs. I:2/0-2/15

Expansion D.C Outputs.O/12-O/19

LED’s



PLC Lights Maxtrak MK17

If the fault light is flashing on the PLC the display screen usually displays an emergency stop fault but the engine can be started.

There are a couple of checks to carry our if this is the case.

If the fault light is lit permanently lit a new PLC is required.

Power light should be on (green) Run light

should be on (green)

Comm 0 light should flashing green

* fault light should be off *


1300 Maxtrak 100309 issue 2PLC Processor

To remove the processor push the retaining clip to the left and at the same time slide the whole of the processor to the left.

Blow out the pins in the PLC and processor to remove any dust then refit.

Retaining clip



Maxtrak PLC

Open in plastic cover on the left hand side of the PLC to reveal the ‘run rem prog’ switch.

Cover


1300 Maxtrak 100309 issue 2MAXTRAK PLC

Switch on the ignition and let the PLC boot up

Push the switch from the ‘run’ position to the ‘prog’. Wait for 3 seconds and put back into the ‘run’ position. The fault light should now be off.

Switch



Input Output Locks

If the fault light is still flashing there are locking clips that hold

the input / output cards together.

They should be pushed fully to the left to be in the locked position.

If one of the clips unlocks the card and cards to the right of it will go dead and the fault light will flash

on the PLC.

Unlock all of the clips, blow out any dust and lock in position.

The ‘run rem prog’ procedure will need to be carried out again.



PLC Battery

The PLC has its own battery to ensure that there is always a power supply.

This battery should last 3 or 4 years.

When it does start to go flat the PLC screen will display ‘ PLC Battery low’.

The replacement battery will have a cable connected to it so that it is plugged into the spare battery holder and then plugged into the PLC.

Only then can the original battery be removed.

Spare battery



Automax Adjustment Panel Electrics

P L C

Spare Fuses

Layout Diagram

Relays

Fuses


1300 Maxtrak 100309 issue 2Paktronic (Horner) PLC out of Run mode due to low supply voltage (5 volts dc)

OK light Lit

Run Light OFF

Screen 1

NOT USED


1300 Maxtrak 100309 issue 2Paktronic (Horner) PLC out of Run mode due to low supply voltage (5 volts dc)

Press the SYSTEM buttons (Up/Down buttons) simultaneously, this will enter the programme



Paktronic screen will display

“>Set Contract”

“View OCS Status”

Press the down arrow

Paktronic (Horner) PLC out of Run mode due to low supply voltage (5 volts dc)




“Set Contract”

“>View OCS Status”

Press the Enter button.





“>OCS Mode: Idle”

“Scan-Rate: 0.0 mS”


Press down arrow.





“>OCS Mode: Run”

“Scan-Rate: 0.0 mS”


Press Esc button.

Paktronic is now in Run Mode and the plant can be operated


1300 Maxtrak 100309 issue 2Kobold Sensors

If the Kobold is giving a low flow signal, remove both gears and clean the two sensors which are fitted to the gear which is fitted opposite the circuit board.

Clean the teeth on both gears.



Date post:	12-Jan-2016
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1300 Maxtrak

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