1300 Automax - Sand Manual 01EN 070206

AUTOMAX CRUSHER
MODEL 1300
(‘System 2’ Controls)
(ALSO INCLUDING THE ‘AUTOSAND’ VERSION)
MACHINE USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
Safety. This manual contains safety information which the operator

should read and follow. Failure to do this will increase the
risk of injury or may result in death.
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IMPORTANT SAFETY NOTICE!

Read this manual carefully to learn how to operate and service your machine
correctly. Failure to do so could result in personal injury or equipment damage.
Consider this manual a permanent part of your machine. Keep it with the machine
at all times.
Follow all applicable safety regulations and recommendations in this manual as

appropriate to your machine and the situation/conditions prevailing at the time.
Federal, State, National and Local laws and safety regulations must be complied
with at all times to prevent possible danger to person(s) or property from accidents
or harmful exposure.
Where supplied as a basic machine only, (with or without optional extras, eg. drive
elements, etc.), the machine is intended for incorporation into a complete
processing plant that is NOT designed and/or constructed by BL-Pegson Limited.
In these circumstances, or where supplied as a replacement machine, BL-Pegson
Limited will NOT be responsible for addressing environmental issues and/or health
and safety protection measures for the plant installation as a whole and will bear
NO responsibility for ensuring complience with any regulations and/or statutory
requirements that may apply unless specifically included in the Contract of Sale.
INFORMATION AND ADVICE

If you need any information or advice regarding your crusher, you can contact:-
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire LE67 3GN
England
Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : sales@bl-pegson.com
or, for the United Sates of America:-
Terex Crushing & Screening Inc

11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.
Telephone : +1 502 267 2314, Fax : +1 502 267 2317
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EC Conformity
This machine is in conformity with the

provisions of the EC Machinery Directive
98/37/EC together with appropriate EN
Harmonised Standards and Nationional BS
Standards and Specifications.
A Declaration of Incorporation certificate is

applicable to each machine.
Noise Level
HEARING HAZARD
EXCEEDS 90 dB (A)
May cause loss or degradation of hearing

over a period of time.
Wear proper hearing personal protective

equipment.
Dust Generation
INHALATION HAZARD
Death, serious injury or delayed lung disease

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

equipment, use approved respiratory protection,
as required by Federal, State and Local safety and
health regulations.
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Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are
approximate conversions from the actual metric measurement of the item concerned.
Copyright
The copyright of this User Manual is reserved by BL-Pegson Limited.
This User Manual contains information and technical drawings, which may not be copied, distributed,
altered, stored on electronic media, revealed to others or used for the purpose of competition, either
partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright
2002.
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax:- + 44 1530 518618
E mail sales@bl-pegson.com
To order additional copies contact your local BL-Pegson Ltd Dealer.
AUTOMAX/AUTOSAND - EXPLANATORY NOTE
The BL-Pegson ‘Autosand’ cone crusher is the fine crushing version of the
‘Automax’ crusher. Whilst the name ‘Automax’ is used throughout this manual
when referring to the crusher in general, the instructions apply equally to the
alternative ‘Autosand’ version of the machine except for the variations relevant
to the feed material and the product (refer to Section 2) together with appropriate
changes to the Spare Parts (refer to Section 5).
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Automax Crusher
1300
Safety Issue 01 ENG
Page 1
Contents
1.1 Warnings and Symbols ....................................................................................... 2
1.2 Organisation Measures ....................................................................................... 3
1.3 Selection and Qualification of Personnel - Basic Responsibilities .................. 4
1.4 Safety Instructions Governing Specific Operational Phases ........................... 5

1.4.1 Standard Operation ......................................................................................... 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ..................... 5
1.5 Warning of Special Dangers ............................................................................... 8
1.5.1 Electric Energy ................................................................................................ 8
1.5.2 Gas, Dust, Steam, Smoke and Noise .............................................................. 9
1.5.3 Hydraulic and Pneumatic Equipment ............................................................. 10
1.5.4. Hazardous Substances ................................................................................ 10
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
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Safety Issue 01 ENG
Page 2
1.1 Warnings and Symbols
The following signs and designations are used in the manual to designate instructions of particular
importance.
This is the safety alert symbol. When you see this symbol on your machine or in
this manual, be alert to the potential for personal injury or equipment damage.
Follow the recommended precautions and safe operating practices.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe working practices.
Indicates a statement of company policy as the message relates directly or indirectly to the
safety of personnel and protection of property.
IMPORTANT NOTE:
The following Safety section covers a wide variety hazardous situations, (but not
necessarily limited to those described), which may or may not apply to any specific plant
installation. They are given for general guidance only to assist the operator in setting up
and maintaining an appropriate regime for the protection of health and safety.
Where the machine is supplied for incorporation into plant/equipment designed, supplied
and located by others, BL-Pegson Limited cannot be aware of particular hazards that may
be present or might occur and therefore accept no liability for addressing or resolving
these issues.
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1.2 Organisation Measures Observe all safety instructions and warnings

attached to the equipment..
1.2.1
See to it that safety instructions and
Ascertain from the appropriate Authority warnings attached to the equipment are
and observe all statutory and any other always complete and perfectly legible.
regulations that may apply to the planned
location before operating the machine. Keep warnings and instruction labels clean.
Loose or baggy clothing can get caught in Replace unreadable or missing labels with
running machinery. new ones before operating the machinery.
Make sure replacement parts include
Where possible when working close to warning or instruction labels where
engines or machinery, only do so when they necessary.
are stopped. If this is not practical,
remember to keep tools, test equipment 1.2.3
and all other parts of your body well away
from the moving parts. Understand service procedure before doing
work. Keep area clean and dry.
For reasons of safety, long hair must be tied
back or otherwise secured, garments must Never lubricate, clean, service or adjust
be close fitting and no jewellery such as machinery while it is moving. Keep hands,
rings may be worn. Injury may result from feet and clothing clear of power driven
being caught up in the machinery or from parts and in running nip-points. Disengage
rings catching on moving parts. all power and operate controls to relieve
pressure. Stop the engine/motor. Implement
Always wear correctly fitting (EN/ANSI lockout procedure. Allow the machinery to
approved) personal protective equipment. cool.
Personal Protective Equipment includes Keep all parts in good condition. Ensure
Hard Hat, Safety Glasses, Hearing that all parts are properly installed. Fix
Protection, Dust Mask, Close fitting damage immediately. Replace worn and
Overalls, Steel Toed Boots, Industrial broken parts. Remove any build up of
Gloves and a High Visibility Vest. grease, oil and debris.
1.2.2 Disconnect battery ground cable before

making adjustments on electrical systems or
You can be injured if you do not obey the welding on machinery.
safety instructions as indicated on warning
stickers.
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For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted to Qualification of Personnel -
the task on hand are absolutely
Basic Responsibilities
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must be
Never make any modifications, additions or
executed by trained, reliable and authorised
conversions which might affect safety
personnel only. Statutory minimum age
without the supplier’s approval.
limits must be observed.
In the event of safety relevant modifications
1.3.2
or changes in the behaviour of the
machinery during operation, stop the plant Work on electrical system and equipment of
and lock out immediately and report the the plant must be carried out only by a
malfunction to the competent authority/ skilled electrician or by instructed persons
person. under the supervision and guidance of a
skilled electrician and in accordance with
electrical engineering rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
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1.4 Safety Instructions 1.4.2 Special Work In Conjunction

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

equipment in the vicinity of the plant.
Carry out maintenance and repair work
only if the portable/mobile plant is For carrying out overhead assembly work
positioned on stable and level ground and always use specially designed or otherwise
has been secured against inadvertent safety-oriented ladders and working
movement and buckling. platforms.
1.4.2.4 Always use any walkway/platforms
Never allow unqualified or untrained provided or a safe and secure platform
personnel to attempt to remove or replace approved by the regional safety enforcing
any part of the machinery, or anyone to authority.
remove large or heavy components without
adequate lifting tackle. Always use an EN/ANSI approved safety
harness when reaching any points 7ft (2m)
To avoid the risk of accidents, individual or more above the ground level.
parts and large assemblies being moved for
replacement purposes should be carefully Keep all handles, steps, handrails,
attached to lifting tackle and secured. Use platforms, landing and ladders free from
only suitable and technically adequate lifting dirt, oil, snow and ice.
gear.
1.4.2.6
Never work or stand under suspended The fastening of loads and instructing of
loads. crane operators should be entrusted to
experienced persons only. The marshaller
Keep away from the feed hoppers and giving the instructions must be within sight
stockpile conveyor discharge points, where or sound of the operator.
there is risk of serious injury or death due to
the loading and removal of material. 1.4.2.7
1.4.2.5 After cleaning, examine all fuel, lubricant,
and hydraulic fluid lines for leaks, loose
Falling from and/or onto a BL-Pegson connections, chafe marks and damage. Any
machinery can cause injury or even death. defects found must be rectified without
delay.
Do not climb on the machinery whilst it is in
operation. Never use machinery parts as a
climbing aid.
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Safety Issue 01 ENG
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1.4.2.8 Particularly make sure that any part of the

machinery raised for any reason is
Any safety devices removed for setup, prevented from falling by securing in a safe
maintenance or repair purposes must be reliable manner.
refitted and checked immediately upon
completion of the maintenance and repair Never work under unsupported
work to ensure full working order. equipment.
1.4.2.9 Never work alone.
Improperly disposing of waste can threaten
the environment and ecology. Potentially 1.4.2.11
harmful waste used with BL-Pegson Diesel fuel is highly flammable.
equipment includes such items as oil, fuel,
coolant, filters and batteries, etc. Never remove the filler cap, or refuel, with
the engine running.
Use leakproof containers when draining
fluids. Do not use food or beverage Never add gasoline or any other fuels
containers that may mislead someone into mixed to diesel because of increased fire or
drinking from them. explosion risks.
Do not pour waste onto the ground, down Do not carry out maintenance on the fuel
a drain or into any water source. system near naked lights or sources of
sparks, such as welding equipment or whilst
Ensure that all consumables and replaced smoking.
parts are disposed of safely and with
minimum environmental impact. 1.4.2.12
1.4.2.10 Using unapproved structures i.e. walkways/
platforms etc in the vicinity of a BL-Pegson
Always ensure that any safety fitment such machinery is very dangerous and could lead
as locking wedges, securing chains, bars or to serious injury or even death through
struts are utilised as indicated in these falling and/or entanglement with the plant.
operating instructions.
Do not use any unauthorised structures.
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1.5 Warning of Special 1.5.1.4

Dangers Work on the electrical system or equipment
may only be carried out by a skilled and
1.5.1 Electric Energy qualified electrician or by specially
1.5.1.1 instructed personnel under the control and
supervision of such an electrician and in
Use only original fuses with the specified accordance with applicable electrical
current rating. Switch off the machinery engineering rules.
immediately if trouble occurs in the
electrical system. 1.5.1.5
Machinery with high voltage electrical If provided for in the regulations, the power
equipment must be suitably earth bonded supply to parts of machinery and plants, on
by a qualified electrician prior to activating which inspection, maintenance and repair
the main isolator switch. work is to be carried out must be cut off.
Before starting any work, check the de-
1.5.1.2 energized parts for presence of power and
ground or short circuit them in addition to
When working with the machinery, maintain insulating adjacent live parts and elements.
a safe distance from overhead electric lines.
If work is to be carried out close to 1.5.1.6
overhead lines, the working equipment must
be kept well away from them. Check out The electrical equipment of the machinery is
the prescribed safety distances. to be inspected and checked at regular
intervals. Defects such as loose connections
1.5.1.3 or scorched or otherwise damaged cables
must be rectified immediately.
If your machinery comes into contact with a
live wire:
• Warn others against approaching and

touching the plant.
• Have the live wire de-energized.
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1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

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

respective site.
Before starting work on high voltage
assemblies and after cutting out the power Dust found on the machinery or produced
supply, the feeder cable must be grounded during work on the plant should be
and components such as capacitors short- removed by extraction, not blowing.
circuited with a grounding rod.
Dust waste should be dampened, placed in
1.5.1.9 a sealed container and marked, to ensure
safe disposal.
Always observe correct polarity.
1.5.2.2
Always disconnect any battery leads before
carrying out any maintenance to the Carry out welding, flame cutting and
electrical system. grinding work on the machinery only if this
has been expressly authorised, as there may
Batteries contains sulphuric acid, an be a risk of explosion and fire.
electrolyte which can cause severe burns
and produce explosive gases. 1.5.2.3
Avoid contact with the skin, eyes or Before carrying out welding, flame cutting
clothing. and grinding operations, clean the
machinery and its surroundings from dust
and other inflammable substances and make
sure the premises are adequately ventilated
(as there may be a risk of explosion).
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1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with hearing protection of laid and fitted properly. Ensure that no
approved pattern and that these are worn at connections are interchanged. The fittings,
all times when the plant is operating. lengths and quality of the hoses must
comply with the technical requirements.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects 1.5.3.5
of air pollution of any kind.
Always practice extreme cleanliness
1.5.3 Hydraulic and Pneumatic servicing hydraulic components.
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can
Work on hydraulic equipment may be penetrate the skin causing serious injury.
carried out only by persons having special
knowledge and experience in hydraulic If fluid is injected under the skin, it must be
systems. surgically removed or gangrene w ill result
.Get medical help immediately.
1.5.3.2
Always relieve pressure from the hydraulic
Check all lines, hoses and screwed system before carrying out any kind of
connections regularly for leaks and obvious maintenance or adjustment.
damage. Repair damage immediately.
Splashed oil may cause injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4. Hazardous Substances
pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification, labelling,
for the unit concerned before carrying out storage, use and disposal, all strictly in
any repair work. accordance with the manufacturers
instructions and that all applicable
regulations are observed at all times.
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Automax Crusher
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General Information Issue 01 ENG
Page 1
Contents
2.1 Introduction .......................................................................................................... 2

2.1.1 Automax Features ........................................................................................... 2
2.1.2 General Specification ...................................................................................... 4
2.1.3 General Installation Aspects ............................................................................ 6
2.1.4 Base Crusher Content ..................................................................................... 8
2.1.5 Optional Extra Items ........................................................................................ 8
2.1.6 Technical Data................................................................................................. 9
2.1.7 Glossary of Automax Parts ............................................................................ 10
2.1.8 Glossary of Automax Terms ........................................................................... 11
2.1.9 Designated Use ............................................................................................ 12
2.2 Automax Performance ...................................................................................... 13
2.2.1 Estimated Performance ................................................................................ 14
2.2.2 Typical Product Analysis ................................................................................ 15
2.3 Receipt & Storage ............................................................................................. 16
2.4 Installing ............................................................................................................. 16

2.4.1 Preparing the Machine .................................................................................. 16
2.4.2 Siting ............................................................................................................ 16
2.4.3 Installing the Oil Tank ..................................................................................... 17
2.4.4 Installing the Machine .................................................................................... 18
2.4.5 Installing the Hydraulic Control Console ......................................................... 19
2.4.6 Electrical Connections ................................................................................... 19
2.4.7 Feeding the Automax .................................................................................... 20
2.4.8 Discharge from the Automax ......................................................................... 21
2.6 Hydraulic Hose Connections ........................................................................... 22
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Page 2
2.1 Introduction
2.1.1 Automax Features

ROBUST CONSTRUCTION
Fully automatic controls.
Designed for the most arduous applications.
LOW PROFILE
Important where headroom is restricted.
Ideally suited for mobile plant applications.
ADVANCED HYDRAULICS
Accessible external hydraulics.
Hydraulic setting adjustment.
Automatic hydraulic overload protection and reset.
Hydraulic unblocking.
SIMPLE WEAR PART CHANGE

Designed for fast changeover.
Keeps downtime to a minimum.
Readily accessible from above machine - no need to remove cone head.
Unrestricted feed opening reduced blockages and bridging and maximises output.
BALANCED DESIGN
Minimises vibration
ADVANCED BEARING ARRANGEMENT

High capacity taper and cylindrical roller bearings.
Long trouble free service.
Low friction characteristics compared with ‘old fashioned plain bearings’.
PROVEN SEALING ARRANGEMENT

Comprises rotary seal ring, piston rings anddouble row labyrinth seals.
OVERLOAD PROTECTION
Hydraulic relief system with automatic reset.
SETTING ADJUSTMENT/UNBLOCKING FACILITY

Push button controlled hydraulic cylinders raise and lower the upper frame assembly to adjust the
crusher setting and to unblock the crushing chamber.
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CRUSHING APPLICATIONS
This machine is designed for stone crushing applications. It is vitally important that large
pieces of steel or similar uncrushable objects are not allowed to enter the crushing
chamber as severe damage and injury may occur. The Automax crusher includes
automatic hydraulic overload release. However the machine is not designed to accept large
pieces of steel or other uncrushable objects such as bucket teeth. A metal detector should
be fitted prior to the crusher to detect this type of uncrushable material and must be kept
operable at all times whilst the plant is in operation so that these foreign objects can be
prevented from entering the Automax crusher.
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2.1.2 General Specification hydraulic alarms, a grease gun and a

sledging bar for the mantle nut.
The BL-Pegson Automax range has been
designed to crush most rock types as well The purchaser is responsible for carrying
as gravel, ores and other materials. The out all electrical connections to his motor
following specification is intended to outline and starter and the crusher package
the design and application of crushers supplied by BL-Pegson consisting of the
supplied as ‘base’ machines. Automax, the hydraulic panel and the
lubricating oil tank. A wiring diagram is
The crusher body consists of a heavy cast provided for this purpose and to ensure that
steel lower main frame and cast upper main the crusher is fully protected it is a condition
frame. It is driven through a countershaft, of the warranty that the interlocks are fitted
pinion and bevel gear to a cast eccentric on and connected according to our wiring
which the cone head is free to gyrate. The diagram. A start delay timer is also
crusher bearings consist of a combination of required to prevent the crusher from starting
high quality cylindrical roller radial and taper until sufficient oil has circulated through the
roller thrust/radial bearings. machine and an adequate oil return is
established.
Crusher lubrication is provided from a
separate oil lubrication tank designed to be BL-Pegson Limited can, if required,
mounted by the purchaser adjacent to and provide a complete crusher starter panel, or
just below the crusher. Loose oil pipework alternatively, an auxiliary panel containing all
is provided to suit the standard lubrication necessary interlocks to provide the
tank position to enable the buyer to make protection required, as an optional extra.
the connections on site. Any additional
pipework to suit non standard tank In addition to the oil lubrication tank the
positions is the purchasers responsibility crusher comes complete with a hydraulic
and must be at least the same quality as the control panel which houses the controls for
standard pipework. adjusting the crusher settings, providing
tramp release, manganese wear adjustment
Lubricating and hydraulic oil is to be and manganese wear read out facility.
provided by the purchaser as
recommended in our oil schedule and Different crushing chamber cavities are
suitable for the local temperature available to suit different applications. For
conditions. selection of the most suitable machine
please contact our Sales or Projects
Loose items supplied with the standard Department for advice.
machine comprise an audible alarm for the
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The selection and application of cone crushers The procedures in this manual
is a specialised function. Our Sales and relate to the crusher equipped
Projects Departments have many years with the standard ‘System 2’
experience in this area and would be pleased controls.
to assist with this aspect. For the alternative ‘System 3’
and ‘Maxset’ control systems,
The hydraulic panel is supplied with three refer to the separate
hydraulic hoses approximately 4.6m (15’- 0”) Addendum for details.
long and fitted with snap connectors for the
purchaser to connect to the ring main
connections on the crusher lower main frame.
The panel takes an electrical signal from the
crusher mounted sensor unit and translates it
to give a direct read out of crusher close side
setting and manganese wear. This display
requires recalibrating when new manganese is
fitted or as manganese wear takes place.
Remote and automated control options are
also available at extra cost.
The crusher is finished painted in BL-Pegson

Blue RAL 5015 and black gloss finish.
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2.1.3 General Installation Aspects distributed choke feed is maintained at all

times. A steel feed ring is provided with the
You can refer to BL-Pegson’s technical machine to guide material into the crusher
department for advice on installation design mouth.
or any other aspect relating to the Automax.
Although the crusher is designed to open
Automax Crushers should be mounted on a automatically when an uncrushable object
live frame assembly together with motor enters the chamber, like all cone crushers,
drive and guard. These are available as an dump clearance is not infinite. We
optional extra and reduce the risk of strongly recommend therefore that a
vibration being transmitted to the supporting metal detector is fitted immediately prior
structure. Direct mounting can only be used to the crusher to prevent the entry of
provided the structure is substantial enough tramp metal. The metal detector should
to absorb the dynamic forces created be capable of detecting high alloy steels
during the operation of the machine. such as those used in the manufacture of
bucket teeth, manganese steel etc. Some
Access is required all around the machine
oversize material may pass into the
for inspection and maintenance of the
product when dumping occurs.
crusher. Fixed installations usually provide a
lifting beam with hoist over the crusher for The crusher is supplied with a standard
maintenance purposes, principally used vee grooved pulley fitted to the
when changing the manganese concave and countershaft. The purchaser is to supply a
mantle. These should allow for sufficient suitable vee belt drive, drive guard, motor
over capacity (see weights - Section 2.1.6) pulley and main drive motor. The
and height for the major machine assemblies Automax can be driven by either cage
to be lifted, moved to the side and dropped pattern motor with star delta starter or
down to floor level. slip ring motor with stator rotor starter.
Details of motor sizes for each machine
It is important that the crusher is always
are contained in the product literature,
continuously ‘choke’ fed with a well graded
however we recommend the purchaser
feed material that is well mixed around the
consults BL-Pegson Limited for specific
circumference of the crushing chamber to
advice prior to installation. Motor speed
optimise the performance and to give even
and pulley diameter should be selected to
manganese wear. A surge hopper with
give recommended countersha.ft speed.
either a chute or variable speed feeder
should be provided together with level
probes designed to ensure the evenly
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Where guards are provided they are so Every endeavour will be made to supply
designed and manufactured to ensure so equipment as specified, but we reserve
far as reasonably practicable that the the right, where necessary, to amend
machinery and plant on which they are specifications without prior notice as we
fitted can be operated safely and without operate a policy of continual product
risk to health when properly used. development.
However, the Company cannot guarantee
that the guards provided will meet the Advice can also be given on the design of
requirements laid down by individual feed chutes, discharge chutes and discharge
Inspectors and any additional guard and/ conveyors to enhance the installation and
or modification to guarding supplied, performance of your BL-Pegson Automax
which may be required for any reason Crusher.
whatsoever, will be charged as an
addition to the contract price. Also read Section 2.4 - Installing.
As the oil lubrication system uses a After the purchaser has set up the plant
forced feed and gravity return to the ready for operation BL-Pegson or our
separate tank, it is vital that the pipework dealer can provide an Engineer to
does not restrict the flow of oil both from commission the crusher if required at extra
and returning to the tank. A flexible cost. Feed material, and other essentials to
connection must be included in the return be provided by the buyer in good time for
oil line when the crusher is installed on the commissioning being carried out. It is a
anti vibration mountings. condition of our warranty that the crusher is
not run for the first time until our Engineer
BL-Pegson Limited cannot guarantee that or a BL-Pegson authorised Engineer has
the equipment quoted will meet any examined the installation and given his full
specific requirements in respect of noise approval.
or vibration levels, dust emissions, or any
other factors relevant to health and safety
measures or environmental needs.
However, on receipt of detailed
information we will endeavour to
ascertain the need for additional
equipment and, if appropriate, quote
extra to contract prices.
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•
Page 8
2.1.4 Base Crusher Content 2.1.5 Optional Extra Items

The Basic Crusher Price Includes:- Optional Extras available at extra cost include:
• Automax Crusher built with the buyers •Standard vee belt drive.
chosen type of concave (from the
alternatives available - Section 2.2) and •Drive guard to suit standard motor position.
complete with matching feed ring.
•System 3 hydraulic controls providing a
• System 2 hydraulic free standing control remote control system for the crusher
panel with interconnecting hydraulic hydraulic system in lieu of the local controls
hoses approximately 4.6m (15’- 0”) provided with System 2.
long for connection on site to the
crusher hydraulic system. •System 4 hydraulic controls providing a
remote control system for the crusher
• Oil lubrication tank supplied with air hydraulic system together with electronic
blast oil cooler and oil piping to suit monitoring for the hydraulic pressure and
standard tank position. Electrical com- power draw to give minimum setting capability
ponents on the tank are wired to a under extreme operating conditions. This also
junction box mounted on the tank replaces local controls provided with System 2.
• Loose audible alarm, grease gun and •Main crusher drive motor.
sledging bar.
•Starter panel for main drive motor and
If high or low ambient crusher auxiliary items including necessary
temperature conditions apply, interlocks.
specific details need to have
been advised at the time of •Auxiliary electrical panel incorporating
order as special equipment starters for crusher auxiliary items and
may be necessary. including necessary interlocks (not required
if a new starter panel is provided to our
The necessary starters for electric motors, specification).
switchgear, control equipment and the
electrical wiring to the lubricating oil tank •Live frame assembly consisting of crusher
and the hydraulic console is excluded sub-frame (without legs) including drive, drive
unless specifically included in the Sales guard and, if specified, crusher motor. The
Contract. underside of the sub-frame is provided with
four anti-vibration mountings for the client to fit
to his supporting steelwork.
•4 anti vibration mountings, supplied loose.
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2.1.6 Technical Data.
Maximum feed size (Automax or Autosand) See Section 2.2.1
Minimum discharge setting (Automax or Autosand) See Section 2.2.1

(subject to feed material suitability)
Weights (approx.)
Complete machine ( timber packed, no motor. ) 22 000 kg (48,400lb.)

One Piece Upper Frame
Assembly (upperframe with concave) 5 260 kg (11,598lb.)
Cone Head Assembly (with bearings mantle etc.) 2 950 kg (6,505lb.)
Eccentric, assembly (with bearings ring gear etc. ) 1 800 kg (3,970lb.)
Countershaft Assembly 500 kg (1,103lb.)
Concave 760 kg (1,676lb.)
Mantle 852 kg (1,879lb.)
Drive power required

(subject to confirmation against application details) Electric 225 kW
Direction of Countershaft pulley rotation Clockwise
Packs of Mazel required for manganese change.

NB. Always change both at same time.
Mantle 11
Concave 14
Drive pulley details
Speed (Countershaft) 718 rpm

Diameter (pcd) 630 mm
No: & type of belts 8 SPC
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2.1.7 Glossary of Automax Parts

GAP
CRUSHING CHAMBER
DUMPY
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2.1.8 Glossary of Automax Terms

Blocking/Bridging A condition caused by material in the feed being too large to
enter the crushing chamber, too dirty or otherwise unsuitable
material being unable to pass through the machine.
Bouncing Oscillating movement of the Automax upper frame.
Choke Feed The feed rate to the machine that enables optimum crushing
performance to take place. The condition whereby the feed
material completely fills the crushing chamber and the lower
section of the feed box.
Crushing Chamber The region between the manganese (mantle and concave)
where the crushing takes place.
Dumping Automatic lifting of the Automax upper frame to allow

uncrushable material to pass through the crusher.
Manganese (Mang.) The Automax mantle and concave crushing members
Out of Round Uneven wear to the crushing surfaces (mantle and concave),
mainly due to badly segregated feeds.
Packing/Caking Congealed lumps in the product usually due to an excessive

percentage of fines in the feed.
Segregated Feed A poorly mixed, uneven distribution particle sizes in the feed.
Setting (also referred to as the The distance between the crushing surfaces (mantle and
Closed Side Setting, concave) during operation.
Discharge Setting or Gap)
Tramp Metal Pieces of metal present in the feed material that must be removed
in order to prevent damage to the crusher.
Wearing Parts Components subject to wear from the stone being crushed.
Mainly the mantle and concave, but also any other component
subject to stone abrasion, eg. frame arm shields, etc.
Well Graded Feed An even distribution of material particle sizes in the feed.
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2.1.9 Designated Use Refer to the following information in this

Section for guidance regarding the
The BL-Pegson 1300 Automax Cone performance of the Automax crusher.
Crusher is designed to maximise throughput Experienced engineers are available at BL-
and product shape in a wide range of crushing Pegson to give advice when necessary.
applications.
If you have any doubts about any
It is vitally important that pieces aspect of the machine’s capability or
of steel or similar uncrushable any aspect of the servicing procedures,
objects such as bucket teeth are you should consult your local BL-
not allowed to enter the crushing Pegson dealer or BL-Pegson’s technical
chamber as severe damage and departments
injury may occur.
For the above reason it is strongly

recommended that a metal detector is fitted
prior to the Automax where possible so that
the foreign body can be removed before
entering the crushing chamber. If it is not
practical to install a metal detector owing to
the feed arrangement, try to ensure
uncrushable objects are kept out of the feed
material
Operating the Automax

outside it’s recommended
range of applications/operating
parameters or for any use for
which the equipment is not
intended, will result in a loss of
any guarantee and the
manufacturer/supplier cannot
be held liable for any damage
or injury resulting from such
misuse. The risk of such
misuse lies entirely with the
user..
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2.2 Automax Performance Persistent ‘dumping’ (see Glossary) is

most undesirable and likely to be
In order to obtain the optimum overall caused by operating the machine at too
crushing performance from the Automax, close a setting. Increase the ‘Gap’
it is essential to have a continuous and setting to avoid damage to the machine.
regulated ‘choke’ feed of evenly graded
material that is well mixed around the Crusher settings shown in the tabulation are
crushing chamber. Typical feed gradings for general guidance only and crusher
are shown on the product analysis graphs performance will vary depending upon the
in this section. conditions prevailing.
A level sensing device prior to the crusher Capacities shown are for open circuit
will assist in achieving this when used to applications.
control the feed. Additionally, all feed
material should be of a size that will When operation is required towards the
readily enter the crushing chamber. lower end of the setting range. BL-Pegson
Ltd should be consulted to verify the
The gradings and capacities shown in this application.
section are averages base on actual
results taken from tests carried out on The power required and product gradings
various materials at different crusher will vary with the feed and product size,
settings. They will vary dependant upon capacity and rock characteristics.
the grading and nature of the feed
material. For more specific details please Usage of wearing parts will depend upon
contact BL-Pegson Ltd. individual crushing conditions and the
variable factors which govern wear.
The capacities given are approximate only
and based on crushing clean, dry, well
graded quarried hard limestone, weighing
loose about 1600 kg/f/m3 (100 lbs/cu.ft.)
and having a specific gravity of 2.6 - 2.8.
Wet sticky feeds will reduce crusher
capacities.
Performance will be adversely affected if an

excessive percentage of fines in the feed
causes the packing/caking of material, either
to slow the flow of material or cause
congealed lumps in the product.
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AUTOMAX CRUSHER
1300 AUTOMAX CRUSHER CLOSED SIDE SETTINGS (MM & INCHES)

STANDARD MODEL AND APPROXIMATE CAPACITIES (TONNES PER HOUR & US TONS PER HOUR)
MAXIMUM FEED MINIMUM C.S.S. 22MM 25MM 28MM 32MM

SIZE 7/8” 1” 1 1/8” 1 1/4”
220 MM 22 MM 220-225 MTPH 235-275 MTPH 250-295 MTPH 260-320 MTPH
8 1/2” 7/8” 240-250 US TPH 260-300 US TPH 275-325 US TPH 285-350 US TPH
2.2.1 Estimated Performance
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AUTOSAND CRUSHER
1300 AUTOSAND CRUSHER CLOSED SIDE SETTINGS (MM & INCHES)

General Information
STANDARD MODEL AND APPROXIMATE CAPACITIES (TONNES PER HOUR & US TONS PER HOUR)
Figure 2a Estimated Machine Outputs

MAXIMUM FEED MINIMUM C.S.S. 13MM 16MM 19MM 22MM
SIZE 1/2” 5/8” 3/4” 7/8”
63 MM 13 MM 165-185 MTPH 180-200 MTPH 195-220 MTPH 210-240 MTPH
2 1/2” 1/2” 180-200 US TPH 200-220 US TPH 215-240 US TPH 230-260 US TPH
1300
Page 14
Issue 01 ENG
Automax Crusher
Automax Crusher
1300
Page 15
2.2.2 Typical Product Analysis

SCREEN MESH SIZE - INCHES
AUTOMAX
SCREEN MESH SIZE - INCHES
AUTOSAND
Figure 2b Typical Product Analysis Curves
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2.3 Receipt & Storage 2.4 Installing
On receipt of the machine and the separate BL-Pegson dealer’s engineer

lubrication and hydraulic equipment carry is to be employed to
out a careful inspection and immediately commission the machine when
report to the supplier, distributor of BL- the installation is complete and
Pegson Limited any component damage or ready to run and crush stone.
loss. The following notes regarding
installation can only be general
Conduct a careful visual check of the owing to the variable nature of
machine and check all the separate loose plant installations. Always feel
items against the equipment delivery note. free to contact your local
dealer or BL-Pegson for
The equipment should be stored in a dry, guidance on any aspect.
well-ventilated area free of excessive dust.
All openings should be sealed to prevent 2.4.1 Preparing the Machine
the ingress of dirt or moisture.
Remove any temporary sealings added for
If the machinery cannot be stored indoors it storage purposes and clean the factory
must be sheeted over and made thoroughly applied protective coatings from machined
weatherproof to avoid deterioration. surfaces.
Contact BL-Pegson Limited for advice for Visually check the machine for any damage,
any situation wherever storage or inactivity and ensure that all components are clean
is in excess of that reasonably to be and free of any obstructions.
expected or where a possibly hostile
environment exists, as the defects liability 2.4.2 Siting
warranty may be affected. Also read Section 2.1.3 - Installation Aspects.
The machine countershaft pulley should be Confirm that the foundations which are to
rotated at weekly intervals after removal of support the machine and ancillary
any wedges or packing between the equipment are firm and level and are able to
concave assembly and the mantle, and a support the plant when in use.
check has been carried out that the
assembly and the mantle are not in contact Ascertain that adequate space is available
on the closed side; confirm the proper above, around and below the machine for
movement of all moving parts. feed and discharge, and access for servicing
purposes. Consult the General Arrangement
drawing (supplied at time of order) for
loadings, critical dimensions, clearances, etc.
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Ensure also that suitable shims are available Ensure that the oil tank access cover is
for levelling purposes, when these are retained on the tank at all times, with all
necessary. bolts in and tight. This will prevent any
contaminants entering the lubricating oil.
The following points should be noted:-
When choosing a position for the oil tank,
1. Feed chutes should be easily removable, ensure space is available for:-
complete with fixings and supports, to
provide access to the machine. • Oil drainage via the two drain plugs.
2. The discharged material normally flows • Filling the tank via the filler / breather.
vertically from the machine via a dis-
charge chute onto a conveyor; the •. Changing of the twin filters.
discharge chute should be constructed
from a material and to a design which •. Inspection of oil returning from the
allows the discharge to flow freely. Any machine through the sight glass.
restriction in the discharge can cause
build-up of material in the crushing •. Inspection of the flow indicator.
chamber, and possible resultant damage
to the machine. The discharge conveyor • Inspection of the oil level and the oil
must be interlocked with the machine so temperature.
that in the event of a conveyor stop-
page, the material feed to the machine When the siting of the crusher
also stops. and the ancillary components
is being considered provision
As with all crushing equipment the feed should be made so that the
area of the crusher needs to be carefully lubricating oil tank is in a
designed since this is potentially a very position so that it can easily be
dangerous area. Overspill of the material isolated in the case of a fire.
feed must be avoided.
Note the following points:
2.4.3 Installing the Oil Tank
• Do not position the air blast cooler any
Tank Commissioning: closer than 1 m to a wall or similar
Conduct a visual inspection of the system obstruction to avoid warm air dis-
reporting any damage or loss of charged from the cooler being
components. recirculated into the fan inlet.
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• Cool air passes over the fan electric

motor into the fan and through the
cooler.
• Ensure that the fan rotates in the direc-

tion indicated by the arrows on top of
the cooler.
• Ensure the pump rotates in the direction

as indicated by the arrow on top of the
motor.
• Position the tank in a cool place out of Figure 2c - 4 x Lifting Points

the direct rays of the sun, and there
should be adequate ventilation. When lifting the machine or any
part of the machine it is the
• The oil return piping must be installed so responsibility of the customer to
that there is a minimum slope (angle) of ensure that both the crane and the
5º from the horizontal. For reference 5º lifting tackle are suitable and have
in 1000mm is 88mm (1 yard = 3 3/8”). the correct safe working load.
Section 2.1.6 gives the weights of
6. Ensure lubrication tank is not vulnerable the complete machine and also
to dust / spillage build-up. part assemblies. The weight of
the complete machine is approx.
Unless commissioned with control wiring, 22 tonnes (24.2 US tons).
the machine’s lubrication tank must be
wired and protection devices included Level the machine in both directions by using
according to the drawing 603/1524. This a spirit level positioned on the main frame.
will ensure all protecting interlocks perform Fix the live frame securely and grout or shim
correctly. it to its foundation (of concrete or steel
beams).
2.4.4 Installing the Machine
Remove all packing, protective caps and
Lift the machine via the four lifting holes in
plugs from the oil tank, associated pipes and
the upper frame (Figure 2c) using chains
flexible hoses; check for any obstructions and
and suitable lifting equipment. Remove the
make the necessary connections to the
timber packings used to support the
machine using a sealer impervious to oil.
machine whilst in transit and any chocks in
(Refer to BL-Pegson’s Parts manual for
the crushing chamber.
identification of pipe, flexible hose and
couplings).
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Ensure that the oil return pipes from the 2.4.5 Installing the Hydraulic
machine to the oil tank satisfy the minimum Control Console
5º slope requirement. If there are any
obstacles which the oil return piping must Position the System 2 hydraulic control
cross it may be necessary to route the console in a safe position within the length
piping under these rather than over them so of the hydraulic hoses supplied avoiding
as to ensure a return flow down to the tank. tight bends. For safety reasons, bear in
mind that the operator may need to attend
to the controls whilst the Automax is
crushing. Secure on a suitable steel
structure or concrete foundation in order to
prevent vibration.
Remove protective caps and plugs from the

console and the ring-main on the machine;
check for any obstructions and fit the
flexible hoses to the console connections.
Snap together the couplings from the ring
Figure 2d - Return Oil Pipework.
main to the console.
Add 275 litres (73 US galls) of oil (Section
4.4.5) to the tank until the level indicator Check the level of hydraulic fluid in the
shows the required level . This can be seen reservoir and replenish if necessary with
on the level indicator on the side of the the recommended oil . See Sections 4.4.4
tank. and 4.4.5 for the recommended fluid..
Before starting the crusher ensure that there 2.4.6 Electrical Connections
is a flow of oil into the countershaft housing. A suitable qualified and
experienced Electrical
Install the drive motor (BL-Pegson or Engineer is essential for the
another manufacturer’s supply) and vee installation and initial start up
belts following the relevant manufacturer’s of the Automax.
instructions. Ensure that the direction of the
motor is to drive the machine pulley For the standard wiring requirements, see
clockwise. Contact BL-Pegson Limited if a the wiring diagrams supplied with the
combustion engine drive is envisaged. machine or availaable on application.
Check the proper tension of the vee belts Check the incoming power supply and
and alignment of the drive motor ensuring ratings, etc against the wiring diagrams.
that the countershaft and drive motor shaft
are in-line.
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Ensure that all the necessary timers, Lubrication oil heater contactor.
interlocks and safeguards are in place (See
below). Lubrication oil cooler fan contactor.
Note.: The electrical circuitry shown dotted Make the necessary connections to the
on drawing 603/9124 issue 00 is an hydraulic console, the lubrication oil pump,
optional extra available from BL-Pegson flow switch and thermostat on the
Ltd. Within this circuitry there are interlocks lubricating oil tank, and the linear transducer
and alarms, etc. which protect the machine on the machine.
against possible breakdown conditions such
as low oil flow. It is the belief of BL-Pegson Ensure that the lubrication pump has a 5
that these interlocks are essential for minute start delay timer and also that an
efficient automated control of this interlock is connected into the machine
equipment. BL-Pegson Limited shall accept drive motor starter circuit to immediately
no responsibility for any machine which is stop the crusher in the event of a lubrication
not protected by either the optional BL- system fault.
Pegson equipment or equivalent.
Check also that the lubrication pump
The oil tank switches provide connections interlock is connected into the machine
for the purchasers starters for the oil pump drive motor starter circuit.
and cooler fan, immersion heater
switchgear, safety interlocks, alarms, and It is necessary to check that the interlocks
signals for:- are working properly. For this a qualified
electrician will need to be employed. To
Lubrication oil low level relay. check the interlocks the signal from the
SHUT MACHINE DOWN + sensor should be shorted out so that a false
ALARM signal is produced and the appropriate
alarm or action should be witnessed.
Lubrication oil flow fault.
SHUT MACHINE DOWN + 2.4.7 Feeding the Automax
ALARM
When operating the crusher it should
always be fed with clean well graded feed
Lubrication oil filter blocked.
within the recommended parameters
ALARM
(Section 2.2).
Lubrication oil high temperature.
The manner in which a crusher is fed can
SHUT MACHINE DOWN +
have a significant effect on the quality of
ALARM
product produced as well as the life of the
machine and consumable components.
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BL-Pegson would strongly recommend the operator should make suitable inspections to
fitting of a metal detector on the feed to any avoid any trouble arising from this situation.
crusher to prevent the ingress of metal.
Consideration should be given to the
All cone crushers perform better when they situation of foreign objects being passed
are choke fed i.e. The feed in the crusher through the crusher during overload release
should be to at least the top of the mantle and the possible effects on the following
nut. It is important that the feed is evenly equipment and product.
graded around the feed ring (ie. no
segregation of fines / large stones from one
side to the other side). The feed should
drop under gravity or a ‘dead’ box feed
hopper employed to prevent segregation.
To obtain the optimum performance from

your crusher BL-Pegson Limited should be
consulted to discuss the feed arrangements
as each application is different.
2.4.8 Discharge from the Automax

The discharge conveyor is very important
since should this fail then the crushed
product can build up and cause damage to
the Automax. To avoid this condition the
discharge conveyor should be interlocked
to the crusher.
Around the base of the crusher it is possible

that there may be a build up of fine particles
despite correct performance of the
discharge conveyor. Over a period of time
these can build up and work their way in to
the bearings of the crusher which would
cause premature failure. After the initial
installation regular checks should be made
to see if this is happening. When an idea of
the amount of material collecting and over
what time period this is happening, the
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2.6 Hydraulic Hose Connections
Figure 2e - Diagram showing the hydraulic hose connections
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Operation Issue 01 ENG
Page 1
Contents
3.1 Safety Information ............................................................................................... 2

3.1.1 Blocked Crusher Procedures .......................................................................... 5
3.1.2 Safe Operation of the Automax Crusher .......................................................... 6
3.1.3 Checks at Initial Start-Up and Operation .......................................................... 7
3.2 Automax Operation ............................................................................................. 8
3.2.1 Initial Discharge Setting and Calibration - System 2 ...................................... 11
3.2.2 Manganese Wear Calibration ........................................................................ 12
3.2.3 Guidance for Changing the Manganese Mantle and Concave ........................ 13
3.2.4 Initial Start Up ................................................................................................ 14
3.2.5 Actions during running in ............................................................................... 15
3.2.6 Adjustment of the Discharge Setting .............................................................. 16
3.2.7 Manual Raising/Lowering of the Upper Frame ............................................... 17
3.2.8 Automatic Overload Release/Unblocking and Resetting ................................ 18
3.2.9 Checking the Wedge Pressure ...................................................................... 19
3.2.10 Daily Crusher Checks ................................................................................. 20
3.3 Autocone Controls - System 2 .......................................................................... 21
3.3.1 Controls Layout ............................................................................................. 21
3.3.2 Function Keys ............................................................................................... 22
3.3.3 General Operation ......................................................................................... 23
3.3.4 Manual Operation .......................................................................................... 26
3.3.5 Setting the Gap ............................................................................................. 27
3.3.6 Setting New Manganese ............................................................................... 28
3.3.7 Setting Normal Zero ...................................................................................... 29
3.3.8 Tramp Overload or Test (whilst in Manual) ...................................................... 30
3.3.9 Tramp Overload or Test (whilst in Auto) .......................................................... 30
3.3.10 Alarms ........................................................................................................ 31
3.3.11 Alarm List .................................................................................................... 32
3.3.12 Wedge Lock Option .................................................................................... 33
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3.1 Safety Information
Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT
ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment includes Hard

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

ELECTRICITY
BEFORE operating the plant make
sure that the equipment is EARTH
BONDED.
ONLY a qualified Electrical Engineer should

attend to any electrical equipment. Report
malfunctions and damage immediately.
IMMEDIATELY hit the Emergency Stop button

and apply medical treatment in the event of
electric shock.
NEVER tamper with ‘live’ electrical equipment .

Switch off and implement the Lock Out
procedure before opening electrical cabinets.
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In-running nip points can cause ENTANGLEMENT

serious injury or even death.
HAZARD
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and amputated.
SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.
Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.
ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.
ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.
If fluid is injected under the skin, it must be

surgically removed or gangrene will result.
Get medical help immediately.
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When carrying out maintenance or

adjustment to the machinery, follow
LOCKOUT PROCEDURE
the procedure as appropriate to the
particular installation.
LOCKOUT PROCEDURE
1. Switch off engine/motor

2. Remove isolation key/Isolate electrical
supply
3. Keep isolation key on person during
lockout and/or ensure electrical supply
cannot be restored.
4. Place appropriate maintenance warning
signs.
5. NEVER work alone.
Falling from and/or onto a FALLING HAZARD

BL-Pegson machine can cause
DO NOT climb onto the machine

whilst it is in operation.
ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.
ALWAYS use an E.N./A.N.S.I. approved safety

harness when reaching any points 7ft (2m) or
more above ground level.
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3.1.1 Blocked Crusher Procedures When metal enters any type of crusher it does
not shear in the same manner as stone and can
Unblocking stalled crushers become wedged and under considerable
can be hazardous. Do not pressure. In order to release the tramp metal it
undertake without careful risk is necessary to take the pressure off it and at
assessment this time it can be ejected from the machine
with catastrophic consequences
In order to avoid the Crusher becoming
blocked the machine is equipped with an A cone crusher can become ‘bridged’ when
automatic hydraulic release mechanism to oversize material is fed into it. In the event of
raise the upper frame when excessively high this happening the feed conveyor should be
crushing pressure is sensed. The upper stopped immediately. An attempt to clear the
frame automatically returns to the original machine can be made by raising the upper
setting when the foreign object should have frame by putting the machine into ‘manual’
been released through the machine. and pressing ‘open’. Should this not open
However, unduly large uncrushable objects sufficiently to allow the stone to drop through
may stall the crusher and become tightly then it will be necessary to isolate the machine
wedged in the crushing chamber. and remove the rock or break up the stone
manually with a hammer and chisel.
The clearing of blocked crushers should be
given considerable thought prior to In the event that the crusher should stall
attempting to unblock a crusher. These whilst crushing due to an overload or
procedures should be considered under risk blockage, the crushing chamber will be full
assessment review for the implementation of of stone and the feed conveyor should be
a procedure of safe working practice for stopped immediately. This should then be
this operation. released by raising the upper frame as
before and letting the material fall through.
There is a document entitled ‘Clearing
After the machine has stalled, prior to
Blocked Crushers’ available from the
resetting, the reason why the machine has
British Aggregate Construction Materials
stopped should be investigated. In the case
Industries (BACMI) which gives more
that a piece of tramp metal is in the machine
details about this and covers in more detail
extreme care should be taken whilst
risk assessment areas. Tramp metal is a
releasing it. To avoid the tramp metal being
serious problem when it enters a crusher as
ejected it may be necessary to fill the
this can cause more problems than oversize
opening to the machine with stone whilst the
or hard stone.
pressure is released.
EVERY EFFORT MUST BE MADE TO
Check the machine for possible damage
REMOVE TRAMP METAL FROM
(particularly the manganese) before
THE FEED MATERIAL
resuming operations.
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3.1.2 Safe Operation of the

Automax Crusher WARNING
Before attempting to operate WEAR PERSONAL
the Crusher DO read, fully PROTECTIVE EQUIPMENT.
Refer to Section 3.1 Safety
understand and observe the Information for relevant
contents of this manual. Also warning.
any other relevant manual for
LOCKOUT PLANT.
other equipment working in
Refer to Section 3.1, Safety
conjunction with the Automax Information for Lockout
as may be appropriate to the Procedure.
plant installation as a whole.
FALLING HAZARD.
BL-Pegson Ltd cannot over Refer to Section 3.1 Safety
Information for relevant
emphasize the need to ensure
warning.
that all safety aspects are
checked before starting the
machinery.
Check that the machinery has DO NOT allow a build up of

been Earth Bonded by a solid material or dust in any
qualified Electrical Engineer. part of the plant, in particular
keep clean the Crusher
NEVER leave the plant internal frame arms (Section
unattended whilst it is in 3.2.9) and the air blast oil
operation. cooler (on the lubricating oil
tank).
Make sure that you fully
understand the operating DO check frequently the
procedures for the Crusher stability of the equipment. The
before attempting to start supports SHOULD NOT have
undue vibration during
operation.
AVOID frequent starting and

stopping of your Crusher
unnecessarily as it WILL be
detrimental to the machine.
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3.1.3 Checks at Initial Start-Up and

Operation WARNING
• Obtain written confirmation from the WEAR PERSONAL
reponsible person that the installation of the PROTECTIVE EQUIPMENT.
machinery has been entirely completed and Information for relevant
can be operated safely, particularly in warning.
respect of the electrical installation or other
work where unreadiness to operate may
not be obvious.
• Carry out the daily checks and
• Visually check the plant and ensure that all inspections on the Crusher crusher
guards and warning signs are in position (Section 3.2.9).
and that all equipment and tools that are
hazardous to operation are removed from • Check the alignment and tension of the
the immediate area. vee rope drive daily during the initial
days of operation as appropriate.
• Inspect the complete plant to check for fluid
leaks, loose connections, missing equipment • Avoid overloading the machine by not
(particularly relating to personnel health using small discharge settings during the
and safety) or damage, etc. etc. first few days of operation.
• Before starting the crusher, the oil • Ensure that the machine is running
lubrication system must be checked to correctly and that the satisfactory feed
ensure it has been correctly installed and is maintained at a constant rate (Section
is fully operational (Section 2.4). Ensure 2.2). Irregular and excessive feed rates
the 5 minute crusher start delay timer is reduce the efficiency of the Crusher.
included and that the flexible feed piping is
free of air locks or kinks that may block or • Ensure that the Crusher feed is both
restrict the oil flow. Particularly ensure satisfactory and not segregating in the
there is a full flow of oil into the crushing chamber. Note: This applies to
countershaft housing. all machine operations subsequent to
the running in period.
• Ensure that the crusher is empty of
material. • Make sure that the crusher lubrication
system is functioning correctly (Section
• Check levels of lubricant and hydraulic oil 4.5) and that no leaks are present.
are satisfactory on :-
• Check for leaks in the crusher hydraulic
- Crusher lubrication tank system, both externally and inside the
- Crusher hydraulic reservoir. hydraulic console.
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3.2 Automax Operation Selection of the discharge setting is carried out

manually with the controls switched into
The Automax crusher is a high quality cone ‘MANUAL’ as are also other additional
crusher featuring:- functions described later.
• Optimum Performance - Advanced The material product from the Crusher is

crusher geometry. Excellent product governed by the closed side discharge setting
shape through attrition crushing. dimension, ie. the minimum gap between the
High output capability. Maximum concave and mantle manganese crushing
production of high quality material. members. See the Glossary of Terms for other
ways of referring to the ‘setting’. Changes to
• Low Cost Operation - High capacity the discharge setting are achieved by raising or
with energy efficiency. Low wear lowering the Crusher upper frame by means
costs. Exceptional reliability. of the six externally mounted hydraulic rams.
• Ease of Maintenance - Accessible When new manganese is fitted the MANUAL

external hydraulics. Simple assembly hydraulic controls are used for the panel to
and dismantling. Quick manganese record a ‘zero’ point at which the mantle and
changes. concave are just touching. The required
discharge setting dimension is then manually
To assist in understanding the Crusher entered into the panel controls. The hydraulic
hydraulic control functions the following system can then position the upper frame so
brief explanation is given. The actual step that the gap between the mantle and concave
by step procedures are detailed in the equals the entered setting. This procedure is
following pages under the appropriate carried out with the machine stationary.
section headings. Refer also to the Glossary
of Automax Terms (Section 2.1.8 ) for During crushing operations the mantle and
additional information. concave wear under abrasive action of the
material being crushed and the gap between
With the Crusher in normal ‘AUTO’ the two will increase although the panel
crushing operation the hydraulic system display will still show the original gap setting.
automatically maintains a pre-selected
discharge setting which determines the To restore the actual gap between the two
product from the machine. The setting is crushing members to the original setting it is
maintained by hydraulic pressure and, in the necessary to manually reset the ‘zero’ point
event of uncrushable material entering the with the mantle and concave touching. The
machine, the hydraulic overload release is controls can now compare the new zero point
automatically triggered to raise the upper with the original zero point with new
frame to pass the foreign body and then manganese. The machine is to be stationary
automatically returns to the selected setting. when this procedure is carried out.
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By selecting ‘manganese wear’ on the Also available on the hydraulic control

display screen, the panel will now calculate display are additional read out facilities
the amount of wear that has taken place including crusher motor hours run and
since fitting new manganese. The rate of number of tramp overload situations
manganese wear obviously depends upon (Section 3.3.3)
the physical characteristics of the feed
material and other governing factors and In addition to these normal machine control
will confirm the frequency of re-calibrating functions the system also includes a
the zero point to maintain the desired separate audible alarm and hydraulic system
product and also the need to change the malfunction messages which appear on the
manganese mantle and concave. display screen (Sections 3.3.9 to 12)
For guidance on when to change the Additionally, a separate subsidiary hydraulic

manganese mantle and concave liners refer circuit is employed to apply pressure to the
to Section 4.7.1. wedge ring and the requirements for this
system are also covered later in this manual
It is most important to change (Section 3.2.8).
both the liners together when
fitting new replacements. Service schedules in this manual assume
reasonable operating conditions apply.
At the same time as changing the mantle Refer to BL-Pegson Limited’s Technical
and concave, take the opportunity of Department for advice if the operating
replacing the frame arm and countershaft conditions are other than normal.
protection liners.
Genuine replacement parts obtainable from

BL-Pegson are manufactured with the
correct material specification and to the
original dimensions under strict quality The procedures in this section
control. Always quote the machine serial relate to the crusher equipped
number stamped on the machine identity with the standard ‘System 2’
plate when ordering. controls.
For the alternative ‘System 3’
The hydraulic control system also allows the
and ‘Maxset’ control systems,
discharge setting to be altered whilst the
refer to the separate
machine is running and also a number of
Addendum for details.
other functions as described in the following
pages.
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Numeric Keypad Display
AUTO/MANUAL
Switch
OPEN Button CLOSE Button
Pressure
Gauge
TRAMP O/L TEST
Button
Isolator
Switch
Figure 3a Crusher System 2 Hydraulic Panel Controls
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3.2.1 Initial Discharge Setting and

Calibration - System 2 WARNING
FOR THIS OPERATION THE WEAR PERSONAL
CRUSHER MUST NOT BE PROTECTIVE EQUIPMENT.
RUNNING
warning.
Referring to the separate Crusher
Control Panel (Section 3.3.6) for
detailed instructions, action as
follows:-
Procedure 8. Enter the required closed side setting

(mm) using the number keys and press
the Enter key.
1. Observe all safety warnings.
9. Move to the Current Gap display
screen.
2. Turn the Isolator Switch on the Crusher
hydraulic console panel (Figure 3a) into
10. Depress the OPEN button; hold until
the ON position..
the Current Gap display shows the
gap to be above the Set Gap setting
3. Switch to MANUAL and depress the
then switch to AUTO. The machine
OPEN button to raise the Upper Frame
will automatically come down to the
approximately 25-38mm (1” - 1½”).
required setting.
Look into the Automax crushing
chamber to check there is no stone
lodged in the chamber.
4. Now depress the CLOSE button until

the manganese crushing members
(mantle and concave) touch. This is
indicated by a sudden rise in pressure
shown on the gauge on the panel.
5. Select the New Mang display screen.
6. Press the ‘2’ key to Zero the display.
7. Move to the Set Gap display screen.
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3.2.2 Manganese Wear Calibration

FOR THIS OPERATION THE
WARNING
CRUSHER MUST NOT BE WEAR PERSONAL
RUNNING PROTECTIVE EQUIPMENT.
Referring to the separate Crusher warning.
Control Panel (Section 3.3.7) for
detailed instructions, action as
follows:-
Procedure

1. Observe all safety warnings
screen.
the ON position.
gap to be just above the Set Gap
setting then switch to AUTO. The
machine will automatically come down
OPEN button to raise the Upper Frame
to the required setting.
approximately 25-38mm (1” - 1½”).
Look into the Automax crushing
Note: After calibration the amount of
chamber to check there is no stone
manganese worn off the crushing
lodged in the chamber.
members is displayed by selecting the
Mang Wear display screen.
4. Now depress the CLOSE button until
the manganese crushing members
The interval between future
(mantle and concave) touch. This is
calibrations is determined by
indicated by a sudden rise in pressure
machine usage and estimated
shown on the gauge on the panel.
wear of the manganese.
5. Select the Set Zero display screen.
6. press the ‘1’ key to Zero the display

screen.
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3.2.3 Guidance for Changing the When replacing the manganese liners,
Manganese Mantle and Concave always fit both a new mantle and a new
concave at the same time.
Both the mantle and concave liners are
locked against their mating parts using Always fit a new manganese
tapers (angled faces). If these liners are mantle and concave as a ‘pair’.
worn too thin they will not be able to hold It is detrimental to the
tight against their mating faces, coming operation of the machine to do
loose and/or slipping relative to their mating otherwise.
part. The mating will be damaged and will
need reworking.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 55-60mm (21/8”-

23/8”) of wear on the liners, as a pair.
Take note of the ‘wear’ shown on the

display (Section 3.2.2).
Inspect the liners on a daily basis, for

mm minimum
possible ‘tramp metal’ damage and also any

evidence of an uneven wear pattern
developing.
The manganese liners must be changed

/2”)
when the hydraulic rams can be fully closed.

1
774 (30
The pin centre to pin centre distance

(Figure 3b) when the rams are fully closed
is 774mm (301/2”).
Figure 3b Minimum Ram Dimension
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3.2.4 Initial Start Up

WARNING
Procedure WEAR PERSONAL
PROTECTIVE EQUIPMENT.
1. Observe all safety warnings warning.
2. Turn the Isolator Switch Crusher

DANGER
the ON position. FLUID INJECTION HAZARD
3. Start the Crusher oil lubrication pump warning
and, after the preset delay of 5 minutes
(to allow good circulation of oil) start
the crusher drive motor..
4. Check that the overall operation of the

lubrication system is satisfactory.
setting. This pressure should be in the
5. Run the Crusher empty for a short region of 55-82 BAR (800-1200psi).
period and check the machine for
unusual noises, vibration, excessive Note: The cone head rotates with the
heat, leaks of lubricating oil. eccentric while the machine is running
empty, but stops when feed is
6. Check the hydraulic system for leaks introduced into the crushing chamber
and that the discharge setting is being and begins to slowly rotate in the
maintained. opposite direction.
7. Check the travel on the Crusher Upper

Frame by switching into MANUAL on
the Crusher Console Panel (Figure 3a)
and depressing the OPEN button. The
Upper Frame will travel upwards.
Release the button when the hydraulic
cylinders have reached the full extent of
their travel and switch to AUTO. Note
the pressure on the panel gauge as the
machine closes down to it’s discharge
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3.2.5 Actions during running in

• Check the alignment and tension of the WARNING
vee rope drive daily during the initial WEAR PERSONAL
days of operation. PROTECTIVE EQUIPMENT.
• Avoid overloading the machine by not warning.
using small discharge settings during
the first few days of operation.
• Ensure that the machine is running

correctly with no abnormal noises or
leaks evident.
• Make sure a satisfactory feed (Section

2.2) is maintained at a constant rate to
give a choke feed (Section 2.1.8
Glossary). Irregular and excessive feed
rates reduce the efficiency of the
Crusher. Ensure that the feed is not
segregated in the crushing chamber.
Note: This applies to all machine

operations subsequent to the running
in period.
• Keep a check on the lubrication system

to confirm this is operating satisfactorily
and that the system safeguards warn of
any possible high temperature or low
flow (Section 4.5).
• Check the operation of the hydraulic

system (Section 4.6) including the
smooth raising and lowering of the
upper frame and the correct functioning
of the wedge ring (Section 4.8).
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3.2.6 Adjustment of the Discharge

Setting WARNING
CRUSHER RUNNING WEAR PERSONAL
Referring to the separate Crusher Information for relevant
Control Panel (Section 3.3.5) for warning.
detailed instructions, continue as
follows:-
Procedure

the ON position.
3. Switch to MANUAL.
4. Move to the Set Gap display screen.
5. Enter the required closed side setting

(mm) using the Number keys and
then press the Enter key.

screen.

gap to be above the Set Gap setting
then switch to AUTO. The machine
will automatically come down to the
required setting.
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3.2.7 Manual Raising/Lowering of

the Upper Frame WARNING
CRUSHER RUNNING WEAR PERSONAL
Provision is made for raising and lowering
the Upper Frame when under manual warning.
control.
DO NOT RUN UNDER

MANUAL CONTROL
WHILST THE CRUSHER
IS UNATTENDED. 5. On reselection of AUTO the control
automatically resets the discharge
Be aware that when running in setting to that previously specified.
MANUAL the machine will
open under overload but will
not return to the selected
discharge setting and oversize
material will result.
If the machine is left in manual control an

audible warning alarm will sound after a
short period to warn the operator to switch
into auto control.
Procedure

the ON position.
3. Switch to MANUAL.
4. Depress the OPEN button to raise the

Upper Frame to the maximum extent.
On release of the button the Upper
Frame is retained at this position.
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3.2.8 Automatic Overload Release/ In order to protect the Crusher

Unblocking and Resetting from the ingress of damaging
tramp metal a metal detector
The control equipment on the Automax should be fitted on the feed
crusher automatically monitors the conveyor which will sound an
operating conditions of the hydraulic alarm and stop the feed.
system for tramp metal/packing in the
crushing chamber and effects an It is essential to remove the
immediate release. The equipment also offending object before
resets the discharge setting and also resetting the detector and
compensates for any tendency for the restarting the feed.
setting to creep open during normal
operation. Make sure that the metal
detector is operative at all
Normally the hydraulic system clears any times when crushing and
tramp metal from the crushing chamber. correctly set for sensitivity, ie.
However, in the event of the tramp metal will not ignore oversize tramp
being too large to be released, severe metal.
damage to the machine can occur as the
system continues to try and release the
object.
In this event the machine should be

switch to manual control, the Upper
Frame raised, and the blockage removed
manually. Refer to Section 3.1 1 for
Blocked Crusher Procedures.
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3.2.9 Checking the Wedge Pressure

CRUSHER NOT RUNNING
WARNING
WEAR PERSONAL
The pressure on the wedge ring is PROTECTIVE EQUIPMENT.
automatically controlled by the Dumpy Jack
hydraulic circuit. However, as the warning.
adjustment of the wedge ring is critical for
good performance of the Automax crusher
it is recommended that this should be
checked daily. The pressure gauge on the
panel (Figure 3a) gives an accurate
indication of whether the Wedge Ring 4. Switch back to AUTO and observe the
assembly is functioning correctly. pressure reading on the panel pressure
gauge. The pressure should be in the
The Automax must not be range 55-82 BAR (800 - 1200 psi).
allowed to operate with regular
dumping or bouncing of the 5. Whilst the Upper Frame is moving
Upper Frame as damage may check for smooth movement with no
result. Possible causes could sticking at the start or whilst
be crushing at too small a travelling.
setting, out of round
manganese (Section 4.9) or 6. If the pressure reading is above or
poor Wedge Ring adjustment below the range indicated above or
(4.8) the action is not smooth, remedial
action is required (Section 4.8.2).
Procedure
2. Turn the isolator switch on the Crusher

the ON position.

OPEN button lifting the Upper Frame
approximately 20mm (3/4”) above the
set point.
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3.2.10 Daily Crusher Checks

Daily attention should always
WARNING
be a matter of routine to WEAR PERSONAL
ensure maximum efficiency of PROTECTIVE EQUIPMENT.
this vital element of the plant. Information for relevant
warning.
Before starting the Crusher
• Look at the manganese liners to check

DANGER
for wear and/or damage. FLUID INJECTION HAZARD
• Check oil level in lubrication tank Refer to Section 3.1, Safety
• Check oil level in hydraulic tank. warning
• Check oil pressure in hydraulic console.
• Check the operation of the lubrication
oil heater. After starting the lub oil pump
• Check Wedge pressure.
• Re-calibrate the manganese. • Check the oil flow to the crusher and
• Check for any obstructions in the back into the tank (sight glass on top
discharge opening of the Crusher. of oil tank in return pipe) and that oil
• Check the condition of the vee drive. lines do not leak.
• Check for loose bolts, leaks, hose
connections, etc. After starting the Crusher
• WARNING Ensure the frame arms • Set the discharge setting
are free from foreign bodies/stone • Listen for any abnormal noise from the
build up. See the warning sign on the crusher.
machine (Figure 3c). • Check that no bolts have come loose.
During crushing
• Listen for any abnormal noise from the
crusher.
• Check oil pressure at normal running
temperature.
• Check no leaks in the lubrication
system.
• Inspect hydraulic system piping, cylinders, etc.
for leaks which could cause an alteration in
the setting.
Figure 3c Frame Arm Warning Sign • Note the crushing pressure.
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3.3 Autocone Controls - The procedures in this section

System 2 relate to the crusher equipped
with the standard ‘System 2’
The Autocone Crusher is equipped with the controls.
latest ‘System 2’ hydraulic controls having a For the alternative ‘System 3’
Unitronics M-90 control module with numeric and ‘Maxset’ control systems,
keypad and status display. The layout, refer to the separate
functions and displays are described on the Addendum for details.
following pages.
3.3.1 Controls Layout
Figure 3d Controls Layout
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3.3.2 Function Keys
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3.3.3 General Operation
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3.3.4 Manual Operation
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3.3.5 Setting the Gap
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3.3.6 Setting New Manganese
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3.3.7 Setting Normal Zero
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3.3.8 Tramp Overload or Test

(whilst in Manual)
3.3.9 Tramp Overload or Test

(whilst in Auto)
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3.3.10 Alarms
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3.3.11 Alarm List
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3.3.12 Wedge Lock Option
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Blank page
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Maintenance Issue 01 ENG
Page 1
Contents
4.1 Safety Information ............................................................................................... 3
4.2 Weights of Crusher Components ...................................................................... 7
4.3 General Information ............................................................................................. 8
4.4 Lubricants, Oils, etc. .......................................................................................... 10

4.4.1 Service Attention Points ................................................................................ 10
4.4.2 Regular Servicing .......................................................................................... 11
4.4.3 Daily, Weekly and Monthly Checks ................................................................ 12
4.4.4 Lubrication and Servicing Schedule .............................................................. 14
4.4.5 Recommended Oil/Grease Types.................................................................. 15
4.4.6 Lubrication Specifications ............................................................................. 16
4.4.7 Wedge Ring Grease Specification ................................................................ 17
4.5 Lubrication ......................................................................................................... 18
4.5.1 Lubrication System Overview ........................................................................ 18
4.5.2 Lubrication Operating Procedure .................................................................. 19
4.5.3 Lubrication System - Detailed Description ..................................................... 21
4.5.4 Oil Change Intervals ...................................................................................... 23
4.5.5 Recommended Oil ........................................................................................ 24
4.5.6 Oil Filter Change Intervals .............................................................................. 25
4.5.7 Filter Replacement ........................................................................................ 26
4.5.8 Oil Lubrication System - General Maintenance .............................................. 27
4.6 Hydraulics .......................................................................................................... 28
4.6.1 Hydraulic System Overview ........................................................................... 28
4.6.2 Hydraulics Maintenance Procedure - System 2 .............................................. 31
4.7 Manganese Change Procedure ........................................................................ 33
4.7.1 Guidance for Changing the Manganese Mantle and Concave ........................ 33
4.7.2 Filler Handling ............................................................................................... 34
4.7.3 Changing the Manganese ............................................................................. 36
4.8 Wedge Ring Maintenance ................................................................................. 52
4.8.1 Checking Wedge Pressure ........................................................................... 54
4.8.2 Low Wedge Pressure ................................................................................... 55
4.8.3 Readjusting Tight Wedge Ring ...................................................................... 56
141004
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4.9 Out of Round Manganese - Causes and Effects ............................................. 58

4.9.1 Checking Manganese for Out of Round ......................................................... 59
4.10 Fault finding. .................................................................................................... 62
4.11 Crusher Drive Belts (optional extra item) ....................................................... 72

4.11.1 Replacement of the Drive Belts (Optional Extra) .......................................... 73
4.11.2 Method of Drive Belt Tensioning .................................................................. 74
4.11.3 Trouble Shooting - Drive Belts ..................................................................... 77
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4.1 Safety Information
Loose or baggy clothing can get PERSONAL

caught in running machinery. PROTECTIVE EQUIPMENT
ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) personal
protective equipment.
Personal Protective Equipment includes Hard

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

ELECTRICITY
BEFORE operating the plant make
sure that the equipment is EARTH
BONDED.
ONLY a qualified Electrical Engineer should

attend to any electrical equipment. Report
malfunctions and damage immediately.
IMMEDIATELY hit the Emergency Stop button

and apply medical treatment in the event of
electric shock.
NEVER tamper with ‘live’ electrical equipment .

Switch off and implement the Lock Out
procedure before opening electrical cabinets.
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When carrying out maintenance or

adjustment to the machinery, follow
LOCKOUT PROCEDURE
the procedure as appropriate to the
particular installation.
LOCKOUT PROCEDURE
1. Switch off engine/motor

2. Remove isolation key/Isolate electrical
supply
3. Keep isolation key on person during
lockout and/or ensure electrical supply
cannot be restored.
4. Place appropriate maintenance warning
signs.
5. NEVER work alone.
Hydraulic fluid under pressure can SKIN INJECTION

penetrate the skin causing serious
HAZARD
injury.
ALWAYS relieve the pressure from

the hydraulic system before
carrying out any kind of
maintenance or adjustment.
ALWAYS use a piece of cardboard to check for

leaks. DO NOT use your hand.
If fluid is injected under the skin, it must be

surgically removed or gangrene will result.
Get medical help immediately.
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In-running nip points can cause ENTANGLEMENT

HAZARD
DO NOT reach into an unguarded
machine.
Your arm could be pulled in and amputated.
SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.
Falling from and/or onto a FALLING HAZARD

BL-Pegson machine can cause
DO NOT climb onto the machine

whilst it is in operation.
ALWAYS use the walkways/platforms provided

or a safe and secure platform approved by the
local regional safety enforcing authority.
ALWAYS use an E.N./A.N.S.I. approved safety

harness when reaching any points 7ft (2m) or
more above ground level.
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WARNING
PRIOR TO ANY MAINTENANCE
• These instructions are intended for day to day maintenance to keep the machinery in good running
order and do not cover major rectifications, repairs or replacements where specialist expertise is
required. However, only suitably competent and trained personnel should be employed for the task in
hand.
• Observe the safety advice given in Section 1 as appropriate to the task(s) in hand.
• Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk Assessment
for all maintenance operations; have suitable lifting gear available for the weights involved and all
necessary tools/equipment ready for the task(s) in hand before starting work. BL-Pegson’s Service
Department is available for advice when required.
• The machinery should be completely emptied of material i.e. stone. Implement the ‘Lockout
Procedure (Section 4.1).
• Keep clear of moving parts when trying to identify or isolate any unusual noises whilst the machine is
running.
• Fit dismantled parts in the same location from which they were removed.
• Ensure that the area surrounding the maintenance site is clear of any obstructions.
• If arc welding work is involved in any maintenance operation, ensure that the current does not pass
through any bearings.
The machinery must be fully isolated prior to any welding work.
• Implement a lockout procedure by removing the engine isolation key and keeping on person
or take steps to guarantee integrity of electrical isolation whilst working on the machinery,
as appropriate to the installation.
BEFORE WORKING ON THE PLANT, SWITCH OFF, ‘LOCKOUT’ AND ‘TAGOUT’
AFTER EXTENSIVE MAINTENANCE

Refer to Sections 3.2.1 ‘Initial Discharge Setting and Calibration’, also 3.1.3 ‘Checks at initial Start Up’.
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4.2 Weights of Crusher Components
Weights of the crusher components, these should be consulted when arranging suitable lifting
equipment. Refer to BL-Pegson’s Technical Department for any other weights of individual items or
assemblies if not listed.
WEIGHTS (APPROXIMATE) KGS. LBS.
Complete Automax Crusher 22,000 48,400
Upper Frame Assembly (upperframe with concave) 5,260 11,598
Cone Head Assembly (with bearings, mantle etc.) 2,950 6,505
Eccentric Assembly (with bearings, ring gear etc.) 1,800 3,970
Countershaft Assembly 500 1,103
Concave 760 1,676
Mantle 852 1,879
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment
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4.3 General Information Where it is necessary to remove any guards

for maintenance purposes, make sure that
When performing maintenance tasks, they are replaced before the machine is
always observe the local site safety rules or restarted.
as provided in the safety section of this
manual. Refer to the Spare Parts illustrations
(Section 5) to identify the machinery
The arduous task of continuously crushing components mentioned in the maintenance
stone and the generally harsh environment in procedures.
which the Crusher has to operate calls for
reasonable care and consideration to be
taken to keep the machine in A1 order.
Machinery breakdown caused by

insufficient or improper maintenance will
cause high repair costs and long term
standstill. Therefore, regular maintenance is
imperative.
In addition to several other factors, the

reliability e of theutomax crusher depends
on regular and proper maintenance.
The following section contains maintenance

instructions as well as maintenance
schedules for normal operating conditions.
When the crusher is operated

in extreme climatic conditions
e.g. below
-15°C (5°F) or above 30°C
(86°F) or in very dusty
conditions, the maintenance
schedules must be changed to
suit.
Ask your local dealer or BL-

Pegson Technical Department
for advice.
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PRACTICE SAFE
MAINTENANCE
Always wear the appropriate

protective clothing and use the
correct tools and appliances.
Understand service procedures

before doing any work. Keep
the area clean and dry.
Never lubricate, clean, service

or adjust machine whilst it is
moving.
Keep hands, feet and clothing

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

operate controls to relieve
pressure. Stop the engine/
motor. Implement lockout
procedure. Isolate the
electrical supply. Allow the
machinery to cool.
Securely support any machine

elements that must be raised
for service work.
Keep all parts in good

condition and properly
installed. Attend to damage
immediately. Replace worn or
broken parts.
Remove any build up of

stones, dust, grease, oil or
other debris from the machine.
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4.4 Lubricants, Oils, etc.

WARNING
4.4.1 Service Attention Points WEAR PERSONAL
Routine checks/replenishment/changes of
lubricants, oils, etc. must be carried out to the Information for relevant warning.
plant machinery in accordance with the
Lubrication and Servicing Schedule (Sections
LOCKOUT PLANT.
4.4.4 to 4.4.7) in order to maintain efficiency. Refer to Section 4.1, Safety
Information for Lockout
The locations of the Service Attention Procedure.
Points are as follows:-
FALLING HAZARD.
• Crusher lubricating Oil Tank (Figure
Information for relevant warning.
4b).
• Crusher Upper Frame grease nipples.
(Figure 4g).
• Hydraulic Oil Reservoir in the hydraulic
console. (Figure 4c). Failure to carry out scheduled
• Periodically lubricate Cylinder Pivot maintenance or exercise due
Pins and similar points with grease or oil care may invalidate any
(as appropriate) to prevent seizure warranty that might apply.
during lengthy spells of inactivity.
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4.4.2 Regular Servicing

Particular attention should be paid to
WARNING
institute a regime of strict adherence to WEAR PERSONAL
routine regular maintenance schedules from PROTECTIVE EQUIPMENT.
the start of operations. Keep records. Information for relevant warning.
It is most important to keep the oil

LOCKOUT PLANT.
lubrication system in good order by only
using an approved lubricant of the correct Information for Lockout
grade for the prevailing conditions, changing Procedure.
at the appropriate intervals and observing
the filter change schedule using only the FALLING HAZARD.
correct pattern of replacement part. Refer to Section 4.1, Safety
Information for relevant warning.
In addition to taking note of the Lubrication
Schedule and Recommended Oils (Sections
4.4.4 to 4.4.7) always observe the
instructions and recommendations included
under Lubrication System (Section 4.5).
Make sure that all the various lubrication

system protection devices (as detailed on
the wiring diagram) are operative and acted
upon.
The hydraulic system (Section 4.6) as a

whole should not be neglected from regular
inspections for damage or leaks.
Make sure that frequent checks are made

for wear to the manganese mantle and
concave (Section 4.7) and other wearing
surfaces so that replacement can be made
before any damage to the core of the
Crusher is sustained.
Regularly check the wedge pressure

(Section 4.8.1) to avoid damage to the
machine and to obtain the best performance
from the Crusher.
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4.4.3 Daily, Weekly and Monthly

Checks WARNING
It is imperative that the operator
WEAR PERSONAL
carries out regular and diligent PROTECTIVE EQUIPMENT.
checks before operating the Refer to Section 4.1, Safety
plant especially with operational Information for relevant
safety in mind including (but not warning.
limited to) those listed below. LOCKOUT PLANT.
Additionally, the operator should Information for Lockout
always consider what particular Procedure.
safety hazards could occur at FALLING HAZARD.
specific operating sites and take Refer to Section 4.1, Safety
steps to eliminate them before Information for relevant
warning.
commencing work.
Daily Checks 6. Fully raise and lower the Crusher Upper

Frame several times manually (Section
1. Check that all guarding is complete and 3.2.7) to help distribute the grease on the
properly secured prior to start up. Also wedge ring for smooth operation.
that any warning signs are present and
readable. 7. Check the Crusher Wedge Pressure is
satisfactory (Section 3.2.9)
2. Check that all the plant emergency stop
buttons are operative. 8. Ensure that the Crusher internal frame
arms are free of foreign bodies or
3. Carry out a general inspection of the material build up (Section 3.2.10).
machinery to ascertain that nothing
untoward is out of place or damaged so 9. Recalibrate the manganese wear on the
as to cause a safety hazard. Crusher (Section 3.2.2) to compensate
for the previous days wear.
4. Carry out the Crusher daily Lubrication
and Servicing Schedule (Section 4.4.4). Weekly Checks
5. Look for loose fixings and rectify. 1. Perform all checks on the daily check
Check the security of nuts and bolts on list.
the Crusher. Verify there are no leaks of
lubricating/hydraulic oils. 2. Carry out the weekly Lubrication and
Servicing Schedule. (Sections 4.4.4).
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3. Note the Crusher manganese wear.

Arrange renewal when necessary WARNING
(Section 4.7)
WEAR PERSONAL
4. Check the area in and around the PROTECTIVE EQUIPMENT.
Crusher for build-up of material; clean Refer to Section 4.1, Safety
out as necessary. warning.
5. Ensure all hydraulic hoses and joints LOCKOUT PLANT.

are free from leaks.
Procedure.
6. Check drive belts for damage, wear
and fraying. FALLING HAZARD.
7. Clean away dust, dirt and grit from warning.
maintenance platforms and any
moving parts.
8. Check conveyor belts for damage and

fraying.
Monthly/6 Monthly/Annual Checks
1. Perform all checks on the daily and

weekly check list
2. Lubricate and Service to the monthly

requirements also attending to the
longer interval requirements as
necessary (Sections 4.4.4).
3. Visually examine the Crusher for wear

and damage at regular intervals. Renew
as necessary.
4. Inspect crusher drive belts for signs of

wear, renew as necessary..
5. Check all drive belts are at the correct

tension.
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1300 Automax/Autosand Service Schedule
Schedule based on a 40 hour operating week (2000 hours per year). Adjust schedule to suit actual operating hours.
Lubricant Monthly (165 hrs),

Description or Quantity Level Daily Weekly 6 Monthly (1000 hrs),
Fluid Annually (2000 hrs)
275 litres Sight glass First change after 500 working hours
Automax Lubrication See chart
(72.6 US upper mark Check Thereafter change after every 1000
Oil Tank opposite
Galls) (on tank) hours
Inspect
Automax Oil Lubrication complete First change after 100 working hours
Pressure Filter x 2 ~ 2 Check Lubricating Thereafter change after every 500
(Parts List item 10A)
~ Oil system hours
for
Automax Oil Lubrication faults
Replace when changing
Suction Filter ~ 1 ~ ~ lubricating oil
(Parts List item 2)
Automax Hydraulic System 45 litres Sight glass

See chart
Fluid Reservoir (11.9 US upper mark Check Change after 5000 working hours
opposite
4.4.4 Lubrication and Servicing Schedule
(inside hydraulic console) galls) (on reservoir)

Automax Hydraulic System
Pressure Filter ~ 1 ~ ~ Change after 2000 working hours
(Parts List item 11A) Inspect
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complete
Maintenance

Hydraulic
Pressure Filter ~ 1 ~ Change after 2000 working hours
~ system
(Parts List item 12A)
for
Automax Hydraulic System faults
Suction Filter ~ 1 ~ ~ Replace when changing hydraulic fluid
(Parts List item 5)
Suction Filter ~ 1 ~ ~ Replace when changing hydraulic fluid
(Parts List item 6)
Automax Grease Nipples Add 25-50 g (1-2 oz) of grease to each
See chart
(located around the machine 12 Check ~ nipple if the travel of the upper
opposite ~
upper frame) frame is not smooth
1300
Page 14
Issue 01 ENG
Automax Crusher
Equipment Grade Century Mobile Shell Esso Gulf BP
Automax Oil
Lubrication System
> 4º C (39º F) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4º C (39º F) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Automax Hydraulic
System E Centraulic PWL Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLP-HM32
(all temperatures)
Automax Upper
Frame Grease Chemodex MOLY - BENTONE MP Standard Grade
Nipples
15/10/03
Note: > 4°C (39°F) is defined as a daily temperature consistently above 4°C (39°F),
< 4°C (39°F) is defined as a daily temperature consistently below 4°C (39°F),
4.4.5 Recommended Oil/Grease Types
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Issue 01 ENG
Automax Crusher
Automax Crusher
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Page 16
4.4.6 Lubrication Specifications
Oil Specification Grade A Grade B Grade C

Flashpoint: Minimum °C (°F) 199 (390) 204 (399) 216 (421)
Pour Point °C (°F) -18 (0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s 150 220 460
(104°F, in²/s) (0.232) (0.341) (0.713)
Kinematic Viscosity at 100°C, mm²/s 15.4 20.1 32.9
(212°F, in²/s) (0.0238) (0.0312) (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25°C (77°F) 280
Worked Penetration at 25°C (77°F) 285
Drop Point °C (°F) 185 (365)
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135°C (275°F) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40°C mm²/s 32 46 68
(104°F, in²/s) (0.049) (0.0713) (0.105)
Kinematic Viscosity at 100°C mm²/s 5.5 6.5 8.5

(212°F, in²/s) (0.085) (0.010) (0.013)
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes
Figure 4a Lubrication Specifications
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4.4.7 Wedge Ring Grease Specification
WEDGE RING LUBRICANT FOR CONE CRUSHERS

The lubricant grease for BL-Pegson Cone Crushers applied to the grease nipples situated around the upper
frame is recommended to be as follows:-
MOLY - BENTONE M.P. GREASE
This is a special non-melt, long life, multi-purpose grease containing molybdenum disulphide.
CHEMODEX MOLY-BENTONE M.P. Greases are prepared from specially selected oils solidified with a non-
soap gellant which imparts infusible or non-melt characteristics. The gellant is known as Bentone and is
produced by reacting specially selected and refined bentonite with a cationic fatty derivative.
The gellant has a micro-lamellar structure which also applies to micronised molybdenum disulphide, so that
these two components have a synergistic effect in the compounded grease, giving enhanced stability as well as
lubricating value.
Chemodex MOLY-BENTONE M.P. GREASES -
are infusible and have no melting point or drop point
show minimum change of consistency with variations in temperature
are resistant to mechanical working or shearing in the bearing
minimise wear and friction
give greater margins of safety in shock and overload conditions
are resistant to acids and alkalis and to aqueous solutions of most chemicals
are neutral in reaction and suitable for use with all metals and alloys
are excellent lubricants for bearings made from plastic materials
Standard Grade
Gellant Base Bentone

Consistency N.L.G.I No: 3 Medium/Heavy
Penetration at 25 deg. C 220/250
Temperature Range -20 deg. C to 200 C
Drop Point None
Water Resistance Complete
The Standard Grade is recommended for large. slow speed bearings for slides and splines and to resist shock-
load conditions..
The molybdenum disulphide content gives greater margin of safety, especially where intervals between
lubrication are liable to be prolonged, where there may be occasional overload operations and where
temperatures are high.
Chemodex MOLY-BENTONE M.P. GREASES are recommended for the lubrication and protection of - stone
and ore crushers, conveyor systems, cranes, winches, printing machines, rolling mills and foundry equipment,
mechanical stokers, glass works equipment, pumps of all types and marine equipment in general, etc.
Chemodex MOLY-BENTONE M.P. GREASES are available in 450 gm and 3 kilo tins, and 12½, 25 and 50 kilo
kegs.
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4.5 Lubrication
WARNING
4.5.1 Lubrication System Overview WEAR PERSONAL
The Automax cone crusher is lubricated by an
independent motorised oil pump mounted on Information for relevant
the separate oil tank. warning.
LOCKOUT MACHINE.
The electrical wiring of the Refer to Section 4.1, Safety
system and the provision of Information for Lockout
control equipment must be in Procedure.
accordance with the wiring
diagram(s) supplied with the
machine.
Filtered oil from the tank is pumped under

pressure through external pipework to inlet points
on the Crusher at the base of the mainshaft from
where the oil is distributed internally to the cone
head and eccentric roller bearings whilst a second
inlet pipe feeds oil to the countershaft assembly
bearings. Oil from the bearings lubricates the
drive gear and pinion on it’s gravity return to
the oil tank to be filtered and re-circulated.
After the oil pump has been started the control

system must delay the crusher start for 5
minutes (refer to the requirements shown on
the wiring diagram) to allow a good circulation
of oil within the Crusher and should occur
every time the oil pump is started.
Lubrication safety devices included are

monitors for low oil flow, high temperature,
low tank level and low oil pressure. These
protection devices must be operative.
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4.5.2 Lubrication Operating

Procedure WARNING
It is absolutely essential that the oil pump is WEAR PERSONAL
always running and the system fully PROTECTIVE EQUIPMENT.
operational whilst the Crusher is running Information for relevant
and interlocks must be in place to ensure warning.
the crusher drive motor is immediately
LOCKOUT MACHINE.
stopped in the event of an oil system fault. Refer to Section 4.1, Safety
The air blast type cooler mounted on the oil Procedure.
tank is to be controlled by the thermostat to
operate the fan when the oil temperature
reaches a preset level. Abnormally high
ambient temperature situations may require
special equipment.
An immersion heater is provided in the oil

tank to preheat the oil which should be used
in cold conditions to preheat the lubricating
oil prior to starting the machine. Abnormally
low ambient temperature situations may
require special equipment.
To prolong the life of the bearings it is also

good practice when stopping the crusher to
allow the crusher cone head to stop spinning
before switching off the oil pump.
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Oil Flow Meter

Cartridge Filters
Pressure Gauge
Air Cooler
Cooler
Thermostat Oil Filler Cap
Float Switch
Level Sight Glass
Oil Tank
Immersion Heater Terminal Box
Figure 4b Crusher Oil Lubrication Tank
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4.5.3 Lubrication System - Detailed Cold Weather Start-up

Description The system enables immersion heated
lubrication oil to be warmed prior to the
Function lubrication pump and machine operating.
This ensures efficient circulation of the oil as
The primary functions of the lubrication
soon as the machine crushing begins.
system are:-
- to prevent damage due to metal on metal On mobile plants it is advised that the
contact within the bearings. immersion heater is activated 1 hour for
- to dissipate heat generated by the every 10°C (50°F) the ambient temperature
bearings during operation, so acting as a is below 30°C (86°F) prior to crushing, eg.
coolant. with an ambient temperature of 15°C
(59°F) switch the heater on 1½ hours
The bearings can be seriously damaged if
before start-up.
any one of the following characteristics are
inadequate:- Air Blast System
This enable the hot oil to be cooled as is
• Viscosity (grade)
circulated through the system and into the
• Quantity (flow)
machine. This keeps the oil at an optimum
• Cleanliness
working temperature.
• Toughness of the lubricant film
(Timken load rating) BL-Pegson strongly advise against running
the Crusher empty after initial start-up in
Operation
cold weather. Even hot oil can be chilled
when entering a cold machine and it’s
Oil is supplied the Crusher bearings via an
reluctance to return to the tank may result in
electric motor driven pump. This oil is
a slight leak from the machine via the cone
filtered clean and pumped under pressure to
head/seal ring and/or mainframe/seal ring.
the main bearings (eccentric and cone head)
Ideally, once the crusher is started rock
and via a separate line to the countershaft
should be put through it as soon as
bearings. It is then piped back to the tank
possible. BUT THE CRUSHER MUST
under gravity.
NEVER BE STARTED WITH ROCK
PRESENT IN THE CRUSHING
An automatic alarm is necessary which will
CHAMBER.
sound if there is insufficient pressure or flow
to the machine. It is difficult to give a
working pressure as this varies significantly
under different working conditions so the
alarm should be used as an indication of a
fault arising.
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Air Blast Bypass Valve monitored to ensure correct operation. One

During initial start-up the viscosity of the oil is thermostat controls the air-blast cooler fan
very high which results in an increase in pump whilst a second thermostat will stop the
pressure and a reduction in oil flow through machine and will activate an alarm if the oil is
the air blast cooler and into the machine. too hot, ie. greater than 80°C (176°F).
To overcome this a bypass valve is Pressure Relief Valve

incorporated in parallel to the cooler. When a In order to protect the lubrication system
predetermined pressure is reached the valve against dead head pressures a relief valve is
opens allowing oil to pass to the machine situated after the pump. This is set (at
without entering the cooler. Once the viscosity manufacture) to open at a designated pressure
is reduced the valve closes and oil passes of 3.8 BAR (55psi). It is important that this
through the cooler. This is normal on initial device is not adjusted or tampered with.
start-up with cold oil.
Operating the Crusher without
Fluid Level or Float Switch the lubrication system safety
In the event of the lubrication system pipe devices being fully operative
breaking or a leak occurring the level of the oil will invalidate any warranty in
tank will drop. To prevent running in this force for the time being.
condition the switch will stop the machine and
thus prevent damage to the bearings.
Oil Feed Flow Indicator and Switch

To ensure that sufficient oil is being supplied to
the bearings a flow switch is incorporated into
the feed side of the lubrication system. In the
event of the flow reducing below a set level
the switch closes causing warning devices to
operate and the machine stop.
Continued operation of the Crusher with

insufficient oil flow will severely damage the
bearings.
Temperature Monitoring
The temperature of the returning oil is
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4.5.4 Oil Change Intervals Total Acid Number (TAN)

This is the measure of how much the oil has
The first oil change of the lubricating oil degraded. The TAN increases as the oil
should occur after 500 hours operation. degrades. The oil should be changed before
it increase 100% above the original value.
Subsequent oil changes should occurs
every 1000 hours, ie once every 5 months Viscosity Number
working 50 hours per week, An engineering/lubrication laboratory is able
to identify the viscosity number of an oil
Alternatively, BL-Pegson strongly
which can then be compared to the original
recommend that the oil is tested regularly at
value of new oil. If it exceeds a 20%
monthly intervals by a suitable laboratory
increase at an identical test temperature it is
and changed when advised to do so. This
time to change the oil.
will provide optimum use of oil as
replacement is only made when proved Reduction in Additives
necessary. This will also give an indication It is recommended that the oil is changed
on the machines’ condition. This could when the level of additives is reduced by
indicate that the change should be made 50% compared to new oil values.
away from the 1000 hours guideline and
will be because of usage and environment It is suggested that any of the above
effects on the oil life. tests could be carried out by a
laboratory to establish the optimum
There are several indications that it is time time for oil changes. Consultation with
to change the oil in the lubrication system:- your local facility is advisable.
Concentrations of Wear Metal Elements
Increases in certain elements should not
exceed the suggested upper limits in parts
per million (PPM) as table below.
TYPICAL
WEAR METAL CONCENTRATION UPPER LIMIT
(PPM) (PPM)
Chrome 0-5 10
Copper 0 -15 50
Iron 30 - 50 150
Lead 0 - 20 50
Nickel 0-5 10
Silicon (dirt) 10 - 30 75
Figure
BL-Pegson 9? Wear
Limited, MetalEngland.
Coalville, ElementsTel : +44 1530 518600, Fax : +44 1530 518618
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4.5.5 Recommended Oil

The recommended oil is good quality:-
WARNING
WEAR PERSONAL
Summer Grade - EP220 PROTECTIVE EQUIPMENT.
Winter Grade - EP150 Information for relevant
warning.
Refer to the lubrication charts (Section
LOCKOUT MACHINE.
4.4.5) for details. Refer to Section 4.1, Safety
Add oil to the tank (Figure 4b) with a Procedure.
recommended lubricant from the list
provided in this manual through the filler cap
using the level indicator to ensure the
correct level is reached. This should be
approximately 275 litres (72.6 US. galls.).
Unless consistently cold climates are

experienced, ie. below 4ºC (39ºF) it is
recommended that EP220 ISO VG oil is
used. If difficulties with cold starting are
experienced it is recommended that an
EP150 VG oil is used but this could be
changed back to an EP220 ISO VG as
soon as conditions permit.
All oils should have extreme pressure (EP)

additives.
If none of the oil brands specified in Section

4.4.5 are available, ask your supplier to
supply an oil that meets the specification for
GRADE B in Figure 4a.
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4.5.6 Oil Filter Change Intervals

As a general guide it is recommended that
WARNING
the two filter canisters (Section 4.4.4) are WEAR PERSONAL
changed as follows:- PROTECTIVE EQUIPMENT.
The first filter change should be after warning.
100 hours operation.
LOCKOUT MACHINE.
Subsequent filter changes should occur Information for Lockout
every 500 hours unless the oil filter blocked Procedure.
warning activates between these intervals. It
is important the use the correct replacement
filter cartridges as too fine a filter element
will become blocked prematurely whilst too
coarse an element will not filter efficiently
enough to protect the machine.
Remember, these filters are

very efficient at removing
harmful containments from the
oil and it is more economical to
change the filters regularly
than the oil.
It is also recommended that the suction

filters (Section 4.4.4) inside the tank are
replaced when the oil is changed.
In the event the pressure filters become

blocked completely, oil will be supplied to
the machine via a relief valve inside the filter
top body. This bypasses the filter element
and supplies unfiltered oil to the machine.
This MUST be avoided and the oil
lubrication safety system includes an
alarm for this situation.
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4.5.7 Filter Replacement

Both filters are to the same specification
WARNING
and operate in parallel. They must be WEAR PERSONAL
changed at the same time with NEW filters PROTECTIVE EQUIPMENT.
as recommended in Section 4.4.4. Information for relevant
warning.
Both filters are non-cleanable elements and
LOCKOUT MACHINE.
must always be replaced with NEW Refer to Section 4.1, Safety
cartridges of the approved pattern. Information for Lockout
Procedure.
Procedure
2. Close down the plant and implement the

Lockout Procedure.
3. Take steps to collect oil spillage and

remove the old filter cartridges by
unscrewing counter-clockwise
(looking from below) together with
the ‘O’ ring seal. Clean the ‘O’ ring
seating in the filter body.
4. Lightly oil the new ‘O’ ring on the

new filter cartridge and screw onto
the filter body taking care not to
cross the threads. Hand tighten the
cartridge.
Note: After recommencing operation

of the Crusher make sure the seals are
oil tight.
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4.5.8 Oil Lubrication System -

General Maintenance WARNING
Tank WEAR PERSONAL
Ensure that the filler/breather cap is clean, in
place and tight, at all times. warning.
LOCKOUT MACHINE.
Make sure that the oil tank cover is sealed Refer to Section 4.1, Safety
down and that all bolts are in place and Information for Lockout
tight. Keep clean of dust and debris. Procedure.
Before carrying out any maintenance on the

tank or associated parts, thoroughly clean
the area to prevent any contaminants
entering the oil lubrication system.
Air Blast Cooler
Clean the cooling matrix to prevent it

becoming blocked. Cleaning with an air
pressure jet must only be carried out after
taking safety precautions. If the dust is oily
use a low pressure steam cleaner together
with non-caustic detergent.
General
Frequently check for any leaks developing

in the pipework and particularly ensure that
the rubber hoses are not being chafed due
to the movement of the ‘live’ Crusher
baseframe. Make sure the flexible hose in
the return piping (essential when the
Crusher is mounted on a ‘live’ baseframe)
is in good condition. Attend to the oil and
replacement components in accordance
with the schedules and advice in this manual
using only approved quality materials
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4.6 Hydraulics
DANGER
4.6.1 Hydraulic System Overview
FLUID INJECTION HAZARD
There are two elements to the hydraulic Refer to Section 4.1, Safety
system on the Automax:
warning
• Setting adjustment, overload protection

and unblocking hydraulic cylinder ring
main. WARNING
WEAR PERSONAL
• Dumpy jack ring main to exert pressure PROTECTIVE EQUIPMENT.
on the wedge ring. Refer to Section 4.1, Safety
warning.
The two ring main systems have a common
fluid reservoir (Figure 4c) and, together LOCKOUT MACHINE.
with associated equipment, must be Information for Lockout
maintained in accordance with the set Procedure.
levels, schedules and types (Section 4.4.4
& 4.4.5). ONLY USE A
RECOMMENDED FLUID.
The Upper Frame of the Crusher is raised and

lowered by means of external hydraulic rams
to alter the relative position of the concave (in THIS IS A HIGH PRESSURE
the moveable upper frame) to the mantle (on SYSTEM.
DANGER
the fixed position cone head).
Do not tamper with. In the
Six hydraulic cylinders provide control over event of any problems these
the machine’s discharge setting through should only be dealt with by
vertical movement of the upper frame. suitably experienced and
Additionally the system also permits automatic qualified engineers
overload release and reset, unblocking of the
crushing chamber and monitoring and Never carry out any
indication of manganese wear (Section 3.3). maintenance work without
ensuring the hydraulic system is
To hold the upper frame firm and steady locked out and depressurised.
during crushing a supplementary circuit of
hydraulic dumpy jacks is included to activate
the wedge ring.
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The relative position of the upper frame is The procedures in this section
monitored electrically with a linear sensor unit. relate to the crusher equipped
with the standard ‘System 2’
The standard control of the Crusher controls.
hydraulics is from the System 2 - 2000 For the alternative ‘System 3’
separate console (Figure 4c) to be located and ‘Maxset’ control systems,
adjacent to the crusher with connections by refer to the separate
both high pressure hydraulic hoses and Addendum for details.
screened electric cable for the linear sensing
device.
In the event of a blockage occurring in the

crusher the panel senses an increase in
pressure and will automatically raise the
crusher upper frame (including the concave)
to release material in the crushing chamber.
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Crusher Control Panel

(see also Figure 4f)
Hydraulic Pump
Unit
Dumpy Jack
Pressure Gauge
Pump Pressure
Gauge
Pressure Filters
Filler Cap
Level Sight Glass Fluid Reservoir
Figure 4c Crusher System 2 Hydraulic Console
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4.6.2 Hydraulics Maintenance

Procedure - System 2 DANGER
This is a high pressure system FLUID INJECTION HAZARD
and only suitably qualified Refer to Section 4.1, Safety
experienced engineers should Information for relevant
DANGER
warning
tackle any problems that may
arise.
The system also includes high WARNING

voltage electrical equipment WEAR PERSONAL
and any work for maintenance PROTECTIVE EQUIPMENT.
and/or replacement should only Refer to Section 4.1, Safety
be undertaken by suitably
warning.
qualified experienced electrical
engineers. LOCKOUT MACHINE.
In normal operation keep the console Procedure.
cabinet door closed to avoid the ingress of
debris and dust. An observation window is
included for this purpose.
Maintain in accordance with the reservoir

level, filter changes and the schedules and Faults encountered may be listed in under
fluid types (Section 4.4.4 & 4.4.5) ONLY Section 4.10, Fault Finding, together with
USE A RECOMMENDED FLUID. possible remedies. Always contact BL-
Pegson’s local dealer or the factory in case
It is essential when replenishing hydraulic of doubt.
fluid, attending to filters, etc. to apply the
greatest degree of cleanliness as it is most
important that contaminants are not
allowed to enter the system.
In addition to the pressure gauge on the

control panel (Figure 4f) used when
calibrating the manganese, etc., two other
pressure gauges are included in the system
(Figure 4c). The gauge mounted on the oil
reservoir indicates the pump pressure whilst
the other is for the dumpy jack circuit.
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Figure 4d Crusher Hydraulic Circuit

(Dumpy Jack circuit NOT shown)
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4.7 Manganese Change When replacing the manganese liners,

Procedure always fit both a new mantle and a new
concave at the same time.
4.7.1 Guidance for Changing the
Manganese Mantle and Concave Always fit a new manganese
Both the mantle and concave liners are mantle and concave as a ‘pair’.
locked against their mating parts using It is detrimental to the
tapers (angled faces). If these liners are operation of the machine to do
worn too thin they will not be able to hold otherwise.
tight against their mating faces, coming
loose and/or slipping relative to their mating
part. The mating will be damaged and will
need reworking.
Reworking and machining these large

components is expensive and can involve
lengthy downtime. It is for this reason that
the manganese liners must replaced before
the situation described above arises.
There is approximately 55-60mm (2 1/4”)

of wear on the liners, as a pair.
Take note of the ‘wear’ shown on the

display.
774 mm (30 1/2”)minimum
Inspect the liners on a daily basis, for

possible ‘tramp metal’ damage and also any
evidence of an uneven wear pattern
developing.
The manganese liners must be changed

when the hydraulic rams can be fully closed.
The pin centre to pin centre distance
(Figure 4e) when the rams are fully closed
is 774 mm (30 1/2”).
Figure 4e Minimum Ram Dimension
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4.7.2 Filler Handling

Use Pegbak for backing filler.
WARNING
It is necessary to carefully WEAR PERSONAL
read the handling instructions PROTECTIVE EQUIPMENT.
before attempting to use.
Follow all the recommended warning.
handling procedures and
safety precautions.
Filler is used as a backing material to fill the BOTH AGENTS ARE TOXIC.
void spaces behind the manganese concave ALWAYS WEAR A FACE
and mantle where there is no machined MASK, RUBBER OR
mating surface with the upper frame and PLASTIC GLOVES, SAFETY
cone head respectively. The filler is poured GLASSES AND LONG
in after the new manganese has been fitted. SLEEVED WORK
CLOTHING
The Automax cone crusher uses the
gunlock type, self tightening concave ring • Since both agents are toxic, be careful
and must use a release agent or thin layer of not to allow them to attach onto your
grease, oil or wax on the concave ring skin. If they do attach, wash away with
mating surfaces. This is to prevent adhesion tepid water and soap. Do not use petrol
between the mating surfaces and to allow or solvents.
the self tightening features to operate
properly. Care should be taken to plug all Protect eyes. In case of
leaks as the filler will fill a very small void. accidental contact / splashes,
flush eyes with plenty of water
Each pack of Pegbak includes separate and consult a doctor.
filler resin and hardener which are mixed
only when required for immediate use. • Ensure good ventilation of the
workplace.
Packs required • When mixing add the hardener to the

filler backing resin while agitating.
Mantle - 3 x 10kg.Tubs
Concave - 5 x 10kg.Tubs • Completely mix the filler backing resin
and hardener, continue mixing until all of
the filler is one colour, ie. completely
mixed.
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• It is necessary to work with both agents Filler Hardening Time

at 16-32 °C (60°-90°F). Therefore, in
hot weather the container may have to The filler needs about 12 hours to harden at
be cooled and warmed in cold weather 20 °C (68°F).
to within the above temperature range.
• Both agents can be mixed with the In lower temperatures the hardening
supplied agitating adaptor attached to process takes longer and it may be
the top of an electric drill. necessary to heat the mantle and concave
etc. in these circumstances.
• The filler can be used only once (cannot
be reused) and if mixed with the
hardener it cannot be stored.
Low Temperature Mixing
• Always store both agents at 15-30 °C Protect the filler resin / hardener from cold
(59-86°F) and avoid storing in direct weather (< 5°C [41°F] ). Remove the chill
sunlight. from the metal by the use of hot air guns/
blowers. - Do not use an open flame. To
• Never smoke whilst handling these ensure the shortest curing time at low
agents. temperatures, the filler resin component
(LARGER BAG) should be pre-warmed
• Ensure that application surfaces are dry to 25-30°C (77-86°F) before mixing. This
before pouring. Wet surfaces will result is best achieved by applying a hot air
in reduced stength of the filler. blower on the outside of the tin .
NB - REMOVE HARDENER FROM
• Pour the filler immediately after mixing, TIN BEFORE APPLYING HEAT.
ie within 10 - 15 minutes at 25°C. ALTERNATIVELY, place the filler resin
Higher temperatures will shorten, and bag (LARGER BAG) in a bucket of hot
lower temperatures increase, the water.
working time. NB - DO NOT PRE-HEAT THE
HARDENER (SMALLER BAG).
• When making pouring ports with putty, Thoroughly mix the filler resin and hardener
prevent the filler from leaking out. using the included mixing tool or a spiral
paddle and pour immediately.
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4.7.3 Changing the Manganese

To change the manganese Concave and
WARNING
Mantle crushing members it is necessary to WEAR PERSONAL
remove the Upper Frame. PROTECTIVE EQUIPMENT.
4.7.3.1 Removing the Upper Frame warning.
To change the concave it is necessary to lift

off the Crusher Upper Frame complete with
the concave inside First, however, the feed
chutework and feed ring must be removed.
Before the Upper Frame can be easily and 5. Open (turn anticlockwise) the shut off
safely removed it is essential to first valve 20A inside the Hydraulic Console
‘release’ the Wedge Ring as follows. (Figure 4q) to allow all pressure in the
wedge ring circuit to be released
thereby removing the loading from the
Wedge Ring.
Procedure
6. Drop the Upper Frame with the
CLOSE button to push the Wedge
1. Observe all safety warnings. Ring down and thus free it from the
Mainframe to provide clearance needed
2. Turn the isolator switch on the Crusher to lift off the Upper Frame. The wedge
Hydraulic Console (Figure 4f) into the pressure indicated on the pressure
ON position. gauge (Figure 4f) should drop away to
0-28 Bar (0-400 psi) as the wedge ring
3. Select MANUAL and raise the Upper frees off.
Frame to it’s maximum extent using the
OPEN button. Ensure the Wedge Ring is free
otherwise crane overload and/
4. Close (turn clockwise) the shut off valve or sudden violent separation
20B inside the Hydraulic Console may occur when lifting off
(Figure 4q) to isolate the wedge ring (Step 14 below)
hydraulic circuit from the main hydraulic
system. 7. Remove the crusher feed chute and
feed ring, etc. sufficiently for lifting off
the Crusher Upper Frame.
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Numeric Keypad Display
AUTO/MANUAL
Switch
OPEN Button CLOSE Button
Pressure
Gauge
TRAMP O/L TEST
Button
Isolator
Figure 4f Crusher System 2 Hydraulic Panel Controls
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8. With suitable cranage (see weights

Section 4.2) connect lifting tackle to the
four lifting eyes in the Upper Frame
DANGER
(Figure 2c) but leave the slings with FLUID INJECTION HAZARD
a small amount of slack. Information for relevant
warning
Under no circumstances
attempt to take the load on the
cranage at this stage as a
serious overload condition may
WARNING
arise. WEAR PERSONAL
9. Using three 5 tonne (5.5 US tons) Information for relevant
capacity x 150mm (6”) stroke hydraulic warning.
bottle jacks spaced equidistant around
LOCKOUT MACHINE.
the lower rim of the Upper Frame, Refer to Section 4.1, Safety
extend them equally to take the weight Information for Lockout
off the clevis pins to aid their removal. Procedure.
10. Ensure that there is no residual hydraulic

pressure in the Upper Frame hydraulic
cylinder circuit by pressing the OPEN
Note: The clevis pins should be
and CLOSE buttons briefly and in
removed from right to left when
quick succession until the pressure
facing the machine to avoid
gauge (Figure 4f) on the hydraulic panel
disturbing the bearing located
reads zero. Follow this procedure to
against the shoulder inside each lug
remove the clevis pins with the minimum
on the Upper Frame.
of effort.
13. Remove the linear sensor cover (Figure
11. Isolate the electrical supply before
4g) and lay to one side. Disconnect the
proceeding further.
top bolt from the unit. This is essential
to avoid damage to the sensor unit.
Do not neglect to ‘Lockout’ to
prevent the plant being started
14. Lift off the Upper Frame assembly from
whilst maintenance work is
the machine (Refer Section 4.2 for the
being carried out.
weight of the complete assembly).
Support on wooden blocks on the
12. Remove the top clevis pin from each
ground (Figure 4h).
hydraulic cylinder and pull each cylinder
outwards, allowing them to lie flat.
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Upper Frame
Linear Sensor
Unit Cover
Clevis Pin
Upper Frame
Grease Nipple x 12
Hydraulic Cylinder x 6
Figure 4g - Automax Linear Sensor Unit and Hydraulic

Cylinders
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4.7.3.2 Changing the Concave

The concave ring is held in place in the
WARNING
Upper Frame by a self tightening gun lock WEAR PERSONAL
arrangement that automatically tightens the PROTECTIVE EQUIPMENT.
manganese steel Concave on the concave Information for relevant
wedges as the ring stretches under the warning.
crushing load.
LOCKOUT MACHINE.
The Upper Frame should be supported on Information for Lockout
wooden blocks so that there is sufficient Procedure.
space for the concave to be driven out.
Removing the Concave
When gas cutting through the

concave it is essential that
breathing apparatus is worn as
when the metal is broken
through the backing material
gives off toxic fumes.
ground. Remove any nicks or burrs with
a file or grinder. Inspect the ground
surfaces of the new concave and
Procedure remove any nicks or burrs in the same
manner.
2. Following removal of the Upper Frame

(Section 4.7.3.1) gas cut through the
four lugs as shown (Figure 4h).
3. Drive down and out the old Concave

with a heavy sledge hammer.
4. Remove the old backing material and

dowels (these can be driven out from
below) and inspect the lower inside
bevelled edge of the Upper Frame
seating where the surface has been
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Figure 4h Gas Cutting the Old Concave

(only one lug shown for clarity)
Figure 4i Supporting the New Concave
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Mounting the Concave

WARNING
When supporting the new Concave prior to
WEAR PERSONAL
lowering the Upper Frame on to it, ensure PROTECTIVE EQUIPMENT.
that the supports do not protrude past the Refer to Section.4.1, Safety
sides of the Concave (Figure 4i) and that it Information for relevant
is high enough off the ground to allow the warning.
Upper Frame to be fully lowered. LOCKOUT MACHINE.
Release agent needs to be applied to the Information for Lockout Proce-
internal surface of the Upper Frame where dure.
it will be in contact with the backing filler to
ease separation when the manganese is next
changed.
6. After rotation, equally locate the

Procedure concave wedges between the Concave
lugs and upper frame (Figure 4.j).
1. Observe all safety warnings. An estimate should be made of the
correct position for the concave wedges
2. Apply release agent (obtainable from and then tapped in slightly to see how
BL-Pegson) to the cleaned inner the Concave settles. If the position does
surface of the Upper Frame. not look correct with respect to the
dowel holes then they should be
3. Place the new concave on three
removed and replaced.
wooden blocks (see preamble above)
ensuring it is level Also check to see that the Concave is
evenly seated on the machined surfaces
4. Lift the Upper Frame over the Concave
at the bottom and there is an equal
and turn it so that the concave lugs align
depth all around at position A (Figure
with the recesses on the Upper Frame
4k). If there is a gap between the two
and gradually lower the Upper Frame
the Concave must be properly reseated.
until concave lugs pass through the
recesses and stop lowering. Once the position is satisfactory and the
concave correctly seated, the wedges
5. Rotate the Upper Frame to the left so
should be driven fully home.
that the concave lugs are located
approximately 50mm (2”) past the
dowel holes.
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RECESS
Figure 4j Plan View of the Upper Frame showing the correct wedge position
(1300 Crusher has four lugs on the concave)
MATING SURFACE
Figure 4k Sectional view of the concave showing the gap check at A
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7. Insert the dowels into the holes in the

upper frame and drive home. WARNING
WEAR PERSONAL
Note: If there is a gap between the PROTECTIVE EQUIPMENT.
concave wedge and the dowel pin and Refer to Section 4.1, Safety
this cannot be rectified by moving the Information for relevant
wedge position, it may be necessary warning.
to tighten the wedges and then weld a LOCKOUT MACHINE.
piece of steel between the wedge and Refer to Section 4.1, Safety
the dowel pin(s). Information for Lockout Proce-
dure.
The concave wedges must be
inserted evenly so that the
Concave is centrally located
within the Upper Frame.
8. Prepare filler pouring ports with putty

by making four weirs around the
recesses of the Upper Frame so the
filler cannot leak out.
9. After the weirs are completed prepare

the filler (Section 4.7.1) and pour the
correct quantity of mixed filler into each
weir by turns.
After mixing, the filler must be

poured IMMEDIATELY to
ensure complete penetration.
10. Stop pouring when the filler has reached

12-25mm (1/2/1”) below the top of the
Concave. The replacement is now
complete. Refer to Section 4.7.1 for the
filler hardening time.
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4.7.3.3 Replacing the Upper Frame

Whilst the Upper Frame is off the machine DANGER
for the renewal of the manganese wearing FLUID INJECTION HAZARD
parts, take the opportunity of examining the Refer to Section 4.1, Safety
condition of the internal linerplates, frame Information for relevant
warning
and countershaft arm shields and replace if
necessary.
Also, clean out any solidified debris and WARNING

generally check around the machine for any WEAR PERSONAL
faults which need to be rectified. PROTECTIVE EQUIPMENT.
Clean the contact face all around the Information for relevant
warning.
Wedge Ring and apply a coating of fresh
lubricant (use Moly- Bentone only - see LOCKOUT MACHINE.
Section 4.4.7). Make sure this is not Refer to Section 4.1, Safety
contaminated with dirt or grit prior to Procedure.
replacing the Upper Frame.
Procedure

respond at any one time and, ‘toggling’
2. Using the cranage used to remove the
between the buttons, line up and insert
Upper Frame lower over the machine
each of the six clevis pins in turn.
whilst taking care to line up the anti-
Secure with the washers and split pins.
rotation stop on the Upper Frame with
the guide post. Hold in a suspended
Note: The clevis pins should be
position with the crane with a gap
inserted from right to left when
between the mantle and concave.
facing the machine to avoid
disturbing the bearing located in it’s
required position against the
Hydraulic Console (Figure 4f) into the
shoulder inside each lug on the
ON position.
Upper Frame.
4. Select MANUAL and press the
5. Replace the linear position sensor and
OPEN or CLOSE button (as
replace the cover to the housing.
appropriate). Only one cylinder will
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6. Detach the cranage and replace the

feed ring or box and any chutework. DANGER
7. Now take steps to restore the Wedge FLUID INJECTION HAZARD
Ring pressure by returning to the Information for relevant
hydraulic console and closing the shut warning
off valve 20A (Figure 4q) to revert to
the operating position.
8. Open shut off valve 20B (Figure 4q) to

WARNING
revert to the operating position. WEAR PERSONAL
9. Carry out the ‘Initial Discharge Setting Information for relevant
and Calibration’ procedure described in warning.
Section 3.2.1, following which the
LOCKOUT MACHINE.
Crusher is ready to recommence Refer to Section 4.1, Safety
crushing. Information for Lockout
Procedure.
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4.7.3.4 Changing the Mantle

The operation is carried out with the head
WARNING
left in situ. The internal parts of the Crusher WEAR PERSONAL
are therefore not disturbed or exposed to PROTECTIVE EQUIPMENT.
harmful dust. Information for relevant
warning.
In use all manganese steel will ‘creep’ due to
LOCKOUT MACHINE.
the nature of the material. When creep occurs Refer to Section 4.1, Safety
stress is created in the material which will have Information for Lockout Proce-
to be relieved by suitable cutting of the dure.
Mantle. This will be necessary in order to
facilitate removal.
Removing the Mantle
When gas cutting through the

Mantle it is essential that
breathing apparatus is worn as
when the metal is broken
through the backing material
gives off toxic fumes.
Procedure
2. With the Upper Frame removed

(Section 4.7.3.1) gas cut through the
Burning Ring all the way round (Figure
4.l).
3. Once the Mantle is cut the Mantle Nut

can then be removed by turning Figure 4l Gas cutting the Mantle
CLOCKWISE with the mantle nut (showing section through Cone Head)
wrench (Figure 4m overleaf). Ensure
that the Mantle Nut Wrench is secure
by dropping a suitably sized bolt
through the hole in the end of it.
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4. Break loose the fit between the Mantle

and the Cone Head. This is best WARNING
achieved by striking the lower section of
WEAR PERSONAL
the circumference with a hammer then PROTECTIVE EQUIPMENT.
levering the mantle clear of the cone Refer to Section 4.1, Safety
head. Information for relevant
warning.
5. Insert short blocks of wood between LOCKOUT MACHINE.
the Mantle and Cone Head in three Refer to Section 4.1, Safety
places around the circumference so as Information for Lockout Proce-
dure.
to leave a gap through which lifting
chains can be placed. Three equally
spaced lifting chains should be passed
through this gap and the hooks put
round the bottom of the mantle (Figure
4n) and the Mantle lifted off.
6. Remove the old backing material and

inspect the Cone Head seating where
the surface has been ground. Remove
any nicks or burrs with a file or grinder.
Inspect the ground surfaces of the new
Mantle and remove any nicks or burrs
in the same manner.
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MANTLE NUT WRENCH
SECURITY BOLT
Figure 4m Mantle Nut Wrench

securely fitted
Figure 4n Lifting chains correctly fitted
Sections through the Automax Cone Head
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Mounting the Mantle

WARNING
Release agent needs to be applied to the
WEAR PERSONAL
Cone Head where it will be in contact with PROTECTIVE EQUIPMENT.
the backing filler to ease separation when Refer to Section 4.1, Safety
the manganese is next changed. Information for relevant
warning.
LOCKOUT MACHINE.
Procedure
Procedure.
2. Apply release agent (obtainable from

BL-Pegson) to the unmachine surface
all around the Cone Head (Figure 4o).
5. Prepare the filler (Section 4.7.1) and
3. Place the new Mantle and Burning Ring pour the correct quantity of mixed filler
onto the Cone head and tighten down at the top of the Mantle making sure it is
the Mantle Nut by turning COUNTER- equally distributed all round.
CLOCKWISE with the Mantle Nut
Wench (Figure 4m). It is sufficient to After mixing, the filler must be
tighten this by hammer blows without poured IMMEDIATELY to
having to replace the Upper Frame and ensure complete penetration.
wedge against the Concave.
6. When the filler reaches 15mm (5/8”)
4. The Mantle Nut was tightened to align from level B (Figure 4p) stop pouring,
the Mantle and seat it firmly on the fit the Mantle Nut and Burning Ring.
Cone Head at A (Figure 4p). Now the First lightly tighten using the Mantle Nut
Mantle Nut and Burning Ring need to Wrench. Fully tighten by hitting the
be removed so that the filler can be wrench with a hammer in a
poured. Release the Nut by turning COUNTER-CLOCKWISE direction.
CLOCKWISE with the Mantle Nut The replacement is now complete.
Wrench. Refer to Section 4.7.1 for the filler
hardening time.
Note: When the Mantle Nut and Burning
Ring are removed, grease the threads on
the Cone Head so any spills when pouring
the backing filler can be easily wiped off.
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Figure 9o Section through the Cone Head showing where to apply release agent
Figure 9p Section through the Cone Head showing correct filler level
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4.8 Wedge Ring Maintenance

WARNING
The Wedge is fundamental to WEAR PERSONAL
how the cone crusher PROTECTIVE EQUIPMENT.
functions. It provides damping Refer to Section 4.1, Safety
and guidance to the Upper Information for relevant
Frame assembly. warning.
Poor machine performance and

crusher downtime are often The procedures in this section
due to an incorrectly relate to the crusher equipped
maintained Wedge. with the standard ‘System 2’
controls.
The condition of the Wedge is assessed by For the alternative ‘System 3’
observing the hydraulic pressure required to and ‘Maxset’ control systems,
move the Upper Frame. refer to the separate
Addendum for details.
When the Upper Frame is moved there
should be no noticeable sticking on initial
movement or during the travel. If there is
any sticking noticed then this should be
investigated. On factory assembly the
friction pads are greased and it is possible
that grease needs to be added through the
nipples spaced around the Upper Frame
(NB. The minimum amount of Moly Only use Moly Bentone
Bentone grease should be added to grease (Section 4.4.5) for
restore smooth travel). In situations where lubricating the Wedge Ring
the crusher setting is not changed for long
periods it is good practice once a week to
work the Upper Frame from the top to
bottom of it’s stroke several times to
redistribute the grease.
The crusher must not be allowed to operate

with regular dumping or bouncing (see
Glossary Section 2.1.8) of the Upper
Frame or damage may result. Possible
causes of the are crushing at closed side
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settings which are too tight, out of round

manganese or poor Wedge Ring
adjustment.
Low wedge pressures are

equally as undesirable as high
ones. When testing the wedge
pressure it should be between
55 and 82 BAR (800 - 1200
psi).
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4.8.1 Checking Wedge Pressure

WARNING
Procedure WEAR PERSONAL
1. Observe all safety warnings. warning.

ON position.
Note: Ensure the crusher is not

running.
5. On the Crusher Hydraulic Console

panel (Figure 4f) select MANUAL and
depress the OPEN push button lifting
the Upper Frame approximately 20 mm
(3/4”) above the set point, then switch
the controls back into automatic by
depressing the AUTO button.
6. Observe the pressure recorded on the

gauge in the panel (Figure 4f). It should
be in the range 55-82 BAR (800 -
1200 psi). When the Upper Frame is
moving it should be in a smooth
movement with no sticking at the start
or whilst it is travelling. If there is some
sticking then this should be investigated.
If the pressure is above or below the
range, readjust the wedge assembly as
described in Section 4.8.3.
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4.8.2 Low Wedge Pressure

If the wedge pressure has been checked
WARNING
and found to be below 55 bar (800psi) then WEAR PERSONAL
the cause must be investigated and where PROTECTIVE EQUIPMENT.
necessary, the appropriate action taken. Information for relevant
warning.
Procedure
DANGER
1. Low or fluctuating dumpy jack circuit Refer to Section 4.1, Safety
Information for relevant warning
pressure.
Check circuit is free from leaks, and
pressure switches PS3, PS4 (Figure
4d) are functioning correctly.
2. Wedge ring may not be ‘bedded in’

fully following maintenance or
manganese change.
Monitor wedge pressure. Work
machine at wider setting if excessive
bouncing/dumping is seen (Bouncing,
Dumping, see Glossary 2.1.8).
3. Excessive greasing and/or use of wrong Only use Moly Bentone

type of grease. grease (Section 4.4.5) for
This can reduce the friction between the lubricating the Wedge Ring
wedge and the upper frame and hence
limit the wedge pressure.
Monitor the wedge pressure. If no

improvement is seen, it may be
necessary lift off the upper frame,
remove the grease and re-grease,
sparingly.
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4.8.3 Readjusting Tight Wedge Ring

If the wedge pressure has risen above the
WARNING
prescribed maximum and/or the travel of WEAR PERSONAL
the Upper Frame is no longer smooth, the PROTECTIVE EQUIPMENT.
Wedge Ring may need adjusting by the Information for relevant
following procedure. See Section 4.8.1 for warning.
checking the wedge pressure.
DANGER
Procedure Refer to Section 4.1, Safety

ON position.
Shut Off Valve 20B
Note: Ensure the crusher is not
running.
3. On the Crusher Hydraulic Console

panel (Figure 4f) select MANUAL and
raise the Upper Frame to it’s maximum
using the OPEN button.
4. Close the shut off valve 20B inside the

hydraulic console (Figure 4q) to isolate
the wedge ring Dumpy Jack hydraulic
circuit from the main hydraulic system.
5. Open the shut off valve 20A inside the

hydraulic console (Figure 4q) to allow
all pressure in the Dumpy Jack circuit to
Shut Off Valve 20A
be released thereby removing the
loading from the Wedge ring.
Figure 4q Dumpy Jack Circuit Valves
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6. Lower the Upper Frame with the

CLOSE button to push the Wedge WARNING
Ring down and thus free it from the
WEAR PERSONAL
Mainframe. The wedge pressure PROTECTIVE EQUIPMENT.
indicated on the hydraulic panel Refer to Section 4.1, Safety
gauge (Figure 4f) should drop away to Information for relevant
0-28 Bar (0-400 psi) as the Wedge warning.
Ring frees off.
DANGER
7. Close shut off valve 20A (Figure 4q) to
revert to the operating position. Refer to Section 4.1, Safety
8. Open shut off valve 20B (Figure 4q) to
revert to the operating position.
9. Select AUTO control position on

switch. The control system will bring
the machine down to the required gap
position or go through the initial
Closed Side Discharge Setting
procedure (Section 3.2.1) as necessary.
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4.9 Out of Round Manganese F) Increase the wear rate of the

- Causes and Effects manganese, due to the concentrated
crushing area. This gets worse as the
When the Mantle and Concave are new process is a vicious circle.
both of the wearing surfaces are round.
They should remain round throughout their G) Due to effect of E above the machine
working life, ie. the wear should be will become reluctant to accept a
consistent and remain round. Should the choke feed. The machine will dump
manganese become out of round then the as the crushing pressure reaches
life of that manganese will be shortened excessive levels.
considerably. The causes and effects of this
are:- Prevention:
Causes: H) Only fit genuine BL-Pegson manganese

replacement parts.
A) Inaccurate manganese manufacture/
fitting. I) Ensure adequate feed hopper and
efficient dead box are maintained to
B) Poorly distributed feed material distribute the feed material evenly
within the hopper and/or segregated around the feed opening.
feed.
J) Adjust the feed settings to ensure the
C) inconsistent stop/start feed. Crusher is choke fed at all times.
Effects: K) Adjust the feed settings to ensure the

feed to the Crusher is continuous with
D) Produces an uneven load on the stop/starting of the feed kept to a
Wedge, reducing it’s life and minimum.
producing a fluctuating wedge pressure.
E) Produces an inaccurate zero set point,

resulting in an incorrect closed side
setting. This can mean that the machine
is crushing at a much lower closed side
setting than is indicated on the gap
indicator.
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4.9.1 Checking Manganese for Out

of Round WARNING
Check 1 - The Mantle. WEAR PERSONAL
Procedure Information for relevant
warning.
LOCKOUT MACHINE.
1. Observe all safety warnings. Refer to Section 4.1, Safety
2. Close down the plant and implement the Procedure.
Lockout Procedure.
Note: it is important when checking the

Mantle for ‘out of round’ that the
DANGER
Eccentric does not move. Take the NIP POINT HAZARD.
drive guard off and watch for any Refer to Section 4.1, Safety
movement of the countershaft. If Information for relevant
warning.
movement is noted repeat the whole
procedure described below, again.
3. Mark a cross on the top of the Mantle

Nut.
4. Mark the Concave opposite on of the

lines of the cross.
The next steps must be taken with

the Crusher controls activated but
the Crusher NOT running.
5. Ensure that everyone is clear of the

machine. Put the hydraulic panel into
MANUAL and press CLOSE.
Release the button the moment the
pressure starts to rise and note the
figure showing on the gap indicator.
Depress the OPEN button to raise the
Upper Frame approximately 15 - 20
mm (5/8”- 3/4”).
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6. Close down the plant and implement the

Lockout Procedure. WARNING
WEAR PERSONAL
7. Rotate the Cone Head slowly by hand, PROTECTIVE EQUIPMENT.
stopping it when it has gone through 90º Refer to Section 4.1, Safety
whilst doing this watch the vee belts to Information for relevant
ensure that the eccentric does not move warning.
in the Cone Head. The second mark on LOCKOUT MACHINE.
the mantle plate should now be lined up Refer to Section 4.1, Safety
with the mark on the Concave. Information for Lockout
Procedure.
8. Repeat steps 5 to 7.
9. Repeat the process so that you have

four values for the Mantle. If the Mantle
DANGER
is round it should show similar values to NIP POINT HAZARD.
Figure 4r. Refer to Section 4.1, Safety
warning.
-1 -1
Typical values
Mantle OK.
Figure 4r Mantle Check
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Check 2 - The Concave

WARNING
Note: This process is almost identical to the
WEAR PERSONAL
Mantle check. Follow the procedure for the PROTECTIVE EQUIPMENT.
Mantle - Check 1. Refer to Section 4.1, Safety
HOWEVER, this time the Cone head and warning.
Eccentric MUST move as one. To do this LOCKOUT MACHINE.
the Flywheel should be rotated slowly by Refer to Section 4.1, Safety
hand. The Mantle procedure (previous Information for Lockout
Procedure.
page) can be followed but rotating the
Flywheel not the Cone head. It is useful to
have an assistant watch the Cone Head
rotate whilst the vee belts are rotated to
ensure it is moving. In order to prevent slip
DANGER
between the Eccentric and Cone Head:- NIP POINT HAZARD.
A) Ensure slow, gentle movement of the warning.
Eccentric, via the vee belts.
B) Make sure the Concave is well clear

of the Mantle when the Eccentric/
Cone Head is being rotated.
As a final check for any slip between the 0

Eccentric and the Cone Head, repeat the 0
first touch again as the example below:-
If there is a difference of more

than 7mm (9/32”) between any -1 -2
two values of the four
measured, (Figure 4s) that Typical values
piece of manganese must be Mantle OK.
changed immediately.
1
Figure 4s Concave Check
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4.10 Fault finding.
Fault. Possibile Cause. Procedure.
GENERAL.
Machine stops. Overload through discharge Clear machine

setting too low. adjust setting.
Tramp metal fixed in crushing Clear machine

chamber. adjust setting.
Packing in crushing chamber. Clear discharge

chute.
Lubricating oil flow low / Check operation of

temperature high. lubrication system.
Build up in discharge chute. Clear blockage check

chute.
Power supply / drive motor Check power supply /

failure. drive motor, see
manufacturer’s
literature
Broken vee belt (s) Replace belt (s).
Discharge setting not Hydraulic fluid leakage. Check all hydraulic

maintained. components, couplings,
pipes and hoses.
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.
Fault Possible Cause Procedure
Reduction in discharge Crushing pressure too high Adjust setting.

setting not possible.
Hydraulic system faulty Check for internal/
external leaks.
Manganese out of round Check manganese.
Manganese worn out. Change manganese.
Directional control valve Check solenoid.

inoperative.
Relief valve dirty or faulty. Dislodge dirt from

under seat / check
valve spring.
Couplings at hydraulic ring- Investigate and

main faulty. correct.
Packing in crushing chamber. Adjust machine.

(excessives ‘fines’ in feed
Increase in discharge Wedge too tight Grease and

resetting not possible. readjust wedge.
Upper frame assembly Manganese out of round Check manganese

‘bounces’.
Wedge pressure low / Tighten assembly/

Wedge assembly loose. re-pressurise
Adjusting wedge assembly has Check fibre pads

no apparent effect. worn out or require
changing.
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Upper frame assembly Hydraulic cylinder (s) faulty. Investigate and

‘bounces’ continued correct.
Manganese out of round. Check feed

segregatoin.
Check manganese
for out of round,
change as
necessary.
Crushing at excessively tight Change setting.

closed side setting.
Feed chute incorrectly installed. Investigate and

correct.
Erratic movement of Air in hydraulic system. Bleed system / check

hydraulic cylinder(s). for leaks.
Hydraulic system filter (s) Replace.

blocked.
Crusher motor stops. Overcurrent due to voltage drop. Check the

transformer capacity.
Overcurrent due to overload. Suitable feed

amount ?
Uniform feeding ?
No packing ?
Insufficent oil supply?
Damaged bearing ?
Tramp metal ?
Machine overloaded?
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Crusher motor stops Interlock operation. Pump motor rotating?

continued Deteriorated pump
performance or lack
of oil ?
Return oil temperature
too high?
Abnormal sound from Damage of the bearing of the Contact BL-Pegson

the crusher. countershaft.
Damage of the countershaft gear. Contact BL-Pegson
Loose mantle. Inspect conehead/

mantle for damage.
Refit as when changing
manganese.
Loose or falling concave. Adjust the concave

wedge.
Check the mantle

rotating direction.
Check the touching

surface.
Check for partial wear.
The particle size of Mantle / concave worn out of Check for out of round.
the crushed product is round.
coarse.
The indicated setting value is Measure the actual
different from the actual value. setting with a lead ball
etc.
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The particle size of Wedge ring adjustment failure. Adjust the wedge ring.
the crushed product
coarse, continued Partial wear of the mantle and Check the feeding
concave. chute.
HYDRAULICS SYSTEM
The pump doesn’t start. Electrical fault Check the thermal relay
connection and motor,
fuses & connections.
Rotating direction error. Check the rotating

direction and
reconnect.
Insufficent quantity of oil in the Refill oil.

tank.
Pump siezed. Check that pump shaft

rotates, fit replacement
if faulty.
The pump starts but no Clogged suction side piping. Clean the piping and
pressure and discharge carry out flushing.
occur.
Clogged suction side filter. Remove and clean.
Air mixed from the suction side. Re-tighten the coupling

screw.
Replace the piping.
Oil viscosity too high. Check for the specified

brand.
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The pump starts but no Defective or damaged Check and replace.

pressure or discharge pump and coupling.
occur, continued
Relief valve setting failure. Contact BL-Pegson.
Pump noise. Air mixed from the suction Clean the piping and
side. carry out flushing.
Clogged air breather. Disassemble and

clean.
Sound in the relief valve. Disassemble. Clean or

replace the spring
nozzle.
High oil viscosity. Check for the specified

brand.
Irregular motion of the Air mixed in the cylinder. Check the piping, hose
cylinder. and coupling, after
checking and repair,
remove air.
Filters blocked. Replace.
Downward adjustment Unseated unloader valve. Replace valve

possible - system
will not build up or
maintain pressure. Solenoid operated vent valve Replace valve.
unseated.
Directional control valve Check operation of

inoperative. solenoid, replace if
necessary. Check for
possible sticking spool
on valve,dismantle,
clean, replace parts or
complete assembly.
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Downward adjustment Dirt in relief valve. Screw the adjuster out

possible - system will a few turns then in
not build up or maintain again to the original
pressure, continued setting. This will
dislodge dirt under the
ball seat. If no
response,remove unit,
dismantle and clean,
particularly jet.
Replace in system.
Faulty relief valve. Check valve spring,

renew as necessary.
External leakages. Make visual inspection.

Tighten connections.
Renew pipes, hoses or
couplings as
necessary.
Mechanical failure of the Check to see if any

crusher. object touches the
machine.
Insufficent oil quantity. Check the oil level

gauge.
Refill as necessary.
Downward adjustment One or both quick release Inspect, replace as

not possible - high couplings faulty. required.
pressure build - up
occurs.
Directional control valve Check operation of
‘ jammed ‘ half open. valve, dismantle,
clean, replace parts
or complete valve as
necessary.
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Downward adjustment Mechanical blockage on Investigate crusher.

not possible - high crusher.
build up occurs, contd.
Upward adjustment not Directional control valve Check operation of

possible. inoperative. solenoid, replace if
necessary. Check for
possible sticking spool,
dismantle, clean, replace
parts or complete valve as
necessary.
Solenoid operated vent valve Check operation of

inoperative. solenoid, replace if
necessary.
One or both quick release Inspect replace as

couplings faulty. required.
Mechanical blockage on Investigate crusher.

crusher.
External leakages. Make visual inspection.

Tighten connections.
Renew pipes, hoses or
couplings as necessary.
Mechanical failure of the Check to see if any

crusher. object touches the
machine.
Insufficent oil quantity. Check the oil level gauge.

Refill as necessary.
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Oil in system becomes Pump running continuously Check for symtoms of

excessively hot. under pressure. pressure build up.
LUBRICATION SYSTEM.
The oil cooling effiency Cooling matrix choked with Disassemble and
is deteriorating. dust clean.
Dust depositing at the bottom Clean the tank.

of the tank.
Abnormal sound from the High oil viscosity. The sound becomes low
as the oil pump. oil temperature rises.
The gear is damaged. Dissasemble and clean

or replace.
The oil heater cannot Thermostat failure. Replace.

be turned off.
Thermostat setting failure. Correct the setting.
The contact type oil Contact type return oil Replace.

temperature gauge temperature gauge failure.
doesn’t operate at the
preset temperature. Setting failure. Correct the setting.
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Machine stops Lubrication system safety Check system for faults

interlocks activated
Oil chilled on entering cold Look for oil return to

tank. Check oil heater
working.
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4.11 Crusher Drive Belts (optional extra item)
Good alignment of both of the pulleys is important otherwise the belt flanks will wear quickly. Ensure
axis are parallel when viewed from all planes (Figure 4t).
Shafts are not parallel

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

in alignment but pulleys
are not in alignment Both shafts and pulleys
are parallel and in
alignment
Figure 4t Correct Alignment of Pulley Belts
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4.11.1 Replacement of the Drive

Belts (Optional Extra) WARNING
Note: Drive belts should inspected WEAR PERSONAL
regularly for wear and also to monitor any PROTECTIVE EQUIPMENT.
pattern in the wear if it is occuring (Figure Information for relevant
4t). warning.
LOCKOUT MACHINE.
Procedure
Procedure.
2. Close down the machine and implement

the lockout procedure.
3. Remove the drive guard as necessary to

gain access to the vee belt drive.
4. Slacken the belts until it is possible to

remove the belts without the need to
stretch them.
5. Remove the belts.
6. Reposition the new belts in place.
7. Tension the belts to the correct

specification ensuring the engine
coupling pulley is in correct
alignment with the flywheel (Figure 4t).
8. Ensure the crusher drive guarding is

replaced and secured before start-up.
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4.11.2 Method of Drive Belt

Tensioning WARNING
Under no circumstances WEAR PERSONAL
should any check on the belt PROTECTIVE EQUIPMENT.
tension be made whilst the Information for relevant
machine is running. There is a warning.
risk of trapping parts of the
LOCKOUT MACHINE.
body if this is done. Refer to Section 4.1, Safety
Procedure.
Procedure
2. Close down the machine and

implement the lockout procedure.
Remove the guards from around the
belt.
3. Calculate the deflection distance in mm

on a basis of 16mm deflection per 1
metre (0.6” per yard) of belt span
(Figure 4u).
Centre to Centre Distance (metre or

yard) x 16mm or 0.6” = Deflection
(mm or ins)
4. If a belt tension indicator is

available:
a) Set the lower marker ring at the

deflection distance required on the
lower scale.
b) Set the upper marker ring against the

bottom edge of the top tube.
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c) Place the belt tension indicator on top

of the belt at the centre of the belt span, WARNING
and apply a force at right angles to the
WEAR PERSONAL
belt deflecting it to the point where the PROTECTIVE EQUIPMENT.
lower marker ring is level with the top Refer to Section 4.1, Safety
of the adjacent belt. Information for relevant
warning.
d) Read off the setting force value LOCKOUT MACHINE.
indicated by the top edge of the upper Refer to Section 4.1, Safety
marker ring. Information for Lockout
Procedure.
e) Compare this value to the kgf value
shown in the table (Figure 4v)
5. If a belt tension indicator is not

available:
readjusted to the Basic Setting
a) Use a spring balance to pull the belt Force value, if necessary by
down at the centre of the span. repeating the above procedure
from Step 1.
b) When the belt has been pulled down
(measure using a rule) by the
deflection calculated in Step 3, read off
the force from the spring balance.
6. If the measured force falls within the

values given, the drive should be
satisfactory. A measured force below
the lower value indicates under-
tensioning. A new drive should be
tensioned to the 1.25 x Setting Force
value to allow for the normal drop in
tension during the running-in period.
7. Replace all guards before start-up.
After the drive has been

running for 15-20 minutes, the
tension should be checked and
01EN 070206 147/176

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Ce
nt
re
to
Ce
nt
re
Di
sta
nc
e
16mm
Deflection per
1 metre of Belt Span
(0.6” per yard)
Belt Tension Indicator
Applied to Mid-Span
Figure 4u Belt Tensioning Measurements
SETTING FORCE TO DEFLECT BELT 16MM PER METRE OF SPAN

(0.6 INCHES PER YARD OF SPAN)
BELT SECTION
BASIC SETTING 1.25 X SETTING
SMALL PULLEY FORCES FORCES
DIAMETER KILOGRAMS KILOGRAMS
MM (INS) KGF (LBF) KGF (LBF)
224 – 250 (8.8”- 9.8”) 7.1 (15.7) 8.9 (19.5)

SPC 265 – 355 (10.4”– 14”) 9.4 (20.6) 12 (25.8)
OVER 355 (14”) 12 (25.8) 15 (32.3)
1300 - 22/07/04
Figure 4v Belt Tensioning Forces
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4.11.3 Trouble Shooting - Drive

Belts WARNING
Small Cracks on V-Belt side and WEAR PERSONAL
Base PROTECTIVE EQUIPMENT.
Generally caused by insufficient belt tension warning.
but excessive heat and/or chemical fumes
LOCKOUT MACHINE.
can also give same failure. Refer to Section 9.1, Safety
V-Belt Swelling or Softening Procedure.
Caused by excessive contamination by oil,

certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning,

principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires
redesign or a Banded belt. Consult BL
Pegson Ltd.
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Blank page
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Automax Crusher
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5 - Spare Parts Issue 02 ENG
Page 1
Contents
5.1 Automax Crusher Parts ....................................................................................... 3

General Illustration.................................................................................................... 3
5.1.1 Mainframe Assembly ....................................................................................... 4
5.1.2 Upper Frame Assembly................................................................................... 6
5.1.3 Hydraulic Cylinder Fixings ............................................................................... 8
5.1.4 Cone head Assembly .................................................................................... 10
5.1.5 Eccentric Assembly ....................................................................................... 12
5.1.6 Countershaft Assembly .................................................................................. 14
5.1.7 Lubrication Piping Assembly ......................................................................... 16
5.1.8 Hydraulic Cylinder Circuit .............................................................................. 18
5.1.9 Hydraulic Control Panel Assembly ................................................................. 20
5.1.10 Lubricating Oil Tank Assembly ..................................................................... 22
22/03/05
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IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
BL-PEGSON DISTRIBUTOR TO OBTAIN GENUINE PARTS MANUFACTURED
TO ORIGINAL SPECIFICATIONS UNDER STRICT QUALITY CONTROL.
ALWAYS QUOTE THE SERIAL NUMBER STAMPED ON THE

PLANT/MACHINE IDENTITY PLATE
YOUR LOCAL REPLACEMENT PARTS CONTACT

(fill in when known)
BL-PEGSON DISTRIBUTOR.............................................................................
CONTACT NAME(S)..........................................................................................
.........................................................................................
TELEPHONE NUMBER.....................................................................................
FACSIMILE NUMBER........................................................................................
E MAIL ADDRESS.............................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.
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5.1 Automax Crusher Parts
General Illustration
1000 Automax Crusher
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Page 4
5.1.1 Mainframe Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 2500-5004B WEDGE RING SEAL – 1/2SQ X 8M BOX 1
2 2500-5006B MAINFRAME SEAL – 3/4SQ X 8M BOX 1
3 307/19 'O' RING (STUB OIL FLINGER) 1
307/18 ‘O’ RING (STUB SHAFT) 1
4 603/1372 MAINSHAFT 1
5 603/1530 MAINSHAFT STUB 1
6 603/1532 OIL FLINGER 1
7 603/1531 BEARING CLAMP 1
2230-1121 SCREW 4
2212-7109 LOCKWASHER 4
8 603/1208 MAINFRAME LINER SET 1
9 603/1223 COUNTERSHAFT ARM SHIELD 1
10 603/1443 FRAME ARM SHIELD 3
11 603/1459MCD WEDGE RING ASSEMBLY 1
603/1457 ANTI-ROTATION POST 1
12 603/1468 INSERT 12
2147-0101 ADHESIVE – 80 ML 10
2123-2001 MOLYBENTONE GREASE – 0.5 KG 2
13 603/1298 ANTI-ROTATION STOP PLATE 1
2232-1429 BOLT 2
2215-0022 NUT 2
2211-0016 WASHER 2
14 603/1302/1 THRUST BLOCK 2
603/165/2 INSERT 2
2147-0051 ADHESIVE – 300 GM 1
2232-1206 BOLT 4
2211-0010 WASHER 4
2210-0019 WASHER 4
15 603/1473MCD I000 SERIES MAINFRAME ASSEMBLY 1
16 2402-2050 BEARING 6
17 2152-9050 SEAL STRIP – 1 X 1/8 X 48 15
18 603/1373 MAINSHAFT SPACER 1
19 2564-7104 DUMPY JACK 12
603/1465 DUMPY JACK STOOL 12
20 603/1367 TRANSDUCER COVER 1
2230-1153 SCREW 4
BL-Pegson2211-0007
Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 4518618
WASHER
21 2666-9013 LINEAR TRANSDUCER UNIT 1
JUNCTION BOX C/W MULTI CORE
22 2690-0020 1
CABLE
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Automax Crusher
1300
Page 5
21
22
20
1300 Automax - Mainframe Assembly
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Automax Crusher
1300
Page 6
5.1.2 Upper Frame Assembly

1 603/1456 FEED RING - AUTOMAX 1
603/1455 FEED RING - AUTOSAND 1
2 2230-1202 BOLT 4
2210-0019 PLAIN WASHER 4
2211-0010 SPRING WASHER 4
3 320/33 SHOULDERED DOWEL 4
4 603/192 WEDGE 4
5 603/1504MCD UPPER FRAME - AUTOMAX 1
603/1503MCD UPPER FRAME - AUTOSAND 1
6 2402-2050 BEARING 6
2147-0028 LOCTITE - 50ml 1
2530-1135 GREASE NIPPLE 12
2968-4102 GREASE GUN 1
2123-2002 MOLYGREASE CARTRIDGE – 400g 1
7 603/1416E CONCAVE - AUTOMAX 1
603/1407E CONCAVE - AUTOSAND 1
2144-0031 PEGBAK PACK (10KG TUB) 6
2144-0032 RELEASE AGENT 1
22/03/05
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Automax Crusher
1300
Page 7
1300 Automax - Upper Frame assembly
01EN 070206 157/176

Automax Crusher
1300
Page 8
5.1.3 Hydraulic Cylinder Fixings

CYLINDER CLEVIS - UPPER
1 2402-2050 BEARING 6
2 320/25 PIN 6
3 603/1491 SPACER – TOP 12
4 2210-2020 PLAIN WASHER 12
5 2201-0150 SPLIT PIN 12
CYLINDER CLEVIS - LOWER
6 2402-2050 BEARING 6
7 603/1490 PIN 6
8 603/1234 SPACER 12
9 311/10 RUBBER WASHER 12
10 2210-2020 PLAIN WASHER 12
11 2201-0150 SPLIT PIN 24
22/07/04
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Automax Crusher
1300
Page 9
1
2
UPPER CLEVIS
10
11
6
7
8
LOWER CLEVIS
1300 Automax - Hydraulic Cylinder Fixings
01EN 070206 159/176

Automax Crusher
1300
Page 10
5.1.4 Cone head Assembly

1 2410-0496 BEARING – PARALLEL ROLLER 1
2 2415-9802 BEARING – TAPER ROLLER 1
3 2430-0624 CIRCLIP 1
4 603/1244 BURNING RING 1
5 603/1215 MANTLE NUT PLUG 1
6 603/1229 MANTLE NUT 1
7 603/1508E MANTLE 1
N/S 2144-0031 PEGBACK PACK (10KG TUB) 3
N/S 2144-0032 RELEASE AGENT 1
8 603/1236 DISTRIBUTION PLATE 1
2222-0889 SCREW 4
9 603/1313 SNAP RING 1
10 603/1405 COVER PLATE - CONE HEAD 1
2501-1307 'O' RING 1
2230-1220 SCREW 4
2211-0010 WASHER 4
11 603/1329 OIL FLINGER 1
307/5 'O' RING 1
12 603/1255MCD PISTON RING 1
307/3 'O' RING 1
13 603/108 SLEDGING BAR 1
14 603/1318 CONE HEAD 1
22/03/05
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Automax Crusher
1300
Page 11
1300 Automax - Cone Head Assembly
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Automax Crusher
1300
Page 12
5.1.5 Eccentric Assembly

1 2152-9050 SEAL STRIP – 1 X 1/8 X 48” 15
2 2222-6805 SCREW 6
2211-0012 WASHER 6
3 2410-9008 BEARING PAIR – PARALLEL ROLLER 1
4 2415-9801 BEARING – TAPER ROLLER 1
5 2430-0624 CIRCLIP 1
6 302/17 BEVEL GEAR 1
7 323/35 STUD 5
2215-0018 NUT 5
2210-4012 WASHER 5
8 332/8 KEY 2
2222-6748 SCREW 2
9 605/1256 ECCENTRIC 1
10 603/1339 (MCD) PISTON RING 1
307/9 'O' RING 1
11 605/1250 ROTARY SEAL RING 1
12 603/1295 BALANCE RING 1
N/S 2201-5285 SPRING PIN 1
22/07/04
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Automax Crusher
1300
Page 13
11
10
3
12
2 7
9 8
4
1300 Automax - Eccentric Assembly
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Automax Crusher
1300
Page 14
5.1.6 Countershaft Assembly

1 2217-9022 BEARING LOCKNUT 1
2 2230-1221 SCREW 4
2211-0010 WASHER 4
3 2230-1414 SCREW 8
2211-0016 WASHER 8
4 2415-9003 BEARING 2
5 2443-1794 PULLEY 1
6 2443-8370 TAPER LOCK BUSH 1
7 2450-5001 RINGFEDER 1
8 307/7 'O' RING 1
9 2503-4501 OIL SEAL 1
10 302/25 BEVEL PINION 1
11 331/9 KEY 1
12 603/1442 COUNTERSHAFT HOUSING 1
13 603/1219 SHIM PAIR – 1.5mm THICK 2
603/1501 SHIM PAIR – 0.75mm THICK
14 603/1343 OIL GUARD 1
2147-4002 SEALANT – 50 ML 1
15 605/1237 COUNTERSHAFT 1
22/07/04
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Automax Crusher
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Page 15
1300 Automax - CountershaftAssembly
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Automax Crusher
1300
Page 16
5.1.7 Lubrication Piping Assembly

1 341-434 1¼”PIPE, 140 LG 1
2 2510-3791 SOCKET 1
3 2510-3007 BEND 1
4 2510-3639 NIPPLE 1
5 2510-2104 HOSE CAP AND LINER 2
6 2340-4007 JUBILEE HOSE CLIP 4
7 2526-6013 HOSE 4M
8 341/332 PIPE, 236 LG 1
9 2510-3898 BACKNUT 1
10 2510-3114 ELBOW 1
11 2510-3958 UNION 2
12 341/60 PIPE, 645 LG 1
13 25AV194 U BOLT 1
14 2210-0017 WASHER – PLAIN 2
15 2211-0008 WASHER – SPRING 2
16 2215-0014 NUT 2
17 2510-3358 TEE 1
18 2510-3808 HEX NIPPLE 2
21 2526-6027 HOSE 2M
22 2510-3024 BEND 1
23 2520-2077 HOSE CONNECTOR 2
24 2526-6009 HOSE 1M
25 2510-3149 ELBOW 1
26 2510-3147 ELBOW 2
27 2510-3802 HEX NIPPLE 2
30 2526-6003 HOSE 4M
31 2510-3635 REDUCING NIPPLE 1
32 2510-3598 REDUCING BUSH 1
603/1479 – 22/03/05
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Automax Crusher
1300
Page 17
NB. TYPICAL OIL PIPING ARRANGEMENT

AND SUBJECT TO VARATION
603/1479
END VIEW
1300 Automax - Lubricating Oil Piping

01EN 070206 167/176
Automax Crusher
1300
Page 18
5.1.8 Hydraulic Cylinder Circuit

HYDRAULIC CYLINDER CIRCUIT
(ONLY ONE HALF OF COMPLETE CIRCUIT ILLUSTRATED)
1 2500-1021 SEAL 2
2500-1023 SEAL 14
2 2520-0120 QUICK RELEASE COUPLING - MALE 2
3 2520-0130 QUICK RELEASE COUPLING - FEMALE 2
4 2520-6027 REDUCER 8
5 2520-6376 TEE ADAPTOR 10
6 2520-6334 ELBOW ADAPTOR 2
7 2520-6125 SWIVEL NUT 12
8 2521-1800 HOSE ASSY - 200 2
9 2521-1806 HOSE ASSY - 500 4
10 2521-1812 HOSE ASSY - 800 2
11 2521-5203 HOSE ASSY - 350 4
12 2521-5210 HOSE ASSY - 700 4
13 2521-5218 HOSE ASSY – 1200 2
14 2521-5221 HOSE ASSY - 1500 2
15 2564-0054 HYDRAULIC CYLINDER 6
16 2554-0002 OVERLOAD VALVE 1
17 2564-0054B GAITER 6
18 2564-0054A CYLINDER REPLACEMENT SEAL KIT 6
19 2525-5001 HYDRAULIC HOSE – 4600 LG. 2
DUMPY JACK HYDRAULIC CIRCUIT
(CIRCUIT NOT ILLUSTRATED)
20 2564-7104C HOSE ASSY – 334 12
21 2564-7104D HOSE ASSY – 270 1
22
23 2564-7101D HOSE ASSY – 4600 1
24 2520-6002 ADAPTOR 4
25 2564-7101F TEE 1
26 2500-1011 BONDED SEAL 2
27 2564-7101H QUICK RELEASE COUPLING COMPLETE 1
LOOSE ITEMS
28 2147-0024 LOCTITE – 50 ML 1
29 2618-4003 KLAXON 1
22/03/05
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Automax Crusher
1300
Page 19
16
1
17
15
18
11
4
12 5
7
3
14
10
9
13
19
6
ONLY ONE HALF OF THE COMPLETE CIRCUIT ILLUSTRATED
1300 Automax - Hydraulic Cylinder Circuit
01EN 070206 169/176

Automax Crusher
1300
Page 20
5.1.9 Hydraulic Control Panel Assembly
AH SYSTEM 2 C/W WEDGELOCK - L6??

Part No: 2580-1118
SYSTEM 2 - 415/480 VOLTS - 3PHASE - 50/60HZ
NOTE: SPECIFY THE ELECTRICAL SUPPLY IF DIFFERENT FROM ABOVE

1 2589-5119 HYDRAULIC PUMP 1

2 2589-5021 BELL HOUSING 1
3 2589-5297 DRIVE COUPLING 1
4 2589-5291 ELECTRIC MOTOR 1
5 2589-5292 SUCTION FILTER ELEMENT 1
7 2589-5283 FLUID LEVEL GAUGE + THERMOMETER 1
8 2589-5284 FILLER/BREATHER CAP 1
9 2589-5278 CHECK VALVE 1
10 2589-2032 FLOAT LEVEL SWITCH 1
11 2589-5122 PRESSURE FILTER 1
11A 2589-5125 PRESSURE FILTER ELEMENT 1
12 2589-5268 PRESSURE FILTER 1
12A 2589-5277 PRESSURE FILTER ELEMENT 1
13 2589-9008 SOLENOID VALVE 1
14 2589-5265 DOUBLE PILOT OPERATED CHECK VALVE 1
15 2589-5244 UNLOADER VALVE 1
16 2589-5286 PRESSURE RELIEF VALVE 1
17 2589-5287 PRESSURE REDUCING VALVE 2
18 2589-5272 CHECK VALVE 1
20 2589-5266 NEEDLE VALVE 2
21 2538-0051 LOWER MOUNT PRESSURE GAUGE 2
22 2589-5036 BACK MOUNT PRESSURE GAUGE 1
23A 2589-5306 PRESSURE SWITCH – PRESET @ 1800 PSI 1
23B 2589-5307 PRESSURE SWITCH – PRESET @ 1200 PSI 1
24 2589-5301 PRESSURE SWITCH – PRESET @ 2300 PSI 1
25 2589-5293 HYDRAULIC RESERVOIR 1
26 2589-5296 MANIFOLD BLOCK 1
27 2695-0060 PAKTRONIC CONTROL SYSTEM 1
18/08/04
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Automax Crusher
1300
Page 21
22 13, 14, 16 & 17B
17A, 18, 19 & 26 21
21
23B
4
24
15 (behind 23a & 24)

23A
2&3
20B
10
12
5
1 8 7 6 9 11 20A
1300 Automax - Hydraulic Control Panel Assembly
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Automax Crusher
1300
Page 22
5.1.10 Lubricating Oil Tank Assembly
AH 1300 LUB UNIT - L6??

Part No: 2581-8134
STANDARD 415/460 VOLTS - 3PHASE - 50/60HZ
NOTE: SPECIFY THE ELECTRICAL SUPPLY IF DIFFERENT FROM ABOVE

1 2510-3849 DRAIN PLUG 1
4 2589-2084 GEAR PUMP 1
5 2589-2031 FLUID LEVEL GAUGE 1
6 2589-2055 BELL HOUSING 1
7 2589-2109 DRIVE COUPLING 1
8 2589-2002 FILLER/BREATHER CAP 1
9 2589-2082 ELECTRIC MOTOR 1
10 2589-2036 DOUBLE CARTRIDGE FILTER UNIT 1
10A 2589-2030 REPLACEMENT FILTER ELEMENT 2
11 2589-2090 THERMOSTAT 1
12 2589-2058 CHECK VALVE 1
13 2538-7211 KOBOLD FLOW METER 1
14 2589-2081 AIR BLAST COOLER 1
15 2589-2060 BULLS EYE LEVEL GAUGE 2
16 2589-2005 THERMOSTAT 1
17 2589-2032 FLOAT SWITCH 1
18 2589-1019 PRESSURE GAUGE 1
18a 2589-2061 PRESSURE GAUGE ADAPTOR 1
19 2589-2073 IMMERSION HEATER 1
2589-2083 THERMOSTAT FOR HEATER 1
20 2589-2086 OIL RESERVOIR AND LIDS 1
21 2589-2078 ELECTRICAL JUNCTION BOX 1
22 2589-2079 PROTECTIVE COVER 1
18/08/04
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Automax Crusher
1300
Page 23
22 PROTECTIVE COVER NOT SHOWN FOR CLARITY
13
12 9
10
11
10A
16
14
15
17 8
5
21
1
19
18 & 18a 4, 6 & 7 3 (INSIDE TANK)
2
20
1300 Automax - Lubricating Oil Tank Assembly
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Automax Crusher
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Page 24
Blank Page
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1000 and 1300 Cone Crushers and Plants
ADDENDUM TO USER MANUAL
Avoiding Damage to Cone Crusher Linings
INTRODUCTION
To prolong the life of the cone linings and prevent avoidable damage to the main parts of the cone crusher,
please refer to these guidelines.

Avoiding Damage to Cone Crusher Linings
FEEDING MATERIAL INTO CONE

CRUSHERS NOTICE
The crusher should be fully ‘choke‘ fed with a Inspect the liners on a daily basis.
well mixed and well graded material to give best
results. This will also produce even wear on the
cone liners, making them last longer.
Uneven liner wear can occur when material
is ‘trickle’ fed rather than ‘choke’ fed into the
crusher. Unusual wear may also be caused by feed
material being all one size or the size being heavily
segregated.
MAXIMUM CONE SETTINGS

Maximum Cone Setting
Do not operate the crusher with size settings above Cone Size mm Inches
the maximum.
1000 38 1.5
1300 45 1.75
CONE LININGS
INSPECTION
Inspect the liners on a daily basis.
Always check the liners if any non crushable
material may have entered the crusher.
RENEWING
Minimum Cylinder Dimensions
Renew the cone liners before the adjusting
cylinders are working at their minimum. Cone Size mm Inches
1000 690 27.25
Change the liner at or before the adjusting
cylinders reach the dimensions shown in the table. 1300 805 31.75
Do not rely on the minimum dimension shown

in the manual, ignore value stated in the
diagram. This cannot take into account any
features present caused by an unusual wear
pattern or damage by non crushable materials
Monitor the wear on the crusher liners regularly
and renew both the liners before they fail and cause
damage to other parts of the crusher.
II

1300 Automax - Sand Manual 01EN 070206

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AUTOMAX CRUSHER

(ALSO INCLUDING THE ‘AUTOSAND’ VERSION)

MACHINE USER MANUAL

Safety. This manual contains safety information which the operator

01EN 070206 1/176

IMPORTANT SAFETY NOTICE!

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

Terex Crushing & Screening Inc

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

01EN 070206 3/176

This machine is in conformity with the

A Declaration of Incorporation certificate is

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung disease

When dusts are generated by the operation of this

01EN 070206 4/176

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

Telephone:- + 44 1530 518600

Fax:- + 44 1530 518618

To order additional copies contact your local BL-Pegson Ltd Dealer.

AUTOMAX/AUTOSAND - EXPLANATORY NOTE

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

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

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

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

01EN 070206 7/176

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

01EN 070206 8/176

1.2 Organisation Measures Observe all safety instructions and warnings

1.2.2 Disconnect battery ground cable before

01EN 070206 9/176

For the execution of maintenance work, 1.3 Selection and

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1.4 Safety Instructions 1.4.2 Special Work In Conjunction

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1.4.2.3 Beware of moving haulage and loading

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1.4.2.8 Particularly make sure that any part of the

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1.5 Warning of Special 1.5.1.4

• Warn others against approaching and

• Have the live wire de-energized.

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1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

1.5.1.8 Observe the regulations in force at the

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2.1 Introduction .......................................................................................................... 2

2.4 Installing ............................................................................................................. 16

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2.1.1 Automax Features

SIMPLE WEAR PART CHANGE

ADVANCED BEARING ARRANGEMENT

PROVEN SEALING ARRANGEMENT

SETTING ADJUSTMENT/UNBLOCKING FACILITY