1000SR-l Manual Color PDF

Components Manual Issue .
00 Eng
1000SR Cover Sheet
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section A
Cover
Main Switchboard Phone :- +44 (0)1530 518600 Main Switchboard Fax :- +44 (0) 1530 518618
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A-1
E-mail :- sales@bl-pegson.com Website:- www.bl-pegson.com
Page C -1
Copyright © 2002 - 2004 BL-Pegson Ltd . All Rights Reserved
Components Manual Issue .00 Eng
1000SR Introduction
About This Manual

The aim of this manual is to provide Our Dealer network Number dependant, Dealers / Distributors must however
with a comprehensive publication covering Spare parts for be aware Machines do become modified in the field. In ac-
the 1000SR Crushing & screening plant. The manual is in- cordance with Best Practice use of plant serial numbers is
tended to incorporate all design changes from the Proto- recommended when operating this manual .In event of dif-
type machine to those manufactured to Circa November ficulty please contact BL-Pegson Ltd providing Page & Item
2004 Serial Numbers upto 100151BLSR reference together with plant Serial Number.
The publication is presented in CD format configured for Manual is published in English Language only. Repeat cop-
electronic view utilising Adobe Portable Document Format ies of the CD are available to order at a Net Dealer price of
(PDF) compatible with Acrobat 5.0 (PDF 1.4). Earlier ver- £175.00 per Copy. Bound Hard Copy Laminated A4 format
sions of Acrobat may not allow full access to the publica- are available to order at a Net Dealer price of £ 275.00 per
tion. CD includes appropriate Soft Wear package as a sepa- copy. Foreign language copies may be provided subject to
rate folder. quotation and specific order.
The manual is divided into component sections each cov- Confidential data is included intended for use between
ering a logical sub-division of the plant. Dealers & BL-Pegson ltd. Consequently the manual must
not be copied or transmitted to any third party without the
Extensive use of Digital imagery is made throughout the express permission of BL-Pegson ltd. The Document is in-
manual together with drawings to show the arrangement tended to receive periodic revision to reflect anticipated &
& function of the various components so their layout may ongoing plant development. We reserve the write to amend
be clearly understood. Digital images are taken during the contents of this manual without notice
assembly to improve clarity.
Whilst every care is taken to ensure that the information
Original Build data is used throughout the preparation of in this manual is correct no liability can be accepted by the
this manual number. Components are often Plant Serial authors or publishers for loss damage or injury caused by
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section A A
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 1A - 1
Page
1000SR Introduction
any error in or omissions from the information given. In COPYRIGHT

the event of an error or omission please advise in writing
or by E-mail to ©2002 - 2004 BL-Pegson ltd. All Rights Reserved
mwebsell@bl-pegson.com
This Manual contains information and technical data which
may not be copied distributed altered stored on electronic
media revealed to other or used for the purpose of compe-
Safety First tition either partially or in its entirety.
Read this manual carefully & familiarise ALL relevant per-

sonnel with the arrangement of the plant together with
parts available from BL-Pegson ltd.
Please refer to Operation & Maintenance Sections provided

as original equipment with the plant prior to commencing
any work on the plant. Federal, State, National and Local
laws and safety regulations must be complied with at all
times.
Section
Page
1000SR Service Components
Item Description Item Description Part Number Qty

Part Number Qty
Engine C9 Engine Automax & Autosand Lubrication System
Fuel Fi l t er Pri mary El ement 2481-0052 1 Suct i on Fi l t er El ement 2589-1074 1
Fuel Fi l t er Secondary El ement 2481-0053 1 Pres s ure Fi l t er El ement 2589-2030 2
Hydraulic Adjustment
Oi l Fi l t er El ement 2481-0049 1
System
Ai r Fi l t er Pri mary El ement 2481-0054 1 Fi l t er El ement 2589-5277 1
Ai r Fi l t er Secondary El ement 2481-0055 1 Fi l t er El ement 2589-5125 1
Maxtrac Hydraulic Circuit 1000SR T est Data
Suct i on Fi l t er El ement 2531-5150 1 Ref er t o Sect i on 13 Di agnos t i cs
Pres s ure Fi l t er El ement s 2531-5151 2
Ret urn Fi l t er El ement 2531-5253 1
Plant Drives :- HFO Equipped Plants
Crus her Dri ve Bel t s 2441-0470 8
Pump Dri ve Bel t s 2441-0412 4
Section
Page
1000SR Plant Handing
Handing :- Components are Handed Based on Viewing

Plant on Feed ( Rear) End
Right Hand View
Left Hand View
Feed ( Rear) End
Section
Page
1000SR Section Identification
Section 1 :- Feeder Section 2 :- Metal Detector Section 3 :- Crusher Section 4 :- Powerpack Section 5 :- Product
Conveyor Conveyor
Section B :- Screen &

Fines Conveyor
Section 6 :- Transfer
Conveyors
Section 7 :-
Recirculating
Section 8:- Hydraulic Conveyor
Equipment
Section 9 :- Electrical
Equipment Section SP:- Stockpile
Section 10 :- Plant Items Section 11:- Tracks Conveyor
Section 12:- Options
Section
Page
Components Manual Issue.00 Eng
1000SR Section 1:- Feeder Conveyor
Section 1 :- Feeder
Conveyor
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section 1
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page 1 - 1
1000SR Section 1:- Table of Contents
Section 1:- Feeder Conveyor 1 -1 Bearings 1 -14
Section 1:- Table of Contents 1 -2
Feeder Conveyor Layout 1 -3
Frame Upper View 1 -4
H.D.P.E Wear Pads 1 -5
Drive Group 1 -7
Head Drum Bearing Support 1 -8
Tail Section 1 -9
Frame Under View 1 -10
Conveyor Rubber Items 1 -12
Troughing Idlers 1 -13
1000SR Feeder Conveyor Layout
Feed Hopper , Barge Board

& Maintenance Platform :-
Drive Group Refer to Section 10
Head Drum Bearing
Frame Upper View
Metal Detector :-
Refer To Section 2
Tail Section
Frame Under View
1000SR Frame Upper View
1000SR
Item Description / Notes Qty
8 Part Number
2 1 St ri n g e r Se ct i o n AX868/19/1 1
3 2 Rubber Covered Idler Refer t o Page 1-14
3 Impact Idl er 2489-1070 10
1 4 Me t a l De t e ct o r R e f e r t o Se ct i o n 2 1
4 5 Trough Idl er Refer t o Page 1-13
6 Ni p Guard AX848/77/1 1
Cl amp AX848/77/2 2
5
6A Bol t 2232-1126 2
6A Was her Bri ght 2210-0017
Was her Spri ng 2211-0008 1/Bol t
Nut 2217-0005
6 Cl amp AX848/77/3 1
6B Bol t 2232-1126 2
7 6B Was her Bri ght 2210-0017
Was her Spri ng 2211-0008 1/Bol t
Nut 2217-0005
7 Head Drum AX848/113 1
8 Tai l Drum AX848/33 1
1000SR H.D.P.E Wear Pads
13
12
10
12A
11
13 12
1000SR H.D.P.E Wear Pads
1000SR 1000SR
Item Description / Notes Qty Item Description / Notes Qty
Part Number Part Number
Si de Support Wear Pad AX848/70/1 2 Si de Suppo rt We a r P a d AX848/65/3 2
Screw 2226-0816 Support Si de Wedge AX848/65/5 2/Pad

9
Was her 2210-0017 10/Pad Screw 2226-0807
4/Pad
Nut 2217-0005 Screw 2226-0806
Si de Support Wear Pad AX848/70/2 2 Was her Bri ght 2210-0016
13 8/Pad
Screw 2226-0816 Nut 2217-0004
10
Was her 2210-0017 12/Pad Si de Suppo rt St i f f e ne r AX848/65/4 2
Nut 2217-0005 Scre w 2226-0806
St ri nger Support Bracket AX848/66 4 4/
Was her Bri ght 2210-0016
St i f f ener
11 Bol t 2232-1126 2/BRKT Nut 2217-0004
Not Il l us t rat ed Wa s he r Bri ght 2210-0017 4/BRKT
Nut 2215-0014 2/BRK
Ce nt ra l Be l t Suppo rt AX848/65/1
Ce nt ra l Be l t Suppo rt 2
AX848/65/2 Item 12 & 13 Ordering Note
St i f f e ne r
12 Scre w 2226-0809 Items 12 & 13 are Supplied Complete with Stiffeners &
Wa s he r Bri ght 2210-0016 12 Fixings . Parts Must However be Ordered in Accordance with
N ut 2217-0004
the Full Detail Supplied on Page 1-5
Bol t 2232-1129 4
12A Was her 2210-0017 8
N ut 2217-0005 4
1000SR Drive Group
14 1000SR
Part Number
Ge a rbo x Suppo rt AX848/57/1 1
Bol t 2232-1355
14
Was her Bri ght 2210-0023 2
15 Nut 2217-0011
Mot or & Gearbox 2473-00013
15 Seal Ki t 2576-9011 1
Check Val ve
2579-0018
(Not Il l us t rat ed)
15A Hydraul i c Mot or 2576-4092 1
15B
15B "O"Ri ng & Coni cal Seal 2576-9014 1
16 Gearbox Si ght Gl as s 2576-9007 2

16
Caps crew 2222-0247
17A 8
Was her Spri ng 2211-0010
Caps crew 2222-0247

17B 12
15A
17A
17B
1000SR Head Drum Bearing Support
1000SR
6A Item Description / Notes Qty
Part Number
Beari ng Support AX848/58/1 1

2/
Support /St ri nger Bol t 2232-1355
Support
6B
Was her Bri ght 2210-0023 2/Bol t
Nut 2217-0011 1/Bol t
Beari ng Mount i ng Bol t 2232-1278 4

18
18
1/Bol t
Nut 2217-0009
Beari ng l ock Bol t 2232-1134 2

19
Nut 2215-0014 1/Bol t
19 Be a ri ng Refer t o Page 1- 14
19A Gre a s i ng Ki t Not Fi t t ed
20 20 Scra p e r R e f e r t o P a g e 1 -1 0 & 1 -1 1
1000SR Tail Section
1000SR
2 Item Description / Notes Qty
Part Number
2 Rubber Covered Idl er Refer to Page 1- 13
8 Tai l Drum Refer to Page 1- 4

Drum Scra pe r & P l ugh
21 Refer to Page 1- 10 & 1-11
Suppo rt
22 Be a ri ng
22A Refer to Page 1- 14
Gre a s i ng Ki t
Not Il l us trated
Beari ng Mounti ng Bol t 2232-1208 2/Beari ng
8 Was her Bri ght 2210-0019 4/Beari ng

22 & 22A
2/Beari ng
Nut 2217-0007
23 Tens i oner LH AX818/110/1

23A 1
Tens i oner RH AX818/110/1X
Not i l l us trated
Bol t 2232-1203
23 & 23A Was her 2210-0019 4/Uni t
Nut 2217-0007
23 22 21
1000SR Frame Under View
24
28
24 25 26 27 20 29
21 30 31
1000SR Frame Under View
1000SR 1000SR
Scra p e r C a rri e r AX846/36/1 Di s c Rol l er 2495-1196 1
Scra pe r Bl a de AX868/104 1 Rol l er Support Bracket AX868/19/2 2
29
Cl amp St ri p AX848/36/2 Bol t 2232-1125
20 2/Brkt
Bol t 2232-1129 Was her 2210-0017
Was her Bri ght 2210-0017 5 P l o ugh Scra pe r AX848/34/1
1
Nut 2215-0014 Scra pe r Bl a de AX848/34/3
Drum Scra pe r & P l o ugh
21 AX848/79/1 1 Cl a mp AX848/34/2 2
Suppo rt
30
24 Tens i oner AX607/3/46 2 Bol t 2232-1076
25 Si de Ret urn Ni p Guard AX857/10/1 2 Was her Bri ght 2210-0015 12
26 Mi d Se ct i o n Ni p Gua rd AX868/159/1 1 Nut 2217-0003

P l o ugh Sca pe r Suppo rt
27 P a rra l l e l Ro l l e r 2495-1130A 1 AX848/79/2 2
L i nk
Guard AX848/73/1 1 Spl i t Pi n 2201-0145
Bol t 2232-1126 31 Bol t 2232-1202
1/Li nk
28 Was her Bri ght 2210-0017 Was her Bri ght 2210-0019
4
Was her Spri ng 2211-0008 Nut 2215-0016
Nut 2217-0005
1000SR Conveyor Rubber Items
1000SR
Part Number
30 31
32 Rear Ski rt AX868/98/2 1
33 Si de Ski rt AX868/98/1 2
C onveyor Belt
34 Conveyor Bel t 2360-0050/14.0 1
Conveyor Belt :- BL-Pegson Recommend Belt Repla

Repair is effected through VULCANISED Joint. Rep
supplied in Sufficient Length to Allow Joint Format
Mechanical / Clipped Joints will Adversely Effect th
32 of the Metal Detector & Must not be Used.
1000SR Troughing Idlers
1 1 1
1
2
2
Base Plate Trough Idler

Rubber Covered Trough Idler
R ubber C overed Idler Base Plate Mounted Idler

Plant C omponent
Part Number Qty Part Number Qty
Compl et e Set 2495-3011 1 2495-3012 1
1 : - W i ng Rol l er 2489-1060 2 2489-1052 2
Fi xi ng Cl amp 2489-3004
1000SR Fi xi ng Bol t 2232-1072 1/

Was her Bri ght 2210-0015 Rol l er
Nut 2217-0003
2 : - Cent re
2489-1062 1 2489-1063 1
Rol l er
1000SR Bearings
“S” Suffix Style Bearing Grease Bearing Grease Nipple Connection

Nipple Connection
Adaptor Reducing M/M

Part Number :- 2526-6071
Grease Nipple Adaptor

Part Number 2429-0001
P la nt Se r ia l Numb e r Ite m 19 Ite m 19A P la nt Se r ia l Numb e r Ite m 22 Ite m 22A

2530-2013 Pl us
QM018702 2421-0011
QM018702 2429-0001
QM018966
100101BASR QM018966
100102BASR 100101BASR
100101BBSR 2421-2008S Not Fi t t ed 100102BASR
100101BCSR 100101BBSR
100101BDSR 2421-0011S 2530-2012
100101BCSR
100106BDSR Through 100108BDSR 100101BDSR
100106BDSR Thro ugh 100108BDSR
1000SR Section 2 :- Metal Detector
Section 2 :- Metal
Detector
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section A 2
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 12- 1
Page
1000SR Section 2 :- Table of Contents
Section 2 :- Metal Detector 2 -1
Section 2 :- Table of Contents 2 -2
Metal Detector Installation 2 -3
Control Station 2 -4
Metal Detector Components 2 -5
Section
Page
1000SR Metal Detector Installation
4 3
1 2
Not Illustrated Located
Under Detctor Coil
Section
Page
1000SR Control Station
4 5
10
6
5 11
12
13 14 15
Section
Page
1000SR Metal Detector Components
1000 SR 1000SR
Part Number
Part Number
C o mp l e t e D e t e c t o r U n i t 2366-2005 1 Cont rol Knob wi t h
8 2366-2013 2
Me t a l De t e ct o r Suppo rt Poi nt er Cap
AX848/63 2
Bra cke t 9 Rel ay 2366-2014
Bol t 2232-1126
1 10 P.C.B 24V DC 2552-0025
Not Il l us t rat ed Was her Bri ght 2210-0017
2/Brkt 11 Co mbi co n P l ug 6Wa y 2366-2017
12 Co mbi co n P l ug 12Wa y 2366-2019 1
Nut 2217-0005
Co nt ro l Kno b wi t h P l a i n
13 2366-2012
Se a rch Co i l 2366-2005A 1 Ca p
Bol t 2232-1095 14 Co mbi co n P l ug 9Wa y 2366-2018

2
Was her 2210-0016 4 15 Co mbi co n P l ug 4Wa y 2366-2016
Nut 2217-0004
3 Co i l Ca bl e 5Mt r 2366-2007 1
MA3000CE Co mpl e t e
2366-2004 1
Co nt ro l Uni t
Bol t 2232-1092
4
Was her 2210-0016 4
Nut 2217-0004
Indi cat or As s embl y 2366-2008

5 1
Bul b 2366-2010
Mo me nt a ry Il l umi na t e d
2366-2009
6 Swi t ch As s y 1
Bul b 2366-2010
7 Baragraph Modul e 2366-2011 1
Section
Page
1000SR Section 3:- Crusher
Section 3 :- Crusher
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 13 - 1
Page
Section 3:- Table of Contents 3 -1 Eccentric & Bearings 3 -17
Manganese Steels 3 -3 Seal 3 -21
Manganese Options 3 -5 Cone Head Area 3 -23
Pegbak & Release Agent 3 -6 Cone Head Mantle Nut 3 -24
Section Identification 3 -7 Cone Head 3 -25
Upper Frame 3 -8 CounterShaft 3 -26
Upper Frame Units 3 -9 Anti Rotation Plate 3 -29
Upper Frame Parts 3 -10 Hydraulic System 3 -31
Wedge Ring 3 -11 Adustment Cylinders Circuit 3 -32
Lower Frame 3 -13 Cylinder Pins 3 -34
Main Shaft 3 -15 Wedge Dumpy Jacks 3 -35
Section
Page
Crusher Hoses 3 -36
Setting Control System 3 -37
Liniear Indicator 3 -39
Lubrication System 1000SR 3 -40
Lubrication System Parts 3 -41
Lubrication Tank 3 -43
Section
Page
1000SR Manganese Steels
Manganese Steels
As a manufacturer of crushing equipment BL-Pegson Ltd may, in the correct application, achieve 450BHN with
has to provided a product for each application. We sup- work hardening. Material is less suited to Abrasive and /
port a range of crushing chamber profiles selected in or aggressive applications where effective work harden-
accordance with specific applications. These profiles are ing may not be experienced. Grade is supplied to order
dependant upon the machine configuration. only.
1000 Automax:- Extra Coarse , Coarse , Medium Coarse , Mn 16-18 “E” Grade
1000 Autosand:- Sand
This grade exhibits work hardening properties & has the
There are many statements published relating to the advantage of higher initial hardness due to the presence
effect of manganese upon the wear characteristics of of increased Carbon. Material is controlled to include Mn
crusher parts. The “Pros & Cons” of various manganese content 16 –18% & C 1.2 to 1.3%. As quenched ~248
specifications are explored in the Wear parts presenta- BHN may work harden to 400BHN. The material is suited
tion appended to this section. The grades of manganese for applications processing materials whose characteris-
supplied by BL-Pegson Ltd for Automax & Autosand ap- tics prevent efficient work hardening of Hadfield Manga-
plications are as follows: nese or the high capacity action of BL-Pegson crushers.
The material is BL-Pegson ltd standard supply for
Mn 12-14 “ Hadfield Manganese” Automax & Autosand machines & is available from stock.
This material has traditionally been the industry standard Mn 23 “TT” Grade
grade used for normal quarrying applications. Material is
controlled to include Mn content 11.5 –14% & C 1.05 to The material holds the advantage of higher hardness
1.25% than Mn 12-14 exhibits enhanced wear characteristics.
The material displays exceptional work hardening char- Material is controlled to include Mn content 22-24% & C
acteristics providing a sound work hardening process 1.2 to 1.4%. Initial as quenched ~ 248 BHN however
occurs. Typical Brinell hardness ~220 BHN as quenched
Section
Page
1000SR Manganese Steels
work hardening is reduced. Under the right conditions

this material will out perform other grades however
these advantages are outweighed by other factors. Grade
is supplied to order only.
Specific application may be discussed with BL-Pegson Ltd

Engineering Section.
Section
Page
1000SR Manganese Options
1000 Automax & 1000 Autosand
Item "A" Concave "B" Mantle
"XC" "C" "MC" "AS"

Chamber Extra Coarse Coarse Medium Coarse Autosand
Part Number Qty Part Number Qty Part Number Qty Part Number Qty Part Number Qty
Stock "E" Grade 603/9053E 603/9107E 603/9052E 603/9071E 603/9106E

"Hadfield
603/9053 1 603/9107 1 603/9052 1 603/9071 1 603/9106 1
Manganese"
23% "T T "
603/9053T T 603/9107T T 603/9052T T 603/9071T T 603/9106T T
Manganese
Backing:- Qty per Chamber
PEGBAK 2144-0001 9 2144-0001 9 2144-0001 8 2144-0001 9
Release Agent 2144-0002 1 2144-0002 1 2144-0002 1 2144-0002 1
Accelerator 2144-0003 1 2144-0003 1 2144-0003 1 2144-0003 1
Paddle Mixer 2144-0004 1 2144-0004 1 2144-0004 1 2144-0004 1
A A A
XC & C Chamber Profile B MC Chamber Profile B AS Chamber Profile B
Section
Page
1000SR Pegbak & Release Agent
Pegbak Crusher Backing Compound not be Returned to Service Until Backing is Fully
Hardened
Pegbak Backing Material is a Single Use Compound Used
to Fill the Void Spaces Behind Manganese Concave & Pegbak Release Agent
Mantle where there are no Machined Mating surfaces
with the Upper Frame & Cone Head Respectively. Each Release Agent is Used to Prevent Adhesion Between the
Pack of Pegbak includes Two Separate Components, Part Mating Surfaces & Pegbak and to Allow the Concave Gun
A Resin Part B Hardener , and produces 5KG Nominally of Lock Style Self-Tightening System to Operate Properly.
Backing. Pegbak is Poured after the Manganese has been
fitted . Each pack is Mixed only when required . Health & Safety
Pegbak Should be Stored at Temperatures Between 15°°C Pegbak & Release Agent are Toxic. Attached to this
& 26°°C. Temperature: Working Life Depends Upon Publication in a Separate Printable File are Safety Data
Temperatures. Sheets Covering Pegbak Resin, Hardener & Release Agent.
Safety Data Sheets are Current at time of Publication We
The Hardening Process is effected by Temperature . It is reserve the Right to Amend Details Without Notice
Necessary to Work with Both Agents at 16-32°°C (60- Confirmation of Validity Must be Obtained from BL-Pegson
90°°F) Cooling may be required in Hot Weather and Ltd Prior to Issuing Copies of the Safety Data Sheets to
Heating in Cold Weather. At a Temperature of 25°°C Work Appropriate Authority or Body.
Life will be 20 Minutes Approximately , Higher
Temperatures will Decrease Work Life . Heating or
Cooling Effect Produced by Large Metal Items may Transport
Adversely Influence Hardening of Pegbak . Refer to Best
Practice document appended to this section. Pegbak & Release Agent May be Classified as Hazardous
Goods Depending upon the Mode of Transport and Apper-
The Filler Requires Approximately 12 Hours to Harden at taining Regulations. Federal, State, National, Local laws and
an ambient Temperature of 20°°C (68°°F) . Machine Must Safety Regulations must be complied with at all times.
Section
Page
1000SR Section Identification
Cone Head Eccentric
Upper Frame Wedge Ring
Hydraulic System Anti Rotation Plate
Countershaft
Seal
Lower Frame Main Shaft
Section
Page
1000SR Upper Frame
3
5 1
6 2
Section
Page
1000SR Upper Frame Units
1000 Automax / Autosand 1000 Automax / Autosand

Crusher Language Description / Notes Crusher Qty
Upper Frame Warning Labels

R eplacement Upper Frames Assembly Comprising;
IMPORTANT :- Frame Arm 300/99
Upper Frame ,Manganese , Bearings & Grease Nipples Fitted Dut ch 2
IMPORTANT :- Cl evi s Pi n 300/100
"XC" Option 603/P253AMXC IMPORTANT :- Frame Arm 300/45

Engl i s h 2
"C" Option 603/P253AMC IMPORTANT :- Frame Arm 300/67

French 2
1 IMPORTANT :- Cl evi s Pi n 300/68
"MC" Option 603/P253AMMC IMPORTANT :- Frame Arm 300/83

German 2
"AS" Option 603/P253ASXC IMPORTANT :- Frame Arm 300/146

It a l i a n 2
Warni ng Label s ; In Addi t i on t o t he Above a Set of Warni ng Label s i n t he l anguage IMPORTANT :- Frame Arm 300/166
Appl i cabl e t o t he Count ry of Operat i on are requi red Port ugues e 2
IMPORTANT :- Frame Arm 300/115

Manganese Items Must always be replaced as a Pair , It is Detremental to the Spani s h 2
Performance of Automax & Autosand to re use Part Worn Crushing Surfaces.
In Addition to Change of Upper Frame the Following Items will be R equired Screw 2205-3021 4/Label
Mant l e 603/9106E 1
Pegback 2144-0001 5
Rel eas e Agent 2144-0002 1
Section
Page
1000SR Upper Frame Parts
1000Automax / Autosand 1000Automax / Autosand

Item Description / Notes Crusher Qty Crusher
Individual Items 3 Wedge 603/9090 3
" XC " Opt i on 4 Shoul dered Dowel 320/33 3
1 Upperframe 1 Pi ece 603/9083 5 Beari ng 2402-2040 6

1
2 Concave 603/9053E 6 Greas e Ni ppl e 2530-1135 12
" C " Opt i on
1 Upperframe 1 Pi ece 603/9083

1
2 Concave 603/9107E
" MC " Opt i on

1
2 Concave 603/9052E
" AS " Opt i on

1
2 Concave 603/9071E
Warni ng Label s :- Refer t o Page 3-9
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 10
Page 3 - 10
1000SR Wedge Ring
Section
Page 3 - 11
1000SR Wedge Ring
1000 Automax / Autosand

7 Item Description / Notes Crusher Qty
Part Number
Wedge Ri ng As s embl y
Compri s i ng
7 603/9088 1
Expandi ng Wedge Ri ng
W i t h Pads Fi t t ed
8 Expandi ng Wedge Ri ng 603/9088MCD 1
10
Wedge Ri ng Pad 603/9141
( Pack )
9 Adhes i ve 2147-0010 8
Lubri cant 2123-2001 1

8
10 Seal 2500-5004B 1 Box
11 Ant i Rot at i on Bar 603/9034 1
11
10
Section
Page 3 - 12
1000SR Lower Frame
18
15
16
17
13
12
14
Section
Page 3 - 13
1000SR Lower Frame
14 15 16 15
17
12
13

Item Description / Notes Crusher Qty
Part Number 14 18
12 Mai nframe 603/9092FMCD 1
13 Beari ng 2402-2040 6
Labyri nt h St ri p 2152-9050 11
14
As s embl y i ns t ruct i ons refer t o s ervi ce bul l et i n SP 047 04
15 Seal 2500-5006B 1 Box
16 Mai nframe Li ner Set 603/9126 1
17 Frame Arm Shield 603/9125 3
18 Countershaft Arm Shield 603/923 1
Section
Page 3 - 14
1000SR Main Shaft
Section
Page 3 - 15
1000SR Main Shaft

22 Part Number
19 Mai ns haft 603/903 1

23
20 Mai ns haft Spacer 603/6007 1
Beari ng Cl amp
19 20
Screw
21
Lockwas her
Refer t o Servi ce Bul l et i n SP 038 04
" O " Ri ng
21 22 St ub Shaft
Oi l Fl i nger
23
" O " Ri ng
Section
Page 3 - 16
1000SR Eccentric & Bearings
24
27
25
27
29
28
26
Eccentric :- 1000 Automax / Autosand Crusher
Section
Page 3 - 17
24
25
27
29
28 26
Section
Page 3 - 18
30 30
31
32
32
33
33
35 34
Section
Page 3 - 19

Eccent ri c 40mm Throw 603/1120 30 Beari ng 2410-9006
24 1
Eccent ri c 49mm Throw 603/6008 31 Ci rcl i p 2430-0584
26
Refer t o Gear & Bevel Gear 302/15 1 32 Beari ng 2415-9900
Pi ni on Not e 1
33 Beari ng Pai r 2410-9007
Caps crew 2222-6753
27 4 34 Ci rcl i p 2430-0584
35 Beari ng 2415-9901
Key 332/2
2
28 Screw 2222-6748
Loct i t e 2147-0001 1
St ud 323/37 Bearing Note :-

Was her Hard 603/9115 5 Bearings are illustrated as Assembled in to
29 Sub Components of Crusher . Bearings are
Nut 2215-0016
ONLY Supplied as Complete Units
Loct i t e 2147-0001 1
Item 26 & 61 Gear & Pinion Note :-

Gear & Pinion are Machined to Form a
MATCHED Tooth Profile & are only Supplied
as a Pair
Section
Page 3 - 20
1000SR Seal
36
37
39 38
Section
Page 3 - 21
1000SR Seal
1000 Autosand Autosand

Part Number
Labyri nth Stri p 2152-9050 11

36
36 As s embl y i ns tructi on refer to Servi ce Bul l eti n SP 047 04
Rotary Seal Ri ng 40mm
603/9094
Throw
37 1
Rotary Seal Ri ng 49mm
603/9006
Throw
38 Pi s ton Ri ng 603/9079MCD 1
39
" O " Ri ng 307/12 1
Not Il l us trated
37
38
29
Section
Page 3 - 22
1000SR Cone Head Area
Mantle Nut Area
Cone Head
Section
Page 3 - 23
1000SR Cone Head:- Mantle Nut

40 Part Number
Wear Pl at e 603/936 1
40
Screw 2226-0889 4
41
41 Mant l e Nut Pl ug 603/915 1
Cover Pl at e 603/6020 1
Screw 2230-1220 4
42 42
Was her 2211-0010 4
"O" Ri ng 2501-1250 1
43 Mant l e Nut 603/929 1
43
Section
Page 3 - 24
1000SR Cone Head
44 46 49
45
47

Crusher
32 Part Number
Not Fi t t ed t o 1000 Aut omax/
44 Burni ng Ri ng 1
Aut os and
47
32 45 Mant l e 603/9106E 1
46 Cone Head 603/9082 1
47 Snap Ri ng 603/1040 1
48
Pi s t on Ri ng 603/955MCD
48 1
"O" Ri ng 307/1
49
Oi l Fl i nger 603/1039 1
49
"O" Ri ng 307/4 1
Section
Page 3 - 25
1000SR CounterShaft
50
51
56 52
58 59
60
61
Section
Page 3 - 26
1000SR CounterShaft
50 53 52 55
51 54
58
57
60
59
62
56
55 61
Section
Page 3 - 27
1000SR

50 Pul l ey 2443-1787 1 58 "O" Ri ng 307/6 1
51 Taperl ock 2443-8365 1 59 Key 331/8 1
Oi l Guard 603/9019 1 60 Count ers haft 605/909 1
Screw 2230-1122 61
52 6 Refer t o Gear & Bevel Pi ni on 302/26 1
Pi ni on Not e
Seal ent 2147-4002 1 62 Locki ng Ri ng 2450-5002 1
53 Oi l Seal 2503-3153 1
54 Beari ng Locknut 2217-9007 1
55 Beari ng 2415-9002 2
Count ers haft Hous i ng 603/9004 1
Screw 2230-1358 6
56
Was her Spri ng 2211-0014 6
Item 26 & 61 Gear & Pinion Note :-
Seal ent 2147-4002 1 Gear & Pinion are Machined to Form a
Shi m Pai r 1.5mm 603/9022 3 MATCHED Tooth Profile & are only Supplied
57
Shi m Pai r 0.8mm 603/9109 1 as a Pair
Section
Page 3 - 28
1000SR Anti Rotation Plate
64
63
Section
Page 3 - 29
1000SR Anti Rotation Plate

Part Number
Ant i Rot at i on St op Pl at e 603/1014 1
Bol t 2232-1353
63
63 64
Nut 2215-0020
Thrus t Bl ock 603/1022/1 2
Thrus t Bl ock Pad 603/1022/2 2
Adhes i ve 2147-0051 1/Pad

64
Bol t 2232-1204
Was her Spri ng 2211-0010 2/Pad
Section
Page 3 - 30
1000SR Hydraulic System
Section
Page 3 - 31
1000SR Adustment Cylinders Circuit
67 66 67 65
72
68
69
70
68
Note :-
Crushers Uses Two of the Hydraulic
Adjustment Cylinder Circuit Illustrated
71
Section
Page 3 - 32
1000SR Adustment Cylinders Circuit

Crusher
Part Number
68 Hydraul i c Cyl i nder 2564-0040 6
65
66 Seal Ki t 2564-9310 1/ Uni t
Cyl i nder Overl oad Safet y
66 2554-0003 2/Ci rcui t
Val ve As s embl y
72
Reducer 2520-1007
67 67 12
Bonded Seal 2500-1021
68 Tee Mal e 2520-1057 10
69 QR Coupl i ng Mal e 2520-0120 2
QR Coupl i ng Femal e 2520-0130

70 2
71 El bow N/A
72 Reducer 2520-1257 12
1000 SR
73
Loct i t e 2147-0024 1
Not Il l us t rat ed
69 Hos es & Fi t t i ng Ki t 603/B14HY D/A 1
Hos es :- Refer t o Page 3-36
70
Section
Page 3 - 33
1000SR Cylinder Pins

5 & 13 76 75 72 & 72A Item Description / Notes Crusher Qty
Part Number
Upper Frame Pi ns
72 Pi n 603/9100 6
73 Spl i t Pi n 2201-0148
74 Was her 2210-2017

2/Pi n
73 75 Was her Rubber 311/9
76 Spacer 603/934
Mai nframe Pi ns
74 72A Pi n 603/9100 6
73 Spl i t Pi n 2201-0148
74 Was her 2210-2017

2/Pi n
75 Was her Rubber 311/9
76 Spacer 603/934
76
75
72 75 72A
Section
Page 3 - 34
1000SR Wedge Dumpy Jacks
1000Automax / Autosand
“A” Item Description / Notes Crusher Qty
Part Number
80
Dumpy Jack
77
Seal Ki t
Refer t o Servi ce Bul l et i n SP 044 04
78 Dumpy Jack St ool
“B” Dumpy Jack Hos es & Fi t t i ngs ki t
Adapt or Mal e/Mal e 2564-7101E

79 3
Bonded Seal 2564-7101G
80 Tee Femal e 2564-7101F 1

79
81 QR Coupl i ng Compl et e 2564-7101H 1
Hos es :- Refer t o Page 3-36
“C”
77 78 79
81
79
Section
Page 3 - 35
1000SR Crusher Hoses
1000 Crusher 1000 Crusher

Part Number Length mm Qty Part Number Length mm Qty
Hose T ype Insert T ype Hose T ype Insert T ype
Crusher Hydraulic Adjustment Hoses Dumpy Jack Circuit Hoses
2521-1800 3/4BSP F R2A STR x STR 200 2 2564-7101A 190 11
2521-1806 N/A 500 4 2564-7101B Hyd Hos e 1/4 ST/ST 120 1
2521-1810 3/4BSP F R2A STR x STR 700 2 2564-7101C 250 1
2521-1812 N/A 800 2 2564-7102A 297 11

2521-1824 3/4BSP F R2A STR x STR 275 4 2564-7102B N/A 210 1
2521-5202 1/2 BSP F R1A STR x 90 300 4 2564-7102C 350 1
2521-5203 N/A 350 4
2521-5208 1/2 BSP F R1A STR x 90 600 4
2521-5210 N/A 700 4
2521-5216 1/2 BSP F R1A STR x 90 1000 2
2521-5218 N/A 1200 2
2521-5220 1/2 BSP F R1A STR x 90 1400 2
2521-5221 N/A 1500 2
Section
Page 3 - 36
1000SR Setting Control System
86
84 90
91
95
92
88 94
93
82 83 85 84
87
89
Section
Page 3 - 37
1000SR Setting Control System
1000Automax / Autosand
Crusher
1000SR Powerpack Item Description / Notes Qty
Part Number
82 Node Refer t o Sect i on 8
83 Unl oader Val ve 2589-5270 1
84 Pres s ure Guage 2589-5031 3
Pres s ure Fi l t er 2589-5268 1

85
El ement 2589-5277 1/Uni t
MK 1 El ect ri cs 2683-2236
Pres s ure Sens or
86 MK 11 & Mk111 2683-2285 1
Cabl e El ect ri cs 2683-2286
87 Pres s ure Swi t ch 2683-2237 1
88 Needl e Val ve 2589-5266 2

89
El ement 2589-5125 1/Uni t
90 Sol enoi d Val ve 2589-5269 1

96
Doubl e Pi l ot Operat ed
91 2589-5265 1
Check Val ve
92 Pres s ure Reduci ng Val ve 2589-5271 2
93 Mani fol d Bl ock 2589-5275 1
94 Pres s ure Rel i ef Val ve 2589-5273 1
95 Check Val ve 2589-5272 1
96 Check Val ve 2589-5278 1
Section
Page 3 - 38
1000SR Liniear Indicator

Part Number
Sens or Cover 603/1367 1
Cover Pl at e Screw 2232-1061

14
Was her 2210-0013
97
Fi xi ng Bol t 2232-1090
99 98 97
Was her 2211-0007 4
Nut 2215-0013
Sens or Bracket 603/9110
Bol t 2232-1029
98 Was her Bri ght 2210-0012 1

100
Nut 2215-0013
99 Junct i on Box 2690-0020 1
100 Li near Pos i t i on Sens or Refer t o Sect i on 8

101
Adapt or Pl at e 603/9080 1
101 Bol t 2232-1090

2
Was her 2211-0007
102
Bol t 2232-1029 1
102 Was her 2210-0012 2
Nut 2215-0013 1
Section
Page 3 - 39
1000SR Lubrication System 1000SR
103 107
108 105 104
109
Section
Page 3 - 40
1000SR Lubrication System Parts
104
106 107
A
B
104
105
108
106
Section
Page 3 - 41
1000SR Lubrication System Parts
1000 SR 1000SR
Countershaft Feed Parts R eturn Pipe Support Bracket
AX868-184-003 Refer t o Pl ant Hos es Page 1 Support Bracket AX857/27 1

103
El bow 2510-3147 106 " U " Bol t 2512-0007 1
1
Ni ppl e 2520-6571 Nut 2215-0014 4
Crusher Feed Parts Was her Spri ng 2211-0008 2
AX868-184-002 Refer t o Pl ant Hos es Page 1 107 :- Heat Exchanger
El bow Compact 2520-6348 2 Heat Exchanger 2534-4001 1

104
Taper Ni ppl e 2520-6048 Ant i Vi brat i on Mount s 2389-0254 4
A
Socket Reduci ng 2510-3526 1 Wat er Connect i ons Ki t 2534-4001A 1/uni t
Bend 2510-3067 Oi l Connect i ons ki t 2534-4001B
Crusher R eturn Pipework Val ve Uni t 2550-5005 1
Pi pe Threaded 341/439 Fi t t i ngs Ki t 2550-5005A

B Wat er Cont rol Sol enoi d
Backnut 2510-3898 1 2550-5006 1/uni t
Val ve
105 El bow 2510-3114 Coi l 2550-5007
Ni ppl e 2520-6052 2 Flow Meter Connection
Hos e & AX868-184-001 Hos e 89 Refer t o Pl ant Hos es Page

1
Hos e Guard 2529-9904 108 Adapt or 2520-6006
1
Swept 90 Adapt or 2520-6573
Section
Page 3 - 42
1000SR Lubrication Tank
1000 SR
Item Description Qty
Part Number
Lubrication Oil tank 109

109
Lubri cat i on t ank AX868-190-601 1
Section
Page 3 - 43
117 118
113
114
115
116 110 111 112
Section
Page 3 - 44
120A 119 120

117C
121
117A 127
117B
122
126
123
124
125
Section
Page 3 - 45
1000 SR 1000 SR
Item Description / Notes Item Description / Notes Qty
Part Number Qty Part Number
109 Lubrication Unit 121 Fl ow Meter 2538-7210
110 Res ervoi r & Li ds 2589-2062 122 Hydraul i c Motor 2576-4094
111 Level Indi cator 2589-2031
123 Motor Mount Pl ate 2589-2065
Temperature Sens or 2683-2234
124 Sucti on Strai ner 2589-1074
112 Sens or Probe 2683-2283 1
Gear Pump 2589-2054
Sens or Coupl i ng 2683-2284 125
1 Coupl i ng 2589-2108
113 Fi l l er/Breather Cap 2589-2002
126 Bel l Hous i ng 2589-2055
114 Pl ai n Sol i d Pl ug 2510-3849
127 Pres s ure Rel i ef Val ve 2589-2016
115 Bul l s Eye Gl as s 2589-2060
116 Oi l Level Sens or 2683-2234
117 Pres s ure Fi l ter Uni t 2589-2036
117A El ement 2589-2030 2
117B Twi n Fi l ter Head 2589-2045
117C Pres s ure Swi tch 2589-2046
Pres s ure Guage 2589-1019

118
Pres s ure Guage Adaptor 2589-2061
1
119 Check Val ve 2589-2058
St a nda rd Co o l e r Hi gh Ambi e nt Co o l er
Ai rbl a s t Co o l e r 2589-2059 2589-2113

120
Fan & Motor Uni t 2589-2089 2589-2114
Fl exi bl e Mount 2589-2064 4
Section
Page 3 - 46
CRUSHER WEAR PARTS
Dealer Handbook
This document aims to provide
technical support to illustrate
why BL-Pegson genuine wear
parts should be used over 3rd
party suppliers.
Why BL-Pegson Wear
Parts
] So why should owners of BL-Pegson crushers buy
our wear parts?
In comparison to 3rd Party suppliers, our designs
are created specifically for our machines based
upon years of application knowledge and
comparison study. As users of our crushing
equipment our customers demand the best return
on investment without a reduction in quality, this
is dependent upon product design as much as
material (most products are of a similar grade, but
profiles and geometry can vary considerably
however). The smallest change in product design,
no matter how insignificant, can result in drastic
changes to the shape, quantity of product and
result in serious damage. There have been
numerous cases where our crushers have been
fitted with wear parts that have been
dimensionally and materially incorrect by
alternative suppliers. These have on numerous
occasions resulted in major failures in the crusher
which have ended with significant costs from
repairs or new machines.
03 JUNE 2003 REVISION 00 2
Features & Benefits
] OEM quality wear products, backed by the

manufacturers (third party products may
invalidate warranties).
] Our wear products are designed/selected to suit
applications. BL-Pegson will look at the
application and will recommend the most suitable
material for the job backed up by years of
experience in the crushing business. By designing
for manufacturing we don’t overkill the product.
] Cost: BL-Pegson is a real world supplier, we have
to be competitive. OEM products aren’t
necessarily expensive and you are assured quality
of product, reliability and value for money.

History & Development
Manganese Steel ] A nominal composition of

] Manganese steels exhibit unique 1.12% Carbon and 12.5%
properties that have made it the Manganese was used as an
primary material used in crushing optimum condition and this
wear components. Discovered in became known as Hadfield
1882 by Robert Hadfield, it was
found that austenitic steels Manganese Steel.
containing more than 10%
manganese exhibited exceptional
toughness after being being
heated above 1000°C and
quenched in water. This heat
treatment changes the ‘as cast’
condition by dissolving the as-
cast carbides (grain boundary
carbides substantially lower the
mechanical properties) into the
austenite solution and cooling in
cold water to stop them re-
precipitating out. Its structural
condition is retained austenite
which ,holding all the manganese AS CAST
and Carbon in solid solution, is
tough. The steel exhibited
exceptional work hardening
characteristics when subject to
stress caused by deformation
(changing the austenite via
martensitic transformation), a
skin was created whose hardness
increased from 200 to 500 BHN
in the stressed area whilst the
underlying material retained its
toughness.
HEAT TREATED

History & Development
] Ever since Hadfields
manganese steel was created,
metallurgists have sought to
improve upon its wear and
toughness characteristics. This
has been done by different
alloying elements and
adjusting the manganese and
carbon content. No longer
content with the standard 12-
14% configuration
manufacturers have tried many
configurations of manganese,
not always with the best of
results. The standard now, as
adopted by BL-Pegson is an
18% manganese in
conjunction with an increased
carbon content. This provides
much higher initial toughness
and hence improved wear
characteristics. There is no
conclusive proof to suggest
that higher manganese content
above 18% improves wear life
(the only known possible
improvement is the materials
work hardening rate). In fact
increasing the carbon and
hence the toughness improves
the wear (at 18% the material TYPICAL MICROSTRUCTURE
has the maximum carbon
levels that would be
considered acceptable).

Material Specifications
Chromium Characteristics
] Claims
\ Chromium is claimed to improve wear life and to reduce
spreading or metal flow
] Facts
\ Chromium does not improve the wear life of manganese steel,
independent tests done in accordance to ASTM prove this.
\ Chromium is a strong carbide former and the addition to
manganese steels make them difficult to treat and remove the as
cast structure (i.e unsuitable for heat treatment), particularly in
heavy sections.
\ Chromium does arrest spreading by underpinning the grain, but
so does higher manganese contents by stabilising the austenite.
Higher manganese is the preferable option as it forms no
deleterious boundary carbides. However if produced to good
quality standards this is still used in certain applications where
‘spreading’ of jaw plates occurs.
\ Chromium should be regarded as an impurity as if not carefully
controlled can cause failures in manganese steel.

Molybdenum Characteristics
] Claim
\ Raises yield strength
\ Improves ‘as cast’ properties
] Facts
\ Molybdenum does not directly improve wear life.
\ Molybdenum is a particularly costly addition
\ Molybdenum does improve as cast toughness due to the fact that
it forms stable molybdenum carbides within the grain which are
not harmful to mechanical properties.
\ Molybdenum improves ability to carry out weld repairs and
upgrading and suppressing carbide precipitation during heat
treatment.
\ Molybdenum should not be used in conjunction with high carbon
levels or incipient fusion or localised grain boundary melting can
occur reducing mechanical properties.
\ Molybdenum does raise the yield strength and resist cold flow of
metal spreading with no reduction of toughness which is the case
when using chromium and vanadium.
\ Due to the fact that molybdenum coupled with high carbon
content causes incipient fusion, molybdenum bearing grade is not
suitable for high abrasion resistant applications.
\ Molybdenum grades can be dispersion hardened, i.e. heat
treatment cycles can be altered in order to form coherent
precipitates within the structure to improve wear life.

Titanium Characteristics
] Claim
\ Refines the as cast grain size
] Facts
\ It does refine the grain size but quantities required for heavy
sections are not economically viable.
\ Titanium ties up carbon and in doing so has a similar effect as
molybdenum.
Vanadium Characteristics
] Claim
\ Increases yield strength
\ Improves wear life
] Fact
\ Vanadium will form vanadium carbides and in heavy section
castings will cause drastic loss in ductility causing embrittlement
that will lead to premature failure.

The effect of Carbon on

Manganese
] To improve wear life it is essential to
have the highest level of carbon in
solution without precipitating to the
grain boundaries and forming
precipitates which are deleterious to
mechanical properties.
] There is a direct link between the
amount of carbon in an alloy and the
manganese content. As the amount
of carbon is increased in the mix,
manganese levels must also be
increased in order to keep the
carbon in solution by forming
manganese carbides. This in turn
creates the myth that higher
manganese contents improve wear
life, it is in fact the amount of carbon
in the solution.
] How much carbon should be in the
mix depends upon several factors:
\ The section thickness of the
part, the thicker the section the
more difficult to retain the
carbon in solution during heat
treatment.
\ The nature of the material,
whether it has sufficient work
index to cause large impacts. Manganese is a solid solution of carbon in
\ The heat treatment quality gamma iron which is clearly demonstrated
after heat treatment as at the surface the
control at the foundry. area with reduced carbon content due to
oxidization changes phase to martensite.

Manganese ] Mn 20 - This material has a
high initial hardness of 248
There are many statements BHN (as the 16-18% version)
regarding the effect of and will work harden (not as
manganese upon the wear of much as the lower grade
crusher parts. The following versions). Under the right
details the difference between conditions this will out perform
grades: the other grades, however
] Mn 12-14 - This has traditionally these advantages are out
been the standard grade of weighed by other factors so
manganese used in quarrying this material is not seen at the
applications. It work hardens present as a viable solution.
under normal conditions and is
the superior of all three materials
if a sound work hardening
process takes place reaching a
Brinell hardness of up to 450
BHN. In its quenched condition
the hardness is ~ 220 BHN. If
used in an extremely abrasive or
hard application this work
hardened layer can be
worn/removed by gouging
abrasion resulting in rapid wear
on the softer un-hardened
material underneath.
] Mn 16-18 - This is a higher grade
manganese which has the
advantage of a higher initial
hardness (248 BHN), due to the
increased Carbon. The material
will work harden, although to a
lower value of 400BHN. This is
seen as the best all-round
specification for most
applications.

High Chrome White Iron

Selecting compositions to
obtain desired structures
] Optimum performance is
usually achieved with heat
treated martensitic structure.
] Alloying must be sufficient to
ensure a pearlite free
microstructure.
] The heat treatment requires an
air quench from the
austenitizing temperature. CHROMIUM AS CAST
] Very fast cooling rates should

not be used, because the
castings can develop cracks
due to high thermal and/or
transformation stresses.
] Thus, the alloy must have
hardenability to allow air
hardening.
] However, over alloying with
manganese, nickel and copper
promotes retained austenite,
which detracts from resistance
to abrasion and spalling. CHROMIUM HARDENED

High Chrome White

Iron Cont’d.
] Therefore, it is best to obtain
adequate hardenability
primarily with an addition of
Molybdenum the amount being
dependant on section
thickness.
] Can be viewed as a composite
material consisting of hard
primary M7C3 carbides within a
martensitic matrix.
Position of alloys studied
] The carbides providing the relative to the iron-
armour to resist the wear. chromium-carbon diagram.
] The matrix being the
component of the composite
allowing for impact. Factors influencing wear characteristics:
] The higher the ] Chrome : Carbon Ratio
carbon:chromium ratio the less
] Heat Treatment
ductile the more abrasion
resistance the material. ] Molybdenum Additions

MARTENSITIC STEELS
] Factors influencing wear

characteristics:
\ Chrome Carbides
\ Vanadium Carbides
\ Heat Treatment

Material Specification
] Material Chemistry
Major Chemical Elements
Material C Mn Cr Mo Other
Martensitic 0.4 - 3.5 1.0 1.0 Ni
High Chrome 3.1 - 27 1.4 -
14% Manganese 1.05-1.25 11.5-14.5 - - 1.0 Si

Max
18% Manganese 1.2-1.3 16-18 - - 1.0 Si
Max
18% Manganese + 1.15-1.25 17-19 1.75-2.5 - 0.6 Si
Chrome Max

Products
Impactors
We supply three material selections for our blow
bars (long and short).
] Manganese - This material is suitable for
applications where you can expect high impact
forces on the hammers. Unfortunately compared
to High Chrome White Iron the wear life is not
as good in abrasive applications. More tolerable
of steel in feed.
] High Chrome White Iron - The most abrasive
resistant material we supply, unfortunately it has
poor impact performance so is mainly suited to
applications where abrasive materials are
present as opposed to hard rock and recycling
debris such as re-bar. No steel should be
present in the feed
] Martensitic Steel - This material offers a
compromise between the previous two
materials. Good impact resistance against all but
the hardest rocks / recycling applications.
Improved wear resistance means it lasts longer
than manganese in abrasive applications. This is
a good all rounder and a suitable selection when
the feed material varies. Limited steel in the
feed more tolerable

Products
IMPACTORS
] Recycling
Typical medium through crusher - bricks, tile, reinforced concrete and
various construction by-products (re-bar & tramp metal etc).
\ Manganese Steels: Softest Application, Quick Wear & No Work
Hardening
\ Martensitic Steels: Compromise between HiCr abrasion resistance
and manganese impact resistance
\ High Cr White Iron: Most abrasive resistant - composite material
of Cr carbide in steel matrix
] Quarries
Typical medium through crusher - granite, limestone etc, abrasion
variable upon rock properties.
\ Manganese - primary crushing, large feed size, high impact
causes work-hardening.
\ Martensitic Steel - secondary crushing, reduced feed size.
\ High Chrome Iron – fine crushing, highly abrasive materials
] Gravel
Up to 80% of the product is screened, all oversize crushed. Medium-
highly abrasive.
\ Feed size usually smaller than 100mm - High Chromium Irons
\ Feed size larger than 100mm - Martensitic Steels recommended
for superior impact properties.

Products
] Impactors
Type of Feed Material Manganese Blow Bar High Chrome Blow

(max feed size 12”) Bar (max feed size 8”)
River Gravel 360 g/T 90 g/T
Granite 196 g/T 49 g/T
Basalt 80 g/T 20 g/T
Dolomite Limestone 30 g/T 7 g/T
Carboniferous 15 g/T 4 g/T

Limestone
Furnace Slag 40 g/T N/A
Steel Slag 160 g/T N/A
NOTES: g/T = Grammes Per Tonne

Martensitic Data is currently being gathered, the rates should be a
compromise between the other two. Feed size as Manganese
equivalent.
Wear Rates of 428 Based Upon Experience

Products
] Jaw Crushers - We realise that manganese selection on jaw

crushers is dependent upon machine applications as well as
material selection. We supply different manganese profiles
for each machine.
\ The 900x600 and 1100x650 jaw comes with standard profiles

(soon to be discontinued in the 1100x650 range), multi tooth
profiles and super tooth profiles. All of these are supplied as 18%
manganese as standard.
\ The 1100x800 comes with an 18% standard profile.
\ A new lifting system has been adopted to allow the use of more
standard lifting equipment. To replace the previous ‘hook’ design,
facility has been made to allow the connection of shackles to hold
the jaws whilst positioning.

Products
] Jaw Crushers Cont’d
What do these profiles do?
The standard profile has been

used by BL-Pegson for many
years with good success
principally in 13% manganese.
This profile is used in all
applications. To provide improved
wear life, BL-Pegson has
developed the super-tooth profile.
Based upon our standard tooth
outline, we have deepened the
tooth profile and strengthened the
back to increase the jaws working
life without sacrificing strength or
product shape.
For some recycling applications
and for those using their jaws to
crush asphalt, the multi-tooth
profile was created. This has a
‘sharper’ profile suitable for
crushing recycling materials such
as concrete. Historically used in
our 900x600 machine, this profile
is now available for our 1100x650
jaw.

Products
] Cone Crushers
As a manufacturer of crushing
equipment BL-Pegson has to
provide a product for every
application. As our jaws we
support different profiles for our
concaves and mantles and these
come in 18% manganese steel as
standard in all core products
(14% in others - 900 & 1200).
These profiles are dependent
upon the machine configuration
(contact us or our dealers for
assistance), the list below details
the configurations:
\ 900 - Fine, Medium Fine,
Medium Coarse, Coarse,
Extra Coarse and Sand.
\ 1000 - Medium Coarse,
Coarse, Extra Coarse and
Sand.
\ 1200 - Fine, Medium Fine,
Medium Coarse, Coarse and
Extra Coarse.
\ 1300 - Medium Coarse, Extra
Coarse and Sand.
\ 1500 - Fine, Medium, Coarse
and Extra Coarse

MANUFACTURERS OF BROWN LENOX AND PEGSON CRUSHING EQUIPMENT
MAMMOTH STREET, COALVILLE, LEICESTERSHIRE. LE67 3GN. TEL: +44 (0)1530 518600
E-mail: sales@bl-pegson.com Website: www.bl-pegson.com
PEGBACK CRUSHER BACKING.
Best Practice to ensure minimum time to cure.
1. Store Resin and Hardener at 10-18 degrees centigrade.
2. Protect Crusher and Liners from cold weather, and where possible, remove chill from the
metal by the use of hot air guns/blowers.
Do not use naked flames.
3. Increase the temperature of the resin to 20-25 degrees centigrade just prior to mixing. This
is best achieved by placing the resin tub in a bucket of hot water. Ensure all the product is
warmed up.
Do not increase the temperature of the hardener.
4. Thoroughly mix the Resin and Hardener using a spiral paddle and pour immediately.
5. Epoxy reactions are slowed down by a decrease in temperature, as a rough guide, every
10/C that is taken away from the reaction the cure rate will half and vice- versa.
Manufacturing advise that temperatures below 4/C will inhibit the cure.
Mike North
Application Engineering Manager
Henkel Loctite Adhesives
Watchmead
Welwyn Garden City
Hertfordshire
England
0044 (1) 707 358866
Service Bulletin SP 038 04
DATE: 3rd June 2004

MODEL: 900, 1000, 1200, 1300, Autocone Series 11, Automax, Autosand &
Gyracone Crushers
SUBJECT: Stub Shaft Modification.
PERIOD: July 2004
ISSUE: To improve functionality from July 2004 a revised design Stub Shaft & Bearing Clamp arrangement will
be introduced. A compressible “O” ring ensures that the bearing races are secured as the primary
function of the clamp. The secondary function being the retention of the stub shaft.
The revised system replaces all previous arrangements & is the only component available in cases of
complete stub shaft replacement. Each component comprises a kit of parts including
Kit 603/P272 Kit 603/P273

Part Qty Part Qty Description
603/9142 1 603/1530 1 Stub Shaft
603/9143 1 603/1531 1 Bearing Clamp
603/9144 1 603/1532 1 Oil Flinger
307/17 1 307/19 1 O Ring Stub Shaft Oil Flinger
307/16 2 307/18 2 O Ring Stub Shaft
In addition 4 x 2222-6687 Capscrew are required to secure Bearing Clamp to Main Shaft.
The introduction of these parts raises replacement component issues, which are addressed on the
following pages.
ACTION: Note introduction of components & include within dealer inventory commensurate with population of
machines & consumption of superseded items
SPARE PARTS MANUAL: This bulletin is an addendum to the following publications
Dealer Components Manual:- Maxtrak Issue 01.Eng. Section 3 Pages 3-15 & 3-48
Operation & Maintenance Manuals for each Crusher noted above.
Page 1 of 1
TEREX PEGSON
BL-Pegson Ltd, Mammoth Street, Coalville, Leicestershire, LE67 3GN ENGLAND
Tel: +44 (0)1530 518600Fax: +44 (0)1530 518618 Email: sales@bl-pegson.com Website:www.bl pegson.com
Registered Office: 252 Upper Third Street, Grafton Gate East, Central Milton Keynes, MK9 1DZ Registered No. 258409 England

Service Bulletin SP 038 04 Issue.00 Eng
Product : 900,1000,1200 & 1300 Autocone, Automax &

Stub Shaft Location
Autosand Cone Crushers
Stub Shaft
Refer to Page 2
Main Shaft
Main Frame
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. SP 038 - 04
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651
Page 1 - 1

Stub ShaftTypes
3 2
1
2 3
1 1
4
6 5
2 3
603/904 & 603/1204

603/9138 603/P272 & 603/P273
Fluted Style
Page 1 - 2

Components
603/904 603/1204 603/9138 603/P272 603/P273

Item Number
Part Description Replacement Replacement Replacement Replacement Replacement
Build Fit Build Fit Build Fit Build Fit Build Fit
Part Part Part Part Part
1 Stub Shaft Refer to Machi ne Seri al Number Charts pages 1-4 to 1-18 603/9142 603/9142 603/1530 603/1530
2 Oi l Fl i nger 603/905 603/905 603/1205 603/1205 603/905 603/905 603/9144 603/9144 603/1532 603/1532
3 "O" Ri ng 2501-1320 2501-1320 2501-1328 2501-1328 2501-1320 2501-1320 307/17 307/17 307/19 307/19
Bearing Clamp 603/907 603/907 603/1207 603/1207 Not Spares Item Not Spares Item 603/9143 603/9143 603/1531 603/1531
4
"O" Ri ng N/A N/A N/A N/A 2501-1328A 2501-1328A N/A N/A N/A N/A
5 "O" Ri ng N/A N/A N/A N/A N/A N/A 2 x 307/16 2 x 307/16 2 x 307/18 2 x 307/18
6 Fi xi ngs 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887 4 x 2222-6887
Page 1 - 3

Stub Shaft
900 Autocone, Automax , 1300 Autocone , Automax &

1000 Automax & Autosand 1200 Autocone & Gyracone
Autosand & Gyracone Autosand
Item Number
Part Description Replacement Replacement Replacement Replacement
Build Fit Build Fit Build Fit Build Fit
Part Part Part Part
Machine Serial Number Stub Shaft Replacement
603/P272 Pl us
603/B5/1 Through 603/B5/21 603/904
4 X 2222-6687
603/P273 Pl us
603/B6/1 Through 603/B6/20 603/1204
4 X 2222-6687
603/P272 Pl us
603/B9/1 Through 603/B9/149 603/904
4 X 2222-6687
603/P273 Pl us
603/B10/1 Through 603/B10/43 603/1204
4 X 2222-6687
603/P272 Pl us
603/B11/1 Through 603/B11/80 603/904
4 X 2222-6687
603/P273 Pl us
603/B12/1 Through 603/B12/78 603/1204
4 X 2222-6687
603/P272 Pl us
1 603/B14/302 Through 603/B14/343 603/904
4 X 2222-6687
603/P272 Pl us
605/B1/1 Through 605/B1/9 603/904
4 X 2222-6687
603/P273 Pl us
605/B3/1 Through 603/B3/8 603/1204
4 X 2222-6687
603/P272 Pl us
QM100294/1 & QM100295/1 603/904
4 X 2222-6687
603/P273 Pl us
QM100453 603/1204
4 X 2222-6687
603/P272 Pl us
QM004705 603/904
4 X 2222-6687
603/P273 Pl us
QM006371 603/1204
4 X 2222-6687
603/P272 Pl us
QM006824 & QM006825 603/904
4 X 2222-6687
Page 1 - 4

Stub Shaft

Item Number
Part Description R eplacement R eplacement R eplacement R eplacement
Part Part Part Part
Machine Serial Number Stub Shaft R eplacement
603/P273 Pl us
QM007026 603/1204
4 X 2222-6687
603/P273 Pl us
QM007405 & QM007406/1 603/1204
4 X 2222-6687
603/P273 Pl us
QM008027 & QM008028 603/1204
4 X 2222-6687
603/P272 Pl us
QM008065 603/904
4 X 2222-6687
603/P272 Pl us
QM008353 603/904
4 X 2222-6687
603/P272 Pl us
QM008390 & QM008391 603/904
4 X 2222-6687
603/P273 Pl us
QM008478/1 603/1204
4 X 2222-6687
1
603/P272 Pl us
QM008939 603/904
4 X 2222-6687
603/P273 Pl us
QM009211 603/1204
4 X 2222-6687
603/P272 Pl us
QM009270 603/904
4 X 2222-6687
603/P272 Pl us
QM009279 603/904
4 X 2222-6687
603/P272 Pl us
QM009324 603/904
4 X 2222-6687
603/P272 Pl us
QM009333 603/904
4 X 2222-6687
603/P273 Pl us
QM009496 603/1204
4 X 2222-6687
603/P272 Pl us
QM009508 603/904
4 X 2222-6687
Page 1 - 5

Stub Shaft

Item Number
Part Description R eplacement R eplacement R eplacement R eplacement
Part Part Part Part
Machine Serial Number Stub Shaft R eplacement
603/P272 Pl us
QM009645 603/904
4 X 2222-6687
603/P272 Pl us
QM009855 & QM009856 603/904
4 X 2222-6687
603/P272 Pl us
QM010065 603/904
4 X 2222-6687
603/P272 Pl us
QM010317 603/904
4 X 2222-6687
603/P272 Pl us
QM010392 603/904
4 X 2222-6687
603/P272 Pl us
QM010479 603/904
4 X 2222-6687
603/P272 Pl us
QM010481 603/904
4 X 2222-6687
1
603/P272 Pl us
QM010779 603/904
4 X 2222-6687
603/P272 Pl us
QM010878 603/904
4 X 2222-6687
603/P272 Pl us
QM010879/1 603/904
4 X 2222-6687
603/P272 Pl us
QM010779 Through QM010881 603/904
4 X 2222-6687
603/P272 Pl us
QM011156 & QM011157 603/904
4 X 2222-6687
603/P272 Pl us
QM011197 & QM011198 603/904
4 X 2222-6687
603/P272 Pl us
QM011287 603/904
4 X 2222-6687
603/P272 Pl us
QM011555 603/904
4 X 2222-6687
Page 1 - 6

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM011584 603/904
4 X 2222-6687
603/P272 Pl us
QM011649 603/904
4 X 2222-6687
603/P272 Pl us
QM011820 & QM011821 603/904
4 X 2222-6687
603/P272 Pl us
QM011960 & QM011961 603/904
4 X 2222-6687
603/P272 Pl us
QM012057 603/904
4 X 2222-6687
603/P272 Pl us
QM012103 Through QM012105 603/904
4 X 2222-6687
603/P272 Pl us
1 QM012164 603/904
4 X 2222-6687
603/P273 Pl us
QM012265 603/1204
4 X 2222-6687
603/P272 Pl us
QM012332 & QM012333 603/904
4 X 2222-6687
603/P272 Pl us
QM012372 603/904
4 X 2222-6687
603/P273 Pl us
QM012398 603/1204
4 X 2222-6687
603/P272 Pl us
QM012478 603/904
4 X 2222-6687
603/P272 Pl us
QM012492 & QM012493 603/904
4 X 2222-6687
603/P272 Pl us
QM012667 Through QM012669 603/904
4 X 2222-6687
Page 1 - 7

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM012767 603/904
4 X 2222-6687
603/P273 Pl us
QM012811 603/1204
4 X 2222-6687
603/P272 Pl us
QM012844 & QM012845 603/904
4 X 2222-6687
603/P273 Pl us
QM012910 603/1204
4 X 2222-6687
603/P272 Pl us
QM013109 603/904
4 X 2222-6687
603/P272 Pl us
QM013110 603/904
4 X 2222-6687
603/P272 Pl us
1 QM013247 603/904
4 X 2222-6687
603/P272 Pl us
QM013303 603/904
4 X 2222-6687
603/P272 Pl us
QM013306 & QM013307 603/904
4 X 2222-6687
603/P273 Pl us
QM013308 603/1204
4 X 2222-6687
603/P272 Pl us
QM013511 603/904
4 X 2222-6687
603/P273 Pl us
QM013602 & QM013603 603/1204
4 X 2222-6687
603/P273 Pl us
QM013813 603/1204
4 X 2222-6687
603/P272 Pl us
QM013859 603/904
4 X 2222-6687
Page 1 - 8

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM013896 603/904
4 X 2222-6687
603/P272 Pl us
QM013898 603/904
4 X 2222-6687
603/P272 Pl us
QM013924 603/904
4 X 2222-6687
603/P272 Pl us
QM014005 Through QM014010 603/904
4 X 2222-6687
603/P272 Pl us
QM014012 603/904
4 X 2222-6687
603/P273 Pl us
QM014013 & QM014014 603/1204
4 X 2222-6687
603/P272 Pl us
1 QM014324 Through QM014329 603/904
4 X 2222-6687
603/P272 Pl us
QM014579 & QM014580 603/904
4 X 2222-6687
603/P272 Pl us
QM014598 & QM014599 603/904
4 X 2222-6687
603/P272 Pl us
QM014832 Through QM 014836 603/904
4 X 2222-6687
603/P272 Pl us
QM015060 Through QM015064 603/904
4 X 2222-6687
603/P272 Pl us
QM015104 & QM015105 603/904
4 X 2222-6687
603/P272 Pl us
QM015282 Through QM015284 603/904
4 X 2222-6687
603/P272 Pl us
QM015462 Through QM015467 603/904
4 X 2222-6687
Page 1 - 9

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM015624 603/904
4 X 2222-6687
603/P272 Pl us
QM015626 Through QM015628 603/904
4 X 2222-6687
603/P272 Pl us
QM015639 & QM015640 603/904
4 X 2222-6687
603/P273 Pl us
QM015643 & QM015644 603/1204
4 X 2222-6687
603/P272 Pl us
QM015820 603/904
4 X 2222-6687
603/P272 Pl us
QM015862 Through QM015868 603/904
4 X 2222-6687
603/P273 Pl us
1 QM015869 603/1204
4 X 2222-6687
603/P272 Pl us
QM016043 603/904
4 X 2222-6687
603/P272 Pl us
QM016137 Through QM016148 603/904
4 X 2222-6687
603/P273 Pl us
QM016150 603/1204
4 X 2222-6687
603/P273 Pl us
QM016319 603/1204
4 X 2222-6687
603/P272 Pl us
QM016391 & QM016392 603/904
4 X 2222-6687
603/P272 Pl us
QM016394 Through QM016398 603/904
4 X 2222-6687
603/P273 Pl us
QM016499 & QM016400 603/1204
4 X 2222-6687
Page 1 - 10

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM016703 Through QM016706 603/904
4 X 2222-6687
603/P273 Pl us
QM016707 & QM016708 603/1204
4 X 2222-6687
603/P272 Pl us
QM016939 Through QM016946 603/904
4 X 2222-6687
603/P273 Pl us
QM016947 & QM016948 603/1204
4 X 2222-6687
603/P272 Pl us
QM017217 Through QM017223 603/904
4 X 2222-6687
603/P273 Pl us
QM017225 & QM017226 603/1204
4 X 2222-6687
603/P272 Pl us
1 QM017479 & QM017480 603/904
4 X 2222-6687
603/P272 Pl us
QM017482 Through QM017486 603/904
4 X 2222-6687
603/P273 Pl us
QM017487 Through QM017489 603/1204
4 X 2222-6687
603/P272 Pl us
QM017687 Through QM017689 603/904
4 X 2222-6687
603/P272 Pl us
QM017691 Through QM017694 603/904
4 X 2222-6687
603/P273 Pl us
QM017696 Through QM017698 603/1204
4 X 2222-6687
603/P273 Pl us
QM017815 Through QM017821 603/1204
4 X 2222-6687
603/P272 Pl us
QM017858 603/904
4 X 2222-6687
Page 1 - 11

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM017789 Through QM017791 603/904
4 X 2222-6687
603/P272 Pl us
QM017794 Through QM017797 603/904
4 X 2222-6687
603/P272 Pl us
QM017807 & QM017808 603/904
4 X 2222-6687
603/P272 Pl us
QM017812 603/904
4 X 2222-6687
603/P272 Pl us
QM017813 603/9138
4 X 2222-6687
603/P273 Pl us
QM017820 Through QM017823 603/1204
4 X 2222-6687
603/P272 Pl us
1 QM017968 603/9138
4 X 2222-6687
603/P272 Pl us
QM017970 & QM017971 603/9138
4 X 2222-6687
603/P272 Pl us
QM017974 603/904
4 X 2222-6687
603/P272 Pl us
QM017976 603/904
4 X 2222-6687
603/P273 Pl us
QM017991 & QM017992 603/1204
4 X 2222-6687
603/P272 Pl us
QM018120 Through QM018124 603/904
4 X 2222-6687
603/P272 Pl us
QM018323 603/9138
4 X 2222-6687
603/P272 Pl us
QM018325 Through QM018328 603/9138
4 X 2222-6687
Page 1 - 12

Stub Shaft

Item Number
Part Part Part Part
603/P273 Pl us
QM018331 Through QM018333 603/1204
4 X 2222-6687
603/P272 Pl us
QM018335 603/9138
4 X 2222-6687
603/P272 Pl us
QM018450 Through QM018454 603/904
4 X 2222-6687
603/P272 Pl us
QM018457 603/9138
4 X 2222-6687
603/P272 Pl us
QM018460 & QM018461 603/904
4 X 2222-6687
603/P272 Pl us
QM018688 603/904
4 X 2222-6687
603/P272 Pl us
1 QM018706 603/904
4 X 2222-6687
603/P272 Pl us
QM018786 & QM018787 603/9138
4 X 2222-6687
603/P273 Pl us
QM018788 & QM018789 603/1204
4 X 2222-6687
603/P272 Pl us
QM018871 603/904
4 X 2222-6687
603/P272 Pl us
QM018897 & QM018898 603/904
4 X 2222-6687
603/P272 Pl us
QM018897 & QM0188898 603/904
4 X 2222-6687
603/P272 Pl us
QM018899 & QM018900 603/9138
4 X 2222-6687
603/P273 Pl us
QM018917 603/1204
4 X 2222-6687
Page 1 - 13

Stub Shaft

Item Number
Part Part Part Part
603/P273 Pl us
QM019062 603/1204
4 X 2222-6687
603/P272 Pl us
QM019088 603/904
4 X 2222-6687
603/P273 Pl us
QM019286 & QM019287 603/1204
4 X 2222-6687
603/P272 Pl us
QM019290 603/9138
4 X 2222-6687
603/P272 Pl us
QM019292 Through QM019295 603/9138
4 X 2222-6687
603/P272 Pl us
QM019319 603/9138
4 X 2222-6687
603/P272 Pl us
1 QM019320 & QM019321 603/9138
4 X 2222-6687
603/P272 Pl us
QM019569 & QM019570 603/9138
4 X 2222-6687
603/P273 Pl us
QM019827 Through QM019829 603/1204
4 X 2222-6687
603/P272 Pl us
QM019841 & QM019842 603/9138
4 X 2222-6687
603/P272 Pl us
QM019851 603/9138
4 X 2222-6687
603/P272 Pl us
QM019853 603/9138
4 X 2222-6687
603/P273 Pl us
QM020034 603/1204
4 X 2222-6687
603/P272 Pl us
QM020092 & QM020093 603/9138
4 X 2222-6687
Page 1 - 14

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM020097 & QM020098 603/9138
4 X 2222-6687
603/P273 Pl us
QM020112 Through QM020114 603/1204
4 X 2222-6687
603/P272 Pl us
QM020293 Through QM020296 603/9138
4 X 2222-6687
603/P273 Pl us
QM020297 Through QM020299 603/1204
4 X 2222-6687
603/P272 Pl us
QM020486 Through QM020490 603/9138
4 X 2222-6687
603/P273 Pl us
QM020495 Through QM020497 603/1204
4 X 2222-6687
603/P272 Pl us
1 QM020527 Through QM020529 603/9138
4 X 2222-6687
603/P273 Pl us
QM020595 603/1204
4 X 2222-6687
603/P272 Pl us
QM020600 603/9138
4 X 2222-6687
603/P272 Pl us
QM020759 & QM020760 603/9138
4 X 2222-6687
603/P272 Pl us
QM020762 & QM020763 603/9138
4 X 2222-6687
603/P273 Pl us
QM020764 & QM020765 603/1204
4 X 2222-6687
603/P272 Pl us
QM020784 Through QM020786 603/9138
4 X 2222-6687
603/P273 Pl us
QM020787 603/1204
4 X 2222-6687
Page 1 - 15

Stub Shaft

Item Number
Part Part Part Part
603/P273 Pl us
QM021001 & QM021002 603/1204
4 X 2222-6687
603/P272 Pl us
QM021010 603/9138
4 X 2222-6687
603/P272 Pl us
QM021012 & QM021013 603/9138
4 X 2222-6687
603/P272 Pl us
QM021102 603/9138
4 X 2222-6687
603/P272 Pl us
QM021117 603/9138
4 X 2222-6687
603/P272 Pl us
QM021119 603/9138
4 X 2222-6687
603/P272 Pl us
1 QM021135 603/9138
4 X 2222-6687
603/P272 Pl us
QM021340Through QM021342 603/9138
4 X 2222-6687
603/P272 Pl us
QM021581 603/9138
4 X 2222-6687
603/P272 Pl us
QM021603 603/9138
4 X 2222-6687
603/P272 Pl us
QM021846 603/9138
4 X 2222-6687
603/P273 Pl us
QM021877 Through QM021882 603/1204
4 X 2222-6687
603/P272 Pl us
QM021883 Through QM021887 603/9138
4 X 2222-6687
603/P272 Pl us
QM021889 603/9138
4 X 2222-6687
Page 1 - 16

Stub Shaft

Item Number
Part Part Part Part
603/P272 Pl us
QM022002 Through QM022009 603/9138
4 X 2222-6687
QM022010 & QM022011 603/9142 603/9142
603/P272 Pl us
QM022012 603/9138
4 X 2222-6687
QM022015 & QM022016 603/1530 603/1530
603/P273 Pl us
QM022017 & QM022018 603/1204
4 X 2222-6687
603/P272 Pl us
QM022019 603/9138
4 X 2222-6687
603/P272 Pl us
1 QM022045 ThroughQM022048 603/9138
4 X 2222-6687
QM022153 & QM022154 603/1530 603/1530
QM022156 Through QM022159 603/9142 603/9142
603/P272 Pl us
QM022257 Through QM022261 603/9138
4 X 2222-6687
QM022431 Through QM022435 603/9142 603/9142
QM022444 Through QM022446 603/1530 603/1530
603/P273 Pl us
QM022490 603/1204
4 X 2222-6687
603/P272 Pl us
QM022641 Through QM022645 603/9138
4 X 2222-6687
Page 1 - 17

Stub Shaft

Item Number
Part Part Part Part
QM022738 603/9142 603/9142
QM022742 603/1530 603/1530
603/P272 Pl us
1 QM022963 Through QM022967 603/9138
4 X 2222-6687
603/P273 Pl us
QM022968 603/1204
4 X 2222-6687
603/P272 Pl us
QM023009 Through QM023012 603/9138
4 X 2222-6687
603/P273 Pl us
QM023378 603/1204
4 X 2222-6687
Page 1 - 18
Service Bulletin SP 044A 04
DATE: 16th October 2004

MODEL: 900/1000 & 1300 Cone with Hydraulic Wedge
SUBJECT: Dumpy Jacks
PERIOD: October 2004
ISSUE: To enhance the performance of the wedge system a unrestricted dumpy jack will be introduced to
manufacture during October 2004
ACTION: Cylinder 2564-7104 Dumpy jack unrestricted replaces cylinder 2564-7102 Dumpy jack 15mm stroke.
Parts are identified as illustrated in the following image
2564-7104 2564-7102
Dump Jack Replacement 2564-7102:- Continue to supply 2564-7102 as appropriate until

existing dealer stock holdings are consumed then replace by 2564-
7104.
2564-7104 part is directly interchangeable with 2564-7102 on an
individual basis however to maintain the diameter of dump jack circuit
a maximum of 8 cylinders may be replaced before changing hoses as
follows
900/1000 Machines:- 603/P246A/DHOSE Dumpy jack Hose kit Cone

1300 Machines:- 603/P210B/DHOSE Dumpy jack Hose kit 1300 Cone
2564-7104:- Replace with 2564-7104
Seal Replacement Cylinder 2564-7102 Supply Seal kit 2564-9324

Cylinder 2564-7104 Supply Seal kit 2564-7104-1
Page 1 of 2
TEREX PEGSON

CAUTION To prevent Jack rod becoming detached under no circumstances
should the hydraulic circuit be energized unless wedge ring is mounted
in the correct position. Failure to comply will result in loss of hydraulic
fluid and potential contamination by foreign matter of the system
Dealer Action:- Introduce Cylinder 2564-7104 & Seal kit 2564-7104-1 to inventory,
ensure all field engineers & parts personnel are conversant with
amendment
Dealer Components Manual:- Maxtrak 01.Eng
Operation & Maintenance Manuals Maxtrak :- All issues

Automax . Autosand & Autocone with hydraulic wedge:- All
issues
Page 2 of 2
TEREX PEGSON

DATE: 6th October 2004

MODEL: Autocone Series 11 & Automax & Autosand Crushers
SUBJECT: Assembly of Labyrinth Seal Strips
PERIOD: Immediate effect
ISSUE: As a product enhancement measure to improve sealing of crusher internals BL-Pegson ltd have
introduced a revised assembly procedure.
ACTION Note contents of bulletin, introduce cleaner & adhesive to service consumables inventory & circulate
bulletin procedure to all appropriate after sales personnel.
Note contents of Adhesive & Cleaner safety data sheets 5910 EN.pdf & 7063 EN.pdf & formulate
appropriate working practices.
Cleaner Note:- Material is generally available on a world-wide basis from local sources.
Due to the nature of Loctite 7063 Cleaner, for shipping purposes material is classified as Hazardous
cargo .In cases of difficulty BL-Pegson ltd may be able to supply subject to appropriate packing ,
shipping regulations & carriers consent
Dealer Components Manual:- Maxtrak 01.Eng
Operation & Maintenance Manuals :- Maxtrak All Issues

Autocone Series 2, Automax & Autosand All Issues.
Page 1 of 1
TEREX PEGSON

Issue.01 Eng
Product : Automax & Autosand Crushers
Materials
2147-4004 Cartridge of Loctite flange adhesive

2147-9002 Can of Loctite solvent cleaner
2152-9050 Labyrinth strips
Application procedure
Steps 1 & 2 refer to the use of a new cartridge only. Proceed to step
three for application details.
1. Remove application nozzle from Loctite flange adhesive cartridge

and cut a suitable opening.
2. Replace the application nozzle, which should have a small opening at
the end as standard (if this is not the case then remove a small
section from the end to produce a fine nozzle).
CAUTION! All parts must be fully assembled within 10 minutes at 20

centigrade. Ensure all strips are ready for installation before applying
adhesive.
3. Ensure grooves are clean and free from oil/grease. To degrease

grooves use Loctite 7063 cleaner or a similarly quick drying
solvent.
4. Apply a continuous fine bead not greater than 1/8"(3mm) diameter,
to the bottom of the Main frame & Upper Seal Ring labyrinth grooves
only.
Caution! Avoid irregular quantities of adhesive being laid down during
stop start operations
Page 1 - 1
Issue.01 Eng
Product : Automax & Autosand Crushers
Removal procedure
5. Insert labyrinth strips to the groove but do not force them to the
bottom until the entire set is assembled. Removal of the strips depends on their condition however the following
6. Apply firm pressure to the strips or tap with a soft mallet until they guidelines will apply.
bottom in the groove.
1. Firmly grab the strips with a set of grips and pull the strips out of the
Bond will achieve working strength in 24 hours. groove breaking the adhesive bond.
2. If this is not possible then using a flat bladed screw driver, of a
similar width to the grooves, drive the blade through the labyrinth
strip in the direction of the groove until it starts to lift. Run the
screwdriver round the circumference to lift the strip out.
3. Using a flat bladed screwdriver scrap the residue of the adhesive and
any dirt from the groove. It is critical that all the residue and or dirt
is removed from the grooves before new labyrinth strips can be
installed.
Page 1 - 2
Technical Data Sheet
1001 Trout Brook Crossing
Rocky Hill, CT 06067-3910
Telephone: (860) 571-5100
Product 5910
FAX: (860) 571-5465
Worldwide Version, August 2002
PRODUCT DESCRIPTION Depth of Cure

LOCTITE® Product 5910 is a non-slumping, non-corrosive, low The following graph shows the increase in depth of cure with
odor, low volatile, single component, room temperature time when cured at 22°C, 50% RH. This is determined by
vulcanizing (RTV) silicone adhesive/sealant. It is designed to peeling away the product from a 10mm wide channel in a
withstand automotive engine oils. PTFE block. The channel gradually increases in depth from 0
to 10mm. The point where the product remains in the channel
is measured.
TYPICAL APPLICATIONS 10
Designed primarily for flange sealing with good oil resistance 9
Depth of cure, mm
and to withstand high joint-movement requirements. For 8
example, stamped sheet metal covers (timing covers and oil 7
sumps). 6
5
4
PROPERTIES OF UNCURED MATERIAL 3
Typical Value 2
Chemical Type Oxime Silicone Rubber
1
Appearance Metallic Black
0
Specific Gravity @ 20°C 1.34 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Viscosity @ 25°C Thixotropic Paste Days
Extrusion Rate gm/min: 300 minimum
(3mm nozzle, 6 bar, 25°C)
TYPICAL PROPERTIES OF CURED MATERIAL
Flash Point (TCC), °C >93
Electrical Properties
TYPICAL CURING PERFORMANCE
Tack Free time Constan Loss
The surface of this adhesive becomes dry to touch on t
exposure to atmospheric moisture within 40 minutes maximum Dielectric constant & loss, ASTM D150
@ 1 kHz 4.53 0.019
at 23±2°C, 50±5%RH. @ 100kHz 4.09 0.009
@ 1MHz 4.05 0.008
@ 10MHz 4.08 0.017
Cure speed Volume resistivity, ASTM D257, Ω.cm: 1.69 x 1014
The graph below shows shear strength developed with time on Surface resistivity, ASTM D257, Ω 2.81 x 1016
grit blasted mild steel lapshears at a bond gap of 0.5mm. Cure
condition 23±2°C, 60±5%RH. Strength is determined Physical Properties
according to ASTM D1002, DIN 53283.
Hardness, Shore A, ASTM D2240 30
Elongation at break, %, ASTM D412 550
100 2
Tensile strength, N/mm , ASTM D412 1.7 min
PERFORMANCE OF CURED MATERIAL

% Full RT Strength
75
(After 21 days @ 23±2°C, 60±5% RH at 0.5mm gap)
Isopropyl Alcohol wiped substrates
50
Typical
25 Value Range
Shear Strength, ASTM D1002, DIN 53283
2
Mild steel, N/mm 1.1 0.9 to 1.4
0 (psi) (160) (130 to 200)
0 2 4 6 8 10 12 14 16 18 20 21 2
Aluminum (T 2024), N/mm 1.0 0.6 to 1.4
Days (psi) (145) (90 to 200)
2
Aluminum (Alclad), N/mm 1.4 1.0 to 1.6
(psi) (200) (145 to 230)
2
Zinc dichromate, N/mm 1.4 1.0 to 1.6
(psi) (200) (145 to 230)
NOT FOR PRODUCT SPECIFICATIONS

THE TECHNICAL DATA CONTAINED HEREIN ARE INTENDED AS REFERENCE ONLY.
PLEASE CONTACT LOCTITE CORPORATION QUALITY DEPARTMENT FOR ASSISTANCE AND RECOMMENDATIONS ON SPECIFICATIONS FOR THIS PRODUCT.
ROCKY HILL, CT FAX: +1 (860)-571-5473 DUBLIN, IRELAND FAX: +353-(1)-451-9959
TDS 5910 August 2002
TYPICAL ENVIRONMENTAL RESISTANCE GENERAL INFORMATION

Test Procedure : Shear Strength ASTM D1002, DIN 53283 This product is not recommended for use in pure oxygen
Substrate: Aluminum “Alclad” and/or oxygen rich systems and should not be selected as
Cure procedure: 21 days 23±2°C/60±5%RH a sealant for chlorine or other strong oxidizing materials.
For safe handling information on this product, consult the

Hot Strength Material Safety Data Sheet, (MSDS).
Tested at temperature.
100 Directions for use
Product 5910 should be applied as a bead to clean surface.
Assemble parts within 15 minutes. When joint is assembled
% Full RT strength
75 pressure should be applied to spread the adhesive out and fill

the joint completely. The bond should be allowed to cure (e.g.
50 seven days), before subjecting to heavy service loads.
Storage
25 Product shall be ideally stored in a cool, dry location in
unopened containers at a temperature between 8°C to 28°C
0 (46°F to 82°F) unless otherwise labeled. Optimal storage is at
0 25 50 75 100 125 150 175 200 the lower half of this temperature range. To prevent
Temperature, °C contamination of unused product, do not return any material to
its original container. For further specific shelf life information,
contact your local Technical Service Center.
Heat Aging
Aged under temperature indicated and tested at 22°C. Data Ranges
100 The data contained herein may be reported as a typical value
200°C and/or range (based on the mean value ±2 standard
deviations). Values are based on actual test data and are
% Full RT Strength
75 verified on a periodic basis.
50 Note
The data contained herein are furnished for information only
and are believed to be reliable. We cannot assume
25 responsibility for the results obtained by others over whose
methods we have no control. It is the user's responsibility to
0 determine suitability for the user's purpose of any production
0 200 400 600 800 1,000 methods mentioned herein and to adopt such precautions as
Hours may be advisable for the protection of property and of persons
against any hazards that may be involved in the handling and
use thereof. In light of the foregoing, Loctite Corporation
Environmental Aging - Effect on Bulk Properties specifically disclaims all warranties expressed or implied,
Test Procedure: ASTM D412, Tensile Strength, including warranties of merchantability or fitness for a
[Elongation at break] particular purpose, arising from sale or use of Loctite
Film thickness: 2mm Corporation’s products. Loctite Corporation specifically
Cure procedure: 21 days 23±2°C/60±5%RH disclaims any liability for consequential or incidental
Test temperature: 22°C damages of any kind, including lost profits. The discussion
herein of various processes or compositions is not to be
interpreted as representation that they are free from
Typical Values domination of patents owned by others or as a license under
Durability Tensile Strength MPa [% Elongation at break] any Loctite Corporation patents that may cover such processes
or compositions. We recommend that each prospective user
Aging time 100hrs 500hrs 1000hrs
Control 1.7 [700] 2.4 [600] 1.9 [560]
test his proposed application before repetitive use, using this
150°C 2.2 [400] 2.2 [450] 2.3 [470] data as a guide. This product may be covered by one or more
175°C 2.2 [380] 2.1 [350] 1.4 [330] United States or foreign patents or patent applications.
200°C 2.2 [370] 2.0 [340] 1.4 [300]
5W40 oil @ 120°C 1.9 [520] 2.3 [490] 2.1 [590]
5W oil @ 150°C 1.9 [520] 1.8 [450] 2.6 [600]
Water/Glycol 100°C 1.0 [620] 0.6 [540] 0.9 [570]
Loctite is a Trademark of Loctite Corporation U.S.A.

Technical Data Sheet
Research, Development & Engineering Product 7063
Tallaght Business Park,
Dublin, Ireland Worldwide Version, January 2002
PRODUCT DESCRIPTION Directions for use

LOCTITE® Product 7063 is a non-CFC solvent based 1. When Product 7063 is used for cleaning, ensure
formulation for preparation surfaces to be bonded with electrical supply to machines is switched off before use.
Loctite adhesives. Due to its high solvent power it is also Do not reconnect electrical supply before solvent has
very effective in general degreasing or machine part cleaning fully evaporated. Take particular care when using in
applications. It may be used as an alternative to 1,1,1- enclosed spaces such as machine housings, control
Trichloroethane. cabinets, etc.
The product is HIGHLY FLAMMABLE
2. Treat surfaces to be cleaned or bonded by generously
TYPICAL APPLICATIONS spraying with Loctite 7063 cleaner.
LOCTITE 7063 is recommended as a final preassembly
cleaning treatment for all surfaces to be bonded with Loctite 3. Wipe surfaces when still wet with a clean towel to
anaerobic adhesives. The product can also be used for ensure heavy contamination is removed.
cleaning and degreasing machine components during
maintenance operations 4. Spray surfaces again, preferably with surfaces in
vertical position to allow run-off of the cleaner.
LIQUID PROPERTIES Typical Value
Solvent Blend of Hydrocarbon Solvent, 5. Allow the solvent time to evaporate until the surfaces
Aliphatic Alcohol and Methylal* are completely dry.
Appearance Clear colourless
Specific Gravity @ 25°C 0.74
Viscosity @ 20°C, mPa.s (cP) 2 6. Apply the Loctite adhesive immediately after drying and
Flash point (COC), °C -21(HIGHLY FLAMMABLE) assemble bond
Vapour pressure, 20°, mbar <440
TLV, (ACGIH), ppm 600 Storage
Corrosivity none This cleaner is classified as being HIGHLY FLAMMABLE and
Drying time @ 20°C, seconds 60 therefore must be stored in an appropriate manner and in
compliance with relevant regulations. Do not store near
∗ Hydrocarbon, alcohol and Methylal are environmentally
oxidising agents or combustible materials.
friendly solvents. They have zero Ozone Depletion
Potential. Conforms to German WGK, category zero.
Product shall be ideally stored in a cool, dry location in
unopened containers at a temperature between 8°C to 28°C
TYPICAL PERFORMANCE
(46°F to 82°F) unless otherwise labelled. Optimal storage is
ACTIVATOR 7063 is primarily a cleaning agent. The cleaner
at the lower half of this temperature range. To prevent
has no effect on the speed of cure or final strength of
contamination of unused product, do not return any material
LOCTITE® adhesives other than providing a clean surface
to its original container. For further specific shelf life
for good adhesion and adhesive cure. Unclean or partially
information, contact your local Technical Service Centre.
cleaned surfaces can affect adhesive performance.
HANDLING PRECAUTIONS Note

The data contained herein are furnished for information only and are
Cleaner must be handled in a manner applicable to highly believed to be reliable. We cannot assume responsibility for the results
flammable materials and in compliance with relevant local obtained by others over whose methods we have no control. It is the
regulations. For example, special care must be taken to user's responsibility to determine suitability for the user's purpose of any
avoid contact of the activator or its vapour with naked flame production methods mentioned herein and to adopt such precautions as
or any electrical equipment that is not flame proofed. may be advisable for the protection of property and of persons against
any hazards that may be involved in the handling and use thereof. In light
The solvent can affect certain plastics or coatings. It is of the foregoing, Loctite Corporation specifically disclaims all warranties
recommended to check all surfaces for compatibility before expressed or implied, including warranties of merchantability or fitness
for a particular purpose, arising from sale or use of Loctite Corporation’s
use. products. Loctite Corporation specifically disclaims any liability for
• Avoid prolonged or repeated skin contact. consequential or incidental damages of any kind, including lost profits.
• Use only in a well ventilated area. The discussion herein of various processes or compositions is not to be
• No smoking in presence of cleaner. interpreted as representation that they are free from domination of
patents owned by others or as a license under any Loctite Corporation
patents which may cover such processes or compositions. We
GENERAL INFORMATION recommend that each prospective user test his proposed application
For safe handling information on this product, consult before repetitive use, using this data as a guide. This product may be
the Material Safety Data Sheets, (MSDS). covered by one or more United States or foreign patents or patent
applications.
BULK NO. 0178313
NOT FOR PRODUCT SPECIFICATIONS

THE TECHNICAL DATA CONTAINED HEREIN ARE INTENDED AS REFERENCE ONLY.
PLEASE CONTACT LOCTITE CORPORATION QUALITY DEPARTMENT FOR ASSISTANCE AND RECOMMENDATIONS ON SPECIFICATIONS FOR THIS PRODUCT.
ROCKY HILL, CT FAX: +1 (860)-571-5473 DUBLIN, IRELAND FAX: +353-(1)-451 - 9959
1000SR Section 4:- Powerpack
Section 4 :- Powerpack
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page 4- 1
1000SR Powerpack Support Bracket
Powerpack Components
1000 SR
The data contained within this section covers ancillary items
Part Number
associated with the installation of Powerpack within 1000SR u
Data is supplementary to BL-Pegson ltd Track Plant Drives A AX848/16/1 2
Dealer Components Manual which is to be consulted in all insta Engi ne Support Bracket
B AX848/16/2 2
Engine Serial & arrangement numbers MUST be confirmed at t Square Was her AX857/1/4
placing order for either Powerpack and/or Engine Parts.
Transactions effected Without a serial number are performed Was her Large OD 2210-2043 2/Brkt
A&B
entirely at Dealers / Customers risk. Nut 2215-0024
LockNut 2215-0122 1/Brkt
Bol t 2232-1353
C Was her Pl ai n 2210-0023 3/Brk
Nut 2217-0011
A&B
B A
A B
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page 4- 2
1000SR Section 5:- Product Conveyor
Section 5 :- Product Conveyor
Section
Page
Section 5:- Product Conveyor 5 -1 Conveyor Rubbers & Cover 5 -15
Section 5:- Table of Contents 5 -2 Troughing Idlers 5 -16
Product Conveyor Layout 5 -3 Bearings 5 -17
Deflector 5 -4
Stringer Section 5 -5
Stringer Underside 5 -7
Drive Group & Tensioners 5 -8
Lower Section 5 -9
Feed Boot 5 -11
Feed Boot Liners 5 -12
Tail Section 5 -13
Section
Page
1000SR Product Conveyor Layout
Deflector
Drive Group
Tail Section Lower Section Stringer Section
Section
Page
1000SR Deflector
1000 SR
1 6 Item Description / Notes Qty
Part Number
Sp ra yb a r/De f l e ct o r
1 AX868/39/2
Su p p o rt R H
Sp ra yb a r/De f l e ct o r
2 AX868/39/1
3 Su p p o rt L H
P ro d u ct C o n ve yo r
3 AX868/39/4 1
De f l e c t o r
3A De f l e ct o r B ra cke t
AX868/39/3
s ee page 7 Ti e pl a t e
4 De f l e ct o r Su p p o rt
AX868/39/5
2 B ra cke t
Screw Hex 2230-1152 5
4
Was her Pl ai n 2210-0017 10
5 Nut Phi l l i das 2217-0005 5
Defl ect or Pl at e AX868/39/6 1
Screw Hex 2230-1152 6

5
Was her Pl ai n 2210-0017 12
Nut Phi l l i das 2217-0005 6

3
Defl ect or Support Bracket
AX868/39/7 3
Cl amp St ri p
6 Screw Hex 2230-1152
9
Was her Pl ai n 2210-0017
7 7 Defl ect or Rubber AX868/41/1 1

6
Section
Page
1000SR Stringer Section
1000 SR
13 14A Part Number
12A
8 Head Drum AX868/111/1 1
12 11A
Head Guard RH AX868/40/2 1
10A Cl amp AX868/84/1 1
9 Screw Hex 2230-1152

11 9A
Was her Spr 2211-0008
Head Guard LH AX868/40/1 1
Cl amp AX868/84/1 1
10
9A Screw Hex 2230-1152

14
Mi d Sect i on Upper Guard
AX868/82/1 1
RH
Cl amp AX868/84/2 1
10 Screw Hex 2230-1152
9 Was her Bri ght 2210-0017 5

Mi d Sect i on Upper Guard
AX868/82/2 1
LH
8 15 Cl amp AX868/84/2 1
10A Screw Hex 2230-1152
Section
Page
1000 SR 1000 SR
Mi d Sect i on Lower Guard
AX868/81/1 1 Bas epl at e Trough Rol l ers 2495-3005 4
RH 13
Cl amp AX868/84/2 1 Part s :- Refer t o Page 5-16
11 Screw Hex 2230-1152 St ri nger Sect i on Fab AX868/37/1 1
Was her Bri ght 2210-0017 5 Ret urn Idl er brkt AX868/37/3 2
Was her Spr 2211-0008 Bol t Hext 2232-1125

Mi d Sect i on Lower Guard
AX868/81/2 1 14 Was her Bri ght 2210-0017 4
LH
Cl amp AX868/84/2 1 Was her s pr 2211-0008
11A Screw Hex 2230-1152 Pi n ( St ri nger t o Chas s i s ) AX848/56/1

2
Was her Bri ght 2210-0017 5 Spl i t Pi n 2201-0167
Was her Spr 2211-0008 14A Removabl e Cros s Member AX868/37/2

1
St ri nger Sect i on Lower 15 Ni p Guard AX857/55
AX868/38/1 1
Guard RH
Upper Cl amp AX868/84/3 1
12 Screw Hex 2230-1152

St ri nger Sect i on Lower
AX868/38/2 1
Guard LH
12A Screw Hex 2230-1152
Section
Page
1000SR Stringer Underside
1000 SR
3A Item Description / Notes Qty
Part Number
22 16 Tens i oner AX607/3/46 2
16 17 Scraper Frame AX868/64/1
Scraper Bl ade AX868/64/3 1
Scraper Cl amp St ri p AX868/64/2
Bol t Hex 2232-1128

18
5
Nut 2217-0005
U p p e r N i p G u a r d Sp i r a l
19 AX857/57 1
Idl er
20 Idl er- Spi ral 2495-3026 3
19 16 L o w e r N i p G u a r d Sp i r a l
21 AX857/64
Idl er 2
22 Support Ropes AX848/74
18
14 21 20 17
Section
Page
1000SR Drive Group & Tensioners
1000 SR
25 24 23 17 16 Item Description / Notes Qty
Part Number
23 Tens i oner RH AX818/110/1X 1
24 Torque Arm AX818/74 1
25 Ros t er Support Uni t AX868/65/2 1
Beari ngs :- Refer t o Page 5-17
31 Bol t 2232-1027 4
26
Was her Pl ai n 2210-0019 8
Nut 2217-0007 4
27 Greas e Ki t :- Refer t o Page 5-17

28
28 Key 2432-2194 1
29 Shri nk Di s k Coupl i ng 2450-5503 1

32 33
Not Il l us t rat ed Coupl i ng Guard AX868/108/1 1
29
30 Hydraul i c Mot or 2576-4073 1
31 Check Val ve 2579-0020 1
26 32 Tens i oner LH AX818/110/1 1
30 33 Ros t er Support Uni t AX868/65/1 1
27
Section
Page
1000SR Lower Section
36 34 37 38 38A 37 34A 36
35
39
Section
Page
1000SR
1000 SR 1000 SR
Chas s i s Conveyor Guard Cl amp Lower AX868/84/6 2
AX868/56/1 1
RH
Screw Hex 2230-1152
Angl e Support AX868/56/3 1
37
34 Bol t 2232-1125 Was her Spri ng 2210-0017 4
Was her Spri ng 2210-0017 4 Was her Bri ght 2211-0008
Was her Bri ght 2211-0008 Locati on Brkt AX868/56/4 1
C ha s s i s C o nve yo r Gua rd Bol t Hex 2232-1125

AX868/56/2 1 38
LH
Angl e Support AX868/56/3 1
34A Bol t 2232-1125
Locati on Brkt AX868/56/5 1
Bol t Hex 2232-1125
Was her Bri ght 2211-0008 38A
Screw Hex 2230-1152
35 Idl er Trans ome Mtd 2495-3004 2
Was her Spri ng 2210-0017 2 39
Parts :- Refer to Page 5-16
Cl amp Mi ddl e AX868/84/5 2
Screw Hex 2230-1152

36
Section
Page 5- 10
1000SR Feed Boot
40
1000 SR
Part Number
Drawi ng
Feed Boot Fabri cat i ons 1
44 40 AX868/35
Li ners ref er t o Page
43 Back Pl at e AX868/35/3 1
Bol t 2232-1203 4
41 Was her Spri ng 2211-0010
41 42 Was her 2210-0019 1/Bol t
Nut 2217-0007
Rear Cl amp AX868/35/12 1

42
Fi xi ngs as It em 43 & 44 4/Cl amp
43 Cl amp :- Si de Rear AX868/35/11

2
44 Cl amp :- Si de Front AX868/35/10
43 & 44 Was her Bri ght 2210-0017 5/Cl amp
Nut 2217-0005
Section
Page 5- 11
1000SR Feed Boot Liners
40A
40B
1000 SR
40C Part Number
40a Li ner Pl at e Front AX857/69/3 2
40b Li ner Pl at e Cent re AX857/69/1 2
40c Li ner Pl at e Rear AX857/69/2 2
Section
Page 5- 12
1000SR Tail Section
45 51
50
46
47
48 53
52
27
49 53
Section
Page 5- 13
1000SR Tail Section
1000 Maxtrak
Part Number
Pi n AX848/56/2 2
45
Spl i t Pi n 2201-0167 2
46 Tai l Frame AX868/50/1 1
Pi n AX848/56/4 2
47
Spl i t Pi n 2201-0167 2
48 St rut AX868/70/1 2
Pi n AX848/56/3 2
49
Spl i t Pi n 2201-0167 2
50 Parral el Idl er 2495-1129 2
51 R/C Idl er 2495-1159 6
Beari ng Refer t o Page 5-17
Shi m AX857/79 2
53 Bol t 2232-1206 4
Was her 2210-0019 8
Nut 2217-0007 4
27 Greas e Ki t Refer t o Page 5-17
Section
Page 5- 14
1000SR Conveyor Rubbers & Cover
59 58
56
60
55 56 57 56 55
1000 Maxtrak
Part Number
55 AX868/74/1
Ski rt Rubbers
56 AX868/91/1 2
57 Conveyor Bel t 2360-0060/21.0

Feed Boot Upper Rear
58 AX848/89/3 1
Ski rt
Canvas W i nd Cover AX868/83 1
59
Dus t Cover Support s AX818/156 5
60 Feed Boot Rear Ski rt AX848/89/2 1
Section
Page 5- 15
2
2 2
1 1 1
Transome Trough Idler Base Plate Trough Idler
B ase P late Mounted Idler Transome Mounted Idler

P lant C omponent
P art N umber Qty P art N umber Qty
C omplete S et 2495-3005 4 2495-3005 2
1 : - Wi ng Roller 2489-1052 8 2489-1052 4
Fi xi ng C lamp 2489-3004 8 2489-3004 4
1000 Maxtrak Fi xi ng Bol t 2232-1072
1/
Roller
Nut 2217-0003
2 : - C entre Roller 2489-1059 4 2489-1059 2
Section
Page 5- 16
1000SR Bearings
26
53
Head Drum Bearing Tail Drum Bearing
27 27
Head Beari s ngs Tai l Beari ngs

1000 SR Greas i ng ki t
Standard Bearing Arrangement It em 26 It em 53
St andard Fi t t o 1000SR Product Conveyor 2421-0010S 2530-2012

Conveyor is equipped as standard with bearing detail
illustrated. As a production measure machines may be
constructed with alternative bearing grease connection
These bearings hold the same part number omitting the
suffix. Bearing grease fittings are illustrated in Service
bulletin SP 003 03A.
A plant may have the “S” suffix bearings fitted as a spa
by omitting Grease Nipple adapter part 2429-0001 and
connecting hose to bearing housing using Nipple 2520-
Section
Page 5- 17
1000SR Section 6:- Transfer Conveyors
Section 6 :- Transfer
Conveyors
Section
Page
Section 6:- Transfer Conveyors 6 -1
Section 6:- Table of Contents 6 -2
Transfer Conveyor Layout 6 -3
Head Section 6 -4
Stringer Section 6 -6
Drive Group 6 -9
Tail Section 6 -11
Conveyor Rubber Items 6 -13
Bearings 6 -14
Section
Page
1000SR TransferConveyor Layout
Upper Conveyor
Head Section
Drive Group
Stringer Section
Drive Group
Tail Section
Lower Conveyor
Section
Page
1000SR Head Section
Upper Lower
Conveyor Conveyor
Part Number
Pl ant QM018702
Di s charge Chut e AX862/176/1 1

4
Screw Hex 2230-1151
1
Was her Bri ght As product i on 2210-0017 4
Was her Spri ng Pl ant s 2211-0008

5
Scraper Bl ade AX862/183 1
1 6 2 Upper Conveyor 2
Screw SKT CSK 2226-0817 5
Product i on Pl ant s
Di s charge Chut e AX862/179/1 AX868/164/1 1
Screw Hex AX862/179/1 2230-1151

1
Was her Bri ght 2230-1151 2210-0017 4
Was her Spri ng 2210-0017 2211-0008
Scraper Bl ade 2211-0008 AX868/165/1 1

2
Screw SKT CSK AX862/180 2226-0817 5
Rubber Support Bracket AX862/179/2 1
Screw HEX 2226-0815

3 N/A
Lower Conveyor
Nut Phi l l i das 2217-0005
Section
Page
1000SR Head Section
Upper Lower
Item Description / Notes Conveyor Conveyor Qty
Part Number
Plant QM018702
3 Cl amp (Si de)

As Product i on
4 Cl amp ( Front ) N/A
Pl ant s
5 Rubber Ski rt Chut e
Production Pla nts
Cl amp (Si de) AX862/179/4 2
Screw Hex 2230-1152
3 Was her Bri ght 2210-0017

2/cl amp
Cl amp ( Front ) AX862/179/3 N/A 1
Screw Hex 2230-1152

4/cl amp
5 Rubber Ski rt Chut e AX868/54/1 1
Section
Page
7 6
Plant 100138BJSR
Stringer Structural Components
differ from this Manual :- Refer to
BL-Pegson Ltd 10
8
9
13 13A 9 13A
13 15 14
10
10
7AA
7A
7A 12 7B
12
8 7C 7B 11 8 7C 11
Section
Page
Upper Lower Upper Lower

Item Description / Notes C onveyor C onveyor Qty Conveyor Conveyor
Plant QM018702 Plant QM018702
Idl er Rol l er 2495-3024 4 Set t i ng Support Rai l RH AX868/43/1 AX868/45/1 1
6
Fi xi ngs as Product i on pl ant s Screw Hex 2230-1151
Cros s Conveyor St ri nger 8
AX868/47/1 AX862/10/1 1 Was her Bri ght 2210-0017 4
Sect i on
Bel t Gui de Bl ock AX862/220 8 Was her Spri ng 2211-0008
7 Bol t Hex 2232-1130 2/
Ski rt Support Bracket AX862/10/9
9 Conveyor
Was her Spri ng 2211-0008 1/Bl ock
Fi xi ngs as Product i on Pl ant s
Production Pla nts
7AA Hos e Tray Cover Pl at e N/A AX862/87/2 2
7B Scraper Bl ade AX862/262/1 1
7A & 7AA Fi xi ngs as Product i on pl ant s
Cl amp St ri p AX862/263/1 2
Production Pla nts
Screw Hex 2230-1093 4
Parral l el Idl er Fl anged 2495-3027 4 7C
Hex Screw 2230-1150 2/rol l
6 Was her Spri ng 2211-0006 4
Was her Spri ng 2211-0008 2/rol l
Set t i ng Support Rai l AX868/152/1 AX868/150/1 1
Was her Bri ght 2210-0017 2/rol l
Cros s Conveyor St ri nger Screw Hex 2230-1151 6/rai l
7 AX862/222/1 1 8
Sect i on
Was her Bri ght 2210-0017 6/rai l
AX862/87/1 8
7A Cover Cros s Conveyor Was her Spri ng 2211-0008 6/rai l
AX862/87/1 6
2/
Ski rt Support Bracket AX862/225/1
7AA Hos e Tray Cover Pl at e N/A AX862/265/1 2 Conveyor
Screw Hex 2230-1121 Screw Hex 2230-1121 6/rai l

9
7A & 7AA Was her Bri ght 2210-0016 2/pl t Was her Bri ght 2210-0016 12/rai l
Was her Spri ng 2211-0007 Nut Phi l l i das 2217-0004 6/Rai l
Section
Page
1000SR

Conveyor Conveyor Item Description / Notes C onveyor C onveyor Qty
Plant QM018702 Plant QM018702

Ski rt Rubber Cl amp St ri p
AX868/55/1 1 13 AX868/132/1 1
RH
Bargeboard ( RH Onl y)
AX862/10/13 1 Ski rt Rubber Cl amp St ri p
13A AX868/132/2 1
LH
10 Screw Hex 2230-1121 6/Rai l Screw Hex 2230-1121
Was her Bri ght 2210-0016 12/Rai l 13 & 13A Was her Spri ng 2211-0007 7/Cl amp
Nut Phi l l i das 2217-0004 6/Rai l Was her Bri ght 2210-0016
Production Pla nts Set t i ng Support Rai l LH AX868/45/2 1

14
Bargeboard ( RH Onl y) AX862/226/1 AX862/226/1 1 Fi xi ngs as It em 8
Screw Hex 2230-1121 5/Rai l Lower Conveyor Hos e
N/A AX862/10/12 1
10 15 Tray
Was her Bri ght 2210-0016 10/Rai l
Fi xi ngs as Product i on Pl ant s
Nut Phi l l i das 2217-0004 5/Rai l Production Pla nts
Plants QM018966
13 2/
100101BASR & 100102BASR
Ski rt Rubber Cl amp St ri p AX862/233/1
11 & 12 100101BBSR 13A Conveyor
100101BCSR
100114BESR Screw Hex 2230-1122
11 Ni p Guard - Head Drum AX862/224/1 1 13 & 13A Was her Spri ng 2211-0007 7/Cl amp
2/ Was her Bri ght 2210-0016
12 Cl amp Pl at e AX868-223-001
Conveyor
Set t i ng Support Rai l LH AX868/151/1 1
Plants QM018702 & All other Production Plants 14
Fi xi ngs as It em 8
11 Ni p Guard - Head Drum AX868-221-501 1
Lower Conveyor Hos e
2/ AX862/227/1 1
12 Cl amp Pl at e AX868-222-001 Tray
Conveyor
Screw Hex 2230-1151 2
15 N/A
Section
Page
1000SR Drive Group
17 21
20
19
19
C
18
16 17
A A
Section
Page
1000SR

Item Description / Notes Conveyor Conveyor Qty Conveyor Conveyor
All Pla nts All Plants

1/ Screw Hex 2230-1222 2
16 Mot or 2576-4089
Conveyor 19
17A Coupl i ng Guard AX862/137/1 Dri ve s i de Was her Spri ng 2211-0010 2
1 fi xi ngs
Guard Support AX862/137/2 Was her Bri ght 2210-0019 2
Screw Hex 2230-1037 2 Hex Bol t 2232-1207 2
Was her Spri ng 2211-0004 2 19 Screw Hex 2230-1222 2

Non Dri ve Si de
17B Was her Bri ght 2210-0012 2 fi xi ngs Was her Spri ng 2211-0010 4
Screw Hex 2230-1152 1 Was her Bri ght 2210-0019 4
Was her Spr 2211-0008 1 20 Head Drum AX868/112/1 1
Was her Bri ght 2210-0017 1 Beari ng Adjus t ers AX862/167 2
Shri nk Di s c Coupl i ng 2450-5508 1 21 Screw Hex 2230-1167 1/uni t

17C
Key 2432-2110 1 Nut Hex 2215-0014 3/uni t
18A Torque Arm AX862/84 1

Mot or Torque Pl at e
AX862/168 2
Support St ud
18B Nut Phi l l i das 2217-0005 2
Mot or St ud AX862/86 1
18C Was her Bri ght 2210-0017 1
Beari ng 2421-2003S 2
19
Greas e Ni ppl e 2530-1070 2
Section
Page 6- 10
1000SR Tail Section
Upper Conveyor Lower Conveyor

27
26
27 26
28
23
22
23
22
24
25
22 25
23
24
Section
Page 6- 11
1000SR Tail Section

Item Description / Notes C onveyor C onveyor Qty Conveyor Conveyor
QM018702 Production Pla nts
Tai l drum Guard Mount i ng 2/
25 AX862/136/2 End Ski rt Cl amp Pl at e AX862/230/1 1
Pl at e Conveyor
Tai l drum Guard AX868/62/1 1 Screw Hex 2230-1152
26 28 N/A
Fi xi ngs as Product i on Pl ant s Was her Bri ght 2210-0017 4
End Bargeboard AX862/10/4 Was her Spri ng 2211-0008
27
End Ski rt Rubber AX868/46/2 1
End Ski rt Cl amp Pl at e AX862/10/15

28
Fi xi ngs As Product i on Pl ant s
Production Pla nts
Beari ngs 2421-0005S 2
Bol t Hex 2232-1131 4

23
24 Shi m t ai l Beari ng N/A AX868/109/1 2

Tai l drum Guard Mount i ng 2/
25 AX862/266/1
Pl at e Conveyor
Tai l drum Guard AX862/236 1
Screw Hex 2230-1152 4

26
End Bargeboard AX862/234/1

27 1
End Ski rt Rubber AX862/235/1
Section
Page 6- 12
Lower Conveyor
Upper Conveyor
27
29
30
Upper Lower
Item Description / Notes Conveyor Conveyor Qty
Part Number
Production Pla nts

2/
29 Ski rt Rubber AX862/125
Conveyor
30 Bel t Endl es s AX868-227-001 1
Section
Page 6- 13
1000SR Bearings
19
23
Head Drum Bearing
Tail Drum Bearing
Standard Bearing Arrangement Head Beari s ngs Tai l Beari ngs

1000 SR
It em 19 It em 23
illustrated. As a production measure machines may be St andard Fi t t o 1000SR Product Conveyor 2421-2003S 2421-005S
Section
Page 6- 14
SR Screen & Fines Conveyor Introduction
Screen & Fines Conveyor
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section A B
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 1B - 1
Page
SR Screen & Fines Conveyor Table of Contents
Introduction 8-1 Fines Conveyor Layout 8-17
Table of Contents 8-2 Head Section 8-18
Screenbox 8-3 Stringer Section 8-20
Top Deck Mesh Options 8-5 Tail Section 8-23
Bottom Deck Mesh Options 8-6 Drive Group 8-25
Inner Bearing 8-7 Conveyor Rubbers & Cover 8-26
Flywheel 8-8 Troughing Idlers 8-27
Outer Bearing 8-9 Bearings 8-28
Drive 8-11 Dust Supression Spray Bar 8-29
Mesh Tension System 8-13
Screen Rubbers 8-15
Section
Page
SR Screen & Fines Conveyor Screenbox
1
2
8
8A
8B
5 10
6
6B
6A
4
3
Section
Page
SR Screen & Fines Conveyor Screenbox
4242SR & 1000 SR 4242SR & 1000 SR

Item Description / Notes Qty Item De scription / Note s Qty
1 Scre e n Bo x 2371-2032 1 Bo l t He x 2232-1228 3
2 P i pe U ni t 2371-2084 1 Scre w 2230-1152 2

8A
Bo t t o m De ck Ca mbe r Ba r 2371-2058 4 N ut 2217-0005 5
Bo l t 2371-2059 8 Wa s he r 2210-2056 10
3
N ut 2371-2060 12 Bo l t He x 2232-1228 3
Wa s he r 2371-2061 12 N ut 2217-0005 5
4 Spri ng 2371-2044 4 8B Wa s he r 2210-2056 8
5 Sub Fra me AX862/55/4 1 Scre w 2230-1152 2
6 Fl ywheel Guard AX862/202/2 1 Wa s he r 2210-0017 2
Bol t Hex 2232-1128 4 9 Scre e n Mo t o r Unde rgua rd AX862/182/1 1
6A Was her 2210-2056 8 10 Unde rgua rd AX862/182/3 1
Nut 2217-0005 4
Screw 2230-1152 4
6B Was her 2210-2056 8
Nut 2217-0005 4
7 Underguard AX862/182/2 1
8 Mot or Guard AX862/202/1 1
Section
Page
SR Screen & Fines Conveyor Top Deck Mesh Options
12 :- End
11 :- Impact
Ite m Qty T ensioned Qty
Mesh
De scr iption Mesh
Part Number
SCREENBOXT11.2 2371-2126 1 2371-2127 1
SCREENBOXT16 2371-2025 1 2371-2026 1
SCREENBOXT22 2371-2021 1 2371-2022 1
SCREENBOXT30 2371-2019 1 2371-2020 1
SCREENBOXT32 2371-2005 1 2371-2006 1
SCREENBOXT35 2371-2007 1 2371-2008 1
SCREENBOXT40 2371-2120 1 2371-2121 1
SCREENBOXT42 2371-2009 1 2371-2010 1
SCREENBOXT45 2371-2002 1 2371-2003 1

12 11 SCREENBOXT50 2371-2023 1
SCREENBOXT55 2371-2011 1 2371-2012 1
SCREENBOXT58 2371-2013 1 2371-2014 1
11A SCREENBOXT65 2371-2029 1 2371-2030 1
11B SCREENBOXT70 2371-2131 1 2371-2132 1
SCREENBOXT80 2371-2024
Ite m De scr iption 4242SR & 1000SR Qty
11A Top Deck Cl amp Pl at e 2371-2043 2
11B Bol t , Nut , Was her 2371-2042 8
Section
Page
SR Screen & Fines Conveyor Bottom Deck Mesh Options
Ite m 13 :- First Mesh Qty 14:- End Mesh Qty

De scr iption Part Number
SCREENBOXB00 No Mes h Fi t t ed
SCREENBOXB06 2371-2124 1 2371-2124 1
SCREENBOXB12 2371-2015 1 2371-2015 1
SCREENBOXB14 2371-2016 1 2371-2016 1
SCREENBOXB15 2371-2125 1 2371-2125 1
SCREENBOXB16 2371-2017 1 2371-2017 1
SCREENBOXB18 2371-2018 1 2371-2018 1
SCREENBOXB22 2371-2004 1 2371-2004 1
SCREENBOXB25 2371-2123 1 2371-2123 1
14 13 SCREENBOXB28 2371-2122 1 2371-2122 1
SCREENBOXB32 2371-2027 1 2371-2027 1
SCREENBOXB35 2371-2028 1 2371-2028 1
SCREENBOXB6.3H 2371-3001 1 2371-3001 1
Section
Page
SR Screen & Fines Conveyor Inner Bearing
21 17
19 21
17
24
26
2
18
16 20
22
23
22
25
19
Section
Page
SR Screen & Fines Conveyor Flywheel
28
29
27
30
32
31
32
Section
Page
SR Screen & Fines Conveyor Outer Bearing
33 33
35
36 35
38
39
40
38
34
37
Section
Page
SR Screen & Fines Conveyor
4242SR & 1000 SR 4242SR & 1000 SR

Item Description / Notes Qty Ite m De scription / Note s Qty
Part Number Pa rt Numbe r
16 Scre e n Sha f t 2371-2083 1 30 Ha l f Fl ywhe e l 2371-2064 2
B o l t , N ut 2371-2086 24 Co unt e rwe i ght 2371-2065 2
17 Hardened Was her 2371-2087 48 Co unt e rwe i ght 2371-2066 2

31
Spri ng Was her 2371-2088 24 Co unt e rwe i ght 2371-2067 2
Fl a nge Be a ri ng Ga s ke t 2371-2095 2 Co unt e rwe i ght 2371-2068 2

18
Ga s ke t Se a l e r 2371-2096 1 32 B o l t , N ut , Wa s he r 2371-2070 1
19 Ho us i ng L i p Se a l 2371-2094 4 A da pt o r 2371-2078 2
20 Fl a nge Be a ri ng Ho us i ng 2371-2085 2 33 Se a l 2371-2079 3
Inner Beari ng Greas e Out e r Be a ri ng Gre a s e

2371-2082 2 2371-2080 2
Pi pe P i pe
21 Adapt or 2371-2081 2 34 P l umme r Bl o ck Ho us i ng 2371-2072 2
P l umme r Bl o ck Ho us i ng
Seal 2371-2079 2 35 2371-2077 4
Se a l
22 Sl eeve & Nut 2371-2090 2 36 L o ca t i ng Ri ng 2371-2076 2
23 Beari ng 2371-2089 2 37 Be a ri ng 2371-2074 2
24 Locat i ng Ri ng 2371-2091 2 38 Sl e e ve & Nut 2371-2075 2
25 Hous i ng Cap Bol t s 2371-2093 8 39 Rubbe r Be a ri ng Mo unt 2371-2118 2
26 Beari ng Hous i ng Cap 2371-2092 2 40 B o l t , N ut , Wa s he r 2371-2073 4
27 Fl ywheel 2371-2062 2
28 Taperl ock Cent re 2371-2063 2
29 Bol t , Nut , Was her 2371-2069 4
Section
Page B - 10
SR Screen & Fines Conveyor Drive
41
42
48
49
41 42 43 51
46
47
42 45
44
50
Section
Page B - 11
4242SR & 1000 SR

Item De scription / Note s Qty
Part Number
41 Hydra ul i c Mo t o r 2371-2099 1
Co unt e rs unk Bo l t 2371-2100 4
N ut 2371-2101 4
42
Wa s he r 2371-2102 4
Spri ng Wa s he r 2371-2103 4
Hydra ul i c Mo t o r
43 2371-2097 1
Mo unt i ng Bra cke t
Ba cki ng P l a t e 2371-2098 2
44 N ut 2371-2060 4
Wa s he r 2371-2061 4
45 Ta pe rl o ck Ce nt re 2371-2110 1
46 Scre e n Mo t o r P ul l e y 2371-2111 1
47 Ve e Be l t 2371-2112 2
48 Scre e n Sha f t P ul l e y 2371-2113 1
49 Ta pe rl o ck Ce nt re 2371-2115 1
50 Ke y - Scre e n Sha f t 2371-2114 1
51 Mo t o r Ada pt o r Co mpl e t e 2371-2104 2

51A
Fl ow Cont rol Val ve 2579-0018 1
Section
Page B - 12
SR Screen & Fines Conveyor Mesh Tension System
53
55
58
54
52 56
57
59
Section
Page B - 13
Part Number
1000SR 4242SR
52 Hydra ul i c Ho s e 2371-2116 2
Hydra ul i c Ho s e 2371-2117 2
St rut P i n N/A 2371-2129 2

53
Pi n 2371-2130 2
54 Ra m 2371-2128 2
1000SR & 4242SR
55 R e t a i ni ng P i n 2371-2040 6
56 Spri ng P i n 2371-2041 6
57 Ca mbe r Ba r 2371-2039 3
58 Te ns i o ne r 2371-2037 6
59 B o l t , N ut , Wa s he r 2371-2038 12
Section
Page B - 14
SR Screen & Fines Conveyor Screen Rubbers
60
62
65 64 63
61
66 67
Section
Page B - 15
4242SR & 1000SR

Part Number
Scre e n Bo x Ba ck Rubbe r
60 2371-2055 1
U ppe r
Scre e n Bo x Ba ck Rubbe r
61 2371-2054 1
Fl a p
62 B o l t , N ut , Wa s he r 2371-2053 31
Si de Rubbe r 2371-2056 2
63
Si de Rubbe r Cl a mp 2371-2057 6
64 Fro nt Rubbe r Fl a p 2371-2051 1
65 Fro nt Rubbe r St ra p 2371-2052 3

Ca mbe r Ba r Rubbe r - 395
66 2371-2034 6
L o ng
Ca mbe r Ba r Rubbe r -
67 2371-2033 12
1545 L o ng
Section
Page B - 16
SR Screen & Fines Conveyor Fines Conveyor Layout
Drive Group
Head Section
Stringer Section
Tail Section
Section
Page B - 17
SR Screen & Fines Conveyor Head Section
3 39 9
2
4
8
5 7
4A 3A
6
1
Section
Page B - 18
1000 SR 1000 SR
1 Head Drum AX862/20 7 Scraper Bl ade AX862/50/2

1
2 Ni p Guard AX862/66 Scraper Cl amp St ri p AX862/50/3
1
3 Tens i oner RH AX818/110/1 Screw 2230-1153
7A
3A Tens i oner LH AX818/110/1X Was her 2211-0008
See Page B-22 8
Screw 2230-1221 4 Was her 2210-0017
3 & 3A Was her 2210-0019 8 Nut 2217-0005
Nut Phi l l i das 2217-0007 4 8 Spray Bar Bracket RH AX862/158/1 1
4 Ros t a Uni t Suport RH AX815/91/2 9 Spray Bar Bracket LH AX862/158/2 1

1
4A Ros t a Uni t Suport LH AX815/91/1 Screw 2230-1151
Tens i oner AX607/3/46 2 8&9 Was her 2211-0008 2/Brkt
Screw 2230-1153 Was her 2210-0017

5
Was her 2211-0008 1/uni t
Was her 2210-0017
Scraper Frame AX862/50/1 1
Screw 2230-1152
6
Was her 2210-0017 4/uni t
Nut 2217-0005
Section
Page B - 19
SR Screen & Fines Conveyor Stringer Section
3 13 12B 14 15
12
13
12A
12B
11B 11A
13 10 12 11
Section
Page B - 20
4242SR & 1000 SR 4242SR & 1000 SR

Item De scription / Note s Qty Item De scription / Note s Qty
10 St ri nge r Se ct i o n AX862/19/1 1 Mi ddl e Gua rd AX862/26/1 2
11 He a d Gua rd RH AX862/27/2 1 Scre w 2230-1151 5/Uni t

13
11A He a d Gua rd L H AX862/27/1 1 Wa s he r 2210-0017 10Uni t
Scre w 2230-1151 4/Uni t N ut 2217-0005 5/Uni t
11 & 11A Wa s he r 2210-0017 8/Uni t Re mo va bl e Idl e r Suppo rt AX862/19/2 1
N ut 2217-0005 4/uni t Scre w 2230-1220 4

14
Cl a mp AX862/79/3 2 Wa s he r 2210-0019 8
Scre w 2230-1153 N ut 2217-0007 4

11B
Wa s he r 2210-0017 4/Uni t Dus t Co ve r Suppo rt AX862/90 3
Wa s he r 2211-0008 Scre w 2230-1150

15
12 Gua rd Uppe r RH AX862/73/2 1 Wa s he r 2211-0008 4/Brkt
12A Gua rd Uppe r L H AX862/73/1 1 Wa s he r 2210-0017
Scre w 2230-1151 5/Uni t
12 & 12A Wa s he r 2210-0017 10Uni t
N ut 2217-0005 5/Uni t
Cl a mp AX862/79/2 4
Scre w 2230-1153
12B
Wa s he r 2210-0017 6/Uni t
Wa s he r 2211-0008
Section
Page B - 21
4242SR & 1000 SR

Part Number
P i n(wi t h Ha ndl e ) AX862/59/2 2

20 19 16
18 Lynch P i n 2294-0015 1/Pi n
17 17 Suppo rt L i nk AX862/47 2
16
Pi n AX862/59/3 2
18
Lynch P i n 2294-0015 1/Pi n
Uppe r Ni p Gua rd AX862/115 1
Scre w 2230-1151
19
Wa s he r 2211-0008 2/Uni t
Wa s he r 2210-0017
Spi ra l Ro l l e r Bra cke t AX862/212/1 2
Scre w 2230-1220
7A 20
Wa s he r 2211-0010 2/Brkt
Wa s he r 2210-0019
21 21 Spi ra l Re t urn Idl e r 2495-3019 4
L o we r Ni p Gua rd AX862/165 3
22
Fi xi ngs a s It e m 19
Suppo rt L e g AX862/48/1
23
Pi n AX862/48/2
23 1
22 21 Wa s he r M24 pl a i n 2210-0023
Spl i t P i n 2201-0163
Section
Page B - 22
SR Screen & Fines Conveyor Tail Section
28 29 28B
30
26A
28A
24
25
26
27 25
29A
31
Section
Page B - 23
SR Screen & Fines Conveyor Tail Section
4242SR & 1000 SR 4242SR & 1000 SR

Item De scription / Note s Qty Item De scription / Note s Qty
Be a ri ng Gua rd L H AX862/138/1 1 Ta i l Drum Ni p Gua rd L H AX862/132/2 1
Scre w 2230-1152 2/Uni t Scre w 2230-1151
24 28A
Wa s he r 2210-0017 4/Uni t Wa s he r 2211-0008 2/Uni t
N ut 2217-0005 2/Uni t Wa s he r 2210-0017
25 Ta i l Drum AX862/21 1 Cl a mp AX862/79/1 2
Ta i l Se ct i o n Ti e P l a t e AX862/76 1 Scre w 2230-1153
28B
Scre w 2230-1152 4/Uni t Wa s he r 2210-0017 3/Uni t
26
Wa s he r 2210-0017 8/Uni t Wa s he r 2211-0008
N ut 2217-0005 4/Uni t L o we r Gua rd RH AX862/75/1 1
29
Cl a mp P l a t e AX862/78 1 Fi xi ngs a s It e m 28
Scre w 2230-1153 29A Ta i l Drum Ni p Gua rd RH AX862/132/1 2
26A Wa s he r 2210-0017 Fi xi ngs a s It e m 28A
5/uni t
Wa s he r 2211-0008 Ta i l P i n AX862/59/1 2
30
N ut 2217-0005 Lynch P i n 2294-0015 1/Pi n
27 Be a ri ng Gua rd AX862/138/2 1 Ta i l Be a ri ngs Re f e r t o P a ge B-28
L o we r Gua rd L H AX862/75/2 1 Bo l t 2232-1206 4
31
Scre w 2230-1220 2/Uni t Was her 2210-0019 8
28
Wa s he r 2210-0019 3/Uni t Nut 2217-0007 4
Wa s he r 2211-0010 3/Uni t
Section
Page B - 24
SR Screen & Fines Conveyor Drive Group
4242SR & 1000 SR

33 34 4 35 Part Number
Mo t o r 2576-4076 1
Bo l t 2232-1129
32
Wa s he r 2211-0017 4
N ut 2217-0005
33 Che ck Va l ve 2579-0018 1
34 To rque Arm AX815/90 1
He a d Be a ri ngs Refer t o Page B-28
Bo l t 2232-1207 4
35
Wa s he r 2210-0019 8
36 37
N ut 2217-0007 4
36 Shri nk Di s c Co upl i ng 2450-5503 1
37 Ke y 2432-2194 1
38 Gre a s i ng Ki t Refer t o Page B-28
Coupl i ng Guard AX815/82/1 1

38
39 Screw 2230-1056
See Page B-19 Was her 2211-0005 2
Was her 2210-0013

32
Section
Page B - 25
SR Screen & Fines Conveyor Conveyor Rubbers & Cover
42 40 42
44
41
4242SR & 1000 SR

Part Number
40 Ski rt Rubber Tai l Sect i on AX862/116/3 1
41 Ski rt Rubber Upper AX862/116/1 2
42 Ski rt Rubber Lower AX862/116/2 2
43 Bel t 2360-0040/12.5 1
44 Canvas W i nd Cover AX862/89 1

43
Section
Page B - 26
SR Screen & Fines Conveyor Troughing Idlers
2
2
1
Ba se P la te Mounte d Idle r
P la nt C ompone nt
P a r t Numbe r Q ty
Co mpl e t e Se t 2495-3018 4
1 : - W i ng
2489-1072 8
Ro l l e r
Fi xi ng Cl a mp 2489-3004 8
4242SR & 1000 SR Fi xi ng Bo l t 2232-1072
Wa s he r Bri ght 2210-0015
N ut 2217-0003
2 : - Ce nt re
2489-1072 8
Ro l l e r
Section
Page B - 27
SR Screen & Fines Conveyor Bearings
16
53
Tail Drum Bearing

Head Drum Bearing
27
17
Head Beari s ngs Greas i ng ki t Tai l Beari ngs Greas i ng ki t

4242SR & 1000 SR
It em 35 It em 38 It em31
Standard Bearing Arrangement St andard Fi t t o Fi nes Conveyor 2421-0010S 2530-2019 2421-0010S 2530-2022

illustrated. As a production measure machines may be
Section
Page B - 28
SR Screen & Fines Conveyor Dust Supression Spray Bar
4242SR & 1000 SR

Part Number
45 Spray Bar Ki t AX862/159K 1

46 46 Noz z l e Dus t Suppres s i on 2540-0006 4
47 Wat er Hos e 2526-4004A 8Mt r
45
47
Section
Page B - 29
Section 7:- Recirculating

1000SR Conveyor
Section 7 :- Recirculating
Conveyor
Section
Page
Section 7:- Recirculating Conveyor 7-1 Troughing Idlers 7 - 12
Section 7:- Table of Contents 7-2 Bearings 7 - 13
Recirculating Conveyor Layout 7-3
Drive Group 7-4
Stringer Section 7-5
Stringer Underside 7-7
Tail Section& Feed Boot 7-8
Tail Section 7-9
Conveyor Rubber Items 7 - 10
Stockpile Mode Supports 7 - 11
Section
Page
1000SR Recirculating Conveyor Layout
A Revised Design Recirculating Conveyor Will

be Introduced Early in 2005. This section covers
machines serial number up to & including
100153BLSR
Drive Group
Tail Section Stringer Section
Section
Page
1000SR Drive Group
1000 SR
3 Part Number
1 Head Drum AX868/110/1 1
2 Mot or 2576-4076 1
A
3 Check Val ve 2579-0018 1
4A Coupl i ng Guard AX862/91 1
4B Torque Arm AX815/90 1
Shri nk Di s c 2450-5503 1
4C
Key 2432-2194 1
5 4 2 Beari ng 2421-0010S 2
Bol t Hex 2232-1206 2/uni t

6 1 4 5
Was her Pl ai n 2210-0019 4/uni t
Nut 2217-0007 2/uni t
6 Head Beari ng Greas e Ki t 2530-2019 1

B
Not Il l us t rat ed Ni p Guard AX862/74 1
Section
Page
7 7B 8B
7A
7C
8
7A 7
9B
9
10B
8
10
12B
11 11B 9A
13
10A
12
11A
15
14 12
Left Hand View 20A Right Hand View
Section
Page
1000SR 1000 SR
7 Head Guard LH AX868/123/2 10 3rd Guard LH AX868/72/2 1
1
7A Head Guard RH AX868/123/1 10A 3rd Guard RH AX868/72/1 1
Screw Hex M12x30 2230-1151 10 & 10A Fi xi ngs as 7 & 7A 4/Guard
7& 7A Was her Bri ght M12 2210-0017 3/Guard
Cl amp AX868/100/6 2
Was her Spr M12 2211-0008 10B
Fi xi ngs as 7B 4/Cl a mp
Cl amp AX868/100/12 2
11 4t h Guard LH AX868/7/2 1
Screw Hex 2230-1152
7B 11A 4t h Guard RH AX868/7/1 1
2/Cl a mp
11 & 11A Fi xi ngs as 7 & 7A 4/Guard
Cl amp AX868/100/5 2
Cl amp AX868/100/13 2 11B
7C Fi xi ngs as 7B 4/Cl a mp
Lower Guard AX868/58/1 2
Guard Upper AX868/73/1 2 12
8 Fi xi ngs as 7 & 7A 4/Guard
Fi xi ngs as 7 & 7A 3/Guard
Cl amp AX868/100/4 2
Cl amp AX868/100/8 2 12B
8B
9 2nd Guard LH AX868/8/2 1 13 St ri nger Sect i on Fab AX868/6/1 1
9A 2nd Guard RH AX868/8/1 1 14 Mai n Pi vot Fabri cat i on AX868/6/2 1
9 & 9A Fi xi ngs as 7 & 7A 4/Guard Hi nge Pi n AX868/68/4 2
Cl amp AX868/100/7 2 15 Was her 2210-0025

9B 1/Pi n
Fi xi ngs as 7B 4/Cl a mp Spl i t Pi n 2201-0164
Section
Page
1000SR Stringer Underside
1000 SR
Refer to Plant Part Number
Recirculating Chute
Upper Ni p Guard AX862/123/2 1
Screw Hex 2230-1151

16
17 Ret urn Idl er 2495-3022 5

17A
Ret urn Idl er ( Bend) 2495-3023 1
Not i l l us t rat ed
16 Lower Ni p Guard AX862/123/1 3
18
Fi xi ngs as It em 16 2
17 Ni p Guard Ret urn Rol l er AX862/123/3 1

19
17A
18
19
Section
Page
1000SR Tail Section& Feed Boot
20 21A
22
22
21B 20C
24D
23
21C
20B
24E
24A
24C
24B
Section
Page
1000SR Tail Section
1000 SR 1000 SR
Feed Boot LH AX868/10/2 1 Tai l Drum Guard AX862/134 1
20 Screw Hex 2230-1221 Bol t Hex 2232-1101
5/Boot
Was her Pl ai n 2210-0019 Was her Pl ai n 2210-0016
Cl amp AX868/100/3 1
24A Was her Spri ng 2211-0007
Screw Hex 2230-1152 2
20B Bol t Hex 2232-1130
Was her Bri ght 2210-0017 5/Cl amp
20C Ret ai ni ng St ri p AX862/245/1
1 Tai l Beari ngs 2421-0010S
Feed Boot RH AX868/10/1 2
21
Shi m t ai l Beari ng AX862/249/1
Not Il l us t rat ed Fi xi ngs as It em 20 5/Boot
24B Bol t Hex 2232-1207 2/uni t
21A Feed Boot Fi l l i n Panel AX868/10/5
1 Was her Pl ai n 2210-0019 4/uni t
Cl amp AX868/136
21B Nut Hex 2217-0007 2/uni t
Fi xi ngs as It em 20B 2/Cl amp
24C Tai l Drum AX862/17
Cl amp AX868/100/2 1
21C Feed Boot Lower Rear 1
Fi xi ngs as It em 20B 4/Cl amp AX868/10/3
Panel
Feed Boot Upper Rear Feedboot Rear Cl amp
22 AX868/10/4 AX868/100/11
Panel St ri p
23 Tens i oner AX818/110/1 1 24D
Nut Hex 2215-0014
23A
Tens i oner AX818/110/1X Was her Spri ng 2211-0008 4
Screw Hex 2230-1220 4/uni t Was her Pl ai n 2210-0017
23 & 23A Was her Pl ai n 2210-0019
Nut 2217-0007
Section
Page
27
26
26a
29
25
27a
28
1000 SR
Part Number
25 Ski rt Rubber Head AX868/124/3 2
26 Ski rt Rubber RH AX868/124/2 1
26a Si de Ski rt Rubber (Out er) AX868-242-001 1
27 Ski rt Rubber LH AX868/124/1 1
27a Si de Ski rt Rubber (Out er) AX868-241-001 1
28 Feed Boot Ski rt Rubber AX868-239-001 1
29 Bel t 2360-0066/21.0 1
Section
Page 7- 10
1000SR Stockpile Mode Supports
1000 SR
30a Item Description / Notes Qty
Part Number
30b 30
Reci rcul at i ng Conveyor
AX868/69/1 2
Support Brkt
30a Vert i cal pl at e bol t s - 2232-1128
30 8
30b Hori z ont al pl at e bol t s - 2232-1127
Was her 2210-0017

30a & 30b 16
Nut 2217-0005
St ockpi l i er Ret ai ni ng bar AX862/203 1
Screw 2230-1221
31
30 Was her 2210-0019 2
31
Nut 2217-0007
Support St rut
32 AX868/134/01 1
( St ockpi l er)
31
32
Section
Page 7- 11
2
2
1
Ba se Pla te Mounte d Idle r

Pla nt C ompone nt
Pa r t Numbe r Q ty
Co mpl e t e Se t 2495-3021 10
1 : - W i ng
2489-1075 20
Ro l l e r
Fi xi ng Cl a mp 2489-3004
1000 SR Fi xi ng Bo l t 2232-1072 1/
Wa s he r Bri ght 2210-0015 Ro l l e r
N ut 2217-0003
2 : - Ce nt re
2489-1074 10
Ro l l e r
Section
Page 7- 12
1000SR Bearings
5
24B
Standard Bearing Arrangement Head Beari ng

Greas i ng ki t
It e m 5
Conveyor is equipped as standard with bearing detail 2421-0010S 2530-2019

St andard Fi t t o 1000SR Reci rcul at i ng
illustrated. As a production measure machines may be Conveyor Tai l Beari ng
constructed with alternative bearing grease connection Greas i ng ki t
It em 24B
2421-0010S 2530-2022
Section
Page 7- 13
1000SR Section 8:- Plant Hydraulic
Section 8 :- Plant Hydraulic Equipment
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 18a- 1
Page
Section 8:- Table of Contents 8 -1 Bank Valves Installation 8 -12
Hydraulic Circuit Parts 8 -2 Bank Valve 2550-9016 8 -14
Hydraulic Tank 8 -3 Bank Valve 2550-9044 8 -15
C9 Powerpack Items 8 -4 Bank Valve 2550-9045 8 -16
Clutch Oil Flow Control 8 -5 Bank Valve 2550-9060 8 -17
Airblast Cooler 8 -6 Bank Valve 2550-9065 8 -18
Steel Pipes & Pipe Clamps 8 -7 Hoses :- C 9 Powerpack 8 -19
Feed Conveyor Cylinder 8 -8
Recirculating Chute Cylinder 8 -9
Screen Raise / Lower & Recirculating Conveyor

Cylinders 8 -10
Bank Valves General Notes 8 -11
Section
Page
1000SR Hydraulic Circuit Parts
Hydra ulic C ircuit Dra w ing :- AX 868-177-601 Hydra ulic C ircuit Dra w ing :- AX 868-177-601
Pa rt Numbe r De scription / Note s Pa rt Numbe r De scription / Note s
AX868/88 Hydra ul i c Ta nk :- Re f e r t o P a ge 8-3 2573-3038 Fi xe d Di s pl a cme nt P ump:- Re f e r t o P a ge 8-4 & 8-5
2573-6001 Va ri a bl e P umps :- Re f e r t o P a ge 8-4 & 8-5 2550-9016 5 Ba nk Va l ve :- Re f e r t o P a ge 8-12 & 8-14
2531-5057 P re s s ure Fi l t e rs :-Re f e r t o P a ge 8-4 & 8-5 Scre e n Dri ve -

Re f e r t o SR Scre e n & Fi ne s Co nve yo r
2550-9044 4 Ba nk Va l ve :- Re f e r t o P a ge 8-12 & 8-15 Se ct i o n
Fi ne s Co nve yo r Dri ve
2550-9003 Mo t i o n Co nt ro l Va l ve :- Re f e r t o Tra cks
AX857/5 Fe e d Co nve yo r L i f t Cyl i nde r :- Re f e r t o P a ge 8-8
Tra ck Mo t o r :- Re f e r t o Tra cks
Ai rbl a s t Co o l e r :- Re f e r t o P a ge 8-6
P ro duct Co nve yo r Dri ve :- Re f e r t o P ro duct Co nve yo r Se ct i o n
Re ci rcul a t i ng Chut e Ra i s e & L o we r:- Re f e r t o P a ge 8-9
Cro s s Co nve yo r Dri ve :- Re f e r t o Cro s s Co nve yo r Se ct i o n
Scre e n Ra i s e & L o we r :- Re f e r t o P a ge 8-10
2580-1124 Co ne Co nt ro l :- Re f e r t o Crus he r Se ct i o n
HFO Ci rcui t :- Re f e r t o P a ge 8-5
2550-9045
2550-9060 4 Ba nk Va l ve :- Re f e r t o P a ge 8-12 & 8-16 Thro ugh 8-18 2538-0055 Guage & Hos e 56 Bar
2550-9065
Fe e de r Co nve yo r Dri ve :- Re f e r t o Fe e de r Co nve yo r Se ct i o n 2538-0056 Guage & Hos e 250 Bar
Re ci rcul a t i ng Co nve yo r Dri ve -: Re f e r t o Re ci rcul a t i ng Co nve yo r Se ct i o n 2538-0058 Guage & Hos e 600 Bar
St o ckpi l e Co nve yo r Dri ve -: Re f e r t o St o ckpi l e Co nve yo r Se ct i o n
Co ne L ubri ca t i o n Uni t :- Re f e r t o Crus he r Se ct i o n
Section
Page
1000SR Hydraulic Tank
Ite m Pa r t Numbe r De scr iption Qty

7 6 3
1 AX868/88 Hydra ul i c Ta nk 1
2531-5154 Suct i o n Fi l t e r 2
2 2531-5150 Fi l t e r El e me nt
1/Uni t
3A
2580-8009 "O" Ri ng Ki t
2A 2538-0054 Gua ge 1/Uni t
1 2B 2520-8002 Fl a n g e & A d a p t o r 1/Uni t
5 4 2531-5252 Re t urn L i ne Fi l t e r 1
3 2531-5253 Fi l t e r El e me nt 1
2580-8007 "O" Ri ng Ki t 1
3A 2538-0053 Gua ge 1
2A
4 2589-2105 L e ve l Indi ca t o r 1
2580-8005 Ins pe ct i o n Do o r 2
5
2580-8005-A Se a l 1/Uni t
6 2531-1000 Bre a t he r 1
2
7 2683-2233 L e ve l P ro be 1
2B 8
2552-6561 Q R C o upl i ng 1
No t i l l us t ra t e d
Section
Page
1000SR C9 Powerpack Items
Clutch Oil Flow

Control
12
10 11 9 13
9 Under Cover
10 9a
11
Section
Page
1000SR Clutch Oil Flow Control
18 1000 SR
Part Number
9 Fi t t i ngs Ki t f or 2531-5057 2531-5057A

17
Fi l t er El ement 2531-5152 1/Fi l t er
9a Indi cat or 2538-7100
Pump Pul l ey AX801/14 2

16 10
Dri ve Bel t 2441-0412 2/Pump
Hydraul i c Pump 2573-6001 2
11 Fi t t i ngs Ki t f or 2573-6001 2573-6001A

1/Pump
15 Pump Seal Ki t 2576-9010
12 Auxi l l ary Pump 2573-3038
13 Check Val ve 2589-5278
14 Adapt or & Ori f i ce Pl ug 2553-2023
14 Not Il l us t rat ed Res t ri ct or 2553-2020

1
15 3 Way Val ve 2553-2018
17 Tes t Poi nt 2553-2013
16 Pres s ure Swi t ch 2683-2238
18 Rel i ef Val ve 2553-2019
Section
Page
1000SR Airblast Cooler
Cooler Unit Fan & Motor R adiator

Plant Serial Number Qty
Part Number Part Number Part Number
QM018702 2592-2001 2592-9003 N/A
QM018966
17 100101BASR & 100102BASR
100101BBSR
100101BCSR
100106BDSR Through 100108BDSR
100114BESR & 100115BESR

1
1000 SR 100116BFSR
2592-2004 2592-9006 2592-9005
100121BGSR Through 100123BGSR
100127BHSR
100133BHSR & 100134BHSR
100135BJSR Through 100138BJSR
100147BKSR Through 100149BKSR
100150BLSRThrough 100153BLSR
100154BMSR
Section
Page
1000SR Steel Pipes & Pipe Clamps
1000 SR
Part Number
18 St eel Pi pe Ki t & Cl amps 16x2 2517-9010
19 St eel Pi pe Ki t & Cl amps 25x3 2517-9009 1

St eel Pi pe Ki t & Cl amps
20 2517-9011
12x1.5
18 19 20 20 19 18
Section
Page
1000SR Feed Conveyor Cylinder
Item De scr ip tio n / No te s 1000 SR Qty
Part Number
21 Cyl i nde r AX857/5 1
21A Mai nt enance Ki t AX857/5/A 1/Cyl i nder
21
21A
Section
Page
1000SR Recirculating Chute Cylinder
Item De scription / Note s 1000 SR Qty
Part Number
22
Pi vot Pi n Upper AX868/95/2 1
22 Was her 2210-0021

2
Spl i t Pi n 2201-0147
23
P ro t o t ype P l a nt QM018702
23 Cyl i nder 2564-5032 1
23A Mai ntenance Ki t 2564-5032/A 1/Cyl i nder

24
P ro duct i o n U ni t s
23 Cyl i nder 2564-5033 1
23A Mai ntenance Ki t 2564-5033/A 1/Cyl i nder

25
24 Ada pt o r & O ri f i ce P l ug 2553-2036 1
Bol t Hex 2232-1288 1
25 Was her 2210-0021 2
Nut 2217-0009 1
23A
Section
Page
Screen Raise / Lower &

1000SR Recirculating Conveyor
26B
26C
25
26
26D
26A
Item De scription / Note s 1000 SR Qty Item De scription / Note s 1000 SR Qty
25 Screen Support St rut Cyl i nder 2564-5029 P i n ( Co v Cyl t o Cha s s i s ) AX868/68/5 1

2 26B
25A Seal Ki t 2564-9330 Spl t P i n 2201-0182 1
26C Spa ce r AX868/97/1 2

P i ns Refer t o SR Screen & Fi nes Conveyor
P i n ( Cyl i nde r/Ro pe ) AX868-204-001 1
26 Re ci rc Co nve yo r Cyl i nde r AX868/71 1 26D
Spl t P i n 2201-0167 1
26A Ma i t e na nce Ki t AX868/71/A 1
Section
Page 8- 10
1000SR Bank Valves General Notes
Row A
Bank Valves
BL-Pegson Ltd recommend any repair to the Bank
valve is performed by Danfoss approved service
centre who maintain the necessary clean
operational environment and specialist tooling.
Before removal, both the Bank Valve & the
surrounding areas must be cleaned and hoses /
pipe end blanked off to prevent contamination.
Row B
For customers operating in remote areas a range
of components are available from BL-Pegson Ltd
through the local dealer. Each segment of a bank
valve is identified through a simple Alpha Numeric
grid system as illustrated. Row C
E “NO” PS
Section
Page 8- 11
1000SR Bank Valves Installation
Right Hand Bank Valve 2550-9045

Left Hand Bank Valve. 2550-9044 Bank Valve 2550-9016
2550-9060 & 2550-9065
Handing Viewed from Feed End Refer to Page 8-14
Handing Viewed from Feed End
Refer to Page 8-15 Refer to Page 8-16 Through 8-18
Section
Page 8- 12
1000SR Bank Valves Installation
1000SR
Upper Bank
Plant Serial Number L H Bank Valve R H Bank Valve
Valve
Page 8-17
Page 8-16 Page 8-15
T hrough 8-19
QM018702
QM018966
100101BASR & 100102BASR

2550-9045
100101BBSR
100101BCSR
100106BDSR Through 100108BDSR
100114BESR & 100115BESR
100116BFSR 2550-9044 2550-9016
100121BGSR Through 100123BGSR
100127BHSR 2550-9060
100133BHSR & 100134BHSR
100135BJSR Through 100138BJSR
100147BKSR Through 100149BKSR
100150BLSRThrough 100153BLSR
2550-9065
100154BMSR
Section
Page 8- 13
1000SR Bank Valve 2550-9016
R ow A R ow B R ow C
Row A Valve Section
Part No Seals Part No Seals Spool Part No Seals
PS:- Pump Side N/A N/A 2550-8002 2550-9034 N/A N/A N/A
1 :- Screen &
2550-6006 2550-9023
Fines Conveyor
Row B 2 :- Feed
Conveyor Lift
3:-Screen R aise
2550-6005 2550-9017 2550-9019 2550-9025 2550-6010 2550-9018
Lower
2550-9022
4:-Chute R aise
Lower
5:-R ecirc R aise
Row C 2550-6006
Lower
E :- End N/A N/A 2550-8003 2550-9035 N/A N/A N/A
Handle N/A 2550-9032
Bolt Kit & Seals 2550-9038
PS 1 2 3 4 5 E T est Point 2553-2013 Note :- T est Point is located under Part 2550-8002
Section
Page 8- 14
Row A R ow A R ow B R ow C
Valve Section
1 :- LH T rack 2550-6004 2550-9019 2550-9023
2 :-Product
2550-9026
Conveyor
Row B 2550-9017 2550-9025 2550-6010 2550-9018
3:-Cross
2550-6006 2550-6008 2550-9030
Conveyors
4:- Cone
2550-9031
Setting Control
E :- End N/A N/A 2550-8003 2550-9035 N/A N/A N/A

Row C
T est Point 2553-2013 Note :- T est Point is located under Part 2550-8002
PS 1 2 3 4 E
Section
Page 8- 15
Row A Row A Row B Row C

Valve Section
1 :- RH T rack 2550-6004 2550-9019 2550-9023
2 :-Feeder
2550-6014 2550-9042
Motor
Row B 2550-9017 2550-9025 2550-6010 2550-9018
3:- Recirc &
Stockpile 2550-6008 2550-9042
Conveyors 2550-6006
4:- Cone Lube
2550-9052
Motor
Row C E :- End N/A N/A 2550-8003 2550-9035 N/A N/A N/A
PS 1 2 3 4 E T est Point 2553-2013 Note :- T est Point is located under Part 2550-8002
Section
Page 8- 16

Valve Section
1 :- RH T rack 2550-6004 2550-9019 2550-9023
2 :-Feeder
2550-6014 2550-9042
Motor
Row B 2550-9017 2550-9025 2550-6010 2550-9018
3:- Recirc &
Stockpile 2550-6008 2550-9042
Conveyors 2550-6006
4:- Cone Lube
2550-9057
Motor
Section
Page 8- 17

Valve Section
1 :- RH T rack 2550-6004 2550-9019 2550-9023
2 :-Feeder
2550-6014 2550-9042
Motor
Row B 2550-9017 2550-9025 2550-6010 2550-9018
3:- Recirc &
Stockpile 2550-6008 2550-9042
Conveyors 2550-6006
4:- Cone Lube
2550-9057
Motor
Section
Page 8- 18
1000SR Hoses :- C 9 Powerpack
Hose R e fe r e nce Hose R e fe r e nce

Hose De scr iption ALL R 2AT U.O.S Hose De scr iption ALL R 2AT U.O.S
Numbe r Numbe r
ENGINE HOSES R HS Va lve Hose s
1.1/2 Fe ma l e nut / 2"ST x 3400mm 3/4 ST / Swe pt 90 x 950mm HP Mul t i s pi ra l a rmo ure d
HOSE 1 HOSE 12
Ta nk-Suct i o n Tra ck Bl o ck
1.1/2 Fl a nge 90 Swe pt / ST x 500mm 3/4ST / Swe pt 90 x 950mm HP Mul t i s pi ra l a rmo ure d
HOSE 2 HOSE 13
L H P ump-Suct i o n Tra ck Bl o ck
1.1/2 Fl a nge 90 Swe pt / ST x 1200mm 3/4 s we pt 90 / 25mm St Me t ri c Ma l e x 940mm
HOSE 3 HOSE 14
RH P ump-Suct i o n Fe e d Co nv-Va l ve /s t e e l pi pe
1/2"JIC ST / JIC 90Swe pt x 2000mm 3/4 s we pt 90 / 25mm St Me t ri c Ma l e x 940mm
HOSE 4 HOSE 15
Ca s e dra i n-P umps Fe e d Co nv-Va l ve /s t e e l pi pe
1/2"JIC ST / ST BSP x 5000mm 3/4 ST / 25mm ST Me t ri c Ma l e x 5000mm
HOSE 5 HOSE 16
Ca s e dra i n-Ta nk Fe e d Co nv-s t e e l pi pe /Mo t o r
1/4" ST / 7/16"JIC Swe pt 90 x 2800mm 3/4 ST / 25mm ST Me t ri c Ma l e x 5000mm
HOSE 6 HOSE 17
L .S. L H P ump Fe e d Co nv-s t e e l pi pe /Mo t o r
1/4" ST / 7/16"JIC Swe pt 90 x 2800mm 3/8 ST / ST x 12400mm
HOSE 7 HOSE 18
L .S. L H P ump e d Co nv-Mo t o r/Ta nk
3/4 ST / Fl a nge 90 Swe pt x 710mm HP Mul t i s pi ra l R e cir cula ting C onve yor ( R H Va lve )
HOSE 8
L H P ump-Fi l t e r
3/4 ST / s we pt 90 x 2850mm - Va l ve t o
3/4 ST / Swe pt 90 x 2530mm HP Mul t i s pi ra l HOSE 19
HOSE 9 Bul khe a d (s na p co nne ct o r)
Fi l t e r-L H Va l ve
3/4 ST / Fl a nge 90 Swe pt x 800mm HP Mul t i s pi ra l 3/4 ST / s we pt 90 x 1520mm - Va l ve t o
HOSE 10 HOSE 20
RH P ump-Fi l t e r Bul khe a d (s na p co nne ct o r)
3/4 ST / Swe pt 90 x 2500mm HP Mul t i s pi ra l 3/4 ST / s we pt 90 x 1500mm - s na p co nne ct o rn t o Co nve yo r
HOSE 11 HOSE 21
Fi l t e r-RH Va l ve (l o o p)
3/4 ST / s we pt 90 x 1500mm - s na p co nne ct o r t o Co nve yo r
HOSE 22
(l o o p)
HOSE 23 3/4 ST / s we pt 90 x 6900mm - Co nve yo r
HOSE 24 3/4 ST / s we pt 90 x 6900mm - Co nve yo r
HOSE 25 3/4 ST / ST x 560mm - Bul khe a d t o mo t o r
HOSE 26 3/4 ST / ST x 460mm - Bul khe a d t o mo t o r
Section
Page 8- 19
Hose R e fe re nce Hose R e fe re nce

Hose De scription ALL R 2AT U.O.S Hose De scription ALL R 2AT U.O.S
Numbe r Numbe r
Lube Motor ( R H Va lve ) C ross C onve yors
HOSE 27 3/8 ST / Swe pt 90 x 1230mm - Va l ve t o St e e l pi pe HOSE 40 1/2 ST / Swe pt 90 x 4000mm - Va l ve t o To p X Co nve yo r
HOSE 28 3/8 ST / Swe pt 90 x 1230mm - Va l ve t o St e e l pi pe HOSE 41 1/2 ST / Swe pt 90 x 1450mm - To p X Co nve yo r t o Bul khe a d
HOSE 29 3/8 ST / ST x 2600mm - St e e l pi pe t o mo t o r 1/2 ST / Swe pt 90 x 1800mm - Sna p co n t o L o we r X

HOSE 42
Co nve yo r
HOSE 30 3/8 ST / ST x 2600mm - St e e l pi pe t o mo t o r 1/2 ST / Swe pt 90 x 1800mm - L o we r X Co nve yo r t o Sna p
HOSE 43
Co nne ct o r
3/4 ST / Swe pt 90 x 2000mm - Re t urn Te e 'd i nt o Co o l e r
HOSE 31 1/2 ST / Swe pt 90 x 2750mm - Re t urn t o Ta nk f ro m Sna p
o ut l e t HOSE 44
Co nne ct o r
LHS Va lve
C one C ontrol
3/4 ST / Swe pt 90 x 950mm HP Mul t i s pi ra l Armo ure d -
HOSE 32
Tra ck bl o cks HOSE 45 1/2 ST / Swe pt 90 x 2200mm - Va l ve t o Co ne P a ne l (Fe e d)
3/4 ST / Swe pt 90 x 950mm HP Mul t i s pi ra l Armo ure d -
HOSE 33 HOSE 46 3/4 ST / Swe pt 90 x 1740mm - Va l ve Re t urn t o Co o l e r
Tra ck bl o cks
Product C onve yor HOSE 47 1.1/2 ST / ST x 3500mm - Oi l Co o l e r re t urn t o Ta nk
3/4 ST / ST x 1440mm - Co nt ro l P a ne l t o Che ck Va l ve
HOSE 34 3/4 ST / Swe pt 90 x 4850mm - Va l ve t o Bul khe a d HOSE 48
(Suct i o n)
HOSE 35 3/4 ST / Swe pt 90 x 4850mm - Va l ve t o Bul khe a d HOSE 49 3/4 ST / Swe pt 90 x 5300mm - Ful l bo re t o Co ne
HOSE 36 3/4 ST / ST x 970mm - Bul khe a d t o Mo t o r HOSE 50 3/4 ST / Swe pt 90 x 5000mm - Co ne - Annul a r s i de
HOSE 37 3/4 ST / ST x 990mm - Bul khe a d t o Mo t o r (Re t urn) HOSE 51 1/4 ST / ST x 5300mm - We dge Ci rcui t
HOSE 38 3/8 ST / ST x 1070mm - Bul khe a d t o Mo t o r (Bl e e d) HOSE 52 3/4 ST / Swe pt 90 x 4100mm - Re t urn t o Ta nk
HOSE 39 3/8 ST / Swe pt 90 x 7000mm - Bul khe a d t o Ta nk
Section
Page 8- 20
Hose R e fe r e nce Hose R e fe r e nce

Hose De scr iption ALL R 2AT U.O.S Hose De scr iption ALL R 2AT U.O.S
Numbe r Numbe r
T op Va lve Fe e d C onve yor
1.1/4 ST / Swe pt 90 x 4300mm - Auxi l l a ry P ump (Engi ne ) 3/8 ST / Swe pt 90 x 1130mm -
HOSE 53 HOSE 68
Suct i o n L i f t / L o we r Va l ve t o St e e l pi pe
3/4 ST / Swe pt 90 x 5520mm HP Mul t i Spi i ra l - Auxi l l a ry 3/8 ST / Swe pt 90 x 1130mm -
HOSE 54 HOSE 69
P ump t o Va l ve L i f t / L o we r Va l ve t o St e e l pi pe
HOSE 55 3/4 ST / Swe pt 90 x 1800mm - Re t urn t o Ta nk HOSE 70 3/8 ST / ST x 2350mm - L i f t / L o we r St e e l pi pe t o Cyl i nde r
Scr e e n HOSE 71 3/8 ST / ST x 2350mm - L i f t / L o we r St e e l pi pe t o Cyl i nde r

3/4 ST / Swe pt 90 x 5700mm HP Mul t i Spi ra l - Scr e e n R a ise / Low e r
HOSE 56
Va l ve t o Scre e n (Sna p co nne ct o r)
3/4 ST / ST x 1320mm HP Mul t i Spi ra l - HOSE 72 3/8ST / Swe pt 90 x 2760mm - Va l ve t o Che ck Va l ve (up)
HOSE 57
Sna p co nne ct o r t o Mo t o r HOSE 73 3/8ST / Swe pt 90 x 2760mm - Che ck Va l ve t o Va l ve (do wn)
HOSE 58 3/4 ST / Swe pt 90 x 380mm HP Mul t i Spi ra l - L o o p
HOSE 74 3/8ST / Swe pt 90 x 1320mm - Cyl i nde r Ra i s e
3/4 ST / Swe pt 90 x 1480mm HP Mul t i Spi ra l -
HOSE 59 HOSE 75 3/8ST / Swe pt 90 x 1320mm - Cyl i nde r Ra i s e
Mo t o r t o Bul khe a d (Fi ne s )
3/4 ST / Swe pt 90 x 3680mm HP Mul t i Spi ra l - HOSE 76 3/8ST / Swe pt 90 x 1320mm - Cyl i nde r L o we r
HOSE 60
Bul khe a d t o Bul khe a d (Fi ne s )
3/4 ST / ST x 700mm HP Mul t i Spi ra l - HOSE 77 3/8ST / Swe pt 90 x 1320mm - Cyl i nde r L o we r
HOSE 61
Bul khe a d t o Mo t o r (Che ck Va l ve )
HOSE 78 3/8ST / ST x 2100mm - Re t urn t o Ta nk f ro m T
HOSE 62 3/4 ST / ST x 740mm HP Mul t i s pi ra l - Mo t o r t o Bul khe a d
R e cir cula ting C hute
3/4 ST/Swe pt 90 x 3760mm HP Mul t i s pi ra l -
HOSE 63
Bul khe a d/Bul khe a d (Re t urn) HOSE 79 3/8ST / Swe pt 90 x 10800mm - L i f t
3/4 ST / Swe pt 90 x 1320mm HP Mul t i s pi ra l -
HOSE 64 HOSE 80 3/8ST / Swe pt 90 x 10800mm - L o we r
Fi ne s t o Sna p Co nne ct o r
HOSE 65 3/4 ST / Swe pt 90 x 3790mm - Sna p Co nne ct o r t o Co o l e r
3/8 ST / Swe pt 90 x 1540mm - Scre e n mo t o r bl e e d o f f t o
HOSE 66
Sna p Co nne ct o r
3/8 ST / ST x 7000mm - Scre e n bl e e d o f f Sna p Co nne ct o r t o
HOSE 67
Ta nk
Section
Page 8- 21
1000SR
Hose R e fe re nce Hose R e fe r e nce

Hose De scription ALL R 2AT U.O.S Hose De scr iption ALL R 2AT U.O.S
Numbe r Numbe r
R e circ ula ting Lift / Low e r Lubr ica tion Hose s
HOSE 99 3/8ST / Swe pt 90 x 2100mm - Cyl L i f t HOSE 89 3/4 ST / Swe pt 90 x 800mm - Ta nk t o St e e l pi pe

3/4 ST / 25mm S Me t ri c Ma l e x 1780mm -
HOSE 100 3/8ST / Swe pt 90 x 2100mm - Cyl L o we r HOSE 90
St e e l pi pe t o He a t Excha nge r
T ra ck Motors HOSE 91 He a t Excha nge r t o Co ne us e pa rt AX868-184-002
HOSE 81 1/4 ST / Swe pt 90 x 620mm - Bra ke Re l e a s e RH He a t Excha nge r(T) t o Co unt e rs ha f t us e pa rt

HOSE 92
AX868-184-003
HOSE 82 1/4 ST / Swe pt 90 x 620mm - Bra ke Re l e a s e L H HOSE 93 Co ne t o Ta nk - Re t urn us e pa rt AX868-184-001
HOSE 83 3/8 ST / Swe pt 90 x 260mm - Ca s e Dra i n RH HOSE 94 3/8 ST / ST x 4640mm - L H Va l ve t o HFO Va l ve
HOSE 84 3/8 ST / Swe pt 90 x 260mm - Ca s e Dra i n L H HOSE 95 3/8 ST / ST x 5410mm - Di ve rt e r Re t urn t o Ta nk
HOSE 85 3/8 ST / Swe pt 90 x 260mm - Ca s e Dra i n RH HOSE 96 3/8 ST / ST x 5410mm - Bl o ck Re t urn t o Ta nk
HOSE 86 3/8 ST / Swe pt 90 x 260mm - Ca s e Dra i n L H HOSE 97 3/8 ST / Swe pt 90 x 1900mm - Bl o ck t o Cl ut ch
HOSE 87 3/8 ST / Swe pt 90 x 4680mm - Ca s e Dra i n/Ta nk RH HOSE 98 1/2 ST / ST x 880mm - L o o p ho s e f o r X Co nve yo rs
HOSE 88 3/8 ST / Swe pt 90 x 4680mm - Ca s e Dra i n/Ta nk L H R e cir cula ting contr ol va lve hose s
3/4 ST / Swe pt 90 x 2850mm -
AX862HOSE101
s t o ckpi l e r t o re ci rcul a t i ng co nve yo r
Hoses Identification Label 3/8 ST / ST x 4900mm - s t o ckpi l e dra i n s na p co nne ct o r t o
AX862HOSE102
Ta nk
AX862HOSE103 3/4 ST / ST x 700mm - L o o p ho s e s t o ckpi l e
Section
Page 8- 22
Section 9:- Electrical

1000SR Equipment
Section 9 :- Electrical
Equipment
Section
Page
1000SR Section 9 :- Table of Contents
Section 9:- Electrical Equipment 9-1 R R C Components 9 - 15
Section 9 :- Table of Contents 9-2
Electrical Data 1000 SR 9-3
Control Box Location 9-5
Control Panel 9-6
Control Panel Internal 9-7
P.L.C. & Display Unit 9 - 10
Crusher Feed level Control 9 - 11
Crusher Control 9 - 12
Product Conveyor Motion Control 9 - 13
R R C System 9 - 14
Section
Page
1000SR Electrical Data 1000 SR
1000SR
R adio R emote R adio R emote
Parts R eference Plant Wiring
Plant Serial Numbers Panel MK Control ( R R C) Control ( R R C)
Page Diagram
System Parts Page
1000SR
QM018702 2686-0038
07_CAN-V00
QM018966 2686-0038
100101BASR 2686-0038
100102BASR 2686-0039
1000SR
100101BBSR MK1 2686-0039
07_CAN-MK1
100101BCSR 2686-0039
100106BDSR 2686-0039
100107BDSR 2686-0039
1000SR
9-6 Through 9-9 07_CAN-MK2 + 9-15
100108BDSR MK2 1000SR 2686-0042
07_CAN-MK2
860RRCMOD
1000SR
100114BESR MK1 2686-0042
07_CAN-MK1
100115BESR 2686-0042
100116BFSR 2686-0042
100121BGSR 1000SR 2686-0042

MK3
100122BGSR 07_CAN-MK3 2686-0042
100123BGSR 2686-0042
100127BGSR 2686-0042
Section
Page
1000SR Electrical Data 1000 SR
1000SR
R adio R emote R adio R emote
Parts R eference Plant Wiring
Plant Serial Numbers Panel MK Control ( R R C) Control ( R R C)
Page Diagram
System Parts Page
100133BHSR
100134BHSR
100135BJSR
100136BJSR
100137BJSR
1000SR
100138BJSR MK3 9-6 Through 11-9 2686-0042 9-15
07_CAN-MK3
100147BKSR
100148BKSR
100149BKSR
100150BKSR
100151BKSR
Section
Page
1000SR Control Box Location
Electrical Control Box Crusher Control Box Electrical Control Box Crusher Control Box
Section
Page
1000SR Control Panel
3 2
Powerpack Control Panel

4 Refer to Track Palnt Drives
Dealer Components
Manual
Section
Page
1000SR Control Panel Internal
Top Row
Middle Row
Bottom Row
Control Panel Internal

View
Section
Page
5 Top Row 6 7
12 13 14
8 Middle Row 9 10 11
Bottom Row
Section
Page
1000 SR 1000 SR
Item Description / Notes Qty Item De scr iption / Note s Qty
1 Audi bl e Warni ng Uni t 2683-2110 P L C 1000SR 2683-2217
13
2 Key 2683-2149 P L C Co nne ct o r 2683-2218 1
E/M St op But t on W i t h 2 1
3 2683-2193 14 RRC Dri ve r Mo dul e Refer t o Pages 11-14 & 11-15
N/C Bl ock
4 Text Di s pl ay 1000 SR. 2683-2220
Si ngl e Pol e Ci rcui t
2683-2227
Breaker 16 A
2683-2231
Breaker 6 A
2683-2229
Breaker 4A To Sui t
5
Si ngl e Pol e Ci rcui t Panel
2683-2230
Breaker 2A
2683-2228
Breaker 1A
Ci rcui t breaker auxi l l ary
2683-2232
cont act
6 Emergency St op Rel ay 2683-2155 1
11 Pi n Rel ay 2683-2106
7 2
Rel ay Bas e 2683-2106A
8 DC/DC Power Convert er 2683-2224

1
9 Heavy Dut y Rel ay 2683-2114
8 Pi n Rel ay 2683-2107
10 2
Rel ay Bas e 2683-2107A
11 Dump Load Modul e 2683-2219
Node 1 2683-2221 1
12
Connect or 2683-2222
Section
Page
1000SR P.L.C. & Display Unit
Item 4 & 13 Ordering Requirements

PLC Processor Unit is Programmed Specifically for
Individual Plants & for Operation with a Compatibly
Programmed Display Unit. Plant Serial Number and
Together with Plant Control System Model Data
Obtained from labels located as shown, MUST be
advised at time of Enquiry & Confirmed at time of
Order.
Section
Page 9 - 10
1000SR Crusher Feed level Control
1000 Maxtrak
Part Number
15 Crus he r Bo wl L e ve l
2683-2251
Se ns o r
Crus he r Bo wl L e ve l
15 2683-2288 1
Se ns o r Ca bl e
Crus he r Bo wl L e ve l
2683-2289
Se ns o r No de Ca bl e
Section
Page 9 - 11
1000SR Crusher Control
16
1000 SR
Part Number
16 Trans ducer 2666-9013 1
17 Junct i on Box 2690-0020 1
17
Section
Page 9 - 12
Product Conveyor Motion

1000SR Control
18
1000 SR
Part Number
Speed Sens or As s embl y 2366-0400

18 1
Cabl e for Speed Sens or 2683-2151
Section
Page 9 - 13
1000SR R R C System
A B
E
Item 3 : Identification
Red Button (Illustrated) Rest of World Model
Black Button European Model
Section
Page 9 - 14
1000SR R R C Components
R R C Unit 2686-0038 T rack Control Kit R R C Unit 2686-0042 T rack Control Kit
Item Part Number Description / Notes Qty Item Part Number Description / Notes Qty
A 2686-9029 Umbi l i cal 15 Pi n A 2686-9029 Umbi l i cal 15 Pi n
2686-9043 Trans mi t er 2686-9043 Trans mi t er

B B
2686-9044 Trans mi t er 2686-9044 Trans mi t er
C 2686-9008 Ant enna & Cabl e 1 C 2686-9008 Ant enna & Cabl e 1
24V/12V Ci gar Cabl e 24V/12V Ci gar Cabl e

D 2686-9025 D 2686-9025
Charger Charger
Recei ver Compl et e W i t h Recei ver Compl et e W i t h
E 2686-9028 E 2686-9034
Chas s i s Socket & Cabl e Chas s i s Socket & Cabl e
R R C Unit 2686-0039 T rack Control Kit
Item Part Number Description / Notes Qty
A 2686-9029 Umbi l i cal 15 Pi n
2686-9043 Trans mi t er
B
2686-9044 Trans mi t er
C 2686-9008 Ant enna & Cabl e 1
24V/12V Ci gar Cabl e

D 2686-9025
Charger
Recei ver Compl et e W i t h
E 2686-9033
Chas s i s Socket & Cabl e
Section
Page 9 - 15
NEW 860 RADIO MODIFICATION
CAN PLANT
(1000SR)
2. Re-connect wire 67 to relay K5

COM-11 or 21. [Note: The wire
should reach the relay, if not,
1. Remove wire 67 then use the new longer wire].
from terminal 67 and
re-mark terminal 68.
3. Connect the new wire 68
between Relay K5 NO-14 or 24 and
the newly marked terminal 68.
Normally Open
Contact on Relay
K5
RED wire feed to Tele-radio
Relay K5
1000SR Section 10 - Plant Items
Section 10 :- Plant
Items
Section
1 -1
Page
1000SR Section 10:-Table of Contents
Section 10 - Plant Items 10 -1 Recirculating Chute Liners 10 -15
Section 10:-Table of Contents 10 -2 Crusher Feed Box 10 -16
Feed Hopper Isometric 10 -4 Buffer & Anti Vibration Mounts 10 -17
Feed Hopper 10 -5 Drive Guard 10 -18
Feed Hopper Supports 10 -6 Maintenance Platforms 10 -19
Strickle Gates 10 -8 Side Maintenance Platforms 10 -20
Barge Boards 10 -9 Hydraulic Tank Platform 10 -22
Feeder Guards 10 -10 Walkway Panels 10 -23
Feed Conveyor TailGuards 10 -12 Plant Boxes 10 -25
Feeder Maintenance Platform 10 -13 Dust Suppression Manifold 10 -26
Recirculating Chute 10 -14 Spray Bars 10 -27
Section
2 -2
Page
1000SR Section 10:-Table of Contents
Swan Neck 10 -28
H Frame & Cross Conveyor Support 10 -29
Screen Support Arms 10 -31
Transport Brackets 10 -32
Crusher & Valve Chassis Guards 10 -33
Recirculating Conveyor Support Ropes 10 -34
Paint , Decals & Manuals 10 -35
Section
3 -3
Page
1000SR Feed Hopper Isometric
Feed Hopper
Strickle Gates
Bargeboards
Guards
Maintenance Platform
Section
4 -4
Page
1000SR Feed Hopper
1
2
Item Description / Notes 1000SR Qty
Part Number
1 Feed Hopper AX868/53/1 1
Cl a mp St ri p Ho ppe r Si de AX868/79/1 4
Screw ( Wel ded t o Hopper) 2226-0818 3 2

4/Cl amp
Nut 2217-0005
Cl a mp St ri p Ho ppe r Re a r AX868/79/3 1
3
Fi t t i ngs as i t em 2 3/Cl amp
Section
5 -5
Page
1000SR Feed Hopper Supports
5A
7A
5
5B
6A
7
7B 6
8 8A
Section
6 -6
Page
1000SR Feed Hopper
Item De scription / Note s 1000SR Qty Item Description / Notes 1000SR Qty
4 Fro nt Suppo rt Tre s t l e L o we r AX868/125/1 1 Pi n AX857/16/3

7B 2
5 Fro nt Suppo rt Tre s t l e Uppe r AX857/4/2 1 Spl i t Pi n 2201-0165
Pi n AX848/80/1 2 Fe e d Co nve yo r Re a r P i vo t AX857/1/3 2

5A
Spl i t P i n 2201-0167 Bol t 2232-1278
8
Pi n AX857/16/2 2 Was her 2210-0021 4/Pi vot
5B
Spl i t P i n 2294-0015 Nut 2217-0009
Fe e d Co nve yo r Fro nt P i vo t AX857/1/2 1 Pi n AX848/80/1

8A 2
Bo l t 2232-1278 Spl i t Pi n 2201-0167
6 Wa s he r 2210-0021 8
N ut 2217-0009
St a uf f Cl a mp 28mm Do ubl e 2512-5029 2
P i n (Tre s t l e t o Cha s s i s ) AX857/16/1 2

6A
Spl i t pi n 2201-0167 2
7 Cyl i nde r Refer t o Sect i on 8
Pi n AX857/16/4
7A 1
Spl i t P i n 2201-0167
Section
7 -7
Page
1000SR Strickle Gates
9D
9C 9B 9A
9E
Part Number
9A Si de Gat e AX857/49/3 1
9B Cent re Gat e AX857/49/4 1
9C Si de Gat e AX857/49/2 1
Angl e Mount i ng Bracket AX857/49/1 1
Bol t 2232-1203
9D
Was her 2210-0019 8
Nut 2217-0007
Hi nge Pi n AX857/49/5 1
9E
Pl ug 2510-3850 2
Section
8 -8
Page
1000SR Barge Boards
13
10D
11 Part Number
L H Ba rge Bo ra d Ext e ns i o n
11 AX857/76/2 1
Pl at e
12 Ba rge Bo a rd Ri ght Ha nd AX868/59/1 1
RH Ba rge Bo ra d Ext e ns i o n
13 AX857/76/1 1
Pl at e
Ext e ns i o n P l a t e Ba rge Bo a rd
14 AX868/135/1 1
(RH)
10
12
10
11 13
10A 12
12
Item De scription / Note s 1000SR Qty
10B 14
Part Number
10 Ba rge Bo a rd L e f t Ha nd AX868/59/2 1 10C

10A
Cl a mp St ri p Ba rge bo a rd
AX868/79/2 2
10D 10A
U ppe r
10B Ins e rt Cl a mp Fl a t AX848/62/2 2 10D 10B
Cl a mp St ri p Ba rge bo a rd
10C AX868/79/4 2
L o we r
10C
10D Ba rge Bo a rd Ins e rt HDP E AX848/62/1 2
Section
9 -9
Page
1000SR Feeder Guards
15
A D
K
M L C
H
G F E F G
Section
10 - 10
Page
1000SR Feeder Guards
Item De scription / Note s 1000SR Qty
Part Number
15A Head Barge Board Guard LH AX868/87/12 1
15B Mi d Barge Board Guard Short AX868/87/10

2
15C Mi d Barge Board Guard Long AX868/87/9
15D Lower Barge Board Guard LH AX868/87/8

Hopper / Barge Board Guard 1
15E AX868/87/6
LH
15F Front Hopper Guard AX868/87/4
4
15G Mi d Hopper Guard AX868/87/3
15H Lower Hopper Guard LH AX868/87/2
15J Head Barge Board Guard RH AX868/87/11
15K Lower Barge Board Guard RH AX868/87/7 1

Hopper / Barge Board Guard
15L AX868/87/5
RH
15M Lower Hopper Guard RH AX868/87/1
Fi xi ngs per Guard
Screw 2230-1121
Was her 2211-0007 4/Guard
Was her 2210-0016
Section
11 - 11
Page
1000SR Feed Conveyor TailGuards
16
B A
Part Number
A C
D 16 Tai l Drum Guard
E
16A Guard AX857/90/1 1
Bracket Ri ght Hand AX857/90/2 1
Bracket Left Hand AX857/90/3 1

16B
Bol t 2232-1125
6/Bracket
Bot t om Pl at e AX857/90/5 2
16C Bol t 2232-1125

E D 6/Pl at e
16D Cl amp AX857/90/4 1
Scraper AX8868/105 1
C 16E Bol t 2232-1125

4/Scraper
Was her 2211-0008
Section
12 - 12
Page
1000SR Feeder Maintenance Platform

17 17F 17A
Upper Pl at form Out er Handrai l AX848/26 1
17G Bol t 2232-1201
17A
Was her 2210-0019 6
17F Nut 2217-0007
17H 17B Upper Pl at form Support AX857/12/1 1
Shi ps Ladder Handrai l AX857/14/1 1
Bol t 2232-1201
17C
Was her 2210-0019 4
Nut 2217-0007
Shi ps Ladder AX857/11/1 1

17D
Spacer AX857/11/2 2
Shi ps l ader Bracket l ower i nner AX848/30 1
Bol t 2232-1201
17E
Was her 2210-0019 3
17B Nut 2217-0007
Upper Pl at form Inner Handrai l AX848/106/1 1
Bol t 2232-1201
17C 17F
Was her 2210-0019 4
Nut 2217-0007
17E 17D 17G Sel f Cl os i ng Gat e AX857/74 1
17H Refer t o Page 10-23
Section
13 - 13
Page
1000SR Recirculating Chute
18A 18D 18E
18A
18F
18F
18K 18B
18G
18N
18C 18H
18P
18M
18L 18J
Section
14 - 14
Page
1000SR Recirculating Chute Liners
Item Description / Notes 1000SR Qty Item Description / Notes 1000SR Qty
18;- Part Number 18;- Part Number

18A Re ci rcul a t i ng Chut e AX868/12/1 1 Si de Li ner Ri ght Hand AX868/85/3 1
18B Support Bracket Out e r AX868/12/4 1 Scre w SKT CSK 2226-0815
18C Support Bracket Inner AX868/12/3 1
18H
Nut 2217-0005 5
Fe e d Chut e To p Co ve r AX868/12/2 1
Was her 2210-0017
Scre w H e x 2230-1091 4
18D Pi vot Pi n AX868/95/1 1
Was her 2210-0015
18J Was her 2210-0023
Was her 2211-0006 2
Spl i t Pi n 2201-0147
Ext ended Li ner Pl at e AX868/137/1 1
18K Fo l d Cyl i nde r re f e r t o pa ge 8-10
Scre w SKT CSK 2226-0815
18E 18L
Nut 2217-0005 8
Refer t o Page 8-10
Was her 2210-0017 18M
Rubber Li ner AX868/92/1 1 18N Chut e Suppo rt St rut AX868/122/1 1
Scre w SKT CSK 2226-0816 Pi n AX868/122/2

18F 18P 1
Nut 2217-0005 6 L i nch P i n 2294-0015
Was her 2210-0017
Si de l i ner Left Hand AX868/137/2 1
Scre w SKT CSK 2226-0815

18G
Nut 2217-0005 5
Was her 2210-0017
Section
15 - 15
Page
1000SR Crusher FeedBox
20B
Item De scription / Note s 1000 Maxtrak Qty
Part Number
Crus her Feed Box AX868/20/1 1
Bo l t 2230-1222
19 Was her 2210-0019 5

20A
Was her 2211-0010
Ant i l uce Fi t t i ng 2294-0009 4
Crus her Feed Box Door AX868/20/2 1
Bo l t 2232-1286 2
19A
19A 19 Was her 2210-0021 4
Nut 2217-0009 2
Level Probe Support AX868/120/1 1

20A
Cl amp 2512-4029 2
20B Feed Box Sens or Guard Top AX868/171/1 1
Section
16 - 16
Page
1000SR Buffer & Anti Vibration Mounts
1000 SR Qty
Item Description / Notes
Part Number
21 Buf f er Support Bracket AX857/33/1 2

21A
Cover Pl at e AX857/33/3 2
Bo l t 2232-1090
21A
Was her Spri ng 2211-0007 4/Cover

21 21B
Shi l d Crus her Foot
AX868-213-001 2
21B ( Rubber)
22 Rubber Buf f er 2389-1001 6
As
23 Spacer AX857/33/2
Requi red
Screw 2226-0815
Was her 2210-0017 2/Buf f er

22 & 23
Nut 2217-0005
22
Ref er t o Servi ce Bul l et i n SP046 04
23 24A 24 Cone Support Bracket AX848/18/1 2
Was her 2210-0025

24A 1/Bracket
24 Nut 2217-0013
25 Anti vi brati on Mount 2389-0250 4

25 Bol t 2232-1126 4/Mount
25A 25A Was her 2210-0019
8/Mount
Nut 2217-0005
Section
17 - 17
Page
1000SR Drive Guard

B 26
Part Number
26 Dri ve Guard AX848/59 1
26A Upper Dri ve Guard Panel AX848/59/3 1

A
Ins pect i on Cover AX848/59/4 1
Bol t 2232-1090
26B
G B Was her Spri ng 2211-0007
26C AX848/59/1 1
A Lower Dri ve Guard Panel
26D AX848/59/2 1
Bol t 2232-1125
C&D Was her Bri ght 2210-0017 14
C F Nut 2215-0014
Support Angl e AX848/59/6 2

D Bol t 2232-1125
26E
E 26F
Support Angl e AX848/59/5 2
Fi xi ngs As "E"
G
Cl amp AX848/59/7 2
Bol t 2232-1125
F 26G Was her Bri ght 2210-0017 2/Cl amp
D E Was her Spri ng 2211-0014
Rubber AX857/24/1 1
Section
18 - 18
Page
1000SR Maintenance Platforms
17 :- Refer to
Page 10-13 27 :- Refer to 28:- Refer to Page 29 :- Refer to
Page 10-20 10-20 Page 10-22
30 :- Refer to
Page 10-20
Section
19 - 19
Page
1000SR Side Maintenance Platforms
30B
28D1, D2 & D3 30C
27E
27F
30A
30D
28E
28A
28B
28C
27C 27B 30E
27D1 & D2
27A
Section
20 - 20
Page
1000SR Side Maintenance Platforms
Item Description / Notes 1000SR Qty Item Description / Notes 1000SR Qty Item Description / Notes 1000SR Qty
Part Number Part Number Part Number
Lower Pl atform Frame AX848/42/2 1 Pl atform Frame Outer AX868/24/1 1 30A Engi ne Pl atform AX868/77/1 1
Bol t 2232-1202 Screw 2226-0816 30B Wal kway Refer to Page 10-23
27A 28A
Washer 2210-0019 6 Was her 2210-0017 9 Engi ne Pl atform Handrai l AX868/57/1 1
Nut 2217-0007 Nut 2217-0005 Bol t 2232-1202

30C
Support AX848/43/2 1 Pl atform Frame Inner AX868/24/2 1 Was her 2210-0019 10
Bol t 2232-1202 Screw 2226-0816 Nut 2217-0007

27B 28B
Washer 2210-0019 3 Was her 2210-0017 9 30D Wal kway Refer to Page 10-23
Nut 2217-0007 Nut 2217-0005 Frame Pi n AX868/68/2 2

30E
Support AX848/43/1 1 Engi ne Pl atform Handrai l AX868/26/1 1 Spl i t Pi n 2201-0164 1/Pi n
Bol t 2232-1202 Bol t 2232-1202

27C 28C
Washer 2210-0019 3 Was her 2210-0019 10
Nut 2217-0007 Nut 2217-0007
27D1 & D2 Wal kway Refer to Page 10-23 28D1 -D3 Wal kway Refer to Page 10-23
Crusher Pl atform Handrai l AX848/84/1 1 Engi ne Pl atform Support AX868/66/1 1
Bol t 2232-1202 Bol t 2232-1202

27E 28E
Washer 2210-0019 4 Was her 2210-0019 5
Nut 2217-0007 Nut 2217-0007
27F Safety Gate AX857/47 1
Section
21 - 21
Page
1000SR Hydraulic Tank Platform
29C
Part Number
29A Engi ne Si de Ki cki ng St ri p AX848/37/2 1
Bol t 2232-1127
29A
Was her 2210-0017 4
29B Nut 2217-0005
29B Wal kway Refer t o Page 10-23
29C Handrai l AX868/67/1 1
Section
22 - 22
Page
1000SR Walkway Panels
17H 27D2 27D1 28D3 28D2 32D1
Walkways
17H Upper Pl at form Fl oor Panel AX857/13/1 1
27D1 AX848/44/1A 1
29B 27D2
Lower Pl at form Fl oor Panel
AX848/44/1B 1
28D1 AX868/25/3
28D2 Engi ne Pl at form Fl oor Panel AX868/25/2 1
28D3 AX868/25/1
29B Engi ne Pl at form Fl oor Panel AX868/34/1 1
30B Wal kway ( Front ) AX868/86/1

1
30D Wal kway ( Incl i ned) AX868/86/2
30B 30D
Section
23 - 23
Page
1000SR Rear Guards & Engine Beam
31
31B
31A
34
31C
33
32
31A Open Mes h Tank Cover AX848/96/1 32 Guard Rai l ( Crus her Engi ne) AX868/129/1 1
31B AX868/116/1 1 33 Guard Rai l ( Chas s i s ) AX868/128/1 1

Pl at e Tank Cover
31C AX857/70/1 Engi ne Support Beam AX868/15/1 1
34
Engi ne Support Bracket Refer t o Sect i on 4
Section
24 - 24
Page
1000SR Plant Boxes
38
Part Number
36 Cont rol Box Body AX868/93/1 1

39A
36A 44 Cont rol Box Li d AX868/93/2 1
Screw 2230-1091 6
36A
Was her 2210-0015 12
Nut 2215-0012 6
37 Gas St rut 2563-0006 2
38 Lock 2301-0001 2
39 Hydraul i c Cabi net Body AX868/94/1 1
Cont rol Box Li d AX868/94/2 1

37 36 37 39 39A
Fi xi ngs as |It em 36A
40 Sl edgi ng Bar 603/1051 1
41 Greas e Gun 2968-4101 1
Greas e Gun ( Mol y) 2968-4102 1

40 41 42 42
Mol ygreas e Cart ri dge 400gm 2123-2002 1
43 Met al Det ect or Tes t Bl ock AX860/151 1
44 Operat i on Manual s Refer To Page 8-33
43
Section
25 - 25
Page
1000SR Dust Suppression Manifold
Item Part Number Description Qty
1000SR AX868-182-601 Dus t Suppres s i on Ki t 1
48 45 AX815/132/1 Ma ni f o l d Suppo rt Bra cke t 2
46 2556-3001 Gat e Val ve 3
47 2550-1004 Bal l Val ve 3
48 2531-8001 In-Li ne Fi l t er 1
46 47 45
Section
26 - 26
Page
1000SR Spray Bars
51
49 50
Part Number
Crus he r Fe e dBo x AX848/78/2K 1
49 Wat er Spray Jet 2540-0006 3
Hos e 2526-4004A 12Mt r
P ro duct Co nve yo r Ta i l AX848/78/3K 1
Hos e 2526-4004A 10Mt r
Fi ne s Co nve yo r Head AX862/159K 1
Hos e 2526-4004A 15Mt r
Section
27 - 27
Page
Swan Neck
1000SR
Screen Support Arms
H Frame & Cross

Conveyor Support
Section
28 - 28
Page
H Frame & Cross Conveyor

1000SR Support
57
58
52
59
56A 60
53
54
55
56
Section
29 - 29
Page
1000SR

QM018702 57 & 58 :- QM018966 Onwards Onl y
Front Support Frame AX868/16/1 1 57 Rol l er AX862/260/1
52
QM018966 Onwards Bol t Hex 2232-1283
9
Front Support Frame AX868/144/1 1 58 Was her 2210-0021
Front Frame Pi n
AX862/56/4 Nut 2217-0009
53 (Frame/Screen Frame) 2
Spl t Pi n 2201-0167 59 Cover Ai rbl as t Cool er AX862/96/2 1
Front Frame pi n ( Frame/ 60 Ai rbl as t Cool er Frame AX862/96/1 1
AX862/56/3
54 Hori z ont al Frame) 2
52A
Spl t Pi n 2201-0169 Support St rut AX868/96/1 2
See Page 10-31
QM018702 Onl y 52B
Ri ggi ng Screw 2323-0006 2
See Page 10-31
Lower Cros s Conveyor Support
55 AX862/197/1 1
Rai l
End St op AX862/197/2 1
QM018702
Hori z ont al Frame AX868/16/2 1

56
QM018966 Onwards
Hori z ont al Frame AX868/144/2 1
QM018702
Upper Cros s Conveyor
AX868/16/3 1
Support
Spri ng Bol t 2294-0002 1
56A
QM018966 Onwards
Upper Cros s Conveyor
AX868/144/3 1
Support
Spri ng Bol t 2294-0002 1
Section
30 - 30
Page
Screen Support Arms

1000SR
61 52A 52B
62 Item Description / Notes 1000SR Qty
Part Number
61 Chas s i s Mount i ng Pi n AX862/60/1 2
63 62
Out er Member :- Screen
Support St rut
AX862/45/1 2
63 St rut Adj us t i ng Pi n AX862/60/2 2

Inner Member :- Screen
64 AX862/45/2 2
Support St rut
St rut Cyl i nder pi n AX862/60/3 2
Bol t Speci al AX868/80/1 2

65
64
Nut 2217-0011 1/Bol t
65
Section
31 - 31
Page
Transport Brackets
1000SR
66
Part Number
66 Travel Bracket Chut e Tres t l e AX868/130/1 1

Reci rcul at i ng Conveyor Travel
67 AX868/167/1 1
Bracket
Li nch pi n 2294-0015 1
68
Travel Bracket Pi n AX868/114/3 1
67 69
69 Refer t o SR Screen
71 72
70 Travel Brkt Locat i ng pi n AX868/158/1 1
QM018966 Onwards
71 Upper Conveyor Travel Brkt AX868/157/1 1
Lower Conveyor Travel Brkt AX868/156/1 1
72 Spri ng Bol t 2294-0002 2

68
70
Section
32 - 32
Page
Crusher & Valve Chassis

1000SR Guards
74
Part Number
73
73 AX868/89/2 1
Guard Cone Bas e
74 AX868/89/1 1
1
76 75 Val ve Guard ( 2550-9016) AX868/160
Val ve Guard ( 2550-9044) AX868/162 1

Val ve Guard ( 2550-
76 AX868/163 1
9045/9060/&9065)
Val ve Guard ( 2550-
AX868/166/1 1
9045/9060/&9065)
1
77 Lever Guard AX857/45
75
77
Section
33 - 33
Page
Recirculating Conveyor
1000SR Support Ropes
Part Number
78 W i re Rope As s y AX868/78 1
79
Ri ggi ng Screw 2323-0008 1
78
Section
34 - 34
Page
1000SR Paint , Decals & Manuals
Paint Finish
Plant Plant C olour T rack C olour Decal C olour Warning:- Plant Parts are Supplied in Primer
or Suppliers Standard Colour Unless Quoted
St andard Bl ue RAL5015 RAL7015 W hi t e
& Ordered Otherwise
Decal Set Part Number
1000 SR AX868DECALUK
1000 SR
Language Maxt rak Aut omax/Sand
Pl ant Warni ng Pl ant Cone
Decal Set Operat i on Operat i on
Label Ki t Label s
Manual Manual
Dani s h AX868LABELDA
Dut ch AX868LABELDU 603/P70CP/DU UM1000SRDU UM1000AMDU
Fi nni s h AX868LABELFI
Warning Labels are Available as
French AX868LABELFR 603/P70CP/FR UM1000SRFR UM1000AMFR Complete kits only
German AX868LABELGE 603/P70CP/GE UM1000SRGE UM1000AMGE
Greek AX868DECALUK AX868LABELGK 603/P70CP/GK
It a l i a n AX868LABELIT 603/P70CP/IT UM1000SRIT UM1000AMIT
Port ugues e AX868LABELPO 603/P70CP/PO UM1000SRPO UM1000AMPO
Spani s h AX868LABELSP 603/P70CP/SP UM1000SRSP UM1000AMSP
Engl i s h UM1000SRUK UM1000AMUK

AX868LABELUK 603/P70CP
USA UM1000SRUS UM1000AMUS
Section
35 - 35
Page
1000SR Section 11:- Tracks
Section 11 :- Tracks
Section
Page
Section 11:- Tracks 11-1
Section 11:- Table of Contents 11-2
Track Expanded View 11-3
Drive Group 11-5
Motion Control Valve 11-7
Idler & Tension Group 11-8
Track & Support Rollers 11-9
Section
Page
1000SR Track Expanded View
Drive Group
Idler & Tension Group
Track & Support Rollers
Section
Page
1000SR
Important:- S Track Serial Number S Track Serial Number
“S” tracks contain serial number dependant Part number columns contained in this section are
components. To negate potential for in-correct service divided into A & B
or parts supply, it is of prime importance track serial Column A covers “S” tracks having serial numbers
number is confirmed at time of enquiry and before Up to and including 184056 & including 184411,
commencement of works. 184412, 184507 & 184845, excluding 183999
Transactions effected without a serial number are Column B Covers “S” tracks having serial numbers
performed entirely at Dealers / Customers risk. 184145 Onwards & including 183999, excluding
184411, 184412, 184507 & 184845
“S” Traks Serial Number

Location
“T” Traks Currently Not
Fitted to 1000SR
Section
Page
1000SR Drive Group
Item 1 Warning :-
1a It is Recommended that the Track Drive Unit & Hydraulic Motor are
NOT Opened in Site Conditions
Gearbox units are Only Supplied Complete with Motor
1c
1b
1
2a
2
Section
Page
1000SR
Part Number
Q
Item Q Description
1000 SR T
"T " T racks T
"S" T racks Y
Y
Serial
A B
Number
2372-0110 2372-0129 2 Mot or & Gearbox
2372-0088 4 Gearbox Drai n Pl ug
N/A Was her
2372-0078 2 Adapt or
1 2372-0079 2 Bonded Seal
AX818TRAKS04 2 St and Of f Pi pe
2520-6595 4 F/F Ext ent i on
N/A 2520-6006 4 N/A M/M ni ppl e
2500-1021 4 Bonded St eal
2372-0107 32 Caps crew

1a
N/A Spri ng Was her
1b 2372-0086 2372-0130 2 Hydraul i c Mot or

Dri ve Mot or Mai n
1c 2372-0119 2372-0131 2
'O' ri ng
2 2372-0111 2372-0108 2 Sprocket
2372-0109 40 Bol t
2a
N/A Spri ng Was her
Section
Page
1000SR Motion Control Valve
Part Number
Item Q Q Description
1000SR
T "T " T racks T
"S" T racks
Y Y
Serial
3 Number
A B
Mot i on Cont rol

2550-9003
Val ve
3a
TBA 2 Seal Ki t
N/A
2550-9004 Trans f er Pl at e
3b
TBA Seal Ki t
3a & 3b 2222-0188 8 Mount i ng s Srew
3a 3b
Section
Page
1000SR Idler & Tension Group
4 5 6
Item 6 Warning :
Do Not Attempt to Dismantle Recil Units.
Specialist Workshop Equipment is Necessary
Part Number
Item Q Q Description
1000SR
T "T " T racks T
"S" T racks
Y Y
Serial
A B
Number
4 2372-0073 2 Front Idl er
N/A
5 2372-0074 2 Yoke
6 2372-0072 2
Recoi l /
Tens i oner
7 N/A
8 9 10 11 Greas er for
8 AX818TRAKS02 2
Tens i oner
9 AX818TRAKS03 2 Gas ket for Greas er
N/A
10 AX818TRAKS01 Adapt or
11 2372-0075 2 Tens i oner Seal Ki t
Section
Page
1000SR Track & Support Rollers
Part Number
12a Item Description

1000 SR QT QT
"T " T racks
"S" T racks Y Y
Serial
A B
Number
12 2372-0017 16 Lower Rol l er
2372-0018 Bol t
12a 64
2372-0019 Was her
12 Track Chai n
13 2372-0112 2
Compl et e
N/A
14 2372-0010 Repai r Li nk Ki t
Track Shoe 400
15 2372-0007 112
14 W i de
2372-0008 Track Shoe Bol t
13 15 16 448
2372-0009 Track Shoe Nut
Mas t er Pi n &
17 2372-0011 2
Col l ars
Torque Set t i ngs
It e m Torque t o
2372-0008 Torque t o 358Nm ( 264l bs ft )

17 2372-0107 Torque t o 615Nm ( 454l bs ft )
16
Section
Page
1000SR Section 12:- Optional Items
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A - 11 2- 1
Page
Section 12:- Optional Items 12 - 1
Section 12:- Table of Contents 12 - 2
Refuelling Pumps 12 - 3
Feed Hopper Extensions 12 - 4
Section
Page
1000SR Refuelling Pumps
Item Part Number Description / Notes Qty
1 1 2573-7002 Pump & Mot or 1
Model 23540-1330
1A 2573-7006 Servi ce Ki t 1
Name Plate
1B 2573-7007 Rot or 1
Model s VM 050-2112 & VM050-2122
1A 2573-7008 Servi ce Ki t 1
2
1B 2573-7009 Rot or 1
Hos e Component s
2 2573-7003 90 Deg Hos e Bend 2
3 2573-7004 Hos e Ki t 1
3
4 2573-7005 St rai ner 2
Not e:- Pump Model Number cont ai ned on name Pl at e MUST be conf i rmed a
at t i me of pl aci ng Order . Trans act i ons perf ormed wi t hout a model number are
ef f ect ed ent i rel y at Deal ers / Cus t omers Ri s k
Refuelling Pump Kit Part Numbers 2573-7001 & 2573-7010
Section
Page
1000SR Feed Hopper Extensions
1000 SR Qty
Item Description / Notes
Part Number
Feed Hopper Extens i on
AX857/35 1
Pl ates Set
Bol t 2232-1282 8
Bol t 2232-1279 3
1 Bol t 2232-1289 4
Screw 2226-0889 10
Was her 2210-0021 40
Nut 2217-0009 25
Section
Page
1000SR Table of Contents
Table of Contents 13 - 1
Diagnostics 13 - 2
Diagnostics - Feed Conveyor 13 - 3
Diagnostics - Metal Detector 13 - 5
Diagnostics - Crusher 13 - 7
Diagnostics - Powerpack 13 - 13
Diagnostics - Screen 13 - 15
Diagnostics -Conveyors 13 - 19
Hydraulic Trouble Shooting 13 - 20
Test Data 13 - 27
Section
1 -1
Page
1000SR Diagnostics
Diagnostics
This Section covers possible malfunctions of the Plant, Identifies the fault, indicates possible cause(s) and provides the initial procedure
to remedy the occurrence or establish a source from which a detailed investigation can be undertaken. Dealers must be aware a mal-
function may hold a number of interrelated causes .
The Section should be considered as a Guide only to a possible fault which must always be confirmed by customer prior to supply of
spare parts & repair attempted.
Procedures referenced in this section are contained in Plant Users Manual supplied with the Machine
It is the responsibility of the Owner , End User, Safety Officer and / or Fitter to ensure any work is performed by a suitably quali-
fied competent person and in accordance with all Statutory and any other regulations.
Section
2 -2
Page
1000 SR Diagnostics - Feed Conveyor
Symptom Possible Fault Correction
Belt Tracking off Centre Belt Tension Not Even Adjust Belt Tension
Trough & / or Parallel Idlers Out of Square Adjust Trough Sets and /or Parallel
Roller Alignment
Conveyor Belt Obstructed Clear Obstruction, Adjust & train Belt
Screeching Noise when Belt Is Running Lack Of Bearing lubrication Check Grease Pipes & Replace as
Required Check Bearings & Replace as
Required
Conveyor Belt Obstructed Clear Obstruction, Adjust & Train Belt
Scrapers In-correctly Adjusted Adjust Scrapers or Replace if Worn
Trough or Parallel Rollers Failed Replace Rollers
Conveyor Belt Slipping on Head Drum Tension or Replace Belt
Stone(s) Trapped on Structure, Drums or Rollers Clear Obstruction
Belt Fails to Run Drive Motor & /or Gearbox Failure Investigate & repair or replace as Re
quired
Valve Actuator Failure Replace Actuator
Electrical Failure Check Circuit (s)
Slipping or Broken Pump Drive Belts Adjust Drive or Replace Belts
Pump Failed Replace Pump
Conveyor Belt Broken Replace Belt
Spool Valve Sticking Remove & Clean or Replace
Section
3 - 3
Page
1000 SR Diagnostics - Feed Conveyor
Uneven Discharge of Material Feed Hopper Loading off Centre Ensure Feed directed On to Feed
Hopper Impact Bar
Strickle Gate(s) Obstructed Clean out Obstruction Check Gate & / or
Hinge Pin for Damage
Section
4 - 4
Page
1000SR Diagnostics - Metal Detector
Normally , once the metal detector has been set up at the time of commissioning there should be no need to alter installation or any of the controls within the
control cabinet . However in event of subsequent adjustment being necessary reference to Plant Maintenance section of “ Plant User Manual” will be required.
False trips may be produced from environmental interference.
Environmental Interference
The Metalarm Control Unit generates a high frequency alternating field within and near the sensor coil. While the field is strongest on the sensor coil face or in the
throat of the sensor coil , it is inherent in the sensor coil design that a certain amount of the field exists outside of the sensor coil. Certain environmental condi-
tions may sometimes effect this alternating field causing false and erratic signals.
If after installation the unit does not work properly , check for compliance with the following hook-up and installation details before proceeding to the specific
causes of interference.
All cable connections should be tight on the terminal blocks in the control unit . Any sensor coil lead splices should be soldered & taped.
The power source cables should be isolated from varying inductive loads and should be run in separate conduit.
The control unit should have a good electrical ground connection.
In certain locations more than one problem may exist and the problems may be interrelated.
Observing the installation site and the operation of the metal detector for repeating symptoms is very helpful in isolating the causes of the problem.
Correlating malfunctioning occurrences is invaluable for environmental interference trouble shooting.
Observe whether interference occurs at certain specific times and in conjunction with specific activity.
Observe whether interference occurs when operated by certain personnel or only after physical change of the environment.
Use the following to help diagnose problems and problem sources and to implement corrective measures.
Basically environmental interference may be of four types
Section
5 -5
Page
1000SR Diagnostics - Metal Detector
Movement of Metal. Metal objects moving into or out of the electromagnetic field of the sensor coil
Large masses of metal such as Shaker screens , metal deflection plates , Vehicles etc may effect metal detector operation even when at a considerable
distance from the sensor coil . Other smaller masses of moving metal when sufficiently close to the search unit may also cause false trips.
Interference may exist outside of the immediate location & hidden from operators view
Intermittent loops of Metal surrounding the Sensor ( Shorted Turns) . A source of interference which is difficult to recognise is that of the shorted turn . A
shorted turn is formed by metal pieces forming a complete path in some plane around or near the sensor.
If it is intermittent , as in the case of two pieces of conduit occasionally touching together , the detector will trip each time the conduits make or break
connections. The intermittence may be caused by physical deflection or vibration of equipment and by expansion or contraction of metal due to tempera-
ture changes
The effect of the “Shorted Turn” is that of a secondary “Coil” or “Turn” coupled to the metal detector sensor coil. The varying load of this secondary “coil”
when it makes or breaks is reflected to the sensor coil tripping the control unit.
The following metal objects may be part of or form a “ Shorted Turn” by themselves : metal framework , pipes, conduit , flexible conduit , guard railing ,
metal catwalks conveyor rollers etc.
Excessive Line Voltage Fluctuations . Electrical interference may be in the form of line voltage “ spikes” caused by on/off varying inductive loads of electrical
equipment on the same power line as the metal detector , or other lines in close proximity to the supply line of the metal detector.
Proximity of Severe RF Radiation Sources. Electrical or electronic interference can be radiated into the sensor coil or introduced into the metal detector from
other energy emitting devices i.e Arcing Motors , Arc Welders , Arcing Relay Points
Section
6 -6
Page
1000 SR Diagnostics - Crusher
Machine Stops Power Failure Check Powerpack & Repair

Broken Drive Belts Replace Drive Belts
Crusher Blocked Refer to Blocked and/or Stalled Crusher
Situation
Lubrication Failure Investigate for Leaks & Pump Failure
Interlock Operation Identify Fault & Rectify
Overload Closed Side Setting ( C.S.S) to Low Clear Machine & Adjust C.S.S
Tramp Metal Fixed in Crushing Chamber Refer to Blocked and/or Stalled Crusher
Situation
Packing in Crusher Chamber Clear Machine, Correct Grading & Re-
move excess fines ,if present From Feed
Stock
Excessive Speed Variations Drive Belt Sipping Inspect Drive Belts Re-tension or Replace
Clutch Slipping Inspect , Adjust or Repair Clutch
Engine Speed Incorrect Refer to Operating Instructions
Low Capacity Crusher Damaged or Worn Stop & Inspect Repair as Required
Speed Incorrect Refer to Operating Instructions
Worn Manganese Replace Manganese
Manganese Profile Incorrect Replace Manganese with Suitable Profile
Feed Rock Shape not “ Gripped” by Chamber Adjust Primary Crusher to Provided
Reduced Feed Size
Change Manganese for “ Coarser” Cham-
ber
Section
7 - 7
Page
Low Capacity Cntd Bridging over Crusher Chamber Slabs in Feed :- Investigate Primary
Reduction & Modify Pre Screen to
Extract from FeedStock
Incorrect Drive Tension Adjust and /or Replace Drive Belts
Incorrect Clutch Adjustment Adjust Clutch
Incorrect Close Side Setting Adjust Crusher Setting
Sticky Material Remove Clay and/or Fines From Feed,
Clean Manganese & Crusher Chamber
Lack of Raw Material, Erratic Feed, Correct Grading & Condition Of
Feed Oversize, Inclusion of Fines Feed Material
Excessive Wear Loose Manganese Check Manganese Seating Tighten

Wedge and /or Replace Manganese
Change to Feed Characteristics Change Manganese Specification
Excessive Moisture Endeavour to dry material prior to Crush-
ing
Material Very Abrasive Change Manganese Specification
Excessive Fines In Feed Material Blend Feed Material to Provided a
Graded Feed
Crusher Operating Below Minimum Recommended Adjust Crusher Setting
Closed Side Setting
Crusher Speed High Refer to Operating Instructions
Section
8 - 8
Page
Manganese Worn “Out of Round” Check Feed Stock & Feeder for Segrega-
tion , Replace Manganese
Lack of Raw Material, Erratic Feed,) Correct Grading & Condition Of
Feed Oversize, Inclusion of Fines ) Feed Material
Crushing Pressure to High Hard Rock Open machine & Re Set C.S.S To
Operate within Acceptable Limits
Friable Material / Packing of Chamber Clear Machine, Correct Grading & Re-
move excess Fines ,if present From Feed
Stock .
Upper Frame Bounce Manganese “Out of Round” Refer to Operating Instructions

Wedge Pressure Low Tighten Wedge Assembly
Wedge Assembly Loose Re-pressurise
Wedge Ring Over Greased Clean Wedge Ring & Correctly Lubricate
Dumpy Jacks Bottomed Out Check Wedge Ring Pads Replace as
required
Reposition Wedge Ring
Adjusting Wedge Assembly Has no Eeffect Check Fibre Pads & Replace Pads
Or Service Exchange Wedge Ring
Crushing at Excessively Tight C.S.S Adjust ( Open) Crusher C.S.S
Hydraulic Cylinder Circuit Fault Check for Internal & External Leaks
Section
9 - 9
Page

Manganese Worn “ Out of Round” Poor Manganese Replace Manganese With Genuine
BL-Pegson ltd Parts
Incorrectly Fitted Manganese Replace Manganese
Feed Segregation Ensure Fully Blended Feed is Provided to
Crusher
Constant Stop Start Feeding Check Position of Feed Box Sensor
Ensure Continuous Feed Available
Trickle Feeding Investigate Application & Modify to
Provide Choke Feed
Manganese Loose Poor Manganese / Poor Fit Replace Manganese With Genuine
BL-Pegson ltd Parts
Incorrectly Fitted Manganese Replace Manganese
Backing Failure Incorrect Mixing :- Refit Manganese if
slightly worn using Correctly Mixed
PEGBACK
Machine returned to Service prior to Backing Refit / Replace Manganese
Becoming Fully Cured May be temperature related
Backing “Out of Date” Refit / Replace Manganese
Rock Strength Exceeds Yield Strength of
STANDARD Backing Refer to BL-Pegson Ltd
Cone Head Lifting Fines Build up on Body Shields Stop Machine, Fully Strip & inspect For
Contamination & Damage Repair as
required
Section
10 - 10
Page
Erratic Movement of Hydraulic Cylinders Air in Hydraulic System Check for Leaks & Bleed System
Dirt in Hydraulic System Flush Circuit , Change Fluid & Filter
Elements
Blocked Filters Replace Element.
Severe Cylinder Internal Wear Replace Cylinder(s)
Excess Bearing Temperature Excessive or Inadequate Lubrication Investigate & Correct Lubrication Proce
dures , Replace Bearings as Required.
Mechanical Failure Of Bearing Investigate & Replace Broken & Dam
aged Components.
Reduction in C.S.S not Possible Crushing Pressure to High Adjust C. S. S
Hydraulic System Fault Check for Internal & External Leaks
Manganese “Out of Round” Refer to Operating Instructions
Cylinders Fully Retracted Change Manganese
Manganese Worn Out Change Manganese
Friable Material / Packing of Chamber Clear Machine, Correct Grading & Re
move excess fines ,if present From Feed
Stock
Directional Control Valve Inoperative Check Solenoid
Relief Valve Faulty or Dirty Check valve , Clean or replace
Increase In C.S.S not Possible Wedge Ring to Tight Grease & Adjust Wedge
Wedge Circuit Fault Investigate & Adjust Dumpy Jack Circuit
Pressure
Section
11 - 11
Page
C.S.S Not Maintained Hydraulic Fluid Leakage Check all Hydraulic Components Cou
plings , Pipes & Hoses
Pump Fails to Start Electrical Fault Check Relay Connections & Actuator
Low Oil Level Top Up / Refill Oil Tank
Pump Starts But No Flow Obtained Pipework Blockage Clean & Flush Pipework
Air Ingress Check Pipework for Leakage’s
Oil Viscosity to High Change Oil to a Grade Suitable for
Operating Conditions.
Valve Failure
High Oil Temperature Heat Exchanger Failure Adjust or Replace Solenoid Valve
Incorrect Grade of Oil Change Oil to a Grade Suitable for
Operating Conditions.
Cooler Blocked Disassemble & Clean Matrix
Thermostat Failure Replace Thermostat
Mechanical Failure Of Bearing Investigate & Replace Broken & Dam-
aged Components.
Section
12 - 12
Page
1000 SR Diagnostics - Powerpack
Engine Will Not Crank Over Battery Terminals Loose

Ignition Switch Faulty
Starter Motor Faulty
Pump Button Engaged
Faulty Contact on Pump Button
Engine Cranks over But Fails to Start Remote On/Off Switch in ON Position with Remote Switched OFF
Contact on Remote On/Off Switch Faulty
Remote Control Faulty
Emergency Stop Engaged
Hydraulic Oil Level Low
Timer 1 Faulty
Link Wire in 6 Pin Plug Loose or Disengaged
Poor Contact on 6 Pin Plug
CAT Relay Faulty in Engine Compartment
Over-Ride Switch Fault
Relay or Relay Block Faulty
Fuel Solenoid Heard When Over-Ride Switch Operated Fault is Within Engine
Fuse 1 Blown
Engine Starts But Stops When Over-Ride Switch Released Engine Overheated
Engine Temperature Sender Faulty
Engine Oil Pressure Low
Engine Oil Pressure Sender Faulty
Section
13 - 13
Page
Engine Shutdown Fault

1000SR Diagnosis
Check 24V DC Supply Check Emergency

Machine Will Not Start Check All Emergency
Control Panel to Fuse Yes Stop Relay ES No
Check Fuse Is Relay Energised Stop Buttons
Machine Cuts Out
No Yes
Check Supply From
Engine
Does The Pre-Start Check Timer

No Operation
Alarm Sound
Check Lubrication Oil
Level
Yes
No Are Relay’s Energised Check Stop Button On
On
Check Lubrication Oil The Transmitter
Level Sensor
Is The Remote Control

Yes Switch On Or Off
Is Plug on Side Of Is Umbilical Plugged
Panel Correctly in & Stop Button
Inserted Released ? Off Will Engine Start ?
Section
14 - 14
Page
1000 SR Diagnostics - Screen

Machine Stops Power Failure Check Powerpack & Repair
Broken Drive Belts Replace Drive Belts
Screen Blocked Stop Plant & Clear Blockage
Overload Crusher Operating in Dump Mode Stop Plant & Clear Blockage
Excessive Speed Variations Drive Belt Sipping Inspect Drive Belts Re-tension or
Replace
Drive Pulleys Contaminated with Spillage Stop Plant & Clean Drive
Engine Speed Incorrect Refer to Operating Instructions
Anti Vibration Mount Failed Replace Mount (s)
Low Capacity Insufficient Feed Stop Plant & Investigate

Speed Incorrect Refer to Operating Instructions
Bridging over Mesh Due to Crusher Dump Stop Plant & Clear Blockage
Incorrect Drive Tension Adjust and /or Replace Drive Belts
Sticky Material Remove Clay and/or Fines From
Plant Feed, Clean Screen Cloths
Excessive Moisture Endeavour to dry material prior to
Processing
Lack of Raw Material, Erratic Feed, Correct Grading & Condition Of
Feed Oversize, Inclusion of Fines Feed Material
Material Bulk Density Under 1.6Tonnes/ Cubic Meter No Action Possible
Section
15 - 15
Page

Excessive Wear Loose Screen Cloths Check Screen Cloth Condition &
Replace as required
Change to Feed Characteristics Check Crusher Settings & Adjust as
required
Excessive Moisture Endeavour to dry material prior to
Processing
Material Very Abrasive Investigate Alternative Screening Sur-
faces
Excessive Fines In Feed Material Adjust Crusher Setting and/or Raw Plant
Feed Stock
Excess Bearing Temperature Excessive or Inadequate Lubrication Investigate & Correct Lubrication
Procedures , Replace Bearings as
Required.
Mechanical Failure Of Bearing Investigate & Replace Broken &
Damaged Components.
Lack of Airflow in High Ambient Temperatures Contact BL-Pegson ltd with
Condition
Screening Efficiency
High R-circulating Load Screen Cloth Pegged Clean Screening Surface &
ascertain mesh selection is correct for
application & feed grading.
Investigate direction of screen
rotation & reverse if required. Note
reversing screen direction will
Section
16 - 16
Page

impact upon plant capacity
Investigate characteristics of
material processed & change mesh
cloths for a suitable construction
Increase amplitude of Vibration
Moisture Content Investigate moisture content of Material ,

High inherent content may lead to Blind-
ing of screen cloth especially when fine (
-14mm) Screening
Excess Fines High proportion of fines may exceed

stratification ability of screen , Adjust
Crusher C.S.S , Change direction of
Rotation , Adjust amplitude of Screen or
change mesh cloth apertures or construc-
tion.
Excess Oversize Reduce Crusher C.S.S
Product Nominal Content Incorrect Excess Oversize Screen Cloth damaged or failed.
Investigate & replace as required.
Adjust Crusher C.S.S
Section
17 - 17
Page

Screen Cloth Apertures incorrect Ascertain mesh selection is correct for
application & feed grading & change
mesh as required.
Excess Fines Refer to Screening Efficiency
High Re-circulating Load
Section
18 - 18
Page
1000 SR Diagnostics -Conveyors
Belt Tracking off Centre Belt Tension Not Even Adjust Belt Tension
Troughing & Parallel Idlers Out of Square Adjust Trough Sets and/or Parallel Roller
Alignment
Conveyor Belt Obstructed Clear Obstruction, Adjust & train Belt
Screeching Noise when Belt Is Running Lack Of Bearing lubrication Check Grease Pipes & Replace as
Required
Check Bearings & Replace as Required
Conveyor Belt Obstructed Clear Obstruction, Adjust & Train Belt
Scrapers In-correctly Adjusted Adjust Scrapers or Replace if Worn
Trough or Parallel Rollers Failed Replace Rollers
Conveyor Belt Slipping on Head Drum Tension or Replace Belt
Stone(s) Trapped on Structure, Drums or Rollers Clear Obstruction
Belt Fails to Run Drive Coupling Broken or Loose Replace or Tighten Coupling
Valve Actuator Failure Replace Actuator
Electrical Failure Check Circuit (s)
Slipping or Broken Pump Drive Belts Adjust Drive or Replace Belts
Drive Motor Failed Replace Motor
Pump Failed Replace Pump
Conveyor Belt Broken Replace Belt
Spool Valve Sticking Remove & Clean or Replace
Section
19 - 19
Page
1000SR Hydraulic Trouble Shooting
Feeder Slow
Check Hydraulic Pump Belts
Feeder Still Slow
Check & Record Feeder Speed
Check & Record Standby Pressure
Section
20 - 20
Page
Check & Record Standby

Pressure
Standby Pressure OK Standby Pressure Low
Operate the Feeder Manually. Set the Stanby Pressure to 29 Bar

Is The Feeder Speed OK
Yes Feeder Speed Slow Feeder Speed OK

Check Voltage Supply to Actuator . Should be 75% of
Supply Voltage . If not Problem is Electrical
Feeder Speed Slow
If Voltage is Correct
Check Spool Limit Screws . Less than 13mm Will Restrict Oil Flow
Spool Sticking Remove &

Actuator Faulty
Inspect
Limit Screws Correct . Feeder Still Slow Reset Limit Screws . Feeder OK
Section
21 - 21
Page
Limit Screws Correct . Feeder Still Slow
Dead Head Feeder Circuit & Check Relief Valve is at 180 BAR
Pressure OK Pressure Low . Adjust to 180 BAR . (1 Turn = 100BAR Approximatly)
Fit Flow Meter in Feeder Circuit & Check Flow Feeder Speed OK
Flow Measuring Less Than 45 Litres/Min

Flow Measuring Approx 50 Litres/Min .
Feeder Moror at Fault
Check flow Going to Bank Valve
50 Litres / Min
Less Than 45 Litres/Min Bank Valve at Fault
Pump at Fault
Section
22 - 22
Page
Product Conveyor Running Slow
Check & Record Belt Speed
Check Hydraulic Pump Belts
The Belt is Still Slow .

Screw in the Needle valve on The HFO& Back Off 1/4 Turn

The Belt is now Running at The Correct Speed
Check The standby Pressure . Adjust if it Below 28 BAR

Check the Running Pressure of the Belt . It should be Approximate
100 BAR
Section
23 - 23
Page

Check the Running Pressure of the Belt . It should be Approximate
100 BAR
The Running Pressure is High The Running Pressure is OK
Slacken Off the Belt so the Head Drum can Turn Without the Belt
If the Pressure has Dropped there is a Problem with the Belt If the Pressure is Still High There is a Problem with the Motor or There
I.E Trapped stone , Tension to High , Skirt Rubbers to Tight is a Restriction in the Hydraulic Line
Check Spool Limit Screws . Less than 13mm Will Restrict Oil Flow
The Limit Screw is Correct . The Belt is Still Slow The Belt is Now Running at the Correct Speed
Section
24 - 24
Page
The Limit Screw is Correct . The Belt is Still Slow
Dead head the Conveyor Circuit . You Should Register 238 BAR from the Test point . Back
off thr Relief & reset if Pressure is Low
Operate The Belt Manually The Belt is Now Running at the Correct Speed
No Change in the Belt Speed If Belt is now Running at the Correct

Fit a Flow Meter in the Product Speed Either the Actuator is at Fault or
Conveyor Line . Flow Should The Spool is Sticking
Register Approximatly 55 Litres / Min
Less than 50 Litres/ Min . Fit the Flow 55 Litres.

Meter After The Pump The Product Conveyor is at Fault
Section
25 - 25
Page
Less than 50 Litres/ Min . Fit the Flow

Meter After The Pump
Less Than 50 Litres/ Min 55 Litres / Min
Track the Machine There is an Internal Leak Within The

If There is 90 Litres / Min There is a Bank Valve
Fault Within the Load Scensing
Less Than 90 Litres/ Min

The Pump is at Fault
Section
26 - 26
Page
1000SR Test Data
R eading Tolerance Limits R eading Tolerance Limits

Item Measured Position / Time Item Measured Position / Time
R equired Upper Lower
R equired Upper Lower
Left 29 31 28 Screen Speed (RPM) 1120 1130 1110

Stand By Pressure- BAR
Ri ght 29 31 28 Fi nes C onveyor Belt Speed -M/MIN 125 130 120
Left 330 336 320 Stockpi le/Re-ci rculati on C onveyor Pressures ( BAR) <70 70 N/A
Pump Stall Pressure - BAR
Ri ght 330 336 320 Stockpi le C onveyor Belt Speed - M/MIN 65 70 60
Reci rculati on C onveyor Belt Speed - M/MIN 65 70 60

Ri ght Hand Track Fast Runni ng
- BAR C ross C onveyor Pressure ( BAR) <95 <95 N/A
Runni ng <115 115 N/A
C ross C onveyor , Belt Speed - M/MIN 80 85 75

Left Hand Track Fast Runni ng -
BAR
Runni ng <115 115 N/A
Product C onveyor Pressure -

BAR
Runni ng 125 125 N/A
Product C onveyor Belt Speed -M/MIN 105 105 N/A
Feeder C onveyor Pressure -

BAR
Runni ng <80 80 N/A
Feeder C onveyor Belt Speed - M/MIN 30 32 28
Lubri cati on Pump ( BAR) 169 169 163
C luch C ontrol ( BAR) 30/31 31 30
Screen/Fi nes C onveyor Pressure ( BAR) <90 90 N/A
Section
27 - 27
Page
1000SR & 4242SR SR Stockpile Conveyor
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. Section A SP
Section
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 Page A -SP
1 - 1
Page
1000SR & 4242SR Section SP- Table of Contents
SR Stockpile Conveyor SP - 1
Section SP- Table of Contents SP - 2
Stockpile Conveyor Layout SP - 3
Drive Group SP - 4
Stringer Section SP - 5
Tail Section & Feed Boot SP - 8
Tail Section SP - 9
Conveyor Rubber Items SP - 10
Supports SP - 11
Troughing Idlers SP - 13
Bearings SP - 14
Section
2 - 2
Page
1000SR & 4242SR Stockpile Conveyor Layout
Drive Group
Tail Section Stringer Section
Section
3 - 3
Page
1000SR & 4242SR Drive Group
1000 SR
Part Number
1 Head Drum AX862/16 1
2 Mot or 2576-4076 1
A
3 Check Val ve 2579-0018 1
4A Coupl i ng Guard AX862/91 1
4B Torque Arm AX815/90 1
Shri nk Di s c 2450-5503 1
4C
Key 2432-2194 1
5 4 2 Beari ng 2421-0010S 2
Bol t Hex 2232-1206 2/uni t

6 1 4 5
Was her Pl ai n 2210-0019 4/uni t
Nut 2217-0007 2/uni t
B 6 Head Beari ng Greas e Ki t Refer t o Page SP-14 1
Section
4 - 4
Page
1000SR & 4242SR Stringer Section
8 9B
7 8B
8A
Left Hand 9
8C
9B
10 8
14
10A
13 9B
15 8A
11
10A 9A
11B
16
12
12B
11B 10
20
12C 12B
19
11A
Right Hand
12C
17
18 12A
Section
5 - 5
Page
1000SR 1000 SR
7 Ni p Guard AX862/74 1 Cl amp AX862/88/5 2
Head Guard LH AX868/123/2 1 Screw 2230-1152
Screw 2230-1151 3/Uni t
9B
8 Was her 2210-0017 5/Uni t
Was her 2210-0017 6/Uni t
Was her 2211-0008
Nut 2217-0005 3/Uni t
Mi ddl e Guard AX862/228/1 2
Head Guard RH AX868/123/1 1
8A Screw 2230-1151 4/Uni t
Cl amp (Long) AX862/88/9 2
Nut 2217-0005 4/Uni t
Screw 2230-1152
8B Cl amp AX862/88/4 2
Screw 2230-1152
Was her 2211-0008 10A
Cl amp (Short ) AX862/88/8 2
8C
Fi xi ngs as It em 8B Was her 2211-0008
Upper Guard LH AX862/80/2 1 Lower Guard LH AX862/67/1 1
Screw 2230-1151 3/Uni t Screw 2230-1151 4/Uni t

9 11
Was her 2210-0017 6/Uni t Was her 2210-0017 8/Uni t
Nut 2217-0005 3/Uni t Nut 2217-0005 4/Uni t
1
Upper Guard RH AX862/80/1 Lower Guard RH AX862/67/2 1
9A 11A
Fi xi ngs as It em 8B Fi xi ngs as It em 11
Section
6 - 6
Page
1000 SR 1000 SR
Cl amp AX862/88/4 2 14 Support Bracket AX862/261/1 1
Screw 2230-1152 Upper Ni p Guard AX862/123/2 1

11B
Was her 2210-0017 4/Uni t Screw 2230-1151
15
Was her 2211-0008 Was her 2211-0008 2/uni t
Feed Boot LH AX862/161/2 1 Was her 2210-0017
Screw 2230-1221 5/Uni t Mi ddl e Ni p Guard AX862/123/1 2

12 16
Was her 2210-009 10/Uni t Fi xi ngs as It em 15
Nut 2217-0007 5/Uni t Lower Ni p Guard AX862/123/3 1

17
Feed Boot RH AX862/161/1 1 Fi xi ngs as It em 15
12A
Fi xi ngs as It em 12 18 Ret urn Idl er 2495-3023 1
Cl amp AX862/88/3 2 19 Ret urn Idl er 2495-3022 4
Screw 2230-1152 20 Idl er Bas epl at e Mt d Refer t o Page SP-13 8

12B
Was her 2211-0008
Ret ai ni ng St ri p AX862/245/1 2
Screw 2230-1153
12C
Was her 2211-0008
13 St ri nger Sect i on Fab AX862/13/1 1
Section
7 - 7
Page
1000SR & 4242SR Tail Section& Feed Boot
21
22
23
35
24A
24C
24B
Section
8 - 8
Page
1000SR & 4242SR Tail Section
1000 SR 1000 SR
21 Feed Boot Rear Panel AX862/161/3 1 Tai l Beari ngs 2421-0010S 2
Feedboot Rear Cl amp
AX862/161/4 1 Shi m t ai l Beari ng AX862/249/1 2
St ri p
Was her 2210-0017 24B Bol t Hex 2232-1207 2/uni t
22
Was her 2211-0008 4/Uni t Was her Pl ai n 2210-0019 4/uni t
Nut 2215-0014 Nut Hex 2217-0007 2/uni t
23 Tens i oner LH AX818/110/1 1
24C Tai l Drum AX862/17 1
23A
Tens i oner AX818/110/1 1 35 Greas i ng Ki t Refer t o Page SP-14 1
Screw 2230-1220
23 & 23A Was her 2210-0019 4/uni t
Nut 2217-0007
Tai l Drum Guard AX862/134 1
Bol t Hex 2232-1101
24A Was her Spri ng 2211-0007

2
Bol t Hex 2232-1130
Section
9 - 9
Page
1000SR & 4242SR Conveyor Rubber Items
26 29 30
27
28
25
1000 SR
Part Number
25 Ski rt Rubber Head AX862/218/3 2
26 Ski rt Rubber Ful l Lengt h AX862/218/2 2
27 Feed Boot Ski rt Rubber AX868-239-001 1
28 Bel t 2360-0066/18.0 1
29 AX868-241-001 1
Ski rt Rubber (Out er)
30 AX868-242-001 1
Section
10 - 10
Page
1000SR & 4242SR Supports
30b
30a 30
33
31 30
32
34
31
32
Section
11 - 11
Page
1000SR & 4242SR
Item Description / Notes Part Number Qty
1000 SR 4242SR
St ockpi l e Conveyor
30 AX862/187 2
Support Brkt
30a Vert i cal pl at e bol t s - 2232-1128
8
30b Hori z ont al pl at e bol t s - 2232-1127
Was her 2210-0017

30a & 30b 16
Nut 2217-0005
St ockpi l i er Ret ai ni ng bar AX862/203 1
Screw 2230-1221
31
Was her 2210-0019 2
Nut 2217-0007
32 Support St rut AX868/133/1 1
Support Rope AX862/146

33 1
Support Rope Pi n AX862/147
34 Braci ng Bar AX868/133/1 1
Section
12 - 12
Page
1000SR & 4242SR Troughing Idlers
2
2
1
Ba se Pla te Mounte d Idle r

Pla nt C ompone nt
Pa r t Numbe r Q ty
Co mpl e t e Se t 2495-3021 8
1 : - W i ng
2489-1075 16
Ro l l e r
Fi xi ng Cl a mp 2489-3004
1000 SR & 4242SR Fi xi ng Bo l t 2232-1072 1/
Wa s he r Bri ght 2210-0015 Ro l l e r
N ut 2217-0003
2 : - Ce nt re
2489-1074 8
Ro l l e r
Section
13 - 13
Page
1000SR & 4242SR Bearings
5
24B
6 35
Standard Bearing Arrangement

illustrated. As a production measure machines may be Head Beari ng
Greas i ng ki t
constructed with alternative bearing grease connection. It e m 5
These bearings hold the same part number omitting the “S” 2421-0010S 2530-2021
suffix. Bearing grease fittings are illustrated in Service St andard Fi t t o 1000SR & 4242SR
bulletin SP 003 03A. St ockpi l i ngConveyor Tai l Beari ng
Greas i ng ki t
A plant may have the “S” suffix bearings fitted as a spares It em 24B
by omitting Grease Nipple adapter part 2429-0001 and 2421-0010S 2530-2018
connecting hose to bearing housing using Nipple 2520-6071
Section
14 - 14
Page
Spare Parts Advisory Bulletin
Service Advisory Bulletin SP-003-03
SP-003-03
DATE: 31st October 2003

MODEL: All Trak Plants
SUBJECT: Remote Grease Kits
ISSUE: Identification of Bearing Grease Nipple Connections to Pipework
ACTION: Note Introduction of Part.
An issue has been identified concerning correct identification of Spare parts required
To install remote grease lubrication systems to bearing lubrication points
The two styles of Fittings utilised are identified & illustrated on the attached pages.
TEREX PEGSON

Dealer Service Bulletin SP 003-03 Issue.03 Eng
Product : All Trak Plants Grease Nipple Connection

Part : Conveyor Bearing Grease Nipple Connections
“S” Suffix Style Bearing Grease

Bearing Grease Nipple Connection
Nipple Connection
Adaptor Reducing M/M Grease Nipple Adaptor Adaptor Reducing M/M

Part Number :- 2520-6071 Part Number 2429-0001 Part Number :- 2520-6071
BL-Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom. SP 003-03
Page 1 - 1

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any error in or omissions from the information given. In COPYRIGHT

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Please refer to Operation & Maintenance Sections provided

1000SR Service Components

Item Description Item Description Part Number Qty

Fuel Fi l t er Pri mary El ement 2481-0052 1 Suct i on Fi l t er El ement 2589-1074 1

Fuel Fi l t er Secondary El ement 2481-0053 1 Pres s ure Fi l t er El ement 2589-2030 2

Ai r Fi l t er Secondary El ement 2481-0055 1 Fi l t er El ement 2589-5125 1

Maxtrac Hydraulic Circuit 1000SR T est Data

Suct i on Fi l t er El ement 2531-5150 1 Ref er t o Sect i on 13 Di agnos t i cs

Pres s ure Fi l t er El ement s 2531-5151 2

Ret urn Fi l t er El ement 2531-5253 1

Plant Drives :- HFO Equipped Plants

Crus her Dri ve Bel t s 2441-0470 8

Pump Dri ve Bel t s 2441-0412 4

1000SR Plant Handing

Handing :- Components are Handed Based on Viewing

Right Hand View

Left Hand View

Feed ( Rear) End

1000SR Section Identification

Section B :- Screen &

1000SR Section 1:- Feeder Conveyor

1000SR Section 1:- Table of Contents

Section 1:- Feeder Conveyor 1 -1 Bearings 1 -14

Section 1:- Table of Contents 1 -2

Feeder Conveyor Layout 1 -3

Frame Upper View 1 -4

H.D.P.E Wear Pads 1 -5

Head Drum Bearing Support 1 -8

Frame Under View 1 -10

Conveyor Rubber Items 1 -12

Troughing Idlers 1 -13

1000SR Feeder Conveyor Layout

Feed Hopper , Barge Board

Head Drum Bearing

Frame Upper View

Frame Under View

1000SR Frame Upper View

3 2 Rubber Covered Idler Refer t o Page 1-14

3 Impact Idl er 2489-1070 10

6A Was her Bri ght 2210-0017

Was her Spri ng 2211-0008 1/Bol t

Was her Spri ng 2211-0008 1/Bol t

7 Head Drum AX848/113 1

8 Tai l Drum AX848/33 1

1000SR H.D.P.E Wear Pads

1000SR H.D.P.E Wear Pads

Si de Support Wear Pad AX848/70/1 2 Si de Suppo rt We a r P a d AX848/65/3 2

Screw 2226-0816 Support Si de Wedge AX848/65/5 2/Pad

Nut 2215-0014 2/BRK

12A Was her 2210-0017 8

1000SR Drive Group

Ge a rbo x Suppo rt AX848/57/1 1

Mot or & Gearbox 2473-00013

16 Gearbox Si ght Gl as s 2576-9007 2

Caps crew 2222-0247

1000SR Head Drum Bearing Support

Beari ng Support AX848/58/1 1

Nut 2217-0011 1/Bol t