900 X 600 Metrotrak User Manual EN7

METROTRAK
900 x 600
PLANT USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
Safety. This manual contains safety information which the operator

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

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

appropriate to your plant and the situation/conditions prevailing at the time.
Federal, State, National and Local laws and safety regulations must be complied
with at all times to prevent possible danger to person(s) or property from
accidents or harmful exposure.
See also the separate Operation and Maintenance Manual provided for the diesel
engine fitted to your plant and in particular read and observe the instructions
within the Safety Section of the engine manual.
INFORMATION AND ADVICE

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

11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.
Telephone : +1 502 267 2314, Fax : +1 502 267 2317

ed
Advanscher
Cru hnology
Tec
EC Conformity
This plant is in conformity with the

provisions of the EC Machinery
Directive 98/37/EC together with
appropriate EN Harmonised Standards
and Nationional BS Standards and
Specifications.
Noise Level
Measured to satisfy the noise information

requirements of the Supply of Plantry
(Safety) Regulations 1992, which
implement in the UK the European
Council Directive 89/392/EEC (the
Plantry Directive).
Year 2000 Compliancy
All electrical components on this plant

comply with year 2000 specifications.
ed
Advanscher
Cru hnology
Tec
Defects Liability Guarantee

Conditions of Sale for Machinery (Clause 12 Liability)
The following information is an extract from BL-Pegson Limited Conditions of Sale for Machinery. For a full copy
of Conditions of Sale for Machinery contact BL-Pegson Limited.
12 Liability
12.1 Introduction
12.1.1 Nothing in Clause 12 shall be deemed to exclude or restrict the Company’s liability for death or
personal injury or damage to property caused by defective products for which the Company is liable and
which there is not defence under the Consumer Protection Act 1987 or liability for death or personal
injury resulting from the Company’s negligence.
12.1.2 Each of the sub clauses in 12 is to be treated as separate and independent.
12.1.3 The Company is willing to undertake liability additional to that provided by this clause in consideration
of a higher price.
12.2 Limitation
12.2.1 In the case of parts not manufactured by the Company or work not performed by the Company the buyer
shall only be entitled to the benefit insofar as it may be transferred to the buyer of any rights which the
Company has against the supplier of such parts or components or the performer of such work and the
Company’s liability in respect of such cases is limited to endeavouring to make the benefit of such rights
available to the buyer.
12.3 General Exclusion
12..3.1 Clause 12.3 only covers the defects cause by faulty design manufacture materials or workmanship in
respect of goods manufactured or work performed by the Company.
12.3.2 The Company agrees that if any defect covered by clause 12 is discovered
(a) in the case of complete new quarry plants and machines during the period of twelve months or
2000 operating hours whichever is the shorter commencing with the date of delivery or if the
Company shall be responsible for erection then within a period of twelve months from the date
when the machinery is ready for starting up or
(b) in the case of pumps and all spare parts during the period of six months or 1000 operating hours
whichever is the shorter commencing with the date of delivery the company will either repair the
machinery at it’s own expense or if it chooses to do so replace the machinery in which case any
machinery replaced will belong to the Company
12.3.3 The buyer cannot claim the benefit of this clause unless
he informs the Company of the relevant in writing within 7 days of discovering it and
he shall have at all times complied with the advice and abided by the procedure and instructions
set out in the Company’s operating and instruction manuals and shall not have subjected
machinery to any unauthorised use or repair or improperly installed or connected the machinery
or failed to observe any maintenance requirements
he returns the machinery / defective part to the Company at his own expense. It is agreed that the
Company will deliver the machinery / defective part after repair / replacement carriage paid
within the United Kingdom or FOB to the United Kingdom port of exportation
he is not in breach of this or any other contract made with the Company.
12.3.4 The risk of accidental loss whilst the machinery is being returned to the Company will be borne by the
buyer.
Metrotrak
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Page 1
Contents
1.1 Warnings and Symbols ....................................................................................... 2
1.2 Organisation Measures .......................................................................................3
1.3 Selection and Qualification of Personnel - Basic Responsibilties .................. 4
1.4 Safety Instructions Governing Specific Operational Phases ........................... 5

1.4.1 Standard Operation ......................................................................................... 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ..................... 5
1.5 Warning of Special Dangers ............................................................................... 8
1.5.1 Electric Energy ................................................................................................ 8
1.5.2 Gas, Dust, Steam, Smoke and Noise .............................................................. 9
1.5.3 Hydraulic and Pneumatic Equipment .............................................................10
1.5.4.Hazardous Substances ................................................................................. 10
1.6 Transporting, Manoeuvring and Recommissioning ....................................... 11
1.7 Position of Emergency Stop Buttons ..............................................................13
1.8 Plant Warning Signs .......................................................................................... 14

1.8.1 Location of Warning Signs. ...........................................................................14
1.8.2 Safety Sign Illustrations................................................................................. 16
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
Metrotrak
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Page 2
1.1 Warnings and Symbols
The following signs and designations are used in the manual to designate instructions of
particular importance.
This is the safety alert symbol. When you see this symbol on your plant or in this
manual, be alert to the potential for personal injury or equipment damage.
Follow the recommended precautions and safe operating practices.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentiallly hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe working practices.
Indicates a statement of company policy as the message relates directly or indirectly

to the safety of personnel and protection of property.
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1.2 Organisation Measures Observe all safety instructions and

warnings attached to the plant.
1.2.1
See to it that safety instructions and
Ascertain from the appropriate Authority warnings attached to the plant are always
and observe all statutory and any other complete and perfectly legible.
regulations that may apply to the planned
location before operating the Metrotrak. Keep warnings and instruction labels
clean.
Loose or baggy clothing can get caught
in running machinery. Replace unreadable or missing labels
with new ones before operating the plant.
Where possible when working close to Make sure replacement parts include
engines or machinery, only do so when warning or instruction labels where
they are stopped. If this is not practical, necessary.
remember to keep tools, test equipment
and all other parts of your body well 1.2.3
away from the moving parts.
Understand service procedure before
For reasons of safety, long hair must be doing work. Keep area clean and dry.
tied back or otherwise secured, garments
must be close fitting and no jewellery Never lubricate, clean, service or adjust
such as rings may be worn. Injury may machinery while it is moving. Keep
result from being caught up in the hands, feet and clothing clear of power
machinery or from rings catching on driven parts and in running nip-points.
moving parts. Disengage all power and operate controls
to relieve pressure. Stop the engine.
Always wear correctly fitting (EN/ANSI Implement lockout procedure. Allow the
approved) protective clothing. machinery to cool.
Protective clothing includes Hard Hat, Keep all parts in good condition. Ensure
Safety Glasses, Ear Protection, Dust that all parts are properly installed. Fix
Mask, Close fitting Overalls, Steel Toed damage immediately. Replace worn and
Boots and a High Visibility Vest. broken parts. Remove any build up of
grease, oil and debris.
1.2.2
Disconnect battery ground cable before
You can be injured if you do not obey the making adjustments on electrical systems
safety instructions as indicated on or welding on plant.
warning stickers.
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For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted Qualification of Personnel -
to the task on hand are absolutely
Basic Responsibilties
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must
Never make any modifications, additions
be executed by trained, reliable and
or conversions which might affect safety
authorised personnel only. Statutory
without the supplier’s approval.
minimum age limits must be observed.
In the event of safety relevant
1.3.2
modifications or changes in the behaviour
of the plant during operation, stop the Work on electrical system and equipment
plant and lock out immediately and of the plant must be carried out only by a
report the malfunction to the competent skilled electrician or by instructed
authority/person. persons under the supervision and
guidance of a skilled electrician and in
accordance with electrical engineering
rules and regulations.
1.3.3
Work on the hydraulic system must be
carried out only by personnel with special
knowledge and experience of hydraulic
equipment.
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Page 5
1.4 Safety Instructions 1.4.2 Special Work In Conjunction

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

Your arm could be pulled in and plant in appropriate positions.
amputated.
Switch off and lockout the plant before

removing any safety devices or guarding.
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1.4.2.3 For carrying out overhead assembly

work always use specially designed or
Carry out maintenance and repair work otherwise safety-oriented ladders and
only if the plant is positioned on stable working platforms.
and level ground and has been secured
against inadvertent movement and Always use any walkway/platforms
buckling. provided or a safe and secure platform
approved by the regional safety enforcing
1.4.2.4 authority.
Never allow unqualified or untrained
personnel to attempt to remove or Always use an EN/ANSI approved safety
replace any part of the plant, or anyone harness when reaching any points 7ft
to remove large or heavy components (2m) or more above the ground level.
without adequate lifting tackle.
Keep all handles, steps, handrails,
To avoid the risk of accidents, individual platforms, landing and ladders free from
parts and large assemblies being moved dirt, oil, snow and ice.
for replacement purposes should be
carefully attached to lifting tackle and 1.4.2.6
secured. Use only suitable and technically The fastening of loads and instructing of
adequate lifting gear. crane operators should be entrusted to
experienced persons only. The marshaller
Never work or stand under suspended giving the instructions must be within
loads. sight or sound of the operator.
Keep away from the feed hopper and 1.4.2.7
product conveyor discharge, where there
is risk of serious injury or death due to After cleaning, examine all fuel,
the loading and removal of material. lubricant, and hydraulic fluid lines for
leaks, loose connections, chafe marks
1.4.2.5 and damage. Any defects found must be
rectified without delay.
Falling from and/or onto a BL-Pegson
plant can cause injury or even death. 1.4.2.8
Do not climb on the plant. Never use Any safety devices removed for set-up,
plant parts as a climbing aid. maintenance or repair purposes must be
refitted and checked immediately upon
Beware of moving haulage and loading completion of the maintenance and repair
equipment in the vicinity of the plant. work to ensure full working order.
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1.4.2.9 1.4.2.11
Improperly disposing of waste can Diesel fuel is highly flammable.
threaten the environment and ecology.
Potentially harmful waste used with BL- Never remove the filler cap, or refuel,
Pegson equipment includes such items as with the engine running.
oil, fuel, coolant, filters and batteries, etc.
Never add gasoline or any other fuels
Use leakproof containers when draining mixed to diesel because of increased fire
fluids. Do not use food or beverage or explosion risks.
containers that may mislead someone
into drinking from them. Do not smoke or carry out maintenance
on the fuel system near naked lights or
Do not pour waste onto the ground, sources of sparks, such as welding
down a drain or into any water source. equipment.
Ensure that all consumables and replaced 1.4.2.12

parts are disposed of safely and with
Using unapproved structures i.e.
minimum environmental impact.
walkways/platforms etc in the vicinity of
1.4.2.10 a BL-Pegson plant is very dangerous and
could lead to serious injury or even death
Always ensure that any safety fitment through falling and/or entanglement with
such as locking wedges, securing chains, the plant.
bars or struts are utilised as indicated in
these operating instructions. Do not use any unauthorised structures.
Particularly make sure that any part of

the plant raised for any reason is
prevented from falling by securing in a
safe reliable manner.
Never work under unsupported

equipment.
Never work alone.
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1.5 Warning of Special 1.5.1.4

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

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

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

respective site.
Before starting work on high voltage
assemblies and after cutting out the Dust found on the plant or produced
power supply, the feeder cable must be during work on the plant should be
grounded and components such as removed by extraction, not blowing.
capacitors short-circuited with a
grounding rod. Dust waste should be dampened, placed
in a sealed container and marked, to
1.5.1.9 ensure safe disposal.
These plants are wired on negative earth. 1.5.2.2
Always observe correct polarity.
Carry out welding, flame cutting and
Always disconnect battery leads before grinding work on the plant only if this
carrying out any maintenance to the has been expressly authorised, as there
electrical system. may be a risk of explosion and fire.
The battery contains sulphuric acid, an 1.5.2.3

electrolyte which can cause severe burns
Before carrying out welding, flame
and produce explosive gases.
cutting and grinding operations, clean the
Avoid contact with the skin, eyes or plant and its surroundings from dust and
clothing. other inflammable substances and make
sure the premises are adequately
ventilated (as there may be a risk of
explosion).
Metrotrak
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1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must
provided with ear defenders of approved be laid and fitted properly. Ensure that no
pattern and that these are worn at all connections are interchanged. The
times when the plant is operating. fittings, lengths and quality of the hoses
must comply with the technical
Ensure operators wear a suitable face requirements.
mask where exposed to possible harmful
effects of air polution of any kind. 1.5.3.5
1.5.3 Hydraulic and Pneumatic Always practice extreme cleanliness

Equipment servicing hydraulic components.
1.5.3.1 1.5.3.6
Work on hydraulic equipment may be Hydraulic fluid under pressure can
carried out only by persons having penetrate the skin causing serious injury.
special knowledge and experience in
hydraulic systems. If fluid is injected under the skin, it must
be surgically removed or gangrene will
1.5.3.2 result.Get medical help immediately.
Check all lines, hoses and screwed Always relieve pressure from the
connections regularly for leaks and hydraulic system before carrying out any
obvious damage. Repair damage kind of maintenance or adjustment.
immediately. Splashed oil may cause
injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4.Hazardous Substances
pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification,
for the unit concerned before carrying labelling, storage, use and disposal, all
out any repair work. strictly in accordance with the
manufacturers instructions and that all
applicable regulations are observed at all
times.
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1.6 Transporting, Manoeuvring 1.6.7

and Recommissioning When travelling on public roads, ways
and places, always observe the valid
1.6.1 traffic regulations and, if necessary,
The plant must be loaded and transported ensure beforehand that the plant is in a
only in accordance with the operating condition compatible with these
instructions. regulations.
1.6.2 1.6.8
For manoevering the plant, observe the In conditions of poor visibility and after
prescribed transport position, admissible dark, always switch on the lighting
speed and itinerary. system of the transporting vehicle..
1.6.3 1.6.9
Use only appropriate means of transport When crossing underpasses, bridges and
and lifting gear where applicable of tunnels or when passing under overhead
adequate capacity. lines always make sure that there is
sufficient clearance.
1.6.4
1.6.10
The recommissioning procedure must be
strictly in accordance with the operating Never travel across slopes; always keep
instructions. the working equipment and the load
close to the ground, especially when
1.6.5 travelling downhill.
Before starting work or travelling with 1.6.11

the plant, check that the braking, and any
signalling and lighting systems are fully On sloping terrain, always adapt your
functional. travelling speed to the relevant ground
conditions. Never change to a lower gear
1.6.6 on a slope. Always change gear before
reaching a slope.
Before setting the plant in motion always
check that the accessories have been
safely stowed away.
Metrotrak
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Page 12
1.6.12
Explosive separation of a tyre and rim
parts can cause injury or death.
Do not attempt to mount a tyre unless

you have the proper equipment to
perform the job.
Always maintain the correct pressure. Do

not inflate the tyre above the
recommended pressure. Never weld or
heat wheel and tyre assembly. The heat
can cause an increase in air pressure
resulting in a tyre explosion. Welding can
structurally weaken or deform the wheel.
When inflating tyres, use a clip-on chuck

and extension hose long enough to allow
you to stand to one side and not in front
or over the assembly. Use safety cage if
available.
Check wheels for low pressure, cuts,

bubbles, damaged rims or missing lug
bolts and nuts.
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1.7 Position of Emergency

Emergency Stop Button
Stop Buttons (Feeder/Conveyor Control Box)

(Chassis Side)

(Control Panel)

(Chassis Side)
Figure 1a Emergency Stop Buttons
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1.8 Plant Warning Signs
1.8.1 Location of Warning Signs.

Left Hand side of plant
300/38
300/120
300/36
300/32
300/40
300/118
300/33
300/39
300/44
300/35
300/40
300/118
300/34, 300/37, 300/40
300/38, 300/43
300/32
Figure 1b Warning Signs
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Location of Warning Signs, Right

Hand side of plant
300/32
300/42
300/43
300/33, 300/39
300/34
300/40
300/118
300/120
300/34
300/36
300/38
Figure 1c Warning Signs
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1.8.2 Safety Sign Illustrations
300/32 300/33 300/34
300/38 300/39 300/40
300/43 300/44 300/120
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Safety Sign Illustrations, continued
300/35 300/118
300/36 300/37
300/42
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Blank Page
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Technical Information Issue 07 ENG
Page 1
Contents
2.1 Dimensions .......................................................................................................... 2
2.2 Plant Description ................................................................................................. 3
2.3 Feeder .................................................................................................................. 4
2.4 Crusher .................................................................................................................4
2.5 Product Conveyor ............................................................................................... 4
2.6 Tracks ................................................................................................................... 4
2.7 Standard Powerpack ........................................................................................... 5
2.8 Dustsprays ........................................................................................................... 5
2.9 Dirt Conveyor * .................................................................................................... 5
2.10 Magnetic Separator * ......................................................................................... 5
2.11 Hydraulic Folding Hopper * .............................................................................. 6
2.12 Fixed Feed Hopper * .........................................................................................6
2.13 Belt Weigher * ....................................................................................................6
2.14 Water Pump * .....................................................................................................6
2.15 Fuel transfer Pump * .........................................................................................6
2.16 Caterpillar Power Pack * ................................................................................... 6
2.17 Hydraulic Clutch * ............................................................................................. 7
2.18 Anti-vandal Guards * ........................................................................................ 7

PLEASE NOTE
BL-Pegson Limited have designed and built the Metrotrak to provide the Buyer with a
range of equipment choices to meet a wide variety of individual needs and preferences
as selected at the time of initial purchase.
Please note that the asterisk * in the text of this User Manual signifies:
Not included in all plants - only appropriate if the item is fitted.
4020
3200
3400
2.1 Dimensions
2875
Hopper Raised
2800 3300 6120
12220
ALL DIMENSIONS ARE IN MILLIMETRES
Travelling Height (Excluding Transport Trailer) 3150

Technical Information
Overall Height (Hopper Raised) 3400

2027
Overall Width (Dirt Conveyor Folded) 2500
Gross Weight approx 26,000kg

2400
3793
Page 2
Metrotrak
900 x 600
Issue 07 ENG
Viewed from the rear of the Metrotrak

Figure 2a Dimensions
Metrotrak
900 x 600
Page 3
2.2 Plant Description
Many of the terms used in this manual may not at first be obvious. Figure 2b identifies the main
areas of the plant and the term with which they are referred to in this manual.
Dirt Conveyor (Head drum guard and

Diesel side skirt plates removed)
FRONT Engine
REAR
Magnetic Overband
Seperator
Engine Maintenance Control Box

LEFT
Platform Tool Box
Crusher Maintenance
Platform
Feed Hopper
Side Plate
Feeder FRONT
Jaw Crusher
REAR
Product Conveyor
Maintenance
RIGHT Tracks
Platform Figure 2b Plant Terms
Metrotrak
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Page 4
2.3 Feeder
Type Spring mounted vibrating pan

Width 800mm (32”)
Length 3800mm (12’-6”)
Unit Twin shaft oil lubricated
Grizzly Fixed bars at nominal 50mm (2”) spaces
Underscreen Blank rubber mat standard fitment
Drive Hydraulic motor
Control Variable speed
Hopper Manual folding (to reduce height when transporting)
2.4 Crusher
Type Single toggle jaw

Feed Gape 600 mm (24”)
Feed Width 900 mm (36”)
Adjustment Shims – hydraulically assisted
Lubrication Greased roller bearings
Drive Vee belts from engine
Control Engine clutch
2.5 Product Conveyor
Type Plain troughed belt

Width 800 mm (32”)
Lubrication Grease
Control Fixed speed
Skirts Full length
2.6 Tracks
Type 160mm (6.3”) pitch heavy duty

Width 400 mm (16”)
Centre 3300 mm (10’-10”)
Drive Hydraulic integral motors
Control Remote handset – dual speed
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900 x 600
Page 5
2.7 Standard Powerpack
Type Cummins 6BT DIT, 6 cyl. water cooled diesel

Rating 149hp @ 1800 rpm
Drives Manual twin disc clutch to crusher
Vee belts to twin hydraulic pumps
Housing Steel enclosure with integral fuel tank and battery
2.8 Dustsprays
Type Clean water multi atomising nozzles

Positions Crusher feed & discharge and product conveyor
discharge
Inlet Single point
Required supply Approx. 7 litres/min @ 2.8 bar / 42 psi.
Frost protection System drain valves
2.9 Dirt Conveyor *

Type Plain troughed belt, hydraulically folded for transport
by engine driven pump.
Width 600 mm (24”)
Lubrication Grease
Control Fixed speed
Skirts Full length
2.10 Magnetic Separator *

Type Suspended self cleaning crossbelt overband
Magnet Permanent
Width 600 mm (24”)
Centres 800 mm (32”)
Control Preset variable
Metrotrak
900 x 600
Page 6
2.11 Hydraulic Folding Hopper *

Type Hydraulically folded by engine driven
pump, side plates only.
2.12 Fixed Feed Hopper *

Type One piece construction. Cannot be folded to reduce
height for transporting.
2.13 Belt Weigher *

Type Single idler load sensor type including flow rate and
totalizer displays on chasis mounted control box
2.14 Water Pump *

Type Hydraulically driven to provide pressurised water
supply for the dust suppression sprays.
2.15 Fuel transfer Pump *

Type Electrically driven from engine 24 volt supply.
2.16 Caterpillar Power Pack *

Type 3116 DIT, 6 cyl. water cooled dieasel engine, 132 hp
@ 1800 rpm with steel enclosure and twin disc
manual clutch (fitted in lieu of Cummins engine).
Metrotrak
900 x 600
Page 7
2.17 Hydraulic Clutch *

Type Hydraulically actuated HFO clutch, operated with an
electric push button, in lieu of the manual twin disc
clutch.
2.18 Anti-vandal Guards *

Type Lockable covers over control stations
Metrotrak
900 x 600
Page 8
Blank Page
Metrotrak
900 x 600
General Information Issue 07 ENG
Page 1
Contents
3.1 Introduction ......................................................................................................... 2
3.2 General information ............................................................................................ 2
3.3 Designated Use ...................................................................................................3
3.4 Crusher Capacity ................................................................................................. 3
3.5 Copyright ............................................................................................................. 5
Metrotrak
900 x 600
Page 2
3.1 Introduction 3.2 General information
This instruction manual contains The Metrotrak which you have now
important information on how to operate received has been manufactured,
the plant safely, properly and most assembled and tested with the utmost
efficiently. care and was built with first class
materials.
Observing these instructions and
exercising Common Sense helps to avoid Close attention has been paid to all
danger, to reduce repair costs and details in assembly, running tests and final
downtimes and to increase the reliability inspection.
and life of the plant. Failure to do so may
invalidate any warranties in force. We are confident that you have received
a plant which will give you every
The operating instructions must always satisfaction over a long period.
be available wherever the plant is in use.
To be assured of faultless operation we
These operating instructions must be would ask you to carefully read the
read and applied by any person in charge following paragraphs and give the
of and/or working on the plant such as:- required time and attention to essential
maintenance, cleaning and inspection.
Operation
The plant is simple to operate,
Includes manoeuvring, setting up, adjustments are easy to make and expert
operation during the course of work, assistance is seldom required, provided
evacuation of production material and that ordinary care is exercised in daily
waste, care and disposal of fuels and use.
consumables, etc.
The plant has been built in accordance
Maintenance with state-of-the-art standards and
recognised safety rules. It is designed to
Servicing, inspection and repair be reliable, efficient and safe when used
and maintained in accordance with the
and/or instructions given in this manual.
Transport Nevertheless, it’s use may constitute a

risk to life and limb of the user or of third
Follow all applicable laws and safety parties, or cause damage to the plant and
regulations for accident prevention and to other material property.
environmental protection.
Metrotrak
900 x 600
Page 3
3.3 Designated Use The crusher must not be operated at a

discharge opening less than 50mm
The Metrotrak has been designed without prior consultation with BL-
exclusively as a self-contained mobile Pegson Limited, the only exception to
unit for crushing materials in a wide this being for crushing bricks and
range of quarry, demolition and recycling demolition materials only. Operating the
applications within the parameters set out crusher below this setting may result in
and described within this manual. extensive damage.
Closed Side Setting Crusher Output

(mm) (M.tph)
3.4 Crusher Capacity
40* 60-70*
50 70-90
In order to obtain the optimum output
from the crusher it’s feed should be 63 85-110
continuous and regulated. Additionally, 75 90-115
all feed should be of a size that will 90 110-125
readily enter the crusher chamber and, in 100 120-140
order to avoid packing of the discharge 125 145-175
opening and excessive wear of the plant
jaws, undersize material should be *Demolition materials only
removed from the feed prior to entry to
the crusher. Figure 3a Crusher Capacity
The discharge rates given are based on

crushing clean, dry limestone weighing Note:- The crusher has been designed to
approximately 1600Kg/m3, loose and work with feed materials having a 10%
having a specific gravity of 2.6. Wet feed fines value not exceeding 390kN.
material reduces the crusher discharge
rate. Product gradings are typical only and will
vary depending on material
The percentage of oversize output from characteristics.
the crusher, for a given discharge
opening, will depend largely on the
quality and character of the feed material.
Figure 3b shows an estimated analysis of
the product for different discharge
openings.
Metrotrak
900 x 600
Page 4
Operating the plant outside it’s The optional magnetic overband

recommended range of applications and separator, where fitted, is intended to
operating parameters, will result in a loss extract ferrous materials from the
of guarantee and the manufacturer/ crushed product but this material in the
supplier cannot be held liable for any feed must be limited to a size that will
damage resulting from such use. The risk not cause damage to the crusher.
of such misuse lies entirely with the user.
If you have any doubts about
When the optional dirt conveyor is fitted, any aspect of the plant’s
material passing through the feeder capability or servicing
grizzly bars will be extracted from the procedures, you must consult
crusher feed material to by-pass the your local BL-Pegson dealer
crusher (coarse material) and discharge or BL-Pegson technical
to the dirt conveyor (fines material). department.
Figure 3b Product Analysis
Metrotrak
900 x 600
Page 5
3.5 Copyright
The copyright of this User Manual is

reserved by BL-Pegson Limited.
This User Manual contains infornation

and technical drawings, which may not
be copied, distributed, altered, stored on
electronic media, revealed to other or
used for the purpose of competition,
either partially or in its entirety.
The right is reserved to alter any

details contained in this manual
without notice. Copyright 1999.
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax::- + 44 1530 518618
E mail:- sales@bl-pegson.com
Metrotrak
900 x 600
Page 6
Blank Page
Metrotrak
900 x 600
Design and Function Issue 07 ENG
Page 1
Contents
4.1 General Information ............................................................................................ 2
4.2 Construction Units .............................................................................................. 3

4.2.1 Single Toggle Jaw Crusher ............................................................................ 3
4.2.2 Vibrating Grizzly Feeder ................................................................................ 3
4.2.3 Track Frame ...................................................................................................4
4.2.4 On-Plant Product Conveyor ...........................................................................4
4.2.5 Magnet ........................................................................................................... 4
4.2.6 Plant Chutework ............................................................................................. 4
4.2.7 Maintenance Platforms .................................................................................. 4
4.2.8 Standard Power-Pack .................................................................................... 5
4.2.9. Dirt Conveyor ................................................................................................ 5
4.2.10 Controls........................................................................................................ 5
4.2.11 Chassis ........................................................................................................ 5
4.2.12 Guards ......................................................................................................... 5
4.2.13 Painting ........................................................................................................ 6
4.2.14 Dust Suppression Sprays ............................................................................6
4.2.15 Optional Extras * .......................................................................................... 6
4.2.16 Optional Exclusions * ................................................................................... 6
4.2.17 Specifications ............................................................................................... 6
Metrotrak
900 x 600
Page 2
4.1 General Information
The BL-Pegson Metrotrak Plant has been designed for a wide range of quarry and
recycling applications, its features include:-
• Rapid set up time
• Easily transported on and off site
• Well proven high performance 900 x 600mm (24” x 36”) ‘M’ series single toggle roller
bearing jaw crusher
• Fully skirted product conveyor
• Folding Hopper
• Two step self cleaning grizzly with under screen
• Facility to remove scalping or clean second product
• Heavy duty chassis and track frame
• Remote control
• Dust suppression sprays
• Cummins water cooled diesel engine
• Optional dirt conveyor and magnetic separator
• CE Approved
Metrotrak
900 x 600
Page 3
4.2 Construction Units Grizzly Section:- Double section of

welded tapered finger type bars at 50mm
BL-Pegson 900 x 600 Metrotrak (2”) spaces (at discharge end) fabricated
Recycling/Crushing plant with Diesel/ in 20mm (0.8”) thick abrasion resistant
Hydraulic drive. steel.
4.2.1 Single Toggle Jaw Crusher Under Screen:- Standard fitting of a

removable mesh of 20mm (0.8”) nominal
BL-Pegson 900 x 600mm (24” x 36”) aperture to allow (when dirt conveyor
‘M’ series Single Toggle Roller Bearing fitted and material screenable) extraction
Jaw Crusher including:- of smaller fines onto the dirt conveyor
with the coarser fines discharging onto
Lubrication:- Eccentric shaft roller the product conveyor. Alternatively, by
bearings are lubricated by grease. removing the mesh entirely, direct all the
grizzly fines to the dirt conveyor. A
Setting Adjustment:- Hydraulically rubber blanking mat will be fitted where
assisted and pre-set in the factory at the plant does not have the dirt conveyor
50mm fitted.
Drive:- Through vee belts from the Drive:- Hydraulic motor mounted on
diesel engine with screw tension vibrating unit.
adjustment of the engine baseframe.
Control:- Variable speed is achieved via
a rotary control located on the Feeder/
Conveyor control box. Facility is also
4.2.2 Vibrating Grizzly Feeder included to stop/start the feeder from the
BL-Pegson 800 wide x 3800mm long remote control handset.
(32” x 12’-6”) Vibrating Grizzly Feeder,
including:- Hopper:- having hydraulic folding of
the hopper sides, (manual back plate),
Vibrating Unit:- Heavy duty mechanical fabricated in 8mm (0.3”) thick abrasion
type with twin counter rotating shafts resistant steel plate suitable braced with
with oil lubricated bearings and gears. steel sections.
Pan:- 12mm (0.5”) thick abrasion

resisting steel bottom plate is included in
the welded construction.
Metrotrak
900 x 600
Page 4
4.2.3 Track Frame Adjustment:- Belt tensioning to be

maintained and adjustment at the head
Heavy duty size nine track frame having drum.
160mm (6.3”) pitch chain and 3.3m (10’-
10”) longitudinal centres with 400mm Covers:- Canvas type removable dust
(16”) wide tracks fitted as standard. covers are fitted at the head end.
Total plant weight approximately
26 tonnes.
4.2.5 Magnet
Overall Track width 2400mm
Overband magnetic separator with
Plant operating height 3400mm (hopper permanent magnet, suspended over tyhe
raised). main on-plant product conveyor and
complete with hydraulic drive.
Plant travel height with hopper folded -
3150mm, or 3400mm with fixed hopper,
(plus low loader height).
4.2.6 Plant Chutework
4.2.4 On-Plant Product Conveyor Crusher Feed Chute:- Fabricated in

10mm (0.4”) mild steel plate sides with
800mm (32”) wide plant mounted 25mm (1.0”) thick wear resistant bottom
troughed belt conveyor, 9’-5” discharge and including integral safety grid.
height, having a fixed tail section.
Grizzly Fines Chutes:- Chutework is
Belt:- EP 500/3 with 5mm (0.2”) top and provided for discharge of material to the
1.5mm (0.06”) bottom heavy duty rubber on-plant product conveyor and/or the
covers to BS490 and DIN 22102. Maximum optional dirt conveyor, fabricated in 6mm
stretch over life of belt running in normal (0.25”) mild steel plate.
working conditions will be no greater than
1%. A vulcanised joint is include.
Drive:- Hydraulic motor drive via 4.2.7 Maintenance Platforms

coupling to drive drum at pre-set speed.
A steel grid platform is provided on one
Feedboot:- Fabricated in mild steel plate side of the feeder fitted with double row
with abrasion resistant steel liners at feed handrails and access ladder. Platforms are
point, fully skirted wear resistant rubber also included to gain access to the rear of
sealing strips along the entire conveyor the crusher and to the power-pack.
length.
Metrotrak
900 x 600
Page 5
4.2.8 Standard Power-Pack This also provides stop and start control
for the vibrating grizzly feeder from a
Cummins 6BT 5.9 6 cylinder, 4 stroke, remote position. An alternative unbilical
direct injection, emission compliant water control unit is also provided for use in
cooled diesel power-pack in a steel case of remote control unit failure
enclosure, 149HP continuous rated 1800
rpm under NTP conditions designed to Emergency stop buttons are provided on
drive the crusher via a manually operated each side of the plant.
twin disc clutch.
Hydraulic transmissions powered from

the engine are provided to drive the 4.2.11 Chassis
tracks, feeder, product conveyor and,
where fitted, the dirt conveyor and/or the Fabricated steel frame of welded
overband magnetic separator. construction with supports for the feeder,
crusher, on-plant conveyor, power unit,
track frame and where fitted, the dirt
conveyor and/or overband magnetic
4.2.9. Dirt Conveyor separator.
Plant mounted 600 mm (24”) wide side
discharge dirt conveyor with hydraulic 4.2.12 Guards
flding facility giving a discharge height of
2.0m from the top of the head drum. The Wire mesh or sheet metal guards are
conveyor is hydraulically driven from the provided for all drives, flywheels, pulleys,
head drum and is mounted on the left couplings, gears and vee belts. The
hand side viewed from the feed end. guards provided are designed and
manufactured to ensure so far as
reasonably practicable that the machinery
4.2.10 Controls and plant on which they are fitted can be
operated safely and without risk to health
Controls are fitted on the plant for the
when properly used. However, the
feeder (on/off and speed), conveyors etc
company cannot guarantee that the
with engine and master controls sited in a
guards provided will meet the
lockable box mounted below the engine.
requirements laid down by individual
inspectors and any additional guard and/
A remote radio control unit is provided
or modification to guarding supplied,
for the tracking function giving a
which may be required for any reason
tracking speed of approximately 0.62mph
whatsoever, will be charged as an
a “creep” facility for loading, off loading
additional contract price.
and precise slewing movements.
Metrotrak
900 x 600
Page 6
4.2.13 Painting • Alternative wire mesh panel for the

feeder underscreen, available in
The plant is finish painted in RAL 5015 apertures of 10mm,30mm, 40mm. or
blue. 50mm (Buyer to decide which sepa-
ration size is required).
4.2.14 Dust Suppression Sprays

Spray bars with atomiser nozzles are
4.2.16 Optional Exclusions *
mounted over the crusher mouth and the
Available at time of initial purchase:-
product conveyor feed and discharge
points piped to a single inlet manifold for • Dirt Conveyor.
clients pressurised clean water supply.
• Overband Magnetic Separator.
4.2.15 Optional Extras * • Hydraulic folding feed hopper
Available at the time of initial purchase:- (replaced by fixed type one piece
hopper).
• Milltonics single idler belt weigher
with integrator and speed sensing
wheel fitted to main product con-
veyor. 4.2.17 Specifications
Every endeavour will be made to supply
• Water pump, hydraulically driven, to equipment as specified, but we reserve
provide pressurised water supply for the right, where necessary, to amend
the dust suppression sprays. specifications without prior notice as we
operate a policy of continual product
• Fuel transfer pump electrically driven development.
from the engine 24 volt supply.
BL-Pegson cannot guarantee that the
• Caterpillar engine in lieu of Cummins. equipment specified will meet any
specific requirements in respect of noise
• HFO Hydraulically actuated clutch in
or vibration levels, dust emission, or any
lieu of manual twin disc clutch.
other factors relevant to health and safety
measures or environmental protection
• Anti-vandal guards.
needs.
• Addtional maintenance platform on
the opposite side of the feeder.
Metrotrak
900 x 600
Transport Issue 07 ENG
Page 1
Contents
5.1 Safety Information ............................................................................................... 2
5.2 Transportation .....................................................................................................3

5.2.1 Manoeuvring ................................................................................................... 3
5.2.2 Unloading ........................................................................................................ 7
5.2.3 Loading .......................................................................................................... 8
5.3 Folding Hopper Plates * .................................................................................... 11
5.3.1 Hydraulic Folding Hopper Plates * .................................................................12
5.3.2 Manual Folding Hopper Plates * .................................................................... 15
Metrotrak
900 x 600
Page 2
5.1 Safety Information
Loose or baggy clothing can get PROTECTIVE CLOTHING

caught in running machinery.
ALWAYS wear correctly fitting

(E.N./A.N.S.I. approved) protective
clothing.
Protective clothing includes Hard Hat, Safety

Glasses, Ear Protection, Dust Mask, Close
Fitting Overalls, Steel Toed Boots and High
Visibility Vest.
Falling from and/or onto a SAFETY PLATFORMS/

BL-Pegson machine can cause
HARNESS
serious injury or even death.
DO NOT climb onto the machine.
ALWAYS use the walkways/platforms provided

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

harness when reaching any points 7ft (2m) or
more above ground level.
Metrotrak
900 x 600
Page 3
5.2 Transportation When manoeuvring your

Metrotrak to its operating
5.2.1 Manoeuvring position make sure you stand
well clear of the plant but are
(Refer to Section 7.3) in a position to have all-round
vision to see any obstacles,
Prior to attempting any dangers that may lie ahead e.g
manoeuvring of the plant the personnel, overhead cables,
tracks must be free of ditches, unsafe roadways etc.
obstructions, including (Refer to Figure 2a
crushed material and fines. Dimensions)
Do not push or tow the plant.
Failure to observe this • Make sure that you do not
warning could result in manoeuvre your Metrotrak on a
danger to persons and gradiant steeper than 30 degrees,
damage to the plant which damage may occur to the engine and/
may invalidate warranty. or plant.
• Before manoeuvring the Metrotrak, • Avoid manoeuvring the plant over

ensure the feed hopper and crusher extremely uneven ground or damage
are empty, and that all materials have may occur.
run off the conveyors. STOP the
feeder, dirt conveyor, product • Control valves mounted on the engine
conveyor and disengage the clutch. and beneath the feeder are NOT to be
used to manoeuvre the Metrotrak.
• The plant cannot be manoeuvred in the They are for use by BL-Pegson
PLANT mode of operation. Service Engineers only.
• DO NOT manoeuvre the Metrotrak • Initial start up in cold weather may

whilst the crusher running. result in a tendency to steer to the
right whilst tracking fast forward due
• The safety warning horn sounds to the hydraulic oil being cold. Run
continuously whilst the plant is being the plant for approx. 10 minutes with
manoeuvred. the conveyor and feeder running prior
to manoeuvring the plant.
DO NOT stand on any of the
platforms or ladders of the • When transporting the Metrotrak, it
Metrotrak whilst it is being is the responsibility of the haulage
manoeuvred using the remote contractor to safely secure the plant
control handset. to the transporter.
Metrotrak
900 x 600
Page 4
To manoeuvre the Metrotrak with

the remote control hand set :- WARNING
WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Procedure Refer to Section 5.1, Safety
Information for relevant
warning.
1. Observe all safety instructions.
2. Start the engine (Section 7.2.1).

Increase the engine speed to
1800rpm.
3. On the Control Panel, turn the

Operation switch to ‘TRACK’.
4. Take the Remote Control Hand Set

from the Control Box and first
become familiar with the functions of
all the individual buttons (Figure 5b)
before the next step.
Foward = Product Conveyor first
Reverse = Hopper first
5. Standing well clear of the plant, hold

the hand set facing the Metrotrak.
Press the Power On/Off button to
turn the hand set ‘ON’. An LED will
flash ‘GREEN’ to indicate the hand
set is functioning.
6. Pressing the Horn button will sound

the safety warning horn and engage
the tracks ready for manoeuvring.
7. The tracks on the Metrotrak work

independent to each other. Press the
slow speed buttons on the hand set to
manoeuvre the plant in the desired
Metrotrak
900 x 600
Page 5
direction (Figure 5b). Employ the 10. On the Control Panel turn the
‘Fast’ speed only where safe to do so. Operation switch to ‘PLANT’. The
safety warning horn will sound for 15
8. When the Metrotrak is in the correct seconds. Stop the engine (Section
position, press the Horn button to 8.2), unless required further.
turn the safety warning horn ‘OFF’
and disengage the tracks.
9. Press the Power On/Off button to

turn the hand set ‘OFF’. The LED
will extinguish. Replace the remote
control hand set in Control Box
Operation Feeder Remote Dirt Conveyor Hopper

Plant/Track Off/On Lower/Raise * Lower/Raise *
Figure 5a Control Panel
Metrotrak
900 x 600
Page 6
Stop Button
LED
Power On/Off
3
2
4
5
6 Horn
Not Required By
Metrotrak Plant
Feeder On Feeder Off
Press Buttons 1 & 2 Slow Forward Press Button 1 Right Turn*

Press Button 3 Fast Forward Press Button 2 Left Turn*
Press Buttons 4 & 5 Slow Reverse Press Buttons 1 & 5 Sharp Right Turn*
Press Button 6 Fast Reverse Press Buttons 2 & 4 Sharp Left Turn*
* Travelling ‘Forward’
Figure 5b Remote Control Hand Set
Metrotrak
900 x 600
Page 7
5.2.2 Unloading
WARNING
Procedure WEAR PERSONAL
Refer to Section 5.1, Safety
The Metrotrak will arrive on site securely warning.
fastened to a low loader. It is the
responsibility of the haulage contractor
to remove the fastenings.
1. Observe all safety warnings.
2. Position easy slope ramps at the end

of the transporter to help with
unloading of the Metrotrak.
3. Locate the control box and raise the

spring loaded cover to reveal the
control panel and engine control
panel (Figure 7b).

1800rpm.
5. Turn the Operation switch to

‘TRACK’ (Figure 5a). Using the
remote control hand set, steer the
Metrotrak off the transporter
(Section 5.2.1 and Section 7.3).
Metrotrak
900 x 600
Page 8
5.2.3 Loading
WARNING
Refer to Section 5.1 Safety
1. Observe all safety warnings. warning.
FALLING HAZARD.
2. Ensure that both conveyors, feed Refer to Section 5.1 Safety
hopper and crusher are free from warning.
stone and dirt.
3. On the left hand side of the Metrotrak

raise the bottom section of the front
ladder and secure (Figure 5c).
4. Remove the dirt conveyor head drum

guard (Figure 5d). This is necessary
before folding the conveyor for
transport.
5. Ensure all loose items are carefully

stowed and secured if these are to be
transported on the plant.
6. Locate the control box and raise the

cover to reveal the control panel and
engine control panel.
7. Start the engine (Section 7.2.1). Figure 5c Front Ladder Folded for
Increase the engine speed to Transportation
1800rpm.

‘PLANT’, the safety warning horn
will sound for 15 seconds.
Metrotrak
900 x 600
Page 9
9. Turn the Dirt Conveyor switch to ‘é’

and fold the dirt conveyor fully in to WARNING
the travelling position. Secure with
WEAR PERSONAL
the transportation safety chain PROTECTIVE EQUIPMENT.
(Figure 5e) Refer to Section 5.1 Safety
During folding of the dirt warning.
conveyor ensure that the FALLING HAZARD.
hydraulic hoses and conveyor Refer to Section 5.1 Safety
belt do not foul any part of Information for relevant
warning.
the structure.
10. Lower the hopper plates into the

travelling position (Section 5.2.4).
11. Position easy slope ramps at the end

of the transporter to help with
loading of the Metrotrak.

‘TRACK’. Using the remote control
hand set, steer the Metrotrak onto the
transporter(Section 5.2.1 and Section
7.3).
13. When the plant is loaded turn the

remote control hand set ‘OFF’ using
the Power On/Off button and replace
the hand set in the Control Box.
14. Switch off the engine (Section 8.2).

Remove the ignition key and lock the
control box.
15. Securing the Metrotrak to the

transporter is the responsibility of
the haulage contractor.
Metrotrak
900 x 600
Page 10
Head Drum Dirt Conveyor

Guard
Figure 5d Dirt Conveyor
Dirt Conveyor Safety

Chain
Dirt Conveyor
Figure 5e Dirt Conveyor Safety Chain
Metrotrak
900 x 600
Page 11
5.3 Folding Hopper Plates *

WARNING
Do Not attempt to undo any WEAR PERSONAL
fastenings holding the Manual PROTECTIVE EQUIPMENT.
folding hopper side plates or Refer to Section 5.1 Safety
end plate until securely held
warning.
by lifting equipment to
FALLING HAZARD.
prevent any movement. Refer to Section 5.1 Safety
Road transportation warning.
regulations may require that
the hopper plates be lowered
for road transportation.
Figure 5f Dirt Conveyor Folded and

Secured with Chain
Metrotrak
900 x 600
Page 12
5.3.1 Hydraulic Folding Hopper
Plates * WARNING
WEAR PERSONAL
The hydraulic folding hopper system PROTECTIVE EQUIPMENT.
consists of two side plates hydraulically
operated into position and an end plate warning.
located manually. The plates are locked FALLING HAZARD.
into position using the attached wedges. Refer to Section 5.1 Safety
Raising the Hydraulic Folding warning.
Hopper Plates into the Working
Position.
Procedure

1800rpm.
3. Remove the locking wedges from the

tool box (Figure 5g).
4. On the Control Panel located inside

the Control Box, the Hopper switch
(Figure 5a) turned to ‘é’ will raise
the side plates into the working
position but first remove the fixings
securing the hopper plates in folded Figure 5g Side Plate Locking Wedges
above. End plate locking wedges below.
condition.
5. Raise the side plates into position and

lock into place using the four locking
wedges (Figure 5g, two wedges for
each side plate). Attach the locking
wedge chains to the plant.
Metrotrak
900 x 600
Page 13
(Note; The Hopper hydraulic switch

may need to be ‘toggled’ briefly WARNING
to‘ê’ in order to align the wedges).
WEAR PERSONAL
6. With suitable lifting equipment rotate Refer to Section 5.1 Safety
the hopper end plate and lock the side Information for relevant
plates to the end plate using the two warning.
locking wedges. Attach the locking FALLING HAZARD.
wedge chains to plant. Refer to Section 5.1 Safety
warning.
7. Stop the engine (Section 8.2), unless
further required.
Metrotrak
900 x 600
Page 14
Lowering the Hydraulic Folding

Hopper Plates into the Travelling WARNING
Position
WEAR PERSONAL
Procedure Information for relevant
warning.
1. Observe all safety warnings.. FALLING HAZARD.
2. Using suitable lifting equipment to Information for relevant
warning.
hold the end plate, remove the
wedges securing the end plate to the
side plates and lower the end plate.
3. Start the engine (Section 7.2).

Increase the engine speed to 1690
rpm.
4. Remove the four hopper side plate

wedges (two for each side plate
Figure 5g).
(Note : The Hopper hydraulic switch

may need to be briefly ‘toggled’ in
order to remove the wedges)
5. Lower the side plates into the

travelling position and secure in place
at the crusher feed chute using the
fixing points provided.
6. Stop the engine (Section 8.2), unless

further required.
7. Store the locking wedges in the tool

box.
Metrotrak
900 x 600
Page 15
5.3.2 Manual Folding Hopper
Plates * WARNING
WEAR PERSONAL
Do Not attempt to undo any Refer to Section 5.1 Safety
fastenings holding the manual Information for relevant
folding hopper side plates or warning.
end plate until securely held FALLING HAZARD.
by lifting equipment to
prevent any movement. warning.
Raising the Manual Folding

Hopper Plates into the Working
Position
Procedure 6. With suitable lifting equipment rotate

the hopper end plate and lock the side
1. Observe all safety warnings. plates to the end plate using the two
locking wedges. Attach the locking
2. Open the tool box and remove the side wedge chains to plant.
plate locking wedges (Figure 5h).
3. Remove the bolts securing the folding

hopper plates to the chassis. Store the
bolts in the toolbox.
4. Using lifting equipment, raise one

side plate into position and lock into
place using the locking wedges
(Figure 5h & 5i, two wedges for each
side plate). Attach the locking wedge
chains to plant.
5. Repeat Steps 4 for the other side

plate.
Metrotrak
900 x 600
Page 16
Lowering the Manual Folding

Hopper Plates into the Travelling WARNING
Position
WEAR PERSONAL
Procedure Refer to Section 5.1 Safety
warning.
1. Observe all safety warnings. FALLING HAZARD.
3. Using lifting equipment support the Information for relevant
warning.
end plate.
4. Remove the wedges securing the end

plate to the side plates. Lower the
end plate into the travelling position.
5. Using lifting equipment support one

of the side plates.
6. Remove the locking wedges holding

the side plate in position. Lower the
side plate into the travelling position.
7. Repeat Steps 5 & 6 for the other side

plate.
5. Secure the side plates in place at the

crusher feed chute using the fixing
points provided.
9. Store the locking wedges in the tool

box.
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 1
Contents
6.2 Setting Up ............................................................................................................ 5
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 2


clothing.

Visibility Vest.

BL-Pegson plant can cause
HARNESS
DO NOT climb onto the plant.


Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 3
In-running nip points can cause NIP POINTS

DO NOT reach into an unguarded

plant.
Your arm could be pulled in and amputated.
SWITCH OFF and LOCKOUT plant before

opening or removing guards.
Hydraulic fluid under pressure can HYDRAULIC HOSES

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

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

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

surgically removed or gangrene will result.
Get medical help immediately.
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 4
When carrying out maintenance or LOCKOUT PROCEDURE

adjustment to the plant the
following procedure must be
followed.
LOCKOUT PROCEDURE
1. Switch off engine.

2. Remove isolation key.
3. Keep isolation key on person during
lockout.
4. Place appropriate maintenance warning
signs.
5. NEVER work alone.
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 5
6.2 Setting Up
WARNING
Plant Location Considerations WEAR PERSONAL
warning.
Prior to setting up your Metrotrak, LOCKOUT PLANT.
consideration should be given to a Refer to Section 6.1, Safety
suitable layout to prevent oversize Information for Lockout
Procedure.
material or tramp metal from entering the
plant. In order to prevent bridging of the FALLING HAZARD.
crusher no material above the size Refer to Section 6.1 Safety
recommended by the manufacturer Information for relevant
should be fed into the plant. warning.
1. Observe all safety instructions.
2. Position the plant in a safe level

operating position making sure both
tracks are in full contact with the
ground to minimise movement of the
Metrotrak. Pay attention to access
from the loading area and to where
material is to be deposited (Section
5.2.1), and ensure the area under the
tail drum is free of large stones etc
which may cause belt damage.
3. Raise the hopper plates * into the

working position (Section 5.3.1).
4. Remove the dirt conveyor *

transportation safety chain (Figure
6a).
5. Turn the Operation switch

to’PLANT’(Figure 6b).
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 6
6. Start the engine (Section 7.2). 9. Replace and secure the dirt conveyor
Increase the engine speed to head drum guard and side plates.
1800rpm.
7. Lower the dirt conveyor fully by

turning the dirt conveyor switch to
‘ê’ (Figure 6b).
During lowering of the dirt

conveyor ensure that the
hydraulic hoses and conveyor
belt do not foul any part of
the structure. Do not operate
the plant with the dirt
conveyor folded.
8. Switch off the engine (Section 8.2)

and lockout.
Dirt Conveyor Safety

Chain
Dirt Conveyor
Figure 6a Dirt Conveyor Safety Chain
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 7

Figure 6b Control Panel
Metrotrak
900 x 600
Set Up Issue 07 ENG
Page 8
Blank Page
Metrotrak
900 x 600
Operating Instructions Issue 07 ENG
Page 1
Contents

7.1.1 Blocked Crusher Situation ............................................................................... 5
7.1.2 Stalled Crusher Procedure (1) ......................................................................... 6
7.1.3 Stalled Crusher Procedure (2) ......................................................................... 7
7.2 Safe Start-Up Procedure ..................................................................................... 8
7.2.1 Engine Start-Up .............................................................................................. 9
7.2.2 Crusher Engagement
(manual or hydraulically * activated) ..............................................................14
7.2.3 Feeder/Conveyor Start-Up ............................................................................15
7.2.4 Safe Operation of the Plant ...........................................................................17
7.2.5 Checks Prior to Initial Daily Start ................................................................... 17
7.2.6 Initial Start Up and Running In ........................................................................ 18
7.3 Remote Control Operation ................................................................................ 21
7.3.1 Remote Control Hand Set .............................................................................22
7.3.2 Feeder Remote Operation ............................................................................23
7.3.3 Battery Replacement Remote Control Hand Set ............................................ 24
7.3.4 Alternate Control Hand Set (with Umbilical Cable) .........................................26
Metrotrak
900 x 600
Page 2


clothing.

Visibility Vest.

HARNESS


Metrotrak
900 x 600
Page 3


machine.
SWITCH OFF and LOCKOUT machine before


injury.



Metrotrak
900 x 600
Page 4

followed.
LOCKOUT PROCEDURE

lockout.
signs.
Metrotrak
900 x 600
Page 5
7.1.1 Blocked Crusher Situation

It is the responsibility of the Owner, End
WARNING
User and/or Safety Officer of the Metrotrak WEAR PERSONAL
to provide a safe means of dealing with PROTECTIVE EQUIPMENT.
oversize material and construct a safe Information for relevant
procedure for unblocking a stalled machine warning.
which is full of material.
LOCKOUT PLANT.
To comply with British Health and Safety Information for Lockout
Law it is necessary to conduct an Procedure.
adequate risk assessment of the
procedures for unblocking a blocked FALLING HAZARD.
crusher. Refer to Section 9.1, Safety
warning.
Should an oversize piece of material be
fed to a jaw crusher and cause the feed
opening to be bridged the recommended
procedure for removing this is to use a
hydraulic arm. When a hydraulic arm is
used no pressure should be put on the Under most arrangements pinch bars and
rock when the crusher is STATIONARY hand hammers cannot be used safely. Their
as this will cause premature failure of the use should be limited to situations under risk
bearings. A crane and hook can be used assessment where there is every indication
although EXTREME caution must be that they can be worked safely.
exercised to ensure that the crane is not
overloaded by trying to lift a jammed Once this has been decided it should be
rock. incorporated into a permit to work
procedure to be issued by the manager.
The following methods SHOULD This system should cover things such as
NOT be attempted.:- notification to the manager, isolation,
methods of removal of excess stone, safe
positions for personnel.
The use of wedges.
TURN TO NEXT PAGE FOR STALLED
Using mobile plant to drag stones out of the CRUSHER PROCEDURES.
crusher or feeder.
Metrotrak
900 x 600
Page 6
7.1.2 Stalled Crusher Procedure (1)

In the situation where an oversize piece of
WARNING
WEAR PERSONAL
material causes the crusher to stall, it is Refer to Section 9.1, Safety Informa-
possible the pressure will be sustained on tion for relevant warning.
the moving swing jaw. This pressure will LOCKOUT PLANT.
need to be released under controlled Refer to Section 9.1, Safety
conditions to enable safe removal of the Information for Lockout
material that has created the stall condition FALLING HAZARD.
BEFORE ANY ATTEMPT TO Information for relevant warning.
CARRY OUT THE
PROCEDURES TO CLEAR
THE STALLED CONDITION
OF THE CRUSHER THE
3. Carefully ascertain if this has allowed
MACHINE MUST BE some possible movement of the toggle
ISOLATED FROM ALL beam/plate which has released the
SOURCES OF SUPPLY AND pressure on the blocking material.
THE SAFETY GRID AT THE
MOUTH OF THE CRUSHER 4. If the procedure is sucessful and the
MUST BE SECURELY blocking material removed, retighten the
FASTENED IN PLACE. locking wedges before recommencing
operation.
In certain circumstances it may be possible
to release the pressure on the moving swing
jaw by slackening off the toggle beam
locking wedges which may allow the toggle 1
beam to be raised sufficiently to allow the
jaw to fall back by a small amount
Procedure 3
Toggle Beam 2
5. Loosen both of the toggle beam locking

mechanism nuts (1 & 2) (Figure 7) so
Mainframe
releasing the locking wedges (3).
Figure 7 Toggle Beam Locking Mechanism
Metrotrak
900 x 600
Page 7
7.1.3 Stalled Crusher Procedure (2)

If the previous procedure fails to provided
WARNING
WEAR PERSONAL
sufficient means of releasing the pressure on Refer to Section 9.1, Safety Informa-
the toggle plate to enable the stalling tion for relevant warning.
blockage to be removed, more radical LOCKOUT PLANT.
means may be required. This could incur Refer to Section 9.1, Safety
the cutting through of the toggle plate (from Information for Lockout
above the plate) with the aid of a thermic FALLING HAZARD.
lance or other similar cutting device. A new Refer to Section 9.1, Safety
toggle plate will be required to be fitted Information for relevant warning.
before crushing operations can be re-
commenced (Section 9.7.3).
CUTTING THROUGH THE IMPORTANT

TOGGLE PLATE WILL The above, or any other procedure
CAUSE THE RELEASE OF developed to remove tramp metals, or any
STORED ENERGY IN THE other material that results in the stalling of the
MOVING JAW WHICH WILL crusher should be incorporated into a permit
SWING VIOLENTLY BACK to work procedure. This procedure should be
TOWARDS THE OPERATOR maintained under the control of the competent
PERFORMING THE person appointed by the management.
CUTTING OPERATION.
The system should cover all factors of safety
including notification to the manager, isolation
Procedure of systems and locking out procedures,
methods of removal, safe positions for
persons and any other precautions as may be
1. Observe all safety warnings. deemed necessary.
2. Before the cutting operation is Should any futher information be required with
commenced adequate and appropriate regard to the clearing of blocked crushers,
provision MUST be made to support reference can be made to the :-
the weight of the jawstock to control
the release of the stored energy in order British Aggregate Construction Materials
to prevent the violent swinging Industries (BACMI) document ‘Clearing
movement of the jawstock. Blocked Crushers’.
3. Cut the toggle plate across its line, This document provides recommended
observing any movement prior to the procedures and advice on risk assessment
final separation. and permit to work.
Metrotrak
900 x 600
Page 8
7.2 Safe Start-Up Procedure • Check that all guards are in position and
secure and that all personnel are clear
BL Pegson Ltd cannot over of the plant.
emphasise the need to ensure
that all safety aspects are
checked before starting the
engine.
Whilst the engine is running

and the Operation switch is
turned from ‘TRACK’ to
‘PLANT’ mode the safety
warning horn will sound for 10
seconds. When the horn has
stopped the conveyor(s) and/or
feeder can be started.
With the engine switched ‘OFF’
• Ensure the full length of both vehicle

tracks are in contact with a firm level
surface.
• Check that the crushing chamber and

feed hopper are empty.
• Measure the crusher discharge

opening and adjust if necessary.
(Section 9.9)
• Check that all four Emergency Stops

are pulled out (Figure 1a).
• Manual Clutch only. Ensure the

engine clutch is disengaged (lever
fully away from the engine) and the
throttle is set to the lowest position,
screwed fully in (Figures 7d and 7f).
Metrotrak
900 x 600
Page 9
7.2.1 Engine Start-Up

WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
1. Observe all safety warnings warning.
2. Ensure the engine Isolation key (refer to

Figure 7a) is turned to the ‘ON’
position.
3. Locate the Control Box and raise the

cover to reveal the control panel and
engine control panel (Figure 7b).
4. Turn the Operation switch, located on

the Control Panel to ‘PLANT’
(Figure 7c).
5. Ensure the Hand Throttle (Figure 7d)

located above the Control Panel
inside the Control Box is set to the
lowest position, screwed fully in.
Figure 7a Isolation Key
6. Turn the Ignition switch to position
‘I’. The safety warning horn will
sound for 10 seconds before the engine
can be started (Figure 7e).
7. Depress and hold the Override switch 9. Using the Hand Throttle set the rpm of
in the ‘ON’ position. Turning the the engine to 1350rpm (view on
Ignition switch to position ‘START’, tachometer) and allow to run for 3-5
the engine will then start. minutes before proceeding further.
8. Release the Ignition switch to

position ‘I’. Let the engine run for a
few seconds before releasing the
Override switch.
Metrotrak
900 x 600
Page 10
Control Panel Access Cover Engine Control Panel
Figure 7b Control Box (Cummins Engine with Manual Clutch)

Figure 7c Control Panel (Manual Clutch)
Metrotrak
900 x 600
Page 11
Figure 7d Hand Throttle
Tachometer
Figure 7e Engine Control
Panel (Cummins Engine)
Service Meter Fuel Level
Water Oil Pressure

Temperature
Battery Charge
Override Button
Ignition Switch
Metrotrak
900 x 600
Page 12
Control Panel Access Cover Engine Control Panel
Figure 7b Control Box (Caterpillar* Engine with HFO* Clutch)
Operation
Plant/Track
Dirt Conveyor *
Lower/Raise
Crusher Off/On Hopper

Buttons* Lower/Raise *
Feeder Remote
Off/On
Figure 7c Control Panel (with HFO* Clutch)
Metrotrak
900 x 600
Page 13
Figure 7d Hand Throttle Adjustment
Tachometer
Water
Temperature Oil Pressure
Fuel Level Battery Charge
Service Meter
Override Switch Ignition Switch
Figure 7e Engine Control Panel

(Caterpillar* Engine)
Metrotrak
900 x 600
Page 14
7.2.2 Crusher Engagement

(manual or hydraulically * WARNING
activated) WEAR PERSONAL
With the engine speed set at 1350rpm :- Refer to Section 7.1, Safety
warning.
Procedure
1. Observe all Safety Warnings.
2. Manual Clutch only. Slowly engage

the clutch by moving the clutch lever
towards the engine unit, this will start
the crusher (Figure 7f).
Hydraulic Clutch only. On the

Feeder/Conveyor Control Box
(Figure 7g) located on the left hand
side of the Premiertrak, press the
‘GREEN’ Product Conveyor button
to start the conveyor (fixed speed)
and the magnetic overband separator
(Th e speed of the separator can be
altered, refer to section 9.17). Note
that the Crusher cannot be started
until the Product Conveyor is
Figure 7f Clutch Lever
running. (manual clutch)
On the Control Panel (Figure 7c)

press the ‘GREEN’ Crusher button to
operate the hydraulic clutch on the 1800rpm under crushing load). This
engine. A warning horn will sound for is the crusher and engine’s optimum
10 seconds before the clutch engages. speed.
3. Using the hand throttle increase the 4. Check the plant is stable with no
engine rpm to 1830-1860rpm, view excessive vibration.
on tachometer (engine speed
Metrotrak
900 x 600
Page 15
7.2.3 Feeder/Conveyor Start-Up

The control valves mounted on
WARNING
the engine and beneath the WEAR PERSONAL
feeder are NOT to be used in PROTECTIVE EQUIPMENT.
any circumstances to operate Information for relevant
the feeder or conveyors. warning.
The operation switch on the

control panel has to be in
‘PLANT’ mode for the feeder
and conveyors to work material to be crushed so as to maintain
(Figure 7c). The safety an even regular flow through the crusher
warning horn will sound for 10 (Section 7.2.7).
seconds when the Operation To adjust the speed of the feeder turn
switch is turned from the Feeder Speed Control knob and
‘TRACK’ to ‘PLANT’ mode. adjust to the required setting.
The feeder can be switched ON and OFF

remotely (Section 7.3.2). However the
Procedure speed cannot be adjusted from the
remote control handset.
2. Manual Clutch only. On the Feeder/

Conveyor Control Box press the
‘GREEN’ Product Conveyor button
NOTE FOR HYDRAULIC *
to start the conveyor (fixed speed) CLUTCH:
and the magnetic separator (The
speed of the separator can be altered, Should the Pressure Fault Light on the
refer to Section 9.17). control box (Figure 7g) remain
illuminated the feeder cannot be
3. Press the ‘GREEN’ Dirt Conveyor started. This red warning light
button to start the dirt conveyor indicates insufficient pressure for the
(fixed speed). hydraulic engine clutch to operate
under crushing loads. Investigate the
4. Press the ‘GREEN’ Feeder button to cause and rectify.
start the feeder.
The speed of the feeder will need
adjusting depending on the type of
Metrotrak
900 x 600
Page 16
Emergency Stop Feeder Speed

Button Control
Low Hydraulic Oil

Pressure Warning
Light *
(hydraulic clutch
only)
Crusher Stop
Button
*
(hydraulic clutch
only)
Dirt Conveyor On/ Product Conveyor Feeder On/Off

*
Off Buttons On/Off Buttons Buttons
Figure 7g Feeder/Conveyor Control Box
Metrotrak
900 x 600
Page 17
7.2.4 Safe Operation of the Plant 7.2.5 Checks Prior to Initial Daily
Start
NEVER leave your Metrotrak
unattended whilst it is in Plant
operation.
• Visually check the plant and ensure
Do check regularly that the oil that all guards and warning signs
cooler fan (located on the (Section 1) are in position and that all
Engine Maintenance equipment and tools that are
Platform) is running correctly hazardous to operation are removed
and that dust/dirt has not from the immediate site.
built up in the fan and
radiator unit (over heating • Manual Clutch only. Ensure that the
can occur if dust/dirt is jaw crusher clutch on the diesel
allowed to build up). Blow engine is disengaged.
out dust/dirt if necessary.
• Ensure that the jaw crusher and the
DO NOT allow a build up of grizzly feeder hopper are empty.
material at the feed on points
to enter either the product • Check discharge opening with
conveyor or dirt conveyor. calipers and adjust as necessary, to
the required settings (Section 9.9).
DO check frequently the
stability of the Metrotrak. The • Check the oil cooler fan and radiator
chassis SHOULD NOT unit (located on the Engine
bounce during operation. Mainenance Platform) for any build
up of dust/dirt. Blow out dust/dirt if
DO NOT run the engine necessary.
below its recommended
working speed of 1800 RPM, Crusher should be fed by an
and DO NOT slip the engine excavator such that the
clutch. bucket does not pass over or
near to the operator.
AVOID starting and stopping
your Metrotrak unnecessarily
as it WILL cause damage to
the plant.
Metrotrak
900 x 600
Page 18
7.2.6 Initial Start Up and Running 2. Check frequently the overall stability
In of the plant; re-check the level of the
plant and re-level if necessary.
Initial Start-Up
3. Manual Clutch only. After several
• Check the vibrating unit oil level and days use re-check clutch engagement
hydraulic oil level (Figure 7h & 7i). torque as described in engine manual.
• Refer to engine manual for engine Crusher
initial start up.
1. Regularly check drive belts (crusher
• Run the plant empty for a short and hydraulic pumps) to ensure
period of time and check for correct tension, particularly during
abnormal noises, vibration or the initial 2 weeks of use (Section
excessive heat from the shaft 9.15).
bearings.
2. Check the alignment and tension of
• Check the direction of rotation of the the vee belt drive daily during the
crusher flywheels, ie. over the top of initial days of operation (Section
the flywheels towards the feeder. 9.15).
Actions during Running-In Period 3. Check the shaft bearing temperature
daily using a contact thermometer
Checks on the Metrotrak are
and record for future reference and
crucial during the first week
fault diagnosis. The maximum
of operation.
acceptable working temperature is
The following section should
80°C.
be read and understood prior
to starting the Metrotrak. If 4. Avoid overloading the crusher; restrict
there are any doubts, contact loading to 50% and 75% of full capacty
BL Pegson Ltd. Service during the first and second days of
Department. operation respectively.
Plant
5. Ensure that all drives are running before
any feed is introduced to the plant and
1. Each day during the initial days of
that the feed is maintained at a constant
operation check the tension of the
rate, irregular and excessive feed rates
conveyor belts on the main product
reduce the efficiency of the plant.
conveyor and dirt conveyor (if fitted).
6. Ensure that all undersize feed (smaller
Metrotrak
900 x 600
Page 19
Hydraulic Oil Level Hydraulic Oil Hydraulic Oil Return

Breather/Filler Filter and Gauge
Hydraulic Oil Tank
Figure 7h Hydraulic Oil Tank & Level Indicator
Oil Filler Plug
Oil Level
Signt Glass
Oil Drain Plug
Figure 7i Feeder Vibrating Unit
Metrotrak
900 x 600
Page 20
than the discharge setting) and oversize

feed (greater that 80% of the feed
opening) is removed prior to
introduction into the crusher.
Feeder
1. Frequently check the oil levels in the

vibrating unit end covers and the
hydraulic oil level in the tank (Figure
7h &7i).
2. After first 8 hours of operation,

change the oil in the vibrating unit
end covers
3. Check the vibrating unit bearing

temperatures using a contact
thermometer on the end covers;
record for future reference and fault
diagnosis. (Maximum acceptable
temperature is 80ºC).
4. Ensure that the vibrating unit is

operating before any feed is
introduced to the plant.
Metrotrak
900 x 600
Page 21
7.3 Remote Control

Operation
DO NOT stand on any of the

platforms or ladders of the
Metrotrak whilst it is being
manoeuvered using the remote
control handset.
When manoeuvring your

Metrotrak to its operating
position make sure you stand
well clear of the machine but
are in a position to have all-
round vision to see any
obstacles, dangers that may lie
ahead e.g personnel, overhead
cables, ditches, unsafe
roadways etc.
(Refer to Figure 2a for
dimensions)
The Metrotrak ‘GREEN

BAND’ remote control system
is set to the following radio
frequency:-
Radio System Code -

PEG.RADEX.05.433
• If the plant moves out of the operating

range of the remote control hand set the
plant will stop.
Metrotrak
900 x 600
Page 22
7.3.1 Remote Control Hand Set

(Figures 5a & 7e)
WARNING
WEAR PERSONAL
Procedure Information for relevant warning.
To operate the hand set:-

Stop Button
1. Remove the remote control hand set
from the Control Box (Figure 7b).
2. Ensure that the four Emergency Stops

on the plant and the stop button on the
hand set are pulled out (Figures 1a and
5b). LED Power
On/Off
3. Start the engine (Section 7.2).
4. Refer to Section 5.2.1 if the plant is to

manouvered to a new position.
Refer to Section 7.3.2 if the feeder is to
be operated remotely.
• An LED on the hand set flashes ‘RED’

to indicate low battery power. To
change the battery refer to Section
7.3.2
• In the event of interference from another

radio signal, the plant will stop. The Figure 7j Remote Control Hand Set
additional hand set with the unbilical
connection to the plant can be used to
avoid this problem (Section 7.3.4) or a
change of radio frequency may be
necessary if the problem persists..
Metrotrak
900 x 600
Page 23
7.3.2 Feeder Remote Operation

To operate the feeder remotely the
WARNING
conveyors and feeder must first be switched WEAR PERSONAL
on manually and the feeder speed set PROTECTIVE EQUIPMENT.
manually (Section 7.2.3). Information for relevant warning.
Procedure Stop Button
2. On the Control Panel located within the

Control Box (Figure 7b), turn the
Operation switch to ‘PLANT’, the LED Power
safety warning horn will sound for 10 On/Off
seconds.
3. Turn the Feeder Remote switch to

‘ON’.
4. On the hand set (Figure 7k), press the

Power On/Off button to turn the hand
set ‘ON’. An LED will flash ‘GREEN’ Feeder Feeder
to indicate the hand set is functioning. On Off
5. The feeder can be turned on and off

using the Feeder On and Feeder Off
buttons on the hand set. The speed of
the feeder can not be adjusted using the Figure 7k Feeder Remote Operation
hand set. To adjust the speed of the
feeder refer to Section 7.2.3.
6. To turn the Remote Control hand set

‘OFF’, press the Power On/Off button.
The LED will extinguish.
Metrotrak
900 x 600
Page 24
7.3.3 Battery Replacement Remote

Control Hand Set WARNING
The remote control hand set uses a 9 volt WEAR PERSONAL
battery, PP3 or equivalent high capacity cell PROTECTIVE EQUIPMENT.
or a RX 22+ rechargeable battery where Information for relevant warning.
there is a charging point in the plant control
box.
An LED will flash ‘RED’ to indicate low

battery power and that the battery needs to
be replaced.
Where the plant is fitted with a

charging point a second rechargeable
battery is supplied. Alway keep this 6. Close the inner and outer door.
charged to be available to swap over
when needed. 7. Switch the hand set ON, the LED
should flash ‘GREEN’ to indicate the
Changing the Battery hand set is functioning.
Procedure
1. Switch the hand set OFF using the

Power On/Off button, the LED will
extinguish.
2. To open the battery outer door, push

the base of the outer door up and flip
the top of the door to open (Figure 7l).
DO NOT PRISE THE DOOR OPEN.
3. Flip the inner door open.
4. Slide the battery out and unclip the

battery from the socket.
5. Fit a new battery and slide back into

position.
Metrotrak
900 x 600
Page 25
LED
Remote Control
Hand Set
Power On/Off
The remote control hand set uses a

9 volt battery, PP3 or equivalent high
capacity cell or a RX22+ rechargeable
battery where there is a charging point
Battery Compartment in the plant control box.
(Battey Outer Door)
Push Base of Battery

Door Up and
Flip Top to
Open
Battery Outer Door
Battery Inner Door
Figure 7l Remote Control Handset Battery Compartment
Metrotrak
900 x 600
Page 26
7.3.4 Alternate Control Hand Set

(with Umbilical Cable) WARNING
In addition to the standard remote control WEAR PERSONAL
hand set an alternative hand set with PROTECTIVE EQUIPMENT.
umbilical cable is provided to manoeuvre Information for relevant warning.
the Metrotrak (Figure 7m). This hand set is
located in the Control Box.
If the remote control system of the

Metrotrak fails to operate (flat battery in the
hand set, temporary interference) the
umbilical control hand set is used in place of
the remote control hand set.
Connecting the Umbilical Control

Hand Set
Procedure

Figure 7m Umbilical Control Hand Set
2. Close down the plant (Section 8.2).
3. Remove the access cover (Figure 7b)

on the Control Panel and unscrew the
black plug.
4. Plug in the umbilical control hand set.
5. On the Control Panel turn the

Operation switch to ‘PLANT’.
6. Start the engine (Section 7.2). Increase

the engine speed to 1800rpm.
Metrotrak
900 x 600
Page 27
7. Standing clear of the tracks, turn the Extreme care must be used
Operation switch to ‘TRACKS’. when manoeuvring the plant
with the umbilical control hand
8. Standing as far away from the plant set. Stand as far away as
as possible, hold the hand set facing possible from the plant. Do not
the plant. The tracks on the Metrotrak allow the cable of the hand set
work independent of each other. Press to sag and become entangled
the slow speed buttons on the hand set with the tracks.
to manoeuvre the plant in the desired
direction (Figure 7n). Employ the ‘Fast’
speed only where safe to do so.
Stop Button
Press Buttons 1 & 2 Slow Forward

Press Button 3 Fast Forward
Press Buttons 4 & 5 Slow Reverse
3
Press Button 6 Fast Reverse
2
1 Press Button 1 Right Turn*
Press Button 2 Left Turn*
Press Buttons 1 & 5 Sharp Right Turn*
Press Buttons 2 & 4 Sharp Left Turn*
4 5
* Travelling ‘Forward’
Figure 7n Umbilical Control Hand Set
Metrotrak
900 x 600
Page 28
Blank Page
Metrortak
900 x 600
Shut Off Issue 07 ENG
Page 1
Contents
8.2 Closing Down the Plant ...................................................................................... 5
8.3 Emergency Stopping of the Engine ................................................................... 8

8.3.1 Emergency Stop Buttons ............................................................................... 8
8.3.2 Testing Buttons .............................................................................................. 8
Metrotrak
900 x 600
Page 2


clothing.

Visibility Vest.

HARNESS


Metrortak
900 x 600
Page 3


machine.


injury.



Metrotrak
900 x 600
Page 4

followed.
LOCKOUT PROCEDURE

lockout.
signs.
Metrortak
900 x 600
Page 5
8.2 Closing Down the Plant

WARNING
1. Observe all safety warnings. Information for relevnat
warning.
2. Ensure that the feeder and crusher are LOCKOUT MACHINE.
empty, and that all materials have run Refer to Section 8.1, Safety
off the conveyor(s). Information for Lockout
Procedure.
3. On the Feeder/Conveyor Control Box

(Figure 8a) located on the left hand
side on the Metrotrak, press the
‘RED’ Feeder button to Stop the
feeder.
9. Let the engine idle for 3-5 minutes.
4. Hydraulic Clutch only. Press the
Crusher ‘OFF’ button to disengage 10. Turn the Ignition switch to the ‘0’
the hydraulic clutch drive to the position to switch off the engine.
crusher. Remove the Isolation Key. Shut and
lock the Control Box door.
5. Press the ‘RED’ Dirt Conveyor
button to Stop the dirt conveyor. 11. Following the closing down
proceedure above, it is recommended
6. Press the ‘RED’ Product Conveyor that at the end of operation for the
button to Stop the the product con- day the plant is routinely cleaned
veyor and also the magnetic overband down and thoroughly examined to
separator. check for any damage, breakages,
wear, leaks etc which should be
7. Using the hand throttle, decrease the rectified before further operation.
engine rpm to 1350rpm (Figure 8b &
8d). Use of high pressure washing
equipment is to be avoided
8. Manual Clutch only. Disengage the where the ingress of water will
engine clutch by slowly moving the be detrimental to plant com-
clutch lever (Figure 8c) away from ponents eg crusher bearings,
the engine unit (this will disengage conveyour bearings, hydraulic
the crusher). tank, electrical equipment etc.
Metrotrak
900 x 600
Page 6
Emergency Stop Feeder Speed

Button Control
Low Hydraulic Oil

Pressure Warning
Light *
(hydraulic clutch
only)
Crusher Stop
Button
*
(hydraulic clutch
only)
Dirt Conveyor On/ Product Conveyor Feeder On/Off

**
Off Buttons On/Off Buttons Buttons
Figure 8a Feeder/Conveyor Control Box
Figure 8b Hand Throttle Adjustment Figure 8c Clutch Lever

(manual clutch)
Metrortak
900 x 600
Page 7
Tachometer
Service Meter Fuel
Water Oil Pressure

Temperature
Battery Charge
Override Button
Ignition Switch
Figure 8d Engine Control Panel

(Cummins Engine panel shown)
Metrotrak
900 x 600
Maintenance Issue 07 ENG
Page 1
Contents
9.2 Weights of Components ..................................................................................... 7
9.3 General Information ............................................................................................. 8
9.4 Plant - Lubrication and Servicing ..................................................................... 10

9.4.1 Lubrication Points .........................................................................................10
9.4.2 Regular Servicing .......................................................................................... 11
9.4.3 Lubrication and Servicing Schedule ..............................................................12
9.5 Crusher - Adjustment of Discharge Opening ..................................................15
9.5.1 Adjustment ....................................................................................................16
9.6 Crusher - Fitting of Tension Rod Assembly ....................................................18
9.7 Crusher - Toggle Plate Replacement ...............................................................20

9.7.1 Tension Rod Removal ................................................................................... 20
9.7.2 Toggle Plate Removal ................................................................................... 22
9.7.3 Fitting New Toggle Plate ................................................................................ 24
9.8 Crusher - Fitting New Toggle Seat ................................................................... 25
9.9 Crusher - Manganese Replacement .................................................................26

9.9.1 Changing the Swing Jaw ............................................................................... 26
9.9.2 Changing the Fixed Jaw ................................................................................ 28
9.10 Crusher - Changing of Cheek Plates .............................................................31
9.10.1 Removal ...................................................................................................... 31
9.10.2 Fitment ........................................................................................................ 33
9.11 Crusher - Fitting and Removing Flywheel Locking Mechanism .................34
9.11.1 Loosening the Ringfeder .............................................................................34
9.11.2 Tightening the Ringfeder .............................................................................. 35
9.12 Feeder - Operation ........................................................................................... 36
9.12.1 Removing the Underscreen Mesh or Blanking Mat .......................................37
Metrotrak
900 x 600
Page 2
9.13 Plant - Hydraulic System Description ............................................................39

9.13.1 General Description .................................................................................... 39
9.13.2 Track Drives ................................................................................................40
9.13.3 Feeder Drive ...............................................................................................40
9.13.4 Circuit Protection ........................................................................................40
9.13.5 Changing the Suction Filter .........................................................................42
9.14 Plant - Electrical System Description .............................................................43
9.15 Plant - Crusher and Hydraulic Pump Drive Belts .......................................... 44

9.15.1 Replacement of Crusher Drive Belts ............................................................45
9.15.2 Adjustment of Crusher Drive Belts ...............................................................46
9.15.3 Replacement and Adjustment of Hydraulic Pump Drive Belts .......................49
9.15.4 Method of Drive Belt Tensioning .................................................................. 52
9.15.5 Trouble Shooting - Drive Belts ..................................................................... 55
9.16 Plant - Conveyor Belts ....................................................................................56
9.16.1 Training of Belts .......................................................................................... 56
9.16.2 Conveyor Belt Tensioning ............................................................................58
9.16.3 Maintenance of Conveyor(s) ........................................................................60
9.16.4 Cleaning the Conveyor Belts .......................................................................62
9.17 Plant - Overband Magnet (Optional) ...............................................................64
9.18 Plant - Dust Suppression ................................................................................ 66
9.19 Plant - Diesel Engine .......................................................................................67

9.19.1 Manual Clutch Adjustment ...........................................................................68
9.19.2 Engine Coolant Minimum Temperature ........................................................ 69
9.19.3 Check Fuel Level ........................................................................................70
9.19.4 Top Up Fuel Level .......................................................................................71
9.20 Plant - Vehicle Tracks ......................................................................................72
9.20.1 Measuring Track Tension .............................................................................72
9.20.2 Adjusting Track Tension ............................................................................... 73
9.20.3 Track Maintenance ......................................................................................77
9.20.4 Drive Oil Filling and Draining .......................................................................78
Metrotrak
900 x 600
Page 3


clothing.

Glasses, Ear Protection, Dust Mask, Close Fit-
ting Overalls, Steel Toed Boots and High Vis-
ibility Vest.

HARNESS


Metrotrak
900 x 600
Page 4


machine.


injury.



Metrotrak
900 x 600
Page 5

followed.
LOCKOUT PROCEDURE

lockout.
signs.
Metrotrak
900 x 600
Page 6
WARNING
PRIOR TO ANY MAINTENANCE
1. The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout
Prcedure (Section 9.1).
2. Keep clear of moving parts when trying to identify or isolate any unusual noises.
3. Fit dismantled parts in the same location from which they were removed.
4. Ensure that the area surrounding the maintenance site is clear of any obstructions.
5. If arc welding work is involved in any maintenance operation, ensure that the current does
not pass through the bearings. Never attach the earth lead to the bearing caps on the
crusher. Remove the Isolation Key.
The plant must be fully isolated prior to any welding work.
AFTER EXTENSIVE MAINTENANCE

Refer to Section 7.2.5 ‘Checks Prior to Initial Daily Start Up’ and 7.2.7 ‘Initial Start Up and
Running In’.
Metrotrak
900 x 600
Page 7
9.2 Weights of Components
Weights of crusher and feeder assemblies, these should be consulted when arranging suitable
lifting equiptment.
Component Kg
Complete Jaw Crusher 11 304
Swing Jaw Assembly Including Flywheels 7 063
Swing Jaw Assembly Excluding Flywheels 4 623
Swing Jaw Manganese 650
Fixed Jaw Manganese 596
Toggle Plate 110
Feeder Including Vibrating Unit 1 620
Vibrating Motor Unit 556
Total Weight of Plant approx 26 000
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment
Metrotrak
900 x 600
Page 8
9.3 General Information The plant has been designed to facilitate

easy routine maintenance, but where
When performing maintenance, always necessary to remove any guards make
observe rules provided in the safety sure that they are replaced before the
section. machine is restarted.
Breakdown caused by insufficient or Refer to the Spare Parts illustrations

improper maintenance will cause high (Section 10) to identify the machinery
repair costs and long term standstill. components mentioned in the
Therefore, regular maintenance is maintenance procedures.
imperative.
In addition to several other factors, the

reliability and life of the Metrotrak
depends on regular and proper
maintenance.
The following section contains

maintenance instructions as well as
mainteenance schedules for normal
operating conditions.
When the Metrotrak is

operated in extreme climatic
conditions (e.g. below -15°C
or above 30°C) or in very
dusty conditions for a longer
period of time, the
maintenance schedules will
change.
Ask your local BL-Pegson

dealer or BL-Pegson
Technical Department for
advice.
Metrotrak
900 x 600
Page 9
PRACTICE SAFE
MAINTENANCE
Understand sevice procedure

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

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

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

operate controls to relieve
presure. Stop the engine.
Implement lockout procedure.
Allow machinery to cool.
Securely support any machine

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

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

grease, oil or debris.
Disconnect battery ground

cable (-) before making
adjustments on electrical
systems or welding on
machine.
Metrotrak
900 x 600
Page 10
9.4 Plant - Lubrication and

Servicing WARNING
WEAR PERSONAL
9.4.1 Lubrication Points PROTECTIVE EQUIPMENT.
Regular lubrication of the plant machinery Information for relevant
in accordance with the Lubrication and warning.
Servicing Schedule (Section 9.4.3) is LOCKOUT PLANT.
essential. Refer to Section 6.1, Safety
Information for Lockout
The locations of the lubrication points Procedure.
are as follows:-
FALLING HAZARD.
• Crusher jawstock bearing grease Information for relevant
nipples (2) situated on the back of the warning.
crusher jawstock behind the guard
panel.
• Crusher mainframe bearing grease
nipples (2) on the crusher bearing
caps.
• Feeder vibrating unit bearing oil baths
on both sides of the feeder (Section
7.2.7 and Figure7i).
• On-plant conveyor head and tailshaft
bearing grease nipples located on the
bearing housings except for tailshaft
piped to grease points on plant
chassis sides.
• Track unit gearbox (2) oil levels (Section
9.19.3).
• Optional dirt conveyor head and
tailshaft bearing housing grease
nipples.
Metrotrak
900 x 600
Page 11
• Optional overband magnetic

separator head and tailshaft bearing WARNING
housing grease nipples.
WEAR PERSONAL
The belt magnet assembly is Information for relevant
very powerful and warning.
permanently charged. The LOCKOUT PLANT.
strong magnetic field Refer to Section 6.1, Safety
produced could affect heart Information for Lockout
Procedure.
pacemakers, watches, credit
cards, mobile phones etc. The FALLING HAZARD.
operator has the sole Refer to Section 6.1 Safety
responsibility to keep anyone Information for relevant
at risk clear of the machine. warning.
• Periodically lubricate hinges, cylinder

pivot pins and similar points with oil
to prevent seizure during lengthy
spells of inactivity.
9.4.2 Regular Servicing

The Lubrication and Servicing Schedule
(Section 9.4.3) lists, in addition to the
lubrication points, the attention required
to the hydraulic system (Section 9.13)
and particular attention should be paid to
institute a regime of adherence.
NOTE: Do not overlook the service

requirements of the plant diesel engine
which are detailed in the engine
manufacturer’s manual.
900 x 600 Metrotrak Lubrication Schedule
Frequency of Lubrication: X = Change
O = Check, top up or clean as necessary
R = Re-grease
Schedule based on a 40 hour operating week. Adjust schedule to suit actual operating hours.
No of
Location Description Lubricant Quantity Daily Weekly 2 Weekly Monthly Bi-Monthly 6 Monthly
s
2 Jawstock grease nipple D 120 grams R
Mainframe bearing cap
2 D 120 grams R
grease nipple
Feeder drive side filler To middle of X(200
1 See chart O
plug sight glass hours)
Feeder non-drive side filler To middle of X (200
1 See chart O
plug sight glass hours)
On-plant conveyor head
2 shaft bearing grease D R
nipples
On-plant conveyor tail
9.4.3 Lubrication and Servicing Schedule
2 shaft bearing grease D R

nipples
Dirt conveyor head shaft
2 D R
bearing grease nipples
Dirt conveyor tail shaft
Maintenance
2 D R
bearing grease nipples
X
X Change
1 Hydraulic reservoir See chart 360 litres O change
Annuallyat
12 months
In-line hyd filters on hyd
2 - O X
reservoir
change at
Hyd suction filter in engine 1000 hours
1 - O
canopy or sooner if
indicator
Hyd return filter in engine shows RED
1 - O
canopy
Refer to approx. 5 X Change
Tracks
Sec 9.20 litres ±10% Annually
Metrotrak
900 x 600
Page 12
Issue 07 ENG
NB. Refer to the separate engine manual for the lubrication schedules & specifications for the plant diesel engine.
Where the Optional Magnetic Separator is fitted, regrease the head and tailshaft bearings same as the Plant Conveyors.
Lubricant Specifications - As Recommended by the Suppliers
Equipment Grade Century Mobile Shell Esso Gulf BP
M Series Jaw Crusher

Shaft bearings (grease) D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
All temperatures
Hydraulic System E Centraulic PW LA Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLPP-HM32
D Style jaw Crusher
Shaft bearings (grease) D Regulus A2EP Mobilgear EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
All temperatures
Shaft bearings (oil)
>4ºC B Centlube F76 Mobilgear 630 Omala 220 Spartan 220 EP LUB HD220 Energol GR-XP220
<4ºC A Centlube E76 Mobilgear 629 Omala 150 Spartan 150 EP HD MULTI H Energol GR-XP150
Tension rod (grease) D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
Hydraulic System E Centraulic PW LA Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLP-HM32
Gyrasphere & Gyrasand
Circulating System (oil)
>4ºC B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
Maintenance
<4ºC A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Hydraulic system E Centraulic PW LA Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLP-HM32
Autocone, Autosand,
Automax & Gyracone
Circulating System (oil)
>4ºC A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP LUB HD150 Energol GR-XP150
Hydraulic System E Centraulic PW LA Mobil DTE24 Tellus 37 Nuto H32 Hydrasil 32 Energol HLP-HM32
Inclined Screens
Shaft Bearings (grease) D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energreas LS-EP2
All temperatures
Shaft bearings (oil)
<4ºC A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP HD MULTI H Energol GR-XP150
Horizontal Screens &
Vibrating Feeders
Oil Bath Lubrication
>15ºC C Centlube H76 Mobilgear 634 Omala 680 Spartan EP460 EP LUB HD460 Energol GR-XP460
Issue 07 ENG
4ºC to 15ºC B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
900 x 600
Page 13
Metrotrak
< 4ºC A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP HD MULTI H Energol GR-XP150
Plant Hydraulic Systems
(NOT Cone Crushers) F Centraulic PW LB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
<30ºC G Centraulic PW LC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
>30ºC
Note: <4°C is defined as a daily temperature consistently below 4°C, >15°C is defined as a daily temperature consistently above 15°C,
>30°C is defined as a daily temperature consistently above 30°C
Metrotrak
900 x 600
Page 14
Lubrication Specifications
Oil Specification Grade A Grade B Grade C
Flashpoint: Minimum °C 199 204 216
Pour Point °C -18 -18 -18
Kinematic Viscosity at 40°C, mm²/s 150 220 460
Kinematic Viscosity at 100°C, mm²/s 15.4 20.1 32.9
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R & O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D
NGLI Grade Number 2
Unworked Penetration at 25°C 280
Worked Penetration at 25°C 285
Drop Point °C 185
ASTM Corrosion Test Pass (14 days) Yes
Wheel Bearing Test Pass at 135°C Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade E Grade F Grade G
ISO VG No 32 46 68
Kinematic Viscosity at 40°C mm²/s 32 46 68
Kinematic Viscosity at 100°C mm²/s 5.5 6.5 8.5
Viscosity Index 95+ 95+ 95+
Rust Inhibitor Yes Yes Yes
Defoament Yes Yes Yes
Anti Scuff Yes Yes Yes
Metrotrak
900 x 600
Page 15
9.5 Crusher - Adjustment of

Discharge Opening DANGER
FLUID INJECTION HAZARD
Measurement Refer to Section 9.1, Safety
The discharge opening is the distance warning
between the fixed and moving jaw plates at
the bottom of the crushing chamber and
regulates the size of the product material. WARNING
The opening is measured from the top of
WEAR PERSONAL
the tooth on one jaw plate to the PROTECTIVE EQUIPMENT.
corresponding root between two teeth on Refer to Section 9.1, Safety
the other jaw plate - see Figure 9a. Information for relevant
warning.
The opening should be measured when the LOCKOUT MACHINE.
eccentric shaft is at its highest point, and the Refer to Section 9.1, Safety
measurement should be made at a point of Information for Lockout
Procedure.
shortest distance between the two jaw
plates.
Adjustment
Adjustment to the crusher discharge

opening is made by inserting or removing Discharge Root Swing Jaw
steel shims that are accessed from the back Opening
of the crusher.Various shim thicknesses are
supplied (some in the crusher and several
spare), not only to enable the product size
to be varied, but also to compensate for
wear on the manganese jaws so as to
maintain the crushed material product size.
Tip Fixed Jaw
To assist the process of making setting
adjustments the crusher is fitted with a hand
Figure 9a Discharge Opening
operated hydraulic ram system which is also Measurement
used when changing the toggleplate.
Metrotrak
900 x 600
Page 16
9.5.1 Adjustment
DANGER
Procedure FLUID INJECTION HAZARD
warning
2. Run the plant until the crushing chamber

is empty; close down the plant (Section WARNING
8.2) and implement the Lockout WEAR PERSONAL
Procedure. PROTECTIVE EQUIPMENT.
3. Before starting work on the adjusting Information for relevant
warning.
mechanism it is very important to
thoroughly clean down the area on top LOCKOUT MACHINE.
of the rear cross beam and spacing
shims to prevent debris from falling into Procedure.
the shim slot whilst carrying out the
adjusting procedure.
4. Check the servicability of the hydraulic

handpump unit.
1
5. Loosen both of the toggle beam locking
mechanism nuts (1 & 2) (Figure 9b) so
releasing the locking wedges (3).
3
6. Measure and note the compressed
Toggle Beam 2
length of the tension rod spring.
7. Unscrew the locking nuts and release

the compression on the tension rod
spring (Figure 9d).
Mainframe
8. Before operating the pump ensure the
pressure relief valve knob is fully Figure 9b Toggle Beam Locking Mechanism
tightened. Push the valve lever ‘X’ of
the hydraulic handpump unit
Metrotrak
900 x 600
Page 17
(Figure 9c) forward of the central Pressure Relief Handpump

position and operate the handpump to Valve Knob
move the toggle beam forward and so
permit insertion/removal of spacing
shims as necessary.
Always lift the spacing shims

by the lifting eyes provided.
Never allow hands inside the
shim slot whilst changing the
shims as accidental closure
would result in serious injury.
9. Pull the valve lever ‘X’ of the hydraulic

handpump unit backward of the central
position and operate the handpump to
clamp the shims between the toggle
beam and the main frame crossbeam.
10. Reset both the toggle beam locking

mechanisms by tightening the clamping
Valve Lever ‘W’ Valve Lever ‘X’
and locking nuts (1 & 2).
Figure 9c Hydraulic Handpump Unit
11. Compress the tension rod spring to the
length noted (Step 6). Do Not over
compress the spring.
12. Run the crusher empty. If ‘knocking’ is

heard from the toggle plate, stop the
plant and lockout. Increase the
compression on the tension rod spring
slightly.
Repeat Step 11 until the crusher runs
smoothly. Do Not over compress the
spring.
13. Return the valve lever ‘X’ of the

hydraulic handpump unit to the central
position.
Metrotrak
900 x 600
Page 18
9.6 Crusher - Fitting of

Tension Rod Assembly WARNING
WEAR PERSONAL
(Figure 9d) PROTECTIVE EQUIPMENT.
Removal of the tension rod assembly will Information for relevant
warning.
be necessary when replacing the toggle
plate. When fitting or removing shims the LOCKOUT MACHINE.
tension rod may need to be slackened. Refer to Section 9.1, Safety
Procedure.
Procedure

Tighten the nuts until the spring is
compressed by 20mm. They should
2. Close down the plant (Section 8.2)
then be tightened until no knocking is
and implement the Lockout
experienced on the toggle plate.
Procedure.
It is important that the spring
3. Pass the threaded end of the bare
is correctly adjusted. If it is
tension rod through the the bracket
too tight the spring or tension
from the jawstock side. The brackets
rod may break. If it is too
are screwed to the underside of the
loose the toggle plate will
crossbeam and should be checked
knock or drop out. Although
regularly for tightness.
not shown in Figure 9d it is
important to check that the U
4. Install the clevis end of the tension
shaped cylinder protection
rod between the cast eyes at the
bracket is fitted correctly and
bottom of the jawstock. Secure the
is secure.
pin at each side with the washer and
pin.
7. Operate the crusher and check the
locknuts for tightness. Ensure that
5. Check that the washers are in good
the crusher runs without the toggle
condition and fitted correctly,
plate knocking.
replacing if necessary.
For the removal of the tension rod
6. Assemble the spring, cap, washer and
assembly see Section 9.7.1.
two locknuts on the tension rod.
Metrotrak
900 x 600
Page 19
Locknuts
Plain
Washer Bracket
Spring
Tension Rod
Split Pins
Bush
Washer
Pin
Nipple
Figure 9d Tension Rod Assembly (Cylinder Protection Bracket NOT Shown)
Metrotrak
900 x 600
Page 20
9.7 Crusher - Toggle Plate

Replacement DANGER
This will need replacing due to wear or Refer to Section 9.1, Safety
breakage due to uncrushable feed. The Information for relevant
toggle plate must be installed from warning
beneath the crusher. A hoist suspended
from a spreader bar positioned at the
top-rear of the crusher is the most WARNING
convenient method of lifting and
WEAR PERSONAL
lowering the toggle plate. PROTECTIVE EQUIPMENT.
warning.
Procedure LOCKOUT MACHINE.
Procedure.
9.7.1 Tension Rod Removal
2. Run the crusher until completely

empty. Close down the plant (refer
to Section 8.2) and implement the
Lockout Procedure.
3. Attach suitable support cables to the

toggle plate (Figure 9f).
4. Remove the tension rod assembly

(Figure 9d).
a Remove the two locknuts, washer,

spring cap and spring.
b Remove the split pin with washer. Figure 9e Tension Rod Location
c Remove the pin from the tension rod
bush through the cast eyes of the
jawstock. The tension rod at the
clevis end will then drop free - BE
PREPARED FOR THIS.
Metrotrak
900 x 600
Page 21
d Pull the bare tension rod through the

bracket from the jawstock side.
Under no circumstances
should the rod be burnt or cut
through whilst it is still
tensioned.
Metrotrak
900 x 600
Page 22
9.7.2 Toggle Plate Removal

(Figure 9f & 9g) DANGER
In order to remove the toggle plate it is Refer to Section 9.1, Safety
first necessary to take the weight of the Information for relevant
warning
jawstock off the toggle plate.
Procedure WARNING
WEAR PERSONAL
1. Observe all safety warnings. Refer to Section 9.1, Safety
warning.
empty. Close down the plant (Section LOCKOUT MACHINE.
8.2) and implement the Lockout Refer to Section 9.1, Safety
Procedure. Procedure.
3. Take the hydraulic cylinder from the

toolbox on the plant and attach by the
quick release hose couplings to the
hydraulic handpump unit.
4. Mount the hydraulic cylinder on the

lug of the crusher body (Figure 9g) Toggle Beam
Toggle Plate
so that the ram will engage in the
recess in the back of the jawstock.
5. Push the valve lever ‘W’ forward of

the central position. Operate the
handpump to locate the ram in the
recess of the jawstock and move the
jawstock forward. If the toggle plate
is not broken allow it to become free Jawstock Seat
and be lowered from the crusher.
Figure 9f Toggle Plate Assembly
Metrotrak
900 x 600
Page 23
6. Provide temporary blocking at the

lower jawstock edge to prevent
accidental movement.
In addition use a chain pull lift to
secure the free jaw.
It is imperative that Part 5 is

adhered to.
Nobody is to enter the gap
between the jawstock and the
crossbeam.
Failure to do so may cause
injury or death.
Detachable Hydraulic Cylinder
7. Remove slings or chains from broken

toggle plate. Figure 9g Hydraulic Cylinder Location
Handpump
Jawstock
Toggle Beam
Port K
Port A Port L 74 Port C
72 72
Port B Port D
Cross Beam
Valve 151
N
E F M
G H
Y
W X Handpump 150
Valve Lever ‘W’ Valve Lever ‘X’
Figure 9h Hydraulic Hand Pump and Circuit Diagram
Metrotrak
900 x 600
Page 24
9.7.3 Fitting New Toggle Plate

DANGER
warning
2. Run the crusher unitl completely WARNING

empty. Close down the plant (Section WEAR PERSONAL
8.2) and implement the Lockout PROTECTIVE EQUIPMENT.
Procedure. Refer to Section 9.1, Safety
warning.
3. Position new toggle plate beneath the
crusher. LOCKOUT MACHINE.
4. Hoist or jack the new toggle plate Procedure.
into position and remove the blocking
from the jawstock.
5. Pull the valve lever ‘W’ bacward of

the central position and operate the hydraulic hoses. Replace the
the handpump and allow the jawstock hydraulic cylinder in the toolbox.
to return under its own weight. The
toggle plate must locate between the NOTE: The detachable hydraulic
two retainers and the toggle beam. cylinder must be removed before
crusher start up.
6. When the jawstock has returned,
support the hydraulic cylinder and Finally:
operate the handpump to retract the
cylinder ram from the jawstock. 9. Fit the tension rod assembly (Section
9.4).
7. Return the valve lever ‘W’ to the
central position and relieve the 10. Check the discharge opening and
pressure. adjust as necessary (Section 9.5).
8. Detach the hydraulic cylinder from

the crusher body and disconnect the
Metrotrak
900 x 600
Page 25
9.8 Crusher - Fitting New

Toggle Seat WARNING
WEAR PERSONAL
warning.
1. Observe all safety warnings. LOCKOUT MACHINE.

2. Run the crusher until completely Procedure.
empty. Close down the machine
(Section 8.2) and implement the
Lockout Procedure.
8. Make several indents on the jawstock
3. Remove the toggle plate (Section
adjacent to one side of the seat with a
9.5.2)
centre punch to secure it in place.
4. Inspect the canvas apron (Figure 9i).
9. Fit toggle plate (Section 9.5.3).
Replace the apron if it is worn.
10. Fit tension rod assembly (Section
5. Using an oxy-acetylene cutting torch,
9.4).
cut the toggle seat in half
lengthways. There is a groove in the
Note : Toggle seat faces operate dry
toggle seat recess to minimise
and must not be lubricated.
damage to the jawstock. The toggle
seat can then be removed.
6. Inspect the recess for rough spots.

Remove any rough spots with a file
and smooth with emery. Canvas Apron
7. Fit the dowel of the new toggle seat

into the hole in the jawstock and
press the toggle seat home. It is
important that the toggle seat fits
tightly.
Figure 9i Canvas Apron
Metrotrak
900 x 600
Page 26
9.9 Crusher - Manganese

Replacement WARNING
WEAR PERSONAL
9.9.1 Changing the Swing Jaw PROTECTIVE EQUIPMENT.
warning.
Procedure LOCKOUT MACHINE.
1. Observe all safety warnings Procedure.

empty. Close down the plant (Section
8.2) and implement the Lockout Lifting hooks are availible from
Procedure. Lifting Gear Supplies Ltd,
Leicester.
3. Remove the swing jaw wedge nuts, England.
washers and fabreeka washers. Tel : +(44) 0116 262 8023
Fax : +(44) 0116 251 8864
4. Retract bolts and remove the two
wedges.
5. Tip the top of the jaw forward and

insert a lifting hook of a similar type
shown in Figure 9j.
Lifting
Hook
Extreme care must be taken
when moving the jaw
forward. After moving the
jaw forward wedge in place
prior to locating the hook in
Jaw
the back of the jaw.
Face
6. Lift out the jaw and place it on blocks Slot

with the wearing side face down.
Figure 9j Lifting Hook
Metrotrak
900 x 600
Page 27
Remember - The manganese can be

rotated through 180°, the worn area of
the manganese then being at the top of
the crusher.
DO NOT wear the manganese below

the bottom of the grooves. Any wear
below this level will result in the
support block at the base of the
manganese being worn.
Continued crushing with heavily worn

manganese increases crushing forces
and power consumption. This may
limit the minimum closed side setting
on hard materials.
7. Insert lifting hook in the back of the

jaw (refer to Figure 9j).
8. Hoist the jaw into position and locate

onto the centering key at the bottom
of the jawstock.
9. Fit the wedge and the bolts.
10. Fit the washers, fabreeka washers and

nuts - TIGHTEN SECURELY.
After fitting the jaws operate

the crusher for 15 minutes.
Stop the crusher and check
the bolt tightness. Continue to
check the nuts at the
beginning of each shift.
Metrotrak
900 x 600
Page 28
9.9.2 Changing the Fixed Jaw

The fixed jaw is held into position by two
WARNING
fixed jaw wedges. When changing the WEAR PERSONAL
fixed jaw it will be necessary to undo and PROTECTIVE EQUIPMENT.
remove the four wedge bolts holding the Information for relevant
jaw wedges in place. To increase access warning.
to the jaw wedge nuts, the dirt by-pass
LOCKOUT MACHINE.
chute needs to be dropped down out of Refer to Section 9.1, Safety
the way. Information for Lockout
Procedure.
Lowering the Dirt By-Pass Chute
Procedure
A (4 off, 2 each side)

8.2) and implement the Lockout
Procedure.
3. Using lifting equipment support the

dirt by-pass chute.
4. Remove the four bolts ‘A’ (two bolts

on each side of the chute, refer to
Figure 9k).
5. Raise the chute off the two locating

mountings. Move the chute slightly Location Dirt By-Pass
forward of the locating mountings. Mounting Chute
Carefully lower the chute until it rests
on the chassis of the plant.
Figure 9k Dirt By-Pass Chute
6. The lifting equipment can now be

removed.
Metrotrak
900 x 600
Page 29
Removal of the Fixed Jaw 10. Lift out the jaw and place it on blocks
with the wearing side face down.
7. Remove the jaw wedge nuts,
washers, and fabreeka washers Remember - The manganese can be
(Figure 9l). rotated through 180°, the worn area of
the manganese then being at the top of
8. Withdraw the bolts and remove the the crusher.
wedges.
DO NOT wear the manganese below
9. Tip the top of the jaw forward and the bottom of the grooves. Any wear
insert a lifting hook of the type shown below this level will result in the
in Figure 9j into the back of the jaw. support block at the base of the
manganese being worn.
Extreme care must be taken
when moving the jaw
forward. After moving the
jaw forward wedge in place
prior to locating the hook in
the back of the jaw.
Nut Mainframe
Washer
Wedge
Fabreeka
Washer
Washer Manganese
Wedge Bolt Wedge Bolt
Figure 9l Fixed Jaw Wedge and Bolt Assembly
Metrotrak
900 x 600
Page 30
Replacement of the Fixed Jaw
11. Insert the lifting hook into the slot at

the back of the new jaw (Figure 9j).
12. Hoist the jaw into position and locate

onto the Jaw Support at the bottom
of the Front wall.
13. Fit the wedges and bolts.
14. Fit the washers, fabreeka washers and

nuts. TIGHTEN SECURELY.
Locating the Dirt By-Pass Chute
15. Using lifting equipment raise and

locate the dirt by-pass chute onto the
two mountings.
16. Replace the four bolts and tighten the

nuts.
17. Remove the lifting equipment.
After fitting the jaws operate

the crusher for 15 minutes.
Stop the crusher and check
the bolt tightness. Continue to
check the nuts at the
beginning of each shift.
Metrotrak
900 x 600
Page 31
9.10 Crusher - Changing of

Cheek Plates WARNING
WEAR PERSONAL
Cheek plates should be inspected PROTECTIVE EQUIPMENT.
regularly for wear and all cheek plate Refer to Section 9.1, Safety
bolts checked for tightness. Information for relevant
warning.
Note : Cheek plates are not reversible. LOCKOUT MACHINE.

There are four cheek plates, two on each Procedure.
side of the machine; the upper plate is
retained at three fixing points. The cheek
plates are not interchangable.
9.10.1 Removal
Lift and lower cheekplates with a crane.
DO NOT ATTEMPT TO MOVE BY
HAND.
Procedure
1. Observe all safety procedures.

Procedure.
3. Remove necessary guards to gain

access.
4. Remove the upper fixing nut, bolt and

washer from the cheek plate and
machine frame and loosen the
remaining fixing bolt(s) - (Figure
9m).
Metrotrak
900 x 600
Page 32
5. Insert a lifting hook in the bolt recess 7. Remove the remaining fixing nuts,
in the cheek plate with the lifting bolts and washers from the cheek
equipment. plate then lift it clear of the machine.
6. Take the weight of the cheek plate

with the crane.
Cheek Plate
Cheek Mainframe
Plate
Locking
Pin
Philidas
Nut
Figure 9m Cheek Plate Fixing and Bolt Assembly
Metrotrak
900 x 600
Page 33
9.10.2 Fitment
When fitting both cheek plates on one
WARNING
side, always fit the lower plate first. WEAR PERSONAL
Lift and lower cheekplates with a crane.
DO NOT ATTEMPT TO INSTALL warning.
BY HAND.
LOCKOUT MACHINE.
Procedure
Procedure.

Procedure.
3. Insert a lifting hook in the upper

fixing bolt recess in the cheek plate;
lower the cheek plate into the
machine, align the lower bolt holes in
the cheek plate and the machine side.
4. Insert the lower fixing bolt, washer

and nut, but do not tighten.
5. Remove the lifting hook from the

upper bolt recess in the cheek plate
and fit and tighten the upper fixing
nut, bolt and washer, tighten the
remaining fixing bolts.
Metrotrak
900 x 600
Page 34
9.11 Crusher - Fitting and

Removing Flywheel Locking WARNING
Mechanism WEAR PERSONAL
These Ringfeder locking mechanisms are Refer to Section 9.1, Safety
used to secure the drive side and non warning.
drive side flywheels on the crusher to the
LOCKOUT MACHINE.
eccentric shaft. Should they need to be
loosened to reposition the flywheel, the Information for Lockout
following procedure should be followed. Procedure.
9.11.1 Loosening the Ringfeder
Procedure
Removal
2. Loosen locking screws a turn at a

time and in diametrically opposite
sequence.
3. Now the loosened connection

(between the shaft and the flywheel) Tightening
can be readjusted or dis-assembled.
If necessary, the front and rear thrust

ring are to be dis-assembled as shown in
Figure 9n. The removal threads are
located on the silver capped screws.
Figure 9n Front/Rear Thrust Ring
These should be removed and three of
the black headed screws used to push the
assembly apart. There are only 3 - 5
threads on the removal holes and are
therefore not suitable for high torques.
These threads should only be used for
the removal/dis-assembly of the
ringfeder.
Metrotrak
900 x 600
Page 35
9.11.2 Tightening the Ringfeder

Once the flywheel is aligned properly
WARNING
(arrow on flywheel cap and flywheel line WEAR PERSONAL
up) the Ringfeder can be tightened up. PROTECTIVE EQUIPMENT.
When doing this on the drive side it
should always be done whilst the drive warning.
belts are slack because it may result in
LOCKOUT MACHINE.
the flywheel being tightened at an angle. Refer to Section 9.1, Safety
In addition to this on both sides a piece Information for Lockout
of square bar should be secured by the Procedure.
threaded holes on the eccectric shaft and
used like a press to push the flywheel in
to also ensure that it is square (refer to
Section 9.15.2 for details of how to
slacken the belts).
Procedure
2. Tighten locking screws lightly and

align hub.
3. Tighten screws evenly in diametrically

opposite sequence and do this in two
or three stages up to the indicated
tightening torque of 190 Nm.
4. Re-check tightening torque by

applying it to all screws all the way
around. When the screws have
reached the correct torque the
assembly is complete.
Metrotrak
900 x 600
Page 36
9.12 Feeder - Operation

WARNING
The vibrating feeder must, in addition to WEAR PERSONAL
the scheduled lubrication requirements PROTECTIVE EQUIPMENT.
(Section 9.4), be regularly inspected for Refer to Section 6.1 Safety
any wear, damage or breakage with the Information for relevant
mainframe and support springs being warning.
paid particular attention. Rectify faults LOCKOUT PLANT.
immediately. Refer to Section 6.1, Safety
Procedure.
Make sure that the feeder can vibrate
freely without fouling against the FALLING HAZARD.
adjacent hopper or chutework and that Refer to Section 6.1 Safety
hardened material inside the pan is not Information for relevant
allowed to build up and affect the warning.
performance of the machine. Also
check to ensure that the hydraulic drive
is operating efficiently. The variable
speed control is situated on the Feeder/
Conveyor control box.
Where the plant is supplied with the

optional dirt conveyor, periodically
check the condition of the mesh panel
beneath the grizzly bars for both wear
and bulid up of material and recitify if
necessary.
When the plant is supplied without the

optional dirt conveyor the feeder is
fitted with a blanking mat instead of
the mesh. In this case all the material
passing through the grizzly bars will
by-pass the crusher and discharge onto
the product conveyor.
Metrotrak
900 x 600
Page 37
9.12.1 Removing the Underscreen

Mesh or Blanking Mat WARNING
Where the plant is fitted with the optional WEAR PERSONAL
dirt conveyor the feeder will normally be PROTECTIVE EQUIPMENT.
fitted with an underscreen panel having 20
mm square apertures to allow the coarser warning.
material extracted through the grizzly bars
LOCKOUT PLANT.
to be passed to the product conveyor
whilst discharging the ‘fines’ onto the dirt Information for Lockout
conveyor. If it is required to alter this Procedure.
configuration for operational reasons to
either change the mesh size, remove the FALLING HAZARD.
mesh completely or fit a blanking mat in Refer to Section 6.1 Safety
lieu, follow the procedure below.
warning.
Procedure
2. Run the plant until the feeder and

crusher are completly empty. Close
down the plant (Section 8.2) and
implement the Lockout Procedure.
3. Lower the mesh access panel at the

rear of the dirt by-pass chute (Figure
9o).
4. Slacken the 2 clamping screws Figure 9o Mesh Access Panel

located in the slots each side of the
feeder (Figure 9p).
5. Loosen the locking nuts on the 3

screws located underneath the feeder
sufficiently to disengage the hooked
ends of the panel.
Metrotrak
900 x 600
Page 38
6. With the hooked rod tool provided,

reach through the grizzly bars from
above to lift and slide the panel out.
7. When replacing a panel carry out the

procedure in reverse order making
sure that the panel is sufficiently
tensioned but take care not to over
tighten otherwise the panel may be
damaged.
Clamping Screw
Figure 9p RH Side Feeder Clamping

Screw
Metrotrak
900 x 600
Page 39
9.13 Plant - Hydraulic

System Description DANGER
(Figure 9q & 9r) Refer to Section 9.1, Safety
9.13.1 General Description warning
All hydraulic functions are powered by two

pumps,one mounted either side of the diesel
engine and driven from the main crankshaft The flows and pressures to each service is
pulley via two SPB belts. limited by the relevant spool as shown
below and the pump supplies only the
Each pump is an axial piston variable required flow by automatically backing off
displacement unit capable of up to the swash plate angle thus reducing wasted
65 litres/min at 320 bar and each feeds a power and resulting heat generation.
directional control valve.
Front Pump (valve mounted in engine canopy)

Max Flow Max Pressure
Service Spool Type
(litres/min) (Bar)
L/H track drive motor Proportional 65 320
Product conveyor plus Magnet
On/Off 48 180
and Water Pump (when fitted)
Grid (when fitted) On/Off 15 50
Rear Pump (valve mounted under feeder)
Max Flow Max Pressure
Service Spool Type
(litres/min) (Bar)
R/H track drive motor Proportional 65 320
Feeder Proportional 48 180
Dirt Conveyor On/Off 17 180
Dirt Conveyor Fold On/Off 25 100
Figure 9q Front/Rear Hydraulic Pumps
Metrotrak
900 x 600
Page 40
This is achieved by means of a load sensing It is recommended that adjustment is not

line from the valve to the pump which undertaken without BL-Pegson Ltd.
measures the pressure required which is consent and under no circumstances should
then matched by the pump. the slow speed be adjusted greater than
0.2m/s.
Note:-
All relief valve pressures are factory set and Motor mounted counterbalance valves are
should not be adjusted on site. utilised to prevent the machine over running
when moving downhill.
Although the maximum flows from each
spool is limited as shown, these can be This block also incorporates a shuttle valve
individually adjusted downwards by means to release the spring applied track parking
of limit screws if desired. Please contact brake together with a pressure reducing
BL-Pegson Ltd. valve, pre set to 60 bar so that the brakes
are not overpressurized.
9.13.2 Track Drives
9.13.3 Feeder Drive
Although these valves sections have
proportional controls and are theoretically This valve section is fitted with a
infinitely variable they are electrically limited proportional solenoid so that the feeder
to two speeds for simplicity. speed can be controlled by means of a
chasis mounted control box potentiometer.
a) SLOW - For slewing and fine
positioning. 9.13.4 Circuit Protection
b) FAST - For straight line running, The system is equiped with the following
forward or reverse. protection:-
Note:- The maximum power take off from • Suction Filter (20µm )
one side of the engine is limited to
• Pressure Filter (10µm ) in each pump
approximately 30 KW, therefore the system
circuit prior to the directional control
is electronically limited such it is only
valves.
possible to slew (operate one side only)
when in the ‘SLOW’ mode.
• Return Filter (25µm )
Fine adjustment of the slow speeds is
• Low oil level cut out.
possible. Consult BL-Pegson Ltd.
Note:- For Hydraulic Pump Drive Belt
adjustment refer to Section 9.15.3.
Metrotrak
900 x 600
Page 41
Figure 9r Hydraulic Circuit Diagram
Metrotrak
900 x 600
Page 42
9.13.5 Changing the Suction Filter

Located at the base of the hydraulic DANGER
reservoir tank is the hydraulic suction FLUID INJECTION HAZARD
filter. The filter housing has an internal Refer to Section 9.1, Safety
shut off valve to permit work on the Information for relevant
warning
system.
Procedure WARNING
WEAR PERSONAL
1. Observe all safety warnings. Refer to Section 9.1, Safety
warning.
2. Close down the machine (Section
8.2) and implement the Lockout LOCKOUT MACHINE.
Procedure. Refer to Section 9.1, Safety
Procedure.
3. Unscrew the black knob in the centre
of the filter housing until it reaches
the stop (Figure 9s).
4. Undo the six socket head screws on

the front of the housing and remove
the cover plate.
5. Change the filter.
6. Replace the cover plate and refit the

screws.
7. Fully screw in the black knob in

the centre of the filter housing.
It is important to ensure that

the black knob is fully
screwed in before starting the
plant. Damage will occur to
the plant if this procedure is Figure 9s Suction Filter
not followed.
Metrotrak
900 x 600
Page 43
9.14 Plant - Electrical System

Description WARNING
WEAR PERSONAL
For the electrical circuit diagram see PROTECTIVE EQUIPMENT.
Appendix section of the manual Refer to Section 9.1, Safety
warning.
The electrical system on the Metrotrak
provides protection against incorrect LOCKOUT MACHINE.
operation, such as low oil level in the Refer to Section 9.1, Safety
hydraulic tank cutting out the motor. In Procedure.
addition to this, parts of the hydraulic
system are controlled by electrical
contacts operating solenoid valves.
On this plant the electrical circuit

breakers are located behind the control
panel within the control box attached to
the chasis on the left hand side of the
machine.
In the event that a circuit breaker is

tripped out investigations should be made
as to why prior to resetting.
Metrotrak
900 x 600
Page 44
9.15 Plant - Crusher and Hydraulic Pump Drive Belts
Good alignment of the flywheel and drive pulley is important otherwise the belt flanks will
wear quickly. Ensure axis are parallel when viewed from all planes (Figure 9t).
Shafts are not parallel

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

in alignment but pulleys
are not in alignment Both shafts and pulleys
are parallel and in
alignment
Figure 9t Correct Alignment of Pulley Belts
Metrotrak
900 x 600
Page 45
9.15.1 Replacement of Crusher

Drive Belts WARNING
Note: Drive belts should inspected WEAR PERSONAL
regularly for wear and also to monitor PROTECTIVE EQUIPMENT.
any pattern in the wear if it is occuring
(Figure 9t). warning.
LOCKOUT MACHINE.
Procedure Procedure.

Procedure.
3. Slacken the belts until it is possible to

remove the belts without the need to
stretch them (Section 9.15.2).
4. Remove the belts.
5. Reposition the new belts in place.
6. Tension the belts to the correct

specification ensuring the engine
pulley is in correct alignment with the
flywheel (Figure 9t, Section 9.15.2).
7. Ensure the crusher flywheel guard

and diesel engine guard are in place
before start-up.
Metrotrak
900 x 600
Page 46
9.15.2 Adjustment of Crusher Drive

Belts WARNING
The tension of the crusher drive belts is WEAR PERSONAL
adjusted with the two screws one located PROTECTIVE EQUIPMENT.
on either side of the engine sliding base Information for relevant
(Figure 9u). warning.
LOCKOUT MACHINE.
Slackening of Crusher Drive Belts Refer to Section 9.1, Safety
Procedure.
Procedure
2. Close down the machine (Section 8.2)

and implement the Lockout Procedure.
3. Remove the crusher flywheel guard.
4. Loosen the 4 nuts holding the engine

pulley guard in position behind the
engine pulley.
5. Loosen nuts (A) (4 off) Figure 9.
6. Unscrew nut (B) a few turns. Repeat

B C A (4 off)
this step for the other adjusting screw,
turning the nut an equivalent amount.
Figure 9u Crusher Drive Belt Tensioning
7. Tighten nut (C). Repeat this step for the Mechanism LH Side
other adjusting screw.
8. If the belts are to be removed,

repeat Steps 6 and 7 to further slacken
the belts until it is possible to remove
the belts without the need to stretch
them.
Metrotrak
900 x 600
Page 47
If the tension is being adjusted,

repeat Steps 6 and 7 to further slacken
the belts, ensuring the engine pully is in
correct alignment with the crusher
flywheel (Figure 9t).
When the belts have reached the
correct tension (Figure 9v, Section
19.15.4), tighten nuts (A) 4 off.
Tighten the 4 nuts of the engine pulley
guard to secure the guard in position.
Replace the crusher flywheel guard and
diesel engine guard before start-up.
Metrotrak
900 x 600
Page 48
Tightening of the Drive Belts

WARNING
WEAR PERSONAL
LOCKOUT MACHINE.
2. Close down the machine (Section 8.2) Refer to Section 9.1, Safety
and implement the Lockout Procedure. Information for Lockout
Procedure.
3. Remove the crusher flywheel guard.
4. Loosen the 4 locking nuts holding the 9. When the belt has reached the correct
engine pulley guard in position behind tension (Figure 9v, Section 9.15.4),
the engine pulley. tighten nuts (A) 4 off.
5. Loosen nuts (A) (4 off) Figure 9u. 10. Tighten the 4 nuts of the engine pulley
guard to secure the guard in position.
6. Unscrew nut (C) a few turns. Repeat
this step for the other adjusting screw, 11. Replace the crusher flywheel guard and
turning the nut an equivalent amount. diesel engine guard before start-up.
7. Tighten nut (B). Repeat this step for the

other adjusting screw.
8. Repeat steps 6 and 7 to further tighten

the belts, ensuring the engine pully is in
correct alignment with the crusher
flywheel (Figure 9t).
Deflection Dimension Basic Setting Force 1.25 x Setting Force

(mm) (kgf) (kgf)
See Section 9.15.4 (Step 3) 5.1 6.3
Figure 9v Crusher Drive Belt Tensioning Specifications
Metrotrak
900 x 600
Page 49
9.15.3 Replacement and

Adjustment of Hydraulic Pump
Drive Belts
DANGER
Note:- Drive belts should be inspected Refer to Section 9.1, Safety
regularly for wear, correct tension and Information for relevant
warning
contamination.
The tension of the hydraulic pump drive

belts is adjusted by two bolts located WARNING
beneath the hydraulic pump. WEAR PERSONAL
Replacement of Drive Belts Refer to Section 9.1, Safety
warning.
(Figures 9w & 9x)
LOCKOUT MACHINE.
Procedure Information for Lockout
Procedure.

Procedure. 7. Turn the 2 adjusting screws anti-
clockwise to tighten the two drive
3. Remove the diesel engine access belts. Continue until the belts have
covers. reached the correct tension (Figure
9x, Section 9.15.4), making sure the
4. Loosen the 4 bolts (A) securing the pump pulley is aligned with the drive
pump bracket to the pump stool. pulley.
5. Turn the 2 adjusting screws (B) 8. Tighten the 4 bolts (A) to lock the
clockwise to slacken the two drive pump bracket to the pump stool.
belts. Continue until it is possible to
remove the belts. 9. Replace the diesel engine access
covers before start-up.
6. Remove the two drive belts and re-fit
with new belts.
Metrotrak
900 x 600
Page 50
Adjustment of Drive Belts

DANGER
warning
(Figures 9w & 9x)

WARNING
WEAR PERSONAL
2. Close down the machine (Section PROTECTIVE EQUIPMENT.
8.2) and implement the Lockout Information for relevant
Procedure. warning.
LOCKOUT MACHINE.
3. Remove the diesel engine access Refer to Section 9.1, Safety
covers. Information for Lockout
Procedure.
4. Loosen the 4 bolts (A) securing the
pump bracket to the pump stool.
5. If the drive belts need to be 6. Tighten the 4 bolts (A) to lock the
slackened, turn the 2 adjusting pump bracket to the pump stool.
screws (B) clockwise. Continue to
turn the adjusting screws equal 7. Replace the diesel engine access
amounts until the drive belts have covers before start-up.
reached the correct tension (Section
9.15.4), making sure the pump pulley
is aligned with the drive pulley.
If the drive belts need to be

tightened, turn the 2 adjusting
screws (B) anti-clockwise. Continue
to turn the adjusting screws equal
amounts until the drive belts have
reached the correct tension
(Section 9.15.4), making sure the
pump pulley is aligned with the drive
pulley.
Metrotrak
900 x 600
Page 51
Hydraulic Pump
Drive Belt
Hydraulic Pump
Adjusting Screws (B)
Bolts (4 off) (A)
Pump Bracket
Pump Stool
Adjusting Screws (B)

Figure 9w Hydraulic Pump Drive Belt Tension Mechanism
Deflection Dimension Basic Setting Force 1.25 x Setting Force

(mm) (kgf) (kgf)
See Section 9.15.4 (Step 3) 6.3 7.9
Figure 9x Hydraulic Pump Drive Belts Tensioning Specifications
Metrotrak
900 x 600
Page 52
9.15.4 Method of Drive Belt

Tensioning WARNING
Under no circumstances WEAR PERSONAL
should any check on the belt PROTECTIVE EQUIPMENT.
tension be made whilst the
machine is running. There is warning.
a risk of trapping parts of the
LOCKOUT MACHINE.
body if this is done. Refer to Section 9.1, Safety
Procedure.
Procedure

Crusher/Engine Drive Belts
8.2) and implement the Lockout 8 x 6000mm SPB,
Procedure. Remove the guards from Part Number 2441-0447
around the belt.
Hydraulic Pump Drive Belts
3. Calculate the deflection distance in
mm on a basis of 16mm deflection 4 x 1700mm SPB,
per 1 metre of belt span (Figure 9y). Part Number 2441-0409
Centre to Centre Distance (m) x 16

= Deflection (mm)
4. If a belt tension indicator is

available:
a) Set the lower marker ring at the

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

bottom edge of the top tube.
Metrotrak
900 x 600
Page 53
c) Place the belt tension indicator on top

of the belt at the centre of the belt WARNING
span, and apply a force at right angles
WEAR PERSONAL
to the belt deflecting it to the point PROTECTIVE EQUIPMENT.
where the lower marker ring is level Refer to Section 9.1, Safety
with the top of the adjacent belt. Information for relevant
warning.
d) Read off the setting force value LOCKOUT MACHINE.
indicated by the top edge of the upper Refer to Section 9.1, Safety
marker ring. Information for Lockout
Procedure.
e) Compare this value to the kgf value
shown in the table:
Figure 9v - Crusher Drive Belt
Tensioning Specifications
Figure 9x - Hydraulic Pump Drive
Belt Tensioning Specifications
5. If a belt tension indicator is not After the drive has been

available: running for 15-20 minutes,
the tension should be checked
a) Use a spring balance to pull the belt and re-adjusted to the Basic
down at the centre of the span. Setting Force value, if
necessary by repeating the
b) When the belt has been pulled down procedure from Step1.
(measure using a rule) by the
deflection calculated in Step 3, read
off the force from the spring balance.
6. If the measured force falls within the

values given, the drive should be
satisfactory. A measured force below
the lower value indicates under-
tensioning. A new drive should be
tensioned to the 1.25 Setting Force
value to allow for the normal drop in
tension during the running-in period.
7. Replace all guards before start-up.
Metrotrak
900 x 600
Page 54
Ce
nt
re
to
Ce
nt
re
Di
sta
nc
e
16mm
Deflection
per Metre of
Belt Tension Belt Span
Indicator Applied
to Mid-Span
Figure 9y Belt Tensioning Measurements
Metrotrak
900 x 600
Page 55
9.15.5 Trouble Shooting - Drive

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

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

principally on long centre drives. If a
slightly higher (or lower) tension does
not cure the problem there may be a
critical vibration frequency in the system
which requires re-design or a Banded
belt. Consult BL Pegson Ltd.
Metrotrak
900 x 600
Page 56
9.16 Plant - Conveyor Belts

DANGER
9.16.1 Training of Belts
NIP POINT HAZARD.
Before starting the conveyor, it is Refer to Section 9.1, Safety
essential to check that:-
warning.
• The conveyor is straight and correctly

levelled.
WARNING
• The head and tail drums are correctly WEAR PERSONAL
fitted. i.e. they are level, and that their PROTECTIVE EQUIPMENT.
axes are square to the centre line of Refer to Section 9.1, Safety
the conveyor.
warning.
• All troughing and parallel idlers are

correctly fitted with their axles square
to the centre line of the conveyor, the Tracking should be carried out with the
side roller lead is in the correct belt empty. With very stiff belts, which
direction (i.e. forward of centre) and do not trough well nor make proper
all rollers are rotating freely. contact with the centre idlers roller when
empty, it may only be possible to track
• In the case of screw-type take up the return strand when empty and the
gears, that these are adjusted initially troughed side when loaded.
to take up slack from the belt and that
equal tension is applied to each side If the belt tends to run to one side the
such that the pulley is square to the most likely cause of the trouble will
centre line of the conveyor. usually be some distance before the point
where the running off is apparent, and in
• Where skirt rubbers are fitted they are the case of troughed strand probably at
not bearing down heavily on the belt. the second or third idler behind the point
where the belt is moving out of its true
• There is no obstruction on the line.
conveyor that could cause accident or
damage when the conveyor is started. Under no circumstances
should any adjustment be
made on the belt whilst the
machine is running. There is
a risk of trapping parts of the
body if this is done.
Metrotrak
900 x 600
Page 57
Side Roller and

Spindle
Slots for
Adjustment
Belt Travel of Transome
Side Roller and

Spindle
Centre Roller
and Spindle
Slots for
Adjustment
of Transome
Figure 9z Transome Breakdown
Metrotrak
900 x 600
Page 58
9.16.2 Conveyor Belt Tensioning

Both the product conveyor and the dirt
WARNING
conveyor (if fitted) are tensioned on the WEAR PERSONAL
conveyor head drum(s). Tensioning PROTECTIVE EQUIPMENT.
mechanisms are located on either side of Information for relevant
the drum(s) (Figure 9aa). warning.
LOCKOUT MACHINE.
Best practice is to tension each side a Refer to Section 9.1, Safety
little at a time and by the same amount Information for Lockout
until the belt is tensioned. When Procedure.
tensioned, the drum must be square to
the conveyor frame.
The correct tension is achieved when the

drive drum starts the belt and keeps it Belt Tensioning
Mechanism
running when loaded without any slip
occuring.
The tension screws should be kept clean

and well oiled.
Tightening the Conveyor Belt
(Figure 9aa)
Procedure
Locknut A (2 off) Square End

1. Observe all safety warnings. Adjusting
Bar B (2off)
8.2) and implement the Lockout Figure 9aa Conveyor Belt Tensioning
Procedure. Mechanism
3. Loosen locknut A(2 off).
4. Tighten square end adjusting screw

B(2 off).
Metrotrak
900 x 600
Page 59
5. Once correct tension has been

achieved, tighten locknut A(2 off). WARNING
WEAR PERSONAL
Under no circumstances PROTECTIVE EQUIPMENT.
should any adjustment be Refer to Section 9.1, Safety
made on the belt whilst the Information for relevant
machine is running. There is a warning.
risk of trapping parts of the LOCKOUT MACHINE.
body if this is done. Refer to Section 9.1, Safety
Slackening the Conveyor Belt Procedure.
(Figure 9aa)
Procedure

Procedure.
3. Loosen locknut A(2 off).
4. Slacken square end adjusting screw

B(2 off).
5. Once correct tension has been

achieved, tighten locknut A(2 off).
Under no circumstances
should any adjustment be
made on the belt whilst the
machine is running. There is a
risk of trapping parts of the
body if this is done.
Metrotrak
900 x 600
Page 60
9.16.3 Maintenance of Conveyor(s)

The following checks should be made DANGER
regularly in order to keep the NIP POINT HAZARD.
conveyor(s) in good working order: Refer to Section 9.1, Safety
warning.
• Observe all safety warnings.
• Close down the machine (Section

8.2) and implement the Lockout WARNING
Procedure. WEAR PERSONAL
• Ensure that central feed onto the Refer to Section 9.1, Safety
conveyor belt is maintained at all Information for relevant
warning.
times and that the belt at the point of
feed is kept straight and central at all LOCKOUT MACHINE.
times. Refer to Section 9.1, Safety
Procedure.
• Inspect the skirt plate sealing strips
and ensure that they are adjusted
close enough to the belt to prevent
spillage or material jamming between
the seals and the belt, but at the same
time not bearing hard on the belt.
• Check that the belt generally is

running centrally and straight on both
the carrying strand and the return
strand. If not, refer to Section 9.16.1
Training of Belts.
• Inspect the condition of the conveyor

belt regularly and arrange for the
earliest possible repair of any damage
which may have occurred as this can
make a worthwhile extension of the
useful life of the belt. Repair a cut or
tear in the rubber by cleaning with
benzine and plugging with a rubber
repair compound.
Metrotrak
900 x 600
Page 61
• Check that there is no evidence of Note:- The grease nipples for the
belt slip at the driving drum, as belt product conveyor tail drum are remote
slip will cause premature wear on the and located either side of the Metrotrak
belt. Check also for undue sag chassis below the operating and viewing
between idlers. Both would indicate platforms.
lack of belt tension (Section 9.16.2)
• In the interests of efficient operation
• Check regularly that the idler rollers and general safety, it is important that
are rotating freely. If not either free operating conditions are kept as clean
them or replace the idler. Failure to as possible and that any spillages are
do so will result in belt wear and cleaned up regularly and are not
tracking problems. allowed to build up.
• Check that the belt cleaning As many inspections as

equipment is operating correctly and possible should be made
efficiently. In the case of scrapers whilst the belt is stationary.
ensure that they are not choked with When this is not possible
a build up of material. Also check extreme care should be taken
that the blades are not bearing on the when inspecting the belt
belt any more than necessary, and that whilst it is moving as this
any blades which are unevenly worn creates a risk of trapping
or in a condition likely to cause parts of the body.
damage to the belt are renewed
immediately. Where brushes are
involved, ensure that these are
correctly adjusted relative to the belt,
that they are not operating in a
choked condition and that any badly
or unevenly worn brushes are
renewed immediately.
• Lubricate product conveyor tail

section pivots and dirt conveyor
pivots.
• The grease in the head and tail drum

bearings of the product and dirt
conveyors needs re-greasing bi-
monthly (Section 9.4).
Metrotrak
900 x 600
Page 62
9.16.4 Cleaning the Conveyor Belts

If your machines’ conveyor belts are not
WARNING
properly maintained and skirting rubbers are
WEAR PERSONAL
not kept in proper adjustment, it may be PROTECTIVE EQUIPMENT.
necessary to remove resultant spillage Refer to Section 9.1, Safety
material and / or blockages from the Information for relevant warning.
conveyor belts, particularly at the feed
section. LOCKOUT PLANT.
It is important that these Information for Lockout
Procedure.
procedures are followed when
cleaning the conveyor belts. FALLING HAZARD.
Failure to follow these Refer to Section 9.1, Safety
procedures can result in death Information for relevant warning.
or serious injury.
Procedure
1. The equipment should be switched off

and isolated by means of the lockout and
tagout procedure prior to the
commencement of any work.
2. Use suitable personal protective

equipment i.e. eye, foot, hand and head
protection etc as may be required or
necessary to undertake the task.
3. Gloves to protect the skin against

abrasive materials, sharp surfaces, or
penetration of the skin should be worn.
4. Goggles should be worn to protect from

fragments, particles, or dust that could be
ejected into the eyes.
Metrotrak
900 x 600
Page 63
5. Not only the worker(s) cleaning the

belts but also others close by who may WARNING
be affected, must also wear protective
equipment. WEAR PERSONAL
The conveyor belts can be Refer to Section 9.1, Safety
Information for relevant warning.
cleaned using a number of
methods. Before commencing,
make sure all aforementioned LOCKOUT PLANT.
procedures have been
followed: - Procedure.
• Using a high pressure air hose; FALLING HAZARD.

• Using a water hose;
Information for relevant warning.
• Using a rod with scraper attached, or a
brush or shovel.
In the case of a blockage at a drive or tail

drum it may be necessary to loosen the
tension on the conveyor belt so that the
blockage can be removed. See Sections
9.16.2 and 9.16.3 for re-tensioning and re-
aligning the belt after blockage is removed.
When work is complete, make sure that all

guards are closed / replaced and secured
before re-starting the machine.
Metrotrak
900 x 600
Page 64
9.17 Plant - Overband Magnet Magnetic Belt

(Optional)
The self cleaning suspended magnet

utilises a two pulley design. The tail
pulley has approximately 150mm (6”) of
take up available for both belt stretch and
tracking purposes. To track the belt, the
tail pulley should be moved in a direction
to tighten the belt on the side opposite
to the direction in which the belt
wanders.
The belt magnet assembly is

very powerful and
permanently charged. The
strong magnetic field
produced could affect heart
pacemakers, watches, credit
cards, mobile phones etc. The
Shedder Plate
operator has the sole
responsibility to keep anyone
Figure 9ab Magnetic Belt
at risk clear of the machine.
Start-Up of Self Cleaning Magnet
1. Be sure the magnet frame is visibly

square and has not been damaged or
twisted.
2. Check belt alignment.
3. Momentarily energise the belt drive

and check that the belt is tracking
properly and is not wandering
laterally. Never start the belt drive
and allow it to run continuously
until the belt is properly “trained”.
If the belt wanders, note the direction
and adjust as follows:
Metrotrak
900 x 600
Page 65
Maintenance
• Belt tracking should be checked

DANGER
frequently and adjusted as necessary. NIP POINT HAZARD.
Tighten the side of the belt to which Information for relevant
you want the belt to move. warning.
• When tracking or tensioning the belt

take care not to over-tension as this
will cause the shaft bearings to fail
WARNING
WEAR PERSONAL
• Regularly check the hydraulic motor PROTECTIVE EQUIPMENT.
mounting bolts for tightness and that Information for relevant
both halves of the coupling between warning.
the motor and the drive shaft are in
LOCKOUT MACHINE.
alignment. Refer to Section 9.1, Safety
• Lubricate bearings on a schedule Procedure.
consistent with other equipment in
use with your product.
• Adjust the speed of the belt magnet

by turning the belt magnet speed
adjusting screw which is located in
the hydraulic line to the belt magnet
motor.
As many inspections as
possible should be made
whilst the belt is stationary.
When this is not possible
extreme care should be taken
when inspecting the belt
whilst it is moving as this
creates a risk of trapping
parts of the body.
Metrotrak
900 x 600
Page 66
9.18 Plant - Dust Suppression
Where the Metrotrak plant supplied is

fitted with a dust suppression system.
The system consists of three spray bars
each one having three nozzles. The
spray bars are located in the following
areas:-
• Crusher feed chute.
• Crusher discharge area.
• Product conveyor discharge.
It is the responsibility of the customer to

supply the system with clean water. This
is supplied at the manifold (Figure 9ac). Crusher Crusher Product
Feed Discharge Conveyor
The total flow requirement for the system Chute Area Discharge
is 7 litres/min. This equates to a pressure
requirement of 2.8 bar or 42 psi. Figure 9ac Dust Suppression Manifold
Maintenance
All nozzles should be kept free of dirt

and blockages. Each nozzle should be
checked every time the dust suppression
is switched on. Shut-off valves are
provided for each spray bar at the
manifold.
The system can be drained after

operation by the drain valves located
below the inlet manifold. This is
particularly important in winter time
when there is the likelihood of the system
freezing.
Metrotrak
900 x 600
Page 67
9.19 Plant - Diesel Engine

WARNING
For the diesel engine
WEAR PERSONAL
powerpack fitted to your PROTECTIVE EQUIPMENT.
Metrotrak to continue to Refer to Section 9.1, Safety
perform safely, efficiently and Information for relevant
reliably it is imperative that warning.
all the recommendations given LOCKOUT MACHINE.
in the separate engine manual Refer to Section 9.1, Safety
are strictly followed with Information for Lockout
Procedure.
regard to:-
• Safety
• Operation
• Lubrication
• Maintenance
• Service
• Parts
Adhere to the regular maintenance
schedules and procedures specified by
the manufacturer using the numbers of
hours run as displayed on the engine
Service Meter on the Engine Control Panel.
All matters relating to the diesel engine can

be dealt with directly by your local official
engine dealer for the unit fitted without
consulting BL-Pegson Limited.
For Twin Disc mechanically operated

clutches refer to the instruction plate on
the clutch for correct adjustment and
lubrication information - see overleaf.
NOT APPLICABLE FOR PLANTS

FITTED WITH HYDRAULIC CLUTCH
(See Section 11.2)
Metrotrak
900 x 600
Page 68
9.19.1 Manual Clutch Adjustment

IMPORTANT -TWIN DISC MANUAL
WARNING
CLUTCH INSTRUCTIONS WEAR PERSONAL
Refer to the Appendix (Section 11) for
instructions regarding the engine clutch warning.
adjustment check to be made at the time
LOCKOUT MACHINE.
of initial commissioning at new and the Refer to Section 9.1, Safety
essential regular maintenance of the Information for Lockout Proce-
clutch thereafter. dure.
New clutch plates have a ‘wear in’ period and

the clutch may require several adjustments
until new plates are ‘worn in’.
A newly fitted power take off must have it’s

clutch adjustment checked at the following
intervals:-
• After installation
• After 4 hours operation.
• After 10 hours operation.
• At the end of each working day for
approximately 1 week.
• Once a week.
After ‘wear in’, clutch adjustments should

be made on a weekly basis.
Metrotrak
900 x 600
Page 69
9.19.2 Engine Coolant Minimum Temperature
.
CATERPILLAR DIESEL ENGINE COOLANT
IMPORTANT NOTICE
Note.
The engine cooling system is protected to -15°C (+5° F) with 30% Caterpillar
Antifreeze concentration when shipped from the factory unless special
requirements have been defined.
ENGINE COOLANT - GENERAL INFORMATION
Protection Temperatures for Antifreeze Concentration - Ethylene Glycol Based
Protection to Concentration
-15° C (+5° F) 30% antifreeze, 70% water
-24° C (-10° F) 40% antifreeze, 60% water
Note.
In cold weather, frequently check the specific gravity of the coolant solution to ensure
adequate protection.
For more detailed information refer to Caterpillar Publication:
SEBU6250-11 Caterpillar Machine Fluids Recommendations.
Metrotrak
900 x 600
Page 70
9.19.3 Check Fuel Level

WARNING
WEAR PERSONAL
warning.
LOCKOUT MACHINE.
2. Check the fuel level indicator (Figure Information for Lockout
9ad) Procedure.
3. Top up fuel level if required (Section

9.19.2).
• Fill the tank at the end of each day,

where possible, to reduce overnight
condensation within the tank.
Diesel fuel is highly Fuel

flammable. Level
Never remove the filler cap or

refuel, with the engine running.
Never add gasoline or any

other fuel mixes to diesel
because of increased fire or
explosion risks.
Do Not smoke while refilling

or carrying out maintenance on Figure 9ad Fuel Level Indicator - Engine
the fuel system. Control Panel
Do Not carry out maintenance

on the fuel system near naked
lights or sources of sparks,
such as welding equipment.
Metrotrak
900 x 600
Page 71
9.19.4 Top Up Fuel Level

Do Not fill the tank to
WARNING
capacity. WEAR PERSONAL
Monitor the gauge located on
the Control Panel (Figure 9ad). warning.
LOCKOUT MACHINE.
Allow room for expansion and Refer to Section 9.1, Safety
wipe up spilt fuel immediately, Information for Lockout
otherwise paintwork will be Procedure.
damaged.
Procedure Never add gasoline or any

other fuel mixes to diesel
because of increased fire or
1. Observe all safety warnings. explosion risks.
2. Close down the plant (Section 8.2) and Do Not smoke while refilling
implement the lockout procedure. or carrying out maintenance on
the fuel system.
3. Remove the engine side access panel on Do Not carry out maintenance
the side nearest to the crusher to reveal on the fuel system near naked
the filler cap.(Figure 9ae). Clean the lights or sources of sparks,
area around the filler cap. such as welding equipment.
4. Remove the filler cap.
5. Fill the tank will diesel fuel.
6. Replace the cap and refit the engine

access panel before start up.
Diesel fuel is highly

flammable.
Never remove the filler cap or

refuel, with the engine running.
Figure 9ae Filler Cap
Metrotrak
900 x 600
Page 72
9.20 Plant - Vehicle Tracks

WARNING
Keeping the track properly adjusted will WEAR PERSONAL
increase the service life of the track and PROTECTIVE EQUIPMENT.
drive components. Refer to Section 9.1, Safety
The track tension has to be set as warning.
required by the current operating LOCKOUT MACHINE.
conditions. Adjust the track as slack as Refer to Section 9.1, Safety
possible if the soil is heavy. Information for Lockout
Procedure.
When ordering Spare Parts it is essential

to quote the plant serial number with
either a /S or /T suffix.
Prior to attempting any
Frequently check for loose bolts, oil manoeuvring of the plant the
leaks, master pins are correctly located tracks must be free of
and tight, general wear and damage, obstructions, including
correct track tension, etc. to ensure safe crushed material and fines.
working and long life. Do not push or tow the plant.
Failure to observe this
When travelling on a gradient, the tracks warning could result in
should be driven forward,(ie. Idlers first). danger to persons and
damage to the plant which
9.20.1 Measuring Track Tension may invalidate warranty.
Procedure
2. Position the plant on solid and level 15mm

ground and drive 2 metres minimum
in a forward direction (ie. product
conveyor leading).

Procedure. Figure 9af Measuring Track Tension
Metrotrak
900 x 600
Page 73
4. One track at a time, measure the sag on

the top part of the track on the longest
section of unsupported track by placing
DANGER
a ‘straight edge’ long enough to reach FLUID INJECTION HAZARD
from the drive sprocket to the nearest Information for relevant
skid plate. warning
5. Measure the maximum amount of track

sag from the high point of the track
grouser to the bottom of the ‘straight
edge’ (Figure 9af). Correctly adjusted
the sag should be approximately 0.6” DO NOT OVER TENSION
but must not be less that 0.25”. THE TRACKS (Refer to
Section 9.20.1).
Over tensioning the tracks can
cause severe damage to the
undercarriage components and
may invalidate the warrant.
6. Depending upon the need to either

slacken or tension the track(s)
proceed as below
9.20.2 Adjusting Track Tension

‘GREASE UNDER HIGH
PRESSURE’
Grease coming out of the relief
valve under pressure can
penetrate the body causing
injury or death; do NOT watch
the relief valve to see if grease is
escaping but instead watch the
track adjustment cylinder to
verify that the track is being
loosened.
Metrotrak
900 x 600
Page 74
Track Surface Idler Roller
Drive Sprocket
Relief Valve
Final Drive Track Roller

Unit
Figure 9ag Vehicle Track Parts
Metrotrak
900 x 600
Page 75
To Release Track Tension (After

measurement - Section 9.20.1):- DANGER
warning

WARNING
WEAR PERSONAL
Procedure.
3. Locate the access aperture on the Information for relevant
side of the track frame and remove warning.
the cover (where fitted) to reveal the LOCKOUT MACHINE.
relief valve inside. Refer to Section 9.1, Safety
4. Next loosen the relief valve by Procedure.
turning anti-clockwise using gradual
increments until the grease begins to
be expelled. Care must be taken not
to loosen the relief valve too
quickly because the grease inside is
under high pressure.
5. When the correct track tension has

been measured (Section 9.20.1), turn
the relief valve clockwise to tighten
and then clean away all trace of
expelled grease.
6. Operate the plant in manoeuvring

mode (Section 5.2.1) and drive the
plant 50 metres forwards and 50
metres backwards, measure the sag
and repeat the steps 1 - 4 if the
track(s) sag is not enough. If room
for manoeuvring the plant is
restricted,
Metrotrak
900 x 600
Page 76
drive the plant forwards and backwards

several times over a shorter distance. DANGER
If the track fails to slacken after the FLUID INJECTION HAZARD
grease fitting has been loosened, do Information for relevant
not attempt to remove the tracks or warning
disassemble the track tensioner, or
remove the grease fitting. It is
possible that running the tracks with
the grease fitting loosened may help
WARNING
WEAR PERSONAL
to expel the grease.
To Increase Track Tension (After Information for relevant
measurement - Section 9.20.1):- warning.
LOCKOUT MACHINE.
Procedure Information for Lockout
Procedure.

Procedure. metres backwards, measure the sag
and repeat the steps 1 - 4 if the
3. Locate the access aperture on the track(s) sag is too great. If room for
side of the track frame and remove manoeuvring the plant is restricted,
the cover (where fitted) to reveal the drive the plant forwards and
relief valve inside. backwards several times over a
shorter distance.
4. Connect the grease gun to the grease
fitting and add grease until the track
tension is within the specified
dimension (Section 9.20.1). See
Section 9.4.3. for the grease type and
specification.
5. Operate the plant in manoeuvring

mode (Section 5.2.1) and drive the
plant 50 metres forwards and 50
Metrotrak
900 x 600
Page 77
9.20.3 Track Maintenance

(Figure 9ag)
WARNING
WEAR PERSONAL
Maintenance Schedule PROTECTIVE EQUIPMENT.
• The first drive oil replacement is to be warning.
carried out after 100 operating hours
LOCKOUT MACHINE.
of the gearbox. Refer to Section 9.1, Safety
• There after replace the drive oil every Procedure.
1000 hours or at least once per year.
• Check the drive oil level every 100

working hours.
Daily
Procedure

Procedure.
3. Check the track rollers and idler

wheels for possible leakage.
4. Check the track surface of the track

rollers, idler wheels, track shoes and
drive sprockets for wear and loose
mounting bolts.
5. Clean out any heavy build up of

material from around the tracks.
6. Check the tension of the tracks

(Section 9.20.1) and adjust tension if
necessary (Section 9.20.2).
Metrotrak
900 x 600
Page 78
9.20.4 Drive Oil Filling and Draining

Oil Filling
WARNING
WEAR PERSONAL
warning.
LOCKOUT MACHINE.
Use gear oil SAE 80W/90 Refer to Section 9.1, Safety
1. Observe all safety warnings. Procedure.

Procedure.
Note:- Over filling the final drive will
3. Make sure the gearbox housing is cause the travel motor seal to allow
horizontal. hydraulic oil or water to enter and
contaminate the drive.
4. Rotate the gearbox housing so that
one plug is at the 12 o’clock position
and the other plug is at the 9 o’clock
position (Figure 9ah).
Oil Fill (A)
5. Unscrew the two plugs and fill from

the upper hole until the oil flows from
the hole located at the 9 o’clock
position.
6. Clean plugs using a clean non-

flammable solvent.
7. Apply pipe sealant to the plugs and

install.
Oil Level (B)
8. Repeat procedure on the other final
drive.
Figure 9ah Tracks - Oil Filling
Metrotrak
900 x 600
Page 79
Oil Draining
WARNING
WEAR PERSONAL
LOCKOUT MACHINE.
2. Close down the machine (Section Refer to Section 9.1, Safety
8.2) and implement the Lockout Information for Lockout
Procedure. Procedure.
3. Rotate the gearbox housing until a

plug is at the 6 o’clock position (A)
(Figure 9ai).
4. Unscrew both plugs and discharge the

oil.
5. Clean plugs using a clean non-

flammable solvent.
6. Apply pipe sealant to the plugs and

install.
7. Repeat procedure on the other final

Oil Drain (B)
drive.
Figure 9ai Tracks - Oil Draining
Metrotrak
900 x 600
Page 80
Blank Page
Metrotrak
900 x 600
Page 8
8.3 Emergency Stopping of 8.3.2 Testing Buttons

the Engine Daily, before commencing
crushing operations, test each
Refer to Section 8.2 emergency stop button is
operative.
IN AN EMERGENCY STOP SITUA-
TION, STOP THE ENGINE (AND
PLANT OPERATION ) USING THE Procedure
EMERGENCY STOP BUTTONS.
1. Observe all safety warnings
(Figures 1a)
2. Follow the safe start-up procedure
Note:- The Metrotrak should not be (section 7.2)
re-started if the crusher is full of
material. 3. Start the engine (section 7.2.1)
When the Metrotrak has been stopped 4. Test each emergency stop button in
using the emergency stop button the turn to cut out the engine and, fol-
Ignition Switch stays in position ‘I’. If lowing the resetting of the tested
the emergency stop button is then button, repeat the process for each of
released whilst the Ignition Switch is the other emergency stop buttons
in position ‘I’ the safety warning horn (Section 1.7) and also the stop button
will sound for 15 seconds before the on the remote control handset (Figure
engine can be restarted. (Section 7.2) 5b).
When an emergency stop has The emergency stop button on the

been intiated, DO NOT at- main control panel can be tested
tempt to restart the engine during the 15 second warning prior to
until it is safe to do so. engine start in which case the sound
will cease if the button is operative.
8.3.1 Emergency Stop Buttons

Pressing any of the buttons will stop the
diesel engine and the button will remain
engaged until physically released by
pulling or twisting (depending upon the
type fitted) the button knob. The engine
cannot be started if any of the emergency
buttons remain depressed
Metrotrak
900 x 600
Spare Parts Issue 07 ENG
Page 1
Contents
10.1 Jaw Crusher Parts ............................................................................................. 3

Jaw Crusher Unit - Metrotrak 900 x 600.................................................................... 3
Jaw Crusher - Mainframe Assembly ......................................................................... 4
Jaw Crusher - Swing Jaw Assembly ......................................................................... 6
Jaw Crusher - Eccentric Shaft Assembly .................................................................. 8
Jaw Crusher - Toggle Plate Assembly .................................................................... 10
Jaw Crusher - Tension Rod Assembly .................................................................... 12
Jaw Crusher - Hand Pump Hose Assembly ............................................................ 14
Jaw Crusher - Hand Pump Assembly ..................................................................... 16
10.2 Feeder Parts .....................................................................................................18
3800 x 800 Grizzly Feeder - Mainframe Assembly ..................................................18
3800 x 800 Grizzly Feeder - Vibrating Unit Assembly ............................................. 20
3800 x 800 Grizzly Feeder - Vibrating Unit Shaft Assembly .................................... 22
10.3 Conveyor Parts ................................................................................................ 26
Product Conveyor - Conveyor Frame Parts Assembly ............................................ 26
Product Conveyor - Conveyor Mechanical Parts Assembly .....................................28
Dirt Conveyor - Conveyor Frame Parts Assembly...................................................30
Dirt Conveyor - Conveyor Mechanical Parts Assembly ........................................... 32
10.4 Overband Magnetic Separator........................................................................ 34
10.5 Plant Component Parts ................................................................................... 36

Plant Guards/Feed Hopper Assembly .................................................................... 36
Plant Platforms Assembly ......................................................................................38
10.6 Track Parts ....................................................................................................... 40
‘S’ Mark Tracks ...................................................................................................... 40
‘T’ Mark Tracks ...................................................................................................... 42
10.7 Hydraulic Parts ................................................................................................ 44
Hydraulic Components ........................................................................................... 44
Hydraulic Hoses .....................................................................................................46
Hydraulic Hoses .....................................................................................................48
10.8 Electrical Parts .................................................................................................50
10.9 Warning Labels ................................................................................................ 52
Metrotrak
900 x 600
Page 2
IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
BL-PEGSON DISTRIBUTOR TO OBTAIN GENUINE PARTS MANUFACTURED
TO ORIGINAL SPECIFICATIONS UNDER STRICT QUALITY CONTROL.
ALWAYS QUOTE THE SERIAL NUMBER STAMPED ON THE

PLANT/MACHINE IDENTITY PLATE
YOUR LOCAL REPLACEMENT PARTS CONTACT

(fill in when known)
BL-PEGSON DISTRIBUTOR.............................................................................
CONTACT NAME(S)..........................................................................................
.........................................................................................
TELEPHONE NUMBER.....................................................................................
FACSIMILE NUMBER........................................................................................
E MAIL ADDRESS.............................................................................................
...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
REMEMBER!
THE LOCAL DISTRIBUTOR WILL ALSO CATER FOR YOUR SERVICE
REQUIREMENTS WITH TRAINED SERVICE ENGINEERS.
Metrotrak
900 x 600
Page 3
10.1 Jaw Crusher Parts
Jaw Crusher Unit - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 4
Jaw Crusher - Mainframe Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 600/8004MCD MAINFRAME 1
2 323/32 STUD 4
3 2217-0047 NUT 4
4 2210-2018 WASHER 4
5 600/8014 CHEEK PLATE UPPER RH 1
N/S 600/8015 CHEEK PLATE UPPER LH 1
6 600/8016 CHEEK PLATE LOWER RH 1
N/S 600/8017 CHEEK PLATE LOWER LH 1
7 2226-0896 SCREW 10
8 2217-0009 NUT 10
9 2210-0021 WASHER 10
10 2530-1044 GREASE NIPPLE 2
11 2520-6221 BUSH 2
12 600/8011 FIXED JAW 1
13 600/8021 WEDGE FIXED JAW 2
14 600/842 BOLT FIXED JAW WEDGE 4
15 2217-0015 NUT 4
16 310/16 WASHER 8
17 311/5 WASHER FIBRE 4
Metrotrak
900 x 600
Page 5
Mainframe Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 6
Jaw Crusher - Swing Jaw Assembly

1 600/848 JAWSTOCK 1
2 600/8012 SWING JAW 1
3 600/8022 WEDGE SWING JAW 2
4 600/843 BOLT SWING JAW WEDGE 4
310/16 WASHER 8
311/5 WASHER FIBRE 4
2217-0015 NUT 4
5 600/808 JAWSTOCK GUARD 1
6 2232-1353 BOLT 3
2211-0014 WASHER 3
2215-0020 NUT 3
7 600/829 APRON 1
8 600/830 APRON CLAMP PLATE 1
9 2211-0008 WASHER 6
2232-1125 BOLT 6
10 2530-1044 GREASE NIPPLE 2
2520-6221 BUSH 2
Metrotrak
900 x 600
Page 7
Swing Jaw Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 8
Jaw Crusher - Eccentric Shaft Assembly

1 600/810 ECCENTRIC SHAFT 1
2 600/807 INNER SPACER 2
3 2416-1520 BEARING 2
4 2430-0628 CIRCLIP 2
5 600/846 BEARING SPACER 2
6 600/847 BEARING SPACER 2
7 2416-4472 BEARING 2
8 2400-7153 BEARING SLEEVE 2
9 2430-0632 CIRCLIP 1
10 2503-5112 V RING 2
11 303/49 FLY WHEEL GROOVED 1
12 318/8 SLIT BUSH 2
13 2450-5007 RINGFEDER 2
14 600/872 END CAP 1
15 600/845 TAB WASHER 2
16 2232-1349 BOLT 4
17 600/870 COUNTERBALANCE 1
18 600/871 END CAP 1
DRIVE PULLEY COMPONENTS(NOT SHOWN ON ILLUSTRATION)
N/S 2443-1530 ENGINE PULLEY 1
N/S 2443-8707 TAPER LOCK BUSH 1
Crusher/Engine Drive Belts
8 x 6000mm SPB,
Part Number 2441-0447
Metrotrak
900 x 600
Page 9
Eccentric Shaft Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 10
Jaw Crusher - Toggle Plate Assembly

1 600/809 TOGGLE SEAT 1
2 600/825 TOGGLE PLATE 1
3 600/8013 TOGGLE BEAM 1
4 600/8025 CROSSBEAM KEY 1
2226-0816 SCREW 3
5 600/832 TOGGLE PLATE RETAINER 2
2232-1207 BOLT 4
2211- 0010 LOCKWASHER 4
6 600/8033 ADJUSTING SHIM 19MM 4
600/8034 ADJUSTING SHIM 11.5MM 4
600/8035 ADJUSTING SHIM 7MM 2
7 600/8019 WEDGE 2
8 600/8020 WEDGE ROD 2
9 2215-0020 NUT 8
10 2210-0023 WASHER 6
11 600/8023RH LOCKING BRACKET RH 1
N/S 2232-1429 BOLT 2
N/S 2217-0013 NUT 2
N/S 600/8023LH LOCKING BRACKET LH 1
N/S 2232-1429 BOLT 2
N/S 2217-0013 NUT 2
12 2960-0020 SPANNER 1
Metrotrak
900 x 600
Page 11
Toggle Plate Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 12
Jaw Crusher - Tension Rod Assembly
REF PART NUMBER DESRIPTION QUANTITY

1 600/850 TENSION ROD 1
2215-0024 NUT 2
2210-2016 WASHER 1
2 600/8018 SPRING BRACKET 1
2232-1204 BOLT 4
2211-0010 WASHER 4
3 301/10 SPRING 1
4 600/250 SPRING CAP 1
5 2210-2017 WASHER 2
6 311/9 WASHER 2
7 600/1058 SPACER 2
8 2402-2040 BEARING 1
9 320/23 PIN 1
2201-0148 SPLIT PIN 2
10 2220-7194 SCREW 1
11 600/3093 TENSION ROD GUARD 1
12 2960-0024 SPANNER 1
Metrotrak
900 x 600
Page 13
Tension Rod Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 14
Jaw Crusher - Hand Pump Hose Assembly

1 2527-1003 HOSE 1
2 2527-1008 HOSE 1
3 2527-1010 HOSE 1
4 2527-1016 HOSE 1
5 2527-1016 HOSE 1
6 2527-1017 HOSE 1
7 2527-1014 HOSE 1
8 2527-1015 HOSE 1
9 2564-2004 CYLINDER 1
10 2520-3004 SNAP CONNECTOR 2
11 2564-2003 CYLINDER 2
12 2520-3002 MALE TEE 2
13 2520-3003 FEMALE UNION 2
14 2520-3001 MALE ADAPTOR 18
15 2500-1015 BONDED SEAL 18
16 2210-0017 WASHER 10
17 320/29 PIN 5
18 2201-0124 SPLIT PIN 10
19 2341-2012 CLAMP 2
Metrotrak
900 x 600
Page 15
Hand Pump Hose Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 16
Jaw Crusher - Hand Pump Assembly
REF PART NUMBER DESCIPTION QUANTITY

1 2571-1970 HAND PUMP 1
2232-1094 BOLT 4
2211-0007 WASHER 4
2215-0013 NUT 4
2 2553-1101 VALVE 1
2232-1079 BOLT 3
2211-0006 WASHER 3
2215-0012 NUT 3
3 600/1044 BRACKET 1
2230-1220 SCREW 2
2211-0010 WASHER 2
Metrotrak
900 x 600
Page 17
Hand Pump Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 18
10.2 Feeder Parts
3800 x 800 Grizzly Feeder - Mainframe Assembly

1 620/490 MAINFRAME 1
2 84NV9 SPRING 8
3 620/491 MESH TENSIONER 1
4 2215-3018 NUT 6
2211-0012 SPRING WASHER 6
2211-0021 WASHER 6
5 2230-1290 SCREW 2
2210-0021 WASHER 2
2211-0012 SPRING WASHER 2
6 620/492 MESH SUPPORT 1
7 2236-4204 BOLT 4
2215-9001 NUT 4
2212-2005 WASHER 4
8 2315/0005 SCREEN CAPPING RUBBER 0.8M
9 620/493 TENSIONED RUBBER MAT 1
10 426/1 TENSIONED WIRE MESH 10MM 1
426/2 TENSIONED WIRE MESH 20MM 1
Metrotrak
900 x 600
Page 19
Feeder Mainframe Assembly - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 20
3800 x 800 Grizzly Feeder - Vibrating Unit Assembly

1 629/264 HOUSING 1
2 180HS28 COVER PLATE 1
3 629/47 END COVER GEAR END 1
4 629/160 DRIVE END COVER 1
5 2510-3864 RECESSED PLUG 2
6 2230-1122 SCREW 48
7 2211-0007 WASHER 48
8 2236-4278 BOLT 20
9 2212-2006 WASHER 20
10 2215-9002 NUT 20
11 2230-1150 SCREW 18
12 2211-0008 WASHER 18
13 2538-5152 SIGHT GLASS 2
14 2510-9848 MAGNETIC PLUG 2
2510-4574 RDG BUSH BRASS 2
15 2531-1021 BREATHER 3
2510-3020 BEND M/F 2
343/13 ADAPTOR 2
LOCTITE 574 ( 160 ML ) FOR SEALING
N/S 2147-0027
COVERPLATES AND END HOUSING
Metrotrak
900 x 600
Page 21
Feeder Vibrating Unit Housing - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 22
3800 x 800 Grizzly Feeder - Vibrating Unit Shaft Assembly

1 629/181 DRIVEN SHAFT 1
2 629/180 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 SCREW 32
5 629/153 BEARING HOUSING 4
6 629/158 BEARING SPACER NONDRIVE SIDE 2
7 2416-1909 BEARING 4
8 629/159 LOCKING RING 4
9 629/162 ‘O’ RING INNER 4
10 629/163 ‘O’ RING OUTER 4
11 629/156 BEARING CAP 4
2510-3864 RECESSED PLUG 4
12 2232-1279 BOLT 40
13 2217-0009 NUT 40
14 310/28 WASHER 1
15 2212-8014 LOCKING WASHER 1
16 2217-7014 BEARING LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 3
19 325/20 SCREW 6
20 18HS50 KEY SPUR GEAR 2
21 18HS54 DRIVE GEAR 2
22 629/157 BEARING SPACER DRIVE SIDE 2
23 326/11 BOLT 4
2217-0005 NUT 4
24 2576-4002 HYDRAULIC MOTOR 1
25 629/174 COUPLING 1
Metrotrak
900 x 600
Page 23
Feeder Driveside Shaft Assembly - Metrotrak 900 x 600
Note:- There is also a third hose coming off the motor which is not illustrated which is the
return to tank for the motor.
Metrotrak
900 x 600
Page 24
3800 x 800 Grizzly Feeder - Vibrating Unit Shaft Assembly(cont’)

1 629/181 DRIVEN SHAFT 1
2 629/180 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 SCREW 32
5 629/153 BEARING 4
6 629/158 BEARING SPACER NONDRIVE SIDE 2
7 2416-1909 BEARING 4
8 629/159 LOCKING RING 4
9 629/162 ‘O’ RING INNER 4
10 629/163 ‘O’ RING OUTER 4
11 629/156 BEARING CAP 4
2510-3864 RECESSED PLUG 4
12 2232-1279 BOLT 40
13 2217-0009 NUT 40
14 310/28 WASHER 1
15 2212-8014 BEARING 1
16 2217-7014 BEARING LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 3
19 325/20 SCREW 6
20 18HS50 KEY SPUR GEAR 2
21 18HS54 DRIVE GEAR 2
22 629/157 BEARING SPACER DRIVE SIDE 2
23 326/11 BOLT 4
2217-0005 NUT 4
25 629/174 COUPLING 1
Metrotrak
900 x 600
Page 25
Feeder Non Driveside Shaft Assembly- Metrotrak 900 x 600
Metrotrak
900 x 600
Page 26
10.3 Conveyor Parts

Product Conveyor - Conveyor Frame Parts Assembly
1 AX818/6/1 TAIL SECTION 1
AX818/6/2 BELT PLOUGH 1
AX818/6/3 BRACKET 2
AX818/6/4 CLAMP STRIP 2
AX818/6/5 PIVOT BUSH 2
2 AX818/5/1 CHUTE 1
3 AX818/5/2 CHUTE WEAR PLATE 2
4 AX818/5/3 CLAMP STRIP (FRONT) 2
5 AX818/5/4 CLAMP STRIP (SIDE) 2
6 AX818/5/5 CLAMP STRIP (BOTTOM REAR) 1
AX818/5/6 CHUTE SUPPORT 2
AX818/5/6X CHUTE SUPPORT 2
7 AX818/5/7 CLAMP STRIP (TOP REAR) 1
8 AX818/16 STRINGER SECTION 1
9 AX789/40/1 ROSTER UNIT SUPPORT RH 1
10 AX789/40/1A ROSTER UNIT SUPPORT LH 1
11 AX818/34/1 SCRAPER BLADE FRAME 1
12 AX818/34/3 SCRAPER BLADE CLAMP STRIP 1
13 AX818/23 DUST COVER SUPPORTS 4
14 AX815/32/9 NIP GUARD 1
15 AX818/22 HEAD GUARD RH 1
16 AX8218/22X HEAD GUARD LH 1
17 AX818/25/3 CLAMP - OPC 2
18 AX818/21 GUARD - OPC 1
19 AX818/21/X GUARD - OPC 1
20 AX818/25/2 CLAMP - OPC 2
21 AX818/122/3 DEFLECTOR BRACKET 1
22 AX818/20X MAGNET GUARD 1
23 AX818/25/1 CLAMP - OPC 2
24 AX818/19 LOWER GUARD – OPC 1
25 AX818/19X LOWER GUARD - OPC 1
26 AX818/19/2 CLAMP STRIP - OPC 2
27 AX818/26 MID SECTION GUARD - OPC 1
28 AX818/26X MID SECTION GUARD - OPC 1
29 AX818/26/2 CLAMP STRIP 2
30 AX818/63/3 PIN 2
31 AX818/63/2 PIN 2
N/S AX801/16 SPRAY BAR BRACKET 2
GERMAN VERSION ONLY
32 DISC IDLER GUARD 1
NB. Fixings are not included with the above parts unless specifically ordered
Metrotrak
900 x 600
Page 27
Product Conveyor - Conveyor Frame Parts - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 28
Product Conveyor - Conveyor Mechanical Parts Assembly

1 AX818/8 TAIL DRUM 1
2 2421-0010 BEARING 2
3 AX817/7 HEAD DRUM 1
4 2421-0010 BEARING 2
5 2360-2001 TENSIONING ELEMENT 2
6 2360-2020 TELESCOPER 2
8 AX764/36/1 TORQUE ARM 1
9 AX764/36/2 TORQUE PLATE 1
10 AX818/34/2 SCRAPER BLADE 1
11 2450-5503 SHRINK DISC 1
12 2495-3005 MULTI TROUGH IDLER 4
12A 2489-1052 SEPARATE OUTER ROLLER FOR ITEM 12 8
12B 2489-3004 FIXING CLAMP WITH BOLTS FOR ITEM 12A 8
12C 2489-1059 CENTRE ROLLER FOR ITEM 12 4
12D BASEPLATE FOR ITEM 12 4
13 2495-3004 MULTI TROUGH IDLER 2
13A 2489-1052 SEPARATE OUTER ROLLER FOR ITEM 13 4
13B 2489-3004 FIXING CLAMP WITH BOLTS FOR ITEM 13A 4
13C 2489-1059 CENTRE ROLLER FOR ITEM 13 2
13D BASEPLATE FOR ITEM 13 2
14 2495-1129 RETURN IDLER 6
15 2495-1184 DISC IDLER 1
N/S 2360-0060/20.0 CONVEYOR BELT 1
N/S AX818/58 CANVAS WIND COVER 1
Metrotrak
900 x 600
Page 29
Product Conveyor - Conveyor Parts - Metrotrak 900 x 600

12A
12B
12C
12D
12B
12A
Metrotrak
900 x 600
Page 30
Dirt Conveyor - Conveyor Frame Parts Assembly

1 AX818/133 TAIL SECTION 1
2 AX818/41/1 FEED BOOT 1
3 AX789/30/1 PIVOT PIN 4
4 AX789/32 HEAD FRAME 1
5 AX815/115/1 SIDE SKIRT 1
6 AX818/115/2 SIDE SKIRT 1
7 AX789/45/1 HEAD GUARD 1
8 AX789/39/3 SCRAPER BLADE CLAMP 1
9 AX789/39/1 SCRAPER BLADE FRAME 1
10 AX815/91/1 TENSIONER SUPPORT LH 1
11 AX815/91/2 TENSIONER SUPPORT RH 1
12 AX789/30/2 PIVOT PIN 2
13 AX815/6 NIP GUARD 1
16 AX815/32/9 NIP GUARD 1
17 AX815/32/10 NIP GUARD CLAMP 2
18 AX815/82 COUPLING GUARD 1
Metrotrak
900 x 600
Page 31
Dirt Conveyor - Conveyor Frame Parts- Metrotrak 900 x 600
Metrotrak
900 x 600
Page 32
Dirt Conveyor - Conveyor Mechanical Parts Assembly

2 AX815/90 TORQUE ARM 1
3 2450-5503 SHRINK DISC 1
4 2421-0010 BEARING 2
5 AX789/13 TAIL DRUM 1
6 2564-5015 HYDRAULIC CYLINDER 2
7 AX815/92 HEAD DRUM 1
8 2421-0010 BEARING 2
9 AX789/39/2 BELT SCRAPER BLADE 1
10 AX607/3/46 TENSIONING ELEMENT 2
11 AX818/110/1 TELESCOPER LH 1
AX818/110/1X TELESCOPER RH 1
12 AX815/31 MULTITROUGH IDLER 4
12A SEPARATE OUTER ROLLER FOR ITEM 12 8
12B CLAMP WITH BOLTS FOR ITEM 12A 8
12C SEPARATE CENTRE ROLLER FOR ITEM 12 4
12D SEPARATE BASEPLATE FOR ITEM 12 4
13 AX607/658/3 RETURN IDLER 1
14 AX818/56/1 SKIRT RUBBER 2
15 AX818/56/2 SKIRT RUBBER 1
16 2360-0062 CONVEYOR BELT (8.20 METRES) 1
Metrotrak
900 x 600
Page 33
Dirt Conveyor - Conveyor Mechanical Parts - Metrotrak 900 x 600

12A
12B
12C
12D
12B
12A
Metrotrak
900 x 600
Page 34
10.4 Overband Magnetic Separator

1 2650-9017 FRAME 1
2 2650-9018 MAGNET 1
4 2650-9002 DRIVE PULLEY 1
5 2650-9003 NON-DRIVE PULLEY 1
6 2650-9005 BEARING 4
7 2650-9006 BEAING CAP 3
8 2650-9007 BEARING BACK PLATE 2
9 2650-9008 BEARING TAKE-UP PLATE 2
10 2650-9009 BEARING SPACER PLATE 2
11 2650-9020 SIDE PLATE LEFT HAND 1
12 2650-9021 SIDE PLATE RIGHT HAND 1
13 2360-0002 BELT 1
14 2650-9010 EYENUT 4
15 2650-9011 MOTOR MOUNTING PLATE 1
16 2650-9004 COUPLING ASSEMBLY 1
Metrotrak
900 x 600
Page 35
14
15
5 8
10
3 16
4 12
11
13
Overband Magnetic Separator- Metrotrak 900 x 600
Metrotrak
900 x 600
Page 36
10.5 Plant Component Parts
Plant Guards/Feed Hopper Assembly

1 AX818/42/1 FEED HOPPER - HYDRAULIC FOLDING 1
2 AX818/42/2 SIDEPLATE LOCKING WEDGE-FEED END 2
AX818/42/3 SIDEPLATE LOCKING WEDGE-DISCH. END 2
3 AX818/42/6 ENDPLATE LOCKING WEDGES 2
4 2564-5016 HYDRAULIC CYLINDER 2
5 AX818/42/4 UPPER CONNECTING PINS 2
6 AX818/42/5 LOWER CONNECTING PINS 2
NB. ITEMS 4, 5 & 6 ARE NOT APPLICABLE TO THE
MANUAL FOLD HOPPER
7 AX818/64 FEED HOPPER - FIXED NON FOLDING 1
8 AX818/77/1 CRUSHER DRIVE GUARD 1
9 AX818/77/2 LARGE REMOVABLE ACCESS PANEL 1
10 AX818/77/3 SMALL REMOVABLE ACCESS PANEL 1
11 AX818/78/1 CRUSHER FLYWHEEL GUARD 1
12 AX818/78/2 REMOVABLE ACCESS PANEL 1
13 AX818/78/3 TOOLBOX LID 1
14 AX818/78/4 LOCK ASSEMBLY FOR TOOLBOX LID 1
15 TOOLBOX LID GAS STRUTS 2
16 AX818/68/1 CONTROL BOX 1
17 AX818/68/2 CONTROL BOX LID 1
18 AX818/68/3 LOCK ASSEMBLY FOR CONTROL BOX LID 1
19 CONTROL BOX LID GAS STRUTS 2
20 AX818/83 REAR GUARD 1
21 AX818/84 CRUSHER HEAD GUARD 1
22 AX818/85 CONVEYOR NIP GUARD 1
23 AX818/86 RETURN IDLER GUARD 2
24 AX818/72/1 PUMP BRACKET GUARD 1
25 AX818/72/2 ENGINE SHAFT GUARD 1
26 AX818/44 FEED CHUTE SAFETY GRID 1
NB. Fixings are not included with the above parts unless specifically ordered.
NOTE: Conveyor guarding is included with the Conveyors on pages 28 & 32
Metrotrak
900 x 600
Page 37
21 11 12 26
1 - 6 OR 7
13 & 15
14
16 18 17 & 19
9 8 10
20
Plant Parts - Guards - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 38
Plant Platforms Assembly

FEEDER MAINTENANCE PLATFORM
1 AX818/46 FLOORING PANEL 1
2 AX818/47/1 HANDRAIL - REAR 1
3 AX818/47/1X HANDRAIL - FRONT 1
4 AX818/47/2 HANDRAIL SAFETY GATE 1
5 AX818/49X ACCESS LADDER 1
CRUSHER PLATFORM
6 AX818/13/1 FLOORING PANEL 1
7 AX818/13/2 FLOORING PANEL - RH SIDE 1
8 AX818/13/2X FLOORING PANEL - LH SIDE 1
9 AX818/14 ACCESS LADDER 1
ENGINE PLATFORM
10 AX818/17 FLOORING PANEL 1
11 AX818/18/1 ACCESS LADDER - TOP 1
12 AX818/18/2 ACCESS LADDER - BOTTOM 1
13 AX818/54/1 HAND GRIP - ENGINE PLATFORM 1
14 AX818/54/2 HAND GRIP - ENGINE & CRUSHER 3
FLYWHEEL GUARD
NB. Fixings are not included with the above parts unless specifically ordered.
Metrotrak
900 x 600
Page 39
3 4 2
14
13
10
11
12 9 6-8
Plant Parts - Platforms - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 40
10.6 Track Parts
‘S’ Mark Tracks

Before ordering track parts it is essential to look for the identifying ‘S’ suffix to
the plant serial number on the plant identity plate, eg. QMXXXXXXS. If suffixed
‘T’ refer to the part numbers on the following pages.

TRACK DRIVE GEARBOX C/W MOTOR - DRIVE
1 2372-0039 2
SYSTEM
2 2372-0002 BOLTS - DRIVE SYSTEM 40
3 2372-0003 DRIVE SPROCKET - DRIVE SYSTEM 2
4 2372-0004 BOLTS -DRIVE SYSTEM 32
5 2372-0040 TRACK CHAIN -TRACK CHAIN 2
6 2372-0007 TRACK SHOE - TRACK CHAINS 98
7 2372-0008 TRACK SHOE BOLT -TRACK CHAINS 392
8 2372-0009 TRACK SHOE NUTS -TRACK CHAINS 392
9 2372-0012 IDLER - IDLER GROUP 2
10 2372-0013 YOKE - IDLER GROUP 2
11 2372-0044 RECOIL - IDLER GROUP 2
12 2372-0015 GREASER - IDLER GROUP 2
13 2372-0016 GASKET - IDLER GROUP 2
14 2372-0017 ROLLER - LOWER ROLLER GROUP 16
15 2372-0018 BOLT - LOWER ROLLER GROUP 64
16 2372-0019 WASHER - LOWER ROLLER GROUP 64
2372-0041 REPAIR LINK - TRACK CHAIN

2372-0042 MASTER PIN - TRACK CHAIN
400 WIDE METROTRAK 900 X 600, SERIAL NOS 181416 - PRESENT
Metrotrak
900 x 600
Page 41
9 -11
14 - 16
Tracks Assembly - Metrotrak 900 x 600

12- 13
1-4
5-8
Metrotrak
900 x 600
Page 42
‘T’ Mark Tracks

Before ordering track parts it is essential to look for the identifying ‘T’ suffix to
the plant serial number on the plant identity plate, eg. QMXXXXXXT. If suffixed
‘S’ refer to the part numbers on the previous pages.

1 2372-1001 TRACK FRAME LH 1
2 2372-1002 TRACK FRAME RH 1
3 2372-1003 TRACK GUIDE 2
4 2372-1004 TRACK GUIDE BOLT 20
5 2372-1005 TRACK GUIDE WASHER 20
6 2372-1006 GEARBOX C/W MOTOR
7 2372-1007 HYDRAULIC GEARBOX 2
9 2372-1009 GEARBOX MOUNTING BOLT 20
10 2372-1010 GEARBOX MOUNTING WASHER 20
11 2372-1011 SEAL, 18MM 2
12 2372-1012 SEAL, 1/4” 2
13 2372-1013 ADAPTER, 3/8” X 18MM 2
14 2372-1014 ADAPTER, 1/4” X 1/4” 2
15 2372-1015 SPROCKET 2
16 2372-1016 SPROCKET MOUNTING BOLT 32
17 2372-1010 SPROCKET MOUNTING WASHER 32
18 2372-1017 TRACK GROUP COMPLETE
19 2372-1018 LINK ASSEMBLY, 53 LINK 2
20 2372-1019 MASTER PIN 2
21 2372-1020 TRACK SHOE 400 MM WIDE 106
22 2372-1021 TRACK SHOE BOLT 424
23 2372-1022 TRACK SHOE NUT 424
24 2372-1023 IDLER GROUP 2
25 2372-1024 TRACK ADJUSTER GREASE VALVE 2
26 2372-1025 TRACK ADJUSTER GREASE VALVE GASKET 2
27 2372-1026 TRACK ADJUSTER GREASE GUN CONNECTOR 1
28 2372-1027 TRACK ROLLER 18
29 2372-1028 ROLLER MOUNTING BOLT 72
30 2372-1029 ROLLER MOUNTING WASHER 72
2372-1030 COMPLETE SINGLE REPAIR LINK

2372-1031 COMPLETE 2 LINK REPAIR KIT
2372-1032 COMPLETE 3 LINK REPAIR KIT
Metrotrak
900 x 600
Page 43
28 - 30
24
Tracks Assembly - Metrotrak 900 x 600

25 - 27
1-5
6 - 17
18 - 23
Metrotrak
900 x 600
Page 44
10.7 Hydraulic Parts
Hydraulic Components

A AX818/4 TANK 1
B 2550-9009 PVG32-2 VALVE (2 BANK) 1
C 2550-9002 PVG32-5 VALVE (5 BANK) 1
D 2550-9003 MOTION CONTROL VALVES TRACK 2
E 2531-5057 FILTER 2
F 2552-0024 MAGNET CONTROL FLOW ASSEMBLY 1
G 2553-3010 SINGLE C/N BALANCE VALVE 1
H 2579-0018 CHECK VALVE 1
I 2520-8001 2.5SAE 1
J 2553-2013 TEST POINTS 2
K 2666-2001 THERMOSTAT 1
L 2576-4073 PRODUCT CONVEYOR MOTOR 1
M 2573-6001 HYDRAULIC PUMP 2
N 2564-5016 FOLDING HOPPER RAMS 2
O 2564-5015 DIRT CONVEYOR RAMS 2
P 2576-4078 DIRT CONVEYOR MOTOR 1
Q 2576-4002 FEEDER MOTOR 1
N/S 2441-0410 HYDRAULIC PUMP DRIVE BELTS 2
Metrotrak
900 x 600
Page 45
N
O
F
G
B
P
H
Q
J
D
D
E
E
M
M
A
Metrotrak
900 x 600
Page 46
Hydraulic Hoses

00 AX818HOSE00 HYDRAULIC HOSE 1
Metrotrak
900 x 600
Page 47
Metrotrak
900 x 600
Page 48
Hydraulic Hoses
HYDRAULIC FOLDING HOPPER (WHERE FITTED)

2526-5002 HYDRAULIC HOSE 2
Metrotrak
900 x 600
Page 49
Metrotrak
900 x 600
Page 50
10.8 Electrical Parts

1 2683-2100 FUSE SET - 2*3A, 2*5A, 2*10A & 2*16A 1
2 2683-2101 EM/STOP TWIST TO RELEASE PUSH 2
BUTTON WITH CONTACT BLOCKS
3 2683-2103 2 POSITION STAYPUT SWITCH WITH 1
CONTACT BLOCKS
4 2683-2104 3 POSITION SPRING RETURN SWITCH 1
WITH CONTACT BLOCKS
5 2683-2105 1 HOLE EMERGENCY STOP 1
ENCLOSURE
6 2683-2107 10 AMP 8 PIN 2 POLE MINI RELAY 24V 2
DC
7 2683-2108 15 SECOND TIMER 1
8 2683-2109 FEEDER SPEED CONTROL 1
POTENTIOMER
9 2683-2110 AUDIBLE WARNING UNIT 24V DC 1
10 2683-2114 HEAVY DUTY EM/STOP RELAY 1
11 2683-2117 GREEN START BUTTON COMPLETE 1
12 2683-2118 RED STOP BUTTON COMPLETE 1
N/S 2666-0001 PRESSURE SWITCH (OPTIONAL ITEM) 1
13 2686-0025 RADIO CONTROL COMPLETE KIT - 433 1
Hz. COMPRISING, CONTROL BOX
INTERNALS, RECEIVER UNIT AND
REMOTE HANDSET
14 2686-0028 RADIO CONTROL AERIAL ONLY 1
15 2686-0013 RADIO CONTROL HANDSET ONLY 1
16 2686-0030 RADIO CONTROL DRIVER MODULE 1
ONLY (CONTROL PANEL COMPONENT)
17 2686-0003 UNBILICAL CONTROL HANDSET ONLY 1
2686-0017 BATTERY CHARGER 1
2686-0019 REPLACEMENT BATTERY 1
18 2593-2001 HYDRAULIC OIL COOLER 1
HFO CLUTCH CONVERSION PARTS

19 2683-2121 INDICATOR LAMP WITH LED 1
2683-2120 RELAY BASE AND CLIP 1
2683-2122 BLUE CABLE 1
2683-2123 TERMINALS 1
2683-2102 CRUSHER START/STOP PUSH BUTTON 1
NB. SEE THE HYDRAULIC SYSTEM FOR THE HYDRAULIC VALVE SOLENOIDS.
Metrotrak
900 x 600
Page 51
10 6 7 1 (7.5A)
16
REMOTE CONTROL RECEIVER BOARD (ALSO PART OF 13)
2 19 * 8
4 3 11 12
Electrical Parts - Metrotrak 900 x 600
Metrotrak
900 x 600
Page 52
10.9 Warning Labels

300/32 DANGER – NIP POINT HAZARD 4
300/33 WARNING – READ MANUAL 2
300/34 DANGER – SKIN INJECTION HAZARD 3
300/35 DANGER – DRAWBACK ROD GUARD 1
300/36 IMPORTANT – CHECK FEEDER OIL LEVEL 2
300/37 IMPORTANT – CHECK HYDRAULIC FILTERS 2
300/38 WARNING – FALLING MATERIAL 3
300/39 WARNING – STOP & LOCKOUT 3
300/40 WARNING – GUARDS/LABELS IN PLACE 5
300/42 IMPORTANT – DRAIN WATER 1
300/43 WARNING – STRONG MAGNETIC HAZARD 2
300/44 WARNING – SPRING LOADED DOOR 2
300/118 DANGER – MAINTENANCE PLATFORM 2
300/120 WARNING – FALLING FROM PLANT 2
Metrotrak
900 x 600
Page 53
300/32 300/33 300/34 300/35
300/36 300/37 300/38 300/39
300/42
300/40 300/43 300/44
300/118 300/120
Metrotrak
900 x 600
Page 54
Blank Page
Metrotrak
900 x 600
Appendix Issue 07 ENG
Page 1
Contents
11.1 Noise Levels ....................................................................................................... 2
11.2 Manual Engine Clutch .......................................................................................3
11.3 HFO Hydraulic Engine Clutch * ........................................................................ 5

11.3.1 HFO Clutch Hydraulic Circuit ......................................................................... 6
11.4 Electrical Wiring Diagrams ................................................................................ 7
11.4.1 Plant with Manually Operated Engine Clutch. ................................................. 7
11.4.2 Plant with HFO Hydraulically Operated Engine Clutch .................................... 8
Metrotrak
900 x 600
Page 2
11.1 Noise Levels
Noise levels for the Metrotrak (running on empty) recorded in open area on acoustically hard
ground under dry, windless conditions, with sound level meter 1.6m above ground.
71.6dB
Maximum Noise on Plant
Platforms 98.2dB
75.5dB
77.5dB
(10m Radius)
(5m Radius)
(1m Radius)
80.0dB
83.1dB
88.7dB
87.3dB
82.8dB
77.4dB
86.0dB
79.6dB
76.9dB
Figure 11a Noise Levels
Metrotrak
900 x 600
Page 3
11.2 Manual Engine Clutch
Metrotrak
900 x 600
Page 4
Metrotrak
900 x 600
Page 5
11.3 HFO Hydraulic Engine Clutch *

The engine clutch controls the engagement/disengagement of the crusher drive and on the
standard plant this is activated by a manual hand lever on the engine clutch bell housing.
Electro/hydraulic activation is the optional alternative in the form of the HFO clutch.
Where the Metrotrak is fitted with the Optional Extra HFO hydaulically operated clutch, the manu-
ally operated clutch lever is replaced by electrical start/stop push buttons on the main plant control
panel and also a stop button on the feeder/conveyor control box. The appropriate instructions
relating to the operation of the HFO clutch are included in sections 7 & 8 of this manual.
The hydraulically operated HFO clutch is a minimum maintenance unit which does not require the
initial and regular checking and adjustments necessary for the mechanically operated Twin Disc
clutch as described on page 65 of the Maintenance section of this manual.
The HFO clutch is operative when the engine powered plant hydraulic system is at operating pres-
sure. Should the hydraulic pressure fall below a preset level, a low pressure warning light on the
feeder/conveyor control box will illuminate and the feeder will stop operating. This prevents any
further material entering the crusher whilst there is a risk of the clutch slipping due to low hydraulic oil
pressure and until the reason for the fall in oil pressure has been established and rectified.
Metrotrak
900 x 600
Page 6
11.3.1 HFO Clutch Hydraulic Circuit
Metrotrak
900 x 600
Page 7
11.4 Electrical Wiring Diagrams
11.4.1 Plant with Manually Operated Engine Clutch.
Metrotrak
900 x 600
Page 8
11.4.2 Plant with HFO Hydraulically Operated Engine Clutch
Metrotrak
900 x 600
Notes Issue 07 ENG
Page 1
Hours Run / Date Notes Name
Metrotrak
900 x 600
Notes Issue 07 ENG
Page 2
Metrotrak
900 x 600
Notes Issue 07 ENG
Page 3
Metrotrak
900 x 600
Notes Issue 07 ENG
Page 4
OEM BL - PEGSON
OEM PART NO 2480-0029
OEM MODEL 900X600 (36x24) Metrotrak
ENGINE MODEL 3116TA 160 HP @ 1800 RPM
TRANSMISSION TRANSFLUID HFO 214
SPECIFICATION 15057A00
15057A00
STATEMENT (Please Read)
IMPORTANT - Many of the parts listed in this manual are NOT SOURCED FROM
CATERPILLAR.
Finning works closely with your OEM manufacturer to provide a complete Power Pack for the
installation. Many of the parts detailed in this manual are manufactured in the United
Kingdom for Finning (UK) Ltd. As such they are NOT available or warrantable by the local
Caterpillar Dealer Network. Specifically they are: Canopy, Base, Wiring Loom.
Non-Caterpillar items are identified with 12345E00 or 00000001E part numbers . These parts
can only be ordered from your OEM Parts Manager. In case of difficulty, contact Finning (UK)
Ltd. Power Systems - Industrial OEM Group, for assistance.
e-mail powersystems@finning.co.uk
Fax 00 +44 (0)1543 461 773.
IMPORTANT - Your Caterpillar engine MUST BE REGISTERED FOR WARRANTY with your
local Caterpillar dealer. Failure to do so will result in extensive delays and frustration while
cover is established.
Please complete the "Engine Delivery Service Record" and return it to your nearest
Caterpillar dealer OR complete the form on Caterpillar's web page at www.cat.com. This can
be found under the engines tab, then select service & support followed by the engine
warranty registration link.
Your Caterpillar engine is equipped with factory fitted attachments that are supported by
your local Caterpillar dealer. In the construction of the Power Pack "wear items", "controls",
"instrumentation" are mainly Caterpillar parts, identified by part number format "1N1234" or
"123-1234".
Your local Caterpillar dealer can be located using the website www.cat.com
Due to continual development this manual is subject to change without notice . Whilst every effort has been made to ensure accuracy,
Finning (UK) Ltd. accepts no liability for errors or omissions in this document.
Index
Section
A. Canopy Enclosure
B. Engine Hardware
C. Base
D. Air Cleaner System
E. Exhaust System
F. Wiring / Control Panel
G. Battery / Control Box
H. Miscellaneous
I. Change Level
Diagram 1
L
Left And Right Are Denoted By Viewing
RADIATOR
The Power Pack From The Drive Shaft SHAFT

See Diagram 1
R
Canopy A
15057A00 Canopy
Canopy A
Item No. Qty Part No. Description

1 1 1371OEOO Roof Panel
2 1 13711EOO Right Hand Corner Panel
3 1 13712EOO Left Hand Corner Panel
4 1 13172EOO Door Left Hand Removable
5 1 13172EOO Door Right Hand Removable
6 1 13173EOO Upper Right Hand Panel
7 1 13173EOO Upper Left Hand Panel
8 1 13174EOO Left Hand Rear Corner Panel
9 1 14422EOO Right Hand Rear Corner Panel
10 1 13713EOO Centre Panel
11 1 Rear Upper Centre Panel(Behind Attenuator)
12 1 OOOOO25M Rear Lower Centre Panel(Behind Attenuator)
13 1 134O9EOO Attenuator Acoustic
14 1 12OOOEOO Louver Assembly
15 1 O5646DOO Hinges Assembly
16 4 13728DOO Deflector
17 1 11925EOO Roof Access Cover
18 1 O5174DOO Radiator Filler Cover(Not Shown)
19 1 O5519DOO Literature Pocket(Not Shown)
20 1 7N0718 Isolator
21 1 SBV25 19 X3 MM Foam Gasket
22 O5177EOO 3 Way Lock
23 3 O5211EOO Round Rod
24 6 M5 X25 Pan Head Screw
25 6 M6 X 16 Hex Set Bolt
26 16 M6 Washer
27 16 M10 X 30 Countersunk Screw
30 10 M10 Washer
31 54 M10 Nyloc Nut
32 54 O8O23EOO Label' Warning Clutch'
33 2 1O97O Label 'Cat Power'
34 1 5P-2506 Literature
35 1 O5762EOO 5" Tee Key
36 1 Transfluid HFO214 (BL-Pegson Supply)
15057A00 Canopy
Engine Hardware 1 B
15057A00 Engine Hardware

Engine Hardware 1 B

1 1 13840EOO Radiator Assy
2 1 OOOOO23M Radiator Support Frame
3 1 10648EOO Radiator Support Brace
4 1 13841EOO Fan Blower Multiwing 24"
5 1 OOOO24M Fan Spacer
6 4 Bolt M8 x 90
7 4 Washer
8 1 OOOOO22M Fan Guard
9 1 1O651EOO Radiator Upper Pipe
10 1 7C9646 Hose Modified
11 8 9M0164 Clamp
12 1 OOOOO37M Radiator Lower Pipe
13 1 5P1259 Hose Length 12Cm
14 1 O38415O Hose 45 Deg Elbow
15 1 O5726EOO 28.6 Clear Pipe Length 150Cm
16 1 1O332DOO Oil Filler Pipe
17 1 OOOOO20M Fuse Bracket (Not Shown)
18 1 O5187DOO Clutch Plate
19 1 M16 x 50 Hex Set Bolt
20 1 M16 Nyloc nut
21 1 M16 Washer
22 1 156-9888 Flexible Fuel Lines
23 1 13121EOO Governer Cable
24 1 13122EOO Vernier Head (For Governor Cable)
15057A00 Engine Hardware

Base C
15057A00 Base
Base C

1 2 Battery Trays
2 2 Clutch Support Plate Mounting Bracket
3 2 Setting Bracket
4 1 Fuel Feed Pipe/Adaptor 3/4 X 3/8 BSP
5 1 Fuel Return Pipe/Adaptor 3/4 X 3/8 BSP
6 2 Fuel Socket 3/4 BSP
7 1 OO214E1O Fuel Filler Collar
8 1 OO216E1O Fuel Filter
9 1 OO215E1O Filler Cap
10 1 Drain Socket 1 1/4 BSP
11 1 Drain Plug 1 1/4 BSP
12 1 Oil Drain Pipe
13 1 13166DO2 Kick Plate (Side) Removed For Clarity
14 2 Bracket Filter Housing
15 2 Pump Posistion Bracket
16 1 Connection Box Mounting Bracket
17 8 Kick Plate Supports
18 1 Bracket Valve Bank
19 2 Engine Mounting Channel
20 1 6T367O Fuel Sender (Modified To Suit)
21 1 O51-4733 Gasket
22 5 M4 X 16pan Head Screw
23 1 Socket 3/4 BSP
24 1 Plug 3/4 BSP
15057A00 Base
Air Cleaner D
15057A00 Air Cleaner

Air Cleaner D

1 1 124-3237 Air Cleaner
2 1 125-2736 Air Cleaner Assembly
3 1 108-8069 Air Cleaner Bracket Modified
4 1 1W-0613 Service Indicator
5 1 9Y2699 90 Deg Elbow
6 1 Tube Length 5" (Joining Elbows)
7 1 149-3242 Elbow Angled Rubber
8 4 5P-1717 Clamp
15057A00 Air Cleaner

Exhaust E
15057A00 Exhaust
Exhaust E

1 1 Turbo Outlet Modified
2 1 11622EOO Bellows Assy (Not Shown)
3 1 8H8604 Clamp (Not Shown)
4 1 12478EOO Muffler
5 1 7S4994 Rain Cap
7 4 M10 Nyloc Nut
8 4 M10 Washer
15057A00 Exhaust
Control Panel F
15057A00 Control Panel

Control Panel F

1 1 9X-1117 Tacho (Digital)
2 1 4W-2065 Oil Pressure Gauge
3 1 105-1457 Volt Gauge
4 1 9G-6762 Hour Meter
5 1 9W-1077 Ignition Switch
6 1 8J-4785 Ignition Switch Plate
7 2 6T-3644 20 Amp Circuit Breaker
8 1 6T-3643 15 Amp Circuit Breaker
9 6 Pan Head Screw
10 1 8M-2777 Terminal Rail 6 Way (Other Side)
11 2 Pan Head Screw
12 2 Locking Nut
13 1 9D-3721 Override Switch
14 1 7G-0685 Fuel Gauge
15 1 4W-0483 Water Temperature Gauge
16 1 13177DOO Instrument Front Panel
17 1 E-4798E1O Label
15057A00 Control Panel

Wiring Control Panel F
EARTH
BLACK
BLUE
24 WAY PLUG
ORANGE
BLACK
BLUE
WHITE
1
BLUE TACHO PICK-UP
13
BLACK TACHO PICK-UP
2
TACHOMETER EARTH TACHO PICK-UP
17
ORANGE/PURPLE OIL SWITCH
GREEN
SETTING 3
16
A B BLACK ETR
11
BLACK/GREEN
BLACK/YELLOW CUSTOMER EARTH

23
BLACK/GREY CUSTOMER EARTH
OIL SCREEN
PRESS CLAMP
ORANGE
I S I WATER S
TEMP
G
G
15
ORANGE GREEN FUEL SENDER
BLACK
BLACK 4
BLACK/GREEN FUEL SENDER
ORANGE
VOLTMETER FUEL 5
PURPLE ETR SOLENOID
I S I S 3
BLUE OIL SENDER
G G
WHITE WATER SENDER 14
ORANGE
RED
18
ORANGE RELAY ENERGISE
BLACK
ORANGE/PURPLE
ORANGE 10
YELLOW RELAY OUTPUT
24
HOURMETER GREY RELAY OUTPUT
6
PINK START SOLENOID
ORANGE
BLACK
+ 20
_
RED IGNITION
PURPLE
20
PURPLE BULLET F
BLACK CONN M
START
SEE DETAIL 25mm DIA PMA
CONDUIT TO PLUG
RED
SWITCH SOLENOID
RED
OVERRIDE
B
IG R
ST
PINK
24v TERMINAL RAIL
(6 WAY, MAX 16 AMPS)
CUSTOMER SWITCH
YELLOW (NORMALLY CLOSED)
GREY BLACK 0v TERMINALS 0v & 3A - FOR BELT WEAR
OVERRIDE
RED 3A SWITCH
BLACK/YELLOW 0v TERMINAL 10A FOR - REMOTE CONTROL
20 15 YELLOW 10A
BLACK/GREY 0v
TERMINAL 16A FOR - OIL COOLER RELAY ENERGISE F
16A BULLET
GREY 20 A FUSE
ALL ABOVE SWITCHED BY IGNITION M CONN
10A & 16A NEUTRALS ARE TAKEN FROM STARTER M
BULLET
20 F CONN
ORANGE
SEE NOTE A
REMOTE MOUNTED VERTICAL PANEL (VIEWED FROM REAR; 13177D00 REV A)
NOTES :-
A. FOR CUSTOMER ACCESS TO ENGINE SHUTDOWN CIRCUIT,
BREAK ORANGE WIRE BULLET CONNECTOR, (BETWEEN 20A FUSE
AND OVERRIDE SWITCH ON PANEL), AND ADD N/C SWITCH (24V 5A)
WARNING!!
VOLTAGE DROP, CURRENT RISES AS CUSTOMER CIRCUIT CABLE
RUN INCREASES!!
15057A00 Wiring Control Panel

MAGNETIC
PICKUP CAT
7W3355GRP CONNECTOR
DENOTES WIRES RUN WITHIN LOOM 1 BLACK
AND NOT TO CONNECTOR. NUMBERS 2 RED
SHOW EACH END. (SEE SHEET 2)
BLACK SOCKET 3
BLUE PIN OIL PRESSURE 6
C NO
OIL PRESS
SENDER NC SWITCH
BLUE
BLUE
TACHO CABLE NOT
TO EXCEED 3.6m (12ft)
CUT SCREEN WIRE
WATER TEMP 6 CAT
SCREENED SENDER CONNECTOR
PURPLE/ORANGE
2 CORE 1
24 WAY SOCKET WHITE 2 WHITE WATER
1 3 BLACK TEMP
RED SWITCH
13 5 NO C NC
ORANGE/PURPLE
Wiring Engine Loom
2
PURPLE
17
ORANGE/PURPLE
16 PURPLE
BLACK
11 5
BLACK/YELLOW RACK
23 SOLENOID (ENERGISE TO RUN)
BLACK/GREY
FUEL LEVEL
SENDER BLACK/ORANGE 7
GASKET 8
RED/ORANGE
15 3 4
GREEN
4
BLACK/PURPLE
BLACK/GREEN 7
BLACK
5 2
PURPLE STARTER
MOTOR
3
BLUE
14 BLACK KEY ISOLATOR
WHITE SWITCH
18 4 (KEY 8H5306)
ORANGE ISOLATION SOLENOID
10 (ENERGISE TO RUN)
YELLOW
RED
24
GREY 3
BLACK
BLACK
6
PINK
20
RED
15 BLACK
BROWN
8
F 15
- 1 1
25mm DIA PMA
M
CONDUIT TO ENGINE
D+ ??
+ RED
NOT REQUIRED FOR 33A & 45A ALTERNATOR 2
ALTERNATOR
60A FOR 45A & 52A ALTERNATOR

F
40A FOR 33A ALTERNATOR
15057A00 Wiring Engine Loom

CAT CONNECTOR OIL PRESS
SWITCH
ORANGE/PURPLE
BATTERY CABLES
POS1 6
PURPLE/ORANGE PLASTIC PROTECTIVE
SHEATH 12mm
POS 2 7 RING
+ +
BLACK/PURPLE 1.5mm PLASTIC PROTECTIVE
5mm RING - RED SHEATH 10mm
RING
- -
ETR
SOLENOID
PLASTIC PROTECTIVE
THESE WIRES ARE RUN WITHIN THE LOOM SHEATH 12mm
RING
ONLY AND NOT TO THE CONNECTOR
2 OFF PURPLE - -
(NUMBERS SHOW EACH END) 10mm
ON SAME 5mm RING - YELLOW RING
5
BATTERY TERMINAL COVERS SUPPLIED
BLUE
LOOSE FOR CUSTOMER USE
5mm RING
Wiring Conduit Layout
BLACK RED
OIL
-
SENDER
GREEN FUEL
5mm RING SENDER
RELAY 8
4 BLACK/GREEN +BLACK
3
ON SAME 5mm RING - YELLOW (LINKED)
BLACK +BLACK/ORANGE
RED/ORANGE
ON SAME 5mm RING (LINKED) STARTER MOTOR
8mm RING
BROWN
SOLENOID (NEG) ALTERNATOR
ORANGE 4mm RING
5mm RING BLACK/GREY +BLACK/YELLOW 4 7 RED 1
BROWN ON SAME 12mm RING (LINKED)
YELLOW +GREY 8mm RING
15 BLACK/ORANGE +BLACK/PURPLE
ON SAME 8mm RING (LINKED) 8mm RING
ON SAME 12mm RING (LINKED) BLACK 8
6mm RING - YELLOW
SPECIAL M
F
TACHO PLUG NOT REQUIRED FOR 33A BULLET WATER
OR 45A ALTERNATOR CONNECTOR 6
SPIRABAND
SWITCH PURPLE/ORANGE
15 POS 2
CAT CONNECTOR
PURPLE 5
POS 3 WATER TEMP
BLANK SENDER
SPIRABAND
WHITE
5mm RING - YELLOW
CONN BOX (14431D00)
WITH PLUG & SOCKET
2
PINK
5mm RING RED 1 2
12mm RING
RED RED
RED/ORANGE
RED 5mm RING 5mm RING
3 12mm RING
12mm RING
FUSE
STARTER MOTOR
SOLENOID
PANEL
13177E00
F
15057A00 Wiring Conduit Layout

Battery / Control Box G
15057A00 Battery Control Box

Battery Control Box G
BATTERY ARRANGEMENT
1 2 FIN 5004 Battery
2 1 Battery Clamp Angle
3 4 O5189DOO Battery Clamp Bar
4 8 M6 Nut
5 1 OOOOO34M Battery Lead Set
6
PLUG AND SOCKET CONNECTION BOX

7 1 405-607 24 Way Plug (Not Shown For Clarity)
8 1 405-613 24 Way Socket
9 1 816-287 Wire Clamp Nut (Inside Connection Box)
10 1 SC 25G Coupler
11 1 330-4995 Conduit Conector
12 1 14585D00 Connection Box Mounting Bracket
13 1 14431D00 Conection Box
14 4 M5 X 16 Pan Head Screw(Connection Box)
15 4 M4 X 16 Pan Head Screw(Socket)
16 1 PAHD235 25mm Diameter Conduit
17 1 3P4358 Relay
18 2 7P7913 A. V. Mount
19 4 1/4" UNC Nyloc Nut
20 4 1/4" Washer
15057A00 Battery Control Box

Miscellaneous H

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
15057A00 Miscellaneous
Change Level Information I
Section G Page17
Loom Changed From Spiral Band To Conduit Protection
Wire Colours Changed From Single To By Colour
Relay Moved From Engine to Plug and Socket Connection Bar
Please Refer To Change Level Wiring Diagrams
Canopy Section A Page 1/2

Rear Corner Panels (Left & Right) Depth Decreased From 305 To 280 Items 8&9
Rear Upper Center Panel Width Increased Item12
Rear Lower Panel Width Increased Item 13
Please Quote Engine Serial Number, Page, Item Number and also
Dimension of Item Required
All Dimension Are in Millimetres
Change Level
Wiring Conduit Layout I
Finning Branch Network - United Kingdom

900 X 600 Metrotrak User Manual EN7

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900 X 600 Metrotrak User Manual EN7

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METROTRAK

PLANT USER MANUAL

Safety. This manual contains safety information which the operator

IMPORTANT SAFETY NOTICE!

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

Terex Crushing & Screening Inc

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

This plant is in conformity with the

Measured to satisfy the noise information

Year 2000 Compliancy

All electrical components on this plant

Defects Liability Guarantee

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

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

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

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

1.7 Position of Emergency Stop Buttons ..............................................................13

1.8 Plant Warning Signs .......................................................................................... 14

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

Indicates a statement of company policy as the message relates directly or indirectly

1.2 Organisation Measures Observe all safety instructions and

For the execution of maintenance work, 1.3 Selection and

1.4 Safety Instructions 1.4.2 Special Work In Conjunction

Do not reach into unguarded machinery. • Attaching a warning sign(s) to the

Switch off and lockout the plant before

1.4.2.3 For carrying out overhead assembly

Ensure that all consumables and replaced 1.4.2.12

Particularly make sure that any part of

Never work under unsupported

Never work alone.

1.5 Warning of Special 1.5.1.4

• Warn others against approaching and

• Have the live wire de-energized.

1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke

1.5.1.8 Observe the regulations in force at the

The battery contains sulphuric acid, an 1.5.2.3

1.5.3 Hydraulic and Pneumatic Always practice extreme cleanliness

1.6 Transporting, Manoeuvring 1.6.7

Before starting work or travelling with 1.6.11

Do not attempt to mount a tyre unless

Always maintain the correct pressure. Do

When inflating tyres, use a clip-on chuck

Check wheels for low pressure, cuts,

1.7 Position of Emergency

Emergency Stop Button

Emergency Stop Button

Emergency Stop Button

Figure 1a Emergency Stop Buttons

1.8 Plant Warning Signs

1.8.1 Location of Warning Signs.

Figure 1b Warning Signs

Location of Warning Signs, Right

Figure 1c Warning Signs

1.8.2 Safety Sign Illustrations

300/32 300/33 300/34

300/38 300/39 300/40

300/43 300/44 300/120

Safety Sign Illustrations, continued

2.1 Dimensions .......................................................................................................... 2

2.2 Plant Description ................................................................................................. 3

2.3 Feeder .................................................................................................................. 4