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PREMIERTRAK 1100 x 650
PREMIERTRAK 26 x 44
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TEREXPEGSON
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PLANT USER MANUAL
OPERATION
INSTALLATION
PARTS
MAINTENANCE AND SERVICE
This manual contains safety information which the

operator should read and follow. Failure to do this will
Safety increase the risk of injury or may result in death.
AX815-901-8EN-07b 1/318
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AX815-901-8EN-07b 2/318
IMPORTANT
TEREX PEGSON PLANTS CAN INCLUDE
OPTIONAL EQUIPMENT AND/OR SPECIAL
FEATURES ADDITIONAL TO THE
STANDARD SPECIFICATION.
THESE MAY AFFECT THE INFORMATION

GIVEN IN THIS OPERATORS MANUAL.
LOOK IN SECTION 11 - APPENDIX OF THIS

MANUAL FOR ANY ADDENDUM WHICH
MAY RELATE TO ADDITIONAL EQUIPMENT
OR VARIATIONS TO THE STANDARD
SPECIFICATION.
TAKE NOTE OF ANY VARIATIONS TO THE

STANDARD PROCEDURES AND/OR
COMPONENT SPECIFICATIONS.
Options EN
AX815-901-8EN-07b 3/318
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Advanscheer
Cru gy
Technolo
IMPORTANT SAFETY NOTICE!
The environment in which the plant will operate contains inherent risks to health
and safety which the operator must take steps to guard against. Dangers from
overhead conveyor discharges, overspill material, vehicle movements, etc., as well
as other site related hazards must be anticipated. Avoid these by carrying out risk
assessments before the plant is put into operation to ensure appropriate exclusion
zone measures are put in place and site personnel safety awareness training has
been undertaken.
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 Premiertrak 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
AX815-901-8EN-07b 5/318
d
Advanscheer
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 National BS
Standards and Specifications.
Noise Level
HEARING HAZARD
EXCEEDS 90 dB (A)
May cause loss or degradation of hearing

over a period of time.
Wear proper hearing personal protective

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

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

equipment, use approved respiratory protection,
as required by Federal, State and Local safety and
health regulations.
AX815-901-8EN-07b 6/318
ed
Advanscher
Cru hnology
Tec
Units of Measure
Within this User Manual figures shown within brackets ( ) after the Metric unit of measure are
approximate conversions from the actual metric measurement of the item concerned.
CALIFORNIA
CALIFORNIA
Proposition 65 Warning
Proposition 65 Warning
WARNING: Battery Posts, terminals and
WARNING: Diesel engine exhaust and
related accessories contain lead and lead
some of it’s constituents are known to the
compounds, chemicals known to the State
State of California to cause cancer, birth
of California to cause cancer and
defects, and other reproductive harm.
reproductive harm.
WASH HANDS AFTER HANDLING.
Copyright
The copyright of this User Manual is reserved by BL-Pegson Limited.
This User Manual contains information and technical drawings, which may not be copied, distributed,
altered, stored on electronic media, revealed to others or used for the purpose of competition, either
partially or in its entirety.
The right is reserved to alter any details contained in this manual without notice. Copyright
2004.
BL-Pegson Limited
Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax:- + 44 1530 518618
E mail sales@bl-pegson.com
To order additional copies contact your local BL-Pegson Ltd Dealer.
AX815-901-8EN-07b 7/318
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
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, Manoevering and Recommissioning ....................................... 11
1.7 Position of Emergency Stop Buttons .............................................................. 13
1.8 Plant Warning Signs- locations and illustrations ............................................ 15
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
AX815-901-8EN-07b 9/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
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.
AX815-901-8EN-07b 10/318

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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 3
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 Plant. Keep warnings and instruction labels clean.
Loose or baggy clothing can get caught in Replace unreadable or missing labels with
running machinery. new ones before operating the plant. Make
sure replacement parts include warning or
Where possible when working close to instruction labels where necessary.
engines or machinery, only do so when they
are stopped. If this is not practical, 1.2.3
remember to keep tools, test equipment
and all other parts of your body well away Understand service procedure before doing
from the moving parts. work. Keep area clean and dry.
For reasons of safety, long hair must be tied Never lubricate, clean, service or adjust
back or otherwise secured, garments must machinery while it is moving. Keep hands,
be close fitting and no jewellery such as feet and clothing clear of power driven
rings may be worn. Injury may result from parts and in running nip-points. Disengage
being caught up in the machinery or from all power and operate controls to relieve
rings catching on moving parts. pressure. Stop the engine. Implement
lockout procedure. Allow the machinery to
Always wear correctly fitting (EN/ANSI cool.
approved) protective clothing.
Keep all parts in good condition. Ensure
Protective clothing includes Hard Hat, that all parts are properly installed. Fix
Safety Glasses, Ear Protection, Dust Mask, damage immediately. Replace worn and
Close fitting Overalls, Steel Toed Boots and broken parts. Remove any build up of
a High Visibility Vest. grease, oil and debris.
1.2.2 Disconnect battery ground cable before

making adjustments on electrical systems or
You can be injured if you do not obey the welding on plant.
safety instructions as indicated on warning
stickers.
AX815-901-8EN-07b 11/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 4
For the execution of maintenance work, 1.3 Selection and

tools and workshop equipment adapted to Qualification of Personnel -
the task on hand are absolutely
Basic Responsibilties
indispensable.
1.3.1
1.2.4
Any work on and/or with the plant must be
Never make any modifications, additions or
executed by trained, reliable and authorised
conversions which might affect safety
personnel only. Statutory minimum age
without the supplier’s approval.
limits must be observed.
In the event of safety relevant modifications
1.3.2
or changes in the behaviour of the plant
during operation, stop the plant and lock Work on electrical system and equipment of
out immediately and report the malfunction the plant must be carried out only by a
to the competent authority/person. skilled electrician or by instructed 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.
AX815-901-8EN-07b 12/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
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 indicator
Operate the plant only for it’s designed
calls for immediate action.
purpose and only if all guarding, protective
and safety orientated devices, emergency
B : Adverse conditions necessitate more
shut-off equipment, sound proofing
frequent servicing.
elements and exhausts, are in all place and
fully functional.
Observe information on the replacement of
parts and equipment. These activities may
Before starting the engine ensure it is safe to
be executed by skilled personnel only.
do so.
1.4.2.2
1.4.1.2
When the plant is completely shutdown for
In the event of material blockage, any
maintenance and repair work, it must be
malfunction or operational difficulty, stop
secured against inadvertent starting by:
the plant immediately and lockout. Have
any defects rectified immediately.
• Switching off the engine and remove the
ignition switch/key.
1.4.1.3
In-running nip points on moving machinery • Implementing the lockout procedure.

can cause serious injury or even death.
• Attaching a warning sign(s) to the plant
Do not reach into unguarded machinery. in appropriate positions.
Your arm could be pulled in and amputated.
Switch off and lockout the plant before

removing any safety devices or guarding.
AX815-901-8EN-07b 13/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 6
1.4.2.3 For carrying out overhead assembly work

always use specially designed or otherwise
Carry out maintenance and repair work
safety-oriented ladders and working
only if the plant is positioned on stable and
platforms.
level ground and has been secured against
inadvertent movement and buckling.
Always use any walkway/platforms
provided or a safe and secure platform
1.4.2.4
approved by the regional safety enforcing
Never allow unqualified or untrained authority.
personnel to attempt to remove or replace
any part of the plant, or anyone to remove Always use an EN/ANSI approved safety
large or heavy components without harness when reaching any points 7ft (2m)
adequate lifting tackle. or more above the ground level.
To avoid the risk of accidents, individual Keep all handles, steps, handrails,
parts and large assemblies being moved for platforms, landing and ladders free from
replacement purposes should be carefully dirt, oil, snow and ice.
attached to lifting tackle and secured. Use
only suitable and technically adequate lifting 1.4.2.6
gear. The fastening of loads and instructing of
crane operators should be entrusted to
Never work or stand under suspended
experienced persons only. The marshaller
loads.
giving the instructions must be within sight
or sound of the operator.
Keep away from the feed hopper, all belt
conveyor and the magnetic separator
1.4.2.7
discharges, where there is risk of serious
injury or death due to the loading and After cleaning, examine all fuel, lubricant,
removal of material. and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any
1.4.2.5 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 plant Any safety devices removed for set-up,
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.
AX815-901-8EN-07b 14/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 7
1.4.2.9 1.4.2.11
Improperly disposing of waste can threaten Diesel fuel is highly flammable.

the environment and ecology. Potentially
harmful waste used with BL-Pegson Never remove the filler cap, or refuel, with
equipment includes such items as oil, fuel, the engine running.
coolant, filters and batteries, etc.
Never add gasoline or any other fuels
Use leakproof containers when draining mixed to diesel because of increased fire or
fluids. Do not use food or beverage 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 sources
Do not pour waste onto the ground, down of sparks, such as welding equipment.
a drain or into any water source.
1.4.2.12
Ensure that all consumables and replaced
Using unapproved structures i.e. walkways/
parts are disposed of safely and with
platforms etc in the vicinity of a BL-Pegson
minimum environmental impact.
plant is very dangerous and could lead to
serious injury or even death through falling
1.4.2.10
and/or entanglement with the plant.
Always ensure that any safety fitment such
as locking wedges, securing chains, bars or Do not use any unauthorised structures.
struts are utilised as indicated in these
operating instructions.
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.
AX815-901-8EN-07b 15/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 8
1.5 Warning of Special 1.5.1.4

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

touching the plant.
• Have the live wire de-energized.
AX815-901-8EN-07b 16/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 9
1.5.1.7 1.5.2 Gas, Dust, Steam, Smoke and

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

1.5.1.8
respective site.
Before starting work on high voltage
assemblies and after cutting out the power Dust found on the plant or produced during
supply, the feeder cable must be grounded work on the plant should be removed by
and components such as capacitors short- extraction, not blowing.
circuited with a grounding rod.
Dust waste should be dampened, placed in
1.5.1.9 a sealed container and marked, to ensure
safe disposal.
These plants are wired on negative earth.
Always observe correct polarity. 1.5.2.2
Always disconnect battery leads before Carry out welding, flame cutting and
carrying out any maintenance to the grinding work on the plant only if this has
electrical system. been expressly authorised, as there may be
a risk of explosion and fire.
The battery contains sulphuric acid, an
electrolyte which can cause severe burns 1.5.2.3
and produce explosive gases.
Before carrying out welding, flame cutting
and grinding operations, clean the plant and
Avoid contact with the skin, eyes or
its surroundings from dust and other
clothing.
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
AX815-901-8EN-07b 17/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 10
1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with ear defenders of approved laid and fitted properly. Ensure that no
pattern and that these are worn at all times connections are interchanged. The fittings,
when the plant is operating. lengths and quality of the hoses must
comply with the technical requirements.
Ensure operators wear a suitable face mask
where exposed to possible harmful effects 1.5.3.5
of air polution of any kind.
Always practice extreme cleanliness
servicing hydraulic components.
1.5.3 Hydraulic and Pneumatic
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can
Work on hydraulic equipment may be penetrate the skin causing serious injury.
carried out only by persons having special
knowledge and experience in hydraulic If fluid is injected under the skin, it must be
systems. surgically removed or gangrene will
result.Get medical help immediately.
1.5.3.2
Always relieve pressure from the hydraulic
Check all lines, hoses and screwed
system before carrying out any kind of
connections regularly for leaks and obvious
maintenance or adjustment.
damage. Repair damage immediately.
Splashed oil may cause injury and fire. Always use a piece of cardboard to check
for leaks. Do not use your hand.
1.5.3.3
Depressurise all system sections and 1.5.4.Hazardous Substances

pressure pipes (hydraulic system, Ensure that correct procedures are
compressed air system) to be removed in formulated to safely handle hazardous
accordance with the specific instructions materials by correct identification, labelling,
for the unit concerned before carrying out storage, use and disposal, all strictly in
any repair work. accordance with the manufacturers
instructions and that all applicable
regulations are observed at all times.
AX815-901-8EN-07b 18/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 11
1.6 Transporting, 1.6.7

Manoevering and When travelling on public roads, ways and
Recommissioning places, always observe the valid traffic
regulations and, if necessary, ensure
1.6.1 beforehand that the plant is in a condition
compatible with these regulations.
The plant must be loaded and transported
only in accordance with the operating
1.6.8
instructions.
In conditions of poor visibility and after
1.6.2 dark, always switch on the lighting system
of the transporting vehicle..
For manoevering the plant, observe the
prescribed transport position, admissible
1.6.9
speed and itinerary.
When crossing underpasses, bridges and
1.6.3 tunnels or when passing under overhead
lines always make sure that there is
Use only appropriate means of transport
sufficient clearance.
and lifting gear where applicable of
adequate capacity.
1.6.10
1.6.4 Never travel across slopes; always keep
the working equipment and the load close
The recommissioning procedure must be
to the ground, especially when travelling
strictly in accordance with the operating
downhill.
instructions.
1.6.11
1.6.5
On sloping terrain, always adapt your
Before starting work or travelling with the
travelling speed to the relevant ground
plant, check that the braking, and any
conditions. Never change to a lower gear
signalling and lighting systems are fully
on a slope. Always change gear before
functional.
reaching a slope.
1.6.6
Before setting the plant in motion always

check that the accessories have been safely
stowed away.
AX815-901-8EN-07b 19/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
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.
AX815-901-8EN-07b 20/318

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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 13
1.7 Position of Emergency

Emergency Stop Button
Stop Buttons (Maintenance Platform)

(Chassis Side)

(Feeder/Conveyor Control Box)
(Control Panel)

(Maintenance Platform)

(Chassis Side)
Figure 1a Emergency Stop Buttons
AX815-901-8EN-07b 21/318
1.8 Plant Warning Signs

Premiertrak
1.8.1 Location of Warning Signs. 1100 x 650 (26 x 44)
Left Hand side of plant

Safety Issue EN 07
Page 14
y
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Figure 1b Warning Signs
AX815-901-8EN-07b 22/318
Location of Warning Signs, Right

Premiertrak
Hand side of plant
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 15
y
l
n
o
r
e
h
s
u
r
C
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il
u
a
r
d
y
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*
Figure 1c Warning Signs

AX815-901-8EN-07b 23/318
Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 16
1.8.2 Safety Sign Illustrations
1 2 3 4
5 6 7 8
11
9 12 13
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 17
Safety Sign Illustrations, continued
20
17 19
21
25
27
22 23
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Premiertrak
1100 x 650 (26 x 44)
Safety Issue EN 07
Page 18
Blank Page
AX815-901-8EN-07b 26/318
Premiertrak
1100 x 650 (26 x 44)
Technical Information Issue EN 07
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 Manual Folding Hopper * .................................................................................. 6
2.12 Feed Hopper Liner Plates * ............................................................................... 6
2.13 Belt Weigher * ....................................................................................................6
2.14 Water Pump *......................................................................................................6
2.15 Anti-vandal Guards * ......................................................................................... 6
2.16 Manual Clutch * ..................................................................................................6

PLEASE NOTE
BL-Pegson Limited have designed and built the Premiertrak 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.
AX815-901-8EN-07b 27/318
Premiertrak
1100 x 650 (26 x 44)
Page 2
2.1 Dimensions k
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AX815-901-8EN-07b 28/318
Premiertrak
1100 x 650 (26 x 44)
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
Platform LEFT Tool Box
Control Box Crusher Maintenance
Platform
Feed Hopper
Side Plate FRONT
Feeder
REAR Jaw Crusher
Product Conveyor
Maintenance
RIGHT Tracks
Platform Figure 2b Plant Terms
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1100 x 650 (26 x 44)
Page 4
2.3 Feeder
Type Spring mounted vibrating pan

Width 1060mm (32”)
Length 4200mm (13’-9”)
Unit Twin shaft oil lubricated
Grizzly Stepped cartridge type, bars pre set at nom. 50mm (2”)
spaces
Drive Hydraulic motor
Control Variable speed
Hopper Hydraulic folding (to reduce height when transporting)
2.4 Crusher
Type Single toggle jaw

Feed Gape 650mm (26”)
Feed Width 1100mm (44”)
Adjustment Shims – hydraulically assisted
Lubrication Greased spherical roller bearings
Drive Vee belts from engine
Control Engine clutch
2.5 Product Conveyor
Type Plain troughed belt

Width 1000mm (40”)
Lubrication Grease
Control Fixed speed
Skirts Full length
2.6 Tracks
Type 190mm (7.5”) pitch heavy duty

Width 500mm (1’-8”)
Centre 3880 mm (12’-9”)
Drive Hydraulic integral motors
Control Remote handset – dual speed
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Page 5
2.7 Standard Powerpack
Type Caterpillar C9 EU/EC Emmission Regulations

compliant 6 cyl. water cooled diesel
Rating 230hp @ 1600 rpm
Drives Hydraulically activated clutch to engage the crusher
Vee belts to twin hydraulic pumps
Housing Canopy 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 US galls/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 - 450 gauss @ 250mm (10”)
Width 750 mm (30”)
Centres 1700 mm (5’-7”)
Control Preset variable
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Page 6
2.11 Manual Folding Hopper *

Type Manually folding sides and rear plates in lieu of hydraulic
operation.
2.12 Feed Hopper Liner Plates *

Type Mild steel
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 Anti-vandal Guards *

Type Lockable covers over control stations
2.16 Manual Clutch *

Type Lever operated twin disc clutch in lieu of hydraulically
actuated clutch.
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Premiertrak
1100 x 650 (26 x 44)
3 - General Information Issue EN 07
Page 1
Contents
3.1 Introduction..........................................................................................................2
3.2 General information ............................................................................................. 2
3.3 Designated Use ...................................................................................................3

3.3.1 Operating Temperature Range ........................................................................ 3
3.4 Crusher Capacity.................................................................................................3
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3.1 Introduction 3.2 General information
This instruction manual contains important The Plant which you have now received has
information on how to operate the Plant been manufactured, assembled and tested
safely, properly and most efficiently. with the utmost care and was built with first
class materials.
Observing these instructions and exercising
Common Sense helps to avoid danger, to Close attention has been paid to all details
reduce repair costs and downtimes and to in assembly, running tests and final
increase the reliability and life of the plant. inspection.
Failure to do so may invalidate any
warranties in force. We are confident that you have received a
plant which will give you every satisfaction
The operating instructions must always be over a long period.
available wherever the plant is in use.
To be assured of faultless operation we
These operating instructions must be read would ask you to carefully read the
and applied by any person in charge of and/ following paragraphs and give the required
or working on the plant such as:- time and attention to essential maintenance,
cleaning and inspection.
Operation
The plant is simple to operate, adjustments
Includes manoeuvring, setting up, operation are easy to make and expert assistance is
during the course of work, evacuation of seldom required, provided that ordinary
production material and waste, care and care is exercised in daily use.
disposal of fuels and consumables, etc.
The plant has been built in accordance with
Maintenance state-of-the-art standards and recognised
safety rules. It is designed to be reliable,
Servicing, inspection and repair 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 to
regulations for accident prevention and other material property.
environmental protection.
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Page 3
3.3 Designated Use The crusher must not be operated at a

discharge opening less than 75mm without
The Plant has been designed exclusively as prior consultation with BL-Pegson
a self-contained mobile unit for crushing Limited, the only exception to this being
materials in a wide range of quarry, for crushing bricks and demolition materials
demolition and recycling applications within only. Operating the crusher below this
the parameters set out and described within setting may result in extensive damage.
this manual.
The percentage of oversize output from the
3.3.1 Operating Temperature Range crusher, for a given discharge opening, will
depend largely on the quality and character
The normal operating temperature range of of the feed material. Figure 3b shows an
the plant is from -10°C to +40°C (+14°F estimated analysis of the product for
to +104°F). For use in temperatures different discharge openings.
outside of this range, contact your local
dealer or BL-Pegson for details. Note:- The crusher has been designed to
work with feed materials having a 10%
Note: Appropriate oil & coolant to suit the fines value not exceeding 390kN.
local operating conditions must be used, as
specified elsewhere in this manual. Product gradings are typical only and will
vary depending on material characteristics.
3.4 Crusher Capacity
In order to obtain the optimum output from

the crusher, it’s feed should be continuous
and regulated. Additionally, all feed should
be of a size that will readily enter the
crusher chamber and, in order to avoid
packing of the discharge opening and
excessive wear of the plant jaws, undersize
material should be removed from the feed
prior to entry to the crusher.
*
The discharge rates given (Figure 3a) are *

based on crushing clean, dry limestone
weighing approximately 1600Kg/m3 ,
(100lbs/cuft.), loose and having a specific
gravity of 2.6. Wet feed material reduces
the crusher discharge rate. * Demolition materials only
Figure 3a Crusher Capacity
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Page 4
Operating the plant outside it’s material in the feed must be limited to a size
recommended range of applications and that will not cause damage to the crusher.
operating parameters, will result in a loss of
guarantee and the manufacturer/supplier If you have any doubts about
cannot be held liable for any damage any aspect of the plant’s
resulting from such use. The risk of such capability or servicing
misuse lies entirely with the user. procedures, you must consult
your local BL-Pegson dealer or
When the optional dirt conveyor is fitted, BL-Pegson technical
material passing through the feeder grizzly department.
bars will be extracted from the crusher feed
material to by-pass the crusher (coarse
material) and discharge to the dirt conveyor
(fines material).
The optional magnetic overband separator,

where fitted, is intended to extract ferrous
materials from the crushed product but this
Figure 3b Product Analysis
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1100 x 650 (26 x 44)
Design and Function Issue EN 07
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....................................................................................................3
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 ..................................................................................... 4
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 ........................................................................................................5
4.2.15 Optional Extras * ...........................................................................................5
4.2.16 Optional Exclusions *.....................................................................................6
4.2.17 Specifications ...............................................................................................6
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Page 2
4.1 General Information
The BL-Pegson Premiertrak 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 1100x650mm (26” x 44”) ‘M’ series single toggle roller bearing
jaw crusher
• Fully skirted product conveyor with hydraulic tail lift
• Folding Hopper
• Stepped cartridge type grizzly section, pre set at 50mm (2”) aperture
• Two way dirt chute
• Facility to remove scalpings
• Heavy duty chassis and track frame
• Remote control
• Dust suppression sprays
• Caterpillar water cooled diesel engine
• Optional dirt conveyor and magnetic separator
• CE Approved
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1100 x 650 (26 x 44)
Page 3
4.2 Construction Units Grizzly Section:- A stepped cartridge type

grizzly section with tapered finger type bars
BL-Pegson 1100 x 650 Premiertrak at nom.50mm (2”) spaces (at mid point
Recycling /Crushing plant with Diesel/ along bar). A renewable feeder discharge
Hydraulic drive. lip is also included.
4.2.1 Single Toggle Jaw Crusher Drive:- Hydraulic motor mounted on

vibrating unit.
BL-Pegson 1100 x 650mm (26” x 44”)
‘M’ Series Single Toggle Roller Bearing Control:- Variable speed is achieved via a
Jaw Crusher including:- rotary control located on the Feeder/
Conveyor control panel. Facility is also
Lubrication:- Eccentric shaft spherical included to stop/start the feeder from the
roller bearings are lubricated by grease. remote control handset.
Setting Adjustment:- Hydraulically Hopper:- Hydraulic folding feed hopper

assisted and pre-set in the factory at 75mm. fabricated in 15mm (0.6”) thick abrasion
resistant steel plate suitable braced with
Drive:- Through vee belts from the diesel steel sections. An optional manual folding
engine with screw tension adjustment of the hopper is available.
engine baseframe.
4.2.3 Track Frame
4.2.2 Vibrating Grizzly Feeder Heavy duty size nine track frame having
190mm (7.5”) pitch chain and 3880mm
BL-Pegson 1060 wide x 4200mm long (12’-9”) longitudinal centres with 500mm
(42” x 13’-9”) Vibrating Grizzly Feeder, (20”) wide tracks fitted as standard.
including:-
Total plant weight approximately -
Vibrating Unit:- Heavy duty mechanical 45.4 tonnes (49.9 US. tons).
type with twin counter rotating shafts with
oil lubricated bearings and gears. Overall Track width - 2800mm (9’- 2”).
Pan:- 12mm (0.5”) thick abrasion resisting Plant overall height - 4200mm (13’ 9”)
steel bottom and side plates. (hopper raised).
Plant travel height with hopper folded -

3400mm (11’- 2”) (plus low loader height).
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Page 4
4.2.4 On-Plant Product Conveyor 4.2.6 Plant Chutework
1000mm (39”) wide plant mounted Crusher Feed Chute:- Fabricated in

troughed belt conveyor, 3225mm (10’-7”) 12mm (0.5”) mild steel plate sides with
discharge height, with hydraulic lift tail 25mm (1.0”) thick wear resistant bottom
section. and including integral safety grid.
Belt:- EP 500/3 with 5mm (0.2”) top and Grizzly Fines Chutes:- A hand operated
1.5mm (0.06”) bottom heavy duty rubber two way dirt chute is provided to
covers to BS490 and DIN 22102. discharge to the on-plant product
Maximum stretch over life of belt conveyor or the optional dirt conveyor
running in normal working conditions (when fitted) as required.
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.
Steel grid platforms are provided each
side of the feeder fitted with double row
Feedboot:- Fabricated in mild steel plate
handrails having safety bar and access
with abrasion resistant steel liners at feed
ladder. Platforms are also included to
point, fully skirted wear resistant rubber
gain access to the rear of the crusher and
sealing strips along the entire conveyor
to the power-pack.
length.
Adjustment:- Belt tensioning to be

4.2.8 Standard Power-Pack
maintained and adjustment at the head
drum. Caterpillar C9 EU/EC Emmissions
Regulation Compliant 6 cylinder, 4 stroke,
Covers:- Canvas type removable dust direct injection, emission compliant water
covers are fitted at the head end. cooled diesel power-pack, 230HP
continuous rated 1600 rpm under NTP
conditions designed to drive the crusher via
a hydraulically actuated clutch.
4.2.5 Magnet
Overband magnetic separator with Hydraulic transmissions powered from the

permanent magnet, suspended over the engine are provided to drive the tracks,
main on-plant product conveyor and feeder, product conveyor, hydraulic rams
complete with hydraulic drive. and, where fitted, the optional dirt conveyor
and/or the overband magnetic separator.
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Page 5
4.2.9. Dirt Conveyor 4.2.12 Guards
Plant mounted 600 mm (24”) wide side Wire mesh or sheet metal guards are
discharge dirt conveyor with hydraulic flding provided for all drives, flywheels, pulleys,
facility giving a discharge height of couplings, gears and vee belts. The guards
2125mm (7’-0”) from the top of the head provided are designed and manufactured to
drum. The conveyor is hydraulically driven ensure so far as reasonably practicable that
from the head drum and is mounted on the the machinery and plant on which they are
left hand side viewed from the feed end. fitted can be operated safely and without
risk to health when properly used.
However, the company cannot guarantee
that the guards provided will meet the
4.2.10 Controls requirements laid down by individual
inspectors and any additional guard and/or
Controls are fitted on the plant for the
modification to guarding supplied, which
feeder (on/off and speed), conveyors etc.
may be required for any reason whatsoever,
with engine and master controls sited in a
will be charged as an additional contract
lockable box mounted below the engine.
price.
A remote control unit is provided for the

tracking function giving a tracking speed of
approximately 0.96kmh (0.62mph) a
4.2.13 Painting
“creep” facility for loading, off loading and
precise slewing movements. There is also a The plant is finish painted in RAL 5015
stop and start control for the vibrating blue.
grizzly feeder from a remote position.
Emergency stop buttons are provided on

each side of the plant.
4.2.15 Optional Extras *
Available at the time of initial purchase:-
4.2.11 Chassis
• Manual folding feed hopper in lieu of
Fabricated steel frame of welded hydraulic folding..
construction with supports for the feeder,
crusher, on-plant conveyor, power unit, • Mild steel liner plates for feed hopper.
track frame and where fitted, the dirt
conveyor and/or overband magnetic • Water pump, hydraulically driven, to
separator. provide pressurised water supply for
the dust suppression sprays.
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Page 6
• Single idler belt weigher with integrator

and speed sensing wheel fitted to main
product conveyor.
• Anti-vandal guards.
• manual twin disc clutch in lieu of hy-

draulically actuated clutch..
4.2.16 Optional Exclusions *

Available at time of initial purchase:-
• Dirt Conveyor.
• Overband Magnetic Separator.
4.2.17 Specifications
Every endeavour will be made to supply

equipment as specified, but we reserve the
right, where necessary, to amend
specifications without prior notice as we
operate a policy of continuous product
development.
BL-Pegson cannot guarantee that the

equipment specified will meet any specific
requirements in respect of noise or vibration
levels, dust emission, or any other factors
relevant to health and safety measures or
environmental protection needs.
AX815-901-8EN-07b 42/318
Premiertrak
1100 x 650 (26 x 44)
Transport Issue EN 07
Page 1
Contents
5.1 Safety Information ............................................................................................... 2
5.2 Transportation .....................................................................................................4

5.2.1 Manoeuvring - General .................................................................................... 4
5.2.2 Manoeuvring with the remote RADIO control hand set
(where fitted)...................................................................................................6
5.2.3 Radio Hand Set (where fitted) ....................................................................... 10
5.2.4 Manoeuvring with the remote UMBILICAL control hand set
(where fitted).................................................................................................12
5.2.5 Unloading......................................................................................................16
5.2.6 Loading ........................................................................................................17
5.3 Folding Hopper Plates ......................................................................................20
5.3.1 Hydraulic Folding Hopper - lowering for transport . ......................................... 20
5.3.2 Manual Folding Hopper * - lowering for transport .......................................... 22
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Page 2
5.1 Safety Information

Loose or baggy clothing can get PERSONAL
caught in running machinery. PROTECTIVE EQUIPMENT
ALWAYS wear correctly fitting

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

Hat, Safety Glasses, Hearing Protection, Dust
Mask, Close Fitting Overalls, Steel Toed Boots,
Industrial Gloves and High Visibility Vest.
Falling from and/or onto a FALLING HAZARD

BL-Pegson machine can cause
serious injury or even death.
DO NOT climb onto the machine

whilst in operation.
ALWAYS use the walkways/platforms provided

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

harness when reaching any points 7ft (2m) or
more above ground level.
In-running nip points can cause ENTANGLEMENT

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

before opening or removing guards.
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Page 3
Hydraulic fluid under pressure can SKIN INJECTION
penetrate the skin causing serious
HAZARD
injury.
ALWAYS relieve the pressure from

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

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

surgically removed or gangrene will result.
Get medical help immediately.
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 the ignition key.
3. Keep the ignition key on person during
lockout.
4. Place appropriate maintenance warning
signs, (ie. TAG OUT).
5. NEVER work alone.
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1100 x 650 (26 x 44)
Page 4
5.2 Transportation
WARNING
5.2.1 Manoeuvring - General WEAR PERSONAL
PROTECTIVE EQUIPMENT.
Refer to Section 5.1, Safety
Information for relevant warning.
Prior to attempting any
manoeuvring of the plant the
tracks must be free of
obstructions, including crushed
material and fines. Do not push
or tow the plant. Failure to
observe this warning could
result in danger to persons and
damage to the plant which may
invalidate warranty.
• Before manoeuvring the Plant, ensure

the feed hopper and crusher are empty,
and that all materials have run off the
conveyors. STOP the feeder, dirt
conveyor, product conveyor and
disengage the clutch.
• The plant cannot be manoeuvred in the

PLANT mode of operation.
• DO NOT manoeuvre the Premietrak

whilst the crusher running.
• The safety warning horn sounds

continuously whilst the plant is being
manoeuvred.
DO NOT stand on any of the

platforms or ladders of the
Plant whilst it is being
manoeuvred using the remote
control handset.
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Page 5
When manoeuvring the Plant

to its operating position make WARNING
sure you stand well clear of the
WEAR PERSONAL
plant but are in a position to PROTECTIVE EQUIPMENT.
have all-round vision to see Refer to Section 5.1, Safety
any obstacles, dangers that Information for relevant warning.
may lie ahead e.g personnel,
overhead cables, ditches,
unsafe roadways etc. (Refer
to Figure 2a Dimensions)
• Make sure that you do not manoeuvre

the Plant on a gradiant steeper than 30
degrees, damage may occur to the
engine and/or plant.
• Avoid manoeuvring the plant over

extremely uneven ground or damage
may occur.
• Control valves mounted on the engine

and beneath the feeder are NOT to be
used to manoeuvre the Plant. They are
for use by BL-Pegson Service
Engineers only.
• Initial start up in cold weather may

result in a tendency to steer to the right
whilst tracking fast forward due to the
hydraulic oil being cold. Run the plant
for approx. 10 minutes with the
conveyor and feeder running prior to
manoeuvring the plant.
• When transporting the Plant, it is the

responsibility of the haulage
contractor to safely secure the plant
to the transporter.
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1100 x 650 (26 x 44)
Page 6
5.2.2 Manoeuvring with the remote

RADIO control hand set WARNING
(where fitted)
WEAR PERSONAL
The plant is manoeuvred using the remote PROTECTIVE EQUIPMENT.
hand held radio transmitter control unit (Fig
5a). This hand set also has the facility to
switch the plant feeder on and off whilst the
Plant is in the crushing mode.
Procedure
Note: The transmitter has a built in safety
function that prevents another function from
1. Observe all safety instructions. involuntary cutting-in when the transmitter
starts. The transmitter will not start if a
2. Take the Remote Control Hand Set button is stuck in the activated position.
from the Control Box and first become This is indicated by the red LED coming on.
familiar with the functions of all the
individual buttons (Figure 5a) before the 4. Start the engine (Section 7.2.1).
next step. Increase the engine speed to 1600rpm.
Forward = Product Conveyor first
Reverse = Hopper first 5. Before manoeuvring the Plant ensure
the tail section of the product conveyor
3. To start up the handset transmitter first is fully raised.
stand well clear of the plant. Hold the To raise the tail section:-
hand set with the stop button nearest to On the Control Panel located within the
the operator and proceed as follows:- Control Box (Figure 5b), turn the Tail
Lift switch to ‘!’ and raise the tail
• Ensure the stop button is pulled out. section.
• Depress both of the safety buttons
(Fig.5a) at the same time for at least 1 6. On the Control Panel, turn the
second. Release the safety buttons. Operation switch to ‘TRACK’.
• The red LED will change to green.
• The transmitter is in function status 7. Press the Horn button for 5 seconds to
when the green LED comes on. sound the safety warning horn. This will
also ready the tracks for manoeuvring.
continued overleaf..............
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Premiertrak
1100 x 650 (26 x 44)
Page 7
PLAN VIEW OF THE PLANT
LED Red/Green
Forward slow or fast, track 1 & 2

**Reverse Forward
**
Right turn slow, forward track 1
** Left Turn
(travelling forward)
Right Turn **
(travelling forward)
Left turn slow, forward track 2
Not used to
Reverse slow or fast, track 1 & 2 Manoeuvre
Right turn slow, reverses track 1

Safety Button Safety Button
Left turn slow, reverses track 2 (Horn) (Feeder On/Off)
Rotate clockwise, track 1 forward, track 2

reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
For more information on the Radio Hand Set see Section 7 of this manual.
Figure 5a Remote RADIO Control Hand Set
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1100 x 650 (26 x 44)
Page 8
8. The radio handset directional buttons

(forward, reverse and turn) are double WARNING
pressure switches with the initial
WEAR PERSONAL
pressure operating the slow speed PROTECTIVE EQUIPMENT.
mode and depressing further operates Refer to Section 5.1, Safety
the higher speed. Press the buttons to Information for relevant warning.
manoeuvre the plant in the desired
direction (Figure 5a). Employ the ‘Fast’
speed only where safe to do so.
Pressing the Stop button at any time will

immediately halt the operation and cut
out the engine but it is necessary to
manually switch off the engine ignition
(Section 8.2) (and disengage the manual
clutch if applicable.
9. When the Plant is in the correct

position, press the Horn button to turn
the safety warning horn ‘OFF’ and
disengage the tracks.
10. On the Control Panel turn the

Operation switch to ‘PLANT’. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.
11. To shut down the radio handset

transmitter, push in the stop button.
Lock out the hand set when finished
with to prevent unauthorised use.
AX815-901-8EN-07b 50/318
Premiertrak
1100 x 650 (26 x 44)
Page 9
TEREX
PEGSON
18
1NOr,5
Operation Feeder Remote Dirt Conveyor Tail Lift - Product

Plant/Track Off/On Lower/Raise * Conveyor Lower/Raise
Figure 5b Control Panel
AX815-901-8EN-07b 51/318
Premiertrak
1100 x 650 (26 x 44)
Page 10
5.2.3 Radio Hand Set (where fitted)
Features of the 860 System include:-
• Unique ID code in each transmitter. The

receiver self learns this code, without
the need to change DIP switches
internally in either component.
• No need to open transmitter to change

frequency (changed from buttons -
Dealer function). Receiver detects any
change automatically.
• Transmitter can be programmed to

work with either 840 or 860 receivers
(Dealer function).
• Enhanced reliability.
Transmitter’s Use NiMh batteries instead of

NiCd, which means the following:-
• Input charging voltage is now 12VDC TRANSMITTER 860TX-PEG

to 35VDC instead of 12/24VDC, no
universal adapter required.
• Battery capacity is changed from Buttons 1 to 4 = Used for plant directional

control
800mA to 2000mA.(Charging time
from completely empty battery is now Buttons 1 to 9 and 0 = Used for signal
approximately 4 hours). frequency programming (factory preset -
contact Dealer for change)
• Operating time with fully charged
Buttons 9 and 0 = Used to activate the
battery is approximately 30 hours.
radio hand set transmitter
Button 9 = Used to activate the audible

warning horn
Button 0 = Used to stop / start the plant

feeder (where appropriate)
AX815-901-8EN-07b 52/318
Premiertrak
1100 x 650 (26 x 44)
Page 11
2 versions of the 860 system transmitter will

be supplied, one for European Operations WARNING
and one for the Rest of the World. The only
WEAR PERSONAL
difference is that the European version will PROTECTIVE EQUIPMENT.
include a black stop button. The Rest of the Refer to Section 5.1, Safety
World transmitter will feature a Red Stop Information for relevant warning.
button. Channel 01 (434.650 MHz)
through channel 16 (433.900 MHz)
available in .050 MHz steps. Refer to
Dealer if frequency change needed. • To conserve the battery charge the hand
set should be switched off when not in
Battery Recharging use..
The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
5c). A 12/35 volt charging lead suitable for
plugging into a vehicle cigarette lighter point
is supplied.
• Battery charge status is indicated by the

LED light in the transmitter;
Red - batteries need charging;
Green - batteries fully charged.
During the charging of the batteries the
LED light will be red until changing to
green when fully charged. The batteries
cannot be overcharged.
• Fully charged batteries provide about

30 hours continuous running and
recharging time takes about 4 hours.
• The LED light on the hand set changes

from green to red when there is about
10% power left in the batteries (1 hour
continuous operation remaining) and Charging point
indicates it is time to recharge. The plant
warning horn will also sound when Figure 5c Remote Control
battery recharging is required Charger Connection
AX815-901-8EN-07b 53/318
Premiertrak
1100 x 650 (26 x 44)
Page 12
5.2.4 Manoeuvring with the remote

UMBILICAL control hand set WARNING
(where fitted)
WEAR PERSONAL
As an alternative to the radio remote PROTECTIVE EQUIPMENT.
control hand set, a hand set with umbilical
cable is supplied to manoeuvre the
Premiertrak (Figure 5e).
Connecting and using the

Umbilical Control Hand Set
Procedure
1. Observe all safety warnings.
2. Close down the plant (Section 8.2).
3. Locate the connection point (Figure 5d)

on the Control Panel. Release the
retaining clip and remove the multi pin
plug already in situ. (only where radio
unit fitted) Replace with the umbilical
lead plug (Figure 5e) and secure with
the retaining clip.

Operation switch to ‘PLANT’ and the
Feeder Remote switch to ‘OFF’
(Figure 5b).
5. Start the engine (Section 7.2). Increase

the engine speed to 1600rpm.
6. Standing clear of the tracks, turn the

Operation switch to ‘TRACKS’.
continued overleaf...............
AX815-901-8EN-07b 54/318
Premiertrak
1100 x 650 (26 x 44)
Page 13
Figure 5d Umbilical Connection
Figure 5e Umbilical Control Hand Set
AX815-901-8EN-07b 55/318
Premiertrak
1100 x 650 (26 x 44)
Page 14
PLAN VIEW OF THE PLANT
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1
Left turn slow, forward track 2 **Reverse Forward **

Reverse slow or fast, track 1 & 2 ** Left Turn Right Turn **
(travelling forward) (travelling forward)
Right turn slow, reverses track 1
Not used Not used
Left turn slow, reverses track 2
Safety Button Not used
Rotate clockwise, track 1 forward, track 2
(Horn)
reverse (second step)
Rotate counterclockwise, track 1 reverse,
track 2 forward (second step)
Stop Button
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 5f Remote Umbilical Control Hand Set
AX815-901-8EN-07b 56/318
Premiertrak
1100 x 650 (26 x 44)
Page 15
7. Press the Horn button for 5 seconds to 12. Unplug the umbilical cable and replace
sound the safety warning horn. This will with the original plug (where radio unit
also ready the tracks for manoeuvring. fitted). Store the umbilical hand set unit
in the tool box to keep available for
8. The umbilcal handset directional buttons future use.
(forward, reverse and turn) are double
pressure switches with the initial Extreme care must be used
pressure operating the slow speed when manoeuvring the plant
mode and depressing further operates with the umbilical control hand
the higher speed. set. Stand as far away as
possible from the plant. Do not
Pressing the Stop button at any time will allow the cable of the hand set
immediately halt the operation and cut to sag and become entangled
out the engine but it is necessary to with the tracks.
manually switch off the engine ignition
(Section 8.2) (and disengage the manual
clutch if applicable).
9. Hold the hand set with the stop button

nearest to the operator and proceed as
follows. Press the slow speed buttons
on the hand set to manoeuvre the plant
in the desired direction (Figure 5f).
Employ the ‘Fast’ speed only where
safe to do so.
10. When the Plant is in the correct

position, press the Horn button to turn
the safety warning horn ‘OFF’ and
disengage the tracks.

Operation switch to ‘PLANT’. The
safety warning horn will sound for 10
seconds. Stop the engine (Section 8.2),
unless required further.
AX815-901-8EN-07b 57/318
Premiertrak
1100 x 650 (26 x 44)
Page 16
5.2.5 Unloading
The Premiertrak will arrive on site securely

WARNING
fastened to a low loader. It is the WEAR PERSONAL
responsibility of the haulage contractor to PROTECTIVE EQUIPMENT.
remove the fastenings.
Procedure
2. Position easy slope ramps at the end of

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

spring loaded cover to reveal the
control panel and engine control panel
(Figure 7b).
4. Follow the instructions for manoeuvring

the Premiertrak (Section 5.2.1).
5. Using the remote control hand set, steer

the Premiertrak off the transporter
(Section 5.2.1).
AX815-901-8EN-07b 58/318
Premiertrak
1100 x 650 (26 x 44)
Page 17
5.2.6 Loading
Before loading onto a low height trailer, the

WARNING
Plant must be prepared for transportation. WEAR PERSONAL
Refer to Section 2.1 for the travel PROTECTIVE EQUIPMENT.
Refer to Section 5.1 Safety
dimensions. This includes raising the
product conveyor tail and the dirt conveyor
(where fitted) and lowering the feed hopper. FALLING HAZARD.
Additionally, where the Premiertrak is Information for relevant warning.
supplied with the rear running gear bogie
system, the maximum permissable highway
axle loadings may require the dirt conveyor
and magnetic separator (if fitted) to be
removed.
Only experienced engineers

using suitable tools and lifting
equipment should remove
these items.
Procedure
2. Ensure that both conveyors, feed

hopper and crusher are free from stone
and dirt.
3. Lower the safety grid (Figure 6d) on the

crusher feed chute.First support the grid
with suitable lifting equipment before
unbolting and removing the two
supports to allow the grid to fold flat. Figure 5g Front Ladder Folded for
Transportation
4. On the left hand side of the Premiertrak
raise the bottom section of the front
ladder and secure (Figure 5g).
continued overleaf.............
AX815-901-8EN-07b 59/318
Premiertrak
1100 x 650 (26 x 44)
Page 18
5. Remove the dirt conveyor head drum

guard, side plates (Figure 5h) and the WARNING
rear handrails on the feeder
WEAR PERSONAL
maintenance platforms on both sides of PROTECTIVE EQUIPMENT.
the plant . This is necessary before Refer to Section 5.1 Safety
folding the dirt conveyor for transport. Information for relevant warning.
6. Ensure all loose items are carefully FALLING HAZARD.

stowed and secured if these are to be Refer to Section 5.1 Safety
transported on the plant.
7. Locate the control box and raise the

cover to reveal the control panel and
engine control panel (Figure 5b).
8. Start the engine (Section 7.2.1).

Increase the engine speed to 1600rpm.
9. Turn the Operation switch to ‘PLANT’,

the safety warning horn will sound for
10 seconds.
10. Turn the Tail Lift switch to ‘!’ and fully

raise the tail section of the product
conveyor into the travelling position.
11. Turn the Dirt Conveyor switch to‘!’

and fold the dirt conveyor fully in the
travelling position. Secure with the
transportation safety chain (Figure Figure 5h Dirt Conveyor Head Drum
5i) Guard and Side Plates
During folding of the dirt

conveyor ensure that the
hydraulic hoses and conveyor
belt do not foul any part of the
structure.
AX815-901-8EN-07b 60/318
Premiertrak
1100 x 650 (26 x 44)
Page 19
12. Lower the hopper plates into the

travelling position (Section 5.3).
Dirt Conveyor Safety
13. Position easy slope ramps at the end of Chain
the transporter to help with loading of
the Premiertrak.
14. Turn the Operation switch to

‘TRACK’. Using the remote control
hand set, steer the Premiertrak onto the
transporter (Section 5.2.1).
15. When the plant is loaded shut down the

remote control hand set using stop
button on the unit (figure 5a or 5f).
16. Switch off the engine (Section 8.2).
17. Securing the Premiertrak to the Dirt Conveyor

transporter is the responsibility of
the haulage contractor. Figure 5i Dirt Conveyor Safety Chain
Prior to transportation always

check the plant for loose or
damaged components.
Fasten all loose parts, replace

missing items or make repairs
as found necessary to ensure
that all components are safely
secured during transportation.
AX815-901-8EN-07b 61/318
Premiertrak
1100 x 650 (26 x 44)
Page 20
5.3 Folding Hopper Plates

WARNING
Road transportation regulations WEAR PERSONAL
may require that the hopper PROTECTIVE EQUIPMENT.
plates be lowered for road Refer to Section 5.1 Safety
transportation. Information for relevant warning.
When the hopper side plates are FALLING HAZARD.

lowered into the travelling
position, one of the hopper sides
plates will fold on top of the
folded dirt conveyor. The dirt
conveyour head drum guard and
side plates and also the rear
feeder maintenance platforms
(Figure 5j) must be removed
before the hopper side plates
are folded into the travelling
postion.
Procedure
5.3.1 Hydraulic Folding Hopper -

lowering for transport
2. Using lifting equipment support the

Figure 5j Dirt Conveyor Folded Hopper Lowered
hopper tie bar. Remove the locking
wedges and lift off the tie bar (Figure5k).
3. Remove the bolts securing the end plate

to the side plates.
4. Remove the four hopper side plate

wedges (two for each side plate (Figures
5l and 5m).
Figure 5k Hopper Tie Bar
AX815-901-8EN-07b 62/318
Premiertrak
1100 x 650 (26 x 44)
Page 21
4. Start the engine (Section 7.2). Increase

the engine speed to 1600rpm.
5. Using the two hydraulic operating levers

located inside the rear of the chassis
(Figure 5n), lower the hopper side
plates and end plate into the travelling
position.
Figure 5l Hopper Side Plate Locking Wedge
6. Close down the plant and implement the

Lock Out procedure (Section 8.2).
Hopper Locking Wedge
7. Store the locking wedges in the tool
box and secure the tie bar to the plant.
Figure 5m Hopper Raised - Wedge Location
Figure 5n Hopper Hydraulic Control Levers
AX815-901-8EN-07b 63/318
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This manual contains safety information which the

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THESE MAY AFFECT THE INFORMATION

LOOK IN SECTION 11 - APPENDIX OF THIS

TAKE NOTE OF ANY VARIATIONS TO THE

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

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

This plant is in conformity with the

May cause loss or degradation of hearing

Wear proper hearing personal protective

Death, serious injury or delayed lung disease

When dusts are generated by the operation of this

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

Telephone:- + 44 1530 518600

Fax:- + 44 1530 518618

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

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- locations and illustrations ............................................ 15

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

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1.2 Organisation Measures Observe all safety instructions and warnings

1.2.2 Disconnect battery ground cable before

For the execution of maintenance work, 1.3 Selection and

Work on the hydraulic system must be

1.4 Safety Instructions 1.4.2 Special Work In Conjunction

In-running nip points on moving machinery • Implementing the lockout procedure.

Switch off and lockout the plant before

1.4.2.3 For carrying out overhead assembly work

Improperly disposing of waste can threaten Diesel fuel is highly flammable.

Particularly make sure that any part of the

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 and

Observe the regulations in force at the

Depressurise all system sections and 1.5.4.Hazardous Substances

1.6 Transporting, 1.6.7

Before setting the plant in motion always

Explosive separation of a tyre and rim parts

Do not attempt to mount a tyre unless you

Always maintain the correct pressure. Do

When inflating tyres, use a clip-on chuck

Check wheels for low pressure, cuts,

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1.7 Position of Emergency