4242SR Plant User Manual 2007 (L) .PDF Versión 1

ADVANCED CRUSHING TECHNOLOGY
Powerscreen of Florida.
5125 N. Frontage Road,
Lakeland, FL 33810
4242SR Tel: (863) 687-7153
Fax: (863) 680-1289
Web: www.powerscreenfla.com
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.
AX862-901-8EN-01f 1/360
Powerscreen of Florida - 5125 N. Frontage Rd., Lakeland, FL, 33810 Page 2 of 360
Ph : 863-687-7153 / Web : www.powerscreenfla.com
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
IMPORTANT SAFETY NOTICE!
The environment in which the plant will operate can contain risks to health and safety
which the operator must take steps to identify and guard against. Dangers from overhead
conveyor discharges, overspill material, vehicle movements, etc., as well as other site
related hazards must be anticipated. Avoid these dangers by carrying out risk
assessments before the plant is put into operation to ensure appropriate measures are
implemented and site personnel safety awareness training has been undertaken.
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 4242SR Tracked Impactor contact:-
Terex Pegson Limited

Mammoth Street
Coalville
Leicestershire LE67 3GN
England
Telephone : +44 1530 518600, Fax : +44 1530 518618, E-mail : [email protected]
or
Terex Crushing & Screening Inc

11001 Electron Drive
Louisville
Kentucky 40299
U.S.A.
Telephone : +1 502 267 2314, Fax : +1 502 267 2317
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.
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
related accessories contain lead and lead WARNING: Diesel engine exhaust and
compounds, chemicals known to the State some of it’s constituents are known to the
of California to cause cancer and State of California to cause cancer, birth
reproductive harm. defects, and other reproductive harm.
WASH HANDS AFTER HANDLING.
Copyright
The copyright of this User Manual is reserved by Terex 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.
Terex Pegson Limited

Mammoth Street
Coalville
Leicestershire
LE67 3GN
England
Telephone:- + 44 1530 518600
Fax:- + 44 1530 518618
E mail [email protected]
To order additional copies contact your local BL-Pegson Ltd Dealer.
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1 - Safety EN
Page 1 - 1
1 - Safety
1.1 Warnings and Symbols .................................................................................. 1 - 2
1.2 Organisation Measures .................................................................................. 1 - 3
1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4
1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 5

1.4.1 Standard Operation .................................................................................... 1 - 5
1.4.2 Special Work In Conjunction with Utilisation of the Plant and Maintenance and
Repairs During Operation; Disposal of Parts and Consumables ................ 1 - 5
1.5 Warning of Special Dangers .......................................................................... 1 - 8
1.5.1 Electric Energy ........................................................................................... 1 - 8
1.5.2 Gas, Dust, Steam, Smoke and Noise ......................................................... 1 - 9
1.5.3 Hydraulic and Pneumatic Equipment .......................................................... 1 - 9
1.5.4. Hazardous Substances ........................................................................... 1 - 10
1.6 Transporting, Manoeuvring and Recommissioning .................................. 1 - 11
1.7 Position of Emergency Stop Buttons & Isolation Switch .......................... 1 - 13
1.8 Plant Warning Signs ..................................................................................... 1 - 14

1.8.1 Location of Warning Signs ....................................................................... 1 - 14
1.8.2 Location of Warning Signs - ENTANGLEMENT HAZARD ........................ 1 - 16
1.8.3 Safety Sign Illustrations............................................................................ 1 - 18
Safety Sign Illustrations, continued .................................................................... 1 - 19
Safety Sign Illustrations, continued .................................................................... 1 - 20
Terex Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
4242SR
1 - Safety EN
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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.
! DANGER !
Indicates an imminently hazardous situation which, if not avoided, WILLl
result in death or serious injury.
! WARNING !
Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury.
! CAUTION !
Indicates a potentially hazardous situation which, if not avoided, MAY
result in minor or moderate injury. It may also be used to alert against
unsafe working practices.
! NOTICE !
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 1.2.2

You can be injured if you do not obey the
1.2.1 safety instructions as indicated on warning
Ascertain from the appropriate Authority and stickers.
observe all statutory and any other
regulations that may apply to the planned Observe all safety instructions and warnings
location before operating the 4242SR attached to the plant.
Tracked Impactor.
See to it that safety instructions and
Loose or baggy clothing can get caught in warnings attached to the plant are always
running machinery. complete and perfectly legible.
Where possible when working close to Keep warnings and instruction labels clean.
engines or machinery, only do so when they
are stopped. If this is not practical, Replace unreadable or missing labels with
remember to keep tools, test equipment and new ones before operating the plant. Make
all other parts of your body well away from sure replacement parts include warning or
the moving parts. instruction labels where necessary.
For reasons of safety, long hair must be tied 1.2.3

back or otherwise secured, garments must
Understand service procedure before doing
be close fitting and no jewellery such as
work. Keep area clean and dry.
rings may be worn. Injury may result from
being caught up in the machinery or from
rings catching on moving parts. Never lubricate, clean, service or adjust
machinery while it is moving. Keep hands,
feet and clothing clear of power driven parts
Always wear correctly fitting (EN/ANSI
and in running nip-points. Disengage all
approved) personal protective equipment.
power and operate controls to relieve
pressure. Stop the engine. Implement lockout
Personal Protective Equipment includes
procedure. Allow the machinery to cool.
Hard Hat, Safety Glasses, Hearing
Protection, Dust Mask, Close fitting
Keep all parts in good condition. Ensure that
Overalls, Steel Toed Boots, Industrial Gloves
all parts are properly installed. Fix damage
and a High Visibility Vest.
immediately. Replace worn and broken
parts. Remove any build up of grease, oil and
debris.
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Disconnect battery ground cable before 1.3 Selection and

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

Governing Specific with Utilisation of the Plant and
Maintenance and Repairs During
Operational Phases
Operation; Disposal of Parts and
Consumables
1.4.1 Standard Operation
1.4.2.1
1.4.1.1
Observe the adjusting, maintenance and
Take the necessary precautions to ensure
intervals set out in these operating
that the plant is used only when in a safe and
instructions, except where:
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 elements
frequent servicing.
and exhausts, are in all place and fully
functional.
Observe information on the replacement of
parts and equipment. These activities may be
Before starting the engine ensure it is safe to
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 the
secured against inadvertent starting by:
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.
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1 - Safety EN
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1.4.2.3 1.4.2.5
Carry out maintenance and repair work only Falling from and/or onto a Terex Pegson
if the plant is positioned on stable and level plant can cause injury or even death.
ground and has been secured against
inadvertent movement and buckling. Do not climb on the plant whilst it is in
operation. Never use plant parts as a
1.4.2.4 climbing aid.
Never allow unqualified or untrained Beware of moving haulage and loading

personnel to attempt to remove or replace equipment in the vicinity of the plant.
any part of the plant, or anyone to remove
large or heavy components without adequate For carrying out overhead assembly work
lifting tackle. always use specially designed or otherwise
safety-oriented ladders and working
To avoid the risk of accidents, individual platforms.
parts and large assemblies being moved for
replacement purposes should be carefully Always use any walkway/platforms provided
attached to lifting tackle and secured. Use or a safe and secure platform approved by
only suitable and technically adequate lifting the regional safety enforcing authority.
gear.
Always use a suitable lifting platform before
Never work or stand under suspended loads. attempting any work 2 metres (6’- 6”) or
more above the ground level.
Keep away from the feed hopper, all belt
conveyor and magnetic separator belt Keep all handles, steps, handrails, platforms,
discharges, where there is risk of serious landing and ladders free from dirt, oil, snow
injury or death due to the loading and and ice.
removal of material.
1.4.2.6
The fastening of loads and instructing of
crane operators should be entrusted to
experienced persons only. The marshaller
giving the instructions must be within sight or
sound of the operator.
1.4.2.7
After cleaning, examine all fuel, lubricant,
and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any
defects found must be rectified without
delay.
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1.4.2.8 1.4.2.11
Any safety devices removed for set-up, Diesel fuel is highly flammable.
maintenance or repair purposes must be
refitted and checked immediately upon Never remove the filler cap, or refuel, with
completion of the maintenance and repair the engine running.
work to ensure full working order.
Never add gasoline or any other fuels mixed
1.4.2.9 to diesel because of increased fire or
explosion risks.
Improperly disposing of waste can threaten
the environment and ecology. Potentially Do not carry out maintenance on the fuel
harmful waste used with BL-Pegson system near naked lights or sources of
equipment includes such items as oil, fuel, sparks, such as welding equipment or whilst
coolant, filters and batteries, etc. smoking.
Use leakproof containers when draining
1.4.2.12
fluids. Do not use food or beverage
containers that may mislead someone into Using unapproved structures i.e. walkways/
drinking from them. platforms etc. in the vicinity of a BL-Pegson
plant is very dangerous and could lead to
Do not pour waste onto the ground, down a serious injury or even death through falling
drain or into any water source. and/or entanglement with the plant.
Ensure that all consumables and replaced Do not use any unauthorised structures.
parts are disposed of safely and with
minimum environmental impact.
1.4.2.10
Always ensure that any safety fitment such
as locking wedges, securing chains, bars or
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.
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1 - Safety EN
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1.5 Warning of Special 1.5.1.4

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

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

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

respective site.
Before starting work on high voltage
assemblies and after cutting out the power Dust found on the 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 a
1.5.1.9 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 grinding
carrying out any maintenance to the work on the plant only if this has been
electrical system. 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
Avoid contact with the skin, eyes or clothing. and grinding operations, clean the plant and
its surroundings from dust and other
inflammable substances and make sure the
premises are adequately ventilated (as there
may be a risk of explosion).
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1 - Safety EN
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1.5.2.4 1.5.3.4
Always ensure that the operator(s) are Hydraulic and compressed air lines must be
provided with hearing protection of 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 of 1.5.3.5
air pollution of any kind.
Always practice extreme cleanliness
1.5.3 Hydraulic and Pneumatic servicing hydraulic components.
Equipment
1.5.3.6
1.5.3.1
Hydraulic fluid under pressure can penetrate
Work on hydraulic equipment may be carried the skin causing serious injury.
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 for materials by correct identification, labelling,
the unit concerned before carrying out any storage, use and disposal, all strictly in
repair work. accordance with the manufacturers
instructions and that all applicable regulations
are observed at all times.
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1.6 Transporting, 1.6.7

Manoeuvring 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 towed, loaded and
transported only in accordance with the 1.6.8
operating instructions.
In conditions of poor visibility and after dark,
1.6.2 always switch on the lighting system of the
transporting vehicle..
For towing the plant, observe the prescribed
transport position, admissible speed and 1.6.9
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 and sufficient clearance.
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 to the
The recommissioning procedure must be ground, especially when travelling downhill.
strictly in accordance with the operating
instructions. 1.6.11
1.6.5 On sloping terrain, always adapt your

travelling speed to the relevant ground
Before starting work or travelling with the conditions. Never change to a lower gear on
plant, check that the braking, and any a slope. Always change gear before
signalling and lighting systems are fully reaching a slope.
functional.
1.6.6
Before setting the plant in motion always
check that the accessories have been safely
stowed away.
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1 - Safety EN
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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 - Safety EN
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1.7 Position of Emergency Stop Buttons & Isolation Switch
Lockable
Isolation Switch
(Diesel Engine)
Emergency Stop Button

(Control Panel) Emergency Stop Buttons
(Chassis Side and Screen Support )
Emergency Stop Button

(Control Panel) Emergency Stop Button
(Recirculating Conveyor))
Figure 1a Emergency Stop Buttons
1.8 Plant Warning Signs
1.8.1 Location of Warning

Signs
Left Hand side of plant
KEY TO SIGN REFERENCE

NUMBERS ON NEXT PAGES
Location of Warning Signs, Right
Hand side of plant
KEY TO SIGN REFERENCE

NUMBERS ON NEXT PAGES
1.8.2 Location of Warning Signs - ENTANGLEMENT HAZARD
Safety Decal: 300/268 ‘Danger - Entanglement Hazard for Crusher & Panel’
Decal Location - 4242SR Impactor:
Control Panel, 4242SR
Impactor non-drive side, 4242SR
Impactor drive side, 4242SR

Safety Decal: 300/269 ‘Danger - Entanglement Hazard for Inspection Door’
Decal Location - 4242SR Impactor:
Inspection door both sides of impactor,

4242SR
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1 - Safety EN
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1.8.3 Safety Sign Illustrations
1 2 3 5
6 7 8 9
11
12 13 16
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Safety Sign Illustrations, continued
17 18 19 21
26
27
22 23
31 32
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Safety Sign Illustrations, continued
Upper and Lower Transfer Conveyors, each:-
2x
4x
Recirculating and Stockpile Conveyors, each:-
2x
4x
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Page 2 - 1
2 - Technical Information
2.1 Dimensions ..................................................................................................... 2 - 2
2.2 Plant Description ............................................................................................ 2 - 3
2.3 Vibrating Grizzly Feeder ................................................................................ 2 - 4
2.4 Impact Crusher ............................................................................................... 2 - 4
2.5 Impactor Product On Plant Conveyor ........................................................... 2 - 5
2.6 Tracks .............................................................................................................. 2 - 5
2.7 Engine Powerpack ......................................................................................... 2 - 5
2.8 Dust Suppression Sprays ............................................................................. 2 - 5
2.9 Dirt Conveyor .................................................................................................. 2 - 5
2.10 Magnetic Separator ...................................................................................... 2 - 6
2.11 Sizing Screen ................................................................................................ 2 - 6
2.12 Fines Conveyor ............................................................................................ 2 - 6
2.13 Top Deck Side Transfer Conveyor .............................................................. 2 - 6
2.14 Re-Circulating Conveyor (Stockpile Conveyor optional) .......................... 2 - 6
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2.1 Dimensions
2560mm (101”)
TRACK WIDTH
Figure 2a
Travel Height (Excluding Transport Trailer): 3440mm (135.4in) without spray bars
Travel Width: 3100mm (122in)
Track Width: 2560mm (101in)
Working Height: 4022mm (158.5in)
Gross Weight approx. 40.82 tonnes (45 US tons)
Note: Weights and dimensions are for guidance only and appropriate
allowances should be applied when being used for transportation purposes.
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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.
Diesel Engine REAR

Impactor Product Power Pack
Sizing Screen
On Plant Conveyor
Vibrating
Grizzly Feeder
FRONT
Fines Conveyor
Re-circulating Conveyor
(Or Stockpile option) Dirt Conveyor
Tracks
LEFT HAND SIDE
Feed Hopper Engine Maintenance

Impact Crusher
Platform
FRONT
REAR
Fines Conveyor
Maintenance
Platform Control Box Top Deck Side Bottom Deck Side
Transfer Conveyor Transfer Conveyor
RIGHT HAND SIDE

Figure 2b Plant Terms
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2.3 Vibrating Grizzly Feeder

Type ............................. Spring mounted vibrating pan
Width ........................... 1080mm (42in)
Length .......................... 3800mm (12’- 6”)
Unit .............................. Twin shaft oil lubricated
Grizzly .......................... Stepped fixed bars preset at nominal 50mm (2in) spaces at discharge end.
Renewable tips at discharge end.
Underscreen ................. Blanking mat fitted as standard. Wire mesh underscreen optional.
Drive ............................ Hydraulic motor
Control ......................... Variable speed
Hopper ........................ Heavy duty fixed type
2.4 Impact Crusher

Type ............................. Fixed blow bar Impactor
Feed Opening ............... 1067 x 711mm (42 x 28in)
Liners ........................... Fully lined internally with renewable abrasion resistant steel
Adjustment ................... Manual adjustment of impact faces - front and rear aprons - with overload
compression springs on rear apron
Rotor ........................... 1067mm (42in) diameter with 2 x 2 reversible/replaceable fixed blow bars
running in two heavy duty self aligning spherical roller bearings
Lubrication ................... Greased roller bearings, inner and outer labyrinth seals
Drive ............................ Vee belts from engine
Crusher Speed ............. Nom. 504 or 630 rpm - Two engine pulleys are provided - one fitted and
the other supplied loose. Stock build plants are fitted with the faster speed
pulley. Refer to 4.2.1 also
Control ......................... Engine clutch
Blow Bars .................... Cast high manganese steel blow bars are fitted as standard suitable for
recycling applications with feed sizes up to 400mm and including some
small quantity of steel reinforcing bar. They are secured with locking plates
and can be turned when worn. For alternative applications and feed size,
please consult Terex Pegsons Sales Department
Maintenance ................. Hydraulic case opening
Optional fitting ............. Lower swing beam/ grinding path, having overload compression spring,
available for certain quarry applications please consult TerexPegsons Sales
Department
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2.5 Impactor Product On Plant Conveyor

Type ............................. Steel reinforced troughed belt
Width ........................... 1000mm (39in)
Lubrication ................... Grease
Control ......................... Fixed speed
Skirts ........................... Full length
2.6 Tracks
Type ............................. 160mm (6in) pitch heavy duty
Width ........................... 400mm (15.8in) - 500mm optional
Centres ........................ 3715mm (12’- 2”)
Drive ............................ Hydraulic integral motors
Control ......................... Remote handset - dual speed
2.7 Engine Powerpack

Type ............................. Caterpillar C9 EU/EC Emmission Regulations compliant 6 cyl. water
cooled diesel
Rating ........................... 230kW (309hp) @ 1800 rpm
Drives .......................... Manual clutch to crusher through vee belts
Vee belts to twin hydraulic pumps
Housing ........................ Totally enclosed canopy with integral fuel tank and battery
2.8 Dust Suppression Sprays

Type ............................. Clean water multi atomising nozzles
Positions ....................... Crusher discharge and fines conveyor discharge
Inlet .............................. Single point
Required supply ............ Up to approx. 7 litres/min @ 2.8bar (1.8 US galls @ 42psi)
Frost protection ............ System drain valves
2.9 Dirt Conveyor

Type ............................. Plain troughed belt, hydraulically folded for transport by engine driven
pump. Extended conveyor optional
Width ........................... 600mm (24in)
Skirts/Hood .................. Full length (removable for transport)
4242SR
Page 2 - 6
2.10 Magnetic Separator

Type ............................. Suspended self cleaning crossbelt overband
Magnet ......................... Permanent
Belt width ..................... 750 mm (30in)
Bearing centres ............. 1800 mm (71in)
Control ......................... Preset variable
2.11 Sizing Screen

Type ............................. Vibrating two deck - 4 bearing type
Screen decking ............. Wire mesh apertures as available to order
Width ........................... 1525mm (5’- 0”)
Length .......................... 3350mm (11’- 0”)
2.12 Fines Conveyor

Type ............................. Plain troughed belt
Width ........................... 1400mm (55in)
2.13 Top Deck Side Transfer Conveyor

Type ............................. Plain troughed belt
Width ........................... 500mm (20in)
2.14 Re-Circulating Conveyor (Stockpile Conveyor optional)

Type ............................. Chevron type troughed belt
Width ........................... 500mm (20in)
4242SR
3 - General Information EN
Page 3 - 1
3 - General Information
3.1 Introduction ..................................................................................................... 3 - 2
3.2 General information ........................................................................................ 3 - 2
3.3 Designated Use .............................................................................................. 3 - 3

3.3.1 Operating Temperature Range ................................................................... 3 - 3
3.4 Plant Features ................................................................................................. 3 - 4
3.5 Plant Performance .......................................................................................... 3 - 6

3.5.1 Impactor Settings ....................................................................................... 3 - 7
3.5.2 Feed and Product Material Data ................................................................ 3 - 8
4242SR
Page 3 - 2
3.1 Introduction 3.2 General information
This instruction manual contains important The 4242SR which you have now received
information on how to operate the 4242SR has been manufactured, assembled and
Tracked Impactor safely, properly and most tested with the utmost care and was built
efficiently. with first class materials.
Observing these instructions and exercising Close attention has been paid to all details in
Common Sense helps to avoid danger, to assembly, running tests and final inspection.
reduce repair costs and downtimes and to
increase the reliability and life of the plant. We are confident that you have received a
Failure to do so may invalidate any plant which will give you every satisfaction
warranties in force. over a long period.
The operating instructions must always be To be assured of faultless operation we

available wherever the plant is in use. would ask you to carefully read the following
paragraphs and give the required time and
These operating instructions must be read attention to essential maintenance, cleaning
and applied by any person in charge of and/ and inspection.
or working on the plant such as:-
The plant is simple to operate, adjustments
Operation are easy to make and expert assistance is
seldom required, provided that ordinary care
Includes manoeuvring, setting up, operation is exercised in daily use.
during the course of work, evacuation of
production material and waste, care and The plant has been built in accordance with
disposal of fuels and consumables, etc. state-of-the-art standards and recognised
safety rules. It is designed to be reliable,
Maintenance efficient and safe when used and
maintained in accordance with the
Servicing, inspection and repair instructions given in this manual.
and/or
Transport
Follow all applicable laws and safety

regulations for accident prevention and
environmental protection.
4242SR
Page 3 - 3
3.3 Designated Use In addition to the tremendous advantages

arising from the mobility of a tracked unit,
IMPORTANT NOTICE the standard design and specification is
intended to give the plant operator a wide
choice of operating configurations. These
This plant is designed for both
are described in the guidance notes on plant
demolition and quarrying applications.
performance (Section 3.4).
When fitted with manganese steel blow
bars the crusher will tolerate small
quantities of steel reinforcing bar in the Additional choices are available to the buyer
feed. However, the machine is not to select additional equipment from the range
designed to accept large pieces of steel of optional extras (Section 4).
or other uncrushable objects and the
feed material should be assessed / 3.3.1 Operating Temperature Range
inspected for suitability prior to use. It
The normal operating temperature range of
is vitally important that large pieces of
the plant is from -10°C to +40°C (+14°F to
steel or similar uncrushable objects are
+104°F). For use in temperatures outside of
not allowed to enter the crushing
this range, contact your local dealer or BL-
chamber as severe damage and injury
Pegson for details.
may occur. When High Chromium steel
bars are fitted, NO steel should be
Note: Appropriate oil & coolant to suit the
allowed to enter the crushing chamber
local operating conditions must be used, as
and the machine should only be used on
specified elsewhere in this manual.
quarry applications or clean materials
such as asphalt.
Operating the plant outside it’s

recommended range of applications and
operating parameters, will result in a loss of
guarantee and the manufacturer/supplier
cannot be held liable for any damage
resulting from such use. The risk of such
misuse lies entirely with the user.
TheTerex Pegson Tracked Impactor Plant

has been designed to give a controlled
product size whilst maximising throughput
and product shape. Applications include:
quarry, demolition and recycling.
4242SR
Page 3 - 4
3.4 Plant Features Material passing over the wire mesh (or
blank rubber mat) and through the end
In order to obtain the optimum output from section of the feeder grizzly bars is
the crusher, it’s feed should be continuous discharged to the main product conveyor
and regulated. Additionally, all feed should be via a bypass chute. Material passing
of a size that will readily enter the crusher through the underscreen mesh is
chamber and undersize material should be discharged to the dirt conveyor and a flap
removed from the feed prior to entry to the door will also allow a portion of the
crusher. material to be diverted to the main product
conveyor.
Product curves shown overleaf are typical
only, based on average limestone, and Impact Crusher
indicate the product gradings from the For differing applications the crusher is
Impactor only. Any natural fines in the feed provided with two engine pulleys, (one
material which bypass the Impactor are not supplied fitted, the other supplied loose) to
taken into account. Curves will vary cater for either recycling or quarry
dependant on nature, type and grading of the applications. Additionally, the settings of
material being processed. Any capacity the impact aprons can be varied and an
shown is based on feed material weighing additional grinding path can be supplied
loose, approximately 100lbs/ft and indicates (optional) to vary the product.
the throughput of the plant. For suitability of
particular applications, please consult your Double Deck Sizing Screen
local dealer or BL-Pegson Ltd. The standard supply is for the top deck to
be fitted with a 45mm (c 13/4”) aperture
The very variable nature of feed materials wire mesh and the bottom deck left open.
and of the products required by the plant Different meshes (optional extras) can be
operator make it difficult to be specific when supplied to suit customer requirements.
predicting plant performance. Also the plant Additionally, facility is included to vary the
is designed to allow the plant operator a wide angle of the screen whereby screening
choice of operating modes as described may be improved.
below:
Re-circulating Conveyor
Grizzly Feeder Provided to return rejects from the screen
The underscreen deck below the grizzly bars back to the impact crusher for recrushing,
can be fitted with a blanking mat for the facility is also included to suspend from
‘fines’ to be directed onto the main product the plant and turn at 90o to form a
conveyor but the standard fitment is a wire stockpile.
mesh pane with apertures to pass 20 mm
material (subject to suitability).
4242SR
Page 3 - 5
Side Transfer Conveyor(s)

A conveyor is supplied to transfer rejected ! WARNING !
material from the screen top deck to the re-
If you have any doubts about any
circulating conveyor. Another similar transfer
conveyor (optional extra) is available to handle
aspect of the plant’s capability or
material from the bottom deck (if fitted) for servicing procedures, you must
recirculating or stockpiling. consult your local Terex Pegson
dealer or Terex Pegsons technical
Fines Conveyor department.
This is sited immediately below the sizing
screen and, in the normal arrangement of a top
deck only being fitted to the screen, discharges
! NOTICE !
the one screened all-in product onto a ground If high or low ambient temperature
stockpile or to other equipment for further conditions apply and/or any other
processing.
unusual situation(s) may occur,
either during operation or
Stockpile Conveyor (optional extra)
otherwise, refer to Terex Pegson
A conveyor similar to the re-circulating
conveyor suspended from the opposite side of for advice as to the suitability of
the plant for a sized material coming off the the plant. Full details are required
bottom deck screen mesh (when fitted). for an assessment, as plant
performance could be affected.
Overband Magnetic Separator
The magnetic overband separator is intended The Caterpillar engine cooling
to extract ferrous materials from the crushed system is protected to -15º C (+5º)
product but this material in the feed must be with 30% (Caterpillar antifreeze
limited to a size that will not cause damage concentration when shipped from
to the crusher. the factory unless special
requirements have been defined.
4242SR
Page 3 - 6
3.5 Plant Performance

! NOTICE !
The overall maximum plant capacity can be The crusher in the standard plant
governed by the nature of the feed material, has a rotor speed of 630rpm and is
the screen mesh size(s) fitted, the Impactor fitted with 2 long x 2 short ‘High
speed and apron settings, the conveyor Manganese’ blow bars. This may
capacities, etc., etc. or a combination of all
have been altered to specific
these type of factors.
order.
When selecting the impact crusher settings
(Section 3.6), it is best practice to keep the The very variable nature of feed
amount of oversize material recirculating material and crushing applications
back to the crusher to a maximum of 20 may require consideration of
percent of the original feed. The mesh alternative configurations in order
apertures on the screen are also a governing to achieve optimum performance.
factor. In any case, material flows must be
kept within the handling capability of the Refer to the Addendum ‘428
system. Impact Crusher - Guide to Efficient
Operation’ in Section 11 of this
Selecting the size of mesh apertures fitted to
manual for details.
the sizing screen must not be detrimental to
the screen for reasons of wear or screening
efficiency and must provide an acceptable
balance of material flows from the screen.
Estimates of performance are given as a

guide only due to the wide variety and
variable nature of the numerous factors that
can be involved. In respect of specific
applications seek prior advice from BL-
Pegson’s technical department
Operating the plant outside it’s

recommended range of applications and
operating parameters, will result in a loss of
guarantee and the manufacturer/supplier
cannot be held liable for any damage
resulting from such use. The risk of such
misuse lies entirely with the user.
4242SR
Page 3 - 7
3.5.1 Impactor Settings
Figure 3a Impactor Setting Gaps
Settings mm (ins.)
Adjustment Setting Ratio Setting Ratio
Minimum Maximum
Upper Impact 60 175

Apron ~
Dimension 'A' (2 1/2”) (7”) Keep ratio of settings
(Upper Impact Apron
to Lower Impact Apron)
between
Lower Impact 30 85 2 : 1 and 2.5 : 1
Apron
Dimension 'B' Keep ratio of settings
(1 3/8”) (3 3/8”)
(Lower Impact Apron
to Swing Beam)
Swing Beam between
Liner/Rails 1 : 1 and 2 : 1 20 63 ~
Dimension 'C' (7/8”) 2 1/2”)
(optional item)
Figure 3b Impactor Min and Max settings

NOTES:
1) The Swing Beam (Grinding Path) should be set 0 – 5mm (0 – 0.2”) smaller than the
desired maximum product size.
2) When the optional Swing Beam is NOT fitted, set the Lower Impact Apron at 0 – 5mm
(0 – 0.2”) smaller than the desired maximum product size.
3) Whilst conforming with the Setting Ratios in the table make sure the settings ‘A’, ‘B’ or
‘C’ do not fall outside the minimum and maximum dimensions shown.
4) All settings are subject to the suitability of the feed material.
4242SR
Page 3 - 8
3.5.2 Feed and Product Material Data
Technical Information for Impact Crusher – standard configuration

Refer to the Addendum ‘428 Impact Crusher – Guide to Efficient Operation’ in Section 11
for alternative types of blow bar and rotor speed
Feed Rotor Rotor Blow Bar
Opening Diameter Speed Configuration
1067 x 711mm 1060mm 630rpm 2 x long
(28”x42”) (42”) 2 x short
Maximum Feed Size
‘High Manganese’ Blow Bars - 700mm [28”] diagonal length or 400mm [16”] cube
Plant Capacity - Dependant on application – See Section 3.5

011204 – 4242SR
Figure 3c Impact Crusher Data
Material Sizes
Estimated Product Envelope

with Grinding Path Fitted
Estimated Product Envelope

with Grinding Path Excluded
Percentage Passing %
Typical
Feed
Grading
Figure 3d Typical Estimates of Product Analysis - (single pass)
4242SR
4 - Design and Function EN
Page 4 - 1
4 - Design and Function
4.1 Brief Specification .......................................................................................... 4 - 2
4.2 Construction Units ......................................................................................... 4 - 3

4.2.1 Impact Crusher ........................................................................................... 4 - 3
4.2.2 Vibrating Grizzly Feeder ............................................................................. 4 - 3
4.2.3 Impactor Product On-Plant Conveyor .......................................................... 4 - 4
4.2.4 Side Dirt Conveyor (optional) ..................................................................... 4 - 4
4.2.5 Sizing Screen............................................................................................. 4 - 4
4.2.6 Fines Conveyor .......................................................................................... 4 - 5
4.2.7 Top Deck Side Transfer Conveyor .............................................................. 4 - 5
4.2.8 Bottom Deck Side Transfer Conveyor ........................................................ 4 - 5
4.2.9 Re-Circulating Conveyor ............................................................................ 4 - 5
4.2.10 Stockpiling Conveyor (optional extra) ........................................................ 4 - 5
4.2.11 Belt Scrapers ........................................................................................... 4 - 5
4.2.12 Track Frame............................................................................................. 4 - 6
4.2.13 Plant Chutework ....................................................................................... 4 - 6
4.2.14 Magnet (optional) ..................................................................................... 4 - 6
4.2.15 Dust Suppression .................................................................................... 4 - 6
4.2.16 Operators Platforms ................................................................................. 4 - 6
4.2.17 Power-Pack ............................................................................................. 4 - 6
4.2.18 Controls ................................................................................................... 4 - 6
4.2.19 Chassis ................................................................................................... 4 - 7
4.2.20 Guards ..................................................................................................... 4 - 7
4.2.21 Painting ................................................................................................... 4 - 7
4.2.22 Optional Extras ........................................................................................ 4 - 7
4.2.23 Authorisation ............................................................................................ 4 - 8
4.2.24 Site Preparation ....................................................................................... 4 - 8
4.2.25 Commissioning ........................................................................................ 4 - 8
4242SR
Page 4 - 2
4.1 Brief Specification
The Terex Pegson 4242SR Plant has been designed for a wide range of quarry and recycling
applications, its features include:-
• Rapid set up time and easily transported on and off site
• Impact Crusher, feed opening 42 x 28in with 42in diameter rotor
• Two step self cleaning grizzly with under screen with blank mat (wire mesh optional)
• Facility to direct “grizzly fines” to dirt conveyor and/or bypass crusher
• Fully skirted product conveyor from beneath the impactor discharging on to the sizing screen
• Double deck vibrating sizing screen 1525 x 3350mm (5ft x 11ft) with simple access for screen
maintenance
• Re-circulating conveyor to return material from top deck of the screen for re-working, alternatively
this conveyor can be slewed to enable oversize material to be stockpiled
• Side conveyor from lower sizing screen to a freestanding stockpiling conveyor (optional)
• Heavy duty chassis and track frame
• Remote control for tracks
• Dust suppression sprays
• Caterpillar emission compliant water cooled diesel engine Powerpack
• Dirt conveyor and magnetic separator available as optional extras
• Alternative blow bars and mesh screens available
• CE Approved
4242SR
Page 4 - 3
4.2 Construction Units Impact Aprons:- Fitted in the front and rear
positions and lined with wear resistant
Terex Pegson 4242 SR Crushing and impact plates, some of which are
Screening Plant with Diesel/Hydraulic interchangeable. The setting is made
Drive, generally as shown and described manually by adjusting rods from the back of
in leaflet 4242 SR 2002/3 together with the machine.
specification 4242SR/103
Drive:- Through wedge belts with screw
4.2.1 Impact Crusher tension adjustment.
The Terex Pegson 4242SR fixed blow bar Engine Pulleys:- Two are provided, one is
impact crusher has a feed opening of 1067 supplied fitted and the other is supplied loose.
711mm (42 x 28in). Machines built for stock are fitted with the
faster speed pulley as standard. The slower
The features of the machine are as follows:- speed pulley will only be fitted against a
specific order prior to the plant being
Crusher Frame:- Fabricated from steel completed.
plate and rolled steel sections to form a
rugged construction which is fully lined with Impactor speeds:-
replaceable liner plates.
Slow - 504 rpm nominal - 224mm (8.8in)
Rotor:- Running in two heavy duty self pitch circle diameter engine pulley.
aligning spherical roller bearings and fitted
with four reversible and replaceable fixed Fast - 630 rpm nominal - 280mm (11in) pitch
blow bars. circle diameter engine pulley.
Blow Bars:- Two full size and two half size An optional lower swing beam/grinding path
standard manganese steel blow bars are with overload compression spring is
fitted as standard and are suitable for available for certain quarry applications. See
material recycling applications. They are optional extras (Section 4.2.20) for details.
secured with locking plates and can be
turned when worn.
Blow bars are available alternative
materials for crushing applications other
than materials for recycling. Please
consult the Addendum in Section 11 - 428
Impact Crusher, ‘Guide to Efficient
Operation’.
4242SR
Page 4 - 4
4.2.2 Vibrating Grizzly Feeder 4.2.3 Impactor Product On-Plant

Conveyor
Terex Pegson 1080mm wide (42in) x
3800mm (12’- 6”) long Vibrating Grizzly 1000mm (39in) wide plant mounted troughed
Feeder, including:- belt conveyor carrying the product from
beneath the impactor and discharging on to
Vibrating Unit:- Heavy duty mechanical the sizing screen.
type with twin counter rotating shafts with oil
lubricated bearings and gears. Belt:- Ripstop EP500/3 with 10mm (3/8in)
top and 3mm (1/8in) bottom heavy duty
Pan:- 12mm (0.5in) thick abrasion resisting rubber covers. A vulcanised joint is included.
steel bottom plate is included in the welded
construction. Feedboot:- Fabricated in mild steel plate
with abrasion resistant steel liners, access
Grizzly Section:- Double section of fixed door in one side, and fully skirted wear
welded tapered finger type bars at 50mm resistant rubber sealing strips along the entire
(2in) spaces (at discharge end) fabricated in conveyor length.
20mm (0.75in) thick abrasion resistant steel.
Impact Cradle:-This is provided beneath
Underdeck:- Supplied with a removable the belt below the impactor outlet.
blank rubber mat fitted to allow all grizzly
fines to be directed on to the main product Covers:- Canvas type removable dust
conveyor. An optional wire mesh can be covers are fitted at the head end.
supplied; the screened fines would then
discharge to the plant mounted dirt conveyor 4.2.4 Side Dirt Conveyor (optional)
and the oversize onto the main product
conveyor. A plant mounted 600mm (24”) wide side
discharge conveyor is included with a
Drive:- Hydraulic motor mounted on the hydraulic folding facility, giving
vibrating unit. approximately 2.0m (6’- 6”) at the top of the
head drum.
Control:- Variable speed control is achieved
through a proportional flow control valve
from the plant mounted control panel. A
device is also included to stop/start the
feeder remotely.
Hopper:- Fixed feed hopper fabricated in

abrasion resistant steel plate braced with
steel sections.
4242SR
Page 4 - 5
4.2.5 Sizing Screen 4.2.8 Bottom Deck Side Transfer

Conveyor
1525 x 3350mm (5ft x 11ft) inclined double
deck vibrating screen mounted beneath the 500mm (20in) wide conveyor to transfer
impactor product conveyor. The screen is material from the bottom deck of the screen
complete with hydraulic drive, wire meshes to an optional plant mounted stockpiling
on the top deck to separate at 40mm (45mm) conveyor..
square aperture.
Belt:- Roply EP400/2 with 5mm (3/16in) top
Different meshes can be supplied to suit and 1.5mm (1/16in) bottom rubber covers. A
customer requirements. vulcanised joint is included.
4.2.6 Fines Conveyor 4.2.9 Re-Circulating Conveyor

1400mm (55in) wide fines conveyor mounted 500mm (20in) wide conveyor to return
beneath the screen giving a discharge height material transferred from the top deck of the
of approximately 2900mm (9’- 6”) to the top screen, back to the impactor for re-crushing.
of the head drum. This conveyor includes a slewing facility to
enable oversize material to be stockpiled at
the side of the plant.
Belt:- Roply EP400/2 with 5mm (3/16in) top
and 1.5mm (1/16in) bottom rubber covers. A Belt:- Roply EP315/2 with 3mm (1/8in) top
vulcanised joint is included. and 1mm (1/32in) bottom rubber covers,
35mm (13/8in) high cleats and a vulcanised
4.2.7 Top Deck Side Transfer joint.
Conveyor
4.2.10 Stockpiling Conveyor
500mm (20in) wide conveyor to transfer
(optional extra)
material from the top deck of the screen to
the re-circulating conveyor. 500mm (20in) wide conveyor to return
material transferred from the bottom deck of
Belt:- Roply EP400/2 with 5mm (3/16in) top the screen to the side of the plant.
and 1.5mm (1/16in) bottom rubber covers. A
vulcanised joint is included. Belt:- Roply EP315/2 with 3mm (1/8in) top
and 1mm (1/32in) bottom rubber covers,
35mm (13/8in) high cleats and a vulcanised
joint.
4242SR
Page 4 - 6
4.2.11 Belt Scrapers Grizzly Fines/Bypass Chute:- Fabricated

in mild steel plate, is provided with a two-
Torsion type belt scrapers with polyurethane way flap door. Material passing over the
blades are fitted as standard and are suitable blank rubber mat (or optional underscreen)
for most applications. Special scrapers can and through the end section of the feeder
be fitted at extra cost but only on machines grizzly bars is discharged to the main product
that are built to a specific order. conveyor via the by-pass chute. Material
Dealer?Customer to specify type if different passing through the under screen (when
from standard. fitted) is discharged to the side dirt conveyor
and the flap door will also allow a portion of
4.2.12 Track Frame the material to be diverted to the main
product conveyor.
Heavy duty track frame having 3.7m (12’-
11/2”) longitudinal centres with 400mm (1’-
4”) wide tracks fitted as standard. 4.2.14 Magnet (optional)
Overband magnetic separator is suspended
Total Plant Weight - approx. 40.82 tonnes over the impactor product conveyor and is
(45 US tons). complete with 1m (39”) long permanent
Overall Track Width - 2.56m (8’- 43/4”). magnet and hydraulic drive.
Plant Operating Height - 4.02m (13’- 21/2”)
Plant Transport Height - 3.44m (11’- 31/2”) 4.2.15 Dust Suppression
Plant Transport Width - 3.10m (10’- 2”)
Plant Transport Length - 15.9m (52’- 2”) Dust suppression spray nozzles are fitted to
the impactor dischatge point and head of the
NB. Transport height excluded trailer. fines conveyor and piped to a central inlet
manifold.
4.2.13 Plant Chutework
4.2.16 Operators Platforms
Impactor Feed Chute:-Fabricated in mild
steel plate with full width single strand chain A steel grid platform is provided on one side
curtain and rubber curtain. Liners are fitted of the feeder and impactor fitted with double
at wear points. row handrails and access ladder. Platforms
are also included to gain access to the rear
of the impactor and to the powerpack.
4242SR
Page 4 - 7
4.2.17 Power-Pack 4.2.20 Guards

Caterpillar C9 six cylinder, water cooled, Wire mesh or sheet metal guards are
emission compliant diesel powerpack provided for all drives, pulleys, couplings,
developing 309 HP (230kW) at 1800 rpm. wedge belts and belt conveyors.
Powerpack is complete with electronic
control system and manually operated Twin The guards provided are designed and
Disc clutch. manufactured to ensure so far as reasonably
practicable that the machinery and plant on
Hydraulic power is provided from the engine which they are fitted can be operated safely
to drive the tracks, feeder, all on-plant and without risk to health when properly
conveyors, sizing screen and overband used.
magnetic separator. All necessary pipework
is provided with steel pipe run to inaccessible 4.2.21 Painting
areas.
The plant is finish painted in blue RAL5015.
4.2.18 Controls
4.2.22 Optional Extras
Feeder controls are mounted on the plant for
the feeder (on/off and speed control) with Standard optional extras, which can be
the engine and other plant controls sited in a added to plants:-
lockable box mounted below the engine.
Miltronics belt weigher.
A control unit is provided for the tracking
function giving a tracking speed of approx. 1 Hydraulically driven water pump
KM/hour (0.62 mph) and a “creep” facility assembly for dust suppression sprays.
for loading, off loading and precise slewing
movements. This also provides stop and Electronic Refuelling pump kit
start control for the vibrating grizzly feeder
from a remote position. Anti-vandal guards
Emergency stop buttons are provided on Wire meshes for feeder underscreen to
each side of the plant. separate scalpings at 10, 20, 30, 40 or 50mm
(0.39, 0.79, 1.25, 1.5 or 2in).
4.2.19 Chassis
Fabricated steel frame of welded
construction with supports for the feeder,
impactor, on-plant conveyors, sizing screen,
power unit, track frame, dirt conveyor and
overband magnetic separator.
4242SR
Page 4 - 8
Grinding path, (not suitable for recycling 4.2.23 Authorisation

applications), fitted in the lower position and
lined with wear resistant impact plates on the This is a requirement of the Environmental
upper section, and reversible manganese Protection Act that the Purchaser must
impact bars on the lower section. When fitted, obtain Local Authority authorisation to
greater control on product size is achieved, operate this plant in the United Kingdom or
together with product shape. Terex Pegson as may be required elsewhere to comply
Limited sales department can advise whether with local regulatory controls.
the grinding path is required following receipt
of full application details prior to the machine 4.2.24 Site Preparation
being built. Under crusher crash box is deleted
The buyer shall be responsible for ensuring
when this option is fitted.
that a suitably prepared, flat and level site is
available for the plant and that the ground is
High Chrome blow bars (not suitable for
capable of sustaining the working of the
demolition applications) or in Martensitic
equipment. Unit dimensions and loadings
steel.
can be provided to the buyer for both
transportation and operating purposes.
Kit of parts required to replace grinding
path consisting of liner plates, crash box,
4.2.25 Commissioning
bolts etc. (Note this is standard on plants
supplied without grinding path). On arrival of the plant on site Terex Pegson
or your local dealer can provide an Engineer
500 mm (20”) wide stockpiling conveyor if required at extra cost to commission the
for the bottom oversize transfer conveyor. plant.
500 mm (20”) wide reversible bottom Feed material, and other essentials to be
deck oversize side transfer conveyor. provided by the buyer in good time for the
commissioning being carried out.
Alternative sizes of screen meshes.
OPTIONAL EXTRAS WHICH CAN BE

OMITTED FROM THE STANDARD
BUILD - this does not apply to plants
already built.
Overband magnetic separator.
Side dirt conveyor (Note: Griizzly fines by-

pass chute will be fitted when the dirt
conveyor is not supplied).
4242SR
5 - Transport EN
Page 5 - 1
5 - Transport
5.1 Safety Information .......................................................................................... 5 - 2
5.2 Transportation ................................................................................................ 5 - 4

5.2.1 Manoeuvring (where radio control unit fitted)
See Section 7.4.3 for alternative umbilical control unit. ............................... 5 - 6
5.2.2 Unloading ................................................................................................. 5 - 11
5.2.3 Loading - from re-circulating mode ........................................................... 5 - 12
5.2.4 Loading - from conveyor stockpiling mode................................................ 5 - 19
4242SR
5 - Transport EN
Page 5 - 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

Terex-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 a suitable lifting platform when

reaching any points 2m (6’- 6”) or more above
ground level.
In-running nip points can cause ENTANGLEMENT

HAZARD
DO NOT reach into an unguarded
machine.
SWITCH OFF, LOCKOUT & TAGOUT machine

before opening or removing guards.
4242SR
5 - Transport EN
Page 5 - 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.
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.
6. Turn the Isolation Switch to ‘O’ when the
plant is not being used (especially while
plant is being transported).
4242SR
5 - Transport EN
Page 5 - 4
5.2 Transportation
! DANGER !
DO NOT stand on any of the
! WARNING ! platforms or ladders of the plant
Prior to attempting any whilst it is being manoeuvred
manoeuvring of the plant the using the remote control handset.
tracks must be free of
obstructions, including crushed Ensure all personnel are clear of
material and fines. Do not push or the plant before manoeuvring.
tow the plant. Failure to observe
this warning could result in When manoeuvring your 4242SR
serious injury to persons and Tracked Impactor to its operating
damage to the plant which may position make sure you stand well
invalidate warranty. clear of the plant but are in a
position to have all-round vision to
Do not manoeuvre the plant with see any obstacles or hazards that
the re-circulating and/or stockpile may lie ahead e.g personnel,
conveyors in their operating overhead cables, ditches, unsafe
positions to avoid damaging the roadways etc. (Refer to Figure 2a
tail drum section(s) on uneven Dimensions)
ground.
• Make sure that you do not
• Before manoeuvring the plant, manoeuvre your 4242SR on a
ensure the feed hopper and crusher gradient (fore and aft directions)
are empty and shut down the plant steeper than 10 degrees in
(Section 8). transportation mode (5 degrees
maximum in operating mode) or
• The plant cannot be manoeuvred in damage may occur to the engine
the PLANT mode of operation. and/or plant.
• The safety warning horn sounds • Avoid manoeuvring the plant over
continuously whilst the plant is being uneven ground where damage could
manoeuvred. occur.
4242SR
5 - Transport EN
Page 5 - 5
• Control valves mounted on the

engine and beneath the feeder are
NOT to be used to manoeuvre the
plant. They are for use by Terex
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 4242SR

Tracked Impactor, it is the
responsibility of the haulage
contractor to safely secure the
plant to the transporter.
4242SR
5 - Transport EN
Page 5 - 6
5.2.1 Manoeuvring (where radio

control unit fitted)
See Section 7.4.3 for alternative
WARNING
WEAR PERSONAL
umbilical control unit.
PROTECTIVE EQUIPMENT.
The plant is manoeuvred using the remote Refer to Section 5.1, Safety
hand held radio transmitter control unit (Fig Information for relevant warning.
5b). 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
1. Observe all safety instructions. function that prevents another function from
involuntary cutting-in when the transmitter
2. Take the Remote Control Hand Set from starts. The transmitter will not start if a
the Control Box and first become button is stuck in the activated position. This
familiar with the functions of all the is indicated by the red LED coming on.
individual buttons (Figure 5b) before the
next step. 4. Ensure the engine Isolation Switch
Forward = Product Conveyor first (Figure 5a) is turned to the I position.
Reverse = Hopper first
3. To start up the handset transmitter first

stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:-
• Ensure the stop button is pulled out.

• Depress both of the safety buttons
(Fig.5b) at the same time for at least
1 second. Release the safety buttons.
• The red LED will change to green.
• The transmitter is in function status
when the green LED comes on.
Figure 5a Isolation Switch
4242SR
5 - Transport EN
Page 5 - 7
PLAN VIEW OF THE PLANT
LED Red/Green
SELECT AND PRESS BUTTON(S) TO MOVE
Forward slow or fast, track 1 & 2
Right turn slow, forward track 1 **Reverse Forward

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

(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
RELEASE BUTTON(S) TO STOP MOVEMENT
**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 5b Remote Control Hand Set
4242SR
5 - Transport EN
Page 5 - 8
Engine Control Panel Plant Control Panel
Figure 5c Control Box
Radio Mode Escape

button button
Figure 5d Selection Screen Display
4242SR
5 - Transport EN
Page 5 - 9
5. On the engine control panel (Figure 5c),

insert the engine Ignition Key and turn
only to the first position. The pre-start
audible warning will sound for 10
seconds during the SYSTEM START
DELAY before the initial screen display
appears on the Control Panel (Figure
5d).
6. Press the RADIO MODE and TRACK

MODE buttons for the LEDs to
illuminate to confirm active status.
7. Fully turn the Ignition Key to start the

engine. Release the key to the first
position when engine running. Keep the
engine speed at 1200 rpm
8. Press the hand set Horn button for 5

seconds to sound the safety warning
horn. This will also ready the tracks for
manoeuvring.
9. The radio handset directional buttons

(forward, reverse and turn) are double
pressure switches with the initial
pressure operating the slow speed mode
and depressing further operates the
higher speed. Press the buttons to
manoeuvre the plant in the desired
direction (Figure 5b). 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) .
4242SR
5 - Transport EN
Page 5 - 10
10. When the 4242SR plant is in the desired

position, press the Horn button to turn
the safety warning horn ‘OFF’ and
disengage the tracks.
11. Press the ESCAPE button on the panel

(Figure 5d) to return to the initial display
screen for the selection of PUMP
MODE, SET UP MODE or PLANT
MODE, as required.
12. If not required further, switch off the

engine ignition. To shut down the radio
handset transmitter, push in the stop
button. Lock out the hand set when
finished with to prevent unauthorised
use.
4242SR
5 - Transport EN
Page 5 - 11
5.2.2 Unloading
The 4242SR Tracked Impactor will arrive on WARNING
site securely fastened to a low loader. It is WEAR PERSONAL
the responsibility of the haulage contractor to PROTECTIVE EQUIPMENT.
remove the fastenings. Refer to Section 5.1, Safety
Information for relevant
Once the plant is unloaded and crushing warning.
operations are to follow, it is necessary to
prepare the plant by following the Set Up
procedures (Section 6).
Procedure
1. Observe all safety warnings.
2. Position easy slope ramps at the end of

the transporter to help with unloading of
the plant.
! NOTICE !
Position the transporting trailer
and unload the plant in an area of
level ground.
When manoeuvring the 4242SR on

or off a transport trailer or at a
sharp change in gradient, make
sure that the overhanging screen
support structure does not foul on
the ground. The maximum
clearance is 550mm (22”).
3. Manoeuvre the 4242SR plant off the

transporter and into the desired position
(Section 5.2.1). Refer to Section 6 for
the Set Up procedures.
4242SR
5 - Transport EN
Page 5 - 12
5.2.3 Loading - from re-circulating

mode WARNING
If the 4242SR Tracked Impactor has been in WEAR PERSONAL
crushing operation it must be suitably PROTECTIVE EQUIPMENT.
prepared prior to transportation. This mainly Refer to Section 5.1 Safety
involves repositioning the conveyors from the Information for relevant
way they operate and, very importantly, warning.
securing all equipment to prevent movement FALLING HAZARD.
during transportation. Refer to Section 5.1 Safety
warning.
! NOTICE !
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.
Procedure
2. Ensure that all the conveyors, feed

hopper and crusher are free from stone
and dirt.
3. On the right hand side of the plant raise

the bottom section of the front ladder
and secure with the bolts (Figure 5e).
4. Remove the dirt conveyor head drum

guard (Figure 5f). This is necessary Figure 5e Front Ladder (shown unfolded)
before folding the conveyor for
transport.
4242SR
5 - Transport EN
Page 5 - 13
Figure 5f Dirt Conveyor Folded and

Secured with Chain
Dirt Conveyor Safety

Chain
Dirt Conveyor
Figure 5g Dirt Conveyor Safety Chain
4242SR
5 - Transport EN
Page 5 - 14
5. Bolt the 2 (or 4) off anti-rock stays at 11. At the control panel (Figure 5d) press
the screen spring mountings on both the SET UP button for the LED to
sides of the machine (Figure 6h).. illuminate to confirm active status with
the message ‘PROCEED TO SET UP
6. Unbolt and securely stow the magnetic STATION’. This is situated on the
separator extension shedder plate opposite side of the plant (Figure 5i).
(Figure 9ab).
Note: The controls for all services are a
7. Unbolt and remove the discharge chutes two handed operation and will only operate
from both transfer conveyors.. if the ‘enable’ button is pressed and held
whilst pressing any of the Set Up buttons.
8. Slide the Top Deck Side Transfer The audible warning will sound whenever
Conveyor back into it’s travelling position the ‘enable button is pressed.
by pulling out the spring loaded locking
pin. Retract the conveyor into the plant
until the locking pins can be fully inserted
into the holes provided (Figure 5h).
Repeat for the bottom deck conveyor if
necessary.
! WARNING !
In step 8, it is most important to
check that the locking pins (Figure
5h) on both Side Transfer
Conveyors are fully inserted into
their respective holes to ensure
the conveyors do not break free
during transportation.
9. Locate the control box and raise the

cover to reveal the control panel and
engine control panel (Figure 7b).
10. Start the engine (Section 7.2.1). Keep

the engine speed at 1200rpm,
4242SR
5 - Transport EN
Page 5 - 15
Conveyor Locking Pins

shown when in transporting mode
Figure 5h Transfer Conveyor Locking Pins
‘Enable’ Button
Figure 5i Set Up Control Station
4242SR
5 - Transport EN
Page 5 - 16
12. Pressing and holding the ‘enable’ button, 15. Pressing and holding the ‘enable’ button,
press the DIRT CONVEYOR RAISE press the RE-CIRC CHUTE LOWER
button until the conveyor is raised to the button to fully lower making sure the
fullest extent. Secure with the loose bottom end of the feed chute
transportation safety chain (Figure 5f support brace does not foul the plant
and 5g). tracks.
16. Detach the feed chute support brace at

! NOTICE ! the top end. Secure the pin and ‘R’ clip
in the bracket against loss (Figure 5j).
During folding of the dirt conveyor
ensure that the hydraulic hoses
17. Remove the pin from the lugs on the re-
and conveyor belt do not foul any circulating conveyor before pressing
part of the structure. and holding the ‘enable’ button and
pressing the button RE-CIRCULATING
! NOTICE ! CONVEYOR LOWER. When the
conveyor is fully lowered fit the securing
Do not under any circumstances pin through the eye of the hinged
lower the re-circulating conveyor transport stay (Figure 5k).
without removing the top
discharge chute and sliding the
upper transfer conveyor into the
! WARNING !
travelling position. Also ensure It is most important the conveyor
that the lower transfer conveyor is is secured to the transport stay as
also in it’s travelling position it would be unstable and might
which is the first hole from the become detached during
head drum end of the conveyor. transportation if not fitted.
13. Pressing and holding the ‘enable’ button,

press the RE-CIRCULATING
CONVEYOR RAISE button to
disengage the support bar at the head
from the feed chute.
14. Detach the feed chute support brace at

the bottom end. Secure the pin and ‘R’
clip in the bracket against loss (Figure
5j).
4242SR
5 - Transport EN
Page 5 - 17
Figure 5j 4242SR Plant shown in Operating Mode
Feed Chute
Support Brace
Figure 5k 4242SR Plant shown in Transport Mode
Re-circulating Conveyor Transport Stay
4242SR
5 - Transport EN
Page 5 - 18
18. Position easy slope ramps at the end of

the transporter to help with loading of the ! WARNING !
plant.
Prior to transporting the 4242SR
ensure that the weight of the
! NOTICE ! screen is lowered onto the
support pins (Figure 5l). To do this
Position the transporting trailer make sure the pin on each side is
and load the plant in an area of in place and operate the SCREEN
level ground. LOWER button. This ensures the
load is taken on the pins rather
When loading the 4242SR on or off than the internal hydraulic rams.
a transport trailer or at a sharp
change in gradient, make sure that
the overhanging screen support
structure does not foul on the
ground. The maximum clearance
is 550mm (22”).
19. Manoeuvre the 4242SR plant onto the

transporter and shut down (Section
5.2.1).
20. To adhere to transport height restrictions

it may be necessary to remove the
engine exhaust stack. Do this only Hydraulic rams inside support leg
when sufficiently cooled.
21. Securing the 4242SR plant to the

transporter is the responsibility of
the haulage contractor. Pin
Figure 5l Screen Support Pin

(left hand side only shown)
4242SR
5 - Transport EN
Page 5 - 19
5.2.4 Loading - from conveyor

stockpiling mode
! WARNING !
Dismounting on-plant conveyor(s)
from the stockpiling mode
involves the use of suitable
craneage and slinging expertise in
addition to the employment of
skilled erection engineers to carry
out the task of both mounting and
dismounting. Undertake only in
these circumstances, making sure
a risk assessment exercise is
carried out prior to commencing
the work.
The procedure is generally the

reverse of that described in Set Up,
Section 6.2.2
4242SR
5 - Transport EN
Page 5 - 20
Blank page
4242SR
6 - Set Up EN
Page 6 - 1
6 - Set Up
6.2 Setting Up ....................................................................................................... 6 - 5

6.2.1 Set Up - Re-circulating Mode ..................................................................... 6 - 5
6.2.2 Set Up - Conveyor(s) mounted in Stockpiling mode .................................. 6 - 12
4242SR
6 - Set Up EN
Page 6 - 2







ground level.
4242SR
6 - Set Up EN
Page 6 - 3

HAZARD
machine.


HAZARD
injury.



4242SR
6 - Set Up EN
Page 6 - 4

followed.
LOCKOUT PROCEDURE

lockout.
4242SR
6 - Set Up EN
Page 6 - 5
6.2 Setting Up
WARNING
Plant Location Considerations
WEAR PERSONAL
Prior to setting up your 4242SR Tracked Refer to Section 6.1 Safety
Impactor, consideration should be given to a Information for relevant
suitable layout to prevent oversize material warning.
or tramp metal from entering the plant. In FALLING HAZARD.
order to prevent bridging of the crusher no Refer to Section 6.1 Safety
material above the size recommended by the Information for relevant
manufacturer should be fed into the plant. warning.
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 plant. 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.
Procedure
6.2.1 Set Up - Re-circulating Mode
2. Remove the pin from the hinged

transport stay on the Re-circulating
Conveyor (Figure 6a). Drop down the
stay and replace the pin to avoid loss.
3. Remove the dirt conveyor transportation

safety chain (Figure 6d).
4242SR
6 - Set Up EN
Page 6 - 6
Figure 6a 4242SR Plant shown in Transport Mode
Re-circulating Conveyor Transport Stay
Figure 6b Initial Screen Display
4242SR
6 - Set Up EN
Page 6 - 7

5. Start the engine (Section 7.2.1) but it is

not necessary to switch on the Radio
Remote Hand Set. Keep the engine
speed at 1200rpm.
NB. Before attempting to start the

engine refit the engine exhaust stack if
this has been removed to reduce the
travel height.
6. At the control panel (Figure 6b) press

the SET UP button for the LED to
illuminate to confirm active status with
the message ‘PROCEED TO SET UP ‘Enable’ Button
STATION’. This is situated on the
opposite side of the plant (Figure 6c).

two handed operation and will only
operate if the ‘enable’ button is pressed
and held whilst pressing any of the Set
Up buttons. The audible warning will
sound whenever the ‘enable’ button is
pressed.
7 Pressing and holding the ‘enable’ button,

press the button RE-CIRCULATING
CONVEYOR RAISE until the conveyor
is at maximum height.
Figure 6c Set Up Control Station
4242SR
6 - Set Up EN
Page 6 - 8

press the RE-CIRC CHUTE RAISE ! NOTICE !
button to partially raise until the feed
During lowering of the dirt
chute support brace can be easily
attached at the top and secured with the
conveyor ensure that the
pin and ‘R’ clips (Figure 5j). Complete hydraulic hoses and conveyor belt
the elevation of the feed chute until the do not foul any part of the
support brace (Figure 6f) can be secured structure. Do not operate the plant
in the bottom bracket with the pin and ‘R’ with the dirt conveyor folded.
clip.
11. Switch off the engine (Section 8.2) and
9. Pressing and holding the ‘enable’ button, implement the lockout procedure.
press the RE-CIRCULATING
CONVEYOR LOWER button until the 12. Slide the upper transfer conveyor into it’s
support bar at the head locates fully into working position by pulling out the spring
the gussets on the feed chute. Then loaded locking pin. Push the transfer
press the RE-CIRCULATING conveyor towards the re-circulating
CONVEYOR RAISE until the wire conveyor to allow the locking pin to
support rope is just taut. locate into the second hole from the end.
Ensure the locking pin is fully inserted
into the hole (Figure 6e).
! NOTICE !
Do not under any circumstances
lower the re-circulating conveyor
without removing the top
discharge chute and sliding the
upper transfer conveyor into the
travelling position. Also ensure
that the lower transfer conveyor is
also in it’s travelling position
which is the first hole from the
head drum end of the conveyor.
10. Lower the dirt conveyor fully by pressing

and holding the ‘enable’ button and
pressing the DIRT CONVEYOR
LOWER button.
4242SR
6 - Set Up EN
Page 6 - 9
Dirt Conveyor Safety

Chain
Dirt Conveyor
Figure 6d Dirt Conveyor Safety Chain
Discharge Chute
Conveyor Locking Pins

shown when in operating mode
Figure 6e Transfer Conveyor Locking Pins
4242SR
6 - Set Up EN
Page 6 - 10
Figure 6f 4242SR Plant shown in Operating Mode
Feed Chute
Support Brace
Figure 6h Screen Anti-Rock Stays
Figure 6g Front Ladder (shown unfolded)
4242SR
6 - Set Up EN
Page 6 - 11
13. Hang the discharge chute (complete with

rubber curtain) for upper transfer ! WARNING !
conveyor onto the mounting bolts and
Prior to operating the 4242SR
tighten.
ensure that the weight of the
14. Leave the lower transfer conveyor in
screen is lowered onto the
place and hang the lower chute onto the support pins (Figure 6i). To do this
mounting bolts and tighten. make sure the pin on each side is
in place and operate the SCREEN
15. Replace and secure the dirt conveyor LOWER button. This ensures the
head drum guard and side skirts. load is taken on the pins rather
than the internal hydraulic rams.
16. On the right hand side of the plant raise
the bottom section of the front ladder
and secure with the bolts (Figure 6g).
17. Remove the anti-rock stays at the screen

spring mountings on both sides of the
machine (Figure 6h).
Hydraulic rams inside support leg
Pin
Figure 6i Screen Support Pin

(left hand side only shown)
4242SR
6 - Set Up EN
Page 6 - 12
6.2.2 Set Up - Conveyor(s) mounted conveyor(s) suspended out from the plant.
in Stockpiling mode
Before repositioning the re-circulating
conveyor, retract the upper side transfer
! WARNING ! conveyor, first removing the discharge chute
Fitting on-plant conveyor(s) to and also fully lower the return chute. In
stockpile material involves the use order to reposition the re-circulating
of suitable craneage and slinging conveyor it is first necessary support the
conveyor with suitable lifting equipment and
expertise in addition to the
appropriate length slings using both the upper
employment of skilled erection and lower lifting points (Figure 6k). Operate
engineers to carry out the task of the CONVEYOR LOWER control (Section
both mounting and dismounting. 6.2.1) to fully extend the wire rope hydraulic
Undertake only in these cylinder. Disconnect the conveyor at the
circumstances, making sure a upper stay, pivot point and at the quick
Risk Assessment exercise is release hydraulic couplings so that the unit
carried out prior to commencing can be lifted clear of the plant.
the work.
Using the separate bracket kit supplied, bolt
The plant design includes the facility to to the plant structure (Figure 6j). Position the
alternatively use the plant mounted re- conveyor at right angles to the plant and drop
circulating conveyor as a stockpile conveyor. the tail locating bar into the brackets.
This involves lifting the conveyor off the Operate the CONVEYOR RAISE control
plant and remounting the tail end at right (Section 6.2.1) so that the tie bar (supplied
angles whilst the head is suspended with the as part of the separate kit of parts) can be
same wire rope system used when re- secured in position. Do not operate the plant
circulating. This conveyor takes material without this tie bar being fitted. Do not press
from the upper side transfer conveyor but, CONVEYOR RAISE/LOWER buttons
additionally if required, also from the lower once the tie bar is fitted as damage will
transfer conveyor (Figure 6k). result. When the conveyor is fully supported
off the plant and all security pins are in
Additionally, a similar conveyor is available place, disconnect the lifting gear slings.
as an optional extra which can be mounted in
the same fashion on the opposite side of the Reconnect the hydraulic hoses at the quick
plant to form a stockpile for material release couplings. Pull out the upper (or
discharging from the lower side transfer lower) side transfer conveyor and refit the
conveyor. This conveyor assembly requires chutework. Test for correct running, belt
transporting separately from site to site. tracking, etc. before crushing operations.
Setting up the plant mounted stockpile The optional stockpile conveyor is supplied
conveyor(s) is an operation carried out once with a kit of parts to fit in a similar fashion.
the plant is in the operating position. The
plant should not be moved with the
4242SR
6 - Set Up EN
Page 6 - 13
Detachable Brackets for

mounting the conveyor
tail
Security Bolts - must be

fitted before operation
Figure 6j Stockpile Conveyor Tail Mounting
Wire Rope Support with

hydraulic cylinder
Cranage lifting slings
Tie Bar (hidden on far side)

- must be fitted before
operation
Figure 6k Positioning the Conveyor for Stockpiling
4242SR
6 - Set Up EN
Page 6 - 14
Blank page
4242SR
7 - Operating Instructions EN
Page 7 - 1
7 - Operating Instructions

7.1.1 Blocked Crusher Procedures ..................................................................... 7 - 4
7.2 Safe Start-Up Procedure ................................................................................ 7 - 5
7.2.1 Engine Start-Up .......................................................................................... 7 - 6
7.2.2 Crusher Engagement ................................................................................. 7 - 8
7.2.3 Plant Start-Up ............................................................................................. 7 - 9
7.2.4 Feeder Engagement ................................................................................ 7 - 11
7.2.5 Engine Diagnostic Functions .................................................................... 7 - 12
7.2.6 Active Plant Alarms .................................................................................. 7 - 14
7.2.7 Dirt Conveyor Disengagement ................................................................. 7 - 15
7.3 Safe Operation of the Plant .......................................................................... 7 - 16
7.3.1 Checks Prior to Initial Daily Start............................................................... 7 - 17
7.3.2 Initial Start Up and Running In ................................................................... 7 - 18
7.4 Remote Radio Control.................................................................................. 7 - 21
7.4.1 Feeder Remote Control............................................................................ 7 - 23
7.4.2 Radio Hand Set (where fitted) .................................................................. 7 - 24
7.4.3 Alternative Control Hand Set (with Umbilical Cable) .................................. 7 - 26
4242SR
Page 7 - 2







ground level.

HAZARD
machine.

4242SR
Page 7 - 3

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
4242SR
Page 7 - 4
7.1.1 Blocked Crusher Procedures

It is the responsibility of the Owner, End WARNING
User and/or Safety of the 4242SR Tracked WEAR PERSONAL
Impactor plant to provide a safe means of PROTECTIVE EQUIPMENT.
dealing with oversize material and construct Refer to Section 7.1, Safety
a safe procedure for unblocking a stalled Information for relevant
machine which is full of material. warning.
LOCKOUT MACHINE.
To comply with British Health and Safety Refer to Section 7.1, Safety
Law it is necessary to conduct an adequate Information for Lockout Proce-
risk assessment of the procedures for dure.
unblocking a blocked crusher.
Should an oversize piece of material be fed

to a crusher and cause the feed opening to
be bridged the recommended procedure for In the case of a stalled crusher it should
removing this is to open the crusher (as always be treated as possibly being jammed
described in Section 9.5) if the bridged with tramp metal. A safe system of work
material is not accessible otherwise. Only should be devised for approaching this
open the crusher slowly with caution and situation due to the potential dangers of
with all personnel well clear. A crane and tramp metal being released. Due care and
hook can be used although EXTREME attention should be given to where the
caution must be exercised to ensure that the released tramp metal will fall to avoid any
crane is not overloaded by trying to lift a injury to personnel. Once this has been
jammed rock. decided it should be incorporated into a
permit to work procedure to be issued by the
The following methods SHOULD NOT be manager. This system should cover things
attempted.:- such as notification to the manager, isolation,
methods of removal of excess stone, safe
The use of wedges. positions for personnel. Should any further
information be required with regard to the
Using mobile plant to drag stones out of the clearance of blocked crushers then
crusher or feeder. reference can be made to the British
Aggregate Construction Materials Industries
Under most arrangements pinch bars and (BACMI) document “ Clearing Blocked
hand hammers cannot be used safely. Their Crushers “. This document provides
use should be limited to situations under risk recommended procedures and advice on risk
assessment where there is every indication assessment.
that they can be worked safely.
4242SR
Page 7 - 5
7.2 Safe Start-Up Procedure • Check that the Emergency Stops are
pulled out (Figure 1a).
! WARNING ! • Ensure the engine clutch is disengaged

(lever fully towards the crusher drive
Terex Pegson Ltd. cannot guard) and the engine speed is 1200 rpm
overemphasise the need to ensure (Figures 7b and 7c).
that all safety aspects are checked
before starting the engine. • Check that all guards are in position and
secure and that all personnel are clear of
Whilst the engine is running and the plant.
the Operation switch is turned
from ‘TRACK’ to ‘PLANT’ mode the • Ensure that the recirculating system has
safety warning horn will sound for been properly set up and the screen/
10 seconds. When the horn has conveyors are in the operating (ie.
PLANT MODE).
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 size of the engine pulley

is correct for the crushing application
(refer to section 4.2.1 for correct pulley
size for crushing duty and section 9.11.3
if change required)
• Check that the crushing chamber and

feed hopper are empty.
• Measure the crusher settings and adjust

if necessary. (Section 9.6)
4242SR
Page 7 - 6
7.2.1 Engine Start-Up

When operating the 4242SR in PLANT WARNING
MODE the plant operator has the facility to WEAR PERSONAL
use the Radio Hand Set (where fitted) to PROTECTIVE EQUIPMENT.
switch the Feeder ‘on’ and ‘off’ remotely. Refer to Section 7.1, Safety
For this purpose the Radio Hand Set must be Information for relevant
switched on prior to starting the engine in the warning.
manner described below.
Procedure
2. Take the Remote Control Hand Set from

the Control Box. See Figure 7i for the
button functions.
3. To start up the handset transmitter first

stand well clear of the plant. Hold the
hand set with the stop button nearest to
the operator and proceed as follows:-
• Ensure the stop button is pulled out.

• Depress both of the safety buttons
(Fig.7i) at the same time for at least
Figure 7a Isolation Switch
1 second. Release the safety buttons.
• The red LED will change to green.
• The transmitter is in function status
when the green LED comes on.
Note: The transmitter has a built in safety

function that prevents another function from
involuntary cutting-in when the transmitter
starts. The transmitter will not start if a
button is stuck in the activated position. This
is indicated by the red LED coming on.
4. Ensure the engine Isolation Switch

(Figure 7a) is turned to the I position.
4242SR
Page 7 - 7
5. On the engine control panel (Figure 7b), 6. Press the RADIO MODE and PLANT
insert the engine Ignition Key and turn MODE buttons for the LEDs to
only to the first position. The pre-start illuminate to confirm active status.
audible warning will sound for 10
seconds during the SYSTEM START 7. Fully turn the Ignition Key to start the
DELAY before the initial screen display engine. Release the key to the first
appears on the Control Panel (Figures position when engine running. Keep the
7d & 7e). engine speed at 1200 rpm.
Speed Control Maintenance Due Lamp
Ignition Key EMS Scroll Switch Diagnostic Lamp
US/Metric Switch Fuel Gauge Tachometer
Figure 7b Engine Control Panel
4242SR
Page 7 - 8
7.2.2 Crusher Engagement

After starting the engine (Section 7.2.1) the
WARNING
Impact Crusher must be started with the WEAR PERSONAL
engagement of the manually operated clutch PROTECTIVE EQUIPMENT.
lever (Figure 7c) whilst the engine is still Refer to Section 7.1, Safety
running at 1200 rpm. and before proceeding Information for relevant
to start the various plant conveyors, sizing warning.
screen, etc. (Section 7.2.3).
It is important that no material passes ! NOTICE !

through the Impact Crusher whilst the On
Plant Conveyor taking the discharge from To avoid damaging the clutch DO
the crusher is not running. NOT increase the engine speed to
the operating 1850 RPM until after
starting the Crusher (Section 7.2.2)
Procedure
1. Observe all Safety Warnings.
Crusher Drive Guard
2. Slowly engage the clutch by pulling the
clutch lever away from the crusher drive
guard (Figure 7c) until the crusher is up
to speed, then pull over fully to maintain
drive engagement..
3. Using the Speed Control switch (Figure

7b) increase the engine speed to 1850
rpm, viewed on the Tachometer .
4. Check the plant is stable with no

excessive vibration. If necessary,
reposition the plant on firm, level area
with full length of both tracks in contect
with the ground.
Figure 7c Clutch Lever
4242SR
Page 7 - 9
7.2.3 Plant Start-Up

Once the Impact Crusher has been started
WARNING
(Section 7.2.2) the running of the plant WEAR PERSONAL
conveyors, sizing screen, etc. is performed at PROTECTIVE EQUIPMENT.
the main Control Panel (Figure 7d). Refer to Section 7.1, Safety
When PLANT MODE has been selected warning.
the normal operating screen is displayed on
the control panel (Figure 7e). The system
can now be operated in the normal sequence
as described below.
Operation of each button sounds the pre

start alarm for 3 seconds and flashes the
associated LED before running the item.
The LED will then show continuous
illumination to confirm the item is enabled.
The PLANT MODE items operate in a pre-

defined sequence to ensure downstream
items are running first.
! NOTICE !
! NOTICE !
When not in use, the Dirt
The OUT OF SEQUENCE facility Conveyor hydraulic drive can be
button is NEVER to be used in disconnected by means of two
normal operation and, when change over valves situated at the
pressed, the message ‘warranty rear of the chassis. See Section
invalid’ will be displayed. 7.2.7.
Procedure 3. Press SCREEN & FINES button to start

the Screen and the Fines Conveyor.
4. Press OPC & MAGNET button to start
2. Press CONVS & DIRT button to start the On Plant Conveyor and Magnetic
the 2 x Side Transfer Conveyors, the Re- Separator.
circulating Conveyor and the Dirt
Conveyor.
4242SR
Page 7 - 10
Engine Control Panel Plant Control Panel

Figure 7d Control Box
Radio Mode Escape

button button
Figure 7e Feeder/Conveyor/Screen Controls
4242SR
Page 7 - 11
7.2.4 Feeder Engagement

The feed rate can be varied between 0 to WARNING
100 percent using the INCrease and WEAR PERSONAL
DECrease buttons (Figure 7e). PROTECTIVE EQUIPMENT.
Refer to Section 7.1, Safety
It is recommended that initially 50% should Information for relevant warning.
be selected to evaluate the material flows
are satisfactory on the conveyors and over
the screen deck(s). Particularly check to
ensure the oversize material being rejected
back to the crusher via the Re-circulating
conveyor is not excessive.
Procedure
2. Select the FEEDER RATE % on the

display screen.
3. Press the FEEDER button to start the

Feeder and thus commence crushing.
! NOTICE !
The Feeder can be switched ‘on’
and ‘off’ remotely using the Radio
Hand Set (Section 7.4.1). However,
the speed cannot be adjusted from
the remote hand set.
4242SR
Page 7 - 12
7.2.5 Engine Diagnostic Functions
DIAGNOSTIC DISPLAY
The main unit has ten warning lamps available for system related diagnostics.
These diagnostics can be used for system troubleshooting and diagnostic information.
They are located on the main EMS unit in two rows of five:
High Engine Coolant Low Engine Oil Pressure

Temperature or Sensor Fault or Sensor Fault
High Inlet Manifold Low Fuel Pressure

Temperature or Sensor Fault or Sensor Fault
High Fuel Temperature Low Engine Coolant Level
or Sensor Fault or Sensor Fault
Low Battery Voltage

Engine Derate
or Sensor Fault
High Auxiliary Temperature High Auxiliary Pressure
or Sensor Fault or Sensor Fault
Figure 7f Caterpillar Engine Diagnostic Panel
4242SR
Page 7 - 13
Engine Diagnostic Functions - EMS Main Unit, continued
LCD Display
Beneath the warning lamps is an LCD digital display for engine parameters.
Display Scroll Feature
Each time the scroll forward switch (Figure 7d) is depressed and held, EMS will page through the
engine parameters in the order listed below. When the scroll backward is depressed and held, EMS will
page through the engine parameters in reverse order. The abbreviation for the parameter will be
displayed. When the scroll switch is released, EMS will display the current ‘real time’ value for that
parameter.
Abbreviation Parameter
Spd Engine Speed

GA-1 Engine Oil Pressure
GA-2 Coolant Temperature
GA-3 Battery Voltage
GA-4 Fuel Pressure
Boost Boost Pressure
IAirT Inlet Air Temperature
FuelT Fuel temperature
AccrP Auxiliary Pressure
AccrT Auxiliary Temperature
Fuel Fuel Rate
Hrs Engine Hours
Load Engine (Percent) Load
4242SR
Page 7 - 14
7.2.6 Active Plant Alarms

The plant Control Panel will display a WARNING
number of alarm situations should these WEAR PERSONAL
occur. PROTECTIVE EQUIPMENT.
When an active alarm occurs the Feeder will Information for relevant warning.
stop, the plant siren will sound and the
appropriate fault message will appear on the
screen together with ACKN ALARM
(Figure 7g).
Pressing the button below the ACKN ! NOTICE !

ALARM message will mute the siren but if
the system remains switched on and the fault A fault must be rectified before
is not rectified, the siren will repeat after a crushing operations can be
preset period of 5 minutes. resumed.
Figure 7g Selection Screen Display
Active Alarm Message Displays - with audible warning sound
1 EMERGENCY STOP FAULT - twist emergency stop knob to release

2 RADIO STOP FAULT - pull out stop knob on hand set
3 OIL LEVEL LOW FAULT - top-up to level on gauge
4 PRODUCT CONVEYOR PRESSURE HIGH
5 IMPACTOR DOOR OPEN
9 ENGINE OVERLOAD - FEED INHIBIT
10 ENGINE OVERLOAD - CUT OUT
11 CAN BLOCK ERROR
12 CAN BUS ERROR
13 OUTPUT ERROR - VALVE FAULT
4242SR
Page 7 - 15
7.2.7 Dirt Conveyor Disengagement

Material passing through the Feeder grizzly WARNING
bars can either be extracted from the plant WEAR PERSONAL
via the Dirt Conveyor or may by-pass the PROTECTIVE EQUIPMENT.
Impactor Crusher and discharge onto the On Refer to Section 7.1, Safety
Plant Product Conveyor. In the latter Information for relevant warning.
situation the Dirt Conveyor hydraulic drive
can be disengaged by means of two change-
over valves situated at the rear of the plant
chassis.
5. Follow the Plant Start-Up procedure
! WARNING ! (Section 7.2.3)
For the safety of personnel and

also for technical reasons, do not
make the change-over whilst the
plant is in operation.
Procedure
2. Close down the plant (Section 8.2) and

implement the Lockout Procedure
3. Rotate the levers on the valves (Figure

7gg) so that both levers are either
positioned vertically or horizonally.
Levers Vertical = Dirt Conveyor OFF

Levers Horizontal = Dirt Conveyor ON
Note: To ensure that the levers are not

moved inadvertantly during operation,
remove and store safely in the tool box.
4. If the Dirt Conveyor is to be used make Valve Levers

sure that it has been lowered (Section
6.2.1)
Figure 7gg Dirt Conveyor Control Valves
(positioned for conveyor OFF)
4242SR
Page 7 - 16
7.3 Safe Operation of the

Plant WARNING
WEAR PERSONAL
! WARNING ! Refer to Section 7.1, Safety
NEVER leave your 4242SR
warning.
Tracked Impactor unattended
whilst it is in operation.
DOcheck regularly that the oil

cooler fan (located adjacent to the ! NOTICE !
transfer conveyors) is running
Regular lubrication of the plant
correctly and that dust/dirt has not
machinery in accordance with the
built up in the fan and radiator unit
Lubrication and Servicing
(over heating can occur if dust/dirt
Schedule (Section 9.4.3) is
is allowed to build up). Blow out
essential.
dust/dirt if necessary.
DO NOT allow a build up of

material at the feed on points to
enter either the product conveyor
or dirt conveyor.
DO check frequently the stability

of the plant. The chassis SHOULD
NOT bounce during operation.
DO NOT allow the engine RPM to

drop below it’s operating speed,
and DO NOT slip the engine
clutch.
AVOID frequent starting and

stopping of your 4242SR plant
unnecessarily as it WILL cause
damage to the plant.
4242SR
Page 7 - 17
7.3.1 Checks Prior to Initial Daily

Start WARNING
Plant WEAR PERSONAL
• Visually check the plant and ensure that Refer to Section 7.1, Safety
all guards and warning signs (Section 1) Information for relevant
are in position and that all equipment and warning.
tools that are hazardous to operation are
removed from the immediate site.
• Ensure that the impact crusher clutch on

the diesel engine is disengaged. ! DANGER !
Other than when operating the
• Ensure that the impact crusher and the engine clutch, the impact crusher
grizzly feeder hopper are empty.
and grizzly feeder must be
stationary and disabled at the
• Check setup of the impact crusher and
adjust as necessary to the required engine control panel.
settings (refer to Sections 3.4 and 9.6).
Discontinue loading the feed
• Check the oil cooler fan and radiator unit hopper when the operator is
(located near the transfer conveyors) for attending to the controls on the
any build up of dust/dirt. Blow out dust/ feeder/conveyor box.
dirt if necessary.
• Before putting the plant into operation

check that all emergency stop buttons
are operative. (refer to Section 8.3)
! DANGER !
The plant should be fed by an
excavator such that the bucket
does not pass over or near to
personnel.
DO NOT STAND ON THE UPPER

MAINTENANCE PLATFORM
WHILST THE IMPACT CRUSHER
AND FEEDER ARE OPERATING.
4242SR
Page 7 - 18
7.3.2 Initial Start Up and Running In

Initial Start-Up WARNING
WEAR PERSONAL
• Check the vibrating unit oil level and PROTECTIVE EQUIPMENT.
hydraulic oil level (Figure 7h & 7i). Refer to Section 7.1, Safety
• Refer to engine manual for engine initial warning.
start up.
• Run the plant empty for a short period of

time and check for abnormal noises,
vibration or excessive heat from the shaft Crusher
bearings.
1. Regularly check drive belts (crusher and
Actions During Running-In Period hydraulic pumps) to ensure correct
tension, particularly during the initial 2
weeks of use (Section 9.11).
! NOTICE !
Checks on the plant are crucial 2. Check the alignment and tension of the
during the first week of operation. vee belt drive daily during the initial days
The following section should be of operation (Section 9.11).
read and understood prior to
3. Check the shaft bearing temperature
starting the plant. If there are any
daily using a contact thermometer and
doubts, contact Terex Pegson Ltd. record for future reference and fault
Service Department. diagnosis. The maximum acceptable
working temperature is 80°C (176°F).
Plant
4. Avoid overloading the crusher; restrict
1. Each day during the initial days of loading to 50% and 75% of full capacity
operation check the tension of the during the first and second days of
conveyor belts on the main product operation respectively.
conveyor and dirt conveyor..
5. Ensure that all drives are running before
2. Check frequently the overall stability of any feed is introduced to the plant and
the plant; re-check the level of the plant that the feed is maintained at a constant
and re-level if necessary. rate, irregular and excessive feed rates
reduce the efficiency of the plant.
3. After several days use re-check clutch
engagement torque as described in
Section 9.15.
4242SR
Page 7 - 19
Hydraulic Oil Return Hydraulic Oil

Filter and Gauge Breather/Filler
Hydraulic Oil Level Hydraulic Oil Tank
Figure 7h Hydraulic Oil Tank & Level Indicator
Oil Filler Plug
Oil Level
Sight Glass
Oil Drain Plug
Figure 7i Feeder Vibrating Unit
4242SR
Page 7 - 20
Feeder
1. Frequently check the oil levels in the

WARNING
vibrating unit end covers and the WEAR PERSONAL
hydraulic oil level in the tank (Figure 7h PROTECTIVE EQUIPMENT.
& 7i). Refer to Section 7.1, Safety
warning.
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 [176°F] ) .
4. Ensure that the vibrating unit is operating

before any feed is introduced to the plant
fee hopper.
Screen
1. Ensure that the tension of the screen

mesh(es) is satisfactory.
2. Check the drive ropes are correctly

tensioned.
3. Frequently check the flow of material

over the screen mesh(es) to confirm
satisfactory separation is taking place.
4. Make sure that the screen mesh

apertures are free of ‘pegged’ material
and that they remain in good condition.
5. 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 [176°F] ).
4242SR
Page 7 - 21
7.4 Remote Radio Control • To use the remote hand set to switch the
feeder on/off during crushing operations
refer to Section 7.2.1
! DANGER !
• For recharging the hand set battery, see
DO NOT stand on any of the Section 7.4.2
platforms or ladders of the plant
whilst it is being manoeuvred • When the plant is not operating take the
using the remote control handset. opportunity to recharge the internal
battery. For convenience a lead is
When manoeuvring your plant to supplied to plug into 12/35 volt DC
it’s operating position make sure vehicle cigar lighter point.
you stand well clear of the
machine but are in a position to • In the event of the remote radio hand set
have all-round vision to see any being inoperable for any reason, the
alternative ‘umbilical’ hand set is
obstacles, dangers that may lie
supplied (Section 7.4.3).
ahead e.g. personnel, overhead
cables, ditches, unsafe roadways • If the hand set transmitter does not start
etc. when the two safety buttons are
(Refer to Figure 2a for dimensions) depressed at the same time for at least 1
second (Section 5.2.1), check if the stop
button is pushed ‘in’, or the battery
! NOTICE ! needing a recharge.
The 4242SR Tracked Impactor
remote control system is supplied
to the following:-
Radio System/Umbilical handset.
• If the plant moves out of the operating

range of the remote control hand set the
plant will stop.
• Operating the stop button on the remote

hand set whilst the plant is in either
TRACK or PLANT (Feeder Remote
switch ‘on’) operating mode will stop the
engine.
• To manoeuvre the plant with the remote

hand set, refer to the instructions in
Section 5.2.1.
4242SR
Page 7 - 22
LED Red/Green
Right turn slow, forward track 1 **Reverse Forward

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

(Horn) (Feeder On/Off)
RELEASE BUTTON(S) TO STOP MOVEMENT 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 7j Remote Control Hand Set
4242SR
Page 7 - 23
7.4.1 Feeder Remote Control

To use this facility the Radio Hand Set must WARNING
be switched on prior to starting the engine. WEAR PERSONAL
Procedure
1. Remove the Radio Remote Hand Set warning.
from the Control Box (Figure 7b).
2. Ensure that the Emergency Stops on the

plant and the stop button on the hand set
are pulled out (Figures 1a and 7k).
3. Follow the procedures in Sections 7.2.1

to 7.2.4.
4. Stop and start the Feeder by pressing the Feed Conveyor

hand set button (Figure7k). stop/start button
Stop Button
Figure 7k Feeder Remote Operation
4242SR
Page 7 - 24
7.4.2 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 to

35VDC instead of 12/24VDC, no
universal adapter required. TRANSMITTER 860TX-PEG
• Battery capacity is changed from 800mA

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

radio hand set transmitter
Button 9 = Used to activate the audible

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

feeder (where appropriate)
4242SR
Page 7 - 25
Two versions of the 860 system transmitter

will be supplied, one for European
Operations and one for the Rest of the
WARNING
World. The only difference is that the WEAR PERSONAL
European version will include a black stop PROTECTIVE EQUIPMENT.
button. The Rest of the World transmitter Refer to Section 7.1, Safety
will feature a Red Stop button. Channel 01 Information for relevant warning.
(434.650 MHz) through channel 16 (433.900
MHz) available in .050 MHz steps. Refer to
Dealer if frequency change needed.
Battery Recharging
The remote control handset includes a built

in chargeable batteries and a charging
contact point on the back of the unit (Figure
7l). 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
indicates it is time to recharge. The plant
warning horn will also sound when
battery recharging is required Charging point
• To conserve the battery charge the hand Figure 7l Remote Control

set should be switched off when not in Charger Connection
use.
4242SR
Page 7 - 26
7.4.3 Alternative Control Hand Set

(with Umbilical Cable) WARNING
As an alternative to the radio remote control WEAR PERSONAL
hand set, a hand set with umbilical cable is PROTECTIVE EQUIPMENT.
supplied to manoeuvre the 4242SR (Figure Refer to Section 7.1, Safety
7m). Information for relevant
warning.
Connecting and using the Umbilical
Control Hand Set
Procedure
2. Close down the plant (Section 8.2).
3. Locate the connection point (Figure 7n)

on the Control Panel..
4. Plug in the umbilical control hand set.
5. On the engine control panel (Figure 7b),

insert the engine Ignition Key and turn
only to the first position. Wait 8/10 Figure 7m Umbilical Control Hand Set
seconds until the initial screen display to
appear on the Control Panel (Figure 7e).
6. Press the TRACK MODE button for

the LED to illuminate and to confirm
active status.
7. Fully turn the Ignition Key to start the

engine. Release the key to the first
position when engine running. Keep the
engine speed at 1200 rpm.
Figure 7n Umbilical Connection Point
4242SR
Page 7 - 27
8. Press the Horn button for 5 seconds to

sound the safety warning horn. This will ! DANGER !
also ready the tracks for manoeuvring.
Extreme care must be used when
manoeuvring the plant with the
9. The umbilical handset directional buttons
(forward, reverse and turn) are double
umbilical control hand set. Stand
pressure switches with the initial as far away as possible from the
pressure operating the slow speed mode plant. Do not allow the cable of the
and depressing further operates the hand set to sag and become
higher speed. entangled with the tracks.
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).
10. 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 7o). Employ
the ‘Fast’ speed only where safe to do
so.
11. When the plant is in the correct position,

press the Horn button to turn the safety
warning horn ‘OFF’ and disengage the
tracks. Shut down the plant with the
hand set stop button. Turn off the engine
ignition.
12. Unplug the umbilical cable and replace

with the original plug (where radio unit
fitted). Store the umbilical hand set unit
in the tool box to keep available for
future use,
4242SR
Page 7 - 28
Right turn slow, forward track 1 **Reverse Forward **

Left turn slow, forward track 2 **Left Turn Right Turn **
(forward travel) (forward travel)
Reverse slow or fast, track 1 & 2
Not used Not used
Safety Button Not used
Left turn slow, reverses track 2 (Horn)

Stop Button
RELEASE BUTTON(S) TO STOP MOVEMENT
**Double pressure buttons - 1st pressure = slow speed / 2nd pressure = fast speed
Figure 7n Remote Umbilical Control Hand Set
4242SR
8 - Shut Off EN
Page 8 - 1
8 - Shut Off
8.2 Closing Down the Plant ................................................................................. 8 - 4
8.3 Emergency Stopping of the Engine .............................................................. 8 - 8

8.3.1 Emergency Stop Buttons ............................................................................ 8 - 9
8.3.2 Testing Buttons ........................................................................................... 8 - 9
4242SR
8 - Shut Off EN
Page 8 - 2







ground level.

HAZARD
machine.

4242SR
8 - Shut Off EN
Page 8 - 3

HAZARD
injury.




followed.
LOCKOUT PROCEDURE

lockout.
4242SR
8 - Shut Off EN
Page 8 - 4
8.2 Closing Down the Plant

WARNING
The closing down procedure must be carried
WEAR PERSONAL
out in the reverse order to that for starting
the plant. After stopping the feeder, keep the
remainder of the plant running until the Information for relevant warning.
screen and conveyors (particularly the re-
circulating) are clear of material. This may LOCKOUT MACHINE.
take several minutes to complete. Refer to Section 8.1, Safety
Information for Lockout
On pressing a panel control button the LED Procedure.
will extinguish to show that item is now
inactive.
Procedure
2. On the Control Panel (Figure 8a), press

the FEEDER button to stop the feeder.
DO NOT proceed to the next step
until the screen and all conveyors
are clear of material.
3. Press the ON PLANT CONVEYOR &

MAGNET button to stop the product
conveyor and also the magnetic
overband separator.
5. Press the SCREEN & FINES button to

stop the screen and fines conveyor..
6. Press the CONVEYORS & DIRT

button to stop the plant conveyors (other
than the ‘on plant conveyor’).
7. Using the engine speed control, decrease

the engine rpm to 1200rpm (Figure 8d).
4242SR
8 - Shut Off EN
Page 8 - 5
8. Disengage the engine clutch by slowly

moving the clutch lever (Figure 8b)
towards the crusher drive guard (this will
disengage the crusher).
9. Let the engine idle for 3-5 minutes.
10. Turn the Ignition Key to the off position

to shut down the engine. Remove the
Ignition Key. Shut and lock the Control
Box door. Lockout the Isolation Switch
(Figure 8c).If the radio hand set (where
fitted) has been in use, shut down by
depressing the stop button on the unit.
11. Following the closing down procedure

above, it is recommended that at the end
of operation for the day the plant is
routinely cleaned down and thoroughly
examined to check for any damage,
breakages, wear, leaks etc. which should
be rectified before further operation.
! NOTICE !
Use of high pressure washing
equipment is to be avoided where
the ingress of water will be
detrimental to plant components
eg crusher bearings, conveyor
bearings, hydraulic tank, electrical
equipment etc.
Do not use the emergency stop

buttons for routinely stopping the
plant.
4242SR
8 - Shut Off EN
Page 8 - 6
Radio Mode Escape

button button
Figure 8a Feeder/Conveyor/Screen Controls
Figure 8b Clutch Lever Figure 8c Engine Isolation Switch

(manual clutch)
4242SR
8 - Shut Off EN
Page 8 - 7
Speed Control Maintenance Due Lamp
Ignition Key EMS Scroll Switch Diagnostic Lamp
US/Metric Switch Fuel Gauge Tachometer
Figure 8d Engine Control Panel
4242SR
8 - Shut Off EN
Page 8 - 8
8.3 Emergency Stopping of

the Engine WARNING
WEAR PERSONAL
IN AN EMERGENCY STOP PROTECTIVE EQUIPMENT.
SITUATION, STOP THE ENGINE Refer to Section 8.1, Safety
(AND PLANT OPERATION ) USING Information for relevant warning.
THE EMERGENCY STOP BUTTONS.
LOCKOUT MACHINE.
(See Section 1, Figure 1a, for locations Refer to Section 8.1, Safety
of all the emergency stop buttons). Information for Lockout
Procedure.
When the plant has been stopped using
the emergency stop button the Ignition
Switch stays ‘on’. Immediately turn the
key to the off position.
! WARNING !
When an emergency stop has
been initiated, DO NOT attempt to
restart the engine until it is safe to
do so.
In the event of an emergency stop

operation leaving material in the
Impact Crusher, this MUST be
cleared prior to restarting. Refer to
Section 7.1.1 for Blocked Crusher
Procedure.
Before restart (Section 7.2.1 to 7.2.3)

ensure the engine clutch is manually
disengaged. Delay starting the feeder
until material left of the conveyors and
screen has cleared.
If the emergency stop button is then

released whilst the Ignition Switch is in
‘on’ position’ the safety warning horn
will sound for 10 seconds before the
engine can be restarted. (Section 7.2).
4242SR
8 - Shut Off EN
Page 8 - 9
8.3.1 Emergency Stop Buttons

Pressing any of the buttons will stop the WARNING
diesel engine and the button will remain WEAR PERSONAL
engaged until physically released by pulling PROTECTIVE EQUIPMENT.
or twisting (depending upon the type fitted) Refer to Section 8.1, Safety
the button knob. The engine cannot be Information for relevant warning.
started if any of the emergency buttons
remain depressed LOCKOUT MACHINE.
8.3.2 Testing Buttons Information for Lockout
Procedure.
! WARNING !
Daily, before commencing
crushing operations, test each
emergency stop button is
operative.
Procedure
1. Observe all safety warnings
2. Follow the safe start-up procedure

(section 7.2)
3. Start the engine (section 7.2.1)
4. Test each emergency stop button in turn

to cut out the engine and, following the
resetting of the tested button, repeat the
process for each of the other emergency
stop buttons (Section 1.7) and also the
stop button on the remote control
handset (Figure 5b).
The emergency stop button on the main

control panel can be tested during the 10
second warning prior to engine start
4242SR
8 - Shut Off EN
Page 8 - 10
Blank page
4242SR
9 - Maintenance EN
Page 9 - 1
9 - Maintenance
9.2 Weights of Components ................................................................................ 9 - 7
9.3 General Information ........................................................................................ 9 - 8
9.4 Plant - Lubrication and Servicing ................................................................ 9 - 10

9.4.1 Lubrication Points .................................................................................... 9 - 10
9.4.2 Regular Servicing ..................................................................................... 9 - 11
9.4.3 Daily, Weekly and Monthly Checks ........................................................... 9 - 12
9.4.4 Lubrication and Servicing Schedule ......................................................... 9 - 14
9.5 Crusher - Opening and Closing................................................................... 9 - 18
9.5.1 Safety Cutout Switch ................................................................................ 9 - 19
9.5.2 Opening the Crusher ................................................................................ 9 - 20
9.5.3 Closing the Crusher .................................................................................. 9 - 22
9.6 Crusher - Adjustment ................................................................................... 9 - 24
9.6.1 Entanglement Hazard for Inspection Door ................................................. 9 - 25
9.6.2 Adjusting the Front Impact Apron .............................................................. 9 - 26
9.6.3 Adjusting the Rear Impact Apron ............................................................... 9 - 28
9.6.4 Adjusting the Swing Arm (where fitted) ...................................................... 9 - 30
9.7 Crusher - Replacement of Wear Parts ........................................................ 9 - 32
9.7.1 Replacing worn Blow Bars ....................................................................... 9 - 33
9.7.2 Replacing the Impact Plates of the Front and Rear Impact Aprons ............ 9 - 38
9.7.3 Replacing the Side Wall Liner Plates ........................................................ 9 - 41
9.7.4 Replacing the Bottom Inlet Beam .............................................................. 9 - 42
9.7.5 Replacing the Retractable Beam .............................................................. 9 - 44
9.8 Vibrating Grizzly Feeder .............................................................................. 9 - 47
9.8.1 Removing the Underscreen Mesh or Blanking Mat .................................... 9 - 48
9.9 Sizing Screen ................................................................................................ 9 - 50
9.9.1 Screen Lower/Raise ................................................................................ 9 - 51
9.9.2 Re-Tuning Screen Unit .............................................................................. 9 - 54
9.9.3 Changing the impact screen mesh ........................................................... 9 - 56
9.9.4 Changing the screen sizing meshes - manual tensioning .......................... 9 - 57
9.9.5 Changing the screen sizing meshes - hydraulic tensioning ........................ 9 - 58
4242SR
9 - Maintenance EN
Page 9 - 2
9.10 Plant - Hydraulic System Description ....................................................... 9 - 60

9.10.1 General Description ............................................................................... 9 - 60
9.10.2 Track Drives ........................................................................................... 9 - 60
9.10.3 Feeder Drive .......................................................................................... 9 - 61
9.10.4 Circuit Protection ................................................................................... 9 - 61
9.10.5 Changing the Suction Filter .................................................................... 9 - 64
9.10.6 Changing the Return Filter ...................................................................... 9 - 66
9.10.7 Changing the Tank Breather ................................................................... 9 - 66
9.10.8 Changing the Pressure Filters ................................................................ 9 - 67
9.11 Plant - Electrical System Description ........................................................ 9 - 68
9.12 Plant - Crusher and Hydraulic Pump Drive Belts ..................................... 9 - 69

9.12.1 Replacement of Crusher Drive Belts ....................................................... 9 - 70
9.12.2 Adjustment of Crusher Drive Belts .......................................................... 9 - 71
9.12.3 Changing the engine pulley .................................................................... 9 - 74
9.12.4 Replacement and Adjustment of Hydraulic Pump Drive Belts .................. 9 - 75
9.12.5 Method of Drive Belt Tensioning ............................................................. 9 - 78
9.12.6 Trouble Shooting - Drive Belts ................................................................ 9 - 81
9.13 Plant - Conveyor Belts ............................................................................... 9 - 82
9.13.1 Training of Belts ..................................................................................... 9 - 82
9.13.2 Conveyor Belt Tensioning ....................................................................... 9 - 84
9.13.3 Maintenance of Conveyor(s) ................................................................... 9 - 86
9.13.4 Cleaning the Conveyor Belts .................................................................. 9 - 88
9.14 Plant - Overband Magnetic Separator ....................................................... 9 - 90
9.15 Plant - Dust Suppression ........................................................................... 9 - 92
9.16 Plant - Diesel Engine .................................................................................. 9 - 93

9.16.1 Engine Clutch Adjustment ....................................................................... 9 - 94
9.16.2 Clutch Maintenance ................................................................................ 9 - 94
9.16.3 Engine - ELC Coolant ............................................................................ 9 - 95
9.16.4 Check Fuel Level ................................................................................... 9 - 96
9.16.5 Top Up Fuel Level .................................................................................. 9 - 97
9.17 Plant - Vehicle Tracks ................................................................................. 9 - 98
9.17.1 Measuring Track Tension ........................................................................ 9 - 98
9.17.2 Adjusting Track Tension ........................................................................ 9 - 100
9.17.3 Track Maintenance ............................................................................... 9 - 103
9.17.4 Drive Oil Filling and Draining ................................................................ 9 - 104
4242SR
9 - Maintenance EN
Page 9 - 3







ground level.
4242SR
9 - Maintenance EN
Page 9 - 4

HAZARD
machine.


HAZARD
injury.



4242SR
9 - Maintenance EN
Page 9 - 5

followed.
LOCKOUT PROCEDURE

lockout.
4242SR
9 - Maintenance EN
Page 9 - 6
! WARNING !
PRIOR TO ANY MAINTENANCE
• The maintenance instructions are intended for day to day maintenance to keep the plant in good
running order and do not cover major rectifications, repairs or replacements where specialist
expertise is required. However, ensure that only suitably competent personnel with the necessary
training/experience for the task(s) in hand are employed. A person should never work alone.
• Observe the safety advice in Sections 1 and 9.1 as appropriate to the task(s) in hand.
• Read the appropriate manual literature relevant to the operation in hand. Carry out a Risk
Assessment for all maintenance operations. Have suitable lifting equipment available for the
components involved together with all necessary (and suitable) tools/equipment ready for the
task(s) in hand and always secure parts liable to movement before starting work.
BL-Pegson’s Service Department is available for advice when required.
• The plant should be completely emptied of material i.e. stone. Implement the ‘Lockout Procedure
(Section 9.1). Display a prominent ‘tag’ at the control station (or other appropriate place) to warn
of maintenance work being carried out.
• Keep clear of moving parts when trying to identify or isolate any unusual noises.
• Fit dismantled parts in the same location from which they were removed.
• Ensure that the area surrounding the maintenance site is clear of any obstructions.
• If arc welding work is involved in any maintenance operation, ensure that the current does not pass
through any bearings. FOLLOW INSTRUCTIONS OPPOSITE FOR ENGINE
PROTECTION. The plant must be fully isolated prior to any welding work.
• BEFORE WORKING ON THE PLANT, SWITCH OFF, ‘LOCKOUT’ AND ‘TAGOUT’
AFTER EXTENSIVE MAINTENANCE

Refer to Section 7.3.1 ‘Checks Prior to Initial Daily Start Up’ and 7.3.2 ‘Initial Start Up and Running
In’.
4242SR
9 - Maintenance EN
Page 9 - 7
9.2 Weights of Components
Weights of crusher and feeder assemblies, these should be consulted when arranging suitable lifting
equipment.
Component
Weight – (kg) Weight - (lb)
Rotor Shaft Assembly 3204 7065
Rotor 1250 2756
Rotor Shaft 339 748
Bearing Housing 101.3 223
Bearing 41.5 91.5
Inner Labyrinth 25.5 56.2
Outer Labyrinth 4.22 9.31
Outer Labyrinth 126 278
Blow Bar 214 472
Crusher (complete) 10690 23520
NOTE: FOR INDIVIDUAL WEIGHTS OF THE IMPACT CRUSHER LINER PLATES PLEASE REFER TO
THE PARTS LISTS IN SECTION 10
! WARNING !
All weights given are for guidance only and appropriate allowances should be
applied for the sizing of lifting or transporting equipment.
Warning
Welding on a Machine/Unit Equipped with an Electronic Engine
Before welding on a machine/unit equipped with an electronic engine, the

following precautions should be observed.
• Turn the Engine Control Switch to the ‘OFF’ position.
• Disconnect the NEGATIVE battery cable at the battery. If a battery
disconnect switch is provided, open the switch.
• Disconnect the multi-pin connectors from the Electronic Control Module
(ECM) located on side of engine.
• Connect the welder ground cable directly to the member to be welded.
Place the ground cable clamp as close as possible to the weld to reduce
the possibility of welding current damage to the bearings, hydraulic
components, electrical components and ground straps. Do not use
electrical components, the ECM or Electronics Ground Stud for grounding
the welder.
• Protect wiring from welding debris or splatter.
Use standard welding techniques to weld the materials together.
4242SR
9 - Maintenance EN
Page 9 - 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 sure
observe rules provided in the safety Section. that they are replaced before the machine is
restarted.
Breakdown caused by insufficient or
improper maintenance will cause high repair Refer to the Spare Parts illustrations
costs and long term standstill. Therefore, (Section 10) to identify the machinery
regular maintenance is imperative. components mentioned in the maintenance
procedures.
In addition to several other factors, the
reliability and life of the 4242SR Tracked
Impactor depends on regular and proper
maintenance.
The following Section contains maintenance

instructions as well as maintenance
schedules for normal operating conditions.
! NOTICE !
When the plant is operated in
extreme climatic conditions e.g.
below -10°C or above 40°C (+14° to
+ 104°F) or in very dusty
conditions for a longer period of
time, the maintenance schedules
will change.
Ask your local Terex Pegson

dealer or Terex Pegson Technical
Department for advice.
4242SR
9 - Maintenance EN
Page 9 - 9
PRACTICE SAFE MAINTENANCE

WARNING
! WARNING ! WEAR PERSONAL
Understand service procedure Refer to Section 9.1, Safety
before doing any work. Keep area Information for relevant
clean and dry. warning.
LOCKOUT PLANT.
Never lubricate, clean, service or Refer to Section 9.1, Safety
adjust machine whilst it is moving. Procedure.
Keep hands, feet and clothing

FALLING HAZARD.
clear of power driven parts and in-
running nip points. Information for relevant
warning.
Disengage all the power and
operate controls to relieve
pressure. 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.
4242SR
9 - Maintenance EN
Page 9 - 10
9.4 Plant - Lubrication and

Servicing WARNING
WEAR PERSONAL
9.4.1 Lubrication Points PROTECTIVE EQUIPMENT.
Regular lubrication of the plant machinery in Information for relevant
accordance with the Lubrication and Servicing warning.
Schedule (Section 9.4.4) is essential. LOCKOUT PLANT.
The locations of the lubrication points are as Information for Lockout
follows:- Procedure.
• Crusher rotor shaft bearing housing FALLING HAZARD.

grease nipples (5) Refer to Section 9.1, Safety
• Feeder vibrating unit bearing oil baths on warning.
both sides of the feeder vibrating unit
(Section 7.3.2 and Figure7i).
• On-plant product conveyor head and
tailshaft bearing grease nipples located ! WARNING !
on the bearing housings (tailshaft piped
to grease points on plant chassis sides). The overband magnet assembly is
very powerful and permanently
• Re-circulating Conveyor and 2 x
charged. The strong magnetic field
Transfer Conveyor head and tailshaft
bearing grease nipples. produced could affect heart
pacemakers, watches, credit
• Screen vibrating unit bearing 4 x grease cards, mobile phones etc. The
nipples. operator has the sole
• Track unit gearbox (2) oil levels (Section responsibility to keep anyone at
9.16..3). risk clear of the machine.
• Dirt conveyor head and tailshaft bearing • Periodically lubricate hinges, cylinder pivot
housing grease nipples (tailshaft piped to pins, tensioning screws and similar points
grease points on plant chassis sides). with oil or grease (as appropriate) to
prevent seizure during lengthy spells of
• Overband magnetic separator head and
inactivity. Keep the runners for the side
tailshaft bearing housing grease nipples
transfer conveyors well lubricated with
grease.
4242SR
9 - Maintenance EN
Page 9 - 11
9.4.2 Regular Servicing

The Lubrication and Servicing Schedule WARNING
(Section 9.4.4) lists, in addition to the WEAR PERSONAL
lubrication points, the attention required to PROTECTIVE EQUIPMENT.
the hydraulic system (Section 9.10). Refer to Section 9.1, Safety
Particular attention should be paid to institute Information for relevant
a regime of strict adherence from the start warning.
of operations for all aspects of routine LOCKOUT PLANT.
maintenance. Refer to Section 9.1, Safety
Keep a detailed Maintenance Log of all Procedure.
work carried out, recording faults
experienced and actions taken, details of FALLING HAZARD.
routine maintenance, personnel name(s), Refer to Section 9.1, Safety
method statements, parts fitted, consumables Information for relevant
used, dates, hours run, etc. etc. Also note warning.
any extended periods when the plant is
inactive and steps taken for protection whilst
the plant is laid up.
NOTE: Do not overlook the service

requirements of the plant diesel engine
which are detailed in the engine
manufacturer’s manual. Also attend to
the service requirements of the clutch
as detailed (Sections 9.16.2 and 11.1)
4242SR
9 - Maintenance EN
Page 9 - 12
9.4.3 Daily, Weekly and Monthly

Checks WARNING
WEAR PERSONAL
! WARNING ! PROTECTIVE EQUIPMENT.
It is imperative that the operator Information for relevant
carries out regular and diligent warning.
checks before operating the plant
LOCKOUT PLANT.
especially with operational safety
in mind including (but not limited Information for Lockout
to) those listed below. Procedure.
Additionally, the operator should FALLING HAZARD.

always consider what particular Refer to Section 9.1, Safety
safety hazards could occur at
warning.
specific operating sites and take
steps to eliminate them before
commencing work.
6. Check the crusher shaft bearing
Daily Checks temperatures using a contact
thermometer and record for future
1. Check that all guarding is complete and reference and fault diagnosis. The
properly secured prior to start up. Also maximum acceptable working
that all warning signs (Section 1.8) are temperature is 176°F
present and readable.
2. Check that all the plant emergency stop

buttons are operative (Section 1.7)
3. Carry out a general inspection of the

plant to ascertain that nothing untoward is
out of place or damaged so as to cause a
safety hazard.
4. Carry out daily lubrication schedule

(Section 9.4.4).
5. Attend to Track Maintenance (Section

9.17.3).
4242SR
9 - Maintenance EN
Page 9 - 13
Weekly Checks Monthly Checks
1. Perform all checks on the daily check 1. Perform all checks on the daily and
list. weekly check list
2. Lubricate to the weekly schedule. 2. Lubricate to the monthly schedule

(Section 9.4.4) (Section 9.4.4)
3. Check the area around the rotary 3. Visually examine the rotary impactor,
impactor for buildup of material; clean liners and aprons for wear and damage.
out as necessary. Renew as necessary.
4. Ensure all hydraulic hoses and joints are 4. Inspect crusher drive belts for signs of
free from leaks. wear, renew as necessary.
5. Lubricate the crusher rotor bearings. 5. Inspect both crusher aprons and, if fitted,
the swing beam adjustment mechanisms
6. Check drive belts for damage, wear and for wear and damage. Renew as
fraying. necessary.
7. Check crusher rotor, blow bars etc. for 6. Check all drive belts are at the correct
security and wear/damage. tension.
8. Check crusher setting. 7. Clean oil strainers and filters. Inspect for
metal chips or flakes indicating excessive
9. Clean away dust, dirt and grit from bearing pressure or bearing failure.
maintenance platforms and any moving
parts.
10. Check side wall liners for wear damage

and security.
11. Check both aprons and, if fitted, the

swing beam adjusters for security wear
and damage.
12. Check conveyor belts for damage and

fraying.
4242SR 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 2
Description Lubricant Quantity Daily Weekly Monthly Other
Locations Weekly
2 Crusher Shaft Bearing grease nipples D 30g (1oz) each R
3 Labyrinth Lid (left and right) D 5g (0.2oz) each R

Crusher Door Ram Bearing grease
4 D R
nipples
Nuts of Lower Apron adjusting Multi-purpose
- 3g (0.1oz) each R
assembly grease
Adjusting Cylinders of Swing Arm and Molybdenum-
- - As required
Upper Adjusting Spindles. disulphide-spray
Vibrating Feeder Non-drive & Drive See table To middle of sight X(200
2 O
side Oil Baths opposite glass hours)
9.4.4 Lubrication and Servicing Schedule
Conveyor Head & Tail Shaft Bearings:

24 Impactor Product, Dirt, Side D R
Transfer, Fines & Re-circulating
4 Sizing Screen Inner & Outer Bearings H 12g (0.4oz) each R

9 - Maintenance
See table 360 litres X 2000hrs

1 Hydraulic Reservoir O
opposite (95 US gal) (Annually)

In-line Hydraulic Filters inside engine
2 - O X 1000hrs
canopy
(6 months)
Powerscreen of Florida - 5125 N. Frontage Rd., Lakeland, FL, 33810

Hydraulic Suction Filters at bottom of Sooner if
2 - O
the hydraulic reservoir indicator
shows
Hydraulic Return Filter on top of the RED
1 - O
hydraulic reservoir
Approx. 5 litres X 2000hrs
2 Track Gearbox Oil See chart O
(1.3 US gal) ±10% (Annually)
EN
4242SR
Note 1: See the separate Engine and Clutch manuals for the lubrication schedules & specifications for those items.
Note 2: Where the optional Magnetic Separator or Conveyors are supplied, re-grease as the On-plant conveyors
Page 9 - 14
Page 136 of 360

4242SR Oil and Grease Lubricants
Equipment Grade Century Mobile Shell Esso Gulf BP
4242 Impactor
Shaft bearings (grease) D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
All temperatures
Vibrating Feeder
Oil Bath Lubrication
>15ºC (>59°F) C Centlube H76 Mobilgear 634 Omala 680 Spartan EP460 EP LUB HD460 Energol GR-XP460
4ºC to 15ºC (39 to 59°F) B Centlube F76 Mobilgear 630 Omala 220 Spartan EP220 EP LUB HD220 Energol GR-XP220
< 4ºC (<39°F) A Centlube E76 Mobilgear 629 Omala 150 Spartan EP150 EP HD MULTI H Energol GR-XP150
Conveyors & Magnet
Shaft Bearings Grease D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
(all temperatures)
Plant Hydraulic System
<30ºC (<86°F) F Centraulic PWLB Mobil DTE25 Tellus 46 Nuto H46 Hydrasil 46 Energol HLP-HM46
>30ºC (>86°F) G Centraulic PWLC Mobil DTE26 Tellus 69 Nuto H68 Hydrasil 68 Energol HLP-HM68
Sizing Screen H Retinax EP2
Track Tension D Regulus A2EP Mobilux EP2 Alvania EP2 Beacon EP2 Gulfcrown EP2 Energrease LS-EP2
9 - Maintenance
Track Gearboxes SAE 80W/90 Gear Oil

Note: <4°C (<39°F) is defined as a daily temperature consistently below 4°C (39°F).
>15°C (>59°F) is defined as a daily temperature consistently above 15°C (59°F).
Powerscreen of Florida - 5125 N. Frontage Rd., Lakeland, FL, 33810

>30°C (>86°F) is defined as a daily temperature consistently above 30°C (86°F).
Diesel Engine Powerpack
Refer to Engine Operation and Maintenance Manual for Lubricating Oil, Coolant and Fuel. Also to the Twin Disc Manual for
the lubrication requirements for the manually operated Clutch.
EN
4242SR
Page 9 - 15
Page 137 of 360

4242SR
9 - Maintenance EN
Page 9 - 16
Lubrication Specifications
Oil Specification Grade A Grade B Grade C
Flashpoint: Minimum °C (ºF) 199 (390.2) 204 (399.2) 216 (420.8)
Pour Point °C (ºF) -18 (-0.4) -18 (-0.4) -18 (-0.4)
Kinematic Viscosity at 40°C, mm²/s (104ºF, in²/s) 150 (0.232) 220 (0.341) 460 (0.713)
Kinematic Viscosity at 100°C, mm²/s (212ºF, in²/s) 15.4 (0.0238) 20.1 (0.0312) 32.9 (0.051)
Viscosity Index 105+ 105+ 105+
Timken OK lb. Minimum 50 50 50
Extreme Pressure Agent Yes Yes Yes
R&O Agent Yes Yes Yes
Anti Foaming Agent Yes Yes Yes
Copper Strip Corrosion Test Pass Yes Yes Yes
ISO VG 150 220 460
Grease Specification Grade D Grade H

NGLI Grade Number 2
Unworked Penetration at 25°C (77ºF) 280
Worked Penetration at 25°C (77ºF) 285
Drop Point °C (ºF) 185 (365)
ASTM Corrosion Test Pass (14 Days) Yes
Wheel Bearing Test Pass at 135°C (275ºF) Yes
Timken Test lbs. Pass 40/50
Extreme Pressure Agent Yes
Hydraulic Oil Specification Grade F Grade G

ISO VG No 46 68
Kinematic Viscosity at 40°C, mm²/s (104ºF, in²/s) 46 (0.0713) 68 (0.105)
Kinematic Viscosity at 100°C, mm²/s (212ºF, in²/s) 6.5 (0.010) 8.5 (0.013)
Viscosity Index 95+ 95+
Rust Inhibitor Yes Yes
Defoament Yes Yes
Anti Scuff Yes Yes
4242SR
9 - Maintenance EN
Page 9 - 17
Crusher Shaft Bearing

Grease Nipples & Front Adjusting
Labyrinth Lid Spindle
Crusher Door Ram

Bearing Grease Nipple
Nuts of Apron Adjusting

Assembly
Crusher Door Ram

Bearing Grease Nipple
Adjusting Assembly of
Swing Arm (where
fitted)
Figure 9a Crusher Lubrication Points
4242SR
9 - Maintenance EN
Page 9 - 18
9.5 Crusher - Opening and

! WARNING !
Closing
Both sets of bolts must NOT be
Access to the inside of the Impact Crusher undone at the same time and it is
body is gained by first releasing some of the essential that when requiring to
swivelling eye bolts on the crusher body and change from one opening mode to
then operating the hydraulic rams to open the the other that the crusher body
pivoted upper frame of the crusher. should be completely closed off
(Section 9.5.3) before attempting to
The crusher upper frame opens in two reopen (Section 9.5.2) into the
modes depending upon the servicing required
other mode.
for the machine. By releasing only the
internal swivelling eye bolts (‘A’ in Figure
All maintenance on the impact crusher must
9b) the rotor is accessed whereas by only
only be carried out when the plant lockout
releasing the outer eye bolts (‘B’ in Figure
procedure has been carried out and the
9b) only the top of the body is raised for
crusher rotor is stationary.
access to the impact aprons area.
Swivelling Eye Bolts ‘A’ Swivelling Eye Bolts ‘B’

(5 each side) (6 each side)
Figure 9b Swivelling Eye Bolts
4242SR
9 - Maintenance EN
Page 9 - 19
9.5.1 Safety Cutout Switch

Before opening the crusher, the following safety check must be carried out.
4242SR
9 - Maintenance EN
Page 9 - 20
9.5.2 Opening the Crusher

WARNING
Before attempting to open the PROTECTIVE EQUIPMENT.
crusher body make sure that all Information for relevant
tools and personnel are evacuated warning.
from the maintenance platform. LOCKOUT MACHINE.
Procedure Information for Lockout
Procedure.
2. Run the crusher until completely empty.

Close down the plant (Section 8.2) and
implement the lockout procedure.
! NOTICE !
A safety cutout switch on the
crusher body prevents the engine
being turned over or started whilst
the crusher body is open.
3. Secure both of the Front Apron Adjusting

Mechanisms (Figure 9g) with the chains
(D) to the protective caps (A) to hold the
mechanisms in place when the crusher
body is open. Failure to do this will
result in damage to the plant.
4. Depending upon the access required,

loosen the swivelling eye bolts ‘A’ or
‘B’on the crusher flange and rotate them
through 180º Ensure that only one set
of bolts ‘A’ OR ‘B’ (Figure 9b) have
been released before attempting to
open the crusher body, ie. NOT both
sets of bolts undone at the same
time.
4242SR
9 - Maintenance EN
Page 9 - 21
5. Insert the engine Ignition Key and turn 9. Turn the engine ignition switch to position
to the first position only. The pre-start ‘O’ and implement the lockout
audible warning will sound for 10 procedure.
seconds during the SYSTEM START
DELAY before the initial screen display
appears on the Control Panel (Figure
Hydraulic Valve Lever
6b)). DO NOT START THE ENGINE
Quick Release
6. Press the PUMP MODE button for the Couplings
LED to illuminate to confirm active
status.
7. To operate the hydraulic rams press (and

keep depressed) the button below
PUMP MODE and at the same time
operate the control lever on the hydraulic
valve on the maintenance platform.
Avoid prolonged use of the pump to
avoid draining the engine battery.
8. Using the two locking pins provided Figure 9c Hydraulic Operating Lever
always lock the crusher door in the
open position. (Figure 9d).
Locking Pin Location
Locking Pin
Figure 9d Locking Pin & Crusher Open-Locking Pin Location
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9.5.3 Closing the Crusher
Procedure
WARNING
WEAR PERSONAL
1. Observe all safety warnings. PROTECTIVE EQUIPMENT.
2. Remove the two locking pins from the Information for relevant
crusher door and keep safe for future warning.
use. LOCKOUT MACHINE.
! WARNING ! Procedure.
Before attempting to close the

crusher body make sure that all
the opened swivelling eye bolts
are folded back from the
mainframe flange and that all tools
and personnel are evacuated from
the maintenance platform.
3. Reverse the lockout procedure. Insert

the engine Ignition Key and turn to the
first position only. The pre-start audible
warning will sound for 10 seconds during
the SYSTEM START DELAY before
the initial screen display appears on the
Control Panel (Figure 6b)). DO NOT
START THE ENGINE
4. Press the PUMP MODE button for the

LED to illuminate to confirm active status.
5. To operate the hydraulic rams press (and

keep depressed) the button below
PUMP MODE and at the same time
operate the control lever on the hydraulic
valve on the maintenance platform.
Avoid prolonged use of the pump to
avoid draining the engine battery.
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Page 9 - 23
6. Turn the engine ignition switch to the ‘O’

position and implement the lockout
procedure.
7. Rotate the swivelling eye bolts through

180º and thoroughly tighten.
8. Detach the chains (D) from the

Protection caps (A) on the Front Apron
Adjusting mechanisms (Figure 9g). It is
essential these chains are detached
before operating the crusher in
order to allow movement of the
Front Apron.
! NOTICE !
After blow bars, apron liners or
swing arm rails have changed, the
gap settings MUST be checked,
and adjusted if necessary, to
within the permissible limits
(Sections 3.5 and 9.6) before
attempting to start the crusher
otherwise serious damage could
occur if the rotor is not free to turn.
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9.6 Crusher - Adjustment It is most important that settings between

the rotor blow bars and the front and rear
Adjustments are required to the impact aprons and also the swing beam (optional), if
crusher to enable the product size to be fitted, do not exceed the minimum or
varied and to compensate for wear on the maximum dimensions given in Figure 3b and
aprons, swingbeam (where fitted) and blow that ratios are maintained between the front
bars. Refer to Section 3.5, Figure 3a and 3b and rear apron settings and between the rear
for the setting gaps. apron and the swing beam (if fitted)
otherwise any warranty may be invalidated.
Front Impact Apron Adjustment

Mechanism
Front Impact Apron
Rear Impact Apron

Adjustment Mechanism
Rear Impact Apron
Retractable Beam
Swing Beam Adjustment

Mechanism
Bottom Inlet Beam
Rotor Protection Cap
Blow Bars Swing Beam Rails
Axial Lock & Securing Pin
Figure 9e Impact Crusher Parts
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9.6.1 Entanglement Hazard for Inspection Door

Keep doors (Figure 9f) closed, latched and bolted except when performing
maintenance.
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9.6.2 Adjusting the Front Impact

Apron WARNING
WEAR PERSONAL
After any maintenance and before Information for relevant
starting the crusher, ensure the warning.
rotor can turn without any LOCKOUT MACHINE.
impedance. Check the distance Refer to Section 9.1, Safety
between the ‘long’ blow bars Information for Lockout
(Section 9.7.1) and impact plates Procedure.
and if necessary adjust the impact
aprons and swing arm
See Section 3.5.1 Impactor Settings
Procedure

3. Only when the rotor shaft is stationary

open the upper inspection doors on the
side of the crusher (Figure 9f).
Figure 9f Upper Inspection Door
! WARNING !
Do NOT in any circumstances
! NOTICE !
open the Upper Inspection Doors Each blow bar must be in contact
whilst the crusher is running. with the lower seat engaging
surfaces of the rotor when
4. Measure the smallest gap between each measuring the gap. If the blow bar
blow bar and the lowest wear plate of is not in contact with the lower
the front apron. seat engaging surfaces, the gap
MUST be increased by 10mm (3/
8”) to compensate for the lifting of
the blow bars under centrifugal
force.
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Page 9 - 27
5. Loosen the locknut with protective

sleeve (A) a few turns (Figure 9g). ! NOTICE !
Repeat this step for the other adjusting
Ensure the adjusting nut (B)
mechanism.
always sits on the guiding sleeve
6. To increase the gap, between the blow
and disc springs (C).
bar and apron, tighten (turn clockwise)
8. When the gap is correct, tighten the
both adjusting nuts (B) (Figure 9g) in
locknut with protection cap (A) and lock
turn a little at a time and by an equal
against the adjusting nut (B). Repeat
amount.
this step for the other adjusting
mechanism.
7. To decrease the gap, between the
blow bar and apron loosen (turn anti-
9. Close the inspection doors and secure
clockwise) both adjusting nuts (B)
with the locking clip..
(Figure 9g) in turn by a little at a time
and by an equal amount.
Locknut with Protection Cap (A)
Adjusting Nut (B)

Disc Springs (C)
Chain (D) - shown

fixed
Chain (D) - shown loose
Figure 9g Front Impact Apron Adjustment
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9.6.3 Adjusting the Rear Impact

Apron WARNING
WEAR PERSONAL
between the ‘long’ blow bars (Refer Information for Lockout
to Section 9.7.1) and impact plates Procedure.
and if necessary adjust the impact
aprons and swing arm.
Procedure

3. Open the upper inspection doors on the

side of the crusher (Figure 9f).
4. Measure the smallest gap between each

blow bar and the lowest wear plate of the
rear apron.
! NOTICE !
The blow bar must be in contact
with the lower seat engaging
measuring the gap. If the blow bar is
not in contact with the lower seat
engaging surfaces, the gap MUST
be increased by 10 mm (3/8”) to
compensate for the lifting of the
blow bars under centrifugal force.
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Page 9 - 29
5. On one of the Rear Impact Apron 8. When the gap is correct, replace both
Adjusting mechanisms (Figure 9h) undo keep plates and secure with the 2 set
the set screws (A) and remove the keep screws in each keep plate.
plate (B). Repeat this step for the other
adjusting mechanism. 9. Close the inspection doors and secure
with the locking clip.
bar and the rear apron, tighten (turn
clockwise) both adjusting sleeves (C)
each in turn a little at a time and by
equal amounts.
7. To decrease the gap between the blow

bar and the rear apron, loosen (turn anti-
clockwise) both adjusting sleeves (C)
each in turn a little at a time and by
equal amounts.
Set Screws (A) Keep Plate (B) Adjusting Sleeve (C)
Figure 9h Rear Impact Apron Adjustment
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9.6.4 Adjusting the Swing Arm

(where fitted) WARNING
WEAR PERSONAL
between the ‘long’ blow bars Information for Lockout
(Refer to Section 9.7.1) and impact Procedure.
plates and if necessary adjust the
impact aprons and swing arm.
Procedure

3. Lift out the platform between the

crusher and engine canopy, to increase
access to the swing beam adjusting
mechanism.
4. Measure the smallest gap between each

blow bar and the swing beam rails. Figure 9i Swing Arm and Blow bar
(Figure 9i).
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Page 9 - 31
! NOTICE !
The blow bar must be in contact
with the lower seat engaging
measuring the gap. If the blow bar
is not in contact with the lower
seat engaging surfaces, the gap
MUST be increased by 10mm (3/
8”) to compensate for the lifting of
the blow bars under centrifugal
force
5. On the swing arm adjusting mechanism

(similar to Figure 9h) undo the set
screws (A) and remove the keep plate
(B).

bar and the swing arm rail, tighten (turn
clockwise) the adjusting sleeve (C).
7. To decrease the gap between the blow

bar and the swing arm rail, loosen (turn
anti-clockwise) the adjusting sleeve (C).
8. When the gap is correct, replace the

keep plate and secure with the 2 set
screws.
9. Close the inspection doors and secure

with the locking clips.
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Page 9 - 32
9.7 Crusher - Replacement All maintenance on the impact crusher must

only be carried out when the plant lockout
of Wear Parts
procedure has been carried out and the
crusher rotor is stationary.
Use only genuine Terex Pegson replacement
wear parts. Check daily for wear on all parts
When replacing wear parts check there is no
affected particularly where the material
build up of material within the crusher, eg.
being crushed is known to be abrasive. It is
between the impact aprons, swing beam (if
important that designed replaceable wearing
fitted) and the crusher side walls, and clear
parts are renewed before the underlying
as necessary. Always make sure that the
machine is subjected to wear.
seating of a wear part is clean and the part is
properly ‘bedded’ in position.
One working day after fitting new
replacement wear parts always check the
fixing bolts for tightness.
Front Apron Adjustment Mechanism
Body Side Liner Plates

Rear Apron Adjustment
Mechanism
Front Apron
Liner Plates
Rear Apron Liner

Plates
Rotor Protection
Caps
Blow Bars Swing Beam

Rails Swing Beam (Grinding Path)
Adjustment Mechanism
Figure 9j Impact Crusher Parts
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Page 9 - 33
9.7.1 Replacing worn Blow Bars

WARNING
! NOTICE ! WEAR PERSONAL
The crusher must be fitted with PROTECTIVE EQUIPMENT.
matched pairs of blow bars fitted Information for relevant
diametrically opposite to each warning.
other. The maximum weight LOCKOUT MACHINE.
difference between the two blow Refer to Section 9.1, Safety
bars supplied as a pair is 0.47 kg. Information for Lockout
(1 lb) Procedure.
ONLY REPLACE/TURN BLOW

BARS AS MATCHED OPPOSITE
PAIRS TO MAINTAIN THE ! WARNING !
CORRECT ROTOR BALANCE Before replacing the blow bars,
the impact aprons and swing
Of the two pairs of blow bars fitted beam should be set fully open.
to the rotor, one pair is shorter (ie. (Fully Open - maximum gap
having a smaller projection from between blow bar and impact
the rotor periphery) than the other apron/swing beam).
pair.
Reverse the wearing face of a pair ! WARNING !

of blow bars through 180° when
After any maintenance and before
the original face is worn but
starting the crusher, ensure the
maintain the one pair ‘long’ and
rotor can turn without any
one pair ‘short’ blow bar
impedance. Check the distance
configuration on the rotor by fitted
between the ‘long’ blow bars and
appropriate new blow bars when
impact plates and, if necessary,
necessary.
adjust the impact aprons and
swing arm (Section 9.6) in
accordance with data set out in
Sections 3.3 (Designated Use), 3.5
(Plant Performance) and 3.6
(Impactor Performance).
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Page 9 - 34
Removal of each Blow Bar

WARNING
Procedure WEAR PERSONAL
2. Run the crusher until completely empty. warning.
Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the lockout procedure. Refer to Section 9.1, Safety
3. Open the crusher (Section 9.5.2) Procedure.
4. To remove the two axial locks - remove

the split pins, withdraw the securing pins
and remove the axial locks. (Figure 9k).
To prevent the rotor from turning whilst
the blow bar is removed, lock the rotor 7. In the same manner of operation as
into position using the rotor lock when opening the crusher body, push out
(Figure 9l) Insert the pin end of the the blow bar with the extraction tool. As
rotor lock into the hole in the rotor just the blow bar is extracted support the
vacated by the axial lock and secure the weight with suitable slings and lifting
lock to the crusher body by the adjacent gear. Extension bars are included with
swivelling eye bolt (Figure 9m). the extraction tool to be inserted, when
necessary, when the limit of travel is
5. Clean out the debris between the blow reached.
bar and rotor recess.
8. Retract the piston in the extraction tool
6. Using the hydraulic blow bar extraction by moving the operating lever in the
tool provided mount the tool as shown reverse direction and remove the tool
(Figure 9m) on the drive guard side of from the rotor.
the crusher. Using the quick release hose
couplings connect to the crusher ram
operating valve on the platform
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Page 9 - 35
Split Pin
Axial Lock &

Securing Pin
Blow Bar
Figure 9k Impact Crusher - Blow Bar and Axial Lock
Figure 9l Rotor Lock

(fit where indicated)
Figure 9m Removing the Blow Bar
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Page 9 - 36
Fitting of Blow Bars

WARNING
ONLY REPLACE/TURN BLOW Refer to Section 9.1, Safety
BARS AS MATCHED OPPOSITE Information for relevant
PAIRS TO MAINTAIN THE warning.
CORRECT ROTOR BALANCE LOCKOUT MACHINE.
Every time a blow bar is rotated or

replaced, check the 4 rotor
protection caps for wear and
damage. If necessary replace all 4
rotor protection caps. Do not
replace individual rotor protection
caps. NEVER work with worn or
damaged rotor protection caps.
9. Using suitable lifting equipment support

the blow bar in the middle.
10. Slide the blow bar halfway into the rotor.
11. Reposition the lifting equipment and

support the blow bar at its end.
12. Slide the blow bar into position.
13. Remove to rotor lock.
14. Fit the both axial locks and axial securing

pins. Fit new split pins.
15. Rotate the rotor and repeat Steps 4 to 14

for the other diametrically opposite blow
bar MAKING SURE THAT IT IS
THE OTHER BLOW BAR OF THE
MATCHING PAIR.
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9 - Maintenance EN
Page 9 - 37
! WARNING !
impedance.
16. Close the crusher (Section 9.5.3).
17. Check the distance between the ‘long’

blow bars and impact plates and if
necessary adjust the impact aprons and
swing arm (Section 9.6).
18. When the blow bar changing process is

complete disconnect the extraction tool
and reconnect the crusher door ram
hoses to the valve unit on the platform.
! NOTICE !
Run the crusher empty for 30
minutes to allow the blow bars to
bed into position and also check
that the crusher is running
smoothly.
! WARNING !
Never open the inspection doors
while the crusher is in operation.
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Page 9 - 38
9.7.2 Replacing the Impact Plates

of the Front and Rear Impact
Aprons
WARNING
WEAR PERSONAL
Procedure Refer to Section 9.1, Safety
1. Observe all the safety warnings.
warning.
2. Run the crusher until completely empty. LOCKOUT MACHINE.

Close down the plant (Section 8.2) and Refer to Section 9.1, Safety
Procedure.
3. Remove the appropriate access panels

on the outside of the crusher using
suitable lifting equipment.
4. Open the crusher (Section 9.5.2).

9. Close the crusher (Section 9.5.3).
5. Remove the worn impact plates.
10. Refit the access panels.
6. Clean the seats of the impact plates.
11. Check the distance between the blow
7. Fit new impact plates. Strike the bolt bars and impact plates and if necessary
heads repeatedly during tightening to adjust the impact aprons and swing beam
ensure the bolts are seated correctly in (Section 9.6).
the bores of the of impact plates. To help
prevent the special countersunk bolts
from turning when the nuts are tightened,
! WARNING !
a suitable chisel or screw driver can be After any maintenance and before
pushed between the bore and the starting the crusher, ensure the
bevelled part of the bolts head. rotor can turn without any
impedance.
8. Tighten the nuts to the specified torque
(Figure 9n).
! NOTICE !
Only use NEW Philidas locking
nuts when fitting new liner plates.
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9 - Maintenance EN
Page 9 - 39
Figure 9n Front & Rear Impact Plate Bolts - Tightening Torques
Access Panels
Figure 9o Front Impact Apron Access Panels and Wear Plates
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Page 9 - 40
Wear Plates
Access Panels
Figure 9p Rear Impact Apron Access Panels and Wear Plates
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9 - Maintenance EN
Page 9 - 41
9.7.3 Replacing the Side Wall Liner

Plates WARNING
1. Observe all the safety warnings. Refer to Section 9.1, Safety
warning.
Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the lockout procedure. Refer to Section 9.1, Safety
Procedure.
3. Open the crusher (Section 9.5.2)
4. Remove one of the axial locks from the

top blow bar. (Figure 9k)
5. Secure the rotor lock into the place

where the axial lock seats and bolt the ! NOTICE !
rotor lock to the side of the crusher body.
(Figure 9l) In the main wear area, the liner
plates can be rotated or
6. Clean out any debris from the liner interchanged to achieve optimal
plates. utilisation of the liner plates.
7. All the side wall liner plates are bolted

into position from the outside of the
! DANGER !
crusher. To remove/replace any of the The bottom inlet beam is located
side wall liner plates, support the liner on two side wall liner plates A6984/
from the inside of the crusher whilst
9/2 (Figure ).DO NOT attempt to
removing/fitting the bolt.
remove the side wall liner plates
Side Liner Tightening Torque
A6984/9/2, without first removing
420Nm (310lbf ft). the bottom inlet beam A6984/9/23
(Section 10)
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Page 9 - 42
9.7.4 Replacing the Bottom Inlet

Beam WARNING
Removal of the Bottom Inlet Beam WEAR PERSONAL
Procedure Information for relevant
warning.
LOCKOUT MACHINE.
2. Run the crusher until completely empty. Information for Lockout
Close down the plant (Section 8.2) and Procedure.
3. Remove the rubber panels on either side

of the crusher.
4. Undo the three bolt protection caps on

the front access door.
5. Loosen the three toggle bolts and rotate

them through 180º.
6. Using suitable lifting equipment support

the front access door.
7. Standing clear of the access door, prise

open the door, using the lifting equipment
to take the weight of the door. Lower
the door until it is fully open.
! DANGER !
DO NOT enter the area between
the front access door of the
crusher and the crusher feed
chute whilst opening/closing the
access door.
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9 - Maintenance EN
Page 9 - 43
8. Remove the lifting equipment.
9. Screw two M20 eye bolts into the two

tapped holes of the bottom inlet beam.
10. Using suitable lifting equipment lift out

the beam using the eye bolts.
Fitment of the Bottom Inlet Beam
11. Screw two M20 eye bolts into the two

tapped holes of the new bottom inlet
beam.
12. Using suitable lifting equipment position

the beam onto the two side wall liner
plates and slide the beam into position.
13. Using suitable lifting equipment, close the

access door.
! DANGER !
DO NOT enter the area between
the front access door of the
crusher and the crusher feed
chute whilst opening/closing the
access door.
14. Rotate the three toggle bolts through

180º and fully tighten.
15. Refit the three bolt protection caps.
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Page 9 - 44
9.7.5 Replacing the Retractable

Beam WARNING
Removal of Retractable Beam WEAR PERSONAL
warning.
LOCKOUT MACHINE.
2. Run the crusher until completely empty. Information for Lockout
Close down the plant (Section 8.2) and Procedure.
3. Remove the retractable beam access

covers on either side of the crusher
(Figure 9q).
4. Using a heavy hammer or beetle, drive

out the retractable beam, supporting the
beam with suitable lifting equipment.
! CAUTION !
When driving out the retractable
beam splinters may be produced.
Where protective clothing and
safety glasses.
! NOTICE !
To aid removal of the beam the front
wall can be opened (Figure 9s). A
cantilever bar can then be used to
assist with the driving out procedure.
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Page 9 - 45
Figure 9q Access Cover - Retractable

Beam
Retractable
Beam
Bottom Inlet
Beam
Figure 9r Retractable Beam Detail Figure 9s Front Wall Open
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Fitting of Retractable Beam

WARNING
The retractable beam can be rotated Refer to Section 9.1, Safety
through 180° if the v-grooves are in Information for relevant
good condition. warning.
DO NOT rotate the beam if the v- LOCKOUT MACHINE.
grooves are worn. Refer to Section 9.1, Safety
Procedure.
! DANGER !
Whenever the retractable beam is
rotated or replaced, the bottom
intake armouring should be
checked and replaced if necessary.
5. Using suitable lifting equipment support the

beam.
6. Using a hammer or beetle drive the beam

into position.
! CAUTION !
When driving in the retractable
beam splinters may be produced.
Wear protective clothing and safety
glasses.
7. Close the front wall of the machine.
8. Replace the retractable beam covers on

either side of the crusher.
! WARNING !
impedance.
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Page 9 - 47
9.8 Vibrating Grizzly Feeder

WARNING
The vibrating feeder must, in addition to
WEAR PERSONAL
the scheduled lubrication requirements
(Section 9.4), be regularly inspected for
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 9.1, Safety
Make sure that the feeder can vibrate Procedure.
freely without fouling against the
adjacent hopper or chutework and that FALLING HAZARD.
hardened material inside the pan is not Refer to Section 9.1, Safety
allowed to build up and affect the Information for relevant
performance of the machine. Also warning.
check to ensure that the hydraulic drive
is operating efficiently. The variable
speed control is situated on the Feeder/
Conveyor control box. A two-way hand operated flap door can
be positioned so that a portion of the
Periodically check the condition of the undersize can be directed to the bypass
blanking mat or mesh panel beneath the chute.
grizzly bars for both wear and build up
of material and rectify if necessary.
The plant is supplied with the feeder

fitted with a blanking mat; all the
material passing through the grizzly bars
will bypass the crusher and discharge
onto the product conveyor.
If a wire mesh underscreen is fitted (an

alternative option to the blanking mat)
the material rejected will bypass the
crusher whilst the material passing
through the mesh will discharge onto the
dirt conveyor.
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Page 9 - 48
9.8.1 Removing the Underscreen

Mesh or Blanking Mat WARNING
The plant feeder can be fitted with wire WEAR PERSONAL
underscreen to discharge material to the dirt PROTECTIVE EQUIPMENT.
conveyor or may initially be fitted with a Refer to Section 9.1, Safety
blanking mat which directs all material passing Information for relevant
through the grizzly bars on to the on-plant warning.
product conveyor. If required to alter the LOCKOUT PLANT.
configuration either to change from one to the Refer to Section 9.1, Safety
other or to remove altogether, follow the Information for Lockout
Procedure.
procedure below.
FALLING HAZARD.
1. Observe all safety warnings. warning.
2. Run the plant until the feeder and

crusher are completely 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 chute (Figure 9t).
4. Slacken the 2 clamping screws located in

the slots each side of the feeder (Figure
9u).
5. Loosen the locking nuts on the 3 screws

located underneath the feeder
sufficiently to disengage the hooked ends
of the panel.
6. With the hooked rod tool provided, reach Figure 9t Mesh/Mat Access Panel
through the grizzly bars from above to lift
and slide the panel out.
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Page 9 - 49
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 9u Feeder Clamping Screw
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9.9 Sizing Screen

WARNING
The sizing screen box is spring mounted on
WEAR PERSONAL
an incline, an eccentric shaft providing the
screening action, driven by a hydraulic motor,
pulleys and vee-belt. The eccentric shaft Information for relevant warning.
has a balance flywheel at each side to
balance the shaft and reduce the movement
transmitted to the rubber mounted bearing LOCKOUT PLANT.
blocks. The flywheel counter balance can Refer to Section 9.1, Safety
be tuned by the addition or removal of
Procedure.
weights to compensate for the varying
weight of the screen box if different meshes FALLING HAZARD.
are fitted. Refer to Section 9.1, Safety
A short impact screen mesh is fitted below warning.
the conveyor discharge point with the
remainder of the top deck fitted with the
mesh having an aperture to pass the desired
material size. Unless otherwise stipulated at
the time of order the screen is fitted with a Regularly check the screen to make sure
45mm (13/4”) woven wire mesh. that the screen can vibrate freely without
fouling against the adjacent conveyors or
Whilst the standard build does not include a chutework and that hardened material is
bottom deck mesh, the screen includes the not allowed to build up and affect the
facility to fit a mesh of suitable aperture. performance of the machine. Also check
to ensure that the hydraulic and vee belt
The normal operating incline of the screen is drives are operating efficiently.
25 degrees although this can be adjusted to
23 or 21 degrees if the application is suitable.
The sizing screen must, in addition to the

scheduled lubrication requirements (Section
9.4), be regularly inspected for any wear,
damage or breakage, with the mesh(es),
mainframe and support springs being paid
particular attention. Make sure the screen
meshes are correctly tensioned to avoid
flexing. Rectify faults immediately.
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9.9.1 Screen Lower/Raise

For transportation and normal screening WARNING
operations the screen remains at an angle of WEAR PERSONAL
25 degrees. The screen, together with the PROTECTIVE EQUIPMENT.
fines conveyor, can be lowered from this Refer to Section 9.1, Safety
position for maintenance purposes by using Information for relevant
the hydraulic rams situated inside the warning.
telescopic suspension units (Figure 9w). LOCKOUT PLANT.
Use this facility only when the plant is on Information for Lockout
Procedure.
level hard standing which will provide solid
support. Once the conveyor support leg is
solidly grounded the screen/fines conveyor FALLING HAZARD.
link pins can be removed so that the screen Refer to Section 9.1, Safety
can be raised. In this manner, maintenance Information for relevant
works can be more easily undertaken on warning.
both the screen and fines conveyor.
! WARNING !
When the screen is in the raised
position it is essential for it to be
supported with both locating pins
securely fastened in place with
their spring clips (Figure 9w).
Procedure

3. Start the engine (Section 7.2.1) but it is

not necessary to switch on the Radio
Remote Hand Set. Keep the engine
speed at 1200rpm.
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4. At the control panel (Figure 6b) press

the SET UP button for the LED to
illuminate to confirm active status with
the message ‘PROCEED TO SET UP
STATION’. This is situated on the
opposite side of the plant (Figure 9v).

two handed operation and will only
operate if the ‘enable’ button is pressed
and held whilst pressing any of the Set
Up buttons. The audible warning will
sound whenever the ‘enable’ button is
pressed.

press the button SCREEN RAISE very
briefly to take the weight off both screen
support locking pins. After removing
their spring clips, extract the pins.
(Figure 9w).The operate the SCREEN
LOWER button until the fines conveyor
‘Enable’ Button
support leg is solidly grounded.
6. Disconnect the screen from the fines

conveyor by removing the link pins
(Figure 9w).
Note: ‘Toggle’ between the SCREEN

RAISE and SCREEN LOWER buttons
to remove the weight off the links and
allow the pins to be extracted.
7. Operate the SCREEN RAISE to the

limit of the hydraulic rams so that both
locating pins can be securely fastened in
place with their spring clips. Operate the
SCREEN LOWER button so that the
pins take the weight of the screen.
8. Switch off the engine (Section 8.2) and

Figure 9v Set Up Control Station
4242SR
9 - Maintenance EN
Page 9 - 53
Raising the Screen

! NOTICE !
Carry out the actions described in steps 6 Each linking bar between the
and 7 opposite in REVERSE order.
screen frame and the fines
conveyor has an additional
Prior to operating the 4242SR ensure that
the weight of the screen is lowered onto the
locating hole which can be used to
support pins (Figure 9w). To do this make lower the angle of the conveyor in
sure the pin on each side is in place and relation to the screen by 2
operate the SCREEN LOWER button. This degrees. This may be of benefit if
ensures the load is taken on the pins rather roll-back of material occurs on the
than the internal hydraulic rams. conveyor.
Fines Conveyor Sizing Screen Screen Telescopic Suspension Units
Fines Conveyor Support Leg Screen Support Pins
Screen/Fines Conveyor Link Pins Set Up Control Station
Figure 9w Screen/Fines Conveyor Lowered
4242SR
9 - Maintenance EN
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9.9.2 Re-Tuning Screen Unit

WARNING
! CAUTION ! WEAR PERSONAL
Re-tune the sizing screen only PROTECTIVE EQUIPMENT.
when the weight of the screen has Information for relevant
altered if fitting a new or different warning.
screen, or if it is causing vibration LOCKOUT PLANT.
in the sub-frame of the plant. DO Refer to Section 9.1, Safety
NOT OPERATE THE PLANT IF Information for Lockout
VIBRATION IS PRESENT IN THE Procedure.
SUB FRAME.
FALLING HAZARD.
warning.
2. Operate the plant normally until the

sizing screen and conveyors are empty
of material.
3. Lower the screen together the fines

conveyor (Section 9.9.1).
4. Stop the plant and implement the

lockout procedure (Section 8.2).
5. Remove the flywheel access panels on

both side of the plant.
6. Add or remove weights as deemed

necessary. Always fit identical weights
in the same positions on both flywheels
on the shaft.
7. Re-fit the flywheel access panels.
4242SR
9 - Maintenance EN
Page 9 - 55
8. Ready the plant for operation by raising

the screen together with the fines 11. If vibration is detected, repeat proce-
conveyor, taking care to lower the dure from 3.
weight of the screen assembly onto the
locking pins (Section 9.9.1).
12. If vibration is not present in the sub
frame, the plant may be operated.
9. Start the plant (Section 7) including the
sizing screen.
10. Check for vibration in the sub frame.
Screen Box
Flywheel
Balance Weights
Figure 9x Screen Balance Weights

(shown with flywheel guard removed)
4242SR
9 - Maintenance EN
Page 9 - 56
9.9.3 Changing the impact screen

mesh WARNING
1. Observe all safety warnings. Refer to Section 9.1, Safety
warning.
LOCKOUT PLANT.
sizing screen and conveyors are empty Refer to Section 9.1, Safety
of material. Information for Lockout
Procedure.
conveyor (Section 9.9.1). FALLING HAZARD.
4. Stop the plant and implement the Information for relevant
warning.
5. Release the side tensioning strips by

slackening the 4 x nuts and bolts on
each side until the mesh can be re-
moved from under the clamp plates..
6. Fit replacement mesh and tension it

sufficiently so it will not move or flex
during operation.

the screen together with the fines
conveyor, taking care to then lower the
locking pins before operation of the plant
or transportation (Section 9.9.1).
4242SR
9 - Maintenance EN
Page 9 - 57
9.9.4 Changing the screen sizing

meshes - manual tensioning WARNING
warning.
LOCKOUT PLANT.
of material. Information for Lockout
Procedure.
conveyor (Section 9.9.1). FALLING HAZARD.
4. Stop the plant and implement the Information for relevant
lockout procedure (Section 8.2). warning.
5. Slacken the tensioning screws on each

side sufficiently to pull the tension bar
from the sizing mesh (Figure 9y),
enabling the mesh to be removed from
the screen hooks at each end.. Retaining Pin & Spring Clip
6. Check the mesh support cushions and

Tension Bar Tensioning Screws
replace if necessary. Also clean out any
build up of material in the screen box.
7. Hook the new mesh over the cross bar

at the far end. Re-insert the tensioning
bar to locate within the mesh hook.
8. Tighten the tensioning screws on each

side sufficiently to enable the spring clips
and retaining pins to be refitted behind
tensioning bar (Figure 9.y).

the screen together with the fines
conveyor, taking care to then lower the
locking pins before operation of the plant
Figure 9y Screen Tensioner
or transportation (Section 9.9.1).
4242SR
9 - Maintenance EN
Page 9 - 58
9.9.5 Changing the screen sizing

meshes - hydraulic tensioning WARNING
Where this equipment has been included in WEAR PERSONAL
the order specification, tensioning of the PROTECTIVE EQUIPMENT.
screen mesh is assisted by two detachable Refer to Section 9.1, Safety
hydraulic cylinders (Figure 9z). On each side Information for relevant
of the screen are quick release couplings to warning.
which the hydraulic ram hoses are attached. LOCKOUT PLANT.
The cylinders are mounted on the brackets Refer to Section 9.1, Safety
on the screen box with the piston clevis pin Information for Lockout
Procedure.
locating in the hole at each end of the screen
tensioning bar (Figure 9y) in order to retract
or tension as required. FALLING HAZARD.
Operation of the cylinders is by utilising the
warning.
same system that is used to open and close
the Impact Crusher body (Section 9.5). This
requires changing over the quick release
couplings adjacent to the hydraulic control
lever (Figure 9c).
Procedure

of material.

conveyor (Section 9.9.1).

5. Remove both screen tension cylinders

from their storage point then position
and secure with pins and spring clips
(Figure z). Connect the hoses to the
quick release couplings.
Figure 9z Screen Tensioner
4242SR
9 - Maintenance EN
Page 9 - 59
6. Operate the controls (Section 9.5) to 14. Remove the spring clips and pins to
extend the tension cylinders sufficiently release cylinders at both sides.
to enable the spring clips and retaining Disconnect the hydraulic hoses at the
pins to be removed from behind the quick coupling points. Place cylinders in
their storage point.
tensioning bar.
15. Raise the screen together the fines
7. Retract the cylinders sufficiently to pull
conveyor into the working position
the tension bar from the sizing mesh, (Section 9.9.1).
enabling mesh to be removed from the
screen hooks at each end.
! NOTICE !
The screen box may need
re-tuning after fitting replacement
screen meshes (Section 9.9.2).
9. Remove screen tensioning bar
(Figure 9y), also the spring clips and
pins that connect tensioning bar to
cylinders.
Remove main screen mesh.
10. Check all mesh support cushions and

replace if necessary. Clean any build up
of material in the screen box.
11. Locate lower hook of the replacement

screen mesh around the lower bar.
Insert the tensioning bar through slots
into the upper hook of screen. Refit the
pins and spring clips to connect cylin-
ders to the tensioning bar.
12. Operate the controls (Section 9.5) to

extend the tension cylinders sufficiently
to enable the spring clips and retaining
pins to be refitted behind tensioning bar.

4242SR
9 - Maintenance EN
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9.10 Plant - Hydraulic System

Description DANGER
SKIN INJECTION HAZARD
(Figure 9ab & Hydraulic circuit diagram Refer to Section 9.1, Safety
in Section 11- Appendix) Information for relevant warning
9.10.1 General Description

The hydraulic functions are powered by two 9.10.2 Track Drives
pumps, one mounted either side of the diesel
engine and driven from the main crankshaft Although these valves Sections have
pulley via two SPB belts plus a third pump proportional controls and are theoretically
driven from the engine power take-off.. infinitely variable they are electrically limited
to two speeds for simplicity.
The flows and pressures to each service is
limited by the relevant spool as shown in a) SLOW - For slewing and fine
Figure 9aa, and the pump supplies only the positioning.
required flow by automatically backing off
the swash plate angle thus reducing wasted b) FAST - For straight line running, forward
power and resulting heat generation. or reverse.
This is achieved by means of a load sensing Note:- The maximum power take off from
line from the valve to the pump which one side of the engine is limited to
measures the pressure required which is approximately 30 kW, therefore the system
then matched by the pump. is electronically limited such it is only
possible to slew (operate one side only)
Note:- when in the ‘SLOW’ mode.
All relief valve pressures are factory set and
should not be adjusted on site. Fine adjustment of the slow speeds is
possible. Consult Terex Pegson Ltd.
Although the maximum flows from each
spool is limited as shown, these can be It is recommended that adjustment is not
individually adjusted downwards by means of undertaken without Terex Pegson Ltd.
limit screws if desired. Please contact Terex consent and under no circumstances should
Pegson Ltd. the slow speed be adjusted greater than
0.2mph.
4242SR
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Page 9 - 61
Motor mounted motion control valves are

utilised to prevent the machine over running
when moving downhill.
DANGER
This block also incorporates a shuttle valve Refer to Section 9.1, Safety
to release the spring applied track parking Information for relevant warning
brake together with a pressure reducing
valve, pre set to 60 bar so that the brakes
are not overpressurised.
9.10.3 Feeder Drive The hydraulic oil filters are fitted with
condition indicators to shown when the
This valve Section is fitted with a renewable filter element needs to be
proportional solenoid so that the feeder changed. These should be checked on a
speed can be adjusted by increasing or daily basis whilst the plant is running at
decreasing using buttons on the main control normal operating temperature (Sections
panel. 9.13.5 - 6 & 8). In cold ambient
temperatures the filter indicators may show
9.10.4 Circuit Protection red until the system reaches normal
operating temperature.
The system is equipped with the following
protection:-
• Suction Filter (90μm nominal)
• Pressure Filter (10μm absolute) in each

pump circuit prior to the directional
control valves.
• Return Filter (10μm nominal)
• Low oil level cut out.
Note:- For Hydraulic Pump Drive Belt

adjustment refer to Section 9.11.4.
4242SR
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Front Pump
Max Flow Max Pressure
Service Spool Type
(Litres/min) (Bar)
L/H track drive motor Proportional 65 350
Product conveyor plus Magnet
On/Off 65 210
and Water Pump (when fitted)
Dirt & 2 x Transfer Conveyors On/Off 25 210
Rear Pump
Service Spool Type
(Litres/min) (Bar)
R/H track drive motor Proportional 65 350
Feeder Proportional 0-55 180
Re-circulating/Stockpile Conveyor Spool Type 40 210
Engine Power Take-Off Pump
Service Spool Type Max Flow Max Pressure
(Litres/min) (Bar)
Screen & Fines Conveyor On/Off 70 230
Dirt Conveyor Raise/Lower On/Off 10 175
Screen Raise/Lower On/Off 10 175
Re-Circ. Conveyor Raise/Lower On/Off 10 175
Feed Chute Raise/Lower On/Off 10 175
22/10/04
Figure 9aa Hydraulic Pump Flow/Pressure Chart (METRIC)
4242SR
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Page 9 - 63
Front Pump
Service Spool Type
(US galls/min) (Bar)
L/H track drive motor Proportional 17 350
Product conveyor plus Magnet
On/Off 17 210
and Water Pump (when fitted)
Dirt & 2 x Transfer Conveyors On/Off 6.60 210
Rear Pump
Service Spool Type
R/H track drive motor Proportional 17 350
Feeder Proportional 0 to 14.5 180
Re-circulating/Stockpile Conveyor Spool Type 10.57 210
Engine Power Take-Off Pump
Service Spool Type Max Flow Max Pressure
Screen & Fines Conveyor On/Off 18.49 230
Dirt Conveyor Raise/Lower On/Off 2.64 175
Screen Raise/Lower On/Off 2.64 175
Re-Circ. Conveyor Raise/Lower On/Off 2.64 175
Feed Chute Raise/Lower On/Off 2.64 175
22/10/04
Figure 9aB Hydraulic Pump Flow/Pressure Chart (USA)
4242SR
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9.10.5 Changing the Suction Filter

Located at the base of the hydraulic DANGER
reservoir tank are the two hydraulic suction SKIN INJECTION HAZARD
filters. When the dial gauge needle (Figure Refer to Section 9.1, Safety
9ac) enters into the red segment whilst the Information for relevant warning
system is running at normal operating
temperature this is an indication that the
filter must be replaced immediately . The
filter housing has an internal shut off valve to
permit work on the system. Make sure the
WARNING
oil has cooled before changing the filter. WEAR PERSONAL
warning.
1. Observe all safety warnings. LOCKOUT MACHINE.
2. Close down the machine (Section 8.2) Information for Lockout
and implement the Lockout Procedure. Procedure.
3. Unscrew the black plastic nut in the FALLING HAZARD.

centre of the filter housing anticlockwise Refer to Section 9.1, Safety
until it reaches the stop (Figure 9ac). Information for relevant
warning.
4. Take steps to collect spillage of oil
(approx. 2 quarts) before undoing the six
socket head screws on the front of the
housing to remove the cover plate.
5. Remove the old filter and clean inside 7. Fully screw in the black plastic nut in
the housing with lint free cloth before the centre of the filter housing.
fitting a new filter of the approved
pattern and specification.
! NOTICE !
6. Before replacing the cover plate, lightly
oil the ‘O’ ring and make sure it is It is important to ensure that the
properly seated in the groove. Replace black knob is fully screwed in
the cover plate and refit the screws to before starting the plant. Damage
ensure an oil tight seal. will occur to the plant if this
procedure is not followed.
4242SR
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Page 9 - 65
Filter Condition Indicator Dial
Black Knob
Removable Cover Plate
! NOTICE !
It is important to ensure that the
black knob is fully screwed in
Figure 9ac Suction Filter
before starting the plant. Damage
will occur to the plant if this
procedure is not followed.
Hydraulic Oil Return Hydraulic Oil

Filter and Gauge Breather/Filler
Hydraulic Oil Level Hydraulic Oil Tank Filter Condition Indicator Dial
Figure 9ad Hydraulic Oil Tank & Level Indicator
4242SR
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Page 9 - 66
9.10.6 Changing the Return Filter

Located on top of the hydraulic reservoir DANGER
tank is the hydraulic return filter. When the SKIN INJECTION HAZARD
dial gauge needle (Figure 9ad) enters into the Refer to Section 9.1, Safety
red segment whilst the system is running Information for relevant
at normal operating temperature this is warning
an indication that the filter must be replaced
immediately. Make sure the oil has
cooled before changing. WARNING
WEAR PERSONAL
In the event hydraulic oil needs to be added
to maintain the correct level on the gauge
(Figure 9ad), this should be poured in after Information for relevant
removing the cover (see below) but with the warning.
filter element left in place. Check the system
LOCKOUT MACHINE.
for leaks if topping up becomes necessary.
Information for Lockout Proce-
Procedure dure.
1. Observe all safety warnings. FALLING HAZARD.

2. Close down the machine (Section 8.2) Information for relevant
and implement the Lockout Procedure. warning.
3. Remove the four hexagon head screws

on the top of the housing to remove the
cover plate together with internal spring.
9.10.7 Changing the Tank Breather
4. Remove the old filter and clean inside
the housing with lint free cloth before This should be changed after the first 100
fitting a new filter of the approved hours of operating and thereafter after 500
pattern and specification. Replace the hours but in dusty atmosphere it is
spring which holds the filter in place recommended to change more frequently
depending upon conditions. Simply unscrew
5. Before replacing the cover plate, lightly and replace whilst the plant is shut down.
oil the ‘O’ ring and make sure it is
properly seated in the filter housing.
Replace the cover plate and refit the
screws to ensure an oil tight seal.
4242SR
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Page 9 - 67
9.10.8 Changing the Pressure

Filters DANGER
Located on each side on the engine within the SKIN INJECTION HAZARD
canopy are the hydraulic pressure filters. Refer to Section 9.1, Safety
When the ‘telltale’ (Figure 9ae) changes from Information for relevant
green to red whilst the system is running at warning
normal operating temperature this is an
indication that the filter must be replaced
immediately. Make sure the oil has cooled
before changing.
WARNING
WEAR PERSONAL
warning.
2. Close down the machine (Section 8.2) LOCKOUT MACHINE.

and implement the Lockout Procedure. Refer to Section 9.1, Safety
Procedure.
3. Unscrew (turn anticlockwise looking
from below) the filter bowl using the
hexagon ‘nut’ cast into the base. Take
steps to contain spillage of oil Filter condition ‘Telltale’ Filter body
4. Remove the old filter and clean inside

the bowl and housing with lint free cloth
before fitting into position a new filter
and small ‘O’ ring of the approved
pattern and specification.
5. Before replacing the bowl, lightly oil the

‘O’ ring and place on it’s seating in the
bowl making sure it is properly seated.
Screw the bowl into the housing taking
Bowl
care not to ‘cross’ the threads when
doing so. Tighten with the ‘nut’ at the
base of the bowl to ensure an oil tight
seal.
‘Nut’
Figure 9ae Pressure Filter
4242SR
9 - Maintenance EN
Page 9 - 68
9.11 Plant - Electrical

System Description WARNING
WEAR PERSONAL
For the plant electrical circuit diagram PROTECTIVE EQUIPMENT.
see Appendix Section of the manual. Refer to Section 9.1, Safety
The Caterpillar engine electrics are Information for relevant
covered separately. warning.
LOCKOUT MACHINE.
The electrical system on the 4242SR Refer to Section 9.1, Safety
Tracked Impactor is 24v DC powered from Information for Lockout
the plant diesel engine powerpack. Procedure.
Electrical circuits are employed to control

functions by means of solenoid valves in the
plant hydraulic system and also for safety It is important to the operation of the plant
purposes such as for the emergency stop that the electrical system is kept in good
buttons. order and, in the event of any damage to
components and wiring, this is only rectified
The main PLC panel controls the operating by an electrician having the necessary skill
procedures and also provides a number of and competence. Whilst the plant is under
alarm indicators, whilst a separate push warranty, no work on the system should be
button station is provided for setting up the undertaken before contacting Terex Pegson
plant prior to operation or transportation. Limited.
The electrical system also allows the remote

control facilities for the caterpillar track
system and the stopping/starting of the
feeder to operate.
The PLC panel includes a Configuration

Mode which is a password protected
installation diagnostic tool only for use by
Terex Pegson Limited.
The PLC also includes an Out of Sequence

Mode which MUST NOT be used in the
course of normal operation.
4242SR
9 - Maintenance EN
Page 9 - 69
9.12 Plant - Crusher and Hydraulic Pump Drive Belts
Good alignment of both pulleys is important otherwise the belt flanks will wear quickly. Ensure axis are
parallel when viewed from all planes (Figure 9af).
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 9af Correct Alignment of Pulley Belts
4242SR
9 - Maintenance EN
Page 9 - 70
9.12.1 Replacement of Crusher

Drive Belts WARNING
Note: Drive belts should inspected regularly WEAR PERSONAL
for wear and also to monitor any pattern in PROTECTIVE EQUIPMENT.
the wear if it is occurring (Figure 9t). Refer to Section 9.1, Safety
warning.
Procedure LOCKOUT MACHINE.
Procedure.
3. Open the hinged ends of the crusher

drive guard and also the underside panel 10. Tighten and tension the belts to the
by removing the securing hex. hd. set correct specification (Section 9.12.2)
screws. (captive nuts inside guard). ensuring the engine pulley is in correct
alignment with the crusher pulley (Figure
9t).
4. On the engine base frame, loosen nuts A
(Figure 9u) - 4 off
11. Ensure the crusher drive guarding is fully
replaced and secured before start-up.
5. Unscrew nut B a few turns. Repeat this
step for the other adjusting screw,
turning the nut an equivalent amount.
6. Tighten nut C. Repeat this step for the

other adjusting screw.
7. Slacken the belts until it is possible to

remove the belts without the need to
stretch them (Section 9.12.2).
8. Remove the belts.
9. Reposition the new belts in place by

threading through the guard, utilising the
underside access to assist this process.
4242SR
9 - Maintenance EN
Page 9 - 71
9.12.2 Adjustment of Crusher Drive

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

3. Open the crusher drive guard panels as

necessary to gain access to the vee belt
drive. (refer to Section 9.11.1 step 3)
4. Loosen nuts (A) (4 off) Figure 9u.
5. Unscrew nut (B) a few turns. Repeat

this step for the other adjusting screw,
turning the nut an equivalent amount.
6. Tighten nut (C). Repeat this step for the

7. If the belts are to be removed, repeat

Steps 5 and 6 to further slacken the belts
until it is possible to remove the belts
without the need to stretch them.
4242SR
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Page 9 - 72
If the tension is being adjusted,

repeat Steps 5 and 6 to further slacken
the belts, ensuring the engine pulley is in
correct alignment with the crusher pulley
(Figure 9af).
When the belts have reached the correct

tension (Figure 9ah, Section 9.12.5),
tighten nuts (A) 4 off.
8. Ensure the crusher drive guarding is fully

B C A (4 off)
Figure 9ag Crusher Drive Belt Tensioning Mechanism LH Side
4242SR
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Page 9 - 73
Tightening of the Drive Belts

WARNING
2. Close down the plant (Section 8.2) and warning.
implement the Lockout Procedure. LOCKOUT MACHINE.
3. Open the access panels from the Information for Lockout
crusher drive and flywheel guard as Procedure.
necessary. To gain access to the vee
belt drive (refer to Section 9.12.1 step 3)
4. Loosen nuts (A) (4 off) Figure 9ag. 9. When the belt has reached the correct
tension (Figure 9ah and Section 9.12.5),
5. Unscrew nut (C) a few turns. Repeat tighten nuts (A) 4 off.
this step for the other adjusting screw,
turning the nut an equivalent amount. 10. Ensure the crusher drive guarding is
6. Tighten nut (B). Repeat this step for the
7. Repeat steps 5 and 6 to further tighten

the belts, ensuring the engine pulley is in
correct alignment with the crusher
flywheel (Figure 9af).
Deflection Dimension Pulley Size (pcd) Basic Setting Force 1.25 Setting Force
mm / inches mm (inches) kgf (lbf) kgf (lbf)
See Section 9.12.5 224 (8.82) 7.1 (15.62) 8.9 (19.58)

(Step 3) 280 (11.02) 9.4 (20.68) 12.0 (26.40)
Figure 9ah Crusher Pulley Belt Tensioning Specifications
4242SR
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Page 9 - 74
9.12.3 Changing the engine pulley

When changing the plant crushing application WARNING
from recycling duties to quarry operation or WEAR PERSONAL
vice versa, the engine pulley needs to be PROTECTIVE EQUIPMENT.
changed to alter the crusher speed. Refer to Section 9.1, Safety
Plant are supplied with an engine pulley sized warning.
to suit each type of crushing application, one LOCKOUT MACHINE.
fitted and one loose Refer to Section 9.1, Safety
Procedure.
Before commencing a new crushing
operation check if it necessary to change the
pulley. This can most easily be done by
measuring the size of the loose pulley. Refer
to Section 4.2.1 for the appropriate pulley
size for each type of crushing operation.
Under no circumstances fit pulleys of a

different size unless authorised by Terex
Pegson Limited.
Procedure
1. Observe all safety warnings

3. Slacken the crusher drive belts (Section

9.12.2)
4. Change over the engine pulley keeping

the taper locking bush on the engine
shaft. Ensure that the new pulley is in
the same alignment as the original pulley
(Figure 9af) and firmly secure with the
taper locking socket screws.
5. Tighten the crusher drive belts (Section

9.12.2)
4242SR
9 - Maintenance EN
Page 9 - 75
9.12.4 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 beneath the
hydraulic pump.
WARNING
WEAR PERSONAL
Replacement of Drive Belts PROTECTIVE EQUIPMENT.
Procedure warning.
LOCKOUT MACHINE.
2. Close down the plant (Section 8.2) and Procedure.
3. Remove the diesel engine access covers.
4. Loosen the 4 bolts (A) securing the

8. Tighten the 4 bolts (A) to lock the pump
pump bracket to the pump stool (Figure
bracket to the pump stool.
9ai).
9. Replace the diesel engine access covers
5. Turn the 2 adjusting screws (B)
before start-up.
clockwise to slacken the two drive belts.
Continue until it is possible to remove the
belts.
6. Remove the two drive belts and refit

with new belts.
7. Turn the 2 adjusting screws

anticlockwise to tighten the two drive
belts. Continue until the belts have
reached the correct tension (Figure 9ai
and Section 9.12.5), making sure the
pump pulley is aligned with the drive
pulley (Figure 9af).
4242SR
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Page 9 - 76
Adjustment of Drive Belts

DANGER
Procedure
warning
3. Remove the diesel engine side access WARNING

covers.
WEAR PERSONAL
4. Loosen the 4 bolts (A) securing the Refer to Section 9.1, Safety
pump bracket to the pump stool (Figure Information for relevant
9ai). warning.
LOCKOUT MACHINE.
5. If the drive belts need to be Refer to Section 9.1, Safety
slackened, turn the 2 adjusting screws Information for Lockout
(B) clockwise. Continue to turn the Procedure.
adjusting screws equal amounts until the
drive belts have reached the correct
tension (Figure 9aj and Section 9.12.5),
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) anticlockwise. Continue to turn the
adjusting screws equal amounts until the
drive belts have reached the correct
tension
(Figure 9aj, Section 9.12.5), making sure
the pump pulley is aligned with the drive
pulley.
6. Tighten the 4 bolts (A) to lock the pump

bracket to the pump stool.
7. Replace the diesel engine side access

covers before start-up.
4242SR
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Page 9 - 77
Pump Bracket
Bolts (4 off) (A)

Pump Stool
Adjusting Screws (B)
Figure 9ai Hydraulic Pump Drive Belt Tension Mechanism
Deflection Dimension Basic Setting Force 1.25 x Setting Force

mm / inches kgf (lbf) kgf (lbf)
See Section 9.12.4 (Step 3) 6.3 (13.95) 7.9 (17.4)
Figure 9aj Hydraulic Pump Drive Belts Tensioning Specifications
4242SR
9 - Maintenance EN
Page 9 - 78
9.12.5 Method of Drive Belt

Tensioning WARNING
WEAR PERSONAL
Under no circumstances should Information for relevant
any check on the belt tension be warning.
made whilst the machine is LOCKOUT MACHINE.
running. There is a risk of Refer to Section 9.1, Safety
trapping parts of the body if this is Information for Lockout
done. Procedure.
Procedure
Crusher/Engine Drive Belts
implement the Lockout Procedure. 6 x 7500mm SPC,
Remove the guards from around the belt. Part Number 2441-0482
3. Calculate the deflection distance in Hydraulic Pump Drive Belts

inches on a basis of 16mm (0.625”)
deflection per 1 metre (1 yard) of belt 4 x 2000mm SPB,
span (Figure 9y). Part Number 2441-0412
Centre to Centre Distance - metres

(yards) x 16mm (0.625”) = Deflection
in mm (ins).
eg a centre distance of 2 metres (72”)

would be calculated as:
2 x 16mm = 32mm (0.625” = 11/4”)
4. If a belt tension indicator is

available:
a) Set the lower marker ring at the

deflection distance required on the lower
scale.
4242SR
9 - Maintenance EN
Page 9 - 79
b) Set the upper marker ring against the 6. If the measured force falls within the
bottom edge of the top tube. values given, the drive should be
satisfactory. A measured force below the
c) Place the belt tension indicator on top of lower value indicates under-tensioning. A
the belt at the centre of the belt span, new drive should be tensioned to the
and apply a force at right angles to the 1.25 x Setting Force value to allow for
belt deflecting it to the point where the the normal drop in tension during the
lower marker ring is level with the top of running-in period.
the adjacent belt.
7. Replace all guards before start-up.
d) Read off the setting force value
indicated by the top edge of the upper
marker ring. ! NOTICE !
After the drive has been running
e ) Compare this value to the lbf value
for 15-20 minutes, the tension
shown in the table:
Figure 9ah - Crusher Drive Belt
should be checked and readjusted
Tensioning Specifications to the Basic Setting Force value, if
Figure 9aj - Hydraulic Pump Drive Belt necessary by repeating the above
Tensioning Specifications procedure from Step 1.
5. If a belt tension indicator is not

available:
a) Use a spring balance to pull the belt

down at the centre of the span.
b) When the belt has been pulled down

(measure using a rule) by the deflection
calculated in Step 3, read off the force
from the spring balance.
4242SR
9 - Maintenance EN
Page 9 - 80
Ce
nt
re
to
Ce
nt
re
Di
sta
nc
e
16mm
Deflection
per 1 metre
(0.625in per
Belt Tension 1 yard) of
Indicator Applied Belt Span
to Mid-Span
Figure 9k Belt Tensioning Measurements
4242SR
9 - Maintenance EN
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9.12.6 Trouble Shooting - Drive

Belts WARNING
Small Cracks on V-Belt side and Base WEAR PERSONAL
Generally caused by shortage of belt tension Refer to Section 9.1, Safety
but excessive heat and/or chemical fumes Information for relevant
can also give same failure. warning.
LOCKOUT MACHINE.
V-Belt Swelling or Softening
Procedure.
Caused by excessive contamination by oil,
certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning,

principally on long centre drives. If a slightly
higher (or lower) tension does not cure the
problem there may be a critical vibration
frequency in the system which requires
redesign or a Banded belt. Consult Terex
Pegson Ltd.
4242SR
9 - Maintenance EN
Page 9 - 82
9.13 Plant - Conveyor Belts

DANGER
9.13.1 Training of Belts
ENTANGLEMENT
Before starting the conveyor, it is essential to HAZARD.
check that:- Refer to Section 9.1, Safety
warning.
• The conveyor is straight and correctly
levelled.
WARNING
• The head and tail drums are correctly
fitted. i.e. they are level, and that their WEAR PERSONAL
axes are square to the centre line of the
conveyor. Information for relevant
warning.
• All troughing and parallel idlers are
correctly fitted with their axles square to
the centre line of the conveyor, the side Tracking should be carried out with the belt
roller lead is in the correct direction (i.e. empty. With very stiff belts, which do not
forward of centre) and all rollers are trough well nor make proper contact with the
rotating freely. centre idlers roller when empty, it may only
be possible to track the return strand when
• In the case of screw-type take up gears, empty and the troughed side when loaded.
that these are adjusted initially to take up
slack from the belt and that equal tension If the belt tends to run to one side the most
is applied to each side such that the likely cause of the trouble will usually be
pulley is square to the centre line of the some distance before the point where the
conveyor. running off is apparent, and in the case of
troughed strand probably at the second or
• Where skirt rubbers are fitted they are third idler behind the point where the belt is
not bearing down heavily on the belt. moving out of its true line.
• There is no obstruction on the conveyor

that could cause accident or damage ! DANGER !
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.
4242SR
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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 9al Transome Breakdown
NB. The fixings for the side roller spindles may vary slightly from those shown
in the above typical illustration. The centre roller may be fastened with nuts
or clips.
4242SR
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9.13.2 Conveyor Belt Tensioning

All the plant conveyors have screw type belt WARNING
tensioning. Tensioning mechanisms are WEAR PERSONAL
located on either side of the drum (Figures PROTECTIVE EQUIPMENT.
9am/1 & /2). Refer to Section 9.1, Safety
Best practice is to tension each side a little at warning.
a time and by the same amount until the belt LOCKOUT MACHINE.
is tensioned. When tensioned, the drum must Refer to Section 9.1, Safety
be square to the conveyor frame. Information for Lockout
Procedure.
The correct tension is achieved when the
drive drum starts the belt and keeps it running
when loaded without any slip occurring. ! WARNING !
The tension screws should be kept clean and Under no circumstances should
well oiled. any adjustment be made on the
Procedure
1. Observe all safety warnings. Belt Tensioning
Mechanism
2. Close down the plant (Section 8.2) and Clamping Screws
3. Loosen the clamping setscrews and also

the 2 x locknuts (A) (Figure 9am/1) a.
4. Tighten square or hexagon ended of both

adjusting screws (B).
5. Once correct tension has been achieved,

tighten both locknuts and then the
clamping screws.
Locknut A (2 off) Square/Hex.

Ended Adjusting
Bar B (2off)
Figure 9am Conveyor Belt Tensioning

Mechanism
4242SR
9 - Maintenance EN
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Transfer Conveyor Tensioning

WARNING
LOCKOUT MACHINE.
3. Loosen the 4 x hex. screws (A) securing Information for Lockout
the bearings on both sides of the Procedure.
conveyor just enough for the bearing
housing to move (Figure 9am/2).
4. Loosen the 2 x locking nuts (B) on each

tensioning screw.
4. Tighten both adjusting screws (C).
5. Once correct tension has been achieved,

tighten the screws (A) and nuts (B). Adjusting Screw (C)
! WARNING !
Under no circumstances should
any adjustment be made on the
2 x Nuts (B) 4 x Screws (A)
Figure 9am Conveyor Belt Tensioning

Mechanism
4242SR
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9.13.3 Maintenance of Conveyor(s)

The following checks should be made DANGER
regularly in order to keep the conveyor(s) in ENTANGLEMENT
good working order: HAZARD.
• Observe all safety warnings. Information for relevant
warning.
• Close down the plant (Section 8.2) and
WARNING
• Ensure that central feed onto the WEAR PERSONAL
conveyor belt is maintained at all times PROTECTIVE EQUIPMENT.
and that the belt at the point of feed is Refer to Section 9.1, Safety
kept straight and central at all times. Information for relevant
warning.
LOCKOUT MACHINE.
• Inspect the skirt plate sealing strips and
ensure that they are adjusted close
enough to the belt to prevent spillage or Procedure.
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 9.13.1 Training of
Belts.
• Inspect the condition of the conveyor

belt regularly and arrange for the earliest
possible repair of any damage which ! DANGER !
may have occurred as this can make a
worthwhile extension of the useful life of
Do not use clip joints for belt
the belt. Repair a cut or tear in the repairs or replacements, as they
rubber by cleaning with benzine and can be dangerous. Belt repairs/
plugging with a rubber repair compound. replacements should be
performed by vulcanising only.
4242SR
9 - Maintenance EN
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• Check that there is no evidence of belt • In the interests of efficient operation and
slip at the driving drum, as belt slip will general safety, it is important that
cause premature wear on the belt. operating conditions are kept as clean as
Check also for undue sag between possible and that any spillages are
idlers. Both would indicate lack of belt cleaned up regularly and are not allowed
tension (Section 9.13.2) to build up.
• Check regularly that the idler rollers are

rotating freely. If not either free them or ! DANGER !
replace the idler. Failure to do so will
As many inspections as possible
result in belt wear and tracking
problems.
should be made whilst the belt is
stationary. When this is not
• Check that the belt cleaning equipment is possible extreme care should be
operating correctly and efficiently. In taken when inspecting the belt
the case of scrapers ensure that they are whilst it is moving as this creates a
not choked with a build up of material. risk of trapping parts of the body.
Also check that the blades are not
bearing on the belt any more than
necessary, and that any blades which are
unevenly worn or in a condition likely to
cause damage to the belt are renewed
immediately.
• Lubricate the dirt conveyor pivots.
• The grease in the head and tail drum

bearings of the product conveyor and dirt
conveyor need re-greasing bimonthly
(Section 9.4).
Note:- The grease nipples for the product

conveyor and dirt conveyor tail drum are
remote and located either side of the plant
chassis.
4242SR
9 - Maintenance EN
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9.13.4 Cleaning the Conveyor

Belts WARNING
If your machines’ conveyor belts are not WEAR PERSONAL
properly maintained and skirting rubbers PROTECTIVE EQUIPMENT.
are not kept in proper adjustment, it may be Refer to Section 9.1, Safety
necessary to remove resultant spillage warning.
material and / or blockages from the
conveyor belts, particularly at the feed LOCKOUT PLANT.
section.
Procedure.
! DANGER ! FALLING HAZARD.
It is important that these Refer to Section 9.1, Safety
procedures are followed when warning.
cleaning the conveyor belts.
Failure to follow these procedures
can result in death 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.
4242SR
9 - Maintenance EN
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5. Not only the worker(s) cleaning the

belts but also others close by who
may be affected, must also wear
! NOTICE !
The conveyor belts can be
cleaned using a number of
methods. Before commencing,
make sure all aforementioned
procedures have been followed: -
• Using a high pressure air hose;

• Using a water hose;
• 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
9.13.1 and 9.13.2 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.
4242SR
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9.14 Plant - Overband Magnetic Separator

Magnetic Separator
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.
! WARNING !
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
operator has the sole
responsibility to keep anyone at
Shedder Plate (To be removed
risk clear of the machine. for transportation)
Start-Up of Self Cleaning Magnetic

Separator
Figure 9an MagneticSeparator
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:
4242SR
9 - Maintenance EN
Page 9 - 91
Maintenance
• Belt tracking should be checked

DANGER
frequently and adjusted as necessary. ENTANGLEMENT
Tighten the side of the belt to which you HAZARD.
want the belt to move. Refer to Section 9.1, Safety
warning.
• Lubricate bearings on a schedule
consistent with other equipment in use
with your product. WARNING
• The speed of the belt on the magnetic WEAR PERSONAL
overband separator is preset at the
factory but can be altered by turning the Information for relevant
adjusting screw located in the hydraulic warning.
line. LOCKOUT MACHINE.
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.
4242SR
9 - Maintenance EN
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9.15 Plant - Dust

Suppression
The 4242SR plant is fitted with a plain water

dust suppression system. The system
consists of two spray bars each one having
three nozzles. The spray bars are located in
the following areas:-
• 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 9ao). The
total flow requirement for the system is
7litres/min (2 US galls). This equates to a
pressure requirement of 2.8 bar (42 psi).
Product Crusher
Maintenance Conveyor Discharge
Discharge Area
All nozzles should be kept free of dirt and
blockages. Each nozzle should be checked Figure 9ao Dust Suppression Manifold
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.
! NOTICE !
Do not spray water into the
crusher as this will increase the
wear.
4242SR
9 - Maintenance EN
Page 9 - 93
9.16 Plant - Diesel Engine

WARNING
For the diesel engine powerpack Refer to Section 9.1, Safety
fitted to your 4242SR Tracked Information for relevant
warning.
Impactor to continue to perform
LOCKOUT MACHINE.
safely, efficiently and reliably it is
imperative that all the Information for Lockout
recommendations given in the Procedure.
separate engine manual are
strictly followed with regard to:-
• Safety
• Operation
• Lubrication For the Twin Disc mechanically
operated clutch refer to the instruction
• Maintenance
plate on the clutch (or separate
• Service manufacturers manual) for the correct
adjustment and lubrication information.
• Parts Also Section 9.16.2.
Adhere to the regular maintenance
schedules and procedures specified by the
manufacturer using the numbers of hours run
as displayed on the engine control panel.
The diesel engine powerpack incorporates a

Caterpillar engine but the external housing
and some of the associated ancillary engine
components are not necessarily of CAT
origin.
For after sales and warranty matters, first

contact your local Terex Pegson dealer for
assistance
4242SR
9 - Maintenance EN
Page 9 - 94
9.16.1 Engine Clutch Adjustment

IMPORTANT -TWIN DISC MANUAL WARNING
CLUTCH INSTRUCTIONS WEAR PERSONAL
Full instructions regarding the engine clutch Refer to Section 9.1, Safety
are detailed in the separate manufacturers Information for relevant
manual. Extracts given here are for easy warning.
reference only. The operator should always LOCKOUT MACHINE.
comply with the manufacturers instructions Refer to Section 9.1, Safety
given in their manual. Information for Lockout
Procedure.
Refer to the Appendix (Section 11) for
instructions regarding the engine clutch
adjustment check to be made at the time
of initial commissioning at new and the 9.16.2 Clutch Maintenance
essential regular maintenance of the
clutch thereafter. Adhere to the manufacturers separate
manual, particularly in respect of the
New clutch plates have a ‘wear in’ period and adjustment (9.16.1) and for lubricating the
the clutch may require several adjustments output shaft bearing (Figure 9ap).
until new plates are ‘worn in’.
A newly fitted power take off must have it’s

clutch adjustment checked at the following
intervals:- Bearing Grease Nipple
• 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.
Figure 9ap Clutch Bearing Lubricator
4242SR
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Page 9 - 95
9.16.3 Engine - ELC Coolant

Engines fitted with aluminium cored radiators are filled with Extended Life Coolant (ELC) and must
ONLY be topped up or refilled with Cat ELC or a coolant that meets Cat EC-1 specification. If this is
not available top up with deionized water and adjust mixture concentration in the shop. Under no
circumstances use any other coolant as damage will result and any warranty invalidated.
Equipment is intended for use in ambient temperatures between -10°C to +40°C (+14°F to +104°F).
Appropriate lubricants and coolant must be used as specified within the plant and engine operating and
maintenance manuals.
For use in temperatures outside the above range consult your Terex Pegson Dealer or Terex Pegson
Limited for details prior to commencement of operations.
ELC Coolant can be used where Ethylene Glycol based antifreeze has been used previously BUT
THE COOLING SYSTEM MUST BE THOUGHLY DRAINED AND FLUSHED THROUGH
before refilling with ELC coolant.
Adhere to the instructions on the external labelling as shown below.
4242SR
9 - Maintenance EN
Page 9 - 96
9.16.4 Check Fuel Level
Procedure
WARNING
WEAR PERSONAL
2. Check the fuel level indicator (Figure Information for relevant
warning.
9aq)
LOCKOUT MACHINE.
3. Top up fuel level if required (Section
9.16.5). Procedure.
• Fill the tank at the end of each day,

where possible, to reduce overnight
condensation within the tank.
! DANGER !
Diesel fuel is highly flammable and
is an explosion/burns hazard.
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 Fuel Level

carrying out maintenance on the
fuel system. Figure 9aq Fuel Level Indicator - Engine
Control Panel
DO NOT carry out maintenance on
the fuel system near naked lights
or sources of sparks, such as
welding equipment.
4242SR
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Page 9 - 97
9.16.5 Top Up Fuel Level

WARNING
DO NOT fill the tank to capacity. PROTECTIVE EQUIPMENT.
Monitor the gauge located on the warning.
Control Panel (Figure 9aq). LOCKOUT MACHINE.
Allow room for expansion and Information for Lockout
wipe up spilt fuel immediately, Procedure.
otherwise paintwork will be
damaged.
Procedure ! DANGER !
1. Observe all safety warnings. NEVER add gasoline or any other
fuel mixes to diesel because of
2. Close down the plant (Section 8.2) and increased fire or explosion risks.
DO NOT smoke while refilling or
3. Remove the engine side access panel on carrying out maintenance on the
the side nearest to the crusher to reveal fuel system.
the filler cap. (Figure 9ar). Clean the
area around the filler cap. DO NOT carry out maintenance on
the fuel system near naked lights
4. Remove the filler cap.
or sources of sparks, such as
welding equipment.
5. Fill the tank will diesel fuel.
6. Replace the cap and refit the engine

access panel before start up.
! DANGER !
Diesel fuel is highly flammable and
is an explosion/burns hazard.
NEVER remove the filler cap or

refuel, with the engine running.
Figure 9ar Filler Cap
4242SR
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Page 9 - 98
9.17 Plant - Vehicle Tracks

WARNING
It is essential that the tracks are Refer to Section 9.1, Safety
correctly tensioned at all times. Information for relevant
warning.
Check track tension regularly.
LOCKOUT MACHINE.
Keeping the track properly adjusted will Refer to Section 9.1, Safety
increase the service life of the track and
Procedure.
drive components.
When ordering Spare Parts it is essential

to quote the plant serial number with
either a /S or /T suffix.
! WARNING !
Frequently check for loose bolts, oil leaks,
master pins are correctly located and tight, Prior to attempting any
general wear and damage, correct track manoeuvring of the plant the
tension, etc. to ensure safe working and long tracks must be free of
life. obstructions, including crushed
material and fines. Do not push or
When travelling on a gradient, the tracks tow the plant. Failure to observe
should be driven with the track idler rollers this warning could result in injury
(Figure 9at) in front (ie. Feed Hopper first).. to persons and damage to the
plant which may invalidate
9.17.1 Measuring Track Tension warranty.
Procedure
2. Position the plant on solid and level

ground and drive 2 metres (2 yards)
minimum in a forward direction, track
idler roller leading.
4242SR
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Page 9 - 99

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 a
‘straight edge’ long enough to reach
from the drive sprocket to the nearest
skid plate.
5. Measure the maximum amount of track

sag from the high point of the track
grouser to the bottom of the ‘straight
edge’ (Figure 9as). Correctly adjusted
the sag must be a maximum of 15mm
(5/8”) but must not be less that 5mm
(1/4”).
! WARNING !
5 - 15mm
Tracking the machine with (1/4 - 5/8”)
incorrectly tensioned tracks can
cause severe damage to the
undercarriage components and
may invalidate the warrant.
Figure 9as Measuring Track Tension
6. Depending upon the need to either
slacken or tension the track(s) proceed
as below.
4242SR
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9.17.2 Adjusting Track Tension

DANGER
! DANGER ! SKIN INJECTION HAZARD
‘GREASE UNDER HIGH Information for relevant
PRESSURE’ warning
To Release Track Tension (After

measurement - Section 9.17.1):-
WARNING
1. Observe all Safety Warnings. Refer to Section 9.1, Safety
implement the Lockout Procedure. LOCKOUT MACHINE.
3. Locate the access aperture on the side Information for Lockout
of the track frame and remove the cover Procedure.
(where fitted) to reveal the relief valve
inside.
4. Next loosen the relief valve by turning

anti-clockwise using gradual increments
until the grease begins to be expelled.
Care must be taken not to loosen ! WARNING !
the relief valve too quickly because
Grease coming out of the relief
the grease inside is under high
pressure.
valve under pressure can
penetrate the body causing injury
5. When the correct track tension has been or death; do NOT watch the relief
measured (Section 9.17.1), turn the relief valve to see if grease is escaping
valve clockwise to tighten and then clean but instead watch the track
away all trace of expelled grease. adjustment cylinder to verify that
the track is being loosened.
DO NOT OVER TENSION THE

TRACKS (Refer to Section 9.17.2).
4242SR
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6. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) 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, drive the plant
forwards and backwards several times
over a shorter distance.
If the track fails to slacken after the

grease fitting has been loosened, do not
attempt to remove the tracks or
disassemble the track tensioner, or
remove the grease fitting. It is possible
that running the tracks with the grease
fitting loosened may help to expel the
grease.
Track Surface Idler Roller

Skid plate
Drive Sprocket
Relief Valve
(inside access aperture)
Final Drive Track Roller
Unit
Figure 9at Vehicle Track Parts
4242SR
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To Increase Track Tension (After

measurement - Section 9.17.1):- DANGER
1. Observe all Safety Warnings. warning

WARNING
3. Locate the access aperture on the side WEAR PERSONAL
of the track frame and remove the cover PROTECTIVE EQUIPMENT.
(where fitted) to reveal the relief valve Refer to Section 9.1, Safety
inside. Information for relevant
warning.
4. Connect the grease gun to the grease LOCKOUT MACHINE.
fitting and add grease until the track Refer to Section 9.1, Safety
tension is within the specified dimension Information for Lockout
(Section 9.17.1). See Section 9.4.4. for Procedure.
the grease type and specification.
5. Operate the plant in manoeuvring mode

(Section 5.2.1) and drive the plant 50
metres (50 yards) forwards and 50
metres backwards, measure the sag and
repeat the steps 1 - 4 if the track(s) sag
is too great. If room for manoeuvring the
plant is restricted, drive the plant
forwards and backwards several times
over a shorter distance.
4242SR
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9.17.3 Track Maintenance

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

working hours.
Daily
Procedure ! NOTICE !
1. Observe all safety warnings. To maximise the life of the track,
keep it movable and avoid
2. Close down the machine (Section 8.2)
damage, the plant should be
and implement the Lockout Procedure.
moved at least every week, by a
3. Check the track rollers and idler wheels distance exceeding four times the
for possible leakage. track length. It should also be
parked on level ground overnight
4. Check the track surface of the track and during periods to of non-
rollers, idler wheels, track shoes and usage. This is particularly
drive sprockets for wear and loose important when working in
mounting bolts. adverse conditions.
5. Clean out any heavy build up of material

from around the tracks.
6. Check the tension of the tracks (Section

9.16.1) and adjust tension if necessary
(Section 9.16.2).
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9.17.4 Drive Oil Filling and Draining

Oil Filling WARNING
WEAR PERSONAL
Procedure PROTECTIVE EQUIPMENT.
1. Observe all safety warnings. Information for relevant
warning.
2. Close down the plant (Section 8.2) and LOCKOUT MACHINE.
implement the Lockout Procedure. Refer to Section 9.1, Safety
Procedure.
3. Make sure the gearbox housing is
horizontal.
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 9au).
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.
See Section 9.4.4 for oil type and
specification.
Oil Fill (A)
6. Clean plugs using a clean non-flammable
solvent.
7. Apply pipe sealant to the plugs and

install.
8. Repeat procedure on the other final

drive.
Note:- Over filling the final drive will cause

the travel motor seal to allow hydraulic oil or
water to enter and contaminate the drive.
Oil Level (B)
Figure 9au Tracks - Oil Filling
4242SR
9 - Maintenance EN
Page 9 - 105
Oil Draining
WARNING
Procedure
WEAR PERSONAL
2. Close down the plant (Section 8.2) warning.
and implement the Lockout LOCKOUT MACHINE.
Procedure. Refer to Section 9.1, Safety
3. Rotate the gearbox housing until a Procedure.
plug is at the 6 o’clock position (Figure
9av).
4. Unscrew both plugs and discharge the (A)

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

drive.
Oil Drain (B)
Figure 9av Tracks - Oil Draining
4242SR
9 - Maintenance EN
Page 9 - 106
Blank page
4242SR
10 - Spare Parts EN
Page 10 - 1
Contents
10.1 Impact Crusher Parts ........................................................................................ 5

Impact Crusher - Blow Bar Assembly ........................................................................ 6
Impact Crusher - Rotor Shaft Assembly .................................................................... 8
Impact Crusher - Mainframe Liner Plates................................................................ 10
Impact Crusher - Front Impact Apron Liner Plates ................................................... 12
Impact Crusher - Rear Impact Apron Liner Plates ................................................... 14
Impact Crusher - Grinding Path - Swing Beam Liners ............................................. 16
Impact Crusher - Front Apron Adjustment Mechanism ............................................. 18
Impact Crusher - Rear Apron Adjustment Mechanism ............................................. 20
Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism ................... 22
10.2 Feeder Parts ..................................................................................................... 24
Grizzly Feeder - Mainframe assembly .................................................................... 24
Grizzly Feeder - Vibrating Unit Assembly ................................................................ 26
Grizzly Feeder - Driveside Shaft Assembly ............................................................. 28
Grizzly Feeder - Non Driveside Shaft Assembly ...................................................... 30
10.3Screen Parts ..................................................................................................... 32
Screen Box Assembly ............................................................................................ 32
Screen Box Assembly, continued ........................................................................... 34
Screen Shaft & Drive Assembly ............................................................................. 36
Screen Shaft & Drive Assembly, continued ............................................................. 38
10.4 Conveyor Parts ................................................................................................ 40
Dirt Conveyor - sheet 1 ......................................................................................... 40
Dirt Conveyor - sheet 2 ......................................................................................... 42
Crushed Product Conveyor - sheet 1 ...................................................................... 44
Upper Side Transfer Conveyor ............................................................................... 50
Lower Side Transfer Conveyor ............................................................................... 52
Recirculating Conveyor ......................................................................................... 54
Recirculating Conveyor Chute ............................................................................... 56
Fines Conveyor ..................................................................................................... 58
Stockpile Conveyor (Optional) ................................................................................ 60
4242SR
10 - Spare Parts EN
Page 10 - 2
10.5 Plant Parts ....................................................................................................... 62

Chassis Assembly Parts ........................................................................................ 62
Engine Assembly Parts .......................................................................................... 64
Control Cabinet and Toolbox Assembly Parts ......................................................... 64
Screen and Conveyor Assembly Parts ................................................................... 66
10.6 Plant Tracks ..................................................................................................... 68
‘S’ Mark Tracks ...................................................................................................... 68
‘T’ Mark Tracks ...................................................................................................... 70
10.7 Overband Magnetic Separator........................................................................ 72
10.8 Hydraulic Components ................................................................................... 74

Hydraulic Oil Reservoir ........................................................................................... 74
Impact Crusher Door Ram Hoses .......................................................................... 74
Hydraulic Hoses - sheet 1 ...................................................................................... 76
Hydraulic System Components .............................................................................. 80
10.9 Electrical Components .................................................................................... 82
10.10 Safety Signs (with part numbers) ................................................................. 84
4242SR
10 - Spare Parts EN
Page 10 - 3
IMPORTANT
TO ORDER REPLACEMENT SPARE PARTS CONTACT YOUR LOCAL
TEREX 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)
TEREX 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.
4242SR
10 - Spare Parts EN
Page 10 - 4
Blank page
4242SR
10 - Spare Parts EN
Page 10 - 5
10.1 Impact Crusher Parts
14 11 12 13
10
3 4 5 15 6 16
1 Feed Opening 9 Rear Apron Adjustment

2 Shaft 10 Rear Apron
3 Rotor 11 Front Apron Liner Plates
4 Rotor Protection Cap 12 Front Apron Adjustment
5 Blow Bars 13 Front Apron
6 Swing Beam (Grinding Path) 14 Crusher Mainframe
7 Swing Beam Liner Plates 15 Swing Beam Rails
8 Rear Apron Liner Plates 16 Swing Beam Adjustment
Impact Crusher - 428 Trakpactor
Spare Parts - 4242 SR Page 6
Impact Crusher - Blow Bar Assembly
REF PART NUMBER DESCRIPTION QUANTITY

1 A6984/93 ROTOR SHAFT 1
2 A6984/76H CAST ROTOR 1
3 IM 020 4228 AXIAL SECURING PLATE 8
4 A6984/80 STD. HIGH Mg. BLOW BAR (LONG) 2
4A A6984/79 STD. HIGH Mg. BLOW BAR (SHORT) 2
5 IM 024 4228 ROTOR PROTECTION CAP 16
6 A6984/23/117 PIN – AXIAL SECURE PLATE 8
2201-0165 SPLIT PIN 8
A6984/23/8 WASHER 8
7 2450-5108 RINGFEDDER 2
N/S 2971-2002 HYDRAULIC HAMMER EXTRACTION TOOL 1
N/S 2527-1048 HOSE ASSY 2
N/S 2520-6557 3/8 M COUPLING THESE PARTS ARE 3
N/S 2520-6558 3/8 F/M COUPLING FOR THE 3
EXTRACTION TOOL
N/S 2520-6003 3/8 M/M ADAPTOR 10
N/S 2500-1015 BONDED SEAL 10
A6984/96 – 23/11/04
ALTERNATIVE HIGH CHROME / HIGH MANGANESE BLOW BARS

OF 2 x LONG / 2 x SHORT CONFIGURATION SHOWN BELOW
BUT CAN BE 4 LONG HIGH CHROME BARS
4 A6984/83 HIGH CHROME BLOW BAR (LONG) 2

4A A6984/79 HIGH MANGANESE BLOW BAR (SHORT) 2
ALTERNATIVE MARTENSITIC / HIGH MANGANESE BLOW BARS

OF 2 x LONG / 2 x SHORT CONFIGURATION SHOWN BELOW
BUT CAN BE 4 LONG MARTENSITIC BARS
4 A6984/121 MARTENSITIC BLOW BAR (LONG) 2

4A A6984/79 HIGH MANGANESE BLOW BAR (SHORT) 2
IMPORTANT
BEFORE FITTING BLOW BARS OF ALTERNATIVE TYPES OF STEEL, READ THE
ADDENDUM ‘428 IMPACT CRUSHER – GUIDE TO EFFICIENT OPERATION’
OR CONSULT YOUR TEREX PEGSON DEALER
01/12/04
4A
3
6
7
4
4
5
2
1
4A
4
4
3
5
5
3
428 Impact Crusher - Hammer Assembly

Impact Crusher - Rotor Shaft Assembly

1 A6984/93 ROTOR SHAFT 1
2 A6984/5 BEARING HOUSING 2
3 A6984/94 SPACING COLLAR 1
4 A6984/7 OUTER LABYRINTH – FIXED 2
5 A6984/8 OUTER LABYRINTH – FLOATING 1
6 A6984/97 SHAFT END DISC 1
7 A6984/52 BEARING HOUSING COVER PLATE 1
8 IM 027D 4228 INNER LABYRINTH – 125 BORE 1
9 IM 027F 4228 INNER LABYRINTH – 160 BORE 2
10 A6984/76P CAST ROTOR 1
11 A6984/81 ROTOR END CAP 2
12 2416-0417 BEARING – SPHERICAL ROLLER 2
13 2430-1101 CIRCLIP – EXTERNAL ? 150 1
14 AX846/113 PULLEY 1
15 2450-8060 PULLEY LOCKING BUSH 1
16 2450-5108 RINGFEDDER 2
17 2510-3861 PLUG – RECESSED 4
18 2530-1008 GREASE NIPPLE 5
19 2222-0187 SCR – HEX SKT – CAP HD. 6
2211-0008 WASHER - SPRING 6
20 2222-0188 SCR - HEX SKT - CAP HD. 18
2211-0008 WASHER - SPRING 18
21 2226-0795 SCR - CSK HD. 12
22 2226-0584 SCREW - CSK HD. 2
23 2222-0356 SCR - HEX SKT - CAP HD. 8
2210-0023 WASHER - PLAIN 8
2217-0011 NUT - HEX 8
N/S A6984/50/1 ROTOR LOCK THESE ITEMS ARE 1
N/S A6984/50/2 ROTOR LOCK LH & RH HANDED 1
A6984/96 – 23/11/04
17
15
6
22
14
20
4
2
18
12
4
21
9
11
16
10
1
16
11
20
21
9
2
18
12
19
23
7
13
17
428 Impact Crusher - Rotor Shaft Assembly

Impact Crusher - Mainframe Liner Plates

1 A6984/9/1 LINER PLATE – 9.8 kg. EACH 2
11 A6984/9/11 LINER PLATE – 30. 8 kg. EACH 6
12 A6984/9/148 LINER PLATE – 39 kg. EACH 2
23 A6984/9/23 LINER PLATE – 102 kg. 1
25
26 2222-0297 SCREW 56
27 2230-1285 SCREW 177
28 2230-1287 SCREW 28
29
30 2232-1281 BOLT 20
31
32 2211-0012 WASHER-SPRING 281
A6984/19_02mod – 23/11/04
428 Impact Crusher - Mainframe Liner Plates

Impact Crusher - Front Impact Apron Liner Plates

1 A6984/106 FRONT IMPACT APRON 1
2 A6984/9/25 LINER PLATE 2
5 A6984/102 LINER PLATE 2
7 A6984/25/1 SCREW 20
8 A6984/25/2 SCREW 8
9 A6984/25/3 SCREW 4
10
11
12 2210-0021 WASHER – PLAIN – FORM A 20 4
14
15 2217-0009 NUT – HEX – PHILIDAS MKV M20 4
16 2217-0011 NUT – HEX – PHILIDAS MKV M24 28
17
18 2220-0206 SCREW 4
19
20 0577
2220-06 KEY – 36x20x200 SQ END. 12
A6984/109_01 – 26/09/03
ITEM PART NO: DESCRIPTION QTY WEIGHT

1 A6984/106 FRONT IMPACT APRON 1 685 kg.
2 A6984/9/25 LINER PLATE 2 19.8 kg. each
3 A6984/9/26 LINER PLATE 4 43 kg. each
4 A6984/9/28 LINER PLATE 4 47.2 kg. each
5 A6984/102 LINER PLATE 2 84 kg. each
6 A6984/103 LINER PLATE 2 56 kg. each
A6984/109_01 – 26/09/03
Pivot Pin A6984/150 with

2 x A6984/149 aluminium bronze Bushes
428 Impact Crusher - Front Impact Apron Liner Plates

Impact Crusher - Rear Impact Apron Liner Plates

1 A6984/107 REAR IMPACT APRON 1
4 A6984/25/1 SCREW 8
5
6
7 2220-0206 SCREW 4
8 2222-0313 SCREW 8
9
11 2211-0012 WASHER – SPRING -SQ SECT. 20 8
12
13 2217-0011 NUT – HEX 8
14
15 2432-0577 KEY 4
A6984/110_01 – 26/09/03
ITEM PART NO: DESCRIPTION QTY WEIGHT

1 A6984/107 REAR IMPACT APRON 1 435 kgs
2 A6984/9/24 LINER PLATE 4 24.2 kgs each
3 A6984/9/28 LINER PLATE 4 47.2 kgs each
A6984/110_01 – 26/09/03
Pivot Pin A6984/150 with

2 x A6984/149 aluminium bronze Bushes
428 Impact Crusher - Rear Impact Apron Liner Plates

Impact Crusher - Grinding Path - Swing Beam Liners

1 A6984/43/1 SWING BEAM 1
2 A6984/43/2 SHEAR BLOCK 1
3 A6984/23/13 SWING BEAM CONNECTING PIN 1
4 A6984/23/14 SWING BEAM CONNECTING PIN WASHER 1
5 A6984/25/4 SCREW 4
6 A6984/26 SWING BEAM PIVOT BAR 1
7 A6984/51 SWING BEAM LOCATING SLEEVE 2
9 A6984/132 SWING BEAM RAIL 6
10
11
12 2201-0182 PIN – SPLIT COTTER 1
13
14 2210-0023 WASHER 4
15
16 2217-0011 NUT 4
17
18 2432-0577 KEY 36 x 20 x 200 SQ END 2
CHAIN CURTAIN FOR FINES CHUTE – NOT ILLUSTRATED
A6984/145 CHAIN MOUNTING PLATE 2
A6984/146 CHAIN SPACER 1
A6984/147 CLAMP STRIP 1
AX864/119 RUBBER FOR CHAIN CURTAIN 1
2321-1102 CHAIN – 2 LINKS LONG 2
2232-1214 BOLT 13
A6984/42_00 – 23/11/04
428 Impact Crusher - Grinding Path - Swing Beam Liners
Impact Crusher - Front Apron Adjustment Mechanism

1 A6984/12 ADJUSTING ROD 1
2 A6984/37 ADJUSTING BOLT SLEEVE 4
3 2436-9144 DISC SPRING 4
4 2215-0024 ADJUSTING NUT 1
LOCKNUT (WITH PROTECTIVE SLEEVE
5 A6984/84 1
AND CHAIN)
1 – 26/-9/03
A6984/35_00
NB. THERE ARE 2 OF THE ABOVE MECHANISMS ON THE 428 IMPACTOR
428Impact Crusher - Front Apron Adjustment Mechanism

Impact Crusher - Rear Apron Adjustment Mechanism

1 A6984/11/1 ADJUSTING ROD 1
2 A6984/38 FABRICATED SEAT-REAR 1
4 IA6984/71 THRUST WASHER 1
5 A6984/10 SLEEVE 1
6 A6984/13 SPRING CAP 1
7 A6984/141 KEEP PLATE 1
8 2210-0016 WASHER 2
9 2211-0007 SPRING WASHER 2
10 2232-1099 BOLT 2
11 A6984/136 HOLLOW PLUG 1
12 A6984/11/2 END CAP 1
14 2222-0118 CAPSCREW 2
15 A6984/143 PROTECTION CAP WITH CHAIN 2
16 2215-0018 NUT 2
17 2210-0021 WASHER 2
18 IM 029H 4228 SPRING 1
19 A6984/40 TENSION ROD 2
20 A6984/41 SPRING SUPPORT 1
A6984/36_06 – 01/12/04
NB. THERE ARE 2 OF THE ABOVE MECHANISMS ON THE 428 IMPACTOR
428 Impact Crusher - Rear Impact Apron Adjustment

Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism

1 A6984/47/1 SWING BEAM - ADJUSTING ROD 1
2 2215-0018 NUT 4
3 2210-0021 WASHER 4
5 A6984/71 THRUST WASHER 1
6 A6984/10 SLEEVE 1
7 A6984/13 SPRING CAP 1
8 A6984/86 KEEP PLATE 1
9 2210-0016 WASHER - PLAIN 2
10 2211-0007 WASHER - SPRING 2
11 2230-1153 SCREW 2
12 2510-3836 HOLLOW PLUG 1
13 A6984/47/2 END CAP 1
14 2211-0006 WASHER - SPRING` 2
15 2222-0118 CAPSCREW 2
16 A6984/39 PROTECTION CAP 2
17 IM.030H.4228 SPRING 1
18 A6984/49 TENSION ROD 2
19 A6984/48 SPRING SUPPORT 1
A6984/46_04 – 26/09/03
428 Impact Crusher - Grinding Path - Swing Beam Adjustment Mechanism

10.2 Feeder Parts
Grizzly Feeder - Mainframe assembly

1 620/541 MAINFRAME 1
2 301/13 SPRING (FEED END) 4
301/13 SPRING (DISCHARGE END) 4
3 620/514 MESH TENSIONER 1
4 2215-3018 NUT 8
2211-0021 WASHER 8
2210-0012 WASHER 8
5 2230-1290 SCREW 2
2210-0021 WASHER 2
2211-0012 SPRING WASHER 2
6 620/515 MESH SUPPORT 1
7 2236-4203 BOLT WITH NUT 4
2212-2005 WASHER 4
8 2315/0005 SCREEN CAPPING RUBBER 1.2M
9 620/516 TENSIONED RUBBER MAT 1
10 432/1 TENSIONED WIRE MESH 10MM 1
432/2 TENSIONED WIRE MESH 20MM 1
04/11/03
NOTE: The above parts are for the standard feeder with straight grizzly
bars. Refer to your Terex Pegson Dealer for parts required for optional
feeder having ‘zig-zag’ grizzly bars.
Feerder Mainframe Assembly - 428 Trakpactor

Grizzly Feeder - Vibrating Unit Assembly

1 629/269 UNIT HOUSING 1
2 629/151 COVER PLATE 1
3 629/47 END COVER (GEAR) 1
4 629/160 END COVER (DRIVE) 1
5 2510-3864 PLUG 2
6 2230-1122 SCREW 48
7 2211-0007 WASHER 48
8 2236-4278 BOLT WITH NUT 20
9 2212-2006 WASHER 20
10 NUT (SUPPLIED WITH ITEM 8) 20
11 2230-1152 SCREW 20
2230-1153 SCREW (FOUR CORNER SCREWS) 4
12 2211-0017 WASHER 24
13 2538-5152 OIL LEVEL GLASS 2
14 2510-9848 MAGNETIC PLUG 2
2510-4574 REDUCING BUSH 2
15 2531-1021 BREATHER 1
LOCTITE GASKET COMPOUND
2141-0027 160ML (FOR SEALING END PLATES 1
AND COVER PLATES
23/11/04
Feeder Vibrating Unit Housing - 428 Trakpactor

Grizzly Feeder - Driveside Shaft Assembly

1 629/154 DRIVEN SHAFT 1
2 629/155 DRIVE SHAFT 1
3 331/58 KEY 1
4 325/45 BOLT 16
5 629/153 BEARING HOUSING 2
6 629/157 BEARING SPACER 2
7 2416-1909 BEARING 2
8 629/159 LOCKING RING 2
9 629/162 ‘O’ RING INNER 2
10 629/163 ‘O’ RING OUTER 2
11 629/156 BEARING CAP 2
12 2232-1279 BOLT 20
13 2217-0009 NUT 20
14 310/28 WASHER 1
15 2212-8014 LOCKWASHER 1
16 2217-7014 LOCKNUT 1
17 629/9 OIL FLINGER 1
18 18HS39 RETAINING WASHER 1
19 325/20 SCREW 2
20 2576-4087 HYDRAULIC MOTOR 1
21 629/174 MOTOR COUPLING 1
22 326/11 BOLT 4
2217-0005 NUT 4
2210-0017 WASHER 4
04/11/03
SEE NEXT PAGE FOR THE DRIVESIDE SHAFT COMPONENTS.
Feeder Driveside Shaft Assembly - 428 Trakpactor

Grizzly Feeder - Non Driveside Shaft Assembly

1 325/45 BOLT 16
2 629/153 BEARING HOUSING 2
3 2416-1909 BEARING 2
4 629/159 LOCKING RING 2
5 629/162 ‘O’ RING INNER 2
6 629/163 ‘O’ RING OUTER 2
7 629/156 BEARING CAP 2
2510-3864 PLUG 2
8 2232-1279 BOLT 20
9 2217-0009 NUT 20
10 18HS39 RETAINING WASHER 2
11 325/20 SCREW 4
12 18HS50 KEY (SPUR GEAR) 2
13 18HS54 DRIVE GEAR 2
14 629/158 BEARING SPACER 2
04/11/03
SEE PREVIUOS PAGE FOR THE DRIVESIDE SHAFT COMPONENTS.
Feeder Non Driveside Shaft Assembly- 428 Trakpactor

10.3Screen Parts
Screen Box Assembly

1 AX862/55/4 SUB FRAME 1
2 2371-2032 SCREEN BOX 1
3 2371-2033 CAMBER BAR RUBBER – 1545 LONG 8
2371-3034 CAMBER BAR RUBBER – 395 LONG 6
4 2371-2037 TENSIONER 6
5-7 2371-2038 BOLT, NUT AND WASHER EACH X 12
8 2371-2039 CAMBER BAR 3
9 2371-2040 RETAINING PIN 6
10 2371-2041 SPRING PIN 6
14 2371-2043 TOP DECK CLAMP PLATE 2
15 2371-2044 SPRING 4
16 2371-2045 TRANSPORT STAY 4
17 2371-2046 BOLT, NUT, WASHER 2
TOP DECK SIDE TENSIONED WIRE
48 SPECIFY 1
MESH
APERTURE
TOP DECK END TENSIONED WIRE
49 REQUIRED 1
MESH
50 AX862/202/2 FLYWHEEL GUARD 1
AX862/182/2 UNDER GUARD 1
57 AX802/202/1 MOTOR GUARD 1
23/11/04
48 - SIDE TENSIONED MESH

(NOT SHOWN)
11 - 14
50 - 56
1
2
57 - 63
15 - 17
49 - END TENSIONED MESH

(NOT SHOWN)
4 - 10
4242SR - Screen Box Assembly

Screen Box Assembly, continued

1 2371-2051 FRONT RUBBER FLAP 1
2 2371-2052 FRONT RUBBER STRAP 3
4 2371-2054 SCREEN BOX BACK RUBBER FLAP 1
5 2371-2055 SCREEN BOX BACK RUBBER UPPER 1
7 2371-2056 SIDE RUBBER 2
8 2371-2057 SIDE RUBBER CLAMP 6
15 2371-2058 BOTTOM DECK CAMBER BAR 4
16 2371-2033 CAMBER BAR RUBBER – 1545 LONG 4
17 2371-2059 BOLT 8
18 2371-2060 NUT 8
19 2371-2061 WASHER 8
SPECIFY
BOTTOM DECK END TENSIONED WIRE
22 APERTURE 2
MESH
REQUIRED
23/11/04
4-6
15 - 19
7-9
22 - BOTTOM DECK MESHES

(NOT SHOWN)
1-3
4242SR - Screen Box Assembly

Screen Shaft & Drive Assembly
PART
REF DESCRIPTION QUANTITY
NUMBER
1 2371-2062 FLYWHEEL 2
2 2371-2063 TAPERLOCK CENTRE 2
3 2371-2064 HALF FLYWHEEL 2
5 2371-2065 COUNTER WEIGHT 2
2371-2066 COUNTER WEIGHT 2
7 2371-2071 BEARING – COMPLETE 2
8 2371-2072 PLUMMER BLOCK HOUSING 2
10 2371-2074 BEARING 2
11 2371-2075 SLEEVE & NUT 2
12 2371-2076 LOCATING RING 2
13 2371-2077 PLUMMER BLOCK HOUSING SEAL 2
14 2371-2078 ADAPTOR 2
15 2371-2079 SEAL 1
16 2371-2080 OUTER BEARING GREASE PIPE 2
17 2371-2081 ADAPTOR 2
18 2371-2079 SEAL 2
19 2371-2082 INNER BEARING GREASE PIPE 2
20 2371-2083 SCREEN SHAFT 1
21 2371-2084 PIPE UNIT 1
25 2371-2085 FLANGE BEARING HOUSING 2
26 2371-2086 BOLT, NUT 24
27 2371-2087 HARDENED WASHER 48
29 2371-2089 BEARING 2
30 2371-2090 SLEEVE & NUT 2
18/11/03

Screen Shaft & Drive Assembly, continued
PART
REF DESCRIPTION QUANTITY
NUMBER
31 2371-2091 LOCATING RING 2
32 2371-2092 BEARING HOUSING CAP 2
33 2371-2093 HOUSING CAP BOLTS 8
34 2371-2094 HOUSING LIP SEAL 4
35 2371-2095 FLANGE BEARING GASKET 2
36 2371-2096 GASKET SEALER 1
37 2371-2097 HYDRAULIC MOTOR MOUNTING BRKT. 1
38 2371-2098 BACKING PLATE 2
39 2371-2061 WASHER 4
40 2371-2060 NUT 4
41 2371-2099 HYDRAULIC MOTOR 1
42 2371-2100 COUNTERSUNK BOLT 4
43 2371-2101 NUT 4
44 2371-2102 WASHER 4
48 2371-2104 MOTOR ADAPTOR COMPLETE 2
49 2371-2105 SEAL 2
50 2371-2106 ADAPTOR 2
51 2371-2107 SEAL 1
52 2371-2108 ADAPTOR 1
53 2371-2109 HYDRAULIC HOSE 1
54 2371-2110 SCREEN MOTOR PULLEY 1
56 2371-2112 VEE BELT 2
57 2371-2113 SCREEN SHAFT PULLEY 1
58 2371-2114 KEY – SCREEN SHAFT 1
67 2371-2118 RUBBER BEARING MOUNT 1

18/11/03

10.4 Conveyor Parts
Dirt Conveyor - sheet 1
NB. Fixings are not included with the above parts unless specifically ordered
4242SR - Dirt Conveyor

Dirt Conveyor - sheet 2
4242SR - Dirt Conveyor

Crushed Product Conveyor - sheet 1
4242SR - Crushed Product Conveyor



Upper Side Transfer Conveyor
4242SR - Upper Side Transfer Conveyor

AX862-901-8EN-01f 279/360
Lower Side Transfer Conveyor
AX862-901-8EN-01f 280/360
4242SR - Lower Side Transfer Conveyor

AX862-901-8EN-01f 281/360
Recirculating Conveyor
AX862-901-8EN-01f
NB. Fixings are not included 282/360
with the above parts unless specifically ordered
AX862-901-8EN-01f 283/360 4242SR - Recirculating Conveyor

Recirculating Conveyor Chute
AX862-901-8EN-01f 284/360
4242SR - Recirculating Conveyor Chute

AX862-901-8EN-01f 285/360
Fines Conveyor
AX862-901-8EN-01f 286/360
4242SR - Fines Conveyor

AX862-901-8EN-01f 287/360
Stockpile Conveyor (Optional)
AX862-901-8EN-01f 288/360
TO READ, USE PULL OUT PAGE 51
4242SR - Stockpile Conveyor

AX862-901-8EN-01f 289/360
10.5 Plant Parts
Chassis Assembly Parts
AX862-901-8EN-01f 290/360
4242SR - Chassis Assembly Parts

AX862-901-8EN-01f 291/360
Engine Assembly Parts
Control Cabinet and Toolbox Assembly Parts (not illustrated)
The following parts only relate to units fitted with a plastic door hinge. For units fitted
with a steel hinge, please specify the plant serial number to your Terex Pegson Dealer
when ordering replacement parts.

CONTROL CABINET - AX862-303-601
1 2301-0005 COMPRESSION LOCKING LATCH 1
2 AX815-251-001 PLASTIC HINGE 1
3 AX862-304-003 INNER PANEL 1
4 AX862-304-501 4242SR CONTROL CABINET 1
5 AX862-304-502 CABINET DOOR 1
6 GAS-STRUT-05 GAS STRUT ASSEMBLY 1
7 GAS-STRUT-06 GAS STRUT ASSEMBLY 1
TOOL BOX – AX862-339-601

1 2301-0005 COMPRESSION LOCKING LATCH 1
2 AX815-253-001 PLASTIC HINGE 1
3 AX846-133-CHAIN CHAIN ASSEMBLY 2
4 AX862-340-501 4242SR TOOLBOX 1
5 AX862-340-502 TOOLBOX DOOR 1
23/11/04
AX862-901-8EN-01f 292/360
4242SR - Engine Assembly Parts

AX862-901-8EN-01f 293/360
Screen and Conveyor Assembly Parts
AX862-901-8EN-01f 294/360
4242SR - Screen and Conveyor Support Assembly

AX862-901-8EN-01f 295/360
10.6 Plant Tracks
‘S’ Mark Tracks

Before ordering track parts it is essential tolook 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.
ALSO please quote the serial number stamped on the track mainframe to ensure
the correct replacement part(s) and quantities are supplied.

TRACK DRIVE GEARBOX C/W HYDRAULIC
1
MOTOR
HYDRAULIC MOTOR ONLY
ADAPTOR
BONDED SEAL
STAND OFF PIPE
GEARBOX DRAIN PLUG
2 GEARBOX BOLTS
3 DRIVE SPROCKET
4 SPROCKET BOLTS
5 TRACK CHAIN –COMPLETE
6 TRACK SHOE
7 TRACK SHOE BOLT
8 TRACK SHOE NUTS
9 IDLER
10 YOKE
11 RECOIL UNIT
TENSIONER SEAL KIT
12 GREASER
13 GASKET
ADAPTOR
14 ROLLER
15 ROLLER BOLT
16 ROLLER BOLT WASHER
REPAIR LINK - TRACK CHAIN

MASTER PIN - TRACK CHAIN
4242SR-S-23/11/04
AX862-901-8EN-01f 296/360
4
1
8
2
7
6
16
12
13
15
14
10
11
4242SR - Tracks Assembly

AX862-901-8EN-01f 297/360
‘T’ Mark Tracks

Before ordering track parts it is essential tolook 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.
ALSO please quote the serial number stamped on the track mainframe to
ensure the correct replacement part(s) and quantities are supplied.

TRACK DRIVE GEARBOX C/W HYDRAULIC
1
MOTOR
HYDRAULIC MOTOR ONLY
ADAPTOR
BONDED SEAL
STAND OFF PIPE
GEARBOX DRAIN PLUG
2 GEARBOX BOLTS
3 DRIVE SPROCKET
4 SPROCKET BOLTS
5 TRACK CHAIN –COMPLETE
6 TRACK SHOE
7 TRACK SHOE BOLT
8 TRACK SHOE NUTS
9 IDLER
10 YOKE
11 RECOIL UNIT
TENSIONER SEAL KIT
12 GREASER
13 GASKET
ADAPTOR
14 ROLLER
15 ROLLER BOLT
16 ROLLER BOLT WASHER
REPAIR LINK - TRACK CHAIN

MASTER PIN - TRACK CHAIN
4242SR-T-231104
AX862-901-8EN-01f 298/360
4
1
8
2
7
6
16
12
13
15
14
10
11
4242SR - Tracks Assembly

AX862-901-8EN-01f 299/360
Components Manual
.
Terex Overband Separator
A Qty
Item
A 1
B B 2
C 2
Terex Pegson Limited , Mammoth Street , Coalville, Leicester , LE67 3GN , United Kingdom.
Main Switchboard Phone :- +44 (0)1530 518600 Main Switchboard Fax :- +44 (0) 1530 518618
Quarry Spares Department Phone :- +44 (0) 1530 518666 , Fax +44 (0) 1530 518651 07/01 TXT - 1
E-mail :- [email protected] Website:- www.terexpegson.com
Copyright © 2007 Terex Pegson Ltd . All Rights Reserved
AX862-901-8EN-01f 300/360
Components Manual .
Terex Overband Separator
15 Item Q ty
1 1
16
2 1
3 1
2 4 1
5 1
1 6 1
7 4
3
8 3
9 9 2
7
10 2
8
6
21 14 11 2
4 11
10 12 1
13 1
13
5 14 2
15 1
22 20 19 12 16 1
17 1
17
19 1
20 1
21 1
22 1
07/01 TXT - 2
AX862-901-8EN-01f 301/360
10.8 Hydraulic Components
Hydraulic Oil Reservoir

1 1
2 2589-2105 FLUID LEVEL GAUGE & SWITCH 1
3 2531-1000 BREATHER 1
4 2531-5252 RETURN LINE FILTER 1
2531-5253 FILTER ELEMENT 1
4a 2538-0053 RETURN LINE FILTER GAUGE 1
5 INSPECTION COVERS 2
6 2531-5154 SUCTION FILTER 2
2531-5150 FILTER ELEMENT 2
6a 2538-0054 SUCTION FILTER GAUGE 2
6b 2520-8002 FLANGED ADAPTOR – 1B32-40 1
6b 2520-8002 FLANGED ADAPTOR – 1B20-40 1
L795_1 – 23/11/04
Impact Crusher Door Ram Hoses
Hose Number Tag
DESCRIPTION X 1 OFF EACH

HOSE
HOSE FITTING LENGTH
REF
428 IMPACT CRUSHER DOOR RAM HOSES
1
2
3
4
5 R2AT-06 ST / ST 1170
6 R2AT-06 ST / ST 1170
7 R2AT-06 ST / ST 1170
8 R2AT-06 ST / ST 1170
9 R2AT-06 ST / ST 4000
10 R2AT-06 ST / ST 4000
11 R2AT-06 ST / ST 6680
12 R2AT-06 ST / 90S 2200
13 R2AT-08 ST / 90S 1660
AX862-901-8EN-01f 302/360
AX846HYDAUXHC9 – Iss. 00 - 121203
6
6a 4
5 3 6b 4a 1 2
4242SR - Hydraulic Reservoir

AX862-901-8EN-01f 303/360
Hydraulic Hoses - sheet 1
Hose Number Tag

HOSE
HOSE x LENGTH
REF
ENGINE
1 1/4R2AT-ST/ST Rev cone one end x 1270mm - load sense
2 3/4R9R-90/STx360mm
3 3/4R9R-ST/Flange fitting x 970mm
4 3/4R9R-90/ST Flange fitting x 830mm
5 1/2R2AT-90/ST x 1660mm - Elec/Pump suction
6 1/2R2AT-ST/ST Rev cone 1 end x 5250mm-Dan/pumps drain
7 1/2R2AT-90/ST Rev cone both ends x 2000mm
8 1/4R2AT-90/ST Rev cone on 90 x 3610mm - load sense
9 3/4R9R-90/ST x 3000mm
10 1.1/2R2AT-90/ST flange fitting on 90 x 600mm - front suction
11 1.1/2R2AT-90/ST flange fitting on 90 x1660mm -back suction
12 2RAT-2" 90/1.1/2" ST x 500mm - main suction
13 1.1/4R2AT-90/ST x 1600mm - pto suction
14 1/2R2AT 90/ST x 2450mm -to d/con motor
15 3/4R9R 90/STx3620mm-wire cover from ST for 550mm
16 3/4R9R 90/STx3770mm-wire cover from ST for 550mm
17 3/4R2AT 90/ST x 4420mm - to T
RIGHT HAND SIDE 3 BANK
18 3/4R2AT 90/ST x 5000mm - ret to cooler
19 3/4R2AT 90/ST male steel pipe fitting x 2860mm
20 3/4R2AT 90/ST male steel pipe fitting x 2880mm
21 3/4R2AT 90/ST x 1650mm - stockpiler snap on
22 3/4R2AT 90/ST x 3300mm - stockpiler snap on
23 3/4R9R 90/ST x 550mm - wire cover
24 3/4R9R 90/ST x 550mm - wire cover
STOCKPILE CONVEYOR
25 1/2R2AT 90/ST x 3720mm - ret to tank
26 3/4R2AT ST/ST x 520mm - loop hose
PRODUCT CONVEYOR
27 3/8R2AT ST/90 x 6180mm
28 3/4R2AT ST/90 x 6700mm
29 3/4R2AT ST/90 x 6180mm
30 3/4R2AT ST/ST x 910mm
32 AX862-901-8EN-01f 304/360
3/8R2AT ST/ST x 940mm
AX862HOSEA – Iss. 02 - 041203
Hose Number Tag

HOSE
HOSE x LENGTH
REF
FINES CONVEYOR
34 371-12(3/4) ST/ST x 610mm – Pressure hose
36 371-12(3/4) 90/ST x 3680mm – Pressure hose
37 3/4R2AT 90/ST x 3760mm
38 3/4R2AT 90/ST x 1320mm
DIRT CONVEYOR + 2 x TRANSFER CONVEYORS
39 1/2R2AT 90/ST x 1920mm
40 1/2R2AT 90/ST x 1920mm
42 1/2R2AT 90/ST x 1490mm
MAGNETIC SEPARATOR
45 1/2R2AT 90/ST x 570mm
46 1/2R2AT 90/ST x 370mm
47 1/2R2AT 90/ST x 730mm
48 1/2R2AT 90/ST x 775mm
RE-CIRCULATING CONVEYOR
50 NOT REQUIRED
53 3/4R2AT 90/ST x 5450mm
54 3/4R2AT 90/ST x 5480mm
55 NOT REQUIRED
56 3/4R2AT 90/ST x 1500mm
57 3/4R2AT 90/ST x 1500mm
58 NOT REQUIRED
RE-CIRCULATING CONVEYOR RAM
59 3/8R2AT 90/ST x 1720mm
60 3/8R2AT 90/ST x 1720mm
61 3/8R2AT 90/ST x 920mm
62 3/8R2AT 90/ST x 900mm
AX862-901-8EN-01f
AX862HOSEA – Iss. 02 – 121203 + AX862/18HK –305/360
23/11/04
Hose Number Tag

HOSE
HOSE x LENGTH
REF
SCREEN
63 371-12(3/4) ST/90 x 380mm - Pressure hose
64 371-12(3/4) ST/ST x 1320mm - Pressure hose
65 371-12(3/4) 90/ST x 1480mm - Pressure hose
66 3/8R2AT 90/ST x 1540mm
67 3/4R2AT 90/ST x 2300mm
68 371-12(3/4) 90/ST x 5470mm Pressure hose
69 NOT REQUIRED
70 NOT REQUIRED
SCREEN RAMS
72 3/8R2AT 90/ST x 1320mm
73 3/8R2AT 90/ST x 1320mm
74 3/8R2AT 90/ST x 1320mm
75 3/8R2AT 90/ST x 1320mm
76 3/8R2AT 90/ST x 3110mm
77 3/8R2AT 90/ST x 3065mm
5 BANK VALVE
78 3/8R2AT 90/ST x 1250mm
78 3/8R2AT 90/ST x 1300mm
80 3/4R9R 90/ST x 3100mm Pres hose
81 3/4R2AT 90/ST x 2300mm
82
COOLER
83 1.1/2R2AT ST/ST x 2690mm
TRACKS
84 3/8R2AT 90/ST x 5230mm
85 3/8R2AT 90/ST x 4040mm
86 1/4R2AT 90/ST x 480mm
87 1/4R2AT 90/ST x 480mm
88 3/8R2AT 90/ST x 300mm
89 3/8R2AT 90/ST x 300mm
90 3/8R2AT 90/ST x 260mm
91 3/8R2AT 90/ST x 260mm
AX862HOSEA – Iss. 02 - 121203 AX862-901-8EN-01f 306/360
Hose Number Tag

HOSE
HOSE x LENGTH
REF
FEED END OF PLANT
92 1/2R2AT ST/ST x 2700mm - D/con ret
93 1/2R2AT ST/ST x 3200mm - D/con pres
94 3/8R2AT ST/ST x 2700mm - D/con drain
95 NOT REQUIRED
97 3/4R2AT 90/ST x 970mm
98 3/4R2AT 90/ST x 1030mm
99 3/8R2AT ST/ST x 710mm - D/con fold
101 3/8R2AT ST/90 x 400mm - D/con fold
102 3/8R2AT ST/90 x 440mm - D/con fold
105 3/8R2AT 135/ST x 1860mm - D/con fold
109 3/8R2AT 90/ST x 1350mm
110 3/8R2AT 90/ST x 1500mm
111 3/8R2AT ST/ST x 2150mm
112 3/8R2AT ST/ST x 2150mm
114 1/2R2AT 90/ST x 900mm
AX862HOSEA – Iss. 02 - 121203
AX862-901-8EN-01f 307/360
Hydraulic System Components
FOR PART NUMBERS OF INDIVIDUAL COMPONENTS

REFER TO THE HYDRAULIC DIAGRAM OPPOSITE
AX862-901-8EN-01f 308/360
AX862-901-8EN-01f 309/360
10.9 Electrical Components

1 2683-2198 FUSE SET 1
E/M STOP TWIST TO RELEASE PUSH BUTTON
2 2683-2193 1
WITH CONTACT BLOCKS
EMERGENCY STOP & IMPACTOR DOOR
3 2683-2155 2
RELAYS
4 2683-2186 LOAD DUMP MODULE 1
5 2685-0001 EMERGENCY STOP STATION ASSEMBLY 1
6 2683-2107 10 AMP 8 PIN 2 POLE MINI RELAY 24V DC 2
2683-2107A 8 PIN RELAY BASE 2
6A 2683-2106 10AMP 11 PIN 3 POLE RELAY 24V DC 1
2683-2106A 11 PIN RELAY BASE 1
7 2683-2183 PLC UNIT R360PLC 1
2683-2184 PLC CONNECTOR 1
8 2683-2187 TEXT DISPLAY UNIT 1
9 2683-2114 POWER INPUT RELAY 1
10 2683-2110 AUDIBLE WARNING UNIT 24V DC 1
11 SET UP CONTROL STATION COMPLETE WITH
2683-2159 1
12 ENABLE BUTTON BOX
13 2683-2111 BLACK PUSH BUTTON ASSEMBLY 9
TELERADIO CONTROL (WHERE FITTED
14 2686-0042 COMPLETE KIT INCLUSIVE OF ITEMS 15 TO 20 1
BELOW
TELERADIO RECEIVER UNIT ONLY (CONTROL
15 2686-9034 1
PANEL COMPONENT)
RADIO HAND SET TRANSMITTER – RED STOP
16 2686-0043 1
BUTTON (USA & REST OF THE WORLD)
RADIO HAND SET TRANSMITTER – BLACK
17 2686-0044 1
STOP BUTTON (EUROPE)
18 2686-9008 TELERADIO ANTENNA ONLY WITH CABLE 1
19 2686-9007 12/35VDC CHARGER CABLE 1
20 2683-9029 TELERADIO UMBILICAL HAND SET ONLY 1
IMPACTOR DOOR LIMIT SWITCH – CAN PLC 4
21 2683-2160 1
WIRE SYSTEM
Mk V04 – 23/11/04
AX862-901-8EN-01f 310/360
2
3
6 & 6A
1
4
9
14 7
12
2
13
11
19
15
16 & 17
20
4242SR - Electrical Parts

AX862-901-8EN-01f 311/360
10.10 Safety Signs (with part numbers)

Note: For positions of these Warning Signs refer to Section 1.8, Figures 1b & 1c
300/32 300/33 300/34 300/36
300/39 300/40
300/37 300/38
300/43 300/44 300/52 300/118
AX862-901-8EN-01f 312/360
300/119 300/120 300/182 300/189
300/42
300/196 300/217 300/268 300/224
AX868-198-001
300/269 300/284
AX868-203-001 AX868-206-001
AX862-901-8EN-01f 313/360
4242SR
10 - Spare Parts EN
Page 10 - 86
Blank page
AX862-901-8EN-01f 314/360
4242SR
11 - Appendix EN
Page 11 - 1
Contents
11.1 Noise Assessment ............................................................................................. 2

Noise Plan ............................................................................................................... 2
Noise Levels ............................................................................................................ 3
11.2 Manual Engine Clutch ....................................................................................... 4
AX862-901-8EN-01f 315/360
11.1 Noise Assessment
Noise Plan
AX862-901-8EN-01f 316/360
Noise Levels
Engine running under no load (ie. not
AX862-901-8EN-01f 317/360
4242SR
11 - Appendix EN
Page 11 - 4
11.2 Manual Engine Clutch
AX862-901-8EN-01f 318/360
4242SR
11 - Appendix EN
Page 11 - 5
AX862-901-8EN-01f 319/360
4242SR
11 - Appendix EN
Page 11 - 6
AX862-901-8EN-01f 320/360
All Plants - Tier 3, Stage IIIa - ACERT
Addendum to User Manual
AM0013 Engine Change
Due to the change of engines to comply with requirements

of Tier 3/Stage IIIa standards, this plant may have a different
engine fitted
Caterpillar C13 engines are replacing the C12

Caterpillar C9 engines have been revised to comply with the standards
Caterpillar C6.6 engines are replacing the 3126B engines
EN AM0013-1
AX862-901-8EN-01f 321/360
Change of Engine Type
The change of engines has resulted in the following changes to engine controls
and information in the user manual.
Power Output
The engine power may have changed slightly.
The power of the engine as stated in the manual will not necessarily be correct but the power stated on the
plate fixed to the plant is correct.
Engine Speed
The engine working speed may have changed slightly.
The engine speed stated in the manual will not necessarily be correct but the speed set by the engine controls
and display is correct.
The engine working speed with no load and speed at full load are now the same.
Engine Monitoring System

The engine monitoring system and engine control panel shown and referred to in the user manual will not be
correct.
The engine information will be displayed on a different type of screen.
To operate the engine monitor screen, refer to the appropriate addendum for the controls fitted.
Engine Controls
Some engine controls and warning lamps are not as shown and referred to in the manual as they have been
repositioned with other plant controls.
Power Plant Spares

Some engine electrical controls and power pack spare parts will be different to those referred to in the user
manual, therefore please contact Terex Pegson and quote plant and engine serial numbers for assistance.
AM0013-2
AX862-901-8EN-01f 322/360
All Plants - Messenger Control
Caterpillar Messenger Display
INTRODUCTION
The engine fitted on this plant may not have the engine monitoring system shown and referred to in the Terex
Pegson User Manual but has the Caterpillar Messenger system.
Messenger is an electronic monitoring system with real-time visual display of engine operating conditions,
historical data and diagnostic information.
If applicable, also refer to ‘Messenger Display’ in Features and Controls in the Operation Section of the
Caterpillar Operation and Maintenance Manual for the engine.
AM0014 - EN M-1
AX862-901-8EN-01f 323/360
Caterpillar Messenger Engine Monitoring System
Operation
The operator button functions are:
1
1. Previous button
Return to previous level and screen display
2
2. Scroll Up / Left button
Scroll display to view different menus and use to set up display settings.
3. Scroll Down / Right button

3
Scroll display to view different menus and use to set up display settings.
4. OK button
4
Confirm selection on the display / continue to next screen
Performance Display
The displays available are:
Engine speed
Coolant temperature
Totals Display
Cumulative totals displays available are:
Service hours engine has accumulated
Total time system in use
M-2
AX862-901-8EN-01f 324/360
All Plants - Messenger Control
Settings Display
System options available are:
Language used on display screen
Units shown on display
Adjust screen contrast
Adjust screen back light
Identification numbers available are:
Equipment identification number
Product identification number
Service Display
Service events display is:
View logged events, errors or alarms
System parameters are:
Battery voltage
Engine speed
Coolant temperature
Boost pressure
Self Test
Perform a self test, similar to when the start switch
is turned to the ON position
Monitoring information displays are:
Software part number
ECM (Electrical Control Module) part number
Software release date
Software description
AM0014 - EN M-3
AX862-901-8EN-01f 325/360
Caterpillar Messenger Engine Monitoring System
Engine information displays are:

ECM serial number
Software part number
Software release date
Software description
Engine serial number
Tattle tale
(To display maximum values reached during
operation).
Full tattle tale read-out
Engine coolant
Tachometer
Spare Parts
Some engine electrical controls and power pack
spare parts will be different to those referred to in
the user manual, therefore please contact Terex
Pegson and quote plant and engine serial numbers
for assistance.
M-4
AX862-901-8EN-01f 326/360
All Plants - Cantrak Control
AM0020 Plants with Cantrak Engine Monitoring System
EN AM0020-1
AX862-901-8EN-01f 327/360
Cantrak Engine Monitoring System
Introduction
The Cantrak Engine Monitor is a graphical
instrument clusters to display parameters and
alarms.
The display has five buttons that change to suit
the screen in use. The buttons give to access a
graphical menu structure that uses standard and
easily-understood icons to indicate the button’s
current function.
The required engine data and display can display
the following formats:
Analogue gauges
Digital values
Historical trend graphs
Current and stored alarm messages
AM0020-2
AX862-901-8EN-01f 328/360
Buttons
If any button from 1 to 4 is pressed, the display
shows a context dependent icon representing the
current function of the button.
The button icon part of the display will disappear
after five seconds of inactivity.
This ‘top level’ button icon bar shows the selection
options of the Engine Monitor:
1 2 3 4 5
Pressing button 5 when the menu icons are not
being displayed displays a Contrast and Lighting
adjustment menu. If held for 3 seconds, the
Configuration menu is shown
Button Icons
TRI DISPLAY - shows one large window and two
smaller windows. Repeat presses cycle the
display through the view options.
QUAD DISPLAY - shows data four equal sized

windows. Repeat presses cycle the display
around three different quad view options.
UNI DISPLAY - shows data using a single

window. Repeat presses cycle display through
available parameters.
ACTIVE ALARM DISPLAY - shows current

active alarm. Holding the key displays Stored
Alarms.
EXIT from the menu.
EN AM0020-3
AX862-901-8EN-01f 329/360
PAGES - indicates that further pages of

information are available by pressing to cycle
through options for the screen being viewed.
ARROW UP - move up to next item.
ARROW DOWN - move down to next item.
RIGHT ARROW - go to next screen or select

option.
RETURN ARROW - go back to previous screen.
ALARM - acknowledge active alarm when an

active alarm is being displayed.
CONFIGURE QUAD SCREEN - press button 2

and immediately button 5. The data displayed
on a particular window can be selected by
repeat pressing the
Button Lock
The buttons can be locked so that they cannot be
accidentally pressed.
Press buttons 1 and 5 simultaneously for one
second to switch the button lock on or off.
A key symbol is displayed when a button is pressed
and they are locked.
1 2 3 4 5
AM0020-4
AX862-901-8EN-01f 330/360
Displays
When power is applied, a start-up screen displays
for approximately 7 seconds while the display
performs a self test.
After the start-up screen disappears, the Engine
Monitor displays readings on its virtual gauges.
The Engine Monitor displays the screen that was
last displayed.
If data is not available from the engine, it will not
be possible to select it.
If data becomes unavailable, dashes (- - -) will be
shown on the screen.
Tri Display
Three windows intended to show the most
frequently accessed engine data.
Quad Display
Four windows to display available data in digital
number format only or as a gauge with numbers
also displayed.
The windows can be configured to display various
available data as listed in the data parameter
and icons.
Uni Display
A single window to display data in a graph format,
together with a numeric data header.
EN AM0020-5
AX862-901-8EN-01f 331/360
Data Parameters and Icons

The following data can be displayed
Engine Speed
Oil Pressure
Oil Temperature
Coolant Temperature
Battery volts or amps
Engine Hours
AM0020-6
AX862-901-8EN-01f 332/360
Alarm Messages
When a current engine alarm is received, a flashing
window appears overlaid over the screen in use
and an alarm sound is activated.
If a current alarm message is flashing, press any

button to view the message details.
The current alarm message will be displayed
with a black background, which indicates an
unacknowledged alarm.
The alarm can be acknowledged by pressing:
Alarms must be acknowledged before the normal

monitoring screen can be displayed.
Acknowledged alarm messages are displayed with
a grey background.
Alarm messages can also be displayed at any time

from the normal monitoring display by pressing
button 4 twice.
To return to the monitoring screen press:
EN AM0020-7
AX862-901-8EN-01f 333/360
Configuration Options
Screen Brightness and contrast
Press button 5 when the normal monitoring screen
is being displayed.
Adjust the screen using buttons 1 to 4.

Press button 5 to exit
1 2 3 4 5
Settings Menu
Press and hold button 5 for three seconds, when the
normal monitoring screen is being displayed.
Scroll to point to SETTINGS and select by

pressing:
The following options can then be selected:

UNITS - Metric or Imperial
LANGUAGE - Select from list
BLEEP - Button press sound on or off
Set the options for each of these by pressing:
Return to previous screens by pressing:
Exit by pressing:
AM0020-8
AX862-901-8EN-01f 334/360
428 Impact Crusher
Operator’s Guide
MANUAL ADDENDUM Issue EN 01
Page 1
428 IMPACT CRUSHER
GUIDE TO EFFICIENT OPERATION
Section 3 of the Plant User Manual includes the

recommendations for setting the relative positions
of the impact aprons and swing beam.
This addendum provides further information to

help the plant operator appreciate the underlying
principles for selecting the operating settings
and the effects on crusher performance.
Guidence is also included on alternative crusher

blow bar types and configurations.
THIS ADDENDUM IS TO BE INSERTED INTO THE

BL-PEGSON PLANT USER MANUAL - SECTION 11
BL-Pegson Limited, Coalville, England. Tel : +44 1530 518600, Fax : +44 1530 518618
01/12/04
AX862-901-8EN-01f 335/360
428 Impact Crusher
Operator’s Guide
Page 2
428 Impactor Application Data
Effect of each apron setting on grading curve
Front (Upper) Apron: This apron affects a large proportion of the grading curve. Reducing the
setting on this apron will hold material in the first chamber for longer, allowing the rotor to deliver
more impacts to the stone, thus reducing it further. This reduction is offset by a drop in throughput.
Rear (Lower) Apron: It is a common misconception that in order to reduce oversize from an
impactor the rotor speed must be increased. In fact, this will create more fines and reduce through-
put. A far more effective way to reduce oversize is to reduce the rear apron setting. Reducing this
setting will reduce the amount of oversize from the machine without affecting greatly affecting the
throughput, nor the rest of the grading curve (as shown below).
AX862-901-8EN-01f 336/360
428 Impact Crusher
Operator’s Guide
Page 3
Grinding path (Swing Beam): Affecting the whole of the grading curve, including the fines output,
the grinding path will also shape the material as it grinds.
Effect of rotor speed on grading curve
Increasing the rotor speed has the benefit of displacing the grading curve completely, creating a finer
product throughout the curve. The disadvantages with this are an increase in fines and wear, and a
drop in throughput.
AX862-901-8EN-01f 337/360
428 Impact Crusher
Operator’s Guide
Page 4
Blowbar utilisation
The impactor blow bars may be turned after wearing on one side, allowing 80mm wear on each
side. With new blow bars of 300mm height, this gives a utilisation of 160mm/300mm = 53%.
Blowbar tip profiles
The tip profile on the blow bars shows if the material is sufficiently penetrating the rotor. If the
impactor is overfed, the feed size too large, or the tip speed too fast, then the material will not pen-
etrate deep enough into the rotor for breakage to take place. If the blow bars are seen to wear
unevenly, or the tip shown below is not evident, then the penetration of the material is insufficient.
Rotor speeds at the engine speed of 1800rpm under crushing load. Do not deviate from this
operating speed.
BLOW BAR TIP SPEED - METRES/SECOND
ENGINE PULLEY ROTOR (feet/second)
PITCH CIRCLE SPEED CRUSHING
DIAMETER - MM RPM NEW BLOW BARS WORN BLOW BARS APPLICATION
(inches)
**224 pcd (8.82”) 504 28m/s (91.6ft/s) 24m/s (78.5ft/s) Primary
*280 pcd (11.02”) 630 35m/s (114.5ft/s) 28.5m/s (93.2ft/s) Primary/Secondary
***315 pcd (12.4”) 709 39.5m/s (129.2ft/s) 33.5m/s (109.6ft/s) Secondary
01/12/04
* Fitted to plant as standard. ** Supplied loose with plant. *** Available to order. .
Rotor diameter
Full hammers = 1060mm (41.73”)

Worn hammers = 900mm (35.43”)
AX862-901-8EN-01f 338/360
428 Impact Crusher
Operator’s Guide
Page 5
Choosing the right blow bar material
‘High Chrome’ steel blow bars
The chromium carbides in ‘High Chrome’ blow bars provide good resistance to wear: useful against
fine or high silica (SiO2) content feeds. It’s composition and heat treatment means the blow bar is
delivered extremely hard (600+HB), with no further work hardening required. The disadvantage of
this is a relatively low ductility. High chrome damage occurs as a function of it being unable to
dissipate the energy delivered to it by the stone quickly enough. Therefore, if the feed size is too big
(or more precisely, too heavy), or the tip speed too fast, then the energy imparted to the blow bar as
it strikes the material will cause catastrophic failure of the blowbar. It is for this reason that tougher
blowbars are used on large, hard, dense stone, and steel rebar.
Martensitic steel blow bars
It is the needle-like martensitic grains, formed through alloying and heat-treatment, which impart
hardness (up to 520HB) to this steel. Therefore, it again does not require work-hardening within the
impactor, and gives good wear against fine and high silica feeds. However, the real benefit with this
blow bar is its ability to accept a small proportion of steel in the feed, such as rebar. This makes it
the hardest blow bar that may be used in recycling applications.
‘High Manganese’ steel blow bars
High Manganese blow bars are an austenitic steel, and as such are supplied in a soft condition.
When large material impacts the blow bar, the plastic deformation undergone at the surface of the
blow bar instantly hardens it to 500+HB. Thus, it resists abrasion at the surface with a layer of
martensite, while still maintaining the toughness of the underlying material. High Manganese blow
bars therefore tolerate large, hard, dense stone, and steel within the feed, better than any other blow
bar. However, should the blow bar not achieve this work-hardening, due to excessive fines or
abrasive feed material, or due to grinding on slabby feed that may not penetrate the rotor well, then it
will wear quickly and unevenly.
Turn to next page for blow bar selection summary
AX862-901-8EN-01f 339/360
428 Impact Crusher
Operator’s Guide
Page 6
Summary
Identify the Feed Material to be crushed (Hard, Medium or Soft). Next refer to the relative
performance guides shown against the items marked *. Do not exceed the maximum feed size.
Note the suggested Blow Bar material for abrasive stone or recycling applications. Estimates
of performance and the suitability of equipment are given as a guide only.
2 x LONG and 2 x SHORT BLOW BARS

Feed Material Hard Medium Soft
Compressive Strength (N/mm²) >220 100-220 <100
Specific Gravity >2.7 <2.7 <2.7
Rotor Speed (rpm) 709 630 504
* Max. Feed Size (diagonal mm) - 300 - 700 - 700

* Throughput High Moderate High
* Reduction Moderate High Low
* Blow Bar Wear Moderate Moderate Low
* Fines produced High Moderate Low
Suggested Blow Bar Material

Abrasive Stone >10% SiO2 Martensitic Steel High Chrome Steel High Chrome Steel
Recycling - 20mm dia. rebar Martensitic Steel Martensitic Steel Martensitic Steel
01/12/04
4 x LONG BLOW BARS
Material Hard Medium Soft
Compressive Strength (N/mm²) >220 100-220 <100
Specific Gravity >2.7 <2.7 <2.7
Rotor Speed (rpm) 709 630 504
* Max. Feed Size (diagonal mm) - 150 - 300 - 700

* Throughput Moderate High Low
* Reduction High Moderate High
* Blow Bar Wear High Moderate Moderate
* Fines produced High Moderate Moderate
Suggested Blow Bar Material

Abrasive Stone >10% SiO2 High Chrome Steel High Chrome Steel High Chrome Steel
Recycling - 20mm dia. rebar Martensitic Steel Martensitic Steel Martensitic Steel
01/12/04
IMPORTANT NOTE:
When considering the type of blow bar material to be used for any particular application,
also refer to the plant User Manual, Section 3.3 - Designated Use - Important Notice.
AX862-901-8EN-01f 340/360
All Plants

OPERATING INSTRUCTIONS
AM0009 Fuel Transfer Pump 2573-7002

��
Introduction and Specification

This option is available as originally fitted
equipment installed at the time of plant
manufacture.
The pump is for the purpose of transferring diesel
fuel from a fuel container positioned at ground
level alongside the plant fuel tank.
The pump is permanently mounted in a suitable
position on the plant in the vicinity of the engine
and is electrically driven from a 24v DC supply.
The unit is fitted with an integral on/off switch.
Also supplied as part of the kit are lengths of plain
hose 25mm (1in) bore for suction (with strainer)
and delivery.
The pump is suitable for equipment with diesel
fuel tanks between 200 and 500 litres (53 and
132 US gallons). Duty is continuous up to 40°C
(104°F) ambient. Flow is 50 l/min (13.2 US gal/
min) at a self priming dry, up to 3m (9.8 ft) head.
Maximum head 10m (32.8 ft).
 DANGER
Do not use the fuel transfer pump
for any other purpose than filling the
diesel fuel tank on a Terex Pegson
plant.
Observe the safety instructions in
these instructions plus safety and
information given in the Re-fuelling
section of the plant user manual.
EN AM0009-1
AX862-901-8EN-01f 341/360
Fuel Transfer Pump [if fitted]
SAFETY
1. DO NOT USE A TRGGER NOZZLE FOR

1
DELIVERY INTO THE FUEL TANK.
2. FLASHPOINT BELOW 37°C (99°F)

2
PETROL
GASOLINE
BENZINE
3. FLASHPOINT ABOVE 37°C (99°F)

3
DIESEL
GASOIL
GASOLIO
AM0009-2
AX862-901-8EN-01f 342/360
All Plants
INSTALLATION & USE

4
4. CONTINIOUS DUTY AT 40°C (104°F)
5. TEMPERATURE RANGE
6. DO NOT ALLOW THE PUMP TO RUN DRY.

6
7. SWITCH OFF IMMEDIATELY DELIVERY

OF THE FUEL IS COMPLETED.
EN AM0009-3
AX862-901-8EN-01f 343/360
Fuel Transfer Pump [if fitted]
Top Up With Fuel
NOTICE
Do Not fill the tank to overflow or full
capacity.
Allow room for expansion and wipe up
spilt fuel immediately.
Check the fuel gauge on the plant.
Observe all safety warnings.
Follow the instructions to re-fuel in the plant user
manual
Connect both hoses to the pump and insert the
suction hose into the fuel supply.
Remove the filler cap and insert the delivery hose
into the plant fuel tank.
Operate the switch on the pump to top up the
fuel tank. Use only in accordance with the
introduction and specification.
When re-fuelling is complete, switch off the pump
and stow the hoses.
Replace the filler cap.
If the plant is to be operated, refer to engine
starting in the user manual to start up.
If the plant is not being used, set the isolation
switch to the ‘0’ position.
 DANGER
Diesel fuel is highly flammable and is
an explosion/burns hazard. NEVER
remove the filler cap or re-fuel, with the
engine running.
NEVER add petrol, 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 the fuel
system. DO NOT carry out maintenance
on the fuel system near naked lights
or sources of sparks, such as welding
equipment.
AM0009-4
AX862-901-8EN-01f 344/360
All Plants

OPERATING INSTRUCTIONS
AM0011 Water Pump

2575-2002 for dust suppression system
2575-2009 for dust suppression system plus additional requirements
TYPICAL INSTALLATION SHOWN

Optional Water Pump (If fitted)
This option is available as originally fitted
equipment installed at the time of plant
manufacture. Two models are available:
2575-2002
25 l/min nominal (6.6 US gall/min) to supply
the plant spray bars only.
2575-2009
65 l/min nominal (17 US gall/min) to supply
the plant spray bars, plus additional capacity for
requirements additional to the plant.
The pump is to provide a pressurised supply of
clean water to the dust suppression spray nozzles
included on plants. For details of clean water
requirements for the dust suppression system, refer
to the plant user manual.
The pump is permanently mounted in a suitable
position on the plant near to the water system inlet
and is driven by the plant hydraulic system.
AM0011 -EN W01-1

AX862-901-8EN-01f 345/360
Water Pump (if fitted)
 DANGER
Refer to Safety Notices Section for
relevent warning and procedure
SKIN INJECTION
HAZARD
Controls
1. The water inlet is a hose connector for the
provision of suitable supply piping from a clean
water container close to the plant.
2 3
2. Initial ON/OFF control of the pump is by means

of a three position valve lever.
3. Whilst valve lever 2 is in the ‘ON’ position the
screw type valve can be used to regulate the
supply to the plant water system.
W01-2
AX862-901-8EN-01f 346/360
All Plants
4. If the higher capacity pump is fitted, the supply

to the additional equipment can be taken off one
of the drain valves.
Servicing
No specific maintenance is required for the pump
unit except to check for hydraulic oil leaks when
carrying out the normal plant checks.
Protection from Freezing
Precautions must be taken in cold weather to
ensure water does not freeze within the system,
by opening the water manifold drain valves and
draining the system. Detach the pump water inlet
feed pipe and any additional equipment supply
also.
Pump Hydraulic and Water Circuits

A. Hydraulic Fluid
B. Water
C. Three Position Valve
D. Flow Control Valve
E. Hydraulic Motor
F. Water Pump
AM0011 -EN W01-3

AX862-901-8EN-01f 347/360
Water Pump (if fitted)
W01-4
AX862-901-8EN-01f 348/360
All Plants
AM0010 M.C.S. Belt Weigher BW100
EN AM0010-1
AX862-901-8EN-01f 349/360
BW100 Belt Weigher (if fitted)
ROUTINE CALIBRATION SIMPLIFIED GUIDE

The Following procedures may be performed on a routine basis as required.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration.
Safe working practice should be adopted at all times.
Zero Calibration
With belt running empty at normal speed with test weights removed
ZERO CALIBRATION REQUIRED
INITIAL ZERO COUNT
FREQUENCY COUNT DISPLAYED DURING

CALIBRATION
DEVIATION
NEW ZERO COUNT CALIBRATION

COMPLETE - RETURN TO RUN MODE
PRESS TO RETURN TO RUN MODE
SPAN REQUIRED
AM0010-2
AX862-901-8EN-01f 350/360
All Plants
Span Calibration
With belt running empty at normal speed with test weights applied
INITIAL SPAN COUNT
FREQUENCY COUNT DISPLAYED DURING

CALIBRATION
DEVIATION
NEW SPAN COUNT
CALIBRATION COMPLETE - REMOVE TEST WEIGHTS
PRESS TO RETURN TO RUN MODE
EN AM0010-3
AX862-901-8EN-01f 351/360
INITIAL CALIBRATION SIMPLIFIED GUIDE

The Following procedures may be performed when messages E3 and E4 are displayed during routine
calibration.
The E3 and E4 messages indicate a mechanical problem
i.e. Bearing failure on weigh idler and also idlers adjacent to the weigher,new belt fitted,build up on the
weigher etc.
Important: The belt should be stopped and secured prior to suspending or removing the test weights for span
calibration. Safe working practice should be adopted at all times.
Zero Calibration
With belt running empty at normal speed with test weights removed
SELECT PARAMETER P377
INVOKE INITIAL ZERO ENTER “ 1 “
CURRENT ZERO COUNT
ZERO CALCULATION FREQUENCY COUNT

DISPLAYED
ZERO DEVIATION
ZERO DEVIATION ACCEPTED INITIAL ZERO

COUNT= ####
PROCEED WITH SPAN CALIBRATION OR

RETURN TO RUN MODE
AM0010-4
AX862-901-8EN-01f 352/360
All Plants
Span Calibration
With belt running empty at normal speed with test weights applied
SELECT P388
INVOKE INITIAL SPAN ENTER “ 1 “
CURRENT SPAN COUNT= ####
SPAN CALCULATION,
FREQUNCY COUNT DISPLAYED
SPAN DEVIATION= ##
ZERO DEVIATION ACCEPTED

INITIAL ZERO COUNT= ####
RETURN TO RUN MODE
EN AM0010-5
AX862-901-8EN-01f 353/360
AM0010-6
AX862-901-8EN-01f 354/360
All Plants
AM0030 - Routine Inspection Checks
 WARNING
Refer to safety in maintenance section of
the user manual for relevant warning and
procedure
LOCKOUT
PLANT
Introduction
General plant items should be inspected on a
weekly basis and at 500 hr intervals for damage
in the following areas;
1. Crusher body
2. Wear Parts
3. Flywheel(s) Area to inspect

3
4. Main chassis
5. Feeder
6. Track frames
7. Conveyor frames
EN AM0030-1
AX862-901-8EN-01f 355/360
Routine InspectionChecks
AM0030-2
AX862-901-8EN-01f 356/360
12 - Notes Page 1
Hours Run / Date Notes Name
BL-Pegson Limited, Coalville, England. Tel : +44 (0)1530 518600, Fax : +44 (0)1530 518618
E-mail : [email protected] Website : www.bl-pegson.com
AX862-901-8EN-01f 357/360
Page 2 12 - Notes
AX862-901-8EN-01f 358/360
12 - Notes Page 3
AX862-901-8EN-01f 359/360
AX862-901-8EN-01f 360/360

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ADVANCED CRUSHING TECHNOLOGY

PLANT USER MANUAL

Follow all applicable safety regulations and recommendations in this manual as

INFORMATION AND ADVICE

Terex Pegson Limited

Terex Crushing & Screening Inc

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

This plant is in conformity with the provisions

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 Terex Pegson Limited.

Terex 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 .................................................................................. 1 - 2

1.2 Organisation Measures .................................................................................. 1 - 3

1.3 Selection and Qualification of Personnel - Basic Responsibilities ............. 1 - 4

1.4 Safety Instructions Governing Specific Operational Phases ...................... 1 - 5

1.7 Position of Emergency Stop Buttons & Isolation Switch .......................... 1 - 13

1.8 Plant Warning Signs ..................................................................................... 1 - 14

1.1 Warnings and Symbols

Follow the recommended precautions and safe operating practices.

1.2 Organisation Measures 1.2.2

For reasons of safety, long hair must be tied 1.2.3

Disconnect battery ground cable before 1.3 Selection and

1.4 Safety Instructions 1.4.2 Special Work In Conjunction

Switch off and lockout the plant before

Never allow unqualified or untrained Beware of moving haulage and loading

Particularly make sure that any part of the

Never work under unsupported equipment.

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

1.5.1.8 Observe the regulations in force at the

1.6 Transporting, 1.6.7

1.6.4 Never travel across slopes; always keep the

1.6.5 On sloping terrain, always adapt your

Do not attempt to mount a tyre unless you

Always maintain the correct pressure. Do

When inflating tyres, use a clip-on chuck and

Check wheels for low pressure, cuts,

1.7 Position of Emergency Stop Buttons & Isolation Switch

Emergency Stop Button

Emergency Stop Button

Figure 1a Emergency Stop Buttons

1.8.1 Location of Warning

KEY TO SIGN REFERENCE

KEY TO SIGN REFERENCE

Decal Location - 4242SR Impactor:

Control Panel, 4242SR

Impactor non-drive side, 4242SR

Impactor drive side, 4242SR

Decal Location - 4242SR Impactor:

Inspection door both sides of impactor,