Tesab 1012T OperationManual Issue4

RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
CONTENTS
Jan 2005 Issue
TABLE OF CONTENTS
SECTION 1:
1.0
1.1
1.2
1.3
1.4
1.5
EU directive
Declaration
Machine Specification Details
Foreword / Reservation Of Rights
Familiarisation
General Specification
SECTION 2:
2.0
2.1
2.2
2.3
2.4
SAFETY
Safety Introduction
Safety Notes
Position of Emergency Stops
Emergency Situation
Lockout Procedure
SECTION 3:
3.0
3.1
3.2
3.3
3.4
INTRODUCTION
TRACKING INSTRUCTIONS
Tracking Familiarisation
Tracking the Machine
Tracking using the Remote Control
Tracking using the Dog Lead
Remote Control Battery Charging
RK1012T ROTOCRUSHER
CONTENTS
Jan 2005 Issue
TABLE OF CONTENTS
SECTION 4:
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
Set-up Procedure Safety

Installation
Loading & Off-Loading
Starting Engine
Engine Starting Procedure
Tracking Instructions
Tracking the Machine
Tracking using the Remote Control
Tracking using the Dog Lead
Remote Control Battery Charging
Positioning
Preparing for Initial Startup
Dirt Conveyor Unfolding
Crib Folding and Assembly
Feeder Beacon
Feed-In Chute
Hoist
Crusher Settings
Dust Suppression
SECTION 5:
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
SET-UP PROCEDURE
OPERATION
Operation Safety
Operation Lockout Procedure
General Information
Pre Operation Check List
Feeder Information
Feeder Instructions
Machine Starting
Setting Engine Revs
ESM Main Unit
Engaging Clutch
Product Conveyor Starting
Dirt Conveyor Starting
Feeder Starting
Machine Shutdown Sequence
RK1012T ROTOCRUSHER
CONTENTS
Jan 2005 Issue
TABLE OF CONTENTS
SECTION 6:
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
MAINTENANCE
The RK1012 Rotocrusher

Replacing or Turning Hammers
Setting The Crusher Gap
Replacing or Turning Impact Bars
Manual Clutch
Hydraulic Clutch
Maintenance
General Information
Safety Information
Hydraulic System
Tracks
Hydraulic Fluids
Oil Tank, Pipes & Fittings
Diesel Engine
Product Conveyor Reduction Gear
Feeder
Bearing & Lubrication
General Specification Inspection
Routine Maintenance Schedule
Daily Maintenance
Weekly Maintenance
Six Monthly Maintenance
Belt Tracking
V-Belt Tensioning
Recommended Gear Oil
Recommended Lubricants
Automatic Greasing System (Autolube)
Autolube Maintenance
Autolube Troubleshooting
Recommended Fluids
Fault Finding
RK1012T ROTOCRUSHER
CONTENTS
Jan 2005 Issue
TABLE OF CONTENTS
SECTION 7:
7.0
Preparing for Transport
SECTION 8:
8.0
RK1012 CRUSHER PARTS LIST
Index
Main Assembly
Chamber Wear Plates
Shaft and Bearing Assembly
Top Apron Adjuster Assembly
Middle Apron Adjuster Assembly (Manual Adjustment)
Bar Carrier Adjuster Assembly (Manual Adjustment)
Middle Apron & Bar Carrier Adjuster Assembly (Hydraulic Adjustment)
SECTION 10:
10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
WARRANTY
Warranty
SECTION 9:
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
PREPARING FOR TRANSPORT
HYDRAULIC & ELECTRIC DIAGRAMS
Hydraulic Diagram (Standard)

Hydraulic Diagram (inc. Conveyor Folding)
Electric Diagram (Fuse Relay Description)
Electric Diagram (Panel Layout)
Electric Diagram
Electric Diagram
Electric Diagram
Electric Diagram
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 1
INTRODUCTION
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 1
The TESAB RK 1012T ROTOCRUSHER complies with the EU directive 89/392/

EEC and all relevant amendments.
READ THIS MANUAL CAREFULLY AND LEARN HOW TO OPERATE AND

SERVICE YOUR MACHINE CORRECTLY.
FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT

DAMAGE.
REMEMBER:
GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS IN

INCREASED PRODUCTION AND EXTENDED PLANT
LIFE !
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.1 EC DECLARATION OF CONFORMITY

We hereby declare that the following machinery complies with the Essential Health
and Safety requirements of the EU Machinery Directive 89/392/EEC as amended
by 91/368/EEC, 93/44/EEC and 93/68/EEC.
Manufactured by:
Tesab Engineering Ltd.

7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Machine Description:
Mobile Crushing Plant
Model:
RK 1012T ROTOCRUSHER
Serial No:
This machinery has been designed and manufactured in accordance with all the
relevant ESRs of the EU Machinery Directive.
A technical construction file for this machinery is retained at the following address:
Tesab Engineering Ltd.
7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Signed:
Name:
Brian A. Mills
Position:
Project Manager
Date:
Being the nominated representative of Tesab Engineering Ltd.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.2 MACHINE SPECIFICATION DETAILS
MACHINE SERIAL NUMBER:
ENGINE TYPE:
ENGINE SERIAL NUMBER:
CLUTCH TYPE:
CLUTCH SERIAL NUMBER:
DESPATCH DATE:
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.3 FOREWORD/RESERVATION OF RIGHTS

The TESAB RK 1012T ROTOCRUSHER is a robust skilfully engineered piece of
equipment incorporating diesel, hydraulic and mechanical components of the
highest quality.
In the interest of continuous plant reliability, it is essential that the machine is

maintained with meticulous care and attention. This operation and maintenance manual has been produced to assist the user to obtain the maximum
output from the machine and to trace and remedy faults, should they arise,
failure to do so could result in personal injury or equipment damage. We recommend that the user should pay particular attention to the maintenance and
safety sections of this manual.
Consider this manual a permanent part of your machine. Keep a copy of this
manual at the operational site.
This operation and maintenance manual must not be copied, reproduced
or loaned to a third party without written consent of
TESAB ENGINEERING LTD.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.4 FAMILIARISATION
The following conventions have been used throughout this operation and maintenance manual when describing component locations:
Right and left hand sides -
as viewed from the product conveyor end of

machine.
Front
product conveyor end of machine.
Rear
feeder end of machine.
REAR
RIGHT
LEFT
FRONT
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.4 FAMILIARISATION contd.
1.
Feeder
2.
Crusher Unit
3.
Dirt Conveyor
4.
Chassis
5.
Drive System
6.
Product Conveyor
7.
Tracks
3. Dirt conveyor front view
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.5 GENERAL SPECIFICATION
Chassis
The chassis is constructed of heavy-duty profiles and welded steel plates ribbed
and stiffened to withstand all operational and travelling stresses. The chassis is
mounted on 3.75m centre heavy-duty tracks, with remote control or dog lead operational facility.
Feeder
The 4.25m x 0.9m spring mounted heavy duty vibrating feeder is of twin shaft
design. The controls and variable speed are located on the feeder catwalk or
alternatively the feeder can be operated from the tracks remote control, this allows
the operator full control of crusher feed rate. The bar frame cassette can be manufactured to the customers specification depending on application and site conditions. The customer has the option of feeding the fines onto the product conveyor
belt or onto a 3.6m x 500mm side dirt conveyor. The feeder is fitted with hydraulic
folding heavy-duty cribs to give extra hopper capacity.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.5 GENERAL SPECIFICATION contd.

Crusher Unit
The RK 1012 crusher unit is fitted with four hammers, 1000mm wide. It has a feed
opening of 1020 x 780mm and a rotor diameter of 1200mm. There are two adjustable aprons and a final bar carrier which can be adjusted from 4 to 80mm depending on material feed size and reduction required. It is driven through 8 V-Belts and
the chamber can be easily accessed by hydraulic control lever. There is a deadbox
fitted under the crusher to allow easy flow of material onto the product conveyor. A
speed sensor is fitted to the rotor that cuts of the feed before the crusher overloads.
Product Conveyor
The product conveyor is fitted with a 1000mm heavy duty 4 ply belt and runs on
heavy duty troughing rollers, impact bars are fitted under crusher to give belt full
support at crusher exit. The conveyor is driven hydraulically through a flexible coupling at the rubber lagged top end drum.
Power Unit
The engine is a Caterpillar C9 (300HP at 1800rpm) Power Pack and the crusher is
driven through a heavy duty Twin Disc IBF 314 (3 plate) PTO. The pulley on the
clutch can be easily changed to alter the rotor speed or if finer tuning is required the
engine speed can vary between 1700 and 2200rpm. The conveyors, feeder, and
rams are all driven hydraulically through pumps fitted to the engines auxiliary drive.
Catwalks and Guards
All relevant catwalks, handrails and guards are fitted to this machine allowing access to all relevant maintenance points. Emergency stops are fitted to all necessary
points. The machine carries the European CE mark and therefore complies with all
Essential Safety Requirements.
Options
-
Self-cleaning magnet
Dust suppression
Re-cycling apron
Vibrating feeder under crusher
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 2
SAFETY
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.0 SAFETY INTRODUCTION

In this next section you will find the safety sign conventions used throughout
this manual and on the machine.
Please read this section carefully and become familiar with the signs used.
These signs are used frequently throughout this manual to indicate any potential warning or danger when operating this machine.
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER
Electrical Hazard. Risk of serious injury or

death.
Never work on the electrical system of any
equipment unless you are fully familiar with
system details.
Work on the electrical system must be
carried out by a qualified electrician.
NIP HAZARD
1.
2.
3.
DANGER
Nip Hazard. Do not reach into an

unguarded machine.
In-running nip points can cause
serious injury or death.
Switch off and lockout machine
before opening or removing guard doors.
FALL HAZARD
1.
2.
3.
Fall Hazard. Do not climb onto moving or

working machinery.
Switch off and lockout machine before
attempting maintenance on the machine.
Always use a suitable lifting platform before
attempting maintenance above 2m (6-6).
RK1012T ROTOCRUSHER
SAFETY
WARNING
Section 2
CRUSH HAZARD
1.
2.
3.
WARNING
Crush Hazard. Beware of dangerous hand

and foot crush points.
Do not use any body parts e.g. hands or
feet to check hole alignment or support
machinery.
Always use pins and/or mechanical
supports provided.
PROTECTION
1.
2.
3.
WARNING
Loose or baggy clothing can get caught in

running machinery.
Always wear correct fitting (EN/ANSI
approved) protective clothing.
Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
CONSULT MANUAL
1.
2.
3.
WARNING
Read and understand the operators manual

before you work at this machine.
Study the different safety signs on this
machine.
Only qualified and trained personnel should
attempt to work at this machine.
LOCKOUT
1.
2.
3.
When performing maintenance or

adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
Keep ignition key on person during
maintenance.
Never work alone.
RK1012T ROTOCRUSHER
SAFETY
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
Fall rock hazard. Do not walk near material

discharge areas. You are at risk of serious
injury or death.
Wear a Hard Hat at all times when working
in the vicinity of the machine.
BATTERY HAZARD
1.
2.
BATTERY
Burn or Heat Hazard. Beware of hot sur

faces at engine and exhaust areas.
HEAD PROTECTION
1.
EXPLOSIVE
Beware of escaping hydraulic oil. High

pressure hydraulic oil can penetrate the
skin causing serious injuries.
Always relieve pressure from the hydraulic
system before attempting maintenance.
If oil is injected under the skin, it must be
surgically removed or gangrene will result.
HOT SURFACE
1.
ACID
Section 2
Battery Hazard. Battery electrolyte contains

acid and can cause serious injury. Avoid
any contact.
Batteries give off flammable fumes which
can explode. Avoid the formation of sparks
and naked lights in the vicinity of the
batteries. Do not smoke when working in
this area.
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.1 SAFETY
Operators should be trained in the
correct and safe use of all equipment including the studying of this
manual, failure to do so could result in serious injury.
Any work on and with the machine
must be executed by reliable, trained
and authorised personnel only. Statutory minimum age limits must be observed.
Work on the electrical system and
equipment of the machine must be
carried out only by a skilled electrician or by instructed persons under the supervision and guidance of
a skilled electrician and in accordance with electrical engineering
rules and regulations.
Work on the hydraulic system must be
carried out by personnel with special
knowledge and experience of hydraulic equipment.
There are several specific signs on
your machine. Please take time to
familiarise yourself with the safety
signs and the operation and maintenance manual.
See to it that safety instructions and
warnings attached to the machine are
always complete and completely legible.
Replace unreadable or missing labels

with new ones before operating the
machine.
Wear a hard hat, protective glasses,
hearing protection, close fitting
overalls, steel toed boots and high
visibility vest (E.N / A.N.S.I. approved) as required by job conditions.
Do not wear loose clothing or jewellery and tie back long hair that can
catch on controls or moving parts.
Make certain all protective guards
and covers are secured and in place
at all times. All guards should be in
place whenever maintenance is not
being performed. Never disable or
remove any safety mechanism or
guard.
Where possible when working close to
engines or machinery, only do so when
they are stopped. If this is not practicable, remember to keep tools, test
equipment and all other parts of your
body well away from the moving parts.
Understand service procedure before doing work. Keep all areas

clean and dry.
Keep warning and instruction labels

clean.
RK1012T ROTOCRUSHER
SAFETY
2.1
Section 2
SAFETY contd.
Never lubricate, clean, service or

adjust machine while it is moving.
Keep hands, feet and clothing clear
of power driven parts and nippoints. Disengage all power and
operate controls to relieve pressure.
Stop the engine. Implement lockout
procedure. Allow machine to cool.
Keep all parts in good condition and
properly installed. Fix any damage immediately and replace any broken
parts with genuine TESAB parts. Remove any built up of grease, oil or debris.
For the execution of maintenance
work, tools and workshop equipment adapted to the task on hand
are absolutely indispensable.
Isolate all electrical supplies before
carrying out repairs or maintenance,
and should only be carried out by qualified personnel.
Stay clear of all rotating and moving parts. Do not attempt to clear
obstructions or debris by hand before isolating the equipment by implementing the lockout procedure.
In running nip points can cause serious injury even death. Do not reach
into an unguarded machine.
Take the necessary precautions to

ensure that the machine is used
only when in a safe and reliable
state.
In the event of malfunctions or operational difficulty stop the machine immediately and lockout. Have any defects
rectified immediately.
Do not attempt repairs or adjustments to the machine while it is running.
Relieve all pressure in hydraulic systems before any lines, fittings or related
items are disconnected or removed.
Hydraulic lines must be laid and fitted properly. Ensure that no connections are inter-changed. The fittings
lengths and quality of the hoses
must comply with the technical requirements.
Always practice extreme cleanliness
when servicing hydraulic components.
Hydraulic fluid under pressure is
very dangerous, it can penetrate the
skin causing serious injury.
If fluid is injected under the skin it must
be surgically removed immediately.
Switch off engine and lockout machine before opening or removing

guards or doors.
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.1 SAFETY contd.

Always use a piece of cardboard to
check for leaks. Do not use your
hand.
Use caution while removing filler caps,
filters, drain plugs or hydraulic fittings,
hold a rag over the connection to prevent being sprayed or splashed by liquids.
Diesel engine exhaust emissions
contain products of combustion
which may be harmful to your
health. Ensure the machine is in a
well ventilated area, if the machine
is operating in an enclosed area
vent the emissions elsewhere.
Observe the regulations in force at that
site.
Dust found on the machine or produced during operation should be
removed by extraction not blowing.
Disconnect the battery leads and tape
the leads to prevent accidental start
up when performing maintenance or
servicing.
Battery electrolyte contains acid
and can cause serious injury. Avoid
contact with skin and eyes. Use
gloves and protective glasses.
Batteries give off flammable fumes

which can explode. Ensure that
there is proper ventilation. Avoid
the formation of sparks and naked
lights in the vicinity of the batteries. Do not smoke when working in
this area.
Fires may result from lubricating oil or
fuel spraying on hot surfaces.
Avoid smoking whilst refuelling or
in the refuelling area.
Do not climb on conveyor belts or
stand on components that cannot support your weight, always use ladders,
steps and walkways when mounting
and dismounting machine.
Only use emergency stop buttons
in an emergency situation or during
safety checks.
Do not use fingers to check hole alignments as this can cause serious injury.
Do not stand beneath equipment as
it is being raised or lowered into position.
Never check the tension of V-belts
whilst machine is running.
Whenever maintenance and servicing is being carried out a minimum
of two persons must be present at
all times.
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.1 SAFETY contd.

The preparations to transport the
machine should be supervised by a
minimum of two persons.
TESAB ENGINEERING LTD. have
provided walkways and platforms to
enable operatives to carry out daily inspection and maintenance from a position of safety. More irregular maintenance tasks will necessitate persons
to work on the machine at a height
were fall hazards exist. (It is the responsibility of the operators management to provide the necessary safe
working access).
Falling from and/or onto a TESAB
machine can cause serious injury or
even death. Do not climb on the machine and never use machine parts
as a climbing aid.
Always use an EN/ANSI approved
harness if reaching any points 2m (7ft)
or more above ground level.
Keep all handles, steps, handrails,
walkways and ladders free from dirt,
oil, snow and ice.
Observe the adjusting, maintenance
and intervals set out in these operating instructions, except where warning
light or indicator calls for immediate
action or adverse conditions require
more frequent servicing.
When the machine is completely shut

down for maintenance or repair work,
it must be secured against inadvertent starting by implementing the lockout procedure (see lockout section for
details).
Never allow anyone to remove large
or heavy components without adequate lifting tackle.
To avoid the risk of accidents, individual
parts and large assemblies being removed for replacement purposes
should be carefully attached to the lifting tackle and secured.
The fastening of loads and the instructing of crane operators should
be entrusted to experienced personnel only.
Any safety devices removed for setup,
maintenance or repair must be fitted
and checked immediately upon completion of the work.
Before activating the machine in any
manner, or energising the electrical
and/or hydraulic controls, make certain that no person or obstruction
is standing in or in the immediate
vicinity of the machine.
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.1 SAFETY contd.

Always be aware that fully automatic machinery with moving parts
may move at any time without warning. Never assume the machine to
be safe because of the lack of movement.
Never alter any equipment or parts of
any equipment which may effect safety
without consulting and gaining permission from TESAB ENGINEERING
LTD.
Improperly disposing of waste can
threaten the environment and ecology. Potentially harmful waste used
with the TESAB machine include oil,
fuel, coolant, filters and batteries.
Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead
someone into drinking from them.
Do not open any door of the crusher

until the rotor has stopped completely and the control power have
been broken, in the case of the diesel powered unit the clutch is disengaged, the engine has stopped
and the ignition key has been removed.
Never start the machine until all doors
on the crusher are closed and locked.
When removing hammers and impact plates always use protective
goggles.
When the crusher chamber has been
opened ensure that the chamber is
pinned open.
When working at the inside of the
crusher lock the rotor inserting a
locating bar.
Do not pour the fluids onto the

ground, down a drain or into any
water source.
Ensure that all consumables and replaced parts are disposed of correctly
and with the minimum environmental
impact.
RK1012T ROTOCRUSHER
SAFETY
Section 2
1.
LHS & RHS
4.
RAMS CONTROL
CONSOLE
3.
FEEDER
CONSOLE
2.
LHS & RHS
2.2 POSITION OF EMERGENCY STOPS
RK1012T ROTOCRUSHER
SAFETY
2.3
Section 2
EMERGENCY SITUATION
WARNING
In the case of an incident of any part failure on the
machine you must follow the following procedure.
1.
Engage the nearest emergency stop.
2.
Switch of engine and remove the ignition key.
3.
Implement the lockout procedure (see Section 2.4).
4.
Only when the machine is fully switched off and the crusher
rotor has completely stopped revolving (approximately 120
seconds), should an attempt be made to solve the problem.
5.
It is always important to never work alone.
Restart after Emergency Stop.
1.
Ensure the problem has been rectified.
2.
Ensure that all personnel are clear of the machine.
3.
Ensure that all guards and relevant safety devices have

been fitted / refitted correctly.
4.
Release all emergency stops.
5.
Restart the machine (see section 4.3)
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.4 LOCKOUT PROCEDURE
WARNING
1.
2.
3.
When carrying out maintenance, repairs

or adjustment to the TESAB RK 1012T
ROTOCRUSHER the following lockout
procedure must be followed.
Deactivate all controls, switch off engine and remove key.

Activate, or, if fitted, lock one emergency stop button.
Relieve all pressures in the hydraulic system.
IMPORTANT: THE PERSON CARRYING OUT THE WORK ON THE

MACHINE MUST KEEP THE KEYS WITH THEM AT ALL
TIMES.
IMPORTANT SAFETY NOTICE
ENSURE ISOLATOR SWITCH IS IN THE OFF POSITION
PRIOR TO WELDING.
ISOLATOR IN OFF POSITION
ISOLATOR IN ON POSITION
Engine Access Catwalk
ENGINE CANOPY
CONTROL PANEL
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 3
RK1012T ROTOCRUSHER
3.0
Section 3
TRACKING FAMILIARISATION
READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOUR

TESAB RK1012T ROTOCRUSHER.
DAMAGE.
1.
Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
2
4
4
1
4
6 3
1.
Main engine starter panel.
2.
Remote control box.
3.
Dog lead controller.
4.
Emergency stop.
5.
Remote control
6.
Fast Track Console
Remote Control
Dog Lead Control
RK1012T ROTOCRUSHER
3.0
Section 3
TRACKING FAMILIARISATION contd.
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
WHEN TRACKING THE MACHINE
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
>
>
>
DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.

ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH
POSITION PRIOR TO STARTING ENGINE.
NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
NEUTRAL(middle) POSITION
RK1012T ROTOCRUSHER
3.1
Section 3
TRACKING THE MACHINE
The following sections describe how to track your machine, read the complete
manual before tracking. Check that there is a clear area around the machine and
that all control levers including clutch lever are in the neutral position.
Engine Control Panel
IGNITION STARTER
a
b
a)
Check that no emergency stops are in the on position, if an emergency stop is in the on position lamp A (green) will NOT be
illuminated.
b)
Turn the starter ignition key B to position no. 1 which is the on

position.
c)
Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
d)
Release the key when the engine has started.
RK1012T ROTOCRUSHER
3.1
Section 3
TRACKING THE MACHINE contd.

Note: Do not activate the starter for more than 20 seconds at a time.
You will protect the batteries if you wait one minute between each
starting attempt.
e. Set the engine revs to approximately 1000 r.p.m., this can be done by
adjusting the throttle scroll button (Pushing button up increases engine
revs, Pushing button down decreases engine revs).
Throttle Adjustment
- revs
+ revs
Increase Revs
Decrease Revs
Revs Displayed on LCD
RK1012T ROTOCRUSHER
3.2
Section 3
TRACKING THE MACHINE USING THE REMOTE CONTROL
Getting to know your remote control.
a
h
SIDE Y
SIDE X
b
f
SIDE X
A
B
C
D
E
F
G
H
I
J
SIDE Y
RHS track forward.

RHS track reverse
LHS track forward
LHS track reverse
Remote control activation & Tracks On/Off
Engine stop (only active when handset on)
Key Switch
Feeder on
Feeder off
Remote Control Lockout switch (Prevents remote from being used when
button is depressed.
RK1012T ROTOCRUSHER
3.2
Section 3
TRACKING THE MACHINE USING THE REMOTE CONTROL contd.
The following procedure is to be carried out to allow operator to track the machine
using the remote control.
a) Firstly ensure that the isolator switch location on the main engine
canopy is in the ON position as shown below.
b) Ensure that the track switch (A) on the main engine starter panel is in
the ON position and that the control switch (B) is in the REMOTE
position.
A
B
c) Start the engine as per previous instructions (it is important that

instruction a) is carried out before starting engine).
d) Press button E on the remote control the beacon and siren will
automatically sound and the track system will activate allowing the
operator to begin moving the machine.
RK1012T ROTOCRUSHER
3.2
Section 3

e) To track press relevant buttons on the remote control (refer to section
3.2 Getting to know your remote control), for safety reasons Tesab
have fitted a siren and orange beacon to make other persons in the
vacinity aware that the machine is going to or is being moved and it is
always important for the operator to be aware of his surroundings.
RK1012T ROTOCRUSHER
3.3
Section 3
TRACKING THE MACHINE USING THE DOG LEAD
Tesab have also supplied a dog lead controller as another way of tracking the
machine
The following procedure is to be carried out to allow operator to track the
machine using the dog lead.
e)
Ensure that the control switch (B) is in the DOG LEAD position
and the Track Switch on the main engine starter panel is in the ON
position prior to operating the dog lead.
Track Switch
continued over...
RK1012T ROTOCRUSHER
3.3
Section 3
TRACKING THE MACHINE USING THE DOG LEAD contd.

f)
Start the engine as per previous instructions (it is important that

g)
Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
B
F
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
h)
To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
RK1012T ROTOCRUSHER
Section 3
3.4 REMOTE CONTROL BATTERY CHARGING

Follow the procedure below to charge the battery for the remote control.
Charger
Unit
1.
2.
3.
Green Indicator
Place battery into

charger unit.
Plug in charger unit and
switch on at mains.
The green indicator light
shows that the battery is
being charged.
Battery
NOTE:
This charger requires a 3 pin
European to UK mains adaptor if
being used in the UK or Ireland.
IMPORTANT SAFETY NOTE

ENSURE ISOL
ATOR SWITCH IS
ISOLA
IN OFF POSITION PRIOR TO
WELDING.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 4
SET-UP PROCEDURE
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.0 SET-UP PROCEDURE SAFETY

DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

death.
system details.
NIP HAZARD
1.
2.
3.
DANGER

unguarded machine.
FALL HAZARD
1.
2.
3.

working machinery.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
Section 4
CRUSH HAZARD
1.
2.
3.
WARNING

machinery.
supports provided.
PROTECTION
1.
2.
3.
WARNING

running machinery.
CONSULT MANUAL
1.
2.
3.
WARNING

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING

injury or death.
BATTERY HAZARD
1.
2.
BATTERY

HEAD PROTECTION
1.
EXPLOSIVE

HOT SURFACE
1.
ACID
Section 4

any contact.
this area.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.1
Section 4
INSTALLATION
The following section will take you step by step through the installation of your
RK 1012T ROTOCRUSHER.
Note:
Due to different transport and shipping regulations throughout the world the RK
1012T Rotocrusher will be delivered in different packing arrangements. For the
purposes of this manual it will be considered that the machine is delivered in its
most un-assembled configuration therefore some of the installation sections
may not be applicable. If this is the case ignore that particular instruction/section
and proceed to next section.
Before installing the RK1012T ROTOCRUSHER ensure that you have read all sections of this manual in order to familiarise yourself with the machine and its function,
paying particular attention to the SAFETY SECTION 2.
Installation, operation, and maintenance of the RK1012T ROTOCRUSHER mush
be carried out by reliable, authorised personnel only, statutory minimum age limits must be observed.
TESAB ENGINEERING Ltd. recommend that the installation of the RK1012T
ROTOCRUSHER is carried out by a recommended TESAB dealer and/or service
department.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.2
Section 4
LOADING AND OFF LOADING
Loading and off loading the RK1012T should be carried out by trained and experienced personnel only. They should first read the operation manual paying particular attention to the safety and installation sections.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 4
STARTING THE ENGINE
IMPORTANT
THE SYSTEM.
PRIOR TO STARTING THE ENGINE
Before starting the engine please ensure that the two manual valves shown in the
picture below are in one of the following positions.
1.
2.
TRACK: When the machine has to be moved.

CRUSH: When the machine is in its working position and ready to work.
Both levers in
Track Position
WARNING
>
>
>

RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 4
STARTING THE ENGINE contd.
The engine starter panel is located at the engine catwalk as highlighted below.
Starter Panel
Starter Panel
This area can be accessed by lowering the access steps (B). It is important, for
safety reasons, that when these steps have been lowered that they are locked
into position using clamps (C) at both sides. This is illustrated below.
C
C
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4
ENGINE STARTING PROCEDURE
Before staring the engine check diesel and engine oil levels.
Throttle
scroll
button
A
B
IGNITION STARTER
a)
Check that no emergency stops are in the on position, if an emergency

stop is in the on position lamp A (green) will NOT be illuminated.
b)
Turn the starter ignition key C to position no. 1 which is the on position.
c)
Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
d)
Note:
e)
Do not activate the starter for more than 20 seconds at a time.

You will protect the batteries if you wait one minute between
each starting attempt.
Set the engine revs to approximately 1000 r.p.m., this can be

done by adjusting the throttle scroll button (Pushing button up increases
engine revs, pushing button down decreses engine revs).
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4
ENGINE STARTING PROCEDURE contd.
IMPORTANT NOTE:
Before tracking we recommend that you fold up the engine area access steps in
order to prevent them from fouling unneccessarily.
WARNING
ENSURE MACHINE IS CLEAR OF ALL OVER HEAD CABLES
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.5
Section 4

DAMAGE.
1.
Familiarisation
shows the names and there locations.
4
2
4
4
1
4
2
6 3
1.
Main engine starter panel.
2.
Remote control box.
3.
Dog lead controller.
4.
Emergency stop.
5.
Remote control
6.
Fast Track Console
Remote Control
Dog Lead Control
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.5
Section 4
TRACKING FAMILIARISATION contd.
IMPORTANT
THE SYSTEM.
WHEN TRACKING THE MACHINE
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
>
>
>

RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.6 TRACKING THE MACHINE

The following sections describe how to track your machine read the complete
manual.
Before tracking check that there is a clear area around the machine and that all
control levers including clutch lever are in the neutral position.
1.
How to start the engine (Main engine starter panel)
THROTTLE
SCROLL
BUTTON
IGNITION STARTER
a
b
a)
Check that no emergency stops are in the on position, if an emergency stop is in the on position lamp A (green) will NOT be illuminated.
b)
Turn the starter ignition key C to position no. 1 which is the on

position.
c)
Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
d)
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.6 TRACKING THE MACHINE contd.

Note: Do not activate the starter for more than 20 seconds at a
time. You will protect the batteries if you wait one minute between
g. Set the engine revs to approximately 1000 r.p.m., this can be
done observing the digital tachometer D on the starter panel
and adjustment of the throttle.
Throt
tle Adjustment
Throttle
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4
TRACKING THE MACHINE USING THE REMOTE CONTROL
Getting to know your remote control.
a
h
SIDE Y
SIDE X
b
f
SIDE X
A
B
C
D
E
F
G
H
I
J
SIDE Y
RHS track forward.

RHS track reverse
LHS track forward
LHS track reverse
Remote control activation & Tracks On/Off
Engine stop (only active when handset on)
Key Switch
Feeder on
Feeder off
Remote Control Lockout switch (Prevents remote from being used when
button is depressed.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4
The following procedure is to be carried out to allow operator to track the machine
using the remote control.
a) Firstly ensure that the isolator switch located on the main engine
canopy is in the ON position
b) Ensure that the track switch (A) on the main engine starter panel is in
the ON position and that the control switch (B) is in the REMOTE
position.
A
B
c) Start the engine as per previous instructions (it is important that

d) Press button E on the remote control the beacon and siren will
automatically sound, the track system will activate allowing the
operator to begin moving the machine.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4

e) To track press relevant buttons on the remote control, for safety
reasons Tesab have fitted a siren and orange beacon to make other
persons in the vacinity aware that the machine is going to or is being
moved and it is always important for the operator to be aware of his
surroundings.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.8
Section 4
TRACKING THE MACHINE USING THE DOG LEAD
Tesab have also supplied a dog lead controller as another way of tracking the
machine
The following procedure is to be carried out to allow operator to track the
machine using the dog lead.
e)
Ensure that the control switch (B) on the main engine starter panel is
in the DOG LEAD position. Ensure that the Track Switch is in the on
position prior to operating the dog lead.
Track Switch
continued over...
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.8
Section 4
TRACKING THE MACHINE USING THE DOG LEAD contd.

g)
Start the engine as per previous instructions (it is important that

h)
Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
B
F
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
i)
To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.9 REMOTE CONTROL BATTERY CHARGING

Follow the procedure below to charge the battery for the remote control.
Charger
Unit
1.
2.
3.
Green Indicator
Place battery into

charger unit.
Plug in charger unit and
switch on at mains.
Battery is fully charged
when green indicator light
is on.
Battery
NOTE:
This charger requires a 3 pin
European to UK mains adaptor if
being used in the UK or Ireland.
IMPORTANT SAFETY NOTE

DISCONNECT BA
T TERY
BAT
TERMINALS AND REMOTE UNIT
PRIOR TO WELDING.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.10 POSITIONING
Before the RK 1012T Rotocrusher is positioned on site it is necessary to have a
level surface and spacious surroundings, if required level the work-site foundation
using a loading shovel.
The machine must be placed on solid ground capable of carrying its weight.
Track the machine into the desired position and ensure the machine is level. This
can be done with the aid of a spirit level.
(Ensure it is level both along the chassis and across the chassis.)
We recommend that when the machine is positioned correctly the dog lead and
the remote control are located in a safe place (i.e. works office or shovel cab).
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.11 PREPARING FOR INITIAL START-UP

i)
Unfold the handrails into the working position and bolt to secure (sections 1 & 2
first, then sections 3 & 4 and finally section 5). Ensure that the tab (6) is fitted
between the inside handrail (2) and the crusher for extra stability.
6
3
ii)
If required fit the pre-cleaner and exhaust. We would recommend that if the
machine has to be tracked for a long distance that you fit these items as soon
as possible.
Pre-Cleaner
iii)
Exhaust
For safety reasons once the machine is in the correct working position switch
the tracks off. This disables the system and prevents the machine from moving
if the remote or dog lead are touched accidentally. Move switch to off position
on control panel to disable tracks. See diagram over. It is also advisable to
switch the manual control valves to the CRUSH position in order prepare the
machine for working. See diagram over.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.11 PREPARING FOR INITIAL START-UP contd.
Both Levers in
CRUSH Position
Tracks
ON/OFF Switch
WARNING

Remove any parts, which have been packed on the catwalks and hopper. This is to
give fully access to all control areas and reduces any fall hazards.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.12 DIRT CONVEYOR UNFOLDING

Important Safety Note:
Unfolding the Dirt Conveyor will require the use of a crane.
The fastening of loads and the instructing of crane operators should be entrusted to experienced personnel only.
Connect the crane lifting chains to the dirt conveyor at the two points
indicated A.
Take the weight of the top section to allow you to remove the transport
bracket (remember to put the transport bracket in the toolbox).
Lower the dirt conveyor top section carefully and pin together at points
indicated B.
Fit belt scrapper C.
B
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.13 CRIB FOLDING & ASSEMBLY

NOTE:
Bolts and pins required to carry out this set-up procedure can be found in the
machine toolbox.
i)
Firstly check around the cribs area to ensure there are no obstructions
and that the hydraulic hoses are not fouling.
ii)
Fold up side cribs approximately half way, one side at a time, using the
highlighted levers below.
Cribs RHS
Cribs LHS
iii)
Fold up rear cribs approximately half way using the highlighted lever
shown over the page.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.13 CRIB FOLDING & ASSEMBLY contd.
Cribs Rear
iv)
At this stage carefully fold up each crib alternately until the three sides are up
in position.
v)
Using the M30x110 bolts and M30 nuts (found in the toolbox) bolt the cribs in
position.
M30x110 bolt
(3 off each side)
M30 nut
(3 off each side)
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.13 CRIB FOLDING & ASSEMBLY contd.

vi)
Insert pins in rear cribs at point A as shown (Note: pins located in toolbox).
vii)
Fit cribs front cross tie and pin.
viii) Tesab have designed an extra crib cross tie above the grizzly bars. This is
designed to ensure that the material which passes this point is at the correct
height to enter the crusher. We highly recommend that this beam is fitted as it
will reduce any down-time due to crusher blockages.
The bolts for this can be found in the tool box. Ensure that the chains and shackles
are connected up appropriately.
Cross Tie & Pin
Securing Chains
Crib Cross Tie
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.14 FEEDER BEACON

The RK1012T has been fitted with a feeder beacon to warn the user when the feeder
has stopped, either by handlever, remote control or speed sensor activation. The
feeder beacon if fitted to a piece of angle that is bolted onto the hoist.
Feeder beacon location

(remember to connect wires
using couplings provided)
4.15 FEED-IN CHUTE

Due to differing height restrictions the assembled feed-in chute maybe too high.
Hence the feed-in extension box, which carries the feed chains, rubber and dust
suppression spray bar is packed separately.
Therefore the next stage of set-up is to fit this extension box as shown using lift points
A and connecting up the spray bar pipe at point B.
A
NOTE:
Fitting the extension box will require the use of a crane.

The fastening of loads and the instructing of crane operators should be
entrusted to experienced personnel.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.16 HOIST
Tesab may have supplied a swinging arm for use when changing hammers, etc.
(this is an optional extra). For transport purposes it is normally folded down. Elevate into the working position and bolt as shown.
Hoist in transport
position
Pivot hoist
around hinge
Bolt in place
using the 4 bolts
IMPORTANT:
Tesab only recommend that this arm is used for changing items up to a
maximum weight of one RK1012T Hammer (Part No 2-423-3) or 200kgs.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.17 CRUSHER SETTINGS

Before we start crushing the final stage of installation is to set the crusher gaps.
This means the distance between the hammers and the impact path at the three
impact areas, these are named as follows:
Top apron (stroke carrier).
Middle apron (stroke carrier)
Bar carrier
Manual adjustment is standard and a spanner is provided for this (found in the toolbox).
Middle apron and bar carrier hydraulic adjustment is an optional extra.
Warning:
The crusher settings must NOT be altered while the crusher is in operation.
Top apron adjustment

When first starting to crush adjust this apron fully open by adjustment at point A.
Adjust a small amount each side alternatively, this will prevent damaging the threads.
IMPORTANT
Clockwise rotation to
adjust apron fully open
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.17 CRUSHER SETTINGS contd.

Bar carrier manual adjustment
Open door B and measure the setting between the LOWER blow bar (grinding list)
and the hammer. Set the desired gap by adjusting the outer nuts at point C.
Note:
The setting is carried out at

the outer bolts of the yoke.
The pre-tension of the
spring unit is factory set at
the inner bolts and should
not require any adjustment.
IMPORTANT
adjust bar carrier forward
IMPORTANT
Anti-Clockwise rotation to
adjust bar carrier
backwards.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4

Bar carrier hydraulic adjustment
Open door B and measure the setting between the LOWER blow bar (grinding list)
and the hammer (as shown on previous page). Set the desired gap as follows:
-
Using the control lever (D), very carefully extend the rams just enough to compress
the disc springs slightly (E).
Remove the shims (F) and again using the control lever, carefully close the
rams to allow the removal of the remaining shims (G).
Set the gap using the control lever. The gap can be checked through door B.
Once the gap is set, replace the shims (F &G) in the necessary order.
NOTE:
Once the bar carrier gap has been set, rotate the rotor to ensure that
there is enough clearance between the hammers and the blow bars. This
is necessary as, due to wear, the size of the blow bars can change.
D
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4

Middle apron manual adjustment
Adjust the middle apron by adjusting the outer nuts at points H until it is overlapping
the top of the bar carrier by a MINIMUM of 15mm (as shown). The middle apron
should be adjusted by APPROXIMATELY twice the distance (or less) that the bar
carrier was adjusted. This distance can be checked by opening door B.
IMPORTANT
H
adjust apron forward
IMPORTANT
adjust apron backwards.
Minimum
15mm
Note:
The setting is carried out at the outer bolts of the
yoke. The pretension of the spring unit is factory
set at the inner bolts and should not require any
adjustment.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4

Middle apron hydraulic adjustment
-
Using the control lever (J), very carefully extend the rams just enough to compress
the disc springs slightly (E).
Set the gap using the control lever. The gap can be checked through door B.
J
NOTE:
The middle apron should be adjusted by APPROXIMATELY twice the

distance (or less) that the bar carrier was adjusted. The middle apron
should overlap the top of the bar carrier by a MINIMUM of 15mm as
shown on the previous page.
Once the gap is set, replace the shims (F & G) in the necessary order.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4

Important:
The measurement of the setting depends on the following:
(i)
The size of the feed material.
(ii)
Cubing or crushing required.
(iii)
Desired quantities of the different fractions produced.
The following applies in general:

(i)
Do not adjust the crusher settings to an unnecessarily narrow

gap.
(ii)
Study the produced material and use that as a guide-line for your
setting.
For additional advise on the settings on your RK 1012T Rotocrusher please

consult TESAB ENGINEERING LTD. or your local authorised TESAB dealer
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.18 DUST SUPPRESSION

The RK1012T may be fitted with a completely self sufficient system which includes
the following.
i)
Water Tank.
Water Tank
This tank should be topped up regularly to ensure an efficient dust
suppression system. The system is designed for approximately one fill of
water to last one 10 hour shift depending on nozzle adjustment, etc.
ii)
Manifold
This allows you to turn off and adjust spray bars independently, depending
on site conditions. An extra outlet has been fitted if required.
Important Notes
1)
There is a tap at the base of the manifold (A). It is important that the
manifold is drained at the end of each working day, especially in cold
conditions. This is to prevent freezing of water in the manifold and any
subsequent damage.
2)
The water tank should be drained during extreme cold conditions in order
to prevent any unnecessary damage caused by expansion.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.18 DUST SUPPRESSION contd.

iii)
Spray Bar Location

1
2
1.
2.
Feed into crusher

Feed out of crusher
iv)
Start / Stop
Button to start/stop
dust suppression
v)
Water Filtration
The tank has been fitted with a basic
water filter that should be changed
regularily and as when necessary
depending on the quality of the water
put into the tank.
Water Filter
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 5
OPERATION
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.0 OPERATION SAFETY

DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

death.
system details.
NIP HAZARD
1.
2.
3.
DANGER

unguarded machine.
FALL HAZARD
1.
2.
3.

working machinery.
RK1012T ROTOCRUSHER
OPERATION
WARNING
Section 5
CRUSH HAZARD
1.
2.
3.
WARNING

machinery.
supports provided.
PROTECTION
1.
2.
3.
WARNING

running machinery.
CONSULT MANUAL
1.
2.
3.
WARNING

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
RK1012T ROTOCRUSHER
OPERATION
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING

injury or death.
BATTERY HAZARD
1.
2.
BATTERY

HEAD PROTECTION
1.
EXPLOSIVE

HOT SURFACE
1.
ACID
Section 5

any contact.
this area.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.1 LOCKOUT PROCEDURE
WARNING
1.
2.
3.



TIMES.
PRIOR TO WELDING.
ENGINE CANOPY
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.2 GENERAL INFORMATION

Please Note:
All crushing applications differ due to material composition and customer
requirements.
There are numerous adjustments that can be made in order to achieve
required results.
Therefore we recommend that you contact Tesab Engineering LTD or
your local Tesab dealer to advise you on the best customized Tesab
arrangement to suit your particular application.
For the purposes of this section we assume engine speed requirements
of 2000 rpm.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.3 PRE-OPERATION CHECK LIST

Before operation check and ensure the following:
Nothing on product conveyor
Nothing on dirt conveyor
All guards are fitted correctly
The diesel tank has been topped up
Engine oil level has been checked and topped up if necessary
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.4 FEEDER INFORMATION
IMPORTANT FEEDER INFORMATION

It is important to read this section carefully before operating in order to acquaint
yourself fully with the detailed operation of the feeder.
RK1012T ROTOCRUSHER
OPERATION
5.5
Section 5

DAMAGE.
Familiarisation
shows the names and their locations.
4
1&2
4
4
1.
Main engine starter panel
2.
Remote control box
3.
Dog lead controller
4.
Emergency stop
5.
Remote control
6.
Fast Track Console
1&2
4
Remote Control
4
Dog Lead Control
RK1012T ROTOCRUSHER
OPERATION
5.5
Section 5
FEEDER INSTRUCTIONS contd.
Your TESAB RK1012T feeder has been supplied with the following features, the
following section gives a brief description and how they work.
-
You can operate the machine manually (as per standard RK1012T), this
can be done by positioning the Feeder operation button (on the Main
engine starter panel) in the manual position. This allows you to start and
stop the feeder from the platform at the feeder control console (A).
(important note: there is no speed sensor facility when operating the
machine in this way)
A UTO
MANUAL
You can operate the machine by remote control, this can be done by positioning the Feeder operation button (on the Main engine starter panel) in
the Auto position, This allows you to operate the feeder using your Remote control hand piece.
The speed sensor facility is in operation when using this form of control,
this stops the feeder when the rotor drops below a factory pre-set speed
and re-starts the feeder again when rotor regains the pre-set speed. The
speed sensor facility over-rides the remote control stop and start
(important note: when using this form of control ensure that the lever at
the feeder control console is in the on position)
1
How to use your remote control:
2
Note:
1.
2.
Press the start stop button

Press feeder on/off as required
A blue beacon has been fitted to the machine this notifies the
operator that the feeder is currently off.
RK1012T ROTOCRUSHER
OPERATION
5.6
Section 5
ENGINE STARTING PROCEDURE
Before staring the engine check diesel and engine oil levels.
Engine control panel
Throttle scroll button

A
B
a)
Check that no emergency stops are in the on position, if an emergency

stop is in the on position lamp A (green) will NOT be illuminated.
b)
Turn the starter ignition key C to position no. 1 which is the on position.
c)
Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
d)
Note:
Do not activate the starter for more than 20 seconds at a time.

You will protect the batteries if you wait one minute between
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.7 SETTING ENGINE REVS

Set the engine revs to approximately 1000 rpm. This can be done by observing the
digital tachometer on the starter panel and adjusting the throttle scroll button (pushing button up increases engine revs, pushing button down decreses engine revs).
Throttle Adjustment
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.8 ESM MAIN UNIT

5.8.1
Diagnostic Display
High Inlet Manifold

Temperature*
High Engine Coolant
Temperature*
Low Battery
Voltage*
High Fuel
Temperature*
High Auxiliary
Temperature*
High Auxiliary
Pressure*
Engine Derate
Low Engine Oil
Pressure*
Low Fuel
Pressure*
* IMPORTANT:
Low Engine
Coolant Level*
LCD Digital
Display
May also indicate sensor fault.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.8 ESM MAIN UNIT cont.

5.8.2
Display Scroll Feature
Each time the scroll forward switch is depressed and held, EMS will page through
the engine parameters in the order listed below. 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
Spd
GA-1
GA-2
GA-3
GA-4
Boost
IAirT
FuelT
AccrP
AccrT
Fuel
Hrs
Load
Parameter
Engine Speed
Engine Oil Pressure
Coolant Temperature
Battery Voltage
Fuel Pressure (Customer Installed Sensor)
Boost Pressure
Inlet Air Temperature
Fuel Temperature
Auxiliary Pressure
Auxiliary Temperature
Fuel Rate
Engine Hours
Engine (%) Load
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.9 ENGAGING THE CLUTCH

5.9.1 Manual Clutch
Start crusher by bumping-in clutch.
Bumping-in involves several partial engagements with the hand lever.
Engage clutch gradually until engine labours heavily, disengage clutch momentarily
to allow engine torque/speed to recover.
Repeat this procedure two or three times and then engage clutch completely by
forcing lever to the fully over-centre position.
Operator experience often dictates the number of bumps required.
bump-in
clutch
Engage Clutch
gradually
IMPORTANT: Read Section 6.4 on manual clutch maintenance this states that
the clutch, initially when new, will require several adjustments (it
will also require further adjustments during clutch life).
It is important that this procedure is adhered in order to achieve
pro-longed clutch life.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.9 ENGAGING THE CLUTCH contd.

5.9.2 Hydraulic Clutch
-
Increase the engine revs to 1200 rpm. This can be done by observing the digital tachometer on the starter panel and adjusting the throttle scroll button.
Throttle Adjustment
Increase Revs
Decrease Revs

-
Start the hydraulic clutch by pressing the ON button on the starter panel as
shown below.
Clutch start button
NOTE:
Wait until the crusher speed has built up (approximately 45 seconds)

before proceeding.
IMPORTANT: Read Section 6.5 on hydraulic clutch maintenance.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.10 PRODUCT CONVEYOR STARTING

Increase engine speed to 2000 rpm. This can be done observing the digital tachometer on the starter panel and adjustment of the throttle.
Throttle Adjustment
Increase Revs
Decrease Revs
Start the product conveyor by engaging the appropriate control lever.
Magnet / Dirt Conveyor

Control Lever
Product Conveyor
Control Lever
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.10 PRODUCT CONVEYOR STARTING contd.

Due to the design of the product conveyor in order to track it correctly please carry
out the following procedure:
i)
The conveyor can be TENSIONED correctly at the top end drum using the
adjuster bars as shown.
Note: The conveyor belt tension is factory set but you will find due to running it over time or climatic conditions the belt will stretch and require retensioning.
Important: DO NOT over tension the belt as this will cause excessive strain on the
bearings and drive system.
A
Product Conveyor
Adjuster bars
NOTE:
Slacken off Bolts A
prior to Tensioning Belt
ii)
In order to track the belt correctly you must adjust the return rollers as shown.
For further details on the

tracking of conveyor
belt section 6.23.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.11 DIRT CONVEYOR STARTING

Note: The dirt conveyor and magnet run through the one hydraulic circuit, therefore one single lever activation will start both conveyors.
Start the dirt conveyor by engaging the appropriate lever highlighted.
Dirt Conveyor
Control Lever
Initiallythe conveyor belt is tracked when running empty. The conveyor may need to be retracked when under load.
In order to track this belt correctly please carry out the following procedure:
A
The belt can be adjusted by adjusting the drums at points A.
Note:
The conveyor belt can be tracked by slackening as well as tensioning

the adjusters.
Important:
DO NOT over tension the belt as this will cause excessive strain
on the bearings and drive system.
For further details on the tracking of conveyor belts see section 6.23.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.12 FEEDER STARTING

Start the feeder by engaging the appropriate control lever.
Feeder Control Lever

Feeder Speed Control
Feeder speed can be adjusted by turning the feeder speed control knob.
The operator must set the speed of the feeder depending on the application and
finished product required.
This is why we would recommend running feeder slowly initially and increase the
speed in order to avoid blockages.
If you are having difficulty in obtaining the required product please contact
your local Tesab dealer and he will assist on calibrating your machine.
RK1012T ROTOCRUSHER
OPERATION
Section 5
5.13 MACHINE SHUT-DOWN SEQUENCE

The following procedure should be followed when shutting the machine down at the
end of each shift.
It is important to ensure that you allow the machine to run empty at the end of the
shift before closing machine down, including hopper and feeder. By not allowing
this to happen will put unnecessary pressure on the feeder bearings, springs and
hydraulic system.
1.
Stop feeder
2.
Wait and ensure crusher has cleared completely of material
3.
Stop product conveyor
4.
Reduce engine revs to approximately 1300 r.p.m.
5.
Dis-engage clutch
6.
Reduce engine revs to idle and run engine for 60 seconds
7.
Switch engine off and implement lockout procedure

IMPORTANT: DO NOT LEAVE KEYS IN IGNITION
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 6
MAINTENANCE
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.0 The RK1012 ROTOCRUSHER UNIT

Remove Bolts
18 off
Crusher Opening
Crusher opening lever
Crusher opening pin
IMPORTANT
Ensure all bolts are re-fitted after closing
IMPORTANT
DO NOT OPEN ANY DOOR OF THE CRUSHER UNTIL THE ROTOR HAS
STOPPED COMPLETELY AND THE CONTROL POWER HAS BEEN BROKEN,
OR, IN THE CASE OF A DIESEL POWERED CRUSHER, THE CLUTCH IS DISENGAGED, THE ENGINE HAS STOPPED AND THE IGNITION KEY HAS BEEN REMOVED.
NEVER START THE CRUSHER UNTIL ALL DOORS ARE CLOSED AND LOCKED.
WHEN REMOVING HAMMERS AND IMPACT BARS, ALWAYS USE PROTECTIVE
GOGGLES (YOU CAN, ACCIDENTALLY HIT ASKEW AND A METAL SHIVER MAY
HIT YOUR EYES).
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.1 REPLACING OR TURNING THE HAMMERS

1.
Open the setting (gap)

of the crusher to a maximum.
2.
Rotate the rotor so that one

hammer appears straight up
(see picture No. 1). Insert a
locating bar or similar through
the rotor.
The Rotor is now secured.
Picture No. 1
3.
Clean away the stone powder

and such around the hammer.
4.
Take away the securing

brackets (A) at both sides of
the hammer.
5.
The turned or new hammer is

pushed into position.
6.
Secure the hammer with

bracket (A) at both sides.
Then remove the securing rod.
7.
Repeat from Item 2 until all

hammers are replaced.
8.
Close and lock all doors.
9.
Start the crusher.
NOTE: Should any abnormal sound be

heard, a thumping or knock, stop the
crusher immediately and check if any
of the hammers are positioned too far
to one side, so it touches the side
plates.
After the necessary measures have
been taken, start the crusher again
and run it empty for approximately 5
minutes.
Picture No. 2
If everything is OK, make the final gap
settings, close and lock all doors. ALL
SET FOR CRUSHING.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.2 SETTING THE CRUSHER GAP

Manual Setting of the Crusher
Gap
NOTE:
The setting must not be
altered while crusher is in operation.
1.
Open the door B by thebar

carrier and measure the
setting at the lower impact
bar C (see Picture 4).
The measure of the setting
depends on:
-
Picture No. 3
The size of the feed

material
Cubing or crushing
Desired quantities of
the different fractions
produced
The following applies in

general:
-
2.
Do not adjust the

crusher setting to an
unnecessary narrow
gap
Study the produced
material and use that
as a guideline for your
setting
The setting is carried out at

the outer bolts of the Yoke A.
The pretension of the spring
unit is set at the inner bolts.
Picture No. 4
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.2 SETTING THE DRUSHER GAP contd.

Hydraulic Setting of the Crusher Gap
D
NOTE:
The setting must not be altered
while the crusher is in operation.
1.
Open the door B by thebar carrier and

measure the setting at the upper impact bar C (see Picture 4).
The measure of the setting
depends on:
-
The size of the feed material

Cubing or crushing
Desired quantities of the different
fractions produced
The following applies ingeneral:

Picture No. 5
2.
The setting is carried out as follows:
Using the appropriate control lever (D,

picture 5), very carefully open the rams
just enough to compress the springs
slightly (E, picture 6).
Set the gap using the control lever. The
gap can be checked through door B.
Once the gap is set, replace the shims
(F&G) in the necessary order.
Picture No. 6
Do not adjust the crusher setting

to an unnecessary narrow gap
Study the produced material and
use that as a guideline for your
setting
NOTE:
Once the bar carrier gap has
been set, rotate the rotor to ensure that there
is enough clearance between the hammers
and the blow bars. This is necessary as, due
to wear, the size of the blow bars can change.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.3 REPLACING OR TURNING OF IMPACT BARS (BLOW BARS)
1.
Open the settings (gap)

of the crusher (see
section 6.2).
2.
Open both doors A by

the bar carrier.
3.
Knock out the impact

bars B aterally using an
iron bar or similar.
4.
Clean the sockets and

insert the turned or new
impact bars.
5.
Set the desired gap,

close and lock the
doors. CRUSH!
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.4 MANUAL CLUTCH

The Manual Power Take Off (or Clutch) in conjunction with your diesel engine is the
central part of your RK1012T ROTOCRUSHER. A lot of care and thought has gone
into its selection.
Correct maintenance of your PTO will increase its effectiveness and prolong its lifespan.
The following sections are a short simple outline of duties that the owner and operator must perform for satisfactory service from his TWIN DISC POWER TAKE OFF.
PTO
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.4 MANUAL CLUTCH contd.

6.4.1
Clutch Adjustment
New manual power take offs should have clutch adjustment checked before being
placed in service. A newly placed in service power take off should have its clutch
adjustment checked again after the first 10 hours of operation. New clutch plates
have a wear-in period and the clutch may require several adjustments until the new
plates are worn-in. After wear in, clutch adjustments should be checked regularly.
As this is classed as a heavy duty application which has frequent engagements and
relatively long periods of slip when bumping-in it will require more frequent attention in relation to readjustment.
The clutch requires adjustment when:
-
The clutch is easy to engage to its fully over-centre position
The lever jumps out during operation
The clutch heats up excessively
To adjust the clutch:

-
Lockout the engine by removing the key from the ignition.
Remove the hand hole plate (1) in the housing and turn the clutch until the
locking pin (2) can be reached (see picture 6.4.1.1).
Disengage the adjusting locking pin (2), by pulling it out towards the pulley,
and turn the adjusting yoke or ring (3) to the right (clockwise) until the operating
lever requires a distinct pressure to engage (see picture 6.4.1.1).
Regular adjustment dictates that no more than 1 or 2 notches should be required

each time, any more than this would indicate that the clutch is not adjusted regularly.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Picture 6.4.1.1
NOTE:
The majority of clutch failures are not caused by a unit being under sized
for the application. Failures often are the result of the clutch not being
properly adjusted. Check and adjust the clutch on a regular basis, to the
correct engaging effort as specified on the instruction cover plate.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6

6.4.2
Clutch Lubrication
Throwout Collar:
Apply a small amount of lubricant once a day, before

starting, through the fitting on the tapered part of the
housing.
Main Bearings:
Apply a small amount of lubricant once a week, through

the fittings highlighted below.
Lever Shaft:
Apply a small amount of lubricant once a week, through

the fittings highlighted below, please note that there are
grease nipples on both left and right hand side.
6.4.3
Lubricant Specification
Use any high grade, high temperature, lithium based gun lubricant. For further details see recommended lubricant section in this manual.
NOTE:
Although this section details the greasing points on the clutch, it is important to note that if the machine is fitted with the Autolube system,
these points are supplied with grease by it. See the Autolube section
for further details.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.5 HYDRAULIC CLUTCH

The Hydraulic Power Take Off (or Clutch) in conjunction with your diesel engine is
the central part of your RK1012T ROTOCRUSHER. A lot of care and thought has
gone into its selection.
Correct maintenance of your PTO will increase its effectiveness and prolong its lifespan.
Following is a short simple outline of duties that the owner and operator must perform for satisfactory service from his TRANSFLUID POWER TAKE OFF.
6.5.1
Clutch Maintenance
Change the oil after the first 100 working hours, and every 4000 working
hours thereafter. The correct oil level is the blue line on the oil level indicators.
After replacing the oil, run the pump with the electric valve OFF to fully fill the
heat exchanger. Re-check the oil level again once this has been done and
top-up if necessary.
Recommended oils are as follows:

AGIP
ARAL
BP
CASTROL
CHEVRON
ESSO
MOBIL
SHELL
TEXACO
TOTAL
OSO 32
VITAM GF 32
ENERGOL HLP 32
HYSPIN AWS 32
RPM EP HYDRAULIC 32
NUTO H 32
DTE 24
TELLUS 32
RANDO HD 32
AZOLLA ZS 32
Change the oil filter cartridge (25 micron) when the pressure is 1.7 bar over
the rated value and/or the pressure switch is on.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.5 HYDRAULIC CLUTCH contd.

-
In cases where there is considerable oil leakage the rotating seals should be
changed (see picture 6.5.1.1).
Keep the oil cooler clean. The radiator pack can be cleaned by either washing
carefully by hand or by using air pressure.
IMPORTANT: Never use water pressure as this can damage the aluminium pack.
-
Check periodically (approximately every 1000 hours) that the pump chain is
the correct length (see table below). The chain can be stretched by hanging
a 20 kg weight from it.
KPTO
15
17-19
21-24
27
Max. Length (mm)

1265
1362
1556
1914
Periodically check the condition of the elastic coupling.
Pressure gauge
switch
Elastic coupling
(not shown)
Rotating seal
(not shown)
Rotating seal
(not shown)
Oil filter
Solenoid valve
Oil level
indicator
Picture 6.5.1.1
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.6 MAINTENANCE
The maintenance instructions for your RK 1012T Rotocrusher are set out under
the following headings.
General Information
Safety Information
Hydraulic System
Tracks
Hydraulic Fluids
Oil Tanks, Pipes and Fittings
Diesel Engine
Product Conveyor Reduction Gear
Feeder
Bearings and Lubrication
General Specification Inspection
Routine Maintenance Schedule
Daily Maintenance
Weekly Maintenance
Six Monthly Maintenance
Belt Tracking
V-Belt Tensioning
Recommended Gear Oil
Recommended Lubricants
Automatic Greasing System
Recommended Fluids
Fault Finding
Note:
Diesel engine maintenance and service required or the frequency

thereof is not covered by this operation manual. All matters relating
to this should be referred to the makers publication Operation and
Maintenance Manual, a copy is included with this manual.
IMPORTANT SAFETY NOTE:

IMPLEMENT LOCKOUT
PROCEDURE BEFORE
CARRYING OUT
MAINTENANCE TO YOUR
RK 1012T ROTOCRUSHER
SEE SECTION 2 (safety)
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.7 GENERAL INFORMATION

This section provides detailed maintenance instructions as well as a maintenance
schedule for normal operating conditions.
When performing maintenance on your machine please adhere to the safety information listed in the safety section.
It is important to note that high repair costs and lenghty downtime will occur if inadequate or improper maintenance is performed on your machine. Regular maintenance is imperative.
The reliability and service life of your 1012T unit depends on the regular and correct maintenance of the machine.
Good housekeeping pays untold dividends in increased production and
extended plant life!
IMPORTANT NOTE
If the RK1012T is operated for long periods of time in extreme conditions either
climatic (-15C to 33C) or very dusty the maintenance schedule will change. If this
scenario arises please consult your local Tesab dealer or Tesab Engineering technical/service department.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.8 SAFETY INFORMATION
DANGER
NIP HAZARD
1.
2.
3.
WARNING

unguarded machine.
HIGH PRESSURE
1.
2.
3.
DANGER

FALL HAZARD
1.
2.
3.
WARNING

working machinery.
PROTECTION
1.
2.
3.

running machinery.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.9 HYDRAULIC SYSTEM

The hydraulic system which is used in the RK 1012T Rotocrusher was chosen
for its effectiveness and resistance to climatic and operating conditions. This
must be topped up with the correct hydraulic fluid and regular checks must be
made to ensure this. The system should be checked for leaks and drained
every 1500 hours.
Filtration
In order to maintain the hydraulic oil at its peak performance, two High Pressure
filters are used in the system of the RK 1012T Rotocrusher. These are coupled
with 2 Strainer Valves fitted inside the tank.
Regular monitoring of gauges on the filters is essential. The filter element requires
changing when the indicator is in the red at operating temperature.
Fast Track Console
High Pressure
Filters
DANGER
HIGH PRESSURE
The filter
element needs
to be changed
when the
indicator turns
red.
High Pressure Filters - 2x High Pressurefilters are fitted to

the main pressure lines between Pump and manual spool
valves, and they are used to prevent any tiny particles contaminating the system which could cause damage to the pumps
or motors. The filter elements should be checked regularly
and changed in accordance with the routine maintenance
schedule.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS
Each Track Frame Assemblies fitted to the TESAB RK1012T Rotocrusher
comprise of five main components:
1.
A STEEL FRAME CHASSIS onto which all other components are

mounted. The weight of the machine which is to be carried by these assemblies is distributed along the length of the frames.
2.
The DRIVE ASSEMBLY is a planetary gearbox, mounted at the rear of the

frame, which is driven by a hydraulic motor. A drive sprocket is bolted to the
gearbox.
3.
A total of nine BOTTOM ROLLERS are attached to the underside of each

frame. The entire weight of the machine is carried on these rollers.
4.
The FRONT IDLER is mounted at the opposite end of the frame to the
sprocket, the idler slides on guides. The track is adjusted by a hydraulic
cylinder attached to the idler arrangement. Between the idler, and the track
adjusting cylinder is a recoil spring, which will allow the idler to move backwards in the event that excessive load is placed on the track.
5.
The TRACK ASSEMBLY comprises of sectional chain with triple bar

grouser shoes bolted to it.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.

Track Maintenance
It is important that to ensure trouble free track operation that the following maintenance operations are adhered to:
1.
Track Adjustment.
Check if the track is correctly adjusted. As the track wears it will become
slack and should be checked regularly.
To establish if the track requires adjustment move the machine backwards
and forwards a few metres on level ground and in a straight line (do not slew).
This enables the track to adopt its natural degree of tension.
Measure the droop as shown on figure 1.
30mm approx.
Equal
Equal
Inspection
Cover
Figure 1
This measurement should not exceed 30mm (1.25)

The adjustment of the track is accessed via the inspection cover on the
side of the track frame as shown in figure 1.
Remove the cover using a 6mm allen key.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.

Adjustment is carried out as follows:
a)
To increase track tension:

Ensure the grease fitting is tight, using a 22mm socket or ring spanner.
Using the special grease gun adapter (M1442), fitted to a standard
grease gun, filled with the correct grease, pump the track out to the
correct adjustment.
M1442 Adapter
Important:
Do not tension the track too tightly as this places unacceptable
loads on the gearbox bearings and idler bearings.
It will lead to accelerated wear and premature failures.
b)
To release the track tension:

Slacken the grease fitting on the end of the hydraulic track tensioning
cylinder, by one half turn only, using a 22mm spanner.
Warning:
Grease under extreme pressure is released by this action.
Personal injury could result if the fitting is removed whilst under
pressure.
When the track droop appears to be correct, move the machine backwards and
forwards and re-check the droop.
Add more grease if required.
Replace the inspection cover when the correct adjustment has been made.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.

1.
Gearbox Oil Level.

Cleanliness is absolutely essential.
Use only clean oil, in clean containers.
Gearbox life will be dramatically reduced if dirt is allowed to enter.
Oil Level
The oil level must be checked every 200 working hours.
Method of Checking and Filling
See lubrication chart for correct grade of oil.
Ensure machine is on level ground and until the filler plugs are in the
correct position (see figure 2).
FILLING
LEVEL
Figure 2
Clean the area around the plugs and remove any surrounding debris.
Remove both plugs and fill through the upper plug hole.
Wait a few minutes until any trapped air has escaped then recheck the
level.
Add more oil if necessary.
Note: approximately oil quantity 5 litres per gearbox
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.

Method of Draining
Move the machine until the filler plugs are in the position as shown in
figure 3.
DRAINING
Figure 3
Clean the area around both plugs and remove any surrounding debris.
Remove both plugs and allow to drain.
More effective draining will occur if this operation is carried out when
the oil is hot.
Important:
Do not move the machine, except to re-position the plug holes
for re-filling, without oil in the gearboxes.
Oil Change Periods.
The oil should be drained from the gearboxes after the first 200 hours of
operation, and re-filled with the correct lubricant (see lubrication chart).
Following this initial oil change the oil should then be replaced after
2000 hours of use or at least once per year.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.

Oil Change Periods.
The oil should be drained from the gearboxes after the first 200 hours of
operation, and re-filled with the correct lubricant (see lubrication chart).
Following this initial oil change the oil should then be replaced after
2000 hours of use or at least once per year.
3.
Leakage
Check daily for any signs of oil leakage, particularly, front idler seals,
roller seals and gearbox.
If any leakage is found, action must be taken to correct the problem
before the machine is used.
4.
Bottom Rollers and Idlers
These components are lubricated at the time of manufacture and are

termed lubricated for life.
No servicing is therefore required.
If however an oil leak is detected on any of these components, an
exchange unit should be fitted before using machine again.
Removal of the filler plug invalidates the warranty.
5.
Loose Bolts.
It is the responsibility of the operator to check the machine on a daily

basis for any loose bolts, or signs of undue wear.
In the event that any bolts are found to be loose, they should be retightened to the following torque:
Bottom Roller Bolts
Sprocket Mounting Bolts
Gearbox Mounting Bolts
350 ft lbs.
350 ft lbs.
350 ft lbs.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS contd.
Motion Valve
Track Shoes
33 ft lbs.
120 ft lbs. plus 1/3 turn
It is the operators responsibility to ensure that the machine is properly

maintained and does not pose a safety hazard to himself or other
people.
TRACK LUBRICATION CHART

Gearbox Lubrication
Transmital Bonfiglioli
Gear Oil should conform to the following specifications:MIL-L-2105
or
API GL5
Grade 80W/90
Examples of oil to these specifications are:Texaco
Geartex EP-B
80W/90
Century Oils
BOA
80W/90
All leading lubricating oil suppliers offer equivalents.
Track Adjustment
A good quality all purpose grease should be used.
Texaco
EP2 All Purpose Grease.
All leading lubricating oil suppliers offer equivalents.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.11 HYDRAULIC FLUIDS

Hydraulic fluids play a most important part in any hydraulic system. They
have three main functions.
to transmit power.
to lubricate moving parts.
to seal clearances between parts.
As a power transmitting medium the fluid must flow easily and be as incompressible as possible. In most hydraulic components, internal lubrication is
provided by fluid only. For long component life, fluids are available containing
additives which have high anti-water properties. The fluids are known as antiwear type hydraulic oils, which are recommended for your RK 1012T
ROTOCRUSHER. In most cases the fluid is the oil seal present. For example
there are no sealing rings between the spool and the body of the directional
valve. As the sealing characteristics of the fluid depends on its retaining viscosity, it is important that the oil selected is
capable of maintaining the
minimum viscosity change over a wide range of operating temperatures.
Some adverse effects of incorrect viscosity being:
-
High oil temperatures.

Entrapment of air in oil.
Increased pressure drop.
Excessive wear or even seizure under heavy load.
Poor pump/system performance.
In addition to qualities outlined earlier the selected fluid should also:

-
Prevent rot.
Depress foaming.
Prevent formation of sludge, gum and varnish.
Retain its own stability, thereby reducing fluid replacement.
Prevent corrosion and pitting.
For best operating results it is strongly recommended that the hydraulic fluid
used is selected from the recommended range listed in section 12. In the service it is recommended that the hydraulic system is drained and refilled at least
once every 1500 hours of operation. The hydraulic fluid should be changed
after the machine has stopped work. The drain plug for the hydraulic system is
mounted on the side of the tank. In the event of pump or motor failure, both
suction and return line filter elements must be changed.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.12 OIL TANK, PIPES AND FITTINGS

In order to prevent contamination, the oil tank on the RK 1012T Rotocrusher is of
sealed construction. Access to the tank, if required, is an inspection cover which
is mounted on top of the tank. The tank must be thoroughly cleaned before the
removal of this cover. It is very important that the hydraulic pipes and hoses are
checked regularly for leaks, scuffing and wear. Loose fittings should be securely
tightened. Worn or leaking hosing should be replaced. Replacement hoses are
available on request.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.13 DIESEL ENGINE

The diesel engine is the heart of your RK 1012T Rotocrusher and a great deal of
care and thought has gone into its selection. All engines are put through rigorous
test programmes by the manufacturers before reaching us, to be assembled into
the RK 1012T.
On completion machines are again run and tested for several hours before
dispatch.
This is to guarantee the dependability of TESAB equipment.
In the interest of continued peak performance from your RK 1012T Rotocrusher
the engine must be maintained and cared for with meticulous attention in
accordance with the manufacturers instructions as detailed in the Operation and
Maintenance Manual a copy of which is included with this manual.
IMPORTANT
The engine water trap (A) must be changed every engine service.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.14 PRODUCT CONVEYOR REDUCTION GEAR

Introduction:
Attention:
Maintenance can be routine or unscheduled.
All maintenance activities must be carried out under safety

conditions.
Routine Maintenance:
The operator is responsible for routine maintenance and must carry out the following activities.
After a brief operating period of about 100 hours (breaking-in), change the
oil in the gear unit (Grade EP150 or equivalent).
Check that there are no metallic parts with unusual dimension in the magnetic plug of the gear unit.
Change the oil in the gear unit while it is hot so that it is easier to drain.
Subsequent oil changes should be made every 200-250 hours at operation, or, in any case, every year.
Do not mix different types of oil.
Periodically check the level (about once a month) and top up if necessary.
Attention:
When checking the oil levels in gear unit, if the levels have risen this
means that oil is penetrating from the rotary seal. Contact the local
Brevini Service Dealer.
For your unit it is recommended to keep a chart that you duly fill and up-date each
time maintenance is performed.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.14 PRODUCT CONVEYOR REDUCTION GEAR contd.

Oil Change
Unscrew the drain plug and the filler plug to help drain the oil from the gear unit.
Once the oil has been emptied, replace the drain plug. Wash the interior of the
gear unit with a suitable cleaning liquid that is recommended by the lubricant
manufacturer. By putting liquid into gear unit and running at high speed for few
minutes, then remove the cleaning liquid from the unit and fill with appropriate gear
oil.
Unscheduled Maintenance
Brevini Riduttori prohibits the gear unit to be opened to carry out any operation that
is not included in routine maintenance procedures. Brevini Riduttori do not undertake any liability for all those operations out of routine maintenance which may
have caused damages to people or things. When the need arises, contact the
nearest Brevini Service Centre.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.15 FEEDER
The vibrating feeder is robustly designed. The twin shafted design will give you
years of continuous trouble free operation. The feeder is made from heavy
steel plate reinforced at appropriate places with channel and gussets. The
feeder is supported and isolated by a nest of heavy coil springs mounted on a
sub-frame constructed of heavy I Beam. The springs need only be inspected
weekly for damage and fatigue. Two shafts with bolt-on weights are driven via
hydraulic motor through flexible coupling on one side. Maintenance of your
feeder is minimal. However, we recommend the following guide to increase its
effectiveness and prolong its life-span.
The four bearings require greasing in general every week (50 hours). Grease
nipple access points are accessible above bearing. Three shots or four grams
of grease each, will be adequate for these bearings. Take care not to over-grease.
For further details see AutoLube section (6.27).
On the non-drive side of the vibrating mechanism there are gear wheels between the shafts to transfer the drive from one shaft to the other. These gear
wheels are lubricated using an oil bath design. The gear oil should be
changed every 6 months to maintain efficient power transfer from one gear
wheel to the other. To fill (or top up gear wheel) do so as described below.
Refill oil at top
Level
Over-spill bung
WARNING:
1.
Remove overspill bung.
2.
Refill oil at top.
3.
When oil over-spills out of hole

it is at correct level.
Drain Bung
The feeder must not be run when any of the vibrating

mechanism guards are removed. Ensure all guards are
replaced after maintenance.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.16 BEARINGS AND LUBRICATION

1.
The bearings of the crusher are spherical roller bearings with labyrinth packings.
2.
The bearings are to be lubricated once a week at single shifts.
Force feed the grease until it is forced out into the labyrinths, so as
to press out any impurities.
Use only lithium base grease (i.e.., SKF LGEP 2)
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 6
6.17 GENERAL SPECIFICATION INSPECTION

Check all abrasion of hammers, blow bars and wear plates regularly.
Adjustments of bar carrier maybe necessary.
Careful inspection of all wearing components is essential as
excessive wear will cause damage to the crusher chamber.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.18 ROUTINE MAINTENANCE SCHEDULE

In addition to the daily, weekly and six monthly maintenance schedule, the
engine and air cleaner must be meticulously maintained.
Diesel engine maintenance is details in a book Operation and Maintenance
Manual a copy of which is included with this manual. Details on the air filter
maintenance are also found in that publication. Failure to comply with this will
reduce engine performance and life-span and may effect your customer warranty rights.
WARNING:
No guards should be removed while the machine is in

operation.
NOTE:
Provided in this section is a Greasing Schedule for your machine. This section is
only applicable for machines that do not incorporate the Autolube System. If your
machine uses the Autolube please ignore this section.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.19 DAILY MAINTENANCE

The purpose of daily maintenance is to discover minor irregularities in your
machine before they develop into major problems.
-
Check the machine for loose parts, check that all bolts and nuts
are
secure.
Check the hydraulic oil level in the tank and top up if necessary.
Ensure that all safety systems are intact (i.e. all the wires to sensors are intact)
Check that fuel oil level in the tank and the supply line to the
engine.
Check all the hydraulic motors, pumps, cylinders and hoses for oil
leaks and tighten if necessary. When tightening the hydraulic
fittings always use two spanners, one for holding, one for tightening.
Ensure that all the troughing and return rollers are free running
and clear of obstructions.
Check for material build up.
Check conveyor belts for alignment and adjust them if necessary.
Check air filter for clogging.
Visually inspect the conveyor belting for tears etc.
grease clutch (see clutch section).
When all checks have been made, close and fasten all the guards before operating the machine. At the end of the day carefully clean the machine and the
ground immediately around the machine, of all the material and debris build up.
Good housekeeping pays untold dividends in increased production and extended plant life.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.20 WEEKLY MAINTENANCE (50 HOURS)

In addition to the daily programme:
-
Grease feeder bearings using the correct lubricant.
Grease crusher bearings using the correct lubricant.
Check all skirting rubbers (i.e. that they bear down lightly on the
conveyor belt.)
Check the acid level in the batteries and top up with distilled
water if necessary.
Check the gauges on the hydraulic filters.
Adjust belt scrapper blades, renew if necessary.
Check the water trap on the engine.
Check clutch setting and adjust if necessary.
Check quality and tension of crusher V belts.
Check rubbers on machine, renew if necessary.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.21 SIX MONTHLY MAINTENANCE

-
Drain and refill hydraulic system with the correct hydraulic fluid.
Refer to the recommended lubricants for the correct hydraulic oils
to suit various ambient temperature conditions.
Drain and refill feeder oil bath with the correct gear oil. Refer to
the recommended lubricants section.
Check the alignment of the plant with a precision spirit level.
Grease the axle bearings.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.22 BELT TRACKING

Belt Tension.
The belts on your RK1012T Rotocrusher will normally have to be tensioned a
number of times during the machines lifetime due to the natural stretching of
the belt. It is very important the belts are tensioned evenly to the correct level,
not too tight and not too loose, ensuring efficient belt running and skirting alignment. A loose belt can cause slippage and reduced throughput, an over tight
belt can reduce drum and bearing life.
Trouble Tracing
Oblique travel may cause a fast deterioration, although the belts on the RK 1012T
Rotocrusher is of the highest quality. In order to assist we have compiled some
of the reasons for oblique travel with appropriate correction action.
REASONS FOR
OBLIQUE TRAVEL
REMEDIES
1.
Insufficient aligning of
drums and idlers.
a. Align non-drive drum, carrying idlers,

and return idlers at right angles to the travelling direction of the belt.
b. Check that all drums and idlers are
level to each other
If a & b are as above then perform the
following.
Adjustment is made as indicated on Figs
1,2&3 by turning non-drive drum and carrying idlers in direction of arrow until the
belt is running straight and centered on
the conveyor.
Also return idlers may cause oblique belt
travel and therefore they must be aligned
at right angles to the travelling direction
of the belt and after that adjustment can
be made.
2.
Misalignment of frame
Oblique travel can be reduced by turning

forward outer carrying idlers 1-3 degrees
in travelling direction of the belt. See Fig4.
If this does not correct the oblique travel
then align the frame.
3.
Material build up on
drums and idlers
Clean idlers and drums. Check belt cleaners and replace if necessary. Possibly
change to more efficient type.
EXAMPLES OF OBLIQUE TRAVEL
Fig 1: Turning carrying idlers
Fig 2: Turn Drum
Fig 3: Turn both Drum and carrying idlers
Fig 4: Turning forward carrying idlers
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.23 V-BELT TENSIONING

Crusher V Belts
The RK1012 Rotocrusher is driven through eight SPC V belts.
The belts can be tensioned as follows:
-
Losen the bolts at the four points highlighted.
2 bolts either side

of engine stand
Adjust the engine stand using the adjusters as highlighted.
Adjusters
IMPORTANT NOTE:
Do not over-tighten V belts this will cause excessive

pressure on the clutch bearings leading to premature
clutch failure.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.23 V-BELT TENSIONING contd.

One shot tensioning
Put the belts around the pulleys, set them to the appropriate tension value as stated in
the Tension Forces table
below (using the belt tension
indicator as shown), run the
drive under load for 30 minutes, stop the drive, check the
tension, resetting to catalogue
value if necessary. On a
proper designed drive for the
application there will be no
need for further attention during the life of the drive.
The setting tensions opposite are designed to cover
a wide range of drives. A
precise setting force for individual applications can
be calculated. Please consult Fenner Technical
Services.
BELT TENSION INDICATOR

APPLIED TO MID-CENTE
DISTANCE
CE
NT
RE
DI
ST
AN
CE
16
m
pe m
r 1 de
m flec
of
sp tion
an
Belt
Section
SPB
SPC
Force required to deflect belt 16mm per

metre of span
Small Pulley
Diameter (mm)
80 to 132
140 to 200
112 to 224
236 to 315
Newtons (N)
25 to 35
35 to 45
45 to 65
65 to 85
Kg - Force (kgf)
2.5 to 3.6
3.6 to 4.6
4.6 to 6.6
6.6 to 8.7
For short centre distance

drives where the deflection of
the belt is too small to measure accurately, it is recommended that both deflection
and applied force be doubled.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.23 V-BELT TENSIONING contd.
Method of Belt Tensioning using Fenner

Belt Tension Indicator.
Calculate the deflection in mm on a basis of
16mm per metre of centre distance.
CentreDistance(m)x16 =deflection(mm).
Set the lower marker ring at the deflection distance required in mm on the lower scale.
Set the upper marker ring against the bottom
edge of the top tube.
Place the belt tension indicator on top of the
belt at the centre of span, and apply a force at
right angles to the belt deflecting it to the point
where the lower marker ring is level with the
top of the adjacent belt.
Read off the force indicated by the top edge
of the upper marker ring.
Compare this force to the kgf value shown in
the previous table.
If a Fenner Belt Tension Indicator is not available, a spring balance and rule will surface.
With branded belts use a bar across the band
width to ensure even distribution of the force
measured by the number of belts in the band
for comparison with the values in the table.
NOTE:
For single belt drives a straight edge should
be placed across the two pulleys to act as a
datum for measuring the amount of deflection.
If the measured force falls within the values
given, the drive should be satisfactory. A new
drive should be tensioned to the higher value
to allow for the normal drop in tension during
the run in period.
After the drive has been running for 30 minutes, the tension should be checked and readjusted to the higher value, if necessary.
TROUBLE SHOOTING
Small Cracks on V-Belt side and base.
Generally caused by shortage of belt tension
but excessive heat and/or chemical fumes can
also give same failure.
V-Belt Swelling or softening
Caused by excessive contamination by oil,
certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning, principally on long centre drives. If a slightly higher
(or lower) tension does not cure the problem
there amy be a critical vibration frequency in
the system which requires redesign or a
banded belt. Consult Fenner Technical Services.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.24 RECOMMENDED GEAR OIL

Below are listed the recommended alternatives suitable for use with your
RK 1012T Rotocrusher.
If there are any difficulties the user should contact a local supplier or authorised
TESAB dealer.
MANUFACTURER
SPECIFICATION
ESSO
GX 80-90
CASTROL
HYPO Y EP 80-90
MOBILUBE
HD 90
BP
HYPOGEAR EP 90
TEXACO
GEARTEX EP-B 90
SHELL
SPIRAX HD 80W-90
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.25 RECOMMENDED LUBRICANTS

Below are listed the recommended alternatives suitable for use with your RK
1012T Rotocrusher.
The special greases are lithium based greases are Class 2 with extreme pressure additives.
They work within special conditions up to 120 degrees Celsius.
GREASE LUBRICATION
SPECIAL SCREEN
GREASE FOR HOT
METALS
SPECIAL SCREEN
GREASE
GENERAL PURPOSE
GREASE
BP
Energrease LS-EP2
Energrease L21M
Total
Multis EP2
Multis MS2
Duckhams
Adamax LEP2
Adamax LM2
Castrol
Spheerol EPL2
Spheerol AP3
Shell
Alvania EP2
Liplex EP2
Alvania R3
Esso
Becon EP2
Unirex EP2
Becon Q2
Texaco
Multifak EP2
Molytex 2
Chevron
Duralith EP2
Gulf
Gulfcrown EP2
Supercrown EP2
Mobile
Modilux EP2
Mobilgrease HP2
Mobilgrease MP
Century
Regulus A2EP
Luplex M2
Regulus A3
F.A.G.
Arcanol L135
Arcanol L71
Rocol
Sapphire
BG 151
Optimol
Longtime PD
Omega
85
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.25 RECOMMENDED LUBRICANTS contd.
Pos.
No. of
Locations
Description
Frequency
(Hours)
Qty
Clutch Throw-out Collar
10 (daily)
4g
Clutch Main Bearings
50 (weekly)
4g
Clutch Lever Shaft
50 (weekly)
4g
Crusher Rotor Bearings
50 (weekly)
8g
Feeder Bearings
50 (weekly)
4g
Product Conveyor *TED Bearings
50 (weekly)
4g
Product Conveyor *BED Bearings
50 (weekly)
4g
Dirt Conveyor *TED Bearings
50 (weekly)
4g
Dirt Conveyor *BED Bearings
50 (weekly)
4g
NOTE
Four grammes of grease is the equivalent of three shots/pumps from the
grease gun.
*TED - Top End Drum

*BED Bottom End Drum
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.26 AUTOMATIC GREASING SYSTEM

Your RK 1012T Rotocrusher is equipped with a Automatic Lubrication System
(AUTOLUBE) to ensure that all necessary equipment is lubricated at regular intervals in order to maintain the operational efficiency of the equipment.
The AUTOLUBE grease points are shown in the diagram below.
5
3
1
6
1.
2.
3.
4.
5.
6.
7.
Product Conveyor top end drum (2 points)

Product Conveyor bottom end drum (2 points)
Main Crusher bearings (2 points)
Dirt Conveyor top end drum (2 points)
Dirt Conveyor bottom end drum (2 points)
Clutch (4 points)
Feeder Main drive bearings (4 points)
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.26 AUTOMATIC GREASING SYSTEM contd.

Your RK 1012T has been fitted with a Quicklub central lubricating pump. It is a
compact multiline pump consisting of the following.
1.
Reservoir
2.
Pump Element
3.
Safety Valve
4.
Filling Fitting (For

special cartridge gun)
5.
Connection Plug 2A1

(To push button)
6.
Filling Fitting, Pump
7.
P.C.B. and Rotary

Time Switches
8.
Connection Plug 1A1

(Power Supply to pump)
2
6
7
The Quicklube system operates according to cycles (pause and operating times).
During the operation time the pump dispenses lubricant to the connected lube points
via one or more metering device.
Operational Notes:
-
The Quicklube system is designed for the delivery of greases up to NLGI

grade 2 at temperatures from -25C to 70C.
Can be used at low temperatures down to -40C (lubricants must still be

pumpable at these temperatures).
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.27 AUTOLUBE MAINTENANCE

-
Basically the only maintenance required is to refill lubricant in good time with
clean lubricant. However check regularly that lubricant is actually reaching all
lubricants points.
Also check the high-pressure plastic hoses and plastic tubes for damage.
If necessary replace them.
If the AUTOLUBE system is not functioning properly then the following will
occur.
During the Pump operation the Indicator Pin in the control value
mounted beside the AUTOLUBE Pump (Fig 1, A) will move in and
out approximately every 40 seconds. If this is not happening then
one of the following may have occurred.
(a)
(b)
(c)
(d)
-
The Pump is out of grease

Pump Operating failure.
The Pump element needs to be replaced.
There is a blockage in the system or bearing.
If lubricant is emerging from the pressure relief valve, (Fig 2, B)

this indicates a blockage in the system and the fault should be
immediatly rectified.
FIG 1
FIG 2
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.27 AUTOLUBE MAINTENANCE contd.

CLEANING
Whenever work is done on the AUTOLUBE system, particular attention should be
given to absolute cleanliness. Dirt in the system will cause problems
For cleaning the system use naphtha or petroleum benzine. Tri or Per or similar
solvents must not be used. Do not use polar organic solvents such as alcohol,
methyl alcohol, acetone or similar.
FILLING PUMP RESEVOIR
Fill the resevoir via the grease nipple filling fitting (B), female port filling fitting (A)
or (C) Special cartridge filler gun supplied with each pump up to the max mark on
the resevoir.
C
A
B
IMPORTANT
-
The grease/oil must be free from impurities and must not be liable to
change its consistency in the course of time.
If the reservoir has been completely emptied, the pump may require 10
minutes operation before it operates with its full output again.
Induce several lubrication cycles by pressing the Autolube button on the main
engine control panel a minimum of 5 seconds. Then check the indicator pin is
moving.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.27 AUTOLUBE MAINTENANCE contd.

Test Run / Triggering and Additional Lubrication
There is a facility on your AUTOLUBE system where by the following functions can
be performed.
-
Test Run on system to ensure correct operation.

Additional cycle to top up grease points.
To carry out either of the above depress the test button on the main control panel
as shown below for at least 5 seconds.
Autolube test button
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.28 AUTOLUBE TROUBLESHOOTING

Consult the troubleshooting table below in order to fix system fault
Fault of Pump: motor does not run
CAUSE
-
Voltage supply interrupted
REMEDY
-
Electric motor defective
Check voltage supply and fuses. If

necessary rectify the fault and replace
fuses.
Check the line leading from the fuses to the
pump plug.
Check voltage supply to motor.
If necessary replace motor.
Faults: Pump does not deliver lubricant

CAUSE
-
Reservoir empty
REMEDY
-
Refill reservoir with clean grease or

oil. Allow pump to run (additional lubricant)
until lubricant issues from all lubrication
points.
Check the line leading from the
fuses to the pump plug.
NOTE: Depending on the ambient temperature

and or type of lubricant it may take10 minutes of
operation until the pump elements will reach their
full lubricant output.
-
Air Pockets in Lubricant
Trigger an additional lubrication (see

previous page). Loosen the outlet fitting or
main line on safety valve. Lubricant must
issue without air bubbles.
Unsuitable lubricant has been

used.
Renew the lubricant. See lubricant list.
Suction hole of pump element

clogged.
Remove pump element. Check suction hole

for foreign particles. If found remove.
Pump piston worn
Replace pump element.
Check valve in pump element

defective or clogged.
Replace pump element.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.29 RECOMMENDED FLUIDS
HYDRAULIC OIL EQUIVALENTS

AMBIENT TEMPERATURE RANGE
10 - 20C
(58 - 68F)
20 - 30C
(58 - 68F)
30 - 48C
(86 - 120F)
ESSO
NUTO H 32
NUTO H 68
UNIVIS N 68
BP
ENERGOL HLP 32
ENERGOL HLP 68
ENERGOL SHF 68
MOBIL
DTE 13
DTE 15
DTE 16
SHELL
TELLUS R37
TELLUS R37
TELLUS R37
TEXACO
RANDO HD 32
RANDO HD 68
RANDO HD 100
TOTAL
AZOLLA 32
AZOLLA 68
EQUIVIS ZS 68
NOTE:
The use of brands, other than those shown above should be subject to
the approval of TESAB ENGINEERING LTD.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.30 FAULT FINDING

SYMPTOM
1.
2.
Engine wont start Clutch engaged
Engine stops
NOTE:
3.
4.
POSSIBLE FAULT
REMEDY
Disengage clutch
Solenoid switch not

operating when ignition on and
override button in
Repair possible break

in wire
Safety circuit tripped
Check each circuit component
Crusher jammed
Clear obstruction
Low fuel level
Top up tank and bleed system
Obstruction or break
in the fuel line system
Repair and bleed system
See engine manufacturers publication Operators Handbook Trouble shooting

section for detailed analysis of engine trouble.
No response
from any
hydraulic
system
Machine
operating slowly
No external oil
leaks.
Low oil level
Top up hydraulic system
Choked suction line

filter
Wash and clean filter element
Pump shaft broken
Replace pump
Worn pump
Pressure relief valve
stuck in open position
Replace pump
Repair or replace valve
cartridge
Restricted or broken suction

line
Check restriction in tank.

Repair if broken
Low oil level
Top up hydraulicsystem
Incorrect hydraulic fluid
Drain tank and replace with

correct fluid
Choked suction line filter
Replace filter element
Leaking relief valve
Repair or replace relief valve
Worn control valve
Replace control valve
Worn pump
Replace pump
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.30 FAULT FINDING contd.
5.
6.
Excessive noise
from hydraulic
pump
Worn head drum motor
Replace head drum motor
Engine performance not

to standard
Consult your engine

manual fault finding
section
Choked suction line filter
Replace filter element
Damaged pump coupling
Replace pump
Low oil level pump cavitating
Top up hydraulic tank
Loose connections in suction

Line
Tighten all joints
Flexible suction hose worn
Replace hose
Screeching noise Lack of bearing lubricants

when conveyors
are running
Conveyor wedged rubbing
Against fixed parts
Grease all bearings
Clear obstructions, adjust

and re-track conveyor belt
Belt drive coupling broken
Replace or tighten coupling

or loose
Top end drum belt scrapper

Too tight
Ease pressure at scrapper
7.
Conveyor belt
Non-return valve worn or
tends to run back
if stopped with a
load on the belt
Repair or replace non-return run back

valve
8.
Product conveyor Conveyor still bolted in

wont fold position
Unbolt at relevant point
9.
Crusher not
turning when the
rest of system
operational
V belts slipping
Tighten belts
10.
Crusher wont
turn machine not
operational
Material jammed in crusher
Clear obstruction
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.30 FAULT FINDING contd.

11.
12.
Feeder not
working
Rams not
operational
Screen bearings seized
Replace bearings
Motor coupling broken
Replace coupling
Oil motor shaft broken
Replace motor
Gear wheel teeth stripped
Replace gear wheels
Control lever at central console

in wrong position
Put control lever in

correct position
If you cannot identify the cause of the trouble or are unable to put it right yourself please contact TESAB ENGINEERING LTD., or your local TESAB authorised dealer.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
May 2002 Issue
Section 7
PREPARING FOR
TRANSPORT
RK1012T ROTOCRUSHER
Section 7
7.0 PREPARING FOR TRANSPORT

In order to transport the RK1012T Rotocrusher the following preparations should
be followed to ensure correct and safe movement of the machine.
Note: Some of the functions carried out when preparing the machine for transport will require the use of a crane.
The fastening of loads and the instructing of crane operators should be
entrusted to experienced personnel.
Check with local authorities regarding transport restrictions, you may not have to
carry out all the instructions listed below.
1.
Observe all safety instructions and warnings, all work is to be carried out by
qualified personnel only.
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

death.
system details.
NIP HAZARD
1.
2.
3.

unguarded machine.
RK1012T ROTOCRUSHER
WARNING
Section 7
CRUSH HAZARD
1.
2.
3.
WARNING

machinery.
supports provided.
PROTECTION
1.
2.
3.
WARNING

running machinery.
CONSULT MANUAL
1.
2.
3.
WARNING

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
RK1012T ROTOCRUSHER
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING

injury or death.
BATTERY HAZARD
1.
2.
BATTERY

HEAD PROTECTION
1.
EXPLOSIVE

HOT SURFACE
1.
ACID
Section 7

any contact.
this area.
RK1012T ROTOCRUSHER
Section 7
7.0 PREPARING FOR TRANSPORT contd.
WARNING
1.
2.
3.



TIMES.
PRIOR TO WELDING.
ENGINE CANOPY
RK1012T ROTOCRUSHER
Section 7

3.
Fold and position the machine ready for transport as follows:

a)
Remove any ramp that may have been used to load machine and tidy
around tracks ensuring a clear exit.
b)
Track machine to a clear space away from the working area (for full
details on tracking machine see section 3).
c)
Adjust top apron on the crusher unit down fully, thus lowering the height
of the adjuster bars.
IMPORTANT
adjust apron fully down
d)
Remove feed-in chute extension box and disconnect the dust

suppression water pipe.
Feed-in Chute
Extension Box
Dust Suppression
Water Pipe
RK1012T ROTOCRUSHER
Section 7

e)
Remove crib cross channel and beam.
Cross Tie & Pin
f)
Securing Chains
Unbolt cribs at rear and remove rear crib pins (A).
A
Cribs
Remove bolts
RK1012T ROTOCRUSHER
Section 7

g)
Lower both side cribs and rear cribs slowly and alternatively until fully
lowered.
Cribs RHS
Cribs Rear
Cribs LHS
h)
Fold up Dirt conveyor using lift point A. Insert the transport brackets at
point B and remove belt scrapper.
B
RK1012T ROTOCRUSHER
Section 7

i)
Remove feeder beacon.
Feeder Beacon location

(remember to disconnect wires)
j)
Lower hoist to transport position (if applicable).

Hoist in transport
position
Pivot hoist
around hinge
Remove 4 bolts
before placing in
position
RK1012T ROTOCRUSHER
Section 7

k)
Undo the tab (6) that is fitted between the inside handrail (2) and the
crusher. Fold the handrails down into the transport position and secure
with the appropriate straps and cable ties (fold sections 3, 4 & 5 first,
then sections sections 1 & 2).
6
l)
Ensure all items which have been removed for transport purposes and
repositioned on the machine have been well secured (ie., all items are
tied down satisfactorily around catwalk area).
m)
Ensure all bolts/brackets have been placed in a secure location (ie., the
toolbox).
n)
Remove the exhaust and pre-cleaner remembering to fit the rain-cap

on the exhaust opening and fit the cover over the air filter casing.
Pre-Cleaner
Exhaust
RK1012T ROTOCRUSHER
Section 7

Tesab have supplied a specially adapted cover for this function still
allowing the filtration system to breath but preventing any ingression
of water etc.,
Note:In some cases you may have to track the machine relatively long
distances from the working area to the loading area. If this is the case
Tesab recommend that the exhaust and pre-cleaner remain on the
machine and is removed after loading.
o)
Ensure that the engine access steps are folded up when tracking
machine before and after loading thus reducing the possibility of
fouling.
IMPORTANT NOTE:
TESAB ENGINEERING LTD RECOMMEND THE OFFLOADING AND LOADING OF THE RK1012T
ROTOCRUSHER IS CARRIED OUT BY TRAINED AND
EXPERIENCED PERSONNEL ONLY.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 8
WARRANTY
RK1012T ROTOCRUSHER
WARRANTY
Section 8
8.0 WARRANTY
All conditions and warranties expressed or implied by any statue common law.
Trade usage or otherwise are hereby excluded. No liability is accepted by
TESAB ENGINEERING Ltd. for any loss, damage or injury to property or persons arising directly or indirectly from any failure or direct in the machinery
supplied. The materials employed by TESAB ENGINEERING LTD. in the
manufacture of their machinery, to the best of their knowledge, are the highest
available quality of their respective kinds. TESAB ENGINEERING LTD. undertakes to replace or repaid free of cost any part supplied by them direct to the
customer of which they shall receive notice and which shall be proved to the
satisfaction of TESAB ENGINEERING LTD. within a period of six months of
delivery to be defective in workmanship or materials provided.
A:-
That written notice of complaint is given within seven days of the discovery of the defect.
B:-
That the part is returned carriage paid to TESAB ENGINEERING LTD.

and shall, in the event of replacement become their property.
C:-
That the defect has not been caused by carelessness or improper or

inadequate lubrication.
D:-
TESAB ENGINEERING LTD. shall not be liable for the cost of removal
of the defective part or the cost of fitting a new part.
E:-
That the guarantee period shall be proportionally reduced if the machinery is run for more that one eight hour shift per day.
No unauthorised alteration or modification has been made to the plant or machine or component the subject of the claim.
The new part will be delivered by TESAB ENGINEERING LTD., carriage paid
to the customers nearest station in the U.K. or F.A.S. port of exportation.
In case of parts or components not manufactured by TESAB ENGINEERING
LTD. the customer shall be entitled to the benefits in so far as it may be transmitted to the customer, of any guarantees given by the manufacturer in respect
thereof and TESAB ENGINEERING LTD. liability in respect of such goods is
limited to making the benefits of the manufacturers guarantees available to the
customer to the extent aforesaid.
RK1012T ROTOCRUSHER
WARRANTY
Section 8
8.0 WARRANTY contd.

This understanding is in lieu of and excludes any other conditions guarantees, or
warranties expressed or implied, statutory or otherwise. In no event shall TESAB
ENGINEERING LTD. be liable (except to the extent if any of its undertaking as
foresaid) for any loss injury or damage howsoever caused or arising.
The guarantee contained aforesaid is personal to TESAB ENGINEERING LTD.
customer and may not be assigned.
IMPORTANT NOTE:TESAB ENGINEERING LTD. hereby emphasise that a dust suppression system must be used when the RK 1012T is in operation.
TESAB ENGINEERING LTD. cannot be held responsible for any failure due to
the disregard of dust suppression.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 9
RK1012 CRUSHER
PARTS LIST
RK1012T ROTOCRUSHER
SPARE AND WEARING PARTS

LIST
Section 9
SPARE AND WEARING PARTS LIST
TYPE RK 1012
ROTOCRUSHER
UNIT
RK1012T ROTOCRUSHER

LIST
Section 9
9.0 INDEX
Section
Description
9.1
Main Assembly
9.2
Chamber Wear Plates
9.3
Shaft and Bearing Assembly
9.4
Top Apron (Stroke Carrier) Adjuster Assembly
9.5
Middle Apron (Stroke Carrier) Adjuster Assembly
9.6
Bar Carrier Adjuster Assembly
Important Note:
To ensure supply of the correct parts with the minimum
delay please quote crusher serial number.
RK1012T ROTOCRUSHER

LIST
Section 9
9.1 MAIN ASSEMBLY

5
12
15
12
5
13
3
4
3
10
3
7
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Amount
4
10
8
8
2
1
1
1
16
16
8
2
48
16
2
Description
Stroke
Grinding List
Stroke Plate
Stroke Plate
Stroke Carrier
Bar Carrier
Shaft
Rotor
Protector Plate
Protector Plate Pin
Stroke Securing Plate
Shaft
Stroke Plate Bolt Assy
Bolt Assembly
Wear Plate
Drawing
No.
2-423-3
3-604
2-431
2-432
1-593
1-592-1
1-592-5
1-587-2
3-660-1
11
14
Wgt kg/
item
196
30
85
85
248
835
28
1730
18
Notes
From s/n 1027

From s/n 1027
From s/n 1027
From s/h 1027
1-593-3
3-748
28
From s/n 1027
RK1012T ROTOCRUSHER

LIST
Section 9
9.2 CHAMBER WEAR PLATES
13
A
4
2
1
5
1
13
9
12
1
1
10
1
6
8
6
1
1
11
10
1
7
7
7
7
7
7
7
7
1
1
1
A-A
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Amount
34
2
2
2
2
2
10
2
2
4
2
2
2
Description
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate4-820
Drawing
No.
4-820
4-821
4-822
4-823
4-824
4-825
4-826
4-827
4-828
4-829
4-830
4-831
4-832
Wgt kg/
item
31.5
29.1
36
22.5
27
27.7
15.4
20.3
16.4
30.1
24.1
31.4
63
Notes
RK1012T ROTOCRUSHER

LIST
Section 9
9.3 SHAFT AND BEARING ASSEMBLY
4 13 14
8
12
10
11
15
16
3
7
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Amount
2
1
2
3
1
1
1
1
2
1
2
1
24
2
2
1
Description
Bearing House
Labyrinth Seal
Labyrinth Seal
Labyrinth Seal
End Cover
Retaining Ring
Scored Pulley
End Cover
Sperical Roller Bearing
Clamping Sleeve
Clamping Sleeve
Screw
Screw
Lubricant Nipple
Washer
Shaft
Drawing Wgt kg/

No.
item
1-589-1
2-425-1
2-426-1
2-428-1
2-433-1
2-436
2-430-2
4-743-1
22330
150x200
170x225
M6S30x60
M6S12x35
4-735-1
2-424-1
Notes
320.0
RK1012T ROTOCRUSHER

LIST
Section 9
9.4 TOP APRON (STROKE CARRIER) ADJUSTER ASSEMBLY
5
6
4
Part No.
1
2
3
4
5
6
Amount
2
4
2
2
2
6
Description
Adjustment Screw
Nut
Stud
Washer
Split Pin
Disc Spring
Drawing
No.
3-619-1
510206
4-742-2
Wgt kg/
item
Notes
M39
100414
RK1012T ROTOCRUSHER

LIST
Section 9
9.5 MIDDLE APRON (STROKE CARRIER) ADJUSTER ASSEMBLY

(MANUAL ADJUSTMENT)
Lower Stroke Carrier

1
8
7
Part No.
1
2
3
4
5
6
7
8
Amount
4
2
2
2
86
20
2
2
Description
Adjustment Screw
Adjustment Screw
Adjustment Yoke
Stud
Disc Spring
Nut
Washer
Split Pin
Drawing
No.
4-740-1
3-614-1
4-742-1
4-741-2
100414
510206
Wgt kg/
item
Notes
M39
RK1012T ROTOCRUSHER

LIST
Section 9
9.6 BAR CARRIER ADJUSTER ASSEMBLY (MANUAL ADJUSTMENT)
Lower Stroke
Carrier
1
Part No.
1
2
3
4
5
6
7
8
Amount
4
2
2
2
86
20
4
4
Description
Adjustment Screw
Adjustment Screw
Adjustment Yoke
Stud
Disc Spring
Nut
Split Pin
Washer
4 7 8
Drawing
No.
4-740-1
3-614-1
4-742-1
4-741-1
100414
510206
Wgt kg/
item
Notes
M39
RK1012T ROTOCRUSHER

LIST
Section 9
9.7 MIDDLE APRON (STROKE CARRIER) & BAR CARRIER ADJUSTER

ASSEMBLY (HYDRAULIC ADJUSTMENT)
15
2
3
16
14
9
1
6
5
10
13
11
12
RK1012T ROTOCRUSHER

LIST
Section 9
9.7 MIDDLE APRON (STROKE CARRIER) & BAR CARRIER ADJUSTER

ASSEMBLY (HYDRAULIC ADJUSTMENT) CONTD.
ITEM
DESCRIPTION
QTY
STORES PART NO.
Adjustment screw
3-701-3
Adjustment screw
3-701-2
Adjustment yoke
3-701-1
Hydraulic ram
3-701-4
Disc spring
4-110 x 10
Disc spring
15
4-110
M39 nut
16
90-04-0003
3-701-6
End cap
M20x50 bolt
10
50mm shim
3-701-5-50
11
30mm shim
3-701-5-30
3-701-5-10
12
10mm shim
12
13
5mm shim
12
14
Pin
15
Washer
16
Split pin
4-741-2
10-07-0004
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Jan 2005 Issue
Section 10
HYDRAULIC & ELECTRIC
SCHEMATIC DIAGRAMS
RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM
(Standard)
Section 10.0
RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM
(inc. Conveyor Hyd. Folding)
Section 10.1
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
(Fuse Relay Description)
Section 10.2
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
(Panel Layout)
Section 10.3
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.4
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.5
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.6
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.7

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RK1012T ROTOCRUSHER

Jan 2005 Issue

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

Set-up Procedure Safety

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

The RK1012 Rotocrusher

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

Preparing for Transport

RK1012 CRUSHER PARTS LIST

PREPARING FOR TRANSPORT

HYDRAULIC & ELECTRIC DIAGRAMS

Hydraulic Diagram (Standard)

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

The TESAB RK 1012T ROTOCRUSHER complies with the EU directive 89/392/

READ THIS MANUAL CAREFULLY AND LEARN HOW TO OPERATE AND

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT

GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS IN

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

1.1 EC DECLARATION OF CONFORMITY

Tesab Engineering Ltd.

Mobile Crushing Plant

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

1.2 MACHINE SPECIFICATION DETAILS

MACHINE SERIAL NUMBER:

ENGINE SERIAL NUMBER:

CLUTCH SERIAL NUMBER:

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

1.3 FOREWORD/RESERVATION OF RIGHTS

In the interest of continuous plant reliability, it is essential that the machine is

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

as viewed from the product conveyor end of

product conveyor end of machine.

feeder end of machine.

1.4 FAMILIARISATION contd.

3. Dirt conveyor front view

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

1.5 GENERAL SPECIFICATION

1.5 GENERAL SPECIFICATION contd.

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Jan 2005 Issue

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

2.0 SAFETY INTRODUCTION

Electrical Hazard. Risk of serious injury or

Nip Hazard. Do not reach into an

Fall Hazard. Do not climb onto moving or

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Crush Hazard. Beware of dangerous hand

Loose or baggy clothing can get caught in

Read and understand the operators manual

When performing maintenance or

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

Fall rock hazard. Do not walk near material

Burn or Heat Hazard. Beware of hot sur

Beware of escaping hydraulic oil. High

Battery Hazard. Battery electrolyte contains

Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.