Tesab 1412T Operation Manual UK

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

RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

Operation Manual

March 2005 Issue


RK1412T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 1: INTRODUCTION

1.0 EU directive1.1 Declaration of conformity1.2 Machine specification details1.3 Foreword/reservation of rights1.4 Familiarisation1.5 General specification

SECTION 2: SAFETY

2.0 Safety introduction2.1 Safety2.2 Position of emergency stops2.3 Emergency situation2.4 Lockout procedure

SECTION 3: TRACKING INSTRUCTIONS

3.0 Tracking familiarisation3.1 Starting the engine3.2 Tracking using the dog lead

March 2005 Issue


RK1412T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 4: SET-UP PROCEDURE

4.0 Set-up procedure safety4.1 Installation4.2 Loading & off-loading4.3 Prior to starting the engine4.4 Engine starting procedure4.5 Tracking familiarisation4.6 Tracking the machine using the dog lead4.7 Positioning4.8 Preparing for initial start-up4.9 Product conveyor unfolding4.10 Hopper extensions4.11 Feed-in chute4.12 Hoist4.13 Crusher settings4.14 Dust suppression

SECTION 5: OPERATION

5.0 Operation safety5.1 Lockout procedure5.2 General information5.3 Pre-operation check list5.4 Engine starting procedure5.5 Setting engine revs5.6 ESM main unit5.7 Engaging clutch5.8 Product conveyor starting5.9 Feed conveyor starting5.10 Machine start-up sequence5.11 Machine shut-down sequence

March 2005 Issue


RK1412T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 6: MAINTENANCE

6.0 General information6.1 Safety information6.2 Opening the RK1412T rotocrusher unit6.3 Replacing or turning the hammers6.4 Setting the crusher gap6.5 Replacing or turning of impact bars6.6 Manual clutch6.7 Hydraulic clutch6.8 Hydraulic system6.9 Tracks6.10 Hydraulic fluids6.11 Oil tank, pipes & fittings6.12 Diesel engine6.13 Feed conveyor & product conveyor reduction gears6.14 Bearings & lubrication6.15 General inspection6.16 Routine maintenance schedule6.17 Daily maintenance6.18 Weekly maintenance6.19 Six monthly maintenance6.20 Belt tracking6.21 V-belt tensioning6.22 Recommended lubricants6.23 Automatic greasing system6.24 Autolube maintenance6.25 Autolube troubleshooting6.26 Recommended fluids6.27 Fault finding

March 2005 Issue


RK1412T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 7: PREPARING FOR TRANSPORT

7.0 Preparing for transport safety7.1 Lockout procedure7.2 Preparing for transport

SECTION 8: WARRANTY

8.0 Warranty

March 2005 Issue


RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

Section 1

INTRODUCTION

March 2005 Issue


RK1412T ROTOCRUSHER

INTRODUCTION Section 1.0

1.0 EU DIRECTIVE

The TESAB RK1412T ROTOCRUSHER complies with the EU directive 89/392/EEC and all relevant amendments.

READ THIS MANUAL CAREFULLY AND LEARN HOW TO OPERATE AND SERV-ICE YOUR MACHINE CORRECTLY.

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENTDAMAGE.

REMEMBER:

GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS IN IN-CREASED PRODUCTION AND EXTENDED PLANT LIFE!


RK1412T ROTOCRUSHER


1.1 DECLARATION OF CONFORMITY

We hereby declare that the following machinery complies with the Essential Healthand Safety requirements of the EU Machinery Directive 89/392/EEC as amendedby 91/368/EEC, 93/44/EEC and 93/68/EEC.

Manufactured by: Tesab Engineering Ltd.7B Gortrush Industrial EstateOmaghCo. TyroneNorthern Ireland BT78 5EJ

Machine description: Mobile Crushing Plant

Model: RK1412T ROTOCRUSHER

Serial No:

This machinery has been designed and manufactured in accordance with all therelevant 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 EstateOmaghCo. TyroneNorthern Ireland BT78 5EJ

Signed:

Name: Brian A. Mills

Position: Project Manager

Date:

Being the nominated representative of TESAB ENGINEERING LTD.


RK1412T ROTOCRUSHER


1.2 MACHINE SPECIFICATION DETAILS

MACHINE SERIAL NUMBER:

ENGINE TYPE:

ENGINE SERIAL NUMBER:

CLUTCH TYPE:

CLUTCH SERIAL NUMBER:

DISPATCH DATE:


RK1412T ROTOCRUSHER


1.3 FOREWORD/RESERVATION OF RIGHTS

The TESAB RK1412T ROTOCRUSHER is a robust skilfully engineered piece ofequipment incorporating diesel, hydraulic and mechanical components of the high-est quality.

In the interest of continuous plant reliability, it is essential that the machine ismaintained with meticulous care and attention. This operation and maintenancemanual has been produced to assist the user to obtain the maximum output fromthe machine and to trace and remedy faults, should they arise. Failure to do socould result in personal injury or equipment damage. We recommend that theuser should pay particular attention to the maintenance and safety sections of thismanual.

Consider this manual a permanent part of your machine. Keep a copy of thismanual at the operational site.

This operation and maintenance manual must not be copied, reproduced orloaned to a third party without written consent of TESAB ENGINEERINGLTD.


RK1412T ROTOCRUSHER


1.4 FAMILIARISATION

The following conventions have been used throughout this operation and mainte-nance manual when describing component locations:

Rear - feed conveyor end of machine

Front - product conveyor end of machine

Right and left hand sides - as viewed from the rear of the machine

REAR

FRONT

RIGHT LEFT


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1.4 FAMILIARISATION cont.

1. Hopper

2. Feed Conveyor

3. Crusher Unit

4. Tracks

5. Chassis

6. Drive System

7. Product Conveyor


RK1412T ROTOCRUSHER


1.5 GENERAL SPECIFICATION

Chassis

The chassis is constructed of heavy-duty profiles and welded steel plates ribbedand stiffened to withstand all operational and travelling stresses. The chassis ismounted on 3.75m (12-4") centre heavy-duty tracks, with dog lead operationalfacility.

Belt Feeder

The belt feeder into the crusher is fitted with a 1200mm wide heavy duty 4 ply beltwhich runs on full length 4 roll impact roller sets. The conveyor is driven througha flexible coupling and high torque reduction gear at the rubber lagged top enddrum. The heavy duty hopper mounted on top of the conveyor is fully lined with10mm wear plates and is ribbed and stiffened to withstand impact from the feedsource. Full length replaceable 15mm skirting is fitted to the hopper to preventany spillage and smooth material flow. The feed-in canopy is fully lined and canbe easily accessed through a hinged hood were any essential maintenance canbe carried out.


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1.5 GENERAL SPECIFICATION cont.

Crusher unit

The RK1412 crusher unit is fitted with four hammers, 1000mm (39.375") wide. Ithas a feed opening of 1020 x 650mm (40" x 25.5") and a rotor diameter of 1200mm(47"). There is one adjustable apron and a final bar carrier which can be adjustedfrom 4 to 80mm (3/16" to 3") depending on material feed size and reduction re-quired. Both the apron and the bar carrier are hydraulically adjustable as stand-ard. It is driven through 8 V-Belts and the chamber can be easily accessed byhydraulic control lever. There is a deadbox fitted under the crusher to allow easyflow of material onto the product conveyor.

Product Conveyor

The product conveyor is fitted with a 1000mm (40") heavy duty 4 ply belt and runson heavy duty troughing rollers, impact bars are fitted under the crusher to givethe belt full support at the crusher exit. The conveyor is driven hydraulically througha flexible coupling and high torque reduction gear at the rubber lagged top enddrum.

Power Unit

The engine is an electronic Caterpillar C9 (300HP at 1800rpm) Power Pack andthe crusher is driven through a heavy duty Twin Disc IBF 314 (3 plate) PTO. Thepulley on the clutch can be easily changed to alter the rotor speed or if finer tuningis required the engine speed can vary between 1700 and 2200rpm. The tracks,conveyors and rams are all driven hydraulically through pumps fitted to the en-gines auxiliary drives.

Catwalks and Guards

All relevant catwalks, handrails and guards are fitted to this machine allowingaccess to all relevant maintenance points. Emergency stops are fitted to all nec-essary points. The machine carries the European CE mark and therefore com-plies with all Essential Safety Requirements.

Hydraulic Tank Capacity

500 litres (110 gallons 132 US gallons)


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Section 1.5INTRODUCTION

1.5 GENERAL SPECIFICATION cont.

Diesel Tank Capacity

1150 litres (255 gallons 306 US gallons)

Transport Dimensions

3.40m high x 14.40m long x 2.9m wide(11-2" high x 47-3" long x 9-6" wide)

Machine Weight

43,000 kgs (94,800 lbs)

Options

19 KPTO hydraulic clutch Metal detector Hopper extension to suit shovel load Scales Conveyor cover Self cleaning magnet


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Section 2

SAFETY

March 2005 Issue


RK1412T ROTOCRUSHER

SAFETY Section 2.0

DANGER ELECTRICAL HAZARD

2.0 SAFETY INTRODUCTION

In this next section you will find the safety sign conventions used throughout thismanual 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 potentialwarning or danger when operating this machine.

1. Electrical Hazard. Risk of serious injury ordeath.

2. Never work on the electrical system of anyequipment unless you are fully familiar withsystem details.

3. Work on the electrical system must be carried out by a qualified electrician.

1. Nip Hazard. Do not reach into anunguarded machine.

2. In-running nip points can causeserious injury or death.

3. Switch off and lockout machinebefore opening or removing guard doors.

DANGER NIP HAZARD

DANGER FALL HAZARD1. Fall Hazard. Do not climb onto moving or

working machinery.2. Switch off and lockout machine before attempting maintenance on the machine.3. Always use a suitable lifting platform before

attempting maintenance above 2m (6-6).


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SAFETY Section 2.0

WARNING CRUSH HAZARD1. Crush Hazard. Beware of dangerous hand

and foot crush points.2. Do not use any body parts e.g. hands or

feet to check hole alignment or supportmachinery.

3. Always use pins and/or mechanicalsupports provided.

WARNING PROTECTION1. Loose or baggy clothing can get caught in

running machinery.2. Always wear correct fitting (EN/ANSI

approved) protective clothing.3. Protective clothing includes Hard Hat,

Safety Clothing, Ear Defenders, Overalls,Steel Toed Boots, and a High Visibility Vest.

WARNING CONSULT MANUAL1. Read and understand the operators manual

before you work at this machine.2. Study the different safety signs on this machine.3. Only qualified and trained personnel should

attempt to work at this machine.

WARNING LOCKOUT1. When performing maintenance or

adjustment to this machine always switchoff engine and remove the ignition key. (ifelectric isolate power supply at source).

2. Keep ignition key on person duringmaintenance.

3. Never work alone.


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SAFETY Section 2.0

WARNING HIGH PRESSURE1. Beware of escaping hydraulic oil. High

pressure hydraulic oil can penetrate theskin causing serious injuries.

2. Always relieve pressure from the hydraulicsystem before attempting maintenance.

3. If oil is injected under the skin, it must besurgically removed or gangrene will result.

CAUTION HOT SURFACE1. Burn or Heat Hazard. Beware of hot sur

faces at engine and exhaust areas.

WARNING HEAD PROTECTION1. Fall rock hazard. Do not walk near material

discharge areas. You are at risk of seriousinjury or death.

2. Wear a Hard Hat at all times when workingin the vicinity of the machine.

WARNING BATTERY HAZARD1. Battery Hazard. Battery electrolyte contains

acid and can cause serious injury. Avoidany contact.

2. Batteries give off flammable fumes whichcan explode. Avoid the formation of sparksand naked lights in the vicinity of thebatteries. Do not smoke when working inthis area.

ACID EXPLOSIVE

BATTERY


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SAFETY Section 2.1

2.1 SAFETY

Operators should be trained in thecorrect and safe use of all equip-ment including the studying of thismanual, failure to do so could re-sult in serious injury.

Any work on and with the machinemust be executed by reliable, trainedand authorised personnel only. Statu-tory minimum age limits must be ob-served.

Work on the electrical system andequipment of the machine must becarried out only by a skilled electri-cian or by instructed persons underthe supervision and guidance of askilled electrician and in accord-ance with electrical engineeringrules and regulations.

Work on the hydraulic system must becarried out by personnel with specialknowledge and experience of hydrau-lic equipment.

There are several specific signs onyour machine. Please take time tofamiliarise yourself with the safetysigns and the operation and main-tenance manual.

See to it that safety instructions andwarnings attached to the machine arealways complete and completely leg-ible.

Keep warning and instruction labelsclean.

Replace unreadable or missing labelswith new ones before operating themachine.

Wear a hard hat, protective glasses,hearing protection, close fittingoveralls, steel toed boots and highvisibility vest (E.N. / A.N.S.I. ap-proved) as required by job condi-tions.

Do not wear loose clothing or jewel-lery and tie back long hair that cancatch on controls or moving parts.

Make certain all protective guardsand covers are secured and in placeat all times. All guards should bein place whenever maintenance isnot being performed. Never disableor remove any safety mechanism orguard.

Where possible when working close toengines or machinery, only do so whenthey are stopped. If this is not practi-cable, remember to keep tools, testequipment and all other parts of yourbody well away from the moving parts.

Understand service procedure be-fore doing work. Keep all areasclean and dry.


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SAFETY Section 2.1

2.1 SAFETY cont.

Never lubricate, clean, service oradjust machine while it is moving.Keep hands, feet and clothing clearof power driven parts and nip-points. Disengage all power andoperate controls to relieve pressure.Stop the engine. Implement lock-out procedure. Allow machine tocool.

Keep all parts in good condition andproperly installed. Fix any damage im-mediately and replace any brokenparts with genuine TESAB parts. Re-move any built up of grease, oil or de-bris.

For the execution of maintenancework, tools and workshop equip-ment adapted to the task on handare absolutely indispensable.

Isolate all electrical supplies beforecarrying out repairs or maintenance,and should only be carried out by quali-fied personnel.

Stay clear of all rotating and mov-ing parts. Do not attempt to clearobstructions or debris by hand be-fore isolating the equipment by im-plementing the lockout procedure.

In running nip points can cause seri-ous injury even death. Do not reachinto an unguarded machine.

Switch off engine and lockout ma-chine before opening or removingguards or doors.

Take the necessary precautions toensure that the machine is usedonly when in a safe and reliablestate.

In the event of malfunctions or opera-tional difficulty stop the machine im-mediately and lockout. Have any de-fects rectified immediately.

Do not attempt repairs or adjust-ments to the machine while it is run-ning.

Relieve all pressure in hydraulic sys-tems before any lines, fittings or relateditems are disconnected or removed.

Hydraulic lines must be laid and fit-ted properly. Ensure that no connec-tions are interchanged. The fittingslengths and quality of the hosesmust comply with the technical re-quirements.

Always practice extreme cleanlinesswhen servicing hydraulic components.

Hydraulic fluid under pressure isvery dangerous, it can penetrate theskin causing serious injury.

If fluid is injected under the skin it mustbe surgically removed immediately.


RK1412T ROTOCRUSHER

SAFETY Section 2.1

2.1 SAFETY cont.

Always use a piece of cardboard tocheck for leaks. Do not use yourhand.

Use caution while removing filler caps,filters, drain plugs or hydraulic fittings,hold a rag over the connection to pre-vent being sprayed or splashed by liq-uids.

Diesel engine exhaust emissionscontain products of combustionwhich may be harmful to yourhealth. Ensure the machine is in awell ventilated area, if the machineis operating in an enclosed areavent the emissions elsewhere.

Observe the regulations in force at thatsite.

Dust found on the machine or pro-duced during operation should beremoved by extraction not blowing.

Disconnect the battery leads and tapethe leads to prevent accidental start upwhen performing maintenance or serv-icing.

Battery electrolyte contains acidand can cause serious injury. Avoidcontact with skin and eyes. Usegloves and protective glasses.

Batteries give off flammable fumeswhich can explode. Ensure thatthere is proper ventilation. Avoidthe formation of sparks and nakedlights in the vicinity of the batteries.Do not smoke when working in thisarea.

Fires may result from lubricating oil orfuel spraying on hot surfaces.

Avoid smoking whilst refuelling orin the refuelling area.

Do not climb on conveyor belts or standon components that cannot supportyour weight, always use ladders, stepsand walkways when mounting and dis-mounting machine.

Only use emergency stop buttonsin an emergency situation or duringsafety checks.

Do not use fingers to check hole align-ments as this can cause serious injury.

Do not stand beneath equipment asit is being raised or lowered into po-sition.

Never check the tension of V-beltswhilst machine is running.

Whenever maintenance and servic-ing is being carried out a minimumof two persons must be present atall times.


RK1412T ROTOCRUSHER

SAFETY Section 2.1

2.1 SAFETY cont.

The preparations to transport themachine should be supervised by aminimum of two persons.

TESAB ENGINEERING LTD. haveprovided walkways and platforms toenable operatives to carry out daily in-spection and maintenance from a po-sition of safety. More irregular main-tenance tasks will necessitate personsto work on the machine at a heightwere fall hazards exist. (It is the re-sponsibility of the operators manage-ment to provide the necessary safeworking access).

Falling from and/or onto a TESABmachine can cause serious injuryor even death. Do not climb on themachine and never use machineparts as a climbing aid.

Always use an E.N./A.N.S.I. approvedharness 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, maintenanceand intervals set out in these operat-ing instructions, except where warninglight or indicator calls for immediateaction or adverse conditions requiremore frequent servicing.

When the machine is completely shutdown for maintenance or repair work,it must be secured against inadvert-ent starting by implementing the lock-out procedure (see lockout section fordetails).

Never allow anyone to remove largeor heavy components without ad-equate lifting tackle.

To avoid the risk of accidents, indi-vidual parts and large assemblies be-ing removed for replacement purposesshould be carefully attached to the lift-ing tackle and secured.

The fastening of loads and the in-structing of crane operators shouldbe entrusted to experienced person-nel only.

Any safety devices removed for setup,maintenance or repair must be fittedand checked immediately upon com-pletion of the work.

Before activating the machine in anymanner, or energising the electricaland/or hydraulic controls, make cer-tain that no person or obstructionis standing in or in the immediatevicinity of the machine.


RK1412T ROTOCRUSHER

SAFETY Section 2.1

2.1 SAFETY cont.

Always be aware that fully auto-matic machinery with moving partsmay move at any time without warn-ing. Never assume the machine tobe safe because of the lack of move-ment.

Never alter any equipment or parts ofany equipment which may effect safetywithout consulting and gaining permis-sion from TESAB ENGINEERINGLTD.

Improperly disposing of waste canthreaten the environment and ecol-ogy. Potentially harmful waste usedwith the TESAB machine include oil,fuel, coolant, filters and batteries.

Use leakproof containers when drain-ing fluids. Do not use food or bever-age containers that may misleadsomeone into drinking from them.

Do not pour the fluids onto theground, down a drain or into anywater source.

Ensure that all consumables and re-placed parts are disposed of correctlyand with the minimum environmentalimpact.

Do not open any door of the crusheruntil the rotor has stopped com-pletely and the control power havebeen broken, in the case of the die-sel powered unit the clutch is dis-engaged, the engine has stoppedand the ignition key has been re-moved.

Never start the machine until all doorson the crusher are closed and locked.

When removing hammers and im-pact plates always use protectivegoggles.

When the crusher chamber has beenopened ensure that the chamber ispinned open.

When working at the inside of thecrusher lock the rotor inserting alocating bar.


RK1412T ROTOCRUSHER

SAFETY Section 2.2

2.2 POSITION OF EMERGENCY STOPS

5.D

OG

LE

AD

1 &

2.

LHS

& R

HS

3 &

4.

LHS

& R

HS


RK1412T ROTOCRUSHER

SAFETY Section 2.3

2.3 EMERGENCY SITUATION

IMPORTANT: In the case of an incident of any part failure on the machine thefollowing procedure must be followed.

Engage the nearest emergency stop.

Switch off engine and remove the ignition key.

Implement the lockout procedure (see Section 2.4).

Only when the machine is fully switched off and the crusher rotor has com-pletely stopped revolving (approximately 120 seconds), should an attemptbe made to solve the problem.

It is always important to never work alone.

2.3.1 Restart after Emergency Stop

Ensure the problem has been rectified.

Ensure that all personnel are clear of the machine.

Ensure that all guards and relevant safety devices have been fitted/refittedcorrectly.

Release all emergency stops.

Restart the machine (see section 4.4)


RK1412T ROTOCRUSHER

SAFETY Section 2.4

WARNING

When carrying out maintenance, repairs or adjustment to the TESAB RK1412TROTOCRUSHER 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 thekeys with them at all times.

Ensure the isolator switch is in the OFF position prior to welding.

2.4 LOCKOUT PROCEDURE

Isolator in ON positionIsolator in OFF position

Engine canopy


RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

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Section 3

TRACKING INSTRUCTIONS

March 2005 Issue


RK1412T ROTOCRUSHER

TRACKING INSTRUCTIONS Section 3.0

3.0 TRACKING FAMILIARISATION

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOURTESAB RK1412T ROTOCRUSHER.FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENTDAMAGE.

1. Main engine starter panel

2. Dog lead controller

3. Emergency stop

4. Fast track console

2


RK1412T ROTOCRUSHER


3.0 TRACKING FAMILIARISATION cont.

THIS RK1412T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FORCONTROLLING THE CRUSHING AND TRACKING OPERATIONS. PLEASEREAD THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERA-TION OF THE SYSTEM.

When tracking the machine please ensure the both levers inside the fast trackconsole are located in the TRACK position prior to starting the engine (see picturebelow).

WARNING Do not activate levers while engine is running

Always ensure both valves are in the TRACK or CRUSH position prior tostarting the engine

Never operate the machine with either valve in the neutral (vertical)position

Both levers inTRACK position


RK1412T ROTOCRUSHER

TRACKING INSTRUCTIONS

3.1 STARTING THE ENGINE

NOTE: Check that there is a clear area around the machine and that all controllevers including the clutch lever are in the neutral position.

Check that no emergency stops are in the on position, if an emergencystop is in the on position lamp A (green) will NOT be illuminated.

Turn the starter ignition key B to position 1 which is the ON position.

Turn the key to position 3 and hold, the start delay siren will sound forapproximately 7 seconds then the engine will crank and start.

Release the key when the engine has started.

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 start-ing attempt.

B

A

Engine control panel

Section 3.1

Position 1

Position 3


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3.1 STARTING THE ENGINE cont.

Set the engine revs to approximately 1200rpm. This can be done by adjustingthe throttle scroll button (pushing button up increases engine revs, pushingbutton down decreases engine revs).

- revs

+ revs

Revs displayed on LCD

Increase revs

Decrease revs


RK1412T ROTOCRUSHER


3.2 TRACKING THE MACHINE USING THE DOG LEAD

The following procedure is to be carried out to allow the operator to track themachine using the dog lead.

Ensure that the control switch (E) is in the DOG LEAD position and the TrackSwitch on the main engine starter panel is in the ON position prior tooperating the dog lead.

Track switch

E

Start the engine as per previous instructions (it is important that the emer-gency stop status is checked before starting the engine).

NOTE: For safety reasons there is an emergency stop button (F) fitted to thedog lead.


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3.2 TRACKING THE MACHINE USING THE DOG LEAD cont.

F

CCCCC AAAAA

DDDDD BBBBB

B

AC

D

IMPORTANT: Once the machine has been tracked into position, remove thedog lead and place in a secure place (ideally the works office orshovel cab)

To track the machine, move the relevant toggle buttons on the dog leadcontrol (as shown above). For safety reasons Tesab have fitted a siren andorange beacon to make other persons in the vicinity aware that the machineis going to be, or is being, moved. It is always important for the operator tobe aware of his surroundings.


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RK1412T ROTOCRUSHER

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Section 4

SET-UP PROCEDURE

March 2005 Issue


RK1412T ROTOCRUSHER

SET-UP PROCEDURE Section 4.0

4.0 SET-UP PROCEDURE SAFETY



DANGER ELECTRICAL HAZARD1. Electrical Hazard. Risk of serious injury or

death.2. Never work on the electrical system of any

equipment unless you are fully familiar withsystem details.

3. Work on the electrical system must becarried out by a qualified electrician.




DANGER NIP HAZARD

1. Fall Hazard. Do not climb onto moving orworking machinery.

2. Switch off and lockout machine beforeattempting maintenance on the machine.

3. Always use a suitable lifting platform beforeattempting maintenance above 2m (6-6).

DANGER FALL HAZARD


RK1412T ROTOCRUSHER











before you work at this machine.2. Study the different safety signs on this

machine.3. Only qualified and trained personnel should







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ACID EXPLOSIVE

BATTERY


RK1412T ROTOCRUSHER


4.1 INSTALLATION

The following section will take you step by step through the installation of yourRK1412T ROTOCRUSHER.

NOTE: Due to different transport and shipping regulations throughout the worldthe RK1412T ROTOCRUSHER will be delivered in different packingarrangements. For the purposes of this manual it will be consideredthat the machine is delivered in its most unassembled configurationtherefore some of the installation sections may not be applicable. Ifthis is the case ignore that particular instruction/section and proceed tonext section.

Before installing the RK1412T ROTOCRUSHER ensure that you have read allsections of this manual in order to familiarise yourself with the machine and itsfunction, paying particular attention to SECTION 2: SAFETY.

Installation, operation, and maintenance of the RK1412T ROTOCRUSHER mustbe carried out by reliable, authorised personnel only, statutory minimum age limitsmust be observed.

TESAB ENGINEERING LTD. recommend that the installation of the RK1412TROTOCRUSHER is carried out by a recommended TESAB dealer and/or servicedepartment.


RK1412T ROTOCRUSHER


4.2 LOADING AND OFF LOADING

Loading and off loading the RK1412T should be carried out by trained and expe-rienced personnel only. They should first read the operation manual paying par-ticular attention to the safety and installation sections.


RK1412T ROTOCRUSHER


4.3 PRIOR TO STARTING THE ENGINE


Before starting the engine please ensure that the two diverter valves shown in thepicture below are in one of the following positions:

TRACK: When the machine has to be moved CRUSH: When the machine is in its working position and ready to work






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4.3 PRIOR TO STARTING THE ENGINE cont.

The engine starter panel is located at the engine catwalk as highlighted below.

This area can be accessed by lowering the access steps (A). It is important, forsafety reasons, that when these steps have been unfolded they are locked intoposition using the clamps at both sides (move bolt from point B to point C). Thisis illustrated below.

B

C

A


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4.4 ENGINE STARTING PROCEDURE

NOTE: Before starting the engine check diesel and engine oil levels.

Check that no emergency stops are in the on position, if an emergency stopis in the on position lamp A (green) will NOT be illuminated.

Turn the starter ignition key C to position 1 which is the ON position.




Set the engine revs to approximately 1200 rpm. This can be done by ad-justing the throttle scroll button (pushing button up increases engine revs,pushing button down decreases engine revs).

Throttle scrollbutton

B

A


Position 1

Position 3


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4.4 ENGINE STARTING PROCEDURE cont.

IMPORTANT: Before tracking we recommend that you fold up the engine areaaccess steps in order to prevent them from fouling unneccessarily.

WARNING

ENSURE MACHINE IS CLEAR OF ALL OVER HEAD CABLES


RK1412T ROTOCRUSHER


4.5 TRACKING FAMILIARISATION

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOURTESAB RK1412T ROTOCRUSHER.FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENTDAMAGE.

1. Main engine starter panel

2. Dog lead controller

3. Emergency stop

4. Fast track console

2


RK1412T ROTOCRUSHER


4.5 TRACKING FAMILIARISATION cont.


When tracking the machine please ensure the both levers inside the fast trackconsole are located in the TRACK position prior to starting the engine (see picturebelow).






RK1412T ROTOCRUSHER


4.6 TRACKING THE MACHINE USING THE DOG LEAD

The following procedure is to be carried out to allow the operator to track themachine using the dog lead.

Ensure that the control switch (E) is in the DOG LEAD position and the TrackSwitch on the main engine starter panel is in the ON position prior tooperating the dog lead.

Start the engine as per previous instructions (it is important that the emer-gency stop status is checked before starting the engine).

NOTE: For safety reasons there is an emergency stop button (F) fitted to thedog lead.

Track switch

E


RK1412T ROTOCRUSHER


4.6 TRACKING THE MACHINE USING THE DOG LEAD cont.

F

CCCCC AAAAA

DDDDD BBBBB

B

AC

D

IMPORTANT: Once the machine has been tracked into position, remove thedog lead and place in a secure place (ideally the works office orshovel cab)

To track the machine, move the relevant toggle buttons on the dog leadcontrol (as shown above). For safety reasons Tesab have fitted a siren andorange beacon to make other persons in the vicinity aware that the machineis going to be, or is being, moved. It is always important for the operator tobe aware of his surroundings.


RK1412T ROTOCRUSHER


4.7 POSITIONING

Before the RK1412T ROTOCRUSHER is positioned on site it is necessary tohave a level surface and spacious surroundings, if required level the work-sitefoundation 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. Thiscan be done with the aid of a spirit level (ensure that it is level both along thechassis and across the chassis).

We recommend that when the machine is positioned correctly the dog lead andthe remote control (if fitted) are located in a safe place (ideally in the works officeor shovel cab).


RK1412T ROTOCRUSHER


4.8 PREPARING FOR INITIAL START-UP

If required, fit the pre-cleaner and exhaust. We would recommend that if themachine has to be tracked for a long distance that you fit these items assoon as possible.

For safety reasons, once the machine is in the correct working position switchthe tracks off. This disables the system and prevents the machine frommoving if the dog lead is touched accidentally. Move switch to OFF positionon control panel to disable tracks (see picture below). It is also advisableto switch the manual control valves to the CRUSH position in order to preparethe machine for working (see below).

Pre-cleaner Exhaust

Tracks ON/OFF switch

Both leversin CRUSHposition


RK1412T ROTOCRUSHER


4.8 PREPARING FOR INITIAL START-UP cont.



Never operate the machine with either valve in the neutral (vertical) position

Remove any parts, which have been packed on the catwalks and hopper. This isto give full access to all control areas and reduces any fall hazards.


RK1412T ROTOCRUSHER

4.9 PRODUCT CONVEYOR UNFOLDING

Set the engine revs to approximately 1200* rpm. This can be done by ad-justing the throttle scroll button (pushing button up increases engine revs,pushing button down decreases engine revs).

Fold the conveyor up more to relieve the weight from the transport bracketusing the lever as shown below.

* NOTE: If having difficulty unfolding the conveyor, increase the engine revs toachieve the desired hydraulic pressure.


Product conveyorfolding lever

- revs

+ revs


Increase revs

Decrease revs


RK1412T ROTOCRUSHER


4.9 PRODUCT CONVEYOR UNFOLDING cont.

Unhook the transport bracket, hinge it around and hook it on to the side ofthe conveyor.

Using the same control lever, unfold the conveyor into its working position.

NOTE: Ensure that the holes marked A in the picture below line up.

AA

Transportbracket

C

D

B

Insert pins into holes (A) to secure. The pins can be found in the tool box.

IMPORTANT: Ensure that the R pin is inserted into the end of each pin.

Unpin bracket (B) at point C and re-pin at point D.


RK1412T ROTOCRUSHER

SET-UP PROCEDURE

4.10 HOPPER EXTENSIONS

IMPORTANT: Assembling the hopper extension unit will require the use of acrane. The fastening of loads and the instruction of crane opera-tors should be entrusted to experienced personnel only.

Remove the crossmember (A).

Using the crane, lower the extension unit into place and bolt to secure.

To raise the sides, use appropriate lifting equipment to rotate the sides (oneat a time) into the working position and bolt to secure.

Lower the rear section into place and bolt to both the hopper and the sideextensions to secure.

Add the extension crossmember at point B below.

A

B

Section 4.10


RK1412T ROTOCRUSHER

4.11 FEED-IN CHUTE

Due to differing height restrictions the assembled feed-in chute may be too high.

Hence the feed-in extension box, which carries the feed chains and rubber issometimes packed separately.

To fit the extension box, lower into position using lift point A and fasten using the 6I-bolts.

NOTE: Fitting the extension box will require the use of a crane. The fasteningof loads and the instructing of crane operators should be entrusted toexperienced personnel.


A

I-bolts


RK1412T ROTOCRUSHER


4.12 HOIST

Tesab have supplied a swinging arm for use when changing hammers, etc. Fortransport purposes it is folded down. To elevate the hoist, follow the steps below.

IMPORTANT: Tesab recommend that this arm is only used for changing itemsup to a maximum weight of one RK1412T Hammer (Part No. 2-423-3) or 200kgs.

Hoist in transportposition

Pivot hoistaround hinge

Bolt in placeusing the 4 bolts


RK1412T ROTOCRUSHER


4.13 CRUSHER SETTINGS

Before starting 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 twoimpact areas. These are named as follows:

Middle apron (stroke carrier)

Bar carrier

These are adjusted hydraulically. The bar carrier gap should always be set first.

WARNING

The crusher settings must not be altered while the crusher is in operation.

4.13.1 Bar carrier adjustment

Open door A and measure the setting between the LOWER blow bar (grindinglist) and the hammer.

A


RK1412T ROTOCRUSHER


4.13.2 Middle apron adjustment

Using the control lever (F), very carefully extend the rams just enough tocompress the disc springs slightly (C).

BC

D

E

4.13 CRUSHER SETTINGS cont.

The gap is set as follows:

Using the control lever (B), very carefully extend the rams just enough tocompress the disc springs slightly (C).

Remove the shims (D) and again using the control lever, carefully close therams to allow the removal of the remaining shims (E).

Set the gap using the control lever. The gap can be checked through doorA.

Once the gap is set, replace the shims (D & E) in the necessary order.

NOTE: Once the bar carrier gap has been set, rotate the rotor to ensure thatthere 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.


RK1412T ROTOCRUSHER





NOTE: The middle apron should be adjusted by APPROXIMATELY twice thedistance (or less) that the bar carrier was adjusted. The middle apronshould overlap the top of the bar carrier by a MINIMUM of 15mm asshown.


15mmminimum

A

FC

D

E


RK1412T ROTOCRUSHER



The measurement of the setting depends on the following:

The size of the feed material

Cubing or crushing required

Desired quantities of the different fractions produced

The following applies in general:

Do not adjust the crusher settings to an unnecessarily narrow gap.

Study the produced material and use that as a guide-line for your setting.

For additional advice on the settings on your RK1412T ROTOCRUSHER pleaseconsult TESAB ENGINEERING LTD. or your local authorised TESAB dealer.


RK1412T ROTOCRUSHER


4.14 DUST SUPPRESSION

The RK1412T crusher unit is fitted with a dust suppression system. It is theresponsibility of the customer to supply the system with clean water (see below).

Water supplyconnected here Shut-off valve


RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

Section 5

OPERATION

March 2005 Issue


RK1412T ROTOCRUSHER

OPERATION Section 5.0

5.0 OPERATION SAFETY

DANGER ELECTRICAL HAZARD



1. Electrical Hazard. Risk of serious injury ordeath.

2. Never work on the electrical system of anyequipment unless you are fully familiar withsystem details.

3. Work on the electrical system must becarried out by a qualified electrician.




DANGER NIP HAZARD




DANGER FALL HAZARD


RK1412T ROTOCRUSHER







before you work at this machine.2. Study the different safety signs on this

machine.3. Only qualified and trained personnel should











RK1412T ROTOCRUSHER














ACID EXPLOSIVE

BATTERY


RK1412T ROTOCRUSHER


WARNING

When carrying out maintenance, repairs or adjustment to the TESAB RK1412TROTOCRUSHER 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 thekeys with them at all times.

Ensure the isolator switch is in the OFF position prior to welding.

5.1 LOCKOUT PROCEDURE

Isolator in ON positionIsolator in OFF position

Engine canopy


RK1412T ROTOCRUSHER


5.2 GENERAL INFORMATION

All crushing applications differ due to material composition and customer require-ments.

There are numerous adjustments that can be made in order to achieve requiredresults.

Therefore we recommend that you contact TESAB ENGINEERING LTD. or yourlocal Tesab dealer to advise you on the best customized Tesab arrangement tosuit your particular application.


RK1412T ROTOCRUSHER


5.3 PRE-OPERATION CHECK LIST

Before operation check and ensure the following:

Nothing on product conveyor

Nothing on feed conveyor

All guards are fitted correctly

The diesel tank has been topped up

Engine oil level has been checked and topped up if necessary

Ensure the diverter valve levers are in the CRUSH position before startingthe engine


RK1412T ROTOCRUSHER


5.4 ENGINE STARTING PROCEDURE

NOTE: Before starting the engine check diesel and engine oil levels.

Check that no emergency stops are in the on position, if an emergency stopis in the on position lamp A (green) will NOT be illuminated.

Turn the starter ignition key C to position 1 which is the ON position.




Throttle scrollbutton

B

A


Position 1

Position 3


RK1412T ROTOCRUSHER


5.5 SETTING ENGINE REVS

Set the engine revs to approximately 1100 rpm. This can be done byadjusting the throttle scroll button (pushing button up increases engine revs,pushing button down decreases engine revs).

- revs

+ revs


Increase revs

Decrease revs


RK1412T ROTOCRUSHER


5.6 ESM MAIN UNIT

5.6.1 Diagnostic Display

* IMPORTANT: May also indicate sensor fault.

High Engine CoolantTemperature*

High Inlet ManifoldTemperature*

High FuelTemperature*

Low BatteryVoltage*

High AuxiliaryTemperature*

High AuxiliaryPressure*

Engine Derate

Low EngineCoolant Level*

LCD DigitalDisplay

Low FuelPressure*

Low Engine OilPressure*


RK1412T ROTOCRUSHER


5.6 ESM MAIN UNIT cont.

5.6.2 Display Scroll Feature

Each time the scroll forward switch is depressed and held, EMS will page throughthe engine parameters in the order listed below. The abbreviation for the param-eter will be displayed. When the scroll switch is released, EMS will display thecurrent real time value for that parameter.

Abbreviation ParameterSpd Engine SpeedGA-1 Engine Oil PressureGA-2 Coolant TemperatureGA-3 Battery VoltageGA-4 Fuel Pressure (Customer Installed Sensor)Boost Boost PressureIAirT Inlet Air TemperatureFuelT Fuel TemperatureAccrP Auxiliary PressureAccrT Auxiliary TemperatureFuel Fuel RateHrs Engine HoursLoad Engine (%) Load


RK1412T ROTOCRUSHER


5.7 ENGAGING THE CLUTCH

5.7.1 Manual clutch

Start the crusher by bumping-in the clutch. Bumping-in involves several partialengagements with the hand lever.

Engage the clutch gradually until the engine labours heavily, disengage theclutch momentarily to allow engine torque/speed to recover.

Repeat this procedure two or three times and then engage the clutchcompletely by forcing the lever to the fully over-centre position.

Operator experience often dictates the number of bumps required.

IMPORTANT: Read section 6.6 on manual clutch maintenance this states thatthe clutch, initially when new, will require several adjustments (itwill also require further adjustments during clutch life).

It is important that this procedure is adhered to in order to achieveprolonged clutch life.

Engage Clutchgradually

bump-inclutch


RK1412T ROTOCRUSHER


5.7 ENGAGING THE CLUTCH cont.

5.7.2 Hydraulic clutch

Increase the engine revs to 1300rpm. This is done by adjusting the throttlescroll button.

Start the hydraulic clutch by pressing the clutch START button on the starterpanel as shown below.

Clutch START button

- revs

+ revs


Increase revs

Decrease revs


RK1412T ROTOCRUSHER


5.7 ENGAGING THE CLUTCH cont.

NOTE: Wait until the crusher speed has built up (approximately 45 seconds)before proceeding.

IMPORTANT: Read section 6.7 on hydraulic clutch maintenance


RK1412T ROTOCRUSHER


5.8 PRODUCT CONVEYOR STARTING

Increase the engine revs to the desired crushing engine speed (1800-2200rpm depending on the application). This is done by adjusting the throttlescroll button.

Start the product conveyor by pressing the product conveyor START buttonon the starter panel as shown below.

NOTE: Initially the product conveyor belt is tracked when running empty. Thebelt may require re-adjustment when loaded.

Product conveyorSTART button

- revs

+ revs


Increase revs

Decrease revs


RK1412T ROTOCRUSHER


5.8 PRODUCT CONVEYOR STARTING cont.

In order to correctly track the product conveyor belt please carry out the followingprocedure:

The belt can be TENSIONED correctly at the top end drum using the adjusterbars as shown. Slacken the 4 bolts (A) prior to tensioning belt.

NOTE: The conveyor belt tension is factory set but due to running it over timeor climatic conditions the belt will stretch and require re-tensioning.

IMPORTANT: DO NOT over tension the belt as this will cause excessive strainon the bearings and drive system.

In order to track the belt correctly the return rollers must be adjusted asshown below. For further details on the tracking of the conveyor belt seesection 6.20.

Adjuster bar

A


RK1412T ROTOCRUSHER


5.9 FEED CONVEYOR STARTING

NOTE: Ensure that the product conveyor is started before starting the feedconveyor.

Start the feed conveyor by pressing the feed conveyor START button on thestarter panel as shown below.

NOTE: Initially the feed conveyor belt is tracked when running empty. The beltmay require re-adjustment when loaded.

The feed conveyor belt can be correctly tracked by adjusting the drum as shownbelow.

Feed conveyorSTART button

Adjuster bar


RK1412T ROTOCRUSHER


5.9 FEED CONVEYOR STARTING cont.

NOTE: The belt can be tracked by slackening as well as tensioning the adjust-ers.

IMPORTANT: DO NOT over tension the belt as this will cause excessive strainon the bearings and drive system.

For further details on the tracking of conveyor belts see section 6.20.


RK1412T ROTOCRUSHER


5.10 MACHINE START-UP SEQUENCE

Start engine

Set revs to engage clutch (1100rpm for manual clutch, 1300rpm for hydraulicclutch)

Engage clutch

Increase revs to desired crushing speed

Start product conveyor

Start feed conveyor

Ready to crush!


RK1412T ROTOCRUSHER


5.11 MACHINE SHUT-DOWN SEQUENCE

The following procedure should be followed when shutting the machine down atthe end of a shift.

IMPORTANT: Ensure that you allow the machine to run empty at the endofthe shift before closing the machine down. Not allowing this tohappen will put unnecessary pressure on the hydraulic system.

Stop feed conveyor

Wait and ensure crusher has cleared completely of material

Stop product conveyor

Reduce engine revs to approximately 1300rpm

Disengage clutch

Reduce engine revs to idle and run engine for 60 seconds

Switch engine off and implement lockout procedure

IMPORTANT: DO NOT LEAVE KEYS IN IGNITION


RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

RK1412T ROTOCRUSHER

Section 6

MAINTENANCE

March 2005 Issue


RK1412T ROTOCRUSHER

MAINTENANCE Section 6.0

6.0 GENERAL INFORMATION

This section provides detailed maintenance instructions as well as a maintenanceschedule for normal operating conditions.

NOTE: Diesel engine maintenance and service required or the frequencythereof is outside the scope of this manual. All matters relating tothis should be referred to the makers publication Operation andMaintenance Manual, a copy of which is included with this manual.

When performing maintenance on your machine please adhere to the safety in-formation listed in the safety section.

WARNING

Implement LOCKOUT procedurebefore carrying out maintenanceto your RK1412T ROTOCRUSHER

It is important to note that high repair costs and lengthy downtime will occur ifinadequate or improper maintenance is performed on your machine. Regularmaintenance is imperative.

The reliability and service life of your RK1412T unit depends on the regular andcorrect maintenance of the machine.

Good housekeeping pays untold dividends in increased production and extendedplant life!

IMPORTANT: If the RK1412T is operated for long periods of time in extremeconditions either climatic (-15C to 33C) or very dusty, the mainte-nance schedule will change. If this scenario arises please con-sult your local Tesab dealer or Tesab Engineering technical/serv-ice department.


RK1412T ROTOCRUSHER


6.1 SAFETY INFORMATION




DANGER NIP HAZARD








DANGER FALL HAZARD






RK1412T ROTOCRUSHER


6.2 OPENING THE RK1412T ROTOCRUSHER UNIT

Ensure that the diverter valve levers are in the CRUSH position.

Start the engine and set the revs to 1200rpm.

Unfasten the 6 I-bolts (shown below).

Using the control lever (shown below) open the crusher until the holes inbrackets A and B line up and insert the crusher opening pin (this can befound mounted on the crusher beside the hydraulic adjustment mechanism).

Crusher opening lever

I-Bolts

A

BInsert pin


RK1412T ROTOCRUSHER


DO NOT OPEN ANY DOOR OF THE CRUSHER UNTIL THE ROTOR HASSTOPPED COMPLETELY AND THE CONTROL POWER HAS BEEN BROKEN,OR, IN THE CASE OF A DIESEL POWERED CRUSHER, THE CLUTCH IS DISEN-GAGED, THE ENGINE HAS STOPPED AND THE IGNITION KEY HAS BEENREMOVED.

NEVER START THE CRUSHER UNTIL ALL DOORS ARE CLOSED AND LOCKED.

WHEN REMOVING HAMMERS AND IMPACT BARS, ALWAYS USE PROTECTIVEGOGGLES (YOU CAN ACCIDENTALLY HIT ASKEW AND A METAL SHARD MAYHIT YOUR EYES)

WARNING

6.2 OPENING THE RK1412T ROTOCRUSHER UNIT cont.

IMPORTANT: Ensure all bolts are re-fastenedafter closing


RK1412T ROTOCRUSHER


6.3 REPLACING OR TURNING THE HAMMERS

Open the setting (gap) of thecrusher to a maximum.

Rotate the rotor so that onehammer appears straight up(see picture 6.3.1). Insert alocating bar or similar throughthe rotor. The rotor is nowsecured.

Clean away the stone powderand such from around thehammer.

Take away the securing brack-ets (A) at both sides of thehammer.

The turned or new hammer ispushed into position.

Secure the hammer withbracket (A) at both sides.Then remove the securing rod.

Repeat from step 2 until allhammers are replaced.

Close and lock all doors.

Start the crusher.

A

Picture 6.3.1

NOTE: Should any abnormal sound be heard (a thumping or knock), stop thecrusher immediately and check if any of the hammers are positionedtoo far to one side, so it touches the side plates.

After the necessary measures have been taken, start the crusher againand run it empty for approximately 5 minutes.

If everything is OK, make the final gap settings, close and lock all doors.ALL SET FOR CRUSHING.

Picture 6.3.2


RK1412T ROTOCRUSHER


6.4 SETTING THE CRUSHER GAP

WARNING

The crusher settings must not be altered while the crusher is in operation.

Open the door A by the bar carrier and measure the setting at the lowerimpact bar B (see picture 6.4.2). The measure of the setting depends on:

The size of the feed material Cubing or Crushing Desired quantities of the different fractionsproduced.

The following applies in general:

Do not adjust the crusher setting to an unnecessary narrow gap.

Study the produced material and use that as a guideline for your setting.

Adjust the bar carrier before the middle apron.

BPicture 6.4.2A

Minimum15mm

Picture 6.4.1


RK1412T ROTOCRUSHER


6.4 SETTING THE CRUSHER GAP cont.

The crusher gap is set as follows:

Using the appropriate lever (see picture 6.4.3), very carefully extend therams just enough to compress the disc springs slightly (picture 6.4.4, itemC).



NOTE: The middle apron should be adjusted by APPROXIMATELY twice thedistance (or less) that the bar carrier was adjusted. The middle apronshould overlap the top of the bar carrier by a MINIMUM of 15mm asshown in picture 6.4.2.


NOTE: Once the bar carrier gap has been set, rotate the rotor to ensure thatthere 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.

Middle apronadjustment

Bar carrieradjustment

Picture 6.4.3

CD E

Picture 6.4.4


RK1412T ROTOCRUSHER


6.5 REPLACING OR TURNING OF IMPACT BARS (BLOW BARS)

Open the settings(gap)of the crusher(A).

Open both doors (B)by the bar carrier.

Knock out the impactbars (C) laterallyusing an iron bar orsimilar.

Clean the socketsand insert the turnedor new impact bars.

Set the desired gap,close and lock thedoors. CRUSH!

C

A

B


RK1412T ROTOCRUSHER


6.6 MANUAL CLUTCH

The Manual Power Take Off (or Clutch) in conjunction with your diesel engine isthe central part of your RK1412T ROTOCRUSHER. A lot of care and thought hasgone into its selection.

Correct maintenance of your PTO will increase its effectiveness and prolong itslife-span.

The following sections are a short simple outline of duties that the owner andoperator must perform for satisfactory service from his TWIN DISC POWER TAKEOFF.

PTO


RK1412T ROTOCRUSHER


6.6 MANUAL CLUTCH cont.

6.6.1 Clutch Adjustment

New manual power take offs should have clutch adjustment checked before be-ing placed in service. A newly placed in service power take off should have itsclutch adjustment checked again after the first 10 hours of operation. New clutchplates have a wear-in period and the clutch may require several adjustmentsuntil the new plates are worn-in. After wear in, clutch adjustments should bechecked regularly. As this is classed as a heavy duty application which has fre-quent engagements and relatively long periods of slip when bumping-in it willrequire 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 thelocking pin (2) can be reached (see picture 6.6.1.1).

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 operatinglever requires a distinct pressure to engage (see picture 6.6.1.1).

Regular adjustment dictates that no more than 1 or 2 notches should be requiredeach time, any more than this would indicate that the clutch is not adjusted regu-larly.


RK1412T ROTOCRUSHER



NOTE: The majority of clutch failures are not caused by a unit being undersized for the application. Failures often are the result of the clutch notbeing properly adjusted. Check and adjust the clutch on a regularbasis, to the correct engaging effort as specified on the instruction coverplate.

Picture 6.6.1.1


RK1412T ROTOCRUSHER



6.6.2 Clutch Lubrication

Throwout Collar: Apply a small amount of lubricant once a day, beforestarting, through the fitting on the tapered part of thehousing.

Main Bearings: Apply a small amount of lubricant once a week, throughthe fittings highlighted below.

Lever Shaft: Apply a small amount of lubricant once a week, throughthe fittings highlighted below, please note that thereare grease nipples on both left and right hand side.

6.6.3 Lubricant Specification

Use any high grade, high temperature, lithium based gun lubricant. For furtherdetails see recommended lubricant section in this manual.

NOTE: Although this section details the greasing points on the clutch, it is im-portant to note that if the machine is fitted with the Autolube system,these points are supplied with grease by it. See the Autolube sectionfor further details.


RK1412T ROTOCRUSHER


6.7 HYDRAULIC CLUTCH

The Hydraulic Power Take Off (or Clutch) in conjunction with your diesel engine isthe central part of your RK1412T ROTOCRUSHER. A lot of care and thought hasgone into its selection.

Correct maintenance of your PTO will increase its effectiveness and prolong itslife-span.

Following is a short simple outline of duties that the owner and operator mustperform for satisfactory service from his TRANSFLUID POWER TAKE OFF.

6.7.1 Clutch Maintenance

Change the oil after the first 100 working hours, and every 4000 workinghours 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 theheat exchanger. Re-check the oil level again once this has been done andtop-up if necessary.

Recommended oils are as follows:

AGIP OSO 32ARAL VITAM GF 32BP ENERGOL HLP 32CASTROL HYSPIN AWS 32CHEVRON RPM EP HYDRAULIC 32ESSO NUTO H 32MOBIL DTE 24SHELL TELLUS 32TEXACO RANDO HD 32TOTAL AZOLLA ZS 32

Change the oil filter cartridge (25 micron) when the pressure is 1.7 bar overthe rated value and/or the pressure switch is on.


RK1412T ROTOCRUSHER

MAINTENANCE

6.7 HYDRAULIC CLUTCH cont.

In cases where there is considerable oil leakage the rotating seals should bechanged (see picture 6.7.1.1).

Keep the oil cooler clean. The radiator pack can be cleaned by either washingcarefully 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 isthe correct length (see table below). The chain can be stretched by hanginga 20 kg weight from it.

KPTO Max. Length (mm) 15 126517-19 136221-24 1556 27 1914

Periodically check the condition of the elastic coupling.

Picture 6.7.1.1

Elastic coupling(not shown)

Rotating seal(not shown)

Oil filter

Oil levelindicator

Rotating seal(not shown)

Solenoid valve

Pressure gaugeswitch

Section 6.7


RK1412T ROTOCRUSHER


6.9 TRACKS

Each Track Frame Assembly fitted to the TESAB RK1412T ROTOCRUSHER iscomprised of five main components:

A STEEL FRAME CHASSIS onto which all other components are mounted.The weight of the machine which is to be carried by these assemblies isdistributed along the length of the frames.

The DRIVE ASSEMBLY is a planetary gearbox, mounted at the rear of theframe, which is driven by a hydraulic motor. A drive sprocket is bolted tothe gearbox.

A total of nine BOTTOM ROLLERS are attached to the underside of eachframe. The entire weight of the machine is carried on these rollers.

The FRONT IDLER is mounted at the opposite end of the frame to the sprock-et, the idler slides on guides. The track is adjusted by a hydraulic cylinderattached to the idler arrangement. Between the idler, and the track adjustingcylinder is a recoil spring, which will allow the idler to movebackwards inthe event that excessive load is placed on the track.

The TRACK ASSEMBLY comprises of sectional chain with triple bar grousershoes bolted to it.


RK1412T ROTOCRUSHER


6.9 TRACKS cont.

TO ENSURE TROUBLE FREE TRACK OPERATION, IT IS IMPORTANT THATTHE FOLLOWING MAINTENANCE OPERATIONS ARE ADHERED TO.

6.9.1Track Adjustment

Check if the track is correctly adjusted. As the track wears it will become slackand should be checked regularly.

To establish if the track requires adjustment move the machine backwards andforwards a few metres on level ground and in a straight line (do not slew). Thisenables the track to adopt its natural degree of tension.

Measure the droop as shown on figure 6.9.1.1. This measurement shouldnot exceed 30mm (1.25).

The adjustment of the track is accessed via the inspection cover on the side of thetrack frame as shown in figure 6.9.1.1. Remove the cover using a 6mm allen key.

30mm approx.

Equal Equal

Figure 6.9.1.1

InspectionCover


RK1412T ROTOCRUSHER


6.9 TRACKS cont.

Adjustment is carried out as follows:

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 standardgrease gun, filled with the correct grease, pump the track out to thecorrect adjustment.

IMPORTANT: Do not tension the track too tightly as this places unacceptableloads on the gearbox bearings and idler bearings. It will lead toaccelerated wear and premature failures.

To release the track tension:

Slacken the grease fitting on the end of the hydraulic track tensioningcylinder, by one half turn only, using a 22mm spanner.

WARNING

Grease under extreme pressure is released by this action. Personal injury couldresult if the fitting is removed whilst under pressure.

When the track droop appears to be correct, move the machine backwardsand forwards and re-check the droop.

Add more grease if required. Replace the inspection cover when the correctadjustment has been made.

M1442 adapter


RK1412T ROTOCRUSHER


6.9 TRACKS cont.

6.9.2Gearbox Oil Level

Cleanliness is absolutely essential as gearbox life will be dramatically reduced ifdirt is allowed to enter. Use only clean oil, in clean containers.

The oil level must be checked every 200 working hours (see section 6.9.6 forcorrect grade of oil).

To drain the gearbox:

Move the machine until the filler plugs are in the position as shown in figure6.9.2.1.

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 oilis hot.

IMPORTANT: Do not move the machine (except to reposition the plug holes forrefilling) without oil in the gearboxes.

Draining

Figure 6.9.2.1


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6.9 TRACKS cont.

To refill the gearbox:

Ensure machine is on level ground and track until the filler plugs are in thecorrect position (see figure 6.9.2.2).

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 re-check thelevel.

Add more oil if necessary.

NOTE: Approximate oil quantity 5 litres per gearbox

The oil should be drained from the gearboxes after the first 200 hours of opera-tion, and refilled with the correct lubricant (see section 6.9.6).

Following this initial oil change the oil should then be replaced after 2000 hours ofuse or at least once per year.

FillingLevel

Figure 6.9.2.2


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6.9 TRACKS cont.

6.9.3Leakage

Check daily for any signs of oil leakage, particularly around the front idler seals,roller seals and gearbox.

If any leakage is found, action must be taken to correct the problem before themachine is used.

6.9.4Bottom Rollers and Idlers

These components are lubricated at the time of manufacture and are termed lu-bricated for life.

No servicing is therefore required.

If however an oil leak is detected on any of these components, an exchange unitshould be fitted before using machine again.

NOTE: Removal of the filler plug invalidates the warranty.

6.9.5Loose Bolts

It is the responsibility of the operator to check the machine on a daily basis for anyloose bolts, or signs of undue wear.

In the event that any bolts are found to be loose, they should be re-tightened tothe following torque:

Bottom Roller Bolts 350 ft lbs.Sprocket Mounting Bolts 350 ft lbs.Gearbox Mounting Bolts 350 ft lbs.Motion Valve 33 ft lbs.Track Shoes 120 ft lbs. plus 1/3 turn

It is the operators responsibility to ensure that the machine is properly maintainedand does not pose a safety hazard to himself or others.


RK1412T ROTOCRUSHER


6.9 TRACKS cont.

6.9.6Track Lubrication

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.

For track adjustment, a good quality all purpose grease such as TEXACO EP2ALL PURPOSE GREASE should be used.

All leading lubricating oil suppliers offer equivalents.


RK1412T ROTOCRUSHER


6.10 HYDRAULIC FLUIDS

Hydraulic fluids play a most important part in any hydraulic system. They havethree 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 incompress-ible as possible. In most hydraulic components, internal lubrication is provided byfluid only. For long component life, fluids are available containing additives whichhave high anti-water properties. The fluids are known as anti-wear type hydraulicoils, which are recommended for your RK 1412T ROTOCRUSHER. In most casesthe fluid is the oil seal present. For example there are no sealing rings b

Documents

Tesab 1412T Operation Manual UK