Tesab_1012T_OperationManual_Issue4

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

RK1012T ROTOCRUSHER

RK1012T ROTOCRUSHER Jan 2005 Issue


RK1012T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 1: INTRODUCTION

1.0 EU directive1.1 Declaration1.2 Machine Specification Details1.3 Foreword / Reservation Of Rights1.4 Familiarisation1.5 General Specification

SECTION 2: SAFETY

2.0 Safety Introduction2.1 Safety Notes2.2 Position of Emergency Stops2.3 Emergency Situation2.4 Lockout Procedure

SECTION 3: TRACKING INSTRUCTIONS

3.0 Tracking Familiarisation3.1 Tracking the Machine3.2 Tracking using the Remote Control3.3 Tracking using the Dog Lead3.4 Remote Control Battery Charging

Jan 2005 Issue


RK1012T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

SECTION 4: SET-UP PROCEDURE

4.0 Set-up Procedure Safety4.1 Installation4.2 Loading & Off-Loading4.3 Starting Engine4.4 Engine Starting Procedure4.5 Tracking Instructions4.6 Tracking the Machine4.7 Tracking using the Remote Control4.8 Tracking using the Dog Lead4.9 Remote Control Battery Charging4.10 Positioning4.11 Preparing for Initial Startup4.12 Dirt Conveyor Unfolding4.13 Crib Folding and Assembly4.14 Feeder Beacon4.15 Feed-In Chute4.16 Hoist4.17 Crusher Settings4.18 Dust Suppression

SECTION 5: OPERATION

5.0 Operation Safety5.1 Operation Lockout Procedure5.2 General Information5.3 Pre Operation Check List5.4 Feeder Information5.5 Feeder Instructions5.6 Machine Starting5.7 Setting Engine Revs5.8 ESM Main Unit5.9 Engaging Clutch5.10 Product Conveyor Starting5.11 Dirt Conveyor Starting5.12 Feeder Starting5.13 Machine Shutdown Sequence

Jan 2005 Issue


RK1012T ROTOCRUSHER

CONTENTS

TABLE OF CONTENTS

Jan 2005 Issue

SECTION 6: MAINTENANCE

6.0 The RK1012 Rotocrusher6.1 Replacing or Turning Hammers6.2 Setting The Crusher Gap6.3 Replacing or Turning Impact Bars6.4 Manual Clutch6.5 Hydraulic Clutch6.6 Maintenance6.7 General Information6.8 Safety Information6.9 Hydraulic System6.10 Tracks6.11 Hydraulic Fluids6.12 Oil Tank, Pipes & Fittings6.13 Diesel Engine6.14 Product Conveyor Reduction Gear6.15 Feeder6.16 Bearing & Lubrication6.17 General Specification Inspection6.18 Routine Maintenance Schedule6.19 Daily Maintenance6.20 Weekly Maintenance6.21 Six Monthly Maintenance6.22 Belt Tracking6.23 V-Belt Tensioning6.24 Recommended Gear Oil6.25 Recommended Lubricants6.26 Automatic Greasing System (Autolube)6.27 Autolube Maintenance6.28 Autolube Troubleshooting6.29 Recommended Fluids6.30 Fault Finding


RK1012T ROTOCRUSHER

Jan 2005 Issue

SECTION 7: PREPARING FOR TRANSPORT

7.0 Preparing for Transport

SECTION 8: WARRANTY

8.0 Warranty

SECTION 9: RK1012 CRUSHER PARTS LIST

9.0 Index9.1 Main Assembly9.2 Chamber Wear Plates9.3 Shaft and Bearing Assembly9.4 Top Apron Adjuster Assembly9.5 Middle Apron Adjuster Assembly (Manual Adjustment)9.6 Bar Carrier Adjuster Assembly (Manual Adjustment)9.7 Middle Apron & Bar Carrier Adjuster Assembly (Hydraulic Adjustment)

SECTION 10: HYDRAULIC & ELECTRIC DIAGRAMS

10.0 Hydraulic Diagram (Standard)10.1 Hydraulic Diagram (inc. Conveyor Folding)10.2 Electric Diagram (Fuse Relay Description)10.3 Electric Diagram (Panel Layout)10.4 Electric Diagram10.5 Electric Diagram10.6 Electric Diagram10.7 Electric Diagram

CONTENTS

TABLE OF CONTENTS


RK1012T ROTOCRUSHER


Section 1INTRODUCTION


RK1012T ROTOCRUSHERRK1012T ROTOCRUSHER

RK1012T ROTOCRUSHER

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 ANDSERVICE YOUR MACHINE CORRECTLY.

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

REMEMBER:

GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS ININCREASED PRODUCTION AND EXTENDED PLANTLIFE !

Section 1


RK1012T ROTOCRUSHER

GENERAL INFORMATION Section 1

1.1 EC 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: RK 1012T 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.


RK1012T ROTOCRUSHER


1.2 MACHINE SPECIFICATION DETAILS

MACHINE SERIAL NUMBER:

ENGINE TYPE:

ENGINE SERIAL NUMBER:

CLUTCH TYPE:

CLUTCH SERIAL NUMBER:

DESPATCH DATE:


RK1012T ROTOCRUSHER


1.3 FOREWORD/RESERVATION OF RIGHTS

The TESAB RK 1012T ROTOCRUSHER is a robust skilfully engineered piece ofequipment incorporating diesel, hydraulic and mechanical components of thehighest quality.

In the interest of continuous plant reliability, it is essential that the machine ismaintained with meticulous care and attention. This operation and mainte-nance manual has been produced to assist the user to obtain the maximumoutput 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 rec-ommend that the user should pay particular attention to the maintenance andsafety sections of this manual.

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, reproducedor loaned to a third party without written consent ofTESAB ENGINEERING LTD.


RK1012T ROTOCRUSHER


1.4 FAMILIARISATION

RIGHT LEFT

REAR

FRONT

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

Right and left hand sides - as viewed from the product conveyor end ofmachine.

Front - product conveyor end of machine.

Rear - feeder end of machine.


RK1012T ROTOCRUSHER


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

12 3 456 7


RK1012T 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 centre heavy-duty tracks, with remote control or dog lead op-erational facility.

Feeder

The 4.25m x 0.9m spring mounted heavy duty vibrating feeder is of twin shaftdesign. The controls and variable speed are located on the feeder catwalk oralternatively the feeder can be operated from the tracks remote control, this allowsthe operator full control of crusher feed rate. The bar frame cassette can be manu-factured to the customers specification depending on application and site condi-tions. The customer has the option of feeding the fines onto the product conveyorbelt or onto a 3.6m x 500mm side dirt conveyor. The feeder is fitted with hydraulicfolding heavy-duty cribs to give extra hopper capacity.


RK1012T ROTOCRUSHER


Crusher Unit

The RK 1012 crusher unit is fitted with four hammers, 1000mm wide. It has a feedopening of 1020 x 780mm and a rotor diameter of 1200mm. There are two adjust-able aprons and a final bar carrier which can be adjusted from 4 to 80mm depend-ing on material feed size and reduction required. It is driven through 8 V-Belts andthe chamber can be easily accessed by hydraulic control lever. There is a deadboxfitted under the crusher to allow easy flow of material onto the product conveyor. Aspeed 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 onheavy duty troughing rollers, impact bars are fitted under crusher to give belt fullsupport at crusher exit. The conveyor is driven hydraulically through a flexible cou-pling at the rubber lagged top end drum.

Power Unit

The engine is a Caterpillar C9 (300HP at 1800rpm) Power Pack and the crusher isdriven through a heavy duty Twin Disc IBF 314 (3 plate) PTO. The pulley on theclutch can be easily changed to alter the rotor speed or if finer tuning is required theengine speed can vary between 1700 and 2200rpm. The conveyors, feeder, andrams 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 ac-cess to all relevant maintenance points. Emergency stops are fitted to all necessarypoints. The machine carries the European CE mark and therefore complies with allEssential Safety Requirements.

Options

- Self-cleaning magnet- Dust suppression- Re-cycling apron- Vibrating feeder under crusher

1.5 GENERAL SPECIFICATION contd.


RK1012T ROTOCRUSHER


Section 2SAFETY


RK1012T ROTOCRUSHERSAFETY Section 2

DANGER ELECTRICAL HAZARD

In this next section you will find the safety sign conventions used throughoutthis 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 poten-tial warning or danger when operating this machine.

2.0 SAFETY INTRODUCTION

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.

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).


RK1012T ROTOCRUSHER

SAFETY Section 2

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.

WARNING1. 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.

CONSULT MANUAL


RK1012T ROTOCRUSHER

SAFETY Section 2

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


RK1012T ROTOCRUSHER

SAFETY Section 2

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 un-der the supervision and guidance ofa skilled 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 be inplace whenever maintenance is notbeing performed. Never disable orremove 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.


RK1012T ROTOCRUSHER

SAFETY Section 2

2.1 SAFETY contd.

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 lockoutprocedure. Allow machine to cool.

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 imme-diately and lockout. Have any defectsrectified 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 inter-changed. 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.


RK1012T ROTOCRUSHER

SAFETY Section 2

2.1 SAFETY contd.

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 startup when performing maintenance orservicing.

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 batter-ies. Do not smoke when working inthis area.

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 orstand on components that cannot sup-port your weight, always use ladders,steps and walkways when mountingand dismounting 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.


RK1012T ROTOCRUSHER

SAFETY Section 2

2.1 SAFETY contd.

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 injury oreven death. Do not climb on the ma-chine and never use machine partsas a climbing aid.

Always use an EN/ANSI 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, individualparts and large assemblies being re-moved 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 per-sonnel 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.


RK1012T ROTOCRUSHER

SAFETY Section 2

2.1 SAFETY contd.

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.


RK1012T ROTOCRUSHER

SAFETY Section 2

2.2 POSITION OF EMERGENCY STOPS

3.FE

EDER

CONS

OLE

4.R

AM

S C

ON

TRO

LCO

NSO

LE

1.LH

S &

RH

S2.

LHS

& R

HS


RK1012T ROTOCRUSHER

SAFETY Section 2

2.3 EMERGENCY SITUATION

WARNING

In the case of an incident of any part failure on themachine 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 crusherrotor has completely stopped revolving (approximately 120seconds), 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 havebeen fitted / refitted correctly.

4. Release all emergency stops.

5. Restart the machine (see section 4.3)


RK1012T ROTOCRUSHER

SAFETY Section 2

WARNING When carrying out maintenance, repairsor adjustment to the TESAB RK 1012TROTOCRUSHER the following lockoutprocedure must be followed.

1. Deactivate all controls, switch off engine and remove key.2. Activate, or, if fitted, lock one emergency stop button.3. Relieve all pressures in the hydraulic system.

IMPORTANT: THE PERSON CARRYING OUT THE WORK ON THEMACHINE MUST KEEP THE KEYS WITH THEM AT ALLTIMES.

Engine Access Catwalk

ENSURE ISOLATOR SWITCH IS IN THE OFF POSITIONPRIOR TO WELDING.

2.4 LOCKOUT PROCEDURE

IMPORTANT SAFETY NOTICE

ISOLATOR IN ON POSITIONISOLATOR IN OFF POSITION

ENGINE CANOPYCONTROL PANEL


RK1012T ROTOCRUSHER


Section 3TRACKING INSTRUCTIONS


RK1012T ROTOCRUSHER

TRACKING INSTRUCTIONS Section 3

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOURTESAB RK1012T ROTOCRUSHER.FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENTDAMAGE.

1. Familiarisation

The following terms/panel names have been used in this instruction leaflet, belowshows the names and there locations.

1. Main engine starter panel.

2. Remote control box.

3. Dog lead controller.

4. Emergency stop.

5. Remote control

6. Fast Track Console

3.0 TRACKING FAMILIARISATION

Remote Control Dog Lead Control

5

44

44

4

44

3

4

12

1

2

4

6


RK1012T ROTOCRUSHER

3.0 TRACKING FAMILIARISATION contd.

THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FORCONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READTHE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OFTHE SYSTEM.

IMPORTANT

WHEN TRACKING THE MACHINE

Please ensure the both levers inside the Fast Track Console are located in the TrackOperation position prior to starting the engine. This can be seen in the diagrambelow.


Both levers inTrack Position

WARNING>>>>> DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.>>>>> ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH

POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.>>>>> NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE

NEUTRAL(middle) POSITIONNEUTRAL(middle) POSITIONNEUTRAL(middle) POSITIONNEUTRAL(middle) POSITIONNEUTRAL(middle) POSITION


RK1012T ROTOCRUSHER


The following sections describe how to track your machine, read the completemanual before tracking. Check that there is a clear area around the machine andthat all control levers including clutch lever are in the neutral position.

a) Check that no emergency stops are in the on position, if an emer-gency stop is in the on position lamp A (green) will NOT beilluminated.

b) Turn the starter ignition key B to position no. 1 which is the onposition.

c) Turn the key to position no. 3 and hold, the start delay siren willsound for approximately 7 seconds then the engine will crank andstart.

d) Release the key when the engine has started.

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3.1 TRACKING THE MACHINE

IGNITION STARTER

Engine Control Panel


RK1012T ROTOCRUSHER


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 eachstarting attempt.

e. Set the engine revs to approximately 1000 r.p.m., this can be done byadjusting the throttle scroll button (Pushing button up increases enginerevs, Pushing button down decreases engine revs).

3.1 TRACKING THE MACHINE contd.

- revs

+ revs

Throttle Adjustment

Increase Revs

Decrease Revs

Revs Displayed on LCD


RK1012T ROTOCRUSHER


3.2 TRACKING THE MACHINE USING THE REMOTE CONTROL

Getting to know your remote control.

CCCCC AAAAA

DDDDD BBBBB

A RHS track forward.B RHS track reverseC LHS track forwardD LHS track reverseE Remote control activation & Tracks On/OffF Engine stop (only active when handset on)G Key SwitchH Feeder onI Feeder offJ Remote Control Lockout switch (Prevents remote from being used when

button is depressed.

SID

E X SID

E Y

SIDE X

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bbbbb

ccccc

ddddd

SIDE Y

EEEEE

fffff

ggggg

hhhhh

IIIII

JJJJJ


RK1012T ROTOCRUSHER

The following procedure is to be carried out to allow operator to track the machineusing the remote control.

a) Firstly ensure that the isolator switch location on the main enginecanopy is in the ON position as shown below.

b) Ensure that the track switch (A) on the main engine starter panel is inthe ON position and that the control switch (B) is in the REMOTEposition.


3.2 TRACKING THE MACHINE USING THE REMOTE CONTROL contd.

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c) Start the engine as per previous instructions (it is important thatinstruction a) is carried out before starting engine).

d) Press button E on the remote control the beacon and siren willautomatically sound and the track system will activate allowing theoperator to begin moving the machine.

BBBBB


RK1012T ROTOCRUSHER

e) To track press relevant buttons on the remote control (refer to section3.2 Getting to know your remote control), for safety reasons Tesabhave fitted a siren and orange beacon to make other persons in thevacinity aware that the machine is going to or is being moved and it isalways important for the operator to be aware of his surroundings.




RK1012T ROTOCRUSHER


3.3 TRACKING THE MACHINE USING THE DOG LEAD

Tesab have also supplied a dog lead controller as another way of tracking themachine

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

e) Ensure that the control switch (B) is in the DOG LEAD positionand the Track Switch on the main engine starter panel is in the ONposition prior to operating the dog lead.

continued over...

Track Switch

BBBBB


RK1012T ROTOCRUSHER


3.3 TRACKING THE MACHINE USING THE DOG LEAD contd.

f) Start the engine as per previous instructions (it is important thatinstruction a) is carried out before starting engine).

g) Note: for safety reasons there is an emergency stop button (F) fittedto the dog lead.

h) To track press relevant buttons on the dog lead control (as shownabove), for safety reasons Tesab have fitted a siren and orangebeacon to make other persons in the vacinity aware that themachine is going to or is being moved and it is always important forthe operator to be aware of his surroundings.

FFFFF

CCCCC AAAAA

DDDDD BBBBB

CCCCC AAAAA

DDDDD BBBBB

Important:Once machine has been trackedinto place remove dog lead andplace in secure premises. (Ideallyworks office or shovel cab)


RK1012T ROTOCRUSHER


IMPORTANT SAFETY NOTE

ENSURE ISOLENSURE ISOLENSURE ISOLENSURE ISOLENSURE ISOLAAAAATOR SWITCH ISTOR SWITCH ISTOR SWITCH ISTOR SWITCH ISTOR SWITCH ISIN IN IN IN IN OFFOFFOFFOFFOFF POSITION PRIOR TO POSITION PRIOR TO POSITION PRIOR TO POSITION PRIOR TO POSITION PRIOR TO

WELDING.WELDING.WELDING.WELDING.WELDING.

3.4 REMOTE CONTROL BATTERY CHARGING

Follow the procedure below to charge the battery for the remote control.

ChargerUnit

Battery

Green Indicator

1. Place battery intocharger unit.

2. Plug in charger unit andswitch on at mains.

3. The green indicator lightshows that the battery isbeing charged.

NOTE:

This charger requires a 3 pinEuropean to UK mains adaptor ifbeing used in the UK or Ireland.


RK1012T ROTOCRUSHER


Section 4SET-UP PROCEDURE


RK1012T ROTOCRUSHER

SET-UP PROCEDURE Section 4

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.





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


RK1012T ROTOCRUSHER










WARNING CONSULT MANUAL1. Read and understand the operators manual









RK1012T ROTOCRUSHER













ACID EXPLOSIVE

BATTERY



RK1012T ROTOCRUSHER


4.1 INSTALLATION

The following section will take you step by step through the installation of yourRK 1012T ROTOCRUSHER.

Note:Due to different transport and shipping regulations throughout the world the RK1012T Rotocrusher will be delivered in different packing arrangements. For thepurposes of this manual it will be considered that the machine is delivered in itsmost un-assembled configuration therefore some of the installation sectionsmay not be applicable. If this is the case ignore that particular instruction/sectionand proceed to next section.

Before installing the RK1012T ROTOCRUSHER ensure that you have read all sec-tions 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 mushbe carried out by reliable, authorised personnel only, statutory minimum age lim-its must be observed.

TESAB ENGINEERING Ltd. recommend that the installation of the RK1012TROTOCRUSHER is carried out by a recommended TESAB dealer and/or servicedepartment.


RK1012T ROTOCRUSHER


4.2 LOADING AND OFF LOADING

Loading and off loading the RK1012T should be carried out by trained and experi-enced personnel only. They should first read the operation manual paying particu-lar attention to the safety and installation sections.


RK1012T ROTOCRUSHER

4.3 STARTING THE ENGINE


IMPORTANT

PRIOR TO STARTING THE ENGINE

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

1. TRACK: When the machine has to be moved.2. CRUSH: When the machine is in its working position and ready to work.







RK1012T ROTOCRUSHER


4.3 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, forsafety reasons, that when these steps have been lowered that they are lockedinto position using clamps (C) at both sides. This is illustrated below.

CC

B


RK1012T ROTOCRUSHER


4.4 ENGINE STARTING PROCEDURE

Before staring the engine check diesel and engine oil levels.

a) 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.

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 forapproximately 7 seconds then the engine will crank and start.


Note: Do not activate the starter for more than 20 seconds at a time.You will protect the batteries if you wait one minute betweeneach starting attempt.

e) Set the engine revs to approximately 1000 r.p.m., this can bedone by adjusting the throttle scroll button (Pushing button up increasesengine revs, pushing button down decreses engine revs).


B

A

IGNITION STARTER

Throttlescrollbutton


RK1012T ROTOCRUSHER


4.4 ENGINE STARTING PROCEDURE contd.

IMPORTANT NOTE:

Before tracking we recommend that you fold up the engine area access steps inorder to prevent them from fouling unneccessarily.

WARNING

ENSURE MACHINE IS CLEAR OF ALL OVER HEAD CABLES


RK1012T ROTOCRUSHER



1. Familiarisation

The following terms/panel names have been used in this instruction leaflet, belowshows the names and there locations.

1. Main engine starter panel.

2. Remote control box.

3. Dog lead controller.

4. Emergency stop.

5. Remote control




5

44

44

4

44

3

4

12

1

2

4

6


RK1012T ROTOCRUSHER

4.5 TRACKING FAMILIARISATION contd.


IMPORTANT

WHEN TRACKING THE MACHINE

Please ensure the both levers inside the Fast Track Console are located in the TrackOperation position prior to starting the engine. This can be seen in the diagrambelow.







RK1012T ROTOCRUSHER

4.6 TRACKING THE MACHINE

The following sections describe how to track your machine read the completemanual.Before tracking check that there is a clear area around the machine and that allcontrol levers including clutch lever are in the neutral position.

1. How to start the engine (Main engine starter panel)

a) Check that no emergency stops are in the on position, if an emer-gency stop is in the on position lamp A (green) will NOT be illumi-nated.

b) Turn the starter ignition key C to position no. 1 which is the onposition.

c) Turn the key to position no. 3 and hold, the start delay siren willsound for approximately 7 seconds then the engine will crank andstart.



IGNITION STARTERTHROTTLESCROLLBUTTON

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RK1012T ROTOCRUSHER


Note: Do not activate the starter for more than 20 seconds at atime. You will protect the batteries if you wait one minute betweeneach starting attempt.

g. Set the engine revs to approximately 1000 r.p.m., this can bedone observing the digital tachometer D on the starter paneland adjustment of the throttle.

4.6 TRACKING THE MACHINE contd.

ThrotThrotThrotThrotThrottle Adjustmenttle Adjustmenttle Adjustmenttle Adjustmenttle Adjustment

Increase Revs

Decrease Revs



RK1012T ROTOCRUSHER


4.7 TRACKING THE MACHINE USING THE REMOTE CONTROL

Getting to know your remote control.

CCCCC AAAAA

DDDDD BBBBB

A RHS track forward.B RHS track reverseC LHS track forwardD LHS track reverseE Remote control activation & Tracks On/OffF Engine stop (only active when handset on)G Key SwitchH Feeder onI Feeder offJ Remote Control Lockout switch (Prevents remote from being used when

button is depressed.

SID

E X SID

E Y

SIDE X

aaaaa

bbbbb

ccccc

ddddd

SIDE Y

EEEEE

fffff

ggggg

hhhhh

IIIII

JJJJJ


RK1012T ROTOCRUSHER


The following procedure is to be carried out to allow operator to track the machineusing the remote control.

a) Firstly ensure that the isolator switch located on the main enginecanopy is in the ON position

b) Ensure that the track switch (A) on the main engine starter panel is inthe ON position and that the control switch (B) is in the REMOTEposition.


AAAAA

c) Start the engine as per previous instructions (it is important thatinstruction a) is carried out before starting engine).

d) Press button E on the remote control the beacon and siren willautomatically sound, the track system will activate allowing theoperator to begin moving the machine.

BBBBB


RK1012T ROTOCRUSHER



e) To track press relevant buttons on the remote control, for safetyreasons Tesab have fitted a siren and orange beacon to make otherpersons in the vacinity aware that the machine is going to or is beingmoved and it is always important for the operator to be aware of hissurroundings.


RK1012T ROTOCRUSHER


continued over...

4.8 TRACKING THE MACHINE USING THE DOG LEAD

Tesab have also supplied a dog lead controller as another way of tracking themachine

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

e) Ensure that the control switch (B) on the main engine starter panel isin the DOG LEAD position. Ensure that the Track Switch is in the onposition prior to operating the dog lead.

BBBBB

Track Switch


RK1012T ROTOCRUSHER


4.8 TRACKING THE MACHINE USING THE DOG LEAD contd.

g) Start the engine as per previous instructions (it is important thatinstruction a) is carried out before starting engine).

h) Note: for safety reasons there is an emergency stop button (F) fittedto the dog lead.

i) To track press relevant buttons on the dog lead control (as shownabove), for safety reasons Tesab have fitted a siren and orangebeacon to make other persons in the vacinity aware that themachine is going to or is being moved and it is always important forthe operator to be aware of his surroundings.

FFFFF

CCCCC AAAAA

DDDDD BBBBB

CCCCC AAAAA

DDDDD BBBBB

Important:Once machine has been trackedinto place remove dog lead andplace in secure premises. (Ideallyworks office or shovel cab)


RK1012T ROTOCRUSHER


IMPORTANT SAFETY NOTE

DISCONNECT BADISCONNECT BADISCONNECT BADISCONNECT BADISCONNECT BATTTTTTERYTERYTERYTERYTERYTERMINALS AND REMOTE UNITTERMINALS AND REMOTE UNITTERMINALS AND REMOTE UNITTERMINALS AND REMOTE UNITTERMINALS AND REMOTE UNIT

PRIOR TO WELDING.PRIOR TO WELDING.PRIOR TO WELDING.PRIOR TO WELDING.PRIOR TO WELDING.

4.9 REMOTE CONTROL BATTERY CHARGING

Follow the procedure below to charge the battery for the remote control.

ChargerUnit

Battery

Green Indicator

1. Place battery intocharger unit.

2. Plug in charger unit andswitch on at mains.

3. Battery is fully chargedwhen green indicator lightis on.

NOTE:

This charger requires a 3 pinEuropean to UK mains adaptor ifbeing used in the UK or Ireland.


RK1012T ROTOCRUSHER


4.10 POSITIONING

Before the RK 1012T Rotocrusher is positioned on site it is necessary to have alevel surface and spacious surroundings, if required level the work-site foundationusing 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 it is level both along the chassis and across the chassis.)

We recommend that when the machine is positioned correctly the dog lead andthe remote control are located in a safe place (i.e. works office or shovel cab).


RK1012T ROTOCRUSHER


4.11 PREPARING FOR INITIAL START-UP

i) Unfold the handrails into the working position and bolt to secure (sections 1 & 2first, then sections 3 & 4 and finally section 5). Ensure that the tab (6) is fittedbetween the inside handrail (2) and the crusher for extra stability.

ii) 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 as soonas possible.

iii) For safety reasons once the machine is in the correct working position switchthe tracks off. This disables the system and prevents the machine from movingif the remote or dog lead are touched accidentally. Move switch to off positionon control panel to disable tracks. See diagram over. It is also advisable toswitch the manual control valves to the CRUSH position in order prepare themachine for working. See diagram over.

Pre-Cleaner Exhaust

1 12 23 45

6


RK1012T ROTOCRUSHER


4.11 PREPARING FOR INITIAL START-UP contd.

TracksON/OFF Switch

Remove any parts, which have been packed on the catwalks and hopper. This is togive fully access to all control areas and reduces any fall hazards.

WARNING DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING. ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSHALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH

POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE.POSITION PRIOR TO STARTING ENGINE. NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THENEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE


Both Levers inCRUSH Position


RK1012T ROTOCRUSHER


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 en-trusted to experienced personnel only.

Connect the crane lifting chains to the dirt conveyor at the two pointsindicated A.

Take the weight of the top section to allow you to remove the transportbracket (remember to put the transport bracket in the toolbox).

Lower the dirt conveyor top section carefully and pin together at pointsindicated B.

Fit belt scrapper C.

AAAAAAAAAA

BBBBB

CCCCC


RK1012T ROTOCRUSHER


4.13 CRIB FOLDING & ASSEMBLY

NOTE:

Bolts and pins required to carry out this set-up procedure can be found in themachine toolbox.

i) Firstly check around the cribs area to ensure there are no obstructionsand that the hydraulic hoses are not fouling.

ii) Fold up side cribs approximately half way, one side at a time, using thehighlighted levers below.

iii) Fold up rear cribs approximately half way using the highlighted levershown over the page.

Cribs RHS

Cribs LHS


RK1012T ROTOCRUSHER


4.13 CRIB FOLDING & ASSEMBLY contd.

Cribs Rear

iv) At this stage carefully fold up each crib alternately until the three sides are upin position.

v) Using the M30x110 bolts and M30 nuts (found in the toolbox) bolt the cribs inposition.

M30x110 bolt(3 off each side)

M30 nut(3 off each side)


RK1012T ROTOCRUSHER


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 isdesigned to ensure that the material which passes this point is at the correctheight to enter the crusher. We highly recommend that this beam is fitted as itwill reduce any down-time due to crusher blockages.

The bolts for this can be found in the tool box. Ensure that the chains and shacklesare connected up appropriately.

Securing ChainsCross Tie & Pin

Crib Cross Tie

A


RK1012T ROTOCRUSHER


4.14 FEEDER BEACON

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

Feeder beacon location(remember to connect wiresusing 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 dustsuppression spray bar is packed separately.

Therefore the next stage of set-up is to fit this extension box as shown using lift pointsA and connecting up the spray bar pipe at point B.

A B

NOTE: Fitting the extension box will require the use of a crane.The fastening of loads and the instructing of crane operators should beentrusted to experienced personnel.


RK1012T ROTOCRUSHER


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. El-evate into the working position and bolt as shown.

Hoist in transportposition

Pivot hoistaround hinge

Bolt in placeusing the 4 bolts

IMPORTANT:

Tesab only recommend that this arm is used for changing items up to amaximum weight of one RK1012T Hammer (Part No 2-423-3) or 200kgs.


RK1012T ROTOCRUSHER


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 threeimpact 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.

A

Clockwise rotation toadjust apron fully open

IMPORTANT


RK1012T ROTOCRUSHER


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.

C

B

Clockwise rotation toadjust bar carrier forward

IMPORTANT

Anti-Clockwise rotation toadjust bar carrier

backwards.

IMPORTANT

Note: The setting is carried out atthe outer bolts of the yoke.The pre-tensionof thespring unit is factory set atthe inner bolts and shouldnot require any adjustment.


RK1012T ROTOCRUSHER



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 compressthe disc springs slightly (E).

- Remove the shims (F) and again using the control lever, carefully close therams 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 thatthere is enough clearance between the hammers and the blow bars. Thisis necessary as, due to wear, the size of the blow bars can change.

D

E F G


RK1012T ROTOCRUSHER



Middle apron manual adjustment

Adjust the middle apron by adjusting the outer nuts at points H until it is overlappingthe top of the bar carrier by a MINIMUM of 15mm (as shown). The middle apronshould be adjusted by APPROXIMATELY twice the distance (or less) that the barcarrier was adjusted. This distance can be checked by opening door B.

H

B

Note:The setting is carried out at the outer bolts of theyoke. The pretension of the spring unit is factoryset at the inner bolts and should not require anyadjustment.

Minimum15mm

Clockwise rotation toadjust apron forward

IMPORTANT

Anti-Clockwise rotation toadjust apron backwards.

IMPORTANT


RK1012T ROTOCRUSHER



Middle apron hydraulic adjustment

- Using the control lever (J), very carefully extend the rams just enough to compressthe disc springs slightly (E).

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

- Set the gap using the control lever. The gap can be checked through door B.

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 on the previous page.

- Once the gap is set, replace the shims (F & G) in the necessary order.

J

E F G


RK1012T ROTOCRUSHER



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 narrowgap.

(ii) Study the produced material and use that as a guide-line for yoursetting.

For additional advise on the settings on your RK 1012T Rotocrusher pleaseconsult TESAB ENGINEERING LTD. or your local authorised TESAB dealer


RK1012T ROTOCRUSHER


4.18 DUST SUPPRESSION

The RK1012T may be fitted with a completely self sufficient system which includesthe following.

i) Water Tank.

This tank should be topped up regularly to ensure an efficient dustsuppression system. The system is designed for approximately one fill ofwater to last one 10 hour shift depending on nozzle adjustment, etc.

ii) Manifold

This allows you to turn off and adjust spray bars independently, dependingon 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 themanifold is drained at the end of each working day, especially in coldconditions. This is to prevent freezing of water in the manifold and anysubsequent damage.

2) The water tank should be drained during extreme cold conditions in orderto prevent any unnecessary damage caused by expansion.

A

Water Tank


RK1012T ROTOCRUSHER


4.18 DUST SUPPRESSION contd.

iii) Spray Bar Location

1. Feed into crusher2. Feed out of crusher

iv) Start / Stop

v) Water Filtration

The tank has been fitted with a basicwater filter that should be changedregularily and as when necessarydepending on the quality of the waterput into the tank.

Water Filter

1

2

Button to start/stopdust suppression


RK1012T ROTOCRUSHER


Section 5OPERATION


RK1012T ROTOCRUSHER

OPERATION Section 5

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.





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


RK1012T ROTOCRUSHER

OPERATION Section 5









WARNING CONSULT MANUAL1. Read and understand the operators manual









RK1012T ROTOCRUSHER

OPERATION Section 5













ACID EXPLOSIVE

BATTERY


RK1012T ROTOCRUSHER

OPERATION Section 5

WARNING When carrying out maintenance, repairsor adjustment to the TESAB RK 1012TROTOCRUSHER the following lockoutprocedure must be followed.

1. Deactivate all controls, switch off engine and remove key.2. Activate, or, if fitted, lock one emergency stop button.3. Relieve all pressures in the hydraulic system.

IMPORTANT: THE PERSON CARRYING OUT THE WORK ON THEMACHINE MUST KEEP THE KEYS WITH THEM AT ALLTIMES.

Engine Access Catwalk

ENSURE ISOLATOR SWITCH IS IN THE OFF POSITIONPRIOR TO WELDING.

5.1 LOCKOUT PROCEDURE

IMPORTANT SAFETY NOTICE

ISOLATOR IN ON POSITIONISOLATOR IN OFF POSITION

ENGINE CANOPY


RK1012T ROTOCRUSHER

OPERATION Section 5

5.2 GENERAL INFORMATION

Please Note:

All crushing applications differ due to material composition and customerrequirements.

There are numerous adjustments that can be made in order to achieverequired results.

Therefore we recommend that you contact Tesab Engineering LTD oryour local Tesab dealer to advise you on the best customized Tesabarrangement to suit your particular application.

For the purposes of this section we assume engine speed requirementsof 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 acquaintyourself fully with the detailed operation of the feeder.


RK1012T ROTOCRUSHER

OPERATION Section 5


Familiarisation

The following terms/panel names have been used in this instruction leaflet, belowshows the names and their locations.

1. Main engine starter panel

2. Remote control box

3. Dog lead controller

4. Emergency stop

5. Remote control




4

4

4

4

44

44

4

1&26 3 1&2


RK1012T ROTOCRUSHER

OPERATION Section 5

Your TESAB RK1012T feeder has been supplied with the following features, thefollowing section gives a brief description and how they work.

- You can operate the machine manually (as per standard RK1012T), thiscan be done by positioning the Feeder operation button (on the Mainengine starter panel) in the manual position. This allows you to start andstop the feeder from the platform at the feeder control console (A).

(important note: there is no speed sensor facility when operating themachine in this way)

- You can operate the machine by remote control, this can be done by posi-tioning the Feeder operation button (on the Main engine starter panel) inthe Auto position, This allows you to operate the feeder using your Re-mote 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 speedand re-starts the feeder again when rotor regains the pre-set speed. Thespeed sensor facility over-rides the remote control stop and start(important note: when using this form of control ensure that the lever atthe feeder control console is in the on position)

How to use your remote control:

1. Press the start stop button2. Press feeder on/off as required

Note: A blue beacon has been fitted to the machine this notifies theoperator that the feeder is currently off.

MANUALMANUALMANUALMANUALMANUAL AAAAAUTOUTOUTOUTOUTO

11111

5.5 FEEDER INSTRUCTIONS contd.

22222


RK1012T ROTOCRUSHER

OPERATION Section 5

5.6 ENGINE STARTING PROCEDURE

Before staring the engine check diesel and engine oil levels.

a) 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.

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 forapproximately 7 seconds then the engine will crank and start.


Note: Do not activate the starter for more than 20 seconds at a time.You will protect the batteries if you wait one minute betweeneach starting attempt.

B

A

Throttle scroll button

Engine control panel


RK1012T ROTOCRUSHER

OPERATION Section 5

5.7 SETTING ENGINE REVS

Set the engine revs to approximately 1000 rpm. This can be done by observing thedigital tachometer on the starter panel and adjusting the throttle scroll button (push-ing 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

* 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*


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 throughthe engine parameters in the order listed below. The abbreviation for the parameterwill be displayed. When the scroll switch is released, EMS will display the currentreal 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


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 momentarilyto allow engine torque/speed to recover.

Repeat this procedure two or three times and then engage clutch completely byforcing lever to the fully over-centre position.

Operator experience often dictates the number of bumps required.

IMPORTANT: Read Section 6.4 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 in order to achievepro-longed clutch life.

bump-inclutch Engage Clutch

gradually


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 dig-ital tachometer on the starter panel and adjusting the throttle scroll button.

- Start the hydraulic clutch by pressing the ON button on the starter panel asshown below.

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

IMPORTANT: Read Section 6.5 on hydraulic clutch maintenance.

Throttle Adjustment

Increase Revs

Decrease Revs


Clutch start button


RK1012T ROTOCRUSHER

OPERATION Section 5

5.10 PRODUCT CONVEYOR STARTING

Increase engine speed to 2000 rpm. This can be done observing the digital tachom-eter on the starter panel and adjustment of the throttle.

Start the product conveyor by engaging the appropriate control lever.

Product ConveyorControl Lever

Magnet / Dirt ConveyorControl Lever

Throttle Adjustment

Increase Revs

Decrease Revs



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 carryout the following procedure:

i) The conveyor can be TENSIONED correctly at the top end drum using theadjuster bars as shown.

Note: The conveyor belt tension is factory set but you will find due to run-ning it over time or climatic conditions the belt will stretch and require re-tensioning.

Important: DO NOT over tension the belt as this will cause excessive strain on thebearings and drive system.

ii) In order to track the belt correctly you must adjust the return rollers as shown.

For further details on thetracking of conveyor

belt section 6.23.

Product ConveyorAdjuster bars

NOTE:Slacken off Bolts Aprior to Tensioning Belt

A


RK1012T ROTOCRUSHER

OPERATION Section 5

5.11 DIRT CONVEYOR STARTING

Note: The dirt conveyor and magnet run through the one hydraulic circuit, there-fore one single lever activation will start both conveyors.

Start the dirt conveyor by engaging the appropriate lever highlighted.

In order to track this belt correctly please carry out the following procedure:

The belt can be adjusted by adjusting the drums at points A.

Note: The conveyor belt can be tracked by slackening as well as tensioningthe adjusters.

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 6.23.

Dirt ConveyorControl Lever

A

Initiallythe conveyor belt is tracked when run-ning empty. The conveyor may need to be re-tracked when under load.


RK1012T ROTOCRUSHER

OPERATION Section 5

5.12 FEEDER STARTING

Start the feeder by engaging the appropriate control lever.

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 andfinished product required.

This is why we would recommend running feeder slowly initially and increase thespeed in order to avoid blockages.

If you are having difficulty in obtaining the required product please contactyour local Tesab dealer and he will assist on calibrating your machine.

Feeder Control Lever

+-

Feeder Speed Control


RK1012T ROTOCRUSHER

OPERATION Section 5

5.13 MACHINE SHUT-DOWN SEQUENCE

The following procedure should be followed when shutting the machine down at theend of each shift.

It is important to ensure that you allow the machine to run empty at the end of theshift before closing machine down, including hopper and feeder. By not allowingthis to happen will put unnecessary pressure on the feeder bearings, springs andhydraulic 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


Section 6MAINTENANCE


RK1012T ROTOCRUSHER

MAINTENANCE Section 6

6.0 The RK1012 ROTOCRUSHER UNIT

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 BEEN RE-MOVED.

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 SHIVER MAYHIT YOUR EYES).

IMPORTANT

Crusher Opening

Crusher opening lever Crusher opening pin

Remove Bolts18 off

IMPORTANTEnsure all bolts are re-fitted after closing


RK1012T ROTOCRUSHER


6.1 REPLACING OR TURNING THE HAMMERS1. Open the setting (gap)

of the crusher to a maximum.

2. Rotate the rotor so that onehammer appears straight up(see picture No. 1). Insert alocating bar or similar throughthe rotor.

The Rotor is now secured.

3. Clean away the stone powderand such around the hammer.

4. Take away the securingbrackets (A) at both sides ofthe hammer.

5. The turned or new hammer ispushed into position.

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

7. Repeat from Item 2 until allhammers are replaced.

8. Close and lock all doors.

9. Start the crusher.

NOTE: Should any abnormal sound beheard, a thumping or knock, stop thecrusher immediately and check if anyof the hammers are positioned too farto one side, so it touches the sideplates.

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

If everything is OK, make the final gapsettings, close and lock all doors. ALLSET FOR CRUSHING.

AAAAA

Picture No. 1

Picture No. 2


RK1012T ROTOCRUSHER


6.2 SETTING THE CRUSHER GAPManual Setting of the Crusher

Gap

NOTE: The setting must not bealtered while crusher is in operation.

1. Open the door B by thebarcarrier and measure thesetting at the lower impactbar C (see Picture 4).The measure of the settingdepends on:

- The size of the feedmaterial

- Cubing or crushing- Desired quantiti

Documents

Tesab_1012T_OperationManual_Issue4