Tesab 1412T Operation Manual UK

RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Operation Manual
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1412T ROTOCRUSHER
CONTENTS
March 2005 Issue
TABLE OF CONTENTS
SECTION 1:
1.0
1.1
1.2
1.3
1.4
1.5
EU directive
Declaration of conformity
Machine specification details
Foreword/reservation of rights
Familiarisation
General specification
SECTION 2:
2.0
2.1
2.2
2.3
2.4
SAFETY
Safety introduction
Safety
Position of emergency stops
Emergency situation
Lockout procedure
SECTION 3:
3.0
3.1
3.2
INTRODUCTION
TRACKING INSTRUCTIONS
Tracking familiarisation
Starting the engine
Tracking using the dog lead
RK1412T ROTOCRUSHER
CONTENTS
March 2005 Issue
TABLE OF CONTENTS
SECTION 4:
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Set-up procedure safety

Installation
Loading & off-loading
Prior to starting the engine
Engine starting procedure
Tracking familiarisation
Tracking the machine using the dog lead
Positioning
Preparing for initial start-up
Product conveyor unfolding
Hopper extensions
Feed-in chute
Hoist
Crusher settings
Dust suppression
SECTION 5:
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
SET-UP PROCEDURE
OPERATION
Operation safety
Lockout procedure
General information
Pre-operation check list
Engine starting procedure
Setting engine revs
ESM main unit
Engaging clutch
Product conveyor starting
Feed conveyor starting
Machine start-up sequence
Machine shut-down sequence
RK1412T ROTOCRUSHER
CONTENTS
March 2005 Issue
TABLE OF CONTENTS
SECTION 6:
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
MAINTENANCE
General information
Safety information
Opening the RK1412T rotocrusher unit
Replacing or turning the hammers
Setting the crusher gap
Replacing or turning of impact bars
Manual clutch
Hydraulic clutch
Hydraulic system
Tracks
Hydraulic fluids
Oil tank, pipes & fittings
Diesel engine
Feed conveyor & product conveyor reduction gears
Bearings & lubrication
General inspection
Routine maintenance schedule
Daily maintenance
Weekly maintenance
Six monthly maintenance
Belt tracking
V-belt tensioning
Recommended lubricants
Automatic greasing system
Autolube maintenance
Autolube troubleshooting
Recommended fluids
Fault finding
RK1412T ROTOCRUSHER
CONTENTS
March 2005 Issue
TABLE OF CONTENTS
SECTION 7:
7.0
7.1
7.2
Preparing for transport safety

Lockout procedure
Preparing for transport
SECTION 8:
8.0
PREPARING FOR TRANSPORT
WARRANTY
Warranty
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 1
INTRODUCTION
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 SERVICE YOUR MACHINE CORRECTLY.
FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT

DAMAGE.
REMEMBER:
GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS IN INCREASED PRODUCTION AND EXTENDED PLANT LIFE!
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.1
1.1 DECLARATION OF CONFORMITY

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

7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Machine description:
Mobile Crushing Plant
Model:
RK1412T ROTOCRUSHER
Serial No:
This machinery has been designed and manufactured in accordance with all the
relevant ESRs of the EU Machinery Directive.
A technical construction file for this machinery is retained at the following address:
Tesab Engineering Ltd.
7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Signed:
Name:
Brian A. Mills
Position:
Project Manager
Date:
Being the nominated representative of TESAB ENGINEERING LTD.
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.2
1.2 MACHINE SPECIFICATION DETAILS
MACHINE SERIAL NUMBER:
ENGINE TYPE:
ENGINE SERIAL NUMBER:
CLUTCH TYPE:
CLUTCH SERIAL NUMBER:
DISPATCH DATE:
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.3
1.3 FOREWORD/RESERVATION OF RIGHTS
The TESAB RK1412T ROTOCRUSHER is a robust skilfully engineered piece of

equipment incorporating diesel, hydraulic and mechanical components of the highest quality.
In the interest of continuous plant reliability, it is essential that the machine is

maintained with meticulous care and attention. This operation and maintenance
manual has been produced to assist the user to obtain the maximum output from
the machine and to trace and remedy faults, should they arise. Failure to do so
could result in personal injury or equipment damage. We recommend that the
user should pay particular attention to the maintenance and safety sections of this
manual.
Consider this manual a permanent part of your machine. Keep a copy of this
manual at the operational site.
This operation and maintenance manual must not be copied, reproduced or

loaned to a third party without written consent of TESAB ENGINEERING
LTD.
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.4
1.4 FAMILIARISATION
The following conventions have been used throughout this operation and maintenance 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
RIGHT
LEFT
FRONT
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.4
1.4 FAMILIARISATION cont.
1.
Hopper
2.
Feed Conveyor
3.
Crusher Unit
4.
Tracks
5.
Chassis
6.
Drive System
7.
Product Conveyor
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.5
1.5 GENERAL SPECIFICATION
Chassis
The chassis is constructed of heavy-duty profiles and welded steel plates ribbed
and stiffened to withstand all operational and travelling stresses. The chassis is
mounted on 3.75m (12-4") centre heavy-duty tracks, with dog lead operational
facility.
Belt Feeder
The belt feeder into the crusher is fitted with a 1200mm wide heavy duty 4 ply belt
which runs on full length 4 roll impact roller sets. The conveyor is driven through
a flexible coupling and high torque reduction gear at the rubber lagged top end
drum. The heavy duty hopper mounted on top of the conveyor is fully lined with
10mm wear plates and is ribbed and stiffened to withstand impact from the feed
source. Full length replaceable 15mm skirting is fitted to the hopper to prevent
any spillage and smooth material flow. The feed-in canopy is fully lined and can
be easily accessed through a hinged hood were any essential maintenance can
be carried out.
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.5
1.5 GENERAL SPECIFICATION cont.

Crusher unit
The RK1412 crusher unit is fitted with four hammers, 1000mm (39.375") wide. It
has 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 adjusted
from 4 to 80mm (3/16" to 3") depending on material feed size and reduction required. Both the apron and the bar carrier are hydraulically adjustable as standard. It is driven through 8 V-Belts and the chamber can be easily accessed by
hydraulic control lever. There is a deadbox fitted under the crusher to allow easy
flow of material onto the product conveyor.
Product Conveyor
The product conveyor is fitted with a 1000mm (40") heavy duty 4 ply belt and runs
on heavy duty troughing rollers, impact bars are fitted under the crusher to give
the belt full support at the crusher exit. The conveyor is driven hydraulically through
a flexible coupling and high torque reduction gear at the rubber lagged top end
drum.
Power Unit
The engine is an electronic Caterpillar C9 (300HP at 1800rpm) Power Pack and
the crusher is driven through a heavy duty Twin Disc IBF 314 (3 plate) PTO. The
pulley on the clutch can be easily changed to alter the rotor speed or if finer tuning
is required the engine speed can vary between 1700 and 2200rpm. The tracks,
conveyors and rams are all driven hydraulically through pumps fitted to the engines auxiliary drives.
Catwalks and Guards
All relevant catwalks, handrails and guards are fitted to this machine allowing
access to all relevant maintenance points. Emergency stops are fitted to all necessary points. The machine carries the European CE mark and therefore complies with all Essential Safety Requirements.
Hydraulic Tank Capacity
500 litres (110 gallons 132 US gallons)
RK1412T ROTOCRUSHER
INTRODUCTION
Section 1.5
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
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 2
SAFETY
RK1412T ROTOCRUSHER
SAFETY
Section 2.0
2.0 SAFETY INTRODUCTION

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

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

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

working machinery.
Switch off and lockout machine before
attempting maintenance on the machine.
Always use a suitable lifting platform before
attempting maintenance above 2m (6-6).
RK1412T ROTOCRUSHER
SAFETY
WARNING
Section 2.0
CRUSH HAZARD
1.
2.
3.
WARNING
Crush Hazard. Beware of dangerous hand

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

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

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

adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
Keep ignition key on person during
maintenance.
Never work alone.
RK1412T ROTOCRUSHER
SAFETY
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
Fall rock hazard. Do not walk near material

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

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

pressure hydraulic oil can penetrate the
skin causing serious injuries.
Always relieve pressure from the hydraulic
system before attempting maintenance.
If oil is injected under the skin, it must be
surgically removed or gangrene will result.
HOT SURFACE
1.
ACID
Section 2.0
Battery Hazard. Battery electrolyte contains

acid and can cause serious injury. Avoid
any contact.
Batteries give off flammable fumes which
can explode. Avoid the formation of sparks
and naked lights in the vicinity of the
batteries. Do not smoke when working in
this area.
RK1412T ROTOCRUSHER
SAFETY
Section 2.1
2.1 SAFETY
Operators should be trained in the
correct and safe use of all equipment including the studying of this
manual, failure to do so could result in serious injury.
Any work on and with the machine
must be executed by reliable, trained
and authorised personnel only. Statutory minimum age limits must be observed.
Work on the electrical system and
equipment of the machine must be
carried out only by a skilled electrician or by instructed persons under
the supervision and guidance of a
skilled electrician and in accordance with electrical engineering
rules and regulations.
Work on the hydraulic system must be
carried out by personnel with special
knowledge and experience of hydraulic equipment.
There are several specific signs on
your machine. Please take time to
familiarise yourself with the safety
signs and the operation and maintenance manual.
See to it that safety instructions and
warnings attached to the machine are
always complete and completely legible.
Replace unreadable or missing labels

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

clean and dry.
Keep warning and instruction labels

clean.
RK1412T ROTOCRUSHER
SAFETY
Section 2.1
2.1 SAFETY cont.

Never lubricate, clean, service or
adjust machine while it is moving.
Keep hands, feet and clothing clear
of power driven parts and nippoints. Disengage all power and
operate controls to relieve pressure.
Stop the engine. Implement lockout procedure. Allow machine to
cool.
Take the necessary precautions to

ensure that the machine is used
only when in a safe and reliable
state.
Keep all parts in good condition and

properly installed. Fix any damage immediately and replace any broken
parts with genuine TESAB parts. Remove any built up of grease, oil or debris.
Do not attempt repairs or adjustments to the machine while it is running.
For the execution of maintenance

work, tools and workshop equipment adapted to the task on hand
are absolutely indispensable.
Isolate all electrical supplies before
carrying out repairs or maintenance,
and should only be carried out by qualified personnel.
Stay clear of all rotating and moving parts. Do not attempt to clear
obstructions or debris by hand before isolating the equipment by implementing the lockout procedure.
In running nip points can cause serious injury even death. Do not reach
into an unguarded machine.
In the event of malfunctions or operational difficulty stop the machine immediately and lockout. Have any defects rectified immediately.
Relieve all pressure in hydraulic systems before any lines, fittings or related
items are disconnected or removed.
Hydraulic lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings
lengths and quality of the hoses
must comply with the technical requirements.
Always practice extreme cleanliness
when servicing hydraulic components.
Hydraulic fluid under pressure is
very dangerous, it can penetrate the
skin causing serious injury.
If fluid is injected under the skin it must
be surgically removed immediately.
Switch off engine and lockout machine before opening or removing

guards or doors.
RK1412T ROTOCRUSHER
SAFETY
Section 2.1
2.1 SAFETY cont.

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

which can explode. Ensure that
there is proper ventilation. Avoid
the formation of sparks and naked
lights in the vicinity of the batteries.
Do not smoke when working in this
area.
Fires may result from lubricating oil or
fuel spraying on hot surfaces.
Avoid smoking whilst refuelling or
in the refuelling area.
Do not climb on conveyor belts or stand
on components that cannot support
your weight, always use ladders, steps
and walkways when mounting and dismounting machine.
Only use emergency stop buttons
in an emergency situation or during
safety checks.
Do not use fingers to check hole alignments as this can cause serious injury.
Do not stand beneath equipment as
it is being raised or lowered into position.
Never check the tension of V-belts
whilst machine is running.
Whenever maintenance and servicing is being carried out a minimum
of two persons must be present at
all times.
RK1412T ROTOCRUSHER
SAFETY
Section 2.1
2.1 SAFETY cont.

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

down for maintenance or repair work,
it must be secured against inadvertent starting by implementing the lockout procedure (see lockout section for
details).
Never allow anyone to remove large
or heavy components without adequate lifting tackle.
To avoid the risk of accidents, individual parts and large assemblies being removed for replacement purposes
should be carefully attached to the lifting tackle and secured.
The fastening of loads and the instructing of crane operators should
be entrusted to experienced personnel only.
Any safety devices removed for setup,
maintenance or repair must be fitted
and checked immediately upon completion of the work.
Before activating the machine in any
manner, or energising the electrical
and/or hydraulic controls, make certain that no person or obstruction
is standing in or in the immediate
vicinity of the machine.
RK1412T ROTOCRUSHER
SAFETY
Section 2.1
2.1 SAFETY cont.

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

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

ground, down a drain or into any
water source.
Ensure that all consumables and replaced parts are disposed of correctly
and with the minimum environmental
impact.
RK1412T ROTOCRUSHER
SAFETY
Section 2.2
1 & 2.
LHS & RHS
5.
DOG LEAD
3 & 4.
LHS & RHS
2.2 POSITION OF EMERGENCY STOPS
RK1412T ROTOCRUSHER
SAFETY
2.3
Section 2.3
EMERGENCY SITUATION
IMPORTANT:
In the case of an incident of any part failure on the machine the

following 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 completely stopped revolving (approximately 120 seconds), should an attempt
be 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/refitted
correctly.
Release all emergency stops.
Restart the machine (see section 4.4)
RK1412T ROTOCRUSHER
SAFETY
2.4
Section 2.4
LOCKOUT PROCEDURE
WARNING
When carrying out maintenance, repairs or adjustment to the TESAB RK1412T
ROTOCRUSHER the following lockout procedure MUST be followed.
Deactivate all controls, switch off engine and remove key.

Activate, or, if fitted, lock one emergency stop button.
Relieve all pressures in the hydraulic system.
IMPORTANT:
The person carrying out the work on the machine must keep the
keys with them at all times.
Ensure the isolator switch is in the OFF position prior to welding.
Isolator in OFF position Isolator in ON position
Engine canopy
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 3
RK1412T ROTOCRUSHER
Section 3.0
3.0 TRACKING FAMILIARISATION

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOUR
TESAB RK1412T ROTOCRUSHER.
DAMAGE.
1.
Main engine starter panel
2.
Dog lead controller
3.
Emergency stop
4.
Fast track console
RK1412T ROTOCRUSHER
3.0
Section 3.0
TRACKING FAMILIARISATION cont.
THIS RK1412T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR

CONTROLLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE
READ THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF THE SYSTEM.
When tracking the machine please ensure the both levers inside the fast track
console are located in the TRACK position prior to starting the engine (see picture
below).
Both levers in
TRACK position
WARNING
Do not activate levers while engine is running
Always ensure both valves are in the TRACK or CRUSH position prior to
starting the engine
Never operate the machine with either valve in the neutral (vertical)
position
RK1412T ROTOCRUSHER
3.1
Section 3.1
STARTING THE ENGINE
NOTE:
Check that there is a clear area around the machine and that all control
levers including the clutch lever are in the neutral position.
Engine control panel
Position 1
A
Position 3
Check that no emergency stops are in the on position, if an emergency

stop is in the on position lamp A (green) will NOT be illuminated.
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 for
approximately 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 starting attempt.
RK1412T ROTOCRUSHER
3.1
Section 3.1
STARTING THE ENGINE cont.

Set the engine revs to approximately 1200rpm. This can be done by adjusting
the throttle scroll button (pushing button up increases engine revs, pushing
button down decreases engine revs).
- revs
+ revs
Increase revs
Decrease revs
Revs displayed on LCD
RK1412T ROTOCRUSHER
3.2
Section 3.2
TRACKING THE MACHINE USING THE DOG LEAD
The following procedure is to be carried out to allow the operator to track the
machine using the dog lead.
Ensure that the control switch (E) is in the DOG LEAD position and the Track
Switch on the main engine starter panel is in the ON position prior to
operating the dog lead.
Track switch
Start the engine as per previous instructions (it is important that the emergency stop status is checked before starting the engine).
NOTE:
For safety reasons there is an emergency stop button (F) fitted to the
dog lead.
RK1412T ROTOCRUSHER
3.2
Section 3.2
TRACKING THE MACHINE USING THE DOG LEAD cont.
IMPORTANT:
Once the machine has been tracked into position, remove the
dog lead and place in a secure place (ideally the works office or
shovel cab)
To track the machine, move the relevant toggle buttons on the dog lead
control (as shown above). For safety reasons Tesab have fitted a siren and
orange beacon to make other persons in the vicinity aware that the machine
is going to be, or is being, moved. It is always important for the operator to
be aware of his surroundings.
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 4
SET-UP PROCEDURE
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.0
4.0 SET-UP PROCEDURE SAFETY

DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

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

unguarded machine.
FALL HAZARD
1.
2.
3.

working machinery.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
Section 4.0
CRUSH HAZARD
1.
2.
3.
WARNING

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

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

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING

injury or death.
BATTERY HAZARD
1.
2.
BATTERY

HEAD PROTECTION
1.
EXPLOSIVE

HOT SURFACE
1.
ACID
Section 4.0

any contact.
this area.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.1
Section 4.1
INSTALLATION
The following section will take you step by step through the installation of your
RK1412T ROTOCRUSHER.
NOTE:
Due to different transport and shipping regulations throughout the world

the RK1412T ROTOCRUSHER will be delivered in different packing
arrangements. For the purposes of this manual it will be considered
that the machine is delivered in its most unassembled configuration
therefore some of the installation sections may not be applicable. If
this is the case ignore that particular instruction/section and proceed to
next section.
Before installing the RK1412T ROTOCRUSHER ensure that you have read all
sections of this manual in order to familiarise yourself with the machine and its
function, paying particular attention to SECTION 2: SAFETY.
Installation, operation, and maintenance of the RK1412T ROTOCRUSHER must
be carried out by reliable, authorised personnel only, statutory minimum age limits
must be observed.
TESAB ENGINEERING LTD. recommend that the installation of the RK1412T
ROTOCRUSHER is carried out by a recommended TESAB dealer and/or service
department.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.2
Section 4.2
LOADING AND OFF LOADING
Loading and off loading the RK1412T should be carried out by trained and experienced personnel only. They should first read the operation manual paying particular attention to the safety and installation sections.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 4.3
PRIOR TO STARTING THE ENGINE

Before starting the engine please ensure that the two diverter valves shown in the
picture 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
Both levers in
TRACK position
WARNING
starting the engine
position
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 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, for
safety reasons, that when these steps have been unfolded they are locked into
position using the clamps at both sides (move bolt from point B to point C). This
is illustrated below.
C
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4.4
ENGINE STARTING PROCEDURE
NOTE:
Before starting the engine check diesel and engine oil levels.

Throttle scroll
button
Position 1
Position 3
Check that no emergency stops are in the on position, if an emergency stop

is in the on position lamp A (green) will NOT be illuminated.
Turn the starter ignition key C to position 1 which is the ON position.
NOTE:

Set the engine revs to approximately 1200 rpm. This can be done by adjusting the throttle scroll button (pushing button up increases engine revs,
pushing button down decreases engine revs).
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4.4
ENGINE STARTING PROCEDURE cont.
IMPORTANT:
Before tracking we recommend that you fold up the engine area

access steps in order to prevent them from fouling unneccessarily.
WARNING
ENSURE MACHINE IS CLEAR OF ALL OVER HEAD CABLES
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.5
4.5 TRACKING FAMILIARISATION

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOUR
TESAB RK1412T ROTOCRUSHER.
DAMAGE.
1.
Main engine starter panel
2.
Dog lead controller
3.
Emergency stop
4.
Fast track console
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.5
Section 4.5
TRACKING FAMILIARISATION cont.

When tracking the machine please ensure the both levers inside the fast track
console are located in the TRACK position prior to starting the engine (see picture
below).
Both levers in
TRACK position
WARNING
starting the engine
position
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.6
Section 4.6
TRACKING THE MACHINE USING THE DOG LEAD
The following procedure is to be carried out to allow the operator to track the
machine using the dog lead.
Ensure that the control switch (E) is in the DOG LEAD position and the Track
Switch on the main engine starter panel is in the ON position prior to
operating the dog lead.
Track switch
Start the engine as per previous instructions (it is important that the emergency stop status is checked before starting the engine).
NOTE:
For safety reasons there is an emergency stop button (F) fitted to the
dog lead.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
4.6
Section 4.6
TRACKING THE MACHINE USING THE DOG LEAD cont.
IMPORTANT:
Once the machine has been tracked into position, remove the
dog lead and place in a secure place (ideally the works office or
shovel cab)
To track the machine, move the relevant toggle buttons on the dog lead
control (as shown above). For safety reasons Tesab have fitted a siren and
orange beacon to make other persons in the vicinity aware that the machine
is going to be, or is being, moved. It is always important for the operator to
be aware of his surroundings.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.7
4.7 POSITIONING
Before the RK1412T ROTOCRUSHER is positioned on site it is necessary to
have a level surface and spacious surroundings, if required level the work-site
foundation using a loading shovel.
The machine must be placed on solid ground capable of carrying its weight.
Track the machine into the desired position and ensure the machine is level. This
can be done with the aid of a spirit level (ensure that it is level both along the
chassis and across the chassis).
We recommend that when the machine is positioned correctly the dog lead and
the remote control (if fitted) are located in a safe place (ideally in the works office
or shovel cab).
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.8
4.8 PREPARING FOR INITIAL START-UP
If required, fit the pre-cleaner and exhaust. We would recommend that if the
machine has to be tracked for a long distance that you fit these items as
soon as possible.
Pre-cleaner
Exhaust
For safety reasons, once the machine is in the correct working position switch
the tracks off. This disables the system and prevents the machine from
moving if the dog lead is touched accidentally. Move switch to OFF position
on control panel to disable tracks (see picture below). It is also advisable
to switch the manual control valves to the CRUSH position in order to prepare
the machine for working (see below).
Both levers
in CRUSH
position
Tracks ON/OFF switch
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.8
4.8 PREPARING FOR INITIAL START-UP cont.
WARNING
starting the engine
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 is
to give full access to all control areas and reduces any fall hazards.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.9
4.9 PRODUCT CONVEYOR UNFOLDING
Set the engine revs to approximately 1200* rpm. This can be done by adjusting the throttle scroll button (pushing button up increases engine revs,
- revs
+ revs
Increase revs
Decrease revs
Fold the conveyor up more to relieve the weight from the transport bracket
using the lever as shown below.
Product conveyor
folding lever
* NOTE: If having difficulty unfolding the conveyor, increase the engine revs to
achieve the desired hydraulic pressure.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.9
4.9 PRODUCT CONVEYOR UNFOLDING cont.
Unhook the transport bracket, hinge it around and hook it on to the side of
the 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.
B
Transport
bracket
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
Section 4.10
4.10 HOPPER EXTENSIONS

IMPORTANT:
Assembling the hopper extension unit will require the use of a

crane. The fastening of loads and the instruction of crane operators should be entrusted to experienced personnel only.
Remove the crossmember (A).

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 (one
at a time) into the working position and bolt to secure.
Lower the rear section into place and bolt to both the hopper and the side
extensions to secure.
Add the extension crossmember at point B below.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.11
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 is
sometimes packed separately.
To fit the extension box, lower into position using lift point A and fasten using the 6
I-bolts.
NOTE:
Fitting the extension box will require the use of a crane. The fastening
of loads and the instructing of crane operators should be entrusted to
experienced personnel.
A
I-bolts
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.12
4.12 HOIST
Tesab have supplied a swinging arm for use when changing hammers, etc. For
transport purposes it is folded down. To elevate the hoist, follow the steps below.
Bolt in place
using the 4 bolts
Hoist in transport
position
Pivot hoist
around hinge
IMPORTANT:
Tesab recommend that this arm is only used for changing items
up to a maximum weight of one RK1412T Hammer (Part No. 2423-3) or 200kgs.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.13
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 two
impact 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 (grinding
list) and the hammer.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.13
4.13 CRUSHER SETTINGS cont.

The gap is set as follows:
Using the control lever (B), very carefully extend the rams just enough to
compress the disc springs slightly (C).
Remove the shims (D) and again using the control lever, carefully close the
rams to allow the removal of the remaining shims (E).
Set the gap using the control lever. The gap can be checked through door
A.
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 that
there is enough clearance between the hammers and the blow bars.
This is necessary as, due to wear, the size of the blow bars can change.
D
B
C
E
4.13.2
Middle apron adjustment
Using the control lever (F), very carefully extend the rams just enough to
compress the disc springs slightly (C).
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.13
D
F
C
E
A.
NOTE:
The middle apron should be adjusted by APPROXIMATELY twice the

distance (or less) that the bar carrier was adjusted. The middle apron
should overlap the top of the bar carrier by a MINIMUM of 15mm as
shown.
15mm
minimum
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.13

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 please

consult TESAB ENGINEERING LTD. or your local authorised TESAB dealer.
RK1412T ROTOCRUSHER
SET-UP PROCEDURE
Section 4.14
4.14 DUST SUPPRESSION

The RK1412T crusher unit is fitted with a dust suppression system. It is the
responsibility of the customer to supply the system with clean water (see below).
Water supply
connected here
Shut-off valve
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 5
OPERATION
RK1412T ROTOCRUSHER
OPERATION
Section 5.0
5.0 OPERATION SAFETY

DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

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

unguarded machine.
FALL HAZARD
1.
2.
3.

working machinery.
RK1412T ROTOCRUSHER
OPERATION
WARNING
Section 5.0
CRUSH HAZARD
1.
2.
3.
WARNING

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

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

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
RK1412T ROTOCRUSHER
OPERATION
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING

injury or death.
BATTERY HAZARD
1.
2.
BATTERY

HEAD PROTECTION
1.
EXPLOSIVE

HOT SURFACE
1.
ACID
Section 5.0

any contact.
this area.
RK1412T ROTOCRUSHER
OPERATION
5.1
Section 5.1
LOCKOUT PROCEDURE
WARNING

IMPORTANT:
Engine canopy
RK1412T ROTOCRUSHER
OPERATION
Section 5.2
5.2 GENERAL INFORMATION

All crushing applications differ due to material composition and customer requirements.
There are numerous adjustments that can be made in order to achieve required
results.
Therefore we recommend that you contact TESAB ENGINEERING LTD. or your
local Tesab dealer to advise you on the best customized Tesab arrangement to
suit your particular application.
RK1412T ROTOCRUSHER
OPERATION
Section 5.3
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 starting
the engine
RK1412T ROTOCRUSHER
OPERATION
5.4
Section 5.4
ENGINE STARTING PROCEDURE
NOTE:
Before starting the engine check diesel and engine oil levels.

Throttle scroll
button
Position 1
Position 3
Check that no emergency stops are in the on position, if an emergency stop

is in the on position lamp A (green) will NOT be illuminated.
Turn the starter ignition key C to position 1 which is the ON position.
NOTE:

RK1412T ROTOCRUSHER
OPERATION
5.5
Section 5.5
SETTING ENGINE REVS

Set the engine revs to approximately 1100 rpm. This can be done by
adjusting the throttle scroll button (pushing button up increases engine revs,
- revs
+ revs
Increase revs
Decrease revs
RK1412T ROTOCRUSHER
OPERATION
Section 5.6
5.6 ESM MAIN UNIT

5.6.1
Diagnostic Display
High Inlet Manifold

Temperature*
High Engine Coolant
Temperature*
Low Battery
Voltage*
High Fuel
Temperature*
High Auxiliary
Temperature*
High Auxiliary
Pressure*
Engine Derate
Low Engine Oil
Pressure*
Low Fuel
Pressure*
* IMPORTANT:
Low Engine
Coolant Level*
LCD Digital
Display
May also indicate sensor fault.
RK1412T ROTOCRUSHER
OPERATION
Section 5.6
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 through
the engine parameters in the order listed below. The abbreviation for the parameter will be displayed. When the scroll switch is released, EMS will display the
current real time value for that parameter.
Abbreviation
Spd
GA-1
GA-2
GA-3
GA-4
Boost
IAirT
FuelT
AccrP
AccrT
Fuel
Hrs
Load
Parameter
Engine Speed
Engine Oil Pressure
Coolant Temperature
Battery Voltage
Fuel Pressure (Customer Installed Sensor)
Boost Pressure
Inlet Air Temperature
Fuel Temperature
Auxiliary Pressure
Auxiliary Temperature
Fuel Rate
Engine Hours
Engine (%) Load
RK1412T ROTOCRUSHER
OPERATION
Section 5.7
5.7 ENGAGING THE CLUTCH

5.7.1
Manual clutch
Start the crusher by bumping-in the clutch. Bumping-in involves several partial
engagements with the hand lever.
Engage the clutch gradually until the engine labours heavily, disengage the
clutch momentarily to allow engine torque/speed to recover.
Repeat this procedure two or three times and then engage the clutch
completely by forcing the lever to the fully over-centre position.
Operator experience often dictates the number of bumps required.
bump-in
clutch
IMPORTANT:
Engage Clutch
gradually
Read section 6.6 on manual clutch maintenance this states that

the clutch, initially when new, will require several adjustments (it
will also require further adjustments during clutch life).
It is important that this procedure is adhered to in order to achieve
prolonged clutch life.
RK1412T ROTOCRUSHER
OPERATION
Section 5.7
5.7 ENGAGING THE CLUTCH cont.

5.7.2
Hydraulic clutch
Increase the engine revs to 1300rpm. This is done by adjusting the throttle
scroll button.
- revs
+ revs
Increase revs
Decrease revs
Start the hydraulic clutch by pressing the clutch START button on the starter
panel as shown below.
Clutch START button
RK1412T ROTOCRUSHER
OPERATION
Section 5.7
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
OPERATION
Section 5.8
5.8 PRODUCT CONVEYOR STARTING
Increase the engine revs to the desired crushing engine speed (1800-2200
rpm depending on the application). This is done by adjusting the throttle
scroll button.
- revs
+ revs
Increase revs
Decrease revs
Start the product conveyor by pressing the product conveyor START button
on the starter panel as shown below.
Product conveyor
START button
NOTE:
Initially the product conveyor belt is tracked when running empty. The
belt may require re-adjustment when loaded.
RK1412T ROTOCRUSHER
OPERATION
Section 5.8
5.8 PRODUCT CONVEYOR STARTING cont.

In order to correctly track the product conveyor belt please carry out the following
procedure:
The belt can be TENSIONED correctly at the top end drum using the adjuster
bars 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 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 the bearings and drive system.
Adjuster bar
In order to track the belt correctly the return rollers must be adjusted as
shown below. For further details on the tracking of the conveyor belt see
section 6.20.
RK1412T ROTOCRUSHER
OPERATION
Section 5.9
5.9 FEED CONVEYOR STARTING

NOTE:
Ensure that the product conveyor is started before starting the feed
conveyor.
Start the feed conveyor by pressing the feed conveyor START button on the
starter panel as shown below.
Feed conveyor
START button
NOTE:
Initially the feed conveyor belt is tracked when running empty. The belt
may require re-adjustment when loaded.
The feed conveyor belt can be correctly tracked by adjusting the drum as shown
below.
Adjuster bar
RK1412T ROTOCRUSHER
OPERATION
Section 5.9
5.9 FEED CONVEYOR STARTING cont.

NOTE:
The belt can be tracked by slackening as well as tensioning the adjusters.
IMPORTANT:
DO NOT over tension the belt as this will cause excessive strain
on the bearings and drive system.
For further details on the tracking of conveyor belts see section 6.20.
RK1412T ROTOCRUSHER
OPERATION
Section 5.10
5.10 MACHINE START-UP SEQUENCE
Start engine
Set revs to engage clutch (1100rpm for manual clutch, 1300rpm for hydraulic
clutch)
Engage clutch
Increase revs to desired crushing speed
Start product conveyor
Start feed conveyor
Ready to crush!
RK1412T ROTOCRUSHER
OPERATION
Section 5.11
5.11 MACHINE SHUT-DOWN SEQUENCE

The following procedure should be followed when shutting the machine down at
the end of a shift.
IMPORTANT:
Ensure that you allow the machine to run empty at the endof
the shift before closing the machine down. Not allowing this to
happen 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
March 2005 Issue
RK1412T ROTOCRUSHER
Section 6
MAINTENANCE
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.0
6.0 GENERAL INFORMATION

This section provides detailed maintenance instructions as well as a maintenance
schedule for normal operating conditions.
NOTE:
Diesel engine maintenance and service required or the frequency
thereof
is outside the scope of this manual. All matters relating to
this should
be referred to the makers publication Operation and
Maintenance
Manual, a copy of which is included with this manual.
When performing maintenance on your machine please adhere to the safety information listed in the safety section.
WARNING
Implement LOCKOUT procedure
before carrying out maintenance
to your RK1412T ROTOCRUSHER
It is important to note that high repair costs and lengthy downtime will occur if
inadequate or improper maintenance is performed on your machine. Regular
maintenance is imperative.
The reliability and service life of your RK1412T unit depends on the regular and
correct maintenance of the machine.
Good housekeeping pays untold dividends in increased production and extended
plant life!
IMPORTANT:
If the RK1412T is operated for long periods of time in extreme

conditions either climatic (-15C to 33C) or very dusty, the maintenance schedule will change. If this scenario arises please consult your local Tesab dealer or Tesab Engineering technical/service department.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.1
6.1 SAFETY INFORMATION
DANGER
NIP HAZARD
1.
2.
3.

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

FALL HAZARD
DANGER
1.
2.
3.
WARNING

working machinery.
PROTECTION
1.
2.
3.

running machinery.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.2
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).
I-Bolts
Using the control lever (shown below) open the crusher until the holes in
brackets A and B line up and insert the crusher opening pin (this can be
found mounted on the crusher beside the hydraulic adjustment mechanism).
A
Crusher opening lever
Insert pin
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.2
6.2 OPENING THE RK1412T ROTOCRUSHER UNIT cont.
IMPORTANT:
Ensure all bolts are re-fastened

after closing
WARNING
DO NOT OPEN ANY DOOR OF THE CRUSHER UNTIL THE ROTOR HAS
STOPPED COMPLETELY AND THE CONTROL POWER HAS BEEN BROKEN,
OR, IN THE CASE OF A DIESEL POWERED CRUSHER, THE CLUTCH IS DISENGAGED, THE ENGINE HAS STOPPED AND THE IGNITION KEY HAS BEEN
REMOVED.
NEVER START THE CRUSHER UNTIL ALL DOORS ARE CLOSED AND LOCKED.
WHEN REMOVING HAMMERS AND IMPACT BARS, ALWAYS USE PROTECTIVE
GOGGLES (YOU CAN ACCIDENTALLY HIT ASKEW AND A METAL SHARD MAY
HIT YOUR EYES)
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.3
6.3 REPLACING OR TURNING THE HAMMERS
Picture 6.3.1
Open the setting (gap) of the

crusher to a maximum.
Rotate the rotor so that one

hammer appears straight up
(see picture 6.3.1). Insert a
locating bar or similar through
the rotor. The rotor is now
secured.
Clean away the stone powder

and such from around the
hammer.
Take away the securing brackets (A) at both sides of the

hammer.
The turned or new hammer is

pushed into position.
Secure the hammer with

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

hammers are replaced.
Close and lock all doors.
Start the crusher.
Picture 6.3.2
NOTE:
Should any abnormal sound be heard (a thumping or knock), stop the

crusher immediately and check if any of the hammers are positioned
too far to one side, so it touches the side plates.
After the necessary measures have been taken, start the crusher again
and run it empty for approximately 5 minutes.
If everything is OK, make the final gap settings, close and lock all doors.
ALL SET FOR CRUSHING.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.4
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 lower
impact 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 fractions produced.
Minimum
15mm
Picture 6.4.1
Picture 6.4.2
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.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.4
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 the
rams just enough to compress the disc springs slightly (picture 6.4.4, item
C).
Middle apron
adjustment
Picture 6.4.3
Bar carrier
adjustment
Picture 6.4.4
A.
NOTE:
The middle apron should be adjusted by APPROXIMATELY twice the

distance (or less) that the bar carrier was adjusted. The middle apron
should overlap the top of the bar carrier by a MINIMUM of 15mm as
shown in picture 6.4.2.
NOTE:
Once the bar carrier gap has been set, rotate the rotor to ensure that
there is enough clearance between the hammers and the blow bars.
This is necessary as, due to wear, the size of the blow bars can change.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.5
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 impact

bars (C) laterally
using an iron bar or
similar.
Clean the sockets

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

close and lock the
doors. CRUSH!
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.6
6.6 MANUAL CLUTCH

The Manual Power Take Off (or Clutch) in conjunction with your diesel engine is
the central part of your RK1412T ROTOCRUSHER. A lot of care and thought has
gone into its selection.
Correct maintenance of your PTO will increase its effectiveness and prolong its
life-span.
The following sections are a short simple outline of duties that the owner and
operator must perform for satisfactory service from his TWIN DISC POWER TAKE
OFF.
PTO
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.6
6.6 MANUAL CLUTCH cont.

6.6.1
Clutch Adjustment
New manual power take offs should have clutch adjustment checked before being placed in service. A newly placed in service power take off should have its
clutch adjustment checked again after the first 10 hours of operation. New clutch
plates have a wear-in period and the clutch may require several adjustments
until the new plates are worn-in. After wear in, clutch adjustments should be
checked regularly. As this is classed as a heavy duty application which has frequent engagements and relatively long periods of slip when bumping-in it will
require more frequent attention in relation to readjustment.
The clutch requires adjustment when:
The clutch is easy to engage to its fully over-centre position
The lever jumps out during operation
The clutch heats up excessively
To adjust the clutch:
Lockout the engine by removing the key from the ignition.
Remove the hand hole plate (1) in the housing and turn the clutch until the
locking pin (2) can be reached (see picture 6.6.1.1).
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 operating
lever 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 required

each time, any more than this would indicate that the clutch is not adjusted regularly.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.6
Picture 6.6.1.1
NOTE:
The majority of clutch failures are not caused by a unit being under
sized for the application. Failures often are the result of the clutch not
being properly adjusted. Check and adjust the clutch on a regular
basis, to the correct engaging effort as specified on the instruction cover
plate.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.6

6.6.2
Clutch Lubrication
Throwout Collar:
Apply a small amount of lubricant once a day, before

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

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

the fittings highlighted below, please note that there
are grease nipples on both left and right hand side.
6.6.3
Lubricant Specification
Use any high grade, high temperature, lithium based gun lubricant. For further
details see recommended lubricant section in this manual.
NOTE:
Although this section details the greasing points on the clutch, it is important to note that if the machine is fitted with the Autolube system,
these points are supplied with grease by it. See the Autolube section
for further details.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.7
6.7 HYDRAULIC CLUTCH

The Hydraulic Power Take Off (or Clutch) in conjunction with your diesel engine is
the central part of your RK1412T ROTOCRUSHER. A lot of care and thought has
gone into its selection.
Correct maintenance of your PTO will increase its effectiveness and prolong its
life-span.
Following is a short simple outline of duties that the owner and operator must
perform for satisfactory service from his TRANSFLUID POWER TAKE OFF.
6.7.1
Clutch Maintenance
Change the oil after the first 100 working hours, and every 4000 working
hours thereafter. The correct oil level is the blue line on the oil level indicators.
After replacing the oil, run the pump with the electric valve OFF to fully fill the
heat exchanger. Re-check the oil level again once this has been done and
top-up if necessary.
Recommended oils are as follows:

AGIP
ARAL
BP
CASTROL
CHEVRON
ESSO
MOBIL
SHELL
TEXACO
TOTAL
OSO 32
VITAM GF 32
ENERGOL HLP 32
HYSPIN AWS 32
RPM EP HYDRAULIC 32
NUTO H 32
DTE 24
TELLUS 32
RANDO HD 32
AZOLLA ZS 32
Change the oil filter cartridge (25 micron) when the pressure is 1.7 bar over
the rated value and/or the pressure switch is on.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.7
6.7 HYDRAULIC CLUTCH cont.
In cases where there is considerable oil leakage the rotating seals should be
changed (see picture 6.7.1.1).
Keep the oil cooler clean. The radiator pack can be cleaned by either washing
carefully by hand or by using air pressure.
IMPORTANT:
Never use water pressure as this can damage the aluminium pack.
Check periodically (approximately every 1000 hours) that the pump chain is
the correct length (see table below). The chain can be stretched by hanging
a 20 kg weight from it.
KPTO
15
17-19
21-24
27
Max. Length (mm)

1265
1362
1556
1914
Periodically check the condition of the elastic coupling.
Pressure gauge
switch
Elastic coupling
(not shown)
Rotating seal
(not shown)
Rotating seal
(not shown)
Oil filter
Solenoid valve
Oil level
indicator
Picture 6.7.1.1
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS
Each Track Frame Assembly fitted to the TESAB RK1412T ROTOCRUSHER is
comprised 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 is
distributed along the length of the frames.
The DRIVE ASSEMBLY is a planetary gearbox, mounted at the rear of the

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

frame. The entire weight of the machine is carried on these rollers.
The FRONT IDLER is mounted at the opposite end of the frame to the sprocket, the idler slides on guides. The track is adjusted by a hydraulic cylinder
attached to the idler arrangement. Between the idler, and the track adjusting
cylinder is a recoil spring, which will allow the idler to movebackwards in
the event that excessive load is placed on the track.
The TRACK ASSEMBLY comprises of sectional chain with triple bar grouser
shoes bolted to it.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS cont.

TO ENSURE TROUBLE FREE TRACK OPERATION, IT IS IMPORTANT THAT
THE FOLLOWING MAINTENANCE OPERATIONS ARE ADHERED TO.
6.9.1 Track Adjustment
Check if the track is correctly adjusted. As the track wears it will become slack
and should be checked regularly.
To establish if the track requires adjustment move the machine backwards and
forwards a few metres on level ground and in a straight line (do not slew). This
enables the track to adopt its natural degree of tension.
Measure the droop as shown on figure 6.9.1.1. This measurement should

not exceed 30mm (1.25).
30mm approx.
Equal
Equal
Figure 6.9.1.1
Inspection
Cover
The adjustment of the track is accessed via the inspection cover on the side of the
track frame as shown in figure 6.9.1.1. Remove the cover using a 6mm allen key.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
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 standard

grease gun, filled with the correct grease, pump the track out to the
correct adjustment.
M1442 adapter
IMPORTANT:
Do not tension the track too tightly as this places unacceptable

loads on the gearbox bearings and idler bearings. It will lead to
accelerated wear and premature failures.
To release the track tension:
Slacken the grease fitting on the end of the hydraulic track tensioning
cylinder, by one half turn only, using a 22mm spanner.
WARNING
Grease under extreme pressure is released by this action. Personal injury could
result if the fitting is removed whilst under pressure.
When the track droop appears to be correct, move the machine backwards
and forwards and re-check the droop.
Add more grease if required. Replace the inspection cover when the correct
adjustment has been made.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS cont.

6.9.2 Gearbox Oil Level
Cleanliness is absolutely essential as gearbox life will be dramatically reduced if
dirt 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 for
correct grade of oil).
To drain the gearbox:
Move the machine until the filler plugs are in the position as shown in figure
6.9.2.1.
Draining
Figure 6.9.2.1
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 oil
is hot.
IMPORTANT:
Do not move the machine (except to reposition the plug holes for
refilling) without oil in the gearboxes.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS cont.

To refill the gearbox:
Ensure machine is on level ground and track until the filler plugs are in the
correct position (see figure 6.9.2.2).
Filling
Level
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 the
level.
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 operation, 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 of
use or at least once per year.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS cont.

6.9.3 Leakage
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 the
machine is used.
6.9.4 Bottom Rollers and Idlers

These components are lubricated at the time of manufacture and are termed lubricated for life.
No servicing is therefore required.
If however an oil leak is detected on any of these components, an exchange unit
should be fitted before using machine again.
NOTE:
Removal of the filler plug invalidates the warranty.
6.9.5 Loose Bolts

It is the responsibility of the operator to check the machine on a daily basis for any
loose bolts, or signs of undue wear.
In the event that any bolts are found to be loose, they should be re-tightened to
the following torque:
Bottom Roller Bolts
Sprocket Mounting Bolts
Gearbox Mounting Bolts
Motion Valve
Track Shoes
350 ft lbs.
350 ft lbs.
350 ft lbs.
33 ft lbs.
120 ft lbs. plus 1/3 turn
It is the operators responsibility to ensure that the machine is properly maintained

and does not pose a safety hazard to himself or others.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.9
6.9 TRACKS cont.

6.9.6 Track 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 EP2
ALL PURPOSE GREASE should be used.
All leading lubricating oil suppliers offer equivalents.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.10
6.10 HYDRAULIC FLUIDS

Hydraulic fluids play a most important part in any hydraulic system. They have
three main functions:
To transmit power
To lubricate moving parts
To seal clearances between parts
As a power transmitting medium the fluid must flow easily and be as incompressible as possible. In most hydraulic components, internal lubrication is provided by
fluid only. For long component life, fluids are available containing additives which
have high anti-water properties. The fluids are known as anti-wear type hydraulic
oils, which are recommended for your RK 1412T ROTOCRUSHER. In most cases
the fluid is the oil seal present. For example there are no sealing rings between
the spool and the body of the directional valve. As the sealing characteristics of
the fluid depends on its retaining viscosity, it is important that the oil selected is
capable of maintaining the minimum viscosity change over a wide range of operating temperatures.
Some adverse effects of incorrect viscosity are:
High oil temperatures

Entrapment of air in oil
Increased pressure drop
Excessive wear or even seizure under heavy load
Poor pump/system performance
In addition to qualities outlined earlier the selected fluid should also:
Prevent rot
Depress foaming
Prevent formation of sludge, gum and varnish
Retain its own stability, thereby reducing fluid replacement
Prevent corrosion and pitting
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.10
6.10 HYDRAULIC FLUIDS cont.

For best operating results it is strongly recommended that the hydraulic fluid used
is selected from the recommended range listed in section 6.26.
In the service it is recommended that the hydraulic system is drained and refilled
at least once every 1500 hours of operation. The hydraulic fluid should be changed
after the machine has stopped work.
The drain plug for the hydraulic system is mounted on the side of the tank.
In the event of pump or motor failure, both suction and return line filter elements
must be changed.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.11
6.11 OIL TANK, PIPES & FITTINGS

In order to prevent contamination, the oil tank on the RK1412T ROTOCRUSHER
is of sealed construction. Access to the tank, if required, is via an inspection
cover which is mounted on top of the tank. The tank must be thoroughly cleaned
before the removal of this cover.
It is very important that the hydraulic pipes and hoses are checked regularly for
leaks, scuffing and wear. Loose fittings should be securely tightened. Worn or
leaking hosing should be replaced. Replacement hoses are available on request.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.12
6.12 DIESEL ENGINE

The diesel engine is the heart of your RK1412T ROTOCRUSHER and a great
deal of care and thought has gone into its selection. All engines are put through
rigorous test programmes by the manufacturers before reaching us, to be assembled into the RK1412T.
On completion machines are again run and tested for several hours before dispatch. This is to guarantee the dependability of TESAB equipment.
In the interest of continued peak performance from your RK1412T
ROTOCRUSHER the engine must be maintained and cared for with meticulous
attention in accordance with the manufacturers instructions as detailed in the Operation and Maintenance Manual a copy of which is included with this manual.
IMPORTANT:
The engine water trap (A) must be drained every day (as per
sticker) and replaced every engine service.
Sticker
A
Sediment bowl
Tap
6.12.1
Draining the water trap
The water trap should be drained by opening the tap on the bottom of the sediment bowl and allowing all the water to drain out. When diesel is flowing out,
close the tap.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.13
6.13 FEED CONVEYOR & PRODUCT CONVEYOR REDUCTION GEARS

Maintenance can be routine or unscheduled.
IMPORTANT:
6.13.1
All maintenance activities must be carried out under safety conditions.
Routine Maintenance
The operator is responsible for routine maintenance and must carry out the following activities.
After a brief operating period of about 100 hours (breaking-in), change the
oil in the gear unit (Grade EP150 or equivalent).
Check that there are no foreign metallic parts in the magnetic plug of the
gear unit.
Change the oil in the gear unit while it is hot so that it is easier to drain
(taking precautions to avoid burns).
Subsequent oil changes should be made every 200-250 hours at operation,

or, in any case, every year.
Do not mix different types of oil.
Periodically check the level (about once a month) and top up if necessary.
IMPORTANT:
When checking the oil levels in gear unit, if the levels have risen
this means that oil is penetrating from the rotary seal. Contact
the local Brevini Service Dealer.
It is recommended that you keep a chart for your reduction gear to record details
of maintenance performed.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.13
6.13 FEED CONVEYOR & PRODUCT CONVEYOR REDUCTION GEARS cont.

6.13.2
Oil Change
To drain the oil from the reduction gear, unscrew the drain plug and the filler
plug. Once the oil has been emptied, replace the plugs.
Wash the interior of the gear unit with a suitable cleaning liquid that is recommended by the lubricant manufacturer. Put the liquid into the gear unit
and run it at high speed for few minutes, then remove the cleaning liquid
from the unit and fill with appropriate gear oil.
The Brevini recommended method of filling the reduction gear is as follows:
Unscrew the filler and oil level plugs.
Pour oil into the filler port and when it starts to flow out of the oil level port,
stop filling and replace the plugs. The approximate volumes required are:
Feed conveyor reduction gear (11.2:1)
Product conveyor reduction gear (6.3:1)
2.0 litres
1.25 litres
Run the gear unit for a few minutes to eliminate any air pockets and then
check the level.
Drain plug
Oil level
plug
Breather & filler plug
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.13
6.13 FEED CONVEYOR & PRODUCT CONVEYOR REDUCTION GEARS cont.

6.13.3
Unscheduled Maintenance
Brevini Riduttori prohibits the gear unit to be opened to carry out any operation
that is not included in routine maintenance procedures. Brevini Riduttori do not
undertake any liability for all those operations out of routine maintenance which
may have caused damages to people or things. When the need arises, contact
the nearest Brevini Service Centre.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.14
6.14 BEARINGS AND LUBRICATION
The bearings of the crusher are spherical roller bearings with labyrinth
packings.
The bearings are to be lubricated once a week at single shifts.
Force feed the grease until it is forced out into the labyrinths, so as to press out
any impurities.
Use only lithium based grease (i.e. SKF LGEP 2)
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.15
6.15 GENERAL INSPECTION

Check all abrasion of hammers, blow bars and wear plates regularly. Adjustments of the bar carrier may be necessary.
Careful inspection of all wearing components is essential as excessive wear will
cause damage to the crusher chamber.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.16
6.16 ROUTINE MAINTENANCE SCHEDULE

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

section is only applicable for machines that do not incorporate the
Autolube system. If your machine uses the Autolube system please
ignore this section.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.8
6.8 HYDRAULIC SYSTEM

The hydraulic system which is used in the RK1412T ROTOCRUSHER was chosen for its effectiveness and resistance to climatic and operating conditions. This
must be topped up with the correct hydraulic fluid and regular checks must be
made to ensure this. The system should be checked for leaks and drained every
1500 hours.
6.8.1
Filtration
In order to maintain the hydraulic oil at its peak performance, two high pressure
filters are used in the system of the RK1412T ROTOCRUSHER. These are coupled with 2 strainer valves fitted inside the tank.
Regular monitoring of gauges on the filters is essential. The filter element requires changing when the indicator is in the red at operating temperature.
High pressure filters
DANGER
HIGH PRESSURE
The filter element

needs to be changed
when the indicator
turns red
High Pressure Filters - 2 x High pressure filters are fitted to

the main pressure lines between the pump and manual spool
valves, and they are used to prevent any tiny particles contaminating the system which could cause damage to the pumps or
motors. The filter elements should be checked regularly and
changed in accordance with the routine maintenance schedule.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.17
6.17 DAILY MAINTENANCE

The purpose of daily maintenance is to discover minor irregularities in your machine before they develop into major problems.
Check the machine for loose parts, check that all bolts and nuts are secure
Check the hydraulic oil level in the tank and top up if necessary
Ensure that all safety systems are intact (ie. all the wires to sensors are
intact)
Check that fuel oil level in the tank and the supply line to the engine
Check all the hydraulic motors, pumps, cylinders and hoses for oil leaks and
tighten if necessary. When tightening the hydraulic fittings always use two
spanners, one for holding, one for tightening
Ensure that all the troughing and return rollers are free running and clear of
obstructions
Check for material build up
Check conveyor belts for alignment and adjust them if necessary
Check air filter for clogging
Visually inspect the conveyor belting for tears etc.
Grease clutch (manual clutch only - see section 6.6)
Drain the water trap on the engine
When all checks have been made, close and fasten all the guards before operating the machine. At the end of the day carefully clean the machine and the ground
immediately around the machine, of all the material and debris build up.
Good housekeeping pays untold dividends in increased production and extended
plant life.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.18
6.18 WEEKLY MAINTENANCE (50 hours)

In addition to the daily programme:
Grease feed and product conveyor bearings using the correct lubricant
Grease crusher bearings using the correct lubricant
Check all skirting rubbers (i.e. that they bear down lightly on the conveyor
belt)
Check the acid level in the batteries and top up with distilled water if necessary
Check the gauges on the hydraulic filters
Adjust belt scrapper blades, renew if necessary
Check clutch setting and adjust if necessary
Check quality and tension of crusher V belts
Check rubbers on machine, renew if necessary
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.19
6.19 SIX MONTHLY MAINTENANCE
Drain and refill hydraulic system with the correct hydraulic fluid. Refer to the
recommended lubricants for the correct hydraulic oils to suit various ambient
temperature conditions.
Drain and reduction gears with the correct gear oil. Refer to the recommended
lubricants section.
Check the alignment of the plant with a precision spirit level.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.20
6.20 BELT TRACKING

6.20.1
Belt Tension
The belts on your RK1412T ROTOCRUSHER will normally have to be tensioned

a number of times during the machines lifetime due to the natural stretching of the
belt. It is very important the belts are tensioned evenly to the correct level, not too
tight and not too loose, ensuring efficient belt running and skirting alignment. A
loose belt can cause slippage and reduced throughput, an over tight belt can
reduce drum and bearing life.
6.20.2
Trouble Tracing
Oblique travel may cause a fast deterioration, although the belts on the RK1412T
ROTOCRUSHER is of the highest quality. In order to assist we have compiled
some of the reasons for oblique travel with appropriate correction action.
REASONS FOR
OBLIQUE TRAVEL
Insufficient aligning of
drums and idlers
REMEDIES
EXAMPLES OF OBLIQUE TRAVEL
Align non-drive drum, carrying idlers, and

return idlers at right angles to the travelling direction of the belt.
Check that all drums and idlers are level
to each other
If a & b are as above then perform the
following.
Adjustment is made as indicated on Figs
6.21.2.1,2&3 by turning non-drive drum
and carrying idlers in direction of arrow
until the belt is running straight and centred on the conveyor.
Also return idlers may cause oblique belt
travel and therefore they must be aligned
at right angles to the travelling direction
of the belt and after that adjustment can
be made.
Misalignment of
frame
Oblique travel can be reduced by turning forward outer carrying idlers 1-3 degrees in travelling direction of the belt.
See Fig 6.21.2.4. If this does not correct
the oblique travel then align the frame.
Material build up on
drums and idlers
Clean idlers and drums. Check belt

cleaners and replace if necessary. Possibly change to more efficient type.
Fig 6.21.2.1: Turning carrying idlers
Fig 6.21.2.2: Turn Drum
Fig 6.21.2.3: Turn both Drum and carrying

idlers
Fig 6.21.2.4: Turning forward carrying idlers
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.21
6.21 V-BELT TENSIONING

6.21.1
Crusher V-Belts
The RK1412 ROTOCRUSHER is driven through eight SPC V-belts.

The belts can be tensioned as follows:
Loosen bolts at the four points highlighted below.
2 bolts either side

of engine stand
Adjust engine stand using the adjusters (2 off) as highlighted.
Adjuster
IMPORTANT:
Do not over-tighten V belts as this will cause excessive pressure

on the clutch bearings leading to premature clutch failure.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.21
6.21 V-BELT TENSIONING cont.

6.21.2
One shot tensioning
Put the belts around the pulleys and set them to the appropriate tension
value as stated in the tension forces table below (using the belt tension
indicator as shown).
Run the drive under load for 30 minutes.
Stop the drive, check the tension and reset to the catalogue value if necessary.
On a proper designed drive for the application there will be no need for further
attention during the life of the drive.
The setting tensions below are designed to cover a wide range of drives. A precise setting force for individual applications can be calculated. Please consult
Fenner Technical Services.
Belt tension indicator
applied to mid-centre
distance
CE
NT
RE
DI
ST
AN
CE
16
pe mm
r 1 de
m fle
of ctio
sp
an n
Belt
Section
SPB
SPC
Force required to deflect belt 16mm

per metre of span
Small Pulley
Diameter (mm)
80 to 132
140 to 200
112 to 224
236 to 315
Newtons (N)
25 to 35
35 to 45
45 to 65
65 to 85
Kg - Force (kg.f)
2.5
3.6
4.6
6.6
to
to
to
to
3.6
4.6
6.6
8.7
For short centre distance drives where the deflection of the belt is too small to
measure accurately, it is recommended that both deflection and applied force be
doubled.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.21

6.21.3
Method of Belt Tensioning using Fenner Belt Tension Indicator
Calculate the deflection in mm on a basis of 16mm per metre of centre

distance:
Centre distance (m) x 16 = deflection (mm)
Set the lower marker ring at the deflection distance required in mm on the
lower scale.
Set the upper marker ring against the bottom edge of the top tube.
Place the belt tension indicator on top of the belt at the centre of span,
and
apply a force at right angles to the belt deflecting it to the point where
the
lower marker ring is level with the top of the adjacent belt.
Read off the force indicated by the top edge of the upper marker ring.
Compare this force to the kg.f value shown in the table on the previous page.
If a Fenner Belt Tension Indicator is not available, a spring balance and rule will
suffice.
With branded belts use a bar across the band width to ensure even distribution of
the force measured by the number of belts in the band for comparison with the
values in the table.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.21

NOTE:
For single belt drives a straight edge should be placed across the two
pulleys to act as a datum for measuring the amount of deflection.
If the measured force falls within the values given, the drive should be satisfactory. A new drive should be tensioned to the higher value to allow for the normal
drop in tension during the run in period.
After the drive has been running for 30 minutes, the tension should be checked
and readjusted to the higher value, if necessary.
6.21.4
Trouble Shooting
Small cracks on V-belt side and base:
Generally caused by shortage of belt tension but excessive heat and/or chemical
fumes can also give same failure.
V-belt swelling or softening:
Caused by excessive contamination by oil, certain cutting fluids or rubber

solvent.
Whipping during running:
Usually caused by incorrect tensioning, principally on long centre drives. If a slightly

higher (or lower) tension does not cure the problem there amy be a critical vibration
frequency in the system which requires redesign or a banded belt. Consult Fenner
Technical Services.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.22
6.22 RECOMMENDED LUBRICANTS

Below are listed the recommended alternatives suitable for use with your RK1412T
ROTOCRUSHER.
The special greases are Class 2 lithium based greases with extreme pressure
additives.
They work within special conditions up to 120C.
SPECIAL SCREEN
GREASE
BP
Energrease LS-EP2
Total
Multis EP2
Duckhams
Adamax LEP2
Castrol
Spheerol EPL2
Shell
Alvania EP2
Esso
Becon EP2
Texaco
Multifak EP2
Chevron
Duralith EP2
Gulf
Gulfcrown EP2
Mobile
Modilux EP2
Century
Regulus A2EP
F.A.G.
Arcanol L135
Rocol
Sapphire
Optimol
Longtime PD
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.22
6.22 RECOMMENDED LUBRICANTS cont.

1
6-8
2
Pos.
No. of
Locations
Description
Frequency
(Hours)
Qty
Product Conveyor TED* Bearings
50 (weekly)
4g
Product Conveyor BED* Bearings
50 (weekly)
4g
Crusher Rotor Bearings
50 (weekly)
8g
Feed Conveyor TED* Bearings
50 (weekly)
4g
Feed Conveyor BED* Bearings
50 (weekly)
4g
Clutch Main Bearings
50 (weekly)
4g
Clutch Lever Shaft
50 (weekly)
4g
Clutch Throw-out Collar
10 (daily)
4g
NOTE:
Four grams of grease is the equivalent of three shots/pumps from the

grease gun. Positions 6-8 are only relevant where a manual clutch is
fitted.
TED* - Top End Drum

BED* - Bottom End Drum
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.23
6.23 AUTOMATIC GREASING SYSTEM

Your RK1412T Rotocrusher may be equipped with a Automatic Lubrication System (AUTOLUBE) to ensure that all necessary equipment is lubricated at regular
intervals in order to maintain the operational efficiency of the equipment. Please
note that this feature is not standard.
The Autolube grease points are shown in the diagram below.
1
1.
Product Conveyor top end drum (2 points)
2.
Product Conveyor bottom end drum (2 points)
3.
Main Crusher bearings (2 points)
4.
Feed Conveyor top end drum (2 points)
5.
Feed Conveyor bottom end drum (2 points)
6.
Clutch (manual clutch only) (4 points)
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.23
6.23 AUTOMATIC GREASING SYSTEM cont.

The grease is pumped by a Quicklube central lubricating pump. It is a compact
multiline pump consisting of the following.
1.
Reservoir
2.
Pump Element
3.
Safety Valve
4.
Filling Fitting (For

special cartridge gun)
5.
Connection Plug 2A1

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

Time Switches
8.
Connection Plug 1A1

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

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

pumpable at these temperatures).
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.24
6.24 AUTOLUBE MAINTENANCE

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

Pump operating failure
The pump element needs to be replaced
There is a blockage in the system or bearing
If lubricant is emerging from the pressure relief valve, (B) this indicates a
blockage in the system and the fault should be immediately rectified.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.24
6.24 AUTOLUBE MAINTENANCE cont.

6.24.1
Cleaning
Whenever work is done on the Autolube system, particular attention should be

given to absolute cleanliness. Dirt in the system will cause problems.
For cleaning the system use naphtha or petroleum benzine. Tri or Per or similar
solvents must not be used. Do not use polar organic solvents such as alcohol,
methyl alcohol, acetone or similar.
6.24.2
Filling Pump Reservoir
Fill the reservoir via the grease nipple filling fitting (B), female port filling fitting (A)
or (C) up to the max mark on the reservoir. A special cartridge filler gun is
supplied with each pump.
C
B
A
IMPORTANT:
The grease/oil must be free from impurities and must not be

liable to change its consistency in the course of time.
If the reservoir has been completely emptied, the pump may

require 10 minutes operation before it operates with its full
output again.
Induce several lubrication cycles by pressing the Autolube

button on the main engine control panel for a minimum of 5
seconds. Then check that the indicator pin is moving.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.24
6.24 AUTOLUBE MAINTENANCE cont.

6.24.3
Test Run / Triggering and Additional Lubrication
There is a facility on your Autolube system where by the following functions can
be performed:
Test run on system to ensure correct operation.

Additional cycle to top up grease points.
To carry out either of the above, depress the test button on the main control panel
as shown below for at least 5 seconds.
Autolube
test button
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.25
6.25 AUTOLUBE TROUBLESHOOTING

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

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

CAUSE
Reservoir empty
REMEDY
Refill reservoir with clean grease or

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

or type of lubricant it may take 10 minutes of
operation until the pump elements will reach their
full lubricant output.
Air Pockets in Lubricant
Trigger an additional lubrication (see

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

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

clogged.
Remove pump element. Check suction hole

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

defective or clogged.
Replace pump element.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.26
6.26 RECOMMENDED FLUIDS
HYDRAULIC OIL EQUIVALENTS

AMBIENT TEMPERATURE RANGE
10 - 20C
(58 - 68F)
20 - 30C
(58 - 68F)
30 - 48C
(86 - 120F)
ESSO
NUTO H 32
NUTO H 68
UNIVIS N 68
BP
ENERGOL HLP 32
ENERGOL HLP 68
ENERGOL SHF 68
MOBIL
DTE 13
DTE 15
DTE 16
SHELL
TELLUS R37
TELLUS R37
TELLUS R37
TEXACO
RANDO HD 32
RANDO HD 68
RANDO HD 100
TOTAL
AZOLLA 32
AZOLLA 68
EQUIVIS ZS 68
NOTE:
The use of brands, other than those shown above should be subject to
the approval of TESAB ENGINEERING LTD.
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.27
6.27 FAULT FINDING

SYMPTOM
POSSIBLE FAULT
REMEDY
Engine wont start
Clutch engaged
Disengage clutch
Safety circuit tripped
Check each circuit

component
Crusher jammed
Clear obstruction
Low fuel level
Top up tank and

bleed system
Obstruction or break
in the fuel line system
Repair and bleed

system
Engine stops
NOTE:
See engine manufacturers publication Operators Handbook troubleshooting section for detailed analysis of engine trouble.
No response
from any hydraulic
system
Low oil level
Top up hydraulic
system
Choked suction line

filter
Wash and clean filter

element
Pump shaft broken
Replace pump
Worn pump
Replace pump
Pressure relief valve

stuck in open position
Repair or replace
valve cartridge
Restricted or broken suction

line
Check restriction in
tank, repair if
broken
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.27
6.27 FAULT FINDING cont.

SYMPTOM
POSSIBLE FAULT
REMEDY
Machine
operating slowly,
no external oil
leaks.
Low oil level
Top up hydraulic
system
Incorrect hydraulic fluid
Drain tank and replace with correct

fluid
Choked suction line filter
Replace filter element
Leaking relief valve
Repair or replace
relief valve
Worn control valve
Replace control
valve
Worn pump
Replace pump
Worn head drum motor
Replace head drum

motor
Engine performance not

to standard
Consult your engine

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

line
Tighten all joints
Flexible suction hose worn
Replace hose
Excessive noise
from hydraulic
pump
RK1412T ROTOCRUSHER
MAINTENANCE
Section 6.27
6.27 FAULT FINDING cont.

SYMPTOM
POSSIBLE FAULT
REMEDY
Screeching noise
when conveyors
are running
Lack of bearing lubricants
Grease all bearings
Conveyor wedged, rubbing

against fixed parts
Clear obstructions,
adjust and re-track
conveyor belt
Belt drive coupling broken

or loose
Replace or tighten
coupling
Top end drum belt scrapper

too tight
Ease pressure at
scraper
Conveyor belt
tends to run back
if stopped with a
load on the belt
Non-return valve worn
Repair or replace
non-return run back
valve
Product conveyor
wont fold position
Conveyor still bolted in
Unbolt at relevant
point
Crusher not
turning when
rest of system
operational
V belts slipping
Tighten belts
Crusher wont
turn, machine
not operational
Material jammed in crusher
Clear obstruction
If you cannot identify the cause of the trouble or are unable to put it right yourself,
please contact TESAB ENGINEERING LTD. or your local TESAB authorised
dealer.
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 7
PREPARING FOR TRANSPORT
PREPARING FOR
TRANSPORT
RK1412T ROTOCRUSHER
Section 7.0
7.0 PREPARING FOR TRANSPORT SAFETY

In order to transport the RK1412T ROTOCRUSHER the following preparations
should be followed to ensure correct and safe movement of the machine.
NOTE:
Some of the functions carried out when preparing the machine for transport will require the use of a crane.
The fastening of loads and the instructing of crane operators should be entrusted
to experienced personnel.
Check with local authorities regarding transport restrictions, you may not have to
carry out all the instructions listed below.
Observe all safety instructions and warnings, all work is to be carried out by qualified personnel only.
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER

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

unguarded machine.
PREPARING FOR
TRANSPORT
WARNING
RK1412T ROTOCRUSHER
Section 7.0
CRUSH HAZARD
1.
2.
3.
WARNING

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

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

machine.
LOCKOUT
1.
2.
3.

maintenance.
Never work alone.
PREPARING FOR
TRANSPORT
WARNING
RK1412T ROTOCRUSHER
Section 7.0
HIGH PRESSURE
1.
2.
3.
CAUTION
HOT SURFACE
1.
WARNING
HEAD PROTECTION
1.
2.
WARNING
2.
EXPLOSIVE
BATTERY

injury or death.
BATTERY HAZARD
1.
ACID


any contact.
this area.
PREPARING FOR
TRANSPORT
7.1
RK1412T ROTOCRUSHER
Section 7.1
LOCKOUT PROCEDURE
WARNING

IMPORTANT:
Engine canopy
PREPARING FOR
TRANSPORT
RK1412T ROTOCRUSHER
Section 7.2
7.2 PREPARING FOR TRANSPORT

Fold and position the machine ready for transport as follows:
Remove any ramp that may have been used to load the machine and tidy
around the tracks to ensure a clear exit.
Track machine to a clear space away from the working area (for full details
on tracking machine see section 3).
Remove feed-in chute extension box (A).
Fold up product conveyor. Ensure that the transport bracket is fitted.
Transport bracket fitted
PREPARING FOR
TRANSPORT
RK1412T ROTOCRUSHER
Section 7.2
7.2 PREPARING FOR TRANSPORT cont.
Lower hoist to transport position.
Remove the
4 bolts
Hoist in transport
position
Pivot hoist
around hinge
Ensure that all items which have been removed for transport purposes and
repositioned on the machine have been well secured (ie. all items are tied
down satisfactorily around the catwalk area).
Ensure all bolts/brackets have been placed in a secure location (ie. the
toolbox).
Remove the exhaust and pre-cleaner remembering to fit the rain-cap on the
exhaust opening and fit the cover over the air filter casing. Tesab have
supplied a specially adapted cover for this function still allowing the filtration
system to breath but preventing any ingression of water etc.
PREPARING FOR
TRANSPORT
RK1412T ROTOCRUSHER
Section 7.2
7.2 PREPARING FOR TRANSPORT cont.
Pre-cleaner
NOTE:
Exhaust
In some cases you may have to track the machine relatively long distances from the working area to the loading area. If this is the case
Tesab recommend that the exhaust and pre-cleaner remain on the
machine until after loading.
Ensure that the engine access steps are folded up when tracking the machine
before and after loading thus reducing the possibility of fouling.
IMPORTANT:
TESAB ENGINEERING LTD. recommend that the loading and

off-loading of the RK1412T ROTOCRUSHER is carried out by
trained and experienced personnel only.
RK1412T ROTOCRUSHER
RK1412T ROTOCRUSHER
March 2005 Issue
RK1412T ROTOCRUSHER
Section 8
WARRANTY
RK1412T ROTOCRUSHER
WARRANTY
Section 8.0
8.0 WARRANTY
All conditions and warranties expressed or implied by any statue common law.
Trade usage or otherwise are hereby excluded. No liability is accepted by TESAB
ENGINEERING LTD. for any loss, damage or injury to property or persons arising
directly or indirectly from any failure or direct in the machinery supplied. The
materials employed by TESAB ENGINEERING LTD. in the manufacture of their
machinery, to the best of their knowledge, are the highest available quality of their
respective kinds. TESAB ENGINEERING LTD. undertakes to replace or repay
free of cost any part supplied by them direct to the customer of which they shall
receive notice and which shall be proved to the satisfaction of TESAB ENGINEERING LTD. within a period of twelve months of delivery to be defective in
workmanship or materials provided.
A:
That written notice of complaint is given within seven days of the discovery
of the defect.
B:
That the part is returned carriage paid to TESAB ENGINEERING LTD. and
shall, in the event of replacement become their property.
C:
That the defect has not been caused by carelessness or improper or inadequate lubrication.
D:
TESAB ENGINEERING LTD. shall not be liable for the cost of removal of
the defective part or the cost of fitting a new part.
E:
That the guarantee period shall be proportionally reduced if the machinery

is run for more that one eight hour shift per day.
No unauthorised alteration or modification has been made to the plant or machine

or component the subject of the claim.
The new part will be delivered by TESAB ENGINEERING LTD., carriage paid to
the customers nearest station in the U.K. or F.A.S. port of exportation.
In case of parts or components not manufactured by TESAB ENGINEERING
LTD. the customer shall be entitled to the benefits in so far as it may be transmitted to the customer, of any guarantees given by the manufacturer in respect thereof
and TESAB ENGINEERING LTD. liability in respect of such goods is limited to
making the benefits of the manufacturers guarantees available to the customer to
the extent aforesaid.
RK1412T ROTOCRUSHER
WARRANTY
Section 8.0
8.0 WARRANTY cont.

This understanding is in lieu of and excludes any other conditions guarantees, or
warranties expressed or implied, statutory or otherwise. In no event shall TESAB
ENGINEERING LTD. be liable (except to the extent of any of its undertaking as
aforesaid) for any loss injury or damage howsoever caused or arising.
The guarantee contained aforesaid is personal to TESAB ENGINEERING LTD.
customer and may not be assigned.
IMPORTANT:
TESAB ENGINEERING LTD. hereby emphasise that a dust suppression system must be used when the RK1412T is in operation.
TESAB ENGINEERING LTD. cannot be held responsible for any
failure due to the disregard of dust suppression.

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RK1412T ROTOCRUSHER

March 2005 Issue

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

March 2005 Issue

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

March 2005 Issue

Set-up procedure safety

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

March 2005 Issue

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

March 2005 Issue

Preparing for transport safety

PREPARING FOR TRANSPORT

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

March 2005 Issue

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

The TESAB RK1412T ROTOCRUSHER complies with the EU directive 89/392/

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT

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

1.1 DECLARATION OF CONFORMITY

Tesab Engineering Ltd.

Mobile Crushing Plant

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

1.2 MACHINE SPECIFICATION DETAILS

MACHINE SERIAL NUMBER:

ENGINE SERIAL NUMBER:

CLUTCH SERIAL NUMBER:

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

1.3 FOREWORD/RESERVATION OF RIGHTS

The TESAB RK1412T ROTOCRUSHER is a robust skilfully engineered piece of

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

This operation and maintenance manual must not be copied, reproduced or

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

feed conveyor end of machine

product conveyor end of machine

Right and left hand sides -

as viewed from the rear of the machine

1.4 FAMILIARISATION cont.

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

1.5 GENERAL SPECIFICATION

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

1.5 GENERAL SPECIFICATION cont.

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

1.5 GENERAL SPECIFICATION cont.

19 KPTO hydraulic clutch

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

March 2005 Issue

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

2.0 SAFETY INTRODUCTION

Electrical Hazard. Risk of serious injury or

Nip Hazard. Do not reach into an

Fall Hazard. Do not climb onto moving or

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

Crush Hazard. Beware of dangerous hand

Loose or baggy clothing can get caught in

Read and understand the operators manual

When performing maintenance or

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

Fall rock hazard. Do not walk near material

Burn or Heat Hazard. Beware of hot sur

Beware of escaping hydraulic oil. High

Battery Hazard. Battery electrolyte contains

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

Replace unreadable or missing labels