1012T Manual Iss2 PDF
1012T Manual Iss2 PDF
1012T Manual Iss2 PDF
Section 1
INTRODUCTION
REMEMBER:
TABLE OF CONTENTS
SECTION 1: Introduction
1.0 EU directive
1.1 Declaration
1.2 Machine Specification Details
1.3 Forward / Reservation Of Rights
1.4 Familiarisation
1.5 General Specification
SECTION 2: Safety
TABLE OF CONTENTS
SECTION 5: OPERATION
TABLE OF CONTENTS
SECTION 6: MAINTENANCE
TABLE OF CONTENTS
SECTION 8: WARRANTY
8.0 Warranty
9.0 Index
9.1 Main Assembly
9.2 Chamber Wear Plates
9.3 Shaft and Bearing Assembly
9.4 Top Apron Adjuster Assembly
9.5 Middle Apron Adjuster Assembly
9.6 Bar Carrier Adjuster Assembly
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.
Serial No:
This machinery has been designed and manufactured in accordance with all
the relevant ESR’s of the EU Machinery Directive.
A technical construction file for this machinery is retained at the following ad-
dress:
Signed:
Date:
ENGINE TYPE:
CLUTCH TYPE:
DESPATCH DATE:
Consider this manual a permanent part of your machine. Keep a copy of this
manual at the operational site.
1.4 FAMILIARISATION
The following conventions have been used throughout this operation and main-
tenance manual when describing component locations:
Right and left hand sides - as viewed from the product conveyor end of
machine.
RIGHT LEFT
FRONT
4 1 3 7 2 5 6
1. Feeder.
2. Crusher Unit.
3. Dirt Conveyor.
4. Chassis.
5. Drive System.
3. DIRT CONVEYOR
6. Product Conveyor FRONT VIEW
7. Tracks
Chassis
The chassis is constructed of heavy-duty profiles and welded steel plates ribbed
and stiffened to withstand all operational and travelling stresses. The chassis is
mounted on 3.75m centre heavy-duty tracks, with remote control or dog lead op-
erational facility.
Feeder
The 4.25m x 0.9m spring mounted heavy duty vibrating feeder is of twin shaft
design. The controls and variable speed are located on the feeder catwalk or
alternatively the feeder can be operated from the tracks remote control, this allows
the operator full control of crusher feed rate. The bar frame cassette can be manu-
factured to the customers specification depending on application and site condi-
tions. The customer has the option of feeding the fines onto the product conveyor
belt or onto a 3.6m x 500mm side dirt conveyor. The feeder is fitted with hydraulic
folding heavy-duty cribs to give extra hopper capacity.
The RK 1012 crusher unit is fitted with four hammers, 1000mm wide. It has a feed
opening of 1020 x 780mm and a rotor diameter of 1200mm. There are two adjust-
able aprons and a final bar carrier which can be adjusted from 4 to 80mm depend-
ing on material feed size and reduction required. It is driven through 8 V-Belts and
the chamber can be easily accessed by hydraulic control lever. There is a deadbox
fitted under the crusher to allow easy flow of material onto the product conveyor. A
speed sensor is fitted to the rotor that cuts of the feed before the crusher overloads.
Product Conveyor
The product conveyor is fitted with a 1000mm heavy duty 4 ply belt and runs on
heavy duty troughing rollers, impact bars are fitted under crusher to give belt full
support at crusher exit. The conveyor is driven hydraulically through a flexible cou-
pling at the rubber lagged top end drum.
Power Unit
The engine is a Caterpillar 3306TA (300HP at 1800rpm) Power Pack and the
crusher is driven through a heavy duty Twin Disc IBF 314 (3 plate) PTO. The pulley
on the clutch can be easily changed to alter the rotor speed or if finer tuning is
required the engine speed can vary between 1700 and 2200rpm. The conveyors,
feeder, and rams are all driven hydraulically through pumps fitted to the engines
auxiliary drive.
All relevant catwalks, handrails and guards are fitted to this machine allowing ac-
cess to all relevant maintenance points. Emergency stops are fitted to all necessary
points. The machine carries the European CE mark and therefore complies with all
Essential Safety Requirements.
Options
- Self-cleaning magnet
- Dust suppression
- Re-cycling apron
- Vibrating feeder under crusher
Section 2
SAFETY
Please read this section carefully and become familiar with the signs used.
These signs are used frequently throughout this manual to indicate any poten-
tial warning or danger when operating this machine.
WARNING PROTECTION
1. Loose or baggy clothing can get caught in
running machinery.
2. Always wear correct fitting (EN/ANSI
approved) protective clothing.
3. Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
WARNING LOCKOUT
1. When performing maintenance or
adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
2. Keep ignition key on person during
maintenance.
3. Never work alone.
2.1 SAFETY
In running nip points can cause seri- If fluid is injected under the skin it must
ous injury even death. Do not reach be surgically removed immediately.
into an unguarded machine.
Always use an EN/ANSI approved Any safety devices removed for setup,
harness if reaching any points 2m (7ft) maintenance or repair must be fitted
or more above ground level. and checked immediately upon com-
pletion of the work.
Keep all handles, steps, handrails,
walkways and ladders free from dirt, Before activating the machine in any
oil, snow and ice. manner, or energising the electrical
and/or hydraulic controls, make cer-
Observe the adjusting, maintenance tain that no person or obstruction
and intervals set out in these operat- is standing in or in the immediate
ing instructions, except where warning vicinity of the machine.
light or indicator calls for immediate
action or adverse conditions require
more frequent servicing.
2.
RAMS CONTROL
CONSOLE
1.
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.
Section 3
TRACKING INSTRUCTIONS
1. Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
1&2
4 4
6
4 1&2 4 4
3
4 4
4
4. Emergency stop.
5. Remote control
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
> DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.
> ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH
POSITION PRIOR TO STARTING ENGINE.
> NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
NEUTRAL(middle) POSITION
The following sections describe how to track your machine, read the complete
manual before tracking. Check that there is a clear area around the machine and
that all control levers including clutch lever are in the neutral position.
b a
d) Turn the starter ignition key C to position no. 1 which is the ‘on’
position.
e) Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
f) Release the key and then release the system over-ride button.
Throttle Adjustment
- revs
+ revs d
J g
c a E
h
SIDE X
SIDE Y
I
d
b
f
C A
D B
SIDE X SIDE Y
a) Firstly ensure that leads A, B, C and the aerial lead, are connected to
the panel.
A B C
Remote Control Panel
b) Ensure that the track switch (A) on the main engine starter panel is in
the “ON” position.
d) Press button E on the remote control the beacon and siren will
automatically sound and the track system will activate allowing the
operator to begin moving the machine.
e) Ensure that the dog lead switch (B) and the Track Switch on the main
engine starter panel are both in the “dog lead” position. Ensure that the
‘Track Switch’ is in the on position prior to operating the dog lead.
Track Switch
continued over...
g) Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
C A
D B
F
C A
D B
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
h) To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
Follow the procedure below to charge the battery for the remote control.
Battery
NOTE:
DISCONNECT BATTERY
TERMINALS AND REMOTE UNIT
PRIOR TO WELDING.
Section 4
SET-UP PROCEDURE
These signs are used frequently throughout this manual to indicate any poten-
tial warning or danger when operating this machine.
WARNING PROTECTION
1. Loose or baggy clothing can get caught in
running machinery.
2. Always wear correct fitting (EN/ANSI
approved) protective clothing.
3. Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
WARNING LOCKOUT
1. When performing maintenance or
adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
2. Keep ignition key on person during
maintenance.
3. Never work alone.
4.1 INSTALLATION
The following section will take you step by step through the installation of your
RK 1012T ROTOCRUSHER.
Note:
Due to different transport and shipping regulations throughout the world the RK
1012T Rotocrusher will be delivered in different packing arrangements. For the
purposes of this manual it will be considered that the machine is delivered in its
most un-assembled configuration therefore some of the installation sections
may not be applicable. If this is the case ignore that particular instruction/section
and proceed to next section.
Before installing the RK1012T ROTOCRUSHER ensure that you have read all sec-
tions of this manual in order to familiarise yourself with the machine and its function,
paying particular attention to the SAFETY SECTION 2.
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
Before starting the engine please ensure that the two manual valves shown in the
picture below are in one of the following positions.
Both levers in
Track Position
WARNING
> DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.
> ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH
POSITION PRIOR TO STARTING ENGINE.
> NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
NEUTRAL(middle) POSITION
Starter Panel
Starter Panel
This area can be accessed by lowering the access steps (B). It is important, for
safety reasons, that when these steps have been lowered that they are locked
into position using clamps (C) at both sides. This is illustrated below.
C
C
b a
d) Turn the starter ignition key C to position no. 1 which is the ‘on’ position.
e) Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
f) Release the key and then release the system over-ride button.
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.
Before tracking we recommend that you fold up the engine area access steps in
order to prevent them from fouling unneccessarily.
WARNING
1. Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
1&2
4 4
6
4 1&2 4 4
3
4 4 4
4. Emergency stop.
5. Remote control
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
> DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.
> ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH
POSITION PRIOR TO STARTING ENGINE.
> NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
NEUTRAL(middle) POSITION
The following sections describe how to track your machine read the complete
manual.
Before tracking check that there is a clear area around the machine and that all
control levers including clutch lever are in the neutral position.
b a
d) Turn the starter ignition key C to position no. 1 which is the ‘on’
position.
e) Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
f) Release the key and then release the system over-ride button.
Throttle Adjustment
- revs
+ revs d
J g
c a E
h
SIDE X
SIDE Y
I
d
b
f
C A
D B
SIDE X SIDE Y
a) Firstly ensure that leads A, B, C and the aerial lead, are connected to
the panel.
A B C
Remote Control Panel
b) Ensure that the track switch (A) on the main engine starter panel is in
the “ON” position.
d) Press button E on the remote control the beacon and siren will
automatically sound, the track system will activate allowing the
operator to begin moving the machine.
e) Ensure that the dog lead switch (B) on the main engine starter panel is
in the “dog lead” position. Ensure that the ‘Track Switch’ is in the on
position prior to operating the dog lead.
Track Switch
continued over...
h) Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
C A
D B
F
C A
D B
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
i) To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
Follow the procedure below to charge the battery for the remote control.
Battery
NOTE:
DISCONNECT BATTERY
TERMINALS AND REMOTE UNIT
PRIOR TO WELDING.
4.10 POSITIONING
Before the RK 1012T Rotocrusher is positioned on site it is necessary to have a
level surface and spacious surroundings, if required level the work-site foundation
using a loading shovel.
The machine must be placed on solid ground capable of carrying its weight.
Track the machine into the desired position and ensure the machine is level. This
can be done with the aid of a spirit level.
(Ensure it is level both along the chassis and across the chassis.)
We recommend that when the machine is positioned correctly the dog lead and
the remote control are located in a safe place (i.e. works office or shovel cab).
2 4
1
3
ii) If required fit the pre-cleaner and exhaust. We would recommend that if
the machine has to be tracked for a long distance that you fit these items
as soon as possible.
Pre-Cleaner Exhaust
iii) For safety reasons once the machine is in the correct working position
switch the tracks off. This disables the system and prevents the machine
from moving if the remote or dog lead are touched accidentally. Move switch
to off position on control panel to disable tracks. See diagram over. It is also
advisable to switch the manual control valves to the ’CRUSH’ position in
order prepare the machine for working. See diagram over.
Both Levers in
CRUSH Position
Tracks
ON/OFF Switch
WARNING
® DO NOT ACTIVATE LEVERS WHILE ENGINE IS RUNNING.
® ALWAYS ENSURE BOTH VALVES ARE IN THE TRACK OR CRUSH
POSITION PRIOR TO STARTING ENGINE.
® NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
NEUTRAL(middle) POSITION
Remove any parts, which have been packed on the catwalks and hopper. This is to
give fully access to all control areas and reduces any fall hazards.
The fastening of loads and the instructing of crane operators should be en-
trusted to experienced personnel only.
• Connect the crane lifting chains to the dirt conveyor at the two points
indicated ‘A’.
• Take the weight of the top section to allow you to remove the transport
bracket (remember to put the transport bracket in the toolbox).
• Lower the dirt conveyor top section carefully and pin together at points
indicated ‘B’.
A
A
Bolts and pins required to carry out this set-up procedure can be found in the
machine toolbox.
i) Firstly check around the cribs area to ensure there are no obstructions
and that the hydraulic hoses are not fouling.
ii) Fold up side cribs approximately half way, one side using the highlighted
levers below.
Cribs RHS
Cribs LHS
iii) Fold up rear cribs approximately half way using the highlighted lever
shown over the page.
Cribs Rear
iv) At this stage carefully fold up each crib alternatively until the three sides
are up in position.
v) Locate and tighten eye bolts and for extra stability insert extra bolts
(located in tool box).
viii) Tesab have designed an extra crib cross tie above the grizzly bars. This is
designed to ensure that the material, which passes this point is at the
correct height to enter the crusher. We highly recommend that this beam
is fitted as it will reduce any down-time due to crusher blockages.
SECURING CHAINS
Crib Cross
Tie
The bolts for this can be found in the tool box. Ensure that the chains and shackles
are connected up appropriately.
4.16 HOIST
Tesab have supplied a swinging arm for use when changing hammers, etc. For
transport purposes it is folded down therefore elevate it to the working position
and bolt as shown.
Hoist in transport
position
Pivot hoist
around hinge
Bolt in place
using the 4 bolts
IMPORTANT:
Tesab only recommend that this arm is used for changing items up to a
maximum weight of one RK1012T Hammer (Part No 2-423-3) or 200kgs.
This means the distance between the hammers and the impact path at the
three impact areas, these are named as follows:
· Bar carrier
Warning:
The crusher settings must NOT be altered while the crusher is in opera-
tion.
When first starting to crush adjust this apron fully open by adjustment at point
‘A’.
Adjust a small amount each side alternatively, this will prevent damaging the
threads.
IMPORTANT
Clockwise rotation to
adjust apron fully open
Adjust middle apron by adjusting the outer nuts at points ‘B’ until it is approximately
overlapping the top of the Bar carrier by approximately 15mm (as shown).
IMPORTANT
Clockwise rotation to
adjust apron forward
IMPORTANT
Anti-Clockwise rotation to
adjust apron backwards. F
15mm Note:
The setting is carried out
at the outer bolts of the
yoke. The pretension of
the spring unit is factory
set at the inner bolts and
should not require any
adjustment.
Open door ‘F’ and measure the setting between the LOWER blow bar
(grinding list) and the hammer. Set the desired gap by adjusting the outer
nuts at point ‘C’.
Note: The setting is carried out at the outer bolts of the yoke. The pre-
tension of the spring unit is factory set at the inner bolts and should
not require any adjustment.
IMPORTANT
Clockwise rotation to
adjust bar carrier forward
IMPORTANT C
Anti-Clockwise rotation to F
adjust bar carrier
backwards.
(ii) Study the produced material and use that as a guide-line for your
setting.
i) Water Tank.
Water Tank
ii) Manifold
This allows you to turn off and adjust spray bars independently, depending
on site conditions. An extra outlet has been fitted if required.
Important Notes
1) There is a tap at the base of the manifold (A). It is important that the
manifold is drained at the end of each working day, especially in cold
conditions. This is to prevent freezing of water in the manifold and any
subsequent damage.
2) The water tank should be drained during extreme cold conditions in order
to prevent any unnecessary damage caused by expansion.
v) Water Filtration
Water Filter
Section 5
OPERATION
These signs are used frequently throughout this manual to indicate any poten-
tial warning or danger when operating this machine.
WARNING PROTECTION
1. Loose or baggy clothing can get caught in
running machinery.
2. Always wear correct fitting (EN/ANSI
approved) protective clothing.
3. Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
WARNING LOCKOUT
1. When performing maintenance or
adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
2. Keep ignition key on person during
maintenance.
3. Never work alone.
1. Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
1&2
4 4
6
4 1&2 4 4
3
4 4 4
4. Emergency stop.
5. Remote control
- you can operate the machine manually (as per standard RK1012T), this can
be done by positioning the “Feeder operation button” (on the Main engine
starter panel) in the “manual” position. This allows you to start and stop the
feeder from the platform at the feeder control console (A).
MANUAL AUTO
- you can operate the machine by remote control, this can be done by
positioning the “Feeder operation button” (on the Main engine starter
panel) in the “Auto” position, This allows you to operate the feeder using
your Remote control hand piece.
The speed sensor facility is in operation when using this form of control,
this stops the feeder when the rotor drops below a factory pre-set speed
and re-starts the feeder again when rotor regains the pre-set speed. The
speed sensor facility over-rides the remote control stop and start
(important note: when using this form of control ensure that the lever at
the feeder control console is in the on position)
1
How to use your remote control:
2
1. Press the start stop button
2. Press feeder on/off as required
Note: A blue beacon has been fitted to the machine this notifies the
operator that the feeder is currently off.
b a
d) Turn the starter ignition key C to position no. 1 which is the ‘on’ position.
e) Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
f) Release the key and then release the system over-ride button.
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.
Set the engine revs to approximately 1000 r.p.m., this can be done observing the
digital tachometer D on the starter panel and adjustment of the throttle.
Throttle Adjustment
- revs
+ revs
Repeat this procedure two or three times and then engage clutch
completely by forcing lever to the fully over-centre position.
“bump-in”
clutch Engage Clutch
gradually
Important:
Read Section 6.4 on clutch maintenance – this states that the clutch, initially
when new, will require several adjustments (it will also require further ad-
justments during clutch life).
Increase engine speed to 2000 r.p.m., this can be done observing the digital
tachometer D on the starter panel and adjustment of the throttle.
- revs
Throttle Adjustment
- +revs
revs
+ revs
Product Conveyor
Control Lever
Due to the design of the product conveyor in order to track it correctly please carry
out the following procedure:
i) The conveyor can be TENSIONED correctly at the top end drum using the
adjuster bars as shown.
Note: The conveyor belt tension is factory set but you will find due to run-
ning it over time or climatic conditions the belt will stretch and require re-
tensioning.
Important: DO NOT over tension the belt as this will cause excessive strain on the
bearings and drive system.
Product Conveyor
Adjuster bars
NOTE:
Slacken off Bolts A
prior to Tensioning Belt
A
ii) In order to track the belt correctly you must adjust the return rollers as shown.
Note: The dirt conveyor and magnet run through the one hydraulic circuit, there-
fore one single lever activation will start both conveyors.
Dirt Conveyor
Control Lever
In order to track this belt correctly please carry out the following procedure:
Important: DO NOT over tension the belt as this will cause excessive
strain on the bearings and drive system.
For further details on the tracking of conveyor belts see section 6.23.
Feeder
Control Lever
Feeder Speed
Control
- +
A
Feeder Speed
Control
The operator must set the speed of the feeder depending on the application
and finished product required.
This is why we would recommend running feeder slowly initially and increase
the speed in order to avoid blockages.
It is important to ensure that you allow the machine to run empty at the end
of the shift before closing machine down, including hopper and feeder. By
not allowing this to happen will put unnecessary pressure on the feeder
bearings, springs and hydraulic system.
1. Stop feeder.
5. Dis-engage clutch.
Section 6
MAINTENANCE
IMPORTANT
Ensure all bolts are re-fitted after closing
IMPORTANT
DO NOT OPEN ANY DOOR OF THE CRUSHER UNTIL THE ROTOR HAS
STOPPED COMPLETELY AND THE CONTROL POWER HAS BEEN BROKEN,
OR, IN THE CASE OF A DIESEL POWERED CRUSHER, THE CLUTCH IS DISEN-
GAGED, THE ENGINE HAS STOPPED AND THE IGNITION KEY HAS BEEN RE-
MOVED.
NEVER START THE CRUSHER UNTIL ALL DOORS ARE CLOSED AND
LOCKED.
Picture No. 4
6.4 CLUTCH
The Power Take Off (or Clutch) in conjunction with your diesel engine is the central
part of your RK 1012T ROTOCRUSHER a lot of care and thought has went into
its selection.
Therefore 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
If the clutch is easy to engage to its fully over-centre position, lever jumps out
during operation, or clutch heats up excessively. To adjust the clutch firstly
lockout your engine by removing the key from the ignition, then remove the
hand hole plate 1 in the housing and turn the clutch until the locking pin 2 can
be reached. Disengage the adjusting locking pin 2, by pulling it out towards the
pulley, and turn the adjusting yoke 3 (or ring) to the right (clockwise) until the
operating lever requires a distinct pressure to engage.
Note: The majority of clutch failures are not caused by a unit being
undersized for the application. Failures often are the result of the
clutch 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.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
MAINTENANCE Section 6
3. Lever Shaft - Apply 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.
Lubricant Specification
Use any high grade, high temperature, lithium base gun lubricant. For further
details see recommended lubricant section in this manual.
NOTE: Although this section details the greasing point on the clutch, it
is important to note that these points are supplied with grease
through the Autolube System.
See Autolube section for further details
6.7 MAINTENANCE
The maintenance instructions for your RK 1012T Rotocrusher are set out under
the following headings.
· General Information
· Safety Information
· Hydraulic System
· Tracks
· Hydraulic Fluids
· Oil Tanks, Pipes and Fittings
· Diesel Engine
· Product Conveyor Reduction Gear
· Feeder
· Bearings and Lubrication
· General Specification Inspection
· Routine Maintenance Schedule
· Daily Maintenance
· Weekly Maintenance
· Six Monthly Maintenance
· Belt Tracking
· V-Belt Tensioning
· Recommended Gear Oil
· Recommended Lubricants
· Automatic Greasing System
· Recommended Fluids
· Fault Finding
IMPLEMENT LOCKOUT
PROCEDURE BEFORE
CARRYING OUT
MAINTENANCE TO YOUR
RK 1012T ROTOCRUSHER
When performing maintenance on your machine please adhere to the safety in-
formation listed in the safety section.
It is important to note that high repair costs and lenghty downtime will oc-
cur if inadequate or improper maintenance is performed on your machine.
Regular maintenance is imperative.
The reliability and service life of your 1012T unit depends on the regular and cor-
rect maintenance of the machine.
IMPORTANT NOTE
If the RK1012T is operated for long periods of time in extreme conditions
either climatic (-15C to 33C) or very dusty the maintenance schedule will
change. If this scenario arises please consult your local Tesab dealer or
Tesab Engineering technical/service department.
WARNING PROTECTION
1. Loose or baggy clothing can get caught in
running machinery.
2. Always wear correct fitting (EN/ANSI
approved) protective clothing.
3. Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
Filtration
In order to maintain the hydraulic oil at its peak performance, two High Pressure
filters are used in the system of the RK 1012T Rotocrusher. These are coupled
with 2” Strainer Valves fitted inside the tank.
Regular monitoring of gauges on the filters is essential. The filter element requires
changing when the indicator is in the red at operating temperature.
The filter
element needs
to be changed
when the
indicator turns
High Pressure red.
Filters
6.11 TRACKS
Each Track Frame Assemblies fitted to the TESAB RK1012T Rotocrusher
comprise of five main components:
4. The FRONT IDLER is mounted at the opposite end of the frame to the
sprocket, the idler slides on guides. The track is adjusted by a hydraulic
cylinder attached to the idler arrangement. Between the idler, and the track
adjusting cylinder is a recoil spring, which will allow the idler to move back-
wards in the event that excessive load is placed on the track.
Track Maintenance
It is important that to ensure trouble free track operation that the following mainte-
nance operations are adhered to:
1. Track Adjustment.
Check if the track is correctly adjusted. As the track wears it will become
slack and should be checked regularly.
30mm approx.
Equal Equal
Inspection
Cover
Figure 1
The adjustment of the track is accessed via the inspection cover on the
side of the track frame as shown in figure 1.
Ensure the grease fitting is tight, using a 22mm socket or ring spanner.
M1442 Adapter
Important:
Slacken the grease fitting on the end of the hydraulic track tensioning
cylinder, by one half turn only, using a 22mm spanner.
Warning:
When the track droop appears to be correct, move the machine backwards and
forwards and re-check the droop.
Oil Level
Ensure machine is on level ground and until the filler plugs are in the
correct position (see figure 2).
FILLING
LEVEL
Figure 2
Clean the area around the plugs and remove any surrounding debris.
Remove both plugs and fill through the upper plug hole.
Wait a few minutes until any trapped air has escaped then recheck the
level.
Move the machine until the filler plugs are in the position as shown in
figure 3.
DRAINING
Figure 3
Clean the area around both plugs and remove any surrounding debris.
More effective draining will occur if this operation is carried out when
the oil is hot.
Important:
The oil should be drained from the gearboxes after the first 200 hours of
operation, and re-filled with the correct lubricant (see lubrication chart).
Following this initial oil change the oil should then be replaced after
2000 hours of use or at least once per year.
The oil should be drained from the gearboxes after the first 200 hours of
operation, and re-filled with the correct lubricant (see lubrication chart).
Following this initial oil change the oil should then be replaced after
2000 hours of use or at least once per year.
3. Leakage
Check daily for any signs of oil leakage, particularly, front idler seals,
roller seals and gearbox.
5. Loose Bolts.
In the event that any bolts are found to be loose, they should be re-
tightened to the following torque:
Gearbox Lubrication
Transmital Bonfiglioli
Track Adjustment
As a power transmitting medium the fluid must flow easily and be as incom-
pressible 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 1012T
ROTOCRUSHER. In most cases the fluid is the oil seal present. For example
there are no sealing rings between the spool and the body of the directional
valve. As the sealing characteristics of the fluid depends on its retaining vis-
cosity, it is important that the oil selected is capable of maintaining the
minimum viscosity change over a wide range of operating temperatures.
- Prevent rot.
- Depress foaming.
- Prevent formation of sludge, gum and varnish.
- Retain its own stability, thereby reducing fluid replacement.
- Prevent corrosion and pitting.
For best operating results it is strongly recommended that the hydraulic fluid
used is selected from the recommended range listed in section 12. In the serv-
ice 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.
On completion machines are again run and tested for several hours before
dispatch.
This is to guarantee the dependability of TESAB equipment.
IMPORTANT
The engine water trap (A) must be changed every engine service.
Routine Maintenance:
The operator is responsible for routine maintenance and must carry out the follow-
ing activities.
- After a brief operating period of about 100 hours (breaking-in), change the
oil in the gear unit (Grade EP150 or equivalent).
- Check that there are no metallic parts with unusual dimension in the mag-
netic plug of the gear unit.
- Change the oil in the gear unit while it is hot so that it is easier to drain.
- Periodically check the level (about once a month) and top up if necessary.
Attention: When checking the oil levels in gear unit, if the levels have risen this
means that oil is penetrating from the rotary seal. Contact the local
Brevini Service Dealer.
For your unit it is recommended to keep a chart that you duly fill and up-date each
time maintenance is performed.
Unscrew the drain plug and the filler plug to help drain the oil from the gear unit.
Once the oil has been emptied, replace the drain plug. Wash the interior of the
gear unit with a suitable cleaning liquid that is recommended by the lubricant
manufacturer. By putting liquid into gear unit and running at high speed for few
minutes, then remove the cleaning liquid from the unit and fill with appropriate gear
oil.
Unscheduled Maintenance
Brevini Riduttori prohibits the gear unit to be opened to carry out any operation that
is not included in routine maintenance procedures. Brevini Riduttori do not under-
take 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.
6.16 Feeder
The vibrating feeder is robustly designed. The twin shafted design will give you
years of continuous trouble free operation. The feeder is made from heavy
steel plate reinforced at appropriate places with channel and gussets. The
feeder is supported and isolated by a nest of heavy coil springs mounted on a
sub-frame constructed of heavy I Beam. The springs need only be inspected
weekly for damage and fatigue. Two shafts with bolt-on weights are driven via
hydraulic motor through flexible coupling on one side. Maintenance of your
feeder is minimal. However, we recommend the following guide to increase its
effectiveness and prolong its life-span.
The four bearings require greasing in general every week (50 hours). Grease
nipple access points are accessible above bearing. Three shots or four grams
of grease each, will be adequate for these bearings. Take care not to over-grease.
For further details see AutoLube section (6.27).
On the non-drive side of the vibrating mechanism there are gear wheels be-
tween the shafts to transfer the drive from one shaft to the other. These gear
wheels are lubricated using an “oil bath” design. The gear oil should be
changed every 6 months to maintain efficient power transfer from one gear
wheel to the other. To fill (or top up gear wheel) do so as described below.
WARNING: The feeder must not be run when any of the vibrating
mechanism guards are removed. Ensure all guards are
replaced after maintenance.
Force feed the grease until it is forced out into the labyrinths, so as
to press out any impurities.
Provided in this section is a Greasing Schedule for your machine. This section is
only applicable for machines that do not incorporate the Autolube System. If your
machine uses the Autolube please ignore this section.
- Check the machine for loose parts, check that all bolts and nuts
are
secure.
- Check the hydraulic oil level in the tank and top up if necessary.
- Ensure that all safety systems are intact (i.e. all the wires to sen-
sors 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 tighten-
ing.
- Ensure that all the troughing and return rollers are free running
and clear of obstructions.
When all checks have been made, close and fasten all the guards before oper-
ating 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 ex-
tended plant life.
- 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.
- Drain and refill hydraulic system with the correct hydraulic fluid.
Refer to the recommended lubricants for the correct hydraulic oils
to suit various ambient temperature conditions.
- Drain and refill feeder oil bath with the correct gear oil. Refer to
the recommended lubricants section.
Trouble Tracing
Oblique travel may cause a fast deterioration, although the belts on the RK 1012T
Rotocrusher is of the highest quality. In order to assist we have compiled some
of the reasons for oblique travel with appropriate correction action.
REASONS FOR
REMEDIES EXAMPLES OF OBLIQUE TRAVEL
OBLIQUE TRAVEL
2 Bolts either
side of engine
stand
Adjusters
Important Note:
Read off the force indicated by the top edge Small Cracks on V-Belt side and base.
of the upper marker ring.
Generally caused by shortage of belt tension
Compare this force to the kgf value shown in but excessive heat and/or chemical fumes can
the previous table. also give same failure.
If there are any difficulties the user should contact a local supplier or authorised
TESAB dealer.
MANUFACTURER SPECIFICATION
ESSO GX 80-90
MOBILUBE HD 90
BP HYPOGEAR EP 90
The special greases are lithium based greases are Class 2 with extreme pres-
sure additives.
GREASE LUBRICATION
Optimol Longtime PD - -
Omega - 85 -
NOTE
2 5
7 3
2
3
1
4
8
5
7 6
1. Resevoir
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
OPERATIONAL NOTES:
- Also check the high-pressure plastic hoses and plastic tubes for damage.
If necessary replace them.
- If the AUTOLUBE system is not functioning properly then the following will
occur.
- During the Pump operation the Indicator Pin in the control value
mounted beside the AUTOLUBE Pump (Fig 1, A) will move in and
out approximately every 40 seconds. If this is not happening then
one of the following may have occurred.
A
FIG 1
FIG 2 B
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
MAINTENANCE Section 6
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.
Fill the resevoir via the grease nipple filling fitting (B), female port filling fitting (A)
or (C) Special cartridge filler gun supplied with each pump up to the “max” mark on
the resevoir.
B
IMPORTANT
- The grease/oil must be free from impurities and must not be liable to
change its consistency in the course of time.
- If the reservoir has been completely emptied, the pump may require 10
minutes operation before it operates with its full output again.
- Induce several lubrication cycles by pressing the Autolube button on the main
engine control panel a minimum of 5 seconds. Then check the indicator pin is
moving.
There is a facility on your AUTOLUBE system where by the following functions can
be performed.
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
CAUSE REMEDY
CAUSE REMEDY
- Unsuitable lubricant has been - Renew the lubricant. See lubricant list.
used.
- Suction hole of pump element - Remove pump element. Check suction hole
clogged. for foreign particles. If found remove.
NOTE:
The use of brands, other than those shown above should be subject to
the approval of TESAB ENGINEERING LTD.
7. Conveyor belt Non-return valve worn or Repair or replace non-return run back
tends to run back valve
if stopped with a
load on the belt
12. Rams not Control lever at central console Put control lever in
operational in wrong position correct position
If you cannot identify the cause of the trouble or are unable to put it right your-
self please contact TESAB ENGINEERING LTD., or your local TESAB author-
ised dealer.
Section 7
PREPARING FOR
TRANSPORT
Note: Some of the functions carried out when preparing the machine for trans-
port will require the use of a crane.
Check with local authorities regarding transport restrictions, you may not have to
carry out all the instructions listed below.
1. Observe all safety instructions and warnings, all work is to be carried out by
qualified personnel only.
Please read this section carefully and become familiar with the signs used.
These signs are used frequently throughout this manual to indicate any poten-
tial warning or danger when operating this machine.
WARNING PROTECTION
1. Loose or baggy clothing can get caught in
running machinery.
2. Always wear correct fitting (EN/ANSI
approved) protective clothing.
3. Protective clothing includes Hard Hat,
Safety Clothing, Ear Defenders, Overalls,
Steel Toed Boots, and a High Visibility Vest.
WARNING LOCKOUT
1. When performing maintenance or
adjustment to this machine always switch
off engine and remove the ignition key. (if
electric isolate power supply at source).
2. Keep ignition key on person during
maintenance.
3. Never work alone.
a) Remove any ramp that may have been used to load machine and tidy
around tracks ensuring a clear exit.
b) Track machine to a clear space away from the working area (for full
details on tracking machine see section 3).
c) Adjust top apron on the crusher unit down fully, thus lowering the height
of the adjuster bars.
IMPORTANT
Anti-Clockwise rotation to
adjust apron fully down
Dust Suppression
Feed-in Chute Water Pipe
Extension Box
CRIBS Remove
bolts
Cribs RHS
Cribs LHS
Cribs Rear
h) Fold up Dirt conveyor using lift point A. Insert the transport brackets at
point B and remove belt scrapper.
A
A
Hoist in transport
position
Pivot hoist
around hinge
Remove 4 bolts
before placing in
position
l) Ensure all items which have been removed for transport purposes and
repositioned on the machine have been well secured (ie., all items are
tied down satisfactorily around catwalk area).
m) Ensure all bolts/brackets have been placed in a secure location (ie., the
toolbox).
Pre-Cleaner Exhaust
Tesab have supplied a specially adapted cover for this function – still
allowing the filtration system to breath but preventing any ingression
of water etc.,
Note:In some cases you may have to track the machine relatively long
distances from the working area to the loading area. If this is the case
Tesab recommend that the exhaust and pre-cleaner remain on the
machine and is removed after loading.
IMPORTANT NOTE:
Section 8
WARRANTY
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 per-
sons 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. under-
takes to replace or repaid free of cost any part supplied by them direct to the
customer of which they shall receive notice and which shall be proved to the
satisfaction of TESAB ENGINEERING LTD. within a period of six months of
delivery to be defective in workmanship or materials provided.
A:- That written notice of complaint is given within seven days of the discov-
ery 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 machin-
ery is run for more that one eight hour shift per day.
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.
IMPORTANT NOTE:-
TESAB ENGINEERING LTD. cannot be held responsible for any failure due to
the disregard of dust suppression.
Section 9
RK1012 CRUSHER
PARTS LIST
TYPE RK 1012
ROTOCRUSHER
UNIT
9.0 INDEX
Section Description
Important Note:
12
15
12
5 13
3
4
3
10
4
3
7
6 2 1 9 8 11 14
13
A
4 2 3
13
5 1 1
9
1 1 12
1 1 1 1
1 1 11
7 7
6 7 7
10 10
7 7
8 7 7
1
6
1
1
1 1 1 1
1
1
1 1
A 7 7
A-A
4 1 4 4 13 14 1 5
6
12
10
11 15
9
2 9
3 16
7
5
6
4
2 1 3
1 8
7
3
6 5 2 4
Lower Stroke
Carrier
6 5 2 4 7 8
Section 10
HYDRAULIC & ELECTRIC
SCHEMATIC DIAGRAMS