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RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
CONTENTS
TABLE OF CONTENTS
SECTION 1:
1.0
1.1
1.2
1.3
1.4
1.5
EU directive
Declaration
Machine Specification Details
Foreword / Reservation Of Rights
Familiarisation
General Specification
SECTION 2:
2.0
2.1
2.2
2.3
2.4
SAFETY
Safety Introduction
Safety Notes
Position of Emergency Stops
Emergency Situation
Lockout Procedure
SECTION 3:
3.0
3.1
3.2
3.3
3.4
INTRODUCTION
TRACKING INSTRUCTIONS
Tracking Familiarisation
Tracking the Machine
Tracking using the Remote Control
Tracking using the Dog Lead
Remote Control Battery Charging
RK1012T ROTOCRUSHER
CONTENTS
TABLE OF CONTENTS
SECTION 4:
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
SECTION 5:
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
SET-UP PROCEDURE
OPERATION
Operation Safety
Operation Lockout Procedure
General Information
Pre Operation Check List
Feeder Information
Feeder Instructions
Machine Starting
Setting Engine Revs
ESM Main Unit
Engaging Clutch
Product Conveyor Starting
Dirt Conveyor Starting
Feeder Starting
Machine Shutdown Sequence
RK1012T ROTOCRUSHER
CONTENTS
TABLE OF CONTENTS
SECTION 6:
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
MAINTENANCE
RK1012T ROTOCRUSHER
CONTENTS
TABLE OF CONTENTS
SECTION 7:
7.0
SECTION 8:
8.0
Index
Main Assembly
Chamber Wear Plates
Shaft and Bearing Assembly
Top Apron Adjuster Assembly
Middle Apron Adjuster Assembly (Manual Adjustment)
Bar Carrier Adjuster Assembly (Manual Adjustment)
Middle Apron & Bar Carrier Adjuster Assembly (Hydraulic Adjustment)
SECTION 10:
10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
WARRANTY
Warranty
SECTION 9:
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 1
INTRODUCTION
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 1
REMEMBER:
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
Machine Description:
Model:
RK 1012T ROTOCRUSHER
Serial No:
This machinery has been designed and manufactured in accordance with all the
relevant ESRs of the EU Machinery Directive.
A technical construction file for this machinery is retained at the following address:
Tesab Engineering Ltd.
7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Signed:
Name:
Brian A. Mills
Position:
Project Manager
Date:
Being the nominated representative of Tesab Engineering Ltd.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
ENGINE TYPE:
CLUTCH TYPE:
DESPATCH DATE:
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
Consider this manual a permanent part of your machine. Keep a copy of this
manual at the operational site.
This operation and maintenance manual must not be copied, reproduced
or loaned to a third party without written consent of
TESAB ENGINEERING LTD.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.4 FAMILIARISATION
The following conventions have been used throughout this operation and maintenance manual when describing component locations:
Right and left hand sides -
Front
Rear
REAR
RIGHT
LEFT
FRONT
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
1.
Feeder
2.
Crusher Unit
3.
Dirt Conveyor
4.
Chassis
5.
Drive System
6.
Product Conveyor
7.
Tracks
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
Chassis
The chassis is constructed of heavy-duty profiles and welded steel plates ribbed
and stiffened to withstand all operational and travelling stresses. The chassis is
mounted on 3.75m centre heavy-duty tracks, with remote control or dog lead operational facility.
Feeder
The 4.25m x 0.9m spring mounted heavy duty vibrating feeder is of twin shaft
design. The controls and variable speed are located on the feeder catwalk or
alternatively the feeder can be operated from the tracks remote control, this allows
the operator full control of crusher feed rate. The bar frame cassette can be manufactured to the customers specification depending on application and site conditions. The customer has the option of feeding the fines onto the product conveyor
belt or onto a 3.6m x 500mm side dirt conveyor. The feeder is fitted with hydraulic
folding heavy-duty cribs to give extra hopper capacity.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 1
Self-cleaning magnet
Dust suppression
Re-cycling apron
Vibrating feeder under crusher
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 2
SAFETY
RK1012T ROTOCRUSHER
SAFETY
Section 2
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER
NIP HAZARD
1.
2.
3.
DANGER
FALL HAZARD
1.
2.
3.
RK1012T ROTOCRUSHER
SAFETY
WARNING
Section 2
CRUSH HAZARD
1.
2.
3.
WARNING
PROTECTION
1.
2.
3.
WARNING
CONSULT MANUAL
1.
2.
3.
WARNING
LOCKOUT
1.
2.
3.
RK1012T ROTOCRUSHER
SAFETY
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
BATTERY HAZARD
1.
2.
BATTERY
HEAD PROTECTION
1.
EXPLOSIVE
HOT SURFACE
1.
ACID
Section 2
RK1012T ROTOCRUSHER
SAFETY
Section 2
2.1 SAFETY
Operators should be trained in the
correct and safe use of all equipment including the studying of this
manual, failure to do so could result in serious injury.
Any work on and with the machine
must be executed by reliable, trained
and authorised personnel only. Statutory minimum age limits must be observed.
Work on the electrical system and
equipment of the machine must be
carried out only by a skilled electrician or by instructed persons under the supervision and guidance of
a skilled electrician and in accordance with electrical engineering
rules and regulations.
Work on the hydraulic system must be
carried out by personnel with special
knowledge and experience of hydraulic equipment.
There are several specific signs on
your machine. Please take time to
familiarise yourself with the safety
signs and the operation and maintenance manual.
See to it that safety instructions and
warnings attached to the machine are
always complete and completely legible.
RK1012T ROTOCRUSHER
SAFETY
2.1
Section 2
SAFETY contd.
RK1012T ROTOCRUSHER
SAFETY
Section 2
RK1012T ROTOCRUSHER
SAFETY
Section 2
RK1012T ROTOCRUSHER
SAFETY
Section 2
RK1012T ROTOCRUSHER
SAFETY
Section 2
1.
LHS & RHS
4.
RAMS CONTROL
CONSOLE
3.
FEEDER
CONSOLE
2.
LHS & RHS
RK1012T ROTOCRUSHER
SAFETY
2.3
Section 2
EMERGENCY SITUATION
WARNING
In the case of an incident of any part failure on the
machine you must follow the following procedure.
1.
2.
3.
4.
Only when the machine is fully switched off and the crusher
rotor has completely stopped revolving (approximately 120
seconds), should an attempt be made to solve the problem.
5.
1.
2.
3.
4.
5.
RK1012T ROTOCRUSHER
SAFETY
Section 2
WARNING
1.
2.
3.
ISOLATOR IN ON POSITION
ENGINE CANOPY
CONTROL PANEL
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 3
TRACKING INSTRUCTIONS
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.0
Section 3
TRACKING FAMILIARISATION
Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
2
4
4
1
4
6 3
1.
2.
3.
4.
Emergency stop.
5.
Remote control
6.
Remote Control
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.0
Section 3
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
WHEN TRACKING THE MACHINE
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
>
>
>
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.1
Section 3
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.
IGNITION STARTER
a
b
a)
Check that no emergency stops are in the on position, if an emergency stop is in the on position lamp A (green) will NOT be
illuminated.
b)
c)
Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
d)
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.1
Section 3
- revs
+ revs
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.2
Section 3
a
h
SIDE Y
SIDE X
b
f
SIDE X
A
B
C
D
E
F
G
H
I
J
SIDE Y
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.2
Section 3
The following procedure is to be carried out to allow operator to track the machine
using the remote control.
a) Firstly ensure that the isolator switch location on the main engine
canopy is in the ON position as shown below.
b) Ensure that the track switch (A) on the main engine starter panel is in
the ON position and that the control switch (B) is in the REMOTE
position.
A
B
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.2
Section 3
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.3
Section 3
Tesab have also supplied a dog lead controller as another way of tracking the
machine
The following procedure is to be carried out to allow operator to track the
machine using the dog lead.
e)
Ensure that the control switch (B) is in the DOG LEAD position
and the Track Switch on the main engine starter panel is in the ON
position prior to operating the dog lead.
Track Switch
continued over...
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
3.3
Section 3
g)
Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
B
F
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
h)
To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS
Section 3
Charger
Unit
1.
2.
3.
Green Indicator
Battery
NOTE:
This charger requires a 3 pin
European to UK mains adaptor if
being used in the UK or Ireland.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 4
SET-UP PROCEDURE
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER
NIP HAZARD
1.
2.
3.
DANGER
FALL HAZARD
1.
2.
3.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
Section 4
CRUSH HAZARD
1.
2.
3.
WARNING
PROTECTION
1.
2.
3.
WARNING
CONSULT MANUAL
1.
2.
3.
WARNING
LOCKOUT
1.
2.
3.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
BATTERY HAZARD
1.
2.
BATTERY
HEAD PROTECTION
1.
EXPLOSIVE
HOT SURFACE
1.
ACID
Section 4
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.1
Section 4
INSTALLATION
The following section will take you step by step through the installation of your
RK 1012T ROTOCRUSHER.
Note:
Due to different transport and shipping regulations throughout the world the RK
1012T Rotocrusher will be delivered in different packing arrangements. For the
purposes of this manual it will be considered that the machine is delivered in its
most un-assembled configuration therefore some of the installation sections
may not be applicable. If this is the case ignore that particular instruction/section
and proceed to next section.
Before installing the RK1012T ROTOCRUSHER ensure that you have read all sections of this manual in order to familiarise yourself with the machine and its function,
paying particular attention to the SAFETY SECTION 2.
Installation, operation, and maintenance of the RK1012T ROTOCRUSHER mush
be carried out by reliable, authorised personnel only, statutory minimum age limits must be observed.
TESAB ENGINEERING Ltd. recommend that the installation of the RK1012T
ROTOCRUSHER is carried out by a recommended TESAB dealer and/or service
department.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.2
Section 4
Loading and off loading the RK1012T should be carried out by trained and experienced personnel only. They should first read the operation manual paying particular attention to the safety and installation sections.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 4
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.
PRIOR TO STARTING THE ENGINE
Before starting the engine please ensure that the two manual valves shown in the
picture below are in one of the following positions.
1.
2.
Both levers in
Track Position
WARNING
>
>
>
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.3
Section 4
The engine starter panel is located at the engine catwalk as highlighted below.
Starter Panel
Starter Panel
This area can be accessed by lowering the access steps (B). It is important, for
safety reasons, that when these steps have been lowered that they are locked
into position using clamps (C) at both sides. This is illustrated below.
C
C
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4
Before staring the engine check diesel and engine oil levels.
Throttle
scroll
button
A
B
IGNITION STARTER
a)
b)
Turn the starter ignition key C to position no. 1 which is the on position.
c)
Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
d)
Note:
e)
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.4
Section 4
IMPORTANT NOTE:
Before tracking we recommend that you fold up the engine area access steps in
order to prevent them from fouling unneccessarily.
WARNING
ENSURE MACHINE IS CLEAR OF ALL OVER HEAD CABLES
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.5
Section 4
TRACKING FAMILIARISATION
Familiarisation
The following terms/panel names have been used in this instruction leaflet, below
shows the names and there locations.
4
2
4
4
1
4
2
6 3
1.
2.
3.
4.
Emergency stop.
5.
Remote control
6.
Remote Control
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.5
Section 4
IMPORTANT
THIS RK1012T ROTOCRUSHER IS FITTED WITH TWO MANUAL VALVES FOR
CONTROLING THE CRUSHING AND TRACKING OPERATIONS. PLEASE READ
THE FOLLOWING CAREFULLY SO AS TO UNDERSTAND THE OPERATION OF
THE SYSTEM.
WHEN TRACKING THE MACHINE
Please ensure the both levers inside the Fast Track Console are located in the Track
Operation position prior to starting the engine. This can be seen in the diagram
below.
Both levers in
Track Position
WARNING
>
>
>
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
1.
THROTTLE
SCROLL
BUTTON
IGNITION STARTER
a
b
a)
Check that no emergency stops are in the on position, if an emergency stop is in the on position lamp A (green) will NOT be illuminated.
b)
c)
Turn the key to position no. 3 and hold, the start delay siren will
sound for approximately 7 seconds then the engine will crank and
start.
d)
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4
a
h
SIDE Y
SIDE X
b
f
SIDE X
A
B
C
D
E
F
G
H
I
J
SIDE Y
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4
The following procedure is to be carried out to allow operator to track the machine
using the remote control.
a) Firstly ensure that the isolator switch located on the main engine
canopy is in the ON position
b) Ensure that the track switch (A) on the main engine starter panel is in
the ON position and that the control switch (B) is in the REMOTE
position.
A
B
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.7
Section 4
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.8
Section 4
Tesab have also supplied a dog lead controller as another way of tracking the
machine
The following procedure is to be carried out to allow operator to track the
machine using the dog lead.
e)
Ensure that the control switch (B) on the main engine starter panel is
in the DOG LEAD position. Ensure that the Track Switch is in the on
position prior to operating the dog lead.
Track Switch
continued over...
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
4.8
Section 4
h)
Note: for safety reasons there is an emergency stop button (F) fitted
to the dog lead.
B
F
Important:
Once machine has been tracked
into place remove dog lead and
place in secure premises. (Ideally
works office or shovel cab)
i)
To track press relevant buttons on the dog lead control (as shown
above), for safety reasons Tesab have fitted a siren and orange
beacon to make other persons in the vacinity aware that the
machine is going to or is being moved and it is always important for
the operator to be aware of his surroundings.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Charger
Unit
1.
2.
3.
Green Indicator
Battery
NOTE:
This charger requires a 3 pin
European to UK mains adaptor if
being used in the UK or Ireland.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.10 POSITIONING
Before the RK 1012T Rotocrusher is positioned on site it is necessary to have a
level surface and spacious surroundings, if required level the work-site foundation
using a loading shovel.
The machine must be placed on solid ground capable of carrying its weight.
Track the machine into the desired position and ensure the machine is level. This
can be done with the aid of a spirit level.
(Ensure it is level both along the chassis and across the chassis.)
We recommend that when the machine is positioned correctly the dog lead and
the remote control are located in a safe place (i.e. works office or shovel cab).
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Unfold the handrails into the working position and bolt to secure (sections 1 & 2
first, then sections 3 & 4 and finally section 5). Ensure that the tab (6) is fitted
between the inside handrail (2) and the crusher for extra stability.
6
3
ii)
If required fit the pre-cleaner and exhaust. We would recommend that if the
machine has to be tracked for a long distance that you fit these items as soon
as possible.
Pre-Cleaner
iii)
Exhaust
For safety reasons once the machine is in the correct working position switch
the tracks off. This disables the system and prevents the machine from moving
if the remote or dog lead are touched accidentally. Move switch to off position
on control panel to disable tracks. See diagram over. It is also advisable to
switch the manual control valves to the CRUSH position in order prepare the
machine for working. See diagram over.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Both Levers in
CRUSH Position
Tracks
ON/OFF Switch
WARNING
Remove any parts, which have been packed on the catwalks and hopper. This is to
give fully access to all control areas and reduces any fall hazards.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
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.
B
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Firstly check around the cribs area to ensure there are no obstructions
and that the hydraulic hoses are not fouling.
ii)
Fold up side cribs approximately half way, one side at a time, using the
highlighted levers below.
Cribs RHS
Cribs LHS
iii)
Fold up rear cribs approximately half way using the highlighted lever
shown over the page.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Cribs Rear
iv)
At this stage carefully fold up each crib alternately until the three sides are up
in position.
v)
Using the M30x110 bolts and M30 nuts (found in the toolbox) bolt the cribs in
position.
M30x110 bolt
(3 off each side)
M30 nut
(3 off each side)
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Insert pins in rear cribs at point A as shown (Note: pins located in toolbox).
vii)
viii) Tesab have designed an extra crib cross tie above the grizzly bars. This is
designed to ensure that the material which passes this point is at the correct
height to enter the crusher. We highly recommend that this beam is fitted as it
will reduce any down-time due to crusher blockages.
The bolts for this can be found in the tool box. Ensure that the chains and shackles
are connected up appropriately.
Securing Chains
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
A
NOTE:
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
4.16 HOIST
Tesab may have supplied a swinging arm for use when changing hammers, etc.
(this is an optional extra). For transport purposes it is normally folded down. Elevate into the working position and bolt as shown.
Hoist in transport
position
Pivot hoist
around hinge
Bolt in place
using the 4 bolts
IMPORTANT:
Tesab only recommend that this arm is used for changing items up to a
maximum weight of one RK1012T Hammer (Part No 2-423-3) or 200kgs.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Bar carrier
Manual adjustment is standard and a spanner is provided for this (found in the toolbox).
Middle apron and bar carrier hydraulic adjustment is an optional extra.
Warning:
The crusher settings must NOT be altered while the crusher is in operation.
IMPORTANT
Clockwise rotation to
adjust apron fully open
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
IMPORTANT
Clockwise rotation to
adjust bar carrier forward
IMPORTANT
Anti-Clockwise rotation to
adjust bar carrier
backwards.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Using the control lever (D), very carefully extend the rams just enough to compress
the disc springs slightly (E).
Remove the shims (F) and again using the control lever, carefully close the
rams to allow the removal of the remaining shims (G).
Set the gap using the control lever. The gap can be checked through door B.
Once the gap is set, replace the shims (F &G) in the necessary order.
NOTE:
Once the bar carrier gap has been set, rotate the rotor to ensure that
there is enough clearance between the hammers and the blow bars. This
is necessary as, due to wear, the size of the blow bars can change.
D
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
H
Clockwise rotation to
adjust apron forward
IMPORTANT
Anti-Clockwise rotation to
adjust apron backwards.
Minimum
15mm
Note:
The setting is carried out at the outer bolts of the
yoke. The pretension of the spring unit is factory
set at the inner bolts and should not require any
adjustment.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Using the control lever (J), very carefully extend the rams just enough to compress
the disc springs slightly (E).
Remove the shims (F) and again using the control lever, carefully close the
rams to allow the removal of the remaining shims (G).
Set the gap using the control lever. The gap can be checked through door B.
J
NOTE:
Once the gap is set, replace the shims (F & G) in the necessary order.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
(ii)
(iii)
(ii)
Study the produced material and use that as a guide-line for your
setting.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
Water Tank.
Water Tank
This tank should be topped up regularly to ensure an efficient dust
suppression system. The system is designed for approximately one fill of
water to last one 10 hour shift depending on nozzle adjustment, etc.
ii)
Manifold
This allows you to turn off and adjust spray bars independently, depending
on site conditions. An extra outlet has been fitted if required.
Important Notes
1)
There is a tap at the base of the manifold (A). It is important that the
manifold is drained at the end of each working day, especially in cold
conditions. This is to prevent freezing of water in the manifold and any
subsequent damage.
2)
The water tank should be drained during extreme cold conditions in order
to prevent any unnecessary damage caused by expansion.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
SET-UP PROCEDURE
Section 4
2
1.
2.
iv)
Start / Stop
Button to start/stop
dust suppression
v)
Water Filtration
The tank has been fitted with a basic
water filter that should be changed
regularily and as when necessary
depending on the quality of the water
put into the tank.
Water Filter
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 5
OPERATION
RK1012T ROTOCRUSHER
OPERATION
Section 5
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER
NIP HAZARD
1.
2.
3.
DANGER
FALL HAZARD
1.
2.
3.
RK1012T ROTOCRUSHER
OPERATION
WARNING
Section 5
CRUSH HAZARD
1.
2.
3.
WARNING
PROTECTION
1.
2.
3.
WARNING
CONSULT MANUAL
1.
2.
3.
WARNING
LOCKOUT
1.
2.
3.
RK1012T ROTOCRUSHER
OPERATION
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
BATTERY HAZARD
1.
2.
BATTERY
HEAD PROTECTION
1.
EXPLOSIVE
HOT SURFACE
1.
ACID
Section 5
RK1012T ROTOCRUSHER
OPERATION
Section 5
WARNING
1.
2.
3.
ISOLATOR IN ON POSITION
ENGINE CANOPY
RK1012T ROTOCRUSHER
OPERATION
Section 5
RK1012T ROTOCRUSHER
OPERATION
Section 5
RK1012T ROTOCRUSHER
OPERATION
Section 5
RK1012T ROTOCRUSHER
OPERATION
5.5
Section 5
TRACKING FAMILIARISATION
1&2
4
4
1.
2.
3.
4.
Emergency stop
5.
Remote control
6.
1&2
4
Remote Control
4
Dog Lead Control
RK1012T ROTOCRUSHER
OPERATION
5.5
Section 5
Your TESAB RK1012T feeder has been supplied with the following features, the
following section gives a brief description and how they work.
-
You can operate the machine manually (as per standard RK1012T), this
can be done by positioning the Feeder operation button (on the Main
engine starter panel) in the manual position. This allows you to start and
stop the feeder from the platform at the feeder control console (A).
(important note: there is no speed sensor facility when operating the
machine in this way)
A UTO
MANUAL
You can operate the machine by remote control, this can be done by positioning the Feeder operation button (on the Main engine starter panel) in
the Auto position, This allows you to operate the feeder using your Remote control hand piece.
The speed sensor facility is in operation when using this form of control,
this stops the feeder when the rotor drops below a factory pre-set speed
and re-starts the feeder again when rotor regains the pre-set speed. The
speed sensor facility over-rides the remote control stop and start
(important note: when using this form of control ensure that the lever at
the feeder control console is in the on position)
1
How to use your remote control:
2
Note:
1.
2.
A blue beacon has been fitted to the machine this notifies the
operator that the feeder is currently off.
RK1012T ROTOCRUSHER
OPERATION
5.6
Section 5
Before staring the engine check diesel and engine oil levels.
a)
b)
Turn the starter ignition key C to position no. 1 which is the on position.
c)
Turn the key to position no. 3 and hold, the start delay siren will sound for
approximately 7 seconds then the engine will crank and start.
d)
Note:
RK1012T ROTOCRUSHER
OPERATION
Section 5
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
OPERATION
Section 5
Diagnostic Display
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
RK1012T ROTOCRUSHER
OPERATION
Section 5
Each time the scroll forward switch is depressed and held, EMS will page through
the engine parameters in the order listed below. The abbreviation for the parameter
will be displayed. When the scroll switch is released, EMS will display the current
real time value for that parameter.
Abbreviation
Spd
GA-1
GA-2
GA-3
GA-4
Boost
IAirT
FuelT
AccrP
AccrT
Fuel
Hrs
Load
Parameter
Engine Speed
Engine Oil Pressure
Coolant Temperature
Battery Voltage
Fuel Pressure (Customer Installed Sensor)
Boost Pressure
Inlet Air Temperature
Fuel Temperature
Auxiliary Pressure
Auxiliary Temperature
Fuel Rate
Engine Hours
Engine (%) Load
RK1012T ROTOCRUSHER
OPERATION
Section 5
bump-in
clutch
Engage Clutch
gradually
IMPORTANT: Read Section 6.4 on manual clutch maintenance this states that
the clutch, initially when new, will require several adjustments (it
will also require further adjustments during clutch life).
It is important that this procedure is adhered in order to achieve
pro-longed clutch life.
RK1012T ROTOCRUSHER
OPERATION
Section 5
Increase the engine revs to 1200 rpm. This can be done by observing the digital tachometer on the starter panel and adjusting the throttle scroll button.
Throttle Adjustment
Increase Revs
Decrease Revs
Start the hydraulic clutch by pressing the ON button on the starter panel as
shown below.
NOTE:
RK1012T ROTOCRUSHER
OPERATION
Section 5
Increase Revs
Decrease Revs
RK1012T ROTOCRUSHER
OPERATION
Section 5
The conveyor can be TENSIONED correctly at the top end drum using the
adjuster bars as shown.
Note: The conveyor belt tension is factory set but you will find due to running it over time or climatic conditions the belt will stretch and require retensioning.
Important: DO NOT over tension the belt as this will cause excessive strain on the
bearings and drive system.
A
Product Conveyor
Adjuster bars
NOTE:
Slacken off Bolts A
prior to Tensioning Belt
ii)
In order to track the belt correctly you must adjust the return rollers as shown.
RK1012T ROTOCRUSHER
OPERATION
Section 5
Dirt Conveyor
Control Lever
Initiallythe conveyor belt is tracked when running empty. The conveyor may need to be retracked when under load.
In order to track this belt correctly please carry out the following procedure:
A
The belt can be adjusted by adjusting the drums at points A.
Note:
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.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
OPERATION
Section 5
Feeder speed can be adjusted by turning the feeder speed control knob.
The operator must set the speed of the feeder depending on the application and
finished product required.
This is why we would recommend running feeder slowly initially and increase the
speed in order to avoid blockages.
If you are having difficulty in obtaining the required product please contact
your local Tesab dealer and he will assist on calibrating your machine.
RK1012T ROTOCRUSHER
OPERATION
Section 5
It is important to ensure that you allow the machine to run empty at the end of the
shift before closing machine down, including hopper and feeder. By not allowing
this to happen will put unnecessary pressure on the feeder bearings, springs and
hydraulic system.
1.
Stop feeder
2.
3.
4.
5.
Dis-engage clutch
6.
7.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 6
MAINTENANCE
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Crusher Opening
IMPORTANT
Ensure all bolts are re-fitted after closing
IMPORTANT
DO NOT OPEN ANY DOOR OF THE CRUSHER UNTIL THE ROTOR HAS
STOPPED COMPLETELY AND THE CONTROL POWER HAS BEEN BROKEN,
OR, IN THE CASE OF A DIESEL POWERED CRUSHER, THE CLUTCH IS DISENGAGED, THE ENGINE HAS STOPPED AND THE IGNITION KEY HAS BEEN REMOVED.
NEVER START THE CRUSHER UNTIL ALL DOORS ARE CLOSED AND LOCKED.
WHEN REMOVING HAMMERS AND IMPACT BARS, ALWAYS USE PROTECTIVE
GOGGLES (YOU CAN, ACCIDENTALLY HIT ASKEW AND A METAL SHIVER MAY
HIT YOUR EYES).
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
2.
Picture No. 1
3.
4.
5.
6.
7.
8.
9.
Picture No. 2
If everything is OK, make the final gap
settings, close and lock all doors. ALL
SET FOR CRUSHING.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
NOTE:
The setting must not be
altered while crusher is in operation.
1.
Picture No. 3
2.
Picture No. 4
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
D
NOTE:
The setting must not be altered
while the crusher is in operation.
1.
2.
Picture No. 6
NOTE:
Once the bar carrier gap has
been set, rotate the rotor to ensure that there
is enough clearance between the hammers
and the blow bars. This is necessary as, due
to wear, the size of the blow bars can change.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
1.
2.
3.
4.
5.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
PTO
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
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:
-
Remove the hand hole plate (1) in the housing and turn the clutch until the
locking pin (2) can be reached (see picture 6.4.1.1).
Disengage the adjusting locking pin (2), by pulling it out towards the pulley,
and turn the adjusting yoke or ring (3) to the right (clockwise) until the operating
lever requires a distinct pressure to engage (see picture 6.4.1.1).
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Picture 6.4.1.1
NOTE:
The majority of clutch failures are not caused by a unit being under sized
for the application. Failures often are the result of the clutch not being
properly adjusted. Check and adjust the clutch on a regular basis, to the
correct engaging effort as specified on the instruction cover plate.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Clutch Lubrication
Throwout Collar:
Main Bearings:
Lever Shaft:
6.4.3
Lubricant Specification
Use any high grade, high temperature, lithium based gun lubricant. For further details see recommended lubricant section in this manual.
NOTE:
Although this section details the greasing points on the clutch, it is important to note that if the machine is fitted with the Autolube system,
these points are supplied with grease by it. See the Autolube section
for further details.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.5.1
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.
OSO 32
VITAM GF 32
ENERGOL HLP 32
HYSPIN AWS 32
RPM EP HYDRAULIC 32
NUTO H 32
DTE 24
TELLUS 32
RANDO HD 32
AZOLLA ZS 32
Change the oil filter cartridge (25 micron) when the pressure is 1.7 bar over
the rated value and/or the pressure switch is on.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
In cases where there is considerable oil leakage the rotating seals should be
changed (see picture 6.5.1.1).
Keep the oil cooler clean. The radiator pack can be cleaned by either washing
carefully by hand or by using air pressure.
IMPORTANT: Never use water pressure as this can damage the aluminium pack.
-
Check periodically (approximately every 1000 hours) that the pump chain is
the correct length (see table below). The chain can be stretched by hanging
a 20 kg weight from it.
KPTO
15
17-19
21-24
27
Pressure gauge
switch
Elastic coupling
(not shown)
Rotating seal
(not shown)
Rotating seal
(not shown)
Oil filter
Solenoid valve
Oil level
indicator
Picture 6.5.1.1
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.6 MAINTENANCE
The maintenance instructions for your RK 1012T Rotocrusher are set out under
the following headings.
General Information
Safety Information
Hydraulic System
Tracks
Hydraulic Fluids
Oil Tanks, Pipes and Fittings
Diesel Engine
Product Conveyor Reduction Gear
Feeder
Bearings and Lubrication
General Specification Inspection
Routine Maintenance Schedule
Daily Maintenance
Weekly Maintenance
Six Monthly Maintenance
Belt Tracking
V-Belt Tensioning
Recommended Gear Oil
Recommended Lubricants
Automatic Greasing System
Recommended Fluids
Fault Finding
Note:
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
IMPORTANT NOTE
If the RK1012T is operated for long periods of time in extreme conditions either
climatic (-15C to 33C) or very dusty the maintenance schedule will change. If this
scenario arises please consult your local Tesab dealer or Tesab Engineering technical/service department.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
DANGER
NIP HAZARD
1.
2.
3.
WARNING
HIGH PRESSURE
1.
2.
3.
DANGER
FALL HAZARD
1.
2.
3.
WARNING
PROTECTION
1.
2.
3.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
High Pressure
Filters
DANGER
HIGH PRESSURE
The filter
element needs
to be changed
when the
indicator turns
red.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.10 TRACKS
Each Track Frame Assemblies fitted to the TESAB RK1012T Rotocrusher
comprise of five main components:
1.
2.
3.
4.
The FRONT IDLER is mounted at the opposite end of the frame to the
sprocket, the idler slides on guides. The track is adjusted by a hydraulic
cylinder attached to the idler arrangement. Between the idler, and the track
adjusting cylinder is a recoil spring, which will allow the idler to move backwards in the event that excessive load is placed on the track.
5.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Track Adjustment.
Check if the track is correctly adjusted. As the track wears it will become
slack and should be checked regularly.
To establish if the track requires adjustment move the machine backwards
and forwards a few metres on level ground and in a straight line (do not slew).
This enables the track to adopt its natural degree of tension.
Measure the droop as shown on figure 1.
30mm approx.
Equal
Equal
Inspection
Cover
Figure 1
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
M1442 Adapter
Important:
Do not tension the track too tightly as this places unacceptable
loads on the gearbox bearings and idler bearings.
It will lead to accelerated wear and premature failures.
b)
When the track droop appears to be correct, move the machine backwards and
forwards and re-check the droop.
Add more grease if required.
Replace the inspection cover when the correct adjustment has been made.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
LEVEL
Figure 2
Clean the area around the plugs and remove any surrounding debris.
Remove both plugs and fill through the upper plug hole.
Wait a few minutes until any trapped air has escaped then recheck the
level.
Add more oil if necessary.
Note: approximately oil quantity 5 litres per gearbox
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Figure 3
Clean the area around both plugs and remove any surrounding debris.
Remove both plugs and allow to drain.
More effective draining will occur if this operation is carried out when
the oil is hot.
Important:
Do not move the machine, except to re-position the plug holes
for re-filling, without oil in the gearboxes.
Oil Change Periods.
The oil should be drained from the gearboxes after the first 200 hours of
operation, and re-filled with the correct lubricant (see lubrication chart).
Following this initial oil change the oil should then be replaced after
2000 hours of use or at least once per year.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Leakage
Check daily for any signs of oil leakage, particularly, front idler seals,
roller seals and gearbox.
If any leakage is found, action must be taken to correct the problem
before the machine is used.
4.
Loose Bolts.
350 ft lbs.
350 ft lbs.
350 ft lbs.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Motion Valve
Track Shoes
33 ft lbs.
120 ft lbs. plus 1/3 turn
or
API GL5
Grade 80W/90
Geartex EP-B
80W/90
Century Oils
BOA
80W/90
Track Adjustment
A good quality all purpose grease should be used.
Texaco
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Prevent rot.
Depress foaming.
Prevent formation of sludge, gum and varnish.
Retain its own stability, thereby reducing fluid replacement.
Prevent corrosion and pitting.
For best operating results it is strongly recommended that the hydraulic fluid
used is selected from the recommended range listed in section 12. In the service it is recommended that the hydraulic system is drained and refilled at least
once every 1500 hours of operation. The hydraulic fluid should be changed
after the machine has stopped work. The drain plug for the hydraulic system is
mounted on the side of the tank. In the event of pump or motor failure, both
suction and return line filter elements must be changed.
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
IMPORTANT
The engine water trap (A) must be changed every engine service.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Attention:
Routine Maintenance:
The operator is responsible for routine maintenance and must carry out the following activities.
After a brief operating period of about 100 hours (breaking-in), change the
oil in the gear unit (Grade EP150 or equivalent).
Check that there are no metallic parts with unusual dimension in the magnetic plug of the gear unit.
Change the oil in the gear unit while it is hot so that it is easier to drain.
Subsequent oil changes should be made every 200-250 hours at operation, or, in any case, every year.
Periodically check the level (about once a month) and top up if necessary.
Attention:
When checking the oil levels in gear unit, if the levels have risen this
means that oil is penetrating from the rotary seal. Contact the local
Brevini Service Dealer.
For your unit it is recommended to keep a chart that you duly fill and up-date each
time maintenance is performed.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
6.15 FEEDER
The vibrating feeder is robustly designed. The twin shafted design will give you
years of continuous trouble free operation. The feeder is made from heavy
steel plate reinforced at appropriate places with channel and gussets. The
feeder is supported and isolated by a nest of heavy coil springs mounted on a
sub-frame constructed of heavy I Beam. The springs need only be inspected
weekly for damage and fatigue. Two shafts with bolt-on weights are driven via
hydraulic motor through flexible coupling on one side. Maintenance of your
feeder is minimal. However, we recommend the following guide to increase its
effectiveness and prolong its life-span.
The four bearings require greasing in general every week (50 hours). Grease
nipple access points are accessible above bearing. Three shots or four grams
of grease each, will be adequate for these bearings. Take care not to over-grease.
For further details see AutoLube section (6.27).
On the non-drive side of the vibrating mechanism there are gear wheels between the shafts to transfer the drive from one shaft to the other. These gear
wheels are lubricated using an oil bath design. The gear oil should be
changed every 6 months to maintain efficient power transfer from one gear
wheel to the other. To fill (or top up gear wheel) do so as described below.
Refill oil at top
Level
Over-spill bung
WARNING:
1.
2.
3.
Drain Bung
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
The bearings of the crusher are spherical roller bearings with labyrinth packings.
2.
Force feed the grease until it is forced out into the labyrinths, so as
to press out any impurities.
RK1012T ROTOCRUSHER
GENERAL INFORMATION
Section 6
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
WARNING:
NOTE:
Provided in this section is a Greasing Schedule for your machine. This section is
only applicable for machines that do not incorporate the Autolube System. If your
machine uses the Autolube please ignore this section.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Check the machine for loose parts, check that all bolts and nuts
are
secure.
Check the hydraulic oil level in the tank and top up if necessary.
Ensure that all safety systems are intact (i.e. all the wires to sensors are intact)
Check that fuel oil level in the tank and the supply line to the
engine.
Check all the hydraulic motors, pumps, cylinders and hoses for oil
leaks and tighten if necessary. When tightening the hydraulic
fittings always use two spanners, one for holding, one for tightening.
Ensure that all the troughing and return rollers are free running
and clear of obstructions.
When all checks have been made, close and fasten all the guards before operating the machine. At the end of the day carefully clean the machine and the
ground immediately around the machine, of all the material and debris build up.
Good housekeeping pays untold dividends in increased production and extended plant life.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
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.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
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.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
REMEDIES
1.
Insufficient aligning of
drums and idlers.
2.
Misalignment of frame
3.
Material build up on
drums and idlers
Clean idlers and drums. Check belt cleaners and replace if necessary. Possibly
change to more efficient type.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Adjusters
IMPORTANT NOTE:
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
CE
NT
RE
DI
ST
AN
CE
16
m
pe m
r 1 de
m flec
of
sp tion
an
Belt
Section
SPB
SPC
80 to 132
140 to 200
112 to 224
236 to 315
Newtons (N)
25 to 35
35 to 45
45 to 65
65 to 85
Kg - Force (kgf)
2.5 to 3.6
3.6 to 4.6
4.6 to 6.6
6.6 to 8.7
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
NOTE:
For single belt drives a straight edge should
be placed across the two pulleys to act as a
datum for measuring the amount of deflection.
If the measured force falls within the values
given, the drive should be satisfactory. A new
drive should be tensioned to the higher value
to allow for the normal drop in tension during
the run in period.
After the drive has been running for 30 minutes, the tension should be checked and readjusted to the higher value, if necessary.
TROUBLE SHOOTING
Small Cracks on V-Belt side and base.
Generally caused by shortage of belt tension
but excessive heat and/or chemical fumes can
also give same failure.
V-Belt Swelling or softening
Caused by excessive contamination by oil,
certain cutting fluids or rubber solvent.
Whipping During Running
Usually caused by incorrect tensioning, principally on long centre drives. If a slightly higher
(or lower) tension does not cure the problem
there amy be a critical vibration frequency in
the system which requires redesign or a
banded belt. Consult Fenner Technical Services.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
SPECIFICATION
ESSO
GX 80-90
CASTROL
HYPO Y EP 80-90
MOBILUBE
HD 90
BP
HYPOGEAR EP 90
TEXACO
GEARTEX EP-B 90
SHELL
SPIRAX HD 80W-90
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
GREASE LUBRICATION
SPECIAL SCREEN
GREASE FOR HOT
METALS
SPECIAL SCREEN
GREASE
GENERAL PURPOSE
GREASE
BP
Energrease LS-EP2
Energrease L21M
Total
Multis EP2
Multis MS2
Duckhams
Adamax LEP2
Adamax LM2
Castrol
Spheerol EPL2
Spheerol AP3
Shell
Alvania EP2
Liplex EP2
Alvania R3
Esso
Becon EP2
Unirex EP2
Becon Q2
Texaco
Multifak EP2
Molytex 2
Chevron
Duralith EP2
Gulf
Gulfcrown EP2
Supercrown EP2
Mobile
Modilux EP2
Mobilgrease HP2
Mobilgrease MP
Century
Regulus A2EP
Luplex M2
Regulus A3
F.A.G.
Arcanol L135
Arcanol L71
Rocol
Sapphire
BG 151
Optimol
Longtime PD
Omega
85
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Pos.
No. of
Locations
Description
Frequency
(Hours)
Qty
10 (daily)
4g
50 (weekly)
4g
50 (weekly)
4g
50 (weekly)
8g
Feeder Bearings
50 (weekly)
4g
50 (weekly)
4g
50 (weekly)
4g
50 (weekly)
4g
50 (weekly)
4g
NOTE
Four grammes of grease is the equivalent of three shots/pumps from the
grease gun.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
5
3
1
6
1.
2.
3.
4.
5.
6.
7.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Reservoir
2.
Pump Element
3.
Safety Valve
4.
5.
6.
7.
8.
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:
-
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
Basically the only maintenance required is to refill lubricant in good time with
clean lubricant. However check regularly that lubricant is actually reaching all
lubricants points.
Also check the high-pressure plastic hoses and plastic tubes for damage.
If necessary replace them.
If the AUTOLUBE system is not functioning properly then the following will
occur.
During the Pump operation the Indicator Pin in the control value
mounted beside the AUTOLUBE Pump (Fig 1, A) will move in and
out approximately every 40 seconds. If this is not happening then
one of the following may have occurred.
(a)
(b)
(c)
(d)
-
FIG 1
FIG 2
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
C
A
B
IMPORTANT
-
The grease/oil must be free from impurities and must not be liable to
change its consistency in the course of time.
If the reservoir has been completely emptied, the pump may require 10
minutes operation before it operates with its full output again.
Induce several lubrication cycles by pressing the Autolube button on the main
engine control panel a minimum of 5 seconds. Then check the indicator pin is
moving.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
To carry out either of the above depress the test button on the main control panel
as shown below for at least 5 seconds.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
REMEDY
-
Reservoir empty
REMEDY
-
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
20 - 30C
(58 - 68F)
30 - 48C
(86 - 120F)
ESSO
NUTO H 32
NUTO H 68
UNIVIS N 68
BP
ENERGOL HLP 32
ENERGOL HLP 68
ENERGOL SHF 68
MOBIL
DTE 13
DTE 15
DTE 16
SHELL
TELLUS R37
TELLUS R37
TELLUS R37
TEXACO
RANDO HD 32
RANDO HD 68
RANDO HD 100
TOTAL
AZOLLA 32
AZOLLA 68
EQUIVIS ZS 68
NOTE:
The use of brands, other than those shown above should be subject to
the approval of TESAB ENGINEERING LTD.
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
2.
Engine stops
NOTE:
3.
4.
POSSIBLE FAULT
REMEDY
Disengage clutch
Crusher jammed
Clear obstruction
Obstruction or break
in the fuel line system
No response
from any
hydraulic
system
Machine
operating slowly
No external oil
leaks.
Replace pump
Worn pump
Pressure relief valve
stuck in open position
Replace pump
Repair or replace valve
cartridge
Top up hydraulicsystem
Worn pump
Replace pump
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
5.
6.
Excessive noise
from hydraulic
pump
Replace pump
Replace hose
7.
Conveyor belt
Non-return valve worn or
tends to run back
if stopped with a
load on the belt
8.
9.
Crusher not
turning when the
rest of system
operational
V belts slipping
Tighten belts
10.
Crusher wont
turn machine not
operational
Clear obstruction
RK1012T ROTOCRUSHER
MAINTENANCE
Section 6
12.
Feeder not
working
Rams not
operational
Replace bearings
Replace coupling
Replace motor
If you cannot identify the cause of the trouble or are unable to put it right yourself please contact TESAB ENGINEERING LTD., or your local TESAB authorised dealer.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 7
PREPARING FOR
TRANSPORT
RK1012T ROTOCRUSHER
Section 7
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 potential warning or danger when operating this machine.
DANGER
ELECTRICAL HAZARD
1.
2.
3.
DANGER
NIP HAZARD
1.
2.
3.
RK1012T ROTOCRUSHER
WARNING
Section 7
CRUSH HAZARD
1.
2.
3.
WARNING
PROTECTION
1.
2.
3.
WARNING
CONSULT MANUAL
1.
2.
3.
WARNING
LOCKOUT
1.
2.
3.
RK1012T ROTOCRUSHER
WARNING
HIGH PRESSURE
1.
2.
3.
CAUTION
WARNING
2.
WARNING
BATTERY HAZARD
1.
2.
BATTERY
HEAD PROTECTION
1.
EXPLOSIVE
HOT SURFACE
1.
ACID
Section 7
RK1012T ROTOCRUSHER
Section 7
WARNING
1.
2.
3.
ISOLATOR IN ON POSITION
ENGINE CANOPY
RK1012T ROTOCRUSHER
Section 7
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
d)
Feed-in Chute
Extension Box
Dust Suppression
Water Pipe
RK1012T ROTOCRUSHER
Section 7
f)
Securing Chains
A
Cribs
Remove bolts
RK1012T ROTOCRUSHER
Section 7
Lower both side cribs and rear cribs slowly and alternatively until fully
lowered.
Cribs RHS
Cribs Rear
Cribs LHS
h)
Fold up Dirt conveyor using lift point A. Insert the transport brackets at
point B and remove belt scrapper.
B
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.
RK1012T ROTOCRUSHER
Section 7
j)
Pivot hoist
around hinge
Remove 4 bolts
before placing in
position
RK1012T ROTOCRUSHER
Section 7
Undo the tab (6) that is fitted between the inside handrail (2) and the
crusher. Fold the handrails down into the transport position and secure
with the appropriate straps and cable ties (fold sections 3, 4 & 5 first,
then sections sections 1 & 2).
6
l)
Ensure all items which have been removed for transport purposes and
repositioned on the machine have been well secured (ie., all items are
tied down satisfactorily around catwalk area).
m)
Ensure all bolts/brackets have been placed in a secure location (ie., the
toolbox).
n)
Pre-Cleaner
Exhaust
RK1012T ROTOCRUSHER
Section 7
Ensure that the engine access steps are folded up when tracking
machine before and after loading thus reducing the possibility of
fouling.
IMPORTANT NOTE:
TESAB ENGINEERING LTD RECOMMEND THE OFFLOADING AND LOADING OF THE RK1012T
ROTOCRUSHER IS CARRIED OUT BY TRAINED AND
EXPERIENCED PERSONNEL ONLY.
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 8
WARRANTY
RK1012T ROTOCRUSHER
WARRANTY
Section 8
8.0 WARRANTY
All conditions and warranties expressed or implied by any statue common law.
Trade usage or otherwise are hereby excluded. No liability is accepted by
TESAB ENGINEERING Ltd. for any loss, damage or injury to property or persons arising directly or indirectly from any failure or direct in the machinery
supplied. The materials employed by TESAB ENGINEERING LTD. in the
manufacture of their machinery, to the best of their knowledge, are the highest
available quality of their respective kinds. TESAB ENGINEERING LTD. undertakes to replace or repaid free of cost any part supplied by them direct to the
customer of which they shall receive notice and which shall be proved to the
satisfaction of TESAB ENGINEERING LTD. within a period of six months of
delivery to be defective in workmanship or materials provided.
A:-
That written notice of complaint is given within seven days of the discovery of the defect.
B:-
C:-
D:-
TESAB ENGINEERING LTD. shall not be liable for the cost of removal
of the defective part or the cost of fitting a new part.
E:-
That the guarantee period shall be proportionally reduced if the machinery is run for more that one eight hour shift per day.
No unauthorised alteration or modification has been made to the plant or machine or component the subject of the claim.
The new part will be delivered by TESAB ENGINEERING LTD., carriage paid
to the customers nearest station in the U.K. or F.A.S. port of exportation.
In case of parts or components not manufactured by TESAB ENGINEERING
LTD. the customer shall be entitled to the benefits in so far as it may be transmitted to the customer, of any guarantees given by the manufacturer in respect
thereof and TESAB ENGINEERING LTD. liability in respect of such goods is
limited to making the benefits of the manufacturers guarantees available to the
customer to the extent aforesaid.
RK1012T ROTOCRUSHER
WARRANTY
Section 8
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 9
RK1012 CRUSHER
PARTS LIST
RK1012T ROTOCRUSHER
Section 9
TYPE RK 1012
ROTOCRUSHER
UNIT
RK1012T ROTOCRUSHER
Section 9
9.0 INDEX
Section
Description
9.1
Main Assembly
9.2
9.3
9.4
9.5
9.6
Important Note:
To ensure supply of the correct parts with the minimum
delay please quote crusher serial number.
RK1012T ROTOCRUSHER
Section 9
13
3
4
3
10
3
7
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Amount
4
10
8
8
2
1
1
1
16
16
8
2
48
16
2
Description
Stroke
Grinding List
Stroke Plate
Stroke Plate
Stroke Carrier
Bar Carrier
Shaft
Rotor
Protector Plate
Protector Plate Pin
Stroke Securing Plate
Shaft
Stroke Plate Bolt Assy
Bolt Assembly
Wear Plate
Drawing
No.
2-423-3
3-604
2-431
2-432
1-593
1-592-1
1-592-5
1-587-2
3-660-1
11
14
Wgt kg/
item
196
30
85
85
248
835
28
1730
18
Notes
1-593-3
3-748
28
RK1012T ROTOCRUSHER
Section 9
13
A
4
2
1
5
1
13
9
12
1
1
10
1
6
8
6
1
1
11
10
1
7
7
7
7
7
7
7
7
1
1
1
A-A
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Amount
34
2
2
2
2
2
10
2
2
4
2
2
2
Description
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate
Wear Plate4-820
Drawing
No.
4-820
4-821
4-822
4-823
4-824
4-825
4-826
4-827
4-828
4-829
4-830
4-831
4-832
Wgt kg/
item
31.5
29.1
36
22.5
27
27.7
15.4
20.3
16.4
30.1
24.1
31.4
63
Notes
RK1012T ROTOCRUSHER
Section 9
4 13 14
8
12
10
11
15
16
3
7
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Amount
2
1
2
3
1
1
1
1
2
1
2
1
24
2
2
1
Description
Bearing House
Labyrinth Seal
Labyrinth Seal
Labyrinth Seal
End Cover
Retaining Ring
Scored Pulley
End Cover
Sperical Roller Bearing
Clamping Sleeve
Clamping Sleeve
Screw
Screw
Lubricant Nipple
Washer
Shaft
Notes
320.0
RK1012T ROTOCRUSHER
Section 9
5
6
4
Part No.
1
2
3
4
5
6
Amount
2
4
2
2
2
6
Description
Adjustment Screw
Nut
Stud
Washer
Split Pin
Disc Spring
Drawing
No.
3-619-1
510206
4-742-2
Wgt kg/
item
Notes
M39
100414
RK1012T ROTOCRUSHER
Section 9
8
7
Part No.
1
2
3
4
5
6
7
8
Amount
4
2
2
2
86
20
2
2
Description
Adjustment Screw
Adjustment Screw
Adjustment Yoke
Stud
Disc Spring
Nut
Washer
Split Pin
Drawing
No.
4-740-1
3-614-1
4-742-1
4-741-2
100414
510206
Wgt kg/
item
Notes
M39
RK1012T ROTOCRUSHER
Section 9
Lower Stroke
Carrier
1
Part No.
1
2
3
4
5
6
7
8
Amount
4
2
2
2
86
20
4
4
Description
Adjustment Screw
Adjustment Screw
Adjustment Yoke
Stud
Disc Spring
Nut
Split Pin
Washer
4 7 8
Drawing
No.
4-740-1
3-614-1
4-742-1
4-741-1
100414
510206
Wgt kg/
item
Notes
M39
RK1012T ROTOCRUSHER
Section 9
15
2
3
16
14
9
1
6
5
10
13
11
12
RK1012T ROTOCRUSHER
Section 9
ITEM
DESCRIPTION
QTY
Adjustment screw
3-701-3
Adjustment screw
3-701-2
Adjustment yoke
3-701-1
Hydraulic ram
3-701-4
Disc spring
4-110 x 10
Disc spring
15
4-110
M39 nut
16
90-04-0003
3-701-6
End cap
M20x50 bolt
10
50mm shim
3-701-5-50
11
30mm shim
3-701-5-30
3-701-5-10
12
10mm shim
12
13
5mm shim
12
14
Pin
15
Washer
16
Split pin
4-741-2
10-07-0004
RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER
Section 10
HYDRAULIC & ELECTRIC
SCHEMATIC DIAGRAMS
RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM
(Standard)
Section 10.0
RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM
(inc. Conveyor Hyd. Folding)
Section 10.1
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
(Fuse Relay Description)
Section 10.2
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
(Panel Layout)
Section 10.3
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.4
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.5
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.6
RK1012T ROTOCRUSHER
ELECTRIC SYSTEM
Section 10.7