1012T Manual Iss2 PDF

RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER May 2002 Issue
Tesab Engineering Ltd., Unit 7B Gortrush Industrial Estate, Omagh, N.Ireland.

RK1012T ROTOCRUSHER
Section 1
INTRODUCTION

RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER Section 1
The TESAB RK 1012T ROTOCRUSHER complies with the EU directive 89/392/EEC

and all relevant amendments.
READ THIS MANUAL CAREFULLY AND LEARN HOW TO OPERATE AND

SERVICE YOUR MACHINE CORRECTLY.
FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIP-

MENT DAMAGE.
REMEMBER:
GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS

IN INCREASED PRODUCTION AND EXTENDED
PLANT LIFE !

RK1012T ROTOCRUSHER
INDEX May 2002 Issue
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
2.0 Safety Introduction

2.1 Safety Notes
2.2 Position of Emergency Stops
2.3 Emergency Situation
2.4 Lockout Procedure
SECTION 3: TRACKING INSTRUCTIONS
3.0 Tracking Familiarisation

3.1 Tracking the Machine
3.2 Tracking using the Remote Control
3.3 Tracking using the Dog Lead
3.4 Remote Control Battery Charging

RK1012T ROTOCRUSHER
TABLE OF CONTENTS
SECTION 4: SET-UP PROCEDURE
4.0 Set-up Procedure Safety

4.1 Installation
4.2 Loading & Off-Loading
4.3 Starting Engine
4.4 Engine Starting Procedure
4.5 Tracking Instructions
4.7 Tracking using the Remote Control
4.8 Tracking using the Dog Lead
4.10 Positioning
4.11 Preparing for Initial Startup
4.12 Dirt Conveyor Unfolding
4.13 Crib Folding and Assembly
4.14 Feeder Beacon
4.15 Feed-In Chute
4.16 Hoist
4.17 Crusher Settings
4.18 Dust Suppression
SECTION 5: OPERATION
5.0 Operation Safety

5.1 Operation Lockout Procedure
5.2 General Information
5.3 Pre Operation Check List
5.4 Feeder Information
5.5 Feeder Instructions
5.6 Machine Starting
5.7 Setting Engine Revs
5.8 Engaging Clutch
5.9 Product Conveyor Starting
5.10 Dirt Conveyor Starting
5.11 Feeder Starting
5.12 Machine Shutdown Sequence

RK1012T ROTOCRUSHER
TABLE OF CONTENTS
SECTION 6: MAINTENANCE
6.0 The RK1012 Rotocrusher

6.1 Replacing or Turning Hammers
6.2 Setting The Crusher Gap
6.3 Replacing or Turning Impact Bars
6.4 Clutch
6.5 Clutch Adjustment
6.6 Clutch Lubrication
6.7 Maintenance
6.9 Safety Information
6.10 Hydraulic System
6.11 Tracks
6.12 Hydraulic Fluids
6.13 Oil Tank, Pipes & Fittings
6.14 Diesel Engine
6.15 Product Conveyor Reduction Gear
6.16 Feeder
6.17 Bearing & Lubrication
6.18 General Specification Inspection
6.19 Routine Maintenance Schedule
6.20 Daily Maintenance
6.21 Weekly Maintenance
6.22 Six Monthly Maintenance
6.23 Belt Tracking
6.24 V-Belt Tensioning
6.25 Recommended Gear Oil
6.26 Recommended Lubricants
6.27 Automatic Greasing System (Autolube)
6.28 Autolube Maintenance
6.29 Autolube Troubleshooting
6.30 Recommended Fluids
6.31 Fault Finding

RK1012T ROTOCRUSHER
TABLE OF CONTENTS
SECTION 7: PREPARING FOR TRANSPORT
7.0 Preparing for Transport
SECTION 8: WARRANTY
8.0 Warranty
SECTION 9: RK1012 CRUSHER PARTS LIST
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
SECTION 10: HYDRAULIC & ELECTRIC DIAGRAMS
10.0 Hydraulic Diagram (Standard)

10.1 Hydraulic Diagram (inc. Conveyor Folding)
10.2 Electric Diagram (Tracks Control)
10.2 Electric Diagram (Engine Control)

RK1012T ROTOCRUSHER
GENERAL INFORMATION Section 1
1.1 EC DECLARATION OF CONFORMITY
We hereby declare that the following machinery complies with the Essential
Health and Safety requirements of the EU Machinery Directive 89/392/EEC as
amended by 91/368/EEC, 93/44/EEC and 93/68/EEC.
Manufactured by: Tesab Engineering Ltd.

7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ
Machine Description: Mobile Crushing Plant
Model: RK 1012T ROTOCRUSHER
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:
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
1.2 MACHINE SPECIFICATION DETAILS
MACHINE SERIAL NUMBER:
ENGINE TYPE:
ENGINE SERIAL NUMBER:
CLUTCH TYPE:
CLUTCH SERIAL NUMBER:
DESPATCH DATE:

RK1012T ROTOCRUSHER
1.3 FOREWORD/RESERVATION OF RIGHTS
The TESAB RK 1012T ROTOCRUSHER is a robust skilfully engineered piece of

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

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

or loaned to a third party without written consent of
TESAB ENGINEERING LTD.

RK1012T ROTOCRUSHER
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.
Front - product conveyor end of machine.
Rear - feeder end of machine.

REAR
RIGHT LEFT
FRONT

RK1012T ROTOCRUSHER
1.4 FAMILIARISATION (contd.)
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

RK1012T ROTOCRUSHER
1.5 GENERAL SPECIFICATION
Chassis
The chassis is constructed of heavy-duty profiles and welded steel plates ribbed
and stiffened to withstand all operational and travelling stresses. The chassis is
mounted on 3.75m 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.

RK1012T ROTOCRUSHER
1.5 GENERAL SPECIFICATION contd.

Crusher Unit
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.
Catwalks and Guards
All relevant catwalks, handrails and guards are fitted to this machine allowing ac-
cess to all relevant maintenance points. Emergency stops are fitted to all 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

RK1012T ROTOCRUSHER
Section 2
SAFETY

RK1012T ROTOCRUSHER
SAFETY Section 2
2.0 SAFETY INTRODUCTION

In this next section you will find the safety sign conventions used throughout
this manual and on the machine.
Please read this section carefully and become familiar with the signs used.
These signs are used frequently throughout this manual to indicate any poten-
tial warning or danger when operating this machine.
DANGER ELECTRICAL HAZARD

1. Electrical Hazard. Risk of serious injury or
death.
2. Never work on the electrical system of any
equipment unless you are fully familiar with
system details.
3. Work on the electrical system must be
carried out by a qualified electrician.
DANGER NIP HAZARD

1. Nip Hazard. Do not reach into an
unguarded machine.
2. In-running nip points can cause
serious injury or death.
3. Switch off and lockout machine
before opening or removing guard doors.
DANGER FALL HAZARD

1. Fall Hazard. Do not climb onto moving or
working machinery.
2. Switch off and lockout machine before
attempting maintenance on the machine.
3. Always use a suitable lifting platform before
attempting maintenance above 2m (6-6”).

RK1012T ROTOCRUSHER
SAFETY Section 2
WARNING CRUSH HAZARD

1. Crush Hazard. Beware of dangerous hand
and foot crush points.
2. Do not use any body parts e.g. hands or
feet to check hole alignment or support
machinery.
3. Always use pins and/or mechanical
supports provided.
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 CONSULT MANUAL

1. Read and understand the operators manual
before you work at this machine.
2. Study the different safety signs on this
machine.
3. Only qualified and trained personnel should
attempt to work at this machine.
WARNING 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.

RK1012T ROTOCRUSHER
SAFETY Section 2
WARNING HIGH PRESSURE

1. Beware of escaping hydraulic oil. High
pressure hydraulic oil can penetrate the
skin causing serious injuries.
2. Always relieve pressure from the hydraulic
system before attempting maintenance.
3. If oil is injected under the skin, it must be
surgically removed or gangrene will result.
CAUTION HOT SURFACE

1. Burn or Heat Hazard. Beware of hot sur
faces at engine and exhaust areas.
WARNING HEAD PROTECTION

1. Fall rock hazard. Do not walk near material
discharge areas. You are at risk of serious
injury or death.
2. Wear a Hard Hat at all times when working
in the vicinity of the machine.
WARNING BATTERY HAZARD

1. Battery Hazard. Battery electrolyte contains
acid and can cause serious injury. Avoid
any contact.
2. Batteries give off flammable fumes which
ACID EXPLOSIVE can explode. Avoid the formation of sparks
and naked lights in the vicinity of the
batteries. Do not smoke when working in
this area.
BATTERY

RK1012T ROTOCRUSHER
SAFETY Section 2
2.1 SAFETY
Operators should be trained in the Replace unreadable or missing labels

correct and safe use of all equip- with new ones before operating the
ment including the studying of this machine.
manual, failure to do so could re-
sult in serious injury. Wear a hard hat, protective glasses,
hearing protection, close fitting
Any work on and with the machine overalls, steel toed boots and high
must be executed by reliable, trained visibility vest (E.N / A.N.S.I. ap-
and authorised personnel only. Statu- proved) as required by job condi-
tory minimum age limits must be ob- tions.
served.
Do not wear loose clothing or jewel-
Work on the electrical system and lery and tie back long hair that can
equipment of the machine must be catch on controls or moving parts.
carried out only by a skilled electri-
cian or by instructed persons un- Make certain all protective guards
der the supervision and guidance of and covers are secured and in place
a skilled electrician and in accord- at all times. All guards should be in
ance with electrical engineering place whenever maintenance is not
rules and regulations. being performed. Never disable or
remove any safety mechanism or
Work on the hydraulic system must be guard.
carried out by personnel with special
knowledge and experience of hydrau- Where possible when working close to
lic equipment. engines or machinery, only do so when
they are stopped. If this is not practi-
There are several specific signs on cable, remember to keep tools, test
your machine. Please take time to equipment and all other parts of your
familiarise yourself with the safety body well away from the moving parts.
signs and the operation and main-
tenance manual.
Understand service procedure be-
See to it that safety instructions and fore doing work. Keep all areas
warnings attached to the machine are clean and dry.
always complete and completely leg-
ible.
Keep warning and instruction labels

clean.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.1 SAFETY contd.
Never lubricate, clean, service or Take the necessary precautions to

adjust machine while it is moving. ensure that the machine is used
Keep hands, feet and clothing clear only when in a safe and reliable
of power driven parts and nip- state.
points. Disengage all power and
operate controls to relieve pressure. In the event of malfunctions or opera-
Stop the engine. Implement lockout tional difficulty stop the machine imme-
procedure. Allow machine to cool. diately and lockout. Have any defects
rectified immediately.
Keep all parts in good condition and
properly installed. Fix any damage im- Do not attempt repairs or adjust-
mediately and replace any broken ments to the machine while it is run-
parts with genuine TESAB parts. Re- ning.
move any built up of grease, oil or de-
bris. Relieve all pressure in hydraulic sys-
tems before any lines, fittings or related
For the execution of maintenance items are disconnected or removed.
work, tools and workshop equip-
ment adapted to the task on hand Hydraulic lines must be laid and fit-
are absolutely indispensable. ted properly. Ensure that no connec-
tions are inter-changed. The fittings
Isolate all electrical supplies before lengths and quality of the hoses
carrying out repairs or maintenance, must comply with the technical re-
and should only be carried out by quali- quirements.
fied personnel.
Always practice extreme cleanliness
Stay clear of all rotating and mov- when servicing hydraulic components.
ing parts. Do not attempt to clear
obstructions or debris by hand be- Hydraulic fluid under pressure is
fore isolating the equipment by im- very dangerous, it can penetrate the
plementing the lockout procedure. skin causing serious injury.
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.
Switch off engine and lockout ma-

chine before opening or removing
guards or doors.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.1 SAFETY contd.
Always use a piece of cardboard to Batteries give off flammable fumes

check for leaks. Do not use your which can explode. Ensure that
hand. there is proper ventilation. Avoid
the formation of sparks and naked
Use caution while removing filler caps, lights in the vicinity of the batter-
filters, drain plugs or hydraulic fittings, ies. Do not smoke when working in
hold a rag over the connection to pre- this area.
vent being sprayed or splashed by liq-
uids. Fires may result from lubricating oil or
fuel spraying on hot surfaces.
Diesel engine exhaust emissions
contain products of combustion Avoid smoking whilst refuelling or
which may be harmful to your in the refuelling area.
health. Ensure the machine is in a
well ventilated area, if the machine Do not climb on conveyor belts or
is operating in an enclosed area stand on components that cannot sup-
vent the emissions elsewhere. port your weight, always use ladders,
steps and walkways when mounting
Observe the regulations in force at that and dismounting machine.
site.
Only use emergency stop buttons
Dust found on the machine or pro- in an emergency situation or during
duced during operation should be safety checks.
removed by extraction not blowing.
Do not use fingers to check hole align-
Disconnect the battery leads and tape ments as this can cause serious injury.
the leads to prevent accidental start
up when performing maintenance or Do not stand beneath equipment as
servicing. it is being raised or lowered into po-
sition.
Battery electrolyte contains acid
and can cause serious injury. Avoid Never check the tension of V-belts
contact with skin and eyes. Use whilst machine is running.
gloves and protective glasses.
Whenever maintenance and servic-
ing is being carried out a minimum
of two persons must be present at
all times.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.1 SAFETY contd.
The preparations to transport the When the machine is completely shut

machine should be supervised by a down for maintenance or repair work,
minimum of two persons. it must be secured against inadvert-
ent starting by implementing the lock-
TESAB ENGINEERING LTD. have out procedure (see lockout section for
provided walkways and platforms to details).
enable operatives to carry out daily in-
spection and maintenance from a po- Never allow anyone to remove large
sition of safety. More irregular main- or heavy components without ad-
tenance tasks will necessitate persons equate lifting tackle.
to work on the machine at a height
were fall hazards exist. (It is the re- To avoid the risk of accidents, individual
sponsibility of the operator’s manage- parts and large assemblies being re-
ment to provide the necessary safe moved for replacement purposes
working access). should be carefully attached to the lift-
ing tackle and secured.
Falling from and/or onto a TESAB
machine can cause serious injury or The fastening of loads and the in-
even death. Do not climb on the ma- structing of crane operators should
chine and never use machine parts be entrusted to experienced per-
as a climbing aid. sonnel only.
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.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.1 SAFETY contd.

Always be aware that fully auto- Do not open any door of the crusher
matic machinery with moving parts until the rotor has stopped com-
may move at any time without warn- pletely and the control power have
ing. Never assume the machine to been broken, in the case of the die-
be safe because of the lack of move- sel powered unit the clutch is dis-
ment. engaged, the engine has stopped
and the ignition key has been re-
Never alter any equipment or parts of moved.
any equipment which may effect safety
without consulting and gaining permis- Never start the machine until all doors
sion from TESAB ENGINEERING on the crusher are closed and locked.
LTD.
When removing hammers and im-
Improperly disposing of waste can pact plates always use protective
threaten the environment and ecol- goggles.
ogy. Potentially harmful waste used
with the TESAB machine include oil, When the crusher chamber has been
fuel, coolant, filters and batteries. opened ensure that the chamber is
“pinned open”.
Use leakproof containers when drain-
ing fluids. Do not use food or bever- When working at the inside of the
age containers that may mislead crusher lock the rotor inserting a
someone into drinking from them. locating bar.
Do not pour the fluids onto the

ground, down a drain or into any
water source.
Ensure that all consumables and re-

placed parts are disposed of correctly
and with the minimum environmental
impact.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.2 POSITION OF EMERGENCY STOPS

CONSOLE
FEEDER
LHS & RHS

3.
2.
RAMS CONTROL
CONSOLE
LHS & RHS

4.
1.

RK1012T ROTOCRUSHER
SAFETY Section 2
2.3 Emergency Situation

WARNING
In the case of an incident of any part failure on the

machine you must follow the following procedure.
1. Engage the nearest emergency stop.
2. Switch of engine and remove the ignition key.
3. Implement the lockout procedure (see Section 2.4).
4. Only when the machine is fully switched off and the crusher
rotor has completely stopped revolving (approximately 120
seconds), should an attempt be made to solve the problem.
5. It is always important to never work alone.
Restart after Emergency Stop.
1. Ensure the problem has been rectified.
2. Ensure that all personnel are clear of the machine.
3. Ensure that all guards and relevant safety devices have

been fitted / refitted correctly.
4. Release all emergency stops.
Restart the machine (see section 4.3)

RK1012T ROTOCRUSHER
SAFETY Section 2
WARNING When carrying out maintenance, repairs

or adjustment to the TESAB RK 1012T
ROTOCRUSHER the following lockout
procedure must be followed.
1. Deactivate all controls, switch off engine and remove key.

2. Activate, or, if fitted, lock one emergency stop button.
3. Relieve all pressures in the hydraulic system.
IMPORTANT: THE PERSON CARRYING OUT THE WORK ON THE

MACHINE MUST KEEP THE KEYS WITH THEM AT ALL
TIMES.
IMPORTANT SAFETY NOTICE
DISCONNECT BATTERY TERMINALS AND
DISCONNECT LEADS A,B, & C PRIOR TO WELDING.
Main Control Panel (rear)
NOTE: Leads may be

hidden inside panel housing
A B C
RK1012T ROTOCRUSHER
Section 3
TRACKING INSTRUCTIONS

RK1012T ROTOCRUSHER
TRACKING INSTRUCTIONS Section 3

READ THIS SECTION CAREFULLY BEFORE OPERATING TRACKS ON YOUR
TESAB RK1012T ROTOCRUSHER.
FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT
DAMAGE.
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
1. Main engine starter panel. Remote Control Dog Lead Control
2. Remote control box.
3. Dog lead controller.
4. Emergency stop.
5. Remote control
6. Fast Track Console

RK1012T ROTOCRUSHER
3.0 Tracking Familiarisation contd.
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
> 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

RK1012T ROTOCRUSHER

TRACKING THE MACHINE
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.
1. How to start the engine (Main engine starter panel)
b a
a) Check that no emergency stops are in the on position, if an emer-

gency stop is in the on position lamp A (green) will NOT be illumi-
nated.
b) Adjust the throttle to approximately half way.
c) Press and hold the safety system over-ride button B.
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.

RK1012T ROTOCRUSHER
3.1 Tracking the Machine contd.

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.
g. 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 d

RK1012T ROTOCRUSHER
3.2 Tracking machine using Remote Control.
“Getting to know your remote control.”
J g
c a E
h
SIDE X
SIDE Y
I
d
b
f
C A
D B
SIDE X SIDE Y
A RHS track forward.

B RHS track reverse
C LHS track forward
D LHS track reverse
E Remote control activation & Tracks On/Off
F Engine stop (only active when handset on)
G Key Switch
H Feeder on
I Feeder off
J Remote Control Lockout switch (Prevents remote from being used when
button is depressed.

RK1012T ROTOCRUSHER
3.2 Tracking machine using Remote Control contd.

The following procedure is to be carried out to allow operator to track the machine
using the remote control.
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.
c) Start the engine as per previous instructions (it is important that

instruction a) is carried out before starting engine).
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.

RK1012T ROTOCRUSHER

e) To track press relevant buttons on the remote control (refer to section
3.2 ‘Getting to know your remote control), 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
3.3 Tracking machine using “Dog Lead”.

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 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...

RK1012T ROTOCRUSHER
3.3 Tracking machine using “Dog Lead” contd.

f) Start the engine as per previous instructions (it is important that
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.

RK1012T ROTOCRUSHER
Follow the procedure below to charge the battery for the remote control.
Charger 1. Place battery into

Unit charger unit.
2. Plug in charger unit and
switch on at mains.
3. The green indicator light
Green Indicator shows that the battery is
being charged.
Battery
NOTE:
This charger requires a 3 pin

European to UK mains adaptor if
being used in the UK or Ireland.
IMPORTANT SAFETY NOTE
DISCONNECT BATTERY
TERMINALS AND REMOTE UNIT
PRIOR TO WELDING.

RK1012T ROTOCRUSHER
Section 4
SET-UP PROCEDURE

RK1012T ROTOCRUSHER
SET-UP PROCEDURE Section 4
4.0 Set-Up Procedure Safety


death.
system details.
DANGER NIP HAZARD

unguarded machine.
DANGER FALL HAZARD

working machinery.

RK1012T ROTOCRUSHER

machinery.
supports provided.
WARNING PROTECTION
running machinery.

machine.
WARNING LOCKOUT
maintenance.

RK1012T ROTOCRUSHER

CAUTION HOT SURFACE


injury or death.

any contact.
this area.
BATTERY

RK1012T ROTOCRUSHER
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.
Installation, operation, and maintenance of the RK1012T ROTOCRUSHER mush

be carried out by reliable, authorised personnel only, statutory minimum age lim-
its 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
4.2 LOADING and OFF LOADING

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

RK1012T ROTOCRUSHER
4.3 STARTING ENGINE
IMPORTANT
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. TRACK: When the machine has to be moved.

2. CRUSH: When the machine is in its working position and ready to work.
Both levers in
Track Position
WARNING

RK1012T ROTOCRUSHER
4.3 STARTING ENGINE contd.

The engine starter panel is located at the engine catwalk as highlighted below.
Starter Panel
Starter Panel
This area can be accessed by lowering the access steps (B). It is important, 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
4.4 Engine Staring Procedure

Before staring the engine check diesel and engine oil levels.
How to start the engine (Main engine starter panel)
b a
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.
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.
You will protect the batteries if you wait one minute between
each starting attempt.
g) Set the engine revs to approximately 1000 r.p.m., this can be


RK1012T ROTOCRUSHER
4.4 Engine Staring Procedure contd.

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

DAMAGE.
1. Familiarisation
4
1&2
4 4
6
4 1&2 4 4
3
4 4 4
4. Emergency stop.
5. Remote control

RK1012T ROTOCRUSHER
4.5 Tracking Familiarisation contd.
IMPORTANT
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
4.6 Tracking The Machine
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.
1. How to start the engine (Main engine starter panel)
b a
a) Check that no emergency stops are in the on position, if an emer-

gency stop is in the on position lamp A (green) will NOT be illumi-
nated.
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.

RK1012T ROTOCRUSHER
4.6 Tracking The Machine contd.

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
g. Set the engine revs to approximately 1000 r.p.m., this can be

Throttle Adjustment
- revs
+ revs d

RK1012T ROTOCRUSHER
4.7 Tracking machine using Remote Control.
“Getting to know your remote control.”
J g
c a E
h
SIDE X
SIDE Y
I
d
b
f
C A
D B
SIDE X SIDE Y
A RHS track forward.

B RHS track reverse
C LHS track forward
D LHS track reverse
E Remote control activation & Tracks On/Off
F Engine stop (only active when handset on)
G Key Switch
H Feeder on
I Feeder off
J Remote Control Lockout switch (Prevents remote from being used when
button is depressed.

RK1012T ROTOCRUSHER

The following procedure is to be carried out to allow operator to track the machine
using the remote control.
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.
c) Start the engine as per previous instructions (it is important that

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.

RK1012T ROTOCRUSHER
e) To track press relevant buttons on the remote control, 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
4.8 Tracking machine using “Dog Lead”.

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 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...

RK1012T ROTOCRUSHER
4.8 Tracking machine using “Dog Lead” contd.

g) Start the engine as per previous instructions (it is important that
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.

RK1012T ROTOCRUSHER
Follow the procedure below to charge the battery for the remote control.
Charger 1. Place battery into

Unit charger unit.
2. Plug in charger unit and
switch on at mains.
3. Battery is fully charged
Green Indicator when green indicator light
is on.
Battery
NOTE:
This charger requires a 3 pin

European to UK mains adaptor if
being used in the UK or Ireland.
IMPORTANT SAFETY NOTE
DISCONNECT BATTERY
TERMINALS AND REMOTE UNIT
PRIOR TO WELDING.

RK1012T ROTOCRUSHER
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
4.11 PREPARING FOR INITIAL START-UP

i) Fit hand rails 1, 2 & 3 securely ensuring tab 4 is fitted between handrail 3
and the crusher for extra stability.
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.

RK1012T ROTOCRUSHER
4.11 PREPARING FOR INITIAL START-UP contd.
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
® NEVER OPERATE THE MACHINE WITH EITHER VALVE IN THE
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
4.12 DIRT CONVEYOR UNFOLDING

Important Safety Note:
Unfolding the Dirt Conveyor will require the use of a crane.
The fastening of loads and the instructing of crane operators should be en-
trusted to experienced personnel only.
• Connect the crane lifting chains to the dirt conveyor at the two 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’.
• Fit belt scrapper ‘C’.
A
A

RK1012T ROTOCRUSHER
4.13 CRIB FOLDING & ASSEMBLY

NOTE:
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.

RK1012T ROTOCRUSHER
4.13 CRIB FOLDING & ASSEMBLY contd.
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).
CRIBS insert extra

bolts

RK1012T ROTOCRUSHER
4.13 CRIB FOLDING & ASSEMBLY contd.

vi) Insert pins on rear cribs at point A as shown. (Note: Pins located in tool
box).
vii) Fit front cribs front cross tie and pin
Cross Tie &

Pin
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.

RK1012T ROTOCRUSHER
4.14 FEEDER BEACON

The RK1012T has been fitted with a feeder beacon to warn the user when the
feeder has stopped, either by handlever, remote control or speed sensor activa-
tion.
The feeder beacon if fitted to the right hand side of the Rams control console.
Feeder Beacon location

(remember to connect wires using
couplings provided)
4.15 Feed-in Chute.
Due to differing height restrictions the as-

sembled feed-in chute maybe to high.
Hence the feed-in “extension box”, which

carries the feed chains, rubber and dust
suppression spray bar is packed separately.
Therefore the next stage of set-up is to fit

this extension box as shown using lift points
A and connecting up the spray bar pipe at
point B.
Note: Fitting the extension box will A B

require the use of a crane.
The fastening of loads and the instructing

of crane operators should be entrusted to
experienced personnel.

RK1012T ROTOCRUSHER
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.

RK1012T ROTOCRUSHER
4.17 Crusher Settings

Before we start crushing the final stage of installation is to set the crusher gaps.
This means the distance between the hammers and the impact path at the
three impact areas, these are named as follows:
· Top apron (stroke carrier).
· Middle apron (stroke carrier)
· Bar carrier
The spanner for adjusting these can be found in the toolbox.
Warning:
The crusher settings must NOT be altered while the crusher is in opera-
tion.
Top apron adjustment.
When first starting to crush adjust this apron fully open by adjustment at point
‘A’.
Adjust a small amount each side alternatively, this will prevent damaging the
threads.
IMPORTANT
Clockwise rotation to
adjust apron fully open

RK1012T ROTOCRUSHER
4.17 Crusher Settings contd.

Middle apron adjustment.
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).
This distance can be checked by opening door ‘F’.
IMPORTANT
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.

RK1012T ROTOCRUSHER

Bar carrier 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
adjust bar carrier forward
IMPORTANT C
Anti-Clockwise rotation to F
adjust bar carrier
backwards.

RK1012T ROTOCRUSHER

Important:
The measurement of the setting depends on the following:
(i) The size of the feed material.
(ii) Cubing or crushing required.
(iii) Desired quantities of the different fractions produced.
The following applies in general:
(i) Do not adjust the crusher settings to an unnecessarily narrow

gap.
(ii) Study the produced material and use that as a guide-line for your
setting.
For additional advise on the settings on your RK 1012T Rotocrusher please

consult TESAB ENGINEERING LTD. or your local authorised TESAB dealer

RK1012T ROTOCRUSHER
4.18 DUST SUPPRESSION

The RK1012T may be fitted with a completely self sufficient system which includes
the following.
i) 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.

RK1012T ROTOCRUSHER
4.18 DUST SUPPRESSION contd.

iii) Spray Bar Location
1. Feed into Crusher

2. Feed out of Crusher
iv) Start / Stop
Switch 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
Section 5
OPERATION

RK1012T ROTOCRUSHER
OPERATION Section 5
5.0 Operation Safety


death.
system details.
DANGER NIP HAZARD

unguarded machine.
DANGER FALL HAZARD

working machinery.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.0 Operation Safety Contd.

machinery.
supports provided.
WARNING PROTECTION
running machinery.

machine.
WARNING LOCKOUT
maintenance.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.0 Operation Safety Contd.

CAUTION HOT SURFACE


injury or death.

any contact.
this area.
BATTERY

RK1012T ROTOCRUSHER
OPERATION Section 5



TIMES.
NOTE: Leads may be

A B C
RK1012T ROTOCRUSHER
OPERATION Section 5

Please Note:
All crushing applications differ due to material composition and customer

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

required results.
Therefore we recommend that you contact Tesab Engineering LTD or

your local Tesab dealer to advise you on the best customized Tesab
arrangement to suit your particular application.
For the purposes of this section we assume engine speed requirements

of 2000 rpm.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.3 Pre Operation Check List
PRE OPERATION CHECK LIST.

Before operation check and ensure the following:
• nothing on product conveyor
• nothing on dirt conveyor
• all guards are fitted correctly
• the diesel tank has been topped up
• engine oil level has been checked and topped up if necessary

RK1012T ROTOCRUSHER
OPERATION Section 5
5.4 Feeder Information
IMPORTANT FEEDER INFORMATION

It is important to read this section carefully before operating in order to acquaint
yourself fully with the detailed operation of the feeder.

RK1012T ROTOCRUSHER
OPERATION Section 5

DAMAGE.
1. Familiarisation
4
1&2
4 4
6
4 1&2 4 4
3
4 4 4
4. Emergency stop.
5. Remote control

RK1012T ROTOCRUSHER
OPERATION Section 5
5.5 Feeder Instructions contd.

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)
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.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.6 Machine Staring

1. Start Engine
Before staring the engine check diesel and engine oil levels.
How to start the engine (Main engine starter panel)
b a
a) Check that no emergency stops are in the on position, if an emegency

stop is in the on position lamp A (green) will NOT be illuminated.
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.
You will protect the batteries if you wait one minute between
g) Set the engine revs to approximately 1000 r.p.m., this can be

RK1012T ROTOCRUSHER
OPERATION Section 5
5.7 Setting Engine Revs

2. Set Engine Revs
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

RK1012T ROTOCRUSHER
OPERATION Section 5
5.8 Engaging Clutch

3. Start Crusher
Start crusher by “bumping-in” clutch.
“Bumping-in” involves several partial engagements with the hand lever.
Engage clutch gradually until engine labours heavily, disengage clutch

momentarily to allow engine torque/speed to recover.
Repeat this procedure two or three times and then engage clutch
completely by forcing lever to the fully over-centre position.
Operator experience often dictates the number of “bumps” required.
“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).
It is important that this procedure is adhered in order to achieve pro-longed

clutch life.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.9 Product Conveyor Starting

4. Start Product Conveyor
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
Start product conveyor by engaging the appropriate control lever.
Magnet / Dirt Conveyor

Control Lever
Product Conveyor
Control Lever
Note: Initially we would track the

product conveyor when running empty
you may then find that the conveyor
may need re-adjusted when under load.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.9 Product Conveyor Starting contd.

4. Start Product Conveyor contd.
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.
For further details on the

tracking of conveyor
belt section 6.23.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.10 Dirt Conveyor Starting

5. Start Dirt Conveyor (and Magnet if Fitted)
Note: The dirt conveyor and magnet run through the one hydraulic circuit, there-
fore one single lever activation will start both conveyors.
Start the dirt conveyor by engaging the appropriate lever highlighted.
Dirt Conveyor
Control Lever
Initially we would recommend that

you track the conveyor belt when
running empty, you may find that
the conveyor may need re-tracked
when under load.
In order to track this belt correctly please carry out the following procedure:
The belt can be adjusted by adjusting the drums at points A.
Note: The conveyor belt can be tracked by slackening as well as

tensioning adjusters.
Important: DO NOT over tension the belt as this will cause excessive
strain on the bearings and drive system.
For further details on the tracking of conveyor belts see section 6.23.

RK1012T ROTOCRUSHER
OPERATION Section 5
5.11 Feeder Starting

6. Start Feeder
Start feeder by engaging appropriate control lever.
Feeder
Control Lever
Feeder Speed
Control
7. Set Feeder Speed
Feeder speed adjustment can be done by turning knob at point A.
- +
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.
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
5.12 Machine Shutdown Sequence

8. Machine Shutdown
The following procedure should be followed when shutting machine down at

end of shift.
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. Wait and ensure crusher has cleared completely of

material.
3. Stop product conveyor.
4. Reduce engine revs to approximately 1300 r.p.m.
5. Dis-engage clutch.
6. Reduce engine revs to idle and run engine for 60

seconds.
7. Switch engine off and implement lockout procedure.
IMPORTANT: DO NOT LEAVE KEYS IN IGNITION

RK1012T ROTOCRUSHER
Section 6
MAINTENANCE

RK1012T ROTOCRUSHER
MAINTENANCE Section 6
6.0 The RK 1012 ROTOCRUSHER UNIT

Remove Bolts
Crusher Opening 18 off
Crusher opening Crusher opening

Lever pin
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.
WHEN REMOVING HAMMERS AND IMPACT BARS, ALWAYS USE PROTECTIVE

GOGGLES.
(YOU CAN, ACCIDENTALLY HIT ASKEW AND A METAL SHIVER MAY HIT YOUR
EYES)

RK1012T ROTOCRUSHER
6.1 Replacing or Turning the Hammers

1. Open the setting (gap)
of the crusher to a maximum.
2. Rotate the rotor so that one

hammer appears straight up
(see picture No. 1). Insert a
locating bar or similar through
the rotor.
The Rotor is now secured.
3. Clean away the stone powder

and such around the hammer.
4. Take away the securing

brackets (A) at both sides of
the hammer.
5. The turned or new hammer is

Picture No. 1 pushed into position.
6. Secure the hammer with

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

hammers are replaced.
8. Close and lock all doors.
9. Start the crusher.
NOTE: Should any abnormal sound be

heard, a thumping or knock, stop the
crusher immediately and check if any
of the hammers are positioned too far
to one side, so it touches the side
plates.
After the necessary measures have

been taken, start the crusher again
and run it empty for approximately 5
minutes.
If everything is OK, make the final gap

settings, close and lock all doors. ALL
SET FOR CRUSHING.

RK1012T ROTOCRUSHER
6.2 Setting the Crusher Gap

Setting of the Crusher Gap
A NOTE: The setting must not be

altered while crusher is in opera-
tion.
1. Open the door F by the

bar carrier and measure the
setting at the upper impact
bar G (see Picture 4).
The measure of the setting
depends on:
1) The size of the feed

material.
2) Cubing or Crushing.
3) Desired quantities of
the different fractions
produced.
G The following applies in

F
general:
- Do not adjust the
crusher setting to an
unnecessary narrow
gap.
- Study the produced
material and use that
as a guideline for your
setting.
2) The setting is carried out at

the outer bolts of the Yoke A.
The pretension of the spring
unit is set at the inner bolts.
Picture No. 4

RK1012T ROTOCRUSHER
6.3 Replacing or Turning Impact of Bars (Blow Bars)

Replacement or Turning of
Impact Bars
A 1. Open the settings (gap)

of the crusher A
2. Open both doors F by

the Bar Carrier.
3. Knock out the Impact

Bars G laterally using an
iron bar or similar.
4. Clean the sockets and

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

close and lock the
doors. CRUSH!
F G

RK1012T ROTOCRUSHER
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

RK1012T ROTOCRUSHER
6.5 Clutch Adjustment

New power take off’s 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 ten (10) hours of operation. New
clutch plates have a “wear-in” period and the clutch may require several adjust-
ments 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.
When do you know your clutch requires adjustment?
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.
Regular adjustment dictates that no more than 1 or 2 notches should be re-

quired each time, any more than this would indicate that the clutch is not ad-
justed regularly.
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.
RK1012T ROTOCRUSHER
6.6 Clutch Lubrication

1. Throwout Collar - Apply small amount of lubricant once a day, before
starting, through the fitting on the tapered part of the housing.
2. Main Bearings - Apply small amount of lubricant once a week, through

the fittings highlighted below.
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

RK1012T ROTOCRUSHER
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
Note: Diesel engine maintenance and service required or the frequency

thereof is not covered by this operation manual. All matters relating
to this should be referred to the makers publication “Operation and
Maintenance Manual”, a copy is included with this manual.
IMPORTANT SAFETY NOTE:
IMPLEMENT LOCKOUT
PROCEDURE BEFORE
CARRYING OUT
MAINTENANCE TO YOUR
RK 1012T ROTOCRUSHER
SEE SECTION 2 (safety)

RK1012T ROTOCRUSHER

This section provides detailed maintenance instructions as well as a mainte-
nance schedule for normal operating conditions.
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.
‘Good housekeeping pays untold dividends in increased production and

extended plant life!’
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
6.9 Safety Information
DANGER NIP HAZARD

unguarded machine.

DANGER FALL HAZARD

working machinery.
WARNING PROTECTION
running machinery.

RK1012T ROTOCRUSHER
6.10 Hydraulic System

The hydraulic system which is used in the RK 1012T Rotocrusher was chosen
for its effectiveness and resistance to climatic and operating conditions. This
must be topped up with the correct hydraulic fluid and regular checks must be
made to ensure this. The system should be checked for leaks and drained
every 1500 hours.
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.
Fast Track Console
The filter
element needs
to be changed
when the
indicator turns
High Pressure red.
Filters
DANGER High Pressure Filters - 2x High Pressurefilters are fitted to

the main pressure lines between Pump and manual spool
valves, and they are used to prevent any tiny particles con-
taminating the system which could cause damage to the pumps
or motors. The filter elements should be checked regularly
HIGH PRESSURE
and changed in accordance with the routine maintenance
schedule.

RK1012T ROTOCRUSHER
6.11 TRACKS
Each Track Frame Assemblies fitted to the TESAB RK1012T Rotocrusher
comprise of five main components:
1. A STEEL FRAME CHASSIS onto which all other components are

mounted. The weight of the machine which is to be carried by these assem-
blies is distributed along the length of the frames.
2. The DRIVE ASSEMBLY is a planetary gearbox, mounted at the rear of the

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

frame. The entire weight of the machine is carried on these rollers.
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.
5. The TRACK ASSEMBLY comprises of sectional chain with triple bar

grouser shoes bolted to it.

RK1012T ROTOCRUSHER
6.11 TRACKS contd.
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.
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
This measurement should not exceed 30mm (1.25”)
The adjustment of the track is accessed via the inspection cover on the
side of the track frame as shown in figure 1.
Remove the cover using a 6mm allen key.

RK1012T ROTOCRUSHER
6.11 TRACKS contd.
Adjustment is carried out as follows:
a) To increase track tension:
Ensure the grease fitting is tight, using a 22mm socket or ring spanner.
Using the special grease gun adapter (M1442), fitted to a standard

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

loads on the gearbox bearings and idler bearings.
It will lead to accelerated wear and premature failures.
b) To release the track tension:
Slacken the grease fitting on the end of the hydraulic track tensioning
cylinder, by one half turn only, using a 22mm spanner.
Warning:
Grease under extreme pressure is released by this action.

Personal injury could result if the fitting is removed whilst under
pressure.
When the track droop appears to be correct, move the machine backwards and
forwards and re-check the droop.
Add more grease if required.

Replace the inspection cover when the correct adjustment has been made.

RK1012T ROTOCRUSHER
6.11 TRACKS contd.

1. Gearbox Oil Level.
Cleanliness is absolutely essential.
Use only clean oil, in clean containers.
Gearbox life will be dramatically reduced if dirt is allowed to enter.
Oil Level
The oil level must be checked every 200 working hours.
Method of Checking and Filling
See lubrication chart for correct grade of oil.
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.
Add more oil if necessary.
Note: approximately oil quantity – 5 litres per gearbox

RK1012T ROTOCRUSHER
6.11 TRACKS contd.

Method of Draining
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.
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
6.11 TRACKS contd.

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.
3. 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. Bottom Rollers and Idlers
These components are lubricated at the time of manufacture and are

termed “lubricated for life”.
No servicing is therefore required.
If however an oil leak is detected on any of these components, an

exchange unit should be fitted before using machine again.
Removal of the filler plug invalidates the warranty.
5. Loose Bolts.
It is the responsibility of the operator to check the machine on a daily

basis for any loose bolts, or signs of undue wear.
In the event that any bolts are found to be loose, they should be re-
tightened to the following torque:
Bottom Roller Bolts 350 ft lbs.

Sprocket Mounting Bolts 350 ft lbs.
Gearbox Mounting Bolts 350 ft lbs.

RK1012T ROTOCRUSHER
6.11 TRACKS contd.
Motion Valve 33 ft lbs.

Track Shoes 120 ft lbs. plus 1/3 turn
It is the operators responsibility to ensure that the machine is properly

maintained and does not pose a safety hazard to himself or other
people.
TRACK LUBRICATION CHART
Gearbox Lubrication
Transmital Bonfiglioli
Gear Oil should conform to the following specifications:-
MIL-L-2105 or API GL5 Grade 80W/90
Examples of oil to these specifications are:-
Texaco Geartex EP-B 80W/90
Century Oils BOA 80W/90
All leading lubricating oil suppliers offer equivalents.
Track Adjustment
A good quality all purpose grease should be used.
Texaco EP2 All Purpose Grease.
All leading lubricating oil suppliers offer equivalents.

RK1012T ROTOCRUSHER
6.12 Hydraulic Fluids

Hydraulic fluids play a most important part in any hydraulic system. They
have three main functions.
- to transmit power.
- to lubricate moving parts.
- to seal clearances between parts.
As a power transmitting medium the fluid must flow easily and be as 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.
Some adverse effects of incorrect viscosity being:
- High oil temperatures.

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

RK1012T ROTOCRUSHER
6.13 Oil Tank, Pipes and Fittings

In order to prevent contamination, the oil tank on the RK 1012T Rotocrusher is of
sealed construction. Access to the tank, if required, is an inspection cover which
is mounted on top of the tank. The tank must be thoroughly cleaned before the
removal of this cover. It is very important that the hydraulic pipes and hoses are
checked regularly for leaks, scuffing and wear. Loose fittings should be securely
tightened. Worn or leaking hosing should be replaced. Replacement hoses are
available on request.

RK1012T ROTOCRUSHER
6.14 Diesel Engine

The diesel engine is the heart of your RK 1012T Rotocrusher and a great deal of
care and thought has gone into its selection. All engines are put through rigorous
test programmes by the manufacturers before reaching us, to be assembled into
the RK 1012T.
On completion machines are again run and tested for several hours before
dispatch.
This is to guarantee the dependability of TESAB equipment.
In the interest of continued peak performance from your RK 1012T Rotocrusher

the engine must be maintained and cared for with meticulous attention in
accordance with the manufacturers instructions as detailed in the “Operation and
Maintenance Manual” a copy of which is included with this manual.
IMPORTANT
The engine water trap (A) must be changed every engine service.

RK1012T ROTOCRUSHER
6.15 Product Conveyor Reduction Gear

Introduction: Maintenance can be “routine or unscheduled”.
Attention: All maintenance activities must be carried out under safety

conditions.
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.
- Subsequent oil changes should be made every 200-250 hours at opera-

tion, or, in any case, every year.
- Do not mix different types of oil.
- Periodically check the level (about once a month) and top up if necessary.
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
6.15 Product Conveyor Reduction Gear contd.

Oil Change
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.

RK1012T ROTOCRUSHER
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.
Refill oil at top
1. Remove “overspill” bung.
2. Refill oil at top.
3. When oil over-spills out of hole

Level it is at correct level.
Over-spill bung Drain Bung
WARNING: The feeder must not be run when any of the vibrating
mechanism guards are removed. Ensure all guards are
replaced after maintenance.

RK1012T ROTOCRUSHER
6.17 Bearing and Lubrication

1. The bearings of the crusher are spherical roller bearings with laby-
rinth packings.
2. The bearings are to be lubricated once a week at single shifts.
Force feed the grease until it is forced out into the labyrinths, so as
to press out any impurities.
Use only lithium base grease (i.e.., SKF LGEP 2)

RK1012T ROTOCRUSHER
6.18 General Specification Inspection

Check all abrasion of hammers, blow bars and wear plates regularly.
Adjustments of bar carrier maybe necessary.
Careful inspection of all wearing components is essential as

excessive wear will cause damage to the crusher chamber.

RK1012T ROTOCRUSHER
6.19 Routine Maintenance Schedule

In addition to the daily, weekly and six monthly maintenance schedule, the
engine and air cleaner must be meticulously maintained.
Diesel engine maintenance is details in a book “Operation and Maintenance

Manual” a copy of which is included with this manual. Details on the air filter
maintenance are also found in that publication. Failure to comply with this will
reduce engine performance and life-span and may effect your customer war-
ranty rights.
WARNING: No guards should be removed while the machine is in

operation.
NOTE:
Provided in this section is a Greasing Schedule for your machine. This section is
only applicable for machines that do not incorporate the Autolube System. If your
machine uses the Autolube please ignore this section.

RK1012T ROTOCRUSHER
6.20 Daily Maintenance

The purpose of daily maintenance is to discover minor irregularities in your
machine before they develop into major problems.
- Check the machine for loose parts, check that all bolts and nuts
are
secure.
- Check the hydraulic oil level in the tank and top up if necessary.
- Ensure that all safety systems are intact (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.
- Check for material build up.
- Check conveyor belts for alignment and adjust them if necessary.
- Check air filter for clogging.
- Visually inspect the conveyor belting for tears etc.
- grease clutch (see clutch section).
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.

RK1012T ROTOCRUSHER
6.21 Weekly Maintenance (50 hours)

In addition to the daily programme:
- Grease feeder bearings using the correct lubricant.
- Grease crusher bearings using the correct lubricant.
- Check all skirting rubbers (i.e. that they bear down lightly on the
conveyor belt.)
- Check the acid level in the batteries and top up with distilled
water if necessary.
- Check the gauges on the hydraulic filters.
- Adjust belt scrapper blades, renew if necessary.
- Check the water trap on the engine.
- Check clutch setting and adjust if necessary.
- Check quality and tension of crusher ‘V’ belts.
- Check rubbers on machine, renew if necessary.

RK1012T ROTOCRUSHER
6.22 Six Monthly Maintenance
- Drain and refill hydraulic system with the correct hydraulic fluid.
Refer to the recommended lubricants for the correct hydraulic oils
to suit various ambient temperature conditions.
- Drain and refill feeder oil bath with the correct gear oil. Refer to
the recommended lubricants section.
- Check the alignment of the plant with a precision spirit level.
- Grease the axle bearings.

RK1012T ROTOCRUSHER
6.23 Belt Tracking

Belt Tension.
The belts on your RK1012T Rotocrusher will normally have to be tensioned a

number of times during the machines lifetime due to the natural stretching of
the belt. It is very important the belts are tensioned evenly to the correct level,
not too tight and not too loose, ensuring efficient belt running and skirting align-
ment. A loose belt can cause slippage and reduced throughput, an over tight
belt can reduce drum and bearing life.
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
1. a. Align non-drive drum, carrying idlers,

Insufficient aligning of and return idlers at right angles to the trav-
drums and idlers. elling direction of the belt.
b. Check that all drums and idlers are

level to each other
If a & b are as above then perform the Fig 1: Turning carrying idlers
following.
Adjustment is made as indicated on Figs

1,2&3 by turning non-drive drum and car-
rying idlers in direction of arrow until the
belt is running straight and centered on Fig 2: Turn Drum
the conveyor.
Also return idlers may cause oblique belt

travel and therefore they must be aligned
at right angles to the travelling direction
of the belt and after that adjustment can
be made. Fig 3: Turn both Drum and carrying idlers
2. Oblique travel can be reduced by turning

Misalignment of frame forward outer carrying idlers 1-3 degrees
in travelling direction of the belt. See Fig4.
If this does not correct the oblique travel
then align the frame.
3. Clean idlers and drums. Check belt clean-

Material build up on ers and replace if necessary. Possibly
drums and idlers change to more efficient type.
Fig 4: Turning forward carrying idlers

RK1012T ROTOCRUSHER
6.24 V-Belt Tensioning

Crusher V Belts
The RK1012 Rotocrusher is driven through eight SPC V belts.
The belts can be tensioned as follows:
Losen bolts at the four points highlighted.
2 Bolts either
side of engine
stand
Adjust engine stand using the adjusters as highlighted.
Adjusters
Important Note:
Do not over-tighten V belts – this will cause excessive pressure on the

clutch bearings leading to premature clutch failure.

RK1012T ROTOCRUSHER
6.24 V-Belt Tensioning contd.

One shot tensioning
Put the belts around the pulleys, set

them to the appropriate tension value
as stated in the “Tension Forces” ta-
ble below (using the belt tension indi-
cator as shown), run the drive under BELT TENSION INDICATOR CE
APPLIED TO MID-CENTE NT
load for 30 minutes, stop the drive, RE
DISTANCE DI
check the tension, resetting to cata- ST
AN
logue value if necessary. On a proper CE
16
designed drive for the application there pe mm
will be no need for further attention r 1 de
m flec
of
during the life of the drive. sp tion
an
The setting tensions opposite are

designed to cover a wide range of
drives. A precise setting force for
individual applications can be cal-
culated. Please consult Fenner
Technical Services.
For short centre distance drives where

the deflection of the belt is too small
to measure accurately, it is recom-
mended that both deflection and ap-
plied force be doubled.
Force required to deflect belt 16mm per

Belt metre of span
Section Small Pulley
Diameter (mm) Newtons (N) Kg - Force (kgf)
SPB 80 to 132 25 to 35 2.5 to 3.6

140 to 200 35 to 45 3.6 to 4.6
SPC 112 to 224 45 to 65 4.6 to 6.6
236 to 315 65 to 85 6.6 to 8.7

RK1012T ROTOCRUSHER
6.24 V-Belt Tensioning contd.
Method of Belt Tensioning using Fenner NOTE:

Belt Tension Indicator. For single belt drives a straight edge should
be placed across the two pulleys to act as a
Calculate the deflection in mm on a basis of datum for measuring the amount of deflec-
16mm per metre of centre distance. tion.
CentreDistance(m)x16 =deflection(mm).
If the measured force falls within the values
Set the lower marker ring at the deflection dis- given, the drive should be satisfactory. A new
tance required in mm on the lower scale. drive should be tensioned to the higher value
to allow for the normal drop in tension during
Set the upper marker ring against the bottom the run in period.
edge of the top tube.
After the drive has been running for 30 min-
Place the belt tension indicator on top of the utes, the tension should be checked and re-
belt at the centre of span, and apply a force at adjusted to the higher value, if necessary.
right angles to the belt deflecting it to the point
where the lower marker ring is level with the
top of the adjacent belt. TROUBLE SHOOTING
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 a Fenner Belt Tension Indicator is not avail- V-Belt Swelling or softening

able, a spring balance and rule will surface.
Caused by excessive contamination by oil,
With branded belts use a bar across the band certain cutting fluids or rubber solvent.
width to ensure even distribution of the force
measured by the number of belts in the band Whipping During Running
for comparison with the values in the table.
Usually caused by incorrect tensioning, prin-
cipally 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 Serv-
ices.

RK1012T ROTOCRUSHER
6.25 RECOMMENDED GEAR OIL

Below are listed the recommended alternatives suitable for use with your
RK 1012T Rotocrusher.
If there are any difficulties the user should contact a local supplier or authorised
TESAB dealer.
MANUFACTURER 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
6.26 RECOMMENDED LUBRICANTS

Below are listed the recommended alternatives suitable for use with your RK
1012T Rotocrusher.
The special greases are lithium based greases are Class 2 with extreme pres-
sure additives.
They work within special conditions up to 120 degrees Celsius.
GREASE LUBRICATION
SPECIAL SCREEN SPECIAL SCREEN GENERAL PURPOSE

GREASE GREASE FOR HOT GREASE
METALS
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
6.26 RECOMMENDED LUBRICANTS contd.
Pos. No. of Description Frequency Qty

Locations (Hours)
1 1 Clutch Throw-out Collar 10 (daily) 4g
2 1 Clutch Main Bearings 50 (weekly) 4g
3 2 Clutch Lever Shaft 50 (weekly) 4g
4 2 Crusher Rotor Bearings 50 (weekly) 8g
5 8 Feeder Bearings 50 (weekly) 4g
6 2 Product Conveyor *TED Bearings 50 (weekly) 4g
7 2 Product Conveyor *BED Bearings 50 (weekly) 4g
8 2 Dirt Conveyor *TED Bearings 50 (weekly) 4g
9 2 Dirt Conveyor *BED Bearings 50 (weekly) 4g
NOTE
Four grammes of grease is the equivalent of three shots/pumps from the

grease gun.
*TED - Top End Drum
*BED – Bottom End Drum

RK1012T ROTOCRUSHER
6.27 Automatic Greasing System

Your RK 1012T Rotocrusher is equipped with a Automatic Lubrication System
(AUTOLUBE) to ensure that all necessary equipment is lubricated at regular inter-
vals in order to maintain the operational efficiency of the equipment.
The AUTOLUBE grease points are shown in the diagram below.

1
6
1
2 5
7 3
1. Product Conveyor top end drum (2 points)

2. Product Conveyor bottom end drum (2 points)
3. Main Crusher bearings (2 points)
4. Dirt Conveyor top end drum (2 points)
5. Dirt Conveyor bottom end drum (2 points)
6. Clutch (4 points)
7. Feeder Main drive bearings (4 points)

RK1012T ROTOCRUSHER
6.27 Automatic Greasing System contd.

Your RK 1012T has been fitted with a Quicklub central lubricating pump. It is a
compact multiline pump consisting of the following.
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
The Quicklub system operates according to cycles (pause and operating

times). During the operation time the pump dispenses lubricant to the con-
nected lube points via one or more metering device.
OPERATIONAL NOTES:
- The Quicklub system is designed for the delivery of greases up to NLGI

grade 2 at temperatures from -25°C to 70°C
- Can be used at low temperatures down to -40°C (Lubricants must still be
pumpable at these temperatures).

RK1012T ROTOCRUSHER
6.28 AUTOLUBE Maintenance

- 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) The Pump is out of grease

(b) Pump Operating failure.
(c) The Pump element needs to be replaced.
(d) There is a blockage in the system or bearing.
- If lubricant is emerging from the pressure relief valve, (Fig 2, B)

this indicates a blockage in the system and the fault should be
immediatly rectified.
A
FIG 1
FIG 2 B
RK1012T ROTOCRUSHER
6.28 AUTOLUBE Maintenance contd.

CLEANING
Whenever work is done on the AUTOLUBE system, particular attention should be

given to absolute cleanliness. Dirt in the system will cause problems
For cleaning the system use naphtha or petroleum benzine. Tri or Per or similar
solvents must not be used. Do not use polar organic solvents such as alcohol,
methyl alcohol, acetone or similar.
FILLING PUMP RESEVOIR
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.

RK1012T ROTOCRUSHER
6.28 AUTOLUBE Maintenance contd.
Test Run / Triggering and Additional Lubrication
There is a facility on your AUTOLUBE system where by the following functions can
be performed.
- Test Run on system to ensure correct operation.

- Additional cycle to top up grease points.
To carry out either of the above depress the test button on the main control panel
as shown below for at least 5 seconds.
Autolube
test button

RK1012T ROTOCRUSHER
6.29 AUTOLUBE Troubleshooting

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

necessary rectify the fault and replace
fuses.
- Check the line leading from the fuses to the
pump plug.
- Electric motor defective - Check voltage supply to motor.

If necessary replace motor.
Faults: Pump does not deliver lubricant
CAUSE REMEDY
- Reservoir empty - Refill reservoir with clean grease or

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

and or type of lubricant it may take10 minutes of
operation until the pump elements will reach their
full lubricant output.
- Air Pockets in Lubricant - Trigger an additional lubrication (see

previous page). Loosen the outlet fitting or
main line on safety valve. Lubricant must
issue without air bubbles.
- Unsuitable lubricant has been - 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.
- Pump piston worn - Replace pump element.
- Check valve in pump element - Replace pump element.

defective or clogged.

RK1012T ROTOCRUSHER
6.30 Recommended Fluids
HYDRAULIC OIL EQUIVALENTS
AMBIENT TEMPERATURE RANGE
10 - 20°C 20 - 30°C 30 - 48°C

(58 - 68°F) (58 - 68°F) (86 - 120°F)
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
6.31 Fault Finding

SYMPTOM POSSIBLE FAULT REMEDY
1. Engine won’t start Clutch engaged Disengage clutch
Solenoid switch not Repair possible break

operating when ignition on and in wire
override button in
Safety circuit tripped Check each circuit component
2. Engine stops Crusher jammed Clear obstruction
Low fuel level Top up tank and bleed system
Obstruction or break Repair and bleed system

in the fuel line system
NOTE: See engine manufacturers publication “Operators Handbook” Trouble shooting

section for detailed analysis of engine trouble.
3. No response Low oil level Top up hydraulic system

from any
hydraulic Choked suction line Wash and clean filter element
system filter
Pump shaft broken Replace pump
Worn pump Replace pump

Pressure relief valve Repair or replace valve
stuck in open position cartridge
Restricted or broken suction Check restriction in tank.

line Repair if broken
4. Machine Low oil level Top up hydraulic

operating slowly system.
No externa oil
leaks. Incorrect hydraulic fluid Drain tank and replace with
correct fluid
Choked suction line filter Replace filter element
Leaking relief valve Repair or replace relief valve
Worn control valve Replace control valve
Worn pump Replace pump

RK1012T ROTOCRUSHER
6.31 Fault Finding contd.

Worn head drum motor Replace head drum motor
Engine performance not Consult your engine

to standard manual fault finding
section
5. Excessive noise Choked suction line filter Replace filter element

from hydraulic
pump Damaged pump coupling Replace pump
Low oil level pump cavitating Top up hydraulic tank
Loose connections in suction Tighten all joints

Line
Flexible suction hose worn Replace hose
6. Screeching noise Lack of bearing lubricants Grease all bearings

when conveyors
are running
Conveyor wedged rubbing Clear obstructions, adjust
Against fixed parts and re-track conveyor belt
Belt drive coupling broken Replace or tighten coupling

or loose
Top end drum belt scrapper Ease pressure at scrapper

Too tight
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
8. Product conveyor Conveyor still bolted in Unbolt at relevant point

won’t fold position
9. Crusher not ‘V’ belts slipping Tighten belts

turning when the
rest of system
operational
10. Crusher won’t Material jammed in crusher Clear obstruction

turn machine not
operational

RK1012T ROTOCRUSHER
6.31 Fault Finding contd.

11. Feeder not Screen bearings seized Replace bearings
working
Motor coupling broken Replace coupling
Oil motor shaft broken Replace motor
Gear wheel teeth stripped Replace gear wheels
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.

RK1012T ROTOCRUSHER
Section 7
PREPARING FOR
TRANSPORT

RK1012T ROTOCRUSHER
PREPARING FOR TRANSPORT Section 7
7.0 Preparing For Transport

In order to transport the RK1012T Rotocrusher the following preparations should
be followed to ensure correct and safe movement of the machine.
Note: Some of the functions carried out when preparing the machine for trans-
port will require the use of a crane.
The fastening of loads and the instructing of crane operators should be

entrusted to experienced personnel.
Check with local authorities regarding transport restrictions, you may not have to
carry out all the instructions listed below.
1. Observe all safety instructions and warnings, all work is to be carried out by
qualified personnel only.

death.
system details.
DANGER NIP HAZARD

unguarded machine.

RK1012T ROTOCRUSHER

machinery.
supports provided.
WARNING PROTECTION
running machinery.

machine.
WARNING LOCKOUT
maintenance.

RK1012T ROTOCRUSHER

CAUTION HOT SURFACE


injury or death.

any contact.
this area.
BATTERY

RK1012T ROTOCRUSHER
7 Preparing For Transport contd..



TIMES.
NOTE: Leads may be

A B C
RK1012T ROTOCRUSHER
7.0 Preparing For Transport contd.

3. Fold and position the machine ready for transport as follows:
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
d) Remove feed-in chute extension box and disconnect the dust

suppression water pipe.
Dust Suppression
Feed-in Chute Water Pipe
Extension Box

RK1012T ROTOCRUSHER

e) Remove crib cross channel and beam.
Cross Tie &

Pin
f) Unbolt cribs at rear and remove rear crib pins (A).
CRIBS Remove
bolts

RK1012T ROTOCRUSHER

g) Lower both side cribs and rear cribs slowly and alternatively until fully
lowered.
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

RK1012T ROTOCRUSHER

i) Remove feeder beacon.
Feeder Beacon location

(remember to disconnect wires)
j) Lower hoist to transport position.
Hoist in transport
position
Pivot hoist
around hinge
Remove 4 bolts
before placing in
position

RK1012T ROTOCRUSHER

k) Remove upper level handrails 1, 2 & 3.
2
1
3
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) Remove the exhaust and pre-cleaner remembering to fit the rain-cap

on the exhaust opening and fit the cover over the air filter casing.
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.

RK1012T ROTOCRUSHER

k) 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 OFF-

LOADING AND LOADING OF THE RK1012T
ROTOCRUSHER IS CARRIED OUT BY TRAINED AND
EXPERIENCED PERSONNEL ONLY.

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 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.
No unauthorised alteration or modification has been made to the plant or ma-

chine 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 trans-
mitted 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
8.0 Warranty contd.

This understanding is in lieu of and excludes any other conditions guarantees, or
warranties expressed or implied, statutory or otherwise. In no event shall TESAB
ENGINEERING LTD. be liable (except to the extent if any of its undertaking as
foresaid) for any loss injury or damage howsoever caused or arising.
The guarantee contained aforesaid is personal to TESAB ENGINEERING LTD.

customer and may not be assigned.
IMPORTANT NOTE:-
TESAB ENGINEERING LTD. hereby emphasise that a dust suppression sys-

tem must be used when the RK 1012T is in operation.
TESAB ENGINEERING LTD. cannot be held responsible for any failure due to
the disregard of dust suppression.

RK1012T ROTOCRUSHER
RK1012T ROTOCRUSHER MAY 2002 Issue
Section 9
RK1012 CRUSHER
PARTS LIST

RK1012T ROTOCRUSHER
SPARE AND WEARING PARTS Section 9
LIST
SPARE AND WEARING PARTS LIST
TYPE RK 1012
ROTOCRUSHER
UNIT

RK1012T ROTOCRUSHER
LIST
9.0 INDEX
Section Description
9.1 Main Assembly
9.4 Top Apron (Stroke Carrier) Adjuster Assembly
9.5 Middle Apron (Stroke Carrier) Adjuster Assembly
Important Note:
To ensure supply of the correct parts with the minimum

delay please quote crusher serial number.

RK1012T ROTOCRUSHER
LIST
9.1 Main Assembly

5
12
15
12
5 13
3
4
3
10
4
3
7
6 2 1 9 8 11 14
Drawing Wgt kg/

Part No. Amount Description No. item Notes
1 4 Stroke 2-423-3 196
2 10 Grinding List 3-604 30
3 8 Stroke Plate 2-431 85
4 8 Stroke Plate 2-432 85
5 2 Stroke Carrier 1-593 248
6 1 Bar Carrier 1-592-1 835
7 1 Shaft 1-592-5 28
8 1 Rotor 1-587-2 1730 From s/n 1027
9 16 Protector Plate 3-660-1 18 From s/n 1027
10 16 Protector Plate Pin From s/n 1027
11 8 Stroke Securing Plate From s/h 1027
12 2 Shaft 1-593-3
13 48 Stroke Plate Bolt Assy
14 16 Bolt Assembly
15 2 Wear Plate 3-748 28 From s/n 1027

RK1012T ROTOCRUSHER
LIST
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
Drawing Wgt kg/

1 34 Wear Plate 4-820 31.5
2 2 Wear Plate 4-821 29.1
3 2 Wear Plate 4-822 36
4 2 Wear Plate 4-823 22.5
5 2 Wear Plate 4-824 27
6 2 Wear Plate 4-825 27.7
7 10 Wear Plate 4-826 15.4
8 2 Wear Plate 4-827 20.3
9 2 Wear Plate 4-828 16.4
10 4 Wear Plate 4-829 30.1
11 2 Wear Plate 4-830 24.1
12 2 Wear Plate 4-831 31.4
13 2 Wear Plate4-820 4-832 63

RK1012T ROTOCRUSHER
LIST
4 1 4 4 13 14 1 5
6
12
10
11 15
9
2 9
3 16
7
Drawing Wgt kg/

1 2 Bearing House 1-589-1
2 1 Labyrinth Seal 2-425-1
5 1 End Cover 2-433-1
6 1 Retaining Ring 2-436
7 1 Scored Pulley 2-430-2
8 1 End Cover 4-743-1
9 2 Sperical Roller Bearing 22330
10 1 Clamping Sleeve 150x200
11 2 Clamping Sleeve 170x225
12 1 Screw M6S30x60
13 24 Screw M6S12x35
14 2 Lubricant Nipple
15 2 Washer 4-735-1
16 1 Shaft 2-424-1 320.0

RK1012T ROTOCRUSHER
LIST
9.4 Top Apron (STROKE CARRIER) Adjuster Assembly
5
6
4
2 1 3
Drawing Wgt kg/

1 2 Adjustment Screw 3-619-1
2 4 Nut 510206 M39
3 2 Stud 4-742-2
4 2 Washer
5 2 Split Pin
6 6 Disc Spring 100414

RK1012T ROTOCRUSHER
LIST
9.5 Middle Apron (Stroke Carrier) Adjuster Assembly
Lower Stroke Carrier
1 8
7
3
6 5 2 4
Drawing Wgt kg/

3 2 Adjustment Yoke 4-742-1
4 2 Stud 4-741-2
6 20 Nut 510206 M39
7 2 Washer
8 2 Split Pin

RK1012T ROTOCRUSHER
LIST
Lower Stroke
Carrier
6 5 2 4 7 8
Drawing Wgt kg/

3 2 Adjustment Yoke 4-742-1
4 2 Stud 4-741-1
6 20 Nut 510206 M39
7 4 Split Pin
8 4 Washer

RK1012T ROTOCRUSHER
Section 10
HYDRAULIC & ELECTRIC
SCHEMATIC DIAGRAMS

RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM Section 10.0
(Standard)

RK1012T ROTOCRUSHER
HYDRAULIC SYSTEM Section 10.1
(inc. Conveyor Hyd. Folding)

RK1012T ROTOCRUSHER
ELECTRIC SYSTEM Section 10.2
(Tracks Control)

RK1012T ROTOCRUSHER
ELECTRIC SYSTEM Section 10.3
(Engine Control)

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RK1012T ROTOCRUSHER

RK1012T ROTOCRUSHER May 2002 Issue

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

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

The TESAB RK 1012T ROTOCRUSHER complies with the EU directive 89/392/EEC

READ THIS MANUAL CAREFULLY AND LEARN HOW TO OPERATE AND

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIP-

GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS

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

2.0 Safety Introduction

SECTION 3: TRACKING INSTRUCTIONS

3.0 Tracking Familiarisation

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

SECTION 4: SET-UP PROCEDURE

4.0 Set-up Procedure Safety

5.0 Operation Safety

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

6.0 The RK1012 Rotocrusher

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

SECTION 7: PREPARING FOR TRANSPORT

7.0 Preparing for Transport

SECTION 9: RK1012 CRUSHER PARTS LIST

SECTION 10: HYDRAULIC & ELECTRIC DIAGRAMS

10.0 Hydraulic Diagram (Standard)

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

1.1 EC DECLARATION OF CONFORMITY

Manufactured by: Tesab Engineering Ltd.

Machine Description: Mobile Crushing Plant

Model: RK 1012T ROTOCRUSHER

Tesab Engineering Ltd.

Name: Brian A. Mills

Position: Project Manager

Being the nominated representative of Tesab Engineering Ltd.

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

1.2 MACHINE SPECIFICATION DETAILS

MACHINE SERIAL NUMBER:

ENGINE SERIAL NUMBER:

CLUTCH SERIAL NUMBER:

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

1.3 FOREWORD/RESERVATION OF RIGHTS

The TESAB RK 1012T ROTOCRUSHER is a robust skilfully engineered piece of

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

This operation and maintenance manual must not be copied, reproduced

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

Front - product conveyor end of machine.

Rear - feeder end of machine.

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

1.4 FAMILIARISATION (contd.)

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

1.5 GENERAL SPECIFICATION

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

1.5 GENERAL SPECIFICATION contd.

Catwalks and Guards

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

RK1012T ROTOCRUSHER May 2002 Issue

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

2.0 SAFETY INTRODUCTION

DANGER ELECTRICAL HAZARD

GOOD HOUSEKEEPING PAYS UNTOLD DIVIDENDS