`` O & M 02/2016 Issue Original.

(English)

CRUSHERS . SCREENERS . BULK HANDLING

1012TS
With C13 Engine

OPERATION & MAINTENANCE

MANUAL
Subject to change without notice.
 GB

DECLARATION OF CONFORMITY

Manufacturers: Tesab Engineering Ltd.

9 Gortrush Industrial Estate, Omagh, Co. Tyrone
Northern Ireland, United Kingdom BT78 5EJ

Description of Machinery: Mobile Crushing Plant

Model: 1012TS

The undersigned, authorized by Tesab Engineering Ltd., certifies that the machine described above,
provided that it is installed, used and maintained in accordance with the instructions for use and the
codes of practise, meets the essential safety and health requirements of the following directives:

Machinery Directive 2006/42/EC

IMPORTANT! Read the installation, Operation and Maintenance manual for the above described
machine before using the machine. If you require additional copies contact your local Tesab dealer.

A technical construction file for the above named machinery is retained at the above address:

Signed:

Name: Colin Wilson

Position: Technical Director Date: 14.04.2014

Being the nominated representative of TESAB ENGINEERING LTD.

P2. 1012TS (C13) O & M 02-2016.

FOREWORD/RESERVATION OF RIGHTS:
The TESAB 1012TS Mobile Crushing Plant is a robust, skilfully engineered piece of equipment incorporating
diesel, hydraulic, electrical and mechanical components of the highest quality.
In the interest of continuous plant reliability, it is essential that the machine is maintained with meticulous care
and attention. This operation and maintenance manual has been produced to assist the user to obtain the
maximum output from the machine and to trace and remedy faults, should they arise. Failure to do so could
result in personal injury or equipment damage.
We strongly insist that the owners, operators, health & safety staff and all personnel associated with this
machine, must read and understand all aspects of this manual and pay particular attention to the safety and
maintenance sections.
Keep a copy of this manual at the operational site at all times.
Follow all applicable safety regulations and recommendations in this manual as appropriate to your machine.
Also take into account all on-site conditions and situations prevailing at the time.
Where the supply of this machine is intended for incorporation into a complete processing machine or system
that has not been designed and/or constructed by Tesab Engineering Ltd. then Tesab will NOT be responsible
for addressing environmental issues and/or health and safety protection measures for the machine installation as
a whole and will bear NO responsibility for ensuring compliance with any regulations and/or statutory
requirements that may apply unless specifically included in the contract of sale.

MACHINE DESIGNATED USE:

This machine is a portable, self-contained, material crushing plant. Typical materials include rock, ore, gravel,
coal and recycled materials. If you need to crush any other material not listed please contact Tesab Engineering
Ltd.

COPYRIGHT:
The copyright of this manual is reserved by Tesab Engineering Ltd.
No copies or reproductions in any form may be made of any part of this manual without prior written consent of
Tesab Engineering Ltd. This manual, complete or in part, must not be loaned or given to a third party.
Future updated issues of this manual, or manuals belonging to other Tesab equipment, will not be specific to this
machine. Tesab Engineering reserve the right to change the specification of their equipment and therefore
reserve the right to alter any information contained in this manual without prior notice.
Additional copies of this manual are readily available, however, a charge may be payable to cover printing and
administrative costs. To order additional copies contact your local dealer.
Copyright Protected:
Tesab Engineering Ltd.
Unit 9 Gortrush Ind. Estate
Omagh, Co.Tyrone
BT78 5EJ

P3. 1012TS (C13) O & M 02-2016.

 CERTIFICATE OF WARRANTY.
Tesab Engineering Ltd. warrants that the components within its products shall be free from defects for a period of 12 months,
or 1000 hours of operation, from the date that the product has been put into service and in any case for a maximum period of
15 months from the date of despatch from Tesab Engineering Ltd.

The warranty period shall be proportionally reduced if the product is operated for more than one eight hour shift per working
day or is operated in extreme environments or corrosive applications.

Warranty registration is mandatory and must be completed when the product is put into service. In the event that warranty
has not been correctly registered with Tesab Engineering, the warranty period will begin from the date of despatch from Tesab
Engineering Ltd.

Tesab Engineerings warranty is limited to:

a) The repair or replacement of any defective Tesab component(s) plus warranty labour costs, travel time and mileage
to repair the fault, for a period of 6 months and or up to 500 hours, whichever comes first, from the date of warranty
registration.

b) The replacement of any defective Tesab component for an additional 6 months (up to 1 year) and or up to 1000
hours, whichever comes first, from the date of warranty registration.

Tesab Engineering warranty is subject to acceptance of a defective component and provided that the following conditions are
met:

Written notice of the defect is given to Tesab Engineering Ltd. within seven days of the discovery of the defect.

No unauthorised alteration or modification has been made to the product or to the individual component that is the
subject of the claim.

The product was correctly commissioned and the operation & safety induction was carried out at the time of
commissioning.

Warranty was correctly registered with Tesab Engineering and notice was given to Tesab that the operation & safety
induction was carried out correctly.

The product has not been used in any application that it was not intended or designed for.

The defective component has been (when requested) returned, carriage paid, to Tesab Engineering Ltd. and shall, in
the event of replacement, become Tesab Engineerings property.

Warranty does not extend to CAT or Deutz engines that may have been fitted to Tesab products. Both CAT and Deutz have
dealers worldwide and where a problem occurs with the engine on your machine you must contact your local CAT or Deutz
dealer. IMPORTANT: Engine warranty registration is mandatory.

Warranty will be null and void if the defect has been caused by improper or unsuitable use of the product, inadequate
maintenance, carelessness, negligence or wilful damage.

Replacement parts will be sent by Tesab Engineering Ltd. on a standard ground shipping service, carriage paid, to the
customers nearest port of importation on a C.F.R. (Cost & Freight to port of destination) basis.

In the case of components not manufactured by Tesab Engineering Ltd. the customer shall be entitled to the benefits in so far
as it may be transmitted to the customer, of any guarantees given by the manufacturer in respect thereof and Tesab
Engineering Ltd. liability in respect of such goods is limited to making the benefits of the manufacturers guarantees available
to the customer to the extent aforesaid.

This understanding is in lieu of and excludes any other conditions, guarantees or warranties expressed or implied, statutory or
otherwise. In no event shall Tesab Engineering Ltd. be liable (except to the extent of any of its undertaking as aforesaid) for
any loss, injury or damage howsoever caused or arising.

The guarantee contained aforesaid is personal to Tesab Engineerings customer and may not be assigned.

P4. 1012TS (C13) O & M 02-2016.

 CONTENTS. Page No.
SECTION 1.0: FAMILIARISATION. 7
1.1 MAIN ASSEMBLY DESCRIPTIONS & ORIENTATION. 7
1.2 TECHNICAL SPECIFICATION. 8
1.3 MAIN CONTROL PANEL FAMILIARISATION. 9 10
1.4 IMPORTANT FEATURES OF THIS MACHINE. 11 12
1.5 FAMILIARISATION OF OPERATION LABELS DISPLAYED ON THE MACHINE. 13 15

SECTION 2.0: SAFETY. 16

2.1 SAFETY INTRODUCTION. 16
2.2 SAFETY WARNING LABELS. 17 20
2.3 SAFETY HAZARDS. 21
2.3.1 WORKING AT HEIGHTS. 21
2.3.2 NIP/CRUSH POINTS. 21
2.3.3 MATERIAL FALLING FROM HEIGHTS. 21
2.3.4 MOVING THE MACHINE. 21
2.3.5 SLIPPERY SURFACES. 21
2.3.6 DIESEL FUMES. 21
2.3.7 ELECTRICAL SAFETY. 21
2.3.8 NOISE. 22
2.4 HAZARD ZONE. 23
2.5 LOCKOUT PROCEDURE. 23
2.6 EMERGENCY STOPS LOCATIONS. 24
2.7 EMERGENCY SHUT DOWN. 25
2.7.1 RE-START PROCEDURE AFTER EMERGENCY SHUT DOWN. 25
2.8 SAFETY BEFORE AND DURING SET-UP. 26
2.9 SAFETY BEFORE AND DURING OPERATION. 27
2.10 SAFETY BEFORE AND DURING MAINTENANCE. 28
2.10.1 SAFETY WHEN WORKING WITH HYDRAULICS. 29
2.10.2 SAFETY WHEN WORKING WITH BATTERIES. 29
2.10.3 SAFE DISPOSAL OF WASTE PRODUCTS. 28

SECTION 3.0: ENGINE START-UP INSTRUCTIONS. 30

3.1 IMPORTANT CHECKS PRIOR TO STARTING THE ENIGNE. 30
3.2 ENGINE START UP PROCEDURES. 31

SECTION 4.0: TRACKING INSTRUCTIONS. 32

4.1 TRACKING THE MACHINE WHEN USING THE ENGINE. 32
4.1.1 TRACKING THE MACHINE USING THE DOGLEAD. 33
4.1.2 TRACKING THE MACHINE USING THE REMOTE CONTROL. 34

SECTION 5.0: INSTALLATION. 35

5.1 INSTALLATION OVERVIEW. 35
5.2 INSTALLATION PROCEDURES. 35
5.3 STEP 1: UNLOAD THE MACHINE. 36
5.4 STEP 2: POSITION THE MACHINE INTO THE DESIRED LOCATION. 36
5.5 STEP 3: FIT THE FEEDER BEACON. 36
5.6 STEP 4: FIT THE PRE-CLEANER. 37
5.7 STEP 5: SET THE MACHINE TO CRUSHING MODE. 37
5.8 STEP 6: CHECK THE FEEDER ALIGNMENT. 37
5.9 STEP 7: FOLD UP THE CRIBS. 38
5.10 STEP 8: FIT THE CHAIN BOX. 39
5.11 STEP 9: FOLD OUT THE DIRT CONVEYOR. 39
5.12 STEP 10: FOLD OUT THE DISCHARGE CONVEYOR. 40
5.13 STEP 11: SET THE CRUSHING SIZE. 41
5.13.1 SETTING THE BAR CARRIER. 41 42
5.13.2 SETTING THE MIDDLE APRON. 43
5.13.3 SETTING THE TOP APRON. 43
5.14 STEP 12: FIT THE WORKING LIGHTS. 44
5.15 STEP 13: CONNECT THE DUST SUPPRESSION. 44
5.16 STEP 14: ADJUST THE PRODUCT CONVEYOR AND DIRT CONVEYOR BELTS. 45
5.16.1 BELT TENSIONING. 45
5.16.2 BELT TRACKING (ALIGNMENT). 45

SECTION 6.0: OPERATION. 46

6.1 OPERATION OVERVIEW. 46
6.2 IMPORTANT CHECKS PRIOR TO OPERATING THIS MACHINE. 46
6.3 MACHINE START-UP SEQUENCE. 47
6.3.1 STEP 1: SET THE MACHINE TO CRUSH MODE. 47
6.3.2 STEP 2: SELECT THE TROUSER CHUTE POSITION. 48
6.3.3 STEP 3: START THE ENGINE. 48
6.3.4 STEP 4: START THE PRODUCT CONVEYOR. 48
6.3.5 STEP 5: START THE MAGNET AND DIRT CONVEYOR. 49
6.3.6 STEP 6: START THE CRUSHER UNIT. 49
6.3.7 STEP 7: ADJUST THE ENGINE SPEED. 49

P5. 1012TS (C13) O & M 02-2016.

 CONTENTS CONTINUED. Page No.
6.3.8 STEP 8: START THE FEEDERS. 50
6.4 CONTROLLING THE SPEED OF THE FEEDERS. 51
6.5 MACHINE SHUT-DOWN SEQUENCE. 51

SECTION 7.0: MAINTENANCE. 52

7.1 GENERAL MAINTENANCE INFORMATION. 52
7.2 DAILY MAINTENANCE. 53
7.3 VISUAL CHECKS DURING OPERATION. 53
7.4 WEEKLY MAINTENANCE. 53
7.5 LUBRICATION POINTS. 54
7.6 LUBRICATION SCHEDULE. 54
7.7 AUTOMATIC LUBRICATION 55 57
7.8 SERVICE SCHEDULE: 58
7.8.1 OIL & FLUID REPLACEMENT QUANTITIES: 58
7.8.2 RECOMMENDED LUBRICANTS 59
7.9 ENGINE MAINTENANCE. 60
7.9.1 ROUTINE DAILY ENGINE MAINTENANCE. 60
7.10 MANUAL CLUTCH MAINTENANCE. 61
7.10.1 MANUAL CLUTCH LUBRICATION. 61
7.11 HYDRAULIC CLUTCH MAINTENANCE. 62
7.12 TRACKS MAINTENANCE: 63
7.12.1 TRACKS ADJUSTMENT. 63
7.12.2 TRACKS ADJUSTMENT SETTINGS. 64
7.12.3 INCREASING THE TRACK TENSION. 64
7.12.4 RELEASING THE TRACK TENSION. 65
7.12.5 TRACKS GEARBOX MAINTENANCE. 65
7.12.6 CHECKING AND FILLING THE GEARBOX OIL. 65
7.12.7 DRAINING THE GEARBOX OIL. 65
7.13 HYDRAULIC OIL SYSTEM MAINTENANCE. 66
7.14 PRODUCT CONVEYOR GEARBOX MAINTENANCE. 67
7.14.1 CHANGING THE OIL IN THE GEARBOX. 67
7.15 CRUSHER DRIVE BELT MAINTENANCE. 68
7.15.1 DRIVE BELT TENSIONING. 68
7.16 CONVEYORS MAINTENANCE. 69
7.17 PRIMARY FEEDER MAINTENANCE. 70
7.17.1 CHECKING THE OIL BATH LUBRICANT LEVEL. 70
7.17.2 CHANGING THE OIL BATH LUBRICANT. 70
7.17.3 FITTING ADDITIONAL WEIGHTS TO THE PRIMARY FEEDER. 71
7.18 SETTING THE ROTOR SPEED RELAY. 72
7.19 CRUSHER UNIT MAINTENANCE. 73
7.19.1 INSPECTING THE CRUSHER UNIT. 73
7.19.2 OPENING THE CRUSHER UNIT. 74
7.19.3 CRUSHER UNIT WEAR LIMITS. 75
7.19.4 TURNING OR REPLACING THE HAMMERS. 76
7.19.5 REPLACING THE STROKE PLATES. 77 79
7.19.6 REPLACING THE BLOW BARS. 80
7.20 REALIGNING THE SCALPING FEEDER. 80
7.21 HYDRAULIC SYSTEM LAYOUT. 80

SECTION 8.0: TRANSPORTATION: 82

8.1 TRANSPORTATION OVERVIEW. 82
8.2 PREPARING FOR TRANSPORT SEQUENCE. 82
8.2.1 STEP 1: CLEAR THE MACHINE OF ALL MATERIAL. 83
8.2.2 STEP 2: FOLD DOWN THE PRODUCT CONVEYOR. 83
8.2.3 STEP 3: FOLD UP THE DIRT CONVEYOR. 84
8.2.4 STEP 4: LOWER THE CRIBS. 85
8.2.5 STEP 5: REMOVE THE PRE-CLEANER, WORKING LIGHTS & FEEDER BEACON. 86

P6. 1012TS (C13) O & M 02-2016.

 SECTION 1.0

FAMILIARISATION
! CAUTION Ensure that all personnel are completely
familiar with all aspects of this machine.

1.1 MAIN ASSEMBLY DESCRIPTIONS & ORIENTATION.

LEFT HAND SIDE

REAR FRONT

RIGHT HAND SIDE

(A). (B). (C). (D). (E). (F). (G).

(H). (I). (J).

Main Assembly Descriptions:

(A). Product (Discharge) Conveyor (I). Trouser Chute

(B). Hydraulic Tank (J). Dirt (Fines) Conveyor
(C). Engine & Clutch Assembly
(D). Crusher Unit
(E). Scalping Feeder
(F). Cribs
(G). Primary Feeder
(H). Tracks

P7. 1012TS (C13) O & M 02-2016.

 1.2 TECHNICAL SPECIFICATION.

TRANSPORT DIMENIONS (mm).

3,810
(12 6)

14,250 (46 9)

Transport Length: 14,250mm

Transport Width: 3,330mm
Transport Height: 3,810mm
Machine Weight: 45,200kgs (99,649lbs)

NOTE: The weights and dimensions stated here are given for a standard
machine only. Optional extras fitted to the machine and/or transportation
laws in force in various countries, may alter the weight and transport
dimensions of the machine.

3,330 (10 11)

OPERATING DIMENIONS (mm).

Operating Length: 15,688mm

Operating Width: 5,850mm
Operating Height: 4,233mm

P8. 1012TS (C13) O & M 02-2016.

1.3 MAIN CONTROL PANEL FAMILIARISATION.

(1)
(4)
(2)

(5)

(3) (6)

(11) (12)
(13) (14) (7)
(15) (16) (8)
(17)
(18) (19) (9)
(10)
(20) (21)

(22)

1) Feeder Switch. This switch is used to
select either manual or automatic feeder
operation.
Manual feeder operation
Automatic feeder operation
2) Clutch Start Switch. When this switch is
pressed the clutch will start. Note: This
switch is only present when a KPTO clutch
is fitted to the machine.
3) Clutch Stop Switch. When this switch is
pressed the clutch will stop. Note: This
switch is only present when a KPTO clutch
is fitted to the machine.
4) Engine Display Module. This device
indicates various parameters of the engine
performance. See the engine
manufacturers operation & maintenance
manual for more information.
5) Engine Throttle Switch. This switch is
used to increase or decrease the engine
speed. Push the switch up to increase the
engine speed. Push the switch down to
decrease the engine speed. Note: If a
constant speed engine has been fitted to
your machine then there will only be two
engine speed settings: Idle (1000rpm) and
High (1800rpm). Push the throttle switch
up once to increase the engine speed to
High. Push the throttle switch down once
to decrease the engine speed to Idle.
With this option, if the engine speed is
reduced the engine must be re-started
before the engine speed can be increased
again.
6) Doglead / Remote Control Key Switch.
This switch is used to select either the
doglead or the remote control for tracking
and operation.
Doglead

Remote Control

7) Dust Suppression Switch. This switch

operates the automatic dust suppression
system. Note: This switch is only present
when a dust suppression system is fitted to
the machine.

P9. 1012TS (C13) O & M 02-2016.

1.3 MAIN CONTROL PANEL FAMILIARISATION CONTINUED.
8) Autolube Switch. This switch operates
the automatic greasing system. Note:
This switch is only present when an
autolub system is fitted to the machine.
9) Work Lamps On/Off Switch. This
switch operates the work lamps. Note:
This switch is only present when working
lamps are fitted to the machine.
10) Engine Start/Stop Switch. This switch
starts and stops the engine.
Ignition Off
18) Feeder Run Lamp. When illuminated this
lamp indicates that the feeders are being
operated manually.
19) Doglead Activated Lamp. When
illuminated this lamp indicates that the
doglead function has been activated.
20) Automatic Feeder Run Lamp. When
illuminated this lamp indicates that the
feeders are operating automatically.
21) Remote Control Activated Lamp. When
illuminated this lamp indicates that the
remote control function has been activated.

Ignition ON 22) Tracks Activated Lamp. When illuminated

this lamp indicates that the tracking function
has been activated.
Engine Start

11) Engine Fault Lamp. When illuminated

red this indicates a potential engine fault.
See the engine manufacturers operation
& maintenance manual for more
information.

12) Diagnostic Lamp. When flashing

orange this represents a Fault Flash
Code for the engine. See the engine
manufacturers operation & maintenance
manual for more information.

13) Dust Suppression Lamp. When

illuminated this indicates that the dust
suppression system is operating. Note:
This lamp is only active when a dust
suppression system is fitted to the
machine.

14) Hydraulic Clutch Engaged Lamp.

When illuminated green, this indicates
that the hydraulic clutch is engaged.
Note: This lamp is only active when a
KPTO clutch is fitted to the machine.

15) Maintenance Due Lamp. When

illuminated this indicates that the engine
requires maintenance. See the engine
operation & maintenance manual for
more information.

16) Emergency Stop Lamp. When

illuminated green this indicates that no
emergency stops are pressed. If not
illuminated this indicates that an
emergency stop has been pressed.

17) Work Lights Lamp. When illuminated

this lamp indicates that the work lamps
are turned on. Note: This lamp is only
active when working lamps are fitted to
the machine.

P10. 1012TS (C13) O & M 02-2016.

1.4 IMPORTANT FEATURES OF THIS MACHINE.
This machine is fitted with several important mechanisms and systems that provide various operating and safety
features. Please ensure that you make yourself completely familiar with these systems so that you get the best
performance and reliability from your machine.

1). Tracking:
Crawler tracks have been fitted to the machine so that it can be (A). (B).
easily transported and manoeuvred into position. The tracks are
operated through either a doglead handset, as shown at (A), or a
remote control, as shown at (B).
NOTE: The remote control is an optional extra and may not be
fitted to all machines.

2). Variable Feed Control of the Primary Feeder.

In order to control the rate of material being fed into the crusher,
the primary feeder has been fitted with a variable speed control.
The speed of the feeder is adjusted by turning the variable
control valve located on the top catwalk, as shown at (C). (C).

3). Rotor Speed Sensor and Automatic Feeder Shut off:

A speed sensor has been fitted to the rotor on the crusher to
detect if the speed of the rotor reduces. This helps prevent the
crusher from overloading and stalling the engine.
If the rotor slows down below a pre-set speed the feeders will
automatically stop. When the rotor speeds up again above
another pre-set speed, the feeders will automatically start again.
A speed relay, as shown at (D), controls the settings of the
speed sensor.
NOTE: This sensor only works when the machine is being (D).
operated in Automatic mode.

4). Manual and Remote Control Feeder Operation:

The feeders on this machine can be operated either manually,
through hydraulic levers, or through a remote control handset, as
shown at (E).
Prior to operation you must choose which mode of operation you
wish to use. If you choose the remote control or Automatic (E). (F).
mode, the automatic feeder shut off system will also be in
operation.
NOTE: If youre using the remote control function you can also
start and the stop the feeders by pressing the buttons on the side
of the receiver box, as shown at (F).

P11. 1012TS (C13) O & M 02-2016.

1.4 IMPORTANT FEATURES OF THIS MACHINE CONTINUED.

5). Fines Trouser Chute:

(A).
A trouser chute has been fitted underneath the scalping feeder,
as shown at (A). This chute provides the option to direct the
fines material from the scalping feeder out through the side dirt
conveyor or back onto the main discharge conveyor belt.

There is also an option to have the larger material flow onto the
product conveyor while the fines material travels onto the side dirt
conveyor.

A handle has been fitted to the side of the chute which allows the (B).
direction of the fines material to be easily changed.

6). Hydraulically Adjusting Crusher Aprons.

In order to allow the crusher settings to be easily and quickly

changed, hydraulic adjusters, as shown at (B), have been fitted
to the machine. Different settings are obtained by moving the
spacers on the adjuster bars.

7). Separate Crushing and Tracking Modes.

The tracking and crushing functions on this machine have been

kept separate. Therefore, the machine cannot be tracked while it
is in the crushing mode, and the rams, conveyors or crushing
function will not operate while it is in the tracking mode.

Two hydraulic diverter valves, as shown at (C), are used to select

either the tracking or crushing modes. (C).

To track the machine both valves must be set to the Track

position. To carry out any other function, such as crushing or
operating the rams, both valves must be set to the Crush
position.

WARNING: Both valves MUST be set to either the Crush or the

Track positions. Never have one valve in the Track position and
the other in the Crush position, or vice versa. The valves MUST
NEVER be moved while the engine is running.

P12. 1012TS (C13) O & M 02-2016.

1.5 FAMILIARISATION OF OPERATION LABELS DISPLAYED ON THE MACHINE.
The following sign conventions are used throughout this manual and on the machine. Please read this section
carefully to become familiar with the signs used. NOTE: Hazard warning labels are shown in the safety section.

Hydraulic Oil.
Keep radiators and oil
coolers clean.
Clogged radiators will
cause over-heating.
Diesel Oil.

Grease Point. Battery Isolator.

Drain water separator Engine Oil Level.

once a day.

Discharge conveyor
operation.

1. Feeders operation.

Activate crusher
adjustment control
bank.

1) Middle apron 1. Dirt conveyor folding.

adjustment.
2. Dirt conveyor
2) Bar carrier telescopic.
adjustment.

P13. 1012TS (C13) O & M 02-2016.

1.5 FAMILIARISATION OF OPERATION LABELS DISPLAYED ON THE MACHINE CONTINUED.

1) Left hand side crib folding.

2) Rear crib folding.

3) Right hand side crib folding.

1) Up Dirt conveyor operation.

Down Activate dirt conveyor folding control bank.

2) Crusher opening.

3) Discharge conveyor folding.

Auxiliary Hydraulic
Scalping feeder
Drive Pressure
speed control.
Line.

Primary feeder Auxiliary Hydraulic

speed control. Drive Bleed Line.

Auxiliary Hydraulic
Magnet speed
Drive Return
control.
Line.

P14. 1012TS (C13) O & M 02-2016.

1.5 FAMILIARISATION OF OPERATION LABELS DISPLAYED ON THE MACHINE CONTINUED.

Diverter valve Diverter valve

selection - Tracking selection - Crushing

Correct Operation of Diverter Valves

1. The engine must be stopped before the diverter valves

can be switched from tracking mode to crushing mode
or vise versa.
2. The machine MUST NOT be operated with one
diverter valve in tracking mode and one in crushing
mode or vise versa.
3. Both diverter valves must be in either tracking mode or
crushing mode before the machine can be operated.

Transport tie-down
point.

WARNING:

Disconnect grease
hoses before
folding discharge
conveyor

No tie-down
point

P15. 1012TS (C13) O & M 02-2016.

 SECTION 2.0

SAFETY
2.1 SAFETY INTRODUCTION.

It remains the responsibility of the owner and/or operator of this machine to ensure the Health & Safety of all
persons who are inspecting, operating or carrying out any work on or close to the machine.

This safety section in no way replaces any laws or other binding accident prevention and environmental
protection regulations.

All personnel who operate, maintain, repair or carry out any type of work on or near to Tesab equipment must be
properly trained in the correct and safe procedures for the work they are to carry out.

They MUST:

Be reliable, experienced and have a sound knowledge of materials processing equipment. Statutory
minimum age limits must also be observed.
Read and understand all aspects of this manual prior to carrying out any work.
Be aware of all the hazards associated with this machine.
Have received specific and adequate training for any particular task to be carried out.
Be completely familiar with all parts of the machine.
Be aware of all moving parts on the machine.
Be aware of the operation and limits of performance of the machine.
Know the location of safety features such as emergency stop buttons and safety guards etc.
Have read and understood any on-site safety manual produced by the site owner.
Be prepared to carry out all safety instructions regardless of how unimportant they may seem.

IMPORTANT: All instructions given in this manual have been provided based on ideal site conditions and plant
set-up. However, not all sites or machine set-ups will be the same, therefore, in the interests of safety the
instructions given here should be adapted to suit the conditions and set-up of each particular machine.

The person carrying out work to the machine must assess all on-site risks and take these into account before
performing any work. All efforts must be made to find and eliminate all on-site risks associated with this
machine.

2.1.1 CALIFORNIA PROPOSTION 65 WARNINGS:

Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth
defects, and other reproductive harm.

P16. 1012TS (C13) O & M 02-2016.

2.2 SAFETY WARNING LABELS.
The following safety sign conventions are used throughout this manual and on the machine. Please read this
section carefully and become familiar with the signs used.

WARNING! WARNING!
ENTAGLEMENT HAZARD. IMPACT HAZARD.
Keep all guards in place! Stand clear of machine when
Do not operate the machine discharge conveyor is being folded.
without all guards fitted.

WARNING! WARNING!
FALL HAZARD. IMPACT HAZARD.
Do not climb onto high areas of Stand clear when dirt conveyor is
the machine. being folded.
Use a suitable lift to access high
areas of the machine.

WARNING! WARNING!
CRUSH HAZARD. CRUSH HAZARD.
Stand clear of tracks when the Stand clear of the machine when
machine is being moved. tracking.
Keep a look out on all sides of the
machine when tracking.

WARNING! WARNING!
CRUSH HAZARD. IMPACT HAZARD.
Keep feet and limbs clear when Risking of falling objects.
lowering jacking legs. Stand clear of machine when it is
being operated.

P17. 1012TS (C13) O & M 02-2016.

2.2 SAFETY WARNING LABELS CONTINUED.

WARNING! WARNING!
PENETRATION HAZARD. CRUSH HAZARD.
If hydraulic hose bursts stand Before tracking the machine
clear. ensure that you read the operation
Stop machine immediately. manual.
Read maintenance manual.

WARNING! WARNING!
ELECTROCUTION HAZARD. POTENTIAL HAZARD.
Keep clear of overhead cables Before starting the engine ensure
when moving or setting up the that you read the operation
machine. manual.

WARNING! WARNING!
DUST HAZARD. POTENTIAL HAZARD.
During operation high levels of Before carrying out any
dust may be created. maintenance ensure that the
Ensure that a suitable dust engine has been stopped and the
suppression system is being machine has been locked out.
used.

WARNING!
EXPLOSION HAZARD.
If carrying out welding on or
close to the machine ensure that
the batteries have been isolated.
WARNING!
POTENTIAL HAZARD.
Before carrying out any
maintenance ensure that you read
the maintenance manual.

P18. 1012TS (C13) O & M 02-2016.

2.2 SAFETY WARNING LABELS CONTINUED.

WARNING!
ENTAGLEMENT HAZARD.
Before opening the engine
canopy ensure that engine has
been switched off and locked out.
WARNING!
IMPACT HAZARD.
Risking of falling objects.
Stand clear of magnet chute when
the machine is being operated.

WARNING! WARNING!
BURN HAZARD. VIBRATION & NIP HAZARD.
Ensure that the engine has been Vibrating components present.
switched off and has cooled down Stand clear of vibrating
before carrying out any components when the machine is
maintenance. being operated.

WARNING!
WARNING!
BURN HAZARD.
EXPLOSION & BURN
Do not touch hot surfaces.
HAZARD.
Battery acid can burn.
Keep naked flames away from EMERGENCY STOP.
batteries.
In cases of emergency press the
e-stop button.

MANDATORY! MANDATORY!
Head protection must be
Ear protection must be worn.
worn.

MANDATORY! MANDATORY!
Eye protection must be worn. Protective gloves must be
worn.

P19. 1012TS (C13) O & M 02-2016.

2.2 SAFETY WARNING LABELS CONTINUED.

MANDATORY! MANDATORY!
Protective clothes must be Protective boots must be
worn. worn.

MANDATORY! MANDATORY!
Dust mask must be worn. High visibility vest must be
worn.

Noise Levels!

P20. 1012TS (C13) O & M 02-2016.

2.3 SAFETY HAZARDS.
The following hazards have been identified on this machine and therefore precautions must be taken to avoid
injury or death. Note, these are not all the risks associated with this machine. A complete and comprehensive
risk assessment should be carried out by the site owner before operating this machine.
2.3.1 WORKING AT HEIGHTS.
Falling from a TESAB machine can cause serious injury or even death. Some maintenance tasks will
necessitate that persons work on the machine at a height were fall hazards exist. In these cases it is the
responsibility of the machine owner to provide adequate safe working access. Even when using safe platforms
an EN/ANSI Safety Harness must be worn by all personnel when working above heights of 2 metres (7ft).
Always keep access ladders and walkways clean and free from debris, material, snow, ice, rags and tools.
Never use machine parts as climbing aids. Access platforms only be used by authorised personnel. If any work
or adjustments, of any kind, are to be carried out the machine must be shut down and "Locked out". etc.
2.3.2 NIP/CRUSH POINTS.
Travelling belts, rotating drums & rollers, vibrating mechanisms and various moving parts on this machine create
potentially serious nip points. No one should ever reach into any part of the machine, for whatever reason, while
it is running. Always stop the machine and lock out when maintenance, repairs or adjustments are required.
Loose clothing, jewellery and long hair should be tied back or removed to avoid entanglement with the
components. Guards are provided at certain high risk nip points on the machine. These guards must be kept in
place at all times. The machine must not be operated while any guards are missing or damaged. The machine
should only be started when the operator has checked that everyone is clear of the machine.
2.3.3 MATERIAL FALLING FROM HEIGHTS.
Material is fed on to, and discharged off the machine at great heights. Therefore, it is imperative that no one is
permitted to stand or walk close to the machine when it is operating. In some situations material can roll back
down conveyor belts and even fall off the side of the conveyors. It is also important that, even when the machine
is not operating, personal protective equipment is worn at all times. Loose material can easily fall from the
machine even when it is stopped.
2.3.4 MOVING THE MACHINE.
Major hazards exist when moving and manoeuvring this machine which could cause serious injury or death. All
personnel authorised to move this machine must be trained on the operation of the track drives. Extreme care
must be taken before and during moving of this machine.
2.3.5 SLIPPERY SURFACES.
Due to environmental and operating conditions, some parts of the machine can become very slippery when wet,
especially metal surfaces. Extra care should be taken during wet conditions. Proper footwear should always be
worn and walkways and ladders should always be keep clean and free from obstructions.
2.3.6 DIESEL FUMES.
Diesel engine exhaust emissions contain products of combustion which may be harmful to your health. Ensure
the machine is in a well ventilated area. If the machine is operating in an enclosed area ensure that emissions
are vented outdoors.
2.3.7 ELECTRICAL SAFETY.
While the electrical equipment on this machine is rated at only 24 volts, safety should not be taken lightly. If
components are connected wrongly or are tampered with, serious burns or injuries can be caused.
Work on the electrical system must only ever be carried out by a fully qualified electrician.
Never work on the electrical system unless you are thoroughly familiar with the system details.
Special care must be taken when disconnecting, replacing and /or charging the batteries. Ensure that
the batteries are re-connected correctly. Contact across the terminals on the batteries can cause sparks
or explosions.
The electrical equipment on this machine must be inspected at regular intervals. Damaged cables or
loose connections must be repaired immediately. Use only genuine replacement parts with the correct
load rating especially fuses.
Always isolate the batteries if welding on the machine.

P21. 1012TS (C13) O & M 02-2016.

2.3.8 NOISE.
Due to the type and nature of this machinery, excessive noise levels will occur. Over time exposure to noise can
cause serious injury, therefore, precautions must be taken including the wearing of adequate ear protection. The
length of exposure to such noise levels should be kept to a minimum. Adequate noise risk assessments must be
carried out.
The diagram below shows the noise rating at 2m, 6m & 12m

P22. 1012TS (C13) O & M 02-2016.

2.4 HAZARD ZONE.
It is strongly recommended that a hazard or restriction zone should be placed at least 10 metres around the
entire machine. Access to this restricted zone should only be permitted to those people who meet all the criteria
listed below. This procedure, if enforced at all times, even when the machine is shut down, will significantly
reduce the potential for accidents and injuries.
Those permitted to enter the hazard zone should comply with all of the following:

They must have authorisation from the machine supervisor to enter the restricted zone.
They must have read and understood the safety section of this manual.
They must carry out all safety procedures required.
They must be fully trained and qualified in the work they are carrying out.
They must have experience in working with this type of plant.
They must be wearing the required Personal Protective Equipment".
They must be accompanied by another person who also meets this criteria.

2.5 LOCKOUT PROCEDURE.

When carrying out maintenance, repairs, adjustment or work of any kind on this machine, ensure that the
following lockout procedure is followed:

Deactivate all controls, switch the engine off and remove the key.
Activate at least one emergency stop.
Relieve all pressures in the hydraulic system.
The person doing the work on the machine must keep the keys with them at all times.
Ensure that the isolator switch, as shown at (A), is in the OFF position and is padlocked.

(A).

P23. 1012TS (C13) O & M 02-2016.

2.6 EMERGENCY STOPS LOCATIONS.
There are nine emergency stops located on a standard 1012TS crusher. There locations are given below.
Optional extras fitted to the machine may require additional emergency stops to be fitted.

Ensure that everyone who operates, maintains or is anyway associated with this machine, makes themselves
completely familiar with the location of all the emergency stops on the actual machine.

1
2

1 2

5
3

3 4 5

P24. 1012TS (C13) O & M 02-2016.

2.7 EMERGENCY SHUT DOWN.
IMPORTANT: In the case of any major incident on the machine the following procedure must be followed
immediately.

NOTE: Do not use the Emergency Stop procedure to stop the machine under normal situations.

Engage the nearest emergency stop.

Stop all other equipment feeding or working near the machine.

Perform the Lock Out procedure.

Inform all other operators working on or close to the machine.

Only when all parts of the machine are stationary and the Lockout procedure has been preformed,
should any attempt be made to repair the fault.

Ensure that at least two people are present when fault finding or accident investigation is being
carried out.

2.7.1 RE-START PROCEDURE AFTER EMERGENCY SHUT DOWN.

IMPORTANT: Only authorised, competent and fully trained personnel should be permitted to re-start the
machine after an emergency shut down.

Ensure that the problem has been rectified.

Replace all guards correctly.

Ensure that all personnel are clear of the machine.

Ensure that all tools etc. have been cleared from around the machine including the walkways.

Release all emergency stops.

Follow the correct engine start up procedure as shown in section 3.0.

Do not leave the machine until you are sure the problem will not re-occur.

If the problem persists carry out the emergency shut down procedure again and carry out further
fault finding.

P25. 1012TS (C13) O & M 02-2016.

2.8 SAFETY BEFORE AND DURING SET-UP.

IMPORTANT: All instructions given in this manual regarding installation, operation, maintenance and
replacement of parts have been provided based on ideal site conditions and machine set-up. However, not all
sites or machine set-ups will be the same, therefore, in the interests of safety the instructions given should be
adapted to suit the conditions and set-up of each particular machine.
Any person carrying out work on the machine must assess all on-site risks and take these into account before
performing any work. All efforts must be made to find and eliminate all on-site risks associated with this
machine.

The set-up of this machine must only be carried out by competent and well trained staff.

Ensure that the area where the machine is to be set-up is stable, level and has adequate all-round
clearance etc.

Always request and observe the regulations that are in force at the site.

Ensure that at least two people are present when set-up of this machine is being carried out.

Ensure that all personal protective equipment is worn. Loose clothing, jewellery and long hair must
be tied back or removed to avoid entanglement in the machinery.

Before beginning set-up ensure that all loose items and packaging materials have been removed
from the machine.

Before starting the machine and operating any of the hydraulic levers ensure that you have removed
all transport bolts, fixtures and fittings.

When working on areas of the machine where no walkways have been provided, an approved lifting
platform must be used. Never climb onto the machine to reach areas not accessible from the ground
or from the walkways. Never use unauthorised or unsafe platforms to reach inaccessible areas of
the machine. If working above heights of 2 metres, even when using the walkways provided, an
EN/ANSI safety harness must be worn.

Never work under unsupported equipment.

Only use lifting equipment, including slings and chains, that are in good working order, have been
adequately tested and have the required lifting capacity for the job at hand.

Do not stand beneath equipment as it is being raised or lowered into position.

Do not use fingers to check hole alignments as this can cause serious injury.

Before testing the machine ensure that all tools, parts and components have been removed from the
machine and walkways. Ensure that no one is on or near the machine before testing.

Test the machine to ensure that it is functioning properly. If problems occur during testing shut down
the machine and carry out fault finding to rectify the problem.

P26. 1012TS (C13) O & M 02-2016.

2.9 SAFETY BEFORE AND DURING OPERATION.

IMPORTANT: All instructions given in this manual regarding installation, operation, maintenance and
replacement of parts have been provided based on ideal site conditions and machine set-up. However, not all
sites or machine set-ups will be the same, therefore, in the interests of safety the instructions given should be
adapted to suit the conditions and set-up of each particular machine.
Any person carrying out work on this machine must assess all on-site risks and take these into account before
performing any work. All efforts must be made to find and eliminate all on-site risks associated with this
machine.
Keep all parts of this machine in good condition and properly installed. Fix any damage immediately and replace
any broken parts with genuine TESAB parts. Remove any build up of grease, oil or debris before operating the
machine.

Ensure that all operators of this machine are reliable, experienced and have a sound knowledge of
this type of equipment. Statutory minimum age limits must also be observed.

Ensure that you have read and understand all safety hazards and operating procedures before
starting the machine.

Study all safety and hazard warning signs on the machine.

Ensure that all personal protective equipment is worn. Loose clothing, jewellery and long hair must
be tied back or removed to avoid entanglement in the machinery.

Ensure that onlookers and untrained or inexperienced persons are well away from the machine.

Prior to operation check the condition of the machine for worn, broken, missing or damaged parts,
water leaks or obstructions etc. Ensure that all safety guards and emergency stops are correctly
fitted and in good working order. Carry out any daily maintenance required - see maintenance
schedule.

Before starting, walk completely around the machine. Ensure no one is under it, on it, or close to it.

Let other workers and bystanders know that you are starting the machine and do not start until
everyone is clear of the machine.

In the event of malfunctions or operational difficulty stop the machine immediately and lock out. Have
any defects rectified immediately.

While the machine is running only use the ladders, steps or walkways supplied to visually inspect the
machine.

Never attempt to carry out repairs, maintenance or adjustments of any type while the machine is
running.

Never stand or work beneath the machine while it is being loaded with material.

Never stand or work beneath the machine while it is being fed or is discharging material.

Only use emergency stops in emergency situations or during safety drills.

P27. 1012TS (C13) O & M 02-2016.

2.10 SAFETY BEFORE AND DURING MAINTENANCE.

IMPORTANT: All instructions given in this manual regarding installation, operation, maintenance and
replacement of parts have been provided based on ideal site conditions and machine set-up. However, not all
sites or machine set-ups will be the same, therefore, in the interests of safety the instructions given should be
adapted to suit the conditions and set-up of each particular machine.
Any person carrying out work on this machine must assess all on-site risks and take these into account before
performing any work. All efforts must be made to find and eliminate all on-site risks associated with this
machine. Never alter any equipment or parts which may affect safety without consulting and gaining permission
from TESAB ENGINEERING LTD.

Before performing any maintenance of any kind the Lock Out procedure MUST be carried out.
Ensure that all moving parts of the machine have come to a stand still before attempting any repairs
or maintenance.
Ensure that at least two people are present when maintenance or service work is being carried out.
Ensure that all personal protective equipment is worn. Loose clothing, jewellery and long hair must
be tied back or removed to avoid entanglement in the machinery.
Ensure that the personnel carrying out the service or repair have a good understanding of the job
they are about to undertake.
Use caution when removing filler caps, filters, drain plugs or hydraulic fittings, hold a rag over the
connection to prevent being sprayed or splashed with liquids.
Repairs, maintenance or adjustments to the machine must never be performed while it is running
especially the lubrication of bearings and moving parts etc.
Guards or access doors should be replaced or closed before leaving the machine unattended, even
for short periods of time. Onlookers or bystanders should be kept well away during maintenance.
When performing maintenance or repairs to areas of the machine where no walkways have been
provided, an approved lifting platform must be used. Never climb onto the machine to reach areas
not accessible from the ground or from the walkways. Never use unauthorised or unsafe platforms
to reach inaccessible areas of the machine. If working above heights of 2 metres, even when using
the walkways provided, an EN/ANSI Safety Harness must be worn.
Never work under unsupported equipment.
All damaged, missing or dirty safety signs that cannot be read should be cleaned or replaced.
Even though the machine has been designed to operate at various temperatures some parts may
reach high temperatures on warm days. Always wait until all the equipment has cooled before
working on the machine especially around the engine exhaust system.
Always observe the maintenance intervals set out in these operating instructions, except where a
warning light or indicator calls for immediate action or adverse conditions require more frequent
servicing.
Avoid smoking whilst around this machine especially when refuelling or in the refuelling area.
Dust found on the machine or produced during operation should be removed by extraction not
blowing.
During or after repair or maintenance, inspect all other parts of the machine for damage or wear.
When maintenance or repair has been completed ensure that all bolts, fittings and connections have
been replaced and tightened. Re-fit all parts, guards and covers before testing or operating the
machine.
Before testing the machine ensure that all tools, parts and components have been removed from
the plant and walkways. Ensure that no one is on or near the machine before testing.
Test the machine to ensure that it is functioning properly. If problems occur during testing shut
down the machine and carry out all the safety procedures listed above before trying to rectify the
problem.
After testing shut down the machine and check for loose or missing bolts, washers or nuts, etc.
After operating the machine for a few hours, shut down and check for any further problems.
Only use lifting equipment, including slings and chains that are in good working order, have been
adequately tested and have the required lifting capacity for the job at hand.

P28. 1012TS (C13) O & M 02-2016.

2.10.1 SAFETY WHEN WORKING WITH HYDRAULICS.

Work on the hydraulic system must only be carried out by personnel with special knowledge and
experience of hydraulic equipment.

Never, under any circumstances, disconnect any hydraulic line or component while the engine or
main hydraulic pumps are running.

Relieve all pressure in hydraulic systems before any lines, fittings or components are disconnected
or removed.

Hydraulic lines must be laid and fitted properly. Ensure that no connections are interchanged. The
fittings, lengths and quality of the hoses must comply with the technical requirements.

Always practice extreme cleanliness when servicing hydraulic components.

Where the hydraulic system is used to carry suspended loads, ensure that these loads are
mechanically supported prior to disconnecting or servicing any hydraulic component.

Hydraulic fluid under pressure is very dangerous, it can penetrate the skin causing serious injury.
Pinhole jets are most dangerous.

If fluid is injected under the skin seek medical attention immediately.

Always use a piece of cardboard or similar to check for leaks. Do not use your hands.

Do not work on oil flooded surfaces. Apply an oil dry material and clean up before starting work.

2.10.2 SAFETY WHEN WORKING WITH BATTERIES.

Disconnect the battery leads and tape the leads to prevent accidental start up when performing
maintenance or servicing.

Battery electrolyte contains acid and can cause serious injury. Avoid contact with skin and eyes.
Use gloves and protective glasses.

Batteries give off flammable fumes which can explode. Ensure that there is proper ventilation.
Avoid the formation of sparks and naked lights in the vicinity of the batteries. Do not smoke when
working in this area.

2.10.3 SAFE DISPOSAL OF WASTE PRODUCTS.

Improperly disposing of waste can threaten human health and the environment. Potentially harmful
waste created from TESAB machines include oil, fuel, coolant, filters and batteries. Always dispose
of waste in a safe and environmentally friendly manner. Seek advice from your local government
environmental department regarding the safe disposal of waste products.

Use leak proof containers when draining fluids. Do not use food or beverage containers that may
mislead someone into drinking from them.

Do not pour the fluids onto the ground, down a drain or into any water source.

Ensure that all consumables and replaced parts are disposed of correctly and with the minimum
environmental impact.

P29. 1012TS (C13) O & M 02-2016.

 SECTION 3.0

ENGINE START-UP
INSTRUCTIONS
Before attempting to start this machine you must

! WARNING read and understand all safety instructions listed

in Section 2.0

3.1 IMPORTANT CHECKS PRIOR TO STARTING THE ENGINE.

Only fully trained and authorised personnel should be given permission to start the engine on this machine.

Before starting the engine ensure that the following checks are carried out. Failure to do so may result in
substantial damage to the machine or injury to persons.

Before starting the engine ensure that all switches on the control panel are in the OFF or
NEUTRAL position.
Check that all hydraulic levers are in the neutral position.
Check that no emergency stops are pressed.
Check that there is sufficient diesel in the diesel tank to run the machine.
Check the hydraulic oil level and top up if necessary.
Check the engine oil level and top up if necessary.
Check the radiator coolant level and top up if necessary.
Check that the clutch lever (if manual clutch is fitted) is in the neutral position.
Check around the machine for oil or coolant leaks.
Check that the radiator and hydraulic oil coolers are clean and free from dirt.
Do a final check around the machine to ensure that no one is on or near the machine.
Consult the engine manufacturers operation & maintenance manual for further information on
running the engine.

P30. 1012TS (C13) O & M 02-2016.

3.2 ENGINE START UP PROCEDURES.
(A).
IMPORTANT: If starting the engine first thing in the morning or
where the machine has been inactive for a period of one day or
more, you MUST ALWAYS check the engine oil level and air filters
prior to starting the engine.

IMPORTANT: Before starting the engine, consult the engine

manufacturers operation & maintenance manual.

IMPORTANT: Prior to starting the engine the hydraulic diverter

valves, as shown at (A), must be set to the correct position.

To track the machine, set the valves to the Track position.

To carry out any other function, such as crushing or operating any

of the rams, set the valves to the Crush position. Both valves
MUST be in either the Track or the Crush position and they MUST
NOT be moved while the engine is running.

The engine starter panel, as shown at (B), is located at

the right hand side of the machine.

Check that all other levers, switches and buttons are in

the neutral position.
(B).
Ensure that no one is working on or near the machine
before you start the engine.

Turn the ignition key, located on the front of the starter

panel, to the "crank" position, as shown at (C).

At this point the safety siren will sound. Hold the

ignition key in this position for 10 seconds until the (C).
engine cranks and starts.

If the engine does not start, an emergency stop may be

pressed. If this happens, the green emergency stop
light on the control panel, as shown at (D), will not be
illuminated. Check all emergency stops including the
one on the doglead.

Once the engine has started immediately release the (D).

ignition key.

IMPORTANT: If you have trouble starting the engine

do not activate the starter for more than 20 seconds at
a time. You will protect the batteries if you wait at least
one minute between each starting attempt.

To switch the engine off, reduce the revs to idle speed

and turn the ignition key to the vertical 'OFF' position.

NOTE: If a constant speed engine has been fitted to

your machine then there will only be two engine speed
settings: Idle (1000rpm) and High (1800rpm). Push the
throttle switch up once to increase the engine speed to
High. Push the throttle switch down once to decrease
the engine speed to Idle. With this option, if the engine
speed is reduced the engine must be re-started before
the engine speed can be increased again.

P31. 1012TS (C13) O & M 02-2016.

 SECTION 4.0

TRACKING
INSTRUCTIONS
Before attempting to move this machine you

! WARNING must read and understand all safety instructions

listed in Section 2.0

4.1 TRACKING THE MACHINE.

Tracking of this machine can be carried out using either the doglead handset or a remote control (if it is fitted to
the machine). The following sections detail the procedures for using both types of handsets. Please ensure that
you follow these instructions carefully.

P32. 1012TS (C13) O & M 02-2016.

4.1.1 TRACKING THE MACHINE USING THE DOGLEAD.
(A).
IMPORTANT: You must make yourself completely familiar with the
(B).
operation of the doglead before attempting to manoeuvre this
machine see (A).

WARNING: Ensure that everyone is clear of the machine before

tracking. (1). (2).

Connect the doglead to the machine, as shown at (C). (3). (4).

Ensure that the controls on the doglead handset are

in the neutral position and that they are operating
freely.

IMPORTANT: Prior to starting the engine the

hydraulic diverter valves, as shown at (D), must be (1). Left Hand Side Track Forward.
set to the Track position. Ensure that BOTH valves
are in the Track position. They MUST NOT be (2). Right Hand Side Track Forward.
moved while the engine is running. (3). Left Hand Side Track Reverse.
(4). Right Hand Side Track Reverse.
Start the engine as per the engine start-up procedure
shown in section 3.0.
(C).
NOTE: The machine should only be tracked using low
engine speed, especially in confined spaces.

Insert the key into the Doglead/Remote switch,

located on the main control panel, and turn it to the
Doglead position, as shown at (E).

Turn the doglead handset On / Off switch to the ON (D).

position, as shown at (B). The lamp on the handset
switch should illuminate green.

At this point the tracks warning alarm should sound

and remain on while the machine is being tracked.

There is a 10 second safety delay before the machine

can be tracked. After the safety delay has elapsed,
the machine can be tracked using the controls on the
doglead handset.

WARNING: When moving the machine, ensure that

you use the entire length of the doglead. This will
allow you to stay as far from the machine as possible
and will improve your view around the entire machine. (E).
Constantly check all sides of the machine for
clearance. Also, ensure that you keep the lead clear
of the tracks to avoid it becoming entangled or
damaged by the tracks.

When you have finished tracking the machine; return

all the switches to the Off or Neutral position, switch
the engine off and remove the doglead from the
machine.

P33. 1012TS (C13) O & M 02-2016.

4.1.2 TRACKING THE MACHINE USING THE REMOTE CONTROL. (if fitted).
IMPORTANT: You must make yourself completely familiar with the (A).
operation of the remote control before attempting to manoeuvre
this machine see (A).
(1). (2).
WARNING: Ensure that everyone is clear of the machine before
tracking.

IMPORTANT: Prior to starting the engine the hydraulic diverter

valves, as shown at (B), must be set to the Track position. Ensure (3). (4).
that BOTH valves are in the Track position. They MUST NOT be
moved while the engine is running.
(5). (6).
Start the engine as per the engine start-up procedure
shown in section 3.0.

NOTE: The machine should only be tracked using low

engine speed, especially in confined spaces.

Insert the key into the Doglead/Remote switch,

located on the main control panel, and turn it to the
Remote position, as shown at (C). (1). Remote control ON/OFF switch.
(2). Engine Stop switch.
At this point the tracks warning alarm should sound
and remain on while the machine is being tracked. (3). Left Hand Side Track Forward.
(4). Right Hand Side Track Forward.
To switch on the remote control press the on/off
switch on the remote, as shown at (1). (5). Left Hand Side Track Reverse.
(6). Right Hand Side Track Reverse.
After a 10 second safety delay the machine can be
tracked using the controls on the remote control (B).
handset.

WARNING: When moving the machine, ensure that

you stay as far from the machine as possible in order
to improve your view around the entire machine.
Constantly check all sides of the machine for
clearance.

When you have finished tracking the machine; return

all the switches to the Off or Neutral position, switch
the engine and the remote control handset off.

(C).

P34. 1012TS (C13) O & M 02-2016.

 SECTION 5.0

INSTALLATION.
Before attempting to install this machine you

! WARNING must read and understand all safety instructions

listed in Section 2.0

5.1 INSTALLATION OVERVIEW.

This section will guide you through the installation procedures for this machine. Ensure that you
carry out all the listed procedures in order to prevent injury and/or damage to your machine.
IMPORTANT: Due to different transport and shipping regulations throughout the world this machine
may be delivered in different packaged arrangements. For the purposes of this manual it will be
considered that the machine is delivered in the most unassembled configuration. Therefore, some of
the installation sections given may not be applicable. If this is the case ignore that particular
instruction/section and proceed to the next section.
Before installing this machine ensure that you have read all sections of this manual in order to
completely familiarise yourself with the machine and its function, paying particular attention to the
safety section.
The installation of this machine MUST only be carried out by reliable, authorised and experienced
personnel. At least two people must be present during installation and statutory minimum age limits
must be observed.
TESAB ENGINEERING LTD. strongly recommends that the installation of this machine is carried
out by a recommended TESAB dealer and/or service agent.

5.2 INSTALLATION PROCEDURES.

The following procedures must be carried out in the sequence given in order to set up the machine correctly.
Details of each procedure are given on the following pages.
Step 1: Unload the machine from the transportation lorry.
Step 2: Position the machine in the desired location.
Step 3: Fit the feeder beacon.
Step 4: Fit the pre-cleaner.
Step 5: Set the machine to crushing mode.
Step 6: Fold up the cribs.
Step 7: Fit the chain box.
Step 8: Fold out the dirt conveyor.
Step 9: Fold out the discharge conveyor.
Step 10: Set the crushing size.
Step 11: Fit the working lights (if option is available).
Step 12: Connect the dust suppression.
Step 13: Adjust the discharge conveyor and dirt conveyor belts.

P35. 1012TS (C13) O & M 02-2016.

5.3 STEP 1: UNLOAD THE MACHINE.

Unloading of the machine from the transport trailer must be carried out by experienced personnel.
For tracking procedures refer to section 4.0 of this manual.

5.4 STEP 2: POSITION THE MACHINE INTO THE DESIRED LOCATION.

Before the machine is positioned ensure that the site surface is level and has spacious
surroundings. Ensure that the machine is not positioned under or near to overhead electric cables.
The ground must be solid and be capable of carrying the weight of the machine when fully loaded.
Manoeuvre the machine into the desired location.
The machine must be sitting level during operation and it must be stable. If not stable the machine
may rock or vibrate which could cause damage or injury. Therefore, ensure that the entire length
and width of the tracks are sitting firmly on the ground. Use a spirit level on the points shown at (A)
and (B), to ensure that the machine is level across its width and length.
Once in position switch the engine off, remove the doglead from the machine and insert the blanking
plug into the doglead socket.

(A).

(B).

5.5 STEP 3: FIT THE FEEDER BEACON.

(C).
The Feeder Beacon is used to indicate when the feeder
has stopped if the "Automatic Feeder Option" has been
selected. When the feeder beacon flashes this indicates
that the feeder has stopped.

The feeder beacon much be fitted, as shown at (C).

P36. 1012TS (C13) O & M 02-2016.

5.6 STEP 4: FIT THE PRE-CLEANER.

IMPORTANT: The pre cleaner must be fitted as soon as possible (A).

after the machine has arrived on site. Do not run the engine for a
long period while the pre cleaner has been removed.

WARNING: Ensure that the engine has been shut down before
fitting the pre cleaner.

Remove the transport cover from the air breather, as

shown at (A).

Fit the pre cleaner as shown at (B).

Ensure that the all the bolts and clamps are fastened (B).
securely.

5.7 STEP 5: SET THE MACHINE TO CRUSHING MODE.

The tracking and crushing functions on this machine have been
kept separate. Therefore, the machine cannot be tracked while it
(C).
is in the crushing mode, and the rams, conveyors or crushing
function will not operate while it is in the tracking mode.

In order to install the machine the crushing mode must be

selected. This will allow the rams to operate.
Prior to starting the engine rotate the two hydraulic
diverter valves to the CRUSH position, as shown at (C).

WARNING: Both valves MUST be set to the Crush

position and they MUST NEVER be moved while the
engine is running.

5.8 STEP 6: CHECK THE FEEDER ALIGNMENT.

Its important that the scalping feeder is aligned centrally

within the crusher opening, as shown at (D). Before
operating the machine check the alignment of the feeder
at the points shown at (D)

If the feeder is not aligned centrally then it must be

adjusted. For instructions on adjusting the alignment of
the scalping feeder, see the maintenance section of this (D).
manual.

After material has been fed through the machine for a

few hours, stop the machine, lock out and re-check the
alignment of the scalping feeder.

P37. 1012TS (C13) O & M 02-2016.

5.9 STEP 7: FOLD UP THE CRIBS.

IMPORTANT: The crib locking wedges, crib leg locking brackets (A).
and the crib cross beams must all be fitted correctly before loading
material onto the machine. Failure to have all these items fitted
correctly may allow severe damage to be caused to the machine!

IMPORTANT: If the machine has been fitted with crib extension

wings, as shown at (A), ensure that the transport brackets have
been removed and the extension wings have been bolted to the
main crib sides before raising the cribs.

Start the engine as per the engine start up procedure. (B).

With the engine at low revs gently operate the

hydraulic control levers labelled, LHS CRIBS, RHS
CRIBS and REAR CRIBS.

Raise up the cribs in a constant motion until they have

reached the working position.

NOTE: All three cribs must be raised together in

increments, so that the closing brackets join together
correctly, as shown at (B).
(C).
Insert the locking wedges into the closing brackets, as
shown at (C). Fit bolts through the holes in the
wedges to prevent them coming loose.

Fit the crib leg locking brackets, as shown at (D).

Using appropriate lifting gear and access platforms, fit

the two crib cross beams, as shown at (E).
(D).

(E).

P38. 1012TS (C13) O & M 02-2016.

5.10 STEP 8: FIT THE CHAIN BOX.

The chain box will normally come fitted onto the machine. However, (A).
in some situations it may have to be removed for transport. If this is
the case it must be fitted before the machine is operated.
(B).
WARNING: Lifting equipment and working platforms will be required
to fit the chain box.

Fit the feed in chain box, as shown at (A).

Ensure that the rubber skirt, as shown at (B), is also fitted

in place.

5.11 STEP 9: FOLD OUT THE DIRT CONVEYOR.

WARNING: Ensure that the transport brackets and ALL tie straps, as (C).
shown at (C), are removed from the dirt conveyor before attempting to
fold it out.

IMPORTANT: The cribs must be folded up into position and secured

before the dirt conveyor can be folded out.

Start the engine as per the engine start up procedure

given in section 3.0.

In order to fold the dirt conveyor down and extend it

outwards, the hydraulic control bank beside the dirt
conveyor must be activated. Push the control bank lever
labelled Activate Rams, as shown at (D), inwards. (D).

With the engine at low revs, gently operate the hydraulic

control lever labelled, DIRT CONVEYOR FOLDING.
This lever is located beside the conveyor.

Unfold the conveyor in a constant motion until it has (E).

reached its working position.
NOTE: Unfolding the conveyor too quickly or jerking it
suddenly, may result in damage to the machine

Pay particular attention to the conveyor belt and attached

hydraulic hoses while the conveyor is unfolding. Ensure (F).
that they do not catch or snag on any part of the
machine.

Bolt the two sections of the conveyor together. The

bolting points are located on the inside of the conveyor
frame at the pivot point, as shown at (E).
(G).
.
Extend the conveyor out fully by gently operating the
hydraulic control lever labelled, TELESCOPIC DIRT
CONVEYOR. This lever is located beside the conveyor.

Insert the locating pins into both sides of the conveyor,

as shown at (F).
(H).
Fit the wire rope supports, as shown at (G) and tension
appropriately.
Fit the belt scraper, as shown at (H).

P39. 1012TS (C13) O & M 02-2016.

5.12 STEP 10: FOLD OUT THE DISCHARGE CONVEYOR.

IMPORTANT: In order to ship the machine overseas, the folding (A).

rams on the discharge conveyor will have been disconnected and
the conveyor will be tied up into its highest transport position, as
shown at (A).

For shipping throughout the UK and Ireland, the conveyor will be

in the lower transport position and the rams will remain fitted.
(B).
Once the machine has reached its country of destination and has
been folded out for the first time, it will only ever need to be
folded back down into the lower transport position for further
shipping within that country.

WARNING: You will require lifting gear in order to fold out the
discharge conveyor for the first time. Lifting gear will not be
required for subsequent conveyor folding.

Using lifting gear, raise the top end of the conveyor

up slightly to take the weight off the transport (C).
brackets and tie straps, as shown at (B).

Remove the transport brackets and tie straps.

Lower the conveyor down until its hanging freely in

the vertical position.

Attach the folding mechanism to the conveyor, as

shown at (C).
(D).
Start the engine.

Using the hydraulic lever labelled Discharge

Conveyor Folding, slowly and gently fold the
conveyor out fully.

With the conveyor fully folded out, insert the top

mounting pin, as shown at (F).

Attach the wire ropes, as shown at (E). (E).

Fold up the transport brackets, as shown at (G).

Connect the grease pipes, as shown at (H). (F).

If folding out the machine for the first time, two (G).
returns rollers will need to be re-fitted, as shown at
(D). When folding the machine back into the lower
transport position it will not be necessary to remove
these return rollers again.

(H).

P40. 1012TS (C13) O & M 02-2016.

5.13 STEP 11: SET THE CRUSHING SIZE.
Before crushing material or after maintenance, the crusher unit will (A).
need to be set to achieve the required material crush size. .
NOTE: There are several variables that will determine the crush size of (B).
the material: .
1) The size and type of material being crushed. (C).
2) The size and type of material that is required. .
3) The desired quantities of each type of material produced.
Initially the crusher may need to be set several times in order to achieve
the desired material output. A study of the crushed material will
determine if any further adjustments are necessary.
Three adjustable aprons inside the crusher unit determines the output
size of the material being crushed. The aprons are as follows:
The Top Apron, as shown at (A). (D).
The Middle Apron, as shown at (B).
The Bar Carrier, as shown at (C).
When setting the crusher the bar carrier must be set first and then the
middle apron. The top apron is factory set and should not need to be
adjusted. If it does it should be adjusted last.
WARNING: The crusher must have come to a complete stop before
attempting to set any of the aprons in the crusher.
To activate the hydraulic control valve that operates the crusher
adjustment, the hydraulic control lever labelled ACTIVATE CRUSHER
ADJUSTMENT, as shown at (D), must be engaged. Outer Outside Inside Adjuster
Springs Shims. Yoke. Shims. Bar.
5.13.1 SETTING THE BAR CARRIER. .
(E).
The bar carrier is adjusted hydraulically and is set by moving shims, as
shown at (E), from one side of the yoke to the other.
Open the side doors of the crusher, as shown at (F), to
gain access to the bar carrier, hammers and blowbars.
Start the engine as per the engine start-up procedure
shown in section 3.0.
(F).
Using the hydraulic control lever labelled Bar Carrier
Adjustment, slowly and gently open the bar carrier just
enough so that the yoke moves out and compresses the
outer springs, as shown at (G). This will release the
pressure on the inside shims.
Remove all the inside shims from the Adjuster Bar.
Close the bar carrier inwards a small amount. This will (G).
release the pressure on the outside shims.
Remove all the outside shims from the adjuster bar.
The bar carrier spacing can now be set.
IMPORTANT: The bar carrier space must only be set
between the hammer and the bottom blowbar, as shown
at (H). Do NOT set this space using any of the other (H).
blowbars.
To set the bar carrier, measure between the bottom
blowbar and the hammer, as shown at (H). Move the bar
carrier in or out to leave the desired space between the
blowbar and the hammer.

Continued on the next page:

P41. 1012TS (C13) O & M 02-2016.

5.13.1 SETTING THE BAR CARRIER CONTINUED.

WARNING: Setting the crush gap too narrow will adversely affect (I).
the performance of the machine, and may cause excessive wear
and/or damage to the crusher unit.

When the desired bar carrier space has been

achieved, the shims on the adjuster bars must be
replaced. To do this measure the space between the
inner face plate and the inside of the yoke, as shown
at (I). This will determine how many inside shims
youll need.

Count out the correct number of shims to match the (J).

inside spacing, as shown at (J), but do not fit them
to the adjuster bar just yet.

First, take all the remaining shims and place them on

the outside of the yoke, as shown at (K). You may
need to adjust the yoke inwards slightly in order to
get all these shims on.

Slowly and gently open the bar carrier just enough (K).
so that the yoke moves out and compresses the
outer springs again.

Now the inside shims can be fitted, as shown at (L).

Ensure that the same number of shims are placed

on all three adjuster bars.

Slowly and gently close the bar carrier inwards. Do

(L).
this just enough to ensure that the yoke is clamped
against the inside shims and that the compression
springs are clamping the outside shims against the
yoke.

Both the inside and outside sets of shims must be

firmly clamped. Otherwise they may dislodge during
operation. There must also be a little space left
between the outside springs, as shown at (M), so
that the springs are not clamped flat. (M)
.
Re-check the measurement between the blowbars
and the hammers on both sides of the crusher to
ensure that the desired spacing has been achieved.

Once completed, manually rotate the rotor in the

crusher slowly to ensure that all the hammers are
able to clear the blowbars without contact.

Close all doors on the crusher unit securely before

operation.

P42. 1012TS (C13) O & M 02-2016.

5.13.2 SETTING THE MIDDLE APRON.
The middle apron is adjusted using the same type of hydraulic
(A).
adjustment system that the bar carrier is adjusted with. Refer to the
bar carrier adjustment section on the previous page, for details of
how to operate the hydraulic adjustment. 15mm
Min
The hydraulic lever for the middle apron adjustment is labelled
SECOND APRON ADJUSTMENT.
The bar carrier must always be set to the correct position before the
middle apron is adjusted.
As a rule of thumb the distance between the edge of the hammers
and lowest stroke plate on the middle apron should be double the
distance that the bar carrier was set. For example; if the bar carrier
spacing was set to 50mm then the distance from the lowest stroke
plate on the middle apron to the hammer should be at approximately
100mm.
However, there must always be a minimum of 15mm overlapping
from the lower stroke plate on the middle apron to the top stroke
plate on the bar carrier, as shown at (A).

5.13.3 SETTING THE TOP APRON.

IMPORTANT: The top apron is factory set and cannot be adjusted (B).
very far. Therefore, it should not need to be adjusted. However, if
for some reason the top apron needs adjusted slightly, you must
carry out the following instructions.

To adjust the top apron, rotate the hex nuts on the adjuster
bars, as shown at (B).

Rotate each nut a small amount alternating between the two

adjuster bars in order to prevent damage to the threaded
bars.

Never screw the nuts completely off the threaded bar as the
apron will swing down into the crusher. Leave at least 25mm
of threaded bar protruding above the nuts.

Do not adjust the apron up so high that the springs become

flat. Always leave a space between the springs.

Ensure that both nuts are fitted to the adjuster bars at all
times and always lock the two nuts together to ensure that
they do not come loose.

P43. 1012TS (C13) O & M 02-2016.

5.14 STEP 12: FIT THE WORKING LIGHTS (Optional Extra).

If working lights are an option on your machine (A).

they need to fitted, as shown at (A).

Connect the electrical wires together and test the

operation of the lights.

5.15 STEP 13: CONNECT THE DUST SUPPRESSION.

If a dust suppression system has been fitted to your machine it (B).

will have at least two dust suppression bars fitted. One will be
at the crusher feed in and one on the crusher feed out. Both
these are pre-fitted. A third spraybar located on the product
conveyor, as shown at (C), is an optional extra. This spraybar
will have been removed for transport and will need to be fitted.

Reducing dust created by the machine is essential therefore it

will be necessary to connect up an adequate clean water supply
to the dust suppression system.

Ensure that all the brown spray tips are securely

fastened to all the spray nozzles.

If a water pump has not already been fitted to the

system, connect an adequate water supply direct to (C).
the water manifold, as shown at (B).

Ensure that the water supply is clean in order to

prevent the spray nozzles from clogging. Where
possible use a water filter in the system.

If a water pump has already been fitted to the

system on the machine, ensure that the main water
supply is connected to the water filter. This filter
ensures that the water going to the pump is clean,
otherwise, contaminated water will cause damage
to the pump.

Once the main water supply is connected, test the

system and set the spray tips to create the most
efficient dust suppression. You may need to adjust
the spray tips after operation and/or depending on
the volume of dust being created.

P44. 1012TS (C13) O & M 02-2016.

5.16 STEP 14: ADJUST THE PRODUCT CONVEYOR AND DIRT CONVEYOR BELTS.
In order for the product and dirt conveyor belts to run efficiently, they must be tensioned and tracked correctly.
After loading material into the machine, and over time, the belts may require further tensioning or tracking.
However, prior to loading the machine for the first time, the belt tension and alignment should be checked during
the set-up process.

WARNING: In the interests of safety, belt tensioning or tracking must NOT be performed while the belts are
running.

5.16.1 BELT TENSIONING.

(A).
IMPORTANT: The belt must be sufficiently tight in order to
prevent slippage on the drive drum when the belt is loaded with
material. However, an over-tight belt will cause reduced life on
the drums, bearings and belts.
Belt tensioning is carried out at the drive drum on
each conveyor.
Adjuster bars are fitted to the product conveyor, as
shown at (A) and dirt conveyor, as shown at (B).
The belt can be tightened or loosened by rotating
the nuts on the adjuster bars. It may only require a (B).
small rotation of the adjuster nut to adequately
adjust the belt.
NOTE: A natural stretching of the belt will occur
over time. Therefore, belt tensioning may be
required regularly.

5.16.2 BELT TRACKING (ALIGNMENT).

With the belt running, visually check the alignment of

the belt on the idle and drive drums. Also check that
all skirting rubbers are located well inside the belt. Idle Drum Drive Drum

If the belt is running too far over the edge of any of

the drums, or if the belt has moved across at the
centre of the conveyor, then the alignment of the belt (C).
must be adjusted.
Direction of
Stop the belts and lock-out the machine before Travel
doing any adjustments.
If the miss-alignment is at the idle drum, adjust the
underside return roller that is closest to the idle
drum. Move one side of the return roller forward and
(D).
one side backwards. The direction of alignment will
depend on which side the belt is running off.
NOTE: It may only take a small adjustment of the
return roller in order to move the belt across
significantly on the drum.
If the misalignment is at the drive drum, slightly
adjust the carrying rollers that are located closest to
the drive drum, as shown at (C).
NOTE: It may only take a small adjustment of the
return roller in order to move the belt across
significantly on the drum.
If the misalignment is at the centre of the conveyor,
slightly adjust the carrying rollers along the centre of
the conveyor, as shown at (D).

P45. 1012TS (C13) O & M 02-2016.

 SECTION 6.0

OPERATION
Before attempting to operate this machine you

! WARNING must read and understand all safety instructions

listed in Section 2.0

6.1 OPERATION OVERVIEW.

All material processing applications differ due to material composition and customer requirements.
There are numerous adjustments that can be made in order to achieve the 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.

6.2 IMPORTANT CHECKS PRIOR TO OPERATING THIS MACHINE.

Only fully trained and authorised personnel should be given permission to operate this machine. Before starting
the engine ensure that the following checks are carried out. Failure to do so may result in substantial damage to
the machine or injury to persons.

Check that there are no people, objects or tools etc. on the machine, especially on the feed or
product conveyors.
Ensure that all guards and safety devices are fitted and are working correctly.
Ensure that all down-stream machines have been started and are running correctly.
Before starting the engine ensure that all switches on the control panel are in the OFF or
NEUTRAL position.
Check that all hydraulic levers are in the neutral position.
Check that no emergency stops are pressed.
Check that there is sufficient diesel in the diesel tank to run the machine for a sustained period.
Check the hydraulic oil level and top up if necessary.
Check the engine oil level and top up if necessary.
Check the radiator coolant level and top up if necessary.
Check that the clutch is in the neutral position.
Check around the machine for oil or coolant leaks.
Check that the radiator and hydraulic oil coolers are clean and free from dirt.
Do a final check around the machine to ensure that no one is on or near the machine.

P46. 1012TS (C13) O & M 02-2016.

6.3 MACHINE START-UP SEQUENCE.

WARNING: The machine must NOT be started if material has already been loaded into the crusher unit.
Where a blockage has occurred and/or the machine has been shut down in an emergency with material still in
the crusher, it must be cleared of all material before attempting to re-start the machine.

WARNING: It is imperative that NO metal components enter the crusher unit. If this happens severe damage
will be caused to the crusher.

START UP SEQUENCE:

In order to prevent damage to the machine a specific start-up sequence, given below, must be followed. Details
of each step in the sequence are given on the following pages.

STEP 1 Set the machine to CRUSH mode.

STEP 2 Select the trouser chute position.
STEP 3 Start the engine.
STEP 4 Start the product conveyor.
STEP 5 Start the magnet and dirt conveyor.
STEP 6 Start the crusher unit.
STEP 7 Increase the engine speed.
STEP 8 Start the feeders.

WARNING: Starting the feeders before starting either the crusher unit or the product conveyor, may cause the
machine to stall. This may also cause damage to the machine!

6.3.1 STEP 1: SET THE MACHINE TO CRUSH MODE.

The tracking and crushing functions on this machine have been kept
separate. Therefore, the crushing function will not operate while it is in the
tracking mode and the machine cannot be tracked while it is in the crushing
mode.

In order to operate the machine the crushing mode must be selected.

(A).
Prior to starting the engine, rotate the two hydraulic diverter valves,
as shown at (A), to the CRUSH position.

WARNING: Both valves MUST be set to the Crush position and

they MUST NEVER be moved while the engine is running.

P47. 1012TS (C13) O & M 02-2016.

6.3.2 STEP 2: SELECT THE TROUSER CHUTE POSITION.

The trouser chute underneath the scalping feeder, as shown at (A), directs (A).
the screened material from the scalping feeder onto either the discharge
conveyor belt or onto the side conveyor belt.
(B).
There are three options for setting the trouser chute which will divert
material from the scalping feeder in different directions. The options are as
follows:

1) All the material can be fed onto the side conveyor belt.
To set the trouser chute in this position rotate the trouser
chute handle, as shown at (B), fully to the left. This will
divert all the material onto the side conveyor belt. (C).

2) All the material can be fed onto the product conveyor.

To set the trouser chute in this position rotate the trouser
chute handle, as shown at (B), fully to the right. Ensure
that the handle is bolted in place. There is also a rubber
attached to the lower deck of the scalping feeder. This
rubber must be placed on top of the lower deck screen, as
shown at (C), in order to blank it off. This will divert all the
material onto the product conveyor.

3) The fines material can be fed onto the side conveyor belt while
at the same time the middle size material is fed onto the
product conveyor.
To set the trouser chute in this position rotate the trouser
chute handle, as shown at (B), fully to the right. Ensure
that the handle is bolted in place. There is also a rubber
attached to the lower deck of the scalping feeder. This
rubber must be removed from the lower deck screen in
order to allow the fines material to travel through the
screen and onto the side dirt conveyor.

6.3.3 STEP 3: START THE ENGINE.

Start the engine as the engine start-up procedure.

Increase the engine speed to 1000 RPM using the throttle

switch on the front of the control panel, as shown at (D). (D).

NOTE: If a constant speed engine has been fitted to your

machine then there will only be two engine speed
settings: Idle (1000rpm) and High (1800rpm). Push the
throttle switch up once to increase the engine speed to
High. Push the throttle switch down once to decrease
the engine speed to Idle. With this option, if the engine (E).
speed is reduced the engine must be re-started before
the engine speed can be increased again.

6.3.4 STEP 4: START THE PRODUCT CONVEYOR.

Start the product conveyor by engaging the hydraulic

control lever labelled Product Conveyor, as shown
at (E).
At this point the product conveyor will start to run.

P48. 1012TS (C13) O & M 02-2016.

6.3.5 STEP 5: START THE MAGNET AND DIRT CONVEYOR.

Start the magnet and dirt conveyor by engaging the

hydraulic control lever labelled Magnet/Dirt Conveyor, as
shown at (A).
At this point the magnet and dirt conveyor will start to
run.

NOTE: If there is no magnet fitted to the machine the dirt (A).

conveyor will run on its own.

6.3.6 STEP 6: START THE CRUSHER UNIT.

(B).
WARNING: Before starting the crusher unit the engine speed MUST be
running at 1100 RPM. If the speed is set lower than this the engine may
stall during start-up. If the speed is set higher than this, damage may be
caused to the clutch or drive belts during start-up.

NEVER attempt to engage the clutch if the crusher is full of material.

To start the crusher using the hydraulic clutch, press

the green clutch ON button, as shown at (B), and hold
for 2 seconds.
The clutch on lamp on the control panel will illuminate
green to indicate that the clutch is on.
It will take a few seconds for the clutch to engage.
Wait approximately 45 seconds for the crusher speed to
build up before proceeding.

Before proceeding check again that the green clutch

on lamp on the control panel is still illuminated. This
will indicate that the clutch is still on.

6.3.7 STEP 7: ADJUST THE ENGINE SPEED.

Before starting the feeders or feeding material into the

machine, the engine speed MUST be set to 1800
(C).
RPM. Failure to do so may result in the engine stalling
and/or damage to the machine.
Using the Throttle switch, as shown at (C), increase
the engine speed to 1800 RPM.

P49. 1012TS (C13) O & M 02-2016.

6.3.8 STEP 8: START THE FEEDERS.
The feeders on this machine can be operated either manually, or in automatic mode.
In the manual mode the feeders are operated using a hydraulic control lever.
In the automatic mode the feeders are operated through a remote control handset. When operating the feeders
in this mode the engine overload sensor and automatic feeder shut off system also operates. This system does
not function when operating the feeders in the manual mode.

OPERATING THE FEEDERS IN MANUAL MODE.

On the main control panel rotate the feeder switch, as shown at (A), to (A).
the MANUAL position.
On the side catwalk, engage the hydraulic control lever labelled
FEEDER, as shown at (B).
At this point the feeders should start to run.
IMPORTANT: When operating the feeders in manual mode there is
no protection for crusher or engine overload. In this case the speed at
which the crusher is fed with material must be constantly maintained
by the operator. Overfeeding the crusher with material can cause the
engine speed to drop significantly and may cause the engine to stall (B).
and/or the crusher to jam with material. Overfeeding will also reduce
the efficiency of the machine and increase fuel consumption.
Set the speed of the primary feeder see section 6.4.
NOTE: The feeders can be stopped by either disengaging the
hydraulic control lever, as shown at (B), or flipping the feeder switch,
as shown at (A), to the vertical neutral position.

OPERATING THE FEEDERS IN AUTOMATIC MODE. (C).

On the main control panel rotate the feeder switch, as shown at (C), to
the AUTO position.
On the top catwalk, engage the hydraulic control lever labelled
FEEDER, as shown at (B).
To operate the feeders press the START button on the remote
control handset, as shown at (D).
(D).
At this point the feeders should start to run.
Set the speed of the primary feeder see section 6.4.
NOTE: The feeders can also be started and stopped in this mode by
pressing the buttons on the side of the remote control receiver box, as
shown at (E).

IMPORTANT: When operating the feeders in automatic mode, the engine

overload sensor and automatic feeder shut off system is also operational.
This system detects if the crusher is overloaded and/or if the engine speed (E).
drops below a pre-set speed. It shuts off the feeders automatically to stop
material being fed to the crusher. When the load goes off the crusher and/or
the engine speed rises above another pre-set speed the feeders automatically
start up again.
This helps to prevent the crusher from overloading and stalling the engine or
prevents the crusher from jamming if the engine cuts out unexpectedly.
Before feeding material onto the machine carry out one final visual check to
ensure that everything is running correctly.
After material has been run on the belt for a few minutes visually check the
alignment of the product and dirt conveyor belts. If the belts require re-
alignment, stop the machine and re-align the belts.

P50. 1012TS (C13) O & M 02-2016.

6.4 CONTROLLING THE SPEED OF THE FEEDERS.
(A).
The rate at which material is fed into the crusher is determined by the
(B).
operating speed of the primary feeder. The primary feeder speed can be
adjusted by rotating the variable flow control dial, located on the side catwalk,
as shown at (A).
NOTE: Turning these dials clockwise will decrease the speed of the feeders.
Turning them anti-clockwise will increase the speed of the feeders.
The scalping feeder speed is pre-set during manufacture. In certain
applications it can also be varied. However, we strongly recommend that you
contact your dealer before attempting to alter the speed of the scalping feeder.

6.5 MACHINE SHUT-DOWN SEQUENCE.

(C).
This machine must be shut-down in the correct sequence. Stopping the
machine in any other sequence may cause damage to the machine!

STEP 1 Run all the material off the machine.

Stop feeding material into the hopper.
Wait for ALL the material to be run through the machine.
Only continue to shut-down when the product conveyor is
running clear.
STEP 2 Shut-down the feeders.
If operating the feeders in manual mode, stop the feeders
either by disengaging the feeder control bank lever, as
shown at (B), or flipping the feeder switch on the control
panel to the vertical neutral position.
If operating the feeders in automatic mode, stop the
feeders by pressing the STOP button on the remote
control handset, as shown at (C), or flipping the feeder (D).
switch on the control panel to the vertical neutral position.
STEP 3 Reduce the engine speed to 1000 RPM.
STEP 4 Shut-down the crusher unit.
Disengage the clutch by pressing the red CLUTCH OFF
button, as shown at (D).
The crusher will slowly come to a complete stop.
(E).
STEP 5 Shut-down the product conveyor.
Stop the product conveyor by disengaging the discharge
conveyor control bank lever, as shown at (E).
STEP 6 Shut-down the dirt conveyor and magnet.
Stop the dirt conveyor and magnet by disengaging the dirt (F).
conveyor and magnet control bank lever, as shown at (F).
STEP 7 Shut down the engine.
Wait until the crusher has come to a complete stop before
shutting down the engine.
Reduce the engine to idle speed.
Switch off the engine and return all levers and switches to
the off or neutral positions.

P51. 1012TS (C13) O & M 02-2016.

 SECTION 7.0

MAINTENANCE
Before attempting maintenance on this machine

! WARNING you must have read and understand all the safety
instructions listed in Section 2.0

7.1 GENERAL MAINTENANCE INFORMATION.

This section provides detailed maintenance instructions and guidelines. These guidelines are
based on the assumption that the machine will be operated under normal conditions and in a normal
material processing environment. If this machine is to be operated for long periods in extreme
conditions, either climatic (-15oC to 33oC) or extremely dusty, these maintenance guidelines must be
altered to suit. If this arises you must consult your local Tesab dealer or Tesab Engineering
technical/service department.

When performing maintenance on your machine you must adhere to the safety information listed in
the safety section.

It is important to note that high repair costs and lengthy downtime will occur if inadequate or
improper maintenance is performed on your machine. Regular maintenance is imperative.

The performance, reliability and throughput of this machine depends on regular and correct
maintenance.

Good housekeeping pays untold dividends with increased production and extended plant life!

IMPORTANT:

It is important to note that certain items on this machine are classed as Wear or Service Parts. These parts will
naturally deteriorate during the normal operation of the machine and will need replacing regularly.

The deterioration, failure or replacement of these items, are not covered under the terms of the warranty policy.
It is therefore imperative that these items are regularly checked and serviced to ensure that they remain within
acceptable working parameters. Failure to do so may result in significant damage to the machine as well as
expensive repair costs.

The items classed as Wear or Service Parts are, but are not limited to, the following:

Crusher, deadbox & hopper liner plates

Hammers, blow bars & impact plates
Skirting, scraper & protection rubbers
Conveyor belts
Coupling inserts
Oil & air filters
Oils & fluids
Track shoes and track drive components
Screen meshes & grid bars

P52. 1012TS (C13) O & M 02-2016.

7.2 DAILY MAINTENANCE.
The purpose of daily maintenance is to discover minor irregularities on your machine before they develop into
major problems.
Check the machine for loose parts and check that all nuts and bolts are secure.
Check all oil and coolant levels and top up if necessary, including the hydraulic clutch.
Ensure that all safety systems are intact and functioning i.e. all emergency stops and sensors etc.
Grease the crusher bearings as per the lubrication schedule using the correct lubricant.
Check the fuel level in the diesel tank.
Check all hydraulic motors, pumps, cylinders and hoses for oil leaks and tighten if necessary.
Ensure that the idle and return rollers on the conveyors are turning freely and are clear of
obstructions.
Check for material build-up, especially around the bottom end drums on the conveyors.
Check the conveyor belts for tension and alignment.
Inspect the conveyor belting for damage and wear.
Check the air filter for clogging and clean if necessary.
Drain any water from the fuel separator.
Inspect the engine cooling system hoses for cracks and loose clamps.
Check the oil cooler and engine radiator pack for clogging. These must be kept clean to prevent
over-heating.
Check all drive belts, including the crusher drive belts and fan drive belts, for correct tension wear,
cracks or other damage.
Check the wear parts in the crusher for wear. It is imperative that the wear parts are replaced
before they exceed their maximum wear limits.
Check the alignment of the scalping feeder. The feeder should be centrally located within the mouth
of the crusher with equal spacing from the crusher sides. Adjust the feeder if necessary.
Check the alignment of the scalping feeder. The feeder should be centrally located within the
crusher opening. Adjust the feeder alignment if necessary.

When all checks have been made, close and fasten all guards before operating the machine. At the end of each
working day carefully clear all excess material and debris build-up from the machine and the ground immediately
around the machine. Good housekeeping pays will give increased production and extended plant life.

7.3 VISUAL CHECKS DURING OPERATION.

WARNING: These are visual checks only. Never try to adjust any setting while the machine is running and
never put yourself in any form of danger while carrying out the checks.
Check that the machine is sitting level and is stable during operation.
Check for oil and water leaks.
Check for excessive spillage or build-up of material around the machine.
Check the alignment of the conveyor belts.
Check for the required quality and throughput of material.

7.4 WEEKLY MAINTENANCE.

In addition to the daily maintenance the following weekly maintenance should be carried out once a week:
Grease all bearings as per the lubrication schedule using the correct lubricant.
Check all skirting rubbers i.e. check that they bear down lightly onto the conveyor belt.
Check the acid level in the batteries.
Check the gauges on the hydraulic oil filters.
Inspect all belt scrapers on the conveyors. Adjust or renew if necessary.
Check the oil level in the product conveyor reduction gear unit and primary feeder oil bath.
Check the clutch adjustment (if manual clutch is fitted).
Check the quality and tension of the Crusher V belts.
Check all springs on the machine especially on the primary and scalping feeders.
Check and tighten all wear plate bolts on the crusher.

P53. 1012TS (C13) O & M 02-2016.

7.5 LUBRICATION POINTS. Note: These points will not exist if an automatic greasing system is fitted.

B
A
B

D
E
F

G
G

D
C
E
F

7.6 LUBRICATION SCHEDULE.

On this machine there is an option to have an automatic greasing system fitted. If this option
has not been fitted then the following manual lubrication schedule must be followed. Grease
points on the machine have been fitted at easily accessible locations, as shown above. Each
grease point will be highlighted on the machine with a blue grease point sticker, as shown here.
NOTE: 4g (grams) of grease is the equivalent of three shots (pumps) from a standard grease
gun.

Grease Description No. of Grease Frequency Qty.

Point Points
(A) Product Conveyor Drive Drum Bearings. 2 50 Hours 8g
(B) Crusher Bearing Left Hand Side. 1 50 Hours 16g
(C) Dirt Conveyor Drive & Idle Drum Bearings. 4 50 Hours 4g
(D) Primary Feeder Bearings. 4 50 Hours 4g
(E) Scalping Feeder Bearings. 2 50 Hours 4g
(F) Product Conveyor Idle Drum Bearings. 2 50 Hours 8g
(G) Crusher Bearing Right Hand Side. 1 50 Hours 16g
* For manual clutch lubrication info, refer to the manual clutch maintenance section

P54. 1012TS (C13) O & M 02-2016.

7.7 AUTOMATIC LUBRICATION. (If fitted)

An option exists for this machine to be fitted with an Automatic

Lubrication System (Autolube). If this option has been chosen it will
ensure that all the necessary bearings etc. are lubricated at regular
intervals.
The Autolube system will automatically pump grease to all the
points on the machine. The system operates according to cycles of
"pause" and "operating" sequences. During the operating times the
(D).
pump dispenses lubricant to the points for a period of time.

7.7.1 AUTOLUBE OVERVIEW.

(A).
(E).
Access point to fill the Reservoir using a special grease
(B).
gun fitting.
Access to the P.C.B board and Rotary time switches. (C). (F).
Connection Plug 1A1 (Power Supply to Pump).
Grease Reservoir.
Pressure Relief Valve.
Connection Plug 2A1 (To Push Button).
(G).
The Quicklube system is designed for the delivery of greases
up to NLGI grade 2 at temperatures from -25C to 70C.
It can be used at low temperatures down to -40C (lubricants
must still be pumpable at these temperatures).

7.7.2 AUTOLUBE MAINTENANCE.

The Autolube system is generally maintenance free other than to refill the lubricant reservoir in good
time with clean lubricant.
Regularly check that lubricant is reaching all the lubrication points.
Check that the high-pressure grease hoses have not been damaged or frayed. If necessary replace
them.
If the AUTOLUBE system is not functioning properly then the following will occur:
During the Pump operation the Indicator Pin, as shown at (G), in the control valve mounted close to
the Autolube Pump will move in and out approximately every 40 seconds. If this is not happening
then one of the following may have occurred.
1. The Pump is out of grease
2. Pump Operating failure.
3. The Pump element needs to be replaced.
4. There is a blockage in the system or bearing.
If lubricant is emerging from the pressure relief valve, as shown at (E), this indicates a blockage in
the system and the fault should be immediately rectified.

P55. 1012TS (C13) O & M 02-2016.

7.7.3 CLEANING THE AUTOLUBE SYSTEM.

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", "Per" or similar solvents must NOT be
used. Do not use polar organic solvents such as alcohol,
methyl alcohol, acetone or similar

7.7.4 FILLING THE GREASE RESERVOIR.

Fill the reservoir via the grease nipple fitting, as

shown at (A), using a conventional Grease Gun
fitting. For fast filling of the reservoir use the
special cartridge filler gun supplied by attaching it (A).
directly to the fitting, as shown at (B).
(B).
Do not fill past the max mark on the reservoir.

The grease used 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 manual operation
before it will operate to full capacity.

7.7.5 TEST RUN / MANUAL LUBRICATION. (C).

There is a facility on the Autolube system that will

allow you to manually operate a greasing cycle.
This will allow you to test the system to ensure that
all points are getting grease or to add additional
grease to the points if required.

To carry out a lubrication cycle press the Autolube

button on the main control panel. Hold the button in
for a minimum of 5 seconds until the green lamp on
the button lights.

Then check that the indicator pin on the main

control valve as shown at (C), is moving in and out.

You can run the lubrication cycle as much as you

want, however, it is important to note that over
greasing of some bearings is equally as bad as
under greasing them.

P56. 1012TS (C13) O & M 02-2016.

7.7.6 AUTOLUBE FAULT FINDING.

1. Motor does run:

Voltage supply interrupted: - Check voltage supply and fuses.

- Check the line leading from the fuses to the pump plug.

Electric motor defective: - Check voltage supply to the motor. Replace motor if faulty.

2. The pump is not supplying lubricant to any of the points:

Reservoir empty: - Refill reservoir with clean grease. Manually run the pump until
lubricant reaches all points. NOTE: Depending on the ambient
temperature and or type of lubricant it may take 10 minutes of
operation until the pump elements will reach their full lubricant
output.

Air Pockets in Lubricant: - Operate a manual lubrication sequence, see previous page.
Loosen the outlet fitting or main line on the safety valve.
Lubricant must be pumped without air bubbles.

Unsuitable lubricant has been used - Renew the lubricant. See lubricant list.

Suction hole of pump element clogged: - Remove pump element. Check suction hole for foreign
particles. If found remove.

Pump piston worn: - Replace pump element.

Check-valve in pump element defective. - Replace pump element.

3. Lubricant is not being supplied to one lubrication point:

Burst hose leading to that point. - Find burst and repair.

4. Lubricant is escaping from Pressure Relief Valve:

Blockage in one or more hose lines. - Find blockage and clear.

P57. 1012TS (C13) O & M 02-2016.

7.8 MACHINE SERVICE SCHEDULE:

The following schedule is only a basic guide to the servicing requirements of the machine. Please refer to the
individual component maintenance information contained in the rest of this section. Also, where applicable refer
to the manufacturers operation and maintenance manuals for individual components on the machine.

These service details are over and above the daily and weekly maintenance tasks that must be carried out on
the machine.

Description Initial Service Requirements Ongoing Service Requirements

Engine service:
Manual clutch adjustment (if fitted):
Hydraulic clutch service (if fitted):
Tracks gearbox service:
Hydraulic oil service:
Product conveyor gearbox service:
Primary feeder oil bath service:
After first 250 hours of operation. After every 250 hours of operation.
After first 10 hours of operation. Check and adjust only if necessary.
After first 100 hours of operation. After every 4000 hours of operation.
After first 200 hours of operation. After every 2000 hours of operation.
After first 1500 hours of operation. After every 1500 hours of operation.
After first 100 hours of operation. After every 2500 hours of operation.
After first 1500 hours of operation. After every 1500 hours of operation.
* In all cases above, regardless of hours of
operation, servicing must be carried out at
least once every 12 months.

7.8.1 OIL & FLUID REPLACEMENT QUANTITIES:

The following values are the approximate volumes of fluids needed for servicing. Figures are given in litres.

IMPORTANT: These are only approximate values. When replacing oils & fluids you must follow the instructions
given in the maintenance section and observe the maximum fill levels when replacing oils and fluids.

Engine Oil Coolant Hydraulic Hydraulic Reduction Tracks Diesel Tank Primary
Oil Clutch Oil Gear Oil Gearbox Oil Capacity Feeder Oil
32 40 850 60 2.5 3.5 800 4

P58. 1012TS (C13) O & M 02-2016.

7.8.2 RECOMMENDED LUBRICANTS

ENGINE OIL: CATERPILLAR DEO 3E - 9840 SAE 15W - 40

RADIATOR COOLANT: CATERPILLAR EXTENDED LIFE COOLANT 205 - 6613V

HYDRAULIC OIL:

(in climates up to 30oc) FUCHS RENOLIN B15 VG46

ESSO NUTO H 46

(in climates above 30oc) FUCHS RENOLIN B20 VG68

ESSO NUTO H 68

STANDARD BEARING GREASE: FUCHS RENOLIT EP2

These are class 2 lithium based ESSO BECON EP2
grease with extreme pressure additives. SHELL ALVANIA EP2
They work within special conditions up
to 120oC

PRODUCT CONVEYOR GEAR OIL: MOBIL SHC 220 GEAR OIL (Note: This is a synthetic oil)

HYDRAULIC CLUTCH OIL: FUCHS RENOLIN B10 VG32

ESSO NUTO H 32

TRACKS TENSIONING GREASE: FUCHS RENOLIT EP2

ESSO BECON EP2
SHELL ALVANIA EP2

TRACKS GEARBOX OIL: FUCHS TITAN GEAR HYP SAE 80W/90

FEEDER OIL BATH LUBRICANT: SLS CHASSIS GREASE (NLGI000)

P59. 1012TS (C13) O & M 02-2016.

7.9 ENGINE MAINTENANCE.

The diesel engine is the heart of this machine. All engines are put through (A).
rigorous test programmes by the manufacturers before being assembled
into the crushers. On completion these machines are again run and tested
for several hours before dispatch.
(B).
In the interest of continued peak performance from this machine the engine
must be maintained and cared for with meticulous attention.

The engine MUST be serviced every 250 hours of operation. When the
engine is due to be serviced, the maintenance lamp on the main control
panel, as shown at (A), will remain illuminated.

After the engine has been serviced you will need to re-set the maintenance
lamp. To do this, open the main control panel door. On the inside of the
panel there is an engine service re-set switch, as shown at (B). Press and
hold this switch until the maintenance due lamp goes off.

IMPORTANT: For more information on the service and maintenance of this (C).
engine consult the engine manufacturers operation & maintenance manual
supplied with this machine.

7.9.1 ROUTINE DAILY ENGINE MAINTENANCE.

The engine water separator, as shown at (C), must be drained (D).

every day and the filter must be changed at every engine
service.
Check the level of coolant in the radiator.
Check all the fan drive belts etc. for cracks and wear.
Check the air filter service indicator, as shown at (D).
If the air filters require cleaning, access to the filters can be
gained by removing the housing cover, as shown at (E). (E).
Check the engine oil level.

For more information on the service and maintenance of this engine consult
the engine manufacturers operation & maintenance manual for further
details.

P60. 1012TS (C13) O & M 02-2016.

7.10 MANUAL CLUTCH MAINTENANCE. (If fitted)
The correct maintenance of your clutch will increase its effectiveness and prolong its life-span.

The following is a short outline of the duties that the owner and operator must perform for satisfactory service of
the clutch. For more detailed information on the service and maintenance of the clutch, please consult the clutch
manufacturers operation & maintenance manual supplied along with this machine.

IMPORTANT: The majority of clutch failures are caused as the result of the clutch not being properly adjusted.
Check and adjust the clutch to the correct engaging effort on a regular basis, as specified on the instruction
cover plate, as shown at (A).

The Clutch adjustment must be checked before running the machine for the first time. It should again be checked
after the first 10 hours of operation. New clutch plates have a wear-in period and the clutch may require
several adjustments until the new plates are worn-in. After wear in, the clutch 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 re-adjustment.

The clutch requires adjustment when:

- The clutch is easy to engage to its fully over-centre position

- The lever jumps out during operation

- The clutch heats up excessively

To adjust the clutch, please refer to the clutch manufacturers operation & maintenance manual.

7.10.1 MANUAL CLUTCH LUBRICATION.

If the machine is fitted with a manual clutch the following
lubrication schedule must be observed:
(A).
Main Bearings, as shown at (B). 4g every 50 hours or (B).
weekly.
(C).
Throw out Collar, as shown at (C). 4g every 10 hours or
Daily.

Lever Shaft, as shown at (D). 4g every 50 hours or weekly. (D).

NOTE: There are grease nipples on both sides of the lever shaft.

P61. 1012TS (C13) O & M 02-2016.

7.11 HYDRAULIC CLUTCH MAINTENANCE. (If fitted)

The oil level in the clutch should be checked on a daily basis. (A).
Only check the oil when it is cold.
(B).
To check the level start the engine and run it at idle speed.
Do NOT engage the clutch. After 30 seconds check the oil (C).
level on the gauge at the side of the clutch, as shown at (H).
The oil level should be at the blue line on the gauge.

If the oil needs topped up, stop the engine, add oil and carry
out the above procedure again.

The oil in the clutch must be changed after the first 100 hours
of operation and then after every 4000 hours.

If at any point the oil in the clutch becomes over heated or

discolours, it must be changed immediately regardless if a
regular service is due or not.
(D).
During an oil change the oil filter cartridge, as shown at (G),
must also be changed.
(E).
Drain the oil from the clutch through the lower drain hole and (F).
re-fill with approximately 48 litres of oil if 19KPTO and 58
litres if 21 KPTO. (G).

Check the oil level as per the above procedure and top-up if
necessary. Do not overfill the oil.
(H).
A pressure gauge, as shown at (D), is fitted to the clutch.
The clutch will stop if the oil pressure reaches a pre-set limit.
If the stops on a regular basis then it may be possible that the
oil filter has become clogged and needs to be replaced.

In cases where there is considerable oil leakage from the

rotating seals, they should be replaced.
(A). Hydraulic Oil Filler Cap
Approximately every 1000 hours check that the pump drive (B). Hydraulic Pump
chain has not stretched beyond the correct length. For a 19 (C). Rotating Seal
KPTO the max length should be 1362mm. For a 21 KPTO
the max length should be 1556mm. (D). Temperature and
Pressure Gauges
Periodically check the condition of the elastic coupling. (E) Solenoid Valve
(F). Elastic Coupling
In order to keep the hydraulic oil in the clutch at an effective (G). Oil Filter
operating temperature, an integrated oil cooler has been fitted
to the machine. On some machines an external oil cooler will (H). Oil Level Indicator
be fitted, as shown at (I). The radiator pack on this oil cooler
must be kept clean. It can be cleaned by either washing it
carefully by hand or by using air pressure. Never use water
pressure as this can damage the aluminium pack. (I).
For more information on the maintenance of the clutch, consult the
clutch manufacturers manual supplied along with this machine.

P62. 1012TS (C13) O & M 02-2016.

7.12 TRACKS MAINTENANCE:
In order to maintain the reliability of the track systems, MAINTENANCE CHECKS:
regular maintenance is essential. It is imperative that the Please note the maintenance intervals specified below
are for track systems working under normal conditions. If
tracks are maintained as outlined within this maintenance the track system is used in severe working conditions, the
section. maintenance and safety checks must be performed more
frequently.
Perform maintenance on a level and solid surface.
Ensure the track system is solidly supported if work
is necessary under the track systems.
Remove any build-up of grease, oil or debris.
Repair all damage and replace worn or broken parts
immediately. Check for oil leaks and damaged
hydraulic hoses.
Use only specified lubricants. Do not mix different
brands or types.
Use great care when maintaining the hydraulic
system since oil may be very hot when the machine
has just been working.
Use only approved replacement parts. Use of
unapproved parts will invalidate the warranty.
Dispose of lubricants in the proper manner.
WARNING: Do NOT operate the tracks with damaged or
defective parts.
(Carrier roller or
7.12.1 CHECKING THE TRACK TENSION: skid plate
whichever is fitted) Sag of Track

Stop the machine on solid and level ground and drive 2

metres (minimum) in a forward direction. Measure the sag
on the top part of the track on the longest section of
unsupported track as shown opposite.
The sag of the track must be between 5mm and 15mm. The
above conditions must be fulfilled on a new track system.
This must also be regularly checked and corrected if
necessary, by adding grease to the grease tensioner, as
described later in this section.
Track systems use a grease cylinder to keep each track
Tensioner Seals
chain in tension. Screwed into the end of the grease cylinder Straight Edge
is a grease fitting, enabling grease to be pumped into, and Grease Fitting
released from, the grease chamber. This in turn tightens
and slackens the track.
The grease inside the track tensioner (Lithium EP2) is
pressurised so care must be taken when loosening the
grease fitting. If the tracks repeatedly become slack, carry
out the below mentioned checks:
Check for any leakage on the outer face of grease fitting, if so replace grease fitting.
Check if there is any grease leakage at contact surface between the grease tensioner and
grease fitting, if so replace bonded seal.
Make sure the tensioner seals are not damaged. To replace tensioner seals, simply unscrew grease
fitting, push or pull out inner cylinder to expose lip seal and inner seal.
Replacement seals should be ordered from Tesab, if required. Prior to replacing tensioner seals, place a
straight edge along the cylinder barrel as shown above to ensure the outer sleeve has not swollen due to
overloading. If the tensioner is damaged, the complete tensioner unit need to be replaced.

P63. 1012TS (C13) O & M 02-2016.

7.12.2 INCREASING THE TRACK TENSION.
(A).
Remove the inspection cover on the side of the track
frame, as shown at (A).
Ensure that the track adjuster valve, as shown at (C), (B).
is tight.
Connect a grease gun to the grease fitting, as shown
at (B). Ensure the grease fitting and grease gun
adaptor are clean; ingress of dirt into the grease
fitting can result in failure.
Ensure that a good quality EP2 All Purpose grease is
used. Add grease into the valve until the sag of the
track is correct.
Move the machine 50 metres backwards and then 50 (C).
metres forwards and then re-check the sag. Repeat
the above procedure if the track has slackened.
Check for any escaping grease around the tensioning
unit and finally close the inspection cover when
finished.

7.12.3 RELEASING THE TRACK TENSION.

Remove the inspection cover on the side of the track

frame.
Loosen the track adjuster valve, as shown at (C), by
turning it in an anticlockwise direction in small
increments until grease begins to be expelled.
WARNING: Do not allow the grease to escape too
quickly.
If the track fails to slacken after grease fitting has
been loosened; DO NOT attempt to remove the
tracks or disassemble the track tensioner, and
DO NOT remove the grease fitting from the
tensioner. It is possible that running the tracks a
short distance in both directions with the grease
fitting loosened may help to expel the grease.
WARNING: The above procedure involves working
with grease contained at high pressure and must only
be carried out by qualified fitters.

P64. 1012TS (C13) O & M 02-2016.

7.12.4 TRACKS GEARBOX MAINTENANCE.

IMPORTANT: Cleanliness is essential when checking, filling or replacing oil in the gearbox. Gearbox operating
life will be dramatically shortened if the oil becomes contaminated. Only use new clean oil in clean containers
and fillers.

The oil should be drained from the gearboxes after the first 200 hours of operation, and re-filled with the correct
lubricant.

Following this initial oil change the oil should then be replaced after 2000 hours of use or at least once per year.

7.12.5 CHECKING AND FILLING THE GEARBOX OIL.

Move the machine to a level surface and bring the oil fill (A).
and drain holes to the position shown at (A).

Thoroughly clean around both plugs removing all potential Oil Fill
contaminants. Port

Remove both plugs.

Oil Drain
Fill the oil through the upper oil drain hole until it runs out Port
of the lower oil drain hole.

Wait a few moments until any trapped air has escaped and
then re-check the level. Add more oil if necessary.

7.12.6 DRAINING THE GEARBOX OIL.

Move the machine to a level surface and bring the fill

and drain holes to the position shown at (B). (B).

Thoroughly clean around both plugs removing all

potential contaminants. Venting

Remove both plugs and allow the oil to drain. The

oil will drain quickly if it is hot, however, care should
be taken to avoid burns to the operator. Oil Drain
Port
NOTE: Dispose of used oil safely and in a
environmentally friendly manner.

Move the machine to bring the plugs to the fill

position, as shown at (A).

IMPORTANT: Do not move the machine any further

until the oil has been replaced into the gearbox.

Re-fill the oil as per the oil fill procedure above.

P65. 1012TS (C13) O & M 02-2016.

7.13 HYDRAULIC OIL SYSTEM MAINTENANCE.
The hydraulic system in this machine has been designed to be
effective and resistant to extreme climatic and operating conditions.
All components are sized and matched to work together to make up an
efficient and effective hydraulic system. If replacement of any (A).
component in this the system is necessary, it must be replaced with a
genuine Tesab component. Fitting any unauthorised component may
result in damage to the machine or injury to personnel and will void all
warranties.
To ensure that the system remains effective it must be properly
maintained.
Regularly check the hydraulic oil level in the tank. This
should be checked when the oil is cold.
The oil should be at the level on the gauge, as shown at (B).
(A). Do NOT fill the oil higher than this point because the
volume of oil will expand when it heats up.
When topping up the oil ensure that the correct oil type is
used. Never mix different types of oil.
In order to maintain the hydraulic oil at its peak
performance two high pressure filters are used in the
system, as shown at (B).
The gauges, located on the top of the filter housings
should be checked regularly. If the indicator is showing
red when the oil is at operating temperature, then the
filters must be changed.
To change the filter elements unscrew the lower housing, (C).
as shown at (C).
The machine MUST never be operated without the
correct hydraulic filter elements.

The hydraulic oil should be changed every 1500 hours of

operation. At this point the two high pressure filter
elements and the air breather, as shown at (E), should
also be changed. (D).

Two suction strainers are also fitted to the inside on the (E).
hydraulic tank. These strainers should be replaced at
every service interval as well.
The entire hydraulic system should be regularly checked
for leaks and loose fittings. Damaged or worn hoses
should be repaired immediately.
At all times ensure that the hydraulic oil filler cap, as
shown at (D), is kept clean, especially when topping-up or
replacing the hydraulic oil. The filler cap must be in place
at all times.
(F).
In order to keep the hydraulic oil at an effective operating
temperature, the system has been fitted with an oil cooler,
as shown at (F). The radiator pack on the oil cooler must
be kept clean. It can be cleaned by either washing it
carefully by hand or by using air pressure. Never use
water pressure as this can damage the aluminium pack.

P66. 1012TS (C13) O & M 02-2016.

7.14 PRODUCT CONVEYOR GEARBOX MAINTENANCE.
After the initial operating period of approximately 100 hours, the oil (A).
in the product conveyor reduction gear unit, as shown at (A), must
be changed.
Subsequent oil changes should be made every 2500 hours of
operation or, in any case, once per year.
Regularly check the oil level and top up if necessary. If more than
10% of the total volume of oil has to be added to top up the
gearbox, carefully check the gearbox for leaks.
To check the oil level, unscrew the oil level plug as shown at (C).
If the oil level is not at this height then it needs to be topped up.
WARNING: If the oil level in the gearbox has risen this means that
oil is penetrating from the rotary seal. Contact your local service
dealer for further details.
It is advisable to keep a record of the maintenance, including oil
top-ups, performed on the gearbox.

7.14.1 CHANGING THE OIL IN THE GEARBOX.

Change the oil in the reduction gear while it is warm (B).
so that it is easier to drain.
WARNING: Take extra precautions with hot liquids.
(C).
Unscrew the drain plug, as shown at (D). Also
unscrew the oil level plug, as shown at (C), as this will
help allow the oil to drain from the gearbox. (D).
Check that there are no unusual metallic parts on the
magnetic plugs.
Once the oil has completely drained from the
gearbox, replace the drain plug.
Wash the interior of the gearbox with a suitable
cleaning liquid that is recommended by the lubricant
manufacturer. Drain the cleaning liquid.
Re-fill the gearbox through the oil level port, as shown
at (C), with the appropriate gear oil.
The gearbox will be filled with the correct amount of
oil when the oil level has reached the level of the oil
level port.
Replace all bungs.

IMPORTANT: Do not mix different types of oil even if it from the

same manufacturer. It is especially important to avoid mixing
mineral oil with synthetic oil.
WARNING: The reduction gearbox manufacturer prohibits the unit
to be opened to carry out any operation that is not included in their
specified routine maintenance procedures. The manufacturers do
not undertake any liability for any out of routine maintenance
which may have caused damage to people or parts.
For more information on the service and maintenance of the
reduction gearbox, consult the gearbox manufacturers operation
and maintenance manual, supplied along with this machine.

P67. 1012TS (C13) O & M 02-2016.

7.15 CRUSHER DRIVE BELT MAINTENANCE.
The crusher drive belts are tensioned using the adjuster bars, as
shown at (A). When adjusting the belts the complete engine (A).
assembly moves along the top of the chassis.

Before adjusting the belts ensure that the four engine mounting
bolts, as shown at (B), have been loosened.

NOTE: Two of the engine mounting bolts are not shown on the
photograph. They are located on the opposite side of the engine.

Adjust the tension on the drive belts by rotating the nuts on the
adjuster bars.

Ensure that both adjuster bars have been adjusted exactly the
same amount in order to keep the pulleys parallel.

IMPORTANT. Do not over tighten the drive belts as this will cause
excessive pressure on the clutch bearings which may lead to
premature failure.

After the belts have been adjusted ensure that the engine (C).
mounting bolts are adequately tightened before the machine is
started.

7.15.1 DRIVE BELT TENSIONING.

Proper tensioning of the drive belts ensures a longer life for both
(D). (c)
the belts and the clutch bearings. To check the belt tension use a
belt tension indicator and follow the procedure below.
(d)
Refer to the illustration shown at (D).

(c) = the centre distance of the pulleys. (f)

(d) = the deflection of one belt.
Deflection (d) = centre distance (c) x 16
(f) = the force, applied at right angles to the mid-point of (E). Belt Force req. to deflect belt
the belt, required to achieve the correct deflection. Section 16mm per one metre
span.
Small Newton Force
Compare the force required with the value stated in the Pulley (N) (kgf)
table, as shown at (E).
Dia
SPB 80-132 25 - 35 2.5 3.6
If the measured force is within the values stated in the SPB 140-200 35 - 45 3.6 4.6
table then the belt tensioning should be satisfactory. If the
force measured is below or above the stated values then SPC 112-224 45 - 65 4.6 6.6
the belt should be tightened or loosened respectively. SPC 236-315 65 - 85 6.6 8.7

New belts should be tensioned to the higher value stated

as this will allow for normal drop in tension during running
in period.

When fitting a new set of drive belts a measured set of

belts must be used. This will ensure that all the belts in
the set are exactly the same length which will give the
most efficient drive on the crusher.

After running the machine for 30 minutes shut down the

engine and lock-out. Re-check the tension of the belts
and adjust if necessary.

P68. 1012TS (C13) O & M 02-2016.

7.16 CONVEYORS MAINTENANCE.

The product and dirt conveyors on this machine are critical components and should be correctly maintained. The
throughput and efficiency of the entire machine is dependent on the smooth operation of the conveyors.

Regularly check the drums and rollers on the machine for any build-up of material around them.

Ensure that all drums and rollers are running freely and operating as they should.

Check the belts for wear and damage. Repair or replace damaged or worn belts immediately.

Check that all skirting rubbers are pressing lightly onto the belts. Large gaps between the skirting
rubbers and the belts will allow excessive spillage. Spillage may cause severe problems with other
components on the machine.

Check that all the scraper rubbers on both conveyors are adequately scrapping dirt from the belts.

Check the tension and alignment of the belts.

Ensure that all bearing lubrication is carried out as per the lubrication schedule.

Ensure that all guards are in place at all times.

P69. 1012TS (C13) O & M 02-2016.

7.17 PRIMARY FEEDER MAINTENANCE.

The bearings on the feeder must be greased every week as per the lubrication schedule.

On the non-drive side of the vibrating mechanism there are gear wheels on the shafts to transfer the drive from
one shaft to the other. These gear wheels are lubricated using an oil bath design, as shown at (A). The
lubricant in the oil bath should be changed after every 1500 hours of operation.

In order to let air flow in the oil bath and air breather has been fitted to the top of the bath, as shown at (E). This
breather should be checked for clogging at every service and changed if necessary.

7.17.1 CHECKING THE OIL BATH LUBRICANT LEVEL.

(A).
Remove the oil level plug, as shown at (B).

If the lubricant in the bath is not at the level shown

at (C), then the bath needs to be topped-up.
(B).
To top up the oil remove the air breather located on top
on top of the bath, as shown at (E). (C).

Add in the correct lubricant until it reaches the oil level (D).
hole.

Replace the air breather and all plugs.

(E).

7.17.2 CHANGING THE OIL BATH LUBRICANT.

The lubricant in the oil bath should be changed after every 1500
hours of operation. Change the lubricant while it is warm so that it is
easier to drain.

WARNING: Take extra precautions with hot liquids.

Remove the oil drain plug on the bottom of the bath, as

shown at (D). The lubricant should drain easily from the
bath. To help drain the lubricant remove the air
breather, as shown at (E).

Check that there are no unusual metallic parts on the

plugs.

Wash the interior of the oil bath with a suitable cleaning

liquid that is recommended by the lubricant
manufacturer.

Replace the drain plug and fill the oil bath with the
correct lubricant as per the procedure above.

IMPORTANT: Do not mix different types of oil.

P70. 1012TS (C13) O & M 02-2016.

7.17.3 FITTING ADDITIONAL WEIGHTS TO THE PRIMARY FEEDER.

In some applications additional weights may need to be

fitted to the primary feeder in order to obtain an efficient
machine throughput. The weights are fitted to the drive
shafts within the feeder mechanism, as shown at (A).
(A).
Additional weights are supplied on each machine. They are
fitted inside the rear end of the chassis, as shown at (B).

WARNING: Each shaft on the feeder must be fitted with

exactly the same number of weights. Fitting an uneven
number of weights to each shaft will unbalance the
mechanism which may cause damage to the machine.

A maximum of two additional weights can be fitted to each

shaft. Never operate the feeder with less than five weights (B).
fitted to each shaft.

To fit the additional weights remove the cover from

underneath the primary feeder, as shown at (C).

Remove five of the six bolts that hold the weights to

the shaft. Leave one of the bolts at one end of the
shaft tight, as shown at (D). This will ensure that
the weights stay attached to the shaft while the
additional weights are being fitted. (C).

Attach the additional weights to the other end of the

shaft. Position the weights at an angle, slightly to
one side of the existing weights. This will allow the
remaining bolt to be removed.

Fit one bolt to the other end of the shaft, as shown

at (E). Tighten this bolt just enough so that it will
hold all the weights in place but that will also allow
the additional weights to slide around and line up
with the rest of the bolt holes.

Remove the other bolt that is still holding the

existing weights in place, as shown at (D). (D).

Slide the additional weights around until all the bolts

holes line up.

Re-fit all the bolts and tighten them adequately.

Repeat this process with the second shaft ensuring

that both shafts have the same number of weights (E).
fitted.

P71. 1012TS (C13) O & M 02-2016.

7.18 SETTING THE ROTOR SPEED RELAY.
A speed sensor has been fitted to the rotor on the crusher to
detect if the speed of the rotor reduces. This helps prevent the (A).
crusher from overloading and stalling the engine. (B).
(C).
If the rotor slows down below a pre-set speed the feeders will (D).
automatically stop. When the rotor speeds up again above (E).
another pre-set speed, the feeders will automatically start again.
NOTE: This sensor only works when the machine is being
operated in Automatic mode.
A speed relay, as shown at (A), controls the settings of the speed
sensor. When the ignition is turned on the speed relay will
illuminate and show the "high" and "low" speed settings. The high
speed setting is the speed at which the relay will turn on the
feeders. The low speed setting is the speed at which the relay will
turn off the feeders.
To set the speed relay press the "program" button once,
as shown at (B). The display will change to read "shaft
teeth". This corresponds to the number of pulses per
crusher shaft revolution. This should be set to 6 for the
1012TS. It can be changed by pressing the "up" and
"down" buttons, as shown at (D) & (E).
Next press the "enter" button, as shown at (C). The
display should read "Overspeed Auto". The setting can be
changed if it is incorrect by pressing the Up" and "Down"
buttons.
Press the "Enter" button again. The display will change to
read "Trip High Value". This reading is the crusher speed
at which the feeders will start. The high speed value will
be displayed with the first digit of the high setting
highlighted. This value can be changed while it is
highlighted by using the "Up" and "Down" buttons. When
the first digit is set press the "Enter" button and the
highlight will move to the next digit and so on.
When the last high speed digit has been set, press the
"Enter" button and the display will move to the "Trip Low
Value". This is the crusher speed at which the feeders will
stop. The low speed value will be displayed with the first
digit of the low setting highlighted. This value can be
changed while it is highlighted by using the "Up" and
"Down" buttons. When the first digit is set press the
"Enter" button and the highlight will move to the next digit
and so on.
When all the speed settings have been entered press the
"Enter" button after which the display will change to show
the actual speed together with the "High" and "Low" speed
settings. The new settings are now programmed into the
speed relay.
NOTE: During the programming if there is a delay of more
than 15 seconds before operating a button, the
programming operation will be aborted and the display will
return to show the current speed and trip values. The
programming can also be aborted at any time by pressing
the "Program" button.

P72. 1012TS (C13) O & M 02-2016.

7.19 CRUSHER UNIT MAINTENANCE.
The crusher unit is one of the most critical components on the machine. Proper and continuous maintenance of
the crusher is vital in order to achieve the optimum performance from the machine.
Due to the huge variation in the wear rate of different materials, it is impossible to stipulate an exact maintenance
schedule for the crusher wear parts. Therefore, the following maintenance information is a guide only. It is the
responsibility of each site owner to assess wear rates for their particular machine and to create their own
inspection and maintenance schedule.
Underestimating the wear rate of the wear parts, or failing to regularly check and replace them, may result in
severe wear to the crusher body or inner components of the crusher unit. In some cases catastrophic failure of
the crusher may occur if components are allowed to wear beyond their limits.
WARNING: Before carrying out any checks or maintenance on the crusher ensure that the machine has come to
a complete stop, the engine has been switched off and the lock-out procedure has been performed.

Depending on the wear rate of the material, regularly (A).

check the wear on the hammers and wear parts
inside the crusher unit.
Also check the wear on the deadbox wear parts and
check the Deadbox skirting rubbers and the product
conveyor impact bed.
If any of the hammers or wear plates have reached or
exceeded their wear limits, they MUST be replaced
with genuine TESAB parts. See the crusher wear
limits in the following sections.
Ensure that the crusher bearings are lubricated as per
the lubrication schedule.
Once a week check and tighten all bolts on the
crusher.
Ensure that chain and rubber curtain on the feed in
chute, as shown at (A), is in place and is functioning
correctly. This curtain in necessary in order to
prevent small rocks or material from exiting back out
of the crusher unit at speed.

7.19.1 INSPECTING THE CRUSHER UNIT.

In order to inspect the inside of the crusher unit there are three
(B).
inspection doors. One door is located at the back of the crusher
unit, as shown at (B), and two doors are located either side of the
crusher, as shown at (C).
WARNING: Never open any of the inspection doors unless the
machine has come to a complete stop, the engine has been
switched off and the lock-out procedure has been performed.
To inspect the inside of the crusher, loosen the locking bolts and
brackets on each of the doors and swing the doors open.
After inspection or maintenance ensure that the doors are correctly
closed and that the locking brackets are properly secured. Never,
under any circumstances, operate the machine while the
inspection doors are open.
(C).

P73. 1012TS (C13) O & M 02-2016.

7.19.2 OPENING THE CRUSHER. (A).
.
To gain access to the inside of the crusher unit, hydraulic rams
have been fitted. These rams are used to open the top section of
the crusher unit, as shown at (A).

WARNING: Before opening the crusher unit ensure that the

machine has come to a complete stop, the engine has been
switched off and the lock-out procedure has been performed.
Never, under any circumstances, operate the crusher while it is
open.

Release the six eye bolts from around the centre of

the crusher, as shown at (B) and (C). Note: Two of
the eye bolts are located on the opposite side of the
crusher and are not shown in these photographs.
Start the engine. (B).
.
With the engine at low revs, gently operate the
hydraulic control lever labelled, CRUSHER
OPENING.
Open the crusher in a constant motion until it has
opened fully.
NOTE: Opening the crusher too quickly or jerking it
suddenly may result in damage to the machine.
Insert the crusher safety pin, as shown at (D). (C).
IMPORTANT: Ensure that the crusher safety pin .
remains in place at all times during maintenance. The
safety pin can be found on the front of the crusher
above the bottom apron adjusters.
Stop the engine and perform the lock-out procedure.
To close the crusher unit carry out the above
sequence in reverse order. Take care when closing
the crusher to ensure that the two sections join
together correctly. Ensure that the six eye bolts are
fitted and tightened correctly. Never operate the
crusher without the eye bolts fitted correctly.

(D).
.

P74. 1012TS (C13) O & M 02-2016.

7.19.3 CRUSHER WEAR LIMITS.

The following information is a general guide only. On-site variables such as the size, consistency and
abrasiveness of the material being crushed, will impact on the speed and patterns of the wear on the
components.

WARNING: Failure to change the wear parts when they reach their wear limits may result in severe damage to
the crusher unit. In some cases catastrophic failure of the crusher may occur if components are allowed to wear
beyond their limits.

HAMMERS: The hammers must not be allowed to over-wear. When the hammer has worn to a
point where only 40mm of the hammer remains above the rotor, as shown at (A), it must be turned
or replaced. When turning or fitting new hammers, ensure that all four hammers are replaced or
turned, otherwise a serious imbalance may be caused in the crusher.

STROKE PLATES Top Apron: If the stroke plates on the top apron, as shown at (B), have worn
to a point where there is only 50mm thickness left, they must be replaced.

STROKE PLATES Middle Apron: If the stroke plates on the middle apron, as shown at (C),
have worn to a point where there is only 50mm thickness left, they must be replaced.

STROKE PLATES Bottom Apron: If the stroke plates on the bottom apron have worn to a point
where the blowbars protrude past them by more than 25mm, as shown at (D), they must be
replaced. It is very important to check this dimension when fitting new blowbars.

BLOWBARS: If the blowbars have worn to a point where only 15mm of the blowbar remains past
the bar carrier, as shown at (E), they must be turned or replaced.

ALL OTHER WEAR PLATES: Generally, all wear plates must be replaced if only 5mm wall
thickness remains. Some wear plates will wear more quickly than others. For example; the
protector shoes in front of the hammers and the wear plates around the crushing circle will wear
more quickly. These plates should be checked more regularly.

(B).
.

(C).
.
(A).
.

(D).
.

(E).
.

P75. 1012TS (C13) O & M 02-2016.

7.19.4 TURNING OR REPLACING THE HAMMERS.
IMPORTANT: When turning or replacing the hammers, it is preferred that all four hammers are turned or
replaced together. However, on occasions, depending on the material being crushed, it may be necessary to
just turn or replace two of the hammers.
On these occasions the two hammers being turned or replaced MUST be opposite each other. Never turn or
replace just one hammer and never leave just one hammer unturned or not replaced. Doing so will result in
rotor imbalance. This will cause vibration on the machine which may cause damage.
When turning or replacing just two of the hammers the other two hammers MUST remain in the rotor. Never
operate the machine with one or more of the hammers missing! Also, you must check regularly to ensure that
the two remaining hammers are not continuing to wear past their maximum wear limit.

To turn or change the hammers, firstly fully adjust out the bar (A).
carrier. This will allow the maximum clearance around the rotor .
when changing the hammers. Instructions on adjusting out the (B).
bar carrier are given in section 6.0 .
Open the crusher chamber as per the instructions given in
section 7.19.2. (C).
.
Ensure that the crusher safety pin is fitted and that the machine
is switched off and locked-out.
Manually rotate the rotor until the first hammer is located at the
top, as shown at (A). (D).
.
Insert the crusher safety bar through the side of the crusher
(E).
body and through the holes in the rotor, as shown at (E). This
.
will prevent the rotor from turning while the hammers are being
replaced.
Each hammer is held in place by two locking flats on either side
of the hammer, as shown at (B). Remove both locking flats.
It is possible that there will be a build-up of material in the space
behind the hammer, as shown at (C). Use a power washer to
remove this material.
Once the material has been removed the hammer will be free to slide out the side of the crusher chamber.
WARNING: Each hammer weighs approximately 200kgs therefore, an adequate safe working lifting
device MUST be used to replace the hammers.
Slide the hammer half way out of the rotor. Attach a lifting chain around the centre of the hammer and
using the lifting device, take the weight of the hammer. Take care not to lift the hammer upwards.
Slide the hammer completely out of the rotor. With the hammer out, check the wear on the protector
shoes, as shown at (D). If the shoes need replaced do this before the hammers are refitted.
Turn or replace the hammer and slide it back into the rotor again. NOTE: If the hammers have already
been turned once then you will need to fit new hammers.
When the hammer has been refitted, ensure that it is centred on the rotor so that it is an equal distance
from each side of the crusher chamber.
Refit the two locking flats on either side of the hammer, as shown at (B).
Remove the safety bar and manually rotate the rotor until the next hammer is located at the top.
WARNING: When a new or turned hammer has been fitted the rotor will be top heavy. Extreme care must
be taken when manually rotating the rotor as the heavier hammer will attempt to rotate quickly to the
bottom side of the rotor.
Repeat the above steps until all four hammers have been turned or replaced.
Once all four hammers have been replaced or turned, slowly rotate the rotor for two complete rotations.
This will ensure that there is adequate clearance within the crusher chamber.
Close the crusher chamber and ensure that the six eye bolts are fitted correctly and tightened adequately.
After the hammers have been replaced or turned, the crusher settings will have to be adjusted in order to
obtain the required material crush size. See section 6.0 for details on setting the crusher.

P76. 1012TS (C13) O & M 02-2016.

7.19.5 REPLACING THE STROKE PLATES.
The stroke plates on the inside of the crusher are fitted to three (A).
separate aprons; the top apron, as shown at (A), the middle apron, .
as shown at (B) and the bar carrier, as shown at (C). The instructions
(B).
for replacing the stroke plates on each of the aprons are on the
.
following pages.
(C).
(A). Replacing the stroke plates on the top apron. .
Ensure that the machine has been fully shut down and
locked out.
Remove all the bolts from around the top lid of the crusher,
as shown at (D). (D).
.
Lift the lid and apron off the crusher unit. To do this you will
require a lifting device capable of lifting at least 900kgs.
There are three lift points located on the lid of the crusher.
Set the lid and apron onto the ground.
Remove the large hex nuts from the two threaded bars, as
shown at (E).
The lid of the crusher can now be lifted clear of the apron.
Once the lid is removed you will see the lock nuts on the
back side of the apron that hold the stroke plates on.
Remove all the stroke plates from the apron.
(E).
Thoroughly clean the flat side of the apron, onto which the .
stroke plates are fitted. This plate MUST be free of dust,
material and burrs in order to ensure that the stroke plates sit
correctly onto the apron.
Use a straight edge along the apron to ensure that it is flat. If
the apron is bowed or bent in any way the stroke plates may
not tighten correctly and may become loose over time.
Fit the new stoke plates ensuring that they are placed in the
correct order on the apron (see the parts section for details
of each type of stroke plate).
IMPORTANT: Only fit genuine Tesab manganese stroke
plates to this apron. If any of the stroke plates on this apron
need replaced then all six stroke plates MUST be replaced.
Never mix and match worn stroke plates with new ones.
You MUST use new bolts and nuts when fitting the new
stroke plates.
It is critically important that the stroke plate bolts are
tightened to their maximum. Once the lock nuts are fully
tightened the bolts will need to be further bedded in. To do
this, place a bar on the face of the bolt. Strike the bar with a
heavy hammer several times. Do this with all three bolts and
then re-tightened the nuts. Carry out this procedure at least
four times on each bolt to ensure that its properly bedded
into the stroke plate.
Re-attach the lid of the crusher to the apron and tighten up
the hex nuts on the threaded bars. The lid and apron can
now be fitted back onto the crusher. Ensure that all bolts
around the lid of the crusher are tightened up correctly.
After the machine has been operated for 50 hours, check all
the bolts in all the stroke plates to ensure that they are still
tight.

P77. 1012TS (C13) O & M 02-2016.

(B). Replacing the stroke plates on the middle apron.

To replace the stroke plates on the middle apron, firstly fully

adjust the middle apron inwards. This will leave the apron
sitting horizontal when the crusher chamber is opened up. (A).
Instructions on adjusting in the apron are given in section 6.0 .
Open the crusher chamber as per the instructions given in
section 7.19.2.
Ensure that the machine has been fully shut down and
locked out.
Ensure that the crusher opening safety pin is fitted. Also fit
the crusher safety bar through the side of the crusher body
and through the holes in the rotor. This will prevent the rotor
from turning while the work is being carried out on the apron.

At this point the middle apron should be sitting horizontal, as

shown at (A).
Remove the bolts that hold the stroke plates on. Using the
appropriate lifting gear, remove the stroke plates from the
apron.
Thoroughly clean the flat side of the apron, onto which the
stroke plates are fitted. This plate MUST be free of dust,
material and burrs in order to ensure that the new stroke
plates sit correctly onto the apron.
Use a straight edge along the apron to ensure that it is flat. If
the apron is bowed or bent in any way the stroke plates may
not tighten correctly and may become loose over time.
Fit the new stoke plates ensuring that they are placed in the
correct order on the apron (see the parts section for details
of each type of stroke plate).
IMPORTANT: Only fit genuine Tesab manganese stroke
plates to this apron. If any of the stroke plates on this apron
need replaced then all six stroke plates MUST be replaced.
Never mix and match worn stroke plates with new ones.
You MUST use new bolts and nuts when fitting the new
stroke plates.
It is critically important that the stroke plate bolts are
tightened to their maximum. Once the lock nuts are fully
tightened the bolts will need to be further bedded in. To do
this, place a bar on the face of the bolt. Strike the bar with a
heavy hammer several times. Do this with all three bolts and
then re-tightened the nuts. Carry out this procedure at least
four times on each bolt to ensure that its properly bedded
into the stroke plate.
Once completed, remove the safety pins, close the crusher
chamber and ensure that the crusher eye bolts are fitted
correctly and tightened adequately.
The apron will have to be reset in order to obtain the required
material crush size. See section 6.0 for details on setting the
aprons in the crusher.
After the machine has been operated for 50 hours, check all
the bolts in all the stroke plates to ensure that they are still
tight.

P78. 1012TS (C13) O & M 02-2016.

(C). Replacing the stroke plates on the bar carrier.
IMPORTANT: Only Chromium stroke plates MUST be fitted to the bar
carrier on this machine.
To replace the stroke plates on the bar carrier it is easier to
lift the bar carrier out of the crusher unit.
(A).
Open the crusher chamber as per the instructions given in .
section 7.19.2.
Ensure that the machine has been fully shut down and
locked out.
Ensure that the crusher opening safety pin is fitted. Also fit
the crusher safety bar through the side of the crusher body (B).
and through the holes in the rotor. This will prevent the rotor .
from turning while the work is being carried out on the bar
carrier.
Open the inspection doors on each side of the crusher and
remove the adjuster bar pins from the back of the bar carrier,
as shown at (B). The bar carrier will swing back towards the
back of the crusher when the pins have been removed.
Therefore, you will need to support the bottom of the bar
carrier before you remove the pins.
Attach lifting chains to the top of the bar carrier and lift it straight up and out of the crusher chamber.
Remove the bolts that hold the stroke plates on and remove the stroke plates from the bar carrier.
Thoroughly clean the flat side of the bar carrier, onto which the stroke plates are fitted. This plate
MUST be free of dust, material and burrs in order to ensure that the new stroke plates sit correctly onto
the bar carrier.
Use a straight edge along the face to ensure that it is flat. If the bar carrier is bowed or bent in any way
the stroke plates may not tighten correctly and may become loose over time.
Fit the new stoke plates ensuring that they are placed in the correct order on the apron (see the parts
section for details of each type of stroke plate).
IMPORTANT: Only fit genuine Tesab Chromium stroke plates to the bar carrier. If any of the stroke
plates on the bar carrier need replaced then all four stroke plates MUST be replaced. Never mix and
match worn stroke plates with new ones.
You MUST use new bolts and nuts when fitting the new stroke plates.
It is critically important that the stroke plate bolts are tightened to their maximum. Once the lock nuts
are fully tightened the bolts will need to be further bedded in. To do this, place a bar on the face of the
bolt. Strike the bar with a heavy hammer several times. Do this with all three bolts and then re-
tightened the nuts. Carry out this procedure at least four times on each bolt to ensure that its properly
bedded into the stroke plate.
While the bar carrier is out of the crusher unit this is a good time to turn or replace the blow bars.
Once completed, fit the bar carrier back into the crusher chamber. Attach the adjuster bars to the bar
carrier and fit the mounting pins, as shown at (B).
Remove the safety pins, close the crusher chamber and ensure that the crusher eye bolts are fitted
correctly and tightened adequately.
The bar carrier will have to be reset in order to obtain the required material crush size. See section 6.0
for details on setting the aprons in the crusher.
After the machine has been operated for 50 hours, check all the bolts in all the stroke plates to ensure
that they are still tight.

P79. 1012TS (C13) O & M 02-2016.

7.19.6 REPLACING THE BLOW BARS.
(A).
Ensure that the machine has been fully shut down and
.
locked out.
Open the inspection doors on the side of the crusher unit to
access the bar carrier, as shown at (A).
Use a power washer to wash excess material from around
the bar carrier. Doing this will allow the blow bars to be
removed more easily.
Slide the blow bars out of the bar carrier, turn or replace
them and slide them back in again.
IMPORTANT: Ensure that all 10 blow bars are turned or
replaced. Do NOT mix and match worn blow bars with new
ones.
When refitting the blow bars ensure that they are centralised
on the bar carrier.
After the blow bars have been turned or replaced the bar
carrier will have to be reset in order to obtain the required
material crush size. See section 6.0 for details on setting the
bar carrier.

7.20 REALIGNING THE SCALPING FEEDER.

Its important that the scalping feeder is aligned centrally
within the crusher opening, as shown at (B). Otherwise
the feeder may cause damage to the walls of the crusher
unit.
If the feeder is not aligned centrally then it must be
adjusted as follows:
Ensure that all material has been run off the (B).
feeder.
Shut down the machine and lock out.
Loosen the bolts on all four of the scalping feeder
mounting stools, as shown at (C). Do not take the
bolts off completely.
The mounting stools are slotted and can therefore
be moved in any direction.
Adjust the mounting stools in whatever direction
necessary in order to align the feeder with the
crusher opening.
Ensure that all four mounting stools are adjusted
evenly so that the feeder is in line with the
crusher.
(C).
Also check the rear of the scalping feeder to
ensure that the primary feeder is also aligned
correctly.
Tighten all bolts correctly and re-start the
machine.
After the machine has been re-started and
material has been run through the crusher for a
few hours, stop the machine and re-check the
alignment of the scalping feeder.

P80. 1012TS (C13) O & M 02-2016.

7.21 HYDRAULIC SYSTEM LAYOUT.

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P81. 1012TS (C13) O & M 02-2016.

 SECTION 8.0

TRANSPORTATION

Before attempting to transport this machine you

! WARNING must have read and understand all the safety

instructions listed in Section 2.0

8.1 TRANSPORTATION OVERVIEW.

This section will guide you through the procedures to prepare the machine for transportation.
Ensure that you carry out all these procedures in order to prevent injury and/or damage to your
machine.

IMPORTANT: Due to different transport and shipping regulations throughout the world this machine
may require different packing arrangements. For the purposes of this manual it will be considered
that the machine will be transported in its most unassembled configuration. Therefore, some of the
procedures may not be applicable. If this is the case ignore that particular instruction and proceed
to the next section.

Check local transport regulations before attempting to transport this machine.

The preparation of this machine for transportation MUST only be carried out by fully trained and
authorised personnel only. At least two people must be present and statutory minimum age limits
must be observed.

8.2 PREPARING FOR TRANSPORT SEQUENCE.

The following operations must be carried out in the sequence given in order to prepare the machine correctly for
transport. Details of each procedure are given on the following pages.

STEP 1 Clear the machine of all material.

STEP 2 Fold down the discharge conveyor.
STEP 3 Fold up the dirt conveyor.
STEP 4 Remove the crib cross beams and lower the cribs.
STEP 5 Remove the pre-cleaner, working lights, feeder beacon and water supply.

P82. 1012TS (C13) O & M 02-2016.

8.2.1 STEP 1: CLEAR THE MACHINE OF ALL MATERIAL.

Remove all material from all around the machine.

It may be necessary to powerwash the machine to
remove all the loose material.
Ensure that there is no material remaining on the
machine that could dislodge while the machine is
being transported.

8.2.2 STEP 2: FOLD DOWN THE DISCHARGE CONVEYOR.

Disconnect the grease pipes, as shown at (A).

If dust covers have been fitted to the machine they

must be removed before the conveyor is folded.

Remove the wire ropes, as shown at (B).

Remove the top mounting pins, as shown at (C).

(A).
Ensure that the transport bracket is fitted in the top
hole, as shown at (D).

Start the engine.

Using the hydraulic lever labelled Discharge (B).

Conveyor Folding, slowly and gently fold the
conveyor down.
(C).
Fit the transport brackets, as shown at (E).

(D).

(E).

P83. 1012TS (C13) O & M 02-2016.

8.2.3 STEP 3: FOLD UP THE DIRT CONVEYOR.

The dirt conveyor will need to be folded up into the transport (A).
position before the machine can be transported.

WARNING: The dirt conveyor must be folded up into the transport

position before the cribs are folded down.

IMPORTANT: Extreme care must be taken when folding the dirt

conveyor up into the transport position. Ensure that the engine is (B).
running at low speed. Use a gentle touch when operating the .
hydraulic control lever so that the conveyor folds up in a gentle,
continuous motion.

Remove the dirt conveyor scraper, as shown at (A).

Remove the wire ropes, as shown at (B). (C).

Remove the locking pins, as shown at (C).

Remove the mounting bolts. These bolts secure the

top and bottom sections of the conveyor and are
located on the inside of the conveyor frame at the (D).
pivot point, as shown at (D).

Start the engine as per the engine start up procedure.

In order to pull the dirt conveyor inwards and fold it

up, the hydraulic control bank beside the dirt conveyor
must be activated. Push the control bank lever
labelled Activate Rams, as shown at (D), inwards.

With the engine at low revs, gently operate the

hydraulic control lever labelled, TELESCOPIC DIRT
CONVEYOR,
(E).
Close the conveyor in fully.

Using the hydraulic control lever labelled DIRT

CONVEYOR FOLDING, fold the conveyor up into the
transport position.
(F).
Fit the transport brackets, as shown at (F).

Tie the hydraulic hoses and belt up, as shown at (G).

(G).

P84. 1012TS (C13) O & M 02-2016.

8.2.4 STEP 4: LOWER THE CRIBS.

WARNING: Lifting equipment and working platforms will be (A).

required to fold the shroud down into the transport position.

Ensure that the dirt conveyor has been folded up correctly

before the cribs are folded down.

Remove the crib cross beams, as shown at (A).

Remove the crib leg locking brackets, as shown

at (B).

Remove the locking wedges, as shown at (C). (B).

Start the engine as per the engine start up

procedure given in section 3.0.

With the engine at low revs, gently operate the

hydraulic control levers labelled, LHS CRIBS,
RHS CRIBS and REAR CRIBS.

Lower the cribs down until they are fully down in

the transport position, as shown at (D).
NOTE: All three cribs must be lowered in (C).
increments starting with the rear crib, so that they
do not foul on each other.
If the machine has been fitted with crib extension
wings, the mounting bolts, as shown at (E), must
be removed from the wings. Transport brackets will
need to be fitted to the wings in order to tie them to
the chassis.

(D).

(E).

P85. 1012TS (C13) O & M 02-2016.

8.2.5 STEP 5: REMOVE THE PRE CLEANER, WORKING LIGHTS, FEEDER BEACON AND WATER SUPPLY.

Remove the pre-cleaner, as shown at (A). (A).

Fit the filter housing cover, as shown at (B), to protect
the filters.
If working lights have been fitted to the machine they
must also be removed before transport.
Remove the feeder beacon, as shown at (C).
If a dust suppression water supply has been
connected to the machine it should be removed now.

(B).

(C).

FINAL CHECKS:

Carry out a final check to ensure that no tools or objects have been left on the machine.
Ensure that all components have been secured correctly so that they cannot move or swing during
transport.
Ensure that no material or debris will dislodge and fall from the machine during transport.
Check that the transport dimensions are correct for the jurisdiction in which the machine is to be
transported.
Ensure that the machine is correctly secured to the trailer on which it is to be transported.

WARNING: When securing the machine to the transportation trailer DO NOT use any point on the tracks to tie
the machine down to the trailer. Always use the tie down points provided on the chassis.

P86. 1012TS (C13) O & M 02-2016.

END OF MANUAL

P87. 1012TS (C13) O & M 02-2016.