10570 JAW CRUSHER.

OPERATION
& PARTS MANUAL

TESAB ENGINEERING Ltd.

Unit 7, Gortrush Industrial Estate,
Omagh, Co. Tyrone, Northern Ireland. BT78 5EJ
Tel: +44 (0) 28 82252781
Fax: +44 (0) 28 82252801
Email: sales@tesab.com
www.tesab.com
DECLARATION OF CONFORMITY

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

Manufactured by:

Tesab Engineering Ltd.

7B Gortrush Industrial Estate
Omagh
Co. Tyrone
Northern Ireland BT78 5EJ

Machine description:

Mobile Crushing Plant

Model:

10570 JAW CRUSHER

This machinery has been designed and manufactured in accordance with all the relevant ESR’s of the EU
Machinery Directive.

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

Signed: _____________________________

Name: Brian A. Mills

Position: Technical Manager

Date: ___________

Being the nominated representative of TESAB ENGINEERING LTD.

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FOREWORD/RESERVATION OF RIGHTS:

The TESAB 10570 JAW CRUSHER is a robust, skilfully engineered piece of equipment incorporating diesel,
hydraulic and mechanical components of the highest quality.

In the interest of continuous plant reliability, it is essential that the machine is maintained with meticulous care
and attention. This operation and maintenance manual has been produced to assist the user to obtain the
maximum output from the machine and to trace and remedy faults, should they arise. Failure to do so could
result in personal injury or equipment damage.

We 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.

While all the information, illustrations and specifications in this manual are based on the latest information
available at the time of publication, some variations do exist between machine specifications. Therefore, some
of the information may be slightly inaccurate.

Future updated issues of this manual or manuals belonging to other Tesab crushers, will not be specific to all
machines. Tesab Engineering reserve the right to change the specification of their Crushers and therefore
reserve the right to alter any information contained in this manual without prior notice.

COPYRIGHT:

No copies of any part or any form of reproductions may be made from this manual without prior written consent
of TESAB ENGINEERING Ltd. This manual, complete or in part, must not be loaned to a third party.

Additional copies of this manual are readily available, however, a charge may be payable to cover printing and
administrative costs.

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WARRANTY:

All conditions and warranties expressed or implied by any statue common law. Trade usage or otherwise are
hereby excluded. No liability is accepted by TESAB ENGINEERING LTD. for any loss, damage or injury to
property or persons arising directly or indirectly from any failure in the machinery supplied. The materials
employed by TESAB ENGINEERING LTD. in the manufacture of our machinery, to the best of our knowledge,
are the highest available quality of their respective kinds. TESAB ENGINEERING LTD. undertakes to replace
or repay free of cost any part supplied by us direct to the customer of which we shall receive notice and which
shall be proved to the satisfaction of TESAB ENGINEERING LTD. within a period of twelve months of delivery
to be defective in workmanship or materials provided.

A: That written notice of complaint is given within seven days of the discovery of the defect.

B: That the part is returned carriage paid to TESAB ENGINEERING LTD. and shall, in the event of
replacement, become our property.

C: That the defect has not been caused by carelessness or improper or inadequate lubrication.

D: TESAB ENGINEERING LTD. shall not be liable for the cost of removal of the defective part or the cost of
fitting a new part.

E: That the guarantee period shall be proportionally reduced if the machinery is run for more that one eight
hour shift per day.

No unauthorised alteration or modification has been made to the plant or machine or component the subject of
the claim.

The new part will be delivered by TESAB ENGINEERING LTD., carriage paid to the customers nearest station
in the U.K. or F.A.S. port of exportation.

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

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

The guarantee contained aforesaid is personal to TESAB ENGINEERING LTD. customer and may not be
assigned.

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 CONTENTS
PAGE No.
SECTION 1.0 FAMILIARISATION. 7 - 11

1.1 Main Assembly Descriptions. 7

1.2 Orientation. 8
1.3 Technical Specification. 9 - 10
1.4 Main Control Panel Familiarization. 11

SECTION 2.0 SAFETY. 12 - 21

2.1 Safety Introduction. 12

2.2 Safety Signs on the Machine. 13
2.3 Safety Hazards. 14
2.4 Hazard Zone. 15
2.5 Lockout Procedure. 15
2.6 Emergency Stop Locations. 16
2.7 Emergency Shut Down. 17
2.8 Safety Before and During Set-Up. 18
2.9 Safety Before and During Operation. 19
2.10 Safety Before and During Maintenance. 20

SECTION 3.0 TRACKING INSTRUCTIONS. 22 - 26

3.1 Tracking Introduction. 23

3.2 Engine Start Up Procedure before Tracking. 24
3.3 Tracking the Machine using the Doglead. 25
3.4 Tracking the Machine using the Remote Control. 26

SECTION 4.0 INSTALLATION. 27 - 36

4.1 Installation Overview. 27

4.2 Installation Procedure. 27
4.3 Unloading the Machine. 28
4.4 On-Site Positioning. 28
4.5 Fitting the Exhaust and Air Breather. 28
4.6 Engine Start-Up Procedure before Set-Up. 29
4.7 Raising the Product Conveyor Head Section to the Working Position. 30
4.7 Lowering the Product Conveyor Tail Section to the Working Position. 31
4.8 Fitting the Feed In Chute Lid. 31
. 4.9 Fitting the Viewing Platform and Spray Bars. 31
4.10 Raising the Hopper Cribs to the Working Position. 32
4.11 Lowering the Short Dirt Conveyor to the Working Position. 33
4.12 Fitting the Long Dirt Conveyor into the Working Position. 34
4.13 Adjusting the Jaw Crusher. 35 - 36

SECTION 5.0 OPERATION. 37 - 40

5.1 Operation Overview. 37

5.2 Pre-Operation Check List. 37
5.3 Engine Start Up Procedure before Operation. 38
5.4 Machine Start Up Sequence. 39
5.5 Machine Shut Down Sequence. 39
5.6 Operating the Feeder using the Remote Control. 40
5.7 Feeder Variable Speed Control. 40

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 CONTENTS CONTINUED:

PAGE No.
SECTION 6.0 MAINTENANCE. 41 - 72

6.1 General Maintenance Information. 41

6.2 Daily Maintenance. 42
6.3 Daily Checks during Operation. 42
6.4 Weekly Maintenance. 43
6.5 Six Monthly Maintenance. 43
6.6 Lubrication Points. 44
6.7 Lubrication Schedule. 45
6.8 Manual Clutch Lubrication. 45
6.9 Recommended Lubricants. 46
6.10 Automatic Lubrication. 47 - 49
6.11 Hydraulic Clutch Maintenance. 50
6.12 Manual Clutch Maintenance. 51
6.13 Tracks Maintenance. 52 - 53
6.14 Engine Maintenance. 54
6.15 Hydraulic System Maintenance. 55
6.16 Product Conveyor Gearbox Maintenance. 56
6.17 Primary Feeder Maintenance. 57
6.18 Belt Alignment. 58
6.19 Crusher Drive Belt Adjustment. 59
6.20 Load Sensors. 60
6.21 Hydraulic Diagram. 61
6.22 Electrical Wiring Diagram. 62 - 70
6.23 Electrical Panel Layout 71 - 72

SECTION 7.0 TRANSPORTATION. 73 - 78

7.1 Transportation Overview. 73

7.2 Preparation for Transport Procedure. 73
7.3 Removal of Miscellaneous items from the Machine 74
7.4 Raising the Short Dirt Conveyor to the Transport Position. 74
7.5 Removing the Long Dirt Conveyor from the Machine. 75
7.6 Lowering the Hopper Cribs to the Transport Position. 76
7.7 Raising the Product Conveyor Tail Section to the Transport Position. 77
7.8 Lowering the Product Conveyor Head Section to the Transport Position. 77
7.9 Removing the Exhaust and Air Breather. 78
7.10 Transportation. 78

SECTION 8.0 SPARE PARTS. 79 - 96

8.1 Spare Parts Ordering Information. 79

8.2 Parts Illustration. 80
8.3 Primary Feeder Parts List. 81
8.4 Scalping Feeder Parts List. 82
8.5 C9 Engine & Drive System Parts List. 83 - 84
8.6 Hydraulic System Parts List. 85 - 87
8.7 Product Conveyor Parts List. 88 - 89
8.8 Long Dirt Conveyor Parts List. 90 - 91
8.9 Short Dirt Conveyor Parts List. 92 - 93
8.10 Jaw Crusher Parts List. 94 - 95
8.11 Misc. Parts List. 96

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 SECTION 1.0

FAMILIARISATION

! CAUTION Ensure that all personnel are completely familiar

with all aspects of this machine.

1.1 MAIN ASSEMBLY DESCRIPTIONS.

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

(J). (K) (L). (M)

No. Description. No. Description.

(A). Hopper / Hydraulic Folding Cribs (J). Chassis

(B). Primary Feeder (K). Side Dirt / Fines Conveyor (Optional Length)
(C). Scalping Feeder (L). Tracks
(D). Crusher Feed in Chute (M). Hydraulics Console
(E). Jaw Crusher Unit
(F). Engine Powerpack / Drive System
(G). Hydraulic Tank
(H). Overband Magnet (Optional)
(I). Product / Discharge Conveyor

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1.2 ORIENTATION.

The following conventions have been used throughout this manual when describing component locations:

REAR - Feeder end of the machine.

FRONT - Product Conveyor end of the machine.

LEFT & RIGHT SIDES - As viewed from the rear of the machine.

FRONT

LEFT RIGHT

REAR

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1.3 TECHNICAL SPECIFICATION.

1.3.1 GENERAL SPECIFICATION.

Transport Length: - 16.60 Metres ( 54' 6").
Transport Width: - 3.10 Metres (10' 2").
Transport Height: - 3.66 Metres (12').
Working Length: - 16.215 Metres ( 53' 2").
Working Width: - 3.1 Metres (10' 2") (Not including Dirt Conveyor)
Working Height: - 4.170 Metres (13' 8").
Weight: - 54,500 kg (120,150 lbs)

Note: These details are liable/subject to change due to machine specifications and developments. this
information has been supplied based on the information to date.

1.3.2 PRIMARY FEEDER.

Type: - Spring Mounted Vibrating Pan.
Length: - 3.75 Metres ( 12' 4").
Width: - 0.9 Metres (20").
Drive: - Hydraulic Motor.
Control: - Variable Speed Hydraulic Valve provides full control in any application.
Hopper: - Heavy duty Hydraulic folding Hopper.
Other: - 20mm Hardox base plate.
- Radio Remote Control Start/Stop facility.

1.3.3 SCALPING FEEDER.

Type: - Spring Mounted Vibrating Twin Deck.
Length: - Top Deck 1.75 Metres ( 5' 9"), Lower Deck 0.95 Metres (37").
Width: - Top Deck 1.0 Metre ( 40"), Lower Deck 1.0 Metre (40").
Drive: - Hydraulic Motor.
Hopper: - Heavy duty Hydraulic folding Hopper.
Other: - Interchangeable Grizzly and Mesh.
- Adjustable chutework below the Feeder allows fines to be directed onto Product
Conveyor or onto Side Dirt Conveyor.
- Automatic shut-off if Crusher becomes full.

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1.3.4 JAW CRUSHER.
Type: - Single Toggle Jaw.
Feed Width: - 1.1 Metres (43").
Feed Gape: - 0.7 Metres (28").
Jaw Length: - 1.55 Metres (61").
Adjustment: - Hydraulically assisted / Electrically operated.
Drive: - Parallel drive via V-belts from the Engine.
Other: - Overload release built into the Hydraulic Adjustment system.

1.3.5 PRODUCT CONVEYOR.

Type: - Plain Troughing 4-Ply Belt.
Width: - 1.2 Metres (48").
Drive: - Hydraulic Motor and Torque Hub.
Other: - Full Skirting along the length of the Conveyor.
- Rubber Lagged Top End Drum.
- Adjustable Return Rollers for efficient Belt Tracking.

1.3.6 SIDE DIRT / FINES CONVEYOR.

Type: - Plain Troughing 3-Ply Belt.
Width: - 0.65 Metres (26").
Drive: - Hydraulic Motor.
Other: - Option for Long or Short Dirt Conveyor.

1.3.7 POWER UNIT.

Type: - CAT C9 6 Cylinder Diesel Engine
Transmission: - Transfluid 19KPTO.
Drives: - Directly driven Hydraulic Pumps.
Other: - Canopy enclosure with integral Diesel Tank.
- Diesel Tank has a capacity of 750 litres (165 gallons, 198 US gallons)

1.3.8 TRACKS.
Width: - 500 mm (20").
Length: - 4.52 Metres (14'8")
Drive: - Hydraulic Motor and integral Gearbox.
Control: - Doglead or Radio Remote Control option.

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1.4 MAIN CONTROL PANEL FAMILIARISATION.
(1).
(2).
(3).
(13).
(4).
(5). (14).
(6). (15).

(7). (16).
(8). (17).
(9).
(10). (18).
(11).
(12).

(1). Product Conveyor "On / Off" Button - When (10). Engine Fault Lamp - If this light is illuminated this
pressed this button will either start or stop the indicates that a fault has occurred in the Engine.
Product Conveyor.
(11). Emergency Stop Lamp - This lamp should be
(2). Clutch "On / Off" Button - When pressed this illuminated at all times when the ignition is switched on. If it
button will either start or stop the Clutch. is not illuminated then this indicates that an Emergency Stop
has been pressed.
(3). Primary Feeder "On / Off" Button - When
pressed this button will either start or stop the (12). Maintenance Due Lamp - This light will illuminate for 5
Primary Feeder. seconds each time the ignition is turned on. If it illuminates
at any other time, this indicates that a scheduled service is
(4). Scalping Feeder "On / Off" Button - When due. Consult the Caterpillar Operation & Maintenance
pressed this button will either start or stop the Manual supplied along with this Machine..
Scalping Feeder.
(13). Caterpillar Messenger Display. For further information
(5). Magnet "On / Off" Button - When pressed this and explanation of the Messenger Display and it's
button will either start or stop the Magnet. functions, consult the Caterpillar Operation & Maintenance
Manual supplied along with this Machine.
(6). Side Dirt Conveyor "On / Off" Button - When
pressed this button will either start or stop the (14). Tracks Switch. Used to choose either Doglead or
Side Dirt Conveyor. Remote Control for Tracking.

(7). Tracks activation button. When this button is (15). Throttle Switch - This switch is used to increase or
pressed it enables the Tracks to work. decrease the revs on the Engine.

(8). Crusher Adjustment activation button. When (16). Working Lights "On / Off" Switch. Note, this is a
this button is pressed it enables the Crusher machine Option.
Adjustment to operate.
(17). Autolub Button - When this button is pressed and held
(9). Diagnostic Lamp - This light will flash a code until the light illuminates then the manual lubrication cycle
indicating a fault that has occurred in the Engine. will begin. Note, this is a machine Option.
Refer to the Caterpillar Operation & Maintenance
manual for further information. (18). Ignition Switch - The is used to start the Engine when
required.

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 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 Rock Crushers
must be properly trained in the correct and safe procedures for the work they are to carry out.

They MUST:

(i). Be reliable, experienced and have a sound knowledge of rock crushing equipment. Statutory minimum age
limits must also be observed.

(ii). Have read and understood all aspects of this manual.

(iii). Be aware of all the hazards associated with this machine.

(iv). Have received specific and adequate training for any particular task to be carried out.

(v). Be completely familiar with all parts of the machine.

(vi). Be aware of all moving parts on the machine.

(vii). Be aware of the operation and limits of performance of the machine.

(viii). Know the location of safety features such as emergency stop buttons and safety guards etc.

(ix). Have read and understood any "On-Site" safety manual produced by the site owner.

(ix). 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 plant set-ups will be the same, therefore, in the interests of safety, the
instructions given should be altered to suit the conditions and set-up of each particular machine.
The person carrying out work on or near 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.

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2.2 SAFETY INTRODUCTION.
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.

1. Nip Hazard. Do Not reach into an 1. Electrical Hazard. Risk of serious

unguarded machine. injury or death.
2. In-running nip points can cause 2. Never work on the electrical
serious injury or death. systems of any equipment unless you
3. Switch off and Lockout machine are fully familiar with system details.
before opening or removing guard 3. Switch off and Lockout machine
doors. before opening or removing guard
doors.

1. Read & understand the operators 1. Loose or baggy clothes can get
manual before you work at this caught in running machinery.
machine. 2. Always wear correct fitting
2. Study the different safety signs on (EN/ANSI approved) protective
this machine. clothing including:
3. Only qualified and trained Hard Hat, Safety Clothing, Ear
personnel should attempt to work Protectors, Overalls, Steel Toed Boots
this machine. & High Visibility Vest.

1. When working on this machine 1. Falling material hazard. Do not walk

always isolate power supply at near material discharge areas. You
source. are at risk of serious injury or death.
2. Place a lock on an emergency 2. Wear a Hard Hat at all times when
stop switch and keep the key on in the vicinity of the Plant.
person during work.
3. Never work alone.

FALL HAZARD CRUSH HAZARD

1. Fall hazard. 1. Crush hazard.
Do not climb onto moving machinery Beware of dangerous hand and foot
2. Use an approved lifting platform. crush points.
3. When working above heights of 2 2. Do not use any body parts e.g.
metres, even when on walkways or hands or feet to check hole alignment
platforms, use an EN/ANSI approved or to support machinery.
safety harness.. 3. Always use pins and/or mechanical
supports provided.

SLIP HAZARD HOT SURFACE

1. Some surfaces may be slippery 1. Burn or Heat Hazard. Beware of
when wet, therefore extra care must hot surfaces at engine and exhaust
be taken. areas.
2. Always clean up spilled materials
and liquids immediately.
3. Ensure that walk ways and
ladders etc. are kept clean and dry.

HIGH PRESSURE BATTERY HAZARD

1. Beware of escaping hydraulic oil. 1. Battery hazard. Battery electrolyte
High pressure oil can penetrate the contains acid and can cause serious
skin causing serious injuries. injury. Avoid any contact.
2. Always relieve pressure from the 2. Batteries give off flammable
hydraulic system before attempting fumes which can explode. Avoid
maintenance. naked flames near the batteries. Do
3. If oil is injected under the skin, it not smoke when in this area.
must be surgically removed.

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2.3 MACHINE 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 through 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. Access ladders and walkways have
been fitted to provide access to some areas of the machine. Never use machine parts as climbing aids. The
ladders and platforms provided must only be accessed by authorised personnel. While the machine is running
the ladders and platforms must only be used as a means of visual inspection. If any work or adjustments, of
any kind, are to be carried out the machine must be shut down and "Locked out". More irregular maintenance
tasks will necessitate persons to 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 etc.

2.3.2 NIP/CRUSH POINTS.

Travelling belts, rotating drums and rollers, vibrating mechanisms and various moving parts on this machine
create potentially serious nip points. Know 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 feed onto and discharged off the machine at great heights, therefore, it is imperative that know 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 NOISE.
Due the type and nature of Rock Crushing 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
protectors. Length of exposure to such noise levels should be kept to a minimum.

2.3.5 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 the tracks drives. Extreme care
must be taken before and during moving of this machine.

2.3.6 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.

2.3.7 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 vent the emissions
elsewhere.

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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:

(i). They must have authorisation from the Plant supervisor to enter the restricted zone.
(ii). They must have read and understood the safety section of this manual.
(iii). They must carry out all safety procedures required.
(iv). They must be fully trained and qualified in the work they are carrying out.
(v). They must have experience in working with this type of Plant.
(vi). They must be wearing the required "Personal Protective Equipment".
(vii). 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 to this machine, ensure that the
following lockout procedure is followed:

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

Isolator ON
(A)

Isolator OFF

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2.6 EMERGENCY STOPS LOCATIONS.

1. BATTERY BOX 2. DOGLEAD 3. CHASSIS

4. CHASSIS 5. CATWALK 6. POWERPACK

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2.7 EMERGENCY SHUT DOWN.

IMPORTANT: In the case of an incident or any part failure on the machine the following procedure must be
followed immediately. Do not use the Emergency Stop Procedure to stop the machine under normal situations.

(i). Engage the nearest emergency stop.

(ii). Stop all other equipment feeding or working near the machine.

(iii). Perform the "Lock Out" Procedure.

(iv). Inform all other operators working on or close to the Machine.

(v). 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.

(vi). 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.

(i). Ensure that the problem has been rectified.

(ii). Replace all guards correctly.

(iii). Ensure that all personnel are clear of the machine.

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

(v). Release all emergency stops.

(vi). Follow the start up procedure.

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

(viii). If the problem persists carry out the Emergency Shut down procedure again and carry out fault
finding.

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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
altered to suit the conditions and set-up of each particular machine.
The 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 fine and eliminate all on-site risks associated with this
machine.

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

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

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

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

(v). 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.

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

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

(viii). Only the walkways and platforms provided should be used to access the machine. 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.

(ix). Never work under unsupported equipment.

(x). 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.

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

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

(xiii). Before testing the machine ensure that all tools, parts and components have been removed from the
machine and walkways. Ensure that know one is on or near the machine before Testing.

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

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2.9 SAFETY BEFORE AND DURING OPERATION.

IMPORTANT: 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.

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

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

(iii). Study all safety and hazard warning signs on the machine.

(iv). 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.

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

(vi). 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 section ?? for maintenance schedule.

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

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

(ix). In the event of malfunctions or operational difficulty stop the machine immediately and lockout. Have any
defects rectified immediately.

(x). While the Plant is running only use the ladders, steps or walkways supplied to visually inspect the Plant.

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

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

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

(xiv). Only use Emergency stops in Emergency situations or during safety drills.

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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
altered to suit the conditions and set-up of each particular machine.
The 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 fine and eliminate all on-site risks associated with this
machine. Never alter any equipment or parts of any equipment which may effect safety without consulting and
gaining permission from TESAB ENGINEERING LTD.

(i). Before performing any maintenance of any kind the "Lock Out" procedure MUST be carried out, see section
2.5.
(ii). Ensure that all moving parts of the machine have come to a stand still before attempting any repairs or
maintenance.
(iii). Ensure that at least two people are present when maintenance or service work is being carried out.
(iv). 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.
(v). Ensure that the person carrying out the service or repair has a good understanding of the job they are to
undertake.
(vi). 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.
(vii). Repairs, maintenance or adjustments to the machine must never be performed while it is running
especially the lubrication of bearings and moving parts etc.
(viii). 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.
(ix). Only the walkways and platforms provided should be used to access the Plant. 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.
(x). Never work under unsupported equipment.
(xi). All damaged, missing or dirty safety signs that cannot be read should be cleaned or replaced.
(xii). Even though the machine has been designed to operate at low temperatures some parts may reach high
temperatures in hot places or on warm days. Always wait until all the equipment has cooled before working on
the machine especially around the engine exhaust.
(xiii). Always observe the adjusting, maintenance and intervals set out in these operating instructions, except
where warning light or indicator calls for immediate action or adverse conditions require more frequent
servicing.
(xiv). Avoid smoking whilst refuelling or in the refuelling area.
(xv). Dust found on the machine or produced during operation should be removed by extraction not blowing.
(xvi). During or after repair or maintenance inspect all other parts of the machine for damage or wear.
(xvii). 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.
(xviii). Before testing the machine ensure that all tools, parts and components have been removed from the
Plant and walkways. Ensure that know one is on or near the machine before Testing.
(ixx). Test the machine to ensure that it is functioning properly. If problems occur during testing shut down the
Plant and carry out all the safety procedures listed above before trying to rectify the problem.
(xx). After testing shut down the machine and check for loose or missing bolts, washers or nuts, etc.
(xxi). After operating the machine for a few hours shut down and check for any further problems.
(xxii). 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.

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2.10.1 SAFETY WHEN WORKING WITH HYDRAULICS.

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

(ii). Relieve all pressure in hydraulic systems before any lines, fittings or related items are disconnected or
removed.

(iii). 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.

(iv). Always practice extreme cleanliness when servicing hydraulic components.

(v). Hydraulic fluid under pressure is very dangerous, it can penetrate the skin causing serious injury.

(vi). If fluid is injected under the skin it must be surgically removed immediately.

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

2.10.2 SAFETY WHEN WORKING WITH BATTERIES.

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

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

(iii). 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.

(i). Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used
with the TESAB machine include oil, fuel, coolant, filters and batteries. Always dispose of waste in a safe and
environmentally manner. Seek advice from your local government environmental department regarding the
safe disposal of waste products.

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

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

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

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 SECTION 3.0

TRACKING INSTRUCTIONS

Before attempting to move this machine you must

! WARNING have read and understand all the safety

instructions listed in Section 2.0

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3.1 TRACKING INTRODUCTION.

Manoeuvring of this machine can be carried out using

either the Doglead Handset Controls, as shown at (A). (A). (B)
or using the Radio Remote Control, as shown at (B), if
fitted.

You must make yourself completely familiar with all the

control devices before attempting to manoeuvre this
machine.

See section 2.6 to view the locations of the Emergency

Stops on this machine.

(C) (D).

(E). (F). (G).

No. Description.

(C). Tracks Control Valves

(D). Starter Panel
(E). Remote Control Receiver Box
(F). Electrical Isolator
(G). Doglead Connection

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3.2 ENGINE START UP PROCEDURE BEFORE TRACKING.

IMPORTANT: Before starting the Engine on this Machine you must

consult the Caterpillar Engine Operation & Maintenance Manual
supplied wrong with this Machine.

WARNING: Only start this machine after all the safety procedures in
section 2.0 of this manual have been carried out.
(A)
(i). The engine starter panel is located on the engine canopy and can
be accessed via the engine access platform at the front of the
machine.

(ii). To access the platform, unclip the fasteners at each side of the
steps, as shown at (A) and fold down into position. It is important, for (B)
safety reasons, that when these steps have been unfolded they are
locked into position using the clamps at both sides. Before moving
the machine ensure that all access steps are folded back up again
and are secured using the fasteners.

(iii). Ensure that the Track Control Levers, as shown at (B). are in the
"TRACK" position. Both control levers MUST be either in the
"TRACK" or "CRUSH" position at any given time. Do not attempt to
move these levers while the Engine is running.

(iv). Check that all other levers, switches and buttons are in the
neutral position. (C)

(v). Turn the ignition key, located on the front of the Starter Panel, to
the "On" position, as shown at (C).

(vi). Check that the Emergency Stop lamp, as shown at (D), is

illuminated. If it's not then this indicates than an Emergency Stop has
been pressed. Check all Emergency stops including the Doglead
Handset.

(vii). Turn the ignition key to the "Crank" position, as shown at (E).
At this point the "Safety" siren will sound. Hold the ignition key in this
position until the engine cranks and starts. Note, for safety reasons
there is a 7 second delay before the engine will start.

(viii). Immediately release the ignition key once the engine has
started.
(D)
IMPORTANT: 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.

(ix). To switch off the Engine reduce the revs to 'Idle' and turn the (E).
ignition key to the vertical 'OFF' position.

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 Before operating this Machine you Must have read

! WARNING and understand the safety instructions given in

section 2.0 of this manual.

3.3 TRACKING THE MACHINE USING THE DOGLEAD.

IMPORTANT: This machine will only track if the Product Conveyor bottom
end section is in the raised transport position.

(i). Ensure that the Doglead is connected to the machine as shown at (A).

(ii). Ensure that the controls on the Doglead Handset are in the neutral
position and that they are operating freely.
(A)
(iii). Check that the Track Control Levers are in the "TRACK" position, as
shown at (B).

WARNING: Do NOT activate these levers while the Engine is running.

(iv). Start the Engine as per the Engine start up procedure in section 3.2.

(v). Choose your Engine speed. The Machine can be tracked at either idle or
full revs.

WARNING: In confined spaces always Track the Machine on low Engine (B)
revs.

(vi). Switch the Tracks operation switch, as shown at (D), to the "Doglead"
position.

(vii). The Machine can now be tracked using the controls on the doglead
handset as shown at (E).

WARNING: When moving the machine use the whole length of the Doglead
to stay as far back from the machine as possible. Constantly check all sides
of the machine for clearance.

(C)
(E).
(D)

1 3

2 4 1 3

2 4

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 Before operating this Machine you Must have read

! WARNING and understand the safety instructions given in

section 2.0 of this manual.

3.4 TRACKING THE MACHINE USING THE REMOTE CONTROL.

IMPORTANT: This machine will only track if the Product Conveyor bottom (A).
end section is in the raised transport position.

(i). Check that the Track Control Levers are in the "TRACK" position, as
shown at (A). WARNING: Do NOT activate these levers while the Engine is
running.

(ii). Start the engine as per the engine start up procedure in section 3.2.

(iii). Choose your Engine speed. The Machine can be tracked at either idle
or full revs.

WARNING: In confined spaces always Track the Machine on low Engine

revs.

(iv). Activate the Remote Control by pulling up the red button, as shown at
(B).
(H).
(C).
(v). Insert the key into the Remote Control handset and turn it to the "On"
position, as shown at (D).

NOTE: At this point the LED shown at (G), should flash red for a few
seconds and then turn to a constant green. If it continues to flash red this
indicates the battery is low. Ensure that the battery is fully charged before
operating the Remote Control. There is also a seven second delay on the
handset before the tracks can operate.

(vi). Switch the tracks operation switch, as shown at (C), to the "Remote
Control" position.

(vii). The machine can now be tracked using the controls on the Remote
Control handset as shown at (F).

WARNING: When tracking stay as far back from the machine as possible.
Constantly check all sides of the machine for clearance.

(F). (G). (H).

(D).
1 3 1 3
(E).

2 4 2 4

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 SECTION 4.0

INSTALLATION
Before attempting to Set-Up this machine you must

! WARNING have read and understand all the safety

instructions listed in Section 2.0

4.1 INSTALLATION OVERVIEW.

(i). This section will guide you through the installation procedures for this machine, ensure that you carry 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 packing arrangements. For the purposes of this manual it will be considered that the
machine is delivered in its most unassembled configuration, therefore, some of the installation sections may not
be applicable. If this is the case ignore that particular instruction/section and proceed to next section.

(ii). 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 Section 2: Safety.

(iii). The installation of this machine MUST be carried out by reliable, authorised personnel only. At least two
people must be present during installation and statutory minimum age limits must be observed.

(iv). TESAB ENGINEERING LTD. strongly recommend that the installation of this machine is carried out by a
recommended TESAB dealer and/or service agent.

4.2 INSTALLATION PROCEDURE.

The following operations 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.

(i). Unload the machine from the transportation lorry.

(ii). Fit the Exhaust and Pre-Cleaner.
(iii). Start the Engine in order to operate the Rams.
(iv). Raise the Product Conveyor Top End into the working position.
(v). Lower the Product Conveyor Bottom End into the working position.
(vi). Raise up the Hopper Cribs into the working position and fit the cross beams.
(vii). Lower the Dirt Conveyor (if a Short Conveyor) into the working position.
(viii). Fit the Dirt Conveyor (if a Long Conveyor) into the working position.
(ix). Fit the extra/misc. items to the machine.
(x). Adjust the setting for crushing.

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4.3 UNLOADING THE MACHINE.

(i). Unloading the machine from the transport trailer must be carried out by experienced personnel only.

(ii). For Tracking procedures refer to section 3.0 of this manual.

4.4 ON-SITE POSITIONING.

(i). Before the machine is positioned ensure that the site surface is level and has spacious surroundings.

(ii). The ground must be solid and be capable of carrying the weight of the machine.

(iii). Manoeuvre the machine into the desired location ensuring that it is left in a level position. Use a spirit level
to ensure that the machine is level along and across the chassis, as shown at (A).

(iv). Once in position switch off the engine and remove the Doglead from the machine.

(A)

4.5 FITTING THE EXHAUST AND AIR BREATHER.

(A).
WARNING: Do not fit the exhaust or Pre-Cleaner while the
Engine is running. Ensure that the Engine has adequately
cooled do wn before touching the Exhaust chamber.

(i). The Pre-Cleaner and Exhaust must be fitted as soon as

possible before the Engine is run for very long.

(ii). Remove the transport covers from the Air Breather

housing and Exhaust chamber.

(iii). Fit the Pre-Cleaner as shown at (A).

(iv). Fit the Exhaust as shown at (B).

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

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4.6 ENGINE START UP PROCEDURE BEFORE SET-UP.

IMPORTANT: Before starting the Engine on this Machine you must

consult the Caterpillar Engine Operation & Maintenance Manual
supplied wrong with this Machine.

WARNING: Only start this machine after all the safety procedures in
section 2.0 of this manual have been carried out.
(A)
(i). The engine starter panel is located on the engine canopy and can
be accessed via the engine access platform at the front of the
machine.

(ii). To access the platform, unclip the fasteners at each side of the
steps, as shown at (A) and fold down into position. It is important, for (B)
safety reasons, that when these steps have been unfolded they are
locked into position using the clamps at both sides. Before moving
the machine ensure that all access steps are folded back up again
and are secured using the fasteners.

(iii). Ensure that the Track Control Levers, as shown at (C). are in the
"CRUSH" position. Both control levers MUST be either in the
"TRACK" or "CRUSH" position at any given time. Do not attempt to
move these levers while the Engine is running.

(iv). Check that all other levers, switches and buttons are in the
neutral position. (C)

(v). Turn the ignition key, located on the front of the Starter Panel, to
the "On" position, as shown at (C).

(vi). Check that the Emergency Stop lamp, as shown at (D), is

illuminated. If it's not then this indicates than an Emergency Stop has
been pressed. Check all Emergency stops including the Doglead
Handset.

(vii). Turn the ignition key to the "Crank" position, as shown at (E).
At this point the "Safety" siren will sound. Hold the ignition key in this
position until the engine cranks and starts. Note, for safety reasons
there is a 7 second delay before the engine will start.

(viii). Immediately release the ignition key once the engine has
started.
(D)
IMPORTANT: 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.

(ix). To switch off the Engine reduce the revs to 'Idle' and turn the (E).
ignition key to the vertical 'OFF' position.

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4.7 RAISING THE PRODUCT CONVEYOR HEAD SECTION
TO THE WORKING POSITION.

(A)
(i). With the Engine running increase the revs to approximately
1200rpm using the throttle switch on the starter panel.

(ii). Remove the transport brackets, as shown at (A) and place

them in the toolbox.

(iii). Using the control bank lever labelled "DISCHARGE

CONVEYOR FOLDING" raise the conveyor up into the
working position so that the folding heels line up with each (B)
other.

(iv). Fit the mounting pins, supplied along with the machine,
through the folding heels to secure the conveyor in the
working position, as shown at (C).

(v). Attach the Wire Rope Supports to the Conveyor, as shown

at (D).

(vi). Tension the Wire Ropes by rotating the bottle screw, as

(C)
shown at (E). Only apply enough tension to support the
conveyor not to lift it up.

(E). (D)

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4.8 LOWERING THE PRODUCT CONVEYOR TAIL (A)
SECTION INTO THE WORKING POSITION.

WARNING: Never operate the Crusher with the Product

Conveyor tail section in the transport position.

(i). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(ii). Locate the control bank lever at the rear of the chassis
labelled "DISCHARGE CONVEYOR FOLDING", as shown at
(A).

(iii). Raise the conveyor up slightly to relieve the pressure on

the carrying chains. (B)

(iv). Remove the transport straps and chains.

(v). Ensure that the area is clear underneath Conveyor.

(vi). Lower the conveyor down through the full stroke of the (C)
ram to get it into the working position.

(vii). For security re-attach the mtg. chains.

IMPORTANT: This machine cannot be moved when the

Product Conveyor is in the working position.

4.8 FITTING THE FEED IN CHUTE LID.

(i). Fit the Feed in Chute Lid, as shown at (C).

(ii). Ensure that 'R' Pins are fitted to the locating pins, as
shown at (D). (D)

4.9 FITTING THE VIEWING PLATFORM HANDRAIL AND

SPRAY BARS.

(i). Remove all the transport straps from the handrails and fold
up into position, as shown at (E). (E).

(ii). Using the bolts provided with the machine, securely fasten
the handrails together.

(iii). Fit the spray bars as shown at (F) & (G).

(G). (F).

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4.10 RAISING THE HOPPER CRIBS INTO THE WORKING
POSITION.

WARNING: Ensure that all items and tie-down straps have

been removed from the Feeder before raising the Cribs. (A)

(i). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(ii). Locate the three control bank levers labelled "CRIB

FOLDING", as shown at (A).

(iii). Raise the two side cribs up into the working position.

(iv). Raise the rear crib up into the working position so that the
mtg. flats meet, as shown at (B). (B)

(v). Fit the mounting bolts and large flats, supplied along with
the machine, through the mtg. heels and tighten to secure the
Cribs into the working position.

(vi). Fit the Crib Leg Locking Flats to each of the 4 Crib Legs,
as shown at (C).

(vii). Fit the 2 Crib-Cross Beams, as shown at (D).

(C)

(D)

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4.11 LOWERING THE SHORT DIRT CONVEYOR INTO THE
WORKING POSITION.

(i). With the Engine running increase the revs to approximately (A)
1200rpm using the throttle switch on the starter panel.

(ii). Locate the control bank lever at the rear of the chassis
labelled "DIRT CONVEYOR FOLDING", as shown at (A).

(iii). Raise the conveyor up slightly to relieve the pressure on

the transport brackets..

(iv). Remove the transport brackets at the conveyor pivot point.

(B)
(v). Lower the conveyor into the working position.

(vi). Fit the mounting pins, supplied along with the machine,
through the folding heels to secure the conveyor in the working
position, as shown at (C).

(vii). Attach the Wire Rope Supports to the Conveyor, as shown

at (D).

(viii). Tension the Wire Ropes by rotating the bottle screw, as

shown at (E). Only apply enough tension to support the
conveyor not to lift it up. (C).

(ix). Fit the Drive Drum Scraper as shown at (B).

(E). (D).

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4.12 FITTING THE LONG DIRT CONVEYOR INTO THE
WORKING POSITION.

If the machine has been purchased with the "Long Dirt

Conveyor" option the machine will arrive without the
conveyor fitted. The Conveyor will therefore have to be
fitted into place before operation.

(i). Using appropriately rated lifting gear lift the Conveyor

into the machine, as shown at (F), taking great care not
to collide with the Fines chute.

(ii). Align the mounting heels as shown at (A) and (C). (A)

(iii). Fit and securely tighten the mounting bolts.

(B)
(iv). Match and fit the Hydraulic hoses and Grease pipes,
as shown at (B).

(v). Attach the Wire Rope Supports to the Conveyor, as

shown at (E).

(viii). Tension the Wire Ropes by rotating the bottle

screw, as shown at (D). Only apply enough tension to
support the conveyor not to lift it up. (C)

(ix). Ensure that all guards are securely fitted to the

Conveyor.

(E). (D).

(F).

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4.13 ADJUSTING THE DISCHARGE OPENING ON THE CRUSHER.

The size of the material being discharged from the Crusher is dependant
on the space between the Fixed and Swing Jaws in the Crusher. This
space can be increased or decreased using the Hydraulically operated
Wedge and Spring system. Moving the wedges in or out from behind the
(A)
Swing Jaw allows it to move closer to or further away from the Fixed Jaw.
The Jaw Spring Tension is controlled hydraulically through an independent
control system, as shown at (D).

IMPORTANT: The Crusher must not be adjusted while it is operating!

(i). Before attempting to adjust the Crusher you must familiarise yourself
(B)
with the Adjustment System.

- The Adjuster Spring and Ram are shown at (A).

- The Adjuster Wedge Ram is shown at (B). This Ram is on the
drive side of the Crusher.
- The Release Wedge Ram is shown at (C). This Ram is on the non-
drive side of the Crusher.
- The Spring Tension Control system, as shown at (F), is located on
the side of the Crusher. (C)

(ii). Ensure that both the Track Control Levers are in the "CRUSH"
position.

(ii). Connect the Crusher Adjustment Doglead, as shown at (D).

(D)
(iii). Turn the ignition to the on position but do not start the Engine.

(iv). Activate the Crusher Adjustment controls by pressing the "Crusher

Adjustment" button located on the Main Control Panel, as shown at (E).

(v). The Spring Tension must be released before the Crusher can be
adjusted. The tension is released by turning and holding the control
switch, as shown at (G), to the number "1" position. At this point the pump
will activate and the tensioning rams will open.

(vi). The crusher can now be adjusted. For information on adjusting the
crusher turn to the next page.

(vii). After the crusher has been adjusted turn the control switch back to
position "2" and the Springs will automatically tension.

(E).
(G)

(F).

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4.14 ADJUSTING THE DISCHARGE OPENING CONTINUED.

IMPORTANT: Before adjusting the crusher ensure that the tension has been (A)
released off the Adjuster Springs. To do this refer to the procedures on the
previous page.

4.14.1 DECREASING THE SPACE BETWEEN THE JAWS.

(i). To decrease the space between the Jaws the doglead controls, as shown
at (A) must be used.

(ii). Check that the Release Wedge is in the fully in position.

(iii). Move the Adjuster Wedge inwards until the space between the Jaws has
reached the desired distance.

(iv). After the crusher has been adjusted turn the control switch, located inside
the control box, back to position "2" and the Springs will automatically tension.

4.14.2 INCREASING THE SPACE BETWEEN THE JAWS.

(i). To increase the space between the Jaws the doglead controls, as shown
at (A) must be used.

(ii). Check that the Release Wedge is in the fully in position.

(iii). Move the Adjuster Wedge outwards until the space between the Jaws
has reached the desired distance.

(iv). After the crusher has been adjusted turn the control switch, located inside
the control box, back to position "2" and the Springs will automatically tension.

Note: In the unlikely situation that you want to open the jaws further than the
adjuster ram will allow, you can move the release wedge outwards to achieve
the extra distance. However, the release wedge must not be moved out
further than half way!

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 SECTION 5.0

OPERATION
Before attempting to operate this machine you

! WARNING must have read and understand all the safety

instructions listed in Section 2.0

5.1 OPERATION OVERVIEW.

All crushing 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.

5.2 PRE-OPERATION CHECK LIST.

Before operation ensure that:

(i). No people, objects or tools etc. are on or near the machine especially on the Feeders, Discharge Conveyor,
Crusher and Dirt Conveyor.

(ii). All guards and safety devices are fitted.

(iii). All oil and water levels have been checked and are adequate.

(iv). All required maintenance has been carried out and the machine is in good working order.

(v). That all down-stream machines have been started and are running correctly.

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5.3 ENGINE START UP PROCEDURE BEFORE OPERATION.

IMPORTANT: Before starting the Engine on this Machine you must

consult the Caterpillar Engine Operation & Maintenance Manual
supplied wrong with this Machine.

WARNING: Only start this machine after all the safety procedures in
section 2.0 of this manual have been carried out. (A)

(i). The Engine starter panel is located on the engine canopy and can
be accessed via the engine access platform at the front of the
machine.

(ii). To access the platform, unclip the fasteners at each side of the
steps, as shown at (A) and fold down into position. It is important, for (B)
safety reasons, that when these steps have been unfolded they are
locked into position using the clamps at both sides. Before moving
the machine ensure that all access steps are folded back up again
and are secured using the fasteners.

(iii). Ensure that the Track Control Levers, as shown at (C). are in the
"CRUSH" position. Both control levers MUST be either in the
"TRACK" or "CRUSH" position at any given time. Do not attempt to
move these levers while the Engine is running.

(iv). Check that all other levers, switches and buttons are in the
(C)
neutral position.

(v). Turn the ignition key, located on the front of the Starter Panel, to
the "On" position, as shown at (C).

(vi). Check that the Emergency Stop lamp, as shown at (D), is

illuminated. If it's not then this indicates than an Emergency Stop has
been pressed. Check all Emergency stops including the Doglead
Handset.

(vii). Turn the ignition key to the "Crank" position, as shown at (E).
At this point the "Safety" siren will sound. Hold the ignition key in this
position until the engine cranks and starts. Note, for safety reasons
there is a 7 second delay before the engine will start.

(viii). Immediately release the ignition key once the engine has
started.
(D)

IMPORTANT: 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.
(E).
(ix). To switch off the Engine reduce the revs to 'Idle' and turn the
ignition key to the vertical 'OFF' position.

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5.4 MACHINE START UP SEQUENCE.

In order to prevent jamming and/or damage to the machine the (A).

starting of the various components must be carried out in a detailed (B).
sequence. (C).
(D).
Ensure that the Track Control Levers are in the "CRUSH" position. (E).
(F).
(i). Start the Engine as per the "Engine Start-up" procedure given in
section 5.3.

(ii). Increase the Engine Revs to 1100 rpm.

(iii). Start the Discharge/Product Conveyor by pressing the

"Product Conveyor" button, as shown at (A).

NOTE. When any of the buttons, as shown from (A) to (F), are
pressed they will illuminate.

(iv). Start the Clutch and Crusher by pressing the "Clutch" button, as shown at (B).

(v). Increase the Engine Revs to 1800 rpm.

IMPORTANT. Ensure that the Green Clutch light remains illuminated to indicate that the Clutch is "On"

(vi). Start the Scalping Feeder by the pressing the "Scalping Feeder Button, as shown at (D).

(vii). Start the Primary Feeder by pressing the "Primary Feeder" button, as shown at (C).

(viii). Start the Dirt/Fines Conveyor by pressing the "Dirt Conveyor" button as, shown at (E).

(ix). If fitted, start the magnet by pressing the "Magnet" button, as shown at (F).

5.5 MACHINE SHUT DOWN SEQUENCE.

WARNING: Only stop this machine after all the material has been discharged through the Crusher and off the
Conveyor Belts.

(i). Stop the Primary Feeder by pressing the "Primary Feeder" button, as shown at (C).

(ii). Stop the Scalping Feeder by the pressing the "Scalping Feeder Button, as shown at (D).

(iii). Stop the Dirt/Fines Conveyor by pressing the "Dirt Conveyor" button as, shown at (E).

(iv). Stop the Discharge/Product Conveyor by pressing the "Product Conveyor" button, as shown at (A).

(v). If fitted, stop the magnet by pressing the "Magnet" button, as shown at (F).

(vi). Decrease the Engine Revs to idle speed.

(vii). Stop the Clutch and Crusher by pressing the "Clutch" button, as shown at (B).

(viii). Shut down the Engine.

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5.6 OPERATING THE FEEDER USING THE REMOTE
CONTROL.

A remote control facility has been fitted to this machine to

provide remote operation of the Scalping and Primary Feeders. (A).

The feeders can be operated using either the Remote Control

provided or the "Start/Stop" button, as shown at (A).

5.7 VARIABLE SPEED CONTROL.

In order to regulate the speed of the feed material into the (B).
Crusher during operation, a Variable Speed Control Valve, as
shown at (B), has been fitted to the machine. This valve
controls the speed at which the Primary Feeder feeds the
Scalping Feeder. The speed can be increased or decreased by
turning the Dial on the front of the Valve.

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 SECTION 6.0

MAINTENANCE

Before attempting maintenance on this machine

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

6.1 GENERAL MAINTENANCE INFORMATION.

(i). 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 quarry machine
environment. If this Machine is to be operated for long periods of time in extreme conditions, either climatic (-
15oC to 33oC) or extremely dusty, these maintenance guidelines and schedule must be altered to suit. If this
arises you must consult your local Tesab dealer or Tesab Engineering technical/service department.

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

(iii). 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.

(iv). The reliability and service life of this machine depends on regular and correct maintenance.

(v). ‘Good housekeeping pays untold dividends in increased production and extended plant life!’

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6.2 DAILY MAINTENANCE.

The purpose of daily maintenance is to discover minor irregularities on your machine before they develop into
major problems.

(i). Check the machine for loose parts and check that all nuts and bolts are secure.

(ii). Check all Oil levels and top up if necessary.

(iii). Ensure that all safety systems are intact i.e. all the wires to sensors are intact.

(iv). Check the Fuel level in the Diesel Tank.

(v). Check all the hydraulic motors, pumps, cylinders and hoses for oil leaks and tighten if necessary.

(vi). Ensure that all the Troughing and return rollers are free running and clear of obstructions.

(vii). Check for material build up especially around the Feeder and Conveyor Rollers etc.

(viii). Check Conveyor Belts for alignment and adjust if necessary.

(ix). Check the Air Filter for clogging and clean if necessary.

(x). Visually inspect the Conveyor Belting for tears etc.

(xi). If a Manual Clutch is fitted ensure that the daily lubrication schedule is carried out.

(xii). Carry out all other lubrication as per the daily schedule.

(xiii). Check and ensure that the Radiator and Oil Coolers Radiator Packs are adequately clean.

(xiv). Drain any water from the Fuel Separator.

(xv). Inspect the Engine Cooling system hoses for cracks and loose clamps.

(xvi). Ensure that the level of Coolant in the Engine Coolant System is correct.

(xvii). Check all drive belts including the Fan Drive Belts, for wear, cracks or other damage.

When all checks have been made, close and fasten all the guards before operating the machine. At the end of
the day carefully clean the machine and the ground immediately around the machine, of all the material and
debris build up. Good housekeeping pays untold dividends in increased production and extended plant life.

6.3 DAILY CHECKS DURING OPERATION.

IMPORTANT: Never try to adjust any setting while the machine is running or put yourself in any form of danger
while carrying out the checks.

(i). Regularly check the quality of the output material from the machine. A dramatic change in material sixe
may indicate excessive crusher wear.

(ii). Check for oil and water leaks.

(iii). Check for excessive spillage or build up of material around the machine.

(iv). Check the alignment of the Conveyor Belts.

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6.4 WEEKLY MAINTENANCE.

In addition to the carrying out any daily maintenance the following weekly maintenance should be carried out
once per week:

(i). Grease all the bearings as per the lubrication schedule using the correct lubricant.

(ii). Check all skirting rubbers i.e. that they bear down lightly on the conveyor belt.

(iii). Check the acid level in the batteries.

(iv). Check the gauges on the Hydraulic Oil Filters.

(v). Inspect and adjust all belt scrapper blades and/or renew if necessary.

(vi). Check and empty the water trap on the Engine if necessary.

(vii). Check the clutch setting, if a manual clutch is fitted, and adjust if necessary.

(viii). Check the quality and tension of the Crusher ‘V’ belts.

(ix). Check the oil level in the Product Conveyor Reduction Gear Unit.

(x). Check all Springs on the Machine.

6.5 SIX MONTHLY MAINTENANCE.

In addition to the carrying out any daily and weekly maintenance the following maintenance schedule should be
carried out once every six months:

(i). Drain and refill the Hydraulic oil system with the correct Hydraulic oil. Refer to the recommended lubricants
for the correct Hydraulic oils to suit various ambient temperature conditions.

(ii). Drain and refill the Feeder oil bath with the correct gear oil. Refer to the recommended lubricants section
for the correct oil type.

(iii). Check the alignment of the machine with a precision spirit level.

(iv). If an Automatic Greasing system is fitted remove all the grease points at the bearings and manually
operate the greasing system to ensure that grease is being pumped to all the bearings.

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6.6 LUBRICATION POINTS - See next page for details. Note: These Grease point will not exist if an Automatic Greasing System is fitted to the machine.

(A). (B).

(C). (D). (E). (F). (G) (H). (I). (J). (K).(L). (M). (N).(O). (P). (Q) (R).

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6.7 LUBRICATION SCHEDULE

On this 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 should be followed. Grease points have been brought out to
easily accessible central locations as shown on the previous page.

NOTE: 4g (grams) of grease is the equivalent of three shots/pumps from the grease gun.

Grease No. of
Description Frequency Qty.
Point Bearings

A Dirt/Fines Conveyor Drive Drum Bearings 2 50 Hours 4g

B Dirt/Fines Conveyor Idle Drum Bearings 2 50 Hours 4g
C Primary Feeder Bearing - Rear (Left Hand Side) 1 50 Hours 4g
D Primary Feeder Bearing - Front (Left Hand Side) 1 50 Hours 4g
E Scalping Feeder Bearing (Left Hand Side) 1 50 Hours 4g
F Discharge/Product Conveyor Idle Drum Bearing (Left Hand Side) 1 50 Hours 4g
G Discharge/Product Conveyor Idle Drum Bearing (Right Hand Side) 1 50 Hours 4g
H Scalping Feeder Bearing (Right Hand Side) 1 50 Hours 4g
I Primary Feeder Bearing - Front (Right Hand Side) 1 50 Hours 4g
J Primary Feeder Bearing - Rear (Right Hand Side) 1 50 Hours 4g
K Crusher Bearing (Right Hand Side) 1 8 Hours 15g
L Crusher Bearing (Right Hand Side) 1 8 Hours 15g
M Crusher Bearing (Right Hand Side) 1 8 Hours 15g
N Crusher Bearing (Left Hand Side) 1 8 Hours 15g
O Crusher Bearing (Left Hand Side) 1 8 Hours 15g
P Crusher Bearing (Left Hand Side) 1 8 Hours 15g
Q Discharge/Product Conveyor Drive Drum Bearing (Left Hand Side) 1 50 Hours 4g
R Discharge/Product Conveyor Drive Drum Bearing (Right Hand Side) 1 50 Hours 4g

6.8 MANUAL CLUTCH LUBRICATION.

(A).
If the machine is fitted with a Manual Clutch the following
lubrication schedule must be observed: (B).

(i). Main Bearings, as shown at (A). 4g every 50 hours or weekly.

(ii). Throw out Collar, as shown at (B). 4g every 10 hours or (C).

Daily.

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

NOTE: There are grease nipples on both left and right hand side
of the Lever Shaft.

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6.9 RECOMMENDED LUBRICANTS

(i). ENGINE OIL:

CATERPILLAR DEO 3E - 9840 SAE 15W - 40

(ii). RADIATOR COOLANT:

CATERPILLAR EXTENDED LIFE COOLANT 205 - 6613V

(iii). HYDRAULIC OIL:

ESSO NUTO H 46
BP ENERGOL HLP 46
MOBIL DTE 25
SHELL TELLUS 46
TEXACO RANDO 46
TOTAL AZOLLA 46

(iv). GENERAL PURPOSE BEARING GREASE:

ESSO BECON EP2

BP ENERGREASE LS-EP2
MOBIL MOBILUX EP2
SHELL ALVANIA EP2
TEXACO MOLYTEX EP2
TOTAL MULTIS EP"

(v). PRODUCT CONVEYOR REDUCTION GEAR OIL:

MAXOL INDUSOL 150

(vi). FEEDER OIL BATCH OIL:

MAXOL INDUSOL 150

(vii). HYDRAULIC CLUTCH OIL:

ESSO NUTO H 32
BP ENERGOL HLP 32
MOBIL DTE 24
SHELL TELLUS 32
TEXACO RANDO HD 32
TOTAL AZOLLA ZS 32

(viii). TRACKS TENSIONING GREASE:

ESSO BECON EP2

BP ENERGREASE LS-EP2
MOBIL MOBILUX EP2
SHELL ALVANIA EP2
TEXACO MOLYTEX EP2
TOTAL MULTIS EP"

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6.10 AUTOMATIC LUBRICATION.

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 (D).
regular intervals.

The Autolube system will automatically pump grease to all the (E).
points on the machine, as shown in section ???. The system (A).
operates according to cycles of "pause" and "operating"
(B).
sequences. During the operating times the pump dispenses
(F).
lubricant to the points for a period of time.
(C).
6.10.1 AUTOLUBE OVERVIEW.

(A). Access point to fill the Reservoir using a special grease gun
fitting.

(B). Access to the P.C.B board and Rotary time switches.

(C). Connection Plug 1A1 (Power Supply to Pump). (G).

(D). Grease Reservoir.

(E). Pressure Relief Valve.

(F). Connection Plug 2A1 (To Push Button).

- The Quicklube system is designed for the delivery of greases up to NLGI grade 2 at temperatures from -25°C
to 70°C.

- It can be used at low temperatures down to -40°C (lubricants must still be pumpable at these temperatures).

6.10.2 AUTOLUBE MAINTENANCE.

(i). The Autolube system is generally maintenance free other than to refill the lubricant reservoir in good time
with clean lubricant.

(ii). Regularly check that lubricant is reaching all the lubrication points.

(iii). Check that the high-pressure grease hoses have not been damaged or frayed. If necessary replace them.

(iv). 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 value 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.

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

6.10.4 FILLING THE GREASE RESERVOIR.

(i). 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
directly to the fitting, as shown at (B).

(ii). Do not fill past the “max” mark on the reservoir.

(iii). The grease used must be free from impurities and must not be
liable to change its consistency in the course of time.
(C).
(iv). If the reservoir has been completely emptied, the pump may
require 10 minutes manual operation before it will operate to full
capacity.

6.10.5 TEST RUN / MANUAL LUBRICATION.

(i). 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.
(D).
(ii). To carry out a lubrication cycle press the Autolube button on the
main engine control panel, as shown at (C). Hold the button in for a
minimum of 5 seconds until the green lamp on the button lights.

(iii). Then check that the indicator pin on the main control valve as
shown at (D), is moving in and out.

(iv). 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.

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6.10.6 AUTOLUBE FAULT FINDING.

(i). Motor does run:

- Voltage supply interrupted:

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

- Electric motor defective:

- Check voltage supply to the motor. If necessary replace the motor.

(ii). 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 take10 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 or clogged.

- Replace pump element.

(iii). Lubricant is not being supplied to one lubrication point:

- Burst hose leading to that point.

- Find burst and repair.

(iv). Lubricant is escaping from Pressure Relief Valve:

- Blockage in one or more hose lines.

- Find blockage and clear.

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6.11 HYDRAULIC CLUTCH (If Fitted). (A). (B). (C). (D).

The 'Hydraulic Power Take-Off' (Clutch) in conjunction with the

Diesel Engine is the central part of the machine. Correct
maintenance of the PTO will increase its effectiveness and
prolong its life-span.
(E).
The following is a short outline of the duties that the owner and
(F).
operator must perform for satisfactory service from the Clutch.

6.11.1 HYDRAULIC CLUTCH MAINTENANCE. (G).

(i). Change the oil in the clutch after the first 100 working hours (H).
and every 4000 working hours thereafter.

(ii). The correct oil level is at the blue line on the oil level
indicators, as shown at (I). (I).

(iii). After replacing the oil, run the pump with the electric
solenoid valve OFF to fully fill the heat exchanger.
(A). Hydraulic Oil Filler
(iv). Re-check the oil level again once this has been done and
top-up if necessary. (B). Temperature Gauge

(v). Change the oil filter cartridge (25 micron) when the pressure (C). Pressure Gauge
is at 1.7 bar over the rated value and/or the pressure switch is
on. (D). Rotating Seal (Not Shown)

(vi). In cases where there is considerable oil leakage from the (E). Elastic Coupling (Not Shown)
rotating seals then these should be replaced.
(F). Rotating Seal (NOT Shown)
(vii). In order to keep the Hydraulic Oil in the Clutch at an
effective operating temperature, an Oil Cooler has been fitted, as (G). Solenoid Valve
shown at (J). The Radiator pack on the Oil Cooler must be kept
clean. It can be cleaned by either washing it carefully by hand or (H). Oil Filter
by using air pressure. Never use water pressure as this can
damage the aluminium pack. (I). Oil Level Indicator

(viii). Check @ every 1000 hours that the pump drive chain has
not stretched beyond the correct length. For a 19 KPTO the max
length should be 1362mm. For a 21 KPTO the max length
should be 1556mm.

(ix). Periodically check the condition of the Elastic Coupling.

Recommended oils for the Hydraulic Clutch are:

ESSO NUTO H 32
BP ENERGOL HLP 32 (J).
MOBIL DTE 24
SHELL TELLUS 32
TEXACO RANDO HD 32
TOTAL AZOLLA ZS 32

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6.12 MANUAL CLUTCH (If Fitted).

The Manual Power Take Off (Clutch) in conjunction with your

Diesel Engine is the central part of your Machine.

Correct maintenance of your PTO will increase its effectiveness

and prolong its life-span.
(A).
The following is a short outline of the duties that the owner and
operator must perform for satisfactory service from the Power Take- (B).
Off.

6.12.1 MANUAL CLUTCH MAINTENANCE.

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.

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, clutch adjustments should be
checked regularly. As this is classed as a heavy duty application
which has frequent engagements and relatively long periods of slip
when “bumping-in”, it will require more frequent attention in relation
to 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 refer to the Clutch Manufacturers Operation &

Maintenance Manual supplied along with theis Machine.

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 Grease under pressure can cause serious injury.

! WARNING Never unscrew a Track Adjuster Valve by more than

a 1/2 turn, when the Track is under tension.

6.13 TRACK ADJUSTMENT.

After maintenance or over time the Track will become slack
and will have to be adjusted. The adjustment of the tracks
operates through a Tensioning Cylinder located inside the
Spring Tension Unit. When the Cylinder is filled with grease it
extends and pushes the Spring Tension unit, (B), and the
Idler, (A), forward. The grease is filled through the Track
Adjuster Grease Valve, (C). (A)
(B)
6.13.1 TRACK ADJUSTMENT SETTINGS.
In order to establish if the track requires tensioning move the (C)
machine a few metres forwards and backwards on level
ground. This allows the tracks to adopt their natural degree
of tension.
IMPORTANT: Do not slew the machine.
(E). 20mm
Using a straight edge and a measuring tape measure the
droop of the Track Group, as shown at (E). For this particular
Track Set the droop should not exceed 20mm.
NOTE: It is also important that the Track is not tensioned too
tightly as this places excessive loads on the Gearbox and
Idler bearings. It will also lead to accelerated wear and
premature failures.

6.13.2 INCREASING THE TRACK TENSION.

To increase the tension of the Track: (F).
(i). Remove the inspection cover on the side of the Track
Frame, as shown at (F).
(ii). Ensure that the Track Adjuster Valve, (H), is tight.
(iii). Attach the special grease gun connector, (G), to a (G).
grease gun and fit it onto the Track Adjuster Valve, (H).
(iv). Pump grease into the valve until the droop of the Track is
correct. Ensure that a goog quality EP2 All purpose grease is
used.
(v). Move the machine backwards and forwards a few times
more and then re-check the droop. Add more grease if
required.
(vi). Check for any escaping grease around the Tensioning
unit and finally close the inspection cover when finished.
(H).
6.13.3 RELEASING THE TRACK TENSION.
To the release the tension on the Tracks:
(i). Remove the inspection cover on the side of the Track
Frame, as shown at (F).
(ii). Loosen the Track adjuster valve, (H), by turning it one
half turn anticlockwise.
(iii). Grease should now escape slowly from the Track
Tensioning Cylinder and the Track should slacken.
(iv). If the Track fails to loosen apply a little pressure to the
Idler end of the Track to push the Idler group in.
(v). Replace the inspection cover when completed.

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6.13.4 TRACKS GEARBOX MAINTENANCE.

IMPORTANT: Cleanliness is essential when checking, filling or (A)

replacing oil in the gearbox. Gearbox operating life will be
dramatically shortened if the oil becomes contaminated. Only use
Oil Fill
new clean oil in clean containers and fillers.
Hole
6.13.5 Oil Change Periods.
Oil Drain
The oil should be drained from the gearboxes after the first 200 Hole
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.
(B)
The Gear Oil for the Transmital Bonfiglioli gearbox must conform to
the following specifications:- Oil Fill
Hole
MIL-L-2105 or API GL5 Grade 80W/90
Oil Drain
Examples of oil to these specifications are Texaco Geartex EP-B
Hole
80W/90 and Century Oils BOA 80W/90

All leading lubricating oil suppliers will offer equivalents.

6.13.6 CHECKING AND FILLING GEARBOX OIL.

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

(ii). Thoroughly clean around both plugs removing all potential contaminants.

(iii). Remove both plugs.

(iv). Fill the oil through the upper hole until it runs out of the lower hole.

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

6.13.7 DRAINING GEARBOX OIL.

(i). Move the machine to a level surface and bring the fill and drain Holes to the position shown at (B).

(ii). Thoroughly clean around both plugs removing all potential contaminants.

(iii). 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.

NOTE: Dispose of used oil safely and in a environmentally friendly manner.

(iv). 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.

(iv). Re-fill the oil as per the Oil fill procedure above.

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6.14 ENGINE MAINTENANCE.

The Diesel Engine is the heart of this Machine. All Engines are
put through rigorous test programmes by the manufacturers
before to being assembled into the Crushers. On completion
these Machines are again run and tested for several hours before (A).
dispatch.

In the interest of continued peak performance from this Machine

the Engine must be maintained and cared for with meticulous
attention. For all relevant maintenance information on this Engine
consult and adhere to the Caterpillar Operation & Maintenance
Manual supplied with this machine.

6.14.1 DAILY ENGINE MAINTENANCE.

(i). The Engine Water Separator, as shown at (A), must be

drained every day and the Filter must be changed at every
Engine Service. Consult the Caterpillar Operation & Maintenance
Manual for further details.

(ii). Check the level of Coolant in the Radiator. (B).

(iii). Check all the Fan Drive belts etc. for cracks and wear.

(iv). Check the Air Filter Service Indicator, as shown at (B).

Consult the Caterpillar Operation & Maintenance Manual for
further details.

(v). If the Air Filters require cleaning, access to the Filters can be
gained by removing the Housing cover, as shown at (C). Consult
the Caterpillar Operation & Maintenance Manual for further details
on cleaning/replacing the Air Filters.

(vi). Check the Engine Oil Level. Consult the Caterpillar

Operation & Maintenance Manual for further details.
(C).

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6.15 HYDRAULIC SYSTEM.

The hydraulic system in this Machine has been designed in (A).

order to be effective and resistant to climatic and operating
conditions. To ensure that the system remains effective it must
be properly maintained.

(i). Regularly check the level of the Hydraulic Oil on the Tank
indicator, as shown at (A). When topping up the oil ensure that
the correct oil type is used. Never mix different types of Oil.
(B).
(ii). The Hydraulic oil in the entire Hydraulic System should be
changed every 1500 hours.

(iii). The system should be regularly checked for leaks and if

found these should be repaired immediately.

(iv). In order to maintain the Hydraulic Oil at its peak

performance High Pressure Filters are used in the system. The
gauges on the Filters, as shown at (B), should be regularly
checked. If the Indicator on the Gauge is in the Red when the (C).
oil is at operating temperature, then the Filters must be
changed.
(D).
(v). The Hydraulic Tank is fitted with an Air Breather Filter, as
shown at (C). This Filter should be monitored regularly and
replaced when necessary.

(vi). 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.

(vii). In order to keep the Hydraulic Oil at an effective operating

temperature, the System has been fitted with an Oil Cooler, as
shown at (E). The Radiator pack on the Oil Cooler must be
kept clean. It can be cleaned by either washing it carefully by (E).
hand or by using air pressure. Never use water pressure as
this can damage the aluminium pack.

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6.16 PRODUCT CONVEYOR REDUCTION GEAR
MAINTENANCE.
(A).
(i). After a brief operating period of @ 100 hours, the oil in the
Reduction Gear Unit, as shown at (A), must be changed.
(Use Grade EP150 or equivalent See the Lubrications Chart).

(ii). Subsequent oil changes should be made every 2500 hours of

operation or, in any case, once per year.

(iii). Regularly check the oil level and top up if necessary.

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
(B).
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 (C).
Dealer for further details.
(D).
(iv). It is advisable to keep a record of the maintenance, including
oil top-ups, performed on the Gearbox.

6.16.1 CHANGING THE OIL IN THE REDUCTION GEAR.

(i). Change the oil in the Reduction Gear while it is warm so that it
is easier to drain.

WARNING: Take extra precautions with hot liquids.

(ii). Unscrew the drain plug, as shown at (D), and the breather
plug, as shown at (B), to help drain the oil from the Gearbox.

(iii). Check that there are no unusual metallic parts on the

magnetic plugs.

(iv). Once the oil has emptied, replace the drain plug.

(v). Wash the interior of the gear unit with a suitable cleaning liquid
that is recommended by the lubricant manufacturer.

(vi). Drain the cleaning liquid and then fill the Gearbox with the
appropriate gear oil.

(vii). Replace all bungs.

IMPORTANT: Do not mix different types of oil.

WARNING: The Reduction Gear 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 all those operations out of routine
maintenance which may have caused damage to people or parts.
When the need arises consult the manufacturers O & M manual.

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6.17 PRIMARY FEEDER MAINTENANCE

(i). While maintenance of the Primary Feeder is minimal the (A).

following maintenance is recommended.

(ii). The four bearings requires greasing every week (50 hours). (B).
See the lubrication schedule for further details.

IMPORTANT: Take care not to over-grease the bearings.

(C).
(iii). On the non-drive side of the vibrating mechanism there are (D).
gear wheels between the shafts to transfer the drive from one shaft
to the other. These gear wheels are lubricated using an “oil bath”
design. The gear oil should be changed every 6 months to maintain
efficient power transfer from one gear wheel to the other.

6.17.1 CHECKING THE OIL BATH OIL LEVEL.

(i). Remove the "Oil Level" plug, as shown at (B).

(ii). If the oil in the bath is not at this level then it needs to be topped-
up.

(iii). To top up remove the "Oil Fill" plug, as shown at (A) and add in
the correct grade of oil.

(iv). Continue to fill the oil until it comes out of the "Oil Level" hole.

(v). Replace all the plugs.

6.17.2 CHANGING THE OIL BATH OIL.

(i). Change the oil in the Feeder Oil Bath while it is warm so that it is
easier to drain.

WARNING: Take extra precautions with hot liquids.

(ii). Remove the "Oil Drain" plug, as shown at (D), and the "Oil Fill"
plug, as shown at (A), to help drain the oil from the bath.

(iii). Check that there are no unusual metallic parts on the plugs.

(iv). Once the oil has emptied, replace the "Oil Drain" plug.

(v). Wash the interior of the oil bath with a suitable cleaning liquid
that is recommended by the lubricant manufacturer.

(vi). Drain the cleaning liquid and then fill the Gearbox with the
appropriate gear oil as per the procedure outlined above.

IMPORTANT: Do not mix different types of oil.

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 Belt alignment corrections MUST not be carried

! WARNING out while the Conveyor Belts or any other parts of

the Plant are running.

6.18 BELT ALIGNMENT.

Oblique travel may cause fast deterioration of the belt. Some causes of oblique travel are shown below with
suggested solutions.

IMPORTANT: Re-alignment of the Belts must not be achieved by off-setting the Drive or Idle Drums. The
Drum Bearings on this Plant have no room for shaft miss-alignment, therefore, all Drums must remain perfectly
square to the Roller Bearings. Adjusting one side of a Drum more than another will cause shaft alignment-
alignment and therefore cause premature failure of the Bearings.

Re-alignment of the Belt can normally be achieved by adjusting the Carrying Rollers and/or Return Rollers as
shown below:

Reasons for Oblique Remedies Examples of Oblique Travel

Travel

1. Insufficient aligning of (i). Align all drums, carrying idlers and return (A). Turning Carrying Rollers.
Drums and Idlers. idlers at right angles to the travelling direction
of the belt, as shown at (A).
(ii). Check that all Drums and Idlers are level
to each other.
(iii). If misalignment is still present at the
(B). Turning Carrying Rollers
Drive Drum turn the first Carrying Roller
towards the direction you want the
closest to the Drum, towards the direction of
Belt to move at the Drive Drum
Belt travel you want to achieve, as shown at
end.
(B). The second Carrying Roller can also be
moved if necessary. Note: Only a small
movement may be necessary to re-align the
Belt.
(iv). If misalignment is still present at the Idle (C). Turning Return Rollers
Drum turn the first Return Roller closest to the towards the direction you want the
Drum, towards the direction of Belt travel you Belt to move at the Idle Drum end.
want to achieve, as shown at (C). The
second Return Roller can also be moved if
necessary. Note: Only a small movement
may be necessary to re-align the Belt.

(i). Oblique travel can be reduced by turning (D). Turning forward Carrying
2. Misalignment of frame. forward outer carrying idlers 1-3 degrees in Rollers.
travelling direction of the belt, as shown at
(D): if this does not correct the oblique travel
then align the frame.

(i). Clean Drums and Rollers. Check belt

3. Material built up on Drums
cleaners and replace if necessary.
and Rollers.

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6.19 CRUSHER DRIVE BELT ADJUSTMENT.

(i). The Crusher Drive belt tension can be adjusted using (A).
the Adjuster Bolts, as shown at (A).
(ii). Before adjusting the Bolts ensure that the four Engine
mtg. bolts, as shown at (B), have been loosened.
(iii). Increase the tension on the Drive Belts by screwing
the Adjusters forward. Reduce the tension on the Drive
Belts by screwing the Adjusters backwards.
(iv). Ensure that both Adjuster Bolts have been adjusted
exactly the same amount in order to keep the Pulley's
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.
(B).
6.19.1 DRIVE BELT TENSIONING.

Proper tensioning of the drive belts ensures a longer life

for both the belt and the roller bearings. To check for
correct tensioning using a Belt Tension Indicator please
refer to the illustration shown at (C).

(c) = the centre distance of the Pulleys.

(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
the belt, required to achieve the correct deflection.

Compare the force required with the value stated in the

table, as shown at (D). (c)

(C).
If the measured force is within the values stated in the (d)
table then the belt tensioning should be satisfactory. If the
force measured is below or above the stated values then
the belt should be tightened or slackened respectively. (f)

A new belt should be tensioned to the higher value stated

to allow for normal drop in tension during running in period.

After running the Plant for 30 minutes shut down, "Lock (D). Force req. to deflect belt 16mm
Out" and re-check the tension of the belts. Adjust if Belt per one metre span.
necessary. Section Small
Newton Force
Pulley Dia
SPZ 67-95 10 - 15 1.0 - 1.5
SPZ 100-140 15 - 20 1.5 - 2.0
SPA 100-132 20 - 27 2.0 - 2.7
SPA 140-200 28 - 35 2.8 - 3.5
SPB 160-224 35 - 50 3.5 - 5.1
SPB 236-315 50 - 65 5.1 - 6.6
SPC 224-355 60 - 90 6.1 - 9.2
SPC 375-560 90 - 120 9.2 - 12.2

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6.20 LOAD SENSORS.

Load sensors have been fitted to the machine in order to help

prevent overload situations.
(A).
(i). A Crusher Load sensor has been fitted to the Feed in
Chute, as shown at (A). This sensor detects when material
has built up in the Crusher to this height. If the material has
not dropped below the sensor height after 4 second the
Scalping and Primary Feeders will automatically shut off.
The Feeders will start again 10 seconds after the blockage
has cleared.

(ii). A Crusher Speed sensor, as shown at (B), has also been

fitted to the machine to detect if the speed of the rotor
reduces. If the speed drops below a pre-set rpm setting then
(B).
the Scalping and Primary Feeders will automatically stop.
When the rotor speed rises above another pre-set rpm
setting then the Feeders will automatically start again. A
Speed Relay, as shown at (C), 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.

6.20.1 SETTING THE SPEED RELAY. (C).

(i). To set the speed relay press the "Program" button once, (D).
as shown at (D). The display will change to read "Shaft (E).
Teeth". This corresponds to the number of pulses per (F).
crusher shaft revolution. This should be set to 4. It can be (G).
changed by pressing the "Up" and "Down" buttons, as shown
at (F) & (G).
(ii). Next press the "Enter" button, as shown at (E). The
display should read "Overspeed Auto" The setting can be
changed if it is incorrect by pressing the Up" and "Down"
buttons.

(iii). 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" and the highlight will move to next digit and so on.
(iv). When the last high speed digit has been set press the "Enter" button and the display will move to the "Trip
Low Value". This the crusher speed at which the feeder 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" and the highlight will move to next digit and so
on.
(v). 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.

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6.21 HYDRAULIC DIAGRAM.

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6.22.1 ELECTRICAL WIRING DIAGRAM (1 of 9).

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6.22.2 ELECTRICAL WIRING DIAGRAM CONTINUED (2 of 9).

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6.22.3 ELECTRICAL WIRING DIAGRAM CONTINUED (3 of 9).

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6.22.4 ELECTRICAL WIRING DIAGRAM CONTINUED (4 of 9).

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6.22.5 ELECTRICAL WIRING DIAGRAM CONTINUED (5 of 9).

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6.22.6 ELECTRICAL WIRING DIAGRAM CONTINUED (6 of 9).

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6.22.7 ELECTRICAL WIRING DIAGRAM CONTINUED (7 of 9).

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6.22.8 ELECTRICAL WIRING DIAGRAM CONTINUED (8 of 9).

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6.22.9 ELECTRICAL WIRING DIAGRAM CONTINUED (9 of 9).

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6.23.1 ELECTRICAL PANEL BASE LAYOUT.

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6.23.2 ELECTRICAL PANEL LID LAYOUT.

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 SECTION 7.0

TRANSPORTATION
Before attempting to transport this machine you

! WARNING must have read and understand all the safety

instructions listed in Section 2.0

7.1 TRANSPORTATION OVERVIEW.

(i). This section will guide you through the procedures to prepare this machine for transportation, ensure that
you carry 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
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/section and proceed to next section.

(ii). Check local transport regulations before attempting to transport this machine.

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

7.2 TRANSPORTATION PREPARATION PROCEDURE.

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.

(i). Remove the extra/misc. items from the machine.

(ii). Start the Engine in order to operate the Rams.
(iii). Raise the Dirt Conveyor (if a Short Conveyor) into the transport position.
(iv). Remove the Dirt Conveyor (if a Long Conveyor) from the machine.
(v). Remove the Crib Cross Beams and Lower the Hopper Cribs into the transport position.
(vi). Raise the Product Conveyor Bottom End into the transport position.
(vii). Lower the Product Conveyor Top End into the transport position.
(viii). Stop the Engine and allow the Exhaust to cool.
(ix). Remove the Exhaust after it has cooled down.
(x). Remove the Pre-Cleaner and fit the custom made cover.
(xi). Pack all brackets and loose items onto the machine and secure for transport.
(xii). Start the machine in the Tracking mode and load the machine onto the transportation lorry.
(xiii). Ensure that the Machine is adequately secured to the lorry so that it can be transported safely.

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7.3 REMOVING THE MISC. ITEMS FORM THE MACHINE. (A)

(i). Remove the bar frame, as shown at (A), from the Crusher.
IMPORTANT: Ensure that adequate lifting equipment is used to
remove these items.

(ii). Unbolt the viewing platform handrails and fold down, as

shown at (B), and secure for transport.

(iii). Remove the Crusher Feed-in Spray bar and Product (B)
Conveyor top-end Spray bar.

7.4 RAISING THE SHORT DIRT CONVEYOR INTO THE

TRANSPORT POSITION.

IMPORTANT: The short Dirt Conveyor must be folded up

before the Hopper Cribs are folded down.

(i). Remove the Wire Rope Supports from the Conveyor, as

shown at (C).
(C)
(ii). Remove the Drive Drum Scraper as shown at (D).

(iii). Remove the mounting pins from the lower folding heels, as
shown at (E).

(iv). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(v). Locate the control bank lever at the rear of the chassis
labelled "DIRT CONVEYOR FOLDING", as shown at (F).

(vi). Raise the conveyor up slowly until it reaches its maximum (D)
folding position.

(iv). Fit the transport brackets at the conveyor pivot point, as

shown at (G).

(G). (F). (E).

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7.5 REMOVING THE LONG DIRT CONVEYOR FROM
THE MACHINE.

If the machine has been purchased with the "Long Dirt

Conveyor" option then the conveyor have to be removed
the machine is transported.

(i). Using appropriately rated lifting gear attach lifting (A)

chains to the conveyor and tension for lifting.

(ii). Disconnect the Hydraulic and Grease hoses as

shown at (B).
(B)
(iii). Disconnect the Wire Rope Supports from the
Conveyor, as shown at (E).

(iv). With the Conveyor properly secured to the lifting

gear, remove the mounting bolts shown at (A) & (C).

(v). Gently remove the conveyor from the machine taking

extreme care not to damage any of the components.

(C)

(E).

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7.6 LOWERING THE HOPPER CRIBS INTO THE (A)
TRANSPORT POSITION.

(i). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(ii). Locate the three control bank levers labelled "CRIB

FOLDING", as shown at (A).

(iii). Raise the two side cribs up so that the weight of the Cribs (B)
is being supported by the rams.

(iv). Remove the two Crib-Cross Beams, as shown at (B).

(v). Remove the Crib Leg Locking Flats from each of the four
Crib Legs, as shown at (C).

(vi). Remove the mounting bolts and large flats from the mtg.
heels, as shown at (D).

(vii). Fold the three cribs down fully for transport.

(C)

(D)

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7.7 RAISING THE PRODUCT CONVEYOR TAIL SECTION INTO (A)
THE WORKING POSITION.

WARNING: A sensor in the Conveyor prevents the Machine

from being tracked while Product Conveyor tail section is in
the working position.

(i). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(ii). Locate the control bank lever at the rear of the chassis labelled
"DISCHARGE CONVEYOR FOLDING", as shown at (A).

(iii). Raise the Conveyor up as high as possible.

(B)
(iv). Attach the mtg. chains, as shown at (B).

IMPORTANT: Straps, as shown at (C), must also be attached to

the Conveyor to prevent it from dropping slightly when the
machine is being tracked.

7.8 LOWERING THE PRODUCT CONVEYOR HEAD SECTION (C)

TO THE TRANSPORT POSITION.

(i). With the Engine running increase the revs to approximately

1200rpm using the throttle switch on the starter panel.

(ii). Remove the Wire Rope Supports from the Conveyor, as

shown at (E).

(iii). Using the control bank lever labelled "DISCHARGE

CONVEYOR FOLDING", as shown at (G), raise the conveyor up (D)
slightly so that the weight of the Conveyor is supported by the ram.

(iv). Remove the mounting pins, as shown at (D), from the upper
folding heels.

(v). Lower down the Conveyor to the transport position, as shown

at (F), and fit the transport brackets shown.

(E).
(G)
(F).

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7.9 REMOVING THE EXHAUST AND AIR BREATHER.

WARNING: Do not remove the exhaust or Pre-Cleaner while the (A)

Engine is running. Ensure that the Engine has adequately cooled
down before touching the Exhaust chamber.

(i). Remove the Pre-Cleaner and fit the transport cover, as shown
at (A).

(ii). Remove the Exhaust.

(iii). Ensure that the exhaust and pre-cleaner are packed securely
onto the machine for transport.

IMPORTANT: After the Pre-Cleaner and Exhaust have been

removed only run the Engine for short intervals.

7.10 TRANSPORTATION (B)

(i). Ensure that all the access ladders are folded up and securely
fastened for transport, as shown at (B).

(ii). Ensure that all loose material, tools and debris are removed
from the machine.

(iii). Ensure that all loose parts being shipped with this machine are
securely packed so that don't risk falling off the machine during
transport.

IMPORTANT: The loading of this machine onto the transport trailer

must be carried out by experienced personnel only.

(iv). For Tracking procedures refer to section 3.0 of this manual.

(v). Ensure that the lorry being used to transport this machine is of
adequate rating for the purpose and complies with all local
transportation regulations.

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 SECTION 8.0

SPARE PARTS.

8.1 SPARE PART ORDERING INFORMATION.

To ensure that you receive the parts you require without delay we will require the following information at the
time of order:

Your company name and delivery address.

Your contact name and number.
The machine serial number (see below for details).
The machine model number (see below for details).
The part number.
The part description.
The quantity required.

Note: Ensure that you order all the required parts such as Bolts and Washers etc. Do not assume that such
items will automatically be sent with main components.

To order spares please contact:

TESAB ENG. Ltd. Tel: +44 (0) 2882252781

Unit 7,
Gortrush Industrial Estate, Fax: +44 (0) 2882252801
Omagh,
Co Tyrone, Email: paul@tesab.com
N. Ireland BT78 5EJ
Web: www.tesab.com

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8.1 PARTS ILLUSTRATION.
(A) (B). (C) (D) (E).

(F). (G).

(A). Primary Feeder - See 8.2. (F). Dirt/Fine Conveyor - See 8.7 (Long), See 8.8. (Short)

(B). Scalping Feeder - See 8.3. (G). Jaw Crusher - See 8.9.

(C). Engine and Drive System - See 8.4. (H). Misc. - See 8.10.

(D). Hydraulic System - See 8.5.

(E). Discharge/Product Conveyor - See 8.6

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8.2 PRIMARY FEEDER PARTS ILLUSTRATION.

Part No. Description. Qty. Photo.

01-05-008104 Primary Feeder - Drive Motor 1

02-25-0180 Primary Feeder - F-Flange 2

02-26-0180 Primary Feeder - F-Flange Rubber Insert 1

02-30-2532 Primary Feeder - F-Flange Taper Lock (32mm) 1

02-30-2550 Primary Feeder - F-Flange Taper Lock (50mm) 1

65-10-0004 Primary Feeder Mounting Spring 8

PF-Bear Primary Feeder Bearing 4

PF-Shaft Primary Feeder Shaft 2

PF-Bear House Primary Feeder Bearing Housing 4

PF - Labyrinth Primary Feeder Labyrinth - Drive Side 2

- Drive

PF - Labyrinth Primary Feeder Labyrinth - Non Drive Side 2

- Drive

PF - Seal Primary Feeder Seal - Drive Side 2

- Drive

PF - Seal Primary Feeder Seal - Non Drive Side 2

- Drive

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8.3 SCALPING FEEDER PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
01-05-3061 Scalping Feeder - Drive Motor 1

02-23-0090 Scalping Feeder - F90F Coupling 1

02-23-0090 Scalping Feeder - FF x T90 Coupling Tyre 1

02-30-2522 Scalping Feeder - Coupling Taper Lock (22mm) 1

02-30-2550 Scalping Feeder - F-Flange Taper Lock (50mm) 1

65-10-0006 Scalping Feeder Mounting Spring 8

13-01-8040 Scalping Feeder Mesh (40mm) 1

SF-Stainless Scalping Feeder - Stainless Steel Plate 1

02-56-22322 Scalping Feeder - Bearing 2

SF-Bear House Scalping Feeder - Bearing Housing 2

SF-Shaft Scalping Feeder - Shaft 1

SF-Shaft Caps Scalping Feeder - Shaft Caps & Boss Set 2

Tel: +44 (0) 28 82252781 10570 - P82

8.4 ENGINE & DRIVE SYSTEM PARTS ILLUSTRATION. (TO SUIT C9 ENGINE)
Part No. Description. Qty. Photo.
8S-6558 Exhaust Muffler 1

9S-7148 Rain Cap 1

6F-8814 Exhaust Clamp 1

5L-8484 Exhaust Gasket 2

130-3281 Pre-Cleaner 1

107-7495 Pre-Cleaner Reducer 1

132-7167 Air Filter - Outer Element 1

6I-2510 Air Filter - Inner Element 1

8N-2694 Air Filter Sensor 1

177-9778 Fuel Filter Housing 1

270-5320 Fuel Filter Water Separator Bowl 1

1R-0771 Fuel Filter 1

07-22-3309 6" - 5" 90o Rubber Bend 1

07-22-3006 6" - 6" Straight Hump Hose 1

Tel: +44 (0) 28 82252781 10570 - P83

8.4 ENGINE & DRIVE SYSTEM PARTS ILLUSTRATION. (TO SUIT C9 ENGINE) CONTINUED……..
Part No. Description. Qty. Photo.
07-22-1482 4" - 5" 90o Rubber Bend 1

07-25-1065 6" Clamp 3

07-25-1055 5" Clamp 2

07-25-1045 4" Clamp 1

02-01-0019 Hydraulic Clutch 1

02-04-0095 Hydraulic Clutch - Shaft Seal 1

01-10-002024 Hydraulic Clutch - Solenoid 1

02-07-7074B Hydraulic Clutch - Sight Gauge 2

02-01-0019 - Hydraulic Clutch - Pressure Clock 1

Pressure Clock

02-01-0019 - Hydraulic Clutch - Temperature Clock 1

Temp Clock

01-96-4670 Hydraulic Clutch - Oil Cooler 1

02-15-2248 Drive Pulley 1

02-61-6700 Drive Belt 8

02-30-35380 Drive Pulley - Taper Lock 1

Tel: +44 (0) 28 82252781 10570 - P84

8.4 HYDRAULIC SYSTEM PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
01-01-5051 Main Hydraulic Pump 2

01-02-4444A Auxiliary Hydraulic Pump (Tandem) 1

01-10-009002 210 Bar Pressure Relief Valve 2

01-15-2208 High Pressure Filter (B08) 2

01-15-3210 High Pressure Filter (B10) 2

01-10-0256 Diverter Valve 2

01-10-003008 Flow Control Valve 2

01-11-4463 4 Bank Control Valve 1

01-11-4464 2 Bank Control Valve 2

01-12-007002 C-Top 7 Solenoid Valve 1-Station 2

01-12-005002 C-Top 5 Solenoid Valve 2-Station 2

01-12-1613 C-Top 5 Solenoid Valve 1-Station 1

01-12-1614 C-Top 3 Solenoid Valve 2

01-12-0002 Overcentre Valve for C-Top 3 Solenoid Valve 1

Tel: +44 (0) 28 82252781 10570 - P85

8.5 HYDRAULIC SYSTEM PARTS ILLUSTRATION CONTINUED ……...
Part No. Description. Qty. Photo.
01-10-002024 DFE 20 Solenoid Valve 1

01-10-0200 Webtec Flow Control Valve 2

01-10-009007 Flow Control Valve 1

01-96-0203BC Twin Fan Hydraulic Oil Cooler complete with Fans 1

01-96-0203BC - Hydraulic Oil Cooler Radiator 1

Radiator

01-96-0203BC - Hydraulic Oil Cooler Fan 2

Fan

01-15-4930 Hydraulic Tank Air Breather 1

01-80-0015 Jaw Crusher Unit - Wedge Adjuster Ram 1

01-80-0016 Jaw Crusher Unit - Wedge Release Ram 1

01-80-0008 Product Conveyor - Folding Ram 2

01-80-0012 Product Conveyor - Tail Lift Ram 1

01-80-0010 Dirt/Fines Conveyor Folding Ram 1

(Only require on Short Dirt Conveyor Option)

01-80-0013 Crib Folding Ram - Rear 1

01-80-0014 Crib Folding Ram - Side 2

Tel: +44 (0) 28 82252781 10570 - P86

8.5 HYDRAULIC SYSTEM PARTS ILLUSTRATION CONTINUED ……...
Part No. Description. Qty. Photo.
01-80-0006 Jacking Leg Ram 1

Tel: +44 (0) 28 82252781 10570 - P87

8.6 PRODUCT/DISCHARGE CONVEYOR PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
01-06-1045C Hydraulic Drive - Reduction Gearbox 1

01-05-0001 Hydraulic Drive - Reduction Gearbox Motor 1

02-25-0230 Hydraulic Drive - F-Flange 2

02-26-0230 Hydraulic Drive - F-Flange Rubber Insert 1

02-30-3065 Hydraulic Drive - F-Flange Taper Lock (65mm) 1

02-30-3070 Hydraulic Drive - F-Flange Taper Lock (70mm) 1

02-14-13030 Drive Drum 1

02-43-0001 Drive Drum - Bearing Housing 2

02-45-0080 Drive Drum - Bearing 2

02-44-0001 Drive Drum - Bearing Seal Kit 3

02-46-0080 Drive Drum - Bearing Sleeve 2
02-47-0001 Drive Drum - Bearing Housing End Cap 1
02-48-0001 Drive Drum - Bearing Locating Ring 2
65-11-0027 Rosta Scraper Tensioner 2

06-25-0007 Plain Idle Roller (300mm) 36

06-30-0750 Rubber Impact Roller (300mm) 12

06-20-1200 Conveyor Belt 1

Tel: +44 (0) 28 82252781 10570 - P88

8.6 PRODUCT/DISCHARGE CONVEYOR PARTS ILLUSTRATION CONTINUED……..
Part No. Description. Qty. Photo.
Dis Con - Skirt - Skirting Rubber Kit 1
Rubbers

06-15-1460 Disc Return Roller 6

02-35-0030 Disc Return Roller - Mounting Bearing 12

06-18-0130 Guide Roller 2

06-65-70025 Rubber Impact Bed 1

02-11-13025 Idle Drum 1

02-55-0001 Idle Drum - Bearing Housing 2

02-55-0002 Idle Drum - Bearing 2

02-55-0005 Idle Drum - Bearing Seal Kit 2

02-55-0003 Idle Drum - Bearing Sleeve 2
02-55-0006 Idle Drum - Bearing Housing End Cap 2
02-55-0004 Idle Drum - Bearing Locating Ring 2

Tel: +44 (0) 28 82252781 10570 - P89

8.7 LONG DIRT/FINES CONVEYOR PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
01-05-003109 Hydraulic Drive - Motor 1

02-25-0150 Hydraulic Drive - F-Flange 2

02-26-0150 Hydraulic Drive - F-Flange Rubber Insert 1

02-30-2050 Hydraulic Drive - F-Flange Taper Lock (50mm) 1

02-30-2040 Hydraulic Drive - F-Flange Taper Lock (40mm) 1

02-13-0858 Drive Drum 1

02-32-0050 Drive Drum - Bearing 2

65-11-0027 Rosta Scraper Tensioner 2

06-03-004026 Idle Roller Set 4

06-05-004026 Rubber Impact Roller Set 4

06-25-0007 Idle Roller 12

06-30-0650 Impact Roller 12

06-15-0930 Disc Return Roller 2

02-35-0030 Disc Return Roller - Mounting Bearing 4

Tel: +44 (0) 28 82252781 10570 - P90

8.7 LONG DIRT/FINES CONVEYOR PARTS ILLUSTRATION CONTINUED……..
Part No. Description. Qty. Photo.
02-10-0858 Idle Drum 1

02-34-0050 Idle Drum - Bearing 2

06-20-0650 Conveyor Belt 1

65-05-0004 Conveyor Supports - Wire Rope 2

65-01-0003 Conveyor Supports - Screw Adjuster 2

65-02-0020 Conveyor Supports - D Shackle 2

65-03-0020 Conveyor Supports - Bow Shackle 2

Dirt Con - Skirt - Skirting Rubber Kit 1

Rubbers

Tel: +44 (0) 28 82252781 10570 - P91

8.8 SHORT DIRT/FINES CONVEYOR PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
01-05-003109 Hydraulic Drive - Motor 1

02-25-0150 Hydraulic Drive - F-Flange 2

02-26-0150 Hydraulic Drive - F-Flange Rubber Insert 1

02-30-2050 Hydraulic Drive - F-Flange Taper Lock (50mm) 1

02-30-2040 Hydraulic Drive - F-Flange Taper Lock (40mm) 1

02-13-0858 Drive Drum 1

02-32-0050 Drive Drum - Bearing 2

65-11-0027 Rosta Scraper Tensioned 2

06-03-004026 Idle Roller Set 2

06-05-004026 Rubber Impact Roller Set 4

06-25-0007 Idle Roller 12

06-30-0650 Impact Roller 12

06-15-0930 Disc Return Roller 2

02-35-0030 Disc Return Roller - Mounting Bearing 4

Tel: +44 (0) 28 82252781 10570 - P92

8.8 Short DIRT/FINES CONVEYOR PARTS ILLUSTRATION CONTINUED……..
Part No. Description. Qty. Photo.
02-10-0858 Idle Drum 1

02-34-0050 Idle Drum - Bearing 2

06-21-2476 Conveyor Belt 1

65-05-0003 Conveyor Supports - Wire Rope 2

65-01-0003 Conveyor Supports - Screw Adjuster 2

65-02-0020 Conveyor Supports - D Shackle 2

65-03-0020 Conveyor Supports - Bow Shackle 2

Dirt Con - Skirt - Skirting Rubber Kit 1

Rubbers

Tel: +44 (0) 28 82252781 10570 - P93

8.9 JAW CRUSHER UNIT PARTS ILLUSTRATION
Part No. Description. Qty. Photo.
82-05-0001 Side Wear Plate - Upper 2

82-05-0006 Side Wear Plate - Lower 2

82-03-0001 Side Wear Plate - Bolt (120mm) 12

82-01-0007 Jaw Stock Top Wear Plate 1

82-02-0015 Jaw Stock Top Wear Plate 3

82-01-0008 Fixed Jaw Plate 1

82-01-0009 Fixed Jaw Wedge 1

82-03-0002 Fixed Jaw Wedge Bolt (485mm) 4

82-01-0010 Swing Jaw Plate 1

82-01-0011 Swing Jaw Wedge 1

02-03-0003 Swing Jaw Wedge Bolt (810mm) 3

82-01-0013 Wedge - Release Side 1

82-01-0014 Wedge - Adjuster Side 1

82-35-0001 Toggle Spring 2

Tel: +44 (0) 28 82252781 10570 - P94

8.9 JAW CRUSHER UNIT PARTS ILLUSTRATION CONTINUED………...
Part No. Description. Qty. Photo.
82-02-0021 Toogle Spring End Cap 2

82-02-0018 Toogle Adjuster Rod 2

82-02-0019 Toogle Adjuster Rod Pin 2

82-01-0015 Toogle (440mm) 1

82-01-0016 Toogle (480mm) 1

82-01-0017 Toogle Slide Plate 1

82-01-0019 Toogle Seat - Adjuster Side 1

82-01-0018 Toogle Seat - Jaw Side 1

82-01-0016 Toogle Seat - Locating Plug 2

82-02-0017 Toogle Seat - Spacer 1

82-01-0003 Pulley 1

82-01-0004 Flywheel 1

82-02-0013 Flywheel End Cap 2

82-05-0001 Ring Fedder Locking Assembly 2

Tel: +44 (0) 28 82252781 10570 - P95

8.10 MISC PARTS ILLUSTRATION.
Part No. Description. Qty. Photo.
Sp - Bar (1000) Spray bar complete with Fittings & Nozzles 2
(1000mm)

20-40-2404 Spray Nozzle 6

Tracks - TV Tracks Tensioner Valve 2

Tracks - GGF Tracks Tensioner Grease Gun Fitting 1

Tracks - PRV Tracks Pressure Relief Valve 2

Tel: +44 (0) 28 82252781 10570 - P96