MAXIMUS - 516 руководство пользователя - 1

MAXIMUS 516
PRODUCT USER MANUAL
OPERATION AND MAINTENANCE
Do not operate machine without reading this manual.

Risk of death or serious injury may result.
Edition 1 June 2010

Section Page
Index 1
MANUFACTURERS EC DECLARATION OF CONFORMITY

(DIRECTIVE 2006/42/EC)
Manufacturer: Tesab Engineering Ltd.
Address: Gortrush Industrial Estate, Omagh, Co. Tyrone, N. Ireland. BT78 5EJ
Contact details: Tel. +44(0)28 8225 2781 Fax. +44(0)28 8225 2801
Description of Machine: Mobile vibrating screen
Declares that: Machine Model: Tesab 1550 Serial No:
Complies with the provisions of the following EC Directives.
European Machinery Directive 2006/42/EC.

Electromagnetic Compatibility Directive 2004/108/EC.
Low Voltage Directive 2006/95/EC.
Noise Emission Directive 2000/14/EC, amended by 2005/88/EC
CE mark affixed, Date _____________
Basis on which conformity is declared
The above machinery complies with the relevant harmonised essential health and safety
requirements of the European Machinery Directive.
The above machinery complies with the requirements of the EMC Directive and the Low Voltage
Directive.
Technical File held at Unit 9 Gortrush Industrial Estate, Omagh, Co. Tyrone, N. Ireland. BT78 5EJ.
Signed by
Don Smyth (Company Director)
____ ______________________
Section Page
Index 1
Section
1. Introduction
2. Definitions and abbreviations
3. Safety
4. General information
5. Designated use
6. Technical information
7. Design and function
8. Transport
9. Set up
10. Operating instructions
11. Shut down
12. Maintenance
13. Appendix
14. Trouble shooting
15. Specifications
16. Warranty
Section Page
1 Introduction 1
The operator must read and understand all of the information contained in
this manual before operating this machine.
This symbol is used for all safety warnings. Please follow them carefully. The
attention of operating personnel should be drawn to these safety instructions. General
safety and accident prevention regulations laid down by law must also be observed.
Dear Customer,
A Tesab machine represents a considerable capital investment. It should therefore be operated and
maintained only by people who are responsible, safety conscious and who are capable of being
trained to operate and maintain the machine safely in the field and in all other foreseeable situations.
Federal, State, National and Local laws including all safety regulations must be complied with at all
times to prevent possible accidents and harmful exposure to persons or property.
The operating instructions are laid out in such a manner as to acquaint the user with the construction,
correct operation and maintenance of the machine. These instructions should be studied carefully
before operating the Tesab machine.
By following this advice you will always obtain the best possible results with the Tesab machine and
will also avoid unnecessary down time.
Due to our policy of continuous improvement, the descriptions and illustrations used in these
operating instructions are with out prejudice. We reserve the right to make alterations to improve
performance, efficiency or for any other reason. We are not obliged to alter these instructions
accordingly. These instructions do not assert to be complete.
If you need any advice or information regarding your Tesab machine Contact.
Tesab Engineering Ltd.

Gortrush Industrial Estate
Oamgh
Co. Tyrone
N. Ireland
BT78 5EJ
Tel: +44 (0) 2882 252781

Fax: +44 (0) 2882 252801
Section Page
2 Definitions and abbreviations 1
Assembly
Components of the machine joined together to
form individual sections.
Auxiliary Control Valve

A single or multiple lever valve which
controls various functions on the machine.
Belt Scraper
A self adjusting or fixed device fitted across a
conveyor belt for removing sticky material.
Centre Roller
A horizontal steel roller that supports a loaded
conveyor belt.
Control panel
A panel situated in the powerunit. Used to
start the Diesel engine and contains the engine
warning lights.
Conveyor
A device fitted with a continuous rubber band
for transporting material from the loading
point to the discharge point.
Conveyor Belt
A continuous rubber band of various available
widths fitted to a conveyor for the transporting
of objects from one place to another.
Control Valve
A hydraulic valve, when operated, causes a
movement function on the machine.
Discharge Area
An area where material is ejected from the
machine.
Drive
A rotating mechanical / hydraulically powered
component.
Section Page
Drive Drum
A powered rotating drum that transmits
motion to a conveyor belt.
Drum Lagging
Rubber bonded to a drive drum to increase
friction with a conveyor belt.
Feed (Feeder) Conveyor

Conveyor used to eject material from the
hopper to the main conveyor
Feedboot
Located at the loading point of a conveyor.
Steel side plates guide the material unto the
conveyor belt.
Filler Cap
A plastic or metal cap used to seal a fuel tank
and a hydraulic tank.
Fines Material
Screened material which passes through the
vibrating screen lower deck.
Flywheel
A steel half moon shaped counter weight.
Fitted to both ends of the vibrating screen
shaft. When rotated at high speed it causes the
screenbox to vibrate.
Jacking Legs
For the purpose of raising, lowering or
supporting the machine.
King Pin
The coupling pin, welded or bolted in the
centre of the front underside of the chassis,
which couples to the fifth wheel of the towing
tractor.
Section Page
LHS
Referring to the left hand side of the machine. PO
Viewed from the hopper end of the machine. Purchase order
Lockout Powerunit
The placement of a lockout device on an The diesel engine and hydraulic oil tank
energy isolating device, in accordance with an enclosure.
established procedure, ensuring that the
energy isolating device and the equipment Prop Leg
being controlled cannot be operated until the An adjustable telescopic strut used to support
lockout device is removed. a conveyor, or other equipment.
Main Conveyor P.S.I.

A conveyor used to collect ejected material Pounds per square inch. Unit of pressure.
from the hopper and transport it to the
screenbox. Return Roller
A horizontal steel roller that supports the
Material safety data sheet return side of the conveyor belt.
Documentation of the safety, health and
environment hazards of a chemical product. Remote Control
Control of a machine or apparatus from a
Mesh distance by means of signals transmitted from
A net-like material with spaces in it, made a radio or electronic device.
from steel wire, rubber or plastic.
RHS
Nip Point Referring to the right hand side of the
A point of convergence between two rolling machine. Viewed from the hopper end of the
parts, or a moving part and a stationary part, machine.
where all or part of the human body could
become trapped and injured. Safety Stay
Metal bar used to restrain equipment in a
Oversize Material certain position. Usually bolted or pinned in
Material that won’t pass through the place.
screenbox top mesh.
Screenbox
Pin Vibratory device fitted with meshes to
Round metal bar tapered at one end. Used for separate material by size.
temporarily holding machine components in
position. Shall
Used to indicate requirements strictly to be
Platform followed in order to conform to the standard
An elevated structure for persons to maintain and from which no deviation is permitted.
or repair the machine safely.
Section Page
Should Tagout.
Used to indicate that among several The placement of a tagout device on an energy
possibilities one is recommended as isolating device, in accordance with an
particularly suitable, without mentioning or established procedure, to indicate that the
excluding others, or that a certain course of energy isolating device and the equipment
action is preferred but not necessarily being controlled may not be operated until the
required. tagout device is removed.
Shredder Tail Conveyor

A machine that is used for cutting things into Belt conveyor located under the screenbox .
very small pieces. Fitted to the discharge end Used to collect the fines material and transport
of the feed conveyor. it to the discharge area.
Side Conveyor Tracks (Crawler Tracks)

Belt conveyor used to collect the oversize Ribbed metal shoes fitted to a roller chain and
material from the top and bottom screen driven by sprockets. Located to either side of
meshes. chassis. Used for self propelling the machine
over all types of terrain.
Side Roller
Fitted to conveyors on either side of the centre Transport Bracket
roller. Used to incline the edges of the Metal bar used to restrain equipment in the
conveyor belt to prevent spillage. transport position. Usually pinned in place.
Spillage Transport Position

Material that falls from the edge of a conveyor The state of the machine when it has been
belt. folded up for placing on a trailer.
Spreader Plate Variable Speed Flow Control

An adjustable steel plate fitted at the discharge A hydraulic valve fitted with an inscribed
end of the main conveyor. Used to spread the knob. Rotate the knob to control the speed of a
material across the width of the vibratory conveyor belt.
screen.
WE
Strut Working environment
A brace fitted into a framework to stabilize the
structure. Work Equipment
‘Work equipment’ is almost any equipment
Sub-Assembly used by a worker at work including:
A machine that cannot function Machines such as drilling machines;
independently, and that is intended for Hand tools such as screwdrivers, knives, hand
incorporation into machinery. saws and hammers;
Lifting equipment such as lift trucks, elevating
work platforms, hoists and lifting slings;
Other equipment such as ladders and water
pressure cleaners.
Section Page
Working Environment
The totality of all physical, chemical,
biological and psychological factors at work
that may affect the employees’ health and
wellbeing through acute trauma or lasting
exposure.
The influence from lasting exposure may be

positive and negative.
Section Page
3 Safety 1
Manual Edition 2 (March 2010)
Section Contents Page

3.1 Safety notice ………………………………….………………………………... 2
3.2 Warning alerts and symbols…………………………………………………….. 3
3.3 Safety in the working environment………………………………………………4
3.4 Selection and qualification of personnel…………………………………………8
3.5 Tools and equipment……………………………………………………………..9
3.6 Lockout and Tagout of machine………………………………………………...10
3.7 Electrical energy………………………………………………………………...12
3.8 Hydraulic system………………………………………………………………..13
3.9 Disposal of parts and contaminants……………………………………………..14
3.10 Transport and stability………...……………………………………………...…15
3.11 Emergency stop positions…………………………………………………….....16
3.12 Safety hazard decals…………………………………………………………….17
3.13 Position of safety hazard decals…………………………………………………
3.14 Material safety data sheets………………………………………………………
Section Page
3 Safety 1
3.1 Safety notice (Proposition

65. California USA)
Proposition 65. Calfornia. USA Eye protection must be worn

WARNING: Batteries contain lead and lead when operating, maintaining
compounds, chemicals known to the State of or in the working area of the
California to cause cancer and birth defects or Tesab machine.
other reproductive harm. Wash hands after
handling.
Protective footwear must be
Proposition 65. Calfornia. USA worn when operating,
WARNING: Diesel fuel may contain maintaining or in the working
Benzene and Toluene, chemicals known to the area of the Tesab machine.
State of California to cause cancer and birth
defects or other reproductive harm. Use gloves
impervious to Diesel fuel to prevent skin High visibility clothing must
contact. Wash hands after handling. be worn when operating,
maintaining or in the
Proposition 65. Calfornia. USA working area of the Tesab
WARNING: Diesel engine exhaust and many machine.
individual substances contained in it
(including arsenic, benzene, formaldehyde and
nickel) are known to the State of California to Head protection must be
cause cancer and birth defects or other worn when operating,
reproductive harm. maintaining or in the working
area of the Tesab machine.
This machine
complies with the Noise level – Hearing hazard
provisions of the dB (A) Levels
following EC
Directives. The Tesab machines are
tested according to guideline
European Machinery Directive 2006/42/EC. 2000/14/EC.This machine
Electromagnetic Compatibility Directive falls below these levels.
2004/108/EC.
Low Voltage Directive 2006/95/EC.
Noise Emission Directive 2000/14/EC,
amended by 2005/88/EC
Section Page
3 Safety 3
3.2 Warnings and symbols
This safety alert symbol is used to draw your attention to potentially hazardous
situations that may cause death, permanent disability, lost time injury, first aid
injury or damage to property.
Comply with all safety alerts that follow this symbol.
DANGER
This symbol indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
CAUTION
This symbol indicates a potentially hazardous situation which, if not avoided, could
result in serious injury or death.
WARNING
This symbol indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices.
Section Page
3 Safety 4
3.3 Safety in the working Always wear correctly fitting (EN/ANSI

environment approved) protective clothing.
Protective clothing includes Ear protection,

3.3.1 Eye Protection (Safety Goggles), Head
Above all think safety first. Protection (Hard Hat), High Visibility Vest,
Close fitting Overalls, Steel toed boots.
Before using your Tesab, it is your
responsibility to read, understand and follow Loose clothing, long hair or jewellery can get
all of the safety instructions in your operator's caught in moving parts of the machine. These
manual. Also make sure that everyone items including jewellery rings can also get
working near your Tesab understands and caught on fixed objects. Always remove
follows all of the safety instructions in the jewellery, tie or fix back long hair and use tight
manual. fitting clothing.
Read all danger, warning and caution signs. Always stay well back from moving
components, never work on a machine with
Do not operate this machine with any safety any of the safety guards or devices removed.
guards or devices removed or bypassed.
3.3.4
Make sure that everyone in the WE know and Maintenance of Safety decals.
understand the hazards and risks involved and Use mild soap and water to clean decals. Never
that they must comply fully with all warning use detergents or solvent based cleaners as
and safety precautions while working on or these cleaners may damage the decals.
near the machine. Replace any damaged or missing safety decals.
Always check around, under, on and in the 3.3.5

machine for personnel. Make sure they are Keep work area clean, dry and free from any
clear of the machine or possible falling objects obstacles.
before starting up the machine.
Do not under any circumstances clean,
3.3.2 lubricate, adjust, service or ride on the machine
Observe all warnings and safety instructions whilst it is moving.
attached to the machine.
3.3.6
Make sure that all warning and safety If a safety related issue arises during the
instruction decals are kept clean at all times. operation of the machine. For instance if
something sounds different or behaves
Always replace illegible warning and safety abnormally on the machine, the operator must
instruction decals with new ones before shut down, lock out and tagout the machine
operating the machine. When replacing parts immediately. The operator must report the fault
make sure warning and safety instruction without hesitation to the relevant person.
decals are fitted where necessary.
3.3.3
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3 Safety 5
3.3.7 3.3.11
Do not climb on the machine or use any parts In the event of malfunctions, stop the machine
as a climbing aid, except access ladders and immediately, lockout. Have any defects
maintenance platforms where fitted. rectified immediately.
Always use work equipment or other 3.3.12

measures to prevent falls. Warning! Never stand beneath conveyors;
Always use EN/ANSI approved safety harness Do not unfold conveyors near power lines;
when working 2m (6’-7”) above ground level.
Do not touch hot surfaces;
The operator must keep all steps, ladders,
walkways, handrails, platforms and landings Never stop up burst hydraulic hoses, pipes or
free from dirt, oil, ice and snow. fittings with hands as hydraulic oil under
pressure will penetrate skin and cause serious
3.3.8 injury.
Warning! Before servicing, cleaning or
lubricating, always lockout and tagout Do not start or stop (unless in an emergency)
machine. Also operate controls to relieve with any control levers in the operating
pressure in the hydraulic system. Make sure position. This could stall the engine; shear
the machine has cooled down. keys and couplings, blow seals and cause
damage to the machine structure;
All parts must be kept in good condition and
properly installed. Replace damaged parts When the machine is completely shut down
immediately. for maintenance and repair work, it must be
secured against inadvertent starting by:
Before servicing electrical components, - Switching off the engine and removing the
always lockout and tagout machine. ignition key.
- Implementing the lockout procedure.
3.3.9 - Attaching a warning sign to the control panel
Do not make any modifications, additions or door.
conversions to the machine, which may affect
safety without the supplier’s approval. 3.3.13
Observe the adjusting, maintenance and
inspection activities and intervals set out in the
3.3.10 operating instructions, except where:
Operate the machine only if all protective and
safety-oriented devices, such as removable A: Warning light/ gauge or indicator calls for
safety devices, emergency shut-off equipment, immediate action.
soundproofing elements and exhausts, are in B: Adverse conditions necessitate more
place and fully functional. frequent servicing.
Take the necessary precautions to ensure that Observe information on the replacement of
the machine is used only when in a safe and parts and equipment. These activities may be
reliable state. executed by skilled personnel only.
Section Page
3 Safety 6
3.3.14 3.3.19
Make sure the machine is on level stable After cleaning, examine all fuel, lubricant, and
ground and has been immobilised before any hydraulic fluid lines for leaks, loose
maintenance and repair work is carried out. connections, chafe marks and damage.
Never work alone. Any defects found must be rectified without
delay.
3.3.15 See safety data sheets (Section 3.13) for the
Never allow unqualified personnel to attempt safe use of liquids used in the Tesab machine.
to remove or replace any part of the machine,
or anyone to remove large or heavy 3.3.20
components without adequate lifting tackle. Danger! A raised part of the machine can fall
To avoid the risk of accidents, individual parts causing serious injuries or death.
and large assemblies being moved for Always fit a safety support strut if any part of
replacement purposes should be carefully the machine must be raised for any reason.
attached to lifting tackle and secured. Never work under unsupported equipment.
Use only suitable and technically adequate Never work alone.
lifting gear.
Never work or stand under suspended loads. 3.3.21
Follow the regulations when disposing of
3.3.16 waste. Careless waste disposal can threaten
The fastening of loads and the instructing of the environment and ecology. Always read the
crane operators should be entrusted to safety data sheets provided. Potentially
experienced slingers only. harmful waste used with Tesab machines
The slinger giving the instructions must be includes such items as diesel fuel, grease, oil,
within sight and have contact with the crane batteries, filters and coolant.
operator.
Use proper leak proof containers when
3.3.17 draining liquids.
If the machine is completely shut down for
maintenance and repair work, it must be Do not use beverage or food containers that
secured against inadvertent starting by: may mislead someone into drinking from
- Switching off the engine and removing the them.
ignition key.
- Engage the key type emergency stop. Do not pour waste onto the ground, down a
- Implementing the lockout procedure. drain or into any water source.
- Attaching a warning sign to the control panel Ensure that all consumables and replaced parts
door. are disposed of safely and with minimum
environmental impact.
3.3.18
Any safety devices removed for set-up,
maintenance or repair purposes must be
refitted and checked immediately upon
completion of the maintenance and repair
work.
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3 Safety 7
3.3.22
Diesel fuel is highly inflammable.
Never remove the filler cap, or refuel, with the

engine running.
Never add gasoline (petrol) or any other fuel

mixes to diesel fuel because of increased fire
or explosion risks.
Do not smoke or carry out maintenance on the

fuel system near naked lights or sources of
sparks, such as welding equipment.
3.3.23
When running a machine nip points can cause
serious injury or even death.
DANGER! Never reach or put your foot into

an unguarded machine.
Your arm or leg could be pulled in and
amputated, or your whole body maybe pulled
in.
Lockout machine before opening guard doors.
Never work alone.
3.3.24
DANGER! Fire / Explosion hazard
Never allow inflammable dust to build up on
any part of the machine for example; Coal
dust.
Remove dust by extraction methods, not by
blowing.
Dust waste should be disposed of with regard

to the environment.
3.3.25
When welding or maintenance is to be carried
out on the machine, the machine must be
cleaned by extraction, not by blowing.
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3 Safety 8
3.4 Selection and

qualification of personnel
3.4.1
The authorised operator shall be a safety 3.4.5
conscious person and have a full Repairs and maintenance to the Diesel engine
understanding of the operation manual and must be carried out by a qualified Diesel
follow all of the safety instructions before technician.
being trained to use the machine and to
operate all of its functions. 3.4.6
The fastening of loads and the instructing of
Statuary minimum age limits must be crane operators should be entrusted to
observed. experienced slingers only.
3.4.2
Repairs and maintenance on the mechanical
components must be carried out by skilled
fitters who have been trained in the repairs
and maintenance of mobile screening
equipment.
.
3.4.3
Repairs and maintenance on the electrical
components must be carried out by a qualified
electrician or by persons under instruction
from a qualified electrician.
All electrical work must be carried out in

accordance with electrical engineering rules
and regulations.
3.4.4
Repairs and maintenance to the hydraulic
system must be carried out by qualified
hydraulic-mechanical personnel.
Section Page
3 Safety 9
3.5 Tools and equipment

3.5.1
Check that the tools and equipment that is Know where fire extinguishers and other fire
suitable for the work- think about how and suppression equipment are located. Learn how
where it will used. All tools used in EEC to use them effectively. Maker sure they are
should be: maintained as per regulations.
CE marked; 3.5.3
Make sure hand tools are safe.
Safe – never rely exclusively on the CE mark
to guarantee machinery is safe. You must Clean tools properly, label and store them
make your own safety checks; away.
Provided with an EC Declaration of Many risks can be controlled by ensuring hand

Conformity. (Ask for a copy if you have not tools are properly used and maintained, for
been given one) example:
Provided with instructions in your own Hammers - avoid split, broken or loose shafts
language. and worn or chipped heads. Make sure the
heads are properly secured to the shafts;
3.5.2
Keep the work place clean and tidy where it is Spanners – avoid splayed jaws. Scrap any
practical. which show signs of slipping. Have enough
spanners of the correct size. Do not improvise
Make sure all electrical equipment is properly by using pipes etc as extension handles.
grounded. Wet areas near electrical current are
especially dangerous. 3.5.4
Avoid working from ladders use scaffolding
Never start an engine in an enclosed space or mobile platforms.
without venting the exhaust.
Use mobile work platforms safely.
Always use mechanical assistance to lift
heavy loads. Replace damaged lifting This is equipment that travels from one work
equipment immediately. area to another, for example Cherry Picker
and scissor lift.
Do not smoke or allow smoking near solvents
and fuels. Do not carry people on work equipment unless
it is designed for that purpose.
Store hazardous materials in restricted areas
and mark them clearly. Federal regulations 3.5.5
require special labelling of certain materials. Before carrying out maintenance on any part
of the machine. Lockout and tagout (See
section 3.6)
Section Page
3 Safety 10
3.6 Lockout and tagout

3.6.1
The OSHA standard for The Control of
Hazardous Energy (Lockout/Tagout), Title 29 procedures. The training must cover at least
three areas:
Code of Federal Regulations (CFR)
Aspects of the employer’s energy control
Part 1910.147, addresses the practices and
program;
procedures necessary to disable machinery or
Elements of the energy control procedure
equipment, thereby preventing the release of
relevant to the employee’s duties or assignment;
hazardous energy while employees perform
and the various requirements of the OSHA
servicing and maintenance activities. The standard
standards related to lockout/tagout.
outlines measures for controlling hazardous
3.6.4
energies—electrical, mechanical, hydraulic,
The standards establish requirements that
pneumatic, chemical, thermal, and other energy
employers must follow when employees are
sources. Read full publication. Check often for
exposed to hazardous energy while servicing
OSHA updates.
and maintaining equipment and machinery.
In addition, 29 CFR 1910.333 sets forth
Some of the most critical requirements from
requirements to protect employees working on
these standards are outlined below:
electric circuits and equipment. This section
_ Develop, implement, and enforce an energy
requires workers to use safe work practices,
control program.
including lockout and tagging procedures. These
_ Use lockout devices for equipment that can be
provisions apply when employees are exposed to
locked out. Tagout devices may be used in lieu
electrical hazards while working on, near, or with
of lockout devices only if the tagout program
conductors or systems that use electric energy.
provides employee protection equivalent to that
provided through a lockout program.
3.6.2 _ Ensure that new or overhauled equipment is
The lockout/tagout standard establishes the capable of being locked out.
employer’s responsibility to protect employees _ Develop, implement, and enforce an effective
from hazardous energy sources on machines and tagout program if machines or equipment are
equipment during service and maintenance. The not capable of being locked out.
standard gives each employer the flexibility to _ Develop, document, implement, and enforce
develop an energy control program suited to the energy control procedures. [See the note to
needs of the particular workplace and the types of
29 CFR 1910.147(c)(4)(i) for an exception to
machines and equipment being maintained or
the documentation requirements.]
serviced. This is generally done by affixing the
_ Use only lockout/tagout devices authorized for
appropriate lockout or tagout devices to energy-
the particular equipment or machinery and
isolating devices and by de-energizing machines
ensure that they are durable, standardized, and
and equipment. The standard outlines the steps
substantial.
required to do this.
_ Ensure that lockout/tagout devices identify the
individual users._ Establish a policy that permits

3.6.3 only the employee who applied a lockout/tagout
Employees need to be trained to ensure that they device to remove it. [See 29 CFR
know, understand, and follow the applicable
1910.147(e)(3) for exception.
provisions of the hazardous energy control
Section Page
3 Safety 11
3.6 Lockout and tagout

(continued)
_ Inspect energy control procedures at least

annually.
_ Provide effective training as mandated for all
employees covered by the standard.

_ Comply with the additional energy control
provisions in OSHA standards when machines or

equipment must be tested or repositioned, when
outside contractors work at the site, in group
lockout situations, and during shift or personnel
changes.
3.6.5
OSHA’s Safety and Health Management
Program Guidelines identify elements that are
critical to the development of a safety and health
management system. This and other information
are available on OSHA’s website at
www.osha.gov.
3.6.6
For compliance requirements of OSHA standards
or regulations, refer to Title 29 of the Code of
Federal Regulations.
Section Page
3 Safety 12
3.7 Electrical energy 3.7.6

Repairs and maintenance on the electrical
3.7.1 components must be carried out by a qualified
If a fault occurs in the electrical system Switch electrician or by persons under instruction
off the machine immediately. from a qualified electrician. All electrical
work must be carried out in accordance with
Before servicing electrical components always electrical engineering rules and regulations.
lockout and tagout the machine.
3.7.7
Only use original fuses with the specified DANGER! High voltage devices must be de-
current rating. energized after lockout and tagout. Before
starting any work check for the presence of
3.7.2 power then if necessary short-circuit or
Do not recharge the battery or weld around the ground them. Make sure that you are insulated
machine with the remote control unit connected; from adjacent live components.
3.7.3 3.7.8
Always disconnect battery ground cable before Inspect the electrical system for visual damage
making adjustments on electrical systems or every time the machine is cleaned or at least
welding on machine. every four weeks. If any wires or electrical
components are damaged or have loose
3.7.4 connections they must be rectified
Keep the machine away from overhead power immediately.
lines.
3.7.9
DANGER! If working in the vicinity of When the necessity arises for work on live
overhead power lines, observe prescribed safety components there must be a second person
distances. present, who can cut off the power supply in the
event of an emergency.
Touching a live wire with the machine is very Make sure a secured working area has been
dangerous, this can cause death. cordoned of with a safety barrier and warning
signs.
3.7.5
3.7.10
Never use the Tesab machine near live wires. This machine is wired negative earth.
If the machine comes into contact with a live Always observe correct polarity.
wire: Always disconnect battery leads before carrying
- Do not touch any part of the machine, out any maintenance to the electrical system.
including the remote control. The battery contains sulphuric acid, an
- Warn other people to not approach or electrolyte that can cause severe burns and
touch the machine. produce explosive gases. DANGER! Keep
- Contact the relevant authorities and get naked flames and sparks clear of the battery
the live wire de-energized. Avoid contact with the skin, eyes or clothing.
-
Section Page
3 Safety 13
3.8 Hydraulic System

3.8.1
Repairs and maintenance to the hydraulic Always relieve pressure from the hydraulic
system must be carried out by qualified system before carrying out any kind of
hydraulic-mechanical personnel. maintenance or adjustment.
Never work alone.
3.8.2
Inspect all hydraulic hoses, screwed
connections, hydraulic pumps and valves for Always use a piece of cardboard to check for
leaks; chafe marks and damage on a daily basis. leaks. Do not use your hand.
Any defects found must be rectified without
delay. Get medical help immediately.
3.8.3
Before commencing work on the hydraulic
system, it must be depressurized.
3.8.4
DANGER! Any hose or fitting that is to be
replaced must be of the correct thread, length,
pressure rating and of the same quality and
comply with all technical requirements for the
Tesab machine.
WARNING! High-pressure hydraulics are

extremely dangerous, always comply with the
above.
3.8.5
Extreme cleanliness is required when servicing
hydraulic components.
3.8.6
WARNING! Hydraulic fluid under pressure
can penetrate the skin causing serious injury.
If fluid is injected under the skin, it must be

surgically removed or gangrene will result.
Section Page
3 Safety 14
3.9 Disposal of parts and

contaminants
3.9.1
Do not pour waste onto the ground, down a
drain or into any water source.
Ensure that all consumables and replaced

components are disposed of safely and with
minimum environmental impact.
See Material Safety Data Sheets (Section 3.14)

for the safe use of contaminants used in the
Tesab machine.
3.9.2
Always recycle removed parts, if possible.
3.9.3
Waste oils should always be recycled.
3.9.4
Follow the regulations when disposing of waste.
Careless waste disposal can threaten the
environment and ecology.
Always read the safety data sheets provided.

Potentially harmful waste used with Tesab
machines includes such items as diesel fuel,
grease, oil, batteries, filters and coolant /
antifreeze.
Section Page
3 Safety 15
3.10 Transport and stability

3.10.1
WARNING! Whenever the machine is to be 3.10.6
towed, loaded and transported, do so only in WARNING! When transporting the machine
accordance with the operating instructions. on a trailer on sloping terrain, always adapt
your traveling speed to the relevant ground
Make sure that you always comply with road conditions.
traffic regulations for example;
Transport width, height, weight, axle load and Never select a lower gear on an incline.
illumination. Always select the proper gear before reaching
an incline.
3.10.2
WARNING! It imperative that the machine is 3.10.7
always cleaned before transporting. Material DANGER! Never attempt to use the crawler
falling from the machine maybe hazardous for tracks to ascend or descend a slope of more
other road users. than 25° in good conditions. Reduce the angle
when working in slippery conditions.
Check for any components that may have The stability of the machine maybe
become loose and that could fall of the machine compromised if you do not adhere to this rule.
during transport. Tighten all loose fastenings to
the appropriate torque. 3.10.8
When setting the machine up in the working
Check that all pins have clips fitted, to prevent position, always make sure that the machine is
the pins from being dislocated during transport. set up on stable ground.
3.10.3 The machine must be set up so that it is sitting

WARNING! Store all loose accessories away level in all directions. Use a spirit level to help
and make sure they are secure. achieve this.
3.10.4 If the machine is not level, conveyor belts will

DANGER! When crossing underpasses, bridges tend to run off line, which in turn will cause
and tunnels or when passing under overhead material spillage and damage to the conveyor
power lines always make sure that there is belts.
sufficient clearance.
WARNING! Never raise the machine up on
3.10.5 built up material to increase the stockpile
WARNING! Never traverse across slopes; heights unless the material has been well
always keep the machine as close to the ground packed and is very stable and level. It is up to
as possible when transporting on a trailer, to the operator to make this decision.
prevent an overturning hazard.
Section Page
3 Safety 16
3.11 Emergency stop positions

Section Page
3 Safety 17
3.12 Safety hazard decals
3D176.011EN 3D176.012EN 3D176.014EN
3D176.015EN 3D176.016EN 3D176.017EN 3D176.018EN
3D176.019EN 3D176.020EN 3D176.021EN 3D176.023EN
3D176.047
3.13 Position of safety hazard decal
Section Page
4 General Information 1

4.1 Introduction.....….……………………………………………………………….2
4.2 General information.....………………………….…………………………...….2
4.3 Care and maintenance.………………..…………………………………………2
4.4 Service….…………..……………………………………………………………2
Section Page
4 General information 2
4.1 Introduction 4.4 Service
This instruction manual must always be Please contact one of our authorized service
available when the Tesab machine is in use. representatives in the event of breakdowns or
for spare parts queries. Our trained specialists
The instruction manual contains information will carry out repairs quickly and
on how to safely operate the machine. professionally, using only genuine spare parts.
Always think safety first, make sure that you

adhere to all of the instructions within this
instruction manual. This will help to avoid
hazards, reduce machinery downtime and
repair bills.
This instruction manual must be read and

adhered to by any person transporting,
maintaining or operating the machine.
4.2 General information

Tesab machines are the product of engineers
who have many years of experience of
research and development. The resulting
knowledge, coupled with stringent quality
standards, will give high reliability and long
service life.
4.3 Care and maintenance

Sound care and maintenance practices will
ensure that the machine continues to meet the
requirements placed on it. Recommended
service intervals must be observed and service
and maintenance work carried out
conscientiously. Special care should be taken
under abnormally demanding operating
conditions.
Section Page
5 Designated use 1

5.1 Designated use.....….…………………………………………………………2
Section Page
5 Designated use 2
5.1 Designated use

Warning! The machine has been built
The machine has been designed as an
exclusively for the application specified in the
independent mobile vibrating screen with
intended purpose by the manufacturer and its
three integral stockpile conveyors for
use is only for the intended purpose. Any use
separating materials into various sizes.
exceeding that scope is considered to be
contrary to the intended purpose. The
The material is fed by the operator into a feed
manufacturer will not assume responsibility
hopper either by loading shovel or a conveyor.
for any damage resulting there from. The risks
involved are to be borne solely by the user.
A variable speed feed conveyor transfers the
material via a main conveyor to a vibrating
Use in accordance with the intended purpose
screen. The screen has interchangeable
also implies compliance with the conditions
meshes with different apertures for different
laid down by the manufacturer for operation,
sizes of material.
maintenance and servicing. The machine shall
only be operated by personnel trained in its
The screen divides the material into separate
use and the hazards involve.
sizes.
The sized material is transferred to stockpiles

via three integral stockpile conveyors.
Typical materials that can be screened;

- Coal
- Grain
- Refuse
- Rock
- Sand and gravel
- Top soil
- Wood bark
- Wood chips
If you would like to process another material
not on the above list, please contact us.
Section Page
6 Technical information 1

6.1 Machine designation and type.……..…………………………………………...2
6.2 General information.....………………………….…………………………...….2
6.3 Sub assembly positions / technical info...……......……...………………………3
Section Page
6.1 Machine designation
Machine designation………………… Tesab

Designation type……………………... 1550
Hopper capacity ……………………. 8.7m3 (11.7yd3)
Screenbox…………………………... 6.7m x 1.525m (22’ x 5’) top deck

6.1m x 1.525m (20’ x 5’) bottom deck
Engine………………………………. Caterpillar C4.4 TA (Tier III)

96kw (129hp)
Belt feed conveyor………………….. 1400mm (55”)
Collection conveyor………………… 1200mm (48”)
Fines side conveyor………………… 900mm (36”)
Mid size conveyors………………… 900mm (36”) chevron belt
Tail Conveyor……………………… 1600mm (63”) chevron belt
Estimated gross weight……………… 35,000 kg (77,175 pounds)

Section Page
6.3 Sub assembly positions / technical info
6.3.1 Nomenclature
A D B C D E
F G H
Construction Unit (Component)
A Feeder Unit & Hopper F Power unit (Engine)

B Collection conveyor G Hydraulics
C Screen Unit (Screenbox & Mesh) H Chassis (crawler tracks)
D Side conveyors
E Oversize conveyor (Tail conveyor)
Section Page
6.3.2 (A) Feeder Unit
6.3.2.1 Hopper
Length……………………………………….. 5800mm
Width………………………………………... 2010mm
Height……………………………………….. 1550mm
Capacity…………………………………….... 8.7m3 (11.7yd3)
Weight………………………………………. 1920kg
6.3.2.2 Belt Feed Conveyor
Length……………………………………….. 5007mm
Width………………………………………... 1858mm
Height……………………………………….. 600mm
Belt width……………………………………. 1400mm
Weight……………………………………….. 1872kg
6.3.2.3 Apron Feed Conveyor
Length……………………………………….. 4923mm
Width………………………………………... 2030mm
Height……………………………………….. 700mm
Shoe width……………………………………. 1230mm
Weight……………………………………….. 3750kg
6.3.3 (B) Collection Conveyor
Length……………………………………….. 4915mm
Width………………………………………... 1960mm
Height……………………………………….. 705mm
Belt width…………………………………… 1200mm
Incline (variable)……………………………. 14o
Weight………………………………………. 950kg
Section Page
6.3.4 (C) 2 Deck Screenbox, subframe and walkway (Screen Unit)
6.3.4.1 2 Deck Screenbox, sub frame and walkway

2 Bearing screen
Direct drive with hydraulic motor
Approximate stroke 7mm
Top deck 16x5
Bottom deck 15x5
Top deck x 4 # meshes……………………… 1500x1220mm
Bottom deck x 3 # meshes…………………… 1525x1525mm
Sub assy. Dimensions subframe and walkway included

Length……………………………………….. 6000mm
Width………………………………………... 2900mm
Height……………………………………….. 1814mm
Weight………………………………………. 5070kg
6.3.4.2 Screen Meshes
Screen meshes
Weight (min to max)………………………… 19kg to 135kg
Section Page
6.3.5 (D) Side Conveyors

Length……………………………………….. 9800mm
Width………………………………………... 1780mm
Height……………………………………….. 1600mm
Belt width…………………………………… 900mm

Incline………………………………………. 24o
Weight………………………………………. 1800kg Each
6.3.6 (E) Over Size Conveyor (Tail Conveyor)
Length……………………………………….. 5900mm
Width………………………………………... 2538mm
Height……………………………………….. 730mm
Belt width…………………………………… 1600mm

Incline (variable)……………………………. 24o Max.
Weight………………………………………. 2700kg
6.3.7 (F) Power Unit
Length……………………………………….. 2600mm
Width………………………………………… 1820mm
Height……………………………………….. 1700mm
Engine power………………………………... 96 kW (129 HP)
Battery............................................................. 12 Volt
Weight………………………………………. 1890kg
Section Page
6.3.8 (G) Hydraulics (Hoses)
Type Diameter Working Pressure Test Pressure Burst Pressure
R1 AT
DIN 20022 Part 3
3/8” 2570 psi 6307 psi 10440 psi
1/2” 2295 psi 5582 psi 9280 psi
3/4” 1500 psi 3697 psi 6090 psi
1” 1255 psi 3045 psi 5075 psi
1 1/4” 900 psi 2175 psi 3625 psi
1 1/2” 715 psi 1740 psi 2900 psi
2” 570 psi 1392 psi 2320 psi
R2 AT
DIN 20022 Part 4
3/8” 4710 psi 11527 psi 19140 psi
1/2” 3930 psi 9570 psi 15950 psi
3/4” 3070 psi 7395 psi 12325 psi
1” 2355 psi 5655 psi 9425 psi
1 1/4” 1785 psi 4350 psi 7250 psi
1 1/2” 1285 psi 3190 psi 5220 psi
2” 1140 psi 2827 psi 4640 psi
Pix XP 3/4” 4500psi 17980 psi
6.3.9 (H) Chassis (Crawler Tracks)
Length……………………………………….. 10380mm
Width ……………………………………….. 2918mm
Height……………………………………….. 2600mm
Triple grouser width………………………… 500mm
Hydraulic drive motor……………………… . 90 cc/rev
Gearbox ratio………………………………… 1:144
Max. motor oil pressure……………………... 210 bar
Max. oil flow per track………………………. 65 Ltr
Max. speed …………………………………... 0.55 Km/h
Total tractive effort………………………….. 211.7 kN
Gradient (degrees)…………………………… 30.33o
Gradient (percent)…………………………… 58.49%
Weight………………………………………. 8400kg
Section Page
7 Design and function 1

7.1 Machine orientation.……………………………...………………...…………... 2
7.2 Machine construction units….…………………………………………………...3

7.2.1 (A) Feeder unit………………………………….……………………….3
Typical Conveyor unit assembly…………………………………4
Belt performance…………………………………………………5
Belt tension…………………………………………………….…6
Belt alignment…………………………………………………….6
Belt slippage………………………………………………………6
7.2.2 (B) Collection Conveyor……...………………………………………….7
7.2.3 (C) Screen Unit…………...……………………………………………...8
7.2.4 (D) Side Conveyors……….……………………………………………..11
7.2.5 (E) Oversize Conveyor (Tail Conveyor)...………………………………13
7.2.6 (F) Power unit…………………………………………………...……….14
7.2.6.1 (F1) Starter Panel warning lights…………………………………16
7.2.6.2 (F2) Main Control Valve Unit……………………………………19
7.2.6.3 (14) Throttle Switch………………………………………………23
7.2.6.4 (F4) Rear RHS Control Valve Unit………………………………24
7.2.6.5 (F5) Rear LHS Control Valve Unit………………………………25
7.2.6.6 (F6) Crawler Track Remote Control Unit………………………..26
7.2.7 (G) Hydraulic System…………………………………………………………….28
7.2.8 (H) Chassis………………………………………………………………………..29

Section Page
7.1 Machine orientation
LHS Left hand side
Rear
Front
RHS Right hand side
Section Page
7.2 Machine construction units
7.2.1 (A) Feeder unit

The feeder unit is made up from
4 main components as shown below.
Hopper
The steep sided hopper has 8.7m3 capacity. It is used to store
enough material to keep a constant flow of material to the
feed conveyor.
Belt feed conveyor

This is a variable speed conveyor. It controls the flow of
material from the hopper to the main conveyor.
The conveyor is fitted with a heavy duty vulcanized endless
belt which can be aligned without removing guards.
The conveyor is driven by 2 hydraulic motors and gearboxes.
Apron feed conveyor (Option)

This is a variable speed conveyor. It controls the flow of
material from the hopper to the main conveyor.
The conveyor is fitted with heavy duty Hardox shoes which
can be tensioned without removing guards.
The conveyor is driven by a hydraulic motor and gearbox.
Feeder enclosure
This unit consists of supporting members which supports
the feeder conveyor, hopper and reject grid. It is bolted to
to the chassis and is fitted with 2 hydraulically operated
support legs.
Section Page
7.2.1 Typical conveyor unit assembly
This is a typical view for all of the conveyors fitted to the Tesab machine.
With the exception of the gearbox the following items are used in all conveyors.
1 Tail drum guard with viewing apertatures

2 Belt alignment adjuster
3 Tail drum
4 Tail drum scraper
5 Conveyor belt
6 Centre roller
7 Side roller (wing roller)
8 Return roller
9 Belt scraper
10 Gearbox
11 Hydraulic motor
12 Drive drum
Section Page
Conveyor Belt Performance

All conveyor belts and drum The correct procedure for
lagging on Tesab machines are changing a belt/lagging is to
made to the highest standards and contact your local Tesab dealer
are tough and durable. who will either carry out the work
himself or get it carried out by
However these are consumable personnel trained in this field.
items and will need to be replaced
as a result of normal wear and To ensure optimum performance
tear. and safety, the conveyor(s) must
be:
Spliced belts are less effective
than vulcanized and have an 1. Cleaned on a daily basis or
increased tendency to slip. more frequently depending on the
application.
A belt which has been adjusted to
its maximum must be replaced 2. Checked for cuts, tears, rips or
with a new belt. any other physical damage.
Worn lagging must also be 3. Tensioned properly.

replaced.
4. Kept in alignment.
Section Page
Belt Tension
The belt will normally have to

be tensioned a number of times 1. Machine not perfectly
during the belt‘s lifetime due to levelled.
the natural stretching of the
belt. 2. Faulty belt tension.
It is very important that the 3. Incorrect position of the

conveyor belt is tensioned drums.
evenly and to the correct level,
not too tight and not too loose. Solutions refer to section
“troubleshooting.”
A loose belt can cause
slippage, resulting in reduced Belt Slippage
throughput. So long as the described
maintenance procedures have
An over-tight belt can damage been properly observed, your
drum bearings, resulting in machine should not experience
increased downtime. Correct belt slippage.
tension is obtained when no
slippage occurs during normal Slippage occurs when the drum
use. turns and the belt does not
move.
Belt alignment Slippage can occur for a
number of reasons including:
For safe, proper and efficient
1. Incorrectly tensioned belts.
operation of the machine, it is
important that conveyor belts
2. Worn belts.
are properly aligned.
3. Ineffective lagging.
The belt alignment can be
checked without removing any
4. Too much load on the belt.
guard by looking through the
viewing apertures.
5. Rollers cannot rotate freely.
The conveyor belts are aligned
Solutions refer to Section
by adjusting the drum
“Troubleshooting.”
adjusters.
Reasons for the conveyor belts

not running in alignment:
Section Page
7.2.2 (B) Collection Conveyor

The collection conveyor is attached to the Tesab chassis for the purpose of
collecting material from the screen unit and then transferring the screened
material to the fines side conveyor.
The collection conveyor belt is driven by a hydraulic motor.
It is fully skirted; belt tension adjustments can be made at the bottom of the
conveyor under the screenbox.
B
Section Page
7.2.3 (C) Screen Unit
The screen unit is attached at the end of the Tesab feed conveyor where it screens
raw material into different sizes.
The screen unit is direct driven by a hydraulic motor and flexible coupling.
The screenbox angle is changed by raising or lowering the screenbox

hydraulically.
To prepare for operation, raise the screenbox. To prepare for transport, lower the
screenbox.
The screenbox has 4 rubber isolators. These prevent the screenbox from moving
while in transport position.
Before the Tesab is towed on the highway the Screenbox must be lowered into the
towing position.
Section Page
7.2.3 (C) Screen Unit

This is a two-bearing Screenbox which gives three-way separation of raw
material.
Meshes of differing sizes are available to cater for all applications.

Finger decks. Punch plate and Bofor bars are an option.
The screen unit consists of a 2 Deck screenbox fitted with 2 flange mounted
bearings (1) and a sealed pipe unit.
Within the pipe unit and rotating on the two bearings is an eccentric screen shaft
(2).
On the outer end of the screen shaft is fitted a flywheel complete with weights (3)
and coupling (4).
The screen shaft is driven from the motor fitted (5) on the Screenbox flywheel
guard (6).
The subframe in turn is rigidly connected to the chassis of the machine.
Screen springs (7) are used to support the Screenbox totally.
6 1 2 3 4 5 7
Section Page
7.2.3
(C) Screen Unit
The rotation of the screen shaft (2) causes the screen unit to follow a circular path
and provide the screening action (i.e. vibration.)
The natural motion of the Screenbox would be to cause an undesirable “out of-
balance” reaction.
To prevent this two flywheels are mounted on the screen shaft to balance the
Screenbox.
These flywheels (3) are normally fitted with additional balance weights (flywheel
weights), to adjust their overall weight to compensate for varying weights of
Screenbox as a result of different sizes of meshes being fitted.
Hence the two-bearing screen unit can easily be adjusted (tuned) to achieve
perfect overall balance and transmit no vibration into the subframe or chassis.
1 2 3 4 5 7
Section Page
7.2.4 (D) Side Conveyors

The side conveyors are attached to the Tesab chassis for the purpose of feeding
material at 90 degrees to the chassis. They are hydraulically opened and closed.
The side conveyor belts are both driven by a hydraulic motor.
For transport purposes the side conveyors are pinned into position (P).
They include a feedboot and incorporate head drum guarding.
Belt tension adjustments can be made external to the guard doors.
D
Left hand side conveyor
Right hand side conveyor
P P
P
Section Page
7.2.4 (D) Side Conveyors (Continued)
Right Hand Side Conveyor Left Hand Side Conveyor
P
Section Page
7.2.5 (E) Oversize Conveyor (Tail Conveyor)

The tail conveyor is attached to the rear end of the chassis for the purpose of
feeding the oversize material from the screen.
The conveyor is hydraulically opened to working position and retracted to ground

level facilitating quick machine set up and shut down.
For transport purposes the tail conveyor is pinned into position (P).
The tail conveyor belt is driven by a hydraulic motor.
E E
P
Section Page

The power unit (F) is attached at the chassis (H) of the Tesab, under the Feeder
unit and hopper (B).
The power unit is completely enclosed and lockable.
F H
F
Section Page
7.2 Machine construction units F2 F3 F1
The Tesab has seven control units.

Starter panel (F1)
Main control valve unit (F2)
Throttle (F3)
Control valve unit (F4)
Control valve unit (F5)
Remote Crawler Track control (F6) F4
Radio remote Crawler Track control (F7)
Starter panel F1, control valve

unit F2,hand throttle F3 and control valve unit
F4 are situated at the powerunit on the
right hand side of the machine.
The control valve (F5) is

situated at the powerunit of the machine.
(F5) can be found to the left hand side of the
powerunit.
F5
Control unit (F6) type A or type B is an
independent control unit.
It controls the movement of the tracks.
Control unit (F7) (Option) is a radio remote

independent control unit.
It controls the movement of the tracks.
F7
F6
Section Page
7.2.6.1 (F1) Starter Panel warning lights
1.Battery Charging Warning Light

This light should illuminate when the key 16
switch is turned to the On position.
As soon as the engine starts it should go 1
out. If it fails to illuminate when the key is 2
3
turned on, or if it illuminates when the
4
engine is running, it indicates that there 5
is a fault in the charging circuit. Stop the 6
engine and have the circuit checked. 7
8
2.Oil Pressure Warning Light 9
This light should illuminate when the key 10
11
switch is turned to the ON position.
As soon as the engine starts it should go 12
out. If a fault occurs in the oil pressure 13
system the engine will shut down after 2 15 14
seconds.
3.Coolant Warning Light

This light will only illuminate if a problem
occurs in the coolant system, such as low
water level. The engine will shut down 5
seconds after the fault has been
detected.
4. Fuel Contamination Warning Light

This light will only illuminate if a problem occurs in the fuel system, such as water
contamination. The engine will shut down 1second after the fault has been
detected.
5. Engine Run light

This light will only illuminate when the key is turned to the ON position and will
remain on at all times. If it goes out then an Emergency-Stop has been pressed
and the engine will shut down immediately.
Section Page
7.2.6.1 (F1) Starter Panel warning lights (Continued)
6. Air breather Restriction Warning Light.

This light should illuminate if a problem occurs in the air breather system. If the
panel continues to receive a fault signal, the light will remain on for 30 minutes.
After 30 minutes the engine will shut down but the light will remain on until the
fault has been repaired.
7. Fuel on Light
This light should illuminate when the engine starts and will remain on at all times.
It will go out when the engine has been shut down.
8. Hydraulic Oil level Warning Light

This light will only illuminate if the hydraulic oil level is low. The engine will
shut down 5 seconds after the fault has been detected.
9. Emergency-Stop Activated Light
This light will only illuminate when an
Emergency-Stop has been pressed. This will immediately shut down the engine. If
the light is flashing after shut down, this indicates that the manual tracking dog
lead Emergency-Stop has been pressed. If the light remains on constantly then
another Emergency-Stop has been pressed.
10. Engine Pre-heat Indicator Light

This light only illuminates when the pre-heat switch is operated during start up.
11. Engine Warning Light
12. Engine Shut Down Light
13. Key Start Switch

This is used to start the engine.
14. Throttle switch.

This is used to control the engine speed.

Section Page
7.2.6.1 (F1) Starter Panel warning lights (Continued)
15. Hour Meter

This records the number of hours that the engine has been running.
16. Fuel Level Gauge.
See attached JMG Control Panel Operation Manual for further information
Section Page
7.2.6.2 (F2) Main control valve unit

A
The levers of the main control valve

unit, are for the purpose of powering
all functions on the machine.
A) Main control valve bank.
B) Variable speed flow control

valve for FEEDER conveyor.
C) Variable speed flow control

valve for tail conveyor.
D) Variable speed flow control

valve for LHS side conveyor. B C D E
E) Variable speed control valve

for RHS side conveyor.
Note that all control valve levers

are labelled on the machine.
Lever Symbols
In the manual the following
symbols are used to show the
position (up (in), neutral, down (out)) of
the levers.
Section Page
(A) Main control valve bank A
The Main control bank performs

the following function:
Engaging/stopping the drive
(1) Feed Conveyor

Drive: OUT
Stop: NEUTRAL
(2) Drive Screenbox / Engage Track

Drive: OUT
Stop: NEUTRAL
Engage Track: IN
(3) Drive Tail Conveyor / Engage Track

Drive: OUT
Stop: NEUTRAL
Engage Track: IN
(4) Drive Collection & L/H Side Conveyor

/ Engage Auxiliary Valve
Drive: OUT
Stop: NEUTRAL
Engage Aux. Valve IN
(5) Drive R/H Side Conveyor

Drive: OUT
Stop: NEUTRAL
Section Page
(B) Variable speed flow control valve
The variable speed flow control

valve (B) controls the speed of
the feeder conveyor when the
feeder control valve (1) is engaged.
Rotating clockwise
decreases the speed of the
feeder conveyor.
Rotating counter clockwise

increases the speed of the
feeder conveyor.
(C) Variable speed flow control valve /

Tail Conveyor

valve (C) controls the speed of
the tail conveyor, when the tail conveyor
control valve (3) is engaged.
Rotating clockwise decreases the speed

of the tail conveyor.
Rotating counter clockwise increases

the speed of the tail conveyor. C
Section Page
(D) Variable speed flow control valve /

Left Hand Side Conveyor

valve (D) controls the speed of
left hand side conveyor, when
the drive collection an LHS side
conveyor control valve (4) is
engaged.
Rotating clockwise
decreases the speed of the left
hand side conveyor.
Rotating counter clockwise D

increases the speed of the right
hand side conveyor.
(E) Variable speed flow control valve /

Right Hand Side Conveyor

valve (E) controls the speed of
right hand side conveyor, when
the side conveyor control valve (5) is
engaged.
Rotating clockwise
decreases the speed of the right
hand side conveyor.
Rotating counter clockwise

increases the speed of the right
hand side conveyor. E
Section Page
7.2.6.3 (14) Throttle Switch
The throttle switch (located on

powerunit starter panel has two
functions:
Increasing/decreasing the engine

speed.
(14) Throttle Switch

14
To increase power / engine speed
Turn switch clockwise to (Engine Speed
Intermediate) position for fast idle.
Turn switch clockwise to (Full) for
Maximum engine speed / Maximum power.
To decrease power / engine speed

Turn switch counter clockwise to (Engine Speed
Intermediate) position for fast idle.
Turn switch counter clockwise to (Idle) for
Minimum engine speed / Minimum power.
Section Page
7.2.6.4 (F4) Right Hand Side Control Valve Unit
The control valve unit (F4) is

situated on the right hand side of the powerunit.
F4
(1) RHS side conveyor

Raise / close in (fold). Lower / open out (unfold).
Fold: IN
Stop: NEUTRAL
Unfold: OUT
(2) Feed conveyor / hopper

Raise and lower.
Raise: IN
Stop: NEUTRAL
Lower: OUT
(3) Screen Angle

Raise and lower.
Raise: IN
Stop: NEUTRAL
Lower: OUT
(4) Screen Raise

Raise and lower.
Raise: IN
Stop: NEUTRAL
Lower: OUT
Section Page
7.2.6.5 (F5) Left Hand Side Control Valve Unit
The control valve unit (F5) is situated

on the left hand side of the powerunit.
(1) Tail conveyor F5

Lower / open out (unfold). Raise / close in (fold).
Unfold: IN
Stop: NEUTRAL
Fold: OUT
(2) Tail conveyor

Raise / Lower.
Raise: IN
Stop: NEUTRAL
Lower: OUT
(3) LHS side conveyor

Raise / close in (fold). Lower / open out (unfold).
Fold / Raise: IN
Stop: NEUTRAL
Unfold / Lower: OUT
Section Page
7.2.6.6 (F6) Crawler track

Remote Control Unit
This remote control is only used to

operate the crawler tracks. It performs no
other operation.
The remote control unit consists of a
hand-held unit and direct lead.
It is located inside the front right hand

corner of the powerunit.
F6
To operate the remote control;
1A
Make sure the Emergency Stops are
not engaged.
Start Engine.
(2) Drive Screenbox / Engage Track

Engage Track: IN
(3) Drive Tail Conveyor / Engage Track

Engage Track: IN
F6
Switch the “AUX / TRACK” switch (1A)
on the doglead handset, to “TRACK“
position.
The warning siren will sound for 7 1A

seconds before the tracks can operate.
The flashing beacon will also light up.

Section Page
7.2.6.6 (F6) Crawler track

Remote Control Unit
Reverse Reverse
Left Hand Right Hand

Track Track
Forward Forward
Emergency Track
Stop ON / OFF
Button Switch
Reverse Reverse

Track Track
Forward
Forward
Section Page
7.2.7 (G) Hydraulic system

The system which is able to supply
hydraulic power from a pump along
a hose to activate a piece of
equipment .
1) Hydraulic Oil Level

Indicator
2) Filler Cap
3) Drain Plug
4) Suction Filters
5) Return Line Filter
6) Oil Level Switch
7) Service Panel 8 9
8) Clogging Indicator
9) Typical Control Valve
10) Hydraulic pumps
10
Section Page
7.2.8 (H) Chassis
The chassis is sturdily

constructed and supports the
hopper, collection conveyor, side conveyors, tail conveyor, powerunit and screen
unit.
In working position the machine

is supported by one pair of crawler
tracks.
H
Section Page
8 Transport 1
Contents Page
8.1 Tracked machine ............................................................................2
8.2 Repositioning on the work site .......................................................4

Section Page
8 Transport 2
8.1 Tracked machine

C HAZARDS
Prior to towing the WEAR PERSONAL PROTECTIVE
Tesab 1550 on the highway, EQUIPMENT
See Section 3.1 Page 2, safety information
the machine must be put in for relevant warning.
towing position in
CRUSHING HAZARD
accordance with Section 11, Hopper Jack Legs
“Shut down. “ Refer this Section 3.3, safety information
for relevant warning.
PRO
1. Observe all safety
warnings. READ OPERATOR‘S MANUAL
ENTANGLEMENT MANUAL
2. Remove all loose materials Refer this Section 3.3.23, safety information
such as rocks from the
machine. PRIOR TO TRANSPORT HAZARD
Refer to Safety Chapter Section -
Machine Safety Hazard Decals for
3. Put the machine in the relevant warning
transport position. (Refer to
Section 11, “Shut down. “)
Section Page
8 Transport 3
5: The machine should be positioned on a semi low loader or low loader as

shown, with the Screenbox at its lowest position and the tail conveyor fully
folded.
The transport height should not be more than 4m.

Section Page
8 Transport 4
8.2 Repositioning on the work site

1. Observe all safety warnings. HAZARDS
2. Shut-off machine. WEAR PERSONAL PROTECTIVE
(Refer to Section 11, “Shut down.“) EQUIPMENT
Refer to Safety Chapter Section 3.1 Page 2
3. Put the machine in the transport position. CRUSHING HAZARD

Hopper Jack Legs
(Refer to Section 11, “Shut down.“) Refer to Safety Chapter Section 3.3 -
LOCKOUT MACHINE
Refer to Safety Chapter Section 3.6 -
PRIOR TO TRANSPORT HAZARD

Refer to Safety Chapter Section -
Prior to repositioning the Tesab on the

work site, the machine must be put in
towing position in accordance with
Section 11, “Shut down.“
PROCE
Section Page
8 Transport 5
Section Page
9 Setup 1
9.1 General information ........................................................................................... 2
9.2 Dimensions, required space and weight .............................................................2
9.3 Measures before set up ........................................................................................2
9.4 Measures after long term standstill ......................................................................3
9.5 Machine set up .....................................................................................................3
9.5.1 Machine set up sequence......................................................................................4
9.5.1.1 Starting the engine ...............................................................................................5
9.5.2 Removing machine from a low loading trailer.....................................................6
9.5.2.1 Remote control…………………………………………………………………..6
9.5.3 Prior to installation………………………………………………………………9
9.5.4 (D) Opening out (unfolding) RHS side conveyor………...................................10
9.5.5 (D) Opening out (unfolding) LHS side conveyor................................................15
9.5.6 (E) Opening out (unfolding) Tail conveyor .......................................................20
9.5.7 (E) Setting the Tail conveyor incline...................................................................22
9.5.8 (C) Raising the screen box into the working position.........................................25
9.5.9 (A) Setting the Feed conveyor into the working position...................................29
9.5.10 (A) Setting the Hopper wing plates into the working position............................31
Section Page
9 Setup 2
9.1 General information 9.3 Measures before set up
We recommend that the assembly/ 1. Ensure all guards are fully secured in
installation work of the Tesab be carried out correct/closed position.
by the Tesab customer service department.
The manufacturer/supplier will not be liable 2. Remove all loose items from the belt by
for damage caused by improper assembly / untying the securing ropes.
installation.
3. Put control valve levers in neutral (non-
operational) position. When setting up the
Tesab pay particular attention to the
9.2 Dimensions, required space and
following points:
weight
1) The Tesab must be placed on solid
Dimensions ground capable of carrying the machine‘s
Refer to Section 13, “Appendix.” weight.
Required space 2) Before detaching the Tesab from the
Refer to Section 13, “Appendix.” prime mover, it is important that the chosen
site is level. Level the worksite foundation
Weight with the loading shovel.
Refer to Section 6, “Technical Information.”
3) Level the Tesab with a precision spirit
level.
4) Do not position the machine above

ground level, e.g. on blocks etc..
Section Page
9 Setup 3
9.4 Measures after long term

standstill
HAZARDS
Check all tracks, fluid levels and remove
WEAR PERSONAL PROTECTIVE
loose debris before transporting or moving EQUIPMENT
the machine. Refer to Safety Chapter Section 3.1 Page 2
CRUSHING HAZARD
Hopper Jack Legs
9.5 Machine set up Refer to Safety Chapter Section 3.3 -
PRIOR TO TRANSPORT HAZARD

For dusty conditions some account should Refer to Safety Chapter Section -
be taken of the prevailing wind direction to
minimize the possibility of dust entering the
air intake. Prior to repositioning the Tesab on the
work site, the machine must be put in
When setting up the Tesab ensure that towing position in accordance with
enough space is available around the Section 11, “Shut down.“
machine to enable easy set up, servicing and
repair work. Prior to putting into operation perform
daily (10 hour) maintenance schedule.
Machines arranged before and after the
Tesab will have to be placed accordingly.
The general arrangement diagram giving

you the basic information of the Tesab
including measurements and weight is
provided in Section 13, “Appendix.”
Before setting up the Tesab this Section and

all of the previous Sections must be read,
understood and observed. Any work on and
with the machine must be carried out only
by personnel with specialized knowledge of
and experience with maintenance and
operation. Statutory minimum age limits
must be observed.
Section Page
9 Setup 4
9.5.1 Machine set up sequence

HAZARDS
The following steps are outlined within this EQUIPMENT
chapter: Refer to Safety Chapter Section 3.1 Page 2
ENTANGLEMENT HAZARD
1. Observe all safety Warnings. Refer this Section 3.3.23, safety information
2. Remove from low loader. SKIN INJECTION HAZARD

Refer this Section 3.8.6, safety information
3. Unfold (open out) Side Conveyors.
4. Unfold Tail Conveyor (Oversize

Conveyor) head section.
5. Setting the Tail conveyor into working

position.
6. Raise Screenbox into working position.
7. Setting Hopper and Feed conveyor into

working position.
Section Page
9 Setup 5
9.5.1.1 Starting the engine

All control levers must be in the neutral (non-operational) position.
PROCEDURE
1. Observe all safety warnings.
2. Turn ignition key to position
3. The following warning lights

on the control panel will illuminate:
Charge light
Engine run light
Oil pressure light
4. Turn ignition key clockwise to position,

the safety siren will start, hold in this
position until the warning siren stops after 7
seconds.
5. Release ignition key immediately after the IMPORTANT

engine starts. The key will return to run NOTICE
position.
If the warning lights fail to extinguish,
stop the engine immediately detect
and repair the fault before using the
machine.
Section Page
9 Setup 6
A
9.5.2 Removing Tesab
from a low loading trailer
9.5.2.1 Remote control

Refer to Section 7,
“Design & Function, “for complete
specification on remote control unit
before attempting the following
procedures.
IMPORTANT
All control levers must be in the neutral

(non-operational) position.
PROCEDURE
2. Prepare the low loading trailer, for removing

the Tesab.
3. Start the engine. Run engine at idle speed.

(Refer to Section 9.5.1.)
SAFETY NOTICE
Ensure all personnel are clear of the

machine.
Section Page
9 Setup 7

5. Locate the remote control (refer to section
(Continued)
7.2.6.7) Switch the “Aux /Track” switch to
“TRACK”. The siren will sound and the
4. Push in levers (2) and (3) at (A) Main
flashing beacon will operate. The remote
Control Valve. This will engage power to the
control unit will not work for 7 seconds, giving
tracks. The tracks will not move until the
personnel a prior warning to the machine
buttons are pressed on the remote control.
moving.
SAFETY NOTICE
Ensure all personnel are clear of the

machine.
Reverse Reverse

Track Track
Forward Forward
Emergency Track
Stop ON / OFF
Button Switch
Section Page
9 Setup 8

(Continued)
8. Standing at a safe distance from the

machine, operate the track switches to move
the Tesab off the low loading trailer.
9. Move the Tesab into the required position

on the work site.
Section Page
9 Setup 9
9.5.3 Prior to installation:
Important Information
PROCEDURE
2. Remove items, such as packing kit etc.,

from the feed conveyor / hopper.
Section Page
9 Setup 10
9.5.4 (D) Opening out

(unfolding) HAZARDS
RHS Side Conveyor
EQUIPMENT
SAFETY NOTICE ENTANGLEMENT HAZARD
Refer this Section 3.3.23 , safety information
All control levers must be in the
neutral (non-operational) position.
PROCEDURE
2. All control levers must be in the neutral

P3
3. Remove the transport pins, 3 off (P1, P2

& P3) right hand side conveyor.
P1
4. Start the engine. (Refer to engine starting

instructions 9.5.1.1)
P2
5. Remove all ropes or straps from each of
the side conveyors. (The ropes or straps
retain the conveyor belt in position for
transport).
Section Page
9 Setup 11

(unfolding)
HAZARDS
RHS Side Conveyor. WEAR PERSONAL PROTECTIVE
(Continued) EQUIPMENT
CRUSHING HAZARD
6. Slide the pin support box section (S) Refer this Section 3.3, safety information for relevant warning.
down and place the pin in the lowest hole
(H).
8. Pull out lever (1) at (F4) Control Valve.
This will start to open out (unfold) the RHS
Side conveyor. Do this operation very
slowly.
S
H
F4
7. Engage Auxiliary control valve (4).
9. When the conveyor moves to the

horizontal position, the conveyor starts to
open out.
Release the lever to stop opening the
conveyor when the conveyor has opened
out about 40° from the side of the machine.
Section Page
9 Setup 12

(unfolding) HAZARDS
RHS Side Conveyor.
Take care not to nip the CRUSHING HAZARD

conveyor belt between moving Refer this Section 3.3, safety information for relevant warning.
parts.
11. Pull out lever (1) at (F4) Control
Valve, move the conveyor very slowly
10. Lift the conveyor belt over the troughing
roller (T) to prevent the belt from snagging on until it is almost opened out fully.
the roller. Applies to both side conveyors. Make sure the “Turn Buckle” handle (B)
will not catch on the hoses.

11. Make sure the conveyor belt is lifted to the Valve, move the conveyor very slowly
inside of the drive drum guard (G).
until the conveyor is opened out fully.
F4
G
Section Page
9 Setup 13

(unfolding)
RHS Side Conveyor.
(Continued)
HAZARDS
EQUIPMENT
15. Fit pin (C) into Turn Buckle and Refer to Safety Chapter Section 3.1 Page 2
locking bracket. Tighten turnbuckle using CRUSHING HAZARD

handle (B). Refer this Section 3.3, safety information for relevant warning.
17. Remove the side conveyor prop leg

pins (P) 2 off. Slide the pin supports (S) up
and place the pin in the appropriate holes
(H) to set the side conveyor angle.
16. Push in lever (1) at (F4) Control Valve.

This will start to raise the RHS Side
conveyor to its working position.
H S
F4
P
18. Pull out lever (1) so that the weight of

the conveyor is carried on the pins (P).
Section Page
9 Setup 14

(unfolding)
RHS Side Conveyor.
HAZARDS
(Continued) WEAR PERSONAL PROTECTIVE
EQUIPMENT
CRUSHING HAZARD
Refer this Section 3.3, safety information for relevant warning.
19. Position hose retaining hooks (D) as

shown. 1 off on each of the side
conveyors.
IMPORTANT: These retaining

hooks prevent the side conveyor
hydraulic hoses from resting on
the conveyor belt.
Severe damage to the hoses and
conveyor belt will occur unless
this instruction is carried out
prior to starting the side
conveyors. D
Section Page
9 Setup 15

(unfolding)
LHS Side Conveyor HAZARDS
EQUIPMENT
SAFETY NOTICE Refer to Safety Chapter Section 3.1 Page 2
ENTANGLEMENT HAZARD
All control levers must be in the Refer this Section 3.3.23 , safety information
PROCEDURE

P3
3. Remove the transport pins, 3 off (P1, P2

& P3) left hand side conveyor.
P2
4. Start the engine. (Refer to engine starting

instructions 9.5.1.1)
5. Remove all ropes or straps from each of

the side conveyors. (The ropes or straps
P1 retain the conveyor belt in position for
transport).
Section Page
9 Setup 16

(unfolding)
LHS Side Conveyor.
HAZARDS
EQUIPMENT
6. Slide the pin support box section (S)
down and place the pin in the lowest hole CRUSHING HAZARD
(H). Refer this Section 3.3, safety information for relevant warning.

This will start to open out (unfold) the LHS
Side conveyor. Do this operation very
slowly.
S
H
F5
9. When the conveyor moves to the

horizontal position, the conveyor starts to
open out.
Release the lever to stop opening the
conveyor when the conveyor has opened
out about 40° from the side of the machine.
Section Page
9 Setup 17

(unfolding)
LHS Side Conveyor.
HAZARDS
EQUIPMENT
Take care not to nip the
conveyor belt between moving CRUSHING HAZARD
parts.
10. Lift the conveyor belt over the troughing 11. Pull out lever (3) at (F5) Control
roller (T) to prevent the belt from snagging on Valve, move the conveyor very slowly
the roller. Applies to both side conveyors. until it is almost opened out fully.
Make sure the “Turn Buckle” handle (B)
will not catch on the hoses.
T
11. Make sure the conveyor belt is lifted to the

inside of the drive drum guard (G).
Valve, move the conveyor very slowly
until the conveyor is opened out fully.
F5
G
Section Page
9 Setup 18

(unfolding)
LHS Side Conveyor.
(Continued)
HAZARDS
EQUIPMENT
15. Fit pin (C) into Turn Buckle and Refer to Safety Chapter Section 3.1 Page 2
locking bracket. Tighten turnbuckle using CRUSHING HAZARD

handle (B). Refer this Section 3.3, safety information for relevant warning.

pins (P) 2 off. Slide the pin supports (S) up
and place the pin in the appropriate holes
(H) to set the side conveyor angle.

This will start to raise the RHS Side
conveyor to its working position.
H S
F5
18. Pull out lever (3) so that the weight of

the conveyor is carried on the pins (P).
Section Page
9 Setup 19

(unfolding) HAZARDS
LHS Side Conveyor.
CRUSHING HAZARD
19. Position hose retaining hooks (D) as

shown. 1 off on each of the side
conveyors.
IMPORTANT: These retaining

hooks prevent the side conveyor
hydraulic hoses from resting on
the conveyor belt.
Severe damage to the hoses and
conveyor belt will occur unless
this instruction is carried out
prior to starting the side
conveyors. D
Section Page
9 Setup 20
9.5.6 (E) Opening out

(unfolding)
Tail Conveyor.
HAZARDS
EQUIPMENT
CRUSHING HAZARD
Use a Cherry Picker or scaffolding
for this operation.
PROCEDURE
1. Observe all safety warnings. F5
2. Start the engine. (Refer to engine

starting instructions 9.5.1.1)
5. Remove transport Linchpins (P) 2 off, 1 on

each side of tail conveyor. This will release
the transport bracket (TB).
Linchpin
P
4. This operation must be carried out very
slowly. Pull out lever (1) at (F5) control valve
just enough to release the tail conveyor
transport pins.
TB
Section Page
9 Setup 21
HAZARDS
(unfolding) WEAR PERSONAL PROTECTIVE
EQUIPMENT
Tail Conveyor. Refer to Safety Chapter Section 3.1 Page 2
CRUSHING HAZARD
8. Remove Linchpins (LP) 2 off, 1 on each

6. Fit transport brackets (TB) in position side of conveyor. This will allow the
shown. Secure transport brackets with return idler to swing down vertically and
Linchpins (P). relieve tension on the conveyor belt when
unfolding.
P
LP
TB
7. Push lever (1) at (F5) control valve to

unfold the tail conveyor head section. Stop
unfolding when the head section is close to
the ground.
7. Push lever (1) at (F5) control valve to

unfold the tail conveyor head section. Stop
unfolding when the head section is parallel
with the tail section.
Section Page
9 Setup 22
HAZARDS
(unfolding) EQUIPMENT
Tail Conveyor. Refer to Safety Chapter Section 3.1 Page 2
CRUSHING HAZARD
8. Remove tail conveyor locking pin 2 off

10. Return control valves to neutral and shut
(LP) from pin holder (PH). Then fit pin
down engine.
(LP) in hole shown, 1 on each side of
conveyor. Secure with Linchpins.
11. Remove pins (A) 4 off from conveyor
LP belt retainers (R).Remove tail conveyor belt
retainers (A) (2 off).
PH
A
9. Slowly pull out lever (3) at (F5) so that
the weight of the conveyor is carried on
the pins (LP). 12. Place retainers (R) on the sides of the tail
conveyor and fit linchpins (A) 4 off.
A R A
F5
Section Page
9 Setup 23
9.5.7 (E) Setting Tail Conveyor

Incline.
HAZARDS
EQUIPMENT
CRUSHING HAZARD
Use a Cherry Picker or scaffolding Refer this Section 3.3, safety information for relevant warning.
for this operation.
IMPORTANT 4. This operation must be carried out very

The normal working position for the slowly. Push in lever (2) at (F5) control valve
Tail conveyor is at the maximum just enough to release the tail conveyor pins
angle (incline). (P).
You can damage the tail conveyor if
you decrease its incline and then
increase the screenbox incline. The
screenbox will collide with the tail
conveyor if you are not careful!
PROCEDURE

F5
P
Section Page
9 Setup 24
9.5.7 (E) Setting Tail Conveyor

Incline. (Continued) HAZARDS
EQUIPMENT
CRUSHING HAZARD
5. Remove pins (P) 2 off.
P 7. Fit pins (P) in the appropriate holes.
8. Disengage auxiliary control valve (4)
6. This operation must be carried out very

slowly. To decrease the tail conveyor incline,
pull out lever (2) at (F5) control valve. Be
careful that the screenbox doesn’t collide
with the tail conveyor, there must be a
minimum of 50mm (2”) clearance at all
times. Keep checking the clearance between
the screenbox and the tail conveyor, the
minimum clearance must be 50mm (2”).
F5
Section Page
9 Setup 25
9.5.8 (C) Raising the Screenbox

into the working position HAZARDS
PROCEDURE WEAR PERSONAL PROTECTIVE
EQUIPMENT
1. Observe all safety warnings. CRUSHING HAZARD

2. Machine must be switched off. FALL HAZARD

Refer this Section 3.5.4, safety information for relevant
warning.
3. Prior to raising the screenbox, the safety
handrails must be set in position.
5. Slide the upper hand rails fully and then
4. Slide up side hand rails fully and then rotate the handrails up to the working
rotate the handrails up to the working position. See E, F and G. 1 on each side of
position. See A, B, C and D. 1 on each machine.
side of machine.
E F
G
Section Page
9 Setup 26

into the working position
(Continued) HAZARDS
6. Start the engine. (Refer to engine EQUIPMENT
starting instructions 9.5.1.1) Refer to Safety Chapter Section 3.1 Page 2
CRUSHING HAZARD
7. Engage auxiliary control valve (4) at Refer this Section 3.3, safety information for relevant warning.
(A) main control valve bank.
FALL HAZARD
warning.
9. Remove linchpins and then withdraw pins

(P1) from each side of machine.
8. Slowly push in lever (3) at (F4) control
valve to raise the Screenbox slightly to P1
relieve the load on the support pins (P1) one
on each side of machine.
P2
F4
valve to raise the Screenbox to the required
angle. Be careful that the screenbox doesn’t
collide with the tail conveyor, there must be a
minimum of 50mm (2”) clearance at all
times. Keep checking the clearance between
the screenbox and the tail conveyor, the
minimum clearance must be 50mm (2”).
Section Page
9 Setup 27

(Continued)
EQUIPMENT
CRUSHING HAZARD
11. Fit pins (P1) into the appropriate prop leg 13. Remove pins (P2).
holes, 1 on each side of machine.
Sometimes it maybe necessary to raise the
screenbox at its lower end to be able to
locate the (P1) pins.
P2
P1

valve to raise the Screenbox to the required
position allowing you to fit pins P1. Be
12. To raise the discharge end of the screen. careful that the screenbox subframe upper
Slowly push in lever (4) at (F4) control crossmember (CM) doesn’t collide with the
valve to raise the Screenbox to relieve the collection conveyor (CC).
load on the support pins (P2) one on each
side of machine. CM
CC
Section Page
9 Setup 28

(Continued)
EQUIPMENT
CRUSHING HAZARD
15. Lower the discharge end of the screenbox Refer this Section 3.3, safety information for relevant warning.
and fit pins (P2) as shown. Fit linchpins.
FALL HAZARD
warning.
P2
16. The screenbox is now in the working

position.
Section Page
9 Setup 29
9.5.9 (A) Setting the Feed HAZARDS

conveyor into the working
position EQUIPMENT
CRUSHING HAZARD
SAFETY NOTICE Refer this Section 3.3, safety information for relevant warning.
FALL HAZARD
Use a Cherry Picker or scaffolding warning.
for this operation.
PROCEDURE

valve to raise the feed conveyor just enough
to relieve the load on the support pins (P3) 2
off, 1 on each side of machine.
3. Engage auxiliary control valve (4) at

(A) main control valve bank.
F4
Section Page
9 Setup 30
9.5.9 (A) Setting the Feed

HAZARDS
conveyor into the working WEAR PERSONAL PROTECTIVE
position. (Continued) EQUIPMENT
CRUSHING HAZARD
5. Remove support pins (P3) 2 off, 1 on each Refer this Section 3.3, safety information for relevant warning.
side of machine.
FALL HAZARD
warning.
P3
7. Fit support pins (P3) 2 off, 1 on each side

of machine into holes (H).
The feed conveyor is now in the working
position.
P3 H
6. Push in lever (2) at (F4) control valve to

raise (slide up) the feed conveyor to the
working position.
F4
Section Page
9 Setup 31
9.5.10 (A) Setting the Hopper

Wing plates into the
working position.
HAZARDS
EQUIPMENT
SAFETY NOTICE
CRUSHING HAZARD
neutral (non-operational) position. FALL HAZARD
warning.

for this operation.
PROCEDURE
1. Observe all safety warnings. 4. Rotate wing plates into transport

position shown.
3. Remove 8 bolts from Hopper wing

plates (W), 4 bolts on each side of
machine.
B W
Section Page
10 Operation 1
10.1 General information ……………………………………….................................2
10.2 Normal operation………………………………………………………………..3
10.2.1 Putting into operation ..........................................................................................3
10.3 Emergency Stop ...................................................................................................6
10.4 Restart after emergency stop ................................................................................6

Section Page
10 Operation 2
The Tesab may only be

operated if the safety
instructions provided in
the previous chapters Hopper
have been observed and the
Conveyor
described procedures have been
performed.
Operate the machine only if all protective

and safety devices, such as removable
safety devices, emergency shut-off
equipment, sound-proofing elements and
exhausts are in place, fully functional and
properly maintained.
In the event the machine malfunctions for Conveyor

any reason, stop the machine and lock out
immediately. Report the malfunction to
the competent authority in charge. STAY CLEAR OF THE
HOPPER, where there is
DO NOT continue to operate the machine risk of serious injury or
UNTIL the malfunction is corrected! death due to falling
material and danger from other heavy
machinery working in the area,
unless you are a fully trained
operator engaged in loading the
machine and wearing appropriate
ALWAYS WEAR AN EN / PPE, i.e. Head Protection etc.
ANSI approved HARD
HAT AND FOOTWEAR
WITH ADEQUATE TOE STAY CLEAR OF ALL
PROTECTION when working in the CONVEYOR BELTS, where
vicinity of the machine and on the there is risk of serious
work site. injury or death due to
rejected processed material and
danger from other heavy machinery
working in the area, unless you are a
fully trained operator engaged in
collecting processed material.
Section Page
10 Operation 3
HAZARDS
10.2 Normal operation
EQUIPMENT
10.2.1 Putting into operation
ENTANGLEMENT HAZARD
warning.
PROCEDURE
5. To obtain maximum side conveyor speed,

1. Observe all safety warnings. turn the control knob of the variable speed
flow control valve counter clockwise (D)
LHS side conveyor, (E) RHS side conveyor.
.
3. Pull lever (5) at (A) main control valve

bank to start the RHS Side conveyor.
B C D E
4. Pull lever (4) at (A) main control valve to

start the collection and LHS side conveyors. 6. Pull lever (3) at (A) main control valve to
start the Tail conveyor.
Section Page
10 Operation 4
10.2.1 Putting into operation

(Continued)
HAZARDS
EQUIPMENT
7. To obtain maximum tail conveyor speed,
ENTANGLEMENT HAZARD
turn the control knob of the variable speed Refer this Section 3.3.23, safety information for relevant
flow control valve counter clockwise (C). warning.
10. To obtain maximum feeder speed, turn

the control knob of the variable speed flow
control valve counter clockwise (B).
11. Check that all conveyor belts are running

in alignment.
If an adjustment is necessary refer to Section
12 “Maintenance.”
B C D E
12. Turn the control knob of the feeder
speed flow control (B) valve to position 2.
8. Pull lever (2) at (A) main control valve to
start the screenbox.
13. Put the material into the feed hopper.

Gradually let the material out of the loading
shovel bucket, do not drop the material in
one go.
9. Pull lever (1) at (A) main control valve to 14. To obtain optimal feeder speed, turn the
start the feed conveyor. control knob of the variable speed flow
control valve (B).
Check all of the conveyors that they are not
over loaded.
Section Page
10 Operation 5
10.2.1 Putting into operation HAZARDS

(Continued)
EQUIPMENT
Counter clockwise:
To increase the feeder speed. ENTANGLEMENT HAZARD
warning.
Clockwise:
To decrease the feeder speed.
15. Re-check that all conveyor belts are

running in alignment.
If an adjustment is necessary refer to Section
12 “Maintenance.”
16. Re-fill feed hopper.
17. To obtain optimal feeder speed, turn the

control knob of the variable speed flow
control valve (B).
Check all of the conveyors that they are not
over loaded.
Counter clockwise:
To increase the feeder speed.
Clockwise:
To decrease the feeder speed.
18. The machine is now adjusted for

continuous operation.
Section Page
10 Operation 6
10.3 Emergency stop

HAZARDS
10.3 In the event of an incident or
problem, you MUST follow the WEAR PERSONAL PROTECTIVE
EQUIPMENT
following procedure: Refer to Safety Chapter Section 3.1 Page 2
ENTANGLEMENT HAZARD
1. Engage the nearest emergency stop. warning.
2. Switch off the engine and remove the

ignition key.
3. Implement the lockout / tagout procedure.
4. Only when the machine is fully switched

off, should an attempt be made to solve the
problem.
10.4 Restart after emergency

stop
1. Ensure that the problem has been solved.
2. Ensure that all personnel are clear of the

machine.
3. Ensure that all guards and safety devices

are correctly fitted and fully functional.
4. Release all emergency stops.
5. Re-start the engine. (Refer to engine

starting instructions, Section 9.5.1.1)
Section Page
11 Shut down 1
11.1 Shut down...........................................................................................................2
11.2 Setting the machine in the transport position.......................................................3
11.2.1 Setting the hopper wing plates in the transport position......................................3
11.2.2 Setting the feed conveyor into the transport position...........................................4
11.2.3 Lowering the Screenbox into the transport position............................................4
11.2.4 Setting the handrails into the transport position..................................................7
11.2.5 Folding the tail conveyor into the transport position………...............................8
11.2.6 Close (fold in LHS side conveyor)………..........................................................12
11.2.7 Close (fold in RHS side conveyor)………..........................................................16

Section Page
11 Shut down 2
11.1 Shut down HAZARDS

EQUIPMENT
Empty the hopper and all Refer to Safety Chapter Section 3.1 Page 2
conveyors of material
ENTANGLEMENT HAZARD
prior to shut down Refer this Section 3.3.23, safety information for relevant
warning.
CRUSHING HAZARD
Refer this Section 3.3, safety information for relevant
PROCEDURE warning.
1. Observe all safety warnings. 5. Push lever (3) at (A) main control valve to
neutral position to stop the tail conveyor.

3. Push lever (1) at (A) main control valve

into neutral position to stop the feeder
conveyor. 6. Push lever (4) at (A) main control valve
into neutral position to stop the LHS side
and collection conveyors.
4. Push lever (2) at (A) main control valve

into neutral position to stop the screenbox. 6. Push lever (5) at (A) main control valve
into neutral position to stop the RHS side
conveyor
7. Switch off engine. Remove ignition keys.

Section Page
11 Shut down 3
11.2 Setting the machine in

the transport position
HAZARDS
Shut-off the Tesab in accordance to
Section 11.1, WEAR PERSONAL PROTECTIVE
EQUIPMENT
“Shut down, “prior to setting the Refer to Safety Chapter Section 3.1 Page 2
machine into the transport position.
CRUSHING HAZARD
warning.
WARNING! It imperative
that the machine is always FALL HAZARD
cleaned before transporting. Material falling Refer this Section 3.5.4, safety information for relevant
warning.
from the machine maybe hazardous for other
road users.
3. Remove 8 bolts from Hopper wing plates
(W), 4 bolts (B) on each side of machine.
11.2.1 (A) Setting the Hopper
Wing plates into the B W
working position.
SAFETY NOTICE


for this operation.
4. Rotate wing plates into transport
position shown. Refit bolts into hopper
PROCEDURE and tighten them.

Section Page
11 Shut down 4
11.2.2 Setting the feed conveyor HAZARDS

In the transport position
EQUIPMENT
CRUSHING HAZARD
warning.
FALL HAZARD
warning.
PROCEDURE

1. Observe all safety warnings. valve to raise the feed conveyor just enough
to relieve the load on the support pins (P3) 2
off, 1 on each side of machine. Remove
2. Clean down the machine before setting Pins.
the machine into the transport position.
3. Check the machine for loose parts and if

any are found they must be fastened
securely in place.
4. Check the machine for leaking fluids i.e.

engine oil, coolant and hydraulic oil. F4
If any leaks are found they must be repaired
before transporting the machine.

7. Engage auxiliary control valve (4) at

(A) main control valve bank. P3
Section Page
11 Shut down 5
11.2.2 Setting the feed conveyor

In the transport position HAZARDS
(continued)
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
CRUSHING HAZARD
warning.
9. Pull lever (2) at control valve (F4) and

slide (lower) the feed conveyor down
fully.
10. Fit pins (P3) in holes (H) one on each

side of machine.
P3
Section Page
11 Shut down 6
11.2.3 (C) Lowering the

Screenbox into the
HAZARDS
transport position WEAR PERSONAL PROTECTIVE
EQUIPMENT
ENTANGLEMENT HAZARD
PROCEDURE Refer this Section 3.3.23, safety information for relevant
warning.
1. Start the engine. (Refer to engine CRUSHING HAZARD

starting instructions 9.5.1.1) Refer this Section 3.3, safety information for relevant
warning.
2. Engage auxiliary control valve at 4 (A)

main control valve bank.
P1
3. Slowly push in lever (3) at (F4) control 4. Remove pins (P1) from prop leg holes, 1
valve to raise the Screenbox slightly to on each side of machine.
relieve the load on the support pins (P1) one Sometimes it maybe necessary to raise the
on each side of machine. screenbox at its lower end to be able to
remove the (P1) pins. Refer to Section
9.5.8, 12. to 14.
5. Lower screenbox and fit pins (P1) in

position shown. Make sure the weight of the
screenbox is supported on the pins.
F4
P1
Section Page
11 Shut down 7
11.2.4 Setting the handrails

into the transport
position
HAZARDS
EQUIPMENT
PROCEDURE Refer to Safety Chapter Section 3.1 Page 2
ENTANGLEMENT HAZARD
1. Observe all safety warnings. Refer this Section 3.3.23, safety information for relevant
warning.
2. Machine must be switched off. Remove CRUSHING HAZARD

ignition keys. Refer this Section 3.3, safety information for relevant
warning.
3. Prior to raising the screenbox, the

safety handrails must be set in position.
5. Lift up side hand rails fully and then
4. Lift up upper hand rails fully and then rotate the handrails down to the working
rotate the handrails down to the transport position. See D, E, F and G. 1 on each
position. See A, B and C. 1 on each side side of machine.
of machine.
A B
C
Section Page
11 Shut down 8

4. Lower the Screenbox. (Refer to 11.2.3)
5. Set tail conveyor in correct position

before folding head section.
Push in lever (2) at control valve (F5) to
raise tail conveyor slightly to remove pins
(P) from tail conveyor support, 1 on each
side of machine.
11.2.5 Folding the tail conveyor
into the transport position
HAZARDS
PROCEDURE
EQUIPMENT
IMPORTANT Refer to Safety Chapter Section 3.1 Page 2
ENTANGLEMENT HAZARD
Make sure that the tail conveyor Refer this Section 3.3.23, safety information for relevant
warning.
head section does not collide with
the ground CRUSHING HAZARD
warning.
SAFETY NOTICE

for this operation.

F5
Section Page
11 Shut down 9
8. Disengage auxiliary control valve (4)
9. Switch off engine and remove keys.
10. Remove linchpins (A) 4 off, then

retainers (R) from the sides of the tail
conveyor.
A R A
6. Remove pins (P) 2 off.
11.2.5 Folding the tail conveyor

into the transport position
(continued)
7. Push in lever (2) at control valve (F5) to

raise tail conveyor into the transport HAZARDS
position. Fit pins (P) into tail conveyor
support, 1 on each side of machine. WEAR PERSONAL PROTECTIVE
EQUIPMENT
P ENTANGLEMENT HAZARD
warning.
CRUSHING HAZARD
warning.
Section Page
11 Shut down 10
11. Place conveyor belt retainers (R) in

positions shown on tail conveyor. Fit
linchpins (A) to secure retainers in place.
A F5
A P

PH
16. Fit pins (LP) into pin holders (PH).

Secure with linchpins.
11.2.5
Folding the tail conveyor
HAZARDS
into the transport position WEAR PERSONAL PROTECTIVE
(continued) EQUIPMENT
ENTANGLEMENT HAZARD
warning.
15. Slowly push in lever (3) at (F5) to take
the load of the pins (LP). Remove pins CRUSHING HAZARD
(LP). warning.
Section Page
11 Shut down 11
folding when the head section is close to

the ground.
17. Remove Linchpins (LP) 2 off, 1 on

each side of conveyor. This will allow the
return idler to swing down vertically and
relieve tension on the conveyor belt when
folding.
LP
19. Push up return idler under tail
conveyor and fit linchpins (LP) to secure
return idler in position shown.
LP
HAZARDS
11.2.5 Folding the tail conveyor WEAR PERSONAL PROTECTIVE
EQUIPMENT
into the transport position Refer to Safety Chapter Section 3.1 Page 2
(Continued)
CRUSHING HAZARD
warning.
20. Pull lever (1) at (F5) control valve to

18. Pull lever (1) at (F5) control valve to fold the tail conveyor head section. To
fold the tail conveyor head section. Stop position shown.
Section Page
11 Shut down 12

P
2. Engage auxiliary control valve at 4 (A)
TB
21. Remove linchpin (P) 2 off, 1 on each

side of conveyor.
3. Lift hoses out off retaining hook (D).
22. Fit transport bracket (TB) and secure
with linchpins in position shown.
Linchpin
P
TB
D HAZARDS
11.2.6 (D) Close (fold) in
LHS Side Conveyor WEAR PERSONAL PROTECTIVE
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
SAFETY NOTICE
CRUSHING HAZARD
warning.
PROCEDURE
Section Page
11 Shut down 13
4. Push in lever (3) at (F5) Control Valve. 5. Remove the side conveyor prop leg
Raise the LHS Side conveyor to take the pins (P), 2 off. Slide the pin supports (S)
load of the prop leg pins. Down and place the pin in the holes (H).
F5
H S
11.2.6 (D) Close (fold) in HAZARDS

LHS Side Conveyor
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
CRUSHING HAZARD
Take care not to nip the conveyor Refer this Section 3.3, safety information for relevant
warning.
belt between moving parts.
Section Page
11 Shut down 14
8. Push in lever (3) at (F5) Control Valve,

move the conveyor very slowly until the
6. Pull out lever (3) at (F5) Control Valve. conveyor is out about 40° from the side of the
This will start to lower the LHS Side machine. Release the lever to stop at this
conveyor to its horizontal position. position.
N
7. Loosen turnbuckle using handle (B).
Remove pin (C) from Turn Buckle (D).
9. Lift the conveyor belt to prevent the belt

C from being nipped between the steel
components at (N).

This will start to close in (fold) the RHS
D Side conveyor. Do this operation very
slowly.

LHS Side Conveyor
(Continued) HAZARDS
EQUIPMENT
Take care not to nip the conveyor
ENTANGLEMENT HAZARD
belt between moving parts. Refer this Section 3.3.23, safety information for relevant
warning.
CRUSHING HAZARD
Section Page
11 Shut down 15

warning.
11. When the conveyor is parallel with 13. Continue folding the conveyor until it
the side of the machine, the conveyor will fold no further.
starts to fold up (rise).
14. Slide the pin support box section (S)
12. Stop folding the conveyor and lift the up and place the pin (P1) in the upper
conveyor belt (C) over the walkway (W) hole (H).
to prevent the belt from getting trapped Secure with linchpin.
and damaged.
S
P1
C W
11.2.6 (D) Close (fold) in HAZARDS

LHS Side Conveyor
ENTANGLEMENT HAZARD
warning.
CRUSHING HAZARD
warning.
Section Page
11 Shut down 16
15. Fit transport pin (P2) and secure with 1. Start the engine. (Refer to engine
linchpin. starting instructions 9.5.1.1)
P2 2. Engage auxiliary control valve at 4 (A)

15. Fit transport pin (P3) and secure with 3. Lift hoses out off retaining hook (D).
linchpin.
P3
D
RHS Side Conveyor
HAZARDS
EQUIPMENT
SAFETY NOTICE ENTANGLEMENT HAZARD

warning.
CRUSHING HAZARD
PROCEDURE warning.
Section Page
11 Shut down 17

4. Push in lever (1) at (F4) Control Valve. pins (P), 2 off. Slide the pin supports (S)
Raise the RHS Side conveyor to take the down and place the pin in the hole (H).
load of the prop leg pins.
S
F4
H P

This will start to lower the RHS Side
conveyor to its horizontal position.

RHS Side Conveyor
(Continued) HAZARDS
EQUIPMENT
ENTANGLEMENT HAZARD
Take care not to nip the conveyor Refer this Section 3.3.23, safety information for relevant
warning.
CRUSHING HAZARD
Section Page
11 Shut down 18
Refer this Section 3.3, safety information for relevant Take care not to nip the conveyor
warning.
7. Loosen turnbuckle using handle (B).

Remove pin (C) from Turn Buckle (D). 9. Lift the conveyor belt to prevent the belt
from being nipped between the steel
components at (N).
N
B

8. Push in lever (3) at (F5) Control Valve, This will start to close in (fold) the RHS
move the conveyor very slowly until the Side conveyor. Do this operation very
conveyor is out about 40° from the side of the slowly.
machine. Release the lever to stop at this
position.

RHS Side Conveyor HAZARDS
(Continued)
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
Section Page
11 Shut down 19
CRUSHING HAZARD
warning.
13. Continue folding the conveyor until it
will fold no further.
11. When the conveyor is parallel with

the side of the machine, the conveyor 14. Slide the pin support box section (S)
starts to fold up (rise). up and place the pin (P1) in the upper
hole (H).
Secure with linchpin.
12. Stop folding the conveyor and lift the
conveyor belt (C) over the walkway (W)
to prevent the belt from getting trapped
and damaged. H
.
P1
P3
C W

HAZARDS
RHS Side Conveyor WEAR PERSONAL PROTECTIVE
ENTANGLEMENT HAZARD
warning.
CRUSHING HAZARD
warning.
Section Page
11 Shut down 20

15. Fit transport pin (P2) and secure with for this operation.
linchpin.
17. Tie up the conveyor belts with ropes

P2 or straps.
(The ropes will keep the conveyor belts in
position for transport).
18. Tesab is now ready for transport.
P1
16. Fit transport pin (P3) and secure with

linchpin.
Tesab 1550 in
transport position

RHS Side Conveyor HAZARDS
(Continued)
EQUIPMENT
FALL HAZARD
SAFETY NOTICE warning.
Section Page
11 Shut down 21
Section Page
12 Maintenance 1

12.1 General information ..............................................................................4
12.2 (A) Feed conveyor

12.2.1 Clean & check conveyor belt .................................................................. 6
12.2.2 Tensioning the feed conveyor belt ...........................................................7
12.2.3 Feed conveyor belt alignment .................................................................18
12.3 (B) Collection conveyor

12.3.1 Clean & check conveyor belt ..................................................................10
12.3.2 Tensioning the collection conveyor belt .................................................11
12.3.3 Collection conveyor belt alignment ........................................................12
12.4 (D) Side conveyor

12.4.1 Clean & check conveyor belt ................................................................ 14
12.4.2 Tensioning the side conveyor belt ..........................................................15
12.4.3 Side conveyor belt alignment ................................................................ 16
12.5 (E) Tail conveyor

12.5.1 Clean & check conveyor belt ..................................................................18
12.5.2 Tensioning the tail conveyor belt.............................................................19
12.5.3 Tail conveyor belt alignment ...................................................................20
12.6 Screen unit

12.6.1 Re-tuning screen unit................................................................................22
12.6.2 Changing the bottom deck screen mesh....................................................24
12.6.3 Changing the top deck screen mesh..........................................................27
12.7 Power unit / (Engine Maintenance)……………………………..............28

12.7.1 Fuel system................................................................................................29
12.7.1.1 Check fuel level........................................................................................ 29
12.7.1.2 Adding fuel .............................................................................................. 30
12.7.1.3 Drain fuel pre filter water trap ..................................................................31
12.7.1.4 Replace fuel pre filter ...............................................................................32
12.7.2 Air cleaner………………………………………………………………..33
12.7.2.1 Replace the outer air cleaner element....................................................... 33
12.7.2.2 Cleaning the air filter housing.................................................................. 35
12.7.2.3 Inspect both air filter elements .................................................................36
12.7.2.4 Replace inner air filter element..................................................................37
12.7.3 Electrical safety instructions (wiring diagrams, Sect 9, Appendix)..........38
12.7.3.1 Check battery.............................................................................................39
12.7.3.2 Battery removal..........................................................................................40
12.7.3.3 Battery installing........................................................................................41
Section Page
12 Maintenance 2
12.8 Chassis
12.8.1 Tracks.....................................................................................................42
12.8.1.1 Tensioning the tracks............................................................................ 42
12.8.1.2 Releasing track tension……. ............................................................... 43
12.8.1.3 Cleaning the tracks ............................................................................... 44
12.9 Hydraulic system

12.9.1 Hydraulic oil...........................................................................................45
12.9.1.1 Check hydraulic oil level .......................................................................46
12.9.1.2 Adding hydraulic oil... ...........................................................................47
12.9.1.3 Change hydraulic oil filter .....................................................................48
12.9.2 Return line filter......................................................................................50
12.9.2.1 Check return line filter ...........................................................................50
12.9.2.2 Change return line filter .........................................................................51
12.10 Maintenance schedules

12.10.1 Daily or 10 hour maintenance schedule ..................................................52
12.10.2 Weekly or 50 hour maintenance schedule ...............................................54
12.10.3 250 hour maintenance schedule................................................................55
12.10.4 500 hour maintenance schedule................................................................56
12.10.5 1000 hour maintenance schedule..............................................................57
12.10.6 2000 hour maintenance schedule..............................................................57
12.11 Lubricants and fluids .............................................................................58
12.12 Capacities - Fluid.....................................................................................59
12.13 Adjustment Data.....................................................................................59
12.14 Pressures .................................................................................................59
12.15 Greasing schedule ..................................................................................60
12.16 Recommended Lubricants.....................................................................61

Section Page
12 Maintenance 3
This page is intentionally left blank

Section Page
12 Maintenance 4

The machine has been designed to facilitate
When performing maintenance, always easy routine maintenance without the
observe rules provided in the safety section. removal of any fixed guards.
Breakdown caused by insufficient or All greasing points can be accessed from

improper maintenance will cause high repair ground level, or by lowering the side and tail
costs and long-term standstill. Therefore, conveyors, or any walkways provided and
regular maintenance is imperative. all belt adjustments can be made without
removing any protective guards.
In addition to several other factors, the
reliability and life of the Tesab depends on If it is necessary to remove any guard doors,
regular and proper maintenance. all are fitted with captive nuts and bolts to
ensure that they are replaced before the
The following section contains maintenance machine is restarted.
instructions as well as maintenance
schedules for normal operating conditions.
NOTICE Important
Notice
If a bolt or Nyloc nut becomes loose,
When the Tesab is operated in replace the bolt with a new spring
extreme climatic conditions (e.g. washer or if fitted with a Nyloc nut.
below -15°C or above 33°C) or in very Always replace the Nyloc nut with a
dusty conditions for a long period of new one.
time, the maintenance schedules will
change. Nyloc nuts must be discarded after
Ask your local Tesab dealer or Tesab they have been used once.
Technical Department for advice.
Section Page
12 Maintenance 5
PRACTICE SAFE
MAINTENANCE.
Read and understand all service and

operation procedures before A raised part of the machine can fall
performing maintenance or operating causing serious injuries or death.
the machine.
Always fit the safety support strut
Keep work area clean, dry and free provided if any part of the machine,
from obstacles. such as a guard door, must be raised
for any reason.
Never lubricate, clean, service or
adjust machine while it is running. Never work under unsupported
equipment.
Keep hands, feet and clothing clear
of power driven parts and in-running Keep all parts in good condition and
nip points. properly installed. Fix damage
immediately. Replace worn and
Before performing maintenance or broken parts.
repairs:
Remove any build up of grease, oil or
(1) Disengage all power and operate debris.
controls to relieve all pressure.
Disconnect battery ground cable (-)
(2) Stop the engine. before making adjustments on
electrical systems or welding on the
(3) Implement lockout procedure. machine.
(4) Allow the machine to cool.

Section Page
12 Maintenance 6
12.2 (A) Feed conveyor

HAZARDS
12.2.1 Clean & check the WEAR PERSONAL PROTECTIVE
EQUIPMENT
conveyor belt Refer to Safety Chapter Section 3.1 Page 2
SWITCH OFF AND LOCKOUT

Do not unfasten or remove warning.
any guard while the
machine is running or start
the machine while a guard
is unfastened or removed.
PROCEDURE
2. Stop the engine, Lockout and Tagout.
3. Remove the guards, (G) 17 off. G G
4. Clean the conveyor (B) belt using a high- B

pressure water hose. Ensure that your eyes
are protected by wearing safety glasses.
5. Check the belt for cuts, tears, rips or any

other physical damage.
6. Refit and secure the guards (G).
If any damage to the belt or

components is found, do
not operate the machine
until it is repaired or replaced by your
local dealer.
Section Page
12 Maintenance 7
12.2.2 Tensioning the feed HAZARDS

conveyor belt
EQUIPMENT
PROCEDURE ENTANGLEMENT HAZARD
warning.
2. Start the feed conveyor. (Refer to Section

10, “Operating instructions.”)
3. Run the feeder conveyor at desired speed.
4. Tighten the belt by adjusting both belt

adjusters (clockwise) evenly, 1 turn at a time
until slippage stops.
Notice
Do not over tension the belt, as this
will cause damage to the drum
bearings.
Section Page
12 Maintenance 8
12.2.3 Feed conveyor

belt alignment HAZARDS
EQUIPMENT
warning.
2. Pull out lever (1) to start feed conveyor

A
(A - LEVER 1 - PULL).
3. Turn control knob of the variable-speed

control valve COUNTERCLOCKWISE to
run the feeder conveyor at maximum speed B C D E
(FLOW CONTROL VALVE B).

Section Page
12 Maintenance 9
12.2.3 Feed conveyor

belt alignment
(Continued) HAZARDS
Do not unfasten or remove EQUIPMENT
any guard while the Refer to Safety Chapter Section 3.1 Page 2
machine is running or start ENTANGLEMENT HAZARD
the machine while a guard Refer this Section 3.3.23, safety information for relevant
warning.
4. Observe the conveyor through the

viewing apertures and determine to which
side the conveyor is “tracking off.”
5. The conveyor belt is tracking off to the

right side.
Solution
Use a spanner to rotate the right side
adjuster - one turn (clockwise) at a
time until the belt tracks correctly.
Or if the belt would be under too

much tension, rotate the left side
adjuster - one turn (counter
clockwise) at a time until the belt
tracks correctly.

left side.
Solution
Use a spanner to rotate the left side
Or if the belt would be under too

much tension, rotate the right side
adjuster - one turn (counter
clockwise) at a time until the belt
tracks correctly.
Section Page
12 Maintenance 10
12.3 (B) Collection conveyor

HAZARDS
12.3.1 Clean & check the
conveyor belt EQUIPMENT
ENTANGLEMENT HAZARD
Do not unfasten or remove Refer this Section 3.3.23, safety information for relevant
warning.
any guard while the
PROCEDURE
2. Stop the engine. Lockout and Tagout

(Refer to 3.6 Lockout and Tagout of
machine)
3. Remove guards, (G) 8 off. Collection

Conveyor G
B
5. Clean the conveyor (B) belt using a high-
are protected, by wearing safety glasses.

7. Refit and secure the guards in the correct

position.

components is found, do
local Tesab dealer.
Section Page
12 Maintenance 11
12.3.2 Tensioning the collection

conveyor belt
HAZARDS
PROCEDURE
EQUIPMENT
1. Observe all safety warnings. ENTANGLEMENT HAZARD
warning.
2. Start the collection conveyor. (Refer to

Section 10, “Operating instructions.”)
3. Run the collection conveyor.

adjusters (clockwise) evenly, 1 turn at a time
until slippage stops.
Notice
bearings.
Section Page
12 Maintenance 12
12.3.3 Collection conveyor

belt alignment
HAZARDS
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
2. Pull out lever (4) to start collection A

conveyor
B C D E
Section Page
12 Maintenance 13
12.3.3 Collection conveyor

belt alignment
(Continued)
HAZARDS
Do not unfasten or remove EQUIPMENT
any guard while the Refer to Safety Chapter Section 3.1 Page 2
machine is running or start ENTANGLEMENT HAZARD

the machine while a guard Refer this Section 3.3.23, safety information for relevant
warning.


right side.
Solution
Or if the belt would be under too much

tension, rotate the left side adjuster - one
turn (counter clockwise) at a time until the
belt tracks correctly.

left side.
Solution

tension, rotate the right side adjuster - one
Section Page
12 Maintenance 14
12.4 (D) Side conveyor

HAZARDS
ENTANGLEMENT HAZARD
warning.
any guard while the
Side
Conveyor
PROCEDURE

machine)
3. Remove side conveyor guards.

Side
4. Clean the conveyor (D) belt using a high- Conveyor

6. Close and secure the side conveyor guards components is found, do
in the correct position not operate the machine
local Tesab dealer.
Section Page
12 Maintenance 15
12.4.2 Tensioning the side HAZARDS

conveyor belt
EQUIPMENT
warning.
2. Start the side conveyor. (Refer to Section

3. Run the side conveyor.

adjusters (counter clockwise) evenly, 1 turn
at a time until slippage stops.
Notice
bearings.
Section Page
12 Maintenance 16
12.4.3 Side conveyor

EQUIPMENT
warning.
2. Pull out levers to start side conveyors

run the LHS side conveyor at maximum A
speed.
(FLOW CONTROL VALVE ‘D’).

run the RHS side conveyor at maximum
speed.
(FLOW CONTROL VALVE ‘E’).
B C D E
Section Page
12 Maintenance 17
12.4.3 Side conveyor

(Continued)
EQUIPMENT
Do not unfasten or remove Refer to Safety Chapter Section 3.1 Page 2
any guard while the ENTANGLEMENT HAZARD
machine is running or start Refer this Section 3.3.23, safety information for relevant
warning.


left side.
right side.
Solution
Solution
tension, rotate the right side adjuster - one
Section Page
12 Maintenance 18
12.5 (E) Tail conveyor

HAZARDS
ENTANGLEMENT HAZARD
warning.
any guard while the
Tail
PROCEDURE Conveyor

machine)
3. Remove tail conveyor guards.
4. Clean the conveyor belt using a high-


other physical damage. Repair if necessary.
6. Refit and secure all of the guards in the If any damage to the belt or
correct position before starting the machine. components is found, do
local Tesab dealer.
Section Page
12 Maintenance 19
12.5.2 Tensioning the tail

conveyor belt
HAZARDS
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
2. Do not remove any guards.

Tail
3. Start the tail conveyor. (Refer to Section Conveyor
4. Run the tail conveyor.

adjusters (A) (clockwise) evenly, 1 turn at a
time until slippage stops.
Do not unfasten or remove

any guard while the
Notice A

bearings.
Section Page
12 Maintenance 20
12.5.3 Tail conveyor

HAZARDS
belt alignment WEAR PERSONAL PROTECTIVE
EQUIPMENT
ENTANGLEMENT HAZARD
warning.
2. Pull out tail conveyor lever to start tail

conveyor
(A - LEVER 3 - PULL

run the tail conveyor at maximum speed.
A
(FLOW CONTROL VALVE ‘C’).
B C D E
Section Page
12 Maintenance 21
12.5.3 Tail conveyor

belt alignment
HAZARDS
EQUIPMENT
ENTANGLEMENT HAZARD
warning.

3. Observe the conveyor through the left side.
Solution
Do not unfasten or remove adjuster - one turn (clockwise) at a
any guard while the time until the belt tracks correctly.
the machine while a guard Or if the belt would be under too much
is unfastened or removed. tension, rotate the right side adjuster - one
right side.
Solution

Section Page
12 Maintenance 22
12.6 (C) Screen unit

HAZARDS
12.6.1 Re-tuning screen unit
EQUIPMENT
Notice ENTANGLEMENT HAZARD

warning.
Re-tuning should only be performed FALL HAZARD

by personnel trained in accordance warning.
with instructions provided in this
manual or by trained Tesab
personnel.
When altering the flywheel counter

weights, always use the same
weights on both ends of the screen
shaft.
PROCEDURE
2. Set up the machine to it‘s

working/operating position.
3. Fit meshes and speed harps as required.

(Refer Section 12, “Maintenance,” relevant
paragraph.)
4. Remove cover over aperture (A). Do not

A
put fingers inside opening while machine is
running, fingers maybe amputated.
4. Start Screenbox / tail conveyor and all

other conveyors in normal sequence.
Section Page
12 Maintenance 23
12.6.1 Re-tuning screen unit

(Continued) HAZARDS
5. Run all components on the machine for EQUIPMENT
45 minutes until the hydraulic oil has Refer to Safety Chapter Section 3.1 Page 2
warmed up. Make sure the engine speed is ENTANGLEMENT HAZARD
set to Full. Refer this Section 3.3.23, safety information for relevant
warning.
The screen is slow to pick up speed when
the oil is cold. FALL HAZARD
warning.
6. This operation should only carried out
by Tesab trained personnel.
Set the screen speed at 930-1120 rpm using
a digital tachometer, through aperture. (A).
Do not put fingers inside opening, fingers
maybe amputated.
The speed is set according to the amount

of stroke the screenbox has i.e. 10mm
stroke = 930rpm. 6mm stroke = 1120rpm.
The screenbox shaft should never run
over 930rpm when the stroke is 10mm as
the screenbox will self destruct in a short A
space of time.
The screenbox shaft speed is set at 1050rpm
and 6-7mm stroke before leaving our
factory.
7. Replace cover over aperture.
8. Stop the machine and implement

“Lockout” procedure. (Refer to 3.6 Lockout
and Tagout of machine)
Screen Shaft Screen Stroke
RPM Max. (mm)
930 10
1050 8
1120 6
Section Page
12 Maintenance 24
12.6 Screen unit HAZARDS

EQUIPMENT
12.6.2 Changing the bottom deck
screen mesh FALL HAZARD
warning.
Never allow unqualified personnel to

attempt to operate, maintain, remove
3. Lock out and tag out. (Refer to 3.6
or replace any part of the machine.
Lockout and Tagout of machine)
Never allow anyone to remove large
or heavy components without
adequate lifting tackle.
4. Remove tensioner bolts (B) 2 L/H and 2
Only lifting equipment capable of
R/H.
lifting 500 Kg or more may be used
for this operation. B C
2. Raise screenbox as shown. Fit pins (P) 4

off and secure with linchpins
5. Remove camber bar (C) by sliding it out

through the side of the Screenbox.
6. The mesh can now be removed from the

Screenbox.
7. The second and third screen mesh is

P removed in a similar fashion.
Section Page
12 Maintenance 25
12.6.2 Changing the bottom deck HAZARDS

screen mesh.
FALL HAZARD
8. Remove tensioner bolts (B) 2 L/H and 2 warning.
R/H. by rotating counter clockwise.
13. Insert new screen mesh over fixed hook.
B C
14. Insert camber bar (C) ensuring it is fitted
as shown.
9. Remove camber bar (C) by sliding it out

through the side of the Screenbox.
15. Replace tensioner (D) 1 R/H and 1 L/H.

10. The mesh can now be removed from the
Screenbox.
D
11. Clean the Screenbox by removing any

build up of material.
12. Check rubber cushions and replace as

necessary.
Section Page
12 Maintenance 26
12.6.2 Changing the bottom deck

screen mesh. HAZARDS
(Continued)
EQUIPMENT
FALL HAZARD
warning.
B C
16. Replace tensioner bolts (B) 2 L/H and 2

R/H.
17. Tighten tensioner bolts (B) 2 L/H and 2

R/H. by rotating clockwise.
18. The mesh will start to tension on its

centreline first. Continue tightening the bolts
until you are unable lift the mesh of the
rubber cushions (E) along the mesh edges.
E
19. Fit the all bottom deck meshes in the
same fashion.
Section Page
12 Maintenance 27
12.6.3 Changing the top deck

screen mesh HAZARDS
EQUIPMENT
Never allow unqualified personnel to Refer to Safety Chapter Section 3.1 Page 2
attempt to operate, maintain, remove
or replace any part of the machine. FALL HAZARD
Never allow anyone to remove large warning.
or heavy components without
adequate lifting tackle.
Only lifting equipment capable of
lifting 500 Kg or more may be used
for this operation.
2. Set the screen box to the position which

leaves most clearance between the main
conveyor and screenbox and pin in position.
3. Lock out and tag out. (Refer to 3.6 N

Lockout and Tagout of machine)
4. To release top deck side tension mesh, 5. When replacing the mesh, the mesh will
slacken the nuts (N) until the mesh (M) can start to tension on its centreline first.
be removed from under the clamps (CL). Continue tightening the bolts until you are
unable lift the mesh of the rubber cushions
(RC).
RC
CL M CL
Section Page
12 Maintenance 28
12.7 Power unit
Engine Maintenance Every 500 Service Hours or 1 Year

The normal engine oil change is every 500 Battery Electrolyte Level - Check
Crankcase Breather (Canister) if fitted - Replace
service hours or 12 months. Conduct
Engine Air Cleaner Element (Dual Element) -
controlled oil sampling at every 250 service Clean/Replace
hours or 6 months. The engine oil change Engine Oil and Filter - Change
interval may have to be reduced for some Fuel System Secondary Filter - Replace
applications depending on the controlled oil Hoses and Clamps - Inspect/Replace
sampling. Radiator - Clean
When Required Every 1000 Service Hours

Engine Valve Lash - Inspect/Adjust
Battery - Replace
Battery or Battery Cable - Disconnect Every 2000 Service Hours
Engine - Clean Alternator - Inspect
Engine Air Cleaner Element - Clean/Replace Starting Motor - Inspect
Fuel System - Prime Turbocharger - Inspect
Water Pump - Inspect
Daily
Alternator Belt - Inspect/Adjust/Replace Every 2000 Service Hours or 1 Year
Cooling System Coolant Level - Check Engine Mounts - Inspect
Driven Equipment - Check
Engine Air Cleaner Service Indicator - Inspect
Engine Air Precleaner (if fitted) - Check/Clean Every Year
Engine Oil Level - Check Cooling System Coolant Sample (Level 2) -
Fuel System Primary Filter/Water Separator - Obtain
Drain
V-Belts - Inspect/Adjust/Replace Every 3000 Service Hours
Walk-Around Inspection Alternator Belt - Inspect/Adjust/Replace
Fuel Injection Nozzles - Test/Exchange
Every 250 Service Hours
Cooling System Coolant Sample (Level 1) - Every 3000 Service Hours or 2 Years
Obtain Cooling System Coolant (ELC) – Add Cat ELC
Engine Oil Sample - Obtain extender
Cooling System Water Temperature Regulator -
Every 500 Service Hours Replace
V-Belts - Inspect/Adjust/Replace
Every 12 000 Service Hours or 6 Years
Every 500 Service Hours or 6 Months Cooling System Coolant (ELC) - Change
Engine Protective Devices - Check
Section Page
12 Maintenance 29
12.7.1 Fuel system

HAZARDS
12.7.1.1 Check fuel level
EQUIPMENT
PROCEDURE
2. Check the fuel level indicator in the

starter panel.
3. Fill the fuel tank (A) at the end of each

day, where possible, to reduce overnight
condensation within the tank.
4. Lock out and tag out. (Refer to 3.6

Lockout and Tagout of machine) A
Diesel fuel is highly

flammable.
Never remove filler cap or

refuel, with the engine running.
Never add gasoline or any other fuel

mixes to diesel because of increased
fire or explosion risks.
Do not smoke or carry out

maintenance on the fuel system near
open flame or sources of sparks,
such as welding equipment, etc...
Section Page
12 Maintenance 30
12.7.1 Fuel system

HAZARDS
12.7.1.2 Adding fuel
EQUIPMENT
NOTICE
DO NOT fill the tank to capacity.
Monitor fuel gauge on starter panel.
Allow room for expansion and wipe

up spilt fuel immediately, otherwise
paintwork will be damaged.
PROCEDURE
2. Clean the area around the filler cap. A
3. Remove the filler cap (F).
4. Fill the tank with diesel, check fuel gauge F

level.

flammable.



such as welding equipment, etc..
Section Page
12 Maintenance 31
12.7.1 Fuel system
12.7.1.3 Drain fuel pre filter

HAZARDS
water trap WEAR PERSONAL PROTECTIVE
EQUIPMENT
PROCEDURE
LOCKOUT AND TAGOUT
2. Unscrew the drain bung (D) at the bottom

of the water trap attached to the fuel filter
(FF) and allow the water to drain out into a
container.
3. Tighten the drain bung when pure diesel

starts to come out.

flammable. FF



such as welding equipment, etc..
D
Section Page
12 Maintenance 32
12.7.1 Fuel system HAZARDS

12.7.1.4 Replace fuel pre filter EQUIPMENT
LOCKOUT AND TAGOUT

2. Lock out and tag out.
3. Unscrew the fuel filter.
4. Fill new fuel filter with clean diesel fuel. B
5. Put lube oil on new filter rubber seal.
6. Screw new filter on and tighten by hand.
7. Push button (B) on top of fuel filter

housing until the fuel system is pressurized.
8. The engine will turn over much longer

than normal until it starts up, due to the self
bleeding system.

flammable.



such as welding equipment, etc.
Section Page
12 Maintenance 33
12.7.2 Air cleaner

HAZARDS
12.7.2.1 Replace the outer air
cleaner element EQUIPMENT
NOTICE LOCKOUT AND TAGOUT

Always obey the air cleaner
restriction indicator immediately if
the control panel light illuminates.
(Never attempt to clean and reuse an

element.)
During normal service, the outer

element (C) will require replacing
only when the restriction indicator is
illuminated.
1. Observe safety warnings.

Air Cleaner
2. Release the three clips (A).
3. Remove cover (B).

A E
4. Carefully remove outer filter (C).
C
Do not run the engine with

the dust cover (C)
removed as this will result
in dust ingression and subsequent
engine failure.
B
5. Lift the tabs on the outer edge and remove

D
inner element (D).
Section Page
12 Maintenance 34
12.7.2.1 Replacing the outer air

cleaner element
(Continued) HAZARDS
EQUIPMENT
6. Clean the inside of the air cleaner casing Refer to Safety Chapter Section 3.1 Page 2
using a damp, lint free cloth, paying LOCKOUT AND TAGOUT

particular attention to the element seals. Refer to Safety Chapter Section 3.6 Page 10
7. Replace the existing inner element (D).
8. Insert outer element (C) into place.
9. Re-fit cover (B).
10. Fasten the three clips (A).
If the outer element has

not been changed for 500 Air Cleaner
operating hours, a leak in
the induction system must
be suspected. Check that the air A E
cleaner casing and hoses to the
engine are not damaged. Check that C
all hose connections are airtight.
D
Section Page
12 Maintenance 35
12.7.2.2 Cleaning air filter housing
Always obey the Air

HAZARDS
Cleaner restriction
indicator immediately if the WEAR PERSONAL PROTECTIVE
EQUIPMENT
control panel light Refer to Safety Chapter Section 3.1 Page 2
illuminates.
(Never attempt to clean and reuse an LOCKOUT AND TAGOUT
element.)
1. Observe safety warnings.
4. Carefully remove outer filter

(C).
5. Wipe the bowl clean.

Remove oil or grease by washing in hot Air Cleaner
water with a mild detergent.
A E
6. Refit the outer filter (C).
C
7. Refit cover (B).
8. Fasten the three clips (A).
D
Section Page
12 Maintenance 36
12.7.2.3 Inspect both air filter

Elements
HAZARDS
PROCEDURE EQUIPMENT
LOCKOUT AND TAGOUT

1. Observe safety warnings. Refer to Safety Chapter Section 3.6 Page 10
4. Carefully remove outer filter (C) and

inner filter (D).
5. Discard the elements if they are distorted

or the bonded gaskets are loose.
6. Hold each element up to the light to check

for damage to the paper. The elements
should be discarded if pin pricks of light can
be seen or if there are areas of paper that Air Cleaner
appear damaged.
7. Refit new or existing elements as

required.
A E
C

the dust cover (C)
engine failure.
B
D
Section Page
12 Maintenance 37
12.7.2.4 Replace inner air filter

Element
PROCEDURE
HAZARDS
1. Implement lockout procedure EQUIPMENT
2. Release the four clips (A). LOCKOUT AND TAGOUT

4. Carefully remove outer filter

(C).
5. Remove inner element (D).
6. Clean the inside of the air cleaner casing

(E) using a damp, lint free cloth, paying
particular attention to the element seal
locations.
8. Fit a new inner element (D) and also fit a

new outer element (C).
9. Re-fit cover (B). Air Cleaner
10. Fasten the four clips (A).

A E
C

the dust cover (C)
engine failure.
D
Section Page
12 Maintenance 38
12.7.3 Electrical safety

instructions
Switch off the machine The electrical equipment of

immediately if the machine is to be
malfunctions occur in the inspected and checked at
electrical system. regular intervals.
Before beginning work on Defects such as loose connections or
any of the machine‘s electrical scorched or otherwise damaged
components, any power supplied to components must be rectified
the machine (whether the battery or a immediately.
power line) must be cut-off by
disconnecting or de-energizing.
Before starting any work, check the Work on the electrical

machine and the electrical parts to be system and equipment of
worked on for the presence of power. the machine must be
carried out by a skilled
Ground or short-circuit the parts to electrician or by instructed persons
be worked on to prevent the under the supervision and guidance
possibility of an electrocution hazard. of a skilled electrician and in
accordance with electrical
Insulate any live parts which cannot engineering rules and regulations.
be de-energized to prevent the
possibility of an electrocution hazard.
Always use insulated tools when Wiring Diagram see Section

working on the electrical systems. “Appendix.”
Section Page
12 Maintenance 39

instructions HAZARDS
12.7.3.1 Check battery WEAR PERSONAL PROTECTIVE
EQUIPMENT
LOCKOUT AND TAGOUT

Always disconnect battery
leads before carrying out
any maintenance to the
electrical system.
The battery contains sulphuric acid,

electrolyte which can cause severe
burns and produce explosive gasses.
Avoid contact with the skin, eyes or
clothing.
PROCEDURE
2. Ensure that all electrical connections are

clean and tight and coat the terminals with
petroleum jelly to protect them from Battery
corrosion.
3. Disconnect battery at isolator switch

(BIS) before performing any maintenance.
4. Remove the battery filler plugs and check

that the electrolyte level is between
6 and 9 mm (0.25 - 0.37 ins) above the tops
of the separators.
5. If necessary, fill up with distilled water.
6. Where batteries have trough fillers, add

distilled water to the filling trough until the
trough just begins to fill with water.
Section Page
12 Maintenance 40

instructions
HAZARDS
12.7.3.2 Battery removal
EQUIPMENT
PROCEDURE
LOCKOUT AND TAGOUT
2. Ensure all electrical circuits are switched

off.

4. Disconnect the ground (-) lead from the

battery (B.)
5. Disconnect the positive (+) lead from the

battery.
6. Loosen bolts from the battery retaining

frame. Battery
7. Remove the battery retaining frame.
8. Remove the battery from the machine.
Always disconnect battery

leads before carrying out
any maintenance to the
electrical system.
The battery contains sulphuric acid,

electrolyte which can cause severe
burns and produce explosive gasses.
Avoid contact with the skin, eyes or
clothing.
Section Page
12 Maintenance 41

instructions HAZARDS
12.7.3.3 Battery installing WEAR PERSONAL PROTECTIVE
EQUIPMENT
PROCEDURE LOCKOUT AND TAGOUT

2. Ensure all electrical circuits are switched

off.

4. Lift the battery onto the machine.
5. Fit the battery retaining frame.
6. Tighten bolts on the battery retaining

frame.
7. Connect the positive (+) lead.
8. Connect the ground (-) lead. Battery
NOTICE
When installing the battery the

positive (+) lead must be connected
first.
These machines are wired negative

ground. Always observe correct
polarity.
Section Page
12 Maintenance 42
12.8 Chassis
HAZARDS
12.8.1 Tracks WEAR PERSONAL PROTECTIVE
EQUIPMENT
Check that the tracks are tensioned at all LOCKOUT AND TAGOUT
times. To tension the tracks follow the Refer to Safety Chapter Section 3.6 Page 10
following steps.
12.8.1.1 Tensioning the tracks
PROCEDURE
2. Stop the engine.
3. Remove cover (B.)
4. Place a 90° bend onto the end of a grease

pipe.
5. Insert grease pipe onto the grease nipple

(C,) situated behind the cover (B.)
6. By pumping grease via this grease nipple,

a ram is being actuated and extends the
tracks until taut.
Section Page
12 Maintenance 43
12.8 Chassis
12.8.1.2 Releasing track tension HAZARDS

EQUIPMENT
LOCKOUT AND TAGOUT

SKIN INJECTION HAZARD
Refer this Section 3.8.6, safety information
2. Stop the engine.
3. Remove cover (B.)
Grease exiting the relief

valve is under high
pressure.
Grease can penetrate the skin.
Ensure correct personal protective
equipment is worn.
C
4. To release tension unscrew the grease
nipple (C) slowly until grease flows out.
Ensure a suitable container is

available to collect ejected grease.
5. When the tracks are at the required

position, tighten the grease nipple (C).
6. Replace cover (B.)

Section Page
12 Maintenance 44
12.8 Chassis
12.8.1.3 Cleaning the tracks

HAZARDS
EQUIPMENT
1. Observe all safety warnings. Refer to Safety Chapter Section 3.1 Page 2
LOCKOUT AND TAGOUT

2. On a weekly basis the tracks should be

hosed down in area shown (P), to dislodge
any build up of material on the tracks.
Section Page
12 Maintenance 45
12.9 Hydraulic system

HAZARDS
NOTICE
EQUIPMENT
The air vents in the cap must be kept LOCKOUT AND TAGOUT
open to allow the hydraulic system to Refer to Safety Chapter Section 3.6 Page 10
“breathe.”
Always use the correct grade of oil,

otherwise overheating will occur.
(Refer to this Section, “lubricants and
fluids.”)
If the hydraulic system requires

filling up on a regular basis, all
hydraulic parts and hoses should be
inspected for leaks. Any repairs
should be made prior to continued
operation of the machine.
ALWAYS practice extreme
cleanliness when servicing.
E
A
A Hydraulic Oil Level Indicator
B Filler Cap
C Drain Bung
D Suction Filters
E Return Line Filters D
C
Section Page
12 Maintenance 46
12.9.1 Hydraulic oil

HAZARDS
12.9.1.1 Check hydraulic oil WEAR PERSONAL PROTECTIVE
EQUIPMENT
level Refer to Safety Chapter Section 3.1 Page 2
LOCKOUT AND TAGOUT

PROCEDURE SKIN INJECTION HAZARD
warning.
2. Machine must be on level ground. A
3. Always have the hydraulic oil at normal

operating temperature.
4. Always have all cylinders retracted

(where possible).
5. Check the level indicator (A.)

The oil level must be between the red and
black marks on the gauge.
Section Page
12 Maintenance 47
12.9.1 Hydraulic oil
12.9.1.2 Adding hydraulic oil

HAZARDS
EQUIPMENT
LOCKOUT AND TAGOUT


warning.
2. Machine must be on level ground. A

(where possible).
4. Implement lock-out procedure.
5. Clean the area around the filler cap (B).
6. Open the filler cap (B).
7. Fill the tank to midway between red and B

black marks on the level indicator.
(Correct grade of hydraulic oil see this E
Section, “lubricants and fluids.”)
A
NOTICE
Never overfill the hydraulic tank as D

this will cause leakage from the filler
cap.
C
Section Page
12 Maintenance 48
12.9 Hydraulic system HAZARDS

EQUIPMENT
12.9.1.3 Change hydraulic oil Refer to Safety Chapter Section 3.1 Page 2
filter LOCKOUT AND TAGOUT

warning.

F
B
(where possible.) E
4. Drain the tank by removing the drain A

bung (C).
NOTICE
D
Before removing the drain plug (C)
a) Release any pressure in the

hydraulic tank by slowly unscrewing
C
the filler cap (B).
b) Ensure a suitable container is

placed on the ground to catch the full
capacity of oil in the tank. NOTICE
c) Remember to stand on one side to

avoid oil which will spill from the ALWAYS practice extreme
drain hole. cleanliness when servicing.
5. Remove the cover plate (F)

Section Page
12 Maintenance 49
12.9.1.3 Change hydraulic oil

Filter (Continued)
HAZARDS
EQUIPMENT
6. Remove the suction filters (D) by
LOCKOUT AND TAGOUT
unscrewing them counter clockwise from Refer to Safety Chapter Section 3.6 Page 10
the suction pipes.
7. Flush out the tank with clean hydraulic oil warning.
taking extreme care to remove all dirt and
foreign matter.
8. Fit new suction filters (D) to the suction

pipes. F
9. Re-fit cover plate (F) to the tank using a B

new gasket and refit drain plug (C)
E
10. Change the return line filter element
(refer this Section.) A
11. Refill the tank with clean hydraulic oil to

midway between the red and black marks on
level indicator. (Correct grade of hydraulic
oil see this Section, “lubricants and fluids.”) D
12. Run the engine to circulate the oil.

Operate the hydraulic controls to purge any
air from the system.
13. Stop the engine and fill up the system as C

required.
NOTICE
Change the suction elements when

an oil change is being carried out.
Section Page
12 Maintenance 50
12.9.2 Return line filter

HAZARDS
12.9.2.1 Check return line filter
EQUIPMENT
PROCEDURE
LOCKOUT AND TAGOUT

warning.
2. Always have the engine running at

maximum speed.
3. Always have all hydraulic equipment A

working.
C
D
5. Check the return line filter blockage

indicator (A.) B
6. Change the filter element immediately

when the green sector of the blockage
indicator goes to red.
NOTICE
Red indicates no filtration.

Always change the filter element
immediately when the indicator
shows red.
Section Page
12 Maintenance 51
12.9.2.1 Change return line filter

HAZARDS
PROCEDURE
EQUIPMENT
1. Observe all safety warnings. LOCKOUT AND TAGOUT


2. Release any pressure in the hydraulic warning.
tanks by slowly unscrewing the filler cap.
3. Clean the outside of the filter housing (C).

A
4. Remove the filter by unscrewing the

retaining bolts (D).
C
5. Lift out the old element which is inside D

housing (B) and discard it safely.
B
6. Wash out the filter cap and dry it.
DO NOT USE A RAG.
7. Re-fit new filter ensuring seal ring is in

good condition and correctly positioned.
8. Tighten cap securely.
NOTICE
ALWAYS practice extreme

cleanliness when servicing.
Section Page
12 Maintenance 52
12.10.1 Daily (10 hour) maintenance schedule
Construction unit/ Job Remarks Sign

component
VIEW
Guards check / replace
Hydraulic hoses / seals check / replace
Valves check / replace
Bolts & pins check / tighten/ replace
ENGINE
Coolant level check / fill up
Engine lube oil level check / fill up
Fuel tank level check / fill up
Fuel water seperator check / drain
Engine air cleaner service inspect / replace air filter if
indicator illuminated
MOVING COMPONENTS
Material build up remove
Turning/ moving freely check / repair
SCREEN UNIT
Material build up remove
Screen meshes, wear check / replace
Screen meshes tension check / tighten
Rubber cushions check / replace
Bearings Grease / 2 grease strokes
of Shell Albida HD2
Section Page
12 Maintenance 53
12.10.1 Daily (10 hour) maintenance schedule (continued)

component
POWER UNIT
Return line filter indicator check / replace filter
Hydraulic oil level check / fill up
CONVEYOR BELTS
Alignment check / align
Tension check / tension
Section Page
12 Maintenance 54
12.10.2 Weekly (50 hour) maintenance schedule (machine stopped)

component
FIRST YOU MUST
Carry out daily (10) hour check / replace
maintenance schedule
FEEDER HOPPER
Skirting rubbers check / adjust / replace
Feeder gearbox oil check level / replenish
Belt cleaners check / adjust
COLLECTION CONVEYOR
TAIL CONVEYOR
SCREEN UNIT
Screen mesh tension check / tighten
check / tighten / replace nyloc
Bolts
nuts if loose
ENGINE
Fuel system primary filter / Drain
water seperator
Vee belts check / adjust / replace
Section Page
12 Maintenance 55
12.10.3 250 hour maintenance schedule (machine stopped)

component
FIRST YOU MUST
Carry out weekly (50) hour check / replace
ENGINE
Air cleaner elements check / replace
Engine oil sample obtain
Coolant system sample obtain
Radiator clean
Section Page
12 Maintenance 56

component
FIRST YOU MUST
Carry out 250 hour check / replace
POWER UNIT
Hydraulic oil return line replace
filters / 2 No. Off
ENGINE (Refer to Section 12.7 Power unit Engine Maintenance)
Battery electrolyte level check
Engine lube oil and filter replace
Fuel filters / 3 No. Off replace
Air cleaner inner filter replace
Air cleaner outer filter replace
Alternator and V‐belts check / adjust / replace
Engine protective devices check
Section Page
12 Maintenance 57

component
FIRST YOU MUST
Engine valve lash Inspect / Adjust

component
FIRST YOU MUST
POWERUNIT
Analyze oil sample, check
for condition and
Hydraulic Oil contamination. Change
only as necessary
Section Page
12 Maintenance 58
12.11 Lubricants and fluids
Component International Spec Grade
Engine -9.5°C API: CH-4, CG-4, CF-4 Shell Rimula R3X 15W/40
-18°C 10W/30
Check with local Engine agent for lubricant viscosity in extreme temperatures
Hydraulics - up to 30°C ISO VG 46 Shell Tellus 46

Hydraulics - above 30°C ISO VG 100 Shell Tellus 100
Engine Coolant • Cat EC-1 • TMC RP-329 Valvoline HD Extended Life RTU
• ASTM D-3306, D-6210 Or
• TMC RP-338 • SAE J1034 Cat Extended Life Coolant (ELC)
General Grease Shell Alvania EP 2
Grease for Screen Bearings Shell Albida HD2
Feeder Gearbox MOBIL SHC 629
Crawler Track Gearbox MIL-L-2105 API GL5 Shell Spirax A 80W-90
Crawler Track Adjusters Shell Alvania EP 2
Always use lubricants and fluids that meet or better the above international
specifications.
The grades shown are for reference only.

Section Page
12 Maintenance 59
12.12 Capacities - Fluid
CAT C4.4 96kw (129hp)
Engine coolant 20ltr

Engine oil including filter 13.5ltr
Hydraulic tank 460ltr (121 U.S. gal)
Fuel tank 320ltr (84.5 U.S. gal)
12.13 Adjustment Data

Engine maximum speed is fixed @ 2200 rpm
Screen Shaft Screen Stroke
RPM Max. (mm)
930 10
1050 8
1120 6
12.14 Hydraulic system pressure

Hydraulic system 210 bar to 225 bar (3045 psi to 3250 psi)
Hydraulic hose Pressure rating refer to section 6, “Technical Information. “
Section Page
12 Maintenance 60
12.15 Greasing schedule
AREA DESCRIPTION FREQUENCY GREASE QTY.
1 Screenbox bearings…….2 off 10 Hours (Total 10grammes per bearing)
1
Section Page
12 Maintenance 61
12.16 Recommended lubricants
Engine lube oil Shell Rimula R3X 15W/40
Hydraulics - up to 30°C Shell Tellus 46
Hydraulics - above 30°C Shell Tellus 100
General Grease Shell Alvania EP (LF) 2
Grease for Screen Bearings Shell Albida HD2
Feeder Gearbox MOBIL SHC 629
Crawler Track Gearbox Shell Spirax A 80W-90
Crawler Track Tensioner Shell Alvania EP (LF) 2

Section Page
13 Appendix 1
13.1.1 General plan

Section Page
13 Appendix 2
13.1.2 Transport dimensions

Section Page
13 Appendix 3
13.1.3 Work area required (excluding stock piles)

Section Page
13 Appendix 4
13.1.4 Engine Wiring Diagram and Starter Panel Operation Manual
See attached
Tesab 1550 JMG STARTER PANEL MANUAL
Section Page
13 Appendix 5
13.1.6 Noise Levels

Section Page
14 Trouble shooting 1
14.1 General Troubleshooting.....................................................................................2
14.2 Electrical Troubleshooting...................................................................................4
14.3 Engine Troubleshooting.......................................................................................5
14.4 Tracks Troubleshooting.......................................................................................7
Notice
TROUBLE SHOOTING GUIDE

If any problem arises that is not listed, or if a problem persists after carrying out the
recommended checks, contact Tesab. After sales Service Department for further
assistance.
Section Page
14.1 General trouble shooting
FAULT CAUSE CORRECT MEASURE
DRIVE DRUM TURNS BUT Too much load on belt Reduce load on belt

CONVEYOR BELT DOES NOT Incorrectly tensioned belt Tension belt
MOVE Worn belt Replace belt
CONVEYOR BELT Material jam Remove material jam
COMPLETELY STOPPED Taperlock is broken Replace taperlock
BELTS ARE TRACKING OFF Machine is not level Ensure machine is on level
ground
Belts are not aligned Align belts
Belts are not being fed evenly, Ensure conveyor is fed more
material is tending to be fed to evenly
one side of conveyor
MATERIAL COLLECTS Skirting rubbers not adjusted Adjust skirting rubbers
UNDER BELT
NOISY BEARING Bearing lacking lubricant Follow greasing procedure
Incorrectly aligned bearing Align bearing
Bearing is damaged Replace bearing
SCREECHING NOISE WHEN Conveyor belt wedged or rubbing against Clear obstruction, adjust and
CONVEYOR BELT IS fixed parts align conveyor belt
RUNNING Belt scraper too tightly placed against Re‐adjust conveyor belt scraper
conveyor belt
TIPPING GRID WILL NOT Low battery charge level Charge battery. Top up
OPERATE IN EITHER electrolyte level
MANUAL OR REMOTE Insufficient flow to hydraulic ram Check oil flow from pump and
CONTROL MODE control valve
Electrical problem Check fuses, relays and all
connections
Seals damaged in hydraulic ram replace seals or ram
Bad connection between tipping grid
reciever and solenoids
Damaged solenoid Replace solenoid
Section Page
14.1 General trouble shooting (continued)
MACHINE COMPONENTS Obstruction (e.g stone, material build up Clear obstruction

RUNNING SLOWLY etc.)
Check general condition of machine (e.g oil Correct problem
leaks, excessive heat, hose blockages etc.)
Low engine speed Adjust engine speed
Low hydraulic oil level Top up hydraulic oil level
Return line filter blockage Replace return line filter
Hydraulic suction filters blocked Replace filters and oil
Incorrect control valve relief settings Check and correct relief valve
pressure settings setting
Hydraulic pump cavitation, suction line Open gate valve
collapsed Replace hose & suction filters
EXCESSIVELY NOISEY Blockage at tank outlet Replace suction filters & oil

HYDRAULIC PUMP Coupling misalignment between pump and Realign coupling
power source
Incorrect hydraulic oil Drain hydraulic tank and replace w
Obstruction at pump inlet Remove obstruction
LOW OR ERRATIC Hydraulic oil contaminated Drain hydraulic tank then replace
PRESSURE oil and filter
Worn or sticking relief valve Replace relie valve
Control valve relief pressure set to low Set relief valve to correct
pressure
Section Page
14.2 Electrical trouble shooting
7 SECOND DELAY WARNING Fuse blown Replace fuse, refer to electrical

SIREN DOES NOT WORK circuit diagram
Siren damaged Replace siren
CONTROL PANEL Low hydraulic oil level illuminated Top up oil level
ILLUMINATES BUT ENGINE Low engine lube oil level illuminated Top up oil level
DOES NOT START Emergency stop light illuminated Reset emergency stop
Bad connection Check all connections
Faulty starter motor relay Replace starter motor relay
Faulty ignition switch Replace ignition switch
Faulty starter motor Replace starter motor
CONTROL DOES NOT Low battery voltage Top up electrolyte level and
ILLUMINATE charge battery
Fuse blown Replace fuse
Bad electrical connections Check and repair
Damaged battery Replace battery
BATTERY DISCHARGES Fuse blown Replace fuse
WHILE ENGINE IS RUNNING Faulty battery Check / replace battery
Faulty starter motor relay Replace starter motor relay
Faulty alternator Check / replace alternator
TIPPING GRID REMOTE Remote control is out of range Move remote control to within
CONTROL DOES NOT WORK 100m of machine
Batteries are discharged Replace batteries
Tipping grid cycle not set Set program
Remote control not programmed to Program receiver box
receiver box
TRACKS DO NOT WORK Control valve levers are not engaged Place levers in correct position
Umbilical cord damaged Check / replace
Fuse blown Replace fuse
Remote control unit faulty Check / replace
Section Page
14.3 Engine trouble shooting

Section Page
14.4 Tracks trouble shooting
(i) One Track not operating or operating slower than the other
- Check that the same size of Motors have been fitted to both Tracks.
- Check if the brake is releasing.
Fit a pressure clock to the Brake Hose. A pressure of at least 285 PSI / 20 bar is
required to release the brakes.
If the correct pressure is not going to the Brake hose it is likely to be a problem with the
Motion Control Block possibly contamination. If a Load Control Valve should jam due to
oil-entrained debris then the likelihood is that it will not open and will not allow the motor
to turn in one direction.
This will cause the Host Machine to ‘crab’ in one direction. Swapping the valves over
from one Track to the other will usually transfer the problem to the opposite direction.
Similarly, if the Brake Pressure Regulator Valve is jammed due to debris the motor will
stop turning on one side. Swap the Pressure Regulator from the opposite block to see if
the problem is in the Brake Valve.
Try removing the Valves and cleaning them thoroughly taking care not to damage the
external cavity seals.
Also check the ports in the Block for dirt etc. If this does not work replace the valves
with new ones. Always cross-reference the part numbers on the new valves with the old
valve, before fitting. It is critical that the correct Valves are fitted. Valves should never be
dismantled as no internal seals or parts are available.
If the valves continue to jam then the oil in the hydraulic system is not being filtered to
the required level of cleanliness.
If the correct pressure is going to the Brake Hose then the Motor, Brake or Brake Piston
Seals may be damaged.
- To check for a Motor fault swap over the Motors on the two Tracks. If the fault is in the
Motor, replace with a new Motor.
- To check for a faulty Brake remove the Motor and look into the Gearbox for heat
discolouration and/or fragments of Brake disc. If the fault is in the Brakes the complete
Gearbox will have to be replaced.
-To check for faulty Brake Piston seals remove the Motor. If there is Hydraulic oil in the
Gearbox entrance then the seals are damaged. While it may be possible to replace
these seals on-site we strongly recommended that a replacement Gearbox is fitted and
an overhaul of the damaged Gearbox be carried out off-site.
Section Page
14.4 Tracks trouble shooting (continued)
(ii). Excessive oil leaking around Drive Assembly
- Seals damaged between Motion Control Block and Motor.
Remove Motion Control Block and replace seals.

Note: Seal damage may be caused by excessive oil temperatures. Check oil operating
temperature and environmental conditions.
- Seal damaged between Motor and Gearbox.
Remove Motor and replace seal.

Note: Seal damage may be caused by excessive oil temperatures. Check oil operating
temperature and environmental conditions.
(iii) Track will not stay tensioned

- Grease escaping.
Check that the Track Adjuster Grease Valve is tight, has a properly fitted seal and that
there is no grease leaking past it.
Check around the Tensioning Cylinder for escaping grease. This will indicate that the
seals are damaged in the Tensioning Cylinder. Replace with a new Cylinder
immediately.
(iv) Track Group running off Sprocket and/or Idler
- Track Group too loose. Check Track tension

- Excessive misalignment. Check alignment of Sprocket, Idler and Track Rollers.
- Excessive component wear. Check wear limits,
- Twisted Track Frame. Check Track Frame.
v) Excessive Component Wear Rate
- Included in this section
(vi) Track Roller leaking oil
- Damaged or worn seals. Replace with a new Track Roller.

Section Page
15 Fault Finding 1
11.1 Hydraulic Fault Finding........................................................................................2

Section Page
15 Fault Finding 2
15.1 Hydraulic Fault Finding
15.1.1 None of the machine hydraulics are working when the machine is switched on
Section Page
15 Fault Finding 3
15.1 Hydraulic Fault Finding
15.1.2 One circuit is not working, all other circuits are working
Always ensure hydraulic test unit is fully open when connecting to

circuit.
Never attach a hydraulic test unit between the pump and a control valve
and restrict the flow using the adjustable screw.
Never attach any measurement device that restricts or blocks flow from a pump
THIS WILL CAUSE SERIOUS DAMAGE TO THE PUMP
Section Page

16 Warranty 1

Tesab
Standard Terms & Conditions
GENERAL:
1.1 In these conditions (unless the context otherwise requires) the expression
“Company” means Tesab, and the Expression “Customer” means the person, firm
or company to whom the tender/quotation is addressed or whose order the
Company accepts.

1.2 These conditions shall be incorporated into all contracts made by the company and
all work undertaken by the company shall be carried out pursuant to a contract
incorporating these conditions not withstanding anything to the contrary in the
customer’s order.

1.3 No representative or agent of the company has any authority to vary or add to these
conditions. Any variation or alteration shall only be valid if authorised in writing
signed by the director of the company.

1.4 The customer shall be liable to the company as a principal for all costs, charges and
expenses that shall be due to the company in respect of work carried out by the
company subject to these conditions whether or not such customer purports to
contract as an agent. A customer may not assign the benefits or burden of any
contract with the company.

1.5 Any tender or quotation by the company shall be deemed to be withdrawn unless
accepted within 30 days of the date thereof. No order shall bind the company unless
and until the customer has received written conformation from the company.

1.6 Any information from the customer necessary to enable the company to proceeed
with any order must be furnished within a reasonable time otherwise the company
may, at its option, cancel the order or charge the customer an additional price for
the delay.

1.7 The singular in all cases shall include the plural and vice versa.

PRICES:
Gortrush Industrial Estate, Omagh Co Tyrone, BT78 5EJ.
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 2

2.1 All published prices are subject to V.A.T. where applicable and are subject to revision
without notice.
2.2 Orders are only accepted on condition that they are executed at the price agreed
between the customer and the company.
CONDITIONS AND WARRANTIES:
3.1 Whilst the company shall make every endeavour to use the best materials available
no liability is accepted by the company for loss, damage or injury to property or
person arising directly from failure or defect in the machinery or equipment
supplied.
3.2 The company at its discretion undertakes to replace or repair free of cost any part or
parts supplied by it direct to the customer of which it will receive written notice and
which shall be proved to the satisfaction of the company to be defective in either
workmanship or materials within a period of 12 months from dispatch or 1500
hours, whichever is the shorter.
A, That written notice of complaint is given to the company within seven days of the
discovery of the defect.
B, That the part is returned carriage paid to the company.
C, That the part, if replaced, shall become the property of the company.
D, That the company shall not be liable for the cost of removal of the defective part or
the cost of fitting a new part, except otherwise at the discretion of the company.
E, No unauthorised alteration or modification has been made to the plant or machine
or component subject to claim.
3.3 The new part will be delivered by the company to the customer’s works in the
United Kingdom or port of exportation.
3.4 In the case of parts or components not manufactured by the company the customer
shall be entitled to the benefits in so far as they may be transmitted to the customer
of any guarantees given by the manufacturer in respect thereof and the company’s
liability in respect of such parts or components is limited to make the benefits of the
manufacturer’s guarantees available as aforesaid.
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 3

3.5 In so far permitted state or otherwise the guarantee which is contained in paragraph
3.2 above is in lieu of and excludes any other conditions guarantees or warranties
expressed or implied statutory or otherwise and in no event shall the company be
liable( except to the extent (if any) of its undertaking or by statute as foresaid) for
any loss, in jury or damage howsoever caused or arising.
DRAWING CAPACTIES, ETC:
4.1 Dimensions, details and statements as to the suitability of machinery for any
particular purpose or as to the capacity, type or power specified or contained in any
drawings, quotations, catalogues, shipping or other specifications etc. and any
illustrations or photographs referred to, though carefully given, are not intended as
and must not be treated as the contractual description.
4.2 The company undertakes no responsibility for sites or foundations or for any
framework or support for machinery or for compliance with any local by‐law or
statutory regulations, observe or fulfil. The customer shall be responsible for the
proper adoption or any designs to his own circumstances.
DELIVERY
5.1 The company shall not be liable for delays caused by any of the following:
A, Industrial deputes.
B, Strikes.
C, Lock‐outs.
D, Fire.
E, Accident.
F, Non Delivery or late delivery of materials or parts by other manufactures.
G, Works breakdown
H, Any other cause beyond the company’s control;
5.2 Times and dates for delivery or performance are estimates only and not contractual
obligations of the company.
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 4

5.3 The company will make every endeavour to deliver by the time or date given, but
accepts no liability for loss, consequential or otherwise, caused by delay howsoever
caused.
5.4 If the customer shall be unable or unwilling to take delivery when the goods or any
part thereof are ready for dispatch, then the customer shall pay to the company a
reasonable charge for storage until such time as he is able and willing to take
delivery of such goods or part thereof. Any payments due but delayed because the
customer is unable or unwilling to take delivery shall, if not already due, fall
immediately due.
TRANSIT:
6.1 Not withstanding anything in the tenders, quotations, order or contract, as to the
place of delivery, or payment of carriage the customer agrees that any goods in
transit shall be at his risk, and accordingly all consignments shall be deemed to be in
the customer’s possession (whether the property therein shall have passed or not)
to deliver to United Kingdom docks, shall be at the customers’ expense.
6.2 All shipping delays, demurrage charges and shipping charges of any description, after
the company has fulfilled its obligation (if appropriate) to deliver to United Kingdom
docks, shall be at the customers’ expense.
6.3 All unloading shall be at the risk of and expense of the customer.
6.4 The customer shall keep the goods fully insured and shall, if appropriate, indemnify
the company against any loss or damage.
PACKING:
7.1 All machinery shall be freighted open with small component parts crafted specifically
requested on the order “to be crated”. Packing cases on all exports will be charged
to the customer at cost.
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 5

COMMISSIONING:
8.1 Where the company’s sale includes commissioning the company accepts no
contractual obligation in respect of provision of work or materials for the
preparation of a proper site with suitable and sufficient access thereto. Unless
otherwise expressly agreed in writing the customer shall be responsible for and
bound to provide at his own expense:
A, A Properly prepared site, with suitable foundations and adequate access.
B, All necessary lifting tackle, Fuel, Water, Oil and other stores, and.
C, Also Sufficient labour and assistance to enable the company to proceed
properly with and complete the erection of and starting and setting to work
of the machinery.
8.2 If the customer shall require training for his personnel he shall provide operators of
acceptable calibre and physical capability to the company who shall be made
available at the customer’s expense.
8.3 The customer shall indemnify the company against any claims, damages, costs and
expenses in respect of any accident, injury or loss sustained by personnel recruited
by the customer and arising of and in the personnel effect the necessary employer’s
liability insurance in respect of them.
8.4 The company’s workmen are supplied with time sheets, which shall be submitted by
such workmen to the customer who shall check or cause the same to bee checked
and signed. These time sheets shall be deemed to be the correct record of all
matters therein set out.
8.5 Prices quoted for erection and/or services are based on the company’s normal order
and acceptances terms and overseas travel of the company’s employees, board and
keep shall be the responsibility of the customer unless specific alternative
arrangement are agreed in writing between the customer and company.
PATENT RIGHTS:
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 6

9.1 The customer shall indemnify and keep indemnified the company against all claims,
damages, costs and expenses to which it may become liable through executing an
order in accordance with the customer’s specification which constitutes an
infringement of any patent or registered design.
PAYMENT:
10.1 Payment shall be made net to the company’s head office or its appointed bank upon
notice of the goods being ready for collection or dispatch. Cheque, money orders or
other negotiable documents must be made payable to the company and only the
customer’s official receipt shall be valid. For export ordered, payments shall be in
sterling or in a currency specified by the company against documents at the United
Kingdom, unless expressly stated otherwise by the company.
10.2 The contract price will be payable by the customer is strict accordance with the
contact terms, not withstanding any delay in delivery of performance on the contract
or any adjustment or correction of minor defects which may be required to the
plant, machinery or work. The company may suspend performance on any
contractual obligation to the customer so long as any account of the customer is
overdue.
10.3 Interest at 2% above minimum bank lending rate with a minimum of 9% per annum
will be charged at the company’s discretion on all overdue accounts. The term
“minimum bank lending rate” in this context shall mean the minimum‐lending rate
from time to time fixed by the Bank of England.
10.4 Legal Title remains with the company until payment by the customer has been made
in full. In case of default by the customer after delivery of any goods and before
goods have become the customers property, the company may give notice to the
customer terminating the customer’s right to possession whereupon the customer
shall be bound and it’s expense, to redeliver the goods to the company. In all such
case the company may (whether with or without previous notice) itself retake
possession of the goods and the company is in such circumstances irrevocably
authorised by the customer to enter the premises on which the goods are situated
and to dismantle and remove from the same at the customer’s expense. The
customer will not sell, deal with or otherwise dispose of the goods until such time as
they have been paid for in full or collected by the company.
SAFETY:
Tel‐ 028 82 252781
Fax‐ 028 82 252801
Section Page

16 Warranty 7

11.1 To the best of the company’s knowledge the machinery and plant manufactured by
the company complies with the requirements imposed on a manufacturer under
regulations enforced in the United Kingdom or any part thereof. Should special or
additional guards be required to meet the particular local requirements of the
customer they will be charged as additional items
JURISDICTION
This contract is governed in all respects by the law of Northern Ireland within the
United Kingdom and the customer submits to the jurisdiction of the courts of
Northern Ireland.

Tel‐ 028 82 252781
Fax‐ 028 82 252801

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MAXIMUS 516

PRODUCT USER MANUAL

OPERATION AND MAINTENANCE

Do not operate machine without reading this manual.

Edition 1 June 2010

MANUFACTURERS EC DECLARATION OF CONFORMITY

Manufacturer: Tesab Engineering Ltd.

Description of Machine: Mobile vibrating screen

Declares that: Machine Model: Tesab 1550 Serial No:

Complies with the provisions of the following EC Directives.

European Machinery Directive 2006/42/EC.

CE mark affixed, Date _____________

Basis on which conformity is declared

Don Smyth (Company Director)

Tesab Engineering Ltd.

Tel: +44 (0) 2882 252781

2 Definitions and abbreviations 1

Auxiliary Control Valve

2 Definitions and abbreviations 2

Feed (Feeder) Conveyor

2 Definitions and abbreviations 3

Main Conveyor P.S.I.

2 Definitions and abbreviations 4

Shredder Tail Conveyor

Side Conveyor Tracks (Crawler Tracks)

Spillage Transport Position

Spreader Plate Variable Speed Flow Control

2 Definitions and abbreviations 5

The influence from lasting exposure may be

Manual Edition 2 (March 2010)

Section Contents Page

3.1 Safety notice (Proposition

Proposition 65. Calfornia. USA Eye protection must be worn

3.2 Warnings and symbols

3.3 Safety in the working Always wear correctly fitting (EN/ANSI

Protective clothing includes Ear protection,

Always check around, under, on and in the 3.3.5

Always use work equipment or other 3.3.12

Never remove the filler cap, or refuel, with the

Never add gasoline (petrol) or any other fuel

Do not smoke or carry out maintenance on the

DANGER! Never reach or put your foot into

Dust waste should be disposed of with regard

3.4 Selection and

All electrical work must be carried out in

3.5 Tools and equipment

Provided with an EC Declaration of Many risks can be controlled by ensuring hand

3.6 Lockout and tagout

individual users._ Establish a policy that permits

3.6 Lockout and tagout

_ Inspect energy control procedures at least

employees covered by the standard.

provisions in OSHA standards when machines or

3.7 Electrical energy 3.7.6

3.8 Hydraulic System

WARNING! High-pressure hydraulics are

If fluid is injected under the skin, it must be

3.9 Disposal of parts and

Ensure that all consumables and replaced

See Material Safety Data Sheets (Section 3.14)

Always read the safety data sheets provided.

3.10 Transport and stability