Red Rhino 4000 Series Operation & Maintenance Handbook
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Red Rhino 4000 Series Operation & Maintenance Handbook

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OPERATION & MAINTENANCE
Serial Number
Date of manufacture
Publication Number
Publication Date
HANDBOOK
4011065
January 2023
411001
July 2022
Crushers (UK) Ltd
Isaac Newton Way
United Kingdom
Tel: +44 (0) 1476 590 790
E-mail: info@redrhinocrushers.net
Web: www.redrhinocrushers.com
Red
Rhino
Grantham
Lincolnshire
NG31 9RT

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  • Page 1 OPERATION & MAINTENANCE HANDBOOK Rhino Crushers (UK) Ltd Isaac Newton Way Serial Number 4011065 Grantham Date of manufacture January 2023 Lincolnshire NG31 9RT United Kingdom Publication Number 411001 Tel: +44 (0) 1476 590 790 Publication Date July 2022 E-mail: info@redrhinocrushers.net Web: www.redrhinocrushers.com...
  • Page 3 The purpose of this manual is to give a quick reference to the owner and operators of the Red Rhino 4000 Series. For more Technical, Maintenance and Operational Information please refer to the following: Kubota Engine Operations Manual Red Rhino Technical / Service Department Email: service@redrhinocrushers.net...

  • Page 4: Table Of Contents

    Contents Terms & Definitions………………….…………………………………………………………………………………………………..5 Warranty………………………………………………………………………………………………………………………………………6-8 Warranty Registration and Installation Certificate…………………………………………………………………..….9-10 EU Declaration of Conformity………………………………………………………………………………………………………..11 Introduction to the Handbook………………………………………………………………………………………………...12-14 Warning Labels & Symbols…………………………………………………………………………………………………………...15 Stopping the Machine in an Emergency…………………………………………………………………………………….….16 Component Locations………………………………………………………………………………………………………………17-18 General Safety………………………………………………………………………………………………………………………..19-21 Operating Safety……………………………………………………………………………………………………………..……...22-24 Maintenance Safety……………………………………………………………………………………………………………………...25 Crushing………………………………………………………………………………………………………………………………..26-27 Operation Instructions………………………………………………………………………………………………………………...28 Pre-Start Safety Checks………………………………………………………………………………………………………………..29 Guidance to Machine Pre-Start Checks…………………………………………………………………………………..30-31 Engine Controls……………………………………………………………………………………………………………………...32-33 Discharge Conveyor……………………………………………………………………………………………………….…………...34...

  • Page 5: Terms & Definitions

    Terms & Definitions For the purposes of this document, the terms and definitions given in ISO 6165 and the following apply. Left-hand side Side which is on the left when an observer is facing in the normal forward direction of travel of the machine. [ISO 3600:1996] Right-hand side Side which is on the right when an observer is facing in the normal forward direction of travel of the machine.

  • Page 6: Warranty

    Warranty Terms, Conditions & Procedures Warranty Terms and Conditions. Your Red Rhino 4000 series Compact Crusher has been designed and manufactured in the UK and meets all current EU legislation on safety, emissions and noise levels. The product is warranted against any defects in material and workmanship for a period of 1 year or 1000 hours usage from date of installation whichever occurs first.
  • Page 7 Red Rhino Crushers (UK) Ltd warranty does not cover any indirect loss and/or expense or costs (including loss of profit), and Red Rhino Crushers (UK) Ltd are not liable for any such costs, loss or expense suffered arising out of a breach by Red Rhino Crushers (UK) Ltd of this contract.
  • Page 8 Warranty Audits and Surveys Red Rhino Crushers (UK) Ltd reserves the right to carry out audits and inspections from time to time in relation to any reimbursed or outstanding warranty claims in order to determine that all relevant details and information is correct.

  • Page 9: Warranty Registration And Installation Certificate

    Terms Red Rhino products are warranted against defect in material and workmanship for a period of 12 months or 1000 working hours from the date of installation, whichever occurs first. Two years on the engine. Warranty Claim Submission Procedure The warranty liability is limited to diagnosis, repair or replacement of the defective part.
  • Page 10 DELIVERY DATE: ___________________ I confirm that I have been instructed on the safe use of the Red Rhino Crusher or Screener as detailed above, and that I have retained and read a copy of the operator instruction manual in full and that I understand the terms of the warranty.
  • Page 11 Machine Description: Track mounted compact diesel/hydraulic powered jaw crusher for recycling all types of aggregate based building materials. MAKE: Red Rhino Crusher MODEL: 4000 Series SERIAL NUMBER: ENGINE NUMBER: NAME of MANUFACTURER: Red Rhino Crushers (UK) Limited Isaac Newton Way Alma Park Road, Grantham, Lincolnshire, NG31 9RT, United Kingdom.

  • Page 12: Eu Declaration Of Conformity

    The technical documentation for the machinery is available from: Red Rhino Crushers (UK) Ltd Isaac Newton Way, Alma Park Industrial Estate, Grantham, Lincs, NG31 9RT Signed for & on behalf of Red Rhino Crushers (UK) Ltd Place of Issue ------------------------------------------------------------------------------ January 2023...

  • Page 13: Introduction To The Handbook

    If the machine is used in any way contrary to its intended use, or if the machine is modified or altered in any way without the prior written consent of Red Rhino Crushers (UK) LTD, or if the machine is incorrectly or recklessly driven, operated or maintained, Red Rhino Crushers (UK) LTD will not accept any liability whatsoever for any damage or injury (whether direct or consequential).
  • Page 14 It must not be removed from the machine and should be kept clean and in good condition. Additional copies of the handbook can be obtained from Red Rhino Crushers (UK) LTD. Only trained operators should use this machine. Red Rhino Crushers (UK) LTD strongly recommend that anyone who is responsible for the operation and servicing of this machine be fully trained &...
  • Page 15 Caution Denotes a reminder of safety practices could result in injury to the operator (or others) and possible damage to the machine. In general, these notes are used to indicate that the procedures being described in the Handbook must be followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine from unsafe servicing practices.

  • Page 16: Warning Labels & Symbols

    Warning Labels & Symbols Found on the Red Rhino 4000 Read Operation Manual Emergency Stop Danger of trapping Tie Down Points Wear protective Clothing...

  • Page 17: Stopping The Machine In An Emergency

    Stopping the Machine in an Emergency Warning The machine can be stopped in an emergency by pressing the emergency stop buttons located along each side of the machine or by turning the ignition key directly to the “off” position. Make sure that all persons in the area of the machine are fully trained in the location of the emergency stops and how to use them.

  • Page 18: Component Locations

    Component Locations CONVEYOR EMERGENCY STOP CONVEYOR TIE DOWN TENSION BATTERY TIE DOWN ADJUSTER LOCATION...
  • Page 19 Component Locations HYDRAULIC CONTROLS FEEDER HOPPER FUEL LEVEL RUNNING START HYDRAULI C THROTTLE TRACKS PANEL LEVER LEVER OPERATOR PLATFORM...

  • Page 20: General Safety

    You and others could be killed or seriously injured if you operate or maintain the machine without first studying the operator manual. You must understand and follow the instructions in the operator manual. If you do not understand anything, ask your employer or Red Rhino dealer to explain it.
  • Page 21 Warning Feeling unwell: Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with. Warning Mobile Phones: • Switch off your mobile phone before entering an area with a potentially explosive atmosphere;...
  • Page 22 Warning Lifting: This machine is NOT permitted to be lifted for transport or any other reason. Warning Power Source: Before any maintenance, service or adjustments are carried out on the machine the “POWER SOURCE” must be isolated. Any persons carrying out repairs or maintenance must isolate the machine and remove the ignition control key.

  • Page 23: Operating Safety

    Operating Safety Warning Machine Condition: • A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine. Warning Airborne Debris: •...
  • Page 24 Warning Communication: • Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everyone. Warning Transportation: •...
  • Page 25 Warning Fire Machine fires must not be put out using water. Always use foam, dry chemical or carbon dioxide extinguishers.

  • Page 26: Maintenance Safety

    Maintenance Safety Warning Repairs: • If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. • Do not try to do repairs or any other type of maintenance work you do not understand.

  • Page 27: Crushing

    Crushing All crushing should be done on a level surface. Safety Warnings Crushing machine uses powerful moving jaws so under no circumstances should the machine run without all covers attached or when moving parts are exposed. Safety Warnings Under no circumstances should you attempt to remove blockages by hand. When the crusher is running you may begin to feed material into the hopper either manually or by machine, ensuring not to overfill the hopper.
  • Page 28 Possible crushing materials include stones, rocks, bricks, concrete, kerb stones and general construction rubble. It may be possible to also crush steel reinforced concrete though you should first consult your Red Rhino dealer in order to determine if your machine is capable.

  • Page 29: Operation Instructions

    Operation Instructions Gradient Transportation When loading the Machine for transport, the ramp must NOT exceed 20°. It should also be noted that ground conditions should be taken into consideration as to whether the conditions are wet or slippery because this will greatly reduce this value. Travelling When moving the machine slope of the ground should exceed 15°...

  • Page 30: Pre-Start Safety Checks

    Pre-Start Safety Checks The following checks must be carried out prior to commencing work. Particular attention must be given if the machine has been left idle for any period of time. All of these checks concern the continued operation of the machine and some concern your safety.

  • Page 31: Guidance To Machine Pre-Start Checks

    Guidance to Machine Pre-Start Checks Engine Oil Dipstick is located through the top inspection panel at the rear of the crusher. ENGINE OIL DIPSTICK Hydraulic oil level is located on the right hand rear side of the machine. Hydraulic Oil capacity 33 litres. HYDRAULIC OIL LEVEL GAUGE The Fuel level gauge is located on...
  • Page 32 RADIATOR COOLANT LEVEL BOTTLE RADIATOR INSPECTION COOLANT Inside the rear top inspection panel the water coolant level tank is located. The water level should remain between MIN—MAX. Ignition control panel located on the right hand rear of the machine. IGNITION CONTROL PANEL...

  • Page 33: Engine Controls

    Engine Controls Control Panel The Ignition Control Panel and the Engine Throttle lever are located at IGNITION CONTROL the rear right hand side of the PANEL machine. Ignition Control THROTTLE LEVER...
  • Page 34 Indication Lights Hours Run Counter Records the total running time of the engine.

  • Page 35: Discharge Conveyor

    Discharge Conveyor Starting the Conveyor system Before attempting to crush any material, you should first ensure that the conveyor is running so there will not be a build-up on material in the crusher. The conveyor is started by using the touch pad on the remote control, when using the radio remote control the conveyor will stop after 30 seconds if the remote signal is lost.

  • Page 36: Dust Suppression

    Dust Suppression Above the conveyor discharge belt a dust suppression water spray bar is mounted. This is a cross belt assembly fitted with three water nozzle jet valves. A mains water supply is required to connect to the spray bar. This connection point is on the left hand side of the machine.

  • Page 37: Running Gears (Tracks)

    Running Gear (Rubber Tracks) Checking tracks for cuts and abrasions: Whilst visually inspecting the tracks, attention should also be taken for any signs of wear on the tracks such as damage that may indicate the tracks need to be replaced. TRACK TENSION POINT BEHIND THE PLATE COVER...

  • Page 38: Track Adjustment

    Track Adjustment Track Adjustment Settings In order to establish if the track requires tensioning move the Host machine a few metres forwards and backwards on level ground. This allows the tracks to adopt their natural degree of tension Note: Do not slew the machine Using a straight edge and a tape measure, measure the droop of the Track Group.

  • Page 39: Jaw Crusher Unit

    Jaw Crusher Unit The Jaw Crusher Unit is an integral part of the crusher and is situated centrally within the chassis. The Crusher is hydraulically driven via flywheels, belt and tensioner to give the crusher reciprocating motion. JAW PLATES The Crusher unit consists of fixed and moving jaw wear plates.
  • Page 40 Hydraulic rams are operated from the remote control. This operates a wedge system to narrow or widen the bottom opening of the jaw. This adjustment allows the sizing of the discharge crushed material. CRUSHER BOX MAIN GREASE POINT The Crusher Box has a central greasing point for the inner and outer bearings, situated on the rear left hand side of the machine.
  • Page 41 To inspect the crusher drive belt and tension arm remove the left hand side inspection panel. This will give full access to the crusher drive assembly. LEFT HAND SIDE INSPECTION REMOVED...

  • Page 42: Guide To Servicing Your Machine

    Left Hand Lower Inspection Panel FOR FULL ENGINE SERVICE DETAILS REFER TO THE KUBOTA ENGINE MANUAL. FOR SERVICE AND TECHNICAL ASSISTANCE PLEASE CONTACT: RED RHINO SERVICE DEPARTMENT EMAIL: service@redhinocrushers.net TELEPHONE: +44 (0) 1476 590790 REMOVE INSPECTION PANELS FOR ENGINE SERVICING...
  • Page 43 Engine Service Engine Oil Dipstick Accessible through the top engine inspection panel. ENGINE OIL DIPSTICK Engine Oil Filter Accessible through the rear radiator cover panel on the right hand side of the engine. ENGINE OIL FILTER (NOT VISABLE) ACCESS VIA REAR COVER GUARD...
  • Page 44 Engine Oil Drain Plug Accessible from beneath the engine under the machine. ENGINE OIL DRAIN PLUG. ACCESS FROM UNDERSIDE ENGINE ENGINE OIL FILLER CAP Engine Oil Filler Cap Accessible through the top engine inspection panel. ENGINE OIL GRADE SAE 10W-40 ENGINE OIL CAPACITY 2.6 LITRES...
  • Page 45 AIR FILTRATION The Air Filter Element is accessible via the left hand side inspection panel. Remove the Filter End Cap and pull out the Air Filter Element. INSPECT REGULARLY (Knock out dust contamination) REPLACE—Refer to the Kubota Engine Manual. FILTER FUEL SYSTEM The fuel filter is located via the rear radiator inspection cover.

  • Page 46: Cooling System

    COOLING SYSTEM The radiator cooling system is filled with a 50% water, 50% antifreeze mix. If the water is drained for any reason then the Main Fill is though the Radiator Cap at the rear of the machine. Inside the engine compartment is a Header Tank Bottle. This is for accurate top up and should be maintained between MAX-MIN Level.

  • Page 47: Hydraulics

    HYDRAULICS The Hydraulic Oil tank is accessible via the top rear inspection cover. The hydraulic tank is fitted with a Hydraulic Filter. To change the filter the cap of the Filter Element should be unscrewed and the element will lift out. HYDRAULIC TANK HYDRAULIC LOCATION...

  • Page 48: Hydraulic Manual Controls

    Hydraulic Manual Controls The Red Rhino 4000 is operated by a manual hydraulic controls. These are operated from the rear of the machine by standing on the fold down platform step. The Hydraulic Levers operate: • Left hand track •...

  • Page 49: Deploying Machine Into Crushing Operation

    Deploying Machine into Crushing Operation • Start the machine and run engine revs at 1/2 throttle for 15 minutes to warm up the hydraulic system. • Manoeuvre the machine into position ensuring the material to be crushed can be loaded from the side of the machine into the hopper.

  • Page 50: Closing The Machine Down After Crushing Process

    Closing The Machine Down After Crushing Process • Ensure all crushed material has run out of the Crusher Box and exited the main conveyor. • Disengage the Crusher Box lever to stop the crusher. • Disengage the conveyor lever to stop the main conveyor. •...

  • Page 51: Replacement Parts

    Replacement Parts For replacement parts and / or spares you will need to quote the Red Rhino Model and engine serial number. These are available from the Red Rhino Parts and Service Department. Please email service@redrhinocrushers.net or call +44 (0) 1476 590790.

  • Page 52: Model Specifications

    Model Specifications Model 4000 (Water Cooled) Prime Mover Type Internal Combustion Engine Power Installed 10.8kw (14.6hp) Length 3260mm Overall dimensions in Width 780mm operating mode Height 1600mm General Data Mass in operating mode 1400kg Length 3100mm Overall dimensions in Width 780mm transportation mode Height...

  • Page 53: General Arrangement Dimension

    General Arrangement Dimension...

  • Page 55: Electrical Components

    Electrical Components Engine Loom...

  • Page 56: Noise Emissions

    RED RHINO MINI CRUSHERS (UK)LTD. NOISE EMISSION DATA IN ACCORDANCE WITH – MACHINERY DIRECTIVE 2006/42/EC OUTDOOR NOISE DIRECTIVE 2000/14/EC NOMAD (9) 2016 NOISE MACHINERY PROJECT. RED RHINO MODEL 4000 Equipment Type THIS EQUIPMENT HAS THE FOLLOWING NOISE EMISSION DATA COMPILED – NOVEMBER 2022. UNDER NON- CRUSHING CONDITIONS.

  • Page 57: Blank Page For Notes On Individual Conditions

    An example is shown below. HEARING PROTECTION MUST BE WORN! Owners of a Red Rhino machine should carry out further noise testing and risk assessments to reflect the relevant site conditions where the machine is in operation...

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