Red Rhino 4000 Series Manual

OPERATION & MAINTENANCE
HANDBOOK
Red Rhino
Crushers (UK) Ltd
Isaac Newton Way
Grantham
Lincolnshire
NG31 9RT
United Kingdom
Tel: [phone]
E-mail: [e-mail]
Web: www.redrhinocrushers.com
Serial Number 4011065
Date of manufacture January 2023
Publicaon Number 411001
Publicaon Date July 2022

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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: [e-mail]
Telephone: [phone]

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Contents
Terms & Denions………………….………………………………………………………………………………………………….....5
Warranty………………………………………………………………………………………………………………………………………6-8
Warranty Registraon and Installaon Cercate…………………………………………………………………..….9-10
EU Declaraon of Conformity………………………………………………………………………………………………………..11
Introducon to the Handbook………………………………………………………………………………………………...12-14
Warning Labels & Symbols…………………………………………………………………………………………………………...15
Stopping the Machine in an Emergency…………………………………………………………………………………….….16
Component Locaons………………………………………………………………………………………………………………17-18
General Safety………………………………………………………………………………………………………………………....19-21
Operang Safety……………………………………………………………………………………………………………..……...22-24
Maintenance Safety……………………………………………………………………………………………………………………...25
Crushing………………………………………………………………………………………………………………………………....26-27
Operaon Instrucons………………………………………………………………………………………………………………...28
Pre-Start Safety Checks………………………………………………………………………………………………………………..29
Guidance to Machine Pre-Start Checks…………………………………………………………………………………..30-31
Engine Controls……………………………………………………………………………………………………………………...32-33
Discharge Conveyor……………………………………………………………………………………………………….…………...34
Dust Suppression…………………………………………………………………………………………………………….………….35
Running Gears (Tracks)……………………………………………………………………………………………………............36
Track Adjustment……………………………………………………………………………………………………………….……...37
Jaw Crusher Unit…………………………………………………………………………………………………………………..38-40
Guide to Servicing Your Machine………………………………………………………………………………………….41-44
Cooling System………………………………………………………………………………………………………………………....45
Hydraulics………………………………………………………………………………………………………………………………....46
Hydraulic Manual Controls………………………………………………………………………………………………….…….47
Deploying Machine into Crushing Operaon……………………………………………………………………………..48
Closing the Machine Down Aer Crushing Process…………………………………………………………………...49
Replacement Parts…………………………………………………………………………………………………………………….50
Model Specicaons………………………………………………………………………………………………………………….51
General Arrangement Dimension……………………………………………………………………...……………………...52
Hydraulics Schemac………………………………………………………………………………………………………………...53
Electrical Components……………………………………………………………………………………………………………….54
Noise Emissions………………………………………………………………………………………………………………………...55
Blank page for notes on individual condions…………………………………………………………………………...56

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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.
[ISO 3600:1996]
Operator's manual
Document describing and illustrating the safe operation, maintenance and safety precautions related to an earth-
moving machine.
Direction of Travel
(Forward)
FRONT
REAR

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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.
This warranty is subject to:
Adherence to the routine maintenance procedures as detailed in the instruction book, the use of genuine Red Rhino
parts and approved lubricants.
Adherence to the service schedule, undertaken by Red Rhino Crushers (UK) Ltd or an approved Red Rhino service
agent, using genuine Red Rhino parts and approved lubricants.
Adherence to the requirement to utilize and record service actions with Red Rhino Crushers (UK) Ltd service record
documentation, and to supply Red Rhino Crushers (UK) Ltd with originals of service record documentation.
Return (within 30 days) of a signed collection/delivery note confirming acceptance of goods in satisfactory condition,
and all warranty registrations including: The Red Rhino Warranty Registration & Installation Certificate and Kubota
engine manufacturers Warranty Certificate.
Adherence to the correct warranty claim procedure as stated below, including the provision of a valid purchase order
number by the customer, and utilization of a valid Red Rhino Crushers (UK) Ltd reference number.
Subject to adherence to the above conditions and during the warranty period, any failed parts will be supplied free of
charge, except for the following limitations:
Warranty Limitations:
The following items are consumable parts and not covered by warranty:
1. Tracks
2. Battery & Starter motor
3. Wear parts - crusher jaws, conveyor belts, toggle-plate, drive belts, conveyor roller lagging, internal and
conveyor rubber wear parts.
4. Paintwork
5. Warranty exclusions as determined by the engine manufacturer:
6. Service parts - filters, glow-plugs, fanbelts, fuel injection equipment, stop solenoid, leaks (oil, water, and air)
hoses, coolants and lubricants. Brake parts (where applicable).
Warranty does not extend to cover normal routine maintenance, cleaning, or servicing, nor any materials used to
carry out routine servicing. The buyer hereby acknowledges and accepts that any costs incurred on repairs, mileage
or servicing required outside of warranty periods or in the event that a warranty claim is rejected, will be chargeable
at our standard rates. (Please contact us for further information).
All engine warranty issues must be directed to the engine manufacturer or the engine manufacturers approved /
appointed engine dealer. No liability shall be attached to us where repairs cannot reasonably be affected, or where,
following partial repair, a fault or breakdown occurs in the parts or portion not repaired.

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The warranty liability of Red Rhino Crushers (UK) Ltd is restricted in all cases to the repair or replacement of the
defective parts(s), and no liability is accepted for consequential damage or any other expense, loss, or costs
(including loss of profit). Red Rhino Crushers (UK) Ltd may actuate the repair or provide compensation in the form
of a credit note only, for labour incurred in actuating the repair. In all cases, a credit note for labour will only be
provided for the replacement or repair of the defective part(s) and in accordance with the time allowances detailed
in the Red Rhino workshop manual and limited in all cases to the standard hourly rate mentioned above.
The warranty does not apply to defects caused by accident, misuse, neglect or wear and tear.
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.
The equipment is checked for contaminants in fuel, oils and lubricants prior to dispatch. If routine service or
warranty work reveals any contamination in the fuels, engine, or hydraulic system, then the works carried out to
amend the problem will be chargeable and not included within warranty.
The warranty is not transferable without written authority from Red Rhino Crushers (UK) Ltd.
Red Rhino Crushers (UK) Ltd cannot recognize any liability, in cases where alterations or modifications have been
executed or replacement parts fitted other than those approved without prior knowledge and consent in writing from
Red Rhino Crushers (UK) Ltd.
Red Rhino will not be held responsible if:
The machine has been used to perform tasks that demand more than its design and strength limitations.
Modifications, alterations, or the use service parts, consumables or lubricants which are not genuine or
recommended will invalidate any warranty.
The machine has undergone modifications not approved in writing by Red Rhino Crushers (UK) Ltd, or conditions of
use have been abnormal.
The conditions of warranty supply listed above have not been met.
Warranty does not extend to cover normal maintenance, cleaning, or servicing, nor any materials used to carry out
routine servicing.
FUNCTION
The 4000 series: for the crushing and recycling of secondary debris and demolition waste materials of a size not
exceeding the dimensions of the jaw-bite aperture. Not for primary mineral extraction. Not for use with reinforced
material containing metals, or contaminants such as wood, clay, metal, plastics, wet cement, textiles, asbestos,
tarmac, etc.
Subject to the function and conditions of use stated, the 4000 series should be capable of handling the following;
1. Mineral crush typically found within recycling and demolition areas.
2. Materials typically pre-formed such as brick and composite base.
3. Materials also shaped from mineral solids such as stone and block work.

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CONDITIONS OF USE: (for standard units) **
The 4000 series compact crusher is designed for use only in the following conditions:
Temperature: Do not operate the crusher in temperatures below minus 5°Centigrade or above plus 30°Centigrade.
Environment: the crusher is designed for use outside only, in normal humidity conditions only.
Platform: firm, level ground only.
Personnel: only to be used by trained personnel.
Atmosphere: operate only in clean, unpolluted air, and do not operate in excessive wind speeds, or abnormal altitude.
Duration: maximum 12 hours operation in any 15-hour period
Operation: use only with correct loading methods and with correct loading equipment (not exceeding 7t excavator or
equivalent), as detailed in the Operation Manual.
Maintenance: use only if serviced in accordance with the service and maintenance schedules outlined in the
Operation Manual, utilizing only genuine parts and lubricants.
Transportation: for use only in accordance with all applicable legal transportation restrictions. Legislation: for use only
in accordance with all relevant and applicable legislation and regulations. **
** Please refer to the engine manual supplied for the restrictions imposed upon the engine for the limitations of the
environment (temperature, altitude, humidity, etc) in which the engine can be operated.
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.
Service & Warranty Training
Service & Warranty training for service fitters can be requested in writing to [e-mail]
Initial training will be carried out at an appropriate Red Rhino Crushers (UK) Ltd workshop. Once this initial training
has been carried out, you are responsible to carry out further training as required by your own service centre, and to
record service actions in accordance with Red Rhino Crushers (UK) Ltd service record documentation.
Service Bulletins
Red Rhino Crushers (UK) Ltd may from time to time issue service bulletins to keep you up to date as to any
developments or changes that take place on the complete assembly or component parts.

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Warranty Claim Procedure(s):
Installation:
It is mandatory that the Warranty Registration and Installation Certificates are completed, signed and returned by the
original purchaser to Red Rhino Crushers (UK) Ltd. This is essential for the Red Rhino Warranty Registration &
Installation Certificate, and Kubota engine manufacturers Warranty Certificate. Warranty commences from date of
collection from our premises.
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. Depending on the product
terms and conditions, and subject to the above, Red Rhino Crushers (UK) Ltd may actuate the repair or provide
compensation in the form of a credit note only, for labour incurred in actuating the repair. In all cases, a credit note
for labour will only be provided for the replacement or repair of the defective part(s) and in accordance with the time
allowances detailed in the Red Rhino workshop manual, and limited in all cases to the standard hourly rate
mentioned above
Claims must be reported accurately, and all relevant details given, as follows:
• OWNERS NAME AND ADDRESS: full name and address of customer and site locaon if dierent
• SERIAL NUMBER:
• MACHINE TYPE: state machine type
• DATE OF PURCHASE:
• DATE OF DELIVERY/COLLECTION: ENGINE NUMBER:
• HOURS USED: DATE OF FAILURE:
• CUSTOMER PURCHASE ORDER NUMBER: (This must be supplied)
• RED RHINO CRUSHERS (UK) LTD REF. NO.: (This must be quoted)
Please contact Red Rhino for a Claim Form.
Warranty Registration and Installation Certificate

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Warranty Registration and Installation Certificate
MODEL: ___________________________
SPECIFICATION: ____________________
SERIAL NUMBER: ___________________
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.
Purchased From: _____________________
Date: _______________________________
Name: ______________________________
Signed: _____________________________
Position: ____________________________
Company Address _____________________
____________________________________
____________________________________
____________________________________
____________________________________
Tel: _________________________________
Email: _______________________________
Web: ________________________________
IT IS ESSENTIAL TO RETURN THIS FORM TO ACTIVATE AND REGISTER YOUR WARRANTY. FAILURE TO
RETURN ANY OF THE WARRANTY REGISTRATION FORMS WILL INVALIDATE WARRANTY.
(See “ Contents” page).
Please complete the following form to register your warranty and post to:
Red Rhino Crushers (UK) Ltd
Isaac Newton Way
Alma Park Road
Grantham
Lincolnshire
NG31 9RT
United Kingdom

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We hereby certify that the machinery detailed below complies with all the relevant provisions of the EC Machinery
Directive as amended and the National Laws and Regulations adopting this Directive.
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.
T: [phone]
E: [e-mail]
W: www.redrhinocrushers.com
Conforms to the Machinery Directive; 2006/42/EC and amended directive 95/16/EC (re-cast).
Conforms to Electromagnetic Compatibility Directive (EMC); 2004/108/EC
Conforms to Radio Equipment Directive (RED); 2014/53/EC
It also complies with the Essential Health and Safety Requirements (EHSR), national standards and transposed
harmonized standards appropriate for this product type.
BS ISO 21873: 2009 Building Construction Machinery and Equipment- Mobile
BS EN1009: Machines for mechanical processing of minerals and similar solid materials.
Crushers, parts 1 & 2
SIGNED: …………………………………………………
DATE: ……………….................................................
NAME: Andrew Hall
POSITION: Operations Manager – (Being the responsible person appointed by the Manufacturer.)
EU Declaration of Conformity

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Product Model/Type
Product Red Rhino
Model 4000
Serial Number 4011065
Manufacturer Red Rhino Crushers (UK) Ltd
Address Isaac Newton Way, Alma Park Industrial Estate, Grantham, Lincs, NG31 9RT
This declaraon is issued under the sole responsibility of the product manufacturer.
The object of the declaraon described above is in conformity with the relevant UK Statutory Instruments and their
amendments.
We hereby declare that the product described above, to which this declaraon of conformity refers to, is in conformity
with the essenal requirements of the following standards.
Reference & Date
Conforms to the Machinery Direcve 2006/42/EC and amended direcve 95/16/E
Conforms to Electromagnec Compability Direcve (EMC) 2004/108/EC
Conforms to Radio Equipment Direcve (RED) 2014/53/EC
It also complies with the Essenal Health and Safety Requirements (EHSR), naonal standards and transposed
harmonized standards appropriate for this type
BS ISO 21873 2009 Building Construcon Machinery and Equipment Mobile
BS EN1009 Machines for mechanical processing of minerals and similar solid materials
Addional Informaon The technical documentaon 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
Date of Issue ------------------------------------------------------------------------------
Andrew Hall
Name ---------------------------------------------------------------------------------------
Operaons Manager
Posion -------------------------------------------------------------------------------------
Signature ------------------------------------------------------------------------------------
Red Rhino Crushers (UK) Ltd
Declaraon of Conformity
In accordance with UK Government Guidance

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Introduction to the Handbook
This handbook covers the following models in the Red Rhino Crusher range:
4000 Series
The above machine is designed primarily for the crushing of waste construction material and
aggregate for recycling purposes or ease of transportation
Modifications or alterations to the machine are strictly forbidden without the prior written consent of Red
Rhino Crushers (UK) LTD.
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).
The methods of Operation & Maintenance specified in this handbook should be strictly adhered to.
For your parts requirements it is essential that only Red Rhino Crushers (UK) LTD genuine parts are
fitted. Any damage resulting from the fitment of non-genuine parts will invalidate the machine warranty.
The content of this handbook whilst correct at the time of publication may be subject to alteration by the
company at any time without notice.
Red Rhino Crushers (UK) LTD operates a policy of continuous improvement and reserve the right to
change specification and equipment without notice. Therefore, some illustrations and accompanying
text may differ slightly from your machine.
References to Left or Right contained in this handbook are as seen from the rear of machine forward.

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The contents of the Operators Handbook are intended as a guide to the operation and servicing of the
4000 Series.
The general method of operation of all these machines is the same. Any individual differences
in the specification or operation are detailed separately.
This handbook is not a training manual. It is designed as a guide to the machine’s controls and
working capacities and general maintenance only. 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 & competent operator.
If you have any doubts about any aspects of the machine’s capability or servicing procedures, you must
consult Red Rhino Crushers (UK) LTD.
Throughout this handbook and on the machine, there are safety notes. Each note starts with a single
word.
The meaning of these single words are explained below.
Introduction to the Handbook
Safety Warnings
This safety alert system identifies important safety messages in this manual. When
you see this symbol, be alert, your safety is involved, carefully read the message that
follows, and inform other operators.
In this publication and on the machine, there are safety notices; each notice starts with
a signal word meaning are provided below.
Danger
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly
probable that the operator (or others) could be killed or seriously injured.
Warning
Denotes a hazard exists. If proper precautions are not taken, the operator (or others)
could be killed or seriously injured.

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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.
These notes do not replace safety codes, insurance requirements & local laws. Make sure the machine
has the correct equipment to comply with local regulations.
Pay particular attention to the safety notes given throughout the handbook.
It is the responsibility of the Operator to fully read all of the handbook & understand it before attempting
to operate the machine.

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

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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.
Emergency stop switches can be located on front and rear of the feed hopper. In the case of an
emergency press one of these switches to disengage the engine and stop the crusher.
Ensure the Hazard is corrected before re-starting the engine.
In an emergency shut down the crusher. This will normally be full of material it is possible to restart
the crusher whilst full but you should read and follow the instructions below.
Return all controls to neutral.
Rotate the emergency button until it is released.
Return the key to the “OFF” position. The engine will not start until this has been done.
Restart by turning key to “ON”, then “START”.
Start the conveyor first, followed by the crusher.
NOTE: If the crusher does not operate immediately you MUST run the crusher in reverse for 10
seconds in order to release material caught in the crusher jaws, and it may be necessary to do this
several times in order to ensure the machine is running correctly.
Adjust engine speed as necessary.
REAR OF
MACHINE
FRONT OF
MACHINE

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Component Locations
EMERGENCY
STOP
TIE DOWN
CONVEYOR
CONVEYOR
TENSION
ADJUSTER
BATTERY
LOCATION
TIE DOWN

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Component Locations
FUEL
LEVEL
HYDRAULIC
CONTROLS
OPERATOR
PLATFORM
HYDRAULI C
LEVER
THROTTLE
LEVER
START
PANEL
FEEDER
HOPPER
RUNNING
TRACKS

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Warning
To operate the machine safely you must know the machine and have the skills to use it. You
must abide by all relevant laws, health and safety regulations that apply to the country you
are operating in.
The operator manual instructs you on the machine, its controls and its safe operation.
General Safety
Warning
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.
Warning
Care and alertness:
All the time you
• Are working with or on the machine, take care and stay alert.
• Always be careful.
• Always be alert for hazards.
Warning
Clothing:
• You can be injured if you do not wear the proper clothing. Loose clothing can get
caught in the machinery.
• Wear protective clothing to suit the job. Examples of protective clothing are: a hard
hat, safety shoes, safety glasses, a well-fitting overall, ear-protectors and industrial
gloves.
• Keep cuffs fastened.
• Do not wear a necktie or scarf.
• Keep long hair restrained.
• Remove rings, watches and personal jewellery.
Warning
Alcohol and drugs:
• It is extremely dangerous to operate machinery when under the influence of
alcohol or drugs.
• Do not consume alcoholic drinks or take drugs before or while operating the
machine.
• Be aware of medicines which can cause drowsiness.