Kleemann

INSTRUCTION MANUAL
MOBICAT MC110R EVO
K005
Series
29.05.2017
Date of issue
2593274_00_EN-GB
Order number
© Kleemann GmbH 2017 K005-0121 -9999

Issuer Kleemann GmbH
Manfred-Wörner-Straße 160
D-73037 Göppingen
Germany
Telephone: + 49 (0) 71 61 / 20 6 - 0
Website: www.kleemann.info
Document number BAL_K005_2593274_00_EN-GB
Translation of the original instruction manual
Date of first edition 06.05.2013
Revision date 09.05.2017
Copyright © Kleemann GmbH 2017

This documentation including all of its parts is protected by cop-
yright. Any use or modification beyond the strict restrictions of
copyright law without the consent of Kleemann GmbH is prohib-
ited and may result in prosecution.
This applies in particular to duplications, translations, micro-
filming and saving and processing work in electronic systems.
2 © Kleemann GmbH 2017

TABLE OF CONTENTS
TABLE OF CONTENTS
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.01 Foreword/Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.01.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.01.02 Changes/provisos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.01.03 Packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.01.04 Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.01.05 Warning sign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.01.06 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.01.07 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.01.07.01 Declaration of Conformity EAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.01.07.02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EuroTest certificate
1.01.08 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.02 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.02.01 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.02.02 Abnormal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.02.03 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.03 Climatic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.04 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.04.01 Safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.04.02 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.04.03 Disposal of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.04.04 Notes on the electrical/electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.04.05 Danger areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.04.05.01 Safety distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.04.06 Fire fighting appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.05 Emissions and loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.05.01 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.05.02 Dust emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.05.03 Vibration emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.05.04 Magnetic emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.06 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.06.01 Sign diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.06.02 Signs/decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.06.03 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.06.03.01 Plant identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.07 Personnel - qualifications and duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.07.01 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.07.02 Available training courses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
© Kleemann GmbH 2017 3

TABLE OF CONTENTS
1.07.03 Contact persons for operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.07.04 Suitable climbing aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.08 Revision statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2.01 Chassis/guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.01.01 Information and hazard signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.01.02 Chassis with beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.01.03 Folding locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.01.04 Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.01.05 Lighting/warning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.01.06 Socket outlets on the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.01.07 Guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.01.08 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.01.09 Safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.02 Control stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.02.01 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.02.02 Operator panels/Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.02.02.01 Touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.02.03 Frequency converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.02.04 Remote controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.02.05 Local controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.02.06 Operating unit for cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.03 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.04 Power supply unit/engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.04.01 Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.04.02 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.04.03 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.04.04 Air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.04.05 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.04.06 Hydraulic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.04.07 Diesel engine, heat package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.04.08 Diesel engine cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.05 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.05.01 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.05.02 Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.05.03 Valve blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.05.04 Hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.05.05 Driving clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.06 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.06.01 24 V voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.06.02 Battery isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

TABLE OF CONTENTS
2.06.03 Switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.06.04 Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.06.05 Electric motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.06.06 Socket outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.06.07 Electrical system, heat package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.06.07.01 Heat package, control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.06.08 Electrical system, cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.06.08.01 Voltage supply, cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.06.08.02 Control cabinet, cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.06.08.03 Starter batteries, cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.06.08.04 Fuses, cold package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.07 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.08 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.08.01 Crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.08.01.01 Crawler chassis track pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.08.02 Track drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.09 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.10 Conveyor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.10.01 Belt conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.10.02 Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.10.03 Magnetic separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.10.04 Line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.10.04.01 General line coupling .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.10.04.02 Operating principle of line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.11 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.12 Water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.12.01 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.12.02 Spraying nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.13 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.14 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.15 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.16 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.17 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.18 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.19 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.20 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.21 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.22 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.23 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.24 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.25 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.26 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.27 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

TABLE OF CONTENTS
2.28 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

2.29 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.30 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.31 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.32 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.33 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.34 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.35 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.36 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.37 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.38 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.39 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.40 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.41 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.42 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.43 Feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.43.01 Feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.43.02 Hopper extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.43.03 Grizzly feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.44 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.45 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.45.01 Grizzly feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.46 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.01 Operator panels/Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

3.01.01 Touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.02 Measures before initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.03 Putting the plant into operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.04 Automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.04.01 Switching on plant after emergency stop/emergency switching off actuation . . . . 139
3.05 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.06 Line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.06.01 Perform test routine for line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.06.02 Adjusting the line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.07 Operating the plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.07.01 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.07.02 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.07.03 Shutting down the plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.08 Refuelling the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.09 Switching cold package on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.10 Operating the water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

TABLE OF CONTENTS
3.11 Loading the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

3.11.01 Suitable loading vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.11.02 Preparing the charged material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.11.03 Loading the feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.11.04 Loading the jaw crusher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.12 Eliminating material congestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.13 Operating the auxiliary drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.14 Setting the jaw crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.14.01 Checking the crushing gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.14.02 Setting the crushing gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3.15 Clearing away waste tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.16 Winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.17 Help and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.17.01 Starting the engine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.17.02 Troubleshooting, remote control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.17.03 Lubrication system troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.17.04 Troubleshooting, line coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.17.05 Troubleshooting for water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.01 Chassis/guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.01.01 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.01.02 Checking warning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.01.03 Checking guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.01.04 Checking emergency-stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.01.04.01 Emergency-stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.01.04.02 Emergency switching off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.02 Control stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.02.01 Checking switch cabinet protective housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.02.02 Carrying out lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.02.03 Checking remote controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.03 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.04 Power supply unit/engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.04.01 Servicing diesel generator power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.04.02 Cleaning fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.04.03 Servicing the fuel supply LRC diesel engine / cold package . . . . . . . . . . . . . . . . . . . 209
4.04.04 Connecting diagnostics device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.04.05 Servicing toothed belt for generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.04.05.01 Checking toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.04.05.02 Aligning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.04.05.03 Tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.04.06 Checking cyclone prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

TABLE OF CONTENTS
4.04.07 Servicing air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

4.04.08 Cleaning the cooler fins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.04.09 Check / Refill coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.04.10 Changing engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.04.11 Servicing the hydraulic coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.04.11.01 Flushing hydraulic coupling .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.04.11.02 Checking hydraulic oil fill level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.04.11.03 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4.04.11.04 Changing vent filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.04.11.05 Changing drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.05 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.05.01 Servicing hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.05.01.01 General maintenance tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.05.01.02 Depressurising the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.05.02 Servicing hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.05.02.01 Checking hydraulic fill level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.05.02.02 Changing hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.05.02.03 Changing hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.06 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.06.01 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
4.06.02 Servicing 24 V voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.06.02.01 Servicing diesel generator electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
4.06.02.02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Servicing starter batteries
4.06.03 Servicing switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.06.03.01 Checking electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.06.03.02 Checking switch cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.06.04 Checking grounding straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.06.05 Servicing electric motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.06.06 Servicing control cabinet heat package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.06.07 Repairing electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.06.07.01 Fuses
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.06.07.02 Motor protecting switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.06.07.03 Earth fault circuit interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.07 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.08 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.08.01 Servicing crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.08.01.01 Checking/tensioning crawler carrier chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
4.08.01.02 Checking fastenings for track rollers and base plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.08.01.03 Checking/Replacing the track pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.08.02 Servicing track drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.08.02.01 Servicing planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.08.02.02 Checking components for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.08.03 Repairing crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.08.03.01 Opening/closing crawler carrier chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

TABLE OF CONTENTS
4.08.03.02 Repairing chain link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

4.09 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.10 Conveyor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.10.01 Servicing belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.10.01.01 Check conveyor belts .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.10.01.02 Checking conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
4.10.01.03 Checking/setting return roller guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.10.01.04 Servicing scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.10.01.05 Adjusting rubber plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.10.01.06 Changing guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.10.01.07 Servicing bevel helical gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.10.01.08 Servicing drum motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.10.01.09 Checking tensioning bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.10.01.10 Lubricating clamping bearings and plummer blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.10.01.11 Lubricating plummer blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.10.02 Servicing belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.10.02.01 Tensioning conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.10.02.02 Changing conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4.10.02.03 Checking conveyor belt run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4.10.02.04 Adjusting conveyor belt run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.10.03 Checking chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4.10.03.01 Checking rubber curtains and sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4.10.04 Servicing electromagnetic separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4.10.04.01 Checking conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
4.10.04.03 Servicing worm gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4.10.04.04 Lubricating bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
4.10.05 Servicing permanent magnetic separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4.10.05.01 Checking conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
4.10.05.03 Servicing worm gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.10.05.04 Lubricating bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4.11 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
4.12 Water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
4.13 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.14 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.15 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.16 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.17 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.18 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.18.01 Servicing lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
4.18.01.01 Filling lubrication system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.18.01.02 Checking lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
4.19 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

TABLE OF CONTENTS
4.20 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

4.21 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.22 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.23 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.24 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.25 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.26 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.27 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.28 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.29 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.30 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.31 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.32 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.33 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.34 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.35 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.36 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
4.37 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.38 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.39 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.40 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.41 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.42 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.43 Feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
4.43.01 Servicing feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
4.43.02 Servicing hopper extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4.43.03 Servicing feeder trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.43.03.01 Servicing rubber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.43.03.02 Checking vibration motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4.43.03.03 Servicing wear lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.43.04 Repairing feeder trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4.43.04.01 Replacing vibration motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4.43.04.02 Checking rocker width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4.43.04.03 Adjusting rocker width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.44 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.44.01 Checking position of balancing weights for crusher drive . . . . . . . . . . . . . . . . . . . . . 342
4.44.02 Lubricating bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
4.44.03 Listen to bearing, check its temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4.44.04 Checking/tensioning V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.44.04.01 Checking V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.44.04.02 Tensioning/changing V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.44.05 Servicing tension roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
4.44.05.01 Lubricating bearings of tension roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

TABLE OF CONTENTS
4.44.05.02 Checking the tension roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

4.44.06 Checking securing elements of crushing jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4.44.07 Checking crusher mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4.44.08 Repairing crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4.44.08.01 Checking wear of crushing jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.44.08.02 Changing the lateral wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.44.08.03 Changing fixed crusher jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.44.08.04 Changing articulated crusher jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4.44.08.05 Changing articulated crusher jaw with weld-on eyelet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
4.44.08.06 Changing pressure plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4.44.08.07 Changing shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
4.44.08.08 Changing V-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
4.45 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
4.45.01 Checking screen surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
4.45.02 Tensioning screen surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
4.45.03 Other maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
4.45.04 Repairing screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
4.45.04.01 Changing grizzly feeder screen surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
4.45.04.02 Replacing rubber profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
4.46 Cleaning the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.46.01 Cleaning the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.46.02 Cleaning with high-pressure cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.46.03 Cleaning touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.47 Performing welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5 TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.01 Technical details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

5.01.01 Complete plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.01.01.01 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.01.01.02 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5.01.01.03 Driving operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.01.01.04 Charged material and size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.01.01.05 Crushing ratio and compressive strength of feed material . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.01.01.06 Feed and crushing capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.01.01.07 Screen capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.01.01.08 Ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5.01.01.09 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5.01.02 Power supply unit/engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
5.01.03 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
5.01.04 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
5.01.05 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
5.01.06 Conveyor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
5.01.07 Water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415

TABLE OF CONTENTS
5.01.08 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

5.01.09 Feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
5.01.10 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
5.02 Maintenance schedule/maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.02.01 One-time maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.02.02 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
5.03 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
5.04 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
5.04.01 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
5.04.02 Diesel Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
5.05 Separate documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
5.05.01 Documentation on the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
5.05.02 Information material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
5.06 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
6 INSTALLATION AND REMOVAL, TRANSPORT. . . . . . . . . . . . . . . . . . . . . 438
6.01 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

6.01.01 Approval of special transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
6.01.02 Transport details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
6.01.02.01 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
6.01.02.02 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
6.01.03 Loading and unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
6.02 Plant installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
6.02.01 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
6.02.02 Moving out warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
6.02.03 Earthing the plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
6.02.04 Folding ladders and steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
6.02.05 Folding up hopper walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
6.02.06 Extending short prescreen conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
6.02.07 Moving long prescreen conveyor out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
6.02.08 Folding out the extended crusher discharge conveyor hydraulically . . . . . . . . . . . . 465
6.02.09 Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
6.02.09.01 Test run without material
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
6.02.09.02 Test run in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
6.03 Removal of plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
6.03.01 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
6.03.02 Moving in warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
6.03.03 Folding in the extended crusher discharge conveyor hydraulically . . . . . . . . . . . . . 473
6.03.04 Moving in short prescreen conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
6.03.05 Moving in long prescreen conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
6.03.06 Folding in hopper walls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
6.03.07 Folding ladders and steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491

TABLE OF CONTENTS
6.03.08 Removing earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

6.03.09 Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
6.04 Storage, shutdown, disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
6.04.01 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
6.04.02 Shutdown, restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
6.04.03 Disposal of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494

GENERAL
Foreword/Introduction
1 GENERAL
During all activities, observe the information in your safety
manual!
1.01 Foreword/Introduction
1.01.01 Introduction
DThis KLEEMANN plant is a product from the wide product range
of mobile KLEEMANN crushing and screening plants.
The vast experience of KLEEMANN combined with the latest pro-
duction and test procedures guarantees the high dependability
of your plant.
Instruction manual and This instruction manual is only valid in conjunction with the
safety instructions safety manual and the manufacturer's documentation included
in the delivery. Please note:
• This instruction manual was prepared for operating, mainte-
nance and service personnel at the place of use.
• This instruction manual should put you in a position to oper-
ate the plant safely and to utilise the permissible application
options it provides.
• It also provides you with information on the function of im-
portant units or components.
• Certain terms and concepts are used in the instruction man-
ual to do this. To avoid misunderstandings, you should al-
ways use these terms.
• Only qualified, instructed and trained personnel may work
on this plant.
• The instruction manual, safety manual, manufacturer's doc-
umentation and the regulations and specifications applicable
at the place of use must be observed (for example, accident
prevention regulations).
• The instruction manual, safety manual and manufacturer's
documentation are elements of the product. Ensure that
they are available for viewing at all times during the entire
service life of the plant.
• Pass on the instruction manual, safety manual and manufac-
turer's documentation to new owners of the plant and draw
their attention to the importance of the documentation.
Use of this instruction makes it easier for you:
• to become familiar with the plant.
• to avoid faults through incorrect operation.

GENERAL
Observance of the instruction manual:

• helps avoid dangers.
• increases dependability at the place of use.
• increases the service life of the plant.
• reduces repair costs and downtimes.
Always place this instruction manual within reach in the switch
cabinet protective housing of the plant or in the container pro-
vided for this purpose.
If you should receive further information from us about your
plant (for example, additional technical information), these in-
structions must also be observed and attached to the instruc-
tion manual.
If you do not understand the instruction manual or individual
chapters, please ask us before starting the corresponding activ-
ity.
KLEEMANN GmbH shall not be liable for safe operation of the
system:
• if plant handling does not comply with specified use.
Warranty claims shall become invalid in the event of:
• Operating errors.
• Inadequate maintenance.
• Incorrect fluids and lubricants.
• Applications not named in the instruction manual.
Warranty and liability provisions of the general terms and con-
ditions of business of KLEEMANN GmbH are not extended by the
above information.
In the course of technical development, we reserve the right to
make changes without prior announcement. This instruction
manual also describes optional equipment that may not be fit-
ted on your plant. Specifications and illustrations in this instruc-
tion manual must not be reproduced, disseminated or used for
competition purposes.
Translations are carried out in good faith. We shall not be liable
for translation errors and their consequences, even if we trans-
lated the text ourselves or assigned the task to a third party.
All rights under copyright laws are explicitly reserved. We wish
you every success with your KLEEMANN plant.
1.01.02 Changes/provisos
We make every effort to ensure that this instruction manual is
correct and up to date. To maintain our technological head start,
it may be necessary to make changes to the product and its op-
eration without prior announcement. We shall not be liable for
any faults, failures and resultant damage.

GENERAL
Please also observe any additional information that may be in-

cluded in the delivery.
1.01.03 Packaging and storage

The components were carefully packed to guarantee adequate
protection during shipment. When you receive the goods, the
packaging and contents should be checked for damage.
If damage is discovered, the components must not be put into
operation. Damaged cables and plug connectors are also a safe-
ty risk and must not be used. In this case, please contact your
local KLEEMANN branch.
If components are not put into operation immediately after un-
packing, they must be protected against dampness and con-
tamination.
1.01.04 Signs and symbols

The signs and symbols are designed to help you use the instruc-
tion manual and the plant quickly and safely.
In this instruction manual, potential dangers are indicated by
danger, warning, caution and important signs. They are identi-
fied by a colour and a signal word corresponding to the serious-
ness of the danger.
Hazard warning
DANGER
Sources of danger are named here.
The possible consequences are also named here.
• And measures for avoiding the danger.
The hazard warning uses the signal word DANGER to indicate an

imminent danger. Nonobservance can result in serious or fatal
injury.
Warning sign
WARNING
The warning sign uses the signal word WARNING to indicate a

possible threatening danger. Nonobservance can result in seri-
ous or fatal injury.
Caution sign

GENERAL
CAUTION
The caution sign uses the signal word CAUTION to indicate a

possible dangerous situation. Nonobservance can result in mi-
nor injury and material damage.
Attention notice
NOTICE
The source of the danger is stated here.
The attention notice uses the signal word ATTENTION to indi-
cate a possible dangerous situation. Nonobservance may re-
sult in material damage.
• The measures for avoiding the danger are stated here.
Information
A capital "I" for information at the start of every main chapter

provides you with brief information on the content of the chap-
ter. You will also be informed at relevant points about the most
effective or practical usage of the plant and this instruction
manual.
Activity steps
The defined sequence of the activity steps facilitates correct and
safe use of the plant.
Result
The result of a sequence of activity steps is described here.
Item number
Item or position numbers are marked in the text by square
brackets [].
Material flow direction
The arrow indicates the material flow direction of the plant or a
component to provide better orientation.
1.01.05 Warning sign

Warning signs provide a graphic illustration of a danger source.
The warning signs in the complete technical documentation cor-
respond to the harmonised standard EN 61310 Part 2: Safety of
machinery - Indication, marking and actuation and EC Directive
92/58/EEC - Minimum Requirements for the Provision of Safety
and/or Health Signs at Work (Ordinance on Industrial Safety
and Health).
They match the illustrations on the signs attached to the rele-
vant danger areas on the plant.

GENERAL
Warning of a general danger

The warning sign appears before activities where there are sev-
eral possible causes of dangerous situations.
Warning of dangerous voltage

This warning sign appears before activities where there is a
danger of electric shock with possible fatal consequences.
Warning! Suspended load

danger through falling objects with possible fatal consequences.
Warning of rotating parts

danger through rotating parts with possible fatal consequences.
Warning! Risk of stumbling

danger of stumbling with possible fatal consequences.
Warning! Risk of crushing injuries

danger of crushing parts of the body with possible fatal conse-
quences.
Warning! Risk of crushing injuries to hands
The warning sign appears before activities where there is a risk
of crushing your hands.
Warning! Risk of crushing injuries to feet

The warning sign appears before activities where there is a risk
of crushing your feet.
Warning! Hot surface

The warning sign appears before activities where there is a dan-
ger through hot surfaces.
Warning! Hot fluids

ger through hot fluids.

GENERAL
Warning of batteries
ger through escaping explosive gas and caustic fluids.
Warning of flammable materials

danger through flammable materials with possible fatal conse-
quences.
Warning of potentially explosive materials
danger through potentially explosive materials with possible fa-
tal consequences.
Warning of toxic substances
danger through toxic substances with possible fatal conse-
quences.
1.01.06 Documentation
A paper copy of this instruction manual must be available to au-
thorised operating and maintenance personnel at all times.
This instruction manual must always be regarded as an unit to-
gether with the operating instructions to be prepared by the op-
erating company.
This instruction manual and the operating instructions of the
company must be handed over to operating and maintenance
personnel.
If the plant changes owner, the completion documentation must
also be handed over.
Before putting the plant into operation for the first time and be-
fore starting any kind of work on the plant, you must read
through this instruction manual carefully and understand it.
This instruction manual serves to familiarise you with the basic
tasks and activities on the plant.
This instruction manual contains important information on how
to use the plant safely and correctly.
Your observance helps:
• to avoid dangers.
• to reduce repair costs and downtimes.
• to increase the dependability, availability and service life of
the plant.
Irrespective of this instruction manual, the laws, ordinances, di-
rectives and standards applicable in the respective country of
use and place of application must be observed.

GENERAL
This instruction manual describes how to use the plant. The in-
struction manual is only valid in conjunction with the safety
manual and, where applicable, the transport instructions from
KLEEMANN.
A safety manual and, where applicable, transport instructions
must be accessible to plant operating and maintenance person-
nel at all times.
1.01.07 Declaration of Conformity

The Declaration of Conformity is part of the separately provided
documentation from KLEEMANN GmbH and will be handed over
to you upon delivery of the plant.
The CE marking for the plant is an element of the type plate.
The pictograph identifies the conformity of the plant to valid EC
directives, which prescribe the CE marking.

GENERAL
EG/EU-Konformitätserklärung
nach
Maschinenrichtlinie 2006/42/EG
EMV-Richtlinie 2014/30/EU
Hiermit erklärt der Hersteller: Kleemann GmbH

Manfred-Wörner-Straße 160
73037 Göppingen
Deutschland
dass die nachfolgend bezeichnete Maschine / Maschinenanlage aufgrund ihrer Konzipierung und
Bauart sowie in der von uns in Verkehr gebrachten Ausführung konform ist mit den
Bestimmungen der oben aufgeführten Richtlinien.
Die Schutzziele der Niederspannungsrichtlinie wurden gemäß Anhang I, Nr. 1.5.1 der
Maschinenrichtlinie eingehalten.
Bezeichnung der Maschine /

Maschinenanlage:
Baureihe / Typ:
Seriennummer:
Bei einer erheblichen Veränderung der Maschine / Maschinenanlage verliert diese Erklärung ihre
Gültigkeit.
Person, die bevollmächtigt ist, Jürgen Köstlin, Kleemann GmbH

die technischen Unterlagen
zusammenzustellen:
Die EG-Konformitätserklärung in der Originalfassung in in der übersetzten Amtssprache

liegt vor: deutsch des Anwenders
Ort, Datum / Unterschrift: Göppingen, 21.06.2016
Angaben zu den Unterzeichnern: Dr. Rüdiger Kaub / Dr. Volker Nilles (Geschäftsführer)
1.01.07.01 Declaration of Conformity EAC

The EAC mark on the plant is an element of the type plate if the
plant is destined for one of the countries in the Eurasian Cus-
toms Union.
The EAC pictograph EAC (Eurasian Conformity) confirms con-
formity of the plant with the requirements of the Customs Un-
ion.

GENERAL
Use
1.01.07.02 EuroTest certificate

The test mark EuroTest certificate of the German statutory ac-
cident insurance association (DGUV) certifies that this plant
complies with the relevant provisions of the EC Machinery Di-
rective 2006/42/EC.
1.01.08 Warranty and liability

The general terms and conditions of business of KLEEMANN
GmbH shall apply. These are available to the buyer or operating
company upon conclusion of agreement at the latest.
Refer to the general terms and conditions of business for war-
ranty and material defect claims.
1.02 Use
1.02.01 Intended use

The plant is state-of-the-art equipment and complies with the
safety regulations applicable at the time of marketing and ap-
plicable to its intended use.
Design measures cannot avoid foreseeable misuse or residual
dangers without restricting the specified range of functions.
The plant is built and designed:
• for processing mineral materials as specified in chap.
5.01.01.04.
• for loading with the help of a digger with shovel or bucket
adapted to the plant size and the charged material. With a
suitable hopper extension (option), the plant can also be
loaded with an appropriately large wheel loader.
• for loading with the help of an upstream plant or belt con-
veyor, provided it has the required discharge height and is
adapted to the plant size and charged material.
• for crushing material with a compressive resistance as spec-
ified in chap. 5.01.01.04.
• for screening different grain sizes using a grizzly.
• for discharging different grain sizes via a belt conveyor onto
waste tips or downstream plants for further processing.
• for clearing waste tips with a wheel loader, the size of which
matches the plant power.
The plant is designed exclusively for commercial operation with-
in enclosed areas such as building sites and quarries.

GENERAL
Use
The plant must be operated by instructed operators in accord-

ance with the specifications in the technical documentation.
All types of non-specified use, or all activities on the plant not
described in this instruction manual, amount to misuse not cov-
ered by the statutory limits of liability of the manufacturer.
1.02.02 Abnormal use

In the case of non-specified use, or misuse of the plant, the
warranty obligation of the manufacturer shall become null and
void and responsibility shall be borne solely by the operating
company.
Non-specified use includes:
• Conveying of persons.
• Climbing on the plant for purposes other than maintenance
and repair.
• Operation with disassembled, defective or bypassed safety
devices.
• Operation following incorrectly performed or neglected
maintenance and repair work.
• Operation following failure to observe the maintenance in-
tervals.
• Operation following neglected measurements and inspec-
tions for early detection of damage or wear.
• Feeding with lorries, dumpers or skip lorries or with exces-
sively large or small shovels or buckets or digger and wheel
loader.
• Clearing the waste tip with an unsuitable device that leads
to damage to the belt conveyors.
• Operation in unsuitable climatic conditions.
• Operation in a position other than horizontal.
• Operation following independent, unauthorised construc-
tional modifications to the plant.
The following are unsuitable for crushing in the crusher:
• Material that exceeds the specified compressive resistance
and dimensions.
Material that is too large and hard results in material con-
gestions, considerable wear and damage to the crusher.
• Unbreakable materials such as scrap metal.
Even sporadic feeding of scrap metal, in particular hardened
and solid steel parts, leads to damage and serious wear to
crushing jaws, belt conveyors and other moving parts.
• All other materials not named in the section on intended use,
such as wood, coal, scraps, rubbish, boulders of ore and oth-
er non-mineral materials.

GENERAL
Use
The following must not be fed into the crusher:

• Hazardous and explosive substances.
• Chemicals.
• Solvents, oils and greases.
• Asbestos-containing scraps, e.g. cement asbestos.
• Pressurised vessels.
1.02.03 Residual risks

The residual risks were analysed and evaluated before the start
of the design and planning phase of the plant.
The documentation makes reference to existing residual risks.
Existing residual risks can be avoided through the practical im-
plementation and observance of the following specifications:
• The special warning signs on the plant.
• The general safety instructions in this instruction manual
and in the safety manual.
• The special warning information in this instruction manual.
• The instructions in the safety manual.
• The operating instructions of the operating company.
Danger to life/risk of injury to persons can exist at the plant
through, e.g.:
• Misuse.
• Incorrect handling.
• Transport.
• Missing safety devices.
• Defective or damaged components.
• Handling/operation by personnel without training or instruc-
tion.
The plant can cause dangers to the environment through, e.g.:
• Fluids and lubricants, etc.
• Noise and dust emission.
Damage to the plant is possible through, e.g.:
• Nonobservance of operating and maintenance specifica-
tions.
• Unsuitable fluids and lubricants.
Damage to further material assets in the operating area of the
plant is possible through, e.g.:

GENERAL
Climatic conditions
Limitations to the performance and range of functions of the

plant can result due to, e.g.:
• Incorrect maintenance or repair.
• Unsuitable fluids and lubricants.
1.03 Climatic conditions

The minimum and maximum permissible ambient temperature
of the plant is indicated in chap. 5.01.01.08.
Low ambient In cold weather, the starting behaviour and operation of the die-
temperature sel engine depend on the following:
• Fuels used.
• Engine oil viscosity.
• State of the starter batteries.
Suggestions for operation in cold weather:
• After start-up, allow the diesel engine to run until an oper-
ating temperature of at least 80 °C has been reached.
Reaching the correct operating temperature prevents the in-
take and exhaust valves from jamming.
• When the diesel engine is shut down, the cooling and lubri-
cation systems are not immediately cold. This means that
the diesel engine can be shut down for a few hours and then
started again without any problems.
• Below 0 °C, use winter diesel with sufficient fluidity.
• Fill with the correct lubricant before the start of the cold sea-
son.
• Check all rubber parts (hoses, V-belts, etc.) once a week.
• Check all electric cables and connections for abrasion and
damage to the insulation.
• Charge the starter batteries and keep them warm.
• Fill the fuel tank at the end of every work shift.
In special operating conditions, it may be necessary to use

other suitable fluids and lubricants.
WARNING
Risk of injury and property damage
The use of alcohol or other starting aid fluids involves a risk of
explosion and injury.
• Never use aerosol starting aids, e.g. aether.

GENERAL
Safety information
High ambient With increasing altitude or ambient temperature, the maximum

temperature, high output of the diesel engine, the exhaust gas quality, the tem-
altitude perature level and, in extreme cases, the starting behaviour, are
impaired.
If the plant is operated at an altitude above 1000 m or at an am-
bient temperature above 30 °C, a reduction in the injected fuel
quantity is necessary.
Heavy rain and storms During heavy rainfall, rain water can enter the air intake of the
running diesel engine. Rain is then drawn into the combustion
chambers where the water impact can cause engine damage.
Suggestions for operation during heavy rainfall and storms:
• If heavy rain or a storm is expected, switch off the plant and
the diesel generator.
• If opened, close the protective housing of the power supply
unit.
• Close the control cabinet.
• Keep away from the plant until the storm has passed.
DANGER
Dangerous voltage
Operation of the plant during storms can attract lightning and
result in serious or fatal injury and damage to property.
• Switch off the plant and move away from the plant until the
storm has passed.
• Check the electrical system if it is struck by lightning.
Strong wind Basically, the plant can be operated irrespective of the wind
force. However, strong wind can affect dust creation in the area
around the plant.
Influence of strong wind:
• Strong wind impairs the perfect formation of the dust-bind-
ing spray mist of the spray system and thus also contributes
to the increased spread of dust.
• Strong wind can influence the grain size of the discharged
material by blowing away the fines.
• An unfavourable wind direction can result in increased clog-
ging of the cooler fins and the filter for the drive unit.
Dust formation can be reduced by the additional use of belt

covers and ejector chutes but not completely eliminated.
1.04 Safety information

Due to the intended use of the plant, neither foreseeable misuse
nor residual dangers can be avoided without restricting the

GENERAL
Safety information
specified range of functions. This situation presents a risk to life

and limb of operating, maintenance and service personnel
which, however, can be minimised if the basic safety instruc-
tions are observed.
1.04.01 Safety manual

Read through the safety manual provided separately by KLEE-
MANN GmbH. It describes the general hazards involved in oper-
ation, maintenance and repair of the plant and how to avoid
them. The safety manual is an element of the instruction man-
ual.
1.04.02 Environmental protection

Packaging material, cleaning agents, used or residual fluids and
lubricants as well as removed wear parts, such as conveyor belt,
baffle plates, impact toggles, crushing jaws, wear lining, rubber
seals, etc. must be brought to a recycling centre in accordance
with locally applicable environmental specifications.
1.04.03 Disposal of machine

Nature conservation is one of the most urgent priorities. Correct
disposal prevents negative effects on humans and the environ-
ment and permits reuse of valuable raw materials.
Fluids and lubricants
Dispose of fluids and lubricants according to the relevant spec-
ifications and the respective national regulations.
Materials (metals, plastics)
Correct disposal of materials means that they are unmixed. Re-
move adhering impurities from the materials.
Dispose of materials according to the respective national regu-
lations.
Electrical system/electronics
The electrical/electronic components are not subject to the
WEEE Directive 2002/96/EC and corresponding national laws
(in Germany, e.g. ElektroG = Electrical and Electronic Equip-
ment Act).
Deliver the electrical/electronic components directly to a spe-
cialised recycling company.
1.04.04 Notes on the electrical/electronic components

Please note the following safety instructions for optionally avail-
able electrical/electronic devices:

GENERAL
Safety information
• Check the goods immediately upon receipt for damage or

defective parts.
• Do not put defective devices into operation.
• Damaged cables and plug connectors are a safety risk and
must not be used.
• Contact your local KLEEMANN branch, who will supply a re-
placement immediately.
Installing
Prior to assembly and operation of the devices, carefully read
through the entire instruction manual. If you have any ques-
tions, please contact your local KLEEMANN branch. During as-
sembly of the devices, only use the original KLEEMANN cables.
The connectors must not be removed from the cables as they
are protected against dampness and opening would destroy this
protection. Ensure that the securing screws are firmly fitted at
the plug connectors. Further assembly instructions for the de-
vices and sensors are available in the separate data sheets or
instruction manuals.
If the above-described points are not observed, KLEEMANN

GmbH cannot provide warranty for the electrical/electronic de-
vices.
Safety precautions
The safety precautions recommended here basically correspond
to the guidelines for installation and commissioning of electrical
systems. They can be applied to all applications in conjunction
with KLEEMANN devices.
Wiring
The wiring must be installed in accordance with the specifica-
tions in this instruction manual. All feeds and connecting termi-
nals must be dimensioned for the relevant strength of current.
Furthermore, all connections must be made according to the
valid VDE specifications in Germany or the respective national
specifications.
Interference resistance
The devices are designed for industrial use and tested accord-
ingly. In spite of this, the microprocessor technology makes
some demands on the installation. We would therefore like to
draw your attention to the following installation features which,
if not observed, could result in subsequent malfunctions:

GENERAL
Safety information
• Ensure the terminals have the correct polarity.

• Do not exceed or undershoot the specified supply voltage
range.
• Ensure that the electrical connections between the device
housing and components and chassis of the plant are correct
to guarantee trouble-free operation.
• Only connect shielded cables on one side to earth (device
side).
• Never supply other devices directly from the connecting ter-
minals of the supply voltage.
• Never use free terminals as a connection for other terminals
or devices.
Fuses
The devices are equipped with fuses to protect against short cir-
cuits. The supply voltages specified in the technical details must
not be exceeded.
Configuration
The devices can also be configured by the user. Any reconfigu-
ration made by the user must always correspond to the actual
situation of the plant.
Potentially explosive areas
The devices are not designed for use in potentially explosive ar-
eas.
Troubleshooting
Before starting troubleshooting, ensure that all supply voltage
to the device is interrupted. Defective devices should be exam-
ined in an area properly equipped for test purposes. Any at-
tempt to eliminate malfunctions on a device that is still installed
could be dangerous to operating personnel and the plant. Be-
fore removing or replacing sensors fitted on the device, ensure
that all supply voltage is interrupted.
If you have any questions on operation and assembly, please

contact your local KLEEMANN branch.
If the above-listed precautionary measures are not observed,
this can result in failure of the device or the plant. Damage re-
sulting from nonobservance of the above-listed precautionary
measures shall not be covered by the manufacturer's warranty.

GENERAL
Safety information
1.04.05 Danger areas
2
1
Fig. 1.1: Danger area
[1] Danger area of the plant, [2] Danger area safety dis-
loading and loading vehi- tance
cles
During automatic mode and while the plant is moving, persons
must stay clear of the danger area of the plant and the feeding
and loading vehicles.
In the following situations, authorised personnel must only en-
ter the danger area when the plant is stationary and secured:
• For maintenance, repair and service work.
• During installation, removal and conversion work.
• During ongoing transport work.

GENERAL
Emissions and loads
1.04.05.01 Safety distance
1 2
3
Fig. 1.2: Safety distance between working and traffic area
[1] Traffic area [2] Safety distance

[3] Working area
If the plant is operated directly beside public roads, e.g. during
road construction work, the safety distance to the traffic area
must be observed.
The safety distance between the working and traffic area must
be defined according to the conditions on site based on the haz-
ard assessment by the operator and also in accordance with na-
tional regulations.
1.04.06 Fire fighting appliance
For fire fighting at the plant, at least one fire extinguisher for
fire classes A, B and C and a sufficient quantity of filling com-
pound must be provided. Observe country-specific specifica-
tions.
The serviceability of the fire extinguisher must be checked at
least once a year by a specialist.
Make sure that operating, maintenance and repair personnel
are familiar with the handling of the fire extinguisher. The plant
owner is responsible for this.
1.05 Emissions and loads
No modifications must be made to the plant that result in in-

creased noise, dust and vibration emissions.

GENERAL
Emissions and loads
• Read and observe the safety manual.

• Always wear your personal hearing protection and a breath-
ing mask when required.
• Ensure that all devices for reducing noise and dust emissions
are installed and operable.
• Do not make any modifications to the plant.
1.05.01 Noise emission

Sound power level
The sound power level of the plant is usually surpassed during
crusher operation by the process noise. The sound power level
is specified in chap. 5.01.01.09.
Emission sound pressure level
In automatic mode, the plant runs fully automatically without
operating personnel. For this reason, there is no directly as-
signed workplace, so that the emission sound pressure level is
not directly relevant.
WARNING
Danger of hearing damage
When working directly beside the plant or on its platforms, the
permissible daily noise exposure level (LEX,8h) of 80 dB (A) is
exceeded.
• Always wear your personal hearing protection when re-
quired.
WARNING
Danger due to communication disturbance
Noise development at the plant can interfere with communica-
tion between personnel and result in dangerous situations.
• Agree on unambiguous hand signals to avoid misunder-
standing. Use radiotelephony where possible.
• Avoid the danger area during operation, maintenance, in-
stallation, removal and transport of the plant.
1.05.02 Dust emission
WARNING
Risk of health damage
The inhalation of dust can cause serious illnesses.
• Wear a breathing mask.
For design and process-related reasons, the creation of dust

during plant operation cannot be completely prevented.

GENERAL
Emissions and loads
However, the dust emissions and the resulting danger can be

minimised by observing a few measures:
• Always switch on the spray system during operation.
• Align the spraying nozzles correctly to ensure effectiveness.
• Always keep a sufficient supply of water ready. Depending
on the number of spraying nozzles used, between approx. 5-
10 m3 per shift.
• Ensure that the spraying nozzles, supply lines and other wa-
ter system components are in perfect condition.
• Use belt covers and ejector chutes (optional equipment).
• Replace defective or worn dust seals.
Further information on dust development, avoidance and the

spray system is available in chap. 2.12 and chap. 1.03.
1.05.03 Vibration emission

In automatic mode, the plant runs fully automatically without
operating personnel. For this reason, there is no directly as-
signed workplace, which makes the vibration emission pressure
level irrelevant.
During its operation, however, the plant is subject to stress from
vibrations. Personnel authorised to enter the platforms only for
maintenance and repair work are subject to stress through vi-
bration.
However, observance of a few measures permits minimisation
of the vibration emissions and the resulting danger:
• Do not remain on the platforms longer than necessary when
performing maintenance and repair work.
• Do not walk on the vibratory screens, feeder trough and ex-
tractor channels until they have come to a complete stand-
still.
1.05.04 Magnetic emission

Observe the following information:
• Danger due to magnetic fields always exists with a perma-
nent magnet, also with the plant switched off.
• Danger due to magnetic fields exists with an electromagnet-
ic separator only with the plant and the magnetic separator
switched on.

GENERAL
Signs
DANGER
Danger due to magnetic fields
Electric and permanent magnetic separators generate strong
magnetic fields that present a risk to personnel.
• Persons with pacemakers and other medical-technical de-
vices must stay well clear of magnetic separators.
• Keep a distance of at least 3 metres from magnetic separa-
tors.
• Observe the Safety Instructions.
Electromagnetic and permanent magnetic separators or mag-

netic removers emit magnetic fields. Impacts on individuals,
particularly individuals with pacemakers, cannot be ruled out.
Radio remote controls may become impaired and disabled as a
result of the effect of the magnetic field.
Magnetic-based storage media may be destroyed by the impact
of the magnetic field. The magnetic properties of parts, e.g.
tools, may be attracted with a high force.
However, the risks posed by the magnetic field can be mini-
mized by observing some measures:
• Always maintain a safety distance of at least 3 metres.
• Keep radio remote controls at least 1 metre from the mag-
netic separator or magnetic remover.
• Keep storage media at least 2 metres from the magnetic
separator or magnetic remover.
• Exercise extreme caution when working with magnetic tools
in the range of the magnet.
1.06 Signs
1.06.01 Sign diagram

The sign diagram is in the spare parts catalogue.
1.06.02 Signs/decals
This section informs you about the special function of the

signs. The hazard warnings are described in the safety instruc-
tions.

GENERAL
Signs
Welding work
Before carrying out welding work on the plant, note the specifi-
cations in the instruction manual.
Lifting point
When lifting machines and components, always used the iden-
tified lifting points.
F20010031
Lashing point
When lashing the plant of individual machines and components,
always used the identified lashing points.
F20010035
Vibrating conveyor trough rocker width gauge

For specifications of the vibrating conveyor trough rocker width
gauge, see chap. 4.43.04.02.
Grease lubrication points

Details on grease quantity and interval of corresponding lubri-
cation point.
Direction of rotation arrows

Direction of rotation of the drive shaft of a screen.

GENERAL
Signs
Battery change
After removal of the charged battery of the radio remote con-
1. trol, wait at least 30 seconds before the battery to be charged
is inserted.
2.
> 30 sec.
3.
2443204
1.06.03 Identification plates
The entire identification documents the certification and must

not be modified or made unrecognisable.
For the transport weight of the plant and the machines and
components to be transported individually, please refer to
chap. 6.01.02.02.
1.06.03.01 Plant identification plate
Kleemann GmbH . Manfred-Wörner-Straße 160 . D-73037 Göppingen . Germany

Bezeichnung
Designation
Baureihe / Typ Seriennummer

Series / Type Serial number
Leistungsdaten Motor
Rating information motor
Leistungsdaten Generator
Rating information generator
Betriebsgewicht Baujahr
Operating mass Year of construction
Transportgewicht Siehe Betriebsanleitung und/oder Transportanleitung

Transport mass See Instruction Manual and/or Transportation instructions
2323977
Fig. 1.3: Plant identification plate
[1] Identification plate

Enter the data of the type plate in the following table:
Designation Data
1. Designation

GENERAL
Personnel - qualifications and duties
Designation Data
2. Series / model
3. Serial number
4. Engine performance data
5. Generator performance data
6. Operating weight
7. Year of manufacture
Tab. 1.1: Type plate data
When retrofitting optional equipment, take into consideration

the weight of the optional equipment.
1.07 Personnel - qualifications and duties

All activities at the plant must only be carried out by authorised
personnel.
The authorised personnel must:
• have reached the age of 18.
• be trained in first aid and be able to administer it.
• have read and understood the safety manual.
• be familiar with and know how to apply the accident prevent
regulations and safety instructions for the plant.
• be trained and instructed on how to conduct themselves in
the event of a fault.
• have the physical and mental ability to perform the tasks
and activities at the plant for which they are responsible.
• be trained and instructed in the tasks and activities at the
plant in their area of responsibility.
• have understood and be able to practically implement the
technical documentation on the tasks and activities at the
plant for which they are responsible.
Read the following before initial operation of the plant:
• the instruction manual.
• the safety manual.
The plant can only be operated and moved by persons
who, in addition:
• have received instruction in operation and moving the plant.
• have provided the operating company with proof of their
ability to perform the work.
• can be expected to reliably carry out the tasks assigned to
them.

GENERAL
They have to be appointed by the plant's owner to operate and

move the plant.
• Familiarise yourself with the plant's equipment.
• Move the plant only after making yourself fully familiar with
the operating and control elements as well as the method of
functioning.
• Familiarise yourself with your working area.
• Use the plant only for its intended purpose.
• Always use suitable hoisting gear and lifting accessories for
transportation and installation of heavy components.
• Always wear your protective equipment, such as safety
shoes, protective helmet and hearing protection.
• If deficiencies are determined at the safety devices, inform
the plant owner immediately.
• If other deficiencies are determined that impair safe opera-
tion of the plant, inform the plant owner immediately.
• If defects are found that endanger personnel, shut down
plant operation immediately.
• If unauthorised conversions or changes to the plant are de-
termined that impair safe operation of the plant, inform the
plant owner immediately.
• Observe the following elements attached to the plant
– Safety signs.
– Health protection signs.
– Safety information.
• Read the safety specifications and information additionally
prepared by the plant owner for special cases.
• Check the completeness and legibility of the
– safety signs.
– health protection signs.
– safety information (plates, decals, pictographs).
• Before starting work, inform yourself about
– first aid.
– rescue options (emergency doctor, fire brigade, helicop-
ter).
• Ensure that a first-aid box with standard specified contents
is available.
Banksman A banksman is always required when the driver has an incom-
plete view of the movement or transport route.
Independent guiding of plants is only possible by persons who,
in addition:

GENERAL
• have receive training in how to guide the plant.

• can provide verification of successful participation in the
training course.
• have provided the plant's owner with proof of their ability to
perform the work.
• can be expected to reliably carry out the tasks assigned to
them.
They have to be appointed by the plant's owner to function as
a banksman for the plant.
To avoid misunderstandings, unambiguous hand signals should
be used, e.g. according to the German Employer's Liability In-
surance Association specification "Safety and health signs at the
workplace" (BGV A 8).
• Make yourself familiar with the dimensions of the plant and
the transport vehicle.
• When guiding the plant or vehicles, always wear a warning
waistcoat.
• During movement of the plant, guiding can be by means of
hand signals; when loading the plant with a crane, use radi-
otelephony where possible.
• The meaning of the hand signals between driver and banks-
man must be clarified beyond doubt before starting.
Service and maintenance Service, maintenance and repair personnel are responsible for:
personnel • ensuring safety and hazard warnings are in a legible condi-
tion.
• protecting the plant against unauthorised use.
• ensuring that maintenance and repair work is co-ordinated
with the plant owner.
• ensuring that the plant is only operated when fully functional
and inherently safe.
• ensuring that service, repair and maintenance tasks are car-
ried out safely and correctly.
1.07.01 Protective equipment

All elements of the personal protective equipment must be worn
during all activities at the plant described in this instruction
manual.
Wear protective gloves made from full-grain leather, split leath-
er, polyamide-polyurethane:
• For all activities when in contact with crushing and screening
plants.
Wear nitrile-coated protective gloves made from cotton when
using:

GENERAL
• Oils / Greases (minor).

Wear protective gloves made from nitrile when handling:
• Oils / Greases.
• Diesel fuel.
• Caustic potash (up to 50%)
• Hydrochloric acid (up to 35%)
• Sulphuric acid (up to 50%)
Wear protective gloves made from butyl when handling:
• Methanol.
• Acetone.
• Acetonitrile.
Wear viton protective gloves when handling:
• Petrol.
• Benzene, xylene.
• Styrene.
• Carbon disulphide.
• Sulphuric acid (over 50%)
Wear protective helmets according to DIN EN 397:
plants.
Wear safety shoes according to EN ISO 20344 and 20345, safe-
ty class S3:
plants.
• When handling oils, greases and diesel fuel.
Wear visibility clothing according to DIN EN 471:
plants.
Furthermore, in certain working conditions the following safety
equipment must be worn for all activities when in contact with
crushing and screening plants:
• Hearing protection according to EN 352-1 up to EN 352-2.
• Protective goggles according to DIN 0169, AS/NZS 1337.
• Respiratory mask according to EN 133.
1.07.02 Available training courses

To provide operating, maintenance and service personnel with
appropriate qualifications, KLEEMANN GmbH offers a series of
training courses that form the basis of optimum and safe use of
the plants.

GENERAL
Revision statuses
The training courses can take place at KLEEMANN GmbH or di-

rectly at the operating company following consultation.
• Basic principles of crushing and screening technology.
• Design and method of operation of the plants.
• Basic principles of plant operation.
• Maintenance and repair.
• Basic principles of electrical systems.
• Basic principles of hydraulics.
1.07.03 Contact persons for operation and maintenance

Contact persons for operation, maintenance and service are list-
ed under "Customer service" on the homepage of KLEEMANN
GmbH: www.kleemann.info
1.07.04 Suitable climbing aids
1 2 3
Fig. 1.4: Climbing aids
[1] Forklift (platform not [2] Articulated work platform

shown)
[3] Telescopic handler with
platform
1.08 Revision statuses

Changes to instruction manual K005 MC110R EVO:

GENERAL
Revision statuses
Date Revision level Change Valid from serial

no.:
03.05.2013 2321403_00 • Regeneration K005-0001
08.08.2013 2340211_00 • Revision and extension of con- K005-0014
tents
13.10.2014 2426908_00 • Content addition: cold package, K005-0036
lubrication system, correction of
toothed belt tension and others
21.10.2015 2492865_00 • CI conversion and various up- K005-0090
dates
09.05.2017 2591379_00 • Revision and extension of con- K005-0121
tents

DESCRIPTION
Revision statuses
2 DESCRIPTION
This chapter contains a description of the functions of the plant
and the assemblies.
manual!
Standard and optional equipment
This instruction manual describes all standard and optional
equipment of the plant. For optional equipment in this series,
see chap. 2.46. All equipment not listed here belongs to the
standard equipment of the plant.
1 2 3 4 5
10 9 8 7 6
Fig. 2.1: Plant overview
[1] Feed hopper [2] Jaw crusher

[3] Power supply unit [4] Magnetic separator
[5] Crusher discharge con- [6] Running gear
veyor
[7] Bypass [8] Changing flap
[9] Prescreen conveyor [10]Grizzly feeder
With the help of a digger or wheel loader, material is loaded into
the feed hopper [1]. The grizzly feeder [10] conveys the mate-
rial and separates the incoming material depending on the in-
stalled screen surface.
a) Upper deck covered with steel perforated panel or slotted
grate, lower deck covered with rubber screen surface:
• Coarse material that does not pass the upper deck is
conveyed directly into the jaw crusher [2].

DESCRIPTION
Revision statuses
• Material that passes the upper deck is guided via the rub-
ber screen surface and the bypass device [7] past the
crusher directly onto the crusher discharge conveyor [5].
This is used, for example, with clean feed material to supply
the entire feed material to the final product without having
to dispense with the advantage of prescreening and thereby
relieving the burden on the crusher.
b) Upper deck covered with steel perforated panel or slotted
grate, lower deck with screen surface and change flap in
prescreen conveyor position:
• Material that passes the upper deck but not the lower
deck is guided via the bypass device [7] past the crusher
directly onto the crusher discharge conveyor [5].
• Material that passes the lower deck is guided via the ch-
ange flap [8] onto the prescreen conveyor [9] and then
onto a stockpile or a downstream plant.
c) Upper deck covered with steel perforated panel or slotted
grate, lower deck with screen surface and change flap in by-
pass device position:
deck is guided via the bypass device [7] past the crusher
directly onto the crusher discharge conveyor [5].
• Material that passes the lower deck is guided via the ch-
ange flap [8] into the bypass device [7] and then onto
the crusher discharge conveyor.
This is used to feed the entire charged material to the end
product without having to dispense with the advantage of
prescreening and thus relieving the burden on the crusher.
d) Upper deck covered with dummy cover:
• The entire feed material reaches the crusher. Pre-
screening is not active.
Used for crushing hard rock if this achieves a more compact
crusher jaw filling.
The jaw crusher [2] crushes the oversized product of the pre-
screen depending on the setting of the crushing gap to a final
grain size with oversized product share and passes it on to the
crusher discharge conveyor [5].
The crusher discharge conveyor [5] discharges the material ei-
ther to a stockpile or transfers it to a downstream crushing or
screen plant.
The magnetic separator [4] removes the ferrous elements and
ejects them onto a stockpile.

DESCRIPTION
Revision statuses
10 2 5
9
8
Fig. 2.2: Flow chart
[1] Feed hopper [2] Jaw crusher

[5] Crusher discharge con- [8] Changing flap
veyor
[9] Prescreen conveyor [10]Grizzly feeder
The flow chart demonstrates the material flow within the plant.
The grain sizes produced depend on the charged material, set
gap width of the crusher, fitted screen surfaces and other fac-
tors.
Operating modes
The plant is run in four different operating modes:
• Automatic operation (recommended operating mode)
• Manual mode
• Repair mode
• Driving mode
Automatic mode During automatic mode, all mechanical and electrical safety
functions are active. The individual drives are interlocked by the
plant control system according to the material flow.
After the start enable is issued, the plant can be started using
the "Plant ON" button. All drives are started in accordance with
the switch-on sequence. This operating mode is used in normal
crushing operation.
Manual mode During manual operation, all mechanical and electrical safety
functions are active. The difference to automatic operation is
that there is no reciprocal locking of the drives.
After the start enable is issued, individual drives of the plant can
be started in any combination you desire. This operating mode

DESCRIPTION
Chassis/guard devices
is mainly used for fault elimination, e.g. in the event of material

congestions.
Repair mode In repair mode, the following conditions must be met:
• The plant is switched off.
• The main switch is switched off and with the Lockout /
Tagout safety system locked.
• The control cabinet is locked.
• A warning sign against restart is attached.
The electric drives can no longer start up. Safety devices can
therefore be removed for maintenance and repair work.
The diesel generator can be started if, for example, current is
required from the external circuits for maintenance and repair
work.
Driving mode Driving mode is used for transporting and moving the plant.
Driving is via the wired remote control or the radio remote con-
trol. In driving mode, only limited functions are available, for
e.g. driving or switching individual components on and off. It is
not possible to switch the plant on and off.
The operating modes automatic mode, manual mode and driv-

ing mode are selected via the touch screen (see chap.
2.02.02.01).
2.01 Chassis/guard devices
2.01.01 Information and hazard signs

The signs (hazard, prohibition, mandatory and information
signs) must be attached to the plant and be easily legible. Signs
fitted directly on the plant must be observed.
An overview of the signs is provided in the spare parts cata-
logue.
The information sign are described in chap. 1.06.02. The haz-
ard, prohibition and mandatory signs are described in the safety
instructions.

DESCRIPTION
2.01.02 Chassis with beams
2
3
Fig. 2.3: Chassis with beams
[1] Chassis at feeding side [2] Magnetic separator

mounting
[3] Chassis at discharge side [4] Track drive
[5] Chassis beam
The chassis consists of a welded design of sheet steel and spe-
cial section tubes. The chassis beams (5) are welded onto the
chassis.
The mountings, belt suspensions and supports for the individual
machines and components, e.g. hopper extension, vibrating
conveyor troughs, crusher, belt conveyors and magnetic sep-
arator are mechanically secured to the chassis.

DESCRIPTION
2.01.03 Folding locks
Fig. 2.4: Folding lock
[1] Folding lock [2] Guide with limit position

lock
[3] Service flap
Fig. 2.5: Folding lock
[1] Folding lock [4] Power pack housing cover

The folding locks prevent closing of the service doors and main-
tenance cover of the power supply unit.
The service doors must always be opened until the until the
folding locks engage in the limit position lock.

DESCRIPTION
Folding locks are fitted at the following components:

• Power pack housing, left and right.
• Pulley and flywheel of the crusher drive, left and right.
• Cover of the power pack housing.
2.01.04 Platforms
5 6
4
3
7
3
2 2
1
Fig. 2.6: Platforms and ladders
[1] Platform for grizzly feed- [2] Steps to grizzly feeder

er, left
[3] Railing [4] Ladder to platform for
crusher and power supply
unit
[5] Platform between crusher [6] Handrail
and power supply unit
[7] Platform for grizzly feed-
er, right
The ladders and platforms permit access to machines and plant
components.
The railings are bolted with the platforms.
The platforms are mounted on rubber buffers to reduce vibra-
tions and bolted onto the chassis.
The ladders can be folded up for transport.

DESCRIPTION
WARNING
Risk of falling
Incorrectly fitted platforms, ladders, handrails and anti-fall
guards can result in people falling.
• Ensure that platforms, ladders, handrails and anti-fall
guards are correctly fitted.
2.01.05 Lighting/warning devices
Fig. 2.7: Lighting, warning light and warning siren
[1] LED lamps [2] Warning light

[3] Warning siren
The warning light and warning siren light up or sound for ap-
prox. 7 seconds after the control voltage is switched on. After a
fault occurs or an emergency stop or emergency off is tripped,
they remain active until the fault is acknowledged in the opera-
tor panel.
The LED lamps and the warning light are secured to a mast,
which is moved out before putting the plant into operation and
clamped.
The LED lamps can be used to illuminate specific working areas.
The warning siren is secured in the area of the prescreen con-
veyor on the left-hand side of the chassis.
The lighting can only be switched on after the control voltage

is activated.

DESCRIPTION
2.01.06 Socket outlets on the chassis

Socket outlet for crusher discharge conveyor
Fig. 2.8: Socket outlet for crusher discharge conveyor
[1] Crusher discharge con-

veyor drive terminal
The socket outlet of the crusher discharge conveyor is installed

on the right-hand side of the chassis.
Socket outlet for prescreen conveyor (option)
Fig. 2.9: Socket outlet for prescreen conveyor

DESCRIPTION
[1] Connection for prescreen

conveyor drive
The socket outlet is installed on the mounting of the prescreen

conveyor.
If the plant is operated without a prescreen conveyor, the
socket outlets must be covered with a dummy end to protect
against dust and dirt.
Socket outlets for magnetic separator (option)
1
2
Fig. 2.10: Sockets for the magnetic separator
[1] Magnetic separator drive [2] Electromagnet terminal

terminal
If the plant is operated without a magnetic separator, the sock-

et outlets must be covered with a dummy end to protect
against dust and dirt.
2.01.07 Guard devices
Guard devices can be detached or opened with the help of

tools or special spanners and must remain fixed in position for
operation and routine maintenance tasks. They can be taken
off for repair work.

DESCRIPTION
Safety devices on the plant
2
4
Fig. 2.11: Safety devices on the plant
[1] Safety devices for magnet [2] Crusher drive flywheel

valves protective cover
[3] Crusher drive belt pulley [4] Crusher inlet cover
protective cover
[5] Protective cover for griz- [6] Safety device for hopper
zly feeder spring element extension hydraulic cylin-
der (option)
The crusher inlet cover prevents the ejection of material from
the crusher. It must be set such that ejection is prevented but
charged material can still reach the crusher unobstructed.
The guard devices of the hopper extension hydraulic cylinder
are fitted on the rod side of the cylinder. When the hopper walls
are folded down, the guard devices move with them.

DESCRIPTION
Guard devices on belt conveyors
3 4
5
1
Fig. 2.12: Guard devices on belt conveyors
[1] Guard for bend pulley [2] Guard for track rollers
[3] Guide rails [4] Guard for drive pulley
[5] Guard for return rollers
The guard devices of the belt conveyors protect against being
drawn in or caught by machinery and against lateral falling of
material. They are fitted on all belt conveyors where it is neces-
sary to protect against hazards.
The guard devices must be set so that the gap at the draw-in
point is a maximum of 5 mm.
Component securing elements
3
1

DESCRIPTION
Fig. 2.13: Component securing elements
[1] Locking pin with securing [2] Spring pin

element
[3] Locking pin with securing
chain
Locking pins used to install components are secured with spring
pins and securing elements. If components are not installed on
the plant, the locking pins must be kept for reuse.
2.01.08 Emergency stop

Emergency stop and emergency switching off on the
plant
1 2 3 2
Fig. 2.14: Emergency stop devices on the plant and remote

control
[1] Emergency-stop button [2] Emergency-stop button

on the remote control on the plant
[3] Emergency switching off
button on the operator's
stand
The emergency-stop button [2] at the plant switches off all
plant drives with the exception of the diesel generator. The
crusher is switched off after a defined run-after time.
The emergency-stop button [1] at the radio and wired remote
control switches off all drives with the exception of the diesel
generator. The crusher is switched off after a defined run-after
time.
The emergency switching off button [3] on the operator's stand
switches off the entire plant including the diesel generator.

DESCRIPTION
The emergency stop and emergency switching off button are re-
leased by turning the button. The plant components and ma-
chines then have to be restarted at the touch screen in the
switch cabinet.
2.01.09 Safety functions

The table lists the safety functions of this series arranged ac-
cording to Performance Level as per the standard ISO 13849-1:
2015 for:
Implementation of the SRP/CS, category 1 PL c

Actuating the emergency-off command device leads directly at All drives
the control cabinet to shutdown (of)... Diesel generator
Actuating the emergency-stop command device leads to delayed Jaw crusher
shutdown of...
Actuating the emergency-stop command device leads to immedi- Prescreen conveyor
ate shutdown of... Magnetic separator
Crusher discharge con-
veyor
Drive system
Release of the enable pushbutton (local control) leads to the safe Hopper wall, left
stop of the folding movement of the... Hopper wall, right
Hopper wall, rear
veyor
Prescreen conveyor
Release of the acknowledge pushbutton (local control) leads to Prescreen conveyor
the safety stop of the...
Release of the levers of the radio remote control leads to the safe Drive movement
stop of the...
Actuating the emergency-stop command device at the radio re- Vibrating feeder
mote control or interruption of the radio signal (outside the range Prescreen conveyor
/ the battery has low voltage) leads to safe shutdown of the...
Jaw crusher
Magnetic separator
veyor
Drive system
Function activation K1 and magnet valve M-Y1 prevent unexpected transmission of a drive
torque to the jaw crusher in repair operating mode.
Safe enable of the control pressure (CCO valve) prevents unexpected transmission of the
drive torque to the drive system.

DESCRIPTION
Control stand
Implementation of the SRP/CS, category 3 PL d

Actuating the EMERGENCY-STOP command device leads to imme- Vibrating feeder
diate shutdown of...
CCO valve = Compact Change-Over valve.

PL = Performance Level.
SRP/CS = Safety Related Parts of Control Systems.
2.02 Control stand
4 3
1 5
Fig. 2.15: Plant operator's stand
[1] Operator panel [2] Operator panel flap

[3] Control cabinet flap [4] Belt drive panelling
[5] Control cabinet
All plant functions are controlled from the operator's stand dur-
ing commissioning and setting or maintenance work.
The operator panel and the main switches are accessible by
opening the operator panel flap.
The control cabinet, the main switch, the socket outlets, the op-
erating unit for the cold package, the centralised lubrication and
receiver for the radio and wired remote control are accessible
by raising the control cabinet flap. The control cabinet flap is
held in its folded open position by gas struts.
During regular crusher operation the plant is controlled exclu-
sively via radio remote control. The operator therefore does not
need to stay at the operator's stand.

DESCRIPTION
Control stand
During regular crusher operation, the control cabinet flap of the

panelling must remain closed to prevent ingress of water and
dust. The operator panel flap can remain open during regular
crusher operation so that operating statuses and fault messag-
es can be viewed on the display.
During setting or maintenance tasks without feeding unit, the
control cabinet flap can remain open for operating the receiver
of the radio and wired remote control system. In this case, it
serves as weather protection for operating, maintenance and
repair personnel.
The instruction manual and other technical documents can be

found in the document holder in the control cabinet protective
housing.
2.02.01 Main switch
Fig. 2.16: Main switch
[1] Main switch

The main switch deactivates the electric main switch in the
switch cabinet. The diesel generator can be started, the individ-
ual plant components cannot be started.
The main switch can be secured against unintentional restart in
the "Off" position using a U-lock.

DESCRIPTION
Control stand
2.02.02 Operator panels/Interfaces
2 3
4 5 6 7 8 9 10 11
500
400
200
12
Fig. 2.17: Operator panel

DESCRIPTION
Control stand
Pos.: Control element/indica- Function

tor
[1] Emergency-off button Switches plant off in emergencies, see chap. 2.01.08
[2] Touch screen Interface for operating the plant and setting different
plant parameters, see description of "Touch screen"
[3] Rotary switch for radio re- Switches plant on/off via radio remote control
mote control
[4] Key switch for control volt- Switches plant control voltage on/off
age
[5] Acknowledge fault button Acknowledges faults and emergency stops
[6] Diesel generator ON button Switches diesel generator on
[7] Diesel generator OFF but- Switches diesel generator off
ton
[8] Start enable button Display and confirm start enable
[9] Plant ON button Switches plant on
[10] Plant OFF button Switches plant off
[11] Rotary switch for lighting Switches plant headlights on/off
[12] Voltmeter Displays the voltage between the phases with the main
switch activated
Tab. 2.1: Operator panel control elements
General functions of the control elements

Key switch
Key switches are actuated by a key. The key can be inserted and
removed in the OFF and ON positions.
Rotary switch
The rotary switch is actuated by turning it. Turning to the left or
right switches the desired function on or off.
The rotary switches are either momentary-contact or main-
tained-contact switches.
Button
This control element is actuated by pressing it.
• Pressing the button activates the corresponding function
and the button lights up.
Control lamps
Control lamps light up upon activation of a corresponding func-
tion. When the function is deactivated, the corresponding con-
trol lamp also goes out.

DESCRIPTION
Control stand
Warning lights
Warning lights light up if a fault is pending. After eliminating or
acknowledging the corresponding fault, the warning light goes
out.
2.02.02.01 Touch screen
11:30
3 4
User: Kleemann
2
6
1 7
Fig. 2.18: Touch screen
[1] Information and alarm [2] Situation-related operat-

message area ing and display area
[3] Static operating and dis- [4] User, date and time infor-
play area mation
[5] Operating elements and [6] Touch-sensitive surface
indicators
[7] Plant overview
The touch screen permits operation of the plant and display el-
ements of the current operating status via the operating and in-
dicator elements.

DESCRIPTION
Control stand
The system is operated through contact with the touch screen

using a finger or other suitable object.
During automatic, manual and driving operation, the touch
screen is generally divided into three areas:
• Static operating and display area [3] with access to user set-
tings, component information, main menus, fault messages
and others.
• Situation-related operating and display area [2] with access
to components and functions of the plant.
• Information and alarm message area [1], which can be hid-
den or shown, with current status messages and informa-
tion.
Actuated control elements are pressed in optically or shown in-
verted to give the user a realistic impression.
If the touch screen does not display the operating mode selec-
tion window or the plant overview, tap on the "Static operating
and display area" [3] to display the plant overview again.
2.02.03 Frequency converter

Frequency converter operating unit
2
3
Fig. 2.19: Frequency converter
[1] Frequency converter [2] Display

housing
[3] ESC button [4] Enter button
[5] Rotating wheel for menu
navigation and parameter
setting

DESCRIPTION
Control stand
NOTICE
Risk of material damage
Changes to the settings of the frequency converter made by
KLEEMANN GmbH can result in material damage.
• Do not change the settings.
The three-phase current frequency converter permits speed

control of the vibration motors of the grizzly feeder.
The frequency converter is set at the touch screen of the oper-
ator panel.
If the frequency converter fails, operation of the plant is no

longer possible. Contact KLEEMANN GmbH Service.
2.02.04 Remote controls

Radio and wired remote control
3 4
11 10 9 8 7 6
1
Fig. 2.20: Remote control
[1] Crawler chassis slow/fast [2] Magnetic separator lift-

ing/lowering
[3] Left crawler chassis for- [4] Right crawler chassis for-
wards / backwards wards / backwards, auxil-
iary drive impact crusher
forwards / backwards
[5] Connection for wired re- [6] Vibrating feeder slow /
mote control fast
[7] Vibrating feeder on/off [8] Remote control on
[9] LED for operation and [10]Remote control off and
fault display emergency stop

DESCRIPTION
Control stand
[11]LED for display of driving

speed
The remote control system is designed for either wired or radio

remote use.
For use as wired remote control, the transmitter is connected
with the associated cable to the receiver of the remote control
system in the control cabinet.
The remote control system is supplied with power from a re-
chargeable battery. Operational readiness is indicated by the
red illuminated LED [9]. The LED flashes red once a second if
the battery has low voltage. Prior to this, the warning buzzer of
the remote control system also sounds three times.
When the transmitter is switched on, it carries out a self-test. If
faults are detected, the red LED [9] issues fault messages via a
flashing code (see chap. 3.17.02).
Display of driving speed The selected driving speed is indicated by the LED [11].
Press the switch [1] to the right to select fast driving speed. The
LED [11] is not lit.
Press the switch [1] to the left to select slow driving speed. The
LED [11] flashes green.
Impact crusher auxiliary If the auxiliary drive system of the crusher is activated, the ro-
drive controls tational direction of the auxiliary drive is set by means of the
control lever [4] to forwards or backwards.
With the use of several plants, the operator must ensure that
the transmitter of the radio remote control can be clearly as-
signed to the respective plant.
If necessary, mark the plant and the respective transmitter of
the radio remote control using suitable aids, e.g. flags of the
same colour.

DESCRIPTION
Control stand
Range of radio remote control
Fig. 2.21: Range, radio remote control

The radio remote control permits operation and movement of
the plant independently of the operator panel of the switch cab-
inet. The range of the radio remote control is approx. 100 m
with visual contact between transmitter and receiver. The range
can be smaller if there are obstacles between transmitter and
receiver.
The emergency-stop function of the radio remote control is
tripped automatically by the following events:
• If the range of the transmitter is exceeded.
• Interruption of the radio signal, e.g. interference with trans-
mitter or receiver.
• Removal of the battery from the radio remote control.
• Battery undervoltage.
• Manual actuation of the emergency stop at the radio remote
control.
When the emergency-stop function is tripped, all plant drives
with the exception of the diesel generator are switched off.

DESCRIPTION
Control stand
NOTICE
Danger of material congestion
If the range of the radio remote control is exceeded, the emer-
gency stop is tripped and material congestion in the plant can
result.
• During plant operation, ensure that the range of the radio
remote control is never exceeded.
• Never carry the radio remote control along in the wheel
loader or digger and thus leave the range.
• Always ensure there is visual contact between transmitter
and receiver.
• Store the radio remote control in the plant's switch cabinet
housing when not in use.
Remote control system components and accessories
1 2 3 4 5 6 7
Fig. 2.22: Components and accessories
[1] LEDs "Status" and "DV" [2] Connection for wired re-
mote control
[3] Receiver [4] Display for operation and
fault display
[5] Battery [6] Charger
[7] Receiver aerial
The receiver [3] of the remote control system is installed in the
control cabinet housing. The receiver aerial [7] is installed on
the right-hand side on the mounting of the magnetic separator.
The charger [6] and battery [5] are stowed in the control cabi-
net housing.

DESCRIPTION
Control stand
If the charged battery is removed from the charger, the battery

to be charged must not be placed back in the charger until a
time of 30 seconds has elapsed. If the battery is inserted earlier,
no charging will take place.
The LEDs "DV" and "Status" [1] and the display [4] indicate the
operating status and fault messages of the receiver.
If the LED "Status" is red, the receiver is in standby mode. If it
lights up green, the connection with the transmitter is active.
In the event of a malfunction, the "Status" LED flashes red and
the corresponding fault is shown on the display (see chap.
3.17.02).
If the "DV" LED is red, the DV output is active.
If radio remote control is used, "1H" lights up in the display [4]
of the receiver.
If wired remote control is used, "1-" lights up in the display [4]
after the cable is inserted.
2.02.05 Local controls

Local control for prescreen conveyor
1 2 3 4 5 6
Fig. 2.23: Local control for prescreen conveyor

tor
[1] Button to fold out pre- Folds out prescreen conveyor
screen conveyor (long)
[2] Button to fold in prescreen Folds in prescreen conveyor
conveyor (long)

DESCRIPTION
Control stand

tor
[3] Button to swing out pre- Swings out prescreen conveyor
screen conveyor
[4] Button to swing in pre- Swings in prescreen conveyor
screen conveyor
[5] Button Has no function
[6] Button Has no function
Tab. 2.2: Control elements for onsite control system
Local control for hopper walls
2 3 4 5
1 1 5 4 3 2
1 2 3 4 5 6
Fig. 2.24: Local control for hopper walls

tor
[1] Movement direction "fold Selects movement direction folding up for hopper walls.
up".
[2] Movement direction "fold Selects movement direction folding down for hopper
down". walls.
[3] Button for left hopper wall Selects left hopper wall fold up / down.
[4] Button for right hopper Selects right hopper wall fold up / down.
wall
[5] Button for middle hopper Selects middle hopper wall fold up / down.
wall
[6] Button for hopper wall Selects hopper lock / unlock.
locking
Tab. 2.3: Control elements for local control system

DESCRIPTION
Control stand
The order of the buttons to be actuated is made clear by the

coloured numbers. After selection of the respective function,
e.g. fold up left hopper wall, the enable pushbutton for execu-
tion must be actuated.
Local control enable pushbutton
Fig. 2.25: Enable pushbutton
[1] Enable pushbutton

Depending on the plant configuration, the enable pushbutton
for operation of the local control for the hopper walls and pre-
screen conveyor, as well as for folding the extended crusher dis-
charge conveyor, must be actuated.
The enable pushbutton for folding extended crusher discharge
conveyor in and out is located in the control cabinet housing.

DESCRIPTION
Control stand
2.02.06 Operating unit for cold package
5
4
Fig. 2.26: Operating unit for cold package
[1] Automatic circuit-break- [2] Control lamp

ers
[3] Rotary switch for switch- [4] Connection for internal or
ing cold package on and external power supply
off (NE-MA6-20 20 A)
[5] Connection for internal or
external power supply
(CEE 32 A)
The operating unit for the cold package is located in the control
cabinet housing.
When the diesel generator is running the cold package heaters
are switched on at the operating unit.
A 230 V connection for connection to an emergency generator
supplies the heaters overnight for example with power when the
diesel generator is not in operation or the diesel generator is not
to be used.
The following heaters are switched on and off with the cold
package operating unit:
• Control cabinet heaters.
• Control cabinet heating touch screen.
• Engine block heater.
• Heating element, fuel prefilter.
• Heating bindings, starter batteries.

DESCRIPTION
Not assigned
2.03 Not assigned
2.04 Power supply unit/engine
3
2
5
1
Fig. 2.27: Diesel generator power supply unit
[1] Cooling system, see chap. [2] Generator, see chap.

[3] Air intake, see chap. [4] Diesel engine, see chap.
[5] Fuel supply, see chap.
2.04.01 Diesel engine
Fig. 2.28: Diesel engine Scania DC9

DESCRIPTION
Power supply unit/engine
[1] Engine oil filler neck [2] Exhaust turbocharger

[3] Diesel engine [4] Oil dipstick
The 5-cylinder in-line diesel engine has direct fuel injection and
a liquid cooler. It has an exhaust turbocharger with charge-air
cooling.
All components can be accessed after opening the protective
housing of the power supply unit.
For technical details, see chap. 5.01.02.
LRC diesel engine
5
4
Fig. 2.29: Scania diesel engine
[1] Charge-air cooler return [2] Charge-air cooler supply

line line
[3] Exhaust turbocharger [4] Exhaust pipe with thermal
insulation
[5] Clean air pipe
Low Regulated Countries (LRC) diesel engines are used in coun-
tries in which the quality of the diesel fuel is insufficient and the
sulphur content in the diesel fuel is too high.
Suitability of the LRC diesel engines for use with these diesel fu-
els is achieved, among other things, through a modified engine
management system.
The LRC diesel engines are equipped with a fuel prefilter with
automatic water separation, see chap. 2.04.02.
Technical data, see chap. 5.01.02.

DESCRIPTION
2.04.02 Fuel supply
Fig. 2.30: Fuel supply
[1] Hand delivery pump with [2] Fuel filter with water sep-
prefilter arator
[3] Main fuel filter
3
6
Fig. 2.31: Fuel supply LRC set
[3] Main fuel filter [4] Water separator collecting

reservoir
[5] Water separator hose [6] Fuel prefilter with auto-
matic water separator

DESCRIPTION
7
8
[7] Fuel return line [8] Fuel supply line

[9] Level sensor
11
10
[10]Diesel fuel drain [11]Filler neck with closing

cover
If required the diesel fuel tank can be drained via the diesel out-
let. It is secured against unauthorised removal by a lock.
The hand delivery pump can be used to vent the fuel lines to the
diesel engine.

DESCRIPTION
The fuel prefilter of the LRC version diesel engine has an auto-
matic water separator. The collecting reservoir collects the fluid
separated by the fuel prefilter.
2.04.03 Exhaust system
2
3
Fig. 2.34: Exhaust system
[1] Exhaust turbocharger [2] Exhaust pipe with thermal

insulation
[3] Silencer
The silencer is located between the suspension elements of the
magnetic separator.

DESCRIPTION
2.04.04 Air intake
2
3
Fig. 2.35: Air intake
[1] Clean air pipe [2] Cyclone prefilter

[3] Air filter
The cyclone prefilter removes coarse dust particles from the in-
take air. The air filter, with its inserted filter element, filters out
finer contamination.
2.04.05 Cooling system
3 4
6
2
7
8
Fig. 2.36: Cooling system

DESCRIPTION
[1] Return line from charge- [2] Supply line to charge-air

air cooler cooler
[3] Exhaust turbocharger [4] Expansion tank with filler
neck
[5] Charge-air cooler [6] Coolant cooler
[7] Hydraulic coupling cooler [8] Auxiliary hydraulic sys-
tem cooler
The cooler forms a unit of the charge-air cooler [5], the coolant
cooler [6], the cooler for the hydraulic coupling [7] and the aux-
iliary hydraulic system [8].
2.04.06 Hydraulic coupling
3
1
Fig. 2.37: Hydraulic coupling
[1] Hydraulic coupling [2] Diesel engine

[3] Crusher drive pulley
The hydraulic coupling [1] is installed as a hydrodynamic clutch
coupling between the diesel engine [2] and the belt pulley of the
crusher drive [3]. Filling and draining the hydraulic coupling
cuts the drive in and out.
In addition, a resilient connection coupling between diesel en-
gine [2] and hydraulic coupling [1] guarantees a jolt-free start-
up.
The drive is cut in with the crusher unloaded. The directly driven
filling pump fills the working chamber of the hydraulic coupling
via the integrated oil supply system. The hydraulic coupling
starts the power transmission. When the filling time has
elapsed, continuous operation starts up and feeding to the
crusher can begin.

DESCRIPTION
The drive is cut out again when the crusher is unloaded. The hy-
draulic coupling is then drained.The directly driven filling pump
is in operation continuously and feeds the integrated oil supply
system, which guarantees lubrication of the mounting and cool-
ing of the hydraulic coupling.
2.04.07 Diesel engine, heat package

The heat package of the diesel engine consists of a coolant cool-
er with a higher cooling capacity.
2.04.08 Diesel engine cold package
Fig. 2.38: Engine block heater
[1] Diesel engine [2] Heating element, engine

block

DESCRIPTION
6
4
Fig. 2.39: Diesel and cooling water heater
[3] Water separator hose [4] Connection, heating ele-

ment, fuel prefilter
[5] Fuel prefilter with auto- [6] Water separator collecting
matic water separator reservoir
The heating element of the diesel engine is mounted in the en-
gine block.
The diesel engine is heated when the cold package is switched
on.
The heating element in the diesel engine remains active during
operation until the cold package is switched off.
It is possible to start the diesel generator without preheating

below - 15 °C ambient temperature, although this is not rec-
ommended.
The heating element of the fuel prefilter is active after the diesel
engine starts. When the diesel engine is switched off, the heat-
ing element is shut down too.
A collecting reservoir collects the fluid separated by the auto-
matic water separator.

DESCRIPTION
Hydraulic oil supply
2.05 Hydraulic oil supply
2.05.01 Hydraulic oil tank
3
4
5
6
1
7
8
Fig. 2.40: Hydraulic oil tank
[1] Level indicator [2] Suction filter

[3] Maintenance cover for [4] Thermostat
suction filter
[5] Filler neck and tank vent [6] Return filter
with coarse strainer
[7] Cleaning cover [8] Drain cock
The hydraulic oil tank supplies the entire hydraulic system with
hydraulic oil.
The hydraulic oil tank is equipped with two return filters [6] and
a tank vent with coarse strainer [5]. The temperature of the hy-
draulic oil is monitored by the thermostat [4]. The interior suc-
tion filter [2] filters particles out of the hydraulic oil. It can be
serviced via the maintenance cover [3].
The fill level of the hydraulic oil tank is displayed at the level in-
dicator [1].

DESCRIPTION
2.05.02 Hydraulic pumps
Fig. 2.41: Hydraulic pumps
[1] Auxiliary hydraulics gear [2] Drive system feed pres-

pump sure gear pump
[3] Drive system tandem
pump
The tandem pump [3] provides the drive system and hydraulic
motor of the auxiliary drive of the jaw crusher with pressure and
volume flow.
The gear pump [2] flange-mounted on the tandem pump sup-
plies feed pressure to the tandem pump.
The gear pump of the auxiliary hydraulic system [1] is respon-
sible for the hydraulic oil supply of the following components
and machines:
• Folding of hopper extension up and down and locking.
• Raising and lowering magnetic separator.
• Adjust gap width.
• Clamp and relieve spring pack of pretension device hydrau-
lically.
• Moving short prescreen conveyor out and in.
• Folding long prescreen conveyor, moving out and in.
• Jaw crusher auxiliary drive hydraulic cylinder.
• Folding extended crusher discharge conveyor.

DESCRIPTION
2.05.03 Valve blocks
6
7
4
2
8
Fig. 2.42: Valve block for magnet valves
[1] Magnet valves for folding [2] Magnet valves for gap
and hydraulically locking setting and pull rod spring
hopper walls pretension
[3] Magnet valve for auxiliary [4] Magnet valve for hydrau-
drive hydraulic cylinder lic folding of extended
crusher discharge con-
veyor
[5] Magnet valve for raising / [6] Magnet valve for moving
lowering magnetic sep- prescreen conveyor in /
arator out
[7] Magnet valve for folding [8] Hopper wall locking pres-
long prescreen conveyor sure accumulator
Depending on the plant equipment, the magnet valves [1] - [7]
are activated from the touch screen or electrically from the local
control.
The auxiliary hydraulic system supplies the valve blocks with
pressure and volume flow.
The valve block in the illustration shows the version with all op-
tions. If an option is not installed, the position of this valve
block is occupied by the adjacent valve block.

DESCRIPTION
2.05.04 Hydraulic motor
Fig. 2.43: Hydraulic motor, auxiliary drive
[1] Friction wheel hydraulic [2] Friction wheel hydraulic

cylinder pressure accu- cylinder
mulator
[3] Hydraulic motor [4] Friction wheel
[5] Belt pulley
The hydraulic motor [3] of the auxiliary drive assumes the task
of jaw crusher start-up with the crushing jaw filled.
The friction wheel [4] is pressed by the hydraulic cylinder [2]
onto the belt pulley [5].
When the feeding components are switched off, the auxiliary
drive can be used to operate the jaw crusher against the direc-
tion of material flow.

DESCRIPTION
2.05.05 Driving clutch
Fig. 2.44: Driving clutch
[1] Tandem pump connection [2] Cam ring

side
[3] Claw clutch [4] Clamping screw
The power transmission from the electric motor to the tandem
pump of the drive system is by means of a claw clutch.
A spacer sleeve is installed between electric motor and claw
clutch. The claw clutch is secured against slipping on the shaft
of the electric motor with a grub screw and a feather key.
The clamping screw secures the claw clutch on the gear shaft of
the tandem pump.
The cam ring serves as a start-up damper and guarantees jolt-
free start-up of the tandem pump.

DESCRIPTION
Electrical system
2.06 Electrical system
Fig. 2.45: Electrical system
[1] Socket outlets on the con- [2] Control cabinet with fus-
trol cabinet, see chap. es, see chap.
Fig. 2.46: Electrical system
[3] 24 V diesel engine gener- [4] 400 V generator, see

ator, see chap. chap.
[5] 24 V power supply, see
chap.
In the electrical system, a distinction is made between two pow-
er-supply systems:

DESCRIPTION
Electrical system
• The 24 V direct current power system supplies the engine

and control electronics with the necessary current.
• The 400 V three-phase current power system supplies the
electric drives with the necessary current.
2.06.01 24 V voltage supply
Fig. 2.47: Starter batteries
[1] 12 V starter batteries

The 12 V starter batteries [1] are located above the diesel fuel
tank and can be accessed after the left power pack panelling is
opened.
The 24 V power supply is provided by the generator of the diesel
engine and two 12 V starter batteries [1] connected in series.

DESCRIPTION
Electrical system
2.06.02 Battery isolator
Fig. 2.48: Battery isolator
[1] Battery isolator

The mechanical battery isolator [1] is installed in the front left
area of the lateral service flap.
The battery isolator can be switched off through an opening in
the front area of the fuel tank panelling and removed.
For maintenance and repair work, the battery isolator must be
switched off and removed if necessary.
The battery isolator disconnects the electrical system from the
12 V starter batteries.
If the battery isolator is switched on and the transport plug is

inserted, the battery of the radio remote control is not
charged.

DESCRIPTION
Electrical system
2.06.03 Switch cabinet
4
4
3
Fig. 2.49: Switch cabinet and plant fuses
[1] Ground fault circuit inter- [2] Automatic circuit-breaker

rupter
[3] Contactors [4] Motor protection device
[5] Frequency converter [6] Overload relay
The switch cabinet contains all electrical switching and fuse el-
ements and plant wiring systems.
The switching and fuse elements can be accessed after opening
the switch cabinet door.
All electrical switching and fuse elements are identified by short
codes.
All electrical switching and fuse elements are listed in detail in

the electric circuit diagram.
• Do not bridge the fuses.
• If an automatic circuit-breaker trips repeatedly, notify au-
thorised personnel.
• Do not spray switch cabinets with water.

DESCRIPTION
Electrical system
2.06.04 Generators
Fig. 2.50: 24 V generator
[1] 24 V generator
Fig. 2.51: 400 V generator
[2] Belt drive [3] 400 V generator

[4] Terminal box
The 24 V generator is driven by the diesel engine via a V-ribbed
belt. The 24 V power supply is provided by two 12 V starter bat-
teries connected in series.
The 400 V generator is driven by a belt drive directly from the
diesel engine.

DESCRIPTION
Electrical system
The 400 V generator is a brushless, self-excited and self-con-

trolling synchronous generator. It supplies the three-phase cur-
rent required by the plant.
2.06.05 Electric motors

All electric motors in the plant run on 400 V three-phase cur-
rent.
The vibration motors of the grizzly feeder can be controlled over
a defined speed range by the frequency converter.
2.06.06 Socket outlets
4 6
2
1
Fig. 2.52: Sockets on control cabinet
[1] Service socket 400 V / 32 [2] Service socket 230 V / 16

A A
[3] Connection for operating [4] Transport plug
and transport plug
[5] Receiver for radio remote [6] Service socket 110 V / 16
control and wired remote A
control connection
Transport plug
The transport plug [4] is inserted in the operating and temper-
ature plug [3] for transporting the plant. This is placed at the
position of the transport plug for safe storage of the operating
plug.
External circuits
The socket outlets of the external circuits [1], [2] and [6] are
live even when the main switch is switched off. They only be-
come de-energised when the diesel generator is switched off.

DESCRIPTION
Electrical system
2.06.07 Electrical system, heat package

2.06.07.01 Heat package, control cabinet
1
4
Fig. 2.53: Heat package, control cabinet
[1] Corrugated hose [2] Ventilator, control cabinet

aeration
[3] Ventilator, control cabinet [4] Air filter
ventilation
[5] Motor protection switches [6] Circuit breaker lines

The ventilators of the switch cabinet ventilation and deaeration
are located in the switch cabinet doors. The ventilator of the

DESCRIPTION
Electrical system
switch cabinet ventilation is connected to the air filter via a cor-

rugated hose.
The ventilators start after starting the diesel generator and
switching on the main switch.
2.06.08 Electrical system, cold package

2.06.08.01 Voltage supply, cold package
5
4
Fig. 2.55: Voltage supply, cold package
[1] Automatic circuit-break- [2] Control lamp

ers
[3] Rotary switch for switch- [4] Connection for internal or
ing cold package on and external power supply
off (NE-MA6-20 20 A)
[5] Connection for internal or
external power supply
(CEE 32 A)
The connection [5] can only be used for an external power

supply with connector NEMA6-20 20 A
2.06.08.02 Control cabinet, cold package
Example illustration, cold package switch cabinet.

DESCRIPTION
Electrical system
2 3
1 4
Fig. 2.56: Switch cabinet heating
[1] Thermostat, switch cabi- [2] Heating element, switch

net cabinet
[3] Heating element, switch [4] Thermostat, switch cabi-
cabinet, touch screen net, touch screen

The heating elements and the thermostat of the switch cabinet
heater are located in the switch cabinet and can be accessed af-
ter the switch cabinet doors have been opened.
The heating element and the thermostat of the touchscreen are
housed in the operator panel switch cabinet.
The thermostats can be used to preselect the ambient temper-
ature at which the heaters in the switch cabinet switch on and
off automatically.

DESCRIPTION
Electrical system
2.06.08.03 Starter batteries, cold package
Fig. 2.57: Battery heater
[1] Heating bindings [2] Starter battery

The heating bands of the starter batteries are supplied with 230
V.
The heating bands are connected in series. The battery heater
stops functioning after a heating band is removed or if a heating
band is faulty.
2.06.08.04 Fuses, cold package
5
4
Fig. 2.58: Fuse, cold package

DESCRIPTION
Not assigned
[1] Automatic circuit-break-

ers
The automatic circuit-breakers are accessible after the cover of
the operating unit has been removed.
thorised personnel.
2.07 Not assigned
2.08 Drive system
2.08.01 Crawler running gear
4 5
6
3
7
1
Fig. 2.59: Crawler running gear
[1] Sprocket [2] Chain tensioner

[3] Crawler carrier chain [4] Chassis beam
[5] Sprocket [6] Track drive
[7] Track rollers [8] Chain guide
The left and right chassis beams are welded onto the chassis.
The individual components of the crawler running gear are in-
stalled in the chassis beam.
The left and right track drive with flange-mounted sprocket
drive the crawler carrier chains.

DESCRIPTION
Drive system
The crawler carrier chain is tensioned via the chain tensioner

and the sprocket. The chain guide holds the crawler carrier
chain in the track.
The preload pressure of the chain tension and overload pressure
is set at the safety valve of the chain tensioner. If the set
preload pressure is exceeded during tensioning of the crawler
carrier chains, the safety valve opens and grease is drained.
If the crawler carrier chain blocks during driving operation or
the crawler running gear bottoms out, the overload pressure
safety valve opens and grease is drained.
2.08.01.01 Crawler chassis track pads
1 3
Fig. 2.60: Crawler chassis
[1] Crawler carrier chain [2] Track pad

[3] Chassis beam
Example illustration of the track pads.

Track pads protect the ground against damage.
The track pads are installed on the individual chain links of the
crawler carrier chain.

DESCRIPTION
Drive system
2.08.02 Track drive
2
3
Fig. 2.61: Track drive
[1] Sprocket [2] Gearbox

[3] Hydraulic motor with con-
nections
The left and right crawler chassis are driven by one track drive
respectively.
Integrated in the track drive is a spring-fed pressurised brake,
which secures the plant against rolling away and can be re-
leased hydraulically. In driving operation, the brakes are re-
leased hydraulically.
The two hydraulic motors of the track drive are powered by axial
piston pumps, which are supplied with pressure and volume
flow by an electric motor.

DESCRIPTION
Not assigned
2.09 Not assigned
2.10 Conveyor unit
Fig. 2.62: Conveyor unit
[1] Crusher discharge con- [2] Magnetic separator, see

veyor chap.
[3] Prescreen conveyor
The conveyor unit is formed by various machines and compo-
nents within the plant. This is demonstrated in the plant over-
view and the flow chart, see chap. 2.

DESCRIPTION
Conveyor unit
2.10.01 Belt conveyor
4 5
6
3
2
7
8
1
9
Fig. 2.63: Belt conveyor
[1] Return roller [2] Support rollers

[3] Material guide ledges [4] Conveyor belt
[5] Tensioning device [6] Drive pulley
[7] Electric motor with bevel [8] Return roller with return
helical gear box roller guard
[9] Conveyor belt frame
All belt conveyors have the same design in principle. The main
differences are the belt width, the centre distance between the
drive and return rollers and the belt conveyor drive.
Electric motors with flange-mounted bevel helical gearboxes or
drive pulleys with integrated electric drum motors are used as
belt conveyor drives.
In automatic operation, the belt conveyors are controlled auto-
matically by the programmable logic controller. In manual oper-
ation, they can be switched on and off individually.
The conveyor belt frame [9] supports the components of the
belt conveyor. The conveyor belt [4] is guided and driven via the
drive pulley [6]. The support rollers [2] bear the load of the ma-
terial to be conveyed. The arrangement of the support rollers
means that the shape of the conveyor belt in the cross-section
may be flat or trough-shaped.
The tensioning devices [5] are used to set the conveyor belt to
the correct tension.
Scrapers ensure that the top and bottom segment of the con-
veyor belt are clear of adhering material, which would otherwise
damage the conveyor belt and pulleys.

DESCRIPTION
Conveyor unit
Optional equipment
• Extended crusher discharge conveyor.
• Preparation for belt scale in crusher discharge conveyor.
• Preparation for belt scale in the fine grain conveyor.
2.10.02 Chutes
Fig. 2.64: Chutes
[1] Screen underpass and [2] By-pass device

change flap
[3] Crusher outlet
Chutes such as the screen underpass [1] and the crusher outlet
[3] guide and pass on the material on belt conveyors.
The rubber plates fitted on the steel structure of the chutes re-
duce the dust discharge from the plant and form the flexible
transitions to the downstream machines and components.
The by-pass device [2] guides the material that has passed the
upper deck, but not the lower deck of the grizzly, past the
crusher onto the crusher discharge conveyor.
The change flap directs the material that has passed the lower
deck of the grizzly, depending on the position, onto the pre-
screen conveyor (option) or into the by-pass device.

DESCRIPTION
Conveyor unit
2.10.03 Magnetic separator
Fig. 2.65: Magnetic separator
[1] Run-off chute [2] Belt of crusher discharge

conveyor
[3] Conveyor belt of magnetic [4] Return roller
separator with ribs
[5] Hydraulic lifting device
The magnetic separator uses magnetic force to remove ferrous
material from the crusher discharge conveyor [2] and conveys
it via the conveyor belt [3] and the run-off chute [1] into a con-
tainer provided.
The magnetic separator is driven by an electric motor with a
flange-mounted gear unit.
The magnetic separator can be raised and lowered hydraulically
by the lifting device [5] in order to set the optimum distance to
Optional equipment
• Electromagnetic magnetic separator.
• Permanent magnetic separator.
• Magnetic separator preparation.

DESCRIPTION
Conveyor unit
2.10.04 Line coupling

2.10.04.01 General line coupling
2
2
3 3
Fig. 2.66: Line coupling
[1] Crusher fill level probes [2] Drives of the feeding

components
[3] Emergency stop and [4] Line coupling cable
emergency switching-off
devices
Example illustration of a line coupling.

With line coupling crushing plants and screens are linked by
means of a line coupling cable [4]. The line coupling has two ob-
jectives:
• Process linking of plants for optimal material flow
• Emergency stop and emergency switching-off linking of
plants for safe operation
With the process linking, the material flow of the upstream or
downstream plants is controlled by the fill level monitor [1] of
the respective crusher and the drives of the feeding compo-
nents [2].
In the case of the emergency stop and emergency switching-off
linking, signals of activated emergency stop and emergency
switching-off buttons [3] at the upstream or downstream plants
are forwarded so that the entire plant linkage comes to a stand-
still in the event of an emergency.
Only the plants in the MC EVO series and the MCO EVO series
can be linked by means of line coupling.

DESCRIPTION
Conveyor unit
2.10.04.02 Operating principle of line coupling

The fill level in the crusher is monitored using a crusher fill level
probe. Every plant in a line coupling recognises its capacity level
and whether it requires or is able to deliver more or less mate-
rial. The information on the current fill level of the crusher is
sent to the respective feeding components such as the vibrating
feeder or feeding conveyor.
If a plant requires more or less material, this information is also
sent to the upstream plant. This plant then supplies more or
less material depending on its capacity and setting.
Irrespective of the information from the downstream plant, the
upstream plant decides whether more material is able to be de-
livered (CFS = Continuous Feed System).
A B
Fill level monitor crusher Fill level monitor crusher
Speed of feeding conveyor:

Enable
Slow
Medium
Fast
Error
Speed of vibrating feeder: Information to vibrating feeder:

Speed 1 Enable
Speed 2 Slow
Speed 3 Medium
Speed 4 Fast
Overload speed Error
Fig. 2.67: Line coupling

The diagram shows a line coupling and the information flow,
starting with plant B.
Green arrows = Process linking
Red arrows = emergency stop and emergency off linking
Emergency stop and emergency switching-off functions
Depending on which plant activated an emergency stop or
emergency switching-off button, the plants switch to different
operating conditions.
The following tables provide an overview of the operating con-
ditions of the linked plants depending on which plant activated
an emergency stop or emergency switching-off button.

DESCRIPTION
Not assigned
Operating conditions after emergency stop
Emergency stop Operating condition of plant Operating condition of plant B

triggered A (upstream plant) (downstream plant)
Plant A: Components are switched off, Components are switched off, die-
diesel engine continues to run. sel engine continues to run.
Plant B: Components are switched off, Components are switched off, die-
diesel engine continues to run. sel engine continues to run.
Operating conditions after emergency switching-off
Emergency switch- Operating condition of plant Operating condition of plant B

ing-off triggered A (upstream plant) (downstream plant)
Plant A: Components and diesel engine Components are switched off, die-
are switched off. sel engine continues running1.
Plant B: Components are switched off, Components and diesel engine are
diesel engine continues to run. switched off.
1
Only with plants in the MCO EVO series. For linking with plants
in the MC EVO series, the diesel engine is switched off.
2.11 Not assigned
2.12 Water system

The spray system ensures a reduction in dust development at
the material transfer points on the plant. A low-pressure water
pump generates the necessary water pressure and volume flow.
Spray nozzles, which can be cut in and out individually, create
a finely atomised spray at the required points. The water drops
bind most of the dust particles, which then fall down.
The water system is cut in manually.
The spray system is usually sufficient to bind the dust created

during the crushing and screen procedure so that there is only
locally limited dust development. This restricts neither vision
at the plant nor the range of functions.
As dust development essentially depends on the type of stone
and weather, in special cases, e.g. when processing dry, brittle
material such as limestone, tiles/bricks or demolished con-
crete, increased dust formation is possible. Dust formation can
be reduced by the additional use of belt covers and ejector
chutes (special options) but not completely eliminated.
When processing demolished or cut asphalt, thorough cleaning
of the cooler fins must be carried out more frequently because
the dust created in this case tends to jam the cooler fins.

DESCRIPTION
Water system
2.12.01 Water pump
4
6
3
7
1
Fig. 2.68: Water pump
[1] Shut-off cocks [2] Fluid control

[3] Socket 230 V [4] Pump housing filling hose
closure
[5] Connection for suction [6] Connection for flooded
mode suction mode
[7] Prefilter
The multi-stage self-priming water pump is designed for suction
mode. In flooded suction mode, the spraying nozzles are sup-
plied directly with water.
The water pump forwards the drawn-in water via the fluid con-
trol to the individual feed lines for the nozzles. The fluid control
guarantees a constant pressure and prevents water running
back from the feed lines. The individual feed lines to the spray-
ing nozzles are opened and closed by shut-off cocks.
The water pump is switched on and off using the touch screen.
The water pump must first be connected to the 230 V socket.
Prerequisites for suction mode
• Clean water and water tank.
• Maximum length of suction line 5 m.
• Water pump must be filled with water prior to operation.
• Water must be directed through an intake filter before the
water pump.
Prerequisites for flooded suction
• Maximum pressure of supply line 4 bar.

DESCRIPTION
Water system
2.12.02 Spraying nozzles
Fig. 2.69: Spraying nozzles
[1] Spraying nozzles
Fig. 2.70: Shut-off cocks
[2] Shut-off cocks

The water directed via the shut-off cocks [2] and feed lines of
the spray system is distributed by the spraying nozzles [1] in
the form of a finely atomised spray.

DESCRIPTION
Not assigned
Spraying nozzles are fitted at the following points:

• Belt discharge
• Crusher inlet
• Crusher outlet
2.13 Not assigned
2.14 Not assigned
2.15 Not assigned
2.16 Not assigned
2.17 Not assigned
2.18 Lubrication system

Lubrication system operator panel
3
2
4 5 6
7 8
Pos.: Designation Function

[1] Pause LED Pause time
[2] LED display, 3-digit Operating status and values
[3] Contact LED Contact time display (pump operation)

DESCRIPTION
Lubrication system
Pos.: Designation Function

[4] Up/down button • Switch on display
• Display values and parameters
• Set values and parameters
[5] SET button • Switch between programming and display mode
• Confirm values
[6] 1 = CS LED Plunger detector system function monitoring, CS = Cy-
cle Switch
2 = PS LED
Pressure switch function monitoring, PS = Pressure
Switch
[7] DK button • Trigger intermediate lubrication
• Delete fault message
[8] Fault LED Error and fault message
Tab. 2.4: Operator panel
Crusher lubrication system
3
4
2
5
6
1
Fig. 2.72: Crusher lubrication system
[1] Pump element with pres- [2] Filling connection

sure relief valve
[3] Lubricant tank [4] Plunger detector
[5] Lubricant line from pump [6] Distributor
unit

DESCRIPTION
Lubrication system
Fig. 2.73: Crusher lubrication
[7] Connection points for

bearing/distributor
NOTICE
Changes to the settings of the lubrication system made by KL-
EEMANN GmbH can result in material damage.
The pump unit meters the lubricant and directs it via the main
line to the distributor. The lubricant is forwarded from the dis-
tributor to the downstream lubrication points. Metering of the
lubricant for the corresponding bearings is carried out in the dis-
tributor at the lubricant line connections. These connections
must not be interchanged.
A plunger detector monitors the distribution function and the
supply of the lubricant lines with lubricating grease. The supply
to the bearings is not monitored.
Malfunctions and faults in the lubrication system are displayed

in the operator panel of the lubrication system, as well as on
the touch screen. The warning light also lights up.
If lubrication pressure too high, lubricating grease is drained via
the pressure relief valve.
The distributor with plunger detector is located below the plat-
form between crusher and power supply unit.
Lubricant volumes and intervals are defined by the integrated
control system and must not be altered without consultation
with KLEEMANN GmbH.

DESCRIPTION
Lubrication system
Crusher lubrication points, see chap. 4.44.02.

DESCRIPTION
Not assigned
2.19 Not assigned
2.20 Not assigned
2.21 Not assigned
2.22 Not assigned
2.23 Not assigned
2.24 Not assigned
2.25 Not assigned
2.26 Not assigned
2.27 Not assigned
2.28 Not assigned
2.29 Not assigned
2.30 Not assigned
2.31 Not assigned
2.32 Not assigned
2.33 Not assigned
2.34 Not assigned
2.35 Not assigned
2.36 Not assigned

DESCRIPTION
Not assigned
2.37 Not assigned
2.38 Not assigned
2.39 Not assigned
2.40 Not assigned
2.41 Not assigned
2.42 Tools
Fig. 2.74: Tools and accessories
[1] Toolbox [2] Flap

DESCRIPTION
Tools
Fig. 2.75: Special tools
[3] Special tool for shim

change
[4] Lubrication system

grease gun
The toolbox [1] contains all tools and accessory parts required
for maintenance and repair work.
The toolbox is located behind the flap [2] on the right-hand
side.
The toolbox is secured with a padlock to prevent unauthorised
removal of tools.

DESCRIPTION
Feeding unit
The special tool for shim changing [3] is installed on the chassis
between crusher outlet and crawler running gear on the right in
direction of travel.
2.43 Feeding unit
2.43.01 Feed hopper
Fig. 2.77: Feed hopper
[1] Chassis [2] Wear lining for feed hop-

per
The feed hopper receives the material loaded by an excavator,
wheel loader or an upstream plant.
The feed hopper is integrated in the chassis and equipped with
bolted wear plates.

DESCRIPTION
Feeding unit
2.43.02 Hopper extension
4
5
3
6
Fig. 2.78: Hopper extension
[1] Hydraulic hopper wall [2] Mounting for hopper walls

locking
[3] Hopper wall, rear [4] Hopper wall, left
[5] Hopper wall, right [6] Hydraulic cylinder
9
5
10
3
7 11
Fig. 2.79: Hydraulic interlock/release
[3] Hopper wall, rear [5] Hopper wall, right

[7] Wedge [8] Hydraulic cylinder
[9] Mounting link [10]Hydraulic cylinder lock
and guard

DESCRIPTION
Feeding unit
[11]Locking pin with spring

pin
The hopper walls, [3], [4] and [5] can be folded by the auxiliary
hydraulic system and are actuated from the touch screen or the
local control. The hydraulic cylinders [6] are equipped with an
excess flow valve to secure the hopper walls when they are fold-
ed up and down.
When folded up, the left and right hopper walls [4] and [5] are
secured with the help of the hydraulic cylinder locks [10] and
the locking pin [11]. Additional support is provided by the hy-
draulic hopper wall locking elements [1] at the connecting
points of the hopper walls.
The hydraulic cylinder locks [10] are fastened with the help of
mounting links [9] and locking pins [11] to secure them against
swinging out.
The wear lining consists of welded wear plates.
2.43.03 Grizzly feeder
1 4
Fig. 2.80: Grizzly feeder
[1] Vibration motors [2] Wear lining

[3] Spring elements [4] Chute trough

DESCRIPTION
Feeding unit
Fig. 2.81: Vibration motors
[1] Electric motors 400 V [5] Unbalance weights

The grizzly feeder is a vibrating conveyor that conveys the ma-
terial loaded into the feed hopper by means of its oscillating
movement to a downstream machine. It separates the feed ma-
terial depending on the slotted grate or steel perforated plate
into two defined grain sizes.
The chute trough [4] is supported on vibrating elements [3] on
the chassis. The feeding surface and flanks are covered with a
wear lining [2].
The speed of the electric motors [1] can be controlled by the
frequency converter. By means of the adjustable unbalance
weights [5], they generate a periodic vibratory movement.
The two vibration motors rotate in opposite directions.
The steel perforated plate is bolted directly onto the vibrating

feeder.

DESCRIPTION
Crusher
2.44 Crusher
4
6
2 7
1
8
Fig. 2.82: Jaw crusher
[1] Fixed crusher jaw [2] Lateral wedges

[3] Articulated crusher jaw [4] Clamping wedge for artic-
ulated crusher jaw
[5] Flywheel [6] Belt pulley
[7] Crusher frame [8] Mounting
12
13
11
14
10
Fig. 2.83: Crushing gap setting
[9] Hydraulic cylinder and [10]Wedges

spring pack preloading
device

DESCRIPTION
Crusher
[11]Rocker [12]Securing elements for ar-

ticulated crusher jaw
[13]Crushing gap setting hy- [14]Pressure plate
draulic cylinder
The single toggle jaw crusher crushes charged material by
means of static pressure between the crushing jaws. A rocker
[11] mounted on the eccentric shaft effects the ellipsoidal
movement of the articulated crusher jaw [3]. The articulated
crusher jaw [1] on the opposite side is fixed to the crusher
frame [7]. The lateral wedges [2] form the side closure of the
crushing jaw.
The jaw crusher is driven directly by the power supply unit,
which transfers its power via a fluid coupling and V-belt onto the
eccentric shaft.
The crushing gap at the lower end of the crushing jaws is hy-
draulically adjustable. The hydraulic cylinders [13] displace the
wedges [10] and the lower part of the rocker is adjusted via the
pressure plate [14].
The spring packs of the preloading device [9] guarantee the se-
curity of the pressure plate [14] during operation.
The crushing gap is set at the touch screen. The gap displayed
is the theoretical gap with new crusher jaws. No allowance is
made for wear.
If the jaw crusher is overloaded by unbreakable material, the
pressure plate protect the jaw crusher against damage.
Continuous Feed System CFS (Option)
An ultrasonic sensor at the crusher inlet monitors the fill level
of the crushing jaw and, in the event of overfilling, reduces or
stops material conveying of the grizzly feeder. When the crush-
ing jaw is free again, material feed is switched on again without
delay.

DESCRIPTION
Screens
2.45 Screens
2.45.01 Grizzly feeder
2
4
1
5
Fig. 2.84: Grizzly feeder
[1] Vibration motors [2] Chute trough

[3] Slotted grate [4] Screen surface
[5] Screen outlet
The grizzly feeder serves as a process screen. It separates the
feed material into three defined grain sizes depending on the
screen surface used (perforated plate, slotted grate, wire cloth).
The chute trough [2] is mounted with vibrating elements on the
chassis.
Either steel perforated panels or a slotted grate [3] are secured
on the upper deck with the help of screws. On the lower deck,
screen surfaces [4] are clamped on with the help of clamping
systems.
Screening procedure
a) Upper deck covered with steel perforated panel or slotted
grate, lower deck covered with rubber screen surface:
• Coarse material that does not pass the upper deck of the
prescreen is conveyed directly into the crusher.
• Material that passes the upper deck is guided via the rub-
ber dummy screen surface and the bypass device past
the crusher directly onto the discharge chute and then
onto the crusher discharge conveyor.
This is used, for example, with clean feed material to supply
the entire feed material to the final product without having

DESCRIPTION
Screens
to dispense with the advantage of prescreening and thereby

relieving the burden on the crusher.
b) Upper deck covered with steel perforated panel or slotted
grate, lower deck with screen surface and change flap in
prescreen conveyor position:
prescreen is conveyed directly into the jaw crusher.
• Material that passes the upper deck but does not pass
the lower deck is guided via the bypass device past the
crusher directly onto the crusher discharge conveyor.
• Material that passes the lower deck of the prescreen is
discharged via the change flap onto the prescreen con-
veyor and then onto a stockpile or a downstream plant.
c) Upper deck covered with steel perforated panel or slotted
grate, lower deck with screen surface and change flap in by-
pass device position:
prescreen is conveyed directly into the jaw crusher.
deck is guided via the bypass device (8) past the crusher
directly onto the crusher discharge conveyor.
• Material that passes the lower deck of the prescreen is
directed via the change flap into the bypass device and
then onto the crusher discharge conveyor.
This is used to feed the entire feed material to the end prod-
uct without having to dispense with the advantage of pre-
screening and thus relieving the burden on the crusher.
d) Upper deck covered with dummy cover:
• The entire feed material reaches the crusher. Pre-
screening is not active.
Used for crushing hard rock if this achieves a more compact
crusher jaw filling.
In the standard equipment version, the upper deck is covered

with punched plates. The lower deck is covered with a rubber
dummy screen surface so that the entire material is guided
past the crusher via the bypass device.
Optional equipment
• Slotted grate in the upper deck.
• Steel perforated plate in upper deck.
• Dummy cover in upper deck.
• Wire cloth in lower deck.
• Dummy cover in lower deck.

DESCRIPTION
Options
2.46 Options
Options for the series K005 MC110R
This instruction manual describes all standard and optional
equipment. The following equipment is available as optional
equipment for this series:
Function group Designation See chap.

02 Operator's stand Local control 2.02.05
04 Power supply unit/Engine Heat package 2.04.07
Cold package 2.04.08
05 Hydraulic oil supply Hydraulic motor 2.05.04
06 Electrical system Heat package 2.06.07
Cold package 2.06.08
110 V socket 2.06.06
08 Drive system Track pads 2.08.01.01
10 Conveyor unit Magnetic separator 2.10.03
Extended crusher discharge convey- 6.02.08
or
Prescreen conveyor (2.7 metres) 6.02.06
Prescreen conveyor (5.0 metres) 6.02.07
Line coupling 2.10.04
18 Lubrication system Crusher lubrication system 2.18
43 Feeding unit Hopper extension 2.43.02
44 Crusher Continuous Feeding System (CFS) 2.44
45 Screens Slotted grate, steel perforated plate, 2.45
dummy plate, wire cloth and screen
cover

OPERATION
Options
3 OPERATION
This chapter describes how the plant and the individual ma-
chines and components are operated.
manual!

OPERATION
Operator panels/Interfaces
3.01 Operator panels/Interfaces
2 3
4 5 6 7 8 9 10 11
500
400
200
12

OPERATION

tor
[1] Emergency-off button Switches plant off in emergencies, see chap. 2.01.08
[2] Touch screen Interface for operating the plant and setting different
plant parameters, see description of "Touch screen"
[3] Rotary switch for radio re- Switches plant on/off via radio remote control
mote control
[4] Key switch for control volt- Switches plant control voltage on/off
age
[5] Acknowledge fault button Acknowledges faults and emergency stops
[6] Diesel generator ON button Switches diesel generator on
[7] Diesel generator OFF but- Switches diesel generator off
ton
[8] Start enable button Display and confirm start enable
[9] Plant ON button Switches plant on
[10] Plant OFF button Switches plant off
[11] Rotary switch for lighting Switches plant headlights on/off
[12] Voltmeter Displays the voltage between the phases with the main
switch activated
Tab. 3.1: Operator panel control elements

OPERATION
3.01.01 Touch screen
11:30
3 4
User: Kleemann
2
6
1 7
[1] Information and alarm [2] Situation-related operat-

message area ing and display area
[3] Static operating and dis- [4] User, date and time infor-
play area mation
[5] Operating elements and [6] Touch-sensitive surface
indicators
[7] Plant overview
If the touch screen does not display the operating mode selec-
tion window or the plant overview, you can tap on the touch
screen in the "Static operating and display area" to call up the
plant overview.

OPERATION
11:30 3
-
Line coupling
Overload speed 25
2 Speed 1 (minimal) 35
Speed 2 40
Speed 3 45
Speed 4 55 4
Speed without linie 55
E-Stop E-Stop
1 Linie Feeding Grizzly
On/Off
0.0 Hz 0.0 Hz
Fig. 3.3: Input field and display panel of vibrating feeder
[1] Display: Emergency stop [2] Display panel: Speed

and emergency switch- ranges of vibrating feeder
ing-off button actuated
(upstream plant)
[3] Display panel and input [4] LEDs (display of active
field: Speed of vibrating speed)
feeder
The touchscreen shows the current operating status and down-
stream plant information on the material flow of the plant in the
line coupling.
The speed (in Hz) of the vibrating feeder is indicated by a LED.
The speed of the individual speed ranges can be adapted to the
material requirement by increasing or decreasing the Hz figure.
The input value of a speed range always has to be greater than

the value of the previous speed range and less than the value
of the next speed range.
Example: Speed 2 equals 40 Hz and speed 4 equals 55 Hz.
• Speed 3 is maximum 54 Hz
• Speed 3 is minimum 41 Hz
The LEDs of the emergency stop and emergency switching-off

buttons display whether an emergency stop and/or emergency
switching-off button was activated for the downstream plant.

OPERATION
11:30
User: KLeemann
10
11
9 0 rpm 9
12
8
13
Fig. 3.4: Plant overview
[8] Submenu, spray system [9] Current operating dis-

or water system plays
[10]Display of machines and [11]Submenu and status of
components the components
[12]Jaw crusher submenu [13]Auxiliary hydraulics sub-
menu
Status displays for the machines and components
The plant overview displays the operating status of the individ-
ual machines and components with colours. The buttons are
also used for accessing the submenu of the respective machine
or component.
Button colour Operating status

Machine or component is switched off
Machine or component is switched on

and running

OPERATION
Button colour Operating status

Caution! Crusher is starting up
Caution! Machine or component is

starting up
Fault in machine or component
Tab. 3.2: Status displays
If the crusher is overloaded, the feeder trough and the grizzly

are turned down to 20 Hz by the frequency converter. The sta-
tus displays of the two machines then flash alternately yellow
and green.
Menu guidance
Language selection
System data
Language selection
for touch screen
Select user Edit settings
User administration
Edit settings
11:30
Time
Operating Current values of

status of com- the diesel genera-
ponents tor
Fault messag- View/edit informa-

es tion and fault mes-
sages
Progress / History Edit
Automatic Start/stop diesel

mode generator/plant

OPERATION
Manual mode Start/stop diesel Switch main switch

generator on/off
Driving mode Start/stop diesel Switch main switch Switch track drive
generator on/off on/off
Plant over- Call up compo- View/edit settings

view nents of individual com-
ponents (User: Op-
(can be called
erator)
up from every
page) Start/stop compo-
nent (only in man-
ual mode)
Track drive Start/stop diesel
generator
Switch main switch
on/off
Switch track drive
on/off
Spray system Switch water pump
on/off
Select/deselect au-
tomatic mode
Auxiliary hydrau- Switch auxiliary
lics hydraulics on/off
View hydraulic oil
level and tempera-
ture
Crusher gap set- Move wedge sys-
ting tem back and forth
Specified travel
Function and menu buttons
Button Function
Call up settings for touch screen, user,
language
Call up operating status of the diesel

generator
Call up fault messages
Call up automatic mode menu

OPERATION
Button Function
Call up manual mode menu
Call up driving mode menu
Switch component on/off
Select component or confirm selec-

tion, deselect component
Call up spray system or water system

menu
Call up auxiliary hydraulics menu
Call up crushing gap setting menu
Call up auxiliary drive
Call up fill level monitor menu
Call up pressure plate change menu
Call up diagnosis mode
Call up operating system of the touch

screen
Change settings
Call up menu for downstream plant. If

the socket outlet for a downstream
plant is occupied at the control cabi-
net, the status display switches to
green (for line coupling, see chap.
3.06)
Call up submenu of machines and
components. For operating status of
machines and components, see status
displays
Back to plant overview

OPERATION
Button Function
Scroll forward/back
Fade in/hide fault messages window
Call up history
Activate Autoscroll
Scroll all the way to the top or bottom
Gradually scroll to the top or bottom
Call up user administration
Carry out login or logout
.. .. Select display language

..
Displays and symbols
General symbols Explanation

Engine oil pressure
Engine oil temperature
Coolant level
Coolant temperature
Charge-air temperature
Diesel fuel tank fill level
Revolutions per minute

OPERATION
Measures before initial operation
General symbols Explanation

Electrical voltage
Actuated or selected
Not actuated or deselected
3.02 Measures before initial operation
DANGER
Danger due to unqualified personnel
Installation and initial operation by unqualified and unauthor-
ised personnel can result in serious or fatal injuries.
• Only assign personnel installation and initial operation
tasks who are qualified and authorised according to the re-
quirements in this instruction manual.
NOTICE
Foreign bodies in the plant, such as tools, accessories and
packaging materials, can result in malfunctions and material
damage.
• Following installation and prior to initial operation, search
the entire plant for foreign bodies and remove them.
During initial operation and after every transport, different

tasks and checks have to be performed.
» Completely install the plant, see chap. 6.02.
» Remove foreign bodies such as tools, accessories and pack-
aging materials from the plant.
Software and downloads
Before and at any time after initial operation you can update the
installed software of the PLC control and carry out downloads.

OPERATION
Putting the plant into operation
3.03 Putting the plant into operation
DANGER
Before the initial operation of the plant, the following items

must be checked:
Lubricating and • Oil level of the diesel engine (also refer to the manufactur-
operating materials er's documentation).
• Fill level of the coolant (see chap. 4.04.09).
• Fill level of the diesel fuel tank.
• Fill level of the water system, see chap. 3.10).
• Fill level of the lubrication system (see chap. 4.18.01).
• Check hydraulic oil level (see chap. 4.05.02.01).
• Lubrication of crusher bearings (see chap. 4.44.02).
• Lubrication of conveyor belt drives (see chap. 4.10.01).
Leak-tightness and • Check fuel supply for leaks.
condition • Check hydraulic oil supply for leaks.
• Leak-tightness of water system.
• Filling of the pump housing of the water system (see chap.
3.10).
• Leak-tightness of the lubrication system (see chap.
4.18.01.02).
• Condition of power supply unit.
• Condition of V-belt (see chap. 4.44.04).
• Condition of toothed belt (see chap. 4.04.05).
• Check condition of conveyor belts (see chap. 4.10.01.02).
• Check condition and presence of safety devices (see chap.
4.01.03).
• Check condition of screen surfaces, vibrating elements and
rubber profiles (chap. 4.45).
• Secure fitting of screw connections.
• Check condition and tension of crawler carrier chains.
• Check closure of all service doors and flaps.
• Check that crusher inlet cover is closed.
• Correct earthing of the plant, see chap. 4.06.04).
• Attaching the power plug (see chap. 2.06.06).

OPERATION
Automatic operation
Functions • Function of the emergency stop and emergency switching

off devices (see chap. 4.01.04).
• Function of the warning devices (see chap. 4.01.02).
• Check function of drive system and brakes (see chap. 3.07).
• Check conveyor belt running during material feed (see chap.
4.10.02.03).
Special care must be taken before long working periods or af-

ter a long downtime.
Top up lubricants and operating materials where necessary.
Maintenance schedule and operating material and lubricants
tables are provided in chap. 5.
3.04 Automatic operation
DANGER
Risk of falling material
Persons in the danger zone of the plant can be injured by fall-
ing material when the plant is started up.
• Do not enter the danger zone when the plant is being start-
ed up.
• Warn persons in the danger zone prior to starting the plant.
• Wear protective equipment.
In automatic operation, plant components are switched on au-

tomatically in the opposite direction of material flow. This pre-
vents material congestions when the plant is started up.
Before the plant components can be started, all emergency-

stop devices must be unlocked.
The position of emergency-stop devices that are not unlocked
is also displayed on the touch screen.
For unlocking of emergency-stop devices, also refer to chap.
2.01.08.

OPERATION
Automatic operation
Switching on the plant
4 5 6 7 8 9 10 11
Fig. 3.5: Switches and buttons on operator panel

» Unlock emergency stop of the radio remote control.
» Press the "Radio remote control on" button (see chap.
2.02.04) for 1 second.
» Switch on the "Radio remote control" [3] rotary switch.
» Switch on the "Control voltage" [4] key switch.
11:30
User: KLeemann
 The system and touch screen power up. The plant overview
is displayed. The warning siren sounds and the "Acknowl-
edge fault / emergency off" button flashes.
0 rpm
» Press the "Acknowledge fault / Emergency off" [5] button.

 If the emergency-stop or emergency-off buttons are no
longer pressed, the warning siren turns off.
» Press diesel generator "ON" [6] button and hold for 3 sec-
onds.
 The diesel generator starts up and the touch screen shows
the "Main switch" selection window.

OPERATION
Automatic operation
» First turn the main switch in the direction of (1) and then to
position (2).
2  The diesel generator "ON" button lights up. The "Start-up
enable" [8] button flashes.
» Press the "Start-up enable" [8] button as soon as the button

flashes.
 The "Start-up enable" [8] button flashes quickly and then
lights up continuously, the "Plant ON" [9] button flashes and
the warning siren sounds for approx. 7 seconds. Plant over-
view is displayed.
As soon as the button of the start-up enable illuminates con-

tinuously, the start-up enable is active for 60 seconds. If no ac-
tivity takes place within this time, the button flashes and must
be actuated again.
» Press the "Plant ON" [9] button.
 Magnetic separator and crusher discharge conveyor power
up in the opposite direction to material flow. The status dis-
plays light up green. The fluid coupling is filled and the
crusher starts up. The status display lights up blue. When a
defined speed is reached, the status display of the crusher
lights up green and the remaining plant components start up
automatically opposite to the material flow direction. The
status displays in the plant overview light up green. The
plant is switched on.
 The "Plant ON" [9] button flashes quickly during the filling
time for approx. 60 seconds and then lights up continuously.
» Press the "Spray system" button in the Plant overview.
11:30
User: KLeemann
 The menu for the water pump is opened.
0 rpm
If the "Automatic mode" ON button is pressed, the water

pump runs in automatic mode as soon as the plant is switched
on. The border of the button is green. If automatic mode is not
active, the water pump can be switched on manually. After
switching off the plant, the water pump runs for another 60
seconds and then switches off. Before activation of the water
pump, ensure that the water pump is filled with water.

OPERATION
Automatic operation
» If necessary, press the water pump ON button.

11:30:15
Wasserpumpe
p p
 The water pump runs and the border of the button is green.
I/0 Automatik
Automa
A t tik AUS
AUS 60 s
Automatik Modus
Switching off the plant
NOTICE
When plant components are switched off, material congestion
in the crusher is possible.
• Allow all plant components, in particular the crushers, to
run empty before switching them off.
» If necessary, press the water pump OFF button.

11:30:15
Wasserpumpe
sserpumpe
 The water pump switches off.
I/0 Automatik AUS 60 s
6
Automatik Modus
» Allow the plant and crusher to run completely empty.

» Press the "Plant OFF" [10] button.
 All plant components with the exception of the crusher are
switched off immediately. The crusher is switched off after
15 seconds. The "Start-up enable" [8] button and the "Plant
ON" [9] button go out. The status displays in the Plant over-
view go grey.
» Switch off main switch at control cabinet.
In order to guarantee the lubrication of the hydraulic coupling,

the diesel generator cannot be shut down until the rotor speed
has fallen below 60 rpm.

OPERATION
Automatic operation
» Press the diesel generator "OFF" [7] button.

 The diesel generator is switched off.
» Switch off the "Control voltage" [4] key switch.
 The plant is switched off.
» Actuate the emergency stop of the radio remote control.
 The radio remote control is switched off.
3.04.01 Switching on plant after emergency stop/emergency

switching off actuation
DANGER
ed up.
Switching plant on again after emergency stop

When the emergency stop function is tripped, all plant drives
with the exception of the diesel generator are switched off.The
plant then has to be switched on again.
Observe the run-after time of the crusher of approx. 60 sec-

onds following actuation of an emergency stop.
» Eliminate material congestions in the plant if necessary, see
chap. 3.12.
» Unlock emergency-stop button, see chap. 2.01.08.
» Press the "Acknowledge fault / emergency switching off" [4]
button.
 If no more emergency stop or emergency switching-off but-
tons have been pressed, the light in the button goes out. The
plant is ready to be switched on again.
» Switch the plant on again.
Switching plant on again after emergency switching off
After actuation of the emergency switching off button in the
switch cabinet, all plant drives including the diesel generator are
switched off straight away. The plant then has to be switched on
again.
» Eliminate material congestion in the plant if necessary, see
chap. 3.12.
» Unlock emergency switching off button, see chap. 2.01.08.
 The plant is ready to be switched on again.

OPERATION
Manual operation
» Switch the plant on again.
3.05 Manual operation
DANGER
Execution of "Manual mode" by unqualified and unauthorised
personnel can result in serious or fatal injuries.
• Only assign maintenance, repair and service tasks to per-
sonnel who are qualified and authorised according to the
requirements in this instruction manual.
NOTICE
Manual mode is not suitable for feeding the plant with materi-
al. Switching on individual plant components in manual mode
can result in material congestion.
• Do not feed material into the plant in manual mode.
• Check the current situation before switching on a plant
component.
Unlike automatic mode, the plant components are not automat-

ically switched on in manual mode in the opposite direction to
material flow.
After the diesel generator has been started, the plant compo-
nents can be switched on and off individually.
Switching on plant components in "Manual mode"
4 5 6 7 8 9 10 11

OPERATION
Manual operation
» Switch off rotary switch "Radio remote control" [3].

11:30

User: KLeemann
is displayed. The siren sounds and the "Acknowledge fault /
emergency off" button flashes.
0 rpm

 The "Diesel generator ON" [6] button flashes.
» Press the "Acknowledge fault / emergency off" button once
again if necessary.
 If no more emergency-stop or emergency-off buttons are
pressed, the light in the button goes out.
onds.
the main switch.
position (2).
2  The diesel generator "ON" button lights up. The touch screen
shows the switch and button sequence. The "Start-up ena-
ble" [8] button flashes.
» Press the "Automatic mode" button in the Plant over-

view of the touch screen.
 The operating mode selection window is displayed.
» Press the "Manual mode" symbol in the operating
mode selection window.
11:30
User: Kleemann
 The plant overview is displayed.

OPERATION
Manual operation
» Select desired plant component.

11:30
User: KLeemann
 The menu for the plant component appears. The touch
screen shows the info "Start-up enable".
0 %
75.0
75. 1500 rpm
» Press the "Start-up enable" [8] button.

 The "Start-up enable" [8] button flashes and the warning si-
ren sounds for approx. 10 seconds.
» Press Plant component ON as soon as the "Start-up en-
able" button lights up.
11:30:15
Brecherabzugsband
I/0 Ein- / -klap
Ein -klappen
klap
klap
kla
klappen / Aus-  The plant component starts up and the status display is
green.
» Select Plant overview to switch on further plant compo-

nents.
 The plant overview appears.
» Start desired plant component or components as described.
 The status displays of the started components are green.
Crusher: The fluid coupling is filled and the crusher starts
up. The "Plant ON" [7] button flashes quickly during the fill-
ing time for approx. 60 seconds and then lights up continu-
ously.
The "Start-up enable" button be lit to start a plant component.

Press the "Start-up enable" button once again if necessary.
» If necessary, make settings for the plant component.
Settings for the plant components can only be made if you

have the corresponding user rights.

OPERATION
Manual operation
Switching off plant components in "Manual mode"
NOTICE
Danger of material damage
Switching of the plant or the diesel generator via the emergen-
cy-off button causes lubrication of the hydraulic coupling to
stop and results in bearing damage.
• Never switch off the plant or diesel generator with the
emergency switching off button.
• Always switch off the plant or diesel generator via the but-
tons on the operator panel.
» Select Plant overview to switch off individual plant com-

ponents.
» Select desired plant component.
11:30
User: KLeemann
 The menu for the plant component appears.
0 %
75.0
75. 1500 rpm
» Press plant component OFF button.

11:30:15
Brecherabzugsband
 The plant component is switched off. The status display is
I/0 Ein-
Ein-
Ein
i / -klap
-klappen
klap
pppe
pen
en / Aus- grey.

OPERATION
Manual operation
4 5 6 7 8 9 10 11

» To switch off the entire plant, press the "Plant OFF" [10] but-
ton.
 All plant components are switched off immediately. The
"Start-up enable" [8] button and the "Plant ON" [9] button
go out. The status displays in the Plant overview go grey.
To guarantee the lubrication of the fluid coupling, the diesel

generator cannot be shut down until the speed of the coupling
has fallen below 200 rpm.
» Press the diesel generator "OFF" [7] button.
 The diesel generator is switched off.
» Switch off the "Control voltage" [4] key switch and remove
the key.
 The plant is switched off.

OPERATION
Line coupling
3.06 Line coupling
3.06.01 Perform test routine for line coupling
The test routine of a line coupling must be performed at each

individual plant. The plants cannot be locked during the test
routine. The test routine runs automatically and checks the
sent and received signals.
The test routine checks the function of the plant. However,
malfunctions between two or more plants may be caused by
other factors such as faulty fill level probes, incorrect settings,
etc.
The line coupling must be selected for performing the test rou-
tine. The diesel generator is not started.
4 5 6 7 8 9 10 11

» Switch off rotary switch for the radio remote control [3].
11:30
User: KLeemann
is displayed. The warning siren sounds and the "Acknowl-
edge fault / emergency off" button flashes.
0 rpm

 The "Acknowledge fault / Emergency off" and the "Diesel
generator ON" [6] buttons flash.
» Do not start diesel generator.

OPERATION
Line coupling
» Press the "Acknowledge fault / Emergency off" [5] button

again.
» Press the "Manual mode" symbol in the operating
11:30
User: Kleemann
» On the touch screen, press the downstream plant button.

11:30
User: KLeemann
 The line coupling touch screen displays "Line ON / OFF" .
5..0 %
75.
7 5 0 rpm
» Press "Line ON/OFF" button.

 The touch screen displays "Line ON / OFF"
» Press the "Menu back" button.
 "Line coupling selected" is displayed in the plant over-
view.
» Press the button.
11:30
User: KLeemann
0 rp
rpm
pm
» Press "Menu forward" button in the Plant overview.

 The start screen of the system is displayed.

OPERATION
Line coupling
» Press the Line I/0 button in the start screen of the line coupling
test.
11:32:25
-
System
CAN Werkseinstellung
M258 I/0 Line I/0
Parameter
» Press "Settings" button on the touch screen.

 The "Test line coupling" touch screen is displayed.
The display of the "Test line coupling" touch screen is shown

as an example.
11:32:25
-
Test line coupling

XS_IN 2 4 6 8 10 12
XS_OUT 2 4 6 8 10 12
Fig. 3.9: Line coupling test
At the start of the line coupling test only the inputs and outputs
up to 12 are displayed. All inputs and outputs are displayed af-
ter the end of the line coupling test. The displays at the end of
the line coupling test provide information on whether the line
coupling is OK.
If there is a fault with one or several inputs and/or outputs,
this is displayed at the corresponding input and output.

OPERATION
Line coupling
» Press "Test ON" button.

11:32:25
-
 The test starts and the touch screen changes the display.
Test Linien Kopplung
XS_IN 2 4 6 8 10 12
XS_OUT 2 4 6 8 10 12
11:32:25
-
Test line coupling

XS_IN 2 4 6 8 10 12
XS_OUT 2 4 6 8 10 12
Fig. 3.10: Line coupling test ON

» Performing request to "Insert line coupling cable"
The line coupling cable is the cable which links two plants.

OPERATION
Line coupling
Fig. 3.11: Line coupling sockets
[1] Socket of upstream plant [2] Socket of downstream

XS_IN plant XS_OUT
» Insert line coupling cable connector into the corresponding
sockets at the control cabinet.
 The request to "Press emergency-stop button on the chas-
sis" is displayed.
Emergency stop and emergency switching off on the
plant
1 2 3 2
Fig. 3.12: Emergency stop devices on the plant and remote

control

OPERATION
Line coupling
[1] Emergency-stop button [2] Emergency-stop button

on the remote control on the plant
[3] Emergency switching off
button on the operator's
stand
» Press any emergency stop button [2] on the chassis.
 The request to "Press emergency switching-off button on the
control cabinet" is displayed.
» Actuate the emergency switching-off button [3] on the con-
trol cabinet.
 The line coupling test starts and runs automatically.
» Press the "Acknowledge fault / Emergency Off" button.
11:32:25
-
Test line coupling

XS_IN 2 4 6 8 10 12
CAN
M258 I/0
XS_OUT 2 4 6 8 10 12
Fig. 3.13: Line coupling test active

OPERATION
Line coupling
11:32:25
-
Test line coupling

XS_IN 14 16 18 20 22 24
XS_OUT 14 16 18 20 22 24
Fig. 3.14: Line coupling test active
In the line coupling test outputs/relays are switched and

checked to see whether the signal arrives at the right input
without any interference.
• = Output (no error)
• = Input
Following the line coupling test the touch screen displays

whether the line coupling is OK or NOT OK.
» Acknowledge display on the touch screen "Line coupling OK
or NOT OK".
 The touch screen shows the result of the line coupling test.

OPERATION
Line coupling
11:32:25
-
Test line coupling

XS_IN 14 16 18 20 22 24
XS_OUT 14 16 18 20 22 24
Fig. 3.15: Line coupling OK

All inputs and outputs have the OK symbol :
• Inputs and outputs are correctly wired.
• Relays function properly.
• Line coupling cable is correctly wired.
» If all inputs and outputs do not have the OK symbol, see
chap. 3.17.04, the plant must not be integrated in a line
coupling.
» Press the "Plant overview" button.
 Actuated emergency stop buttons and emergency switch-
ing-off buttons are displayed.
 "Line coupling selected" is displayed in the plant over-
view.
» Press "Line coupling selected" button.
 The touch screen displays "Line ON / OFF" .
 The touch screen displays "Line ON / OFF" .
» Deactivate control voltage key.
» Unlock emergency stop button on the chassis and emergen-
cy switching-off button at the operator's stand.

OPERATION
Line coupling
» Unplug line coupling cable and close sockets with the protec-
tive covers.
Test intervals of line coupling:

• First time during initial operation of line coupling.
• After every fault.
• After every relocation of the plant or plant linkage.
3.06.02 Adjusting the line coupling
The aim of line coupling is to ensure that the crusher of a plant

in a plant linkage does not run empty or overflow at any stage
and shut down as a result.
In the line coupling menu, the parameters of the various speed
ranges can be adapted to the information of the downstream
plant.
The settings of the individual parameters for an optimal mate-
rial flow can only be made during an operational process. The
line coupling must be switched on.
In the case of initial operation, after every fault or relocation
of the plant linkage the test routine must be carried out be-
forehand for every plant, see chap. 3.06.01.
The setting of the parameters of an upstream MC EVO are de-
scribed below.
Setting up the line The plants in a plant linkage must be correctly linked using a
coupling line coupling cable.
Fig. 3.16: Line coupling sockets
[1] Socket of upstream plant [2] Socket of downstream

XS_IN plant XS_OUT

OPERATION
Line coupling
» Insert line coupling cable for the downstream plant in socket

[2] XS_OUT.
» Insert line coupling cable for the downstream plant in the
corresponding socket XS_IN.
» Link all plants in a plant linkage accordingly.
 The line coupling is set up.
Starting the line coupling » Start all plants in automatic mode, see instruction manual of
the respective plant.
 The touch screen displays the plant overview in automatic
mode.
When starting the line linkage always start with the last down-
stream plant.
11:32:25
-
0 rpm
Fig. 3.17: Anlagenübersicht Linienkopplung EIN

» Ensure that the line coupling is active, if necessary switch
on line coupling.
Switching on line » On the touch screen press the "Downstream plant" but-
coupling ton.
 "Line coupling" is displayed on the touch screen.
 The touch screen displays line coupling "ON/OFF"
» Ensure that "Line coupling active" is displayed in the plant
overview.

OPERATION
Line coupling
Starting the crushing operation
The crushing operation should be started with the standard pa-

rameters preset by the factory, and adjusted if necessary dur-
ing the operational process.
Adjusting the line » Press "Line coupling active" button in the Plant overview.
coupling  "Line coupling" is displayed on the touch screen.
The parameters of the vibrating feeder are displayed.
11:30
-
2
Linienkopplung
Overload speed 25
Speed 1 (minimal) 35
Speed 2 40
Speed 3 45
1 Speed 4 55 3
Speed without linie 55
E-Stop E-Stop
Linie Aufgabe Vorsieb
Ein/Aus
0.0 Hz 0.0 Hz
Fig. 3.18: Input field and display panel of vibrating feeder
[1] Display panel: Speed [2] Display panel and input

ranges of vibrating feeder field: Speed of vibrating
feeder
[3] LEDs (display of active
speed)
Tap the display panel and input field [2] to open the numeric
keypad for inputting the speed of the vibrating feeder for the
respective speed range.
The possible value of a speed range to be entered is predefined
by the value of the speed before and after.
The speed ranges 4 and speed without line (55 Hz), which are
preset at the factory, are not reduced.

OPERATION
Line coupling
• Speed 4 guarantees quick filling of the crusher.

• Speed without line is intended for operation outside the
plant linkage.
Speed Lowest value (Hz) Highest value (Hz)

Speed without line = 55 = 55
Speed 4 > Speed 3 = Speed without line
Speed 3 > Speed 2 < Speed 4
Speed 2 > Speed 1 < Speed 3
Speed 1 > Speed in the event < Speed 2
of an overload
Speed in the event of an overload = 25 < Speed 1
After all plants of the plant linkage have been started, the
feeding unit may be started. The downstream plant sends the
signal "Speed 4" to the upstream plant. The vibrating feeder
switches to speed 4 and conveys at the preset speed. (Prereq-
uisite: Crushers are empty)
» Observe material flow and operating conditions of the
plants.
Procedure for adjusting the upstream and downstream
plant of the line coupling
• Vibrating feeder conveys at speed 4 and fills the crusher.
• Crusher of downstream plant is filled at speed 4.
• CFS (Continuous Feed System) monitors the fill level of the
crusher.
• Crusher fill levels of the upstream and downstream plants
increase continuously = Speed 4 too high.
• Upstream and downstream plants switch to speed 3.
• Crusher fill levels of the upstream and downstream plants
are constant = Speed 3 is OK.
• Crusher fill level of the downstream plant reduces at preset
speed 3 = Speed 3 of upstream plant is too low.
» Tap the display panel and input field "Speed 3".
 The numeric keypad is opened.
» Enter and confirm new speed. Higher value must be < speed
4.
 The crusher is filled at higher speed 3.
• Crusher fill level of downstream plant is constant = Higher
speed 3 is OK.
• Crusher fill level increases continuously at preset speed 3 =
Preset speed 3 is too high.
» Adjust speed 3 to the lowest value as described. The value
must be > speed 2.

OPERATION
Operating the plant
• Crusher fill level of downstream plant reduces = Reduced

speed 3 is too low.
» Gradually increase speed 3 again until the crusher fill level
of downstream plant is virtually constant.
• Crusher fill level of downstream plant increases continuously
at lowest speed 3 = Lowest speed 3 is too high.
• Upstream and downstream plants switch to speed 2.
• Crusher fill level constant = Speed 2 is OK.
» If necessary, adjust speed ranges 2 and 1 according to the
description for speed 3.
In an ideal situation the plant runs between the speed ranges

2 and 3.
Irrespective of the downstream plant information, the up-
stream plant determines how much material it is able to sup-
ply.
If the upstream plant regularly runs at "Speed in the event of
overload", it must be clarified why the downstream plant
switches to no delivery.
Possible causes:
• Crushing gap is too small (process engineering)
• Incorrectly set or adjusted crusher fill level probe.
3.07 Operating the plant
DANGER
Danger of being run over
Tracked plants can cause serious or fatal injuries.
• Before moving the plant, ensure that there are no persons
in the driving area.
• Use banksmen and/or flagmen to monitor the driving area.
• Keep a safe distance away from the crawler running gear
when the plant is moving.
3.07.01 Preparations
The plant can also be moved with all components installed.

OPERATION
Operating the plant
NOTICE
Danger of material damage when driving
Crawler carrier chains can freeze up and seize up and break
when driving off.
When the plant is moved and turned, untensioned crawler car-
rier chains can spring off the sprocket and cause damage to
the crawler running gear.
• Do not drive the plant with frozen or rusted crawler carrier
chains.
• Move the plant every day approx. 10 metres to prevent
freezing up and seizing up due to rust.
• Check the tension of the crawler carrier chain before mov-
ing and tighten it if necessary.
Prior to moving the plant, a few preparatory measures must be

carried out:
» Run all components, such as hopper, crusher and belt con-
veyors, until they are emptied of all material.
» Remove the earthing rod.
» Detach ladders to the platforms or fold up the bottom part
of the steps.
» Remove stones and adhering dirt from the running wheels
and crawler carrier chains of the crawler running gear.
» Check the tension of the crawler carrier chains and tighten
them if necessary.
» Check driving path and ground and remove obstacles if nec-
essary.
» Observe ground clearance of the plant.
» Appoint banksman/banksmen.
 The plant is ready to be moved.
Moving plant on ascending slopes and downward slopes
DANGER
Danger of plant toppling
Persons in the driving range of the plant can sustain serious or
fatal injury.
• Keep a safe distance away from the plant when it is mov-
ing.
• Only move the plant within the specified inclination values.

OPERATION
Operating the plant
NOTICE
Driving on downward and ascending slopes subjects the com-
ponents of the crawler running gear to very high loads.
• When driving on gradients, always ensure that the track
drive of the crawler running gear faces downhill.
• Drive carefully on slopes and always directly upwards or
downwards.
• Avoid driving in transverse direction on downward slopes.
17
Fig. 3.19: Ascending slopes and downward slopes
[1] Track drive

» Fill diesel fuel up to approx. ¾ of the maximum fill height so
that the diesel engine does not stall on ascending or down-
ward slopes.
» Before driving off on ascending and downward slopes, align
the plant at right angles to the slope.
» Ensure the track drive [1] is facing downhill.
» Start driving on the slope.

OPERATION
Operating the plant
3.07.02 Driving
DANGER
Danger due to blind spots
Persons who are not in the visible driving range of the plant
can sustain serious or fatal injury.
• Use banksmen and flagmen to monitor the driving area.
• Maintain continuous visual contact with banksmen and
flagmen.
• In dangerous situations, stop the plant immediately.
WARNING
Danger due to plant starting up
Upon activation of the operating mode "Move the plant" when
the levers are released, there is a risk of fatal injury by uncon-
trolled start-up of the plant.
• Before activation of the drive control, ensure that the le-
vers are at zero.
WARNING
Danger due to unlit travel paths
Due to the unlit travel paths, there is an increased risk of inju-
ry.
• Before moving the plant, ensure that sufficient lighting of
the travel path is available.
Moving using the radio » Ensure that the levers of the radio remote control are at ze-
remote control ro. If necessary, move the lever to zero.
» Ensure that the travel path of the plant is flat and firm.
» If necessary, provide sufficient lighting for the travel path.
» Unlock all emergency-stop buttons on the plant.
» Press the "Radio remote control ON" button for 1 second
(see chap. 2.02.04).

OPERATION
Operating the plant
4 5 6 7 8 9 10 11

11:30
User: KLeemann
0 rpm

onds.
the main switch.
position (2).
2  The diesel generator "ON" [6] button lights up.

OPERATION
Operating the plant

» Press the "Driving mode" button in the operating
11:30
User: Kleemann
 The driving mode menu and the info press "Start-up enable"
button is displayed.

11:30:25
Fahrsteuerung
 The touch screen shows the drive control. The Start-up en-
I/0 1500 rpm able [8] button lights up.
28.00 V
» Press the Drive system on button.

11:30:25
Fahrsteuerung
 The drive system starts up with a delay of approx. 4 sec-
I/0 1500 rpm onds. The plant is ready to be moved.
28.00
28
28.0
8.000 V
The crawler carrier chains start moving after actuation of the

two levers of the drive control. The left lever is for the left
crawler carrier chain, the right lever for the right crawler car-
rier chain.
The crawler carrier chains always move in the direction in
which the lever is moved. The speed changes proportionate to
the deflection of the levers.
Driving with wired » Ensure that the levers of the radio remote control are at ze-
remote control ro. If necessary, move the lever to zero.
» Ensure that the travel path of the plant is flat and firm.
» Unlock all emergency-stop buttons on the plant.

OPERATION
Operating the plant
4 5 6 7 8 9 10 11

» Insert radio remote control with corresponding cable in the
socket at the receiver in the control cabinet (see chap.
)2.06.06.
» Press the "Radio remote control ON" button for 1 second
(see chap. 2.02.04).
4 5 6 7 8 9 10 11


OPERATION
Operating the plant

11:30
User: KLeemann
0 rpm

onds.
the main switch.
position (2).
2  The diesel generator "ON" [6] button lights up.

» Press the "Driving mode" button in the operating
11:30
User: Kleemann
 The driving mode menu and the info press "Start-up enable"
button is displayed.

11:30:25
Fahrsteuerung
 The touch screen shows the drive control. The "Start-up en-
I/0 1500 rpm able" [8] button lights up.
28.00 V

OPERATION
Operating the plant
» Press the Drive system on button.

11:30:25
Fahrsteuerung
 The drive system starts up with a delay of approx. 4 sec-
I/0 1500 rpm onds. The plant is ready to be moved.
28.00
28
28.0
8.000 V
The crawler carrier chains start moving after actuation of the

two levers of the drive control. The left lever is for the left
crawler carrier chain, the right lever for the right crawler car-
rier chain.
The crawler carrier chains always move in the direction in
which the lever is moved. The speed changes proportionate to
the deflection of the levers.
3.07.03 Shutting down the plant
NOTICE
Increased wear
The plant can only operate correctly on flat ground. Inclina-
tions in the longitudinal and transverse axis result in reduced
crushing capacity, one-sided wear and material congestion.
• Move the plant to align it on flat ground.
Spirit levels installed at the plant allow the precise alignment

of the plant. The spirit levels are installed in the control cabinet
housing.

OPERATION
Operating the plant
Fig. 3.23: Shutting down the plant
[1] Spirit level for longitudi- [2] Spirit level for transverse
nal axis axis
» Park the plant on a flat and stable surface and align using
the spirit levels.
4 5 6 7 8 9 10 11

» In the "Drive control" menu of the touch screen, press the
"Drive system" symbol.
» Press the diesel generator "Off" [7] button.
» If applicable, switch off the "Radio remote control" [3] rotary
switch.
» Switch off the "Control voltage" [4] key switch.
» Press the emergency stop button on the remote control.
 The remote control is switched off and the plant is ready
again for automatic mode.
» Correctly earth the plant before initial operation. Earthing
the plant, see chap. 6.02.03.

OPERATION
Refuelling the plant
3.08 Refuelling the plant
WARNING
Risk of explosion
When refuelling the plant, the is a risk of explosion due to
charge accumulation. An explosion can result in serious or fa-
tal injury.
• Earth the dispensing system.
• Establish potential equalisation between dispensing system
and plant.
• Check and ensure that the dispensing system complies
with applicable standards on refuelling.
Fig. 3.25: Refuelling the plant
[1] Filler neck
Before the plant is refuelled, ensure that the dispensing sys-

tem is correctly earthed and plant potential equalisation has
been created.
Correct potential equalisation exists if a continuous electrically
conductive connection is present between all components of
the dispensing system and the plant to be refuelled.
Creating potential » Fit a connecting cable between dispensing system and chas-
equalisation sis.
» Ensure that all components of the dispensing system have a
continuous electrically conductive connection.
 Potential equalisation is established.

OPERATION
Switching cold package on and off
Earthing dispensing » Establish the earth connection between tank of dispensing

system system and the ground.
 Dispensing system is earthed.
» Position the tanker or dispensing system as close as possible
to the filler neck.
» Take off the end cover of the filler neck.
» Fill the plant's fuel tank.
» Close the filler neck again.
 The level of the diesel fuel rank is displayed on the touch
screen.
» Remove connection of potential equalisation between dis-
pensing system and chassis.
» Remove the earth connection between tank of dispensing
system and the ground.
3.09 Switching cold package on and off

Preparatory measures must be taken before the cold package is
switched on:
» Set ambient temperature at the thermostats in the switch
cabinet to the desired value.
» Establish the electrical connection for operating the cold
package with the aid of the diesel generator or an external
power source.
Setting ambient temperature
2 3
1 4
Fig. 3.26: Switch cabinet heating

OPERATION
[1] Thermostat, switch cabi- [2] Heating element, switch

net cabinet
[3] Heating element, switch [4] Thermostat, switch cabi-
cabinet, touch screen net, touch screen
Setting control cabinet » Fold up flap of control cabinet protective housing.

ambient temperature
» Switch off diesel engine. Switch off and remove battery iso-
lator and carry it with you.
» If necessary, disconnect external power supply.
DANGER
Danger of electric shock
Incorrect work inside the control cabinet can result in life-
threatening situations.
• Maintenance, repair and service work on the electrical sys-
tem must only be carried out by qualified and authorised
personnel.
» Open control cabinet doors.

» Set thermostat [1] to the desired ambient temperature.
 The heating elements [2] switch on and off automatically at
a defined ambient temperature.
» Open the control cabinet door of the operator panel and the
touch screen on the reverse side of the left control cabinet
door.
» Set thermostat [4] to the desired ambient temperature.
 The heating element [3] switches on and off automatically
at a defined ambient temperature.
» Close the control cabinet door of the operator panel and the
touch screen.
» Close control cabinet doors.
 The ambient temperature of the control cabinet heaters is
set.
» Insert battery isolator and switch on.

OPERATION
8 7
Fig. 3.27: Voltage supply, cold package
[5] Control lamp [6] Rotary switch for switch-

ing cold package on and
off
[7] Connection for internal or [8] Connection for internal or
external power supply external power supply
(NE-MA6-20 20 A) (CEE 32 A)
The connection [7] can only be used for an external power

supply with connector NE-MA6-20 20 A.
Switching on the cold » For internal power supply by the diesel generator, connect
package the connector [8] at the service socket on the control cabi-
net.
» For the external power supply, connect the connector [8] to
the external power source.
» Turn rotary switch [6] to "I" position.
 With the diesel generator running the control lamp lights up
and the corresponding plant components are heated.
Switching cold package » Turn rotary switch [6] to "0" position.
off  The cold package heating elements are switched off. The
control lamp goes out.
» If necessary, switch diesel generator off.

OPERATION
Operating the water system
3.10 Operating the water system
NOTICE
Operation without water and operation with contaminated or
frozen water destroys the water pump.
• Always ensure there is a sufficient water supply.
• Only use clean water that is not frozen.
• If there is a risk of frost, completely drain the water sys-
tem.
In order to guarantee fault-free suction mode, the pump hous-

ing and the intake hose must be filled with water prior to
switching on. Use intake hose with check valve from chassis to
point of use.
» Ensure the prerequisites for operating the water system
have been fulfilled, see chap. 2.12.
Fig. 3.28: Filling the water pump
[1] Closure for filling hose [2] Pump housing
Filling the pump housing » Remove the closure [1] of the filling hose.
» With a suitable tool, e.g. watering can, to fill the pump hous-
ing and the intake hose with water as far as the connection
for suction mode. Connection for suction mode, see chap.
2.12.
» Fit closure [1].
» Fill intake hose with check valve with water as far as point
of use.

OPERATION
Loading the plant
» Install intake hose at the connection for suction mode.

 The water pump can be put into operation.
» Switch on the plant in automatic operation (see chap. ) or
manual operation (see chap. ).
» Open or close the corresponding shut-off cocks of the supply
lines to the spraying nozzles.
» Press the "Spray system" symbol in the plant overview
of the touch screen.
 The water system sprays mist at the relevant points.
Switching off water » Press the "Menu back" button.
system  The plant overview appears.
» Select spray system.

 The menu for the spray system appears.
» Press water pump OFF button or, in automatic mode, de-
select the water pump.
» Close the corresponding shut-off cocks of the supply lines to
the spraying nozzles.
 The water system is switched off.
3.11 Loading the plant
DANGER
Danger due to loading vehicles
During loading of the plant, there is a risk of fatal injury
through active wheel loaders and diggers as well as falling ma-
terial.
• Do not enter the danger zone during loading.
• Warn persons in the danger zone prior to the start of plant
loading.
• Stay clear of the plant during loading and operation.
3.11.01 Suitable loading vehicles
NOTICE
The use of unsuitable loading vehicles and devices can result
in damage to the plant components.
• Do not load the plant with lorries, dumpers or skip lorries.
• Do not load the plant with digger shovels or buckets that
are too small or too large.

OPERATION
Loading the plant
Correct loading of the plant is possible with diggers with shovels

or buckets or upstream crushing and screening plants. With a
suitable hopper attachment (option), the plant can also be load-
ed with a wheel loader.
Requirements of loading vehicles
• Sufficient loading capacity of the shovel or bucket of the dig-
ger, which is matched to the plant size and the charged ma-
terial.
• Wheel loader suitable for the plant size and charged materi-
al.
The loading of unhomogeneous materials and materials for
selection, such as reinforced demolished concrete, with a
wheel loader leads to reduced availability and increase plant
wear.
• Sufficient lifting height of shovel or bucket.
• Stability of the wheel loader or digger.
If necessary, suitable ramps and raised bases must be prepared
for the loading vehicles.
The plant can also be loaded via a belt conveyor provided it has
the required discharge height.
Requirement of ramps and bases
• Correct compaction of ramps and bases.
• Clear view into the feed hopper.
• Secured against lateral slipping.
• Accumulated material for ramps or bases must not cover
plant components.
• No risk of collisions between the plant and loading vehicles.
3.11.02 Preparing the charged material

Well prepared charged material permits optimum use of the
plant, reduces wear on the individual machines and components
and guarantees trouble-free operation.
Requirements of the charged material
• Do not exceed the specified size, length of the edge and
compressive resistance of the material, see chap.
5.01.01.04.
• Select the feeding size to match the final grain and the max-
imum crushing ratio.
• Never load unbreakable material, e.g. steel girders.
• Never load pressure vessels, explosives, chemicals or simi-
lar materials.
• Shorten reinforcing steel in demolished concrete to less than
one metre.

OPERATION
Loading the plant
Exceeding the size, length of edge and compressive resistance

of the material results in material congestion and damage to
the crusher and material conveying components. Furthermore,
the crushing capacity is considerably reduced.
3.11.03 Loading the feed hopper
1 1
Fig. 3.29: Loading the feed hopper
[1] Maximum loading height [2] Layer height and material

flow
Correctly loaded material permits an optimum material flow,
good primary screening results and avoids material conges-
tions.
• Load material at regular intervals and in approximately
equal quantities into the feed hopper.
• Do not fill the feed hopper higher than the hopper edge. En-
sure that no material falls over the hopper walls. Use of a fill-
ing cone is possible.
• Where possible, ensure that a material bed always remains
in the feed hopper and trough. Recurrent loading of the
empty feeder trough can result in deformation and increased
wear of the drive and also leads to avoidable noise pollution.
• Make sure that the material flow and layer thickness in the
feeder trough are even.

OPERATION
Loading the plant
NOTICE
If the range of the radio remote control is exceeded, the emer-
gency stop is tripped and material congestion in the plant can
result.
• During plant operation, ensure that the range of the radio
remote control is never exceeded.
• Never carry the radio remote control along in the wheel
loader or digger and thus leave the range.
• Always ensure there is visual contact between transmitter
and receiver.
• Store the radio remote control in the plant's switch cabinet
housing when not in use.
3.11.04 Loading the jaw crusher
DANGER
Danger due to yielding gap setting device
Risk of fatal injury through sudden retraction of the gap setting
device or breaking of the pressure plate due to overloading.
• Stay clear of the danger area of the gap setting device dur-
ing crusher operation.
Fig. 3.30: Loading the jaw crusher
[1] Fill level of the jaw crush- [2] Oversized charged mate-
er rial
[3] Crushing ratio

OPERATION
Loading the plant
Correctly loaded material permits optimum utilisation of the

crushing capacity and avoids material congestions.
• The optimum fill level of the jaw crusher up to the chamfers
of the crushing jaws must not be exceeded.
• Do not exceed the maximum size and length of the edge of
the charged material.
• Do not exceed the maximum size ratio of charged material
and final grain, see table.
• Ensure that the material flow to the jaw crusher is even.
Crushing ratio = ratio of feeding size to desired final grain size.
Charged material Crushing ratio

Hard rock 1:4 - 1:5
Softer materials and recycling mate- up to 1:7
rial
Tab. 3.3: Crushing ratio
The main influences on the optimum loading of the jaw crusher

are loading of the feed hopper, an even material flow and the
setting of the crushing gap.
Overloading of the jaw crusher with unbreakable material can
result in damage to the pressure plate.
» Following material congestion in the jaw crusher, check the
pressure plate for deformation and damage.
» Replace pressure plate if necessary, see chap. 4.44.08.06.
NOTICE
Continuous overfilling of the jaw crusher results in premature
wear and can cause damage to the pressure plate.
• Ensure that loading of the jaw crusher is correct.
NOTICE
Non-original pressure plates do not meet the overload protec-
tion requirements. Damage to the jaw crusher may result and
the warranty is voided.
• Only use original pressure plates from KLEEMANN.

OPERATION
Eliminating material congestion
3.12 Eliminating material congestion
DANGER
Danger due to material congestion
Intervention in the running plant, in particular, in the running
or coasting crusher, can result in serious or fatal injury.
• Eliminate material congestion when the plant is not run-
ning.
• Do not climb on vibrating conveyor troughs and screens
that are running.
• Never open service doors and flaps when the plant is run-
ning.
• Allow the crusher to coast to a complete standstill.
• Switch off diesel generator and control voltage.
• Lock main switch.
• Switch off battery isolator, remove key and carry it with
you.
• Attach appropriate warning sign in a clearly visible area.
• Wear personal protective equipment.
Material congestions can have different causes:

• Settings that do not match the plant, for e.g. delivery speed
of feeder trough is too high.
• Crushing jaw gap width too small.
• Unsuitable screen mesh size.
• Maximum feeding size is exceeded.
• Feeding of unbreakable materials, e.g. steel girders or pipes.
• Feeding of reinforced concrete with long protruding reinforc-
ing steel.
Material congestions can occur at different points of the mate-
rial flow:
• At the crusher inlet due to blockages before the crushing
jaw.
• Crusher standstill through jamming of unbreakable material
between the crushing jaws.
• At the crusher outlet through accumulation of broken mate-
rial on the crusher discharge conveyor.
• Blockages or jams at all other material transfer points due
to bulky material.
Preparations Before starting to clear material congestion at a blocked or sta-
tionary crusher, it is essential to carry out the following steps:
» Allow the crusher to coast to a complete standstill.

OPERATION
Eliminating material congestion
» Switch off all plant components.

» Switch diesel generator off.
» Remove key and secure against reactivation.
» Remove battery isolator and carry it with you.
» Completely swing open the crusher inlet cover.
» Attach appropriate warning sign in a clearly visible area.
» Warn other persons before starting work on the plant.
» Prepare suitable tools.
» Wear protective equipment.
 All preparations have been made. The material congestion
can be cleared.
Eliminating material Material congestion always differs according to the situation.
congestions The following listed items describe possible procedures and in-
formation on avoiding hazards:
• Never eliminate material congestions in the crusher by your-
self.
• First remove bulky or oversized material on the feeding side
with the digger shovel or bucket so that no follow-up mate-
rial can slide into the crusher.
• Completely open the crushing gap of the crusher to allow
material to pass the crusher.
• Crush the oversized and bulky material in the crusher with
hydraulic or electric rock chisels.
• If necessary, secure anchor screws to the oversized material
and lift out with suitable lifting gear.
• Note that stones, unbreakable material and, in particular, re-
inforcing steel in a stationary crusher can accumulate a con-
siderable amount of stored energy.
• Proceed with great care when clearing material congestions
in the crusher. Stored energy in the material can result in
unexpected movements of the material and crusher.
• Always clear material congestion from top to bottom to
avoid the danger of follow-up material slipping and material
falling.
• Remove material that has passed the crusher with the help
of the crusher discharge conveyor. Never move under a
crusher when there is a danger of falling stones.
• If necessary, remove material under the crusher with shov-
els or high-pressure water jets.
• Use suitable tools, such as crowbars, pickaxes or shovels, to
loosen and remove material congestion at vibrating convey-
or troughs and belt conveyors. Never attempt to clear ma-
terial congestion in the area of the feeding unit and in the

OPERATION
Operating the auxiliary drive system
crusher with wheel loaders or diggers. This could destroy

plant components.
• Never use explosives to eliminate material congestions.
• Never use flame cutters to cut out material or components.
Stored energy in the material can result in unexpected
movements of the material and crusher.
Final tasks After elimination of material congestions, the following final
tasks must be carried out:
NOTICE
Starting up the crusher drive against a blocked crusher can de-
stroy the crusher and control elements.
• Eliminate material congestion before starting the crusher.
• Completely empty the crushing chamber.
» Remove all tools used from plant machines and components.

» Ensure that no oversized material on the crusher discharge
conveyor is moved on. This can result in damage to the fol-
lowing components.
» Reinstall disassembled guard devices and components, en-
suring they are correctly fitted.
» Fold in crusher inlet cover.
» Ensure that there are no more persons in the hazard area.
 The plant is ready to be switched on again.
3.13 Operating the auxiliary drive system
DANGER
Hazard posed by auxiliary drive system
An open running auxiliary drive system can catch and draw in
personnel, leading to serious or fatal injury.
• Only operate the auxiliary drive system with the jaw crush-
er safety device closed.
WARNING
Hazard posed by auxiliary drive system
There is a risk of injury when the auxiliary drive system is
pressed against the belt pulley of the jaw crusher.
• Only activate the auxiliary drive system if the safety device
is closed.

OPERATION
NOTICE
Activating the auxiliary drive system while material is being
crushed causes material damage to the plant components.
• Do not activate the auxiliary drive system during crushing
operation.
• Only activate the auxiliary drive system to clear the crush-
ing jaw.
• Deactivate the auxiliary drive system as soon as the crush-
ing jaw is empty.
Activating auxiliary drive The auxiliary drive system is activated hydraulically via the
system "Auxiliary drive system" menu on the touch screen. It is activat-
ed when the crushing jaw is stationary and full and is designed
exclusively for clearing the crushing jaw, e.g. after an emergen-
cy stop.
» If necessary, switch on the plant in automatic mode (see
chap. 3.04) and follow the instructions up to and including
"Switching on main switch on control cabinet".
The "Start-up enable" button in the operator panel must light

up continuously.
4 5 6 7 8 9 10 11

» If necessary, press the "Start-up enable" [8] button.
 The "Start-up enable" button flashes first and then lights up
continuously.

OPERATION
» Press the Crusher status display button in the Plant over-

view.
11:30
User: KLeemann
 The touch screen shows the menu for the crusher.
0 rpm
» Press the "Auxiliary drive" button on the touch screen.

11:30:15
1
11:30:1 5
Brecher
Brech
che
ch
ch r
 The touch screen shows the Auxiliary drive menu.
Brecher
DANGER
Hazard posed by falling material
ing material when the auxiliary drive system is started up.
• When starting the auxiliary drive system, do not enter the
discharge area of the magnetic separator or the crusher
withdrawal belt.
• Warn persons in the discharge area prior to starting the
auxiliary drive system.
• Ensure that there are no persons in the discharge area.
» Press the "Auxiliary drive" button on the touch screen.

11:30:15
Hilfsantrieb
 The auxiliary drive is pressed against the belt pulley of the
crusher. Start the magnetic separator and the crusher dis-
charge conveyor.
Operating the auxiliary » Set selector switch "Crawler chassis slow / fast" to Fast at
drive the radio remote control, see chap. 2.02.04.
» Push the right lever of the radio remote control to the front.
 The crusher rotates forwards.

OPERATION
» Push the right lever of the radio remote control to the rear.
 The crusher rotates backwards.
Any seized material in the crushing jaw can be worked loose

by operating it in reverse.
» Press the "Deactivate auxiliary drive" button on the touch

screen as soon as the crushing jaw is clear.
11:30:15
Hilfsantrieb
 The auxiliary drive moves back. The crusher discharge con-
veyor and magnetic separator continue to run.
» Press the Plant overview button on the touch screen.

4 5 6 7 8 9 10 11

» Press the "Start release" button [8] in the operator panel.
» Press the "Plant on" button [9] in the operator panel.
 The fluid coupling is filled and the crusher starts up. The sta-
tus display lights up blue. When a defined speed is reached,
the status display of the crusher lights up green and the re-
maining plant components start up automatically opposite
to the material flow direction. The status displays in the
plant overview light up green. The plant is switched on.
 The "Plant ON" [9] button flashes quickly during the filling
time for approx. 60 seconds and then lights up continuously.
» Switch off the plant, see chap. 3.04.

OPERATION
Setting the jaw crusher
3.14 Setting the jaw crusher
3.14.01 Checking the crushing gap
DANGER
Danger due to crusher operation
Checking of the crushing gap with the crusher running or
coasting can result in serious or fatal injuries.
• Run the crusher empty prior to making the check.
• Do not move under the crusher when it is running.
• Allow the crusher to coast to a complete standstill.
• Remove loose material lying on the crusher.
• Switch off the plant, remove the key and secure against re-
activation.
Fig. 3.33: Checking the crushing gap
[1] Crushing gap

OPERATION
WARNING
Danger due to moving and rotating parts
If the eccentric shaft of the rocker is the top dead centre after
switching off the plant or crusher, there is a risk of injury due
to rotating pulley and flywheels or moving crusher jaw and
belts.
• Ensure that the balancing weights of the flywheel and belt
pulley are in the upper permissible area after standstill of
the crusher.
The setting of the crushing gap has an essential influence on the

crushing capacity and grain size produced by the crusher.
The crushing gap [1] is measured between the tooth root sur-
face and the tip.
» Allow the crusher to coast to a complete standstill.
» Switch off all plant components.
» Switch off diesel generator and control voltage.
» Switch off battery isolator. Remove key and carry it with you.
» Warn other individuals before starting work on the plant.
» Open the protective housing of the belt pulley of the crusher
drive.
» Ensure that the balancing weights of the belt pulley are in
the upper area, see chap. 4.44.01.
» If necessary, start crusher again and then switch it off. Vis-
ually check the position of the balancing weights once again.
 The crushing gap can now be safely measured.
» Climb onto crusher discharge conveyor.
» Measure the crushing gap from below between the tooth
root surface and the tip.
 The crushing gap has been checked and, if necessary, can
be adapted using the gap setting device.
The crushing gap at the lower end of the crushing jaws varies
only slightly according to the position of the articulated crusher
jaw. This inaccuracy is negligible during the measurement.
3.14.02 Setting the crushing gap

The "Setting crushing gap" menu displays the uncritical and
critical areas of the gap setting.
Uncritical gap setting.
Critical gap setting.

OPERATION
Collision of crusher jaws with new crusher jaws.

Impermissible gap setting with removal of all shims in-
cluding the deblocking plates.
NOTICE
Adjusting the crushing gap with the crusher loaded can dam-
age the gap setting device.
Nonobservance of the specified crushing gap can result in in-
creased wear and cause damage to the crusher.
• Only set the gap width when the crusher is empty.
• Do not exceed or undershoot the specified crushing gap.
Setting crushing gap The crushing gap is set hydraulically via the "Setting crushing
during operation gap" menu on the touch screen. For the setting of the crushing
gap s during the operation of the plant, the prescreen must be
switched off, the material feed stopped and the crusher must be
run empty.
» Select Prescreen in the Plant overview.
11:30:25
User: KLeemann
 The Prescreen menu is shown.
» Press the Switch off prescreen button.

11:30:15
Vorsieb
 The prescreen and vibrating feeder switch off and the feed-
I/0 ing unit is stopped. The status displays Prescreen and Vi-
brating feeder are grey.

» Run the crusher until empty.

OPERATION
» Press the Setting crushing gap button.

11:30
User: KLeemann
 The gap setting menu is displayed.
2282RPM
82RPM
1500 rpm
Operation of the symbols "Close crushing gap" and "Open

crushing gap" on the touch screen is only possible when the
Start-enable button in the operator panel illuminates continu-
ously.
4 5 6 7 8 9 10 11

Closing/opening » If necessary, press the "Start-up enable" [8] button.
crushing gap  The Start-enable button lights up continuously, the crushing
gap can be set.
» Press the "Close crushing gap" button on the touch
screen and hold it in.
11:30:15
11:30:1
30:1
30
0:1
0:1
: 5
 The crushing gap width is reduced and the actual stroke is

displayed on the touch screen.
Spalt » Press the "Open crushing gap" button on the touch
 The crushing gap width is increased and the actual stroke is
displayed on the touch screen.


OPERATION
» Press the "Plant ON" [9] button.

 Start the prescreen and vibrating feeder. The plant is run-
ning in automatic mode and the status displays are green.
The guide value for the largest grain size to be expected at the
jaw crusher is: dimension between tooth root surface and tip
x factor 1.6.
An assumption can be made that 80% of the grain will proba-
bly be between 0 and the largest grain. Approx. 20% of the
grain can be outside this range.
For specified minimum and maximum crushing gap, see chap.
5.01.10.
Alternatively, the crushing gap can also be set in manual

mode. When setting the crushing gap in manual mode, make
sure that the crusher has been run empty.
Crushing gap setting in » Switch on the plant in manual mode and follow the instruc-
manual mode tions up to and including "Press start-up enable button".
» Press the Magnetic separator menu button.
11:30
 The menu for the magnetic separator appears.
5.. 0 %
75 1500 rpm
» In the menu for the magnetic separator press the ON

button.
 The magnetic separator starts up and the status display is
green.
» Press the Plant overview button.
» Press the Crusher discharge conveyor menu button.
11:30
 The menu for the crusher discharge conveyor appears.
5.. 0 %
75 1500 rpm
» In the Crusher discharge conveyor menu, press the ON

button.
 The crusher discharge conveyor starts up and the status dis-
play is green.

OPERATION
Clearing away waste tip

» Press the Crusher menu button.
11:30
 The crusher menu appears.
7 5. 0 % 1500 rpm
» In the Crusher menu, press the ON button.

 The fluid coupling is filled and the crusher starts up. The sta-
tus display lights up blue. When a defined speed is reached,
the status display of the crusher lights up green.
» Run the crusher until empty.
» Press the Setting crushing gap button.
11:30
User: KLeemann
 The gap setting menu is displayed.
2282RPM
82RPM
M
1500 rpm
» Set the crushing gap as described under "Closing / opening

crushing gap".
 The crushing gap is set in manual mode.
3.15 Clearing away waste tip

The dispersion and height of the stockpile created below the dis-
charge areas of the belt conveyors and magnetic separators
must be monitored.
• The stockpiles must not be allowed to spread as far as the
crawler chassis and plant components.
• Never let the stockpiles reach the lower edges of the belt
conveyors. The clearance between the top of the stockpile
and the belt conveyor must not be less than 250 mm. Stock-

OPERATION
Winter operation
piles that are too high and touch the belt conveyors can
cause damage to conveyor belts, scrapers and sealing.
• Always clear stockpiles with wheel loaders in good time. En-
sure that wheel loaders do not collide with plant components
during this operation.
• When clearing the stockpiles, ensure that they are not
pushed against the plant causing the crawler chassis or oth-
er plant components to become buried or damaged.
• Have extracted iron from the magnetic separator ejected
into prepared collecting containers. Empty the collecting
containers in good time.
• If ferrous material is discharged directly onto the ground, re-
move it in good time with a digger and suitable hoisting gear.
3.16 Winter operation

Before and during the winter period, the plant must be prepared
for the cold season.
Coolants
» Fill the cooling system with a sufficient concentration of ap-
proved antifreeze.
» During frost periods, check the corrosion inhibitor and anti-
freeze more frequently.
For permissible antifreezes for the diesel engine, refer to the
manufacturer's documentation.
Engine oil
» Replace the oil of the diesel engine in good time with an ap-
proved engine oil in the specified SAE classes.
For permissible engine oils for the diesel engine, refer to the
Winter diesel fuel

» At outside temperatures below 0 °C, switch over to a diesel
fuel with sufficient fluidity.
For permissible measures for improving the fluidity of the diesel
fuel, refer to the manufacturer's documentation.
Cold-resistant winter diesel fuels in Germany are inherently

safe up to approx. -20 °C. In other countries deviations are
possible.
With the cold package special equipment, the diesel fuel must
have an operating range of up to -25 °C.
12 V starter batteries
» Check the charge state of the starter batteries. Charge the
starter batteries as required.

OPERATION
Winter operation
Sealing and scrapers

» Before switching on plant components, check that sealing
and scrapers that make contact with moving components
are not frozen.
Crawler running gear

» Before moving the plant, check that the components of the
crawler running gear are not frozen.
Water system (option)
1
4
Fig. 3.35: Water system for winter operation
[1] Spray system shut-off [2] Water supply for suction

cocks operation
[3] Water supply inlet [4] Prefilter plug screw
At outside temperatures below 0 °C, the water pump and the
spray system can be operated provided that continuous opera-
tion is guaranteed. When the plant is out of service for long pe-
riods, for example overnight, the water must be drained from
the water system and the feed lines to the spraying nozzles to
prevent freezing.
» Disconnect the water supply connections from the plant or
unscrew the cap closures of the suction and supply line.
» Fit a suitable drain channel under the oil drain plug on the
pump housing.
» Unscrew the oil drain plug on the pump housing.
 Water runs out of the pump housing.
» Turn all shut-off cocks of the supply lines to the direction of
flow and drain the water.

OPERATION
Help and troubleshooting
» Open the plug screw on the prefilter and drain the water.
Then retighten the plug screw again.
» Refit the cap closures and turn the shut-off cocks so that
they are transverse to the direction of flow. Screw in the
drain plug on the pump housing.
 The water system is protected against freezing.
3.17 Help and troubleshooting
3.17.01 Starting the engine with jump leads
DANGER
Danger when handling batteries
Risk of explosion due to explosive gas!
• After opening the protective housing of the power supply
unit, wait some time to allow air to enter.
• Never use an open flame and do not smoke.
• Avoid short circuits and sparks.
• Do not place tools on the batteries.
Precautionary measures • Ensure that batteries have same rated voltage.

• A discharged battery can even freeze at temperatures of
around 0 °C. It is essential to defrost batteries in a warm
room before connecting jump leads.
• Use jumps leads with isolated pole terminals and a cross-
section of at least 25 mm2.
• The pole terminals of one cable must not make contact with
the terminals of another cable.
• Do not disconnect discharged battery from the diesel gener-
ator.
• The charging vehicle and the plant must not touch each oth-
er.
Connecting cables » Connect one pole terminal of a cable to the positive pole of
the charged battery (plus sign).
» Connect the other pole terminal of this cable to the positive
pole of the discharged battery (plus sign).
» Connect one pole terminal of the second cable to the nega-
tive pole of the charged battery (minus sign).
» Connect the other pole terminal of the second cable to the
earth of the diesel generator, e.g. at the engine block or the
securing screw of the engine suspension. Do not connect the
pole terminal to the negative pole of the discharged battery
(risk of explosion) but rather as far as possible from the dis-
charged battery.

OPERATION
» Route the cables such that they cannot be caught by rotating

parts and that they can be safely removed with the diesel
generator running.
Starting engine » Start the engine of the charging vehicle and run at average
engine speed.
» Start the diesel generator after approx. 5 minutes.
» Continue running both engines with the connected jump
leads for approx. 3 minutes at average engine speed.
Removing cables » To avoid overvoltages in the electrical system, prior to re-
moval of the jump leads switch on an electrical consumer in
the plant (e.g. water pump).
» Remove the jump leads in reverse sequence to connection.
 The starting aid procedure is complete.
3.17.02 Troubleshooting, remote control system

Troubleshooting, When the transmitter is switched on, it carries out a self-test. If
transmitter faults are detected, the red LED on the right beside the emer-
gency stop issues fault messages by means of a flashing code.
The warning buzzer of the transmitter also sounds.
Number of Meaning
flashes
1-8 A switching lever is not in neutral position during
the start-up phase or is faulty.
13 The emergency stop is defective.
Malfunction of the radio remote control by magnetic field
If the distance between the magnetic separator or magnetic re-
mover and the transmitter of the radio remote control is too
small, this may cause a malfunction of the radio remote control.
The emergency stop of the radio remote control is activated.
Start plant after » Switch off transmitter of the radio remote control by press-
emergency stop ing the emergency stop button.
» Switch off rotary switch "Radio remote control" in the oper-
ator panel.
» Press the "Acknowledge fault / emergency off" button in the
operator panel.
» Press the "Radio remote control ON" button for 1 second,
see chap. 2.02.04.
» Switch on the rotary switch "Radio remote control" in the op-
erator panel.
» Start plant after emergency stop, see chap. 3.04.01.

OPERATION
If the fault cannot be acknowledged and the plant cannot be

started, the plant must be switched off completely and then
restarted.
Troubleshooting, In the event of a malfunction, the "Status" LED at the receiver

receiver lights up red.
The receiver display shows "Er", followed by four digits in two
blocks.
Example of a fault message: "Er" "15" "1A".
Block 1 Block 2 Meaning

01. 01-07 Checksum error (block 2 indicates the
type).
02. 02 Short circuit at DV output.
04. 01-14 Short circuit at digital output (block 2 indi-
cates the relevant output).
07. 1A-8B Fault at analogue output (block 2 indicates
the corresponding output).
15. 1A-8B Short circuit at analogue output (block 2
indicates the corresponding output).
16. 1A-8B Interruption at analogue output (block 2
indicates the corresponding output).
17. 01 Mains voltage too low.
17. 02 Mains voltage too high.
If the malfunction is only temporary, it will be repeated three
times in the display. The receiver then returns to Standby mode.
If the malfunction is serious, it will be shown continuous in the
display. It does not go out until the receiver is disconnected
from the mains supply.
A malfunction can occur after the receiver or transmitter is
switched on or after a switching lever has been activated.
3.17.03 Lubrication system troubleshooting

If there is a fault in the lubrication system, this is indicated by
the fault LED, see chap. 2.18, as a group fault and displayed on
the touch screen of the operator panel.
Fault display mode is started by actuating the Up or Down but-
ton on the operator panel.
The fault message is deleted by pressing the DK button on the
operator panel. Prior to deleting the fault message, determine
and eliminate the cause of fault.
Depending on the type of fault that has occurred, the control
system issued a warning or a fault message.

OPERATION
Example of a warning: fill level in tank falls to the level of the

prewarning sensor (only on systems with this equipment).
Example of a fault: insufficient number of plunger detector sig-
nals of a lubrication segment within the pump runtime.
Faults must always be eliminated immediately.
NOTICE
Maintenance, repair and service work performed by unquali-
fied and unauthorised personnel leads to damage to the plant
or plant components.
Fault Cause Remedy

FCS, no signal from plunger Defective lubricant line. Check lubricant line, replace if
detector. necessary.
Defective plunger detector. Replace plunger detector.
Insufficient lubricant. Top up lubricant.
Agitator paddle in pump unit Mechanical damage. Replace pump unit.
not turning during pump runt-
Undervoltage. Check or replace fuses, check
ime.
electrical connections.
Pump does not operate when Electrical control system Check fuses.
DK button is actuated. failed.
Replace pump unit.
Pump drive/motor defective.
Fill lubricant tank up to max.
Lubricant in tank below min. level.
level.
Replace pump element, ob-
Agitator paddle not turning. serve metering marking with
grooves.
Pump not conveying lubri- Air inclusions in lubricating Disassemble pump element
cant, agitator paddle is turn- grease. and actuate pump unit with
ing. the DK button until grease
emerges at the housing out-
let.
Pump element not building up Replace pump element, ob-
pressure. serve metering marking with
grooves.
Lubricant too stiff. Adapt lubricant to the lowest
operating temperature.
The pressure relief valve System pressure above 200 Check system and make re-
opens and lubricant emerges. or 300 bar, e.g. as a result of pair or modification so that
a distributor blockage or system pressure at 20 °C
blocked lubrication point. does not exceed 200 bar.

OPERATION
Fault Cause Remedy

Valve damaged or contami- Replace the pressure relief
nated. valve.
Tab. 3.4: Lubrication system troubleshooting
3.17.04 Troubleshooting, line coupling
The following section uses an example of a fault message after

the line coupling test is complete.
In the event of a fault message, the plant must not be inte-
grated in a line coupling. In this case, notify the Service De-
partment of KLEEMANN GmbH.
After the test routine, see chap. 3.06.01, the display "Line cou-
pling NOT OK" is shown on the touchscreen.
Possible faults include:
• Inputs and outputs are not correctly wired or are faulty.
• Relays are faulty or incorrectly connected.
• Wiring fault in the line coupling cable.
Display fault message » Acknowledge "Line coupling NOT OK".
 The touch screen displays faulty inputs and outputs.
11:32:25
-
Test line coupling

XS_IN 2 4 6 8 10 12
XS_OUT 2 4 6 8 10 12
Fig. 3.36: Line coupling fault
The example shows that there is a fault at item 8.

This means there is a problem at:

OPERATION
• XS_IN Contact 8
and/or
• XS_OUT contact 8
» Contact the Service Department of KLEEMANN GmbH.
» End line coupling test, see chap. 3.06.01.
3.17.05 Troubleshooting for water pump

If there is a fault with the water pump, this is indicated by the
red LED of the fluid control.
After the fault has been eliminated, the Reset button must be
pressed until the pressure in the system is built up. If there is
inadequate pressure the pump registers a fault again.
Fault with water pump
Fault Device-dependent cause Device-independent cause

Pump does not start • Circuit board faulty • Network failure
• Membrane faulty • Conveying capacity too
weak
• Pump blocked mechanically
• Connections of the WILO-
Fluidcontrol interchanged
• Lack of water
Pump does not switch off • Circuit board faulty • Leakage loss > 0.6 l/min
• Flow monitor blocked
• Reset button disabled
• Pump does not generate
sufficient pressure
Pump running irregularly • Circuit board faulty • Leakage loss > 0.6 l/min
• Pump does not generate
sufficient pressure
Pump blocked • Circuit board faulty • Lack of water
• Pump generates pressure • Conveying capacity too
< Start-up pressure weak
• Membrane faulty
If the fault cannot be eliminated, please contact the Service

Department of KLEEMANN GmbH.
Repair work must only be carried out by authorised and qual-
ified personnel only.

MAINTENANCE
4 MAINTENANCE
This chapter describes maintenance and repair work that has
to be arranged or carried out. Filling volumes and maintenance
intervals are specified in chap. 5.01 and chap. 5.02.
Specifications for lubricating greases and oils are provided in
the section on fluids and lubricants in chap. 5.04.
manual!
DANGER
Performance of maintenance, repair and service work by un-
qualified and unauthorised personnel can result in serious or
fatal injuries.
All safety devices, panelling and component securing elements

must be returned to their safety position following mainte-
nance, repair and service work.
Check the security of nuts and screws on a regular basis and

tighten if necessary! The tightening torques are specified in
chap. 5.03.
In order to guarantee perfect operation of the machines and
components and to reduce wear, the maintenance intervals
must be observed.
All maintenance, repair and service work not described in this

chapter must only be carried out by personnel trained by KL-
EEMANN GmbH. This includes repair work at the hydraulic and
electrical system and on the diesel generator.
Observe the following safety instructions:
• Allow all plant components, such as crushers, vibrating dis-
charge chutes, vibrating screens and belt conveyors to com-
pletely run empty.
• Always carry out repair, maintenance and cleaning work, in-
cluding the elimination of malfunctions, when the plant is
shut down and at a complete standstill.
• Park the plant on a flat and stable surface.
• Safeguard the plant against unauthorised start-up.
– Remove ignition key.
– Switch off and lock main switch.
– Switch off and remove the battery isolators.

MAINTENANCE
– Lock control cabinet.

– Attach warning sign warning against restart.
• When performing maintenance and repair work at the crush-
er and crusher drive, ensure that the balancing weights for

MAINTENANCE
the pulley or flywheel are in the upper permissible area, see

chap. 4.44.01.
• Switch off the hydraulic system and safeguard against re-
start.
• Replace hydraulic hoses after six years usage at the latest,
including a storage time of a maximum of two years.
• Switch off all upstream and downstream plants and ma-
chines and secure against accidental reactivation.
• Only open doors and flaps of the plant after moving parts are
stationary and secure with the folding locks, see chap.
2.01.03.
• Inform operating personnel before starting maintenance, re-
pair and service work.
• Follow the safety instructions to avoid injury and accidents.
• Retrofitting, welding and repair work on the plant must only
be carried out by personnel authorised or trained by KLEE-
MANN.
• Follow instructions for welding work, see chap. 4.47.
• When replacing heavy components, always use suitable
hoisting equipment and lifting tackle and secure them after
setting down.
• Set the replaced electrical and hydraulic components in ac-
cordance with the specifications on the type plates and the
circuit diagrams.
• Before working on valves, hydraulic cylinders or hydraulic
lines, provide a base or support for belt conveyors, hopper
walls and other hydraulically actuated components.
• Fold down hopper walls and, if necessary, move back friction
wheel of the auxiliary drive.
• Settings on throttle and pressure relief valves must only be
carried out by service personnel trained by KLEEMANN. It is
prohibited to remove lead seals from safety valves.
• Tighten screw connections to specified tightening torque and
check for secure seating.
• Once maintenance, repair and service work is finished,
check whether all safety devices are working properly.
• Perform the specified maintenance tasks in accordance with
the schedules.
• Only use spare parts, filters, lubricating greases and oils of-
fered by KLEEMANN. Components, fluids and lubricants from
other manufacturers may cause damage.
• Place old filters in a suitable container to catch escaping
used oil or fuel.
• Dispose of filters, used oil, fuel and grease in an environ-
mentally friendly manner in accordance with local specifica-
tions.

MAINTENANCE
Start "Repair" operating mode
Fig. 4.1: Main switch
[1] Main switch

Before performing maintenance, repair and service work, the
plant must be switched to "Repair mode".
» Switch off the plant.
» Turn main switch [1] to "OFF".
» Secure the main switch using a padlock to prevent uninten-
tional activation. Remove key and carry it with you.
» Close control cabinet protective housing. Lock with U-lock,
remove key and carry it with you.
» Attach warning sign warning against restart.
 The plant has been switched to "Repair mode".
After the control cabinet protective housing is opened, the die-
sel generator can be started if, for example, current is required
from the external circuits for maintenance and repair work.
4.01 Chassis/guard devices
4.01.01 General maintenance tasks

Carry out the following maintenance tasks:
Signs
» Check that the plant signs (hazard, prohibition, mandatory
and information signs) are all attached and are easily legi-
ble. Replace damaged decals.

MAINTENANCE
Protective housing of the power supply units

» Check mounts and hinges of engine bonnet for ease of
movement and oil lightly.
» Visually check piston rods of gas struts of engine bonnet and
oil lightly.
NOTICE
Damaged piston rods
Minor damage, corrosion or paint fragments on the piston rod
of the gas struts results in failure of the spring and the sealing
is damaged.
• In case of damage or reduced power, replace the gas
struts.
• If oil escapes, replace the gas struts.
» Visually check mounts and hinges of lateral guards and ap-

ply a thin coat of oil.
» Check handles, tie bars and locks for correct function and
security.
Platforms
WARNING
Risk of stumbling
There is a risk of stumbling when walking on platforms and
transitions to the steps and ladders.
• Ensure that the platform handrails provide safe protection.
• Do not jump from platforms or plant components.
• Keep platforms free of tools and contamination.
» Check the anti-fall guards for correct function.

» Check for the presence of ladders and their secure installa-
tion.
» Remove coarse contamination and stones from platforms,
ladders and handrails.
Screw connections
» Perform a visual check of the screw connections on the chas-
sis and plant components and machines. Tighten loose
screw connections to specified tightening torque.
For tightening torques, see chap. 5.03.
Lubricating nipple
» Check lubricating nipple for obstructions. Replace defective
lubricating nipples and cover caps.

MAINTENANCE
4.01.02 Checking warning devices

» Activate key switch for "Control voltage ON".
 The system and touch screen power up. The siren sounds
and the "Acknowledge fault / emergency off" button flashes.
» Press the "Acknowledge fault / emergency off" button.
 The warning light and warning siren go out or stop. The
check of the warning devices is complete.
» Repair damaged or inoperative warning devices.
4.01.03 Checking guard devices

» Visually check all protective hoods, guard grids and covers
for presence and secure installation.
» Visually check all component securing elements, such as
spring pin, securing chains and locking pins, for presence
and secure installation.
» Replace missing or damaged guard devices and component
securing elements.
4.01.04 Checking emergency-stop devices

4.01.04.01 Emergency-stop button
NOTICE
Danger of material congestions
The immediate deactivation of all plant drives during the emer-
gency stop can result in material congestions.
• Only actuate the emergency-stop button if the plant has
run empty.
» Run the plant completely empty.

» Switch on the plant in automatic mode.
» Actuate the emergency-stop button on the plant.
 All drives are shut down immediately. The crusher still runs
on for approx. 60 second and then is also shut down. The
diesel generator continues running.
» Release the emergency-stop button and repeat the proce-
dure with all emergency-stop buttons on the plant.
» Check free accessibility of plant emergency-stop buttons.
» Check emergency-stop buttons of the radio remote control
and wired remote control.
» If there is a malfunction, find the cause and eliminate it.
 The emergency stop has been checked.

MAINTENANCE
Control stand
4.01.04.02 Emergency switching off button
NOTICE
» Run the plant completely empty.

» Switch on the plant in automatic mode.
» Actuate the emergency switching off button on the switch
cabinet.
 All drives, including the diesel generator, are shut down im-
mediately.
» Release the emergency switching off button.
» Check free accessibility of plant emergency switching-off
buttons.
» If there is a malfunction, find the cause and eliminate it.
 The emergency switching-off button has been checked.
4.02 Control stand
4.02.01 Checking switch cabinet protective housing
2
1
Fig. 4.2: Control cabinet protective housing
[1] Gas struts [2] Hinges

Carry out the following maintenance tasks:
» Check the gas struts [1] for correct operation and leak-tight-
ness. Replace if necessary.

MAINTENANCE
Control stand
The flap of the switch cabinet protective housing must be held

safely in the opened position by the gas struts.
» Check secure fastening and correct operation of hinges [2].
» Lightly oil the locks and check for correct operation.
» Check cable entries for damage. Replace if necessary.
 The switch cabinet protective housing has been checked.
4.02.02 Carrying out lamp test
WARNING
Danger due to defective control lamps
Defective buttons and control lamps can result in dangerous
operating statuses and risks to personnel.
• Perform a lamp test once a day.
• Have defective lamps replaced by authorised, qualified per-
sonnel.
The lamp test permits you to check the function of buttons and
control lamps in the operator panel of the crushing plant.
» Switch on control voltage.
 Plant overview is displayed.
» Press the button in plant overview.
 The system screen is displayed.
» Press the "Lamp test" symbol and hold.
 All control lamps and buttons in the operator panel light up.
The function of buttons and control lamps has been checked.
4.02.03 Checking remote controls

Checking the radio remote control
NOTICE
Check by specialist
The radio remote control must be checked at least once a year
by a specialist. A specialist is
• someone who, based on technical training and experience,
has sufficient knowledge in the area of the wireless trans-
mission of control commands.
• someone who is familiar with the relevant national occupa-
tion safety regulations, accident prevention regulations,
guidelines and generally recognised rules of technology,
and can thus evaluate the safe working condition of devices
for wireless transmission of control commands.
» Have radio remote control checked by a specialist.

MAINTENANCE
Not assigned
» Check the radio remote control, receiver, receiver aerial and

charger for visible damage. Replace components if neces-
sary.
» Check the functions of the radio remote control with the
plant switched on.
» Check the emergency stop of the radio remote control, see
chap. 4.01.04.
» Always charge one battery in the charger; insert the second
charged battery in the radio remote control.
 The radio remote control has been checked.
If the charged battery is removed from the charger, the battery

to be charged must not be placed back in the charger until a
time of 30 seconds has elapsed. If the battery to be charged is
inserted earlier, no charging will take place.
Checking wired remote control
» Visually check the wired remote control, cables and connec-
tors for damage. Replace components if necessary.
» Check the functions of the wired remote control with the
plant switched on.
» Check the emergency stop of the wired remote control, see
chap. 4.01.04.
 The wired remote control has been checked.
4.03 Not assigned
4.04 Power supply unit/engine
4.04.01 Servicing diesel generator power supply unit
CAUTION
Danger due to hot diesel engine
Parts of the diesel engine can be very hot; there is a risk of in-
jury.
• Where possible, avoid touching any parts of the diesel en-
gine.

MAINTENANCE
WARNING
Risk of crushing in folding area of service flaps
Serious crushing injuries are possible when folding or swinging
service flaps, protective housings and safety covers.
• Stay well clear of the folding and swinging range.
• Ensure that there are no persons in the hazard area during
assembly.
The maintenance and repair work on the diesel generator is

described in the manufacturer's documentation.
• Carry out all maintenance and repair work based on the
• Observe the safety instructions in the manufacturer's doc-
umentation.
Additional maintenance tasks on the drive unit
In addition to the maintenance tasks described in the manufac-
turer's documentation, the following maintenance tasks must
also be carried out:
• Clean fuel filter.
• Service the fuel supply LRC/cold package (option).
• Service toothed belt drive for generator.
• Check the cyclone prefilter.
• Service the air filter.
• Clean the cooler fins.
• Check/refill coolant.
• Service the fluid coupling.

MAINTENANCE
4.04.02 Cleaning fuel filter
[1] Filter housing with filter [2] Hand delivery pump

element
[3] Handle
WARNING
Danger of fire
Diesel fuel can ignite.
• Do not smoke or use an open flame during maintenance
and repair work.
• Keep burning objects well away from the fuel system.
The fuel filter filters coarse particles out of the diesel fuel before
they reach the fuel prefilter of the diesel engine. Water con-
tained in the diesel fuel collects in the filter housing [1].
» Switch off diesel generator and secure against reactivation.
» Open power supply unit service flap.
» Switch off and remove battery isolator and carry it with you.
» Unscrew filter housing [1]. Collect escaping diesel fuel in a
suitable vessel.
» Drain diesel fuel in the filter housing and dispose of it in an
eco-friendly manner.
» Remove and clean filter element.
» Re-insert filter element.
» Screw in filter housing on hand delivery pump [2]

MAINTENANCE
[4] Fuel prefilter [5] Vent plug
Venting fuel system » Twist handle [3] open.

» Pump diesel fuel with hand delivery pump into the fuel sys-
tem until pressure is built up.
» Slowly open vent plug [5], but do not unscrew fully.
 Diesel mist or diesel fuel emerges.
» Catch diesel fuel with rags and dispose of it in an eco-friend-
ly manner.
» Screw vent plug back in.
» Built up pressure again with hand delivery pump.
» Twist handle [3] closed and tighten down.
 The fuel system has been vented.
» Start diesel generator, see chap. 3.04.
» Visually check fuel supply for leaks. If necessary, retighten
screw connections or replace fuel hoses.
» Close service flap for power supply unit again.
 The fuel filter has been serviced.

MAINTENANCE
4.04.03 Servicing the fuel supply LRC diesel engine / cold package
WARNING
Danger of fire
Diesel fuel can ignite.
• Do not smoke or use an open flame during maintenance
and repair work.
• Keep burning objects well away from the fuel system.
[1] Screw cap [2] Filter element with guide

and seal
[3] Fuel prefilter
Changing filter element » Switch diesel generator off. Switch off and remove battery
isolator and carry it with you.
» Open power supply unit service flap.
» Remove unit protective housing side section.
» Screw out screw cap [1] together with filter element [2].
» Remove filter element from screw cap.
» Dispose of used filter element in an eco-friendly manner.
» Insert new filter element in screw cap.
» Check screw cap seal for damage. Change seal if necessary.
» Insert screw cap [1] together with a new filter element and
tighten down screw cap.
 Filter element has been changed.

MAINTENANCE
Fig. 4.6: Water separator
[4] Water separator hose [5] Water separator collecting

reservoir
[6] Holder
The water separator collecting reservoir is located underneath

the fuel prefilter.
Servicing water » Pull water separator hose [4] out of collecting reservoir [5].
separator
» Remove collecting reservoir from holder [6].
» Dispose of water separator fluid in accordance with statutory
provisions.
» Place collecting reservoir in holder and reinsert hose [4].
» Check hose [4] for damage and secure seating on the fuel
prefilter [3]. If necessary, replace hose and establish secure
seating.
 The water separator has been serviced.

MAINTENANCE
[7] Vent plug [8] Hand delivery pump
Venting fuel system » Twist handle of hand delivery pump [8] open.
» Pump diesel fuel with hand delivery pump into the fuel sys-
tem until pressure is built up.
» Slowly open vent plug [7], but do not unscrew fully.
 Diesel mist or diesel fuel emerges.
» Catch diesel fuel with rags and dispose of it in an eco-friend-
ly manner.
» Screw vent plug back in.
» Built up pressure again with hand delivery pump.
» Twist handle of hand delivery pump closed and tighten
down.
 The fuel system has been vented.
» Start diesel generator.
» Visually check fuel supply for leaks. If necessary, retighten
screw connections or replace fuel hoses.
» Fit unit protective housing side section.
» Close service flap for power supply unit again.
 The fuel filter has been serviced.
For maintenance intervals, see chap. 5.02.

MAINTENANCE
4.04.04 Connecting diagnostics device
Fig. 4.8: Diagnostics connector socket
[1] Diagnostics connector

socket
DANGER
fatal injuries.
» Open cover on power pack housing and secure against clos-

ing.
» Connect the diagnostics device at the socket outlet of the di-
agnostics connector [1].

MAINTENANCE
4 5 6 7 8 9 10 11

» Ensure that no emergency off or emergency stop has been
pressed.
 The system and touch screen power up. The siren sounds
and the "Acknowledge fault / emergency off" button flashes.
» As soon as the operating mode selection window is dis-
played, press the "Acknowledge fault / Emergency off" [5]
button and hold for 1 second.
 The ignition of the diesel generator is switched on. The sta-
tus display for diesel generator in the plant overview turns
yellow.
 Engine data can be read out.

MAINTENANCE
4.04.05 Servicing toothed belt for generator

4.04.05.01 Checking toothed belt
Fig. 4.10: Checking toothed belt
[1] Generator toothed belt [2] Toothed belt

pulley
[3] Diesel engine toothed belt
pulley
WARNING
Danger due to belt drives
When the belt drives are running with guard devices are re-
moved, there is a risk of injury because limbs can be drawn in.
• When performing maintenance and repair work on belt
drives, always switch off plant components and the diesel
generator.
• Secure the plant against reactivation.
• Never place your hands in the running belt drives.
Checking toothed belt » Switch off diesel generator and secure against reactivation.
» Switch off and remove battery isolator, see chap.
2.06.02and carry it with you.
» Visually check toothed belt for porosity, fraying and other
damage. Replace if necessary.
» Visually check the middle position of the toothed belt on the
toothed belt pulleys [1] and [3]. Align belt pulley if neces-
sary, see chap. 4.04.05.02.
 The toothed belt has been checked.

MAINTENANCE
4.04.05.02 Aligning toothed belt
Example presentation of the toothed belt drive.
2
3
Fig. 4.11: Aligning toothed belt
[1] Laser pointer [2] Generator toothed belt

pulley
[3] Target magnet [4] Diesel engine toothed belt
pulley
» Switch off diesel engine.
» Switch off and remove control voltage key and carry it with
you.
For checking and setting the toothed belt drive, KLEEMANN

recommends laser measuring device Laser Pointer II and the
frequency meter Optibelt TT mini from Optibelt.
Aligning toothed belt » Mount Laser Pointer [1] at toothed belt pulley of generator
pulleys [2].
Depending on the version of the toothed belt pulley, the Laser

Pointer must be supported underneath by the spacer rail be-
longing to the maintenance set.
» Pretension the toothed belt using the tensioning device. Ten-
sion the toothed belt, see chap. 4.04.05.03.
» Mount three target magnets [3] on the toothed belt of the
diesel engine [4] in positions offset by 90°.
» Align toothed belt pulley for generator [2] using the tension-
ing and adjusting device of the generator until the laser
beam intersects the zero line of the target magnet. When

MAINTENANCE
doing this, ensure that the zero line is in the centre of the
laser beam.
When the spacer rail is used under the Laser Pointer, the value
on the target magnets changes by 5 mm.
Fig. 4.12: Measuring toothed belt tension
[5] Frequency meter [6] Toothed belt
Measuring the toothed » Hold the frequency meter Optibelt TT mini [5] at approx. 90°
belt tension in relation to the toothed belt back and vibrate the toothed
belt.
» Check the tension of the toothed belt at the frequency me-
ter. Repeat toothed belt tensioning and checking until the
correct tension is reached. Toothed belt tension, see chap.
4.04.05.03.
» When tensioning the toothed belt, the alignment of the
toothed belt pulleys at the target magnets must be checked
and corrected if necessary.

MAINTENANCE
2 4
Fig. 4.13: Checking axial parallelism
[2] Generator toothed belt [4] Diesel engine toothed belt

pulley pulley
[7] Parallel and angle error
max. 1 mm
Checking axial
parallelism
Fine adjustment of the toothed belt pulleys is carried out with

a straight-edge.
» Check axial parallelism of the toothed belt pulleys with
straight-edge.
» If necessary, adjust the axial parallelism using the tension-
ing and adjusting device.
 The axial parallelism has been checked.
The measuring points must lie within two parallel lines a

max. distance of 1 mm from one another.
» Remove Laser Pointer, target magnets and, if applicable,
spacer rail.
 The toothed belt pulleys are aligned.

MAINTENANCE
4.04.05.03 Tensioning toothed belt
Fig. 4.14: Tensioning toothed belt
[1] Clamping nut [2] Tensioning carriage re-

taining nut
[3] Tensioning carriage [4] Tensioning carriage se-
curing screws
The generator is mounted on a tensioning carriage [3], which is
moved via the two clamping screws [1].
Check the tension of the toothed belt with the pretension

gauge.
An exact setting of the toothed belt tension can be carried out
with a frequency belt tensioning gauge.
• Specified value with new toothed belt: 61.1 Hz.
• Specified value with run-in toothed belt: 51.6 Hz.
Tensioning toothed belt » Measure the belt tension.

» Release all nuts on securing screws [4] but do not remove.
Ensure that the tensioning carriage can be moved.
» Release retaining nuts [2] and correctly tension toothed belt
by screwing clamping nuts [1] in or out.
» If necessary, check the axial parallelism of the toothed belt
pulleys via the tensioning device of the generator.
» Tighten retaining nuts [2].
» Tighten all nuts on securing screws [4].
 The toothed belt has been tensioned.

MAINTENANCE
Changing toothed belt » Release clamping nuts [1] and unscrew until the toothed belt
can be removed. If necessary, push generator in direction
diesel engine.
» Remove old toothed belt from the toothed belt pulleys and
place new toothed belt in position.
» Tension the toothed belt.
 The toothed belt has been changed.
4.04.06 Checking cyclone prefilter
2
Fig. 4.15: Cyclone prefilter
[1] Dust outlet [2] Cyclone prefilter housing

Due to its functional principle, the cyclone prefilter is self-clean-
ing. In damp weather, however, the dust outlet can become
clogged with dirt and dust.
» Check the dust outlet [1] for obstructions and clean if nec-
essary.
» If it is seriously clogged with dust and dirt, remove cyclone
prefilter and clean it.
» Install cyclone prefilter again. Ensure that the dust outlet
faces downwards.
 The cyclone prefilter is ready for operation again.

MAINTENANCE
4.04.07 Servicing air filters
Fig. 4.16: Servicing air intake
[1] Dust outlet closure [2] Filter housing cover

[3] Clean air pipe [4] Main filter element
NOTICE
The use of incorrect or damaged filter elements can result in
engine damage. Penetration of contamination can cause en-
gine damage.
• Only use filter elements as specified in the spare parts cat-
alogue.
• Even filter elements with only slight damage must be re-
placed.
• Do not wash out or brush filter elements.
• Never start the diesel engine with the filter elements re-
moved.
• Ensure that all work on the air intake is carried out with the
utmost cleanliness.
General work » Check clean air pipe for damage and replace if necessary.
» Check the connecting points of the cyclone prefilter and the
air filter for leaks and secure installation.
» Check dust discharge valve [1] for obstructions.
Servicing main filter Replace the main filter element [4] after the fifth cleaning at the
element latest.
» Open closure clamps on filter housing cover [2] and take off
cover.

MAINTENANCE
» Remove main filter element [4].

» Blow out main filter element [4] with dry compressed air
(maximum 2 bar or 30 psi), working from the inside to the
outside.
» Use a torch to light up the main filter element and check ex-
ternally for cracks and holes. Replace main filter element if
necessary.
» Reassemble main filter element and filter housing. Ensure
that the dust discharge valve [1] faces downwards.
 The main filter element is serviced.
Replacing safety filter
element
Fig. 4.17: Replacing safety filter element
[5] Safety filter element

Replace the safety filter element [5] after the fifth cleaning of
the main filter element at the latest. Never clean the safety filter
element. This would destroy it.
» Remove main filter element [4].
» Remove safety filter element [5].
» Wipe the interior walls of the filter housing with a damp cloth
before inserting the filter elements.
» Insert new safety filter element.
» Reassemble main filter element and filter housing. Ensure
that the dust discharge valve [1] faces downwards.
 The air intake is ready for operation again.

MAINTENANCE
4.04.08 Cleaning the cooler fins.
Fig. 4.18: Cleaning the cooler fins.
[1] Cooling fins
NOTICE
Incorrect cooling of the cooler fins can result in damage to the
cooling system and, consequently, engine damage.
• Switch off the diesel engine and allow it to cool down.
• Do not clean the cooler fins with high-pressure cleaners.
• Do not clean the cooler fins with objects, e.g. screwdrivers.
• Do not use benzene or acidic cleaning agents.
• Observe the specifications in the manufacturer's documen-
tation.
Coolant coolers, charge-air and hydraulic oil coolers clog up

quickly with dust, in particular, where there is high dust devel-
opment. This reduces the cooling capacity, which makes over-
heating possible.
» Switch off the plant components and diesel generator and
allow to cool down.
» Open the protective housing of the power supply unit.
» Visually check the cooling fins for clogging with dust.
» If necessary, spray the cooling fins with a suitable cleaning
agent, let it take effect for a while and then spray with a wa-
ter jet from the inside to the outside.

MAINTENANCE
4.04.09 Check / Refill coolant
Fig. 4.19: Filler neck
[1] Coolant cooler [2] Equalising tank, coolant

cooler
[3] Closing cover, filler neck
CAUTION
Danger due to hot diesel engine
Parts of the diesel engine can be very hot; there is a risk of in-
jury.
• Where possible, avoid touching any parts of the diesel en-
gine.
The maintenance and repair work on the diesel generator is

described in the manufacturer's documentation.
• Carry out all maintenance and repair work based on the
umentation.

MAINTENANCE
4.04.10 Changing engine oil
Fig. 4.20: Oil drain pump
[1] Drain hose [2] Oil drain pump

[3] Pump lever
CAUTION
Danger due to hot oil
Oil and machine parts can be very hot; there is a risk of injury.
• Where possible, avoid touching any parts of the units.
• Avoid skin contact with oils and greases.
• In case of injury, consult a doctor immediately.
As the oil drain plug of the diesel engine is inaccessible, the en-
gine oil is pumped out via the oil drain pump [2].
For details on changing and specifications of the engine oil,

also refer to the manufacturer's documentation.
» Guide the drain hose out of the power supply unit.
» Place a suitable container with capacity of at least 40 litres
for collecting the used oil under the drain hose.
» Actuate the pump lever until the used oil is pumped away
completely.
» Fill fresh engine oil with the corresponding specifications and
filling volume via the engine oil filler neck.
 The engine oil has been changed.
» Dispose of used oil in accordance with the applicable envi-
ronmental specifications. Observe national specifications.

MAINTENANCE
4.04.11 Servicing the hydraulic coupling
WARNING
assembly.
WARNING
belts.
the crusher.
CAUTION

• Before the start of maintenance and repair work at the cou-
pling, ensure that the balancing weights for the pulley and
flywheel are in the upper permissible area, see chap.
4.44.01.
• The quality of the hydraulic oil as a lubricating and service
product in any hydraulic coupling is the main determining

MAINTENANCE
factor of the performance, operational reliability and service

life of the clutch components used in the plant.
• The operating temperature has a central influence on mal-
functions and damage in the plant.
• During assembly work on clutch components for the purpose
of maintenance, repair or replacement, ensure all compo-
nents are perfectly clean.
• Use specified coupling oil, see chap. 5.04.
• Carry out oil level controls regularly.
• Observe the oil change intervals.
• Always change the oil at operating temperature.
• Change oil filters according to the specifications.
• Before removing, clean clutch components and all connect-
ing elements thoroughly of dirt.
• Protect loose and exposed line connections against contam-
ination.
• Tighten loose threaded connections when at operating tem-
perature.
• Dispose of escaping hydraulic oil, collected material and
cleaning agents in accordance with environmental regula-
tions.
» Switch off plant components and the diesel generator.
» Check all hydraulic lines and hoses, hydraulic cylinders, hy-
draulic pumps and other hydraulic components for leaks.
» Repair or replace leaking hydraulic components.
» Retighten or replace loose screw-couplings.
» Replace hydraulic hoses that are cracked, brittle, aged or
otherwise damaged.
NOTICE
Danger due to aged hydraulic hoses
Replace hydraulic hoses after 6 years usage at the latest, in-
cluding a storage time of a maximum of two years.
• Recommended replacement intervals
• Under normal loads, at least every 6 years.
• Under increased loads (longer operating times, e.g. multi-
shift operation, or when subject to special external influ-
ence, e.g. climatic conditions), at least every 2 years.
• Recommended checking intervals
• Under normal loads, every 12 months.
• Under increased loads, every 6 months.

MAINTENANCE
4.04.11.01 Flushing hydraulic coupling
DANGER
Maintenance and repair work carried out with plant compo-
nents running can result in serious or fatal injury.
• Maintenance and repair work must always be carried out
with the plant at a standstill.
• Switch off plant components and the diesel generator.
To remove production residue and contamination from the hy-

draulic coupling, it must be flushed after 500 hours of operation.
To do this, four nozzles must be removed from the hydraulic
coupling and reinstalled after flushing has been performed.
1
2
3
4
[1] Vent filter [2] Maintenance cover

[3] Screws [4] Plug of starter ring
[5] Special tool
Removing maintenance » Switch off diesel generator and secure against reactivation.
cover
» Clean area around maintenance cover [2].
» Unscrew screws [3] of maintenance cover [2] and remove
maintenance cover.
Inserting special tool » Remove plug [4] from underneath starter.

MAINTENANCE
» Insert special tool [5] in opening of housing for starter ring.

Ensure that the special tool sits correctly in the teeth of the
starter ring.
 The special tool is inserted and the crankshaft can be turned
by hand.
8
6
9
5
[5] Special tool [6] Underside of starter ring

housing
[7] Hydraulic coupling hous- [8] Coupling
ing
[9] Nozzle
To facilitate removal of the four nozzles from the hydraulic cou-

pling, the crankshaft of the diesel engine must be turned by
hand until the nozzles appear in the service opening. There-
fore, work with an assistant.
Removing nozzles » Place a suitable tool, e.g. ratchet, in the special tool [5] and
turn the crankshaft until the first nozzle [9] appears in the
service opening.
Extreme caution must be exercised when removing and install-

ing the nozzles to prevent the nozzles from falling into the
housing of the hydraulic coupling. Should this happen, the hy-
draulic coupling would have to be removed and dismantled.
» Unscrew nozzle [9] with Allen key (size 3/16") and store for
later assembly. If necessary, use suitable aids to prevent the
nozzles from falling into the housing.
» Perform the same work steps until all four nozzles have been
removed.

MAINTENANCE
» Fit the maintenance cover [2] with the screws [3] and tight-
en.
» Remove the special tool [5] and insert the plug [4] in the
housing of the starter ring.
Flushing hydraulic » Switch on the plant in manual mode (see chap. 3.05).
coupling
» Switch on the crusher.
 Fill the hydraulic coupling with hydraulic oil.
» Switch off the crusher.
 Oil filling stops. The diesel engine and hydraulic coupling
continue to run. Contamination and residue are flushed out
through the holes with the hydraulic oil.
» Repeat the flushing procedure four to five times.
 The hydraulic coupling is flushed.
» Switch off diesel generator and secure against reactivation.
Installing nozzles » Visually inspect nozzles for free passage. If necessary, es-
tablish free passage using suitable tools.
NOTICE
If the hydraulic coupling is operated with incorrectly installed
and tightened nozzles, this can result in damage to the hy-
draulic coupling.
• Install nozzles with correct tightening torque.
» When installing the nozzles, perform the same work steps as

described for removing the nozzles.
» Tighten nozzles to a tightening torque of 11.7 Nm.
» Grease O-ring of maintenance cover [2] before fitting main-
tenance cover.
NOTICE
Starting the plant with the special tool inserted will damage
the diesel engine.
• Remove the special tool before starting the plant.
• Seal the opening for the special tool using a suitable plug.
» Ensure that the special tool [5] is removed and the plug [4]
is fitted.
 The nozzles are fitted.

MAINTENANCE
After the hydraulic coupling has been flushed, the hydraulic oil
and the oil filter must be replaced.
To change the hydraulic oil and oil filter, see chap. 3.05.
4.04.11.02 Checking hydraulic oil fill level
2
1
Fig. 4.23: Hydraulic oil tank fill level
[1] Hydraulic oil tank [2] Filler neck plug

[3] Level indicator
The level indicator [3] shows the current fill level of hydraulic oil
in the plant's operating position.
» Take the fill level reading while the plant is stationary. The
hydraulic oil fill level must be at the blue line of the inspec-
tion window.
» If necessary, replenish hydraulic oil via the filler neck [2].
 Fill level has been checked.
The filler neck of the tank breather filter is not suitable for re-
plenishing.

MAINTENANCE
4.04.11.03 Changing hydraulic oil
WARNING
Risk of falling
There is a risk of falling during maintenance and repair work
on the plant components.
• Use suitable climbing aids.
• Check if the climbing aids are secure and safe to use.
• Ensure that the three-point contact on the climbing aid is
secure.
• Do not jump from the climbing aids or the plant.
CAUTION
Draining hydraulic oil Drain plugs [1] are located on the front side and drain plug [3]
on the rear side of the hydraulic oil tank. The drain plugs are
magnetic and must be cleaned before they are screwed in.
Depending on the installation position of the power supply unit,
the drain plug on the rear side of the hydraulic oil tank must be
used for draining. The drain plug on the rear side is accessed via
» Bring the hydraulic oil up to operating temperature. If nec-
essary, run the diesel generator in manual mode for approx.
10 minutes.
» Observe the special safety instructions at the start of this
chapter.
» Switch off plant components and diesel generator and se-
cure against reactivation.
» Switch off the battery isolator, remove the key and carry it
with you.
» Place a suitable container with capacity of at least 40 litres
under the drain plug.
When draining coupling oil at drain plug [3], use a funnel and
hose. Guide the hose out of the plant and into a suitable ves-
sel.

MAINTENANCE
3 2
1
2
Fig. 4.24: Hydraulic oil tank
[1] Magnetised drain plug [2] Filler neck plug screws

[3] Magnetic drain plug, rear
side
» Unscrew magnetic drain plug [1] or [3].
» Drain the hydraulic oil completely.
» Clean magnetised drain plug.
» Dispose of used coupling oil in an environmentally friendly
manner.
 The coupling oil has been drained.
Depending on the installation position of the power supply

unit, it may not be possible to drain the coupling oil via the
drain plugs. In this case, the coupling oil must be pumped out
through the filler neck. It will then not be possible to clean the
magnetic drain plugs.
Pumping out coupling oil » Clean area of filler neck plug screw [2].
» Unscrew plug screw [2].
» Using a suitable device, pump out the coupling oil complete-
ly.
» Dispose of used coupling oil in an environmentally friendly
manner. Observe national requirements.
 The hydraulic oil has been pumped out.
When changing the coupling oil, the coarse filter must always
be cleaned at the same time.

MAINTENANCE
6
5
Fig. 4.25: Intake filter
[4] Coarse strainer [5] Screws for maintenance

cover
[6] Intake pipe [7] Hydraulic pump intake
pipe screw-coupling
Removing coarse » Clean area around maintenance cover.

strainer
» Release screw-coupling for intake pipe [7].
» Unscrew screws [5] on maintenance cover and keep ready
for reassembly.
» Pull intake pipe together with coarse strainer [4] out of cou-
pling housing.
 The coarse strainer has been removed.
WARNING
Danger of eye injury
Work with compressed air can cause serious visual impair-
ment.
• Wear suitable protective goggles.
• Never direct the compressed-air jet at persons.
Cleaning coarse filter » Disassemble coarse strainer from intake pipe.

» Clean coarse strainer with suitable cleaning agent. Blow out
coarse strainer with compressed air if necessary.
» Install cleaned coarse strainer.
 The coarse strainer has been cleaned.

MAINTENANCE
Fig. 4.26: Assembling intake filter
[8] Surface sealant [9] Maintenance cover con-

tact surface
Installing coarse strainer » Clean contact surface [9] of maintenance cover.

» Apply surface sealant to contact surface.
» Insert coarse strainer together with intake pipe.
» Ensure that the intake pipe is correctly seated at the hydrau-
lic pump connection.
» Insert screws in maintenance cover and tighten them.
» Tighten screw connection for hydraulic pump intake pipe.
 The coarse strainer has been installed.
Pouring in hydraulic oil » Replenish hydraulic oil tank up to the blue line in the level
indicator with fresh hydraulic oil.
The fill level must be visible in the level indicator. When the
plant is switched off, the fill level must not be below the red
line of the level indicator.
» Insert plug screw of filler neck [2] and tighten it.
 The coupling oil has been changed.
When changing the coupling oil, the oil filter must always be
changed at the same time.
Only use the oil filters specified in the spare parts catalogue.
Dispose of removed hydraulic oil and oil filters in an environ-
mentally friendly manner.

MAINTENANCE
10
Fig. 4.27: Hydraulic oil filter
[10]Oil filter cartridge
Changing oil filter » Unscrew the old oil filter cartridge [10] from the connecting
point.
» Lightly oil the new oil filter cartridge seal.
» Screw on new oil filter cartridge to connecting point and
tighten.
» Start the plant in manual operation and allow the diesel gen-
erator to run for approx. 5 minutes. Do not switch on the
crusher.
» Switch off the battery isolator, remove the key and carry it
with you.
» Check the fill level at the level indicator and, if necessary, re-
plenish the hydraulic oil up to the blue line.
 The oil filter has been changed.

MAINTENANCE
4.04.11.04 Changing vent filter
Fig. 4.28: Vent filter
[1] Vent filter
CAUTION
Changing vent filter » Clean area of vent filter.

» Release vent filter [1] and remove.
» Install new vent filter and new seal.
» Hand-tighten vent filter. Ensure that the seal is not dam-
aged.
 The vent filter has been changed.
4.04.11.05 Changing drive chain

The hydraulic pump for the hydraulic coupling is driven by the
diesel engine via a chain. To prevent damage to the hydraulic
coupling, the drive chain must be checked at regular intervals,
see chap. 5.02, and replaced if necessary.

MAINTENANCE
Two persons are always required for replacement of the drive

chain.
1
2
[1] Maintenance cover for [2] Hydraulic pump

drive chain
[3] Plug of starter ring [4] Special tool
Removing maintenance » Switch off diesel generator and secure against reactivation.
cover
» Clean area around maintenance cover [1].
» Unscrew screws on maintenance cover and remove mainte-
nance cover.
Inserting special tool » Remove plug [3] from underneath starter.
» Insert special tool [4] in opening of housing for starter ring.
Ensure that the special tool sits correctly in the teeth of the
starter ring.
 The special tool is inserted and the crankshaft can be turned
by hand.

MAINTENANCE
Fig. 4.30: Chain joint
[2] Hydraulic pump [5] Pump drive gear wheel

[6] Chain joint [7] Drive chain
In order to replace the drive chain, the crankshaft of the diesel

engine must be turned manually until the chain joint is at top
dead centre. Therefore, work with an assistant.
» Insert a suitable tool, e.g. ratchet, in the special tool [4] and
turn the crankshaft until the chain joint [6] is at top dead
centre.
Proceed with extreme caution when opening the chain joint to

prevent the chain joint from falling into the housing of the hy-
draulic coupling.
» Open the chain joint [6].
» Secure the drive chain on the left and right of the chain joint
against falling into the housing.
» Remove the chain joint and set aside ready for assembly.

MAINTENANCE
Fig. 4.31: Securing drive chain
[7] Drive chain [8] Securing cord

[9] Assembly point for new
drive chain
Attaching drive chain » Secure a sufficiently long securing cord [8] to the drive
chain.
Fit securing cord on both ends of old drive chain.

» Attach new drive chain on assembly [9] with chain joint.
10
Fig. 4.32: Pulling in drive chain
[7] Drive chain [10]New drive chain

MAINTENANCE
Pulling in drive chain » Keep drive chain [7] and new drive chain [10] under tension.
» Use special tool to turn crankshaft and pull in new drive
chain. Keep drive chains under tension to prevent detach-
ment at the lower gear wheel.
10
Fig. 4.33: Chain joint
[2] Hydraulic pump [5] Pump drive gear wheel

[6] Chain joint [10]New drive chain
Installing chain joint » Pull in drive chain with an assistant until the chain joint can
be installed in the illustrated position.
» Secure drive chain against falling into the housing.
» Remove securing cord.
» Insert chain joint and close.
 The drive chain has been installed.
The open side of the chain joint must be installed counter to

the direction of rotation to prevent it from being released.
NOTICE
An incorrectly inserted chain joint results in damage to the hy-
draulic coupling.
• Install chain joint with open side counter to the direction of
rotation.
» Clean contact surface of maintenance cover and housing.

» Apply sealing compound on the contact surface of the hous-
ing.
» Install maintenance cover and tighten screws.

MAINTENANCE
» Remove special tool and insert plug in the housing of the

starter ring.
NOTICE
Starting the plant with the special tool inserted will damage
the diesel engine.
• Remove the special tool before starting the plant.
• Seal the opening for the special tool using a suitable plug.
» Ensure that the special tool is removed and the plug is fitted.
 The new drive chain has been installed.
4.05 Hydraulic oil supply
DANGER
Danger due to hydraulic oil escaping under high pres-
sure
The oil in the hydraulic system is pressurised when the plant is
switched on; there is a risk of injury!
activation.
CAUTION
WARNING
assembly.

MAINTENANCE
NOTICE
The hydraulic system can be damaged if biological oil and min-
eral oil come into contact.
• Before biological oil is filled, all parts that were in contact
with mineral oil must be cleaned thoroughly.
• Before biological oil is filled, the whole hydraulic system
must be emptied and flushed thoroughly.
• Before biological oil is filled, all hydraulic filters must be
changed.
• After changing to biological hydraulic oil, hydraulic oil filters
with maintenance indicators must be checked weekly for
filter blockage/clogging.
NOTICE
Changes to the settings of the throttle and pressure relief
valves made by KLEEMANN GmbH can result in material dam-
age.
• Never remove lead seals from safety valves.

• The quality of the hydraulic oil as a lubricating and operating
material is the main determining factor of the performance,

MAINTENANCE
operational reliability and service life of the hydraulic com-

ponents used in the plant.
• The operating temperature has a central influence on mal-
functions and damage in the plant.
• During assembly work on hydraulic components for the pur-
pose of maintenance, repair or replacement, ensure all com-
ponents are perfectly clean.
• Select hydraulic oils carefully.
• Carry out oil level controls regularly.
• Observe the oil change intervals.
• Always change the oil at operating temperature.
• Change oil filters according to the specifications.
• Avoid contamination to the hydraulic oil cooler.
• Prior to disassembly, thoroughly clean hydraulic components
and all connecting elements to remove dirt.
• Protect loose and exposed line connections against contam-
ination.
• Tighten loose screw connections at operating temperature
and when depressurised.
• Dispose of escaping hydraulic oil, collected material and
cleaning agents in accordance with environmental specifica-
tions.
4.05.01 Servicing hydraulic system

4.05.01.01 General maintenance tasks
» Check all hydraulic lines and hoses, hydraulic cylinders, hy-
draulic pumps and other hydraulic components for leaks.
» Repair or replace leaking hydraulic components.
» Retighten or replace loose screw-couplings.
» Replace hydraulic hoses that are cracked, brittle, aged or
otherwise damaged.

MAINTENANCE
NOTICE
Danger due to aged hydraulic hoses
Replace hydraulic hoses after 6 years usage at the latest, in-
cluding a storage time of a maximum of two years.
• Recommended replacement intervals
• Under normal loads, at least every 6 years.
• Under increased loads (longer operating times, e.g. multi-
shift operation, or when subject to special external influ-
ence, e.g. climatic conditions), at least every 2 years.
• Recommended checking intervals
• Under normal loads, every 12 months.
• Under increased loads, every 6 months.
4.05.01.02 Depressurising the hydraulic system
DANGER
sure
The oil in the hydraulic system is pressurised when the plant is
switched on; there is a risk of injury!
activation.
Depressurising driving After the plant components and the diesel generator are
hydraulics switched off, the hydraulic circuit of the driving hydraulic system
is depressurised.
» Switch off plant components.
 The driving hydraulic system is depressurised.
Depressurising auxiliary The hydraulic circuits of the auxiliary hydraulic system are de-
hydraulic system pressurised after switching off the plant components and the
diesel generator.
Pressure accumulators are installed in the hydraulic circuit of
the hopper wall locking and auxiliary drive. Therefore, the hy-
draulic circuits must be depressurised before the start of main-
tenance and repair work on the components.

MAINTENANCE
WARNING
sure
The oil in the hydraulic circuit of the hopper wall locking device
and the auxiliary drive is pressurised; there is a risk of injury.
• Depressurise the hydraulic circuit.
• Ensure that the pressure in the respective menu of the
components in the touch screen displays the value zero.
• Work on the hydraulic system must only be carried out by
qualified and authorised personnel only.
» Unlock and fold down hopper walls of the hopper extension,

see chap. 6.03.06.
» In the menu of the vibrating feeder, check whether the pres-
sure the value zero displays any pressure.
» If necessary, move back friction wheel of the auxiliary drive,
see chap. 3.13.
» In the menu of the auxiliary drive, check whether the pres-
sure value zero is displayed.
 The pressure accumulators of the hopper walls and auxiliary
drive are depressurised.
 The auxiliary hydraulic system is depressurised.

MAINTENANCE
4.05.02 Servicing hydraulic oil tank

4.05.02.01 Checking hydraulic fill level
max.
min.
Fig. 4.34: Fill level of hydraulic oil tank
[1] Hydraulic oil tank [2] Level indicator

The level indicator [2] shows the current fill level of the hydrau-
lic oil in the plant's operating position. Deviations are possible,
for example, in transport position with folded-down hopper
walls.
» Read off the fill level in operating position and with the plant
at a standstill. The fill level of the hydraulic oil must be be-
tween ½ and ¾ of the inspection glass.
» If necessary, top up hydraulic oil via the filler neck with in-
tegrated ventilation filter.
 The fill level has been checked.
The level indicator also allows you to visually check the tem-
perature of the hydraulic oil.

MAINTENANCE
4.05.02.02 Changing hydraulic oil
2
4
Fig. 4.35: Hydraulic oil tank top side
[1] Hydraulic oil tank [2] Suction filter

[3] Suction filter service [4] Filler neck and tank vent
opening with coarse strainer
[5] Return filter [6] Drain cock
Draining hydraulic oil The hydraulic oil drain [6] is at the bottom right of the hydraulic
oil tank. An oil drain hose can be installed at the connection.
WARNING
Risk of falling
secure.
» Warm up hydraulic oil to operating temperature. If neces-

sary, run the plant for approx. 10 minutes.
chapter.
» Fit oil drain hose at the hydraulic oil drain [6] and provide a
suitable container.

MAINTENANCE
CAUTION
» Remove filler neck screw cap and tank ventilation [4].

» Open shut-off cock of hydraulic oil drain [6].
» Completely drain the hydraulic oil.
» Close shut-off cock of hydraulic oil drain again.
» Reinstall filler neck screw cap and tank ventilation [4].
» Dispose of used hydraulic oil in accordance with environ-
mental regulations.
 Hydraulic oil is drained.
Filling hydraulic oil » Remove filler neck screw cap and tank ventilation [4].
» Fill the hydraulic oil tank with fresh hydraulic oil up to the
middle of the level indicator.
The fill level must be visible in the level indicator and should be
between ½ and ¾ of the maximum fill height. With the plant
switched off, the level indicator must not be below the MIN dis-
play.
» Install filler neck screw cap and tank vent and tighten.
» Switch on plant components and warm up hydraulic oil to
service temperature.
» Check the fill level at the level indicator and, if necessary,
top up hydraulic oil up to approx. ¾ of the maximum fill
height.
 Hydraulic oil is filled.

MAINTENANCE
4.05.02.03 Changing hydraulic oil filter
Fig. 4.36: Hydraulic oil filter
[1] Suction filter [2] Maintenance cover for

suction filter
[3] Tank vent with coarse [4] Return filter
strainer
Preparatory work » Observe the special safety instructions at the start of this
chapter.
When changing the hydraulic oil, both the suction filter and the
return line filter must always be changed.
Only use filters as specified in the spare parts catalogue.
Dispose of escaping hydraulic oil and filter in accordance with
environmental specifications.

MAINTENANCE
Changing suction filter
2
1
Fig. 4.37: Suction filter
[1] Filter element [2] O-ring

[3] Maintenance cover
CAUTION
For change intervals of suction filter, see chap. 5.02.
To change the suction filter, the hydraulic oil must be drained.
Changing suction filter » Drain hydraulic oil, see chap. 4.05.02.02.

» Clean area of maintenance cover [3].
» Unscrew screw on maintenance cover until it can be re-
moved.
» Take out old filter element [1].
» Screw new filter element onto connection and tighten.
» Clean O-ring of maintenance cover and apply a thin coat of
grease.

MAINTENANCE
» Mount maintenance cover and tighten screw.

 Suction filter has been changed.
» Fill fresh hydraulic oil, see chap. 4.05.02.02.
Changing return filter
Fig. 4.38: Return filter
[1] Filter element [2] Closing cover
CAUTION
For change intervals of return filter, see chap. 5.02.

Change return filter » Remove closing cover.
» Withdraw the old filter element [1] with dirt catching pan
vertically at the bracket.
NOTICE
If the filter element is not withdrawn carefully, dirt particles
from the dirt catching pan may mix with the hydraulic oil.
• Carefully withdraw the filter element vertically out of the
housing.

MAINTENANCE
» Unscrew old filter element from dirt catching pan.

» Clean dirt catching pan.
» Insert new filter element in dirt catching pan and tighten.
Ensure that the filter element is correctly seated.
» Clean the seal of the closing cover and oil lightly.
» Mount closing cover and tighten.
 Return filter is changed.
Cleaning coarse screen
CAUTION
WARNING
ment.
If the flow of hydraulic oil in the filler neck is restricted, the

coarse screen must be cleaned.
Fig. 4.39: Coarse strainer

MAINTENANCE
Electrical system
[1] Coarse strainer [2] Seal

[3] Filler neck [4] Screw cap for filler neck
and tank vent
Removing filler neck » Unscrew screw cap [4].

» Clean area of filler neck [3].
» Remove screws of filler neck and take off filler neck.
Cleaning coarse screen » Pull out coarse screen [1].
» Clean coarse screen with suitable cleaning agent. Blow out
coarse screen with compressed air if necessary.
» Clean seal [2] and check for damage. Replace seal if neces-
sary.
» Insert clean coarse screen.
» Mount filler neck and tighten screws.
» Mount screw cap [4] and tighten.
 The coarse screen has been cleaned.
Serious contamination of the coarse strainer obstructs the flow

of hydraulic oil. As a result, the hydraulic oil overflows in the
filler neck.
4.06 Electrical system
DANGER
Cables and components are live; there is a risk of injury.
The cables and components of the external circuits are live
even if the diesel generator is switched off.
The frequency converter is still energised after shutdown or
disconnection from the network.
• Only carry out work on the electrical system with the plant
components and diesel generator switched off.
• After switching off the diesel generator, wait 10 minutes
before starting work on the electrical system.
DANGER
personnel.

MAINTENANCE
Electrical system
NOTICE
Failure to inspect the plant following replacement of electrical
components and cables can result in malfunctions and failures.
• Check plant functions after every replacement of electrical
components and cables.
• Observe applicable VDE guidelines and country-specific
specifications.

personnel.
• Observe the safety manual when performing all mainte-
nance, repair and service work.
• Park the plant on a flat and stable surface.
• Earth the plant correctly with an earthing rod.
– Remove ignition key.
– Switch off and lock main switch and carry the key with
you.
– Switch off and remove battery isolator and carry it with
you.
– Attach warning sign warning against restart.
4.06.01 General maintenance tasks

» Switch off battery isolator, remove key and carry it with you.
chapter.
» Visually inspect electric cables on the plant for damage.
» Visually inspect cable entries and cable ducts on the chassis
for damage.
» Visually inspect sockets on the chassis for damage and se-
curity.
» Replace damaged electrical cables, cable entries and sock-
ets.

MAINTENANCE
Electrical system
4.06.02 Servicing 24 V voltage supply

4.06.02.01 Servicing diesel generator electrical system
The maintenance work on the diesel generator electrical sys-

tem is described in the manufacturer's documentation.
• Carry out all maintenance work based on the manufactur-
er's documentation.
umentation.
Additional maintenance tasks on the diesel generator
electrical system
In addition to the maintenance tasks described in the manufac-
turer's documentation, the following maintenance tasks must
also be carried out:
• Service the starter batteries.
4.06.02.02 Servicing starter batteries
Fig. 4.40: Starter batteries
[1] 12 V starter batteries

The starter batteries [1] must be kept clean and dry.
The starter batteries are maintenance-free; it is not possible to
check the acid level or top up distilled water.
The vent openings of the starter batteries must be free of con-
tamination and clear from end to end. The vent openings must
be checked on a regular basis.

MAINTENANCE
Electrical system
DANGER
Danger when handling batteries
Risk of explosion due to explosive gas!
• After opening the protective housing of the power supply
unit, wait some time to allow air to enter.
• Never use an open flame and do not smoke.
• Avoid short circuits and sparks.
• Do not place tools on the batteries.
WARNING
assembly.
Checking starter battery » Observe the special safety instructions at the start of this
holders chapter.
» Visually inspect mounts and retaining brackets of starter
batteries for damage. Repair or replace damaged parts.
» Check security of fastening screws and retaining brackets on
starter batteries. Tighten fastening screws if necessary.
 The mounts have been checked.
Changing the starter » Switch off, remove and carry the battery isolator with you,
battery see chap. 2.06.02, and remove and carry it with you.
» Identify defective starter battery.
» Remove protective caps from cable connections.
» Slacken and remove the cables from the starter batteries in
the following sequence:
– Ground connection of jumper between the starter batteries
– Positive connection of jumper between the starter batteries
– Cables of defective starter battery
» Remove retaining bracket of starter battery.
» Replace the starter battery, ensuring the installation position
is correct.
» Clean the battery poles and terminals and grease with acid-
free and acid-resistant grease.
» Install cables on the starter batteries in the reverse se-
quence. The terminal clamps must have good contact.

MAINTENANCE
Electrical system
» Ensure that the battery poles are not reversed (risk of short
circuit!).
» Reinstall the protective caps of the cable connections.
» Reinstall retaining bracket for starter battery.
» Insert and switch on battery isolator.
 The starter battery has been changed.
Fig. 4.41: Vent openings
[1] 12 V starter battery [2] Vent openings
Cleaning vent openings » Visually inspect vent openings for contamination and ob-
structions.
» If necessary, carefully clean the vent openings.
» Close service flap of the power supply unit.
 Vent openings have been cleaned.
4.06.03 Servicing switch cabinet

4.06.03.01 Checking electrical components
DANGER
personnel.

MAINTENANCE
Electrical system
NOTICE
Blowing out the switch cabinet with compressed air can result
in failure of the electrical system.
• Remove dust and dirt in the switch cabinet by vacuuming
or brushing out.
» Open the control cabinet protective housing; keep control

cabinet closed.
» Visually check the electric cables inside the control cabinet
protective housing for damage.
» Visually check the cable entries on the control cabinet pro-
tective housing for damage.
» Visually check socket outlets on the control cabinet for dam-
age and security.
» Visually check operating and display elements for damage.
» Remove dust deposits and dirt from the control cabinet pro-
tective housing, e.g. by vacuuming.
» Have damage to electric components repaired by qualified
and authorised personnel only.
 Electrical components in the switch cabinet have been
checked.
4.06.03.02 Checking switch cabinet mounting
2
1
Fig. 4.42: Switch cabinet mounting
[1] Spring element [2] Damping element

» Visually check spring and damping element for damage.

MAINTENANCE
Electrical system
» Check fastening of spring elements.

 The switch cabinet mounting has been checked.
4.06.04 Checking grounding straps
Fig. 4.43: Earthing strap
[1] Earthing strap [2] Chassis

[3] Fastening screw, earthing [4] Conveyor belt frame
strap
The earthing straps guarantee safe connection of the protective
conductor to earth. The earthing straps also help to safely dis-
sipate static charges generated by plant components.
The correct assembly and presence of earthing straps must be
checked.
The illustration shows the assembly of the earthing strap at the

crusher discharge conveyor.
Earthing straps are installed at the following components:

MAINTENANCE
Electrical system
• Diesel fuel tank / console, diesel fuel tank / chassis

• Power supply unit/chassis
• Electric motor for drive system/power supply unit frame
• Hydraulic oil tank/chassis
• Magnetic separator/chassis
• Hydraulic motor/power pack
• Generator/power pack
• Crusher discharge conveyor/chassis
• Grizzly feeder/chassis
• Jaw crusher/chassis
• Prescreen conveyor/chassis
Checking earthing straps » Check earthing straps for proper installation and damage.
» Ensure that the screws of earthing straps are tightened. If
necessary, tighten screws.
» Replace damaged or missing earthing straps immediately.
 The earthing straps have been checked.
4.06.05 Servicing electric motors
Fig. 4.44: Terminal box
[1] Cable entry [2] Terminal box cover

[3] Seal
Damaged and loose terminal boxes and cable entries for electric
motors can cause contact problems and short circuits if pene-
trated by moisture.
» Visually check all cable entries [1] for damage.

MAINTENANCE
Electrical system
» Visually check cables for chafing and secure installation.
During operation, cables must not scuff due to an excessively

large swinging range. The dead weight of the swinging cables
must not exert excessive pull on the cable entries.
» Check all terminal box covers [2] for security and leaks.
» Replace sealing [3] if necessary.
 The terminal boxes are checked.
The following terminal boxes must be checked:
• Drives of the belt conveyors
• Drives of the vibrating conveyor troughs
• Drive of the water pump
• Tandem pump drive
• Auxiliary hydraulic pump drive
• Terminal box of generator
4.06.06 Servicing control cabinet heat package
2 4
5
1
[1] Dust outlet valve [2] Corrugated hose

[3] Ventilator, control cabinet [4] Ventilator, control cabinet
aeration ventilation
[5] Filter housing cover
Checking heat package, » Press the sealing lips of the dust outlet valve together to al-
control cabinet low accumulated dust and water to escape.
» Loosen and remove dust deposits.
 The dust outlet valve is ready for operation again.

MAINTENANCE
Electrical system
» Check the corrugated hose [2] for damage and replace if

necessary.
» Check the connecting points of the corrugated hose for leaks
and secure installation.
[4] Filter housing cover [6] Closure clips

[7] Filter element
Checking/cleaning filter » Open closure clips [6] of filter housing cover and take off
element cover.
» Take out filter element [7] and blow out with dry compressed
air (maximum 2 bar or 30 psi), working from the inside to
the outside. Do not wash out or brush out filter element.
» Wipe the interior walls of the filter housing with a damp cloth
before inserting the filter element.
 The overpressure system is ready for operation again.
Do not reuse filter elements with cracks and holes. Replace fil-
ter element if necessary. Replace filter element after 5 clean-
ing procedures at the latest.
Checking ventilators » During operation, check the function of the ventilators.

» Replace defective ventilators.
 The ventilators have been checked.

MAINTENANCE
Electrical system
4.06.07 Repairing electrical system

4.06.07.01 Fuses
DANGER
Electric shocks can result in fatal injuries and cause fires in the
electrical system.
• Only carry out work on the electrical system with the plant
components and diesel generator switched off.
• Do not bridge or repair fuses or replace them with fuses
with an incorrect ampere value.
Automatic circuit-breakers
Fig. 4.47: Automatic circuit-breaker
[1] Safety switch [2] Auxiliary contact test trip-

ping device
[3] Auxiliary contact
Automatic circuit-breakers, like fuses, disconnect the electric
circuit automatically in the event of overload. They protect lines
against damage through excessive heating as a result of exces-
sively high current.
After an automatic circuit-breaker trips, perform the following
work steps:
» Before switching on again, find the cause and eliminate it.
» Switch on safety switch [1] once again.

MAINTENANCE
Electrical system
All electrical switching and fusing elements are identified by

short codes. When a fault occurs, this short code is displayed
on the touch screen.
Testing auxiliary contact
» Push test tripping device upwards with a flat screwdriver to
the left.
 The safety switch jumps to OFF.
thorised personnel.
4.06.07.02 Motor protecting switch
DANGER
personnel.
Motor protecting switch for drives
1
2
1
3
Fig. 4.48: Motor protecting switch
[1] Test tripping device [2] Rotary switch

[3] Tripping range setting

MAINTENANCE
Electrical system
The motor protecting switches protect electric motors against

thermal overload due to mechanical overload or in the case of a
failure of an individual or both external conductors.
After a motor protecting switch trips, perform the following
work steps:
» Wait approx. 5 minutes for the components to cool down.
» Switch rocker switch or rotary switch [2] back on.

The short codes (e.g. 4Q1) are also assigned to the numbers
on the buttons at the operator panel and thus to the plant
components.
Testing motor protecting switch
» Actuate test tripping device [1] with a flat screwdriver.
 Rotary switch [2] jumps back to 0 or OFF.
Feeder trough overload relay
3
2
1 4
Fig. 4.49: Feeder trough overload relay
[1] Selector switch Automat- [2] Test tripping device

ic/Manual
[3] Tripping range [4] Stop and Reset button
The overload relays protect the vibration motors of the feeder
trough against thermal overload due to mechanical overload or

MAINTENANCE
Electrical system
in the case of a failure of an individual or both external conduc-

tors.
In automatic mode, the relay resets automatically after the vi-
bration motor has cooled down. In manual mode, the Reset [4]
button has to be pressed.
After an overload relay trips, perform the following work steps:
» Wait approx. 5 minutes for the components to cool down.
» In automatic mode, wait until the relay resets.
» In manual mode, press the Reset [4] button once again.

Testing overload relay
» Push test tripping device [2] with a flat screwdriver to the
left.
 In automatic mode, resetting is automatic after the test trip-
ping device is released.
» In manual mode, press the Reset [4] button once again.
 Overload relay is reset.
Switching to Manual/Automatic reset
» Set selector switch [1] with a flat screwdriver to Manual or
Automatic.
4.06.07.03 Earth fault circuit interrupter
DANGER
personnel.

MAINTENANCE
Electrical system
3
2
Fig. 4.50: Earth fault circuit interrupter
[1] System circuit-breaker [2] Test tripping device

[3] Indicator
Ground fault circuit interrupters compare the current flowing to
the consumer with the current flowing from the consumer.
These currents are normally identical. In the event of a fault,
the current flows to earth. The ground fault circuit interrupter
detects this situation and interrupts the electric circuit.
The ground fault circuit interrupter serves the complete plant
and the socket outlets of the external circuits.
After a ground fault circuit interrupter trips, perform the follow-
ing work steps:
» Switch on circuit breaker [1] once again.

Testing ground fault circuit interrupter
To test the ground fault circuit interrupter, the diesel generator

must be started and the main switch must be switched on.
Working in the control cabinet must only be carried out by
qualified and authorised personnel.
» Start diesel generator and switch on the main switch.

MAINTENANCE
Not assigned
» Actuate the test tripping device [2].

 The circuit breaker [1] jumps back to 0 and the indicator is
red.
4.07 Not assigned
4.08 Drive system
4.08.01 Servicing crawler running gear

4.08.01.01 Checking/tensioning crawler carrier chains
Checking chain tension
Fig. 4.51: Crawler carrier chain
[1] Test body [2] Slack of the crawler carri-

er chain
The crawler carrier chains must be tensioned such that they

have a slack of approx. 2 cm for every metre length. If the dis-
tance between sprocket and track roller or slide rail is 1.5 me-
tres, for example, the crawler carrier chain should have a slack
of approx. 3 cm at the furthest point.
NOTICE
Increased wear through incorrect chain tension
Increased wear will result if the crawler carrier chains are too
tight or too slack.
• Always tension crawler carrier chains in accordance with
the specifications.

MAINTENANCE
Drive system
» Move the plant on flat ground until the upper segment of the
crawler carrier chain is free of tension.
» Place test body [1], e.g. long straight rod, on the crawler
carrier chain between sprocket and track roller or slide rail.
» Measure slack of the crawler carrier chain [2]. Increase or
decrease tension of the crawler carrier chain as required.
 The chain tension has been checked.
Always check the left and right crawler carrier chain.
Increasing/decreasing crawler carrier chain tension
1
3
Fig. 4.52: Chain tensioner
[1] Chain tensioner cover [2] Grease clamping cylinder

[3] Filling valve
The crawler carrier chains are tensioned and slackened via hy-
draulic clamping cylinders filled with grease.
DANGER
Danger due to pressurised chain tensioner
The interior components of the chain tensioner are highly pres-
surised and can cause serious or fatal injury.
• Do not open the chain tensioner.
• Repair work must be carried out by authorised and quali-
fied personnel only.
Tensioning crawler » Check crawler carrier chain for damage and repair if neces-
carrier chain sary.

MAINTENANCE
Drive system
» Unscrew the cover of the chain tensioner [1].

» Mount slide coupling on filling valve [3].
» Tension crawler carrier chain by pressing grease into the
grease clamping cylinder [2].
» Check the tension of the crawler carrier chain during the ten-
sioning procedure and correct if necessary.
» Wipe up excess grease with a lint-free cloth and dispose of
in accordance with environmental specifications.
» Screw on the cover of the chain tensioner [1] again.
 The crawler carrier chain is tensioned.
Always tension the left and right crawler carrier chain.

The slide coupling and grease gun are in the toolbox.
Slackening crawler
carrier chainSlackening
crawler carrier chain
WARNING
Danger due to grease escaping under high pressure
Grease can be ejected under pressure; there is a risk of injury!
• Never release the lubricating nipple manually.
• Never completely unscrew the lubricating nipple.
» Unscrew the cover of the chain tensioner [1].

» Carefully release filling valve [3] until grease emerges. Do
not unscrew fully.
» Close filling valve again when no more grease emerges.
» Wipe up grease that emerges with a lint-free cloth and dis-
pose of in accordance with environmental specifications.
» Screw on the cover of the chain tensioner [1] again.
 The crawler carrier chain is slackened.
Always slacken the left and right crawler carrier chain.

MAINTENANCE
Drive system
4.08.01.02 Checking fastenings for track rollers and base plates
Fig. 4.53: Base plates
[1] Screws [2] Base plates

[3] Nuts
» Hammer-test or visually inspect base plates [2], screws and
nuts [1, 3].
» Tighten loose screws and nuts.
» Replace damaged base plates, screws and nuts if necessary.
 The base plates have been checked.
» Hammer-test or visually check screws on track rollers.
» Tighten loose screws.
 The track roller securing elements are checked.

MAINTENANCE
Drive system
4.08.01.03 Checking/Replacing the track pads
3
2
Fig. 4.54: Track pads
[1] Screws [2] Clamp

[3] Support [4] Rubber pad
DANGER
fatal injuries.
requirements in these assembly instructions.
DANGER
Danger of being run over
Tracked plants can cause serious or fatal injuries.
• Use banksmen and/or flagmen to monitor the driving area.
• Keep a safe distance away from the crawler running gear
when the plant is moving.
Track pads protect the ground against damage caused by the

chain links. In case of damage and wear, the track pads must
be changed. To check or replace the track pads, the plant must
be moved.
Checking track pads » Switch off diesel generator and control voltage.

MAINTENANCE
Drive system
» Switch off and remove battery isolating switch and carry it

with you.
» Check screws [1] of clamp [2] for firm seating. Carry out
check of all upper track pads.
» Tighten screws to specified tightening torque. For tightening
torques, see chap. 5.03.
» Visually inspect rubber pads [4] for damage and wear. Re-
place damaged or worn track pads immediately.
» Move plant, ensuring that the lower unchecked track pads
are at the top. Check track pads as described above. Moving
the plant, see chap. 3.07.
 The track pads have been checked.
Replacing track pad » Switch off diesel generator and control voltage.
» Switch off and remove battery isolating switch and carry it
with you.
» Slacken screws [1] and remove.
» Remove clamps [2].
» Disassemble carrier with defective or worn rubber pad.
» Attach new rubber pad and carrier to the inside of the chain.
» Attach new clamp to chain and mount on carrier.
» Secure clamp with new screws. Ensure carrier and clamp are
correctly seated.
torques, see chap. 5.03.
» If necessary, move plant to replace further track pads. Move
the plant, see chap. 3.07.
 The track pad has been changed.

MAINTENANCE
Drive system
4.08.02 Servicing track drive

4.08.02.01 Servicing planetary gear
Checking oil fill level
1 3
Fig. 4.55: Planetary gear drive system
[1] Oil level inspection plug [2] Oil filler screw

[3] Maximum oil fill level
CAUTION
» Move the plant on flat ground so that the oil filler screw [2]
is facing upwards.
» Clean the housing to prevent dirt entering the planetary
gear.
» Unscrew oil level inspection plug [1] and, if applicable, wipe
up escaping oil with a lint-free cloth.
» Check whether the oil fill level is visible at the lower edge of
the threaded bore.
» If necessary, top up gear oil to the maximum oil fill level [3].

MAINTENANCE
Drive system
» Insert oil level inspection plug with new sealing ring and
tighten.
 The oil fill level has been checked.
Always check the oil fill level of the left and right planetary
gear.
Changing gear oil
Fig. 4.56: Planetary gear drive system
[1] Oil drain screw [2] Oil filler screw
CAUTION
Draining gear oil » If necessary, warm gear oil up to service temperature by

moving the plant.
» Move the plant on flat ground so that the oil drain screw [1]
is facing downwards.
» Clean the housing to prevent dirt entering the planetary
gear.
» Place an oil catching pan with a capacity of approx. 10 litres
under oil drain screw [1].
» Unscrew oil filler screw [2].

MAINTENANCE
Drive system
» Unscrew oil drain screw [1] and drain the gear oil complete-
ly.
» Insert oil drain screw [1] with new sealing ring and tighten.
» Dispose of used oil in accordance with environmental speci-
fications.
 The gear oil has been drained.
Filling gear oil » Fill fresh gear oil with the corresponding specifications with
the help of a funnel through the opening of the oil filler
screw. For specifications and filling volume, see chap. 5.
» Fill gear oil up to the lower edge of the threaded bore of the
oil filler screw [2].
» Insert oil filler screw [2] with new sealing ring and tighten.
» Wipe up overflowing oil with a lint-free cloth and dispose of
in accordance with environmental specifications.
 The gear oil has been filled.
Always change gear oil of the left and right planetary gear.
4.08.02.02 Checking components for leaks

The planetary gears and hydraulic motors and hydraulic lines of
the drive system must be checked every day for leaks. Any
leaks must be eliminated immediately.
» Visually check housing of planetary gears for oil discharge.
» Visually check hydraulic components of the drive system for
escaping oil.
» Have leaks eliminated by repair and service personnel.
 The planetary gear and drive systems have been checked.

MAINTENANCE
Drive system
4.08.03 Repairing crawler running gear

4.08.03.01 Opening/closing crawler carrier chains
3
5
2
6
Fig. 4.57: Crawler carrier chain lock
[1] Screw holes for base [2] Outer chain link

plates
[3] Inner chain link [4] End rings
[5] End bushing [6] End pin
[7] Chain bolt marking
9
8
10
Fig. 4.58: Crawler carrier chain lock
[8] Chain bolt [9] Base plates

MAINTENANCE
Drive system
[10]Sprocket
For repair to the crawler running gear, the crawler carrier chain
can be opened at the chain lock.
WARNING
Risk of injury due to heavy components
During repair work at the crawler running gear, there is a risk
of injury due to heavy and falling components.
• Always use suitable hoisting gear and lifting accessories.
• Secure components against falling down.
In contrast the end pin, the chain bolt [8] is provided with a
centring device or a turned shoulder depending on the design.
Opening chain lock » Move the plant on flat ground so that the chain bolt [8] is
approx. in the 1 o'clock position above the sprocket [10].
» Unscrew one or two base plates [9] before and after the
chain bolt.
» Provided wedges of hard wooden blocks between the chassis
and inner chain link before and after the chain bolt respec-
tively. The chain links must be secured so that springing
back is not possible when the chain bolt is driven out.
» Using suitable hoisting gear, e.g. chain hoist, secure the
crawler carrier chain at the end bushing [5] against falling
from the sprocket [10].
 The chain lock is ready for knocking out the chain bolt.
» If necessary, heat the chain links around the chain bolt [8]
to approx. 400 °C to expand the fits.
» Drive the chain bolt [8] with a drift and heavy hammer out
of the fits in the outer and inner chain link [3] and [2].
» Lower the separated crawler carrier chain from the sprocket
with the help of the fitted hoisting gear.
» Remove end rings [4] from the sinks of the chain link and
store for reuse.
 The crawler carrier chain has been separated.
Closing chain lock » Coat end rings [4] with grease and insert in the sinks of the
chain links.
» Using a chain hoist at the end bushing [5], pull the crawler
carrier chain between the outer and inner chain link.
» Clean and polish fits of chain bolt [8] and coat with lubricat-
ing grease.

MAINTENANCE
Drive system
» Use a heavy hammer to drive the chain bolt [8] into the fits
of the outer and inner chain link [3] and [2].
» Secure chain bolt [8] with weld points to outer chain link [2].
» Remove wedged wooden blocks from between chassis and
chain links.
» Screw on base plates [9].
 The crawler carrier chain has been closed.
4.08.03.02 Repairing chain link
1
5
Fig. 4.59: Chain link
[1] End bushing [2] Cutting points

[3] Inner chain link [4] End pin
[5] Outer chain link [6] Damaged chain link
Damaged chain links on the crawler carrier chain can be re-
paired with a repair kit provided for this purpose.
WARNING
Risk of injury due to heavy components
During repair work at the crawler running gear, there is a risk
of injury due to heavy and falling components.
• Secure components against falling down.

MAINTENANCE
Drive system
NOTICE
Danger of fires due to welding torch
Welding torches, hot metal and sparks can set fire to compo-
nents and objects in the surrounding area.
• Where possible, cover components and objects exposed to
a risk of fire.
• Protect components and objects against dripping hot metal
and sparks.
• Ensure fire extinguisher is ready before starting work.
• Ensure a fire watch is present during and after welding
work.
Removing chain link » Move the plant on flat ground so that the damaged chain link
is approx. in the one o'clock position above the sprocket.
» Unscrew one or two base plates before and after the chain
link.
» Using suitable hoisting gear, e.g. chain hoist, secure the
crawler carrier chain at the end bushing of the undamaged
chain link against falling from the sprocket.
» Using a welding torch, cut through the outer and inner chain
link [5] and [3] as well as end bushing [1] including the end
pins inside it at the cutting points [2] shown.
» Remove cut-out debris and scraps of the end bushing.
» If necessary, heat the chain links around the end pin [4] to
approx. 400 °C to expand the fits.
» Drive the end pin [4] with a drift and heavy hammer out of
the fits in the outer and inner chain link [5] and [3].
» Grind off and deburr projecting bushing ends of the intact
chain link.
» Use a welding torch to burn holes centrally in the cut-

through end pin of the intact chain link on the opposite side.
» Drive out remaining parts of the end pin with a drift and a
heavy hammer.
» Clean fits of the chain link and coat with lubricating grease.
 The damaged chain link has been removed.

MAINTENANCE
Drive system
Inserting chain link The repair kit for the chain link contains all components re-
quired to repair a chain link.
Fig. 4.60: Chain link repair kit
[1] End bushing [4] End pins, 2 pieces

[7] End rings, 4 pieces [8] Repair chain link 1 piece
» Coat two end rings [7] with grease and insert with the cham-
fered side in the sinks of the intact chain link.
» Clean and polish fits of end pin [4] and coat with lubricating
grease.
The fit surfaces of the end pins must be polished until they can
be inserted in the bores of the chain links without great effort.
» Insert end bushing [1] of the repair chain link [8] in the in-
tact chain link and insert end pin [4].
» Coat the two remaining end rings [7] with grease and insert
with the chamfered side in the sinks of the repair chain link.
» Using a chain hoist, pull the other end of the crawler carrier
chain into the repair chain link [8] and insert second end pin.
Ensure that the end rings remain in the sinks.
» Secure both end pins [4] with weld points at the repair chain
link [8].
 The repair chain link is inserted.

MAINTENANCE
Not assigned
4.09 Not assigned
4.10 Conveyor unit
4.10.01 Servicing belt conveyors
DANGER
WARNING
Risk of falling
secure.
4.10.01.01 Check conveyor belts
4
2

MAINTENANCE
Conveyor unit
Fig. 4.61: Assembly of crusher discharge conveyor
[1] Chassis beam [2] Console, crusher dis-

charge conveyor
[3] Top connecting rod [4] Mounting for crusher dis-
charge conveyor/chassis
In order to avoid material damage, the consoles of the crusher
discharge conveyor must be at the chassis beam.
WARNING
Risk of falling
secure.
NOTICE
Incorrectly set top connecting rods cause damage to the con-
veyor belt and plant components.
• Ensure that the consoles of the conveyor belt are at the
chassis beam.
• Adjust the top connecting rods so that the consoles are at
the chassis beam.
» Switch off plant components and the diesel generator. Re-

move key and carry it with you.
» Check proper assembly of the crusher discharge conveyor.
Ensure that the consoles [2] are at the chassis beam [1] on
both sides.
» If necessary, tighten the top connecting rods until the con-
soles [2] are at the chassis beam [1].
 The belt conveyor has been checked.
4.10.01.02 Checking conveyor belts

The belt conveyors are first inspected while running and then
while stationary.
» Start the belt conveyors in manual mode and, from a safe
distance, visually check for the following damage:
• Conveyor belts.
– Damage to edges
– Damage to deck plates

MAINTENANCE
Conveyor unit
– Damage to wire cloth

– Detachments from endless connection
– Detachment of cleats
– Scuff markings and scores
– Tension of the conveyor belt. Insufficient tension causes
belt sagging and slipping of the drive pulley. Excessive
belt tension causes the bottom segment to vibrate.
– Belt drift
• Components of the belt conveyor.
– Jammed and worn support, deflection and return rollers
– Loosened screw connections
– Jammed and worn scrapers
– Worn sealing lips of material guide ledges
• Other.
– Abnormal running noises
– Jammed stones
– Contamination and caking
– Eccentric conveyor belt loading
» Switch off belt conveyors and diesel generator and secure
against reactivation.
» Visually check the above-named items once again
» Eliminate damage and deficiencies determined.
 The belt conveyors have been checked.
4.10.01.03 Checking/setting return roller guard
4
5
Fig. 4.62: Return roller guard

MAINTENANCE
Conveyor unit
[1] Conveyor belt [2] Adjusting and retaining

screws for return roller
guard
[3] Gap dimension for con- [4] Return roller guard
veyor belt, return roller
guard (max. 5 mm)
[5] Return roller
To avoid personal injury and material damage, the return roller
guards must be set to the correct gap dimension.
WARNING
Risk of being drawn in by rotating components
When controlling and visually checking running belt conveyors,
there is a risk of limbs being drawn in by rotating components.
• Keep well away from rotating components.
• Carry out maintenance and service work only on stationary
belt conveyors.
WARNING
Risk of falling
secure.
NOTICE
Incorrectly set return roller guards cause damage at the con-
veyor belt and downstream plant components.
• Ensure that the conveyor belt does not lie on the return
roller guard.
• Ensure that the gap dimension of 5 mm between conveyor
belt and return roller guard is set.
Checking return roller » Switch off plant components and the diesel generator. Re-
guard move key and carry it with you.
» Check return roller guard [4] on both sides for safe and firm
installation. Tighten screws if necessary [2]
» Visually inspect return roller guard for damage. Replace
damaged return roller guard.

MAINTENANCE
Conveyor unit
» Check all return roller guards.

 The return roller guards have been checked.
Checking gap dimension » Use suitable measuring instrument to check the gap dimen-
conveyor belt, return sion [3] over the complete conveyor belt width.
roller guard
» Check the gap dimensions on all return roller guards.
 The gap dimension has been checked.
Setting gap dimension » Slacken adjusting and retaining screws [2] on both sides.
conveyor belt, return
» Set gap dimension [3] between conveyor belt and return
roller guard
roller guard.
» Ensure that the gap dimension [3] is set over the complete
width of the conveyor belt.
» Tighten adjusting and retaining screws [2] on both sides.
» Check gap dimension again and adjust as described if nec-
essary.
 The gap dimension has been set.
4.10.01.04 Servicing scraper

Adjusting wedge stripper
Fig. 4.63: Wedge stripper
[1] Clamping rails [2] Chain

[3] Rubber scraper
The wedge stripper cleans loose material from the inside of the
bottom segment. It is attached to the conveyor belt frame with
a chain [2] and adjusts itself automatically through its own dead
weight.
» Visually check rubber scraper [3] for damage and wear.

MAINTENANCE
Conveyor unit
» If necessary, unscrew clamp rails [1] and replace rubber

scraper [3].
 The wedge stripper has been serviced.
Adjusting flat scraper
3
2
Fig. 4.64: Flat scraper
[1] Scraper strip [2] Screw

[3] Fork spanner [4] Clamping element
The flat scraper cleans loose material from the outside of the
conveyor belt. The clamping elements [4] guarantee a constant
contact pressure of the scraper strip [1]. If the scraper strip
does not make contact with the conveyor belt, or contact pres-
sure is too low, it has to be adjusted.
» Place open-end wrench of the correct size [3] on the clamp-
ing element [4] and loosen screw [2] but do not fully remove
it.
» Turn the clamping element [4] to increase or reduce the con-
tact pressure of the scraper strip on the conveyor.
» Retighten screw [2].
» Repeat the procedure at the clamping element on the other
side.
» If necessary, reverse or replace damaged or worn scraper
strip.
 The flat scraper has been serviced.

MAINTENANCE
Conveyor unit
If the conveyed material tends to form deposits on the convey-

or, e.g. cohesive material such as clay, wet dust, etc., the con-
tact pressure of the scraper strip has to be increased.
With cohesionless material, it is sufficient to apply the scraper
strip to the conveyor belt without contact pressure.
Flat scrapers are installed at the following belt conveyors:
• Crusher discharge conveyor
• Prescreen conveyor
4.10.01.05 Adjusting rubber plates
3 4
Fig. 4.65: Rubber plates
[1] Conveyor belt [2] Rubber plate

[3] Screw [4] Clamping plate
[5] Belt conveyor
WARNING
Risk of falling
secure.
The rubber plates seal the lateral guide ledges off from the con-
veyor belt so that no material can reach the rotating compo-

MAINTENANCE
Conveyor unit
nents or fall off the belt conveyor. In case of damage and wear,
the rubber plates must be adjusted or changed.
» Slacken screws [3] on clamping plates [4], but do not un-
screw.
» Adjust rubber plates [2] until they make contact on the con-
veyor belt.
» If necessary, replace damaged or worn rubber plates.
» Retighten screws [3] on clamping plates [4].
 The rubber plates have been adjusted.
4.10.01.06 Changing guide rails
2
4
Fig. 4.66: Guide rails for prescreen conveyor
[1] Conveyor belt [2] Guide rail for drive pulley

[3] Guide rail fastening [4] Guide rail for feed skirt
WARNING
Risk of falling
secure.
The guide rails seal the material guide ledges off from the con-
veyor belt so that no material can enter the rotating compo-
nents. In case of damage and wear, the guide rails must be
adjusted or changed.

MAINTENANCE
Conveyor unit
» Release screws and nuts of clamping plates [3].

» Disassemble clamping plates with screws and nuts.
» Remove damaged or worn guide rails [2] and [4].
» Adjust guide rails until they make contact on the conveyor
belt.
» Reinstall clamping plates [3] with screws and nuts and tight-
en screws.
 The guide rails have been changed.
4.10.01.07 Servicing bevel helical gearbox
Fig. 4.67: Belt conveyor drive with bevel helical gearbox
[1] Oil drain screw with in- [2] Oil filler screw and venti-
clined installation lation
[3] Oil drain screw with hori-
zontal installation
It is not possible to check the oil fill level with bevel helical gear-
boxes as the belt conveyor drives are installed in different posi-
tions and a fill level screw is not provided. If leaks are
determined, the fill volume must be determined by draining.
CAUTION

MAINTENANCE
Conveyor unit
If installation is inclined, the oil drain screw [1] must be used;

oil drain screw [3] must be used for horizontal installation.
Checking oil fill level » Warm up gear oil to service temperature. If necessary, run
belt conveyor approx. 10 minutes.
» Clean housing of bevel helical gearbox. In particular, the oil
filler and oil drain screws must be free of contamination.
» Place a clean oil catching pan with a capacity of approx. 10
litres under oil drain screw [1] or [3].
» Unscrew oil drain screw [1] or [3] and drain gear oil.
» Determine the fill volume. For correct filling volume, see
chap. 5.01.06.
» Insert oil drain screw [1] or [3] again and tighten.
» Refill drained gear oil with the help of a funnel. If necessary,
top up missing volume with oil of corresponding specifica-
tions.
» Insert oil filler screw [2] again and tighten.
» Wipe up overflowing oil with a cloth and dispose of in accord-
ance with environmental specifications.
» Check bevel helical gearbox for leaks.
Changing gear oil » Warm up gear oil to service temperature. If necessary, run
» Clean housing of bevel helical gearbox. In particular, the oil
filler and oil drain screws must be free of contamination.
» Place an oil catching pan with a capacity of approx. 10 litres
under oil drain screw [1] or [3].
» Unscrew oil drain screw [1] or [3], drain gear oil and dispose
of in accordance with local environmental specifications.
» Insert oil drain screw [1] or [3] again and tighten.
» Fill fresh gear oil with the corresponding specifications with
screw. For correct filling volume, see chap. 5.01.06.

MAINTENANCE
Conveyor unit

» Check bevel helical gearbox for leaks.
 The gear oil has been changed.
4.10.01.08 Servicing drum motors
Fig. 4.68: Drum motor for belt conveyor drive
[1] Identification plate [2] Oil drain screw with mag-

netic filter (red dot)
[3] Oil filler screw and venti-
lation
It is not possible to check the oil fill level with drum motors. If
leaks are determined, the fill volume must be determined by
draining.
CAUTION
Checking oil fill level » Warm up gear oil to service temperature. If necessary, run
» Switch off battery isolator, remove it and carry it with you.

MAINTENANCE
Conveyor unit
» Clean the drum motor. In particular, the oil filler and oil drain
screws must be free of contamination.
» Turn the drum motor until the oil drain screw [2] is at the
lowest point.
» Place a clean oil catching pan with a sufficient capacity under
oil drain screw [2].
» Unscrew the oil drain screw [2] and drain the gear oil.
» Determine the fill volume. For correct fill volume, see iden-
tification plate [1].
» Insert oil drain screw [2] again and tighten.
» Refill drained gear oil with the help of a funnel. If necessary,
top up missing volume with oil of corresponding specifica-
tions.
» Check drum motor for leaks.
Changing gear oil » Warm up gear oil to service temperature. If necessary, run
» Clean the drum motor. In particular, the oil filler and oil drain
screws must be free of contamination.
» Place an oil catching pan with sufficient capacity under oil
drain screw [2].
» Unscrew oil drain screw [2], drain gear oil and dispose of in
accordance with local environmental specifications.
» Insert oil drain screw [2] again and tighten.
» Fill fresh gear oil with the corresponding specifications with
screw. For correct fill volume, see identification plate [1].
» Check drum motor for leaks.

MAINTENANCE
Conveyor unit
4.10.01.09 Checking tensioning bearings
The tensioning bearings must be checked and lubricated at

regular intervals.
The tensioning bearings are installed at the following belt con-
veyor:
• Crusher discharge conveyor (drive pulley)
WARNING
Risk of falling
secure.
NOTICE
Excessive offset of the drive shaft can result in damage to the
felt seal. This results in consequential damage to the tension-
ing bearings.
• Align the drive drum at a right angle to the conveyor belt
frame.
• Check correct seating of felt seal on the drive shaft.
• Maximum offset of the drive shaft of 3 cm should not be ex-
ceeded.
» Switch off plant and control voltage.

» Provide and use suitable climbing aids, see chap. 1.07.04.
» Disassemble guard devices of the tensioning bearings on
both sides.
Due to the installation position, only the outer bearing caps

and felt seals can be checked in some circumstances. During
repair work always replace the felt seals of all bearing caps.
Contact the Service Department of KLEEMANN GmbH.

MAINTENANCE
Conveyor unit
4
3
Fig. 4.69: Checking tensioning bearings
[1] Bearing cap, outer [2] Drive shaft

[3] Felt seal [4] Fastening screw, bearing
cap
Checking tensioning » Wipe grease collar on bearing cover and drive shaft, e.g.
bearings with a cloth. Dispose of collected grease in accordance with
environmental regulations. Observe national requirements.
» Clean drive shaft and bearing cap.
» Check felt seal [3] for correct seating on the drive shaft.
If there is a gap between the drive shaft and felt seal, this is
an indication that the offset is too high. The maximum offset
is 3 cm.
» If necessary, check the offset and, using the tensioning de-
vice, align the drive pulley at a right angle to the conveyor
belt frame. Tensioning device, see chap. 4.10.02.01.
» Check felt seal once again for correct seating.
» Check fastening screws [4] on bearing cap for firm seating.
Tighten screws if necessary.
» Repeat the same work steps on the opposite side.
 The tensioning bearings have been checked.
In the case of improper seating of a felt seal, replace the felt

seals of the inner and outer bearing cap. Contact the Service
Department of KLEEMANN GmbH.
» Install safety devices and tighten screws to specified tight-
ening torque. For tightening torques see chap. 5.03.

MAINTENANCE
Conveyor unit
4.10.01.10 Lubricating clamping bearings and plummer blocks
Fig. 4.70: Tensioning bearing lubricating nipples
[1] Conveyor belt frame [2] Lubricating nipples
The tensioning bearings of the drive pulley of the crusher dis-

charge conveyor are each lubricated via a lubricating nipple
and a lubrication tube. The lubricating nipples are located on
the bottom side of the conveyor belt frame. If necessary, a
suitable climbing aid must be used to lubricate the tensioning
bearings at the short crusher discharge conveyor. Use suitable
climbing aids see chap. 1.07.04.
The lubricating nipples of the tensioning bearings at the ex-
tended crusher discharge conveyor are located in the area of
the run-off chute of the magnetic separator.
Lubricating plummer blocks, see chap. 4.10.01.11.
DANGER
Lubricating tensioning » Switch off diesel generator and control voltage.

bearings
» Switch off battery isolator, remove key and carry it with you.
» If necessary, use a suitable climbing aid, see chap. 1.07.04.

MAINTENANCE
Conveyor unit
» Use a grease gun to press approx. 3 g of grease with the ap-

propriate specifications into the lubricating nipples [1].
» Remove grease gun.
» Clean away any excess grease on the lubricating nipples and
dispose of in accordance with the country-specific regula-
tions.
» Switch on plant and start crusher discharge conveyor in
manual operation, see chap. 3.05.
» Run belt conveyor for 15 seconds.
 The tensioning bearings have been lubricated.
Lubrication point Amount of grease per lu-

brication point
Lubricating nipples Approx. 3 grammes
Tab. 4.1: Tensioning bearing lubrication points
One stroke of the grease gun corresponds to approx. 3 g lubri-

cating grease.
For lubricants, see chap. 5.04.01.
4.10.01.11 Lubricating plummer blocks
3
4
2
1
3
Fig. 4.71: Plummer block
[1] Drive pulley and/or return [2] Lubricating nipple

roller
[3] Block cover screws [4] Dummy plug

MAINTENANCE
Conveyor unit
[5] Sealing lips

The plummer blocks are installed at the following belt convey-
ors:
• Crusher discharge conveyor (return roller)
The plummer blocks of the drive pulley and / or return roller are
disassembled for lubrication. The plummer block is completely
filled with lubricating grease via the lubricating nipple [2] and
the dummy plug [5].
NOTICE
Escaping grease expands the sealing lips of the plummer
blocks. Dust and moisture can penetrate the expanded and
damaged sealing lips and destroy the blocks.
• Unscrew dummy plugs before pressing in grease via the lu-
bricating nipple.
• Never press in grease with the dummy plug installed.
• Replace damaged sealing lips.
Checking plummer » Switch off plant components and the diesel generator.
blocks
» Unscrew protective covers of plummer blocks.
» Remove dirt and dust from plummer blocks.
» Wipe up escaping grease with a cloth and dispose of it in ac-
cordance with environmental regulations.
» Visually inspect inner and outer sealing lips [5] for damage
and replace if necessary.
» Screw protective covers of plummer blocks back on.
 The plummer blocks have been checked.
Lubricating plummer » Unscrew protective covers of plummer blocks.
blocks
» Remove dirt and dust from plummer blocks.
» Using a suitable securing element, e.g. tension belt, secure
drive pulley and/or return roller [1] against slipping out of
the plummer blocks.
» Unscrew screws on bearing caps [3] and remove bearing
caps.
» Remove sealing lips [5] from the plummer block. The sealing
lips are divided into two parts and can be removed as such
from the shaft.
» Remove old grease from the plummer block and bearing cap
and dispose of it in an environmentally friendly manner.
» Insert new sealing lips in the plummer block and bearing
cap.

MAINTENANCE
Conveyor unit
» Fill plummer block and bearing cap with the corresponding

amount of fresh lubricating grease with the relevant specifi-
cations.
The specified lubricating grease quantity must be filled com-

pletely into the plummer block and the bearing cap.
» Reinstall suitable bearing cap with screws [3] and tighten
screws to specified tightening torque.
The plummer blocks and bearing caps are marked to prevent

confusion.
» Unscrew dummy plug [4].
» Use a grease gun to press grease with the appropriate spec-
ifications into the lubricating nipple [2] until grease emerges
from the bore of the dummy plug.
» Screw in dummy plug [4], wipe off excess lubricating grease
and dispose of it in accordance with environmental regula-
tions.
» Screw protective covers of plummer blocks back on.
 The plummer blocks have been lubricated.
Lubrication via Bearing type Grease qty. in

grammes
Plummer block SE 513-611 300
housing1
Plummer block SNL 513-611 340
housing1
housing1
housing1
Tab. 4.2: Plummer block lubrication
1
The bearing caps must be disassembled prior to lubricating the
plummer blocks.
Tightening torque of bearing cap screws
Thread Tightening torque in Nm

M12 80
M16 150
Tab. 4.3: Tightening torque of bearing cap screws

MAINTENANCE
Conveyor unit
4.10.02 Servicing belt conveyors

4.10.02.01 Tensioning conveyor belt
2 5
Fig. 4.72: Belt conveyor tensioning device
[1] Conveyor belt [2] Conveyor belt frame

[3] Threaded rod [4] Clamping nut
[5] Locknut [6] Guide
Example presentation of a return roller tensioning device
1 6
Fig. 4.73: Belt conveyor tensioning device
[1] Conveyor belt [2] Conveyor belt frame

[3] Threaded rod [4] Clamping nut

MAINTENANCE
Conveyor unit
[5] Locknut [6] Guide
WARNING
Risk of falling
secure.
NOTICE
A conveyor belt with belt drift, or which is too tightly or loosely
tensioned, wears faster and can cause consequential damage
on conveyor components.
• Tension the drive pulley or return roller evenly and at right
angles to the conveyor belt frame.
• Tighten the conveyor belt to the correct tension.
The belts on all belt conveyors are tensioned with two mechan-
ical tensioning devices respectively, which in principle have the
same design.
Tensioning the conveyor » If necessary, unscrew protective covers of tensioning devic-
belt es.
» Slacken the left and right locknuts [5] until the tensioning
path is free.
» Turn the left and right clamping nuts [4] evenly until the
conveyor belt is correctly tensioned. Ensure that the drive
pulley and/or return roller are at right angles to the convey-
or belt frame [2].
» Retighten the left and right locknuts [5].
» If necessary, screw back on protective covers of tensioning
devices.
 The conveyor belt is tensioned.
A conveyor belt that is tensioned too loosely can be recognised

by sagging between the return rollers. A conveyor belt that is
tensioned too tightly can be recognised by vibrating of the bot-
tom segment during operation.
A rule of thumb: The correct tension is the lowest possible ten-
sion that prevents the drive pulley from slipping at the convey-
or belt.

MAINTENANCE
Conveyor unit
Slackening the conveyor » If necessary, unscrew protective covers of tensioning devic-

belt es.
» Turn the left and right clamping nuts [4] evenly until the
conveyor belt is loosened. Ensure that the drive pulley and/
or return roller are at right angles to the conveyor belt frame
[2].
» Tighten the left and right locknuts [5].
» If necessary, screw back on protective covers of tensioning
devices.
 The conveyor belt has been slackened.
4.10.02.02 Changing conveyor belt

There are two basic different procedures for changing the con-
veyor belt:
• Place split conveyor on belt conveyor and join the ends by
vulcanising.
• Remove belt conveyor and partly disassemble and mount
endless conveyor belt.
Contact persons for repair of conveyor belts are listed under

"Customer service" on the homepage of KLEEMANN GmbH:
www.kleemann.info
4.10.02.03 Checking conveyor belt run
Fig. 4.74: Conveyor belt run
[1] Support rollers [2] Conveyor belt frame

[3] Conveyor belt

MAINTENANCE
Conveyor unit
A correctly aligned conveyor belt runs centrally on the guide

rollers and between the drive and bend pulleys. This ensures re-
duced repair costs and trouble-free operation.
The conveyor belt must not touch the conveyor belt frame.
WARNING
Risk of being drawn in by rotating components
When controlling and visually checking running belt conveyors,
there is a risk of limbs being drawn in by rotating components.
• Keep well away from rotating components.
• Carry out maintenance and service work only on stationary
belt conveyors.

» Observe conveyor belt running with and without charged
material and record deficiencies determined.
 Conveyor belt running has been checked.
4.10.02.04 Adjusting conveyor belt run
Fig. 4.75: Conveyor belt run
[1] Return roller [2] Return rollers

[3] Conveyor belt [4] Drive pulley
The illustration shows a conveyor belt [3] with a drift to the right
and how the return rollers [2] have to be adjusted accordingly.

MAINTENANCE
Conveyor unit
Reasons for faulty conveyor belt run

• Inadequate alignment of the drive pulley and/or return roll-
er.
• Drums and rollers contaminated on one side.
• Eccentric feeding unit and guide of the conveyor belt.
• Scrapers placed in the material stream at an inclination that
discharge the material via the side conveyor edge.
• Scraping of the conveyor belt at the conveyor belt frame or
at jammed material pieces.
• Uneven power transmission over the conveyor belt width
due to dampness.
• Incorrectly installed connection of the conveyor belt with
kink in longitudinal direction.
• Jammed material at the sealing.
• Uneven contact pressure.
Adjusting conveyor belt run
If the faulty conveyor belt run is caused by a reason other than
those listed above, the belt run must be adjusted via the return
rollers [2].
At the point where the conveyor belt [3] begins to drift, one or
several return rollers [2] can be adjusted.
» Rule out the above-mentioned reasons for faulty belt run.
» Tension the conveyor belt if necessary.
» Slacken mount of return roller [2] and turn slightly in the
elongated holes.
» Tighten mount again.
» Switch on plant components and diesel generator and ob-
serve conveyor belt run with and without feed material.
» Check setting as required.
 The conveyor belt run has been adjusted
Even a few millimetres in the setting range of the return rollers

is sufficient to make a correction to the conveyor belt run. To
check the conveyor belt run, the belt conveyor must run for at
least 2 minutes.
Due to incorrect manufacture, usage or storage, conveyor

belts can be deformed or bent and their setting is therefore no
longer correct.

MAINTENANCE
Conveyor unit
4.10.03 Checking chutes

4.10.03.01 Checking rubber curtains and sealing
Fig. 4.76: Rubber curtains and sealing
[1] Rubber curtains for [2] Crusher outlet rubber cur-

change flap and by-pass tains
device
[3] Rubber curtains for by-
pass device
The rubber curtains and sealing of chutes guide the material at
the transfer points and reduce dust emission. Damaged rubber
curtains can no longer completely fulfil this task.
» Visually check rubber curtains [1] of the change flap and by-
pass device for damage.
» Visually check rubber curtains of by-pass device outlet [3]
and crusher outlet [2] for damage.
» Check securing strips of rubber curtains for damage and se-
curity.
» Replace damaged components if necessary.
 The chutes have been checked.
4.10.04 Servicing electromagnetic separator

switched on.

MAINTENANCE
Conveyor unit
DANGER
DANGER
tors.
WARNING
Risk of falling
secure.
4.10.04.01 Checking conveyor belt

The magnetic separator is inspected while running first and then
while stationary.
» Start the magnetic separator in manual mode and, from a
safe distance, visually check for the following damage:
• Conveyor belt.
– Damage to edges
– Detachments from endless connector
conveyor belt sagging and slipping of the drive pulley.

MAINTENANCE
Conveyor unit
– Conveyor belt drift

• Other.
– Trapped bits of metal
» Switch off magnetic separator and diesel generator and take
measures to prevent them from being switched on again.
» Visually check the aforementioned points once again.
 Magnetic separator has been checked.
Fig. 4.77: Magnetic separator tensioning device
[1] Tensioning carriage re- [2] Locknut

taining screws
[3] Clamping screw
NOTICE
A conveyor belt with belt drift or one that has been tensioned
too tightly or loosely wears faster and can result in damage to
the components of the magnetic separator.

MAINTENANCE
Conveyor unit
The conveyor belts of all magnetic separators are each ten-

sioned with two mechanical tensioning devices that basically
share the same design.
Tensioning conveyor belt » Switch off diesel generator and plant.
» Provide and use a suitable climbing aid such as a lifting plat-
form or scaffolding.
» If necessary, remove the protective covers of the tensioning
devices.
» Loosen the retaining bolts [1] of the tensioning carriage.
» Loosen the locknut [2] until the tension is free.
» Turn the tensioning bolts (3) until the conveyor belt is ten-
sioned correctly.
» Tighten locknuts [2] again.
» Tighten the retaining bolts [1] of the tensioning carriage.
» If they were removed, reinstall the protective covers of the
tensioning devices.

or belt.
Detensioning conveyor » Switch off diesel generator and plant.

belt
devices.
» Loosen the retaining bolts [1] of the tensioning carriage.
» Slacken locknuts [2].
» Turn the tensioning bolts [3] evenly until the conveyor belt
is relieved of tension.
» Tighten the locknuts [2].
» Tighten the retaining bolts [1] of the tensioning carriage.

MAINTENANCE
Conveyor unit

tensioning devices.
 The conveyor belt has been detensioned.
4.10.04.03 Servicing worm gear

To check the oil fill level, the magnetic separator must be low-
ered.
CAUTION
2
1
Fig. 4.78: Magnetic separator drive with worm gear
[1] Magnetic separator [2] Crusher discharge con-

veyor
Checking oil fill level » Start the plant in automatic mode and perform the steps in-
cluding "Press start-up enable button", see chap. 3.04.
» Lower completely with the aid of the magnetic separator ra-
dio remote control [1], see chap. 2.02.04.

MAINTENANCE
Conveyor unit
Fig. 4.79: Worm gear
[3] Fill level plug

» Clean the worm gear housing. In particular, the oil filler plug
[3] must be free of contamination.
» Unscrew the fill level plug [3].
» Check the fill level. Oil must be evident on the fill level plug;
replenish if necessary.
» Screw in the fill level plug [3] again and tighten.
» Check the worm gear for leaks.
Preparations for
changing gear oil
To change the gear oil, the worm gear must be moved to the
vertical position and the magnetic separator must be lowered.

MAINTENANCE
Conveyor unit
Fig. 4.80: Magnetic separator drive
[4] Securing bolts for mag- [5] Eye bolt

netic separator drive
Rotating worm gear » If necessary, lower the magnetic separator in the same way
as described for checking the oil level.
» Warm up gear oil to service temperature. Allow the magnetic
separator to run for about 10 minutes if required.
» Attach suitable lifting gear and equipment to the ring bolt
[5] of the worm gear and take up the weight slightly.
» Unscrew all securing bolts [4].
» Mark the position of the worm gear for later alignment.
» Turn the worm gear so that it is vertical and lock in place us-
ing one securing bolt [5].
» Clean the worm gear housing. In particular, the fill filler plug
must be free of contamination.
CAUTION

MAINTENANCE
Conveyor unit
Fig. 4.81: Worm gear
[3] Fill level plug [6] Drain plug for gear oil
Changing gear oil » Unscrew the fill level plug [3].

» Place an oil tray with a capacity of approx. 4 litres under the
oil drain plug [6].
» Unscrew the oil drain plug [6], drain the gear oil and dispose
of in an eco-friendly manner.
» Screw in the drain plug [6] again and tighten.
» Turn the worm gear back to the correct position.
» Screw in all securing bolts [5] and tighten.
» Remove lifting gear and lifting apparatus.
» Fill fresh gear oil with the corresponding specifications
through the opening of the fill filler plug with the help of a
funnel.
» Ensure that gear oil is up to the opening of the fill level plug.
» Screw in the fill level plug [3] again and tighten.
» Wipe away any oil that has escaped using a cloth and dis-
pose of in an eco-friendly manner.
» Check the worm gear for leaks.
» Raise the magnetic separator again if necessary.

MAINTENANCE
Conveyor unit
4.10.04.04 Lubricating bearings
Fig. 4.82: Magnetic separator bearings
[1] Lubricating nipple [2] Dust cap

The bearings of the drive pulley and return roller are lubricated
via a lubricating nipple.
Lubricate bearings » Switch off diesel generator and plant.
» Provide and use a suitable climbing aid.
ifications into the lubricating nipples of the drive pulley and
return roller bearings.
» Clean away any excess lubricating grease and dispose of in
an environmentally friendly manner.
 The bearings have been lubricated.

brication point
Bearings 2.5 grammes
Tab. 4.4: Lubricating point of magnetic separator

cating grease.

MAINTENANCE
Conveyor unit
4.10.05 Servicing permanent magnetic separator

switched on.
DANGER
DANGER
tors.
WARNING
Risk of falling
secure.
4.10.05.01 Checking conveyor belt

The magnetic separator is inspected while running first and then
while stationary.
» Start the magnetic separator in manual mode and, from a
safe distance, visually check for the following damage:

MAINTENANCE
Conveyor unit
• Conveyor belt.
– Damage to edges
– Detachments from endless connector
conveyor belt sagging and slipping of the drive pulley.
– Conveyor belt drift
• Other.
– Trapped bits of metal
» Switch off magnetic separator and diesel generator and take
measures to prevent them from being switched on again.
» Visually check the aforementioned points once again.
 Magnetic separator has been checked.
Fig. 4.83: Magnetic separator tensioning device
[1] Tensioning carriage re- [2] Clamping nut

taining screws
[3] Locknut

MAINTENANCE
Conveyor unit
NOTICE
A conveyor belt with belt drift or one that has been tensioned
too tightly or loosely wears faster and can result in damage to
the components of the magnetic separator.
The conveyor belts of all magnetic separators are each ten-

sioned with two mechanical tensioning devices that basically
share the same design.
Tensioning conveyor belt » Switch off diesel generator and plant.
devices.
» Loosen the retaining nuts [1] of the tensioning carriage.
» Loosen the locknut [3] until the tension is free.
» Turn the tensioning nuts (2) evenly until the conveyor belt is
tensioned correctly.
» Tighten locknuts [3] again.
» Tighten the retaining nuts [1] of the tensioning carriage.
tensioning devices.

or belt.
Detensioning conveyor » Switch off diesel generator and plant.

belt

MAINTENANCE
Conveyor unit

devices.
» Loosen the retaining nuts [1] of the tensioning carriage.
» Loosen the locknuts [3].
» Turn the tensioning nuts [2] evenly until the conveyor belt is
relieved of tension.
» Tighten the locknuts [3].
» Tighten the retaining nuts [1] of the tensioning carriage.
tensioning devices.
 The conveyor belt has been detensioned.
4.10.05.03 Servicing worm gear

The gearbox used is a filled-for-life version. If it therefore not
necessary to check the oil level and change or drain the oil.
For repair work, the gear motor has to be removed.
Following repair measures at the gearbox, it must be filled with
the correct quantity of oil.
The oil capacity of the gearbox is 0.48 litres.
CAUTION

MAINTENANCE
Conveyor unit
4.10.05.04 Lubricating bearings
Fig. 4.84: Magnetic separator bearings
[1] Lubricating nipple [2] Dust cap

The bearings of the drive pulley and return roller are lubricated
via a lubricating nipple.
Lubricate bearings » Switch off diesel generator and plant.
» Provide and use a suitable climbing aid.
ifications into the lubricating nipples of the drive pulley and
return roller bearings.
» Clean away any excess lubricating grease and dispose of in
an environmentally friendly manner.

brication point
Bearings 2.5 grammes
Tab. 4.5: Lubricating point of magnetic separator

cating grease.

MAINTENANCE
Not assigned
4.11 Not assigned
4.12 Water system
Fig. 4.85: Water system
[1] Water pump [2] Fluid control

[3] Spraying nozzles
WARNING
Risk of falling
secure.
The water pump [1] and the fluid control [2] are maintenance-
free. Only a visual inspection and regular controls and cleaning
of the prefilter of the suction line must be carried out.
» Visually inspect the housing and connections of the water
pump [1] and fluid control [2] for leaks.
» Have damage eliminated by authorised and qualified per-
sonnel.
» Visually inspect connections for spraying nozzles [3] for
leaks.
» Check alignment of the spray jet and correct it if necessary.

MAINTENANCE
Water system
» Visually inspect feed lines of spraying nozzles for leaks.

Eliminate leaks.
 The water system has been checked.
Spraying nozzles are installed at the following locations:
• Crusher inlet
• Belt discharge
• Crusher discharge conveyor after crusher outlet
Fig. 4.86: Water system
[4] Prefilter for suction line [5] Filter
WARNING
ment.
Cleaning the prefilter » Unscrew screw cap on the prefilter [4].

» Remove filter [5] and wash off any dirt. If necessary, blow
out filter [5] with compressed air.
» Insert filter [5] and screw on screw cap and tighten.
 The prefilter has been cleaned.
For maintenance intervals, see chap. 5.02

MAINTENANCE
Not assigned
4.13 Not assigned
4.14 Not assigned
4.15 Not assigned
4.16 Not assigned
4.17 Not assigned
4.18 Lubrication system
4.18.01 Servicing lubrication system
DANGER
Danger when lubrication system is pressurised
During operation, the lubrication system is under pressure and
there is a risk of injury.
with the system switched off.
• Switch off the system, remove the key and secure against
reactivation.
WARNING
assembly.
NOTICE
Changes to the settings of the lubrication system made by KL-
EEMANN GmbH can result in material damage.

MAINTENANCE
Lubrication system
4.18.01.01 Filling lubrication system
2
3
3
[1] Grease gun [2] Filling connection

[3] Filling connection screw [4] Grease gun cap closure
cap
» Open handle of control cabinet flap open and fold up control
cabinet flap.
» Open screw cap [3] and remove it.
» Remove cap closure [4] from grease gun [1].
The grease gun is in the toolbox, see chap. 2.42.

» Insert grease gun in filling connection.
» Fill lubricant tank, see chap. 2.18, with lubricating grease.
Ensure that the maximum fill level is not exceeded.
» Remove grease gun, clean away any excess grease and dis-
pose of in an eco-friendly manner. Observe national specifi-
cations for disposal.
» Fit cap closure on grease gun.
» Fit screw cap on filling connection and screw on.
 The lubrication system has been filled.
If the grease gun is not available, the lubricant tank can be

filled at the operator panel with grease with the help of a filling
system via the lubricating nipple.
» Check connections and lubricant lines for leaks. Repair leak-
ing connections and lubricant lines.
» Fold down the control cabinet flap and close the handle.

MAINTENANCE
Lubrication system
For lubricants, see chap. 5.04.01.
4.18.01.02 Checking lubrication system
2 3
4
1
[1] Distributor [2] Crusher bearing lubricant

lines
[3] Lubricant line from pump [4] Crusher bearing lubricant
unit lines
NOTICE
Damaged or loose lubricant lines result in damage to the
crusher bearings.
• Check lubricant lines for damage.
• Check screw-couplings for leaks and firm seating.
The crusher bearings are supplied with lubricating grease from

the lubrication system via lubricant lines. The lubrication from
the pump unit to the distributor [1] is monitored by a plunger
detector. Correct lubrication from the distributor to the crusher
bearings must be checked regularly.
NOTICE
A malfunction or fault in the lubrication system results in dam-
age to the crusher bearings.
• The plant must only be operated with an operable lubrica-
tion system.
• Have faults eliminated immediately by KLEEMANN GmbH
Service.

MAINTENANCE
Lubrication system

» Switch off, remove and carry the battery isolator with you,
see chap. 2.06.02.
» Visually inspect lubricant lines [2], [3] and [4] for damage
and leaks. Replace damaged lubricant lines.
» Check screw connections on lubricant lines at the distributor
for leaks and firm seating. Tighten loose screw connections.
[5] Connection points for lu- [6] Crusher bearing lubricant

bricant lines lines (from connection
points)
» Check screw connections on connection points of the lubri-
cant lines for leaks and firm seating. Tighten loose screw
connections.
» Visually check lubricant lines [6] for damage and leaks. Re-
place damaged lubricant lines.
» Check screw-couplings on lubricant lines at the crusher for
leaks and firm seating. Tighten loose screw connections.
» Carry out tasks on both sides of the crusher.
 The lubricant lines have been checked.

MAINTENANCE
Lubrication system
NOTICE
Incorrectly connected lubricant lines can result in damage to
the crusher bearings.
• When installing lubricant lines, ensure the position at the
distributor is correct.
If lubricant lines are disassembled for assembly or repair work,

ensure that the lubricant lines are reinstalled in the correct po-
sition at the distributor. If necessary, make markings prior to
disassembly.

MAINTENANCE
Not assigned
4.19 Not assigned
4.20 Not assigned
4.21 Not assigned
4.22 Not assigned
4.23 Not assigned
4.24 Not assigned
4.25 Not assigned
4.26 Not assigned
4.27 Not assigned
4.28 Not assigned
4.29 Not assigned
4.30 Not assigned
4.31 Not assigned
4.32 Not assigned
4.33 Not assigned
4.34 Not assigned
4.35 Not assigned
4.36 Not assigned

MAINTENANCE
Not assigned
4.37 Not assigned
4.38 Not assigned
4.39 Not assigned
4.40 Not assigned
4.41 Not assigned
4.42 Tools
Fig. 4.90: Tools and accessories
[1] Toolbox [2] Flap

MAINTENANCE
Tools
[3] Special tool for shim

change
[4] Lubrication system

grease gun
» Check toolbox and cover for damage. Repair if necessary.
» Check tools and accessories for completeness and damage.
Replace or exchange missing or damage tools.
 Toolbox, tool and accessories have been checked.
» Check special tool for secure installation and damage.

MAINTENANCE
Feeding unit
» Replace missing or damage special tool.

 Special tool has been checked.
4.43 Feeding unit
4.43.01 Servicing feed hopper
Fig. 4.93: Wear lining for feed hopper
[1] Screw [2] Washer

[3] Spacer sleeve [4] Wear plates
WARNING
Risk of falling
secure.
Checking wear plates » Visually check wear plates [4] of the feed hopper for wear
and chipping.
» Check secure seating of the wear plates by knocking on
them.
» Replace worn or damaged wear plates. Tighten loose
screws.
 The wear lining is checked.

MAINTENANCE
Feeding unit
Changing wear plates The wear plates [4] are all bolted from the outside onto the
chassis.
» Unscrew screws [1] from worn or damaged wear plates and
remove with washers [2] and spacer sleeves [3].
Fig. 4.94: Wear lining for feed hopper
[4] Wear plates [5] Wear plates transition

[6] Lock screw
» Unscrew lock screw [6] of worn or damage wear plates and
insert eye bolt.
» Fit suitable lifting gear on the eye bolt.
» Remove worn or damaged wear plates.
» Fit eye bolt and suitable lifting gear on new wear plate.
» Insert and align new wear plate. Ensure that transitions [5]
of wear plates are flat.
» Insert spacer sleeves [3] with screws [1] and washers [2].
torques see chap. 5.03.
» Remove lifting gear and eye bolt and reinstall lock screw [6].
 The wear plate has been changed.

MAINTENANCE
Feeding unit
4.43.02 Servicing hopper extension
2
3
1 4
Fig. 4.95: Hopper extension
[1] Hydraulic cylinder [2] Hydraulic cylinder and

wedges of the hopper wall
locking element
[3] Mountings of hopper walls [4] Hydraulic cylinder lock
and guard
WARNING
Risk of falling
secure.
» Visually check the interlocks and guard devices of the hy-

draulic cylinder [4] for damage.
» Visually check the hydraulic cylinder of the hopper wall lock-
ing elements [2] for leaks.
» Check wedges of the hopper wall locking elements [2] for
ease of movement.
» Visually check mountings of the hopper walls [3] for damage
and check security of bolts and cotter pins.
» Visually check hydraulic cylinder [1] for leaks.

MAINTENANCE
Feeding unit
» Replace damaged components if necessary.

 The hopper extension has been checked.
If the hydraulic unit is defective the hopper walls can be low-

ered using suitable hoisting gear. The hoisting gear is mounted
to the intended mounting links on the hopper walls.
4.43.03 Servicing feeder trough

4.43.03.01 Servicing rubber mountings
WARNING
Risk of falling
secure.
NOTICE
Defective rubber mountings can no longer absorb the existing
loads and vibrations and lead to consequential damage on
plant components.
• Replace damaged rubber mountings immediately.
WARNING
Risk of crushing in the area of the spring elements
When lowering the feeder trough, serious crushing injuries are
possible.
• When lowering the feeder trough, never place your hands
between spring elements and feeder trough.

MAINTENANCE
Feeding unit
Fig. 4.96: Feeder trough spring elements
[1] Spring elements [2] Half shell

[3] Spring element fastening [4] Screw and nuts of half
shell
[5] Rear lifting points
Checking vibrating Cracks in springs quickly lead to destruction of the entire vibrat-
elements ing element. Components can then knock against neighbouring
plant components or the chassis and damage them.
» Visually check springs [1], [6] and [10] for cracks and defor-
mation.
» Replace vibrating elements if necessary.
 The vibrating elements have been checked.
Replacing outer vibrating » Unscrew earthing strap between vibrating feeder and chas-
elements sis.
» Remove screws and nuts of wear plate fastening at the lifting
points [5].
» Insert suitable lifting gear, e.g. eye bolt, with sufficient car-
rying capacity and length at lifting points [5] and secure with
nuts.
» Remove screws and nuts [4] of half shells [2].
» Remove half shell [2].
» Raise the vibrating feeder until the vibrating elements [1]
and [6] are unloaded.
 The outer vibrating elements can be removed to the side
from the securing elements [3].

MAINTENANCE
Feeding unit
DANGER
Danger due to falling components
When maintenance tasks are carried out on the spring ele-
ments, there is a risk to persons in the danger zone due to fall-
ing components.
• Secure spring elements against falling.
• Ensure that there are no persons in the hazard area.
9
6
[6] Centre spring element [7] Chassis

[8] Securing element for cen- [9] Screw
tre spring element
Replacing centre » Secure centre vibrating element [6] with suitable lifting gear
vibrating element against falling.
» Release screws [9] on securing elements of centre vibrating
element and remove them.
» Remove securing elements [8] for centre vibrating ele-
ments.
» Slowly lower centre vibrating element through the opening
in the chassis and set aside.
 The centre vibrating element has been removed.
» Replace vibrating elements and install in reverse order.
» Lower vibrating feeder back onto the vibrating elements.
» Remove lifting devices, insert screws and nuts on wear plate
fastening and tighten nuts.
 The outer and centre vibrating elements have been re-
placed.

MAINTENANCE
Feeding unit
11
12
10
13
[10]Front spring element [11]Front lifting points

[12]Screw [13]Securing element for
front spring elements
Replacing front vibrating

elements
Always raise the vibrating feeder at one side only when chang-
ing the corresponding vibrating elements.
» Install suitable lifting gear and tackle at the lifting points
[11].
» Slacken screws [12] and remove.
» Raise the vibrating feeder with suitable lifting gear until the
vibrating elements [10] are unloaded.
» Remove vibrating elements [10] with securing elements
[13] at the side.
 The front vibrating elements have been removed.
» Replace vibrating elements and install in reverse order.
» Lower vibrating feeder back onto the vibrating elements.
» Remove lifting gear and tackle from the lifting points.
 The front vibrating elements have been replaced.
» Screw earthing strap back on.

MAINTENANCE
Feeding unit
4.43.03.02 Checking vibration motors
Fig. 4.99: Vibration motors
[1] Securing screws [2] Protective covers
WARNING
Risk of injury due to unprotected unbalance weights
Contact with the uncovered unbalance weights of the vibration
motors can result in serious or fatal injury.
Material that enters the unbalance weights can be thrown out
suddenly and cause serious or fatal injuries.
• Only operate vibration motors with installed protective cov-
ers.
• During maintenance and repair work, secure plant compo-
nents against activation.
NOTICE
Water and dust can enter vibration motors not protected with
protective covers and cause bearing damage and winding
short circuits.
• Only operate vibration motors with installed protective cov-
ers.
• Replace damaged protective covers.
As the securing screws [1] of the vibration motors are subject

to strong cyclic stressing, they can become loose over the
course of time. With the securing screws loosened, transmission
of the vibratory forces is no longer guaranteed and the vibration
motors will be prematurely destroyed.

MAINTENANCE
Feeding unit

» Tighten all securing screws [1] with torque wrench. For
tightening torques, see chap. 5.03.
» Visually check protective covers [2] for damage and replace
if necessary.
 The vibration motors have been checked.
4.43.03.03 Servicing wear lining
1
2
Fig. 4.100: Wear lining for vibrating conveyor trough
[1] Wear plates [2] Nuts
WARNING
Risk of falling
secure.
» Visually check wear plates [1] of the vibrating conveyor

trough for wear and chipping.
» Check secure seating of the wear plates by knocking on
them.
» Replace worn or damaged wear plates. Tighten loose wear
plates.
 The wear lining is checked.

MAINTENANCE
Feeding unit
As the hexagon sockets of the screws become eroded or

clogged by material, the screw heads can be secured with weld
points to prevent them from turning. After unscrewing the
nuts, the wear plates can be removed and/or the screws can
be knocked out.
The wear plates [1] are all bolted from the outside onto the
chute trough.
» Unscrew nuts [2] of worn or damaged wear plates and re-
move wear plates.
» Insert new wear plates and screw in nuts with locking rings.
» Tighten nuts to specified tightening torque. For tightening
torques see chap. 5.03.
 The wear plates have been changed.
4.43.04 Repairing feeder trough

4.43.04.01 Replacing vibration motor
DANGER
Danger due to open running unbalance weights
Open running unbalance weights can catch and draw in per-
sonnel leading to serious or fatal injury.
• Only operate vibration motors with the guard devices firmly
in place.
• Read off the rocker width only with the guard devices in po-
sition.
• Before starting repair work, switch off the plant, remove
the key and secure against reactivation.
If a fault occurs at the vibration motors, it may be necessary to

replace one of the two vibration motors.
Observe the following items when replacing vibration motors.
• The vibration motors must be the same model from the
same manufacturer.
• The setting of the unbalance weights must be the same on
both vibration motors.
• The direction of rotation of the two vibration motors must al-
ways be counter-acting.
• Retighten securing screws of the replaced vibration motors
after 10 operating hours to specified tightening torque.

MAINTENANCE
Feeding unit
Directions of rotation of the vibration motors

Depending on the version of the chute, the installation of the vi-
bration motors varies. The prescribed directions of rotation are
shown in the illustration.
1 2 3
Fig. 4.101: Installation situation of the vibration motors
[1] Side installation [2] Installation on back, ver-

tical
[3] Installation on back, hori-
zontal
4.43.04.02 Checking rocker width
2
1
Fig. 4.102: Vibrating conveyor trough rocker width gauge

MAINTENANCE
Feeding unit
[1] Rocker width gauge decal [2] Intersection
DANGER
in place.
sition.
During operation of the vibrating conveyor trough, the rocker

width can be read off at the rocker width gauge [1] based on
the intersection [2] of the straight lines. The intersection spec-
ifies the rocker width in millimetres. In the example illustrated,
the width is approx. 8.5 mm.
Prerequisite
The rocker width gauge [1] must be fixed in the centre of the
vibrating conveyor trough transverse to the vibratory direction.
Checking rocker width » Allow the vibrating conveyor trough to run empty.
» Read off the rocker width at the rocker width gauge [1].
» Adjust the rocker width if necessary, see chap. 4.43.04.03.
 The rocker width has been checked.
4.43.04.03 Adjusting rocker width
2
1
Fig. 4.103: Unbalance weights for vibrating conveyor trough

MAINTENANCE
Feeding unit
[1] Outer unbalance weight [2] Clamping screws

[3] Scale
DANGER
in place.
sition.
NOTICE
Incorrectly set unbalance weights can result in damage to vi-
bration motors and vibrating conveyor troughs.
• Repair work on vibration motors must be carried out by au-
thorised and qualified personnel only.
• Ensure that all unbalance weights of a vibrating conveyor
trough have exactly the same settings.
Adjusting rocker width The unbalance weights are set ex works to a certain percent-
age. This setting permits usage of the defined speed range via
the frequency converter. Before adjusting to a higher percent-
age, in particular, please consult with the Customer Service of
KLEEMANN GmbH.
» Remove all protective covers from vibration motors.
» Release clamping screws [2] on outer unbalance weights.
» Set the outer unbalance weights so that the bottom edge of
the outer unbalance weight is at the desired percentage on
the scale [3]. Set all outer unbalance weights to the same
percentage value.
» Tighten clamping screws [2] of outer unbalance weights to
specified tightening torque.
» Check the rocker width with the vibrating conveyor trough
running and correct if necessary.
» Reinstall all protective covers on vibration motors. Ensure
that the seals of the protective covers are seated correctly
in their supports.
 The rocker width has been adjusted.

MAINTENANCE
Crusher
Every graduation of the scale [3] corresponds to one percent

of the maximum centrifugal force of the unbalance weight.
Tightening torques for clamping screws
Tightening torques in Nm
M6 M8 M10 M12
10 25 53 89
Tab. 4.6: Tightening torques for clamping screws
4.44 Crusher
DANGER
4.44.01 Checking position of balancing weights for crusher drive
WARNING
belts.
the crusher.

MAINTENANCE
Crusher
Fig. 4.104: Balancing weights for pulley and flywheel
[1] Jaw crusher belt pulley [2] Balancing weights for fly-
wheel
[3] Permissible range for bal- [4] Balancing weights for belt
ancing weights pulley
When performing maintenance and repair work on the crusher
or on the belt drive, make sure that the balancing weights for
the pulley and flywheel are in the upper permissible area. If the
balancing weights are located outside the permissible range, no
work must be carried out on the crusher or belt drive.
» Switch off plant component, diesel generator and control
voltage.
» Open the protective housing of the pulley or flywheel.
» Position of the balancing weights.
» If the balancing weights are outside the permissible range,
restart the crusher and switch it off again.
» Check the position of the balancing weights once again.
 The position of the balancing weights has been checked.

MAINTENANCE
Crusher
4.44.02 Lubricating bearings
5
2
Fig. 4.105: Jaw crusher centralised lubrication
[1] Lubricating nipple for [2] Lubricating nipple for

right rocker bearing right labyrinth rocker
[3] Lubricating nipple for [4] Lubricating nipple for left
right bearing and laby- bearing and labyrinth
rinth crusher frame crusher frame
[5] Lubricating nipple for left [6] Lubricating nipple for left
labyrinth rocker rocker bearing
7 8 9 10 11 11 10 9 8 7
Fig. 4.106: Bearings and labyrinths
[7] Crusher frame outer laby- [8] Crusher frame bearing

rinth

MAINTENANCE
Crusher
[9] Crusher frame inner laby- [10]Rocker labyrinth

rinth
[11]Rocker bearing
The bearings and labyrinths of the jaw crusher are lubricated via
the lubricating nipples. The blocks of the lubricating nipples are
arranged on the right and left of the crusher housing.
The jaw crusher is equipped with spherical roller bearings which
are designed for grease lubrication. Labyrinth seals are installed
to protect against contamination. However, they only function
properly if sufficient grease is filled.
voltage.
ifications and volume into the lubricating nipples.
 The bearings and labyrinths have been lubricated.

brication point
Frame bearings 100 grammes
Rocker bearing labyrinth 40 g
Rocker bearings 20 grammes
Tab. 4.7: Crusher lubrication points
One stroke of the grease gun corresponds to approx. 3 g

grease. The grease volumes to be filled are noted on the blocks
of the centralised lubrication.
If the plant is equipped with a lubrication system (option), the
bearings are lubricated automatically.
It is possible that bearings become very hot after lubrication.

However, this has no negative effect on bearings.
Please note that the temperature of the bearings must drop
again to roughly 50 °C no later than 8 hours afterwards.
If the increased bearing temperature has not fallen again after
this time, this indicates a probable malfunction of the relevant
bearing.

MAINTENANCE
Crusher
4.44.03 Listen to bearing, check its temperature
WARNING
Danger due to moving and rotating components
Incorrect procedures when monitoring the sound and measur-
ing the temperature of the bearings can result in injuries due
to crushing and catching.
• Always keep a sufficient distance away from moving and
rotating components.
CAUTION
Danger due to hot surfaces
Bearings can heat up intensely during operation.
• Use a temperature gauge to check the bearing tempera-
ture.
Unusual bearing noises or excessive bearing temperatures can

be an indication of possible bearing malfunctions or increasing
wear. The check must be carried out with the crusher at service
temperature.
Due to the high ambient noise level, recognition of unusual

bearing noises requires a lot of experience. This check must be
carried out by authorised and qualified personnel only.
» Switch the diesel generator on.
» Switch on the crusher in manual mode and warm up the
bearing to service temperature.
» Listen to the sound of the bearing and check the bearing
temperature with a temperature gauge.
» If necessary, have bearing repaired by authorised and qual-
ified personnel.
 The bearings have been checked.
It is possible that bearings become very hot after lubrication.

However, this has no negative effect on bearings.
Please note that the temperature of the bearings must drop
again to roughly 50 °C no later than 8 hours afterwards.
If the increased bearing temperature has not fallen again after
this time, this indicates a probable malfunction of the relevant
bearing.

MAINTENANCE
Crusher
4.44.04 Checking/tensioning V-belt

4.44.04.01 Checking V-belt
Fig. 4.107: Crusher drive V-belt
[1] Jaw crusher belt pulley [2] Balancing weights for belt
pulley
[3] Tension roller for V-belt [4] Crusher drive belt pulley
tension
[5] V-belt
WARNING
When the belt drive guard devices are removed, there is a risk
of injury because limbs can be drawn in.
generator.
WARNING
assembly.

MAINTENANCE
Crusher
WARNING
belts.
the crusher.
NOTICE
If the V-belt tension is insufficient, this results in vibrations of
the V-belt and even ejection from the belt pulleys.
Excessive V-belt tension subjects the bearings to excessive
loads and leads to V-belt wear.
• Always ensure that the V-belt tension is correct.
• Adjust the clamping screws evenly to guarantee axial par-
allelism of the belt pulleys.
Power is transmitted to the jaw crusher via belt pulleys and sev-
eral V-belts arranged beside each other. The tension and condi-
tion of the V-belts must be checked to ensure loss-free power
transmission.
voltage.
» Carefully open the panelling of the belt drive.
» Ensure that the balancing weights [2] of the belt pulley are
in the upper permissible area, see chap. 4.44.01.
» If necessary, switch off crusher and start it again. Visually
check the position of the balancing weights once again.
Before the start of maintenance and repair work, always en-

sure that the balancing weights of the belt pulley are in the up-
per area.
Checking condition of V- » Visually inspect V-belts for cracks, fraying and other dam-
belts age. Replace worn or damaged V-belts.
» Return twisted V-belts to their correct position.
 Condition of the V-belts has been checked.

MAINTENANCE
Crusher
Fig. 4.108: Checking V-belt tension
[5] V-belt [6] Frequency meter
The V-belt tension must be measured in the centre between

the crusher drive belt pulley and the jaw crusher belt pulley.
Measuring V-belt tension » Hold the frequency meter Optibelt TT mini [6] at approx. 90°
in relation to the V-belt and vibrate the V-belt with a suitable
tool, e.g. box wrench.
» Check the tension of the V-belts [5] at the frequency meter
and correct the tension if necessary. Tension V-belts, see
chap. 4.44.04.02. For operating tension of V-belts, see chap.
5.01.02.
» Close the panelling of the belt drive.
 The V-belts have been checked.

MAINTENANCE
Crusher
4.44.04.02 Tensioning/changing V-belts
1
3
Fig. 4.109: Crusher drive V-belt
[1] Locknut [2] Tension roller

[3] V-belt [4] Tensioning device
WARNING
generator.
WARNING
belts.
the crusher.

MAINTENANCE
Crusher
NOTICE
If the V-belt tension is insufficient, this results in vibrations of
the V-belt and even ejection from the belt pulleys.
Excessive V-belt tension subjects the bearings to excessive
loads and leads to V-belt wear.
• Always ensure that the V-belt tension is correct.
• Adjust the clamping screws evenly to guarantee axial par-
allelism of the belt pulleys.
The V-belts are tensioned via the tensioning device [4] and the
tension roller [2].
The tensioning device can be accessed via the platform between
power supply unit and crusher.
Tensioning V-belts » Switch off plant components and diesel generator and se-
» Allow crusher to coast until it is at a complete standstill.
» Open the panelling of the belt drive.
» Ensure that the balancing weights [2] of the belt pulley are
in the upper area of the belt pulley [1], see chap. 4.44.01.
» Release locknut [1] of tensioning device [4].
» Turn tensioning device [4] until the optimum pretension of
the V-belts has been reached.
» Check the tension of the V-belts and correct the tension if
necessary, see chap. 4.44.04.01.
» Retighten counter screw nut [1].
» Close panelling of belt drive and tighten screws.
 The V-belts have been tensioned.
Changing V-belts » Carry out preparatory work as described under "Tensioning
V-belts".
» Turn tensioning device [4] until the tension roller [2] is
raised to maximum and the V-belts can be removed from the
belt pulleys.
» Install new V-belt in position.
» Turn tensioning device [4] until the optimum pretension of
the V-belts has been reached.
» Check the tension of the V-belts and correct the tension if
necessary, see chap. 4.44.04.01.
» Carry out final tasks as described under "Tensioning V-
belts".
 The V-belts have been changed.

MAINTENANCE
Crusher
Retension newly installed V-belts after 50 operating hours due

to elongation.
4.44.05 Servicing tension roller

4.44.05.01 Lubricating bearings of tension roller
Fig. 4.110: Lubrication for tension roller
[1] Lubricating nipple for ten- [2] Tension roller

sion roller
[3] V-belt
The bearings of the tension roller are lubricated via a lubricating
nipple.
ifications and volume into the lubricating nipple.

brication point
Bearings 2.5 - 3 g
Tab. 4.8: Lubrication point for tension roller

cating grease. The grease volume to be injected is also noted
at the tension roller.

MAINTENANCE
Crusher
4.44.05.02 Checking the tension roller
Fig. 4.111: Lubrication of tension roller
[1] Tension roller [2] Hollow area, tension roller
WARNING
drives, always switch off plant or components.
• Secure the plant or component against reactivation.
WARNING
belts.
the crusher.

MAINTENANCE
Crusher
NOTICE
Dust and dirt deposits in the hollow areas of the tension roller
result in an imbalance and cause material damage to plant
components.
• Remove deposits at regular intervals.
• Observe maintenance intervals of tension roller.
Check hollow areas of » Ensure that the balancing weights of the belt pulley are in
tension roller the upper permissible area, see chap. 4.44.01.
» Switch off diesel generator and plant.
» Remove cover of belt drive.
» Check all hollow areas [2] of the tension roller [1] for depos-
its. Clean the hollow areas if necessary.
» Mount cover of belt drive.
 The hollow areas have been checked.
» Switch on battery isolator.
WARNING
Risk of health damage
The inhalation of dust can cause serious illnesses.
• Wear a breathing mask.
WARNING
ment.
Clean hollow areas » Switch off diesel generator and plant.

» Remove cover of belt drive.
» Clean all hollow areas using suitable tools, such as com-
pressed air or a chisel.
» Mount cover of belt drive.
 The tension roller has been cleaned.
» Switch on battery isolator.

MAINTENANCE
Crusher
4.44.06 Checking securing elements of crushing jaws
2 5
Fig. 4.112: Securing elements of crushing jaws
[1] Screws of the clamping [2] Articulated crusher jaw

claws for lateral wedges
[3] Clamping wedge [4] Lateral wedges
[5] Fixed crusher jaw
» Hammer-test lateral wedges [4] and clamping wedges [3].
Rattling impact noises indicate loose securing elements.
» Visually check all screws of the clamping claws [1] and
clamping wedges [3] and tighten if necessary.
 The crushing jaw securing elements are checked.

MAINTENANCE
Crusher
4.44.07 Checking crusher mounting
Fig. 4.113: Jaw crusher mounting
[1] Chassis [2] Base

[3] Guide lug
The jaw crusher is mounted on bases [2] on the chassis [1] and
secured in guide lugs [3]. Vibrations during crushing operation
can loosen the jaw crusher on the securing element at the guide
lugs.
» Visually check bases [2] for damage.
» Visually check securing elements at the guide lugs [3].
 The mounting of the jaw crusher has been checked.
4.44.08 Repairing crusher
DANGER

MAINTENANCE
Crusher
DANGER
Danger! Heavy loads
Raised or suspended loads can fall, resulting in serious or fatal
injury.
• Attach lifting accessories carefully to components, ensuring
they cannot slip.
• Where possible, attach components to be lifted at their
centre of gravity.
• Do not enter or stand in the danger zone.
• Keep a safe distance away.
• Do not place your hands under the components when being
lowered.
4.44.08.01 Checking wear of crushing jaws
1 2
Fig. 4.114: Crushing jaw wear
[1] Articulated crusher jaw [2] Fixed crusher jaw

The lower section of the jaws of the jaw crusher is subject to
more wear than the top section. The wear limit is reached when
the teeth of the crushing jaws are worn down to the root sur-
face.
The crusher jaws have a symmetrical shape and can therefore
be reversed once after the wear limit has been reached.
» Visually check the crushing jaws by looking into the jaw from
above.

MAINTENANCE
Crusher
» If necessary, reverse or change the crushing jaws.

 The crushing jaws have been checked.
4.44.08.02 Changing the lateral wedges
Fig. 4.115: Jaw crusher lateral wedges
[1] Clamping screws [2] Crusher inlet

[3] Crusher inlet cover [4] Lateral wedges
[5] Crusher housing
The lateral wedges [4] have two sections and are secured via
clamping wedges on the crusher housing [5].
Removing lateral wedges » Switch off plant components and the diesel generator.
» Disconnect cable connection for fill level sensor at crusher
inlet.
» Disconnect water connection for spraying nozzles at crusher
inlet.
» Remove crusher inlet [2] with crusher inlet cover [3].
» Release all clamping screws [1] on the lateral wedges but do
not remove them.

MAINTENANCE
Crusher
» Completely loosen upper lateral wedge using a hammer.

» Lift out upper lateral wedge using suitable hoisting gear and
lifting accessories.
» Complete release lower lateral wedge by knocking with a

hammer, loosening with suitable tool if necessary.
» Check clamping wedge and clamping claws of fixed crusher
jaw for security, see chap. 4.44.08.03.
» Lift out lower lateral wedge using suitable hoisting gear and
lifting accessories.
» Clean the contact surfaces of the clamping wedges and lat-
eral wedges.
» Carry out the instructions listed on the opposite page.
 The lateral wedges have been removed.
Installing lateral wedges
» Using suitable hoisting gear and lifting accessories, insert

the new lower lateral wedge and knock with a hammer into
the guides.

MAINTENANCE
Crusher
» Using suitable hoisting gear and lifting accessories, insert

the new upper lateral wedge and knock with a hammer into
the guides.
» Tighten all clamping screws [1] of the lateral wedges.
» Ensure that the clamping wedges, when tightened, are a

maximum of 10 millimetres behind the lateral wedges.
» Carry out the instructions listed on the opposite page.
» Reinstall crusher inlet [2] with crusher inlet cover [3].
 The lateral wedges have been installed.
NOTICE
Newly installed lateral wedges settle after a few hours opera-
tion and can become loose.
• Check security of newly installed lateral wedges after ap-
prox. 8 hours operation and retension if necessary.
4.44.08.03 Changing fixed crusher jaw
3
2
Fig. 4.116: Fixed crusher jaw

MAINTENANCE
Crusher
[1] Screw [2] Nut

[3] Clamping nut with Bel- [4] Clamping claw
leville springs
[5] Clamping wedge [6] Attachment point for
crusher jaw
Prior to removal and installation of the fixed crusher jaw, the

attachment points of the crusher jaw must be checked for
heavy wear and damage.
If attachment points are damaged, e.g. as a result of crack for-
mation or heavily worn, the attachment points must not be
used for removing or mounting the crusher jaw. If necessary,
consult with KLEEMANN GmbH Service.
Attaching fixed crusher » Set the gap setting device to maximum gap width, see chap.
jaw 3.14.02.
» Remove lateral wedges, see chap. 4.44.08.02.
For installation and removal of the crusher jaw, both shackles

must always be used and installed on the lifting points. If lifting
points are worn or damaged, a weld-on eyelet must be in-
stalled. The use of the shackles at the lifting points is then no
longer permissible. Install weld-on eyelet, see chap.
4.44.08.05.
» Fit shackles [7] in the lifting points [6] of the crusher jaw
7 and tighten. The shackles are in the toolbox. Ensure that the
lifting points are not damaged or are worn.
» Attach suitable hoisting gear, such as lifting sling or chain, to

shackles. Observe weight of the crusher jaw. Weight of the
crusher jaw is approx. 1200 kg.
» Tension the fixed crusher jaw lightly.

MAINTENANCE
Crusher
Removing the clamping

claw
5
4
Fig. 4.117: Removing the clamping claw
[1] Screw [3] Clamping nut with Bel-

leville springs
[4] Clamping claw [5] Clamping wedge
WARNING
Knocking in clamping wedges and clamping pins with a ham-
mer can result in serious eye injury.
• Visually check clamping wedges and clamping pins for
burring.
• Remove any burring.
» Turn the clamping nut [3] and remove with the Belleville
springs.
» Remove clamping claw [4] with screw [1] and nut. Keep
clamping claw, clamping nut and Belleville springs ready for
installation.
 The clamping wedge [5] can be disassembled.
» Knock out clamping wedge with a hammer.
» Perform the same work steps on the clamping wedge on the
opposite side.
 The clamping wedges have been removed and the crusher
jaw can be removed.

MAINTENANCE
Crusher
Removing fixed crusher

jaw
» Pull the crusher jaw laterally out of the holders on the crush-
er housing.
» Lift crusher jaw out of crusher housing.
» Deposit the crusher jaw at a suitable place with the teeth

pointing upwards.
» Clean the contact surfaces of the crusher housing.
 The fixed crusher jaw has been removed.
Installing fixed crusher
jaw
» Insert shackle in the lifting points of the reversed or new

crusher jaw and tighten.
» Lower the crusher jaw with suitable hoisting equipment and
lifting tackle into the crusher housing.
» First position the crusher jaw under the holder at the crusher
housing.
» Pull the crusher jaw upwards until it contacts with the lower
holder without a gap.
» Pull top crusher jaw over the holder. Ensure that the crusher
jaw is positioned centrally.
» When inserting the clamping wedges, the crusher jaw must
be kept under tension.
 The clamping wedges and the clamping claws can be in-
stalled.

MAINTENANCE
Crusher
Installing clamping claw
Fig. 4.118: Installing clamping claw

leville springs
[5] Clamping wedge
WARNING
Knocking in clamping wedges and clamping pins with a ham-
mer can result in serious eye injury.
• Visually check clamping wedges and clamping pins for
burring.
• Remove any burring.
» Insert clamping wedges [5] on both sides and knock in with

a hammer.
» Fit clamping claw [4] with the clamping nut and the Belleville
4 springs [3]. Ensure the Belleville springs are arranged in the
correct series.

MAINTENANCE
Crusher
Aligning and tightening

clamping claw
1
2
Fig. 4.119: Installing clamping claw
[1] Screw [2] Nut

leville springs
[9] Side panel crusher hous-
ing
To guarantee correct clamping of the clamping wedges, the

clamping claw may have to be rotated. Screw [1] and nut [2]
then have to be unscrewed and installed on the other side on
the clamping claw.
» Position clamping claw [4] at the clamping wedge [5] and
secure with the clamping nut [3].
» Align clamping claw using a screw [1] parallel to the side
panel [9].
» Tighten clamping nut [3] to specified tightening torque. For
tightening torques, see chap. 5.03.
» Ensure that the clamping claw is aligned parallel to the side
panel. If necessary, align the clamping claw.
» Tighten nut [3].
» Perform same work steps on opposite side.
» Remove hoisting gear and shackle.
» Reinstall side wedges.
 The fixed crusher jaw has been installed.

MAINTENANCE
Crusher
4.44.08.04 Changing articulated crusher jaw
DANGER
Danger due to defective lifting points
Broken or worn lifting points may result in dangerous situa-
tions when installing and removing crusher jaws.
• Check lifting points before installation and removal check
for damage and wear.
• Weld on an eyelet if necessary.
• Never stand under a suspended load.
• In case of doubt, contact KLEEMANN GmbH Service.
1
3
5
2
Fig. 4.120: Articulated crusher jaw
[1] Lifting points [2] Clamping screw

[3] Forcing bore [4] Clamping wedge
[5] Articulated crusher jaw
WARNING
belts.
the crusher.

MAINTENANCE
Crusher
Prior to removal and installation of the articulated crusher jaw,

the lifting points of the crusher jaw must be checked for seri-
ous wear and damage.
If attachment points are damaged, e.g. as a result of crack for-
mation or heavily worn, the attachment points must not be
used for removing or mounting the crusher jaw. If necessary,
consult with KLEEMANN GmbH Service.
Changing articulated crusher jaw with weld-on eyelet, see
chap. 4.44.08.05.
Removing articulated » Ensure that the balancing weights of the belt pulley are in
crusher jaw the upper permissible area, see chap. 4.44.01.
» Set the gap setting device to maximum gap width, see chap.
3.14.02.
» Disassembling crusher inlet.
» Release nuts on clamping screws [2] and remove them.
» Remove clamping screws [2].
» Insert screws in forcing bores [3] of clamping wedges [4]
and press out clamping wedges.
For installation and removal of the crusher jaw, both shackles

must always be used and installed on the lifting points. If lifting
points are worn or damaged, a weld-on eyelet must be in-
stalled. The use of the shackle at the lifting points is then no
longer permissible.
» Fit shackles [6] in the lifting points [1] of the crusher jaw
6 6 and tighten. The shackles are in the toolbox. Ensure that the
lifting points are not damaged or are worn.
» Attach suitable hoisting gear, such as lifting sling or chain, to

shackles and lift crusher jaw up out of the crusher housing.
Observe weight of the crusher jaw. Weight of the crusher
jaw is approx. 1500 kg.

MAINTENANCE
Crusher
» Set down crusher jaw.

» Clean the contact surfaces of the rocker.
 The articulated crusher jaw has been removed.
Installing articulated » Clean rear side of the crusher jaw.

crusher jaw
» Insert shackle in the lifting points of the reversed or new
crusher jaw and tighten.
» Lower the crusher jaw with suitable hoisting equipment and
lifting tackle into the crusher housing.
» Position crusher jaw [5] first on the bottom of the support
[7] of the rocker.
» Position crusher jaw at the rocker. Ensure that the crusher
jaw is positioned centrally.
7 5
» Lower top crusher jaw into the holder. Ensure that the crush-
er jaw is positioned centrally.
5
» Insert clamping wedge [4] and tighten with clamping screws

[2] and nuts.
4
» Remove hoisting gear and shackles. Store the shackles in
the toolbox.
2
» Ensure that the clamping wedge does not make contact with
5 the rocker after tightening. Clamping of the crusher jaw is
otherwise not guaranteed.
» Install crusher inlet.

 The articulated crusher jaw has been installed.

MAINTENANCE
Crusher
NOTICE
Newly installed articulated crushing jaws settle after a few
hours operation and can become loose.
• Check security of newly installed articulated crushing jaws
after approx. 8 hours operation and retension clamping
wedges if necessary.
4.44.08.05 Changing articulated crusher jaw with weld-on eyelet

Disassembling/installing
crusher jaw with weld-on
eyelet
DANGER
Danger due to defective lifting points
Broken or worn lifting points may result in dangerous situa-
tions when installing and removing crusher jaws.
• Check lifting points before installation and removal check
for damage and wear.
• Weld on an eyelet if necessary.
• Never stand under a suspended load.
• In case of doubt, contact KLEEMANN GmbH Service.
DANGER
Danger from welding work
Welding work can lead to severe or fatal injury due to danger-
ous body currents.
• Always connect the welding current return line to the com-
ponent being welded.
• Insulate the electrode holder when placing down.
• Observe protection class IP 23 when using the welding cur-
rent source in the open.
WARNING
belts.
the crusher.

MAINTENANCE
Crusher
1 2 3
X X
Fig. 4.121: Articulated crusher jaw
[1] Weld-on eyelet (fillet weld [2] Distance from top edge of
a10) (both sides) the crusher jaw/weld-on
bolt
[3] Central alignment weld- [4] Weld-on eyelet
on eyelet
When welding on the weld-on eyelet bolt, the following speci-

fications and information must be observed:
• Use suitable rod electrode, e.g. 4370AC.
• The welding area must be preheated to 350 to 400 °.
• The materials to be welded:
– Manganese steel with manganese content between
16% and 21%
– 23MnNiCrMo52, material no.: 1.6541
Welding on weld-on » Ensure that the balancing weights of the belt pulley are in
eyelet the upper permissible area, see chap. 4.44.01.
» Align weld-on eyelet centrally and with the distance [2] to
the top edge of the crusher jaw of 30 mm and mark the po-
sition of the welding area.
» Preheat welding area to 350 to 400 °C.
» Weld on the weld-on eyelet on both sides with a fillet weld
a=10 mm [1] across the entire length of the weld-on eyelet.
» Fit suitable lifting gear onto the weld-on eyelet. Observe
weight of the crusher jaw. Weight of the crusher jaw is ap-
prox. 1500 kg.
 The crusher jaw can be changed.

MAINTENANCE
Crusher
The installation and removal of the articulated crusher jaw with

a weld-on eyelet is carried out with the same work steps as in
chap. 4.44.08.04"Changing articulated crusher jaw ".
NOTICE
Newly installed articulated crushing jaws settle after a few
hours operation and can become loose.
• Check security of newly installed articulated crushing jaws
after approx. 8 hours operation and retension clamping
wedges if necessary.
If the crusher jaw was installed with the help of the weld-on
eyelet in the crusher, the weld-on eyelet must be severed
again prior to operation of the crusher. Operation of the plant
with a weld-on eyelet is not permitted.
» Prior to initial operation, ensure that the weld-on eyelet at
the crusher jaw is severed.
4.44.08.06 Changing pressure plate
WARNING
belts.
the crusher.
» Ensure that the balancing weights of the belt pulley are in

the upper permissible area, see chap. 4.44.01.
NOTICE
Non-original pressure plates do not meet the overload protec-
tion requirements. Damage to the jaw crusher may result and
the warranty is voided.
• Only use original pressure plates from KLEEMANN.

MAINTENANCE
Crusher
The pressure plate is clamped between the pressure plate

bearings of the rocker and the crushing gap setting device. To
change the pressure plate, the rocker must be pulled back.
When vibrating pressure is released, the pull rod on the rocker
can be detached and the rocker can be pulled further by me-
chanical means.
Depending on the degree to which the pressure plates are

damaged, it may be that the crushing jaw can no longer be run
clear. In this case, the crushing jaw must be cleared manually,
see chap. 3.12.
4 5 6 7 8 9 10 11

crusher is switched off after 15 seconds. The "Start-up ena-
ble" [8] button flashes and the "Plant ON" [9] button goes
out. The status displays in the Plant overview go grey.
» Completely open the crushing gap, see chap. 3.14.02.
» If necessary, press the "Plant overview" button to display
the plant overview.

MAINTENANCE
Crusher
» Press the Crusher menu button in the Plant overview.

11:30
User: KLeemann
 The Crusher menu is displayed.
0 rpm
» Press the "Change pressure plate" button on the touch

screen.
11:30:15
Brecher
Brec
ech
ec
ecche
h r
Brecher  The pressure plate menu is displayed.
» Press the "Relieve pressure plate tension" button.

11:30:15
 The pressure gauge for the rod shows maximum 2 bar. The
Druckplatte
Stange pressure plate is detensioned.
0RPM

» Lock the main switch using a U-lock. Remove key and carry
it with you.

MAINTENANCE
Crusher
4 5 6 7 8 9 10 11

» Press the "Diesel OFF" button [7] in the operator panel.
 The diesel engine is switched off.
WARNING
Risk of falling
secure.
DANGER
Hazard posed by falling material
During maintenance and repair measures on the pressure
plate, persons in the danger zone could become injured from
falling material.
• Run the plant and crusher completely clear.
• Never perform work on the pressure plate if the crushing
jaw is full.

MAINTENANCE
Crusher
Fig. 4.124: Attaching pressure plate
[1] Lifting gear [2] Rocker

» Guide suitable hoisting equipment and lifting tackle between
rocker and crusher frame.
» Climb onto crusher discharge conveyor.
4
5
[3] Lifting gear for pressure [4] Pressure plate

plate
[5] Mounting and pull rod pin
» Install suitable lifting gear [3], e.g. lifting sling, on pressure
plate [4].

MAINTENANCE
Crusher
» Ensure that the carrying capacity of the lifting gear used is

at least 500 kg.
» Join lifting gear [1] and pressure plate lifting gear [3] with
suitable lifting tackle. To avoid lateral tilting of the pressure
plate, align the attachment point centrally above the pres-
sure plate.
» Tension hoisting equipment lightly.
 The pressure plate is attached and secured.
7
4
Fig. 4.126: Securing pressure plate bearing
[4] Pressure plate [6] Screw

[7] Gap setting device pres- [8] Gap setting device pres-
sure plate bearing secur- sure plate bearing
ing element
» Release screw [6] and turn securing element for pressure
plate bearing [7] upwards.
» Retighten screw [6].
 The pressure plate bearing of the gap setting device is se-
cured.
If the pressure plate bearing is not secured, it will slip down-

wards when the pressure plate is removed. Installation of the
pressure plate is then not possible without difficulty.

MAINTENANCE
Crusher
Retracting rocker
4
5
[3] Lifting gear for pressure [4] Pressure plate

plate
» Remove pin at mounting [5] of pull rod.
2 10
11
9
Fig. 4.128: Retracting rocker
[2] Rocker [9] Chain hoist

[10]Shackle [11]Pull rod
» Place pull rod [11] on the crusher discharge conveyor.
» Fit shackle [10] on mounting of pull rod.

MAINTENANCE
Crusher
» Attach two chain hoists to shackle [10].

» Secure rope slings on left and right of chassis in area of
steps to the platforms.
» Attach chains of chain hoists with shackle on left and right
of rope slings.
» Pull back rocker [2] with chain hoists. At the same time, ob-
serve the pressure plate as it is released from the pressure
plate bearings.
 The rocker is pulled back and the pressure plate is free.
Removing pressure plate » Slowly lower pressure plate [4] onto pull rod [11] and crush-
er discharge conveyor and set aside.
» Remove lifting gear from pressure plate.
» Remove pressure plate from plant.
 The pressure plate has been removed.
Installing pressure plate
12
13
Fig. 4.129: Installing pressure plate
[4] Pressure plate [8] Gap setting device pres-

sure plate bearing
[12]Rocker pressure plate [13]Feather key
bearing
» Clean pressure plate bearings of rocker and gap setting de-
vice.
» Replace damaged or worn pressure plate bearings.
» Place new pressure plate on crusher discharge conveyor and
pull rod.

MAINTENANCE
Crusher
» Join lifting gear [1] and pressure plate lifting gear [3] with
suitable lifting tackle. Align attachment point centrally above
the pressure plate.
» Raise new pressure plate and guide into pressure plate bear-
ing [12] of rocker.
Moving rocker forward
WARNING
Danger due to moving parts
There is a danger of being crushed when the rocker is being
moved back.
• Always keep a sufficient distance away from moving com-
ponents of the gap adjustment device.
• Never place hands between pressure plate and pressure
plate bearing.
» Allow rocker [2] to move forward slowly with chain hoist

while guiding the pressure plate into the pressure plate
bearing of the gap setting [8]. The feather key [13] aligns
the pressure plate centrally.
» Remove chain and shackle of the chain hoist from the rope
slings.
» Remove rope slings from left and right of chassis.
» Remove chain hoists and shackle from mounting of pull rod.
» Remove lifting gear at pressure plate and lift out lifting gear
[1].
» Switch on the plant in automatic mode, see chap. 3.04.
» Perform work steps up to an including "Activate main switch
on control cabinet".
» Press the Crusher menu button in the Plant overview.
11:30
User: KLeemann
 The Crusher menu is displayed.
0 rpm

MAINTENANCE
Crusher
» Press the "Change pressure plate" button on the touch

screen.
11:30:15
Brecher
Brec
ech
ec
ecche
h r
Brecher  The pressure plate menu is displayed.
WARNING
When moving the pull rod, there is a risk of crushing injuries.
ponents of the rocker and the pull rod.
• Do not place your hands between rocker and pull rod.
Fig. 4.130: Mounting for pull rod

» Align pull rod on the mounting. Ensure that the pin can be
inserted.

MAINTENANCE
Crusher
» Press the "Tension pressure plate" button until the pin at

mounting [5] and the pull rod can be inserted.
11:30:15
Druckplatte
Stange
0RPM
M
» Secure pin with cotter pin.

Unlocking pressure plate
bearing
7
4
Fig. 4.131: Unlocking pressure plate bearing
[4] Pressure plate [6] Screw

[7] Securing element for gap [8] Gap setting device pres-
setting device pressure sure plate bearing
plate bearing
» Remove screws [6] of the securing elements [7].
» Turn securing elements [7] of pressure plate bearing to the
side and tighten screws [6].
 The pressure plate has been changed.

MAINTENANCE
Crusher
NOTICE
When operating the plant with secured pressure plate bearing,
the securing elements of the pressure plate can become dam-
aged.
• After changing the pressure plate, always turn the securing
elements to the side.
• Never operate the plant with secured pressure plate bear-
ings.
» Press the "Tension pressure plate" button and hold until

the display for the rod and ground pressure ceases to rise.
11:30:15
Druckplatte
Stange  The pressure plate is tensioned.
0RPM
M
» Press the "Display plant overview button on the touch

screen.
» Switch off main switch.
» Switch off control voltage and diesel engine.
 The pressure plate has been changed.
» Setting crushing gap, see chap. 3.14.02.
4.44.08.07 Changing shims
NOTICE
Adjusting the crushing gap with the crusher loaded can dam-
age the crushing gap adjustment device.
• Run the crusher empty prior to adjusting the crushing gap.
» Switch on the plant in automatic mode, see chap. 3.04.


MAINTENANCE
Crusher
4 5 6 7 8 9 10 11

crusher is switched off after 15 seconds. The "Start-up ena-
ble" [8] button flashes and the "Plant ON" [9] button goes
out. The status displays in the plant overview go grey.
» Observe the speed indicator of the crusher in the plant over-
view and wait until the crusher comes to rest.
WARNING
assembly.
» Loosen the bolt of the protective cover for the crusher drive
and slowly fold up the protective cover.
» Press the "Crushing gap adjustment" button in the plant
overview of the touch screen.
11:30
User: KLeemann
 The menu for the crushing gap adjustment and the info
"Start-up enable" is displayed.
2282RPM
82RPM
M
1500 rpm

MAINTENANCE
Crusher
The "Start-up enable" button in the operator panel must light

up continuously.
» If necessary, press the "Start-up enable" [8] button.
 The button flashes first and then lights up continuously.
» Press "Settings" button on the touch screen.
11:30:15
 The menu for shim change is displayed.
Spalt
133
The "Close crushing gap", "Tension setting wedges" and "De-

tension setting wedges" symbols on the touch screen can only
be actuated after the "Start-up enable" button has been
pressed in the operator panel.
Relieving shims
» Press the "Close crushing gap" button on the touch

11:30:15
Distanzplattenwechsel
 The setting wedges for adjusting the gap move together.
1 4
When the button is released, the cylinder of the push rod
system
Messsystem
palt
Spalt
2 108 ejects and is blocked.
3
After the "Close crushing gap" button is released, the "Re-

lieve setting wedges" can only be actuated a time of ap-
prox.30 seconds has elapsed.
» Press the "Relieve setting wedges" button and hold it in.

11:30:15
 The setting wedges move apart. The shims are detensioned.

Distanzplattenwechsel
1 system
Messsystem 4
alt
Spalt
2 108

MAINTENANCE
Crusher
4 5 6 7 8 9 10 11

 The diesel generator switches off and the shims can be re-
placed.
Fig. 4.134: Removing shims
[1] Setting wedges [2] Deblocking plates

[3] Shims [4] Special tool for shim
change
[5] Hydraulic cylinder for gap
setting

MAINTENANCE
Crusher
Removing shims » Screw special tool [4] in threads of shims [3].
The special tool is located on the right side of the plant be-
tween crawler running gear and crusher outlet.
» If the thread turns of the special tool cannot be used or no
longer exist due to damage and / or soiling, raise shims and
use suitable auxiliary equipment to knock them out from the
opposite side until they can be pulled out.
» Raise shims and remove the desired number of shims [3].
A maximum of three shims [3] can be removed. Each shim has

a thickness of 20 millimetres.
The crushing gap is adjusted via the hydraulic cylinders of the
crushing gap setting. If necessary, the crushing gap can be
changed by removing or inserting shims. A change in the
crushing gap is possible with a maximum of three shims.
Operation of the plant without the two deblocking plates [2]

with a thickness of 25 mm is not permitted.
NOTICE
Operation of the plant without deblocking plates results in
damage to the jaw crusher, in particular, to the crushing gap
adjustment device.
• Never put the plant into operation without deblocking
plates.
• Only use shims and wedge adjustment to alter the crushing
gap.
WARNING
When moving the wedges for the crushing gap adjustment de-
vice, there is a risk of crushing injuries.
ponents of the gap adjustment device.
• Never place hands into the area of the gap adjustment de-
vice.
• Only use the special tool for inserting or removing shims.
Inserting shims » Insert shims [3] between the deblocking plates [2] and
wedge setting [1] and push in fully using the special tool [4].
Ensure that the shims lie flush on top of one another.

MAINTENANCE
Crusher
4 5 6 7 8 9 10 11

» Press the "Diesel ON" button [6] in the operator panel.
» Activate main switch on control cabinet.
» Press the "Tension setting wedges" button on the touch
screen.
11:30:15
llattenwechsel
latt
 The setting wedges move together and the cylinder of the
4
ssystem
push rod retracts.
mm 5
6

MAINTENANCE
Crusher
Fig. 4.136: Pressure plate bearings
[6] Crusher housing pressure [7] Rocker pressure plate

plate bearing bearing
» Ensure that the pressure plate sits correctly in the pressure
plate bearings [6] and [7] after the push rod has retracted.
If necessary, repeat the work steps from "Close crushing
gap" and insert the pressure plate in the pressure plate
bearings before "Tensioning".
 The shims have been changed.
» Switch off main switch.
 The diesel generator switches off.
» Switch off control voltage.
» Fold the protective cover of the crusher drive down and
tighten the bolt.
NOTICE
Knocking noises in area of pressure plate bearings could indi-
cate damaged pressure plate bearings and/or incorrect spring
preload, which in turn could result in damage at crusher gap
adjustment.
• Do not alter spring preload unless Kleemann GmbH service
department has first been consulted.
» Setting crushing gap, see chap. 3.14.02.

MAINTENANCE
Crusher
4.44.08.08 Changing V-belt pulley
4
5
3
3
2
2
Fig. 4.137: Removing V-belt pulley
[1] Drive shaft [2] Securing screws

[3] Taper-lock bushing [4] Forcing thread
[5] V-belt pulley
The description refers to the removal and installation of belt pul-
leys that are installed with taper-lock bushings.
Removing V-belt pulley » If necessary, slacken V-belt and take off.
» Mark position of V-belt pulley [5] on the drive shaft [1].
» Remove securing screws [2].
» Clean forcing thread [4] and grease slightly.
» Insert two of the securing screws [2] in the forcing thread
[4].
» Tighten the two securing screws evenly until the taper-lock
bushing [3] breaks out of the cone.
» If necessary, release cone seat by knocking on the taper-
lock bushing [3].
» Take off V-belt pulley [5] and taper-lock bushing [3].
» Clean drive shaft but do not grease it.
 The V-belt pulley has been removed.
Installing V-belt pulley

MAINTENANCE
Crusher
2 1
Fig. 4.138: Installing V-belt pulley
[1] Drive shaft [2] Securing screws

[3] Taper-lock bushing
» Clean the cone of the taper-lock bushing and V-belt pulley
but do not grease them.
» Insert taper-lock bushing [3] into V-belt pulley and slightly
screw in the securing screws [2].
» Push V-belt pulley [5] including taper-lock bushing onto
drive shaft [1].
» Ensure that the V-belt pulley is at the previously marked po-
sition. If necessary, check alignment with V-belt pulley on
opposing side.
» Insert securing screws [2] diagonally and evenly and tighten
to specified torque.
» Drive taper-lock bushing [3] in further with light knocks of a
wooden block or soft metal bushing.
» Tighten securing screws [2] to specified torque.
» Fill forcing thread [4] to protect against dirt penetration.
» Fit V-belt and tension it.
» Retighten securing screws [2] following brief run under drive
load.
 The V-belt pulley has been installed.

MAINTENANCE
Screens
Tightening torques of taper-lock bushings
Bushing Tighten- Number of Thread size

ing torque screws
2012 30 Nm 2 7/16"
2017
2517 50 Nm 2 1/2"
2525
3020 90 Nm 2 5/8"
3030
3525 115 Nm 3 1/2"
3535
4030 170 Nm 3 5/8"
4040
4535 190 Nm 3 3/4"
4545
5040 270 Nm 3 7/8"
5050
Tab. 4.9: Tightening torques of taper-lock bushings
4.45 Screens
DANGER
WARNING
Risk of falling
secure.

MAINTENANCE
Screens
4.45.01 Checking screen surfaces

Checking wear Wear on the screen surface must be checked visually. The
screen surfaces must be inspected for the following signs of
damage and wear:
Slotted grates
• Signs of wear on wear plates.
• Bent profile sections.
• Damaged screw connections.
Rubber covers
• Eroded, thin areas.
• Cracks, holes and other damage.
• Damaged screw connections.
Wire cloth and wire screen
• Eroded, thin areas.
• Torn off or bent wires.
• Damaged clamping systems.
» Visually check screen surfaces for the above-mentioned
points.
» If serious signs of damage and wear are determined, replace
the corresponding screen surface.
 The screen surfaces have been checked.
Checking tension
WARNING
Danger due to moving and rotating components
When checking components on the screen when it is running,
there is a risk of injury due to crushing and catching.
• Always keep a sufficient distance away from moving and
rotating components of the screen.
• Do not climb into the screen when in it is running.
NOTICE
Loose screen surfaces cause flapping cracks and damage to
the screen.
• Check screen surfaces for correct tension and secure fit-
ting.
The tension of the screen surface must be checked by monitor-

ing the sound with the screen running. Listen for the following
noises:

MAINTENANCE
Screens
Slotted grates, steel perforated plates, wire cloth and

wire screen
• Rattling of screw connections.
• Rattling and knocking of screen surfaces.
• Rattling and knocking of clamping systems.
Rubber covers
• Rattling of screw connections.
• Knocking of screen surfaces.
» Ensure that the screen surface makes contact with the entire
surface of the distance frame.
» Run the screen completely empty to avoid interfering noise
from loaded material.
» Monitor the sound at the screen surfaces for the above-men-
tioned points.
» If noises are determined, tension the corresponding screen
surface or retighten screw connections.
 The screen surfaces have been checked.
The security of the screen surfaces and screw connections can

also be checked by knocking with a hammer. When doing this,
it is essential to switch off plant and secure against reactiva-
tion.
Screen surfaces are possibly custom-designed special parts.
Please order these special parts in good time because they
have longer delivery times.
4.45.02 Tensioning screen surfaces

Longitudinal tensioning of screen surface
3
2

MAINTENANCE
Screens
Fig. 4.139: Clamping system for longitudinal tension
[1] Clamping nut [2] Locknut

[3] Clamping rail [4] Screen surface
[5] Counterholder
» Ensure that no material makes contact between the clamp-
ing folds of the screen surface[4], the counterholder [5] and
the clamping rail [3]. The screen surface must make contact
over the entire area of the distance frame.
» Attach screen surface [4] to the counterholder [5].
» Attach clamping rail [3] in clamping fold of screen surface
[4].
» Clamp screen surface by turning clamping nut [1].
» Tighten locknut [2].
» Knock on the screen to check tension and correct it if neces-
sary.
 The screen surface is tensioned.
4.45.03 Other maintenance tasks
NOTICE
Screens that knock against components during operation
cause cracks in machine components and rubber mountings.
• Guarantee freedom of movement and minimum clearance
of fixed and swinging components.
• Clear the gap between the fixed and swinging components
regularly of stones and contamination.
» Visually check the components of the screen for damage.

» Visually check the screen casing for freedom of movement
and monitor the sound.
» Visually check chutes and rubber curtains of the screen out-
let, screen overpass and screen underpass for damage, such
as cracks and embrittlement, and for correct fastening.
» Visually check rubber mountings of the screen for damage,
such as wear, increasing fatigue, embrittlement and cracks.
» Visually check the wear lining for security, contamination,
caking and wear.
» Visually check security of screw connections and tighten to
specified tightening torque if necessary.
» Replace damaged components of the screen and chutes if
necessary.
 Components and screw connections have been checked.

MAINTENANCE
Screens
4.45.04 Repairing screens

4.45.04.01 Changing grizzly feeder screen surfaces
Changing lower deck screen surface
3
2 5
Fig. 4.140: Grizzly feeder lower deck screen surface
[1] Screen surface [2] Clamping nut and locknut

[3] Clamping fold [4] Clamping rail
[5] Counterholder
Changing lower deck screen surface
The description covers the removal and installation of a screen
surface with wire cloth. When removing and installing a dummy
cover made of rubber, a chain hoist or similar pulling device
must be used for withdrawal and insertion.
Removing screen surface » Switch off plant components and the diesel generator.
» Position suitable climbing aids at the rear side of the screen-
ing unit.
» Remove rubber curtain at the rear side of the screening unit.
» If necessary, remove screen underpass to create more
space.
» Release locknut of clamping nut [2] and unscrew, but do not
remove.
» Release clamp nut [2] a few turns until the screen surface
[1] is slackened.
» Run vibrating feeder for a brief period until contamination
and deposits between screen surface and distance frame
have loosened.
» Switch off plant components and the diesel generator again.

MAINTENANCE
Screens
» Unscrew clamping nut [2] until the screen surface [1] can be
removed from the clamping fold. If necessary, unscrew
clamping nut and locknut [2] and remove clamping rail [4].
» Press screen surface out of counterholder [5] and then with-
draw to the rear.
» Remove coarse contamination from the distance frame,
counterholder [5] and clamping rail [4].
» Visually check rubber profiles for damage and correct seat-
ing; replace or move into correct position as required.
 The screen surface has been removed.
Installing screen surface » Insert new screen surface and attach with clamping fold [3]
in counterholder [5] and in clamping rail [5].
» Tension screen surface, see chap. 4.45.02.
» If applicable, reinstall screen underpass.
» Reinstall rubber curtain.
 The screen surface is installed.
NOTICE
Newly installed screen surfaces settle after a few hours oper-
ation and can become loose.
• Retension newly installed screen surfaces after approx. 8
hours operation.
Changing upper deck screen surface
Fig. 4.141: Grizzly feeder upper deck screen surface
[1] Cover strip [2] Screws

[3] Slotted grate

MAINTENANCE
Screens
A description of removal and installation of the slotted grate is

provided.
The same procedure can be used for removal and installation

of a steel perforated plate. Note that the maximum clearance
between the slotted grate and contact surfaces must not ex-
ceed 2 millimetres. If it is more than 2 millimetres, support
with metal plates to ensure safe support.
Removing slotted grate
The screws of the slotted grate are partly through-bolts and

bolted from below with nuts. To release the nuts, the screen
surface and the rubber chute have to be removed.
» Remove rubber chute.
» Remove screen surface.
» Unscrew screws [2] and nuts on slotted grate.
» Lift slotted grate [3] with suitable lifting gear and tackle to
remove it.
» Remove coarse contamination from the contact surfaces on
the distance frame.
 The screen surface has been removed.
Installing slotted grate
When replacing steel perforated plates and slotted grates, al-

ways use new screws and nuts.
» Lift slotted grate [3] with suitable lifting gear and tackle onto
the distance frame.
» Insert screws [2] and nuts and tighten to specified torque.
» Install and tension screen surface, see chap. 4.45.02.
» Install rubber chute correctly.
 The screen surface is installed.

MAINTENANCE
Screens
4.45.04.02 Replacing rubber profiles
Fig. 4.142: Rubber profiles for screen surface
[1] Bearing iron [2] Rubber profile
DANGER
The rubber profiles [2] are attached to bearing irons [1] and
prevent the screen surface from sagging and knocking. Worn
and missing rubber profiles lead to damage to the screen sur-
face and screen components.
» Remove screen surface, see chap. 4.45.04.01.
» Replace worn and missing rubber profiles [2].
» Reinstall screen surface.
 The rubber profiles have been replaced.

MAINTENANCE
Cleaning the plant
4.46 Cleaning the plant
4.46.01 Cleaning the plant
WARNING
Risk of falling
secure.
To ensure that the plant is always operable, it must be cleaned

every day. If cleaning tasks are not carried out, this results in
increased wear of the moving components and interferences
when in operation.
After completion of crushing and screening work, the following
cleaning tasks must be carried out:
» Remove loose material from the chassis, platforms and
climbing aids.
» Remove adhering material from the feed hopper, vibrating
conveyor troughs, prescreen and the chutes.
» Remove jammed and adhering material from belt conveyors
and associated chutes.
» Remove material from the crawler chassis and the area be-
tween the sprockets and track rollers.
 The plant has been cleaned.
Suitable cleaning agents
The following objects and auxiliary aids are suitable for cleaning
the plant:
• Clear water for rinsing.
• Coarse brush for sweeping.
• Shovels and picks for removing build-ups and caking.
• Crowbars and similar tools for releasing jammed material.

MAINTENANCE
Cleaning the plant
4.46.02 Cleaning with high-pressure cleaners
DANGER
Danger of burns, explosion and/or poisoning
The atomised spray of cleaning agents containing solvents can
lead to serious or fatal injury.
• Never extract non-solvent-free fluids. This includes ben-
zene, paint thinners, diesel/heating oil, acetone, undiluted
acids, solvents, etc.
• Cover electric parts, insulating material and intake open-
ings for combustion air and do not expose to a direct jet.
Refit all covers after cleaning.
• Do not jam the lever of the spray gun during operation.
• To protect against parts splashing back, wear suitable pro-
tective equipment, e.g. face mask or safety goggles.
• Never direct the cleaning agent jet at people, animals, the
high-pressure unit, sealing or electric components.
» Note and observe the specifications on high-pressure clean-

ers in the safety manual.
4.46.03 Cleaning touch screen
[1] Touch-sensitive surface

MAINTENANCE
Performing welding work
NOTICE
The touch screen can be damaged by pointed or sharp objects
and by fluids.
• Never use pointed or sharp objects, e.g. knives, for clean-
ing.
• Do not use aggressive or abrasive cleaning agents or sol-
vents.
• Never let fluids penetrate the housing. Risk of short circuit!
• Ensure that the screen protector is fitted at the touch
screen.
If the touch screen or screen protector is contaminated, it can

be cleaned with a damp cloth. In the case of stubborn deposits
on the screen protector, it can be replaced.
» Clean contact-sensitive surface [1] with a clean, damp cloth.
» If contamination is stubborn, spray a washing agent onto the
damp cloth.
» Replace screen protector if necessary.
4.47 Performing welding work
Fig. 4.144: Performing welding work

MAINTENANCE
WARNING
Danger as a result of welding work
Welding work may cause serious or fatal injuries due to dan-
gerous body currents.
• Connect welding current return wire directly at the compo-
nent to be welded.
• Set down electrode holder in an insulated area.
• Observe protection class IP23 when using welding power
sources outside.
NOTICE
Danger of fires due to welding torch
Welding torches, hot metal and sparks can set fire to compo-
nents and objects in the surrounding area.
• Where possible, cover components and objects exposed to
a risk of fire.
• Protect components and objects against dripping hot metal
and sparks.
• Ensure fire extinguisher is ready before starting work.
• Ensure a fire watch is present during and after welding
work.
Safety precautions and • Welding work must only be carried out by personnel trained
prerequisites or authorised by KLEEMANN.
• Check welding apparatus, welding lead and equipment for
proper working condition.
• Use a fully insulated electrode holder.
• Never jam the electrode holder under your arm.
• Never place the welding lead over your shoulder.
• Use dry, undamaged protective gloves free of metallic parts.
• Do not install the welding lead parallel to electric lines.
• Ensure the housing of electronic components and electrical
lines do not make contact with the welding electrode.
• Remove layers of paint, grease or rust in the area of the ter-
minal.
• Where possible, connect the earth terminal directly to the
component being welded to avoid straying welding currents.
Otherwise there is a danger of destroying electronic compo-
nents.
• Never connect via rotating components. This can result in
bearing damage.

MAINTENANCE
Welding work on the plant must only be carried out with an ex-
ternal power supply.
Welding with an external » Switch off plant components and the diesel generator.
power supply
» Switch off main switch and secure against reactivation.
» Switch off control voltage, remove key and carry it with you.
» Use external network connection or external power supply
unit.
 Welding work can begin.

TABLES
Technical details
5 TABLES
This chapter lists all technical details relevant to your plant.
The complete technical details of the manufacturers' compo-
nents are provided in the respective manufacturer's documen-
tation.
manual!
5.01 Technical details
5.01.01 Complete plant

5.01.01.01 Weights
Designation Weight
Plant without optional equipment but with approx. 38500
mandatory alternatives, e.g. screen surfaces kg
Electromagnet approx. 1500
kg
Permanent magnet approx. 1100
kg
Hopper extension approx. 1300
kg
Prescreen conveyor, short approx. 1000
kg
Prescreen conveyor, long approx. 1200
kg
In addition, foldable crusher discharge con- approx. 300 kg
veyor
Maximum weight with complete equipment1 approx. 42800
kg
Tab. 5.1: Weight of entire plant
Weight of the plant including fluids and lubricants and 400 li-
tres of diesel fuel.
1 The respective operating weight of the plant is noted on the
type plate.

TABLES
Technical details
5.01.01.02 Dimensions
Dimensions in operating position
3962
4015
3382
3402
24°
669
4285 3000 6629 1377
15291
15593
Fig. 5.1: Side view MC110R
2193
1900
2700 1028
4030
Fig. 5.2: Front view MC110R

TABLES
Technical details
3083
1900
2700 3133
6130

All dimensions in millimetres.
5.01.01.03 Driving operation
Designation Value
Maximum climbing ability forward/back 30 %
Maximum permissible lateral inclination 17 %
Maximum driving speed 1.5 km/h
Max. generated ground pressure1 1.80 kg/cm²
Tab. 5.2: Plant driving operation
1 The maximum generated ground pressure is calculated ac-

cording to the following formula: Max. total weight of the plant
/ distance between centres x track shoe width x 2.
5.01.01.04 Charged material and size
Designation Value
Permissible feed material Mineral materials such as rubble,
demolished asphalt and demol-
ished concrete, tiles/bricks and
natural stone.
Materials such as slag, coal, ores,
etc., only after express approval
from KLEEMANN GmbH.

TABLES
Technical details
Designation Value
Permissible feeding size Maximum edge dimensions 990 x
990 x 620 mm (length in material
direction of flow x width 90° in re-
lation to material direction of flow x
height).
Tab. 5.3: Feed material and size
5.01.01.05 Crushing ratio and compressive strength of feed material
Designation Value
Reduction ratio at com- 7:1 at <100 MPa
pressive strength
5:1 at < 150 MPa
3-4:1 at < 300 MPa
Tab. 5.4: Crushing ratio and compressive strength
5.01.01.06 Feed and crushing capacity
Designation Value
Feed capacity Up to 330 t/h depending on the
type and composition of the feed
material and size or volume of the
prescreening or the final grain size.
Crushing capacity Approx. 115 - 130 t/h at a gap
width of 60 mm. (CSS).
Approx. 190 - 210 t/h at a gap
width of 100 mm. (CSS).
Approx. 250 - 270 t/h at a gap
width of 130 mm* (CSS).
Tab. 5.5: Feeding and crushing capacity
Feed capacity for with crushing gap marked with * and active
prescreening, feed size adapted to the crushing ratio.
5.01.01.07 Screen capacity
Designation Value
Permissible charged ma- As described in chap. 5.01.01.04.
terial and size

TABLES
Technical details
Designation Value
Permissible screen sur- Original standard series and op-
faces tional equipment from KLEEMANN
GmbH.
Deviating screen surfaces only af-
ter prior approval by KLEEMANN
GmbH. Primary screening in the
upper deck maximum 100 mm.
Mesh size ratio of upper Maximum 1:5.
deck to lower deck
Tab. 5.6: Screen capacity
5.01.01.08 Ambient temperatures

The plant can be continuously operated at ambient tempera-
tures of -15 °C to +40 °C.
With the cold package special equipment, plant operation up

to -25 °C is also possible.
With the hot package special equipment, it is also possible to
operate the plant at ambient temperatures up to + 50° C.
5.01.01.09 Sound power level
Fig. 5.4: Sound power level
[A] Measuring point on the [B] Measuring point in front

steps to diesel generator of the control cabinet
Emission sound pressure level

TABLES
Technical details
Designation Sound pressure level

LPA
Measuring point A* 93.4 dB
*
Measuring point B 84.7 dB
Tab. 5.7: Sound pressure level
*
Measured at a distance of 1 metre from the plant and 1.6 me-
tres above the ground.
Sound power level
Designation Sound power level LWA

Plant 113 dB
Tab. 5.8: Sound power level
The sound power level is a quantitative variable independent

of the environment.
The emission sound pressure level is an acoustic pressure
measured a specific distance from the source under certain
ambient conditions.
Determination and implementation according to the standard:
Determination of the sound power level of noise sources from
sound pressure measurements EN ISO 3744.
Measuring conditions
• Plant is running in automatic operation.
• Operation out of doors.
• No material crushing.
• Speed of the diesel generator 1500 rpm.
5.01.02 Power supply unit/engine

Technical data of diesel generator exhaust emission
stage IIIA
Designation Value
Type designation AAD110-EU1
Manufacturer of power supply Kleemann
unit
Type of power supply unit DE 248/135 SC/MA/TF
Rated output 135 kVA
Rated current 188 A
Rated power factor 0.8
Rated voltage 400 V
Frequency 50 Hz

TABLES
Technical details
Designation Value
Rotational speed 1500 rpm
Weight Approx. 3100 kg
Reference conditions*
Installation altitude approx. 100 m above sea level
Ambient temperature 25 °C
Relative humidity 60%
Diesel engine manufacturer Scania
Engine type DC 09-071A (02-02)
Number of cylinders 5 in-line
Displacement 9.3 l
Rated speed 1500 rpm
Continuous output according to DIN 248 kW
6280 / ISO 3046-1
Fuel consumption according to DIN 208 g/kWh
51601 at full load approx.
Starter 24 V, 6.0 KW
Generator 28 V, 100 A
Batteries 2 x 185 Ah, 24 V (2 x 12
V)
Cooling system Liquid cooling, charge air
cooling, oil cooling
Diesel fuel filling capacity Approx. 520 l
Filling volume of engine oil during Approx. 33 l
oil change1
Exhaust emissions stage Stage IIIA
Generator manufacturer MECC ALTE S.P.A.
Generator type ECP 34-1 L/4
Rated voltage 400 V
Voltage stability, static ± 1.5%
Frequency 50 Hz
2
Operating voltage of toothed belt 5699 N
or frequency3, new toothed belt
61.1 Hz
Run-in toothed belt 4071 N
51.6 Hz
Type of protection IP 23
Fluid coupling manufacturer Transfluid
Coupling type KPTO 19

TABLES
Technical details
Designation Value
Design Switchable fluid coupling
with variable filling and
chain-driven oil pump
Drive speed 1500 rpm
Power transmission at drive speed 160 kW
mentioned
Fill capacity of hydraulic oil tank Approx. 35 l
Weight without hydraulic oil Approx. 314 kg
Tab. 5.9: Power supply unit/engine of plant
* The above-mentioned performance data of the power supply

unit is based on the specified reference conditions. Deviations
above these values sometimes indicate a considerable loss in
performance.
1
Check at oil dipstick, also refer to manufacturer's documenta-
tion
2 Static strand force of toothed belt
3 Measured in tight span
Technical data of diesel generator exhaust emission level
LRC
Designation Value
Type designation AAD110-EU1
Manufacturer of power supply Kleemann
unit
Type of power supply unit DE 248/135 SC/MA/TF
Rated current 188 A
Rated power factor 0.8
Rated voltage 400 V
Frequency 50 Hz
Reference conditions*
Installation altitude approx. 100 m above sea level
Ambient temperature 25 °C
Relative humidity 60%
Diesel engine manufacturer Scania
Engine type DC 09-073A (02-22)
Number of cylinders 5 in-line
Displacement 9.3 l

TABLES
Technical details
Designation Value
Rated speed 1500 rpm
Continuous output according to DIN 248 kW
6280 / ISO 3046-1
Fuel consumption according to DIN 203 g/kWh
51601 at full load approx.
Starter 24 V, 6.0 KW
Generator 28 V, 100 A
Batteries 2 x 185 Ah, 24 V (2 x 12
V)
Cooling system Liquid cooling, charge air
cooling, oil cooling
Diesel fuel filling capacity Approx. 520 l
Filling volume of engine oil during Approx. 33 l
oil change1
Exhaust emissions stage LRC
Generator manufacturer MECC ALTE S.P.A.
Generator type ECP 34-1 L/4
Rated voltage 400 V
Voltage stability, static ± 15%
Frequency 50 Hz
Operating voltage of toothed belt2 5699 N
or frequency3, new toothed belt
61.1 Hz
Run-in toothed belt 4071 N
51.6 Hz
Fluid coupling manufacturer Transfluid
Coupling type KPTO 19
Design Switchable fluid coupling
with variable filling and
chain-driven oil pump
Drive speed 1500 rpm
Power transmission at drive speed 160 kW
mentioned
Fill capacity of hydraulic oil tank 35 l
Weight without hydraulic oil 314 kg
Tab. 5.10: Power supply unit/engine of plant
* The above-mentioned performance data of the power supply

unit is based on the specified reference conditions. Deviations

TABLES
Technical details
above these values sometimes indicate a considerable loss in

performance.
1
Check at oil dipstick, also refer to manufacturer's documenta-
tion
2
Static strand force of toothed belt
3
Measured in tight span
5.01.03 Hydraulic oil supply
Designation Value
Type designation AMC110-Z1
Hydraulic oil tank filling capacity 220 l
Filling capacity of hydraulic system, Approx. 280 l
complete
Driving hydraulics operating pressure 350 bar
Driving hydraulics feed pressure 28 bar
Operating pressure of auxiliary hy- 200 bar, ±10 bar
draulics
Tab. 5.11: Hydraulic system of plant
5.01.04 Electrical system
Designation Value
Type designation EMC110-EU1
Operating voltage 400 V
Control voltage 24 V
Frequency 50 Hz
Additional socket outlets (external 230 V / 16 A
circuits)
400 V / 32 A
Tab. 5.12: Electrical system
5.01.05 Drive system
Designation Value
Type designation FWD004-300
Crawler running gear with installed hydraulic motors and chas-
sis in between.
Holding brake: depressurised closing spring force brake. Ser-
vice brake in crusher operation hydraulically actuated, in driv-
ing operation, hydraulically released.
Crawler running gear type D4D

TABLES
Technical details
Designation Value
Distance between centres, sprock- 3000 mm
ets
Base plate width 400 mm
Gear motor maximum torque 45 kNm
Planetary gear filling capacity 3.5 l per side
Tab. 5.13: Plant driving operation
5.01.06 Conveyor unit

Crusher discharge conveyor
Designation Value
Type designation BFB100-092 / 107
Design Sectional steel structure
Weight Approx. 1956 kg / 2290
kg
Distance between centres 9200 mm / 10700 mm
Belt width 1000 mm
Drive output 9.2 kW
Conveyor belt speed 1.78 m/s
Belt conveyor drive Electric motor with
flange-mounted bevel
helical gearbox with re-
verse lock
Filling volume for bevel-helical Approx. 5.0 l
gearbox
Tab. 5.14: Crusher discharge conveyor
Prescreen conveyor (option)
Designation Value
Type designation BFS050-270 / BFS050-
500
Design Sectional steel structure
Weight* Approx. 950 kg / 1100 kg
Distance between centres 2700 mm / 5000 mm
Belt width 500 mm
Drive output 3.0 kW
Belt conveyor drive Electrically driven drum
motor with reverse lock
Gearbox filling capacity Approx. 5.2 l

TABLES
Technical details
Tab. 5.15: Prescreen conveyor
* Including belt support

Electromagnetic separator
Designation Value
Type designation 452-75/110-290 G6 S-O
Drive output 2.2 kW
flanged-on worm gear
Fill capacity of worm gear Approx. 3 l
Tab. 5.16: Electromagnetic separator
Permanent magnetic separator
Designation Value
Type designation 10 PCB 7 KEL SP
Distance between centres 1840 mm
Belt width 750 mm
Drive output 1.5 kW
flanged-on gearbox
Gearbox filling capacity Approx. 0.48 l
Tab. 5.17: Permanent magnetic separator
5.01.07 Water system
Designation Value
Type designation NDS110-MC1
Conveying medium temperature + 5 °C to + 35 °C
Maximum permissible operating 8 bar
pressure
Minimum / maximum permissible - 0.8 / 4 bar
pressure on suction side
Maximum suction height 5m
Maximum ambient temperature + 40 °C
Water consumption 2 to 5 m³ per day

TABLES
Technical details
Designation Value
Tab. 5.18: Water system
5.01.08 Lubrication system
Designation Value
Type designation SCH100-MC1
Flow pressure up to max. 700 mbar
Permissible service temperature - 25 °C to + 75 °C
Tab. 5.19: Lubrication system
5.01.09 Feeding unit

Feed hopper
Designation Value
Type designation TRI110-S1
Design Integrated in chassis
with screwable wear lin-
ing
Feeding volume Approx. 5.5 m³
Feeding width, front face Approx. 1900 mm
Feeding width, longitudinal Approx. 3900 mm
Feeding height Approx. 3400 mm
Tab. 5.20: Feed hopper
Hopper extension
Designation Value
Type designation TRI110-K1
Design Hydraulic foldable hop-
per walls
Feed volume, feed hopper and hop- Approx. 9.5 m³
per extension
Feeding width, front face Approx. 3200 mm
Feeding width, longitudinal Approx. 3200 mm
Feeding height Approx. 3960 mm
Tab. 5.21: Hopper extension

TABLES
Technical details
Grizzly feeder
Designation Value
Type designation AGR110-R1
Design Vibrating conveyor
trough designed with
wear plates and integrat-
ed prescreening unit
Trough width Approx. 1000 mm
Trough length Approx. 4390 mm
Screen width Approx. 1000 mm
Screen length Approx. 1830 mm
Screen inclination, upper deck 2°
Screen inclination, lower deck 10°
Screen surface clamping system Upper deck axial tension,
lower deck longitudinal
tension
Rocker width adjustment Via unbalance weights
Drive 2 vibration motors with
stepless speed adjust-
ment via frequency con-
verter
Drive output 2 x 4.8 kW
Permissible ambient temperature - 20 °C to + 40 °C
Tab. 5.22: Grizzly feeder
5.01.10 Crusher
Designation Value
Type designation STR110-070
Design Single toggle jaw crusher, welded
construction with rocker support-
ed in spherical roller bearing
Crusher jaw width 1100 mm
Feed opening 700 mm
Crushing jaw version Manganese rigid steel, reversible
Crusher gap adjustment Hydraulically adjustable
Gap width 30-180 mm
Drive Direct drive via V-belt

TABLES
Maintenance schedule/maintenance intervals
Designation Value
Auxiliary drive Hydraulic motor
Operating voltage1
or fre- 1395 N or 14 Hz
quency2 per V-belt, new V-
belt
Run-in V-belts 1073 N or 12 Hz
Tab. 5.23: Jaw crusher
1 Static strand force per V-belt, measured with Optikrik II + III

tension gauge.
2 Measured in tight span
5.02 Maintenance schedule/maintenance intervals
5.02.01 One-time maintenance tasks

One-time maintenance after initial operation
Component Maintenance work Material, After See chap.

h
spare parts
Power supply unit Visually check / lubricate Multipurpose Grease1 50 4.01.01
protective housing
Servicing/repair diesel 50 4.04.01
engine2
Service generator 50 4.04.05
Fluid coupling Flush coupling 500 4.04.11.01
Change oil filter See spare parts cata- 500 4.04.11.03
logue
Clean coarse filter 500 4.04.11.03
1
Change oil Clutch Fluid VG 32 , 500 4.04.11.03
approx. 35 l
Change vent filter See spare parts cata- 500 4.04.11.04
logue
Change drive chain See spare parts cata- 2500 4.04.11.05
logue
Hydraulic system Visually check compo- 50 4.05
nents
Change oil Hydraulic Oil HVLP 500 4.05.02.02
461, tank approx.
220 l, total ca. 280 l
Changing ventilation fil- See spare parts cata- 500 4.05.02.03
ter logue
Change suction filter See spare parts cata- 500 4.05.02.03
logue

TABLES
Component Maintenance work Material, After See chap.

h
spare parts
Change the return filter See spare parts cata- 500 4.05.02.03
logue
Electrical system Visually check compo- 50 4.06.01
nents
Visually check cables and 50 4.06.01
plug
Drive system Changing gear oil Special Gear Oil 500 4.08.02.01
75W-901, approx.
3.5 l per side
Belt conveyors Change gear oil of bevel High-Performance 500 4.10.01.07
helical gearbox Gear Oil VG 2201, ap-
prox. 5 l
Check assembly X3 4.10.01.01
Electromagnetic Changing gear oil High-Performance 500 4.10.04.03
separator Gear Oil VG 2201, ap-
prox. 3 l
Feeding unit Visually check vibration 50 4.43.03.02
motors
Check unbalance setting 50 4.43.04.03
of vibration motors
Crusher Check/tension V-belt Frequency4 per V- 50 4.44.04
belt: 12 Hz (run-in V-
belts)
Visually check/retighten 50 4.44.07
crusher mounting
Screens Tensioning screen surfac- 50 4.45.02
es
Retightening screws for 50 4.45.03
vibration motors
Check rocker width X3 4.43.04.02
Tab. 5.24: One-time maintenance after initial operation
1 Operating fluids and lubricants, see chap. 5.04.

2 See manufacturer's documentation.
3 With initial operation.
4 Measured in tight span.

TABLES
5.02.02 Regular maintenance tasks

Component Maintenance Material, See chap.
Every 1000 h
Every 2000 h
Every 500 h
work
Every 50 h
spare parts
Every 8 h
Signs check/replace See spare parts cat- X 1.06
alogue
Protective check/lubricate Multipurpose X 4.01.01
housing for Grease1
power supply
unit
Platforms check X 2.01.04
2
Screw connec- check/retighten X 4.01.01
tions
Lubricating nip- check/replace X 4.01.01
ples
Warning devic- check X 4.01.02
es
Guard devices visually check/re- See spare parts cat- X3 4.01.03
place alogue
Emergency check/repair See spare parts cat- X 4.01.04
stop alogue
Tab. 5.25: Chassis/guard devices maintenance schedule
1 Operating fluids and lubricants, see chap. 5.04.

2 Retighten screw connections earlier.
3 Replace if necessary.
Operator's stand

Every 1000 h
Every 2000 h
Every 500 h
work
Every 50 h
spare parts
Every 8 h
Panelling check/repair X 4.02.01

Touch screen clean Cloth, washing X 4.46.03
agent
Remote con- check/repair X2 4.02.03
trols, compo-
nents

TABLES
Every 1000 h
Every 2000 h
Every 500 h
work
Every 50 h
spare parts
Every 8 h
Emergency check/repair X 4.01.04
stop and func-
tions
Tab. 5.26: Control stand maintenance schedule
1 operating fluids and lubricants, see chap. 5.04.

2 check of radio remote control only by specialist.
Every 1000 h
Every 2000 h
Every 500 h
work
Every 50 h
spare parts
Every 8 h
Diesel engine service/repair X2 4.04.01

Change the engine X2 4.04.10
oil
Coolants check/replace X6 4.04.09
Cooler fins clean X3 4.04.08
Fuel prefilter change filter5 See spare parts cat- X 4.04.03
alogue
Collecting con- check/drain5 X5 4.04.03
tainer for water
separator
Air filter clean/change See spare parts cat- X3 4.04.07
alogue
Cyclone prefil- check X3 4.04.06
ter
Generator check X 4.04.05.01
toothed belt
tension Specified value for X 4.04.05.03
run-in toothed belt:
51.6 Hz
Specified value for
new toothed belt:
61.1 Hz
replace See spare parts cat- X4 4.04.05.03
alogue

TABLES
Every 1000 h
Every 2000 h
Every 500 h
work
Every 50 h
spare parts
Every 8 h
Fluid coupling Change oil filter See spare parts cat- X 4.04.11.03
alogue
Clean coarse filter X 4.04.11.03
1
Change oil Clutch Fluid VG 32 , X 4.04.11.03
approx. 63 l
Change vent filter See spare parts cat- X 4.04.11.04
alogue
Change drive chain See spare parts cat- X 4.04.11.05
alogue
Tab. 5.27: Power supply unit/engine maintenance schedule
1
operating fluids and lubricants, see chap. 5.04.
2See manufacturer's documentation.
3Daily in case of large accumulations of dust.
4For safety reasons, replace the toothed belt every 2000 oper-
ating hours at the latest.
5 Only when using cold package or LRC diesel engine.
6 Every 3000 operating hours or at the latest after 2 years.
Component Maintenance Material, spare See chap.

Every 8 h / daily
work parts
Every 1000 h
Every 2000 h
Every 500 h
Every 50 h
Hydraulic com- check/repair See spare parts cat- X1 4.05.01

ponents, tight- alogue
ness1
Hydraulic oil check/top up Hydraulic oil2 X 4.05.02.01
tank, fill level
Hydraulic oil change/carry out oil Hydraulic Oil HVLP X 4.05.02.02
analysis 462, tank approx.
220 l, total approx.
280 l
Tank vent filter replace See spare parts cat- X 4.05.02.03
alogue

TABLES
Every 8 h / daily
work parts
Every 1000 h
Every 2000 h
Every 500 h
Every 50 h
Filler neck clean X 4.05.02.03
coarse strainer
Suction filter replace See spare parts cat- X 4.05.02.03
alogue
Return filter replace See spare parts cat- X 4.05.02.03
alogue
Tab. 5.28: Hydraulic oil supply maintenance schedule
1
Observe checking and replacement intervals of hydraulic hos-
es!
2
Fluids and lubricants, see chap. 5.04.
Electrical system
Every 2000 h / annually

work parts
Every 8 h / daily
Every 1000 h
Every 500 h
Every 50 h
Electrical com- check/repair See electric diagram X 4.06.01

ponents
Earthing straps check/replace See spare parts cat- X 4.06.04
alogue
Starter batter- check X 4.06.02.02
ies
Check/clean vent X 4.06.02.02
openings
Control cabi- clean X 4.06.03
net1
Cables, sock- check/repair See electric diagram X 4.06.03
ets, control ele-
ments and
indicators

TABLES
Every 2000 h / annually

work parts
Every 8 h / daily
Every 1000 h
Every 500 h
Every 50 h
Control cabinet check X 4.06.03.02
mounting
Terminals 400V check/retighten X 4.06.03
components
Earth fault cir- check X 4.06.07.03
cuit interrupt-
ers
Motor protec- check X 4.06.07.02
tion switches
Electric motors, check/repair X 4.06.05
terminal boxes
Heat package2, check/repair See spare parts cat- X 4.06.06
components alogue
Filter element clean/change3 See spare parts cat- X 4.06.06
alogue
Ventilators check/change4 See spare parts cat- X 4.06.06
alogue
Tab. 5.29: Electrical system maintenance schedule
1
Work in the control cabinet must only be carried out by qual-
ified and authorised personnel.
2
Only with use of heat package.
3
Change filter element after 5 cleaning operations at the latest.
4
Replace defective ventilators immediately.
Drive system

Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Crawler carrier check/tension Multipurpose X3 4.08.01.01

chains Grease1

TABLES
Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Track pads check X 4.08.01.03
4
change See spare parts cat- 4.08.01.03
alogue
Base plates, check/repair See spare parts cat- X 4.08.01.02
track rollers alogue
Planetary gear, check X 4.08.02.01
leak-tightness
Filling level check X 4.08.02.01
2
Gear oil change Special Gear Oil X 4.08.02.01
75W-901, approx.
3.5 l per side
Tab. 5.30: Drive system maintenance schedule
1
2
But at least every 2 years.
3
Tension earlier if necessary.
4
With damage or wear.
Conveyor unit

Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Belt conveyors
Belt conveyors Check assembly4 4.10.01.01
Conveyor belts check/repair See spare parts cat- X 4.10.01.02
alogue
Return roller check X 4.10.01.03
guards
adjust5 4.10.01.03
Scraper check/repair See spare parts cat- X 4.10.01.04
alogue
adjust5 4.10.01.04
Rubber plates check/repair See spare parts cat- X 4.10.01.05
alogue

TABLES
Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
adjust5 4.10.01.05
Guide rails check X 4.10.01.06
8
replace See spare parts cat- 4.10.01.06
alogue
Bevel helical check/top up High Performance 4.10.01.07
gearbox fill lev- Gear Oil VG2201
el
Changing gear oil High Performance X3 4.10.01.07
Gear Oil1, 2, approx.
5l
Drum motor check/top up High Performance 4.10.01.08
filling level Gear Oil VG2201
Change gear oil6 High Performance 4.10.01.08
Gear Oil VG2201, 2
Tensioning check X 4.10.01.09
bearings
lubricate Multipurpose X 4.10.01.10
Grease1
Plummer blocks check/repair See spare parts cat- X 4.10.01.11
alogue
Perform grease Multipurpose X3 4.10.01.11
change Grease1
Chutes
Chutes check/repair See spare parts cat- X 4.10.03
alogue
Magnetic separator
Conveyor belts check/tension See spare parts cat- X 4.10.04.01
alogue
Bearing for lubricate Multipurpose X 4.10.04.04
electromagnet- Grease1
ic separator
Permanent lubricate Multipurpose X 4.10.05.04
magnetic sep- Grease1
arator bearing
Worm gear fill check/top up7 4.10.04.03
level, electro-
magnetic sep-
arator

TABLES
Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Changing gear oil High Performance X3 4.10.04.03
Gear Oil1, 2, approx.
3l
Dust deposits clean Brush X
on electric mo-
tor
Tab. 5.31: Conveyor unit maintenance schedule
1
Fluids and lubricants, see chap. 5.04
2
Filling volume, see type plate.
3
With fewer operating hours, at least every 2 years.
4
After each assembly.
5
Adjust if necessary.
6
Change interval every 10000 operating hours, with synthetic
oil filling every 30000 operating hours.
7
Top up if necessary.
8
With damage and / or if worn.
Water system

Every 1000 h
Every 2000 h
Every 500 h
work parts
Every 50 h
Every 8 h
Water pump Leaks, check/repair X 4.12

Check/clean prefil- X 4.12
ter
Spraying nozzles X 4.12
check/repair
Tab. 5.32: Water system maintenance schedule

TABLES
Tools/accessories
Every 1000 h
Every 2000 h
Every 500 h
work parts
Every 50 h
Every 8 h
Tools and ac- check/replace X 4.42
cessories
Tab. 5.33: Tools/accessories maintenance schedule
Feeding unit
Every 1000 h
Every 2000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Feed hopper check/repair1 See spare parts cat- X 4.43.01

alogue
Vibrating feed- check/repair vibrat- See spare parts cat- X 4.43.03.01
er ing elements1 alogue
check/repair vibra- See spare parts cat- X 4.43.03.02
tion motors1 alogue
check/replace wear X 4.43.03.03
lining1
Tab. 5.34: Feeding unit maintenance schedule
1
Replace/repair if necessary.
Jaw crusher

Every 1000 h
Every 2000 h
work parts
Every 500 h
Every 50 h
Every 8 h
Rocker bearing lubricate Multipurpose X 4.44.02

Grease1
Labyrinths lubricate Multipurpose X 4.44.02
Grease1
Bearing noises, check/repair3 See spare parts cat- X 4.44.03
heating alogue

TABLES
Tightening torques
Every 2000 h
Every 1000 h
work parts
Every 500 h
Every 50 h
Every 8 h
V-belt check/tension4 Frequency2 per V- X 4.44.04
belt: 12 Hz (worn-in
V-belts)
Tension roller lubricate Multipurpose X 4.44.05.01
bearing Grease1
Tension roller check/clean X 4.44.05.02
cavities
Attachment of check/retighten X 4.44.06
crusher jaws
and lateral
wedges
Crusher mount- check X 4.44.07
ing
Lubrication sys- check X 4.18.01.01
tem, fill level
Lubrication sys- fill5 Multipurpose 4.18.01.01
tem grease Grease1
Lubricant lines check See spare parts cat- X 4.18.01.02
alogue
Tab. 5.35: Jaw crusher maintenance schedule
1
2
Measured in tight span. Frequency when installing new V-belt:
14 Hz
3
Repair if necessary.
4
Tension if necessary.
5
Fill if necessary.
5.03 Tightening torques
This section presents the tightening torques for screws and

nuts in tabular form.

TABLES
Tightening torques
NOTICE
Danger due to incorrect tightening torques
Incorrectly tightened or retightened screws and nuts can be-
come loose or tear.
• Check the security of nuts and screws on a regular basis
and retighten if necessary.
• Tighten or retighten screws and nuts to specified tightening
torque.
Tightening torques for standard metric threads
Dimension Maximum tightening torques MA in Nm
8.8 10.9 12.9

M4 3.3 4.8 5.6
M5 6.5 9.5 11.2
M6 11.3 16.5 19.3
M8 27.3 40.1 46.9
M10 54 79 93
M12 93 137 160
M14 148 218 255
M16 230 338 395
M18 329 469 549
M20 464 661 773
M22 634 904 1057
M24 798 1136 1329
M27 1176 1674 1959
M30 1597 2274 2652
M33 2161 3078 3601
M36 2778 3957 4631
M39 3597 5123 5994
Tab. 5.36: Tightening torques for standard metric threads
Tightening torques for fine-pitch thread
8.8 10.9 12.9

M8 x 1.00 29.2 42.8 50.1
M10 x 1.25 57 83 98
M12 x 1.25 101 149 174
M12 x 1.50 97 143 167
M14 x 1.50 159 234 274

TABLES
8.8 10.9 12.9

M16 x 1.50 244 359 420
M18 x 1.50 368 523 613
M20 x 1.50 511 728 852
M22 x 1.50 692 985 1153
M24 x 2.00 865 1232 1442
M27 x 2.00 1262 1797 2103
M30 x 2.00 1756 2502 2927
Tab. 5.37: Tightening torques for fine-pitch thread
5.04 Fluids and lubricants

A complete presentation of the individual fluids and lubricants
with all data and approvals, e.g. from combustion engine and
gearbox manufacturers, is not possible for reasons of space.
The specification details take DIN and ISO standards, in particu-
lar, into consideration.
The fluids and lubricants table is designed to provide initial ori-
entation for servicing KLEEMANN plants and machines. Howev-
er, it does not replace the advice of a lubrication specialist or the
recommendation of the engine and gearbox manufacturers.
For environmental protection reasons, it is absolutely necessary
to dispose of used oil in accordance with the specifications after
every service or oil change.
Fluids and lubricants for special application conditions are not
included in this lubricant table.
We shall assume liability for our plants or machines only if the

listed fuids and lubricants are used!
The use of other lubricants is only possible after approval by
the Service Department of KLEEMANN GmbH!
5.04.01 Lubricants
Fluid/lubricant Specification Brand Product

1
Engine oil 10W-40 Wirtgen Group Engine Oil
15W-402 Wirtgen Group Engine Oil
Corrosion inhibitors, cool- Cooler protection Gly- Wirtgen Group Glysantin G48
ants and anti-freeze santin G48
agents

TABLES
Tab. 5.38: Engine oil, corrosion inhibiting and anti-freeze

agents for the cooling system
1
Temperature range -20 °C to 50 °C
2
Temperature range -15 °C to 50 °C
Viscosity in accordance with the requirements of the installa-

tion location.
Fluid coupling

Coupling hydraulic oil Coupling oil ISO-VG 32 Wirtgen Group Clutch Fluid VG 32
DIN 51524-2
Type HLP
DIN EN ISO 6743-4
type HM ISO VG 32
Tab. 5.39: Lubrication table for fluid coupling
Fluid/lubricant Specifikation1 Brand Product

Hydraulic oil Zinc-based multipur- Wirtgen Group Hydraulic Oil HVLP 46
pose hydraulic oil
Type HVLP 46
ISO 11158 (HV)
Tab. 5.40: Hydraulic oil supply lubricant table
EP additives (extreme-pressure additives) are added to lubri-

cants and improve their tribological characteristics, i.e. they
prevent the fusing of two metallic materials that rub against
each other.
1
Before changing the hydraulic oil to a hydraulic oil with a dif-
ferent specifications, contact the Service Department of KLEE-
MANN GmbH.
Drive system

Gear oil for track drive SAE 75W-90 with EP Wirtgen Group Special Gear Oil 75W-
additives 90
API MT-1
API GL-4, GL-5

TABLES

Chain tensioner grease Lubricating grease with Wirtgen Group Multipurpose Grease
EP additives (lithium
saponified)
ISO 6743-9: L-XBCEB
2
DIN 51825: KP2K-25
ISO NLGI 2
Tab. 5.41: Drive system lubricant table

each other.
Conveyor unit

Belt conveyor drive gear oil Synthetic polyglycol Wirtgen Group High performance
gear oil ISO-VG 220 gear oil VG 220
DIN 51517-3 (CLP)
ISO 6743-6 (CKS/CKT)
Bearing lubricating grease Lubricating grease with Wirtgen Group Multipurpose Grease
saponified)
ISO 6743-9: L-XBCEB
2
DIN 51825: KP2K-25
ISO NLGI 2
Tab. 5.42: Conveyor unit lubricant table

each other.
Crusher

Crusher grease Lubricating grease with Wirtgen Group Multipurpose Grease
saponified)
ISO 6743-9: L-XBCEB
2
DIN 51825: KP2K-25
ISO NLGI 2
Tab. 5.43: Crusher lubricant table

TABLES

each other.
5.04.02 Diesel Fuels

At low temperature, paraffin separations can cause obstruction
in the fuel supply resulting in malfunctions. Below outside tem-
peratures of 0 °C, use winter diesel fuel (up to -15 °C). In many
cases, diesel fuel with additives with an application temperature
of up to approx. -20 °C is offered.
At outside temperatures below 0 °C, the temperature properties
of diesel fuel can be improved as a preventive measure by add-
ing petroleum. A maximum of 20% can be added. When refuel-
ling, the petroleum must be filled first so that it mixes with the
diesel fuel.
NOTICE
Danger of engine damage
The addition of petroleum to diesel fuels (winter diesel fuel) al-
ready adapted to low outside temperatures can result in en-
gine damage.
• Only add petroleum to summer diesel fuels.
• Do not add any other flow improvers or benzene.
Necessary properties of diesel fuel
Property Requirement
Viscosity at 40 °C 2.0 - 4.5 mm2/s (cSt)
Density at 15 °C 0.82 - 0.86 kg/dm3
Sulphur content (percent by maximum 0.035 %
weight)
Ignitability (cetane num- at least 51
ber)
Flash point 56 °C
Complies with standards EN 590
ASTM D 975 Grade No. 1-D and
2-D
Tab. 5.44: Properties of diesel fuel
Observe and adhere to the specifications in the manufacturer's

documentation.
Requirements of diesel fuel for LRC engine

TABLES
Separate documentation
Property Requirement
Viscosity at 40 °C 2.0 - 4.5 mm2/s (cSt)
Density at 15 °C 0.82 - 0.86 kg/dm3
Sulphur content (percent by maximum 0.2 %
weight)
Ignitability (cetane num- at least 49
ber)
Flash point 56 °C
Complies with standards EN 590
ASTM D 975 Grade No. 1-D and
2-D
Tab. 5.45: Properties of diesel fuel
If the sulphur content is between 0.2% and 0.4 %, the oil

change intervals must be halved.
Sulphur content greater than 0.4% is not permitted.
Observe and adhere to the details about oil change intervals in
the manufacturer's documentation.
5.05 Separate documentation

Apart from this instruction manual, further documents and in-
formation are available on the plant.
The listed documents are an integral element of the instruction
manual as defined by EC Directive 2006/42/EC.
5.05.01 Documentation on the plant
Component Document
Plant Spare parts catalogue
Electric diagram
Transport instructions
Tab. 5.46: Documents from KLEEMANN GmbH
Safety manuals
Language Document number

Bulgarian F20016714
Chinese 2390372
Danish F20015433
German F20007548

TABLES
Separate documentation
Language Document number

German US F20011137
English F20008844
English US F20011138
Estonian F20016711
Finnish F20016706
French F20008845
Italian F20011375
Japanese 2343108
Croatian 2367373
Latvian F20016712
Lithuanian F20016713
Dutch F20010337
Norwegian F20011374
Polish F20011376
Portuguese F20016710
Romanian F20016715
Russian F20008847
Serbian F20013946
Slovakian F20016708
Spanish F20008846
Swedish F20012128
Czech F20016501
Turkish F20016722
Hungarian F20016707
Tab. 5.47: Safety manuals from KLEEMANN GmbH
Manufacturer's documentation
Assembly Component Manufacturer Document

Power supply unit/engine Diesel engine Scania Instruction manual
Spare parts catalogue
Tab. 5.48: Manufacturer's documentation
5.05.02 Information material

Information and material can be called up or downloaded under
"Products" on the homepage of KLEEMANN GmbH: www.klee-
mann.info.

TABLES
Fuses
5.06 Fuses
Short code Value Number Assignment

004+S-F1 160 A 1x Main switch
004+S-OF1 6A 1x In-series fuse for undervoltage circuit breaker
0020+S- 32 A 4x In-series fuses for service socket 400 V at control cabinet
OF1
020+S-OF2 40 A/ 1x Earth fault circuit interrupter for service socket outlets
0.03 A
020+S-OF3 10 A 2x In-series fuse for service socket outlet 230 V at control
cabinet
030+S-F1 6A 1x Control voltage
030+S-F2 6A 1x Emergency stop for direct drives
030+S-F3 6A 1x Emergency stop for crusher
030+S-F4 3A 1x Supply for PLC
003+S-F6 15 A 1x Fuse for drive system (24 V activation)
520+S-F1 100 A 1x Fuse for drive system
490+S-F1 10 A 1x Lubrication system
030+S-F5 1A 1x Supply for PLC
070+S-F1 10 A 1x Lighting
270+S-FQ1 8-32 A 1x Crusher discharge conveyor
290+S-FQ1 3-12 A 1x Prescreen conveyor
080+S-F1 2A 1x Warning light and warning siren
250+S-FQ1 3-12 A 1x In-series fuse for magnetic separator
260+S-F1 30 A 1x Electromagnet in-series fuse
400+S-FQ1 3-12 A 1x Auxiliary hydraulic system
410+S-FQ1 3-12 A 1x Water pump
330+S-F1 32 A 1x In-series fuse for vibrating feeder frequency converter
600+S-F1 20 A 1x Starter fuse
600+S-F2 20 A 1x Engine control unit fuse (EMS6)
600+S-F3 20 A 1x Engine control unit fuse (EMS1)
600+S-F4 10 A 1x Enable fuse
600+S-F5 2A 1x Electric generator fuse
Tab. 5.49: Fuses in the control cabinet

short codes. When a fault occurs, corresponding short desig-
nations are displayed at the touch screen.
Change fuses, see chap.4.06.07.01.

INSTALLATION AND REMOVAL, TRANSPORT
Transport
6 INSTALLATION AND REMOVAL, TRANS-

PORT
This chapter describes the installation, removal and transport
tasks that have to carried out prior to initial operation or trans-
port of the plant. Furthermore, you will also find details here
on storage, shutdown and return to operation.
manual!
6.01 Transport
Existing specifications UVV, DIN, VDI and country-specific spec-
ifications and regulations on transport must be observed.
DANGER
Removal and transport by unqualified and unauthorised per-
sonnel can result in serious or fatal injuries.
• Only assign personnel removal and transport tasks who are
qualified and authorised according to the requirements in
this instruction manual.
DANGER
Danger! Heavy loads
When loading by crane, the plant can slip away or tilt; there is
a risk of fatal injury.
• When loading by crane, consultation with Kleemann GmbH
is essential.
DANGER
Danger due to excess width or height
Excess width or height can result in material damage and per-
sonal injury.
• Remove all projecting plant components as described in
"Removal of plant".
• Secure loose components and other components to be
transported on the plant.
• Read the safety manual.
All transport work not described in this chapter must only be

carried out by personnel trained by KLEEMANN GmbH, or per-
sonnel who have appropriate qualifications, e.g. transport
company.

Transport
6.01.01 Approval of special transport

If the plant is to be transported on public roads, the official ap-
proval for special transport required must be obtained.
Transport approvals are subject to country-specific specifica-

tions and have to be applied for from or via the commissioned
transport company.
6.01.02 Transport details
Changes to the described transport dimensions and weights

through attachments and conversions that are not authorised
by Kleemann GmbH must be taken into consideration when
applying for transport approval.
Transport dimensions can be exceeded due to damage to plant
components, e.g. protruding or hanging components. Repair
damage prior to transport.
6.01.02.01 Dimensions
Transport dimensions of plant
3382
2338
1788
1064
669
3887 3798 6228
14313
Plant with standard crusher discharge conveyor.

Transport
4287 5730
Plant with extended and folded-down crusher discharge con-

veyor.
1900
2700
400 400
2950 2984

All dimensions in millimetres.
6.01.02.02 Weights
Plant weights
Designation Weight
Plant without optional equipment but with approx. 38500
mandatory equipment kg

Transport
Designation Weight
Plant with mandatory equipment and electro- approx. 40000
magnet kg
Plant with mandatory equipment, electromag- approx. 41300
net and hopper extension kg
net, hopper extension and short prescreen kg
conveyor
net, hopper extension and long prescreen con- kg
veyor
Plant with mandatory equipment and perma- approx. 39600
nent magnet kg
Plant with mandatory equipment, permanent approx. 40900
magnet and hopper extension kg
magnet, hopper extension and short pre- kg
screen conveyor
magnet, hopper extension and long prescreen kg
conveyor
Tab. 6.1: Transport weights of plant
If the plant is equipped with an extended crusher discharge

conveyor, in each case the transport weight is increased by ap-
prox.300 kg.
6.01.03 Loading and unloading
1 2 3 1
Fig. 6.4: Lashing and tilting points

Transport
[1] Lashing points on chassis [2] Tilting point without op-

tional equipment
[3] Tilting point with magnet-
ic separator
Fig. 6.5: Loading on low loader

Preparations for loading » Run all plant components until empty.
on a low loader
» Remove all projecting plant components, see chap. 6.03.
» Secure loose components and other components to be
transported on the plant.
» If necessary, fit transport locks on belt conveyors and mag-
netic separators.
» Clean plant, see chap. 4.46.
» Fill at least 300 litres in the fuel tank to prevent the diesel
engine from stalling on the loading ramp.
» Remove grey power plug and insert red transport plug in the
power and transport plug connection, see chap. 2.06.06.
» Set "Crawler running gear slow/fast" switch [1] to slow using
the remote control.
 The plant is ready for loading.

Transport
Driving plant onto low

loader/tying down
WARNING
Danger when loading the plant
Incorrect or careless loading and lashing can result in personal
injury and/or material damage.
• Take great care when loading and lashing.
• Observe general and locally applicable safety and accident
prevention specifications.
• Only use the marked lashing points.
• Only apply load to the lashing points in the lashing equip-
ment provided for this purpose.
WARNING
Danger due to unlit travel paths
Due to the unlit travel paths, there is an increased risk of inju-
ry.
• Before moving the plant, ensure that sufficient lighting of
the travel path is available.
» Ensure that the route and ground between plant and low
loader is firm and flat. Remove any obstacles.
» Use securely positioned loading ramps with sufficient load
bearing capacity and width.
» Remove contamination such as oil, snow or sludge from the
loading ramps.
» Provide transport surface with anti-slip mats.
» Observe the maximum permissible drive-up angle (climbing
ability).
» Using the levers of the remote control, drive the plant onto
the low loader so that it is straight.
» Drive the plant carefully over tilting point [2] or [3] and align
it on the low loader.
» Lash the plant on the lashing points [1] provided for this
purpose.
 The plant is loaded on the low loader and tied down.

Transport
Loading plant with crane
WARNING
Danger when transporting plant with crane
Incorrect crane transport can result in personal injury and/or
material damage.
• Only lift the plant at the lifting points provided for this pur-
pose using suitable hoisting equipment and lifting tackle.
• Do nut use lashing points and components for lifting the
plant.
1
2
Fig. 6.6: Crane loading
[1] Centre of gravity area [2] Lifting points
The lifting points for crane loading are fitted on the plant's
chassis and are marked in red.
The centre of gravity shifts depending on the plant's equip-
ment. When loading with cross-beams and several crane
hooks, they must be able to lift the total weight of the plant.

Plant installation
Observe the following items when lifting the plant with a crane:
• Prior to crane transport or ship loading of the plant, consult
Kleemann GmbH.
• Only the red lifting points on the plant are designed for lifting
with a crane.
• Guide the lifting gear for the rear lifting points at the side
past the grizzly feeder.
• Pull plant up vertically at the lifting points. Use several crane
hooks and load beams if necessary.
• Ensure that each crane hook and load bar, as well as the
hoisting gear, such as chains, ropes, etc., are capable of lift-
ing the total weight of the plant.
• Ensure that hoisting equipment, such as chains, ropes, etc.,
do not cause damage to components. Use spacers.
• Observe the transport weight and dimensions of the plant.
To avoid discharging the starter batteries the transport plug of

the plant must be inserted.
» Ensure that the transport plug is inserted, see chap.
2.06.06.
6.02 Plant installation
DANGER

Plant installation
DANGER
Danger due to incorrect installation and removal
Incorrect installation and removal and the use of unsuitable
hoisting gear and lifting accessories can result in serious or fa-
tal injuries.
• Use suitable hoisting gear and lifting accessories and check
that it is in perfect condition.
• Fit hoisting gear, such as chains and ropes, so that it cannot
slip.
• Always suspend components and machines from their cen-
tre of gravity.
• Only lift and transport loads as high and as far as neces-
sary.
• Never move under or stand under a suspended load.
• Only assign personnel installation and removal tasks who
are qualified and authorised according to the requirements
in this instruction manual.
WARNING
Risk of falling
There is a risk of falling during installation and removal work
secure.
WARNING
Risk of stumbling

Plant installation
NOTICE
Incorrect installation of the plant, or sinking of the plant on
soft ground, creates a risk of the plant tilting.
• Only position the plant on secure and firm ground.
Before the plant can be operated, it must be moved from trans-

port position to operating position. To prepare for installation,
carry out the following activities:
The battery isolator is fitted for plant transport at the control

voltage key. For operating the plant, the battery isolator must
be inserted again and switched on.
» Ensure that the battery isolator is inserted and switched on.
» Move the plant onto secure and firm ground. Remove any
obstacles in the direct vicinity.
» Position the plant, ensuring it is horizontal. If necessary, flat-
ten the ground by spreading fine material and levelling it.
For alignment of the plant, use the spirit levels installed in
the control cabinet protective housing.
» Ensure that the plant is standing safely on the ground during
operation. Do not shake or tilt the plant during operation.
» If the plant is not stable, reposition it and/or level the
ground.
» Ensure the plant has sufficient ground clearance. The crush-
er discharge conveyor must not come into contact with loose
material or the ground.
» Switch off the diesel generator and secure plant against re-
activation.
» Insert grey power plug in the power and transport plug con-
nection, see chap. 2.06.06.
» Provide suitable lifting accessories and hoisting gear for in-
stallation.
 Preparations for plant installation are complete.

Plant installation
6.02.02 Moving out warning light
Fig. 6.7: Moving out warning light
[1] Wing screws [2] Mast

[3] Warning light [4] Lighting
The lamps are installed on the mast of the warning light. With
the help of the mast, the warning light and the lamps can be
moved out.
WARNING
Danger of crushing
Severe crushing injuries to the hands may occur when moving
in and out.
• Always work with a second person when moving warning
light out and in.
» Release wing screws [1] and push the mast [2] upwards but
no further than the red marking.
» Tighten wing screws [1].
 Warning light and lighting have been moved out.

Plant installation
6.02.03 Earthing the plant
Fig. 6.8: Earthing the plant
[1] Earthing rod

Earthing of the plant guarantees a safe connection of the pro-
tective conductor with the earth. The correct function of the in-
stalled ground fault circuit interrupter on the plant and thus the
personnel protection can only be guaranteed by a sufficiently
low earthing resistance. The earthing resistance must have a
value significantly lower than 100 ohms.
Prior to every to initial operation of the plant and after every re-
location of the earthing rod, the loop resistance of the earthing
rod must be measured by an electrician.
Also the correct assembly and presence of earthing straps be-
tween the chassis and individual components of the plant must
be checked prior to commissioning.
WARNING
In the case of insulating faults on the plant as well as at exter-
nal equipment that is inserted in the service sockets, there is
a risk due to electric shock.
• Do not insert operating equipment with insulating faults at
the service sockets.
• Eliminate insulating faults on the plant before an external
power supply is used.

Plant installation
WARNING
If the plant is not correctly or only inadequately earthed, there
is a risk of electric shocks.
• After every installation or repositioning, ensure the plant is
correctly earthed.
• Prior to initial operation, the loop resistance of the earthing
rod must be measured by an electrician.
• If the plant is not correctly or insufficiently earthed, do not
put the plant's external power supply into operation.
• If the plant is not correctly or insufficiently earthed, do not
use the service sockets.
• If necessary, water the dry earth around the earthing rod.
• Repair a defective earthing line immediately.
Setting the earthing rod » Remove earthing rod [1] from the brackets on the plant.
» Drive the earthing rod with a hammer into the ground. The
earthing rod must be firmly anchored in the ground to a suf-
ficient depth.
» Have the loop resistance measured by an electrician.
» If necessary, water the earthing rod to increase conductivity.
» Introduce other suitable measures to establish adequate
earthing.
» Verification of the correct earthing must be provided by elec-
trician.
 The earthing rod is correctly set.
Fig. 6.9: Earthing strap

Plant installation
[2] Earthing strap [3] Chassis

[4] Fastening screw, earthing [5] Conveyor belt frame
strap
Example illustration of installing an earthing strap at the

crusher discharge conveyor.
Checking earthing straps » Check earthing straps for proper installation and damage.
Tighten screws if necessary.
» Replace damaged or missing earthing straps immediately,
see chap. 4.06.04.
 The plant is earthed.
6.02.04 Folding ladders and steps
[1] Ladder to platform for jaw [2] Platform between crusher

crusher and power supply and power supply unit
unit
WARNING
Risk of falling
Incorrectly fitted platforms, ladders, handrails and anti-fall
guards can result in people falling.
• Ensure that platforms, ladders, handrails and anti-fall
guards are correctly fitted.

Plant installation
CAUTION
Danger! Folding ladder
When the ladder is folded, there is a risk of crushing your
hands.
• Do not place hands between foldable and fixed section of
the ladders.
» Fold down the ladder for the platform for the power supply
unit and jaw crusher.
» Ensure that all platforms and handrails are correctly fitted.
 The ladders is folded down and the platforms have been
checked.
6.02.05 Folding up hopper walls
WARNING
Risk of falling
secure.
8
9
7
Fig. 6.11: Unlocking/locking hopper walls
[7] Eye bolt [8] Hydraulic cylinder lock

Plant installation
[9] Locking pin with spring

pin
» Visually inspect hydraulic hoses of hopper walls for damage.
» Remove spring pin and locking pin [9] from left and right hy-
draulic cylinder locking element [8].
13
14
12
11
10
Fig. 6.12: Folding hopper walls
[10]Mountings [11]Hopper wall, middle

[12]Hydraulic hopper wall [13]Hopper wall, left
locking
[14]Hopper wall, right
2 3 4 5
1 1 5 4 3 2
1 2 3 4 5 6

Plant installation

tor
up".
down". walls.
wall
wall
locking

15
[15]Enable pushbutton

Plant installation
WARNING
Crushing hazard posed by hopper walls
Hoppers walls can cause serious crushing injuries when being
folded up or down.
• Stay clear of the folding area of the hopper walls.
• Ensure that there are no persons in the folding area.
Folding up hopper walls » Switch on plant and follow the instructions up to and includ-
ing press the "Start-up enable" button, see chap. 3.04.
» Press button [1] for movement direction folding up.
 The movement direction is selected and green control lamp
1 1
2
5
3
4
4
3
5
2 lights up.
1 2 3 4 5 6
» Press button [3].
 The left hopper wall is selected and green control lamp lights
up.
» Press enable pushbutton and hold it in.

 The left hopper wall folds up completely.

 The right hopper wall is selected and green control lamp
lights up.
 The right hopper wall folds up completely.
 The middle hopper wall is selected and green control lamp
lights up.
 The middle hopper wall folds up completely.
Locking hopper walls » Press button [6].
 The hopper wall locking device is selected and the green
control lamp lights up.
 The hopper walls are locked.
 The movement direction is deselected.

Plant installation
6.02.06 Extending short prescreen conveyor
NOTICE
When moving the prescreen conveyor in and out, contaminat-
ed guide rails and guide rollers lead to material damage to the
prescreen conveyor and brackets.
• Clean any dirt off the guide rails and guide rollers before
moving in and out.
• Never move the prescreen conveyor in and out with con-
taminated guide rails and guide rollers.
Checking guide rails » Visually check guide rails and guide rollers on both sides of
the prescreen conveyor for contamination.
» If necessary, clean the guide rails and guide rollers.
» Before moving the prescreen conveyor out, ensure that the
guide rails and guide rollers are free of contamination.
8
8
7
Fig. 6.15: Prescreen conveyor transport lock
[7] Locking pin and spring pin [8] Transport lock

» If necessary, fit electrical connectors of belt conveyor, see
chap. 2.01.06.
» Remove locking pins [7] and spring pins from transport locks
[8].
» Switch on plant (see chap. 3.04) and follow the instructions
up to and including press the "Start-up enable" button.

Plant installation
1 2 3 4 5 6
Fig. 6.16: Local control

After selection of the movement direction, the enable pushbut-

ton for execution of the function must be pressed.

Plant installation
Fig. 6.18: Moving prescreen conveyor out
[9] Prescreen conveyor
WARNING
Crushing hazard posed by prescreen conveyor
When folding the prescreen conveyor in and out, there is a risk
of severe crushing injuries.
• Never place hands between the belt conveyor and chassis
while the prescreen conveyor is moved in and out.
• Ensure that, when the prescreen conveyor is moved in and
out, no-one is in the hazard area.
Moving prescreen » Press "Move out prescreen conveyor" [3] button.

conveyor out  The movement direction is selected and green control lamp
lights up.
» Hold in the enable pushbutton and move the prescreen con-
veyor out completely.
» Ensure that the locking pins [10] can be inserted in the
mounting links [12] of the prescreen conveyor.
The locking pins are located on the console of the prescreen

conveyor in the transport mount, see chap. 6.03.04.

Plant installation
12
11
10
Fig. 6.19: Locking pins for prescreen conveyor
[10]Locking pins and spring [11]Console for prescreen

pins conveyor
[12]Prescreen conveyor
mounting link
» Insert locking pins [10] and spring pins in mounting links
[12] and secure with the spring pins.
» Press "Move in prescreen conveyor" [4] button.
lights up.
» Press enable pushbutton and slowly move in the prescreen
conveyor until the locking pins [10] make contact on the
console [11].
 The prescreen conveyor has been moved out and secured.
After actuation of a button in the local control, the query "Belt

in position?" appears on the touch screen"
Putting the prescreen » Confirm the query "Belt in position?" on the touch screen
conveyor into operation with OK.
 The prescreen conveyor status display is grey. The pre-
screen conveyor is ready for operation.
» If necessary, switch off the plant, see chap. 3.04.

Plant installation
6.02.07 Moving long prescreen conveyor out
8
8
7
[7] Locking pin and spring pin [8] Transport lock

» Remove locking pins [7] and spring pins from transport locks
[8].
10
11
Fig. 6.21: Unlocking prescreen conveyor
[9] Console for chassis [10]Ratchet load binder

[11]Console for prescreen
conveyor

Plant installation
WARNING
Risk of falling
secure.
» Release ratchet load binder [10].

» Remove ratchet load binder from consoles [9] and [11].
» If necessary, fit electrical connectors of belt conveyor, see
chap. 2.01.06.
» Switch on plant (see chap. 3.04) and follow the instructions
up to and including press the "Start-up enable" button.
1 2 3 4 5 6

Plant installation

Fig. 6.24: Folding out prescreen conveyor
WARNING
When folding the prescreen conveyor in and out, there is a
danger of serious crushing injuries.
• Stay clear of the folding area of the prescreen conveyor.

Plant installation
WARNING
Folding out prescreen » Press "Move in prescreen conveyor" [1] button.

conveyor  The movement direction is selected and green control lamp
lights up.
NOTICE
moving in and out.
» Before moving the prescreen conveyor out, ensure that the
Moving prescreen » Press "Move out prescreen conveyor" [3] button.
conveyor out  The movement direction is selected and green control lamp
lights up.
» Ensure that the locking pins [13] can be inserted in the
mounting links [12] of the prescreen conveyor.
The locking pins are located on the console of the prescreen

conveyor in the transport mount, see chap. 6.03.05.

Plant installation
Inserting locking pins
12
13
14
[12]Prescreen conveyor [13]Locking pins and spring

mounting link pins
conveyor
» Insert locking pins [13] and spring pins in mounting links
[12] and secure with the spring pins.
lights up.
» Press enable pushbutton and slowly move in the prescreen
conveyor until the locking pins [13] butt against the console
[14].
 The prescreen conveyor has been moved out and secured.
After actuation of a button in the local control, the query "Belt

in position?" appears on the touch screen".
Putting the prescreen » Confirm the query "Belt in position?" on the touch screen
conveyor into operation with OK.
 The prescreen conveyor status display is grey. The pre-
screen conveyor is ready for operation.
» If necessary, switch off the plant, see chap. 3.04.

Plant installation
6.02.08 Folding out the extended crusher discharge conveyor hy-

draulically
WARNING
Danger of crushing at crusher discharge conveyor
When folding the crusher discharge conveyor up and down,
there is a risk of severe crushing injuries.
• Ensure that there are no persons in the hazard area when
the crusher discharge conveyor is folded up and down.
• Do not place hands in the folding area.
WARNING
Risk of falling
secure.
4
2
Fig. 6.26: Crusher discharge conveyor folded
[1] Transport locking device [2] Transport locking device

for conveyor belt for crusher discharge con-
veyor
[3] Linch pin [4] Eye bolt
» Ensure that the hydraulic cylinders are fully extended. If
necessary, move in the hydraulic cylinders fully, as described

Plant installation
in chap. 6.03.03 "Folding in the crusher discharge conveyor

hydraulically".
» Switch off diesel generator and control voltage. Remove key
and carry it with you.
» Provide suitable climbing aids.
Removing transport » Disassemble transport locking devices for conveyor belt [1]
locks and crusher discharge conveyor [2].
» Detach linch pin [3] if necessary.
» Fold out eye bolt [4] at the side.
 The crusher discharge conveyor is ready for folding out.
» Switch on the plant in manual operation and follow the in-
structions including "Press start-up enable", see chap. 3.04.
» Press the Crusher discharge conveyor button in the plant
overview.
11:30
User: KLeemann
 The menu for the crusher discharge conveyor and the info
"Start-up enable" are displayed.
0 %
75.0
75. 1500 rpm
4 5 6 7 8 9 10 11


Plant installation
» Press the Movement direction button to fold out the belt.

11:30:15
Brecherabzugsband
 The movement direction is selected.
I/0 Ein- / -klappen / Aus-
For folding out the crusher discharge conveyor, after selection

of the movement direction the enable pushbutton of the crush-
er discharge conveyor must be pressed.
Enable pushbutton for crusher discharge conveyor

» Hold in the enable pushbutton and fold out the crusher dis-
charge conveyor completely.

Plant installation
Fig. 6.29: Crusher discharge conveyor folded out
[2] Transport locking device [3] Linch pin

for crusher discharge con-
veyor
[4] Eye bolt [5] Eye bolt securing element
[6] Locknut [7] Nut
» Fold up securing element for eye bolt [5] and fold in eye bolt
[4].
» Fold down securing element for eye bolt and secure with
linch pin [3].
» Tighten nut [7] and locknut [6] to specified tightening
torque.
» Install transport locks on conveyor belt frame for storage
purposes.
 The crusher discharge conveyor has been folded out.
The position of the crusher discharge conveyor is checked

upon start-up of the plant or the crusher discharge conveyor.
If the crusher discharge conveyor has been folded out proper-
ly, the query is confirmed.
» Confirm query "Belt in position" with OK on the touch
screen.
 The crusher discharge conveyor status display is grey. The
crusher discharge conveyor is ready for operation.

Plant installation
6.02.09 Final tasks
NOTICE
Foreign bodies in the plant, such as tools, accessories and
packaging materials, can result in malfunctions and material
damage.
• Following installation and prior to initial operation, search
the entire plant for foreign bodies and remove them.
After every transport and reinstallation of the plant, the follow-

ing checks and test runs must be carried out:
• Carry out checks with plant stationary, see chap. 3.03, "Put-
ting the plant into operation".
• Test run without material, see chap. 6.02.09.01.
• Test run in manual mode, see chap. 6.02.09.02.
6.02.09.01 Test run without material
DANGER
ed up.
The test run without material corresponds to automatic mode,

where all plant components are switched on in the opposite di-
rection to the material flow.
Before the plant components can be started, all emergency

stop devices must be released.
For release of emergency stop devices, also refer to chap.
2.01.08.
» Switch on plant, see chap. 3.04.
» Check whether the individual machines and plant compo-
nents start up in the correct sequence.
» Actuate plant emergency-stop devices and monitor shut-
down, also refer to chap. 4.01.04.
» If faults occur, switch off the plant and eliminate the fault.
 The automatic mode functions have been checked.

Removal of plant
6.02.09.02 Test run in manual mode
DANGER
Execution of "Manual mode" by unqualified and unauthorised
personnel can result in serious or fatal injuries.
As opposed to automatic mode, in the manual mode test run the

plant components are not switched on and off automatically but
rather manually.
Before the plant components can be started, all emergency

stop devices must be released.
For release of emergency stop devices, also refer to chap.
2.01.08.
» Switch machine and plant components on and off individu-
ally, also refer to chap. 3.05.
» If faults occur, switch off the plant and eliminate the fault.
 The manual mode functions have been checked.
6.03 Removal of plant
DANGER
Removal and transport by unqualified and unauthorised per-
sonnel can result in serious or fatal injuries.
• Only assign personnel removal and transport tasks who are
qualified and authorised according to the requirements in
this instruction manual.

Removal of plant
DANGER
Danger due to incorrect installation and removal
Incorrect installation and removal and the use of unsuitable
hoisting gear and lifting accessories can result in serious or fa-
tal injuries.
• Use suitable hoisting gear and lifting accessories and check
that it is in perfect condition.
• Fit hoisting gear, such as chains and ropes, so that it cannot
slip.
• Always suspend components and machines from their cen-
tre of gravity.
• Only lift and transport loads as high and as far as neces-
sary.
• Never move under or stand under a suspended load.
• Only assign personnel installation and removal tasks who
are qualified and authorised according to the requirements
in this instruction manual.
WARNING
Risk of falling
secure.
WARNING
Risk of stumbling
Before the plant can be transported, it must be moved from op-
erating position to transport position. To prepare for removal,
carry out the following activities:

Removal of plant
NOTICE
Incorrect installation of the plant, or sinking of the plant on
soft ground, creates a risk of the plant tilting.
• Only position the plant on secure and firm ground.
» Run all plant components completely empty.

» Clean plant, see chap. 4.46.
» Move the plant onto secure and firm ground. Remove any
obstacles in the direct vicinity.
» Position the plant, ensuring it is horizontal. If necessary, flat-
ten the ground by spreading fine material and levelling it.
» Switch off the diesel generator and secure plant against re-
activation.
» Provide suitable lifting accessories and hoisting gear for re-
moval.
 Preparations for plant removal are complete.
6.03.02 Moving in warning light
Fig. 6.30: Moving out warning light
[1] Wing screws [2] Mast

[3] Warning light [4] Lighting

Removal of plant
WARNING
Danger of crushing
Severe crushing injuries to the hands may occur when moving
in and out.
• Always work with a second person when moving warning
light out and in.
» Release wing screws [1] and move in mast [2] completely.

» Tighten wing screws.
 The warning light has been moved in.
6.03.03 Folding in the extended crusher discharge conveyor hydrau-

lically
WARNING
Danger of crushing at crusher discharge conveyor
When folding the crusher discharge conveyor up and down,
there is a risk of severe crushing injuries.
• Ensure that there are no persons in the hazard area when
the crusher discharge conveyor is folded up and down.
• Do not place hands in the folding area.
WARNING
Risk of falling
secure.

Removal of plant
2
1
Fig. 6.31: Crusher discharge conveyor folded out
[1] Transport locking device [2] Hydraulic cylinder

veyor
[3] Linch pin [4] Eye bolt securing element
[5] Eye bolt [6] Locknut
[7] Nut
» Where applicable, disassemble belt suspension at the folda-
ble section.
» Ensure that the hydraulic cylinders [2] are fully moved in. If
necessary, move in the hydraulic cylinders fully, as described
in chap. 6.02.08 "Folding out the crusher discharge convey-
or hydraulically".
» Use suitable climbing aids.
» Remove linch pin [3].
» Slacken locknut [6] and nut [7].
» Fold up securing element for eye bolt [4] and fold out eye
bolt [5] at side.
 The crusher discharge conveyor is ready for folding in.
Fold in crusher discharge » Insert battery isolator and switch on.
conveyor
» Switch on the plant in manual operation and follow the in-
structions including "Press start-up enable", see chap. 3.04.

Removal of plant
» Press the Crusher discharge conveyor button in the plant

overview.
11:30
User: KLeemann
 The menu for the crusher discharge conveyor and the info
"Start-up enable" are displayed.
0 %
75.0
75. 1500 rpm
4 5 6 7 8 9 10 11

» Press the Movement direction icon for folding in the belt.
11:30:15
Brecherabzugsband
 The movement direction is selected.
I/0 Ein- / -klappen / Aus-
For folding in the crusher discharge conveyor, after selection of

the movement direction the enable pushbutton of the crusher
discharge conveyor must be pressed.

Removal of plant
Enable pushbutton for crusher discharge conveyor

» Hold down the enable pushbutton and fold in the crusher
discharge conveyor fully.
» Switch off diesel generator and control voltage. Remove key
and carry it with you.
Fig. 6.34: Crusher discharge conveyor folded
[1] Transport locking device [3] Linch pin

veyor

Removal of plant
[8] Transport locking device

for conveyor belt
NOTICE
If transport locking devices are not installed, this can result in
damage to the crusher discharge conveyor during transport.
• Install transport locking devices after the crusher discharge
conveyor has been folded in.
Installing transport locks » Install transport locking devices for crusher discharge con-
veyor [1] and conveyor belt [8].
» Attach linch pin [3].
 The crusher discharge conveyor is folded in
» Reinsert control voltage key.
6.03.04 Moving in short prescreen conveyor

» Switch on plant and follow the instructions up to and includ-
1 2 3 4 5 6

Removal of plant

WARNING
NOTICE
moving in and out.

Removal of plant
» Ensure that before swivelling in the prescreen conveyor the

For removing the locking pins at the mountings of the pre-

screen conveyor, the function "Swivel out prescreen conveyor"
must first be executed. In this way, the locking pins are re-
lieved of pressure.
» Press "Move out prescreen conveyor" [3] button.
lights up.
» Hold in enable pushbutton until prescreen conveyor has
moved completely.
10
Fig. 6.37: Moving in prescreen conveyor
[7] Locking pin and spring pin [8] Prescreen conveyor

mounting
[9] Prescreen conveyor [10]Prescreen conveyor
mounting link
» Remove spring pins and locking pins [7] from mounting links
[9].
 The movement direction is selected and the green control
lamp lights up.
» Press enable pushbutton and move in prescreen conveyor
completely.

Removal of plant
Fig. 6.38: Locking pins for transport mount

pin
» Insert locking pin into the transport mount on the console
and secure with the spring pin.
» Repeat the same work steps on the other side.
11
12
12
11
Fig. 6.39: Prescreen conveyor transport locking device
[11]Locking pin with spring [12]Transport locking device

pin

Removal of plant
» Insert locking pins [11] in transport locking devices [12] and

mounting links [9] on prescreen conveyor and secure with
the spring pins.
 The prescreen conveyor has been retracted and secured.
6.03.05 Moving in long prescreen conveyor

1 2 3 4 5 6


Removal of plant

WARNING
NOTICE
moving in and out.
» Ensure that before moving in the prescreen conveyor the
For removing the locking pins at the mountings of the pre-

screen conveyor, the function "Swivel out prescreen conveyor"
must first be executed. In this way, the locking pins are re-
lieved of pressure.
» Press "Move out prescreen conveyor" [3] button.
lights up.
» Hold in enable pushbutton until prescreen conveyor has
moved completely.
 The locking pins are relieved of pressure.

Removal of plant
10
9
[7] Prescreen conveyor [8] Locking pin and spring pin

mounting
[9] Prescreen conveyor [10]Prescreen conveyor
mounting link
» Remove spring pins and locking pins [8].
Moving in prescreen » Press "Move in prescreen conveyor" [4] button.
conveyor  The movement direction is selected and green control lamp
lights up.
» Press enable pushbutton and move in prescreen conveyor
completely.
Fig. 6.43: Locking pins for transport mount

Removal of plant

pin
» Insert locking pin into the transport mount on the chassis
and secure with the spring pin.
» Repeat the same work steps on the other side.
11
11
8
[8] Locking pin and spring pin [11]Transport lock
Installing transport locks » Insert locking pins [8] in transport locking devices [11] and
mounting links [9] on prescreen conveyor and secure with
the spring pins.
Folding in prescreen
conveyor
12

Removal of plant
Fig. 6.45: Folding in prescreen conveyor

conveyor
WARNING
When folding the prescreen conveyor in and out, there is a
danger of serious crushing injuries.
• Stay clear of the folding area of the prescreen conveyor.
1 2 3 4 5 6


Removal of plant

» Press "Fold in prescreen conveyor" [2] button.
lights up.
» Press enable pushbutton and fold in prescreen conveyor.
» Switch off the plant.
Installing transport locks
13
14
Fig. 6.48: Securing prescreen conveyor
[13]Console for chassis [14]Ratchet load binder
WARNING
Risk of falling
secure.
» Attach ratchet load binder [14] in consoles [12] and [13]

and clamp in position.
 The prescreen conveyor has been retracted and secured.

Removal of plant
6.03.06 Folding in hopper walls
WARNING
Risk of falling
secure.
9 9
8
7
Fig. 6.49: Unlocking/locking hopper walls
[7] Locking pin with spring [8] Eye bolt

pin
[9] Hydraulic cylinder lock
» Visually check hydraulic cylinders and hydraulic hoses of the
hopper walls for damage.
» Remove spring pin and locking pin [7] from left and right
hopper wall.
» Swivel out hydraulic cylinder locking elements [9].

Removal of plant
13
14
12
11
10
Fig. 6.50: Folding hopper walls
[10]Mountings [11]Hopper wall, middle

[12]Hydraulic hopper wall [13]Hopper wall, left
locking
[14]Hopper wall, right
» Visually check hydraulic cylinders and hydraulic hoses of the
hopper walls for damage.
2 3 4 5
1 1 5 4 3 2
1 2 3 4 5 6

Removal of plant

tor
up".
down". walls.
wall
wall
locking

15
[15]Enable pushbutton

Removal of plant
» Press button [2] movement direction folding down.

 Movement direction folding down is selected and green
1 1
2
5
3
4
4
3
5
2 control lamp lights up.
1 2 3 4 5 6
 The hopper wall locking device is selected and the green
control lamp lights up.
» Press the enable pushbutton [15] and hold it in.
» Visually check correct unlocking of hopper walls. If neces-

sary, lock and unlock several times until the wedge has
moved in completely.
 The hopper walls are unlocked.
WARNING
Crushing hazard posed by hopper walls
Hoppers walls can cause serious crushing injuries when being
folded up or down.
• Stay clear of the folding area of the hopper walls.

 The middle hopper wall is selected and green control lamp
lights up.
 The middle hopper wall folds down.
 The right hopper wall is selected and green control lamp
lights up.
 The right hopper wall folds down.
 The left hopper wall is selected and green control lamp lights
up.
 The left hopper wall folds down.
 The movement direction is deselected.

Removal of plant
» Secure hydraulic cylinder locks [9] with locking pins and

spring pins [7] on the chassis to prevent from them swivel-
ling out.
 The hopper walls are folded down and secured.
6.03.07 Folding ladders and steps
[1] Ladder to platform for jaw [2] Platform between crusher

crusher and power supply and power supply unit
unit
The platforms do not have to be disassembled for plant trans-
port.
» Ensure that all platforms and handrails are firmly fitted.
» Fold up ladder for platform of power supply unit and jaw
crusher and secure it.
 The ladder has been folded up.

Removal of plant
6.03.08 Removing earthing
Fig. 6.54: Earthing the plant
[1] Earthing rod

» Pull the earthing rod [1] out of the ground.
» Fit earthing rod in bracket on plant.
 The earthing is removed.
6.03.09 Final tasks

After every disassembly of the plant, the following final tasks
must be carried out:
» Close all service doors and flaps and secure against acciden-
tal opening.
» Secure parts and plant components against uncontrolled
movements.
» Secure components and accessories that remain on the
plant against falling down.
» Fit transport locking devices if necessary.
» Lock toolbox.
» In particular, clean plant prior to transport, see chap. 4.46.
 The plant is completely removed and ready for transport.

Storage, shutdown, disposal
6.04 Storage, shutdown, disposal
6.04.01 Storage conditions
NOTICE
Incorrect storage of parts and plant components can result in
damage and premature failure.
• Always store spare parts and remove parts and plant com-
ponents in a correct manner.
Spare parts, wear parts, removed parts and plant components

must be stored in a correct manner. Observe the following
points:
• Clean and dry and plant prior to storage. Take particular care
with moving parts, e.g. conveyor belts.
• Where possible, the plant or plant components and ma-
chines must be stored in closed, dry rooms prior to final as-
sembly.
• If the plant or plant components and machines are stored
outdoors, they must be covered with tarpaulin covers that
are open at the bottom to allow the run-off of any conden-
sation. Secure tarpaulin covers with suitable lashing equip-
ment.
• Place the plant, plant components and machines on suitable
bases to protect them against rising damp.
• On plants with a touch screen, note the operating hours and
remove the touch screen.
• On plants with a conventional control system, remove the
OP3.
• Store electric and electronic components in closed, dry and
frost-free rooms.
• When returning plants with touch screen to operation, check
the basic settings.
• Switch off battery isolator for diesel generator.
• Remove batteries, store in a dry place and charge once a
month using a suitable charger.
• If storage is for periods longer than six months, introduce
additional protective and preservation measures, in particu-
lar, for the diesel generator. Also refer to the manufacturer's
documentation.
• Completely fill fuel tank with suitable winter diesel. Also re-
fer to the manufacturer's documentation.
• Remove water pump and store in a warm and dry place.

6.04.02 Shutdown, restarting

If the period between shutdown and restarting exceeds 6
months, observe the following points:
• Observe storage conditions, see chap. 6.04.01.
• In particular, observe the storage conditions for the diesel
generator. See manufacturer's documentation.
Observe the following points when restarting the plant after a
downtime of longer than 6 months:
• For plants with a touch screen, install the touch screen and
check the basic settings.
• For plants with a conventional control system, install the
OP3.
• Check the charge status of the starter batteries and charge
if necessary. Install the starter batteries.
• Install and fill water pump with water prior to operation, see
chap. 3.10.
• Refer to the manufacturer's documentation for restarting
the diesel generator.
6.04.03 Disposal of machine

At the end of the service life of the plant, plant components and
machines, disposal must be carried out in a professional man-
ner by a specialist disposal company.
This includes, in particular, the correct, environmentally com-
patible disposal of the following components:
• Fluids and lubricants, such as lube oils, greases and diesel
fuel.
• Electric and electronic components.
• Unmixed scrapping of metals.
• Other residual materials.

INDEX
INDEX
A CFS 119
Accessories 113 Change return filter 251
Activating auxiliary drive system 180 Changes 15
Adjusting conveyor belt run 303 Changing articulated crusher jaw 361, 367
Adjusting flat scraper 287 Changing belt pulley 389
Adjusting the gap width 185 Changing conveyor belt 302
Adjusting the line coupling 153 Changing drive chain 236
Adjusting trough rocker width 341 Changing gear oil 275
Adjusting wedge stripper 286 Changing oil in worm gear 310
Air filter 76 Changing planetary gear oil 275
Air intake 76 Changing pressure plate 372
Ambient temperature 25 Changing screen surfaces 395
Ambient temperatures 408 Changing suction filter 250
Ascending slopes 158 Changing the lateral wedges 358
Assembly tool for shims 113 Changing V-belt pulley 389
Automatic mode 45 Changing V-belts 351
Auxiliary drive 83, 180 Changing vent filter 236
B Changing vent filter for hydraulic coupling

236
Banksman 38
Changing wear lining of hopper 329
Bases 173
Changing wear lining on vibrating conveyor
Battery heater 94 troughs 337
Battery isolator 87 Chassis 47
Belt conveyor technical details 414 Chassis beam 95
Belt conveyors 99 Check assembly of crusher discharge convey-
Bevel helical gearbox 290 or 283
Blockage 178 Check crusher discharge conveyor 283
Blockages 178 Check securing elements of lateral wedges

355
By-pass device 100
Checking accessories 328
C
Checking automatic circuit-breakers 263
Carrying out lamp test 204
Checking base plates 271
CE marking 20
Checking chain tension 268
Centralised lubrication of impact crusher
Checking conveyor belt run 303
345

INDEX
Checking crawler carrier chain tension 268 Checking warning devices 202
Checking crusher bearing 356 Checking wear of crushing jaws 357
Checking cyclone prefilter 219 Checking wired remote control 205
Checking earthing straps 259 Chutes 100
Checking emergency off 203 Claw clutch 84
Checking generator toothed belt 214 Clean tension roller 354
Checking ground fault circuit interrupter Cleaning 399
267, 267
Cleaning the plant 399
Checking guard devices 202
Cleaning touch screen 401
Checking hydraulic fill level 246
Clearing stockpiles 188
Checking hydraulic oil fill level 230
Climatic conditions 25
Checking lubricant lines 323
Climbing ability 406
Checking lubrication system 323
Clutch 84
Checking motor protecting switch 265
Coarse screen 252
Checking overload relay 265
Cold package 70
Checking planetary gear oil level 274
Commissioning 134
Checking plant 469
Compressive strength of feed material 407
Checking return roller guard 285
Connecting diagnostics device for diesel en-
Checking rubber curtains 305 gine 212
Checking screen surfaces 392 Contact persons 41
Checking sealing 305 Continuous Feed System 119
Checking securing elements of crushing jaws Control elements 59, 124
355
Conveyor belt magnetic separator 306, 314
Checking switch cabinet mounting 258
Conveyor unit 98, 98
Checking tensioning plate bearings 294
Cooler 77
Checking terminal boxes 260
Cooling system 77
Checking the crushing gap 184
Coupling 77
Checking the emergency stop 202
Crane transport 445
Checking the radio remote control 204
Crawler running gear 95, 95
Checking the tension roller 354
Crusher 118
Checking tools 328
Crushing capacity 407
Checking track pads 272
Crushing gap 184
Checking track rollers 271
Crushing ratio 407
Checking trough rocker width 340
Cyclone prefilter 76
Checking ventilators of heat package 262
D
Checking vibration motors 336
Danger areas 30

INDEX
Decals 34 Enable pushbutton 69

Declaration of Conformity 20 Engine 72
Depressurising auxiliary hydraulic system Engine oil hand pump 224
244
Environmental protection 27
Depressurising hydraulic system 244
EuroTest certificate 22
Description 43
Exhaust pipe 75
Detensioning conveyor belt 308, 316
Exhaust system 75
Diesel engine 72
External circuits 90
Diesel engine heater 79
F
Diesel engine technical data 410, 411
Fault with water pump 196
Diesel engine, heat package 78
Feed capacity 407
Diesel Fuels 434
Feed hopper 114
Disconnecting chain lock 278
Feed hopper technical details 416
Disposal of machine 27, 494
Feed material 406
Documentation 19
Feed size 406
Downloads 133
Feeding unit 114, 116
Downward slopes 158
Fill level monitor 119, 119
Draining hydraulic oil 231, 247
Filler neck 74
Drive chain hydraulic coupling 236
Filling hydraulic oil 248
Drive system technical details 413
Filling lubrication system 322
Driving 157
Fire extinguisher 31
Driving clutch 84
Fire fighting 31
Driving mode 45
Flow chart 45
Driving speed 406
Fluid control 105
Dust emission 32
Fluids and lubricants 431
E
Flushing hydraulic coupling 227
EAC mark 21
Folding crusher discharge conveyor hydrauli-
Earthing 449 cally 474
Earthing the plant 449 Folding in hopper walls 490
Electric motors 90 Folding locks 48
Electrical system 85 Folding out crusher discharge conveyor hy-
draulically 466
Electrical system technical details 413
Folding out prescreen conveyor 463
Eliminating material congestions 178
Folding up hopper walls 453
Emergency off 55
Frequency converter operating unit 63
Emergency stop 55
Fuel prefilter heater 79
Emissions 31

INDEX
Fuel supply 74 Jaw crusher 118

Fuses 437 Jaw crusher technical details 417
Fuses, cold package 95 L
G Ladders 49
Gear pumps 81 Lashing 442
Grizzly feeder 117 Lashing the plant 442
Grizzly feeder prescreen 120 Lateral inclination 406
Ground pressure 406 Liability 15, 22
Guard devices 52 Lighting 50
H Line coupling 153
Heat package 78, 91 Loading 174, 442
Heater 70, 79, 93, 94 Loading plant 442
Heater, starter battery 94 Loading the feed hopper 174
Hopper 114 Loading the jaw crusher 176
Hopper extension 116 Loading the plant 174
Hopper extension, technical data 416 Loading vehicles 173
Hopper technical details 416 Loads 31
Horn 50 Local control 69
Hydraulic coupling 77 Local control enable pushbutton 69
Hydraulic motor 83 Locking pins for prescreen conveyor 464
Hydraulic oil supply technical details 413 Low loader 442
Hydraulic oil tank 80 Lubricants 431
Hydraulic pumps 81 Lubricating conveyor belt plummer blocks

298
I
Lubricating crusher bearings 345
Identification plates 36
Lubricating magnetic separator bearings
Indicators 59, 107, 124 313, 318
Information material 436 Lubricating the tension plate bearings 297
Initial operation 133 Lubrication for tension roller 352
Inserting chain link 281 Lubrication of tension roller 352
Installing plant 447 Lubrication system 109, 322, 416
Instruction manual 14 Lubrication system troubleshooting 194
Intended purpose 22 M
Intended use 22 Magnetic field 34
Interface 59, 124 Magnetic fields 34
J Magnetic separator 101

INDEX
Magnetic separator socket outlets 52 P

Main switch 58 Packaging 16
Maintenance 197 Personal protective equipment 39
Maintenance intervals 418, 420, 420, 421 Personnel 37
Maintenance personnel 39 Plant dimensions 405, 405, 439
Maintenance schedule 418, 420, 420, 421 Plant overview 43
Malfunction of the remote control by magnet- Plant transport dimensions 439
ic field 192
Plant transport weights 440
Manual mode 45
Plant weights 404
Manufacturer's documentation 436
Platforms 49
Material defects 22
Position of balancing weights for pulley and
Menu guidance 129 flywheel 343
Monitoring sound of crusher bearings 346 Potential equalisation 167
Mounting the platforms 452 Power supply 86
Moving 157 Preparing charged material 173
Moving in prescreen conveyor 477, 481 Prescreen conveyor transport locking device
Moving in warning light 473 456
Moving out warning light 448 Protective equipment 39
Moving prescreen conveyor out 456, 460 Provisos 15
Moving rocker forward 379 Pumps 81
Moving using the radio remote control 160 Q

N Qualifications 37
Noise emission 32 R
O Radio remote control 64
Oil capacity of magnetic separator 317 Rain 25
Oil drain pump 224 Ramps 173
Operating cold package 168 Refuelling 167
Operating the plant 134, 157 Refuelling the plant 167
Operating the water system 171 Remote control 160
Operation 123 Remote control troubleshooting 192
Operator panel 107, 107, 107 Removing chain link 279
Operator's stand 57 Removing earthing 492
Optional equipment 43 Removing plant 471
Options 122 Removing the platforms 491
Overview 43 Repair mode 45

Repair personnel 39

INDEX
Repairing crawler running gear 278 Servicing dust filter 262

Repairing crusher 357 Servicing electric motors 260
Repairing electrical system 263 Servicing electrical components 258
Repairing jaw crusher 357 Servicing electrical system 254
Replacing rubber profiles 398 Servicing fuel filter 207
Replacing track pads 273 Servicing hopper 331
Replacing vibration motors 338 Servicing hopper extension 331
Residual risks 24 Servicing hydraulic system 226, 243
Restarting 494, 494 Servicing jaw crusher 345, 352
Retracting rocker 377 Servicing magnetic separator drive 290,
290
Return roller guard 285
Servicing magnetic separators 306, 314
Revision levels 41
Servicing overpressure system 261
S
Servicing safety devices 200
Safety distance 31
Servicing scraper 286, 287
Safety functions 56
Servicing screens 392
Safety information 26
Servicing starter batteries 255
Safety instructions 14
Servicing switch cabinet protective housing
Safety manual 27 203
Safety manuals 435 Servicing tension roller 352
Scrapping 494 Servicing the diesel generator 206
Screen 61 Servicing vibrating chute 333
Securing prescreen conveyor 464 Servicing vibrating conveyors 333
Securing pressure plate 375 Servicing vibrating feeder 333
Securing pressure plate bearing 376 Servicing voltage supply 255
Service personnel 39 Servicing water system 319
Servicing air filters 220 Servicing worm gear 309
Servicing belt conveyor drive 290, 292 Setting return roller guard 285
Servicing belt conveyors 283, 301, 316 Setting the crushing gap 185
Servicing chassis 200 Shutdown 494
Servicing chutes 305 Signs 16, 34, 34
Servicing control cabinet 258 Siren 50
Servicing conveyor belts 283, 301, 316 Slackening the conveyor belt 301
Servicing crawler running gear 268 Socket outlets for crusher discharge conveyor
Servicing drive system 268 51
Servicing drum motor 292 Socket outlets, switch cabinet 90

INDEX
Sockets for prescreen conveyor 52 Tank 74

Software 133 Taper-lock bushing 389
Sound power level 409, 409 Technical data of electromagnetic separator
415
Sound pressure level 32
Technical data of generator 410, 412
Special transport 439
Technical data of permanent magnetic sep-
Specifications 431
arator 415
Spray system 104, 106
Technical details of power supply unit 409,
Spray system for winter operation 190 411
Standard equipment 43 Technical details, grizzly feeder 417
Start repair mode 200 Temperatures 408
Starting aid 191 Tensioning conveyor belt 308, 316
Status displays 128 Tensioning crawler carrier chain 269
Storage 16 Tensioning crusher V-belts 348
Storage conditions 493 Tensioning generator toothed belt 218
Storm 25 Tensioning the conveyor belt 301
Switch cabinet 88 Tensioning V-belts 351
Switch cabinet heating 93 Test run 469, 470
Switching automatic mode on/off 135 Tightening torques 429
Switching cold package on and off 168 Tools 113
Switching manual mode on/off 140 Touch screen 61, 61, 103
Switching off after emergency stop 139 Touch screen of vibrating feeder of line cou-
pling 103
Switching off after emergency switching off
139 Touch screen status displays 128
Switching off automatic mode 135 Touchscreen 127
Switching off manual mode 140 Touchscreen of vibrating feeder of line cou-
pling 127
Switching on after emergency stop 139
Track drive 97
Switching on after emergency switching off
139 Track pads 96
Switching on automatic mode 135 Training courses 40
Switching on manual mode 140 Transport 438
Switching plant on/off after emergency stop Transport plug 90
139
Transport weights 440
Switching plant on/off after emergency
Troubleshooting, remote control system 192
switching off 139
Symbols 16 V
Valve block 82
T
Vibrating chute 117
Tandem pumps 81

INDEX
Vibrating chute technical details 417

Vibrating feeder 117
Vibrating feeder technical details 417
Vibration emission 33
Vibration motors 117
W
Warning light 50, 50
Warning sign 17
Warning siren 50
Warranty 15, 22
Water pump 105
Water separator 207
Water system 104
Water system for winter operation 190
Water system technical details 415
Welding 402
Welding on weld-on eyelet 370
Wind 25
Winter operation 189
Wired remote control 64

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INSTRUCTION MANUAL

MOBICAT MC110R EVO

© Kleemann GmbH 2017 K005-0121 -9999

Revision date 09.05.2017

Copyright © Kleemann GmbH 2017

2 © Kleemann GmbH 2017

© Kleemann GmbH 2017 3

1.07.03 Contact persons for operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.01 Chassis/guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 © Kleemann GmbH 2017

2.06.03 Switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

© Kleemann GmbH 2017 5

2.28 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3.01 Operator panels/Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

6 © Kleemann GmbH 2017

3.11 Loading the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

4.01 Chassis/guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

© Kleemann GmbH 2017 7

4.04.07 Servicing air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

8 © Kleemann GmbH 2017

4.08.03.02 Repairing chain link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

© Kleemann GmbH 2017 9

4.20 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

10 © Kleemann GmbH 2017

4.44.05.02 Checking the tension roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

5.01 Technical details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

© Kleemann GmbH 2017 11

5.01.08 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

6 INSTALLATION AND REMOVAL, TRANSPORT. . . . . . . . . . . . . . . . . . . . . 438

6.01 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438

12 © Kleemann GmbH 2017

6.03.08 Removing earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

© Kleemann GmbH 2017 13

14 © Kleemann GmbH 2017

Observance of the instruction manual:

© Kleemann GmbH 2017 15

Please also observe any additional information that may be in-

1.01.03 Packaging and storage

1.01.04 Signs and symbols

The hazard warning uses the signal word DANGER to indicate an

The warning sign uses the signal word WARNING to indicate a

16 © Kleemann GmbH 2017

The caution sign uses the signal word CAUTION to indicate a

A capital "I" for information at the start of every main chapter

1.01.05 Warning sign

© Kleemann GmbH 2017 17

Warning of a general danger

Warning of dangerous voltage

Warning! Suspended load

Warning of rotating parts

Warning! Risk of stumbling

Warning! Risk of crushing injuries

Warning! Risk of crushing injuries to feet

Warning! Hot surface

Warning! Hot fluids

18 © Kleemann GmbH 2017

Warning of flammable materials

© Kleemann GmbH 2017 19

1.01.07 Declaration of Conformity

20 © Kleemann GmbH 2017

Hiermit erklärt der Hersteller: Kleemann GmbH

Bezeichnung der Maschine /

Person, die bevollmächtigt ist, Jürgen Köstlin, Kleemann GmbH