BAL K0610202 MC140Z en

Instruction manual
Mobicat
MC 140 Z
Please retain for further use!

Product Information
Model Mobicat
Type MC 140 Z
Commission number 4111004512
Order number K0610202
Year of manufacture 2017
Customer entries
Inventory no.
Location
Manufacturer’s address
Street address
Kleemann GmbH
Manfred-Wörner-Straße 160
73037 Göppingen
Postal address
Postbox 760
73007 Göppingen
Germany
Telephone: +49 (0)7161 / 206-0

Fax: +49 (0)7161 / 206-100
http:\\www.kleemann.info
e-mail: info@kleemann.info
Spare parts ordering and customer service

Address: See above
Telephone: +49 (0)7161 / 206-146
Fax: +49 (0)7161 / 206-100
Operating instructions document number: K0610202
Page 2 / 228 Date of printing: 6.11.17 Mobicat MC 140 Z

K0610202 / 4111004512
Purpose of the document
The purpose of this instruction manual is to provide information on all important issues relating to the
technical design and safe operation of your machine.
Like us, you are also required to give close attention to this instruction manual prior to commissioning.
This is necessary to operate your machine economically and to avoid damages and injuries. Unfor-
tunately we cannot accept any liability for faults and damages that can be attributed to inadequate
knowledge of the instruction manual.
In cases of doubt, please contact our in-house consultants or our branches and dealers both at home
and abroad. We will be delighted to provide you with further assistance.
Organisation of the instruction manual

The instruction manual is divided into chapters, which deal with the various types of machine appli-
cation. This division will make it easy for you to find the desired information.
Additional documents
In addition to this instruction manual, the original operating instructions must be used for certain ven-
dor parts. We wish to expressly state at this point that this original instruction manual must be used
with care. Although this instruction manual is designed for the relevant component, deviations in
placement and functioning can occur as a result of installation in the system.
Mobicat MC 140 Z Date of printing: 6.11.17 Page 3 / 228

K0610202 / 4111004512
K0610202 / 4111004512
Table of Contents
1 Product description................................. 13
1.1 Application and intended use..................................... 13
1.1.1 Intended use .............................................................. 13
1.1.2 Non-specified use ...................................................... 13
1.1.3 Residual risks............................................................. 14
1.2 Maschinenübersicht ................................................... 16
1.3 Precautionary measures ............................................ 17
1.4 Conformity.................................................................. 18
1.5 Product designation ................................................... 18
1.6 Technical details ........................................................ 18
1.6.1 Mobicat plant.............................................................. 18
1.6.2 Transport and erection area....................................... 19
1.6.2.1 Transport dimensions ................................................ 19
1.6.2.2 Lashing points............................................................ 26
1.6.2.3 Assembly dimensions ................................................ 26
1.6.3 Components............................................................... 27
1.6.3.1 Power supply unit stage 3A ....................................... 28
1.6.3.2 Hydraulic oil supply .................................................... 29
1.6.3.3 Electrical system ........................................................ 29
1.6.3.4 Drive system .............................................................. 30
1.6.3.5 Conveyor unit............................................................. 30
1.6.3.5.1Crusher discharge conveyor ...................................... 30
1.6.3.5.2Prescreen conveyor ................................................... 30
1.6.3.5.3Permanent magnet separator .................................... 31
1.6.3.6 Water system ............................................................. 31
1.6.3.7 Feeding unit ............................................................... 32
1.6.3.7.1Vibrating feeder.......................................................... 32
1.6.3.7.2Screens...................................................................... 32
1.6.3.8 Crusher ...................................................................... 33
2 Safety regulations ................................... 35

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2.1 General...................................................................... 35
2.2 Symbol and notice explanation ................................. 35
2.3 Responsibility of the operator .................................... 36
2.4 Responsibilities of the personnel............................... 36
2.5 Organisational measures........................................... 36
2.6 Informal safety measures .......................................... 36
2.7 Training of personnel................................................. 37
2.8 Risks and dangers when using the machine ............. 37
2.9 Maintenance and inspection, repairs......................... 38
2.10 Guard devices ........................................................... 38
2.11 Safety measures during normal operation................. 38
2.12 Danger due to electrical power.................................. 38
2.13 Hazards resulting from hydraulic energy ................... 39
2.14 Specials hazards ....................................................... 39
2.15 Structural changes to the machine ............................ 40
2.16 Cleaning the machine and disposal of materials ....... 41
2.17 Vibrations .................................................................. 41
2.18 Noise ......................................................................... 41
2.19 Warranty and liability ................................................. 41
3 Operating and display elements ............ 43
3.1 Switch cabinet ........................................................... 43
3.2 External power supply ............................................... 44
3.3 Sockets on switch cabinet ......................................... 45
3.3.1 Reconnecting between transport mode and crushing
mode47
3.4 Operator panel .......................................................... 49
3.4.1 Operator panel OP3 .................................................. 51
3.4.1.1 Structure .................................................................... 51
3.5 Frequency converter ................................................. 53
3.5.1 Frequency converter main switch.............................. 53
3.5.2 Frequency converter operating unit........................... 54
3.6 Radio remote control ................................................. 56
3.6.1 Range of radio remote control ................................... 57
3.7 Power drive ............................................................... 59
3.8 Rock chisel ................................................................ 60
3.9 Sockets on the chassis.............................................. 61

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3.10 Emergency-stop......................................................... 63
3.10.1 Emergency stop buttons ............................................ 63
3.10.2 Emergency pull-wire .................................................. 65
3.11 Hydraulic functions of valve block.............................. 66
3.11.1 Auxiliary function of valve block ................................. 66
3.12 Operating modes ....................................................... 66
4 Commissioning........................................ 69
4.1 Safety information ...................................................... 69
4.2 Installation.................................................................. 69
4.2.1 Erecting the machine ................................................. 70
4.2.2 Moving out warning light with lighting (option) ........... 70
4.2.3 Earthing the plant....................................................... 71
4.2.4 Assembling/disassembling power supply unit............ 73
4.2.5 Installing exhaust pipe ............................................... 73
4.2.6 Extending the supports .............................................. 74
4.2.7 Installing jaw crusher ................................................. 76
4.2.8 Installing screen drive ................................................ 77
4.2.9 Mounting feeding unit................................................. 79
4.2.10 Mounting rock chisel and cross member ................... 82
4.2.11 Mounting the platforms, stairs and stair railings......... 84
4.2.12 Installing magnetic separator with support................. 86
4.2.13 Installing crusher discharge conveyor........................ 87
4.2.14 Mounting the side discharge conveyor ...................... 89
4.3 Inspection................................................................... 91
4.3.1 Checks with machine stationary ................................ 91
4.3.2 Test run without material............................................ 94
4.3.3 "Repair" test run......................................................... 95
5 Operation.................................................. 97
5.1 Safety informations .................................................... 97
5.2 Switch-on ................................................................... 97
5.2.1 Switching on generator .............................................. 98
5.2.2 Switching on the plant................................................ 99
5.3 Switch-off ................................................................... 99
5.3.1 Switching off the plant.............................................. 100
5.3.2 Switching off generator ............................................ 100

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5.4 Refuelling ................................................................ 101
5.5 Moving the plant ...................................................... 102
5.5.1 Conditions ............................................................... 103
5.5.2 Driving ..................................................................... 104
5.5.3 Shutting down the plant ........................................... 106
5.6 Crushing
Important information for plant operator!106
5.7 Starting the crusher process.................................... 108
5.8 Charging .................................................................. 109
5.8.1 Eliminating material congestions ............................. 110
5.8.1.1 Eliminating material congestions ............................. 110
5.8.1.2 Removing material congestion with crusher running113
5.8.1.3 ................................................................................ 114
5.8.2 Clearing stockpiles .................................................. 114
5.8.3 Recycling ................................................................. 114
5.8.4 Winter operation ...................................................... 115
5.9 Adjustment / Set-up ................................................. 115
5.9.1 Checking gap width (crusher).................................. 115
5.9.2 Adjusting the gap width (crusher) ............................ 117
5.9.3 Controllable vibrating feeder.................................... 119
5.10 Water pump ............................................................. 120
5.11 Switch cabinet overpressure system ....................... 121
5.12 Fuel supply for hand delivery pump......................... 122
6 Maintenance........................................... 123
6.1 Safety information ................................................... 123
6.2 Maintenance schedule ............................................ 124
6.3 Fluids and lubricants ............................................... 128
6.3.1 Lubricants ................................................................ 129
6.3.1.1 Power supply unit/engine ........................................ 129
6.3.1.2 Plant hydraulic oil supply ......................................... 129
6.3.1.3 Jaw and impact crusher........................................... 130
6.3.1.4 Conveyor unit .......................................................... 130
6.3.1.5 Drive system............................................................ 131
6.3.2 Diesel fuels .............................................................. 131
6.4 General maintenance work...................................... 133
6.4.1 Checking emergency-stop devices.......................... 133

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6.4.1.1 Emergency-stop button and release cord ................ 133
6.4.1.2 Emergency-off button............................................... 133
6.4.2 Retightening screw connections .............................. 134
6.4.3 Checking hydraulic system for leaks........................ 134
6.4.4 Testing the electrical indicator lights ........................ 135
6.4.5 Wear lining ............................................................... 135
6.5 Vibrating conveyor chutes........................................ 135
6.5.1 Terminal box (electric motor) ................................... 135
6.5.2 Checking the rubber buffers..................................... 136
6.5.3 Checking security of vibration motors ...................... 136
6.6 Vibrating screen ....................................................... 138
6.6.1 Check screen surfaces (wear and tear + tension) ... 138
6.6.2 Lubricating vibrating screen (grease)....................... 140
6.6.3 Lubricating vibrating screen articulated shaft........... 140
6.7 Jaw crusher.............................................................. 141
6.7.1 Lubricating the bearings........................................... 141
6.7.2 Checking the V-belts................................................ 143
6.7.3 Tensioning the V-belts ............................................. 143
6.7.4 Listening to bearing, checking its temperature ........ 145
6.7.5 Checking the fixing of the crushing jaws.................. 145
6.7.6 Check crusher fixing ................................................ 145
6.8 Belt conveyor ........................................................... 146
6.8.1 Checking the conveyor belts.................................... 146
6.8.2 Adjusting the scraper rubber.................................... 147
6.8.3 Adjusting rubber plates ............................................ 148
6.8.4 Belt drive oil service ................................................. 150
6.8.5 Lubricating belt conveyor ......................................... 151
6.9 Crawler chassis........................................................ 152
6.9.1 Oil service for planetary gear ................................... 152
6.9.2 Chain tension ........................................................... 153
6.9.3 Chain tensioner........................................................ 154
6.9.4 Checking gearbox for leaks ..................................... 155
6.9.5 Checking fastenings for track rollers and base plates ...
155
6.10 Electro-hydraulic drive system ................................. 155
6.10.1 Pump distribution gear oil service ............................ 155

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6.10.2 Traction clutch ......................................................... 157
6.11 Hydraulic system ..................................................... 159
6.11.1 Hydraulic filter.......................................................... 160
6.11.2 Hydraulic hose lines ................................................ 161
6.12 Electrical switch cabinet .......................................... 161
7 Repair ..................................................... 163
7.1 Safety information ................................................... 163
7.2 Repair work ............................................................. 163
7.3 Vibrating conveyor chutes ....................................... 163
7.3.1 Replacing the vibration motor.................................. 163
7.3.2 Measuring the stroke (Chute) .................................. 165
7.3.3 Adjusting rocker width ............................................. 166
7.4 Vibrating screen ...................................................... 169
7.4.1 Checking vibration amplitude (screener) ................. 169
7.4.2 Adjusting vibration amplitude (screener) ................. 172
7.4.3 Changing screen surface ........................................ 173
7.4.4 Springs .................................................................... 174
7.4.5 Sealing elements ..................................................... 174
7.4.6 Wear lining .............................................................. 174
7.4.7 Screen box .............................................................. 175
7.5 Jaw crusher ............................................................. 175
7.5.1 Crusher jaws ........................................................... 176
7.5.1.1 Checking wear of crushing jaws .............................. 177
7.5.2 Changing the lateral wedges ................................... 177
7.5.3 Changing fixed crusher jaw ..................................... 180
7.5.4 Changing articulated crusher jaw ............................ 184
7.5.5 Changing pressure plate and pressure plate bearings..
188
7.6 Belt conveyor........................................................... 193
7.6.1 Tensioning belts ...................................................... 193
7.6.2 Changing belts ........................................................ 195
7.6.3 Replacing scraper ................................................... 195
7.6.4 Adjusting belt run..................................................... 195
8 Transportation ....................................... 199
8.1 Transport between the places of use ...................... 199

K0610202 / 4111004512
8.2 Safety information .................................................... 199
8.3 Retracting the warning light (option) ........................ 200
8.4 Disassembling side discharge conveyor.................. 200
8.4.1 Disassembling rock chisel and cross member......... 202
8.4.2 Disassembling platforms, stairs and handrail sections ..
203
8.5 Removing feeding unit ............................................. 206
8.6 Disassembling screen drive ..................................... 209
8.6.1 Disassembling jaw crusher ...................................... 210
8.6.2 Disassembling crusher discharge conveyor ............ 212
8.6.3 Disassembling magnetic separator with support ..... 214
8.6.4 Retracting the supports............................................ 216
8.6.5 Disassembling exhaust pipe .................................... 217
8.6.6 Assembling/disassembling power supply unit.......... 218
8.7 Remove earth connection ........................................ 218
8.8 Power unit ................................................................ 218
9 Storage ................................................... 219
10 Disposal.................................................. 221

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K0610202 / 4111004512
Product description
1 Product description
1.1 Application and intended use
The MC 140 mobile crusher plant is solely intended for use in crushing medium-hard stones, minerals
and rubble with a crushing strength of 300 N/mm² (43,500 lbs/in²) and a max. feed size
of 1260 x 800 mm (49 in x 31 in).
Any further use, such as the crushing of contaminated materials, wood, scrap, coal, metal parts, etc.,
is contrary to the intended use of the machine.
The manufacturer does not accept responsibility for any resulting damage. The user alone bears the
risk.
1.1.1 Intended use

The plant is state-of-the-art equipment and complies with the safety regulations applicable at the time
of marketing and applicable to its intended use.
Design measures cannot avoid foreseeable misuse or residual dangers without restricting the spec-
ified range of functions.
The plant is built and designed
• for processing mineral materials with a feed size of 0-800 mm.

• for crushing material
• for screening different grain sizes using a classifying screen.
• for discharging different grain sizes via a belt conveyor onto stockpiles or downstream plants
for further processing.
• for clearing stockpiles with a wheel loader, the size of which matches the plant power.
The plant is designed exclusively for commercial operation within enclosed areas such as building
sites and quarries.
The plant must be operated by instructed operators in accordance with the specifications in the tech-
nical documentation.
All types of non-specified use, or all activities on the plant not described in this instruction manual,
amount to misuse not covered by the statutory limits of liability of the manufacturer.
1.1.2 Non-specified use

In the case of non-intended 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-intended use includes:

K0610202 / 4111004512
Product description
• 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 intervals.
• Operation following neglected measurements and inspections for early detection of damage or
wear.
• Feeding with lorries, dumpers or skip lorries or with excessively large or small digger shovels
or buckets.
• Clearing the stockpile 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 constructional 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 congestions, considerable wear and damage to the
crusher.
• Uncrushable 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 the crusher, belt convey-
ors and other moving parts.
• All other materials not mentioned in the section on intended use, such as wood, coal, scraps,
rubbish, boulders of ore and other non-mineral materials.
• The following must not be fed into the crusher:
- Hazardous and explosive substances.
- Chemicals.
- Solvents, oils and greases.
- Scrap containing asbestos, e.g. eternit.
- Pressurised vessels.
1.1.3 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 implementation and observance of the
following specifications:
• The special warning signs on the plant system.

• The general safety instructions in this instruction manual and in the safety manual.
• The special warning signs in this instruction manual.
• The instructions in the safety instructions.

K0610202 / 4111004512
Product description
• The instruction manual 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 instruction.
The plant can cause dangers to the environment through, e.g.:
• Fluids and lubricants, etc.
• Noise and dust emission.
Material damage to the plant is possible through, e.g.:
• Nonobservance of operating and maintenance specifications.
• Unsuitable fluids and lubricants.
Material damage to further material assets in the operating area of the plant is possible through, e.g.:
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.

K0610202 / 4111004512
Product description
1.2 Maschinenübersicht
1 2 3 4 5 6 7/8 9 10
14 12 11
0002742

K0610202 / 4111004512
Product description
1 13
2
3
4
5
10
0002713
1 Aufgabetrichter 8 Gesamtantrieb Diesel-Hydraulik

2 Vibrations-Aufgaberinne 9 Magnet-Abscheider
3 Vorsieb 10 Brecherabzugsband
4 Seitenaustragsband 11 Elektrische Steuerung
5 Einschwingen-Backenbrecher 12 Raupenfahrwerk
6 Meisel 13 Reservebandförderer
7 Dieselgenerator 14 Abweisschild
1.3 Precautionary measures

In the event of incorrect use of the plant, improper operation or faulty repairs, the plant itself or pro-d-
ucts located nearby may be damaged or destroyed. Persons who are in the hazard area are liable to
incur severe or fatal injuries.

K0610202 / 4111004512
Product description
Thus this instruction manual must be read thoroughly and it is imperative to observe the relevant
sa-fety instructions.
1.4 Conformity
The plant corresponds in its setup to valid EC Directives, as well as appropriate European standards.
The development, manufacture and installation of the plant has been carried out with the utmost care.
1.5 Product designation

As the plant contains various individual machines, several type plates are used for the designation
and these are found on the respective individual machines.
1.6 Technical details

All important technical details regarding the entire plant are given. These provide information on the
performance and installation of the plant.
1.6.1 Mobicat plant
Feed material Rubble, demolished concrete, natural stone

Edge dimensions 1260 x 800 x 500 mm (length in
material-
flow direction x width 90° in relation to material flow
direction
Feed size x height).
up to 750 t/h depending on the feed material, prescreening and fi-
Feed capacity nal grain size
approx. 270-340 t/h with gap width of 130 mm
Crushing capacity approx. 575-675 t/h with gap width of 260 mm
Total weight 160,000 kg without options
Emissions Noise, dust
Ground pressure 2.35 kg/ cm² (without options)
Driving speed 1.2 km/h

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Product description
1.6.2 Transport and erection area

1.6.2.1 Transport dimensions
3713
4550
3630
1176,5
1052
686
6093 5430 3644
Haupttransporteinheit
Main transport unit chassis
49000 kg
0002714
4550
1280
463
1820
Haupttransporteinheit 650 2300 650
Main transport unit chassis
49000 kg 3600
0002715

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Product description
3870
3660
2840 7714
Aufgabeeinheit
Feeding unit
25300 kg
0002716
ca. 2890
3007
980 530
828
510
625
980 260
3277
500
8528
1180
Felsmeißel mit Quertraverse

Rock chisel with traverse
6000 kg
0002717

K0610202 / 4111004512
Product description
3130
3717
867
180
3539 440 440
1760
4306 2640
Brecher komplett
Crusher complete
57000 kg
0002718
4618 1950
1950
2054
1950
527
2230x2150
Riemenschutz Schwungscheibenschutz Einlaufkasten

Belt guard Flywheel guard Inlet box
400 kg 290 kg 2400 kg
0002719

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Product description
1200
13500
2190
250
Brecherabzugsband Bandversion
Crusher discharge conveyor belt version
4750 kg
0002720
1372
11013
1750
2375
Brecherabzugsband Rinnenversion
Crusher discharge conveyor chute version
4000 kg
0002785

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Product description
1200
8315
1760
250
Seitenaustragsband
Side discharge conveyor
2800 kg
0002721
2510
2333
2200
1125 1722
Bypass Oberlenker
Bypass Top link
1200 kg 2x 45 kg
0002722

K0610202 / 4111004512
Product description
5060
5690 307 6390
2526
2396
3131
3131 611
630
320
6390
350
5748
3131
3000
3
Trichteraufsatz 35m
3
Hopper extension 35m
10800 kg 630
0002723
1000
120
0
4670
3
Trichterseitenwand 10m
Hopper side wall 10m3
2520 kg
0002786

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Product description
2368
2175
2800
3500 171
1465
1400
500
2420
1780
1600
2610
2470
1002
750
1305
Abweisschild Zubehör; Hydraulikzylinder mit Schutzblech Ausleger oben Magnetabscheider
Defense shield Accessory; Hydraulic cylinder with mudguard Boom Magnetic separator
1090 kg 2 x 50 kg 1115 kg 1405 kg
0002752
SONSTIGES ZUBEHÖR
1560
Bühnen = 4000 kg
- Bühnen rechts
- Bühnen links
- Felsmeiselbühne
- Bühne am Doieselaggregat
- Treppen / Leitern
1100 550
Werkzeug + Zubehöhr = 65 kg
Auffahrbrücke = a 85 kg
Siebantrieb mit Konsole
Screen drive with console
395 kg
0002753

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Product description
1.6.2.2 Lashing points
1 1
0002751
[1] Lashing points
1.6.2.3 Assembly dimensions

1466 802
2061
3901
3630
5430
21183
0002743

K0610202 / 4111004512
Product description
5600
4822
2910
1360 802
6493
7960
8460
5691
4020
1860
3600
10092
0002744
1.6.3 Components

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Product description
1.6.3.1 Power supply unit stage 3A

Designation Value
Manufacturer of power supply
unit AVS
Type of power supply unit DW 503 SC3A 15 L14HH
Rated output 500 kVA
Rated current 720 A
Rated power factor 0.8
Rated voltage 230/400 V
Frequency 50 Hz
Rotational speed 1500 rpm
Weight approx. 5000 kg
Reference conditions*
Installation altitude approx. 100 m above sea level
Ambient temperature 25 °C
Relative humidity 60 %
Diesel engine manufacturer Scania
Engine type DC16-071A (02-01)
Number of cylinders 8V
Displacement 16.4 l
Rated speed 1500 rpm
Continuous output according to 438 kW - 1500 rpm
DIN 6280 / ISO 3046-1 483 kW - 1800 rpm
Fuel consumption according to
DIN 51601 at full load approx. 204 g/kWh
Starter 24 V, 7 kW
Generator 24 V, 100 A
Batteries 2 x 200 Ah, 24 V (2 x 12 V)
Cooling system Liquid cooling, charge air cooling, oil cooling
Diesel fuel filling volume approx. 900 l
Engine oil filling capacity approx. 40-48 l
Exhaust emissions stage Stage 3A
Generator manufacturer Leroy Somer
Generator type LSA 47.2 L9
Rated output 600 kVA

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Product description
Rated voltage 230/400 V

Voltage stability, static ± 1.5 %
Frequency 50 Hz
Rotational speed 1500 rpm
Type of protection IP 23
* The above-mentioned performance data of the power supply unit is based on the specified
reference conditions. Upward deviations from these values indicate a (sometimes consider-
able) loss in performance.
1.6.3.2 Hydraulic oil supply

Designation Value
Hydraulic oil tank filling capacity 280 l
Filling capacity of hydraulic sys-
tem, complete approx. 300 l
Driving hydraulics operating
pressure 365 bar
Operating pressure, auxiliary
hydraulic system 230 bar, ± 10 bar
1.6.3.3 Electrical system

Designation Value
Operating voltage 400 V
Control voltage 24 V
Frequency 50 Hz
230 V / 16 A
Additional sockets (external cir- 400 V / 32 A
cuits) 115 V / 16 A (option)

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Product description
1.6.3.4 Drive system

Designation Value
Design Crawler chassis with installed hydraulic motors and chassis in be-
tween.
Holding brake Depressurised closing spring-applied brake. Service brake in
crusher operation hydraulically actuated, in driving operation, hy-
draulically released.
Crawler chassis type D8H
Axle distance between drive
sprocket and idler sprocket 5430 mm
Track shoe width 650 mm
Gear motor maximum torque 220 kNm
Planetary gear filling capacity 15 l per side
1.6.3.5 Conveyor unit
1.6.3.5.1 Crusher discharge conveyor
Designation Value
Type designation BFB140-13
Design Sectional steel construction
Distance between centers 13000 mm
Belt width 1400 mm
Drive output 22 kW
Conveyor belt speed 1.2 m/s
Electric motor with flange-mounted bevel helical gearbox with
Belt conveyor drive non-return lock
Filling volume of bevel helical
gearbox approx. 8.0 l (horizontal installation position)
1.6.3.5.2 Prescreen conveyor
Designation Value
Type designation BFB100-080
Design Sectional steel construction

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Product description
Distance between centers 8000 mm

Belt width 1000 mm
Drive output 15 kW
Electric motor with flange-mounted bevel helical gearbox with
Belt conveyor drive non-return lock
Filling volume of bevel helical
gearbox approx. 5.3 l (horizontal installation position)
1.6.3.5.3 Permanent magnet separator
Designation Value
Drive output 1.5 kW
Belt conveyor drive Electric motor with flanged-on worm gear
Gearbox filling capacity approx. 0.48 l
1.6.3.6 Water system

Designation Value
Conveying medium temperature + 5 °C to + 35 °C
Maximum permissible operating
pressure 8 bar
Minimum / maximum permissi-
ble pressure on suction side - 0.8 / 4 bar
Maximum suction height 5m
Maximum ambient temperature + 40 °C
Water consumption 3 to 6 m³ per day

K0610202 / 4111004512
Product description
1.6.3.7 Feeding unit
1.6.3.7.1 Vibrating feeder
Designation Value
Type designation AGR125-Z1
Design Vibrating conveyor trough designed with wear plates
Trough width 1150 / 1350 mm
Trough length 4000 mm
2 vibration motors with stepless speed adjustment via frequency
Drive converter
Drive output 2 x 7.5 kW
Permissible ambient tempera-
ture -15 °C to + 40 °C
1.6.3.7.2 Screens
Designation Value
Type designation VUZ400-145
Design Double-deck heavy-piece screen
Weight 5450 kg
Screen width 1450 mm
Screen length 400 mm
Screen slope, upper deck Slotted grate 9°
Screen slope, lower deck 15°
Screen surface tensioning sys- Upper deck bolted
tem Lower deck bolted
Rocker width adjustment Via unbalance weights
Screen drive Electric motor and articulated shaft
Drive output 18.5 kW
Quantity of grease when pack-
ing bearings for first time approx. 500 g per bearing

K0610202 / 4111004512
Product description
1.6.3.8 Crusher
Designation Value
Type designation STR140-113
Design Single toggle jaw crusher, welded construction with rocker sup-
ported in spherical roller bearing
Weight 57,000 kg
Crusher jaw width 1400 mm
Feed opening 1130 mm
Crushing jaw version Manganese rigid steel, reversible
Gap setting Mechanical with spacer plates
Drive Electric motor via V-belt
Operating tension per V-belt
- New V-belts
- Run-in V-belts 1200 N
925 N

K0610202 / 4111004512
Product description

K0610202 / 4111004512
Safety regulations
2 Safety regulations
2.1 General
Knowledge of the essential safety instructions and safety regulations is a basic prerequisite for the
safe use and trouble-free operation of the machine.
The safety instructions in this section make up the general part. Extra instructions are given directly
before the relevant operations.
• This instruction manual contains the most important information required to operate the ma-
chi-ne safely.
• The safety information must be observed by all persons who are working at the machine.
2.2 Symbol and notice explanation

In the instruction manual the following terms and symbols are used for hazards:
DANGER!
This symbol means imminent danger.
Failure to comply with these instructions may lead to severe or fatal in--
jury.
WARNING!
This symbol means possible danger.
Failure to comply with these instructions may lead to severe or fatal in--
jury.
CAUTION!
This symbol means imminent danger.
Failure to comply with these instructions may lead to personal injury or

material damage.

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Safety regulations
NOTE!
This symbol means possible danger.
Failure to comply with these instructions may lead to personal injury or

material damage.
IMPORTANT!
Under this symbol, suggestions and tips for use and other particularly
useful information is found.
These symbols and notices help you to optimally use all functions on the
machine and make your work easier.
2.3 Responsibility of the operator

• The operating company is obligated to only permit persons to work at the machine who
- are aware of the essential regulations with regard to workplace safety and accident preven--
tion and are familiar with the use of the machine.
- have read and understood the safety section and the warning notices in this instruction ma-n-
ual and have confirmed so with their signature.
• The work is controlled at regular intervals to ensure that safety procedures are being followed.
2.4 Responsibilities of the personnel

All persons who are commissioned to work at the machine are obliged before beginning work
• to observe the basic regulations with regard to work safety and accident prevention,
• to read the safety section and the warning notices in the instruction manual and confirm their
understanding of these with their signature,
• to obtain information about the operation before using the machine.
2.5 Organisational measures

• The necessary personal protective equipment must be provided by the operator.
• All existing safety devices must be checked regularly.
2.6 Informal safety measures

• The instruction manual must be permanently retained at the site of the machine. It must be
easily accessible to the operators at all times.
• Supplementary to the instruction manual, the general and local regulations on accident pre--
vention and environmental protection must be provided and adhered to.

K0610202 / 4111004512
Safety regulations
• All safety instructions and hazard warnings must be kept at the machine and must be legible.
• With every change of owner or when the machine is on loan to other persons, the instruction
manual must be handed over and its importance pointed out.
2.7 Training of personnel

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.
• They have to be appointed by the plant's owner to operate and move the plant.
2.8 Risks and dangers when using the machine

The machine is built using the best available technology and in accordance with the recognised saf-e-
ty regulations. However, through its use danger to the life and well-being of the operator or third par-ty
may arise, as well as material damage.
• The machine is only to be used

- for its intended purpose
- and when it is in perfect condition with regard to safety.
• Faults which compromise safety must be eliminated immediately.

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Safety regulations
2.9 Maintenance and inspection, repairs

• All maintenance and repair work must be carried out when the machine is disconnected
from the power supply.
At the same time, the machine must be safeguarded against unintentional restart.
- Lock switch cabinet
- Turn off main switch
- Remove ignition key from machine
- Attach warning sign on the machine to warn against restart
• Compulsory maintenance and inspection work must be carried out in accordance with sched--
ule.
• Operators must be informed before beginning maintenance and repair work.
• Disconnect all machines, upstream and downstream plant components and service mediums
such as hydraulic oil and safeguard against unintentional startup.
• When replacing large components, carefully attach and secure them to hoisting devices.
• Check security of all screw connections.
• Doors and flaps of the machine must only be opened after moving parts are stationary.
• Once maintenance work is finished, check whether all safety devices are working properly.
2.10 Guard devices

• Safety devices must not be bridged or avoided.
• Before the machine is switched on, all safety devices must be properly attached and functio-n-
ing.
• Safety devices must only be removed
- after the machine has shut down and
- safeguarded against its unintentional restart.
• In the case of delivery of part components, the safety devices must be fitted by the operator in
accordance with regulations.
2.11 Safety measures during normal operation

• Only operate the machine when all safety devices are fully functional.
• Before switching on the machine, ensure that nobody can be put at risk from starting up the
machine.
• Inspect the machine at least once a day for noticeable external damage and check the opera--
tion of safety devices.
2.12 Danger due to electrical power

• Work on the electrical system must only be carried out by qualified electricians.
• The electrical equipment of the machine must be checked regularly. Loose connections and
damaged cables must be replaced immediately.
• The switch cabinet must be kept locked at all times. Access only permitted by authorised per--
sonnel with key or appropriate tool.

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Safety regulations
• If work on live parts is necessary, then a second person must be present who can switch off
the main switch in case of emergency.
2.13 Hazards resulting from hydraulic energy

• Only trained experts with special knowledge and experience in hydraulics may work on hydrau--
lic devices.
• System sections and pressure lines that need to be opened must be depressurised before
commencing repair work.
• Replace hydraulic-hose lines at appropriate intervals, even if no safety-relevant defects are de--
tectable.
2.14 Specials hazards

Danger of toppling over due to subsidence or exceeding the permissible driving inclination.
Machine can crush people who are underneath it.
- Only position and move machine on secure and firm ground.

-  Do not exceed permissible driving inclinations
Risk of falling material.
Persons can be struck or become trapped by falling material.
- Stay clear of the discharge area of running belts.

- Avoid the area of the feed hopper during loading.
- Wear a protective helmet.
Injuries caused by reaching into unbalance of screen or conveyor belts.
Loss of limbs may occur.
- Only carry out maintenance work when machine is inoperative.

-  Never bypass safety devices.
Injuries caused by slipping on a machine which has not been cleaned.
This may result in serious bone fractures.
- Keep machine and platforms clean.

- Use stable ladders and service platforms.
Risk of injury when reaching into or falling into the crusher.
Risk of fatal injury!

K0610202 / 4111004512
Safety regulations
- Never loosen obstructions by hand with the crusher running.

- Use the rock chisel (option) to loosen obstructions with the crusher running, see chapter
Eliminating material congestions.
- Operation of the rock chisel with the crusher running is only permitted if the operator is
wearing personal protective equipment and is attached to and secured to a safety rope.
-  Never climb on the vibrating feeder during operation.
- Never insert rods into moving crusher.
Eye injuries caused by stone chips, dust or reinforcing steel.
This may result in irreparable eye damage.
Wear protective goggles.
Eye injuries and scalding through escaping pressurised hydraulic oil.
Can result in burns and loss of eyesight.
-  Only carry out maintenance and repair work with the hydraulic system shut down and de-
pressurised.
- Replace damaged hydraulic hoses immediately.
Danger through contact with electrical cables.
Risk of death by electrocution.
- Repairs to the electrical system must only be carried out by qualified electricians.
- Replace damaged cables immediately.
- Keep switch cabinets closed.
Injuries caused by getting trapped between machine and loading shovel or digger.
This may lead to death by crushing.
- Do not stand between machine and loading device.
2.15 Structural changes to the machine

• Without prior approval from the manufacturer, no changes, fittings or modifications to the ma-
chine are allowed. This also applies to welding on supporting parts.
• All modifications require written approval from the manufacturer.
• Machine parts that are not in perfect condition must be replaced immediately.
• Only use original Kleemann spare and wearing parts.

K0610202 / 4111004512
Safety regulations
2.16 Cleaning the machine and disposal of materials

• The materials used must be handled and disposed of correctly, in particular when
- working with lubrication systems and lubrication devices and
- cleaning using solvents.
2.17 Vibrations
During its operation, the machine is subject to stress from vibrations. On the maintenance platforms,
which can only be used for maintenance purposes, vibration acceleration occurs.
2.18 Noise
A considerable continuous sound pressure level is generated by the machine.
Hearing protection is therefore necessary in the area of the machine in order to avoid damage to
he-aring.
2.19 Warranty and liability

As a basic principle our "General Terms and Conditions of Sale and Delivery" apply. These are avai-l-
able to the operator no later than at conclusion of contract. Warranty and liability claims in the case
of personal and material damage are ruled out if they are caused by one or more of the following:
• use of machine other than its intended purpose
• improper installation, startup, operation and maintenance of machine
• use of machine with defective safety devices or safety devices not fitted according to the rules
or non-functional safety and protective devices
• non-use of original Kleemann replacement and wearing parts
• non-compliance with information in the operating manual with regard to transport, installation
and removal, start-up, positioning and rigging, operation, maintenance and inspection, and re--
pairs.
• structural changes made to machine without manufacturer's authorisation
• inadequate inspection of machine parts that are subject to wear and tear
• repairs carried out improperly
• catastrophes caused by impact of foreign material and Acts of God.

K0610202 / 4111004512
Safety regulations

K0610202 / 4111004512
Operating and display elements
3 Operating and display ele-

ments
3.1 Switch cabinet
4 3 2
0002724
No. Description Function

1 Operator panel Operates and monitors entire plant (see "Operator
panel")
2 External power supply main The plant is run from an external power source
switch
3 Main switch Separates all consumers from the generator.
Exception: External circuits (See "External cir-
cuits").
Main switch can be closed using a padlock
4 Emergency off General emergency off (see "Emergency-Off")

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CAUTION!
Material damage!
Risk of destruction to the electronics inside the switch cabinet due to

contamination.
Keep the switch cabinet closed during operation.
3.2 External power supply

The two main switches of the diesel generator and the external power supply are on the switch cab-
i-net below the power supply unit.
CAUTION!
Danger of material damage!
The electronics inside the switch cabinet may become damaged due to
dust and dirt.
• Always keep the switch cabinet closed during operation.
1 2
0001775

1 Diesel generator main switch The plant is run with a diesel generator
2 Main switch for external power The plant is run from an external power source
supply (Option)
Both main switches are interlocked reciprocally so that only one main switch can be switched on at
any one time.

K0610202 / 4111004512
• To switch over, first switch off one main switch and then switch on the other main switch.
3.3 Sockets on switch cabinet

CAUTION!
Material damage!
Contacts in danger of being destroyed.
Only insert connectors in sockets when de-energised.
Contacts must be clean.
4 5
1 7
0000215

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9 10
0000238

1 Socket outlet Service socket outlet (230 V / 16 A)
2 Socket outlet Socket outlet for additional conveyor belt
3 Socket outlet Connection for emergency stop of additional con-
veyor belt
4 Locking device Connection for electrical locking device of a con-
nected downstream machine (e.g. Mobiscreen)
5 Socket outlet Connection for additional conveyor belt
6 Socket outlet Connection for emergency-off for discharge convey-
or of plant
7 Socket outlet Service socket outlet (440 V / 32 A)
8 Socket outlet Socket outlet for supply of downstream machine
(e.g. Mobiscreen)
9 Socket outlet Connection for wired remote control
10 Socket outlet Connection for belt scale (option)
WARNING!
Electrical voltage!
External circuits
The sockets of the external circuits (1) and (7) and the connection for up-
stream and downstream plants (8) are still live after the main switch has
been switched off. They only become de-energised when the diesel gen-
erator is switched off.

K0610202 / 4111004512
3.3.1 Reconnecting between transport mode and crushing mode
IMPORTANT!
Transport mode
Only use transport mode for transport and not for moving the plant on
site.
1 2
Crushing mode
1 2
Transport mode
0002024
1 operating mode socket outlet

2 dummy socket
NOTE!
The operating mode socket outlet is always the outermost socket outlet
at the switch cabinet.
Transport mode
• Insert transport plug (red) in the operating mode socket.
• Insert operating plug (grey) in dummy socket.

K0610202 / 4111004512
The plant can only be moved.
Crushing mode
• Insert operating plug (grey) in operating mode socket.
• Insert transport plug (red) in dummy socket.
The entire scope of functions of the plant are available.

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3.4 Operator panel
1000
800 1600
500
400 600
400
200
200
0 0
1
2 3
500
400
200
4
5 6
8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 5 6 7
24 25 26 27 28 29 30 31 32 33
34
0002726

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No. Designation Function

1 Engine control unit Engine control unit AVS
2 Current meter Displays current consumption of crusher drive
3 Current meter Displays current consumption of entire plant
4 Key switch Diesel generator
5 Fuel gauge Displays amount of fuel
6 Voltage meter Displays voltage
7 Operator panel OP3 See chapter 3.5.2
8 Lighting Rotary switch for switching light on/off
9 Rotary switch for crusher inlet Left switch position for scanning Max/Min fill level
fill level monitor (ultrasonic (vibrating feeder ON/OFF). Middle switch position
probe) deactivates control by the fill level monitor. Right
switch position for control of vibrating feeder and
prescreen via CFS
10 Supports up / down Rotary switch for retracting / extending supports
11 Centralised lubrication Switches centralised lubrication on/off
12 Coupling Pushbutton for engaging and releasing the coupling
13 Control voltage Key switch for switching control voltage on and off
14 Plant on Pushbutton for switching on the plant
15 Plant off Button for switching off the plant
16 Start release Lights up as soon as plant is ready to start
17 Acknowledge fault / emergen- Pushbutton for acknowledging faults / emergency
cy stop stop
18 Automatic mode / manual Selector switch to change between automatic and
mode manual operating mode. In manual mode position,
the sequential locking device of the machine is
switched off
19 Automatic mode Indicates position of operating mode selector switch
in "automatic"
20 Manual mode Indicates position of operating mode selector switch
in "manual"
21 Magnetic separator Left / 0 / right switch for magnetic separator
22 Radio on / off On/off switch for radio remote control
23 Lamp test Checks control lamps
24 Magnetic separator On/Off pushbutton for magnetic separator
25 Conveyor belt 1 On/off pushbutton for conveyor belt

K0610202 / 4111004512

28 Screen 5 On/off pushbutton for vibrating screen
29 Vibrating chute 6 On/off pushbutton for vibrating feeder
30 Hydraulic system On/off button for hydraulic power unit
31 Water pump Switch for turning the water pump on and off
32 Rock chisel On/off pushbutton for rock chisel
33 Vibrating feeder + / - Switch to increase / reduce speed of the vibrating
feeder
34 EMERGENCY-OFF See chapter 3.8
3.4.1 Operator panel OP3

3.4.1.1 Structure
4
3
2
6
0001688

K0610202 / 4111004512
[1] Numerical keypad

[2] Function keys F1-F5
[3] LCD
[4] Abort key (ESCAPE key)
[5] Sign key
[6] Cursor keys
[7] Input key (ENTER key)
[8] Shift key (SHIFT)
The OP3 operator panel displays messages from plant components and machines in the message
level. All setting values can be read off in the value level. Service personnel can also change setting
values if they have the corresponding password.
The OP3 operator panel has a membrane keyboard. The display can show two lines of text each with
20 characters.
Numeric keys
to Input keys for numerical digits 0-9.
Function keys
+ to The numeric keys 1 to 5 are also function keys. Press the SHIFT key
together with the function key F1 to call up Service mode. Function
keys F2 to F5 have no value assignment.
SHIFT key
Shifts to the second function of keys with dual functions. To do this, the shift key is pressed
at the same time as the relevant key, e.g.:
• Insert comma: press +.

• Call function: press + e.g.
Sign key
Changes sign from "Plus" to "Minus" and vice versa. Second function with pressed SHIFT
key: insertion of a comma.
ENTER key
For switching into the value level. Entries are confirmed and completed with the input key.
ESCAPE key
Depending on the current operating and display situation, pressing the abort key (ES-
CA-PE) has different effects:
• Undo: field entries are undone, provided they have still not been confirmed with ENTER.

K0610202 / 4111004512
• Branch backward: from the value level back to the message level.
• Resetting when scrolling in messages: cancellation of scrolling in pending messages to reset
the display to the currently pending message.
• Masking out a system message.
Cursor keys
Move cursor in the display. Depending on the operating and display
situation, the cursor is moved to the left, right, upwards, downwards
by characters, fields, entries or displays.
3.5 Frequency converter

3.5.1 Frequency converter main switch
0001701
The main switch of the frequency converter is fitted in the switch cabinet. It can be accessed after
opening the switch cabinet door.
CAUTION!
Switching over the frequency converter main switch with the plant run-
ning can result in damage to the electrical system.
• Switch off plant components, diesel generator and the main switch of
the plant.
• Only switch over the frequency converter main switch when the plant
is de-energised.
The main switch has two switching positions:
• Switching position 1 = network operation: all consumers are supplied by the diesel generator

K0610202 / 4111004512
at the rated frequency.

• Switching position 2 = frequency converter operation: the consumers connected to the fre-
quency converter are controlled by the frequency converter.
3.5.2 Frequency converter operating unit
3
1
7
6
0002746
No. Description
1 Frequency converter housing
2 Display
3 Enter button
4 Status LED
5 Stop/Reset button
6 Navigation buttons
7 Start button
8 Escape button
The three-phase current frequency converter permits speed control of the vibration motors of the vi-
brating feeder.
The frequency converter is operated by the programming and operating buttons.
The keypad and the display provide the user with information on the operating status of the converter
and fault codes. They allow him to change parameters and to stop, start and reset the converter.

K0610202 / 4111004512
Display
The display of the operating unit consists of four text lines. The upper two lines display the converter
status and the current menu and parameter number.
In status mode, an area on the right of the display is reserved for displaying actions that are currently
active on the converter.
Symbol Description
Alarm active
Access to the NV media card
Security code (password protection) active
User security code unlocked
Motor parameter set 2 active
On-board user program is executed
Set value via operating unit active
Keypad
The keypad includes:
[3] The Enter button is used to call up the display edit mode of the parameters or to confirm an edited
parameter.
[4] Status LED
[5] The Stop / Reset button is used to stop or reset the converter in operator panel mode. It can also

K0610202 / 4111004512
be used to reset the converter in the mode for terminal control.

[6] The navigation buttons are used to select a specific parameter or for editing parameter values. In
keypad mode, the up and down buttons are also used to increase or reduce motor speed.
[7] The Start button is used to start the converter in operator panel mode
[8] The Escape button is used to exit Parameter editing / display mode or to undo parameter editing.
3.6 Radio remote control

DANGER!
Risk of fatal injury due to bulky dimensions of the plant!
• Risk of fatal injury to persons during operation of the plant due to its
bulky dimensions.
• Plant is only to be operated with the assistance of a reliable banksman.
• Keep constant eye contact with banksman during machine operation.
2 3 4 5
9
11
6
7 12
10
0000914 0000915

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No. Description
1 Left crawler control forwards/backwards
2 Has no function
3 Crawler slow / fast
4 Vibrating feeder frequency slow / fast
5 Vibrating feeder on / off
6 Right crawler control forwards / backwards
7 Warning light LED battery
8 LED operation display
9 EMERGENCY-OFF
10 Has no function
11 Switches horn on / off (optional)
12 Switch on radio remote control
To operate the radio remote control, the "Radio ON/OFF" rotary switch on the switch cabinet must be
set accordingly. The plant must also be manually switched on at the switch cabinet by radio remote
control.
Activating the radio remote control

• Switch on radio remote control using rotary knob (10) on the side.
• Unlock emergency-off button (9).
• Acknowledge the emergency stop using the button "Fault/Emergency off" on the operator pan-
el.
CAUTION!
Caution! Material damage!
Risk of damaging the receiver electronics!
For welding work on the plant, disconnect control cable from receiver.
3.6.1 Range of radio remote control

K0610202 / 4111004512
0002152
The radio remote control permits operation and movement of the plant independently of the operator
panel of the switch cabinet. 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 transmit--
ter 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 transmitter 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 gene-r-
ator are switched off.

K0610202 / 4111004512
NOTE!
Danger of material congestion
If the range of the radio remote control is exceeded, the emergency stop
is tripped and material congestion in the plant can result.
• During plant operation, ensure that the range of the radio remote con--
trol is never exceeded.
• Never carry the radio remote control along in the wheel loader or dig--
ger and thus leave the range.
• Always ensure there is visual contact between transmitter and recei-v-
er.
• Store the radio remote control in the plant's switch cabinet when not in
use.
3.7 Power drive
1 3
0000216

1 Control lever left Left chain forwards/backwards
2 Emergency stop Triggering of an emergency stop signal
3 Control lever right Right chain forwards/backwards

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3.8 Rock chisel
0002777
NOTE!
Operation of the rock chisel is via the control system at the rock chisel
or via the associated radio remote control. For further information on the
rock chisel, refer to the documentation of the rock chisel manufacturer.
The control electrical system and the hydraulic power unit of the rock
chisel are switched on using a button on the plant's operator panel (see
chap. Operator panel).
The control electrical system of the rock chisel is integrated in the

plant's overall control system. If the rock chisel is switched on, the vi-
brating feeder and the prescreen are switched off to prevent material
from running on into the crusher.

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3.9 Sockets on the chassis
1 2 3
0002747

1 Socket outlet Emergency-stop on platform
2 Socket outlet Side discharge conveyor, right, drive
3 Socket outlet Side discharge conveyor, right, emergency stop
4 5
0002748

K0610202 / 4111004512

4 Socket outlet Side discharge conveyor, left, drive
5 Socket outlet Side discharge conveyor, emergency stop
6 Socket outlet Rock chisel
11
7 8 9 10
0002749

7 Socket outlet Emergency-stop on platform
8 Socket outlet Vibrating feeder, left
9 Socket outlet Vibrating feeder, right
10 Socket outlet Screen drive
11 Socket outlet Crusher inlet fill level sensor

K0610202 / 4111004512
12 13
14
0002750

12 Socket outlet Magnetic separator
13 Socket outlet Magnet
14 Socket outlet Manual moving
NOTE!
In order to operate or move the plant without a side discharge conveyor,
a dummy plug must be inserted in the "Emergency off" socket of the side
discharge conveyor.
3.10 Emergency-stop
3.10.1 Emergency stop buttons
WARNING!
The functioning of the emergency stop buttons must be checked daily.

K0610202 / 4111004512
WARNING!
Loads that are connected to the socket-outlets of exempt circuits and to
socket-outlet 0X1 for follow-up machines are not switched off by the
emergency-stop.
Injuries due to connected machines.
=>Switch off the diesel generator in emergencies!
0000226
Press emergency-stop in case of danger!
All drives, except the crusher, are stopped immediately.
To stop the crusher immediately, press the “Crusher” button on the switch cabinet or
the emergency stop button on the switch cabinet.
Pressing the emergency stop button on the switch cabinet stops the entire unit.
Releasing the emergency stop button

- turn clockwise
- and pull out

K0610202 / 4111004512
3.10.2 Emergency pull-wire
0000225
Pull the emergency pull-wire in case of danger!
All drives, except the crusher, are stopped immediately.
To stop the crusher immediately, press the “Crusher” button on the switch cabinet or
the emergency stop button on the switch cabinet.
Pressing the emergency stop button on the switch cabinet stops the entire unit.
Releasing the pull-wire switch

- Return pull-wire switch lever to central position
or
- pull the button out

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3.11 Hydraulic functions of valve block

3.11.1 Auxiliary function of valve block
1 2
0002256

1 Jaw crusher release mechanism Move connected release mechanism in / out.
2 Gap setting for jaw crusher Shift the rocker hydraulically.
3.12 Operating modes

CAUTION!
Accidental activation of a machine in manual mode can cause personal
injuries and/or material congestion.
For this reason, only use "Manual" mode in exceptional cases and with
due care.
There are two operating modes:
• Automatic mode
• Manual mode
The operating modes are switched over using a selector switch at the switch cabinet.

K0610202 / 4111004512
Automatic mode:
Normal operating mode
All machines are locked electrically and can only be switched on against the conveying direction. This
prevents material congestion.
Manual mode:
Special operating mode for repair work and moving the plant.
The electric interlock is disabled. The individual machines can be switched on and off as desired.

K0610202 / 4111004512

K0610202 / 4111004512
Commissioning
4 Commissioning
4.1 Safety information
WARNING!
Incorrect installation may lead to personal injury or damage to machine
when starting up.
• Before switching on machine, ensure that

- nobody is in hazard area,
- the immediate shutdown of machine is guaranteed (emergency
stop function).
• The machine may only be set up by persons with a sound knowledge
of the machine.
• The operator (machinist) accepts full responsibility for the safety of
persons who are in the hazard area of the machine.
4.2 Installation
Before the system can be operated, it must be moved from the transport position to the work position.
The activities described below must be performed for this purpose.
WARNING!
Risk of injury and damage to property through incorrect use of hoisting
machinery and lifting tackle.
If transporting by crane, always use suitable cargo gear. Check proper

condition of chains, ropes etc. beforehand.
Standing under suspended loads is forbidden.
Personal protective gear, e.g. helmet, safety shoes, gloves etc. must be
worn during system installation.
During installation and dismantling, chains or ropes must be attached to

fixed components with slip-resistant fastenings. The mounting must be
located in the centre of gravity.
Installation and dismantling must be carried out by skilled personnel.

K0610202 / 4111004512
Commissioning
4.2.1 Erecting the machine
CAUTION!
Damage to property!
Risk of the machine tipping due to sinking on soft surface or unsuitable

erection.
• Always erect the machine on a stable and solid surface

• Position the machine horizontally
• Machine must not rock
• The crusher must not rock on the chassis during operation
• The surface must be level (spread fine material over the ground and
then level)
If the machine or crusher rocks, reposition the machine and / or re-level the surface.
4.2.2 Moving out warning light with lighting (option)
0002725
No. Description
1 Retaining screws for warning light
2 Retaining pipe for warning light

K0610202 / 4111004512
Commissioning
• Release retaining screws (1) and push up retaining pipe (2).

• Align LED lighting if necessary.
• Tighten retaining screws (1).
4.2.3 Earthing the plant
0002776
No. Description
1 Earthing rod
Earthing of the plant guarantees a safe connection of the protective earth conductor to earth. Proper
operation of the ground fault circuit interrupter installed on the plant and thus effective personal pro--
tection can only be ensured if the earthing resistance is sufficiently low. The earthing resistance value
must be significantly less than 100 ohm.
Prior to commissioning of the plant and every time the earthing rod is moved, the loop resistance of
the earthing rod must be measured by an electrician.
Proper installation and presence of the earthing straps between the chassis and individual compo--
nents of the plant must also be checked before commissioning.

K0610202 / 4111004512
Commissioning
WARNING!
Danger of electric shock
There is a danger of electric shock due to insulation faults on the plant
and on external equipment which is connected to the service sockets.
• Do not plug equipment with insulation faults into the service sockets.
• Rectify any insulation faults on the plant before using an external po-w-
er supply.
WARNING!
Danger of electric shock
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 commissioning, have the loop resistance of the earthing rod
measured by an electrician.
• Never put an incorrectly or insufficiently earthed plant external power
supply into operation.
• Do not use service sockets if the plant is incorrectly or insufficiently
earthed.
• If necessary, water the dry earth around the earthing rod.
• Repair a defective earthing line immediately.
• 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 an-
cho-red in the ground to a sufficient depth.
• Have the loop resistance measured by an electrician.
• If necessary, water the earthing rod to increase conductivity.
• Take further suitable measures to ensure adequate earthing.
• Have an electrician check for proper earthing.

K0610202 / 4111004512
Commissioning
4.2.4 Assembling/disassembling power supply unit
WARNING!
Risk of injury!
Persons are at risk of injury and falling during the assembly / disassem-
bly of the power supply unit.
• Use suitable lifting gear and tackle.

• Use secure climbing aids, e.g. ladders or lifting platforms.
If necessary, the complete power supply unit can be assembled / disassembled separately.
In case of such assembly / disassembly work, please consult Kleemann.
4.2.5 Installing exhaust pipe
1 2
0002256 0002255
• Remove transport cover (1).

• Lift exhaust pipe (2) using suitable lifting gear and lifting tackle onto protective housing of pow-
er supply unit and position it.
• Bolt on exhaust pipe (2).

K0610202 / 4111004512
Commissioning
4.2.6 Extending the supports
WARNING!
Risk of injury when supports are being extended or retracted!
The supports area is difficult to observe when supports are being ex-
tended or retracted.
• Ensure that there are no persons in the area of the supports.
0002728
No. Designation
1 Transport lock
• Remove transport lock (1).

K0610202 / 4111004512
Commissioning
8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23
3
0002727
No. Designation
2 Rotary switch for support
3 Rotary switch for automatic / manual mode
• Switch on diesel generator and control voltage.

• Set rotary switch (3) to manual mode.
• Set rotary switch (2) to extend.
IMPORTANT!
The supports adjust themselves automatically.

K0610202 / 4111004512
Commissioning
4.2.7 Installing jaw crusher
WARNING!
Risk of injury in mounting area!
Persons in mounting area are at risk of serious crushing injuries.
• Before fitting components, place base unit on hard, level standing.

• When mounting, do not stand in danger zone.
CAUTION!
Material damage!
Observe weight of jaw crusher!
• Only use suitable lifting gear and tackle.

• Move jaw crusher carefully and set it down.
1
1
0000689
No. Description
1 Lifting eyes

K0610202 / 4111004512
Commissioning
• Attach and secure the jaw crusher at the designated lifting eyes (1) to suitable lifting gear and
lifting tackle.
• Carefully lift jaw crusher into mounting points on base unit.
• Fit and tension belt (see chapter Maintenance - Tensioning belt).
• Fit belt guard.
• Connect hydraulics.
• Connect centralised lubrication.
0002739
No. Description
2 Ultrasonic probe
• Connect ultrasonic probe (2).
4.2.8 Installing screen drive
CAUTION!
Material damage!
The markings on the splined shaft and splined shank must be opposite
each other.
Ensure alignment of the universal joints is the same.

K0610202 / 4111004512
Commissioning
1
4
0002729
No. Designation
1 Console securing screws
2 Console with electric motor
3 Articulated shaft universal joints
4 Marking
NOTE!
Note marking on splined shaft and splined shank of articulated shaft.
• Install suitable lifting gear with sufficient load carrying capacity on the lifting lugs provided on
the consoles.
• Install console (2) with securing screws (1) on chassis. At the same time, install splined shaft
and splined shank of articulated shaft. Make sure that the markings (4) on the splined shaft and
splined shank are opposite each other.
• Tighten securing screws (1) to specified tightening torque.

K0610202 / 4111004512
Commissioning
0002730
No. Designation
5 Terminal box
6 Articulated shaft guard
• Make electrical connections for electric motor in terminal box (5).

• Install guard (6) on articulated shaft.
4.2.9 Mounting feeding unit
WARNING!
Risk of injury in mounting area of feeding unit!
Persons in mounting area of feeding unit are at risk of serious crushing

injuries.
• Before fitting feeding unit, place base unit on hard, level standing.
• When mounting feeding unit, do not stand in danger zone.

K0610202 / 4111004512
Commissioning
CAUTION!
Material damage!
Observe weight of feeding unit!
• Only use suitable lifting gear.

• Secure feeding unit at several lifting gear.
NOTE!
Platforms and screen drive can be mounted in advance.
0000692
• Clean contact surfaces.

• Attach hopper wall of the hopper extension at the designated lifting eyes (1) to suitable lifting
gear and lifting tackle.
• Carefully lift hopper wall onto feed hopper.
• Secure hopper wall with pin (2) on feed hopper.
• Install second hopper wall correspondingly.

K0610202 / 4111004512
Commissioning
3 3
0000690
• Attach and secure the feeding unit at the designated lifting eyes (3) to suitable lifting gear and
lifting tackle.
• Carefully lift feeding unit into support points of chassis.
0000693
• Mount feeding unit with screws (4) on base unit.

• Insert electrical connections on screen and vibrating chute.

K0610202 / 4111004512
Commissioning
0002797
• Remove transport locks from screen (5).
4.2.10 Mounting rock chisel and cross member
WARNING!
Risk of injury in mounting area of rock chisel!
Persons in mounting area of rock chisel are at risk from crushing inju-
ries.
• Do not stand in danger zone when rock chisel is being installed.
NOTE!
For detailed information about the connection and operation of the rock
chisel, see the manufacturer's documentation.

K0610202 / 4111004512
Commissioning
2
3
1
4
0002296
No. Description
1 Feed hopper
2 Cross member
3 Screw bracket
4 Cable duct
• Clean the contact area on the feed hopper (1).

• Attach the rock chisel and cross member (2) at the designated lifting eyes to suitable lifting
gear and lifting gear.
• Lift the rock chisel and cross member (2) onto the feed hopper (1). Beware of electric cables
and hydraulic lines!
• Install cross member (2) with screws on feed hopper (1).
• Combine electric and hydraulic connections in a cable coil, route along the bottom side of the
cross member and bolt on with a screw bracket (3).
• Bolt cable duct (4) onto the right hopper wall.
• Install electric and hydraulic connections through the cable duct (4).
• Bolt protective cover onto bottom side of cross member (2).
• Guide the electric and hydraulic connections on the right hopper wall downwards to the chassis
and connect.

K0610202 / 4111004512
Commissioning
4.2.11 Mounting the platforms, stairs and stair railings
WARNING!
Risk of injury!
Persons are at risk of injury and falling during assembly of the platforms.

• Take special care when mounting platforms and handrails.
3
2
4
1
0002293
Assembling platforms at prescreen

• Install supports (1) for the platforms at the prescreen.
• Attach and secure platform segment (2) to suitable lifting gear and lift onto designated sup-
ports.
• Screw hexagon screws, washers and hexagon nuts between the platform segment (2) and
support (1) and tighten to the appropriate tightening torque.
Assembling platforms at power supply unit
• Attach the platform segment (3) to suitable lifting gear and tackle and lift into the correct posi-
tion on the chassis.
chassis and tighten to the appropriate tightening torque.
Mounting ladder
• Install support for the ladder.
• Insert ladder (4) for the power supply unit platform in the platform.

K0610202 / 4111004512
Commissioning
• Screw hexagon screws, washers and hexagon nuts between the ladder (4) and support and
tighten to the appropriate tightening torque.
Installing platform for crusher
• Install supports (4) for the platforms at the prescreen.
• Attach platform segment (3) to suitable lifting gear and tackle and lift onto designated supports.
supports (4) and tighten to the appropriate tightening torque.
11
10
9
12
8
13
7
0002295
Mounting access steps

• Install support (7) for access steps.
• Attach access steps (8) to suitable lifting gear and tackle and lift onto support (7) and onto pow-
er supply unit platform.
• Bolt access steps (8) with hexagon screws and washers onto supports and onto power supply
unit platform.
Installing maintenance platform for vibrating chute
• Attach maintenance platform (13) to suitable lifting gear and tackle and move it under the vi-
brating chute.
• Screw hexagon screws, washers and hexagon nuts between maintenance platform (13) and
chassis and tighten to the appropriate tightening torque.
• Attach ladder (12) between maintenance platform for vibrating chute and prescreen platform.

K0610202 / 4111004512
Commissioning
Installing stairs between platform for power supply unit and prescreen platform
• Attach stairs (10) to suitable lifting gear and tackle and lift between platform for power supply
unit and prescreen platform (11).
• Screw in stairs (10) with hexagon screws, washers and hexagon nuts between the platforms
and tighten to specified tightening torque.
Mounting handrail sections
• Lift handrail sections to the designated mounts.
• Screw in hexagon screws, washers and hexagon nuts between the handrail sections and plat-
forms and tighten to the appropriate tightening torque.
4.2.12 Installing magnetic separator with support
WARNING!
Risk of crushing!
Serious crushing injuries are possible when the magnetic separator and
support are installed.
• Ensure that there are no persons in the hazard area when the magnetic
separator with support are being installed.
WARNING!
Risk of falling!
There is a risk of falling during installation and removal work on the plant
components.
• Use suitable climbing aids or lifting platforms.

• 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.

K0610202 / 4111004512
Commissioning
1
4
0002731
No. Designation
1 Securing screws
2 Support
3 Suspension
4 Magnetic separator
• Place support (2) with suitable lifting gear on the mountings on the chassis and install with se-
curing screws (1). Tighten securing screws to specified tightening torque.
• Install suitable lifting gear with sufficient load carrying capacity on magnetic separator (4).
• Install magnetic separator (4) with suspension (3) on the support (2).
• Ensure correct seating of suspension and magnetic separator in relation to the belt.
• Route and establish electrical connections at the suspension and through the support.
4.2.13 Installing crusher discharge conveyor
WARNING!
Risk of crushing!
Serious crushing injuries are possible when the feeding conveyor is in-
stalled.
• Ensure that there are no persons in the hazard area when the feeding
conveyor is being installed.

K0610202 / 4111004512
Commissioning
WARNING!
Risk of falling!
components.

1
4
0002732
No. Designation
1 Crusher discharge conveyor
2 Top connecting rod
3 Locking pin
4 Mounting
• Secure suitable lifting gear with a sufficient load carrying capacity to the crusher discharge con-
veyor. The crusher discharge conveyor weighs approx. 4750 kg.
• Move crusher discharge conveyor (1) into the mounting (4) on the chassis frame and secure it.
• Install top connecting rod (2) on left and right between support and crusher discharge conveyor
(1) with spring pin and secure with locking pin (3).
• Insert electrical connections and emergency-off in respective socket outlets on chassis.

K0610202 / 4111004512
Commissioning
Retain the locking connector for further use.

• Establish the water connection.
0000244 0000242
• Open ventilation (5) of belt conveyor drive.
4.2.14 Mounting the side discharge conveyor
WARNING!
Risk of injury in assembly area!
Persons in the assembly area of side discharge conveyor can sustain

crushing injuries.
Do not stand in danger zone when the side discharge conveyor is being
moved in.
0000207

K0610202 / 4111004512
Commissioning
• Remove feed hopper (1) if installed.
2
4
0002754
• Secure side discharge conveyor to the provided eyelets using suitable lifting gear and tackle.
• Move side discharge conveyor into mounting on chassis frame and secure (3).
• Insert support (2) in mounting (4) and secure it.
• Install support (2) with pin on belt.
• Install feed hopper (1).
0000244 0000242
• Open ventilation (5) of belt conveyor drive.

• Insert electrical connections and emergency-off in respective socket outlets on chassis.

K0610202 / 4111004512
Commissioning
4.3 Inspection
The following inspections and checks must be carried out after every transport and installation of the
machine.
CAUTION!
Danger due to foreign material in conveying devices!
Forgotten parts, e.g. tools or equipment, in conveyors may lead to dis--

ruptions and accidents.
=>After installation, check entire passage of material flow for foreign ma--
terials and remove them.
Main switch must be switched off during inspections.
4.3.1 Checks with machine stationary

Oil levels:
Diesel engine:
• Before the oil level is checked, the engine must be stationary for at least 5 minutes.
• For specified oil grades, refer to the instruction manual of the diesel generator.
Fuel level:
• The fuel gauge at the switch cabinet indicates the fuel level
• Top up fuel if necessary (see chapter "Operation")
Coolant level:
WARNING!
Danger of scalding
Hot steam and water can emerge when the coolant tank is opened and
cause scalding injuries.
=>Open the cover of the equalising tank slowly to allow pressure to be

released.

K0610202 / 4111004512
Commissioning
WARNING!
Danger of poisoning
Corrosion inhibitors and antifreezes are toxic.
=>Do not inhale coolant vapour or allow it to come into contact with food
supplies.
For specified coolant, refer to the instruction manual for the diesel generator.
Note:
• Fill only ready-mixed coolant, which is free of nitrite and has been approved by the manufac-
turer.
• When filling large volumes of coolant, never pour cold coolant into a warm engine because this
can cause cracks in the engine.
V-belt:
• Examine V-belt for:
- Cracks
- Offset position
- Tension
Spray system filling level (option):
The filling level of the spray system must be checked to prevent the pump from running dry.
• Check at suction hose whether the water is at the level of the pump.
• If the water is lower:
- Fill water tank
- Fill suction line
Conveyor belts:
• Check conveyor belts for damage
• Eliminate any damage that exists.
Safety devices:
• Check that protective covers and guard devices are present and that they are in perfect con-
dition and securely fitted.
Damage:
• Check the plant for damage and contamination.
- Repair damage.
- Eliminate contamination.

K0610202 / 4111004512
Commissioning
Retightening loose screws:

If loose screw connections are discovered, tighten them immediately.
Tightening torques for standard metric threads:
Dimension Maximum tightening torques MA in

Nm
8.8 10.9 12.9
M10 54 79 93
M12 93 137 160
M16 230 338 395
M20 464 661 773
M24 798 1136 1329
M30 1597 2274 2652
Maintenance openings:
All maintenance openings must be tightly sealed.
This applies, in particular, to
- doors and flaps at the screen

- service flap at belt conveyor discharge
- service flap at large belt guard
Vibrating screen:
A crude check of the oil level can be performed using the oil level hose. The hose is usually laid in
the form of a loop and consequently enables an oil column to be seen even if the bearing is already
empty.
• Ensure the machine is horizontal.

• Clean the oil hose
• Check oil level
• The oil column in the oil level hose must be significantly higher than the oil hose filling plug.
If this is not the case, check the exact oil level (see section “Maintenance”).
Screen covers:
- Check for wear
• Visual inspection of screen covers.
Note
Mesh cover: signs of wear on welded hard coatings, bent profiles

Rubber cover: thin sections, tears, holes

K0610202 / 4111004512
Commissioning
Mesh cover: signs of wear on welded hard coatings, bent profiles

Wire mesh: torn wires, holes, thin sections
• Replace the relevant cover if excessive wear is noted (see section “Maintenance”)
- Profile rubbers
• If the profile rubbers on the runners have slipped, move them back into their correct position
immediately.
• Replace any damaged or missing profile rubbers immediately to prevent damage to the screen
cover
Vibrating screen springs:
• Check that the vibrating screen springs are positioned correctly in the spring cups or on the
spring bolts
• If the spring is not positioned correctly, or is defective or is missing entirely, remedy the situa--
tion accordingly (see section “Maintenance”)
4.3.2 Test run without material

When carrying out a test run without material, all machines are switched on in succession against the
conveying direction. The correct functioning of each individual machine must be checked before
swit-ching on the next machine.
If an error occurs, the system must be switched off immediately and the error eliminated.
WARNING!
Risk of injury to persons in the system’s danger area.
Persons who linger in the danger area during operation may be injured.
=>Before switching the system on, make sure that no persons are loca-t-
ed in the system’s danger areas.
For information on the individual operating steps, please see the “Operation” chapter.
The performance of all test runs enables comprehensive checking of all important machine functions.
NOTE!
All emergency stop buttons must be released, otherwise it will not be

possible to start the system.

K0610202 / 4111004512
Commissioning
Test run 1:
1. Switch on generator.
2. Turn main switch in the direction of RESET and then to ON.
3. Activate key switch for "control voltage".
The operator panel OP3 powers up and "KLEEMANN GmbH" appears in the display.
4. Set the rotary switch "Automatic mode/manual mode" to automatic mode.
"Automatic mode" control lamp lights up.
5. Switch off rotary switch for radio remote control.
6. Press "Acknowledge fault / emergency off" pushbutton.
If no more emergency-stop or emergency-off buttons are pressed, the light in the button
goes out.
7. Press "Plant on" pushbutton.
The warning light and warning siren lights up or sounds for approx. 10 seconds.
The "Start release" control lamp lights up and the "Plant ON" button flashes.
8. Press "Plant on" pushbutton again.
The plant components run up automatically in the opposite direction to material flow. The
corresponding pushbuttons of the components light up.
9. Press the "Water pump" button as required. The water pump runs and the button lights up.
10.Check that the machines work in the correct manner.
11.Press emergency off on chassis.
12.Monitor the shutdown process.
Crusher switches off with delay; all other drives switch off immediately.
13.Unlock emergency off.
14.Switch off control voltage.
15.Switch off main switch.
16.Switch off generator.
4.3.3 "Repair" test run
DANGER!
Danger if personnel are not properly qualified!
Execution of "Manual mode" by unqualified and unauthorised personnel

can result in serious or fatal injuries.
• Only assign maintenance, repair and service tasks to personnel who

are qualified and authorised according to the requirements in this in-
struction manual.

K0610202 / 4111004512
Commissioning
CAUTION!
Inadvertently switching on the machine in manual mode could lead to in-
juries and/or material congestion.
Therefore, only use "manual" operating mode in exceptional circum-

stances and with due care and attention.
1. Switching on generator
4. Set the rotary switch "Automatic mode/manual mode" to manual mode.
The "Manual mode" control lamp lights up.
If no more emergency-stop or emergency-off buttons are pressed, the light in the button
goes out.
8. Press the buttons of the desired plant components.
The corresponding plant components run up and the button light up.

K0610202 / 4111004512
Operation
5 Operation
5.1 Safety informations
DANGER!
Failure to follow the safety instructions may lead to severe injuries and
also material damage which is not covered under warranty.
• Risk of fatal injury!

When the plant is running, there is the risk of getting caught and crushed between machines
which can lead to fatal injuries.
Work on the machine and unblocking of material jams should only take place when the unit is
switched off.
- Wait for crusher runout.
- Safeguard against restart of machine.
- Attach warning sign.
• Risk of injury to persons in the hazard area of machine.
Persons in the hazard area during operation of the machine may be injured.
=>Before switching on the machine, ensure no persons are in hazard areas of machine.
• The operator (machinist) accepts full responsibility with regard to the safety of persons who are
in the hazard area.
• Operation of machine only with personal protective equipment.
• All operating activities with the exception of "Move plant" must be carried out in "Automatic"
mode.
• After completion of work and during breaks, machine must be switched off and switch cabinet
(operator control panel) locked.
• Only persons familiar with the machine and those authorized to do so may operate the ma-
chi-ne.
• If personnel or the machine are in danger, immediately actuate the nearest emergency-off
switch.
• Switch cabinets and service doors must always be kept locked.
5.2 Switch-on
Switch-on involves two different consecutive stages. Switch-on of the generator and switch-on of the
complete system. The system can only be switched on when the generator is running. Sometimes it
may be necessary to operate the generator on its own for maintenance work.

K0610202 / 4111004512
Operation
5.2.1 Switching on generator
2 3 4
1 500
400
1000
600
800 1600
400
200
200
0 0
500
400
200
0002745
No. Description
1 Key switch for diesel generator
2 Select operating mode
3 Start diesel generator
4 Stop diesel generator
• Insert ignition key in the key switch (1) in position 0.

• Turn ignition to position I.
NOTE!
RUN operating mode must be selected prior to starting the diesel engine.
If necessary, use the two Mode buttons (2) to select the operating mode.
• Press the "Start diesel generator" (3).

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Operation
5.2.2 Switching on the plant
WARNING!
Risk of injury due to falling material!
Persons in hopper feeding area or discharge zones of belt conveyors are

at risk of injury due to falling material.
• Do not stand in hopper feeding area or discharge area of belt convey-

ors.
• Wear a protective helmet.
NOTE!
All emergency switching off pushbuttons must be unlocked. Otherwise,

the plant cannot be started.
Procedure
1. Switch on generator.
4. Set the rotary switch "Automatic mode/manual mode" to automatic mode.
If no more emergency stop or emergency off buttons have been pressed, the light in the
button goes out.
8. Press "Plant on" pushbutton again.
The plant components run up automatically in the opposite direction to material flow. The
corresponding pushbuttons of the components light up.
9. Press the "Water pump" button as required.
The water pump runs and the button lights up.
5.3 Switch-off
A distinction is also made between the system and the generator when switching off.

K0610202 / 4111004512
Operation
IMPORTANT!
The crusher must be run idle before switching off. Otherwise material
jams and blockages can result.
5.3.1 Switching off the plant

• Run the crusher until empty.
• Press "Plant off" pushbutton
- Switches off all drives in conveying direction
• Switch off control voltage
• Switch off plant using main switch
• Switch off generator
5.3.2 Switching off generator
2 3 4
1 500
400
1000
600
800 1600
400
200
200
0 0
500
400
200
0002745
IMPORTANT!
Engine should run for at least 4 minutes after shutdown without load
= Cool down function.

K0610202 / 4111004512
Operation
• Press the "Stop diesel generator" (4) button.

• Turn ignition key (1) to position 0.
• Remove ignition key.
5.4 Refuelling
WARNING!
Danger of fire!
Fuel can ignite during refuelling.
=>Smoking and open lights are prohibited during refuelling.
IMPORTANT!
Before the plant is refuelled, ensure that the dispensing system is cor--
rectly earth and plant potential equalisation has been created.
Correct potential equalisation exists if a continuous electrically conduc--

tive connection is present between all components of the dispensing
system and the plant to be fuelled.
Creating potential equalisation:
• Fit a connecting cable between dispensing system and chassis.

• Ensure that all components of the dispensing system have a continuous electrically conductive
connection.
Earthing dispensing system:
• Establish the earth connection between tank of dispensing system and the ground.
Refuelling the plant:
• Position the tanker or fuel tank as close as possible to the filler neck.
• If necessary, open housing of power supply unit on the side of the diesel fuel tank.
• Take off the end cover of the filler neck.
• Fill the plant's fuel tank.
• Close the filler neck again.
• If necessary, close housing of the power supply unit again.
• Remove connection of potential equalisation between dispensing system and chassis.
• Remove the earth connection between tank of dispensing system and the ground.

K0610202 / 4111004512
Operation
5.5 Moving the plant

It is possible to drive the plant at any time, also when the platforms are extended and the side dis-
charge conveyors are mounted.
CAUTION!
The articulated shaft of the screen drive and the magnetic separator may
incur damage.
• Before moving the plant, the transport securing devices must be

mounted on the magnetic separator and screen box.
WARNING!
Plant operation difficult to monitor!
Risk of fatal injury to persons in area of operation of the plant due to its
bulky dimensions.
• Move the plant only with reliable banksman.

• Maintain constant visual contact with banksman
CAUTION!
Chains may seize up or freeze and break.
• Move the plant at least 10 m (33 ft) in each direction every day to avoid
chains from seizing.
• Never drive plant with chains that are seized up or frozen.

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Important information for driving on inclines and gradients:
NOTE!
During operation and for larger inclines or gradients, a minimum tank of
approx. 300 l (80 gal) is required so the engine does not stall.
Upward gradients: Drive lower Downward gradients: Drive low
Designation Value
Maximum climbing ability forward/back 20 %
Maximum permissible lateral inclination 0%
Maximum driving speed 1.2 km/h
1
Max. generated ground pressure 2.35 kg/ cm3 (without options)
1
The maximum generated ground pressure is calculated according to the following formula: Max.
total weight of the plant / distance between centres x track shoe width x 2.
5.5.1 Conditions
• Run belt conveyor empty.
• Remove earthing.
• The running gear must be kept clean (no dirt and stones between rotors and rollers)
-> Danger of chain breaking
-> Remove material caking
• The running gear must have ease of movement.
Never drive with seized up or frozen chains.
• The chain must be tensioned.

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Operation
NOTE!
Ensure ground clearance for the plant!
• The track must be clear and free of obstacles.

• The subsurface must be stable (note weight).
• The banksman must be assertive.
• Driving uphill preferably with the rotor in front, downhill with the drive wheel in front.
5.5.2 Driving
CAUTION!
The chain may slip from the drive wheel or sprocket when driving or
turning the plant.
The slipping of the chain reduces the service life of the chain and may
lead to the malfunction of the gearbox and the hydraulic drive system.
• Only operate when the chain is tensioned. Readjust the tension of the
chain if necessary.
• Note the direction of movement when driving on slopes.
NOTE!
Before driving the plant, the supporting elements must be retracted. The
retracted supporting elements actuate a position switch, which releases
the plant's movement.
Driving with wired remote control

• Switch off rotary switch for radio remote control and ensure that the emergency stop of the
wired remote control is unlocked.
• Switch on generator.
• Turn main switch in the direction of RESET and then to ON.
• Activate key switch for "control voltage".

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Operation
• Set the rotary switch "Automatic mode/manual mode" to manual mode.

• Press "Acknowledge fault / emergency off" pushbutton.
If no more emergency stop or emergency off buttons have been pressed, the light in the button
goes out.
• Press "Plant on" pushbutton.
• Press "Hydraulics ON" pushbutton.
• If necessary, turn rotary switch for "supports" to "retract".
• Press "Plant on" button.
- Plant starts up; wait until the plant has run up completely.
• Press "Coupling" pushbutton.
• Insert wired remote control into socket outlet in the switch cabinet housing.
• Moving
The crawlers are set in motion using the two levers of the radio remote control. The left lever
is for the left crawler, the right lever for the right crawler. The crawlers always move in the di-
rection in which the lever is moved. The speed is proportional to the movement of the levers.
Moving using the radio remote control
• Switch on rotary switch for radio remote control and ensure that the emergency stop of the ra-
dio remote control is unlocked.
• Switch on radio remote control.
- Activate rotary knob on the side.
• Switch on generator.
• Set the rotary switch "Automatic mode/manual mode" to manual mode.
goes out.
• Press "Hydraulics ON" pushbutton.
• If necessary, turn rotary switch for "supports" to "retract".
• Press "Coupling" pushbutton.
• Switch on rotary switch for radio remote control and ensure that the emergency stop of the ra-
dio remote control is unlocked.
• Driving
The crawlers are set in motion using the two levers of the radio control. The left lever is for the

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Operation
left crawler, the right lever for the right crawler. The crawler always moves in the direction in
which the lever is moved. The speed is proportional to the deflection of the levers.
5.5.3 Shutting down the plant
NOTE!
Increased wear
The plant can only operate correctly on flat ground. Inclinations 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.

• If necessary, use a spirit level for alignment.
• Stop the plant on a flat and stable surface.

• Switch off the radio remote control or disconnect the wired remote control.
• If necessary, switch off the rotary switch "Radio remote control".
• Set the rotary switch "Automatic mode/manual mode" back to automatic mode.
• The plant is ready again for operation.
5.6 Crushing
Important information for plant operator!
DANGER!
Failure to follow the above-mentioned safety instructions may lead to se-
vere injuries and also material damage which is not covered under war-
ranty.
• Risk of fatal injury by flying stones!

During loading there is the risk of flying rocks in area of feed hopper.
Ensure no persons are in the hazard area.
There is a risk of fatal injury when eliminating material congestion in the crusher when it is run-
ning.
- Never unblock material congestion using hands or other objects while the crusher is running.
- For removal of material congestion with the crusher running, see chapter Removing material
congestion. Operation of the rock chisel does not represent normal plant operation.
- Do not enter vibrating screen or mount vibrating conveyor trough outlet.
- Never open service doors when the crusher is running.

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Operation
• Risk of injury due to incorrect gap setting!

In the event of overload, gap settings lose their accuracy.
Standing in the area of the gap setting is prohibited.
• Destruction of drive system or control elements.
Never run the crusher drive against a blocked crusher.
Before starting the crusher, always check that the crushing chamber is empty. Empty the
crushing chamber if there is material in it.
• Material congestion and blockages!
In order to avoid material congestion, only load material in specified feed sizes.
• Risk of destruction of loading devices!
Never use diggers or loading shovels to remove bridging (blockages) in area of material feed.
• Danger of destruction of the frequency converter!
After the vibrating feeder is shut down following overload, NEVER cut in the vibrating feeder
prematurely via the operator panel or by radio remote control.
The vibrating feeder must only be cut in after complete standstill.
• Load vibrating feeder so a material bed constantly remains on trough floor. Constant loading
of the vibrating feeder when empty leads to deformations on the feeder floor and to premature
failure of the drive units.
• Material damage!
Incorrect loading or setting of the vibrating feeder leads to continuous activation and deactiva-
tion of the trough. This faulty operation could lead to destruction of the frequency converter and
/ or vibration motors. Adjust the vibrating feeder and material quantity with frequency converter
in such a way that the automatic shut-off is only actuated in extreme circumstances (maximum
10 times per hour allowed).
NOTE!
If the range of the radio remote control is exceeded, the emergency stop
is tripped and material congestion in the plant can result.
• During plant operation, ensure that the range of the radio remote con--
trol is never exceeded.
• Never carry the radio remote control along in the wheel loader or dig--
ger and thus leave the range.
• Always ensure there is visual contact between transmitter and recei-v-
er.
• Store the radio remote control in the plant's switch cabinet when not in
use.

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Operation
5.7 Starting the crusher process

WARNING!
Risk of injury!
Before starting the system, make sure that no persons in the vicinity can
be put at risk. Warn all persons in the vicinity before starting up the
system.
CAUTION!
Damage to the drive and control elements.
Never start the crusher drive when the crusher is jammed.
Before starting the crusher, always check that the crushing chamber is
empty. If it contains material, empty it.
• Ensure that all emergency-stop and emergency-off buttons are unlocked.

• Switch on radio remote control.
• Activate the radio remote control with the rotary switch at the operator panel.
• Set the rotary switch "Automatic mode/manual mode" to automatic mode.
• Switch the diesel generator on.
goes out.
• Press "Plant on" pushbutton again.
The plant components run up automatically in the opposite direction to material flow. The cor-
responding pushbuttons of the components light up.
• Observe the correct and proper functioning of the machine.
• Feed material.
• Crush.

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Operation
5.8 Charging
WARNING!
Incorrect charging can result in blockages or overfilling of the crusher!

Incorrect elimination of such faults can result in fatal injury.
• Never eliminate blockages when the crusher is running.

• Always maintain a safe distance from the machine, so that there is no
danger from the feed material.
• Lingering in the area of the crushing jaw during operation is strictly
forbidden.
• Never reach into the running crusher with bars or the like.
CAUTION!
Damage to the feed unit!
Constantly overfilling the crusher can result in premature wear or dam-

a-ge to feed units (inlet chamber, screen or chute).
• Ensure uniform feeding of the material to be crushed
The prerequisites for fault-free operation and optimal performance of the crusher are
• Uniform feeding of the material to be crushed

(crushing jaw ½ to ¾ full)
0000035
• Feed material must be smaller than the crushing jaw

(over-large pieces will result in jams and damage to the crusher).

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Operation
0000036
• Ratio of feed material to end particle should be max. 7:1
0000037
5.8.1 Eliminating material congestions

5.8.1.1 Eliminating material congestions
WARNING!
Danger from material congestion
Intervention in the running plant, in particular, in the running or coasting

crusher, can result in serious or fatal injury.
• Never loosen obstructions by hand with the crusher running.

• Do not climb on vibrating conveyor troughs and screens that are run-
ning.
• Never open service doors and flaps when the plant is running.
• Allow the crusher to coast to a complete standstill.
• Switch off the plant, remove the key and secure against reactivation.
• Attach appropriate warning sign in a clearly visible area.
• Wear personal protective equipment.
• Observe the Safety Instructions.

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Operation
Material congestions can have different causes:
• Settings that do not match the plant, for e.g. delivery speed of vibrating feeder is too high.
• Crusher 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 reinforcing steel.
Material congestions can occur at different points of the material flow:
• At the crusher inlet due to blockages before the crushing jaw.

• Crusher standstill through jamming of unbreakable material between the crusher jaws.
• At the crusher outlet through accumulation of broken material on the crusher discharge con-
veyor or discharge chute.
• Blockages or jams at all other material transfer points due to bulky material.
Preparations
Before starting to clear material congestion at a blocked or stationary crusher, it is essential to carry
out the following steps:
• Allow the crusher to coast to a complete standstill.

• Switch off all plant components.
• Switch off main switch.
• Switch off diesel generator and control voltage. Remove key and carry it with you.
• Attach appropriate warning sign in a clearly visible area.
• Warn other persons before starting work on the plant.
• Lay out suitable tools.
Eliminating material congestions
Material congestion always differs depending on the situation. The following listed items describe
possible procedures and information on avoiding hazards:
• Never eliminate material congestions in the crusher by yourself.

• First remove bulky or oversized material on the feeding side with the digger shovel or bucket
so that no follow-up material can slide into the crusher.
• Completely open the crushing gap of the crusher to allow material to pass the crusher.
• If necessary, open the crushing gap by turning the drive in the opposite direction to release the
material. Only switch the drive of the crusher to reverse when stationary.
• 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

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Operation
gear.
• Note that stones, unbreakable material and, in particular, reinforcing steel in a stationary crush-
er can accumulate a considerable 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 the 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 shovels or high-pressure water jets.
• Use suitable tools, such as crowbars, pickaxes or shovels, to loosen and remove material con-
gestions at vibrating conveyor trough, screens and belt conveyors. Never attempt to clear ma-
terial congestion in the area of the feeding unit and in the 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 the crusher.
Final tasks
After elimination of material congestion, the following final tasks must be carried out:
NOTE!
Material damage!
Starting up the crusher drive against a blocked crusher can destroy 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
otherwise result in damage to downstream components.
• Reinstall disassembled guard devices and components, ensuring they are correctly fitted.
• Ensure that there are no more persons in the hazard area.

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5.8.1.2 Removing material congestion with crusher running
WARNING!
Danger from material congestion
Intervention in the running plant, in particular, in the running or coasting

crusher, can result in serious or fatal injury.
• Never loosen obstructions by hand with the crusher running.

• Do not climb on vibrating conveyor troughs and screens that are run-
ning.
• Never open service doors and flaps when the plant is running.
• Use the (optional) rock chisel to remove obstructions.
• Wear safety rope and attach to the rock chisel platform.
• Observe the Safety Instructions.
Material congestions can have different causes:
• Settings that do not match the plant, for e.g. delivery speed of vibrating feeder is too high.
• Crusher 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 reinforcing steel.
Material congestions can occur at different points of the material flow:
• At the crusher inlet due to blockages before the crushing jaw.

• Crusher standstill through jamming of unbreakable material between the crusher jaws.
• At the crusher outlet through accumulation of broken material on the crusher discharge con-
veyor or discharge chute.
• Blockages or jams at all other material transfer points due to bulky material.
Preparations
Before starting to clear material congestion at a blocked running crusher, it is essential to carry out
the following steps:
• Switch on rock chisel button (material flow to crusher is interrupted).

• Warn other persons before starting work on the plant.
• Wear safety rope and secure it to the platforms. Move to working position on the rock chisel

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Operation
platform.
Eliminating material congestions
Material congestion always differs depending on the situation. The following listed items describe
possible procedures and information on avoiding hazards:
• Never eliminate material congestions in the crusher by yourself.

• Crush the oversized and bulky material in the crusher with hydraulic or electric rock chisels.
• Note that stones, unbreakable material and, in particular, reinforcing steel can accumulate a
considerable 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 the crusher.
• Always clear material congestion from top to bottom to avoid the danger of follow-up material
slipping and material falling.
• Material that falls into the running crusher can be ejected in all directions. Extreme caution is
required.
• Never use flame cutters to cut out material or components. Stored energy in the material can
result in unexpected movements of the material and the crusher.
Final tasks
After elimination of material congestion, the following final tasks must be carried out:
• Move rock chisel to parked position.

• Ensure that there are no more persons in the hazard area.
• Switch off the rock chisel button again (material flow to the crusher starts up again).
5.8.1.3
5.8.2 Clearing stockpiles

The height and volume of the stockpiles must be monitored. The stockpile must not extend as far as
the system. The distance between stockpile and conveyor belt must be at least 250 mm (0.82 ft.
If wheel loaders are used for clearing, take care not to damage the system.
5.8.3 Recycling
Demolition materials, concrete, asphalt etc. must be thoroughly prepared before charging.
• Metal objects must be removed before they reach the crusher.

• Cut concrete reinforcements to a length of < 1m (3 ft).
Over-long reinforcements can cause damage to the crusher or the conveying devices.
The most effective mode of operation consists in preparation of the feed material.

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Operation
5.8.4 Winter operation
NOTE!
In the event of frost there is a risk of seals and scrapers freezing.
Before switching the system on, always check the free movement of
scrapers and seals that come into contact with moving parts.
IMPORTANT!
Check antifreeze and cooling water in the motor.
5.9 Adjustment / Set-up

This chapter describes basic adjustments and settings that enable you to achieve the desired crus-h-
ing performance and crushing result.
5.9.1 Checking gap width (crusher)
DANGER!
There is a risk of the operator becoming trapped and suffering fatal inju-
ry upon start-up and during operation of the crusher.
• Never climb under a running crusher.

• Wait until crusher coasts to a standstill (observe coastdown period of
approx. 3-4 mins.)
• Safeguard crusher against restart (lock main switch).
• Attach warning sign.
The setting of the crushing gap has an essential influence on the crushing capacity and grain size
produced by the crusher.
.

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1
0000038
The crushing gap (1) is measured between tooth root and tooth tip.
Min. and max. gap setting (close side setting)

Crusher type Crusher jaw [mm] / [in] Gap width [mm] / [in]
StR 400 x 265 400 mm x 265 mm (15.7 in x 10.4 in) 15-50 mm (0.6-2.0 in)
StR 1000 x 630 1000 mm x 630 mm (39.4 in x 24.8 in 50-100 mm (2.0-3.9 in)
StR 1600 x 1250 1600 mm x 1130 mm (63.0 in x 49.2 in) 200-350 mm (7.9-13.8)

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Operation
CAUTION!
Material damage!
Nonobservance of the specified gap dimension can lead to increased

wear or damage to the crusher, which is no longer covered by the war-
ranty!
• Observe the specified gap dimension in all circumstances.
5.9.2 Adjusting the gap width (crusher)
CAUTION!
Setting the gap width when the crusher is charged may damage the gap
adjustment device.
• Only set the gap width when the crusher is empty.
The crushing gap is altered by inserting or removing spacer plates.
0002012
• Release locknuts (1) on pull rods and back them off.

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Operation
3
2
0000247
0000921
• Remove screws (3) from pressure plate locking device on both sides.
• Start system in manual mode and press "hydraulics" button.
• Push rocker forward with help of valve block of crushing gap adjustment (5) until gap at pres-
sure plate bearing (4) is sufficient to insert or remove shims (2).
• Insert or remove the desired number of spacer plates (2).
• Push the spacer plates in far enough in until locating hole is flush with bore in pressure plate
bearing.
• Remove screws (3) from both sides of pressure plate locking device.
• If necessary, remove or insert spacer plates so that the nuts of the pressure plate locking de-
vice can subsequently be screwed on safely.
• Retract rocker with aid of valve block of crushing gap adjustment (5).
• Screw locknuts (1) onto pull rods and tighten.

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Operation
CAUTION!
If hydraulic cylinder is not fully retracted, damage may result at crusher

gap adjustment.
• Always fully retract hydraulic cylinder after changing spacer plates or

pressure plate.
5.9.3 Controllable vibrating feeder
0002733
No. Description
1 Ultrasonic probe
An ultrasonic probe 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 vibrating feeder. When the crushing jaw is free
again, material feed is switched on again without delay.
Regulation can be switched on or off via the button "Rotary switch for crusher inlet fill level monitor"
on the operator panel.

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5.10 Water pump

CAUTION!
Operation without water and operation with contaminated or frozen wa-

ter 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 system.
2
6
0002687
No. Designation
1 Pump housing
2 Plug screw for filling opening
3 230 V socket
4 Shut-off cocks
5 Connection for supply mode
6 Connection for suction mode
Suction mode
When the water pump is in suction mode (e.g. suction from water tank), the following items must be

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Operation
observed:
- The tank and the water must be clean.

- Suction line no more than 5 m (16 ft) in length.
- Fill water pump with water before bringing into operation.
- Water must only be supplied to the water pump via an on-site filter.
Operation
• Connect water pump to 230 V socket in water pump cabinet.
• Switch on the plant.
• Open or close the corresponding shut-off cocks of the supply lines to the spraying nozzles.
• Press the "Water pump" button on the operator panel.
Operating via existing water mains
Maximum pressure of water mains: 4 bar (58 psi).
• Connect the existing water mains to the supply mode connection.

• Open shut-off cock on supply line.
• Open or close the corresponding shut-off cocks of the supply lines to the spraying nozzles.
5.11 Switch cabinet overpressure system
0002307
The overpressure system builds up overpressure in the switch cabinet. This prevents dust from pen-
etrating the switch cabinet. The overpressure system only functions if there are no leaks.
• Keep the switch cabinet properly closed during operation.

• Regularly check air hoses for damage and replace them if necessary.
• Clean air filter at least once a week and more frequently if necessary.

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5.12 Fuel supply for hand delivery pump
0002734
No. Designation
1 Vent hand pump with fuel filter with and water separator
2 Manual knob
A hand delivery pump is installed for venting the fuel system.
• Unscrew manual knob (2).

• Pump diesel fuel with the manual knob into the fuel system until pressure is built up.
• Close manual knob and tighten.
• Visually inspect fuel filter and water separator on a regular basis and clean if necessary.

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Maintenance
6 Maintenance
WARNING!
Only carry out repair work or maintenance work when machine is turned
off!
• Safeguard against unauthorised start-up of machine:

• Lock switch cabinet
• Switch off and lock main switch.
• Attach warning sign against restart.
NOTE!
Those responsible must ensure that during maintenance work, machine
is inoperative and they must safeguard the machine against its unau--
thorised restart.
IMPORTANT!
Ensure that all work is carried out with the utmost cleanliness.
Throttle valves and pressure relief valves set by Kleemann GmbH may only be changed by personnel
trained by Kleemann. It is forbidden to remove seals from safety valves.
Work on the crushing machine or hydraulics system must only be carried out when the machine has
been switched off.

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Maintenance
6.2 Maintenance schedule

Maintenance work First time Interval Interval At least
Time h
Chassis/guard devices
Signs check/re- daily
place
Protective housing for power supply unit check/lu- 50 h monthly 200 h
bricate
Platforms check daily
Screw connections retighten as required
Lubricating nipple check/re- as required
place
Warning devices check daily
Guard devices check daily
Emergency stop check/re- daily
pair
Operator's stand
Panelling check/re- monthly 200
pair
Remote controls, components check/re- weekly 50 h
pair
Emergency stop and functions check/re- daily
pair
Lamp test perform daily
Power supply unit/engine

See manufacturer's documentation
Diesel engine service/re- after initial
pair operation
Generator service/re-
pair
Cyclone prefilter check weekly 50 h
Air filter clean/re- weekly/dai- 50h/8h in
place ly in the the event
event of of high lev-
high levels els of dust
of dust

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Maintenance

Time h
Cooler fins clean weekly/dai- 50h/8h in
ly in the the event
event of of high lev-
high levels els of dust
of dust
Engine oil change 500 h
Fuel filter clean 500 h
Hydraulic oil supply

Hydraulic components, leak check (observe check/re- after initial daily 1000h/
checking and replacement intervals of hy- pair operation 2000h
draulic hoses!)
Hydraulic oil tank, fill level check/refill daily
change oil/ 500 h yearly 2000 h
carry out oil
Hydraulic oil analysis
change 500 1000 h
Ventilation filter
Filler neck for coarse strainer clean 1000 h
Suction filter change 500 1000 h
Return filter change 500 1000 h
Electrical system
Electrical components check/re- 50 h daily
pair
Starter batteries check/refill 500 h
Degassing opening screw caps clean 200 h
Switch cabinet clean as required
check/re- 50h/as re-
Cables, sockets, control elements and indica- pair quired
tors
replace yearly 2000 h
Switch cabinet doors rubber seal check/ad- 500 h
just
Switch cabinet mounting
Earth fault circuit interrupters check daily

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Maintenance

Time h
Electric motors, terminal boxes check/re- 500 h
pair
Over pressure system function, components check/re- daily
pair
clean/re- weekly 50 h
place
Dust filter
Drive system
Crawler carrier chains check/ten- as required
sion
Base plates, track rollers check/re- monthly 200 h
pair
Planetary gear, leak-tightness check weekly 50 h
check yearly 2000 h
Filling level
Gear oil change 500 h once a 2000 h
year/at
least every
2 years
check/re- daily
Components pair
Conveyor unit
Belt conveyor
Conveyor belts check/re- daily
pair
Scraper check/re- daily
pair
adjust as required
Guide rails check/re- daily
pair
adjust as required
Belt conveyor, bevel helical gearbox filling check/refill 1000 h
level change 500 h once a 2000 h
year/at
Gear oil least every
2 years

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Maintenance

Time h
Plummer block check/lu- weekly 50 h
bricate/re-
pair
Grease change for plummer block perform once a 2000 h
year/at
least every
2 years
Chutes
Chutes check/re- monthly 200 h
pair
Water system
Water pump, leak-tightness check/re- daily
pair
Spraying nozzles check/re- daily
pair
Tools/accessories
Tools and accessories check/re- daily
Jaw crusher special tools place
Jaw crusher
Lubricating the bearings 50 h
Lubricate the labyrinths 50 h
Check the v-belt and tension if necessary 50 h monthly
Listen to bearings, check temperature daily
Check attachment of crusher jaws and lateral Initial oper- as required
wedges ation
Check wear of crusher jaws daily
Checking crusher security Initial oper-
ation
Vibrating screen
Check screen surfaces (wear and tear + ten- daily
sion)
Listen to bearings, check temperature daily

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Maintenance

Time h
Lubricate screen (grease) 50 h
Retighten screws on articulated joint shaft 50 h yearly
Lubricate articulated joint shaft 50 h
Retighten screws on screen bearing 50 h yearly
Check rocker width Initial oper- monthly
ation
Vibrating conveyor troughs

Check terminal boxes for leaks 100 h
Check security of vibration motors 50 h 500 h
Visually inspect vibration motors and check 500 h
function
Check rocker width Initial oper- monthly
ation
Magnetic separator
See separate instructions
6.3 Fluids and lubricants

A completely 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 particular, into consideration.
The fluids and lubricants table is designed to provide initial orientation for servicing KLEEMANN
plants and machines. However, it does not replace the advice of a lubrication specialist or the recom--
mendation 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.

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Maintenance
NOTE!
We shall only assume liability for our plants and machines if the listed
fluids and lubricants, or their verifiable equivalents, have been used!
6.3.1 Lubricants
6.3.1.1 Power supply unit/engine
The fluids and lubricants to be used in the diesel engine are described in the manufacturer's docu--
mentation.
6.3.1.2 Plant hydraulic oil supply
Fluid/lubricant Specifications Brand Product
Plant hydraulic oil Bio hydraulic oil ISO- Wirtgen Group Bio hydraulic oil VG
VG 46 with EP addi- 46
tives*
Type HVLP
HEES ISO 15380
NOTE!
EP additives (extreme-pressure additives) are added to lubricants and
improve their tribological characteristics, i.e. they prevent the fusing of
two metallic materials that rub against each other.

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6.3.1.3 Jaw and impact crusher
Operating material Specifications Brand Product
Crusher grease Lubricating grease Wirtgen Group Multipurpose

with EP additives Grease
(lithium saponified)
ISO 6743-9: L-XB--
CEB 2
DIN 51825: KP2K-25
ISO NLGI 2
NOTE!
6.3.1.4 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 Wirtgen Group Multipurpose

ISO 6743-9: L-XB--
CEB 2
DIN 51825: KP2K-25
ISO NLGI 2
NOTE!

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Maintenance
6.3.1.5 Drive system
Gear oil for track drive SAE 75W-90 with EP Wirtgen Group Special Gear Oil
additives 75W-90
API MT-1
API GL-4, GL-5
Chain tensioner grease Lubricating grease Wirtgen Group Multipurpose

ISO 6743-9: L-XB--
CEB 2
DIN 51825: KP2K-25
ISO NLGI 2
NOTE!
6.3.2 Diesel fuels

At low temperature, paraffin separations can cause obstruction in the fuel supply resulting in malfun-c-
tions.
Below outside temperatures 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 adding petroleum. A maximum of 20% can be added.
When refuelling, the petroleum must be filled first so that it mixes with the diesel fuel.

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Maintenance
CAUTION!
Danger of engine damage!
The addition of petroleum to diesel fuels (winter diesel fuel) already

ad-apted to low outside temperatures can result in engine 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 number) at least 51
Flash point 56 °C
Complies with standard EN 590 ASTM D 975 Grade No. 1-D

and 2-D
IMPORTANT!
It is essential also to note and observe the specifications in the manufac--

turer's documentation.

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Maintenance
6.4 General maintenance work

6.4.1 Checking emergency-stop devices
6.4.1.1 Emergency-stop button and release cord
WARNING!
The immediate deactivation of all plant drives via the emergency-stop

devices can result in material congestion.
• Only actuate the emergency-stop button and release cord 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 seconds and then
is shut down. The diesel generator continues running.
• Release the emergency-stop button and repeat the procedure with all emergency-stop buttons
and release cords on the plant.
• Check free accessibility of plant emergency-stop buttons and release cords.
• If there is a malfunction, find the cause and eliminate it.
6.4.1.2 Emergency-off button

WARNING!
The immediate deactivation of the diesel generator by the emergency
switching off button can cause material congestions.
• Only actuate the emergency switching off button if the plant has run
empty.
• 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 die-
sel generator, are shut down immediately.
• Release the emergency switching off button.
• Switch on the plant once again in automatic mode.
• Check emergency-off buttons of the radio remote control and wired remote control. All drives,
including the diesel generator, are shut down immediately.
• Release the emergency switching off button.
• If there is a malfunction, find the cause and eliminate it.

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Maintenance
6.4.2 Retightening screw connections

If loose screw connections are identified during inspection and maintenance work or during the ma--
chine's operation, they must be retightened immediately. See table for tightening torques.
In addition, after certain maintenance and repair work the respective screws must be retightened after
a specific service life. The details can be found in the specifications.
Tightening torques for standard metric threads

Nm
8.8 10.9 12.9
M10 54 79 93
M12 93 137 160
M16 230 338 395
M20 464 661 773
M24 798 1136 1329
M30 1597 2274 2652
6.4.3 Checking hydraulic system for leaks
DANGER!
Danger of serious bodily injury!
Hydraulic fluid is highly pressurised. When working on the hydraulic

system, hydraulic oil ejected at high speeds can cause very serious eye
and other injuries.
• Only retighten screw-couplings and connections in the depressurised

state.
• Switch off plant components and the diesel generator.

• Depressurise the hydraulic system.
• Check all hydraulic lines and hoses, hydraulic cylinders, hydraulic 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.
• Remove dirt and dust from ventilation filter on a regular basis to prevent clogging.

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Maintenance
CAUTION!
Danger due to aged hydraulic hoses!
Replace hydraulic hoses after six years usage at the latest, including a
storage time of a maximum of two years.
Recommended replacement intervals
• At least every 6 years under normal load.

•Under increased loads (longer operating times, e.g. multi-shift operation, or when subject to
special external influences, e.g. climatic conditions), at least every 2 years.
Recommended checking intervals
• At least every 12 months under normal load.

• Every 6 months under increased loads.
6.4.4 Testing the electrical indicator lights

Testing the indicator lights is necessary to guarantee reliable verification of the machine’s operating
state. Defective lamps can cause false assumptions, resulting in considerable danger.
6.4.5 Wear lining

Regular inspections for fastening, abrasion and cleanliness.
Wear lining must be inspected weekly and replaced if worn.
NOTE!
When new wear plates are installed, they should be retightened after ap-
prox. 1 day.
6.5 Vibrating conveyor chutes

6.5.1 Terminal box (electric motor)
Loose terminal box covers and cable entries can result in contact problems and short-circuits due to
the penetration of water. Parts must be regularly checked for firm positioning and leaks.

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Maintenance
0000099
6.5.2 Checking the rubber buffers
0000105
WARNING!
Danger due to defective rubber buffers!
Check the rubber buffers for damage regularly.
Replace defective rubber buffers immediately.
6.5.3 Checking security of vibration motors

The securing screws (1) of the vibration motors must be checked on a rotational basis because these
screws are subject to high alternating loads and can therefore work loose. The transmission of vibra-
tional forces is no longer guaranteed if screw connections are loosened and premature destruction
of the vibration motors is likely.

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Maintenance
1
1
0001807
• Switch off system and lock main switch.

• Retighten all fastening screws (1) using a torque wrench.

Nm
8.8 10.9 12.9
M10 54 79 93
M12 93 137 160
M16 230 338 395
M20 464 661 773
M24 798 1136 1329
M30 1597 2274 2652
DANGER!
Risk of fatal injury from ejected parts!
Material could be ejected in an uncontrolled manner in all directions

from unguarded vibration motors.
Only operate plant system with protective covers.

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Maintenance
CAUTION!
Risk of material damage from water ingress or dust!
Unguarded vibration motors could fail prematurely. Bearing damage and

short circuits in the winding can be caused by water or dust.
• Only operate plant system with protective covers.

• Replace protective covers without delay if they are found to be defec-
tive.
6.6 Vibrating screen

6.6.1 Check screen surfaces (wear and tear + tension)
NOTE!
Screen surfaces are specially adapted to customer requirements and are

thus special parts. Please order these parts in good time (delivery time).
Wear and tear inspection:

Wear and tear of screen surfaces can only be recognised by visual inspection. To do this, the surfac-
es must be examined for the following:
Slotted grate: Signs of wear and tear of welded-on hard layers, twisted profiles.
Screen cover: Thin areas, cracks, holes.
Wire cloth: Torn off wires, holes, thin areas.
• In the case of severe wear and tear, replace the respective surface.

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Maintenance
Checking for tension:
WARNING!
Risk of fatal injury caused by moving and rotating machine parts!
When inspecting machine during its operation there is a high accident

risk caused by getting caught and entangled.
• Inspections must only be carried out by qualified and competent per-

sons.
• Only approach machine if machine poses no hazard.
The screen tension is best checked by listening.
Important
• The screen surface must be fitted neatly over the entire area of the screen frame.
• Ensure screen is run completely empty so that any interfering noise is kept to a minimum.
Listen for the following noises:
Slotted grate: Rattling of screws or the entire screen surface.

Screen cover: Knocking of the cover.
Wire cloth: Rattling of the screen surface.
Screen surfaces and securing screws can also be tested for security by knocking. However, it is im-
perative that this is carried out when the machine is stationary.
0002307
The screen surface is bolted with clamping plates (2) and hexagon screws (1) onto the distance

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Maintenance
frame.
6.6.2 Lubricating vibrating screen (grease)

The bearing lining is lubricated via the lubrication nipples on the left and right above the mounting of
the screen.
0002245
Bearing lining
• Use a grease gun to press 35 g of grease with the appropriate specifications into the lubrication
nipples (1) of the bearings.
6.6.3 Lubricating vibrating screen articulated shaft

The articulated shaft is lubricated using a grease gun. To ensure that the sliding profile is relubricated
correctly, the articulated shaft must be pushed together completely.
1 3
0002735

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Maintenance
No. Description
1 Protective cover
2 Bearing lubrication nipple
3 Sliding profile lubrication nipple
4 Securing screws
• Switch off the plant. Switch off control voltage, remove key and carry it with you.
• Disassemble protective cover (1).
• Remove the articulated shaft from the electric motor.
• Push the articulated shaft together completely.
• Use a grease gun to press grease into the lubrication nipples of the sliding profile (3).
• Mount the articulated shaft back on the electric motor. Tighten the securing screws (4) to the
specified tightening torque.
• Use a grease gun to press grease into the lubrication nipples of the bearing (2) until grease
emerges from the joints.
• Reinstall protective cover (1).
• Lubrication interval: 50 h
6.7 Jaw crusher

6.7.1 Lubricating the bearings
WARNING!
Risk of fatal injury caused by moving and rotating machine parts!
• Only lubricate bearings when the plant is at a standstill and safeguar-d-

ed against unauthorised restart.
The crusher is equipped with spherical roller bearings which are designed for grease lubrication. La-b-
yrinth seals are fitted to protect against contamination. but they only function properly if sufficient
grease is applied!

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Maintenance
NOTE!
1 stroke = approx. 2 g (0.07 oz) grease
0000101
2 1 22 1 1 22 1 2
0000923
Item Designation Interval Amt. of grease per lubricating area

1 Bearings 50 h 30 gramme (1.41 oz)
2 Labyrinth 50 h 40_gramme/Until grease emerges at laby--
rinths

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Maintenance
0000922
NOTE!
The bearings and labyrinths of the jaw crusher are lubricated using a
central scratch pad (3), which is attached on the rear side of the crusher
frame.
It is possible that after lubrication bearings become very hot.

This has no negative effect on bearings.
Please note that the temperature of the bearings drops again to roughly
50 °C (122 °F) no later than 8 hours afterwards.
If the abnormally high bearing temperature has not dropped after this pe--
riod, there is probably a fault in the bearing.
6.7.2 Checking the V-belts

Checks
• Check the V-belts for:
- Cracks
- Twisting (mainly on the large V-belt pulley)
- Tension
• If a V-belt is twisted, return it to the correct position
• Replace worn V-belts (see chapter “Changing the V-belts”)
• If the V-belt is too loosely or too strongly tensioned, adjust the tension
(see chapter “Tensioning the V-belts”)
6.7.3 Tensioning the V-belts

The V-belt tension is adjusted by adjusting the tensioning spindle. The V-belts must not vibrate when

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Maintenance
the crusher is in no-load operation. If vibrations occur, then the belts are too loose and must be re--
tensioned.
Please note
NOTE!
A newly mounted V-belt must be retensioned after 50 operating hours on

account of elongation.
• Avoid excessively loose belts

=> Belts can jump out of the belt pulley
• Also avoid excessively high belt tension
=> Increased bearing load, greater belt wear
Tensioning
0000390
• Switch the system off and wait for the crusher to coast down
• Lock main switch
• Loosen mounting screws (1)
• Loosen lock nut (2)
• Turn clamping nut (3) forward or back to tension or slacken the belt
• Check the belt tension
• Tighten the lock nut (2)
• Tighten mounting screws (1)

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Maintenance
6.7.4 Listening to bearing, checking its temperature

Unusual bearing noises or too high a temperature may indicate possible defect.
Checks must be carried out on both bearings at operating temperature of machine.
To recognise unusual bearing noises requires much experience due to high ambient noise level.
CAUTION!
Danger of burns!
Bearings can heat up intensely. Physical contact with bearings may lead
to burns.
NOTE!
It is possible that after lubrication bearings may heat up intensely. This
has no negative effect on bearings.
Please note that the temperature of bearings drops again to roughly
50 °C (122 °F) no later than 8 hours afterwards.
If after this period the abnormally high bearing temperature has not
dropped, there is probably a fault in the bearing.
6.7.5 Checking the fixing of the crushing jaws

Check crushing jaws for correct fixing:
• Fixed crushing jaw: Check side wedges for firm position

• Loose crushing jaw: Check clamping wedge for firm position
6.7.6 Check crusher fixing

Vibrations during crusher operation can cause detachment of the crusher from the substructure.
• Regularly check the fixing elements.

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Maintenance
6.8 Belt conveyor

6.8.1 Checking the conveyor belts
WARNING!
Risk of being pulled in!
When performing visual inspections on the running conveyor belt, there

is a danger of limbs being pulled in.
• Maintain safety distance

• Only perform adjustments when the belt is stationary
• Run the belts and check for damage from a safe distance (visual inspection)
Attention must be paid to the following defects

- Edge damage
- Cover plate damage
- Fabric damage
- Detachment of endless connections
- Rubbing points
- Scoring
- Excessively strong or weak belt tensioning
=>too weak: Belt will hang down between the carrier rollers
=>too strong: Vibration of the bottom strand
- Slipping of the drive pulley
- Seized carrier rollers
- Worn carrier rollers
- Seized guide pulleys
- Unusual noises
- Skew running of the belt
- Trapped lumps of material
- Loose screw connections
- Contamination
- Jagged scrapers
- Worn sealing lips
- Seized scrapers (Storage)
- Off-centre conveyed material feed
• If you suspect damages or defects, stop the belt, lock the main switch and investigate the ex--

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Maintenance
tent of the damage with the system stationary

• Eliminate any defects
6.8.2 Adjusting the scraper rubber
DANGER!
Only perform repairs or maintenance work with the machine switched

off!
Protect against unauthorised starting:
• Lock the switch cabinet

• Switch off and lock the main switch
• Affix warning sign to guard against re-starting
NOTE!
The person responsible must ensure that the system is stationary and
has been protected against unauthorised starting during the mainte-
nan-ce work.
Wedge scraper
0000208
The wedge scraper is an internal belt scraper which readjusts itself automatically on account of its
own dead weight.

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Maintenance
Regularly check the scraper lip for wear.
Front scraper
with clamping elements that guarantee the pressure of the scraper lip
Adjusting the front scraper
2
1
0000173
• Place the spanner (1) on the clamping element (2)

• Loosen mounting screw of clamping element
• Press on the scraper with the spanner by turning the clamping element
• Tighten mounting screw
• Repeat this process with the clamping element on the other side
6.8.3 Adjusting rubber plates
DANGER!
Only carry out repair work or maintenance work when machine is

swit-ched off!
Safeguard against unauthorised start-up of machine:

• Switch off and lock main switch
• Attach warning sign on the machine to warn against restart

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Maintenance
NOTE!
Those responsible must ensure that during maintenance work the ma--
chine is inoperative and they must safeguard it against its unauthorised
restart.
The rubber plates seal the material guide ledges off from the conveyor belts. The rubber plates must
be readjusted if the distance to the belt has become too far.
0000174
• Remove belt (only required with belt conveyor side discharge)

• Unscrew guard panel
• Release clamping plates (1)
• Readjust or replace rubber plate (2)
• Tighten clamping plates
• Screw on guard panels
• Install belt (only required with belt conveyor side discharge)
IMPORTANT!
The rubber plates can be made from an old conveyor belt of the same
thickness.

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Maintenance
6.8.4 Belt drive oil service

3
2
0000171
No. Designation
1 Bleed screw
2 Drain screw
3 Motor nameplate
Oil level check

It is not normally possible to perform an oil level check, as the motors are installed at an angle and
therefore the oil inspection holes are not congruent. If a large leak is detected in a gear motor, the oil
quantity should be checked as follows:
• Clean the gear motor, paying particular attention to the bleed screw (1) and the oil
drain-screw (2)
• Remove bleed screw
• Remove drain screw, drain oil and collect in a clean container
• Measure oil quantity. For correct oil quantity, see motor nameplate (3)
• Insert drain screw and tighten

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Maintenance
• Top up oil and replace any shortfall

• Insert bleed screw and tighten
• Check transmission for leaks
Change oil
• Clean the gear motor, paying particular attention to the bleed screw (1) and the oil drain
-screw (2)
• Remove bleed screw
• Remove drain screw, drain oil and collect in a clean container
• Insert drain screw and tighten
• Add new oil, for oil quantity see motor nameplate (3)
• Insert bleed screw and tighten
• Check transmission for leaks
6.8.5 Lubricating belt conveyor

• Ensure particular cleanness
• Keep oil and grease well away from conveyor belt
• Remove grease emerging from bearings and seals
0000140
No. Description
1 Sealing lip
Belt conveyor - side discharge conveyor / crusher discharge conveyor (drive pulley)
• The plummer blocks are maintenance-free (grease change 2000 h; 2 years)
• Check sealing lips on plummer blocks once a week

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Maintenance
NOTE!
Replace without delay if they are found to be defective. Otherwise there

is a risk of bearing damage.
Crusher discharge conveyor (return roller)

Lubrication interval: 50 h
• The plummer blocks of the return roller of the crusher discharge conveyor are lubricated via
the lubrication nipples of the centralised lubrication on the left side of the plant.
Item Description Interval Amount of grease per lubricating area

1 Plummer block 50 h 2.5 grammes
6.9 Crawler chassis

6.9.1 Oil service for planetary gear
• Move the machine such that the filling opening is at the top and the outlet opening is at the side
(oil level inspection plug).
Inscription is embossed on housing.
0000123
Oil level control

• Switch off diesel generator and plant.
• Clean the housing to prevent dirt entering the planetary gear.
• Unscrew oil level inspection plug 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 filling level.
• Insert oil level inspection plug with new sealing ring and tighten.

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Maintenance
Always check the oil filling level of the left and right planetary gear.
Oil change
0000124
• Where possible, bring gear oil up to operating temperature by moving the plant.
• Switch off diesel generator and plant.
• Clean the housing to prevent dirt entering the planetary gear.
• Place an oil tray with a capacity of approx. 10 litres under the oil drain plug.
• Unscrew control and drain plug and drain oil completely.
• Switch on plant and move to position "Oil level control".
• Fill oil into filling opening until oil filling level is visible at the lower edge of the threaded bore.
See Oil level control.
• Insert control and drain plug with new gaskets and tighten.
• Wipe up overflowing oil with a lint-free cloth and dispose of in accordance with environmental
specifications.
Always change gear oil of the left and right planetary gear.
6.9.2 Chain tension

Inspection
max
0000125
• Move chain out on flat ground

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Maintenance
Chain should be free of load where possible

• Check whether the upper run of the chain clearly sags
• If the chain sags more than 3 - 4 cm (1.2 -1.6 in) at the lowest point, it has to be retensioned
Tensioning chain
0000126
• Check the chain for damage

• Unscrew chain tensioning cover
• Push on slide coupling
• Tension chain by pressing in grease with a grease gun
Check changes in chain tension during tensioning
Where possible, use an electric grease gun
• Remove slide coupling
• Bolt on chain tensioning cover
6.9.3 Chain tensioner
0000127
WARNING!
Risk of injury!
There is a high risk of injury when repairing the chain tensioner. Repairs
must only be carried out by a specialist workshop. Under no circum-
stances should you attempt to open the inner cylinder.

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Maintenance
6.9.4 Checking gearbox for leaks

The planetary gear and hydraulic chain drives of the running gear must be checked every day for
leaks. If an oil leak is detected, the damage must be eliminated immediately.
6.9.5 Checking fastenings for track rollers and base plates

• Knock on the screws to check the security of the track rollers
• If the screws move, they must be tightened immediately.
• Replace defective screws immediately
6.10 Electro-hydraulic drive system

6.10.1 Pump distribution gear oil service
• Check all seals and screw connections for leaks during each oil change. Tighten screws if
necessary.
Premature gear failure can occur
- as a result of dry running due to oil losses,

- as a result of water penetrating the gear housing or
- as a result of foreign objects in the lubricant filling.
• After the test run (commissioning), loosen the overflow screw and check the oil level
• Check that the vent filter is screwed in
• Check the seals of the hydraulic pumps with a high oil level

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Maintenance
0000209
No. Designation
1 Vent filter
2 Drain screw
3 Checking screw
Oil change
• Unscrew the vent filter (1)
• Place collecting vessel beneath the drain screw (2)
• Drain oil
• Screw in drain screw and tighten
• Add new oil
• Screw in vent filter
• Check for leaks
Check oil level
• Unscrew checking screw (3).
• Oil must be at the level of the checking screw.
• Check the seals of the hydraulic pumps with a high oil level.
• Top up oil if necessary
• Screw in checking screw and tighten
• Check for leaks

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Maintenance
6.10.2 Traction clutch
0000263
0000262

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Maintenance
No. Name
1 Brake coil body
2 Coil
3 Rotor
5 Armature disk outside
6 Armature disk inside
7 Diaphragm
14 Connecting terminal 2 pole
Check outside air gap
0000264
• Check outside air gap at the perimeter with feeler gage twice. Second inspection position dis--
placed by 180° to the first one.
• Insert feeler gage through two slots in the rotor radially outside
Nominal size = 0.5 mm (0.02 in)

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Maintenance
Emergency locking in case of failure of the coupling
0000265
• Place three feather keys into the slots and fix with screws
IMPORTANT!
After the processing the system, remove the feather keys immediately.
Otherwise it can lead to an overheating of the hydraulics.
6.11 Hydraulic system

Safety information
DANGER!
Danger of serious physical injury!
Hydraulic fluid is under high pressure. When working on the hydraulic

system, squirting hydraulic oil can result in very serious eye injuries or
other injuries.
Work on the hydraulic system must be carried out with the system de--
pressurised.
In the event of injuries consult a doctor immediately, due to the risk of

infection.

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Maintenance
1. Hydraulic system is under high pressure!

2. Use suitable aids for detecting leaks, due to risk of injury!
3. Before carrying out work on the hydraulic system, the system must be depressurised.
4. The motor must be switched off prior to carrying out work on the hydraulic system
NOTE!
Ensure safe and environmentally sound disposal of lubricants and

filters!
6.11.1 Hydraulic filter

The hydraulic system is equipped with two suction filters, a return filter and a tank air filter.
Replacement interval: for the first time 500 hrs

then 1000 hrs
Please note:
• Use the same kind of filter only
Replacing the filter:
• Shut off the machine.
• Remove the cover of the filter housings
• Replace the filter cartridge
• Mount the covers of the filter housing back
• Switch on the hydraulics
• Check filters for leakproofness
0000233

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Maintenance
No. Name
1 Return filter
2 Suction filter
3 Tank air filter
6.11.2 Hydraulic hose lines

Check hydraulic hose lines regularly and in case of damage and aging, replace the old one! The new
lines must correspond to the technical requirements of the equipment manufacturer!
Recommended replacing intervals

- Normal requirements: at least every 6 years
- increased requirements (increased application periods, e.g. multi-shift operation, strong ex--
ternal influences): at least every 2 years
Recommended inspection intervals
- Normal requirements: 12 Months
- increased requirements (increased application periods, e.g. multi-shift operation, strong ex--
ternal influences): 6 Months
6.12 Electrical switch cabinet

We recommend that you carry out an occasional check to see that the terminal and connecting bolts
in the switch cabinet are firmly located and tighten them if necessary.
The system must also be protected from dust. If there are large dust deposits in the cabinet, these
should be removed by aspiration. The seals on the switch cabinet doors must be regularly checked
and replaced annually.
DANGER!
Risk of fatal injury due to electric shock
In the event of contact with live parts, there is a risk of serious injuries
due to electric shock!
Before carrying out work on electrical systems,
• disconnect them from the power supply

• protect them against re-starting
• ensure that they are disconnected from the power supply
• affix maintenance sign

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Maintenance
Switch cabinet mounting
0000178
• Regularly check the rubber air-springs for damage and pressure.
M no. Type Pressure Diameter Height Use

M10015053 FAEBI 100 5 bar (72.5 psi) 118 mm (4.6 in) 72 mm (2.8 in) Double switch
cabinet
M10015474 FAEBI 50 3.5 bar (50.7 psi) 80 mm (3.1 in) 60 mm (2.3 in) Single switch
cabinet
NOTE!
Check height of rubber air springs every three months and add more air
if required.

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Repair
7 Repair
Only carry out repair work or maintenance work when machine is turned off!
- Lock switch cabinet
- Switch off and lock main switch
- Attach warning sign against restart.
• Those responsible must ensure that during maintenance work the machine is inoperative and
they must safeguard it against its unauthorised restart.
• Retrofitting, welding and repair work to the machine may only be carried out by those commis--
sioned by the manufacturer. When welding, the earth terminal must be located as close as pos--
sible to the weld. Otherwise this may lead to destruction of protective earthing system or
bearings.
• If electrical or hydraulic components are replaced, then they must be adjusted in accordance
with the details on type plate or wiring diagram.
• Conveyor belts and hopper walls must be supported as soon as work starts on valves, cylin--
ders or hydraulic pipes.
• Throttle valves and pressure relief valves set by Kleemann may only be changed by personnel
trained by Kleemann. It is forbidden to remove seals from safety valves.
DANGER!
Failure to follow the above-mentioned safety instructions may lead to se--
vere injuries and also material damage which is not covered under war--
ranty.
7.2 Repair work

The following repair work may be carried out by trained and qualified staff themselves. In the case of
doubt, however, the manufacturer must be asked for more precise information.
7.3 Vibrating conveyor chutes

7.3.1 Replacing the vibration motor
If there is a defect in the vibration motors, it may be necessary to replace one or both motors. Only
the same make and type of motor may be used.

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WARNING!
Risk of injury!
During test runs, there is a high risk of crushing and pulling in due to ro--
tating or vibrating motor parts. Limbs can be sheared off or torn out.
Always maintain a safe distance from the machine.
NOTE!
The unbalance setting must be the same on both motors!
NOTE!
After 10 h full operation, retighten the mounting screws of the vibration

motor with the necessary torque.
Rotational directions of vibration motors

Motors have different installation situations. The following illustrations show the prescribed rotational
directions.
0000181 0000182

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0000183
7.3.2 Measuring the stroke (Chute)
CAUTION!
Risk of fatal injury and damage to property!
Incorrectly set unbalances can result in damage to the machine!
• All unbalances must have an identical setting

• All modifications and adjustments to the unbalances require prior con-
sultation with the manufacturer.
0000200 0000063
The stroke must be read off on the plate on the chute with the chute running.
• Switch chute on
• Read off stroke on the stroke meter

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6 mm
0000168
Stroke results from the point of intersection of both straight lines The read-off value corresponds to
the stroke in mm
7.3.3 Adjusting rocker width
0000180

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WARNING!
Only carry out repair work or maintenance work when the machine is
switched off!

NOTE!
Those responsible must ensure that during maintenance work the ma-
chine is inoperative and they must safeguard it against its unauthorised
restart.
CAUTION!
Risk of fatal injury and/or material damage!
Incorrectly adjusted unbalances may lead to destruction of machine!
• All unbalances must be precisely adjusted.

• Changes and adjustments to unbalances may only take place after
consulting manufacturer.
Note:
Both motors must have the same unbalance setting!
• Remove protective covers of unbalance weight.

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0001704
• Release clamping screw (1) of inner unbalance disc.

• Use the scale to set the inner unbalance disc to the desired percentage (2).
• Tighten clamping screw (1) of inner unbalance disc to specified tightening torque.
0000186
• Set the opposite side to the same percentage value

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Nm
8.8 10.9 12.9
M6 11.3 16.5 19.3
M8 27.3 40.1 46.9
M10 54 79 93
M12 93 137 160
M16 230 338 395
M20 464 661 773
M24 798 1136 1329
M30 1597 2274 2652
Maximum unbalance setting as a % at higher speed than rated speed

% Hz
100 % 50 Hz
90 % 53 Hz
80 % 56 Hz
70 % 60 Hz
60 % 65 Hz
7.4 Vibrating screen
7.4.1 Checking vibration amplitude (screener)
WARNING!
If screener is in operation for reading vibration amplitude when unbal-

an-ce protection has been removed, there is a high accident risk caused
by getting caught between moving parts or objects coiling around parts.
Only check screener with built-in unbalance protection.

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CAUTION!

Vibration amplitude must be read while screener is operating.
0000324 0000231
Note:
• Vibration amplitude can be read similar to a clock. One of the 12 small circles makes visual
contact with the inner circle. The point of contact gives the vibration amplitude in mm.
• If vibration amplitude is exceeded, it must be reduced.
• Vibration amplitude meter must be fixed in centre of screener above unbalance.

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0000079
Example: 8 mm vibration amplitude (arrow)
The maximum permissible vibration amplitude depends on the speed of the screener motor. In the
following diagram, the maximum permissible vibration amplitudes can be read.
It is not permissible to exceed the values.
0000078

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7.4.2 Adjusting vibration amplitude (screener)
CAUTION!

Vibration amplitude may be changed with aid of lamellas which are screwed onto external unbalance
components.
0000077
Adjusting vibration amplitude:
• Attach additional lamellas -> Increase vibration amplitude

• Remove lamellas -> Reduce vibration amplitude

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NOTE!
The number and size of the lamellas must be the same on both unbal-
an-ce components. Or else screener vibrates diagonally.
7.4.3 Changing screen surface
NOTE!
When installing new screen liner, it is to be retightened roughly one day

after initial fixture.
Lower screen surface (wire cloth)
0002307
Removal
• Release hexagon screws (1) and remove.
• Attach clamping plate (2) to suitable lifting gear and tackle and lift out.
• Attach screen surface (3) to suitable lifting gear and tackle and withdraw to the front out of the
classifying screen.

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Mounting
• Attach new screen surface (3) to suitable lifting gear and tackle and push to the rear into the
classifying screen.
• Deposit clamping plate with suitable lifting gear and tackle is the designated position.
• Bolt screen surface with new hexagon screws, washers and nuts onto distance frame.
• After installation of a new screen surface, retension it once again after approx. one day.
Upper screen surface (perforated plate)

Removal
• Release hexagon screws and remove.
• Attach perforated plate to suitable lifting gear and tackle and lift out.
Installation
• Clean contact surface.
• Attach perforated plate to suitable lifting gear and tackle and lift it to the designated position.
• Bolt perforated plate with new hexagon screws, washers and nuts onto distance frame.
7.4.4 Springs
Inspect springs for wear and tear, increasing fatigue, brittleness and cracks.
7.4.5 Sealing elements

Sealing elements must be checked regularly for function, cleanliness, tightness, damage, as well as
cracks and brittleness, and must be changed if necessary.
7.4.6 Wear lining

Regular inspections for fastening, abrasion and cleanliness.
Wear lining must be inspected weekly and replaced if worn.

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7.4.7 Screen box
CAUTION!
Material damage!
Machines whose vibration is obstructed cause cracks and destroy the

bearing!
• Observe minimum distance between firmly anchored and freely vibra-t-

ing components.
• Clean machine regularly.
• Regularly check screen box for unobstructed movement, smoothness of running and security.
7.5 Jaw crusher

DANGER!
Risk of fatal injury when plant is running!
Carry out maintenance and repair work only with the plant switched off!
Safeguard the plant against unauthorised start-up:

NOTE!
Those responsible must ensure that during maintenance and repair work
the plant is inoperative and safeguarded against unauthorised restart.

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DANGER!
Risk of fatal injury or serious damage to property through falling compo--
nents!
Raised or suspended loads can cause serious injuries or major damage

to property!
• Never stand under suspended loads

• Keep a safe distance away
• Transport components as near to the ground as possible
• Do not place your hands under the components when being lowered
• Check the lifting gear for correct condition and sufficient load carrying
capacity
• Observe centre of gravity when suspending components
• Attach chains and ropes to components such that they cannot slip
7.5.1 Crusher jaws

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 surface.
The crusher jaws have a symmetrical shape and can therefore be reversed once after the wear limit
has been reached.
NOTE!
If the crusher jaws are used beyond their wear limit, the resultant wea-k-
ening of the material cross-section can cause elongation of the crusher
jaws.
This leads to increased loads or damage to the rocker and/or crusher

fra-me.
Furthermore, crusher jaws without a profile or which are worn result in

poor material feeding behaviour and thus a reduced crushing capacity.

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1 2
0001689
No. Description
1 Fixed crusher jaw
2 Articulated crusher jaw
3 Wear range
7.5.1.1 Checking wear of crushing jaws

• Switch off plant components and the diesel generator.
• Visually check the crushing jaws by looking into the jaw from above.
• If necessary, reverse or change the crushing jaws.
7.5.2 Changing the lateral wedges

Lateral wedge guide bolted
Procedure:

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0000708
1 Disassemble crusher inlet (1).
1
0002210
Remove all screws (2) of the lateral wedge screw-

2
couplings.
2
0002210
• Completely loosen lateral wedges using a hammer.
• Lift out worn upper lateral wedge using appropri-
ate lifting gear.
0000938

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• If necessary, loosen lower lateral wedge using suit-

able tool.
• Lift out worn lower lateral wedge using suitable lift-
ing gear.
• Perform work steps on opposite side.
4
0000939
• Insert new lower lateral wedge.
• Insert new upper lateral wedge.
• Perform work steps on opposite side.
00000938
6 Screw in new screws (5).
5
0002210
7 Install crusher inlet (6).
6
0002210

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NOTE!
Check the security of the lateral wedge after 10 hours of full operation.
7.5.3 Changing fixed crusher jaw
DANGER!
Risk of fatal injury or serious material damage to property through falling
components!

to property!
• Never stand under suspended loads.

• Keep a safe distance away.
• Do not place your hands under the components when being lowered.
capacity.
• Suspend parts in their centre of gravity.
Attach chains and ropes to components such that they cannot slip.
WARNING!
Risk of injury!
When lifting from the rocker, there is a danger of the crusher jaw tilting
and causing serious crushing injuries to personnel in the area.
• Raise the crusher jaw carefully.

• Observe the safety distance.

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NOTE!
Observe weight of the crusher jaw.
IMPORTANT!
Set gap width to maximum.
Removal
0000708
1 Release screws on jaw wedges.
0000702

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Secure extension to release mechanism (short pipe).

2
Connect release mechanism to hydraulic system.
0000696
3 Secure release mechanism to centre jaw wedge.
0000697
Secure release mechanism to upper jaw wedge.

4 Release upper jaw wedges hydraulically and disas-
semble.
0002310
Attach crusher jaw to suitable lifting gear.

5 Observe weight of the crusher jaw.
Lift out crusher jaw.
0000189

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6 Check hook rail for wear and replace if necessary.
0002310
7 Turn crusher jaw or prepare new crusher jaw.
Installation
8 Clean contact surface.
Attach crusher jaw to suitable lifting gear and lift into

9
crusher.
0000192
10 Fit upper jaw wedges with base and tighten lightly.
0002310

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Tighten upper jaw wedges.

Upper jaw wedges must have a clearance to the sup-
11
port, otherwise there will be no bracing of the crush-
ing jaws.
0002310
7.5.4 Changing articulated crusher jaw
WARNING!
Risk of fatal injury or serious material damage to property through falling
components!

to property!
• Never stand under suspended loads

• Keep a safe distance away
• Do not place your hands under the components when being lowered
capacity
• Suspend parts in their centre of gravity
• Attach chains and ropes to components such that they cannot slip
WARNING!
When lifting from the rocker, there is a danger of the crusher jaw tilting
and causing crushing injuries to personnel in the area.
• Raise the crusher jaw carefully

• Observe the safety distance

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IMPORTANT!
Set gap width to maximum.
Disassembling all shims
Removal:
0000708
1 Release screws on jaw wedges.
0000709
Secure extension to release mechanism (long pipe).

2
Connect release mechanism to hydraulic system.
0000696

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3 Secure release mechanism to centre jaw wedge.
0000697
Secure release mechanism to upper jaw wedge.

4 Release upper jaw wedge hydraulically and disas-
sembly.
0002310
Tilt crusher jaw lightly

5
Danger of crusher jaw tilting!
0000195

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6 Lift out crusher jaw with lifting gear.
0000196
7 Turn crusher jaw or prepare new crusher jaw.
Installation
8 Clean contact surface
9 Carefully move in crusher jaw with lifting gear.
0000196

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10 Fit upper jaw wedge with base and tighten lightly.
0002310
Tighten upper jaw wedge

11 Upper jaw wedge must have a clearance to the sup-
port. Otherwise the crusher jaws will not be braced
0000695
NOTE!
Retighten securing screws after 2 operating hours.
7.5.5 Changing pressure plate and pressure plate bearings

The pressure plate is tensioned between the pressure plate bearings of the rocker and the crusher
frame. To change the pressure plate, the rocker must be pushed forwards.
With the aid of the hydraulic cylinder, the pressure plate and thereby the rocker are pushed forwards
via a ram.

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Once the compression springs are secure and the pull rods are relieved of tension, the rocker can be
pulled out further mechanically and the pressure plate is free.
Attaching pressure plate

• Guide suitable lifting gear and lifting tackle between rocker and crusher frame.
• Attach lifting tackle at eye bolts of pressure plate.
• If the threads of the eye bolts cannot be used due to damage and/or soiling, use appropriate
lifting gear, e.g. slings, on the pressure plate.
• Tension hoisting equipment lightly.
IMPORTANT!
Ensure that hoisting equipment is located centrally on rocker. The pres-
sure plate must be slung exactly in the middle to ensure it can be lifted
out safely.
Removing pressure plate locking device
0001671
• Unscrew screw (2) of pressure plate locking device.

• Pull out screw (1) and washers of pressure plate locking device.
• Repeat work steps on opposite side of crusher.

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Pulling out rocker mechanically
0001673
• Screw in all nuts (3) of pull rods until sufficient space is available for rocker to move.
• Using suitable lifting gear, e.g. chain hoist, pull out rocker mechanically until pressure plate be-
comes detached from pressure plate bearings.
Alternatively, rocker can also be pushed forward with the aid of the crusher gap adjustment valve
block. Then counterhold rocker using suitable lifting equipment, e.g. chain hoist, and pull back rocker.
Changing pressure plate

• Lift out old pressure plate between rocker and crusher frame.
• Clean pressure plate bearings of rocker and crusher frame.
IMPORTANT!
Replace damaged or worn pressure plate bearings.
• Insert eye bolts in new pressure plate and attach suitable lifting equipment.
• Lift in new pressure plate between rocker and crusher frame and guide into pressure plate
bearings of rocker.
• Allow rocker with chain hoist to return slowly while guiding pressure plate into pressure plate
bearing of crusher frame.
• Remove chain hoist from rocker.

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Adjusting spring preload
4
5
0001673
• Unscrew nuts of pull rods enough so that washers (5) have a distance of approx. 450 millime-
tres to crusher frame.
• Eject rocker with aid of crusher gap adjustment valve block enough so that screw (4) is relieved
of load.
• Remove screw (4) and nut.
• Fully retract rocker with aid of crusher gap adjustment valve block.
CAUTION!
If hydraulic cylinder is not fully retracted, damage may result at crusher

gap adjustment.
• Always fully retract hydraulic cylinder after changing spacer plates or

pressure plate.

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0001675 0001676
• Check that distance between cross member and crusher frame is approx. 450 millimetres.
When doing this, ensure that cross member is parallel to crusher frame.
• If necessary, correct any deviations in distance and parallelism.
CAUTION!
If spring preload is uneven or excessive, damage may result at crusher

gap adjustment.
• Adjust compression springs so that spring preload is even.

• Do not preload springs on block.

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Attaching pressure plate locking device
0001671
• Insert screw (1) including washers, screw in screw (2) of pressure plate locking device and
tighten to sufficient torque.
• Repeat work steps on opposite side.
• Perform test run of crusher.
• Listen for any unusual knocking noises in area of crusher gap adjustment.
CAUTION!
Knocking noises in area of pressure plate bearings could indicate dam-

aged 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 depart-

ment has first been consulted.
7.6 Belt conveyor

7.6.1 Tensioning belts
The belts are tensioned by means of tensioning spindles. Two spindles are installed per belt.

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2 1
0000132
Brass nuts are used for adjustment:
front -> adjusting nut (1)
rear -> locknut (2)
Tensioning
• Back off locknut so that the tensioning path is free
• Turn the adjusting nut until the belt is tensioned
IMPORTANT!
Adjust both tensioning spindles alternately so that the drive pulley re-
mains at right angles to the frame.
Otherwise the belt run would be skewed.
Do not tension the belt too tightly.
• Tightening locknut
• Note on belt tension:
Excessive or insufficient belt tension
- Insufficient:
Increased sagging of belt between support rollers
- Too strong:
Vibration of the bottom segment
Detensioning
• Release locknut
• Turn adjusting nut until belt reaches the desired tension release.

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IMPORTANT!
Adjust both tensioning spindles alternately so that the drive pulley re-
mains at right angles to the frame.
Otherwise the belt run would be skewed.
• Tighten the locknut
7.6.2 Changing belts

There are two basic options for changing the belt:
a. Have split belt joined on the machine by a vulcaniser.

b. Place continuous belt in position. With continuous belts, the conveyor belts must be re-
moved and partly disassembled.
7.6.3 Replacing scraper

• Switch off machine, lock main switch
Front scraper
NOTE!
For detailed information on the scraper, refer to the manufacturer's doc-

umentation.
Wedge stripper
Replace plastic strips if necessary
7.6.4 Adjusting belt run

Check belt running with and without load and adjust if necessary.

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WARNING!
Danger of being drawn in!
During all inspection and adjustment with a running belt there is a risk
of being drawn in at the drive pulley and return rollers and at all support
and return rollers. Loss of limbs may occur.
• Keep an appropriate safety distance when carrying out visual inspec-

tions.
• Only perform adjustments when the conveyor belt is stopped.
Check
• Check directional stability with and without load and adjust if necessary.
0000134
• The conveyor belt may lie against the lateral guidance rollers. The formation of folds and bulg-
es must be prevented!
Reasons for faulty conveyor belt run

- Inadequate alignment of the drive pulley and/or return roller.
- One-sided dirt encrustation on pulleys or rollers
- Feeding and guidance of conveyed material outside the belt center
- Scrapers positioned obliquely in delivery flow, which pushed the material over the belt edge
- Rubbing of belt on support construction or on jammed material pieces
- Uneven friction connection over the belt width due to rain or snow
- Incorrectly installed connection of the continuous belt with kink in longitudinal direction
Adjustment
• If necessary, align the drive pulley via the tensioning spindles
• Adjust belt tension

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If there is another reason for the incorrect belt run other than the above, adjust the directional stability
via the return rollers.
One or several return rollers must be adjusted at the point where the belt skew starts.
• Releasing return roller

• Turn roller slightly in the elongated holes
• Tighten the return roller
• Empty run test
• Operation under full load
Repeat settings several times if necessary
Example: Drift to the right
0000210
0000199

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8 Transportation
8.1 Transport between the places of use
If the plant must be driven on public roads, the necessary official permissions for special transport
must be obtained. The pertinent regulations must be observed; these differ from country to country.

WARNING!
Risk of injury and material damage due to incorrect use of hoisting de--
vices and lifting accessories.
Parts may be transported by crane only with suitable cargo gear. Check
that chains, ropes etc. are in proper condition.
• It is forbidden to stand under hovering loads.

• Personal protective equipment, such as helmet, safety shoes, gloves
etc. must be worn when installing machine.
• During installation/removal chains or ropes must be attached to fixed
components so they do not slip. Attachment point must be at centre of
gravity.
• Only qualified and competent personnel must carry out installation/re--
moval work.
NOTE!
• Lifting eyes into which the load hooks can be fitted are provided at ma--
chine for transport. Only hook machine to these lifting eyes.
• The lifting eyes are only suitable for the weight of the machine. Addi-
ti-onal loads added to the machine are not allowed to be lifted using
the-se lifting eyes.
• In order to avoid endangering persons or damaging the machine, the
machine must be transported with caution. In addition to the following
information, the general and local regulations on safety and accident
prevention must be observed.
• Machine may be transported by crane only with suitable cargo gear (in--
spect ropes, chains etc and ensure they are in perfect condition).
• It is forbidden to stand under hovering loads.
• During transport the statistical load assumptions must be observed in
order to avoid deformations and other damage.

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8.3 Retracting the warning light (option)
0002725
No. Description
1 Retaining screws for warning light
2 Retaining pipe for warning light
• Release retaining screws (1) and move in retaining pipe (2) completely.
• Tighten retaining screws.
8.4 Disassembling side discharge conveyor

WARNING!
Risk of injury in assembly area!
Persons in assembly area of belt conveyor are at risk from crushing in-
juries.
Do not stand in the area of danger when the belt conveyor is being ex-
tended.

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0001186
• Close vent (1) at belt conveyor drive.
2 3
0000207
• Unplug all electrical connections on belt conveyor.

• Attach and secure suitable lifting gear and lifting tackle to the side discharge conveyor of the
at the designated lifting eyes (3).
• Disassemble inlet hopper (2).

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4
5
0002755
• Raise side discharge conveyor slightly.

• Remove support between belt and chassis (4).
• Remove connector from belt extension (5).
• Move side discharge conveyor out and place on suitable base.
8.4.1 Disassembling rock chisel and cross member
WARNING!
Risk of injury in disassembly area of rock chisel!
Persons in disassembly area of rock chisel are at risk from crushing in-
juries.
• Do not stand in danger zone when rock chisel is being disassembled.
NOTE!
For detailed information about the connection and operation of the rock
chisel, see the manufacturer's documentation.

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2
3
1
4
0002296
• Unplug electrical and hydraulic connections on right hopper wall at the chassis.
• Open cable duct and remove electrical and hydraulic connections.
• Bolt protective cover onto bottom side of cross member (2).
• Attach and secure cable coil with electrical and hydraulic connections to suitable lifting gear
and tackle.
• Disassemble screw bracket (3).
• Remove electrical and hydraulic connections from the cable coil and combine with cable
straps.
• Attach and secure the rock chisel and cross member (2) at the designated lifting eyes to suit-
able lifting gear and tackle.
• Release and remove hexagon screws, washers and hexagon nuts between the cross member
(2) and feed hopper (1).
• Lift the rock chisel and cross member (2) from feed hopper (1) and set down on suitable base.
Beware of electric cables and hydraulic lines!
8.4.2 Disassembling platforms, stairs and handrail sections
WARNING!
Risk of injury!
Persons are at risk of injury and falling during the removal of the plat-
forms.


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3
6
2
7
1
0002295
Removing platform handrail sections

• Release hexagon screws, washers and hexagon nuts between handrail sections and the plat-
form section and remove them.
• Remove handrail section and place on suitable base.
Disassembling access steps between platform for power supply unit and prescreen platform
• Remove loose lying stones and dirt from stairs (4).
• Attach and secure access steps (4) to suitable lifting gear and tackle.
• Release hexagon screws, washers and hexagon nuts between access steps (4) and power
supply unit platform and prescreen platform (5) and remove them.
• Lift the access steps (4) off the plant and place down on a suitable surface.
Disassembling access steps
• Remove loose lying stones and dirt from stairs (2).
• Attach and secure access steps (2) to suitable lifting gear and tackle.
• Release hexagon screws, washers and hexagon nuts between access steps (2) and power
supply unit platform and support (1) and remove them.
• Lift the access steps (2) off the plant and place down on a suitable surface.
• Attach and secure support (1) to suitable lifting gear and tackle.
• Loosen and unscrew hexagon screws, washers and hexagon nuts between support (1) and
chassis.
• Lift the support (1) off the plant and place down on a suitable surface.
Disassembling maintenance platform for vibrating chute
• Attach ladder (6) between maintenance platform for vibrating chute and prescreen platform.
• Attach and secure maintenance platform (7) to suitable lifting gear and tackle.
• Loosen and unscrew hexagon screws, washers and hexagon nuts between maintenance plat-
form (7) and chassis.

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• Move maintenance platform (7) out of plant and place on a suitable surface.
10
9
11
8
12
13
0002293
Disassembling platforms at prescreen

• Attach and secure platform section (9) to suitable lifting gear and tackle.
• Release and remove hexagon screws, washers and hexagon nuts between the platform sec-
tion (9) and supports (8).
• Lift the platform segment (9) from the plant and place down on a suitable surface.
chassis.
• Proceed in the same manner for the second support.
Disassembling crusher platform
• Release and remove hexagon screws, washers and hexagon nuts between the platform sec-
tion (10) and supports (11).
• Lift the platform section (10) from the plant and place down on a suitable surface.
chassis.
• Proceed in the same manner for the second support.
Removing ladder
• Loosen and unscrew hexagon screws, washers and hexagon nuts between ladder (13) and
support.
• Detach ladder (13) from platform for power supply unit.

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• Loosen and unscrew hexagon screws, washers and hexagon nuts between support and chas-
sis.
• Lift the support off the plant.
Disassembling platforms at power supply unit
• Loosen and unscrew hexagon screws, washers and hexagon nuts between platform section
(12) and chassis.
• Lift the platform section (12) from the plant and place down on a suitable surface.
8.5 Removing feeding unit

WARNING!
Risk of injury in mounting area of feeding unit!
Persons in mounting area of feeding unit are at risk of crushing injuries.
• When removing feeding unit, do not stand in danger zone.
CAUTION!
Material damage!
Observe weight of feeding unit!
• Only use suitable lifting gear.

• Secure feeding unit at several lifting gear.
NOTE!
Platforms and screen drive can remain installed.
• Detach electrical connections on screen and vibrating chute.

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0002798
• Remove transport locks from screen (1).
0000692
• Attach and secure the side wall of the hopper extension at the eyelets provided (3) to suitable
lifting gear and tackle.
• Remove all pins (2) between side wall and feed hopper.
• Lift the side wall from the feed hopper and set down on a suitable surface.
• Adopt the same procedure accordingly for the second side wall.

K0610202 / 4111004512
Transportation
4
4
0000690
• Attach and secure feeding unit at lifting eyes provided (4) to suitable lifting gear and lifting tack-
le.
0000693
• Loosen and unscrew hexagon screws, washers and hexagon nuts (5) between feeding unit
and base unit.
• Carefully lift feeding unit off base unit and place on a suitable surface.

K0610202 / 4111004512
Transportation
8.6 Disassembling screen drive
NOTE!
Note existing markings on the electrical connections in the terminal box
and make new ones if necessary.
Ensure that the markings on the splined shaft and splined shank of the
articulated shaft are present and make new ones if necessary.
0002737
No. Description
1 Terminal box
2 Articulated shaft guard
• Switch off diesel generator and control voltage, remove key and carry it with you.
• Disassemble guard (2) on articulated shaft.
• Disconnect electrical connection for drive in terminal box (1).

K0610202 / 4111004512
Transportation
3
5
0002738
No. Designation
3 Console securing screws
4 Console with electric motor
5 Marking
• Install suitable lifting gear with sufficient load carrying capacity on the lifting lugs of the console
(4).
• Tension lifting gear lightly.
• Release and remove securing screw (3).
• Lift console (4) and electric motor with splined shank of articulated shaft from chassis.
8.6.1 Disassembling jaw crusher
WARNING!
Risk of injury in disassembly area!
Persons in disassembly area are at risk of serious crushing injuries.
• Before disassembling components, place base unit on a flat and firm

base.
• When removing, do not stand in danger zone.

K0610202 / 4111004512
Transportation
CAUTION!
Material damage!
Observe weight of jaw crusher!
• Only use suitable lifting gear and tackle.

• Move jaw crusher carefully and set it down.
• Remove belt guard.

• Relieve tension and remove belt (see chapter Maintenance - Tensioning belt).
• Release connections of hydraulics and centralised lubrication.
0002733
No. Description
1 Ultrasonic probe
• Release connections for ultrasonic probe (1) and disassemble.

K0610202 / 4111004512
Transportation
2
2
0000689
No. Description
2 Lifting eyes
• Attach and secure the jaw crusher at the designated lifting eyes (2) to suitable lifting gear and
lifting tackle.
• Carefully lift jaw crusher off the plant and place down on a suitable surface.
8.6.2 Disassembling crusher discharge conveyor
WARNING!
Risk of crushing!
Serious crushing injuries are possible when the feeding conveyor is be-
ing disassembled.
• Ensure that there are no persons in the hazard area when the feeding
conveyor is being disassembled.

K0610202 / 4111004512
Transportation
WARNING!
Risk of falling!
components.

1
4
0002732
No. Description
1 Crusher discharge conveyor
2 Top connecting rod
3 Locking pin
4 Mounting
• Disconnect electrical connection and emergency stop. Lock emergency stop socket with lock-
ing plug.
• Disconnect water connection.
• Secure suitable lifting gear with a sufficient load carrying capacity to the crusher discharge con-

K0610202 / 4111004512
Transportation
veyor. Weight of crusher discharge conveyor is approx. 4750 kg.

• Install suitable lifting gear with sufficient load carrying capacity on top connecting rod (2).
• Remove spring pin and locking pin (3) from top connecting rod (2) and lift top connecting rod
(2) from the plant.
• Proceed in the same manner for the second top connecting rod.
• Remove locking pin from mounting (4).
• Carefully lift crusher discharge conveyor from plant and set down in a safe place.
0001186
• Close ventilation (5) of belt conveyor drive.
8.6.3 Disassembling magnetic separator with support
WARNING!
Risk of crushing!
Serious crushing injuries are possible when themagnetic separator is

being disassembled.
• Ensure that there are no persons in the hazard area when the magnetic
separator is being disassembled.
WARNING!
Risk of falling!
components.


K0610202 / 4111004512
Transportation
1
4
0002731
No. Designation
1 Securing screws
2 Support
3 Suspension
4 Magnetic separator
• Disassemble electrical connections.
• Install suitable lifting gear with sufficient load carrying capacity on magnetic separator (4).
• Disassemble magnetic separator with suspension (3) from support (2), lift from plant and set
down in a safe place.
• Install suitable lifting gear with sufficient load carrying capacity on support (2).
• Disassemble securing screws (1), lift support (2) off plant and set down in a safe place.

K0610202 / 4111004512
Transportation
8.6.4 Retracting the supports
WARNING!
Risk of injury when supports are being extended or retracted!
The supports area is difficult to observe when supports are being ex-
tended or retracted.
• Ensure that there are no persons in the area of the supports.
8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23
0002740
• Start diesel generator and switch on the hydraulic system.

• Set the rotary switch for automatic/manual mode (18) to manual mode.
• Set support rotary switch (10) to retract.

K0610202 / 4111004512
Transportation
0002728
No. Description
1 Transport lock
• Retract support completely.

• Insert transport lock (1) at both supports and secure with spring pin.
• Switch off the plant.
8.6.5 Disassembling exhaust pipe
1 2
0002256 0002255
• Attach and secure exhaust pipe (2) to suitable lifting gear and tackle.

K0610202 / 4111004512
Transportation
• Release and remove screws between exhaust pipe and protective housing of the power supply
unit.
• Lift exhaust pipe (2) off the plant and place down on a suitable surface.
• Screw on transport cover (1).
8.6.6 Assembling/disassembling power supply unit
WARNING!
Risk of injury!
Persons are at risk of injury and falling during the assembly / disassem-
bly of the power supply unit.

If necessary, the complete power supply unit can be assembled / disassembled separately.
In case of such assembly / disassembly work, please consult Kleemann.
8.7 Remove earth connection

• Pull the earth stake out of the ground
• Put the earth stake into the fixture
8.8 Power unit

• Close and secure all service doors

K0610202 / 4111004512
Storage
9 Storage
Safety information
NOTE!
• If possible the machine should be stored in closed rooms until final in--
stallation.
• If the machine is stored outdoors it must be covered with tarpaulin cov--
ers that are open at the bottom to allow run off of any condensation.
• Machine must be erected on suitable bases to protect against effect of
rising damp.
• Electrical components must be stored in closed, dry and frost-protect--
ed rooms.
• A transport and storage period of six months is generally considered
as the period beyond which supplementary protective and preserva--
tion measures must be provided.

K0610202 / 4111004512
Storage

K0610202 / 4111004512
Disposal
10 Disposal
The system must be correctly disposed of at the end of its life cycle.

K0610202 / 4111004512
Disposal

K0610202 / 4111004512
Index Check 91
Checking emergency-stop devices 133
Chute
Maintenance 135
Motor 163
Rubber buffers 136
Stroke 165
Terminal box 135
Nume-rics Classifying screen
0202 2 Changing screen surface 173
Lubricate 140
2007 2 Maintenance 138
Screen surfaces 138
A Cleaning 41
Adjusting rocker width 166 Clearing stockpiles 114
Adjustment 115 Components 27
Application 13 Conformity 18
Articulated crusher jaw 184 Congestion clearing 110
Auxiliary functions 66 Control block
Auxiliary functions of valve block 66 Power drive 59
Conveyor belt
B Adjusting belt run 193
Bearing 145 changing 193
Oil service 150
Belt conveyor 89, 146, 200 tensioning 193
Conveyor belts 146 Crawler chassis 152
Lubricate 151 Crusher 30, 33, 76
Repairs 193
Scraper rubber 147 Adjustment / Set-up 115
Button Crusher gap adjustment 66
Fixing 145
Emergency-stop 63 Gap width 115, 117
Lubricant table 130
C Maintenance 141
Chain tension 152 Repairs 175
V-belt 143
Changing pressure plate 188 Crusher discharge conveyor
Changing pressure plate bearings 188 installing 87
Changing screen surface 173 Crusher jaws 180, 184
Chassis Crushing 106
Sockets 61 Important information 106
Start crushing process 108

K0610202 / 4111004512
D Exhaust pipe
Danger 63 assembling 73
installing 217
Danger due to electrical power 38
External circuits 47
Dangers when using the machine 37
External power supply 44
Designation 18
Diesel fuels 131 F
Diesel generator 44 Fault memory 51
Disassembling crusher discharge conveyor Fault messages
212 Frequency converter 53
Disassembling exhaust pipe 217 Feeding unit 206
Disassembling jaw crusher 210 Controllable 119

mounting 79
Disassembling magnetic separator 214 Fixed crusher jaw 180
Disassembling rock chisel 202 Fließbild 16
Discharge 114 Flow-Sheet 16
Discharge conveyor Frequency converter 53
Sockets 61 Fuel supply for hand delivery pump 122
Display
Frequency converter 53 G
OP3 51
Gap width 115, 117
Disposal 41
Guard devices 38
Drive
V-belt 143
V-belts 143
H
Drive system 155 Hopper
Drive system technical details 30 Hydraulic system 66

Hydraulic system 66, 159
Driving 102, 104
Leaktightness 134
E I
Earth connection 218
Indicator lights 135
Electro-hydraulic 155
Informal safety measures 36
Emergency off
Inspection 38, 91
Switch cabinet 43
Emergency stop Installation 69
Power drive 59 Installing 73

Emergency-stop 63
Erecting 70

K0610202 / 4111004512
J Switch-off 99
Switch-on 97
Jaw crusher
Operation hours 51
V-belts 143
Operator panel 43
L Operator panel OP3 51

Lateral wedges 177 Organisational measures 36
Lubricant table 129 Overpressure system 121
Conveyor unit 130
Crusher 130 P
Drive system 131 Parameter
Plant hydraulic oil supply 129
Power supply unit 129
OP3 51
Lubricate Permanent 31
Classifying screen 140 Planetary gear 152

Plant
M Moving 102
magnetic 214 Shutting down 102
Switching off 100
Main switch 43 Switching on 98
Diesel generator 44 Platform 84, 203
External power supply 44
Power drive 59
Maintenance 38
Power supply unit
Safety information 123
Maintenance work 133 assembling 73, 218
Precautionary measures 17
Maschinenübersicht 16
Prescreen 30
Material congestion 110
Pump distribution gear 155
Mounting magnetic separator 86
Moving 102 R
Radio 56, 57, 60
N Radio control 56
Notice explanation 35
Radio remote control 57, 60
O Recycling 114
Observe 108 Refuelling 101
Oil service Remote control 56, 57, 60
Planetary gear 152 Repair 66, 95
OP3 51
Repairs 38, 163
Operating modes 66
Crusher 175
Operation 66

K0610202 / 4111004512
Responsibilities of the personnel 36 extending 74
Switch cabinet 43, 71
Responsibility of the operator 36
External circuits 47
Retracting the supports 216 Maintenance 161
Rock chisel Overpressure system 121
Sockets 45
mounting 82
Switches
Frequency converter 53
S Switching off 100
Safety information 39, 69, 97, 123, 163,
199, 219 Switching on 98
Storage 219 Switch-off 99
Safety measures 38 Emergency-stop 63
Scrabber rubber 147 Switch-on 97
Screen Symbol legend 35
Disassembling screen drive 209 System
Installing screen drive 77 Clearing stockpiles 114
Oil escape 169 Erecting 70
Screen box 175 Installation 69
Sealing elements 174 Switch-off 99
Springs 174 Switch-on 97
Vibration amplitude 169, 172
Wear lining 174
Screen surface T
Technical data of electromagnetic separator
Clamping systems 138
31, 33
Screens 32
Technical data of permanent magnetic sep-
Screw connections 134
arator 31, 33
Set-up 115
Technical details 18, 27
Shutting down 102
Technical details of conveyor unit 30, 32
Sockets 45
Technical details of electrical system 29
Chassis 61
Discharge conveyor 61 Technical details of hydraulic oil supply 29
External circuits 47 Technical details of power supply unit 28
Service 47
Switch cabinet 45, 47 Test running 94
Specials hazards 39 Tightening torques 134
Starting up Traction clutch 157
Safety information 69 Training of personnel 37
Storage 219
Transport
Structural changes 40
Safety information 199
Supports Transportation 199

K0610202 / 4111004512
U
Übersicht 16
Use 13
V
V-belt 143
V-belts 143
Vibrating 32
Vibrating chute
Rocker width 166
Security 136
Vibrating conveyor chute 135, 163
Vibrating feeder
Controllable 119
Vibrating screen 138
Vibration motor 136
W
Warning light
extending 70
retracting 200
Water pump 120
Water system technical data 31
Wear lining 135
Winter operation 115

K0610202 / 4111004512
K0610202 / 4111004512

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Instruction manual

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Telephone: +49 (0)7161 / 206-0

Spare parts ordering and customer service

Operating instructions document number: K0610202

Page 2 / 228 Date of printing: 6.11.17 Mobicat MC 140 Z

Organisation of the instruction manual

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1.1.1 Intended use

The plant is built and designed

• for processing mineral materials with a feed size of 0-800 mm.

1.1.2 Non-specified use

Non-intended use includes:

Mobicat MC 140 Z Date of printing: 6.11.17 Page 13 / 228

1.1.3 Residual risks

The documentation makes reference to existing residual risks.

• The special warning signs on the plant system.

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• The instruction manual of the operating company.

Mobicat MC 140 Z Date of printing: 6.11.17 Page 15 / 228

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1 Aufgabetrichter 8 Gesamtantrieb Diesel-Hydraulik

1.3 Precautionary measures

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1.5 Product designation

1.6 Technical details

1.6.1 Mobicat plant

Feed material Rubble, demolished concrete, natural stone

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1.6.2 Transport and erection area

6093 5430 3644

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Felsmeißel mit Quertraverse

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Riemenschutz Schwungscheibenschutz Einlaufkasten

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1.6.2.2 Lashing points

[1] Lashing points

1.6.2.3 Assembly dimensions

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1.6.3.1 Power supply unit stage 3A

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Rated voltage 230/400 V

1.6.3.2 Hydraulic oil supply

1.6.3.3 Electrical system

Mobicat MC 140 Z Date of printing: 6.11.17 Page 29 / 228

1.6.3.4 Drive system

1.6.3.5 Conveyor unit

1.6.3.5.1 Crusher discharge conveyor

1.6.3.5.2 Prescreen conveyor