KLEEMANN INSTRUCTION MANUAL MOBICAT MC1i20Z K007 Series 06.10.2016 Date of issue 2556539_00_EN-GB Order number Wednesday, 02,.March 2022 08:21 kikoesttinj printed thi ‘© Kleemann GmbH 2016[w]] KLEEMANN Issuer Kleemann GmbH Manfred-Wérner-StraBe 160 D-73037 Géppingen Germany Telephone: + 49 (0) 71 61 / 206-0 Website: www.kleemann.info Document number BAL_K007_2556539_00_EN-GB ‘Translation of the original instruction manual Date of first edition 22.10.2015 n date 22.10.2015 Copyright © Kleemann GmbH 2016 ‘This documentation including all ofits parts is protected by cop- yright. Any use or modification beyond the strict restrictions of copyright law without the consent of Kleemann GmbH is prohib- ited and may result in prosecution. This applies in particular to duplications, translations, micro- filming and saving and processing work in electronic systems. Revi Weenenday-ba:htaret B-hikowstiint printed Zz © Kleemann GmbH 2016[w]] KLEEMANN TABLE OF CONTENTS TABLE OF CONTENTS 1 GENERAL. 4,01 Foreword/Intreduction «6... 6se ee 1.01.01 Introduction . 1.01.02 Changesyprovisos . . 1.01.03 Packaging and storage .. 4.01.04 Signs and symbols. . 1.01.05 Warning sign. 1.01.06 Documantation ......... 1.01.07 Dedaraion of Conformity. =... 1.01.07.01 Declaration of Conformity EAC 20 4.01.08 Warranty and liability. . 22a 402 Use sees ee eee <2 1.02.01 Intended use. 21 1.02.02 Abnormal use oe 1.02.03 Residual risks ies oy WGN a ea es oF eae om enue a enn HE 1.03 Climatic conditions... 23 1.04 Safety information 25 4.04.01 Safety manual... 66. esse ee 25 1:04.02 Environmental protection. sscseeseeeeeeeeee +526 4.04.03 Disposal of machine. cme 26 1104.04 Notes on the electrcajelectronic components. ....sccscresessererecsecses e126: 1.04.05 Danger areas .. 0... 0. ceeee cesta eeea steers cece eee eee ene 2B 1,04.05.01 Safety distance... 6. vse eeeee 2 1.04.06 Fire fighting appliance .. 29 1.05 Emissions and loads. 30 41.05.01 Noise emission 30 1.05.02 Dust emission er 4.05.03 Vibration emission 3a 1.06 Signs ... 32 4.06.01 Sign diagram 32 4.06.02 Signs/decals...- 0.2. 32 4106.03 dentiction plates sss 33 1.05,03.01 Plant identification plate 4 41.07 Personnel - qualifications and duties. 234 1.07.01 Protective equipment... 1 ooiier oh oats ot sosears ot owire BFE 1.07.02 Available training courses... . 38 1.07.03 Contact persons for operation and maintenance... ..sssseseseeeeeeeseees es 38 Wednestay-e2-htaret pe © Kleemann GmbH 2016 3TABLE OF CONTENTS w KLEEMANN 1.08 Revision statuses r4 DESCRIPTION 2.01 Chassis/guard devices. an 2.01.01 Information and hazard signs. . aL 2.01.02 Chassis with beams . a2 2.01.03 Platforms. 8 2.01.04 —_Lighting/warning devices. . 44 2.01.05 Socket outlets on the chassis. . 45 2.01.06 Guard devices .. : 46 2.0107 Emergency stop...+. ++ 7 50 2.02 Control stand 52 2.0201 Malnswitchsssssevsseeessevees 53 2.02.02 Operator panels/Interfaces 54 2.02.02.01 Operating unit for cold package (option) 58 2.02.02.02 Operating unit bat scale (option) 59 2.02,03 Programmable logic controller PLC/OP3. . - 60 2.02.04 Frequency converter. 62 2.02.05 Remote controls»... ...- +405 6s 2.02.06 Belt scale operator panel (option). . oo 2.03 Notassigned : 70 2.04 Power supply unit/engine. . : 70 2.04.01 Diesel engine/diesel generator........ 27 2.04.02 Fuel supply . 73 2.04.03 Exhaust system . 75 2.04.04 alr intake 76 2.04.05 Cooling system . < 7 2.04.06 Flange coupling ...... 8 ele a ate oe eae 4 wes 64 oT! 2.04.07 Diesel engine cold package (option). ae on onl 2.05 Hydraulic oil supply. seneeee severe 79 2.05.01 Hydraulic oll tank 79 2.05.02 Pump splitter gearbox. . ceeees 80 2.05.03 Driving clutch, - at 2.05.04 Hydraulic pumps a1 2.05.05 Valve blocks. 2 am anna we ef SBI 2.05.06 Rock chisal (option) - 3 ewes wi ae ia ose on HSE 2.06 Electrical system. 4 arse ar aac a ol 206.01 24-V Voltage SUPDNY os os cv vn wires ae vt paints re eniiee i ote 4 eens 0 on 8B 2.06.02 Battery isolator . 87 2.06.03 Switch cabinet .. ce etee ese eeeeeseueseesene esas 87 Weenesday-ea:htaret B-hikowstiint printed 4 © Kleemann GmbH 2016i TABLE OF CONTENTS KLEEMANN 2.06.08 Generators 2.06.05 Electric motors 2.06.06 Socket outlets... cos 2.06.07 Switch cabinet over pressure system . 2.06.08 External power supply (option) . 2.06.08 Electrical system, cold package (option). 2.06.09.01 Switch cabinet, cold package (option) 2.06.10 Voltage supply, cold package (option) 2.07 Not assigned. 2.08 Drive system... 2.08.01 Crawler running gear... eeeeeeveseeeeee es 2.08.02 Track drive .. 2.09 Notassigned....--.e22005 240 Conveyor unit vss eeseeeeveveee 2.10.01 Belt conveyor fie 2.10.02 Extractor channel vv. ssese es 2.10.03 Chutes a3 593 ¢ 210.04 Magnet separtor optional). 2.10.05 Balt scale (option) 2.1 Nol essigeed. se ma wa < 2:12 Water system (option) cscs esescseseseneeeee 2.12.01 Water pump . 2.12.02 Spraying nozzles . : 243 Not assigned... ss sscseeeeeess 214 Notassigned.... ss .eeeee 2A5 Not assigned... sss. eveeeeeees 2.46 Not assigned. 2.17 Notassigned...... ceeeee 2:48 Lubrication system (option). ++. 2.19 Not assigned . 2.20 Not assigned. 2.21 Not assigned. 2.22 Nol assigned. 2.23 Notassigned........ 2.24 Notassigned.... +++. 2.25 Not assigned. 2.26 Not assigned. 2.27 Not assigned. 2.28 Not assigned. : 2.29 Notassigned. s+... + Wednestay-e2-htaret pe © Kleemann GmbH 2016 5:TABLE OF CONTENTS [w]] KLEEMANN 2.30 Not assigned aun 2.31 Notassigned aun 2.32 Notassigned ait 2.33 Not assigned aun 2.34 Notassigned aun 2.35 Notassigned aun 2.36 Not assigned aan 2.37 Nobassigned ...ssssesseereesaseees 112 2.38 Not assigned 112 2.39 Notassigned ..ssssseseseveeseseeee 112 2.40 Not assigned 2 112 21 Service packs/telemaintnance 112 2.41.01 Service packs... ses earn oe 2.41.02 Telemaintenance de mates we mia we ais we eno a ! 2.42 Tools. eee eee 113 2.42.01 Rock chisel (option) «...- +++ ce eee eee eeeeeeen ese eeee ese AME 2.43 Feedingunit......6sssseeueeeeseeee 115 2.43.01 Feed hopper. ta nnaay na amen ne ease ns cue ens EES) 2.43.02 Feeder trough . 116 204 “Gusliens san a ne w ow ote ow Re RS wo Se wa EY 2.45 Screens. 4 BREA 9 8 119 245,01 GHZ ves e essa eevee tn elas ne tas ea eo ae oo ans oo ED 3 OPERATION . . 7 +122 3.01 Measures before initial operation . m5 09 vasa 08 wats on aaa op evens vo HRB) 3.02. Switching external power supply on and off (option) 126 3.03 Putting the plant into operation . . errr ert 3.04 Switching plant on and off . - 128 SGKOL “SHRihing ibe gonaraie On ann. con we wewven owes oc wa ovens oa 6 128 3.04.02 Switching plant components on and off. sine 29 3.04.03 Switching on plant after emergency switching off actuation... 1B 3.05 Manual operation . . 132 2.06 Oporating the plant. 34 3.06.01 Preparations 134 3.06.02 Driving .. 137 3.06.03 Shutting down the plant 140 3.07 Refuelling the plant.. ss. ses00s05 sat 3.08 Operating water system (option) . 142 3.09 Switching cold package on and off (option) 143 3.10 Adjusting the belt scale (option)... 147 Weenenday-ba:htaret B-hikowstiint printed 6 © Kleemann GmbH 2016TABLE OF CONTENTS [w]] KLEEMANN 3.11 Loading the plant..... 3.11.01 Suitable loading vehicles 3.11.02 Preparing the charged material .. 3.11.03 Loading the feed hopper. 3.11.04 Loading the jaw crushar . 3.12 Eliminating material congestion 3.13 Setting the jaw crusher. : 3.43.01 Checking the crushing gap... 3.13.02 Setting the crushing gap 3.44 Clearing away waste tip... 6sse eves 3.15 Winter operation ........ 3.46 Help and troubleshooting . . 3.16.01 Starting the engine with jump leads. . 3.16.02 Emergency locking of driving clutch. . 4 MAINTENANCE . 4.01 Chassis/guard devices 4.01.01 General maintenance tasks. 4.01.02 Checking warning devices. ......sssseeeeeeee es 4.01.03 Checking querd devise « 4.01.04 Checking emergency-stop devices 4.01.04.01_Emergency-siop button and release ord 4.01.04.02 Emergency switching off button 4.02 Control stand... Ha 4.02.01 Checking switch cabinet protective housing 4.02.02 Carrying out lamp test... 4.02.03 Checking remote controls... 4.03 Notassigned...... 208 ara amp _— 4.04.01 Servicing diesel generator power supply Unit +... ss essseeeeeeceseeeeeeeeeATE 4.04.01.01 Servicing the fuel supply LRG dese engine/cod package (option. 4.04.02 Connecting diagnostics device 2174 4.04.03 Checking cyclone prefiter. «+... “377 4.04.04 Servicing air filters... ..ss 0000+ +178 4.04.05 Cleaning the cooler fins. oe ABt 4.04.08 Changing engine oil -182 4.05 Hydraulic oll supply . cee eee ee enna es 83 4.05.01 Servicing hydraulic system... -184 4.08.01.01 _Depressurising the hydraulic system . cette ttttteee ert eee ene 184 4.05.01.02 General maintenance tasks... « 185 4.05.02 Servicing hydraulic oll tank. .... 186 Wednestay-e2-htaret pe © Kleemann GmbH 2016 7TABLE OF CONTENTS ww] KLEEMANN 4.05.02.01 Checking hydraulic fil level 186 4.05.02.02 Changing hydraulic ot 98 Peon He omoR vee Ow - 187 4.05.02.03 Changing hydraulic oll fter «sv . sia seve 189 4.05.03 Servicing pump splitter gearbox. . fa enna eb i v8 anaes 08 0 AD) 4.06 Electrical system. 4.06.01 General maintenance tasks ..... 4.06.02 Servicing 24 V voltage SUppIY «sees ee 4.06.02.01 Servicing diesel generator electrical system . 4.06.02.02 Servicing starter batteries . 4.06.03 Servicing switch cabinet 4.06.03.01 Checking electrical components. 4.06.03.02 Checking switch cabinet mounting 4.06.04 Servicing electric motors. . 4.06.05 Servicing overpressure systam. 4.06.06 Repairing electrical system .. . 4.06.08.01 Fuses 4.06.06.02 Motor protecting switch 4.06.06.03 Earth fault circu interrupter . 4.06.06.04 Engine protection system 3RR24.«« 4.07 Notassigned v6... sseseseverseseens 195 196 196 196 197 201 201 cecteeeecssseeerteene nes 202 a eve 04 baie 9 on wt 8 BOD) = 205 207 208 210 21s 4.08 Drive system 2is 4.08.01 Servicing crawler running gear. . . 215 4.08.01.01 _Checking/tensioning crawler cartier chains... soni asi 6 eevee 245 4.08.01.02 Checking fastenings for track rollers and base plates... 220... ° 218 4.08.02 Servicing track drive. 219 219 224 4.08.02.01 Servicing planetary gear 4.08.02.02 Checking components for leaks. 4.08.03 Repairing crawler running gear. 4.08.03.01 Opening/elosing cravlor cartier chains. <2... ee ses cee eeeeees . 222 4.08.03.02 Repairing chain tink. . sees 224 4.09 Notassigned v6... sees sseeeeeseees 4.10 Conveyor unit. . 4.10.01 Servicing belt conveyors 4 bus 68 9 eas 59 evan ono RAF 4.10.01.01 checking conveyor bats. — mee 2 27 4.10.01.02_Checking/setting return roller guard 228 4.10.01.03 Servicing scraper... - 230 4.10.01.04 Adjusting rubber plates . ces coves 232 4.10.01.05 Servicing beval helical gearbox 236 238 2at 2a 242 4.10.01.05 Servicing drurm motors. 4.10.01.07 Lubricating plummer blocks 4.10.02 Checking chutes. . . - 4.10.02.01 Checking rubber curtains and sealing. . 4.10.03 Servicing belt conveyors... ssssseees Weenenday-ea:htaret B-hikowstiint printed 8 © Kleemann GmbH 2016TABLE OF CONTENTS [w]] KLEEMANN 4.10,03.01 —_Tensloning conveyor belt. . 242 4.10.03.02, Changing conveyor belt - wee ect — ? 28a 4.10.03.03 Checking conveyor belt runes. see 2204+ . . 28a 4.10.03.04 Adjusting conveyor belt run 2245 4.10.04 Servicing extractor channel. asd 09 VaIbae o8 UAE ee ov aa on ouORD H OR PAB’ 4.10.05 Servicing electromagnetic separator (option) . . 247 4.10.05.01 Checking conveyor belt nba 2 sis wat se 7 4.10.05.02—Tensioning conveyor belt ot : 248 4.40.05.03 Servicing worm gear... ++... 250 4.10.05.04 Lubricating bearings sabe cing chase anaes dawn ewes ones recta sae BB 4.10.05.05 Checking oll cooling fil level 254 4.10.06 Servicing permanent magnet separetor (option) 255 4.10,06.01 Checking conveyor belt 250 4.10,06.02 _Tensioning conveyor belt ..- 287 4.10.06.03 Servicing worm gear +++ e+ 238 4.10.06.04 Lubricating bearings = 259 441 Notassigned.. 06.6... eee fees eee eee eee este eee eee ee ens +260 4.12 Water system (option) 6.6... 06+5 +260 4.13 Not assigned . FG Te BERG = 262 44 Nobassigned...ssssseseseveees +262 4.15 Not assigned . + 262, B16 Nobessiymd eee eee eee eee 4 a an 28 wae BODE BaF — NOLRSEIHET ro ie4 v8 v8 is weir ba 6 wate wis Seles HH oie ais WHE #4 He VER! 4.18 Lubrication system (option). = 262 4.18.01 Servicing lubrication system . = 262 4.18.01.01 Filing lubrication system 293 4.18.01.02 _Chocking lubrication systom . 2.2.2... « : 264 419 Notassigned.... 00... ae vans ne maine ee euie ne wow sa nate OF 4.20 Notassigned vss. vseeee =267 421 Notassigned..... 002.0065 = 267 4.22 Notassigned....s.sseseeereees =267 4.23 Not assigned . -267 4.24 Notassigned.......-.05 4 09 O80 o8 wind ee on baw on euORD H4 OREN AREF 4.25 Notassigned....sssssseseveees +267 4.26 Not assigned +267 4.27 Not assigned . 4 re neers ve mone es aula os enews eo evens 67 428 Notassigned....- 0s. eee -267 4.28 Notassigned....sssss ee =267 4.30 Not assigned . = 267 4.31 Not assigned . = 267 4.32 Not assigned . = 267 4.33 Not assigned. -267 Wednestay-e2-htaret B-hiowstiny printed ‘© Kleemann GmbH 2016 9TABLE OF CONTENTS [w]] KLEEMANN 4.34 Notassigned 4.35 Notassigned 4.36 Notassigned 4.37 Not assigned 4.38 Notassigned 4.39 Notassigned 4.40 Notassigned ..... 4.41 Notassigned ..... ABZ —Tholt os seins ss essen oe ae 4,43 Feedingunlt.....ss0eeeeeeee 267 267 267 269 4.43.01 Servicing feed hopper. 269 4.43.02 Servicing feeder trough. 270 4.43.02.01 Servicing rubber mountings 270 4.43.02.02 Checking vibration motors ies 3 an 4.43.02.03 Servicing wear lining 273 4.43.03 Repairing feeder trough. 274 4.43.03.01 Replacing vibration motor. 274 4.43.03.02 Checking rocker width 443.03.03 Adjusting rocker width 4.44 Crusher. “ 4.44.01 Lubricating bearings cow xaa.ce, ‘start buastig, check tr ewrperatura 4.44.03 Checking/tensioning V-belt 444.03.01 Checking V-belt cesses sees coves 281 4.44.03.02 —_Tensioning/changing V-belts 283 4.44.04 Checking securing elements of crushing jaws. 285 4.44.05 Checking crusher mounting 4.44.06 Lubricating crusher drive electric motor 4.44.07 Repairing crusher......+++ 444.07.01 checking wear of crushing Jaws = 275 276 278 278 287 289 a Heri seeies evie & anaes v6 20 4.44.07.02 Changing the lateral wedges. 201 444.07.03 Changing xed crusher Jaw... 0.2.20 293 4.44.07.04 Changing articulated crusher Jaw . 204 4.44.07.05 Changing pressure plate. .. 296 44.07.00 Chonginy sine 4244.07.07 Changing V-belt pulley 4.45 Screens. zoe Hick 445.01 Checking scren surfaces vos ec sees 4.45.02 Tensioning screen surfaces 4.45.03 Servicing angular gear . 4.45.04 Servicing universal-joint shaft . 4.45.05 Lubricating grizzly bearing. oor 34 316 Wednenday-oa:htaret B-hikowstiint printed 10 © Kleemann GmbH 2016i TABLE OF CONTENTS KLEEMANN 4.45.06 Listen to bearing, check its temperature. 4.45.07 Checking rocker width . . 4.45.08 Other maintenance tasks 4.45.09 Repairing screens . . 4.45.09.01 Adjusting rocker with 4.45,09.02. Changing grizzly sereen surface 4.85.09.03 Replay sublet putes 4.46 Cleaning the plant .. 4.46.01 Cleaning the plant . 4.46.02 Cleaning with high-pressure cleaners. .... + 4.47 Performing welding work. . . 5 TABLES. . 5.01 Technical detalls. = 330 5.01.01 Complete plant = 330 5.01.01.01 Weights 330 5.01.01.02 Dimensions: . 330 5.01.01.03 Driving operation... 331 5.01.01.04 Charged material and size a oe a 331 5.01.01.05 Feed and crushing capacity... «« 332 5.01.01.06 Screen capacity. — 332 5.01.01.07 Ambient temperatures... “8 p20 He BGEE 332 5.01.01.08 Sound power level... 222022205 . : 333 5.01.02 Powersupply unit/engine ss. .sssesveeeeesaseeesesesessa eas eseus 1333 5.01.03 Fuel supply, cold package (option) -335 5.01.04 Hydraulic oll supply . 114 ween Ha ans ba ars os vais OH avin HBT 5.01.05 Electrical systems. ..e esses =336 5.01.06 Electrical system, cold package (option) . = 336 5.01.07 Drive systems. eseseeseea eee -337 5.01.08 Conveyor unit -337 5.01.03 Water system (option) . . = 339 5.01.10 Feeding unit . 339 5.0111 Crusher . -340 BOL12 — ScECNS sess eee eee esse eee 2348 5.02 Maintenance schedule/maintenance inte! vals san 5.03 Tightening torques. ..6.e esses see = 353 5.04 Fluids and lubricants. 355 5.04.01 Lubricants... sss eseeseeeeee =355 5.04.02 Diesel Fuels « : -357 5.05 parate documentation, «ss. +++ 5 = 359 5.05.01 Documentation on the plant -359 5.05.02 Information material = 360 Wednestay-e2-htaret eB-hikowstint printed th ‘© Kleemann GmbH 2016 itTABLE OF CONTENTS [w]] KLEEMANN 5.06 Fuses + +362 6 INSTALLATION AND REMOVAL, TRANSPORT. 6.01 Transport... sees sees eee ee 6.01.01 Approval of special transport . . 6.01.02 Transport details. 6.01.02.01 Dimensions. 6.01.02.02 —_Welghts 6.01.03 Loading and unloading . 6.02 Plant installation . 6.02.01 Preparations 2 6.02.02 Moving out warning light. . 6.02.03 —_Earthing the plant... . . 6.02.04 Folding up hopper walls. 6.02.05 Mounting the platforms . . : : 6.02.06 Folding out crusher discharge conveyor mechanically . 6.02.07 Folding out crusher discharge conveyor hydraulically (option) . 6.02.08 Installing prescraen conveyor (option) . . 6.02.09 Final tasks. . ce 9.01 Test run without material 3 wins wi nite os ovens on 0 BT) 6 6.02.09.02 Test run im manual made 6.03 Removal of plant. . . 6.03.01 Preparations vs ....ssscs ees secueseeeeeeseses sete sees eseeseen ees 386 6.03.02 Moving In warning light. as 6.03.03 Disassembling prescreen conveyor (option). 4 6.03.04 Folding in crusher discharge conveyor mechanically . . 6.03.05 Folding in crusher discharge conveyor hydraulically (option) « 6.03.06 Removing the platforms «6... 6se ees 6.03.07 Folding in hopper wells . 6.03.08 Removing earthing. ......2+.0se005 6.03.09 Final tasks... . sees sseseeeeseees 6.04 Storage, shutdown, disposal . 6.04.01 Storage conditions . 6.04.02 Shutdown, restarting - 6.04.03 Disposal of machine vs .sssseseseees Wednenday-ba:htaret B-hikowstiint printed 12 © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Foreword/Introduction 1 GENERAL During all activities, observe the information in your safety manual! 1.01 Foreword/Introduction 1.01.01 Introduction This KLEEMANN plant is a product from the wide product range of tracked KLEEMANN crushing and screening plants. ‘The vast experience of KLEEMANN combined with the latest pro- duction and test procedures guarantees the high dependability of your plant. Instruction manual and This instruction manual is only valid in conjunction with the safety instructions safety manual and the manufacturer's documentation included in the delivery. Please note: + This instruction manual was prepared for operating, mainte- nance and service personnel at the place of use. + This instruction manual should put you in @ position to oper- ate the plant safely and to utilise the permissible application ‘options it provides, + It also provides you with information on the function of im- portant units or components. + Certain terms and concepts are used in the instruction man- ual to do this. To avoid misunderstandings, you should al- ways use these terms. + Only qualified, instructed and trained personnel may work on this plant. + The instruction manual, safety manual, manufacturer's doc- umentation and the regulations and specifications applicable at the place of use must be observed (for example, accident prevention regulations). + The instruction manual, safety manual and manufacturer's documentation are elements of the product. Ensure that they are available for viewing at all times during the entire service life of the plant. * Pass on the instruction manual, safety inanual and manufac turer's documentation to new owners of the plant and draw their attention to the importance of the documentation. Use of this instruction makes it easier for you: + to become familiar with the plant. + to avoid faults through incorrect operation. Wednestay-oa:htaret Ht ktkoestiny printed ‘© Kleemann GmbH 2016 13GENERAL Foreword/Introduction [w]] KLEEMANN 1.01.02 Observance of the instruction manual: + helps avoid dangers. + increases dependability at the place of use. + increases the service life of the plant, ‘+ reduces repair costs and downtimes. Always place this instruction manual within reach in the plant's switch cabinet or in the container provided for this purpose. If you should receive further information from us about your plant (for example, additional technical information), these in- structions must also be observed and attached to the instruc- tion manual. If you do net understand the instruction manual or individual chapters, please ask us before starting the corresponding activ- ity. KLEEMANN GmbH shall not be liable for safe operation of the system: + if plant handling does not comply with specified use. Warranty claims shall become invalid in the event of: + Operating errors. + Inadequate maintenance. + Incorrect fluids and lubricants. ‘+ Applications not named in the instruction manual. Warranty and liability provisions of the general terms and con- jons of business cf KLEEMANN GmbH are not extended by the above information. In the course of technical development, we reserve the right to make changes without prior announcement. This instruction manual also descrites optional equipment that may not be fit- ted on your plant. Specifications and illustrations in this instruc- tion manual must not be reproduced, disseminated or used for competition purposes, Translations are carried out in good faith. We shall not be liable for translation errors and their consequences, even if we trans- lated the text ourselves or assigned the task to a third party. All rights under copyright laws are explicitly reserved. We wish you every succese with your KLEEMANN plant. Changes/provisos We make every effort to ensure that this instruction manual is correct and up to date. To maintain our technological head start, it may be necessary to make changes to the product and its op- eration without prior announcement. We shall not be liable for any faults, failures and resultant damage. Wednesday: 14 tert © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Foreword/Introduction 1.01.03 1.01.04 Please also okserve any additional information that may be in- cluded in the delivery. Packaging and storage ‘The components were carefully packed to guarantee adequate protection during shipment. When you receive the goods, the packaging and contents should be checked for damage. If damage is discovered, the components must not be put into operation. Damaged cables and plug connectors are also a safe- ty risk and must not be used. In this case, please contact your local KLEEMANN branch. If components are not put into operation immediately after un- packing, they must be protected against dampness and con- tamination. Signs and symbols ‘The signs and symbols are designed to help you use the instruc- tion manual and the plant quickly and reliably. In this instruction manual, potential dangers are indicated by danger, waming, caution and important signs. They are identi- fied by a colour and a signal word corresponding to the serious- ness of the danger. Hazard warning Sources of danger are named here. The possible consequences are also named here. ‘And measures for avoiding the danger. ‘The hazard warning uses the signal word DANGER to indicate an imminent danger. Nonobservance can result in serious or fatal injury. Warning sign Sources of danger are named here. The possible consequences are also named here. ‘And measures for avoiding the danger. The warning sign uses the signal word WARNING to indicate a possible threatening danger. Nonobservance can result in seri- ‘ous or fatal injury. Caution sign Wednesttay-oa-htare ‘© Kleemann GmbH 2016 Htktkorestiny printedGENERAL Foreword/Introduction lw] KLEEMANN ‘Sources of danger are named here. ‘The possible consequences are also named here. And measures for avoiding the danger. ‘The caution sign uses the signal word CAUTION to indicate a possible dangerous situation. Nonobservance can result in mi- nor injury and material damage. Attention notice Res ‘The attention notice uses the signal word ATTENTION to indicate 2 possible dangerous situation. Nonobservance can result in material damag: Information A capital "I" for infermation at the start of every main chapter CE) oem re street art etn rae ce ter. You will also be informed at relevant points about the most effective or practical usage of the plant and this instruction manual. > Activity steps ‘The defined sequence of activity steps facilitates correct and safe use of the plant. ¥ Result ‘The result of a sequence of activity steps is described here. [1] Position number Position numbers are marked in the text by square brackets []. Material flow direction For orientation purposes, the arrow indicates the material flow direction of the plant or a component. {option) Optional equipment Optional equipment is marked with the word "Option". All ma- chines and components that are not marked with "Option" are part of the standard equipment of the plant. 1.01.05 Warning sign Warning signs provide a graphic illustration of a danger source. ‘The warning signs in the complete technical documentation cor- respond to the harmonised standard EN 61310 Part 2: Safety of machinery - Indicaton, marking and actuation and EC Directive 92/58/EEC - Minimum Requirements for the Provision of Safety and/or Health Signs at Work (Ordinance on Industrial Safety and Health). Wednesctay-earhtaret H+ ktkoestiny printed 16 © Kleemann GmbH 2016GENERAL [w] KLEEMANN Foreword/Introduction ‘They match the illustrations on the signs attached to the rele- vant danger areas on the plant. Warning of a general danger ‘The warning sign appears before activities where there are sev- eral possible causes of dangerous situations. Warning of dangerous voltage This warning sign appears before activities where there is a danger of electric shock with possible fatal consequences. Warning! Suspended load This warning sign appears before activities where there is a danger through falling objects with possible fatal consequences, Warning of rotating parts This warning sign appears before activities where there is a danger through rotating parts with possible fatal consequences. This warning sign appears before activities where there is a danger of stumbling with poscible fatal concequences. Warnin: Risk of crushing injuries This warning sign appears before activities where there is a danger of crushing parts of the body with possible fatal conse- quences. Warning! ‘isk of crushing injuries to hands The warning sign appears before activities where there is a risk of crushing your hands. Warning! Risk of crushing injuries to feet ities where there is a risk ‘The warning sign appears before at of crushing yeur feet. ‘The warning sgn appears before activities where there is a dan- ger through hot surfaces. Warning! Hot fluids The warning sgn appears before activities where there is a dan- ger through hot fluids. >PPPPPPPPE Wednesttay-oa-htare Htktkorestiny printed ‘© Kleemann GmbH 2016 7GENERAL Foreword/Introduction [w]] KLEEMANN Warning of batteries ‘The warning sign appears before activities where there is a dan- ger through escaping explosive gas and caustic fluids. Warning of flammable materials ‘This warning sign aopears before activities where there is a danger through flammable materials with possible fatal conse- quences. Warning of potentially explosive materials This warning sign appears before activities where there is a danger through potentially explosive materials with possible fa~ tal consequences. Warning of toxic substances This warning sign appears before activities where there is @ danger through tox substances with possible fatal conse- quences. 1.01.06 Documentation ‘A paper copy of this instruction manual must be available to au- thorised operating and maintenance personnel at all times. PPP ‘This instruction manuel must always be regarded es an unit to- gether with the operating instructions to be prepared by the op- erating company. This instruction manual and the operating instructions of the company must be handed over to operating and maintenance personnel. If the plant changes owner, the completion documentation must also be handed over. Before putting the rlant into operation for the first time and be- fore starting any kind of work on the plant, you must read through this instruction manual carefully and understand it This instruction manual serves to familiarise you with the basic tasks and activities on the plant. This instruction manual contains important information on how to use the plant safely and correctly. Your observance helps: + to avoid dangers. ‘+ to reduce repair costs and downtimes. + to increase the dependability, availability and service life of the plant. Irrespective of this instruction manual, the laws, ordinances, di- rectives and standards applicable in the respective country of use and place of application must be observed. Wedresctay-e2rhtare H+ ktkorestiny printedtts 18 © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Foreword/Introduction This instruction manual describes how to use the plant. The in- struction manual is only valid in conjunction with the safety manual and, where applicable, the transport instructions from KLEEMANN. A safety manual and, where applicable, transport instructions must be accessible to plant operating and maintenance person- nel at all times. 1.01.07 Declaration of Conformity CE ‘The Declaraticn of Conformity is part of the separately provided documentation from KLEEMANN GmbH and will be handed over to you upon delivery of the plant. ‘The CE marking for the plant is an element of the identification plate. ‘The pictograph identifies the conformity of the plant to valid EC directives, which prescribe the CE marking. Wednesttay-oa-htare Htktkorestiny printed ‘© Kleemann GmbH 2016 19GENERAL Foreword/Introduction [w]] KLEEMANN KLEEMANN EG-Konformitatserklaérung {r Maschinen ! Maschinenantagen ‘nach EG-Richilinie 2006/42/EG 1557 Soerocn es3 do ratogand bxachnte Maser Maecwneerne urna har eran ne fat somen carvor unin Vane eben Acta cefam i it en Bester der con auf Re ‘eel att on Botrrangen gen were Rae: be Sco der Nedengemintt wen gor Aang M15. er Sneerto segs sagen MotileBrechanlage C € 2 arr enesicten Vranas Mase Machisrags vere dace naa ve Soin Pann de bern tga Kt, Keenan Gb Stier soon eo Aolemttanttinry det Ofgrafesnungin der uretzanArtairne ater toa (oe inde o a (0% Dam Uc Seong. 20.0205, 1.01.07.01 Declaration of Conformity EAC ‘The EAC mark on the plant is an element of the type plate it the plant is destined for one of the countries in the Eurasian Cus- ‘toms Union. “The EAC pictograph EAC (Eurasian Conformity) confirms con- formity of the plant with the requirements of the Customs Un- ion. Weenenday-ea:htaret B-hikowstiint printed 20 © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Use 1.01.08 Warranty and lial 1.02 Use ‘The general terms and conditions of business of KLEEMANN GmbH shall apply. These are available to the buyer or operating ‘company upon conclusion of agreement at the latest. Refer to the general terms and conditions of business for war- ranty and material defect claims. 1.02.01 Intended use ‘The plant is state-of-the-art equipment and complies with the safety regulations applicable at the time of marketing and ap- plicable to its intended use. Design measures cannot avoid foreseeable misuse or residual dangers withcut restricting the specified range of functions. ‘The plant is built and designed: + for processing mineral materials as specified in chap. 5.01.01.04, + for loading with the help of 2 digger with shovel or bucket adapted tc the plant size and the charged material. With a suitable hopper extension (option), the plant ean alsa be loaded with an appropriately large wheel loader. + for loading with the help of an upstream plant or belt con veyor, provided it has the required discharge height and is adapted tc the plant size and charged material, + for crushing material with a compressive resistance as spec iffed in chap. 5.01.01.04, + for screening different grain sizes using a grizzly. + for discharging different grain sizes via a belt conveyor onto waste tips or downstream plants for further processing. + for clearing waste tips with a wheel loader, the size of which matches the plant power. ‘The plant is designed exclusively for commercial operation with- in enclosed areas such as building sites and quarries. The plant must be operated by instructed operators in accord- tance with the specifications in the technical documentation, All types of non-specified use, or all activities on the plant not described in this instruction manual, amount to misuse not cov- ered by the statutory limits of liability of the manufacturer, 1.02.02 Abnormal use In the case of non-specified use, or misuse of the plant, the warranty obligation of the manufacturer shall become null and Wednestay-e2-htare Htktkorestiny printed ‘© Kleemann GmbH 2016 2aGENERAL Use [w]] KLEEMANN 1.02.03 void and responsibi ity shall be borne solely by the operating company. Non-specified use includes: + Conveying of persons. ‘+ Climbing on the plant for purposes other than maintenance and repair. + Operation will: disassembled, defective or bypassed safety devices. ‘* Operation following incorrectly performed or neglected maintenance and repair work. ‘+ Operation following failure to observe the maintenance in- tervals, ‘* Operation following neglected measurements and inspec- tions for early detection of damage or wear. + Feeding with lorries, dumpers or skip lorries or with exces- sively large or small digger shovels or buckets. + Clearing the waste tip with an unsuitable device that leads to damage to the belt conveyors, ‘* Operation in unsuitable climatic conditions. ‘+ Operation in a position other than horizontal. ‘+ Operation following independent, unauthorised construc- tional modifications to the plant. The following are unsuitable for crushing in the crusher: ‘+ Material that exceeds the specified compressive resistance and dimensions. Material that is too large and hard results in material block- ages, considerable wear and damage to the crusher. ‘+ Unbreakable materials such as scrap metal. Even sporadic feeding of scrap metal, in particular hardened and solid steel parts, leads to damage and serious wear to crushing jaws, belt conveyors and other moving parts. ‘+ Allother materials not named in the section on intended use, such as wood, coal, scraps, rubbish, boulders of ore and oth- er non-mineral materials. The following must not be fed into the crusher: ‘+ Hazardous and explosive substances. + Chemicals, + Solvents, oils ard greases. ‘+ Asbestos-containing scraps, e.g. eternit. + Pressurised vessels. Residual risks The residual risks were analysed and evaluated before the start of the design and panning phase of the plant. Wednesday: 22 an © Kleemann GmbH 2016GENERAL [w] KLEEMANN Climatic conditions The documentation makes reference to existing residual risks. Existing residual risks can be avoided through the practical im- plementation and observance of the following specifications: + The special warning signs on the plant. + The general safety instructions in t! and in the safety manual. + The spetial warning information in this instruction manual. * The instructions in the safety manual. + The operating instructions of the operating company. instruction manual Danger to life/risk of injury to persons can exist at the plant through, e.9.: + Misuse. + Incorrect handling. + Transport. + Missing safety devices. + Defective or damaged components. *Handlng/eperation by personnel without training or instruc- ion. The plant can cause dangers to the environment through, ¢.9.: + Incorrect handling. + Fluids and lubricants, ete. + Noise and dust emission. Damage to the plant is possible through, e.9.: + Incorrect handling, + Nonobservance of operating and maintenance specifica- tions. ‘Unsuitable fluids and lubricants. Damage to further material assets in the operating area of the plant is possible through, e. + Incorrect handling. Limitations to the performance and range of functions of the plant can result due to, e, + Incorrect handling. # Incorrect maintenance or repair. + Unsuitable fluids and lubricants. 1.03 Climatic conditions The minimum and maximum permissible ambient temperature of the plant is specified in chap. 5.01.01.07. Low ambient In cold weather, the starting behaviour and operation of the die~ temperature sel engine depend on the following: Wednestay-oa:htaret Ht ktkoestiny printed ‘© Kleemann GmbH 2016 23GENERAL Climatic conditions lw] KLEEMANN + Fuels used, + Engine oll viscosity. ‘+ State of the starter batteries. Suggestions for operation in cold weather: ‘+ After start-up, allow the diesel engine to run until an oper- ating temperature of at least 80°C has been reached. Reaching Une currect service temperature prevents the in take and exhaust valves from jamming. + When the diesel engine is shut down, the cooling and lubri- cation systems are not immediately cold. This means that the diesel engine can be shut down for a few hours and then started again without any problems. + Below 0 °C, use winter diesel with sufficient fluidity. ‘+ Fill with the correct lubricant before the start of the cold sea~ son. + Check all rubber parts (hoses, V-belts, etc.) once a week. + Check all electric cables and connections for abrasion and damage to the insulation, ‘+ Charge the starter batteries and keep them warm, ‘+ Fill the fuel tank at the end of every work shift. wD In special operating conditions, it may be necessary to use oth- er suitable fluids and lubricants. With the cold package special equipment, plant operation up to -25 °C is also possible. Because of the use of low-temperature lubricants, however, operation is limited to a maximum temper- ature of +30 °C. With the hot package special equipment, plant operation from +40 °C to +50 °C is also possible. Risk of injury and property damage ‘The use of alcohol or other starting aid fluids involves a risk of ‘explosion and injury. + Never use aerosol starting aids, e.g. aether, High ambient With increasing altitude or ambient temperature, the maximum, temperature, high output of the diesel engine, the exhaust gas quality, the tem- altitude perature level and, in extreme cases, the starting behaviour, are impaired. If the plant is operated at an altitude above 1000 m or at an am- bient temperature above 30 °C, a reduction in the injected fuel volume is necessary. Heavy rain and storms During heavy rainfall, rain water can enter the air intake of the running diesel engine. Rain is then dravin into the combustion ‘chambers where the water impact can cause engine damage. Weenenday-ba:htaret B-hikowstiint printed 24 © Kleemann GmbH 2016[w] GENERAL KLEEMANN Safety information 1.04 1.04.01 Strong wind @ ‘Suggestions for operation during heavy rainfall and storms: + Ifheavy rain or a storm is expected, switch off the plant and the diesel generator. * If opened, close the housing of the drive unit. + Close the switch cabinet. + Keep away from the plant until the storm has passed Dangerous voltage Operation of the plant during storms can attract lightning and result in serious or fatal injury and damage to property. * Switch off the plant and move away from the plant until the storm has passed. + Check the electrical system if itis struck by lightning. Basically, the plant can be operated irrespective of the wind force. However, strong wind can affect dust creation in the area around the plant. Influence of strong wind: + Strong wird impairs the perfect formation of the dust-bind- ing atomised spray in the spray system and thus also con- ‘tributes to the Increased spread of dust. + Strong wind can influence the grain of the discharged mate- rial by blowing away the fines. + An unfavourable wind direction can result in increased clog ging of the cooler fins and the filter for the drive unit: Dust formation can be reduced by the additional use of belt cov ers and ejector chutes (options), but not eliminated completely. Safety information Due to the intended use of the plant, neither foreseeable misuse nor residual dangers can be avoided without restricting the specified range of functions. This situation presents a risk to life and limb of operating, maintenance and service personnel which, however, can be minimised if the basic safety instruc- tione dre observed. Safety manual Read through the safety manual provided separately by KLEE- MANN GmbH. It describes the general hazards involved in oper- ation, maintenance and repair of the plant and how to avoid them. The safety manual is an element of the instruction man- ual. Wednesday: an Htktkorestiny printed ‘© Kleemann GmbH 2016 25GENERAL Safety information [w]] KLEEMANN 1.04.02 _ Environmental protection Packaging material, cleaning agents, used or residual fluids and lubricants as well as removed wear parts, such as conveyor belt, baffle plates, impac: toggles, crushing jaws, wear lining, rubber seals, etc. must be brought to a recycling centre in accordance with locally applicable environmental specifications. 1.04.03 Disposal of machine Nature conservation is one of the most urgent priorities. Correct disposal prevents negative effects on humans and the environ- ment and permits rouse of valuable raw materials. Fluids and lubricants Dispose of fluids and lubricants according to the relevant spec ifications and the respective national regulations. Materials (metals, plastics) Correct disposal of materials means that they are unmixed. Re- move adhering impurities from the materials. Dispose of materials according to the respective national regu- lations. Electrical system/electronics ‘The electrical/electronic components are not subject to the WEEE Directive 2002/96/EC and corresponding national laws (in Germany, e.g. ElektroG = Electrical and Electronic Equip ment Act). Deliver the electrical/electronic components directly to a spe- cialised recycling company. 1.04.04 Notes on the electrical/electronic components Please note the following safety instructions for optionally avail- able electrical/electonic devices: + Check the goods immediately upon receipt for damage or defective parts. + Do not put defective devices into operation. ‘+ Damaged cables and plug connectors are a safety risk and must not be used. + Contact your local KLEEMANN branch, who will supply a re~ placement immediately. Installing Prior to assembly and operation of the devices, carefully read through the entire instruction manual. If you have any ques tions, please contact your local KLEEMANN branch. During a5- sembly of the devices, only use the original KLEEMANN cables. ‘The connectors must not be removed from the cables as they are protected against dampness and opening would destroy this Wedresctay-aarhtare H+ ktkorestiny printedtts 26 © Kleemann GmbH 2016[w] GENERAL KLEEMANN Safety information protection. Ensure that the securing screws are firmly fitted at the plug connectors. Further assembly instructions for the de- vices and sensors are available in the separate data sheets or instruction manuals. If the above-cescribed points are not observed, KLEEMANN GmbH cannot provide warranty for the electrical/electronic de- vices. Safety precautions The safety precautions recommended here basically correspond to the guidelines for installation and commissioning of electrical systems. They can be applied to all applications in conjunction, with KLEEMANN devices. Wiring The wiring must be installed in accordance with the specifica- tions in this instruction manual. All feeds and connecting termi- nals must be dimensioned for the relevant strength of current. Furthermore, all connections must be made according to the valid VDE specifications in Germany or the respective national specifications. Interference resistance ‘The devices are designed for industrial use and tested accord- ingly. In spite of this. the microprocessor technology makes some demands on the installation. We would therefore like to draw your attention to the following installation features which, if not observed, could result in subsequent malfunctions: + Ensure the terminals have the correct polarity. * Do not exceed or undershoot the specified supply voltage range. + Ensure that the electrical connections between the device housing ard components and chassis of the plant are correct to guarantze trouble-free operation. + Only connect shielded cables on one side to earth (device side). + Never supply other devices directly from the connecting ter- minals of the supply voltage. + Never use free terminals as a connection for other terminals or devices, Fuses The devices are equipped with fuses to protect against short cir- cuits. The supply voltages specified in the technical details must not be exceeded. Configuration The devices can also be configured by the user. Any reconfigu- ration made by the user must always correspond to the actual situation of the plant. Wednesday: Ht ktkoestiny printed ‘© Kleemann GmbH 2016 27GENERAL Safety information lw] KLEEMANN Potentially explosive areas ‘The devices are not designed for use in potentially explosive ar- eas. Troubleshooting Before starting troubleshooting, ensure that all supply voltage to the device is interrupted. Defective devices should be exam- ve itt at aia pruperly equipped for test purposes. Any at- ‘temptto eliminate malfunctions on a device that is stil installed could be dangerous to operating personnel and the plant. Be- fore removing or replacing sensors fitted on the device, ensure that all supply voltage is interrupted If you have any questions on operation and assembly, please (GA) cottace Your Toca KLEEMANN Branch If the above-listed precautionary measures are not observed, this can result in failure of the device or the plant. Damage re- sulting from nonobservance of the above-listed precautionary measures shall not be covered by the manufacturer's warranty. 1.04.05 Danger areas Fig. 1.1:Danger area 1 Danger area of the plant 2 Danger area of feeding and loading vehicles During automatic rode and while the plant is moving, persons must stay clear of the danger area of the plant and the feeding and loading vehicles. In the following situations, authorised personnel must only en- ter the danger area when the plant is stationary and secured Weenenday-ea:htaret Barrows printed 28 © Kleemann GmbH 2016GENERAL [w] KLEEMANN Safety information + For maintenance, repair and service work. * During installation, removal and conversion work. * During ongoing transport work. 1,04,05,01 Safety distance Fig. 1.2:Safety distance between work and traffic area 1 Traffic area 2 Safety distance 3 Work area If the plant is operated directly beside public roads, e.g. during road construction work, the safety distance to the traffic area must be observed. The distance between the work area and traffic area must com- ply with national specifications. 1.04,06 Fire fighting appliance fire classes A, B and C and a sufficient quantity of filling com- pound must be provided. Observe country-specific specifica- tions. ‘The serviceability of the fire extinguisher must be checked at least once a year by a specialist. Make sure that operating, maintenance and repair personnel are familiar with the handling of the fire extinguisher. The plant ‘owner is responsible for this. wD For fire fighting at the plant, at least one fire extinguisher for Wednestay-e2-htaret -2a-nioestin pried © Kleemann GmbH 2016 29GENERAL Emissions and loads [w]] KLEEMANN 1.05 1.05.01 Wednesday 30 Emissions and loads w No modifications must be made to the plant that result in in- creased noise, dust and vibration emissions. ‘+ Read and observe the safety manual. ‘+ Always wear your personal hearing protection and a breath- ing mask when required. + Ensure that all devices for reducing noise and dust emissions are installed and operable. ‘+ Do not make any modifications to the plant. Noise emission tert ‘Sound power level ‘The sound power level of the plant is usually surpassed during crusher operation by the process noise. The sound power level is specified in chap. 5.01.01.08. Emission sound pressure level In automatic mode, the plant runs fully automatically without ‘operating personne’. For this reason, there is no directly as- signed workplace, so that the emission sound pressure level is not directly relevant. The emission sound pressure level is spec- ified in chap. 5.01.01.08. Danger of hearing damage When working directly beside the plant or on its platforms, the permissible daily ncise exposure level (LEX,8h) of 80 dB (A) is exceeded. + Always wear your personal hearing protection when re- quired. Danger due to communication disturbance Noise development at the plant can interfere with communica tion between personnel and result in dangerous situations. © Agree on sunamhiguous hand signals to avaid misunder- standing. Use radiotelephony where possible. ‘+ Avoid the danger area during operation, maintenance, in- stallation, removal and transport of the plant. © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Emissions and loads 1.05.02 Dust emission k of health damage The inhalation of dust can cause serious illnesses. * Wear a breathing mask. For design and process-related reasons, the creation of dust during plant operation cannot be completely prevented. However, the dust emissions and the resulting danger can be minimised by observing a few measures: + Always switch on the spray system during operation. + Align the spraying nozzles correctly to ensure effectiveness. + Always keep a sufficient supply of water ready. Depending on the number of spraying nozzles used, between approx. 5+ 10m? per shift. + Ensure that the spraying nozzles, supply lines and other wa- ter system components are in perfect condition. + Use belt covers and ejector chutes (optional equipment). + Replace defective or worn dust seals. Further information an dst develapment, avaidanee and the @ spray system is avallable in chap. 2.12 and chap. 1.03. 1.05.03 Vibration emission In automatic mode, the plant runs fully automatically without operating personnel. For this reason, there is no directly as~ signed workplace, which makes the vibration emission pressure level irrelevant. During its operation, however, the plantis subject to stress from vibrations. Personnel authorised to enter the platforms only for maintenance and repair work are subject to stress through vi- bration, However, observance of a few measures permits minimisation of the vibration emissions and the resulting danger: + Do not remain on the platforms longer than necessary when perfurning maintenance and repair work: + Donot walk on the vibratory screens, feeder trough and ex- tractor channels until they have come to a complete stand- still. Wednestay-e2-htaret -2a-nioestin pried ‘© Kleemann GmbH 2016 31GENERAL Signs [w]] KLEEMANN 1.06 1.06.01 1.06.02 Wednesday: Signs Sign diagram ‘The sign diagram is in the spare parts catalogue. Signs/decals 8 v This section informs you about the special function of the signs. ‘The hazard warnings are described in the safety instructions. Vibrating conveyor trough rocker width gauge For specifications of the vibrating conveyor trough rocker width gauge, see chap. 4.43,03.02. ‘Screen rocker width gauge For specifications of the screen rocker width gauge, see chap. 4.45.07. Direction of rotation arrows Direction of rotation of the drive shaft of a screen. Grease lubrication points Details on grease quantity and interval of corresponding lubri- ‘ation point. Lifting point When lifting machires and components, always used the iden- tified lifting points. Lashing point When lashing the plant of individual machines and components, always used the identified lashing points. 32 tert throrestiny printed © Kleemann GmbH 2016GENERAL KLEEMANN Signs Before carrying out welding work on the plant, note the specifi- cations in the instruction manual. Raising and lowering magnetic separator [Hydraulic raising and lowering of the magnetic separator. Folding hopper walls Fold up and feld in left, middle and right hopper walls. Folding belt conveyor -—————— Hydraulic folding up and down of belt conveyor. Identification plates ‘The entire identification documents the certification and must not be modified or made unrecognisable. For the transport weight of the plant and the machines and ‘components to be transported individually, please refer to chap. 6.01.02.02. leemann GmbH 2016 33GENERAL Personnel - qualifications and duties [w]] KLEEMANN 1.06.03.01 Plant identification plate Fig. 1.3:Plant identification plate 1 Identification plate Enter the data of the identification plate in the following table: [Designation [etaile 1. Designation 2. Series / model 3. Serial number 4, Engine performance data [5. Generator performance data (6. Operating weight 7. Year of manufac:ure Tab. 1.1: Identification plate details 1.07 Personnel - qualifications and duties All activities at the plant must only be carried out by authorised personnel. Wednesday oehtare +22 Khost printedtth 34 © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Personnel - qualifications and duties 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. Wednestay-oa:htaret theoestin- printed ‘© Kleemann GmbH 2016 35GENERAL Personnel - qualifications and duties [lw] KLEEMANN Observe the following information: + Familiarise yourself with the plant's equipment. + Move the plant only after making yourself fully familiar with the operating and control elements as well as the method of functioning. + Familiarise yourself with your working area. + Use the plant orly for its intended purpose. + Always use suitable hoisting gear and lifting accessories for transportation and installation of heavy components. + Always wear your protective equipment, such as safety shoes, protective helmet and hearing protection. ‘+ If deficiencies are determined at the safety devices, inform the plant owner immediately. + If other deficiencies are determined that impair safe opera- tion of the plant, inform the plant owner immediately. ‘+ If defects are found that endanger personnel, shut down plant operation immediately, + If unauthorised conversions or changes to the plant are de- termined that impair safe operation of the plant, inform the plant owner immediately. ‘+ Observe the following elements attached to the plant = Safely signs, = Health protection signs. = Safety information. ‘+ Read the safety specifications and information additionally prepared by the plant owner for special cases. ‘+ Check the completeness and legibility of the = safety signs. = health protection signs, safety information (plates, decals, pictographs). + Before starting work, inform yourself about = first ai. = rescue options (emergency doctor, fre brigade, helicopter). ‘+ Ensure that a first-aid box with standard specified contents is available, Banksman A banksman is alweys required when the driver has an incom- plete view of the movement or transport route. Independent guiding of plants is only possible by persons who, in addition: Weenenday-ea:htaret sh 36 © Kleemann GmbH 2016GENERAL [w]] KLEEMANN Personnel - qualifications and duties + have receive training in how to guide the plant. * can provide verification of successful participation in the training course. + have provided the plant's owner with proof of their ability to perform the work. + can be expected to reliably carry out the tasks assigned to ‘them. ‘They have to 2e appointed by the plant's owner to function as a banksman for the plant. To avoid misunderstandings, unambiguous hand signals should be used, e.g. according to the German Employer's Liability In- surance Association specification "Safety and health signs at the workplace” (BGV A 8). Observe the following information: + Make yourself familiar with the dimensions of the plant and the transport vehicle. + When guiding the plant or vehicles, always wear a warning waistcoat. * During movement of the plant, guiding can be by means of hand signals; when loading the plant with a crane, use radi- telephony where possible. +The meaning of the hand signals between driver and hanks man must be clarified beyond doubt before starting. Service, mainzenance and repair personnel are responsible for Personnel. ensuring safety and hazard warnings are in a legible condi- tion. + protecting the plant against unauthorised use. + ensuring that maintenance and repair work is co-ordinated with the plant owner. + ensuring that the plant is only operated when fully functional and inherently safe. + ensuring that service, repair and maintenance tasks are car~ ried out safely and correctly 1.07.01 _ Protective equipment All elements cf the protective equipment must be worn during all activities a: the plant described in this instruction manual: + protective helmet. + safety shoes. + protective gloves. + reflective clothing. Furthermore, in certain working conditions the following safety equipment must also be worn: Wednestay-oa:htaret theoestin- printed ‘© Kleemann GmbH 2016 37GENERAL Revision statuses [w]] KLEEMANN + hearing protection. + safety goggles. + breathing mask, 1.07.02 Available training courses ‘To provide operating, maintenance and service personnel with appropriate qualifications, KLEEMANN GinibH offers @ series of training courses that form the basis of optimum and safe use of the plants. ‘The training courses can take place at KLEEMANN GmbH or di- rectly at the operatng company following consultation. + Basic principles of crushing and screening technology. + Design and method of operation of the plants. ‘+ Basic principles of plant operation. + Maintenance and repair. + Basic principles of electrical systems. + Basic principles of hydraulics. 1.07.03 Contact persons for operation and maintenance Contact persons for operation, maintenance and service are list ‘ed under "Customer service" on lhe hurniepaye of KLEEMANN GmbH: www.kleemann.info 1.08 Revision statuses Changes to the instruction manual KO07 MC120Z: Date Revision status [Change \Valid from serial no.: Transfer to editing system FM |KO07-0053, + Revision of contents, technical data = Incorporation of safety notices (08.13.2010 |F20005539_6 [+ Content changes to "Changing |KO07-0207 pressure plate and pressure plate bearings" [23.09.2011 [2223675_00 |» Transfer to editing system TIM _ |KO07-O221 = Comprehensive revision and ex- tension of all contents New structure and layout CI conversior and various up-|KO07-0266 dates (09.01.2006 |F20005539_A 19.10.2015 |2492874_00 Weenesday-o2:htare Het 38 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Revision statuses 2 DESCRIPTION w This chapter contains a description of the functions of the plant and the assemblies. Position numters in assembly graphics are marked in the text by round brackets ( ). Position numbers of single component graphics are 1 the text by square brackets [ ]. During all activities, observe the information in your safety manual! rked int Standard and optional equipment This instruction manual describes all standard and optional equipment of the plant. Optional equipment is identified by the word "Option", All machines and components that are not ‘marked with "Option" are part of the standard equipment of the plant. 12 11:10 Fig. 2.1:Plant overview [1] Feed hopper [2] Grizzly [3] Jaw crusher [4] Power supply unit [5] Magnetic separator (option) [6] Crusher discharge conveyor [7] Running gear [8] Extractor channel [9] By-pass device [10] Prescreen conveyor (option) Wednestay-e2-htaret : ‘© Kleemann GmbH 2016 39DESCRIPTION Revision statuses [w]] KLEEMANN [12] Chassis [12] Feeder trough With the help of a digger or wheel loader, material is loaded into the feed hopper [1]. The vibrating feeder [12] conveys the ma- terial further to the prescreen [2] ‘The prescreen separates the incoming material depending on the clamped serecn eurface. @) Upper deck covered with punched plate or slotted grate (op tion); lower deck covered with rubber screen surface: * Coarse material that does not pass through the upper deck of the ‘grizzly is conveyed directly into the jaw crusher [3] + Material that passes through the upper deck is guided via the rub- ber screen sutface and the bypass [8] past the crusher directly ‘onto the vibrating extractor [8] ‘This is used, for example, with clean feed material to supply the entire feed material to the final product without having to dispense with the advantage of primary screening and thereby relieving the burden on the crusher. b) Upper deck covered with punched plate or slotted grate (op- tion); lower deck with screen surface (option): + Coarse material that does not pass through the upper deck ofthe prescreen is conveyed directly into the jaw crusher (3). + Material that fasana thrugh the upper dank but sot the tower deck is guided via the bypass [8] past the crusher directly onto the vibrating extractor [8 + Material that passes through the lower deck of the prescreen is ‘discharged via the prescreen conveyor [10] onto a waste tip or a ‘downstream plant. ©) Upper deck covered with dummy cover (option): + The entire feed material reaches the crusher. Primary screening is not active Used for crushing hard rock if this achieves a more compact crusher jaw fillirg. ‘The jaw crusher [3] crushes the oversized product of the pre- screen depending on the setting of the crushing gap to a final grain size with oversized product share and passes it on to the, vibrating extractor (8). ‘The vibrating extractor [8] receives the crushed material from the Jaw crusher and Uarsfers i to Ue crusher discharge won veyor [6]. ‘The crusher discharge conveyor [6] discharges the material ei- ther to a waste tip or transfers it to a downstream crushing or screening plant. ‘The magnetic separator [5] removes the ferrous elements and ejects them onto a waste tip. Wednesday: 40 tert throrestiny printed © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Chassis/guard devices EL r BS 0 . eH KNEE — 3 Fig. 2.2:Flow chart [1] Feed hopper [2] Prescreen [3] Jaw crusher [6] Crusher discharge conveyor [7] Vibrating feeue [8] Vibratirg extractor [10] Prescreen conveyor (option) The flow chart demonstrates the material flow within the plant. ‘The grain sizes produced depend on the charged material, set gap width of the crusher, fitted screen surfaces and other fac- tors. 2.01 — Chassis/guard devices 2.01.01 Information and hazard signs ‘The signs (hazard, prohibition, mandatory and information signs) must be attached to the plant and be easily legible. Signs fitted directly on the plant must be observed. ‘An overview cf the signs is provided in the spore parts cata- logue. ‘The information sign are described in chap. 1.06.02. The haz~ ard, prohibition and mandatory signs are described in the safety instructions, Wednestay-oa:htaret theoestin- printed ‘© Kleemann GmbH 2016 41DESCRIPTION Chassis/guard devices ww] KLEEMANN 2.01.02 Chassis with beams Fig. 2.3:Chassis with beams [1] Chassis at feeding side [2] Magnetic separator mounting [3] Chassis at discharge side [4] track drive [5] Chassis beam ‘The chassis consists of a welded design of sheet steel and spe- cial section tubes. The chassis beams (5) are welded onto the chassis. ‘The mountings, belt suspensions and supports for the individual machines and components, e.g. feed hopper, vibrating conveyor troughs, crusher, belt conveyors and magnetic separator are mechanically secured to the chassis. Weenenday-ea:htaret 42 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Chassis/guard devices 2.01.03 Platforms Fig. 2.4:Platforms and ladders (1) [1] Platforra for diesel fuel tank [2] Platform between crusher and power supply unit [3] Steps to crusher and power supply unit [4] Anti-fall guards [5] Platform for grizzly, right [6] Platform on crusher [7] Platforms for grizzly, left [8] Ladders Fig. 2.5:Platforms and ladders (11) [9] Platforms below grizzly Wednestay-e2-htaret -2a-nioestin pried © Kleemann GmbH 2016 43DESCRIPTION Chassis/guard devices [w]] KLEEMANN ‘The steps, ladders and platforms permit access to machines and plant components. ‘The anti-fall guards prevent persons from falling off the plat- forms in the area of the ladder. For plant transport, the ladders can be detached or folded up. Risk of falling Incorrectly fitted platforms, ladders, handrails and anti-fall guards can result ir people falling. + Ensure that platforms, ladders, handrails and antifall guards are correctly fitted. 2.01.04 —_Lighting/warning devices Wednenday-ea-htaret Fig. 2.6:Warning light and warning siren [1] Warning light [2] Warning siren [3] Receiver aerial for radio remote control ‘The warning light [1] and the warning siren [2] light up or sound tor approx. / seconds after activation of the start enable. after 2 fault occurs or an emergency stop is tripped, they remain ac- tive until the fault is acknowledged in the operator panel. ‘The warming light is secured to a mask, which is moved out be- fore putting the plant into operation and clamped, ‘The warning siren is secured on the outside of the switch cabi- net. © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Chassis/guard devices Fig. 2.7:Lighting [1] LED or halogen lamps The LED or ha ogen lamps [1] are secured on a mast, which can be rotated and inclined. They can be used to illuminate working areas individually. ig eh ah ni Unc cn aa Gp eae 2.01.05 Socket outlets on the chassis Sockets for prescreen conveyor, Lf ge c Fig. 2.8:Sockets for prescreen conveyor [1] Connection for prescreen conveyor drive Wednestay-e2-htaret -2a-nioestin pried © Kleemann GmbH 2016 45DESCRIPTION Chassis/guard devices [w]] KLEEMANN [2] Connection for prescreen conveyor emergency stop [3] Plant emergency stop connection (option) The Sockets are fitted on both sides of the chassis to allow the @ prescreen conveyor to be installed on the left or right. ‘To operate or move the plant without the prescreen conveyor, ‘dummy plugs must be inserted in the emergency-stop Sockets. Magnetic separator sockets =~. Fig. 2.9:Sockets for the magnetic separator [1] Electromagnet terminal [2] Magnetic separator drive terminal wo If the plants operated without a magnetic separator, the socket ‘outlets must be covered with a dummy end to protect against dust and dirt. 2.01.06 Guard devices Guard devices can be detached or opened with the help of tools, @ ‘or special spanners and must remain fixed in position for oper- ation and routine maintenance tasks. They can be taken off for repair work. Wednenday-ea:htaret Barrows printed 46 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Chassis/guard devices Guard devi Fig. 2.10:Guard devices on the plant (1) [1] Hydrauie cylinder guard device [2] Crusher inlet cover [3] Crusher drive pulley protective cover [4] Crusher drive flywheel protective cover [5] Screen drive unbalance segments protective covers [6] Grizzly drive protective cover ‘The crusher inlet cover prevents the ejection of material from the crusher. It must be set such that ejection is prevented but charged material can still reach the crusher unobstructed. ‘The guard devices of the hydraulic cylinder at the feed hopper are fitted on the rod side of the cylinder. When the hopper walls are folded down, the guard devices move with them. ‘The guard device of the belt drive covers the V-belt and the V- belt pulleys completely. Wednestay-e2-htaret -2a-nioestin pried © Kleemann GmbH 2016 47DESCRIPTION Chassis/guard devices ww] KLEEMANN Guard devices on belt conveyors Fig. 2.11:Guard devices on belt conveyors [1] Guard for bend pulley [2] Guard for bottom segment, lower [3] Material guide ledges [4] Guard for drive pulley [5] Guard for bottom segment, upper [6] Guard for return rollers. ‘The guard devices of the belt conveyors protect against being ‘drawn in or caught by machinery and against lateral falling of material. They are fitted on all belt conveyors where it is neces- sary to protect against hazards. ‘The guard devices must be set so that the gap at the draw-in point is a maximurr of 5 mm, Weenesday-ea:htaret 48 sh © Kleemann GmbH 2016DESCRIPTION KLEEMANN Chassis/guard devices Component securing elements: Fig. 2.12:Component securing elements [1] Spring pin [2] Securing chain [3] Locking pin Locating pins and locking pins used to Install components are secured with spring pins. IF components are net installed on the plant, the locking pins and spring pins must be kept for reuse. Component securing elements Fig. 2.13:Component securing elements [1] Gas strat [2] Service flap of power pack housing Wednestay-e2-htaret -2a-nioestin pried © Kleemann GmbH 2016 49DESCRIPTION Chassis/guard devices [w]] KLEEMANN [3] Locking mechanisms The locking mecharisms prevent the service fiap from falling shut, During maintenance and repairs, the service flaps must be se- cured with the locking mechanisms. 2.01.07. Emergency stop Emergency stop and emergency switc! plant Fig. 2.14:Emergency stop at the plant [1] Emergency switching off button in the switch cabinet [2] Emergency-stop button on the plant ‘The emergency-stop button [2] at the plant switches off all plant drives with the exception of the diesel generator. The crusher is switched off after a defined run-after time. ‘The emergency swisching off button [1] in the switch cabinet switches off the entire plant including the diesel generator. ‘The emergency stop and emergency switching off button are re- leased by turning the button. The plant components and ma- chines then have to be restarted at the operator panel in the switch cabinet. Weenenday-ea:htaret sh 50 © Kleemann GmbH 2016[w] DESCRIPTION KLEEMANN Chassis/guard devices Emergency stops at conveyor belts Fig. 2.15:Emergency stops at conveyor belts [1] Pull cord [2] Emergeney-stop switch ‘The release cord [1] is routed in eyelets along both sides of the belt conveyor. Pulliiy Ue release wid autualee Une eitnei yetity= stop switch [2], which shuts down all plants drives with the ex- ception of the diesel generator. The crusher is switched off after a defined run-after time. ‘The emergency-stop switch is released by resetting the lever to ‘the middle position. The plant components and machines then have to be restarted at the operator panel in the switch cabinet, Wednesday ©kl thet : leemann GmbH 2016 51DESCRIPTION Control stand [w]] KLEEMANN 2.02 Control stand Weeneaday-ba:htaret Fig. 2.16:Plant control stand (2) Control stand All plant functions are controlled from the control stand during initial operation anc setting or maintenance work. ‘The control stand can be accessed by lifting the switch cabinet flap at the switch cabinet protective housing. The switch cabinet flap is held in its folded open position by telescopic rods. During regular crusver operation the plant is controlled exclu- sively Via radio remote control. The operator, therefore, does not need to stay at the control stand. During regular cruser operation the switch cabinet flap of the ‘switch cabinet protective housing must remain closed to pre- vent ingress of water and dust. During setting or maintenance tasks without feeding unit, the ‘switch cabinet flap can remain open for operating the control ‘system. In this case, it serves as weather protection for operat- ing, maintenance and repair personnel. The instruction manual is in the switch cabinet. 52 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Control stand 2.02.01 Main switch Fig. 2.17:Main switch [1] On position (ON) [2] Tipped position (TRIP) [3] Off postion (OFF) [4] Locking button [5] Control knob ‘The main switch connects and disconnects all plant consumers from the external power supply. The external circuits are not connected or disconnected (see chap. 2.06.06). In the case of undervoltage or a fault in a ground-fault current interrupter, all drives of the plant shut down. The main switch remains in the On position [1]. ‘The main switch is switched off by turning into the tripped po- sition [2]. By turning back to the Reset position and then turn- ing back to the ON position [1], the main switch is activated again. ‘The main switch is secured in the Off [3] position against unau- thorised activation by pressing the lock button [4] and attaching a padlock, ‘The main switch is connected by a square rod to the actuator in @ ‘the switch catinet. When the switch cabinet is closed, the main switch and the actuator must be correctly reconnected with the square rod. Wednestay-e2-htaret -2a-nioestin pried ‘© Kleemann GmbH 2016 53DESCRIPTION Control stand [w]] KLEEMANN 2.02.02 Operator panels/Interfaces LS ISSIR a]Ss lesa]! | R Heel 8 | j 23 2 2 2% 2 2% 2 3 31 32 33 Weenenday-oa:htaret Barrows printed 54 © Kleemann GmbH 2016DESCRIPTION [lw] KLEEMANN Control stand Fig. 2,18: Operator panel [Control element/indi- Function leator [i] [Oi pressure Indicates the current ol pressure ofthe diese engine ar [2] [Coolant temperature Indicates the current coolant temperature of the diesel lengine in °C. [3]___|Fuel gauge Displays the fill level of the diesel fuel tank [41 |fanition switch with control |Starts and stops the diesel engine, displays the operat- lamps ing status of the diesel engine, see description of "Igni- tion switch” [5]__|Amperemeter Displays current consumption of crusher drive [6] |Amperemeter Displays current consumption of entire plant [7]__ [voltmeter Displays the voltage between the phases with the main ‘switch switched on Te] _ Operator panel OPS Interface for setting different plant parameters, see de- scription of "Operator panel OP3" TS]__ [Rotary switch for lighting | Switches plant headlights on/off [10] [Rotary switch for fillTevel | Switches fil level monitor at crusher inlet on/off monitor [i] [Coupling button Disengages/Engagee drive coupling [12] _ [Key switch for control volt- |Switches plant control voltage on/off lage [13]_ [Plant/Crusher on button __| Switches on the plant/crusher [14] _ [Plant off button Switches plant off [15] _ [Start release control lamp_|Displays start release of plant [16] |Acknowledge fault/emer-_|Acknowledges faults and emergency stops lgency stop button [17] [Rotary switch automatic | Switches over to automatic or manual operating modes. Imode/manual mode In marual mode position, the sequential locking device of the machine is switched off. [18] [Automatic mode control [Displays automatic mode lamp [19] _ |Manual mode control lamp [Displays manual mode [20] [Magnetic separator rotary Switches conveying direction of magnetic separator to [swatch left/right [2i] _ |Rotary switch for radio re- | Switches plant on/off via radio remote control mote control [22] __ [Lamp test button Carries out lamp test of control lamps [23] [Button for magnetic sep- | Switches magnetic separator on/off larator [24] |Button for spare belt con- |Switches spare belt conveyor on/off lveyor Wednesday-ee:ttarc trstin printed ‘© Kleemann GmbH 2016 55