MAINTENANCE [w]] KLEEMANN Electrical system > Use a suitable tool to remove the retaining screws and re- taining plates of the starter battery. > Replace the starter battery, ensuring the installation position is correct. > Clean the battery poles and terminals and grease with acid- free and acid-resistant grease. > Install Cables on the starter batteries in the reverse se~ quence. The terminal clamps must have good contact. > Ensure thet the battery poles are not interchanged (risk of short circuit!) Refit the protective caps of the cable connections. > Reinstall retaining screws and retaining plates of the starter battery. ¥ The starter battery has been changed. 4.06.03 Servicing switch cabinet 4,06.03.01 Checking electrical components a DANGER! Danger of electric shock Incorrect work inside the switch cabinet can result in lite-threat- ening situations. + Maintenance, repair and service work on the electrical sys- tem must only be carried out by qualified and authorised personnel, Wes Danger of material damage Blowing out the switch cabinet with compressed air can result in failure of the electrical system. + Remove dust and dirt in the switch cabinet by vacuuming or brushing out. > Open the switch cabinet protective housing; keep switch cabinet closed. > Visually check the electric cables inside the switch cabinet protective housing for damage. Visually check the cable entries on the switch cabinet pro- tective housing for damage. > Visually check socket outlets on the switch cabinet for dam- age and security. > Visually check operating and display elements for damage. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 201MAINTENANCE Electrical system [w]] KLEEMANN > Remove dust deposits and dirt from the switch cabinet pro- tective housing, e.g. by vacuuming. > Have damage te electric components repaired by qualified and authorised personnel only. ¥ Electric components in the switch cabinet are checked. 4.06.03.02 Checking switch cabinet mounting Fig. 4.21:Rubber ai- springs [1] Automatic valve [2] Rubber air spring > Check rubber air springs [2] for damage. > Check fastening of rubber air springs. > Check that the air pressure and height of the rubber air springs are correct. > Pump more air in via the automatic valve [1] as required. ¥ The switch cabinet mounting has been checked, Dia, of air [Height [Pressure [Use spring 80mm 60mm [3 bar/ 43 [Single switch cabinet psi ii8mm [72mm [5 bar/72 [Double switch cabinet psi Tab. 4.1: Rubber air springs Weenesday-o2-htare Het 202 © Kleemann GmbH 2016i MAINTENANCE KLEEMANN Electrical system 4.06.04 — Servicing electric motors ———— Fig. 4.22:Terminal box [1] Cable entry [2] Terminal box cover [3] Seal Damaged and loose terminal boxes and cable entries for electric motors can cause contact problems and short circuits if pene- trated by moisture. > Visually check all cable entries [1] for damage. Visually check cables for chafing and secure installation. During operation, cables must not scuff due to an excessively w large swinging range. The dead weight of the swinging cables must not exert excessive pull on the cable entries. > Check all terminal box covers [2] for security and leaks. > Replace sealing [3] if necessary. ¥ The terminal boxes are checked. The following terminal boxes must be checked: + Drives of the belt conveyors + Drives of the vibrating conveyor troughs + Drives of the screens + Drive of the water pump Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 203MAINTENANCE Electrical system [w]] KLEEMANN 4.06.05 Servicing overpressure system Fig. 4.23:Filter housing overpressure system [1] Dust filter main filter element [2] Flexible corrugated hose [3] Cyclone prefiter, transparent tank [4] Clamping brecket [5] Safety filter element General work > Press the sealing lips of the dust outlet valve together to al- low accumulated dust and water to escape. Loosen and remove dust deposits. ‘The dust outlet valve is ready for operation again. > Check flexible corrugated hoses [2] for damage and replace if necessary. Check the connecting points of the flexible corrugated hoses for leaks and secure installation, Servicing cyclone » Check fill evel of transparent tank [3]. The fill level must not prefilter exceed the MAX mark. > Ifnecessary, open clamping bracket [4], take off cover and drain container. Check air inlet on the bottom side for clogging with dust and dirt and clean if necessary. cv v Close cyclone prefilter again. The cyclone prefilter is ready for operation again. Unscrew nut on filter housing cover and take off cover. ‘Take out main fitter element [1] and blow out with dry com- pressed air (maximum 2 bar or 30 psi), working from the in- Servicing dust filter vvsy Weenenday-oa-htaret sh 204 © Kleemann GmbH 2016[w] KLEEMANN MAINTENANCE Electrical system wo 4.06.06 4,06.06.01 Fuses side to the outside. Do not wash out or brush out main filter element. Do not reuse filter elements with cracks and holes, Replace filter element if necessary. Replace main filter element after 5 clean- ings at the latest. Never clean the safety filter element. This would destroy it. > Take uul safety filter element [5] after fifth cleaning of the main filter element at the latest and replace it. > Wipe the interior walls ofthe filter housing with a damp cloth before inserting the filter elements. > Reassemble filter elements and filter housing in reverse se- quence. Ensure that the dust outlet valve faces downwards. ¥ The dust fiters are ready for operation again. Repairing electrical system Automatic circuit-breakers ait 2 | [= et f 1 6. —~ Fig. 4.24:Automatic circuit-breaker [1] Safety switch [2] Indicator field red/areen [3] Auxiliary contact Automatic circuit-breakers, like fuses, disconnect the electric Circuit automatically in the event of overload. They protect lines against damage through excessive heating as a result of exces- sively high current. After an automatic circuit-breaker trips, perform the following work steps: Wednesday-¢2:htarc ‘roost printectts ‘© Kleemann GmbH 2016 205MAINTENANCE Electrical system [w]] KLEEMANN > Before switching on again, find the cause and eliminate it. > Switch on safety switch [1] once again. ¥ The indicator field [2] is red. a) All electrical switching and fusing elements are identified by short codes. When a fault occurs, this short code is displayed in the operator panel OP3. Ihe short codes (e.g. OF4) are also assigned to the numbers on the buttons at the eperator panel and thus to the plant compo- rents. Safety fuses Fig. 4.25:Safety fuses [1] Screw cap with inspection glass rN Bay Danger of electric shock Electric shocks can result in fatal injuries and cause fires in the electrical system, ‘+ Switch off electrical consumers before inserting a fuse. ‘+ Do not bridge or repair fuses or replace them with fuses with an incorrect ampere value. Blown safety fuses can be recognised by the tripped indicating pins behind the inspection glass. > Switch off diesel generator and main switch. > Determine and eliminate cause of the short circuit or over- load. > Remove screw cap and take out blown fuse. Weenesday-o2:htare Het 206 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Electrical system > Insert new fuse with identical ampere value. ¥ The fuse is changed. Fuses in the switch cabinet, see chap. 5.06. @ Observe the following information: + Do not patch up or bridge fuses. + Always replace blown fuses. + If a fuse continually blows, inform authorised personnel. + Do not spray switch cabinets with water. 4.06,06,02 Motor protecting switch Motor protecting switch for drives LE e Gillie, @ ’ 8 180 as eo ee lee ——* 1 peeelBO : Fig. 4.26:Motor protecting switch [1] Test tripping device [2] Rocker switch/rotary switch [3] Tripping range setting The motor protecting switches protect electric motors against ‘thermal overload due to mechanical overload or in the case of a failure of an individual or both external conductors. After a motor protecting switch trips, perform the following work steps: > Before switching on again, find the cause and eliminate it. > Wait apprex. 5 minutes for the components to cool down. > Switch roccer switch or rotary switch [2] back on. All electrical switching and fusing elements are identified by Ww short codes. When a fault occurs, this short code is displayed in the operator panel OP3. Wednestay-oarhtaret ‘therestiny printed © Kleemann GmbH 2016 207MAINTENANCE Electrical system [w]] KLEEMANN ‘The short codes (e.g. 4Q1) are also assigned to the numbers on the buttons at the operator panel and thus to the plant compo- nents. Testing motor protecting switch > Push test tripping device [1] with a flat screwdriver to the k Y Racker cwitch or rotary switeh [2] jumps hack to 0 or OFF. Feeder trough overload relay FEEEES Seren aaa Aaa Wednesday Fig. 4.27:Feeder trough overload relay [1] Manual/automatic reset [2] Stop button [3] Tripping range [4] Test tripping device ‘The overload relays protect the vibration motors of the feeder trough against thermal overload due to mechanical overload or in the case of a failure of an individual or both external conduc- tors. In automatic mode, the relay resets automatically after the vi- bration motor has cooled down. In manual mode, the Reset [1] button has to be pressed. After an overload relay trips, perform the following work steps: > Before switching on again, find the cause and eliminate it. > Wait approx. 5 minutes for the components to cool down. > In automatic mode, wait until the relay resets. > In manual mode, press the Reset [1] button again. 208 tert © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Electrical system ca All electrical switching and fusing elements are identified by short codes. When a fault occurs, this short code is displayed in the operator panel OP3. Testing overload relay > Push test tripping device [4] with a flat screwdriver to the left, ¥_ Tn automatic mode, resetting is automatic after the test trin- ping device is released. > In manual mode, press the Reset [1] button again. ¥ Overload relay is reset. ‘Switching to Manual/Automatic reset > Press in the Reset [1] button with a flat screwdriver and turn to Manual or Automatic, 4.06.06.03 Earth fault circuit interrupter Fig. 4.28:Earth fault circuit interrupter [1] Test tripping device [2] System circuit-breaker [3] Circuit-breaker for external circuit socket outlets Earth fault circuit interrupters compare the current flowing to the consumer with the current flowing from the consumer. ‘These currents are normally identical, In the event of a fault, the current flows to earth, The earth fault circuit interrupter de- tects this situation and interrupts the electric circuit. The system has one earth fault circuit interrupter respectively for the complete system and for the socket outlets of the exter- nal circuits. After an earth fault circuit interrupter trips, perform the follow- ing work steps: Wednestay-22-htaret : ‘© Kleemann GmbH 2016 209MAINTENANCE Electrical system [ww] KLEEMANN > Before switching on again, find the cause and eliminate it. > Switch circuit-breaker [2] or [3] back on. All electrical switching and fusing elements are identified by @ short codes. When a fault occurs, this short code is displayed in the operator panel OP3. Testing earth fault circuit interrupter > Switch on main switch. > Actuate the test tripping device [1]. ¥ The corresponding circuit-breaker [2] jumps back to 0. 4.06.06.04 Engine protection system 3RR24 Fig. 4.29:Motor protection system [1] Display [2] Arrow keys for menu navigation [3] SET button for menu navigation Weenenday-ea:htaret Barrows printed 210 © Kleemann GmbH 2016[~) KLEEMANN ponetseon xxx wo Fig. 4.30:Current monitoring display [4] Current measured value or fault symbol [5] Monitoring form [6] Symbol for change-over contact The current rronitoring relay 3RR24 is suitable for monitoring motors. In three phazes, it monitors the effective value of AG current for viclation of the upper or lower set limit values. The current monitoring relay also monitors phase sequence, phase failure, ground fault and blocking current. The settings can be made directly using the three buttons and a display on the de- vice. Display messages Flashing symbols on the display (5] and [6] indicate that a fault has occurred. ‘The following statuses and faults are shown on the display. [Display rang- les [Symbol Neaning [5] <> yyy A] |range, No limit value set for lower deviation. (Current value is below the measurable current Ik<> pa, Al __ |TRe current valueis above the measurable current range. No limit value set for limit violation. Wednestay-e2-htare ‘© Kleemann GmbH 2016 sikowstiiny printed 2u1MAINTENANCE Electrical system [w]] KLEEMANN Display rang- [Symbol Meaning es [5] Currently measured current asymmetric value is [Asy <> 5%] |aispiayed. ‘+ Not fiashing: current asymmetric value in the acceptance range of delay time is running. os Flehaingy Hen vation enema or unclernshdl, delay time elapsed, relay has tripped. [} Ix <> SOA) [utertv measured current value is displayed ‘+ Not flashing: current in the acceptance range or delay time is running. + Flashing: limit value exceeded or undershot, delay time elapsed, relay has tripped. TST Flashing: current exceeds the set Blocking cur= nx rent. TST Flashing: Faulk current detected 151 Lise Flashing: cable break / phase failure detected i} Pal Flashing: Incorrect phase sequence detected. } ERA Invalid parameters. ST i Fault during automatic test / internal Faulk. (ce sir Device is in communication mode (TO link). (5) RR TO link communication interrupted, Wednesday ee:htare sthesting printed 212 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Electrical system [Display rang- [Symbol [Meaning les [5] e510 [Device is in SIO mode. Tel Monitorina for excessive current or violation of lupper current asymmetrical limit. Tél [Monitoring of warning limit value for violation of current upper limit. (Only visible if the "Limit val- ue for upper deviation” parameter is set to OFF) [6] x [Monitoring for lower value deviation. [6] ‘Monitoring of warning limit value for violation of = [current lower limit. (Only visible ifthe "Limit value for lower deviation" parameter is set to OFF) [6] Viindow monitorina (monitoring of current upper deviation and current lower deviation). Tél a (Current is in the acceptance range. Tel "The current upper limit value or current asymme- a try upper limit value has been violated. ‘+ Not flashing: limit value exceeded, trip delay running. [+ Flashing: limit value exceeded, trip delay elapsed, relay has tripped. él ~ lashing alternately: the current has exceeded the A set warning limit. Tél 7 "The current is below the lower limit: |+ Not flashing: limit value undershot, trip delay running. |+ Flashing: limit value undershot, trip delay elapsed, relay has tripped. Wednesday-¢2:htarc ‘roost printectts ‘© Kleemann GmbH 2016 213MAINTENANCE Electrical system [w]] KLEEMANN Display rang- [Symbol [s] Flashing alternately: the curren v< warning limit. below the set [4 cai > Not flashina: relay contact 31 / 32 opened, re- pate lay contact 31 / 34 closed, + Flashing: delay time running (start-up delay or trip delay). + Faded out: relay contact 31 / 32 closed, relay contact 31 / 34 opened. Wednesday: 214 tert Tab. 4.2: Current monitoring display messages ‘The value shown in che display always corresponds to the meas- ured value that was just measured, even if the displayed value is flashing due to an upper or lower limit value violation. The symbol for upper or lower limit violation, on the other hand, with manual RESET (Mem=yes) set indicates the tripping fault. This means that before a Reset you can check whether the cause of fault is eliminated and whether a reset would be suc- cessful, throrestiny printed © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Not assigned 4.07 Not assigned 4.08 _ Drive system 4.08.01 Servicing crawler running gear 4,08.01.01 Checking/tensioning crawler carrier chains Checking chain tension Fig. 4.31:Crawler carrier chain [1] Test body [2] Slack of the crawler carrier chain ‘The crawler carrier chains must be tensioned such that they have a slack cf approx. 2 cm for every metre length. If the dis- tance between sprocket and track roller or slide rail is 1.5 me- tres, for example, the crawler carrier chain should have a slack of approx. 3 am at the furthest point. Wes Increased wear through incorrect chain tension Increased wear will result if the crawler carrier chains are too tight or too slack. «Always tension crawler carrier chains in accordance with the specifications. > Move the plant on flat ground until the upper segment of the crawler carrier chain is free of tension. > Switch off plant components and the diesel generator. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 215MAINTENANCE Drive system [w]] KLEEMANN wo > Place test body /1], e.g. long straight rod, on the crawler carrier chain between sprocket and track roller or slide rail > Measure slack o* the crawler carrier chain [2]. Increase or decrease tension of the crawler carrier chain as required. The chain tension has been checked. Always check the left and right crawler carrier chain. Increasing/decreasing crawler carrier chain tension Tensioning crawler Wednesday carrier chain Fig. 4.32:Chain tensioner [1] Chain tensioner cover [2] Grease clamping cylinder [3] Lubricating nipple The crawler carrier chains are tensioned and slackened via hy- draulic clamping cylinders filled with grease. Danger due to pressurised chain tensioner ‘The interior components of the chain tensioner are highly pres- surised and can cause serious or fatal injury. ‘= Do not open the chain tensioner. ‘+ Repair work must be carried out by authorised and qualified personnel only. > Check crawler carrier chain for damage and repair if neces- sary. Unscrew the cover of the chain tensioner [1]. > Mount slide coupling on lubricating nipple [3] v 216 tert © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Drive system @ Slackening crawler carrier chain wD > Tension crawler carrier chain by pressing grease into the grease clamping cylinder [2]. > Check the zension of the crawler carrier chain during the ten- sioning procedure and correct if necessary. > Wipe up excess grease with a lint-free cloth and dispose of in accordance with environmental specifications. > Siew un the cover of the chain tensioner [1] again. ¥_ The crawler carrier chain is tensioned. Always tension the left and right crawler carrier chain. The slide coupling and grease gun are in the toolbox. Danger due to grease escaping under high pressure Grease can be ejected under pressure; there is a risk of injury! + Never release the lubricating nipple manually. + Never completely unscrew the lubricating nipple, + Wear protective equipment. * Incase of injury, consult a doctor immediately. > Unscrew the cover of the chain tensioner [1]. > Release lubricating nipple [3], without fully unscrewing it, until grease emerges. > Wipe up grease that emerges with a lint-free cloth and dis- pose of in accordance with environmental specifications. > Screw on the cover of the chain tensioner [1] again. ¥. The crawler carrier chain is slackened. Always slacker the left and right crawler carrier chain. Wednesday thet © Kleemann GmbH 2016 217MAINTENANCE Drive system ww] KLEEMANN 4.08.01.02 Checking fastenings for track rollers and base plates Fig. 4.33:Base plates [1] Screws [2] Base plates [3] Nuts > Hammer-test or visually Inspect base plates [2], screws and nuts [1, 3], D> Tighten loose screws and nuts. > Replace damaged base plates, screws and nuts if necessary. ¥ The base plates have been checked, > Hammer-test or visually check screws on track rollers. > Tighten loose screws. ¥ The track roller securing elements are checked. Weenenday-ea-htaret Barrows printed 218 © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Drive system 4.03 18.02 Servicing track drive 4,08.02.01 Servicing planetary gear Checking oil fill level Wednesday Fig. 4.34:Planetary gear drive system 11] Oil level inspection pliig [2] Oil filler screw [3] Maximum ofl fill evel Danger due to hot oi ll and machine parts can be very hot; there is a risk of injury. + Wear protective equipment. + Where possible, avoid touching any parts of the units. + Avoid skin contact with oils and greases. + In case of injury, consult a doctor immediately. > Move the plant on flat ground so that the oil filer screw [2] Is facing upwards. > Switch off plant components and the diacel generator > Clean the housing to prevent dirt entering the planetary gear. > Unscrew oil level inspection plug [1] and, if applicable, wipe up escaping oil with a lint-free cloth. > Check whether the oi fill level is visible at the lower edge of the threaded bore. > If necessary, top up gear oil to the maximum oil fill level [3]. kl thet : leemann GmbH 2016 219MAINTENANCE Drive sy ‘stem ww] KLEEMANN w@ > Insert oil level inspection plug with new sealing ring and tighten. ¥ The oil fill level has been checked. Always check the oi fill level of the left and right planetary gear. ‘Changing gear oil Wednesday Draining gear oil Planetary year Uiive systein [1] Oil drain screw [2] Oil filler screw Danger due to hot of Oil and machine parts can be very hot; there is a risk of injury. ‘= Wear protective equipment. ‘+ Where possible, avoid touching any parts of the units, ‘+ Avoid skin contact with oils and greases. ‘+ In case of injury, consult a doctor immediately. > Ifnecessary, warm gear cil up to service temperature by moving the plant. » Move the plant on flat ground so that the oll drain screw [1] is facing downwards. > Switch off plant components and the diesel generator. > Clean the housing to prevent dirt entering the planetary gear. > Place an oll catching pan with a capacity of approx. 10 litres under oil drain screw [1]. > Unscrew oil filler screw (2]. 220 tert © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Drive system Filling gear w v Unscrew ol drain screw [1] and drain the gear oil complete- Vy. Insert oil crain screw [1] with new sealing ring and tighten. Dispose of used oil in accordance with environmental speci- fications. ¥ The gear cil has been drained. > Fill fresh gear oll with the corresponding specifications with the help of a funnel through the opening of the oil filler screw. For specifications and filling volume, see chap. 5. > Fill gear oil up to the lower edge of the threaded bore of the oil filler screw [2]. > Insert oil fller screw [2] with new sealing ring and tighten. > Wipe up overflowing oil with a lint-free cloth and dispose of in accordance with environmental specifications. ¥. The gear cil has been filled. Always change gear vy f the left and right planetary gear. 4,08.02.02 Checking components for leaks ‘The planetary gears and hydraulic motors and hydraulic lines of the drive system must be checked avery day for leaks. Any leaks must be eliminated immediately. > Visually check housing of planetary gears for oil discharge. > Visually check hydraulic components of the drive system for escaping cil. > Have leaks eliminated by repair and service personnel. ¥ The planetary gear and drive systems have been checked. Wednestay-oarhtaret ‘therestiny printed ‘© Kleemann GmbH 2016 221MAINTENANCE Drive system ww] KLEEMANN 4.08.03 Repairing crawler running gear 4.08.03.01Opening/closing crawler carrier chains 4 Fig. 4.36:Crawler carrier chain lock [1] Serew holes for base plates [2] Outer chain link [3] Inner chain link [4] End rings [5] End bushing [6] End pin [7] Chain bolt marking Fig. 4.37:Crawler carrier chain lock [8] Chain bolt Weenenday-ea-htaret Barrows printed 222 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Drive system w Opening chain lock Closing chain lock [9] Base plates [10] Sprocket For repair to the crawler running gear, the crawler carrier chain can be opened at the chain lock. During repair work at the crawler running gear, there is a risk of injury due to heavy and falling components. + Always use suitable hoisting gear and lifting accessories. * Secure components against falling down. + Wear protective equipment. In contrast the end pin, the chain bolt [8] is provided with a cen- tring device or a turned shoulder depending on the design. > Move the plant on flat ground so that the chain bolt [8] is ‘approx. inthe 1 o'clock position above the sprocket [10]. > Switch off plant components and the diesel generator. Unscrew ore or two base plates [9] before and after the chain bolt. > Provided wedges of hard wooden blocks between the chassis and inner chain link before and after the chain bolt respec- tively. The chain links must be secured so that springing back is not possible when the chain bolt is driven out, > Using suitable hoisting gear, e.g. chain hoist, secure the crawler carrier chain at the end bushing [5] against falling from the sorocket [10]. ¥. The chain ock is ready for knocking out the chain bolt. > Ifnecessary, heat the chain links around the chain bolt [8] to approx. 400 °C to expand the fits. > Drive the chain bolt [8] with a drift and heavy hammer out of the fits n the outer and inner chain link [3] and [2]. > Lower the separated crawler carrier chain from the sprocket with the help of the fitted hoisting gear. 1» Remava end rings [4] from the sinks of the chain link and store for reuse. ¥. The crawler carrier chain has been separated, > Coat end rngs [4] with grease and insert in the sinks of the chain links. Using a chain hoist at the end bushing [5], pull the crawler carrier chain between the outer and inner chain link. > Clean and polish fits of chain bolt [8] and coat with lubricat- ing grease. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 223MAINTENANCE Drive system [w]] KLEEMANN 4.08.03.02 Repairing chain li > Use a heavy hammer to drive the chain bolt [8] into the fits of the outer and inner chain link [3] and [2]. > Secure chain bolt [8] with weld points to outer chain link [2]. >» Remove wedged wooden blocks from between chassis and chain links. > Screw on base rlates [9]. the crawler cartier chain has been closed. 3 Weenenday-ea:htaret Fig. 4.38:Chain link [1] End bushing [2] Cutting points [3] Inner chain link [4] End pin [5] Outer chain link [6] Damaged chain link Damaged chain links on the crawler carrier chain can be re- paired with a repair kit provided for this purpose. Risk of injury due to heavy components During repair work at the crawler running gear, there is a risk of, injury due to heavy and falling components. ‘+ Always use suitable hoisting gear and lifting accessories. ‘+ Secure components against falling down ‘+ Wear protective equipment. 224 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Drive system Removing chain link Weed Danger of fires due to welding torch Welding torches, hot metal and sparks can set fire to compo- nents and objects in the surrounding area. + Where possible, cover components and objects exposed to a risk of fire * Protect components and objects against dripping hot metal and sparks. + Ensure fire extinguisher is ready before starting work. + Ensure a fire watch is present during and after welding work + Wear protective equipment. > Move the plant on flat ground so that the damaged chain link is approx. in the one o'clock position above the sprocket. > Switch off plant components and the diesel generator. > Unscrew ove or two base plates before and after the chain link. > Using suitable hoisting gear, e.g. chain hoist, secure the crawler carrier chain at the end bushing of the undamaged chain link against falling from the sprocket, > Using a welding torch, cut through the outer and inner chain link [5] and [3] as well as end bushing [1] including the end pins inside it at the cutting points [2] shown. > Remove cut-out debris and scraps of the end bushing. > Ifnecessary, heat the chain links around the end pin [4] to approx. 400 °C to expand the fits. > Drive the end pin [4] with a drift and heavy hammer out of the fits in the outer and inner chain link [5] and [3]. > Grind off and deburr projecting bushing ends of the intact chain link. > Use a welcing torch to burn holes centrally in the cut- ‘through erd pin of the intact chain link on the opposite side. > Drive out remaining parts of the end pin with a drift and a heavy hammer. > Clean fits of the chain link and coat with lubricating grease. ¥ The damaged chain link has been removed. Wednesday kl thet : leemann GmbH 2016 225MAINTENANCE Drive system [w]] KLEEMANN Inserting chain link The repair kit for the chain link contains all components re- quired to repair a chain link. Fig. 4.39:Chain link repair kit [2] End bushing [4] End pins, 2 pieces [7] End rings, 4 sieces [8] Repair chain link 1 piece > Coat two end rings [7] with grease and insert with the cham- fered side in the sinks of the intact chain link. > Clean and polish fits of end pin [4] and coat grease. lubricating be inserted in the bores of the chain links without great effort. } Insert end bushing [1] of the repair chain link [8] in the in- tact chain link and insert end pin [4]. > Coat the two remaining end rings [7] with grease and insert with the chamfered side in the sinks of the repair chain link. > Using a chain hoist, pull the other end of the crawler carrier chain into the repair chain link [8] and insert second end pin. Ensure that the end rings remain in the sinks. > Secure both end pins [4] with weld points at the repair chain link [8]. ¥. The repair chain link is inserted, wD ‘The fit surfaces of the end pins must be polished until they can Weenenday-oa:htaret Barrows printed 226 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Not assigned 4.09 Not assigned 4.10 Conveyor unit 4.10.01 Servicing belt conveyors ry BGs Danger due to moving and rotating parts Maintenance and repair work carried out with plant components running can result in serious or fatal injury. + Maintenance and repair work must always be carried out with the plant at a standstill. + Switch off plant components and the diesel generator. + Safeguard the plant against unauthorised start-up. + Wear protective equipment. 3k of falling There is a risk of falling during maintenance and repair work on the plant components. + Use suitable climbing aids or lifting platforms. + Check that the climbing aids are secure and safe to use. * Ensure that the three-point contact on the climbing aid is se- cure. ‘+ Do not jump from the climbing aids or the plant. 4,10,01.01 Checking conveyor belts ‘The belt conveyors are first inspected while running and then while stationary. > Start the kelt conveyors in manual mode and, from a safe distance, visually check for the following damage: * Conveyor belts. — Damage to edges = Damage to deck plates = Damage to wire cloth = Detachments from endless connection = Detachment of cleats = Scuff markings and scores ~ Tensionof the conveyor belt. Insufficient tension causes belt sag- ing and slipping of the drive pulley. Excessive belt tension cau- ‘es the 2ottom segment to vibrate, Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 227MAINTENANCE Conveyor unit [w]] KLEEMANN = Belt dit ‘+ Components of the belt conveyor. = _Jammed and wor support, deflection and return rollers = Loosened screw connections = Jammed and worn scrapers — Wom sealing ips of material guide ledges + Other = Abnormal runring noises = Jemmed stones = Contamination and caking = Eccentric conveyor belt loading > Switch off belt conveyors and diesel generator and secure against reactivation. > Visually check the above-named items once again > Eliminate damage and deficiencies determined, The belt conveyors have been checked. 4.10.01.02 Checking/setting return roller guard Fig. 4.40;Return roller guard [1] Conveyor belt [2] Adjusting and retaining screws for return roller guard [3] Gap dimension for conveyor belt, return roller guard (max. 5 mm) [4] Return roller guard [5] Return roller To avoid personal injury and material damage, the return roller guards must be set to the correct gap dimension. Weenenday-ba:htaret Barrows printed 228 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Conveyor unit Checking return roller guard Checking gap dimension conveyor belt, return roller guard Risk of being drawn in by rotating components When controling and visually checking running belt conveyors, there is a risk of limbs being drawn in by rotating components. + Keep well away from rotating components. * Carry out maintenance and service work only on stationary belt conveyors. + Wear protective equipment. isk of falli There is a risk of falling during maintenance and repair work on the plant components. * Use suitable climbing aids or lifting platforms. + Check that the climbing aids are secure and safe to use. + Ensure that the three-point contact on the climbing aid is se- cure. * Do not jump from the climbing aids or the plant. Drie Risk of material damage Incorrectly se: return roller guards cause damage at the con- veyor belt and downstream plant components. + Ensure that the conveyor belt does not lie on the return roll- er guard. * Ensure thet the gap dimension of 5 mm between conveyor belt and return roller guard is set. > Switch off plant components and the diesel generator. Re- move key and carry it with you. > Check return roller guard [4] on both sides for safe and firm installatior. Tighten screws if necessary [2] > Visually check retum roller guard for damage. Replace dam- aged retum roller auard. > Check all return roller guards. ¥ The retum roller guards have been checked. Use suitable measuring instrument to check the gap dimen- sion [3] over the complete conveyor belt width. Check the gap dimensions on all return roller guards. The gap dimension has been checked. Release adjusting and retaining screws [2] on both sides. conveyor belt, return 5 coe 330 dimensi ‘gap dimension [3] between conveyor belt and return roller guard © yoller guard. > Ensure that the gap dimension [3] is set over the complete width of the conveyor belt, > Tighten adjusting and retaining screws [2] on both sides. > Check gap dimension again and adjust as described if nec- essary. ¥ The gap dimension has been set. 4,10.01.03 Servicing scraper Adju: ing wedge stripper 2 1 3 Fig. 4.41: Wedge stripper [1] Clamping rails [2] Chain [3] Rubber scraper ‘The wedge stripper cleans loose material from the inside of the bottom segment. It is attached to the conveyor belt frame with chain [2] and adjusts itself automatically through its own dead weight. > Visually check rubber scraper [3] for damage and wear. > Ifnecessary, unscrew clamp rails [1] and replace rubber scraper [3] ¥- The wedge stripser has been serviced. WeeresctaySerhterct ree testi pated 230 © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Conveyor unit Adjusting flat scraper Fig. 4.42:Flat scraper [1] Clamping element [2] Screw [3] Scraper strip [4] Clamping device ‘The flat scraper cleans loose material from the outside of the conveyor belt. The clamping elements [1] guarantee a constant contact pressure of the scraper strip [3]. If the scraper strip does not make contact with the conveyor belt, or contact pres- sure is too low, it has to be adjusted, > Attach the clamping device [4] to the clamping element [1] and release screw [2] but do not fully remove. > Turn the clamping element [1] to increase or reduce the con- tact pressure of the scraper strip on the conveyor, > Retighten screw [2]. > Repeat the procedure at the clamping element on the other side > Ifnecessary, reverse or replace damaged or worn scraper strip. ¥ The flat scraper has been serviced. If the conveyed material tends to form deposits on the convey- of, e.g. cohesive material such as clay, wet dust, etc., the con- tact pressure of the scraper strip has to be increased. With cohesionless material, it is sufficient to apply the scraper strip to the conveyor belt without contact pressure. Wednesday: sikowstiiny printed ‘© Kleemann GmbH 2016 231MAINTENANCE Conveyor unit ww] KLEEMANN 4.10.01.04 Adjusting rubber plates Crusher discharge conveyor rubber plates Weenenday-ea:htaret Fig. 4.43:Crusher discharge conveyor rubber plates [1] Rubber plate, inner [2] Rubber plate, outer [3] Conveyor bet [4] Protective cover [5] Clamping plate, outer [6] Screw [7] Clamping plate, inner ‘The rubber plates seal the material guide ledges off from the conveyor belt so that no material can reach the rotating compo- nents or fall off the belt conveyor. In case of damage and wear, the rubber plates rrust be adjusted or changed. ‘The outer rubber plates cannot be adjusted and must be re- placed if they are worn. In order to readjust or replace the rubber plates of the crusher discharge conveyor, the crusher discharge conveyor must be re- moved. Remove crusher distharye Convey. > Unscrew protective covers [4]. > Release screws [6] on clamping plates (7] but do not remove them. > Adjust rubber plates [1] until they make contact on the con- veyor belt [3]. > Ifnecessary, replace damaged or worn rubber plates [1]. D> Retighten screws [6] on clamping plates [7]. 232 sh © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Conveyor unit > Check rubber plates [2] for damage or wear. > If necessary, unscrew clamping plates [5] and replace rub- ber plates [2]. > Install clarmping plates [5] and retighten screws. > Screw protective covers [4] back on. ¥ The rubber plates have been adjusted. Prescreen conveyor rubber plates Wednesday Fig. 4.44:Prescreen conveyor rubber plates [1] Rubber plate [2] Clamping plate [3] Screws hans Risk of falling ‘There is a risk of falling during maintenance and repair work on the plant components, * Use suitable climbing aids or lifting platforms. + Check that the climbing aids are secure and safe to use. + Ensure that the three-point contact on the climbing aid is se- cure. + Do not jump from the climbing aids or the plant. ‘The rubber plates seal the material guide ledges off from the conveyor beltso that no material can reach the rotating compo- nents or fall off the belt conveyor. In case of damage and wear, the rubber pletes must be adjusted or changed. > Release screws [3] on clamping rails [2] but do not remove them, kl thet : leemann GmbH 2016 233MAINTENANCE Conveyor unit [w]] KLEEMANN > Adjust rubber plates [1] until they make contact on the con- veyor belt. > If necessary, replace damaged or worn rubber plates. D> Retighten screws [3] on clamping rails [2]. The rubber plates have been adjusted. 4.10.01.05 Servicing bevel helical gearbox Fig. 4.45:Belt conveyor drive with bevel helical gearbox [1] Oil drain screw with horizontal i [2] Oil filler screw and ventilation [3] Identification plate [4] Oil drain screw with inclined installation Itis not possible to check the oil fill level with bevel helical gear- boxes as the belt conveyor drives are installed in different posi- tions and a fill level screw is not provided. If leaks are determined, the fill volume must be determined by draining. Danger due to hot oi Oil and machine parts can be very hot; there is a risk of injury. ‘+ Wear protective equipment. ‘+ Where possible, avoid touching any parts of the units. ‘+ Avoid skin contact with oils and greases. ‘= Incase of injury, consult a doctor immediately. ‘The left oil drain screw [1] must be used with horizontal instal- lation. The right oil drain screw [4] is used with inclined instal- lation. Weenenday-ea:htaret 234 © Kleemann GmbH 2016[w]] KLEEMANN MAINTENANCE Conveyor unit Checking oil fill level > Changing gear oil > sv Warm up gear oil to service temperature. Allow conveyor belt to run for about 10 minutes if required. ‘Switch off plant components and the diesel generator. Clean the gearbox housing. In particular, the oil filler and oil drain screws must be free of contamination. Unscrew ol filler screw [2]. Place a clean oil catching pan with a capacity of approx. 10 litres under oll drain screw [1] or [4]. Unscrew 01 drain screw [1] or [4] and drain gear cil. Determine the fill volume, For correct fill volume, see iden- tification plate [3]. Insert oil crain screw [1] or [4] again and tighten. Refill drained gear oil with the help of a funnel. If necessary, top up missing volume with oil of corresponding specifica- tions. Insert oil fller screw [2] again and tighten. Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications. Check geabox for leaks. The oil fill level has been checked. Warm up gear oil to service temperature. If necessary, run belt conveyor approx. 10 minutes, ‘Switch off plant components and the diesel generator. Clean the gearbox housing. In particular, the oil filler and oil drain screws must be free of contamination. Unscrew o| filler screw [2]. Place an oil catching pan with a capacity of approx. 10 litres under oil drain screw [1] or [4]. Unscrew oil drain screw [1] or [4], drain gear oil and dispose of in accordance with local environmental specifications. Insert oil crain screw [1] or [4] again and tighten. Fill fresh gear oil with the corresponding specifications with ‘the help of a funnel through the opening of the oil filler screw. For correct fill voluine, see identification plate [3]. Insert oil fller screw [2] again and tighten. Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications, Check gearbox for leaks. The gear cil has been changed. Wednestay-o2-htaret theestiny ‘© Kleemann GmbH 2016 235MAINTENANCE Conveyor unit [w]] KLEEMANN 4,10.01.06 Servicing drum motors Checking oil fill level Wednesctay-earhtare Fig. 4.46:Drum motor for belt conveyor drive [1] Identification plate [2] Ol drain screw with magnetic filter (red dot) [3] Oil filler screw and ventilation It Is not possible to check the oll fill level with drum motors. If leaks are determined, the fill volume must be determined by draining. Danger due to hot oi Oil and machine parts can be very hot; there is a risk of injury. ‘+ Wear protective equipment. + Where possible, avoid touching any parts of the units. ‘+ Avoid skin contact with oils and greases. ‘+ In case of injury, consult a doctor immediately. > Warm up gear oil to service temperature. If necessary, run belt conveyor approx. 10 minutes. > Switch off plant components and the diesel generator > Switch off battery isolator, remove it and carry it with you. > Clean the drum motor. In particular, the oil filler and oil drain screws must be free of contamination. > Turn the drum motor until the oil drain screw [2] is at the lowest point. > Unscrew oil filler screw [3]. 236 ihowstiiny printed © Kleemann GmbH 2016[w] KLEEMANN MAINTENANCE Conveyor unit Changing gear oil <¥ v v v sv Place a clean oil catching pan with a sufficient capacity under oil drain screw [2]. Unscrew the oll drain screw [2] and drain the gear oil. Determine the fill volume. For correct fill volume, see iden- tification plate [1]. Insert oil crain screw [2] again and tighten. Refill drained gear oil with the help of a funnel. If necessary, top up missing volume with oil of corresponding specifica- tions. Insert oil filer screw [3] again and tighten. Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications. Check drum motor for leaks. The ail fill level has been checked. Warm up gear oil to service temperature. If necessary, run belt conveyor approx. 10 minutes, ‘Switch off plant components and the diesel generator. ‘Switch off and remove battery isolator and carry it with you. Clean the drum motor. In particular, the oil filler and oil drain SCreWS Must be free of contamination Unscrew ol filler screw [3] Place an oll catching pan with sufficient capacity under oil drain screw [2]. Unscrew oll drain screw [2], drain gear oll and dispose of in accordance with local environmental specifications. Insert oil crain screw [2] again and tighten. Fill fresh gear oil with the corresponding specifications with the help of a funnel through the opening of the oil filer screw. For correct fill volume, see identification plate [1]. Insert oil fller screw [3] again and tighten. Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications. Check drum motor for leaks. ‘The gear cil has been changed. Wednesday: thet ‘therestiny printed ‘© Kleemann GmbH 2016 237MAINTENANCE Conveyor unit ww] KLEEMANN 4.10.01.07 Lubricating plummer blocks Y Fig. 4.47:Plummer dock [1] Block cover screws [2] Dummy plug [3] Sealing lips [4] Lubrication ripple Plummer block grease change All belt conveyors driven by gear unit are equipped with plum- mer blocks. If the plummer blocks are serviced with the crusher discharge @ conveyor installed, a suitable climbing aid (e.g. a work platform or scaffolding) must be provided and used. The plummer blocks of the drive pulley are taken apart to re- place the grease. The plummer block is completely filled with lu- bricating grease via the lubrication nipple [4] and the dummy plug [2]. Drees Risk of material damage Escaping grease expands the sealing lips of the plummer blocks. Dust and maisture can penetrate the expanded and damaged sealing lips and destroy the blocks. + Unscrew dummy plugs before pressing in grease via the lu- bricating nipple. ‘+ Never press in grease with the dummy plug installed. ‘+ Replace damaged sealing lips. Checking plummer > Switch off plant components, diesel engine and control volt- blocks age. Weenenday-ba:htaret Barrows printed 238 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit Lubricating plummer blocks ‘Switch off and remove battery isolator and carry it with you, If necessary, remove protective covers of plummer blocks. Remove dirt and dust from plummer blocks. Wipe up escaping grease with a cloth and dispose of in ac- cordance with environmental specifications. Visually inspect inner and outer sealing lips [3] for damage and replace if necessary. See section on lubricating plummer blocks If necessary, mount protective covers of plummer blocks again. ‘The plummer blocks have been checked. If necessary, remove protective covers of plummer blocks Remove dirt and dust from plummer blocks. Using a suitable securing element, for e.g. tension belt, se- cure the drive pulley to prevent it from slipping out of the plummer blocks. Unscrew screws on block cover [1] and remove block cover, > Remove sealing lips [3] from the plummer block. The sealing lips are divided into two parts and can be removed as such from the siaft. > Remove old grease from the plummer block and block cover and dispose of completely in an environmentally friendly manner. vowvyyy vvys oy v > Insert new sealing lips in the plummer block and block cover. > Fill plummer block and block cover with fresh grease of the corresponding specifications, ‘The specified grease quantity must be filled completely into the plummer block and the block cover. > Reinstall suitable block cover with bolts [1] and tighten bolts to specified tightening torque. ‘The plummer blocks and block covers are marked to prevent confusion. > Unscrew dammy plug [2]. > Use a grease gun to press grease with the appropriate spec- ifications into the lubrication nipple [4] until grease emerges from the bore of the dummy plug. > Screw in dummy plug [2], wipe off excess grease and dis- ose of in accordance with environmental regulations. > Ifnecessary, mount protective covers of plummer blocks again. ¥ The plummer blocks have been lubricated. > Insert battery isolator and switch on. Wednestay-oarhtaret ‘therestiny printed ‘© Kleemann GmbH 2016 239MAINTENANCE Conveyor unit ww] KLEEMANN [Lubrication via [Bearing type __|Grease qty. in larammes: Plummer block [SE 513-611 300 housing! Plummer block SNL S13-61i 340 housing! Plannney Diack [St 516 -G1T la75 housing! Plummer block [SNL 516-611 550 housing! (Plummer block [SNL 518-615 B50 housing? plummer blocks. Tab. 4.3: Plummer block lubrication ‘The block covers must be disassembled prior to lubricating the Tightening torque of block cover screws Thread ‘Tightening torque in Nm Miz [so mis 150 Tab. 4.4: Tightening torque of block cover screws charge conveyor lower plummer blocks of the crusher dis- uh Ps i. Fig. 4.48:Crusher discharge conveyor centralised lubrication [1] Lubricating ripple for left plummer block [2] Lubricating ripple for right plummer block Weenenday-oa:htaret 240 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit @ The plummer blocks of the return roller of the crusher discharge conveyor are ubricated via the lubrication nipples of the cen- tralised lubrication. The blocks of the centralised lubrication are fitted on the right and left on the crusher mountings. > Use a grease gun to press 2.5 g of grease with the appropri- ate specifications into the lubrication nipples [1] and [2]. ¥ The plummer blocks have been lubricated. One stroke of the grease gun corresponds to approx. 3. grease. The grease volumes to be filled are noted on the blocks of the centralised lubrication. If the plant is equipped with a lubrication system (option), the bearings are lubricated automatically. 4.10.02 Checking chutes 4,10,02.01 Checking rubber curtains and sealing Fig. 4.49:Rubber curtains and sealing [1] Screen underpass rubber curtains [2] Grizzly rubber curtains [3] Crusher outlet rubber curtains 14] By-pass device rubber curtains “The rubber curtains and sealing of chutes guide the material at the transfer points and reduce dust emission. Damaged rubber curtains and sealing can no longer completely fulfil this task, > Visually check rubber curtains of the screen underpass and crusher outlet for damage. > Visually check sealing and rubber curtains of the by-pass de- vice for damage. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 241MAINTENANCE Conveyor unit [w]] KLEEMANN > Check securing strips of rubber curtains and sealing for damage and security. > Replace damaged components if necessary. The chutes have been checked. 4.10.03 Servicing belt conveyors 4,10.03.01 Tensioning conveyor belt Fig. 4.50:Belt conveyor clamping device [1] Threaded rod [2] Counter screw nut [3] Clamping nut [4] Conveyor belt frame [5] Guide [6] Belt conveyo- EA Risk of falling ‘There is a risk of fal ing during maintenance and repair work on the plant components. + Use sutabe cimbing aids or iting platforms. © Check that the climbing aids are secure and safe to use. ‘+ Ensure that the three-point contact on the climbing aid is se~ cure. + Do not jump fron the ing aids or the plant. Weenenday-ea:htaret Barrows printed 242 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Conveyor unit Ten: ssioning conveyor belt wo Detensioning conveyor Wednesday belt Weed Risk of material damage A conveyor belt with belt drift, or which is too tightly or loosely tensioned, wears faster and can cause consequential damage on conveyor components. + Tension the drive pulley or return roller evenly and at right angles to the conveyor belt frame. + Tighten the conveyor belt to the correct tension. ‘The belts on all conveyors are tensioned with two mechanical tensioning devices respectively, which in principle have the same design. > Ifnecessary, unscrew protective covers of tensioning devic- es. > Release the left and right counter screw nuts [2] until the tensioning path is free. > Turn the left and right tensioning nuts [3] evenly until the conveyor belt is correctly tensioned. Ensure that the drive pulley andor return roller are at right angles to the convey- or belt frame [4]. > Retighten the left and right counter screw nuts [2]. > If necessary, screw back on protective covers of tensioning devices. ¥. The conveyor belt is tensioned. A conveyor belt that is tensioned too loosely can be recognised by sagging between the return rollers. A conveyor belt that is ‘tensioned too tightly can be recognised by vibrating of the bot- tom segment during operation. Arule of thumb: The correct tension Is the lowest possible ten- sion that prevents the drive pulley from slipping at the conveyor belt. > If necessary, unscrew protective covers of tensioning devic~ es. > Tur the left and right clamping nuts [3] evenly until the conveyor belt is slackened. Ensure that the drive pulley and/ or retum roller are at right anales to the convevor belt frame (4). Tighten the left and right counter screw nuts [2] > Ifnecessary, screw back on protective covers of tensiot devices. ¥ The conveyor belt has been slackened. v kl thet : leemann GmbH 2016 243MAINTENANCE Conveyor unit [w]] KLEEMANN 4.10.03.02 Changing conveyor belt w ‘There are two basic different procedures for changing the con- veyor belt: * Place split conveyor on belt conveyor and join the ends by vuleanising. ‘+ Remove belt conveyor and partly disassemble and mount andlacs conveyer belt. Contact persons for repair of conveyor belts are listed under "Customer service" on the homepage of KLEEMANN GmbH: www.kleemann.info 4.10.03.03 Checking conveyor belt run i v Weenenday-oa:htaret Fig. 4.51: Conveyor belt run (1) [1] Support rollers [2] Lateral guide rollers [3] Conveyor bet Acorrectly aligned conveyor belt runs centrally between the lat- eral guide rollers ard the drive and bend pulleys. This ensures reduced repair costs and trouble-free operation. ‘The conveyor belt must not come into contact with the side guide rollers. 244 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit 3k of being drawn in by rotating components When controling and visually checking running belt conveyors, there is a risk of limbs being drawn in by rotating components. + Keep well away from rotating components. * Carry out maintenance and service work only on stationary belt conveyors. + Wear protective equipment. > Switch off plant components and the diesel generator. > Observe conveyor belt running with and without feed mate- rial and record any shortcomings. ¥ Conveyor belt running has been checked. 4,10,03.04 Adjusting conveyor belt run Fig. 4.52:Conveyor belt run [1] Return roller [2] Return rollers 13] Conveyor belt [1] Drive pulley ‘The illustration shows a conveyor belt [3] with a drift to the right and how the return rollers [2] have to be adjusted accordingly. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 245MAINTENANCE Conveyor unit [w]] KLEEMANN 4.10.04 w wo Reasons for faulty conveyor belt run ‘+ Inadequate alignment of the drive pulley and/or return roll- er. + Drums and rollers contaminated on one side. ‘+ Eccentric feeding unit and guide of the conveyor belt. ‘+ Scrapers placed in the material flow at an inclination that pace on the material vis the cide conveyor edge. ‘+ Scraping of the conveyor belt at the conveyor belt frame or at jammed material pieces. ‘+ Uneven power transmission over the conveyor belt width due to dampness, ‘+ Incorrectly installed connection of the conveyor belt with kink in longitudival direction. Adjusting conveyor belt run If the faulty conveyor belt run is caused by a reason other than those listed above, the belt run must be adjusted via the return rollers [2] ‘At the point where the conveyor belt [3] begins to drift, one or several return rollers [2] can be adjusted. > Rule out the above-mentioned reasons for faulty belt run. Tension the conveyor helt if necessary. ‘Switch off plant components and the diesel generator, Slacken mount of return roller [2] and turn slightly in the elongated holes. Tighten mount again. ‘Switch on plant components and diesel generator and ob- serve conveyor belt run with and without charged material. > Check setting as required. ¥ The conveyor belt run has been adjusted Even a few millimetres in the setting range of the return rollers is sufficient to make a correction to the conveyor belt run, To check the conveyor belt run, the belt conveyor must run for at least 2 minutes. Due to incorrect manufacture, usage or storage, conveyor belts cen be deformed or bent and thcir setting is therefore no longer correct. vv vy Servicing extractor channel ‘The maintenance tasks on the extractor channel must be car- ried out as described in the chapter "Servicing feeder trough” > For servicing of rubber mountings, see chap. 4.43.02.01. > Check vibration motors, see chap. 4.43.02.02. Wednesday: 246 an ihowstiiny printed © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit > For servicing of wear lining, see chap. 4.43.02. For specifications and information on repair of the extractor @ channel, see chap. 4.43.03. 4.10.05 Servicing electromagnetic separator (option) Danger due to moving and rotating parts Maintenance znd repair work carried out with plant components running can result in serious or fatal injury. + Maintenance and repair work must always be carried out with the plant at a standstill. + Switch off plant components and the diesel generator. + Safeguard the plant against unauthorised start-up. + Wear protective equipment. Danger due to magnetic fields Electric and permanent magnetic separators generate strong magnetic fields that present a risk to personnel, + Persons with pacemakers and other medical-technical devic- 5 must stay well clear of magnetic separators. + Keep a distance of at least 2 metres from magnetic separa- tors. + Observe the safety manual. Risk of falling There is a risk of falling during maintenance and repair work on the plant components. * Use suitable climbing aids or lifting platforms. * Check that the climbing aids are secure and safe to use. ‘+ Ensure that the three-point contact on the climbing aid is se~ cure. Do not jump from the climbing aids or the plant. 4.10.05.01 Checking conveyor belt The magnetic separator is inspected while running first and then while stationary. > Start the magnetic separator in manual mode and, from a safe distarce, visually check for the following damage: Wednesttay-oa-htare sikowstiiny printed © Kleemann GmbH 2016 247MAINTENANCE Conveyor unit ww] KLEEMANN + Conveyor belt, = Damage to edges Damage to wire cloth = Detachments from endless connector = Detachment of cleats, ~ Scuff markings and scores = Tension of the conveyor belt. Insufficient tension causes con- ‘veyor belt sagging and slipping of the drive pulley. = Conveyor belt drift ‘+ Components of the belt conveyor. = Loosened screw connections + Other. = Abnormal runring noises ~ Trapped bits 0” metal = Contamination and caking > Switch off magnetic separator and diesel generator and take measures to prevent them from being switched on again. > Visually check the aforementioned points once again. > Eliminate damage and deficiencies determined. Magnetic separator has been checked. 4.10.05.02 Tensioning conveyor belt Fig. 4.53: Magnetic separator tensioning device [1] Tensioning carriage retaining screws [2] Locknut [3] Clamping screw Weenenday-ea:htaret Barrows printed 248 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Conveyor unit Tensioning conveyor belt @ Weed Risk of material damage A conveyor belt with belt drift or one that has been tensioned too tightly or oosely wears faster and can result in damage to the componerts of the magnetic separator. + Tension the drive pulley or return roller evenly and at right angles to the conveyor belt frame. + Tighten the conveyor belt to the correct tension. ‘The conveyor belts of all magnetic separators are each ten- sioned with two mechanical tensioning devices that basically share the same design. > Switch off diesel generator and plant. > Switch off and remove battery isolator and carry it with you, > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. If necessary, remove the protective covers of the tensioning devices. v Loosen the retaining bolts [1] of the tensioning carriage. Loosen the locknut [21 until the tension is free. Repeat the same work steps on the opposite side. ‘Turn the tensioning bolts (3) until the conveyor belt is ten- sioned correctly. Tighten locknuts [2] again, Tighten the retaining bolts [1] of the tensioning carriage. If they were removed, reinstall the protective covers of the tensioning devices. ¥. The conveyor belt is tensioned. Insert battery isolator and switch on. ‘A conveyor belt that is tensioned too loosely can be recognised by sagging between the return rollers, A conveyor belt that is ‘tensioned too tightly can be recognised by vibrating of the bot- ‘tom segment during operation. vvvy vvy A.ule uf Uiuiib: The correct tension is the lowest possible ten= sion that prevents the drive pulley from slipping at the conveyor belt, Detensioning conveyor > Switch off diesel generator and plant. belt, switch off and remove battery isolator and carry it with you. > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. Wednesday e2:htare kl leemann GmbH 2016 249MAINTENANCE Conveyor unit [w]] KLEEMANN v If necessary, remove the protective covers of the tensioning devices. Loosen the retaining bolts [1] of the tensioning carriage. Slacken locknuts [2]. ‘Tum the tensioning bolts [3] evenly until the conveyor belt is relieved of tension. Tighten the locknuts [2]. Tighten the retaining bolts [1] of the tensioning carriage. If they were removed, reinstall the protective covers of the tensioning devices, v_ The conveyor belt has been detensioned. > Insert battery isolator and switch on. vvy vvy 4.10.05.03 Servicing worm gear Checking the oil level of the worm gear is not possible in situ. To change the gear oil, the worm gear must be rotated. Danger due to hot oil Oil and machine parts can be very hot; there is a risk of injury. + Wear protective equipment. ‘+ Where possible, avoid touching any parts of the units. + Avoid skin contact with oils and greases. ‘+ In case of injury, consult a doctor immediately. Risk of falling ‘There is a risk of fal ing during maintenance and repair work on the plant components. ‘+ Use suitable climbing aids or lifting platforms, ‘* Check that the climbing aids are secure and safe to use. ‘+ Ensure that the three-point contact on the climbing aid is se~ cure. ‘¢ Da not jump fran the climbing aids ar the plant. Preparations for changing gear oil To change the gear oil, the worm gear must first be rotated by 90° and then turned back to the start position. Weenenday-ba:htaret sh 250 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit Rotating worm gear Draining gear oil Fig. 4.54:Worm gear [1] Securing bolts of worm gear [2] Oil drain plug > Bring the gear oil up to operating temperature. Allow the ‘magnetic separator to run for about 10 minutes if required, Switch off planit onpurnerits aiid Une diesel yerier ator. > Switch off and remove battery isolator and carry it with you. > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. > Secure the worm gear using suitable lifting tackle and hoist- ing equipment and tension the hoisting equipment lightly. > Unscrew all securing bolts [1]. > Rotate the worm gear by 90° and secure with one securing bolt [1] > Clean the worm gear housing. The oil filler plug [3], in par- ticular, must be free of contamination. > Unscrew the fill level plug [3] > Place an oil tray with a capacity of approx. 4 litres under the drain plug [2]. Unscrew the oil drain plug [2], drain the gear oil and dispose of in an eco-friendly manner. Screw in the drain plug [2] again and tighten. Turn the worm gear back to the start position. Screw in all securing bolts [1] and tighten. Remove lifting tackle and hoisting equipment. v vvvy Wednestay-22-htaret : ‘© Kleemann GmbH 2016 251MAINTENANCE Conveyor unit ww] KLEEMANN 19 gear oil [3] Oil filler plug > Fill fresh gear oil with the corresponding specifications with the help of a funnel through the opening of the fill level plug [3]. > Screw in the fill level pltig [3] again and tighten > Wipe away any oil that has escaped using a cloth and dis- pose of in an eco-friendly manner. > Check the worm gear for leaks. ¥ The gear oil has been changed. For filling volume of cam gear, see chap. 5.01.08. For lubricants, see chap. 5.04.01. Weenenday-oa:htaret 252 © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Conveyor unit 4,10.05,04 Lubricating bearings Wednesday Lubricating bearings wo Fig. 4.56:Magnetic separator bearings [1] Drive pulley bearing [2] Lubrication nipple [3] Return roller bearing with dust cap ‘The bearings of the drive pulley and return roller are lubricated via a lubricating nipple. > Switch off diesel generator and plant. > Switch off and remove battery isolator and carry it with you. > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. Use a grease gun to press grease with the appropriate spec- ifications into the lubricating nipples of the drive pulley and return roller bearings. > Clean away any excess grease and dispose of in an eco- friendly manner. ¥ The bearings have been lubricated. > Insert battery isolator and switch on. [Lubrication point [Amount of greace per lu Ibrication point [Bearings [2.5 grammes Tab. 4.5: Lubricating point of magnetic separator One stroke of the grease gun corresponds to approx. 3 9 grease. For maintenance intervals, see chap. 5.02. kl thet : leemann GmbH 2016 253MAINTENANCE Conveyor unit ww] KLEEMANN 4.10.05.05 Checking oil cooling Checking oil cooli Weenenday-ea:htaret 19 fill level Fig. 4.57:0i1 cooling fill evel [1] Filler neck [2] Oil equalising tank [3] Inspection glass Danger due to hot oil Gil and machine parts can be very hot; there is a risk of injury. ‘+ Wear protective equipment, ‘+ Where possible, avoid touching any parts of the units. ‘+ Avoid skin contact with oils and greases. ‘+ In case of injury, consult a doctor immediately. ‘To improve heat dissipation, the magnetic separator (option) is ‘equipped with an oil cooling system. The fill level in the oil equalising tank must be checked at ser- vice temperature and topped up with oil if necessary. The oil reservoir must be full irrespective of the tilt of the magnet, > Run magnetic coparator oil up to cervice temperature. If necessary, run the magnetic separator in manual mode for approx. 10 minctes. > Switch off the plant components and diesel generator, switch off and remove the battery isolator and carry it with you. D Use suitable climbing aids, such as a lifting platform or scaf- folding, to climb up into the area of the magnetic separator. 254 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Conveyor unit > Check oil level in inspection glass. Oil must be visible in the inspection glass. CE Risk of material damage If too much oll was poured into the oil equalising tank with the equipment cold, oil may be discharged at service temperature. + Only fill the corresponding volume of oll into the equalising tank of the magnetic separator when it is at service temper ature. > Ifnecessary, top up oil of the appropriate specification via ‘the filler neck until oil is visible in the inspection glass. > Check oil nes and threaded connections for leaks. ¥ The fill leval of the oll cooling system has been checked. > Insert battery isolator and switch on. 4.10.06 Servicing permanent magnet separator (option) rN Bu Danger due to moving and rotating parts Maintenance snd repair work carried out wilt plant components: running can result in serious or fatal injury. + Maintenance and repair work must always be carried out with the plant at a standstill. + Switch off plant components and the diesel generator. + Safeguard the plant against unauthorised sta + Wear protective equipment. A Ey Danger due to magnetic fields Electric and permanent magnetic separators generate strong magnetic fields that present a risk to personnel. * Persons with pacemakers and other medical-technical devic~ es must stay well clear of magnetic separators. + Keep a distance of at least 2 metres from magnetic separa- tors. + Observe the safety manual. Wednestay-oarhtaret ‘therestiny printed © Kleemann GmbH 2016 255MAINTENANCE Conveyor unit [w]] KLEEMANN Risk of falling ‘There is a risk of faling during maintenance and repair work on the plant components. ‘+ Use suitable climbing aids or lifting platforms. ‘+ Check that the climbina aids are secure and safe to use. ‘+ Ensure that the three-point contact on the climbing aid is se~ cure. ‘+ Do not jump fron the climbing aids or the plant. 4.10.06.01 Checking conveyor belt ‘The magnetic separator is inspected while running first and then while stationary. > Start the magnetic separator in manual mode and, from a safe distance, visually check for the following damage: + Conveyor belt. = Damage to edges = Damage to wire cloth = Detachments from endless connector = Detachment of cleats = Scuff markings and scores = Tension of the conveyor belt. Insufficient tension causes con- veyor belt sagging and slipping ofthe drive pulley. = Conveyor belt drift ‘+ Components of the belt conveyor. — Loosened screw connections + Other. = Abnormal runring noises — Trapped bits of metal = Contamination and caking > Switch off magnetic separator and diesel generator and take measures to prevent them from being switched on again. > Visually check the aforementioned points once again. Eliminate damage and deficiencies determined, Magnetic separator has been checked, sv Weenenday-ba:htaret Barrows printed 256 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Conveyor unit 4,10,06,02 Tensioning conveyor belt Tensioning conveyor belt Wednesday ©kl thet : leemann GmbH 2016 Fig. 4.58: Magnetic separator tensioning device [1] Tensioning carriage retaining screws [2] Clamping nut [3] Locknut Ws Risk of material damage A conveyor belt with belt drift or one that has been tensioned ‘too tightly or loosely wears faster and can result in damage to ‘the componerts of the magnetic separator. + Tension the drive pulley or return roller evenly and at right angles to the conveyor belt frame. ‘+ Tighten the conveyor belt to the correct tension. ‘The conveyor belts of all magnetic separators are each ten- sioned with two mechanical tensioning devices that basically share the same design. > Switch off diesel generator and plant. > Switch off and remove battery isolator and carry it with you. > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. > Ifnecessary, remove the protective covers of the tensioning devices. > Loosen the retaining nuts [1] of the tensioning carriage. > Loosen the locknut [3] until the tension is free. > Repeat the same work steps on the opposite side. 257MAINTENANCE Conveyor unit [w]] KLEEMANN v Turn the tension ng nuts (2) evenly until the conveyor belt is tensioned correctly. > Tighten locknuts [3] again. > Tighten the retaining nuts [1] of the tensioning carriage. > If they were removed, reinstall the protective covers of the tensioning devices. ¥__ Ihe conveyor belt Is tensioned. > Insert battery isolator and switch on. A conveyor belt that is tensioned too loosely can be recognised @ by sagging between the return rollers. A conveyor belt that is tensioned too tightly can be recognised by vibrating of the bot- tom segment during operation. Arule of thumb: The correct tension is the lowest possible ten- sion that prevents the drive pulley from slipping at the conveyor belt, Detensioning conveyor » Switch off diesel generator and plant. Belt» switch off and remove battery isolator and carry itwith you. > Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. > Ifnecessary, remove the protective covers of the tensioning devices. > Loosen the retaining nuts [1] of the tensioning carriage. Loosen the locknuts [3]. ‘Turn the tension ng nuts [2] evenly until the conveyor belt is relieved of tension. > Tighten the locknuts [3]. > Tighten the retaining nuts [1] of the tensioning carriage. > If they were removed, reinstall the protective covers of the tensioning devices. ¥ The conveyor belt has been detensioned, > Insert battery isolator and switch on. vv 4.10.06.03 Servicing worm gear ‘The gearbox used is a filled-for-life version. If it therefore not necessary to check the oil level and change or drain the oil. For repair work, the gear motor has to be removed. Following repair measures at the gearbox, it must be filled with the correct quantity of oil. The oll capacity of the gearbox is 0.48 litres. Weenesday-02-htare Het 258 © Kleemann GmbH 2016i MAINTENANCE KLEEMANN Conveyor unit Danger due to hot oj Oil and machine parts can be very hot; there is a risk of injury. Wear protective equipment. + Where possible, avoid touching any parts of the units. + Avoid ckin contact with ole and greaces. * In case of injury, consult a doctor immediately. 4,10.06.04 Lubricating bearings Fig. 4.59: Magnetic separator bearings [1] Drive pulley bearing [2] Return roller bearing [3] Lubrication nipple ‘The bearings of the drive pulley and return roller are lubricated via a lubricating nipple. ‘Switch off diesel generator and plant. ‘Switch off and remove battery isolator and carry it with you, Provide and use a suitable climbing aid such as a lifting plat- form or scaffolding. > Use a grease gun to press grease with the appropriate spec- ifications into the lubricating nipples of the drive pulley and return roller bearings. > Clean away any excess grease and dispose of in an eco- friendly manner. ¥_ The bearings have been lubricated. > Insert battery isolator and switch on. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 259MAINTENANCE Not assigned ww] KLEEMANN w@ [Lubrication point Amount of grease per lu- brication point [Bearings 2.5 grammes Tab. 4.6: Lubricating point of magnetic separator One stroke of the grease gun corresponds to approx. 3 g grease. For maintenance intervals, see chap. 5.02. 4.11 Not assigned 4.12. Water system (option) Fig. 4.60:Water system [1] Spraying nozzles [2] Fluid control [3] Water pump Riek of falling ‘There is a risk of faling during maintenance and repair work on the plant components. ‘+ Use suitable climbing aids or lifting platforms. ‘+ Check that the climbing aids are secure and safe to use, ‘+ Ensure that the three-point contact on the climbing aid is se~ cure. ‘= Do not jump fron the climbing aids or the plant. Weenenday-ba:htaret 260 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Water system (option) ‘The water pump [3] and the fluid control [2] are maintenance- free. Only a visual check is required. > Visually check the housing and connections of the water pump [3] and fluid control [2] for leaks. > Have damage eliminated by authorised and qualified per- sonnel. > Visually Lhieck connections for spraying nozzles [1] for leaks, > Check alignment of the spray jet and correct it if necessary. > Visually check feed lines of spraying nozzles for leaks. Elim- inate leaks. ¥ The water system has been checked. Spraying nozzles are fitted at the following points: + Crusher inet + Crusher outlet + By-pass device * Belt discharge for crusher discharge conveyor and prescreen conveyor Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 261MAINTENANCE Not assigned [w] KLEEMANN 4.13 Not assigned 4.14 Not assigned 4.15 Not assigned 4.16 Not assigned 4.17 Not assigned 4.18 Lubrication system (option) 4.18.01 Servicing lubrication system ry Ba Danger when lubrication system is pressurised During operation, the lubrication system is under pressure and there is a risk of injury. + Maintenance and repair work must always be cared out with the system switched off. + Switch off the system, remove the key and secure against reactivation, Risk of crushing in folding area of service flaps Serious crushing injuries are possible when folding or swinging service flaps, protective housings and safety covers. + Stay well clear of the folding and swinging range. ‘+ Ensure that there are no persons in the hazard area during assembly. Des Risk of material damage Changes to the settings of the lubrication system made by KL- EEMANN GmbH can result in material damage. ‘+ Do not change the settings. Wednesctay-earhtare 262 ihowstiiny printed © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Lubrication system (option) 4,18.01.01 Filling lubrication system Fig. 4.61:Lubrication system [1] Lubricant tank [2] Lubrication nipple > Switch diesel generator off. > Switch off and remove battery isolator, see chap, 2.06.02and carry it with you. > Remove cep of lubrication nipple [2]. > Connect filing system to lubrication nipple. > Fill lubricant tank, see chap. 2.18, with lubricating grease. Ensure that the maximum fill level is not exceeded. >» Remove filling system, clean away any excess grease and dispose of in an eco-friendly manner. Observe national spec- ifications for disposal. Fit cap of lubrication nipple. The lubrication system has been filled. > Check connections and lubricant lines for leaks. Repair leak- ing connections and lubricant lines. > Insert battery isolator. For lubricants, see chap. 5.04.01. cy Wednesday © Kleemann GmbH 2016 263MAINTENANCE Lubrication system (option) [w]] KLEEMANN 4.18.01.02 Checking lubrication system Fig. 4.62:Lubrication system [1] Plunger detector [2] Lubricant lines of crusher plant and left crusher discharge conveyor bearing [3] Lubricant line from pump unit [4] Lubricant lines of crusher plant and right crusher dis- charge conveyor bearing [5] Distributor Weed Risk of material damage Damaged or loose lubricant lines result in damage to the crush- er bearings. ‘= Check lubricant lines for damage. © Check screw-couplings for leaks and firm seating. ‘The crusher bearines and the bearings of the return roller from the crusher extractor conveyor are supplied with grease from the lubrication system via lubricant lines. The lubrication from the pump unit to the distributor [5] ic monitored by a plunger detector. Correct lubrication from the distributor to the connec- tion points and the bearings must be checked at regular inter- vals. > Switch off plant components and diesel generator and se~ cure against reactivation. > Switch off, remove and carry the battery isolator with you, see chap. 2.06.02, Weenenday-oa:htaret 264 © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Lubrication system (option) > Visually inspect lubricant lines [2], [3] and [4] for damage and leaks. Replace damaged lubricant lines. > Check screw connections on lubricant lines at the distributor for leaks and firm seating. Tighten loose screw conne w Fig. 4.63:Lubrication system T6] Connection paints for lubricant lines > Check screw connections on connection points of the lubri- cant lines for leaks and firm seating. Tighten loose screw connections. > Visually inspect lubricant lines to lubrication points for dam- age and leaks. Replace damaged lubricant lines. > Check screw connections of lubricant lines at the crusher and crusher discharge conveyor for leaks and firm seating. Tighten loose screw connections, > Perform work on both sides. ¥ The lubricant lines have been checked. > Insert and switch on battery isolator. For maintenance intervals, see chap. 5.02. Deas Risk of material damage Incorrectly connected lubricant lines can result in damage to the bearings of the crusher and crusher discharge conveyor. + When installing lubricant lines, ensure the position on the distributor and connection points is correct. If lubricant lines are disassembled for assembly or repair work, ensure that the lubricant lines are reinstalled in the correct po- Wednesday kl thet : leemann GmbH 2016 265MAINTENANCE Lubrication system (option) w KLEEMANN sition on the distributor and at the connections points. If neces- sary, make markings prior to disassembly. Wednesctay-ea:htare 266 Hoon srprintedtt © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Not assigned 4.19 Not assigned 4.20 Not assigned 4.21 Not assigned 4.22 Not assigned 4.23 Not assigned 4.24 Not assigned 4.25 Not assigned 4.26 Not assigned 4.27 Not assigned 4.28 Not assigned 4.29 Not assigned 4.30 Not assigned 4.31 Not assigned 4.32 Not assigned 4.22 Not assigned 4.34 Not assigned 4.35 Not assigned 4.36 Not assigned Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 267MAINTENANCE Not assigned ww] KLEEMANN Not assigned 4.38 Not assigned 4.39 Not assigned 4.40 Not assigned 4.41 Not assigned 4.42 Tools Fig. 4.64:Tools and accessories (2) Toolbox (2) Tools and accessories > Check the toolbox [1] for safe installation on the plant and for damage. Check tnnis and accessories [2] for completeness and dam- age. Replace or exchange missing or damage tools. ¥ Tools and accessories have been checked, Weenenday-ea:htaret 268 © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Feeding unit 4.43 4.43.01 Feeding unit Servicing feed hopper Wednesday Fig. 4.65:Feed hopper [1] Guard devices of the hydraulic cylinder [2] Hopper wall locking [3] Screw coupling for hopper wall support brace [4] Mountings of hopper walls [5] Hydrauie cylinder Risk of falling There is a risk of falling during maintenance and repair work on the plant components. * Use suitable climbing aids or lifting platforms. * Check that the climbing aids are secure and safe to use. + Ensure that the three-point contact on the climbing aid is se~ cure. + Do not jump from the climbing aids or the plant. > Visually check the guard devices of the hydraulic cylinder [1] for damage. > Visually check hopper wall locking elements [2] for correct installatior: Tighten screw connections [3] for support brace correctly. > Visually check mountings of hopper walls [4] for damage and tighten loose screw connections to specified torque. v kl thet : leemann GmbH 2016 269MAINTENANCE Feeding unit [w]] KLEEMANN > Visually check hydraulic cylinder [5] for leaks. > Replace damaged components if necessary. The feed hopper has been checked. 4.43.02 Servicing feeder trough 4.43.02.01 Servicing rubber mount Weenenday-ea-htaret Fig. 4.66:Feeder trough rubber mountings [1] Attachment points [2] Rubber mountings Risk of falling ‘There is a risk of faling during maintenance and repair work on the plant components. ‘+ Use suitable climbing aids or lifting platforms. ‘+ Check that the climbing aids are secure and safe to use. ‘+ Ensure that the three-point contact on the climbing aid is se- cure. ‘= Do not jump fron the climbing aids or the plant. Bees Risk of material damage Defective rubber mountings can no longer absorb the existing loads and vibrations and lead to consequential damage on plant ‘components. + Replace damaged rubber mountings immediately. 270 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Feeding unit Checking rubber mountings Replacing rubber mountings Cracks in rubber buffers quickly lead to bursting of the complete rubber mounting. Components can then knock against neigh- bouring plant components or the chassis and damage them. Bloating of the rubber buffers, on the other hand, is normal wear and they do not have to be replaced. Visually check rubber mountings [2] for cracks. Replace rubber mountings if necessary. ‘The rubber mountings have been checked. Fold down hopper walls, see chap. 6.03.07. Unscrew earth strap between feeder trough and chassis. Attach suitable hoisting gear and lifting accessories to the attachment points [1] Raise the feeder trough until the rubber mountings [2] can be removed, Replace mountings. Lower feeder trough back onto the rubber mountings. Screw earth strap back on. Fold up hopper walls again, see chap. 6.02.04. The rubber mountings have been replaced. yvowvvy Switch off plant components and the diesel generator. > Tighten all securing screws [1] with torque wrench, For tightening torques, see chap. 5.03. > Visually check protective covers [2] for damage and replace if necessary. ¥ The vibration motors have been checked. Weenenday-ea:htaret Barrows printed 272 © Kleemann GmbH 2016