DESCRIPTION [w]] KLEEMANN Conveyor unit The tensioning device [10] is used to set the conveyor belt to the correct tension. Scrapers [7] ensure that the top and bottom segment of the conveyor belt are free of adhering material, which would other- wise damage the conveyor belt, rollers and pulleys. ‘The material guide ledges [3] prevent the material to be con- veyed falling out of the side of the belt convevor. Optional equipment + Hydraulically foldable head piece of crusher discharge con- veyor. + Extended crusher discharge conveyor. + Preparation for belt scale in crusher discharge conveyor. 2.10.02 Extractor channel al < 5 Fig. 2.73:Extractor channel [1] Vibraticn motors [2] Wear lining [3] Sealing for crusher outlet [4] Chute trough [5] Rubber mountings Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 101DESCRIPTION Conveyor unit ww] KLEEMANN Weenenday-ea:htaret 102 Fig. 2.74:Vibration motors [6] Protective covers for unbalance weights [7] Electric motors 400 V [8] Unbalance weights ‘The extractor channel is a vibrating conveyor that conveys the material arriving from the crusher and by pass to the crusher discharge conveyor by means of its oscillating movement. ‘The chute trough is mounted with rubber mountings on the chassis. The loading surface and flanks are covered with a wear lining. ‘The speed of the electric motors is coupled to the speed of the diesel generator. The two vibration motors rotate in opposite di- rections. By means of the adjustable unbalance weights, they generate a periodic vibratory movement. © Kleemann GmbH 2016[w] DESCRIPTION KLEEMANN Conveyor unit 2.10.03 Chutes Fig. 2.75:Chutes [1] Screen underpass [2] By-pass device [3] Crusher outlet Chutes such as the screen underpass and crusher outlet guide and pass on the material to downstream machines and compo- nents. The rubber plates fitted on the steel structure of the chutes re- duce the dust discharge from the plant and form the flexible transitions to the downstream machines and components. ‘The by-pass device conveys the material which passes the up- per deck, but not the lower deck, past the crusher onto the ex- tractor channel and then onto the crusher discharge conveyor. Wednesday kl thet : leemann GmbH 2016 103DESCRIPTION Conveyor unit ww] KLEEMANN 2.10.04 Magnetic separator (optional) Werneaday-ba:htaret Fig. 2.76: Magnetic separator [1] Conveyor belt of crusher discharge conveyor [2] Suspension [3] Magnetic separator drive [4] Conveyor belt with ribs [5] Run-off chute ‘The magnetic separator uses magnetic force to remove ferrous material from the crusher discharge conveyor and conveysit via the conveyor belt and the run-off chute into a container provid- ed. ‘The magnetic separator is driven by an electric motor with flange-mounted worm gear. Optional equipment ‘+ Electromagnetic magnetic separator. ‘+ Permanent magnetic separator. + Magnetic separator preparation. 104 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Not assigned 2.10.05 _ Belt scale (option) Fig. 2.77:Belt scale [1] Conveyor belt, crusher discharge conveyor [2] Belt scale (in the conveyor belt frame) [3] Measuring wheel The belt scale and the measuring wheel are located in the con- veyor belt frame. ‘The conveyor belt speed is determined using the measuring wheel. In order to obsain precise values, the belt scale must be adjust- ed after each procedure or weekly, see chap. 3.10. 2.41 Not assigned 2.12 Water system (option) wD ‘The spray system ensures a reduction in dust development at ‘the material transfer points on the plant. A low-pressure water pump generates the necessary water pressure and volume flow. Spray nazzies. which can he cut in and out individually, create a finely atomised spray at the required points. The water drops bind most of the dust particles, which then fall down. The water system is cut in manually. “The spray system is usually sufficient to bind the dust created during the crushing and screen procedure so that there is only locally limited dust development. This restricts neither vision at the plant nor the range of functions. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 105DESCRIPTION Water system (option) ww] KLEEMANN ‘As dust development essentially depends on the type of stone ‘and weather, in special cases, e.g. when processing dry, brittle material such as limestone, tiles/bricks or demolished concrete, increased dust formation is possible. Dust formation can be re- duced by the additional use of belt covers and ejector chutes, (special options) but not completely eliminated. When processing demolished or cut asphalt, thorough cleaning uf Ure woke ust be carried out more frequently because the dust created in this case tends to jam the cooler fins. 2.12.01 Water pump $ 4 2 5 1 Fig. 2.78: Water pump [1] Electric motor 230. V [2] Terminal box [3] Connection for water pump [4] Fluid control [5] Pump housing ‘The multi-stage self-priming water pump is designed for suction mode. In flooded suction mode, the spraying nozzles are sup- plied directly with water. ‘The water pump forwards the drawn-in water via the fluid con- trol to the individual feed lines for the nozzles. The fluid control guarantees a constant pressure and prevents water running back from the feed lines, The individual feed lines to the spray- ing nozzles are opened and closed by shut-off cocks. ‘The water pump is switched on and off using the "Water pump" button in the operator panel. The water pump also has to be ‘connected in the water pump cabinet to the 230 V socket outlet, Weeiresctay Serhterct ree testi pated 106 © Kleemann GmbH 2016DESCRIPTION [w] KLEEMANN Water system (option) Prerequisites for suction mode + Clean water and water tank, * Maximum length of suction line 5 m. ‘+ Water pump must be filled with water prior to operation. + Water must be directed through an intake filter before the water pump. Prerequisites for flooded suction + Maximum pressure of supply line 4 bar. 2.12.02 Spraying nozzles Fig. 2.79:Spraying nozzles [1] Spraying nozzles [2] Shut-off cocks ‘The water directed via the shut-off cocks and feed lines of the spray system is distributed by the spraying nozzles in the form of a finely atomised spray. Spraying nozzles are fitted at the following points: © Crusher inet + Crusher outlet: + By-pass device ‘+ Belt discharge for crusher discharge conveyor and prescreen conveyor Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 107DESCRIPTION Not assigned [w]] KLEEMANN 2.13 2.14 2.15 2.16 Liz 2.18 Not assigned Not assigned Not assigned Not assigned Not assigned Lubrication system (option) n system operator panel Fig. 2.80:Operator panel [Designation [Function G4) Pause LED Pause time [21 LED display, 3-digit [Operating status and values (3) (Contact LED [Contact time display (pump operation) [4] [Up/down button J+ Switch on display > Display values and parameters J+ Set values and parameters [ST ‘SET Button = Switch between programming and display mode Js Confirm values Wednenday-ba-htaret Barrows printed 108 © Kleemann GmbH 2016[w]] KLEEMANN DESCRIPTION Lubrication system (option) [Designation Function (6) [2 =CSteD Plunger detector system function monitoring, CS = Cy- —— icle Switch Pressure switch function monitoring, PS = Pressure ‘Switch [7] |DK button > Trigger intermediate lubrication ‘+ Delete fault message [s]__|Fault LED Error and fault message Tab. 2.5: Operator panel Lubrication system of crusher and crusher discharge conveyor Fig. 2.81:Lubrication system [1] Lubrication nipple [2] Pump element with pressure relief valve [3] Lubricant tank [4] Lubricant line from pump unit [5] Distributor [6] Plunger detector 17] Lubricant lines to central lubrication point [8] Lubricant lines to central lubrication point Wednestay-22-htaret © Kleemann GmbH 2016 109DESCRIPTION Lubrication system (option) [w]] KLEEMANN 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. ‘The pump unit meters the lubricant and directs it via the main line to the distributor, The lubricant is forwarded from the dis- ‘ributor to the downstream lubrication points. Metering of the lubricant for the cor-esponding bearings is carried out in the dis tributor at the lubricant line connections. These connections must not be interchanged. A plunger detector monitors the distribution function and the supply of the lubricant lines with lubricating grease. The supply to the bearings is not monitored. Iflubrication pressure too high, lubricating grease is drained via the pressure relief valve. Lubricant volumes and intervals are defined by the integrated control system and must not be altered without consultation with KLEEMANN GmbH. Weenenday-oa-htaret Barrows printed 110 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Not assigned 2.19 Not assigned 2.20 Not assigned 2.21 Not assigned 2.22 Not assigned 2.23 Not assigned 2.24 Not assigned 2.25 Not assigned 2.26 Not assigned 2.27 Not assigned 2.28 Not assigned 2.29 Not assigned 2.30 Not assigned 2.31 Not assigned 2.32 Not assigned 2.23 Not assigned 2.34 Not assigned 2.35 Not assigned 2.36 Not assigned Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 11DESCRIPTION Not assigned ww] KLEEMANN 37 Not assigned 2.38 Not assigned 2.39 Not assigned 2.40 —Not assigned 2.41 Service packs/telemaintenance 2.41.01 Service packs KLEEMANN GmbH offers various service packs and maintenance kits for maintenance and service work. Contact persons for service packs are listed under "Customer service" on the homepage of KLEEMANN GmbH: www.klee- mann. info 2.41.02 Telemaintenance Fig. 2.82:Telemaintenance modem [1] Telemaintenance rotary switch [2] Modem [3] Aerial (not illustrated) ‘The modem for telemaintenance is installed in the switch cabi- net behind the switch cabinet door of the operator panel. Weenenday-ea-htaret 112 © Kleemann GmbH 2016DESCRIPTION KLEEMANN Tools ‘To activate the modem [2], the rotary switch [1] must be switched on and the aerial of the modem [3] must be affixed with the magnetic base outside the switch cabinet. ‘Via the remote radio connection, the PLC control and the set- ‘tings of the frequency converter can now be read and changed. 2.42 Tools Fig. 2.83:Tools and accessories (4) Toolbox (2) Tools and accessories The toolbox (:) contains all tools and accessory parts (2) re- quired for maintenance and repair work. The toolbox is secured with @ padlock to prevent unauthorised removal of tools. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 113DESCRIPTION Tools ww] KLEEMANN 2.42.01 Rock chisel (option) Weenenday-ea:htaret 114 Fig. 2.84:Rock chisel Operation of the rock chisel is via the control system at the rock chisel or via the associated radio remote control. For further in- formation on the rock chisel, refer to the documentation of the rock chisel manufacturer. ‘The control electrical system and the hydraulic power unit of the rock chisel are switched on using a button on the plant's oper- ator panel (see cap. 2.02.02). © Kleemann GmbH 2016[w] DESCRIPTION KLEEMANN Feeding unit 2.43 2.43.01 Feeding unit Feed hopper Fig. 2.85:Feed hopper [1] Hopper wall, rear [2] Hopper wall locking [3] Hopper wall, left [4] Hopper wall support brace [5] Hopper wall, right [6] Suppor: foot with mounting [7] Hydrauie cylinder ‘The feed hopper receives the material loaded by a digger, wheel loader or an upstream plant. ‘The hopper walls, [1], [3] and [5] can be folded by the auxiliary hydraulic system and are actuated manually via valve blocks. ‘The hydraulic cylinders [7] are equipped with an excess flow valve to secure the hopper walls when they are folded up and down, When folded down, the hopper walls are supported against the detents on the Chassis. When folded up, they ote fiitly Conn nected to the chassis with the help of eye bolts on the mount- ings of the suoport feet [6]. Additional support is provided by ‘the hopper wall locking elements [2] at the connecting points of the hopper walls. ‘The support brace [4] must be installed for operation. The sup- port brace is disassembled for transport and folding down of the hopper walls, Wednesday kl thet : leemann GmbH 2016 115DESCRIPTION Feeding unit [w]] KLEEMANN Optional equipment + Welded or bolted Hardox wear lining. 2.43.02 Feeder trough 3 4 Fig. 2.86:Feeder trough [1] Vibration mozors [2] Wear lining [3] Rubber mountings [4] Chute trough 6 Fig. 2.87:Vibration motors [5] Electric motors 400 V [6] Unbalance weights Weenenday-ea:htaret Barrows printed 116 © Kleemann GmbH 2016DESCRIPTION [w]] KLEEMANN Crusher 2.44 Crusher The feeder trcugh is a vibrating conveyor that conveys the ma~ terial loaded into the feed hopper by means of its oscillating movement toa downstream machine. ‘The chute trough [4] is mounted with rubber mountings [3] on ‘the chassis, Tre loading surface and flanks are covered with a wear lining [2]. ‘The speed of the electric motors [5] can be controlled by the frequency converter (see chap. 2.02.04), By means of the ad- justable unbalance weights [6], they generate a periodic vibra- tory movement. ‘The two vibration motors rotate in opposite directions. Fig. 2.88:Jaw crusher [1] Mounting [2] Articuleted crusher jaw [3] Belt pulley [4] Flywheel 5] Clamping wedge for articulated crusher jaw [6] Lateral wedges [7] Fixed crusher jaw [8] Crusher frame Wednestay-22-htaret © Kleemann GmbH 2016 117DESCRIPTION Crusher [w]] KLEEMANN Fig. 2.89:Crushing gap setting [10] Spring pack preloading device [11] Crushing gep setting hydraulic cylinder [12] Securing elements for articulated crusher jaw [13] Rocker [14] Crusher frame pressure plate beating [15] Pressure plate ‘The single toggle jaw crusher crushes charged material by means of static pressure between the crushing jaws. A rocker [13] mounted on the eccentric shaft effects the ellipsoidal movement of the articulated crusher jaw [2]. The articulated ‘crusher jaw [7] on the opposite side is fixed to the crusher frame [8]. The lateral wedges [6] form the side closure of the ‘crushing jaw. ‘The jaw crusher is driven by an electric motor, which transmits its force via a belt crive onto the eccentric shaft. ‘The crushing gap at the bottom end of the crusher jaws can be adjusted mechanically with the help of a hydraulic cylinder [11]. ‘The lower section of the rocker is adjusted by altering the num- ber of shims in the adjusting device. “The spring packs of the preloading device [10] guarantee the security of the pressure plate [15] during operation. If the jaw crusher is overloaded, e.g. through unbreakable ma- terial, the rocker can retract to a certain degree before the pres- sure plate breaks at its predetermined breaking point. Weenesday-ba:htaret 118 © Kleemann GmbH 2016DESCRIPTION KLEEMANN Screens 2.45 Screens 2.45.01 Grizzly Wed Danger of material damage Non-original pressure plates do not meet the overload protec- tion requirements. Damage to the jaw crusher may result and the warranty is voided. * Only use original pressure plates from KLEEMANN. level monitor A fill level monitor at the crusher inlet monitors the fill level of the crushing jaw and, in the event of overfilling, switches off the grizzly and the feeder trough. When the crushing jaw is free again, the grizzly is switched on again first and then the feeder trough. Wednesday Fig. 2.90:Grizely [1] Dust protection [2] Sereen surfaces [3] Screen casing [4] Rubber mountings [5] Unbalance weights [6] Universal-joint shaft [7] Angular gear [8] Electric motor 400 V kl thet : leemann GmbH 2016 119DESCRIPTION Screens [w]] KLEEMANN Wednesday ‘The double-deck grizzly serves as a process screen. It separates the charged material into three defined grain sizes depending ‘on the screen surface used (perforated panel, slotted grate, wire cloth) ‘The screen casing [3] is mounted with rubber mountings [4] on the chassis. Screen surfaces [2] are clamped onto the distance frame of the screen decks with the help of clamping systems. ‘The electric motor [8] drives the eccentric shaft of the screen drive via the angular gear [7] and the universal-joint shaft [6]. The eccentric shaft is lubricated with grease. ‘The replaceable untalance segments [5] can be used to change the rocker width of the grizzly. Screening procedure 2) Upper deck covered with steel perforated panel or slotted grate (option); ower deck covered with rubber screen sur- ce: * Coarse material that does not pass the upper deck of the grizzly is conveyed directly into the crusher. * Material that passes the upper deck is guided via the rubber screen surface and the by-pass device past the crusher directly ‘onto the extractor channel and then onto the crusher discharge conveyor. This is used, for example, with clean charged material to supply the entire charged material to the final product with- out having to dispense with the advantage of primary screening and thus relieving the burden on the crusher. b) Upper deck covered with steel perforated panel or slotted grate (option); lower deck with screen surface (option) * Coarse material that does not pass the upper deck of the grizzly is conveyed directly into the crusher. *+ Material that passes the upper deck but does not pass the lower ‘deck is guided via the by-pass device past the crusher onto the ‘extractor channel and then onto the crusher discharge conveyor. + Material that passes the lower deck of the grizzly is discharged via the prescreen conveyor onto a waste tip or a downstream plant. ) Upper deck covered with screen cover (option): + The entire charged material reaches the crusher. The primary screening is not active. Used for crushing hard rock if this achieves a more compact crusher jaw fillirg. In the standard series version, the upper deck is covered with a steel perforated panel. The lower deck is covered with a rubber screen cover so that the entire material is guided past the ‘crusher via the by-pass device. 120 tert © Kleemann GmbH 2016[w]] KLEEMANN DESCRIPTION Screens Optional equipment ‘+ Slotted grate in the upper deck. + Screen cover in upper deck. + Wire cloth in lower deck. Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 121OPERATION Screens [w]] KLEEMANN 3 OPERATION This chapter describes how the plant and the individual ma- @ chines and components are operated. During all activities, observe the information in your safety manual! Wednesctay-earhtare ihowstiiny printed 122 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Screens LS SSIS ass] allo | J ecell 8 p 23 2 25 287 BCD BD, DB 34 Fig. 3.1:Operator pane! Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 123OPERATION Screens [w]] KLEEMANN [Pos.: |Control element/Indi [Function [2] Oil pressure lindicates the current oil pressure of the diesel engine in bar [2] |Coolant temperature Hindicates the current coolant temperature of the diesel lengine in °C [3]__|Fuet gauge Displays the fill level of the diesel fuel lank [4] [Ignition switch with control lamps [Starts and stops the diesel engine, displays the operat- ing status of the diesel engine, see description of "Igni tion switch" [5] |Amperemeter Displays current consumption of crusher drive [5] __|Amperemeter Displays current consumption of entire plant [7] [voltmeter Displays the voltage between the phases with the main switch switched on [8] [Operator panel OP3 Hinterface for setting different plant parameters, see de- scription of ‘Operator panel OP3" [9] __ [Rotary switch for lighting [Switches plant headlights on/off [0] |Rotary switch for fill level imonitor [Switches Filllevel monitor at crusher inlet on/off [11] [Coupling button Disengages/Engages drive coupling [12] _ |Key switch for control volt- age [Switches plant control voltage on/oft [23] __[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- igency stop button [Acknowledges faults and emergency stops [17] _ [Rotary switch automatic mode/manual mode [Switches over to automatic or manual operating modes. Hin manual mode position, the sequential locking device lof the machine is switched off. [18] [Automatic mode control lamp Displays automatic mode [73] __ [Manual mode control lamp. Displays manual mode [20] [Magnetic separator rotary switch [Switches conveying direction of magnetic separator to left/right [24] [Switches plant on/off vie radio remote control [22] _ [Lamp test button [Carries out lamp test of control lamps [23] _ [Button for magnetic sep- jarator [Switches magnetic separator on/off [24] [Button for spare belt con- lyeyor [Switches spare belt conveyor on/off [25] _ [Button for crusher di charge conveyor. [Switches crusher discharge conveyor on/off Wedneaday-ba:htaret Barrows printed 124 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Measures before initial operation [Control element/Indi- Function lcator [26] [Button for extractor chan- [Switches extractor channel on/off ne [27] [Button for prescreen con- Switches prescreen conveyor on/off lveyor [28] _[Presersen button Switchae precereen on/ot [29] [Vibrating feeder button [Switches vibrating feeder on/off [30] [Button for auxiliary hy- Switches auxiliary hydraulics on/off ldraulics [Si]__|[Button for water pump __| Switches water pump on/off [52] Vibrating feeder rotary | Increases/Reduces vibration velocity of vibrating feeder lswitch [33] [Button for rock chisel | Switches hydraulics and control electrical system of the Fock chisel on/off. For operation of the rock chisel, see manufacturer's documentation [34]__|Emergency-off button _|Switches plant off in emergencies, see chap. Tab. 3.1; Operator panel control elements 3.01 Measures before initial operation A Ba Danger due to unqualified personnel Installation and initial operation by unqualified and unauthor- ised personnel can result in serious or fatal injuries. + Only assign personnel installation and initial operation tasks who are qualified and authorised according to the require- ments in this instruction manual. Risk of material damage Foreign bodies in the plant, such as tools, accessories and pack- aging materials, can result in malfunctions and material dam- age. + Following installation and prior to initial operation, search ‘the entire plant for foreign bodies and remove them, During initial operation and after every transport, different tasks and checks have to be performed. > Completely install the plant, see chap. 6.02. > Remove foreign bodies such as tools, accessories and pack- aging materials from the plant. Wednesday-2@-htare kl leemann GmbH 2016 125OPERATION ‘Switching external power supply on and off (option) [[W]] KLEEMANN ‘Software and downloads Before and at any time after initial operation you can update the installed software of the PLC control and carry out downloads. ‘Access to the PLC control is via the telemaintenance modem, see chap. 2.41.02. 3.02 — Swilchiny external power supply on and off (op- tion) Weeneaday-ba:htaret Fig. 3.2:External power supply main switch [1] Main switch for diesel generator [2] Main switch for external power supply [3] Switch cabinet for external power supply ‘The two main switcies are locked reciprocally and can only be operated separately. Operating plant via external power supply > ‘Turn the "Diesel generator” main switch to the "OFF" posi- tion. > Tur the "Exterral power supply” main switch to the "ON" position. The plant is run via the external power supply. Operating plant via diesel generator > Tum the "Exterral power supply" main switch to the "OFF" position. > Turn the "Diesel generator’ main switch to the "ON" position. The plant is run via the diesel generator. 126 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Putting the plant into operation 3.03 Putting the plant into operation A BO Danger due to unqualified personnel Installation and initial operation by unqualified and unauthor- ised personnel can result in serious or fatal injuries. + Only assign personnel installation and initial operation tasks who are qualified and authorised according to the require- ‘ments in this instruction manual. Before initial cperation of the plant, the following items must be checked: Lubricating and + Oil level of the diesel engine (also refer to the manufactur- operating materials ers documentation). * Fill evel of the coolant (see chap. 2.04.05). + Fill evel of the diesel fuel tank. + Fill evel of water system (see chap. 4.12). + Check fill level of the hydraulic oil (see chap. 4.05.02.01). * Oil level in pump splitter gearbox (see chap. 4.05.03). * Lubrication of screen drives (see chap. 4.45.03) + Lubrication of crusher beanngs (see chap. 4.44.01). + Lubrication of belt conveyor drives (see chap. 4.10.01.05). Leak-tightness and + Check fuel supply for leaks. condition . Check hydraulic oil supply for leaks. + Leak-tightness of water system. * Check condition of power supply unit. * Check condition of V-belt (see chap. 4.44.03). * Check condition of conveyor belts (see chap. 4.10.01.01). + Check condition and presence of safety devices (see chap. 4.01.03). + Check condition of screen surfaces, spring elements and rubber profiles (see chap. 4.45.08). * Check secure fitting of screw connections. * Check condition and tension of crawler carrier chains. + Check closure of all service doors and flaps. + Ensure correct earthing of the plant (see chap. 6.02.03). + Attach operating plug (see chap. 2.06.06), Wednesttay-oa-htare sikowstiiny printed © Kleemann GmbH 2016 127OPERATION Switching plant on and off [w]] KLEEMANN Functions * Check function of the emergency stop and emergency switching off devices. ‘+ Check function of warning devices. ‘+ Check function of drive system and brakes. + Check conveyor belt running during material feed (see chap. 4,10.03.03), spec scrnascerraegwe yur CE) team ‘Top up lubricants and operating materials. The maintenance schedule and operating material and lubricants tables are pro- vided in chap. 5. 3.04 Switching plant on and off 3.04.01 Si ching diesel generator on and off Switching diesel generator on > Insert ignition key in STOP position. > Turn ignition key to START position and hold until the diesel Grtuas engine is running. Y Diesel engine starts up. Release ignition key. Diesel engine runs at preset speed of approx. 1500 rpm. Dod Danger of material damage In critical operating statuses, the diesel engine shuts down au- tomatically and the warning siren sounds. ‘+ Before switching on again, find the cause and eliminate it. ‘oo " cv ‘Switching diesel generator off Before switching off the diesel engine, let it run for approx. 4 G@ minutes without load to cool down. > Tum ignition key to STOP position. > Remove ignition key. ¥ Diesel engine is stationary. Weenenday-ea-htaret Barrows printed 128 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Switching plant on and off 3.04.02 Switching plant components on and off Ee k of falling material Persons in the danger zone of the plant can be injured by falling material wher the plant is started up. + Donot enter the danger zone when the plantis being started up. + Warn persons in the danger zone prior to starting the plant. + Wear protective equipment. After the diesel generator has been started, the plant compo- nents can be switched on. This is carried out in "Automatic" op- erating mode. For manual mode, see chap. 3.05. In automatic mode, plant components are switched on auto- matically in the opposite direction of material flow. This pre- vents material congestions when the plant is started up. Before the plaxt components can be started, all emergency stop devices must be unlocked. For unlocking emergency stop devices, see also chap. 2.01. ‘Switching on plant components > Unlock emergency stop of the remote control. > Switch on radio remote control (see chap. 2.02.05). > Turn the main switch to RESET and then to ON (also refer to chap. 2.02). Fig. 3.3:Switches and buttons on operator panel > Switch on the "Radio remote control" [21] rotary switch. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 129OPERATION ‘Switching plant on and off [ww] KLEEMANN Switch on the "Control voltage” [12] key switch. ‘The operator panel OP3 powers up and "KLEEMANN GmbH" appears in the display. > Press the "Acknowledge fault / emergency switching off” [16] button. ¥_ If no more emergency stop or emergency off buttons have been pressed, the light in the button goes out. > Set the rotary switch "Automatic mode/manual mode" [17] to automatic mede. The "Automatic mode” [18] contro! lamp lights up. > Set the "Magnetic separator” [20] rotary switch to the left or Fight. Press the "Plant ON" [13] button. ‘The warning light and warning siren lights up or sounds for approx. 10 seconds. The "Start release" [15] control lamp lights up and the "Piant ON" [13] button flashes. Press the "Plant ON" [13] button once again. The plant components run up automatically in the opposite direction to material flow. The corresponding buttons of the components [23-29] light up. > Press the "Water pump" [31] button as required. ¥ The water pump runs and Uhe button lights up. ‘Switching off plant components Res Danger of material congestion When plant components are switched off, material congestion in the crusher is possible. ‘+ Allow all plant components, in particular the crushers, to run empty before switching them off. sv sv sv ‘Allow the plant to run completely empty. Press the "Water pump" [31] button if necessary. ‘The water pump switches off and the button light goes out. Run the crusher until empty. Piess Ure "Plait OFT* [1.4] button. Al plant components are switched off immediately. The "Start release” [15] control lamp and the "Plant ON" [13] button light go out. The corresponding button lights of the components [23-29] go out. > Switch off the "Control voltage” [12] key switch and remove the key. ¥ The "Operation" [18] control lamp goes out. sv ¥svy Weenenday-ea-htaret Barrows printed 130 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Switching plant on and off > Tum the main switch to OFF. ¥ The plant components are switched off The diesel generator is still running, 3.04.03 Switching on plant after emergency switching off actuation " 3k of falling material Persons in the danger zone of the plant can be injured by falling material wher the plant is started up. + Donot enter the danger zone when the plantis being started up, + Warn persons in the danger zone prior to starting the plant. + Wear protective equipment. ‘Switching plant on again after emergency stop After actuation of an emergency stop or a release cord, all plant drives with the exception of the diesel generator are switched off. The plant then has to be switched on again. > Eliminate material congestion in the plant if necessary, see chap. 3.12. For release of the emergency stop button or switch of the re- lease cord, refer to chap. 2,01, > Press the ‘Acknowledge fault / emergency switching off” [16] button If no more emergency-stop or emergency switching off but- tons have been pressed, the light in the button goes out. The plant components are ready to be switched on again. > Switch the plant components on again, 1g plant on again after emergency switching off After actuation of the emergency switching off button in the switch cabinet, al plant drives including the diesel generator are switched off. The plant then has to be switched on again. > Eliminate material congestion in the plant if necessary, see chap. 3.12. > Unlock emergeney switching off button, ace chap, 2.04.07. > Press the "Acknowledge fault / emergency switching off” [16] button ¥_ If no more emergency-stop or emergency switching off but- ‘tons have been pressed, the light in the button goes out. The plant components are ready to be switched on again. > Switch the diesel generator on again. > Switch the plant components on again. Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 131OPERATION Manual operation [w]] KLEEMANN 3.05 Manual operation Weenenday-ba-htaret ry Ba Danger due to unqualified personnel Execution of "Manual mode" by unqualified and unauthorised personnel can result in serious or fatal injuries. + Only assign maintenance, repair and service tasks to per- sonnel who are qualified and authorised according to the re- Quirements in this instruction manual. Boe Danger of material congestion Manual mode is not suitable for feeding the plant with material. Switching on individual plant components in manual mode can result in material congestion. ‘+ Do not feed material into the plant in manual mode. ‘+ Check the current situation before switching on a plant com- ponent. Unlike automatic mode, the plant components in manual mode are not automatically switched on the apposite direction of ma- terial flow. ‘After the diesel generator has been started, the plant compo- nents can be switched on and off individually. ‘Switching on plant components in "Manual mode" > Switch on diesel generator (see chap. 3.04.01). > Turn the main switch to RESET and then to ON (also refer to chap. 2.02). 132 © Kleemann GmbH 2016[w] KLEEMANN OPERATION Manual operation Fig. 3.4:Switches and buttons on operator panel > > v Run the crusher until empty. > Press the buttons of the running plant components [23-33]. The corresponding plant components are switched off and the button lights go out. Press the "Plant OFF" [14] button. The "Start release" [15] control lamp and the "Plant ON" [13] button light go out. Switch off the "Control voltage” [12] key switch and remove the key. The "Manual mode" [19] control lamp goes out. Turn the main switch to OFF. ‘The plant components are switched off. The diesel generator is still running. sv svsy 3.06 Operating the plant ry Ey Danger of being run over Tracked plants can cause serious or fatal injuries. ‘+ Before moving the plant, ensure that there are no persons in the driving area. ‘+ Use banksmen and/or flagmen to monitor the driving area. ‘= Keep a safe distance away from the crawler running gear when the plant is moving. 3.06.01 Preparations ‘The plant can also be moved with its equipment installed, i.e. with all components, such as platforms and prescreen conveyor (option) and magnetic separator, attached. With the plant running and the track drive activated, the feeder trough and the grizzly are switched off automatically. Wednesday-ba:htaret Barrows printed 134 © Kleemann GmbH 2016OPERATION KLEEMANN Operating the plant Wed Danger of material damage when driving Crawler carrier chains can freeze up and seize up and break when driving off. When the plant is moved and turned, untensioned crawler car- rier chains can spring off the sprocket and cause damage to the crawler running gear. ‘The suspensicn of the magnetic separator can be damaged by vibrations. + Do not drive the plant with frozen or rusted crawler carrier chains. + Move the plant every day approx. 10 metres to prevent freezing up and seizing up due to rust. * Check the tension of the crawler carrier chain before moving and tighten it if necessary. * Install the transport locking devices of the magnetic separa tor (option). Prior to moving the plant, a few preparatory measures must be carried out: > Run all components, such as hopper, vibrating chutes, screens, crusher and belt conveyors, until they are emptied of all material. > Install the transport locking devices of the magnetic separa~ tor (option). > Remove the earthing rod. > Remove stones and adhering dirt from the running wheels and crawler carrier chains of the crawler running gear. >» Check the tension of the crawler carrier chains and tighten ‘them if necessary. > Check driving path and ground and remove obstacles if nec essary. > Observe ground clearance of the plant. Appoint banksman/banksmen. The plant is ready to be moved. sv Wednesday kl thet : leemann GmbH 2016 135OPERATION Operating the plant [w]] KLEEMANN Moving plant on ascending slopes and downward slopes ry Eo Danger of plant toppling Persons in the driving range of the plant can sustain serious or fatal injury. + Keep a cafe dictance away fram the plant when it is moving, + Before moving the plant, ensure that there are no persons in the driving area. ‘+ Only move the plant within the specified inclination values. Cos Risk of material damage Driving on downward and ascending slopes subjects the compo- nents of the crawler running gear to very high loads. + When driving 07 gradients, always ensure that the track drive of the craviler running gear faces downhill Drive carefully on slopes and always directly upwards or downwards. Avoid driving in transverse direction on downward slopes. all i Mm Weenenday-ba:htaret J <17% Fig. 3.5:Ascending slopes and downward slopes [1] Track drive > Fill diesel fuel up to approx. % of the maximum fill height so that the diesel engine does not stall on ascending or down- ward slopes. > Before driving off on ascending and downward slopes, align the plant at right angles to the slope. 136 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Operating the plant 3.06.02 Driving Driving with radio remote control > Ensure the track drive [1] is facing downhill. > Start driving on the slope. A Pr Danger due to blind spots Persons who are not in the visible driving range of the plant can sustain serious or fatal injury. + Use banksmen and flagmen to monitor the driving area. + Maintain continuous visual contact with banksmen and flag- men. ‘+ In dangerous situations, stop the plant immediately. > Ensure thatthe traverse path of the crushing plantis lat and Firm. > ‘Switch on diesel generator (see chap. 3.04.01). > Turn the main switch of the diesel generator to RESET and then to ON (also refer to chap. 2.02.01) > Unlock emergency stop of the remote control. > Switch on radio remote control (see chap. 2.02.05). OO Dl Sme B08 Fig. 3.6:Switches and buttons on operator panel > Switch on the "Radio remote contro!" [21] rotary switch. > Switch on the "Control voltage" [12] key switch. The operator panel OP3 powers up and "KLEEMANN GmbH” appears in the display. Wednestay-22-htaret : ‘© Kleemann GmbH 2016 137OPERATION Operating the plant [w]] KLEEMANN w Driving with wired remote control > Press the "Acknowledge fault / emergency switching off” [16] button. ¥ When the emergency stop or emergency off button is no longer pressed, the light in the button goes out. > Set the rotary switch "Automatic mode/manual mode" [17] to manual mode. The "Manual mode” [19] control lamp lights up. Press the "Plant/crusher ON" [13] button. ‘The control lamp for "Start release" [15] lights up and the warning sirens sound for approx. 10 seconds. The "Plant/ crusher ON" [13] button flashes. Press the "Plant/crusher ON" [13] button again. ‘The "Plant/crusher ON" [13] button lights up after approx. 60 seconds. > Press the "Coupiing” [11] button. ¥ The "Coupling" button [11] lights up. > Drive the plant with the levers. The crawler carrier chains start moving after actuation of the ‘two levers of the drive control. The left lever is for the left crawi- ‘er carrier chain, the right lever for the right crawler carrier chain, ‘The crawler carrier chains always move in the direction in which the lever is moved. The speed changes in proportion to the de~ flection of the levers. > Ensure that the traverse path of the crushing plant is flat and firm. Vv av > Switch on diesel generator (see chap. 3.04.01). > ‘Turn the main switch of the diesel generator to RESET and then to ON (alsc refer to chap. 2.02). > Unlock emergency stop of the wired remote control. > Insert the wired remote control in the corresponding socket in the switch cabinet (see chap. 2.06.06). Wednesday: 138 tert throrestiny printed © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Operating the plant TD eEbaBamas SO OOERE Fig. 3.7:Switches and buttons on operator panel > Switch off the "Radio" [24] rotary switch. > Switch on the "Control voltage" [12] key switch. > Press the "Acknowledge fault / emergency switching off" [16] button. Y When the eneiysiity stup ur einer yenity uff button is 10 longer pressed, the light in the button goes out. > Set the rotary switch "Automatic mode/manual mode” [17] to manual mode. ¥ The "Manual mode" [19] control lamp lights up. Press the 'Plant/crusher ON" [13] button. The control lamp for "Start release" [15] lights up and the warning sirens sound for approx. 10 seconds, The “Plant ON" [13] button flashes. Press the 'Plant/crusher ON" [13] button again. The "Plant/crusher ON" [13] button lights up after approx. 60 seconds. > Press the "Coupling" [11] button. ¥ The "Couping" button [11] lights up. > Drive the plant with the levers. ‘The crawler carrier chains start moving after actuation of the ‘two levers of the drive control. The left lever is for the left crawl- er carrier chain, the right lever for the right crawler carrier chai ‘The crawler cerrier chains always move in the direction in which the lever is moved, The speed changes in proportion to the de- flection of the levers. sv Stop the plant on a flat and stable surface. > Switch off the redio remote control or disconnect the wired remote control. > If anplicable, switch off the "Radio remote control” [21] ro- tary switch. Set the "Operation/Repair” [17] rotary switch to operation. ‘The plant is ready again for operation. > Correctly earth the plant before initial operation. Earthing the plant, see chap. 6.02.03. Fita connecting cable between dispensing system and chas- sis. v Ensure that all components of the dispensing system have a continuous electrically conductive connection. Potential equalisation is established. Establish the earth connection between tank of dispensing system and the ground. ¥ Dispensing system is earthed. Position the tanker or dispensing system as close as possible to the filler neck. Open the service flap of the power supply unit housing on the side of the filler neck. ‘Take off the cover of the filler neck. Fill the plant's fuel tank. Close the filler neck again. Close the service flap of the power supply unit housing again. The fuel gauge in the switch cabinet indicates Ue fill level of the fuel tank when the diesel engine operator panel is switched on. vs v v vvvy > Remove connection of potential equalisation between dis- pensing system and chassis. > Remove the earth connection between tank of dispensing system and the ground. Operating water system (option) Rees Danger of material damage Operation without water and operation with contaminated or frozen water destroys the water pump. = Alwaye ensure there is a sufficient water supply. ‘+ Only use clean water that is not frozen. ‘+ IFthere isa risk of frost, completely drain the water system. > Guarantee the conditions for operating the water system, see chap. 2.12. > Switch on crushing plant. 142 tert © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Switching cold package on and off (option) > Connect water pump to 230 V socket outlet in water pump cabinet. > Press the "Water pump" [31] button. © Open or close the corresponding shut-off cocks of the supply lines to the spraying nozzles. ¥ The water system sprays a water mist atthe relevant points. n) Preparatory measures must be taken before the cold package is ‘switched on: > Set ambient temperature at the thermostats in the switch cabinet to the desired value. > Establish the electrical connection for operating the cold package with the aid of the diesel generator or an external Power source. Setting ambient temperature 3.09 g cold package on and off (op' Fig. 3.10:Switch cabinet heating [1] Thermestat, switch cabinet [2] Heating element, switch cabinet, left [3] Heating element, switch cabinet, right Setting switch cabinet > Fold up flap of switch cabinet protective housing. Ensure ambient temperature __ that the telescopic supports are secured against folding in. Switch off diesel engine. Switch off and remove battery iso- lator and carry it with you. > If necessary, disconnect external power supply. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 143OPERATION ‘Switching cold package on and off (option) [lw] KLEEMANN Eo Danger of electric shock Incorrect work inside the switch cabinet can result in life-threat- ening situations. ‘+ Maintenance, repair and service work on the electrical sys- tem must only be carried out by qualified and authorised personnel, > Open switch cakinet doors. Set thermostat [1] to the desired ambient temperature. The heating elements [2] and [3] are switched on and off automatically at a defined ambient temperature. sv Fig. 3.11:Switch cabinet heating PLC [4] Thermostat, switch cabinet PLC [5] Heating element, switch cabinet, PLC Setting PLC switch > Open switch cabinet door of the operator panel and the PLC Wednesday cabinet ambient temperature control on the reverse side of the left switch cabinet door. > Set thermostat [4] to the desired ambient temperature. ¥ The heating element [5] switches on and off automatically at a defined ambient temperature. D> Close the switch cabinet door of the operator panel and the PLC control system. Close switch catinet doors. ‘The ambient temperature of the switch cabinet heaters is set. xv 144 tert © Kleemann GmbH 2016(4) KLEEMANN 4 off (option) ing cold package on and off (option) ® Fig. 3.12:Connectors and sockets [7] 32 A connector, cold package [8] Service socket 400 V / 32 A [9] Socket 400 Vv / 16.8 [10] 16 A connector, cold package Insert connector [/] into the service socket [U] on the switch cabinet. Insert connector [10] into the socket [9]. > Switch battery isolator on. > Start diesel generator. (see instruction manual) Operating cold package > with diese " Fig. 3.13:Operating unit for cold package [11] Rotary switch Wednestay-22-htaret © Kleemann GmbH 2016 145OPERATION ‘Switching cold package on and off (option) [w]] KLEEMANN Switching cold package off Operating cold package with 32 A supply lead Operating cold package with 16 A supply lead Disconnecting cold package from external power supply w @ Turn rotary switch [11] to "I" position. ‘The corresponding plant components are heated. Turn rotary switch [11] to "0" position. The cold package heating elements are switched off. > Ifnecessary, switch diesel generator off. ‘The two couplings of the cold package can be used to operate the plant with the aid of an external power supply. The corre- ‘sponding connector and socket must be chosen depending on the version of external supply line used. > Disconnect connector [7] from service socket [8]. > Connect cable with 32 A coupling of the external power sup- ply to connector [7]. Gold package can be operated with an external power sup~ ply. Start external power supply. Tum rotary switch [11] to "I" position. ‘The corresponding plant components are heated. ‘Tum rotary switch [11] to "0" position. Switch external power supply off. Disconnect connector [7] from external pawer supply. Pull connector [10] from socket [9]. Connect cable with 16 A coupling of the external power sup- ply to socket [9 cud package can be operated with an external power sup- > Start external power supply. > ‘Turn rotary switch [14] to "I" position. The corresponding plant components are heated. > Turn rotary switch [14] to "0" position. > » cvs¥ < vvvvvsvy < Switch external power supply off. Disconnect connector of the external power supply from socket [9]. ¥ Cold package is disconnected from the external power sup- ply ‘To operate the cold sackage at a later stage with the diesel gen- erator, itis recommended after disconnecting from the external power supply to reconnect the connectors in the corresponding sockets. Wednesday: 146 an ihowstiiny printed © Kleemann GmbH 2016OPERATION 1g the belt scale (option) [w]] KLEEMANN 3.10 Adjus g the belt scale (option) sos Poe ed ns | ns } cent a errs 7 Fig. 3.14:Belt scale operating unit [1] Zeroing display [2] Quantity counter (total) [3] Display of scales capacity utilisation [4] Weighing device (name) [5] Delivery output [6] Delivery output unit [7] Display field, selectable parameters La] Quantity counter reset [b] Menu selection [c] Setting correction factor [d] Menu exit [e] Input In order to be able to adjust the belt scale, the plant must be emptied completely. > Switch on the plant in automatic mode, see chap. 3.04. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 147OPERATION Adjusting the belt scale (option) [w]] KLEEMANN Performing zeroing point correction Belt scale adjustment Calculating the correction factor Set the correction factor Wednesday earhtaret a w @ w > Stop the feeding unit and run the plant until it is empty. > Do not switch off the plant. The crusher discharge conveyor must be in operation. > allow the empty crusher discharge conveyor to run and press the [c] #4 button. ¥- Zeroing in operation, display shows [Br] he zero point correction is complete once the belt has complet- ed a circuit. > Allow the crusher discharge conveyor to run until empty. > Press the [a] [fa button. ¥ The quantity counter [2] is set to 0.0. If a password if requested, enter 99 via the keyboard. > Ifnecessary, enter 99 via the keyboard and press the [e button. > Press the [a] [i] button again. ¥ The quantity counter [2] is set to 0.0. A correction factor must be calculated and set to adjust a dis- Played t/h value and the actual material output > Load the plant for a defined time. run empty and collect crushed material. > Weigh the crushed material (comparison weight), > Read-off the weight on the quantity counter [2] and make a nate of it. Using button [b], [Zl] select menu item 6 (correction factor). ‘The old correction factor is displayed. A new correction fac- tor can be calcuated. > Work out the correction factor using the following formula: New correction factor = comparison weight/quantity counter display [2]*Old correction factor. > If necessary, press button [b] §§J to select menu item 6 (correction facter) again. > Press the [c] fj button. Ifa password If requested, enter 99 via Live keyboard. > Ifnecessary, enter 99 via the keyboard and press the [e] button, Enter the new correction factor via the keyboard and press the [e] ff button, ¥ The new correction factor has been set. > Press the [d] [J button. ¥ The menu is exited. 148 throrestiny printed © Kleemann GmbH 2016OPERATION [w] KLEEMANN Loading the plant 3.11 Loading the plant A Ba Danger due to loading vehicles During loading of the plant, there is a risk of fatal injury through, active wheel loaders and diggers as well as falling material + Do not enter the danger zone during loading. ‘+ Warn persons in the danger zone prior to the start of plant loading, * Stay clear of the plant during loading and operation. ‘+ Wear protactive equipment. 3.11.01 Suitable loading vehicles Woes Danger of material damage ‘The use of unsuitable loading vehicles and devices can result in damage to the plant components. * Do not load the plant with lorries, dumpers or skip lorries. + Do not load the plant with digger chovele or buckets that are too small or too large. Correct loading of the plant is possible with diggers with shovels cr buckets or upstream crushing and screening plants. With a suitable hopper attachment (option), the plant can also be load- ed with a wheel loader. Requirements of loading vehicles «Sufficient loading capacity of the shovel or bucket of the dig- ger, which is matched to the plant size and the charged ma- terial. + Wheel loader suitable for the plant size and charged materi- al. The loading of unhomogeneous materials and materials for selection, such as reinforced demolished concrete, with a wheel loader leads to reduced availability and increase plant * Sufficient lifting height of shovel or bucket. + Stability of the wheel loader or digger. If necessary, suitable ramps and raised bases must be prepared for the loading vehicles. The plant can also be loaded via a belt conveyor provided it has the required cischarge height. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 149OPERATION Loading the plant [w]] KLEEMANN 3.11.02 Requirement of ramps and bases ‘+ Correct compaction of ramps and bases. ‘+ Clear view into the feed hopper. ‘+ Secured against lateral slipping. ‘= Accumulated material for ramps or bases must not cover plant components. ‘+ No risk of collisions between the plant and loading vehicles. Preparing the charged material Well prepared charged material permits optimum use of the plant, reduces wear on the individual machines and components and guarantees trouble-free operation. Requirements of the charged material + Do not exceed the specified size, length of the edge and compressive resistance of the material, see chap. 5.01.01.04. + Select the feeding size to match the final grain and the max- imum crushing ratio. + Never load unbreakable material, e.g. steel girders. + Never load pressure vessels, explosives, chemicals or simi- lar materials. ‘+ Shorten reinforcing steel in demolished concrete to less than one metre, Exceeding the size, length of edge and compressive resistance of the material results in material congestion and damage to the crusher and material conveying components. Furthermore, the crushing capacity is considerably reduced. Wednesday: 150 an ihowstiiny printed © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Loading the plant 3.11.03 Loading the feed hopper Fig. 3.15:Loading the feed hopper [1] Maximum loading height [2] Layer height and material flow Correctly loaded material permits an optimum material fiow, good primary screening resulls and avoids melerial congestion, + Load material in regular intervals and in approximately equal quantities into the feed hopper. ‘+ Do not fill the feed hopper higher than the hopper edge. En- sure that no material falls over the hopper walls. Use of a fill- ing cone is possible. + Where possible, ensure that a material bed always remains in the feed hopper and trough. Recurrent feeding of the empty feeder trough can result in deformation and increased wear of the drive and also leads to avoidable noise pollution. + Make sure that the material flow and layer thickness in the feeder trough and grizzly are even. ‘+ Adjust the feeder trough via the frequency converter so that. an even material flow is guaranteed. Wes Danger of material damage Incorrect loading or setting of the feeder trough leads to contin= uous activation and deactivation of the feeder trough. This, in ‘tum, places an unnecessary load on the frequency converter Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 151OPERATION Loading the plant [ww] KLEEMANN and/or the vibration motors and results in increased wear to the rubber mountings. ‘+ Adjust the feeder trough via the frequency converter so that the automatic switch-off system only trips in extreme cases (reference value: max. 10 times an hour). ‘+ Only switch the ‘eeder trough back on following an overload shutdown once it has come to a complete standstill. 3.11.04 Loading the jaw crusher ry Py Danger due to yielding gap setting device Risk of fatal injury tarough sudden retraction of the gap setting device or breaking of the pressure plate due to overloading. ‘+ Stay clear of the danger area of the gap setting device dur- ing crusher operation. ‘+ Wear protective equipment. Fig. 3.16:Loading the jaw crusher [1] Fill level of the jaw crusher [2] Oversized charged material [3] Crushing ratio Correctly loaded material permits optimum utilisation of the crushing capacity and avoids material congestion. Wednenday-ea:htaret Barrows printed 152 © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Loading the plant * The optimum fill level of the jaw crusher up to the chamfers of the crushing jaws must not be exceeded. * Do not exceed the maximum size and length of the edge of the charged material. + Do not exceed the maximum size ratio of charged material and final grain, see table. + Ensure that the material flow to the few crusher is even. Crushing ratio = ratio of feeding size to desired final grain size, [Charged material [Crushing ratio Hard rock 4-1 |Softer materials and recycling mate- jup to rial Tab. 3.2: Crushing ratio ‘The main influences on the optimum loading of the jaw crusher are loading of the feed hopper, an even material flow and the setting of the crushing gap. If the jaw crusher is overloaded, e.g. through unbreakable ma- terial, the rocker can retract to a certain degree before the pres- sure plate breaks at its predetermined breaking point. read Danger of material damage Continuous overfilling of the jaw crusher results in premature wear and can cause the overload protection to trip. + Ensure that loading of the jaw crusher is correct. read Danger of material damage Non-original pressure plates do not meet the overload protec- tion requirements. Damage to the jaw crusher may result and the warranty is voided, ‘+ Only use original pressure plates from KLEEMANN, Wednestay-22-htaret : ‘© Kleemann GmbH 2016 153OPERATION Eliminating material congestion [ww] KLEEMANN a42 Eliminating material congestion Preparations ry BE Danger due to material congestion Intervention in the running plant, in particular, in the running or ‘coasting crusher, can result in serious or fatal injury. ‘+ Eliminate material congestion when the plant is not running. ‘+ Do not climb on vibrating conveyor troughs and screens that are running. ‘+ Never open service doors and flaps when the plant is run ring. ‘+ Allow the crusher to coast to a complete standstill. ‘+ Switch off the plant, remove the key and secure against re- activation. ‘+ Attach appropriate warning sign in a clearly visible area. ‘+ Wear protective equipment. ‘+ Observe the safety manual Material congestions can have different causes: ‘+ Settings that do not match the plant, e.g. delivery speed of vibrating feeder is Lov Inigh. + Crusher jaw gap width too small. ‘+ Unsuitable screen mesh size. + Maximum feedirg size is exceeded. ‘+ Feeding of unbreakable materials, e.g. steel girders or pipes. ‘+ Feeding of reinforced concrete with long protruding reinforc~ ing steel. Material congestions can occur at different points of the mate- rial flow: ‘+ At the crusher inlet due to blockages before the crushing jaw. ‘+ Crusher standstill through jamming of unbreakable material between the crusher jaws. ‘+ Atthe crusher outlet through accumulation of broken mate- rial on the crusher discharge conveyor or discharge chute. ‘+ Blockages or jams at all other material transfer points due to bulky materiel. Before starting to clear material congestion at a blocked or sta~ tionary crusher, itis essential to carry out the following steps: > Allow the crusher to coast to a complete standstill, > Switch off all plant components. > Switch off main switch. Wednesctay-e2rhtare 154 ihowstiiny printed © Kleemann GmbH 2016OPERATION [w]] KLEEMANN Eliminating material congestion Eliminating material congestion v Switch diesel generator off. ‘Switch off and remove the battery isolator and carry it with you, Attach appropriate warning sign in a clearly visible area. v Warn othe” persons before starting work on the plant. Lay out suitable tools. Wear personal protective equipment. All preparetions have been made. The material congestion can be cleared. Material congestion always differs according to the situation. ‘The following listed items describe possible procedures and in- formation on avoiding hazards: + Never eliminate material congestion in the crusher by your- self. + First remeve bulky or oversized material on the feeder trough and grizzly with the digger shovel or bucket so that no follow-up material can slide into the crusher + Completely open the crushing gap of the crusher to allow material tc pass the crusher. + If necessary, open the crushing gap by turning the drive in the opposite direction to release the material. Only switch the drive cf the crusher to reverse when stationary. * Crush the oversized and bulky material in the crusher with hydraulic or electric rock chisels. + If necessary, secure anchor screws to the oversized material and lift out with suitable hoisting gear. + Note that stones, unbreakable material and, in particular, re- inforcing steel in a stationary crusher can accumulate a con- siderable zmount of stored energy. + Proceed wth great care when clearing material congestion in the crusher. Stored energy in the material can result in unexpected movements of the material and crusher, + Always clear material congestion from top to bottom to avoid the danger of follow-up material slipping and material falling. + Remove material that has passed the crusher with the help of the crusher discharge conveyer or the extractor channel, Never move under a crusher when there is a danger of fall- ing stones + If necessary, remove material under the crusher with shov- els or highpressure water jets. + Use suitab e tools, such as crowbars, pickaxes or shovels, to loosen and remove material congestion at vibrating convey- or troughs, screens and belt conveyors. Never attempt to clear material congestion in the area of the feeding unit and Remove all tools used from plant machines and components. > Ensure that no oversized material on the crusher discharge conveyor is moved on. This can result in damage to the fol- lowing components, > Reinstall disassembled guard devices and components, en- suring they are correctly fitted, > Ensure that there are no more persons in the hazard area. The plant is ready to be switched on again. Setting the jaw crusher Checking the crushing gap Danger due to crusher operation Checking of the crushing gap with the crusher running or coast- ing can result in serious or fatal injuries. ‘+ Run the crusher empty prior to making the check. ‘+ Do not move under the crusher when itis running. ‘= Allow the crusher to coast to a complete standstill. + Remove loose rraterial lying on the crusher. ‘+ Switch off the plant, remove the key and secure against re- activation. ‘+ Attach appropriate warning sign in a clearly visible area. ‘+ Wear protective equipment. 156 tert © Kleemann GmbH 2016