MAINTENANCE KLEEMANN Crusher 4,44,07.06 Changing shims Was Danger of material damage Adjusting the crushing gap with the crusher loaded can damage the crushing gap adjustment device. © Run the crusher empty prior to adjusting the erushing aap. Fig. 4.89:Changing distance plates [1] Tie-bar [2] Locknuts [3] Nut [4] Screw and nut [5] Distance plates [6] Bolt of pressure plate lock [7] Pressure plate bearing Securing cross member > Measure dstance of cross member [1] to crusher frame as described in chap.4.44,07.05 and note reading for later ad- justment. > Irctall holt [4] and nut on cross member and crusher frame. ‘The nut and bolt for assembly of the crusher frame and cross member are in the tool box. > Tighten bolt [4] until spring pressure can be felt. ¥ Cross member is secured. > Loosen locknuts [2] of pull rods and unscrew up to end of threaded rod, Wednesday ©kl thet : leemann GmbH 2016 301MAINTENANCE Crusher ww] KLEEMANN > Unscrew nuts [3] of pull rods completely as far as locknuts (2). > Remove screws [6] from both sides of pressure plate locking device. > Start the plant in manual mode and press the "Auxiliary hy- draulics system’ button. Fig. 4.90:Valve block for gap setting [8] Valve block for gap setting > Push rocker forward with help of valve block of crushing gap adjustment [8] until gap at pressure plate bearing [7] is suf ficient to insert or remove distance plates [5]. Insert or remove the desired number of distance plates [5]. > Push the distance plates in far enough in until locating hole is flush with bore in pressure plate bearing. > Remove screws [6] from both sides of pressure plate locking device. If necessary, remove or insert shims so that the nuts of the pressure alate locking device can subsequently be screwed on safely. > Retract rocker with aid of valve block of crushing gap adjust- ment [8]. > Screw nuts [3] on to pull rods and tighten. > ¥ v Screw in locknuts [2] and tighten. The distance plates are inserted or removed. Removing cross member > Remove bolt [4] and nut and place in tool box. Tock » Compare distance of cross member [1] to crusher frame with reading previously noted. Correct reading if necessary with nuts [3]. Wren doing this, ensure that cross member is parallel to crusher frame. Weenenday-ba-htaret Barrows printed 302 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Crusher Wed inger of material damage IF hydraulic cylinder is not fully retracted, damage may result at crusher gap adjustment. + Always fully retract hydraulic cylinder after changing shims or pressure plate. 07.07 Changing V-belt pulley Removing V-belt pulley Fig. 4.91:Removing V-belt pulley [1] Drive shaft [2] Securing screws [3] Taper-tock bushing [4] Forcing thread 5] V-belt pulley ‘The description refers to the removal and installation of belt pul- leys that are installed with taper-lock bushings. > Ifnecessary, slacken V-belt and take off. > Mark position of V-belt pulley [5] on the drive shaft [1]. > Remove securing screws [2]. > Clean forcing thread [4] and grease slightly. > Insert two of the securing screws [2] in the forcing thread (4). Tighten the two securing screws evenly until the taper-lock bushing [3] breaks out of the cone. > Ifnecessary, release cone seat by knocking on the taper lock bushing [3]. v Wednesday ©kl thet : leemann GmbH 2016 303MAINTENANCE Crusher ww] KLEEMANN > Take off V-belt rulley [5] and taper-lock bushing [3]. > Clean drive shaft but do not grease it. v The V-belt pulley has been removed. Installing V-belt pulley Fig. 4.92:Installing V-belt pulley [1] Drive shaft [2] Securing screws [3] Taper-lock bushing > Clean the cone of the taper-lock bushing and V-belt pulley but do not grease them. > Insert taper-lock bushing [3] into V-belt pulley and slightly screw in the securing screws [2]. > Push V-belt pulley [5] including taper-lock bushing onto drive shaft [1]. > Ensure that the V-belt pulley is at the previously marked po- sition. If necessary, check alignment with V-belt pulley on opposing side. > Insert securing serews [2] diagonally and evenly and tighten to specified torque. Drive taper-lock bushing [3] in turther with light knocks of a wooden block or soft metal bushing. Tighten securing screws [2] to specified torque. Fill forcing thread [4] to protect against dirt penetration. Fit V-belt and tension it. Retighten securing screws [2] following brief run under drive load. ‘The V-belt pulley has been installed. vvvvv < Weenesday-ba:htaret Barrows printed 304 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Screens 4.45 Screens Tightening torques of taper-lock bushings Bushing |Tighten- [Number of [Thread size ing torque |screws [2012 BONm [2 7 [2017 [2517 soNm [2 a2" jeoes 3020 lsoNm 2 5/8" 3030 [3525 irs nm (3 a2" 3535 \4030 r70 Nm 3 5/8" |4040 \4535 iso nm (3 3/4" |4545 5040 R7ONm [3 778" 5050 Tab. 4.9: Tightening torques of taper-lock bushings Danger due to moving and rotating parts Maintenance end 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. 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. Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 305MAINTENANCE Screens [w]] KLEEMANN 4.45.01 Checking screen surfaces Checking wear Checking tension Weenenday-ba-htaret Wear on the screen surface must be checked visually. The screen surfaces must be inspected for the following signs of damage and wear: Slotted grates ‘+ Signs of wear on the welded-on hard layers. + Bent profile sections. ‘+ Damaged screw connections. Steel and rubber perforated panels + Eroded, thin areas. + Cracks, chipping and other damage, ‘+ Damaged screw connections. Rubber covers + Eroded, thin areas. + Cracks, holes ard other damage. + Damaged screw connections. Wire cloth and wire screen + Eroded, thin areas. + Tom off or bent wires. ‘+ Damaged clamping systems. > Visually check screen surfaces for the above-mentioned points. > Ifserious signs of damage and wear are determined, replace the corresponding screen surface. The screen surfaces have been checked. < Danger due to moving and rotating components. When checking components on the screen when it is running, there is a risk of injury due to crushing and catching. ‘+ Always keep a sufficient distance away from moving and ro- tating components of the screen. + Do not climb int the screen when in it is run + Wear protective equipment. 9 306 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Screens Wed Danger of material damage Loose screen surfaces cause flapping cracks and damage to the screen. + Check screen surfaces for correct tension and secure fitting The tension of the screen surface must be checked by monitor- ing the sound with the screen running, Listen for the following noises: Slotted grates, steel perforated panels, wire cloth and wire screen ‘+ Rattling of screw connections. + Rattling ard knocking of screen surfaces. ‘+ Rattling ard knocking of clamping systems. Rubber covers and rubber perforated plates + Rattling of screw connections, + Knocking of screen surfaces. > Ensure that the screen surface makes contact with the entire surface of the distance frame, > Run the screen completely empty to avoid interfering noice from loaded material. > Monitor the sound at the screen surfaces for the above-men- tioned points. > Ifncises are determined, tension the corresponding screen surface or retighten screw connections. ¥ The screen surfaces have been checked. The security of the screen surfaces and screw connections can @ also be checked by knocking with @ hammer. When doing this, it is essential 20 switch off plant components and diesel gener- ator and secure the plant against reactivation, Screen surfaces are possibly custom-designed special parts. Please order these special parts in good time because they have longer delivery times. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 307— (w] KLEEMANN 4.45.02 Tensioning screen surfaces Longitudinal tensioning of screen surface Fig. 4.93:Clamping system for longitudinal tension | [1] Nut [2] Seren surface [3] Counterholder [4] Clamping rail > Ensure that no material makes contact between the clamp- ing folds of the screen surface [2], the counterholder [3] and the clamping rail [4]. The screen surface must make contact over the entire area of the distance frame. > Attach screen surface [2] to the counterholder [3]. Attach clamping rail [4] to the clamping fold of the screen surface [2] and fit screws and nuts [1]. > Tension screen surface by turning the nuts. Knock on the screen to check tension and correct it if neces- sary. v The screen surface is tensioned. v v Wernenday-ea-htaret Barrows printed 308 © Kleemann GmbH 2016MAINTENANCE (w] KLEEMANN Screens Fig. 4.94:Sereen drive with angular gear [1] Angular gear [2] Oil filer screw and ventilation [3] Articulated shaft IF leaks are determined at the angular gear, the oil fill evel must be determined. The oil fill level is checked using a test wire. hia 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 skin contact with oils and greases. ‘+ In case of injury, consult a doctor immediately. Wednestay-22-htaret -2a-riowsttint printed th © Kleemann GmbH 2016 309MAINTENANCE Screens [w]] KLEEMANN Checking oil fill level Wednesday Beg Danger! Heavy loads Raised or suspended loads can fall, resulting in serious or fatal injury. ‘+ Always use suitable hoisting gear and lifting accessories. ‘+ Attach lifting accessories carefully to components, ensuring they cannot slip, + Where possible, attach components to be lifted at their cen- tre of gravity. ‘+ Do not enter or stand in the danger zone. + Keep a safe distance away. ‘+ Do not place your hands under the components when being lowered. > Switch off plant components and the diesel generator. > Switch off and remove battery isolator and carry it with you, > Secure safety device of articulated shaft using suitable lifting tackle and hoisting equipment. Loosen and unscrew bolts of safety device, Life the safety device off the plant. Clean housing of angular gear. In particular, the oll filer screw must be fee of contamination. vy Unscrew oil filer serew [2]. Insert clean test wire in opening of oil filer screw. Place test wire against outside of housing. The must be at half of the housing height. If necessary, top up missing volume with oil of correspond- ing specifications. Insert oil filler screw [2] again and tighten. Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications. > Fit the safety device back on the articulated shaft. ¥ The oil fill level has been checked. > Insert battery isolator and switch on. Dees Gear damage through oil loss il loss indicates defective sealing and can result in gear failure. ‘+ In case of escaping cil, check the oil level. + Replace damaged seals. fill level vowvvy vy 310 tert © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Screens Changing gear oil To change the gear oil, the angular gear must be removed. > Perform the preparatory measures as described for checking the oil fill level. Wednesday Fig. 4.95:Screen drive with angular gear [1] Angular gear [4] Securing Lulis of angular goat [5] Markings on articulated shaft > Secure the articulated shaft sections using suitable means, €.g, tensioning strap, to prevent them from sliding apart. > Remove the articulated shaft from the angular gear. Ensure ‘that there are markings on the articulated shaft. Apply them if necessary. > Secure angular gear with suitable lifting tackle and hoisting equipment. Remove the angular gear from the flange of the electric mo- tor and place on a suitable base with the oil filler plug point- ing down. > Place oil collecting pan under oil filler screw [2]. > Unscrew ol filler screw [2] and drain the oil. If necessary, position the angular gear so that the ail ean run aut com- pletely, > Fill fresh gear oil with the corresponding specifications with the help ofa funnel through the opening of the oi filler plug. > Insert oil fller screw [2] again and tighten. > Wipe up overflowing oil with a cloth and dispose of in accord- ance with environmental specifications. ©kl thet : leemann GmbH 2016 311MAINTENANCE Screens [w]] KLEEMANN > Check angular gear for leaks. ¥ The gear oil has been changed. When mounting the angular gear, the installation position of the @ atticulated shaft must be checked and adjusted as necessary. This applies in particular i the electric motor of the screen drive and articulated shaft were removed for repair work. Res Risk of material damage Incorrectly adjusted or mounted articulated shafts can lead to bearing damage. ‘+ Adhere to the longitudinal compensation. ‘+ The markings on the spline shaft and socket must align. Mounting angular gear b Place the angular gear on the flange of the electric motor us- ing suitable lifting tackle and hoisting equipment. > Install the angular gear using the securing bolts, and tighten the bolts to the specified torque setting. For tightening tor- ques, see chap. 5.03. The angular gear has been installed, Fig. 4.96:Screen drive with articulated shaft [6] Angular gear flange [7] Articulated shaft longitudinal compensation [8] Screen flange [9] Height offset measurement Fitting articulated shaft > Provided the articulated shaft sections were secured to pre- vent them from sliding apart, remove the securing element. Weenenday-ba:htaret Barrows printed 312 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Screens > Mount the articulated shaft on the angular gear and tighten the bolts to the specified torque setting. For tightening tor- ques, see chap. 5.03. > Check the longitudinal compensation [7]. (Longitudinal compensation = 20 mm). When the electric motor and articulated shaft are installed fol- lowing the repair work, ensure that the articulated shaft is in- stalled correctly. » Make sure that the markings [5] on the splined shaft and socket align, > Mount the articulated shaft on the angular gear and screen, > Measure the height offset [9] with the screen unladen. (Height offset = approx. 30 mm). > Ifnecessary, adjust the height offset using the adjusting de- vice of the electric motor. > Measure the longitudinal compensation [7]. (Longitudinal compensation = 20 mm). ‘The maximurr longitudinal compensation is 35 mm, This meas- urement must not be exceeded as otherwise no sufficient cov- erage can be assured. > Ifnecessary, adjust the longitudinal compensation using the adjusting device of the electric motor. > Tighten all bolts of the electric motor adjusting device and the securing bolts of the articulated shaft to the specified torque setting. ¥ The articulated shaft has been mounted and adjusted. Install the safety device on the articulated shaft. > Insert battery isolator and switch on. v Wednestay-oarhtaret ‘therestiny printed ‘© Kleemann GmbH 2016 313MAINTENANCE Screens ww] KLEEMANN 4.45.04 — Servicing universal-joint shaft Fig. 4.97:Screen drive articulated shaft [1] Bearing lubrication nipple [2] Sliding profile lubrication nipple [3] Securing bolts Lubricating articulated shaft ‘The articulated shaft is lubricated using a grease gun. To ensure @ that the sliding profile is relubricated correctly, the articulated shaft must be pushed together completely. > Switch off plant components and the diesel generator. D> Switch off and remove battery isolator and carry it with you. > Secure safety device of articulated shaft using suitable lifting tackle and hoisting equipment. > Loosen and unscrew bolts of safety device. Weeneaday-ea:htaret Barrows printed 314 © Kleemann GmbH 2016i MAINTENANCE KLEEMANN Screens Danger! Heavy loads Raised or suspended loads can fall, resulting in serious or fatal injury. + Always use suitable hoisting gear and lifting accessories. * Attach lifting accessories carefully to components, ensuring they cannot slip. * Where possible, attach components to be lifted at their cen- tre of gravity. + Do not enter or stand in the danger zone. + Keep a safe distance away. + Do not place your hands under the components when being lowered. Lubricating the sliding Lift the safety device off the plant. profile Remove the articulated shaft from the angular gear. Push the articulated shaft together completely. Use a grease gun to press 6 g of grease with the appropriate specifications into the lubrication nipple [2]. One stroke of ‘the grease gun corresponds to approx. 3 g grease. > Mount the articulated shaft again on the angular gear. > Use a grease gun to press grease with the appropriate spec- ifications into the lubrication nipples [1] until grease emerg- es at the joints. ¥ The articulated shaft is lubricated. Checking securing bolts Check securing bolts [3] for damage and secure seating. > Ifnecessary, retighten the securing bolts to specified tight- ening torque. For tightening torques, see chap. 5.03. > Fit the safety device back on the articulated shaft. ¥ The securing bolts have been checked. > Insert battery isolator and switch on. Wednesttay-oa-htare sikowstiiny printed © Kleemann GmbH 2016 315MAINTENANCE Screens ww] KLEEMANN 4.45.05 Lubricating grizzly bearing wo Fig. 4.98:Grizzly lubrication [1] Bearing lubricating nipple [2] Labyrinth lubricating nipple [3] Ventilation ‘The bearings and labyrinths are lubricated via the lubricating nipples on the left and right above the mounting of the screen. ‘The lubricating nipples are arranged on the opposite side mir- ror-inverted. > Using a grease gun press 15 g of grease with the appropriate specifications into the lubrication nipples of the bearings [1]. > Press in 5g of lubricating grease with the appropriate spec- ifications into the lubricating nipples of the labyrinths [2]. ¥ The bearings and labyrinths have been lubricated. One stroke of the grease gun corresponds to approx. 3.g grease. The grease quantities to be filled are also noted beside the lubrication nippes. 4.45.06 _ Listen to bearing, check its temperature Weenenday-ea:htaret 316 Danger due to moving and rotating components Incorrect procedures when monitoring the sound and measur- ing the temperature of the bearings can result in injuries due to ‘crushing and catching. ‘+ Always keep a sufficient distance away from moving and ro- tating components. + Wear protective equipment. © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Screens Danger due to hot surfaces Bearings can heat up intensely during operation. + Wear protective equipment. + Use a temperature gauge to check the bearing temperature. Unusual bearing noises or excessive bearing temperatures can be an indication of possible bearing malfunctions or increasing wear. The check must be carried out with the screen at service temperature. Due to the high ambient noise level, recognition of unusual bearing noises requires a lot of experience. This check must be carried out by authorised and qualified personnel only. > Switch the diesel generator on. > Switch on the screen in manual mode and warm up the bear- ing to service temperature. > Listen to the sound of the bearing and check the bearing temperature with a temperature gauge. > If necessary, have bearing repaired by authorised and qual- ified personnel. The bearings have been checked. 4.45.07 Checking rocker width Fig. 4.99:Screen rocker width gauge [1] Rocker width gauge decal [2] Display circles Wednestay-22-htaret : ‘© Kleemann GmbH 2016 317MAINTENANCE Screens [w]] KLEEMANN rN Ee Danger due to open running unbalance weights Open running unbalance weights can catch and draw in person- nel leading to serious or fatal injury. + Only operate the screen with the guard devices firmly in place. + Read off the rocker width only with the guard devices in po- sition. + Before starting repair work, switch off the plant, remove the key and secure against reactivation. ‘+ Attach appropriate warning sign in a clearly visible area. During operation of the screen, the rocker width can be read off, the rocker width gauge [1] just like a clock. One of the display Circles [2] make visual contact with the inner circle. The point of contact specifies the rocker width in mm. In the example il- lustrated, the width is 8 mm. Prerequisite ‘The rocker width geuge [1] must be fixed in the centre of the screen above the unbalance. Checking rocker width > Run the screen until empty. > Read off the roccer width at the rocker width gauge. > If the maximum rocker width is exceeded, it must be re- duced. Adjusting rocker width, see chap. 4.45.09.01, The rocker width has been checked. Maximum rocker width Apart from the number of fitted unbalance segments, the rocker width is also influerced by the speed of the electric motor and the gear ratio of the angular gear. ‘The following diagram illustrates the maximum rocker widths. Weenesday-o2:htare Het 318 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Screens a 1290 ON 1130 980 750 4 Fig. 4.100:Rocker width diagram [3] Screen speed in rpm [4] Rocker width in mm 45.08 Other maintenance tasks Wednesday Danger of material damage ‘Screens that knock against components during operation cause cracks in machine components and rubber mountings. ‘+ Guarantee freedom of movement and minimum clearance of fixed and swinging components. + Clear the gap between the fixed and swinging components regularly of stones and contamination. > Visually check the components of the screen for damage. > Visually check the screen casing for freedom of movement and monitor the sound. > Visually check chutes and rubber curtains of the screen out- let, screen overpass and screen underpass for damage, such as cracks and embrittlement, and for correct fastening > Visually check rubber mountings of the screen for damage, such as wear, increasing fatigue, embrittlement and cracks. > Visually check the wear lining for security, contamination, caking anc wear, > Visually check security of screw connections and tighten to specified tightening torque if necessary. kl thet : leemann GmbH 2016 319MAINTENANCE Screens tw] KLEEMANN > Replace damaged components of the screen and chutes necessary. ¥ Components and screw connections have been checked 4.45.09 Repairing screens 4.45.09.01 Adjusting rocker width Fig. 4.101;Screen unbalance segments [1] Discs [2] Unbalance segment Danger due to open running unb: Open running unbalance weights can catch and draw in person- reel leading to serious or fatal injury. ‘+ Only operate the screen with the guard devices firmly in place. + Read off the rocker width only with the guard devices in po- sition, + Before starting repair work, switch off the plant, remove the key and secure against reactivation. ‘+ Attach appropriate warning sign in a clearly visible area. Weenenday-ea:htaret Barrows printed 320 © Kleemann GmbH 2016MAINTENANCE KLEEMANN Screens Adjusting rocker width Wednesday Wed Danger of material damage Incorrectly set unbalance segments can result in damage to the screen, + Repair work on screens must be carried out by authorised and qualified personnel only. + Always fit the same number of discs on both unbalance seg- ments, The rocker width is adjusted with the help of discs that are screwed onto the left and right unbalance segments. > Switch off plant components and the diesel generator. > Remove guard devices of unbalance segments. > Remove screws from discs [1] and alter the number or thick~ ness of the discs. > Install the same number or thickness of discs [1] on the op- posite unbalance segment [2]. > Tighten screws of discs [1] to specified tightening torque. > Reinstall guard devices for unbalance segments. » Check the rocker width with the screen running and correct if necessary. ¥ The rocker width has been adjusted. The installation of additional discs increases the rocker width. Removal of discs reduces the rocker width. The installation or removal of a pair of discs alters the rocker width, depending on the size of the screen, between 0.1 and 0.4 millimetres. kl thet : leemann GmbH 2016 321MAINTENANCE Screens [w]] KLEEMANN 4.45.09.02 Changing grizzly screen surface ‘Changing lower deck screen surface 1 Removing screen surface Weenenday-ba:htaret Fig. 4.102;Grizely screen surface, lower deck [1] Screen surface [2] Counterholder [3] Clamping folds [4] Clamping screws and nuts [5] Clamping rail ‘Changing lower deck screen surface ‘The description covers the removal and installation of a screen surface with wire cloth. When removing and installing a screen ‘cover made of rubber, a chain hoist or similar pulling device must be used for withdrawal and insertion. > Switch off plant components and the diesel generator. > Position suitable climbing aids or lifting platform at the rear side of the screen. v Remove rubber curtain at the rear side of the screen. v If necessary, remove screen underpass to create more space. D> Release nuts on the clamping screws [4] a few turns until the screen surface [1] is slackened, > Run screen for a brief period until contamination and depos- its between screen surface and distance frame have loos- ened. Switch off plant components and the diesel generator again. Unscrew nuts and clamping screws [4] and take out clamp- ing rail [5]. vv 322 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Screens Installing screen surface > Press screen surface out of counterholder [2] and then with- draw to the rear. >» Remove coarse contamination from the distance frame, counterholder [2] and clamping rail [5]. > Visually check rubber profiles for damage and correct seat- ing; replace or move into correct position as required. The cerner, sutface has heen removed. > Insert new screen surface and attach with clamping fold [3] in counterholder [2]. Insert clamping rail [5], clamping screws and nuts. Tension screen surface, see chap. 4.45.02. If applicable, reinstall screen underpass. Reinstall rubber curtain, The screen surface is installed. reas anger of material damage Newly installed screen surfaces settle after a few hours opera- tion and can become loose. + Retension newly installed screen surfaces after approx. 8 hours operation. svvvy Changing upper deck screen surface Fig. 4.103:Grizzly screen surface, upper deck [1] Screws [2] Steel perforated panel on feeding side [3] Steel perforated panel on discharge side Wednestay-22-htaret : ‘© Kleemann GmbH 2016 323MAINTENANCE Screens [w]] KLEEMANN Removing screen surface Installing screen surface wo a w ‘The description covers the removal and installation of the steel perforated panels. ‘The same procedure can be used for removal and installation of a slotted grate. Note that the maximum clearance between the slotted grate and contact surfaces must not exceed 2 millime- tres. If it is more than 2 millimetres, support with metal plates to ensure safe support. ‘Some of the screws on the screen surfaces are through-screws and are fastened frm below with nuts. They are partly screwed into the distance frame fram above. To lock the nuts, they can be reached via the by-pass device of the crusher. > Switch off plant components and the diesel generator. > Remove screws [1] and nuts from steel perforated panels. > Using suitable hoisting gear and tackle, first lift up the steel, perforated pane on the discharge side [3] to remove and then the steel perforated panel on the feeding side [2]. > Remove coarse contamination from the contact surfaces on the distance frame. ¥ The sereen surface has been removed. When replacing steel perforated plates and slotted grates, al- ways use new screws and nuts, > Using suitable hoisting gear and tackle, lift the steel perfo- rated panel for the feeding side [2] onto the distance frame. > Insert screws [1] and nuts and tighten to specified torque. > Using suitable hoisting gear and tackle, lift the steel perfo- rated panel for the discharge side [3] onto the distance frame. > Insert screws [1] and nuts and tighten to specified torque. The screen surface is installed, Wednesday: 324 tert throrestiny printed © Kleemann GmbH 2016[w] MAINTENANCE KLEEMANN Screens 4.45. 03 Replacing rubber profiles | § Fig. 4.104:Rubber profiles for screen surface [1] Bearing iron [2] Rubber profile 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. ‘The rubber profiles [2] are attached to bearing irons [1] and prevent the screen surface from sagging and knocking. Worn and missing rubber profiles lead to damage to the screen sur- face and screen components, > Remove screen surface, see chap. 4.45.09.02. > Replace worn and missing rubber profiles [2]. > Reinstall screen surface. ¥ The rubber profiles have been replaced. Wednesday © Kleemann GmbH 2016 325MAINTENANCE Cleaning the plant [w]] KLEEMANN 4.46 Cleaning the plant 4.46.01 Cleaning the plant i 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. ‘To ensure that the plant is continuously operable, it must be cleaned every day. :f cleaning tasks are not carried out, this re- sults in increased wear of the moving components and impairs operation. ‘After completion of crushing and screening work, the following cleaning tasks must be carried out: > Switch off plant components and the diesel generator > Remove loose rraterial from the chassis, platforms and climbing aids. > Remove adhering material from the feed hopper, vibrating conveyor troughs, grizzly and classifying screen and the chutes, > Remove jammed and adhering material from belt conveyors and associated chutes, > Remove material from on the crawler running gear and the area between the sprocket and track rollers. The plant has been cleaned. Suitable cleaning agents ‘The following objects and auxiliary aids are suitable for cleaning the plant: ‘+ Clear water for flushing. + Coarse brush for sweeping, = Shovels and picks for removing accumulations and caking. ‘+ Crowbars and similar tools for releasing jammed material. Weenenday-ea:htaret 326 © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Performing welding work 4.46.02 4.47 Cleaning with high-pressure cleaners Ew Danger of burns, explosion and/or poisoning ‘The atomised spray of cleaning agents containing solvents can lead to serious or fatal injury. + Never extract non solvent free fluids. This includes ben zene, paint thinners, diesel/heating oil, acetone, undiluted acids, solvents, etc. + Cover elec:ric parts, insulating material and intake openings for combustion air and do not expose to a direct jet. Refit all covers after cleaning. ‘+ Do not jam the lever of the spray gun during operation. + To protect against parts splashing back, wear suitable pro- tective equipment, e.g. face mask or safety goggles. + Never direct the cleaning agent jet at people, animals, the high-pressure unit, sealing or electric components. Note and cbserve the specifications on high-pressure clean- ers in the safety manual. Performing welding work Fig. 4.105:Performing welding work Wednestay-22-htaret : ‘© Kleemann GmbH 2016 327MAINTENANCE Performing welding work [w]] KLEEMANN Safety precautions and Prerequisites Welding with current from Une power supply unit Welding with an external power supply Breed Danger of fires due to welding torch Welding torches, het metal and sparks can set fire to compo- nents and objects in the surrounding area. + Where possible, cover components and objects exposed toa risk of fire. ‘+ Protect components and objects against dripping hot metal and sparks. + Ensure fire extirguisher is ready before starting work. ‘+ Ensure a fire watch is present during and after welding work. ‘+ Wear protective equipment. Welding work must only be carried out by personnel trained or authorised by KLEEMANN + Check welding apparatus, welding lead and equipment for proper working condition. + Use a fully insulated electrode holder. + Never jam the electrode holder under your arm. + Never place the welding lead over your shoulder. + Use dry, undamaged protective gloves free of metallic parts. ‘= Do not install the welding lead parallel to electric lines. + Ensure the housing of electronic components and electrical lines do not make contact with the welding electrode. ‘+ Remove layers of paint, grease or rust in the area of the ter~ minal. ‘+ Where possible, connect the earth terminal directly to the component being welded to avoid straying welding currents. Otherwise there is a danger of destroying electronic compo- nents, + Never connect via rotating components. This can result in bearing damage. Do not connect the earth terminal to the hydraulic cylinder of the lower impact toggle. This would destroy the electro hydraulic adjustng device. ‘Switch the diesel generator on, ‘Switch off control voltage and main switch. Secure the main switch against reactivation, Connect welding apparatus to service socket (see chap.2.06.06).. Welding work can begin. ‘Switch off plant components and the diesel generator. > Switch off main switch and secure against reactivation. vvvy . vs Wednesday 328 tert © Kleemann GmbH 2016MAINTENANCE [w]] KLEEMANN Performing welding work > Switch off and remove the battery isolators. > Use external network connection or external power supply unit. ¥ Welding work can begin. Wednestay-oarhtaret ‘therestiny printed © Kleemann GmbH 2016 329TABLES Technical details [w]] KLEEMANN 5 TABLES wD This chapter lists all technical details relevant to your plant. ‘The complete technical details of the manufacturers’ compo- ents are provided in the respective manufacturer's documen- tation, During all activities, observe Ue information in your safety manual! 5.01 Technical details 5.01.01 Complete plant 5.01.01.01 Weights [Designation [Weight Plant without optional equipment but with _|Approx. 69000 mandatory alternatives, e.g. screen surfac- |kg es. Plant with all optional equipment [Approx. 73500 ka Tab, 5.1; Weight of complete plant wD All weights including fluids and lubricants and 300 litres diesel fuel. 5.01.01.02 Dimen: Dimensions in operating posi IS NA ge | is “ a6 oe aa on soe Fig. 5.1:Side view of MC120Z Weemesdey-Girharel 2 ehevestinr ted 330 © Kleemann GmbH 2016[w] KLEEMANN TABLES Technical details 5.01.01.03 Fig. 5.2:Front view of MC120Z All dimensions in millimetres. Driving operation Designation Value Maximum cliribing ability forward/back [30% Maximum permissible lateral inclination __|17 % Maximum driving speed 20 km/h Max. generated ground pressure™ 1.60 ko/em* Tab. 5.2: Plant driving operation 5.01.01.04 Charged material and size 1 The maximum generated ground pressure is calculated ac- cording to the following equation: Max. total weight of the plant / distance between centres x base plate width x 2. Designation \Value |Permissible charged ma- terial [stone Mineral materials such as rubble, \demolished asphalt and reinforced ‘concrete, tiles/bricks and natural Materials such as slag, coal, ores, letc., only after express approval from KLEEMANN GmbH. [Compressive resistance lof the charged material 280 N/mm? "In continuous operation up to Wednestay-oarhtaret ‘© Kleemann GmbH 2016 ‘therestiny printed 331TABLES Technical details [w]] KLEEMANN [Designation Value Permissible feeding size _|Maximum edge dimensions 1100 x 1100 x 700 mm (length in material direction of flow x width 90° in re- lation to material direction of flow x height). Tab. 5.3: Charged material and size 5.01.01.05 Feed and crushing capacity [Designation Value Feed capacity [Up to 350 t/h depending on the type and composition of the charged material and size or vol- lume of the primary screening or the size of the final grain. ‘Crushing capacity jApprox. 140 - 180 Wh at a gap width of 85 mm. JApprox. 165 - 220 t/h at a gap jwidth of 100 mm. JApprox. 215 - 280 t/h at a gap lwidth of 130 mm. Approx. 250 - 320 t/h at a gap lwidth of 160 mm. Tab. 5.4: Feed and crushing capacity 5.01.01.06 Screen capacity [Designation Value Permissible charged ma- |As described in chap, 5.01,01,04, terial and size Permissible screen sur- [Original standard series and op- faces tional equipment from KLEEMANN GmbH. Deviating screen surfaces only af- ter prior approval by KLEEMANN JGmbH. Primary screening in the lupper deck maximum 150 mm. iMesh size ratio of upper [Maximum 1:5. ideck to lower deck Tab. 5.5: Screen capacity 5.01.01.07 Ambient temperatures ‘The plant can be continuously operated at ambient tempera- tures of -15 °C to +40 °C. Weenesday-o2-htare Het 332 © Kleemann GmbH 2016[w] KLEEMANN TABLES Technical details ca With the Arctic Package special equipment, plant operation up to -25 °C is also possible. Because of the use of low-tempera- ture lubricants, however, operation is limited to a maximum temperature of +30 °C. 5.01.01.08 Sound power level Designation [Sound power level LWA Plant (series) 116 dB Tab. 5.6: Sound power level LWA Determinatior and implementation according to the standard: Determinatior of the sound power level of noise sources from sound pressure measurements EN ISO 3744. 5.01.02 Power supply unit/engine Technical data of diesel generator exhaust stage 3a Designation Value [Type designation (AAE120-EUL Manufacturer of power supply [AVS lunit Hype of power supply unit [Beania DOTS Rated output [275 kVA Rated power factor 08 [Nominal voltage [2307400 V Frequency 50 Hz [Speed 1500 rpm Weight ‘Approx. 3200 kg Reference conditions* [Installation height approx. 100 m above sea level lAmbient temperature [25°C Relative humidity 60% Diesel engine manufacturer [Scania Engine type [DC 13 073A (02-02) Number of cylinders (6 inline Displacement. 12.701 Rated speed 1500 rpm [Continuous output according to DIN |364 KW |6280 / ISO 3046-1 Fuel consumption according to DIN [202 o/kWh [51601 at full load approx. [Starter av [Generator BV Wednesday-ee:ttarc testi printed ‘© Kleemann GmbH 2016 333TABLES Technical details [w]] KLEEMANN [Designation [Value Batteries 2 x 185 Ah, 24V (2x12, wy (Cooling system Liquid cooling, charge-air lcooling [Diesel fuel filling capacity [Approx. 7001 ring volume of engine oll during Approx. 401 oil change! Exhaust stage BA (Generator manufacturer Leroy Somer (Generator type LSA 47.2 S4 Rated current 592 A Rated output [410 kVA Nominal voltage [2307400 V Voltage stability, static je 1.5% Frequency 50 Hz [Speed }1500 rpm Type of protection lip 23 Tab. 5.7: Power supply unit/Engine of plant * The aforementioned performance data of the power supply unit is based on the specified reference conditions. Deviations from these values indicate a (sometimes considerable) loss in performance, 4 Check at oil dipstick, also refer to the manufacturer's docu- mentation. Technical data of diesel generator exhaust stage LRC [Designation [Value [Type designation [AAE120-EU3 (Manufacturer of power supply [AVS unit ‘Type of power supply unit Scania DCIS Rated output 275 kVA Rated power factor 0.8 Nominal voltage [230/400 V Frequency 50 Hz Speed [1500 rpm Weight [Approx. 3200 kg [Reference conditions* installation height approx, [100 m above sea level [Ambient temperature 25°C Weerestay-e:htarc ioestinr petecttin 334 © Kleemann GmbH 2016[w] KLEEMANN TABLES Technical details 5.01.03 [Designation Value Relative humidity (60% Diesel engine manufacturer [Scania Engine type [DC 13 073A (02-22) Number of cylinders (6 inline Displacement 12.701 [Rated speed 1500 rpm [Continuous output according to DIN |364 kW \6280 / 1S 3046-1 Fuel consumption according to DIN [202 g/kWh [51601 at full load approx. [Starter 2aV [Generator [28V Batteries Bx 185 Ah. 24v 2 xi2 |Cooling systen Liquid cooling, charge-air cooling Diesel fuel filling capacity ‘Approx. 700 Filling volume of engine oll during Approx. 401 Joil change! Exhaust stage RC [Generator manufacturer Leroy Somer [Generator type LSA 47.2 $4 Rated current ES Rated output [410 KVA Nominal voltage [230/400 V [Voltage stability, static = 1.5% Frequency 50 Hz [Speed 1500 rpm Hype of protection IP 23 Tab. 5.8: Power supply unit/Engine of plant * The aforementioned performance data of the power supply unit is based on the specified reference conditions. Deviations from these values Indicate a (sometimes considerable) loss In performance. * Check at oil dipstick, also refer to the manufacturer's docu- mentation. Fuel supply, cold package (option) Designation [Value Maximum volume flow lup to 600 7h Wednesttay-oa-htare ‘© Kleemann GmbH 2016 sikowstiiny printed 335TABLES Technical details [w]] KLEEMANN 5.01.04 Hydraulic oil supply 5.01.05 Electrical system 5.01.06 _ Electrical system, cold package (option) [Designation [Value [Temperature range 25 8C bis +90 °C Rated voltage 2aV Filter heating rated output 300 W [Degree of water separation > 95 % according to {ISO CD 16332 Water discharge '8 mm hose connection Tab. 5.9: Fuel prefilter with preheating [Designation \Value ‘Type designation 'AMC120-21, Hydraulic oll tank filling capacity __ [2801 Filling capacity of Fydraulic system, |Approx. 300 | icomplete Driving hydraulics operating pressure [365 bar [Operating pressure of auxiliary hy- [230 bar, #10 bar draulies Tab. 5.10: Hydraulic system of plant [Designation [Value Operating voltage }400 V (Control voltage Dav Frequency 50 Hz Additional sockets (external cir- 230 V/16A ee J400 v / 32.4 115 V / 16 A (option) Tab. 5.11: Electrical system [Designation [value (Operating voltage 230 V [Switch cabinet heating output 2 x 800 W ‘Switch cabinet heating output, PLC |50 W jcontrol Tab, 5,12; Switch cabinet heating Wernescay-eachtaret 336 throrestiny printed © Kleemann GmbH 2016[w] KLEEMANN TABLES Technical details 5.01.07 Drive system Designation \Value |Crawler chassis with installed hydraulic motors and chassis in lbetween, Holding brake: depressurised closing spring force brake. Ser- lvice brake in crusher operation hydraulically actuated, in driv- ling operation, hydraulically released. [Crawler chassis type D7 [Distance between centres, sprock- |4240 mm lets Base plate width [500 mm [Gear motor maximum torque [60 kN Planetary gear filling capacity 5 | per side Tab. 5.13: Plent driving operation 5.01.08 Conveyor unit Crusher discharge belt Designation Value Design ‘Sectional steel structure Weight lApprox. 4050 kg / 4360 kg Distance between centres 10000 mm 7 11500 mm Bele width 1400 mm Drive output 15 KW [Conveyor belt speed 1.2 m/s Belt conveyor drive [Electric motor with flange-mounted angular \gear with reverse lock [Electric motor with flange-mounted angular (gear with reverse lock [Angular gear filling capacity |Approx. 8.01 Tab. 5.14: Crusher discharge belt Prescreen conveyor (option) Designation (Value [Design ‘Sectional steel structure |Weight* [Approx. 1200 kg) [Distance between centres (6000 mm [Belt width (650 mm Wednesday-ee:ttarc testi printed ‘© Kleemann GmbH 2016 337TABLES Technical details [w]] KLEEMANN [Designation [Value Drive output 5.5 kW (Conveyor belt speed 2.0 m/s [Belt conveyor drive Electrically driven drum motor with reverse lock [Gearbox filling capacity [Approx. 6.01 Tab. 5.15: Grizzly side discharge conveyor * Including belt suport Vibrating extractor [Designation [value Design Vibrating conveyor ltrough designed with lwear plates Weight [Approx. 2100 kg [Trough width [1150/1300 mm Trough length [Approx. 2655 mm Drive 2 vibration motors with lconstant speed. Drive output Px 4.0 kW lOperating voltage \400 V Permissible ambient temperature _|- 20 °Cto + 40°C Type of protection iP 65 Tab. 5.16: Vibrating extractor Electromagnetic separator [Designation [Value [Type designation [452-95/140-450/1 G2 KG-4 Weight lapprox. 3300 ka Drive output 2.2 KW (Conveyor belt speed JApprox. 2.7 m/s Belt conveyor drive Electric motor with lfianged-on worm gear lType of geared motor protection [IP 55 Type of magnet protection iP 65, Fill capacity of worm gear lapprox. 2.8 1 Filing volume for oll cooling system [approx. 156 1 Tab, 5.17: Electromagnetic separator Weenenday-ba:htaret sh 338 © Kleemann GmbH 2016[w] KLEEMANN TABLES Technical details 5.01.09 Permanent magnetic separator [Designation Value Hype designation 10 PCB 10 KEL SP Weight lapprox. 1405 kg [Axle spacing 2140 mm [Bole width "750 men Drive output LS kW Belt conveyor drive [Electric motor with flange-mounted gearbox [Gearbox filling capacity (Approx. 0.48 | Tab. 5.18: Permanent-magnet separator Water system (option) [Designation \Value iType designation INDS120-MCI [Operating voltage [230 V [Conveying medium temperature [+ 5°Cto + 35°C Maximum permissible operating [8 bar pressure Minimum 7 maximum permissible |- 0.8/4 bar pressure on suction side Maximum suction height 5m Maximum ambient temperature [+ 40°C |Water consumption [2 to 5 m® per day {Type of protection IP 54 Tab. 5.19: Water system Feed hopper [Designation Value Design [Hydraulic foldable hop- per walls Weight (Approx. 4200 kg) Feeding volurie ‘Approx. 8 m> Feeding width, front face Feeding width, tongitudinal (Approx. 2850 mm (Approx. 4130 mam Feeding height [Approx. 4600 mm Tab. 5.20: Feed hopper Wednesttay-oa-htare ‘© Kleemann GmbH 2016 sikowstiiny printed 339TABLES Technical details [w]] KLEEMANN Vibrating feeder [Designation [value Design \Vibrating conveyor ltrough designed with lwear plates Weight [Approx. 3150 kg Trough width }1000/1190 mm. [Trough length JApprox. 3500 mm Drive 2 vibration motors with [stepless speed adjust- ment via frequency con- verter Drive output 2x 4.0 kW [Operating voltage ]a00V Permissible ambient temperature _|- 20 °C to + 40 °C ‘Type of protection lip 65 Tab, 5.21: Vibrating feeder 5.01.11 Crusher [Designation [value ‘Type designation [STR120-080 Design [Single toggle jaw crusher, welded Iconstruction with rocker support- Jed in spherical roller bearing Weight [Approx. 25720 kg (Crusher jaw width {1200 mm Feed opening [800 mm [Crushing jaw version Manganese rigid steel, reversible Gap setting Mechanical with shims Drive [Electric motor via V-belt (Operating voltage per V- {1082 N belt!, new V-belts Worn V-belts [e33.N lab. 5.22: Jaw crusher 1 Static strand force per V-belt, measured with Optikrik II + IIT tension gauge. Weenenday-ba-htaret sh 340 © Kleemann GmbH 2016[w] KLEEMANN TABLES Maintenance schedule/maintenance intervals 5.01.12 Screens Grizzly Designation Value Type designation \vuz255-120 Design: [Double-deck heavy-duty |Weight [3020-3280 kg, depend- ling on screen surface |Screen width 1200 mm |Screen length 2550 mm [Screen inclination, upper deck ‘Slotted grate 7°, perfo- irated plate 9° Screen inclination, lower deck ise |Screen surface clamping system _|Upper deck transverse ltension, lower deck lon- \gitudinal tension [Rocker width adjustment Via unbalance weights [Screen drive [Electric motor with iflange-mounted angular \gear and universal-joint Shaft Drive output 15 kW |Operating voltage 400 V |Angular gear filling capacity |Approx. 1.21 Tab. 5.23: Grizzly 5.02 Maintenance schedule/ maintenance intervals Chassis/guard devices ‘Machine/ Mainte- [Material, ee |See ‘component —_|nance work |spare parts |= > =| chap. 2 >| |E 3 oe lels| (8 e oe l> 5 Bais |2|_\s|_ le le BEINIE|£ |< |= Jo lo BEitl=\s [sis |e ie [8 Egle ls |g |g 88 |s lf © 8 le [8 [8 [8 [8 |S [8 [5 Selelelelelelele|e Bel ell ailel elle da lal @ ‘Signs |check/re- see spare x }4.01.01 place parts cata~ logue Wednesday 32-Mare fthowstinprtetth ‘© Kleemann GmbH 2016 341TABLES Maintenance schedule/maintenance intervals E) KLEEMANN Machine/ Mainte- Material, = |~ See component —_|nance work|spare parts |= > >| chap. 2 =| | 3 = Z| |g & ee lz|8| 2 IE ses >| je le FEE 2S esigis 2 Egle £ eels (8 (8 (8 la | [8 [s BSlElE\ElE le le le ls Hela aleg Protective \check/lubri- lube oil 50, Xx 4.01.01 housing for cate power supply tit Platforms: icheck IX 4.01.01 Screw connec- |retighten. X |4.01.01, ions Lubricating nip- |check/re- xX |4.01.01 ple place Warning devic- |check IX }4.01.02 es guard devices _|check x (4.01.03 Emergency \check/repair |see spare x 4.01.04 stop parts cata- logue Tab. 5.24: Chassis/guard devices maintenance schedule Control stand Machine/ [Mainte- Material, |~ [see chap. component —_|nance work|spare parts |= > > 2 | le} ig} | 3 Se l>(e| |8| | IE > 5 esi?) =| |. (> RES Slezlelslss e>ele alelgle 2 eee BSR RRR s SREP EEE Ele le SEE E/E E\E|E|E | 2S |i |G | |i |i [it | 2 [Switch cabinet |check/repair [lube oil x \4.02.01 protective housing lLamp test [carry out x '4.02.02 Wedneseay- ters ovate 342 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Maintenance schedule/maintenance intervals Machine/ Mainte- Material, = |~ |see chap. ‘component |nance work |spare parts |= . > 2 >| |e 3 =| |e 2 = | |z| |e E eslz/2| |F| |S eS IEIEE is [slg Egle ls |e ° iS le [a (8 ie eS es Se lelelelelele les ee ENE SA ead | Radio remote —|check/repair x xt 4.02.03 \control, compo- nents |Emergency Jcheck/repair x }4.02.03 |stop and func- tions Tab. 5.25: Control stand maintenance schedule + Check by specialist Power supply unit/engine \Machine/ Mainte- [Material, ~ [See ‘component —_ nance work |spare parts |£ _ >| |chap. 2 =| |e 3 5 Z| |z & e.|>|s| |é 5 Es la |$ = geo lslelele sis Egizis lglg le 8 giz 98 \o [a [a [a |B ia la iS Sm ele lee le le leis SEER IEE |5 5/5 BE ae ola | |e |e |e [Diesel engine _ |service/re- x 14.04 pair? Fuel prefilter change’ See spare [500 x )4.04.01.0 lwith water sep- parts cata- 1 rater fogue ‘Collecting res-_|check/drain? IX }4.04.01.0 lervoir, water iH ‘separator ‘Cyclone prefil- [check x 4.04.03 ter \Air filter Jclean/re- )X° 4.04.04 place Cooler fins clean x" 14.04.05 Wednesday 32-Mare fthowstinprtetth © Kleemann GmbH 2016 343TABLES Maintenance schedule/maintenance intervals E) KLEEMANN Machine? |Mainte-__|Material,_|— [See component [nance work|spare parts |= . >| |chap. ig >| |Z $ é =| | 2 9 3] |8 5 > 5 Efls 2) S| lele ge € /= > \< |= |< Ie [5 2 lz |E |e |g |e [8 |S eels ie aia ie eis SBE E|E EIR le le Bee dd ese ed Engine oil Ichange x 4.04.06 Tab. 5.26: Power supply unit/engine maintenance schedule 1 See manufacturer's documentation. 2 Daily in case of lage accumulations of dust. 3 Only when using cold package or LRC diesel engine. Hydraulic oil supply Machine/ Mainte- Material, I~ see chap. ‘component [nance work |spare parts |= > = s je >| |s z e =| | E e.|>|s| 2 5 Es |e |5 > ele isle lelelsls BEN ZIE/S |S [gla |e els a Slee lala ls Eglelelelejejelels ze S e Be le |e le le la |e Ue |e Hydraulic com- |check/repair |see spare so |X xt [xt /4.05.01.0 ponents, leak- parts cata- 2 |tightness logue Pump splitter [check x 4.05.03 gearbox, leak- tightness Fl level check x jof gear oil ichange gear oil 500 ix: }4.05.03, [Hydraulic oil _|check/refill [hydraulic oll x '4.05.02.0 itank, fill level 1 Hydraulic oil ichange/car- |hydraulic oil {500 Ix '4.05.02.0 ry out oll 2 analysis Weorescy-oe:htere stot printed 344 © Kleemann GmbH 2016[w]] KLEEMANN TABLES Maintenance schedule/maintenance intervals Machine/ Mainte- Material, = |~ |see chap. ‘component |nance work |spare parts |= ie > 2 | jz| | | [2 = Z| |g : Es le(é| || |_|s #8 lS Ie l= |< |e Is lp £8 |2 5 Is Ie | [8 [8 IE 5S (5 (a (a [8 le © (8 |s Sg lelelelele lees eed EA el tee ell 2 \Ventilation filter |change see spare 500 x 4.05.02.0 parts cata- 3 logue ‘Suction filter |change see spare 500 x 4.05.02.0 parts cata- 3 logue [Return filter |change Isee spare 500 IX }4,05.02.0 parts cata- 3 logue Tab. 5.27: Hydraulic oil supply maintenance schedule + Observe checking and replacement intervals of hydraulic hos- es! ? Fluids and lubricants, see chap.5.04. 3 With fewer operating hours, at least every 2 years. Electrical system (Machine/ Mainte- [Material, ~ |See ‘Component __|nance work |spare parts |= le >| |chap. g >| |E 3 e | el le) | dE fe gel El Lf ate SZ] zl. l= l= #5 lx \2 |< | |< |9 lols = lo |8 |8 8 [8 |8 |£ gf lo lh la IA mH et [A |S SEF lElelelelele |e SE lo /6|o/G\5 |5 | 5 23 |g |d |e [a |e |e |e |@ [Electrical com- |check/repair [See electri- [50 |X 4.06 [ponents ‘cal circuit di- fagram |Starter batter- |check x |4.06.02.0 lies 2 Wednesday 32-Mare fthowstinprtetth ‘© Kleemann GmbH 2016 345TABLES Maintenance schedule/maintenance intervals E) KLEEMANN Machine/ Mainte- Material, = |~ ‘See Component _|nance work|spare parts |= . >| |chap. 2 >| = 3 z |>(e| (8 & Eels |s| |£ ~ BE ls le) i>l. ele Eflz ele leis is 2 ee |= = Els SE SRER Ss BEE eleleleiele ls Sates ae al ed | Icharge xt [4.06.02.0 2 |Vent openings |check/clean x '4.06.02.0 2 Control cabinet |clean [x |4.06.03 Cables, sock- _/check/repair |See electri- [50 |x |4.06.03 jets, operating Jcal circuit di- elements and lagram jindicators: Control cabinet [replace [See spare x doors rubber parts cata- seal logue Control cabinet |check/adjust x '4.06.03.0 mounting 2 Ground fault: icheck x '4.06.06.0 circuit inter- * rupters [Electric motors, |check/repair IX '4.06.04 terminal boxes Over pressure |check/repair [See spare Dk (4.06.05 system func- parts cata- \tion, compo- logue nents cyclone prefil- [dean x 4.06.05 ter Dust filter. ‘deanj/re- [See spare ig (4.06.05 place ports cots logue Tab. 5.28: Electrical system maintenance schedule 1 Remove batteries and charge over a period of 12 - 14 hours. Weenesday-o2:htare Het 346 © Kleemann GmbH 2016[w]] KLEEMANN Drive system TABLES Maintenance schedule/maintenance intervals ‘Machine/ [Mainte- [Material, ~ |See ‘component —_|nance work |spare parts |= i [>| chap. £ >| |z 3 = Z| |Z : 5 es |2|8| |e is SS SF) iI lel] #2 SIP le l= |= 9 lolg ee gigig 2 esl © O jm (8 |S 18 |B [8 /R |S ERlEIE|EIE E|EVE|E Pelee lee lc lal l2 (Crawler carrier |check/ten- |grease. x |4.08.01.0 chains sion a 'Base plates, |check/repair |see spare x |4.08.01.0 'track rollers [parts cata- 2 logue Planetary gear, |check x |4.08.02.0 \leak-tightness a Fill level Jcheck x 4,08,02.0 a Gear change gear oil” /500 x la.08.02.0 a \Components |check/repair IX }4.08.02.0 2 Tab. 5.29: Drive system maintenance schedule + Fluids and lubricants, see chap. 5.04. ? But at least every 2 years. Conveyor unit \Machine/ |Mainte- Material, |See ‘components nance work |spare parts a Pd }chap. >| |z 3 = € € 2/8) {2 s $/2\ |S \_ le [= SE |= |= |< |e Jo |B = a Jo |o [8 8 |8 = @ |B |S |8 /8 |8 |R |S elelelelele leis §\5|5/5|5 |5|s|£ i |e | a | a | |e Belt conveyors Wednestay-e2-htare sikowstiiny printed ‘© Kleemann GmbH 2016 347TABLES Maintenance schedule/maintenance intervals E) KLEEMANN Machine/ Mainte- Material, = |~ ‘See components |nance work |spare parts |= . >| |chap. 2 =| = 3 o |>{s| (8 E Eolz|f| \|E IS BE ls le) i>l. ele Eflz ele leis is 2 ee |= = Els SE SRER Ss BEE eleleleiele ls ESN a tear led cd Conveyor belts |check/repair |See spare x '4.10.01.0 parts cata- 1 logue Return roller \check/adjust x JX ]4.10.01.0 guard 2 adjust X |4.10.01.0 2 [Scraper \check/repair |See spare x '4.10.01.0 parts cata- 3 logue jadjust_ X |4.10.01.0 3 Rubber plates [check/repair |See spare x '4.10.01.0 parts cata- 4 logue jadjust xX |4.10.01.0 a Bevel helical (check/refill [Gear oil” )X |4.10.01.0 gearbox fill lev- 5 jel Gear oil replace |Gear oil’ 500, x: '4.10.01.0 5 [Drum moter fill |check/refill [Gear oil? X |4.10.01.0 level 6 Gear oil replace |Gear oil: x? |4.10.01.0 6 Plummer block |check/lubni- [Lubricating x }4.10.01.0 Icate/repair |grease!, see i? spare parts |catalogue Change grease |(action) Grease? x '4.10.01.0 7 (Chutes Weerrenday-62-Mare ftrowstin- pret 348 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Maintenance schedule/maintenance intervals Machine/ Mainte- Material, = |~ [See ‘components |nance work |spare parts |= ie =| |chap. s |= os 2 =| |s 2 3 |ple] 18 E > 5 Eela|s| |= > SESE ltl. l= 2s rl=\e|s ie 8 (3 |B E@ |c = cole 8 le i la (eels Se lel lela le lees £5 212 (3|2 2 2 1E\2 (Chutes |check/repair |See spare x 4.10.02 parts cata- logue ‘Magnetic separator [Conveyor belt |check/ten- [See spare x x ]4.10.05.0 lelectromagnet- |sion [parts cata- 114,10,05, lic separator logue }o2 (Bearing for lubricate |Grease™ x \4.10.05.0 lelectromagnet- 4 ieseparator [Oil cooling elec- |check/refill x X |4.10.05.0 tromagnetic 5 ‘separator Worm gear fill |check/refill [Gear oil iX |4.10.05.0 llevel, electro- 3 Imagnetic sep- arator \Gear oil replace Gear oil! —_|500 x] _|4.10.05.0 3 [Conveyor belt |check/ten- IX xX |4.10.06.0 [permanent Ision’ 14.10.06. Tagnet separa- oa tor [Permanent lubricate |Grease™ x }4.10.06.0 magnetic sep- 4 |arator bearing ‘Dust deposits |clean /Brush x Ix lon electric mo- tor Tab. 5.30: Conveyor unit maintenance schedule | Fluids and lubricants, see chap. 5.04.01. ? For fill volume, see type plate. 3 With fewer operating hours, at least every 2 years. Wesnesday-62-Mare tikceathnr ited © Kleemann GmbH 2016 349TABLES Maintenance schedule/maintenance intervals [w]] KLEEMANN 4 Change interval every 10000 operating hours, with synthetic ail filing every 30000 operating hours. Water system (option) Machine/ ‘Mainte- Material, ae ‘See component —_|nance work |spare parts |= =~ =| |chap. 2 =| |s 2 s (nie) 18 : aS BENS [Sls |< |= |e Ie 3 Files sieges = Els (a (818 (8 (2 |e |S Sg lelele lel lp le|s Be (5 (2/5 (8 (8 (28 |5 a a a a a ae Water pump, |check/repair K lai2 leak-tightness ‘Spraying noz- |check/repair_ IX 4.12 izles Tab. 5.31: Water system maintenance schedule Tools/accessories Machine/ [Mainte- Material, Pe, [See component —_|nance work|spare parts |= Ss =| |chap. : 5 z 4 E 3) Bl | ie Eszi2| |E| |.\s Be 8 |>|_ || hele KEIN [Sle le [2 3 EIDE sissisisie ile [s |g |g ie 18 (8 (2 eels (a (S ( le |e (8 (e Se RIE Ele le le le ls eee |B /2 (8 |S |e 2 Ie 2 | |a |e | [a | oe [Tools and ac- —|check/re- IX 4.42 cessories Iplace Tab. 5.32: Tools/accessories maintenance schedule ‘The maintenance intervals of the rock chisel are specified in the Tranufachurer's documentation. Wednesday 82ers stkoestnr tect 350 © Kleemann GmbH 2016[w]] KLEEMANN TABLES Maintenance schedule/maintenance intervals Feeding unit ‘Machine/ [Mainte- [Material, ~ |See ‘component —_|nance work |spare parts |= i [>| chap. £ >| |s 3 = Z| |z & : es |2|8| |e is SB (SZ) >|, || l= 8 S\>l=£ I< |< \9 lols Egle 5 lig ise git eee Rca lee lait ESERIES IE SIS |E ee ee NEE |e ig |e le Feed hopper |check/repair |see spare x 4.43.01 ports cat logue Feeder trough, |check/repair |see spare x )4.43.02.0 rubber mount- parts cata- 1 lings logue \Vibration mo- _|check/repair |see spare 50 x 4.43.02.0 ies pare cas B oy Wwesrlining, Racy leanne K la43.07-0 place pares cata- 5 logue Tab. 5.33: Feeding unit maintenance schedule Jaw crusher \Machine/ Mainte- |Material, ~ |See ‘Components _|nance work |spare parts |= . =| |chap. E\ | 2 |i z| z =| [5 E EolZ|2| |é iS EPs i\. (>|. \e[2 S24 |< | Is lols Ea |= 5 |g |g 8 8 Bis SAB eiels 5 elelel> lp ip les SET EIEE E/E EE 55 le (8 (818 8 (8 ie le belgie |e (ele gle [Rocker bearing [lubricate |Grease™ x 4.44.01 Labyrinth seals [lubricate |Grease™ IX 4.44.01 ‘Bearing noises, |check/repair |see spare x [4.44.02 heating parts cata- logue Wednestay-e2-htare sikowstiiny printed ‘© Kleemann GmbH 2016 351TABLES Maintenance schedule/maintenance intervals E) KLEEMANN Machine/ Mainte- Material, = |~ ‘See Components |nance work|spare parts |= . >| (chap. 2 >| = 3 oli] 2 E ° 5 eolZ|e| \£ iS Selo ‘ess je lc g€ |= lSlels ls lsle jE |= |< |e |g |e [8 |S cals ese Bele lelelelelele BE\E 2|2 212 |2 (2 V-belt \check/ten- 50, x 4.44.03 sion Attachment of |check/ x IX |4.44.04 crusher jaws —_|retighten and lateral wedges: [Crusher mount- |check x 4.44.05 ing [Bearings of ‘lubricate Grease" x 4.44.06 crusher drive jelectric motor Grease 4.04.08 \change Attachment of |check/ Xx 14.44.03, icrusher drive _|retighten jelectric motor Tab. 5.34: Jaw crusher maintenance schedule 1 Fluids and lubricants, see chap. 5.04.01. ‘Screen machines Machine/ [Mainte- Material, ~ ‘See components nance work |spare parts = = = ichap. g >| [E : = | |Z] |= E gol2|8| /2 . Ey 8 el. z\elel= REIS \2 lo |o Eg |= |o |8 |8 [8 [8 |8 |£ oH le (8 [2 [8 [8 (8 18 fs Sele le lelelelele |e Els |e |e fig ig ls ES [a | | |e a [a | |S Screen surfaces |check/repair |See spare x 4.45.01 parts cata- logue Wectnesday 62-Mare ne 352 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Tightening torques Machine/ Mainte- Material, = |~ [See ‘components |nance work |spare parts |= ie =| |chap. 5 = § Hee z/8 < Eelsls| |= [= B28 |= ele 2s rl=\e|s ie 8 (3 |B E@ |c = Sales (sis iale als Se lel lela le lees £5 212 (312 2 212 \2 |tension X [4.45.02 Angular gear, check x leak-tightness Fill level Jcheck/refill [Gear oil” K }4.45.03 Gear oil replace Gear oil x? 4.45.03 ‘Articulated lubricate |Grease x 4.45.04 shaft [Securing bolts check/ 50 x 4.45.04 retighten 'Bearings lubricate [Grease x 14.45.05 LLabyrintns _|iubricate [Grease x 4.45.05 \Bearing noises, |check/repair See spare x 14.45.06. heating parts cata~ logue (Rocker width —|check x x 4.45.07 ‘Components _|check/repair |See spare x 14.45.08 parts cata- logue (Screen mount- |retighten x x 14.45.08 ing Tab. 5.35: Maintenance schedule of screen machines 2 Fluids and lubricants, see chap. 5.04 2 Change inte-val every 10000 operating hours 5.03 Tightening torques This section presents the tightening torques for screws and nuts @ in tabular form. Wednesttay-oa-htare sikowstiiny printed © Kleemann GmbH 2016 353TABLES Tightening torques [w]] KLEEMANN Breed Danger due to incorrect tightening torques Incorrectly tightened or retightened screws and nuts can be- come loose or tear. ‘+ Check the security of nuts and screws on a regular basis and retighten if necessary. ‘+ Tighten or retighten screws and nuts to specified tightening torque. Tightening torques for standard metric threads [Dimension _ [Maximum tightening torques Ma in Nm [88 10.9 12.9 ma a8 5.6 MS E 9.5 11.2 m6 FEE) 16.5 19.3) oo Bz 140.4 46.9 M10 54 79 93 Miz [93 137 160 mia 145 i218 [255 mis 1230 338 395 mis 329) 469) Ex 20 lags (661 773 M22 leat [904 1057 M24 798 1136 1329 M27 1176 1674 1959 M30 1597 [2274 2652 M33 j2t6t [3078 (3601 M36 l2778 3957 4631 M39 [3597 [S123 (5994 Tab. 5.36: Tightening torques for standard metric threads Tightening torques for fine-pitch thread Dimension _ [Maximum tightening torques M, in Nm 8.8 10.9 12.9 MBxi.00 [292 42.8 [50.1 mio xi.25 (57 [a3 98 Mi2xi.25_ |ioi 149 174 mizxi.50__ [97 143 167 Mi4x 1.50 [159 (234 274 Weenenday-ea:htaret Barrows printed 354 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Fluids and lubricants Dimension — [Maximum tightening torques M, in Nm 88 [10.9 12.9 Mi6x iso [24a 359 [420 Mis xi.s0_ [368 [523 [ens M20xi.50 [Sit [728 je52 M22 x iso [692 985 1153 M24 x 2.00 [865 1232 1442 M27 x 2.00 [1262 1797 2103 M30x 2.00 |1756 [2502 [2927 Tab. 5.37; Tightening torques for fine-pitch thread 5.04 ls and lubricants ‘The fluids and lubricants tables contains a comparison of the re- spective products of the same specifications of different brands. ‘The order in which the brands are listed bears no relation to the quality of the products. The listed brands are simply an abstract of the fluids and lubri- cants available on the market. During a future revision, this se- lection can be changed. ‘A.completely presentation of the individual fluids and lubricants with all data end approvals, e.g. from combustion engine and gearbox manufacturers, is not possible for reasons of space. ‘The specification details take DIN and ISO standards, in particu- lar, into consideration. The fluids and lubricants table is designed to provide initial ori- entation for servicing KLEEMANN plants and machines. Howev- ef, it does not “eplace the advice of a lubrication specialist or the recommendation of the engine and gearbox manufacturers. For environmental protection reasons, itis absolutely necessary ‘to dispose of used oil in accordance with the specifications after every service or oil change. Fluids and lubricants for special application conditions are not included in this lubricant table. We shall only assume liability for our plants and ma- chines isted fluids and lubricants, or their verifia- ble equivalents, have been used! 5.04.01 Lubricants Power supply unit/engine The fluids and lubricants to be used are described in the manu facturer's documentation. Wednesttay-oa-htare sikowstiiny printed © Kleemann GmbH 2016 355TABLES Fluids and lubricants [ww] KLEEMANN Plant hydraulic oil supply (Operating materi [Specifications Brand Product Plant hydraulic oil Bio hydraulic oil ISO- | Wirtgen Group |Bio hydraulic oll V6 46 IVG 46 with EP adai- tives {Type HVLP. ICES 150 15300 [Gear cil for pump splitter [Synthetic polyglycol _|Wirtgen Group [High performance igearbox lgear oil IS0-VG 220 lgear oil VG 220 DIN 51517-3 (CLP) iSO 6743-6 (CKS/CKT) Tab. 5.38: Hydraulic oll supply lubricant table EP additives (extreme-pressure additives) are added to lubri- @ cants and improve their tribological characteristics, i.e. they Prevent the fusing of two metallic materials that rub against each other. Drive system [Operating materi [Specifications Brand Product (Gear oil for track drive __|SAE 75W-90 with EP _|Wirtgen Group |Special Gear Oil 75W- ladditives ls0 JaPr MT=2 JAPI GL-4, GL-S IChain tensioner grease _|Lubricating grease wich |Wirtgen Group [Multipurpose Grease IEP additives (lithium |saponified) ItSo 6743- 2 DIN 51825: KP2K-25 ItSo NuGI 2 Tab. 5.39: Drive system lubricant table L-XBCEB cants and improve their tribological characteristics, i.e. they prevent the fusing of two metallic materials that rub against ‘each other. Conveyor unit @ EP additives (extreme-pressure additives) are added to lubri- Fluid/lubricant [Specifications Brand Product [Belt conveyor drive gear oil [Synthetic polygiycol__|Wirtgen Group |High performance lgear oil IS0-VG 220 lgear oil VG 220 DIN 51517-3 (CLP) ISO 6743-6 (CKS/CKT) Weenenday-ba:htaret sh 356 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Fluids and lubricants [Fluid/lubricant [Specifications Brand Product ‘Bearing lubricating grease Lubricating grease with |Wirtgen Group |Multi-purpose grease EP additives (lithium. saponified) [ISO 6743-9: L-XBCEB 2 DIN 51825: KP2K-25 ISU NUGI 2 [Transformer oil for electro- 'magnetic separator Silicone transformer oil |Wirtgen Group [Transformer oil DOW TEC 836 201 |ASTM D 4652-92 @ Tab. 5.40; Conveyor unit lubricant table EP additives (extreme-pressure additives) are added to lubri- ‘ants and improve their tribological characteristics, i.e. they prevent the fusing of two metallic materials that rub against each other. Crusher [Operating material (Specifications Brand Product (Crusher grease [Lubricating grease with |Wirtgen Group |Multipurpose Grease EP additives (lithium \saponified) 1SO 6743-9: LXBCEB 2 DIN 51825: KP2K-25 150 NUGI2 wo wD Tab. 5.41: Crusher lubricant table EP additives (extreme-pressure additives) are added to lubri- cants and improve their tribological characteristics, i.e, they prevent the fusing of two metallic materials that rub against each other. The lubricants for the rock chisel are specified in the manufac turer's documentation. 5.04.02 Diesel Fuels At low temperature, paraffin separations can cause obstruction in the fuel supply resulting in malfunctions. Below outside tem- peratures of 0 °C, use winter diesel fuel (up to-15 °C). In many cases, diesel fuel with additives with an application temperature of up to approx. -20 °C is offered. At outside terrperatures below 0 °C, the temperature properties of diesel fuel can be improved as a preventive measure by add- ing petroleum. A maximum of 20% can be added. When refuel- ling, the petroleum must be filled first so that it mixes with the diesel fuel. Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 357TABLES Fluids and lubricants [ww] KLEEMANN Breed Danger of engine damage ‘The addition of petroleum to diesel fuels (winter diesel fuel) al- ready adapted to low outside temperatures can result in engine damage. ‘+ Only add petroleum to summer diesel fuels. + Do not add any other flow improvers or benzene. Necessary properties of diesel fuel Property [Requirement Viscosity at 40 °C 2.0 - 4.5 mm?/s (eSt) Density at 15 °C [0.82 - 0.86 ko/dm? ‘Sulphur content (percent by [maximum 0.035 % weight) TTonitability (cetane num- Jat least 51 ber) Flash point 56 °C ‘Complies with standards [EN 590 ASTM D 975 Grade No. 1-D and J2-D Tab. 5.42: Properties of diesel fuel Observe and adhere to the specifications in the manufacturer's @ documentation. Requirements of diesel fuel for LRC engine Property [Requirement Viscosity at 40 °C 2.0 - 4.5 mm?/s (cSt) Density at 15°C [0.82 - 0.86 kg/dm? ‘Sulphur content (percent by |maximum 0.2 % weight) ‘Ignitability (cetane num-_|at least 49 ber) Flash point 56 °C ‘Complies with standards JEN 590 ASTM D 975 Grade No. 1-D and l2-D Tab. 5.43: Properties of diesel fuel If the sulphur content is between 0.2% and 0.4 %, the cil GG change intervals must be halved. Sulphur content greater than 0.4% is not permitted. Weenesday-oa:htaret Barrows printed 358 © Kleemann GmbH 2016TABLES [w]] KLEEMANN Separate documentation Observe and adhere to the details about oil change intervals in the manufacturer's documentation. 5.05 Separate documentation Apart from this instruction manual, further documents and in- formation are available on the plant. The listed documents are an integral element of the instruction manual as defined by EC Directive 2006/42/EC. 5.05.01 Documentation on the plant [Components [Document Piant ‘Spare parts catalogue [Electric diagram Brief instructions for driving [Brief instructions for loperation Tab. 5.44: Documents from KLEEMANN GmbH Safety manuals lLanguage [Document number [Bulgarian 'F20016714 [Chinese [2300372 Danish [F20015433 [German 'F20007548 [German US \F20011137 [English 'F20008844 English US \F20011138 Estonian \F20016711 [Finnish 'F20016706 French 'F20008845 lttalian 'F20011375 Hapanese (2343108 [Croatian [2307373 Latvian 'F20016712 Lithuanian) 'F20016713 Dutch 'F20010337 Norwegian 'F20011374 Polish 'F20011376 Portuguese 'F20016710 Romanian 'F20016715 Wednesday-¢2:htarc ‘roost printectts © Kleemann GmbH 2016 359TABLES Fuses [w]] KLEEMANN [Language [Document number Russian F20008847 ‘Serbian [F20013046 ‘Slovakian F20016708 [Spanish /F20008846 ‘Swedish /F20012128 (Czech [F20016501 [Turkish /F20016722 [Hungarian [F20016707 Tab. 5.45: Safety manuals from KLEEMANN GmbH Manufacturer's documentation [Assembly [Components [Manufacturer [Document Power supply unit/Engine |Diesel engine ‘Scania Instruction manual [Spare parts catalogue ‘Tools/Accessories Rock chisel (option) __ [McQuaid [Instruction manual Tab. 5.46: Manufacturer's documentation 5.05.02 Information material Information and material can be called up or downloaded under "Products" on the homepage of KLEEMANN GmbH: www.klee- mann.info. 5.06 Fuses Short code [Value _ [Number [Assignment (OFOo Za ax [Undervoltage monitoring OFO2 2a ax Voltmeter display at switch cabinet (oFos BSA [3x lin-series fuses for service socket outlet 400 V at switch cabinet ora aa ix Warning light and warning siren (OFOS 6A fax lin-series fuses for service socket outlet 230 V at switch cabinet OFO6 eA x Lighting (option) OFS eA ix Belt scale (option) OFOS 2a ix [Undervoltage monitoring OFZ, HOA [ix [24 V supply ater emergency switching off (OFo 100A [3x [Socket outlet 125 A (OFO7 eA ix Lighting (option) (OF OA [2x [Transformer 230 V Weerestayre2:htarc ttt printed 360 © Kleemann GmbH 2016[w]] KLEEMANN TABLES Fuses [Short code [Value [Number [Assignment 2FL 25a (x Tn-series fuse electromagnetic separator TFA 638A (3x Iin-series fuse for grizzly ‘oFL 35a (x Tin-series fuse for feeder trough (GF2 GOA [ix Tin-series fuse for drive system brake valve Tab. 5.47: Fuses in the switch cabinet short codes. When a fault occurs, this short code is displayed in wD Al electrical switching and fusing elements are identified by the operator panel OP3. Change fuses, see chap.4.06.06, Wednesttay-oa-htare sikowstiiny printed ‘© Kleemann GmbH 2016 361INSTALLATION AND REMOVAL, TRANSPORT Transport [w]] KLEEMANN 6 6.01 Wednesday: INSTALLATION AND REMOVAL, TRANS- PORT oa This chapter describes the installation, removal and transport tasks that have to carried out prior to initial operation or trans- Port of the plant. Furthermore, you will also find details here on Storage, chutdewn and return to aneration. During all activities, observe the information in your safety manual! Transport A A A Existing specifications UVV, DIN, VDI and country-specific spec ifications and regulations on transport must be observed. Danger due to unqualified personnel Removal and transport by unqualified and unauthorised person- nel can result in serious or fatal injuries. ‘+ Only assign personnel removal and transport tasks who are qualified and authorised according to the requirements in this instruction manual. rN Ba Danger! Heavy loads When loading by crane, the plant can slip away or tilt; there is, a risk of fatal injury. ‘+ When loading by crane, consultation with Kleemann GmbH Danger due to excess width or height Excess width or height can result in material damage and per- sonal injury, ‘= Remove all projecting plant components as described in "Re- moval of plant”. + Secure loose components and other components to be transported on the plant. + Read the safety manual. All transport work rot described in this chapter must only be carried out by personnel trained by KLEEMANN GmbH, or per- sonnel who have appropriate qualifications, e.g. transport com- pany. 362 an ihowstiiny printed © Kleemann GmbH 2016