BAL K038 2384672 00 en-GB Print

INSTRUCTION MANUAL
MOBICONE MCO11
K038
Series
15.04.2014
Date of issue
2384672_00_EN-GB
Order number
© Kleemann GmbH 2014

Issuer Kleemann GmbH
Manfred-Wörner-Straße 160
D-73037 Göppingen
Germany
Telephone: + 49 (0) 71 61 / 20 6 - 0
Website: www.kleemann.info
Document number BAL_K038_2384672_00_EN-GB
Translation of the original instruction manual
Date of first edition 01.04.2014
Revision date 01.04.2014
Copyright © Kleemann GmbH 2014
This documentation including all of its parts is protected by copyright. Any
use or modification beyond the strict restrictions of copyright law without
the consent of Kleemann GmbH is prohibited and may result in prosecu-
tion.
This applies in particular to duplications, translations, microfilming and
saving and processing work in electronic systems.
2 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

TABLE OF CONTENTS
TABLE OF CONTENTS
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.01 Foreword/Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.01.01 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.01.02 Changes/provisos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.01.03 Packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.01.04 Signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.01.05 Warning sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.01.06 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.01.07 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.01.08 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.02 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.02.01 Intended use, purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.02.02 Non-specified use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.02.03 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.03 Climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.04 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.04.01 Safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.04.02 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.04.03 Disposal of machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.04.04 Notes on the electrical/electronic components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.04.05 Danger areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.04.05.01 Safety distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.04.06 Fire fighting appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.05 Emissions and loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.05.01 Noise emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.05.02 Dust emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.05.03 Vibration emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.06 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.06.01 Sign diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.06.02 Signs/decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.06.03 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.06.03.01 Plant identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.07 Personnel - qualifications and duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.07.01 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.07.02 Available training courses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.07.03 Contact persons for operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.08 Revision statuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 3

TABLE OF CONTENTS
2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.01 Chassis/guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.01.01 Information and hazard signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.01.02 Chassis with beams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.01.03 Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.01.04 Lighting/warning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.01.05 Socket outlets on the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.01.06 Guard devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.01.07 Emergency stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.02 Control stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.02.01 Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.02.02 Operator panels/Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.02.03 Programmable logic controller PLC/OP3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.02.04 Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.02.05 Remote controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.02.06 Diesel and switch cabinet heating (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.03 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.04 Power supply unit/engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.04.01 Diesel engine/diesel generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.04.02 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.04.03 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.04.04 Air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.04.05 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.04.06 Flange coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.05 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.05.01 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.05.02 Hydraulic / lube oil supply for crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.05.03 Driving clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.05.04 Hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.05.05 Cone crusher hydraulic pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.05.06 Valve blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.06 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.06.01 24 V voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.06.02 Battery isolator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.06.03 Switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.06.04 Generators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.06.05 Electric motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.06.06 Socket outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.06.07 Switch cabinet over pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.06.08 External power supply (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

TABLE OF CONTENTS
2.07 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.08 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.08.01 Crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.08.02 Track drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.09 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.10 Conveyor unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.10.01 Belt conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.10.02 Chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.10.03 Magnetic remover (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.10.04 Metal detector (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.11 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.12 Water system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.12.01 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.12.02 Spraying nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.13 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.14 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.15 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.16 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.17 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.18 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.19 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.20 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.21 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.22 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.23 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.24 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.25 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.26 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.27 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.28 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.29 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.30 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.31 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.32 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.33 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.34 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.35 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.36 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.37 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.38 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

TABLE OF CONTENTS
2.39 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.40 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.41 Service packs/telemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.41.01 Service packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.41.02 Telemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.42 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.43 Feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.43.01 Feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.43.02 Cone crusher inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.43.03 Feeder trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.44 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.01 Measures before initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.02 Switching external power supply on and off (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.03 Putting the plant into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.04 Switching plant on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.04.01 Switching diesel generator on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.04.02 Switching plant components on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
3.04.03 Switching on plant after emergency switching off actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.05 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.06 Moving hopper supports up and down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.07 Operating the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.07.01 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.07.02 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.07.03 Shutting down the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.08 Refuelling the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.09 Operating water system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.10 Loading the plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.10.01 Suitable loading vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.10.02 Preparing the charged material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.10.03 Loading the feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.10.04 Loading the cone crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.11 Eliminating material congestion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.12 Checking/adjusting crushing gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.12.01 Checking the crushing gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.12.02 Setting the crushing gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.13 Clearing away waste tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.14 Winter operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.15 Help and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

TABLE OF CONTENTS
3.15.01 Starting the engine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.01 Chassis/guard devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.01.01 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.01.02 Checking warning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.01.03 Checking guard devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.01.04 Checking emergency-stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.01.04.01 Emergency-stop button and release cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.01.04.02 Emergency switching off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.02 Control stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.02.01 Checking switch cabinet protective housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.02.02 Carrying out lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.02.03 Checking remote controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.03 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.04 Power supply unit/engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.04.01 Servicing diesel generator power supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.04.02 Checking cyclone prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.04.03 Servicing air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.04.04 Cleaning the cooler fins.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.04.05 Changing engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.05 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.05.01 Servicing the plant's hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.05.01.01 Depressurising the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.05.01.02 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.05.02 Servicing the plant's hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.05.02.01 Checking hydraulic fill level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
4.05.02.02 Changing hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
4.05.02.03 Changing hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.05.03 Servicing hydraulic system of cone crusher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.05.03.01 Depressurising the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.05.03.02 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.05.04 Servicing hydraulic/lube oil tank of cone crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.05.04.01 Checking hydraulic/lube oil filling level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.05.04.02 Changing lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.05.04.03 Changing hydraulic oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.05.04.04 Changing hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.05.04.05 Changing lube oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.05.04.06 Checking/cleaning coarse strainer for lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.05.04.07 Cleaning filler neck coarse strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.06 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.06.01 General maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

TABLE OF CONTENTS
4.06.02 Servicing 24 V voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.06.02.01 Servicing diesel generator electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.06.02.02 Servicing starter batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.06.03 Servicing switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.06.03.01 Checking electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.06.03.02 Checking switch cabinet mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.06.04 Servicing electric motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.06.05 Servicing overpressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.06.06 Repairing electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.06.06.01 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
4.06.06.02 Motor protecting switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.06.06.03 Earth fault circuit interrupter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.06.06.04 ZEV motor protective system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.07 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.08 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.08.01 Servicing crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.08.01.01 Checking/tensioning crawler carrier chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.08.01.02 Checking fastenings for track rollers and base plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.08.02 Servicing track drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.08.02.01 Servicing planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.08.02.02 Checking components for leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.08.03 Repairing crawler running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.08.03.01 Opening/closing crawler carrier chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.08.03.02 Repairing chain link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.09 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.10 Conveyor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.10.01 Servicing belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.10.01.01 Checking conveyor belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.10.01.02 Servicing scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.10.01.03 Adjusting guide rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.10.01.04 Servicing angular gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
4.10.01.05 Lubricating plummer blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.10.02 Checking chutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.10.02.01 Checking rubber curtains and sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.10.03 Servicing magnetic remover (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.10.04 Servicing belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.10.04.01 Tensioning conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.10.04.02 Changing conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.10.04.03 Checking conveyor belt run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.10.04.04 Adjusting conveyor belt run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.11 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.12 Water system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.13 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

TABLE OF CONTENTS
4.14 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

4.15 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.16 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.17 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.18 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.19 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.20 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.21 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.22 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.23 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.24 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.25 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.26 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.27 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.28 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.29 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.30 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.31 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.32 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.33 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.34 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.35 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.36 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.37 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.38 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.39 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.40 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.41 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.42 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.43 Feeding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.43.01 Servicing feed hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.43.02 Servicing feeder trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.43.02.01 Servicing rubber mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.43.02.02 Checking vibration motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.43.02.03 Servicing wear lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4.43.03 Repairing feeder trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.43.03.01 Replacing vibration motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.43.03.02 Checking rocker width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.43.03.03 Adjusting rocker width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.44 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.44.01 Checking/tensioning V-belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

TABLE OF CONTENTS
4.44.02 Checking crusher mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

4.44.03 Check support and guide blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.44.04 Checking geared ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.44.05 Theoretical wear limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.44.06 Lubricating cone crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.44.07 Checking/measuring the wear lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.44.08 Changing crushing tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.44.08.01 Removing bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.44.08.02 Changing bowl liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.44.08.03 Removing mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.44.08.04 Changing mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.44.08.05 Installing mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.44.08.06 Installing bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.44.09 Changing wear lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.44.09.01 Replacing counterweight wear element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.44.09.02 Replacing wear element for lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.44.09.03 Changing wear elements for backgear shaft and supporting arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.44.10 Changing V-belt pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4.45 Cleaning the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.45.01 Cleaning the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.45.02 Cleaning with high-pressure cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.46 Performing welding work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
5 TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.01 Technical details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.01.01 Complete plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.01.01.01 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.01.01.02 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.01.01.03 Driving operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5.01.01.04 Charged material and size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5.01.01.05 Feed and crushing capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.01.01.06 Ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.01.01.07 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.01.02 Power supply unit/engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.01.03 Hydraulic oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.01.04 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.01.05 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.01.06 Conveyor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.01.07 Water system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.01.08 Feeding unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5.01.09 Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
5.02 Maintenance schedule/maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.03 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

TABLE OF CONTENTS
5.04 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

5.04.01 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
5.04.02 Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
5.05 Assembly aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
5.06 Separate documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
5.06.01 Documentation on the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
5.06.02 Information material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
5.07 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6 INSTALLATION AND REMOVAL, TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

6.01 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
6.01.01 Approval of special transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
6.01.02 Transport details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
6.01.02.01 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
6.01.02.02 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
6.01.03 Loading and unloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
6.02 Plant installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
6.02.01 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
6.02.02 Swivelling and moving down hopper supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
6.02.03 Moving out warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
6.02.04 Earthing the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
6.02.05 Mounting the platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
6.02.06 Folding out crusher discharge conveyor mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
6.02.07 Crusher inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
6.02.07.01 Installing crusher inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
6.02.07.02 Installing cone crusher fill level monitor (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
6.02.08 Installing feed hopper fill level monitor (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
6.02.09 Hopper extension (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6.02.10 Moving feeding conveyor forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.02.11 Installing magnetic remover (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.02.12 Installing lighting (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
6.02.13 Transport locking devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
6.02.14 Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
6.02.14.01 Test run without material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
6.02.14.02 Test run in manual mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
6.03 Removal of plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
6.03.01 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
6.03.02 Moving in warning light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
6.03.03 Disassembling lighting (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
6.03.04 Crusher inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
6.03.04.01 Disassembling cone crusher fill level monitor (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

TABLE OF CONTENTS
6.03.04.02 Disassembling crusher inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

6.03.05 Hopper extension (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
6.03.06 Moving feeding conveyor back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
6.03.07 Folding in crusher discharge conveyor mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
6.03.08 Transport locking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
6.03.09 Removing the platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
6.03.10 Swivelling and moving up hopper supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6.03.11 Removing earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
6.03.12 Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
6.04 Storage, shutdown, disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6.04.01 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6.04.02 Shutdown, restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6.04.03 Disposal of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

GENERAL
Foreword/Introduction
1 GENERAL
During all activities, observe the information in your safety manual!
1.01 Foreword/Introduction
1.01.01 Introduction
This KLEEMANN plant is a product from the wide product range of
tracked KLEEMANN crushing and screening plants.
The vast experience of KLEEMANN combined with the latest production
and test procedures guarantees the high dependability of your plant.
Instruction manual and safety This instruction manual is only valid in conjunction with the safety manual
manual and the manufacturer's documentation included in the delivery. Please
note:
• This instruction manual was prepared for operating, maintenance
and service personnel at the place of use.
• This instruction manual should put you in a position to operate the
plant safely and to utilise the permissible application options it pro-
vides.
• It also provides you with information on the function of important units
or components.
• Certain terms and concepts are used in the instruction manual to do
this. To avoid misunderstandings, you should always use these
terms.
• Only qualified, instructed and trained personnel must work on this
plant.
• The instruction manual, safety manual, manufacturer's documenta-
tion and the regulations and specifications applicable at the place of
use must be observed (for example, accident prevention regula-
tions).
• The instruction manual, safety manual and manufacturer's documen-
tation are elements of the product. Ensure that they are available for
viewing at all times during the entire service life of the plant.
• Pass on the instruction manual, safety manual and manufacturer's
documentation to new owners of the plant and draw their attention to
the importance of the documentation.
Use of this instruction makes it easier for you:
• to become familiar with the plant.
• to avoid faults through incorrect operation.

GENERAL
Observance of the instruction manual:

• helps avoid dangers.
• increases dependability at the place of use.
• increases the service life of the plant.
• reduces repair costs and downtimes.
Always place this instruction manual within reach in the plant's switch
cabinet or in the container provided for this purpose.
If you should receive further information from us on your plant (for exam-
ple, additional technical information), these instructions must also be ob-
served and attached to the instruction manual.
If you do not understand the instruction manual or individual chapters,
please ask us before starting the corresponding activity.
KLEEMANN GmbH shall not be liable for safe operation of the system:
• if plant handling does not comply with specified use.
Warranty claims shall become invalid in the event of:
• operating errors.
• inadequate maintenance.
• incorrect fluids and lubricants.
• applications not named in the instruction manual.
Warranty and liability provisions of the general terms and conditions of
business of KLEEMANN GmbH are not extended by the above informa-
tion.
In the course of technical development, we reserve the right to make
changes without prior announcement. This instruction manual also de-
scribes optional equipment that may not be fitted on your plant. Specifi-
cations and illustrations in this instruction manual must not be
reproduced, disseminated or used for competition purposes.
Translations are carried out in good faith. We shall not be liable for trans-
lation errors and their consequences, even if we translated the text our-
selves or assigned the task to a third party.
The basis of all liability and warranty claims is, and shall remain, the Ger-
man text.
All rights under copyright laws are explicitly reserved. We wish you every
success with your KLEEMANN plant.
1.01.02 Changes/provisos
We make every effort to ensure that this instruction manual is correct and
up to date. To maintain our technological head start, it may be necessary
to make changes to the product and its operation without prior announce-
ment. We shall not be liable for any faults, failures and resultant damage.
Please also observe any additional information that may be included in
the delivery.

GENERAL
1.01.03 Packaging and storage

The components were carefully packed to guarantee adequate protec-
tion during shipment. When you receive the goods, the packaging and
contents should be checked for damage.
If damage is discovered, the components must not be put into operation.
Damaged cables and plug connectors are also a safety risk and must not
be used. In this case, please contact your local KLEEMANN branch.
If components are not put into operation immediately after unpacking,
they must be protected against dampness and contamination.
1.01.04 Signs and symbols

The signs and symbols are designed to help you use the instruction man-
ual quickly and reliably.
In this instruction manual, potential dangers are indicated by danger,
warning, caution and important signs. They are identified by a colour and
a signal word corresponding to the seriousness of the danger.
Hazard warning
DANGER!
Sources of danger are named here.
The possible consequences are also named here.
And measures for avoiding the danger.
The hazard warning uses the signal word DANGER to indicate an immi-
nent danger. Nonobservance can result in serious or fatal injury.
Warning sign
WARNING!
The warning sign uses the signal word WARNING to indicate a possible
threatening danger. Nonobservance can result in serious or fatal injury.
Caution sign
CAUTION!

GENERAL
The caution sign uses the signal word CAUTION to indicate a possible
dangerous situation. Nonobservance can result in minor injury and dam-
age to property.
Important sign
NOTICE
The important sign uses the signal word NOTICE to indicate a possible
dangerous situation. Nonobservance can result in damage to property.
Information
A capital "I" for information at the start of every main chapter provides you
with brief information on the content of the chapter. You will also be in-
formed at relevant points about the most effective or practical usage of
the plant and this instruction manual.
Activity steps
The defined sequence of activity steps facilitates correct and safe use of
the plant.
 Result
The result of a sequence of activity steps is described here.
(1) Position number of assembly graphic
Position numbers in assembly graphics are marked in the text by round
brackets ( ).
[1] Position number of single component graphic
Position numbers in single component graphics are marked in the text by
square brackets [ ].
Material flow direction
For orientation purposes, the arrow indicates the material flow direction
of the plant or a component.
(option) Optional equipment

Optional equipment is marked with the word "Option". All machines and
components that are not marked with "Option" are part of the standard
equipment of the plant.
1.01.05 Warning sign

Warning signs provide a graphic illustration of a danger source. The
warning signs in the complete technical documentation correspond to the
harmonised standard EN 61310 Part 2: Safety of machinery - Indication,
marking and actuation and EC Directive 92/58/EEC - Minimum Require-
ments for the Provision of Safety and/or Health Signs at Work (Ordinance
on Industrial Safety and Health).
They match the illustrations on the signs attached to the relevant danger
areas on the plant.

GENERAL
Warning of a general danger

The warning sign appears before activities where there are several pos-
sible causes of dangerous situations.
Warning of dangerous voltage

This warning sign appears before activities where there is a danger of
electric shock with possible fatal consequences.
Warning! Suspended load

This warning sign appears before activities where there is a danger
through falling objects with possible fatal consequences.
Warning of rotating parts

through rotating parts with possible fatal consequences.
Warning! Risk of stumbling

stumbling with possible fatal consequences.
Warning! Risk of crushing injuries

crushing parts of the body with possible fatal consequences.
Warning! Risk of crushing injuries to hands

The warning sign appears before activities where there is a risk of crush-
ing your hands.
Warning! Risk of crushing injuries to feet

The warning sign appears before activities where there is a risk of crush-
ing your feet.
Warning! Hot surface

The warning sign appears before activities where there is a danger
through hot surfaces.
Warning! Hot fluids

through hot fluids.

GENERAL
Warning of batteries
through escaping explosive gas and caustic fluids.
Warning of flammable materials

through flammable materials with possible fatal consequences.
Warning of potentially explosive materials

through potentially explosive materials with possible fatal consequences.
Warning of toxic substances

through toxic substances with possible fatal consequences.
1.01.06 Documentation
A paper copy of this instruction manual must be available to authorised
operating and maintenance personnal at all times.
This instruction manual must always be regarded as an unit together with
the operating instructions to be prepared by the operating company.
This instruction manual and the operating instructions of the company
must be handed over to operating and maintenance personnal.
If the plant changes owner, the completion documentation must also be
handed over.
Before putting the plant into operation for the first time and before starting
any kind of work on the plant, you must read through this instruction man-
ual carefully and understand it.
This instruction manual serves to familiarise you with the basic tasks and
activities on the plant.
This instruction manual contains important information on how to use the
plant safely and correctly.
Your observance helps:
• to avoid dangers.
• to reduce repair costs and downtimes.
• to increase the dependability, availability and service life of the plant.
Irrespective of this instruction manual, the laws, ordinances, directives
and standards applicable in the respective country of use and place of
application must be observed.
This instruction manual describes how to use the plant. The instruction
manual is only valid in conjunction with the safety manual and, where ap-

GENERAL
plicable, the transport instructions from KLEEMANN. The corresponding

safety manuals and transport instructions are specified in chap. 5.06.01.
A safety manual and, where applicable, transport instructions must be
accessible to plant operating and maintenance personnel at all times.
1.01.07 Declaration of Conformity

The Declaration of Conformity is part of the separately provided docu-
mentation from KLEEMANN GmbH and will be handed over to you upon
delivery of the plant.
The CE marking for the plant is an element of the identification plate.
The pictograph identifies the conformity of the plant to valid EC direc-
tives, which prescribe the CE marking.

GENERAL
1.01.08 Warranty and liability

The general terms and conditions of business of KLEEMANN GmbH
shall apply. These are available to the buyer or operating company upon
conclusion of agreement at the latest.
Refer to the general terms and conditions of business for warranty and
material defect claims.

GENERAL
Use
1.02 Use
1.02.01 Intended use, purpose

The plant is state-of-the-art equipment and complies with the safety reg-
ulations applicable at the time of marketing and applicable to its intended
use.
Design measures cannot avoid foreseeable misuse or residual dangers
without restricting the specified range of functions.
The plant is built and designed:
• for processing mineral materials as specified in chap. 5.01.01.04.
• for feeding with the help of an upstream plant or belt conveyor, pro-
vided it has the required discharge height and is adapted to the plant
size and charged material.
• for feeding with the help of a digger or wheel loader with correspond-
ing hopper extension (option).
• for crushing material with a compressive resistance as specified in
chap. 5.01.01.04.
• for discharging different grain sizes via a belt conveyor onto waste
tips or downstream plants for further processing.
• for clearing waste tips with a wheel loader, the size of which matches
the plant power.
The plant is designed exclusively for commercial operation within en-
closed areas such as quarries.
The plant must be operated by instructed operators in accordance with
the specifications in the technical documentation.
All types of non-specified use, or all activities on the plant not described
in this instruction manual, amount to misuse not covered by the statutory
limits of liability of the manufacturer.
1.02.02 Non-specified use

In the case of non-specified use, or misuse of the plant, the warranty ob-
ligation of the manufacturer shall become null and void and responsibility
shall be borne solely by the operating company.

GENERAL
Use
Non-specified use includes:

• Climbing on the plant for purposes other than maintenance and re-
pair.
• Operation with disassembled, defective or bypassed safety devices.
• Operation following incorrectly performed or neglected maintenance
and repair work.
• Operation following failure to observe the maintenance intervals.
• Operation following neglected measurements and inspections for
early detection of damage or wear.
• Loading with digger or wheel loader without installed hopper exten-
sion.
• Loading with lorries, dumpers or skip lorries.
• Clearing waste tips with an unsuitable device that leads to damage to
the plant and belt conveyors.
• Operation in unsuitable climatic conditions.
• Operation in a position other than horizontal.
• Operation following independent, unauthorised constructional modi-
fications to the plant.
The following are unsuitable for crushing in the crusher:
• Material that exceeds the specified compressive resistance and di-
mensions.
Material that is too large and hard results in material congestions,
considerable wear and damage to the crusher.
• Unbreakable materials such as scrap metal.
Even sporadic feeding of scrap metal, in particular hardened and sol-
id steel parts, leads to damage and serious wear to the crusher, belt
conveyors and other moving parts.
• All other materials not named in the section on intended use, such as
wood, coal, scraps, rubbish, boulders of ore and other non-mineral
materials.
The following must not be fed into the crusher:
• Hazardous and explosive substances.
• Chemicals.
• Solvents, oils and greases.
• Asbestos-containing scraps, e.g. eternit.
• Pressurised vessels.
1.02.03 Residual risks

The residual risks were analysed and evaluated before the start of the
design and planning phase of the plant.
The documentation makes reference to existing residual risks.
Existing residual risks can be avoided through the practical implementa-
tion and observance of the following specifications:

GENERAL
Climatic conditions
• The special warning signs on the plant.

• The general safety instructions in this instruction manual and in the
safety manual.
• The special warning information in this instruction manual.
• The instructions in the safety manual.
• The operating instructions of the operating company.
Danger to life/risk of injury to persons can exist at the plant through, e.g.:
• Misuse.
• Incorrect handling.
• Transport.
• Missing safety devices.
• Defective or damaged components.
• Handling/operation by personnel without training or instruction.
The plant can cause dangers to the environment through, e.g.:
• Fluids and lubricants, etc.
• Noise and dust emission.
Damage to the plant is possible through, e.g.:
• Nonobservance of operating and maintenance specifications.
• Unsuitable fluids and lubricants.
Damage to further material assets in the operating area of the plant is
possible through, e.g.:
Limitations to the performance and range of functions of the plant can re-
sult due to, e.g.:
• Incorrect maintenance or repair.
• Unsuitable fluids and lubricants.
1.03 Climatic conditions

The minimum and maximum permissible ambient temperature of the
plant is specified in chap. 5.01.01.06.
Low ambient temperature In cold weather, the starting behaviour and operation of the diesel engine
depend on the following:
• Fuels used.
• Engine oil viscosity.
• State of the starter batteries.
Suggestions for operation in cold weather:

GENERAL
Climatic conditions
• After start-up, allow the diesel engine to run until an operating

temperature of at least 80 °C has been reached. Reaching the cor-
rect service temperature prevents the starting and exhaust valves
from jamming.
• When the diesel engine is shut down, the cooling and lubrication sys-
tems are not immediately cold. This means that the diesel engine can
be shut down for a few hours and then started again without any
problems.
• Below 0 °C, use winter diesel with sufficient flowability.
• Fill with the correct lubricant before the start of the cold season.
• Check all rubber parts (hoses, V-belts, etc.) once a week.
• Check all electric cables and connections for chafing and damage to
the insulation.
• Charge the starter batteries and keep them warm.
• Fill the fuel tank at the end of every work shift.
In special operating conditions, it may be necessary to use other suitable
fluids and lubricants.
With the Arctic Package special equipment, plant operation up to -25 °C
is also possible. Because of the use of low-temperature lubricants, how-
ever, operation is limited to a maximum temperature of +30 °C.
WARNING!
Risk of injury and property damage
The use of alcohol or other starting aid fluids involves a risk of explosion
and injury.
• Never use aerosol starting aids, e.g. aether.
High ambient temperature, With increasing altitude or ambient temperature, the maximum output of
high altitude the diesel engine, the exhaust gas quality, the temperature level and, in
extreme cases, the starting behaviour, are impaired.
If the plant is operated at an altitude above 1000 m or at an ambient tem-
perature of above 30 °C, a reduction in the injected fuel volume is neces-
sary.
Heavy rain and storms During heavy rainfall, rain water can enter the air intake of the running
diesel engine. Rain is then drawn into the combustion chambers where
the water impact can cause engine damage.
Suggestions for operation during heavy rainfall and storms:
• If heavy rain or a storm is expected, switch off the plant and the diesel
generator.
• If opened, close the power supply unit protective housing.
• Close the switch cabinet.
• Keep away from the plant until the storm has passed.

GENERAL
Safety information
DANGER!
Dangerous voltage
Operation of the plant during storms can attract lightning and result in se-
rious or fatal injury and damage to property.
• Switch off the plant and move away from the plant until the storm has
passed.
• Check the electrical system if it is struck by lightning.
Strong wind Basically, the plant can be operated irrespective of the wind force. How-
ever, strong wind can affect dust creation in the area around the plant.
Influence of strong wind:
• Strong wind impairs the perfect formation of the dust-binding atom-
ised spray in the spray system (option) and thus also contributes to
the increased spread of dust.
• Strong wind can influence the grain of the discharged material by
blowing away the fines.
• An unfavourable wind direction can result in increased clogging of the
cooler fins and the filter for the power supply unit.
Dust formation can be reduced by the additional use of belt covers and
ejector chutes (options) but not completely eliminated.
1.04 Safety information

Due to the intended use of the plant, neither foreseeable misuse nor re-
sidual dangers can be avoided without restricting the specified range of
functions. This situation presents a risk to life and limb of operating, main-
tenance and service personnel which, however, can be minimised if the
basic safety instructions are observed.
1.04.01 Safety manual

Read through the safety manual provided separately by KLEEMANN
GmbH. It describes the general hazards involved in operation, mainte-
nance and repair of the plant and how to avoid them. The safety manual
is an element of the instruction manual.
1.04.02 Environmental protection

Packaging material, cleaning agents, used or residual fluids and lubri-
cants as well as removed wear parts, such as conveyor belt, baffle plates,
impact toggles, crushing jaws, wear lining, rubber seals, etc. must be
brought to a recycling centre in accordance with locally applicable envi-
ronmental specifications.

GENERAL
Safety information
1.04.03 Disposal of machine

Nature conservation is one of the most urgent priorities. Correct disposal
prevents negative effects on humans and the environment and permits
reuse of valuable raw materials.
Fluids and lubricants
Dispose of fluids and lubricants according to the relevant specifications
and the respective national regulations.
Materials (metals, plastics)
Correct disposal of materials means that they are unmixed. Remove ad-
hering impurities from the materials.
Dispose of materials according to the respective national regulations.
Electrical system/electronics
The electrical/electronic components are not subject to the WEEE Direc-
tive 2002/96/EC and corresponding national laws (in Germany, e.g. Ele-
ktroG = Electrical and Electronic Equipment Act).
Deliver the electrical/electronic components directly to a specialised re-
cycling company.
1.04.04 Notes on the electrical/electronic components

Please note the following safety instructions for optionally available elec-
trical/electronic devices:
• Check the goods immediately upon receipt for damage or defective
parts.
• Do not put defective devices into operation.
• Damaged cables and plug connectors are a safety risk and must not
be used.
• Contact your local KLEEMANN branch, who will supply a replace-
ment immediately.
Installing
Prior to assembly and operation of the devices, carefully read through the
entire instruction manual. If you have any questions, please contact your
local KLEEMANN branch. During assembly of the devices, only use the
original KLEEMANN cables. The connectors must not be removed from
the cables as they are protected against dampness and opening would
destroy this protection. Ensure that the securing screws are firmly fitted
at the plug connectors. Further assembly instructions for the devices and
sensors are available in the separate data sheets or instruction manuals.
If the above-described points are not observed, KLEEMANN GmbH can-
not provide warranty for the electrical/electronic devices.
Safety precautions
The safety precautions recommended here basically correspond to the
guidelines for installation and commissioning of electrical systems. They

GENERAL
Safety information
can be applied to all applications in conjunction with KLEEMANN devic-

es.
Wiring
The wiring must be installed in accordance with the specifications in this
instruction manual. All feeds and connecting terminals must be dimen-
sioned for the relevant strength of current. Furthermore, all connections
must be made according to the valid VDE specifications in Germany or
the respective national specifications.
Interference resistance
The devices are designed for industrial use and tested accordingly. In
spite of this, the microprocessor technology makes some demands on
the installation. We would therefore like to draw your attention to the fol-
lowing installation features which, if not observed, could result in subse-
quent malfunctions:
• Ensure the terminals have the correct polarity.
• Do not exceed or undershoot the specified supply voltage range.
• Ensure that the electrical connections between the device housing
and components and chassis of the plant are correct to guarantee
trouble-free operation.
• Only connect shielded cables on one side to earth (device side).
• Never supply other devices directly from the connecting terminals of
the supply voltage.
• Never use free terminals as a connection for other terminals or devic-
es.
Fuses
The devices are equipped with fuses to protect against short circuits. The
supply voltages specified in the technical details must not be exceeded.
Configuration
The devices can also be configured by the user. Any reconfiguration
made by the user must always correspond to the actual situation of the
plant.
Potentially explosive areas
The devices are not designed for use in potentially explosive areas.
Troubleshooting
Before starting troubleshooting, ensure that all supply voltage to the de-
vice is interrupted. Defective devices should be examined in an area
properly equipped for test purposes. Any attempt to eliminate malfunc-
tions on a device that is still installed could be dangerous to operating
personnel and the plant. Before removing or replacing sensors fitted on
the device, ensure that all supply voltage is interrupted.
If you have any questions on operation and assembly, please contact
your local KLEEMANN branch.
If the above-listed precautionary measures are not observed, this can re-
sult in failure of the device or the plant. Damage resulting from nonobser-

GENERAL
Safety information
vance of the above-listed precautionary measures shall not be covered

by the manufacturer's warranty.
1.04.05 Danger areas
2 2
Fig. 1.1: Danger area

1 Danger area of the plant
2 Danger area of feeding and loading vehicles
During automatic mode and while the plant is moving, persons must stay
clear of the danger area of the plant and the feeding and loading vehicles.
In the following situations, authorised personnel must only enter the dan-
ger area when the plant is stationary and secured:
• For maintenance, repair and service work.
• During installation, removal and conversion work.
• During ongoing transport work.

GENERAL
Emissions and loads
1.04.05.01 Safety distance
1 2
3
Fig. 1.2: Safety distance between work and traffic area

1 Traffic area
2 Safety distance
3 Work area
If the plant is operated directly beside public roads, e.g. during road con-
struction work, the safety distance to the traffic area must be observed.
The distance between the work area and traffic area must comply with
national specifications.
1.04.06 Fire fighting appliance

For fire fighting at the plant, at least one fire extinguisher for fire classes
A, B and C and a sufficient quantity of filling compound must be provided.
Observe country-specific specifications.
The serviceability of the fire extinguisher must be checked at least once
a year by a specialist.
Make sure that operating, maintenance and repair personnel are familiar
with the handling of the fire extinguisher. The plant owner is responsible
for this.
1.05 Emissions and loads

No modifications must be made to the plant that result in increased noise,
dust and vibration emissions.

GENERAL
Emissions and loads
• Read and observe the safety manual.

• Always wear your personal hearing protection and a breathing mask
when required.
• Ensure that all devices for reducing noise and dust emissions are in-
stalled and operable.
• Do not make any modifications to the plant.
1.05.01 Noise emission

Sound power level
The sound power level of the plant is usually surpassed during crusher
operation by the process noise. The sound power level is specified in
chap. 5.01.01.07.
Emission sound pressure level
In automatic mode, the plant runs fully automatically without operating
personnel. For this reason, there is no directly assigned workplace, so
that the emission sound pressure level is not directly relevant. The emis-
sion sound pressure level is specified in chap. 5.01.01.07.
WARNING!
Danger of hearing damage
When working directly beside the plant or on its platforms, the permissi-
ble daily noise exposure level (LEX,8h) of 80 dB (A) is exceeded.
• Always wear your personal hearing protection when required.
WARNING!
Danger due to communication disturbance
Noise development at the plant can interfere with communication be-
tween personnel and result in dangerous situations.
• Agree on unambiguous hand signals to avoid misunderstanding. Use
radiotelephony where possible.
• Avoid the danger area during operation, maintenance, installation,
removal and transport of the plant.
1.05.02 Dust emission
WARNING!
Risk of health damage
The inhalation of dust can cause serious illnesses.
• Wear a breathing mask.
For design and process-related reasons, the creation of dust during plant
operation cannot be completely prevented.

GENERAL
Signs
However, observance of a few measures permits minimisation of the dust

emissions and the resulting danger:
• Always switch on the spray system during operation (optional equip-
ment).
• Align the spray nozzles correctly to ensure effectiveness.
• Always keep a sufficient supply of water ready. Depending on the
number of spray nozzles used, between 5-10 m3 per shift.
• Ensure that the spray nozzles, supply lines and other water system
components are in perfect condition.
• Use belt covers and ejector chutes (optional equipment).
• Replace defective or worn dust seals.
Further information on dust development, avoidance and the spray sys-
tem is available in chap. 2.12 and chap. 1.03.
1.05.03 Vibration emission

In automatic mode, the plant runs fully automatically without operating
personnel. For this reason, there is no directly assigned workplace, which
makes the vibration emission pressure level irrelevant.
During its operation, however, the plant is subject to stress from vibra-
tions. Personnel authorised to enter the platforms only for maintenance
and repair work are subject to stress through vibration.
However, observance of a few measures permits minimisation of the vi-
bration emissions and the resulting danger:
• Do not remain on the platforms longer than necessary when perform-
ing maintenance and repair work.
• Do not walk on the vibratory screens, feeder trough and extractor
channels until they have come to a complete standstill.
1.06 Signs
1.06.01 Sign diagram

The sign diagram is in the spare parts catalogue.
1.06.02 Signs/decals
This section informs you about the special function of the signs. The haz-
ard warnings are described in the safety instructions.
Welding work
Before carrying out welding work on the plant, note the specifications in
the instruction manual.

GENERAL
Signs
Lifting point
When lifting machines and components, always used the identified lifting
points.
F20010031
Lashing point
When lashing the plant of individual machines and components, always
used the identified lashing points.
F20010035
Extending and retracting feeding conveyor

Extending and retracting feeding conveyor hydraulically.
1.06.03 Identification plates

The entire identification documents the certification and must not be
modified or made unrecognisable.
For the transport weight of the plant and the machines and components
to be transported individually, please refer to chap. 6.01.02.02.
1.06.03.01 Plant identification plate
Kleemann GmbH . Manfred-Wörner-Straße 160 . D-73037 Göppingen . Germany

Bezeichnung
Designation
Baureihe / Typ
Series / Type
Seriennummer
Serial number
Baujahr
Year of construction
Verbaut in ...
Installed in ...
Betriebsgewicht
Operating mass
Transportgewicht
Transport mass
Siehe Betriebsanleitung / See Instruction Manual
F20009223
Fig. 1.3: Plant identification plate

GENERAL
Personnel - qualifications and duties
1 Identification plate
Enter the data of the identification plate in the following table:
Designation Details
1. Series / model
2. Serial number
3. Year of manufacture
4. Performance data kW / kVA / Hz
5. Operating weight
Tab. 1.1: Identification plate details
1.07 Personnel - qualifications and duties

All activities at the plant must only be carried out by authorised person-
nel.
The authorised personnel must:
• have reached the age of 18.
• be trained in first aid and be able to administer it.
• have read and understood the safety manual.
• be familiar with and know how to apply the accident prevent regula-
tions and safety instructions for the plant.
• be trained and instructed on how to conduct themselves in the event
of a fault.
• have the physical and mental ability to perform the tasks and activi-
ties at the plant for which they are responsible.
• be trained and instructed in the tasks and activities at the plant in their
area of responsibility.
• have understood and be able to practically implement the technical
documentation on the tasks and activities at the plant for which they
are responsible.
Read the following before initial operation of the plant:
• the instruction manual.
• the safety manual.
The plant can only be operated and moved by persons who, in ad-
dition:
• have received instruction in operation and moving the plant.
• have provided the operating company with proof of their ability to per-
form the work.
• can be expected to reliably carry out the tasks assigned to them.
They have to be appointed by the plant's owner to operate and move the
plant.

GENERAL
Observe the following information:

• Familiarise yourself with the plant's equipment.
• Move the plant only after making yourself fully familiar with the oper-
ating and control elements as well as the method of functioning.
• Familiarise yourself with your working area.
• Use the plant only for its intended purpose.
• Always use suitable hoisting gear and lifting accessories for transpor-
tation and installation of heavy components.
• Always wear your protective equipment, such as safety shoes, pro-
tective helmet and hearing protection.
• If deficiencies are determined at the safety devices, inform the plant
owner immediately.
• If other deficiencies are determined that impair safe operation of the
plant, inform the plant owner immediately.
• If defects are found that endanger personnel, shut down plant oper-
ation immediately.
• If unauthorised conversions or changes to the plant are determined
that impair safe operation of the plant, inform the plant owner imme-
diately.
• Observe the following elements attached to the plant
– Safety signs.
– Health protection signs.
– Safety information.
• Read the safety specifications and information additionally prepared
by the plant owner for special cases.
• Check the completeness and legibility of the
– safety signs.
– health protection signs.
– safety information (plates, decals, pictographs).
• Before starting work, inform yourself about
– first aid.
– rescue options (emergency doctor, fire brigade, helicopter).
• Ensure that a first-aid box with standard specified contents is availa-
ble.
Banksman A banksman is always required when the driver has an incomplete view
of the movement or transport route.
Independent guiding of plants is only possible by persons who, in addi-
tion:
• have receive training in how to guide the plant.
• can provide verification of successful participation in the training
course.
• have provided the plant's owner with proof of their ability to perform
the work.
• can be expected to reliably carry out the tasks assigned to them.

GENERAL
They have to be appointed by the plant's owner to function as a banks-

man for the plant.
To avoid misunderstandings, unambiguous hand signals should be used,
e.g. according to the German Employer's Liability Insurance Association
specification "Safety and health signs at the workplace" (BGV A 8).
• Make yourself familiar with the dimensions of the plant and the trans-
port vehicle.
• When guiding the plant or vehicles, always wear a warning waistcoat.
• During movement of the plant, guiding can be by means of hand sig-
nals; when loading the plant with a crane, use radiotelephony where
possible.
• The meaning of the hand signals between driver and banksman must
be clarified beyond doubt before starting.
Service and maintenance Service, maintenance and repair personnel are responsible for:
personnel • ensuring safety and hazard warnings are in a legible condition.
• protecting the plant against unauthorised use.

• ensuring that maintenance and repair work is co-ordinated with the
plant owner.
• ensuring that the plant is only operated when fully functional and in-
herently safe.
• ensuring that service, repair and maintenance tasks are carried out
safely and correctly.
1.07.01 Protective equipment

All elements of the protective equipment must be worn during all activities
at the plant described in this instruction manual:
• protective helmet.
• safety shoes.
• protective gloves.
• reflective clothing.
Furthermore, in certain working conditions the following safety equip-
ment must also be worn:
• hearing protection.
• safety goggles.
• breathing mask.
1.07.02 Available training courses

To provide operating, maintenance and service personnel with appropri-
ate qualifications, KLEEMANN GmbH offers a series of training courses
that form the basis of optimum and safe use of the plants.
The training courses can take place at KLEEMANN GmbH or directly at
the operating company.

GENERAL
Revision statuses
• Basic principles of crushing and screening technology.

• Design and method of operation of the plants.
• Basic principles of plant operation.
• Maintenance and repair.
• Basic principles of electrical systems.
• Basic principles of hydraulics.
1.07.03 Contact persons for operation and maintenance

Contact persons for operation, maintenance and service are listed under
"Customer service" on the homepage of KLEEMANN GmbH: www.klee-
mann.info
1.08 Revision statuses

Changes to instruction manual K038 MCO11:
Date Revision status Change Valid from serial no.:

01.04.2014 2379102_00 • Regeneration K038-0228

DESCRIPTION
Revision statuses
2 DESCRIPTION
This chapter contains a description of the functions of the plant and the
assemblies.
Position numbers in assembly graphics are marked in the text by round
brackets ( ).
Position numbers of single component graphics are marked in the text by
square brackets [ ].
Standard and optional equipment
This instruction manual describes all standard and optional equipment of
the plant. Optional equipment is identified by the word "Option". All ma-
chines and components that are not marked with "Option" are part of the
standard equipment of the plant.
1 2 3 4 5 6
10 9 8 7
Fig. 2.1: Select plant overview

(1) Feed hopper
(2) Magnetic remover (option)
(3) Feeding conveyor
(4) Cone crusher
(5) Power supply unit
(6) Crusher discharge conveyor
(7) Running gear
(8) Crusher drive
(9) Chassis
(10) Feeder trough

DESCRIPTION
Chassis/guard devices
Material is loaded into the feed hopper (1) by a digger, wheel loader or
an upstream plant. The feeder trough (10) conveys the material on to the
feeding conveyor (3).
The magnetic remover (2) draws ferrous elements from the material.
The cone crusher (4) crushes the depending on the setting of the crush-
ing gap to a final grain size with oversized product share and passes it on
to the crusher discharge conveyor (6).
The crusher discharge conveyor (6) discharges the material either to a
waste tip or transfers it to a downstream plant.
10 4
6
Fig. 2.2: Flow chart

(1) Feed hopper
(4) Cone crusher
(10) Feeder trough
The flow chart demonstrates the material flow within the plant. The grain
sizes produced depend on the charged material, set gap width of the
crusher and other factors.
2.01 Chassis/guard devices
2.01.01 Information and hazard signs

The signs (hazard, prohibition, mandatory and information signs) must
be attached to the plant and be easily legible. Signs fitted directly on the
plant must be observed.
An overview of the signs is provided in the spare parts catalogue.

DESCRIPTION
The information sign are described in chap. 1.06.02. The hazard, prohi-
bition and mandatory signs are described in the safety instructions.
2.01.02 Chassis with beams
1 5
Fig. 2.3: Chassis with beams

(1) Chassis at discharge side
[2] Mounting for magnetic remover
(3) Mounting for feed hopper
(4) Chassis at feeding side
(5) Chassis beam
(6) Track drive
The chassis has a modular structure and consists of bolted-on or welded
sectional steel. The chassis beams are bolted on and welded to the chas-
sis.
At the chassis, the mountings, suspension and supports of the individual
machines and components are fastened mechanically.

DESCRIPTION
2.01.03 Platforms
3
6
Fig. 2.4: Platforms and ladders

[1] Ladder
[2] Platform for cone crusher belt drive
[3] Steps to the platform for hydraulics, power supply unit and cone
crusher
[4] Platform for hydraulics, crusher and power supply unit
[5] Rail
[6] Platform for crusher drive electric motor
10
11
12

[7] Platform for cone crusher hydraulic power unit
[8] Platform for feeding conveyor and cone crusher

DESCRIPTION
[9] Platform for cyclone prefilter, power supply unit and cone crusher
[10] Steps to the platform for cyclone prefilter, power supply unit and
cone crusher
[11] Platform for the steps [10] and [12]
[12] Steps to platform for feeding conveyor and cone crusher
The steps, ladders and platforms permit access to machines and plant
components.
The handrails prevent persons from falling from the platforms and steps.
WARNING!
Risk of falling
Incorrectly fitted platforms, ladders, handrails and anti-fall guards can re-
sult in people falling.
• Ensure that platforms, ladders, handrails and anti-fall guards are cor-
rectly fitted.
2.01.04 Lighting/warning devices
3 1 2
Fig. 2.6: Warning light and warning siren

[1] Warning light
[2] Warning siren
[3] Receiver aerial for radio remote control
The warning light [1] and the warning siren [2] light up or sound for ap-
prox. 7 seconds after activation of the start enable. After a fault occurs or
an emergency stop is tripped, they remain active until the fault is ac-
knowledged in the operator panel.
The warning light is secured to a mask, which is moved out before putting
the plant into operation and clamped.

DESCRIPTION
The warning siren is secured on the outside of the switch cabinet.
Fig. 2.7: Lighting

[1] Halogen lamps (option)
The halogen lamps [1] are secured on a mast, which can be rotated and
inclined. They can be used to illuminate working areas individually.
The lighting can only be cut in after the control voltage is activated.
2.01.05 Socket outlets on the chassis

Socket for feeding conveyor
Fig. 2.8: Feeding conveyor socket

[1] Connection for feeding conveyor drive

DESCRIPTION
Sockets for platform emergency stop
Fig. 2.9: Sockets for platform emergency stop

[1] Connection for platform emergency stop
[2] Platform emergency stop connection (option)
The socket [2] under the platform for the feeding conveyor and crusher is
provided for a retrofittable, additional emergency stop.
To operate the plant without the platform emergency stop, dummy plugs
must be inserted in the emergency-stop sockets.
Socket for magnetic remover
Fig. 2.10: Magnetic remover socket

[1] Electromagnet terminal

DESCRIPTION
If the plant is operated without a magnetic remover, the socket must be

covered with a dummy end to protect against dust and dirt.
Socket for lighting
Fig. 2.11: Lighting socket

[1] Connection for lighting
Sockets for fill level monitor (option)
Fig. 2.12: Sockets for fill level monitor

[1] Connection for cone crusher fill level monitor
[2] Connection for feed hopper fill level monitor
The connection for the fill level monitor of the cone crusher is located be-
low the platform between power supply unit and cone crusher. The con-

DESCRIPTION
nection for the fill level monitor of the feed hopper is fitted on the support
of the feed hopper.
The fill level monitor at the cone crusher monitors the fill level in the
crusher inlet and, in the event of overfilling, switches off the feeder
trough. When the crusher inlet is free again, the feeder trough is switched
on again.
The fill level monitor at the feed hopper of the plant monitors the filling lev-
el in the feed hopper and switches off an upstream plant in the event of
overfilling. When the feed hopper is free again, the upstream plant is
switched on again.
If the plant is operated without a fill level monitor, the socket outlets must
be covered with a dummy end to protect against dust and dirt.
2.01.06 Guard devices

Guard devices can be detached or opened with the help of tools or spe-
cial spanners and must remain fixed in position for operation and routine
maintenance tasks. They can be taken off for repair work.
Guard devices on the plant
Fig. 2.13: Guard devices on the plant

[1] Heat guard for hydraulic oil cooler
[2] Protective shield for hydraulic oil cooler
[3] Protective cover for crusher belt drive
The guard device of the crusher belt drive [3] covers the V-belts and the
V-belt pulley completely. For maintenance and repair tasks, the covers
can be dissembled.
The protective shield [2] protects the hydraulic oil cooler of the lube oil
system against damage.

DESCRIPTION
Guard devices on belt conveyors
3
5
1 6
Fig. 2.14: Guard devices on belt conveyors

[1] Guard for bend pulley
[2] Guard for bottom segment, lower
[3] Material guide ledges
[4] Guard for drive pulley
[5] Guard for bottom segment, upper
[6] Guard for return rollers
The guard devices of the belt conveyors protect against being drawn in
or caught by machinery and against lateral falling of material. They are
fitted on all belt conveyors where it is necessary to protect against haz-
ards.
The guard devices must be set so that the gap at the draw-in point is a
maximum of 5 mm.

DESCRIPTION
Component securing elements
Fig. 2.15: Component securing elements (I)

[1] Locking pin
[2] Safety bolt locking pin
Locking pins used to install components are secured with securing
screws. If components are not installed on the plant, the locking pins and
securing screws must be kept for reuse.
2.01.07 Emergency stop

Emergency stop and emergency switching off on the plant
1 2 3 2
Fig. 2.16: Emergency stop at the plant

[1] Emergency-stop button on the remote controls

DESCRIPTION
[2] Emergency-stop button on the plant

[3] Emergency switching off button in the switch cabinet
The emergency-stop button [2] at the plant switches off all plant drives
with the exception of the diesel generator. The crusher is switched off af-
ter a defined run-after time.
The emergency-stop button [1] at the radio and wired remote control
switches off all drives with the exception of the diesel generator. The
crusher is switched off after a defined run-after time.
The emergency switching off button [3] on the operator's stand switches
off the entire plant including the diesel generator.
The emergency stop and emergency switching off button are released by
turning the button. The plant components and machines then have to be
restarted at the touch screen in the switch cabinet.
Emergency stops at conveyor belts
Fig. 2.17: Emergency stops at conveyor belts

[1] Pull cord
[2] Emergency-stop switch
The release cord [1] is routed in eyelets along both sides of the belt con-
veyor. Pulling the release cord actuates the emergency-stop switch [2],
which shuts down all plants drives with the exception of the diesel gener-
ator. The crusher is switched off after a defined run-after time.
The emergency-stop switch is released by resetting the lever to the mid-
dle position. The plant components and machines then have to be re-
started at the operator panel in the switch cabinet.

DESCRIPTION
Control stand
2.02 Control stand
Fig. 2.18: Plant operator's stand

(1) Operator's stand
All plant functions are controlled from the control stand during initial op-
eration and setting or maintenance work.
The control stand can be accessed by lifting the switch cabinet flap at the
switch cabinet protective housing. The switch cabinet flap is held in its
folded open position by telescopic rods.
During regular crusher operation the plant is controlled exclusively via ra-
dio remote control. The operator, therefore, does not need to stay at the
control stand.
During regular crusher operation the switch cabinet flap of the switch
cabinet protective housing must remain closed to prevent ingress of wa-
ter and dust.
During setting or maintenance tasks without feeding unit, the switch cab-
inet flap can remain open for operating the control system. In this case,
it serves as weather protection for operating, maintenance and repair
personnel.
The instruction manual is in the switch cabinet.

DESCRIPTION
Control stand
2.02.01 Main switch
4
3
5
2
Fig. 2.19: Main switch

[1] On position (ON)
[2] Tripped position (TRIP)
[3] Off position (OFF)
[4] Locking button
[5] Control knob
The main switch connects and disconnects all plant consumers from the
external power supply. The external circuits are not connected or discon-
nected (see chap. 2.06.06).
In the case of undervoltage or a fault in a ground-fault current interrupter,
all drives of the plant shut down. The main switch remains in the On po-
sition [1].
The main switch is switched off by turning into the tripped position [2]. By
turning back to the Reset position and then turning back to the ON posi-
tion [1], the main switch is activated again.
The main switch is secured in the Off [3] position against unauthorised
activation by pressing the lock button [4] and attaching a padlock.
The main switch is connected by a square rod to the actuator in the
switch cabinet. When the switch cabinet is closed, the main switch and
the actuator must be correctly reconnected with the square rod.

DESCRIPTION
Control stand
2.02.02 Operator panels/Interfaces
1 2 3 4
1000
800 1600
500 500
400 400
600
400
200 200
200
0 0 0
5 6 7
9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7
25 26 27 28 29 30 31 32 33
34 35 36 37 38
39
Fig. 2.20: Operator panel

DESCRIPTION
Control stand
Pos.: Operating/indicator element Function

[1] Fuel gauge Display of the fill level of the diesel fuel tank
[2] Coolant temperature Indicates the current coolant temperature of the diesel engine in
°C
[3] Oil pressure Indicates the current oil pressure of the diesel engine in bar
[4] Ignition switch with control Starting and stopping the diesel engine, display of the operating
lamps status of the diesel engine, see description of "Ignition switch"
[5] Amperemeter Displays current consumption of plant
[6] Amperemeter Displays current consumption of the cone crusher
[7] Voltmeter Displays the voltage between the phases with the main switch
switched on
[8] Operator panel OP3 Interface for setting different plant parameters, see description
of "Operator panel OP3"
[9] Rotary switch for winter opera- On/Off switch for heating and lubrication of cone crusher
tion
[10] Rotary switch for probe On/Off switch for probe at feed hopper
[11] Rotary switch for probe On/Off switch for probe at crusher inlet
[12] Rotary switch for supports Moves supports up and down
[13] Rotary switch for lighting Switches plant lamps on/off
[14] Key switch for control voltage Switches plant control voltage on/off
[15] Plant ON button Switching on the plant
[16] Plant OFF button Switching off the plant
[17] Start-up enable control lamp Displays start enable of plant
[18] Acknowledge fault button Acknowledges faults and emergency stops
[19] Automatic mode/manual mode Switches over to operating modes automatic or manual. In man-
rotary switch ual mode position, the sequential locking device of the machine
is switched off
[20] Automatic mode control lamp Display for automatic mode
[21] Manual mode control lamp Display for manual mode
[22] Rotary switch for radio remote Switches plant on/off via radio remote control
control
[23] Button for driving hydraulics Switches driving hydraulics on and off
[24] Lamp test button Carrying out lamp test of control lamps
[25] Button for belt conveyor 1 Switches fine grain conveyor on/off
[26] Button for belt conveyor 2 Switches return conveyor on/off
[27] Button for crusher 3 Switches crusher on/off
[28] Button for magnetic remover 4 Switches magnetic remover on/off
[29] Button for belt conveyor 5 Switches crusher discharge conveyor on/off
[30] Button for feeder trough 6 Switches feeder trough on/off
[31] Button for auxiliary hydraulics Switches auxiliary hydraulics on/off
7

DESCRIPTION
Control stand

[32] Button for water pump Switches water pump on/off
[33] Feeder trough rotary switch Increases/reduces vibratory speed of feeder trough
[34] On/Off pushbutton for cone Switch automatic mode of cone crusher on/off
crusher
[35] Increase crushing gap push- Increases the crushing gap of the cone crusher
button
[36] Reduce crushing gap button Reduces the size of the crushing gap of the cone crusher
[37] RESET button Lowers the bowl and enable automatic mode
[38] Lift bowl button Button for lifting the bowl
[39] Emergency-off button Switches plant off in emergencies, see chap. 2.01.07
Tab. 2.1: Operator panel control elements
General functions of the control elements

Key switch
Key switches are actuated by a key. The key can only be inserted and
removed in the OFF position.
Rotary switch
The rotary switch is actuated by turning it. Turning to the left or right
switches the desired function on or off.
The rotary switches are either momentary-contact or maintained-contact
switches.
Button/pushbutton
This control element is actuated by pressing it.
• Pressing the button activates the corresponding function and the but-
ton lights up.
• Pressing the button again switches the corresponding function off
and the button light goes out.
Control lamps
Control lamps light up upon activation of a corresponding function. When
the function is deactivated, the corresponding control lamp also goes out.
Warning lights
Warning lights light up if a fault is pending. After eliminating or acknowl-
edging the corresponding fault, the warning light goes out.

DESCRIPTION
Control stand
Ignition switch with control lamps

The diesel generator is started and stopped via the ignition switch. The
ignition key is inserted in the STOP position. By turning the key to the
right into the START position, the diesel generator is started and, when
released, moves into the RUN position due to the spring force. By turning
to the left into the STOP position, the diesel generator is stopped and the
ignition key can be removed.
Control lamps
• Battery control lamp - lights up when ignition is switched on and when
starter battery has low voltage.
• Oil pressure control lamp - lights up when ignition is switched on and
if there is insufficient oil in the diesel engine. The diesel generator is
stopped automatically and the warning siren sounds.
• Coolant temperature control lamp - lights up if the coolant is over-
heated. The material feed to the crusher is stopped automatically and
the warning siren sounds.
• Control lamp A insufficient coolant - lights up if the coolant level is too
low. The diesel generator is stopped automatically and the warning
siren sounds.
• Control lamp A air filter - lights up if the air filter is clogged. The diesel
generator is stopped automatically and the warning siren sounds.
Fault messages displayed by the control lamps and the warning sirens
are reset by turning the ignition key back into the STOP position.
2.02.03 Programmable logic controller PLC/OP3
4
3
2
6
Fig. 2.21: Operator panel PLC OP3

[1] Numerical keypad
[2] Function keys F1-F5
[3] LCD

DESCRIPTION
Control stand
[4] Abort key (ESCAPE key)

[5] Sign key
[6] Cursor keys
[7] Input key (ENTER key)
[8] Shift key (SHIFT)
The OP3 operator panel displays messages from plant components and
machines in the message level. All setting values can be read off in the
value level. Service personnel can also change setting values if they
have the corresponding password.
The OP3 operator panel has a membrane keyboard. The display can
show two lines of text each with 20 characters.
Numeric keys
to Input keys for numerical digits 0-9.
Function keys
+ to The numeric keys 1 to 5 are also function keys. The function is called up
by pressing the SHIFT key together with one the numeric keys 1-5.
Shift key (SHIFT)
Switches to the second function on double-assigned keys. To do this, the
shift key is pressed at the same time as the relevant key, e.g.:
• Insert comma: press +
• Call up function: press + e.g.
Sign key
Changes sign from "Plus" to "Minus" and vice versa. Second function
with pressed SHIFT key: insertion of a comma.
Input key (ENTER key)
The input key is switched to the value level. Entries are confirmed and
completed with the input key.
Abort key (ESCAPE key)
Depending on the current operating and display situation, pressing the
abort key (ESCAPE) has different effects:
• Undo: field entries are undone, provided they have still not been con-
firmed with ENTER.
• Branch backward: from the value level back to the message level.
• Resetting when scrolling in messages: cancellation of scrolling in
pending messages to reset the display to the currently pending mes-
sage.
• Masking out a system message.
Cursor keys
Move cursor in the display. Depending on the operating and display situ-
ation, the cursor is moved to the left, right, upwards, downwards by char-
acters, fields, entries or displays.

DESCRIPTION
Control stand
2.02.04 Frequency converter

Frequency converter main switch
Fig. 2.22: Main switch of the frequency converter

[1] Frequency converter main switch
The main switch of the frequency converter is fitted in the switch cabinet.
It can be accessed after opening the switch cabinet door.
NOTICE
Danger of material damage
Switching over the frequency converter main switch with the plant run-
ning can result in damage to the electrical system.
• Switch off plant components, diesel generator and the main switch of
the plant.
• Only switch over the frequency converter main switch when the pant
is de-energised.
The main switch has two switching positions:

• Switching position 1 = network operation: all consumers are supplied
by the diesel generator at the rated frequency.
• Switching position 2 = frequency converter operation: the consumers
connected to the frequency converter are controlled by the frequency
converter.

DESCRIPTION
Control stand
Frequency converter operating unit
3
1
4
5
Fig. 2.23: Frequency converter

[1] Frequency converter housing
[2] Display
[3] Programming buttons
[4] Operating buttons
[5] Slot for Smartstick/Logicstick (option)
The three-phase current frequency converter permits speed control of
the vibration motors of the feeder trough.
The frequency converter is operated by the programming and operating
buttons. The display is divided into two display fields on the left and right.
The left-hand display field shows the current parameter; the right-hand
display shows the corresponding value.
The display can be viewed through a window in the switch cabinet door.
The switch cabinet door must be opened to operate the operating unit.
Mode button
The mode button is used to change the operating unit mode. Three dif-
ferent modes can be selected:
• Status mode.
– Speed display.
– Load display.
• Parameter display mode.
• Parameter input mode.
Arrow keys
+ The arrow keys are used to increase and reduce the speed of the vibra-
tion motors. They are also used to select parameters and process their
values.

DESCRIPTION
Control stand
Start button
Pressing the start button switches the frequency converter on.
Stop button
Pressing the stop button switches the frequency converter off.
Display windows
Operating statuses (status mode)
Left display Status Description

field
Converter ready Converter is enabled and ready to
start.
Converter disa- Converter is blocked due to missing
bled enable or fault shutdown.
Fault shutdown of The fault shutdown of the converter
converter has been tripped. Fault shutdown
code is displayed in the right-hand
display field.
DC injection brak- DC injection braking is active.
ing
Network failure Failure of the power network.
Tab. 2.2: Frequency converter operating statuses
Speed displays
Left display Description

field
Drive output frequency in Hz.
Motor speed in rpm.
User-defined motor speed.
Tab. 2.3: Frequency converter speed displays
Load displays
Left display Description

field
Active load current as a % of motor rated current.
Converter output current per phase in A.
Tab. 2.4: Frequency converter load displays

DESCRIPTION
Control stand
2.02.05 Remote controls

Radio remote control
2 3 4 5 6 7
1 8
13 9
12 11 10
Fig. 2.24: Radio remote control

[1] Left crawler running gear forward/back
[2] Feeding conveyor forward/back
[3] Crawler running gear slow/fast
[4] Feeder trough slow/fast
[5] Feeder trough on/off
[6] Emergency stop and release
[7] Right crawler running gear forward/back
[8] No function
[9] Switch on radio remote control
[10] No function
[11] Aerial
[12] Operation display LED
[13] Warning light for battery LED

DESCRIPTION
Control stand
Range of the radio remote control
Fig. 2.25: Range of the radio remote control

The radio remote control permits operation and movement of the plant in-
dependently of the operator panel of the switch cabinet. The range of the
radio remote control is approx. 100 m with visual contact between trans-
mitter and receiver. The range can be smaller if there are obstacles be-
tween transmitter and receiver.
The emergency-stop function of the radio remote control is tripped auto-
matically by the following events:
• If the range of the transmitter is exceeded.
• Interruption of the radio signal, e.g. interference with transmitter or re-
ceiver.
• Removal of the battery from the radio remote control.
• Battery undervoltage.
• Manual actuation of the emergency stop at the radio remote control.
When the emergency-stop function is tripped, all plant drives with the ex-
ception of the diesel generator are switched off.

DESCRIPTION
Control stand
NOTICE
Danger of material congestion
If the range of the radio remote control is exceeded, the emergency stop
is tripped and material congestion in the plant can result.
• During plant operation, ensure that the range of the radio remote con-
trol is never exceeded.
• Never carry the radio remote control along in the wheel loader or dig-
ger and thus leave the range.
• Always ensure there is visual contact between transmitter and receiv-
er.
• Store the radio remote control in the plant's switch cabinet housing
when not in use.
Components and accessories of the radio remote control
1 2 3 4
Fig. 2.26: Components and accessories

[1] Receiver
[2] Charger
[3] Battery
[4] Receiver aerial
The receiver [1] for the radio remote control is installed in the switch cab-
inet. The receiver aerial [4] is secured to a mast to which the warning light
is also attached.
The charger [2] and battery [3] are stowed in the switch cabinet.

DESCRIPTION
Control stand
Wired remote control
1 3
Fig. 2.27: Wired remote control

[1] Left crawler running gear forward/back
[2] Emergency stop and release
[3] Right crawler running gear forward/back
The wired remote control is used exclusively for moving the plant. As op-
posed to the radio remote control, it remains on the plant during trans-
port. It can be used by qualified and authorised personnel during loading
and unloading.
It is connected to the corresponding socket outlet in the switch cabinet
(see chap. 2.06.06).
When the emergency stop function is tripped, all plant drives with the ex-
ception of the diesel generator are switched off.

DESCRIPTION
Control stand
2.02.06 Diesel and switch cabinet heating (option)
2 3
500
400
200
1 4
Fig. 2.28: Operator panel for diesel and switch cabinet heating
[1] Red control lamp for diesel engine
[2] Green control lamp for diesel engine
[3] Green control lamp for switch cabinet
[4] Red control lamp for switch cabinet
The control lamps for the diesel engine and switch cabinet heating indi-
cate the following operating statuses and faults:
• The green control lamp for the diesel engine [2] lights up when the
coolant temperature has been reached.
• The red control lamp for the diesel engine [1] lights up when the cool-
ant temperature has not been reached or the warm-up phase is run-
ning.
• The green control lamp for the switch cabinet [3] lights up when the
switch cabinet temperature has been reached.
• The red control lamp for the switch cabinet [4] lights up when the
switch cabinet temperature has not been reached or the warm-up
phase is running.
• The green control lamp for the diesel engine flashes slowly when the
starting temperature of the diesel engine has been reached but the
external power supply via the emergency power unit is not yet con-
nected.
• The red control lamp for the switch cabinet flashes quickly if the fuse
cutout monitoring system reports a defective fuse. In this case, check
the fuses.
With the diesel generator running, the heaters for the diesel engine and
the switch cabinet switch on and off automatically at defined ambient
temperatures.

DESCRIPTION
Not assigned
A 400 V socket for connection to an emergency power unit is available

as an option. It supplies the diesel engine and switch cabinet heating with
power, e.g. during night time when the diesel generator is not in opera-
tion.
After the diesel generator is started, the external power supply must be
disconnected again.
It is possible to start the diesel generator below the defined ambient tem-
perature, although this is not recommended.
2.03 Not assigned
2.04 Power supply unit/engine
3
2
1
5
Fig. 2.29: Diesel generator power supply unit

(1) Cooling system, see chap. 2.04.05
(2) Diesel engine, see chap. 2.04.01
(3) Air intake, see chap. 2.04.04
(4) Generator, see chap. 2.06.04
(5) Flange coupling, see chap. 2.04.06

DESCRIPTION
Power supply unit/engine
2.04.01 Diesel engine/diesel generator
3 5
Fig. 2.30: Diesel engine Scania DC12

[1] Diesel engine
[2] Engine oil filler neck
[3] Engine oil filter
[4] Exhaust turbocharger
[5] Centrifugal cleaner
The 6-cylinder in-line diesel engine has direct fuel injection and a liquid
cooler. It has an exhaust turbocharger with charge-air cooling.
All components can be accessed after opening the protective housing of
the power supply unit.
For technical details, see chap. 5.01.02.
4 5

DESCRIPTION
Fig. 2.31: Scania diesel engine

[1] Charge-air cooler return line
[2] Charge-air cooler supply line
[4] Exhaust pipe with thermal insulation
[5] Clean air pipe
Illustration example of the LRC diesel engine design.
Low Regulated Countries (LRC) diesel engines are used in countries in
which the quality of the diesel fuel is insufficient and the sulphur content
in the diesel fuel is too high.
The LRC diesel engines are made suitable for use with these diesel fuels,
among other things, by changing the engine management system.
For technical details, see chap. 5.01.02.
2.04.02 Fuel supply
Fig. 2.32: Fuel supply

[1] Filler neck with closing cover
[2] Platform between crusher and power supply unit
[3] Diesel fuel tank

DESCRIPTION

[4] Shut-off cock
[5] Fuel line to fuel prefilter
[6] Fuel return line

[7] Level sensor

DESCRIPTION

[8] Fuel filter with water separator
[9] Main fuel filter
The filler neck can be accessed via the platform between power supply
unit and crusher. During operation, the filler neck is covered with a base
plate.
The shut-off cock of the fuel supply line prevents diesel fuel from flowing
back during the fuel filter change.
2.04.03 Exhaust system
Fig. 2.36: Exhaust system (I)

[2] Exhaust pipe with thermal insulation

DESCRIPTION
Fig. 2.37: Exhaust system (II)

[3] Silencer
[4] Exhaust flap
The exhaust flap prevents the incursion water into the silencer.
2.04.04 Air intake
2
1
Fig. 2.38: Air intake

[1] Clean air pipe
[2] Cyclone prefilter
[3] Corrugated hose on intake side
[4] Air filter
[5] Dust outlet closure

DESCRIPTION
The cyclone prefilter removes coarse dust particles from the intake air.
The air filter, with its inserted filter element, filters out finer contamination.
2.04.05 Cooling system
4
5
Fig. 2.39: Cooling system

[1] Return line from charge-air cooler
[2] Charge-air cooler with coolant cooler behind it
[3] Equalizing tank with filler neck
[4] Supply line to charge-air cooler
The cooler consists of the charge-air cooler and the coolant cooler be-
hind it.

DESCRIPTION
Hydraulic oil supply
2.04.06 Flange coupling
Fig. 2.40: Flange coupling

[1] Flange
[2] Start-up damper
The power transmission from the diesel engine flywheel to the 400 V gen-
erator is directly via the flange coupling.
The start-up damper ensures a jolt-free start-up of the components and
units driven by the diesel engine.
2.05 Hydraulic oil supply
2.05.01 Hydraulic oil tank

DESCRIPTION
Fig. 2.41: Hydraulic oil tank

[1] Cleaning cover
[2] Return filter
[3] Suction filter
[4] Ventilation filter
Fig. 2.42: Hydraulic oil tank

[5] Level indicator
The hydraulic oil tank supplies the entire hydraulic system with the ex-
ception of the cone crusher with hydraulic oil.
The cone crusher has its own hydraulic circuit with hydraulic oil tank, hy-
draulic pumps, filters and cooler.
The hydraulic oil tank is equipped with two suction filters, a return filter
and a tank ventilation filter.
The filling level of the hydraulic oil tank is displayed at the level indicator.

DESCRIPTION
2.05.02 Hydraulic / lube oil supply for crusher
4
6
3
2 7
Fig. 2.43: Hydraulic/lube oil tank

[1] Lube oil filter
[2] Pressure sensor for gap setting clamping cylinder
[3] Pressure sensor for clamping cylinder
[4] Hydraulic oil filter
[5] Pressure accumulator
[6] Inspection glass for lube oil coarse strainer
[7] Lube oil tank vent neck
[8] Lube oil filler neck
10

[9] Hydraulic oil filler neck

DESCRIPTION
[10] Filling level and temperature sensor for lube oil
16
15
14
17
13
18
12
11 19

[11] Lube oil heating
[12] Shut-off cock for lube oil filter housing
[13] Shut-off cock for lube oil drain
[14] Hydraulic oil drain shut-off cock
[15] Supply line for lube oil to oil cooler
[16] Lube oil cooler
[17] Fan drive
[18] Vent for lube oil filter
[19] Cleaning cover
20

DESCRIPTION
[20] Filling level and temperature sensor for hydraulic oil

Hydraulic oil The hydraulic oil tank supplies the hydraulic system of the cone crusher
with hydraulic oil.
The hydraulic oil tank is equipped with two pressure filters. If the holding
capacity of the hydraulic filter has been reached, the message "Filter
clogged" appears in the display of the operator panel.
The filling level of the hydraulic oil tank is monitored by the filling level and
temperature sensor [20]. If the filling level is too low, the cone crusher is
shut down automatically.
The filling level of the hydraulic oil tank is displayed at the level indicator.
Lube oil The lube oil tank supplies the cone crusher with lube oil.
The lube oil tank is equipped with a coarse strainer in the return line and
a suction filter. If the holding capacity of the lube oil filter has been
reached, the message "Lube oil filter clogged" appears in the display of
the operator panel and the vibrating feeder is stopped.
The filling level of the lube oil tank is monitored by the filling level and
temperature sensor [10]. If the filling level is too low, the cone crusher is
shut down automatically. The lube oil pump continues running for approx.
2 minutes.
The filling level of the lube oil tank is displayed at the level indicator.
The lube oil filter is equipped with a venting device. This prevents foam-
ing of the lube oil during operation. The venting device hose leads directly
into the lube oil tank.
2.05.03 Driving clutch
Fig. 2.47: Driving clutch

[1] Axial piston pump connection side
[2] Cam ring

DESCRIPTION
[3] Claw clutch

[4] Clamping screw
The power transmission from the electric motor to the tandem pump of
the drive system is by means of a claw clutch.
A spacer sleeve is installed between electric motor and claw clutch. The
claw clutch is secured against slipping on the shaft of the electric motor
with a grub screw and a feather key.
The clamping screw secures the claw clutch on the gear shaft of the tan-
dem pump.
The cam ring serves as a start-up damper and guarantees jolt-free start-
up of the tandem pump.
2.05.04 Hydraulic pumps
1
2
Fig. 2.48: Hydraulic pumps

[1] Axial piston pump electric motor
[2] Axial piston pump drive system

DESCRIPTION
3 4
Fig. 2.49: Hydraulic pump for auxiliary hydraulic system

[3] Hydraulic pump electric motor
[4] Auxiliary hydraulics gear pump
The axial piston pump supplies the drive system of the crusher plant with
pressure and volume flow.
The gear pump of the auxiliary hydraulic system is responsible for the hy-
draulic oil supply of the following components and machines and func-
tions:
• Moving hopper support up and down.
• Moving feeding conveyor forward/back.
2.05.05 Cone crusher hydraulic pumps
Fig. 2.50: Hydraulic pumps

DESCRIPTION
[1] Lube oil pump pressure display

[2] Hydraulic pumps pressure display
[3] Double gear pump
[4] Screw pump
The double gear pump supplies the cone crusher with pressure and vol-
ume flow.
The double gear pump is responsible for the hydraulic oil supply of the
following components:
• Clamping cylinder
• Tramp release cylinder
The screw pump of the lube oil tank serves to lubricate and cool the fol-
lowing components:
• Bearing of the main shaft
• Eccentric bearing
2.05.06 Valve blocks
Fig. 2.51: Valve block for feeding conveyor

[1] Feeding conveyor valve block
The operating level of the feeding conveyor valve block can be used to
move it forward and back. The valve block is installed below the feed hop-
per. The operating lever can be reached through a cutout in the chassis.
The auxiliary hydraulic system supplies the valve block with pressure and
volume flow.

DESCRIPTION
Electrical system
2.06 Electrical system
Fig. 2.52: Electrical system

(1) Switch cabinet with fuses, see chap. 2.06.03.
(2) Sockets at the switch cabinet, see chap. 2.06.06.
Fig. 2.53: Electrical system

(3) 400 V generator, see chap. 2.06.04.
(4) Switch cabinet and fuses for diesel engine, see manufacturer's
documentation
(5) 24 V power supply, see chap. 2.06.01.
(6) 24 V generator, diesel engine, see chap. 2.06.04.
In the electrical system, a distinction is made between two power-supply
systems:

DESCRIPTION
Electrical system
• The 24 V direct current power system supplies the engine and control
electronics with the necessary current.
• The 400 V three-phase current power system supplies the electric
drives with the necessary current.
2.06.01 24 V voltage supply
Fig. 2.54: Starter batteries

[1] 12 V starter batteries
The 12 V starter batteries [1] are located in the protective housing of the
power supply unit.
The 24 V voltage supply is provided by the generator of the diesel engine
and two 12 V starter batteries [1] connected in series.

DESCRIPTION
Electrical system
2.06.02 Battery isolator
Fig. 2.55: Battery isolator

[1] Battery isolator
The mechanical battery isolator is installed in the switch cabinet of the
diesel engine.
The battery isolator disconnects the electrical system from the 12 V start-
er batteries.
2.06.03 Switch cabinet
2
4
1 6
Fig. 2.56: Switch cabinet and plant fuses

[1] Securing elements
[2] Ground fault circuit interrupter

DESCRIPTION
Electrical system
[3] Motor protection switch

[4] Contactors
[5] Frequency converter
[6] Connection for external power supply
[7] ZEV motor protective systems
The switch cabinet contains all electrical switching and fusing elements
and plant wiring systems.
The switching and fusing elements can be accessed after opening the
switch cabinet door.
All electrical switching and fusing elements are identified by short codes.
When a fault occurs, this short code is displayed in the operator panel
OP3.
Fig. 2.57: Diesel engine fuses

[8] Safety fuses
The switch cabinet of the diesel generator is installed in the power supply
unit.
It contains all electrical switching and fusing elements of the diesel en-
gine.
• Do not patch up or bridge fuses.
• Always replace blown fuses.
• If a fuse continually blows, inform authorised personnel.
• Do not spray switch cabinets with water.

DESCRIPTION
Electrical system
2.06.04 Generators
1 2
Fig. 2.58: 24 V generator

[1] 24 V generator
[2] Starter
Fig. 2.59: 400 V generator

[3] Terminal box
[4] 400 V generator
[5] Guard grid for flange coupling
The 24 V generator is driven by the diesel engine via a V-ribbed belt. The
24 V voltage supply is provided by two 12 V starter batteries connected
in series.

DESCRIPTION
Electrical system
The 400 V generator is driven directly by the diesel engine via a flange
coupling.
The 400 V generator is a brushless, self-excited and self-controlling syn-
chronous generator. It supplies the three-phase current required by the
plant.
2.06.05 Electric motors

All electric motors in the plant run on 400 V three-phase current.
The vibration motors of the feeder trough can be controlled over a de-
fined speed range by the frequency converter (see chap. 2.02.04).
2.06.06 Socket outlets
6
5
4
3
1
2
Fig. 2.60: Socket outlets on the switch cabinet

[1] Connection for wired remote control
[2] Service socket outlet 400 V / 32 A
[3] Service socket outlet 230 V / 16 A
[4] Socket outlet 16 A for spare conveyors
[5] Connection for spare conveyor emergency stop
[6] Connection or locking device for downstream plant
[7] Connection or locking device for upstream plant
[8] Connection for operating and transport plug
[9] Transport plug
When not in use, the socket of the wired remote control [1] must be cov-
ered with a dummy end to protect against dirt and dust.
In order to operate the plant without upstream or downstream plants, the
connections [6] and [7] must be provided with a locking plug.
Transport plug

DESCRIPTION
Electrical system
The transport plug [9] is inserted in the operating and temperature plug
[8] for transporting the plant. This is placed at the position of the transport
plug for safe storage of the operating plug.
External circuits
The socket outlets of the external circuits [2] and [3] are live even when
the main switch is switched off. They only become de-energised when
the diesel generator is switched off.
2.06.07 Switch cabinet over pressure system
3 4
2 5
1 6
Fig. 2.61: Switch cabinet overpressure system

[1] Flexible corrugated hose
[2] Electrical connection
[3] Electric motor with blower
[4] Cyclone prefilter
[5] Filter housing with dust filter element
[6] Dust outlet valve
The overpressure system draws in outside air via the cyclone prefilter [4]
and the dust filter [5] and blows it by means of the blower [3] into the
switch cabinet. This results in a build-up of overpressure in the switch
cabinet, which prevents the penetration of dust.
The overpressure system can only function if the following requirements
are met:
• During operation, the switch cabinet must be properly closed.
• There must be no leaks in the flexible corrugated hoses and at the
other connections.
• The cyclone prefilter and the dust filter must not be clogged.

DESCRIPTION
Electrical system
2.06.08 External power supply (option)
Fig. 2.62: External power supply main switch

[1] Switch cabinet
[2] Main switch for external power supply
[3] Main switch for diesel generator
DANGER!
Danger of electric shock
Incorrect connection of the external power supply leads to life-endanger-
ing situations.
• Connection of the external power supply must be carried out by au-
thorised and qualified personnel only.
The external power supply supplies the plant with voltage from an exter-
nal source (see also chap. 3.02)
The external power supply is connected directly at the terminals in the
switch cabinet.

DESCRIPTION
Not assigned
2.07 Not assigned
2.08 Drive system
2.08.01 Crawler running gear
5 6
4 7
3
8
2
9
10
Fig. 2.63: Crawler running gear

(1) Sprocket
(2) Chain tensioner
(3) Crawler carrier chain
(4) Support rollers
(5) Chassis beam
(6) Sprocket
(7) Track drive
(8) Chain cover
(9) Track rollers
(10) Chain guide
The left and right chassis beams are welded onto the chassis. The indi-
vidual components of the crawler running gear are installed in the chassis
beam.
The left and right track drive with flange-mounted sprocket drive the
crawler carrier chains.
The crawler carrier chain is tensioned via the chain tensioner and the
sprocket. The chain guide holds the crawler carrier chain in the track.
The preload pressure of the chain tension and overload pressure is set
at the safety valve of the chain tensioner. If the set preload pressure is
exceeded during tensioning of the crawler carrier chains, the safety valve
opens and grease is drained.

DESCRIPTION
Drive system
If the crawler carrier chain blocks during driving operation or the crawler
running gear bottoms out, the overload pressure safety valve opens and
grease is drained.
2.08.02 Track drive
2
3
Fig. 2.64: Track drive

[1] Sprocket
[2] Gearbox
[3] Hydraulic motor with connections
The left and right crawler running gears are driven by one track drive re-
spectively.
Integrated in the track drive is a spring pressurised brake, which secures
the plant against rolling away and can be released hydraulically. In driv-
ing operation, the brakes are released hydraulically.
The two hydraulic motors of the track drive are supplied by the axial pis-
ton pumps of the power supply unit with pressure and volume flow.
The switch-over from crushing to driving operation and vice versa is by
means of a rotary switch in the operator panel, see chap. 2.02.02.

DESCRIPTION
Not assigned
2.09 Not assigned
2.10 Conveyor unit
Fig. 2.65: Conveyor unit

(2) Magnetic remover (option), not illustrated, see chap. .
The conveyor unit is formed by various machines and components within
the plant. This is demonstrated in the plant overview and the flow chart,
see chap. 2.
2.10.01 Belt conveyor
5 6
4
7
8
2
10
1

DESCRIPTION
Conveyor unit
Fig. 2.66: Belt conveyor

[1] Return roller
[2] Feed skirt
[3] Material guide ledges
[4] Support rollers
[5] Conveyor belt
[6] Drive pulley
[7] Scraper
[8] Conveyor belt frame
[9] Return roller with return roller guard
[10] Clamping device
All belt conveyors basically have the same design principle. The main dif-
ferences are the belt width, the distance between centres, the drive pul-
ley and return rollers and the belt conveyor drive.
Electric motors with flange-mounted angular gears or drive pulleys with
integrated electric drum motors are used as belt conveyor drives.
In automatic mode, the belt conveyors are controlled automatically by the
PLC. In manual mode, they can be switched on and off individually.
The conveyor belt frame [8] supports the components of the belt convey-
or. The conveyor belt [5] is guided and driven via the drive and return roll-
ers [6] and [1]. The support rollers [4] bear the load of the material to be
conveyed. Through the configuration of the support rollers, the cross-
section of the conveyor belt can be flat or trough-shaped.
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 freed of adhering material, which would otherwise damage the rollers
and pulleys.
The material guide ledges [3] prevent the material to be conveyed from
falling out of the side of the belt conveyor.

DESCRIPTION
Conveyor unit
2.10.02 Chutes
2
1
Fig. 2.67: Chutes

[1] Crusher inlet
[2] Crusher outlet
The crusher inlet [1] and crusher outlet [2] guide and pass on the material
to downstream machines and components.
The crusher outlet is covered with a wear lining.
2.10.03 Magnetic remover (option)
Fig. 2.68: Magnetic remover

[1] Magnetic remover
[2] Feeding conveyor

DESCRIPTION
Conveyor unit
[3] Magnetic remover suspension

The magnetic remover uses magnetic force to remove ferrous material
from the feeding conveyor. After the end of work, the magnetic remover
must be cleaned manually. The plant and magnetic remover must be
switched off before cleaning. Attracted material that obstructs the mate-
rial flow must be removed immediately.
2.10.04 Metal detector (option)
Fig. 2.69: Metal detector

[1] Metal detector
[3] Control of metal detector
The metal detector is switched on automatically together with the plant.
If metallic charged material is detected that has not been attracted by the
magnetic remover, the feeding conveyor switches off.
The metal detector is installed in material flow direction downstream of
the magnetic remover and below the feeding conveyor.
The sensitivity of the metal detector is set ex works.
NOTICE
Changes to the settings of the metal detectors made by KLEEMANN
GmbH can result in material damage.
• Do not change the settings.
• Repair and setting work on the metal detectors must be carried out
by authorised and qualified personnel only.

DESCRIPTION
Not assigned
2.11 Not assigned
2.12 Water system (option)

The spray system ensures a reduction in dust development at the mate-
rial transfer points on the plant. A low-pressure water pump generates
the necessary water pressure and volume flow. Spray nozzles, which can
be cut in and out individually, create a finely atomised spray at the re-
quired 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.
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 forma-
tion is possible. Dust formation can be reduced by the additional use of
belt covers and ejector chutes (special options) but not completely elim-
inated.
When processing demolished or cut asphalt, thorough cleaning of the
cooler fins must be carried out more frequently because the dust created
in this case tends to jam the cooler fins.
2.12.01 Water pump
5
4
2
7
1
Fig. 2.70: Water pump

[1] Pump housing
[2] Electric motor 230 V

DESCRIPTION
Water system (option)
[3] Terminal box

[4] Connection for water pump
[5] Fluid control
[6] Connection for flooded suction
[7] Connection for suction operation
The multi-stage self-priming water pump is designed for suction mode. In
flooded suction mode, the spraying nozzles are supplied directly with wa-
ter.
The water pump forwards the drawn-in water via the fluid control to the
individual feed lines for the nozzles. The fluid control guarantees a con-
stant pressure and prevents water running back from the feed lines. The
individual feed lines to the spraying 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 wa-
ter pump cabinet to the 230 V socket outlet.
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. 2.71: Spraying nozzles

[1] Spraying nozzles

DESCRIPTION
[2] Shut-off cocks

The water directed via the shut-off cocks and feed lines of the spray sys-
tem is distributed by the spraying nozzles in the form of a finely atomised
spray.
Spraying nozzles are fitted at the following points:
• Belt discharge, crusher discharge conveyor
• Belt discharge, feeding conveyor

DESCRIPTION
Not assigned
2.13 Not assigned
2.14 Not assigned
2.15 Not assigned
2.16 Not assigned
2.17 Not assigned
2.18 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

DESCRIPTION
Not assigned
2.31 Not assigned
2.32 Not assigned
2.33 Not assigned
2.34 Not assigned
2.35 Not assigned
2.36 Not assigned
2.37 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.kleemann.info

DESCRIPTION
Service packs/telemaintenance
2.41.02 Telemaintenance
Fig. 2.72: Telemaintenance modem

[1] Telemaintenance rotary switch
[2] Modem
[3] Aerial (not illustrated)
The modem for telemaintenance is installed in the switch cabinet behind
the switch cabinet door of the operator panel.
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 out-
side the switch cabinet.
Via the remote radio connection, the PLC control and the settings of the
frequency converter can now be read and changed.

DESCRIPTION
Tools
2.42 Tools
1 2
Fig. 2.73: Tools and accessories

(1) Toolbox
(2) Tools and accessories
The toolbox (1) contains all tools and accessory parts (2) required for
maintenance and repair work.
The toolbox is secured with a padlock to prevent unauthorised removal
of tools.

DESCRIPTION
Feeding unit
2.43 Feeding unit
2.43.01 Feed hopper
1
5
Fig. 2.74: Feed hopper

[1] Assembly plate of fill level monitor
(2) Feed hopper walls
[3] Hopper extension attachment point
[4] Hopper extension walls
[5] Hopper extension support brace
The feed hopper receives the material loaded by a digger, wheel loader
or an upstream plant.
The hopper walls are individually welded components. The support brac-
es of the hopper extension provide additional stability for the hopper ex-
tension.
The hopper extension consists of two halves that are bolted to one an-
other on the front and rear side.
The support structure is welded onto the chassis and accommodates the
hopper frame. The hopper extension is disassembled to transport the
plant.
During plant operation, the feed hopper is supported by hydraulic sup-
porting elements. They are retracted for plant transport.
A fill level monitor (option) is arranged above the feed hopper, which
switches off the cone crusher temporarily if the fill level of the charged
material is too low. If the fill level is too high, an upstream plant is
switched off.
If the plant is operated with the hopper extension, the fill level monitor
cannot be installed.

DESCRIPTION
Feeding unit
2.43.02 Cone crusher inlet
Fig. 2.75: Cone crusher inlet

[1] Assembly plate of fill level monitor
[2] Crusher inlet
[3] Crusher inlet attachment points
The crusher inlet guides the material from the feeding conveyor into the
cone crusher.
A fill level monitor (option) is arranged above the crusher inlet, which
switches off the cone crusher temporarily if the fill level of the charged
material is too low. If the fill level is too high, the feeding conveyor is
switched off.
To transport the plant, the crusher inlet and the fill level monitor must be
disassembled.

DESCRIPTION
Feeding unit
2.43.03 Feeder trough
1 2
Fig. 2.76: Feeder trough

[1] Wear lining
[2] Rubber mountings
[3] Chute trough
[4] Vibration motors
Fig. 2.77: Vibration motors

[5] Inner unbalance weight
[6] Electric motors 400 V
[7] Outer unbalance weight

DESCRIPTION
Crusher
The feeder trough is a vibrating conveyor that conveys the material load-
ed into the feed hopper by means of its oscillating movement to a down-
stream machine.
The chute trough [3] is supported on spring elements [2] on the chassis.
The feeding surface and flanks are covered with a wear lining [1].
The speed of the electric motors [6] can be controlled by the frequency
converter (see chap. 2.02.04). By means of the adjustable unbalance
weights [5] and [7], they generate a periodic vibratory movement.
The two vibration motors rotate in opposite directions.
2.44 Crusher
3
4
7
1
Fig. 2.78: Cone crusher

[1] Tramp release cylinder
[2] Adjustment ring
[3] Setting cap
[4] Clamping cylinder
[5] Crusher shell
[6] Crusher cone
[7] Head
Cone crushers crush the charged material in a circulating opening and
closing crushing gap between crusher shell and crusher cone. Thee ma-
terial is moved in the crushing gap until it can pass the discharge side.
The crusher cone runs on a crusher shaft and is support by pressure
bearings. The crusher shaft is moved by an eccentric in a circulatory tum-
bling movement through which the ring-shaped opens and closes.
The cone crusher is driven by an electric motor, which transmits its force
via a belt drive onto the countershaft of the cone crusher.

DESCRIPTION
Crusher
If crusher tools that deviate from the standard version are used, it may be
necessary to work at different speeds or with different belt pulleys.
Change belt pulleys, see chap. 4.44.10.
The crushing gap is adjusted by turning the bowl (see chap. 3.12).
Clamping cylinders block the gap setting device during operation.
In case of overloading, the bowl of the crusher is raised. This procedure
can also be tripped manually to eliminate material congestion (see chap.
3.11).
DANGER!
Danger when bowl moves up
In case of overloading, the bowl is raised abruptly. Contact with the bowl
can result in serious injury.
• During operation always stay clear of the direct vicinity of the cone
crusher.
Fill level monitor (option)

The fill level monitor at the crusher inlet monitors the fill level and switch-
es off the feeding conveyor in case of overfilling. When the crusher inlet
is free again, the feeding conveyor is switched on again.

OPERATION
Crusher
3 OPERATION
This chapter describes how the plant and the individual machines and
components are operated.

OPERATION
Crusher
1 2 3 4
1000
800 1600
500 500
400 400
600
400
200 200
200
0 0 0
5 6 7
9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7
25 26 27 28 29 30 31 32 33
34 35 36 37 38
39

[1] Fuel gauge Display of the fill level of the diesel fuel tank

OPERATION
Crusher

[2] Coolant temperature Indicates the current coolant temperature of the diesel engine in
°C
[3] Oil pressure Indicates the current oil pressure of the diesel engine in bar
[4] Ignition switch with control Starting and stopping the diesel engine, display of the operating
lamps status of the diesel engine, see description of "Ignition switch"
[5] Amperemeter Displays current consumption of plant
[6] Amperemeter Displays current consumption of the cone crusher
[7] Voltmeter Displays the voltage between the phases with the main switch
switched on
[8] Operator panel OP3 Interface for setting different plant parameters, see description
of "Operator panel OP3"
[9] Rotary switch for winter opera- On/Off switch for heating and lubrication of cone crusher
tion
[10] Rotary switch for probe On/Off switch for probe at feed hopper
[11] Rotary switch for probe On/Off switch for probe at crusher inlet
[12] Rotary switch for supports Moves supports up and down
[13] Rotary switch for lighting Switches plant lamps on/off
[14] Key switch for control voltage Switches plant control voltage on/off
[15] Plant ON button Switching on the plant
[16] Plant OFF button Switching off the plant
[17] Start-up enable control lamp Displays start enable of plant
[18] Acknowledge fault button Acknowledges faults and emergency stops
[19] Automatic mode/manual mode Switches over to operating modes automatic or manual. In man-
rotary switch ual mode position, the sequential locking device of the machine
is switched off
[20] Automatic mode control lamp Display for automatic mode
[21] Manual mode control lamp Display for manual mode
[22] Rotary switch for radio remote Switches plant on/off via radio remote control
control
[23] Button for driving hydraulics Switches driving hydraulics on and off
[24] Lamp test button Carrying out lamp test of control lamps
[25] Button for belt conveyor 1 Switches fine grain conveyor on/off
[26] Button for belt conveyor 2 Switches return conveyor on/off
[27] Button for crusher 3 Switches crusher on/off
[28] Button for magnetic remover 4 Switches magnetic remover on/off
[29] Button for belt conveyor 5 Switches crusher discharge conveyor on/off
[30] Button for feeder trough 6 Switches feeder trough on/off
[31] Button for auxiliary hydraulics Switches auxiliary hydraulics on/off
7
[32] Button for water pump Switches water pump on/off

OPERATION
Measures before initial operation

[33] Feeder trough rotary switch Increases/reduces vibratory speed of feeder trough
[34] On/Off pushbutton for cone Switch automatic mode of cone crusher on/off
crusher
[35] Increase crushing gap push- Increases the crushing gap of the cone crusher
button
[36] Reduce crushing gap button Reduces the size of the crushing gap of the cone crusher
[37] RESET button Lowers the bowl and enable automatic mode
[38] Lift bowl button Button for lifting the bowl
[39] Emergency-off button Switches plant off in emergencies, see chap. 2.01.07
Tab. 3.1: Operator panel control elements
3.01 Measures before initial operation
DANGER!
Danger due to unqualified personnel
Installation and initial operation by unqualified and unauthorised person-
nel can result in serious or fatal injuries.
• Only assign personnel installation and initial operation tasks who are
qualified and authorised according to the requirements in this instruc-
tion manual.
NOTICE
Danger of material damage through foreign bodies
Foreign bodies in the plant, such as tools, accessories and packaging
materials, can result in malfunctions and material damage.
• 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 packaging
materials from the plant.
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.

OPERATION
Switching external power supply on and off (option)
3.02 Switching external power supply on and off (option)
Fig. 3.2: External power supply main switch

[1] Switch cabinet
[2] Main switch for external power supply
[3] Main switch for diesel generator
The two main switches are locked reciprocally and can only be operated
separately.
Operating plant via external power supply

 Turn the "Diesel generator" main switch to the "OFF" position.
 Turn the "External power supply" main switch to the "ON" position.
 The plant is run via the external power supply.
Operating plant via diesel generator

 Turn the "External 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.
3.03 Putting the plant into operation
DANGER!
tion manual.

OPERATION
Switching plant on and off
Before initial operation of the plant, the following items must be checked:
Lubricating and operating • Lubricant and hydraulic oil level of the cone crusher.
materials • Lubrication of belt conveyor drives (see chap. 4.10.01.04).
• Fill level of the water system (option) (see chap. 4.12).
Leak-tightness and condition • Check condition of conveyor belts (see chap. 4.10.01.01).
• Check condition and presence of safety devices (see chap. 2.01.06).
• Condition of cone crusher.
• Check security of screw connections.
• Check closure of all service doors and flaps.
• Check water system for leaks (option).
Functions • Check operation of the emergency stop and emergency switching off.
Special care must be taken before long working periods or after a long
period out of use.
Top up lubricants and operating materials. The maintenance schedule
and operating material and lubricants tables are provided in chap. 5.02.
3.04 Switching plant on and off
3.04.01 Switching 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 engine
is running.
 Diesel engine starts up.
 Release ignition key.
 Diesel engine runs at preset speed of approx. 1500 rpm.
NOTICE
In critical operating statuses, the diesel engine shuts down automatically
and the warning siren sounds.
• Before switching on again, find the cause and eliminate it.
Switching diesel generator off

Before switching off the diesel engine, let it run for approx. 4 minutes
without load to cool down.
 Turn ignition key to STOP position.
 Remove ignition key.
 Diesel engine is stationary.

OPERATION
3.04.02 Switching plant components on and off
DANGER!
Risk of falling material
Persons in the danger zone of the plant can be injured by falling material
when the plant is started up.
• Do not enter the danger zone when the plant is 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 components can be
switched on. This is carried out in "Automatic" operating mode. For man-
ual mode, see chap. 3.05.
In automatic mode, plant components are switched on automatically in
the opposite direction to material flow. This prevents material conges-
tions when the plant is started up.
Before the plant components can be started, all emergency-stop devices
must be released.
For release of emergency-stop devices, also refer to chap. 2.01.07.
The operating plug must be connected at the switch cabinet, see chap.
2.06.06.
Switching on plant components
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38
Fig. 3.3: Switches and operator panel buttons

 Switch on diesel generator (see chap. 3.04.01).
 Turn the main switch to RESET and then to ON (also refer to chap.
2.02.01).

OPERATION
 Switch on the "Control voltage" [14] key switch.

 The operator panel OP3 powers up and "KLEEMANN GmbH" ap-
pears in the display.
 Set the rotary switch "Automatic mode/manual mode" [19] to auto-
matic mode.
 The "Automatic mode" [20] control lamp lights up.
 Switch off rotary switch for radio remote control [22] at the operator
panel.
 Press the "Acknowledge fault / Emergency off" [18] button.
 If no more emergency stop or emergency switching-off buttons have
been pressed, the light in the button goes out.
 Press the "RESET" [37] button.
 The "RESET" [37] button flashes.
 Press the "Cone crusher ON/OFF" [34] button.
 The "Cone crusher ON/OFF" [34] button lights up. The cone crusher
powers up.
 Press the "Plant ON" [15] button.
 Belt conveyors 1 and 2 power up automatically. The corresponding
buttons [25] and [26] light up. The "Crusher" [27] button flashes.
 Press the "Plant ON" [15] button once again as soon as the "Crusher"
[27] button lights up.
 The warning light and warning siren lights up or sounds for approx. 7
seconds. The control lamp "Start-up enable" [17] lights up.
 Press the "Magnetic remover" [28] button.
 The remaining plant components power up automatically.
 Press the water pump [32] button as required.
 The water pump runs and the button lights up.
Switching off plant components
NOTICE
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.
 Allow the plant to run completely empty.

 Press the water pump [32] button if necessary.
 The water pump switches off and the button light goes out.
 Run the crusher until empty.

OPERATION
 Press the "Plant OFF" [16] button.

 All plant components are switched off immediately. The "Start-up en-
able" [17] control lamp and the "Plant ON" [15] button light go out.
The corresponding button lights of the components [25-30] go out.
 Switch off the "Control voltage" [14] key switch and remove the key.
 Turn 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
DANGER!
Switching plant on again after emergency stop

After actuation of an emergency stop or a pull 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 congestions in the plant if necessary, see chap.
3.11.
 For unlocking of the plant emergency-stop buttons, emergency-stop
switches of the pull cords and emergency-stop buttons of the radio
and wired remote control, see chap. 2.01.07.
 Press the button "Acknowledge fault and enable" [18].
 If no more emergency-stop buttons are pressed, the button lights up.
The plant components are ready to be switched on again.
 Switch the plant components on again.
The OP3 operator panel shows the actuated emergency stop.
Switching plant on again after emergency switching off
After actuation of the emergency switching off button in the switch cabi-
net, all 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.
3.11.
 Unlock emergency switching off button, see chap. 2.01.07.

OPERATION
Manual operation

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.
3.05 Manual operation
DANGER!
Execution of "Manual mode" by unqualified and unauthorised personnel
can result in serious or fatal injuries.
• Only assign maintenance, repair and service tasks to personnel who
are qualified and authorised according to the requirements in this in-
struction manual.
NOTICE
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 component.
As opposed to automatic mode, in manual mode the plant components

are not switched on automatically in the opposite direction to the material
flow.
After the diesel generator has been started, the plant components can be
switched on and off individually.
Switching on plant components in "Manual mode"

OPERATION
Manual operation
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Ensure that the operating plug is inserted at the switch cabinet (see
chap. 2.06.06).
 Turn the main switch to RESET and then to ON (also refer to chap.
2.02.01).
 Set the rotary switch "Automatic mode/manual mode" [19] to manual
mode.
 The "Manual mode" [21] control lamp lights up.
 Switch off rotary switch for radio remote control [22] at the operator
panel.
 The warning light and warning siren lights up or sounds for approx. 7
seconds. The "Start release" [17] control lamp lights up and the "Plant
ON" [15] button flashes.
 The button [37] flashes.
 Press the "Cone crusher On/Of" [34] button.
 The button [34] lights up. The cone crusher powers up.
 Press the "Plant ON" [15] button once again.

OPERATION
Manual operation
 Press the button of the desired plant components [25-30].

 The corresponding plant components run up and the button light up.
Buttons [25] and [26] must be pressed before pressing the "Crusher ON"
[27] button.
Control lamp "Start enable" [17] must light up; press the "Plant ON" but-
ton a third time if necessary.
Switching off plant components in "manual mode"
NOTICE
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.
 Run the crusher until empty.

 Press the buttons of the running plant components [25-30].
 The corresponding plant components are switched off and the button
lights go out.
 Press the "Plant OFF" [16] button.
 The "Start enable" [17] control lamp and the "Plant ON" [15] button
light go out.
 Switch off the "Control voltage" [14] key switch and remove the key.
 The "Manual mode" [21] control lamp goes out.
 Turn the main switch to OFF.
 The plant components are switched off. The diesel generator is still
running.

OPERATION
Moving hopper supports up and down
3.06 Moving hopper supports up and down
2
3
Fig. 3.5: Supports

[1] Supporting element for hopper support
[2] Securing screws for hopper support
[3] Swivellable hopper support
NOTICE
If support feet are not moved out, this can result in plant instability during
operation and high loads on the chassis.
• Move support feet out before operating the plant.
• Ensure that the support feet are on firm ground.
To prevent damage to the plant and supporting elements, the position of

the supporting elements is queried by the control system.
Driving operation is only possible with the supporting elements moved
up; automatic mode is only possible with supporting elements moved
down.
If the supporting elements are moved up during automatic mode, the
feeding conveyor is switched off and the material supply to the crusher is
thus stopped.

OPERATION
Moving hopper supports up and down
NOTICE
If securing screws are not installed or tightened on the supporting ele-
ments, this results in material damage to the chassis and hopper sup-
ports.
• Ensure that the securing screws of the supporting elements are in-
stalled and tightened.
• Never move out supporting elements with missing or loose securing
screws.
Moving supporting elements  Switch on diesel generator (see chap. 3.04.01).

down
 Turn the main switch of the diesel generator to RESET and then to
ON (also refer to chap. 2.02.01).
mode.
WARNING!
Risk of crushing in the area of the support feet
Severe crushing injuries to the feet may occur when shutting down the
support feet.
• Do not stand in the hazard area of the support feet during shut-down.
• Ensure that there are no persons in the hazard area during shut-
down.
 Use the rotary switch "Move supports up/down" [12] to move the sup-
porting elements down.
 The auxiliary hydraulic system starts up automatically and keeps the
supporting elements under pressure when the plant is running. The
plant is ready again for automatic mode.
Start supporting elements  Switch on diesel generator (see chap. 3.04.01).
mode.
 Press the button for auxiliary hydraulic system [31].

OPERATION
Operating the plant
 Use the rotary switch "Move supports up/down" [12] to move the sup-
porting elements up.
 The supporting elements have been moved up. The auxiliary hydrau-
lic system switches off automatically after approx. 2 minutes.
 The plant is ready to be moved.
To transport the plant, the supporting elements must be swivelled, see
chap. 6.03.10.
3.07 Operating the plant
DANGER!
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 driv-
ing 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.
3.07.01 Preparations
The plant can also be moved with all components installed.
NOTICE
Danger of material damage when driving
Crawler carrier chains can freeze up and seize up and break when driv-
ing off.
When the plant is moved and turned, untensioned crawler carrier chains
can spring off the sprocket and cause damage to the crawler running
gear.
The suspension of the magnetic separator can be damaged by vibra-
tions.
• 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.
• Fit transport locking devices on the magnetic remover (option).
Prior to moving the plant, a few preparatory measures must be carried

out:
 Run all components, such as hopper, feeder trough, crusher and belt
conveyors, until they are emptied of all material.

OPERATION
Operating the plant
 Fit transport locking devices, e.g. lashing straps, on the magnetic re-
mover.
 Remove the earthing rod.
 Remove stones and adhering dirt from the running wheels and crawl-
er 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 necessary.
 Observe ground clearance of the plant.
 Appoint banksman/banksmen.
Moving plant on gradients
DANGER!
Danger of plant toppling
Persons in the driving range of the plant can sustain serious or fatal inju-
ry.
• Keep a safe distance away from the plant when it is moving.
• Before moving the plant, ensure that there are no persons in the driv-
ing area.
• Only move the plant within the specified inclination values.
NOTICE
Danger of material damage when driving
Driving on downward and ascending slopes subjects the components of
the crawler running gear to very high loads.
• When driving on gradients, always ensure that the track drive of the
crawler running gear faces downhill.
• Drive carefully on slopes and always directly upwards or downwards.
• Avoid driving in transverse direction on downward slopes.

OPERATION
Operating the plant
17
Fig. 3.6: Ascending slopes and downward slopes

[1] Track drive
 Fill diesel fuel up to approx. ¾ of the maximum fill height so that the
diesel engine does not stall on upward or downward gradients.
 Before driving off on gradients, align the plant at right angles to the
slope.
 Ensure the track drive [1] is facing downhill.
 Start driving on the slope.
3.07.02 Driving
DANGER!
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 flagmen.
• In dangerous situations, stop the plant immediately.
Driving with radio remote  Ensure that the traverse path of the crushing plant is flat and firm.
control

OPERATION
Operating the plant
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Switch on transmitter of the radio remote control and unlock the
emergency stop, see chap. 3.04.03.
 Switch on rotary switch "Radio remote control" [22] at the operator
panel.
mode.
 Press the "Plant/crusher ON" [15] button.
 The warning light and warning siren lights up or sounds for approx.
10 seconds. Press the "Plant/crusher ON" [15] button.
 Move supports up (see chap. 3.06).
 Press the "Driving hydraulics" [23] button.
 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 crawler 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 deflection of the levers.

OPERATION
Operating the plant
It is not possible to move the plant with extended supports.
Driving with wired remote  Ensure that the traverse path of the crushing plant is flat and firm.
control
mode.
 The "Manual mode" [21] control lamp lights up.
 Switch off rotary switch "Radio remote control" [22].
 The warning light and warning siren lights up or sounds for approx.
10 seconds. Press the "Plant/crusher ON" [15] button.
 Insert the wired remote control in the corresponding socket in the
switch cabinet (see chap. 2.06.06).
 If necessary, release the emergency stop of the wired remote control.
 Move supports up (see chap. 3.06).
 Press the "Driving hydraulics" [23] button.
 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 crawler 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 deflection of the levers.
It is not possible to move the plant with extended hopper supports.
3.07.03 Shutting down the plant
NOTICE
Increased wear
The plant can only operate correctly on flat ground. Inclinations in the lon-
gitudinal and transverse axis result in reduced crushing capacity, one-
sided wear and material congestion.
• Move the plant to align it on flat ground.

OPERATION
Refuelling the plant
Plant accessories include a spirit level, which is secured on the chassis,

and permits exact horizontal alignment of the plant.
 Stop the plant on a flat and stable surface.

 Move supports down (see chap. 3.06).
 The supports are moved hydraulically into operating position.
 Switch off the radio remote control or disconnect the wired remote
control.
 If applicable, switch off the "Radio remote control" [22] rotary switch.
 Set the rotary switch "Automatic mode/manual mode" [19] to auto-
matic mode.
 The plant is ready again for operation.
3.08 Refuelling the plant
WARNING!
Danger of fire
Diesel fuel can ignite during refuelling.
• Do not smoke or use an open flame during refuelling.
• Keep burning objects well away from the fuel tank.
3
2
Fig. 3.8: Refuelling the plant

[1] Diesel fuel tank
[2] Filler neck

OPERATION
Operating water system (option)
[3] Shut-off cock of fuel supply (see also chap. 2.04.02)

 Position the tanker or fuel tank as close as possible to the filler neck.
 Remove base plate from platform for power supply unit and crusher.
 Take off the end cover of the filler neck.
 Fill the plant's fuel tank.
 Close the filler neck again.
 Reinsert base plate for platform for power supply unit and crusher.
 When the diesel generator is switched on, the fuel gauge in the
switch cabinet indicates the fill level of the fuel tank.
3.09 Operating water system (option)
NOTICE
Operation without water and operation with contaminated or frozen water
destroys the water pump.
• Always ensure there is a sufficient water supply.
• Only use clean water that is not frozen.
• If there is a risk of frost, completely drain the water system.
 Guarantee the conditions for operating the water system, see chap.
2.12.
 Switch on crushing plant.
 Connect water pump to 230 V socket outlet in water pump cabinet.
 Press the "Water pump" button in the operator panel (see chap.
2.02.02).
 Open or close the corresponding shut-off cocks of the supply lines to
the spraying nozzles.
 The water system sprays a water mist at the relevant points.
3.10 Loading the plant
DANGER!
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.

OPERATION
Loading the plant
3.10.01 Suitable loading vehicles
NOTICE
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 shovels or buckets that are too small
or too large.
Correct loading of the plant requires upstream crushing and screening

systems or belt conveyors that match the plant size and charged materi-
al. With a suitable hopper attachment (option), the plant can also be load-
ed with a wheel loader or digger.
Requirements of loading vehicles
• Sufficient loading capacity of the shovel or bucket of the digger, which
is matched to the plant size and the charged material.
• Wheel loader suitable for the plant size and charged material.
• 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 re-
quired discharge height.
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 com-
ponents.
• No risk of collisions between the plant and loading vehicles.
3.10.02 Preparing the charged material

Well prepared charged material permits optimum use of the plant, reduc-
es wear on the individual machines and components and guarantees
trouble-free operation.

OPERATION
Loading the plant
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 maximum
crushing ratio.
• Never load unbreakable material, e.g. steel girders.
• Never load pressure vessels, explosives, chemicals or similar mate-
rials.
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.
3.10.03 Loading the feed hopper
Fig. 3.9: Loading the feed hopper

Correctly loaded material permits an optimum material flow and prevents
material congestions.
• Load material in regular intervals and in approximately equal quanti-
ties into the feed hopper.
• Only fill feed hopper approximately half full. If the loading level in the
hopper is too high, the feeding conveyor can no longer draw off the

OPERATION
Loading the plant
material in a trouble-free manner. Particularly with wet, clayey

charged material, the feeding conveyor then passes through empty.
• Where possible, ensure that a material bed always remains in the
feed hopper and feeding conveyor. Recurring loading of the empty
feeding conveyor can lead to deformation and increase drive wear.
• Guarantee a uniform material flow and layer thickness on the feeding
conveyor. Optimum feeding of the cone crusher is mainly determined
by uniform loading of the material.
• Adjust the feeder trough via the frequency converter so that an even
material flow is guaranteed.
NOTICE
If the range of the radio remote control is exceeded, the emergency stop
is tripped and material congestion in the plant can result.
• During plant operation, ensure that the range of the radio remote con-
trol is never exceeded.
• Never carry the radio remote control along in the wheel loader or dig-
ger and thus leave the range.
• Always ensure there is visual contact between transmitter and receiv-
er.
• Store the radio remote control in the plant's switch cabinet housing
when not in use.
NOTICE
Incorrect loading or setting of the feeder trough leads to continuous acti-
vation and deactivation of the feeder trough. This, in turn, places an un-
necessary load on the frequency converter 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 au-
tomatic switch-off system only trips in extreme cases (reference val-
ue: max. 10 times an hour).
• Only switch the feeder trough back on following an overload shut-
down once it has come to a complete standstill.

OPERATION
Loading the plant
3.10.04 Loading the cone crusher
Fig. 3.10: Cone crusher loading

The main influences on the optimum loading of the cone crusher are
loading of the crusher inlet, an even material flow and the setting of the
crushing gap.
If the cone crusher is overloaded, e.g. through unbreakable material, the
crusher shell can retract to a certain degree.
NOTICE
Continuous overfilling of the cone crusher results in premature wear and
can cause the overload protection to trip, thus causing material conges-
tion.
Insufficient material and one-sided filling causes the adjustment ring to
knock against the lower frame and thus causes premature wear or de-
struction of the cone crusher.
• Ensure that loading of the impact crusher is correct.
Correctly loaded material permits optimum utilisation of the crushing ca-

pacity and avoids material congestions.
• Guarantee optimum filling of the cone crusher at all times. The cone
crusher should run at full load, but must not be overfilled.
• Correctly set the gap width between crusher cone and crusher shell,
see chap. 3.12.02.
• Ensure that the material flow to the cone crusher is even, see chap.
3.10.
Condition of material:

OPERATION
Eliminating material congestion
• The material should be as dry as possible and should not contain

sticky or caked shares.
• Do not exceed the maximum size and length of the edge of the
charged material. Excessively large material blocks the crusher inlet.
The cone crusher should operate in its full rated power range. Output
peaks of over 110% of its rated power should be avoid in all circumstanc-
es.
The cone crusher must never be operated continuously below or at 50%
of its output. During the switch-on and switch-off phases, operation at low
power is permissible.
If the material flow to the cone crusher is interrupted for more than 30
minutes, the cone crusher should be switched off.
3.11 Eliminating material congestion
DANGER!
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.
• Never open service doors and flaps when the plant is running.
• Allow the crusher to coast to a complete standstill.
• Switch off the plant, remove the key and secure against reactivation.
• Attach appropriate warning sign in a clearly visible area.
• Observe the safety instructions.
Material congestions can have different causes:

• Settings that do not match the plant, for e.g. delivery speed of feeder
trough is too high.
• Cone crusher gap width is too small.
• Maximum feeding size is exceeded.
• Loading of unbreakable materials.
Material congestions can occur at different points of the material flow:
• At the crusher inlet due to blockages above the crushing jaw.
• Crusher standstill due to jamming of unbreakable materials in the
crusher chamber.
• At the crusher outlet through accumulation of broken material on the
crusher discharge conveyor.
• Blockages or jams at all other material transfer points due to bulky
material.

OPERATION
Eliminating material congestion outside the cone crusher

Preparations Before starting to eliminate material congestion, it is essential to carry out
the following activities:
 Allow the crusher to coast to a complete standstill.
 Switch off all plant components.
 Switch diesel generator off.
 Remove key and secure plant against reactivation.
 Attach appropriate warning sign in a clearly visible area.
 Warn other persons before starting work on the plant.
 Prepare suitable tools.
 Wear protective equipment.
 All preparations have been made. The material congestions can be
cleared.
Eliminating material Material congestion always differs according to the situation. The follow-
congestions ing listed items describe possible procedures and information on avoid-
ing hazards:
• Note that stones, unbreakable material and, in particular, reinforcing
steel can accumulate a considerable amount of stored energy.
• Always clear material congestion from top to bottom to avoid the dan-
ger of follow-up material slipping and material falling.
• Remove material that has passed the crusher with the help of the
crusher discharge conveyor. Never move under a crusher when there
is a danger of falling stones.
• If necessary, remove material under the crusher with shovels or high-
pressure water jets.
• Use suitable tools, such as crowbars, pickaxes or shovels, to loosen
and remove material congestion at vibrating conveyor troughs and
belt conveyors. Never attempt to clear material congestion in the
area of the feeding unit with wheel loaders or diggers. This could de-
stroy plant components.
• Never use explosives to eliminate material congestions.
• Never use flame cutters to cut out material or components. Stored
energy in the material can result in unexpected movements of the
material and crusher.

OPERATION
Eliminating material congestion in cone crusher
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

Removing material Material remaining in the cone crusher can be removed by lifting the
automatically bowl.
 Allow the crusher to coast to a complete standstill.
 Switch off all other plant components; do not switch off the diesel
generator.
 Press the "Lift bowl" [38] button and raise the bowl to the maximum
height. Keep the button held in.
 The material falls out of the crusher at the side.
 Release the "Lift bowl" [38] button. The bowl is lowered onto its lower
frame.
 Repeat procedure if necessary.
 Tramp release cylinders are clamped and the start-up enable is is-
sued.
By pressing the "RESET" button, the bowl is lowered faster and the tramp
release cylinders are clamped.
Removing material by hand If the material in the crusher is large, the bowl of the crusher must be
blocked and the crusher must be cleared.

OPERATION
WARNING!
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 secure.
• Do not jump from the climbing aids or the plant.
WARNING!
Danger of crushing by bowl
When the hydraulic system is actuated, the bowl is moved up or down.
Fingers or hands may be crushed.
• Do not stand or reach between the bowl and lower frame when the
hydraulic system is actuated.
• Never reach into the area between the bowl and lower frame with the
securing blocks inserted.
WARNING!
There is a risk of injury when inserting and removing the securing blocks.
Fingers or hands may be crushed.
• Two persons are always required when inserting and removing the
securing blocks.
• When inserting and removing the securing blocks, raise the bowl to
the maximum height and hold in the button.
WARNING!
Risk of crushing by the cone crusher
Elimination of material congestion in the cone crusher without installed
securing blocks can result in serious or fatal injuries.
• When elimination material congestion in the cone crusher, always in-
stalled the securing blocks.
• Never attempt to remove material from the cone crusher before the
securing blocks are installed.

OPERATION
Fig. 3.12: Raising bowl

[1] Lower frame
[2] Bowl adjustment ring
Raising bowl  Allow the crusher to coast to a complete standstill.
 Switch off all other plant components; do not switch off the diesel
generator.
If the "Lift bowl" button is no longer pressed, the bowl lowers and safe in-
stallation of the securing blocks is no longer guaranteed.
Fig. 3.13: Installing securing block

[2] Adjustment ring

OPERATION
[3] Securing block

 Evenly insert securing blocks [3] between adjustment ring and lower
frame. Ensure that the securing blocks do not bear upon the bush-
ings of the lower frame.
 Release the "Lift bowl" button.
 The adjustment ring on the bowl lowers onto the securing blocks.
 Remove key and secure plant against reactivation.
 The crusher can be cleared manually.
DANGER!
Danger of securing blocks being ejected at high speed
If the tramp release cylinders are subject to clamping pressure while the
securing blocks are inserted, they can be ejected at a high speed and
cause serious injury.
• Remove the securing blocks before the tramp release cylinders are
clamped.
• Never subject the tramp release cylinders to clamping pressure when
the securing blocks are installed.
NOTICE
Placing the tramp release cylinders under pressure when the securing
blocks are installed can result in damage or a failure of the hydraulic sys-
tem.
• Remove securing blocks before actuating the "RESET" button.
• When the securing blocks are installed, never subject the tramp re-
lease cylinders to clamping pressure.
Removing securing blocks  Start diesel generator, see chap. 3.04.01.

 Turn main switch in the direction of RESET and then to ON.
 Activate key switch for "control voltage".
 Remove securing blocks.
 Release the "Lift bowl" button. The bowl is lowered onto its lower
frame.
 Plant components and cone crusher can be started.
By pressing the "RESET" button, the bowl is lowered faster and the tramp
release cylinders are clamped.

OPERATION
Checking/adjusting crushing gap
 Start plant components and cone crusher, see chap. 3.04.02.

Final tasks After elimination of material congestion, the following final tasks must be
carried out:
NOTICE
Starting up the crusher drive against a blocked crusher can destroy the
crusher and control elements.
• Eliminate material congestion before starting the crusher.
• Completely empty the crushing chamber.
 Remove all tools used from plant machines and components.

 Ensure that no oversized material on the crusher discharge conveyor
is moved on. This can result in damage to the following components.
 Reinstall disassembled guard devices and components, ensuring
they are correctly fitted.
 Ensure that there are no more persons in the hazard area.
 The plant is ready to be switched on again.
3.12 Checking/adjusting crushing gap
3.12.01 Checking the crushing gap
WARNING!
Risk of falling
There is a risk of falling during setting work on the plant components.
• Check if the climbing aids are secure and safe to use.

OPERATION
Checking/adjusting crushing gap
2
3
1
4
Fig. 3.14: Checking the crushing gap

[1] Crusher cone
[2] Crusher shell
[3] Adjustment ring
[4] Parallel area
The desired grain size of the product is mainly influenced by the settings
at the cone crusher. Properties of the material to be crushed and the per-
formance of the drive motor also have an influences on the grain size,
shape and crushing capacity.
The distance between the crusher cone and crusher shell in the parallel
area should be slightly smaller than the maximum size of the desired
product.
 Cast lead pieces that are slightly smaller than the crushing gap at the
open side. Cast a wire loop into the lead pieces.
 Fasten a lead piece to a long flexible wire.
Aluminium foil can also be used as an alternative to a lead piece. For this
purpose, a ball is formed from the aluminium foil which is slightly bigger
than the opened crushing area.
 If necessary, fasten the ball of aluminium foil to a long cord.
 Start the plant, see chap. 3.04.
 Fill the cone crusher with crushing material.
 Stop the feeding unit and run the crusher empty.
 Immediately lower the lead piece or ball slowly through the parallel
area of the running cone crusher.
 Withdraw the lead piece or ball.

OPERATION
Clearing away waste tip
 Repeat the procedure with further lead pieces or balls at four posi-
tions approx. 90° apart on the cone crusher.
 By comparing the four thickness, you can determine whether the ad-
justment ring is lying horizontally on the bowl or whether it is offset
due to wear of a crushing tool.
3.12.02 Setting the crushing gap

Setting the crushing gap The crushing gap can be altered during operation. Use the buttons in the
operator panel to do this.
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Stop the feeding unit and run the crusher empty.
 Press the button [34] as soon as the cone crusher is empty.
 The light in the button [34] goes out and the feeding units stop.
 Press the button [35] and hold it in.
 The setting cap and the bowl turn counterclockwise. The crushing
gap is widened.
 Press the button [36] and hold it in.
 The setting cap and the bowl turn clockwise. The crushing gap is nar-
rowed.
 Check crushing gap if necessary, see chap. 3.12.01.
Turning the geared ring by four teeth corresponds to a crushing gap ad-
justment of approx. 1 mm.
3.13 Clearing away waste tip

The dispersion and height of the waste tip created below the discharge
areas of the belt conveyors must be monitored.

OPERATION
Winter operation
• The waste tip must not be allowed to spread as far as the crawler run-
ning gear and plant components.
• Never let the waste tip reach the lower edges of the belt conveyor.
The clearance between the top of the waste tip and the belt conveyor
must not be less than 250 mm. Waste tips that are too high and touch
the belt conveyors can cause damage to conveyors, scrapers and
sealing.
• Always remove waste tips with wheel loaders in good time. Ensure
that wheel loaders do not collide with plant components during this
operation.
• When clearing the waste tip, ensure that it is not pushed against the
plant causing the crawler running gear or other plant components to
be covered or damaged.
3.14 Winter operation

Before and during the winter period, the plant must be prepared for the
cold season.
Coolants
 Fill the cooling system with a sufficient concentration of approved an-
tifreeze.
 During frost periods, check the corrosion inhibitor and antifreeze
more frequently.
For permissible antifreezes for the diesel engine, refer to the manufactur-
er's documentation.
Engine oil
 Replace the oil of the diesel engine in good time with an approved en-
gine oil in the specified SAE classes.
For permissible engine oils for the diesel engine, refer to the manufactur-
er's documentation.
Winter diesel fuel

 At outside temperatures below 0 °C, switch over to a diesel fuel with
sufficient flowability.
For permissible measures for improving the flowability of the diesel fuel,
refer to the manufacturer's documentation.
Cold-resistant winter diesel fuels in Germany are inherently safe up to
approx. -20 °C. In other countries deviations are possible.
With the Arctic Package special equipment, the diesel fuel must have an
operating range of up to -25 °C.
12 V starter batteries
 During the cold season, check the acid level of the 12 V starter bat-
teries more frequently. If necessary, top up with distilled water.
 Charge the starter batteries as required.

OPERATION
Winter operation
Sealing and scrapers

 Before switching on plant components, check that sealing and scrap-
ers that make contact with moving components are not frozen.
Crawler running gear

 Before moving the plant, check that the components of the crawler
running gear are not frozen.
6
1
Fig. 3.16: Water system for winter operation

[1] Water drain screw
[2] Shut-off cock for supply line
[3] Shut-off cock for suction line
[4] Shut-off cock for spraying system
[5] Connection for supply operation
[6] Connection for suction operation
At outside temperatures below 0 °C, the water pump and the spray sys-
tem can be operated provided that continuous operation is guaranteed.
When the plant is out of service for long periods, e.g. over night, the water
must be drained from the water pump and the feed lines to the spraying
nozzles to prevent freezing.
 Fit a suitable drain channel under the water drain screw of the water
pump [1]. The water must be directed out of the switch cabinet.
 Disconnect the water supply [2] on the outside of the switch cabinet
from the plant.
 Unscrew the water drain screw [1] and drain the water.
 Turn all shut-off cocks on feed lines [3] and [4] to the direction of flow
and drain the water.

OPERATION
Help and troubleshooting
 Insert the water drain screw [1] again and turn the shut-off cocks so
that they are transverse to the direction of flow.
 The water system is protected against freezing.
3.15 Help and troubleshooting
3.15.01 Starting the engine with jump leads
DANGER!
Danger when handling batteries
Risk of explosion due to explosive gas!
• After opening the protective housing of the power supply unit, wait
some time to allow air to enter.
• Never use an open flame and do not smoke.
• Avoid short circuits and sparks.
• Do not place tools on the batteries.
Precautionary measures • Ensure that batteries have same rated voltage.

• A discharged battery can even freeze at temperatures of around
0 °C. It is essential to defrost batteries in a warm room before con-
necting jump leads.
• Use jumps leads with isolated pole terminals and a cross-section of
at least 25 mm2.
• The pole terminals of one cable must not make contact with the ter-
minals of another cable.
• Do not disconnect discharged battery from the diesel generator.
• The charging vehicle and the plant must not touch each other.
Connecting cables  Connect one pole terminal of a cable to the positive pole of the
charged battery (plus sign).
 Connect the other pole terminal of this cable to the positive pole of
the discharged battery (plus sign).
 Connect one pole terminal of the second cable to the negative pole
of the charged battery (minus sign).
 Connect the other pole terminal of the second cable to the earth of
the diesel generator, e.g. at the engine block or the securing screw of
the engine suspension. Do not connect the pole terminal to the neg-
ative pole of the discharged battery (risk of explosion) but rather as
far as possible from the discharged battery.
 Route the cables such that they cannot be caught by rotating parts
and that they can be safely removed with the diesel generator run-
ning.
Starting engine  Start the engine of the charging vehicle and run at average engine
speed.

OPERATION
 Start the diesel generator after approx. 5 minutes.

 Continue running both engines with the connected jump leads for ap-
prox. 3 minutes at average engine speed.
Removing cables  To avoid overvoltages in the electrical system, prior to removal of the
jump leads switch on an electrical consumer in the plant (e.g. water
pump).
 Remove the jump leads in reverse sequence to connection.
 The starting aid procedure is complete.

MAINTENANCE
4 MAINTENANCE
This chapter describes maintenance and repair work that has to be ar-
ranged or carried out. Filling volumes and maintenance intervals are
specified in chap. 5.01 and chap. 5.02.
Specifications for lubricating greases and oils are provided in the section
on fluids and lubricants in chap. 5.04.
DANGER!
Performance of maintenance, repair and service work by unqualified and
unauthorised personnel can result in serious or fatal injuries.
struction manual.
All guard devices, panelling and component securing elements must be

returned to their original position following maintenance, repair and serv-
ice work.
Check the security of nuts and screws on a regular basis and tighten if
necessary! The tightening torques are specified in chap. 5.03.
To guarantee perfect operation of the machines and components and to
reduce wear, the maintenance intervals must be observed.
All maintenance, repair and service work not described in this chapter
must only be carried out by personnel trained by KLEEMANN GmbH.
This includes repair work at the hydraulic and electrical system and on
the diesel generator.
Observe the following safety instructions:
• Allow all plant components, such as crushers, vibrating conveyor
troughs, vibrating screens and belt conveyors to completely run emp-
ty.
• Always carry out repair, maintenance and cleaning work, including
the elimination of malfunctions, with the plant shut down and at a
complete standstill.
• Park the plant on a flat and stable surface.
• Safeguard the plant against unauthorised start-up.
– Remove ignition key.
– Switch off and lock main switch.
– Lock switch cabinet.

MAINTENANCE
– Attach warning sign warning against restart.

• Switch off the hydraulic system and safeguard against restart.
• Replace hydraulic hoses after 6 years usage at the latest, including
a storage time of a maximum of two years.
• Switch off all upstream and downstream plants and machines and se-
cure against accidental reactivation.
• Only open plant doors and flaps after movable parts have come to a
standstill.
• Inform operating personnel before starting maintenance, repair and
service work.
• Follow the safety instructions to avoid injury and accidents.
• Retrofitting, welding and repair work on the plant must only be carried
out by authorised personnel trained by KLEEMANN.
• For welding work instructions, see chap. 4.46.
• During replacement, lift heavy components with suitable hoisting
gear and lifting accessories and secure after depositing.
• Set the replaced electrical and hydraulic components in accordance
with the specifications on the identification plates and the circuit dia-
grams.
• Before working on valves, hydraulic cylinders or hydraulic lines, pro-
vide a base or support for belt conveyors, hopper walls and other hy-
draulically actuated components.
• Settings on throttle and pressure relief valves must only be carried
out by service personnel trained by KLEEMANN. It is prohibited to re-
move lead seals from safety valves.
• Tighten screw connections to specified tightening torque and check
for security.
• Once maintenance, repair and service work is finished, check wheth-
er all safety devices are working properly.
• Perform the specified maintenance tasks in accordance with the
schedules.
• Only use spare parts, filters, lubricating greases and oils offered by
KLEEMANN. Components, fluids and lubricants from other manufac-
turers can cause damage.
• Place old filters in a suitable container to catch escaping used oil or
fuel.
• Dispose of filters, used oil, fuel and grease in an environmentally
friendly manner in accordance with local specifications.
4.01 Chassis/guard devices
4.01.01 General maintenance tasks

Carry out the following maintenance tasks:

MAINTENANCE
Signs
 Check that the plant signs (hazard, prohibition, mandatory and infor-
mation signs) are all attached and are easily legible. Replace dam-
aged decals.
Protective housing of the power supply units

 Check mounts and hinges of engine bonnet for ease of movement
and oil lightly.
 Visually check piston rods of gas struts of engine bonnet and oil light-
ly.
NOTICE
Damaged piston rods
Minor damage, corrosion or paint fragments on the piston rod of the gas
struts results in failure of the spring and the sealing is damaged.
• In case of damage or reduced power, replace the gas struts.
• If oil escapes, replace the gas struts.
 Visually check mounts of lateral guards and weather protection grat-

ing and oil lightly.
 Check handles, tie bars and locks for correct function and security.
Platforms
WARNING!
Risk of stumbling
There is a risk of stumbling when walking on platforms and transitions to
the steps and ladders.
• Ensure that the platform handrails provide safe protection.
• Do not jump from platforms or plant components.
• Keep platforms free of tools and contamination.
 Check security of linch pins on detachable handrails. Replace miss-

ing and damaged linch pins.
 Check the anti-fall guards for correct function.
 Check for the presence of ladders and their secure installation.
 Remove coarse contamination and stones from platforms, ladders
and handrails.
Screw connections
 Perform a visual check of the screw connections on the chassis and
plant components and machines. Tighten loose screw connections to
specified tightening torque.
For tightening torques, see chap. 5.03.

MAINTENANCE
Lubricating nipple
 Check lubricating nipple for obstructions. Replace defective lubricat-
ing nipples and cover caps.
4.01.02 Checking warning devices

 Switch on the plant in automatic mode.
 After pressing the "Plant ON" button, the warning light and warning
siren lights up/sounds for approx. 7 seconds.
 Press the "Acknowledge fault / emergency off" button.
 The warning light and warning siren go out or stop. The check of the
warning devices is complete.
 Repair damaged or inoperative warning devices.
4.01.03 Checking guard devices

 Check all protective hoods, guard grids and covers for presence, cor-
rect function and secure installation.
 Check all component securing elements, such as spring pins, secur-
ing chains and locking pins, for presence, correct function and secure
installation.
 Replace missing or damaged guard devices and component secur-
ing elements.
4.01.04 Checking emergency-stop devices

4.01.04.01 Emergency-stop button and release cord
NOTICE
The immediate deactivation of all plant drives during the emergency stop
can result in material congestion.
• Only actuate the emergency-stop button and release cord if the plant
has run empty.
 Run the plant completely empty.

 Actuate the emergency-stop button on the plant.
 All drives are shut down immediately. The crusher still runs on for ap-
prox. 60 second and then is also shut down. The diesel generator
continues running.
 Release the emergency-stop button and repeat the procedure with all
emergency-stop buttons and release cords on the plant.
 Check free accessibility of plant emergency-stop buttons and release
cords.

MAINTENANCE
Control stand
 Check emergency-stop buttons of the radio remote control and wired

remote control.
 If there is a malfunction, find the cause and eliminate it.
 The emergency stop has been checked.
4.01.04.02 Emergency switching off button
NOTICE
The immediate deactivation of the diesel generator by the emergency
switching off button can cause material congestion.
• Only actuate the emergency switching off button if the plant has run
empty.
 Run the plant completely empty.

 Actuate the emergency switching off button on the switch cabinet.
 All drives, including the diesel generator, are shut down immediately.
 Release the emergency switching off button.
 If there is a malfunction, find the cause and eliminate it.
 The emergency switching off button has been checked.
4.02 Control stand
4.02.01 Checking switch cabinet protective housing
1 2
Fig. 4.1: Switch cabinet protective housing

[1] Telescopic supports
[2] PVC cover

MAINTENANCE
Control stand
Carry out the following maintenance tasks:

 Check the telescopic rods [1] for ease of movement and correct op-
eration. Replace if necessary.
The flap of the switch cabinet protective housing must be held safely in
the opened position by the telescopic rods.
 Check PVC cover [2] for damage. Replace if necessary.
 Lightly oil the locks and check for correct operation.
 Check cable entries for damage. Replace if necessary.
 The switch cabinet protective housing has been checked.
4.02.02 Carrying out lamp test
WARNING!
Danger due to defective control lamps
Defective buttons and control lamps can result in dangerous operating
statuses and risks to personnel.
• Perform a lamp test once a day.
• Have defective lamps replaced by authorised, qualified personnel.
The lamp test permits you to check the function of buttons and control
lamps in the operator panel.
 Switch on control voltage.
 Press the "Lamp test" button and hold it in.
 All control lamps and buttons light up. The function of buttons and
control lamps has been checked.
4.02.03 Checking remote controls

Checking radio remote control
NOTICE
Check by specialist
The radio remote control must be checked at least once a year by a spe-
cialist. A specialist is
• someone who, based on technical training and experience, has suf-
ficient knowledge in the area of the wireless transmission of control
commands.
• someone who is familiar with the relevant national occupation safety
regulations, accident prevention regulations, guidelines and general-
ly recognised rules of technology, and can thus evaluate the safe
working condition of devices for wireless transmission of control com-
mands.
 Have radio remote controls checked by a specialist.

MAINTENANCE
Not assigned
 Check the radio remote control, receiver, receiver aerial and charger
for visible damage. Replace components if necessary.
 Check the functions of the radio remote control with the plant
switched on.
 Check the emergency stop of the radio remote control, see chap.
4.01.04.
 Always charge one battery in the charger; insert the second charged
battery in the radio remote control.
 The radio remote control has been checked.
Checking wired remote control
 Visually check the wired remote control, cables and connectors for
damage. Replace components if necessary.
 Check the functions of the wired remote control with the plant
switched on.
 Check the emergency stop of the wired remote control, see chap.
4.01.04.
 The wired remote control has been checked.
4.03 Not assigned
4.04 Power supply unit/engine
4.04.01 Servicing diesel generator power supply unit
CAUTION!
Danger due to hot diesel engine
Parts of the diesel engine can be very hot; there is a risk of injury.
• Where possible, avoid touching any parts of the diesel engine.
The maintenance and repair work on the diesel generator is described in

the manufacturer's documentation.
• Carry out all maintenance and repair work based on the manufactur-
er's documentation.
• Observe the safety instructions in the manufacturer's documentation.
Additional maintenance tasks on the power supply unit
In addition to the maintenance tasks described in the manufacturer's doc-
umentation, the following maintenance tasks must also be carried out:
• Check the cyclone prefilter.
• Service the air filter.
• Clean the cooler fins.

MAINTENANCE
4.04.02 Checking cyclone prefilter
Fig. 4.2: Cyclone prefilter

[1] Cyclone prefilter housing
Due to its functional principle, the cyclone prefilter is self-cleaning.
 If clogging with dust and dirt is serious, open the housing [1] and
clean it.
 The cyclone prefilter is ready for operation again.
4.04.03 Servicing air filters
2
5
Fig. 4.3: Servicing air intake

[1] Dust outlet valve
[2] Filter housing cover

MAINTENANCE
[3] Closure clips

[4] Corrugated hose
[5] Main filter element
NOTICE
The use of incorrect or damaged filter elements can result in engine dam-
age. Penetration of contamination can cause engine damage.
• Only use original filter elements.
• Even filter elements with only slight damage must be replaced.
• Do not wash out or brush filter elements.
• Never start the diesel engine with the filter elements removed.
• Ensure that all work on the air intake is carried out with the utmost
cleanliness.
General work  Check corrugated hose [4] and clean air pipe for damage and replace
if necessary.
 Check the connecting points of the corrugated hose and the clean air
pipe for leaks and secure installation.
 Check dust discharge valve [1] for obstructions.
Servicing main filter element Replace the main filter element [5] after the fifth cleaning at the latest.
 Open closure clips [3] of filter housing cover [2] and take off cover.
 Remove main filter element [5].
 Blow out main filter element [5] with dry compressed air (maximum 2
bar or 30 psi), working from the inside to the outside.
 Use a torch to light up the main filter element and check externally for
cracks and holes. Replace main filter element if necessary.
 Reassemble main filter element and filter housing. Ensure that the
dust discharge valve [1] faces downwards.
 The main filter element is serviced.

MAINTENANCE
Replacing safety filter

element
Fig. 4.4: Replacing safety filter element

[6] Safety filter element
Replace the safety filter element [6] after the fifth cleaning of the main fil-
ter element at the latest. Never clean the safety filter element. This would
destroy it.
 Remove main filter element [5].
 Remove safety filter element [6].
 Wipe the interior walls of the filter housing with a damp cloth before
inserting the filter elements.
 Insert new safety filter element.
 Reassemble main filter element and filter housing. Ensure that the
dust discharge valve [1] faces downwards.
 The air intake is ready for operation again.

MAINTENANCE
4.04.04 Cleaning the cooler fins.
Fig. 4.5: Cleaning the cooler fins.

[1] Cooling fins
NOTICE
Incorrect cooling of the cooler fins can result in damage to the cooling
system and, consequently, engine damage.
• Switch off the diesel engine and allow it to cool down.
• Do not clean the cooler fins with high-pressure cleaners.
• Do not clean the cooler fins with objects, e.g. screwdrivers.
• Do not use benzene or acidic cleaning agents.
• Observe the specifications in the manufacturer's documentation.
Coolant coolers, charge-air and hydraulic oil coolers clog up quickly with
dust, in particular, where there is high dust development. This reduces
the cooling capacity, which makes overheating possible.
 Switch off the plant components and diesel generator and allow to
cool down.
 Open the protective housing of the power supply unit.
 Visually check the cooling fins for clogging with dust.
 If necessary, spray the cooling fins with a suitable cleaning agent, let
it take effect for a while and then spray with a water jet from the inside
to the outside.

MAINTENANCE
4.04.05 Changing engine oil
2 3
Fig. 4.6: Oil drain pump

[1] Pump lever
[2] Oil drain pump
[3] Drain hose
CAUTION!
Danger due to hot oil
Oil and machine parts can be very hot; there is a risk of injury.
• Where possible, avoid touching any parts of the units.
• Avoid skin contact with oils and greases.
• In case of injury, consult a doctor immediately.
As the oil drain screw of the diesel engine is inaccessible, the engine oil
is pumped off via the oil drain pump [2].
For details on changing and specifications of the engine oil, also refer to
the manufacturer's documentation.
 Guide the drain hose [3] out of the power supply unit.
 Place a suitable container for collecting the used oil under the drain
hose.
 Actuate the pump lever [1] until the used oil is pumped away com-
pletely.
 Fill fresh engine oil with the corresponding specifications and filling
volume via the engine oil filler neck.
 The engine oil has been changed.

MAINTENANCE
4.05 Hydraulic oil supply
DANGER!
Danger due to hydraulic oil escaping under high pressure
The oil in the hydraulic system is pressurised; there is a risk of injury.
• Depressurise the hydraulic system.
CAUTION!
NOTICE
The hydraulic system can be damaged if biological oil and mineral oil
come into contact.
• Before biological oil is filled, all parts that were in contact with mineral
oil must be cleaned thoroughly.
NOTICE
Changes to the settings of the throttle and pressure relief valves made by
KLEEMANN GmbH can result in material damage.
• Never remove lead seals from safety valves.

MAINTENANCE

• The quality of the hydraulic oil as a lubricating and operating material
is the main determining factor of the performance, operational relia-
bility and service life of the hydraulic components used in the plant.
• The service temperature has a central influence on malfunctions and
damage in the plant.
• During assembly work on hydraulic components for the purpose of
maintenance, repair or replacement, ensure all components are per-
fectly clean.
• Select hydraulic oils carefully.
• Carry out oil level checks regularly.
• Observe the oil change intervals.
• Always change the oil at service temperature.
• Change oil filters according to the specifications.
• Avoid contamination to the hydraulic oil cooler.
• Prior to disassembly, thoroughly clean hydraulic components and all
connecting elements to remove dirt.
• Protect released and exposed line connections against contamina-
tion.
• Tighten loose screw-couplings at operating temperature and when
depressurised.
• Dispose of escaping hydraulic oil, collected material and cleaning
agents in accordance with environmental specifications.
4.05.01 Servicing the plant's hydraulic system

4.05.01.01 Depressurising the hydraulic system
DANGER!
Depressurising driving and After the plant components and diesel generator are switched off, the hy-
auxiliary hydraulic system draulic circuit of the driving and auxiliary hydraulic system is depressu-
rised.
 Switch off plant components.
 Remove key and secure against reactivation.
 Driving and auxiliary hydraulic systems are depressurised.

MAINTENANCE
4.05.01.02 General maintenance tasks

 Switch off plant components and the diesel generator.
 Depressurise the hydraulic system.
 Check all hydraulic lines and hoses, hydraulic cylinders, hydraulic
pumps and other hydraulic components for leaks.
 Repair or replace leaking hydraulic components.
 Retighten or replace loose screw-couplings.
 Replace hydraulic hoses that are cracked, brittle, aged or otherwise
damaged.
NOTICE
Danger due to aged hydraulic hoses
Replace hydraulic hoses after 6 years usage at the latest, including a
storage time of a maximum of two years.
Recommended replacement intervals
• Under normal loads, at least every 6 years.
• Under increased loads (longer operating times, e.g. multi-shift oper-
ation, or when subject to special external influence, e.g. climatic con-
ditions), at least every 2 years.
Recommended checking intervals
• Under normal loads, every 12 months.
• Under increased loads, every 6 months.
4.05.02 Servicing the plant's hydraulic oil tank

4.05.02.01 Checking hydraulic fill level
Fig. 4.7: Fill level of hydraulic oil tank

MAINTENANCE
[1] Level indicator

[2] Hydraulic oil tank
The level indicator [2] shows the current fill level of the hydraulic oil in the
plant's operating position. Deviations are possible, for example, with
components moved into transport position.
 Read off the filling level in operating position and with the plant at a
standstill. The fill level of the hydraulic oil must be between ½ and ¾
of the upper inspection glass.
 If necessary, top up hydraulic oil via the ventilation filter.
 Fill level has been checked.
The level indicator also allows you to visually check the temperature of
the hydraulic oil.
4.05.02.02 Changing hydraulic oil
1
3
Fig. 4.8: Hydraulic oil tank top side

[1] Return filter
[2] Suction filter

MAINTENANCE
Fig. 4.9: Hydraulic oil tank bottom side

[4] Oil drain screw
[5] Hydraulic oil tank
Draining hydraulic oil The oil drain screw is located on the bottom side of the hydraulic oil tank.
WARNING!
Risk of falling
components.
 Warm up hydraulic oil to service temperature. If necessary, run the

plant for approx. 10 minutes.
 Observe the special safety instructions at the start of this chapter.
 Fit funnel and hose under the oil drain and place suitable container in
position.

MAINTENANCE
CAUTION!
 Unscrew covers on both suction filters.

 Unscrew oil drain screw.
 Completely drain the hydraulic oil.
 Insert the oil drain screw with new sealing ring and tighten.
 Reinstall covers on both suction filters.
 Dispose of used hydraulic oil in accordance with environmental spec-
ifications.
 Hydraulic oil is drained.
Filling hydraulic oil  Remove cover of tank ventilation filter and take out filter element.
 Fill the hydraulic oil tank with fresh hydraulic oil up to the middle of
the upper level indicator.
The fill level must be visible in the level indicator and should be between
½ and ¾ of the maximum fill height. With the diesel generator switched
off, the level indicator must not be below the MIN display.
 Insert the filter element of the ventilation filter again and fit the cover.
 Switch on the diesel generator and plant components and warm up
the hydraulic oil to service temperature.
 Check the fill level at the level indicator and, if necessary, top up hy-
draulic oil up to approx. ¾ of the maximum fill height.
 Hydraulic oil is filled.

MAINTENANCE
4.05.02.03 Changing hydraulic oil filter
1
3
Fig. 4.10: Hydraulic oil tank top side

[1] Return filter
[2] Suction filter
Contamination increases the back pressure in the filters. When the intake
capacity of the filter has been reached, this is shown by the maintenance
indicators of the suction and return filters.
WARNING!
Risk of falling
components.
Preparatory work  Observe the special safety instructions at the start of this chapter.
When changing the hydraulic oil, both suction filters, the return filter and
the ventilation filter must always be changed.
When changing the filters, always use original filters.
Dispose of escaping hydraulic oil and filter in accordance with environ-
mental specifications.

MAINTENANCE
Changing ventilation filter
Fig. 4.11: Ventilation filter

[1] Cover
[2] Filter element
Changing ventilation filter  Remove cover.
 Take out old filter element.
 Clean dust and dirt from housing and ventilation filter cover.
 Insert new filter element.
 Refit cover.
 Ventilation filter has been changed.
Change suction filter

MAINTENANCE
Fig. 4.12: Suction filter

[1] Closing cover
[2] Maintenance indicator
[3] Filter element
CAUTION!
The pointer of the maintenance indicator moves into the red area if there
is an increase in back pressure. The suction filter has to be replaced now
at the latest.
Change suction filter  Unscrew closing cover.
 Take old filter element out of housing.
 Insert new filter element with closed side facing upwards.
NOTICE
If the filter element is inserted the wrong way round, the hydraulic oil flow
will be blocked.
• Ensure that the closed side of the filter element faces upwards.
 Clean the seal of the closing cover and oil lightly.

 Screw on closing cover.
 Suction filter has been changed.

MAINTENANCE
Change return filter
Fig. 4.13: Return filter

[1] Filter element
[2] Maintenance indicator
CAUTION!
The maintenance indicator is pressed out if there is increased back pres-

sure. The return filter has to be replaced now at the latest.
Change return filter  Unscrew the screws on the closing cover and take it off.
 Withdraw the old filter element with dirt catching pan vertically at the
bracket.
NOTICE
If the filter element is not withdrawn carefully, dirt particles from the dirt
catching pan may mix with the hydraulic oil.
• Carefully withdraw the filter element vertically out of the housing.
 Insert new filter element with cleaned dirt catching pan. Ensure that
the filter element is correctly seated.
 Clean the seal of the closing cover and oil lightly.

MAINTENANCE
 Mount closing cover and tighten screws.

 Return filter is changed.
4.05.03 Servicing hydraulic system of cone crusher
DANGER!
CAUTION!
NOTICE
The hydraulic system can be damaged if biological oil and mineral oil
come into contact.
• Before biological oil is filled, all parts that were in contact with mineral
oil must be cleaned thoroughly.
NOTICE
Changes to the settings of the throttle and pressure relief valves made by
KLEEMANN GmbH can result in material damage.
• Never remove lead seals from safety valves.

MAINTENANCE

• The quality of the hydraulic and lube oil as an operating material is
the main determining factor of the performance, operational reliability
and service life of the components used in the plant.
• The service temperature has a central influence on malfunctions and
damage in the plant.
• During assembly work on hydraulic components for the purpose of
maintenance, repair or replacement, ensure all components are per-
fectly clean.
• Carry out oil level controls regularly.
• Observe the oil change intervals.
• Always change the oil at service temperature.
• Change oil filters according to the specifications.
• Avoid contamination to the lube oil cooler.
• Prior to disassembly, thoroughly clean hydraulic and lubrication com-
ponents and all connecting elements to remove dirt.
• Protect released and exposed line connections against contamina-
tion.
• Tighten loose screw-couplings at operating temperature and when
depressurised.
• Dispose of escaping hydraulic and lube oil, collected material and
cleaning agents in accordance with environmental specifications.
4.05.03.01 Depressurising the hydraulic system
DANGER!

MAINTENANCE
Fig. 4.14: Hydraulic pressure valves

[1] Valve for hydraulic system accumulator
[2] Valve for accumulator at cone crusher
Depressurising hydraulic Two pressure accumulators are installed in the crusher hydraulic system.
system Before the start of maintenance and repair work, the circuit must there-
fore be depressurised.
 Switch off the plant.
 Remove key and secure against reactivation.
 Use valve [1] to depressurise the pressure accumulator on the hy-
draulic system. Then close valve again.
 Use valve [2] to depressurise the pressure accumulator on the cone
crusher. Then close valve again.
 Ensure that the valves of the pressure accumulators are closed.
 The pressure accumulators are relieved. The hydraulic system is de-
pressurised.
4.05.03.02 General maintenance tasks

 Depressurise the hydraulic system.
 Check all hydraulic lines and hoses, hydraulic cylinders, hydraulic
pumps and other hydraulic components for leaks.
 Repair or replace leaking hydraulic components.
 Retighten or replace loose screw-couplings.
 Replace hydraulic hoses that are cracked, brittle, aged or otherwise
damaged.

MAINTENANCE
NOTICE
Danger due to aged hydraulic hoses
Replace hydraulic hoses after 6 years usage at the latest, including a
storage time of a maximum of two years.
Recommended replacement intervals
• Under normal loads, at least every 6 years.
• Under increased loads (longer operating times, e.g. multi-shift oper-
ation, or when subject to special external influence, e.g. climatic con-
ditions), at least every 2 years.
Recommended checking intervals
• Under normal loads, every 12 months.
• Under increased loads, every 6 months.
4.05.04 Servicing hydraulic/lube oil tank of cone crusher

4.05.04.01 Checking hydraulic/lube oil filling level
2 3
Fig. 4.15: Hydraulic/lube oil tank fill level

[1] Hydraulic and lube oil tank
[2] Hydraulic oil tank level indicator
[3] Lube oil tank level indicator
The level indicators show the current filling level of the hydraulic oil and
lube oil in the plant.
 If necessary, move plant to flat ground
 Read off the filling level in operating position and with the plant at a
standstill. The filling level of the hydraulic and lube oil must be in the
upper third of the inspection glass.

MAINTENANCE
 If necessary, top up hydraulic and lube oil via the filler and vent necks.
 Fill level has been checked.
The lube oil level indicator also allows you to visually check the temper-
ature of the lube oil.
4.05.04.02 Changing lube oil
2
4
1
Fig. 4.16: Servicing lube oil tank

[1] Lube oil tank drain cock
[2] Lube oil filter drain cock
[3] Lube oil filter
[4] Lube oil tank ventilation filter
[5] Screw cap for filler neck and lube oil tank ventilation filter
Draining lube oil The oil drain cocks are located on the front side of the hydraulic/lube oil
tank. In addition, a drain cock for lube oil is installed on the lube oil filter.
 Warm up lube oil to service temperature. If necessary, run the plant
for approx. 10 minutes.
 Unscrew plug screws at drain cocks. Attach suitable hose and lead
into a container with sufficient volume.

MAINTENANCE
CAUTION!
 Remove cover of lube oil filter.

 Open drain cocks [1] and [2].
 Completely drain lube oil.
 Close drain cocks.
 Screw in plug screws with new sealing rings and tighten.
 Mount cover of lube oil filter again and tighten it. Then back off cover
1/4 of a rotation.
 Dispose of used lube oil in accordance with environmental specifica-
tions.
 The lube oil is drained.
When the lube oil is changed, the lube oil filter must also be changed.
Filling with lube oil  Remove screw cap from filler neck [5].
 Fill lube oil tank with new lube oil.
The fill level must be visible in the level indicator and should be in the up-
per third area of the maximum fill height.
The vent neck of the lube oil tank is located beside the coarse strainer.
Venting of the lube oil tank must take place during initial operation. After
maintenance tasks, it may also be necessary to vent the lube oil tank.
 Install and tighten screw cap.
 Switch on hydraulic and lube oil system and warm up lube oil to serv-
ice temperature.
 Switch off hydraulic and lube oil system.
 Check filling level at level indicator and top up lube oil if necessary.
 The lube oil is filled.

MAINTENANCE
4.05.04.03 Changing hydraulic oil
Fig. 4.17: Servicing hydraulic oil tank

[1] Hydraulic oil drain cock
[2] Screw cap for filler neck and tank ventilation filter
Draining hydraulic oil The drain cock is located on the front side of the hydraulic and lube oil
tank.
 Warm up hydraulic oil to service temperature. If necessary, run the
plant for approx. 10 minutes.
 Unscrew plug screw on drain cock. Attach suitable hose and lead into
a container with sufficient volume.
CAUTION!
 Open drain cock.

 Completely drain the hydraulic oil.
 Close drain cock.
 Insert plug screw with new sealing ring and tighten.

MAINTENANCE
 Dispose of used hydraulic oil in accordance with environmental spec-

ifications.
 Hydraulic oil is drained.
When changing the hydraulic oil, both hydraulic filters must always be
changed.
Filling hydraulic oil  Remove screw cap from filler neck.
 Fill hydraulic oil tank with new hydraulic oil.
The fill level must be visible in the level indicator and should be in the up-
per third area of the maximum fill height.
 Install and tighten screw cap.
 Switch on hydraulic and lube oil system and warm up hydraulic oil to
service temperature.
 Switch off hydraulic and lube oil system.
 Check filling level at level indicator and top up hydraulic oil if neces-
sary.
 Hydraulic oil is filled.
4.05.04.04 Changing hydraulic filter

If the holding capacity of the hydraulic filter has been reached, the mes-
sage "Filter clogged" appears in the OP3 display.
Preparatory work for  Observe the special safety instructions at the start of this chapter.
changing hydraulic filter
 Depressurise the hydraulic system of the crusher, see chap.
4.05.03.01.
Dispose of escaping hydraulic oil and filter in accordance with environ-
mental specifications.

MAINTENANCE

[1] Filter element
[2] Filter element support
[3] Hydraulic oil filter
CAUTION!
The OP3 display shows when the hydraulic filter has to be changed at the
latest.
Changing hydraulic filter  Unscrew support for filter element.
 Withdraw old filter element.
NOTICE
If the filter element is inserted the wrong way round, the hydraulic oil flow
will be blocked.
• Ensure that the filter element is correctly seated.
 Insert new filter element. Ensure that the filter element is correctly
seated.
 Clean seal of support and oil slightly.

MAINTENANCE
 Screw in support with new filter element and tighten.

 The hydraulic filter is changed.
When changing the hydraulic filters, both filter elements must always be
changed.
4.05.04.05 Changing lube oil filter

If the holding capacity of the lube oil filter has been reached, the message
"Lube oil filter clogged" appears in the display of the OP3 and the vibrat-
ing feeder is stopped.
Preparatory work for  Observe the special safety instructions at the start of this chapter.
changing lube oil filter
Dispose of escaping lube oil and filter in accordance with environmental
specifications.

[1] Lube oil filter closing cover
[2] Filter element
CAUTION!

MAINTENANCE
The OP3 display shows when the lube oil filter has to be replaced at the
latest.
Changing lube oil filter  Screw open the closing cover of the lube oil filter and remove it.
 Withdraw old filter element.
NOTICE
If the filter element is inserted the wrong way round, the lube oil flow will
be blocked.
• Ensure that the filter element is correctly seated.
 Insert new filter element. Ensure that the filter element is correctly
seated.
 Check and clean gasket of closing cover. Replace seal if necessary.
 Check venting of lube oil filter, see chap. .2.05.02, for operability. Cor-
rect the operation of the filter if necessary.
 Screw on closing cover as far as the stop and then open 1/4 of a ro-
tation.
 The lube oil filter has been changed.
4.05.04.06 Checking/cleaning coarse strainer for lube oil
Fig. 4.20: Lube oil tank coarse strainer

[1] Lube oil return line
[2] Inspection glass guard
[3] Inspection glass with coarse strainer
[4] Wing screw

MAINTENANCE
CAUTION!
Contamination of the coarse strainer can be checked through the inspec-

tion glass. The coarse strainer has to be cleaned in case of serious con-
tamination.
Checking coarse strainer  Release wing screws.
 Fold back guard of inspection glass.
 Check coarse strainer for contamination.
 Check guard of inspection glass for damage. Replace if necessary.
 The coarse strainer has been checked.
WARNING!
Danger of eye injuries
Work with compressed air can cause serious visual impairment.
• Wear suitable protective goggles.
• Never direct the compressed-air jet at persons.
Clean coarse strainer  Release wing screws and take off.

 Fold back guard of inspection glass.
 Lift out inspection glass and remove coarse strainer.
 Clean coarse strainer with suitable cleaning agent. Blow out coarse
strainer with compressed air if necessary.
 Insert cleaned coarse strainer.
 Clean seal of inspection glass and check for damage. Replace in-
spection glass if necessary.
 Install inspection glass, mount guard for inspection glass and tighten
wing screws.
 The coarse strainer has been cleaned.
Serious contamination of the coarse strainer obstructs the flow of lube oil
through the coarse strainer. As a result, contaminated lube oil is routed
directly into the lube oil tank.
Serious contamination of the coarse strainer with metal chips indicates
imminent damage to the crusher.

MAINTENANCE
4.05.04.07 Cleaning filler neck coarse strainer
Fig. 4.21: Filler neck coarse strainer

[1] Filler neck
[2] Screw cap
CAUTION!
WARNING!
Danger of eye injuries
Work with compressed air can cause serious visual impairment.
• Wear suitable protective goggles.
• Never direct the compressed-air jet at persons.
If the flow of hydraulic and/or lube oil in the filler neck is restricted, the
coarse strainer must be cleaned.
Removing filler neck  Unscrew screw cap.
 Clean area of filler neck.
 Remove screws of filler neck and take off filler neck.

MAINTENANCE
Fig. 4.22: Filler neck coarse strainer

[3] Coarse strainer
[4] Seal
 Withdraw coarse strainer.
 Clean coarse strainer with suitable cleaning agent. Blow out coarse
strainer with compressed air if necessary.
 Clean seal and check for damage. Replace seal if necessary.
 Insert cleaned coarse strainer.
 Mount filler neck and tighten screws.
 The coarse strainer has been cleaned.
Serious contamination of the coarse strainer obstructs the flow of hydrau-
lic and/or lube oil through the coarse strainer. As a result, the hydraulic
and/or lube oil overflows in the filler neck.

MAINTENANCE
Electrical system
4.06 Electrical system
DANGER!
Cables and components are live; there is a risk of injury.
The cables and components of the external circuits are live even if the
diesel generator is switched off.
The frequency converter is still energised after shutdown or disconnec-
tion from the network.
• Only carry out work on the electrical system with the plant compo-
nents and diesel generator switched off.
• After switching off the diesel generator, wait 10 minutes before start-
ing work on the electrical system.
NOTICE
Failure to inspect the plant following replacement of electrical compo-
nents and cables can result in malfunctions and failures.
• Check plant functions after every replacement of electrical compo-
nents and cables.
• Observe applicable VDE guidelines and country-specific specifica-
tions.

• Maintenance, repair and service work on the electrical system must
only be carried out by qualified and authorised personnel.
• Observe the safety manual when performing all maintenance, repair
and service work.
• Park the plant on a flat and stable surface.
• Earth the plant correctly with an earthing rod.
– Remove ignition key.
– Switch off and lock main switch.
– Lock switch cabinet.
– Attach warning sign warning against restart.
4.06.01 General maintenance tasks

 Visually check electric cables on the plant for damage.
 Visually check cable entries and cable ducts on the chassis for dam-
age.

MAINTENANCE
Electrical system
 Visually check socket outlets on the chassis for damage and security.
 Replace damaged electrical cables, cable entries and socket outlets.
4.06.02 Servicing 24 V voltage supply

4.06.02.01 Servicing diesel generator electrical system
The maintenance work on the diesel generator electrical system is de-
scribed in the manufacturer's documentation.
• Carry out all maintenance work based on the manufacturer's docu-
mentation.
• Observe the safety instructions in the manufacturer's documentation.
Additional maintenance tasks on the diesel generator electrical sys-
tem
In addition to the maintenance tasks described in the manufacturer's doc-
umentation, the following maintenance tasks must also be carried out:
• Service the starter batteries.
4.06.02.02 Servicing starter batteries
Fig. 4.23: Starter batteries

[1] 12 V starter batteries
The starter batteries [1] must be kept clean and dry.
The acid level of the starter batteries must be checked regularly and
topped up if necessary.

MAINTENANCE
Electrical system
WARNING!
Danger of battery acid
Battery acid is a caustic fluid; there is a risk of injury!
• Never fill battery acid into drinking bottles or similar vessels.
DANGER!
Danger when handling batteries
Risk of explosion due to explosive gas!
• After opening the protective housing of the power supply unit, wait
some time to allow air to enter.
• Never use an open flame and do not smoke.
• Avoid short circuits and sparks.
• Do not place tools on the batteries.
Topping up starter battery  Open the protective housing of the power supply unit.
 Remove side panelling if necessary.
 Unscrew cap closures of the acid cells.
 Fill with distilled water with the help of a funnel until the acid level is
approx. 10-15 mm above the disc upper edges.
 Refit the cap closures.
 If the starter speed is too low, check the acid density of the starter bat-
teries.
 If the acid cells are damaged, replace the starter battery.
 Check the cable connections.
 The starter battery is charged.
Changing starting battery  Switch off plant components and the diesel generator.
 Switch off and remove the battery isolators.
 Determine defective starter battery.
 Remove protective caps from cable connections.
 Release and remove cables from the starter batteries in the following
sequence:
– Earth connection of bridge between the starter batteries
– Positive connection of bridge between the starter batteries
– Cables of defective starter battery
 Use a suitable tool to remove the retaining screws and retaining
plates of the starter battery.

MAINTENANCE
Electrical system
 Replace the starter battery, ensuring the installation position is cor-

rect.
 Clean the battery poles and terminals and grease with acid-free and
acid-resistant grease.
 Install cables on the starter batteries in the reverse sequence. The
terminal clamps must have good contact.
 Ensure that the battery poles are not interchanged (risk of short cir-
cuit!).
 Refit the protective caps of the cable connections.
 Reinstall retaining screws and retaining plates of the starter battery.
 The starter battery has been changed.
4.06.03 Servicing switch cabinet

4.06.03.01 Checking electrical components
DANGER!
Incorrect work inside the switch cabinet can result in life-threatening sit-
uations.
• Maintenance, repair and service work on the electrical system must
only be carried out by qualified and authorised personnel.
NOTICE
Blowing out the switch cabinet with compressed air can result in failure
of the electrical system.
• Remove dust and dirt in the switch cabinet by vacuuming or brushing
out.
 Open the switch cabinet protective housing; keep switch cabinet

closed.
 Visually check the electric cables inside the switch cabinet protective
housing for damage.
 Visually check the cable entries on the switch cabinet protective
housing for damage.
 Visually check socket outlets on the switch cabinet for damage and
security.
 Visually check operating and display elements for damage.
 Remove dust deposits and dirt from the switch cabinet protective
housing, e.g. by vacuuming.

MAINTENANCE
Electrical system
 Have damage to electric components repaired by qualified and au-

thorised personnel only.
 Electric components in the switch cabinet are checked.
4.06.03.02 Checking switch cabinet mounting
2
1
Fig. 4.24: Rubber air springs

[1] Automatic valve
[2] Rubber air spring
 Check rubber air springs [2] for damage.
 Check fastening of rubber air springs.
 Check that the air pressure and height of the rubber air springs are
correct.
 Pump more air in via the automatic valve [1] as required.
 The switch cabinet mounting has been checked.
Dia. of air Height Pressure Use

spring
80 mm 60 mm 3 bar / 43 psi Single switch cabinet
118 mm 72 mm 5 bar / 72 psi Double switch cabinet
Tab. 4.1: Rubber air springs

MAINTENANCE
Electrical system
4.06.04 Servicing electric motors
Fig. 4.25: Terminal box

[1] Cable entry
[2] Terminal box cover
[3] Seal
Damaged and loose terminal boxes and cable entries for electric motors
can cause contact problems and short circuits if penetrated by moisture.
 Visually check all cable entries [1] for damage.
 Visually check cables for chafing and secure installation.
During operation, cables must not scuff due to an excessively large
swinging range. The dead weight of the swinging cables must not exert
excessive pull on the cable entries.
 Check all terminal box covers [2] for security and leaks.
 Replace sealing [3] if necessary.
 The terminal boxes are checked.
The following terminal boxes must be checked:
• Drives of the belt conveyors
• Drives of the vibrating conveyor troughs
• Drives of the screens
• Drive of the water pump

MAINTENANCE
Electrical system
4.06.05 Servicing overpressure system
3
5
Fig. 4.26: Filter housing overpressure system

[1] Dust filter main filter element
[2] Flexible corrugated hose
[3] Cyclone prefilter, transparent tank
[4] Clamping bracket
[5] Safety filter element
General work  Press the sealing lips of the dust outlet valve together to allow accu-
mulated dust and water to escape.
 Loosen and remove dust deposits.
 The dust outlet valve is ready for operation again.
 Check flexible corrugated hoses [2] for damage and replace if neces-
sary.
 Check the connecting points of the flexible corrugated hoses for
leaks and secure installation.
Servicing cyclone prefilter  Check fill level of transparent tank [3]. The fill level must not exceed
the MAX mark.
 If necessary, open clamping bracket [4], take off cover and drain con-
tainer.
 Check air inlet on the bottom side for clogging with dust and dirt and
clean if necessary.
 Close cyclone prefilter again.
 The cyclone prefilter is ready for operation again.
Servicing dust filter  Unscrew nut on filter housing cover and take off cover.
 Take out main filter element [1] and blow out with dry compressed air
(maximum 2 bar or 30 psi), working from the inside to the outside. Do
not wash out or brush out main filter element.

MAINTENANCE
Electrical system
Do not reuse filter elements with cracks and holes. Replace filter element
if necessary. Replace main filter element after 5 cleanings at the latest.
Never clean the safety filter element. This would destroy it.
 Take out safety filter element [5] after fifth cleaning of the main filter
element at the latest and replace it.
 Wipe the interior walls of the filter housing with a damp cloth before
inserting the filter elements.
 Reassemble filter elements and filter housing in reverse sequence.
Ensure that the dust outlet valve faces downwards.
 The dust filters are ready for operation again.
4.06.06 Repairing electrical system

4.06.06.01 Fuses
Automatic circuit-breakers
Fig. 4.27: Automatic circuit-breaker

[1] Safety switch
[2] Indicator field red/green
[3] Auxiliary contact
Automatic circuit-breakers, like fuses, disconnect the electric circuit auto-
matically in the event of overload. They protect lines against damage
through excessive heating as a result of excessively high current.
After an automatic circuit-breaker trips, perform the following work steps:
 Before switching on again, find the cause and eliminate it.
 Switch on safety switch [1] once again.
 The indicator field [2] is red.

MAINTENANCE
Electrical system
OP3.
The short codes (e.g. 0F4) are also assigned to the numbers on the but-
tons at the operator panel and thus to the plant components.
• Do not patch up or bridge fuses.
• Always replace blown fuses.
• If a fuse continually blows, inform authorised personnel.
• Do not spray switch cabinets with water.
4.06.06.02 Motor protecting switch

Motor protecting switch for drives
3 3
2 2
1
1
Fig. 4.28: Motor protecting switch

[1] Test tripping device
[2] Rocker switch/rotary switch
[3] Tripping range setting
The motor protecting switches protect electric motors against thermal
overload due to mechanical overload or in the case of a failure of an in-
dividual or both external conductors.
After a motor protecting switch trips, perform the following work steps:
 Wait approx. 5 minutes for the components to cool down.
 Switch rocker switch or rotary switch [2] back on.
OP3.

MAINTENANCE
Electrical system
The short codes (e.g. 4Q1) are also assigned to the numbers on the but-
tons at the operator panel and thus to the plant components.
Testing motor protecting switch
 Push test tripping device [1] with a flat screwdriver to the left.
 Rocker switch or rotary switch [2] jumps back to 0 or OFF.
Feeder trough overload relay
Fig. 4.29: Feeder trough overload relay

[1] Manual/automatic reset
[2] Stop button
[3] Tripping range
The overload relays protect the vibration motors of the feeder trough
against thermal overload due to mechanical overload or in the case of a
failure of an individual or both external conductors.
In automatic mode, the relay resets automatically after the vibration mo-
tor has cooled down. In manual mode, the Reset [1] button has to be
pressed.
After an overload relay trips, perform the following work steps:
 Wait approx. 5 minutes for the components to cool down.
 In automatic mode, wait until the relay resets.
 In manual mode, press the Reset [1] button again.
OP3.
Testing overload relay

MAINTENANCE
Electrical system
 Push test tripping device [4] with a flat screwdriver to the left.
 In automatic mode, resetting is automatic after the test tripping de-
vice is released.
 In manual mode, press the Reset [1] button again.
 Overload relay is reset.
Switching to Manual/Automatic reset
 Press in the Reset [1] button with a flat screwdriver and turn to Man-
ual or Automatic.
4.06.06.03 Earth fault circuit interrupter
1
1
Fig. 4.30: Earth fault circuit interrupter

[2] System circuit-breaker
[3] Circuit-breaker for external circuit socket outlets
Earth fault circuit interrupters compare the current flowing to the consum-
er with the current flowing from the consumer. These currents are nor-
mally identical. In the event of a fault, the current flows to earth. The earth
fault circuit interrupter detects this situation and interrupts the electric cir-
cuit.
The system has one earth fault circuit interrupter respectively for the
complete system and for the socket outlets of the external circuits.
After an earth fault circuit interrupter trips, perform the following work
steps:
 Switch circuit-breaker [2] or [3] back on.
OP3.

MAINTENANCE
Electrical system
Testing earth fault circuit interrupter

 Switch on main switch.
 Actuate the test tripping device [1].
 The corresponding circuit-breaker [2] jumps back to 0.
4.06.06.04 ZEV motor protective system
3
2
1
5
Fig. 4.31: ZEV motor protective system

[1] Reset/Test button
[2] Display
[3] Setting button for upwards
[4] Setting button for downwards
[5] Function selection button
9
6

MAINTENANCE
Electrical system
Fig. 4.32: ZEV display

[6] Engine temperature optical display
[7] Phase monitoring
[8] Present current consumption of drive
[9] Tripping class
The ZEV offers a wider range of functions than conventional motor pro-
tecting switches. For example, the trip characteristics can be adjusted.
Display messages
Drive faults that have occurred are shown in the display [2]. The relevant
display in the window flashes.
With a "Manual reset" setting, the Reset/Test button [1] must be pressed
in each case.
Overload
 Determine cause and rectify.

 Wait until the time in the display has elapsed.
 Switch the drive on again.
Thermistor tripping
 Check electric cables at drive for damage and repair if necessary.

 Check temperature of drive manually and repair drive if necessary.
 Wait until the temperature has fallen.
Earth fault


MAINTENANCE
Electrical system
Phase failure

Current unbalance

 Wait until the time in the display has elapsed.
Device fault
1 Connecting cable between tripping device and current converter

disconnected or damaged.
2+3 Tripping device fault.

MAINTENANCE
Not assigned
4.07 Not assigned
4.08 Drive system
4.08.01 Servicing crawler running gear

4.08.01.01 Checking/tensioning crawler carrier chains
Checking chain tension
Fig. 4.33: Crawler carrier chain

[1] Test body
[2] Slack of the crawler carrier chain
The crawler carrier chains must be tensioned such that they have a slack
of approx. 2 cm for every metre length. If the distance between sprocket
and track roller or slide rail is 1.5 metres, for example, the crawler carrier
chain should have a slack of approx. 3 cm at the furthest point.
NOTICE
Increased wear through incorrect chain tension
Increased wear will result if the crawler carrier chains are too tight or too
slack.
• Always tension crawler carrier chains in accordance with the specifi-
cations.
 Move the plant on flat ground until the upper segment of the crawler
carrier chain is free of tension.
 Place test body [1], e.g. long straight rod, on the crawler carrier chain
between sprocket and track roller or slide rail.

MAINTENANCE
Drive system
 Measure slack of the crawler carrier chain [2]. Increase or decrease

tension of the crawler carrier chain as required.
 The chain tension has been checked.
Always check the left and right crawler carrier chain.
Increasing/decreasing crawler carrier chain tension
Fig. 4.34: Chain tensioner

[1] Chain tensioner cover
[2] Grease clamping cylinder
[3] Lubricating nipple
The crawler carrier chains are tensioned and slackened via hydraulic
clamping cylinders filled with grease.
DANGER!
Danger due to pressurised chain tensioner
The interior components of the chain tensioner are highly pressurised
and can cause serious or fatal injury.
• Do not open the chain tensioner.
• Repair work must be carried out by authorised and qualified person-
nel only.
Tensioning crawler carrier  Check crawler carrier chain for damage and repair if necessary.
chain
 Unscrew the cover of the chain tensioner [1].
 Mount slide coupling on lubricating nipple [3].
 Tension crawler carrier chain by pressing grease into the grease
clamping cylinder [2].
 Check the tension of the crawler carrier chain during the tensioning
procedure and correct if necessary.

MAINTENANCE
Drive system
 Wipe up excess grease with a lint-free cloth and dispose of in accord-

ance with environmental specifications.
 Screw on the cover of the chain tensioner [1] again.
 The crawler carrier chain is tensioned.
Always tension the left and right crawler carrier chain.
The slide coupling and grease gun are in the toolbox.
Slackening crawler carrier
chain
WARNING!
Danger due to grease escaping under high pressure
Grease can be ejected under pressure; there is a risk of injury!
• Never release the lubricating nipple manually.
• Never completely unscrew the lubricating nipple.
 Unscrew the cover of the chain tensioner [1].

 Release lubricating nipple [3], without fully unscrewing it, until grease
emerges.
 Wipe up grease that emerges with a lint-free cloth and dispose of in
accordance with environmental specifications.
 Screw on the cover of the chain tensioner [1] again.
 The crawler carrier chain is slackened.
Always slacken the left and right crawler carrier chain.

MAINTENANCE
Drive system
4.08.01.02 Checking fastenings for track rollers and base plates
Fig. 4.35: Base plates

[1] Screws
[2] Base plates
[3] Nuts
 Hammer-test or visually inspect base plates [2], screws and nuts [1,
3].
 Tighten loose screws and nuts.
 Replace damaged base plates, screws and nuts if necessary.
 The base plates have been checked.
 Hammer-test or visually check screws on track rollers.
 Tighten loose screws.
 The track roller securing elements are checked.

MAINTENANCE
Drive system
4.08.02 Servicing track drive

4.08.02.01 Servicing planetary gear
Checking oil fill level
1 3
Fig. 4.36: Planetary gear drive system

[1] Oil level inspection plug
[2] Oil filler screw
[3] Maximum oil fill level
CAUTION!
 Move the plant on flat ground so that the oil filler screw [2] is facing
upwards.
 Clean the housing to prevent dirt entering the planetary gear.
 Unscrew oil level inspection plug [1] and, if applicable, wipe up es-
caping oil with a lint-free cloth.
 Check whether the oil fill level is visible at the lower edge of the
threaded bore.
 If necessary, top up gear oil to the maximum oil fill level [3].

MAINTENANCE
Drive system
 Insert oil level inspection plug with new sealing ring and tighten.
 The oil fill level has been checked.
Always check the oil fill level of the left and right planetary gear.
Changing gear oil
Fig. 4.37: Planetary gear drive system

[1] Oil drain screw
[2] Oil filler screw
CAUTION!
Draining gear oil  If necessary, warm gear oil up to service temperature by moving the
plant.
 Move the plant on flat ground so that the oil drain screw [1] is facing
downwards.
 Clean the housing to prevent dirt entering the planetary gear.
 Place an oil catching pan with a capacity of approx. 10 litres under oil
drain screw [1].
 Unscrew oil filler screw [2].
 Unscrew oil drain screw [1] and drain the gear oil completely.

MAINTENANCE
Drive system
 Insert oil drain screw [1] with new sealing ring and tighten.
 Dispose of used oil in accordance with environmental specifications.
 The gear oil has been drained.
Filling gear oil  Fill fresh gear oil with the corresponding specifications with the help
of a funnel through the opening of the oil filler screw. For specifica-
tions and filling volume, see chap. 5.
 Fill gear oil up to the lower edge of the threaded bore of the oil filler
screw [2].
 Insert oil filler screw [2] with new sealing ring and tighten.
 Wipe up overflowing oil with a lint-free cloth and dispose of in accord-
ance with environmental specifications.
 The gear oil has been filled.
Always change gear oil of the left and right planetary gear.
4.08.02.02 Checking components for leaks

The planetary gears and hydraulic motors and hydraulic lines of the drive
system must be checked every day for leaks. Any leaks must be eliminat-
ed immediately.
 Visually check housing of planetary gears for oil discharge.
 Visually check hydraulic components of the drive system for escap-
ing oil.
 Have leaks eliminated by repair and service personnel.
 The planetary gear and drive systems have been checked.
4.08.03 Repairing crawler running gear

4.08.03.01 Opening/closing crawler carrier chains
3
5
2
6

MAINTENANCE
Drive system
Fig. 4.38: Crawler carrier chain lock (I)

[1] Screw holes for base plates
[2] Outer chain link
[3] Inner chain link
[4] End rings
[5] End bushing
[6] End pin
[7] Chain bolt marking
9
8
10
Fig. 4.39: Crawler carrier chain lock (II)

[8] Chain bolt
[9] Base plates
[10] Sprocket
For repair to the crawler running gear, the crawler carrier chain can be
opened at the chain lock.
WARNING!
Risk of injury due to heavy components
During repair work at the crawler running gear, there is a risk of injury due
to heavy and falling components.
• Always use suitable hoisting gear and lifting accessories.
• Secure components against falling down.
In contrast the end pin, the chain bolt [8] is provided with a centring de-
vice or a turned shoulder depending on the design.
Opening chain lock  Move the plant on flat ground so that the chain bolt [8] is approx. in
the 1 o'clock position above the sprocket [10].

MAINTENANCE
Drive system

 Unscrew one or two base plates [9] before and after the chain bolt.
 Provided wedges of hard wooden blocks between the chassis and in-
ner chain link before and after the chain bolt respectively. The chain
links must be secured so that springing back is not possible when the
chain bolt is driven out.
 Using suitable hoisting gear, e.g. chain hoist, secure the crawler car-
rier chain at the end bushing [5] against falling from the sprocket [10].
 The chain lock is ready for knocking out the chain bolt.
 If necessary, heat the chain links around the chain bolt [8] to approx.
400 °C to expand the fits.
 Drive the chain bolt [8] with a drift and heavy hammer out of the fits
in the outer and inner chain link [3] and [2].
 Lower the separated crawler carrier chain from the sprocket with the
help of the fitted hoisting gear.
 Remove end rings [4] from the sinks of the chain link and store for re-
use.
 The crawler carrier chain has been separated.
Closing chain lock  Coat end rings [4] with grease and insert in the sinks of the chain
links.
 Using a chain hoist at the end bushing [5], pull the crawler carrier
chain between the outer and inner chain link.
 Clean and polish fits of chain bolt [8] and coat with lubricating grease.
 Use a heavy hammer to drive the chain bolt [8] into the fits of the out-
er and inner chain link [3] and [2].
 Secure chain bolt [8] with weld points to outer chain link [2].
 Remove wedged wooden blocks from between chassis and chain
links.
 Screw on base plates [9].
 The crawler carrier chain has been closed.

MAINTENANCE
Drive system
4.08.03.02 Repairing chain link
1
5
Fig. 4.40: Chain link

[1] End bushing
[2] Cutting points
[3] Inner chain link
[4] End pin
[5] Outer chain link
[6] Damaged chain link
Damaged chain links on the crawler carrier chain can be repaired with a
repair kit provided for this purpose.
WARNING!
Risk of injury due to heavy components
During repair work at the crawler running gear, there is a risk of injury due
to heavy and falling components.
• Secure components against falling down.

MAINTENANCE
Drive system
NOTICE
Danger of fires due to welding torch
Welding torches, hot metal and sparks can set fire to components and
objects in the surrounding area.
• Where possible, cover components and objects exposed to a risk of
fire.
• Protect components and objects against dripping hot metal and
sparks.
• Ensure fire extinguisher is ready before starting work.
• Ensure a fire watch is present during and after welding work.
Removing chain link  Move the plant on flat ground so that the damaged chain link is ap-
prox. in the one o'clock position above the sprocket.
 Unscrew one or two base plates before and after the chain link.
 Using suitable hoisting gear, e.g. chain hoist, secure the crawler car-
rier chain at the end bushing of the undamaged chain link against fall-
ing from the sprocket.
 Using a welding torch, cut through the outer and inner chain link [5]
and [3] as well as end bushing [1] including the end pins inside it at
the cutting points [2] shown.
 Remove cut-out debris and scraps of the end bushing.
 If necessary, heat the chain links around the end pin [4] to approx.
400 °C to expand the fits.
 Drive the end pin [4] with a drift and heavy hammer out of the fits in
the outer and inner chain link [5] and [3].
 Grind off and deburr projecting bushing ends of the intact chain link.
 Use a welding torch to burn holes centrally in the cut-through end pin
of the intact chain link on the opposite side.
 Drive out remaining parts of the end pin with a drift and a heavy ham-
mer.
 Clean fits of the chain link and coat with lubricating grease.
 The damaged chain link has been removed.
Inserting chain link The repair kit for the chain link contains all components required to repair
a chain link.

MAINTENANCE
Drive system
Fig. 4.41: Chain link repair kit

[1] End bushing
[4] End pins, 2 pieces
[7] End rings, 4 pieces
[8] Repair chain link 1 piece
 Coat two end rings [7] with grease and insert with the chamfered side
in the sinks of the intact chain link.
 Clean and polish fits of end pin [4] and coat with lubricating grease.
The fit surfaces of the end pins must be polished until they can be insert-
ed in the bores of the chain links without great effort.
 Insert end bushing [1] of the repair chain link [8] in the intact chain link
and insert end pin [4].
 Coat the two remaining end rings [7] with grease and insert with the
chamfered side in the sinks of the repair chain link.
 Using a chain hoist, pull the other end of the crawler carrier chain into
the repair chain link [8] and insert second end pin. Ensure that the
end rings remain in the sinks.
 Secure both end pins [4] with weld points at the repair chain link [8].
 The repair chain link is inserted.

MAINTENANCE
Not assigned
4.09 Not assigned
4.10 Conveyor unit
4.10.01 Servicing belt conveyors
DANGER!
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.
WARNING!
Risk of falling
components.
4.10.01.01 Checking conveyor belts

The belt conveyors are first inspected while running and then while sta-
tionary.
 Start the belt conveyors in manual mode and, from a safe distance,
visually check for the following damage:
• Conveyor belts.
– Damage to edges
– Damage to deck plates
– Damage to wire cloth
– Detachments from endless connection
– Detachment of cleats
– Scuff markings and scores
– Tension of the conveyor belt. Insufficient tension causes belt sag-
ging and slipping of the drive pulley. Excessive belt tension
causes the bottom segment to vibrate.
– Belt drift
• Components of the belt conveyor.

MAINTENANCE
Conveyor unit
– Jammed and worn support, deflection and return rollers

– Loosened screw connections
– Jammed and worn scrapers
– Worn sealing lips of material guide ledges
• Other.
– Abnormal running noises
– Jammed stones
– Contamination and caking
– Eccentric conveyor belt loading
 Switch off belt conveyors and diesel generator and secure against re-
activation.
 Visually check the above-named items once again
 Eliminate damage and deficiencies determined.
 The belt conveyors have been checked.
4.10.01.02 Servicing scraper

Adjusting wedge stripper
1
3
Fig. 4.42: Wedge stripper

[1] Clamping rails
[2] Chain
[3] Rubber scraper
The wedge stripper cleans loose material from the inside of the bottom
segment. It is attached to the conveyor belt frame with a chain [2] and ad-
justs itself automatically through its own dead weight.
 Visually check rubber scraper [3] for damage and wear.
 If necessary, unscrew clamp rails [1] and replace rubber scraper [3].
 The wedge stripper has been serviced.

MAINTENANCE
Conveyor unit
Adjusting flat scraper
Fig. 4.43: Flat scraper

[1] Clamping element
[2] Screw
[3] Scraper strip
[4] Clamping device
The flat scraper cleans loose material from the outside of the conveyor
belt. The clamping elements [1] guarantee a constant contact pressure of
the scraper strip [3]. If the scraper strip does not make contact with the
conveyor belt, or contact pressure is too low, it has to be adjusted.
 Attach the clamping device [4] to the clamping element [1] and re-
lease screw [2] but do not fully remove.
 Turn the clamping element [1] to increase or reduce the contact pres-
sure of the scraper strip on the conveyor.
 Retighten screw [2].
 Repeat the procedure at the clamping element on the other side.
 If necessary, reverse or replace damaged or worn scraper strip.
 The flat scraper has been serviced.
If the conveyed material tends to form deposits on the conveyor, e.g. co-
hesive material such as clay, wet dust, etc., the contact pressure of the
scraper strip has to be increased.
With cohesionless material, it is sufficient to apply the scraper strip to the
conveyor belt without contact pressure.

MAINTENANCE
Conveyor unit
4.10.01.03 Adjusting guide rails

Guide rails for crusher discharge conveyor
3 5
6
2
7
Fig. 4.44: Guide rails for crusher discharge conveyor

[1] Guide rail, inner
[2] Guide rail, outer
[3] Conveyor belt
[4] Protective cover
[5] Clamping plate, outer
[6] Screw
[7] Clamping plate, inner
The guide rails seal the material guide ledges off from the conveyor belt
so that no material can reach the rotating components or fall off the belt
conveyor. In case of damage and wear, the guide rails must be adjusted
or changed.
The outer guide rails cannot be adjusted and must be replaced if they are
worn.
In order to readjust or replace the guide rails of the crusher discharge
conveyor, the crusher discharge conveyor must be removed.
 Remove crusher discharge conveyor.
 Unscrew protective covers [4].
 Release screws [6] on clamping plates [7] but do not remove them.
 Adjust guide rails [1] until they make contact on the conveyor belt [3].
 If necessary, replace damaged or worn guide rails [1].
 Retighten screws [6] on clamping plates [7].
 Check guide rails [2] for damage or wear.
 If necessary, unscrew clamping plates [5] and replace guide rails [2].

MAINTENANCE
Conveyor unit
 Install clamping plates [5] and retighten screws.

 Screw protective covers [4] back on.
 The guide rails are adjusted.
Feeding conveyor guide rails
3
1
Fig. 4.45: Feeding conveyor guide rails

[1] Guide rail
[2] Clamping plate
[3] Screws
WARNING!
Risk of falling
components.
The guide rails seal the material guide ledges off from the conveyor belt
so that no material can reach the rotating components or fall off the belt
conveyor. In case of damage and wear, the guide rails must be adjusted
or changed.
 Release screws [3] on clamping rails [2] but do not remove them.
 Adjust guide rails [1] until they make contact on the conveyor belt.
 If necessary, replace damaged or worn guide rails.
 Retighten screws [3] on clamping rails [2].
 The guide rails are adjusted.

MAINTENANCE
Conveyor unit
4.10.01.04 Servicing angular gear
3
2
1
4
Fig. 4.46: Belt conveyor drive with angular gear

[1] Oil drain screw with horizontal installation
[2] Oil filler screw and ventilation
[3] Identification plate
[4] Oil drain screw with inclined installation
It is not possible to check the oil fill level with angular gears as the belt
conveyor drives are installed in different positions and a fill level screw is
not provided. If leaks are determined, the fill volume must be determined
by draining.
CAUTION!
The left oil drain screw [1] must be used with horizontal installation. The
right oil drain screw [4] is used with inclined installation.
Checking oil fill level  Warm up gear oil to service temperature. If necessary, run belt con-
veyor approx. 10 minutes.
 Clean housing of angular gear. In particular, the oil filler and oil drain
screws must be free of contamination.

MAINTENANCE
Conveyor unit
 Place a clean oil catching pan with a capacity of approx. 10 litres un-
der oil drain screw [1] or [4].
 Unscrew oil drain screw [1] or [4] and drain gear oil.
 Determine the fill volume. For correct fill volume, see identification
plate [3].
 Insert oil drain screw [1] or [4] again and tighten.
 Refill drained gear oil with the help of a funnel. If necessary, top up
missing volume with oil of corresponding specifications.
 Insert oil filler screw [2] again and tighten.
 Wipe up overflowing oil with a cloth and dispose of in accordance
with environmental specifications.
 Check angular gear for leaks.
 The oil fill level has been checked.
Changing gear oil  Warm up gear oil to service temperature. If necessary, run belt con-
veyor approx. 10 minutes.
 Clean housing of angular gear. In particular, the oil filler and oil drain
screws must be free of contamination.
 Place an oil catching pan with a capacity of approx. 10 litres under oil
drain screw [1] or [4].
 Unscrew oil drain screw [1] or [4], drain gear oil and dispose of in ac-
cordance with local environmental specifications.
 Insert oil drain screw [1] or [4] again and tighten.
 Fill fresh gear oil with the corresponding specifications with the help
of a funnel through the opening of the oil filler screw. For correct fill
volume, see identification plate [3].
 Insert oil filler screw [2] again and tighten.
 Wipe up overflowing oil with a cloth and dispose of in accordance
 Check angular gear for leaks.
 The gear oil has been changed.

MAINTENANCE
Conveyor unit
4.10.01.05 Lubricating plummer blocks
3
4
2
1
3
Fig. 4.47: Plummer block

[1] Drive pulley and/or return roller
[2] Lubricating nipple
[3] Block cover screws
[4] Dummy plug
[5] Sealing lips
All belt conveyors driven by angular gears are equipped with plummer
blocks.
The plummer blocks of the drive pulley and return rollers are disassem-
bled for lubrication. The plummer block is completely filled with lubricat-
ing grease via the lubricating nipple [2] and the dummy plug [5].
NOTICE
Danger of block damage
Escaping grease expands the sealing lips of the plummer blocks. Dust
can penetrate the expanded and damaged sealing lips and destroy the
blocks.
• Remove escaping grease.
• Replace damaged sealing lips.
Checking plummer blocks  Unscrew protective covers of plummer blocks.

 Remove dirt and dust from plummer blocks.
 Wipe up escaping grease with a cloth and dispose of in accordance
 Visually check inner and outer sealing lips [5] for damage and replace
if necessary.

MAINTENANCE
Conveyor unit
 Screw protective covers of plummer blocks back on.

 The plummer blocks have been checked.
Lubricating plummer blocks  Unscrew protective covers of plummer blocks.
 Remove dirt and dust from plummer blocks.
 Using a suitable securing element, e.g. tension belt, secure drive pul-
ley and/or return roller [1] against slipping out of the plummer blocks.
 Unscrew screw on block cover [3] and take out block cover.
 Remove sealing lips [5] from the plummer block. The sealing lips are
divided into two parts and can be removed as such from the shaft.
 Remove old grease from the plummer block and block cover and dis-
pose of in an environmentally friendly manner.
 Insert new sealing lips in the plummer block and block cover.
 Fill plummer block and block cover with fresh grease of the corre-
sponding specifications.
The specified grease quantity must be filled completely into the plummer
block and the block cover.
 Reinstall matching block cover with screws [3] and tighten screws to
specified tightening torque.
The plummer blocks and block covers are marked to prevent interchang-
ing.
 Unscrew dummy plug [4].
 Use a grease gun to press grease with the appropriate specifications
into the lubricating nipple [2] until grease emerges at the bore of the
dummy plug.
 Screw in dummy plug [4], wipe off excess grease and dispose of in
accordance with environmental regulations.
 Screw protective covers of plummer blocks back on.
 The plummer blocks have been lubricated.
Lubrication via Block type Grease qty. in

grammes
Plummer block SE 513-611 300
housing1
Plummer block SNL 513-611 340
housing1
Plummer block SE 516 -611 475
housing1
Plummer block SNL 516-611 550
housing1
Tab. 4.2: Plummer block lubrication
1
The block covers must be disassembled prior to lubricating the plummer
blocks.

MAINTENANCE
Conveyor unit
Tightening torque of block cover screws
Thread Tightening torque in Nm

M12 80
M16 150
Tab. 4.3: Tightening torque of block cover screws
4.10.02 Checking chutes
Fig. 4.48: Service flaps

[1] Crusher discharge conveyor
[2] Service flap
[3] Crusher outlet
WARNING!
Hazard posed by falling material
Material falling in the chutes can cause serious injury.
• Only open service flaps and doors with the plant at a standstill.
• Only eliminate material congestion with the plant at a standstill.
 Check service flaps [2] for secure installation and operation.

 Visually inspect rubber seals for damage, see chap. 4.10.02.01.
 Replace damaged components if necessary.
 The service flaps have been checked.

MAINTENANCE
Conveyor unit
Checking wear lining for crusher outlet
Fig. 4.49: Crusher outlet wear lining

[1] Securing screws, wear plates
[2] Wear plates
[3] Crusher outlet
WARNING!
Hazard posed by falling material
Material falling in the chutes can cause serious injury.
• Only open service flaps and doors with the plant at a standstill.
• Only eliminate material congestion with the plant at a standstill.
 Open service flaps and doors on chutes.

 Check wear plates on chutes for wear and chipping.
 Check secure seating of the wear plates by knocking on them.
 Replace worn or damaged wear plates. Tighten loose wear plates.
 Close service flaps and doors on chutes again.
 The wear plates have been checked.

MAINTENANCE
Conveyor unit
4.10.02.01 Checking rubber curtains and sealing
3
1
Fig. 4.50: Rubber curtains and sealing

[1] Crusher discharge conveyor
[2] Crusher outlet
[3] Crusher discharge conveyor seal
4
7

[4] Rubber curtain for feeding conveyor deflection roller
[5] Feeder trough
[6] Feeding conveyor seal

MAINTENANCE
Conveyor unit

[8] Crusher inlet
[9] Seal
The rubber curtains and sealing of chutes guide the material at the trans-
fer points and reduce dust emission. Damaged rubber curtains and seal-
ing can no longer completely fulfil this task.
 Perform visual inspection of all sealing on chutes and check transfer
points for damage.
 Check securing strips of rubber curtains and sealing for damage and
security.
 The chutes have been checked.
4.10.03 Servicing magnetic remover (option)
DANGER!
Danger due to magnetic fields
Electric and permanent magnetic separators generate strong magnetic
fields that present a risk to personnel.
• Persons with pacemakers and other medical-technical devices must
stay well clear of magnetic separators.
• Maintenance and cleaning work on electric magnetic removers must
only be carried out with the plant switched off.
• Observe the safety instructions.
 Run feed hopper, feeding conveyor and crusher empty.

 Switch off plant components.

MAINTENANCE
Conveyor unit
 Switch off diesel generator and secure against reactivation.

 Large magnetic charged material that was attracted by the magnetic
remover falls onto the feeding conveyor.
 Remove magnetic charged material from the feeding conveyor.
Cleaning magnetic removers  Manually remove charged material that remains on the magnetic re-
mover.
 The magnetic remover has been cleaned.
Checking suspension  Check all four suspension points for damage. Replace if necessary.
 Check security of screws for suspension. Retighten screws if neces-
sary.
 The suspension has been checked.
4.10.04 Servicing belt conveyors

4.10.04.01 Tensioning conveyor belt
3
5
6
1
Fig. 4.53: Belt conveyor clamping device

[1] Threaded rod
[2] Counter screw nut
[3] Clamping nut
[4] Conveyor belt frame
[5] Guide
[6] Belt conveyor

MAINTENANCE
Conveyor unit
WARNING!
Risk of falling
components.
NOTICE
A conveyor belt with belt drift, or which is too tightly or loosely tensioned,
wears faster and can cause consequential damage on conveyor compo-
nents.
• Tension the drive pulley or return roller evenly and at right angles to
the conveyor belt frame.
• Tighten the conveyor belt to the correct tension.
The belts on all belt conveyors are tensioned with two mechanical clamp-
ing devices respectively, which have the same design principle.
Tensioning conveyor belt  If necessary, unscrew protective covers of clamping devices.
 Release the left and right counter screw nuts [2] until the tensioning
path is free.
 Turn the left and right clamping nuts [3] evenly until the conveyor belt
is correctly tensioned. Ensure that the drive pulley and/or return roller
are at right angles to the conveyor belt frame [4].
 Retighten the left and right counter screw nuts [2].
 If necessary, screw protective covers of clamping devices back on.
 The conveyor belt is tensioned.
A conveyor belt that is tensioned too loosely can be recognised by sag-
ging between the return rollers. A conveyor belt that is tensioned too
tightly can be recognised by vibrating of the bottom segment during op-
eration.
A rule of thumb: The correct tension is the lowest possible tension that
prevents the drive pulley from slipping at the conveyor belt.
Slackening conveyor belt  If necessary, unscrew protective covers of clamping devices.
 Turn the left and right clamping nuts [3] evenly until the conveyor belt
is slackened. Ensure that the drive pulley and/or return roller are at
right angles to the conveyor belt frame [4].
 Tighten the left and right counter screw nuts [2].
 If necessary, screw protective covers of clamping devices back on.
 The conveyor belt is slackened.

MAINTENANCE
Conveyor unit
4.10.04.02 Changing conveyor belt

There are two basic different procedures for changing the conveyor belt:
• Place split conveyor on belt conveyor and join the ends by vulcanis-
ing.
• Remove belt conveyor and partly disassemble and mount endless
conveyor belt.
Contact persons for repair of conveyor belts are listed under "Customer
service" on the homepage of KLEEMANN GmbH: www.kleemann.info
4.10.04.03 Checking conveyor belt run
Fig. 4.54: Conveyor belt run (I)

[1] Support rollers
[2] Lateral guide rollers
[3] Conveyor belt
A correctly aligned conveyor runs centrally between the lateral guide roll-
ers and the drive and bend pulleys. This ensures reduced repair costs
and trouble-free operation.
The conveyor may make contact on the lateral guide rollers, however, the
formation of folds and bulges must be prevented.

MAINTENANCE
Conveyor unit
WARNING!
Risk of being drawn in by rotating components
When controlling and visually checking running belt conveyors, there is a
risk of limbs being drawn in by rotating components.
• Keep well away from rotating components.
• Carry out maintenance and service work only on stationary belt con-
veyors.

 Observe conveyor belt running with and without charged material
and record deficiencies determined.
 Conveyor belt running has been checked.
4.10.04.04 Adjusting conveyor belt run
Fig. 4.55: Conveyor belt run (II)

[3] Conveyor belt
[4] Return roller
[5] Return rollers
[6] Drive pulley
The illustration shows a conveyor belt [3] with a drift to the right and how
the return rollers [5] have to be correspondingly adjusted.

MAINTENANCE
Conveyor unit
Reasons for faulty conveyor belt run

• Inadequate alignment of the drive pulley and/or return roller.
• Drums and rollers contaminated on one side.
• Eccentric feeding unit and guide of the conveyor belt.
• Scrapers placed in the material flow at an inclination that pass on the
material via the side conveyor edge.
• Scraping of the conveyor belt on the conveyor belt frame or on
jammed material pieces.
• Uneven power transmission over the conveyor belt width due to
dampness.
• Incorrectly installed connection of the conveyor belt with kink in lon-
gitudinal direction.
Adjusting conveyor belt run
If the faulty conveyor belt run is caused by a reason other than those list-
ed above, the belt run must be adjusted via the return rollers [5].
At the point where the conveyor belt [3] begins to drift, one or several re-
turn rollers [5] can be adjusted.
 Exclude the above-mentioned reasons for faulty belt run.
 Tension the conveyor belt if necessary.
 Release mount of return roller [5] and turn slightly in the elongated
holes.
 Tighten mount again.
 Switch on plant components and diesel generator and observe con-
veyor belt run with and without charged material.
 Check setting as required.
 The conveyor belt run has been adjusted
Even a few millimetres in the setting range of the return rollers is sufficient
to make a correction to the conveyor belt run. To check the conveyor belt
run, the belt conveyor must run at least 2 minutes.
Due to incorrect manufacture, usage or storage, conveyor belts can be
deformed or bent and their setting is therefore no longer correct.

MAINTENANCE
Not assigned
4.11 Not assigned
4.12 Water system (option)
Fig. 4.56: Water system

[1] Spraying nozzles
[2] Fluid control
[3] Water pump
WARNING!
Risk of falling
components.
The water pump [3] and the fluid control [2] are maintenance-free. Only
a visual check is required.
 Visually check the housing and connections of the water pump [3]
and fluid control [2] for leaks.
 Have damage eliminated by authorised and qualified personnel.
 Visually check connections for spraying nozzles [1] for leaks.
 Check alignment of the spray jet and correct it if necessary.

MAINTENANCE
 Visually check feed lines of spraying nozzles for leaks. Eliminate

leaks.
 The water system has been checked.
Spraying nozzles are fitted at the following points:
• Belt discharge, crusher discharge conveyor
• Feeding conveyor discharge

MAINTENANCE
Not assigned
4.13 Not assigned
4.14 Not assigned
4.15 Not assigned
4.16 Not assigned
4.17 Not assigned
4.18 Not assigned
4.19 Not assigned
4.20 Not assigned
4.21 Not assigned
4.22 Not assigned
4.23 Not assigned
4.24 Not assigned
4.25 Not assigned
4.26 Not assigned
4.27 Not assigned
4.28 Not assigned
4.29 Not assigned
4.30 Not assigned

MAINTENANCE
Not assigned
4.31 Not assigned
4.32 Not assigned
4.33 Not assigned
4.34 Not assigned
4.35 Not assigned
4.36 Not assigned
4.37 Not assigned
4.38 Not assigned
4.39 Not assigned
4.40 Not assigned
4.41 Not assigned
4.42 Tools

MAINTENANCE
Feeding unit
1 2
Fig. 4.57: Tools and accessories

(1) Toolbox
(2) Tools and accessories
 Check the toolbox [1] for safe installation on the plant and for dam-
age.
 Check tools and accessories [2] for completeness and damage. Re-
place or exchange missing or damage tools.
 Tools and accessories have been checked.
4.43 Feeding unit
4.43.01 Servicing feed hopper
2 3
4
1

MAINTENANCE
Feeding unit
Fig. 4.58: Feed hopper

[1] Screw-coupling, hopper to chassis
[2] Screw-coupling, hopper extension (option)
[3] Support braces with locking pins and spring pins
[4] Screw-coupling, hopper frame braces
WARNING!
Risk of falling
components.
 Visually inspect screw-couplings of support structure and hopper

frame [1] and tighten as specified if necessary.
 Visually inspect screw-coupling of hopper extension [2] and tighten
as specified if necessary.
 Visually inspect locking pins and spring pins of support braces [3].
Replace damaged or missing locking pins and spring pins.
 Visually inspect screw-couplings of brace for hopper frame [4] and
tighten as specified if necessary.
 The feed hopper has been checked.

MAINTENANCE
Feeding unit
4.43.02 Servicing feeder trough

4.43.02.01 Servicing rubber mountings
Fig. 4.59: Feeder trough spring elements

[1] Attachment points
[2] Rubber mountings
WARNING!
Risk of falling
components.
NOTICE
Material damage through defective rubber mountings
Defective rubber mountings can no longer absorb the existing loads and
vibrations and lead to consequential damage on plant components.
• Replace damaged rubber mountings immediately.
Checking spring elements Cracks in rubber buffers quickly lead to bursting of the complete rubber
mounting. Components can then knock against neighbouring plant com-
ponents or the chassis and damage them.
Bloating of the rubber buffers, on the other hand, is normal wear and they
do not have to be replaced.
 Visually check rubber mountings [2] for cracks.

MAINTENANCE
Feeding unit
 Replace spring elements if necessary.

 The spring elements have been checked.
Replacing spring elements  Unscrew earth strap between feeder trough and chassis.
 Attach suitable hoisting gear and lifting accessories to the attachment
points [1].
 Raise the feeder trough until the spring elements [2] can be removed.
 Replace spring elements.
 Lower feeder trough back onto the spring elements.
 Screw earth strap back on.
 The spring elements have been replaced.
4.43.02.02 Checking vibration motors
1
2
Fig. 4.60: Vibration motors

[1] Securing bolts
[2] Protective covers
WARNING!
Risk of injury due to unprotected unbalance weights
Contact with the uncovered unbalance weights of the vibration motors
Material that enters the unbalance weights can be thrown out suddenly
and cause serious or fatal injuries.
• Only operate vibration motors with installed protective covers.
• During maintenance and repair work, secure plant components
against activation.

MAINTENANCE
Feeding unit
NOTICE
Water and dust can enter vibration motors not protected with protective
covers and cause bearing damage and winding short circuits.
• Only operate vibration motors with installed protective covers.
• Replace damaged protective covers.
As the securing screws [1] of the vibration motors are subject to strong
cyclic stressing, they can become loose over the course of time. With the
securing screws loosened, transmission of the vibratory forces is no long-
er guaranteed and the vibration motors will be prematurely destroyed.
 Tighten all securing screws [1] with torque wrench. For tightening tor-
ques, see chap. 5.03.
 Visually check protective covers [2] for damage and replace if neces-
sary.
 The vibration motors have been checked.
4.43.02.03 Servicing wear lining
2
1
Fig. 4.61: Vibrating conveyor trough wear lining

[1] Wear plates
[2] Securing screws and nuts
Checking wear plates  Visually check wear plates [1] of the vibrating conveyor troughs for
wear and chipping.
 Check secure seating of the wear plates by knocking on them.
 Replace worn or damaged wear plates. Tighten loose wear plates.
 The wear lining is checked.

MAINTENANCE
Feeding unit
Changing wear plates

As the hexagon sockets of the screws become eroded or clogged by ma-
terial, the screw heads can be secured with weld points to prevent them
turning. After removal of the nuts, the wear plates can be removed and
the screws can be knocked out.
The wear plates [1] are all bolted from the outside onto the chute trough.
 Unscrew nuts [2] of worn or damaged wear plates and remove wear
plates.
 Insert new wear plates and screw in nuts with locking rings.
 Tighten nuts to specified tightening torque.
 The wear plates have been changed.
Tightening torques of wear plates
Tightening torques in Nm
M10 M12 M16 M20 M24 M30

50 90 230 450 750 1450
Tab. 4.4: Tightening torques of wear plates
4.43.03 Repairing feeder trough

4.43.03.01 Replacing vibration motor
DANGER!
Danger due to open running unbalance weights
Open running unbalance weights can catch and draw in personnel lead-
ing to serious or fatal injury.
• Only operate vibration motors with the guard devices firmly in place.
• Read off the rocker width only with the guard devices in position.
• Before starting repair work, switch off the plant, remove the key and
secure against reactivation.
If a fault occurs at the vibration motors, it may be necessary to replace

one of the two vibration motors.
Observe the following items when replacing vibration motors.
• The vibration motors must be the same model from the same manu-
facturer.
• The setting of the unbalance weights must be the same on both vi-
bration motors.
• The direction of rotation of the two vibration motors must always be
counter-acting.
• Retighten securing screws of the replaced vibration motors after 10
operating hours to specified tightening torque.

MAINTENANCE
Feeding unit
Directions of rotation of the vibration motors

Depending on the version of the chute, the installation of the vibration
motors varies. The prescribed directions of rotation are shown in the il-
lustration.
1 2 3
Fig. 4.62: Installation situation of the vibration motors

[1] Side installation
[2] Installation on back, vertical
[3] Installation on back, horizontal
4.43.03.02 Checking rocker width
2
1
Fig. 4.63: Vibrating conveyor trough rocker width gauge

[1] Rocker width gauge decal
[2] Intersection

MAINTENANCE
Feeding unit
DANGER!
During operation of the vibrating conveyor trough, the rocker width can
be read off at the rocker width gauge [1] based on the intersection [2] of
the straight lines. The intersection specifies the rocker width in millime-
tres. In the example illustrated, the width is approx. 8.5 mm.
Prerequisite
The rocker width gauge [1] must be fixed in the centre of the vibrating
conveyor trough transverse to the vibratory direction.
Checking rocker width  Allow the vibrating conveyor trough to run empty.
 Read off the rocker width at the rocker width gauge [1].
 Adjust the rocker width if necessary, see chap. 4.43.03.03.
 The rocker width has been checked.
4.43.03.03 Adjusting rocker width
Fig. 4.64: Unbalance weights for vibrating conveyor trough

[1] Marking line
[2] Scale
[3] Clamping screw

MAINTENANCE
Feeding unit
DANGER!
NOTICE
Incorrectly set unbalance weights can result in damage to vibration mo-
tors and vibrating conveyor troughs.
• Repair work on vibration motors must be carried out by authorised
and qualified personnel only.
• Ensure that all unbalance weights of a vibrating conveyor trough
have exactly the same settings.
Adjusting rocker width The unbalance weights are set ex works to a certain percentage. This
setting permits usage of the defined speed range via the frequency con-
verter. Before adjusting to a higher percentage, in particular, please con-
sult with the Customer Service of KLEEMANN GmbH.
 Remove all protective covers from vibration motors.
 Release clamping screws on inner unbalance weights.
 Adjust the inner unbalance weights so that the marking line points to
the desired percentage on the scale. Set all inner unbalance weights
to the same percentage.
 Tighten clamping screws of inner unbalance weights to specified
tightening torque.
 Check the rocker width with the vibrating conveyor trough running
and correct if necessary.
 Reinstall all protective covers on vibration motors. Ensure that the O-
rings of the protective covers are correctly seated.
 The rocker width has been adjusted.
Every graduation of the scale corresponds to one percent of the maxi-
mum centrifugal force of the unbalance weights.
The outer unbalance weights are held in position by feather keys and
cannot be adjusted.

MAINTENANCE
Crusher
Tightening torques for clamping screws
Tightening torques in Nm
M6 M8 M10 M12 M16 M24

11 27 55 100 176 490
Tab. 4.5: Tightening torques for clamping screws
4.44 Crusher
4.44.01 Checking/tensioning V-belt
2
3
Fig. 4.65: Crusher drive V-belt

[1] V-belt
[2] Cone crusher belt pulley
[3] Crusher drive pulley
WARNING!
Danger due to belt drives
When the belt drive guard devices are removed, there is a risk of injury
because limbs can be drawn in.
• When performing maintenance and repair work on belt drives, always
switch off plant or components.
• Secure the plant or component against reactivation.
• Never place your hands in the running belt drives.
Power is transmitted to the cone crusher via belt pulleys and several V-
belts arranged beside each other. The tension and condition of the V-
belts must be checked to ensure loss-free power transmission.

MAINTENANCE
Crusher
NOTICE
If the V-belt tension is insufficient, this results in vibrations of the V-belt
and even ejection from the belt pulleys.
Excessive V-belt tension subjects the bearings to excessive loads and
leads to V-belt wear.
• Always ensure that the V-belt tension is correct.
• Adjust the clamping screws evenly to guarantee axial parallelism of
the belt pulleys.
Checking V-belt  Switch off the plant and diesel generator and secure against reacti-
vation.
 Switch off and remove battery isolator and carry it with you.
 Remove cover of belt drive.
 Visually inspect V-belt [1] for cracks, fraying and other damage.
Change all V-belts if necessary.
If one or several V-belts are damaged, a complete set of V-belts must al-
ways be replaced.
 Return twisted V-belts to their correct position.
 Check tension of V-belts [1] with pretension gauge. For operating ten-
sion of V-belts, see chap. 5.01.09.
 Install cover of belt drive.
 The V-belts have been checked.
7
5
4 8
Fig. 4.66: Tensioning device for V-belt

[4] Clamping nut
[5] Locknut for tensioning screws

MAINTENANCE
Crusher
[6] Crusher drive electric motor

[7] Tensioning carriage securing screws
[8] Tensioning carriage
The crusher drive is installed on a tensioning carriage [8] and can be ad-
justed in longitudinal direction. This tightens or releases the V-belts.
Tensioning V-belts  Switch off plant or component and secure against reactivation.
 Allow crusher to coast until it is at a complete standstill.
 Remove cover of belt drive.
 Release all securing screws [7] on tensioning carriage [8].
 Release locknuts [5] of the tensioning device.
 Turn clamping nuts [4] alternately and evenly until the optimum pre-
tension of the V-belts has been reached.
 Check the tension of the V-belts with pretension gauge and correct
the tension if necessary. For operating tension of V-belts, see chap.
5.01.09.
 Tighten locknuts [5].
 Tighten fastening screws [7].
 Refit cover of belt drive.
 The V-belts have been tensioned.
Changing V-belts  Carry out preparatory work as described under "Tensioning V-belts".
 Turn tensioning nuts [4] until the V-belts can be removed from the belt
pulleys.
 Fit new V-belt in position.
 Turn clamping nuts [4] until the optimum pretension of the V-belts has
been reached.
 Check the tension of the V-belts and correct the tension if necessary.
 Carry out final tasks as described under "Tensioning V-belts".
 The V-belts have been changed.
For maintenance intervals for V-belts, see chap. 5.02.

MAINTENANCE
Crusher
4.44.02 Checking crusher mounting
Fig. 4.67: Cone crusher mounting

[1] Main frame
[2] Rubber mount
The lower frame of the cone crusher is secured with rubber mounts [2] to
the chassis. Vibrations during crusher operation can loosen the screw-
couplings.
 Visually check rubber mounts [2] for damage.
 Check security of screw-couplings.
 The mounting of the cone crusher has been checked.
4.44.03 Check support and guide blocks

MAINTENANCE
Crusher
Fig. 4.68: Support and guide blocks, geared ring

[1] Upper support and guide block
[2] Lower support and guide block
WARNING!
Risk of falling
components.
NOTICE
If the support and guide blocks are damaged or missing, they can no
longer guide the geared ring safely. This results in consequential damage
to plant components.
• Replace damaged support and guide blocks.
• Install missing support and guide blocks.
The support and guide blocks guarantee the correct seating of the
geared ring for the crushing gap adjustment device.
 Switch off plant or cone crusher and secure against reactivation.
 Visually inspect support and guide blocks for wear and damage.
 Replace worn or damaged support and guide blocks.
 Check security of all fastening screws on support and guide blocks.
Tighten screws if necessary.
 The support and guide blocks have been checked.

MAINTENANCE
Crusher
4.44.04 Checking geared ring
1
2
Fig. 4.69: Adjusting geared ring

[1] Locknut
[2] Adjusting screw
[3] Geared ring
[4] Setting cap
WARNING!
Risk of falling
components.
NOTICE
Adjusting screws tightened excessively block the bowl. If the bowl is ro-
tate with the adjusting screws tightened, this causes consequential dam-
age to plant components.
• Release adjusting screws that are tightened too far.
• Only insert adjusting screw until they make contact on the bowl.

MAINTENANCE
Crusher
NOTICE
Risk of material damage by damaged or missing adjusting screws
If adjusting screws are damaged or missing, the geared ring can no long-
er be correctly guided. This results in consequential damage to plant
components.
• Replace missing or damaged adjusting screws.
• Ensure that the adjusting screws are correctly installed.
The adjusting screws guarantee correct setting of the geared ring and
correct seating of the geared ring and pinion of the hydraulic motor of the
crushing gap adjustment device.
Checking geared ring  Switch off plant or component and secure against reactivation.
 Check geared ring and pinion of hydraulic motor for crushing gap ad-
justment device for damage.
 Replace damaged components.
 Check geared ring for even distance to setting cap.
 Check correct seating of geared ring and pinion.
 The geared ring has been checked.
The distance from the tooth tip of the drive pinion to the tooth base of the
geared ring is 6 mm.
Adjusting geared ring  Release locknut.

 Use adjusting screw to align geared ring such that the distance from
the geared ring to the setting cap is uniform in all areas.
 Ensure that the setting cap is not clamped and that the adjusting
screws only make loose contact.
 Tighten locknut.
 The geared ring has been adjusted.
Use all three adjustment units to adjust the geared ring.
 If necessary, adjust the distance from the drive pinion and geared ring
to correct dimension. Use the adjusting device of the hydraulic motor
to do this.
4.44.05 Theoretical wear limit

The values specified in the table are theoretical values for worn crushing
tools. No allowance is made for possible production tolerances of crush-
ing tools, crushing tools from other manufacturers and other factors.
The exact setting of the crushing gap can only be determined by check-
ing the crushing gap, see chap. 3.12.

MAINTENANCE
Crusher
A 2
Fig. 4.70: Wear of crushing tools KX300

[1] Setting cap
[2] Dust protection
[3] Adjustment ring
Theoretical wear limit, cone crusher KX300
NOTICE
Distance A is the absolute lowest theoretical wear limit. Below this limit,
damage to the crusher is possible.
• For safety reasons, add 30 mm to distance A to prevent damage to
the crusher.
Example, CSS = 20 mm: distance A = 98 mm + 30 mm (= 128 mm).
Crushing tool KX300 CSS Distance A

Standard, coarse (STD C) 20 mm 98 mm
Standard, medium (STD M) 17 mm 93 mm
Standard, fine (STD F) 13 mm 79 mm
Short head, coarse (SH C) 10 mm 85 mm
Short head, medium (SH M) 6 mm 78 mm
Short head, fine (SH F) 6 mm 77 mm
Tab. 4.6: Theoretical wear limit KX300
If the crushing gap (Closed Side Setting) deviates from the specified val-
ue by a further 6 mm, distance A must be increased or reduced by 9 mm
respectively.

MAINTENANCE
Crusher
4.44.06 Lubricating cone crusher
Fig. 4.71: Lubrication of cone crusher

[1] Lubricating nipple for thread of crushing gap adjustment device
[2] Adjustment ring
WARNING!
Risk of falling
components.
NOTICE
Damage can be caused to the thread of the crushing gap adjustment de-
vice if it is insufficiently lubricated.
• Always ensure that the thread is correctly lubricated.
The thread of the crushing gap adjustment device is lubricated via 4 lu-
bricating nipples at the adjustment ring.

MAINTENANCE
Crusher
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Switch off plant and secure against reactivation.
 Use a grease gun to press in 25 g grease with the corresponding
specifications per lubricating nipple.
 Switch on plant in manual mode and follow the instructions including
"Acknowledge fault / emergency off" (see chap. 3.05).
The button [37] lights up and indicates that the tramp release and clamp-
ing cylinders are relieved. If the button [37] is pressed, it is not possible
to adjust the cone crusher.
 Press the "Increase crushing gap" button [35] to carefully unscrew
the adjustment ring and bowl. Release button [35].
 Switch off plant and secure against reactivation
 Use a grease gun to press in 25 g grease with the corresponding
specifications per lubricating nipple.
"Acknowledge fault / emergency off" (see chap. 3.05).
 Screw in adjustment ring and bowl using button "Decrease crushing
gap" [36].
 Set crushing gap, see chap. 3.12.02.
 The thread of the crushing gap adjustment device is lubricated.
Lubrication point Grease quantity

Adjustment ring 200 g
Tab. 4.7: Cone crusher lubrication points
One stroke of the grease gun corresponds to approx. 2 g grease.

For lubrication intervals, see chap. .

MAINTENANCE
Crusher
Only special grease must be used to lubricate the thread, see chap. .
4.44.07 Checking/measuring the wear lining
1 2
4
3
Fig. 4.73: Checking wear elements

[1] Supporting arm wear element
[2] Lower frame wear element
[3] Counterweight wear element
[4] Backgear shaft wear element
WARNING!
Risk of falling
components.
NOTICE
Risk of material damage by damaged or missing wear elements
Damaged or missing wear elements can result in consequential damage
to components of the cone crusher.
• Replace missing or damaged wear elements.
• Ensure that the wear elements are correctly installed.

MAINTENANCE
Crusher
The wear elements can only be checked if the crushing tools are re-
moved. A check must therefore be carried out every time the crushing
tool is changed.
Checking wear elements  Check the weal elements for damage. Replace damaged or worn
wear elements, see chap. 4.44.09.
 Check screws on wear element [3] for firm seating and tighten screws
if necessary.
 Visually inspect correct seating of wear elements.
 Visually check weld seams on wear elements for firm seating and
damage. Re-weld wear elements if necessary, see chap. 4.44.09.
 The wear elements have been checked.
WARNING!
Risk of falling
components.
NOTICE
Risk of material damage by damaged or missing wear elements
Damaged or missing wear elements can result in consequential damage
to components of the cone crusher.
• Replace missing or damaged wear elements.
• Ensure that the wear elements are correctly installed.

MAINTENANCE
Crusher
Fig. 4.74: Measuring wear element

[5] Level
[6] Installation dimension 12 mm
[7] Wear limit 6 mm
The wear is determined from the distance between the measuring aid,
e.g. level, and the thinnest point of the wear element.
Measuring wear element  Check the wear of the wear element [2] at four positions offset by 90°
using a suitable measuring aid, e.g. a level.
 The wear limit [7] of 6 mm must not be exceeded. Replace wear ele-
ment if necessary, see chap. 4.44.09.
4.44.08 Changing crushing tools
DANGER!
DANGER!
Danger! Heavy loads
Raised or suspended loads can fall, resulting in serious or fatal injury.
• Attach lifting accessories carefully to components, ensuring they can-
not slip.
• Where possible, attach components to be lifted at their centre of grav-
ity.
• 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.

MAINTENANCE
Crusher
4.44.08.01 Removing bowl
WARNING!
Risk of falling
components.
Before the bowl can be removed, the fill level monitor, the tie-bar of fill lev-
el monitor and the crusher inlet must be disassembled.
As an alternative to disassembly of the fill level monitor, it can also be
folded onto the protective housing of the power supply unit.
3
1
Fig. 4.75: Disassembling fill level monitor

[1] Fill level monitor (option)
[2] Protective housing for power supply unit
[3] Screw-coupling for fill level monitor
[4] Tie-bar
Disassembling fill level  Release nuts on screw-coupling of fill level monitor [3].
monitor
 Unscrew three nuts and screws.
 Repeat the same work steps on the opposite side. Ensure that the re-
maining screws are exactly opposite.
 The fill level monitor can be folded forwards.
 Carefully deposit fill level monitor on the power supply unit protective
housing.

MAINTENANCE
Crusher
 If necessary, turn fill level monitor on tie-bar 90°.
X
X
8
9
Fig. 4.76: Removing crusher inlet

[5] Carrier, bowl
[6] Markings for toothed ring and bowl
[7] Profiled guide
[8] Adjusting screw
[9] Bowl
Removing crusher inlet  Secure suitable lifting gear and tackle to mounting links on crusher in-
let.
 Take off crusher inlet and set down slowly on a suitable base.
 For subsequent installation of the bowl, make markings [6] on the
carrier [5] and profiled guide [7].
 The bowl is ready for removal.

MAINTENANCE
Crusher
10
11
Fig. 4.77: Attaching bowl

[8] Adjusting screw
[10] Locknut
[11] Lifting device, bowl
Removing bowl
NOTICE
 Ensure that the adjusting screws [8] do not block the bowl [9].
 Release locknut [10] if necessary and loosen adjusting screws. Do
not unscrew adjusting screws completely.
 Attach suitable lifting gear and tackle on lifting device [11].
 Ensure that the lifting gear is not tensioned.

MAINTENANCE
Crusher
Fig. 4.78: Removing bowl

"Acknowledge fault / emergency off".
The button [37] lights up and indicates that the tensioning and clamping
cylinders are relieved. If the button [37] is pressed, it is not possible to ad-
just the cone crusher.
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Press the "Increase crushing gap" button [35] to carefully unscrew
the bowl.
To determine when the threads of the bowl and crusher housing no long-
er engage in one another, always work with a second person.
 Release the "Increase crushing gap" button [35] as soon as the
threads no longer engage in one another.

MAINTENANCE
Crusher
 Switch off plant and secure against reactivation.
WARNING!
When setting the bowl on the ground, serious crushing injuries to the feet
are possible.
• When setting down, stay clear of the danger zone of the bowl.
• Ensure that there are no persons in the danger zone when it is being
set down.
 Raise bowl and set down on suitable base.

 The bowl has been removed.
4.44.08.02 Changing bowl liner
2 3
Fig. 4.80: Top and bottom feed hopper

[1] Bowl
[2] Top feed hopper
[3] Bottom feed hopper
Before the bowl liner can be removed, the following work steps must be
carried out.
 Lift the top feed hopper [2] with suitable lifting gear and tackle out of
bowl [1].
 Lift the bottom feed hopper [3] with suitable lifting gear and tackle out
of bowl [1].

MAINTENANCE
Crusher
5 6
Fig. 4.81: Guard device square-head bolts

[4] Bowl liner
[5] Adapter ring
[6] Foam rubber and lubricating grease
 If necessary, remove foam rubber and lubricating grease [6] from the
square-head bolts.
 Clean threads of square-head bolts.
 The bowl liner is ready for removal.
1
2
5
6
Fig. 4.82: Wedges

[1] Split pin
[2] Square-head bolt
[3] Cone nut

MAINTENANCE
Crusher
[4] Wedge
[5] Securing element for square-head bolt
[6] Cone nut securing element
[7] Shim
Removing wedges  Disassemble split pin [1] and securing elements [6] of cone nuts [3]
on all wedges.
Fig. 4.83: Wedges

[3] Cone nut
[4] Wedge
 Release cone nuts [3] and unscrew.
 Remove wedges [4], square-head bolts [2] and cone nuts [3] and pre-
pare them for installation.
 If necessary, remove shim [7].
For removal of the wedges, it may be necessary to remove the securing
elements from the square-head bolts.
WARNING!
Danger due to chipped off metal splinters
Chipping caused by knocks with a hammer, chisel or similar tool on the
securing elements of the square-head bolts can result in injury.
• Ensure that there are no persons in the hazard area.
 Use suitable tools, e.g. a hammer and chisel, to separate the secur-
ing elements [5] of the square-head bolts [2] from the bowl.

MAINTENANCE
Crusher
 Keep the securing elements ready for installation.

 The wedges have been removed.
10
11
Fig. 4.84: Bowl and bowl liner

[8] Lifting points
[9] Shackle
[10] Bowl
[11] Bowl liner
Removing bowl  Attach shackles [9] to all lifting points [8] and secure them.
 Attach suitable lifting gear to all shackles [9].
WARNING!
When setting the bowl on the ground, serious crushing injuries to the feet
are possible.
• When setting down, stay clear of the danger zone of the bowl.
set down.
 Slowly remove bowl [10] from crusher shell [11] and deposit carefully
on a suitable base.
 The crusher shell has been removed.

MAINTENANCE
Crusher
10
12
Fig. 4.85: Cleaning bowl

[10] Bowl
[12] Bowl contact surface
Cleaning bowl  Remove old lubricating grease from the thread with a suitable tool.
Dispose of grease in accordance with environmental regulations.
 Perform visual inspection of thread for damage. Remove burring with
suitable tool if necessary.
 Carefully tilt bowl [10] on the side and slightly tension lifting gear at
same time.
WARNING!
Grinding dust is harmful to health
The inhalation of grinding dust can cause serious illnesses.
• Wear suitable breathing mask.
 Carefully clean contact surface [12]. Ensure that there is no more

epoxy resin on the contact surface. Remove epoxy resin if necessary
with a suitable grinding tool.
 Tilt bowl back into initial position.
 The bowl has been cleaned.

MAINTENANCE
Crusher
11
13
Fig. 4.86: Cleaning bowl liner

[11] Bowl liner
[13] Bowl liner contact surface
WARNING!
Work with solvents can result in serious irritation to the eyes, skin and
respiratory tracts.
• Ensure the workplace is well ventilated.
Cleaning crusher shell  Use suitable cleaning agents to clean the contact surface [13] of the
crusher shell [11].
When installing a new crusher shell, ensure that there is no protective
coating on the contact surface. Remove protective coating if necessary.

MAINTENANCE
Crusher
14
15
Fig. 4.87: Marking for bowl liner

[14] Highest point position
[15] Markings
Marking crusher shell  If necessary, make markings [15] at the higher positions [14] of the
crusher shell.
The markings at the higher position of the crusher shell facilitate align-
ment of the crusher shell in the bowl.
10
11
Fig. 4.88: Bowl and bowl liner

[8] Lifting points
[9] Shackle
[10] Bowl
[11] Bowl liner

MAINTENANCE
Crusher
Mounting bowl  Attach shackles [9] to all lifting points [8] and secure them.
WARNING!
When setting the bowl on the bowl liner, serious crushing injuries are pos-
sible.
• When mounting, never place your hands between the bowl and bowl
liner.
 Use suitable lifting gear to lift bowl [10] over the crusher shell [11],
lower slowly, but do not set down.
15
16
11
Fig. 4.89: Aligning bowl

[11] Bowl liner
[15] Markings
[16] Locking device for wedges
Aligning bowl  Align bowl and ensure that the markings [15] of the crusher shell are
located centrally between the locking devices [16].
 Lower the crusher shell completely.
 Remove lifting gear.
 The bowl has been aligned.

MAINTENANCE
Crusher
10
17
16
11
Fig. 4.90: Installing wedges

[3] Cone nut
[4] Wedge
[7] Shim
[10] Bowl
[11] Crusher shell
[16] Locking device for wedges
[17] Space between crusher shell and wedge
NOTICE
Incorrectly positioned wedges can result in damage to the crusher shell.
• Ensure that the wedges do not butt against the crusher shell.
• After the wedges have been clamped, ensure that there is sufficient
distance between crusher shell and wedges.
• Insert shims to prevent the wedges from butting against the crusher
shell.
Installing wedges  Place wedge [4], cone nut [3] and square-head bolt between locking
devices [16].
 Push wedge [4] under the edge of the crusher shell [11].
 Tighten cone nut with suitable tool. Ensure that the square-head bolt
makes contact against the bowl [10].
 Ensure that the wedge does not make contact against the crusher
shell. Use shim [7] if necessary to ensure correct distance [17]. Make
sure that the shim does not protrude over the inner edge of the lock-
ing devices [16].
 Perform the same work steps at all positions of the wedges.

MAINTENANCE
Crusher
Fig. 4.91: Installation position of bowl liner

 Use suitable auxiliary tools to check the uniform installation position
of the crusher shell on all wedges [4].
 If necessary, correct the installation position by tightening the cone
nuts [3].
Fig. 4.92: Securing element for square-head bolts

[5] Securing element
If the securing elements of the square-head bolts were removed during
disassembly of the crusher shell, they must be reinstalled.
 Place securing element [5] in recess of bowl. Ensure that the secur-
ing element butts against the square-head bolt [2].

MAINTENANCE
Crusher
CAUTION!
Danger due to hot surfaces
Components heat up when welding equipment is used. There is a danger
of burns.
• Before continuing the work, wait until the components have cooled
down.
 Weld securing elements [5] onto bowl.

 Perform the same work steps at all square-head bolts.
 The square-head bolts have been secured.
Fig. 4.93: Bracing wedges

 Tighten cone nuts [3] evenly. If necessary, use a suitable extension
for a higher torque.
 Check the distance [17] between wedge and crusher shell.
 The crusher shell is braced and secured.

MAINTENANCE
Crusher
Fig. 4.94: Checking installation height

Checking installation height  Use suitable auxiliary tools to check the uniform installation height of
the crusher shell at two positions offset by 90°.
 Correct the installation height with the cone nuts if necessary.
Securing elements must be installed to prevent the cone nuts from be-
coming loose. When assembling the securing elements, place two sides
of the cone nut respectively in vertical position.
 Align cone nuts [3] and check installation height once again if neces-
sary.
3
6
Fig. 4.95: Installing cone nut securing element

[1] Split pin
[3] Cone nut

MAINTENANCE
Crusher
[6] Cone nut securing element

Installing securing element  Install securing element [6] on cone nut [3].
for cone nuts
 Push new split pin [1] through securing element [6] and wedge [4]
and bend over the ends.
 Perform the same work steps at all cone nuts.
 The cone nuts have been secured.
18
10
11
19
20
Fig. 4.96: Checking gap dimension

[10] Bowl
[11] Bowl liner
[18] Guard device square-head bolts
[19] Gap dimension (max. 0.25 mm)
[20] Feeler gauge
Checking gap dimension  Use a feeler gauge to check whether the gap dimension [19] between
the contact surfaces of the crusher shell and bowl is max. 0.25 mm.
 Fill a larger gap with suitable material to prevent epoxy resin from es-
caping.
 The gap dimension has been checked.
 Use suitable protection [18], e.g. lubricating grease and foam rubber,
to cover all square-head bolts and securing elements [6].

MAINTENANCE
Crusher
23
22
24
21
Fig. 4.97: Filling bowl liner

[21] Epoxy resin
[22] Adapter ring
[23] Feed hopper
[24] Hose
WARNING!
Danger of fire
Epoxy resin and hardener can ignite.
• Do not smoke when carrying out maintenance and repair work.
• Keep burning objects well away from epoxy resin and hardener.
WARNING!
Work with epoxy resin and hardener can result in serious irritation to the
eyes, skin and respiratory tracts.
• Observe the safety instructions of the manufacturer.
Filling space between crusher  Prepare hopper [23] and hose [24] for filling.
shell and bowl
 Mix epoxy resin and hardener according to specifications of manu-
facturer.
 Position hose [24] between crusher shell and bowl.
 Pour the mixed epoxy resin rapidly through the hopper [23] and hose
[24].

MAINTENANCE
Crusher
 Pour in mixed epoxy resin up to the bottom edge of the adapter ring
[22]. Ensure that the epoxy resin [21] is evenly distributed. If neces-
sary, change the position of the hose and hopper.
 Dispose of excess mixed epoxy resin in an environmentally friendly
manner.
 The space has been filled.
Store and process epoxy resin at temperatures of between 16 °C and 33
°C.
When pouring the epoxy resin, the temperature of the crusher shell and
bowl must not be below 15.6 °because otherwise the reaction of the
epoxy resin with the hardener would stop.
After filling with epoxy resin, the cone nuts of the wedge must no longer
be adjusted because otherwise an even filling of the space is not guaran-
teed.
26
25
25
Fig. 4.98: Bottom feed hopper

[26] Filling material
Installing bottom feed hopper  Add filling material [26], e.g. insulating wool, up to the level of the
crusher shell.
 Install bottom feed hopper [25] with suitable lifting gear and tackle in
bowl.
 Add filling material [26] in the space between the bottom feed hopper
and the bowl.
 The bottom feed hopper has been installed.

MAINTENANCE
Crusher
27
25
Fig. 4.99: Top feed hopper

[27] Top feed hopper
WARNING!
Danger of crushing due to feed hopper
Serious injuries are possible when the top feed hopper is being installed
in the bowl.
• When mounting, never place your hands between the top feed hop-
per and bowl.
Installing top feed hopper  Install top feed hopper [27] with suitable lifting gear and tackle in
bowl.
 Ensure that the top feed hopper makes full contact on the bowl.
For correct assembly of the top feed hopper, it may be necessary to sep-
arate the lateral support profiles in the feed hopper.
CAUTION!
Hazard posed by hot surfaces
Components heat up when a cutting torch is used. There is a danger of
burns.
down.
Separating support profiles  Raise the top feed hopper [27] with suitable lifting gear and tackle un-
til the load on the support profiles is relieved.

MAINTENANCE
Crusher
 Use a suitable tool, e.g. cutting torch or cutting wheel, to cut out the
support profiles.
 Lower the top feed hopper completely.
 Remove lifting gear and lifting apparatus.
 The top feed hopper has been installed.
27
25
28
28
Fig. 4.100: Support profiles

[27] Top feed hopper
[28] Support profiles
Installing support profiles  Weld support profiles (28) onto side panel of the top feed hopper. En-
sure that the support profiles make contact at the bottom feed hopper
(25).
The support profiles guarantee reliable positioning of the bottom feed
hopper in the bowl and on the crusher shell.
4.44.08.03 Removing mantle
WARNING!
Risk of falling
components.

MAINTENANCE
Crusher
Fig. 4.101: Removing feed plate

[1] Retaining nut
[2] Securing screws
[3] Feed plate
Removing feed plate
NOTICE
Lifting the mantle at the feed plate can cause damage to the feed plate
and, consequently, to the plant.
• Do not lift the mantle at the feed plate.
• Always use the lifting disc to install and remove the mantle.
 Attach and secure feed plate [3] to suitable lifting gear and tackle.
 Slacken screws [2] on feed plate and remove.
 Take off feed plate and keep ready for installation.

MAINTENANCE
Crusher
6 7
Fig. 4.102: Positioning lifting disc

[4] Special tool, lifting disc
[5] Lifting ring
[6] Closed side
[7] Opened side
Installing lifting disc
NOTICE
If the lifting ring is not positioned correctly, this can cause damage to the
bottom bearing when the mantle is lifted out and placed back in.
• When removing the mantle, always align the lifting disc so that the lift-
ing ring faces the closed side of the mantle and the crusher housing.
• When installing, align the mantle so that the lifting ring is above the
thicker side of the eccentric.
 Secure suitable lifting gear and tackle to the lifting ring [5].
 Align lifting disc [4] at retaining nut [1] so that the lifting ring [5] faces
the closed side [6].
 Mount lifting disc [4] on retaining nut [1] and secure with screws.
 Align lifting gear vertically above mantle.
 The lifting disc is installed and the mantle can be removed.
The eccentric position of the lifting ring tilts the mantle slowly into the cor-
rect removal position, which prevents damage to the bearing.

MAINTENANCE
Crusher
8
4
Fig. 4.103: Removing mantle

[5] Lifting ring
[8] Screws for lifting disc
[9] Mantle
WARNING!
Danger of crushing by mantle
When setting the mantle on the ground, serious crushing injuries to the
feet are possible.
• When setting down, stay clear of the danger zone of the mantle.
set down.
Removing mantle  Lift mantle [9] vertically out of crusher housing and set down on suit-
able base.
 The mantle has been removed
4.44.08.04 Changing mantle
WARNING!
Risk of injury
Serious injuries are possible when separating the packing ring with a cut-
ting torch.
• Ensure that there are no persons in the danger zone during the work
procedure.

MAINTENANCE
Crusher
CAUTION!
Components heat up when a cutting torch is used. There is a danger of
burns.
down.
1
2
3
4
Fig. 4.104: Mantle weld seam

[2] Mantle
[3] Retaining nut
[4] Packing ring
[5] Weld seams, packing ring and retaining nut
Preparation for changing Before the crusher cone can be removed from the head, the following
crusher cone work steps must be carried out.
 Slacken screws on lifting disc [1] and remove.
 Take off lifting disc.
Separating weld seams
NOTICE
Cutting of the packing ring with a cutting torch and cause damage to the
thread on the head.
• Never point the cutting torch beam at a right angle onto the packing
ring.

MAINTENANCE
Crusher
 Separate the weld seams [5] at the packing ring, retaining nut [3] and
crusher cone [2] using a suitable tool.
The crusher cone can expand during operation. This may cause difficul-
ties when the retaining nut is being released. In this case, use the cutting
torch between retaining nut and crusher cone to cut the packing ring tan-
gentially.
Fig. 4.105: Releasing retaining nut

[3] Retaining nut
[6] Eye bolt
[7] Special tool, clamping wrench
Releasing retaining nut  Attach suitable lifting gear and tackle on eye bolt [6].
 Mount clamping wrench [7] on retaining nut [3] and secure with
screws.
 Release retaining nut with wrench. If necessary, use suitable auxiliary
tool, e.g. pipe extension or sledge hammer for releasing the retaining
nut.
 Unscrew the screws on the clamping wrench and take it off.
 The retaining nut has been released.

MAINTENANCE
Crusher
1
4
Fig. 4.106: Removing retaining nut

[3] Retaining nut
[4] Packing ring
[8] Lifting ring
Removing retaining nut and  Install lifting disc [1] with screws on the retaining nut [3].
packing ring
 Secure suitable lifting gear and tackle to the packing ring [8].
 Unscrew retaining nut by hand [3] while slightly tensioning the lifting
gear.
 Turn retaining nut until it can be removed. Keep retaining nut ready
for installation.
 Take off packing ring [4] and keep ready for installation.
 The retaining nut and packing ring have been removed and the
crusher cone is ready for disassembly.
Removing crusher cone with
retaining lug
WARNING!
feet are possible.
set down.
The crusher cone must be removed with the help of the welded-on retain-
ing eyes.

MAINTENANCE
Crusher
Ensure that the retaining eyes are sufficiently dimensioned and that the
welding wire used is suitable for manganese.
10
Fig. 4.107: Removing mantle

[2] Mantle
[10] Mantle retaining eye
Removing crusher cone with  Weld on sufficiently large retaining eyes [10] at the crusher cone with
retaining eyes a minimum thickness of 15 mm.
 Provide an all-round weld seam with a thickness of at least 6 mm at
the retaining eyes.
 Attach suitable lifting gear and tackle to all retaining eyes [10] on the
crusher cone.
WARNING!
feet are possible.
set down.
 Carefully remove crusher cone from head and set down.

 The crusher cone has been removed.

MAINTENANCE
Crusher
13
2
12
14
11
Fig. 4.108: Mounting mantle

[2] Mantle
[11] Head contact surface
[12] Head
[13] Lifting gear
[14] Mantle contact surface
Mounting crusher cone on
head
WARNING!
When setting the mantle on the head, serious crushing injuries are pos-
sible.
• When mounting, never place your hands between the mantle and
head.
 Check threads of head. Eliminate irregularities and carefully clean

threads.
 Carefully clean head [12] and contact surface [11]. Ensure that there
is no more epoxy resin on the head or contact surface [11].
When installing a new head, ensure that there is no protective coating on
the contact surface. Remove protective coating if necessary.
For installation of the crusher cone, it may be necessary to weld retaining
eyes onto the crusher cone. To do this, proceed as described under "Re-
moving crusher cone with retaining eyes".
 Coat contact surface [11] of head [12] with grease.
 Apply a thin coat of oil to the head [12].
 Coat or spray the inside of the crusher cone [2] with oil.

MAINTENANCE
Crusher
 Coat contact surface [14] of crusher cone with grease. If necessary,

turn crusher cone on its side with suitable auxiliary tools to improve
handling.
 Raise crusher cone with suitable lifting gear and tackle and position
above the head.
 Lower crusher cone carefully. Ensure that the crusher cone makes
even and full-surface contact on the head.
 The crusher cone has been mounted.
15 8
4 1
Fig. 4.109: Mounting retaining nut

[3] Retaining nut
[4] Packing ring
[8] Lifting ring
[15] Head threads
Securing crusher cone  Arrange packing ring [4] on crusher cone.
 Check thread of retaining nut [3]. Eliminate irregularities and carefully
clean threads.
 Coat threads of head [15] and retaining nut [3] with grease or oil.
 Use suitable lifting gear and tackle to mount retaining nut [3] carefully
on thread [15].
 Screw retaining nut onto packing ring. Ensure that the retaining nut
makes full contact on the packing ring. Use new retaining nut if nec-
essary.
If the retaining nut does not make sufficient contact, this can result in
breakage of the head thread.
 Use a suitable auxiliary tool to knock on the upper side of the crusher
cone to position is correctly on the head.

MAINTENANCE
Crusher
 Ensure that the packing ring butts against the crusher cone and re-
taining nut. Release retaining nut if necessary, readjust packing ring
and screw on retaining nut once again.
 Tighten retaining nut by hand.
1 4
3
5 2
Fig. 4.110: Welding on packing ring

[2] Mantle
[3] Retaining nut
[4] Packing ring
[5] Weld seams, packing ring and mantle
Welding on packing ring  Weld packing ring [4] with four 90-mm long weld seams onto crusher
cone [2].
 Unscrew screws on lifting disc [1] and take off lifting disc.

MAINTENANCE
Crusher
12
17
16
Fig. 4.111: Bracing mantle

[2] Mantle
[6] Weld seams, packing ring and retaining nut
[7] Special tool, clamping wrench
[12] Head
[16] Feeler gauge
[17] Gap dimension (maximum 0.25 mm)
Checking gap dimension  Mount clamping wrench [7] with suitable lifting gear and tackle on the
retaining nut [3] and secure with the screws.
 Tighten retaining nut [3].
 Use a feeler gauge to check whether the gap dimension between the
contact surfaces of the head and crusher cone is max. 0.25 mm.
 Fill a larger gap with suitable material to prevent epoxy resin from es-
caping.
 The gap dimension has been checked.
Bracing crusher cone  Make a vertical marking line at the retaining nut [3] and packing ring
[4].
CAUTION!
There is a danger of burns when the crusher cone is heated.
 Heat crusher cone in the area of the contact surfaces to 55 °C.

 Tighten retaining nut once again with clamping wrench. Use the
marking line to check whether the retaining nut has turned 25 mm.

MAINTENANCE
Crusher
 Weld packing ring [4] with four 90-mm long weld seams onto retaining
nut [3].
 Remove clamping wrench and install lifting disc.
 The crusher cone has been braced.
NOTICE
Retaining eyes on the mantle that have not been cut off cause serious
damage to the cone crusher.
• Prior to installation of the mantle in the cone crusher, cut the retaining
eyes off the mantle.
 Separate all retaining eyes from the crusher cone with a suitable tool.
For the operation of the plant with a very small crushing gap, the retaining
lugs on the crusher cone must be removed.
20
19
18
Fig. 4.112: Filling mantle

[18] Epoxy resin
[19] Filling channel
[20] Mantle filling openings
WARNING!
Danger of fire
Epoxy resin and hardener can ignite.
• Do not smoke when carrying out maintenance and repair work.
• Keep burning objects well away from epoxy resin and hardener.

MAINTENANCE
Crusher
WARNING!
Work with epoxy resin and hardener can result in serious irritation to the
eyes, skin and respiratory tracts.
• Observe the safety instructions of the manufacturer.
Filling space between crusher  If necessary, prepare a filling channel [19] made of sheet metal or
cone and head cardboard for filling the mixture.
 Mix epoxy resin and hardener according to specifications of manu-
facturer.
 Pour mixed epoxy resin rapidly via through the filling openings [20]
via the filling channel.
 Pour in mixed epoxy resin up to the bottom edge of the filling open-
ings.
 Dispose of excess mixed epoxy resin in an environmentally friendly
manner.
 The space has been filled and the head is ready for installation.
Store and process epoxy resin at temperatures of between 16 °C and 33
°C.
When pouring the epoxy resin, the temperature of the head and crusher
cone must not be below 15.6 °C because otherwise the reaction of the
epoxy resin with the hardener would stop.
4.44.08.05 Installing mantle
WARNING!
Risk of falling
components.
Preparation for installing  Remove old lubricating grease from the thread of the crusher housing
mantle and dispose of in accordance with environmental regulations.

MAINTENANCE
Crusher
Fig. 4.113: Installing mantle

[2] Lifting ring
[3] Mantle
Installing mantle  Secure suitable lifting gear and tackle to the lifting ring [2].
 Position mantle [3] above the crusher housing but do not lower yet.
 The mantle can be aligned above the bearing.
Fig. 4.114: Positioning mantle

[2] Lifting ring
[4] Eccentric (thick side)

MAINTENANCE
Crusher
NOTICE
If the lifting ring is not positioned correctly, this can cause damage to the
bottom bearing when the mantle is lifted out and placed back in.
• When removing the mantle, always align the lifting disc so that the lift-
ing ring faces the closed side of the mantle and the crusher housing.
• When installing, align the mantle so that the lifting ring is above the
thicker side of the eccentric.
 Align mantle [3] such that the lifting ring [2] faces the thick side of the
eccentric [4].
The eccentric position of the lifting ring tilts the mantle into the correct in-
stallation position, which prevents damage to the bearing.
 Carefully lower mantle [3] onto the bearing.
 Unscrew screws on lifting disc [1] and take off lifting disc.
7
6
Fig. 4.115: Installing feed plate

[5] Retaining nut
[6] Securing screws
[7] Feed plate
 Lift feed plate [7] with suitable lifting gear and tackle onto the retaining
nut [5] and tighten screws.
 The mantle has been installed.

MAINTENANCE
Crusher
4.44.08.06 Installing bowl
WARNING!
Risk of falling
components.
Preparation for installing bowl Before the bowl can be installed, all old lubricating grease must be re-
moved from the thread in the crusher housing and new grease must be
applied.
 Remove old lubricating grease from the thread with a suitable tool.
Dispose of grease in accordance with environmental regulations
 Perform visual inspection of thread for damage. Remove burring with
suitable tool if necessary.
 Apply 10 kg of new grease with appropriate specifications, see chap.
Tab. 5.38: using a suitable tool.
X
X
Fig. 4.116: Installing bowl

[1] Markings for toothed ring and bowl
[2] Bowl

MAINTENANCE
Crusher
Inserting bowl
WARNING!
Serious injuries are possible when inserting and screwing the bowl into
the crusher housing.
• When inserting and screwing in, never place your hands between the
bowl and crusher housing.
 Lift bowl [2] with suitable lifting gear and tackle over the crusher hous-
ing.
 Align bowl using the markings [1] made during removal, see chap.
4.44.08.01.
 Carefully lower bowl completely.
 Completely relieve load on lifting gear and tackle.
X
X
5
Fig. 4.117: Installing bowl

[3] Crusher housing
[2] Bowl
[4] Shackle
[5] Adjusting screw
Turning bowl  Switch on plant in manual mode and follow the instructions including
"Acknowledge fault / emergency off".
The button [37] lights up and indicates that the tensioning and clamping
cylinders are relieved. If the button [37] is pressed, it is not possible to ad-
just the cone crusher.

MAINTENANCE
Crusher
14 15 16 17 18 19 20 21 22 23 24
34 35 36 37 38

 Work with a second person to ensure correct insertion.
NOTICE
 Use the "Reduce crushing gap" button [36] to screw in the bowl com-
pletely.
 Ensure that the adjusting screws [5] do not block the bowl. If neces-
sary, unscrew adjusting screws slightly and lock them with the nuts.
 Switch off the plant and safeguard it against unauthorised start-up.
 If necessary, disassemble lifting gear and tackle.
 The bowl has been installed.

MAINTENANCE
Crusher
Fig. 4.119: Installing crusher inlet

[6] Crusher inlet
Installing crusher inlet  Lift crusher inlet [6] with suitable lifting gear and tackle over the cone
crusher.
WARNING!
Danger of crushing by crusher inlet
When setting the crusher inlet on the cone crusher, serious crushing in-
juries are possible.
• When mounting, never place your hands between the crusher inlet
and cone crusher.
 Carefully lower the crusher inlet [6]. Ensure that the crusher inlet
make correct and full contact.
 Disassemble lifting gear and tackle.
 The crusher inlet has been installed.

MAINTENANCE
Crusher
8
7
Fig. 4.120: Fill level monitor

[8] Tie-bar screw-coupling
[9] Tie-bar
Installing fill level monitor  Install fill level monitor [7] with tie-bar [9] and tighten screws [8].
 The fill level monitor has been installed.
4.44.09 Changing wear lining
DANGER!
Danger due to moving and rotating components

MAINTENANCE
Crusher
DANGER!
Danger! Heavy loads
not slip.
ity.
4.44.09.01 Replacing counterweight wear element
DANGER!
DANGER!
Danger! Heavy loads
not slip.
ity.
If repair work is pending, the wear elements of the lower frame, counter-
weight, supporting arms and the backgear shaft must also be replaced.

MAINTENANCE
Crusher
1
2
Fig. 4.121: Counterweight wear element

[1] Wear element securing screw
[2] Counterweight wear element
[3] Lifting ring
Removing wear elements Prior to assembly of the lifting rings [3], the threads in the wear element
of the counterweight [2] must be cleaned to remove contamination.
 Completely screw lifting rings [3] into wear element of counterweight
[2].
 Attach suitable lifting tackle and lifting gear to the lifting rings.
 Unscrew all securing screws [1] on wear element and keep ready for
installation.
 Lift wear element vertically from counterweight.
 The wear element of the counterweight has been removed.
Installing wear element  Clean threads in counterweight and check for damage. Repair thread
if necessary.
 Attach lifting rings [3] and suitable lifting tackle and lifting gear to new
wear element.
WARNING!
Danger of crushing in assembly area of wear element
Serious crushing injuries to the hands are possible when assembling the
wear element.
• During assembly, never place your hands between wear element and
crusher components.
 Position the wear element above the counterweight and lower it slow-
ly.

MAINTENANCE
Crusher
NOTICE
If securing screws of the wear element are not correctly installed or are
missing, this results in damage to the cone crusher.
• Install securing screws as specified and tighten them.
• Ensure that all securing screws are installed.
 Install all securing screws with thread-locking compound, e.g. Loctite

271, and tighten them.
 Remove lifting gear, lifting tackle and lifting ring [3].
 The wear element of the counterweight has been replaced.
4.44.09.02 Replacing wear element for lower frame

The wear elements of the lower frame must be removed and installed
with the help of welded-on retaining eyes.
When doing this, ensure that the retaining eyes are sufficiently dimen-
sioned.
2
1
3
Fig. 4.122: Lower frame wear element

[1] Weld point for lower frame wear element
[2] Weld seam for rail wear element
[3] Rail
[5] Weld seam
Before welding on the retaining eyes, heat up worn wear elements. The
temperature of the wear elements must be between 39 °C and 56 °C
above the ambient temperature.

MAINTENANCE
Crusher
CAUTION!
There is a risk of burns when heating the wear elements.
Removing wear elements  Heat up wear element [4] and ensure that the temperature of the
wear element is between 39 °C and 56 °C above ambient tempera-
ture.
 Weld on sufficiently large retaining eyes at the wear element [4] with
a minimum thickness of 15 mm.
 Attach suitable lifting tackle and lifting gear to the retaining eyes and
tension slightly.
WARNING!
Risk of injury
Serious injuries are possible when separating the weld seams with a
power cutter.
• Ensure that there are no persons in the danger zone during the work
procedure.
 Cut all weld seams [1], [2] and [5] at the wear elements. Ensure that
the lower frame is not damaged.
 Lift the wear element vertically out of the lower frame.
 Perform the same work steps at all three wear elements.
 The wear elements of the lower frame have been removed.
 Replace wear elements of supporting arms and wear element of
backgear shaft, see chap. 4.44.09.03.
WARNING!
wear element.
crusher components.
Installing wear element  Install new wear elements using suitable lifting tackle and lifting gear
in the lower frame.
 Align new wear elements and ensure that they can be welded onto
the wear elements of the supporting arms and the wear element of
the backgear shaft.
 Heat up lower frame in area of welds and ensure that the temperature
of the lower frame is between 39 °C and 56 °C above ambient tem-
perature.

MAINTENANCE
Crusher
 Weld on new wear element at lower frame and the wear elements for
supporting arms and backgear shaft.
 Remove lifting gear and lifting tackle.
 Cut off retaining eyes at wear elements.
 Perform the same work steps at all three wear elements.
 Weld new rails [3] with three weld seam respectively on each side ac-
cording to specifications z6V 50(75) on all wear elements [4].
 The wear elements of the lower frame have been replaced.
4.44.09.03 Changing wear elements for backgear shaft and supporting arms
Fig. 4.123: Wear element for supporting arm and backgear shaft
[1] Lifting ring
[2] Backgear shaft wear element
[3] Supporting arm wear element
Removing wear elements Prior to assembly of the lifting ring [1], the thread in the wear element
must be checked for damage.
If it is not possible to fit the lifting ring, a sufficiently large retaining eye
must be welded on.
To change the wear elements [2] and [3], the wear elements of the lower
frame must be removed, see chap. 4.44.09.02.
 Screw lifting ring [1] completely into wear element [2]. Weld on retain-
ing eye if necessary.
 Secure suitable lifting gear and tackle to the lifting ring or retaining
eye.
 Lift the wear element vertically out of the lower frame.
 The wear element of the backgear shaft has been removed.

MAINTENANCE
Crusher
 Perform the same work steps at both wear elements [3] the support-
ing arms.
Installing wear element  Attach lifting rings [1] and suitable lifting tackle and lifting gear to new
wear element.
WARNING!
wear element.
crusher components.
 Position new wear element and lower it slowly.

 Remove lifting gear, lifting tackle and lifting ring [1].
 Perform the same work steps at all wear elements.
 The wear elements for the supporting arms and backgear shaft have
been changed.
The wear elements of the supporting arms and backgear shaft are weld-
ed onto the wear elements of the lower frame and secured, see chap.
4.44.09.02.
4.44.10 Changing V-belt pulley
4
5
3
3
2
2
Fig. 4.124: Removing V-belt pulley

[1] Drive shaft
[2] Securing screws
[3] Taper-lock bushing
[4] Forcing thread
[5] V-belt pulley

MAINTENANCE
Crusher
The description refers to the removal and installation of belt pulleys that
are installed with taper-lock bushings.
Removing V-belt pulley  If necessary, 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.
 If necessary, release cone seat by knocking on the taper-lock bush-
ing [3].
 Take off V-belt pulley [5] and taper-lock bushing [3].
 Clean drive shaft but do not grease it.
 The V-belt pulley has been removed.
Installing V-belt pulley
2 1
Fig. 4.125: 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].

MAINTENANCE
Crusher
 Ensure that the V-belt pulley is at the previously marked position. If

necessary, check alignment with V-belt pulley on opposing side.
 Insert securing screws [2] diagonally and evenly and tighten to spec-
ified torque.
 Drive taper-lock bushing [3] in further 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.
Tightening torques of taper-lock bushings
Bushing Tightening Number of screws Thread size

torque
2012 30 Nm 2 7/16"
2017
2517 50 Nm 2 1/2"
2525
3020 90 Nm 2 5/8"
3030
3525 115 Nm 3 1/2"
3535
4030 170 Nm 3 5/8"
4040
4535 190 Nm 3 3/4"
4545
5040 270 Nm 3 7/8"
5050
Tab. 4.8: Tightening torques of taper-lock bushings

MAINTENANCE
Cleaning the plant
4.45 Cleaning the plant
4.45.01 Cleaning the plant
WARNING!
Risk of falling
components.
To ensure that the plant is continuously operable, it must be cleaned eve-

ry day. If cleaning tasks are not carried out, this results in increased wear
of the moving components and impairs operation.
After completion of crushing work, the following cleaning tasks must be
carried out:
 Remove loose material from the chassis, platforms and climbing
aids.
 Removing adhering material from the feed hopper, vibrating convey-
or trough and chutes.
 Remove jammed and adhering material from the belt conveyors.
 Remove material from on the crawler running gear and the area be-
tween 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.

MAINTENANCE
Performing welding work
4.45.02 Cleaning with high-pressure cleaners
DANGER!
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 benzene, paint
thinners, diesel/heating oil, acetone, undiluted acids, solvents, etc.
• Cover electric parts, insulating material and intake openings for com-
bustion 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 protective
equipment, e.g. face mask or safety goggles.
• Never direct the cleaning agent jet at people, animals, the high-pres-
sure unit, sealing or electric components.
 Note and observe the specifications on high-pressure cleaners in the

safety manual.
4.46 Performing welding work
Fig. 4.126: Performing welding work

MAINTENANCE
NOTICE
Danger of fires due to welding torch
Welding torches, hot metal and sparks can set fire to components and
objects in the surrounding area.
• Where possible, cover components and objects exposed to a risk of
fire.
• Protect components and objects against dripping hot metal and
sparks.
• Ensure fire extinguisher is ready before starting work.
• Ensure a fire watch is present during and after welding work.
Safety precautions and • Welding work must only be carried out by personnel trained or au-
prerequisites thorised 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 terminal.
• 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 components.
• Never connect via rotating components. This can result in bearing
damage.
• Do not connect the earth terminal to the hydraulic cylinder of the low-
er impact toggle. This would destroy the electrohydraulic adjusting
device.
Welding with current from the  Switch the diesel generator on.
power supply unit
 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.
Welding with an external  Switch off plant components and the diesel generator.
power supply
 Switch off main switch and secure against reactivation.
 Switch off and remove the battery isolators.

MAINTENANCE
 Use external network connection or external power supply unit.

 Welding work can begin.

TABLES
Technical details
5 TABLES
This chapter lists all technical details relevant to your plant.
The complete technical details of the manufacturers' components are
provided in the respective manufacturer's documentation.
5.01 Technical details
5.01.01 Complete plant

5.01.01.01 Weights
Designation Weight
Plant without optional equipment but with mandato- Approx. 56850 kg
ry equipment.
Plant with all optional equipment Approx. 62350 kg
Tab. 5.1: Weight of complete plant
All weights including fluids and lubricants and 300 litres diesel fuel.
5.01.01.02 Dimensions
Dimensions in operating position
4763
4471
3982
3823
1019
7770 4240 5552
18039
Fig. 5.1: Side view of MCO11

TABLES
Technical details
4272
3179
2400
3400
4600
Fig. 5.2: Front view of MCO11

All dimensions in millimetres.
5.01.01.03 Driving operation
Designation Value
Maximum climbing ability forward/back 30 %
Maximum permissible lateral inclination 17 %
Maximum driving speed 1.5 km/h
Max. generated ground pressure1 1.60 kg/cm²
Tab. 5.2: Plant driving operation
1 The maximum generated ground pressure is calculated according to

the following equation: Max. total weight of the plant / distance between
centres x base plate width x 2.
5.01.01.04 Charged material and size
Designation Value
Permissible charged material Natural stone free of unbreakable ele-
ments.
Other materials such as slag and ore
only after analysis and approval by KL-
EEMANN GmbH.
Compressive resistance of In continuous operation up to 280 N/
the charged material mm2.
Permissible feeding size 0-210 mm
Tab. 5.3: Charged material and size

TABLES
Technical details
5.01.01.05 Feed and crushing capacity
Designation Value
Feed capacity Up to 450 t/h depending on the type and
composition of the charged material and
size or volume of the primary screening
or the size of the final grain.
Crushing capacity Natural stone 0 - 100 mm, 10 - 15%
oversized product, approx. 380 t/h.
Tab. 5.4: Feeding and crushing capacity
5.01.01.06 Ambient temperatures

The plant can be continuously operated at ambient temperatures of -
15 °C to +40 °C.
With the Arctic Package special equipment, plant operation up to -25 °C
is also possible. Because of the use of low-temperature lubricants, how-
ever, operation is limited to a maximum temperature of +30 °C.
5.01.01.07 Sound power level
Designation Sound power level LWA

Plant (series) 116 dB
Tab. 5.5: Sound power level LWA
Determination and implementation according to the standard: Determi-

nation of the sound power level of noise sources from sound pressure
measurements EN ISO 3744.
5.01.02 Power supply unit/engine
Designation Value
Type designation AAE120-EU
Power supply unit manufacturer AVS
Power supply unit type DW 354 SC3A 15L13H
Rated output 350 kVA
Rated current 505 A
Rated power factor 0.8
Rated voltage 230/400 V
Frequency 50 Hz
Speed 1500 rpm
Weight Approx. 3200 kg
Reference conditions*
Installation altitude approx. 100 m above sea level
Ambient temperature 25 °C

TABLES
Technical details
Designation Value
Relative humidity 60 %
Diesel engine manufacturer Scania
Engine type DC 13-071A (02-02)
Number of cylinders 6 in-line
Displacement 12.70 l
Rated speed 1500 rpm
Continuous output according to DIN 364 kW
6280 / ISO 3046-1
Fuel consumption according to DIN 202 g/kWh
51601 at full load approx.
Starter 24 V, 6.7 kW
Generator 28 V, 65 A
Batteries 2 x 135 Ah, 24 V (2 x 12 V)
Cooling system Liquid cooling, charge-air
cooling
Diesel fuel filling capacity Approx. 700 l
Engine oil filling capacity Approx. 28 - 33 l
Exhaust emission level IIIa
Generator manufacturer Leroy Somer
Generator type LSA 47.2 M8
Voltage stability, static ± 1.5 %
Frequency 50 Hz
Speed 1500 rpm
Type of protection IP 23
Tab. 5.6: Power supply unit/plant engine
* The above-named performance data of the power supply unit is based

on the specified reference conditions. Deviations above these values in-
dicate, in part, a considerable loss in performance.
Designation Value
Type designation AAE300-EU1
Power supply unit type DW 276 SC2A 15 L13H
Rated current 397 A

TABLES
Technical details
Designation Value
Frequency 50 Hz
Speed 1500 rpm
Diesel engine manufacturer Scania
Engine type DC 13-073A (02-22)
Displacement 12.70 l
6280 / ISO 3046-1
Starter 24 V, 6.7 kW
Generator 28 V, 65 A
cooling
Engine oil filling capacity Approx. 28 - 33 l
Exhaust emission level LRC
Generator type LSA 47.2 S4
Frequency 50 Hz
Speed 1500 rpm

Designation Value
Type designation AAE300-US1

TABLES
Technical details
Designation Value
Power supply unit type DW 300/75 CA 18 L24HH
Rated output 75 kVA
Rated current 104 A
Frequency 60 Hz
Speed 1800 rpm
Diesel engine manufacturer CAT
Engine type C9
Displacement 8.8 l
6280 / ISO 3046-1
Starter 24 V
Generator 28 V
cooling
Engine oil filling capacity Approx. 30 l
Exhaust emission level TIER 3
Generator type LSA 43.2 L8
Rated output 80 kVA
Frequency 60 Hz
Speed 1800 rpm

TABLES
Technical details

5.01.03 Hydraulic oil supply

Plant hydraulic oil supply
Designation Value
Type designation AMCO11-Z1
Hydraulic oil tank filling capacity 280 l
Filling capacity of hydraulic system, com- Approx. 300 l
plete
Driving hydraulics operating pressure 380 bar
Operating pressure of auxiliary hydraulic 190 bar, ±10 bar
system
Tab. 5.9: Hydraulic system of plant
Hydraulic oil and lube oil supply for cone crusher
Designation Value
Type designation AMCO11-Z1
Hydraulic oil tank filling capacity Approx. 100 l
Filling capacity of hydraulic system, com- Approx. 120 l
plete
Filling volume for lube oil tank Approx. 300 l
Filling volume for lube oil, complete Approx. 320 l
Operating pressure for hydraulic oil Approx. 210 bar
Operating pressure for lube oil Approx. 9 bar
Operating pressure for lube oil cooler Approx. 3 bar
Tab. 5.10: Hydraulic/lubrication system for cone crusher
5.01.04 Electrical system
Designation Value
Type designation EMCO11-EU1
Operating voltage 400 V
Control voltage 24 V
Frequency 50 Hz
Additional sockets (external circuits) 230 V / 16 A
400 V / 32 A
Tab. 5.11: Electrical system

TABLES
Technical details
5.01.05 Drive system
Designation Value
Type designation FWD007-424
Crawler running gear with installed hydraulic motors and chassis in be-
tween.
Holding brake: depressurised closing spring force brake. Service brake
in crusher operation hydraulically actuated, in driving operation, hydrau-
lically released.
Crawler running gear type D7
Distance between centres, sprockets 4240 mm
Base plate width 500 mm
Gear motor maximum torque 60 kNm
Planetary gear filling capacity 5 l per side
Tab. 5.12: Plant driving operation
5.01.06 Conveyor unit

Crusher discharge conveyor
Designation Value
Type designation BFB120-100
Design Sectional steel structure
Distance between centres 10000 mm
Belt width 1200 mm
Drive output 15 kW
Conveyor belt speed 1.05 m/s
Belt conveyor drive Electric motor with flange-
mounted angular gear with
reverse lock
Angular gear filling capacity Approx. 2.7 l
Tab. 5.13: Crusher discharge conveyor
Feeding conveyor
Designation Value
Type designation BFA100-060
Design Sectional steel structure
Distance between centres 6000 mm
Belt width 1000 mm
Drive output 11 kW

TABLES
Technical details
Designation Value
Conveyor belt speed 1.31 m/s
Belt conveyor drive Electrically driven drum mo-
tor with reverse lock
Gearbox filling capacity Approx. 2.7 l
Tab. 5.14: Feeding conveyor
5.01.07 Water system (option)
Designation Value
Type designation NDS120-MR1
Conveying medium temperature + 5 °C to + 35 °C
Maximum permissible operating pres- 8 bar
sure
Minimum / maximum permissible pres- - 0.8 / 4 bar
sure on suction side
Maximum suction height 5m
Maximum ambient temperature + 40 °C
Water consumption 2 to 5 m³ per day
Tab. 5.15: Water system
5.01.08 Feeding unit

Feed hopper
Designation Value
Type designation TRI100-S
Design Welded construction
Feeding volume Approx. 4 m³
Feeding width, front face Approx. 3000 mm
Feeding width, longitudinal Approx. 3450 mm
Feeding height Approx. 4000 mm
Tab. 5.16: Feed hopper
Hopper extension (option)
Designation Value
Type designation TRE100-S

TABLES
Technical details
Designation Value
Design Screw-on welded construc-
tion
Feeding volume Approx. 12 m³
Feeding width, front face Approx. 4000 mm
Feeding width, longitudinal Approx. 4400 mm
Feeding height Approx. 4800 mm
Tab. 5.17: Hopper extension
Feeder trough
Designation Value
Type designation AGR 080-210
Design Vibrating conveyor trough
Trough width Approx. 800 mm
Trough length Approx. 210 mm
Rocker width adjustment Via unbalance weights
Drive 2 vibration motors with step-
less speed adjustment via
frequency converter
Drive output 2 x 4.0 kW
Permissible ambient temperature - 15 °C to + 40 °C
Tab. 5.18: Feeder trough
5.01.09 Crusher
Cone crusher
Designation Value
Type designation KX300
Design Cast housing
Inlet diameter Approx. 1081 mm
Clearing stroke 111 mm
Backgear shaft speed 940 - 1215 rpm
Crusher cone 18% austenitic manganese steel
Crusher shell 18% austenitic manganese steel
Drive Electric motor via V-belt

TABLES
Maintenance schedule/maintenance intervals
Designation Value
1
Operating voltage or 1337 N
frequency2 per V-belt, new V-
16.89 Hz
belt
Run-in V-belts 1029 N
14.81 Hz
Tab. 5.19: Cone crusher
1
Static strand force per V-belt, measured with Optikrik II + III
2
Measured in tight span
5.02 Maintenance schedule/maintenance intervals

Machine/compo- Maintenance Material, See chap.

For the first time after h /
Every 2000 h / annually

nent work spare parts
Every 200 h / monthly
Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Signs check/replace see spare X 4.01.01
parts cata-
logue
Protective hous- check/lubri- lube oil 50 X 4.01.01
ing for power sup- cate
ply unit
Platforms check X 4.01.01
Screw connec- retighten X 4.01.01
tions
Lubricating nipple check/replace X 4.01.01
Warning devices check X 4.01.02
guard devices check X 4.01.03
Emergency stop check/repair see spare X 4.01.04
parts cata-
logue
Tab. 5.20: Chassis/guard devices maintenance schedule

TABLES
Control stand
Machine/compo- Maintenance Material, see chap.


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Switch cabinet check/repair lube oil X 4.02.01
protective hous-
ing
Lamp test carry out X 4.02.02
Radio remote check/repair X X1 4.02.03
control, compo-
nents
Emergency stop check/repair X 4.02.03
and functions
Tab. 5.21: Control stand maintenance schedule
1
Check by specialist


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Diesel engine service/repair1 X 4.04.01

1
Generator service/repair X 4.04.01
Cyclone prefilter check X 4.04.02
Air filter clean/replace X2 4.04.03
2
Cooler fins clean X 4.04.04
Tab. 5.22: Power supply unit/engine maintenance schedule
1
See manufacturer's documentation.
2
Daily in case of large accumulations of dust.

TABLES


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Hydraulic compo- check/repair See spare 50 X X1 4.05.01
nents, leak-tight- parts cata-
ness logue
Hydraulic oil tank, check/refill Hydraulic oil2 X 4.05.02.01
fill level
Hydraulic oil change/carry Hydraulic oil2 500 X 4.05.02.02
out oil analysis
Ventilation filter change See spare 500 X 4.05.02.03
parts cata-
logue
Suction filter change See spare 500 X 4.05.02.03
parts cata-
logue
Return filter change See spare 500 X 4.05.02.03
parts cata-
logue
Tab. 5.23: Hydraulic oil supply maintenance schedule
1 Observe checking and replacement intervals of hydraulic hoses!

2 Fluids and lubricants, see chap.5.04.01.
Cone crusher hydraulic oil supply


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Hydraulic compo- check/repair See spare 50 X X 1 X1 4.05.04

ness logue

TABLES


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Hydraulic oil carry out oil Hydraulic oil2 500 X X 4.05.04.03
analysis/
change oil
Hydraulic oil tank, check/refill Hydraulic oil2 X 4.05.04.01
fill level
Hydraulic oil filter change See spare 500 X 4.05.04.04
parts cata-
logue
Filler neck coarse check/clean X 4.05.04.07
strainer, flow
Filler neck tank change See spare 500 X 4.05.04.03
ventilation filter parts cata-
logue
Tab. 5.24: Maintenance schedule for cone crusher hydraulic oil supply
1
Observe checking and replacement intervals of hydraulic hoses!
2
Fluids and lubricants, see chap. 5.04.
Cone crusher and lube oil system


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Lube oil compo- check/repair See spare 50 X X1 X1 2.44

ness logue
Lubrication of carry out oil Lube oil2 500 X X 4.05.04.02
cone crusher analysis/
change oil
Lube oil tank, fill check/refill Lube oil2 X 4.05.04.02
level
Lube oil filter change 500 X 4.05.04.05

TABLES


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Lube oil coarse check/clean X X 4.05.04.06
strainer, flow
Filler neck coarse clean X 4.05.04.06
strainer, flow
Ventilation filter change 500 X 4.05.04.05
Cone crusher
Crushing tools check/repair See spare X X 4.44.05
wear parts cata-
logue
Wear elements check X3 4.44.07
wear
Wear elements change See spare X 4.44.09
parts cata-
logue
Bearing noises check X
Geared ring check X 4.44.04
V-belt check/tension X 4.44.01
Mounting check X 4.44.02
Support and check X 4.44.03
guide blocks
Gap setting de- lubricate X 4.44.06
vice thread
Tab. 5.25: Maintenance schedule for cone crusher and lube oil system
1
Observe checking and replacement intervals of lube oil hoses!
2
Fluids and lubricants, see chap.5.04.
3
Check the wear element during every crushing tool change.

TABLES
Electrical system
Machine/compo- Maintenance Material, see chap.


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
as required
Electrical compo- check/repair see electric 50 X 4.06.01
nents circuit diagram
Starter batteries check/refill distilled water X 4.06.02.02
Switch cabinet clean X 4.06.03.01
cables, socket check/repair see electric 50 X 4.06.03.01
outlets, operating circuit diagram
and display ele-
ments
Switch cabinet replace see spare X
doors rubber seal parts cata-
logue
Switch cabinet check/adjust X 4.06.03.02
mounting
Earth fault circuit check X 4.06.06.03
interrupter
Electric motors, check/repair X 4.06.04
terminal boxes
Overpressure check/repair see spare X 4.06.05
system function, parts cata-
components logue
Cyclone prefilter clean X 4.06.05
Dust filter clean/replace see spare X 4.06.05
parts cata-
logue
Tab. 5.26: Electrical system maintenance schedule

TABLES
Drive system


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Crawler carrier check/tension grease X 4.08.01.01
chains
Base plates, track check/repair see spare X 4.08.01.02
rollers parts cata-
logue
Planetary gear, check X 4.08.02.01
leak-tightness
Fill level check X 4.08.02.01
1 2
Gear oil change gear oil 500 X 4.08.02.01
Components check/repair X 4.08.02.02
Tab. 5.27: Drive system maintenance schedule
1 Fluids and lubricants, see chap. 5.04.

2 But at least every 2 years.
Conveyor unit


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Belt conveyor
Conveyor belts check/repair See spare X 4.10.01.01
parts cata-
logue
Scraper check/repair See spare X 4.10.01.02
parts cata-
logue
adjust X 4.10.01.02

TABLES


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Guide rails check/repair See spare X 4.10.01.03
parts cata-
logue
adjust X 4.10.01.03
Angular gear fill check/refill Gear oil1 X 4.10.01.04
level
Gear oil change Gear oil2 500 X3 4.10.01.04
Plummer block check/lubri- Lubricating X 4.10.01.05
cate/repair grease, see
spare parts
catalogue
Grease change carry out Grease X3 4.10.01.05
Chutes
Chutes check/repair See spare X 4.10.02
parts cata-
logue
Magnetic remover
Suspension check/repair X 4.10.03
Magnet clean X X 4.10.03
Tab. 5.28: Conveyor unit maintenance schedule
1
Fluids and lubricants, see chap. 5.04.
2
For fill volume, see type plate.
3
With fewer operating hours, at least every 2 years.
4
Change interval every 10000 operating hours, with synthetic oil filling
every 30000 operating hours.

TABLES


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Water pump, check/repair X 4.12
leak-tightness
Spraying nozzles check/repair X 4.12
Tab. 5.29: Water system maintenance schedule
Tools/accessories


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
As required
Every 100 h
Every 500 h
Tools and acces- check/replace X 4.42

sories
Tab. 5.30: Tools/accessories maintenance schedule
Feeding unit


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Feed hopper check/repair see spare X 4.43.01

parts cata-
logue

TABLES
Tightening torques


Every 50 h / weekly
Every 8 h / daily
initial operation
Every 1000 h
Every 100 h
Every 500 h
As required
Feeder trough, check/repair see spare X 4.43.02.01
rubber mountings parts cata-
logue
Vibration motors
check/repair see spare 50 X 4.43.02.02
Wear lining parts cata-
logue
check/replace see spare X 4.43.02.03
parts cata-
logue
Tab. 5.31: Feeding unit maintenance schedule
5.03 Tightening torques

This section presents the tightening torques for screws and nuts in tabu-
lar form.
NOTICE
Danger due to incorrect tightening torques
Incorrectly tightened or retightened screws and nuts can become loose
or tear.
• Check the security of nuts and screws on a regular basis and retight-
en 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
8.8 10.9 12.9

M4 3.3 4.8 5.6
M5 6.5 9.5 11.2
M6 11.3 16.5 19.3
M8 27.3 40.1 46.9
M10 54 79 93
M12 93 137 160
M14 148 218 255

TABLES
8.8 10.9 12.9

M16 230 338 395
M18 329 469 549
M20 464 661 773
M22 634 904 1057
M24 798 1136 1329
M27 1176 1674 1959
M30 1597 2274 2652
M33 2161 3078 3601
M36 2778 3957 4631
M39 3597 5123 5994
Tab. 5.32: Tightening torques for standard metric threads
Tightening torques for fine-pitch thread
8.8 10.9 12.9

M8 x 1.00 29.2 42.8 50.1
M10 x 1.25 57 83 98
M12 x 1.25 101 149 174
M12 x 1.50 97 143 167
M14 x 1.50 159 234 274
M16 x 1.50 244 359 420
M18 x 1.50 368 523 613
M20 x 1.50 511 728 852
M22 x 1.50 692 985 1153
M24 x 2.00 865 1232 1442
M27 x 2.00 1262 1797 2103
M30 x 2.00 1756 2502 2927
Tab. 5.33: Tightening torques for fine-pitch thread
5.04 Fluids and lubricants

A completely presentation of the individual fluids and lubricants with all
data and approvals, e.g. from combustion engine and gearbox manufac-
turers, is not possible for reasons of space.
The specification details take DIN and ISO standards, in particular, into
consideration.
The fluids and lubricants table is designed to provide initial orientation for
servicing KLEEMANN plants and machines. However, it does not replace

TABLES
the advice of a lubrication specialist or the recommendation of the engine

and gearbox manufacturers.
For environmental protection reasons, it is absolutely necessary to dis-
pose 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 machines if the listed flu-
ids and lubricants, or their verifiable equivalents, have been used!
5.04.01 Lubricants
The fluids and lubricants to be used are described in the manufacturer's
documentation.
Operating material Specifications Brand Product

Hydraulic oil Bio hydraulic oil ISO-VG Wirtgen Group Bio hydraulic oil VG 46
46 with EP additives*
Type HVLP
HEES ISO 15380
Tab. 5.34: Hydraulic oil supply lubricant table
EP additives (extreme-pressure additives) are added to lubricants and

improve their tribological characteristics, i.e. they prevent the fusing of
two metallic materials that rub against each other.
Cone crusher hydraulic oil supply

Cone crusher hydraulic oil Bio hydraulic oil ISO- Wirtgen Group Bio hydraulic oil VG 46
VG 46 with EP addi-
tives*
Type HVLP
HEES ISO 15380
Tab. 5.35: Cone crusher hydraulic oil supply lubricant table


TABLES
Drive system

Gear oil for track drive SAE 75W-90 with EP ad- Wirtgen Group Special Gear Oil 75W-90
ditives
API MT-1
API GL-4, GL-5
Chain tensioner grease Lubricating grease with Wirtgen Group Multipurpose Grease
EP additives (lithium sa-
ponified)
ISO 6743-9: L-XBCEB 2
DIN 51825: KP2K-25
ISO NLGI 2
Tab. 5.36: Drive system lubricant table

Conveyor unit

Belt conveyor drive gear oil Synthetic polyglycol gear Wirtgen Group High performance gear oil
oil ISO-VG 220 VG 220
DIN 51517-3 (CLP)
ISO 6743-6 (CKS/CKT)
Bearing lubricating grease Lubricating grease with Wirtgen Group Multipurpose Grease
EP additives (lithium sa-
ponified)
ISO 6743-9: L-XBCEB 2
DIN 51825: KP2K-25
ISO NLGI 2
Tab. 5.37: Conveyor unit lubricant table

Cone crusher

Cone crusher lubricating Multi-purpose EP lithi- Wirtgen Group Multis lubricating grease
grease um complex grease
ISO 6743-9 (L-XBE-
HB 2) DIN 51502
(KP2P-20)
Cone crusher lube oil Synthetic gear oil ISO Wirtgen Group Special Gear Oil SH150
VG 32-68
DIN 51524

TABLES
Tab. 5.38: Cone crusher lubricant table
If necessary, consult Kleemann GmbH about lube oils and lubricating

greases for the cone crusher.
5.04.02 Diesel Fuels

At low temperature, paraffin separations can cause obstruction in the fuel
supply resulting in malfunctions. Below outside temperatures of 0 °C, use
winter diesel fuel (up to -15 °C). In many cases, diesel fuel with additives
with an application temperature of up to approx. -20 °C is offered.
At outside temperatures below 0 °C, the temperature properties of diesel
fuel can be improved as a preventive measure by adding petroleum. A
maximum of 20% can be added. When refuelling, the petroleum must be
filled first so that it mixes with the diesel fuel.
NOTICE
Danger of engine damage
The addition of petroleum to diesel fuels (winter diesel fuel) already
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 mm2/s (cSt)
Density at 15 °C 0.82 - 0.86 kg/dm3
Sulphur content (percent by maximum 0.035 %
weight)
Ignitability (cetane number) at least 51
Flash point 56 °C
Complies with standards EN 590
ASTM D 975 Grade No. 1-D and 2-D
Tab. 5.39: Properties of diesel fuel
Observe and adhere to the specifications in the manufacturer's docu-

mentation.
Requisite properties of diesel fuel for LRC engine
Viscosity at 40 °C 2.0 - 4.5 mm2/s (cSt)
Density at 15 °C 0.82 - 0.86 kg/dm3
Sulphur content (percent by maximum 0.2 %
weight)

TABLES
Assembly aids
Ignitability (cetane number) at least 49
Flash point 56 °C
Complies with standards EN 590
ASTM D 975 Grade No. 1-D and 2-D
Tab. 5.40: Properties of diesel fuel
If the sulphur content is higher than 0.2%, the oil change intervals must
be halved.
Observe and adhere to the details about oil change intervals in the man-
ufacturer's documentation.
5.05 Assembly aids

Crusher tool change assembly aid
Assembly aids Specifications Brand Product

Epoxy resin High performance Commercially availa- Sealing compound
ble
Tab. 5.41: Crusher tool changer assembly aid table
5.06 Separate documentation

Apart from this instruction manual, further documents and information are
available on the plant.
The listed documents are an integral element of the instruction manual
as defined by EC Directive 2006/42/EC.
5.06.01 Documentation on the plant
Component Document
Plant Spare parts catalogue
Electrical circuit diagram
Transport instructions
Tab. 5.42: Documents from KLEEMANN GmbH
Safety instructions
Language Document number

Bulgarian F20016714
Danish F20015433
German F20007548

TABLES
Separate documentation
Language Document number

German US F20011137
English F20008844
English US F20011138
Estonian F20016711
Finnish F20016706
French F20008845
Italian F20011375
Japanese 2343108
Croatian 2367373
Latvian F20016712
Lithuanian F20016713
Dutch F20010337
Norwegian F20011374
Polish F20011376
Portuguese F20016710
Romanian F20016715
Russian F20008847
Serbian F20013946
Slovakian F20016708
Spanish F20008846
Swedish F20012128
Czech F20016501
Turkish F20016722
Hungarian F20016707
Tab. 5.43: Safety instructions from KLEEMANN GmbH
Manufacturer's documentation
Assembly Component Manufacturer Document

Power supply unit/engine Diesel engine Scania Instruction Manual
Spare parts catalogue
Tab. 5.44: Manufacturer's documentation
5.06.02 Information material

Information and material can be called up or downloaded under "Prod-
ucts" on the homepage of KLEEMANN GmbH: www.kleemann.info.

TABLES
Fuses
5.07 Fuses
Short code Value Number Assignment

0F03 6A 1x Control voltage
0F2 10 A 1x Control
0F4 6A 1x Horn and flashing light
0F06 6A 1x Lighting
0F06.1 6A 1x Lighting
0F20 10 A 1x Supporting elements
0F05 16 A 1x Socket outlet 16 A
0F1.3 2A 1x Control
0F00 2A 3x Control
0F00.1 2A 2x Control
0F02 2A 2x In-series fuse voltmeter
0Fm 2A 1x Metal detector
0F03 32 A 3x Socket outlet 32 A
0F10 10 A 3x Direct voltage supply
0F1 10 A 2x Control
4F1 16 A 1x Magnetic remover
6F1 20 A 3x Feeder trough
Tab. 5.45: Fuses in the switch cabinet
OP3.
Change fuses, see chap.4.06.06.01.

INSTALLATION AND REMOVAL, TRANSPORT
Transport
6 INSTALLATION AND REMOVAL, TRANSPORT

This chapter describes the installation, removal and transport tasks that
have to carried out prior to initial operation or transport of the plant. Fur-
thermore, you will also find details here on storage, shutdown and return
to operation.
6.01 Transport
Existing specifications UVV, DIN, VDI and country-specific specifications
and regulations on transport must be observed.
DANGER!
Removal and transport by unqualified and unauthorised personnel 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 man-
ual.
DANGER!
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 is essen-
tial.
DANGER!
Danger due to excess width or height
Excess width or height can result in material damage and personal injury.
• Remove all projecting plant components as described in "Removal of
plant".
• Secure loose components and other components to be transported
on the plant.
• Read the safety manual.
All transport work not described in this chapter must only be carried out
by personnel trained by KLEEMANN GmbH, or personnel who have ap-
propriate qualifications, e.g. transport company.
6.01.01 Approval of special transport

If the plant is to be transported on public roads, the official approval for
special transport required must be obtained.

Transport
Transport approvals are subject to country-specific specifications and

have to be applied for from or via the commissioned transport company.
6.01.02 Transport details

Changes to the described transport dimensions and weights through at-
tachments and conversions that are not authorised by Kleemann GmbH
must be taken into consideration when applying for transport approval.
Transport dimensions can be exceeded due to damage to plant compo-
nents, e.g. protruding or hanging components. Repair damage prior to
transport.
6.01.02.01 Dimensions
Transport dimensions, plant
4094
1019
890
998
645
4240
15666
17557
Fig. 6.1: Side view of MCO11

Transport
2400
3400
Fig. 6.2: Front view of MCO11

All dimensions in millimetres.
6.01.02.02 Weights
Weights, plant
Designation Weight
Plant without optional equipment but with mandatory Approx. 63000
alternatives, e.g. screen surfaces. kg
Tab. 6.1: Transport weights of plant
Packaging weights
Designation Weight
Prescreen conveyor 6.0 m Approx. 1200 kg
Electromagnet magnetic separator Approx. 2500 kg
Permanent magnet magnetic separator Approx. 1100 kg

Transport
6.01.03 Loading and unloading
1 2 1
Fig. 6.3: Lashing and tilting points

[1] Lashing points on chassis
[2] Tilting point of plant
Fig. 6.4: Loading on flat bed trailer

Preparations for loading on a  Run all plant components empty.
low loader
 Remove all projecting plant components, see chap. 6.03.
 Secure loose components and other components to be transported
on the plant.
 If necessary, fit transport locking devices on belt conveyors.
 Clean plant, see chap. 4.45.

Transport
 Fill at least 300 litres in the fuel tank to prevent the diesel engine from
stalling on the loading ramp.
 Move up and swivel supporting elements, see chap. 6.03.10.
 Remove grey operating plug and insert red transport plug to the op-
erating and transport plug, see chap. 2.06.06.
 The plant is ready for loading.
Driving plant onto low loader
and lashing
WARNING!
Danger when loading the plant
Incorrect or careless loading and lashing can result in personal injury
and/or material damage.
• Take great care when loading and lashing.
• Observe general and locally applicable safety and accident preven-
tion specifications.
• Only use the marked lashing points.
• Only apply load to the lashing points in the lashing equipment provid-
ed for this purpose.
 Ensure that the travel path and ground between plant and low loader
is firm and flat. Remove any obstacles.
 Use securely positioned loading ramps with sufficient load bearing
capacity and width.
 Remove contamination such as oil, snow or sludge from the loading
ramps.
 Provide transport surface with anti-slip mat.
Start the plant  Switch on diesel generator (see chap. 3.04.01).
 Switch on transmitter of the radio remote control and unlock the
emergency stop.
 Switch on rotary switch "Radio remote control" [22], see chap.
2.02.02.
 Switch on "Control voltage" [14] key switch, see chap. 2.02.02.
 Press the "Acknowledge fault" [18] button.
 Press the "Driving hydraulics" [23] button, see chap. 2.02.02.
 Drive plant using the driving levers of the radio remote control onto
the flat bed trailer, ensuring it is straight. Move the plant, see chap.
3.07.02.

Transport
 Observe the maximum permissible drive-up angle (gradeability).

 Move the plant carefully over the corresponding tilting points [2] and
align on flat bed trailer.
 Lash the plant on the lashing points [1] provided for this purpose.
 The plant is loaded on the low loader and lashed.
Moving the plant with the transport plug is also possible with the emer-
gency stop of plant components actuated. The emergency stop of the ra-
dio remote control must be unlocked and confirmed if necessary.
Loading packages
DANGER!
Danger! Heavy loads
not slip.
ity.
Observe the following items when loading and transporting plant compo-
nents and machines:
• Attach and lift plant components and machines at the lifting points
provided for this purpose.
• Observe the weight of the components to prevent deformation and
other damage.
• The lifting and lashing points are only designed for the weight of the
respective component. Never lift additional weights together with the
components.
• Securely load and lash components and machines.
Loading plant with crane
WARNING!
Danger when transporting plant with crane
Incorrect crane transport can result in personal injury and/or material
damage.
• Do nut use lashing points and components for lifting the plant.
• Raise the plant only on loading platforms provided for this purpose
with suitable hoisting gear and lifting accessories.

Plant installation
Observe the following items when lifting the plant with a crane:
• Prior to crane transport or ship loading of the plant, consult Kleemann
GmbH.
• The lashing points and plant components are not designed for lifting
with a crane.
• Use a loading platform when loading onto a ship.
• Ensure that hoisting gear, such as chains, ropes, etc., does not cause
damage to components. Use spacers.
• Observe the transport weight and dimensions of the plant.
6.02 Plant installation
DANGER!
tion manual.
DANGER!
Danger due to incorrect installation and removal
Incorrect installation and removal and the use of unsuitable hoisting gear
and lifting accessories can result in serious or fatal injuries.
• Use suitable hoisting gear and lifting accessories and check that it is
in perfect condition.
• Fit hoisting gear, such as chains and ropes, so that it cannot slip.
• Always suspend components and machines from their centre of grav-
ity.
• Only lift and transport loads as high and as far as necessary.
• Never move under or stand under a suspended load.
• Only assign personnel installation and removal tasks who are quali-
fied and authorised according to the requirements in this instruction
manual.

Plant installation
WARNING!
Risk of falling
There is a risk of falling during installation and removal work on the plant
components.
• Check if the lifting supports are secure and safe to use.
WARNING!
Risk of stumbling
NOTICE
Danger of material damage due to tilting over
Incorrect installation of the plant, or sinking of the plant on soft ground,
creates a risk of the plant tilting.
• Only position the plant on secure and firm ground.
Before the plant can be operated, it must be moved from transport posi-
tion to operating position. To prepare for installation, carry out the follow-
ing activities:
 Move the plant onto secure and firm ground. Remove any obstacles
in the direct vicinity.
 Position the plant, ensuring it is horizontal. If necessary, flatten the
ground by spreading fine material and levelling it.
 Ensure that the plant is positioned safely on the ground during oper-
ation. Do not shake or tilt the plant during operation.
 If the plant is not stable, reposition it and/or level the ground.
 Ensure the plant has sufficient ground clearance. The crusher dis-
charge conveyor must not come into contact with loose material or
ground.
 Switch off the diesel generator and secure plant against reactivation.
 Insert grey operating plug to the operating and transport plug, see
chap. 2.06.06.

Plant installation
 Provide suitable lifting accessories and hoisting gear for installation.

 Preparations for plant installation are complete.
6.02.02 Swivelling and moving down hopper supports

Swivelling hopper supports
Fig. 6.5: Swivelling hopper supports

[1] Hopper support
[2] Securing screw and nut
WARNING!
Danger of crushing in the swivel area of the hopper supports
When swivelling the hopper supports, serious crushing injuries are pos-
sible.
• During the swivel operation, never place hands between hopper sup-
port and chassis.
Swivelling hopper support  Release securing screw and nut and remove.
 Turn hopper support into vertical position. Ensure that securing
screws and nuts can be installed on the left and right of the hopper
support.

Plant installation
NOTICE
If securing screws are not installed or tightened on the supporting ele-
ments, this results in material damage to the chassis and hopper sup-
ports.
• Ensure that the securing screws of the supporting elements are in-
stalled and tightened.
• Never move out supporting elements with missing or loose securing
screws.
 Install and tighten securing screws and nuts.

 Repeat the same work steps on the opposite side.
 The hopper supports are swivelled and ready for moving out.
Moving hopper supports down
Fig. 6.6: Moving hopper supports down

[3] Supporting element for hopper support
WARNING!
Danger of crushing in the area of the hopper supports
Severe crushing injuries to the feet may occur when moving down the
hopper supports.
• Do not stand in the danger zone of the hopper supports feet during
the downward movement.
• Ensure that there are no persons in the danger zone during the
downward movement.

Plant installation
 Place suitable bases, e.g. solid wooden planks, under the hopper
supports.
 Move hopper supports down (see chap. 3.06).
 Deposit supporting elements on the bases.
 The feed hopper is now supported.
6.02.03 Moving out warning light
3
2
Fig. 6.7: Moving out warning light

[1] Wing screw
[2] Retaining pipe
[3] Warning light
 Release wing screw [1] and push retaining pipe [2] all the way to the
top.
 Tighten wing screw.
 The warning light has been moved out.

Plant installation
6.02.04 Earthing the plant
Fig. 6.8: Earthing the plant

[1] Earthing rod
Earthing of the plant guarantees a safe connection of the protective con-
ductor with the earth. Furthermore, static charges generated by the belt
conveyor are directed away safely.
WARNING!
If the plant is not correctly or only inadequately earthed, there is a risk of
electric shocks.
• After every installation or repositioning, ensure the plant is correctly
earthed.
• If necessary, water the dry earth around the earthing rod.
• Repair a defective earthing line immediately.
 Remove earthing rod [1] from the brackets on the plant. Fit spring
pins back onto the brackets.
 Drive the earthing rod with a hammer into the ground. The earthing
rod must be firmly anchored in the ground to a sufficient depth.
 If necessary, water the earthing rod to increase conductivity.
 The plant is earthed.

Plant installation
6.02.05 Mounting the platforms
4 5
6
1

[1] Ladder
[2] Anti-fall guard
crusher
[5] Rail
10
11

[2] Anti-fall guard

Plant installation
[8] Platform for cyclone prefilter

[9] Steps to platform for cyclone prefilter
WARNING!
Risk of falling
Incorrectly fitted platforms, ladders, handrails and anti-fall guards can re-
sult in people falling.
• Ensure that platforms, ladders, handrails and anti-fall guards are cor-
rectly fitted.
 Install platforms correctly with screws.

 Secure steps to the platforms as specified with screws and nut.
 Secure ladders as specified with screws and nuts.
 Securing handrails as specified with screws and nuts
 Check the function of the anti-fall guards.
 Ensure that all platforms and handrails are correctly fitted.
 The platforms are installed.
6.02.06 Folding out crusher discharge conveyor mechanically

During installation and removal, it may be necessary to remove guard de-
vices or component securing elements for a brief period.
After folding out the crusher discharge conveyor, always ensure that any
guard devices and component securing elements that may have been re-
moved during preceding disassembly of the plant are completely and cor-
rectly reinstalled.
5
3

Plant installation
Fig. 6.11: Crusher discharge conveyor is folded in

[1] Transport locking device for belt conveyor
[2] Transport locking devices for crusher discharge conveyor
[3] Guard grid
[4] Belt suspension
[5] Folding points
NOTICE
If transport locking devices are not disassembled, this can result in dam-
age when the crusher discharge conveyor is folded out.
• Disassemble transport locking devices before folding out the crusher
discharge conveyor.
NOTICE
Lifting tackle that is not correctly fitted can result in damage to the crusher
discharge conveyor or lines in the water system.
• Fasten the lifting tackle to the cross member on the inside of the con-
veyor belt frame.
NOTICE
Folding the crusher discharge conveyor in and out with the discharge belt
bracket unfolded can result in damage to the discharge belt bracket and
components of the crusher discharge conveyor.
• Only fold the crusher discharge conveyor in and out with the dis-
charge belt bracket folded in.
Folding and fastening the  Use suitable lifting gear and tackle to secure foldable part of crusher
crusher discharge conveyor discharge conveyor and tension slightly.
 Disassemble transport locking device [1] for belt conveyor.
 Disassemble transport locking devices [2] on both sides of the crush-
er discharge conveyor.
 Carefully fold out crusher discharge conveyor.

Plant installation
Fig. 6.12: Crusher discharge conveyor folded out

[6] Securing screws
[7] Belt suspension, top
[8] Belt suspension, bottom
 Install belt suspension for foldable part of the crusher discharge con-
veyor, top [7], with pins and spring pins on both side of the frame.
 Install belt suspension for foldable part of the crusher discharge con-
veyor, bottom [8], behind the folding point [5] on both sides.
 Install securing screws [6] at folding point [5] of crusher discharge
conveyor on both sides and tighten to specified tightening torque.
 Remove lifting gear and tackle from crusher discharge conveyor.
 Install guard grid [3] on fixed part and on foldable part of the crusher
discharge conveyor.
 Crusher discharge conveyor is folded out and secured.

Plant installation
Folding out discharge belt bracket for crusher discharge conveyor
11
12
10
Fig. 6.13: Folding out discharge belt bracket

[9] Pivot point screw
[10] Securing screw
[11] Discharge belt bracket for crusher discharge conveyor
[12] Hose coupling
 Climb up using suitable climbing aid or lifting platform in the area of
the discharge belt bracket.
 Release screw with nut in pivot point [9].
 Remove securing screw with nut [10] and keep at hand for subse-
quent use.
 Fold out discharge belt bracket [11].
 Install securing screw with nut and tighten.
 Tighten screw with nut in pivot point [9].
 Connect hose coupling [12] of spray system if necessary.
 The discharge belt bracket is folded out and secured.
 Install guard grid on foldable part of crusher discharge conveyor.

Plant installation
14
13
Fig. 6.14: Gear vent

[13] Gear vent for angular gear
[14] Shut-off cock
WARNING!
Risk of falling
components.
Opening gear vent shut-off  Climb up using suitable climbing aid or lifting platform in the area of
cock the angular gear.
 Open shut-off cock [14] for gear vent [13].
 The shut-off cock for the gear vent has been opened.

Plant installation
6.02.07 Crusher inlet

6.02.07.01 Installing crusher inlet
DANGER!
Danger! Heavy loads
not slip.
ity.
WARNING!
Risk of falling
components.
Fig. 6.15: Crusher inlet

[1] Cone crusher

Plant installation

[3] Crusher inlet
 Raise crusher inlet at the attachment points [2] using suitable lifting
tackle and lifting gear and position above the cone crusher.
 Slowly lower the crusher inlet, but do not place on the cone crusher.
 Align the crusher inlet and ensure that the feeding conveyor can
move into the crusher inlet.
 Lower crusher inlet completely and remove lifting tackle and lifting
gear.
 The crusher inlet has been installed.
6.02.07.02 Installing cone crusher fill level monitor (option)
DANGER!
Danger! Heavy loads
not slip.
ity.
Fig. 6.16: Cone crusher fill level monitor

[1] Assembly point for fill level monitor bracket
[2] Fill level monitor bracket

Plant installation

 Raise the bracket for the fill level monitor [2] using suitable lifting tack-
le and lifting gear and position above the assembly point.
 Install bracket at assembly point and tighten screws to specified tight-
ening torque.
 Insert plug for fill level probe, see chap. 2.01.05. Keep dummy plug
in a safe place for subsequent use.
6.02.08 Installing feed hopper fill level monitor (option)
DANGER!
Danger! Heavy loads
not slip.
ity.
WARNING!
Risk of falling
components.

Plant installation
3 2
1 4
Fig. 6.17: Installing fill level monitor

[1] Socket for fill level monitor
[3] Assembly point
[4] Fill level monitor
 Secure the bracket for the fill level monitor [2] using suitable lifting
tackle and lifting gear and unscrew at the assembly point.
 Position bracket above the feed hopper and assembly point.
 Slowly lower bracket and install with screws and nut at the assembly
position. Tighten nuts to specified torque.
 Insert plug for fill level probe, see chap. 2.06.06. Keep dummy plug
in a safe place for subsequent use.
 The fill level monitor has been installed.
6.02.09 Hopper extension (option)
DANGER!
Danger! Heavy loads
not slip.
ity.

Plant installation
WARNING!
Risk of falling
components.
2 1
Fig. 6.18: Hopper extension

[1] Locking pin and spring pin
[2] Hopper extension support braces
 Install support braces [2] on the upper mounting links of the hopper
extension with locking pins and spring pins.
 Raise hopper extension at the attachment points [3] using suitable
lifting tackle and lifting gear and position above the feed hopper.
 Slowly lower hopper extension onto feed hopper.
 Install support braces [2] on the lower mounting links of the hopper
extension with locking pins and spring pins.
 The hopper extension has been installed.
Prior to assembly of the hopper extension, it may be necessary to disas-
semble the fill level monitor.
When using the hopper extension, assembly of the fill level monitor is not
possible.

Plant installation
6.02.10 Moving feeding conveyor forward

 Start the plant in Manual mode (see chap. 3.05) and switch on auxil-
iary hydraulic system (see chap. 2.02.02).
 Move feeding conveyor with valve block [1] hydraulically as far as the
end position.
 The feeding conveyor has been moved forward and is ready for op-
eration.
6.02.11 Installing magnetic remover (option)
DANGER!
Danger due to magnetic fields
Electric and permanent magnetic separators generate strong magnetic
fields that present a risk to personnel.
• Persons with pacemakers and other medical-technical devices must
stay well clear of magnetic separators.
• Keep a distance of at least 2 metres from magnetic separators.
• Observe the safety manual.

Plant installation
WARNING!
Risk of falling
components.
1
3
Fig. 6.20: Magnetic remover

[1] Magnetic remover (option)
[2] Frame
[3] Mounting
 Attach frame [2] and magnetic remover [1] to suitable lifting gear and
lifting tackle.
 Align frame [2] and magnetic remover [1] on mounting.
 Install frame screws and nuts on mounting and tighten nut to speci-
fied torque.
 The magnetic remover has been installed.

Plant installation
6.02.12 Installing lighting (option)
WARNING!
Risk of falling
components.
2
3
Fig. 6.21: Installing lighting

[1] Magnetic remover frame
[2] Assembly points
[3] Lighting (option)
[4] Fastening plates
 Attach lighting to suitable lifting tackle and lifting gear and lower slow-
ly from above through the recess of the platform.
 Align fastening plates [4] at assembly points [2], bolt on and tighten
to specified torque.
 Insert lighting plug in socket, see chap. 2.06.06.
 The lighting has been installed and connected.

Plant installation
6.02.13 Transport locking devices
Fig. 6.22: Transport locking devices for cone crusher

[1] Locknut
[2] Threaded rod
[3] Clamping nut
 Release locknut.
 Unscrew threaded rod with clamping nut from nut on chassis.
 Remove transport locking device and keep in toolbox for subsequent
reuse.
 Repeat the same work steps on all transport locking devices and on
opposite side.
 The transport locking device has been removed.
6.02.14 Final tasks
NOTICE
Danger of material damage through foreign bodies
Foreign bodies in the plant, such as tools, accessories and packaging
materials, can result in malfunctions and material damage.
• Following installation and prior to initial operation, search the entire
plant for foreign bodies and remove them.

Plant installation
After every transport and reinstallation of the plant, the following checks
and test runs must be carried out:
• Check whether a grey operating plug is inserted at the connection for
operating and transport plug, see chap. 2.06.06.
• Check with plant stationary, see chap. 3.03, "Putting the plant into op-
eration".
• Test run without material, see chap. 6.02.14.01.
• Test run in manual mode, see chap. 6.02.14.02.
6.02.14.01 Test run without material
DANGER!
The test run without material corresponds to automatic mode, where all
plant components are switched on in the opposite direction to the mate-
rial flow.
Before the plant components can be started, all emergency stop devices
must be released.
For release of emergency stop devices, also refer to chap. 2.01.07.
 Switch on plant, see chap. 3.04.
 Check whether the individual machines and plant components start
up in the correct sequence.
 Actuate plant emergency-stop devices and monitor shutdown, also
refer to chap. 4.01.04.
 If faults occur, switch off the plant and eliminate the fault.
 The automatic mode functions have been checked.
6.02.14.02 Test run in manual mode
DANGER!
Execution of "Manual mode" by unqualified and unauthorised personnel
can result in serious or fatal injuries.
struction manual.

Removal of plant
As opposed to automatic mode, in the manual mode test run the plant
components are not switched on and off automatically but rather manu-
ally.
Before the plant components can be started, all emergency stop devices
must be released.
For release of emergency stop devices, also refer to chap. 2.01.07.
 Switch machine and plant components on and off individually, also
refer to chap. 3.04.
 If faults occur, switch off the plant and eliminate the fault.
 The manual mode functions have been checked.
6.03 Removal of plant
DANGER!
Removal and transport by unqualified and unauthorised personnel 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 man-
ual.
DANGER!
Danger due to incorrect installation and removal
Incorrect installation and removal and the use of unsuitable hoisting gear
and lifting accessories can result in serious or fatal injuries.
• Use suitable hoisting gear and lifting accessories and check that it is
in perfect condition.
• Fit hoisting gear, such as chains and ropes, so that it cannot slip.
• Always suspend components and machines from their centre of grav-
ity.
• Only lift and transport loads as high and as far as necessary.
• Never move under or stand under a suspended load.
• Only assign personnel installation and removal tasks who are quali-
fied and authorised according to the requirements in this instruction
manual.

Removal of plant
WARNING!
Risk of falling
components.
WARNING!
Risk of stumbling
Before the plant can be transported, it must be moved from operating po-
sition to transport position. To prepare for removal, carry out the following
activities:
NOTICE
Danger of material damage due to tilting over
Incorrect installation of the plant, or sinking of the plant on soft ground,
creates a risk of the plant tilting.
• Only position the plant on secure and firm ground.
 Run all plant components completely empty.

 Move the plant onto secure and firm ground. Remove any obstacles
in the direct vicinity.
 Position the plant, ensuring it is horizontal. If necessary, flatten the
ground by spreading fine material and levelling it.
 Switch off the diesel generator and secure plant against reactivation.
 Insert red transport plug to the operating and transport plug, see
chap. 2.06.06.
 Clean plant, see chap. 4.45.
 Provide suitable lifting accessories and hoisting gear for removal.
 Preparations for plant removal are complete.

Removal of plant
6.03.02 Moving in warning light
3
2
Fig. 6.23: Moving in warning light

[1] Wing screw
[2] Retaining pipe
[3] Warning light
 Release wing screw [1] and push retaining pipe [2] all the way to the
bottom.
 Tighten wing screw.
 The warning light has been moved in.
6.03.03 Disassembling lighting (option)
WARNING!
Risk of falling
components.

Removal of plant
2
3
Fig. 6.24: Installing lighting

[1] Magnetic remover frame
[2] Assembly points
[3] Lighting (option)
[4] Fastening plates
 Remove lighting plug, see chap. 2.06.06.
 Attach lighting to suitable lifting tackle and lifting gear and tension
slightly.
 Unscrew fastening plates [4] and slowly pull lighting upwards.
 Lower lighting slowly onto the ground.
 The lighting has been disassembled.
6.03.04 Crusher inlet

6.03.04.01 Disassembling cone crusher fill level monitor (option)
DANGER!
Danger! Heavy loads
not slip.
ity.

Removal of plant
Fig. 6.25: Cone crusher fill level monitor

[1] Assembly point for fill level monitor bracket
 Remove fill level monitor plug, see chap. 2.06.06. Insert dummy plug
in socket.
 Secure bracket for fill level monitor [2] with suitable lifting tackle and
lifting gear.
 Unscrew bracket on assembly point and lift slowly from plant.
 Set down bracket slowly and remove lifting gear.
 The fill level monitor has been disassembled.
6.03.04.02 Disassembling crusher inlet
DANGER!
Danger! Heavy loads
not slip.
ity.

Removal of plant
WARNING!
Risk of falling
components.
Fig. 6.26: Cone crusher inlet

[1] Cone crusher
[3] Crusher inlet
 Lift crusher inlet at attachment points [2] with suitable lifting gear and
tackle from the plant.
 Slowly lower crusher inlet and place on a suitable surface.
 Remove lifting gear and lifting tackle.
 The crusher inlet has been disassembled.

Removal of plant
6.03.05 Hopper extension (option)
DANGER!
Danger! Heavy loads
not slip.
ity.
WARNING!
Risk of falling
components.
2 1
Fig. 6.27: Hopper extension

[1] Locking pin and spring pin
[2] Hopper extension support braces

Removal of plant
Disassemble support braces  Remove locking pins and spring pins from lower mounting link of sup-
port brace [2].
 Secure support brace [2] with suitable lifting gear. Work with a second
person if necessary.
 Remove locking pins and spring pins from upper mounting link of
support brace.
 Slowly set down support brace and disassemble the remaining sup-
port braces in the same manner.
 The support braces have been disassembled.
Removing hopper extension  Raise hopper extension at attachment points [3] with suitable lifting
tackle and lifting gear.
 Lower hopper extension slowly onto ground or transport frame.
 The hopper extension has been disassembled.
6.03.06 Moving feeding conveyor back
WARNING!
Danger of crushing by the feeding conveyor
Serious crushing injuries are possible when the feeding conveyor is
moved back.
• When moving back the feeding conveyor, ensure that all persons are
clear of the area between chassis and feeding conveyor.

 Start crushing plant in Manual mode (see chap. 3.05) and switch on
auxiliary hydraulic system (see chap. 2.02.02).

Removal of plant
 Move feeding conveyor back with valve block [1] hydraulically as far
as the end position.
 The feeding conveyor has been moved back.
6.03.07 Folding in crusher discharge conveyor mechanically
4
2
Fig. 6.29: Folding in discharge belt bracket

[1] Pivot point screw
[2] Securing screw
[3] Discharge belt bracket for crusher discharge conveyor
[4] Hose coupling
Folding in discharge belt bracket for crusher discharge conveyor
WARNING!
Risk of falling
components.
The discharge belt bracket of the crusher discharge conveyor [3] can be
folded in. When dismantling the plant, the discharge belt bracket of the
crusher discharge conveyor is folded in. The guard grid on the foldable
part of the crusher discharge conveyor must be removed.
 Climb up using suitable climbing aid or lifting platform in the area of
the discharge belt bracket.
 Connect hose coupling [4] of spray system if necessary.

Removal of plant
 Disassemble guard grid of foldable part of crusher discharge convey-

or.
 Release screw with nut [1] in pivot point.
 Remove securing screw with nut [12] and keep at hand for subse-
quent use.
 Fold in discharge belt bracket [3].
 Secure discharge belt bracket correctly, e.g. with a transport belt.
 Install securing screw with nut [2] and tighten.
 Tighten screw with nut [1] in pivot point.
 The discharge belt bracket is folded in and secured.
6
5
Fig. 6.30: Closing gear vent

[5] Gear vent for angular gear
[6] Shut-off cock
WARNING!
Risk of falling
components.

Removal of plant
Closing gear vent shut-off  Climb up using suitable climbing aid or lifting platform in the area of
cock the angular gear.
 Open shut-off cock [6] for gear vent [5].
 The shut-off cock for the gear vent has been closed.
10
Fig. 6.31: Crusher discharge conveyor folded out

[7] Securing screws, folding point
[8] Belt suspension, top
[9] Guard grid
[10] Belt suspension, bottom
NOTICE
Lifting tackle that is not correctly fitted can result in damage to the crusher
discharge conveyor or lines in the water system.
• Fasten the lifting tackle to the cross member on the inside of the con-
veyor belt frame.
Folding and fastening the  Ensure that the guard grid [9] of the foldable part of the crusher dis-
crusher discharge conveyor charge conveyor is disassembled and the discharge belt bracket is
folded in.
 Use suitable lifting gear and tackle to secure foldable part of crusher
discharge conveyor on both sides and tension slightly.
 Remove securing screws [7] from folding point on crusher discharge
conveyor on both sides.
 Disassemble belt suspension of foldable part of the crusher dis-
charge conveyor and bottom [10] and top [8] on both sides.

Removal of plant
NOTICE
If the guard grids are not disassembled, this can result in damage when
the crusher discharge conveyor is folded.
• Disassemble guard grids before folding the crusher discharge con-
veyor.
NOTICE
Folding the crusher discharge conveyor in and out with the discharge belt
bracket unfolded can result in damage to the discharge belt bracket and
components of the crusher discharge conveyor.
• Only fold the crusher discharge conveyor in and out with the dis-
charge belt bracket folded in.
 Carefully fold in crusher discharge conveyor.
12
11
Fig. 6.32: Crusher discharge conveyor is folded in

[11] Transport locking device for conveyor belt
[12] Transport locking devices for crusher discharge conveyor
NOTICE
If transport locking devices are not installed, this can result in damage to
the crusher discharge conveyor during transport.
• Install transport locking devices after the crusher discharge conveyor
has been folded in.

Removal of plant
 Install transport locking devices for crusher discharge conveyor [12].

 Install transport locking device for belt conveyor [11].
 Remove lifting gear and tackle from crusher discharge conveyor.
 Crusher discharge conveyor is folded in and secured.
The belt suspension for the fixed part of the crusher discharge conveyor
must not be disassembled for plant disassembly.
6.03.08 Transport locking devices
Fig. 6.33: Transport locking devices for cone crusher

[1] Locknut
[2] Threaded rod
[3] Clamping nut
 In transport locking device in chassis of cone crusher, screw into nut
on chassis and tighten.
 Tighten locknut.
 Repeat the same work steps on all transport locking devices and on
opposite side.
 The transport locking device has been installed.

Removal of plant
6.03.09 Removing the platforms
4 5
6
1

[1] Ladder
[2] Anti-fall guard
crusher
[5] Rail
10
11

[2] Anti-fall guard

Removal of plant
[8] Platform for cyclone prefilter

[9] Steps to platform for cyclone prefilter
The platforms and ladders do not have to be disassembled for plant
transport.
The platform between cone crusher and power supply unit does not have
to be disassembled for transport.
 Disassemble handrail.
 Disassembling steps to the platforms
 Disassemble the ladders to the platforms.
 Disassemble platforms.
 Stow disassembled parts safety on the plant and secure them or
transport separately.
 The platforms are ready for transport.
6.03.10 Swivelling and moving up hopper supports

Moving up hopper supports
Fig. 6.36: Moving up hopper supports

[1] Hopper support
Moving up hopper supports  Move up hopper supports (see chap. 3.06).
 Switch off diesel generator and secure against reactivation.
 Release securing screws and nuts and remove.

Removal of plant

 Hopper supports can be swivelled.
Swivelling hopper supports
Fig. 6.37: Hopper support, swivelling

[1] Hopper support
[2] Securing screw and nut
WARNING!
Danger of crushing in the swivel area of the hopper supports
When swivelling the hopper supports, serious crushing injuries are pos-
sible.
• During the swivel operation, never place hands between hopper sup-
port and chassis.
Swivelling hopper support  Swivel the hopper support forward.

 Install securing screw with nut [2] and tighten.
 Hopper supports have been swivelled and secured.

Removal of plant
6.03.11 Removing earthing
Fig. 6.38: Earthing the plant

[1] Earthing rod
 Pull the earthing rod [1] out of the ground.
 Fit earthing rod on brackets on plant and secure with spring pins.
 The earthing is removed.
6.03.12 Final tasks

After every disassembly of the plant, the following final tasks must be car-
ried out:
 Close all service doors and flaps and secure against accidental open-
ing.
 Secure parts and plant components, such as swivel arm, against un-
controlled movements.
 Secure components and accessories that remain on the plant against
falling down.
 If necessary, fit transport locks on magnetic separators and belt con-
veyors.
 Lock toolbox.
 In particular, clean plant prior to transport, see chap. 4.45.01.
 The plant is completely removed and ready for transport.

Storage, shutdown, disposal
6.04 Storage, shutdown, disposal
6.04.01 Storage conditions
NOTICE
Incorrect storage of parts and plant components can result in damage
and premature failure.
• Always store spare parts and remove parts and plant components in
a correct manner.
Spare parts, wear parts, removed parts and plant components must be
stored in a correct manner. Observe the following points:
• Clean and dry and plant prior to storage. Take particular care with
moving parts, e.g. conveyor belts.
• Where possible, the plant or plant components and machines must
be stored in closed, dry rooms prior to final assembly.
• If the plant or plant components and machines are stored outdoors,
they must be covered with tarpaulin covers that are open at the bot-
tom to allow the run-off of any condensation. Secure tarpaulin covers
with suitable lashing equipment.
• Place the plant, plant components and machines on suitable bases
to protect them against rising damp.
• On plants with a touch screen, note the operating hours and remove
the touch screen.
• On plants with a conventional control system, remove the OP3.
• Store electric and electronic components in closed, dry and frost-free
rooms.
• When returning plants with touch screen to operation, check the ba-
sic settings.
• Switch off battery isolator for diesel generator.
• Remove batteries, store in a dry place and charge once a month us-
ing a suitable charger.
• If storage is for periods longer than six months, introduce additional
protective and preservation measures, in particular, for the diesel
generator. Also refer to the manufacturer's documentation.
• Completely fill fuel tank with suitable winter diesel. Also refer to the
manufacturer's documentation.
• Remove water pump and store in a warm and dry place.
6.04.02 Shutdown, restarting

If the period between shutdown and restarting exceeds 6 months, ob-
serve the following points:

• Observe storage conditions, see chap. 6.04.01.

• In particular, observe the storage conditions for the diesel generator.
See manufacturer's documentation.
6.04.03 Disposal of machine

At the end of the service life of the plant, plant components and ma-
chines, disposal must be carried out in a professional manner by a spe-
cialist disposal company.
This includes, in particular, the correct, environmentally compatible dis-
posal of the following components:
• Fluids and lubricants, such as lube oils, greases and diesel fuel.
• Electric and electronic components.
• Unmixed scrapping of metals.
• Other residual materials.


INDEX
INDEX
A Changing guide rails 208
Accessories 99 Changing hydraulic filter 173
Adjusting conveyor belt run 221 Changing hydraulic oil filter 161, 172
Adjusting flat scraper 207 Changing lube oil filter 174
Adjusting trough rocker width 235 Changing planetary gear oil 198
Adjusting wedge stripper 206 Changing V-belt pulley 296
Air filter 70 Changing V-belts 238
Air intake 70 Changing ventilation filter 162
Aligning bowl 260 Changing wear lining on vibrating chutes 231
Aligning mantle 284 Charged material 303
Ambient temperature 23, 304 Chassis 39
Ascending slopes 120 Chassis beam 87
Assembly aids 326 Check hydraulic oil 168
B Checking accessories 227
Banksman 34 Checking adjusting screws 242
Bases 126 Checking automatic circuit-breakers 186
Battery isolator 81 Checking base plates 196
Belt conveyor 90 Checking chain tension 193
Belt conveyor technical details 309 Checking coarse strainer 176
Blockage 131 Checking conveyor belt run 220
Blockages 131, 131 Checking crawler carrier chain tension 193
Bracing crusher cone 280 Checking crusher bearing 239
Bracing wedges 263 Checking cyclone prefilter 150

Checking earth fault circuit interrupter 189, 189
C
Checking gap dimension 265, 280
Carrying out lamp test 148
Checking geared ring 240, 242
CE marking 19
Checking guard devices 146
Change return filter 164
Checking guide blocks 240
Change suction filter 163
Checking guide rails 208
Changes 14
Checking hydraulic fill level 158, 168
Changing belt pulley 296
Checking lube oil 168
Changing bowl liner 253
Checking lube oil fill level 168
Changing conveyor belt 220
Checking motor protecting switch 187
Changing gear oil 198

INDEX
Checking overload relay 188 Control stand 49

Checking planetary gear oil level 197 Conveyor unit 89
Checking plant 356 Cooler 70
Checking radio remote control 148 Cooling system 70
Checking rubber curtains 217 Coupling 71
Checking sealing 217 Crane transport 335
Checking support blocks 240 Crawler running gear 87
Checking switch cabinet mounting 183 Crusher cone weld seam 273
Checking terminal boxes 184 Crusher inlet 348
Checking the crushing gap 137 Crusher technical details 311
Checking the emergency stop 146 Crushing capacity 304
Checking the emergency switching off 147 Crushing strength 303
Checking tools 227 Cyclone prefilter 70, 85
Checking track rollers 196 D
Checking trough rocker width 234 Danger areas 28
Checking vibration motors 231 Decals 31
Checking warning devices 146 Declaration of Conformity 19
Checking wear elements 247 Depressurising crusher hydraulic system 167
Checking wired remote control 149 Depressurising hydraulic system 156
Checking ZEV 191 Description 37
Chutes 91 Diesel engine 65
Claw clutch 76 Diesel engine heating 63
Clean 298 Diesel engine technical details 305, 306, 307
Cleaning bowl 257 Diesel Fuels 325
Cleaning crusher shell 258 Diesel generator fuses 82
Cleaning magnetic removers 217 Dimensions, plant 302
Cleaning the plant 298 Disassembling discharge belt bracket 365
Clearing away waste tip 138 Disassembling fill level monitor 249, 361
Climatic conditions 23 Disassembling handrail 371
Clutch 76 Disassembling platform 371
Commissioning 110 Disconnecting chain lock 200
Cone crusher hydraulic pumps 78 Disposal of machine 26, 375
Cone crusher, technical details 311 Documentation 18
Contact persons 36 Downloads 108
Control elements 51, 106 Downward slopes 120

INDEX
Draining hydraulic oil 159, 171 Feeder trough technical details 311
Draining lube oil 169 Feeding unit 100
Drive system technical details 309 Fill level monitor 350
Driving 119 Filler neck 68
Driving clutch 76 Filling crusher cone 282
Driving speed 303 Filling epoxy resin 266
Driving with radio remote control 121 Filling hydraulic oil 160, 172
Driving with wired remote control 123 Filling with lube oil 170
Dust emission 30 Fire extinguisher 29
Dust filter 85 Fire fighting 29
E Flow chart 38
Earthing 340 Fluid control 94
Earthing the plant 340 Fluids and lubricants 322
Electric motors 84 Frequency converter main switch 56
Electrical system 79 Frequency converter operating unit 57
Electrical system technical details 308 Fuses 328
Eliminating material congestion 132 G

Emergency off 48 Gear pumps 77, 78
Emergency stop 48, 48 Generator 24 V 83
Emissions 29 Generator technical details 305, 306, 307
Engine 65 Gradeability 303
Engine oil hand pump 154 Ground pressure 303
Environmental protection 25 Guard devices 45
Epoxy resin 326 Guide rails 208
Exhaust pipe 69 H
Exhaust system 69 Heating 63
External circuits 85 Hopper 100
External power supply 86, 109, 109 Hopper extension, technical data 310
F Hopper technical details 310
Feed capacity 304 Horn 41
Feed hopper 100 Hydraulic oil supply technical details 308, 308
Feed hopper support profiles 268 Hydraulic oil tank 72, 75
Feed hopper technical details 310 Hydraulic pumps 77
Feed size 303 I
Feeder trough 103 Identification plates 32

INDEX
Ignition switch 54 Loads 29

Indicator elements 51, 106 Low loader 332
Information material 327 Lube oil filter 174
Initial operation 108 Lube oil tank 75
Inserting bowl 286 Lubricants 322
Inserting chain link 204 Lubricating belt conveyor plummer block 212
Installation height of crusher shell 264 Lubricating plummer blocks 212
Installing crusher inlet 288 M
Installing feed hopper 267 Magnetic remover 43,
Installing feed plate 284 Magnetic separator sockets 44
Installing fill level monitor 289, 350 Main switch 50
Installing lifting disc 271 Maintenance 143
Installing lighting 354 Maintenance intervals 312
Installing mantle 283 Maintenance personnel 35
Installing plant 336 Maintenance schedule 312
Installing securing block 135 Manufacturer's documentation 327
Installing wedges 261 Marking crusher shell 259
Instruction manual 13 Material congestion in cone crusher 132
Intended purpose 21 Material defects 20
Intended use 21 Measuring wear element 248
Interface 51, 106 Metal detector 92, 92
L Modem 98
Ladders 41 Mounting crusher cone 277
Lamps 42 Mounting retaining nut 278
Lashing 332 Moving 119
Lashing the plant 332 Moving feeding conveyor forward 352, 364
Lateral inclination 303 Moving in warning light 359
Liability 14, 20 Moving out warning light 339
Lighting 42, 44 Moving the plant 119
Loading 127, 332 N
Loading plant 332 Noise emission 30
Loading the cone crusher 129 O
Loading the feed hopper 127 Obstructions 131
Loading the plant 127 Oil drain pump 154
Loading vehicles 126 Oil tank 72

INDEX
OP3 55 Remote control 62

Operating the plant 110 Removing bowl 252, 256
Operating the water system 125 Removing chain link 202
Operation 105 Removing crusher cone 276
Operator panel 51, 55, 51 Removing crusher inlet 250, 362
Optional equipment 37 Removing earthing 373
Overpressure system 85 Removing feed plate 270
Overview 38 Removing mantle 272
P Removing plant 358
Packaging 15 Removing retaining nut 275
Packing ring 278 Removing wedges 255
Personnel 33 Repair personnel 35
Plant dimensions 302, 330 Repairing crawler running gear 200
Plant transport dimensions 330 Repairing electrical system 186
Plant transport weights 331 Replacing counterweight wear element 291
Plant weights 302, 331 Replacing vibration motors 232
Platforms 41 Replacing wear element for backgear shaft 294
PLC 55 Replacing wear element for lower frame 293
Power supply 80, 86, 109 Replacing wear element for supporting arm 294
Power supply unit technical details 304, 305, 306 Residual risks 22
Preparation for changing crusher cone 273 Restarting 374
Preparing charged material 126 Retaining nut for crusher cone 274
Press the manual mode 114 Revision statuses 36
Protective cover 45 S
Protective equipment 35, 35 Safety distance 29
Provisos 14 Safety information 25
Q Safety instructions 326
Qualifications 33 Safety manual 13, 25
R Scrapping 375
Rain 23 Sealing compound 326
Raising adjustment ring 134 Securing block 135
Ramps 126 Securing element for cone nut 265
Refuelling 125 Securing element for square-head bolt 262
Refuelling the plant 125 Select plant overview 38
Release cord 48 Service packs 97

INDEX
Service personnel 35 Setting the crushing gap 138

Servicing air filters 151 Shutdown 374
Servicing angular gear 210 Shutting down the plant 124
Servicing belt conveyor drive 210 Signs 15, 31, 31
Servicing belt conveyors 205, 219 Silencer 69
Servicing chassis 144 Siren 41
Servicing chute 229 Slackening conveyor belt 219
Servicing chutes 217 Slackening crawler carrier chain 195
Servicing conveyor belts 205, 208, 219 Socket for feeding conveyor 42
Servicing crawler running gear 193 Socket for lighting 44
Servicing cyclone prefilter 185 Socket for magnetic remover 43
Servicing diesel generator 149 Sockets on the switch cabinet 84
Servicing drive system 193 Software 108
Servicing dust filter 185 Sound power level 304
Servicing electric motors 184 Sound pressure level 30
Servicing electrical components 182 Special transport 329
Servicing electrical system 179 Specifications 322
Servicing feed hopper 228 Spray system 93, 95
Servicing feeder trough 229 Standard equipment 37
Servicing flat scraper 207 Starter 54
Servicing hopper 228 Starting aid 141
Servicing hydraulic system 157, 167 Steps 41
Servicing magnetic removers 217 Storage 15
Servicing overpressure system 185 Storage conditions 374
Servicing safety devices 144 Storm 23
Servicing scraper 206 Supporting elements 117
Servicing starter batteries 180 Supports 117
Servicing switch cabinet 182 Switch cabinet 82
Servicing switch cabinet protective housing 148 Switch cabinet heating 63
Servicing the service doors 214 Switching diesel generator off 110
Servicing the service flaps 214 Switching diesel generator on/off 110
Servicing vibrating conveyors 229 Switching off after emergency stop 113
Servicing voltage supply 180 Switching off after emergency switching off 113
Servicing water pump 223 Switching off plant components 111
Servicing water system 223 Switching on after emergency stop 113

INDEX
Switching on after emergency switching off 113 Vibration emission 31

Switching on diesel generator 110 Voltage supply 80
Switching on plant components 111 W
Switching on spraying nozzles 125 Warning light 41, 41
Switching plant components on/off 111 Warning sign 16
Switching plant on/off after emergency stop 113 Warning siren 41
Switching plant on/off after emergency switching off Warranty 14, 20
113
Water pump 94
Swivelling hopper support 337, 372
Water system 93, 95
Symbols 15
Water system for winter operation 140
T
Water system technical details 310
Tank 68
Wear limit, theoretical 242
Taper-lock bushing 296
Wear lining for chutes 215
Telemaintenance 98
Weights, plant 302
Temperatures 304
Welding 300
Tensioning conveyor belt 219
Welding on packing ring 279
Tensioning crawler carrier chain 194
Wind 23
Tensioning crusher V-belts 236
Winter operation 139
Tensioning V-belts 238
Wired remote control 62
Test run 356, 357
Theoretical wear limit 242
Tightening torques 321
Tools 99
Track drive 88
Training courses 35
Transport 329
Transport plug 85
Transport weight of accessories 331
Transport weights 331
Trough 103
Trough technical details 311
Turning bowl 286
Turning off plant 124
V
Ventilation filter 162

INDEX

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INSTRUCTION MANUAL

© Kleemann GmbH 2014

2 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 3

4 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

2.07 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 5

2.39 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

6 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

3.15.01 Starting the engine with jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 7

4.06.02 Servicing 24 V voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

8 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

4.14 Not assigned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 9

4.44.02 Checking crusher mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

10 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

5.04 Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

6 INSTALLATION AND REMOVAL, TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 11

6.03.04.02 Disassembling crusher inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

12 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 13

Observance of the instruction manual:

14 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

1.01.03 Packaging and storage

1.01.04 Signs and symbols

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 15

(option) Optional equipment

1.01.05 Warning sign

16 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

Warning of a general danger

Warning of dangerous voltage

Warning! Suspended load

Warning of rotating parts

Warning! Risk of stumbling

Warning! Risk of crushing injuries

Warning! Risk of crushing injuries to hands

Warning! Risk of crushing injuries to feet

Warning! Hot surface

Warning! Hot fluids

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 17

Warning of flammable materials

Warning of potentially explosive materials

Warning of toxic substances

18 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

plicable, the transport instructions from KLEEMANN. The corresponding

1.01.07 Declaration of Conformity

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 19

1.01.08 Warranty and liability

20 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

1.02.01 Intended use, purpose

1.02.02 Non-specified use

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 21

Non-specified use includes:

1.02.03 Residual risks

22 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

• The special warning signs on the plant.

1.03 Climatic conditions

© Kleemann GmbH 2014 BAL_K038_2384672_00_EN-GB 23

• After start-up, allow the diesel engine to run until an operating

24 BAL_K038_2384672_00_EN-GB © Kleemann GmbH 2014

1.04 Safety information