Operating manual
Mobile contrary separator
with integrated windsifter
Model description :
HURRIFEX
Machine number :
96010
Year of manufacture :
2016
Copyright © 2017 Komptech Umwelttechnik GmbH. All rights reserved.
Printed: 01/2017
Original instruction manual:
Betriebsanleitung_HURRIFEX_Version1_gb
Operating manual
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NOTICE
Before you perform any work on or with the machine, read
the entire operating manual carefully!
Only use the machine for its intended purpose!
Observe all safety instructions described in this operating
manual.
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Structure of the entire operating manual
Operating manual (this chapter)
1. Preface
2. Safety
3. Intended use
4. Product description
5. EC Declaration of Conformity
6. Setting up machine
7. Operation
8. Emergency
9. Annex
Maintenance manual (separate chapter)
10. Maintenance / Cleaning
11. Error, cause, correction
12. Disassembly / Disposal
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Contents
1. Preface ....................................................................... 7
2. Safety ......................................................................... 9
2.1. Operator ................................................................ .... 10
2.2. Qualification of personnel .......................................... 10
2.3. Obligations of personnel ............................................ 11
2.4. Danger zone.............................................................. 13
2.5. Safety devices ........................................................... 15
Safety devices (electrics) ............................. 15
Safety devices (hydraulics) .......................... 16
2.6. Structure of warning signs ......................................... 18
2.6.1. Signal words ................................................ 18
2.6.2. Warning symbols ......................................... 19
2.6.3. Prohibitory symbols ..................................... 20
2.6.4. Command symbols ...................................... 20
2.6.5. Additional symbols (pictograms) used at
the machine ................................................. 21
2.7. Basic safety instructions ............................................ 22
2.8. Residual risks ............................................................ 23
3. Intended use ............................................................ 27
3.1. Intended use ............................................................. 27
3.2. Non-intended use ...................................................... 28
3.3. Basics for operation ................................................... 29
3.3.1. Hand over product documentation ............... 29
3.3.2. Personnel training ........................................ 29
4. Product description ................................................ 30
4.1. General information ................................................... 30
4.1.1. Unit marking ................................................ 31
4.1.2. Technical data ............................................. 31
4.1.3. Machine equipment ..................................... 33
4.1.4. Function of the machine (schematic) ........... 35
4.2. Machine layout .......................................................... 36
4.3. Controls ..................................................................... 38
4.3.1. Operating area BP1 ..................................... 39
Design of starting module ............................ 42
Layout of display with function keys ............. 43
Set the language ......................................... 48
4.3.2. Operating area - EMERGENCY-STOP-
switch .......................................................... 49
4.3.3. Release valve compressed air braking
unit .............................................................. 50
4.3.4. ABS-control – Junction box .......................... 51
4.3.5. Battery master switch .................................. 51
5. EC Declaration of Conformity ................................. 53
6. Setting up the machine ........................................... 54
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6.1. Setting up the machine .............................................. 54
6.1.1. Free space under the machine .................... 55
6.1.2. Decouple the machine from the towing
device .......................................................... 56
Secure machine ........................................... 56
Lower supports ............................................ 56
Disconnect the connections ......................... 57
6.1.3. Setting up the working platform ................... 58
6.1.4. Bring the machine into working position ....... 60
Bring the towing bar into working
position ........................................................ 61
Fix exhaust hoses ........................................ 63
Protective net below diesel engine ............... 64
Establish the power supply .......................... 65
Bring the biomass conveyor to working
position ........................................................ 67
Fold away the discharge belt of inert
material electrically (option) ......................... 68
Final works .................................................. 69
7. Operation ................................................................. 71
7.1. Operating modes ....................................................... 71
7.1.1. Automatic mode ........................................... 71
7.1.2. Manual mode ............................................... 71
7.2. Start and stop in automatic operation ........................ 73
7.2.1. Start machine .............................................. 74
7.2.2. Stop machine............................................... 74
7.3. Optimizing the adjustments for automatic
operation ................................................................... 76
7.3.1. Electric components .................................... 76
7.3.2. Mechanic components ................................. 77
Adjust the height of the suction fan .............. 77
7.3.3. Settings at the suction fans .......................... 78
Inclination of the separating device .............. 79
8. Emergency ............................................................... 81
8.1. Damage to persons ................................................... 81
8.2. Damage to machine .................................................. 82
9. Annex ....................................................................... 83
9.1. Preparation for daily operation .................................. 83
9.1.1. Checking the machine’s stability .................. 83
9.1.2. Checking the mechanics .............................. 83
9.1.3. Checking for working materials, running
out ............................................................... 84
9.1.4. Checks at the diesel engine (option) ............ 84
Cooling water............................................... 85
Engine oil level ............................................ 85
Water pre-separator ..................................... 86
Air filter contamination display ..................... 86
Air filter ........................................................ 87
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Generator .................................................... 87
9.1.5. Checking the fuelling ................................... 88
9.1.6. Checking the electrics .................................. 89
9.1.7. Checking the hydraulics ............................... 90
9.1.8. Checks at the belts ...................................... 91
9.2. Prepare machine for transport ................................... 92
9.3. Functioning description of options ............................. 95
9.3.1. Version in accordance with the EU
Directive ...................................................... 96
9.3.2. Adjustable belt speed at discharge belt........ 97
9.3.3. Housing for feeding belt ............................... 98
9.3.4. Side bar enlargement feeding belt ............... 98
9.3.5. Discharge belt electro-hydraulically
foldable ........................................................ 99
9.3.6. Adjustable belt speed inert material ............. 99
9.3.7. Magnet drum ............................................. 100
9.3.8. Diesel engine ............................................. 101
9.3.9. Soot filter ................................................... 102
9.3.10. Electric motor pre-heating .......................... 103
9.3.11. Cleanfix- fan .............................................. 104
9.3.12. Radio remote control ................................. 105
9.3.13. Frequency converter for fan of
separating chamber ................................... 107
9.3.14. Frequency converter for suction fans 1
and 2 ......................................................... 108
9.3.15. Additional socket 32 amps ......................... 108
9.3.16. Battery master switch ................................ 109
9.3.17. Air conditioner at switch cabinet ................ 110
9.3.18. Central lubrication unit ............................... 110
9.3.19. Gusset shoe .............................................. 111
9.4. Special labels USA .................................................. 112
Index 115
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1. Preface
Dear Customer!
Thank you for the confidence that you have shown in our prod-
ucts by purchasing this machine.
Purpose of the operating manual
This operating manual is a guide for safe and efficient use of
the machine. The purpose of this operating manual is to
avoid injury to persons and damage to the machine: We
have provided the information necessary to operate and
maintain the machine easily. We also want to familiarise you
with the technical details of the machine and point out any
risks and dangers.
WARNING
Danger due to operating the machine without first studying the operating and maintenance manual.
Personal injury and machine damage may occur.
Prior to commissioning the machine read the operating
manual! You must understand and observe all safety instructions!
Persons entrusted with the machine must always be able
to access the operating and maintenance manual!
Availability of the operating manual
Please ensure that this operating manual is available so that
required information can be obtained at any time or training
can be carried out. In case of re-sale we ask you to hand
over the entire documentation together with the machine!
Never commission the machine without first having read the
operating manual!
Resale
Please hand over the complete documentation with the machine in case of resale.
In the case of a later resale into a country of the EEA, the
operating manual must be translated into the language of the
corresponding user's country.
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Translation
If there are any discrepancies occur in the text translated, the
original operating manual (German) is to be consulted for
clarification or the manufacturer is to be contacted.
Pictograms
Other instructions in the form of short texts and pictograms
are attached to the machine itself. Information is therefore
directly available on site without having to consult separate
manuals. Contact us in case of damaged, loose or illegible
pictograms. These are to be replaced immediately with new
pictograms.
The operator is responsible for ensuring that only qualified personnel operate and maintain the machine. Both the operator
and all service and maintenance personnel must be completely
familiar with the safety and operation regulations.
The machine operator must read this operating manual before
starting the machine and follow the guidelines it contains precisely.
Prevent incorrect repair or maintenance. If in any doubt please
contact our customer service:
Komptech Umwelttechnik Deutschland GmbH
Carl-Zeiss-Straße 2
D-59302 Oelde
[t] (+49) 25229345 - 0
[f] (+49) 25229345 - 45
http://www.komptech.de
info@komptech.de
Copyright
Copyright © 2017 Komptech Umwelttechnik Deutschland
GmbH. All rights reserved.
This operating manual or extracts thereof may not be printed,
copied, reproduced, electronically processed or distributed
without the prior written consent of Komptech Umwelttechnik.
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Trademark protection
The Komptech brand, logo beech leaf and word mark “Technology for a better environment” are registered trademarks
and are the intellectual property of Komptech GmbH.
Technical changes
This instruction manual only applies to the machine with the
serial number entered in the file and is not subject to a revision service! In the event of modifications, additions, or
changes, the operator is responsible for keeping the manual
up to date!
The date on the EC Declaration of Conformity is applicable to
the edition of this operating manual.
2. Safety
Marking by safety notices
The systematic marking of certain points (danger locations,
lubrication points, adjusting interval, displays, operation elements) by safety notices allows the machine to be operated
safely. This marking is performed with the same pictograms
as shown in this operating manual.
WARNING
Danger due to commissioning of the machine without
observance of the safety instructions or due to the execution of maintenance work by unqualified personnel.
Serious personal injury and material damage may occur.
Commissioning the machine as well as maintenance work
must only be carried out by qualified persons, observing
the safety instructions.
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2.1. Operator
Operator’s obligations
As operator you are responsible for correct use of the machine. Correct use includes operation and maintenance of
the machine.
The operator shall comply with the legal requirements for
the operation of work machines.
The operator shall confirm to the manufacturer that instruc-
tion regarding safe use of the machine has taken place.
The operator must be familiar with the contents of the oper-
ating and maintenance manual and comply with the instructions contained in it.
The operator will plan for and be responsible for the use of
the machine within the constraints of its intended use.
The operator is responsible for ensuring that the machine is
safe to operate and in proper service condition.
The operator ensures that the machine is only operated by
persons whose mental and physical conditions satisfy the
task assigned.
The operator shall prevent unauthorized modifications and
shall obtain an expert opinion from the manufacturer before
any modification. In the case of safety defects the operator
shall inform the manufacturer or seller.
In the case of loss of the operating manual or the safety
markings (loose or illegible pictograms) the operator shall
ensure they are reordered immediately.
In the case of resale the operator shall ensure that the com-
plete operating manual is handed over to the buyer in a reliable and demonstrable way.
The operator must perform a noise measurement under op-
erating conditions and if necessary supply corresponding
hearing protection.
2.2. Qualification of personnel
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Qualification of personnel
Only the following groups of persons are allowed to work at
or with the machine:
Instructed personnel
Persons who have been trained by a specialist and instructed
about
possible dangers,
appropriate behaviour,
inappropriate behaviour,
safety devices and
safety measures.
Specialists
Persons who have the following qualifications:
professional education,
professional experience and
knowledge about the relevant standards and regulations.
These persons are able independently to evaluate the work
delegated to them with regard to existing and possible dangers.
(Definition according to EN 60204-1)
2.3. Obligations of personnel
Obligations of personnel
All persons, working at or with the machine have the following obligations:
Operate the machine exclusively for its intended purpose.
Follow the operator’s instructions with regard to working pro-
tection and operating safety.
Wear the personal protection equipment specified as per the
operator’s risk assessment.
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Before executing work on or with the machine, read the op-
erating manual.
Avoid all working methods that cause hazards to persons or
damage to the machine or environment.
Perform maintenance and inspection work only according to
the operating manual’s descriptions.
Inform the machine’s operator immediately if the contents of
the operating manual cannot be understood.
Ensure that escape routes are free.
Only carry out changes of location with the machine after
being instructed by the operator.
Inform the machine’s operator immediately if:
the machine is not used for its intended purpose.
you have identified damage on the machine.
you realize that safety devices of the machine are miss-
ing, damaged or do not function perfectly.
you identify that warning signs and/or safety symbols at
the machine are not available or hard to read.
you identify that structural changes have been made to
the machine.
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2.4. Danger zone
WARNING
Danger to persons in the machine’s danger area due to
movable parts or discharged material.
Personal injury resulting in death may occur.
Ensure that only authorized persons stay in any of the
danger areas.
Only operate the machine if no unauthorized person is in
the corresponding danger area.
Stop operating the machine if unauthorized persons enter
the corresponding danger area.
Use personal protection equipment.
Fig. 1: Danger zones
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PROHIBITION
EXCEPTIONS / NOTES
Zone 1:
2 m (6 ft) in a circle around the machine.
Access for personnel or authorized persons
only allowed if
this is necessary to operate the machine.
the operating manual’s safety instructions
are carefully observed.
Zone 2:
2 m (6 ft) in a circle around the discharge areas of the discharge belts.
Access for personnel or authorized persons
only allowed if
the machine is switched off and secured
against being re-started unintentionally.
Zone 3:
50 m (150 ft) circle around the machine.
Access for third persons only allowed if
such persons have received correspond-
ing safety instruction.
Tab. 1: Danger zones
Note:
Authorized persons are authorized by the machine’s operator
to perform work on or with the machine.
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2.5. Safety devices
DANGER
Danger to persons due to missing or not perfectly functioning safety devices.
Personal injury resulting in death may occur.
Before start of work, check whether all safety devices are
available, correctly installed and functioning.
Never put the safety devices out of operation.
Ensure that all safety devices are freely accessible.
DANGER
Danger to persons due to manipulated safety devices.
Personal injury resulting in death may occur.
Do not perform any mechanical changes to safety devices.
Do not perform any electrical changes to safety devices.
Safety devices (electrics)
Position of safety devices:
Fig. 2: Safety devices - electrics
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SAFETY DEVICES
EMERGENCY-STOPswitch
Main electrical switch
Safety devices (hydraulics)
Position of safety devices:
Fig. 3: Safety devices – lock valves 1
Fig. 4: Safety devices – lock valves 2
SAFETY DEVICE
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Lock valves
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2.6. Structure of warning signs
In the separate chapters of this operating manual your attention
is drawn to hazards or special information with warning signs.
These signs are shown either at a chapter’s start or before an
action involving a potential safety hazard.
The following graphic shows the structure of a warning sign:
Symbol
Signal word
Type of hazard
Consequences in the event of non-observance of the hazard or
danger warnings
Avoiding the hazard
2.6.1. Signal words
SIGNAL WORD
MEANING
DANGER
Passages set off in this manner mark a
direct hazard with high risk of death or
serious injury if not avoided.
WARNING
Passages set off in this manner mark a
possible hazard with medium risk of
death or severe injury if not avoided.
CAUTION
Passages set off in this manner mark a
hazard with low risk that may cause
light or moderate personal injury if not
avoided.
NOTICE
This indicates malfunctions during
oper-ation and possible damage to the
ma-chine or environment.
Furthermore notices are provided for
op-timum handling of the machine.
Tab. 2: Signal words
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2.6.2. Warning symbols
SYMBOL
MEANING
Dangerous point or situation.
Danger electricity, electric shock.
Danger engine exhaust gases.
Danger overhead load
Danger of entanglement by rotating
part.
Danger of entrapment by moving parts.
Danger of harmful or irritant materials.
Danger of flammable materials.
Danger of magnetic field.
Danger of hot surface.
Danger of falling
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SYMBOL
MEANING
Danger of hot liquids.
Tab. 3: Warning symbols
2.6.3. Prohibitory symbols
SYMBOL
MEANING
Unauthorized access prohibited.
Do not climb unless authorized.
Fire, naked flame and smoking prohibited.
Access for persons with pacemaker
prohibited.
Do not spray with water.
Tab. 4: Prohibitory symbols
2.6.4. Command symbols
SYMBOL
MEANING
General command symbol.
Marks instructions for operation
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SYMBOL
MEANING
Read the document carefully before
starting work
Activate before working.
Ear protection
Protects against hearing loss in the
event of procedures with high noise
emission.
Tab. 5: Command symbols
2.6.5. Additional symbols (pictograms) used at the machine
SYMBOL
MEANING
Warning sign:
„Open cover completely“
Warning sign:
Maximum suspension load in kg and
lbs.
Sign:
Marks the battery master switch.
Sign:
Marks a fixing point of a securing de-
vice.
Sign:
Marks a lubrication point.
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SYMBOL
MEANING
Sign:
Attend transport securing devices at
the suction fans and the working platform
Sign:
Marks the positioning point for ladders.
Sign:
Marks the connection point on the ABS
braking unit.
Sign:
Shows the date of the next accident
prevention regulation check.
Sign:
Marks the turning direction of the elec-
tro motors.
Sign:
Indicates the maximum admissible
speed for transport in km/h an.
Tab. 6: Pictograms
2.7. Basic safety instructions
WARNING
Personal injury due to non-observance of basic safety
instructions.
Personal injury resulting in death may occur.
Observe the basic safety instructions always.
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Only use the machine
in technically perfect condition,
for its intended purpose, as well as
aware of safety and danger.
Check all safety devices of the machine before starting work
on or with the machine.
Before starting work on or with the machine, check it for vis-
ible damage (mechanics, electrics, hydraulics).
Store the complete operating manual at the machine’s loca-
tion.
Add to the operating manual with documents, such as the
legal regulations for accident prevention.
Only perform work for which you have acquired basic and
specific knowledge or instruction.
Only perform work you have been authorized by the opera-
tor to perform.
Use personal protection equipment.
2.8. Residual risks
Even if you follow all safety instructions, there are still residual
risks when working at or with the machine.
All persons working at or with the machine have to know these
residual risks.
All persons must follow the instructions to prevent residual risks
leading to accidents or injury.
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DANGER
Danger to persons due to electric shock when touching
defective electric cables, plugs or switches.
Personal injury resulting in death may occur.
Work on the machine’s electrics must only be performed
by an electrical specialist.
DANGER
Danger to persons due to exhaust gases from the diesel
generator.
Danger of death from asphyxiation.
Only operate the diesel generator in surroundings that are
sufficiently ventilated.
If necessary, direct the exhaust gases out of the working
environment using a suitable exhaust system.
WARNING
Danger to persons due to using inappropriate lifting devices.
Personal injury may occur.
Only use approved lifting devices.
Only use lifting devices with a sufficient load bearing ca-
pacity (see operating and maintenance manual, technical
notices for transport / assembly).
Never stay under pending load.
Use personal protection equipment.
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WARNING
Danger of falling when using ladders.
Personal injury resulting in death may occur.
Only put ladders onto the machine if this is not operated.
Only use ladders that are free from visible damage.
Ensure that the underground is appropriate for setting up a
ladder.
WARNING
Danger due to high pressure in lines of lubrication,
pneumatics and hydraulics.
Personal injury may occur.
Before executing work on lines, switch them pressureless.
Use personal protection equipment.
WARNING
Danger of fire due to inflame easily inflammable substances.
Personal injury resulting in death may occur.
Avoid fire, open light and smoking in the direct surround-
ings of the machine.
Do not fill the machine with burning or smouldering materi-
als.
Remove easily inflammable materials from the machine’s
direct surroundings.
Familiarize yourself with the local firefighting conditions.
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WARNING
Danger of being drawn in at moving / turning parts.
Personal injury may occur.
Do not remove the protection covers in any case. If this is
necessary for maintenance or cleaning work, secure the
machine against unwanted starting!
Do not grasp into the moving area of machine parts during
a trial run.
Keep a safe distance from rotating parts when the ma-
chine is in operation!
Always wear appropriate working clothes (e. g. no loose
clothing, in case of long hair, use a hair net).
After termination of work, install the protection covers
again!
WARNING
Danger to persons due to improper handling of lubricating, cleaning or working material.
Personal injury due to skin contact and/or breathing in may
occur.
Use personal protection equipment.
Read the corresponding safety data sheets.
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3. Intended use
All figures and drawings in this operating manual serve exclusively for the general illustration.
If necessary, observe the separately attached operating manuals of the engine manufacturers, which are enclosed as original.
We reserve technical changes due to further development of
the machine described in this operating manual.
READ – UNDERSTAND - OBSERVE!
NOTICE
Danger due to improper use.
The manufacturer’s warranty expires.
Attend the descriptions regarding the „Intended use“.
Attend the descriptions regarding the „Non-intended use“.
3.1. Intended use
The mobile contrary separator serves to separate:
stones and
inert material.
Furthermore, the mobile contrary separator serves to separate:
foils,
paper and
FE-metals.
The grain size of 10 … 20 up to 150mm of the biomass-fuelfraction is allowed as input material.
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Furthermore, the following points belong to the intended use:
The machine’s application within the limits of performance,
mentioned in the technical data.
The machine’s use in the manner described in the operating
manual.
Exclusive operation and care by instructed personnel.
The execution of maintenance and repair work by qualified
personnel.
The execution of cleaning, maintenance as well as repair
work is only allowed when the machine is at standstill.
Spare parts must only be installed according to the
manufacturer’s specifications.
Transporting the machine on public roads, with appropriate
means of transport.
Transporting the machine by qualified personnel.
The exclusive, mechanic feed of the machine.
Use of the full-colour printed version of the operating and
maintenance manual only.
3.2. Non-intended use
The mobile contrary separator does not serve to separate materials, containing coarse components.
The following points do not belong to the intended use:
The transport of persons.
The transport of materials.
The application in potentially explosive atmospheres .
Feeding the machine by hand.
Driving the machine on public roads without using the
equipment and transport safety devices necessary for this.
Moving the machine in public road traffic without a
corresponding personal qualification.
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Moving the machine with inappropriate towing vehicle.
Moving the machine in jacked-up status.
The execution of modification work on the machine, not
permitted by the manufacturer.
3.3. Basics for operation
Before commissioning the machine, it must be prepared for
operation. This contains the following listed activities:
3.3.1. Hand over product documentation
When the machine is handed over, you also receive the operating manual, as per the completion certificate.
Check it for completeness and confirm receipt.
3.3.2. Personnel training
When the machine is handed over, initial training for the machine is carried out. The training must contain the following
points:
Safety instructions.
Controls and functions of the machine.
Carry out, check and change basic settings.
Explanations for use of the operating manual.
Invitation to use the operating manual.
Perform regular safety checks.
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4. Product description
4.1. General information
NOTICE
The information stated here refers to the equipment of
the basic machine.
Owing to changes to the machine, the actual dimensions
may differ from the dimensions stated here.
Observe the information in the additional documents that
have to be added to the documentation after modifications
or changes to the machine.
The notices in this manual are only valid for the machine
with the machine identification number stated on the front
page of the operating manual.
Only the observance of permissible values corresponds to
appropriate use of the machine.
SERIAL NUMBERS
Machine No.:
(HURRIFEX)
96010
Vehicle identification No:
W0909601061KB4038
Motor No.:
1104D-44T
NL75517
U267471A
Tab. 7: Serial numbers
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4.1.1. Unit marking
Fig. 5: Type plate
The type plate (1) and the vehicle identification number (2) are
fixed to the machine’s base frame.
4.1.2. Technical data
TRANSPORT DIMENSIONS
Length
12000 mm (472.44 in)
Width
2550 mm (100.39 in)
Height
4000 mm (157.48 in)
WEIGHT
Permitted total weight
14.0 t (30864.69 lbs)
Permitted axle load per axle
8.0 t (17636.97 lbs)
Permitted bearing load
1 t (2204.62 lbs)
SEPARATION
Throughput capacity
60 m³/h (2118.88 (ft³/h)
DIESEL ENGINE
Power at 1,500 min-1
60.0 kVA
Emission standard
EU 97/68/EG stage IIIa
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Operating voltage
400 V (± 10%)
Number of phases
3 Ph / 400 V / PE
Frequency
50 Hz (± 1%)
Tank volume
approx. 300 l (79.25
gal)
AMBIENT CONDITIONS
Temperature range
-10 °C to +37 °C
(14 °F to 98.6 °F)
EMISSIONS
Noise level (measured under
full load, without material)
98 dB (A)
Tab. 8: Technical data
Fig. 6: Working position dimensions
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4.1.3. Machine equipment
The components of the machine and the possible options are
described here.
BASIC MACHINE
Mobile, electrically driven contrary separator with
integrated windsifter to separate input material into three fractions
Tab. 9: Basic machine
ADDITIONAL OPTIONS
Equipment according to EU Directive: Surrounding lights front and rear; side marking lights; rear
underride guard; splash water protection and
mudflap
Preparation European approval
Certificate for obtaining general license as per
Road Traffic Act (StVZO)
Certificate for obtaining general license as per
Road Traffic Act incl. motor vehicle registration
certificate (StVZO)
Housing feeding belt
Side bar enlargement feeding belt
Discharge belt (inert material) electro-hydraulically
adjustable
Belt elongation discharge belt inert material
Variable belt speed inert material
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ADDITIONAL OPTIONS
Magnet drum in conveyor belt
Diesel generator
Soot filter; self cleaning
Electric motor pre-heating
Cleanfix-fan
Socket for external power supply
Radio remote control, 6-channel
Frequency converter fan separation chamber
Frequency converter for suction fan 1
Frequency converter for suction fan 2
Additional socket 32 amps
Battery disconnecting switch
Air conditioner at switch cabinet
Central lubrication unit
Gusset shoe
Special paint
Tab. 10: Options
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4.1.4. Function of the machine (schematic)
Fig. 7: Functions
By means of mechanical feed, the material to be separated is
filled into the machine’s hopper (1).
This material is transported into the separation chamber (3) by
a transport conveyor (2).
There it is loosened by the pressure fan's (4) air flow, so the
heavy inert fraction (5) is separated from the light biomass fraction.
An optimal air flow within the separation chamber is provided
by a first suction fan (8). Its air suction catches and sucks superficial light material (foils or similar).
The inert fraction (5) falls onto the separation chamber's bottom (3) and is then discharged from the machine via a discharge conveyor (6).
The biomass fraction (7) falls onto a transport conveyor and
brought to the first suction fan (9), removing light material specifically.
The material, purified this way, falls onto a second conveyor by
what it is loosened again. Then it is brought to the second suction fan (10). There, the remaining light material is sucked.
The sucked light materials are collected in separate containers.
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The remaining material is then discharged from the machine at
the end (11) of the conveyor.
4.2. Machine layout
The following is a general description of the machine’s layout.
In the case of location specifications (e.g. right, left, front, rear),
the reference direction is always the driving direction of the
machine.
Fig. 8: Machine overview
POS Description
1 Discharge belt biomass
2 Suction fan 2
3 Suction fan 1
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4 Suction fan to optimize the air flow within the sep-
aration chamber
5 Feeding hopper with feeding conveyor
6 Maintenance flap
7 Discharge belt inert fraction
8 Operating area BP1
9 Parking brake
10 Maintenance flap
11 Engine flap
12 Separation chamber
13 Maintenance flap
14 Conveyor hose
15 Hinged towing bar
16 Tandem chassis
17 Grasping protection of the discharge belt for inert
fraction
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4.3. Controls
Fig. 9: Position of controls
POS Description
1 Operating area - EMERGENCY-STOP-switch
2 Switch cabinet
3 Operating area - EMERGENCY-STOP-switch
4 Operating area BP1
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4.3.1. Operating area BP1
Fig. 10: Operating area BP1 - design
(1)
EMERGENCY STOP switch
Press in case of danger.
To unlock the switch, turn it to the right.
(2)
Starting module
By means of the starting module, the diesel engine (option) is
operated.
(3)
Functioning scheme
Numeric marking of machine components, being started,
resp. whose speed can be adjusted.
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(4)
Controls
The switches and keys required for standard operation are
installed here.
The function of the switch or key is related to the corresponding pictogram.
The key switch may only be used for brush adjustment if the
machine is at a standstill.
The following pictograms can mark the operating elements at
the operating area BP1:
PICTOGRAM
FUNCTION
Control light
„OPERATION“ (green)
Control light
„COLLECTIVE FAULT“ (red)
Cleanfix®
AUS oder EIN
Operation mode
„AUTOMATIC OPERATION | MANUAL
OPERATION“
Machine
„START“
Machine
„STOP“
Discharge belt inert fraction
„UP“ or „DOWN“
Belt extension discharge belt inert fraction
„DOWN“ or „UP“
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(5)
Jack switch
By means of this switch machine components to be started or
whose parameters should be changed, can be chosen.
The number of the corresponding machine component can be
obtained from the functioning scheme.
(6)
Display with function keys
At the display machine parameters can be read or adjusted.
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Design of starting module
Fig. 11: Starting module
(1)
Operating hour counter
Display of the operating hours of the diesel generator.
(2)
Ignition lock
0 = Off
1 = Ignition switched on
2 = Motor start
(3)
Control light (red)
Is not occupied with any function.
(4)
Control light (red) for water temperature.
The control light for water temperature lights up, if the ignition
key is turned to „1“ and then it expires. If the cooling water’s
temperature is too high, the control lamp lights up
continuously. In the case of a too high temperature, the diesel
generator is switched off automatically.
(5)
Control light (red) for motor oil pressure.
The control light for motor oil pressure lights up if the ignition
key is turned to position “1”, and then changes to continuous.
It expires directly after starting the generator. If the oil
pressure is too low, the control lamp lights up continuously. In
the case of too low oil pressure, the diesel generator is shut
down automatically.
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(6)
Control light (red) for battery charging.
The charging control lamp lights up, if the ignition key is
turned to position “1”. The light expires directly after motor
start. In case of a defective alternator or a broken V-belt, the
control lamp lights up and the diesel generator shuts down.
(7)
Control light (green) for ignition.
The control light for ignition lights up, if the ignition key is
turned to position „1“. The diesel generator must not be
started until the control light changes to continuous light. The
control light expires directly after starting the diesel generator.
Layout of display with function keys
Fig. 12: Display with function keys
(1)
Display
In this area, the different machine parameters or error
messages are shown.
(2)
Function keys
By means of these keys, the single machine functions can be
chosen, resp. adjusted directly.
(3)
Status-LED
The status-LED indicates the operating condition of the
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display with function keys.
Colour „green" - error-free operation
Colour „yellow“ - display is started
Colour „red“ - Error message/fault
(4)
OK-key
Error messages are acknowledged by pressing this key.
Fig. 13: Display with function keys - error message
The key has no reset-function.
(5)
Multifunction-key
By means of this key, you can navigate through the separate
display screens.
(6)
ESC-key
The key has no function.
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Display-masks (main level)
Fig. 14: Display with function keys - mask 1
POS Description
1 Tank indication
2 Machine type and machine number
3 Total operating hours
4 Daily operating hours
5 Press function key below to delete daily op-
erating hours.
Fig. 15: Display with function keys - mask 2
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POS Description
1 Schematic image of the machine and its adjusta-
ble components.
Colour
Meaning
White
Machine contour
Grey
Machine component
Grey/blue
flashing
Machine component is chosen to be
started by means of a jack switch.
Blue/green
flashing
Machine component started.
Machine component is still chosen by
means of a jack switch.
Green
Machine component started.
Machine component is not chosen by
means of a jack switch anymore.
Red
Machine component has a failure
2 Indication of the adjusted/current speed of the
chosen machine component.
3 Function key to increase the parameters (pressing
the key for a longer time changes the adjusting
speed stepwise)
4 Function key to decrease the parameters (press-
ing the key for a longer time changes the adjusting
speed stepwise)
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Fig. 16: Display with function keys - mask 2
POS Description
1 Error message
green - no error
red - error has occurred
2 Type of error
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Set the language
Condition:
The machine's power supply is established. (see „Establish
the power supply“, page 65)
Fig. 17: Display with function keys - choose language 1
Press the horizontal arrow keys (1) until the display indica-
tion (2) is shown.
Fig. 18: Display with function keys - choose language 2
Press the key (1) and keep it pressed.
Press the key (2) three times in a row.
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The following indication appears:
Fig. 19: Display with function keys - choose language 3
By pressing the vertical arrow keys (1) to choose the lan-
guage.
The chosen language can be recognized from the corresponding field (2) to be marked in grey.
Confirm the choice by pressing the key „OK“ (4).
Leave this display menu by pressing the horizontal arrow
key (3).
4.3.2. Operating area - EMERGENCY-STOP-switch
Fig. 20: Operating area BP3 and BP4
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(1)
EMERGENCY-STOP-switch
Press in case of danger.
To unlock the switch, turn it clockwise.
4.3.3. Release valve compressed air braking unit
NOTICE
Danger of pressure loss at the braking unit due to a long
standstil or too much activation of the release valve.
The release valve cannot be activated anymore, because of
a too low air pressure in the reservoir. Moving the machine is
impossible anymore.
Couple an appropriate towing vehicle onto the machine, to
establish the supply of compressed air.
Fig. 21: Release valve compressed air braking unit
The release valve (1) serves for draining off compressed air.
The brakes of the tandem axle can be released by activating
the valve, if the unit is to be moved without an air-braked towing vehicle.
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4.3.4. ABS-control – Junction box
Fig. 22: Junction box ABS control
The tandem axle has got an integrated ABS-control. The connection is made via a control cable.
To connect the checking device, a connection plug (1) is fixed
to the side of the machine. Here measuring data for service
work on the ABS-unit can be exchanged.
In case of errors, call the after-sales service of the manufacturer.
4.3.5. Battery master switch
NOTICE
Danger due to improper handling of the battery master
switch.
Damage to the battery at the diesel engine can arise.
Do not switch off the diesel engine by means of the battery
master switch.
Activate the battery master switch only when the diesel
engine is switched off.
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Fig. 23: Battery master switch - position
Prior to every operation switch on the option „Battery master
switch“ (1) and switch it off after operation.
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5. EC Declaration of Conformity
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6. Setting up the machine
6.1. Setting up the machine
DANGER
Dangerous electric voltage due to contact with an electric overhead line when setting up.
Danger to personnel and third parties due to electric shock.
Keep sufficient safety distance to electric overhead lines.
Initiate immediate shutdown of the electric overhead line in
case of contact and observe the following points:
Do not touch the machine.
Do not touch the machine until it is ensured that the
electric overhead line was switched off.
Ensure that nobody enters the danger area.
Expel all persons out of the danger area.
WARNING
Danger to persons due to insufficiently solid and/or level
ground on which the machine is to be placed.
Danger to the personnel’s lives due to the machine, sinking
in or turning over.
Follow the instructions in chapter „Operator“, page 10.
Machine assembly must only be performed by qualified employees of the company Komptech GmbH or authorized specialist companies.
Assemble the machine according to the layout plan.
Ensure that an unhindered and error-free material flow is
possible.
Ensure that the machine is set up in a manner so corre-
sponding free space around the machine exists. This should
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ensure that maintenance and / or repair work can be performed safely.
Connect the machine’s electrical power supply. The power
supply can be provided either via the switch cabinet includ-
ed in the scope of supply or via the customer’s electric sys-
tem.
6.1.1. Free space under the machine
WARNING
Danger to persons due to rubbish or screening being
pulled into the machine, or danger of fire due to the motor’s heat emission.
Personal injury resulting in death may occur.
Ensure that the free space under the machine is always
kept free of rubbish and/or flammable materials.
Fig. 24: Free space under the machine
The area below the machine (2) needs to be kept free of
screenings and impurities constantly.
The areas below the discharge belts (1) are to be kept free of
impurities. Furthermore, screenings must not contact the discharge belts.
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6.1.2. Decouple the machine from the towing device
Secure machine
Fig. 25: Wheel chocks and parking brake
Engage the parking brake (2) (crank to the right).
Place the wheel chocks (1) behind the wheels on both
sides.
Lower supports
CAUTION
Danger of being squeezed when lowering the supports.
Damage to persons can arise.
Keep distance to the supports when lowering.
Ensure, that no unauthorized persons stay within the ma-
chine's danger zone.
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NOTICE
Danger due to a non-horizontal alignment of the machine.
Damage to the machine may occur.
The separation performance is negatively affected.
Check the machine’s alignment before each use.
Fig. 26: Support winch
Crank down the support winch (1).
Disconnect the connections
Fig. 27: Cable plug and hose connections
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Disconnect the following connections (1)
the compressed air connections,
the electrical connections and
the ABS connection
to the towing vehicle.
Decouple the machine from the towing vehicle.
6.1.3. Setting up the working platform
WARNING
Danger of falling when setting up the working platform.
Personal injury resulting in death may occur.
Ensure the underground to be appropriate for setting up a
ladder.
Ensure that all securing devices are fixed to the working
platform correctly.
Fig. 28: Set up working platform 1
The machine is equipped with a working platform (1), being situated between suction fan 1 and 2.
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To set up the working platform, place the ladder (2) only at
the points, marked at both sides and hook it into the working
platform.
Fig. 29: Set up working platform 2
Remove all protective bolts (1).
Fig. 30: Set up working platform 3
Fold up the side parts (1) of the working platform on both
sides of the machine.
Secure the side parts (1) with the protective bolts (2).
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Fig. 31: Set up working platform 4
Ensure the door to be locked and secured (1) when entering
the working platform.
6.1.4. Bring the machine into working position
DANGER
Danger to persons due to electric shock when touching
defective electric cables, plugs or switches.
Personal injury resulting in death may occur.
Inform the operator of electrical defects you have identi-
fied.
Secure the machine against being switched on until the
defects have been eliminated.
Work on the machine’s electrics must only be performed
by an electrical specialist.
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WARNING
Danger to persons due to unsafe machine operation, after damage during transport.
Danger of death for persons.
After setting up, check the machine for visible mechanical,
electric or hydraulic damage.
Inform the operator immediately if you identify any dam-
age.
Do not perform any further work on or with the machine.
Secure the machine against being switched on uninten-
tionally.
Bring the towing bar into working position
NOTICE
Danger of collision between the transport vehicle (e.g.
wheel loader) and the towing bar when clearing the discharge area of the biomass discharge belt.
Machine damage can arise.
Always, fold the towing bar away from the machine com-
pletely before operating.
Fig. 32: Towing bar – loose screwing connection 1
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Open the folding mechanism (1) as described following.
Fig. 33: Towing bar – loose screwing connection 2
Remove the locking pin (1).
Remove the safety splints (3)
Loose both screwing connections (2).
Fig. 34: Towing bar – working position
Open the folding mechanism (1).
Fold the towing bar (2) back until stop.
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Fix exhaust hoses
WARNING
Danger of falling when using ladders.
Personal injury, resulting in death can occur.
Ensure the underground to be appropriate for setting up a
ladder.
Ensure the person to be physically able to realize the fol-
lowing tasks at a ladder/working platform.
Fig. 35: Fixing spouts conveyor hose
Loose the transport securing device (1) from the fixing spout
(2).
Fold on the fixing spout (2) and fix it to the suction fan with
the span lock (3).
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Fig. 36: Assemble conveying hose
Fix the conveying hose to the fixing spout of the suction fan
by means of the span locks (1).
Lead the conveying hose into an appropriate container and
cover it.
Protective net below diesel engine
Fig. 37: Protective net below diesel engine
Fix the protective net (1) at the machine frame below the
engine compartment.
Thus, a sucking of garbage by the pressure fan is avoided.
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Establish the power supply
DANGER
Danger to persons due to electric shock when connecting or disconnecting the electrical power supply.
Personal injury resulting in death may occur.
Ensure that the machine is not under voltage when con-
necting or disconnecting the power supply.
The machine’s generator is switched off.
The machine’s main switch is switched off.
NOTICE
Risk of flashovers between the contacts when connecting or disconnecting the plug connection.
Damage to electrical contacts may occur.
Ensure that the machine is not under voltage when con-
necting or disconnecting the power supply.
The machine’s generator is switched off.
The machine’s main switch is switched off.
Fig. 38: Battery disconnecting switch - position
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Switch on the option „battery master switch“ (1).
Fig. 39: Operating area BP1 - ignition key
Open operating area BP1, insert the ignition key (1) and
start the machine.
Fig. 40: Switch cabinet - electro main switch
Open the front maintenance flap (1).
Turn the electro-main switch (2) to the position „I/ON“.
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Bring the biomass conveyor to working position
Conditions:
The machine's power supply is established (see chapter
„Establish the power supply“, page 65).
Then:
Fig. 41: Biomass belt, 1
Ensure the towing bar (1) to be in working position.
Turn the switch at the operating area BP1 (2) to the
right until the belt elongation (3) is folded away until it hangs
vertically.
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Fig. 42: Biomass belt, 2
Loose the two lockings (1) and let the belt cover (2) slide
down carefully.
Turn the switch at the operating area BP1 to the right
until the belt elongation is completely folded up.
Fold away the discharge belt of inert material electrically (option)
Preconditions:
The machine's power supply is established (see chapter
„Establish the power supply“page 65).
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Then:
Fig. 43: Fold away discharge belt for inert material
Turn the switch at the operating area BP1 (1) to the
right until the discharge belt (2) is completely folded away.
Final works
Ensure all maintenance flaps of the machine to be closed.
Ensure all operating areas to be closed.
Switch off the machine.
Turn the electro main switch to position „0/OFF“.
Remove the key.
Switch off the option "Battery master switch“.
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For the first commissioning request a mechanic from the retailer or manufacturer.
Komptech
Umwelttechnik Deutschland GmbH
Carl-Zeiss-Straße 2
D-59302 Oelde
[t] (+49) 25229345 - 0
[f] (+49) 25229345 - 45
http://www.komptech.de
info@komptech.de
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7. Operation
WARNING
Danger to persons due to operating the machine improperly and not aware of danger.
Death or serious injury may occur.
Follow the instructions in chapter „Operator“,page 10.
7.1. Operating modes
7.1.1. Automatic mode
Automatic mode serves as normal operation mode. This guarantees that the unit is started and emptied in the technologically correct order.
If a component fails, the machine is immediately brought to a
complete stop. Safe operation of the unit is therefore guaranteed.
You do not have to intervene in this automatically running
screening process if the right presets have been made for the
given material.
Changing the material, the occurrence of obstructions, or unsuitable settings may necessitate a correction of the settings.
To do so, the corresponding functions are available directly in
the automatic mode.
7.1.2. Manual mode
When operating in manual mode, the individual components
can be switched on or off independently of each other to check
that the components function or to perform maintenance and
repair.
If the stop-button is pressed, all operated components are
stopped.
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If you leave the display "Manual operation" in the main operating area, all operated components are stopped.
The speed of the individual components is freely adjustable in
this operating mode.
If a component fails, the machine is immediately brought to a
complete stop.
Manual mode does not serve as normal operating mode.
Fig. 44: Operating area BP1 - manual operation - select components
The components‘ selection is realized via the jack switch (1) in
combination with their numbered images (2).
The selected component is operated by pressing the button
(start).
By pressing the button (stop) the started components
are stopped.
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7.2. Start and stop in automatic operation
NOTICE
Ensure that the machine is in a perfect operating condition.
Damage to machine can arise.
Prior to every operation, realize the „Preparation for daily
operation“, see page 83.
NOTICE
At ambient temperatures below +1°C (33.8F) there is an
increased danger of the machine icing up .
Machine damage or errors in operation may occur.
Prior to commissioning, ensure that movable machine
parts are not frozen up.
Ensure that the machine is carefully emptied before breaks
or longer periods of standstill so the material cannot freeze
onto the machine.
NOTICE
Danger due to wrongly selected parameters of machine
components.
Damage to machine can arise.
Attend, that the electric components start with the speed,
set at the previous stop of the machine.
If necessary, change the parameter of the machine com-
ponent before start (see chapter 7.3.1, page 76).
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7.2.1. Start machine
Preconditions:
The machine is in working position (see chapter „Bring the
machine into working position“ page 60).
The machine’s power supply is connected (see chapter
„Establish the power supply“ page 65).
The key switch (AUTOMATIC OPERATION |
MANUAL OPERATION) is turned to position
(AUTOMATIC OPERATION) at operating area BP1.
Then:
Press the button (Start).
The control light (operation) starts flashing.
The control light (operation) lights continuously, if all
machine components are started.
The material feed can now be started according to the intended
use (see page 27).
7.2.2. Stop machine
To stop the machine running in automatic mode systematically,
proceed as follows:
Stop the material feed into the machine.
Empty the machine and ensure, that there is no material
within the machine resp. on the belts.
Press the button (stop) at the operating area BP1.
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Option „Diesel engine“:
Fig. 45: Operating area BP1 - stop machine
Stop the diesel engine, by turning the key at the starting
module (1) to position „0“.
Turn the key switch (Automatic operation | Manual
operation) at the operating area BP1 to position
Fig. 46: Switch cabinet - stop machine
Turn the electro main switch (2) to position „0/OFF“.
Close the maintenance flap (1).
Remove the key(s) from the starting module and store
it/them safely.
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7.3. Optimizing the adjustments for automatic operation
7.3.1. Electric components
By means of potentiometers, the performance of the
feeding belt,
pressure fan (fan of separating chamber) (option),
suction fan 1 (option),
suction fan 2 (option) and
discharge belt for inert material (option)
can be adjusted infinitely.
The adjustment can be realized as follows:
Establish the machine's power supply (see „Establish the
power supply“, page 65).
Before starting the machine, adjust the potentiometer to the
desired values and start the machine.
or
change the values, adjusted at the potentiometers during the
machine operation.
Fig. 47: Optimizing adjustments
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On the basis of the functioning scheme (2), choose the
component to be set.
Set the component's number at the jack switch (1).
Change the component's speed by pressing the correspond-
ing function key (3).
left key - decrease speed
right key - increase speed
7.3.2. Mechanic components
Adjust the height of the suction fan
Fig. 48: Adjust suction fan
The distance between the conveyor belt and the suction fan is
adjusted by means of the manual winch (1).
Turn the manual winch (1) clockwise, to enhance the
distance.
Thereby, the suction performance is decreased.
Turn the manual winch (1) anti-clockwise, to reduce the
distance.
Thereby, the suction performance is increased.
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By means of the fixed scale, adjustments, based on experience
values, can be made, resp. these values are determined and
recorded.
7.3.3. Settings at the suction fans
Fig. 49: Adjust suction fan
There are flaps situated at both suction fans (area 1 and 2).
They are used to optimize the air flow.
Fig. 50: Adjust suction fan 1
By means of the adjusting chain, adjust the flaps, so the
distance (B) between the flaps and the material on the
biomass discharge belt is the most possible little.
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Fig. 51: Adjust suction fan 2
The adjusting mechanics (1) are situated behind the maintenance opening, with which you can adjust the flaps in the suction fan.
The lower the distance (A), the higher the air flow's speed.
Inclination of the separating device
Fig. 52: Adjust suction fan
The separating device's adjusting mechanism (1) and the fixing
mechanism (2) are situated behind the maintenance flap (3).
Loose the screw of the fixing mechanism (4).
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Fig. 53: Adjust the separation device's inclination
The separating device's adjusting angle can be adjusted infinitely within a determined range.
Change the adjusting angle until the separation result is sat-
isfying.
Turning direction of crank to direction „1“ => separating
device inclines to direction „B“.
Turning direction of crank to direction „2“ => separating
device inclines to direction „A“.
Tighten the screw of the fixing mechanism again.
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8. Emergency
WARNING
Danger to persons due to switching on the machine, although the danger or its source is not yet eliminated.
Death or serious injury may occur.
Secure the machine against unauthorized re-starting.
Attach corresponding notice signs to the operating panel.
Inform the personnel, being on site about the reason of
shutdown.
8.1. Damage to persons
If a danger to life and health of persons exists, the following
steps must be performed immediately:
Press the EMERGENCY-STOP-switch.
Take precautions against early re-starting of the machine.
As far as necessary, undertake First Aid or measures to
avoid danger or injury.
Make an emergency call (rescue service, fire brigade, po-
lice) or assign someone to make the emergency call.
Inform the supervising personnel/superior and the ma-
chine’s operator immediately.
Do not unlock the EMERGENCY-STOP-switch until the
danger is past and the source or cause has been found and
eliminated.
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8.2. Damage to machine
If there is a danger to the machine, the following steps must be
performed immediately:
Press the EMERGENCY-STOP-switch.
Take precautions against early re-starting of the machine.
Inform the supervising personnel/superior and the ma-
chine’s operator immediately.
Only eliminate damage if authorized by the operator to do
so and if you are specially qualified to eliminate such dam-
age.
Do not unlock the EMERGENCY-STOP-switch until the
danger is past and the source or cause has been found and
eliminated.
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9. Annex
9.1. Preparation for daily operation
In the following chapters, we explain the checking and maintenance works, being necessary every day before commissioning.
After termination of checking and maintenance works, all
maintenance doors and flaps are to be closed again.
9.1.1. Checking the machine’s stability
Check whether the machine has not sunk into the under-
ground.
Check whether the parking brake is tightened.
Check whether the machine stands approximately horizon-
tally.
Check that the wheel chocks are placed behind the wheels.
Ensure that there are no impurities or screenings below the
machine.
9.1.2. Checking the mechanics
Checks at the machine, switched off and secured against restarting:
Ensure, that there are no foreign bodies on the feeding
chute and the conveyor belts.
Secure that the screwing connections are firmly tightened.
Secure that the machine does not show any visible damag-
es.
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9.1.3. Checking for working materials, running out
Secure that the machine does not show any leakages in the
hydraulic system.
Secure that the machine does not show any leakage of oil.
Secure that the machine does not show any loss of fuel.
Secure that the machine does not show any loss of cooling
liquid.
9.1.4. Checks at the diesel engine (option)
NOTICE
Danger due to works at the diesel engine, realized improperly.
Damage to machine can arise.
Attend the indications of the manufacturer documentation,
being attached to this manual.
Principally ensure, the
engine compartment,
cooler,
suction system and
generator
to be free of contamination and cleaned regularly.
Attend the descriptions in the maintenance manual.
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Cooling water
Fig. 54: Level of cooling liquid
Ensure that there is sufficient cooling liquid in the cooler (1).
Engine oil level
Fig. 55: Check motor oil level
Check the oil level with a dipstick (3). The filling level has to
be above the marking of minimum quantity.
If necessary, fill motor oil into the filling opening (1) (see
chapter „Maintenance manual“).
If necessary, change the oil filter (2) (see chapter „Mainte-
nance manual“).
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Water pre-separator
Fig. 56: Water pre-separator
Check, whether the water pre-separator (2) in the fuel line
has to be emptied and if necessary empty the water pre-
separator.
Check, whether the filter insert of the fuel filter (1) or the wa-
ter pre-separator (2) has to be changed (see chapter
„Maintenance manual“).
Air filter contamination display
Fig. 57: Air filter contamination display
Check, whether the air filter contamination display (1) shows
a red stripe.
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If a red stripe is shown, clean or replace the air filter (filter
element) (see chapter „Maintenance manual“).
Air filter
Fig. 58: Air filter – dust valve
Press the dust valve (1) on the sides. Thereby the dust, col-
lected by the inner pre-separator, is removed out of the filter
housing.
Generator
WARNING
Dirt within the generator can inflame, resp. cause a
short-circuit.
Damage to persons due to burnings can arise.
Check the generator’s protection cover regularly for con-
tamination.
Clean the protection cover of the generator if this is con-
taminated.
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Fig. 59: Clean generator
Check the generator’s covers (1) for contamination and
clean them, if necessary.
9.1.5. Checking the fuelling
NOTICE
In the case of a tank not filled completely, the possibility
of condensation water in the tank exists.
Condensation water can lead to corrosion (rust) in the tank.
By and by this can lead to a leakage in the tank resp. to motor damages.
At the end of the working day, fill up the tank completely.
In the case of a longer stand still of the unit it is absolutely
necessary that the tank is filled completely.
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Fig. 60: Check the tank filling level
Turn the key of the starting module (1) at the operating area
BP1 to position 1 („ignition on“).
The current filling level of the diesel tank can be obtained from
the tank display (2).
If the tank's filling level decreases below approx. 10%, an error
message appears at the display with function keys.
9.1.6. Checking the electrics
Checks at the machine, switched off and secured against
unauthorized re-starting.
Check, whether all electric connecting cables lay freely.
Free up squeezed cables. Damaged cables must be re-
placed.
Ensure the cooling openings of the electro motors are not
contaminated – if necessary clean them.
Checks at the machine, switched on:
Check the functionality of the switches.
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Checking the safety devices
Also attend the descriptions regarding „Safety devices“, page
15.
Secure that all safety devices (EMERGENCY-STOP-
switches and electro main switch) are
available,
undamaged and
not manipulated.
Check the function of all safety devices at the machine,
switched on.
Press the EMERGENCY-STOP-SWITCH (unlock by turning
it clockwise).
After activating a safety device the machine has to be decom-
missioned immediately.
9.1.7. Checking the hydraulics
Fig. 45: Hydraulic unit
Check the filling level (1) at the hydraulic tank – if necessary
refill hydraulic liquid.
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Lock valves:
Fig. 61: Safety devices – lock valves 1
Fig. 62: Safety devices – lock valves 2
Check the lock valves (1) for leakage.
9.1.8. Checks at the belts
Realize the following checks at all discharge and conveyor
belts:
Visual check for damage.
Visual check of belt spanning.
Visual check of straight running.
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Visual check for oil leakage at the drive motors.
Visual check of scrapers.
9.2. Prepare machine for transport
DANGER
Danger to persons due to incorrectly closed and secured folding mechanism.
Damage to persons and death can result from a folding
mechanism, opening during transport.
Tighten the two screwings with a torque of 120 Nm (88.51
ft lbs) .
Secure the screwings with corresponding securing media.
WARNING
Danger to persons due to transport and setting up of the
machine performed incorrectly and without awareness
of danger.
Death or serious injury may otherwise occur.
Only carry out changes of location with the machine after
being instructed by the operator.
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WARNING
Danger to persons due to a not perfect machine condition, related to traffic.
Death or serious injury may otherwise occur.
Prior to every transport check the
connections of vehicle electrics,
compressed air connections,
functionality of the braking unit,
functionality of the illumination unit and
signal devices for perfect condition and functionality.
Prior to every transport check the tyre pressure (8.0 bar /
116.03 psi).
Ensure that the wheel nuts are tightened with a torque of
270 Nm (199.14 ft lbs) .
In new machines, check the torque of the wheel nuts after
approx. 50 - 100 km (31.07 - 62.14 mi).
Ensure, that the screws of the towing eye are correctly
tightened.
NOTICE
Damage due to improper transport do not authorize for spare
or (liability) guarantee claims ".
Preconditions:
The machine is in working position (see chapter „Bring the
machine into working position“ page 60).
The machine's power supply is established (see chapter
„Establish the power supply“ page 65).
Then:
Stop the material feed to the machine.
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Empty the machine and secure that there’s no material in the
machine or on the belts anymore.
Press the button (stop) at the operating area BP1 (see
chapter 7.2.2 „Stop machine“, page 74).
Remove the exhaust hoses and the cover net (reverse order
as described in chapter „Fix exhaust hoses“, page 63).
Disassemble the working platform (reverse order as
described in chapter 6.1.3, „Setting up the working
platform“, page 58).
Get the towing bar to transport position (reverse order as
described in chapter „Bring the towing bar into working
position“, page 61).
Get the biomass discharge belt to transport position (re-
verse order as described in chapter „Bring the biomass
belt into working position“, page 67).
Get the discharge belt for inert material to transport position
(reverse order as described in chapter „Fold away the
discharge belt of inert material electrically (option)“,
page 68)
Couple the machine onto an appropriate towing vehicle
(reverse order as described in chapter 6.1.2, „Decouple the
machine from the towing device“, page 56).
Realize the final works (see chapter 69).
Clean the unit carefully, prior to a transport on public roads.
Prior to transport, check the machine’s equipment.
Prior to transport, secure that there are no
persons,
separation residuals and
foreign bodies
in or at the machine anymore.
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9.3. Functioning description of options
NOTICE
Purchased parts are only described on basic terms in this
operating manual.
Special adjusting and maintenance works at the purchased
parts are impossible corresponding to the description in this
operating manual.
Attend the manufacturer's documents for
the central lubrication unit,
the diesel engine,
the radio remote control,
the electric motor pre-heating,
the cleanfix fan and/or
the soot filter,
which you can find in the annex „operating manuals of
suppliers“ in case of the machine's corresponding equip-
ment.
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9.3.1. Version in accordance with the EU Directive
Fig. 63: Version in accordance with EU Directive
POS Description
1 Rear underride protection (rear light bar)
2 Side marking lights
3 Surrounding lights front
4 Splash water protection / mudflap
Function:
This machine equipment is the basis for creating the certificate
to obtain the general license, according to the Road-Traffic-Act,
as well as the creation of a motor vehicle registration certificate.
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9.3.2. Adjustable belt speed at discharge belt
Fig. 64: Adjustable belt speed
Function:
The adjustable belt speed serves to change the conveying
speed at the discharge belt infinitely.
For this, a frequency converter (1) is installed within the machine's switch cabinet. It changes the conveying speed from
minimum to maximum.
The adjustment of the belt speeds is realized at the display with
function keys, being situated at the operating area BP1.
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9.3.3. Housing for feeding belt
Fig. 65: Housing for feeding belt
Function:
The housing (1) serves as protection against wind for the feeding area and consists of a robust tarpaulin.
9.3.4. Side bar enlargement feeding belt
Fig. 66: Side bar enlargement
Function:
The side bar enlargement (1) optimizes the material feed.
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9.3.5. Discharge belt electro-hydraulically foldable
Fig. 67: Discharge belt electro-hydraulically foldable
Function:
Due to this construction group, the discharge belt (1) is folded
on, resp. away electro-hydraulically.
The function is activated at the operating area BP1 (2) with the
switch .
9.3.6. Adjustable belt speed inert material
Fig. 68: Adjustable belt speed inert material
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Function:
By means of the frequency converter (1), the speed of the discharge belt can be adjusted.
The speed is set at the display with function keys, being situated at the operating area BP1.
9.3.7. Magnet drum
DANGER
Danger to persons, due to the magnet drum’s magnetic
field, able to lead to a breakdown or influence of a
pacemaker.
Danger to lives of persons.
Persons with pacemakers must not stay near the magnetic
roller.
The discharge belt must be marked with the labels, used in
this warning indication, in the direct proximity of the magnetic roller.
Fig. 69: Magnet drum
POS Description
1 Magnet drum
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