Mobile screening machine

Transcription

1 Mobile screening machine on tandem chassis Model description : NEMUS 2700 Machine number : Year of manufacture : 2015 Copyright 2015 Komptech Umwelttechnik GmbH. All rights reserved. Print: 03/2015 Translation: Betriebsanleitung_Nemus_2700_Version5_gb

2 NOTICE Before you execute any works at or with the machine, read the entire operating manual carefully! Only use the machine for its intended purpose! Attend all safety instructions, described in this operating manual. Page 2 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

3 Structure of the entire operating manual Operating manual (this chapter) 1. Preface 2. Safety 3. Overview and intended use 4. Function 5. EC-Conformity declaration 6. Transport and setting up 7. Operation 8. Emergency Maintenance manual (separate chapter) 9. Maintenance / Cleaning 10. Error, cause, correction 11. Disassembly / Disposal Betriebsanleitung_Nemus_2700_Version5_gb Page 3 of 146

4 Contents 1. Preface Safety Operator Qualification of personnel The personnel s obligations Danger area Safety devices Structure of warning signs Signal words Warning symbols Prohibition symbols Command symbols Symbols (pictograms) used at the machine Rescue and fire protection signs Basic safety instructions Residual risks Overview and use of the machine Product identification Overview Unit marking Product description Intended use Non-intended use Technical data Equipment of the machine Function Functioning description of the machine Functioning description of options Version according to EU-regulations Preparation for European approval Screening systems Screening drum Center drum Adjustable belt speed Magnet drum Hydraulic connection Hopper pre-screen Gusset shoe Wiper for cleaning brush Central lubrication unit Electric oil cooler Radio remote control - 10-channel resp. 12-channel Electric motor pre-heating Page 4 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

5 Carbide wiper at fine grain collector belt Motor unit hydraulically movable Manual hydraulics Air suspension Positioning unit Hopper-sensor-control Tandem carrier wheels Additional hydraulic rear support Cleanfix -fan Segment screening drum outer wiper Soot filter Battery-disconnecting switch Preparation for screening drum SM Adapter race for screening drum SM EC-Conformity declaration Transport and setting up Prepare machine for transport Empty the machine Secure discharge belts Couple the unit onto the towing machine Final works for transport security Check scope of supply Report transport damages Intermediate storage and wintering Setting up the machine Decouple the machine from the towing device Fold down discharge belts Operation Operating elements Operating elements Overview operating areas Operating elements - Operating area Operating elements Operating area 1 (Display with function buttons) Operating elements Operating area Operating elements Operating area Operating elements Operating area EMERGENCY-STOP-SWITCH Operating elements Filling level screening drum Operating elements Speed fine grain collector belt Operating elements - Regulation of the discharge belts speed (option) Operating elements - Release valve compressed air braking unit Operating elements - ABS-control Betriebsanleitung_Nemus_2700_Version5_gb Page 5 of 146

6 7.2. Commissioning Basics for operation Hand over product documentation Education of personnel Preparation for commissioning Free space under the machine Checking the machine s stability Checking the mechanics Checking for working materials, running out Checking the hopper belt Checks at the diesel motor Checking the hydraulics Checking the fuelling Checking the electrics First commissioning Adjust language (Display with function buttons) Operation modes Daily commissioning in automatic operation Optimization of machine parameters Diesel engine - Change revolution Hopper belt Change speed Screening drum Change revolution Screening drum Optimize filling grade Reverse hopper belt Manual operation Basics for manual operation Machine components for manual operation Display with function buttons Manual operation Choosing, starting and stopping the machine components Modification to the screening drum type SM Shut down Switching off the machine Emergency Damage to persons Damage to machine Index 145 Page 6 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

7 1. Preface Dear Customer! Thank you for the confidence that you have shown in our products by purchasing this machine. Purpose of the opera ting manual This operating manual is a guide for safe and efficient use of the machine. The purpose of this operating manual is to avoid damage to persons and machine. We have taken care, with the necessary information, that the operation and maintenance of the machine is easy to carry out. Furthermore we want to familiarise you with the technical details of the machine and point out any risks and dangers at the same time. WARNING Danger due to operating the machine without studying the operating manual before. Damages to human and machine can result. Prior to commissioning the machine read the operating manual. You have to understand and attend all safety instructions! Persons, entrusted with the machine must always be able to access the operating manual! Availability of the operating manual Please make sure that the availability of this operating manual is ensured, 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 overhand the entire documentation together with the machine! Never commission the machine, without having read the operating manual before! Betriebsanleitung_Nemus_2700_Version5_gb Page 7 of 146

8 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 has to be translated into the language of the corresponding user's country. Translation Should any discrepancies occur in the text translated, the original operating manual (German) is to be consulted for clearance or the manufacturer is to be contacted. Pictograms Information directly on site available, without having to look up in separate manuals. Contact us in case of damaged, loose or illegible pictograms. These are to be replaced immediately with new ones. They contain important information for safety and for machine maintenance. The operator is responsible to make sure that only qualified personnel operate and maintain the machine. Both the operator and the complete service and maintenance personnel have to be completely familiar with the safety and operation regulations. The machine operator has to read this operating manual before starting the machine, and to exactly follow the directives contained. Please prevent incorrect start up or maintenance work. If in any doubt please contact our customer service: Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Straße 2 D Oelde [t] (+49) [f] (+49) info@komptech.de Page 8 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

9 Copyright Copyright 2015 Komptech Umwelttechnik Deutschland GmbH. All rights reserved. This operating manual or extracts thereof may not be printed, copied, reproduced, electronically processed or distributed without prior written approval of Komptech Umwelttechnik. Trademark protection The Komptech brand, logo, beech leaf and word mark Technology for a better environment are registered trademarks and the intellectual property of Komptech GmbH. Technical changes This operating manual is only valid for the machine serial number entered in the folder and is not subject to updating! The operator is responsible for keeping up to date on the latest conversions, supplementary units or changes! The date on the EC-Conformity declaration is representative for the edition of this operating manual. Kind regards, Bernd Thielepape (General manager Komptech Umwelttechnik Deutschland GmbH) 2. Safety Markings by safety advices The systematic marking of certain points (danger locations, lubrication points, adjusting interval, displays, operation elements) by safety advices provides a safe use of the machine. This marking is executed with the same pictograms as shown in this operating manual. Betriebsanleitung_Nemus_2700_Version5_gb Page 9 of 146

10 WARNING Danger due to commissioning the machine by nonattending the safety instructions, resp. the execution of maintenance works by unqualified personnel. Serious personal and material damages can result. Commissioning the machine as well as maintenance works must only be carried out by qualified persons, attending the safety instructions Operator Operator s obligations As operator you are responsible for the specified use of the machine. The specified use comprises operation and maintenance of the machine. The operator has to comply with the legal requests on operating working machines. The operator confirms the executed instruction about the safe use of the machine to the manufacturer. The operator has to familiarise with the contents of the operating manual and comply with the instructions contained in it. The operator plans and takes the responsibility for the use of the machine within the limits of specified use. The operator takes the responsibility for the reliable and functional condition of the machine. The operator makes sure, that the machine is only operated by persons whose mental and physical conditions satisfy the task assigned. The operator avoids unauthorised modifications and obtains an expert s opinion before any modification. In the case of safety defects the operator informs the manufacturer or seller. Page 10 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

11 In the case of loss of the operating manual or the safety markings (loose or illegible pictograms) the operator takes care for the reorder in time. In the case of resale the operator takes care for the reliable and demonstrable transfer of the complete operating manual to the buyer. The operator has to execute a noise measurement under operating conditions and if necessary to supply the corresponding hearing protection Qualification of personnel Qualification of personnel Exclusively the following groups of persons are allowed to work at or with the machine: Instructed personnel Persons who were trained by a specialist and instructed about possible dangers, appropriate behaviour, inappropriate behaviour, protection devices and protective measures. Specialists Persons who have the following qualifications: professional education, professional experience and knowledge about the relevant standards and regulations. These persons are able to evaluate the works delegated to them according to existing and possible dangers, themselves. Betriebsanleitung_Nemus_2700_Version5_gb Page 11 of 146

12 (Definition according to EN ) Operating manual 2.3. The personnel s obligations The personnel s obligations 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 according to working protection and operation safety. Wear the personal protection equipment determined according to the risk assessment. Before executing works at or with the machine, read the operating manual. Refrain all working methods, causing hazards to persons or damages to machine or environment. Execute maintenance and inspection works only according to the operating manual s descriptions. Secure that escape routes are free. Execute changes of locations only after the operator s instructions. Inform the machine s operator immediately, if the machine is not used for its intended purpose. you recognized damages at the machine. you realise, that safety devices of the machine are missing, damaged or do not function perfectly. you realise, that warning signs and/or safety symbols at the machine are not available or hard to read. you realise, that structural changes at the machine have been made. Page 12 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

13 2.4. Danger area WARNING Danger to persons, staying in the machine s danger area, due to movable parts or discharged material. Personal damages and death can arise. Secure that only authorized persons stay in the separate danger areas. Only operate the machine if no unauthorized person stays in the corresponding danger area. Stop operating the machine if unauthorized persons enter the corresponding danger area. Wear the necessary personal protection equipment. Fig. 1: Danger area Betriebsanleitung_Nemus_2700_Version5_gb Page 13 of 146

14 PROHIBITION EXCEPTIONS / NOTES Zone 1: Access strictly forbidden! Zone 2: Access strictly forbidden! Zone 3: Access forbidden! Access for personnel or authorized persons only allowed if conveyor belts are switched off and the operating manual s safety instructions are especially attended.. Access for personnel or authorized persons only allowed if this is necessary for the machine s operation. Access for personnel or authorized persons only allowed if conveyor belts are switched off and the operating manual s safety instructions are especially attended. Zone 4: Access strictly forbidden! Access for personnel or authorized persons only allowed if this is necessary for the machine s operation. the operating manual s safety instructions are especially attended. Zone 5: Access forbidden! Zone 6: Access forbidden! Access for personnel or authorized persons only allowed if The operating manual s safety indications are especially attended. The stay of thirds in the vicinity of 15m (45ft) around the machine is generally prohibited! Access of thirds in the vicinity of 50m (150ft) around the machine only allowed, if they had a corresponding safety instruction! Tab. 1: Danger areas Page 14 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

15 Note: Authorized persons are authorized by the machine s operator to execute works at or with the machine. Betriebsanleitung_Nemus_2700_Version5_gb Page 15 of 146

16 2.5. Safety devices DANGER Danger to persons due to missing or not perfectly functioning safety devices. Personal damages and death can result. Before start of work, check whether all safety devices are available, correctly installed and functioning. Never put the safety devices out of operation. Secure that all safety devices are freely accessible. DANGER Danger to persons due to manipulated safety devices. Personal damages and death can result. Do not execute any mechanical changes at safety devices. Do not execute any electrical changes at safety devices. Fig. 2: Safety devices Page 16 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

17 Safety device Interval Checks Method EMERGENCY-STOP- SWITCH t F Tab. 2: Safety devices (Electrics) t - daily m - monthly w - weekly F - functioning check 2.6. Structure of warning signs In the separate chapters of this operating manual your attention is drawn to hazards or special information due to warning signs. These signs are shown either at a chapter s start or before an action, involving a source of hazard. Betriebsanleitung_Nemus_2700_Version5_gb Page 17 of 146

18 The following graphic shows the structure of a warning sign: Signal word Symbol Type of hazard Consequences in the case of non-attending the danger sign. Avoiding the hazard Signal words SIGNAL WORD DANGER WARNING CAUTION NOTICE MEANING Passages set off this manner, mark a direct hazard with high risk, having the consequence of death or severe injury, if this is not avoided. Passages set off this manner, mark a possible hazard with medium risk having the consequence of death or severe injury, if this is not avoided. Passages set off this manner, mark a hazard with low risk, having the consequence of light or medium personal damage, if this is not avoided. This marks errors during operation or it gives instructions to the optimized handling of the machine. Furthermore indications are given to optimise the machine s handling. Tab. 3: Signal words Page 18 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

19 Warning symbols SYMBOL MEANING Warning against a hazard area or dangerous situation. Warning against dangerous, electrical voltage. Warning against the danger of being crushed due to moving parts. Warning against the danger of being drawn in due to turning parts. Warning against substances harmful to health or irritant. Warning against pending load. Warning against inflammable materials. Warning against hot surfaces. Warning against motor exhaust gases. Warning against hot media (e. g. hot liquids). Warning against danger due to batteries. Betriebsanleitung_Nemus_2700_Version5_gb Page 19 of 146

20 SYMBOL MEANING Warning against hand injury. Warning against falling down Prohibition symbols Tab. 4: Warning symbols SYMBOL MEANING Sprinkling with water is prohibited. Access for unauthorized is forbidden. Climbing for unauthorized is forbidden. Fire, open light and smoking is forbidden. Prohibition of absorbing drugs, affecting the normal physical and psychologic condition. Tab. 5: Prohibition symbols Page 20 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

21 Command symbols SYMBOL MEANING General command symbol. Marks instructions for operation. Read the document unconditionally before executing works. Activate before working. Tab. 6: Command symbols Protection goggles with side shields Protect against injuries to the eye due to solids, liquids or gaseous substances. Safety shoes Protect against crushings and parts falling down. Close fitting working clothes Protect against getting caught or drawn in. Protection gloves Protect against cutting damages and aggressive liquids. Protection helmet Protects against objects falling down. Ear protection Protects against hearing loss in the case of procedures with high noise emission. Betriebsanleitung_Nemus_2700_Version5_gb Page 21 of 146

22 Symbols (pictograms) used at the machine SYMBOL MEANING Marks a load bearing point with the corresponding load capacity in kn Marks a lubrication point Marks the battery disconnecting switch Indication on the connection point for maintenance works of the ABS-braking unit General safety indication for executing maintenance works. Indication on cleaning the engine compartment Indication on attending the operating manual and safety indications Page 22 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

23 SYMBOL MEANING Indication on the next check regarding accident prevention regulation. Indication on the maximum admissible highest speed for transporting the machine Indication on securing bolt, having to be removed, if necessary. Indication for switching off the electro main switch Indication on the danger area around the supports Warning against motor exhaust gases Prohibition for persons with heart pacemaker Only with option magnet drum Warning against magnetic field. Only with option Magnet drum. Transport safety device of oversized grain discharge belt Tab. 7: Pictograms Betriebsanleitung_Nemus_2700_Version5_gb Page 23 of 146

24 Rescue and fire protection signs SYMBOL MEANING Fire extinguisher Fire alert telephone First aid box Escape direction / Escape route Meeting point Tab. 8: Fire protection and rescue protection 2.7. Basic safety instructions WARNING Personal damages due to non-observance of basic safety instructions. Personal damages and death can result. Observe the basic safety instructions always. Only use the machine in technically perfect condition, Page 24 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

25 for its intended purpose, as well as aware of safety and danger. Check all safety devices of the machine before starting works at or with the machine. Before starting works at or with the machine, check it for visible damages (mechanics, electrics, hydraulics). Store the complete operating manual at the machine s location. Extend the operating manual with documents, like the legal regulations for accident prevention. Do only execute works, for which you acquired basic and specific knowledge or you were instructed. Do only execute works you were authorized for by the operator. Wear appropriate personal protection equipment Residual risks Even if you attend 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 have to follow the instructions to avoid that residual risks lead to accidents or damages. Betriebsanleitung_Nemus_2700_Version5_gb Page 25 of 146

26 DANGER Danger to persons due to electric shock when touching defective electric lines, plugs or switches. Personal damages and death can result. Works at the machine s electrics must only be executed by an electro specialist. DANGER Danger to persons due to exhaust gases of the diesel engine. Danger to persons lives due to asphyxiating. Only operate the machine in surroundings, ventilated sufficiently. Only operate the machine outside closed or partly closed rooms. WARNING Danger to persons due to using non-appropriate lifting devices. Personal damages can arise. Only use approved lifting devices. Only use lifting devices with a sufficient load bearing capacity (see operating manual, technical indications for transport assembly). Never stay under pending load. Wear the personal protection equipment. Page 26 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

27 WARNING Danger of falling when using ladders. Personal damages and death can result. Only put ladders onto the machine if this is not operated. Do only use ladders, not showing any visible damages. Secure that the underground is appropriate for setting up a ladder. WARNING Danger of fire due to inflame easily inflammable substances. Personal damages and death can result. Avoid fire, open light and smoking in the direct surroundings of the machine. Do not fill the machine with burning or smouldering materials. Remove easily inflammable materials from the machine s direct surroundings. Familiarize yourself with the local possibilities of fire fighting. WARNING Danger due to high pressure in lines of lubrication, pneumatics and hydraulics. Personal damages and death can result. Before executing works at lines, switch them pressureless. Use personal protection equipment. Betriebsanleitung_Nemus_2700_Version5_gb Page 27 of 146

28 WARNING Danger of being drawn in at moving / turning parts. Personal damages can arise. Do not remove the protection covers in any case. If this is necessary for maintenance or cleaning works, secure the machine against unwanted starting! Do not grasp into the moving area of machine parts during a trial run. Keep distance to turning parts during the machine s operation! Always wear appropriate working clothes (e. g. no loose clothing, in case of long hair, use a hair net). After termination of works, install the protection covers again! WARNING Danger to persons due to improper handling of lubricating, cleaning or working material. Personal damage due to skin contact and/or breathing in can result. Use personal protection equipment. Read the corresponding safety data sheets. Page 28 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

29 3. Overview and use of the machine All figures and drawings in this operating manual serve exclusively for the general illustration. If necessary, attend the separately attached operating manuals of the motor s manufacturer, which are enclosed as original. We reserve technical changes due to further development of the machine described in this operating manual. READ UNDERSTAND - ATTEND! 3.1. Product identification NOTICE The indications, stated here refer to the equipment of the basic machine. Due to changes at the machine the actual measures can differ from the ones, stated here. Attend the indications in the additional documents, having to be added to the documentation after modifications or changes at the machine. The indications in this manual are only valid for the machine of which the machine identification number is stated on the front page of the operating manual. Only the observance of approved values corresponds to the machine s appropriate use. Betriebsanleitung_Nemus_2700_Version5_gb Page 29 of 146

30 Overview Here is a rough description of the machine s construction. In the case of location specifications (e.g. right, left) the reference direction is always seen as driving direction of the machine. Fig. 3: Overview machine POS Description 1 Towing eye 2 Flap of engine compartment 3 Cleaning brush 4 Fine grain discharge belt 5 Oversized grain discharge belt 6 Rear jack 7 Front jack Page 30 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

31 8 Screening or center drum 9 Material feeding hopper 10 Flap of engine compartment 11 Tandem carrier wheels 12 Fine grain cross belt The position of the operating areas, from which the machine s control is realized, is described in chapter 7.1, Operating elements, page Unit marking Fig. 4: Type plate The type plate (1) and the machine number (2) are fixed at the machine s baseframe. Betriebsanleitung_Nemus_2700_Version5_gb Page 31 of 146

32 3.2. Product description Intended use The mobile screening unit serves for screening pre-shredded residual waste, bark mulch, wood, domestic - resp. bulky waste as well as sand, gravel, earth and ground excavation. 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 works by qualified personnel. The execution of cleaning, maintenance as well as repair works is only allowed at the machine, shut down. The application of spare parts and working materials 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. Page 32 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

33 NOTICE Every use of the machine beyond the intended use and/or any other type of use is forbidden! Non-intended use 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. Moving the machine in public road traffic without the application of the equipment and transport safety devices necessary for this. Moving the machine in public road traffic without a corresponding personal qualification. Moving the machine with non-appropriate towing vehicle. Moving the machine in jacked-up condition. The execution of modification works at the machine, not permitted by the manufacturer. NOTICE When using the machine in-appropriately, the manufacturer s warranty expires! Betriebsanleitung_Nemus_2700_Version5_gb Page 33 of 146

34 Technical data TRANSPORT DIMENSIONS Length Width Height mm ( in) 2550 mm ( in) 4000 mm ( in) TANDEM CENTRAL AXLE TRAILER Permitted total weight Permitted axle load per axle Bearing load 17 t ( lbs) 8 t ( lbs) 1 t ( lbs) Tyres 385/65 R 22,5 SCREENING DRUM SIZE Length screening drum Diametre screening drum Effective screening surface 5500 mm ( in) 2000 mm (78.74 in) 30.0 m² ( ft²) SCREENING MATERIAL Throughput capacity 170 m³/h ( ft³/h) MOTOR (DIESEL MOTOR) Power Power at 1,800 min -1 Emission standard Fuel tank 70.0 kw 67.0 kw Directive 97/68 EG Stage IIIA EPA TIER 3 approx. 300 l AMBIENT CONDITIONS Temperature range -10 C to +37 C (14 F to 98.6 F) Page 34 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

35 EMISSIONS Noise level (measured under full load, without material) 89 db (A) Tab. 9: Technical data 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. Betriebsanleitung_Nemus_2700_Version5_gb Page 35 of 146

36 Fig. 5: Dimensions working position 3.3. Equipment of the machine The components of the machine and the possible options are described here. SERIAL NUMBERS Machine No.: (NEMUS) Vehicle identification No.: W KB4 079 Motor No.: 1104D-E44TA NL82514 NLU225526Y Tab. 10: Serial numbers Page 36 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

37 BASIC MACHINE Mobile screening machine as semitrailer, suitable for the application with a center drum or screening drum for material separation into two fractions (according to the indications of the valid document). Tab. 11: Basic machine OPTIONS Diesel motor, power: 96.5 kw, Power at 1,800 min -1 : 90.0 kw Emission standard: Regulation 97/68 EG stage IIIA EPA TIER 3 Certificate for obtaining general license as per Road Traffic Act (StVZO) Certificate for obtaining general license as per Road Traffic Act (StVZO); incl. motor vehicle registration certificate Equipment according to EU-directive: Surrounding lights front and rear; side marking lights; rear underride guard; splash guard and mudflap. Preparation European approval Screening drum, diameter 2000 mm (78.74 in) Screening drum, diameter 2150 mm (84.65 in) Core drum Screening segments Special paint Betriebsanleitung_Nemus_2700_Version5_gb Page 37 of 146

38 OPTIONS Belt elongation fine grain discharge belt Axle distance: 6000 mm ( in) Belt elongation fine grain discharge belt Axle distance: 6550 mm ( in) Only in connection with option Additional hydraulic rear support Belt elongation oversized grain discharge belt Axle distance: 4350 mm ( in) Belt elongation oversized grain discharge belt Axle distance: 5120 mm ( in) Belt elongation oversized grain discharge belt Axle distance: 5120 mm ( in), belt width: 1000 mm (39.37 in) Only in connection with option Additional hydraulic rear support Adjustable belt speed fine grain discharge belt Adjustable belt speed oversized grain discharge belt Magnet drum in fine grain discharge belt, b = 800 mm (31.50 in) Magnet drum in oversized grain discharge belt, b = 800 mm (31.50 in) Magnet drum in oversized grain discharge belt, b = 1000 mm (39.37 in) Hydraulic connection, 26 cm³ (1.59 in³) at the rear of machine Hopper pre-screen Page 38 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

39 OPTIONS Gusset shoe Wiper for cleaning brush Central lubrication unit Central lubrication blocks Additional electric oil cooler Radio remote control, 10-channel incl. EMERGENCY-STOP-switch Radio remote control, 12-channel incl. EMERGENCY-STOP-switch Electric motor pre-heating Carbide wiper for the fine grain discharge belt Motor unit, hydraulically movable Manual hydraulics as emergency activation Air suspension Positioning unit Hopper sensor control Hopper sensor control with 2-channel radio Tandem carrier wheels, drum s inlet side Additional hydraulic rear support Cleanfix-fan for 70.0 kw Diesel motor Cleanfix-fan for 96.5 kw Diesel motor Segment screening drum outer scraper Soot filter, self-cleaning Betriebsanleitung_Nemus_2700_Version5_gb Page 39 of 146

40 OPTIONS Battery disconnecting switch Preparation for screening drum SM620 Adapter ring for screening drum SM620 Tab. 12: Options Page 40 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

41 4. Function 4.1. Functioning description of the machine Fig. 6: Function The material separation is mainly based on the different sizes of the material, fed. By means of mechanical feed, the material to be separated is filled into the machine s hopper (1). With a conveyor belt, situated at the hopper s bottom (2), the input material is conveyed to the screening drum (3). Due to the worm, situated in the screening drum, as well as the screening drum s rotating movement, the material transport into the machine is executed. Corresponding to the size of the screening holes, the material separation is executed. The size of the screen holes corresponds to the customer s specific requirements. Material, not falling through the holes, runs to the screening drum s end and is removed out of the machine by the oversized material discharge belt (4). Material, falling through the screening elements, is discharged by the fine grain discharge belt (5). Betriebsanleitung_Nemus_2700_Version5_gb Page 41 of 146

42 4.2. Functioning description of options Operating manual 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 documentation, which you can find in the annex operating manuals of suppliers Version according to EU-regulations Fig. 7: Version according to EU-regulations POS Description 1 Surrounding lights (both sides) 2 Side marking lights (both sides) 3 Spraying water protection, mud flap (both sides) 4 Rear underride guard Page 42 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

43 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 Preparation for European approval Fig. 8: Lateral underride guard Here, it is about an extension of the EU-regulation. This extension consists of a removable underride guard (1), being fixed in the area of the motor doors on both sides Screening systems Screening drum Fig. 9: Screening drum The screening drum has a determined size of screen holes. Betriebsanleitung_Nemus_2700_Version5_gb Page 43 of 146

44 Changing the hole size can only be realized by exchanging the whole screening drum. Center drum Fig. 10: Center drum with screening elements In this case, the screening drum consists of a basic element (2) on which screening elements (1) with customer-specific holes are spanned. Due to the fixing mechanism (3), consisting of spanning ropes and springs, the screening segments (1) can be exchanged according to the separation requirements Adjustable belt speed Function: By means of hydraulic valves, the speed of both discharge belts can be adjusted as necessary. The operating elements are at the operating area 2, being situated at the machine s rear. Page 44 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

45 Following, the procedure is described: Fig. 11: Adjust speed of discharge belts Adjust the speed of the fine grain discharge belt by turning the valve (1). Adjust the speed of the oversized grain discharge belt by turning the valve (2) 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 with pacemakers. 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 (see Fig. 12, pos. 1). Betriebsanleitung_Nemus_2700_Version5_gb Page 45 of 146

46 Fig. 12: Magnet drum Function: By means of a magnet drum it is possible to sort FE-metal out of the screenings. The magnet drum is a permanent magnet and can be installed at the oversized and fine grain discharge belt. The construction group magnet drum (2) also contains a collection chute (3) with which the separated FE material is guided into a collecting vessel Hydraulic connection WARNING Danger due to high pressures in the hydraulic system of the machine. Personal damages and death can result. Connections at the additional hydraulic unit must only be established when the motor is switched off and secured against switching on. Wear the personal protection equipment. Page 46 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

47 NOTICE Danger due to a non-closed fluid circuit in the hydraulic system, resp. wrong connected hydraulic connections. Damages to the hydraulic system can result. Secure the connecting hose to be situated between the two hydraulic connections, if no other machine is connected. Secure the hydraulics to be connected correctly in regards to the flowing direction. Function: This option serves the possibility to operate an additional, downstreamed component (up to 4.0 kw connecting power). Fig. 13: Additional hydraulic connection - hydraulic pump For this an additional hydraulic pump (1) is flanged onto the diesel engine. At maximum motor revolution at the diesel engine, the additional hydraulic connection has a conveying power of approx. 45 l/min (1.59 ft³/min). The maximum admissible pressure (pressure of switching off) is 180 bar ( psi). Betriebsanleitung_Nemus_2700_Version5_gb Page 47 of 146

48 Fig. 14: Additional hydraulic connection - quick couplings Additional machines are connected at the two quick couplings (1). Fig. 15: Additional hydraulic connection - operating element Activation is realized by the switch operating area 1. (1), being situated on Page 48 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

49 Hopper pre-screen WARNING Danger to persons due to inattention, resp. carelessness when using a radio-remote control. Damages to persons and death can result. A direct visual contact between operator and machine needs to be guaranteed always. Attend the manufacturer documentation. This can be found in the annex under Operating manuals of manufacturers. Function: This option is only available in connection with a 2-channel radio-remote-control. Fig. 16: Hopper pre-screen Betriebsanleitung_Nemus_2700_Version5_gb Page 49 of 146

50 Fig. 17: Hopper pre-screen Radio remote control The hopper s pre-screen is situated above the material feed hopper. Due to this option it is secured, that no really large materials get into the machine. Thus, damages at the machine or increased wearout are avoided. Due to an impulse via radio remote control (key 2) the hopper pre-screen is lifted hydraulically, so it is emptied sidely to driving direction. Due to a further impulse via radio remote control (key 1), the hopper pre-screen is lowered. In connection with the option Hydraulic connection the option Hopper pre-screen affects a halving of power of the hydraulic connection! Page 50 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

51 Gusset shoe DANGER Danger of crushing during transport. Personal damages can arise. This auxiliary device serves exclusively for the application on even and fixed ground. Public roads and slope ways must not be driven with this device. Transport only on walking speed. Due to safety reasons do not use the gusset shoe during repair or service works. Only use this device, if a marshaller is present on the site, to be driven on, but only stays in sufficient safety distance to the unit and within the visual range of the driver! There must no further persons stay within the screening unit s working area. NOTICE The gusset shoe is only usable under different conditions. Moving the machine safely is only possible with an appropriate pin. The counterpart at the wheel loader shovel has to have a round pin with a diameter of approx mm ( in). Fig. 18: Gusset shoe Betriebsanleitung_Nemus_2700_Version5_gb Page 51 of 146

52 Function: The gusset shoe (1) is put onto the towing eyelet and fixed with securing bolts (2). The gusset shoe (1) serves for moving the machine with a correspondingly equipped wheel loader Wiper for cleaning brush Fig. 19: Cleaning brush - Wiper Function: The wiper (1) serves for cleaning the brush on the screening drum. On the one hand the wiper s (1) task is to extend the brush s service life and on the other hand to guarantee a better cleaning of the screening drum according to the screening s consistency. Corresponding to the grade of contamination and the material to be screened, the wiper (1) has to be made free of garbage, like strings, plastic nets and similar to achieve an optimal effect. Page 52 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

53 Central lubrication unit Fig. 20: Central lubrication unit Function: Machines with a central lubrication unit (1) only have a few additional lubrication points. Nearly all lubrication points are fed centrally. Nevertheless, the lubrication intervals do not change Electric oil cooler Fig. 21: Additional oil cooler Function: The electric oil cooler (1), situated in the engine compartment, serves for regulating the hydraulic liquid s temperature. This option can be necessary, if the machine is used in an area with special surrounding conditions (high temperatures). Betriebsanleitung_Nemus_2700_Version5_gb Page 53 of 146

54 Radio remote control - 10-channel resp. 12-channel WARNING Danger to persons due to inattention resp. carelessness, when using the radio remote control. Damages to persons and machine can arise. The direct visual contact between operator and machine must always be guaranteed. Attend the manufacturer s documentation. This documentation can be obtained from the annex under Operating manuals of manufacturers. NOTICE There s a safety function installed at the radio remote control. This keeps the radio contact between sender and receiver, i.e. if errors arise on the same radio route, the radio remote control switches to safe condition (EMERGENCY-STOP). Switching off due to foreign influence can arise always. Avoid possible foreign influences due to battery charger stations, other radio remote controls, radio controlled toys or model aircrafts. Page 54 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

55 NOTICE The radio remote control has a limited range. The radio remote control activated the EMERGENCY-STOPfunction if the range is exceeded. Inform yourself about the range of the remote control with the manufacturer s documentation. Fig. 22: Radio remote control Function: Alternatively to manual operation, some different functions can also be operated via radio remote control. The 10 resp. 12 keys on the operating panel (2) can be occupied by the operator. The key (1) is the standard EMERGENCY-STOP-SWITCH at the radio remote control. Betriebsanleitung_Nemus_2700_Version5_gb Page 55 of 146

56 Fig. 23: Radio remote control - position The radio remote control and the corresponding charging station (1) are situated in the switch cabinet of the operating area 1. Fig. 24: Radio remote control - receiver The receiver (1) of the radio remote control is situated in the machine s motor compartment. Page 56 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

57 Electric motor pre-heating NOTICE The application of the motor pre-heating unit is an option. The following data only refer to the machine s application with motor pre-heating. Attend the manufacturer s documentation. This documentation can be obtained from the annex under Operating manuals of manufacturers. Fig. 25: Motor pre-heating POS Description 1 Heating element with fixing angle 2 Connection cable electrics 3 Connection lines at motor Function: The electric motor pre-heating serves to keep resp. pre-heat the cooling liquid s temperature to 50 C (122 F). Using a motor pre-heating device leads to a reduction of operating costs due to a lower fuel consumption. Furthermore the wearout is reduced and the motor starts better. So the motor gets to operating temperature faster after a longer break or the morning start. Betriebsanleitung_Nemus_2700_Version5_gb Page 57 of 146

58 The period of pre-heating takes approx. 3 hours. The motor pre-heating device (1) is connected to the locally available power supply via the plugging connection with delivered adapter cable Carbide wiper at fine grain collector belt Fig. 26: Carbide wiper fine grain collector belt Function: Carbide wipers (1) serve for cleaning the fine grain cross belt. An application is advisable when the material to be separated is very hard and leads to an increased wearout of the standard wiper Motor unit hydraulically movable Fig. 27: Motor unit hydraulically movable Page 58 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

59 Function: By means of hydraulic cylinders (1) the motor unit can be moved out of the machine for maintenance purposes. By means of securing bolts (2), the motor unit is secured in the engine compartment Manual hydraulics NOTICE The manual hydraulics must not be used for permanent operation of the machine. Damages at the hydraulic unit can arise. Use the manual hydraulics only to get the machine to a transportable condition. NOTICE For normal operation of the machine it is necessary that the ball valve at the manual hydraulics is closed. If the ball valve is open, the entire hydraulic systems is switched off during normal operation. Check the position of the ball valve in case of problems with the machine s hydraulics. Function: The manual hydraulics are an auxiliary system, able to move front and rear jacks, discharge belts and diesel engine in cases of emergency, if the diesel engine or the hydraulic pump fails. Betriebsanleitung_Nemus_2700_Version5_gb Page 59 of 146

60 Fig. 28: Manual hydraulics The pump (1) of the manual hydraulics is installed on the hydraulic tank (3), being situated on the right side of the engine compartment. For a perfect function it is necessary that the ignition of the diesel engine is switched on. Following, the procedure is described: Put the handle (4) into the manual pump (1). Open the ball valve (2) by turning the lever to the right. Activate the manual pump (1). Select the machine parts to be moved, by opening, resp. closing the corresponding hydraulic valves. After temination of works, close the ball valve (2) by turning the lever to the left. Page 60 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

61 Air suspension Fig. 29: Chassis Air suspension Function: To change the trailer s distance to the ground, a lifting and lowering system is installed, making it possible to lift or lower the trailer by means of the air suspension system, as well as to get it to the driving height, preset by the manufacturer. Furthermore the system levels to a standard driving height from a speed of15 km/h (9.32 mph) (at connected power supply of ABS) Positioning unit NOTICE In case of an activated positioning unit, folded on, the machine must not be towed. Damages to chassis and tyres can arise. Prior to towing the machine, secure that the positioning unit is not folded onto the chassis. Betriebsanleitung_Nemus_2700_Version5_gb Page 61 of 146

62 Fig. 30: Positioning unit Function: By means of the positioning unit, it is possible to execute a continuing separation process without interrupting this process for moving the machine. This option consists of a pair running wheels (2), being installed instead of the front jacks. Furthermore there s a drive unit (1), being pressed to the chassis hydraulically Hopper-sensor-control Fig. 31: Hopper sensor control Function: The hopper-sensor-control (1) avoids the screening drum to run empty during the process of screening. Page 62 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

63 The hopper-sensor-control can be activated, resp. deactivated optionally via a 2-channel radio-remote-control. If the hopper-sensor-control is activated, this is signalised by the green light indicator, situated on the machine tunnel. After activating the hopper-sensor-control, the existent filling level in the rear third of the hopper is monitored via the ultrasonic sensor. As soon as the ultrasonic sensor does not recognise any material in the rear third of the hopper, this is signalised by flashing of the green light indicator. Then the procedure of screening is interrupted. Additional a signal is given to the machine control, which switches off the hopper feed and the drive of the screening drum immediately. Shortly after that, all discharge belts are switched off. If the hopper is fed with material again (in the rear third), this is recognised by the ultrasonic sensor and reported to the machine control. Then the automatic start of the screening machine starts. For this the motor revolution of the diesel generator is increased to the value, pre-adjusted and the acoustic start warning sounds. Parallel to this the yellow start warning of the hopper-sensorcontrol is flashing. After this, the discharge belts, the drive of the screening drum and the hopper feed are started and the process of screening is continued Tandem carrier wheels Fig. 32: Tandem carrier wheels Betriebsanleitung_Nemus_2700_Version5_gb Page 63 of 146

64 Function: The tandem carrier wheels (1) serve for a better load capacity, resp. load distribution in case of heavy input material. Thereby the machine s wearout is decreased Additional hydraulic rear support Fig. 33: Additional rear support Function: The additional hydraulic rear support (1) serves for a better stability of the machine. This option is to be used together with options Belt extension at oversized grain belt, axle distance: 5120 mm ( in), belt width: 1000 mm (39.37 in) and / or Belt extension lateral fine grain discharge belt, axle distance: 6550 mm ( in), belt width 800 mm (31.50 in). Page 64 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

65 Cleanfix -fan Fig. 34: Cleanfix-fan The construction groups consists in: Cleanfix - fan (1) Adaptor flange Air line Magnetic valve Small compressor Electronic control (2) and Push switch. Function: The pnuematic system (compressor) serves for switching to blowing direction. Betriebsanleitung_Nemus_2700_Version5_gb Page 65 of 146

66 Segment screening drum outer wiper Operating manual Fig. 35: Segment screening drum outer wiper Function: The segment wiper (1) serves for cleaning the screening drum, instead of the brush. The installed wearout segments are springily beared and exchangable Soot filter Fig. 36: Motor soot filter POS Description 1 Soot filter 2 Display of exhaust gas counter pressure Page 66 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

67 Function: The soot filter regenerates itself continuously and independently, if the averaged exhaust gas temperature increases to over 280 C / 536 F (depending on the type of motor). This regeneration temperature has to be achieved for approx. 25% of the entire operating hours of the diesel motor. Should this temperature not be achieved over a longer period of time, the soot filter (1) is loaded with sooty particles and the exhaust gas counter pressure increases. The longer the exhaust gas counter pressure stays under the regeneration temperature, the higher the exhaust gas counter pressure increases before the particle filter. This is shown by the exhaust gas counter pressure display resp. the warning light, installed at the unit. The soot filter is adjusted via the display and adjusting unit (1) and controlled via the control unit (2). Together with the increasing counter pressure also the carbonparticulate emission of the diesel motor increases. In the case of a high counter pressure value (approx. 130 mbar / 1.89 psi), signalised via the filter monitoring systems, a filter regeneration by increasing the exhaust temperature has to be initiated by the operator. For this, further electrical consumers have to be switched to the unit. NOTICE An increased exhaust counter pressure is indicated. Motor damage can arise. Clean the soot filter. Betriebsanleitung_Nemus_2700_Version5_gb Page 67 of 146

68 Battery-disconnecting switch Fig. 37: Battery-disconnecting switch Function: The equipment with a battery disconnecting switch (1) protects the battery against total discharge Preparation for screening drum SM620 Fig. 38: Preparation for screening drum SM620 Function: By means of this option, the screening drum drive (1) can be moved horizontally and set to two positions. Page 68 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

69 Thereby, the use of a screening drum of the type Doppstadt SM620 is possible Adapter race for screening drum SM620 Fig. 39: Adapter race for screening drum SM620 Function: By means of the adapter race (1), it is possible to use a screening drum of the type Doppstadt SM620 in this machine. The adapter race (1) is fixed at the screening drum by means of a clamping connection (2). Betriebsanleitung_Nemus_2700_Version5_gb Page 69 of 146

70 5. EC-Conformity declaration Operating manual Page 70 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

71 6. Transport and setting up WARNING Danger to persons due to a not perfect machine condition, related to traffic. Death or really severe injury can be the consequence. Prior to every transport check the connections of the vehicle s 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 / psi). Secure that the tyre nuts are tightened with a torque of 450 Nm ( ft lbs). At new machines check the torque of the wheel nuts after approx km ( mi). Secure that the screws of the towing eye are tightened with a torque of 610 Nm ( ft lbs). WARNING Danger to persons due to transport and setting up the machine, executed improperly and not aware of danger. Death or really severe injury can be the consequence. Execute changes of the machine s location only after receiving instructions of the operator. Betriebsanleitung_Nemus_2700_Version5_gb Page 71 of 146

72 NOTICE Damages due to improper transport do not authorize for spare or (liability) guarantee claims Prepare machine for transport NOTICE The equipment of the unit and so, also the possible options are listed in the chapter 3.3, Equipment of the machine, page 36. Precondition: The machine is started in automatic operation Empty the machine Stop the material feed to the machine. Empty the machine and secure that there s no material in the machine or on the belts anymore. Stop the operation and secure the machine against unintended re-starting (see chapter 7.4, Shut down Switching off the machine,page 142). Page 72 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

73 Secure discharge belts Oversized grain discharge belt outlet chute Fig. 40: Swivable outlet chutes Fold up the swivable outlet chutes (1) at the oversized grain discharge belt. Fig. 41: Operating area 1 Oversized grain discharge belt without belt elongation Execute the following steps at the operating area 1: Turn the switch to the left until the oversized grain discharge belt has reached its final position. Betriebsanleitung_Nemus_2700_Version5_gb Page 73 of 146

74 Oversized grain discharge belt with belt elongation Execute the following steps at the operating area 1: Turn the switch to the left until the oversized grain discharge belt is folded up for approx. 75%. Turn the switch to the left until the belt elongation is folded down completely. Turn the switch to the left until the oversized grain discharge belt has reached its final position. Oversized grain discharge belt Transport safety devices Fig. 42: Transport safety device - oversized grain belt Install the transport safety device (1) at the oversized grain discharge belt. Page 74 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

75 Fine grain discharge belt Fig. 43: Operating area 1 Execute the following steps at the operating area 1: Turn the switch to the left until the fine grain discharge belt has reached its final position Couple the unit onto the towing machine Couple the unit onto an appropriate and proved towing vehicle. Fig. 44: Compressed air connection Connect the cable (1) for the machine lighting. Betriebsanleitung_Nemus_2700_Version5_gb Page 75 of 146

76 Connect the hoses of compressed air (2) to the towing vehicle. Connect the cable (3) for the ABS-unit. Fig. 45: Release valve compressed air braking unit Activate the release valve (1), if the machine shall be moved without a towing machine, braked by compressed air. Fig. 46: Parking brake and wheel chocks Remove the wheel chocks and store them in the retainers (1) on both sides of the machine. Release the parking brake (2) by turning it anti-clockwise. Page 76 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

77 Retract jacks Retracting the jacks is only possible, when the diesel engine is switched on. Fig. 47: Operating area 1 - start motor Execute the following steps at the operating area 1: Turn the ignition key (1) to position START and start the diesel engine. to the left until the left rear jack is re- Turn the switch tracted completely. If the machine is equipped with and additional second rear jack, the following procedure is necessary: Turn the switch retracted completely. to the left until the right rear jack is Betriebsanleitung_Nemus_2700_Version5_gb Page 77 of 146

78 Fig. 48: Operating area 2 Execute the following steps at the operating area 2: to the left until both front jacks are re- Turn the switch tracted completely. Execute the following steps at the operating area 1: Turn the ignition key (1) to position 0, to switch off the diesel engine. Remove the ignition key Final works for transport security Close the maintenance doors. Close the switch cabinet s doors. 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. Page 78 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

79 6.2. Check scope of supply Check the machine for completeness of the scope of supply and transport damages immediately at delivery: Check the scope of supply for completeness, according to the accompanying documents. Usually the product documentation is delivered together with the machine. With your order confirmation, check whether and which special equipment is installed at your machine. Contact your seller, if you do not find the operating manual or other parts are missing Report transport damages Check the machine for transport damages at delivery. Document transport damages with appropriate measures (photos, drawings, reports) and report the damage to the forwarding agency in written form. Please, also send a copy of the damage report to your seller resp. to Komptech Umwelttechnik Deutschland GmbH Intermediate storage and wintering If the machine is not commissioned immediately after delivery, it has to be placed at a protective location. Blank and non-painted machine parts have to be protected against corrosion with appropriate means. Liability for corrosion damages due to improper storage is not assumed. For wintering the machine, it has to be placed at a protective location. For this, attend all descriptions of the chapter Maintenance and repair! Execute the following measures: Betriebsanleitung_Nemus_2700_Version5_gb Page 79 of 146

80 Clean the machine thoroughly before wintering. Treat blank and non-painted machine parts with appropriate corrosion protection. Check all oil levels Setting up the machine DANGER Dangerous electric voltage due to contact with an electric overhead line when setting up. Danger to personnel and thirds due to electric shock. Keep sufficient safety distance to electric overhead lines. Initiate the immediate shut down of the electric overhead line in case of contact and attend the following points: Do not touch the machine. Do not touch the machine until it is secured that the electric overhead line was switched off. Secure that nobody enters the danger area. Expel all persons out of the danger area. WARNING Danger to persons due to non-sufficient sustainable and/or even underground, on which the machine is supposed to be placed. Danger to the personnel s lives due to the machine, sinking in or turning over. Attend the chapter 2.1, Operator, page 10. Setting up the machine must only be executed by qualified employees of the company Komptech GmbH or authorized specialist companies. Page 80 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

81 Set up the machine according to the layout plan. Secure that an unhindered and error-free material flow is possible. Secure that the machine is set up in a manner so corresponding free space around the machine exists. Thus it should be secured, that maintenance and / or repair works can be executed safely Decouple the machine from the towing device (Reversed order than described in chapter 6.1.3, Couple the unit onto the towing machine, page 75) Tighten the parking brake (cranking to the rig). Place the wheel chocks at the wheels on both sides. Disconnect the electric lines from the towing vehicle. Disconnect the lines of compressed air from the towing vehicle. Lower all jacks. Thereby make sure, that the machine stands as horizontally as possible. Decouple the machine from the towing device Fold down discharge belts (Reverse order as described under chapter 6.1.2, Secure discharge belts, page 73) Betriebsanleitung_Nemus_2700_Version5_gb Page 81 of 146

82 WARNING Danger to persons due to unsafe machine operation, after damage during transport. Danger to person s lives. After setting up, check the machine for visible mechanic, electric or hydraulic damages. Inform the operator immediately if you recognized any damages. Do not execute any further works at or with the machine. Secure the machine against unintended starting. Fig. 49: Operating area 1 Realize the following steps at the operating area 1: Turn the switch to the right until the fine grain discharge belt reached its final position. Page 82 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

83 Fig. 50: Transport safety device - oversized grain discharge belt Loose the transport securing device (1). By activating the buttons and (if the machine is equipped with an extension of the oversized grain discharge belt) fold down the oversized grain discharge belt. Fig. 51: Swivable outlet chutes Fold down the outlet chutes (1). Betriebsanleitung_Nemus_2700_Version5_gb Page 83 of 146

84 7. Operation WARNING Danger to persons due to operating the machine improperly and not aware of danger. Death or really severe injury can be the consequence. Attend the chapter 2.1, Operator, page 10. The following points are described in this chapter, the operating elements, involved at the machine how the machine is started and shut down Operating elements Basics: The realizing functions of switches and buttons are activated by turning to the right. The reversing, resp. stopping functions of switches and buttons are activated by turning to the left. Page 84 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

85 Operating elements Overview operating areas Fig. 52: Positions of operating areas POS Description 1 Operating area 1 2 Operating area 2 3 Operating area 3 4 Operating area 4 Betriebsanleitung_Nemus_2700_Version5_gb Page 85 of 146

86 Operating elements - Operating area 1 Operating manual Fig. 53: Operating area 1 - Operating elements (1) Display with function buttons At this display, machine parameters can be read or set (see section Operating elements Operating area 1 (Display with function buttons), page 89). (2) Starting module By means of the starting module, the diesel engine is commissioned. 0 = Ignition off 1 = Ignition on Start = Starter is activated motor is started (3) EMERGENCY-STOP-SWITCH Press in case of danger. (4) Operating elements Switches and buttons, being necessary for operating the machine, are installed here. Furthermore, switches and buttons, being necessary for operating the options are installed here. The corresponding functions of the switches and buttons are visible by means of the pictograms. Page 86 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

87 Following pictograms can mark switches/buttons in operating area 1: PICTOGRAM FUNCTION Headlights (option) OFF and ON Hopper-sensor-control (option) OFF or ON Hopper pre-screen (option) DOWN and UP Hopper pre-screen (option) DOWN and UP Cleanfix intermediate cleaning (option) OFF and ON Fine grain discharge belt left UP and DOWN Radio (option) OFF or ON Rear jack left UP and DOWN Additional rear jack right (option) UP and DOWN Auxiliary drive 1 (option) OFF or ON Auxiliary drive 2 (option) OFF or ON Oversized grain discharge belt UP or DOWN Betriebsanleitung_Nemus_2700_Version5_gb Page 87 of 146

88 PICTOGRAM FUNCTION Oversized grain discharge belt (option) UP or DOWN Belt extension oversized grain discharge belt (option) UP or DOWN Positioning unit (option) OFF or ON Positioning unit (option) FOLD AWAY or FOLD ON Positioning unit (option) BACKWARDS or FORWARDS (5) Key-switch to set mode of operation By means of the switch, you set, whether the machine shall be commissioned in Automatic operation (1) or Manual operation (2). Page 88 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

89 Operating elements Operating area 1 (Display with function buttons) Design Fig. 54: Display with function buttons - design (1) Display In this area, the different machine parameters or error messages are shown. (2) Status-LED The status LED shows the operation condition of the display with the function buttons. Colour green - error free operation Colour yellow - Display is started Colour red - Error message/fault (see chapter Maintenance manual ). (3) OK-button By pressing this button, error messages are acknowledged. This button has no reset function! (4) Multi-function button By means of this button you navigate through the separate display indications. machine parameters are set. (5) Function buttons By means of the buttons, separate machine functions can be chosed, resp. set directly. Betriebsanleitung_Nemus_2700_Version5_gb Page 89 of 146

90 Display-masks (main level) Fig. 55: Display with function buttons - Mask 1 POS Description 1 Revolution diesel engine 2 Temperature cooling water (The diagram s colour changes from green to red, if the cooling water temperature is >100 C (>212 F).) 3 Operating hours 4 Tank content (The diagram s colour changes from green to red, if the tank content is <15%.) Fig. 56: Display with function buttons - Mask 2 Page 90 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

91 POS Description 1 Revolution diesel engine 2 Revolution screening drum 3 Speed hopper belt Fig. 57: Display with function buttons - Mask 3 POS Description 1 Error message green - no error red - error exists (see chapter Maintenance manual ). 2 Type of error Fig. 58: Display with function buttons - Mask 4 Betriebsanleitung_Nemus_2700_Version5_gb Page 91 of 146

92 POS Description 1 Symbol for manual operation 2 Revolution diesel engine 3 Machine components (No. 1-4) Display red = Component is not operated Display green = Component is chosen for commissioning or component is operated Operating elements Operating area 2 Fig. 59: Operating area 2 - operating elements (1) EMERGENCY-STOP-SWITCH Press in case of danger. (2) Operating elements Switches and buttons, being necessary for operating the machine, are installed here. Furthermore, switches and buttons, being necessary for operating the options are installed here. The corresponding functions of the switches and buttons are visible by means of the pictograms. Page 92 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

93 The following pictograms can mark the switches / buttons at the operating area 2: PICTOGRAM FUNCTION Front supports UP and DOWN Operating elements Operating area 3 Fig. 60: Operating area 3 - operating elements (1) Operating elements Switches and buttons, being necessary for operating the machine, are installed here. Furthermore, switches and buttons, being necessary for operating the options are installed here. The corresponding functions of the switches and buttons are visible by means of the pictograms. Betriebsanleitung_Nemus_2700_Version5_gb Page 93 of 146

94 The following pictograms can mark the switches / buttons at the operating area 3: PICTOGRAM FUNCTION Hopper IN and OUT Motor unit (option) IN or OUT Side wall UP and DOWN Operating elements Operating area 4 Fig. 61: Operating area 4 - operating elements (1) EMERGENCY-STOP-SWITCH Press in case of danger. NOTICE The operating elements at the operating area 4 are only activated, when the hopper is moved out completely. Thereby, a mis-operation is avoided, which could lead to damages at the machine. Page 94 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

95 (2) Operating elements Switches and buttons, being necessary for operating the machine, are installed here. Furthermore, switches and buttons, being necessary for operating the options are installed here. The corresponding functions of the switches and buttons are visible by means of the pictograms. The following pictograms can mark the switches / buttons at the operating area 4: PICTOGRAM FUNCTION Drum drive RELEASE or SPAN Start-stop-operation drum drive OFF (0), ON (I) Both functions can only be activated, when the hopper is moved out completely (final position) EMERGENCY-STOP-SWITCH By pressing the EMERGENCY-STOP-SWITCH, the machine is stopped immediately in case of danger / emergency. The pressed switch creates an error message, shown at the display with function buttons, being situated at the operating area 1. The indication looks as follows: Betriebsanleitung_Nemus_2700_Version5_gb Page 95 of 146

96 Fig. 62: Display with function buttons - EMERGENCY-STOP After eliminating the danger situation, the machine can be commissioned again. Unlock the EMERGENCY-STOP-SWITCH by turning it clockwise. Press the button OK (1) at the display with function buttons to acknowledge the EMERGENCY-STOP-message. Then, the following indication appears in the display: Fig. 63: Display with function buttons The machine can be started again. Page 96 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

97 Operating elements Filling level screening drum Fig. 64: Optimize filling level of screening drum This function serves to optimize the screening performance qualitatively (see chapter Screening drum Change revolution, page 123). By means of the regulating valve (1), the pressure is regulated. This can be read at the oil pressure manometer (2) Operating elements Speed fine grain collector belt Fig. 65: Adjust speed of fine grain collector belt Betriebsanleitung_Nemus_2700_Version5_gb Page 97 of 146

98 This function serves to optimize the material transport within the machine. By means of the hydraulic valve (1), the speed of the fine grain collector belt is adjusted Operating elements - Regulation of the discharge belts speed (option) NOTICE Danger due to wrong adjustment of hydraulic valves to regulate the conveyor belts speed. Machine damage can arise due to too high adjusted belt speeds. The adjustment 0 at the hydraulic valve is the maximum power. The adjustment 10 at the hydraulic valve is the minimum power. Fig. 66: Adjust speed of discharge belts POS Description 1 Hydraulic valve for speed adjustment of fine grain discharge belt Page 98 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

99 2 Hydraulic valve for speed adjustment of oversized grain discharge belt Operating elements - Release valve compressed air braking unit Fig. 67: Release valve compressed air braking unit The release valve (1) serves for draining off compressed air. The brakes of the tandem axle can be loosed by activating the valve, if the unit shall be moved without a towing machine braked by compressed air Operating elements - ABS-control Fig. 68: Junction box ABS-control The tandem axle has got an integrated ABS-control. The connection is made via a control cable. Betriebsanleitung_Nemus_2700_Version5_gb Page 99 of 146

100 For connecting the checking device a connection plug (1) is fixed sidely at the unit. Here measuring data for service works at the ABS-unit can be exchanged. In the case of errors, call the after-sales service of the manufacturer Commissioning Basics for operation Before commissioning the machine, it has to be prepared for operation. This contains the following listed activities: Hand over product documentation When the machine is handed over, you receive also the operating manual, according to the hand-over certificate. Check the scope of supply and confirm the receipt. Education of personnel When handing over the machine, the training for the machine is executed. The training has to contain the following points: Safety instructions. Operating elements, functions of the machine. Carry out, check and change basic adjustments. Explanations for using the operating manual. Order to use the operating manual. Execute regular safety checks. Page 100 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

101 Preparation for commissioning In the following chapters, we explain the checking and maintenance works, being necessary every day before commissioning. In the maintenance manual you can find a table from which you can obtain the intervals of the checks. After termination of checking and maintenance works, all maintenance doors and flaps are to be closed again. Free space under the machine WARNING Danger to persons due to garbage or screening, being pulled into the machine, resp. danger of fire due to the motor s heat emission. Death or really severe burnings can result. Secure, that the free space under the machine is always kept free of garbage and / or inflammable material. Fig. 69: Free space under the machine - rear Betriebsanleitung_Nemus_2700_Version5_gb Page 101 of 146

102 Fig. 70: Free space under the machine - laterally Secure that the underground (3) is generally free of garbage or impurities. Keep the red marked area (2) under the machine free of screenings and garbage. Check this daily. The blue area (1) is the discharge area and has to be monitored continuously, so there cannot be any contact with the discharge belt. Page 102 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

103 Checking the machine s stability Check whether the machine has not sunk into the underground. Check whether the parking brake is tightened. Check that the wheel chocks are placed behind the wheels. Check whether the machine stands approximately horizontally. Checking the mechanics Checks at the machine, switched off and secured against re-starting: Secure that there are no foreign bodies in the area of the screening drum, the hopper or the conveyor belts. Secure that the screwing connections are firmly tightened. Secure that the machine does not show any visible damages. 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. Betriebsanleitung_Nemus_2700_Version5_gb Page 103 of 146

104 Checking the hopper belt Fig. 71: Gear motor hopper belt Open the sidely maintenance flap of the hopper belt. Check, whether the gear motor (1) has an oil loss. Fig. 72: Hopper belt - check Open the front maintenance flap (1) of the hopper belt (2). Secure that there is no contamination in the area around the hopper belt (2). If necessary remove them. Page 104 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

105 Checks at the diesel motor NOTICE The engine is a construction group. For this construction group an additional manufacturer documentation can be found in the annex Operating manuals of manufacturers. Attend the statements in the manufacturer documentation. Unlock the right and left motor flap with the machine key and open them. Fig. 73: Engine compartment right side The operating area 3 (1), the hydraulic tank (2) and the fuel tank (3) are accessible from the right side of the engine compartment. Fig. 74: Engine compartment left side Betriebsanleitung_Nemus_2700_Version5_gb Page 105 of 146

106 From the left side of the engine compartment, the diesel engine (1) and the tool box (2) are accessible. Clean the motor of rough contamination. Fig. 75: Motor cooling water line Secure that there is sufficient cooling liquid in the cooler. If necessary open the cooler cap (1) and fill in the necessary quantity (see chapter Maintenance manual ). Fig. 76: 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 Maintenance manual ). Page 106 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

107 Fig. 77: Fuel filter and water pre-separator Check, whether the water pre-separator (2) in the fuel line has to be emptied. If necessary empty the water pre-separator. Check, whether the filter insert of the fuel filter (1) or the water pre-separator (2) has to be changed (see chapter Maintenance manual ). Fig. 78: Air filter - contamination display Check, whether the air filter contamination display (1) shows a red stripe. If a red stripe is shown, clean or replace the air filter (filter element) (see chapter Maintenance manual ). Betriebsanleitung_Nemus_2700_Version5_gb Page 107 of 146

108 Fig. 79: Motor Air filterpre-separator Check the filling level of the air filter s pre-separator (1) and empty it, if necessary. Press the dust valve (2) on the sides. Thereby the dust, collected by the inner pre-separator, is removed out of the filter housing. Checking the hydraulics Secure that all hydraulic lines lay freely. They must not be squeezed. Free up squeezed hydraulic lines. Check the hydraulic lines for damages. Check the hydraulic system for leakages. Fig. 80: Hydraulics Filling level display Page 108 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

109 Fig. 81: Hydraulics Pressure display For the following check, it is necessary that the diesel motor is operated. Check, whether the needle in the oil filter maintenance display (1) is underneath the red marking (< 2 bar / psi). 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. Betriebsanleitung_Nemus_2700_Version5_gb Page 109 of 146

110 Fig. 82: Operating area 1 - tank display For the following check it is necessary that the diesel engine s ignition is switched on. Realize the following steps at operating area 1: With the key switch set the operation mode Automatic. Turn the ignition key (1) to position 1. The display with function buttons is activated and the following indication appears: Fig. 83: Display tank display The indication (1) shows the tank s filling level as a percentage. Page 110 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

111 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 replaced! Checks at the machine, switched on: Check the functionality of the switches and the digital display. Fig. 84: Safety devices Secure that all EMERGENCY-STOP-SWITCHES 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 decommissioned immediately. Betriebsanleitung_Nemus_2700_Version5_gb Page 111 of 146

112 First commissioning For the first commissioning request a mechanic from the retailer or manufacturer. Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Straße 2 D Oelde [t] (+49) [f] (+49) info@komptech.de Adjust language (Display with function buttons) The display with function buttons is designed in a way that settings can be realized or read by means of self-explaining pictograms. Only status messages, giving information about the machine s conditions, are designed in text form. To guarantee the comprehensibility of these texts, the display with function buttons serves the possibility to select languages. Fig. 85: Operating area 1 - Adjust language Realize the following steps at the operating area 1: Page 112 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

113 With the key switch set the operation mode Automatic. Turn the ignition key (1) to position 1. The display with function buttons is activated and the following indication appears: Fig. 86: Display with function buttons - choose display Press the horizontal arrow keys (1) until following indication appears: Fig. 87: Display with function buttons - Activate language selection Press the button (1) and keep it pressed. Betriebsanleitung_Nemus_2700_Version5_gb Page 113 of 146

114 Press the button (2) three times. Operating manual The following display occurs: Fig. 88: Display with function buttons - Language selection Select the language by pressing the vertical buttons (1). The selected language field (2) is marked in grey colour. Confirm the selection mode, by pressing the button OK (4). Leave this display by pressing the horizontal arrow button (3) Operation modes Working operation Working operation is understood as the normal use of the machine to separate defined materials, according to the appropriate use. It is differentiated between the operation modes Automatic operation and Manual operation. Automatic operation The automatic operation serves as normal operation. Here it is guaranteed that the unit is started and emptied in the technologically correct order. In the case of a component's breakdown (according to the unit's equipment) the unit is stopped immediately by this affected component and behind it the unit is emptied in the technologically right order. Thus a safe operation of the unit is Page 114 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

115 guaranteed. You must not interfere this automatically running screening process if the right pre-adjustments have been made of the material given. Changing the material, the appearance of impurities or inappropriate pre-adjustments can make it necessary to correct the adjustments. For this the corresponding functions are available directly in the working operation. Manual operation When operating manually, the single components can be switched on, resp. off independently from each other, for checking these for their function or executing maintenance and repair works. The manual operation serves not as normal operation. The fail of a single component does not lead to switching off the unit Daily commissioning in automatic operation Condition: The machine is in working position (see chapter 6.4, Setting up the machine, page 80). Preparation for operation has been executed (see chapter 7.2.1, Basics for operation, page 100). Control and maintenance works were executed (see chapter 7.2.2, Preparation for commissioning, page 101). Prior to the machine start, all maintenance doors and flaps were closed again. All machine components, regulated via speed are set to minimal power. Betriebsanleitung_Nemus_2700_Version5_gb Page 115 of 146

116 Commissioning in automatic operation Operating manual Fig. 89: Operating area 1 - start machine Realize the following steps at the operating area: Set the operation mode (Automatic operation) at the key switch. Turn the ignition key (1) to position 1. The display with function buttons (2) is activated and the following indication occurs: Fig. 90: Display with function buttons - Status LED The status LED (1) lights up in orange colour and changes to green continuous light. Page 116 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

117 NOTICE Danger due to parameters, set incorrectly. Machine damages can arise. Attend, that the machine is started with the diesel motor s revolution, set last time. Change the machine s parameters to minimum before starting it (see chapter 7.2.7, Optimization of machine parameters, page 119). Turn the ignition key (1) to position Start. The diesel motor is started. The following indication appears in the display: Fig. 91: Display started motor The following information is shown: POS Description 1 Revolution diesel engine 2 Cooling water temperature 3 Operating hours 4 Tank display Betriebsanleitung_Nemus_2700_Version5_gb Page 117 of 146

118 Fig. 92: Display with function buttons - machine start diesel motor The drawing (1) shows the current revolution of the diesel motor. Set the diesel motor s revolution to the desired value by means of the multi-function button. Press the vertical arrow button (2), to decrease the revolution. (The minimum revolution is approx. 800 min -1.) Press the vertical arrow button (3), to increase the revolution. (The maximum revolution is approx min -1.) NOTICE Danger due to parameters, set incorrectly. Machine damages can arise. Attend, that the machine is started with the screening drum s and hopper s revolutions, set last time. Change the machine s parameters to minimum before starting it. Press the button at the operating area 1. The acoustic starting warning sounds. All machine components are now started automatically in the technologically correct order. Page 118 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

119 Set the desired revolution for all machine components, regulated by revolution. Discharge belts (see section Regulation of the discharge belts speed (option), page 98). Hopper belt (see section Hopper belt Change speed, page 121). Screening drum (see section Screening drum Change revolution, page 122) Start the material feed Optimization of machine parameters Diesel engine - Change revolution The revolution of the diesel engine can only be changed, if the engine is started. Fig. 93: Display with function buttons - Choose display Press the horizontal arrow keys (1) until the following indication appears: Betriebsanleitung_Nemus_2700_Version5_gb Page 119 of 146

120 Fig. 94: Display with function buttons - Adjust revolution The drawing (1) shows the current revolution of the diesel motor. The diesel engine s revolution is changed by means of the multi-function button. Press the vertical arrow button (2), to decrease the revolution. (The minimum revolution is approx. 800 min -1.) Press the vertical arrow button (3), to increase the revolution. (The maximum revolution is approx min -1.) Page 120 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

121 Hopper belt Change speed The hopper belt s speed can be changed at the ignition as well as the machine, started. Fig. 95: Display with function buttons - Choose the display Press the horizontal arrow keys (1) at the multi-function display, until the following indication is shown: Fig. 96: Display with function buttons - Change hopper belt speed The drawing (1) shows the current speed of the hopper belt. Press the button (2) to decrease the speed. Press the button (3) to increase the speed. Betriebsanleitung_Nemus_2700_Version5_gb Page 121 of 146

122 Screening drum Change revolution The screening drum s speed can be changed at the ignition as well as the machine, started. Fig. 97: Display with function buttons - Choose display Press the horizontal arrow keys (1) at the multi-function display, until the following indication is shown: Fig. 98: Display with function buttons - Change screening drum revolution The drawing (1) shows the current revolution of the screening drum. Page 122 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

123 Press the button (2) to decrease the revolution (The minimum revolution is approx. 8 min -1.) Press the button (3) to increase the revolution (The maximum revolution is approx. 23 min -1.) Screening drum Optimize filling grade WARNING Danger to persons due to adjustment works at a running machine and moving machine parts. Personal damages and death can result. In case of a running machine keep distance to rotating parts! Always wear appropriate working clothes (e.g. close fitting clothes, in case of long hair, wear a hair net). Execute adjusting works aware of danger. Familiarize with the surroundings of the rear operating area and the possible danger sources. This option serves for optimizing the screening capacity qualitatively. Here it is considered that the screening drum s optimal filling level depends on the mass of the material to be screened. Furthermore, the speed of the of the hopper belt is controlled in dependence to the screening drum s load. If the hydraulic pressure of the drum drives increases due to too much material in the screening drum, the speed of the hopper belt is lowered automatically (up to short stopping of the hopper belt). Thus, the screening drum is continuously filled steadily. Betriebsanleitung_Nemus_2700_Version5_gb Page 123 of 146

124 Fig. 99: Adjust filling level of screening drum By means of the regulating valve (1), the pressure s regulation is realized, being able to be read at the oil pressure manometer (2). Basically it is applied that light material needs lower pressure than heavy material. The maximum hydraulic pressure is 170 bar ( psi). When reaching this value, the hopper belt is stopped automatically. The optimal adjustment is recognizable at the fact that there s hardly any fine grain in the oversized grain. Reverse hopper belt This function serves to remove or to avoid material jams or blockages of the hopper belt. Page 124 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

125 NOTICE Danger due to longer, resp. uncontrolled operation of the function Reverse hopper belt. Machine damages can arise. Secure, that the hydraulic pressure for the hopper belt does not exceed 70 bar ( psi) when reversing. Switch off the hopper belt immediately, if the hydraulic pressure exceeds 70 bar ( psi). Pre-condition: The machine is started in automatic operation. Fig. 100: Operating area 1 Press the button at the operating area 1. All machine components are now stopped automatically in the technologically correct order. Turn the key switch to position. Herewith, the operation mode Manual operation is switched on. Betriebsanleitung_Nemus_2700_Version5_gb Page 125 of 146

126 Fig. 101: Operating area 1 - reverse hopper belt Press the button (1) and the button at the same time. Fig. 102: Manometer - reverse hopper belt Attend the hydraulic pressure at the manometer (1) in the engine compartment. The manometer is marked with the following pictogram:. If the blockage is removed, proceed as follows: Page 126 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

127 Fig. 103: Operating area 1 - reverse hopper belt Release the button (1) or the button. Reversing the hopper belt is stopped. Turn the key switch in the operating area 1 to position. Thus, the operation mode Automatic operation is switched on. Press the button at the operating area 1. Thus the separating process is started systematically in operation mode Automatic operation. Betriebsanleitung_Nemus_2700_Version5_gb Page 127 of 146

128 Manual operation This symbol refers to activities or information, being in relation to manual operation. Operating the machine in manual is exclusively for executing maintenance and/or repair works. In manual operation, single machine components can be commissioned. Basics for manual operation The machine is in working position. The key switch at the operating area 1 is turned to position. All machine components, regulated by revolution are set to minimum power. The diesel engine is started. Machine components for manual operation On the basis of the following graphic, also being situated on the machine as a label, it emerges, which components you can start in manual operation: Page 128 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

129 Fig. 104: Label manual operation POS Description 1 Hopper belt 2 Screening drum 3 Fine grain collector belt 4 Fine grain and oversized grain discharge belt Display with function buttons Manual operation Fig. 105: Display manual operation POS Description 1-4 Function buttons By means of these buttons, choose the machine component(s) to be started, according to the indications of the label Manual operation (see Fig. 104, page 129). Betriebsanleitung_Nemus_2700_Version5_gb Page 129 of 146

130 5 Control indicators Operating manual The indicators are numbered and related to the chosen machine component(s), as well as the corresponding function button(s), situated below. Indicator red = Component is not operated Indicator green = Component is chosen for commissioning or component is operated Choosing, starting and stopping the machine components NOTICE Danger due to starting or stopping the separate machine components non-systematically. Machine damages can arise. For the separating process, operate the machine in operation mode Automatic. NOTICE It is possible to commission one or also several machine components in one starting process. By means of the function buttons, chose the machine component(s), to be started. Press the button at the operating area 1. The acoustic starting warning sounds. The chosen machine component(s) is/are started. Setting the desired revolution(s) / performance(s) of the chosen machine component(s) is described in chapter 7.2.7, Optimization of machine parameters, page 119. Page 130 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

131 The machine component(s), being in operation, is/are stopped as follows: Reduce the revolution(s) / performance(s) of the operated machine component(s) to the minimum. Press the button at the operating area 1. All machine components are stopped. Turn the key at the starting module (1) to position 0. The diesel engine is switched off. Remove the key and store it safely Modification to the screening drum type SM620 Pre-condition: The machine is in working position. The machine is switched off and secured against unintended re-starting. The existing screening drum, resp. center drum is removed (see maintenance manual Maintenance screening drum Changing the screening drum ). Betriebsanleitung_Nemus_2700_Version5_gb Page 131 of 146

132 NOTICE Danger due to non-even surfaces at the races of the screening drum, to be installed. Damage to machine can arise. Ensure the surfaces at the screening drum's races on the inlet and outlet side to be free of damage, deposits and fixed markings (e.g. number of screening drum). Repair recognized damage and remove unevenness at the races' surfaces. Fig. 106: Screening drum SM620 - View POS Description 1 Screening drum type Adapter race 3 Fixings at adapter race 4 Spanning element at adapter race Page 132 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

133 Fig. 107: Screening drum SM620 - Detail spanning element POS Description 1 Adapter race 2 Spanning screws for adapter race 3 Chain at screening drum 4 Screening drum body 5 Worm inside screening drum 6 Race of screening drum 7 Teeth at adapter race Fig. 108: Screening drum SM620 - Detail fixing POS Description 1 Chain at screening drum Betriebsanleitung_Nemus_2700_Version5_gb Page 133 of 146

134 2 Screening drum body 3 Adapter race 4 Fixing at adapter race 5 Race of screening drum Operating manual NOTICE Danger due to components, assembled incorrectly. Machine damages can arise. Make sure, that the adapter race is mounted onto the screening drum correctly. The heads of the spanning screws have to direct towards the screening drum s turning direction. Make sure, that the adapter race is mounted onto the screening drum body tightly. Make sure, that the adapter race is aligned on the screening drum thoroughly. Fix the adapter race onto the screening drum. The teeth at the adapter race have to be inserted into the screening drum s chain thoroughly. The fixings at the adapter race have to lay flatly on the screening drum s body. NOTICE Danger when drawing tight the adapter ring. Damage at the adapter ring can arise. Use different screw lengths to draw tight the ring slowly, step by step. Tighten the spanning screws at the adapter race. Page 134 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

135 Fig. 109: Screening drum SM620 - shackle Remove the securing pins at the shackle (1). Open and remove the shackle (1). NOTICE Danger due to wrongly assembled, resp. incorrectly secured components at the drive chain. Machine damage can arise. Ensure the components to be correctly assembled and secured with securing pins. The following described components can be found in the tool box: Betriebsanleitung_Nemus_2700_Version5_gb Page 135 of 146

136 Fig. 110: Screening drum SM620 - extension drive chain Fix the offset links (2) spare links (1). Secure the offset links (2) with securing pins. Fix the components with locking links (3) at the previously opened drive chain. Secure the locking links (3) with securing pins. Lay the drive chain onto the adapter race. Page 136 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

137 WARNING Danger to persons due to using non-appropriate lifting devices. Personal damages can arise. Only use approved lifting devices. Only use lifting devices with a sufficient load bearing capacity (Load capacity minimum 2.5 t (24.52 kn / lbs)). Never stay under pending load. Wear the personal protection equipment. Lift the screening drum into the machine and position it on the carrier wheels. Fig. 111: Screening drum SM620 - rear axial roller Adjust the rear axial roller in dependence to the type of screening drum: Put the axial roller to position 1, if you have installed a screening drum of type Nemus or Mustang. Put the axial rollert o position 2, if you have installed a screening drum of type screening drum SM620. Betriebsanleitung_Nemus_2700_Version5_gb Page 137 of 146

138 Fig. 112: Screening drum SM620 - rear axial roller Adjust the front axial roller in dependence to the type of screening drum: Put the axial roller to position 1, if you have installed a screening drum of type screening drum SM620 Put the axial roller to positoin 2, if you have installed a screening drum of type Nemus or Mustang Fig. 113: Screening drum SM620 - position of motor Remove the securing pin (1). Remove the spacer (2). Move the drum drive (3) to the right final position. Page 138 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

139 Fig. 114: Screening drum SM620 - new positoin of motor Install the spacer (1) on the left side of the motor. Secure the spacer with the securing pin (2). Fig. 115: Screening drum SM620 - put on chain Put the drive chain (1) onto the sprocket (2) of the drive. Align the drum. Betriebsanleitung_Nemus_2700_Version5_gb Page 139 of 146

140 NOTICE Danger due to a too high conveyor worm in the screening drum. Machine damage can arise. Ensure the hopper not to collide with the screening drum s worm, when moving it in. If necessary, grind the worm in the hopper s area, so it doesn t collide with the inlet chute. Fig. 116: Danger zone inlet chute - conveyor worm Make sure, that the conveyor worm (1) in the screening drum has a sufficient circumferential distance (3) to the inlet chute (2). Fig. 117: Operating area 1 - start motor Start the diesel engine with the ignition key (1). Page 140 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

141 Fig. 118: Operating area 4 Turn the switch span the drive chain. at the operating area 4 to the right to Fig. 119: Operating area 2 Turn the switch move in the hopper. at the operating area 2 to the left to Betriebsanleitung_Nemus_2700_Version5_gb Page 141 of 146

142 7.4. Shut down Switching off the machine Pre-condition: The machine is started in Automatic operation. Stop feeding the material into the machine. Empty the machine and make sure, that there is no material in the machine, resp. on the belts anymore. Set all machine components, regulated by revolution, to lowest power (revolution). Fig. 120: Operating area 1 - stop motor Realize the following steps at operating area 1: Press button. All machine components are stopped automatically in technologically correct order. Turn the key at the starting module (1) to position 0. The diesel engine is switched off. Remove the key and store it safely. Page 142 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

143 8. Emergency WARNING Danger to persons due to switching on the machine, although the danger or its source is not yet eliminated. Death or really severe injury can be the consequence. Secure the machine against unauthorized re-starting. Fix corresponding indication signs at the operating panel. Inform the personnel, being on site about the reason of shutdown Damage to persons If a danger for life and health of persons exists, so the following steps are to be executed immediately: Press EMERGENCY-STOP-SWITCH. Take precautions against early re-starting of the machine. As far as necessary, take measures for First Aid resp. for danger or damage defence. Execute emergency call (rescue service, fire brigade, police) or engage someone with executing. Inform the supervising personnel/superior and the machine s operator immediately. Do not unlock the EMERGENCY-STOP-SWITCH until the danger is over and the source, resp. cause is found and eliminated. Betriebsanleitung_Nemus_2700_Version5_gb Page 143 of 146

144 8.2. Damage to machine If a danger to machine exists, so the following steps are to be executed immediately: Press EMERGENCY-STOP-SWITCH. Take precautions against an early re-start of the machine. Inform the supervising personnel/superior and the machine s operator immediately. Only eliminate damages, which you were authorized for by the operator and you are specially qualified for. Do not unlock the EMERGENCY-STOP-SWITCH until the danger is over and the source, resp. cause is found and eliminated. Page 144 of 146 Betriebsanleitung_Nemus_2700_Version5_gb

145 Index Air filter , 108 Basic machine Basic safety instructions Center drum Check scope of supply Checking the hopper belt Checks before commissioning Command symbols Commissioning Cooling water line Copyright... 9 Damage... 7 Danger area Empty Fire protection signs Free space under the machine Fuel tank Function Hydraulic liquid , 109 Instructed personnel Intended use Language Machine identification number Machine overview Motor oil level Non-intended use Operating elements Operating manual Availability of operating manual... 7 Purpose of the operating manual... 7 Operation modes Operator Operator s obligations Options Pictograms... 8 Pictograms at the machine Prohibition symbols Qualification of personnel Resale... 8 Rescue signs Residual risks Risk... 7 Screening drum Serial numbers Signal words Specialists Storage and packaging Switching off the machine Technical changes... 9 Trademark protection... 9 Translation... 8 Transport damages Type plate Warning signs Warning symbols Water pre-separator Working operation Betriebsanleitung_Nemus_2700_Version5_gb Page 145 of 146

146 Komptech Umwelttechnik Deutschland GmbH Carl-Zeiss-Straße 2 D Oelde [t] [f] [e] info@komptech.de Komptech GmbH Kühau 37 A-8130 Frohnleiten [t] [f] [e] info@komptech.com