Kleemann MC110I EVO2

MC110I EVO2 — MOBILE JAW CRUSHER

The crushing plants of the MOBICAT series are used for the pre-crushing of almost all natural rock and in recycling. However, the output of the MOBICAT crushing plants is determined not only by the jaw crusher alone – in fact, the optimal interaction of all components plays a decisive role. The focus is increasingly on cost and environmental awareness, availability of the plants, versatility, and quality of the final product.

FEATURES

FEEDING UNIT

• Feeding unit with integrated hopper walls

PRESCREENING

• Coarse prescreening thanks to vibrating feeder\

CFS (CONTINUOUS FEED SYSTEM)

• Continuous crusher feed via the CFS (Continuous Feed System)

CRUSHER UNIT

• Powerful jaw crusher

DRIVE

• Efficient and powerful diesel-direct drive

CONTROL SYSTEM CONCEPT

• Easy-to-operate control system

MAGNET AND CRUSHER DISCHARGE CONVEYOR

• Optimized conveyor unit

WELL THOUGHT-OUT FEEDING UNIT – With integrated prescreening

FEEDING UNIT WITH INTEGRATED HOPPER WALLS – FOR A FAST SET-UP.

To ensure quick set-up and simple transport, the machines in the MOBICAT MC 100(i) EVO line are equipped with integrated hopper walls. An optional hopper extension is available for loading by means of a wheel loader. It can be folded and locked hydraulically and can also be secured mechanically. Comfortable and safe operation takes place entirely from the ground. Furthermore, an optional small hopper extension is available for permanent installation on the plant – allowing a total hopper volume of 6 m³.

DISCHARGE OF FINES IN ADVANCE

The MC 100(i) EVO has a long vibrating feeder with an integrated slotted grate or punched plate. Fine material is thus coarsely separated from the feed material and does not have to run through the crusher. Rather, it is discharged by the optional side dis-charge conveyor. This guarantees better results and less wear.

SIDE DISCHARGE CONVEYOR

The side discharge conveyor is available in two versions, can be installed on both sides and can remain on the machine for transport. Discharge heights of up to 2,110 mm or 3,000 mm are possible. The belts are provided with a spray system to reduce the dust load.

OPTIMIZED OUTPUT CAPACITY – THANKS TO WELL PREPARED FEED MATERIAL

The composition of the feed material and the feed size significantly influence the output capacity. To guarantee trouble-free and low-wear operation, the feed material should be prepared as well as possible.

• Take note of the size and edge length of the material

• Select the feed size to match the final grain size and max. permissible crushing ratio

• Sort out any uncrushable material, e.g. steel beams, cables, wood, films/foils

• Ensure uniform loading of the plant – an overfilled feed hopper and a continuously empty feed hopper can lead to increased wear

UNIFORM LOADING IS INDISPENSABLE FOR A GOOD PRODUCT, OPTIMUM THROUGHPUT AND LOW WEAR

To ensure that the crushing chamber is always uniformly filled, the optional Continuous Feed System (CFS) monitors the crusher level with an ultrasonic probe and, with the line coupling option, the height of the stockpile.

The CFS independently regulates the frequency of the vibrating feeder and prescreen. A backlog is therefore avoided and crusher utilization is optimized.

The CFS facilitates the operator‘s work as the machine automatically regulates a homogeneous material flow, thus ensuring optimum loading of the crusher.

POWERFUL CRUSHER UNIT – The heart of the machine

POWERFUL CRUSHER UNIT FOR HIGH CRUSHING CAPACITY AND THROUGHPUT

The MC 100(i) EVO‘s crusher unit is the centerpiece of the machine. Its extra-long articulated crusher jaw guarantees optimal material intake. Innovative functions such as the load reduction system or the simple gap setting offer real added value.

• Optimized crusher geometry with long crusher jaw

• Crusher jaws with Regular Teeth, Sharp Teeth

• Gentle material transfer thanks to deflector plate

• Mechanical overload protection thanks to pressure plate

• Crusher unblocking system (optional)

• Convenient gap setting via push button on the touch panel

CRUSHER GEOMETRY

The crusher geometry features an optimum design. Flattened transfer from the prescreen or vibrating feeder to the crushing chamber means the material can tilt into the crushing chamber without any restrictions. When the articulated crusher jaw is pulled up, the material cannot pile up and fewer blockages are created.

The deflector plate at the crusher outlet guarantees gentle material transfer onto the crusher discharge conveyor. The large material tunnel prevents blockades and is easily accessible from the side.

Result: High throughput combined with high reliability

GAP SETTING

The gap setting is made conveniently and safely at the touch display. Adjustment is made fully hydraulically by means of a wedge system.

Rule of thumb: The closed side setting is calculated from final grain size = 1.6 x CSS. With a desired final grain size of 0 – 120, the optimum CSS would therefore be 75 mm.

3 LOAD REDUCTION SYSTEM LRS

If crushers are operated beyond their permissible load range, serious damage can be the result. The Load Reduction System LRS will prevent this from taking place.

The “load monitor” in the software detects the overload and intervenes to control it: the loaded volume is reduced, the filling level of the crushing chamber is adjusted and the forces acting on the housing and rocker are thus reduced. If, on the other hand, an underload is detected, the crusher filling level is increased again in steps to guarantee an optimum plant performance.

Result: The plant can also be operated safely with short-term crusher overloading.

4 CRUSHER UNBLOCKING SYSTEM

If material bridging or a standstill with full crusher should occur, the optional crusher unblocking system provides support. Start-up in normal and opposite directions is also possible with a full crushing chamber. Blockages can thus be quickly broken up and do not have to be cleared manually.

Result: Short downtimes in case of blockages in the crushing chamber.

OPTIMIZED RESULTS THROUGH CORRECT LOADINGS:

• Continuous underfilling leads to uneven wear, a poor grain shape and reduced plant performance

• The maximum feed size of 90% of the feed opening should be observed

• The CSS should always be correctly set

• The optimum fill height of the jaw crusher up to the beveling of the crusher jaws should not be exceeded > Continuous overfilling leads to premature wear, reduced service life of bearings and damage to the prescreen

INNOVATIVE DRIVE CONCEPT

Impressive performance – with the best possible consumption values.

The MOBICAT MC 100(i) EVO features the innovative “diesel-direct” drive concept – it is both powerful and economical.

Equipped with an efficient, powerful diesel engine with fluid coupling, the machine stands out with extremely low efficiency losses: the direct crusher drive provides maximum power directly at the crusher.

All secondary drives – for example, for vibrating chutes and conveyor belts – are driven electrically. The fluid coupling guarantees high operational safety – for both operator and machine.

INTUITIVE CONTROL SYSTEM CONCEPT – For simple operation

The MC 100(i) EVO is operated with a simplified and intuitive control system via a touch panel and illuminated push buttons.

Menu-guided operation with a continuous text fault display enables easy, intuitive operation. All components and functions can be controlled conveniently, status displays of the components help during operation.

The touch panel is integrated into a lockable control cabinet that is protected against dust and vibrations. To avoid always having to open the complete control system flap, rapid access to the operator panel is provided via a separate smaller flap (door-in-door). Radio remote control enables ergonomic operation from the excavator.

Innovative concept: Economical, safe and resource-preserving.

Diesel-electric drives have advantages over hydraulic drives not only with regard to lower fuel consumption.

The machines also require significantly less hydraulic oil, which has a positive effect on the costs of oil changes and which pre-serves resources. In the event of leaks, the risk of contamination and environmental pollution is also lower.

OPTIMISED CONVEYOR UNIT

With robust crusher discharge conveyor and magnetic separator.

The crushed material is discharged via the wide and robust crusher discharge conveyor, which is available in different lengths. The extended version has a discharge height of 3,660 mm. The belt can be folded hydraulically for transport.

The impact table on the crusher discharge conveyor protects the belt. When used for recycling, in particular, puncturing of the belt can be avoided – for a long service life.

To prevent contamination of the final product with ferrous elements, an effective magnetic separator is used. Either an electromagnet or a permanent magnet can be installed, which can both be raised and lowered by remote control. Material bridging can therefore be broken up very easily and the magnet can always be set to its optimum value. To minimize dust creation, the belt is additionally equipped with a spray system at the belt discharge.

DETERMINING THE CRUSHING CAPACITY

The machine‘s crushing capacity can be determined in different ways: apart from the classic method with the help of lorry weigh-bridge, a belt scale integrated into the crushing plant is also available as an option and is installed under the crusher discharge conveyor. This permits quick and simple reading of the crushing capacity via the machine control system.

SIMPLE TRANSPORT

Quickly on site. Immediately ready for work.

In spite of their impressive output values, jaw crushers from the MOBICAT EVO line belong to the compact class of primary crushers: Low weight and compact dimensions enables frequently changing work locations.

The MOBICAT EVO jaw crushers are extremely versatile and, thanks to their compact dimensions, can be deployed almost everywhere directly on site. Even narrow or difficult-to-access building sites in town centers are usually not a problem. And even if the work location changes frequently, the machine can be easily transported and quickly loaded thanks to its relatively light weight.

Upon arrival at the new building site, the machines demonstrate their advantages with their short set-up times: as the feeding unit is integrated into the chassis, folding the hopper walls in and out is not required.

Just as the extended crusher discharge conveyor is simply folded in for transport, the side discharge conveyor also remains on the machine during transport and is moved into position in next to no time. The machine is therefore ready to be started after only a few work steps.

FORMULA FOR SUCCESS

For optimal crushing results.

Ideal crushing results are always achieved when components of the entire plant are perfectly tuned to one another, and ideally combined with the settings made by the operator.

With these tips, it is possible to find the ideal settings for any task.

FEED MATERIAL

• Feed size: where possible, the maximum feed size should not exceed 90% of the specified crusher opening

• Compressive strength: mineral materials can be used with a maximum compressive strength of 300 MPa *

• Mineral type: all soft to hard natural stones, e.g. dolomite, granite, basalt, diabase, quartzite or gneiss as well as residual construction materials such as rubble, bricks and reinforced concrete

CRUSHING RATIO

The maximum crushing ratio (ratio of feed grain size / grain output) largely depends on the physical properties of the feed material. The following standard values result:

> 7:1 at < 100 MPa (recycling)

> 5:1 at < 150 MPa (limestone)

> 3-4:1 at < 300 MPa (hard stone)

Exceeding the crushing ratio leads to an undesirable decrease of the crushing capacity and to an increase in wear.

Similar models may be shown in addition to the featured model. Equipment may be shown with options.

Specifications are subject to change without prior notice.