Highlights

What does that mean exactly?

1. Our operating concept SPECTIVE, which was already successful in the PRO series, has been further developed and supplemented by the SPECTIVE CONNECT concept. This simplifies the operation of the machine for our customers.

We will discuss our control and SPECTIVE CONNECT later on in the presentation.

2. With the new active overload system, the machine reacts a lot faster to uncrushable materials and is therefore less sensitive with significantly higher machine availability above all in recycling applications.

3. Of course, the issue of cost-effectiveness of the machine for the customer is also an important topic at Kleemann. This includes the new drive concept with transfer box with reduced maintenance measures and the load-dependent fan, which allows us to reduce the fuel consumption considerably.

Then we'll take a look at the main points in more detail! Let's start with the feeding unit. The following points play a role here:

• the extension of the hopper from 4.4 to 7.5 m³,
• the hopper filling aid, the locking from the ground by radio
• as well as a revised chute design, based on the MR EVO2 series.

Radio remote control

This is our completely overhauled radio control, which fits in perfectly in our SPECTIVE concept. This control system permits the execution of all folding and securing functions. Whether it is for the hopper or folding the crusher discharge conveyor, the operator always finds a safe position with an optimal overview.

The advantage of this concept for the customer lies primarily in the enhanced safety for the operating personnel and the faster setup times.

Load capacity

In addition, for the standard hopper we have increased the load capacity compared with the predecessor machine and done so with a reduced transport height at the same time.

We were able to reduce the transport height from 3.60 m to 3.40 m. By the way, for the MCO 90(i) EVO2 cone crusher too. The hopper filling aid makes loading from the rear with the wheel loader possible. The new chute design is overall more robust thanks to continuous structures. With the more compact design, which we are already familiar with from the MR 110(i) EVO2, we achieve more stable conveying characteristics. This allows us to achieve a performance increase with a feed capacity of up to 400 t/h.

We have an independently vibrating double-deck prescreen. The advantage here is the effective screening of the fines in the feed material. The bypass flap is installed directly on the prescreen. With the screen vibrations we achieve a cleaning effect for the bypass flap. The screen surfaces of the prescreen have been extended by hexagonal screen surfaces that open to the bottom. A significantly increased open screening surface is created and the clogging of material is reduced by the conical holes. The screen surfaces are fully compatible with the MC EVO1, i.e. they are exchangeable one-to-one.

The long or short side discharge conveyor is very easy to assemble on both sides, whereby the long belt can be folded hydraulically for transport.

The advantages are obvious: shorter set-up times, greater flexibility, higher performance.

The next highlight is our proven Continuous Feed System CFS, which is well-known from other machines and is now included as standard with the machine.

Vibrating feeder and prescreen throttle or increase conveying speed automatically depending on the fill level of the crusher. This guarantees continuous crusher utilisation thanks to optimised loading – for a daily output of up to 10% more and included in the standard equipment.

Line coupling

The crushing process between the crushing plants is then optimised automatically so that material is always conveyed with maximum efficiency through the machine.

For safety reasons, the crushing and screening plants are connected to each other by a cable. If an emergency stop button is pressed on the plant train in the event of an emergency, all machines are safely stopped.

We have introduced the following new features:

The distance and deblocking plates were omitted for the MC EVO2. As a result, we can now start the entire gap setting range of 30 - 180 mm fully hydraulically. The advantage here is obviously the higher application flexibility and higher process reliability in case of overloading.

The replacement of the crusher jaws has been optimised by improving accessibility to the side wedges. The benefits here include the shorter downtimes when changing the fixed crusher jaw.

Apart from that, we have retained the proven technology of the predecessor model: Unblocking system with improved retrofittability, long crusher jaws and optimised feed geometry for the best possible feed behaviour. The crusher jaws are identical and therefore compatible with the EVO1.

For recycling in particular, we now also have the wavy crusher jaw with a round, coarse tooth shape in our offer. Better feed behaviour is achieved for smaller gap widths and sticky material sticks less.

The crusher outlet contains a deflector plate, which can be moved into 2 positions to protect the crusher discharge conveyor against damage. Replaceable wear plates are now also available.

Overload system

We are already familiar with the standard overload system, where the crusher detects a selective, short-term overload via the sensor at the crusher housing and then gradually opens the gap setting to avoid damage to the crusher.

We have also created an option for the tried-and-tested system - an improved hydraulic system - which doubles the opening speed. And with the now completely hydraulically operated gap setting we also have the opportunity to better respond to overloads.

The new revolutionary active overload system is suitable, above all, for recycling applications and makes an even faster reaction to overloading possible. An additional hydraulic unit can be used to open the crushing gap within approx. 2.0 s.

In contrast to the hydraulic overload systems, we separate the normal crushing operation from the overload function. This has 2 main advantages: we have a "hard gap setting", with constant final product. With a hydraulically supported overload system, cylinder movements constantly occur, which reduce the quality of the final product. It is precisely these movements that also cause increased wear in the hydraulics. Maintenance costs and the probability of failure increase. On top of this, in the event of a malfunction the hydraulically supported crusher comes to a standstill, whereas our system can simply be deactivated.

Following an overload the crusher moves back to its original gap setting. The advantages in applications with a higher share of uncrushable material are shorter downtimes, which leads to a higher production output and thus lower costs per ton - i.e. more profit.

The last mechanical overload protection element is the pressure plate on our crushers.

With the Active Overload System we want to avoid the activation of this last safety device. I would like to briefly show you what costs can be saved by preventing the breakage of the pressure plate:

Assuming that the machine produces 200 t of material per hour and the final product can be sold for 4 euros/ton.

If there is a production stop due to a broken pressure plate, then the crusher is usually out of action for half a day, i.e. 4 hours. If you multiply these values, you arrive at a total of 3,200 euros, which is what the breakage of a pressure plate costs the owner/operator. This does not take into account the costs for the pressure plate itself and also for the fitter, who must carry out the repair. These costs can be saved with the Active Overload System for each serious overload.

The long and short crusher discharge conveyors are now only distinguished by a connecting piece, meaning a subsequent conversion is possible. An optional head scraper and a reinforced belt are now available ex works; the latter is suitable, above all, for recycling applications and has a higher resistance to piercing and tearing. For dust-sensitive environments, the crusher discharge conveyor can be provided with belt covers.

For the evaluation and, if necessary, invoicing of the production output, a belt scale is available, which makes the data available on the smartphone via SPECTIVE CONNECT.

If a conveyor belt should nevertheless become damaged, Zip Clip belts are available via Customer Support for a rapid repair. The Zip Clip belts come with a ready-prepared connection point. The belts can be easily raised and locked at the connection point with a connecting element. This is a huge timesaver and makes vulcanisation of the belts by a specialist on site superfluous.

We have also thoroughly overhauled the suspension of the magnet. It is now mounted on chains and can therefore move freely and, for example, avoid larger metal parts, without causing immediate damage to the belt.

The distance to the belt can be adjusted at the same time via the radio remote control. Via the chain even asymmetric special positions can be realised by mounting the magnet somewhere else. We thus offer maximum flexibility for the discharge of iron.

When we move on to the power pack compartment, the first thing we notice is the clearly arranged design and good accessibility. Via a power transfer box we drive the generator via a generously dimensioned cardan shaft, whereby the high-maintenance toothed belt of the predecessor model is no longer used.

The drive system pumps are activated via a clutch coupling and can therefore draw on the full power of the diesel engine.

All other hydraulic pumps for auxiliary and set-up functions and for the cooler drive are also driven via the gearbox.

The cooler is designed so that it is identical in all climate packages both for the MC and for the MCO.

This concept allows us to realise Quick Track as an option with the MC 110(i) EVO2. The plant can be moved when the crusher is running and the conveyor unit is switched off. Quick Track can save the operator a great deal of time when moving the plant, and as we all know, time is money.

Apart from the advantages of the overhauled power supply unit that have already been mentioned, the MC 110(i) EVO2 is also considerably quieter. We achieve a reduction in the sound power level in the range of 5 - 6 decibels.

We achieve this, on the one hand, by the speed-controlled fan and, on the other hand, by cleverly devised air pipework.

This simplifies the approval of the machine operation by the authorities, reduces the area of the machine in which hearing protection must be worn to a few metres and makes the machine perfect for crushing applications in an urban area.

And if that's not enough, we also have a noise insulation package in our offer. For this we have implemented some sound insulation measures in the power pack area. With these measures we reduce the sound level by a further 2 decibels, meaning the operator no longer has to wear hearing protection at the operator panel according to the standard. This is a genuine advantage for the operator.

Apart from the overhauled touch panel,we now offer two radio remote controls that can be operated intuitively. Firstly, the large radio remote control, with which the entire machine can be set up from a safe distance, and secondly, the new small radio remote control with which the user can operate all relevant functions in automatic mode in a space-saving manner from the excavator.

All of this is supplemented by SPECTIVE CONNECT. With this digital application all operating data can be transmitted directly to a mobile end device. The operator therefore has all relevant information, messages, troubleshooting options and reporting functions directly on site. SPECTIVE CONNECT is the logical extension of our operating concept and offers genuine added value.

There are many more details such as the newly developed drive system, which is driven directly by the diesel engine. As a result, the driving speed is increased by 60% compared with the EVO1 and the plant can be controlled very precisely, which considerably facilitates loading and positioning in the plant train. The machine concept also makes ergonomic refuelling of diesel and AdBlue possible from the ground.

The operating fluids can also be changed conveniently from the ground through a central drainage point.

We can meet any request when it comes to the machine lighting. In the standard version, all climbing elements and travel paths are well illuminated; with the optional Premium lighting, the surrounding area of the machine is also well lit.

We have very short make-ready times of less than 15 mins., which makes rapid location change and a fast start of production possible. Thanks to our new radio remote control, all these activities can be carried out at a safe distance with an optimal view of the machine.

Furthermore, the hydraulic folding functions of the side discharge conveyor or the crusher discharge conveyor guarantee simple transport because no parts have to be disassembled.

Finally, the compact design of the MC 110(i) EVO2 permits application on narrow building sites, such as in inner-city areas.

A further positive feature is the reduced transport height of 3.40 m, which corresponds to a reduction of 20 cm compared to the predecessor machine. Transport costs can also be saved, as the machine can in some instances also be transported on simpler semi-trailers.