Kongskilde KDC 4000 PLUS User manual

KDC 4000 & 8000 PLUS 60Hz
Dual cleaner
Manual
Manuel de service

2
GB
This operators manual applies to the Kongskilde Dual
Cleaner type KDC.
Description:
Kongskilde Dual Cleaner is a combined screen- and
aspiration cleaner, designed for separation of grain and
impurities. The cleaner is primarily designed to be used
for pre cleaning of wheat, barley, rye, oats, canola,
maize, peas, soybeans and sunower. Furthermore,
the cleaner can be used for sorting of malting barley
and seed.
The rotating screens are driven by an electrical gear
motor, and the cleaned crop can be conveyed by the
aspirator to a transport system. The impurities are
blown away together with the aspirator air, and should
be separated through a cyclone and collected.
The cleaner can be equipped with screens containing
di󰀨erent hole sizes, depending on the nature of the
crop.
Capacity varies depending on the crop to be pro-
cessed, in easy oating crop the capacity is up to
40 tonnes per hour (KDC4000) / 80 tonnes per hour
(KDC8000), depending on the requirements towards
purity of the crop.
The cleaner should be fed continuously.
Warning notes:
Take care that all guards are in correct position and
xed during operation.
Never operate the cleaner without the side doors
covering the drum is closed - there is great risk of in-
jury if a hand grabs the rotating drum! The cleaner is
equipped with magnetic switches on both side doors,
which switch o󰀨 all motors if the side doors are opened
during operation.
Always stop the cleaner when changing the screen as
well for repair and maintenance, and make sure that
it cannot be started by mistake. This is done by lock-
ing the switch on the cleaner's control cabinet, or by
mounting a safety switch connected to the cleaner.
Keep the cleaner around so there is no risk for fall ac-
cidents.
Provide adequate lighting conditions for safe operation
of the cleaner.
When changing the screen, only turn the screen drum
manually, never attempt to turn the drum by use of the
gear motor.
Wear gloves when replacing the screens - there can
be sharp edges on the screens. As well, use gloves if
samples are taken through the opening in the cleaners
gable, as there could be sharp edges of the hole.
Be careful when closing the side doors - there is risk of
squeezing between door and side panels.
Also beware of head injuries when the doors are
closed, there may be sharp edges.
Never insert your hand into the outlet of the auger,
located at the bottom of the cleaner, the auger can
cause severe injury.
The outlet must never be left open when the cleaner is
in operation. Connect the outlet to a container or a min.
850 mm long OK200 tubing to prevent access to rotat-
ing parts.
To avoid any unintentional contact with rotating parts,
pipes of minimum 800 mm length, with a diameter of
maximum Ø 200 mm must be installed onto the inlet
and outlet connections.
These pipes must be installed with bolt clamps, where
tools are necessary for dismantling.
In case it is not possible to use minimum 800 mm
tubes, it must be insured that there within minimum
800 mm from the cleaner are used bolt clamps,
where tools are necessary for dismantling.
The reason for this is, that according to EU-directive
2006/42/EC (Machinery Directive), it is not allowed for
any unauthorized personnel to gain access to rotating
parts. In case quick couplings are used, unautorized
personnel could dismantle the tubing, and have access
to potentially dangerous /rotating parts.
Never insert your hand into the aspirator blower´s in-
take or outlet while the blower is in operation.
Beware of eye damage - wear goggles in the proximity
of the blowers outlet.
All electrical installations must be carried out in accord-
ance with current regulations.
If abnormal vibrations or noise is detected, the cleaner
should be stopped immediately and the cause exam-
ined. If in doubt, call expert assistance for any repair
and maintenance.
Make sure the cleaner is installed on a stable, horizon-
tal and solid surface to prevent collapse and tipping
over.
If the cleaner is to be moved, it must either be lifted
in the four lifting points in the corners of the cleaner
(marked with chain symbol) or a forklift must be used. It
should always lift at the specied points under the rails
on the cleaner's beams. The forks should be so long
that they lift on both sides of cleaner. If the cleaner is
dropped, there is a great danger of personal injury!
Wear ear protection if working at the cleaner for extend-
ed periods of time, as there is a risk of hearing damage.

3
Warning signs:
Avoid accidents by always following the safety instruc-
tions given in the manual and on the warning signs
placed on the cleaner.
Safety signs without text are used on the machine. The
signs are explained below.
Read carefully the manual before
using the cleaner, and observe
the warning signs on the cleaner.
Never put the hand in the outlet
of the trough auger, while the
cleaner is in
operation.
Location of lifting points for forklift
Do not place the forks here
Location of lifting points

4
1 Intake
2 Inner screen
3 Outer screen
4 Auger
5 Outlet from screen
6 Blower
7 Injektor
8 Scoop elevating system
9 Aspiration chamber
10 Outlet for clean grain
11 Air bleed
12 Outlet from inner screen
13 Outlet for small
grains, used for e.g.
malting barley
Impurities from the screens and
aspirator are collected in the
blower tubing
Impurities from the screens
and aspirator are kept apart
Function description
1. Inlet of uncleaned crop
2. The inner screen separates large
impurities from the crop
3. The outer screen separates small
impurities and kernels from the crop
4. The impurities from both screens
are collected in the bottom through,
where the auger will convey the
impurities towards the inlet end
5. The impurities are guided into the
injector on the blower tubing (if both
shutters are closed)
6. The blower sucks air and light impu-
rities from the aspiration chamber
7. Waste can be conveyed for dis-
charge at a desired place
8. The pump impellers lift the crop
into the aspiration chamber
9. In the aspiration chamber, light
impurities and dust are removed
from the crop
10. OK200 outlet with clean crop
11. Valve for air regulation for suction
power in the aspiration chamber
12. Outlet for large impurities from
the inner screen
13. Outlet for small kernels and
impurities from the outer screen
can be collected via this outlet
Crop Large
impurities
Small
impurities
Light
impurities
The capacity of the cleaner de-
pends of settings and screen se-
lection:
• If the cleaner's inclination is in-
creased, the crop ows faster
over the screens. Capacity is
increased and purity is reduced.
Principle of operation:
• Internal screens with small
holes increases the cleaning
e󰀩ciency and reduces the
capacity.

5
Transport of the cleaner
The cleaner is equipped with transport brackets at
delivery, for the purpose of maneuvering during loading
and unloading, and to protect the cleaner during trans-
portation. The transport brackets will also be used for
transportation on level surfaces.
The cleaner is having small wheels in the back end for
transportation in the length direction. This can be useful
when loading the unit into or out of a container.
On KDC8000 front transport bracket, a fork bracket is
attached. On forklifts having hydraulics to move the
forks sideways, the bracket is put on the end of the
forks, and the forks are pushed together to hold the
bracket. The hydraulics is normally strong enough to
hold the bracket during transportation of the cleaner
forward and backwards.
If the fork lift is not having hydraulics to operate the
forks, the enclosed chain is used to hold the bracket in
such a way that it is not pulled o󰀨 the forks when mov-
ing backwards.
Installation:
The cleaner must be installed on a rm, level and hori-
zontal surface. During installation, pay attention to the
following:
• the side doors of the cleaner bind
• the thumbscrew in the side doors cannot be
screwed in
• the magnetic contacts on the side doors do not
work properly
If one or more of the above problems occur, the cleaner
should be leveled by support under the legs or under
the lifting arrangement. See sections "Operation" and
"Troubleshooting".
If the cleaner is mounted on a platform or similar, it is
important that the cleaner is secured against falling
down. It is therefore advised to bolt it to the oor, by
means of the two supplied oor brackets.
The oor brackets are attached to the angled brace at
delivery of the cleaner. They can be removed for at-
tachment onto the transport wheels´ axle. Hereafter the
oor bracket can be bolted onto the oor.
'
Brackets for fastening the KDC 8000 to the oor
The brackets are attached onto the wheels´ axles
Height adjustment above oor (related to connec-
tion to discharge pipe on auger)
The cleaner should be horizontal before adjusting the
inclination of the drum (see section "Inclination"). If
adjustment is needed, the cleaner can be lifted and
the bolts / legs moved, so that horizontal adjustment is
achieved.
Transport bracket back
end, for protection
during transportation
Transport and protection bracket in the
front end. This cross bar is used to lift the
front end of the cleaner for example with a
fork lift
Wheel

6
This transfer is located on the fork bracket:.
Do not attempt to move the cleaner by dragging it
across a oor, there is risk of bending the cleaner's
legs. Instead, lift the cleaner in the four lifting points or
with a forklift under the cleaner.
NB - Provide adequate clearance when transporting the
cleaner.
The cleaner can be moved by lifting it in the 4 lifting
points located at the top of the corners, or by forklift
under the longitudinal bars.
Rails for lifting the cleaner by forklift - are shown with
this symbol.
Never lift the cleaner with a forklift under the beams of
the lifting arrangement - is shown by this symbol.
When placing the KDC8000 on e.g. a platform where
the cleaner rests on the wheels and feet of the lifting
arrangement, the cleaner must not be placed in a lower
inclination than the horizontal, as there is otherwise
sunstantial risk of deforming the lifting arrangement!
When the cleaner is installed in the nal set up,
the transport brackets can be removed.
The cleaner without transport brackets.
Lifting points

7
Location
The cleaner can advantageously be installed, so that
the crop is cleaned both when it is being put on stock,
and when it is taken out of stock again.
The capacity is generally dependent on the requirement
for purity, as less load of the screens, provides better
opportunities for the removal of impurities.
The transport system must therefore be designed so
that it is possible to regulate the supply of material to
the cleaner.
Make sure there is clearance next to the cleaner, to
make the necessary adjustments and service.
Also, remember that there must be room for replacing
the screens. It is easiest to replace the screens at the
right side of the cleaner (seen from the inlet end). The
screens are easily replaced if there are approx. 1,5 m
clearance beside the cleaner.
Pipeline for blower
The blower pipeline should be of the Kongskilde OK200
dimension. It is recommended to use as few bends as
possible and a cyclone at the end of the pipeline.
At a commonly occurring content of impurities in the
crop, the blower is powerful enough to blow the screen-
ings approx. 20 m (including 4 meters vertical length,
two bends and one cyclone).
If to much blower power is applied to conveying, this
will reduce the air ow and, accordingly, the
cleaning e󰀩ciency of the aspiration cleaner. If addition-
al conveying length is required, an extra blower may be
inserted.
Separation of screenings
The screenings may either be discharged through a
separate gravity outlet or delivered into the trash blow
line (A) and discharged together with the light impuri-
ties.
Impurities separated by screens and aspirator dis-
charged into the trash blow line
Mount the enclosed covering plate in the outlet (B) and
(C) of the trough auger.
Impurities separated by screens and aspirator dis-
charged separately
Remove the covering plate from the outlet (B) of the
trough auger. If desired, a shutter may be tted instead
of the covering plate.
Oversized impurities separated by inner screens can
also be discharged separately.
Oversized impurities separated by inner screens
discharged separately
Remove the covering plate from the outlet (C) of the
trough auger. If desired a shutter may be tted instead
of the covering plate.
Be aware of the danger of touching the rotating auger,
see section "Warning notes" and the warning sign on
the bottom trough.
Drum gear motor
In order to avoid oil spills during transport, the gear vent
is closed with a blunt rubber cord. This sealing cord
must be removed before using the cleaner.
BC
A
90°
90°
4 m
Cyclone
OK200 pipe system

8
Safety switch installation
(on versions without control box)
Mount the magnetic switches to the safety relay accord-
ing to this diagram found in the back of this manual.
Every motor contactor should be switchable by DC cur-
rent and powered by the 24VDC safe circuit.
All local regulatory rules must be followed. The installer
has full responsibility to make sure the local regulatory
rules are followed.
To make sure the safety switches work with the KDC
control panel, follow this procedure step by step:
• Ensure the cleaner is installed correctly and the
magnetic safety switch system on the side doors
is connected correctly according the electrical dia-
gram.
• Close both side doors and start the cleaner.
• To test the safety system, now start opening the
side doors by unscrewing the thumb screw. When
unscrewing, the safety relay should break the cir-
cuit and thus stop the motors.
• It should take approximately 15 seconds to open
the side doors.
• When the side doors have opened, the drum
should have stopped rotating and it should there-
fore be safe to change the cleaning screens.
Motor installation (on 60Hz versions)
The KDC needs motors to be installed before it can
operate. Each motor must be installed with a DC mo-
tor contactor wired up to the safety circuit in the control
panel. This is to ensure the safety in operating the ma-
chine.
The KDC 4000 uses:
• Auger KDC 4000 - 0,75 kW motor with N56C ange
• Drum KDC 4000 - 1,5 kW motor with N140TC
ange
• Blower KDC 4000 - 4 kW motor with FF215 ange
The KDC 8000 uses:
• Drum KDC 8000 - 2,2 kW motor with N140TC
ange
• Auger KDC 8000 - 1,1 kW motor with N143T ange
• Blower KDC 8000 - 4 kW motor with FF215 ange
Ensure that the magnetic safety switch system is in-
spected and maintained regularly according to the
users manual for the cleaner.

9
Electrical installation:
The supply cable is guided through the cable gland in
the control cabinet and connected as shown. Always
use ferrules on the cable ends and tighten the screws
securely.
Electrical diagram for the cleaner can be found in the
control cabinet.
Direction of rotation
The electrical connection must be made, so that the
direction of rotation of the drum, blower and auger in
the bottom trough is counterclockwise (seen from the
inlet end of the cleaner).
Capacity:
Maximum capacity of the cleaner for pre-cleaning of
grain is:
• approx. 40 tons/hour for KDC4000
• approx. 80 tons/hour for KDC8000
Generally, the capacity will depend on the required
cleaning e󰀩ciency - the smaller the load of the screens,
the better the separation of impurities.
The conveying system should therefore be designed to
allow adjustment of the material supply to the cleaner,
to obtain the desired cleaning e󰀩ciency.
General advice concerning capacity and selection
of screens:
The inner screen separates the large impurities from
the crop. The main ow of crop has to pass through
the inner screen. Selecting screen with small hole size
compared to the kernel size gives the most e󰀩cient
cleaning, but reduces capacity. Selecting screen with
large holes compared to kernel size gives capacity but
reduce cleaning e󰀩ciency. If too much crop is feed into
the cleaner, good kernels will be discharged together
with the impurities.
To reach max. capacity, it is then necessary to use
screens with large enough holes to allow the kernels to
pass through fast enough. On the outer screen small
impurities and small kernels are separated from the
crop. For pre cleaning, there is no limitation in capac-
ity in relation to screen selection. For size separation
of kernels on the outer screen approx. 10 – 20% of the
capacity rated for pre cleaning can be obtained.
The best cleaning result is achieved with dry crops.
L1 L2 L3
~

10
Inclination of the cleaner:
In case the cleaner should be used for pre cleaning, it
is advised to adjust the inclination to:
• approx. 6° on KDC4000
• approx. 9° on KDC8000
The inclination has an inuence on the ow rate and
the layer thickness on the screens, and thus also on
the cleaning performance.
At an inclination of approx. 4° the inner screen is hori-
zontal at the bottom. The inclination must there-fore
never be less than 4° as the inner screen should either
be horizontal or incline towards the outlet end.
Normally, there is no need to set the cleaner with an
inclination greater than:
• approx. 7° on the KDC4000
• approx. 12° on the KDC8000
When installing, it is therefore important to take into ac-
count, that the inclination of the machine can be adjust-
ed. In particular, it must be taken into account that the
inlet and outlet connections can be adjusted to changes
in inclination.
Mount for example a exible steel hose on the inlet and
blower outlet (Kongskilde order number 122 050 156) -
see also section "Accessories".
For high-capacity pre-cleaning, it is usually necessary
to adjust the inclination angle from:
• approx 4,5° - 7° on KDC4000
• approx. 8° - 12° on KDC8000
Use the protractor on the side of the cleaner to
adjust the inclination.
Set the arrow to the desired number of degrees. Now
raise the inlet end of the cleaner, until the spirit level
indicates that the arrow is horizontal, by:
• KDC4000 without lifting arrangement - lift the
cleaner, adjust the height of the legs, and lower the
cleaner so that it rests on the legs
• KDC4000 with lifting arrangement and KDC8000
with lifting arrangement - turn the crank at the end
of the cleaner.
Crank for adjustment of inclination

11
The lling of the screens can be checked through
the inspection windows in the side doors. It is recom-
mended to place a powerful lamp next to the inspection
window on the opposite side of the cleaner, to facilitate
control through the window.
Inspection windows
The e󰀨ect of the inclination may be illustrated by the
following general information
Inner screens
The inner screen arrests large impurities.
At increased inclination, it is easier to separate the
large impurities as they move more quickly across the
screen to the outlet, at the end of the screen drum.
The large impurities will have less time to be
rotated or broken and, accordingly, pass through the
screen.
This, however, also allows the crop less time to pass
through the screen before reaching the outlet at the
end of the screen drum - and being mixed with the
impurities.
Outer screens
The small impurities are separated on the outer screen.
The outer screen is also used to separate the small
kernels at sorting by kernel size, such as malt barley
and mixed crops of di󰀨erent kernel sizes.
The cleaning e󰀩ciency depends on the capacity - at
higher capacity, a lower cleaning e󰀨ect is expected, as
the small impurities will have less time to pass through
the outer screen before the crop is lifted into the aspira-
tion cleaner.

12
INNER SCREENS
Screen perforation at each
section (mm)
KDC 8000 1 - 2 - 3 - 4 - 5
KDC 4000 1 - 2 - 3
Maize
(corn)
Wheat Barley Oat Rye Soya
beans
Sun-
ower
Peas Rape
seed
Ø17/Ø17/Ø15/Ø15/Ø15
Ø17/Ø17/Ø5
Ø15/Ø15/Ø13/Ø13/Ø13
Ø15/Ø15/Ø11
Ø13/Ø13/Ø11/Ø11/Ø11
Ø13/Ø13/Ø11
Ø11/Ø11/Ø9/Ø9/Ø9
Ø11/Ø11/Ø9
Ø9/Ø9/Ø7,4/Ø7,4/Ø7,4
Ø9/Ø9/Ø7,4
Ø8/Ø8/Ø7,4/Ø7,4/Ø7,4
Ø8/Ø7,4/Ø7,4
Ø7,4/Ø7,4/#5,2/#5,2/#5,2
Ø7,4/Ø7,4/#5,2
Ø7/Ø7/#5,2/#5,2/#5,2
Ø7/#5,2/#5,2
Ø6,5/Ø6,5/#5,2/#5,2/#5,2
Ø6,5/#5,2/#5,2
#5,2/#5,2/Ø4,3/Ø4,3/Ø4,3
#5,2/#5,2/Ø4,3/Ø4,3
Ø4,3/Ø4,3/Ø3,5/Ø3,5/Ø3,5
Ø4,3/Ø4,3/Ø3,5
Ø3,5/Ø3,5/#2,75/#2,75/#2,75
Ø3,5/Ø3,5/#2,75
Oblong holes 5 x 20 (all sections)
Oblong holes 10 x 30 (all sections)
Screen program:
To obtain optimal e󰀩ciency, it is important to use
screens of correct slot/hole dimensions.
A range of screen sizes suitable for ordinary crops is
available.
If more crop is lled into the cleaner, than the inner
screen can handle, the kernels that do not fall through,
will come out together with the large impurities.
Screens for inner drum
On the inner drum, the crop is to pass through the
screen and the large impurities be arrested.
Screens with a small hole diameter will therefore en-
sure optimum separation of large impurities; at the
same time, however, the capacity will be reduced. A
large hole diameter, on the other hand, will result in a
high capacity and reduced separation of large impuri-
ties.
On KDC4000 it is recommended, as standard, to use
the same hole diameter on the rst two inner sections.
However, in the event of low capacities, a better sepa-
ration will often be obtained by using a smaller hole
diameter on the 2nd section. Still, the main part of the
crop is to pass through 1st and 2nd sections of the in-
ner screen.
It is important to avoid kernel waste, that most of the
kernels have fallen through the inner screens before
section 3.
On KDC8000 it is recommended, as standard, to use
the same hole diameter on the rst two inner sections.
On sections 3 - 5 are usually used screens with slight-
ly smaller holes.
However, most of the crop must pass through the
innner screen of the 1st to 4th sections.
It is important to avoid kernel waste, that most of the
kernels have fallen through the innner screen before
section 5.
In case of lower capacity operation, screens can be
chosen on the inner drum with smaller holes, so that
impurities with smaller oversize relative to the kernels
are also sorted.
Max. capacity
Reduced capacity
1 2 3 4 5
123
KDC 8000 KDC 4000

13
Screens for outer drum
On the outer screens, the crop passes across the
screen while the small impurities will fall through.
Thus it is the slot dimensions of the outer screen that
determine the size of the impurities arrested.
During sorting, the separation of the crop looks takes
place on the outer screen.
In selecting your screen you should also consider the
grain size, as a screen with too large slot dimensions
will also separate small-sized grains.
If an outer screen with oblong holes is used, it is
recommended to mount brushes to keep the screens
clean. For the grading of malting barley the brushes
must always be mounted (see section "Accessories").
OUTER SCREENS
Screen perforation
(mm)
Maize
(corn)
Wheat Barley Oat Rye Soya
beans
Sun-
ower
Peas Rape
seed
Oblong holes 1,0 x 16,5
Oblong holes 1,2 x 16,5
Oblong holes 1,8 x 16,5
Oblong holes 2,0 x 16,5
Oblong holes 2,25 x 16,5
Oblong holes 2,4 x 16,5
Oblong holes 2,5 x 16,5
Oblong holes 2,65 x 16,5
Oblong holes 4,0 x 16,5
Oblong holes 4,3 x 16,5
Oblong holes 4,5 x 16,5
Oblong holes 5,0 x 20,0
Square holes 2,75
Square holes 5,2
Square holes 6,0
Holes Ø2,0
Holes Ø3,5
Holes Ø4,5
Holes Ø7,0
Holes Ø7,4
Holes Ø9,5
No perforation*
*: Blinds screens are used if you only want to use perforated inner screens, e.g. in connection with the re-
moval of large impurities and the aspiration cleaner function.
KDC 8000 KDC 4000 Kernel size
Small
Mid size
Large
1 2 3 1 2

14
Lifting handle Thumbscrew
Replacement of screens
Always stop the cleaner before opening the side doors.
The side doors are provided with magnetic contacts
that switch o󰀨 the cleaner when the side doors are
opened, thereby acting as a safety switch.
When changing the screen with open side doors, the
screen drum can only be turned manually. The drum
turns so easily, that it can be rotated by pushing the
drum from the side of the cleaner.
Always use gloves when replacing screens. The
screens may have sharp edges.
Both the inner and outer screens have a quick-release
system attached to the screens to allow easy replace-
ment. Always mount the screens on the screen drum
with the handle of the quick-release clamps turning
in the direction shown, in order to avoid unintentional
release.
The clamps are released by pushing their sides togeth-
er. The clamp tension can be adjusted by turning the T
thread rod. Make sure the screens t snugly around the
drum.
Operation:
Start / stop
The cleaner is started and stopped on the main switch
located on the control cabinet at the end plate.
Main switch Start/stop contact
Screen selection
To obtain optimal e󰀩ciency, it is important to use
screens of correct slot hole dimensions (see section
"Screen program").
Opening of the cleaner for screen replacement /
cleaning
The side door is opened by turning the thumbscrew
counterclockwise, whereafter the side door is lifted out-
wards and upwards with the lifting handle, to horizontal
position. The gas dampers will then hold the side door
in the open position.
To close the side door, pull down on the door until it is
closed and turn the thumbscrew fully clockwise.
If the thumbscrew is turned while the cleaner is in op-
eration, the magnetic switch disconnects all the motors
of the cleaner. The cleaner must then be started on the
start switch when the side door is closed again.

15
Installation of inner screen
The inner screen is installed by guiding it around the
screen drum, and turning the drum to enable the screen
ends to be clipsed together.
Installation of outer screen
Outer screen replacement is most easily done from the
right-hand side of the cleaner (viewed from the inlet
end).
The outer screen is installed by placing the screen end
opposite of the quick release clamps under the cleaner.
Thereafter the u prole is hooked onto the cross bar
on the drum, in the screen end with the quick release
clamps. The drum is now turned, enabling the screen
clamps to be clipsed together as shown.
Adjustment of aspiration cleaner
1. First open the damper (A) completely by squeezing
the spring and turning the damper.
2. Adjust the guiding plates by means of the handle
(B), to ensure that the crop layer is equally high
in both sides of the cleaner. This may be checked
through the inspection windows (1) on the sides.
D
A
1

16
3. Adjust the spring-loaded device (C) of the "grain
shutter", so that the shutter will not open until there
is grain throughout the width of the shutter. This may
be checked through the inspection window (2) on
the sides.
Loosen the thumbscrew, push to the desired posi-
tion and tighten. As a starting point, the handle
should be placed in the middle for wheat and barley.
For lighter crops, move the thumbscrew to the left,
and for heavier crops, move the screw to the right.
When the cleaner is running, the crop is checked
according to the illustration.
The spring load device determines how long the
grain remains in the aspiration chamber.
4. Adjust the air slot in the aspiration cleaner using the
handle (D), to avoid extraction of too many whole
grains. Loosen the thumbscrew, push to the desired
position and tighten.
This may be checked as follows
4.1 If there are many whole kernels in the
screenings, they will produce noise in blower and
pipeline.
4.2 Collect the screenings after the dust
cyclone and check that there are not too
many whole kernels.
4.3 The screenings can also be inspected
through the window on the back of the
aspiration cleaner.
5. When handling light crops, too many whole kernels
may be extracted, although the aspiration
cleaner is set to minimum extraction. In such cases,
open the damper (A) a little.
Control of cleaning / sorting e󰀩ciency
After the initial adjustment of the cleaner, and operation
at the capacity stated for two or three minutes, samples
should be taken to check if the desired nal result has
been achieved.
Sampling can be done at the opening (E).
Loosen the thumbscrew, push the damper to the left
and extract the sample through the opening. Beware of
sharp edges, and remember to close the shutter after
nishing sampling.
If the cleaner is used for sorting, it is required that there
is a certain size di󰀨erence between the two crops that
are to be sorted.
If the sorting between the two crops is too low, reduce
the capacity, and if it is too high, increase the capacity.
As crops will vary, however, it will be wise to allow for a
minor safety margin.
If the capacity is changed, new samples will have to be
taken. Continue this way until the desired grading result
of the nished product has been obtained. When the
correct capacity setting has been reached, it is recom-
mended to deliver a sample of the nished product to
the feedstu󰀨 dealer for testing, as the test screens are
intended as a guide only.
B
C
E
1
2

17
Malting barley grading
In the grading of malting barley, the small-sized kernels
are separated on the outer screen.
Considerably larger quantities are to pass through the
outer screen when grading malting barley than in or-
dinary pre-cleaning of grain. In the grading of malting
barley it is therefore normally the capacity of the outer
screen that determines the capacity of the cleaner.
In the grading of malting barley the impurities from
screens and aspiration cleaner are usually kept apart,
as it is not desirable that the small grains mix with the
impurities from the aspiration cleaner.
Therefore remove the covering plate from the outlet (B)
of the trough auger.
Use, for instance, a Kongskilde TRL blower with a ven-
turi to discharge the small kernels.
Grading
Basic grading of commercial malting barley is often
based on 90% grains exceeding 2,5 mm (in Denmark).
This has also been assumed in the following.
Before starting the grading of the malting barley, it is
advantageous to know the grading of the starting ma-
terial (the unsorted grain). This may be determined
manually by means of test screens, or you can ask a
feedstu󰀨 dealer to test one or more samples.
Based on the grading of the sample and the outer
screen, use the diagram overleaf to indicate the capaci-
ty required to obtain a nal grading result of 90% grains
exceeding 2,5 mm.
Recommended capacities for malting barley grad-
ing (applies to KDC4000)
(A) Screen 2,5 x 16,5 mm
(B) Screen 2,65 x 16,5 mm
The recommended capacities are subject to the fol-
lowing conditions
Final sorting result: 90 % grains exceeding 2,5 mm
Moisture content:..................................... Max. 14 %
(well threshed malting barley)
Inclination of KDC4000:.........................................5°
Inclination of KDC8000:.........................................9°
Examples (for KDC4000):
1. Starting material sorting: ...........82 %
Desired nal sorting: ..................90 %
Outer screen slots: ....................2,5 x 16,5 mm
Recommended capacity
according to graph: ........................... 5 t/hour
2. Starting material sorting: ...........76 %
Desired nal sorting: ..................90 %
Outer screen slots: ....................2,65 x 16,5 mm
Recommended capacity
according to graph: ....................9 t/hour
If the starting material sorting is lower than the curve of
the outer screen used, this means that two cycles will
be required to reach a nal sorting result of 90 %.
Initial adjustment for malting barley grading
Inclination of KDC4000:.........................................5°
Inclination of KDC8000:.........................................9°
Inner screen (mm): ........ Ø9 / Ø9 / Ø7,4/Ø7,4/Ø7,4
Outer screen (mm): ....... 2,5 x 16,5 or 2,65 x 16,5
Selection of inner screen
The selection of the inner screen depends to a high
degree on the quality of the threshing and the expected
capacity. If the crop is reasonably well threshed, it will
sometimes be advantageous to replace the 2nd section
of the inner screen of Ø9 mm by an Ø7,4 mm screen
and thereby obtain a cleaner crop.
Selection of outer screen
The selection of the outer screen depends on the de-
sired capacity.
Where a high capacity is desired, the 2,65 x 16,5 mm
screen should be selected. You risk, on the other hand,
a separation of good grains of 3 - 12 % depending on
the starting material grading.
The 2,5 x 16,5 mm screen should be selected where a
lower capacity and perhaps two cycles can be accepted
to achieve a nal grading result of 90 %.
Starting material sorting
Capacity (t/hour)
90
88
86
84
82
80
78
76
74
72
70
68
66
64
0 2 4 6 8 10 12 14 16 18 20

18
Service and maintenance:
Bearings
All motor bearings are lubricated for life from the fac-
tory, and requires no maintenance.
Gear for screen drum
The oil level should be checked regularly and lled if
necessary. Also check the gear for leakages, and the
condition of the oil seals. Replace any leaking seals.
Oil is lled through the (top) vent screw hole, checked
through the middle screw hole (located just above the
motor) and drained through the bottom screw hole.
The gear is lled with synthetic oil, ISO VG 680, for
operation in working areas -20 to +40 ° C.
The gear oil is rst replaced after 300 hours of opera-
tion, and then every 2 years or after 10,000 hours of
operation with mineral oil. For synthetic oil, the interval
is every 4 years or every 20,000 operating hours re-
spectively.
See any separate manual for the gear drive.
Recommended synthetic VG 680 oil types are:
Mobil Glygoil 680 or Shell Omala S4 WE 680.
The gear unit ventilates through the vent screw at tem-
perature uctuations.
The gear motor must be cleaned as needed so that
cooling does not decrease.
Gear for auger
The gear units on the gear motors are lled with syn-
thetic oil from the factory, which does not require re-
placement. Pay attention to leaky oil seals, and replace
if necessary.
Oil type
See any separate manual for the gear drive.
Never mix synthetic oil and mineral oil. If you want to
change oil type, it is necessary to clean the gear very
carefully.
Gas dampers on side doors
The dampers must be inspected and replaced as
needed.
Greasing of intermediate bearing on trough auger /
screen drum main bearings
The intermediate bearing on the trough auger is posi-
tioned in the bottom trough in the middle of the cleaner.
The bearing construction is a steel shaft running in a
nylon bushing with facility for greasing.
Greasing of the bearing is extending lifetime of the
nylon bushing. It is benecial to grease the bearing
each 40 hours of running. Preferable grease type is:
Mobiltemp SHC 460 Special, or similar grease with
content of graphite or/and MoS2.
Re tightening
In a new machine, all screws and bolts should be re
tightened after the rst day of operation. Make sure that
they are always securely tightened.
Electrical connection and cable connections
Check the electrical connection in the control cabinet
- the cable glands must be tight and there must be no
loose conductors. Also, check the various cables regu-
larly. Additionally, check the magnetic contacts on the
side doors for proper attachment and function.
Cleaning
Clean the machine if it is left unused for a considerable
period of time. Keep gear and motors free from dirt,
which may reduce the cooling. The inspection windows
can be removed and wiped o󰀨 when necessary. The
window is removed by turning the thumbscrew 90° and
tilting the frame outwards.
Storage
If the cleaner is used for outdoor installation, and will
be out of use for a longer period, it is recommended to
open the outlets from the auger to avoid water being
collected in the bottom of the machine.
Location of intermediate bearing

19
Technical data:
KDC 4000 KDC 8000
Max. capacity pre-cleaning - tonnes/hour 40 80
App. capacity seed cleaning - tonnes/hour 8 13
App. capacity malting barley - tonnes/hour 5 8
Screen drum motor size - kW (HP) 1,5 (2,0) 2,2 (3,0)
Screen drum motor rpm 21,9 23
Blower for aspirator motor size - kW (HP) 4,0 (5,5) 4,0 (5,5)
Blower for aspirator motor rpm 3.000 3.000
Auger drive motor size - kW (HP) 0,75 (1,0) 1,1 (1,5)
Auger drive rpm 450 240
Control panel power supply 3x400V / 50 Hz
Rated 13,4A
3x400V / 50 Hz
Rated 15A
Inlet for crop OK200 FK250
Outlet for cleaned crop OK200 FK250
Conveying pipes for impurities OK200 OK200
Outlet from auger OK160 OK200
Inner screen area - m24,1 7,5
Outer screen area - m26,5 10
Weight of cleaner without screens - kg 890 1.425
Above capacities applies for wheat 700 kg/m3.

20
Troubleshooting
Fault Cause Remedy
The cleaner does not start when
operating the start switch
Missing power supply.
Side doors open.
Disconnected fuse relay in the
control unit.
Malfunction of magnetic con-
tacts in the side doors, or broken
wires.
Magnetic contacts do not close
when the doors are closed, as
the cleaner is not on a level sur-
face.
Defect start switch
Check and restore mains supply.
Close door and tighten thumb screw.
Reconnect circuit breaker (see section
"Electrical installation").
Replace magnets or broken wires.
Check if the thumbscrews on the doors
can be screwed in. Lift one or more of the
cleaner's legs, or raise the legs of the lifting
arrangement, so that the thumbscrews can
be screwed in.
Replace start switch
The cleaner does not stop when
operating the stop switch
Defect stop switch Replace stop switch
The side doors of the cleaner
bind when opening and closing,
or cannot be opened / closed
The cleaner is on a sloping /
uneven surface
Check if the thumbscrews on the doors
can be screwed in. Lift one or more of the
cleaner's legs, or raise the legs of the lifting
arrangement, so that the thumbscrews can
be screwed in
The thumbscrew on the side
door cannot be screwed in
when the door is closed
The cleaner is on a sloping /
uneven surface
Check if the thumbscrews on the doors
can be screwed in. Lift one or more of the
cleaner's legs, or raise the legs of the lifting
arrangement, so that the thumbscrews can
be screwed in
Drum, auger or blower motor
not operating
Power supply disconnected.
Motor or gear defect
Check and restore power supply.
Replace motor or gear
Abnormal noise from drum dur-
ing operation
Rocks, stones and other impuri-
ties in drum.
Quick release clamps on screens
has opened.
Screen dislocated on drum
Make sure there are no larger stones in the
unclean crop.
Close clamp correctly.
Check the bias of the quick-release clamps
- adjust if necessary by turning the screw in
the coupling
Fit the screen correct