At 7:45 on a Saturday morning in February 2025, I was about to sit down for breakfast when my phone rang. Thomas was on the other end, and he wasn't calling to chat. His Kleemann MC110i EVO2 had been making a grinding sound from the elevator all afternoon the previous shift. By the time they shut down, the discharge belt was tracking hard to the left and rubbing against the frame.

'Do I need a new Kleemann elevator part, or can we fix this in place?' he asked. 'We're meant to start a highway sub-base order on Monday.'

That is the right question to ask before you spend any money. The answer depends on a quick, honest checklist. Over more than 200 after-hours calls for crusher parts and emergency breakdowns, I've learned that the fastest fix starts with these six steps.

Who This Checklist Is For

If you run a Kleemann MC110i EVO2 and the elevator—the inclined conveyor that carries crushed material up to the stockpile—fails on a deadline, this is for you. It's also for the people who get the panicked phone call: the maintenance supervisor, the parts buyer, the plant manager.

Before you start, grab three things: your machine's serial number, a clear photo of the problem area, and 15 minutes with the operator's manual. The steps below take you from 'it's making a noise' to 'it's crushing again'.

Step 1: Confirm What Actually Broke

Nobody calls the elevator an elevator during normal operation. They call it 'that belt'. But when it stops, everyone searches for 'Kleemann elevator part'. My first rule: do not order the first part you think is broken.

Start with a visual walk-around. Look at the belt path, the return drums, the rollers, and the scraper at the discharge end. Then start the engine and run the elevator empty for 20-30 seconds, watching from a safe position outside the guard area. Note where the sound is coming from: the upper return drum, the lower tension drum, or the drive pulley.

A slipping belt sounds different from a failing bearing. If the belt itself is intact and the issue is tracking or a trapped piece of debris near a drum, you can often fix it on the spot. No parts needed. That's the difference between a $0 fix and a $2,000 rushed order.

If it's not that simple, take a photo and move to step 2.

Step 2: Find the Right Kleemann Elevator Part Number

This is where the calls usually go wrong. The MC110i EVO2 has been produced for years, and Kleemann has made running changes. The elevator assembly on a 2019 machine is not necessarily the same as on a 2024 machine. The mounting holes might look identical; the pulley diameters might not be.

So get the machine's serial number. It's stamped on a plate on the right side of the main frame, near the engine door. Write down the full number, including the prefix. Then use the Kleemann parts documentation for that exact serial range. The parts book groups the elevator components under the discharge conveyor section, and the part number you need will be specific to your machine configuration.

If you can't find it, call your dealer. Give them the serial number and ask for the part number, not just a price. A supplier who says 'I can send it tomorrow' without asking for your serial number is likely about to send you the wrong thing.

I'm not 100% sure every EVO2 has the same bolt pattern, but on the machines I've worked on, the build year alone wasn't enough. The photo from step 1 helps here too. Photograph the old part before you unbolt it. Twice in my career, that photo was the only reason we ordered the right component.

Step 3: Look for the Root Cause (the Step Everybody Skips)

Under time pressure, the temptation is to order the broken part and be done. But in an emergency, it's often the component next to the broken one that caused the failure. If you don't catch it, you'll be ordering the same Kleemann elevator part again within a week.

I'm not a design engineer, so I can't give you a universal wear-analysis formula. What I can tell you from field work is what I check every time:

Check the return rollers. If one is seized, it will kill a new belt in days. Check the scraper. A worn or misadjusted scraper lets material stay on the belt, and that trapped material is what destroys drums. Check the take-up unit to see if it still has enough travel for a new belt. If there's no adjustment left, you'll need the matching components, not just the belt.

Trust me on this one: order both parts in the same shipment. One freight charge instead of two. One downtime instead of two. Simple.

In Thomas's case, the lower return drum bearing was seized. The drag from that bearing is what pulled the belt out of line. We ordered the drum and the belt together. If we had installed a new belt on that damaged bearing, it would have been scrap by Sunday evening.

Step 4: Compare Parts With Your Eyes Open - and Your Wallet Closed

Here's where people get stuck in the 'which one is better?' loop. I see it often when a customer is under pressure: they spend two days reading opinions instead of one hour checking compatibility and lead time. It's the same kind of question as 'simparica vs nexgard plus' for your dog. If you ask a vet, the answer is 'depends on the dog'. If you ask a website, the answer is whatever they want to sell you.

For an elevator part on a Kleemann MC110i EVO2, the useful criteria are clear: does it fit your serial number, does the construction match the original, and can the supplier deliver it before your deadline? Price is the last thing I look at. Let me tell you why.

In March 2024, I approved a 'compatible' elevator belt for a similar machine because it was $200 cheaper than the genuine component and the label promised the same specs. Six hours after installation, the splice tore. We paid $1,500 in overnight freight for the genuine part and a second crew to install it. That $200 saving turned into a $3,000 problem. The exact dollars change over time; the pattern doesn't.

To be fair, some aftermarket parts are excellent. I've used them. But when we go non-genuine, we know exactly why we're buying it, and we check the supplier as carefully as the price. The bottom line is total cost: part, shipping, downtime, and the risk of a second failure. Price is only one line in that calculation.

Step 5: Get the Repair Ready Before the Part Arrives

When the courier finally arrives, the worst moment is discovering you don't have the right tools, the right manual, or enough lifting capacity.

Before the part gets there, do these:

Get the workshop instructions from your dealer if you don't already have them. Most models have a specific sequence for drum removal and belt tensioning. If you force a new drum into place without following the sequence, you can bend the mounting frame.

Check your lifting gear. A return drum or a complete elevator belt is heavy; you need a hoist or a forklift, not a back and a prayer. Not the time to get creative.

Lock out the machine. Engine off, key out, battery disconnect engaged. This isn't a safety lecture; it's just that the elevator sits right next to the operator's platform, and reaching in without locking out a machine that can crush rock is how you lose a hand.

Have new bolts and washers ready. Reusing old fasteners on a vibrating conveyor is false economy. A loose bolt is exactly what causes the next shutdown.

Step 6: Restock the Spare Before You Take a Shower

The last step is the one most people ignore, because the machine is crushing again and the emergency is over. But the people who don't live through the same emergency twice are the ones who order the spare immediately after the repair.

Here's the sequence: after installation, run the elevator empty for 30 minutes. Then check the tracking and tension again. Then feed material in small increments and watch the belt settle. Only when it's stable should you order a replacement Kleemann elevator part for the shelf. Same day. Not next week.

If you do that, the next time Thomas calls on a Saturday morning, you'll be able to say: 'Already on the shelf. Come get it.'

The Three Mistakes That Turn an Emergency Into a Disaster

Over the years, a few mistakes show up again and again when an elevator fails. Avoid them.

First, ordering from memory. The person who says 'it's the part on the right side, about this big' is usually the same person who overnights the wrong item. Always use the serial number and a photo.

Second, skipping the test run. Replace the part, start the machine, walk away. That's how the same failure shows up two days later. The 30-minute test run is where 90% of hidden installation problems appear.

Third, trusting the 'we need it right now, any part will do' voice. When the pressure is on, choosing a cheap or unproven part to save a few days is the decision that costs you several production days in return. I've seen it. I've done it. The total cost of a bad part always outweighs the price difference.

That's the full checklist. If you take away one thing: identify the real failure, find the right Kleemann elevator part for your serial number, fix the root cause, and keep one spare on the shelf. Do those four things and you'll spend more Saturday mornings eating breakfast than answering emergency calls.