When I first started handling spare parts and service orders for Kleemann equipment back in early 2019, I assumed that the biggest challenge was just getting the right part number. I thought, "The catalog is online. How hard can it be?" A few thousand dollars in expedited shipping and one very angry operations manager later, I realized I was completely wrong. The hard part isn't finding the part; it's understanding what you actually own and how it's configured.

I've personally made (and documented) 11 significant mistakes in the last 5 years, totaling roughly $18,000 in wasted budget, downtime, and rushed logistics. Now I maintain our team's pre-order checklist. This list is for anyone ordering OEM parts, planning a hire, or commissioning a Kleemann mobile plant for the first time. It's not a marketing brochure. It's the list I wish I had in 2019.

Who This Checklist Is For

You should use this checklist if you are:

  • Ordering spare parts for a Kleemann MR 130i EVO2 or similar model.
  • Setting up a new-to-you Kleemann screen (like a Mobiscreen or KLEEMANN sivebanlage).
  • Integrating a used Kleemann plant into an existing fleet.
  • Specifying a new hire or rental equipment from a dealer.

If you're just looking for general specs, this isn't for you. This is for the operational deep end. We're going step-by-step through 7 specific checkpoints.

Step 1: Decode the Serial Number, Not Just the Model Name

This is the most expensive mistake I made. I ordered a set of wear parts for an 'MR 110 Z EVO 2' without checking the build year or serial number prefix. The machine looked standard, but it was a very early production unit with a different hydraulic jaw gap adjustment. The parts didn't fit. The machine sat idle for 4 days.

The Fix: Do not order based solely on the model name. Kleemann machines often have running production changes. Check the actual machine plate. Take a photo of the serial number. Compare it to the spare parts catalog specific to that serial range. The difference between a 2019 and a 2022 build of the same model affects feed hopper liners, conveyor belts, and screen media.

Step 2: Verify Your Screen Media Configuration (Don't Assume "Standard")

Regarding the Kleemann siebanlage (screening plant): I once ordered a complete set of mesh screens for a Mobiscreen MS 703. I ordered the standard 'tensioned' mesh. The machine had 'bolt-in' frames. It was a $3,200 mistake for a special run of material, plus a 1-week delay. The wrong screen deck configuration costs you the entire production shift.

The Fix: Before ordering, climb up and inspect the screen deck frame. Is it a standard tensioned system? Is it a bolt-in modular system? Count the number of bolts per panel. A photo of the deck frame sent to your OEM parts dealer (like Kleemann) will save you money and time. The spare parts catalog won't tell you what the previous owner changed.

Step 3: Distinguish Between 'Wear Parts' and 'Running Gear'

When I first started, I lumped everything into "spare parts." That's a recipe for budget shock. A set of blow bars for an impact crusher is a consumable. A new hydraulic pump for the feed conveyor is a critical mechanical repair. Mixing them up in a single order—or worse, in a single budget—leads to ugly surprises. We saved $80 by not ordering the blow bars in advance with the pump. We ended up spending $500 in rush freight later.

The Fix: Keep two separate trackers:

  • Inventory (Wear): Blow bars, jaw plates, screen meshes, wear liners. Order based on hourly usage.
  • Maintenance (Spares): Filters, belts, hoses, sensors, pumps. Order based on service intervals or breakdown.

This simple separation saves you from running out of consumables while you wait for a critical mechanical part.

Step 4: Ask 'What's NOT Included' Before Asking the Price

I've learned this the hard way. A quote for a new Kleemann plant might look competitive, but it often excludes the first set of wear parts (the 'commissioning set'). It might exclude the remote-control receiver or the specific cable basket needed for your region's wiring code. The vendor who lists all fees upfront—even if the total looks higher—usually costs less in the end.

The Fix: When you get a quote for a new machine or a major hire, ask these three questions:

  1. "Is the first set of wear plates/blow bars included?"
  2. "What are the shipping/rigging costs for your location?"
  3. "Are there any mandatory 'upgrades' for your market (e.g., tier 4 engine modifications, specific lighting)?"

Seeing the quote vs. the final invoice made me realize we were losing 15-20% of our budget on 'unexpecteds' that were, in fact, expected by the factory.

Step 5: Match Your Feeder to the Crusher (The 'Drift' Check)

I get why people look for the cheapest crusher. But I've seen a 'drift' in performance where a perfectly good MR 130i was fed by a tiny excavator. The crusher starved for material. It wasn't the machine's fault. We called it 'drift'—the operational drift where the bottleneck isn't the crusher, it's the feeding system. We monitored this for a month. The crusher ran at 60% capacity.

The Fix: Match your excavator or wheel loader bucket size to the crusher's recommended feed size. For a large Kleemann unit, a 5-ton excavator isn't enough. Ensure your feed hopper has enough wall height to prevent spillage. This isn't a part issue; it's a site layout and equipment matching issue.

Step 6: Don't Overlook the 'Mothership' Software (The Connection)

This one surprised me. We ordered a new machine, but the interface cable for the 'mothership' (the central control unit or telemetry system) wasn't specified. I assumed it came with a standard CAT cable. It didn't. It required a specific OEM-approved module. The machine sat for two days because we couldn't connect it to our fleet management system. Oh, and the service technician cost us $400 for a visit that could have been a software update.

The Fix: When ordering a new machine, specifically ask: "What is required to connect this to a standard fleet management system? Does it need a specific telematics module or cable?" Add this to your purchase order as a mandatory line item.

Step 7: Test Your 'Emergency Shutdown' Before You Need It

This was a near-miss for us. We got a new (to us) used Kleemann plant. The safety labels were there, but the emergency stop for the main conveyor had been bypassed by the previous operator for 'convenience.' We didn't check it in the hire specific contract because we assumed it was standard. I almost lost a finger.

The Fix: On any new machine (new, rental, or used), perform a 'shutdown test' before commissioning. Walk the machine. Hit every emergency stop. Does the engine die? Does the crusher stop immediately? If not, fix it before production starts. It's a simple, cheap test that will save you a major incident report.

Final Notes on Budget and Timing

This checklist worked for us, but our situation is a mid-sized quarry with a single plant. If you are a mobile contractor hopping between sites, your spare parts carrying strategy will be different. I can only speak to that context.

Also, a quick reality check on pricing (as of June 2025): A set of standard blow bars for an MR 130i EVO2 runs roughly $1,800-$2,500. A hydraulic pump for the feed conveyor is about $3,000. Shipping for a pallet of wear parts is around $150-$300 (verify current rates). The cost of not checking the build year? $3,200 plus a week of lost production.

Don't let my mistakes be your startup cost.