ASTEC KPI-JCI FT2640 Troubleshooting Manual

Track mount jaw crusher

Hide thumbs

Table Of Contents

Quick Links

TROUBLE

SHOOTING

TRACK MOUNT

Jaw Crusher

IB-5005 4/10

Table of Contents

Need help?

Do you have a question about the KPI-JCI FT2640 and is the answer not in the manual?

Questions and answers

Summary of Contents for ASTEC KPI-JCI FT2640

Page 1 TROUBLE SHOOTING TRACK MOUNT TRACK MOUNT TRACK MOUNT TRACK MOUNT TRACK MOUNT Jaw Crusher Jaw Crusher Jaw Crusher Jaw Crusher Jaw Crusher IB-5005 4/10...
Page 2 F F F F F AST AST TRAX TRAX TRAX TRAX TRAX TR OUBLESHOO OUBLESHOO OUBLESHOO OUBLESHOO TING TING TING TING OUBLESHOO TING MANU MANU MANU MANU AL MANU Models Covered: FT2640 Track Mounted Jaw Crusher FT2650 Track Mounted Jaw Crusher FT3055 Track Mounted Jaw Crusher...
Page 3 Printed in the USA All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission from Kolberg-Pioneer.
Page 4 0 - 3 0 - 3 0 - 3 0 - 3 0 - 3 Contents Contents Contents Contents Contents Introductory Pages About This Manual Buying Replacement Parts Engine Chapter 1 Conveyor Chapter 2 Vibrating Feeder Chapter 3 Jaw Crusher Chapter 4 Hydraulic Chapter 5...
Page 5 0 - 4 0 - 4 0 - 4 0 - 4 0 - 4 About This Manual Purpose Procedures, once Special Notations The purpose of this manual described in the text, are not Within this manual, is to help you get the best value normally repeated.
Page 6 0 - 5 0 - 5 0 - 5 0 - 5 0 - 5 Buying Replacement Parts Authorized Dealer Parts Purchased Components Serial Number Department Replacement parts for Since replacement parts An authorized dealer parts components purchased by manuals and lists are compiled department is the best source Kolberg-Pioneer such as gear specifically for each unit, the...
Page 7 1 - 1 1 - 1 1 - 1 1 - 1 1 - 1 Engine Problem Solution Symptom 1. Check the fuel separator. 1. Engine not getting enough Engine shuts down. fuel. 2. Follow instructions in engine manual for priming. Problem Solution Symptom...
Page 8 1 - 2 1 - 2 1 - 2 1 - 2 1 - 2 Engine PROBLEM: Engine will not start and unit must 4. Install the M6 x 1mm x 30mm bolt into the sun be moved. gear. SOLUTION: Disengage the track brake. Tools Needed 22mm Hex Wrench •...
Page 9 1 - 3 1 - 3 1 - 3 1 - 3 1 - 3 Engine 6. Reinstall the gasket and track hub cover. Track Brake Re-engagement Use the following procedure to re-engage the 7. Repeat steps 3-5 on the other side. track brake.
Page 10 1 - 4 1 - 4 1 - 4 1 - 4 1 - 4 Engine 4. Insert the sun gear (with M6 x 1mm x 30mm 7. Reinstall the track hub cover. bolt still attached) back into the track hub. Track hub cover The machine may need to be removed slightly to realign gear.
Page 11 2 - 1 2 - 1 2 - 1 2 - 1 2 - 1 Conveyor Problem Solution Symptom 1. Not enough scraper tension. 1. Increase tension. Material build up on belt. 2. Adjust dust suppression. For further troubleshooting information on the belt scraper, refer to the Martin QC belt cleaner operation's manual Tension here Problem...
Page 12 2 - 2 2 - 2 2 - 2 2 - 2 2 - 2 Conveyor Problem Solution Symptom 1. Pulley shaft out of line. 1. Realign shaft. Conveyor belt 2. Dirt built up on pulley. 2. Clean pulley. leaves pulley. 3.
Page 13 2 - 3 2 - 3 2 - 3 2 - 3 2 - 3 Conveyor Problem Solution Symptom 1. Bearing misaligned. 1. Realign bearing. Conveyor bearings 2. Bearings worn out. 2. Replace bearings. overheating 3. Excess bearing load. 3. Reduce belt tension. 4.
Page 14 3 - 1 3 - 1 3 - 1 3 - 1 3 - 1 Jaw Crusher Problem Solution Symptom 1. V-belts slipping. 1. Check v-belts. Replace if needed. Crusher speed varies 2. Check power source. 2. Voltage varies Problem Solution Symptom 1.
Page 15 3 - 2 3 - 2 3 - 2 3 - 2 3 - 2 Jaw Crusher Problem Solution Symptom 1. Under lubrication/over 1. Lubricate bearings High bearing temperature in lubrication according to specifications excess of 180 F (82 in manual. 2.
Page 16 4 - 1 4 - 1 4 - 1 4 - 1 4 - 1 Vibrating Feeder Problem Solution Symptom 1. Under lubrication/over 1. Lubricate bearings High bearing temperature in lubrication according to specifications excess of 180 F (82 in manual. 2.
Page 17 4 - 2 4 - 2 4 - 2 4 - 2 4 - 2 Vibrating Feeder Problem Solution Symptom 1. Plant not level. 1. Replace springs. Make sure plant is level using level indicators. Support spring breakage 2. Excessive loading. 2.
Page 18 5 - 1 5 - 1 5 - 1 5 - 1 5 - 1 Hydraulic PROBLEM: None of the pumps operate on 2. Check and record all belt speeds and the open loop system. pressures when running empty. SYMPTOM: Open loop system Undercrusher conveyor Side delivery conveyor 20 Gpm stacker...
Page 19 5 - 2 5 - 2 5 - 2 5 - 2 5 - 2 Hydraulic Symptom Problem Solution 1. Check charge pressure of circuit which is not operating. a. If less than 250 PSI (18Kg/cm), change filter. Closed Loop System b.
Page 20 5 - 3 5 - 3 5 - 3 5 - 3 5 - 3 Hydraulic Symptom Problem Solution 1. Use manual override to activate pump. a. For the crusher and vibrating feeder, the manual override is a small lever on the EDC pump. Closed Loop System b.
Page 21 5 - 4 5 - 4 5 - 4 5 - 4 5 - 4 Hydraulic Problem: Jaw wedge adjustment cylinders not holding. Solution: 1. Loosen the tension rod spring nuts which will release the toggle plate spring compression. 4. Cycle the cylinders back and forth three times to make sure all the air is out of the system.
Page 22 5 - 5 5 - 5 5 - 5 5 - 5 5 - 5 Hydraulic Measure the distance 2 2 2 2 2 1 1 1 1 1 3 3 3 3 3 11. Tighten nuts until this distance is reduced by 3/4”(19mm).
Page 23 5 - 6 5 - 6 5 - 6 5 - 6 5 - 6 Hydraulic PROBLEM: Tracks build pressure but do not SOLUTION: move. 1. Check filter pressure. 2. Check voltage to brake release. Try manual override. 3. Check DIN connector. 4.
Page 24 5 - 7 5 - 7 5 - 7 5 - 7 5 - 7 Hydraulic Problem Solution Symptom 1. Air in hydraulic fluid. 1. Check for leaks in hydraulic lines. 2. Low hydraulic fluid level. 2. Check oil level and fill if Hydraulic motor or pump needed.
Page 25 6 - 1 6 - 1 6 - 1 6 - 1 6 - 1 Electrical PROBLEM: Alternator circuit breaker tripped (CAT engines only). Battery Disconnect 3. Press the red oval button. This will release Alternator circuit breaker the black reset switch and interrupt the circuit. Alternator Circuit Breaker 4.
Page 26 6 - 2 6 - 2 6 - 2 6 - 2 6 - 2 Electrical PROBLEM: Engine will not start or is sluggish when starting. SYMPTOM: Alternator circuit breaker. SOLUTION: 1. Lockout/tagout all power. 2. Disconnect remote from tether, if used, and turn battery disconnect switch to the “off”...
Page 27 6 - 3 6 - 3 6 - 3 6 - 3 6 - 3 Troubleshooting PROBLEM: Water in resistor plug SYMPTOM: Engine and remote control ceases to function properly. Control displays the follow- ing screen: Resistor location 2. Press release and remove plug. Screen display SOLUTION: 1.
Page 28 7 - 1 7 - 1 7 - 1 7 - 1 7 - 1 Overload Protection System PROBLEM: E-stop Link Loss window flashes. E-stop Radio Remote 4. Refer to schematic for proper wire location. Radio E-stop Window 3. E-stop relay should be lit with a red LED. SYMPTOM: Link has been lost between the overload protection system and the radio remote.
Page 29 7 - 2 7 - 2 7 - 2 7 - 2 7 - 2 Overload Protection System PROBLEM: Radio remote not working. 3. Check pins on tether cable to see if they are bent or pushed in. SYMPTOM: Radio remote is not linked properly.
Page 30 7 - 3 7 - 3 7 - 3 7 - 3 7 - 3 Overload Protection System PROBLEM: High engine temperature SOLUTION: window is flashing. 1. Check active codes on the Engine Fault Code History screen. High Engine Temperature Window SYMPTOM: Engine temperature is above Engine Fault Code History Screen F (100...
Page 31 7 - 4 7 - 4 7 - 4 7 - 4 7 - 4 Overload Protection System Problem Solution Symptom Engine Fault Code History 1. Turned key too fast and 1. Turn key slower. screen shows FMI code system was not able to 6272.
Page 32 T T T T T rack Mount Solutions rack Mount Solutions rack Mount Solutions rack Mount Solutions rack Mount Solutions F F F F F or Ser or Ser or Ser or Ser or Ser vice vice vice vice vice KPI -Toll free - 800-532-9311 (605-665-9311) Fax- 800-514-6115 (605-665-9348) JCI - Toll free - 866-875-4058 (541-736-1400)

This manual is also suitable for:

Kpi-jci ft2650 Kpi-jci ft3055