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KPI-JCI Fast Pack K400FP Crushing Plant Operation Manual And Parts Book

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Crushing Plant Operation Manual
and Parts Book
Model K400FP
86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401
24/7 Parts Number 888-474-0115

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  • Page 1 Crushing Plant Operation Manual and Parts Book Model K400FP 86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401 24/7 Parts Number 888-474-0115...

  • Page 3: Table Of Contents

    Table of Contents SECTION 1: INTRODUCTION Description..............................1 Crushing Plant Component Location......................2 Fast Pack Operation Manual........................2 New parts and equipment warranty........................ 2 Disclaimer/Limitation of Warranties......................3 Address for Notices ............................4 SECTION 2: SAFETY Safety Overview ............................. 7 Hazard and Advisory Statements ........................
  • Page 4 Table of Contents Chains ..............................16 Fiber Or Synthetic Slings ........................16 Transporting Machinery..........................16 Conveyor Safety ............................. 17 Safety Decals ..............................19 Safety Decal Locations........................... 25 Plant Left-Hand Side ..........................25 Right-Hand Side ............................26 SECTION 3: SPECIFICATIONS Plant Specifications ............................29 Operating Dimensions..........................
  • Page 5 Table of Contents Engine Maintenance Light/Maintenance Reset Switch ................ 45 Diesel Fuel Pressure Gauge ........................ 46 Engine Error Warning Light ........................46 Engine Oil Pressure Gauge ......................... 46 Engine Coolant Temperature Gauge ....................46 Engine Shutdown Warning Light......................47 Voltmeter.............................. 47 Tachometer Engine Error Code Display/Hour Meter ................
  • Page 6 Table of Contents Viewing Active Service Codes (MDDM)....................60 Viewing Stored Service Codes in the MDDM..................61 SECTION 5: SET-UP Introduction..............................85 Proper Site Selection............................85 Plant Alignment Procedures........................85 Engine Start-Up .............................. 85 Cone Plant Engine Pre-Start Checks: ....................... 85 Plant Pre-Start Checks..........................
  • Page 7 Table of Contents Oil Recommendations ............................ 105 Grease Recommendations........................105 Hydraulic Oil Recommendations ....................... 105 Scheduled Maintenance ..........................105 Cone Plant Grease Lubrication Items ....................... 106 Scheduled Grease Lubrication Items ......................107 Fast Pack Plant Daily Walk Around Inspection Checklist................108 Maintenance Schedules ..........................
  • Page 8 Table of Contents How to Repair a Broken Conveyor Belt..................... 129 How to Measure for the Proper Length ....................129 How to Square the Ends ........................129 How to Drill and Skive Your Conveyor Belt..................130 How to Attach the Belt Ends ........................ 132 Using the Flexco 840 Belt Cutter ......................

  • Page 9: Section 1: Introduction

    Section 1: Introduction DESCRIPTION The Fast Pack Plant system is composed of portable screening and crushing plants controlled by a centralized computer system. The Fast Pack plant is designed to be set-up and torn down with the minimum amount of man power in a short period of time.

  • Page 10: Crushing Plant Component Location

    Section 1: Introduction Crushing Plant Component Location Material Flow 1)Vibrating Feeder Bin Fast Pack Operation Manual 2)Revisable Magnet Belt This manual provides the information for an 3)Feed Conveyor 4)Side Discharge Conveyor experienced operator to successfully and safely 5)Extend Crusher Hopper operate the Fast Pack Plant.

  • Page 11: Disclaimer/Limitation Of Warranties

    Section 1: Introduction first occurs. JCI further warrants to the Distributor UNDER NO CIRCUMSTANCES SHALL and Distributor’s customers on resale that any and JOHNSON CRUSHERS INTERNATIONAL, INC. all parts supplied by JCI will be free from defect in BE RESPONSIBLE FOR ANY INCIDENTAL OR material and workmanship under normal use CONSEQUENTIAL DAMAGES, INCLUDING, (excluding ordinary wear) for a period of six...

  • Page 12: Address For Notices

    Section 1: Introduction ADDRESS FOR NOTICES Any and all inquiries and/or warranty claims should be submitted in writing to JCI at the following address: Johnson Crushers International, Inc. 86470 Franklin Blvd Eugene OR 97405 For Service Assistants: Johnson Crushers International, Inc. Attention: Service Department 86470 Franklin Blvd Eugene OR 97405...

  • Page 13: Section 2: Safety

    Section 2: Safety SAFETY OVERVIEW follows as your safety and that of others is involved. It is the responsibility of the quarry management team to develop a comprehensive safety Hazard Statements awareness program, and to ensure that all quarry The Caution, Warning and Danger statements workers and support personnel receive are hazard statements used to alert workers of appropriate safety training as required by federal,...

  • Page 14: What Is Lockout/Tagout

    Section 2: Safety What is Lockout/Tagout? hazardous stored energy (electrical, mechanical, hydraulic, pneumatic, etc.) That remains must be Lockout/tagout is a means to ensure that released, dissipated, restrained, or otherwise personnel who install, operate, repair, maintain, rendered safe. If stored energy reaccumulates, service or otherwise disable machines, equipment, monitor it until the possibility of accumulation no or electrical energy systems are protected from...

  • Page 15: Lockout/Tagout Devices

    Section 2: Safety Lockout/Tagout Devices Lockout/Tagout Rules • Always lockout/tagout any machinery before performing any adjustment, inspection, lubrication, maintenance or repair procedures. Failure to observe this precaution may result in serious personal injury or death. • Your company’s lockout/tagout program may be somewhat different than described in this manual.

  • Page 16: Miscellaneous Safety Tips

    Section 2: Safety conveyors, is also tagged and locked out. Serious Be Prepared for Emergencies personal injury or death can result if any of these • Know the proper emergency shut-down items starts unexpectedly while the crusher is procedures for the equipment you operate. being serviced.

  • Page 17: Help Prevent Accidents

    Section 2: Safety death. appropriate personal protective devices. • Keep hair short, if possible. Keep long hair • Before making repairs to the machinery, always securely tied-up to prevent it from becoming clear all quarry material from the feed and caught in the machinery.

  • Page 18: Inspect And Maintain Machinery

    Section 2: Safety slipping hazards. If necessary, use an oil requirements or modifications necessary for JCI absorbent. machinery, please contact the JCI Service • Always be sure that power is tagged and locked Department. out before cleaning spilled material or oils. Never •...

  • Page 19: Electrical Hook-Up

    Section 2: Safety ELECTRICAL HOOK-UP: MAINTENANCE AND REPAIR SAFETY: When installing any electrical equipment, be sure to completely Always lockout/tagout power to follow the manufacturer’s machinery and conveying equipment instructions. Failure to observe this before performing any maintenance or precaution could result in a dangerous repairs.

  • Page 20: Pressurized Systems (Hydraulic And Air)

    Section 2: Safety signs of wear, cracked insulation and worn or replace any defective components immediately. damaged connectors. Repair or replace as • Never place hands on hydraulic cylinder rods while required. equipment is in operation. Do not step on the •...

  • Page 21: Hazardous Materials

    Section 2: Safety —Follow the instructions in the operation and manner. Follow all applicable federal, state and maintenance manual of the affected equipment. local regulations. • To prevent serious personal injury or death, never attempt to remove jammed material while the Flammable and Combustible Liquids machinery is in operation.

  • Page 22: Connecting Or Clamping Wire Ropes

    Section 2: Safety • Be sure that the wire rope is inspected regularly • Inspect links to determine the amount of wear. following the manufacturer’s guidelines. Refer to manufacturer’s specifications for wear • Avoid sudden loading in cold weather. Never use tolerance ranges.

  • Page 23: Conveyor Safety

    Section 2: Safety of any other conditions which may present hazards conveyor system capacities and operate the or obstructions. conveyor accordingly. • Be sure that all tractor-trailer components are • Make sure the operator’s area is clear of any working and in good condition. Test all systems distracting objects.
  • Page 24 Section 2: Safety • Pinch points at fold support areas • Pinch points where locking pins are used • Electrical control panels • Moving parts hazards on drives • Moving parts hazards where contact with belts and idlers is possible Fast Pack Operation and Service Manual Rev 03...

  • Page 25: Safety Decals

    Section 2: Safety SAFETY DECALS SAFETY LABEL SAFETY MEANING WARNING: DO NOT EXCEED 55 MPH! — When towing the equipment do DO NOT EXCEED 55 not exceed 55 MPH (96 KPH). Exceeding the 55 MPH speed limit could result MPH (96 KPH) with this unit fully assembled in tire failure or a serious accident Exceeding the specified...
  • Page 26 Section 2: Safety SAFETY LABEL SAFETY MEANING WARNING: AVOID INJURY — This equipment poses a severe injury risk if you do not read and understand the operation and service manual before performing any service. WARNING: FALLING MATERIAL HAZARD — Operation causes debris to become airborne and poses a risk of injury.
  • Page 27 Section 2: Safety SAFETY LABEL SAFETY MEANING WARNING: READ AND UNDERSTAND MANUAL BEFORE OPERATING — This equipment poses severe injury risk if you do not read and understand the operating instructions. WARNING: PINCH POINT — This equipment poses a pinch hazard. You must keep feet and hands clear of the this equipment while it is operating.
  • Page 28 Section 2: Safety SAFETY LABEL SAFETY MEANING WARNING: ROTATING SHAFT HAZARD — The conveyor return idlers pose a rotating shaft pinch point hazard. Keep away from the idlers when this equipment is operating. Follow lockout/tagout procedures prior to servicing. WARNING: ENTANGLEMENT HAZARD — Exposed conveyor ends pose an entanglement hazard.
  • Page 29 Section 2: Safety SAFETY LABEL SAFETY MEANING WARNING WARNING: STORED ENERGY HAZARD — This equipment’s hydraulic system uses an accumulator to store hydraulic energy. This poses a risk of injury due to explosive decompression of the accumulator. You must relieve all hydraulic pressure before servicing.
  • Page 30 Section 2: Safety SAFETY LABEL SAFETY MEANING WARNING: HAZARDOUS VOLTAGE. 480 VOLTS — The electrical components in the control panel pose a risk of serious burns or shock. You must make sure that all components are shut off and this equipment is properly locked and tagged out before servicing the electrical components.

  • Page 31: Safety Decal Locations

    Section 2: Safety SAFETY DECAL LOCATIONS Plant Left-Hand Side Fast Pack Operation and Service Manual Rev 03...

  • Page 32: Right-Hand Side

    Section 2: Safety Right-Hand Side Fast Pack Operation and Service Manual Rev 03...

  • Page 33: Section 3: Specifications

    Section 3: Specifications PLANT SPECIFICATIONS Operating Dimensions Fast Pack Operation and Service Manual Rev 03...

  • Page 34: Travel Dimensions

    Section 3: Specifications Travel Dimensions Fast Pack Operation and Service Manual Rev 03...

  • Page 35: Capacities

    Section 3: Specifications Batteries Capacities Type System Volts CAPACITY 8D 12V COMPONENT (GAL) Component Weights Engine Coolant Diesel Fuel Tank COMPONENT WEIGHT (LBS) Crusher 59,500 Conveyor Width Hopper 1,367 Engine and Clutch Assembly 10,000 COMPONENT WIDTH Under Crusher Conveyor 4250 Rear Discharge 42”...
  • Page 36 Section 3: Specifications Fast Pack Operation and Service Manual Rev 03...

  • Page 37: Section 4: Controls And Indicators

    Section 4: Controls and Indicators INTRODUCTION This section is designed primarily to familiarize you with the controls and indicators of the Fast Pack plant. It is very important to fully understand the controls and indicators in order to safely and efficiently operate your plant.

  • Page 38: Crushing Plant Control Locations

    Section 4: Controls and Indicators Crushing Plant Control Locations 1) Suspension System Control Panel 9) External Remote Power Connection 2) Fuel Shut Off Value 10) Fuel Gage and Fill 3) Stabilizers and Front Jacks Control Bank 11) Conveyors and Rear Jacks Control Bank 4) Self Screening Axle Control 12) Plant Power Disconnect 5) 60 Amp Circuit Breakers...

  • Page 39: Travel And Set-Up Controls, Indicators, And Gauges

    Section 4: Controls and Indicators TRAVEL AND SET-UP CONTROLS, Height Adjust Valve INDICATORS, AND GAUGES The height adjust valve is a push and hold/pull and hold spring loaded to neutral valve that is used in This section will familiarize you with the controls, conjunction with the manual mode to raise or lower indicators, and gauges that allow you to control the plant by pressurizing or de-pressurizing the...

  • Page 40: Self-Steering Axle Lock Valve

    Section 4: Controls and Indicators The pressure gauge is mounted on the adjustment conveyors, and front jacks. Unless you service the valve. The pressure should be between 35 and 40 valve, you should not need to make any pressure psi before you move the plant. adjustments.

  • Page 41: Stabilizers And Jacks Location

    Section 4: Controls and Indicators Stabilizers and Jacks Location the trailer. The relief pressure for the value is 3000 PSI. Stabilizers and Front Jacks Control Bank 1) Left-Hand Rear Jack 2) Right-Hand Rear Jack 3) Left-Hand Rear Stabilizer 4) Right-Hand Rear Stabilizer 1) Left-Hand Front Stabilizer 5) Left-Hand Middle Stabilizer 2) Right-Hand Front Stabilizer...

  • Page 42: Cone Plant Hydraulic Power Unit Gauges And Indicators

    Section 4: Controls and Indicators CONE PLANT HYDRAULIC POWER UNIT GAUGES AND INDICATORS 1)Conveyor Manifold With Gauges Cone Plant Conveyor Manifold With 2)Crusher Lubrication Oil Filter Restriction Indicator (See Gauges Kodiak Operations Manual) 3)Crusher Lubrication Oil Temperature Gauge 4)Crusher Lubrication Oil Flow Control Meter 5)Crusher Hydraulic Oil Manifold (See Kodiak Operations Manual) 6)Crusher Hydraulic Pressure Switches...

  • Page 43: Operational Controls, Indicators, And Gauges

    Section 4: Controls and Indicators OPERATIONAL CONTROLS, INDICATORS, AND GAUGES The operational controls include the following: Warning Horns The warning horns are mounted at the front and • Warning Horns and Emergency Stop Buttons (E-Stop) rear ends of the Fast Pack plant. They are •...

  • Page 44: 60 Amp Circuit Breaker

    Section 4: Controls and Indicators Fuel Gauge You must turn the Battery Isolation Switch to the OFF position before welding on the plant or changing the crusher manganese. Failure to disconnect the power to the electrical 1) Fuel Fill system prior to welding will result in 2) Fuel Level Site Gauge severe damage to the plant controls.

  • Page 45: Air Intake Restriction Indication

    Section 4: Controls and Indicators Air Intake Restriction Indication the network by removing the plug from the connection. 1)Red Line Indicates Restriction There are two Profinet five (5) port switches 2)Reset Button located near the front and rear of your plant. The restriction indicator is mounted near the charge air cleaner.

  • Page 46: Power Connection Locations

    Section 4: Controls and Indicators quarter turn to the left, and then turn the ON/OFF Your Fast Pack is equipped with three 100 amp knob to the Open position 480 volt input connections located below the Vibrating Feeder at the rear of the plant. 1)External Remote Power Connection 2)Two (2) External Remote Power Connection Your plant is equipped with three (3) 100 amp 480...

  • Page 47: Engine Control Panel

    Section 4: Controls and Indicators Engine Control Panel Engine Maintenance Light/Maintenance Reset Switch 1)Engine Service Due Light 2)15 Amp Fuse 3)Diesel Fuel Pressure Gauge 4)Engine Warning Light 5)Engine Oil Pressure Gauge 6)Engine Temperature Gauge 7)Engine Shutdown Warning Light 8)Voltmeter 9)Tachometer Engine Error Code Display/Hour meter 1) Engine Service Due Light 10)Ignition Switch 2) Engine Service Due Reset Switch...

  • Page 48: Diesel Fuel Pressure Gauge

    Section 4: Controls and Indicators Diesel Fuel Pressure Gauge Engine Oil Pressure Gauge The oil pressure should be greatest after a cold engine is started. The pressure will decrease as the engine warms up. The pressure will increase This gauge indicates fuel pressure to the fuel when the engine rpm is increased.

  • Page 49: Engine Shutdown Warning Light

    Section 4: Controls and Indicators Engine Shutdown Warning Light Tachometer Engine Error Code Display/Hour Meter This light will come on if a general engine fault. Refer to the engine manual for further information concerning engine faults. This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle Voltmeter position without load, the engine is running at high...

  • Page 50: Engine Shutdown Switch

    Section 4: Controls and Indicators will then shut off. In the RUN position, the ECM and electronic systems are powered up. Engine Shutdown Switch 1)Engine Start-Up Bypass Switch The engine start-up bypass switch is a momentary push and hold switch that must be used when starting the engine.

  • Page 51: Fluid Controller Control Panel

    Section 4: Controls and Indicators Fluid Controller Control Panel 1) Engage / Disengage Button 2) Timed Lockout Indicator 3) Clutch Overload Indicator 4) RPM Too High Indicator 5) Coil Fault 6) Clutch Engaged Indicator 7) Oil Pressure Indicator 8) Oil Temperature Indicator 9) Filter Clogged Indicator 10) Safety Switch Indicator 11) Power Indicator...

  • Page 52: Engage / Disengage Button

    Section 4: Controls and Indicators Engage / Disengage Button RPM Too High Indictor When the RPM Too High Indictor is illuminated the engine speed is too high for the clutch to engage. Push and hold for three (3) seconds to Engage Coil Fault Indicator Clutch.

  • Page 53: Oil Temperature Indicator

    Section 4: Controls and Indicators Oil Temperature Indicator Input Speed Detected Indicator While the engine is running the “INPUT Speed When the Oil Temperature Indicator is illuminated Detected Indicator” must be illuminated steady. If the temperature of the clutch oil is over 200 this is not the case, check the Troubleshooting section of PT Tech manual.

  • Page 54: Control Panel Switch Operation

    Section 4: Controls and Indicators controller is connected to a J1939 CAN BUS and is receiving error free communication. Control Panel Switch Operation 1)On Push-Button 2)Stop Push-Button The control panel switches are illuminated push button type dual switches. The top green colored switch starts the conveyor when actuated.

  • Page 55: Plant System Control Panel

    Section 4: Controls and Indicators PLANT SYSTEM CONTROL PANEL 1)Operator Interface 2)Hydraulic Oil Temperature 3)Lube Oil Flow Indicator] 4)Bowl Clamp Pressure Indicator 5)Relief Pressure Indicator 6)Feeder Speed Decrease / Increase Switch 7)Magnetic SEP Start/Stop Switch 8)Cone Clutch Start / Stop 9)Side Discharge Conveyor Start / Stop 10)Feed Conv Start / Stop Switch 11)Feeder Start / Stop Switch...

  • Page 56: Control Panel

    Section 4: Controls and Indicators CONTROL PANEL Manual Controls START STOP CONE CLUTCH Operator Interface (Main Menu) START STOP SIDE DELIVERY CONV. FAST PACK K-400 START STOP FEED CONVEYOR SECONDARY CONE PLANT START STOP VIB. PLATE FEEDER CONE MAIN STATUS MENU The manual control menu allows you to start and CONE...

  • Page 57: Feeder Speed Decrease / Increase Switch

    Section 4: Controls and Indicators Specifications section or the hydraulic schematic Feeder Start / Stop in your parts book for your crusher’s operating This two position rocker switch starts and stops the pressures. Vibrating Feeder for the plant. Feeder Speed Decrease / Increase Switch Bowl Rotate Up / Down This is a three position momentary switch to either This is a three position momentary switch to either...

  • Page 58: Warning Horn Button

    Section 4: Controls and Indicators Warning Horn Button • Active Service Codes • Stored Service Codes • Engine Coolant Temperature • Engine Oil Pressure • Engine RPM • Engine Operating Hours • Engine Manifold Temperature • Electrical System Voltage • Throttle Position •...
  • Page 59 Section 4: Controls and Indicators Note: When the MDDM is first energized some You can change the units of measure on the MDDM between Metric or English units: unused parameters may be displayed. These parameters will automatically be removed 1. To select English or Metric, the Units Sub-Menu after the unit has initialized.

  • Page 60: Viewing Engine Configuration Data (Mddm)

    Section 4: Controls and Indicators The Units Sub-Menu shows the steps for selecting the desired units of measure. Two options are available: 1. Press both buttons to retain the current units desig- nation. 2. Press either UP or DOWN button to toggle the units selection, then press both buttons to select the desired unit of measure.
  • Page 61 Section 4: Controls and Indicators Fast Pack Operation and Service Manual Rev 03...

  • Page 62: Viewing Active Service Codes (Mddm)

    Section 4: Controls and Indicators Viewing Active Service Codes (MDDM) button until the display shows the following label: The MDDM continuously monitors all messages broadcast over the SAE 11939 Control Area Network (CAN) and displays all Active Service Codes at the time the message is broadcast. 2.

  • Page 63: Viewing Stored Service Codes In The Mddm

    Section 4: Controls and Indicators Viewing Stored Service Codes in the MDDM Press both the UP and DOWN buttons SIMULTANEOUSLY to select the “StorCodes” The MDDM can request Stored Service Codes Sub-Menu. The MDDM will display the Stored (DM2) from the engine. The Stored Service Codes Service Codes according to the menus shown in may be used for diagnostic and service needs.
  • Page 64 Section 4: Controls and Indicators Fast Pack Operation and Service Manual Rev 03...

  • Page 65: Section 5: Set-Up

    Section 5: Set-up INTRODUCTION ENGINE START-UP The Fast Pack Plant is normally composed of two Cone Plant Engine Pre-Start Checks: crushing plants, a primary screen plant and a secondary screen plant. The proper set up is crucial to efficient and safe operation of the Fast Pack plant system.

  • Page 66: Plant Pre-Start Checks

    Section 5: Set-up 6. Check the crankcase breather tube. 4. Inspect the drive belts and cooling fan. 1)Fuel Filler Cap 2)Fuel Level Sight Gauge 3. Check the diesel fuel level. Plant Pre-Start Checks 5. Inspect the intake air piping, and clean the air 1.
  • Page 67 Section 5: Set-up OFF position. 1)Fluid Coupling Sight Gauge 2. Check and correct the fluid coupling oil level. 3. Inspect drive belt and sheave. 4. Inspect all hydraulic hoses and connections. 1)Emergency Shut Down Switch (E-Stop) 7. Ensure all Emergency Stop buttons are not activated.

  • Page 68: Fast Pack Engine Starting Procedure For Leveling

    Section 5: Set-up FAST PACK ENGINE STARTING PROCEDURE FOR LEVELING Removing the Bag House Shipping Cover The Bag House is shipped with the shipping cover to protect the filters. This MUST be removed before you start the engine as the air flow will be to low.

  • Page 69: Plant Set-Up

    Section 5: Set-up Position the stabilizers and conveyors. Refer to the appropriate following sections for detailed instructions. PLANT SET-UP Once the site has been prepared and the individual units have been placed, the following must be accomplished before the system can be operated: •...

  • Page 70: Plant Leveling Procedures

    Section 5: Set-up Plant Leveling Procedures 1)Cone Plant Rear Stabilizer engine. (Please refer to the “Engine Startup” 2)Cone Plant Mid-Ship Stabilizers produces on the “Operation” section of the 3)Cone Plant Front Stabilizer manual.) 4)Cone Plant Front Folding Stabilizer 2. Once the engine RPM has been ramped up, raise Operating the Fast Pack Plant requires that each the plant up the fullest extent of the stabilizers.

  • Page 71: Conveyor Unfolding Considerations

    Section 5: Set-up Conveyor Unfolding Considerations is not in use for long periods of time, otherwise the ethernet switches could deplete your Once the engine is running and warmed up, you’ll engine batteries. need to unfold the conveyors in order to align the plants properly.

  • Page 72: Additional Set-Up Information

    Section 5: Set-up Each plant has an input nozzle and an output nozzle. ADDITIONAL SET-UP INFORMATION The following section is designed to help you make needed adjustment to items such as adjusting the vibrating feeder drive belt, general conveyor information, conveyor belts training, creeping and proper loading.

  • Page 73: Conveyor Belt Training

    Section 5: Set-up leakage at the skirt boards. • Run the conveyor empty then add your feed material. • When shutting down, stop the feed unit then shut down your conveyors. • Ensure your electronic controls are set for the proper start-up/shut-down sequence.

  • Page 74: Adjusting Belt Side Creep

    Section 5: Set-up YZ line and use this as your reference to check all idlers for square. 4. Once you have ensure that the tail pulley and all troughing and return idlers are square, run the conveyor empty to check for belt run-out. You must observe the belt running on both the material side and the return side of the conveyor.

  • Page 75: Conveyor Loading

    Section 5: Set-up rotating the idler ends around the circle. Make sure you run the conveyor between each adjustment until the belt creep stops. Conveyor Loading 1)Improper Conveyor Loading 2)Proper Conveyor Loading Proper loading the conveyor will prolong the life of the belt.
  • Page 76 Section 5: Set-up Fast Pack Operation and Service Manual Rev 03...

  • Page 77: Section 6: Operation

    Section 6: Operation INTRODUCTION • Inspect all conveyor guards are installed and functioning properly. This section will describe the safe start-up and • Visually inspect all hoses, lines and belts for leaks, operation of the Fast Pack plant system. It is wear and damage.

  • Page 78: Fast Pack Start-Up Procedures

    Section 6: Operation FAST PACK START-UP PROCEDURES The Fast Pack start-up procedures described below assume that all of the pre-start checks have been completed and the plant system is ready for operation. Fast Pack Crusher Engine Starting Procedure Removing the Bag House Shipping Cover The Bag House is shipped with the shipping cover to protect the filters.

  • Page 79: Fast Pack Post Start-Up Checks

    Section 6: Operation a period of thirty (30) seconds and start the crusher 6. Start your primary crusher. lube pump. The clutch will engage when the horn 7. Start your primary crusher feed system. stops 8. Once the crusher is up to speed you may start Remotely Controlling Your Plant crushing.

  • Page 80: Restarting The Fast Pack After Emergency Stop Activation

    Section 6: Operation First, shut off the primary feed conveyor then the When the Fast Pack Crushing plant is to be moved to a new crushing site, the cone head must be primary cone. Follow the flow of material and once blocked to prevent damage to the crusher each component is clear you can shut it down.

  • Page 81: Travel And Positioning With The Fast Pack Trailers

    Section 6: Operation IMPORTANT: You must place the cone blocks position. 10. Lower the trailer so that the tractor can engage the in the cone chamber of each crusher before hitch. moving the Fast Pack crushing plant. Serious 11. Attach the tractor air system to the trailer system damage to the crusher will result if the cone and charge it to 100 psi.

  • Page 82: Self-Steering Axle Operation

    Section 6: Operation The self-steering axles are designed to turn up to Locking the Axles Prior to Backing twenty degrees in either direction. This means that 1)Self-Steering Axle Lock Valve the tractor can turn as much as 40° with respect to the trailer and the self-steering axles will follow.

  • Page 83: Section 7: Maintenance

    Section 7: Maintenance INTRODUCTION regulations, and any state or local regulations that apply. The proper disposal of oils and other toxic This section covers the proper maintenance of the materials is the user’s responsibility. Fast Pack plant. You should refer to the crusher •...

  • Page 84: Cone Plant Grease Lubrication Items

    Section 7: Maintenance Cone Plant Grease Lubrication Items Kodiak Crusher (See Kodiak Operation Manual) Pillow Block Bearings Take-Up Bearings Tension Rods Folding Conveyor Side Discharge Conveyors Axles Fast Pack Operation and Service Manual Rev 03...

  • Page 85: Scheduled Grease Lubrication Items

    Section 7: Maintenance SCHEDULED GREASE LUBRICATION ITEMS LUBRICATION ITEM INSTRUCTIONS FREQUENCY Crusher Lube Pump Do not over grease. The overhung load adapter is pre-lubed at the Yearly Overhung Load Adapter factory and should not need initial lubrication. You must check the adapter periodically for grease leakage, but do not over lubricate.

  • Page 86: Fast Pack Plant Daily Walk Around Inspection Checklist

    Section 7: Maintenance FAST PACK PLANT DAILY WALK AROUND INSPECTION CHECKLIST OPERATOR’S SERVICE INSPECTION ITEM OKAY INITIALS REQUIRED Before Plant Start-up Check the engine oil level. Check the engine coolant level. Drain the fuel water separator. Inspect the drive belts. Inspect the charge air cleaner and clean intake evacuator valve.

  • Page 87: Maintenance Schedules

    Section 7: Maintenance MAINTENANCE SCHEDULES ITEM INSTRUCTIONS Weekly Or Every 50 Hours of Operation Conveyor Belt Tension Tighten if necessary V-Belts Check the V-Belt tension, clean excess debris. Check for proper alignment. Check sheaves for serviceability. Head and Tail Pulley Hubs Check for tightness Conveyor Gear Reducers Check oil levels.

  • Page 88: Engine Oil Level

    Section 7: Maintenance Engine Oil Level Check the surge tank sight gauge for engine coolant level. The coolant must be at least visible in the gauge. Make sure that you relieve the surge tank pressure prior to removing the cap if the engine has been running.

  • Page 89: Drain The Fuel Water Separator

    Section 7: Maintenance Drain the Fuel Water Separator. Engine Charge Air Cleaner 1)Air Filter Evacuator Valve Note: An adequate supply of clean, filtered air is necessary to maintain correct fuel/air ratios, resulting in a cleaner burning engine. 1)Fuel Water Separator Drain Valve Free flow of air to the intake must not be restricted On the Fast Pack plant, the primary fuel filter also in any way.

  • Page 90: Air Restriction Indicator

    Section 7: Maintenance Air Restriction Indicator Profinet System 1)Restriction Indicator Reset Button Periodically during your shift check the air intake restriction indicator. A clear area, or service indicator window, around the middle of the indicator will fill with a yellow plug that rises to the red area on the indicator.

  • Page 91: Hydraulic System Depressurizing

    Section 7: Maintenance IMPORTANT: Since the fuel tank is IMPORTANT: In order to relieve all hydraulic pressurized during normal plant operation, the pressure on the cone plant, it is necessary to air pressure will be released when you remove open both the Tramp Iron and Locking Ring the cap.

  • Page 92: Changing The Filter Element

    Section 7: Maintenance Changing the Filter Element 4. Open the Locking Ring system needle valve by turning it counter-clockwise. If the valve knob does not turn easily, it may be necessary to use a 1/4” Allen wrench to loosen the valve. 5.

  • Page 93: Hydraulic Hoses And Connections

    Section 7: Maintenance 3. Pull the old filter element up out of the housing. 4. Remove the bypass valve assembly from the used filter element. 5. Remove the cup seal. Clean and inspect it for serviceability. 6. Clean and inspect the bypass assembly O-ring for damage, replace it if necessary.

  • Page 94: Weekly Or Every 50 Hours Of Operation

    Section 7: Maintenance WEEKLY OR EVERY 50 HOURS OF Check battery hold-downs for tightness, and clean if needed with solution used on battery. Ensure OPERATION integrity of hold-downs, and replace if in doubt. Battery Maintenance When working around batteries, avoid any sparks and/or flame.

  • Page 95: Every 1000 Hours Of Operation

    Section 7: Maintenance Inspect belt fasteners for wear and replace as the oil. 4. Clean the inside of the reservoir. If it is difficult to needed. clean, use a mixture of five parts fuel oil to one part Check the empty belt for tears and other damage. of clean lubricating oil.

  • Page 96: Maintenance Recommendations

    Section 7: Maintenance +40ºC). No initial oil change after break in is conditions please consult Dodge. In those needed. mountings that require grease lubrication for specific bearings, re-lubricate the affected The initial factory oil fill is good for up to 10000 bearings every year, or every 4000 operating hours or 3 years of service, whichever comes first, hours whichever comes first.

  • Page 97: How To Determine The Belt Tension

    Section 7: Maintenance How to Determine the Belt Tension 2. If this is the first time you have used your meter the screen will appear as above. If this is not the first time the last settings used will appear. Sonic Tension Meter JCI PN 090417 The following procedure is designed to determine...

  • Page 98: Using The Meter

    Section 7: Maintenance 8. Enter the SPAN value from the above chart on the keypad. This entry will be in grams per meter. If your entry is incorrect, press SPAN again and the cursor will returns to the starting position. 5.

  • Page 99: Adjusting The Drive Belt Tension

    Section 7: Maintenance 5. Strike the belt with a large wrench. 6. The meter will display a measurement in Hz. If the 1)Crusher Drive Belt Guard measurement is higher then the range from the Settings Chart you must loosen the tension. If the 2.
  • Page 100 Section 7: Maintenance 5. The belt tension is measured by using the Gates Sonic Tension Meter. Please refer to the How to Determine the Belt Tension section in this manual for details. Please refer to the Settings Chart in the Setting the Meter section for the proper setting.

  • Page 101: Jci Bag House

    Section 7: Maintenance JCI BAG HOUSE Controller) is designed to control the operation of 2 banks of pneumatic solenoid The Bag House is designed to improve valves used in engine air in-take filter performance, reduce maintenance, and self-cleaning. The following user selectable increase the life span of your engine.

  • Page 102: To Stop The Program

    Section 7: Maintenance pressing both the “ESC” key and the “Right Arrow” key. The new selected setting is automatically saved as the new default. To stop the program: 8. The next screen will ask for confirmation to stop program. 9. Use the “Down Arrow” key or “Up Arrow” key to select “Yes”, and then press “OK”...

  • Page 103: Control Panel Circuit Breaker

    Section 7: Maintenance Note: If the power is removed while program is running, the program will start automatically upon power-up. Note: If the power is removed while program is stopped, you will have to manually start program upon power-up. Control Panel Circuit Breaker The electronics in your Bag House control panel are protected by a 50 amp circuit breaker.
  • Page 104 Section 7: Maintenance material should be placed on or around rough surfaces (such as door frames and handrails) to protect the filtration surface from damage during handling. Do not stack filter elements more than four high. We recommend using an installation sleeve to protect the media during installation of the element into tubesheet.
  • Page 105 Section 7: Maintenance media surface whenever possible. element, 4. Gently push the flexible urethane top of the filter then tuck the remainder of the wire down into the element on one side until it snaps into the tube tube sheet hole, ensuring the braided wire is flat in sheet hole.
  • Page 106 Section 7: Maintenance retainer to expand into the recessed area between the lip rim and the three interior post stops. 10. The snapband retainer should fit snugly between the lip rim and the vertical post stops. Be sure the snapband retainer is level and not installed crooked.

  • Page 107: How To Repair A Broken Conveyor Belt

    Section 7: Maintenance How to Repair a Broken Conveyor Belt Use the following steps: ThIs Service Bulletin will guide you through the proper method of re-attaching the ends of a conveyor belt. It is divided into the following sections: • How to Measure for the Proper Length •...

  • Page 108: How To Drill And Skive Your Conveyor Belt

    Section 7: Maintenance 7. Cut the belt at this line using one of a belt cutters.(Please refer to the end of this bulletin for information on using the Flexco 840 Belt Cutter.) 8. Repeat the above steps on the other end of the belt.
  • Page 109 Section 7: Maintenance 4. Nail the bolt-template in position through the belt to the board below. 3. Place the bolt-template with the Lugs tight against the end of the belt. 5. Use the Flexco drill bit (Part Number HP1) to bore the holes through both ends the template.

  • Page 110: How To Attach The Belt Ends

    Section 7: Maintenance How to Attach the Belt Ends Once your belt ends have been Squared, Drilled, and Skived you are ready to join the ends together. Use the following steps: 15 - 20 2” 7. Place the Skiving template (Part Number 990941) on the belt by inserting the aligning pins in the holes you drilled in Step #5.
  • Page 111 Section 7: Maintenance Correct Incorrect 1. If needed, assemble bottom plate. Insert 2 bolts and attach clip. 2. You may insert all the bolts in the holes of one side of the belt or you may start at one end or middle of the belt and insert one bolt in each end of the belt.

  • Page 112: Using The Flexco 840 Belt Cutter

    Section 7: Maintenance 5. Pull tape tight and hold in position by tightening a Grind bolts smooth to finish. fastener at each end with Flexco Part Number HW1. Then tighten all other plates. Ensure the Using the Flexco 840 Belt Cutter points on the plates do not puncture the tape.
  • Page 113 Section 7: Maintenance 4. Place the Clamp Bar on the belt cutter. 1. Ensure the blade in the belt cutter is to one end or the other. 5. Place the Locking Pin in the belt cutter, and then push down the Clamp Bar Handles to secure the belt.
  • Page 114 Section 7: Maintenance Fast Pack Operation and Service Manual Rev 03...

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