ASTEC 40 Series Operation And Maintenance Manual

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Model 5044-32T

Handling

Sand Prep

Series 40 Tranﬂ ite - Stationary Conveyor

OPERATION AND MAINTENANCE MANUAL

IB-2003 8/14

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Summary of Contents for ASTEC 40 Series

Page 1 Material Model 5044-32T Handling Sand Prep Series 40 Tranﬂ ite - Stationary Conveyor OPERATION AND MAINTENANCE MANUAL IB-2003 8/14...
Page 2 Record your Series 40 conveyor serial and order number in the space provided below. You will ﬁ nd the serial number plate located on the support frame. Please include these numbers when requesting service or ordering replacement parts. JOB ORDER MODEL MANUFACTURED BY KOLBERG-PIONEER, INC.
Page 3 Series 40 Transﬂ ite and Stationary Conveyor OPERATION & MAINTENANCE MANUAL Models Covered: Stationary Model 41 - 8” Channel Frame Model 42 - 24” Lattice Frame Model 43 - 30” Lattice Frame Model 44 - 36” Lattice Frame Model 45 - 42” Lattice Frame Model 46 - Channel and Lattice Frame Transﬂ...
Page 4 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 KPI-JCI.
Page 5 Contents Introductory Pages About This Manual Serial Number Plates Buying Replacement Parts Maintenance Techniques and Tools Lubricants and Fluids Storage Introduction to the Series 40 Covneyor Chapter 1 Safety Chapter 2 Unloading Conveyor Chapter 3 Site Selection and Preparation Chapter 4 Conveyor Setup Chapter 5 Frame Sections/Belt Idlers...
Page 6 About This Manual Purpose Special Notations Procedures, once described in the text, are not normally The purpose of this manual is Within this manual procedures repeated. When it is necessary to help you get the best value or situations that require special to refer to another chapter, from your equipment.
Page 7 Serial Number Plate Modiﬁ cations are a continuing process in the manufacture of this equipment. Since replacement parts, manuals, and lists are compiled speciﬁ cally for each unit, the serial numbers are essential to correctly identify the component required. The serial number plate will show Serial number plate the serial number, job order Tail end...
Page 8 Buying Replacement Parts Authorized Dealer Parts Purchased Components Serial Number Department R e p l a c e m e n t p a r t s f o r Since replacement parts An authorized dealer parts components purchased by manuals and lists are compiled department is the best source KPI-JCI such as gear reducers,...
Page 9 Maintenance Techniques and Tools Tools Fasteners Rusted nuts and bolts should be treated with a penetrating Although a minimal number of Typically, standard SAE fluid to ease removal and tools are needed for operation fasteners are used. Fasteners prevent breakage. Badly and maintenance, a good are nuts, bolts, studs and...
Page 10 Lubricants and Fluids The lubricants shown to the Bearings, Pivot Points and right are “factory ﬁ ll” lubricants. General Lubricant Other lubricants may be used, provided they meet the lubrication requirements speciﬁ ed. Bearings Bearings are lubricated with a high temp EP-2 lithium based grease containing a tackiness agent.
Page 11 Storage When the machine will not • To help prevent corrosion, regreased; or it should be be used for a period of a few the fuel tank should be ﬁ lled replaced. months, use the following to their proper level. Conveyor Belt Storage procedure for storage to minimize corrosion and...
Page 12 Introduction to the Series 40 Conveyor Conveyor orientation is The conveyor is in the operating References to the right hand determined by standing at the position when it has been and/or left hand side will be as tail end of the conveyor looking elevated to a working position.
Page 13 Introduction to the Series 40 Conveyor K P I - J C I s t a t i o n a r y The Series 40 conveyor the tail pulley, and is unloaded conveyors are designed for consists of an endless belt at the head pulley.
Page 14 Introduction to the Series 40 Conveyor T h e f o l l o w i n g brief description of the conveyor’s basic parts and function. Head End The head end is the discharge end and often the drive end of the conveyor.
Page 15 Introduction to the Series 40 Conveyor Troughing Idlers Troughing idlers form the belt in a curved shape to carry material . They are CEMA Class B or C type sealed for life ball bearings, 3 roll 35 degree, 5” diameter steel on 4’ centers. Optional impact idlers cushion impact and protect the belt from damage in high capacity...
Page 16 Introduction to the Series 40 Conveyor Conveyor Belt Take-Up The tensioning of the conveyor belt is accomplished through the use of a take-up screw rod which is attached to a movable tail pulley and tightened against the conveyor frame. Conveyor Belt The belt is a 2 ply 220 PIW, 1/8”...
Page 17 Introduction to the Series 40 Conveyor Receiving Trough A 5’6” long material receiving trough is used at the loading point. This trough keeps the conveyor evenly loaded to maximize capacity and reduce belt wear. The trough is equipped with clamped rubber ﬂ...
Page 18 Safety First! This symbol is used to bring Warning decals have also DANGER attention to safety precautions been placed on the equipment and instructions. to provide instructions and to DANGER is used for imminently identify speciﬁ c hazards which, hazardous situations which, if not heeded, could cause if not avoided, WILL result in bodily injury or death to you...
Page 19 Safety Safety symbols are used This instruction should be Untrained operators with signal words to further reviewed at least annually. maintenance personnel are demonstrate a safety hazard. a hazard to themselves and The table below illustrates O p e r a t o r / E m p l o y e e ’ s others and are not qualiﬁ...
Page 20 Safety The following section presents 5. Check and secure all Operating Safety material on speciﬁ c safety guards before operating. items. Although speciﬁ c Repair or replace any 1. Read and understand the safety guidelines are given, damaged missing Operator’s Manual before each situation can have its guards guarding...
Page 21 Safety 10. Safe working load of the 4. F o l l o w g o o d s h o p Magnet Safety platform is 136 kg (300 lbs.). practices. 1. Magnetic ﬁ eld can be harmful pacemaker Operating Safety Area 5.
Page 22 Safety Tire Safety Hydraulic Safety Transport Safety 1. Failure to follow proper 1. Always place all controls 1. Make sure you are in procedures when mounting in neutral before servicing compliance with all local a tire on a wheel or rim can hydraulic system.
Page 23 Safety Safety Decals In addition to this, operators must observe all safety Operators are responsible to instructions and warning on know the location and function safety decals placed on the of all guards, shields and safety plant. devices. These include drive guards, tail pulley guards, For decal placement, see troughing idler guards, mesh...
Page 24 Safety Moving Parts/Guards P/N 114930 Moving parts can cause injury or death. Do no remove guard while equipment is operating. Conveyor Nip Points P/N 114929 When the plant is operating, do not clean or service the conveyor. IB-2003 Series 40 Transﬂ ite-Stationary Conveyor...
Page 25 Safety Falling/Flying material P/N 114927 When plant is operating, material from the feed hopper may fall from the sides. Make sure no one is on either side of the conveyor when loading. Do not stand on the catwalk or the frame support at any time machine is in operation.
Page 26 Safety Lockout Procedures Each of them might have machine springs a color-coded lock. All ﬁ ve counterweights. term locks could be placed on an Lockout procedures are a zero energy state means that electrical switch, preventing principal means of controlling all of these energy sources the power from being turned energy hazards.
Page 27 Safety Anyone who will be operating and/or maintaining A sign-off sheet has been provided for your the machine must read and clearly understand all record keeping to show that all personnel who safety, operating and maintenance information will be working with this equipment have read and presented in this manual.
Page 28 Safety The following illustrations are shown to help CAUTION identify decals when they require replacement. Make sure machine surface is clean and free Safety decals are provided for your personal safety. If they should become from grease and oil before applying new decal. damaged, they must be replaced.
Page 29 Unloading Conveyor 2. Be careful not to drop the 3. Unload conveyor frame NOTICE c o n v e y o r b e l t w h e n sections(s) and place on a unloading. Store the firm level surface. Be These instructions contain conveyor belt with the core careful not to jerk or twist the...
Page 30 Unloading Conveyor Assembly Marking The Far Side location would be Serial numbers are not shown the piece located further from on the drawings because An assembly marking system the viewer. drawings can be used on is typically used on support different projects.
Page 31 Site Selection and Preparation When selecting a suitable Location of the conveyor is Level Conveyor site for operation many usually determined by the factors need to be taken into location of the intake and The conveyor must be kept consideration. Selecting a site discharge of material to be level to maintain proper without anticipating problems...
Page 32 Conveyor Set-up After all parts have been unloaded, inspect each item for damage and report any damaged or missing items to the carrier. F a s t e n e r s f o u n d i n t h e hardware box will be grouped and marked to indicate use.
Page 33 Set-up Receiving Hopper (optional) Assemble the optional receiving hopper to the conveyor as shown in the picture to the right. Bolt the receiving hopper to the tail end. Drives Reducers are shipped from the Hopper is bolted to conveyor in factory ﬁ...
Page 34 Set-up 4. A f t e r p r o p e r d r i v e r o t a t i o n h a s b e e n Motor rotation decal determined retighten nuts to original position.
Page 35 Conveyor Belt Conveyor Belt Installation 2. Insert a bar through the Belt Tensioning center of the belt roll and The proper installation of onto belt support frame. Proper belt tension is difﬁ cult to the conveyor belt is critical deﬁ ne. The belt must be tight to conveyor performance 3.
Page 36 Conveyor Belt 3. Turn the take-up screw rod A template, cordless drill and 3. From the center point, until the proper tension is clamps will be needed to measure up to the splice on achieved. Tighten each complete the belt splice. the opposite side.
Page 37 Conveyor Belt Belt Fastener Installation Use the following procedure to install belt fasteners on the conveyor belt. Templet 1. Make sure all power is locked out/tagged out. 4. Assemble the bottom plate 7. Place top plates over bolts 2. Support belt ends with by inserting two bolts using bolt horn.
Page 38 Conveyor Belt 13. Break off excess bolt ends using two bolt breakers. Peen or grind bolts to ﬁ nish. 12. Hammer plates in belt with 11. Tighten all fasteners from wood block. Retighten edges to center. nuts. Note: A Flexco Power Wrench used with an impact tool will speed this step considerably.
Page 39 Conveyor Belt Belt Training 1. Idlers should be clear of dirt and any material. Initial installation of the 2. Check conveyor frame for conveyor belt should ensure level. good alignment of pulleys, 3. Check to make sure idlers troughing and return idlers. are square to the direction They should be placed at of belt travel.
Page 40 Conveyor Belt Belt Loading condition is to have the material The slope of the chute is pass from the chute to the belt determined by the nature of the Receiving material off center at almost the same speed and material, its entering velocity will cause the belt to move direction of travel as the belt and length of the chute.
Page 41 Preoperation Checklist The preoperational check should be performed Check each component to insure that it is in any time the equipment is moved to a new site, or operational condition. This check should include, if it has been in storage for an extended period. but not be limited to the following items.
Page 42 Maintenance The following section contains maintenance may need to be WARNING instructions for maintaining the performed more often. series 40 conveyor. Never attempt to service or Failure to perform regular adjust this machine until Maintenance intervals shown maintenance may result in all motion has stopped are for normal operating conveyor failure or damage.
Page 43 Maintenance General Inspection (10 hours) Check the following items: 2. Repair or replace any A walkaround inspection should d a m a g e d h a n d r a i l s , be made on a daily basis. By 1.
Page 44 Maintenance Conveyor Belt Splice (10 hours) Inspect fasteners and tighten or replace if loose or missing. Hinged Belt Splice Shown Conveyor Belt Tension (50 hours) If the conveyor belt slips under load it should be tensioned just enough to prevent slipping. Both take-up screw rods should be tensioned at the same time.
Page 45 Maintenance Hopper Flashing (50 hours) If material is leaking, or becoming wedged between rubber ﬂ ashing on the hopper and conveyor belt, it may need to be extended. 1. Loosen clamp bar bolts and work the ﬂ ashing down so it just contacts the belt.
Page 46 Maintenance V-belt Tension (200 hours) Measure v-belt tension. V-belt tension can be measured using a sonic belt tester or a belt tension gauge. See Appendix C for instruction on measuring belt tension using a sonic belt tester or a belt tension gauge. IB-2003 Series 40 Transﬂ...
Page 47 Maintenance Wheels and Tires (As needed) 1. Clean and repack bearings before towing. 2. Check tire pressure and inﬂ ate to pressure speciﬁ ed on tire sidewall. 3. Check wheel bolts for proper tightness before towing. 4. Check tires for wear. IB-2003 Series 40 Transﬂ...
Page 48 Maintenance Belt Splice Retaining Collar Installation W h e n i n s t a l l i n g a n e w conveyor belt, a new retaining collar with set screws will need to be installed to prevent the belt splice cable from “walking”...
Page 49 Lubrication Interval Ref. No. Item Notes Conveyor Bearings Grease bearings both sides. 50 hours Gear Reducer Check lubrication level. Take-up Screw Rod Clean and coat with oil. hours Change oil. 2500 Gear Reducer hours Electric Motor Lubricate. needed NOTICE Quantities of grease have been speciﬁ...
Page 50 Lubrication Bearings (50 hours) High temp EP-2 lithium based grease containing a tackiness agent. Pulley Bearing Use the following procedure for lubricating the head and tail pulley bearings. 1. Wipe dirt from grease zerk and bearing. Grease purging between housing and outer race 2.
Page 51 Lubrication Gear Reducers (50 hours) Gear reducers should be checked for proper oil level as follows. 1. Remove oil level check plug. Refer to the diagram of gear reducer positions shown to the right. Check plug 2. If oil does not ﬂ ow or is not visible from check plug, add oil as recommended in the reducer service manual.
Page 52 Lubrication Take-up Screw Rod (200 hours) 1. Clean and coat take up screw rods with NLGI2 grease. 2. Repeat procedure for opposite side. Gear Reducers (2500 hours or 6 months) The oil in the gear reducers 1. Drain oil from the gear 4.
Page 53 Lubrication Electric Motors (As needed) Lubrication information forthe WEG electric motor can be found in the bottom left hand corner of the nameplate. A table of lubrication intervals is provided below; however, frame size, speed, lubrication interval should be veriﬁ ed on the nameplate before lubricating.
Page 54 Troubleshooting Problem Solution Symptom Material build up on belt 1. Not enough scraper tension. 1. Increase tension. 2. Adjust dust suppression. Grooves or cuts appearing 1. Rock wedged between 1. Loosen ﬂ ashing and clean. in surface of belt hopper ﬂ ashing and belt. 2.
Page 55 Troubleshooting Belt Cleaner Problem Solution Symptom Insufﬁ cient cleaning and 1. Incorrect tension. 1. I n c r e a s e o r d e c r e a s e carryback tensioner setting. 2. Worn blade. 2. Inspect blade. Replace as needed.
Page 56 Appendix A: Disc Wheel Installation Disc Wheel Installation 2. Install nuts using proper NOTICE installation sequence shown to the right. Snug Never mix hub-piloted and nuts to 50 ft.lbs. Do not stud-piloted wheels, hubs, tighten fully until all nuts and nuts. The result could have been seated.
Page 57 Appendix B: Prevailing Torque Locknut Bolts must be tightened to the coarse threads (UNC) and proper torque as listed in the unified fine threads (UNF) table below and on the next along with standard hex nut page. These values represent and prevailing torque locknut.
Page 58 Appendix B: Prevailing Torque Locknut Bolt Torque Chart - UNF Grade 5 Grade 8 Nominal Size Standard Hex Prevailing Torque Standard Hex Prevailing Torque bolt/nut Ft.-lb. (N-M) Ft.-lb. (N-M) Ft.-lb. (N-M) Ft.-lb. (N-M) 1/4 - 28 7 (10) 6 (8) 10 (14) 8 (11) 5/16-24...
Page 59 Appendix C: Belt Tension Instructions Sonic Belt Tension Instructions Use the following procedure to use the Gates sonic belt tester to measure belt tension. 1. Attach the sensor and turn the power on. Power Measuring Belt Span measured belt tension is 4.
Page 60 Appendix C: Belt Tension Instructions Belt Tension Gauge Instructions Use the following procedure to measure v-belt tension. 1. Lockout/tagout all power. 2. Measure the belt span length of the drive (see Measuring Belt Span and Deﬂ ection Force drawing). 6. C o m p a r e t h e f o r c e 3.
Page 61 Appendix C: Belt Tension Instructions Recommended Deﬂ ection Force (lbs.) Small Sheave Retensioning V-belt Type Dia. Range (in.) Initial Installation Maximum Minimum - 4.6 4.7 - 5.6 5.7 - 7.0 7.1 - 10.0 - 4.6 10.0 4.7 - 5.6 11.0 5.7 - 7.0 11.5 7.1 -...
Page 62 Warranty Registration & Preoperational Check Series 40 Transﬂ ite - Stationary Conveyor Kolberg-Pioneer, Inc. Form may be Sent, Faxed or Emailed 700 W 21st. St., Yankton, SD 57078 IMPORTANT 1-800-532-9311 Fax: 1-800-514-6115 Warranty will be void if this registration is not returned within ten (10) day after the equipment is put into service.
Page 64 JOHNSON CRUSHERS INTERNATIONAL 86470 Franklin Boulevard, Eugene, OR 97405 USA SERVICE 866-875-4058 - 541-736-1400; Fax 541-988-9501 PARTS 888-474-0115 - 541-736-1400; Fax 541-988-9487 ASTEC MOBILE SCREENS 2704 West LeFrevre Road, Sterling, IL 61081 USA SERVICE 800-545-2125; Fax 815-626-6430 PARTS 800-545-2125; Fax 815-626-6430...

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