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ASTEC JCI 1400 RA Operation Manual

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  • Page 1 Astec company 1400 RA Crusher Operation Manual...

  • Page 3: Table Of Contents

    Astec company CRUSHER OPERATION MANUAL 1.0 Introduction ........................3 New parts and equipment warranty Johnson Crushers International, INC....................4 2.0 Safety ..........................5 2.1 Hazard Levels ..........................5 2.2 Personal Safety Tips ........................5 2.3 Equipment Safety Tips ........................ 6 3.0 Specifications .........................9...
  • Page 4 Astec company CRUSHER OPERATION MANUAL...

  • Page 5: Introduction

    CRUSHER OPERATION MANUAL 1.0 INTRODUCTION The JCI 1400 RA cone crusher is designed with numerous features for improving durability, serviceability and performance. It has anti-friction roller bearings, spiral bevel gears, non-contact seals and a heavy-duty base frame design. The 1400 RA...

  • Page 6: New Parts And Equipment Warranty Johnson Crushers International, Inc

    Astec company CRUSHER OPERATION MANUAL New parts and equipment warranty Johnson Crushers International, INC. 1. Johnson Crushers International, Inc. (JCI) Warranty: JCI warrants to the Distributor and Distributor’s customers on resale with respect to JCI products sold that the new equipment will be free from defect in material and workmanship under normal use for a period of one year after the date of start-up or 2,000 hours of operation, whichever first occurs.

  • Page 7: Safety

    Astec company CRUSHER OPERATION MANUAL 1400 RA2.0 SAFETY 2.1 Hazard Levels There are words used by JCI to indicate hazard severity levels. They are DANGER, WARNING, CAUTION, and NOTICE or NOTE These words appear throughout various JCI publications and on JCI machine labels where required.

  • Page 8: Equipment Safety Tips

    Astec company CRUSHER OPERATION MANUAL Hard Hats: Acceptable head protection needs to be worn in all work areas. Material may fall off equipment during operation. It is recommended that hard hats be worn at all times even during times when equipment is not in operation.
  • Page 9 Astec company CRUSHER OPERATION MANUAL Never attempt to clear or adjust the crusher while it is running. Do not adjust the close side setting smaller than the recommended minimum setting for your mantle and bowl liner combination. Do not stand on the crusher upper assembly, infeed hopper or bowl rotation gear boxes while the machine is in operation.
  • Page 10 Astec company CRUSHER OPERATION MANUAL...

  • Page 11: Specifications

    Astec company CRUSHER OPERATION MANUAL 1400 RA3.0 SPECIFICATIONS Model number 1400 RA Horsepower 400 Hp total, (2) 200 Hp motors Machine weight 52,000 lb. Hydraulic unit weight 2,000 lb. Pinion speed 850 to 1000 RPM Capacity See capacity chart...

  • Page 12: General Dimensions

    Astec company CRUSHER OPERATION MANUAL 3.1 General Dimensions Figure1 Overall side and front view...

  • Page 13: Electrical And Hydraulics

    Astec company CRUSHER OPERATION MANUAL 3.1.1 Electrical and Hydraulics Figure 2 1400 RA with electrical and hydraulics OMK40001...

  • Page 14: Capacity Chart

    Astec company CRUSHER OPERATION MANUAL 3.2 Capacity Chart Closed side 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2" setting Gross 210-260 250-315 280-350 300-365 320-425 350-470 370-490 390-540 425-575 throughput Closed side setting 3/8" 1/2" 5/8" 3/4" 7/8"...

  • Page 15: Gradation Chart

    Astec company CRUSHER OPERATION MANUAL 3.3 Gradation Chart Product Crusher closed side setting size 5/16" 3/8" 7/16" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2" 4" 3-1/2" 3" 2-3/4" 2-1/2" 2-1/4" 2" 1-3/4" 1-1/2" 1-1/4" 1" 7/8" 3/4"...

  • Page 16: Cone Chambers

    Astec company CRUSHER OPERATION MANUAL 3.4 Cone Chambers Figure 4 Close side settings (CSS)

  • Page 17: Installation

    CRUSHER OPERATION MANUAL 4.0 INSTALLATION A JCI 1400 RA crusher includes a hopper, hydraulic/lubrication power unit, operator remote control panel, electrical control cables, hydraulic hose lines and special tools for the crusher. The crusher is shipped with transport blocks in place, which need to be removed.

  • Page 18: Clearance

    Astec company CRUSHER OPERATION MANUAL Wrench, mantle nut. Cone lifting eye. 4.1 Clearance When installing the 1400 RA, allow enough clearance to perform daily service, visual inspection and maintenance. See figure 6 for recommended clearances to allow adequate room for workers to service the machine.

  • Page 19: Power Transmission

    Astec company CRUSHER OPERATION MANUAL Mounting the 1400 RA crusher to a portable trailer requires special design consideration. The flexing of the trailer frame can transmit extreme force into the crusher base frame and mounting pads which can crack the base or trailer frame. To correctly mount the crusher to a trailer frame, JCI recommends the use of two (2) adjacent spring loaded mount pads.

  • Page 20: Lubrication Connections

    Astec company CRUSHER OPERATION MANUAL Proper V-belt tension is essential for belt and sheave life, efficient power transmission and pinion shaft component life. The ideal V-belt tension is the lowest tension at which the belt will not slip under peak load conditions. Worn belts and sheaves will require much higher belt tension to convey the same power as normal belts and sheaves.

  • Page 21: Hydraulic Connections

    Astec company CRUSHER OPERATION MANUAL The lubrication oil hoses should be routed with no sharp bends or kinks, and protected from falling rock, sharp edges, moving machinery and other hazards. Figure 9 Lubrication flow 4.5 Hydraulic Connections Before connecting the hydraulic hoses to the crusher make sure that all hydraulic circuits are at zero pressure.

  • Page 22: Electrical Connections

    Astec company CRUSHER OPERATION MANUAL locking ring fitting located on the upper assembly. See figure 10 for hydraulic hose connections. Figure 10 Hydraulic hose connections Quick disconnect fittings are supplied for the hydraulic manifold connections. Normally the hoses are only disconnected at the quick disconnect fittings. If the quick disconnect nipple will not press into the quick disconnect coupling, usually there is pressure in the line.
  • Page 23 Astec company CRUSHER OPERATION MANUAL center cables to the electrical enclosure, wiring the crusher motors to the motor starters and connecting the internal lubrication heater. The crusher will require 100 amp of 120 VAC control power. Due to the various methods of supplying power to the crusher, the customer is responsible for supplying control power to the electrical enclosure.
  • Page 24 Astec company CRUSHER OPERATION MANUAL Control Feed Material It is important to control the feed size being fed to the crusher as well as the velocity of the material. If the feed is falling from a height greater than 36 inches, a rock box or rock ladder should be installed.

  • Page 25: Operation

    Astec company CRUSHER OPERATION MANUAL 1400 RA5.0 OPERATION 5.1 Theory of Operation The 1400 RA remote adjust crusher crushes rock by feeding rock through the hopper and bowl opening into the crushing chamber. The rock is crushed between the bowl liner and the cone mantle, due to the mantles gyratory motion.

  • Page 26: Electrical Controls

    Astec company CRUSHER OPERATION MANUAL by screwing the bowl assembly up or down. Attached to the bowl assembly is a drive ring with a floating gear, which is driven by hydraulic motors to rotate the bowl. When the bowl is positioned at the desired close side setting a locking ring prevents the bowl from turning during crushing operations.
  • Page 27 Astec company CRUSHER OPERATION MANUAL Figure 16 Remote control panel To become familiar with the remote control panel, a description of each component is listed below. •HYDRAULIC PUMP To start the hydraulic pump motor, pull out on the switch.
  • Page 28 Astec company CRUSHER OPERATION MANUAL to the left and held, the hydraulic power unit will supply pressure to the tramp iron system. When the tramp iron system reaches the appropriate pressure, a tramp iron pressure indicator light will illuminate. To de-pressurize the tramp iron system turn the selector switch to the right.

  • Page 29: Electrical Wiring Diagram

    Astec company CRUSHER OPERATION MANUAL 5.3 Electrical Wiring Diagram Figure 17 Typical motor wiring diagram Motor Wiring The main power disconnects, motor control center (MCC) and motor wiring are typically supplied by the customer. These items can be supplied by JCI as optional equipment.
  • Page 30 Astec company CRUSHER OPERATION MANUAL Two current transformers are supplied by JCI for the crusher drive motor amp gauges. The transformers are shipped inside the electrical enclosure. The current transformers need to be installed with one motor lead passing through the transformer. The amp gauges are more accurate if the same power phase motor leads are used.
  • Page 31 Astec company CRUSHER OPERATION MANUAL Control Wiring A pre-wired electrical panel and remote mounted operators control panel are included with the 1400 RA1400 RA crusher. Two quick disconnect electrical cables connect the electrical panel to the motor control center and operators panel.
  • Page 32 Astec company CRUSHER OPERATION MANUAL the equivalent close side setting measurement. See figure 19 electrical control schematic. Figure 19 Electrical control schematic...
  • Page 33 Astec company CRUSHER OPERATION MANUAL Figure 20 Electrical control schematic OMK40001...
  • Page 34 Astec company CRUSHER OPERATION MANUAL Figure 21 Temperature and indicator counter Hydraulic Controls Hydraulic machine adjustments include pressurizing the tramp iron system and bowl clamp, clearing the crushing chamber and adjusting the close side setting. The operator makes machine adjustments by actuating switches on the operators control panel.
  • Page 35 Astec company CRUSHER OPERATION MANUAL cartridge type design that feature a manual override. The cartridge valve manual override is a red knurled knob on top of the valve. To manually activate a solenoid valve push down and turn the red knob counter-clockwise. Normally these valves should not be in the manual override position.
  • Page 36 Astec company CRUSHER OPERATION MANUAL ring clear port. This will raise the upper assembly on the crusher. When the clear button is released the upper assembly will slowly move down until it rests on the radius seat. CLOSE SIDE SETTING The crushing chamber close side setting is adjusted by rotating the bowl, which will screw up or down in the bowl support.

  • Page 37: Daily Start-Up

    Astec company CRUSHER OPERATION MANUAL 1400 RA6.0 DAILY START-UP This section describes how to start-up and run the crusher. Machine adjustments to the close side setting, feed material clear feature, tramp iron pressure and activating the bowl clamp cylinder are covered. For optimum crusher performance and safety, site personnel should observe the following start-up procedures each time the crusher is started.
  • Page 38 Astec company CRUSHER OPERATION MANUAL • Manganese condition During the crushing process, the manganese mantle and Figure 24 Manganese liner distance bowl liner experience wear leading to the need to change the liner set. To maintain the close side setting distance the bowl and liner must be adjusted downward to compensate for the wear.

  • Page 39: Starting The Crusher

    Astec company CRUSHER OPERATION MANUAL 300 psi due to thermal expansion. Should the hydraulic pressure drop below 2500 psi, the crusher will automatically shut down. Figure 25 Hydraulic manifold 6.2 Starting the Crusher Follow the sequence listed below to start the crusher.

  • Page 40: Close Side Setting

    Astec company CRUSHER OPERATION MANUAL 6.3 Close Side Setting The close side setting (CSS) is the minimum distance between the mantle and the bowl liner. It determines the product size produced by the crusher. The crushers production capacity and type of mantle and bowl liner are determined by the close side setting.

  • Page 41: Clear Feature

    Astec company CRUSHER OPERATION MANUAL the crusher is running or the cone is spinning. This will damage the crusher and put the operator at risk. The procedure for setting the close side setting is as follows: 1) Shut down the feed material to the crusher...
  • Page 42 Astec company CRUSHER OPERATION MANUAL 7. Start the crusher motors, and verify that both motors have energized by looking at the amp gauges. Figure 26 Lifting the upper section...

  • Page 43: Maintenance

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 1400 RA7.0 MAINTENANCE This section will describe how to perform routine maintenance on the 1400 RA crusher. For instructions on major repair items, such as bearing replacement, contact the parts department. This section will cover changing lubrication and hydraulic system oil, filters and setting the proper system pressures.

  • Page 44: Lubrication System

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. fitting. The reducer should be lubricated weekly with 1 to 2 pumps using extreme pressure (EP) general purpose grease. The planetary gears are lubricated with EP 80/90 gear oil. The reducer has a fill plug below the grease fitting, and a drain plug located on the bottom of the reducer.
  • Page 45 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Oil Level The 1400 RA has an approximate oil capacity of 24 gallons. Use the dipstick to check Dipstick Full Figure 32 Dipstick for proper level. See Figure 32. Clean off any dirt that may have accumulated around the fill pipe/dipstick area before removing the dipstick.
  • Page 46 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Oil Sampling Observe the condition of the oil on the dipstick. If it appears dirty, turn on the pump NORMAL LEVEL MAXIMUM METAL (PARTS PER MILLION) (PARTS PER MILLION) Aluminum 0-10 Copper 0-15 Nickel Chrome Lead...
  • Page 47 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Oil Type See Table 6 for a listing of the proper oils. The crusher uses ISO 150 oil with extreme pressure (EP) additives. SUPPLIER BRAND NAME AND GRADE Amoco Amogear EP 150 Chevron Ultra Gear EP 150 Exxon Spartan EP 150...
  • Page 48 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Oil Filter Cover Cover O-ring Top spring Insert assembly Insert O-ring Bypass seal Bypass seal gasket Element Element O-ring Bypass assembly Filter housing Plug Figure 33 Oil filter Check the filter indicator for signs of restricted flow and change the oil filter if the needle is in the red area.

  • Page 49: Hydraulic System

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Flow Switch The flow meter protects the crusher from a lack of oil flow to the crusher bearings. Under normal conditions the crusher lubrication oil flow should be 7 to 8 gpm. The flow meter is factory set to alarm at 6-1/2 gpm.
  • Page 50 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. the upper assembly against the base frame. The 1400 RA accumulators are pre-charged to 1900 to 2000 psi at the factory, before shipment. Figure 35 Accumulators When pressurizing the tramp iron system, the pressure will gain fairly quickly until it reaches 2000 psi then the tramp system should pressurize much slower as the accumulators are charged.
  • Page 51 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 4. Using the 11/16" wrench screw on the nitrogen pressure gauge until tight. Turn the Tee-handle clockwise to open the valve. The pressure should read between 1900 to 2000 psi. 5. Close the valve by turning the tee-handle counter-clockwise. Remove the nitrogen pressure gauge.
  • Page 52 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 5. Using the 11/16" open-end wrench screw on the nitrogen charging hose until tight. Turn the Tee-handle clockwise to open the valve. Turn the valve off when the pressure readings between 1900 to 2000 psi. 6.
  • Page 53 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 2. Turn on the pump motor and monitor the pump pressure. 3. Remove the 11/16" capped nut and washer, using care not to lose the brass seal washer. 4. Slowly adjust the allen head adjustment screw. Clockwise rotation will increase pressure, and counter-clockwise rotation will decrease pressure.
  • Page 54 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 6. Cap both port connections with two JIC No. 4, 37° flare caps. 7. Close needle valve on manifold. 8. Remove upper cap nut covering adjustment screw for compensator pressure. Use care when removing cap nut not to lose seal washer. 9.
  • Page 55 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 15. Verify that all gauges are at zero pressure. 16. Remove JIC No 4. caps and reconnect the pilot line to load sense port and aluminum block. Setting horse power compensator 1. Once power is locked-out remove conduct box cover on pump motor. 2.
  • Page 56 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 5. Loosen locknut on pressure relief valve RVI and turn adjusting screw counter- clockwise until screw contracts stop. 6. Turn on motor. 7. Back relief pressure to 1500 psi. The relief valve will make a sound when fluid is vented, and the pressure gauge will dip in pressure when the relief valve starts to vent.
  • Page 57 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. to 8 amps. d.Tighten large jam nut. 10. High pressure - Low flow adjustment. (Pressure relief valve set at 3000 psi) a. Loosen small jam nut using 12mm (9/16") wrench. b. Using 3 mm short allen wrench, adjust motor current to 8 amps. Turn screw clockwise to increase amperage and counter-clockwise to decrease amperage.

  • Page 58: Electrical

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. The pressure switches and pressure gauges are located on the valve manifold block as shown. Figure 40 Valve manifold block Adjusting the pressure switches will require the following tools: 2.5 mm allen wrench 10 mm or 3/8"...
  • Page 59 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Relays The 1400 RA electrical controls use relay logic to activate the crusher functions. Relay logic was used instead of a programmable logic controller (PLC) due to the number of functions, adaptability, and environmental conditions. All five logic relays are the same type and model of relay.
  • Page 60 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Sensor Air Gap Periodically the proximity sensors should be inspected and the sensor air gap checked. The sensor air gap is the distance between the sensor face and the gear teeth. The two proximity sensors are located on a hydraulic motor mount, on the opposite side from the pinion shaft.

  • Page 61: Cone Brake System

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 7. Enter count mode and set value to QUAD1. 8. Enter SELECT ENABLE and set the value to NO. 9. Enter RESET ENABLE and set the value to YES. 10. Enter COUNTER DECIMAL POINT and set the value to 0.00. 11.
  • Page 62 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. cone brake has a clutch, which de-activates the cone brake when the bowl clamp is de- pressurized. This allows the cone to turn freely while adjusting the close side setting. Figure 44 Cross-section of cone brake system Operators should check the cone head daily to make sure the cone head is not spinning.
  • Page 63 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Listed below is the proper procedure for replacing shear bolts in cone brake system. 1. De-pressurize the bowl clamp and tramp iron hydraulic circuits. Verify visually at the hydraulic manifold block, that the hydraulic gauges are at zero pressure. Disconnect the 1/4"...

  • Page 64: Changing Manganese

    Johnson Crushers CRUSHER OPERATION MANUAL International Inc. 7. Assemble the clutch cylinder and piston. Apply silicone sealant around the clutch cylinder flange, just inside the bolt pattern. Install the cylinder and piston. 8. Attach hydraulic hose to clutch fitting. 7.6 Changing Manganese During the crushing process, the manganese mantle and bowl liner experience wear leading to the need to change the liner set.
  • Page 65 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Preparation During normal operation of the crusher to compensate for liner wear the bowl has been screwed downward to maintain the close side setting. Before changing the mantle and bowl liner the bowl should be screwed upward to provide clearance for the new liners. Turn on the hydraulic pump and de-pressurize the bowl clamp.
  • Page 66 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Remove the crusher feed hopper by removing the hopper mounting bolts and attaching lifting cables to the two lifting eyes located inside the hopper. Figure 48 Removing crusher feed hopper For ease of service JCI recommends that the upper section be removed when changing mantle and bowl liners.
  • Page 67 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Changing the Bowl Liner Loosen the 1 1/2-8 UNC nuts on the six bowl liner clevises. Remove four of the clevis nut and washer sets, leaving two opposed clevises to support the bowl liner. If the bowl liner has not separated from the bowl support then hit the top of the bowl liner with a sledge hammer until the bowl separates from the bowl support.
  • Page 68 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Changing the Mantle The cone mantle is changed with the cone in place in the crusher. This will prevent dirt and contamination from entering the internal works of the crusher. Remove the mantle nut protector cap bolt, using the 1" allen wrench supplied with the machine.
  • Page 69 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. to the mantle using McKay Chrome Mang or an equivalent product. Make a first-pass weld on each side of the ears. Repeat for a total of three passes to form a 1/4" fillet on each side of the ears.
  • Page 70 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. mantle if necessary to get a good fit with the washer lug. Make sure all mating surfaces are clean and smooth. Inspect the pour hole in the top of the mantle with the washer in place. Enlarge this opening if necessary to provide an adequate space to pour the backing material in.
  • Page 71 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. the nut and washer. Drive a 1/2" diameter pin the full depth of the hole. Cut off any excess pin protruding from joint. See figure 58. Figure 58 - Locking pin Backing Material Prepare the backing material for pouring according to the instructions on the container label.
  • Page 72 Johnson Crushers CRUSHER OPERATION MANUAL International Inc. Attach grounding strap to the allen wrench while it is still on the bolt head. Weld the mantle nut cap to the washer in three places using McKay Chrome Mang or Equivalent. Mantle (top view) Weld Mantle nut cap bolt Weld...

  • Page 73: Storage

    Astec company CRUSHER OPERATION MANUAL 1400 RA8.0 STORAGE If the crusher is to sit idle for extended periods of time, steps should be taken to rotate the bearings to minimize the chance that rust will develop between the bearing rollers and bearing races.
  • Page 74 Astec company CRUSHER OPERATION MANUAL...

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