Page 1 OPERATION & MAINTENANCE FT3055 TRACK MOUNT FT3055 TRACK MOUNT FT3055 TRACK MOUNT FT3055 TRACK MOUNT FT3055 TRACK MOUNT Jaw Crusher Jaw Crusher Jaw Crusher Jaw Crusher Jaw Crusher IB-3007 06/12...
Page 2 MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A. Serial Number Plate CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, andother reproductive harm. Copyright KPI-JCI 2012...
Page 3 Plant OPERA OPERA TION & OPERA TION & TION & TION & OPERA OPERA TION & MAINTEN MAINTEN ANCE MANU MAINTEN ANCE MANU ANCE MANU AL ANCE MANU MAINTEN MAINTEN ANCE MANU Models Covered: FT3055 Track Mounted Jaw Crusher...
Page 4 KPI-JCI reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes on previously manufactured equipment.
Page 5 Contents Contents Contents Contents Contents Introductory Pages About This Manual Serial Number Plates Buying Replacement Parts Maintenance Techniques and Tools Lubricants and Fluids Storage 0-12 Drawing List 0-13 Specifications Chapter 1 Introduction to the Jaw Crushing Plant Chapter 2 Jaw Crusher Vibrating Feeder/Side Delivery Conveyor Magnet/Dust Suppression System Tracks...
Page 6: Table Of Contents
Contents Auto Adjust Chapter 13 13-1 Adjustments Chapter 14 Tension Rod Spring Compression 14-1 Open Side Setting 14-2 Flywheel Balance/Reversing Jaw Crusher 14-3 Belt Training 14-4 Track Tensioning 14-5 Timing 14-6 Undercrusher Conveyor Removal Chapter 15 15-1 Maintenance Chapter 16 10 hours 16-3 50 hours...
Page 7 Even though this manual situations which, if not Using the Manual has been prepared with observed, could result in extreme care, KPI-JCI. cannot damage to the equipment or The manual is divided into accept responsibility for errors affect the operation of the...
Page 8 The serial number plate for the vibrating number, job order number and model number. feeder is located on the inside of the frame cross support. Frame cross support KPI-JCI Serial Number Plate Plant Serial Number The serial number for the plant is stamped Vibrating feeder...
Page 9 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, specifically for each unit, the electric motors and engines serial numbers are essential for parts, particularly parts...
Page 10 Maintenance Techniques and Tools Tools To avoid pouring them on performing maintenance, Although a minimal number the ground or into the sewage never reuse a damaged of tools are needed for system, pour the used fluids fastener. operation and maintenance, a into large containers, seal them Special locknuts with nylon good selection of basic tools is...
Page 11 F (38 degrees C) that are exposed to wide ambient temperature, use ISO temperature ranges. If MV60 46 with a viscosity index above is not available, KPI-JCI 120. recommends using a high quality oil with an appropriate cold weather...
Page 12 0-10 0-10 0-10 0-10 0-10 Lubricants and Fluids Vibrating Feeder Bearings Vibrating Feeder Shaft Vibrating feeder bearings Bearings are lubricated with an NLGI 2 multipurpose, extreme pressure synthetic grease. Hydraulic Gear Drive The hydraulic gear drive is lubricated with Mobil SHC 630. Crusher Pitman NLGI 2 Synthetic Grease...
Page 13 0-11 0-11 0-11 0-11 0-11 Lubricants and Fluids Track Drive Hubs Track Drive Hubs on Drive hubs are lubricated Fast Trax Plants. using extra high performance SAE grade 50 drive train lubricant. Vibrating Feeder The vibrating feeder gear box is filled with a high performance gear oil having extreme pressure...
Page 14 0-12 0-12 0-12 0-12 0-12 Storage Track Storage Extended Period Storage When the machine will not (6 months or more) be used for a period of a few The following guidelines should months, use the following be followed for track storage on If the machine will be stored for procedure for storage to an FT plant for an extended...
Page 15 0-13 0-13 0-13 0-13 0-13 Drawing List Electrical Drawings 305944-1 Panel Layout 305944-2 Communications, Estop, and engine 305944-3 Outputs and connectors 305944-4 Outputs and connectors 305944-5 Input and accessories 305944-6 Digsy CMV Color Display 321533-2 Transducers (Estop, battery, strobes, brake release, tank level) 321534-2 Solenoids and EDCs 321535-2 Transducers (tension rod) 305949...
Page 16 Specifications - 3055 12’ 10.75” 11’ 10.75” (3.93 m) (3.63 m) 55’ 10” (17.01 m) 11’ 9.25” (3.59 m) 4’ 7” 11’ 3” (1.40 m) (3.43 m) Overall Length: 55’ 10” (17.01 m) Travel Width: 11’ 11.75” (3.43 m) Overall Width: 15’...
Page 17 Specifications 108” 50” Jaw Opening (Gap): 30" (762 mm) Flat Flywheel Weights (each): 3,066 lbs. (1391 kg) Jaw Width: 55" (1397 mm) Toggle Plate Weight: 655 lbs. Moving Jaw, Overall Depth: 60.5" (1537 mm) (297 kg) Stationary Jaw, Overall Top Adjusting Wedge Weight: 583 lbs.
Page 18 Specifications 15’ (4.57 m) 8” Standard 50" x 15' (1.27 m x 4.57 m) Feeder PSI: 3045 psi relief pressure Speed: 500-950 rpm Feeder Weight: 9,400 lbs. (4,264 kg) Length of solid pan deck: 10’ (3.05 m) Feeder Hopper: 5,785 lbs. (2624 kg) Wear plate: 5' x 10', 1/2"...
Page 19 Introduction to the Jaw Crushing Plant Orientation is determined The feed end of the plant References to the right by standing at the feed hopper receives the material to be hand and/or left hand side will end of the plant looking toward crushed and the discharge end be as shown below.
Page 20 Introduction to the Jaw Crushing Plant Large Capacity Side Delivery Power Unit Magnet Hopper Conveyor Variable Speed Undercrusher Vibrating Feeder Heavy Duty Tracks Jaw Crusher Conveyor The following is a brief Eccentric Shaft Tension Rods description of the jaw crushing plant’s basic parts and their eccentric shaft...
Page 21 Introduction to the Jaw Crushing Plant Stationary Jaw Moving Jaw The stationary jaw fits on The moving jaw is located the inside front face of the base. opposite the stationary jaw and The moving jaw impacts moves toward the stationary material against the stationary jaw and downward.
Page 22 Introduction to the Jaw Crushing Plant Vibrating Feeder The feeder's vibrating action is created by a hydraulically driven twin shaft eccentric vibrating mechanism. Huckbolted Assembly The huckbolted frame design reduces stress creating a stronger assembly. The feeder is supported by The hopper has a six cubic yard A 5’...
Page 23 Introduction to the Jaw Crushing Plant Magnet (optional) Belt Tensioner Cleated Belt The magnet is a permanent self-cleaning cross belt that removes rebar and other ferrous metals processed material passes from the impactor under the Support magnet. Brackets The magnet has stainless steel cleats, is hydraulically Hydraulic Drive driven and operates at 600 fpm...
Page 24 Introduction to the Jaw Crushing Plant Track System The track drive is fitted with Achieving proper track an integrated multi-disc brake tension is important to prevent The track system is which acts like a parking brake. damage to the track frame. hydraulically powered with an The brake is activated by spring Over-tensioning can cause...
Page 25 Introduction to the Jaw Crushing Plant Fuel Tank The fuel tank is a heavy duty, large capacity tank with vented filler cap. Fuel tank capacity is 190 gallons (719 liters). Engine CAT C13 The CAT C13 is a 440 HP, 1800 rpm engine.
Page 26 Introduction to the Jaw Crushing Plant Control Panel The plant is operated by an Radio receiver onboard control panel that CGM (Cockpit Graphic features following Monitor) componenents: • Digsy ICNVV - The Digsy ICNVV contains the J1939 Canbus, inputs and outputs. (Cockpit •...
Page 27 The rear crusher, vibrating feeder, and section supplies 12 gpm to the the left and right tracks; the The FT3055 has two double side delivery conveyor and to open loop gear pumps power gear pumps that power four the cylinders for the power fold all other functions.
Page 28 If an operation is not performed as specifically CAUTION YOUR PERSONAL SAFETY recommended by KPI-JCI you IS INVOLVED must satisfy yourself that it is Practices that could result in safe for you and others. You machine damage if not...
Page 29 Safety First! operation, service and safety slip resistant soles Safety Precautions information presented in this c. Eye protection manual and on the machine. d. Protective gloves The safe operation and Untrained operators and e. Hearing protection - maintenance of this machine maintenance personnel are a sound pressure levels of this is the responsibility of the...
Page 30 Safety First! 2. Use only cranes, jacks catwalk or rails while plant working around this and tools with sufficient is in operation. machine. capacity. 10. Safe working load of the 2. Follow lockout/tagout 3. Do not allow spectators in platform is 300 lbs. (136 procedure and wait for all the assembly area.
Page 31 Safety First! Magnet Safety The hydraulic system Transport Safety operates under extremely high-pressure. Such 1. Make sure you are in 1. Magnetic field can be repairs will fail suddenly compliance with all local harmful to pacemaker and create a hazardous regulations regarding wearers.
Page 32 Safety First! Lockout Procedures completed and every worker is of the machine. For example, in a safe place. Lockout procedures are a a device might use electricity This last step often principal means of controlling to power a pump, creating involves placing padlocks on energy hazards.
Page 33 Safety First! Safety Specifics Machine Safety Operators are responsible Operators are responsible to be aware of specific safety to know the location and function of all guards, shields hazard areas and observe and safety devices. These safety instructions warnings on related decals. include drive guards, tail pulley guards, troughing idler guards, mesh side guards and...
Page 34 Safety First! Hydraulic Fluid Pressure and Counterbalance Valves ! ! ! ! ! 1. Loosen WARNING careful when counterbalance valve disconnecting hydraulic locknut and turn the hoses. Fluid may be under adjusting screw clockwise. pressure. 2. To completely release Counterbalance valves are pressure, turn used to maintain pressure.
Page 35 Safety First! Electrical Control Panel Before welding anywhere on this machine, disconnect all electronic devices at six places indicated by circles. Disconnect remote from tether if used and turn battery disconnect switch to off. Failure to disconnect will result in electronic component failure.
Page 36 Safety First! Return Idler Guarding Idler guards have been designed for easy clean-out. Make sure conveyor is turned off before cleaning and use caution when cleaning. Noise Levels Noise levels have been calculated at over 100db near the engine enclosure. Always wear ear plugs to protect hearing when plant is in operation.
Page 37 3-10 3-10 3-10 3-10 3-10 Safety First! Safety Features Safety Labels Safety labels located ! ! ! ! ! CAUTION around the plant warn operator and other personnel of potentially dangerous areas. Falling or flying mate- rial can cause injury. Keep clear of loading equipment and spillage.
Page 38 3-11 3-11 3-11 3-11 3-11 Safety First! Backup Alarm The alarm sounds to warn all personnel that the unit is in operation. E-stops E-stops are placed to provide a method to stop the machine and engine quickly should the need arise.
Page 39 3-12 3-12 3-12 3-12 3-12 Safety First! Anyone who will be operating and/or maintaining A sign-off sheet has been provided for your the machine must read and clearly understand record keeping to show that all personnel who all safety, operation and maintenance will be working with this equipment have read information presented in this manual.
Page 40 3-13 3-13 3-13 3-13 3-13 Safety Decals CAUTION The following illustrations are shown to help identify decals when they require replacement. Make sure machine surface is clean and free Safety decals are provided for your from grease and oil before applying new decal. personal safety.
Page 41 3-14 3-14 3-14 3-14 3-14 Safety Decals...
Page 42 3-15 3-15 3-15 3-15 3-15 Safety Decals ! ! ! ! ! CAUTION ! ! ! ! ! DANGER 1. Read and understand manual before operating. If you do not have a manual contact: Kolberg-Pioneer, Box 20, CONVEYOR NIP POINTS Yankton, SD 57078.
Page 43 3-16 3-16 3-16 3-16 3-16 Safety Decals ! ! ! ! ! ! ! ! ! ! WARNING CAUTION IMPACT HAZARD Counterbalance (CB) valve cartridges Falling or flying mate- are being used in this circuit. Pressure is locked into the circuit and MUST BE rial can cause injury.
Page 44 Application 1. The grizzly feeder can be 2. By utilizing an optional 4. The optional magnet fed from either side by loader side delivery conveyor, assembly separates ferrous or excavator. Oversized undersized material from the contamination from the material continues into the feeder can be transferred out material processed by the Jaw Crusher while undersize...
Page 45 Application The Pioneer Vanguard jaw the moving jaw at the bottom of more information on the crusher can be used as a the crushing chamber can be approximate capacity of the primary or secondary crusher varied. closed side setting. for all types of aggregate material including sand and The material is reduced in gravel or shot rock, as well as...
Page 46 Maximum feed size is 24” area from the bottom of the 24” as well as minimizing the for the FT3055. Quarry and wedge at the top of the jaw amount of fines in the feed shot...
Page 47 Application Choke Point Crushing chamber (outlined in black) The choke point of the crushing cavity is a zone of minimum capacity. It is that point or zone in the chamber where the volume of material can approach a solid mass. Upon entering the crushing chamber, the material is composed of large particles...
Page 48 PSI. jaw is at rest. crushed and the material work index number. Example: FT3055 Jaw Note: The pitman must be in If the compressive strength Gap: 30” its lowest position to measure of the rock is 30,000 PSI or PSI: 40,000 the OSS.
Page 49 Application Filled-in-end Jaw Dies KPI-JCI allows the use of a filled-in-end jaw die on the stationary side only. The use of filled-in-end jaw dies on both sides can generate up to 5x more force in the crushing chamber compared standard ribbed jaw dies.
Page 50 Application Worn Jaw Dies Jaw die maintenance is essential consistent production as well as for overall jaw crusher performance. Worn jaw dies require higher pressure to crush rock and when jaw teeth are worn to 75- 80% of new jaw die tooth depth, the material cannot flow freely causing packing and crusher overload.
Page 51 Site Selection and Preparation Machine Location unlevel, it is necessary to build Leveling indicators are Location of the machine is a level travelway to maintain provided on the crusher to help usually determined by the the crusher in a level position. determine if additional leveling location of the intake and is required.
Page 52 Site Selection and Preparation Using an excavator will Presizing Material provide a more consistent feed rate and a convenient, Before feeding material into continuous prepping process the machine, it must first be to identify oversize and presized. This can be done unwanted contamination in using a BTI breaker to break Uncrushable...
Page 53 Engine Star Engine Star t-up and Shut Do t-up and Shut Do Engine Star Engine Star t-up and Shut Do Engine Star t-up and Shut Do t-up and Shut Do wn Starting the Engine CAUTION 2. Turn the battery disconnect Before starting the engine, switch to ON.
Page 54 Engine Start-up and Shut Down 4. Make sure all switches on the radio remote are in the Right track Left track Horn switch OFF or NEUTRAL position. switch E-stop 5. Toggle horn switch up and then release. (active LED should be flashing for up to 10 seconds).
Page 55 Engine Start-up and Shut Down After proper engine 5. Turn keyswitch to off 1. If desired feeder speed is warmup(water temperature position. known, there is no need to should be between 100-120 adjust the feeder speed deg. F), the machine is now dial.
Page 56 Cold Weather Startup The following section Mobil SHC 220 for feeder • system protection includes guidelines and and conveyor bearings (p/n requirements. recommendations for starting a 208566). Fast Trax unit in cold weather Check all rubber parts • conditions. Hydrex MV 22 for the •...
Page 57 NOTICE failure. 7. Allow the engine to idle for Do not adjust the engine three to five minutes, or KPI-JCI recommends a allow the engine to idle warning device for the inlet speed control during...
Page 58 Cold Weather Startup Cloud Point characteristics in cold weather. weather operation, if No. 1 Solid wax can fill the fuel filters diesel fuel is not available, use It is important to understand and stop the flow of fuel. Fuel No. 2 diesel fuel. There are that the cloud point of a fuel is filters are necessary in order to three major differences...
Page 59 Cold Weather Startup Fuel Filters excess of 65 degress C (149 Kerosene will evaporate in the degrees F). engine. This will cause the oil A primary fuel filter is to thicken. Kerosene will cause installed between the fuel tank Note: Heat exchanger type swelling and softening of the and the engine fuel inlet.
Page 60 Cold Weather Startup Engine Starting Information Category 1 Starting Aids Altitude Engine Model Recommended Optional Category 1 0 to 460 m All Models None None (0 to 1500 ft) 9 to -9.5 degrees C (48 to 15 degrees F) above 0 to C-7 and C9 Continuous Flow None...
Page 61 Cold Weather Startup Category 4 Category 4 Starting Aids -30 to -40 degrees C (-22 to - Altitude Engine Model Recommended Optional 40 degrees F) Continuous Flow Oil Heater Ether Use only SAE 0W-40 or a All Altitudes All Models Coolant Heater Fuel Heater lower viscosity multigrade oil.
Page 62 Cold Weather Startup Battery Information The 1U-7297 Coolant/Battery not be recharged. Whenever Tester (Fahrenheit) or the 1U- an engine is not operated in WARNING 7298 Coolant/Battery Tester cold weather, use a battery (Celsius) is available from CAT charger to keep the battery Personal injury can result for testing the condition of the charged.
Page 63 Unloading the Jaw Crushing Plant After the retaining chains Start engine and using the Unloading and ratchet binders have been radio remote control carefully removed, the plant can be and slowly move the plant off The jaw crusher plant is unloaded.
Page 64 See Appendix A for hydraulic schematics and capacities when connecting a KPI-JCI auxilliary conveyor to the Fast Trax unit.
Page 65 Plant Set-up Open Side Setting (OSS) Closed Side Setting (CSS) Adjustment - Auto Adjust Stroke Crusher Size Minimum Minimum OSS (at rest) CSS * The OSS is the peak to peak 3055 4-1/2” 1-1/2” 3” measurement of the jaw * If compressive strength is greater than 30,000 PSI, or you are using a crusher when it is at rest.
Page 66 Plant Set-up NOTICE Centering the tension rods 11. After all adjustments are inside the base of the spring made, all personnel and plate maintains zero contact tools are clear of the Never set the closed side from tension rod to spring plate. machine, remove lockout/ setting lower than the tagout.
Page 67 Preoperation Checklist The preoperational check should be Check each component to insure that it is in performed any time the equipment is moved to operational condition. This check should include, a new site, or if it has been in storage for an but not be limited to the following items.
Page 68 No Load Operational checklist Adjust Adjust OPERATIONAL CHECKS 6. Magnet Conveyor 1. Engine (600 fpm)* a. Idle 900 RPM* b. 1800 RPM max. 7. Jaw Crusher (275 rpm)* 2. Hydraulic Controls a. Vibrating feeder 8. Crusher Pump Charge Pressure b. Undercrusher conveyor (350 psi)* c.
Page 69 10-1 10-1 10-1 10-1 10-1 Operating Controls The following section Hopper Wing Fold - FT3055 explains the functions of plant operating controls under The hydraulic controls for normal conditions. the hopper wing fold are located on the vibrating feeder NOTICE...
Page 70 10-3 10-3 10-3 10-3 10-3 Operating Controls Hydraulic Controls Stacker conveyor control Hydraulic valves are designed to control side delivery conveyor folding, conveyor on/off, magnet on/ off, and stacker controls. 1. The following controls are located in the left side of the hydraulic control panel: Tension rod...
Page 71 10-4 10-4 10-4 10-4 10-4 Operating Controls Dust Suppression On/off control for the dust suppression system is located to the left of the hydraulic control panel. Dust suppression control valves Tether connect Tether Control Connector - Control Panel Dust Suppression Plant Operating Controls The crushing plant can be operated either as a tethered...
Page 72 11-1 11-1 11-1 11-1 11-1 load Pr load Pr otection System otection System Ov er er load Pr load Pr load Pr otection System otection System otection System The overload protection Overload Condition condition is sensed, the CPU system monitors engine data Protection sends a signal to the vibrating and maintains plant functions.
Page 73 If it displays a name other than the machine it is on, the program will have to be reconfigured by KPI-JCI. Main Screen The Main screen will display after the Initialization screen. Six choices display on this...
Page 74 11-3 11-3 11-3 11-3 11-3 Overload Protection System Engine Information Screens Press F6 on the Main screen to navigate to the Engine Information screens. The engine information screens display engine functions on the plant. Variables displayed include: Gallons/Hour Fuel Average Coolant Temperature Estimated Fuel...
Page 75 11-4 11-4 11-4 11-4 11-4 Overload Protection System warning indicator in the message center of the Engine Information screen alerts the operator that an engine operating conditon has the potential to cause engine damage. blue wait-to-start indicator in the message center of the Engine Information screen alerts the operator that the engine is cold.
Page 76 11-5 11-5 11-5 11-5 11-5 Overload Protection System Running Minimum - the percentage of the output on the feeder. This parameter is password protected. function is to set the minimum speed at which the feeder runs when the feeder is turned on regardless of how low the feeder speed...
Page 77 11-6 11-6 11-6 11-6 11-6 Overload Protection System Machine Performance Screen Press F10 on the main screen to access the Machine Performance screen. This is the preferred screen display during operation. It monitors the relationship of the performance of the machine five benchmark parameters: engine load,...
Page 78 11-7 11-7 11-7 11-7 11-7 Overload Protection System System Diagnostic Screens Press F3 on the Machine Diagnostics screen to access the system diagnostic screens. The main system diagnostics screen displays the CPU temp and system voltage. Press F1 to go to the Inputs diagnostic screen or F2 to go to the Outputs diagnostic screen.
Page 79 11-8 11-8 11-8 11-8 11-8 Overload Protection System...
Page 80 11-9 11-9 11-9 11-9 11-9 Overload Protection System Engine Diagnostic Screens Press F6 to access the engine diagnostic screens. engine diagnostics screen displays three active SPN/FMI engine diagnostics codes. Press F4 for the manual fuel pump prime option. Press F1 to move to the Engine Error History screen.
Page 81 11-10 11-10 11-10 11-10 11-10 Overload Protection System Hydraulic Diagnostic Screens Press F8 to access the hydraulic diagnostic screens. The hydraulic diagnostics screen shows crusher operating pressure, charge pump pressure, hydraulic tank level, and tension rod pressure. Press the F1 key to view the PSI Data Log screen.
Page 82 11-11 11-11 11-11 11-11 11-11 Overload Protection System Radio Diagnostic Screen Press F1 to access the radio diagnostic screen. The radio diagnostic screen simulates real-time use. The bar graph on this screen displays signal strength.
Page 83 11-12 11-12 11-12 11-12 11-12 Overload Protection System Local Mode The Local Mode screen will only display if pendant functions are disabled. Local mode operation is accessed by pressing F7 on the Main screen. You will first need to enter the Local Operation password shown to the right to access the Local Operation screen.
Page 84 11-13 11-13 11-13 11-13 11-13 Overload Protection System Troubleshooting Screens Troubleshooting screens can be accessed by pressing F1 on any screen that shows the yellow triangle with an exclamation mark symbol in the middle. Low Hydraulic Oil Windows Either the low hydraulic oil or critically low hydraulic oil screen will display when the hydraulic tank is below 30%.
Page 85 11-14 11-14 11-14 11-14 11-14 Overload Protection System Machine E-Stop Window This window will flash intermittently if the e-stop button has been pushed on the plant. To reset, all switches on the radio remote must be set to their off position and the plant e-stop must be reset.
Page 86 11-15 11-15 11-15 11-15 11-15 Overload Protection System Radio Remote Link Window This window will display on the diagnostic screen if the operator tries to start the machine without linking the radio remote. Radio E-Stop Window This window will flash intermittently if the e-stop button has been pushed on the handheld radio remote.
Page 87 11-16 11-16 11-16 11-16 11-16 Overload Protection System Radio Link Loss Window This window will display on the diagnostic screen when the radio transmitter is out of range from the plant(approximately 300 yards). System Voltage Window This diagnostic window will flash when the system has less than 22 VDC for a period of 5 seconds.
Page 88 11-17 11-17 11-17 11-17 11-17 Overload Protection System Pressure Transducer Window If the OPS system detects that a pressure transducer is malfunctioning, the following window will flash intermittently. Refer to the system inputs and outputs screen to see which transducer is malfunctioning. High Engine Temperature Window This screen is displayed when...
Page 89 11-18 11-18 11-18 11-18 11-18 Overload Protection System Can Bus Failure Window This screen is displayed when power is lost to the Can Bus. When the Can Bus loses network, it disables the outputs not allowing the normal functions to work. J1939 Failure Window This screen is displayed when there is a J1939 failure.
Page 90 11-19 11-19 11-19 11-19 11-19 Overload Protection System Engine Error Window This window displays when an engine error has occurred. Refer to the Engine Error History screen for more information. Feeder Overload Count Violation Window This window will display over all other active windows when the operator has overloaded the plant more than three times in the past eight...
Page 91 11-20 11-20 11-20 11-20 11-20 Overload Protection System Feeder Stop, Crusher Overloaded for Too Long Window This window will display over all other active windows when the crusher has been overloaded for longer than the preset off-time specified on the Overload Times Screen.
Page 92 11-21 11-21 11-21 11-21 11-21 Overload Protection System Jaw / Feeder Shutdown - Low Tension Rod PSI This screen will flash if the tension rod pressure falls below 900 psi. Follow the instructions on the screen to recharge and reset the auto adjust system.
Page 93 11-22 11-22 11-22 11-22 11-22 Overload Protection System Operator Setup Screens Press F5 on the Main screen to access the Operator Password screen. Enter the password as shown to access the setup screens. Machine Setup Screen After entering the password and pressing F3 for OK, the Machine Setup screen displays options for engine, crusher, and...
Page 94 11-23 11-23 11-23 11-23 11-23 Overload Protection System System Setup Screen Press F3 on the Machine Setup screen to access the System Setup screen. This the first screen that allows the operator with a user level password to access and change the language, disable/ enable the high engine temperature warning, and the...
Page 95 11-24 11-24 11-24 11-24 11-24 Overload Protection System Crusher Setup Press F8 on the Machine Setup screen to access the Crusher Setup screen This setup screen allows the operator to change the tension rod charge pressure. The operator can also view the high tension rod psi count.
Page 96 12-1 12-1 12-1 12-1 12-1 aulics aulics Hy dr dr aulics aulics aulics Track Drive When the solenoid valve is millilamp signal to the EDC is deactivated, the flow of oil decreased to slow the motor from the brake to the tank down.
Page 97 12-2 12-2 12-2 12-2 12-2 Hydraulics - FT3055 In the undercrusher circuit, and the charge pump is set at three section valve used for the oil moves through a 313 PSI. The oil is brought the side fold which is mounted...
Page 98 13-1 13-1 13-1 13-1 13-1 Auto Adjust Auto Adjust Auto Adjust Auto Adjust Auto Adjust cylinder in a fixed position during operation. The Auto Adjust - FT Units wedge cylinders are held in position by dual Auto adjust allows the operator to change the counterbalance valves.
Page 99 13-2 13-2 13-2 13-2 13-2 Auto Adjust NOTICE Phase One - Setting Relief Pressure for Proper Spring Compression Moving the wedges in and out after every relief valve adjustment will give you an 1. With engine at low idle, use the F12 and F13 accurate pressure reading in the spring keys on the Crusher/Feeder screen to fully compression cylinder.
Page 100 13-3 13-3 13-3 13-3 13-3 Auto Adjust Phase Two - Synchronization 5. Turn nuts in or out by amount calculated in step three (screw in to reduce “L” measurement and Once synchronized, you will not need to adjust out to increase “L” measurement). the tension rod nuts when making changes to the closed side setting.
Page 101 14-1 14-1 14-1 14-1 14-1 Adjustments Flywheel Balance Counter weights Flywheels are provided on both sides of the crusher to store energy while the counterweights are added to the flywheels to reduce horizontal motion. If the flywheels are not properly balanced, the crusher will vibrate excessively causing damage reducing...
Page 102 14-2 14-2 14-2 14-2 14-2 Adjustments Belt Training 4. Check belt splice for Initial installation of the squareness. conveyor belt should ensure good alignment of pulleys, 5. Work from idler to idler in troughing and return idlers. the opposite direction of the They should be placed at right belt travel.
Page 103: Track Tensioning
14-3 14-3 14-3 14-3 14-3 Adjustments Track Tensioning Measure here for track sag Achieving proper track tension is important to prevent damage to the track frame. Over-tensioning can cause permanent distortion of the track frame. Excessive track tension is the primary cause of bulkhead plate problems and must be avoided.
Page 104: Timing
14-4 14-4 14-4 14-4 14-4 Adjustments before teeth engage. Timing Rotate driver gear counterclockwise until following valley that is five (4) teeth procedure if the gears on the beyond the 45 degree eccentric shaft of the vibrating mark lines with feeder need to be adjusted.
Page 105 15-1 15-1 15-1 15-1 15-1 Undercrusher Conveyor Removal 2. Keep in mind the weight of these Tools assemblies: The following is a list of tools for removing Undercrusher conveyor - 8,600 lbs. the undercrusher conveyor. (3,901 kg) 6-8 8” x 3’ Cribbing timbers 2 - 1 1/2”...
Page 106 15-2 15-2 15-2 15-2 15-2 Undercrusher Conveyor Removal Use the following procedure to remove the 3. Attach conveyor to a loader for removal undercrusher conveyor. by wrapping chains around the head pulley shaft equally on both sides. 1. On each side of plant, loosen bolt and rotate the keeper upward, attached to support hooks, for conveyor removal.
Page 107 15-3 15-3 15-3 15-3 15-3 Undercrusher Conveyor Removal Remove this dust suppresssion hose. 8. Slide the threaded rod out from the plant. Threaded rod 6. Disconnect hydraulic lines undercrusher conveyor. Disconnect hydraulic lines for undercrusher conveyor 9. Remove support chains at tail pulley of conveyor on each side.
Page 108 15-4 15-4 15-4 15-4 15-4 Undercrusher Conveyor Removal 10. Lower conveyor tail end to the ground. Undercrusher conveyor cylinders Remove cylinder pins on both cylinders Hydraulic Cylinder Fully Extended 11. Remove hydraulic cylinder pins on both sides of undercrusher conveyor. NOTICE Support hook must be in the up position or it will be damaged when removing the...
Page 109 15-5 15-5 15-5 15-5 15-5 Undercrusher Conveyor Removal 15. Remove chains and disconnect conveyor from loader. Conveyor support pin Saddle Undercrusher Conveyor Removed From Plant 16. Replace lower support tube, threaded rod, washer and nuts to prevent track frame from deforming. 14.
Page 110 16-1 16-1 16-1 16-1 16-1 Maintenance The following section contains instructions for maintaining the machine. Maintenance intervals shown are for normal operating conditions. If the machine is operated under severe or adverse conditions maintenance may need to be performed more often. Failure to perform regular maintenance may result in damage to the machine.
Page 111: 1000 Hours
16-2 16-2 16-2 16-2 16-2 Maintenance Ref. Interval Notes General Inspection Loose bolts, set screws, hoses, leaks, or cracks. Conveyor Belts Run belts empty before stopping. Rubber Flashing Check for wear. Extend or replace as needed. Stationary and Moving Jaw Check for wear - reverse or replace if necessary.
Page 112 16-3 16-3 16-3 16-3 16-3 Maintenance 1. Make sure all guards are 4. Hydraulic fluid leaks. If General Inspection in place and functional. leaks found (10 hours) Repair or replace any suspected, repair A walk around inspection right away and check the damaged missing should be made on a daily...
Page 113 16-4 16-4 16-4 16-4 16-4 Maintenance Rubber Flashing (10 hours) If material is leaking or becoming wedged between rubber flashing and the conveyor belt, the flashing may need to be extended. Rubber flashing 1. Loosen the clamp bar bolts work flashing down so it barely contacts the belt when belt is contacting the idler.
Page 114 Make sure there are no open Fuel tank fill cap flames when filling the fuel tank or handling fuel. Never fill when plant is running. KPI-JCI recommends filling the fuel tank at the end of each day to help prevent condensation in the fuel tank.
Page 115 16-6 16-6 16-6 16-6 16-6 Maintenance Stationary and Moving Jaw Dies (10 hours) Check stationary and moving jaw dies for wear. If worn excessively, rotate or replace. NOTICE Failure to properly maintain jaw dies increases crushing pressure resulting damage other components and will void warranty.
Page 116 16-8 16-8 16-8 16-8 16-8 Maintenance Engine Radiator (10 hours) Closely inspect the engine radiator daily for buildup. In some cases, a light coating is not even visible. Cooling loss, which can lead to engine overheating, can occur even with a light coating. NOTICE Cleaned Radiator Visible (Excessive) Buildup on...
Page 117 16-9 16-9 16-9 16-9 16-9 Maintenance Spring Compression (10 hours) Tension rod spring nuts should be tightened just enough to keep the toggle plate from knocking. Normal adjustment requires about 1-1/4" spring compression. Additional compression may be required. See Chapter 13 for information on setting proper spring compression.
Page 118 16-10 16-10 16-10 16-10 16-10 Maintenance Conveyor Belt Splice (50 hours) Inspect splice for damage. Check cable fasteners for loose, torn or excessively worn rivets. Make sure that cable lode collar is installed and set- screw is tight. Toggle Plate and Toggle Seats (50 hours) Toggle plate...
Page 119 16-11 16-11 16-11 16-11 16-11 Maintenance Side Liners (50 hours) Check the side liners for excessive wear. These liners must be replaced before they have worn to the point where damage may be done to the crusher base. Watch especially for wear in the bottom side liner.
Page 120 16-12 16-12 16-12 16-12 16-12 Maintenance Belt Cleaner and Blade (50 hours) Make sure all fasteners are tight. Tighten if necessary. Check blade for excessive wear. Replace blade if it is Adjust tension here worn to the wear line. Refer to the belt cleaner manual included with the plant for instructions on replacing the belt cleaner.
Page 121 16-13 16-13 16-13 16-13 16-13 Maintenance Flywheel and Bearing Bolts (250 hours) Check flywheel bolts and bearing studs and nuts for tightness. Flywheel bolts should be tightened to 850 ft/lbs (1152 Nm). Bearing nuts should be tightened to 5000 ft/lbs (6780 Nm).
Page 122: 2000 Hours
16-14 16-14 16-14 16-14 16-14 Maintenance Air Filter (2000 hours) Donaclone tubes Air filter cover Kolberg-Pioneer Fast Trax units are equipped with a Donaldson Donaclone two- stage air cleaning unit. Use the following procedure to service the air cleaner. 1. Measure restriction of the air cleaner with the service indicator.
Page 123 16-15 16-15 16-15 16-15 16-15 Maintenance Batteries (As needed) Batteries compartment located beneath the walkway between the engine enclosure and the back of the jaw crusher. Access to the battery compartment is gained by removing six bolts from the battery access door and removing the door.
Page 124 16-16 16-16 16-16 16-16 16-16 Maintenance Engine Radiator (As needed) The engine radiator should be cleaned as often as necessary depending on application. In some cases, it may be necessary to clean the engine radiator daily. Removing asphalt and other buildup from the radiator is not possible by power washing alone.
Page 125 16-17 16-17 16-17 16-17 16-17 Maintenance - Wear Part Replacement WARNING Never attempt to service or adjust this machine until all energy sources have been locked out/tagged out. Refer to Chapter 3 for more safety information. Reversal Replacement Jaw die maintenance is essential for consistent production as well as for New Jaw Die...
Page 126: As Needed
16-19 16-19 16-19 16-19 16-19 Maintenance - Wear Part Replacement WARNING Use the following procedure to 4. If the jaw die can be remove and replace the jaw reversed, turn the jaw die dies. over and lower into the Proper procedures must be crusher base.
Page 127 16-20 16-20 16-20 16-20 16-20 Maintenance - Wear Parts Replacement Stationary Jaw Die Retaining wedge following procedure to reverse or replace the stationary jaw die. 1. Unbolt and remove the retaining clamp bar and upper wedge that hold the upper part of the jaw die. 2.
Page 128: Side Liners
16-21 16-21 16-21 16-21 16-21 Maintenance - Wear Parts Replacement Side Liners The side liners line the sides of the crushing chamber to provide wear protection. When they become worn they should be replaced to prevent damage to the crusher base. Use the following procedure to remove and replace the side liners.
Page 129: Belt Splice Retaining Collar
16-22 16-22 16-22 16-22 16-22 Maintenance - Wear Parts Replacement Belt Splice Retaining Collar Installation When installing a new conveyor belt, a new retaining collar with set screws will need to be installed to prevent the belt splice cable from “walking”...
Page 130: Hours 1000 Hours
17-1 17-1 17-1 17-1 17-1 Lubrication - Grease Ref. Notes Interval Vibrating Feeder Add 1 oz. grease to each zerk (4 zerks total) Pitman Bearings Add 32 oz. lubricant to each bearing. Outer Main Bearings Add 16 oz. lubricant to each bearing. 10 Hours Engine Oil and Coolant Check level.
Page 131 17-2 17-2 17-2 17-2 17-2 Lubrication Vibrating Feeder Bearings (10 hours) There are four grease zerks for the vibrating feeder bearings. Each zerk should receive 1 ounce grease. Lube Point Mobilith SHC 220 is a multipurpose, extreme pressure grease recommended for heavy-duty industrial applications.
Page 132 17-3 17-3 17-3 17-3 17-3 Lubrication Bearings (10 hours) Pitman Bearings Pitman - add 32 oz. Grease is added to the pitman via a remote grease line. Add 32 ounces (two pints) of NLGI 00 semifluid grease. Outer Main Bearings Grease is added to the shaft bearings via a remote Outer main bearings - add 16 oz.
Page 133 17-4 17-4 17-4 17-4 17-4 Lubrication Vibrating Feeder Gear Box (10 hours) The gear case on the vibrator mechanism housing is factory filled with 2.5 gallons (9.5 l) Mobilgear 630 industrial gear oil. Check the gear box lubricant level often by viewing the site glass.
Page 134 17-5 17-5 17-5 17-5 17-5 Lubrication Pulley Bearings (50 hours) following procedure for lubricating the head and tail pulley bearings. 1. Wipe dirt from grease zerk and bearing. 2. Slowly lubricate with a Lube Point manual grease gun. Grease should be added until grease purges from Pulley Bearing bearing seal.
Page 135 17-6 17-6 17-6 17-6 17-6 Lubrication Engine Oil and Filter (250 hours) Change (refer to engine manual). Vibrating Feeder Gear Box (250 hours) The gear case on the vibrator mechanism housing is factory filled with 2.5 gallons (9.5 l) Mobilgear 630 industrial gear oil.
Page 136: Hours
17-7 17-7 17-7 17-7 17-7 Lubrication Track Drive Hubs (250 hours) Change oil in the track drive hub after the first 250 hours of service. After this, check the oil level every 250 hours. See page 17-11 for instruction on filling the track drive gearbox with oil.
Page 137 17-8 17-8 17-8 17-8 17-8 Lubrication Durst Gear Box (1000 hours) The oil should be changed Durst gear after the first 500 hours of service. After this, under normal operating conditions, the oil should be changed every 1000 hours of service. drain hose attached to the botttom of the...
Page 138 Chevron Ultra-duty HD00 - 14 quarts pitman and 2 quarts for each main bearing. cold weather Bearing Drain Plug temperatures (ambient temperature below 40 degrees F[4.4 degrees C]), KPI-JCI recommends using Mobilith SHC 007). Same fill amounts apply. Drain plug Pitman Drain Plug...
Page 139 17-10 17-10 17-10 17-10 17-10 Lubrication Track Drive Hubs (1000 hours) following procedure to change the oil in the track drive. 1. Track the machine until one of the two plugs is at the 6 o’clock position. 2. Lockout/tagout all power to the FT unit.
Page 140 18-1 18-1 18-1 18-1 18-1 Hydraulic System Maintenance Ref. Notes Interval Hydraulic Oil Tank Check oil level in sight glass. 10 Hours Oil should be visible in sight glass. Leaks Hydraulic Filter Check dirt indicator alarm with engine running at high idle.
Page 141 18-2 18-2 18-2 18-2 18-2 Hydraulic System Maintenance Hydraulic Oil Tank (10 hours) The hydraulic oil tank fluid Sight glass level should be visible in the sight glass at all times. Should the level fall below the sight glass, be sure to fill the tank so fluid is visible.
Page 142 18-3 18-3 18-3 18-3 18-3 Hydraulic System Maintenance Hydraulic System Filter (10 hours) The hydraulic system filter should be checked regularly to prevent damage to the system. If the three color dirt alarm indicator points to the high side of the yellow area the filter should changed immediately.
Page 143 18-4 18-4 18-4 18-4 18-4 Hydraulic System Maintenance Charge Filters (50 hours) insure maximum productivity, all charge filters should be checked weekly by monitoring charge pressure using the 600 PSI gauge. They should be changed when the pressure drops below 300 PSI when the oil is heated, or when the closed loop system does not operate properly.
Page 144 18-5 18-5 18-5 18-5 18-5 Hydraulic System Maintenance Breather Cap (500 hours) Breather cap Replace. Cylinder Rods (1000 hours) Check cylinder rods for nicks, polish off if found. Cycle the cylinders.
Page 145: 2000 Hours
Clean-out cover Use Hydrex MV60. MV60 is not available, KPI-JCI recommends using a high quality oil with an appropriate viscosity based on the ambient temperature the plant will be operting in until the next oil change.
Page 146 19-1 19-1 19-1 19-1 19-1 Emissions Since industrial following pages revolution, emissions has contain emissions information been an environmental issue. for CAT C13 engines. In 1996, the first of four Also included are noise tiers of stringent emissions levels. These may not have a standards was adopted.
Page 147 19-2 19-2 19-2 19-2 19-2 Emissions - Tier III CAT C13...
Page 148 19-3 19-3 19-3 19-3 19-3 Emissions - Tier III CAT C13...
Page 149 19-4 19-4 19-4 19-4 19-4 Emissions - Tier IV CAT C13...
Page 150: Auxilliary Conveyor Capacities And Hydraulic Schematics
91.4 40.6 40.6 40.6 24.4 76.2 91.4 40.6 40.6 27.4 76.2 40.6 91.4 47.7 40.6 30.5 76.2 47.7 91.4 47.7 *This information is only applicable when connecting KPI-JCI, Inc. conveyors. Results may vary with conveyors not manufactured by KPI-JCI, Inc.
Page 151 Auxilliary Conveyor Capacities and Hydraulic Schematics* *This information is only applicable when connecting KPI-JCI, Inc. conveyors. Results may vary with conveyors not manufactured by KPI-JCI, Inc.
Page 152 Auxilliary Conveyor Capacities and Hydraulic Schematics*...
Page 153 Auxilliary Conveyor Capacities and Hydraulic Schematics*...
Page 154: Hydraulic System Startup
2. Disconnect the external control input signal or high pressure lines (hoses). (EDC or FNR wires) until after initial startup. KPI-JCI uses closed loop hydraulic systems This allows the pump to remain in the in a number of different applications including neutral position.
Page 155 6. Continue to turn the engine over until oil Open Circuit Hydraulic System Startup comes out of the loosened line or ten Use the following procedure as part of startup seconds has passed. on open circuit hydraulic units. If oil does not come out of the line in ten seconds, allow the starter on the engine to Equipment cool for two minutes and try again.
Page 156 Startup Hydraulic Relief Pressure Adjustment Complete both the Startup procedure and Use the following procedure to adjust hydraulic Hydraulic Relief Pressure adjustment procedure relief pressure. for each valve bank. If valves are in a series, set the relief valves in the order in which the oil travels. 1.
Page 157 Appendix C OVERLOAD PROTECTION SYSTEM PLC PARAMETERS - FT3055 Engine Setup Engine Overload RPM/% 1725 RPM Engine Type CAT C13 Tier Level 3 or 4 High Idle Set RPM 1800 Crusher Setup Crusher Set RPM Crusher Max Default % Crusher Overload % RPM...
Page 158: Cat Engine Diagnostic Codes
Appendix D CAT Engine Diagnostic Codes Flash Code SPN/FMI Code Diagnostic Code or Description Event Code 174-03 174-03 Fuel temperature open/short to +batt 174-04 174-04 Fuel temperature short to ground 626-05 2417-05 Ether injection control solenoid open/short to +batt 626-06 2417-06 Ether injection control solenoid open/short to ground 678-03...
Page 159 Appendix D - Continued Cat Engine Diagnostic Codes Flash Code SPN/FMI Code Diagnostic Code or Description Event Code 110-15 E361 (1) High engine coolant temperature warning 110-16 E361 (2) High engine coolant temperature derate 626-05 E361 (3) High engine coolant temperature shutdown 111-17 E2143 (1) Low engine coolant level warning...
Page 160 Appendix E Sonic Belt Tension Instructions following procedure to use the Gates sonic belt tester to measure belt tension. Measuring Belt Span 1. Attach the sensor and turn 4. Measure the belt span. measured belt tension is the power on. Press the blue SPAN then displayed.
Page 161: Belt Tension Instructions
Belt Tension Gauge Instructions following procedure to measure v-belt tension. 1. Lockout/tagout all power. 2. Measure the belt span Measuring Belt Span and Deflection Force length of the drive (see 6. Compare force within the recommended drawing). required in step 5 with the ranges.
Page 162 Recommended Deflection 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 - 12.0 10.1 2.65 - 3.35...
Page 163: Welding Lifting Lugs To Jaw Manganese
Appendix F Welding Lifting Lugs to Jaw Manganese WARNING Use the following information to weld lifting lugs to the jaw manganese. Proper procedures must be used when Guidelines welding to the moving or stationary jaw die. Failure to follow manganese weld Locate welder ground as close to the area •...
Page 164 Typical Operating Procedures: Rockwell Hardness • As-welded (2 layers) - • Work hardened (2 layers) - Current (Amps) Polarity 5/32 in. (4 mm) • • 120-180 • 125-210...
Page 166 Warranty Registration & Preoperational Check FT3055 Kolberg-Pioneer, Inc. Form may be Sent, Faxed or Emailed IMPORTANT Warranty will be void if this registration is not returned within ten (10) day after the equipment is put into service. Date Put Into Service...
Page 167 Quick-Start for Fast Trax Machine Start-up 1. Check e-stops on both sides, they must not be pushed in, twist to release. 2. Battery disconnect switch 4. Press e-stop. must be in “ON” position. “ON” position 8. Toggle HORN switch up then release. 5.
Page 168 Quick-Start for Fast Trax 7. When this screen appears go to step 8. 12. Use left and right controls on remote to move machine. 8. CRUSHER, FEEDER, HORN and IDLE switches must be down. Machine Shut-down 13. Turn control panel switch OFF when finished.
Page 172 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 Service 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) Fax - 541-988-9501...

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