KPI-JCI Fast Pack K400FP Manuals

Manuals and User Guides for KPI-JCI Fast Pack K400FP. We have 1 KPI-JCI Fast Pack K400FP manual available for free PDF download: Crushing Plant Operation Manual And Parts Book

KPI-JCI Fast Pack K400FP Crushing Plant Operation Manual And Parts Book (116 pages)

Brand: KPI-JCI | Category: Construction Equipment | Size: 5 MB

Table of Contents
3
Section 1: Introduction
9
Description
9
Crushing Plant Component Location
10
Fast Pack Operation Manual
10
New Parts and Equipment Warranty
10
Disclaimer/Limitation of Warranties
11
Address for Notices
12
Section 2: Safety
13
Safety Overview
13
Hazard and Advisory Statements
13
Hazard Statements
13
Advisory Statements
13
Lockout/Tagout
13
Who Must Use Lockout/Tagout
13
What Is Lockout/Tagout
14
When Must Lockout/Tagout Occur
14
How Is Lockout/Tagout Performed
14
When Can Lockout/Tagout Devices be Removed
14
Lockout/Tagout Devices
15
Lockout/Tagout Rules
15
Additional Lockout/Tagout Requirements
15
Miscellaneous Safety Tips
16
Know Your Machinery
16
Be Prepared for Emergencies
16
Wear Personal Protective Equipment (PPE)
16
Observe Personal Safety Precautions
16
Help Prevent Accidents
17
Avoid Alcohol and Other Drugs
17
Be Aware of Your Surroundings
17
Practice Good Housekeeping
17
Inspect and Maintain Machinery
18
Machinery Installation Safety
18
Foundations
18
Guarding
18
Customer Modifications
18
Electrical Hook-Up
19
Maintenance and Repair Safety
19
General Precautions
19
Electrical Systems
19
Pressurized Systems (Hydraulic and Air)
20
Welding on Machinery
20
Clearing Jammed Material
20
Hazardous Materials
21
Disposal of Excess Fuels, Lubricants and Liquids
21
Flammable and Combustible Liquids
21
Hoisting and Handling Safety
21
General Precautions
21
Wire Rope
21
Connecting or Clamping Wire Ropes
22
Chains
22
Fiber or Synthetic Slings
22
Transporting Machinery
22
Conveyor Safety
23
Safety Decals
25
Safety Decal Locations
31
Plant Left-Hand Side
31
Right-Hand Side
32
Section 3: Specifications
33
Plant Specifications
33
Operating Dimensions
33
Travel Dimensions
34
Capacities
35
Conveyor Width
35
Engine Components
35
Batteries
35
Component Weights
35
Section 4: Controls and Indicators
37
Introduction
37
Crushing Plant Control Locations
38
Travel and Set-Up Controls, Indicators, and Gauges
39
Suspension System
39
Air Bag Pressure
39
Air Bag Pressure Gauge
39
Height Control Valve
39
Height Adjust Valve
39
Self Steering Axle Pressure Value
39
Self Steering Axle Pressure Gauge
39
Self-Steering Axle Lock Valve
40
Hydraulic System Controls
40
Stabilizers and Jacks Location
41
Conveyor and Rear Jacks Control Bank
41
Stabilizers and Front Jacks Control Bank
41
Crushing Plant Folding Conveyor, Front and Rear Stabilizer Speed Control Valve
41
Cone Plant Hydraulic Power Unit Gauges and Indicators
42
Cone Plant Conveyor Manifold with Gauges
42
Operational Controls, Indicators, and Gauges
43
Cone Plant Emergency Stop (E-Stop) Switches and Warning Horns
43
Emergency Stop (E-Stop) Switches
43
Warning Horns
43
Battery Isolation (ISO) Switch
43
60 Amp Circuit Breaker
44
Fuel Gauge
44
Fuel Shut off Valve
44
Air Intake Restriction Indication
45
Profinet Connection
45
Main Power Disconnect
45
Power Connection Locations
46
Engine Control Panel
47
Engine Maintenance Light/Maintenance Reset Switch
47
Diesel Fuel Pressure Gauge
48
Engine Error Warning Light
48
Engine Oil Pressure Gauge
48
Engine Coolant Temperature Gauge
48
Engine Shutdown Warning Light
49
Voltmeter
49
Tachometer Engine Error Code Display/Hour Meter
49
Ignition Switch
49
Engine Shutdown Switch
50
Engine Idle Speed Adjustment Switch
50
Engine Start-Up Bypass Switch
50
Fluid Controller Control Panel
51
Engage / Disengage Button
52
Timed Lockout Indicator
52
Clutch Overload Indicator
52
RPM too High Indictor
52
Coil Fault Indicator
52
Clutch Engage Indicator
52
Oil Pressure Indicator
52
Oil Temperature Indicator
53
Filter Clogged Indictor
53
Safety Switch Indicator
53
Power Indicator
53
Input Speed Detected Indicator
53
Output Speed Detected Indicator
53
Pressure Transducer Detected Indicator
53
SAE J1939 CAN Indicator
53
Control Panel Switch Operation
54
Plant System Control Panel
55
Control Panel
56
Operator Interface (Main Menu)
56
Cone Status
56
Manual Controls
56
Cone Clutch Engaged Indicator
56
Lube Oil Flow Indicator
56
Bowl Clamp Pressure Indicator
56
Relief Pressure Indicator
56
Feeder Speed Decrease / Increase Switch
57
Magnetic SEP Start / Stop Switch (Optional)
57
Cone Clutch Start / Stop Switch
57
Side Discharge Conveyor Start / Stop Switch
57
Feed Conveyor Start / Stop Switch
57
Feeder Start / Stop
57
Bowl Rotate up / down
57
Hydraulic Clear
57
Emergency Stop Switch
57
Warning Horn Button
58
Display and Diagnostic Module (MDDM)
58
MDDM Operating Instructions
58
Viewing Engine Configuration Data (MDDM)
60
Viewing Active Service Codes (MDDM)
62
Viewing Stored Service Codes in the MDDM
63
Section 5: Set-Up
65
Introduction
65
Proper Site Selection
65
Plant Alignment Procedures
65
Engine Start-Up
65
Cone Plant Engine Pre-Start Checks
65
Plant Pre-Start Checks
66
Fast Pack Engine Starting Procedure for Leveling
68
Removing the Bag House Shipping Cover
68
Plant Set-Up
69
Plant Leveling Procedures
70
Conveyor Unfolding Considerations
71
Remotely Controlling Your Plant
71
Non-Network Plant Operation
71
Spray System Hook-Ups
71
Additional Set-Up Information
72
Adjusting the Vibrating Feeder Drive Belt
72
General Conveyor Information
72
Conveyor Belt Training
73
Adjusting Belt Side Creep
74
Conveyor Loading
75
Section 6: Operation
77
Introduction
77
Fast Pack Pre-Start Checks
77
Fast Pack Plant Pre-Start Checks
77
Conveyor Pre-Start Checks
77
Crusher Pre-Start Checks
77
Fast Pack Start-Up Procedures
78
Fast Pack Crusher Engine Starting Procedure
78
Removing the Bag House Shipping Cover
78
Fast Pack Post Start-Up Checks
79
Fast Pack Start-Up Sequence
79
Remotely Controlling Your Plant
79
Fast Pack Shut down Procedures
79
Restarting the Fast Pack after Emergency Stop Activation
80
Moving the Fast Pack Plant
80
Fast Pack Tear down
80
Travel and Positioning with the Fast Pack Trailers
81
Self-Steering Axle Operation
82
Self-Steering Axle Adjustment Procedure
82
Locking the Axles Prior to Backing
82
Section 7: Maintenance
83
Introduction
83
Maintenance Safety
83
Oil Recommendations
83
Grease Recommendations
83
Hydraulic Oil Recommendations
83
Scheduled Maintenance
83
Cone Plant Grease Lubrication Items
84
Scheduled Grease Lubrication Items
85
Fast Pack Plant Daily Walk Around Inspection Checklist
86
Maintenance Schedules
87
Weekly or Every 50 Hours of Operation
87
Monthly or Every 200 Hours of Operation
87
Every 500 Hours of Operation
87
Every 1000 Hours of Operation
87
Yearly or Every 2000 Hours of Operation
87
Every 5000 Hours of Operation
87
Daily Walk Around Items
87
Engine Oil Level
88
Engine Coolant Level
88
Drain the Fuel Water Separator
89
Cone Plant Fluid Coupling
89
Engine Charge Air Cleaner
89
Air Restriction Indicator
90
Profinet System
90
Engine Fuel Level
90
Hydraulic System Depressurizing
91
Changing the Filter Element
92
Hydraulic Hoses and Connections
93
Hydraulic Oil Pressures
93
Weekly or Every 50 Hours of Operation
94
Battery Maintenance
94
Radiator and Cooler Core
94
Conveyor Checks
94
Every 1000 Hours of Operation
95
Hydraulic Oil Filter
95
Yearly or Every 2000 Hours of Operation
95
Fluid Coupling Oil
95
Hydraulic Oil
95
Additional Maintenance Items
95
Lubrication of the Gear Reducer
95
Maintenance Recommendations
96
Oil Recommendations
96
How to Determine the Belt Tension
97
Setting the Meter
97
Using the Meter
98
Adjusting the Drive Belt Tension
99
JCI Bag House
101
Operation
101
Removing the Bag House Shipping Cover
101
Programing and Operating the Siemens LOGO! PLC
101
To Stop the Program
102
To Restart the Program
102
Control Panel Circuit Breaker
103
Maintenance
103
How to Repair a Broken Conveyor Belt
107
How to Measure for the Proper Length
107
How to Square the Ends
107
How to Drill and Skive Your Conveyor Belt
108
How to Attach the Belt Ends
110
Using the Flexco 840 Belt Cutter
112

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KPI-JCI Fast Pack K400FP Crushing Plant Operation Manual And Parts Book (116 pages)

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