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KPI-JCI FT300DF Manuals
Manuals and User Guides for KPI-JCI FT300DF. We have
1
KPI-JCI FT300DF manual available for free PDF download: Operation And Service Manual
KPI-JCI FT300DF Operation And Service Manual (480 pages)
Brand:
KPI-JCI
| Category:
Industrial Equipment
| Size: 9 MB
Table of Contents
Table of Contents
3
Introduction
11
Operation and Service Manual
11
Address for Notices
11
Track Plant Components
12
Crusher Components
13
Kodiak+ Series Crusher Theory of Operation
15
Crushing Parameters
17
Safety
19
Safety Overview
19
Hazard and Advisory Statements
19
Hazard Warning Symbol
19
Hazard Statements
20
Advisory Statements
20
Arc Flash Safety
20
Lockout/Tagout
21
Who Must Use Lockout/Tagout
21
What Is Lockout/Tagout
21
When Must Lockout/Tagout Occur
21
When Can Lockout/Tagout Devices be Removed
22
Lockout/Tagout Rules
22
Additional Lockout/Tagout Requirements
22
Lockout/Tagout Devices
23
Lockout/Tagout Kit
24
Lockout/Tagout Procedure
25
Miscellaneous Safety Tips
28
Know Your Machinery
28
Be Prepared for Emergencies
28
Wear Personal Protective Equipment (PPE)
28
Observe Personal Safety Precautions
29
Help Prevent Accidents
29
Avoid Alcohol and Other Drugs
30
Be Aware of Your Surroundings
30
Practice Good Housekeeping
30
Inspect and Maintain Machinery
30
Safety Decals
31
Track Plant Safety Decal Locations
39
Crusher Safety Decal Locations
41
Emergency Stop (E-STOP) Locations
43
Omnex Screen (Optional)
44
Standard Screen
44
Setup
45
Hoisting and Handling Safety
45
General Precautions
45
Wire Rope
45
Connecting or Clamping Wire Ropes
45
Chains
46
Fiber or Synthetic Slings
46
Machinery Installation Safety
46
Foundations
46
Guarding
47
Customer Modifications
47
Electrical Connections
47
Site Selection
48
Plant Leveling
48
Track Plant Control Locations
49
Initial Startup Inspections
50
Hopper and Crushing Chamber Inspection
50
Hydraulic System Inspection
50
Lube Assembly Inspection
51
Crusher Inspection
51
Under Crusher Inspection
52
The Importance of Record Keeping and Your Warranty
52
Startup and 30-Day, 90-Day Inspection Checklists
52
Conveyor Preparation
53
Conveyor Safety
53
General Conveyor Information
54
Conveyor Belt Training
55
Adjusting Belt Side Creep
57
Conveyor Loading
59
Baghouse Operation
60
Baghouse Programming LOGO
61
Remote Operation
65
Remote Operation Safety
65
Introduction
65
Preparing for Operation
65
Tethered Remote
66
Kar-Tech Controller
67
Hand-Held Remote Transmitter
67
Remote Receiver
68
Omnex Radio Remote Control (Optional)
69
Transporting Machinery
70
Moving the Plant
71
Plant Travel Pre-Start Checks
71
Transporting the Crusher
72
Conveyor Shipping Bracket
73
Raising/Lowering the Feed Conveyor
74
Baghouse Shipping Cover
75
Track Step
75
Plant Travel Position
77
Moving Plant Using Tethered Remote
78
Moving Plant Using Kar-Tech Remote
84
Moving Plant Using Omnex Remote
91
Operation
99
Crusher Safety
99
Pre-Start Checks
101
Plant Pre-Start Checks
101
Conveyor Pre-Start Checks
101
Crusher Pre-Start Checks
102
Plant Startup, Operation, and Shutdown
103
Plant Startup
103
Plant Operation
107
Plant Shutdown
109
Plant Startup Using Omnex Remote
111
Plant Operation Using Omnex Remote
116
Plant Shutdown Using Omnex Remote
118
Emergency Stop (ESTOP) Re-Start Procedure
120
Digsy Screen Navigation
121
Digsy Icons
123
Main Screen
125
Setup Configuration
128
Password Entry
130
Hopper Level Sensor
132
Hopper Level Sensor Initial Configuration
134
Hopper Sensor Calibration Procedure
137
Local Mode Screen
139
Engine Screen
140
Engine RPM Adjustment
141
Performance Screen
142
Crusher Screen
143
Closed Side Setting (CSS)
143
The Crushing Zone
144
Maximum Bowl Position
145
Bowl Float
146
Bowl Rotation and CSS Adjustment
147
Zeroing out Bowl Position Counter
148
Crusher Clear Procedure
150
Adjusting Conveyor Speed
152
Operating the Plant in Extreme Weather Conditions
153
Crusher Lubrication Heater
153
Ambient Temperature
153
Humidity
153
Automatic Error Guiding
154
Warning Screens
155
Diagnostics
164
Fault Condition Warning
166
Engine Diagnostics
166
Clutch Diagnostics
167
Crusher Diagnostics
168
System Diagnostics
168
Automatic Crusher Shutdown
170
Circuit Breakers
171
Crusher Operational Troubleshooting
172
Maintenance
175
Maintenance and Repair Safety
175
General Precautions
175
Electrical Systems
175
Pressurized Systems
176
Welding on Machinery
176
Clearing Jammed Material
177
Hazardous Materials
178
Disposal of Excess Fuels, Lubricants and Liquids
178
System Controls
179
Maintenance Screen
179
Disconnecting Digsy Control Components
180
Depressurize Plant Hydraulic System Procedure
184
Depressurize Crusher Hydraulic System Procedure
184
Track Plant Maintenance Procedures
186
Track Plant Daily Inspection Checklists
186
Before Plant Startup
186
After Plant Startup
187
During Plant Operation
187
Restriction Indicator
188
Engine Air Cleaner
188
Engine Coolant Level
189
Engine Drive Belts
190
Engine Fuel Level
191
Engine Oil Level
192
Fuel Water Separator
194
Hydraulic Cooler
195
Hydraulic Hoses and Connections
195
Hydraulic Oil Level
196
Hydraulic Restriction Indicator
197
Drive Cog Sheave Alignment and Belt Tension
197
Baghouse Filter Change
213
Track Plant Maintenance Schedules
218
Weekly or Every 50 Hours of Operation
218
Monthly or Every 200 Hours of Operation
219
Every 500 Hours of Operation
219
Every 1,000 Hours of Operation
219
Yearly or Every 2,000 Hours of Operation
219
Every 5,000 Hours of Operation
219
Batteries
220
Feed Conveyor Gear Reducer
221
Plant Grease Points
222
Radiator and Cooler Care
223
Track Checks
223
Track Drive Gearbox Oil
223
Lube Oil Sample Procedure
224
Lube and Hydraulic Reservoir Air Breather Change Procedure
226
Oil Filter Restriction Indicator
228
Lube Oil Filter Change Procedure
228
Lube Oil Reservoir Fill Procedure
230
Lube Oil Change Procedure
231
Hydraulic Filter Change Procedure
232
Hydraulic Oil Change Procedure
235
Hydraulic Accumulator Removal Procedure
235
Hydraulic Accumulator Refill Procedure
237
Hydraulic Accumulator Installation Procedure
240
Conveyor Maintenance
242
Conveyor Daily Inspection Checklist
242
Weekly or Every 50 Hours of Operation
242
Repairing a Broken Conveyor Belt
244
Measuring a Conveyor Belt Procedure
244
Squaring the Ends of the Conveyor Belt
245
How to Drill and Skive the Conveyor Belt
248
Attaching the Belt Ends
252
Using the Flexco 840 Belt Cutter
257
Crusher Maintenance
260
Crusher Hydraulic Safety Precautions
260
Crusher Daily Inspection Checklist
261
Crusher Maintenance Schedules
262
After First 200 Hours of Operation
262
Every 500 Hours of Operation
263
Annually or 4,000 Hours
263
At Every Liner Change
263
Before Recommissioning the Crusher
264
Under Crusher Access Door
265
Bowl Rotation Gear Box Lubrication Procedure
266
Bowl Rotation Gear Box Oil Change Procedure
268
Removing the Hopper Extension
269
Installing the Hopper Extension
270
Hopper Assembly Removal Procedure
272
Hopper Assembly Installation Procedure
273
Upper Assembly Removal Procedure
275
Upper Assembly Installation Procedure
279
Bowl Removal Procedure
285
Bowl Installation Procedure
288
Manganese Liner Changes
291
Bowl Liner Change Procedure
291
Mantle Liner Change Procedure
303
System Relief Valve Testing and Setting Procedure
314
Individual TIR Cylinder Relief Valve Testing and Setting Procedure
318
Bowl Thread Lubrication Procedure
323
Mantle Bolt Thread Maintenance
326
Service
329
Track Plant Service
329
Remote Control System ID Code Procedure
329
Crusher Service
333
Offset Cone Lifting Eye Safety
333
Cone Lifting Eye and Cone Lifting Eye Assembly
334
Cone Lifting Eye (One-Piece)
334
Cone Lifting Eye Assembly (Two-Piece)
336
Cone Lifting Eye Assembly Installation Procedure
336
Cone Removal Procedure
338
Cone Installation Procedure
340
TIR Relief Cylinder Removal Procedure
343
TIR Relief Cylinder Installation Procedure
346
Replacing V-Seat Liners
350
Method 1
350
Method 2
350
Method 3
350
Setup
350
Preheat Considerations
350
V-Seat Liner Removal Procedure
351
V-Seat Liner Installation Procedure
353
Pinion Assembly Removal Procedure
354
Pinion Assembly Installation Procedure
358
Backlash Setting Procedure
360
Setting Gap between Thrustplate and Wedgeplate Procedure
366
Pin Clutch Removal Procedure
367
Pin Clutch Installation Procedure
370
Drive Ring Seal Installation Procedure
374
Bowl Support Thread Removal Procedure
376
Bowl Support Thread Installation Procedure
378
Bowl Clamp Thread Removal Procedure
385
Bowl Clamp Thread Installation Procedure
387
Bowl Clamp Piston Seal Removal Procedure
393
Bowl Clamp Piston Seal Installation Procedure
396
Hydraulic Motor Removal Procedure
402
Gear Box Removal Procedure
403
Hydraulic Motor and Gear Box Installation Procedure
405
Hydraulic Manifold Relief Valve Removal Procedure
416
Hydraulic Manifold Relief Valve Installation Procedure
417
Hydraulic Pressure Transducer Removal Procedure
418
Hydraulic Pressure Transducer Installation Procedure
419
Low Lubrication Oil Level Shutoff Switch Removal Procedure
420
Low Lubrication Oil Level Shutoff Switch Installation Procedure
422
Lube Cooler Bypass Valve Removal Procedure
423
Lube Cooler Bypass Valve Install Procedure
426
Lube Flow Encoder Removal Procedure
428
Lube Flow Encoder Installation Procedure
431
Reference Information
433
Plant Information
433
Specifications
433
Capacities
433
Conveyor Widths
433
Engine
433
Batteries
433
Track Plant Oil Recommendations
434
Grease Recommendations
434
Hydraulic Oil Recommendations
434
Standard Gear Oil Recommendations
434
Track Oil Recommendations
435
Engine Oil Recommendations
435
Omnex Receiver Unit
435
Kar-Tech Controller Troubleshooting
437
Crusher Information
439
Available Liner Configurations
439
K300+ Coarse Chamber
439
K300+ Medium Coarse Chamber
440
K300+ Medium Chamber
441
K300+ Medium Chamber with Feed Slots
442
K300+ Medium Fine Chamber
443
K300+ Fine Chamber
444
K300+ Product Capacities
445
Kodiak Plus Gradation Chart
446
K300+ CSS Chart
448
Crushing Application Guidelines
449
Pinion Speed
453
Choke Feeding
454
Rock Characteristics
454
Fine Crushing
456
Causes of Bowl Float
456
Feed Related Problems
457
Product Specification Troubleshooting
459
Crusher Lubrication Oil Specifications
460
Recommended Oil Type
460
Synthetic Oil
460
Lubrication System Oil Flow
461
Lube Oil Analysis
462
Hydraulic System
465
Hydraulic Pressures
465
Conveyor and Track Pressure
465
Crusher System Pressure
467
Feeder Lift Pressure
467
Lube Flow Pressure
468
Crusher Hydraulic Manifold Assembly
469
Crusher System Relief Pressure
470
Bowl Clamp
471
Bowl Clamp Circuit
473
Bowl Rotation Motor
474
Bowl Rotation Circuit
475
Tramp Iron Relief (TIR) System
476
Tramp Iron Relief (TIR) Circuit
478
TIR Relief Valve Pressure
479
Clear Circuit
480
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