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ASTEC KPI-JCI - User Manual

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IB-1005 5/14
Model 5044-32T
Sand Prep
Crushing &
Screening
OPERATION AND MAINTENANCE MANUAL
Vertical Shaft Impactor
Vertical Shaft Impactor
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Summary

About This Manual

Purpose of the Manual

Explains how the manual helps users get the best value from their equipment.

Using the Manual

Provides guidance on how procedures are described and referenced within the text.

Special Notations

Defines signal words like DANGER, WARNING, CAUTION, and IMPORTANT.

Serial Number Plates

Vertical Shaft Impactor Serial Number

Details the location and importance of the serial number for identification.

Buying Replacement Parts

Parts Sourcing and Identification

Guides on where to source parts and the role of serial numbers.

Maintenance Techniques and Tools

Tools and Procedures

Lists recommended tools and provides guidance on fasteners and waste disposal.

Lubricants and Fluids

Lubricant Types and Applications

Specifies factory fill lubricants for bearings, Hydra-Arm, and oil systems.

Storage

Storage Guidelines

Provides general, electric motor, and extended period storage procedures.

Introduction to the Vertical Shaft Impactor

Orientation and Material Flow

Explains how to determine orientation and the direction of material flow.

Tub and Base Components

Describes the function of the tub and base assemblies.

Lid Assembly and Feed Systems

Details the lid assembly, feed box, and feed tube.

Lid Liners and Hydra-Arm

Explains lid liners, inspection doors, and the optional Hydra-Arm.

Impact Ring, Anvils, and Rock Shelf

Describes the impact ring assembly, anvils, and rock shelf.

Rotor;Table and Feed Disc Assemblies

Details the rotor/table assembly and the feed disc.

Skirt Ring and Pedestal Systems

Explains the skirt ring assembly and pedestal.

Lubrication and Cooling Systems

Describes the lubrication panel and heat exchanger.

Safety

General Safety Principles

Emphasizes safety precautions and the importance of personal safety.

Personal Safety and Responsibilities

Defines owner/operator and operator/employee safety responsibilities.

Safety Symbols and Signal Words

Illustrates safety symbols and defines signal words like DANGER, WARNING, CAUTION.

Operational and Maintenance Safety

Covers general, assembly, and operating safety practices.

System-Specific Safety

Details hydraulic, transport, and magnet safety precautions.

Energy Control and Lockout Procedures

Explains lockout procedures, zero energy state, and lockout policy.

Specifications

Model 82 Specifications

Provides detailed specifications for the VSI Model 82.

Model 120 Specifications

Provides detailed specifications for the VSI Model 120.

Model 1500 Specifications

Provides detailed specifications for the VSI Model 1500.

Model 2500 Specifications

Provides detailed specifications for the VSI Model 2500.

Model 4500 Specifications

Provides detailed specifications for the VSI Model 4500.

Application

Application Basics and Benefits

Describes the VSI's flexibility, benefits, and general applications.

Construction and Mining Uses

Lists specific construction and mining applications for the VSI.

Operating Principles and Configurations

Explains operating principles and the three available configurations.

Feed Rate, Gradation, and Screening

Details the impact of feed rate, gradation, and screening on performance.

Feed Size and Performance Factors

Discusses maximum feed size, speed relationships, and tramp material.

Site Selection and Setup

Site and Foundation Requirements

Covers site selection considerations and foundation requirements.

Feed and Discharge Arrangements

Details proper feed and discharge arrangements for the VSI.

Material Presizing

Emphasizes the importance of presizing material before feeding.

Preoperation Checklist

Preoperation and Operational Checks

Provides checklists for preoperational and operational inspections.

Operation

Pre-Startup Procedures

Outlines the step-by-step procedure for starting the vertical shaft impactor.

Hydra-Arm Operation

Details the procedure for operating the Hydra-Arm for lid movement.

Startup

Startup Procedures

Provides a comprehensive procedure for starting up the crusher.

Lube System (3 rd Gen)

System Overview and Sensors

Describes the 3rd Gen lube system overview and sensor functions.

Quick Reference and Hydraulics

Presents a quick reference for VSI lube system hydraulics and electricals.

Electrical System and Alarms

Details the electrical system, relays, and alarm conditions.

System Operation and Maintenance

Covers lubrication system startup, shutdown, and maintenance.

Adjustments

Cluster Ring Adjustment

Procedure for vertically adjusting the cluster ring assembly.

Impact Ring and Rock Shelf Adjustment

Guides for adjusting the impact ring and rock shelf.

Skirt Ring Adjustment

Procedure for adjusting the skirt ring using shims.

Feed Tube Adjustment

Instructions for adjusting the feed tube height.

Temperature and Flow Switch Adjustment

Guides for adjusting the lube system's temperature and flow switches.

Wear Parts

Tub Liner Replacement

Procedure for replacing worn tub liners.

Anvil Replacement

Instructions for replacing anvils in rock shelf and cluster ring assemblies.

Feed Tube and Lid Liners

Details on feed tube reversal and lid liner replacement.

Feed Disc

Procedure for inspecting and replacing the feed disc.

Skirt Ring and Pedestal Skirt Cone

Instructions for replacing skirt ring and pedestal skirt cone.

Impeller Shoes

Guides for replacing bolt-on and pin-on impeller shoes.

Rotor and Table Liners

Procedures for replacing outer rotor, upper/lower, and flat/pocket liners.

Maintenance

General Inspection and V-Belts

Covers general inspection points and V-belt checks.

Gearbox Drives and Rotor

Details maintenance for gearbox drives and rotor components.

Feed Systems and Table

Maintenance for feed disc, feed ring, and table components.

Anvils and Shoe Brackets

Maintenance procedures for anvils and shoe brackets.

Feed Tube and Liners

Maintenance for feed tubes and lid liners.

Pedestal Skirt Components

Maintenance for pedestal skirt ring and cone.

Lubrication

Pedestal Dust Seal & Gearbox Seal

Lubrication intervals for pedestal dust and gearbox shaft seals.

Pedestal Oil Tank

Instructions for checking and maintaining pedestal oil tank level.

Oil Filter & Hydra-Arm Lubrication

Maintenance for oil filters and Hydra-Arm grease fittings.

Breather Cap & Oil Tank Service

Procedures for replacing breather cap and servicing oil tank.

Electric Motor Lubrication

Guidance on lubricating electric motor bearings.

Hydra-Arm Maintenance

Leaks and Fluid Maintenance

Covers checking for leaks and maintaining hydraulic oil.

Troubleshooting

Vibration, Oil Leaks, and Hydra-Arm Issues

Addresses common issues like vibration, oil leaks, and Hydra-Arm problems.

Appendix A: Belt Tension Instructions

Belt Tension Measurement Methods

Provides instructions for measuring belt tension using sonic testers and gauges.

Appendix B: Prevailing Torque Locknut

Bolt Torque Specifications

Lists torque values for UNC and UNF bolts and nuts.

ASTEC KPI-JCI Specifications

General IconGeneral
BrandASTEC
ModelKPI-JCI
CategoryConstruction Equipment
LanguageEnglish

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