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KPI-JCI FT300DF - User Manual

KPI-JCI FT300DF
480 pages
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86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401
24/7 Parts Number 888-474-0115
FT300DF
Plant Operation and Service Manual
and Parts Book
JCI Track Mounted Crushing Plant
XML Revision 0

Table of Contents

Questions and Answers

Summary

Introduction

Operation and Service Manual

Provides information for experienced operators to safely operate the equipment.

Address For Notices

Details JCI's address for inquiries and warranty claims.

Safety

Safety Overview

General principles and responsibilities for safety awareness programs.

Hazard Warning Symbol

Description and usage of the safety alert symbol.

Hazard Statements

Definitions of Caution, Warning, and Danger statements.

Advisory Statements

Definitions of Note and Notice statements.

Lockout;Tagout

Procedures for controlling hazardous energy during maintenance.

Lockout;Tagout Rules

General rules and company policies for lockout/tagout.

Additional Lockout;Tagout Requirements

Specific procedural requirements for lockout/tagout.

Lockout;Tagout Devices

Description and illustration of lockout/tagout devices.

Lockout;Tagout Kit

Contents and importance of the lockout/tagout kit.

Lockout;Tagout Procedure

Step-by-step lockout/tagout process.

Miscellaneous Safety Tips

General safety advice for machinery operation.

Know Your Machinery

Understanding machine controls, functions, and hazards.

Be Prepared for Emergencies

Emergency preparedness and procedures.

Observe Personal Safety Precautions

Personal safety measures while working.

Help Prevent Accidents

Guidelines for preventing accidents.

Avoid Alcohol and Other Drugs

Risks of operating machinery under influence.

Be Aware of Your Surroundings

Importance of situational awareness.

Practice Good Housekeeping

Maintaining a clean and safe work area.

Inspect And Maintain Machinery

Daily inspection and maintenance procedures.

Safety Decals

Identification and meaning of safety decals.

Track Plant Safety Decal Locations

Visual guide to decal placement on track plant.

Crusher Safety Decal Locations

Visual guide to decal placement on crusher.

Emergency Stop (E-STOP) Locations

Location of emergency stop switches.

Setup

Hoisting and Handling Safety

General precautions for safe lifting and handling.

Chains

Safe use, handling, and maintenance of chains.

Fiber Or Synthetic Slings

Safe use, handling, and maintenance of slings.

Machinery Installation Safety

Safety considerations during equipment installation.

Foundations

Importance of stable foundations for operation.

Guarding

Responsibilities for proper guard installation.

Customer Modifications

Guidelines and approval for machinery modifications.

Electrical Connections

Safety precautions for electrical connections.

Site Selection

Factors to consider when choosing an operational site.

Plant Leveling

Importance of leveling to prevent damage.

Track Plant Control Locations

Identification of control locations on the plant.

Initial Startup Inspections

Critical checks before initial operation.

Hopper and Crushing Chamber Inspection

Pre-startup inspection of hopper and chamber.

Hydraulic System Inspection

Pre-startup inspection of hydraulic system.

Lube Assembly Inspection

Pre-startup inspection of lube assembly.

Crusher Inspection

Pre-startup inspection of crusher components.

Under Crusher Inspection

Pre-startup inspection of the area under the crusher.

Conveyor Preparation

Tasks for preparing conveyors for operation.

Conveyor Safety

Safety precautions for conveyor operation.

General Conveyor Information

Tips for proper conveyor function.

Conveyor Belt Training

Adjusting belt for proper tracking.

Adjusting Belt Side Creep

Correcting belt path deviations.

Conveyor Loading

Proper loading techniques for belt life.

Baghouse Operation

Overview of the baghouse system.

Baghouse Programming LOGO!

Programming the baghouse controller.

Remote Operation

Operating the plant remotely.

Remote Operation Safety

Safety for remote operation.

Tethered Remote

Description of tethered remote control.

Kar-Tech Controller

Details of the Kar-Tech remote control.

Hand-Held Remote Transmitter

Features of the transmitter.

Remote Receiver

Location and function of the receiver.

Omnex Radio Remote Control (optional)

Optional remote control system.

Transporting Machinery

Procedures for transporting the equipment.

Moving the Plant

Procedures for moving the plant on-site.

Plant Travel Pre-Start Checks

Essential checks before moving the plant.

Transporting the Crusher

Blocking the cone head for transport.

Conveyor Shipping Bracket

Bracket removal and installation.

Raising;Lowering the Feed Conveyor

Adjusting feed conveyor position.

Baghouse Shipping Cover

Cover removal and storage.

Track Step

Locating and preparing the track step.

Plant Travel Position

Correct track unit positioning for travel.

Moving Plant Using Tethered Remote

Procedure for moving plant with tethered remote.

Moving Plant Using Kar-Tech Remote

Procedure for moving plant with Kar-Tech remote.

Moving Plant Using Omnex Remote

Procedure for moving plant with Omnex remote.

Operation

Crusher Safety

Crucial safety warnings for crusher operation.

Plant Startup, Operation, and Shutdown

Procedures for starting, operating, and shutting down the plant.

Plant Startup

Steps to follow for starting the plant.

Plant Shutdown

Procedures for shutting down the plant.

Digsy Screen Navigation

Guide to navigating the Digsy display.

Main Screen

Central hub for control system navigation.

Setup Configuration

Adjusting control settings and parameters.

Hopper Level Sensor

Description and configuration of the hopper sensor.

Password Entry

Procedure for entering passwords to access settings.

Hopper Level Sensor Initial Configuration

Sensor setup and initial programming.

Hopper Sensor Calibration Procedure

Sensor calibration steps.

Local Mode Screen

Operating the plant locally.

Engine Screen

Displaying engine status and parameters.

Engine RPM Adjustment

Adjusting engine RPM settings.

Performance Screen

Displaying performance data.

Crusher Screen

Displaying crusher operating conditions.

Closed Side Setting (CSS)

Definition and adjustment of CSS.

The Crushing Zone

Region for bowl drive ring positioning.

Maximum Bowl Position

Operational limit for bowl position.

Bowl Float

Causes and identification of bowl float.

Bowl Rotation and CSS Adjustment

Adjusting bowl rotation and CSS.

Zeroing Out Bowl Position Counter

Resetting the bowl position counter.

Crusher Clear Procedure

Procedure for clearing jammed material.

Adjusting Conveyor Speed

Adjusting conveyor speed via valves.

Operating the Plant in Extreme Weather Conditions

Operating in different weather conditions.

Automatic Error Guiding

System error guidance mechanism.

Warning Screens

Explanation of Digsy warning screens.

Diagnostics

Accessing diagnostic information for troubleshooting.

Fault Condition Warning

System fault notification display.

Engine Diagnostics

Displaying engine error codes.

Clutch Diagnostics

Viewing clutch information.

Crusher Diagnostics

Displaying crusher system status.

System Diagnostics

Status of sensors and communication.

Automatic Crusher Shutdown

Conditions triggering automatic shutdown.

Circuit Breakers

Function and reset of circuit breakers.

Crusher Operational Troubleshooting

Troubleshooting common crusher issues.

Maintenance

Maintenance and Repair Safety

Safety precautions for maintenance and repair.

Pressurized Systems

Safety guidelines for pressurized systems.

Welding On Machinery

Safety precautions for welding operations.

Clearing Jammed Material

Procedures for clearing jams safely.

Hazardous Materials

Handling and awareness of hazardous materials.

Disposal Of Excess Fuels, Lubricants And Liquids

Responsible disposal procedures for fuels, lubricants, and liquids.

System Controls

Independent component control for maintenance.

Maintenance Screen

Access to maintenance procedures.

Disconnecting Digsy Control Components

Steps to disconnect system components before welding.

Depressurize Plant Hydraulic System Procedure

Relieving plant hydraulic pressure.

Depressurize Crusher Hydraulic System Procedure

Relieving crusher hydraulic pressure.

Track Plant Maintenance Procedures

Overview of maintenance schedules.

Track Plant Daily Inspection Checklists

Daily inspection guidelines for track plant.

Before Plant Startup

Pre-startup inspection items.

After Plant Startup

Post-startup inspection items.

During Plant Operation

In-operation inspection items.

Restriction Indicator

Monitoring filter restriction.

Engine Air Cleaner

Air cleaner maintenance.

Engine Coolant Level

Coolant level check procedure.

Engine Drive Belts

Drive belt inspection and service.

Engine Fuel Level

Fuel level check procedure.

Engine Oil Level

Engine oil level check procedure.

Fuel Water Separator

Fuel filter/water separator check.

Hydraulic Cooler

Cooler inspection and cleaning.

Hydraulic Hoses and Connections

Hose and connection inspection.

Hydraulic Oil Level

Hydraulic oil level check.

Hydraulic Restriction Indicator

Restriction indicator check.

Drive Cog Sheave Alignment and Belt Tension

Sheave alignment and belt tension adjustment.

Baghouse Filter Change

Filter replacement procedure.

Track Plant Maintenance Schedules

Maintenance schedule overview.

Weekly or Every 50 Hours of Operation

Weekly/50-hour maintenance tasks.

Batteries

Battery inspection and cleaning.

Feed Conveyor Gear Reducer

Gear reducer oil change procedure.

Plant Grease Points

Identification of lubrication points.

Radiator and Cooler Care

Radiator and cooler maintenance.

Track Checks

Track system inspection.

Track Drive Gearbox Oil

Gearbox oil level check procedure.

Lube Oil Sample Procedure

Oil sampling for analysis.

Oil Filter Restriction Indicator

Filter restriction monitoring.

Lube Oil Filter Change Procedure

Lube filter replacement procedure.

Lube Oil Reservoir Fill Procedure

Adding oil to reservoir.

Lube Oil Change Procedure

Lube oil change procedure.

Hydraulic Filter Change Procedure

Hydraulic filter change procedure.

Hydraulic Accumulator Removal Procedure

Accumulator removal steps.

Hydraulic Accumulator Refill Procedure

Accumulator refill procedure.

Hydraulic Accumulator Installation Procedure

Accumulator installation steps.

Conveyor Maintenance

Conveyor maintenance overview.

Conveyor Daily Inspection Checklist

Daily conveyor inspection checklist.

Weekly or Every 50 Hours of Operation

Weekly/50-hour conveyor maintenance.

Repairing a Broken Conveyor Belt

Guide to repairing conveyor belts.

Measuring a Conveyor Belt Procedure

Procedure for measuring belt length.

Squaring the Ends of the Conveyor Belt

Preparing belt ends for splicing.

How to Square the Ends of the Conveyor Belt

Steps for squaring belt ends.

Using the Flexco 840 Belt Cutter

Instructions for using the belt cutting tool.

Crusher Maintenance

Overview of crusher maintenance.

Crusher Hydraulic Safety Precautions

Safety precautions for hydraulic systems.

Crusher Daily Inspection Checklist

Daily inspection checklist for the crusher.

Crusher Maintenance Schedules

Overview of maintenance schedules.

After First 200 Hours of Operation

Maintenance tasks after 200 hours.

Before Recommissioning the Crusher

Checks before recommissioning.

Under Crusher Access Door

Accessing the area under the crusher.

Bowl Rotation Gear Box Lubrication Procedure

Lubricating the bowl rotation gearbox.

Removing the Hopper Extension

Steps for removing hopper extension.

Installing the Hopper Extension

Steps for installing hopper extension.

Hopper Assembly Removal Procedure

Steps for removing hopper assembly.

Hopper Assembly Installation Procedure

Steps for installing hopper assembly.

Upper Assembly Removal Procedure

Steps for removing upper assembly.

Upper Assembly Installation Procedure

Steps for installing upper assembly.

Bowl Removal Procedure

Steps for removing the crusher bowl.

Bowl Installation Procedure

Steps for installing the crusher bowl.

Manganese Liner Changes

Overview of manganese liner replacement.

Bowl Liner Change Procedure

Procedure for replacing the bowl liner.

Mantle Liner Change Procedure

Procedure for replacing the mantle liner.

Backing Material Procedure

Procedure for mixing and pouring backing material.

System Relief Valve Testing and Setting Procedure

Procedure for testing and setting system relief valve.

Individual TIR Cylinder Relief Valve Testing and Setting Procedure

Procedure for testing and setting TIR cylinder relief valves.

Bowl Thread Lubrication Procedure

Cleaning and lubricating bowl threads.

Mantle Bolt Thread Maintenance

Cleaning and inspecting mantle bolt threads.

Service

Track Plant Service

Service procedures for track plants.

Remote Control System ID Code Procedure

Procedure for matching remote transmitter and receiver ID codes.

Crusher Service

Service procedures for crushers.

Offset Cone Lifting Eye Safety

Safety for using offset cone lifting eyes.

Cone Lifting Eye and Cone Lifting Eye Assembly

Information on cone lifting eyes.

Cone Removal Procedure

Steps for safely removing the crusher cone.

Cone Installation Procedure

Steps for safely installing the crusher cone.

TIR Relief Cylinder Removal Procedure

Steps for removing a TIR relief cylinder.

TIR Relief Cylinder Installation Procedure

Steps for installing a TIR relief cylinder.

Replacing V-Seat Liners

Methods for replacing V-seat liners.

Method 1

Factory welding method using specific wire and gas.

Method 2

Field welding method using Inconel and E7018 electrodes.

Method 3

Welding with stick electrodes, readily available for field service.

Setup

Preparation steps for liner replacement.

Preheat considerations

Guidelines for preheating welding surfaces.

V-Seat Liner Removal Procedure

Steps for removing V-seat liners, including weld grinding.

V-Seat Liner Installation Procedure

Steps for installing V-seat liners using welding and clamping.

Pinion Assembly Removal Procedure

Steps for safely removing the pinion assembly.

Pinion Assembly Installation Procedure

Steps for safely installing the pinion assembly.

Backlash Setting Procedure

Procedure for setting gear backlash using dial calipers.

Setting Gap Between Thrustplate and Wedgeplate Procedure

Setting the gap between thrustplate and wedgeplate.

Pin Clutch Removal Procedure

Steps for safely removing the pin clutch assembly.

Pin Clutch Installation Procedure

Steps for safely installing the pin clutch assembly.

Drive Ring Seal Installation Procedure

Procedure for installing drive ring seals.

Bowl Support Thread Removal Procedure

Steps for removing bowl support threads.

Bowl Support Thread Installation Procedure

Steps for installing bowl support threads.

Bowl Clamp Thread Removal Procedure

Steps for removing bowl clamp threads.

Bowl Clamp Thread Installation Procedure

Steps for installing bowl clamp threads.

Bowl Clamp Piston Seal Removal Procedure

Steps for safely removing the bowl clamp piston seal.

Bowl Clamp Piston Seal Installation Procedure

Steps for safely installing the bowl clamp piston seal.

Hydraulic Motor Removal Procedure

Steps for safely removing the hydraulic motor.

Gear Box Removal Procedure

Steps for safely removing the gearbox.

Hydraulic Motor and Gear Box Installation Procedure

Steps for safely installing the hydraulic motor and gearbox.

Hydraulic Manifold Relief Valve Removal Procedure

Steps for safely removing the manifold relief valve.

Hydraulic Manifold Relief Valve Installation Procedure

Steps for safely installing the manifold relief valve.

Hydraulic Pressure Transducer Removal Procedure

Steps for safely removing the hydraulic pressure transducer.

Hydraulic Pressure Transducer Installation Procedure

Steps for safely installing the hydraulic pressure transducer.

Low Lubrication Oil Level Shutoff Switch Removal Procedure

Steps for safely removing the low oil shutoff switch.

Low Lubrication Oil Level Shutoff Switch Installation Procedure

Steps for safely installing the low oil shutoff switch.

Lube Cooler Bypass Valve Removal Procedure

Steps for safely removing the lube cooler bypass valve.

Lube Cooler Bypass Valve Install Procedure

Steps for safely installing the lube cooler bypass valve.

Lube Flow Encoder Removal Procedure

Steps for safely removing the lube flow encoder.

Lube Flow Encoder Installation Procedure

Steps for safely installing the lube flow encoder.

Reference Information

Plant Information

General plant specifications and data.

Specifications

Technical specifications including capacities and dimensions.

Capacities

Tank capacities for fuel and hydraulics.

Conveyor Widths

Width specifications for conveyors.

Engine

Engine details.

Batteries

Battery specifications.

Track Plant Oil Recommendations

Oil and grease recommendations.

Grease Recommendations

Guidelines for grease selection and compatibility.

Hydraulic Oil Recommendations

Recommended hydraulic oil properties.

Standard Gear Oil Recommendations

Recommended gear oils.

Track Oil Recommendations

Track lubrication recommendations.

Engine Oil Recommendations

Engine oil specifications.

Omnex Receiver Unit

Information on the Omnex receiver.

Kar-Tech Controller Troubleshooting

Troubleshooting guide for the Kar-Tech controller.

Crusher Information

Information on crusher components and configurations.

Available Liner Configurations

Details on liner options and weights.

K300+ Coarse Chamber

Specifications for K300+ coarse chamber.

K300+ Product Capacities

Product output capacities by CSS.

Kodiak Plus Gradation Chart

Product gradation data chart.

K300+ CSS Chart

Chart for CSS adjustments.

Crushing Application Guidelines

Guidelines for optimizing crushing applications.

Pinion Speed

Effect of pinion speed on performance.

Choke Feeding

Importance of choke feeding for performance.

Rock Characteristics

Properties of rock affecting crushing.

Hardness

Rock hardness classification.

Fine Crushing

Techniques for achieving fine crushing.

Causes of Bowl Float

Common causes of bowl float.

Product Specification Troubleshooting

Troubleshooting product specification issues.

Crusher Lubrication Oil Specifications

Recommended oils and their properties.

Lubrication System Oil Flow

Diagram and explanation of oil flow path.

Lube Oil Analysis

Guidelines for oil sample analysis.

Oil Filter Element Beta Ratings

Explanation of oil filter rating system.

Hydraulic System

Hydraulic Pressures

Monitoring operating hydraulic pressures.

Conveyor and Track Pressure

Location of pressure gauges for conveyors and tracks.

Crusher System Pressure

Location of the crusher system gauge.

Feeder Lift Pressure

Location of the feeder lift pressure gauge.

Lube Flow Pressure

Location of the lube flow pressure gauge.

Crusher Hydraulic Manifold Assembly

Diagram and description of the hydraulic manifold.

Crusher System Relief Pressure

Limiting maximum hydraulic pump pressure.

Bowl Clamp

Description of the bowl clamp mechanism.

Bowl Clamp Circuit

Explanation of bowl clamp pressure control.

Bowl Rotation Motor

Description of the bowl rotation drive system.

Bowl Rotation Circuit

How bowl rotation works with the clamp circuit.

Tramp Iron Relief (TIR) System

Description of the TIR system.

Tramp Iron Relief (TIR) Circuit

Explanation of the TIR circuit operation.

TIR Pressure Relief Valve

Function of the TIR pressure relief valve.

Clear Circuit

Procedure for clearing the chamber.

KPI-JCI FT300DF Specifications

General IconGeneral
BrandKPI-JCI
ModelFT300DF
CategoryIndustrial Equipment
LanguageEnglish

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