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KPI-JCI FT300DF - Page 2

KPI-JCI FT300DF

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Table of Contents

Table of Contents3
Introduction11
Operation and Service Manual11
Address for Notices11
Track Plant Components12
Crusher Components13
Kodiak+ Series Crusher Theory of Operation15
Crushing Parameters17
Safety19
Safety Overview19
Hazard and Advisory Statements19
Hazard Warning Symbol19
Hazard Statements20
Advisory Statements20
Arc Flash Safety20
Lockout/Tagout21
Who Must Use Lockout/Tagout21
What Is Lockout/Tagout21
When Must Lockout/Tagout Occur21
When Can Lockout/Tagout Devices be Removed22
Lockout/Tagout Rules22
Additional Lockout/Tagout Requirements22
Lockout/Tagout Devices23
Lockout/Tagout Kit24
Lockout/Tagout Procedure25
Miscellaneous Safety Tips28
Know Your Machinery28
Be Prepared for Emergencies28
Wear Personal Protective Equipment (PPE)28
Observe Personal Safety Precautions29
Help Prevent Accidents29
Avoid Alcohol and Other Drugs30
Be Aware of Your Surroundings30
Practice Good Housekeeping30
Inspect and Maintain Machinery30
Safety Decals31
Track Plant Safety Decal Locations39
Crusher Safety Decal Locations41
Emergency Stop (E-STOP) Locations43
Omnex Screen (Optional)44
Standard Screen44
Setup45
Hoisting and Handling Safety45
General Precautions45
Wire Rope45
Connecting or Clamping Wire Ropes45
Chains46
Fiber or Synthetic Slings46
Machinery Installation Safety46
Foundations46
Guarding47
Customer Modifications47
Electrical Connections47
Site Selection48
Plant Leveling48
Track Plant Control Locations49
Initial Startup Inspections50
Hopper and Crushing Chamber Inspection50
Hydraulic System Inspection50
Lube Assembly Inspection51
Crusher Inspection51
Under Crusher Inspection52
The Importance of Record Keeping and Your Warranty52
Startup and 30-Day, 90-Day Inspection Checklists52
Conveyor Preparation53
Conveyor Safety53
General Conveyor Information54
Conveyor Belt Training55
Adjusting Belt Side Creep57
Conveyor Loading59
Baghouse Operation60
Baghouse Programming LOGO61
Remote Operation65
Remote Operation Safety65
Introduction65
Preparing for Operation65
Tethered Remote66
Kar-Tech Controller67
Hand-Held Remote Transmitter67
Remote Receiver68
Omnex Radio Remote Control (Optional)69
Transporting Machinery70
Moving the Plant71
Plant Travel Pre-Start Checks71
Transporting the Crusher72
Conveyor Shipping Bracket73
Raising/Lowering the Feed Conveyor74
Baghouse Shipping Cover75
Track Step75
Plant Travel Position77
Moving Plant Using Tethered Remote78
Moving Plant Using Kar-Tech Remote84
Moving Plant Using Omnex Remote91
Operation99
Crusher Safety99
Pre-Start Checks101
Plant Pre-Start Checks101
Conveyor Pre-Start Checks101
Crusher Pre-Start Checks102
Plant Startup, Operation, and Shutdown103
Plant Startup103
Plant Operation107
Plant Shutdown109
Plant Startup Using Omnex Remote111
Plant Operation Using Omnex Remote116
Plant Shutdown Using Omnex Remote118
Emergency Stop (ESTOP) Re-Start Procedure120
Digsy Screen Navigation121
Digsy Icons123
Main Screen125
Setup Configuration128
Password Entry130
Hopper Level Sensor132
Hopper Level Sensor Initial Configuration134
Hopper Sensor Calibration Procedure137
Local Mode Screen139
Engine Screen140
Engine RPM Adjustment141
Performance Screen142
Crusher Screen143
Closed Side Setting (CSS)143
The Crushing Zone144
Maximum Bowl Position145
Bowl Float146
Bowl Rotation and CSS Adjustment147
Zeroing out Bowl Position Counter148
Crusher Clear Procedure150
Adjusting Conveyor Speed152
Operating the Plant in Extreme Weather Conditions153
Crusher Lubrication Heater153
Ambient Temperature153
Humidity153
Automatic Error Guiding154
Warning Screens155
Diagnostics164
Fault Condition Warning166
Engine Diagnostics166
Clutch Diagnostics167
Crusher Diagnostics168
System Diagnostics168
Automatic Crusher Shutdown170
Circuit Breakers171
Crusher Operational Troubleshooting172
Maintenance175
Maintenance and Repair Safety175
General Precautions175
Electrical Systems175
Pressurized Systems176
Welding on Machinery176
Clearing Jammed Material177
Hazardous Materials178
Disposal of Excess Fuels, Lubricants and Liquids178
System Controls179
Maintenance Screen179
Disconnecting Digsy Control Components180
Depressurize Plant Hydraulic System Procedure184
Depressurize Crusher Hydraulic System Procedure184
Track Plant Maintenance Procedures186
Track Plant Daily Inspection Checklists186
Before Plant Startup186
After Plant Startup187
During Plant Operation187
Restriction Indicator188
Engine Air Cleaner188
Engine Coolant Level189
Engine Drive Belts190
Engine Fuel Level191
Engine Oil Level192
Fuel Water Separator194
Hydraulic Cooler195
Hydraulic Hoses and Connections195
Hydraulic Oil Level196
Hydraulic Restriction Indicator197
Drive Cog Sheave Alignment and Belt Tension197
Baghouse Filter Change213
Track Plant Maintenance Schedules218
Weekly or Every 50 Hours of Operation218
Monthly or Every 200 Hours of Operation219
Every 500 Hours of Operation219
Every 1,000 Hours of Operation219
Yearly or Every 2,000 Hours of Operation219
Every 5,000 Hours of Operation219
Batteries220
Feed Conveyor Gear Reducer221
Plant Grease Points222
Radiator and Cooler Care223
Track Checks223
Track Drive Gearbox Oil223
Lube Oil Sample Procedure224
Lube and Hydraulic Reservoir Air Breather Change Procedure226
Oil Filter Restriction Indicator228
Lube Oil Filter Change Procedure228
Lube Oil Reservoir Fill Procedure230
Lube Oil Change Procedure231
Hydraulic Filter Change Procedure232
Hydraulic Oil Change Procedure235
Hydraulic Accumulator Removal Procedure235
Hydraulic Accumulator Refill Procedure237
Hydraulic Accumulator Installation Procedure240
Conveyor Maintenance242
Conveyor Daily Inspection Checklist242
Weekly or Every 50 Hours of Operation242
Repairing a Broken Conveyor Belt244
Measuring a Conveyor Belt Procedure244
Squaring the Ends of the Conveyor Belt245
How to Drill and Skive the Conveyor Belt248
Attaching the Belt Ends252
Using the Flexco 840 Belt Cutter257
Crusher Maintenance260
Crusher Hydraulic Safety Precautions260
Crusher Daily Inspection Checklist261
Crusher Maintenance Schedules262
After First 200 Hours of Operation262
Every 500 Hours of Operation263
Annually or 4,000 Hours263
At Every Liner Change263
Before Recommissioning the Crusher264
Under Crusher Access Door265
Bowl Rotation Gear Box Lubrication Procedure266
Bowl Rotation Gear Box Oil Change Procedure268
Removing the Hopper Extension269
Installing the Hopper Extension270
Hopper Assembly Removal Procedure272
Hopper Assembly Installation Procedure273
Upper Assembly Removal Procedure275
Upper Assembly Installation Procedure279
Bowl Removal Procedure285
Bowl Installation Procedure288
Manganese Liner Changes291
Bowl Liner Change Procedure291
Mantle Liner Change Procedure303
System Relief Valve Testing and Setting Procedure314
Individual TIR Cylinder Relief Valve Testing and Setting Procedure318
Bowl Thread Lubrication Procedure323
Mantle Bolt Thread Maintenance326
Service329
Track Plant Service329
Remote Control System ID Code Procedure329
Crusher Service333
Offset Cone Lifting Eye Safety333
Cone Lifting Eye and Cone Lifting Eye Assembly334
Cone Lifting Eye (One-Piece)334
Cone Lifting Eye Assembly (Two-Piece)336
Cone Lifting Eye Assembly Installation Procedure336
Cone Removal Procedure338
Cone Installation Procedure340
TIR Relief Cylinder Removal Procedure343
TIR Relief Cylinder Installation Procedure346
Replacing V-Seat Liners350
Method 1350
Method 2350
Method 3350
Setup350
Preheat Considerations350
V-Seat Liner Removal Procedure351
V-Seat Liner Installation Procedure353
Pinion Assembly Removal Procedure354
Pinion Assembly Installation Procedure358
Backlash Setting Procedure360
Setting Gap between Thrustplate and Wedgeplate Procedure366
Pin Clutch Removal Procedure367
Pin Clutch Installation Procedure370
Drive Ring Seal Installation Procedure374
Bowl Support Thread Removal Procedure376
Bowl Support Thread Installation Procedure378
Bowl Clamp Thread Removal Procedure385
Bowl Clamp Thread Installation Procedure387
Bowl Clamp Piston Seal Removal Procedure393
Bowl Clamp Piston Seal Installation Procedure396
Hydraulic Motor Removal Procedure402
Gear Box Removal Procedure403
Hydraulic Motor and Gear Box Installation Procedure405
Hydraulic Manifold Relief Valve Removal Procedure416
Hydraulic Manifold Relief Valve Installation Procedure417
Hydraulic Pressure Transducer Removal Procedure418
Hydraulic Pressure Transducer Installation Procedure419
Low Lubrication Oil Level Shutoff Switch Removal Procedure420
Low Lubrication Oil Level Shutoff Switch Installation Procedure422
Lube Cooler Bypass Valve Removal Procedure423
Lube Cooler Bypass Valve Install Procedure426
Lube Flow Encoder Removal Procedure428
Lube Flow Encoder Installation Procedure431
Reference Information433
Plant Information433
Specifications433
Capacities433
Conveyor Widths433
Engine433
Batteries433
Track Plant Oil Recommendations434
Grease Recommendations434
Hydraulic Oil Recommendations434
Standard Gear Oil Recommendations434
Track Oil Recommendations435
Engine Oil Recommendations435
Omnex Receiver Unit435
Kar-Tech Controller Troubleshooting437
Crusher Information439
Available Liner Configurations439
K300+ Coarse Chamber439
K300+ Medium Coarse Chamber440
K300+ Medium Chamber441
K300+ Medium Chamber with Feed Slots442
K300+ Medium Fine Chamber443
K300+ Fine Chamber444
K300+ Product Capacities445
Kodiak Plus Gradation Chart446
K300+ CSS Chart448
Crushing Application Guidelines449
Pinion Speed453
Choke Feeding454
Rock Characteristics454
Fine Crushing456
Causes of Bowl Float456
Feed Related Problems457
Product Specification Troubleshooting459
Crusher Lubrication Oil Specifications460
Recommended Oil Type460
Synthetic Oil460
Lubrication System Oil Flow461
Lube Oil Analysis462
Hydraulic System465
Hydraulic Pressures465
Conveyor and Track Pressure465
Crusher System Pressure467
Feeder Lift Pressure467
Lube Flow Pressure468
Crusher Hydraulic Manifold Assembly469
Crusher System Relief Pressure470
Bowl Clamp471
Bowl Clamp Circuit473
Bowl Rotation Motor474
Bowl Rotation Circuit475
Tramp Iron Relief (TIR) System476
Tramp Iron Relief (TIR) Circuit478
TIR Relief Valve Pressure479
Clear Circuit480

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