ASTEC KPI-JCI FT2640 Programming manual

TROUBLE
SHOOTING
IB-5005 4/10
TRACK MOUNTTRACK MOUNT
TRACK MOUNTTRACK MOUNT
TRACK MOUNT
Jaw CrusherJaw Crusher
Jaw CrusherJaw Crusher
Jaw Crusher

Models Covered:
FT2640TrackMountedJawCrusher
FT2650TrackMountedJawCrusher
FT3055TrackMountedJawCrusher
FF
FF
FASTAST
ASTAST
AST TRAXTRAX
TRAXTRAX
TRAX
TRTR
TRTR
TROUBLESHOOOUBLESHOO
OUBLESHOOOUBLESHOO
OUBLESHOOTINGTING
TINGTING
TING
MANUMANU
MANUMANU
MANUALAL
ALAL
AL

Printed in the USA
Allrightsreserved. Nopartofthismanualmaybereproduced
or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording or by any
informationstorageorretrievalsystem,withoutpermission
fromKolberg-Pioneer.
Thismanualcontainsoperatinginstructionsandlubrication-
maintenance information. Application of this information
shouldmaximizetheperformanceandlifeofyourequipment
andminimize downtime.
Safeandefficientoperationrequiresthat anyonewhowillbe
operatingormaintainingthisequipmentreadandunderstand
the safety, operation, maintenance and troubleshooting
informationcontainedintheoperator'smanual.
Continuingimprovementand advancement of KOLBERG-
PIONEERproductsmaycausechangestoyourequipment
which may not be reflected in this publication.
KOLBERG-PIONEER,Inc.reservestherighttomakechanges
or add improvements to its products at any time, without
incurringanyobligationtomakesuchchangesonpreviously
manufacturedequipment.
Althoughcarehasbeentakentoassuretheaccuracyofthis
publication, KOLBERG-PIONEER, Inc. does not assume
any liability for loss, damage or injury caused by errors or
omissions.

Introductory Pages AboutThisManual 0-4
BuyingReplacement Parts 0-5
Engine Chapter 1
Conveyor Chapter 2
Vibrating Feeder Chapter 3
Jaw Crusher Chapter 4
Hydraulic Chapter 5
Electrical Chapter 6
Overload Protection
System Chapter 7
0-30-3
0-30-3
0-3
ContentsContents
ContentsContents
Contents

Purpose
Thepurposeofthismanual
istohelpyougetthebestvalue
fromyourequipment. Itcando
soby helpingyou decidewhat
workmustbedone,evenifyou
decide to have it done by a
dealerservicedepartmentora
repair shop. It also provides
informationandproceduresfor
routine maintenance and
servicing.
Using the Manual
The manual is divided into
chapters which are further
divided into numbered
sections, headed inboldtype
between horizontallines. Each
section consists of
consecutively numbered
paragraphs.
About This Manual
Procedures, once
described in the text, are not
normally repeated. When it is
necessary to refer to another
chapter, the reference will be
given as chapter and section
number. Cross references
givenwithouttheword"chapter"
apply to sections and/or
paragraphs in the same
chapter. For example, "see
section 8" means in the same
chapter.
Eventhoughthismanualhas
been prepared with extreme
care,Kolberg-Pioneercannot
acceptresponsibilityforerrors
in, or omissions from, the
informationgiven.
SpecialNotations
Within this manual,
procedures or situations that
require special attention are
indicated with the words,
DANGER,WARNING,
CAUTION and IMPORTANT.
DANGER,WARNINGand
CAUTIONareusedtoindicate
proceduresorsituations where
personalsafetyisinvolved.
IMPORTANT is used to
indicatespecialproceduresor
situations which, if not
observed, could result in
damage to the equipment or
affect the operation of the
machine.
0-40-4
0-40-4
0-4

Authorized Dealer Parts
Department
Anauthorized dealer parts
department is the best source
forparts,particularlypartswhich
areuniquetothisequipment. If
you do not know who the
authorizeddealerisinyourarea
contact Kolberg-Pioneer.
Dealerships are located
throughout the United States
andsomepartsof theworld.
Buying Replacement Parts
Purchased Components
Replacement parts for
components purchased by
Kolberg-Pioneersuchas gear
reducers, electric motors and
engines are available through
your authorized dealer.
However, items like engine
parts are typically not stocked
by the dealer or Kolberg-
Pioneer.
Serial Number
Since replacement parts
manualsandlistsarecompiled
specifically for each unit, the
serialnumbersareessentialto
correctlyidentifythecomponent
required.
Typical Tail Pulley Assembly Parts Page
Typical Motor Drive Assembly Parts Page
0-50-5
0-50-5
0-5

1-11-1
1-11-1
1-1
Problem Symptom Solution
Engine shuts down. 1. Enginenotgettingenough
fuel.
1. Checkthe fuelseparator.
2. Follow instructions in
enginemanual forpriming.
Problem Symptom Solution
Plant will not start or shuts
down unexpectedly. 1. Fuses in engine fuse holderdisconnected. 1. Check andreconnect fuse.
Problem Symptom Solution
Machine does not operate
at satisfactory speed
1. Engine not operating
properly. 1. Referto enginemanual.
2. Lowhydraulicfluid level. 2. Fillhydraulicoiltank.
3. Hydraulic system filter
partiallyplugged. 3. Clean orreplace filter.
4. Hydraulic pump worn
excessively.
5. Reliefvalve wornor stuck. 5. Repairor replacevalve.
Engine
4. Repairor replace pump.

PROBLEM: Enginewill notstartand unitmust
bemoved.
SOLUTION: Disengage the track brake.
Tools Needed
•22mmHexWrench
•1 - M6 x 1mm x 30mm bolt
Usethefollowingproceduretodisengagethe
trackbrakes.
1. Lockout/tagoutallpowertothe unit.
NOTICE
This procedure must be preformed on level
ground.
2. Placeblocking toprevent trackmovement.
3. Use the 22mm hex wrench to remove the
trackhub coverand gasket.
Blocktracks
Track hub cover
4. InstalltheM6x1mmx30mmboltintothesun
gear.
Track Hub Cover and Gasket
5. Use the installed M6 x 1mm x 30mm bolt to
pullthesungearfrom thetrackhub.
In some cases, a piece of wood and pry bar
maybe needed towork thesun gear free.
M6 x 1mm x 30mm bolt
M6 x 1mm x 30mm Bolt
Removing Sun Gear
Sun gear
Engine 1-21-2
1-21-2
1-2

6. Reinstallthegasket andtrack hubcover.
7. Repeatsteps 3-5 ontheother side.
Whenbothtrackbrakeshavebeendisengaged,
theFTunitcanbefreelytowedineitherdirection.
Gasket
Gasket
Track hub cover
Track Hub Cover
Track Brake Re-engagement
Usethefollowingproceduretore-engagethe
trackbrake.
1. Makesurethatallpowerislockedout/tagged
out.
2. Placeblocking toprevent trackmovement.
Blocktracks
NOTICE
Do not start engine or engage hydraulics
with sun gear removed as this will cause
misalignment of brake discs. Misalignment
will make re-installation of sun gear difficult.
3. Use the 22mm hex wrench to remove the
trackhub coverand gasket.
Track hub cover
Track Hub Cover and Gasket
Engine
1-31-3
1-31-3
1-3
7. Repeatsteps 3-5 ontheother side.
Whenbothtrackbrakeshavebeendisengaged,
the Fast Trax unit can be freely towed in either
direction.

5. Removethe M6x 1mmx30 mmbolt.
6. Reinstallthe gasket.
Sun gear
Sun Gear
7. Reinstallthetrackhub cover.
Gasket
Gasket
8. Use 22mm hex wrench to tighten the track
hubcover.
Track hub cover
Track Hub Cover
9. Repeat procedure for opposite side.
10.Removeblocking.
4. Insertthe sungear(with M6x 1mmx 30mm
boltstill attached)back intothe trackhub.
Themachinemayneedtoberemovedslightly
torealign gear.
Keep hands clear when re-aligning gears.
CAUTION
Engine 1-41-4
1-41-4
1-4

2-12-1
2-12-1
2-1
Problem Symptom Solution
Material sticking to return
idlers. 1. Idlernotturning.
1. Cleanidlers.
2. Adjustor replace idlers.
3. Adjustdust suppression.
Problem Symptom Solution
Grooves or cuts appearing
in surface of belt.
1. Rock wedged between
hopperflashing andbelt. 1. Loosenflashingandclean.
2. Beltovertensioned. 2. Releasetension
Tension here
For further troubleshooting information on the belt scraper, refer to the Martin QC belt
cleaner operation's manual
Problem Symptom Solution
Material build up on belt. 1. Notenoughscrapertension. 1. Increasetension.
2. Adjustdust suppression.
Problem Symptom Solution
Material leakage at hopper. 1. Rubberflashingwornor
spacebetween thebelt
andflashing.
1. Adjustflashing.
2. Replaceflashing.
Conveyor

Conveyor
Problem Symptom Solution
Conveyor belt
slips on driving pulley
1. Notenoughbelt tension. 1. Increase tension by
adjustingscrew.
2. Lagging worn on drive
pulley. 2. Installnewpulley.
3. Belttoo long. 3. Shortenbelt.
Problem Symptom Solution
Conveyor belt
leaves pulley.
1. Pulleyshaft outofline. 1. Realign shaft.
2. Dirtbuilt upon pulley. 2. Cleanpulley.
3. Pulleybadlyworn. 3. Replace pulley.
Problem Symptom Solution
Conveyor belt running to one
side
1. Splice notcut square. 1. Recutand splicebelt.
2. One or more idlers out of
alignment. 2. Realignidlers.
3. Belttensionuneven. 3. Equalizetension.
4. Rolleronidler notturning. 4. Replaceidler.
5. Beltfastenerspullingoutof
one side of the splice. 5. Recutand splicebelt.
2-22-2
2-22-2
2-2

Conveyor
2-32-3
2-32-3
2-3
Problem Symptom Solution
Conveyor bearings
overheating
1. Bearingmisaligned. 1. Realign bearing.
2. Bearingsworn out. 2. Replacebearings.
3. Excessbearing load. 3. Reducebelttension.
4. Bearingloose onshaft. 4. Tightenbearing.
Problem Symptom Solution
Bearings leak
grease excessively
1. Wronglubricant. 1. Changelubricant.
2. Bearingworn out. 2. Replacebearing.
3. Sealworn. 3. Replaceseal.

Problem Symptom Solution
Crusher speed varies 1. V-beltsslipping. 1. Check v-belts. Replace if
needed.
2. Voltagevaries 2. Check powersource.
Problem Symptom Solution
Excessive vibration
1. Toggle plate movement
(lateral). 1. Repair or replace toggle seatsor toggle plate.
2. Crusherspeed incorrect. 2. Check speed. Make sure
is set to 1700 rpm max.
3. Closed side setting
under recommended
range.
3. Check and adjust as
needed.
Problem Symptom Solution
Crusher stops or will not start 1. V-belts slipping. 1. Checkv-belts
2. Feed material plugged in
crushingchamber 2. Clearmaterial.
Jaw Crusher
3-13-1
3-13-1
3-1

Jaw Crusher
3-23-2
3-23-2
3-2
Problem Symptom Solution
Knocking noise when jaw
crusher in operation
1. Not enough rod spring
tension. 1. Increasespringtension.
2. Not enough clearance
betweenjaws. 2. Increaseclearanceso jaws
donottouch.
3. Toggle seats not seated
properly. 3. Check toggle seats and
adjust.
4. Loose bolts, jaws, side
liners. 4. Adjustandtighten.
5. Crushing too high in
chamber. 5. Adjust.
Problem Symptom Solution
High bearing temperature in
excess of 180OF (82OC)
1. Under lubrication/over
lubrication 1. Lubricatebearings
according to specifications
inmanual.
2. Incorrectgrease. 2. Use correct grease as
specifiedin manual.
3. Speed (RPM) toohigh 3. Check speed andadjust.

Problem Symptom Solution
Cracked side plates 1. Feederhittingotherobjects. 1. Remove obstructions and
make repairs as needed.
2. Plantnotlevel.
2. Check plant level using
levelindicators onthe side
and back of the plant.
Adjustas needed.
Check for sagging or
brokensprings, replaceas
needed.
Problem Symptom Solution
High bearing temperature in
excess of 180OF (82OC)
1. Under lubrication/over
lubrication 1. Lubricate bearings accordingto specifications
inmanual.
2. Incorrectgrease. 2. Use correct grease as
specifiedin manual.
3. Speed (RPM)too high 3. Check speedand adjust.
Problem Symptom Solution
Feeder surface has uneven
wear or material flows to one
side.
1. Material feed not properly
distributed.
2. Material buildup on feeder
pan. 2. Removebuildup.
1. Adjust feed method to
distributematerialevenly.
3. Springs brokenor
sagging. 3. Replace as needed.
4. Plantnotlevel. 4. Check level of plant using
levelindicators.
Vibrating Feeder
4-14-1
4-14-1
4-1

Vibrating Feeder
4-24-2
4-24-2
4-2
Problem Symptom Solution
Support spring breakage
1. Plantnotlevel. 1. Replace springs. Make
sureplantislevelusinglevel
indicators.
2. Excessiveloading. 2. Reduce feedrate.
3. Materialbuildup onfeeder
pangrizzlysection. 3. Removebuildup.
Problem Symptom Solution
1. Crushernotrunning 1. Turncrusheron.
Feeder will not start
Problem Symptom Solution
1. Feederhittingotherobjects. 1. Remove obstrucctions and
make any necessary
repairs
“Unusual” noises
Problem Symptom Solution
1. Incorrectspeed. 1. Check and adjust as
required.
Poor efficiency
Problem Symptom Solution
1. Rotation of eccentric shaft
incorrect. 1. Correctrotation.
Oil discharge from breather.
2. Grizzlybarsloose. 2. Tightenas needed.
3. Bearingswornordamaged. 3. Check bearings for wear.
Repair or replace.
2. Material feed not properly
distributed. 2. Adjust feed method to distributematerialevenly.
3. Incorrecttiming. 3. Adjustasrequired.
2. Oilreservoir filledtoo high. 2. Fillorempty oil.

SYMPTOM: Open loop system
- Undercrusherconveyor
- Sidedelivery conveyor
- 20 Gpm stacker
PROBLEM: None of the pumps operate on
theopen loopsystem.
SOLUTION:
2. Check and record all belt speeds and
pressureswhenrunningempty.
3. Check relief pressure. For the
undercrusher conveyor you must
disconnectthe quickcoupler.
4. Install flow meter to check flow if circuit is
runningslow.
5. If unable to build pressure, try adjusting the
relief setting by moving the adjustment
screwuntil desiredlevel isreached.
6. If there is proper flow and pressure, check
the flow coming from motor case drain. If it
is more than 25% of circuit flow then
replacemotor.
1. Checkdiagnostic screenforany problems.
F1 F2 F3 F4 F5 F6
Hydraulic System Monitoring Screen
F1 F2 F3 F4 F5 F6
Hydraulic Data Log Screen
Hydraulic
5-15-1
5-15-1
5-1

5-25-2
5-25-2
5-2 Hydraulic
Problem Symptom Solution
Pumps on the closed
loop system do not have
charge pressure
Closed Loop System
Crusher
Vibrating Feeder
Tracks
1. Checkchargepressureofcircuitwhich
isnot operating.
a. If less than 250 PSI (18Kg/cm),
changefilter.
b. Install flow meter on case drain
line of motor. If it is more than
25% of charge pump output flow
thenchangemotor.
c. Install flow meter on case drain
of pump. If it is less than 75%
of pump output then change
pump.
2. Checkflywheelcoupling.

Hydraulic
Problem Symptom Solution
Pumps have charge
pressure but are not
operating properly
Closed Loop System
Crusher
Vibrating Feeder
Tracks
1. Use manual override to activate
pump.
a. For the crusher and vibrating
feeder, the manual override is a
smalllever onthe EDCpump.
b. For the tracks, the manual
override is the center pin on the
FNRvalveor pump.
Ifthis failstobuild pressurethen change
pump.
2. Ifyouhavepressurebutsystemisnot
activatedthenusevoltmeter tocheck
milliamps on EDC or DC volts or
FNR.
a. If voltage is present on FNR
(tracks only), remove coil and
check magnetic pull of coil using
ascrewdriver. Ifnot workingthen
replacethe coil.
b. If milliamps are present on the
EDC but the pump is not
respondingthenchange theEDC
onpump.
5-35-3
5-35-3
5-3