ASTEC KPI-JCI User manual

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

Copyright KPI-JCI
2014
CALIFORNIA
Proposition 65 Warning
DieselengineexhaustandsomeofitsconstituentsareknowntothestateofCaliforniatocausecancer, birth defects,
an other reproductive harm.
Record your vertical shaft impactor serial number and order number in the space below.
Please include these numbers when requesting service or ordering replacement parts.
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A.
Serial Number Plate
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A.

Vertical Shaft Impactor
OPERATION &
MAINTENANCE MANUAL
Models Covered:
1500 82
2500 120
4500

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
from KPI-JCI.
Thismanualcontainsoperatinginstructionsandlubrication-
maintenance information. Application of this information
shouldmaximizetheperformanceandlifeofyourequipment
and minimize down time.
Safe and efcient operation requires that anyone who
will be operating or maintaining this equipment read
and understand the safety, operation, maintenance and
troubleshooting information contained in the operator’s
manual.
Continuing improvement and advancement of KPI-JCI
products may cause changes to your equipment which
may not be reected in this publication.
KPI-JCI reserves the right to make changes or add
improvementstoitsproductsatanytime,withoutincurring
any obligation to make such changes on previously
manufactured equipment.
Although care has been taken to assure the accuracy of
this publication, KPI-JCI does not assume any liability for
loss, damage or injury caused by errors or omissions.

Contents
Introductory Pages About This Manual 7
Serial Number Plates 8
Buying Replacement Parts 9
Maintenance Techniques and Tools 10
Lubricants and Fluids 11
Storage 12
Introduction to the Vertical
Shaft Impactor Chapter 1 13
Safety Chapter 2 23
Specications Chapter3 34
Application Chapter 4 39
Site Selection and Set-up Chapter 5 45
Preoperation/Operation
Checklist Chapter 6 46
Operation Chapter 7 48
Startup Chapter 8 53
LubePanel(3rdGen.) Chapter9  59
Adjustments Chapter 10
Cluster Ring 67
Skirt Ring 69
Feed Tube 70
Temperature Switch 71
Flow Switch 72
Wear Parts Chapter 11
Tub Liner Replacement/Anvil
Replacement - Rock Shelf 74
Anvil Replacement - Cluster Ring 75
Feed Tube 76
Lid Liners 77
Feed Disc 78
Skirt Ring/Pedestal Skirt Cone 79
Wear Parts - Table Assembly 80
Wear Parts - RotorAssemby 86
Maintenance Chapter 12 91
Lubrication Chapter13  101
Hydraulic Maintenance Chapter 14 107
Troubleshooting Chapter 15 108
Belt Tension Instructions Appendix A
Prevailing Torque Locknut Appendix B

Vertical Shaft Impactor
7
Purpose
The purpose of this manual is
to help you get the best value
from your equipment. It can
do so by helping you decide
what work must be done,
even if you decide to have it
done by a dealer service de-
partment or a repair shop. It
also provides information and
procedures for routine main-
tenance and servicing.
About This Manual
Using the Manual
Procedures, once described
in the text, are not normally
repeated. Whenitisnecessary
toreferto another chapter,the
referencewillbegivenaspage
number.
Even though this manual has
been prepared with extreme
care, KPI-JCI can not accept
responsibility for errors in, or
omissionsfromtheinformation
given.
Special Notations
Withinthismanualprocedures
orsituationsthatrequirespecial
attentionareindicatedwiththe
words, DANGER,WARNING,
CAUTIONandIMPORTANT.
DANGER, WARNING and
CAUTIONareusedtoindicate
proceduresorsituations where
personal safety is involved.
IMPORTANT is used to
indicate special procedures
or situations which, if not
observed, could result in
damage to the equipment
or affect the operation of the
machine.

Vertical Shaft Impactor
8
Serial Number Plates
Modications are a continuing
processinthemanufactureofthis
equipment. Since replacement
parts, manuals, and lists are
compiled specically for each
unit, the serial numbers are
essentialtocorrectlyidentifythe
component required.
Theserialnumberplatewillshow
the serial number, job order
number and model number.
Vertical Shaft Impactor
Serial Number
The serial number for the
vertical shaft impactor is
stamped on a plate which is
located at the bottom of the
vertical shaft impactor near
the lubrication panel and/or
the hydra-arm
The plant serial number is the
numberthatshouldbereferred
to when ordering parts or
requesting service.
Vertical Shaft Impactor Serial Number Plate Location
Serial Number Plate

Vertical Shaft Impactor
9
Authorized Dealer Parts
Department
An authorized dealer parts
department is the best source
for parts, particularly parts
which are unique to this
equipment. Ifyoudonotknow
who the authorized dealer
is in your area contact KPI-
JCI. Dealerships are located
throughout the United States
and some parts of the world.
Buying Replacement Parts
Purchased Components
Replacement parts for
components purchased by
KPI-JCIsuchasgearreducers,
electric motors and engines
are available through your
authorized dealer. However,
items like engine parts are
typically not stocked by the
dealer or KPI-JCI.
Serial Number
Since replacement parts
manualsandlistsarecompiled
specically for each unit, the
serialnumbersareessentialto
correctlyidentifythecomponent
required.

Vertical Shaft Impactor
10
Maintenance Techniques and Tools
Tools
Although a minimal number of
toolsare needed for operation
and maintenance, a good
selection of basic tools is
required.
The following is a list of
recommended tools for
servicing and maintaining the
vertical shaft impactor.
• Tool box
• 3/4” drive socket set
(socket to 2”) with ratchet
and extension and
breaker bar (up to M50)
• 1/2” drive socket set
• Box end open wrench set
3/8” to 1” (M10-M24)
• Allen wrench set 1/8” to
1” (M3-M24)
• Punch and chisel set
• 3 pound sledge
• Pry bar set (dog leg)
• Line bar set
• 1 set of Phillips
screwdrivers
• 1 set of standard
screwdrivers
• 2 - 8” Vise grip curved
• 18” pipe wrench
• 18” crescent wrench
opening to 1-3/4”
• Scraper
• Spanner wrench (p/n
257017)
Theseitemscanbepurchased
from KPI-JCI as a kit.
Order part number 289470
for the vertical shaft impactor
tool kit.
Order part number 363742
for the vertical shaft impactor
metric tool kit.
Waste Oil and Fluids
Waste oil and uids drained
from the engine and hydraulic
system during normal
maintenance and repair can
present a disposal problem.
To avoid pouring them on the
ground or into the sewage
system, pour the used uids
intolargecontainers,sealthem
andtakethemtoanauthorized
disposal or recycling center.
Fasteners
All threaded fasteners should
be clean and straight, with
undamaged threads and
undamaged corners on the
hex heads.
It is a good habit to replace
all damaged fasteners when
performingmaintenance,never
reuse a damaged fastener.
Special locknuts with nylon
insertscanonlybeusedonce.
If they are removed, they lose
their locking ability and must
be replaced.
Rusted nuts and bolts should
be treated with a penetrating
fluid to ease removal and
prevent breakage. Badly
rusted fasteners may have to
bechiseled, sawed or torched
off.
Flatwashersandlockwashers,
when removed from an
assembly, should always be
replaced exactly as removed.
Whenreplacingnutsandbolts,
be sure to use the correct
grade. Never use a different
grade of bolt than the original
equipment.
Any nuts and bolts that are
torquedcanonlybeusedonce.
If they are removed, replace
them with new nuts and bolts.

Vertical Shaft Impactor
11
Lubricants and Fluids
Factory Fill Lubricants
The lubricants listed below in bold type are
factory ll lubricants. Other lubricants may
be used, provided they meet the lubrication
requirements specied.
Cold weather lubricants are listed after the
factory ll, see Cold Weather Startup for
more information.
Bearings and Hydra-Arm
• PhilubeHighTempEP2
Hydra-Arm
• Hydrex MV60
• Hydrex MV22
For extremely cold temperatures -58 degrees
F and below (-50 degrees C), Hydrex MV 22 is
recommended. WhenusinganISO32hydraulic
oil with a viscosity index less than 100, the
temperature limit is 10 degree F above zero.
Oil Circulating System
• Mobilgear 600 XP 68

Vertical Shaft Impactor
12
When the machine will not
be used for a period of a few
months, use the following
procedure for storage to
minimize corrosion and
deterioration.
GeneralStorageGuidelines
• Remove all dirt and debris
fromallareasinandaround
the machine.
• Lubricate all points as
specified in the
maintenance and
lubrication section of this
manual.
• Bearings must be rotated
and lubricated every 30
days (they are in storage)
topreventthemfromdrying
out.
• Loosenandremovev-belts
to prevent them from
stretching.
• Clean the outside of the
machine and repaint any
areas where needed.
• Attach a tag to the plant
indicating what storage
procedures have been
done.
Electric Motor Storage
Guidelines
Thefollowingguidelinesshould
befollowedwhenstoringequip-
ment with an electric motor.
• Loosenandremovev-belts
from the electric motor to
reduce the load on the
bearing.
• Fillthebearingcavitieswith
grease to prevent
condensation.
• Rotate and lubricate the
bearing every 30 days it is
in storage to prevent them
from drying out.
• Ifstoringforlongerthansix
months, follow the
ExtendedPeriodStorage
in the next column for
bearings.
If the equipment will be stored
for periods longer than two
years, the bearing will need
to be removed, cleaned, and
regreased; or it should be
replaced.
ExtendedPeriodStorage
(6 months or more)
Ifthemachinewillbestoredfor
aperiodofsixmonthsormore
follow the guidelines below.
These guidelines should
be completed once every
three months to lubricate
the bearings and/or to purge
condensation and to prevent
the bearings from drying out.
• Lubricate bearings
• Rotate the shaft two
revolutions.
• Replace breather cap.
Storage
• To help prevent corrosion,
thefuelandhydraulictanks
should be lled to their
proper level.

Vertical Shaft Impactor 13
Orientation is determined by
standing at the opening of the
VerticalShaftImpactorlooking
in the direction of material ow.
Introduction to the Vertical Shaft
Impactor The feed end of the Vertical
Shaft Impactor receives the
materialtobecrushedandthe
discharge end discharges the
crushed material.
References to the right hand
and/orlefthandsidewillbeas
shown below.
Material ow
Counterclockwise rotation

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 14
Tub
The tub includes the impact
ring and tub liners. The tub
supports the lid assembly,
impact ring and contains the
crushing action.
Tub
Base
The base supports the tub
andthelidassembly,provides
anchoring for the pedestal
assembly and motor and
provides the discharge area
for the crushed material.
The following is a brief
description of the Vertical
Shaft Impactor’s basic parts
and their function.

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 15
Lid Assembly
Thelidassemblyconsistsofthe
feed box, feed tubes, lid liners
and inspection doors. The lid
contains the crushing action
andprovidesafeedentrypoint.
For access to the complete
crushing chamber, the entire
lidmaybeliftedafterremoving
the hold-down wedges. On
modelsequippedwithaHydra-
Arm, the lid can be raised and
rotated hydraulically. The lid
is equipped with bolt-in alloy
liners.
Feed Box
The feed box collects feed
material and directs it down
the feed tube. The feed box
is designed with a rock shelf
to provide rock on rock wear
protection.
Feed Tube
Thefeedtubeplaysavitalrole
in the overall performance of
the crusher. The feed tube
directs the feed material
directly into the crushing
chamber. It is important that
proper height adjustment
between the feed tube and
accelerator is maintained for
efcient production.
The feed tubes are reversible
and replaceable for abrasion
resistance and ease of
maintenance.
Lid Assembly
Inspection doors
Feed box
Feed Box and Tube
Feed tube
Feed tube Feed box

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 16
Lid Liners
The lid liners are arranged in
a circular pattern in order to
cover the entire underside of
the lid from wear. The inner
liners and outer lid liners bolt
to the lid with hex head bolts.
Inspection Doors
The lid is equipped with large
inspection doors to facilitate
easy internal inspection and
allows for certain table wear
parts replacement or to check
the feed tube measurement.
If access cannot be gained
through the inspection doors,
theHydra-Arm can beusedto
lift and rotate the lid to open
the crushing chamber.
Hydra-Arm
The optional hydra-arm lifts
the lid for a full 360 degree
access for safe and efcient
maintenance procedures.
Hydra-arm
Hydra-Arm
Lid Liners

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 17
Impact Ring
The impact ring assembly
includestheanvils and may or
may not include a rock shelf.
Anvils
The stationary anvils are
arranged in a circular pattern
and provide the main striking
surface for the material
propelled from the table
assembly.
Thefeedmaterialisaccelerated
bytherevolving impeller table.
Crushing takes place when
the feed material impacts
the anvils. The geometry
of the anvils provide a right
angleimpact. Each crusher is
supplied with anvils designed
for optimum performance and
metal utilization. The anvils
are made of high chrome
alloy.
Theimpactringassemblyrests
on a multiple step-retaining
bracket that can also be used
for vertical adjustment.
Rock Shelf
The rock shelf supports
fractured material from the
anvils. This material acts as
Cluster Ring
a cushion to protect the upper
tub area from wear. It also
provides autogenuous (rock-
on-rock) fracturing.
Rock Shelf
Retaining Bracket

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 18
Rotor/Table Assembly
There are two options for
an accelerator on a vertical
shaft impactor: rotor or table
conguration. The accelerator
rotates counterclockwise (as
viewed looking down on the
accelerator) and is bolted to
the ywheel that is keyed and
secured to the pedestal shaft
with a locknut.
A rotor conguration of three or
fourmaterial ports is available
depending on model. 1500
and 2500 model vertical
shaft impactors are equipped
with a three port rotor and
4500 models are equipped
with a four port rotor. A rotor
conguration is not available
on 82 and 120 models.
Table conguration of three,
four, or ve shoes is available.
The impeller shoes are a cast
chrome iron alloy material
and must be replaced prior to
wearing through to the steel
supportbrackets. Theimpeller
shoes are held secured to the
table assembly with two bolts
or a shoe pin.
Each conguration consists of
a center feed disc, at liners
and outer liners.
Rotor Assembly
Table Assembly

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 19
Feed Disc
As the material drops through
the feed tube, it lands on the
rotatingfeeddisclocatedatthe
center of the accelerator. The
feed disc distributes the feed
material and also provides
wear protection for the table
or rotor and shaft assembly.
The feed disc affects:
• Distribution of material
across the shoe face.
• Trajectoryofmaterialtothe
anvils.
• Rate of wear of top table
liners.
• Overall crusher
performance.
FeedDisc-TableConguration
FeedDisc-RotorConguration
Feed disc
Feed disc

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 20
The stationary skirt ring sits
below the accelerator and
protects the flywheel and
pedestal. Theskirtringislined
with cast alloy skirt liners held
in place by hex head bolts (2
per liner).
Skirt Ring Assembly
Skirt Ring
Pedestal
The pedestal assembly
consistsoftheshaft,bearings,
housing and seals. The shaft
is keyed to the ywheel which
is bolted to the accelerator.
The driven speed of the
pedestal shaft determines
the speed of the accelerator.
An independent lubrication
system with external pumps,
filtering and alarm system
insures proper bearing
lubrication.

Introduction to the Vertical Shaft Impactor
Vertical Shaft Impactor 21
Lubrication Panel
There are two options for the
lubrication panel.
The first option includes
a temperature and flow
monitoring system with an
alarm. The pedestal and
gearbox assemblies have
independent lubrication
pumps, oil reservoirs and
monitoring panels.
The grease fitting for the
pedestal(orgearbox)islocated
on the lubrication panel.
Grease is used to purge the
pedestal (or gearbox) seals.
The second lubrication panel
option uses sensors in place
of the temperature and ow
monitoring system as well
as a tank sensor to monitor
lubricationfunctionsoftheVSI.
LubricationPanel-Gen.2Shown
Pedestal Skirt Cone
The pedestal skirt cone is
located behind the skirt ring
assembly and protects the
pedestal and related parts.
The conical shaped guard is
made of an abrasion resistant
polyurethane compound.
Pedestal Skirt Cone