ASTEC KDS 710 User manual

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Astec Mobile Screens Foreword c KDS 710
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FOREWORD

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Astec Mobile Screens Foreword e KDS 710
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Foreword
Introduction
This manual contains safety, setup, operation,
and maintenance sections. This manual should
be stored in the manual container located
beneath the main control panel of the unit.
Keep this manual with the unit at all times. The
manual should remain with the unit to assist
in training, operation, setup and maintenance
procedures.
Please keep in mind that parts and procedures
in this manual may differ from your exact
model. The data used to create this manual
are based on the latest information at the time
of publication. Due to Astec Mobile Screens
policy of continuous improvement, features and
specications are subject to change without
notice. All engineering drawings provided in this
manual are model specic. Refer to engineering
drawings as needed, they are the best source of
model specic information.
Safety
The safety section of this manual is lled
with procedures that should be followed at all
times. Take the time to read the safety section
of the manual and obey all safety information
presented on the unit. Safety is important!
Operation
Do not attempt to operate this machine without
fully reading the manual rst. The operation
section of the manual is arranged in a manner
that must be followed sequentially. If the
description does not match your unit, or there
is a discrepancy in the data, contact your local
Astec Mobile Screens Dealer for assistance.
Maintenance
Due to the nature of equipment and
environmental variables that may be present,
it is imperative to do a daily review of your
equipment. Pay close attention to the daily
checks outlined in the Maintenance section
of this manual. Failure to follow maintenance
guidelines could result in premature wear, or
damage to your equipment.
Appendix
For more detailed information regarding the on
board John Deere Engine, Refer to the complete
John Deere Engine Manual which should be
used as a denitive guide to the safe and
efcient operation of your engine. Also included
in Appendix are the complete manuals for the
belt cleaners, remote control, and tracks.
Phone.......... [phone]
Phone.......... [phone]
Fax.............. [phone]
E-mail
Parts............ [email protected]
Sales........... [email protected]
Contact Astec Mobile Screens
Astec Mobile Screens, Inc.
2704 West LeFevre Road
Sterling, IL 61081

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Astec Mobile Screens Foreword f KDS 710

Astec Mobile Screens Foreword g KDS 710
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Contents
Safety 1
Setup 13
Maintenance 25
Parts 39
Belt Cleaner B1
Warranty C1

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Astec Mobile Screens Safety 1 KDS 710
Safety

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Astec Mobile Screens Safety 2 KDS 710
TRAINING
Safety instructions are important! Read all attachment and power unit manuals; follow all
safety rules and safety decal information. Replacement manuals and safety decals are available from
your dealer. Failure to follow instructions or safety rules can result in serious injury or death. If you do
not understand any part of this manual and need assistance, see your dealer.
Know your controls and how to stop engine and attachment quickly in an emergency.
Operators must be instructed in and be capable of the safe operation of the equipment, its attach-
ments, and all controls.
Do not allow anyone to operate this equipment without proper instructions.
Keep hands and body away from pressurized lines. Use paper or cardboard, not hands or other body
parts to check for leaks. Wear safety goggles. Hydraulic uid under pressure can easily penetrate
skin and will cause serious injury or death.
Make sure that all operating and service personnel know that if hydraulic uid penetrates skin, it must
be surgically removed as soon as possible by a doctor familiar with this form of injury or gangrene,
serious injury, or death will result. CONTACT A PHYSICIAN IMMEDIATELY IF FLUID ENTERS SKIN
OR EYES. DO NOT DELAY.
UNDERSTAND SIGNAL WORDS
A signal word DANGER, WARNING OR CAUTION is used with the safety alert symbol. DANGER
identies the most serious hazards.
DANGER or WARNING safety signs are located near specic hazards. General precautions are
listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
This is a safety alert symbol. When you see this symbol on your machine or in this
manual, be alert to the potential for personal injury. Follow recommended precautions
and safe operating practices.
Indicates an immediately hazardous situation which, if not
avoided, will result in death or serious injury. Danger is
limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. Caution
may also be used to alert against unsafe practices.
IMPORTANT: Indicates that failure to observe can cause damage to equipment.
NOTE: Indicates helpful information.

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Lockout/Tagout
What is the OSHA standard for control of hazardous energy sources?
The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal
Regulations (CFR) Part 1910.147, addresses the practices and procedures necessary to disable ma-
chinery or equipment, thereby preventing the release of hazardous energy while employees perform
servicing and maintenance activities. The standard outlines measures for controlling hazardous ener-
gies—electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources.
In addition, 29 CFR 1910.333 sets forth requirements to protect employees working on electric cir-
cuits and equipment. This section requires workers to use safe work practices, including lockout and
tagging procedures. These provisions apply when employees are exposed to electrical hazards while
working on, near, or with conductors or systems that use electric energy.
Why is controlling hazardous energy sources important?
Employees servicing or maintaining machines or equipment may be exposed to serious physical
harm or death if hazardous energy is not properly controlled. Craft workers, machine operators, and
laborers are among the 3 million workers who service equipment and face the greatest risk. Compli-
ance with the lockout/tagout standard prevents an estimated 120 fatalities and 50,000 injuries each
year. Workers injured on the job from exposure to hazardous energy lose an average of 24 workdays
for recuperation.
How can you protect workers?
The lockout/tagout standard establishes the employer’s responsibility to protect employees from haz-
ardous energy sources on machines and equipment during service and maintenance. The standard
gives each employer the exibility to develop an energy control program suited to the needs of the
particular workplace and the types of machines and equipment being maintained or serviced. This is
generally done by afxing the appropriate lockout or tagout devices to energy-isolating devices and
by de-energizing machines and equipment. The standard outlines the steps required to do this.
What do employees need to know?
Employees need to be trained to ensure that they know, understand, and follow the applicable pro-
visions of the hazardous energy control procedures. The training must cover at least three areas:
aspects of the employer’s energy control program; elements of the energy control procedure relevant
to the employee’s duties or assignment; and the various requirements of the OSHA standards related
to lockout/tagout.
What must employers do to protect employees?
The standards establish requirements that employers must follow when employees are exposed to
hazardous energy while servicing and maintaining equipment and machinery. Some of the most criti-
cal requirements from these standards are outlined below:
Develop, implement, and enforce an energy control program.
Use lockout devices for equipment that can be locked out. Tagout devices may be used in lieu of
lockout devices only if the tagout program provides employee protection equivalent to that pro-
vided through a lockout program.
Ensure that new or overhauled equipment is capable of being locked out.
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Develop, implement, and enforce an effective tagout program if machines or equipment are not
capable of being locked out.
Develop, document, implement, and enforce energy control procedures. [See the note to 29 CFR
1910.147(c)(4)(i) for an exception to the documentation requirements.] Use only lockout/tagout
devices authorized for the particular equipment or machinery and ensure that they are durable,
standardized, and substantial.
Ensure that lockout/tagout devices identify the individual users.
Establish a policy that permits only the employee who applied a lockout/tagout device to remove
it. [See 29 CFR 1910.147(e)(3) for exception.]
Inspect energy control procedures at least annually.
Provide effective training as mandated for all employees covered by the standard.
Comply with the additional energy control provisions in OSHA standards when machines or equip-
ment must be tested or repositioned, when outside contractors work at the site, in group lockout
situations, and during shift or personnel changes.
How can you get more information?
OSHA has various publications, standards, technical assistance, and compliance tools to help you,
and offers extensive assistance through its many safety and health programs: workplace consultation,
voluntary protection programs, grants, strategic partnerships, state plans, training, and education.
Guidance such as OSHA’s Safety and Health Management Program Guidelines identify elements
that are critical to the development of a successful safety and health management system. This and
other information are available on OSHA’s website at www.osha.gov.
For a free copy of OSHA publications, send a self-addressed mailing label to this address:
OSHA Publications Ofce
P.O. Box 37535
Washington, DC 20013-7535
Or send a request to our fax at [phone], or call us at [phone]. To le a complaint by
phone, report an emergency, or get OSHA advice, assistance, or products, contact your nearest
OSHA ofce under the “U.S. Department of Labor” listing in your phone book, or call us toll-free at
(800)-321-OSHA
(6742). The teletypewriter (TTY) number is [phone]
To le a complaint online or obtain more information on OSHA federal and state programs, visit
OSHA’s web site. www.osha.gov
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Astec Mobile Screens Safety 5 KDS 710
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and on your machine safety
signs. Keep safety signs in good condition. Replace missing or damaged safety
signs. Be sure new equipment components and repair parts include the current
safety signs. Replacement safety signs are available from your Astec Mobile
Screens Dealer.
Learn how to operate the machine and how to use controls properly. Do not let
anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modications to
the machine may impair the function and/or safety, affect machine life and/or void
the warranty.
If you do not understand any part of this manual and need assistance, contact
your Astec Mobile Screens Dealer.
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs. See Appendix A for a detailed descrip-
tion of safety label placement. Contact your Astec Mobile Screens Dealer for
replacement safety decals.
PREVENT BYPASS STARTING
Avoid possible injury or death from engine run away. Do not start engine by
shorting across starter terminal. Start engine only from operator’s station.
HANDLE FUEL SAFELY – AVOID FIRES!
Handle fuel with care: it is highly ammable. Do not refuel the machine while
smoking or when near open ame or sparks.
Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent
res by keeping machine clean of accumulated trash, grease, and debris. Always
clean up spilled fuel.
Read this manual before operating your equipment. The information presented will prepare
you to do a better and safer job. Keep this manual handy for ready reference. Require all
operators to read this manual carefully and become acquainted with all adjustment and
operating procedures before attempting to operate. Replacement manuals can be obtained
from your dealer.

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PREPARE FOR EMERGENCIES
Be prepared if a re starts. Keep a rst aid kit and re extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and re depart-
ment near your telephone.
SERVICE ENGINES SAFELY
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or
necklace when you work near machine tools or moving parts. If these items were to
get caught, severe injury or death could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in
moving parts.
HANDLE STARTING FLUID SAFELY
Starting uid is highly ammable. When handling starting uid, keep all sparks and
ame away. Keep starting uid away from batteries and cables. To prevent acci-
dental discharge when storing the pressurized can, keep the cap on the container,
and store in a cool, protected location. Do not incinerate or puncture a starting uid
container.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect
against objectionable or uncomfortable, loud noises.
WEAR PROTECTIVE CLOTHING
Wear close tting clothing and safety equipment appropriate to the job. Operating
equipment safely requires the FULL ATTENTION of the operator. Do not wear radio
or music headphones while operating machine.
INSTALL FAN GUARDS
Rotating cooling system fans can cause serious injury.
Keep fan guards in place at all times during engine operation. Wear close tting
clothes. Stop the engine and be sure fan is stopped before making adjustments or
connections, or cleaning near the front of the engine.

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HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause serious injury. Potentially
hazardous chemicals used with Astec Mobile Screens equipment include such
items as lubricants, coolants, paints, and adhesives. A Material Safety Data
Sheet (MSDS) provides specic details on chemical products: physical and
health hazards, safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way
you will know exactly what the risks are and how to do the job safely. Then fol-
low procedures and recommended equipment. (See your Astec Mobile Screens
dealer for MSDS’s on chemical products used with Astec Mobile Screens equip-
ment)
PRACTICE SAFE MAINTENANCE.
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving.
Keep hands, feet, and clothing from power-drive parts.
Disengage all power and operate controls to relieve pressure.
Lower equipment to the ground.
Stop the engine.
Remove the key, allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately.
Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on machine. On towed implements,
disconnect wiring harnesses from tractor before servicing electrical system com-
ponents or welding on machine.
AVOID HIGH PRESSURE FLUIDS
Escaping uid under pressure can penetrate the skin causing serious injury or
death.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other
lines. Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high
pressure uids.
If an accident occurs, seek medical attention immediately. Any uid injected in the
skin must be surgically removed within a few hours or gangrene may result. Doc-
tors unfamiliar with this type of injury should reference a knowledgeable medical
source.
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SERVICE COOLING SYSTEM SAFELY
Explosive release of uids from pressurized cooling system can cause serious
burns.
Shut off engine. Only remove ller cap when cool enough to touch with bare
hands. Slowly loosen cap to “rst stop” position to relieve pressure before remov-
ing completely.
WORK IN VENTILATED AREA
Expel engine exhaust fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors to get outside air
into the area.
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the environment and ecology. Poten-
tially harmful wastes used with Astec Mobile Screen equipment include such items
as oil, fuel, coolant, brake uid, lters, and batteries.
Use leak proof containers when draining uids. Do not use food or beverage con-
tainers that may mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants escaping into the air can damage the Earth’s atmo-
sphere. Government regulations may require a certied air conditioning service
center to recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your local environ-
mental or recycling center, or from your Astec Mobile Screens Dealer.
AVOID HEATING NEAR PRESSURIZED FLUID LINES
Flammable spray can be generated by heating near pressurized uid lines, result-
ing in severe burns to yourself or bystanders. Do not heat by welding soldering,
or using a torch near pressurized uid lines or other ammable materials. Pres-
surized lines can be accidentally cut when heat goes beyond the immediate ame
area.
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM
High pressure uid remaining in fuel lines can cause serious injury or death. Do
not disconnect or attempt repair of fuel lines, sensors, or any other components
between the high-pressure fuel pump and nozzles on engines with High Pressure
Common Rail (HPCR) fuel system. Only technicians familiar with this type of sys-
tem can perform repairs.

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REMOVE PAINT BEFORE WELDING OR HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by welding, soldering,
or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heat-
ing. If paint cannot be removed, wear an approved respirator before heating
or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respi-
rator.
If you use solvent or paint stripper, remove stripper with soap and water be-
fore welding. Remove solvent or paint stripper containers and other amma-
ble materials from area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Do not use chlorinated solvent in areas where welding will take place. Do all work
in an area that is well ventilated to carry toxic fumes and dust away. Dispose of
paint and solvent properly.
AVOID HOT PARTS
Avoid skin contact with exhaust manifolds, turbochargers, mufers, and other hot
parts. Keep ammable materials clear of all hot parts.
External dry exhaust parts become very hot during operation. Turbochargers
may reach temperatures as high as 500°C (932° F) under full load, and naturally
aspired exhaust manifolds may reach 600° C (1112° F) under full load.
This may ignite paper, cloth or wooden materials. Parts on engines that have
been at full load and reduced to no load idle will maintain approximately 140° C
(302° F) temperatures.
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM
High pressure uid remaining in fuel lines can cause serious injury or death. Do
not disconnect or attempt repair of fuel lines, sensors, or any other components
between the high-pressure fuel pump and nozzles on engines with High Pres-
sure Common Rail (HPCR) fuel system. Only technicians familiar with this type of
system can perform repairs.
PREVENT BATTERY EXPLOSIONS
Keep sparks, lighted matches, and open ame away from the top of battery. Bat-
tery vapors can explode. Never check battery charge by placing a metal object
across the posts. Use a volt meter or hydrometer. Do not charge a frozen battery;
it may explode. Warm battery to 16° C (60° F).
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AVOID HARMFUL ASBESTOS DUST
Avoid breathing dust that may be generated when handling components contain-
ing asbestos bers. Inhaled asbestos bers may cause lung cancer.
Components in products that may contain asbestos bers are brake pads, brake
band and lining assemblies, clutch plates, and some gaskets. The asbestos used
in these components is usually found in a resin or sealed in some way. Normal
handling is not hazardous as long as airborne dust containing asbestos is not
generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or
grinding material containing asbestos. When servicing, wear an approved respira-
tor. A special vacuum cleaner is recommended to clean asbestos. If not available,
apply a mist of oil or water on the material containing asbestos.
Keep bystanders away from the area.
HANDLING BATTERIES SAFELY
CAUTION: Battery vapors can explode. Keep sparks, lighted matches, and open
ame away from the top of battery. Use a ashlight to check battery electrolyte
level.
Never check battery charge by placing a metal object across the posts. Use a volt-
meter or hydrometer. Always remove grounded (-) battery clamp rst and replace it
last.
CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to
burn skin, eat holes in clothing, and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well ventilated area.
2. Wearing eye protection and rubber gloves (CHECK)
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15-30 minutes. Get medical attention imme-
diately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not exceed 2L (2qt)
3. Get medical attention immediately.

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Date Trainee Signature Trainer Signature

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Astec Mobile Screens Safety 12 KDS 710
Date Trainee Signature Trainer Signature