KPI-JCI Fast Pack K400FP User manual

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax [phone]
24/7 Parts Number 888-474-0115
Crushing Plant Operation Manual
and Parts Book
Model K400FP

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
SECTION 1: INTRODUCTION
Description...................................................................................................................................................... 1
Crushing Plant Component Location......................................................................................................... 2
Fast Pack Operation Manual..................................................................................................................... 2
New parts and equipment warranty................................................................................................................ 2
Disclaimer/Limitation of Warranties........................................................................................................... 3
Address for Notices........................................................................................................................................ 4
SECTION 2: SAFETY
Safety Overview ............................................................................................................................................. 7
Hazard and Advisory Statements................................................................................................................... 7
Hazard Statements.................................................................................................................................... 7
Advisory Statements ................................................................................................................................. 7
Lockout/Tagout............................................................................................................................................... 7
Who Must Use Lockout/Tagout?............................................................................................................... 7
What is Lockout/Tagout?........................................................................................................................... 8
When Must Lockout/Tagout Occur?.......................................................................................................... 8
How is Lockout/Tagout Performed?.......................................................................................................... 8
When Can Lockout/Tagout Devices be Removed? .................................................................................. 8
Lockout/Tagout Devices............................................................................................................................ 9
Lockout/Tagout Rules ............................................................................................................................... 9
Additional Lockout/Tagout Requirements ................................................................................................. 9
Miscellaneous Safety Tips.............................................................................................................................. 10
Know Your Machinery ............................................................................................................................... 10
Be Prepared for Emergencies................................................................................................................... 10
Wear Personal Protective Equipment (PPE)............................................................................................. 10
Observe Personal Safety Precautions ...................................................................................................... 10
Help Prevent Accidents............................................................................................................................. 11
Avoid Alcohol and Other Drugs................................................................................................................. 11
Be Aware of Your Surroundings................................................................................................................ 11
Practice Good Housekeeping.................................................................................................................... 11
Inspect And Maintain Machinery ............................................................................................................... 12
Machinery Installation Safety.......................................................................................................................... 12
Foundations............................................................................................................................................... 12
Guarding.................................................................................................................................................... 12
Customer Modifications............................................................................................................................. 12
Electrical Hook-up: ......................................................................................................................................... 13
Maintenance and Repair Safety:.................................................................................................................... 13
General Precautions.................................................................................................................................. 13
Electrical Systems..................................................................................................................................... 13
Pressurized Systems (hydraulic and air)................................................................................................... 14
Welding On Machinery.............................................................................................................................. 14
Clearing Jammed Material ........................................................................................................................ 14
Hazardous Materials ................................................................................................................................. 15
Disposal Of Excess Fuels, Lubricants And Liquids................................................................................... 15
Flammable and Combustible Liquids ........................................................................................................ 15
Hoisting and Handling Safety......................................................................................................................... 15
General Precautions.................................................................................................................................. 15
Wire Rope ............................................................................................................................................ 15
Connecting Or Clamping Wire Ropes.................................................................................................. 16

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
Chains.................................................................................................................................................. 16
Fiber Or Synthetic Slings ..................................................................................................................... 16
Transporting Machinery.................................................................................................................................. 16
Conveyor Safety............................................................................................................................................. 17
Safety Decals ................................................................................................................................................. 19
Safety Decal Locations................................................................................................................................... 25
Plant Left-Hand Side................................................................................................................................. 25
Right-Hand Side........................................................................................................................................ 26
SECTION 3: SPECIFICATIONS
Plant Specifications........................................................................................................................................ 29
Operating Dimensions............................................................................................................................... 29
Travel Dimensions..................................................................................................................................... 30
Capacities.................................................................................................................................................. 31
Conveyor Width......................................................................................................................................... 31
Engine Components.................................................................................................................................. 31
Batteries.................................................................................................................................................... 31
Component Weights.................................................................................................................................. 31
SECTION 4: CONTROLS AND INDICATORS
Introduction..................................................................................................................................................... 35
Crushing Plant Control Locations.............................................................................................................. 36
Travel and Set-up Controls, Indicators, and Gauges ..................................................................................... 37
Suspension System........................................................................................................................................ 37
Air Bag Pressure....................................................................................................................................... 37
Air Bag Pressure Gauge...................................................................................................................... 37
Height Control Valve............................................................................................................................ 37
Height Adjust Valve.............................................................................................................................. 37
Self Steering Axle Pressure Value ............................................................................................................ 37
Self Steering Axle Pressure Gauge ..................................................................................................... 37
Self-Steering Axle Lock Valve.............................................................................................................. 38
Hydraulic System Controls............................................................................................................................. 38
Stabilizers and Jacks Location.................................................................................................................. 39
Conveyor and Rear Jacks Control Bank ................................................................................................... 39
Stabilizers and Front Jacks Control Bank ................................................................................................. 39
Crushing Plant Folding Conveyor, Front and Rear Stabilizer Speed Control Valve.................................. 39
Cone Plant Hydraulic Power Unit Gauges and Indicators.............................................................................. 40
Cone Plant Conveyor Manifold With Gauges............................................................................................ 40
Operational Controls, Indicators, and Gauges ............................................................................................... 41
Cone Plant Emergency Stop (E-Stop) Switches and Warning Horns ...................................................... 41
Emergency Stop (E-Stop) Switches..................................................................................................... 41
Warning Horns..................................................................................................................................... 41
Battery Isolation (ISO) Switch .................................................................................................................. 41
60 Amp Circuit Breaker............................................................................................................................. 42
Fuel Gauge................................................................................................................................................ 42
Fuel Shut Off Valve................................................................................................................................... 42
Air Intake Restriction Indication................................................................................................................. 43
Profinet Connection................................................................................................................................... 43
Main Power Disconnect............................................................................................................................. 43
Power Connection Locations..................................................................................................................... 44
Engine Control Panel ................................................................................................................................ 45

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
Engine Maintenance Light/Maintenance Reset Switch........................................................................ 45
Diesel Fuel Pressure Gauge................................................................................................................ 46
Engine Error Warning Light.................................................................................................................. 46
Engine Oil Pressure Gauge ................................................................................................................. 46
Engine Coolant Temperature Gauge ................................................................................................... 46
Engine Shutdown Warning Light.......................................................................................................... 47
Voltmeter.............................................................................................................................................. 47
Tachometer Engine Error Code Display/Hour Meter ........................................................................... 47
Ignition Switch...................................................................................................................................... 47
Engine Shutdown Switch ..................................................................................................................... 48
Engine Idle Speed Adjustment Switch................................................................................................. 48
Engine Start-up Bypass Switch............................................................................................................ 48
............................................................................................................................................................ 48
Fluid Controller Control Panel................................................................................................................... 49
Engage / Disengage Button ................................................................................................................. 50
Timed Lockout Indicator....................................................................................................................... 50
Clutch Overload Indicator..................................................................................................................... 50
RPM Too High Indictor......................................................................................................................... 50
Coil Fault Indicator ............................................................................................................................... 50
Clutch Engage Indicator....................................................................................................................... 50
Oil Pressure Indicator........................................................................................................................... 50
Oil Temperature Indicator .................................................................................................................... 51
Filter Clogged Indictor.......................................................................................................................... 51
Safety Switch Indicator......................................................................................................................... 51
Power Indicator.................................................................................................................................... 51
Input Speed Detected Indicator............................................................................................................ 51
Output Speed Detected Indicator......................................................................................................... 51
Pressure Transducer Detected Indicator ............................................................................................. 51
SAE J1939 CAN Indicator.................................................................................................................... 51
Control Panel Switch Operation ................................................................................................................ 52
Plant System Control Panel............................................................................................................................ 53
Control Panel.................................................................................................................................................. 54
Operator Interface (Main Menu) ............................................................................................................... 54
Cone Status ......................................................................................................................................... 54
Manual Controls................................................................................................................................... 54
Cone Clutch Engaged Indicator ................................................................................................................ 54
Lube Oil Flow Indicator.............................................................................................................................. 54
Bowl Clamp Pressure Indicator................................................................................................................. 54
Relief Pressure Indicator........................................................................................................................... 54
Feeder Speed Decrease / Increase Switch............................................................................................... 55
Magnetic SEP Start / Stop Switch (Optional) ............................................................................................ 55
Cone Clutch Start / Stop Switch................................................................................................................ 55
Side Discharge Conveyor Start / Stop Switch........................................................................................... 55
Feed Conveyor Start / Stop Switch........................................................................................................... 55
Feeder Start / Stop.................................................................................................................................... 55
Bowl Rotate Up / Down............................................................................................................................. 55
Hydraulic Clear.......................................................................................................................................... 55
Emergency Stop Switch ............................................................................................................................ 55
Warning Horn Button................................................................................................................................. 56
Display and Diagnostic Module (MDDM) .................................................................................................. 56
MDDM Operating Instructions.............................................................................................................. 56
Viewing Engine Configuration Data (MDDM)....................................................................................... 58

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
Viewing Active Service Codes (MDDM)............................................................................................... 60
Viewing Stored Service Codes in the MDDM....................................................................................... 61
SECTION 5: SET-UP
Introduction..................................................................................................................................................... 85
Proper Site Selection...................................................................................................................................... 85
Plant Alignment Procedures...................................................................................................................... 85
Engine Start-Up.............................................................................................................................................. 85
Cone Plant Engine Pre-Start Checks:....................................................................................................... 85
Plant Pre-Start Checks.............................................................................................................................. 86
Fast Pack Engine Starting Procedure for Leveling......................................................................................... 88
Removing the Bag House Shipping Cover................................................................................................ 88
Plant Set-Up................................................................................................................................................... 89
Plant Leveling Procedures ....................................................................................................................... 90
Conveyor Unfolding Considerations.......................................................................................................... 91
Remotely Controlling Your Plant............................................................................................................... 91
Non-Network Plant Operation.............................................................................................................. 91
Spray System Hook-Ups........................................................................................................................... 91
Additional Set-up Information......................................................................................................................... 92
Adjusting the Vibrating Feeder Drive Belt ................................................................................................. 92
General Conveyor Information.................................................................................................................. 92
Conveyor Belt Training......................................................................................................................... 93
Adjusting Belt Side Creep.................................................................................................................... 94
Conveyor Loading................................................................................................................................ 95
SECTION 6: OPERATION
Introduction..................................................................................................................................................... 97
Fast Pack Pre-Start Checks........................................................................................................................... 97
Fast Pack Plant Pre-Start Checks............................................................................................................. 97
Conveyor Pre-Start Checks....................................................................................................................... 97
Crusher Pre-Start Checks......................................................................................................................... 97
Fast Pack Start-up Procedures ...................................................................................................................... 98
Fast Pack Crusher Engine Starting Procedure ......................................................................................... 98
Removing the Bag House Shipping Cover................................................................................................ 98
.................................................................................................................................................................. 98
Fast Pack Post Start-up Checks ............................................................................................................... 99
Fast Pack Start-Up Sequence................................................................................................................... 99
Remotely Controlling Your Plant............................................................................................................... 99
Fast Pack Shut Down Procedures ............................................................................................................ 99
Restarting the Fast Pack After Emergency Stop Activation...................................................................... 100
Moving the Fast Pack Plant............................................................................................................................ 100
Fast Pack Tear Down................................................................................................................................ 100
Travel and Positioning with the Fast Pack Trailers ................................................................................... 101
Self-Steering Axle Operation..................................................................................................................... 102
Self-Steering Axle Adjustment Procedure................................................................................................. 102
Locking the Axles Prior to Backing............................................................................................................ 102
SECTION 7: MAINTENANCE
Introduction.................................................................................................................................................... 105
Maintenance Safety........................................................................................................................................ 105

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
Oil Recommendations.................................................................................................................................... 105
Grease Recommendations........................................................................................................................ 105
Hydraulic Oil Recommendations............................................................................................................... 105
Scheduled Maintenance................................................................................................................................. 105
Cone Plant Grease Lubrication Items ....................................................................................................... 106
Scheduled Grease Lubrication Items ............................................................................................................. 107
Fast Pack Plant Daily Walk Around Inspection Checklist............................................................................... 108
Maintenance Schedules................................................................................................................................. 109
Weekly Or Every 50 Hours of Operation.............................................................................................. 109
Monthly or Every 200 Hours of Operation............................................................................................ 109
Every 500 Hours of Operation.............................................................................................................. 109
Every 1000 Hours of Operation............................................................................................................ 109
Yearly or Every 2000 Hours of Operation ............................................................................................ 109
Every 5000 Hours of Operation............................................................................................................ 109
Daily Walk around Items................................................................................................................................. 109
Engine Oil Level........................................................................................................................................ 110
Engine Coolant Level................................................................................................................................ 110
Drain the Fuel Water Separator. ............................................................................................................... 111
Cone Plant Fluid Coupling......................................................................................................................... 111
Engine Charge Air Cleaner ...................................................................................................................... 111
Air Restriction Indicator ............................................................................................................................. 112
Profinet System......................................................................................................................................... 112
Engine Fuel Level...................................................................................................................................... 112
Hydraulic System Depressurizing ............................................................................................................. 113
Changing the Filter Element................................................................................................................. 114
Hydraulic Hoses and Connections ............................................................................................................ 115
Hydraulic Oil Pressures........................................................................................................................ 115
Weekly Or Every 50 Hours of Operation........................................................................................................ 116
Battery Maintenance ................................................................................................................................. 116
Radiator and Cooler Core ......................................................................................................................... 116
Conveyor Checks...................................................................................................................................... 116
Every 1000 Hours of Operation...................................................................................................................... 117
Hydraulic Oil Filter..................................................................................................................................... 117
Yearly or Every 2000 Hours of Operation....................................................................................................... 117
Fluid Coupling Oil...................................................................................................................................... 117
Hydraulic Oil.............................................................................................................................................. 117
Additional Maintenance Items ........................................................................................................................ 117
Lubrication of the Gear Reducer ............................................................................................................... 117
Maintenance Recommendations.......................................................................................................... 118
Oil Recommendations.......................................................................................................................... 118
How to Determine the Belt Tension........................................................................................................... 119
Setting the Meter.................................................................................................................................. 119
Using the Meter:................................................................................................................................... 120
Adjusting the Drive Belt Tension ............................................................................................................... 121
JCI Bag House ............................................................................................................................................... 123
Operation................................................................................................................................................... 123
Removing the Bag House Shipping Cover........................................................................................... 123
Programing and Operating the Siemens LOGO! PLC ......................................................................... 123
To stop the program:............................................................................................................................ 124
To restart the program: ........................................................................................................................ 124
Control Panel Circuit Breaker............................................................................................................... 125
Maintenance.............................................................................................................................................. 125

Table of Contents
Fast Pack Operation and Service Manual
Rev. 01
How to Repair a Broken Conveyor Belt..................................................................................................... 129
How to Measure for the Proper Length................................................................................................ 129
How to Square the Ends...................................................................................................................... 129
How to Drill and Skive Your Conveyor Belt.......................................................................................... 130
How to Attach the Belt Ends ................................................................................................................ 132
Using the Flexco 840 Belt Cutter ......................................................................................................... 134

Section 1: Introduction
1
Rev 03
Fast Pack Operation and Service Manual
DESCRIPTION
The Fast Pack Plant system is composed of
portable screening and crushing plants controlled
by a centralized computer system. The Fast Pack
plant is designed to be set-up and torn down with
the minimum amount of man power in a short
periodof time.Each FastPackisdesignedto meet
your needs and therefore may not include all
equipment included in this operational manual.
The JCI plant components include cone crushing
plants, a scalping plant, and afinishing plant. Each
plant is equipped with a hydraulically activated
stabilizers, conveyors, and operator walkways.
Diesel engines mounted on each plant provides
drive power for the hydraulic systems and,
electrical power for the screen plants, stacking
conveyors and operator controls. Plant trailers are
equipped with an airbag suspension system and
somearealsoequippedwithself-steering axlesfor
easy towing.

Section 1: Introduction
2Rev 03
Fast Pack Operation and Service Manual
Crushing Plant Component Location
1)Vibrating Feeder Bin
2)Revisable Magnet Belt
3)Feed Conveyor
4)Side Discharge Conveyor
5)Extend Crusher Hopper
6)Engine Compartment
7)Hydraulic Control Unit
8)Rear Stabilizers
9)Mid Stabilizers
10)Front Folding Stabilizers
11)Kodiak 400 Crusher
12)Fuel Tank
The Integrated “Profinet Network” computerized
control system allows the operator to control all
FastPack systemfunctionsfrom thecontroltrailer.
TheProfinetNetworkusesethernetconnectionsto
communicate with all components such as
Crusher plants, Screen plants, Conveyors,
programmable logic controllers (PLC) and touch
screen panels.
Fast Pack Operation Manual
This manual provides the information for an
experienced operator to successfully and safely
operate the Fast Pack Plant. Please review this
manual carefully to insure you receive the most
benefit from your plant. Ensure that all personnel
are aware of, and use, proper safety precautions
when working with and/or around the plant and
related equipment. For information on service,
contact your JCI dealer or the JCI service
department. Please refer to your parts book for
further JCI contact information.
NEW PARTS AND EQUIPMENT
WARRANTY
JCI warrants to the Distributor and Distributor’s
customers on resale with respect to JCI products
sold that the new equipment will be free from
defect in material and workmanship under normal
use for a period of one year after the date of
start-up or 2,000 hours of operation, whichever
Material Flow
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5
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8910
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