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
123
4
5
67
8910
11
12

Section 1: Introduction
3
Rev 03
Fast Pack Operation and Service Manual
first occurs. JCI further warrants to the Distributor
and Distributor’s customers on resale that any and
all parts supplied by JCI will be free from defect in
material and workmanship under normal use
(excluding ordinary wear) for a period of six
months after installation. The sole and exclusive
remedy for any breach of warranty, breach of
contract, or any claim in tort (including, but not
limited to, strict liability and negligence) shall be
the repair or replacement (at JCI’s option) of any
defective part, parts or equipment at JCI’s
manufacturing plant in Lane County, Oregon. Any
part(s) and/or equipment claimed to be defective
shall be returned, freight prepaid, to JCI’s
manufacturing plant in Lane County, Oregon,
following the receipt of JCI’s returned goods
authorization. Written notice of any claimed defect
must be provided to JCI within sixty (60) days of
the discovery of any claimed defect(s).
Disclaimer/Limitation of Warranties
The expressed warranty described above is
expressly in lieu of other warranties, expressed or
implied AND ANY AND ALL IMPLIED
WARRANTIES, INCLUDING, BUT NOT LIMITED
TO, ANY AND ALL IMPLIED WARRANTIES OR
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE ARE HEREBY
EXPRESSLY DISCLAIMED AND EXCLUDED.
NO PERSON(S), INCLUDING, BUT NOT
LIMITED TO, EMPLOYEES AND AGENTS OF
JCI AND/OR ITS DISTRIBUTORS ARE
AUTHORIZED TO MAKE ANY
REPRESENTATION OR WARRANTY
CONCERNING JCI PRODUCTS THAT ARE IN
ANY WAY INCONSISTENT WITH THE
FOREGOING WARRANTY.
JCI MAKES NO WARRANTY OR WARRANTIES,
EXPRESSED OR IMPLIED, WITH RESPECT TO
ANY ACCESSORIES, COMPONENTS OR
PARTS NOT MANUFACTURED BY JCI, AND
THE INSTALLATION OF ANY PARTS OR
COMPONENTS NOT MANUFACTURED OR
SUPPLIED BY JCI, AND ANY ALTERATION OF
EQUIPMENT OR PARTS SUPPLIED BY JCI
WITHOUTJCI’SEXPRESSWRITTENCONSENT
SHALLVOIDTHEWARRANTYGRANTEDHERE
BY.
UNDER NO CIRCUMSTANCES SHALL
JOHNSON CRUSHERS INTERNATIONAL, INC.
BE RESPONSIBLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING,
BUT NOT LIMITED TO, LOST PROFITS OR
LOSS OF USE.

Section 1: Introduction
4Rev 03
Fast Pack Operation and Service Manual
ADDRESS FOR NOTICES
Anyandall inquiriesand/orwarrantyclaimsshould
be submitted in writing to JCI at the following
address:
Johnson Crushers International, Inc.
86470 Franklin Blvd
Eugene OR 97405
For Service Assistants:
Johnson Crushers International, Inc.
Attention: Service Department
86470 Franklin Blvd
Eugene OR 97405
Phone: [phone]
For Parts Sales Assistants:
Johnson Crushers International, Inc.
Attention: Parts Sales
86470 Franklin Blvd
Eugene OR 97405
Phone: [phone]

Section 2: Safety
7
Rev 03
Fast Pack Operation and Service Manual
SAFETY OVERVIEW
It is the responsibility of the quarry management
team to develop a comprehensive safety
awareness program, and to ensure that all quarry
workers and support personnel receive
appropriate safety training as required by federal,
state and local regulations.
Safety is basically common sense. There are
standard safety rules, but each situation has its
own peculiarities which cannot always be covered
by rules. Therefore, quarry personnel must
continually watch for possible safety hazards and
be prepared to take promptcorrective action when
necessary.
Failure to observe the precautions contained in
this chapter can result in serious personal injury
and even loss of life. As with most industrial work
environments, a careful operator is the best
insurance against an accident.
Thecompleteobservanceofonesimplerulewould
prevent many unnecessary injuries and deaths
each year. This rule is:
“Never attempt to clean, lubricate, repair or
adjust any machinery unless it is stopped and
properly locked out.”
Please note that this chapter is only intended as a
brief review of basic quarrysafety precautions and
procedures.Thegeneral guidelinesincludedin the
following paragraphs should not be considered in
lieu of a quarry’s official safety procedures,
insurance company requirements, or applicable
federal, state and local regulations.
HAZARD AND ADVISORY
STATEMENTS
Throughout this manual, the use of hazard and
advisory statements has been emphasized. The
following safety alert symbol is used to bring
attention to the specific advisory:
When you see the symbol, it means that you
should pay particular attention to the advisory that
follows as your safety and that of others is
involved.
Hazard Statements
The Caution, Warning and Danger statements
are hazard statements used to alert workers of
unsafe practises and potentially harmful or
life-threatening situations. Each of these
statements is preceded by the Safety Alert
Symbol.
•CAUTION indicates a potentially hazardous
condition that, if not avoided, may result in MINOR
PERSONAL INJURY.
•WARNING indicates a potentially hazardous
condition that, if not avoided, could result in
SERIOUS PERSONAL INJURY or DEATH.
•DANGER indicates a potentially hazardous
condition that, if not avoided, will result in SEVERE
PERSONAL INJURY or DEATH.
Advisory Statements
The Note and Important statements are advisory
statements which relate to equipment operation,
maintenance and service procedures. They are
used to draw attention to proper procedures and
practises.
•NOTE is a basic informational statement or helpful
suggestion.
•IMPORTANT is used to draw attention to a
procedure that must be observed to prevent
machine damage or malfunction.
LOCKOUT/TAGOUT
Who Must Use Lockout/Tagout?
Quarry owners, managers, and safety officers
must be aware of OSHA’s “lockout/tagout”
standard: CRF Section 29 1910.147, The Control
of Hazardous Energy. This standard is also
recognized by MSHA.
All mechanics, maintenance personnel, operators,
and electricians must fully understand and comply
with this standard to ensure the safety of all
employees.

Section 2: Safety
8Rev 03
Fast Pack Operation and Service Manual
What is Lockout/Tagout?
Lockout/tagout is a means to ensure that
personnel who install, operate, repair, maintain,
serviceorotherwisedisablemachines,equipment,
or electrical energy systems are protected from
harm due to unexpected energizing, or the release
of stored energy by...
1. Lockout – Placing a disconnect switch, circuit
breaker, valve, or other energy-isolating
mechanism in the off or safe position and securing
it with a lock so the energy-isolating mechanism
cannot be activated.
2. Tagout – A prominent written warning (tagor label)
placed on the energy-isolating mechanism
indicating the name of the individual placing the
mechanism out-of-service, and stating that the
energy isolating mechanism cannot be activated
until the tagout device is removed.
When Must Lockout/Tagout Occur?
Lockout/tagout must occur whenever service or
maintenance is performed, and injury could occur
due to the unexpected start-up of equipment, or
the release of stored energy. See Figure 1–2.
• In general, lockout/tagout procedures must be
performed under the following circumstances:
• Before cleaning, lubricating, adjusting or repairing
machinery or equipment.
• Before working on electrical, hydraulic or
pneumatic circuits or devices.
• Before clearing jammed mechanisms, machinery
or equipment.
• Before removing guards or other protective
devices.
• Whenever a machine or its controls will be left
unattended.
How is Lockout/Tagout Performed?
OSHA has identified the following step-by-step
lockout/ tagout procedure:
1. Prepare for shutdown – Before shutting down a
piece of equipment, know the type and magnitude
of the energy that powers it, the hazards of that
energy, and how to control it. Warn all employees
that the machinery is about to be shut down.
2. Shutdown the equipment – After warning all
employees, shut down the machine, equipment, or
electrical system by the normal stopping
procedure.
3. Control stored energy – any potentially
hazardous stored energy (electrical, mechanical,
hydraulic, pneumatic, etc.) That remains must be
released, dissipated, restrained, or otherwise
rendered safe. If stored energy reaccumulates,
monitor it until the possibility of accumulation no
longer exists.
4. Isolate the equipment – Disengage all isolating
devices, both primary and secondary, so that the
equipment is isolated from all of its energy sources
(electrical, mechanical, hydraulic, pneumatic, etc.).
5. Apply lockout/tagout devices – Attach lockout
tagout devices (according to your company’s
safety program) in such a manner that the isolating
device (circuit breaker, control, etc.) will be held in
a safe or off position. Attach tags to alert others
that the machinery is being serviced.
6. Verify that equipment is isolated – After warning
all employees to stay clear, engage the start button
to confirm the machine is inoperable. Return the
control to the off position before proceeding with
servicing.
When Can Lockout/Tagout Devices be
Removed?
Lockout/tagout devices can only be removed after
the following conditions are met:
• All guards and protective devices are properly
re-installed.
• All tools and repair equipment are removed from
the equipment and the immediate area.
• All mechanics and other personnel are clear of the
equipment and its immediate area.
• All personnel have been warned that the
equipment is about to be restarted (sound warning
horn or activate warning lights).
After removing lockout/tagout devices, always use
the normal start-up procedure as described in the
operator’s manual for the machinery.

Section 2: Safety
9
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Fast Pack Operation and Service Manual
Lockout/Tagout Devices
1) Multiple Lockout Device
2) Pad Lock
3) Tag
Lockout/tagout devices include:
•Locks
• Tags and labels
• Multiple lockout devices
A lock must be sufficiently durable, so it can
withstandtheenvironmentalconditions(heat,cold,
moisture, etc.) around it. A lock must also be
strong enough so that it cannot be easily removed
or forced open. A tag or label must be affixed to
each lock to alert others that service work is in
progress. Each tag or label must have the
following characteristics:
• Be sufficiently durable to withstand wear and
abuse, even if used in dirty or damp environments.
• Be securely attached with a cable that is difficult to
remove, cut or tear.
• Contain the name of the person that applied it.
• Contain a warning or other precautionary
statement that briefly indicates why the machine is
locked out and what hazards could result if the
equipment is started while service work is in
progress.
When two or more people are working on a piece
of equipment, a multiple lockout device must be
used. This allows each person to install their own
lock, preventing accidental start-up.
Lockout/Tagout Rules
• Always lockout/tagout any machinery before
performing any adjustment, inspection, lubrication,
maintenance or repair procedures. Failure to
observe this precaution may result in serious
personal injury or death.
• Your company’s lockout/tagout program may be
somewhat different than described in this manual.
If so, be sure to completely follow your company’s
official policies and procedures when lockout/
tagout is necessary. Consult your company’s
safety officer if you have any questions.
• A lock must have only one user and one key.
Anyone who installs a lock must keep the key in
their possession at all times. Except in an
emergency situation, only the person that installs a
lock is authorized to remove it.
• To prevent accidental start-up, never give your lock
or its key to another employee.
• Your key must open your lock only. Your key
should not be capable of opening any other locks.
Keys for other locks should not be capable of
opening your lock.
• Except in an emergency situation, never attempt to
remove anyone else’s lock. Do not allow others to
remove your lock.
• When disconnecting power, be sure that the circuit
breaker handle (or other isolating device) is in the
OFF position. Accidentally locking a control in the
ON position could result in serious personal injury
or death.
• If two or more people are working on a machine, a
multiple lockout device must be used to prevent
accidental start-up in the event that one person
finishes working before another.
• Each lock must have a tag. If two or more people
are working on a machine, each person must
attach a separate tag to their lock. Never attach a
lock without a tag.
• Never use tags alone. A tag should always be
accompanied by a lock which prevents the
isolating device from becoming energized.
Additional Lockout/Tagout Requirements
• Be sure that the power is COMPLETELY turned
off. A motor may be stopped and locked out.
However, interlocks, starters, and other
supplemental electrical components may still be
energized. Use a voltmeter and/or ammeter to
verify that all electrical circuits are completely
dead.
• Always be sure that all peripheral equipment, such
as feed conveyors, grizzly feeders and discharge
1
2
3

Section 2: Safety
10 Rev 03
Fast Pack Operation and Service Manual
conveyors, is also tagged and locked out. Serious
personal injury or death can result if any of these
items starts unexpectedly while the crusher is
being serviced.
• Although lockout/tagout procedures are most
commonly associated with electrical systems, be
aware that hydraulic, pneumatic and mechanical
systems must also be tagged and locked out
before servicing. This may involve the lockout/
tagout of valves, levers and other non-electrical
devices.
• For machinery powered by internal combustion
engines (diesel, gas, etc.), always disconnect
batteries and shut-off fuel supply before servicing
the machinery. Lockout/tagout engine controls to
ensure that engine is not accidentally started while
the machinery is being serviced.
• Always be sure that all hydraulic or air pressure is
completely relieved before working on hydraulic or
pneumatic systems. Dangerous pressures can be
present, even when equipment is turned off and
locked out.
• After maintenance or repairs are completed,
always warn all employees that the machinery is
about to be restarted. Be sure no one is on or near
the equipment before a lock and tag is removed.
• As a precaution, always activate a warning horn or
light before restarting the machinery. This will
provide additional warning for personnel to stay
clear of machinery that is about to be started.
MISCELLANEOUS SAFETY TIPS
Know Your Machinery
• Read the manufacturer’s operation and
maintenance manuals for all machinery and
equipment that you operate. Be sure that all
hazard statements contained within the manuals
are completely understood.
• Become familiar with the controls, functions and
settings of each machine. Fully understand all
phases of each machine’s operation.
• Be sure that you completely understand and follow
all start-up and shut-down procedures as
described in the manufacturer’s manuals.
• Be familiar with the safety signs on your
equipment, and the hazards against which they
warn.
• Check the legibility of all safety signs every day.
Order new signs from the machinery manufacturer
if they become illegible or worn.
Be Prepared for Emergencies
• Know the proper emergency shut-down
procedures for the equipment you operate.
• Know where fire extinguishers are kept and how to
use them. Be sure that fire extinguishers are
properly rated, and that they remain fully charged
and ready for use at all times.
• Know the procedure for contacting emergency
medical personnel. Keep a list of emergency
phone numbers handy at all times.
• Know where first-aid kit, stretcher and other
emergency supplies are kept. Be sure that first aid
supplies are properly maintained and ready for
use.
• Make sure that a clear path to emergency
equipment and exits is always maintained. Do not
allow equipment, spilled materials or other
obstructions to get in the way.
• Know how to report accidents. Always report all
accidents immediately to the appropriate
supervisor.
Wear Personal Protective Equipment
(PPE)
• Wear safety glasses or goggles whenever outside
of an approved operator’s enclosure. Failure to
wear appropriate eye protection can result in
permanent eye injuries and loss of sight.
• Wear appropriate ear protection when working
within 50 feet of any operating quarry machinery,
and in other areas where noise levels are high.
Prolonged exposure to high noise levels can cause
permanent hearing loss.
• Wear steel-toe safety boots, heavy-duty gloves
and a hard hat. This equipment is mandatory in
most areas of the quarry.
• Use respirators in dusty locations and when
working with hazardous substances. Prolonged
exposure to rock dust or chemical fumes can
cause permanent respiratory illness.
• Other personal protective equipment may be
necessary for your specific job assignment, such
as a full face shield and safety harness. Wear or
use these items when necessary and as required
by applicable federal state and local regulations.
Observe Personal Safety Precautions
• Never wear loose or ragged clothing when working
on or around rotating power equipment. Avoid
wearing necklaces, rings or other jewelry. These
items can become caught or tangled in the
machinery, resulting in severe personal injury or

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death.
• Keep hair short, if possible. Keep long hair
securely tied-up to prevent it from becoming
caught in the machinery.
• Be especially careful whenever using wet
walkways, platforms, or ramps. The combination of
rock dust and wet metal can create an extremely
slippery surface. Keep all walkways and other
access structures clean, dry and free of grease or
oil.
• Use walkways and ladders when working near
machinery, or observing its operation. Use a safety
harness when necessary. Keep handrails and
machine contact surfaces clean.
• To avoid back injuries, always use proper lifting
techniques to safely lift heavy objects. Lift with your
legs and keep your back straight. Keep the
materials or object close to your body. Have a
co-worker assist you if the load cannot be lifted
safely by one person.
• Before starting the machinery, check that no
personnel are inside, on, under or beside the
equipment. Unless absolutely necessary, do not
allow anyone to be on or near the equipment while
it is operating.
• Never attempt to catch falling materials or objects.
• Be aware of flammable liquids and other potential
fire hazards. Do not smoke when refilling engines
or using cleaning solvents.
• Do not stand under equipment or components that
are being hoisted or suspended. Never allow other
quarry personnel to do so.
• Before you assemble, operate, clean, lubricate, or
adjust machinery, be sure to read and understand
all procedures contained in the machinery
manufacturer’s manual.
• Be sure to operate quarry machinery in compliance
with current OSHA and MSHA regulations, and all
applicable federal, state or local regulations.
Help Prevent Accidents
• Do not allow unauthorized personnel in or near the
work area. Never allow unauthorized personnel to
operate, adjust, maintain or repair machinery.
• Allow only properly trained and experienced
personnel to operate machinery. Be sure
inexperienced operators are carefully supervised
at all times.
• Do not allow personnel to be near loading areas, or
anywhere else that falling or ejected material could
hit them.
• Use extreme caution if the machinery must be
operated for inspection or observation purposes.
Stay a safe distance from the machinery and wear
appropriate personal protective devices.
• Before making repairs to the machinery, always
clear all quarry material from the feed and
discharge devices (feeders, conveyors, chutes,
etc.).
• In areas which present a danger of falling, use an
appropriate fall protection device, such as a safety
harness and lifeline.
• Always report any unsafe conditions or defective
equipment to the appropriate supervisor.
Avoid Alcohol and Other Drugs
• Do not operate or work near quarry machinery
when under the influence of alcohol or other drugs.
These substances can result in reduced alertness
and impaired judgement. Serious personal injury or
death could result.
• Some prescription and non-prescription
medications can cause drowsiness or other
adverse side effects. Do not operate or work near
quarry machinery when under the influence of such
medications.
Be Aware of Your Surroundings
• The quarry environment contains many situations
that are potentially hazardous. Use extreme
caution to avoid being struck by haul trucks,
loaders and other quarry mobile equipment.
• Be aware of idle machinery that could start-up
without warning. Stay clear of such machinery and
the immediate area.
• Be aware of overhead obstructions, such as
conveyors, support structures or power lines.
Practice Good Housekeeping
• Do not store tools or equipment on walkways.
• Be sure that all walkways, platforms, stairs and
ramps are kept free of spilled material and trash. A
build-up of material in these areas can cause slips
and falls. Make repairs as required in areas where
spillage is present.
• Do not allow machinery to become buried under
piles of spilled material. This will make the
machinery more difficult to inspect and may hide
broken welds, loose fasteners and other serious
problems that could cause a safety hazard.
• Keep the areas around control panels and
machinery free of spilled material. Free access
must be maintained at all times. In the event of an
emergency, quick access to controls could prevent
injury or death.
• Clean up spilled fuel or oil immediately to eliminate

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slipping hazards. If necessary, use an oil
absorbent.
• Always be sure that power is tagged and locked
out before cleaning spilled material or oils. Never
clean-up these items while the machinery is
operating.
Inspect And Maintain Machinery
• Always perform a safety inspection at the
beginning of each shift. Refer to the machinery
manufacturer’s operation and maintenance
manuals for detailed pre-start-up inspection and
maintenance procedures.
• Test all warning devices before starting the
machinery to ensure that they are working
properly. Never disable or bypass any alarm
systems or interlocks.
• Be sure that any defective components or systems
are properly repaired by a qualified technician
before the machinery is started. Immediately report
any serious problems to the appropriate
supervisor.
• Before performing inspections or maintenance,
always lock out power and tag controls to the
machine drive, and to all feed and discharge
equipment. Warn all personnel that the equipment
is being serviced. Refer to the Lockout/Tagout
section of this chapter for additional information.
• Maintenance inspection procedures are included
throughout this manual. Although maintenance is
not typically a safety concern, machinery that is
regularly maintained and in proper working
condition will minimize the occurrence of safety
hazards and emergency situations.
MACHINERY INSTALLATION
SAFETY
Foundations
Proper foundations and support structures are
essential to ensure the safe and efficient operation
of quarry equipment.
• Crushing machinery needs a firm foundation on
which to operate. This does not need to be a
poured pad, but it must not be unstable ground.
When selecting the location, be sure that the entire
area is as level as possible.
• Follow all manufacturer’s installation drawings and
specifications when constructing the base pads for
permanent plants.
• If any questions arise regarding foundation
requirements or modifications necessary for JCI
machinery, please contact the JCI Service
Department.
• Customer-designed support structures for JCI
equipment must meet JCI’s engineering standards.
All plans must be submitted in advance to the JCI
Engineering Department for approval.
Guarding
• Quarry management is responsible for the proper
installation and placement of guards to prevent
personnel from coming in contact with rotating or
moving parts.
• In addition to the guards supplied with the
machinery, additional guards and related safety
equipment may be required to comply with OSHA,
MSHA and any applicable local regulations. The
proper fabrication, installation and placement of
these items is quarry management’s responsibility.
• When fabricating guards, refer to MSHA’s Guide to
Equipment Guarding at Metal and Nonmetal
Mines. Additional information can also be provided
by the safety officer at your worksite.
• Never remove guards until the machinery is
stopped, power is locked out, and controls are
tagged. Be sure that guards are properly
re-installed before reconnecting power.
Customer Modifications
• Do not modify quarry machinery in any way without
prior approval from the manufacturer. Such
modifications may include (but are not limited to)
changing machine speed or direction of rotation,
drilling additional holes and welding or bolting
additional equipment to the machinery.
• All customer modifications to JCI machinery must
be approved in writing by the JCI Engineering
Department.

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ELECTRICAL HOOK-UP:
• Be sure that all electrical equipment is properly
grounded.
• Lay out the power lines, especially those for
portable plants, so that contact with standing water
is minimized.
• Do not place power lines in an area where they will
be driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a
power line across a traffic area, protect the cable
with properly rated bridging.
• Be sure that all auxiliary control panels or power
supply panels can be securely locked out. This
type of panel is mandatary.
• Maintain adequate overhead clearance from power
lines or other obstructions, particularly when
planning to use stacking conveyors for stockpiles.
• Be sure that electrical power supplies are located
in an area that will be safe from accidental contact
during crushing operations.
• All JCI machinery is designed with electrical
components of the proper size and voltage. Any
modifications to these components or to the power
supply must be approved in writing by the JCI
Engineering Department.
• Be sure that all connections are in accordance with
the National Electric Code and any applicable state
or local codes.
•
MAINTENANCE AND REPAIR
SAFETY:
General Precautions
• To help ensure safe machine operation, use only
genuine Original equipment manufacturer (OEM)
replacement parts that are sold or approved by the
machine’s manufacturer. Use of non-OEM parts
may adversely affect machine operation and could
result in an a hazardous situation.
• Always tighten all fasteners to the proper torque as
described in the repair procedures. When torque
specifications are not listed, use the values in the
torque table at the back of this manual.
• Be sure all replacement fasteners are of the proper
grade and specifications. Replace any worn or
damaged fasteners.
Electrical Systems
• Always read, understand and follow appropriate
electrical system troubleshooting, maintenance
and repair instructions in the machinery
manufacturers’ manuals.
• Allow only trained and licensed electricians to
install, troubleshoot and repair electrical
equipment. All procedures must be in compliance
with the National Electric Code and any applicable
state or local regulations.
• When servicing an electrical system, work with the
power locked out and tagged. Always assume that
an electrical system is live until it has been locked
out.
• Always tag and lockout power before removing
cables with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and
connectors.
• Inspect power cables and connections daily for
When installing any electrical
equipment, be sure to completely
follow the manufacturer’s
instructions. Failure to observe this
precaution could result in a dangerous
electrical shock hazard.
Always lockout/tagout power to
machinery and conveying equipment
beforeperforming any maintenanceor
repairs. Warn all personnel that the
machinery is being serviced.

Section 2: Safety
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signs of wear, cracked insulation and worn or
damaged connectors. Repair or replace as
required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three wire
plug or double insulated. Be sure that all extension
cords are grounded with a three wire plug.
Pressurized Systems (hydraulic and air)
• Adjust, maintain and repair all pressurized systems
only in accordance with the instructions contained
in the manufacturer’s manuals provided with the
machinery.
• Never attempt to work on a pressurized system
while it is pressurized or in operation.
• Before performing maintenance or repairs on any
pressurized system:
—Cycle the controls through all operating positions
to relieve any trapped pressure.
—Check that ALL pressure is relieved from the
system. Pressure gauges must read zero (0) PSI.
—Lockout and tag all controls. Be sure electrical
power is properly locked out and tagged.
• Allow time for hot hydraulic oil to cool before
performing any maintenance or repairs. Hot oil can
cause burns.
• Before loosening fittings or removing components,
always recheck that ALL pressure is relieved from
the system. Pressure gauges must read zero (0)
PSI.
• Never attempt to crack a hydraulic fitting while a
hydraulic system is pressurized. You could be
injured or killed by a stream of high pressure oil.
• Never have your face near, or stand directly in front
of a hydraulic line when cracking a fitting, even
after system pressure has been relieved. Always
assume that the line has pressure.
• Use a piece of cardboard to check for hydraulic oil
leaks, not your hand. Escaping fluid under
pressure can penetrate the skin, resulting in
serious personal injury.
• Clean-up any spilled hydraulic fluid. Hydraulic fluid
is extremely slippery, and can be especially
dangerous if spilled on an elevated walkway or
platform.
• Repair any leaks immediately. Always relieve
system pressure and lockout/tagout power before
tightening fittings or making repairs.
• Never attempt to adjust pressure relief valves to
above the machinery manufacturer’s
recommended settings. Serious personal injury
and/or equipment damage could result. Do not
operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always
replace any defective components immediately.
• Never place hands on hydraulic cylinder rods while
equipment is in operation. Do not step on the
hydraulic relief cylinder hoses when climbing on
the crusher.
• Refer to manufacturer’s instructions when
recharging hydraulic accumulators or checking
accumulator pressure. Allow only trained hydraulic
system technicians to depressurize, recharge or
repair hydraulic accumulators.
Welding On Machinery
• Be sure to provide adequate ventilation when
welding inside enclosed areas to prevent the
buildup of hazardous fumes. Special concern
should be exercised when welding chromium,
manganese, cadmium, copper, cobalt, lead and
nickel, as these materials are considered to be
potentially carcinogenic.
• Be sure to wear the proper welding shield, welding
gloves and clothing. Do not wear synthetic fabric
clothing or clothing which could be easily ignited by
sparks.
• Always follow all standard safety procedures when
welding. Be sure that all systems are shut down,
power is locked out, and controls are tagged.
Provide welding screens to protect other
employees working in the area.
• Relieve all hydraulic pressure before welding near
hydraulic components and lines. Cover hydraulic
components to protect them from weld spatter and
sparks.
• Do not weld near flammable liquids or hydraulic
oils.
• Welding lifting eyes or hooks to manganese steel
castings is strongly discouraged, and should be
done only if absolutely necessary. Always use a
stainless steel or manganese weld rod. Never
allow personnel to walk or work underneath
castings being lifted or supported.
• Never ground the welder so that the electrical
power will flow through bearings, hydraulic
components or electrical equipment. Serious
damage could result.
• Be sure all compressed gas cylinders are stored
upright, chained and capped. Turn-off all cylinders
when not in use.
Clearing Jammed Material
• If material becomes jammed in the machinery:
—Immediately stop the machinery.
—Lockout/tagout power. Warn others that the
machinery is being serviced.