KPI-JCI FT4240 Troubleshooting guide

OperOper
OperOper
Operaa
aa
ation & Maintenancetion & Maintenance
tion & Maintenancetion & Maintenance
tion & Maintenance
FF
FF
Fastast
astast
ast TT
TT
Trr
rr
raxax
axax
ax
Impact CrImpact Cr
Impact CrImpact Cr
Impact Crushing Plantushing Plant
ushing Plantushing Plant
ushing Plant
HyHy
HyHy
Hydrdr
drdr
draulic Driaulic Dri
aulic Driaulic Dri
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IB-0271 9/09

SerialNumberPlate
Record your plant serial number and order number in the space below. Please
includethesenumberswhenrequestingserviceororderingreplacementparts.
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofitsconstituentsareknown tothe
state of California to cause cancer, birth defects, and other
reproductiveharm.
MANUFACTUREDBYKOLBERG-PIONEER, Inc. YANKTON,SD, U.S.A.
CopyrightKPI-JCI,INC.
2009
JOBORDER
MODEL S/N

Models Covered:
FT4240HydraulicDriveImpactCrushingPlant
FT4250HydraulicDriveImpactCrushingPlant
FF
FF
Fastast
astast
ast TT
TT
Trr
rr
rax Impactax Impact
ax Impactax Impact
ax Impact
CrCr
CrCr
Crushing Plantushing Plant
ushing Plantushing Plant
ushing Plant
HyHy
HyHy
Hydrdr
drdr
draulic Driaulic Dri
aulic Driaulic Dri
aulic Drivv
vv
vee
ee
e
OPERAOPERA
OPERAOPERA
OPERATION &TION &
TION &TION &
TION &
MAINTENANCEMAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE
MANUMANU
MANUMANU
MANUALAL
ALAL
AL

Printed in the USA
Allrightsreserved. Nopartofthismanualmaybereproduced
or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording or by any
informationstorageorretrievalsystem,withoutpermission
fromKPI-JCI.
Thismanualcontainsoperatinginstructionsandlubrication-
maintenance information. Application of this information
shouldmaximizetheperformanceandlifeofyourequipment
andminimize down time.
Safeandefficientoperationrequiresthat anyonewhowillbe
operatingormaintainingthisequipmentreadandunderstand
the safety, operation, maintenance and troubleshooting
informationcontainedintheoperator'smanual.
ContinuingimprovementandadvancementofKPI-JCIproducts
may cause changes to your equipment which may not be
reflectedin this publication.
KPI-JCI reserves the right to make changes or add
improvementsto its productsat any time,without incurring
any obligation to make such changes on previously
manufacturedequipment.
Althoughcarehasbeentakentoassuretheaccuracyofthis
publication, KPI-JCI does not assume any liability for loss,
damage or injury caused by errors or omissions.

0-30-3
0-30-3
0-3
ContentsContents
ContentsContents
Contents
Introductory Pages AboutThisManual 0-5
SerialNumber Plates 0-6
BuyingReplacement Parts 0-7
MaintenanceTechniquesandTools 0-8
Lubricantsand Fluids 0-9
Storage 0-12
DrawingList 0-13
Specifications Chapter 1
FT4240 1-1
FT4250 1-4
Introduction to the Impact
Crushing Plant Chapter 2
Orientation 2-1
HorizontalShaftImpactor 2-2
VibratingFeeder 2-4
4’ x 12’ Screen 2-5
RecirculatingConveyor 2-6
SideDeliveryConveyor/Magnet 2-7
Water Spray System 2-8
Tracks 2-10
FuelTank/Engine 2-11
ControlPanel 2-13
Hydraulic System 2-14
Safety Chapter 3 3-1
Application Chapter 4 4-1
Site Selection and Preparation Chapter 5 5-1
Engine Start-up and Shutdown Chapter 6 6-1
Cold Weather Startup Chapter 7 7-1
Unloading the Plant Chapter 8
Unloading 8-1
Plant Setup
SideDeliveryConveyor 8-2
AuxillaryConveyor 8-3
AdjustingBy-pass Chute 8-3
RecirculatingConveyor 8-4
ImpactorApron Settings 8-5
Preoperation/Operation Checklist Chapter 9 9-1
Operating Controls Chapter 10 10-1
Overload Protection System Chapter 11 11-1
Hydraulics Chapter 12
FT4240 12-1
FT4250 12-11

0-40-4
0-40-4
0-4
Adjustments Chapter 13
CleaningImpactorChamber 13-1
AdjustingFirst StageApron 13-2
AdjustingSecond StageApron 13-2
VibratingScreenStroke 13-4
BeltTraining 13-5
TrackTensioning 13-6
Timing 13-7
Conveyor Removal Chapter 14
RecirculatingConveyor 14-2
UnderscreenConveyor/Screen 14-2
CrossConveyor 14-6
UndercrusherConveyor 14-8
Maintenance Chapter 15
10hours 15-3
50hours 15-8
250hours 15-11
1000hours 15-12
2000hours 15-14
Asneeded 15-15
WearItems
BlowbarRotation 15-17
BlowbarInstallation 15-19
ApronWearTip Replacement 15-20
ScreenClothReplacement 15-21
BeltSpliceRetaining Collar/
AirFilter Replacement 15-22
Lubrication Chapter 16
10hours 16-2
50hours 16-4
250hours 16-5
1000hours 16-7
Hydraulic System Maintenance Chapter 17
10hours 17-2
50/250hours 17-4
500/1000hours 17-5
2000hours 17-6
RecommendedOil Viscositiesand
CorrespondingOilTemperatureper Oil Grade 17-7
Emissions Chapter 16
FT4240 18-1
FT4250 18-7
Appendix A AuxilliaryConveyorCapacities andHydraulic
Schematics
Appendix B OverloadProtectionSystem Parameters
Appendix C CATEngineDiagnostic Codes
Appendix D Electrical Schematics
Battery Maintenance Information

Purpose
Thepurposeofthismanual
istohelpyougetthebestvalue
fromyourequipment. Itcando
so by helping you decide what
workmustbedone,evenifyou
decide to have it done by a
dealerservicedepartmentora
repair shop. It also provides
informationandproceduresfor
routine maintenance and
servicing.
Using the Manual
The manual is divided into
chapters which are further
divided into numbered
sections, headed in bold type
between horizontallines. Each
section consists of
consecutively numbered
paragraphs.
About This Manual
Procedures, once
described in the text, are not
normally repeated. When it is
necessary to refer to another
chapter, the reference will be
given as chapter and section
number. Cross references
givenwithouttheword"chapter"
apply to sections and/or
paragraphs in the same
chapter,"seesection8"means
inthesamechapter.
Eventhoughthismanualhas
been prepared with extreme
care, KPI-JCI can not accept
responsibility for errors in, or
omissionsfromtheinformation
given.
SpecialNotations
Within this manual
procedures or situations that
require special attention are
indicated with the words,
DANGER,WARNING,
CAUTION and IMPORTANT.
DANGER, WARNING and
CAUTIONareusedtoindicate
proceduresorsituations where
personalsafetyisinvolved.
IMPORTANT is used to
indicate special procedures or
situationswhich,ifnotobserved,
could result in damage to the
equipment or affect the
operationofthemachine.
0-50-5
0-50-5
0-5

0-60-6
0-60-6
0-6
Modifications are a
continuing process in the
manufacture of this equipment.
Since replacement parts,
manuals,andlistsarecompiled
specifically for each unit, the
serial numbers are essential to
correctlyidentifythecomponent
required.
The serial number plate will
show the serial number, job
order number and model
number.
Serial Number Plates
KPI-JCI serial number plate.
Plant Serial Number
The serial number for the
plant is stamped on a plate
which is located inside the
hydrauliccontrolpanel.
The plant serial number is
the number that should be
referredtowhenorderingparts
orrequestingservice.
ComponentSerial Numbers
The serial number for the
vibratingfeeder,impactcrusher
andvibratingscreen isstamped
onaserialnumberplatewhich
isattachedtoeachcomponent
asshownbelow.
Serial Number Plate - Vibrating Feeder
Vibrating feeder
serial number plate
Impactor serial
number plate
Serial Number Plate - Horizontal Shaft Impactor
Serial Number Plate - Vibrating Screen
Vibrating screen
serial number plate Plant serial number
plate
Serial Number Plate - Plant

Authorized Dealer Parts
Department
An authorized dealer parts
department is the best source
forparts,particularlypartswhich
areuniquetothisequipment. If
you do not know who the
authorizeddealerisinyourarea
contact KPI-JCI. Dealerships
are located throughout the
United States and some parts
oftheworld.
Buying Replacement Parts
Purchased Components
Replacement parts for
componentspurchasedbyKPI-
JCI such as gear reducers,
electricmotorsandenginesare
available through your
authorized dealer. However,
items like engine parts are
typically not stocked by the
dealerorKPI-JCI.
Serial Number
Since replacement parts
manualsandlistsarecompiled
specifically for each unit, the
serialnumbersareessentialto
correctlyidentifythecomponent
required.
Typical tail pulley assembly parts page.
Typical motor drive assembly parts page.
0-70-7
0-70-7
0-7

0-80-8
0-80-8
0-8
Tools
Althoughaminimalnumber
of tools are needed for
operationandmaintenance,a
goodselectionofbasictoolsis
required.
Maintenance Techniques and Tools
WasteOilandFluids
Wasteoil andfluidsdrained
from the engine and hydraulic
system during normal
maintenance and repair can
presentadisposal problem.
To avoid pouring them on
the ground or into the sewage
system,pourtheusedfluidsinto
largecontainers,sealthemand
take them to an authorized
disposalorrecyclingcenter.
Fasteners
Typically, standard SAE
fastenersareused. Fasteners
arenuts,bolts,studsandscrews
usedtoholdtwoor moreparts
together.
All threaded fasteners
should be clean and straight,
with undamaged threads and
undamagedcornersonthehex
heads.
Itisagoodhabit toreplace
all damaged fasteners when
performingmaintenance,never
reuseadamagedfastener.
Speciallocknutswithnylon
insertscanonlybeusedonce.
If they are removed, they lose
theirlockingabilityandmustbe
replaced.
Rustednutsandboltsshould
be treated with a penetrating
fluid to ease removal and
preventbreakage. Badlyrusted
fasteners may have to be
chiseled,sawedortorchedoff.
Flat washers and
lockwashers, when removed
from an assembly, should
alwaysbe replaced exactly as
removed.
When replacing nuts and
bolts, besuretousethecorrect
grade. Never use a different
grade of bolt than the original
equipment.
Grade 8 or grade C prevailing
torque locknut
Grade marking standard SAE
bolts.
Grade 5 Grade 8

0-90-9
0-90-9
0-9
Lubricants and Fluids
Bearings, Pivot Points and
GeneralLubricant
HydraulicSystem
EP-2Lithium Based Grease
Hydrex MV60 Hydraulic Oil
For 0 degrees F to 100
degrees F (38 degrees C)
ambienttemperature,useISO
46withaviscosityindexabove
120.
For cold weather
temperatures, Hydrex MV15
canbe used.
Thelubricantsshown tothe
rightare"factoryfill"lubricants.
Otherlubricantsmaybeused,
provided they meet the
lubrication requirements
specified.
Bearings
Bearingsarelubricatedwith
ahightempEP-2lithiumbased
greasecontaining a tackiness
agent. Lube color is red.
Pivot Points
Pivot points are lubricated
usingthesamelubricantasthe
bearings. A high temp EP-2
lithium based grease
containing a tackiness agent.
Lube color is red.
HydraulicSystem
The hydraulic system is
factory filled with Hydrex MV
60, a good quality industrial
hydraulicoilwithawideviscosity
range. Thisoilcanbeusedwith
hydraulic systems that are
exposed to wide temperature
ranges.
If MV60 is not available,
KPI-JCI recommends using a
high quality oil with an
appropriateviscositybasedon
the ambient temperature the
plant will be operating in until
the next oil change. For 20
degrees F (-7 degrees C) to
120degreesF(49degreesC)
ambienttemperature,useISO
68withaviscosityindexabove
120.

0-100-10
0-100-10
0-10 Lubricants and Fluids
FT Units, Hydraulic Gear
Drive on Engine.
VibratingFeeder
ShaftBearings
NLGI 2 Synthetic Grease
NLGI 2 Mining Grease
AGMA 4 Gear Oil
VibratingFeederBearings
Vibrating feeder bearings
are lubricated with an NLGI 2
multipurpose, extreme
pressuresyntheticgrease.
HorizontalShaftImpactor
Horizontal shaft impactor
bearings are lubricated using
a high temperature lithium
complex extreme pressure
mininggrease.
HydraulicGearDrive
Thehydraulicgeardriveis
lubricated with an all purpose
EP 80W-90 gear oil.
HorizontalShaft
ImpactorBearings

Lubricants and Fluids
Vibrating Feeder Gear Box
Above +40OF
Track Drive Hubs On
Fast Trax Plants
SAE grade 50 Drive Train Oil
Track Drive Hubs
Drive hubs are lubricated
usinganextrahighperformance
SAE grade 50 drive train
lubricant.
VibratingFeeders
The vibrating feeder gear
box is filled with a high
performance gear oil having
extreme pressure
characteristics and load
carryingproperties.
For ambient temperatures
below +40OF (4.5 degrees C)
an ISO viscosity grade 150
shouldbeused.
For ambient temperatures
above +40OF (4.5 degrees C)
an ISO viscosity grade 220
shouldbeused.
ISO 150 Gear Oil
Vibrating Feeder Gear Box
Below +40OF
ISO 220 Gear Oil
0-110-11
0-110-11
0-11

0-120-12
0-120-12
0-12
When the impact crushing
plantwillnotbeusedforaperiod
of a few months, use the
followingprocedureforstorage
to minimize corrosion and
deterioration.
1. Removealldirt and debris
from the screen, feeder,
crusher,conveyorsandother
areas.
2. Lubricate all points as
specified in the
maintenancesectionofthis
manual.
Storage
3. Usespraylubricantonany
exposed cylinder rods to
preventrusting.
4. Tohelppreventcorrosion,
thefuelandhydraulictanks
shouldbefilled.
5. Replace all breather type
plugs and caps to prevent
dirt from entering the
system.
6. Covertheengineexhaust.
7. Bearings must be rotated
and lubricated to prevent
themfromdryingout.
8. Clean the outside of the
plantandrepaintanyareas
whereneeded.
9. Attach a tag to the plant
indicating what storage
procedures have been
done.
10.Every month the unit is in
storage,turnontheengine
and run it for 30 minutes to
keepthebatterycharged.

FT4250 Hydraulic Drive
Electricaldrawings
246743-1 FT4250layout
246743-2 Electricalassemblycontrolpanel
246743-3 FT4250switchwiring
Hydraulicdrawings
298142-1 Pumpsandtank
298142-2 Trackdrive-rightandleft
298142-3 Crusherdrive
298142-4 Vibrating feeder drive
298142-5 Set-upfunctionsandundercrusherconveyor
298142-6 20GPMstacker andsidedeliveryconveyor
298142-7 Closed circuit applications
FT4240 Hydraulic Drive
Electrical drawings
246743-1 FT4240layout
246743-2 Electricalassemblycontrolpanel
246743-3 FT4240switchwiring
Hydraulic drawings
298143-1 Pumpsandtank
298143-2 Trackdrive-rightandleft
298143-3 Crusherdrive
298143-4 Vibrating Feeder drive
298143-5 Set-upfunctionsandundercrusherconveyor
298143-6 20GPMstacker andsidedeliveryconveyor
298143-7 Screenandfinesconveyorandrecirculatingconveyor
Drawing List
0-130-13
0-130-13
0-13

1-11-1
1-11-1
1-1
Specifications - FT4240
66’-2”withscreen
(20.17m)
11’-5”
(3.48m)
Foldsdownfortravel
53’-1”withoutscreen
(16.18m)
Overall Length: 66’-2”withscreen
(20.17m)
53’1” withoutscreen
(16.18m)
Overall Width: 15’ 1” (4.6 m) with side
deliveryconveyor
Overall Height: 12’ 8” (3.86 m)
Travel Height: 11’5” (3.48 m)
Travel Width: 11’1 (3.38 m)
Weight: 99,000lbs. with screen
(43,091 kg)
Undercrusher
Conveyor: 5,250 lbs. (2381 kg)
Cross Conveyor/
Screen Support: 1,850 lbs. (839 kg)
Recirculating
Conveyor: 2,700 lbs. (1225 kg)
Side Delivery
Conveyor: 1,245 lbs. (565 kg)
Magnet: 4,300lbs. (1950 kg)
15’-1”
(4.6m)
11’-1”
(3.38m)
12’-8”
(3.86m)
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Specifications 1-21-2
1-21-2
1-2
40"
(1.02m)
H.P. Required: electric -150 (112 kw)
diesel - 190 (142 kw)
Rotor Speed: 450-600 rpm
Rotor Tip Speed: 6500fpm maximum
Weight: 24,500lbs.
(11,113 kg)
Rotor Diameter: 42” (1.07 m)
Rotor Width: 40” (1.02 m)
Blowbar weight: 400 lbs. each
(181 kg)
(approximate)
Inlet Opening: 40” x 38”
(1.02mx.91m)
92"
(2.34m)
87"
(2.21m)
38"
(.97 m)
84"
(2.13m)
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Speed : 1050rpmmax.
Operating angle : 20 degrees
1-31-3
1-31-3
1-3 Specifications
8”
H.P. Required: 30 hp (22 kw)
R.P.M.: 950rpmmax.
Feeder Weight: 7,200 lbs. (3,266 kg)
Feeder Hopper: 5,500lbs.
(2,495 kg)
Length of grizzly: 4’straight (1.22 m)
Timing: 60 degrees from
horizontal
PSI: 3045
Length of solid
pan deck: 10’(3.05m)
Wear Plate: 3/8” thickAR 400
12’
(3.66m)
4’
(1.22m)
14’
(4.27m)
Underscreen/Screen
Conveyor Weight: 7,685lbs.
(3,486 kg)
4 x 12 Double Deck Screen
40" x 14' Feeder
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1-41-4
1-41-4
1-4
Overall Length: 67’with screen (6.45 m)
53’-6”without screen
(5.05m)
Overall Width: 16’-2”
(4.93m)
Overall Height: 12’-7”
(3.84m)
Travel Height: 11’-6”
(3.51m)
Travel Width: 12’
(3.66m)
Specifications - FT4250
12’-7”
(3.84m)
67’with screen
(20.42m)
37’-5”
(11.40m)
11’-5”
(3.48m)
Foldsdownfortravel
12’
(3.66m)
16’-2”
(4.93m)
53’-6” withoutscreen
(16.31m)
Weight: 117,500lbs.with screen
(53,297 kg)
94,000lbs. without screen
(42,637 kg)
Undercrusher
Conveyor: 8,000 lbs. (3,628 kg)
Cross Conveyor/
Screen Support: 2,450 lbs. (1,111 kg)
Recirculating
Conveyor: 2,700 lbs. (1224 kg)
Side Delivery
Conveyor: 1,750 lbs. (794 kg)
Magnet: 4,300 lbs. (1950 kg)
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Specifications
H.P. Required: electric - 200 (149 kw)
diesel - 265 (198 kw)
Rotor Speed: 450-600 rpm
Rotor Tip Speed: 6500 fpmmaximum
Weight: 28,200lb.
(12,792 kg)
Rotor Diameter: 42"
Rotor Width: 50"
Blowbar Weight: 550 lbs. each
(249.48 kg)
(approximately)
Inlet Opening: 50" x 38"
92"
(2.34m) 50"
(1.27m)
96"
(2.44m)
87"
(2.21m)
1-51-5
1-51-5
1-5
38”
(.97m)
5 x 12 Single Deck Screen
Speed: 1050rpmmax.
12’
(3.66m)
5’
(1.52m)
Underscreen Conveyor/
Screen Weight: 9,500lbs.
(4,309 kg)
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