KPI-JCI 1016 Troubleshooting guide

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Operation & Maintenance
IB-1013 4/10
OPERATION &
MAINTENANCE
CRUSHING & SCREENINGCRUSHING & SCREENING
CRUSHING & SCREENINGCRUSHING & SCREENING
CRUSHING & SCREENING
Legendary Jaw CrusherLegendary Jaw Crusher
Legendary Jaw CrusherLegendary Jaw Crusher
Legendary Jaw Crusher

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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the state of California to cause cancer, birth defects, and
other reproductive harm.
Copyright KOLBERG-PIONEER, INC.
2000
Record your Jaw Crusher serial number and order number in the space provided below. You
will find the serial number plate located beneath the main support cross tube at the rear of the
crusher. Please include these numbers when requesting service or ordering replacement
parts.
JOB ORDER
MODEL S/N
MANUFACTURED BY KOLBERG-PIONEER, INC. YANKTON, SD, U.S.A.
Serial Number Plate Location
Rear Front
Right Side

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INTRODUCTION
Thisbulletincontainsoperatinginstructionsandlubrication-maintenanceinformation. Applicationofthisinformation
should maximize the performance and life of your equipment and minimize down time.
Safeandefficientoperationrequiresthatyouandanyoneelsewhowillbeoperatingormaintainingthisequipment
read and understand the safety, operation, maintenance and troubleshooting information contained in the
operator's manual.
Continuing improvement and advancement of KOLBERG-PIONEER Products may cause changes to your
equipment which may not be reflected in this publication.
KOLBERG-PIONEER, Inc. reserves the right to make changes or add improvements to its products at any time,
without incurring any obligation to make such changes on previously manufactured equipment.
Although care has been taken to assure the accuracy of this publication, KOLBERG-PIONEER, Inc. does not
assume any liability for errors or omissions.

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CONTENTS
Safety
Safety Symbol 1
Safety Precautions 2-4
Sign-Off Form 5
Decals 6
Operating Principles 7
Machine Parts Description 8-10
Specifications 11-16
CrushingAggregate 17-18
Set-Up
Site Selection 19
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LiftingCrusher 19-20
Feed Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Discharge Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive 21
BalancingFlywheels................. ............ 22
PreoperationCheck 23
Operation 24-25
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CONTENTS
Adjustments
Jaw Crusher Closed Side Setting 26-27
Wear Part Replacement
MovingJaw 28
StationaryJaw 29-30
Heel & Key Plates 30-31
TogglePlate 31-32
ToggleSeats 33
Maintenance
General 34
MaintenanceChart 35
Daily 36-39
50Hours 40
200Hours 41-42
1000Hours 43-44
MaintenanceRecord 45-46
Storage 47
Troubleshooting 48
Service - Removing Pitman Assembly . . . . . . . . . . . . . . 49-52
Service- Pitman ShaftDisassembly . .. . .. . .. . .. . .. . 53-58
Service - Pitman Shaft Assembly . . . . . . . . . . . . . . . . . . 59-74
Service-InstallingPitman Assembly . .... . . ... . . . ...75-77
Service-InstallingFlywheelAssembly. . . . . .........78-79
LubricationSpecifications 80-81
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SAFETY SYMBOL
This symbol is used to bring attention
tosafetyprecautionsandinstructions.
When you see this symbol, be alert and pay
attention to all instructions.
YOUR PERSONAL SAFETY IS INVOLVED.
Most accidents are caused by failure to
observebasicsafety rules orprecautions. An
accidentcanoftenbe avoided by recognizing
potentially hazardous situations before an
accident occurs.
Improper operation is dangerous and could
resultininjuryordeath.
Basic safety precautions are outlined in the
“SAFETY PRECAUTIONS” portion of this
bulletin and in the description of operations
where hazards exist.
Warningdecalshavealsobeenplacedonthe
equipment to provide instructions and to
identifyspecifichazardswhich,ifnotheeded,
could cause bodily injury or death to you or
other persons.
KOLBERG-PIONEER, Inc. cannot anticipate
everypossiblecircumstancethatmightinvolve
a potential hazard. The warnings in this
publicationandontheequipmentaretherefore
not all inclusive.
Ifanoperationisnotperformedasspecifically
recommendedbyKOLBERG-PIONEER,Inc.
youmustsatisfyyourself that it is safeforyou
and others. You should also ensure that the
equipment will not be damaged or made
unsafebythemethodofoperationyouchoose.
The following signal words may be used in
this manual to designate a degree or level of
hazard and are defined as follows.
Imminently hazardous situation which, if not
avoided, will result in death or hazardous
injury.
Apotentially hazardoussituationwhich,ifnot
avoided,couldresultindeathorseriousinjury.
IMPORTANT
Specific practices that are critical to the
operation or maintenance of the equipment.
Apotentially hazardous situation which,if not
avoided, may result in minor or moderate
injury. It may also be used to alert against
unsafe practices.
BE ALERT ! YOUR SAFETY IS INVOLVED
WARNING
CAUTION
DANGER
CAUTION: Read and understand
all safety precautions and
warnings before operating this
equipment.

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The safe operation and maintenance of the
JawCrusheristheresponsibilityoftheowner/
employer and the operator/employee.
Theowner/employermustensurethatanyone
whooperates,maintains,services,transports
orworksaroundthejawcrusherisfamiliarwith
operation,maintenanceandsafetyprocedures
andinformationoutlinedinthismanual.
Owner/Employer's Responsibility
It is the owner/operator's responsibility to
insure everyone operating the equipment is
familiar with safe operation and maintenance
oftheJawCrusher. Donotriskinjuryordeath
byignoringsafetypracticesorfailingtoinstruct.
It is the owner's responsibility to give the
operator or employee instruction before
allowing them to operate, service, transport
orworkaroundthejawcrusher. Thisinstruction
shouldbereviewedatleastannually.
Operator/Employee's Responsibility
It is the operator's responsibility to read,
understand and follow all operation, service
and safety information presented in this
manualandonthejawcrusher.
Untrained operators and maintenance
personnel are a hazard to themselves and
others and are not qualified to operate or
servicethejawcrusher.
Never modify the jaw crusher in any way.
Unauthorized modifications can affect the
functionand/orsafeoperationandlifeofthejaw
crusher.
The following section presents material on
specificsafetyitems. Althoughspecificsafety
guidelinesare given, eachsituation can have
its own peculiarities which can not always be
covered by specific rules.
General Safety
1. Read and understand the Operator's
Manual before operating, servicing or
working around this machine.
2. Have a first aid kit available and know
how to use it.
3. Have a fire extinguisher available and
know how to use it.
4. Wear necessary protective gear,
including but not limited to:
a. Hard hat
b. Protective shoes with slip resistant
soles
c. Eye protection
d. Protective gloves
e. Hearing protection
f. Respirator or filter mask
5. Check and secure all guards before
operating. Repair or replace any
damaged or missing guards or
guarding devices.
6. Repair or replace any damaged
handrails, ladders or walkways.
7. Place all controls in neutral, stop
engine,removeignitionkey,followlock
out/tagout procedure and wait for all
motion to stop before lubricating,
adjusting or servicing.
8. Reviewsafetypracticesannually.
SAFETY

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Assembly Safety
1. Assemble in an area with sufficient
spacetohandlethelargestcomponent
andaccesstoallsidesofthemachine.
2. Use only cranes, jacks and tools with
sufficient capacity.
3. Donotallowspectatorsintheassembly
area.
Maintenance Safety
1. Itistheowner/operator'sresponsibility
to provide a safe method of access to
service areas.
2. Read and understand the Operator's
Manualbeforelubricating,servicingor
working around this machine.
3. Place all controls in neutral, stop
engine,removeignitionkey,followlock
out/tagout procedure and wait for all
motion to stop before lubricating,
adjusting or servicing.
4. Follow good shop practices.
5. Make sure all guards are in place and
properly secured when maintenance
work is completed.
6. Neverwearpoorfitting,baggyorfrayed
clothing when working around or on
any of the drive system components.
7. Keep hands, feet, hair and clothing
away from moving or rotating parts.
8. Clear the area of bystanders when
carrying out any maintenance or
adjusting.
Operating Safety Area
1. Keep away from loading area.
2. Keep away from discharge end.
3. Always be aware of the location of
other personnel and keep them away
from hazard areas.
9. Keep hands, feet, hair and clothing
away from moving parts.
10.Cleartheareaofpeoplebeforestarting
the Jaw Crusher. Keep people away
from the Jaw Crusher and loading
hopper area while operating.
11.Never operate the Jaw Crusher if it
has been damaged.
SAFETY

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SAFETY
4
Transport Safety
1. Make sure you are in compliance with
all local regulations regarding
transportingequipmentonpublicroads
and highways.
2. Make sure that all the lights and
reflectorsthatarerequiredbythelocal
highwayandtransportationauthorities
are in place, are clean and can be
seen clearly by all overtaking and
oncoming traffic.
3. Do not allow anyone to ride on the
jawcrusherduringtransport.
4. Do not exceed 45 mph when
transporting the machine. Reduce
speed on rough roads and surfaces.
5. Install lighting bar when transporting.
6. The machine is not grounded.
Electrocution can occur without direct
contact. Stay away from overhead
power lines.

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SIGN-OFF FORM
Anyone who will be operating and/or
maintaining the jaw crusher must read and
clearly understand all safety, operating and
maintenance information presented in this
manual.
Donotoperateorallowanyoneelsetooperate
this equipment until this manual has been
read and clearly understood.
A sign-off sheet has been provided for your
recordkeepingtoshowthatallpersonnelwho
willbeworkingwiththisequipmenthaveread
andunderstandtheinformationinthismanual
and that they have been instructed in the
operation of this equipment.
This manual should be reviewed at least
annually.
Date of review and
training completion Trainee Signature Trainer Signature
The following personnel have reviewed and have been trained in the proper operation and
maintenanceofthejawcrusher.
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