KPI-JCI 1016 Troubleshooting guide

page
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

page
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

page
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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page 1
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.

page 2
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

page 3
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

page
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.

page
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.
5

page
SAFETY DECALS
CAUTION: Safety decals are
provided for your personal safety.
If they should become damaged,
they must be replaced. Contact
your local dealer, or the factory at:
605-665-8771.
The following illustrations are shown to
help identify decals to be replaced. Make
sure machine surface is clean and free from
grease and oil before applying decal.
6
Decal, Loading Area
Part No. BB-64826
One each side
Decal, Moving Machinery
Part No. BB-64825
One each side

page 7
OPERATING PRINCIPLES
In this type of crusher a moving jaw is
attached to the pitman, a large pendulum- like
casting, which is mounted at its upper end
with bearings on an eccentric shaft fixed with
another set of bearings to the top of the
crusher base.
The material to be processed is fed into the
crusher hopper directly above the crushing
chamber. The material is reduced in size
as it moves further down into the crushing
chamber and is finally discharged directly
below the crusher.
Feed size is limited to 80% of the jaw gap.
Product size is controlled by adjusting the
closed side setting at the bottom of the jaw
crusher. This setting is adjusted using a set
of shims to increase or decrease discharge
opening. The closed side setting is
adjustable between 2" to 5" for the 1536, 2"
to 4" on 1654, 3" to 6" on 2036, 4" to 8" on
2436 and 4" to 8" on the 3042.
The rotating eccentric shaft induces an oval
motion, each rotation of the shaft causes it
to move toward the stationary jaw and
downward. It is this motion which causes
the material fed into the chamber to be
crushed.
Crusher setting
or Closed
Side Setting
Crushing
Chamber
Oval motion
created
by rotating
shaft
Eccentric
Shaft
Flywheel Rotation
Stationary
Jaw
Moving Jaw
Pitman
Width
Gap
Crushing Chamber
fig. 1
The space between the stationary and
moving jaw is called the crushing chamber.
The opening at the top of the crushing
chamber has fixed dimensions, but the
distance between the stationary jaw and the
moving jaw at the bottom of the crushing
chamber can be varied.
The distance between the two jaws is known
as the jaw crusher setting. It is also referred
to as the closed side setting, or the distance
between the two jaws in their closest
eccentric position measured from peak to
valley.
Jaw Crusher
fig. 2

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MACHINE PARTS DESCRIPTION
8
The following is a brief description of the
jaw crusher's basic parts and their function. Eccentric Shaft The eccentric shaft translates circular motion
into the crushing action of the moving jaw.
The shaft revolves in two roller bearings
mounted at the top of the frame. The center
portion of the shaft is eccentric and carries
the pitman on two inner roller bearings.
Base
The base contains the crushing chamber
between the stationary jaw and the moving
jaw. Steel saddles at the top of the base
supporttheeccentric shaftassemblyand the
pitman. The lower rear section contains the
adjustingmechanismandsupportsthetension
rod assembly. Abrasion resistant steel key
plates and heel plates, bolted to the sides of
thebase,holdthe stationary jaw in placewith
a wedging action and also act as wear plates
to protect the sides of the base.
Eccentric Shaft
Stationary Jaw
Key Plate
Heel Plate
Pitman
Base
Tension Rods
Moving Jaw
Adjusting Mechanism
This mechanism sets the opening at the
bottom of the jaws. Adjustments are made
by moving the toggle block and adding or
removing shims.
Pitman
The pitman carries the moving jaw and
moves in an oval path from the rotation of
the eccentric shaft.
fig.3
Toggle Plate
Pivot Block
Adjusting
Mechanism

page 9
Tension Rods
The tension rod assembly is a threaded rod
extending through a spring. This assembly
pulls the pitman back against the toggle
plate, holding it in place.
Toggle Plate
The toggle plate positions the lower end of
the pitman and acts as an overload device
that will break when excessive pressures
are present.
Thrust Blocks
Split thrust blocks, bolted inside the base
expandwhentightened,clampingtheendsof
the toggle seat to eliminate play between the
base and the adjustable toggle seat.
Jaws
Thejawdiesprovideahardenedsteelsurface
tocrushtherocksagainst. Thestationaryjaw
fitsontheinsidefrontfaceofthebaseandthe
moving jaw is bolted to the pitman. Jaws are
reversible top to bottom for extended jaw life.
Key & Heel Plates
The key and heel plates, which are made of
abrasion resistant steel, line the sides of the
base for wear. They also hold the stationary
jawby awedging actionbetween thejaw and
the pivot blocks welded to the sides of the
base.
Flywheels
Theflywheelsstoreenergytoprovidesmooth
operation when surges of material enter the
crusher. One of the two flywheels is grooved
for V-Belts, to drive the crusher.
MACHINE PARTS DESCRIPTION
Eccentric Shaft
Adjusting
Mechanism
Stationary Jaw
Key Plate
Heel Plate
Pitman
Base
Tension Rods
Toggle Plate
Moving Jaw
fig. 4

page 10
System Filter
Trabon Block
fig. 6
PioneerJawCrushersuseoneoftwotypesof
lubricationsystems: greasetypeorcirculating
oil type.
Grease Type System
The grease type system uses a self purging
seal which allows contaminants to be forced
out when fresh grease is added.
Cirulating Oil Lubrication System
The circulating oil system uses a circulating
oil pump to provide continuous lubrication to
the bearings. A filter system removes
impurities from the oil as it circulates.
There are two types of circulating oil systems
used. One type uses a flow indicator which
indicatesif oilflowispresent. Ifnofloworlow
flowisshownontheflowmeter,itisanindication
ofaproblemwiththecirculatingoilsystem.
The other type of system available uses a
modular centralized lubrication.
Pressure Lines
Circulating Oil Pump
System Filter
Oil Tank Drain Plug
Oil Supply Tank
MACHINE PARTS DESCRIPTION
fig. 5
Return Lines
Flow Meters
Thistypeofsystemutilizesamodularblockto
distribute oil to the bearings.

page
F
SPECIFICATIONS - 1536 Jaw Crusher
Bolt Dia.
C
DE
G
H
KM
L
J
RP
N
fig. 7
B
A
11
* Capacities and weights may vary.
CAPACITY
Crusher Setting
(Closed Side Setting) 2"
54
2 1/2"
68
4"
109
3"
81
5"
136
F - 36"
G - 50"
H - 37 3/4"
J - 67 1/2"
K - 24 3/8"
Stroke - 1 1/4"
Operating Speed - 290 RPM Max.
H.P. Reqd. - 75 Elect.-110 Diesel
A - 22 1/2"
B - 38"
C - 8'-2 1/2"
D - 7 3/4"
E - 5 3/4"
*Weight - 17,300 lbs
Moving Jaw Length - 38 3/4"
Stationary Jaw Length - 35"
L - 66 1/4"
M - 39 7/8"
N - 55"
P - 47"
R - 1 1/8"
* Tons per Hour

page
fig. 8
12
* Capacities and weights may vary.
CAPACITY
Crusher Setting
(Closed Side Setting) 2"
81
2 1/2"
102
3 1/2"
142
3"
122
4"
163
F - 44 1/2"
G - 72"
H - 18 1/2"
J - 55"
K - 36 1/2"
Stroke - 1 1/4"
Operating Speed - 300 RPM Max.
H.P. Reqd. - 125 Elect.-175 Diesel
A - 28 3/4"
B - 49 1/2"
C - 106 7/16"
D - 7/8"
E - 50 1/4"
*Weight - 30,690 lb
Moving Jaw Length - 38 3/4"
Stationary Jaw Length - 35"
L - 73 1/2"
M - 69 1/2"
R - 1 3/8"
* Tons per Hour
SPECIFICATIONS - 1654 Jaw Crusher
F
HK
J
B
ACD
E
G
E
Bolt Dia.
R
D
M
L

page
fig. 9
Bolt Dia.
ABD
G
HJ
KPN
F
R
CE
M
L
SPECIFICATIONS - 2036 Jaw Crusher
13
* Capacities and weights may vary.
3"
93
4"
124
5"
156
6"
187
CAPACITY
Crusher Setting
(Closed Side Setting)
Stroke - 1 1/4"
Operating Speed - 270 RPM Max.
H.P. Reqd. - 100 Elect. 140 Diesel
*Weight - 20,750 lbs
Moving Jaw Length - 42"
Stationary Jaw Length - 40"
F - 36"
G - 50"
H - 45 3/4"
J - 72 1/4"
K - 20"
A - 23"
B - 43 1/2"
C - 8'-2 1/2"
D - 7 3/4"
E - 5 3/4"
L - 60 5/8"
M - 37 5/8"
N - 53 1/2"
P - 47 1/8"
R - 1 1/8"
* Tons per Hour

page
fig. 10
Bolt Dia.
ABC
DE
G
HJ
KLMPN
R
F
* Capacities and weights may vary.
CAPACITY
Crusher Setting
(Closed Side Setting)
SPECIFICATIONS - 2436 Jaw Crusher
14
F - 50"
G - 50"
H - 55"
J - 82 3/4"
K - 17 1/2"
A - 23 1/2"
B - 53 1/2"
C - 8'-6 1/2"
D - 5 3/4"
E - 5 3/4"
L - 67 1/2"
M - 44"
N - 55 1/2"
P - 51 1/2"
R - 1 1/8"
4"
136
5"
171
6"
205
7"
239
8"
273
* Tons per Hour
*Weight - 29,400 lbs
Moving Jaw Length - 54 3/4"
Stationary Jaw length - 48"
Stroke - 1 1/4"
Operating Speed - 260 RPM Max.
H.P. Reqd. - 100 Elect. 150 Diesel

page
CAPACITY
Crusher Setting
(Closed Side Setting)
* Tons per Hour
4"
178
* Capacities and weights may vary.
5"
223
6"
268
7"
313
8"
357
fig. 11
R
Bolt Dia.
ABC
DE
G
HJ
KMPN
F
L
SPECIFICATIONS - 3042 Jaw Crusher
15
L - 80"
M - 50 1/2"
N - 70 1/2"
P - 58 1/2"
R - 1 1/2"
A - 29 1/2"
B - 63 1/2"
C - 8'-7 1/2"
D - 0
E - 0
F - 50 1/4"
G - 50 1/4"
H - 69"
J - 7'-9 5/8"
K - 21 1/2"
Stroke - 1 1/4"
Operating Speed - 260 RPM Max.
H.P. Reqd. - 150 Elect. 190 Diesel
*Weight - 43,500 lbs
Moving Jaw Depth - 65"
Stationary Jaw Depth - 60"