KPI-JCI 8203FP User manual

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax [phone]
24/7 Parts Number 888-474-0115
Screening Plant Operation Manual
and Parts Book
Model 8203FP

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03
SECTION 1: INTRODUCTION
Description...................................................................................................................................................... 1
Fast Pack Operation Manual..................................................................................................................... 4
New parts and equipment warranty................................................................................................................ 4
Disclaimer/Limitation of Warranties........................................................................................................... 4
Address for Notices........................................................................................................................................ 5
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
Chains.................................................................................................................................................. 16

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03
Fiber Or Synthetic Slings ..................................................................................................................... 16
Transporting Machinery.................................................................................................................................. 16
Conveyor Safety............................................................................................................................................. 17
Safety Decals ................................................................................................................................................. 19
Scalping Plant Right-Hand Side................................................................................................................ 25
Scalping Plant Left-Hand Side .................................................................................................................. 26
SECTION 3: SPECIFICATIONS
Screen Plant Specification.............................................................................................................................. 29
Operation Dimension................................................................................................................................. 29
Travel Dimensions..................................................................................................................................... 31
Capacities.................................................................................................................................................. 32
Conveyor Widths....................................................................................................................................... 32
Engine....................................................................................................................................................... 32
Batteries.................................................................................................................................................... 32
Component Weights.................................................................................................................................. 32
Relief Pressures........................................................................................................................................ 32
SECTION 4: CONTROLS AND INDICATORS
Introduction..................................................................................................................................................... 33
Screen Plant Control and Indicator Location............................................................................................. 34
Travel and Set-up Controls, Indicators, and Gauges ..................................................................................... 36
Suspension System................................................................................................................................... 36
Air Bag Pressure.................................................................................................................................. 36
Air Bag Pressure Gauge...................................................................................................................... 36
Height Control Valve............................................................................................................................ 36
Height Adjust Valve.............................................................................................................................. 36
Self Steering Axle Pressure Value....................................................................................................... 36
Self Steering Axle Pressure Gauge ..................................................................................................... 36
Self-Steering Axle Lock Value.............................................................................................................. 37
Hydraulic System Controls........................................................................................................................ 37
Hydraulic Level Operation......................................................................................................................... 37
Hydraulic Stabilizer Control Bank......................................................................................................... 38
Stabilizer Locations.............................................................................................................................. 38
Hydraulic Jack Control Bank................................................................................................................ 39
Jack Laotians....................................................................................................................................... 39
Operational Controls, Indicators, and Gauges ............................................................................................... 39
Plant Emergency Stop (E-Stop) Switches and Warning Horns ................................................................ 39
Emergency Stop (E-Stop) Switches..................................................................................................... 39
Warning Horns..................................................................................................................................... 40
Battery Isolation (ISO) Switch .................................................................................................................. 40
60 Amp Circuit Breaker............................................................................................................................. 40
Generator Shut Off Switch ........................................................................................................................ 41
Fuel Gauge................................................................................................................................................ 41
Air Intake Restriction Indication................................................................................................................. 41
Profinet Connection................................................................................................................................... 41
Electrical Connections............................................................................................................................... 42
Conveyors and Walkways Hydraulic Controls........................................................................................... 43
Conveyor Adjustments......................................................................................................................... 43
Walkway Adjustments.......................................................................................................................... 43
Blending Chute Controls ........................................................................................................................... 43

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03
Hydraulic Power Unit................................................................................................................................. 44
Hydraulic Filter Gauge............................................................................................................................... 44
Hydraulic System PSI Gauge.................................................................................................................... 44
Hydraulic Fluid Temperature Gauge ......................................................................................................... 44
Engine Control Panel ................................................................................................................................ 45
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 Adjust Switch......................................................................................................... 48
Control Panel Switch Operation ................................................................................................................ 48
Finishing Plant Electrical Panel................................................................................................................. 49
Circuit Breakers.................................................................................................................................... 50
Starter and Overload Breaker .............................................................................................................. 50
Scalping Plant Electrical Panel.................................................................................................................. 51
Control Panel Switch Operation........................................................................................................... 52
Finishing Plant Control Panel.................................................................................................................... 53
Transfer Conveyor Start/Stop Switch................................................................................................... 53
Left-Hand Under Screen Conveyor Forward Start/Stop Switch........................................................... 53
Left-hand Under Screen Conveyor Reverse Start/Stop Switch ........................................................... 53
Right-Hand Under Screen Conveyor Forward Start/Stop Switch......................................................... 53
Right-Hand Under Screen Conveyor Reverse Start/Stop Switch ........................................................ 53
Top Deck Conveyor Start/Stop Switch................................................................................................. 53
Local / Remote Switch ......................................................................................................................... 54
Screen Start/Stop Switch ..................................................................................................................... 54
Side Discharge Conveyor Front Start/Stop Switch .............................................................................. 54
Side Discharge Conveyor Middle Start/Stop Switch ............................................................................ 54
Side Discharge Conveyor Rear Start/Stop Switch............................................................................... 54
Hydraulic Pump Start/Stop Switch ....................................................................................................... 54
Emergency Stop Switch....................................................................................................................... 54
Warning Horn Button............................................................................................................................ 55
Scalping Plant Control Panel..................................................................................................................... 56
Left-Hand Under Screen Conveyor Start/Stop Switch ......................................................................... 56
Right-Hand Under Screen Conveyor Start/Stop Switch....................................................................... 56
Top Deck Conveyor Start/Stop Switch................................................................................................. 56
Screen Start/Stop Switch ..................................................................................................................... 56
Side Discharge Conveyor Front Start/Stop Switch .............................................................................. 56
Side Discharge Conveyor Middle Start/Stop Switch ............................................................................ 56
Side Discharge Conveyor Rear Start/Stop Switch............................................................................... 56
Hydraulic Pump Start/Stop Switch ....................................................................................................... 57
Emergency Stop Switch....................................................................................................................... 57
Warning Horn Button............................................................................................................................ 57
Local / Remote Switch ......................................................................................................................... 57