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

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03
SECTION 5: SET-UP
Introduction..................................................................................................................................................... 59
Proper Site Selection................................................................................................................................. 59
Plant Alignment Procedures...................................................................................................................... 59
Engine Start-Up.............................................................................................................................................. 59
Plant Pre-Start Checks.............................................................................................................................. 59
Plant Pre-Start Checks.............................................................................................................................. 61
Engine Start Up Procedures........................................................................................................................... 62
Removing the Bag House Shipping Cover................................................................................................ 62
Plant Set-Up................................................................................................................................................... 63
Conveyor Unfolding Considerations.......................................................................................................... 63
Connecting Profinet System...................................................................................................................... 64
Remotely Controlling Your Plant.......................................................................................................... 64
Non-Network Plant Operation.............................................................................................................. 64
Spray System Hook-Ups........................................................................................................................... 65
Additional Set-up Information......................................................................................................................... 66
Adjusting Screen Drive V-Belts................................................................................................................. 66
General Conveyor Information.................................................................................................................. 66
Conveyor Belt Training......................................................................................................................... 66
Adjusting Belt Side Creep.................................................................................................................... 67
Conveyor Loading................................................................................................................................ 68
Moving a Discharge Conveyor ................................................................................................................. 68
Relieving The Hydraulic System Pressure........................................................................................... 69
To move a conveyor:............................................................................................................................ 69
SECTION 6: OPERATION
Introduction..................................................................................................................................................... 71
Fast Pack Pre-Start Checks........................................................................................................................... 71
Fast Pack Plant Pre-Start Checks............................................................................................................. 71
Conveyor Pre-Start Checks....................................................................................................................... 71
Screen Pre-Start Checks........................................................................................................................... 71
Fast Pack Start-up Procedures ...................................................................................................................... 71
Screen Plant Engine and Generator Set Starting Procedures .................................................................. 72
Fast Pack Post Start-up Checks ............................................................................................................... 73
Fast Pack Start-Up Sequence................................................................................................................... 73
Fast Pack Shut Down Procedures.................................................................................................................. 73
Restarting the Fast Pack After Emergency Stop Activation ........................................................................... 73
Moving the Fast Pack Plant............................................................................................................................ 73
Fast Pack Tear Down................................................................................................................................ 73
SECTION 7: MAINTENANCE
Introduction..................................................................................................................................................... 75
Maintenance Safety................................................................................................................................... 76
Oil Recommendations.................................................................................................................................... 76
Grease Recommendations........................................................................................................................ 76
Hydraulic Oil Recommendations............................................................................................................... 76
Scheduled Maintenance................................................................................................................................. 76
Plant Grease Lubrication Items...................................................................................................................... 77
Scheduled Grease Lubrication Items........................................................................................................ 78
Scheduled Grease Lubrication Items........................................................................................................ 78

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03
Fast Pack Plant Daily Walk Around Inspection Checklist............................................................................... 79
Maintenance Schedules................................................................................................................................. 80
Weekly Or Every 50 Hours of Operation.............................................................................................. 80
Monthly or Every 200 Hours of Operation............................................................................................ 80
Every 500 Hours of Operation.............................................................................................................. 80
Every 1000 Hours of Operation............................................................................................................ 80
Yearly or Every 2000 Hours of Operation ............................................................................................ 80
Daily Walk Around Items ................................................................................................................................ 80
Engine Oil Level........................................................................................................................................ 81
Engine Coolant Level................................................................................................................................ 81
Drain the Fuel Water Separator. ............................................................................................................... 82
Engine Charge Air Cleaner ....................................................................................................................... 82
Restriction Indicator................................................................................................................................... 82
Hydraulic Power Unit................................................................................................................................. 83
Profinet System......................................................................................................................................... 83
Engine Fuel Level...................................................................................................................................... 83
Relieving the Hydraulic System Pressure ...................................................................................................... 84
Hydraulic Hoses and Connections ............................................................................................................ 84
Weekly Or Every 50 Hours of Operation........................................................................................................ 85
Adjusting Drive V-Belts.............................................................................................................................. 85
Battery Maintenance ................................................................................................................................. 86
Radiator and Cooler Core.................................................................................................................... 87
Conveyor Checks...................................................................................................................................... 87
Monthly or Every 200 Hours of Operation...................................................................................................... 87
Hydraulic Oil.............................................................................................................................................. 87
Every 1000 Hours of Operation...................................................................................................................... 88
Hydraulic Oil Filter..................................................................................................................................... 88
Yearly or Every 2000 Hours of Operation....................................................................................................... 88
Fluid Coupling Oil...................................................................................................................................... 88
Hydraulic Oil.............................................................................................................................................. 88
Additional Maintenance items......................................................................................................................... 88
Lubrication of the Gear Reducer ............................................................................................................... 88
Maintenance Recommendations.......................................................................................................... 89
Oil Recommendations.......................................................................................................................... 89
How to Repair a Broken Conveyor Belt.......................................................................................................... 90
How to Measure for the Proper Length ..................................................................................................... 90
How to Square the Ends ........................................................................................................................... 90
How to Drill and Skive Your Conveyor Belt............................................................................................... 91
How to Attach the Belt Ends...................................................................................................................... 93
Using the Flexco 840 Belt Cutter ......................................................................................................... 95

Table of Contents
Fast Pack Operation and Service Manual
Rev. 03

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, therefore you may not be using all of
the 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-steeringaxlesfor
easy towing.

Section 1: Introduction
2Rev 03
Fast Pack Operation and Service Manual