KPI-JCI FT3055 Manual

OPERATION &
MAINTENANCE
IB-300706/12
FT3055 TRACK MOUNTFT3055 TRACK MOUNT
FT3055 TRACK MOUNTFT3055 TRACK MOUNT
FT3055 TRACK MOUNT
Jaw CrusherJaw Crusher
Jaw CrusherJaw Crusher
Jaw Crusher

Serial Number Plate
Record your machine serial number and order number in the space below. Please include these
numbers when requesting service or ordering replacement parts.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the state of California to cause
cancer, birth defects, andother reproductive harm.
MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A.
JOB ORDER
MODEL S/N
CopyrightKPI-JCI
2012
MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A.
JOB ORDER
MODEL S/N

Models Covered:
FT3055TrackMountedJawCrusher
FF
FF
Fastast
astast
ast TT
TT
Trr
rr
rax Jax J
ax Jax J
ax Jaa
aa
aww
ww
w
CrCr
CrCr
Crushing Plantushing Plant
ushing Plantushing Plant
ushing Plant
OPERAOPERA
OPERAOPERA
OPERATION &TION &
TION &TION &
TION &
MAINTENMAINTEN
MAINTENMAINTEN
MAINTENANCE MANUANCE MANU
ANCE MANUANCE MANU
ANCE MANUALAL
ALAL
AL

Printed in the USA
All rights reserved. No part of this manual may be
reproduced or transmitted in any form or by any means,
electronicormechanical,includingphotocopying,recording
or by any information storage or retrieval system, without
permission from KPI-JCI.
Thismanualcontainsoperatinginstructionsandlubrication-
maintenance information. Application of this information
should maximize the performance and life of your
equipment and minimize down time.
Safe and efficient operation requires that anyone who will
be operating or maintaining this equipment read and
understand the safety, operation, maintenance and
troubleshooting information contained in the operator's
manual.
Continuing improvement and advancement of KPI-JCI
products may cause changes to your equipment which
may not be reflected in this publication.
KPI-JCI 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, 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 About This Manual 0-5
Serial Number Plates 0-6
Buying Replacement Parts 0-7
Maintenance Techniques and Tools 0-8
Lubricants and Fluids 0-9
Storage 0-12
Drawing List 0-13
Specifications Chapter 1 1-1
Introduction to the Jaw
Crushing Plant Chapter 2
Jaw Crusher 2-2
VibratingFeeder/SideDeliveryConveyor 2-4
Magnet/DustSuppression System 2-5
Tracks 2-6
FuelTank/Engine 2-7
ControlPanel 2-8
Hydraulic System 2-9
Safety First! 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 Jaw Crushing
Plant Chapter 8
Unloading 8-1
SideDelivery/AuxillaryConveyor 8-2
Preoperation/ No Load Operation
Checklist Chapter 9 9-1
Operating Controls Chapter 10 10-1
Overload Protection
System Chapter 11 11-1
Hydraulics Chapter 12

0-40-4
0-40-4
0-4 Contents
AutoAdjust Chapter 13 13-1
Adjustments Chapter 14
Tension Rod SpringCompression 14-1
OpenSide Setting 14-2
FlywheelBalance/ReversingJawCrusher 14-3
BeltTraining 14-4
TrackTensioning 14-5
Timing 14-6
Undercrusher Conveyor Removal Chapter 15 15-1
Maintenance Chapter 16
10hours 16-3
50hours 16-9
250hours 16-12
1000hours 16-13
2000hours 16-14
Asneeded 16-15
Wear Items
JawDieReversal/Replacement 16-19
SideLiners 16-22
Belt Splice Retaining Collar/
AirFilterReplacement 16-23
Lubrication Chapter 17
10hours 17-2
50hours 17-5
250hours 17-6
1000hours 17-8
Hydraulic System
Maintenance Chapter 18
10hours 18-2
50/250hours 18-4
500/1000hours 18-5
2000hours 18-6
Emissions Chapter 19 19-1
Appendix A Auxilliary Conveyor Capacities and
Hydraulic Schematics
Appendix B Hydraulic System Startup
Appendix C Overload Protection SystemParameters
Appendix D Cat Engine DiagnosticCodes
Appendix E BeltTension Instructions
Appendix F WeldingLiftingLugs to JawManganese

0-50-5
0-50-5
0-5
Purpose
Thepurposeofthismanual
is to help you get the best
value from your equipment. It
can do so by helping you
decide what work must be
done, even if you decide to
haveitdonebyadealerservice
departmentorarepairshop. It
also provides information and
procedures for routine
maintenance and servicing.
Using the Manual
The manual is divided into
chapters which are further
divided into sections headed
in bold type.
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
given without the word
"chapter" apply to sections
and/orparagraphsinthesame
chapter. For example, "see
section 8" means in the same
chapter.
Even though this manual
has been prepared with
extremecare,KPI-JCI.cannot
acceptresponsibilityforerrors
in, or omissions from the
information given.
Special Notations
Within this manual,
procedures or situations that
require special attention are
indicated with the words,
DANGER,WARNING,
CAUTION and IMPORTANT.
DANGER,WARNINGand
CAUTIONareusedtoindicate
proceduresorsituations where
personal safety is involved.
IMPORTANT is used to
indicatespecialproceduresor
situations which, if not
observed, could result in
damage to the equipment or
affect the operation of the
machine.

Modifications are a continuing process in the
manufactureofthisequipment.Sincereplacement
parts,manuals,andlistsarecompiledspecifically
for each unit, the serial numbers are essential to
correctly identify the component required.
The serial number plate will show the serial
number, job order number and model number.
Serial Number Plates
Serial Number Plate - Vibrating Feeder
Serial Number Plate - Jaw Crusher
Jaw crusher serial
number plate
KPI-JCI Serial Number Plate
Plant Serial Number
The serial number for the plant is stamped
on a plate which is located outside and above
thehydraulic/enginecontrolpanel.
The plant serial number should be referred
to when ordering parts or requesting service.
Serial Number Plate - Plant
Plant serial number plate
Frame cross support
Vibrating feeder
serial number plate
0-60-6
0-60-6
0-6
Component Serial Numbers
The serial numbers for the vibrating feeder
and jaw crusher are stamped on serial number
plates which are attached to the various
components as shown below.
The serial number plate for the vibrating
feeder is located on the inside of the frame
cross support.
The serial number plate for the jaw crusher
is located on the upper feed end of the jaw on
the left side of the plant

0-70-7
0-70-7
0-7
Authorized Dealer Parts
Department
Anauthorizeddealer parts
department is the best source
for parts, particularly parts
which are unique to this
equipment. Ifyoudonotknow
whotheauthorizeddealerisin
your area contact KPI-JCI.
Dealerships are located
throughout the United States
andinsomepartsoftheworld.
Buying Replacement Parts
Purchased Components
Replacement parts for
components purchased by
KPI-JCIsuchasgearreducers,
electric motors and engines
are available through your
authorizeddealer. Itemssuch
as engine parts are typically
not stocked by the dealer or
KPI-JCI.
Serial Number
Since replacement parts
manualsandlistsarecompiled
specifically for each unit, the
serial numbers are essential
to correctly identify the
component required.
Typical Tail Pulley Assembly Parts Page.
Typical Motor Drive Assembly Parts Page.

Tools
Althoughaminimalnumber
of tools are needed for
operationand maintenance, a
goodselectionofbasictoolsis
required.
Maintenance Techniques and Tools
Waste Oil and Fluids
Waste oil and fluids
drained from the engine and
hydraulicsystemduringnormal
maintenance and repair can
present a disposal problem.
To avoid pouring them on
the ground or into the sewage
system, pour the used fluids
intolargecontainers,sealthem
andtakethemtoanauthorized
disposal or recycling center.
Fasteners
Typically, standard SAE
fastenersareused. Fasteners
are nuts, bolts, studs and
screws used to hold two or
more parts together.
All threaded fasteners
should be clean and straight,
with undamaged threads and
undamagedcornersonthehex
heads.
Itisagoodhabittoreplace
all damaged fasteners when
performing maintenance,
never reuse a damaged
fastener.
Speciallocknutswithnylon
insertscanonlybeusedonce.
If they are removed, they lose
their locking ability and must
be replaced.
Rusted nuts and bolts
should be treated with a
penetrating fluid to ease
removal and prevent
breakage. Badly rusted
fasteners may have to be
chiseled,sawedortorchedoff.
Flat washer 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 C prevailing torque
locknut
Grade marking standard SAE
bolts.
Grade 5 Grade 8
0-80-8
0-80-8
0-8

0-90-9
0-90-9
0-9
The lubricants shown to
the right are "factory fill"
lubricants. Other lubricants
may be used, provided they
meet the lubrication
requirements specified.
Bearings
Bearings are lubricated
with a high temp EP-2 lithium
based grease containing a
tackinessagent. Lubecoloris
red.
Pivot Points
Pivot points are lubricated
using the same lubricant as
thebearings. AhightempEP-
2 lithium based grease
containing a tackiness agent.
Lube color is red.
Hydraulic System
The hydraulic system is
factory filled with Hydrex MV
60, a good quality industrial
hydraulic oil with a wide
viscosity range. This oil can
beusedwithhydraulicsystems
that are exposed to wide
temperature ranges. If MV60
is not available, KPI-JCI
recommends using a high
quality oil with an appropriate
viscositybasedontheambient
temperature the plant will be
operating in until the next oil
change. For 20 degrees F (-7
degrees C) to 120 degrees F
(49 degrees C) ambient
temperature, use ISO 68 with
a viscosity index above 120.
Lubricants and Fluids
Bearings, Pivot Points and
General Lubricant.
Hydraulic System.
EP-2 Lithium 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 MV22
canbeused.

Lubricants and Fluids
Vibrating Feeder Shaft
Bearings
NLGI 2 Synthetic Grease
Vibrating Feeder Bearings
Vibrating feeder bearings
are lubricated with an NLGI 2
multipurpose, extreme
pressure synthetic grease.
Hydraulic Gear Drive
The hydraulic gear drive is
lubricatedwithMobilSHC630.
Jaw Crusher Pitman
Bearings
Jaw Crusher Pitman
Bearings
The jaw crusher pitman
bearings are lubricated with
Chevron Ultra-Duty HD00, a
lithium based semi-fluid
grease specially formulated
with a high viscosity base oil,
and an additive package that
contains inhibitors and
tackifiers.
Forcoldweatheroperating
conditions, Mobilith SHC 007
can be used.
Chevron Ultra-duty HD00
0-100-10
0-100-10
0-10
FT Units, Hydraulic Gear
Drive on Engine
Mobil SHC 630

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

0-120-12
0-120-12
0-12
Storage
Track Storage
Thefollowingguidelinesshould
befollowedfortrackstorageon
an FT plant for an extended
period of time.
•Move the plant once a
month to keep seals
lubricated and fuctioning
proper.
•Store indoors in extremely
coldenvironments.
If indoor storage is not
possible, apply diesel or
similar lubricant to the link
joints before winter
shutdown. Clean and
dispose of over-applied
liquidproperly.
If, after winter shutdown,
the chain is stiff, use a
hammer to break the links
loose. Strike the hammer
onthepinfaceofthechain.
When the machine will not
be used for a period of a few
months, use the following
procedure for storage to
minimize corrosion and
deterioration.
General Storage Guidelines
•Removealldirtanddebris
fromallareasinandaround
themachine.
•Lubricate all points as
specified in the
maintenance and
lubrication section of this
manual.
•Bearings must be rotated
and lubricated every 30
days (they are in storage)
topreventthemfromdrying
out.
•Clean the outside of the
machine and repaint any
areaswhereneeded.
•Attach a tag to the plant
indicating what storage
procedures have been
done.
•To help prevent corrosion,
thefuelandhydraulictanks
should be filled to their
properlevel.
Extended Period Storage
(6monthsormore)
Ifthemachinewillbestoredfor
aperiodofsixmonthsormore
followtheguidelinesbelow.
These guidelines should be
completed once every three
monthstolubricatethebearings
and/or to purge condensation
andtopreventthebearingsfrom
dryingout.
•Lubricatebearings
•Rotate the shaft two
revolutions.
•Replacebreathercap.

Drawing List
0-130-13
0-130-13
0-13
Electrical Drawings
305944-1 PanelLayout
305944-2 Communications,Estop,andengine
305944-3 Outputsandconnectors
305944-4 Outputsandconnectors
305944-5 Inputandaccessories
305944-6 Digsy CMV Color Display
321533-2 Transducers(Estop,battery,strobes,brakerelease,tanklevel)
321534-2 Solenoids and EDCs
321535-2 Transducers(tensionrod)
305949 Batterycablesandassembly
321542 Speedsensorassemblywith64toothwheel
305918 EnginepanelCATenginelayoutDigsy CMV
Hydraulic Drawings
281112-1 TankPlumbing
281112-2 TrackDrive- rightandlefttrack
281112-3 CrusherDrive
281112-4 Vibrating Feeder Drive
281112-5 JawWedgePlumbing
281112-6 Magnet,UndercrusherConveyor,WingFold,PitmanCylinder
281112-7 SideDeliveryConveyorandStacker

1-11-1
1-11-1
1-1
11’10.75”
(3.63m)
Overall Length: 55’ 10” (17.01 m)
Overall Width: 15’ 10” (4.83 m)
Overall Height: 12’ 10.75” (3.93 m)
Weight: 125,000 lbs. (56,700 kg)
Travel Height: 11’10.75” (3.63 m)
55’10”
(17.01m)
11’ 3”
(3.43m)
4’7”
(1.40m)
Travel Width: 11’ 11.75”
(3.43m)
Undercrusher Conveyor: 8,600lbs.
(3,901 kg)
Side Delivery Conveyor: 1,535lbs.
(696.3 kg)
Magnet: 5,000lbs.
(2268 kg)
12’10.75”
(3.93m)
11’9.25”
(3.59m)
Specifications - 3055

Specifications 1-21-2
1-21-2
1-2
Jaw Opening (Gap): 30"(762 mm)
Jaw Width: 55" (1397 mm)
Moving Jaw, Overall Depth: 60.5"(1537mm)
Stationary Jaw, Overall
Depth: 59.5"(1511.3mm)
RPM: 275
Stroke: 1-1/2"(32 mm)
Weight: 50,000lbs.(22,700 kg)
Base Weight: 16,283lbs. (7386 kg)
Pitman Assembly Weight: 16,450lbs. (7462 kg)
(less flywheels)
Flat Flywheel Weights (each): 3,066 lbs.
(1391kg)
Toggle Plate Weight: 655 lbs.
(297kg)
Top Adjusting Wedge Weight: 583 lbs.
(264 kg)
Bottom Adjusting Wedge Weight: 463 lbs.
(210 kg)
Jaw Die Weights (each): 3,450 lbs.
(1565kg)
A-dimension: 56.870 - 56.880
50”
108”
30”
55”
Peak to Peak Closed Side Setting - Approximate Capacity
CrusherSetting
(Closeof
Stroke)
*TonsperHour
mt/h
mm
3”
76 3 1/2” 4” 5”
89 102 127
300 334
302 402
365 471
428
272
6”
152
265
240
in. 7”
178
528
479

Speed: 500-950 rpm
Feeder Weight: 9,400 lbs. (4,264 kg)
Feeder Hopper: 5,785 lbs. (2624 kg)
Length of grizzly: 5' step (1.52 m)
Spring deflection: static with feeder empty
is 5/8"
Timing: 54 deg.
Standard 50" x 15' (1.27 m x 4.57 m) Feeder
PSI: 3045 psi relief pressure
Length of solid
pan deck: 10’ (3.05 m)
Wear plate: 5' x 10', 1/2" thick
(1.52 m x 3.05 m)
PSI: 3045 psi relief pressure
Length of solid
pan deck: 13' (4 m)
Wear plate: 5' x 13 ', 1/2" thick
(1.52 m x 4 m)
8”
15’
(4.57 m)
Timing: 54 deg.
*Optional
50" x 18' (1.27 m x 5.49 m) Feeder
R.P.M.: 500-950
Feeder Weight: 9967 lbs. (4,521 kg)
Length of grizzly: 5' step (1.52 m)
Spring deflection: staticwithfeederempty
is 3/4"
Specifications
1-31-3
1-31-3
1-3

2-12-1
2-12-1
2-1
Orientation is determined
bystandingatthefeedhopper
endoftheplantlookingtoward
the direction of material flow.
Introduction to the Jaw Crushing Plant
The feed end of the plant
receives the material to be
crushedandthedischargeend
discharges the crushed
material.
References to the right
hand and/or left hand side will
be as shown below.
Right side
Left side
Material flow
Discharge endFeed end

Introduction to the Jaw Crushing Plant
2-22-2
2-22-2
2-2
Power Unit
Variable Speed
Vibrating Feeder Jaw CrusherHeavy Duty Tracks
Magnet
Large Capacity
Hopper
Undercrusher
Conveyor
Side Delivery
Conveyor
The following is a brief
descriptionofthejawcrushing
plant’s basic parts and their
function.
Jaw Crusher
The jaw crusher uses a
stationary and moving jaw
system to fragment rock and
constructiondebris.
Base
The base contains the
crushingchamberbetweenthe
stationary and moving jaw.
Steel saddles at the top of the
basesupporttheeccentricshaft
assemblyandthepitman. The
lowerrearsectioncontainsthe
adjusting mechanism and
supports the tension rod
assembly. Abrasion resistant
steelwearplatesacttoprotect
the sides of the base.
Tension Rods
The tension rod assembly
consists of one tension rod
extendingfromthelowerendof
thepitmanthroughaspringseat
assembly. Ahydrauliccylinder
holdstheassemblyandkeeps
tensiononthetoggleplate. The
spring seat assembly is
hydraulically adjusted with
solenoid operated valves
locatedinthehydrauliccontrol
panel.
Side Liners
The side liners, made of
abrasionresistantsteel,linethe
sides of the base for wear.
Flywheels
Theflywheelsstoreenergy
to provide smooth operation
when surges of material enter
thecrusher.
Eccentric Shaft
The eccentric shaft
translates circular motion into
the crushing action of the
movingjaw. Theshaftrevolves
ontworollerbearingsmounted
at the top of the base. The
center portion of the shaft is
eccentricandcarriesthepitman
ontwoinnerrollerbearings.
Pitman
The pitman carries the
moving jaw and moves in an
oval path from the rotation of
theeccentricshaft.
Auto Adjust System
The adjusting mechanism
setstheopeningatthebottom
ofthejaws. Adjustmentismade
byusingthehydraulicvalveto
movethewedgeswithhydraulic
cylinders to properly adjust
tension rods. Closed side
setting is hydraulically
adjustable to control material
size.