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ASTEC KPI-JCI Operation And Maintenance Manual

Crushing & screening
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Crushing &
Model 5044-32T
Screening
Sand Prep
Vertical Shaft Impactor
OPERATION AND MAINTENANCE MANUAL
IB-1005 5/14

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  • Page 1 Crushing & Model 5044-32T Screening Sand Prep Vertical Shaft Impactor OPERATION AND MAINTENANCE MANUAL IB-1005 5/14...
  • Page 2 MANUFACTURED BY KOLBERG-PIONEER, Inc. YANKTON, SD, U.S.A. Serial Number Plate CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, an other reproductive harm. Copyright KPI-JCI 2014...
  • Page 3 Vertical Shaft Impactor OPERATION & MAINTENANCE MANUAL Models Covered: 1500 2500 4500...
  • Page 4 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.

  • Page 5: Table Of Contents

    Contents Introductory Pages About This Manual Serial Number Plates Buying Replacement Parts Maintenance Techniques and Tools Lubricants and Fluids Storage Introduction to the Vertical Shaft Impactor Chapter 1 Safety Chapter 2 Specifications Chapter 3 Application Chapter 4 Site Selection and Set-up Chapter 5 Preoperation/Operation Checklist...
  • Page 6 CAUTION are used to indicate also provides information and been prepared with extreme procedures or situations where procedures for routine main- care, KPI-JCI can not accept personal safety is involved. tenance and servicing. responsibility for errors in, or omissions from the information IMPORTANT is used to given.
  • Page 7 Serial Number Plates Modifications are a continuing Serial Number Plate process in the manufacture of this equipment. Since replacement parts, manuals, and lists are compiled specifically 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.
  • Page 8 KPI-JCI such as gear reducers, for parts, particularly parts electric motors and engines serial numbers are essential to which are unique to this...
  • Page 9 Maintenance Techniques and Tools These items can be purchased It is a good habit to replace Tools from KPI-JCI as a kit. all damaged fasteners when performing maintenance, never Although a minimal number of Order part number 289470 reuse a damaged fastener.
  • Page 10 Lubricants and Fluids Factory Fill Lubricants The lubricants listed below in bold type are factory fill lubricants. Other lubricants may be used, provided they meet the lubrication requirements specified. Cold weather lubricants are listed after the factory fill, see Cold Weather Startup for more information.
  • Page 11 Storage Extended Period Storage When the machine will not To help prevent corrosion, • be used for a period of a few the fuel and hydraulic tanks (6 months or more) should be filled to their months, use the following procedure for storage to proper level.

  • Page 12: Introduction To The Vertical Shaft Impactor

    Introduction to the Vertical Shaft Impactor Orientation is determined by The feed end of the Vertical References to the right hand standing at the opening of the Shaft Impactor receives the and/or left hand side will be as Vertical Shaft Impactor looking material to be crushed and the shown below.
  • Page 13 Introduction to the Vertical Shaft Impactor The following is a brief description of the Vertical Shaft Impactor’s basic parts and their function. The tub includes the impact ring and tub liners. The tub supports the lid assembly, impact ring and contains the crushing action.
  • Page 14 Introduction to the Vertical Shaft Impactor Lid Assembly Feed box Feed tube The lid assembly consists of the feed box, feed tubes, lid liners and inspection doors. The lid contains the crushing action and provides a feed entry point. For access to the complete crushing chamber, the entire lid may be lifted after removing the hold-down wedges.
  • Page 15 Introduction to the Vertical Shaft Impactor Lid Liners The lid liners are arranged in a circular pattern in order to cover the entire underside of the lid from wear. The inner liners and outer lid liners bolt to the lid with hex head bolts. Inspection Doors Lid Liners The lid is equipped with large...
  • Page 16 Introduction to the Vertical Shaft Impactor Impact Ring The impact ring assembly includes the anvils and may or may not include a rock shelf. Anvils The stationary anvils are arranged in a circular pattern and provide the main striking surface for the material Cluster Ring propelled from the table assembly.
  • Page 17 Introduction to the Vertical Shaft Impactor Rotor/Table Assembly There are two options for an accelerator on a vertical shaft impactor: rotor or table configuration. The accelerator rotates counterclockwise (as viewed looking down on the accelerator) and is bolted to the flywheel that is keyed and secured to the pedestal shaft with a locknut.
  • Page 18 Introduction to the Vertical Shaft Impactor Feed Disc As the material drops through the feed tube, it lands on the rotating feed disc located at the center of the accelerator. The feed disc distributes the feed material and also provides wear protection for the table or rotor and shaft assembly.
  • Page 19 Introduction to the Vertical Shaft Impactor Skirt Ring Assembly The stationary skirt ring sits below the accelerator and protects the flywheel and pedestal. The skirt ring is lined with cast alloy skirt liners held in place by hex head bolts (2 per liner).
  • Page 20 Introduction to the Vertical Shaft Impactor Pedestal Skirt Cone The pedestal skirt cone is located behind the skirt ring assembly and protects the pedestal and related parts. The conical shaped guard is made of an abrasion resistant polyurethane compound. Pedestal Skirt Cone Lubrication Panel There are two options for the lubrication panel.
  • Page 21 Introduction to the Vertical Shaft Impactor Heat Exchanger To provide cooling of the p e d e s t a l ( o r g e a r b o x ) lubricants, a heat exchanger is used. The pedestal heat exchanger is normally mounted integral with the pedestal lubrication tank and uses an electric or...
  • Page 22 If an operation is not performed YOUR PERSONAL SAFETY as specifically recommended IS INVOLVED CAUTION with the safety by KPI-JCI you must satisfy symbol is used for potentially yourself that it is safe for you hazardous situations which, Most accidents are caused and others. You should also...

  • Page 23: Safety

    Safety O p e r a t o r / E m p l o y e e ’ s others and are not qualified to Safety symbols are used with signal words to further Responsibility operate or service the plant. demonstrate a safety hazard.
  • Page 24 Safety 6. Repair or replace any The following section presents Operating Safety material on specific safety damaged handrails, items. Although specific 1. Read and understand the ladders, or walkways. safety guidelines are given, Operator’s Manual before 7. Place each situation can have its controls operating, servicing or own peculiarities which can...
  • Page 25 Safety Operating Safety Area Magnet Safety 5. Make sure all guards are 1. Keep away from receiving 1. Magnetic field can be in place and properly hopper and loading area. s e c u r e d w h e n harmful pacemaker maintenance work is...
  • Page 26 Safety Hydraulic Safety Transport Safety 1. Always place all controls 1. Make sure you are in in neutral before servicing compliance with all local hydraulic system. regulations regarding transporting equipment 2. Replace any worn, cut, on public roads and abraded, flattened or highways.
  • Page 27 Safety Lockout Procedures Each of them might have machine springs a color-coded lock. All five counterweights. term locks could be placed on an Lockout procedures are a zero energy state means that electrical switch, preventing principal means of controlling all of these energy sources the power from being turned energy hazards.
  • Page 28 Safety Anyone who will be operating and/or maintaining A sign-off sheet has been provided for your the machine must read and clearly understand all record keeping to show that all personnel who safety, operating and maintenance information will be working with this equipment have read and presented in this manual.
  • Page 29 Safety The following illustrations are shown to help CAUTION identify decals when they require replacement. Safety decals are provided for your Make sure machine surface is clean and free personal safety. If they should become from grease and oil before applying new decal. damaged, they must be replaced. Contact your local dealer, or the factory at: 605-665- 8771.
  • Page 30 Safety 220762 221578 each side 139006 46-60146 Rock-eater - red dragon 184653* 184654* 184650* 184651* 184652* *Only one decal will appear on the vertical shaft impactor according to model. Vertical Shaft Impactor...
  • Page 31 Safety 46-60124 - Hydra-Arm black decal 46-60108 - Lid lifter decal 46-60082 Do not operate crusher with lid off 46-60091 Secure inspection doors after opening 46-60118 Lockout power to crusher before opening doors 46-60044 46-60097 46-60098 46-60107 Do not run lube pump Horn will sound with inadequate oil flow backward decal...
  • Page 32 Safety 46-60079 46-60095 46-60096 Horn will sound when oil Heating required on temperature is above 180˚F lube oil below 15˚ F 46-60117 Remote shut down switch is required decal 46-60106 46-60072 46-60064 46-60098 Horn will sound with Horn will sound with inadequate oil flow inadequate oil flow 46-60078...

  • Page 33: Specifications

    Specifications - 82 54” (1372 mm) 100” (2540 mm) 90” (2286 mm) Capacity Effective Maximum Minimum Feed Tube Standard Impeller Feed Size Recommended Diameter Crushing Range Table Speed in./cm Closed Circuit Range - RPM MTPH 250-400 227-356 800-1200 Approximate Weight Explosion Chamber Recommended EV-Models (Electric Table/Anvil Clearance Horsepower Electric Volume WK(2) shown)
  • Page 34 Specifications - 120 54” (1372 mm) 107.75” (2737 mm) 90” (2286 mm) Capacity Effective Maximum Minimum Feed Tube Standard Impeller Feed Size Recommended Diameter Crushing Range Table Speed in./cm Closed Circuit Range in. mm MTPH 3/8” 300-500 267-445 800-1080 Table/Anvil Clearance Explosion Chamber Recommended Approximate Weight Horsepower Electric EV-Models (Electric Volume...
  • Page 35 Specifications - 1500 42” (1067 mm) 76” (1930 mm) 72” (1829 mm) Capacity Effective Maximum Minimum Feed Tube Standard Impeller Table Speed Feed Size Recommended Diameter Crushing Range Closed Circuit Range in. mm MTPH 1500 (H) 75-125 67-112 720-2,000* 1500 (A) 75-150 67-135 720-2,000* Approximate Weight Explosion Chamber Recommended EV-Models (Electric...
  • Page 36 Specifications - 2500 36” (914 mm) 84.6” (2149 mm) 84” (2134 mm) Capacity Effective Maximum Minimum Feed Tube Standard Impeller Feed Size Recommended Diameter Crushing Range Table Speed Closed Circuit Range MTPH 2500 (H) 11-3/8 289 150-250 135-223 700-1400 2500 (A) 11-3/8 150-300 135-267 700-1400 Table/Anvil Clearance Explosion Chamber Recommended Approximate Weight Horsepower Electric...
  • Page 37 Specifications - 4500 54” (1372 mm) 103.35” (2625 mm) 90” (2286 mm) Capacity Effective Maximum Minimum Feed Tube Standard Impeller Feed Size Recommended Diameter Crushing Range Table Speed Closed Circuit Range MTPH 4500-3 (H) 300-450 267-401 800-1200 4500-5 (H) 3/8” 300-450 267-401 800-1200 4500 (A) 300-500 367-454 800-1200 Table/Anvil Clearance Explosion Chamber Recommended...

  • Page 38: Application

    Application Configurations Application Basics Operating Principles The vertical shaft impactor is The vertical shaft impactor is a The vertical shaft impactor available in the following three viable and economical impact provides the ultimate in configurations: application flexibility through solution for crushing highly siliceous rock as well as a the ability to operate the Standard configuration...
  • Page 39 Application increasing sand production. Variable reduction ratios are from 3:1 to 12:1 with feed sizes up to 2-1/2” depending on the model. • Fully Autogenous A rotor and rock shelf is used in a fully autogenous configuration. The rotor flings rock against a bed of rock and exposed anvils on the outer hybrid rock shelf.
  • Page 40 Application Feed Rate and Gradation Feeds predominantly large, 100% of maximum impeller • small, or erratically graded, speed. Four or five shoe table configuration. Optimum performance from a will affect crusher production vertical shaft impactor occurs performance. when it is continuously and Producing Minimum Fines uniformly choke fed properly Screening •...
  • Page 41 Application Maximum Feed Size internal castings and machine A d a p t i n g t h e t a b l e components will result. Interior The following maximum feed configuration and optimum casting or component damage sizes must be observed for speed to the material’s resulting from tramp material each VSI model.
  • Page 42 Water may be introduced discharge point of the crusher. at the feed opening of the The factory can suggest crusher to reduce dust, but optional dust suppression doing so can adversely affect equipment suppliers. casting wear. If water must be introduced, do so at the Application Tables Typical Limestone in Standard Configuration Typical Limestone in Standard Configuration -...
  • Page 43 Application Secondary Crushing, Average Materials, Standard Configuration 4500H, 120H Secondary Average Materials Crusher Output Using 3 Shoe/4 Shoe Impeller Max. 80% of Max. Feed 50% of Max. Speed Speed Speed Output Scalped at Sieve Size 1-1/2” Output Inches % Passing 100% 100% 100% 1-1/2 37.5 1-1/4...

  • Page 44: Site Selection And Setup

    Site Selection and Setup Foundation drawings are to open and remove the lid Site Selection typically provided with the on the vertical shaft impactor. crusher or can be obtained The drop height should be no When selecting a suitable from the factory. These less than 18”.
  • Page 45 Preoperation Checklist The preoperational check should be performed Check each component to insure that it is in any time the equipment is moved to a new site, or operational condition. This check should include, if it has been in storage for an extended period. but not be limited to the following items.
  • Page 46 No Load Operational checklist OPERATIONAL CHECKS OK Adjust 1. Unit Vibration - if chains on unit are shaking there is too much vibration. 2. Accelerator Rotation (counterclockwise as viewed from above) 3. Accelerator RPM Model 82 (800-1200 RPM) _________ Model 120 (800-1080 RPM) ________ Model 1500 (720-2000 RPM) _______ Model 2500 (700-1400 RPM) _______ Model 4500 (800-1200 RPM)________...

  • Page 47: Operation

    Operation WARNING Use the following procedure to start the vertical shaft impactor. Do not under any condition, remove crusher lid or The vertical shaft impactor open inspection door while the crusher is running or in should be run empty initially to shutdown procedure. Never run the crusher when the lid insure everything is operating or inspection door is not in place and properly secured.
  • Page 48 Operation b. Diesel gearbox drives: 10. For diesel driven crusher, The following information warm engine at idle 3-5 pertains to the Gen. 2 1. C h e c k c r u s h e r minutes, then engage lubrication system. If your VSI is equipped with a Gen.
  • Page 49 Operation During operation, if the lube As the temperature rises, the is important because if the resistance of the oil cooler lines alarm sounds, immediately crusher motor shuts down and the oil cooler decreases, shut down the feed conveyor before the crusher hopper allowing the oil to begin to while starting a countdown is clear, it could experience...
  • Page 50 Operation Vertical Shaft Impactor...
  • Page 51 Operation Hydra-Arm The following adjustment has been made at the factory. Stop Unclamp lid and remove wedge locks and start hydra- arm pump. When the lever is activated, the lid will raise. Make sure to lift lid for proper clearance. Lever Rotate lid by lifting stop and manually rotating lid.

  • Page 52: Startup

    Startup 6. Inspect rotor daily for wear, Use the following procedure to start the crusher. particularly the carbide tips. 1. Inspect the accelerator for 7. Observe rock shelf wear. loose bolts. Accelerated wear will be 2. Pour two to three buckets of apparent if the rock shelf is d r y s a n d i n t o t h e set too high.
  • Page 53 Lubrication System (Gen. 2) The following information In addition, the oil pump used pertains to the Gen. 2 lubri- does not give any obvious cation system. If your VSI indication when the oil gets too is equipped with a Gen. 3 cold or thick, it just pumps less.
  • Page 54 The system components may lubrication pump on while Power to the lube pump vary slightly but the operating the crusher is coasting to a stop. Consult KPI-JCI for motors must be connected so principal will remain the same. interlock options. The warning system consists of the pumps will be energized before the crusher is started.
  • Page 55 Startup 2. The horn will sound. If the refer to the warning system All switches are wired in series. electrical schematic found in horn sounds, the system is 1. The 120 VAC system uses this section of the Operation working properly. and Maintenance manual.
  • Page 56 Startup Electric Drive Wiring Diagram (Gen. 2) Electric Drive Wiring Panel Vertical Shaft Impactor...
  • Page 57 Startup Diesel Lube Panel (Gen. 2) Horn Mount limit switch on power unit so that wobble stick is actuated by power unit clutch lever horn will blow if lube system motors are not running when clutch is engaged. Flow Switch Temperature Clutch Switch Switch...
  • Page 58 Lube System (3rd Gen) Overview Bearing Flow Sensor Bearing Inlet Temp Sensor The VSI lubrication system uses an HMI (human machine interface) and an I/O (input/ output) interface module that both communicate over a CAN network. The system consists four sensors located on the lubrication module.
  • Page 59 Lube System (3rd Gen) bearing inlet temp VSI Lubrication System Quick Reference sensor temperature sensor in the bearing flow Application circuit before the bearing. It is designed to sense system VSI Models 1500, 2500, 82, Compatible with all fluid temperature. 4500, 120 KPI models -20˚...
  • Page 60 Lube System (3rd Gen) Lubrication System Startup check the fan circuit pressure. pressure gauge mounted off the pump Use the following procedure to start the should read near lubrication system. (21 bar). Actual pressure shown on the gauge will vary based on temperature of 1.
  • Page 61 Lube System (3rd Gen) Electrical System Relays The electrical system includes three relay contacts each with a normally open dry contact. These contacts respond based on temperature, flow, and tank level conditions and are described below. CR1: “OK TO FEED” CR1 is provided as a recommended option to interlock the feed conveyor with crusher operation.
  • Page 62 Lube System (3rd Gen) Alarm Condition Setpoint Alarm Response Low Flow Alarm <.5 GPM/min Sequential shutdown - feeder, crusher, pump Low Tank Alarm Dry sensor Immediate shutdown of feeder, crusher, and pump >180˚ F (82˚ C) High Temp Alarm Sequential shutdown - feeder, crusher <20˚...

  • Page 63: Maintenance

    Lube System (3rd Gen) Hydraulic System Cooling Fan Circuit - The only purpose of the cooling fan circuit is to spin the fan motor. The The hydraulic system of the lubrication panel speed of the fan motor is regulated by the fan speed relief valve.
  • Page 64 Lube System (3rd Gen) To hydraulic tank To Hydra-arm lid lift cylinder 1. Hydraulic oil tank 2. Pump 3. Fan speed valve 4. Control valve 5. Thermal bypass 6. Heat Exhanger Pressure line Tank line Vertical Shaft Impactor...
  • Page 65 Lube System (3rd Gen) Sympton Causes Remedy High Temp Alarm Heat exchanger is plugged Clean heat exchanger. with dirt. Bearings are damaged. Review temperature history. Ambient temperature is too high. Fix all leaks and refill tank. Low Level Alarm Leaky hose connection. Sensor is unplugged.
  • Page 66 Adjustments Cluster Ring To maximize anvil life, it is possible to vertically adjust the cluster ring assembly. Adusting the cluster ring assembly allows the anvil to “pocket” in the lower half first and the top half second. When feed size is at or near maximum allowed, this adjustment is not recommended.
  • Page 67 Adjustments Rock Shelf When adjusting the rock shelf, remove the lower pocket liner and use a straight edge to measure from the rotor base to the rock shelf. The lower “lip” of the rock shelf should sit 1/4” below the straight edge laying on rotor base.
  • Page 68 Adjustments Skirt Ring Adjustment Skirt ring The skirt ring can be adjusted using shims to ensure that the flywheel and pedestal is protected. Use the following procedure to adjust the skirt ring. 1. Lockout/tagout all power to the vertical shaft impactor. 2.

  • Page 69: Feed Tube

    Adjustments Feed Tube Adjustment Feed box Feed tube height can be adjusted by threading the rod on the feed box up or down. Make sure that all power to the vertical shaft impactor is locked out/tagged out before adjusting the feed tube. The distance between the bottom of the feed tube and the top of the impeller shoes...

  • Page 70: Temperature Switch

    Adjustments T e m p e r a t u r e S w i t c h Temperature switch A d j u s t m e n t ( G e n . 2 Lubrication System only) The temperature switch for the lube alarm system must be set to 180˚...

  • Page 71: Flow Switch

    Adjustments Flow Switch Adjustment Flow switch and gauge (Gen. 2 Lubrication System only) The flow switch monitors oil flow through the lubrication system. The process fluid flows through the flow switch meter at a rate of 1-3.5 GPM. The flow causes the sensor, a spring loaded cone/magnet assembly, to move from a large precision orifice.
  • Page 72 Adjustments 4. Remove back cover. Switch tube 5. Use the supplied allen wrench (stored on the back cover) to loosen the set screw on the reed switch. 6. To change the flow setting, grasp the switch tube at one end of the reed switch and slide the wires in or out until the switch activates.

  • Page 73: Tub Liner Replacement/Anvil

    Wear Parts Tub Liner Replacement Use the following procedure to replace tub liners. 1. Open crusher lid (page 52). 2. Remove the impact ring assembly from the tub. 3. Unbolt and remove worn liners. 4. Install new liners using new M 1 2 h e x b o l t s .

  • Page 74: Anvil Replacement - Cluster Ring

    Wear Parts Anvil Replacement - Cluster NOTICE Ring When the anvils have become The anvil/cluster ring assembly is designed to form a worn to within 1/2” from the “material” or “rock” shelf above the assembly and thereby protect the upper tub area. back of the anvil, or 1/4” of the face edge, they should be replaced.

  • Page 75: Feed Tube

    Wear Parts WARNING Feed Tube The feed tube assembly Never attempt to service or adjust this machine until all consists of two identical feed motion has stopped and power has been disconnected and tubes stacked on top of each locked out or the engine control key has been removed and the control panel has been locked.

  • Page 76: Lid Liners

    Wear Parts Lid Liners Remove these bolts (one on each side) to disconnect arm from crusher lid. The lid assembly is made up of three different size liners. There are twelve outer liners, twelve middle liners and six inner liners. Replace lid liners when they wear to 1/2 their original thickness.

  • Page 77: Feed Disc

    Wear Parts Feed Disc Feed disc - up to 150 lbs. NOTICE The feed disc should never be allowed to wear completely through as serious damage can be caused to crusher components. Feed disc wear is evident by a rounding off of its outer edge immediately in front of the impeller shoe.
  • Page 78 Wear Parts Skirt Ring Assembly Skirt liner - up to 23 lbs. The skirt ring sits below the accelerator and protects the flywheel and pedestal. The skirt ring is faced with cast alloy skirt liners held in place by hex head bolts. Liners must be replaced as a set.

  • Page 79: Wear Parts - Table Assembly

    Wear Parts - Table Assembly Outer Table Liners Use the following procedure to remove outer table liners. 1. Open crusher lid (page 52). 2. Remove impeller shoes, feed disc, and flat table liners. 3. Unbolt and remove table from flywheel. 4.
  • Page 80 Wear Parts use all the same weight. Impeller Shoes installed. 4. Check the impeller shoe/ Two impeller shoe types are Tack weld shims in place bracket fit tolerance. and grind flat. available: pin-on shoes and bolt-on shoes. 6. Insert new shoe into The centrifugal force exerted NOTICE on the shoe and the constant...
  • Page 81 Wear Parts Impeller Shoes Pin-on Shoes Use the following procedure to remove worn pin-on impeller shoes. 1. To remove worn shoes, strike the face of the shoe sharply with a hammer to loosen. Shoe 2. Pull out the securing pin and Shoe bracket remove the shoe.
  • Page 82 Wear Parts NOTICE NOTICE The centrifugal force exerted on the shoe and the constant hammering by material will Once the pin has been Use only factory supplied cut from a shoe, under no eventually wear on the face of pins, as they are specifically the shoe bracket and the back circumstances may that designed to support the...
  • Page 83 Wear Parts Outer Shoe Bracket Liners Replace outer shoe bracket liners when they become worn. Use the following procedure to replace outer shoe bracket liners. All outer shoe bracket liners must be replaced at the same time. Outer shoe bracket liner 1.
  • Page 84 Wear Parts Flat Table Liners Impeller table liners should be replaced before they wear through to the impeller table. Replace flat table liners in matching pairs. Use the following procedure to replace flat table liners. Opposing liners may need to be replaced at the same time to keep the table balanced.

  • Page 85: Wear Parts - Rotor Assemby

    Wear Parts - Rotor Assembly Outer Rotor Liners Use the following procedure to replace the outer rotor liners. 1. Open crusher lid (page 52). 2. Unbolt and remove feed disc and lower pocket liners. 3. Unbolt and remove rotor from flywheel. 4.
  • Page 86 Wear Parts Inner Cap with Carbide Tip Use the following procedure to replace the inner caps. 1. Open crusher lid (page 52). 2. Unbolt and remove upper or lower pocket liners. If removing lower pocket liners, feed disc will need to be removed first for access to lower pocket liners.
  • Page 87 Wear Parts Outer Cap and Carbide Tip Assembly Use the following procedure to replace outer caps and carbide edges. 1. Open crusher lid (page 52). 2. Unbolt and remove feed disc and pocket liners. 3. Unbolt and remove worn outer cap assembly. A torch may be used to heat Outer cap the bolts for easier removal.
  • Page 88 Wear Parts Upper and Lower Liners Upper liner Use the following procedure to replace upper and lower liners. All upper and lower liners must Lower liner be replaced at the same time. 1. Open crusher lid (page 52). 2. Unbolt and remove worn upper and lower liners.
  • Page 89 Wear Parts Upper and Lower Flat and Upper flat Upper pocket Pocket Liners liner liner Use the following procedure to replace the upper and lower flat and pocket liners. 1. Open crusher lid (page 52). 2. Unbolt and remove feed disc for access to lower flat and pocket liners.
  • Page 90 Maintenance WARNING The following section contains instructions for maintaining and lubricating the impactor. Lockout/tagout all power to the machine. Maintenance intervals shown are for normal operating conditions. If the impactor is operated WARNING under severe or adverse conditions maintenance may need to be performed more often. Never attempt to open inspection doors while crusher is in operation.
  • Page 91 Maintenance Rotor Table Interval Ref. No. Notes General Inspection Loose bolts, set screws, hoses, leaks, or cracks. 10 Hours V-belt Drives and Tension Check for proper tension. Check for dust buildup, loose bushings, loose or missing mounting bolts. See page 11-5 for more information. Gearbox Drives Rotor/Table Wear parts (feed tube, liners, shoes, feed disc,...
  • Page 92 Maintenance General Inspection 1. Make sure all guards are 4. Hydraulic fluid leaks. If (10 hours) l e a k s a r e f o u n d o r in place and functional. A walk around inspection Repair or replace any suspected, repair right should be made on a daily away.
  • Page 93 Maintenance Gearbox Drives (10 hours) Crushers with diesel and right 3. Missing balance 2. Check input and angle gearbox drives. Check w e i g h t s output shafts of the the following: drivelines. gearbox for possible 4. Possibility of a bent bearing failure.
  • Page 94 Maintenance Feed Disc (10 hours) Feed disc Check feed disc for excessive wear. Rotate feed disc 30 degrees clockwise every time the shoes (table) or carbides (rotor) are changed. Feed Ring Feed Disc - Table (10 hours) Feed ring Feed disc On units with rotor installed, also check the feed ring on the top part of the rotor for wear.
  • Page 95 Maintenance Table (10 hours) Check the table and all liners for wear. Replace any parts if necessary. See page 80 to 85 for instructions on replacing the flat and outer table liners. Inspect impeller shoes for wear . Change worn shoes and anvils before they break or wear through their holding brackets.
  • Page 96 Maintenance Anvils 10 hours) Check for excessive wear and Anvil replace anvils as needed. See page 75 for information on anvil replacement. Cluster Ring Assembly Shoe Brackets (50 hours) Shoe brackets Check shoe brackets for excessive wear and sloppy shoe fit. See page 81 to 83 for information on maintaining and servicing shoe brackets...
  • Page 97 Maintenance Feed Tube (50 hours) M e a s u r e t h e c l e a r a n c e Clearance between feed between the bottom of the tubes and accelerator should be 3/8” depending feed tube and the top of the on application.
  • Page 98 Maintenance Tub Liners (250 hours) Inspect tub liners for excessive Tub liners wear. Liners should be inspected every 250 hours of operation and replaced as necessary. Tub liners should be replaced when they have worn to 1/2 their original thickness. Pedestal Skirt Ring (250 hours) Check pedestal skirt ring...
  • Page 99 Maintenance Pedestal Skirt Cone (250 hours) Inspect the pedestal skirt cone to ensure that material hasn’t build up under the skirt cone pushing up flywheel. Replace the pedestal skirt cone when worn thin or if a hole appears. Pedestal skirt cone Vertical Shaft Impactor...
  • Page 100 Lubrication Ref. No. Interval Notes Grease - 10-15 pumps. Pedestal Dust Seal 10 Hours Gearbox Shaft Seal Grease - 1-2 pumps. Pedestal oil tank Check oil level in sight glass, add as needed. Replace after first 50 hours of operation. After that, 50 Hours Oil Filters change as needed depending on operating conditions.
  • Page 101 Lubrication Pedestal Dust Seal (10 hours) Pedestal dust seal should be Pedestal dust seal greased while the crusher is running or coasting to a stop (10 to 15 pumps required). Gearbox Shaft Seal (10 hours) Grease the gearbox input Gearbox seal shaft .
  • Page 102 Lubrication Pedestal Oil tank (10 hours) Keep oil level in upper half of sight glass. The sight glass is located on the side of the lubrication panel. The oil tank is located on the bottom of the lubrication panel. Sight Glass Pedestal oil tank Gen. 2 Lube Panel Shown Vertical Shaft Impactor...
  • Page 103 Lubrication Oil Filter (50 hours) The oil filter should be changed Oil filter after the first 50 hours of operation. After that, change filters on 250 hour operation intervals or sooner if conditions dictate. Do not use an automotive type filter. On Gen.
  • Page 104 Lubrication Breather Cap (500 hours) Replace the breather cap. Breather cap The breather cap is located above the pedestal oil tank on the lubrication panel. Depending on operating conditions, the breather cap may need to be inspected and replaced more often. Gen. 2 Lube Panel Shown Pedestal Oil Tank (1000 hours)
  • Page 105 Lubrication Electric Motors (See WEG namplate) Lubrication information for the WEG electric motor can be found in the bottom left hand corner of the nameplate. F r a m e s i z e , s p e e d , lubrication interval should be verified on the nameplate before lubricating.
  • Page 106 Hydra-Arm Maintenance Leaks (10 hours) Check thoroughly for oil leaks. Hydraulic Oil Filter (As needed) The hydraulic oil filters should be changed after the first 50 hours of operation. After that, change filters annually or as needed depending on operating conditions Hydra-Arm The hydraulic oil filter is located on the hydra- arm assembly just above the hydraulic tank.
  • Page 107 Troubleshooting Excessive Vibration Hydra-Arm If the vertical shaft impactor is vibrating If the Hydra-arm will not operate as it should it excessively, it might be caused by unlevel might be caused by the relief valve, a change in pressure or because the hydraulic filter may operating conditions or a piece of material (such as a rock or uncrushable) wedged in between need to be changed.
  • Page 108 Appendix A: Belt Tension Instructions Sonic Belt Tension Instructions Use the following procedure to use the Gates sonic belt tester to measure belt tension. 1. Attach the sensor and turn the power on. Power Measuring Belt Span length in millimeters. The red light will display if there is no reading or a 5.
  • Page 109 Appendix A: Belt Tension Instructions Belt Tension Gauge Instructions Use the following procedure to measure v-belt tension. 1. Lockout/tagout all power. 2. Measure the belt span length of the drive (see Measuring Belt Span and Deflection Force drawing). 6. C o m p a r e t h e f o r c e 3. Set the large O-ring on the required in step 5 with the body of the tension gauge...
  • Page 110 Appendix A: Belt Tension Instructions Recommended Deflection Force (lbs.) Small Sheave Retensioning V-belt Type Dia. Range (in.) Initial Installation Maximum Minimum - 4.6 4.7 - 5.6 5.7 - 7.0 7.1 - 10.0 - 4.6 10.0 4.7 - 5.6 11.0 5.7 - 7.0 11.5 7.1 - 12.0 10.1 2.65 - 3.35...
  • Page 111 Appendix B: Prevailing Torque Locknut Prevailing Torque Locknut Bolts must be tightened to the coarse threads (UNC) and proper torque as listed in the unified fine threads (UNF) table below and on the next along with standard hex nut page. These values represent and prevailing torque locknut.
  • Page 112 Appendix B: Prevailing Torque Locknut Bolt Torque Chart - UNF Grade 5 Grade 8 Nominal Size Standard Hex Prevailing Torque Standard Hex Prevailing Torque Ft.-lb. (N-M) Ft.-lb. (N-M) Ft.-lb. (N-M) Ft.-lb. (N-M) bolt/nut 1/4 - 28 7 (10) 6 (8) 10 (14) 8 (11) 5/16-24 14 (20) 12 (16) 20 (28) 16 (22)
  • Page 113 Warranty Registration & Preoperational Check Vertical Shaft Impactor Kolberg-Pioneer, Inc. Form may be Sent, Faxed or Emailed 700 W 21st. St., Yankton, SD 57078 IMPORTANT 1-800-532-9311 Fax: 1-800-514-6115 Warranty will be void if this registration is not returned Email: mail@kpijci.com within ten (10) day after the equipment is put into service.
  • Page 114 JOHNSON CRUSHERS INTERNATIONAL 86470 Franklin Boulevard, Eugene, OR 97405 USA SERVICE 866-875-4058 - 541-736-1400; Fax 541-988-9501 PARTS 888-474-0115 - 541-736-1400; Fax 541-988-9487 ASTEC MOBILE SCREENS 2704 West LeFrevre Road, Sterling, IL 61081 USA SERVICE 800-545-2125; Fax 815-626-6430 PARTS 800-545-2125; Fax 815-626-6430...

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