SUBJECT: FT4250 and FT5260. Shock Absorber Mount Installation.

page 1 of 7

KPI-JCI is requiring the installation of a shock absorber to the lower apron cylinder assembly on FT4250 and FT5260 plants with hydraulic apron adjust.

Tools/Equipment Needed

• Shock absorber kit• Torch• Grinder• Lifting chain or straps that can handle

weights up to 500 lbs.• Forklift or lifting hoist• Drift pin• Standard set of wrenches• Beige paint and primer• Sledge hammer

Use the following procedure to install the shock absorber mount.

1. Extend the cylinder approximately 6” from fully closed until you can rotate the pin with your fi ngers. This indicates that the apron is hanging freely.

2. Remove the existing clevis and cotter pins from the rod end of the cylinder.

3. Carefully let the cylinder rest on the platform.

4. Lockout/tagout all power to the Fast Trax plant.

Remove cotter and cylinder pins here

5. Remove two locknuts and Belleville washers from clevis rods.

Note: Loosen one side and then the other- go back and forth to relieve the spring compression and prevent damage to the apron assembly.

6. Unpin the existing spring plate and remove it completely from the crusher hood. The spring plate weighs approximately 250 lbs.

7. Remove the second stage apron springs.

8. Remove the clevis rods.

9. Use the torch and template (included in the kit) to cut out the center plate between the two holes.

Service BulletinSerial Numbers FT4250 412447-413984

FT5260 410124-414059

January 28, 2015SB 049 1501 FT HSI

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10.Grind the area smooth. If there are any gouges, fi x them before continuing. Prime and paint area to match the rest of the crusher.

11. Install two 2-1/4” washers on each clevis rod. Place both washers on the outside edge between the lug and clevis. This prevents the springs from moving inward towards the shock support. See drawings included with this bulletin for more information.

12. Reinstall the clevis rods.

13. Reinstall second stage apron springs over clevis rods.

14. Lift the spring seat/shock absorber assembly on to the crusher hood. Connect the spring seat with existing clevis and cotter pins to the crusher hood.

Note: This assembly weighs approximately 350 lbs.

You should be able to rotate the shock mount plate out of the way to install the Belleville spring washers.

15. Install four Belleville spring washers on each clevis rod. Note picture below for orientation.

Belleville Washer Orientation

16. Thread locknut onto clevis rod securing springs to clevis rod assembly.

17. Measure springs from end to end to see how much to compress springs.

18.Tighten locknut to compress springs until measurement is 15-13/16”. A tool has been included with the kit for accurately measuring this. Place the measuring tool as shown in the picture below.

19. Position shock mount plate over clevis rods.

20. Thread jam nut to secure clevis rod assembly. Use a wrench to tighten jam nut.

21. Measure the end to end dimension of the shock absorber spring. The dimension must be between 3.5” to 3.75”. Add the 2” washers until this dimension is achieved. Refer to the drawings for more information on this.

15-13/16”(compressed)

SB 049 1501 FT HSI January 28, 2015

SB 049 1501 FT HSI January 28, 2015

22. Weld disconnect at the places shown in decal 321690 (located on electrical control panel).

22. Tack weld jam nut to shock mount plate.

Tack weld jam nut to shock mount plate

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23. Remove lifting chain and hook from spring seat/shock absorber assembly.

24. When ordering the shock absorber kit, someone from the KPI Service department will call you to determine if you need to install a new lower apron cylinder or new sequence valves.

The instructions for installing a new lower apron cylinder can be found on page 6 of this bulletin.

The instructions for installing new sequence valves can be found on page 8 of this bulletin.

Installing Lower Apron Cylinder

The following tools and equipment will be needed to complete this procedure.

• Lower apron cylinder (p/n 321393)• Lifting strap or lifting device (hydraulic

cylinder weighs approximately 60 lbs.)• Standard set of wrenches

Use the following procedure to replace the lower apron cylinder.

Before starting this procedure, the rod end of the cylinder should still be disconnected from the impactor and all power to the plant should be locked out/tagged out.

1. Remove the cotter and cylinder pins from the base end of the cylinder.

2. Remove hydraulic hoses from the cylinder. Plug hoses to prevent hydraulic oil leaks or contamination.

3. Remove existing hydraulic cylinder.

4. Install new hydraulic cylinder.

Install the base end cylinder pin fi rst. Secure with two cotter pins.

5. Connect hydraulic hoses to new hydraulic cylinder. Reference drawing for instructions on connecting the hoses.

6. Remove lockout/tagout.

7. Use the hydraulic valve to extend the new lower apron cylinder until the bottom holes line up.

Install the rod end cylinder pin and secure with two cotter pins.

8. Install the sensor cord into cylinder sensor connection.

Use cable ties to secure the cylinder electrical connection cord to the hydraulic hose as shown in the picture below.

9. Install 3/8MO x 3/8MS fi tting (included in your kit) in place of the orifi ce fi tting to assist in bleeding the air out of the cylinder.

10. Use the hydraulic valves to cycle the cylinder 5 times to get all the air out of the system.

11. Remove the 3/8MO X 3/8MS fi tting and reinstall the orifi ce fi tting.

12. Check the apron clearance using the procedure included on the next page to make sure that apron is not hitting the rotor.

SB 049 1501 FT HSI January 28, 2015

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SB 049 1501 FT HSI January 28, 2015

Hydraulic Apron Adjust

Use the crusher/feeder screen in the OPS program to adjust the lower apron setting.

1. Press F8 on the main screen to access the Crusher/Feeder screen.

F1 F2 F3 F4 F5

F14

F13

F12

F11

F6 F7 F8 F9 F10

F15

F16

F17

F18

2. Use the F2 to toggle between the upper and lower apron adjustment options on the Crusher/Feeder screen.

3. Use the F12 and F13 keys to choose your apron settings.

F1 F2 F3 F4 F5

F14

F13

F12

F11

F6 F7 F8 F9 F10

F15

F16

F17

F18

4. If you need to calibrate the system, go back to the main screen and press F5 to access the setup functions.

5. Enter the setup password (998877) and then choose F8 for crusher setup.

6. Press F10 to calibrate the crusher.

F1 F2 F3 F4 F5

F14

F13

F12

F11

F6 F7 F8 F9 F10

F15

F16

F17

F18

7. After adjustment has been made, verify the setting through the inspection doors.

NOTICENever adjust the aprons closer than the minimum settings. Damage to the impactor could result.

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Installing Sequence Valves

The following tools and equipment will be needed to complete this bulletin.

• Sequence valves (2 - p/n 321411)• Torque wrench• 1-1/16” deep well socket, 7/8” socket,

1-1/8” socket

Use the following procedure to replace the sequencing valves.

1. Unpin the lower apron cylinder from the base end. The cylinder should already be unpinned from the rod end.

2. Lockout/tagout all power to the plant.

3. Slowly loosen the gauge port plug for the rod and base side of the cylinder two turns. This will allow any trapped oil or air to bleed out of the cylinder.

4. Clean area around the sequence valves before removing.

5. Remove the existing sequence valves.

6. Install new sequence valves.

7. Torque to 45-50 ft.lbs. Tighten gauge port plug.

8. Reinstall the lower apron cylinder.

9. Remove orifi ce fi tting and install 3/8MO x 3/8MS fi tting (included in your kit) in the port.

10. Remove lockout/tagout.

11. Use the Hydraulic Controls screen to cycle the cylinder 5 times to get all the air out of the system.

12. Remove the 3/8MO X 3/8MS fi tting and reinstall the orifi ce fi tting.

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SB 049 1501 FT HSI January 28, 2015

Rod end gauge port plug (Dash 10 ORB)

Base end gauge port plug (Dash 8 ORB)

Orifi ce fi tting

Sequence valves

Orifi ce fi tting

SB 049 1501 FT HSI January 28, 2015

Please send to:

Name:

Address:

City: State: Zip:

Attn:

Serial Number:

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Check the boxes below and return to KPI-JCI.

Order one kit for each Fast Trax plant.

Send ______ FT4250 Apron Shock Kit (P/N 344413)

Parts and 8 hours labor will be covered under KPI-JCI warranty.

KPI-JCI700 W 21st. St.Yankton, SD 570781-800-532-9311Fax: 1-800-514-6115Email: mail@kpijci.com

Send ______ FT5260 Apron Shock Kit (P/N 367058) Send ______ Primer (Gray SW# E61AS28) and paint (KPI Beige SW# F88HC700) When ordering the shock absorber kit, the KPI Service department will call you to deter-mine if you may need a new lower apron cylinder or new sequence valves.

Send ______ Lower Apron Cylinder (p/n 321393) Send ______ Sequence valves (quantity 2) (p/n 321411)

SECTION B-B

SCALE 1/25

DESCRIPTIONQTYPART NO.ITEM

CLEVIS PIN, 1" DIA x 4.00L22740151

EFDYN SHOCK 2X613444122

SHOCK MOUNT, LWR APRON13670753

SPRING SEAT, LWR PAN, 526013670544

COTTER PIN; 3/16 X 1 1/2245-480345

WASHER;SAE THRU-HARD,1"445-600116

SHOCK ABSORBER INSTALLATION1SB 0497

TEMPLATE; SHOCK ABS KIT, 526013542708

WASHER;SAE THRU-HARD,1 1/2"445-600159

CORDSET 1M M12 RA FEMALE132167710

CHK GAUGE; SPRING COMPRESSION136709911

B

B

C

SHEETDRAWING NUMBER

700 WEST 21st STREET P.O. BOX 20 YANKTON, SOUTH DAKOTA 57078

TITLEDATE

DATE

DATE

DRAWN

MODELED

APPROVED

SCALE

ECNDATEREVISION

REVISIONS AND PATTERN CHANGES

NO BY

THIS PRINT IS THE PROPERTY OF KOLBERG-PIONEER INC. AND IS SUBJECT TO RECALL AT ANY TIME,

AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THEIR INTEREST.

BETWEEN FINISHED SURFACES ± 0.010"

DETAIL DIMENSIONS: ± 0.06

TOLERANCES - UNLESS NOTED:NOTICE:

MATERIALWEIGHT

367058

5260 Apron Shock Field Kit

7/31/2014JS

1/10

1

2

347

JS 7/31/2014

KOLBERG-PIONEER, INC.

KPI-JCIASTEC COMPANIES

3

156

2

4

6 1 5

1/4 1/2

(1)

TYP

3.63 SHOCK ABSORBER

SPRING LENGTH

9

SHIM WASHER PLACEMENT

(AS NEEDED TO ACHIEVE

SPRING LENGTH DIMENSION)

1

CHG PN 367075(1) WAS 344416(1); ADD 367099

1/20/15 JS 28753