service tool guide - kpi-jci and astec mobile screens · general maintenance & troubleshooting...
TRANSCRIPT
Service Tool Guide
General Maintenance & Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Horizontal Shaft Impactor Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Jaw Crusher Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vertical Shaft Impactor Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cone Crusher Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Unit Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Belt Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Miscellaneous Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parts & Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Feeder Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of Contents
General Maintenance & Troubleshooting Tools For All Equipment
Box end/open end wrenches - 3⁄16” up to 3”
Air or electric impact gun and appropriate sockets – 1⁄2”, 3⁄4” and 1” drives
Electrical and pneumatic extension cables and hoses
Set of hammers - up to 10 lbs .
Drill and set of drill bits
Set of taps - bottom and top
Set of chisels and punches
Hole bars and pry bars
Industrial stick welder
Set of allen wrenches - 1/16” through 3/4”
Set of lifting chains - up to 1/2” and in pairs
Set of lifting straps - 1” up to 4”
Grinders - 4-1/2” and 9”
Acetylene torch
Multimeter
Infra-red temp gun
Tachometer
Lockout/tagout kit
3/4” clevis pin shackle
3 legged cable/chain rated to cone weight
2” lifting Strap
4” lifting Strap
1” NC shouldered lifting eye
1/4” NC shouldered lifting eye
The General Maintenance & Troubleshooting Tools are available in most areas, let us know if you need assistance locating them .
Horizontal Shaft Impactor Tools Shaft and Rotor Assembly
Installation and Removal NutsModel Installation Nut Removal Nut
4233 272876 WSL-02703
4240 272876 WSL-02703
4250 272876 WSL-02703
3850 272876 WSL-02703
4654 N/A N/A
5260 N/A N/A
6064 N/A N/A
AN Nut WrenchesPart Number Used on Lock
NutPart Number Used on Lock
Nut
257029 AN-07 257017 AN-26
257030 AN-09 257018 AN-28
256722 AN-12 257019 AN-30
257013 AN-14 257020 AN-32
256723 AN-15 257021 AN-36
257012 AN-16 257022 AN-38
257014 AN-17 257023 AN-40
256724 AN-18 257024 AN-44
257015 AN-19 257028 AN-048
256725 AN-20 257027 AN-052
257016 AN-21 257025 AN-056
256726 AN-22 257026 AN-060
Torque wrench impactor crusher drive coupling - 220870
Tools for Conveyor Drive Squeeze Coupling FT UnitsPart Number Description
338891 13mm torque wrench box end
338892 9/16" torque wrench box end
338893 17mm torque wrench box end
289402 6mm x 1/4" torque wrench bit
General HSI ToolsPart Number Description
237227 3” apron adjust wrench
227765 4240 blow bar lifting tool
189108 4250 blow bar lifting tool
272864 5260 blow bar lifting tool
82422 Rotor locking pin assembly
341400 Apron adjust gauge set
Wedge ToolsPart Number Description
309953 5/8" Allen wrench
305211 10o 1-1/8" wrench
305212 45o 1-1/8" wrench
Rotor Maintenance ToolsPart Number Template Description
354102 (42 series rotors) Front-side segment profile
354182 (42 series rotors) Back-side segment profile
305715 (42 series & 5260 rotors) Hard surfacing
317483 (5260 rotors) Profile template
1
Jaw Crusher Tools Pitman Shaft and Bearing Assembly
Part Number Installation Nut Removal Nut
1654 WSC-01080 WSC-01079
2148 WSC-01080 WSC-01079
2436 WSC-01080 WSC-01079
2640 WSC-01080 WSC-01079
2650 WSC-01080 WSC-01079
2742 WSC-01080 WSC-01079
2854 WSC-01079 AEP-06731
3055 (older than SN 413335) WSC-01079 AEP-06731
3055 (SN 413335 and newer) WSC-01079 337471
3163 WSC-01079 AEP-06731
3165 WSC-01079 AEP-06731
3042 (older than UH-3959) WSC-01078 WSC-01077
3042 (UH-3959 and newer) WSC-01078 AEP-06731
3144 (older than SN 410494) WSC-01078 AEP-06731
3144 (SN 410494 – SN 413160) WSC-01079 AEP-06731
3144 (SN 413759 and newer) WSC-01079 337471
3350 283543 161941 (SKF) 161942 (FAG)
3352 283543 161941 (SKF) 161942 (FAG)
3546 WSC-01145 WSC-01081
4248 WSC-01082 WSC-01081
4450 (older than SN 413571) WSC-01082 WSC-01081
4450 (SN 413571 and newer) WSC-01082 337467
Dimension ToolPart Number Model Part Number Model
264170 1036 264168 3055
264170 1336 252821 3042
264170 1536 252821 3144
264168 1654 — 3642
264170 2036 260732 4248
264170 2436 260732 4450
264180 2640 264172 3546
264174 2650 264174 2148
264168 2854 — 2436
Common ToolsPart Number Description
255460 Torque multiplier 8,000 ft/lb
800751 Torque wrench 30-250 ft/lb
255462 3-3/4” socket; 1-1/2” Drive
— Measuring (machinist) tool for internal and external dimensions
— Depth gauge - pitman float
— Feeler gauges - (long set) - .001- .040
305719 Shim stock kits with 3 bolts per bearing for one complete jaw
Common Tools ContinuedPart Number Description
305720 Shim stock kits with 2 bolts per bearing for one complete jaw
— Set of Lifting Straps - 1” up to 4”
— Set of Lifting Chains - up to 1/2” and in pairs
— Oil bath container, heat up to 300 degrees . Capable of withstanding the weight of the pitman bearing - up to 300 lb .
AN Nut WrenchesPart Number Used on Lock
NutPart Number Used on Lock
Nut
257029 AN-07 257017 AN-26
257030 AN-09 257018 AN-28
256722 AN-12 257019 AN-30
257013 AN-14 257020 AN-32
256723 AN-15 257021 AN-36
257012 AN-16 257022 AN-38
257014 AN-17 257023 AN-40
256724 AN-18 257024 AN-44
257015 AN-19 257028 AN-048
256725 AN-20 257027 AN-052
257016 AN-21 257025 AN-056
256726 AN-22 257026 AN-060
Vertical Shaft Impactor ToolsFor All VSI Models
General Tools – MetricBox end/open end wrenches - 8mm up to 32mm
VSI Tool Kit – Imperial MeasurePart Number Description
289470 Contains all tools for normal repair and maintenance jobs
VSI Tool Kit – Metric MeasurePart Number Description
363742 Contains all tools for normal repair and maintenance jobs
Pedestal AssemblyPart Number Description
257017 AN-26 spanner wrench
— Retaining ring pliers (1/2 to 2-1/2 bore range)
— Serrated water pump pliers 2” capacity
— Nose wire cutting shear
348330 Socket for AN-26 locknut
348331 Socket for AN-24 locknut
Common ToolsPart Number Description
296097 Sonic Tensioner
2
Cone Crusher Tools Kodiak® Plus Cone Crushers
Recommended ToolsPart Number Description
— Wedgeplate flipping fixture for K500+
450132 Mantle wrench (2 lug)
540014 Mantle wrench (3 lug)
456294 TIR Test Block
87091 Cavity Plug T16A-2
— Misc . set of caps/plugs
456531 Cone offset lifting eye
456532 Cone lifting eye
83074 Needle oil sampler with tubing
450132 Mantle wrench
995136 Dial indicator with magnetic base
450015 Accumulator charging kit with hose
450266 Nitrogen checking gauge
995239 *Pinion bearing puller fixture
995156 *Wedge plate rotation - 406192
995024 *Spreader bar - thrust bearing installation and removal (used with 995023)
995023 *Cable .25 stud x 16 .0 (used with 995024)
991104 *Cone head flipping fixture
995144 *2 Legged radial bearing race puller for 1200LS, K200+, K300 and K300+ Radial bearings
— *3 legged radial bearing race puller for K400, K400+ & K500+ radial bearings
456532 *Cone lifting eye
456531 *Cone offset lifting eye
* Items available for purchase tagged with the ASME load testing/rating certification completed .
LS Cone Crushers
Recommended ToolsPart Number Description
450030 Clamp cylinder wrench
Track Unit Tools FT and GT Models
Recommended ToolsPart Number Description
— Crows foot for shaft coupling
— Digital pressure gauge
Belt ToolsFor All Equipment
Conveyor Installation, Repair and MaintenancePart Number
Description Fastener Type
Belt Width
Degree
313304 Belt template 140 48 90
313303 Belt template 190 48 90
233724 Belt template 190 60 90
1911 Belt template 190 36 90
349836 Belt template 140 24 90
1896 Belt template 140 30 90
46-48010 Belt template 1-1/2 48 90
227104 Belt template 1 18 90
46-48008 Belt template 140 36 90
46-48009 Belt template 140 42 90
323640 Belt template 190 30 90
323639 Belt template 190 36 90
23188 Belt template 190 42 90
323638 Belt template 190 48 90
313362 Belt template 1-1/2 36 90
66650 Belt stapling tool #C-187 2” wide
N/A N/A N/A
1857 Bolt breaker 1, 140, 190 , RP1, & SP6
N/A N/A
19323 Bolt horn flexco #2BH
N/A N/A N/A
233707 Boring bit flexco #BIB
1, 140, 190, RP1, & SP6
N/A N/A
240971 Power boring bit #HB-1
1, 140, 190, RP1, & SP6
N/A N/A
240972 Quick change chuck #5552
N/A N/A N/A
166985 Power punch #HP-1
1, 140, 190, RP1, & SP6
N/A N/A
313360 Power punch #HP-2
1-1/2, 2, 2-1/4, & RP2
N/A N/A
166986 Power wrench #HW-1
1, 140, 190, RP1 & SP6
N/A N/A
313361 Power wrench #HW-2
1-1/2, 2, 2-1/4, & RP2
N/A N/A
46-48003 Punch flexco #P1P
1, 140, 190, RP1, & SP6
N/A N/A
46-48004 Punch flexco #P2P
1-1/2, 2, 2-1/4, & RP2
N/A N/A
46-48005 Wrench flexco #S1S
1,140, 190, RP1, & SP6
N/A N/A
46-48006 Wrench flexco #S2S
1-1/2, 2, 2-1/4, & RP2
N/A N/A
397204 Rivnut Gun N/A N/A N/A
3
Screen Tools Screen Maintenance – Horizontal and Combo Screens
Part Number Description
— Metric sockets (locking assemblies)
090013 Assembly locking socket - 8mm hex
090036 Assembly locking socket - 6mm hex
995149 Nut bearing press AN32
721022 Nut bearing press AN- 38
995150 Wrench locknut AN32
721021 Wrench locknut AN-38
995147 Huck gun with extended nose huck model #3585 & #99-5013
086000 Y-27 pump (porta-power hydraulic pump or equivalent)
620471 Timing wrench LH 26 & 32 (provided)
620470 Timing wrench RH 26 & 32 (provided)
514046 Timing wrench 24 (provided)
514059 Timing wrench 24 LH (provided)
516095 Timing wrench 26 (provided)
720092 Timing wrench RH 38 (provided)
720093 Timing wrench LH 38 (provided)
516252 Bar location WT26 (provided)
620368 Bar location WT32 (provided) (qty 2)
720086 Bar location WT38 (provided)
514032 Bar location WT24 (provided)
721023 Spindle pusher field tool
Screen Lifting Bars
517305 Lifting bar - 5’ incline
516933 Lifting bar - 5’ LP
516909 Lifting bar - 5’ MS & HS
622128 Lifting bar - 6’ LP
622839 Lifting bar - 6’ MS & HS
720854 Lifting bar - 7’ LP
721004 Lifting bar - 7’ MS & HS
821557 Lifting bar - 8’ LP
821763 Lifting bar - 8’ MS & HS
Combo Screens
621049 Lifting/spreading bar - 6’ screens
721036 Lifting/spreading bar - 7’ screens
821075 Lifting/spreading bar - 8’ screens
Optional ToolsPart Number Description
995151 Hydraulic bearing press
620450 Spindle pusher field tool
995154 *Disc assembly offset lifting fixture shaft
995153 *Spindle lifting fixture
821671 Screen jacking bracket
995155 Cone installation shaft 32
* Items available for purchase tagged with the ASME load testing/rating certification completed .
Hydraulic ToolsFor All Equipment
Part Number Usage and Description
340826 Diagnostic Hose Kit
257121 Hydraulic Cap and Plug Assembly
Hydraulic Flow Meter KitsPart Number Usage and Description
321340 Kit includes 1-10 GPM meter and adapters for face seal connections for line sizes 1/2”, 3/4” and 1” .
321341 Kit includes 3-30 GPM meter and adapters for face seal connections for line sizes 1/2”, 3/4” and 1” .
SMA Drive Motor Lifting Lug - FT4240 and FT4250 Model Track Units
Part Number Description
291101 SMA Motor Lifting Lug
Hydraulic Fitting and Nut Wrenches - FT & GT Model Track UnitsPart Number Usage
305701 1-1/4” Wrench
305702 1-3/8” Wrench
305703 1-3/8” Wrench (1 side of jaw is thinner)
305704 1-1/2” Wrench
305705 1-5/8” Wrench
305706 1-5/8” Wrench (Has a flatter nose)
305707 1-3/4” Wrench
305708 1-7/8” Wrench
305709 2” Wrench
305710 2-1/8” Wrench
305711 2-3/16” Wrench
305712 2-1/4” Wrench
305713 2-3/8” Wrench
305714 2-3/4” Wrench
Accumulator Charging AssemblyPart Number Description
42-80042 Used for charging accumulators on KPI track-mounted impactor plants with nitrogen
O-Ring Seal Lock Kit - FT Model Track UnitsPart Number Includes
266581 Qty . 12 of each size Buna O-Rings in kit
2 FS03
3 FS04 (KPI Part #85515)
4 FS06 (KPI Part #85516)
5 FS08 (KPI Part #85517)
6 FS10
8 FS12 (KPI Part #85520)
10 FS14
12 FS16
14 FS20 (KPI Part #194550)
16 FS24
20 FS32
324
Hydraulic ToolsFor All EquipmentSuction Tool
Part Number Usage and Description
389367 Tool for creating a vacuum on the reservoir while replacing components to minimize liquid loss without draining tank .
Digital pressure fauge (ex . parker service junior kit)
Miscellaneous Tools For Various Parts and EquipmentPoly Chain Drive
Part Number Description
090417 Meter, sonic belt tension
AN Nut WrenchesPart Number Used on Lock
NutPart Number Used on Lock
Nut
257029 AN-07 257019 AN-30
257030 AN-09 257020 AN-32
256723 AN-15 257021 AN-36
257012 AN-16 257022 AN-38
257014 AN-17 257023 AN-40
256724 AN-18 257024 AN-44
257015 AN-19 257028 AN-048
257016 AN-21 257027 AN-052
256726 AN-22 257025 AN-056
257017 AN-26 257026 AN-060
257018 AN-28
Electrical Tools For All Equipment
Crimpers and ConnectorsPart Number Description
328497 Deutsch Connector Kit
328498 Deutsch Hand Crimper
328499 Packard Hand Crimper
328500 Packard Pin Removal Tool
Electrical Assembly Repair KitPart Number Description
356325 DT Series Service Kit (328497) - Crimp Tool (328498) - P/N Insert (356324)
Testing ToolsPart Number Description
355802 EDC Test Harness
Parts & Service Support Available 24 Hours a Day, 365 Days a Year
Kolberg-Pioneer, Inc.Parts Support: (800) 766-9793 | +1 (605) 665-9193Service Support: (800) 532-9311 | +1 (605) 665-9311
Johnson Crushers International, Inc.Parts Support: (888) 474-0115 | +1 (541) 988-9408Service Support: (866) 875-4058 | +1 (541) 988-9463
Astec Mobile Screens, Inc.Parts Support: +1(815) 626-6374Service Support: +1(815) 626-6374
Rocky University Our world-class program covers topics from basic component concepts to advanced mechanical troubleshooting as well as industry knowledge and sales trainings . With a variety of courses, including both online and face-to-face offerings, you can ensure that you and your team are thoroughly educated for all aspects of the sales and operating processes .
The complete scheduled training calendar is online at www .rockyuniversity .com .
Feeder Tools Vibrating Mechanism Assembly
AN Nut WrenchesPart Number Used on Lock Nut Used on Feeder
256722 AN-12 30x12, 36x14, 36x16
256723 AN-15 42x15
256725 AN-20 36x20, 42x12, 42x16, 42x18, 50x18, 50x24, 60x24
TRAINING
5
Kolberg-Pioneer, Inc.Parts Support: (800) 766-9793 | +1 (605) 665-9193Service Support: (800) 532-9311 | +1 (605) 665-9311
Johnson Crushers International, Inc.Parts Support: (888) 474-0115 | +1 (541) 988-9408Service Support: (866) 875-4058 | +1 (541) 988-9463
Astec Mobile Screens, Inc.Parts Support: +1(815) 626-6374Service Support: +1(815) 626-6374
www.kpijci.com
Because Kolberg-Pioneer, Inc ., Johnson Crushers International, Inc . and Astec Mobile Screens, Inc . may use in their catalog and literature, field photographs of their products which may have been modified by the owners, products furnished by Kolberg-Pioneer, Inc ., Johnson Crushers International, Inc . and Astec Mobile Screens, Inc . may not necessarily be as illustrated therein . Also continuous design progress makes it necessary that specifications be subject to change without notice . All sales of the products of Kolberg-Pioneer, Inc ., Johnson Crushers International, Inc . and Astec Mobile Screens, Inc . are subject to the provisions of their standard warranty . Kolberg-Pioneer, Inc ., Johnson Crushers International, Inc . and Astec Mobile Screens, Inc . do not warrant or represent that their products meet any federal, state, or local statutes, codes, ordinances, rules, standards or other regulations, including OSHA and MSHA, covering safety, pollution, electrical wiring, etc . Compliance with these statutes and regulations is the responsibility of the user and will be dependent upon the area and the use to which the product is put by the user . In some photographs, guards may have been removed for illustrative purposes only . This equipment should not be operated without all guards attached in their normal position . Placement of guards and other safety equipment is often dependent upon the area and how the product is used . A safety study should be made by the user of the application, and, if required additional guards, warning signs and other safety devices should be installed by the user, wherever appropriate before operating the products .
NOTE: SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE Rev . 2/19