Service Tool Guide - KPI-JCI and Astec Mobile Screens · General Maintenance & Troubleshooting...

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



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 .



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


450030 Clamp cylinder wrench

Track Unit Tools FT and GT Models


— 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






46-48010 Belt template 1-1/2 48 90


46-48008 Belt template 140 36 90

46-48009 Belt template 140 42 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)



721023 Spindle pusher field tool

Screen Lifting Bars

517305 Lifting bar - 5’ incline

516933 Lifting bar - 5’ LP

516909 Lifting bar - 5’ MS & HS







Combo Screens

621049 Lifting/spreading bar - 6’ 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


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


090417 Meter, sonic belt tension



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

Service Tool Guide - KPI-JCI and Astec Mobile Screens · General Maintenance & Troubleshooting...

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