Manual de Operacion y Mantto. ASTEC

Operation and
Maintenance Manual
FNG 2512K
OM-FNG2512K 4/17
Table of Contents
Section 1: Introduction 7
OVERVIEW 9
QUICK FACTS 9
PLANT CAPACITY 9
GETTING TO KNOW YOUR SCREENING PLANT 12
ENGINE ENCLOSURE 13
SERIAL PLATE 14
INTRODUCTION NOTES 15
Section 2: Safety 17
TRAINING 17
UNDERSTAND SIGNAL WORDS 17
DANGER OR WARNING 17
LOCKOUT/TAGOUT 17
FOLLOW SAFETY INSTRUCTIONS 20
REPLACE SAFETY SIGNS 20
PREVENT BYPASS STARTING 20
HANDLE FUEL SAFELY – AVOID FIRES! 20
PREPARE FOR EMERGENCIES 20
SERVICE ENGINES SAFELY 20
HANDLE STARTING FLUID SAFELY 20
PROTECT AGAINST NOISE 21
WEAR PROTECTIVE CLOTHING 21
INSTALL FAN GUARDS 21
HANDLE CHEMICAL PRODUCTS SAFELY 21
PRACTICE SAFE MAINTENANCE 21
AVOID HIGH PRESSURE FLUIDS 21
SERVICE COOLING SYSTEM SAFELY 22
WORK IN VENTILATED AREA 22
DISPOSE OF WASTE PROPERLY 22
AVOID HEATING NEAR PRESSURIZED FLUID LINES 22
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM 22
REMOVE PAINT BEFORE WELDING OR HEATING 22
AVOID HOT PARTS 23
DO NOT OPEN HIGH PRESSURE FUEL SYSTEM 23
PREVENT BATTERY EXPLOSIONS 23
AVOID HARMFUL ASBESTOS DUST 23
FNG 2512K Manual III
Table of Contents
PROTECT AGAINST HIGH PRESSURE SPRAY 23
HANDLING BATTERIES SAFELY 24
SAFETY NOTES 26
Section 3: Setup 27
ADDITIONAL INFORMATION 27
STARTING THE ENGINE 28
DIAGNOSTIC GAUGE 29
LEVELING THE PLANT 30
INITIATE SETUP 30
UNFOLD SIDE CONVEYORS 31
LOWER FINES CONVEYOR HEAD SECTION 33
POSITIONING FINES CONVEYOR 34
FINES CONVEYOR TAIL SECTION 35
RAISE SCREEN BOX TO OPERATING ANGLE 36
SETUP COMPLETE 37
INTRODUCTION TO CONVENTIONAL SCREENING 38
“K” SERIES SCREEN 39
SCREENING APPLICATION 43
SCREENING EFFICIENCY 45
FACTORS FOR CALCULATING SCREEN AREA 46
CHARTS FOR CALCULATING SCREEN AREA 47
SITE SELECTION AND PREPARATION 48
IV FNG 2512K Manual

Table of Contents
DIRECTION OF ROTATION 49
CROWN RUBBER 49
SCREEN CLOTH INSTALLATION 50
SETUP NOTES 52
Section 4: Operation & Maintenance 53

PRE-OPERATION CHECKS 53
OPERATIONAL CHECKS 54
TURNING SCREENING PLANT ON 55
OPERATION 56
SIDE CONVEYOR CONTROL 57
SCREEN 58
GRIZZLY 59
OPTIONAL REMOTE GRIZZLY 59
AGGREGATE SPREADER 60
OVERALL INSPECTION 61
HYDRAULIC MAINTENANCE 61
TRAINING THE BELT 62
BELT TENSION 63
GUARDS 63
BELT CLEANERS 63
FLASHING 63
MAINTENANCE SCHEDULE 64
BEARINGS 64
TRACKS MAINTENANCE SCHEDULE 65
CHECKING TRACK TENSION 67
ADUSTING TRACK TENSION 68
START-UP AND SHUTDOWN 69
OBSERVING SCREEN 70
OPERATION 70
DAILY SHUT-DOWN 70
PRE-OPERATION/OPERATION CHECKLIST 71
SCREEN BOX MAINTENANCE/SERVICE INTERVALS 71
SCREEN ADJUSTMENTS 72
SCREEN MAINTENANCE & LUBRICATION 73
SCREEN TROUBLESHOOTING 78
HYDRAULIC FILTERS 79
FNG 2512K Manual V
Table of Contents
ENGINE FILTERS 80
TURNING THE SHREDDER ON 82
SHREDDER OPERATION 83
SHREDDER VALVE CONTROL 83
SHREDDER MAINTENANCE SCHEDULE 84
DAILY - GENERAL INSPECTION 85
50 HOURS - SHREDDER BEARINGS & DRIVE BOLT 85
200 HOURS - SHREDDER BARS OR TILLERS & CYLINDER RAM 86
TROUBLE SHOOTING 87
OPERATION AND MAINTENANCE NOTES 89
Section 5: Warranty 90
STANDARD WARRANTY 90
VI FNG 2512K Manual

Section 1: Introduction
Introduction Parts
This manual contains safety, setup, operation, The parts section contains drawings of all specific
maintenance, and parts sections. Keep this pieces of the plant. Each drawing contains lines
manual stored in the manual container located with balloons for each sub-part. When calling
beneath the main control panel of the unit. Keep for replacement parts, please provide the parts
this manual with the unit at all times. The manual department with the part number that the balloon
should remain with the unit to assist in training, refers to.
operation, setup, and maintenance procedures.
Contact Astec Mobile Screen
Please keep in mind that parts and procedures Phone (Toll Free).....(800) 545-2125
in this manual may differ from your exact model. Fax...........................(815) 626-6430
The data used to created this manual are based
on the latest information at the time of publication. Email
Due to Astec Mobile Screens’ policy of continuous Parts...... [email protected]
improvement, features and specifications are Sales..... [email protected]
subject to change without notice. All engineering
drawings provided in this manual are model
specific. Refer to engineering drawings as
needed, they are the best source of model specific
information.
Safety
The safety section of this manual is filled with
procedures that should be followed at all times.
Take the time to read the safety section of the
manual and obey all safety information presented
on the unit. Safety is important!
Operation
Do not attempt to operate this machine without
fully reading the manual first. The operation section
of the manual is arranged in a manner that must
be followed sequentially. If the description does
not match your unit, or there is a discrepancy in
the data, contact your local Astec Mobile Screens
Representative for assistance.
Maintenance
Due to the nature of equipment and environmental
variables that may be present, it is imperative to
perform a daily review of your equipment. Pay
close attention to the daily checks outlines in
the Maintenance section of this manual. Failure
to follow maintenance guidelines could result in
premature wear, or damage to equipment.
FNG 2512K Manual 7

8 FNG 2512K Manual

OVERVIEW PLANT CAPACITY

The 2512K is equipped with a double deck Kol- Productivity will vary depending on application
berg® screen. This combination gives the plant requirements: feed material size, material sepa-
the ability to process coarse and fine material rations, type of screens used, weight of product
separations. The Fold ‘n Go® 2512K gives maxi- and other material considerations. The feeder
mum production and efficiency in crushed stone, system on the 2512K consists of a 12 cubic
RAP, sand & gravel, coal, and more. As with yard heaped capacity hopper with a 6’ x 13’ top
the entire line of Fold ‘n Go® mobile screening opening. The heavy duty 25° sloped grizzly with
plants the 2512K, with its wheel mounted base, 6” nominal opening is outfitted with a patented
is able to move around to multiple job sites with scissor action hydraulic dump for easy clean-
a quick setup time of under 15 minutes. ing.
Outfitted with a 99 HP Tier IV water cooled

diesel engine, the plant has a 12 volt battery and
engine mounted pumps which operate all plant
functions and three on-board stacking convey-
ors. Additionally, the NEMA-4 rated instrument
panel, tachometer, hour meter, voltmeter, oil
pressure gauge, oil temperature gauge and
emergency stop come standard on all 2512K
models along with auxiliary power for up to a 30
HP off plant conveyor(s).

QUICK FACTS
Top and Bottom Screen 5’ x 12’ Deck
Feed Hopper Capacity 12 cubic yard heaped capacity
Belt Feeder 42”
Delivery Conveyor 36”
Fines Conveyor 42”
Top Deck Overs Conveyor 24”
Bottom Deck Overs Conveyor 24”
Fuel Tank Capacity 140 Gallon
Hydraulic Tank Capacity 150 Gallon
Engine 99 HP Tier IV
FNG 2512K Manual 9

11'-1 5/16"
14'- 11/16"
4'-5 3/16"
63'-2"
10 FNG 2512K Manual

11 FNG 2512K Manual
216 13/16
[18'-13 16 "]
154 7/8
[12'-107 8 "]
823 7/8
[68'-77 8 "]
158 1/4
[13'-21 4 "]
278 3/16
[23'-23 16 "]
278 3/8
[23'-23 8 "]
157 1/2
[13'-11 2 "]
DELIVERY
CONVEYOR
GRIZZLY
SCREEN
CHASSIS
BELT FEEDER
SUPPORT LEGS
GETTING TO KNOW YOUR SCREENING PLANT

It is important to get to know the main
components of your screening plant.
The names of these components will be
referenced later in this manual.
12 FNG 2512K Manual

FINES CONVEYOR
BOTTOM DECK
OVERS CONVEYOR
TOP DECK
CONVEYOR
ENGINE ENCLOSURE
FEED HOPPER
FNG 2512K Manual 13

Figure 14.1
SERIAL PLATE
Located on the machine frame (usually near Make sure you are aware of where this plate is
the manual container) is the serial plate (Figure located on the machine as it will be essential
14.1) in determining proper parts or service on this
machine.
14 FNG 2512K Manual
INTRODUCTION NOTES
FNG 2512K Manual 15

16 FNG 2512K Manual

Section 2: Safety
TRAINING to the potential for personal injury. Follow
Safety instructions are important! Read all at- recommended precautions and safe operating
tachment and power unit manuals; follow all practices.
safety rules and safety decal information. Re-
placement manuals and safety decals are avail- Indicates a
able from your dealer. Failure to follow instruc- potentially
tions or safety rules can result in serious injury or hazardous
death. If you do not understand any part of this situation which, if not avoided, may result in
manual and need assistance, see your dealer. minor or moderate injury. Caution may also be
used to alert against unsafe practices.
Know your controls and how to stop engine and
attachment quickly in an emergency. Indicates a
potentially
Operators must be instructed in and be capable hazardous
of the safe operation of the equipment, its attach- situation which, if not avoided, could result in
ments, and all controls. death or serious injury.
Do not allow anyone to operate this equipment Indicates an im-

without proper instructions. mediately haz-
ardous situation
Keep hands and body away from pressurized which, if not avoided, will result in death or seri-
lines. Use paper or cardboard, not hands or ous injury. Danger is limited to the most extreme
other body parts to check for leaks. Wear safety situations.
goggles. Hydraulic fluid under pressure can eas-
ily penetrate skin and will cause serious injury or IMPORTANT: Indicates that failure to ob-
death. serve can cause damage to equipment.
Make sure that all operating and service person- NOTE: Indicates helpful information.
nel know that if hydraulic fluid penetrates skin, it
must be surgically removed as soon as possible
by a doctor familiar with this form of injury or gan-
grene, serious injury, or death will result. CON- LOCKOUT/TAGOUT
TACT A PHYSICIAN IMMEDIATELY IF FLUID
ENTERS SKIN OR EYES. DO NOT DELAY. What is the OSHA standard for control of haz-
ardous energy sources?
UNDERSTAND SIGNAL WORDS The OSHA standard for The Control of Hazard-
A signal word DANGER, WARNING OR CAU- ous Energy (Lockout/Tagout), Title 29 Code of
TION is used with the safety alert symbol. DAN- Federal Regulations (CFR) Part 1910.147, ad-
GER identifies the most serious hazards. dresses the practices and procedures necessary
to disable machinery or equipment, thereby pre-
DANGER or WARNING venting the release of hazardous energy while
safety signs are located near specific hazards. employees perform servicing and maintenance
General precautions are listed on CAUTION activities. The standard outlines measures for
safety signs. CAUTION also calls attention to controlling hazardous energies—electrical, me-
safety messages in this manual. chanical, hydraulic, pneumatic, chemical, ther-
mal, and other energy sources.
This is a safety alert symbol.
When you see this symbol on your In addition, 29 CFR 1910.333 sets forth require-
machine or in this manual, be alert ments to protect employees working on electric
circuits and equipment. This section requires
FNG 2512K Manual 17
Section 2: Safety
workers to use safe work practices, including What must employers do to protect employ-
lockout and tagging procedures. These provi- ees?
sions apply when employees are exposed to The standards establish requirements that em-
electrical hazards while working on, near, or with ployers must follow when employees are ex-
conductors or systems that use electric energy. posed to hazardous energy while servicing and
maintaining equipment and machinery. Some of
Why is controlling hazardous energy sources the most critical requirements from these stan-
important? dards are outlined below:
Employees servicing or maintaining machines or ■■ Develop, implement, and enforce an energy
equipment may be exposed to serious physical control program.
harm or death if hazardous energy is not prop- ■■ Use lockout devices for equipment that can
erly controlled. Craft workers, machine opera- be locked out. Tagout devices may be used in
tors, and laborers are among the 3 million work- lieu of lockout devices only if the tagout pro-
ers who service equipment and face the greatest gram provides employee protection equiva-
risk. Compliance with the lockout/tagout standard lent to that provided through a lockout pro-
prevents an estimated 120 fatalities and 50,000 gram.
injuries each year. Workers injured on the job ■■ Ensure that new or overhauled equipment is
from exposure to hazardous energy lose an av- capable of being locked out.
erage of 24 workdays for recuperation. ■■ Develop, implement, and enforce an effective
tagout program if machines or equipment are
How can you protect workers? not capable of being locked out.
The lockout/tagout standard establishes the em- ■■ Develop, document, implement, and enforce
ployer’s responsibility to protect employees from energy control procedures. [See the note to
hazardous energy sources on machines and 29 CFR 1910.147(c)(4)(i) for an exception to
equipment during service and maintenance. The the documentation requirements.] Use only
standard gives each employer the flexibility to lockout/tagout devices authorized for the par-
develop an energy control program suited to the ticular equipment or machinery and ensure
needs of the particular workplace and the types that they are durable, standardized, and sub-
of machines and equipment being maintained or stantial.
serviced. This is generally done by affixing the ■■ Ensure that lockout/tagout devices identify
appropriate lockout or tagout devices to energy- the individual users.
isolating devices and by de-energizing machines ■■ Establish a policy that permits only the em-
and equipment. The standard outlines the steps ployee who applied a lockout/tagout device
required to do this. to remove it. [See 29 CFR 1910.147(e)(3) for
exception.]
What do employees need to know? ■■ Inspect energy control procedures at least
Employees need to be trained to ensure that annually.
they know, understand, and follow the applicable ■■ Provide effective training as mandated for all
provisions of the hazardous energy control pro- employees covered by the standard.
cedures. The training must cover at least three ■■ Comply with the additional energy control pro-
areas: aspects of the employer’s energy control visions in OSHA standards when machines
program; elements of the energy control proce- or equipment must be tested or repositioned,
dure relevant to the employee’s duties or assign- when outside contractors work at the site, in
ment; and the various requirements of the OSHA group lockout situations, and during shift or
personnel changes.
standards related to lockout/tagout.
18 FNG 2512K Manual

Section 2: Safety
How can you get more information?

OSHA has various publications, standards, tech-
nical assistance, and compliance tools to help
you, and offers extensive assistance through its
many safety and health programs: workplace con-
sultation, voluntary protection programs, grants,
strategic partnerships, state plans, training, and
education. Guidance such as OSHA’s Safety and
Health Management Program Guidelines identify
elements that are critical to the development of a
successful safety and health management sys-
tem. This and other information are available on
OSHA’s website at www.osha.gov.
For a free copy of OSHA publications, send a

self-addressed mailing label to this address:
OSHA Publications Office
P.O. Box 37535
Washington, DC 20013-7535
Or send a request to our fax at (202) 693-2498,

or call us at (202) 693-1888. To file a complaint
by phone, report an emergency, or get OSHA ad-
vice, assistance, or products, contact your near-
est OSHA office under the “U.S. Department of
Labor” listing in your phone book, or call us toll-
free at (800)-321-OSHA
(6742). The teletypewriter (TTY) number is (877)
889-5627
To file a complaint online or obtain more informa-

tion on OSHA federal and state programs, visit
OSHA’s web site. www.osha.gov
FNG 2512K Manual 19

Section 2: Safety
Read this manual before operating your HANDLE FUEL SAFELY – AVOID FIRES!
equipment. The information presented will Handle fuel with care: it is highly
prepare you to do a better and safer job. flammable. Do not refuel the
Keep this manual handy for ready reference. machine while smoking or when
Require all operators to read this manual near open flame or sparks.
carefully and become acquainted with all
adjustment and operating procedures before Always stop engine before refu-
attempting to operate. Replacement manuals eling machine. Fill fuel tank outdoors. Prevent
can be obtained from your dealer. fires by keeping machine clean of accumulated
trash, grease, and debris. Always clean up
FOLLOW SAFETY INSTRUCTIONS spilled fuel.
Carefully read all safety mes-
sages in this manual and on PREPARE FOR EMERGENCIES
your machine safety signs. Keep Be prepared if a fire starts. Keep
safety signs in good condition. a first aid kit and fire extinguish-
Replace missing or damaged er handy.
safety signs. Be sure new equip- Keep emergency numbers for
ment components and repair parts include the doctors, ambulance service,
current safety signs. Replacement safety signs hospital, and fire department
are available from your Astec Mobile Screens near your telephone.
Dealer.
SERVICE ENGINES SAFELY
Learn how to operate the machine and how to Tie long hair behind your head.
use controls properly. Do not let anyone operate Do not wear a necktie, scarf,
without instruction. loose clothing, or necklace when
you work near machine tools
Keep your machine in proper working condition. or moving parts. If these items
Unauthorized modifications to the machine may were to get caught, severe injury
impair the function and/or safety, affect machine or death could result.
life and/or void the warranty.
Remove rings and other jewelry to prevent
If you do not understand any part of this manual electrical shorts and entanglement in moving
and need assistance, contact your Astec Mobile parts.
Screens Dealer.
REPLACE SAFETY SIGNS HANDLE STARTING FLUID SAFELY

Replace missing or damaged safety signs. See Starting fluid is highly flam-
Appendix A for a detailed description of safety mable. When handling starting
label placement. Contact your Astec Mobile fluid, keep all sparks and flame
Screens Dealer for replacement safety decals. away. Keep starting fluid away
from batteries and cables. To
PREVENT BYPASS STARTING prevent accidental discharge
Avoid possible injury or death when storing the pressurized can, keep the cap
from engine run away. Do not on the container, and store in a cool, protected
start engine by shorting across location. Do not incinerate or puncture a starting
starter terminal. Start engine fluid container.
only from operator’s station.
20 FNG 2512K Manual

Section 2: Safety
PROTECT AGAINST NOISE safely. Then follow procedures and recommend-

Prolonged exposure to loud ed equipment. (See your Astec Mobile Screens
noise can cause impairment or dealer for MSDS’s on chemical products used
loss of hearing. with Astec Mobile Screens equipment)
Wear a suitable hearing protec- PRACTICE SAFE MAINTENANCE

tive device such as earmuffs Understand service procedure
or earplugs to protect against objectionable or before doing work. Keep area
uncomfortable, loud noises. clean and dry.
■■ Never lubricate, service,

WEAR PROTECTIVE CLOTHING or adjust machine while it is
Wear close fitting clothing and moving.
safety equipment appropriate ■■ Keep hands, feet, and clothing from power-
to the job. Operating equipment drive parts.
safely requires the FULL AT- ■■ Disengage all power and operate controls to
TENTION of the operator. Do relieve pressure.
not wear radio or music head- ■■ Lower equipment to the ground.
phones while operating machine. ■■ Stop the engine.
■■ Remove the key, allow machine to cool.
INSTALL FAN GUARDS
Rotating cooling system fans Securely support any machine elements that
can cause serious injury. must be raised for service work.
Keep fan guards in place at all Keep all parts in good condition and properly in-
times during engine operation. stalled. Fix damage immediately. Replace worn
Wear close fitting clothes. Stop or broken parts. Remove any buildup of grease,
the engine and be sure fan is stopped before oil, or debris.
making adjustments or connections, or cleaning
near the front of the engine. On self-propelled equipment, disconnect battery
ground cable (-) before making adjustments on
HANDLE CHEMICAL PRODUCTS SAFELY electrical systems or welding on machine. On
Direct exposure to hazardous towed implements, disconnect wiring harnesses
chemicals can cause serious from tractor before servicing electrical system
injury. Potentially hazardous components or welding on machine.
chemicals used with Astec Mo-
bile Screens equipment include AVOID HIGH PRESSURE FLUIDS
such items as lubricants, cool- Escaping fluid under pressure
ants, paints, and adhesives. A Material Safety can penetrate the skin causing
Data Sheet (MSDS) provides specific details on serious injury or death.
chemical products: physical and health hazards,
safety procedures, and emergency response Avoid the hazard by relieving
techniques. pressure before disconnecting
hydraulic or other lines. Tighten all connections
Check the MSDS before you start any job using before applying pressure.
a hazardous chemical. That way you will know
exactly what the risks are and how to do the job Search for leaks with a piece of cardboard. Pro-
FNG 2512K Manual 21

Section 2: Safety
tect hands and body from high pressure fluids. can damage the Earth’s atmosphere. Govern-
ment regulations may require a certified air con-
If an accident occurs, seek medical attention im- ditioning service center to recover and recycle
mediately. Any fluid injected in the skin must be used air conditioning refrigerants.
surgically removed within a few hours or gan-
grene may result. Doctors unfamiliar with this Inquire on the proper way to recycle or dispose
type of injury should reference a knowledgeable of waste from your local environmental or recy-
medical source. cling center, or from your Astec Mobile Screens
Dealer.
SERVICE COOLING SYSTEM SAFELY
Explosive release of fluids from AVOID HEATING NEAR PRESSURIZED FLUID
pressurized cooling system can LINES
cause serious burns. Flammable spray can be gen-
erated by heating near pres-
Shut off engine. Only remove surized fluid lines, resulting
filler cap when cool enough to in severe burns to yourself or
touch with bare hands. Slowly bystanders. Do not heat by
loosen cap to “first stop” position to relieve pres- welding soldering, or using a
sure before removing completely. torch near pressurized fluid lines
or other flammable materials. Pressurized lines
WORK IN VENTILATED AREA can be accidentally cut when heat goes beyond
Expel engine exhaust fumes the immediate flame area.
from the area with an exhaust
pipe extension.
DO NOT OPEN HIGH PRESSURE FUEL SYS-
If you do not have an exhaust TEM
pipe extension, open the doors High pressure fluid remaining
to get outside air into the area. in fuel lines can cause serious
injury or death. Do not discon-
nect or attempt repair of fuel
DISPOSE OF WASTE PROPERLY lines, sensors, or any other
Improperly disposing of waste components between the high-
can threaten the environment pressure fuel pump and nozzles on engines
and ecology. Potentially harmful with High Pressure Common Rail (HPCR) fuel
wastes used with Astec Mobile system. Only technicians familiar with this type
Screen equipment include such of system can perform repairs.
items as oil, fuel, coolant, brake
fluid, filters, and batteries. REMOVE PAINT BEFORE WELDING OR
HEATING
Use leak proof containers when draining fluids. Avoid potentially toxic fumes and
Do not use food or beverage containers that dust.
may mislead someone into drinking from them.
Hazardous fumes can be gener-
Do not pour waste onto the ground, down a ated when paint is heated by
drain, or into any water source. welding, soldering, or using a
torch.
Air conditioning refrigerants escaping into the air
22 FNG 2512K Manual

Section 2: Safety
Remove paint before heating: pump and nozzles on engines with High Pres-
■■ Remove paint a minimum of 100 mm (4 in.) sure Common Rail (HPCR) fuel system. Only
from area to be affected by heating. If paint technicians familiar with this type of system can
cannot be removed, wear an approved respi- perform repairs.
rator before heating or welding.
■■ If you sand or grind paint, avoid breathing PREVENT BATTERY EXPLOSIONS
the dust. Wear an approved respirator. Keep sparks, lighted matches,
■■ If you use solvent or paint stripper, remove and open flame away from the
stripper with soap and water before welding. top of battery. Battery vapors
Remove solvent or paint stripper containers can explode. Never check bat-
and other flammable materials from area. tery charge by placing a metal
Allow fumes to disperse at least 15 minutes object across the posts. Use a
before welding or heating. volt meter or hydrometer. Do not charge a frozen
battery; it may explode. Warm battery to 16° C
Do not use chlorinated solvent in areas where (60° F).
welding will take place. Do all work in an area
that is well ventilated to carry toxic fumes and AVOID HARMFUL ASBESTOS DUST
dust away. Dispose of paint and solvent prop- Avoid breathing dust that may
erly. be generated when handling
components containing asbes-
AVOID HOT PARTS tos fibers. Inhaled asbestos
Avoid skin contact with exhaust fibers may cause lung cancer.
manifolds, turbochargers, muf-
flers, and other hot parts. Keep Components in products that may contain as-
flammable materials clear of all bestos fibers are brake pads, brake band and
hot parts. lining assemblies, clutch plates, and some gas-
kets. The asbestos used in these components is
External dry exhaust parts be- usually found in a resin or sealed in some way.
come very hot during operation. Turbochargers Normal handling is not hazardous as long as
may reach temperatures as high as 500°C (932° airborne dust containing asbestos is not gener-
F) under full load, and naturally aspired exhaust ated.
manifolds may reach 600° C (1112° F) under full
load. Avoid creating dust. Never use compressed air
for cleaning. Avoid brushing or grinding material
This may ignite paper, cloth or wooden materi- containing asbestos. When servicing, wear an
als. Parts on engines that have been at full load approved respirator. A special vacuum cleaner
and reduced to no load idle will maintain approx- is recommended to clean asbestos. If not avail-
imately 140° C (302° F) temperatures. able, apply a mist of oil or water on the material
containing asbestos.
DO NOT OPEN HIGH PRESSURE FUEL SYS-
TEM Keep bystanders away from the area.
High pressure fluid remaining in
fuel lines can cause serious inju- PROTECT AGAINST HIGH PRESSURE
ry or death. Do not disconnect or SPRAY
attempt repair of fuel lines, sen- Spray from high pressure nozzles can penetrate
sors, or any other components the skin and cause serious injury. Keep spray
between the high-pressure fuel from contacting hands or body.
FNG 2512K Manual 23

Section 2: Safety
If an accident occurs, seek medical attention im- WARNING: Battery posts, terminals, and related
mediately. Any fluid injected in the skin must be accessories contain lead and lead compounds,
surgically removed within a few hours or gan- chemicals known to the state of California to
grene may result. Doctors unfamiliar with this cause cancer and reproductive harm. Wash
type of injury should reference a knowledgeable hands after handling.
medical source.
HANDLING BATTERIES SAFELY

CAUTION: Battery vapors can
explode. Keep sparks, lighted
matches, and open flame away
from the top of battery. Use a
flashlight to check battery elec-
trolyte level.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer. Always remove grounded (-) battery
clamp first and replace it last.
CAUTION: Sulfuric acid in battery electrolyte

is poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:

1. Filling batteries in a well ventilated area.
2. Wearing eye protection and rubber
gloves (CHECK)
3. Avoiding breathing fumes when electro-
lyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Using proper jump start procedure.
f you spill acid on yourself:

1. Flush your skin with water.
2. Apply baking soda or lime to help neu-
tralize the acid.
3. Flush your eyes with water for 15-30
minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but
do not exceed 2L (2qt)
3. Get medical attention immediately.
24 FNG 2512K Manual

Section 2: Safety
Date Trainee Signature Trainer Signature
FNG 2512K Manual 25

Section 2: Safety
SAFETY NOTES
26 FNG 2512K Manual

Section 3: Setup
ADDITIONAL INFORMATION
Each hydraulic spool valve is labeled with a looking at the machine, the FEED BIN is located
black and white decal. Each decal is marked to your right and the FINES is located to you left.
with a “push” and “pull” side. Pull means to
force the valve UP towards the sky and Push Back: The fines conveyor is located at the back
means to force the valve DOWN towards the of the plant.
ground.
Front: The front of the plant is where the feed
A series of steps must be completed to unfold bin is located. In this section you can gain ac-
the plant before operation can begin. Through- cess to the feed bin conveyor. Also, optional
out the setup and operating sections of this components such as wings and the bulkhead
manual the plant orientation will be referred to are stored on either side of this section.
as if you were standing behind the fines con- Prior to attempting each step, read the entire
veyor facing towards the feed bin. All “sides” step first. At the beginning of each step a brief
and “direction” of the plant will be indicated as explanation of that step will be given. Following
follows: this a more detailed description of how to com-
plete each step will be given. Follow the steps
Roadside: Your left side. The roadside section sequentially. It is important to fold and unfold
of the plant refers to the side, when standing the plant in the proper order.
and looking at the machine, the FEED BIN is
located to your left and the FINES is located to
you right. NOTE: Failure to follow all instructions can
result in damage to the equipment, serious
Curbside: Your right side. The curbside section injury, or DEATH. Please note all safety sym-
of the plant refers to the side, when standing a bols that accompany each step.
FNG 2512K Manual 27
Section 3: Setup
STARTING THE ENGINE
Turn the key past the ON/START positoin and THROTTLE

hold until engine starts. Speed is controlled using the THROTTLE UP/
DOWN button. The manual throttle will allow the
NOTE: Stop engine immediately if there are any engine speed to be adjusted between a defined
signs of part failure. Symptoms that may be early Maximum/Target speed and Min/Cool Down
signs of engine problems are: speed.
■■ Sudden drop in oil pressure Press up on the UP/RABBIT direction to increase

■■ Abnormal coolant temperatures engine RPM or press down on the DOWN/
■■ Unusual noise or vibration TURTLE direction to lower engine RPM.
■■ Sudden loss of power
■■ Excessive black exhaust
■■ Excessive fuel consumption
■■ Excessive oil consumption
■■ Fluid leaks
28 FNG 2512K Manual
Section 3: Setup
DIAGNOSTIC GAUGE The Follow menu of engine parameters can be

The diagnostic gauge allows the operator to view displayed on the diagnostic gauge window:
many readouts of engine functions and trouble ■■ Engine hours
codes (DTCs). The gauge is linked to the elec- ■■ Engine RPM
tronic control system and its sensors. This allows ■■ System voltage
the operator to monitor engine functions and to ■■ Percent engine load at the current RPM
troubleshoot the engine systems when needed. ■■ Coolant temperature
■■ Oil pressure
Press the menu key (circled above) to access the ■■ Throttle position
various engine functions in sequence. The dis- ■■ Intake manifold temperature
plays can be selected as either customary Eng- ■■ Current fuel consumption
lish or metric units. ■■ Active service (diagnostic) codes
■■ Stored service (diagnostic) codes form the
engine
■■ Set the units for display.
NOTE: The engine does not need to be running

to navigate the diagnostic gauge screens. To ac-
cess the diagnostic gauge, turn the key switch to
the ON position.
FNG 2512K Manual 29
Section 3: Setup
FINES
SET-UP AUX. KING PIN
CONVEYOR
FUNCTIONS CIRCUIT
ROAD SIDE CURB SIDE
ON ON RAISE RAISE ON
NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL
LOWER LOWER
Relief Pressure: Relief Pressure: Relief Pressure:

3000 PSI 3000 PSI 2500 PSI
D00110
D00113
Figure 30.1 Figure 30.2
LEVELING THE PLANT INITIATE SETUP

See Figure 30.1 and Figure 30.2 for help locat- The Set-Up Functions lever Figure 30.1 is used
ing the King Pin and the Set-Up Functions to initiate the setup process. Prior to attempt-
control valves. ing setup of the plant, the setup functions lever
Ensure Engine is Running at 1100 RPM. (See must be placed in the ON position (UP). Leave
starting the engine) Pull the King Pin levers UP Set-Up functions lever in the ON position for
to Raise the plant and push the King Pin levers the duration of the setup process, without this
DOWN to lower the plant. Leveling jacks are on lever in the ON position, multiple levers will not
the front of the unit below the feed bin. Level function.
plant prior to operating. Failure to level the
plant from both side to side and from front to AFTER SETUP HAS BEEN COMPLETED, BE
back will result in poor performance or damage SURE TO TURN SETUP FUNCTIONS VALVE
to equipment. OFF!! DAMAGE TO EQUIPMENT WILL OC-
CUR!!!
30 FNG 2512K Manual
Section 3: Setup
SIDE DISCHARGE CONVEYOR

FOLD ROTATE
OPERATION OPERATION
NEUTRAL NEUTRAL
TRANSPORT TRANSPORT
Relief Pressure: Relief Pressure:

3000 PSI 3000 PSI D00317
CAUTION: WHEN RAISING SIDE Figure 31.1 Figure 31.2

CONVEYORS AND SCREEN BOX
BEWARE OF OVERHEAD POWER
LINES!
UNFOLD SIDE CONVEYORS  Ensure the path of travel is clear from all
In order to properly unfold the plant, each con- obstructions and personnel.
veyor must be set into operating position by a  Use the FOLD and ROTATE levers to con-
series of gradual steps (Figure 31.1 - 32.2) using trol the side conveyor. (Figure 31.1 & 31.2)
both the ROTATE and FOLD levers in a simulta-  Raise the conveyor up with the ROTATE
neous fashion. Begin by unfolding the curbside lever.
conveyor. It is highly recommended you follow  After the conveyor has cleared the perch,
the same procedure each time you fold and un- begin unfolding it away from the plant (Figure
fold the plant. To rotate side conveyors: 31.4)
FNG 2512K Manual 31
Section 3: Setup
 After the conveyor has been lifted from the that the belt has been aligned and check
perch and moved away from the plant, continue the hydraulic cylinders’ rods for visible
to both ROTATE and UNFOLD the conveyor chrome. If chrome is visible, the convey-
simultaneously until the side conveyor is in the or has not been fully rotated into oper-
proper operating position. (Figure 32.1 & 32.2) ating position, this could result in poor
productivity or damage to equipment.
DO NOT attempt to rotate the conveyor
to the full upright position before begin- NOTE: The speed at which the conveyors
ning to unfold the side conveyor. Dam- react to the hydraulic controls is directly
age to the equipment WILL occur. related to the current speed of the en-
gine. Do not attempt to run the engine
NOTE: The conveyor belt will not align faster than 1100RPM during the setup
properly if the side conveyor is not fully process.
rotated into operating position. After the
side conveyors have been rotated and
folded into the operating position, check
32 FNG 2512K Manual
Section 3: Setup
FINES SCREEN
CONVEYOR POSITION
(PINS MUST BE
FOLD REMOVED)
OPERATION OPERATION
NEUTRAL NEUTRAL
TRANSPORT TRANSPORT
3000 PSI 3000 PSI D00316
LOWER FINES CONVEYOR HEAD SECTION

The fines conveyor is separated into two sec-  It may be necessary to first raise head section
tions. slightly to relieve pressure from transport pins.
 Head Section: operates by the  Figure 33.3 shows the path the fines conveyor
control valve depicted in Figure 33.1. The head head section will follow when lowered.
section rotates in a manner depicted in figure  Pull the control valve labeled Fines Conveyor
12. Fold to lower the fines conveyor head section
 Tail Section: When the screen box into pre-operating position.
is raised and lowered (Figure 33.2), the head
and tail section of the fines conveyor move Note: After lowering Fines conveyor head
simultaneously via a set of chains connected on section, place transport pins back into unit
each side of the fines conveyor. for use during screening operation.
Begin the process by removing the transport

pins from both sides of conveyor. For pin loca-
tion, refer to Figure 33.3.
FNG 2512K Manual 33
Section 3: Setup
Figure 34.2
POSITIONING FINES CONVEYOR
INFORMATION: When you receive your plant, The fines conveyor can be used for two
the chains that support the fines conveyor will functions:
be bound together by a zip tie. When raising Function 1: Setting the transport pins in posi-
the screen box for the first time, allow zip tie tions 2 or 3 will provide the proper angle to
to break. There is no need to replace zip ties. feed an auxiliary conveyor.
The screen box chains will sag but not impede Function 2: If you would rather create a stock-
the transportation process. pile with the fines, align fines conveyor with
position 4. (See Figure 34.2 for optional pin
placements)
34 FNG 2512K Manual
Section 3: Setup
Figure 35.3
FINES SCREEN
CONVEYOR POSITION
(PINS MUST BE
FOLD REMOVED)
OPERATION OPERATION
NEUTRAL NEUTRAL
TRANSPORT TRANSPORT
3000 PSI 3000 PSI D00316
Figure 35.1 Figure 35.2 NOTE: Lifting Screenbox

will relieve pressure from
Fines conveyor transport
pins. Keep pins in ready
position, they will be used
FINES CONVEYOR TAIL SECTION in subsequent steps.
After the Fines Conveyor head section has been  Remove fines conveyor bottom transport
lowered into pre-operating position, remove pins from BOTH sides of unit. (Figure 35.1)
transport pins from Fines Conveyor and Screen  Pull the Screen Position valve to begin Rais-
Box (Figure 35.1 & 35.3). ing Screen Box. (Figure 35.2)
 Continue to raise Screen Box until Fines
 Remove transport pins from BOTH sides of conveyor reaches desired position.
unit.  Place transport pin in the preferred fixed
 See figure Figure 35.2 for help locating position. (Figure 35.3)
Screen Position Control Valve.
 Raise Screen Box until chains relieve pres-
sure from fines conveyor bottom transport pins.
Note: If you set the fines conveyor to feed an auxiliary conveyor: Before raising screen box
to operating height, release chains from fines conveyor. Failure to release chains will result in
damage to equipment, injury or death.
FNG 2512K Manual 35
Section 3: Setup
Figure 36.1
Figure 36.2
RAISE SCREEN BOX TO OPERATING ANGLE When the screen box is at the desired operating
After setting fines conveyor to desired position, angle:
use the following steps to raise screen box to  Insert hitch pins into the screen box support
operating height: arms. Figure 36.2
 Lower screen box so pressure is placed on
 Lower screen box to relieve tension from support arms and not the cylinders.
lifting chains.
 Remove the retaining clip from the chain
hook by pulling cotter pin.
 Refasten the retaining clip to the lifting
IMPORTANT: If the setup valve
chains for later use. is not turned OFF, oil will con-
 The chains should remain attached to the tinue to flow over the relief
screen box at all times.
 Raise the Screenbox to the desired operat- valve which will heat the oil to
ing angle. an excessively high tempera-
 The recommended operating angle is be-
tween 38° and 43°. ture. This will result in severe
 The angle can be read from the meter lo- damage to the hydraulic sys-
cated on the side of the screen box. Figure 36.1
 For help determining the proper operating tem.
angle, see “Screen Box”
36 FNG 2512K Manual
Section 3: Setup
SET-UP AUX.
FUNCTIONS CIRCUIT
ON ON
NEUTRAL NEUTRAL

3000 PSI 3000 PSI
D00113
Figure 37.1
SETUP COMPLETE
Setup is now complete. Push SETUP valve IMPORTANT: The Setup Valve should only be in
down to the middle or OFF position. the ON position when setting up the plant. If the
setup valve is not turned OFF, oil will continue to
The plant is now ready for operation. flow over the relief valve which will heat the oil to
an excessively high temperature. This will result
in severe damage to the hydraulic system.
FNG 2512K Manual 37
Section 3: Setup
INTRODUCTION TO CONVENTIONAL
SCREENING
Screen orientation is determined by standing at References to the feed end and material flow is
the front of the vibrating screen looking toward shown below.
the direction of travel.
38 FNG 2512K Manual

Section 3: Setup
“K” SERIES SCREEN ing manner from the feed end of the decks to
the discharge end.
A vibrating screen is used to separate material
into different sizes. The inclined vibrating screen has proven to be
the most reliable screen for aggregate separa-
“K” series screens are medium duty screens and tion. The addition of extra counterweights allow
are typically used to size material down to #4 the screen to handle dense, coarse aggregate.
mesh and up to 4” maximum. When properly sized, the inclined vibrating
screen performs relatively maintenance free
This arrangement uses single shaft assembly except for wear from the aggregate being pro-
with counterweight arms that can be adjusted by cessed.
changing speeds and throw. This allows screen
design with reduced investment and installation
costs.
Sorting is done by passing the mixed mate-

rial along a surface having uniform openings.
Those particles small enough to pass through
the openings are called the undersize product.
Vibration is induced by counterweights mounted

on the ends of the shaft. “K” series vibrating
screens can operate between 8 to 35 degrees
from feed end to the discharge end.
The screen cloth is usually formed of woven

wire. Coarse sorting is sometimes done on a
steel plate surface having relatively large holes
either cut or punched in it.
Screen cloths or punched plate surfaces are

held in superimposed frames called decks. “K”
series screens may have one, two, or three
decks.
The undersize from each deck falls to the deck

below it for additional sorting. The decks are
held in a box-like structure called screen box
assembly. The box assembly is mounted on
springs fastened to the base frame. The eccen-
tric shaft, when rotated, makes the screen pan
vibrate.
Each revolution of the powered shaft lifts the

pan assembly and its screening surfaces. At
the same time, it moves the entire assembly in a
circular motion. The vibration and screen angle
causes material on the decks to flow in a bounc-
FNG 2512K Manual 39

Section 3: Setup
The following is a brief description of the vibrat-

ing screen’s basic parts and their function.
Eccentric Shaft
The eccentric shaft translates

circular motion into screening
action. The shaft revolves on
two roller bearings mounted to
the box sides.
Box Side Assembly
The box sides provide the

framework to support the
screen decks, eccentric shaft
housing, and the spring sus-
pension.
40 FNG 2512K Manual

Section 3: Setup

Counterweight Assembly
The counterweight assembly

permits the addition of weights
to change the screen stroke
and balance.
Counterweights can be added

or removed to change the
stroke. (Contact factory for
more information)
Screen Decks
The screen decks support the

screen cloth. The decks are
crowned to prevent screen sag
and promote optimum screen
efficiency.
FNG 2512K Manual 41

Section 3: Setup

Clamp bars
The screen cloth clamp bars

hold the screen cloth securely
in place.
Spring Suspension
The spring suspension isolates

vibration from the support-
ing frame or structure. The
suspension features separate
equalizer springs to maintain
proper drive belt tension and
screen alignment.
42 FNG 2512K Manual

Section 3: Setup
SCREENING APPLICATION
Screening is an “art” not a science. There so Stratification must take place before separation.
many variables and conditions involved that it Stratification is affected more by the material
is impossible to select a screen by just using bed depth than any other factor and the depth
a formula. Familiarity and experience with the must be reasonable for the material and separa-
properties of certain materials is necessary in tion size to be made.
NOTICE
order to make the proper selection of a screen
cloth.
Even though a completely theoretical approach

has never been successful, a formula incorpo- Material depth should not exceed four times
rating theory and experience factors is used as the screen cloth opening.
a guide to screen selection.
Experience is needed because formulas do A factor affecting the bed depth is the rate of
not account for excess moisture, clay, wedge travel which is affected by the type of material,
shaped particles, surge loads, or other special stroke, type of motion, rate of feed, slope, etc.
conditions in the feed material. Each of these factors affects the material bed
depth which affects stratification.
Screening efficiency can be improved by using
one or more of the following when allowed in the It is possible to not have deep enough material
process. bed on the screen. Screen efficiency is related
to percent of capacity as shown below.
1. Slotted openings
2. Washing with water
3. Heated decks
4. Ball tray decks
5. More open area in the screen cloth
6. Controlled feed for maintaining the proper
material bed depth.
Stroke RPM is another factor affecting screen

efficiency. When screening a coarser mate-
rial, the screen should be operated at a lower
EFFICIENCY
speed with a higher sroke. For finer material,

the speed should be increased and the stroke
decreased. Refer to the factory on what the
maximum stroke should be compared to RPM.
Every variable involved in the screening process FEED (TPH)

is application dependent and this should be
taken into consideration before screening. Efficiency decreases when the screen is operat-
ed below approximately 75% of the rated capac-
To better understand screening, there are two ity (for free flowing 100# material).
processes taking place: stratification and sepa-
ration.
FNG 2512K Manual 43

Section 3: Setup
Feed
Screen
Deck
a b c d
a-b Stratification at feed end

b-c Saturation screening
c-d Separation by repeated trails
For very small feed rates, up to point “b”, ef- The rise between “a” and “b” and the location
ficiency actually increases with increased ton- of peak “b”, being at some point along the deck
nage. This happens because a certain bed of rather than at the end of the screen, shows the
oversize material on top of the marginal particles effect stratification taking place.
prevens them from bouncing excessively which
increases their ability to fall through the screen The area “b” to “c” is often referred to as the
openings, and helps to push them through. area of saturation screening in which particles
Beyond the optimum point “b”, efficiency rapidly up to 75% of the aperture size are crowding to
drops off becaue the screen is not large enough get through the deck.
to pass the undersize material.
From “c” to “d”, the process of fit and pass or fit
Stratification also varies with different types and reject takes place.
of material. Generally when screening damp
materials or even when screening fine materi-
als, particularly of lighter density, stratification
is difficult to attain and a relatively thin material
bed depth (no more than four times the screen
cloth opening) from feed to discharge end of the
screen is required.
The chart represents the relative amount of flow

through the screen deck plotted along the deck
length. This graph may also be considered as
the cross section or height of a pile of material
that has passed through the screen deck and
allowed to pile up underneath it after a batch of
material has been screened.
44 FNG 2512K Manual

Section 3: Setup
SCREENING EFFICIENCY
Screening efficiency is the percent of the under-

size in the feed that actually passes through the
surface opening.
The capacity formula (shown to the right) is Efficiency =

based on 92% to 95% screening efficiency. Nor-
mally, 90% to 95% efficiency is an accepted rate % of undersize in feed which actually passes
in most screening operations; however, in some % of undersize in feed (should pass)
instances, even 90% is not always attainable.
Considering the many factors that affect material
classification, it is a difficult task to constantly Capacity Formula
control screening efficiency to an exact percent-
age. Furthermore, multiple deck screens pres- Controlled continuous feeding of proper size
ent separate problems for each deck. material uniformly spread across the screening
surfaces of a well balanced screen is essential
With many factors that govern efficient screen- for maximum vibrating screen production.
ing, it is impractical to expect that a numerical
factor on the capacity formula will automatically Screening capacity and efficiency will be affect-
control this. Industry accepts that 100% ef- ed by the factors listed and additionally by the
ficiency is impossible. It also recognizes there speed, slope, balance of the machine, and the
are screening applications when 90% or even characteristics of the varying materials fed.
80% may be impossible, regardless of screening
NOTICE
area available.
The difficult-to-pass “nearsize” is most often a

controlling factor in determining the problems Controlled continuous feeding of proper
you expect to encounter in attaining a high ef- size material uniformly spread across the
ficiency. Moisture and peculiar particle shapes screening surfaces of a well balanced screen
will compound the problem. is essential for maximum vibrating screen
production.
Material typically remains on a vibrating screen
for only a matter of seconds. Evaluation of
the efficiency of the screen is checked by test-
ing sieves for three to five minutes or longer.
Through material analysis, review of the applica-
tion and testing, an estimate of screen efficiency
can be determined.
To get a reasonable estimate of tons per hour

that can be screened through a square foot of
screen cloth, use the calculations listed on page
33 and 34.
FNG 2512K Manual 45

Section 3: Setup
FACTORS FOR CALCULATING SCREEN AREA
U
Screen Area (ft2) =
AxBxCxDxExFxGxHxJ
Things to remember in regards to charts:
*Basic operating conditions.

- Feed to screening deck contains 25% oversize and 40% half size.
- Feed is granular free-flowing material
- Material weighs 100 lbs. per cubic foot:
Inclined 18-20 degrees with flow rotation.
Horizontal Screen - 0 degrees
- Objective Screening Efficiency - 95%
U = Undersized Factor Amount in tons per hour of material in feed to screen surface (deck)
that is smaller than a specified aperture.
A = Basic Capacity Factor Predetermined rate of material in tons per hour through a square foot
of a specified opening when feed to deck contains 25% oversize (Fac-
tor B) and 40% halfsize (Factor C)
B = Oversize Factor Actual percent of material in feed to deck that is larger than a speci-
fied aperture (adjusts Factor A to suit conditions.
C = Halfsize Factor Actual percent of material in feed to deck that is one-half the size of a
specified aperture (adjusts Factor A to suit conditions)
D = Deck Location Factor Applies to multiple deck screens. Total screening area is available
to top deck separation. Time delay for material to pass through deck
and leaves less effective area available on next deck. This factor is
expressed in a percent of top deck effective areas.
E = Wet Screening Factor Applies when water is sprayed on the material as it moves down
the screening deck. Generally, about 5-7 gpm of water is used per
ton per hour of solids fed to the screen. A sufficient volume of water
should be supplied so that a portion can be combined with the solids
into a feed box to prepare a slurry feed to the screen. The balance of
water is added through a series of spray bars located over the screen-
ing deck.
F = Material Weight Fac- The bulk density of the material being sieved in pounds per cubic foot
tor divided by 100.
G = Screen Surface Applies when open area of screening surface is less than open area
Open Area Factor shown in Factor A capacity chart. Open area of screen surface being
used. Open area indicated on capacity chart.
H = Shape of Opening Applies when rectangular openings are used. Slotted or oblong open-
Factor ings will pass more material per square foot than square openings.
J = Efficiency Factor Applies when objective screening efficiency is less than 95%
46 FNG 2512K Manual

Section 3: Setup
CHARTS FOR CALCULATING SCREEN AREA
Factor “A” Factor “B” - (% of oversize in feed to deck)

Surface % STPH % Over- 5 10 15 20 25 30 35
Square Open Passing size
Opening Area a sq. ft. Factor B 1.21 1.13 1.08 1.02 1.00 0.96 0.92
4” 75% 7.69
% Over- 40 45 50 55 60 65 70
3 1/2” 77% 7.03 size
3” 74% 6.17 Factor B 0.88 0.84 0.79 0.75 0.70 0.66 0.62
2 3/4” 74% 5.85 % Over- 75 80 85 90 95
2 1/2” 72% 5.52 size
2” 71% 4.90 Factor B 0.58 0.53 0.50 0.46 0.33
1 3/4” 68% 4.51
Factor “C” - (% of halfsize feed into deck)
1 1/2” 69% 4.20
1 1/4” 66% 3.89 % Over- 0 5 10 15 20 25 30
size
1” 64% 3.56
Factor C 0.40 0.45 0.50 0.55 0.60 0.70 0.80
7/8” 63% 3.38
5/8” 59% 2.82 % Over- 35 40 45 50 55 60 65
size
1/2” 54% 2.47
Factor C 0.90 1.00 1.10 1.20 1.30 1.40 1.55
3/8” 51% 2.08
1/4” 46% 1.60 % Over- 70 75 80 85 90 95
size
3/16” 45% 1.27
Factor C 1.70 1.85 2.00 2.20 2.40
1/8” 40% 0.95
3/32” 45% 0.76 Factor “D” - Deck Location
1/16” 37% 0.58 Deck Top Second Third
1/32” 41% 0.39 Factor D 1.00 0.90 0.80
Factor “E” - Factor “F” - Material Weight
Wet Screening Lbs./ 150 125 100 90 80 75
60 70 50 30
Opening Factor E cu. ft.
1/32” 1.00 Factor 1.50 1.25 1.00 0.90 0.80 0.75 0.70 0.60 0.50 0.30
1/16” 1.25 F
1/8” 2.00 Factor “G” Factor “H”
3/16” 2.50 (Screen Surface Open Area) (Shape of Surface Opening)
Factor G = Square..................................1.00
1/4” 2.00 % Open Area of Surface Being Used Short Slot (3-4 times width)..1.15
3/8” 1.75 Long Shot
% Open Area Indicated in Capacity (More than 4 times width).....1.20
1/2” 1.40
3/4” 1.30
1” 1.25 Factor “J” - Efficiency
95% 90% 85% 80% 75% 70%
1.00 1.15 1.35 1.50 1.70 1.90
FNG 2512K Manual 47
Section 3: Setup
SITE SELECTION AND PREPARATION the v-belt drive. Be sure the drive will not be
blocked by walls, structures, or other objects.
Selecting a site without anticipating problems
could lead to unsatisfactory operation and plant Support Structure Guidelines
relocation could be required. When selecting a
suitable site for operation the following factors The support structure is a steel or concrete
should be taken into consideration: structure located between the screen and its
foundation. The screen base is mounted on top
1. Ground Stability - If the ground is too of this structure.
soft or unstable, proper leveling and loading
may be impossible. Use the following guidelines when designing
2. Ample Room – Leave plenty of room and installing a support structure.
around the screen to facilitate access of the
loading equipment, assembly of screen compo- 1. The support structure must be firmly an-
nents, and service personnel. chored to a solid foundation. It must be strong
3. Proper Drainage – Proper drainage is enough to carry the weight of the screen and its
important to allow for runoff of normal rainfall. material load.
4. Wind Direction – You may also want to 2. The support structure must be capable
consider prevailing wind direction and its effect of withstanding the forces present during nor-
on the operator or loading personnel. mal screen operation and the additional forces
which occur during startup and shutdown. The
Foundation structure must be sufficiently braced to minimize
vibration and swaying.
Do not locate the foundation on sand, unstable 3. Check side-to-side and end-to-end level-
soil, or anywhere where flooding might occur. ness.
Locate the foundation on level, solid rock, or a
compacted aggregate base only.
Where fill of any kind has been used, the foun-

dation must extend through the fill to a solid sub-
surface. The subsurface must be of adequate
load bearing ability to support the combined
weight of the screen and its supporting structure.
When constructing the foundation, consider
these other factors:
1. Allow adequate space beside the screen

for walkways and service platforms. Observe
all federal, state, and local regulations when
designing and constructing walkways or service
platforms.
2. Allow about ten feet of space on one side
of the screen for eccentric shaft removal.
3. Allow space above the screen so it can
be raised when spring replacement is neces-
sary.
4. Allow space at one end for removal and
replacement of screen cloth.
5. Allow adequate space for access to
48 FNG 2512K Manual
Section 3: Setup
DIRECTION OF ROTATION
Jog the motor and check that the screen sheave

rotates in the correct direction. The top of the
screen should move the same direction as the
sheave.
This is the typical direction of the rotation. The

screen can run in a reverse rotation. This is
done when there is a need to increase the mate-
rial retention time on the screen deck to improve
screening efficiency. The feed rate must be
reduced when screening with reverse rotation.
CROWN RUBBER
Check crown rubber to ensure they are in good

condition and seated properly. Also check for
damage and replace if needed.
Crown rubber forms a cushion between the

screen cloth and the supporting metal bars to
protect the screen cloth from damage.
The screen cloth will fail prematurely if the cush-

ion rubber is not installed on the crown bars.
FNG 2512K Manual 49

Section 3: Setup
SCREEN CLOTH INSTALLATION
Use the following procedure to install screen

cloth:
1. Loosen the clamp bar bolts. This loosens the

clamp bars in the hooked edges of the screen.
2. Slide the screen cloth sections out either end

of the vibrator, whichever end is more conve-
nient. In most cases it may be necessary to
completely remove the clamp bars in order to
take out screen cloth.
3. Install new screen cloth by reversing the

above procedure. Make sure clamp bars en-
gage the hooks along screen edges.
Clamp bars should not extend over a joint be-

tween two lengths of screen mesh or improper
clamping may result.
4. Tighten all clamp bar bolts uniformly to apply

a reasonable tension on the screen. Stretch the
screen tightly enough to prevent fluttering during
operation which will damage the screen, causing
it to wear out. The screen cloth must be cen-
tered to work properly.
50 FNG 2512K Manual

Section 3: Setup
At this point setup is complete and the plant is

ready to be put into production.
Please review the OPERATION section for fur-

ther instructions on how to operate the plant.
FNG 2512K Manual 51
Section 3: Setup
SETUP NOTES
52 FNG 2512K Manual

Section 4: Operation &
Maintenance
PRE-OPERATION CHECKS
The screening plant is now ready for operation. Take a few minutes each day to review the
preoperational and operational checklists. Reviewing these each day will help keep your plant
running efficiently and avoid unneccessary downtime in the future.
PRE-OPERATIONAL CHECKS OK ADJUST

1 Sheet Metal/Appearance/Paint
2 Engine
a. Check the engine oil level.
b. Check the engine coolant level.
c. Drain the fuel water separator.
d. Inspect engine drive belts.
e. Check all air filters.
f. Check the fuel level.
3 Hydraulics
a. Check hydraulic oil level.
b. Check for leaks, loose fittings.
c. Check the pump drive oil level.
d. Inspect the hydraulic cooler, hoses, and connections.
e. Suction line ball valves open.
4 Electrical
a. Check battery level.
b. Make sure battery is secure.
c. All terminals tight and secure.
d. Remote system links and functions properly.
5 Conveyors
a. Inspect and replace worn flashing.
b. Inspect belts for damage or tears.
c. Check belt cleaner tension.
d. Inspect all bushings and shafts.
6 Screen
a. Screen cloth properly tensioned.
b. Check for cracks or broken welds.
c. Make sure shipping brackets are removed.
d. Inspect for excessive wear or damage.
e. Check for material build-up.
f. Inspect ag spreader for damage.
g. Grease bearings according to grease section in this manual
7 General
a. All guards are in place.
b. Decals are in place and legible.
c. Operator's manual in place.
FNG 2512K Manual 53

Section 4: Operation & Maintenance
OPERATIONAL CHECKS
OPERATIONAL CHECKS OK ADJUST

1 Engine
a. Check the engine load and temperature.
b. Inspect radiator overflow.
2 Hydraulics
a. Check hydraulic oil level and temperature.
b. Check for leaks, loose fittings.
3 Electrical
a. Make sure all emergency stops work.
4 Conveyors
a. Belts training properly.
b. Check conveyors for material leakage.
5 Screen
a. Ag Spreader spreading material across width of screen.
b. Listen for any unusual sounds.
c. Look for excess vibration in stucture and handrails.
6 General
a. List for any unusual sounds or vibrations.
b. Machine is clean of debris.
c. Check feed rate.
d. Watch for excess material build-up under plant.
7 Speeds
a. Belt Feeder - 0-35 FPM up to 3000 PSI
b. Delivery Conveyor - 0-425 FPM up to 3000 PSI
c. Screen - 850 RPM up to 4000 PSI
d. Fines Conveyor - 375 FPM up to 3000 PSI
e. Top Deck Overs Conveyor - 0-500 FPM up to 3000 PSI
f. Bottom Deck Overs Conveyor - 0-350 FPM up to 3000 PSI
54 FNG 2512K Manual

Figure 55.1
TURNING SCREENING PLANT ON

Always do a final walk around the plant before Fines Conveyor
turning on any of the circuits. Make sure all Side Conveyors (Top Deck/Bottom Deck)
personnel are clear of machine and all lockout/ Delivery Conveyor/Screen
tagout procedures are followed. Once you are Belt Feeder
certain all personnel are out of harm’s way the
engine can be started. Increase engine speed All circuits can be turned on by pushing down
to 2200 RPM. on the circuit’s valve handle. All conveyors are
adjustable speed with the exception the fines
It is highly recommended to start the items in the and delivery conveyor. These speeds can be
following order to avoid overloading the convey- adjusted by turning the flow control valves up or
or belts. The belt feeder should always be the down. Speed adjustments may be necessary
the last thing turned on. depending on the application.
FNG 2512K Manual 55
OPERATION
After setup is complete, be certain to turn the box. The pressure relief limits have been set at
Setup valve to the neutral (middle) position. the factory. The default settings are between
2500 and 3000 PSI.
NOTE: If the setup valve is not set to neutral,
oil will continue to flow over the relief valve The relief pressure can be checked by pushing
and heat the oil to an excessively high tem- the control valve to the down position. Pushing
perature. This will result in severe damage to the control valve down will deadhead the circuit
the hydraulic system. and the pressure gauge will indicate the current
relief pressure. Do not continue to deadhead the
Be aware of all personnel around plant. When circuit after relief pressure has been determined.
it has been confirmed that all personnel have Damage to equipment will occur.
cleared the area, begin the operating process.
The relief pressure can be tuned by
If conditions are such that the engine needs to Removing the protective nut
be warmed up, let run idle until necessary tem- Turning lock nut counter clockwise
perature is reached. Once the engine has been Twisting the adjusting screw.
thoroughly warmed, increase the engine speed To increase pressure, tighten the adjusting
to 2200 RPM. screw.
To decrease pressure, loosen the adjusting
Ensure all conveyors are clear of debris and ob- screw.
structions. It is recommended that the conveyors
be started in the following order: The variable speed conveyors speed can be
a. Fines Conveyor adjusted by using the flow control knobs located
b. Side Conveyors above the ON/OFF levers.
c. Delivery Conveyor
d. Feed Bin Conveyor To increase the conveyor speed for the feed bin
conveyor, turn the knob counter clockwise. To
Start the fines conveyor by pulling ON the Fines decrease the speed, turn the knob clockwise.
Conveyor handle located on the main control
56 FNG 2512K Manual
SIDE CONVEYOR CONTROL crease. Adjust the Top Deck Side conveyor flow
The speed of the side conveyors can be adjust- control knob so that both conveyors are operat-
ed by referring to the following procedure. ing at approximately the same speed.
NOTE: During the adjustment process it may Generally, the bottom deck side conveyor should
be necessary to place the conveyor control be running slightly faster than the top deck side
lever in the neutral position. conveyor. In general, the amount of material that
is rejected as fines, is greater than the amount
Turn the Top Deck Side Conveyor flow control of material that is rejected as medium.
knob counter clockwise until the limit has been
reached. (To the full ON position) Certain operating conditions may warrant the
adjustment of side conveyor speeds.
Turn the Bottom Deck Side Conveyor flow
control knob clockwise until the limit has been The Top Deck Side Conveyor speed may need
reached. (To the full OFF position) to be increased if bottlenecks occur due to
increased number of overs. Bottlenecks hap-
When the conveyor ON/OFF lever is in the ON pen when the amount of overs coming onto the
position, the Top Deck Side conveyor will run at conveyor are greater than the number of overs
full speed, and the bottom deck side conveyor being ejected by the conveyor.
will be stopped.
The Top Deck Side Conveyor speed may need
It is now necessary to only adjust the Top Deck to be reduced if “rollback” is occurring. Rollback
Side Conveyor flow control knob. By slowly is when the conveyor speed is increased to such
increasing the flow (turning counter clockwise) a level that larger rocks are spinning backwards
of the Top Deck Side conveyor, the speed of the preventing them from “climbing” the conveyor.
Bottom Deck Side conveyor will decrease, while Rollback prevention may need to be addressed
the speed of the Top Deck Side conveyor will in- with overs greater than 3” in diameter.
FNG 2512K Manual 57
SCREEN
The Fold ‘n Go® 2512K is fitted with a 5’ x 10’ The high frequency screen (bottom screen) uti-
top deck scalper screen and a 6’ x 12’ bottom lizes the opposite theory of the scalper screen.
deck high frequency screen. By minimizing amplitude (throw) and increasing
frequency (RPM) the high frequency screen can
The scalper screen is used to separate over- more efficiently separate fines. The oversized
sized material too large to be screened by the material of the high frequency screen will be dis-
high frequency bottom deck. Separation is ac- charged by the bottom deck side conveyor. This
complished by utilizing greater amplitude and conveyor is located on the curb side of the plant.
lower RPM. Both side conveyors are intended to be used in
a manner that creates a stockpile.
This proportion allows the scalper deck to throw
the larger, heavier particles out of the openings; All remaining material (material that has made
thus clearing the way for the smaller and lighter it through both the scalper screen and the high
material to find its way through. The material frequency screen) will be discharged on the
that does not fall through the scalper deck will fines conveyor located at the rear of the plant.
be discharged from the top deck side conveyor.
The top deck side conveyor is located on the
road side of the plant.
58 FNG 2512K Manual
GRIZZLY
NOTE: The optional remote grizzly will only operate
correctly when the engine is running at 2200 RPM. If the
grizzly fails to fully close, increase engine to operating
speed and recycle grizzly.
On top of the 12 cubic yard heaped capacity

hopper is the 25° heavy duty sloped grizzly. The
grizzly has a 6” nominal opening with a patented
scissor action hydraulic dump for easy cleaning.
Accumulated large material can be removed by

activating the manual spool valve or the optional
remote control. If using the manual valve: Pulling
the handle will raise the grizzly and pushing the
handle will bring it back to the down position.
Ensure the area is clear of all personnel and
equipment before activating grizzly.
OPTIONAL REMOTE GRIZZLY

The gray button is used to initiate the cleaning
process. The grizzly is set to raise and lower by
a series of timers in the grizzly control box set at
the factory.
After pressing the gray button on the remote
control, the grizzly screen will raise, hold in the
upright position for a short period of time, and then
return to the down position.
The red button on the remote control is for

emergency purposes only. By pressing the red
button, the grizzly will stop immediately in it’s
current position. The same effect can be achieved
by pressing the e-stop button on the grizzly control
box.
If the e-stop has been pressed, the grizzly will not

return to the down position without first switching
the grizzly control panel e-stop back on (by pulling
it out) After the e-stop has been released, you must
lower the grizzly into the down position manually.
In order to run the grizzly manually from the control

box, the local start button needs to be activated
by pushing it in. (Figure 54b)
FNG 2512K Manual 59

Proper spread
of material
Improper spread
of material
AGGREGATE SPREADER
Located at the end of the delivery conveyor is at its maximum capacity. If the spreader is not
the ag spreader. The primary function of the ag functioning correctly, the aggregate will not be
spreader is to absorb the impact of the material evenly distributed over the screen cloth.
being thrown from delivery conveyor and spread
it evenly across the width of the screen. Maximum efficiency will be obtained if the
aggregate spreader is positioned the proper
The natural direction of the material, after striking distance from the end of the delivery conveyor.
the ag spreader, is down and towards the edges The proper distance greatly depends on the
of the screen box. The optimum projection of material being screened and many other factors.
material after making contact with the ag spreader Because of this, it may be necessary after
is in a fan like shape (Figure 60.1) which covers beginning operations, to adjust the position of the
the entire screen box evenly. Keep in mind that ag spreader. Poor performance will be evident if
unlike conventional screening, high frequency the ag spreader is in the incorrect position. The
screening (because of the severe angle at which distance between the delivery conveyor and the
the screen box operates) has only a short amount ag spreader can be adjusted by changing which
of time to separate the material. Because of this, slot (Figure 60.2) the spreader sits in. Adjust ag
it is essential that the ag spreader perform spreader accordingly.
60 FNG 2512K Manual
OVERALL INSPECTION
A visual inspection of the plant should be done 6. Check battery for corrosion or damage. The
on a daily basis. By inspecting the plant visually battery is located on the outside of the chassis.
each day you may be able to spot and correct To access the battery, remove bolts from cover
potential problems before they become serious. and lift cover off. Make certain battery terminals
are free of corrosion and other debris.
1. Check all grease lines, ensure they are prop-
erly routed, free of rips, punctures and bulges, HYDRAULIC MAINTENANCE
and connected securely.
2. Make sure plant is level. Environmental vari-

ations can cause the plant to become uneven.
Use an accurate level to ensure the plant is
level both front to back and side to side. If the
plant is operated in any matter other than level,
poor performance or damage to the equipment
may occur.
3. Visually inspect all guards. Ensure guards The hydraulic tank fluid level should be visible
are properly aligned and tilted at the correct in the sight meter at all times. Do not allow the
angle. Check to make certain guards are free hydraulic fluid level to fall below this line. If the
from obstructions and are not rubbing belt. amount does fall below this line, add fluid until
visible. Operating the plant with an insufficient
4. Check for loose fittings. Ensure all nuts, level of hydraulic oil can cause premature wear
bolts, and other connections are secure. Check or damage to equipment.
all pins and clips. When a pin is being used to
secure a section, a cotter pin must be used to All motors must have a constant supply of
protect against vibrations working the pin out of hydraulic oil in order to maintain good running
its location. Make sure all pins and clips are in condition. Damage to hydraulic pumps can
proper working order and fastened securely. occur if hydraulic oil level does not stay within
satisfactory levels.
5. Ensure all hydraulic lines are routed cor-
rectly, free of rips, punctures and bulges, and If adding hydraulic oil, be certain to filter the oil
have solid connections. Use a piece of wood or before adding it to the hydraulic oil tank. Even
cardboard as a backstop to pinpoint leaks. new hydraulic oil contains impurities.
Condensation in the hydraulic tank can occur

during certain operating conditions. Keeping
the tank full will minimize the amount of con-
densation. If excess condensation is detected,
drain hydraulic oil tank and fill will new hydrau-
lic oil.
If hydraulic fluid penetrates skin, it must be
surgically removed as soon as possible by At certain times, hydraulic oil will need to be
a doctor familiar with this form of injury or replaced. Additionally, all hydraulic filters, along
gangrene, serious injury, or death will re- with the breather will need to be replaced at
sult. CONTACT A PHYSICIAN IMMEDIATELY certain intervals of operating.
IF FLUID ENTERS SKIN OR EYES. DO NOT
DELAY.
FNG 2512K Manual 61
TRAINING THE BELT
Although the belt is trained at the factory, many Begin the troubleshooting process by performing
variations can cause the belt to become mis- this adjustment on the opposite side of the belt
aligned. The belt should be that runs off the roller.
running directly down the
center of the idlers. Several Do not attempt to make extreme adjustments to
factors can effect the way one idler. Instead, make several slight adjustments
the belt tracks, and depend- to several idlers. Always allow several rotations to
ing on the operating condi- occur before determining belt alignment.
tions, variations of these
factors can occur. After idlers have been adjusted, place a load onto
conveyor and check for alignment. If necessary,
Physical variations can repeat idler adjustments until content with
include: alignment of pulleys alignment.
(head and tail) and idlers. In
rare cases, the squareness
of the belt splice can cause
serious variations in the con-
veyors path.
Operating variations include: the size of load

and levelness of belt. A loaded belt may also run
differently than an empty belt. In order to prop-
erly train the belt, reduce the number of both
physical and operating variables.
If the belt needs to be trained use the follow-

ing procedures. NOTE: the effects of training 2. If adjusting the idlers does not work, an
the belt will not be immediate. Allow several adjustment to the take-up screws may be
complete rotations of the belt before making necessary. The screws are located on either side
further adjustments. of the head/tail pulley.
1. Use an accurate steel square to check the idlers. This is not the most common cause of a misaligned
belt, but the process can be used as a last resort
to troubleshoot the situation.
Ensure the head pulley is properly aligned with

the tail pulley by adjusting the take-up screws. By
increasing the tension on either side of the head/
tail pulley, the belt will shift in that direction.
Improperly aligned idlers are a common cause of

belt misalignment. Start by adjusting the return
idlers. After adjusting return idlers, if belt is still
straying, adjust several idlers behind the point at
which the belt strays.
62 FNG 2512K Manual

By decreasing the tension to either side of

the head/tail pulley, the belt will shift in the
opposite direction. Keep in mind that the head/
tail pulley must stay parallel with the conveyor
frame. If the head/tail pulley is not parallel with
the conveyor, the belt will stray. By adjusting
the head pulley you are attempting to create
a parallel line with the conveyor frame.
After adjusting the take-up screws, run the belt

and check for proper alignment. Allow several full
rotations of the conveyor belt before determining teners are tight. Tighten if necessary. Inspect the
satisfaction of alignment. belt cleaner for excessive wear. Allow 3” of wear
on urethane. If blades are worn beyond the wear
line, replace as follows.
1. Release tension on mainframe and remove

belt cleaner assembly.
2. Use a hammer to remove worn blades from
mainframe by pounding downward on bases of
worn blades. Pound new blades onto mainframe
after old blades have been removed.
3. Change worn blades with appropriate re-
placements.
See the belt cleaner manual for more detailed

instructions.
BELT TENSION
If belt is sagging excessively when a load is ap- FLASHING
plied, it may be necessary to increase belt ten- Check flashing
sion. Use the take-ups to increase and decrease on all conveyors.
belt tension. When adjusting belt tension be Flashing is used
sure that the distance at which the take-ups are to prevent spillage
extended is equal on both sides of head/tail pul- from occurring.
ley. Improperly aligning the head/tail pulley will
cause the belt to stray. Be certain not to create In order to properly
to much tension on the belt. prevent spillage,
flashing must be
GUARDS flush with conveyor
Make sure return idler guards are in proper belt, with a mini-
place and are not damaged. Guards should be mum gap. Check to make certain flashing is not
tilted at the proper angle and free from obstruc- excessively rubbing conveyor.
tions. Guards should not be rubbing the con-
veyor belt. If flashing is not aligned correctly or needs to be
re-aligned, adjust accordingly. If flashing is worn
BELT CLEANERS to the point that it is not preventing spillage,
Located at the head pulley end of the fines replace flashing with correct replacement part.
conveyor is a belt cleaner. Make sure all fas- See parts section for specific flashing sizes.
FNG 2512K Manual 63

BEARINGS
This plant is NOTE! the correct tension of the
equipped with Lube Point cloth greatly depends on the size
ground level
grease zerks for of screen cloth being used! thicker
all bearing ex- screen cloth requires higher
cept the screen tension while thinner screen cloth
box bearings.All grease zerks can be found by
locating the decal shown below. Visually inspect requires lower tension.
all bearings. A small amount of grease around
seal is normal. Excessive grease or lack of
grease around seals may be a sign of bearing
temperature problems. See the lubrication chart
located at the end of this section.
MAINTENANCE SCHEDULE
ITEM INSTRUCTIONS
Weekly or Every 50 Hours of Operation
Conveyor Belt Tension Tighten if necessary
Head and Tail Pulley Hubs Check for tightness
Conveyor Gear Reducers Check oil levels
Conveyor Scraper Blades Check serviceability and adjustment
Batteries Inspect condition
Radiator and Oil Cooler Inspect condition, clean
Monthly or Every 200 Hours of Operation
Hydraulic Tank Breather Replace
Hydraulic Oil Test Oil Sample
Radiator Hoses Check/Correct
Air Intake Piping Inspect
Fan and Cooling System Check
Every 500 Hours of Operation
Conveyor Gear Reducers Change Oil
Engine Coolant - Antifreeze Check
Fuel Filter Replace
Engine Oil and Filters Change
Every 1000 Hours of Operation
Hydraulic Oil Filters Change the filters
Cooling Fan Belt Tensioner Check/Correct
Serpentine Belt Check/Correct
Yearly or Every 2000 Hours of Operation
Hydraulic Oil Change oil and filters
Cooling System Drain, Flush, and Fill
Fluid recommendations:
Hydraulic Oil: ISO 46
Conveyor Gear Box Oil: SAE80W/90
Bearing Grease: Kluber Isoflex NBU15
Engine Oil: CH-4/CI-4
Fuel: Diesel Fuel ASTM D975
Coolant: Must meet ASTM D4985 or D5345
specifications
64 FNG 2512K Manual

TRACKS MAINTENANCE SCHEDULE
Regularly scheduled maintenance on your track

system is vital to maintain the reliability of your
track machine. Organizing and maintaining a
maintenance schedule with the procedures be-
low is imperative to your tracks functionality.
ALWAYS NEVER
• Peform maintenance on a level and solid • Attempt to track the machine if there is any
surface build up of material around the tracks and
• If work is necessary under the track system, rive sprockets.
ensure the tracks are solidly supported. • Attempt to track the machine if the tracks are
• Remove all build-up of grease, oil, and other frozen to the ground.
debris • Push or tow the machine when it is unable to
• Repair and/or replace any damaged, worn, free itself.
or broken parts immediately. • Track the machine constantly more than 30
• Regularly schedule checks for leaks and minutes without providing adequate rest.
damaged hydraulic hoses
• Use only specified lubricants and do not mix

different brands or types of lubricants.
• When maintaining the hydraulic system, use
great care as the oil may be very hot even
when the machine is turned off.
• Use only specified replacement parts as use
of unapproved parts will invalidate the war-
ranty.
• Dispose of lubricants in the proper fashion.
FNG 2512K Manual 65

Components Checklist Daily Checks Weekly Checks Monthly Checks

Idler Oil Leakage X
Wear Limits X
Lower Roller Loose nuts/bolts X

Oil Leakage X
Wear Limits X
Sprockets Loose nuts/bolts X

Wear Limits X
Track Drive Loose nuts/bolts X

Oil Quantity X
Oil Leakage X
Track Group Check for dam- X

age to track links,
pins, & shoes
Loose nuts/bolts X
Tight or seized X
track joins
Track Tension X
Wear Limits on X
track links/shoes
Wear Limits on X
track shoes
Track System Structural X

Fabrication Damage or failure
66 FNG 2512K Manual

CHECKING TRACK TENSION
Stop your machine on solid level ground, then

drive 2 meters/6 1/2 feet (minimum) in a foward
direction. Measure the sag on the top part of the
the track on the longest section of unsupported
track as shown below:
The sag of the track must be between 5mm

(approximately 3/16”) and 15mm (approximately
9/16”).
FNG 2512K Manual 67

ADUSTING TRACK TENSION
Track systems use a grease cylinder to keep

each track chain in tension. A grease fitting
is fastened to the end of the grease cylinder,
pumping and releasing grease into the grease
chamber, tightening and putting slack into the
track.
68 FNG 2512K Manual

START-UP AND SHUTDOWN 5. Do no overload the screen by feeding too

much material at one time. This will create a
Initial Operation material bed that is too deep. Reduced screen
efficiency, material spillage, and plugging may
The screen should be run empty initially to en- result. Damage to bearings and screen struc-
sure everything is operating properly and there ture may alos occur.
are no misaligned or binding parts. Operate a
new screen empty for two hours.
CAUTION
Before starting the screen, be sure all tools Material flowing Material flowing
and foreign objects have been removed and to left side. to right side.
everyone is clear.
Daily Start-Up
Use the following procedures when starting the

screen for daily use.
1. Perform all maintenance and inspection pro-

cedures.
Material evenly
2. Start the screen and allow it to reach normal distributed.
operating speed. Operate the screen for a few
minutes without material and listen for unusual
noises or other signs of trouble.
NOTICE
If unusual noises or other problems are Bed Depth OK
noticed, stop the screen, lockout power, and
make repairs as required.
3. Start material feed and check that the mate-

rial quickly and evenly flows across the full width
of the screen surface. Bed Depth too Deep
4. Feed material at a steady rate. Avoid surge

loads.
FNG 2512K Manual 69

OBSERVING SCREEN
OPERATION
1. As the screen operates, be

aware of any sudden changes
in the sound, movement, or
material flow that might indicate
trouble.
2. Listen for the sound of

loose parts, such as the rattle Blinding
of loose screen cloth panels or
wire cloth tensioners.
3. Listen for whining or howl-

ing sounds that might indicate
under-greased bearings and
potential bearing failure.
4. Always stop the screen Plugging

if any abnormal noises are
heard, or if any obvious chang-
es in operation is observed.
Identify the problem and make
repairs as necessary.
5. Check if the material is spill-

ing over the sides of the screen
or from around the chutes and
hoppers. Reduce feed rate or
make repairs as required.
6. If there is a sudden drop in

screening action, check that
material is not plugging the
screen cloth or backing up DAILY SHUT-DOWN
inthe discharge chutes.
1. Stop the material feed 3. Lockout power and tag con-
7. If blinding or plugging of the and allow the screen to oper- trols for screen and all related
screen openings occurs fre- ate until all quarry material is equipment (conveyors, etc.)
quently, speed, or stroke may discharged. Be sure no quarry
need to be changed. material is discharged. Be sure 4. Perform all schedule inspec-
no quarry material remains on tion and maintenance proce-
any of the screening surfaces. dures.
2. Stop the screen.
70 FNG 2512K Manual

PRE-OPERATION/OPERATION CHECKLIST
Check each component of the vibrating screen

to ensure that is is in operational condition. This
NOTICE
This preoperational check should be per-
check should include, but not be limited to the formed any time the screen is moved to a
following: new site, or after an extended time in stor-
age.
PREOPERATIONAL CHECKS OK Adjust OPERATIONAL CHECKS OK Adjust

1.Sheet Metal/Appearance/Paint
1.Check screen cloth for wear, damage,
2.Electrical and tension
a.Electrical connections 2.Visually inspect all fasteners/electrical
b.Wire condition connections.
3. Inspect ag spreader, chutes, & hoppers
3.Lubrication 4. Inspect crown rubber and dams
a.All fittings greased 5. Inspect safety chains and safety decals
6. Secure all pins and clips
4.Screen
a.Cloth installed (all decks) 7. Ensure vibrators running @3600 RPM
b.Cloth tight 8. Check spread of material
9. Make sure screen is level
SCREEN BOX MAINTENANCE/SERVICE INTERVALS

50 250 500 1000 As
Daily Hours Hours Hours Hours Required
Screen Box
Check Screen Cloth for Wear, Damange & Tension X
Visually Inspect all Fasteners &
hydraulic/electric connections X
Inspect Ag Spreader (if present) X

Inspect Chutes and Hoppers X
Change Filters X
Change Oil X
X
Support Springs
Bearing Housting X
Electric Motor X
Secure All Pins and Clips X
Inspect Safety Chains X
Make sure screen is Level (side to side) X
Inspect that all Safety Decals are legible X
FNG 2512K Manual 71

SCREEN ADJUSTMENTS
CHECKING STROKE LENGTH
The stroke length can measured using the fol-

lowing process:
1. Place masking tape on both sides of the

screen near the discharge and feed ends.
2. Start the screen and allow it to reach operat-

ing speed.
3. Lightly touch a pencil or pen to the making

tape. The size of the oval should be the same
size as the desired stroke. Check both sides of
WARNING
Never attempt to service or adjust this ma-
the screen. chine until all motion has stopped and power
has been disconnected and locked out.
NOTICE
A weak spring or broken spring can be
detected by checking the corners. Replace
springs as needed.
5. If there is a major difference in oval size from

side to side and end to end, the following condi-
4. If the ovals are less than desired, more coun- tions should be checked and corrected if neces-
terweights should be added. sary:
If they are more than desired, counterweights - Check that the foundation is level
should be removed.
- Check for damage on the support
Be sure to add or subtract weights equally to frame
both counterweight arms.
- Check for weak or broken springs
- Check if counterweights are incorrectly

installed.
- Check for buildup of material on screen.
72 FNG 2512K Manual

SCREEN MAINTENANCE & LUBRICATION

The following section contains tons maintenance may need to
WARNING
instructions for maintaining and be performed more often. Never attempt to service or
lubricating the vibrating screen. adjust this machine until
Failure to perform regular all motion has stopped and
Maintenance intervals shown maintenance may result in power has been disconnect-
are for normal operating condi- screening plant failure or dam- ed and locked out.
tions. If the screen is operated age.
under severe or adverse condi-
1
2
Interval Ref. No. Item Notes
10 hours N/A General Inspection Inspect for loose bolts, set screws.
N/A Screen Cloth Tension Check for wear and proper tightness
1 Bearing Housings Add 3 pumps of lubricant to each bearing

housing
3 Crown Rubber Check for wear and replace as required
N/A V-Belt (if applicable) Check for proper tension
50 hours 2 Support Springs Check screen for level and replace springs as
required.
1000 hours 1 Bearing Housings Purge bearings and Relubricate
As Needed N/A Electric Motor Lubricate Motor Bearings
FNG 2512K Manual 73

General Inspection Generally, you should check the following items:

(10 hours)
1. Make sure all guards are in place and func-
tional.
A walk around inspection should be made on a
daily basis. By taking a few minutes each day to Repair or replace any damaged or missing
inspect the screen, you can spot potential prob- guards or guarding devices.
lems and take care of them before they become
serious. 2. Repair or replace any damaged handrails,
ladders, or walkways.
3. Loosen nuts, bolts, and set screws.
4. Clear away built-up dirt and debris.
Bearing Housings
(10 hours)
The daily addition of lubricant

is necessary because a small
amount of lubricant continu-
ally passes through the seals,
flushing out accumulated dirt.
Bearing Housings
1. Clean grease fitting area
2. Add 3 grease gun strokes of

NLGI-2 grease to each bearing
housing, one on each side of
the screen.
Crown Rubber
(10 hours)
Check for loose, missing, or

damaged crown rubber.
Replace as needed.
74 FNG 2512K Manual

Screen Cloth Check clamp bar tension. The clamp bars

(10 hours) should be equal distance from the screen
side. The proper amount of clamp bar tension
is required to maintain proper screen service;
Check screen cloth tension to insure proper however, overtightening can cause damage to
screen operation and prevent premature screen screen and not tightening enough can cause
wear.The screen cloth should rest firmly against premature screen wear and inefficient screen-
all rubber cushion strips. Screen should be ing.
tightened just enough to slightly indent the
crown rubber and prevent fluttering. Check the screen cloth for tears, breaks, or ex-
cessive wear, and replace as required.
Check the clamp bar bolts on all decks for tight-
ness. The screen cloth should be tight enough Check screen cloth for material or debris.
to prevent gaps between the screen cloth and
the center support ribs. Always tighten clamp
bar bolts equally.
FNG 2512K Manual 75

Engine Radiator
(10 hours)
Closely inspect the engine radiator daily

for buildup. In some cases, a light coating is not
even visible. Cooling loss, which can lead to
engine overheating, can occur even with a light
coating.
NOTICE
Do not wait until visible signs of radiator
blockage appear.
Use the following procedure to inspec

the engine radiator:
1. Visually inspect 100% of the entire radiator

for buildup from both sides.
2. If no buildup is detected through visual in-
spection, use a flashlight and shine the light
through the radiator from both sides. This
will determine if there is buildup within the Visible (Excessive) Buildup on
interior section of the radiator core. Engine Radiator
3. Using a 9 or 12 gauge wire, carefully probe
voids between the air fins randomly checking
different areas of the radiator. The radiator
is constructed of three sections and it should
be checked in several places in each of the
three sections. The wire probe will help
determine the severity of blockage by the
resistance of the wire as it penetrates the
buildup.
NOTICE
When probing voids, be careful not to dam-
age air fins.
4. Repair any damaged radiator fins.
By the time the radiator becomes visibly

blocked, intensive cleaning, which may include
removing the radiator, will be required.
Cleaned Radiator
76 FNG 2512K Manual
Radiator
(As needed)
The engine radiator should be cleaned

as often as necessary depending on application.
In some cases, it may be necessary to clean the
engine radiator daily. Ensure that both sides of
radiator are clean.
Removing asphalt and other buildup from

the radiator is not possible by power washing
alone. Use the following procedure to clean the
radiator.
Recommended cleaner, contact factory for
1. Allow engine and radiator to cool down be- specifications.
fore cleaning.
2. Apply cleaner to the radiator using a good
quality garden sprayer.
3. Wait 10-20 minutes for cleaner to penetrate
the buildup, then reapply.
NOTICE
When cleaning the radiator, special care
should be taken not to damage the cooling
fins.
4. Clean the radiator thoroughly using a pres-

sure washer with cold water. Pay special
attention when cleaning corners as they
particularly susceptible to buildup.
5. Inspect the radiator. See page 53 for in-
spection guidelines. Reapply cleaner and
wash as needed. Utilizing quality garden sprayer to apply
6. After cleaning is complete, check the belt cleaner to radiator.
pulley and make sure they are clear of de-
bris.
CAUTION
Failure to keep radiator clean may lead to
severe engine overheating and hydraulic
system issues.
FNG 2512K Manual 77

SCREEN TROUBLESHOOTING
CAUSE SOLUTION
1. Bed of material is too deep 1. Decrease tonnage rate
EFFICIENCY
SCREENING
2. Screen cloth open area too 2. Increase open area of cloth.

small.
3. Screen cloth is blinded. 3. Clean screen cloth.
4. Screen angle may need to be 4. Decrease angle of screen.
flatter
5. Screen speed too fast. 5. Decrease screen speed.
6. Stroke of screen too low. 6. Decrease screen stroke.
CAUSE SOLUTION
1. Material is too wet for the 1. Reduce feed rate.
SCREEN CLOTH
feed rate.
IS BLINDING
2. Screen speed too fast. 2. Decrease screen speed.

3. Screen angle may need to be 3. Increase angle of screen.
steeper.
4. Spread of material is not even 4. Material needs to be spread
across screen panel. across entire screen panel for
proper screening.
SIDE OR CENTER OF SCREEN
CAUSE SOLUTION
MATERIAL FLOWS TO ONE
1. Material is not centered on 1. Center material on feed con-

feed conveyor veyor.
2. Screening plant may not be 2. Check level of plant.
level.
CAUSE SOLUTION
BREAKING SCREEN CLOTH
1. Wire diameter of screen cloth 1. Increase wire size or de-

is too small for size of material. crease material size.
2. Material impact on screen 2. Install rubber strips across
cloth. width of cloth at impact zone to
protect screen cloth.
3. Improper tension of screen 3. Screen cloth is either too
cloth. loose or too tight (depending on
wire diameter). Make sure an-
chor ends are evenly distributed.
4. Crown rubber on decks are 4. Install new crown rubber on
worn out. deck.
5. Improper weave or crimp of 5. Contact screen manufacturer.
screen panel.
78 FNG 2512K Manual
HYDRAULIC FILTERS
Hydraulic filters will need to be checked and

replaced on a regular basis. Review the following
images and descriptions along with maintenance
schedules for each hydraulic filter.
Hydraulic Filter/Breather - C00033
Replace after the first 50 hours, then every 250

hours after the first replacement.
Hydraulic Filter Element - C04203
Replace after the first 50 hours, then every 250

hours after the first replacement.
FNG 2512K Manual 79

ENGINE FILTERS
Engine filters will need to be checked and

replaced on a regular basis. Review the follow-
ing images and descriptions along with mainte-
nance schedules for each hydraulic filter.
Engine Fuel Filter (Primary) - C10083 Engine Oil Filter - C04766
Replace after initial 250 hours. Replace after initial 250 hours.
Replace every 500 hours. Replace every 500 hours.
Engine Air Filter (Primary) - C10178

Engine Fuel Filter (Secondary) - C10083 Engine Air Filter (Secondary) - C10179
Replace after initial 250 hours. Inspect Daily

Replace every 500 hours. Replace every 500 hours
80 FNG 2512K Manual

FNG 2512K Manual 81

TURNING THE SHREDDER ON
Always do a final walk around the plant before

turning on any of the circuits. Make sure all It is highly recommended to start the items in the
personnel are clear of machine and all lockout/ following order to avoid overloading the convey-
tagout procedures are followed. Once you are or belts. The belt feeder should always be the
certain all personnel are out of harm’s way the the last thing turned on.
engine can be started. Increase engine speed Stackers
to 2200 RPM. Screen
Screen Conveyor
All circuits can be turned on by pulling up on the Shredder
circuit’s valve handle. The conveyor is set up Belt Feeder
with adjustable speed. These speeds can be
adjusted by turning the flow control valves up or
down. Speed adjustments may be necessary
depending on the application.
82 FNG 2512K Manual

SHREDDER
ON
SHREDDER VALVE CONTROL
This valve controls shredder operation. The lower disengaged

position retracts the shredder to a nonoperational position.
OFF
The center off position does not affect the shredder position
but does stop shredder rotation. The “on” position engages the
shredder into operating position and starts rotation.
RETRACT
Relief Pressure:
3000 PSI
D00320-B
SHREDDER OPERATION
Start the shredder by pressing the “Control

Valve” handle marked “Shredder” to the “On” Moving the handle to the “Retract” position
position. This will move the shredder to the oper- will stop and retract the shredder from opera-
ating position and start the shredder rotating. tion. Once the shredder is retracted, return the
Moving the handle to the center “Off” position handle to the center “off” position.
will stop the shredder from rotating.
IMPORTANT
WARNING: DO NOT leave the lever in the “Retracted posi-
Before starting the shredder, tion. Leaving the lever in this position could
make sure no on is near the cause overheating of the hydraulic fluid and will
shredder or shredder hood. cause the cylinder valves to not function.
FNG 2512K Manual 83

SHREDDER MAINTENANCE SCHEDULE
84 FNG 2512K Manual

DAILY - GENERAL INSPECTION
A walk around inspection should be made on a daily basis. By taking a few minutes each day to
inspect the shredder, you can spot potential problems and take care of them before they become
serious.
Generally you should check the following items:
1. Make sure all guards are in place and functioning. Repair or replace any dam
aged or missing guards or guarding devices.
2. Check for loose nuts, bolts, and set screws.
3. Ensure there are no hydraulic fluid leaks. If leaks are found or suspected,
and are not repaired right away, be sure to monitor the hydraulic fluid level more
closely.
4. Clarify that the shredder blades are clear of any built up debris or rocks.
50 HOURS - SHREDDER BEARINGS & DRIVE BOLT
Shredder Bearings

1. Wipe dirt from grease zerk and bearing
2. Lubricate using three pumps of NLGI2 grease.
3. Repeat procedure for other side.
Shredder Drive Bolt
The bolt located on the shredder motor mount is double nutted and must remain
loose to prevent binding between the motor and the shaft.
FNG 2512K Manual 85

200 HOURS - SHREDDER BARS OR TILLERS & CYLINDER RAM
Shredder bars or tillers

Inspect the hammer or tiller bars for wear. If hammer bars are worn exclusively they
can be rotated to utilize both sides of the bar. If the hammer bars have been rotated
once they will have to be replaced.
Cylinder Ram
Inspect ram for debris and clean accordingly. Once the ram is clear of debris, coat
the cylinder with NLGI2 grease.
86 FNG 2512K Manual

TROUBLE SHOOTING
FNG 2512K Manual 87

88 FNG 2512K Manual

OPERATION AND MAINTENANCE NOTES
FNG 2512K Manual 89

Section 5: Warranty Section 7: Warranty
STANDARD WARRANTY
Astec Mobile Screens, Inc. (hereinafter referred to as “AMS”) warrants its products to its authorized Distributor,
as specified herein, and Distributor agrees to extend this same warranty (and no other) to each purchaser of the products
of AMS at the time of sale and to notify each purchaser of the terms and conditions of this Warranty. Distributor is not
authorized by AMS to make any other, different, or additional warranty on behalf of AMS, and any such warranty given by
Distributor is not binding on AMS. Distributor shall hold AMS harmless from any loss and/or costs (including attorneys’
fees) arising from failure to observe these conditions. AMS extends this same Warranty to those, in addition to its autho-
rized distributors, who buy the PRODUCTS of AMS directly rather than purchasing from an authorized Distributor.
AMS warrants, commencing with the date of receipt of the goods by first end-user and for a period of one (1)
year or two thousand (2000) hours, whichever comes first, all machinery and parts manufactured by AMS to be free from
defects in workmanship and material. If, within such warranty period, any machinery or parts shall be proved to the satis-
faction of AMS to be defective, it shall be replaced or, at the option of AMS repaired at its factory, F.O.B. AMS’s manufac-
turing plant in Sterling, IL at no charge (providing the defective machinery or parts are returned to AMS’s manufacturing
plant, freight prepaid). At its option, AMS may repair, or arrange to have repaired, any defective machinery or parts, at
the location of the Distributor, at the yard location or operating site of the first end-user, or at any other suitable location at
no charge to first end-user and at no charge to Distributor other than those specified in its Distributor’s Agreement. The
right to have defective machinery or parts repaired or replaced shall constitute Distributor’s and first end-user’s sole and
exclusive remedy.
AMS may, at its sole discretion, refund the purchase price or defective machinery or parts in lieu of repairing or
replacing them, providing the defective machinery or parts are returned to AMS’s manufacturing plant, freight prepaid, and
providing such return is authorized by AMS. AMS may, at its sole discretion, waive the requirement that defective machin-
ery or parts be returned to its factory in connection with a warranty claim.
The obligation of AMS under the terms of this Warranty is limited to the described repair or replacement of defec-
tive machinery or parts. Labor for warranty repair will be paid under a formula determined by AMS. With regard to ma-
chinery, parts or accessories which are furnished by AMS, but not manufactured by it, the warranty obligation of AMS shall
be limited to and the same as that of its supplier. No warranty shall apply to any used machinery or parts. No warranty
shall apply to the products of AMS which, in its opinion, have been adversely affected by the use, on or with its products,
of parts, attachments, equipment or lubricants not manufactured, sold or authorized by AMS.
No warranty shall apply to machinery, parts or accessories which have been furnished, repaired or altered by
others so as (in the opinion of AMS) to have affected the same adversely. No warranty shall apply to machinery, parts or
accessories which (in the opinion of AMS) have been subject to accident, negligence, or improper operation, installation,
maintenance, storage, care or other-than-normal use during and after shipment.
AMS warrants that field services conducted by it in connection with installation or repair of machinery and parts
will be performed in a good workmanlike manner. The obligation and liability of AMS in connection with field services shall
be limited to a refund of the amount it charged for such services, if any.
In as much as the work to be performed by the buyer or end-user with the machinery or parts furnished by AMS
will vary according to the materials used, local conditions, and the results required and that such variation will continue
throughout the use of such machinery or parts, it is not possible to (and AMS does not) warrant or represent that ma-
chinery and parts furnished by it will handle specific materials or will produce specific results from such materials. Any
application analysis and resultant equipment performance expectations are provided as estimates only and are not to be
construed in any manner as a production guarantee.
AMS is wholly discharged of all liability under the foregoing warranties in the event that purchaser of the machin-
ery or parts fails to pay for the goods promptly and in accordance with the terms of the purchase agreement.
AMS’s liability hereunder is conditioned upon Distributor (or in the event of a direct sale to a first end-user, then
first end-user) giving notice in writing to AMS of any alleged defect, and such notice must be given immediately upon the
discovery of such alleged defect; such notice must be received by AMS not later than 30 days after the expiration of the
warranty period.
AMS does not warrant or represent that any machinery, parts, or accessories furnished by it meet any Federal,
State or Local statutes, codes, ordinances, rules, standard or other regulations covering safety, pollution, noise, electrical
wiring, etc.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED (EXCEPT THE
WARRANTY OF TITLE) INCLUDING BUT NOT LIMITED TO ANY WARRANTY OR MERCHANTABILITY, AMS SHALL
NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES WHATSOEVER WITH RESPECT TO MACHINERY,
PARTS, ACCESSORIES, OR SERVICES MANUFACTURED OR FURNISHED BY IT OR ANY UNDERTAKINGS, ACTS
OR OMISSIONS RELATING THERETO. UNDER NO CIRCUMSTANCES SHALL AMS BE LIABLE FOR ANY CONSE-
QUENTIAL OR OTHER DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER CAUSED. THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.
90 2512K Manual
FNG 90
ProSizer 2612V w/ 3136 Manual
TOUGHNESS REFINED.
Kolberg-Pioneer, Inc.
700 West 21st Street 2704 W. LeFEVRE ROAD
Yankton, SD 57078 USA STERLING, IL 61081
800.542.9311 | 605.665.9311
F 605.665.8858
Johnson Crushers International, Inc.

86470 Franklin Boulevard
Eugene, OR 97405 USA
800.314.4656 | 541.736.1400
F 541.736.1424
Astec Mobile Screens

2704 West LeFevre Road
Sterling, IL 61081 USA
800.545.2125 | 815.626.6374
F 815.626.6430
www.kpijci.com
Because KPI-JCI and AMS may use in its catalog & literature, field photographs of its products which may have been modified by the owners, products
furnished by KPI-JCI and AMS 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 KPI-JCI and AMS are subject to the provisions of its standard warranty. KPI-JCI and
AMS does not warrant or represent that its 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 the use to which the product is put. 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. 11/15

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Operation and

IV FNG 2512K Manual

Section 4: Operation & Maintenance 53

VI FNG 2512K Manual

FNG 2512K Manual 7

8 FNG 2512K Manual

OVERVIEW PLANT CAPACITY

Outfitted with a 99 HP Tier IV water cooled

FNG 2512K Manual 9

10 FNG 2512K Manual

GETTING TO KNOW YOUR SCREENING PLANT

12 FNG 2512K Manual

FNG 2512K Manual 13

FNG 2512K Manual 15

16 FNG 2512K Manual

Do not allow anyone to operate this equipment Indicates an im-

18 FNG 2512K Manual

How can you get more information?

For a free copy of OSHA publications, send a

Or send a request to our fax at (202) 693-2498,

To file a complaint online or obtain more informa-

FNG 2512K Manual 19

REPLACE SAFETY SIGNS HANDLE STARTING FLUID SAFELY

20 FNG 2512K Manual

PROTECT AGAINST NOISE safely. Then follow procedures and recommend-

Wear a suitable hearing protec- PRACTICE SAFE MAINTENANCE

■■ Never lubricate, service,

FNG 2512K Manual 21

22 FNG 2512K Manual

FNG 2512K Manual 23

HANDLING BATTERIES SAFELY

Never check battery charge by placing a metal

CAUTION: Sulfuric acid in battery electrolyte

Avoid the hazard by:

f you spill acid on yourself:

24 FNG 2512K Manual

Date Trainee Signature Trainer Signature

FNG 2512K Manual 25

26 FNG 2512K Manual

STARTING THE ENGINE

Turn the key past the ON/START positoin and THROTTLE

■■ Sudden drop in oil pressure Press up on the UP/RABBIT direction to increase

DIAGNOSTIC GAUGE The Follow menu of engine parameters can be

NOTE: The engine does not need to be running

NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL

Relief Pressure: Relief Pressure: Relief Pressure:

Figure 30.1 Figure 30.2

LEVELING THE PLANT INITIATE SETUP

SIDE DISCHARGE CONVEYOR

Relief Pressure: Relief Pressure:

CAUTION: WHEN RAISING SIDE Figure 31.1 Figure 31.2

Figure 31.3 Figure 31.4

Figure 32.1 Figure 32.2

Figure 33.1 Figure 33.3

LOWER FINES CONVEYOR HEAD SECTION

Begin the process by removing the transport

POSITIONING FINES CONVEYOR

Figure 35.1 Figure 35.2 NOTE: Lifting Screenbox

Relief Pressure: Relief Pressure:

38 FNG 2512K Manual