Kolberg-Pioneer, Inc.

SERVICE BULLETIN
Serial Numbers 405317-408189 (FT2640)
406116-408065 (FT2650)

SB 013 0803 FT MSC March 31, 2008

rev. 1 4/10/08
SUBJECT: FT2640 and FT2650. Mainframe Updates

This service bulletin is an update from SB Table of Contents

007 0708 FT MSC FT2640 and FT2650
Mainframe Inspection. Weights.................................................................2

Kolberg-Pioneer is requiring the addition of Tools and Equipment...........................................2

reinforcement plates on mainframe gussets, Safety....................................................................2
feeder leg gussets and under the jaw feet. These
reinforcements address issues with cracks that Phase 1................................................................3
have developed in these areas due to loose jaw
mounting bolts and/or extreme frame racking and Phase 2.................................................................4
they provide the additional strength required to
Undercrusher Hopper Side................................6
prevent cracking. Order kit 272872 (Phase 1)
or 272873 (Phase 2) for an FT2650 or kit 272874 Drawings FT2640............................................7-10
(Phase 1) or 272875 (Phase 2) for an FT2640
to complete the mainframe reinforcements. Drawings FT2650........................................11-14

This service bulletin is organized into two Drawing Undercrusher Hopper Side...............15
phases. Phase 1 is required for all FT2640 and
Parts Order Form.................................................16
FT2650 units listed in the serial number range at
the top of this bulletin. Appendix A - Removing Undercrusher
Conveyor........................................................17-21
Once Phase 1 is complete, Phase 2 will
only be necessary if additional cracking is Appendix B - Removing Hopper and
found on the Fast Trax frame underneath the Feeder................................................................22
jaw feet.
Appendix C - Removing Jaw Crusher.......24-26
The following is a table of contents for this
service bulletin for easy reference.

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Weights 2. Before welding anywhere on the FT2640 or

The following contains weight information
relevant to completing the mainframe updates.
Before beginning these updates, make sure the
proper equipment is available to lift and support
the following components.
FT2650, disconnect all electronic devices on
the control panel at five (FT2650) or six
(FT2640) places. Failure to disconnect will
result in electronic component failure.

Component Weight
Jaw 2640 29,500 lbs.
2650 32,000 lbs.
Walkway Assembly 200 lbs.
Undercrusher 7,300 lbs.
Conveyor
Feeder/Hopper
40” x 14’ 12,700 lbs.
50” x 15’ 14,500 lbs.
50” x 18’ 17,400 lbs.
K-braces FT2640 152 lbs. FT2640 - Clutch Driven Control Panel - Six Places
180lbs.
FT2650 171 lbs.
137 lbs.

Tools and Equipment

• 5/8” socket wrench

• 2-1/4” socket wrench

• Overhead crane with enough capacity to lift

FT components.

• Standard service tools

FT2650 Control Panel - Five Places
• Standard welding equipment
3. Disconnect remote from tether if used and
Safety
turn battery disconnect switch to the “off”
To avoid serious injury to operators and position.
to the equipment, adhere to the following safety
instructions.

1. Lockout/tagout all power to the FT2640 or

FT2650.

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Battery Disconnect on FT2650 and FT2640
Phase 1
Phase 1 mainframe updates are required for
all serial numbers in the range listed on page
one of this service bulletin.
This phase involves welding twelve
reinforcement plates to the mainframe gussets(1)
and the feeder leg gussets(2) on the FT2640 and
fourteen reinforcement plates to the mainframe
gussets (1) and the feeder leg gussets(2) on the
FT2650. Refer to the model below and sheet
one of drawing 272713 (FT2640) and 272709
1 2
One only on FT2640 units
1
2
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4. Hydraulic hoses may be under pressure.
Wear safety glasses, hard hats, and gloves
before disconnecting.
5. Cleanliness of the hydraulic system is critical.
All hydraulic hoses must be recoupled on the
unit, capped, or covered with plastic to
prevent contamination.
6. Welding must be completed by a certified
welder.
(FT2650) for more information. This phase also
includes welding two k-braces on each side of
the frame.
If the reinforcement plates have already been
installed per EB 006, only k-braces will need to
be installed to complete phase 1 mainframe
updates. Use the following procedure to install
updates for phase 1:
1. Remove undercrusher conveyor from the
plant.
One only on FT2640 units
1
1
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Use Appendix A included at the end of 5. On FT2650 units, it will also be necessary
this service bulletin for the procedure on add one guard bracket to each side - part
removing the undercrusher conveyor. number 272711.

Once the undercrusher conveyor has been Phase 2

removed, cut off the curtain angle brace that
is welded to the frame. Phase 2 updates will only be necessary if
cracks are found on and/or around the frame
2. Remove six total track pads from each side underneath the jaw feet.
of the Fast Trax unit. There are four bolts
total per section to remove. When the track
pads are removed, this will allow enough
clearance to weld k-braces to the frame.

Curtain angle
brace Cracking

Cracks Around Jaw Feet

Remove three track pads
in both areas on each side. Thoroughly inspect the area on the Fast Trax
frame around the jaw feet including the inside of
Track Pads the mount pad on the inside of the frame. If cracks
are found here, use the following procedure to
Once the undercrusher conveyor, and
complete phase 2 updates.
track pads have been removed from the
frame, the updates can be installed. 1. Remove the hopper and feeder from the
frame.
3. Grind paint from the surfaces where the
reinforcement plates and k-braces will be Use Appendix B included at the end of this
welded. service bulletin for the procedure on removing
the hopper and feeder.
If any cracks are found in these areas, they
will need to be ground out and rewelded 2. Remove the jaw crusher from the plant.
before the reinforcement plates can be
installed. Use Appendix C included at the end of this
service bulletin for the procedure on removing
4. Follow the weld instructions on Sheet two of the jaw crusher.
drawing 272709 (items 1-6) for the FT2650
and 272713 (items 1-6) for the FT2640.
There is no order in which the reinforcement
plates or k-braces should be welded to the
frame.
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SB 013 0803 FT MSC
3. Grind out the cracks on the frame around the
jaw feet and reweld.
4. Using the weld instructions on Sheet three
and four of drawing 272709 (FT2650) or
272713 (FT2640), install the phase 2 updates
in the following order:
a. Weld top reinforcement plate, part
number 272702 (FT2650) or part number
272714 (FT2640) to the top of the Fast
Trax frame.
b. If cracks are found on the outside of the
frame, grind out and reweld the cracks.
Weld a new butterfly-shaped
reinforcement plate, part number 272710
(FT2650) or part number 266194
(FT2640).
c. Weld part number 272708 as
shown. This is the spacer for the by-pass
chute or side delivery conveyor (if
equipped).
d. Weld part number 272716 (item #11) as
shown for FT2640 units only.
e. Weld part number 800605, 801119, and
272717 as shown.
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March 31, 2008
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5. Once all the reinforcement plates have been
installed on the frame, stitch weld a 3/4” shim
to each foot of the hopper leg (provided in
kit).
Note: This welds the shim to the hooper leg
plate not the mainframe platform mount.
6. Install Fabreeka pads underneath each jaw
foot.
7. Reinstall the jaw, feeder, hopper, and
undercrusher conveyor by reversing the
procedure in Appendix A, B and C.
8. After jaw has been reinstalled, weld new jaw
stop blocks to frame, part number 219685
as shown on sheet three of drawing 272709
(FT2650) and 272713 (FT2640).
Parts and labor up to 40 hours will be covered
by KPI warranty for Phase 1.
Parts and labor up to 90 hours will be covered
by KPI warranty for Phase 1 and 2 updates.
If you have any questions contact the Kolberg-
Pioneer Service Department, 1-800-532-9311.
SB 013 0803 FT MSC March 31, 2008
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Undercrusher Hopper Side

After re-installing the undercrusher conveyor,

a new undercrusher hopper side may need to
be installed. If the undercrusher hopper side is
similar to the picture below, this modification will
not need to be done.

Refer to drawing 272862 on page 15 for more Undercrusher hopper side

information.
Undercrusher Hopper Side
If the undercrusher hopper side needs to be
installed, order kit 272862. Bolt the brackets and Once this modification is complete, the existing
flashing to the plates with handles. Install the curtains will not need to be replaced.
hopper side assembly to the undercrusher
conveyor hopper as shown in the pictures below.

Undercrusher Hopper Side

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Check the box below to order parts for one Fast Trax unit
and return to Kolberg-Pioneer.

FT2650 - Drawing 272709

Send one Kit# 272872 - FT2650 Mainframe Updates Phase 1

Send one Kit# 272873 - FT2650 Mainframe Updates Phase 2

FT2640 - Drawing 272713

Send one Kit# 272874 - FT2640 Mainframe Updates Phase 1

Send one Kit# 272875 - FT2640 Mainframe Updates Phase 2

Undercrusher Hopper Side - FT2640 and FT2650

Send one Kit# 272862 - Undercrusher Hopper Side

Parts and labor will be covered for 40 hours for Phase 1 updates.

Parts and labor will be covered for 90 hours for Phase 1 and 2 updates.

Kit must be ordered and installed within 90 days of receipt of this service bulletin.

Please send to:

Name:

Address:

City: State: Zip:

Attn:

Fast Trax Serial Number:__________________________________________________

Fax to the KOLBERG-PIONEER Parts Department, 1-800-514-6115

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Appendix A

Removing Undercrusher Conveyor

To weld plates to the mainframe gussets and

under the jaw feet, it will be necessary to remove
the undercrusher conveyor and jaw from the plant.

Use the following procedure to remove the

undercrusher conveyor from the plant.

1. On each side of plant, loosen retaining bolt

and rotate the support hook upward.

Loosen retaining bolt

3. Attach conveyor to a loader for removal
Support hook - one by wrapping chains around the head
each side pulley shaft equally on both sides.

Conveyor
support pin

Saddle

2. Remove conveyor hopper side panels and

conveyor hopper end panel.

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4. Disconnect turnbuckle support 6. Disconnect hydraulic lines for

assemblies and conveyor cables (if undercrusher conveyor.
equipped with a folding conveyor).

Disconnect hydraulic
Conveyor cable lines for undercrusher
conveyor

Turnbuckle support 7. Remove the nuts and washer from the

lower frame support tube located to the
front of the tracks at the discharge end.

5. Disconnect dust suppression hose for Remove these nuts

undercrusher conveyor. located on both sides of
the plant

Washer

Remove this dust

suppresssion hose.

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8. Slide the threaded rod out from the plant. 10. Lower conveyor tail end to the ground.

End delivery raise/lower

Threaded rod

9. Remove support chains at tail pulley of

conveyor on each side.

Remove chain
on both sides.

Undercrusher conveyor in lowered position

11. Remove hydraulic cylinder pins on both

sides of undercrusher conveyor.

Undercrusher
conveyor lowered

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Support hook

Conveyor
support
pin

Remove cylinder
pins on both
cylinders

Saddle

14. Back plant straight away from the

conveyor to avoid twisting or misaligning
conveyor.
Hydraulic cylinder fully extended

IMPOR
IMPORTTANT
Support hook must be in the up position or
it will be damaged when removing the
undercrusher conveyor.

12. Retract cylinders.

IMPOR
IMPORTTANT 15. After the plant has cleared conveyor,
Make sure tail end cylinders and chains are the conveyor head section can rest on the
disconnected. ground using the support feet.

13.Slowly, lift the conveyor head section so

that conveyor support pin clears saddle.

IMPOR
IMPORTTANT
When lifting conveyor support pin out of
saddle, make sure conveyor has enough
clearance from the magnet.

Support foot

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16. Remove chains and disconnect conveyor

from loader.

Undercrusher conveyor removed from plant

17. Replace lower support tube, threaded rod,

washer and nuts to prevent track frame
from deforming.

18. To reinstall the undercrusher conveyor,

reverse the procedure.

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Appendix B
Removing Hopper and Feeder

Use the following procedure to remove the

hopper and feeder from the plant.

1. Unbolt and remove the feeder motor guard.

2. Remove the feeder hoses from the feeder

motor (three hoses total).

Feeder Hopper Bolts

Feeder motor guard
5. Lift and remove the hopper from the unit.
Refer to the picture below for the location of
the lifting eyes on the hopper.

Hydraulic hoses for

feeder motor
Feeder Motor - Hydraulic Hoses and Guard

3. Weld a spreader bar across the top of the

hopper on the discharge end to prevent the
hopper from distorting when removing from
the Fast Trax frame.
Hopper Lifting Eyes - Four Total
Hopper Removed from FT Unit for Clarity
4. Loosen and remove the bolts under each
feeder hopper leg. There are four bolts per
6. Lift and remove the feeder from the unit. Refer
leg - sixteen bolts total on 14’ (FT2640 only)
to the picture for the location of the lifting eyes
and 15’ feeders, 24 bolts total on 18’
on the feeder.
feeders (FT2650 only).

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9. Torque locknut to 100 ft.lbs.

Torque locknut
Belleville to 100 ft.lbs.
washers -
orientation.

Feeder Lifting Eyes - Four Total

Feeder Removed from FT Unit for Clarity

7. Reverse the procedure to reinstall the feeder

and hopper.

8. When reinstalling the capscrews on the

hopper and feeder legs, make sure the
orientation of the Belleville washers is as
shown in the diagram in the next column.

Feeder/Hopper Leg Bolt Assembly

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Appendix C

Removing Jaw Crusher 3. Remove two hydraulic lines from the

counterbalance valve as shown in the picture
To remove the jaw crusher from the plant: below.

1. On the FT2650 only, disconnect four bolts that

connect the hydraulic motor to the overhung
load adaptor (OHLA)

Hydraulic Motor Bolts - four total

2. Disconnect two hydraulic lines to the service

cylinder.

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4. If equipped, remove the dust suppression line
to the crusher.

Unbolt two bolts here

to remove walkway

6. On the FT2640, remove the flywheel guard

on the right side of the unit looking toward
the undercrusher conveyor.
7. Remove the bolts on the jaw feet that secure
the jaw to the Fast Trax frame using a 2-1/4”
socket wrench.

5. Attach a loader or other lifting device to the

walkway assembly (assembly weighs 200
lbs.). Use a 5/8” socket wrench to remove
two bolts on the walkway assembly.

Remove walkway assembly from the plant.

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8. The weight of the 2640 jaw crusher is 29,500 9. Carefully and slowly lift the jaw crusher from
lbs. and the weight of the 2650 jaw crusher is the frame and down on cribbing.
32,000 lbs. Be sure that the crane used to
lift the jaw can support these weights. Attach
chains to four points on the jaw as noted in
the picture.
Lifting point - two
behind moving jaw

To reinstall the jaw, repeat these steps in the

reverse order. When reinstalling the jaw mount
bolts, torque to 1250 ft.lbs.

Lifting point - two

on front jaw feet

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