Service Tool Guide

Table of Contents
General Maintenance & Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Horizontal Shaft Impactor Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Jaw Crusher Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vertical Shaft Impactor Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cone Crusher Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Track Unit Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Belt Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Miscellaneous Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parts & Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Feeder Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Maintenance & Troubleshooting Tools AN Nut Wrenches
For All Equipment Part Number Used on Lock Part Number Used on Lock
Nut Nut
Box end/open end wrenches - 3⁄16” up to 3” 257029 AN-07 257017 AN-26
Air or electric impact gun and appropriate sockets – 257030 AN-09 257018 AN-28
1⁄2”, 3⁄4” and 1” drives 256722 AN-12 257019 AN-30
Electrical and pneumatic extension cables and hoses 257013 AN-14 257020 AN-32
Set of hammers - up to 10 lbs. 256723 AN-15 257021 AN-36
Drill and set of drill bits 257012 AN-16 257022 AN-38
Set of taps - bottom and top 257014 AN-17 257023 AN-40
256724 AN-18 257024 AN-44
Set of chisels and punches
257015 AN-19 257028 AN-048
Hole bars and pry bars
256725 AN-20 257027 AN-052
Industrial stick welder
257016 AN-21 257025 AN-056
Set of allen wrenches - 1/16” through 3/4”
256726 AN-22 257026 AN-060
Set of lifting chains - up to 1/2” and in pairs
Torque wrench impactor crusher drive coupling - 220870
Set of lifting straps - 1” up to 4”
Grinders - 4-1/2” and 9” Tools for Conveyor Drive Squeeze Coupling FT Units
Acetylene torch Part Number Description
Multimeter 338891 13mm torque wrench box end
338892 9/16" torque wrench box end
Infra-red temp gun
338893 17mm torque wrench box end
Tachometer
289402 6mm x 1/4" torque wrench bit
Lockout/tagout kit
3/4” clevis pin shackle General HSI Tools
3 legged cable/chain rated to cone weight Part Number Description

2” lifting Strap 237227 3” apron adjust wrench

227765 4240 blow bar lifting tool
4” lifting Strap
189108 4250 blow bar lifting tool
1” NC shouldered lifting eye
272864 5260 blow bar lifting tool
1/4” NC shouldered lifting eye
82422 Rotor locking pin assembly
341400 Apron adjust gauge set
The General Maintenance & Troubleshooting Tools are available in
most areas, let us know if you need assistance locating them.
Wedge Tools
Part Number Description
309953 5/8" Allen wrench
Horizontal Shaft Impactor Tools
Shaft and Rotor Assembly 305211 10o 1-1/8" wrench

Installation and Removal Nuts 305212 45o 1-1/8" wrench

Model Installation Nut Removal Nut

Rotor Maintenance Tools
4233 272876 WSL-02703
Part Number Template Description
4240 272876 WSL-02703
354102 (42 series rotors) Front-side segment profile
4250 272876 WSL-02703
354182 (42 series rotors) Back-side segment profile
3850 272876 WSL-02703
305715 (42 series & 5260 rotors) Hard surfacing
4654 N/A N/A
317483 (5260 rotors) Profile template
5260 N/A N/A
501169 4240/50 HSI; 4-bar
6064 N/A N/A

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Jaw Crusher Tools Common Tools Continued
Pitman Shaft and Bearing Assembly Part Number Description
Part Number Installation Nut Removal Nut 305720 Shim stock kits with 2 bolts per bearing for one
complete jaw
1654 WSC-01080 WSC-01079
— Set of Lifting Straps - 1” up to 4”
2148 WSC-01080 WSC-01079
— Set of Lifting Chains - up to 1/2” and in pairs
2436 WSC-01080 WSC-01079
— Oil bath container, heat up to 300 degrees. Capable of
2640 WSC-01080 WSC-01079 withstanding the weight of the pitman bearing - up to
2650 WSC-01080 WSC-01079 300 lb.
2742 WSC-01080 WSC-01079
AN Nut Wrenches
2854 WSC-01079 AEP-06731
Part Number Used on Lock Part Number Used on Lock
3055 (older than SN 413335) WSC-01079 AEP-06731
Nut Nut
3055 (SN 413335 and newer) WSC-01079 337471
257029 AN-07 257017 AN-26
3163 WSC-01079 AEP-06731
257030 AN-09 257018 AN-28
3165 WSC-01079 AEP-06731
256722 AN-12 257019 AN-30
3042 (older than UH-3959) WSC-01078 WSC-01077
257013 AN-14 257020 AN-32
3042 (UH-3959 and newer) WSC-01078 AEP-06731
256723 AN-15 257021 AN-36
3144 (older than SN 410494) WSC-01078 AEP-06731
257012 AN-16 257022 AN-38
3144 (SN 410494 – SN 413160) WSC-01079 AEP-06731
257014 AN-17 257023 AN-40
3144 (SN 413759 and newer) WSC-01079 337471
256724 AN-18 257024 AN-44
3350 283543 161941 (SKF)
257015 AN-19 257028 AN-048
161942 (FAG)
256725 AN-20 257027 AN-052
3352 283543 161941 (SKF)
161942 (FAG) 257016 AN-21 257025 AN-056
3546 WSC-01145 WSC-01081 256726 AN-22 257026 AN-060
4248 WSC-01082 WSC-01081
4450 (older than SN 413571) WSC-01082 WSC-01081
Vertical Shaft Impactor Tools
For All VSI Models
4450 (SN 413571 and newer) WSC-01082 337467
General Tools – Metric
Box end/open end wrenches - 8mm up to 32mm
Dimension Tool
Part Number Model Part Number Model VSI Tool Kit – Imperial Measure
264170 1036 264168 3055
Part Number Description
264170 1336 252821 3042
289470 Contains all tools for normal repair and maintenance
264170 1536 252821 3144 jobs
264168 1654 — 3642
264170 2036 260732 4248 VSI Tool Kit – Metric Measure
264170 2436 260732 4450 Part Number Description

264180 2640 264172 3546 363742 Contains all tools for normal repair and maintenance
jobs
264174 2650 264174 2148
264168 2854 — 2436 Pedestal Assembly
Part Number Description
Common Tools
257017 AN-26 spanner wrench
Part Number Description
— Retaining ring pliers (1/2 to 2-1/2 bore range)
255460 Torque multiplier 8,000 ft/lb
— Serrated water pump pliers 2” capacity
800751 Torque wrench 30-250 ft/lb
— Nose wire cutting shear
255462 3-3/4” socket; 1-1/2” Drive
348330 Socket for AN-26 locknut
— Measuring (machinist) tool for internal and external
348331 Socket for AN-24 locknut
dimensions
— Depth gauge - pitman float Common Tools
— Feeler gauges - (long set) - .001-.040 Part Number Description
305719 Shim stock kits with 3 bolts per bearing for one 296097 Sonic Tensioner
complete jaw

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Cone Crusher Tools Belt Tools
Kodiak® Plus Cone Crushers For All Equipment
Recommended Tools Conveyor Installation, Repair and Maintenance
Part Number Description Part Description Fastener Belt Degree
— Wedgeplate flipping fixture for K500+ Number Type Width

450132 Mantle wrench (2 lug) 313304 Belt template 140 48 90

540014 Mantle wrench (3 lug) 313303 Belt template 190 48 90

456294 TIR Test Block 233724 Belt template 190 60 90

87091 Cavity Plug T16A-2 1911 Belt template 190 36 90

— Misc. set of caps/plugs 349836 Belt template 140 24 90

456531 Cone offset lifting eye 1896 Belt template 140 30 90

456532 Cone lifting eye 46-48010 Belt template 1-1/2 48 90

83074 Needle oil sampler with tubing 227104 Belt template 1 18 90

450132 Mantle wrench 46-48008 Belt template 140 36 90

995136 Dial indicator with magnetic base 46-48009 Belt template 140 42 90

450015 Accumulator charging kit with hose 323640 Belt template 190 30 90

450266 Nitrogen checking gauge 323639 Belt template 190 36 90

995239 *Pinion bearing puller fixture 23188 Belt template 190 42 90

995156 *Wedge plate rotation - 406192 323638 Belt template 190 48 90

995024 *Spreader bar - thrust bearing installation and 313362 Belt template 1-1/2 36 90
removal (used with 995023) 66650 Belt stapling N/A N/A N/A
995023 *Cable .25 stud x 16.0 (used with 995024) tool #C-187 2”
wide
991104 *Cone head flipping fixture
1857 Bolt breaker 1, 140, 190 , N/A N/A
995144 *2 Legged radial bearing race puller for 1200LS, RP1, & SP6
K200+, K300 and K300+ Radial bearings
19323 Bolt horn N/A N/A N/A
— *3 legged radial bearing race puller for K400, K400+ & flexco #2BH
K500+ radial bearings
233707 Boring bit 1, 140, 190, N/A N/A
456532 *Cone lifting eye flexco #BIB RP1, & SP6
456531 *Cone offset lifting eye 240971 Power boring 1, 140, 190, N/A N/A
bit #HB-1 RP1, & SP6
* Items available for purchase tagged with the ASME load testing/rating
certification completed. 240972 Quick change N/A N/A N/A
chuck #5552
LS Cone Crushers 166985 Power punch 1, 140, 190, N/A N/A
#HP-1 RP1, & SP6
Recommended Tools 313360 Power punch 1-1/2, 2, N/A N/A
#HP-2 2-1/4, & RP2
Part Number Description
166986 Power wrench 1, 140, 190, N/A N/A
450030 Clamp cylinder wrench
#HW-1 RP1 & SP6
313361 Power wrench 1-1/2, 2, N/A N/A
Track Unit Tools #HW-2 2-1/4, & RP2
FT and GT Models
46-48003 Punch flexco 1, 140, 190, N/A N/A
Recommended Tools #P1P RP1, & SP6
Part Number Description 46-48004 Punch flexco 1-1/2, 2, N/A N/A
— Crows foot for shaft coupling #P2P 2-1/4, & RP2
— Digital pressure gauge 46-48005 Wrench flexco 1,140, 190, N/A N/A
#S1S RP1, & SP6
46-48006 Wrench flexco 1-1/2, 2, N/A N/A
#S2S 2-1/4, & RP2
397204 Rivnut Gun N/A N/A N/A

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Screen Tools Hydraulic Tools
Screen Maintenance – Horizontal and Combo Screens For All Equipment
Part Number Description Part Number Usage and Description
— Metric sockets (locking assemblies) 340826 Diagnostic Hose Kit
090013 Assembly locking socket - 8mm hex 257121 Hydraulic Cap and Plug Assembly
090036 Assembly locking socket - 6mm hex 395170 SF62 PLUG/CAP KIT, 1-1/2
995149 Nut bearing press AN32
Hydraulic Flow Meter Kits
721022 Nut bearing press AN- 38
Part Number Usage and Description
995150 Wrench locknut AN32
321340 Kit includes 1-10 GPM meter and adapters for face
721021 Wrench locknut AN-38 seal connections for line sizes 1/2”, 3/4” and 1”.
995147 Huck gun with extended nose huck model #3585 & 321341 Kit includes 3-30 GPM meter and adapters for face
#99-5013 seal connections for line sizes 1/2”, 3/4” and 1”.
086000 Y-27 pump (porta-power hydraulic pump or
equivalent) SMA Drive Motor Lifting Lug - FT4240 and FT4250 Model Track
Units
620471 Timing wrench LH 26 & 32 (provided)
Part Number Description
620470 Timing wrench RH 26 & 32 (provided)
291101 SMA Motor Lifting Lug
514046 Timing wrench 24 (provided)
514059 Timing wrench 24 LH (provided) Hydraulic Fitting and Nut Wrenches - FT & GT Model Track Units
516095 Timing wrench 26 (provided) Part Number Usage
720092 Timing wrench RH 38 (provided) 305701 1-1/4” Wrench
720093 Timing wrench LH 38 (provided) 305702 1-3/8” Wrench
516252 Bar location WT26 (provided) 305703 1-3/8” Wrench (1 side of jaw is thinner)
620368 Bar location WT32 (provided) (qty 2) 305704 1-1/2” Wrench
720086 Bar location WT38 (provided) 305705 1-5/8” Wrench
514032 Bar location WT24 (provided) 305706 1-5/8” Wrench (Has a flatter nose)
721023 Spindle pusher field tool 305707 1-3/4” Wrench
Screen Lifting Bars 305708 1-7/8” Wrench
517305 Lifting bar - 5’ incline 305709 2” Wrench
516933 Lifting bar - 5’ LP 305710 2-1/8” Wrench
516909 Lifting bar - 5’ MS & HS 305711 2-3/16” Wrench
622128 Lifting bar - 6’ LP 305712 2-1/4” Wrench
622839 Lifting bar - 6’ MS & HS 305713 2-3/8” Wrench
720854 Lifting bar - 7’ LP 305714 2-3/4” Wrench
721004 Lifting bar - 7’ MS & HS
Accumulator Charging Assembly
821557 Lifting bar - 8’ LP
Part Number Description
821763 Lifting bar - 8’ MS & HS
42-80042 Used for charging accumulators on KPI track-
Combo Screens mounted impactor plants with nitrogen
621049 Lifting/spreading bar - 6’ screens
O-Ring Seal Lock Kit - FT Model Track Units
721036 Lifting/spreading bar - 7’ screens
Part Number Includes
821075 Lifting/spreading bar - 8’ screens
266581 Qty. 12 of each size Buna O-Rings in kit

Optional Tools 2 FS03

Part Number Description 3 FS04 (KPI Part #85515)
995151 Hydraulic bearing press 4 FS06 (KPI Part #85516)
620450 Spindle pusher field tool 5 FS08 (KPI Part #85517)
995154 *Disc assembly offset lifting fixture shaft 6 FS10
995153 *Spindle lifting fixture 8 FS12 (KPI Part #85520)
821671 Screen jacking bracket 10 FS14
995155 Cone installation shaft 32 12 FS16
14 FS20 (KPI Part #194550)
* Items available for purchase tagged with the ASME load testing/rating
certification completed. 16 FS24
4
 20 FS32 Feeder Tools
32
Vibrating Mechanism Assembly
AN Nut Wrenches
Part Number Used on Lock Nut Used on Feeder
Hydraulic Tools 256722 AN-12 30x12, 36x14, 36x16
For All Equipment
Suction Tool 256723 AN-15 42x15
256725 AN-20 36x20, 42x12, 42x16,
Part Number Usage and Description
42x18, 50x18, 50x24,
389367 Tool for creating a vacuum on the reservoir while 60x24
replacing components to minimize liquid loss
without draining tank.
Grizzly Finger tools
Digital pressure fauge (ex. parker service junior kit) Part Number Description
557869 12 Point Crowfoot Torque Adapter, 30mm
Miscellaneous Tools
For Various Parts and Equipment
Poly Chain Drive Parts & Service Support
Part Number Description Available 24 Hours a Day, 365 Days a Year
090417 Meter, sonic belt tension Kolberg-Pioneer, Inc.
Parts Support: (800) 766-9793 | +1 (605) 665-9193
AN Nut Wrenches Service Support: (800) 532-9311 | +1 (605) 665-9311
Part Number Used on Lock Part Number Used on Lock Johnson Crushers International, Inc.
Nut Nut Parts Support: (888) 474-0115 | +1 (541) 988-9408
257029 AN-07 257019 AN-30 Service Support: (866) 875-4058 | +1 (541) 988-9463
257030 AN-09 257020 AN-32 Astec Mobile Screens, Inc.
256723 AN-15 257021 AN-36 Parts Support: +1(815) 626-6374
257012 AN-16 257022 AN-38 Service Support: +1(815) 626-6374
257014 AN-17 257023 AN-40
256724 AN-18 257024 AN-44
257015 AN-19 257028 AN-048
257016 AN-21 257027 AN-052
256726 AN-22 257025 AN-056
257017 AN-26 257026 AN-060
257018 AN-28

Electrical Tools
For All Equipment
Crimpers and Connectors
Part Number Description
328497 Deutsch Connector Kit
328498 Deutsch Hand Crimper
328499 Packard Hand Crimper
328500 Packard Pin Removal Tool

Electrical Assembly Repair Kit

Part Number Description
Rocky University
356325 DT Series Service Kit (328497) Our world-class program covers topics from basic component concepts to
- Crimp Tool (328498) advanced mechanical troubleshooting as well as industry knowledge and
- P/N Insert (356324) sales trainings. With a variety of courses, including both online and face-
to-face offerings, you can ensure that you and your team are thoroughly
Testing Tools educated for all aspects of the sales and operating processes.
Part Number Description The complete scheduled training calendar is online at
355802 EDC Test Harness www.rockyuniversity.com. TRAINING

5
Kolberg-Pioneer, Inc.
Parts Support: (800) 766-9793 | +1 (605) 665-9193
Service Support: (800) 532-9311 | +1 (605) 665-9311

Johnson Crushers International, Inc.

Parts Support: (888) 474-0115 | +1 (541) 988-9408
Service Support: (866) 875-4058 | +1 (541) 988-9463

Astec Mobile Screens, Inc.

Parts Support: +1(815) 626-6374
Service Support: +1(815) 626-6374

www.kpijci.com

Because Kolberg-Pioneer, Inc., Johnson Crushers International, Inc. and Astec Mobile Screens, Inc. may use in their catalog and literature, field
photographs of their products which may have been modified by the owners, products furnished by Kolberg-Pioneer, Inc., Johnson Crushers
International, Inc. and Astec Mobile Screens, Inc. may not necessarily be as illustrated therein. Also continuous design progress makes it necessary
that specifications be subject to change without notice. All sales of the products of Kolberg-Pioneer, Inc., Johnson Crushers International, Inc. and
Astec Mobile Screens, Inc. are subject to the provisions of their standard warranty. Kolberg-Pioneer, Inc., Johnson Crushers International, Inc. and Astec
Mobile Screens, Inc. do not warrant or represent that their products meet any federal, state, or local statutes, codes, ordinances, rules, standards or
other regulations, including OSHA and MSHA, covering safety, pollution, electrical wiring, etc. Compliance with these statutes and regulations is the
responsibility of the user and will be dependent upon the area and the use to which the product is put by the user. In some photographs, guards
may have been removed for illustrative purposes only. This equipment should not be operated without all guards attached in their normal position.
Placement of guards and other safety equipment is often dependent upon the area and how the product is used. A safety study should be made
by the user of the application, and, if required additional guards, warning signs and other safety devices should be installed by the user, wherever
appropriate before operating the products.
NOTE: SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE Rev. 2/20