FullLine Catalogo

7/22/2019 FullLine Catalogo

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KOLBERG-PIONEER and JCI combine to form the largest, most complete

product offering for aggregate processing equipment obtainable from a single

manufacturer. From rugged scalping screens to roller bearing cone crushers, jaw

and impact crushers, horizontal and incline screens through material washing,

classifying, telescoping stackers, portable screening plants and pugmill plants.

No single distribution network provides a more complete source for local sales –service – parts and financing options.

With a history dating back to 1928, PIONEER is renowned for portable jaw

plants, innovative impact crushers, heavy-duty feeders/screens, recycle and

portable plant designs. Since 1964, KOLBERG conveyors, washing and classifying equipment and

portable screens have set industry standards for capacity, low operating costs and the highest resale

value at trade-in time. JCI employees trace their roots to the original 1950’s ElJay ® roller bearing cone

crushers and field proven horizontal screen designs. Today, JCI designs and manufactures the most

technologically advanced roller bearing cone crushers in the industry.

Mining Stationary Aggregate Portable Aggregate Recycle Bulk Material

PRODUCTS & SERVICES

Material Analysis x x x x xEquipment & Operating

Cost Comparisons x x x x xPlant Layout x x x x xFeeders/Grizzlies x x x x xScreens x x x x x J aw Crushers x x x x

Cone Crushers x x x xHorizontal Shaft Impactors x x x xVertical Shaft Impactors x x xSizing Screens x x x x xWashing x x xClassifying x xConveyors x x x x x Telescoping Stackers x x x x xPortable Crushing Plants x x x x Track Mounted Plants x x x xPortable Screen Plants x x xRecycle Crushers x xComplete Turn Key Systems x x x xRebuilds x x x xPugmills x x x x xParts Support x x x x xService/Training x x x x xRetro-Fit Packages x x x x xSoftware x x x x xWarranty x x x x xFinancing x x x x x

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M ARKETS SERVED

MORE

THAN

IRON



As members of the Astec family of companies,

KOLBERG-PIONEER and JCI are focused on the

aggregate processing and recycle industries. Unlike

other manufacturers who suffer from revolving

ownership or directional changes, our corporate parent truly understands aggregate processing equipment and makes the commitment to continually

invest in new product development, manufacturing technologies, quality assurance and customer

satisfaction. Resources are available from across the Astec family spectrum, assuring you the

technology and support to meet tomorrow’s competitive environment.

KOLBERG–PIONEERLocated in Yankton, South Dakota, this250,000 sq. ft. modern manufacturingfacility contains the latest in CNC

machining centers, torch tables, anglecut/punch and plasma work centers.Design Engineers using 3D AutoCADsoftware, supported by a state-of-the-art ERP system, ensure efficient orderentry and shop throughput. Cellmanufacturing practices deliver quality,value added assembly.

JCI This world class manufacturing facility,located in Eugene, Oregon, boasts130,000 square feet of manufacturingspace. Organized as focused factoriesby product line and supported by CNCmachinery and Robotics. A state-of-the-art ERP system ensures high qualityproducts that are delivered in a timelymanner.

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CORPORATE

FOCUS &

COMMITMENT



ProcessingExperiencePeople make the difference at KOLBERG-PIONEER and JCI. From the initial phone call,our aggregate processing experience isevident – understanding your material andobjectives - lowering your production costs –

maximizing your profits. Hands-onapplication engineers with decades of field experience are available to assist inyour material and process evaluation.Nothing replaces experience!

M aterial AnalysisOur application engineers can assist youwith material evaluations includinggradation and sieve analysis, crushingcharacteristics, abrasion, wear costsestimates and projected production rates.

Customer Focus You have one-on-one access to our designand application engineers. We listen to yourobjectives, adding our field experiences to

meet your specialized requirements. Factorytrained service crews fine-tune youroperation, putting the maximum amount of product in the sell pile. After sale supportwith 24 hour Hotline access to factorypersonnel in no more than 15 minutes. Weunderstand that time is money!

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Horizontal &

Incline Screens J CI's double and triple-deck, ovalmotion screens range in size from5'x14' to 8'x20' and deliver efficientscreening with the ability to quicklychange the speed, length, and angle of

the vibrating action. The screen can beconfigured for either scalping, sizing orfine screening applications.

Combo Screen J CI’s exclusive screen design combinesthe benefits of both a horizontal screenand an incline screen in a single unit.

The unit features a three-deck designwith the top two decks set at an inclinesloping to horizontal. The top deckstarts at 20 degrees then transitions to10, then to horizontal. The second deckis 15 degrees and then 7.5, then tohorizontal. The third deck is completelyhorizontal. The combo screen is ideal

for producers to increase currentcapacity (up to 20%) while retaining thesame footprint.

M ESABI ® ScreenDesigned with a positive throw toincrease production 3 ways: efficientscalping, size multiple products and

fines rejection. Works in typical wet anddirty deposits with virtually noplugging. The 4-bearing scalpingscreen is built with a reinforced mainframe, rigid box-type screen pan,IsoVibe® screen mounting and heavy-duty eccentric shaft assembly.

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Scalping/Feeding The extra heavy-duty PIONEER Mesabi®

and J CI horizontal oval motion designslead a family of screens, grizzly and panfeeders designed for ruggedapplications. Engineered for scalping,separating fines, wet-sticky materialhandling or high production in a low

profile package, the product lineupenables you to select the correctequipment to meet your specificapplication requirements. Allcomponents from a single source,designed to work as an efficientprocessing system.

Vanguard SeriesJaw CrusherAll New DesignPioneer introduces the 2650, 3055, 3144,3352, 4450 and 3165 models as an allnew design with many user friendlyfeatures, including a dual wedge hydraulicadjustment for easy closed side settingchanges. Heavy Duty 63" flywheels optimizewk2 and reduce peak horsepowerrequirements. Optimal 3-D computer design

of stroke, nip and toggle angles produce anaggressive crushing action. Replaceablelower wear lips on pitman and base for longservice life.

Track M ountedApron FeederPioneer makes the only track mountedapron feeder. These are heavy duty ‘mine’

quality machines. Designed andengineered for extreme operatingconditions. Shown here is a 48" x 43'model. Let us take care of all your trackmounted needs.

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391 TrackM ounted Screen

This all new track mounted screen plant(with on board fold out stackingconveyors) joins our growing line of J awand Horizontal Shaft Impactor TrackMounted line of aggregate processing

equipment. Standard equipment includeon-board power. J ust unload from alowboy trailer, unfold the conveyors andyou’re ready to screen. No additional setup required.

RT2650 TrackM ounted Jaw The Pioneer Rocky Trax is the only crawlertrack mounted crusher that is designed,manufactured and supported in the U.S.A.Designed for ultimate in portability youcan just drive off a lowboy trailer andimmediately begin crushing. NO additionalset up required. Standard items include atier II compliant diesel engine and aremote control. Options include a crossbelt permanent magnet.

RT4250 TrackM ounted ImpactFollowing in the ‘tracks’ of our 2650 J awCrusher, the 4250 Horizontal Shaft Impact

crusher track mounted model has anoptional closed circuit conveyor and anincline screen enabling producers to makea ‘spec product’ in a single pass. “Overs”are returned to the crushing material flow,via an optional onboard closed circuitconveyor, for additional size reduction.

This crusher is especially effective incrushing recycled concrete and RAP.

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Fast Pack

Jaw PlantMultiple axle configurations available tomeet all DOT requirements. Specialemphasis on transition points for propermaterial flow. Easy maintenance andservice access. Factory designed in

conjunction with the cone crusher andscreen component engineers to work as asystem, not an afterthought. Innovativesuspension designs.

Fast Pack

Screen Plant J CI builds the largest portable screen(8'x20') on the market today. Completewith onboard Tier II diesel power,hydraulic folding stairway, and on-boardhydraulic foundations enable this plant tobe set up and running in literally justminutes. Dual under screen conveyorscan be reversed for additional productproduction. Side discharge conveyors are

field reversible to either side for optimumwork space utilization.

Fast Pack

Cone Plant J CI engineers and manufactures their fieldproven KODIAK roller bearing cone

crusher in a “Fast Pack” package. Onboard surge bin enables the cone to bechoke fed, optimizing particle shape andproduction (TPH). On-board power forsystem configuration or use as a standalone crushing plant. Hydraulic poweredsteel foundations eliminate the need forcribbing timbers. On-board hydraulicpowered combination discharge/transferconveyor for optimal material transition tothe next process. All on one load, NOadditional load for jump conveyors.

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Fast Pack

Screen PlantFully self-contained screen plant. Threeon-board stacking conveyors for optimumstockpiling capacity. Durable design andheavy duty construction for long servicelife. User friendly controls do not require a

standby operator. Easy operator accessfor service.

Fast PackComplete PlantA true 500 TPH crushing, screening andstockpiling plant that can be ‘set up’ in under

four hours. Self contained on board Tier IIdiesel power for ultimate flexibility andenergy management and eliminate thetraditional manhandling of bulky electricalcables required with a central gen set.Hydraulic steel plate foundations eliminatethe need for cribbing with timbers. Set up,plant adjustments and tear down areefficiently accomplished with the flip of ahydraulic lever.

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Fast PackTelescopingStackerPLC control of radial travel, raise/lowerand extend/retract movements createcustom FULLY non-segregated stockpiles.Patented axle assembly provides optimumroad portability and minimal set-up time.PLC controller and the Gull Wing axle designdeliver uninterrupted stockpiling. Multiplesizes available. Rugged design for long

service life. Available in 60'/110', 70'/130'and 80'/150' lengths.



Horizontal Shaf tImpactorsBig capacity - small foot print – nospecialized transport truck. These entry levelimpactor plants are designed for recyclingconcrete-asphalt & secondary crushing of limestone. Maximum Performance Rotor

offers the mass of a solid design with theclearances of an open configuration.Low charge height and on-plant stackingconveyor. Pioneer recycle impact crushersfeature the MRP rotor design and areavailable in two, three, and four barconfigurations for maximum materialpenetration and control of particle shape.

High VolumePioneer recycle jaw crushers are designedfor high volume production with anaggressive toggle action and pitmanstroke. The crushing chamber is designedwith the maximum nip angle. A pitmanbarrel protector plate prevents damagefrom slabby material. Side deliveryconveyors handle rebar with ease.

2-Pack and3-Pack RecyclerHigh capacity combined with flexibility. Avariety of crushing options: multiple jaws,

cones and horizontal shaft impactor modelsavailable in various sizes/capacities. Multiplescreen sizes and styles (horizontal andincline) to choose from. On-board powerplant and hydraulics simplify set up and teardown times. Engineered as a highly mobilerecycle crushing spread with low operatingcosts in mind.

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Portable VSIPlantsNumerous crusher sizes to meet your TPHrequirements. Multiple drive configurations.EV Series: single motor. EVT Series: dualelectric motor. DCV Series: Diesel – countershaft w/V-belt. DGV Series: Diesel gear box

w/V-Belt. Single or tandem axle chassis invarious lengths, with service platform &power unit support. Optional on-plant fueltanks.

Vertical ShaftImpactors These innovative designs, incorporating ahybrid rock shelf, produce more specproduct in a fully autogenous (rock on rock)configuration. Dramatic reduction in wearcosts with reverse cascade material flow.Reduced re-circulating load. Ideal formeeting Superpave cubicity requirements.

Soil Stabilization The unique spiral paddle design of theKOLBERG pugmill chamber delivers a moreaggressive mixing action. Adjustable bolt-

on paddles allow variable retention time.Available options include: a second feedhopper, electronic belt scales and liquid orsolid additive introduction systems.

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STANDARD FULLY AUTOGENOUS



Complete TurnkeySystems

You benefit from a single source formaterial testing and flow analysis throughintegrated design of feeding, crushing,classifying, screening, washing andstockpiling components for best overall

value. Coordinated delivery and set-up.Equipment pre-assembled at the factory forefficient on-site set up and reducedinstallation time. No excuses.

ExperiencedPeopleEngineers with decades of experience whoare recognized in the industry for theirpublished technical articles, national andregional seminars and workshoppresentations. Engineers with hands-onfield experience using state-of-the-artapplication software and material labanalysis are focused on your individualobjectives.

Partners CreateInvestment ValueKOLBERG-PIONEER and JCI invest inunderstanding your objectives. Our

relationship goal is to look beyond today’sneeds, enabling us to respond to yourfuture opportunities, giving you the greatestvalue for your investment. The result: anengineered system that delivers profits overthe life of your equipment.

We realize there areno commodity solutions.

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Classifying andControlsComputerized Spec-Select® controls letyou meet tomorrow’s stringent SE and FMspecifications. Tanks are available inportable, semi-portable and stationarydesigns. Blend sand particles to produce 3products simultaneously (2 spec products),

rejecting clay, silts and slime. Dart-shapedurethane valves and seats provide preciseslurry discharge and improved sealingcontrol.

Retro-fit your existing controller with eitherSpec-Select I, II or II I models. Upgradeyour current tank (any manufacturers) withstate-of-the-art controllers for more specproduct at a fraction of the cost vs. new.

Wash Plants-SkidKOLBERG quality components in a compactplant feeding 4 stacking conveyors (3screens, 1 sand screw). The 1800 seriesoffers a single water inlet and your choice of incline or J CI horizontal screens in aneconomical package. Standard urethane onboth the outer and inner wear shoes deliverincreased wear life. Standard 36" singleflight fine material washer.

Wash Plants-PortableWhen production rates count... KOLBERG

offers the industry’s largest portable

screening and washing plant with capacity upto 500 tons per hour. Screen sizes up to

6'x20' in either incline or J CI horizontal

configurations. For minimal set up

requirements, all plumbing connects to a

single water inlet. 36" or 44" twin sand screws

and efficient gear reducers make this the low

cost producer.

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Fine M aterialWasherImproved fines separation with controlledmaterial entry feed box-baffle plate andrising current manifold. Standard urethaneouter and inner wear shoes deliverincreased wear life on flights. Long

adjustable weirs handle larger slurryvolume. High efficiency gear reducersrequire less horsepower per tons per hourfor lower operating costs.

Coarse M aterialWasherFlexibility is designed into each coarsematerial washer. Bolt-on design allows youto interchange flights with spiral mountedpaddles for maximum scrubbing action.Paddle tips are replaceable, reversible andadjustable to vary material retention timeand reduce wear costs. High efficiency gearreducers require less HP/TPH.

Log WashersSide-by-side field tests prove thatKOLBERG log washers beat thecompetition. Not only does KOLBERG

produce more TPH at a lower energy costsper ton, but the spiral paddle design hasproven to clean better! The unique spiralpaddle design, combined with a state-of-the-art gear reducer, reduces power surgesand lowers operating costs. The 48"diameter unit is the industry’s largest.

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Remote AdjustPatented features: Internal counterweightsnever need rebalancing. Field replaceable,left hand brass threads. Hydraulic lockring for secure CSS. Dual hydraulic motorbowl rotation. Dual action tramp iron relief cylinders with 7" travel. Fluid ringmanifold. Massive full strut (5 pier) base

frame. User friendly - one finger controlpanel. 300 & 400 HP models (500 HPunder development). High speed -aggressive steep chamber design. Trueremote adjust control of CSS. Highest

TPH.

LS Models J CI's 1200LS and 1400LS cone crushersutilize anti-friction roller bearings thatefficiently transfer power to the crushingchamber and an aggressive stroke formaximum production. The oil reservoirs areself contained, taking less space andallowing for quicker installation. Thesemachines are among the most portable onthe market. The 200 HP 1200LS and the300 HP 1400LS operate at 750-950 RPMand 700-900 RPM respectively.

Stationary PlantsPIONEER offers stationary plant designsin sizes from 2436 through 4248. Designflexibility to meet your application

requirements. All plant componentsengineered to fit as a system for reducedset up time on your job site. Multiplefeeding, scalping, screening and deliverymethods available. Designed to work withKOLBERG and J CI products for a completeaggregate operation without the need forthird party fabricators.

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Portable &Recycle PlantsPIONEER recycle plants, introduced in1978, are designed specifically forprocessing tough recycle materials.Optional side discharge conveyor handlesrebar contamination with less plugging or

belt damage. Barrel protector plate preventspitman damage from slabby material. 8’stepped grizzly. While sized for recycle feedmaterials, all PIONEER jaws are designed towithstand the extreme forces found in hardrock crushing.

PortableConveyorsLengths from 40' to 125'. Highwayportable. Power radial travel option.Standard features include: truck type tires,receiving trough, pin lock undercarriageand correctly sized drives for greater TPHcapacity. Heavy Duty components:bearings, shafts, pulleys and idlers. J ig-welded lattice frame. Proven highest resalevalue at trade-in time.

Radial StackersLengths up to 125'. Belt widths from 24" to36". Side-fold or top-fold designs for easyset up. Power radial travel. Single axle or

tandem walking beam. Cam-arm stylehydraulic under carriage for constant radialtravel radius. J ig-welded lattice frames.Highway portable. Optional hydraulic topfolding frame and axle raise.

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Stackable/TableConveyors

Transport up to 480 feet of conveyor on asingle truck load. J ig-welded channelframe. 50' and 60' lengths. Overland and in-pit compatible. Often used as transferconveyors in portable crushing spreads.

Standard U.S. components and correctlysized drives for maximum TPH. Provenhighest resale value at trade-in time.

StationaryConveyorsCustom designed in various widths: 24",30" or 36". J ob specific lengths and driveconfigurations to compliment your plantlayout. Includes overland systemsthousands of feet long. Optional walkwaysand belt covers. Standard U.S. componentsand correctly sized drives for maximum

TPH.

TripperConveyorsDesigned to meet your specifications andunique applications. Provides efficient,

low costs, continuous transfer of materialonto multiple adjacent stockpiles of different products. Sized to fit youroperations. Rugged design for long

service life and minimal maintenance.

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Factory RebuildsDesigned for the economy mindedaggregate producer, genuine J CI rebuiltcrushers are returned to as-new factoryspecifications. Each component is removedfrom the crusher, inspected and rebuilt, orreplaced, to ensure optimal performance.Confidence in the quality of these machines

is so great that J CI fully warrants the unitsfor 6 months or 1,000 hours, equaling thenew equipment warranties from manymanufacturers! Savings of 20%-30%vs new.

Parts Support J CI offers a 6 month or 1,000 hourswarranty on parts that fit. Always have –always will. Experienced factory partspersonnel with a combined 42+years of hands on knowledge of J CI, ElJ ay® andCedarapids® roller cones and horizontalscreens. 24 hours a day, we’re there whenyou need us.

Parts SupportGenuine KOLBERG-PIONEER factory partsare engineered to work with yourequipment. An Associated Warranty covers

all parts related to the replacement item. You have 24 hour Hotline access to factorypersonnel. Factory rebuild kits allow easycredit for items not used. Over 95% of common parts in-stock for off-the-shelf availability. We understand that time ismoney.

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WarrantyFor expediency, all equipment warrantyclaims are administered through your localKOLBERG-PIONEER & J CI dealer. Yourdealer’s service representative willcoordinate the parts and labor necessary toget you back in operation quickly. All formsand related information are handled

professionally and promptly.

Training &SupportEquipment erection and start-up. On-siteoperator training including: efficientoperation analysis for maximum plantoutput, safety awareness, propermaintenance procedures and troubleshooting. Local dealer service personnel arefactory trained. Factory and regional serviceschools available. 24 hour access to factoryservice technicians.

ServiceEquipment support throughout the life of your investment. We routinely provide wearparts for crushers and screens dating backto the 1930’s and 1940’s. Our servicetechnicians support all KOLBERG, PIONEERand J CI equipment in addition to ElJay® andCedarapids® roller cones and horizontalscreens.

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The vision of KOLBERG-PIONEER & JCI is to be the provider of solutions for producers and contractors.

We are inventive, technology leading, high integrity manufacturers of quality material processing

equipment through continuous assessment and improvement of our products, processes and performance.

Because KOLBERG-PIONEER, INC., and JCI may use in its catalog & literature, field photographs of its products which may have been modified by theowners, products furnished by KOLBERG-PIONEER, INC., and JCI may not necessarily be as illustrated therein. Also continuous design progress makesit necessary that specifications be subject to change without notice. All sales of the products of KOLBERG-PIONEER, INC., and JCI are subject to theprovisions of its standard warranty. KOLBERG-PIONEER, INC., and JCI does not warrant or represent that its products meet any federal, state, or locastatutes, codes, ordinances, rules, standards or other regulations, including OSHA and MSHA, covering safety pollution, electrical wiring, etc. Compliancewith 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 userIn 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 safetystudy should be made by the user of the application, and, if required, additional guards, warning signs and other safety devices should be installed by theuser, wherever appropriate before operating the products.

700 W. 21st Street 86470 Franklin Blvd.

Yankton, SD 57078 Eugene, OR 97405

Equipment Sales: Phone 800.542.9311 All Departments: 800.314.4656

(605.665.8771) (541.736.1400)

Parts Sales: Phone 800.766.9793 (605.665.9793) Parts Sales: Phone 888.474.0115

Service: Phone 800.532.9311 (605.665.8771) Service After Hours: 541.954.7972

Fax: 800.514.6115 (605.665.9348) Fax: 541.988.9401

E-mail contact: [email protected] E-mail contact: [email protected]

kpijci.com kpijci.com

JCI is not affiliated with nor an authorizedagent of Cedarapids ® , Inc., manufacturerof ElJay ® products. ElJay ® is a registered

trademark of Cedarapids ® , Inc.

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