an Astec Company

Kodiak 300 Crusher

Operation and Service Manual
and Parts Book

JCI Kodiak Series Crusher

S/N C060369

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401

24/7 Parts Number 888-474-0115
 Kodiak 300
Crusher Parts Book
Serial Number: C060369

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 JCI Parts Ordering Information
The JCI Parts Department is open from 7 AM to 5 PM Pacific Time. You can contact us in the following
ways:

• *24/7 Phone (24 Hours- 7 Days a week): 1-888-474-0115 (Even holidays!)

• Fax: 541-988-9487
• Email: [email protected]

Model No.

Serial No.

The Serial Number Plate for your screen is usually located on the right-hand side feedbox end of your
screen.
1. Follow the steps to safely lock out/tag out the power source to your crusher. (Lockout/Tagout Kit #
090011)
2. Find the model number and serial number of your crusher from the Serial Number Plate. Located on
the opposite side of the drive side of the crusher.
3. Locate the parts to be replaced by using the parts lists and drawings in this catalog.
4. Call your JCI dealer or use the JCI Parts contact information provided to order your parts. Be sure to
include model number and serial number when ordering.
Information Needed To Order Parts
1. **Serial number of the equipment. (ex. 99C04D1400LS for a crusher or 99LP05G32 for a screen)
2. Model of the equipment. (ex. 1400LS, JCI6203-32LP)
3. Part number(s) and quantity.
4. Shipping information.
5. Priority. (Next day air, ground, truck, etc…)
6. Purchase order number. JCI also accepts Visa and MasterCard. Orders may also be sent COD.
*There is a $100 call in charge for emergency orders shipped outside of normal business hours.
**JCI can also supply you with parts for your Cedarapids/ElJay® Rollercone™ Crusher and 3-shaft screens.

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Important Safety Precautions

WARNING: Failure to adhere to the following safety precautions may result in

serious injury or death.

• Perform a complete inspection before starting the crusher. Be sure that the crushing chamber is
clear. Make sure the cone blocking is removed.
• Be sure that all guards and other safety devices are correctly installed and tightly secured before
starting the crusher. Stay clear of rotating or moving parts during crusher operation.
• Do not allow personnel to be on or near the crusher during operation. The crusher will shake vio-
lently should tramp iron be feed into the machine. Stay clear of feed and discharge areas to prevent
being injured or killed by flying or falling rock.
• Rock projected upwards through the feed opening can injure or kill. Do not look directly into the
feed opening while the crusher is operating. Use mirrors or closed-circuit cameras if close observa-
tion of the feed arrangement is necessary for troubleshooting or evaluation purposes.
• Never attempt to clear jammed material from the crushing chamber while the crusher is operating.
Serious injury or death could result if you are pulled into, or fall inside, the crushing chamber.
• Never attempt to manually clear jammed material from the crushing chamber while the upper frame
is in the lowered (clamping) position. Any material lodged in the chamber could release without
warning, and may be propelled upward through the feed opening. Serious injury or death could
result.
• Do not tamper with crusher alarm components. Never attempt to defeat electrical interlocks or to
disable crusher protective devices.
• Never place hands on cylinder rods. Stay clear of pinch-point area between the upper and main
frames.
• Never stand on hydraulic hoses or use them as steps. If hoses rupture, serious injury or death could
result. As required, use a safety harness during servicing.
• Always lockout/tagout power to the crusher drive motor, crusher oil lubrication system and crusher
hydraulic system before performing any inspection, adjustment, lubrication, maintenance or repair
procedures. Also lockout power to all crusher feed and discharge equipment. Be sure pressure is
fully relieved before servicing the hydraulic system.
• If the crusher is powered by a diesel engine, always disconnect batteries and shut-off fuel supply
before performing any inspection, adjustment, lubrication, maintenance or repair procedures. Lock-
out/tagout engine controls to prevent the engine from being accidentally started while the crusher is
being serviced.
• Support the crusher upper frame with hardwood blocking or steel safety spacers before entering the

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
crushing chamber for service work. Never rely on hydraulic pressure to keep the upper frame raised.
You could be crushed and killed if the upper frame lowers unexpectedly.
• Always stop the crusher immediately if any gauges show abnormal readings, or if there is a sudden
obvious change in operation. Be alert for noises that might indicate trouble.
• Inspect, lubricate, maintain and repair the crusher in accordance with the instructions contained in
this manual and any additional manuals or documentation provided with the crusher.
• Inspect all warning signs and caution decals. If they become torn or not readable contact your local
dealer or Johnson Crushers International for replacement.
• On portable plants be sure that the trailer is properly blocked and level. All blocking must be suit-
able to support the trailer dead load weight plus the crusher impact live loading.
• Before starting the crusher visually check the tramp iron and clamp cylinder pressure gauges on the
hydraulic manifold. Both pressures should range from 2700 psi to 3000 psi. Occasionally check the
system pressure gauge with the hydraulic pump motor running. This pressure shall not exceed 3000
psi.
• Avoid stopping the crusher with material inside the crushing chamber. In the event that the crushing
chamber is full of rock use the hydraulic clearing feature. Always inspect the crushing chamber and
U-seat after a clear for loose or jammed rock.
• Do not adjust the close side setting smaller than the recommended minimum setting for your mantle
and bowl liner combination.
• An oil flow meter has been provided as a safety device to protect the crusher components in the
event of a lubrication system failure. Should the flow meter detect a flow of oil less than its preset
value, the electrical panel will activate the warning horn alerting crusher operators that the machine
needs to be shut down immediately to prevent permanent damage to crusher components. In addi-
tion, it is strongly suggested that the control circuit be wired such that, when the warning system is
activated, the feed device feeding the crusher is shut down. The crusher should be shut down imme-
diately after the rock has cleared the crushing chamber (less than 10 seconds).Wear your hard hat at
all times.
• Stop the crusher, lock out power, and tag controls:
1.Before performing any lubrication, maintenance, adjustments, or repairs.
2.Before removing any spilled materials.
3.Before clearing jams or working on the crusher.
4.Whenever any unusual noises or sudden changes in operation are noticed .
• Refer to the JCI Operation Manual for screen safety information. If your copy of the manual is miss-
ing, please contact your local JCI dealer or the JCI Parts Department for a replacement copy.Read
your Operation Manual for your screen. Be sure that you fully understand all phases of screen opera-
tion. A careful and well-trained operator is the best insurance against an accident.

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Factory Installed Counter Weight Configuration

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 456053 COUNTER WEIGHT 3.5 lb
2 1 456053 COUNTER WEIGHT 3.5 lb
3 0 EMPTY EMPTY
4 0 EMPTY EMPTY
5 0 EMPTY EMPTY
6 0 EMPTY EMPTY
7 0 EMPTY EMPTY
8 0 EMPTY EMPTY
Additional Counterweights available to purchase:

Weight in Pounds Part Number

1.0 456043
1.5 456044
2.0 456045
2.5 456046
3.0 456047
3.5 456053

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Factory Installed K300 Manganese Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456071X MANTLE
2 1 456073X LINER
3 MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Drive Sheave and Rotation Stop Shim Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 N/A HOPPER EXTENSION
2 1 060021 SHEAVE 10GR 8V 24.6 PD 24.8 OD Not Ordered
3 1 060012 QD BUSHING N 3-1/2 Not Ordered
4 4 456194 SHIM, ROT STOP BLOCK,18 GA
5 4 456195 SHIM, ROT STOP BLOCK,.312 THK Not Shown
6 1 090034 WRENCH ALLEN Not Shown
7 1 450132 WRENCH MANTLE NUT STD Not Shown
8 1 N/A MTR300HP1200TEFC60HZ 587UZ TOS Not Ordered
9 1 N/A SHEAVE 10GR 8V 19.8PD 20.0 OD Not Ordered
10 1 N/A QD BUSHING M 4-3/8 Not Ordered
11 10 N/A V-BELT 8V1500 Not Ordered

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
Kits and Additional Spare Parts TIR System Seal Kits

Kit Description Part Number Reference

Accumulator Bag 546216

Port Assembly 546319

Cylinder Seal Kit 546103

Relief Valve Seal Kit 087092

Lube and Hydraulic Oil Filter Element 085001

Kit Description Part Number Reference

TIR Relief Valve Seal Kit 087092 Includes:

087086 O-ring (1)
087087 Back-up (1)
087088 Glyd Seal (3)

TIR Relief Valve 087090

Cavity Plug 087091

Cavity Plug Seal Kit 087112

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 Table of Contents

Upper Assembly ..................................................................................................... 1

Top Plate-Gear Support Assembly ........................................................................ 4

Position Indicator Assembly ................................................................................... 5

K300 Lower Assembly ........................................................................................... 7

Wedge Plate Assembly .......................................................................................... 11

Cone Assembly ...................................................................................................... 13

Pinion Assembly .................................................................................................... 16

TIR Assembly ......................................................................................................... 17

Heater Assembly .................................................................................................... 21

Floating Plate Assembly ........................................................................................ 23

Hopper Assembly ................................................................................................... 24

Hydraulic Power Unit Enclosure Base ................................................................... 25

Hydraulic Schematic .............................................................................................. 26

External Lubrication Panel Housing Assembly ...................................................... 27

Lube Panel J-Box Assembly .................................................................................. 28

Lube Panel Cable ................................................................................................. 29

Decal Location ....................................................................................................... 30

Relief Cylinder Test Block ...................................................................................... 32

JCI 24/7 Parts Number 888-474-0115

© 2006 JCI
 PAGE 1

REFERENCE # 456001

Upper Assembly

Rev. I JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2005 JCI
 PAGE 2

REFERENCE # 456001

Upper Assembly

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 456003 BOWL
2 1 456254 BOWL SUPPORT
3 1 456008 LOCKING RING
4 1 456010 DRIVE RING
5 2 456103 TOP PLATE-GEAR SUPPORT ASSY SEE 456103 ON PAGE 4.
6 2 546015 GEAR DRIVE 14T, 2" DP 7" PD
7 1 456097 GEAR DRIVEN
8 4 546027 EXTENSION, GEAR REMOTE
9 2 546060 SUPPORT, GEAR, STAND
10 4 546502 ROTATION STOP UPPER
11 8 070058 CAP SCREW HEX 1/2 13NC X 1 G5
12 4 090105 BEARING,CAMROLL,
13 8 076085 NUT TOP LOCK 1 1/4-7NC GC
14 16 078056 WASHER HT 1 1/4
15 4 076031 NUT, 7/8-14NF
16 20 070038 CAP SCREW HEX 5/8 11NC X2G5
17 20 078014 WASHER, LOCK, 5/8
18 4 070045 CAP SCREW HEX 3/4 10NC X 2-1/2
19 12 078026 WASHER, LOCK, 3/4
20 8 070046 CAP SCREW HEX 3/4 10NC X 3-1/4
21 16 078021 WASHER, FLAT, 3/4
22 8 070133 CAP SCREW HEX 3/4 10NC X3-3/4
23 8 076017 NUT 3/4-10NC G5
24 4 070336 BOLT,SQ HD,1/2-13 NC X 2-1/4
25 4 076024 NUT, 1/2-13NC
26 14.17 084002 O-RING 1/4
27 6 456258 RETAINER, DUST SEAL, UPPER
28 12 456259 DUST SEAL RUBBER
29 217 084071 ROD,1/2 DIA POLYURETHANE
30 1 082061 HOSE 1/4 x 36.0 NPT M- NPT F
31 4 070155 SETSCREW 3/8-16NC X 3/4 SOC HD
32 8 070008 CAP SCREW HEX 3/8 16NC X1G5
33 8 078024 WASHER, LOCK, 3/8
34 24 078025 WASHER, LOCK, 1/2
35 2 546048 MTR, HYD MLHSB315-G4A REMOTE
36 2 546049 GEARBOX ROT DR.
37 2 546056 GUARD, GEAR, HYD DRIVE REMOTE
38 4 078034 WASHER, LOCK, 7/8
39 2 546124 GEAR HOLD DOWN PLATE

Rev. I JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2005 JCI
 PAGE 3

REFERENCE # 456001

Upper Assembly
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
40 4 070200 CAPSCREW HEX 1/2 20NF X1-1/2
41 4 456016 CLEVIS, BOWL LINER
42 4 546313 PULL PLATE, BOWL
43 4 546121 PIN, CLEVIS, BOWL
44 8 456216 HANGER ROD,RELIEF CYL,2.5 DIA
45 12 546204 COMPRESSION WASHER, POLY
46 4 546311 SPHERICAL WASHER, CLEVIS
47 4 546312 NUT, SPHERICAL
48 4 076067 NUT, HEX JAM, 2"-4.5 UNC PLAIN
49 1 546132 POSITION INDICATOR ASSEMBLY SEE 546132 ON PAGE 6.
50 4 070205 GREASE ZERK,ALEMITE 1728-B
51 1 456017 PISTON SEAL
52 4 546192 ACETAL SQUARE ROD 7/8X7/8X48.0
55 18 070016 CAP SCREW HEX 1/2 13NC X1-1/2
56 2 084076 O-RING, 2-242
57 6 456260 RETAINER, DUST SEAL, LOWER
58 3 456207 PIN, ANTI-ROTATION
59 3 070216 SETSCRW 1/2-13NCX1.0 LG SOC HD
60 8 456215 CLEVIS,RELIEF CYLINDER,2.5 ID
62 8 070169 CAP SCREW HEX 1" 8NC X 4 G8
63 8 076002 NUT 1-8NC G5
64 8 078030 WASHER, HT, 1
65 8 078027 WASHER, LOCK, 1
66 8 546077 HANGER WASHER, RELIEF CYL.
69 8 546282 CLEVIS PIN RELIEF CYLINDER
70 8 070392 CAPSCREW HEX 1 1/4-7NC X 10 G5
71 8 078043 WASHER FLAT 2

Rev. I JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2005 JCI
 PAGE 4

REFERENCE # 456103

Top Plate-Gear Support Assembly

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 1 456198 TOP PLATE, MOTOR BASE
2 1 456105 SUPPORT, GEAR, PLATE

Rev. B JCI 24/7 Parts Number 888-474-0115 06/05/02

© 2003 JCI
 PAGE 5

REFERENCE # 546132

Position Indicator Assembly

Rev. H JCI 24/7 Parts Number 888-474-0115 04/07/04

© 2003 JCI
 PAGE 6

REFERENCE # 546132

Position Indicator Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
3 1 020114 CABLE, SENSOR
4 1 020047 SENSOR PROXI AB-871TM-DH8NN18
5 1 546129 MOUNT, PROXIMITY SENSORS
8 2 083055 MOUNTING CLIP, 1/4 TUBE
9 4 078022 WASHER, LOCK, 1/4
10 4 070061 CAP SCREW HEX 1/4 20NC X 1/2
11 3 020126 TERMINAL,SPADE,22-18,INSUL
12 1 546301 J-BOX,4 X 6,SENSOR

Rev. H JCI 24/7 Parts Number 888-474-0115 04/07/04

© 2003 JCI
 PAGE 7

REFERENCE # 456296

K300 Lower Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 8

REFERENCE # 456296

K300 Lower Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 9

REFERENCE # 456296

K300 Lower Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456257 BASE FRAME, MACHINED
2 1 456035 WEDGE PLATE ASSEMBLY SEE 456035 ON PAGE 12.
3 1 456187 CONE ASSEMBLY SEE 456187 ON PAGE 13.
4 1 456031 PINION ASSEMBLY SEE 456031 ON PAGE 16.
5 1 456285 TIR ASSEMBLY SEE 456285 ON PAGE 17.
6 1 540049 CLUTCH, BRAKE
7 4 070224 CAPSCREW SOC 5/16 18NC X 1-1/4
8 4 070339 CAPSCREW HEX 5/16 24NF X 1 G5
9 12 070048 CAPSCREW HEX 1/2 13NC X 2 G5
10 1 456123 HEATER ASSY, 2000W 120V SEE 456123 ON PAGE 21.
11 20 070027 CAP SCREW HEX 1/2 13NC X1-1/4
12 1 406087 SHAFT, CONE BRAKE
13 1 406110 KEY, BRAKE SHAFT
14 1 406109 CONE BRAKE PLATE
15 1 450166 THRUST PLATE
16 8 070152 CAPSCREW HEX 1 14NF X 3
17 1 450497 FLOATING PLATE, W/ INSERTS SEE 450497 ON PAGE 23.
18 12 070038 CAP SCREW HEX 5/8 11NC X2G5
19 4 456058 STRUT GUARD, BASE FRAME
20 2 083077 PIPE CLAMP 3/4-PARK #41050
21 4 070141 SETSCREW 5/8 X 5/8 NC SOC HD
22 1 540176 KEY, DRIVE, PINION SHAFT
23 1 620150 ARROW
24 32 078025 WASHER, LOCK, 1/2
25 12 078014 WASHER, LOCK, 5/8
26 12 076085 NUT TOP LOCK 1 1/4-7NC GC
27 4 546499 ROTATION STOP LOWER
28 4 070393 CAPSCREW HEX 1 1/4-7NC X 11 G5
29 8 070391 CAPSCREW HEX 1 1/4-7NC X 8 G5
30 12 546507 BEVEL WASHER 1.25 X 4.5 DEG
31 1 456070 SEAL RING, BASE FRAME, RA
32 1 456068 INSERT, SEAL RING, BASEFRAME
33 8 070085 GREASE ZERK, 1/8PIPE-27 STR
34 1 546147 PRESSURE PLATE,CONE CLUTCH
35 1 546346 CLUTCH DISC, FIBER
36 1 546263 PISTON CONE CLUTCH 2.00 BORE
37 1 546264 CYL HOUSING CONE CLUTCH 2.00
38 2 080108 SEAL,PARKER 18701625-STD
39 1 080088 WEAR SLEEVE PARK W2-2000-375

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 10

REFERENCE # 456296

K300 Lower Assembly

40 1 546347 SPACER, CLUTCH

41 12 546270 SPRING SS .375 DIA .041 WIRE
42 4 079023 DOWEL PIN .187 X 1.00 SS
44 1 082011 HOSE 939B32.5 SS WIRE CON TFE
45 2 083033 NIPPLE PIPE BLACK 1-1/4 X 26
46 2 083032 ELBOW PIPE BLACK 1-1/4X90 DEG
48 1 456295 RETAINER, OIL FILL PIPE
49 1 540191 DIPSTICK
50 1 083083 ST ELBOW 1 IN CD 2102-16-16
51 1 083025 ST ELBOW 3/4X1/2 CD 2102-8-12
52 12 078056 WASHER HT 1 1/4
53 1 083170 "NIPPLE, PIPE, BLK 1-1/4X2-1/2"
54 1 546348 SPACER, CLUTCH CYLINDER
55 1 083061 ST ELBOW 45 DEG 1/2 HP
56 1 083075 REDUCER 3/4F X1/2M SW 0107-8
57 1 080032 PLUG, MAGNETIC 1
1 406014 CLUTCH GUIDE RING NOT SHOWN
4 070255 CAPSCREW SOC 3/8 16NC X 1-1/2 NOT SHOWN
4 070130 CAPSCREW HEX 5/16 24NF X 3/4 NOT SHOWN

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 11

REFERENCE # 456035

Wedge Plate Assembly

Rev. I JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 12

REFERENCE # 456035

Wedge Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456036 WEDGE PLATE, MACHINED
2 1 450059 GEAR, RING (SPIRAL)
3 1 456041 SEAL RING, UPPER WP
4 1 456042 SEAL RING, LOWER WP
5 1 456021 GUARD, SEAL, ONE PIECE
6 3 450228 UPPER RADIAL RETAINER
7 2 456128 BEARING, THRUST, 1200RA
8 0.5 456040 LOWER COUNTERWEIGHT WEDGE PL
9 8 070025 CAPSCREW HEX 3/4 16NF X 2-1/2
10 6 070027 CAP SCREW HEX 1/2 13NC X1-1/4
11 1 456066 INSERT, SEAL RING, UPPER WP
12 12 546270 SPRING SS .375 DIA .041 WIRE
13 3 079023 DOWEL PIN .187 X 1.00 SS
14 4 546447 ROLL PIN, 5/32" x 2"
15 4 546335 SETSCREW, SEAL LUBE ASSY
17 8 070222 FH SCREW SOC 3/4-10NC X 1.75
18 1 456043 C' WEIGHT, 1 LB
19 1 456044 C' WEIGHT, 1.5 LB
20 1 456045 C' WEIGHT, 2 LB
21 1 456046 C' WEIGHT, 2.5 LB
22 1 456047 C' WEIGHT, 3 LB
23 1 456053 C'WEIGHT, WEDGEPLATE, 3.5LB
25 5 070017 CAP SCREW HEX 3/4 16NF X 4 G8
27 3 070329 SET SCREW SOC 3/4 10NC X 3/4
28 1 456156 BEARING, RADIAL, KOYO
29 5 456210 PIPE, OIL DRAIN, WP
30 1 070016 CAP SCREW HEX 1/2 13NC X1-1/2
31 1 456308 RETAINER THRUST BEARING RACE
32 1 078004 WASHER, HT 1/2

Rev. I JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 13

REFERENCE # 456187

Cone Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 14

REFERENCE # 456187

Cone Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 15

REFERENCE # 456187

Cone Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456192 CONE WITH STEM
2 1 456191 MANTLE WASHER
3 1 456156 BEARING, RADIAL
4 1 456188 MANTLE BOLT
5 2 450257 PIN, .500 X 1.00
6 1 070105 CAP SCREW SOC 1-1/4
7 1 540103 FOAM, 1
8 1 450053 MANTLE NUT CAP - 45 INCH
9 1 456029 SEAL RING, CONE
10 1 456304 TORQUE BAR
11 2 053053 RDCR .875 T&P
12 1 456249 CONE SKIRT RING FAB
13 2 070189 CAP SCREW SOC 7/8-9 NC X 1-3/4
14 1 456132 RETAINER, CONE RADIAL BEARING
15 4 070032 CAPSCREW HEX 3/8 16NC X 1-1/4

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 16

REFERENCE # 456031

Pinion Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456034 PINION HOUSING
2 1 456032 PINION GEAR
3 1 456033 PINION SHAFT
4 1 540137 PINION NUT LOCK
5 1 540096 BEARING PINION CONE INNER-861
6 1 540095 BEARING PINION CONE OUTER-864
7 2 540097 BEARING PINION CUP - 854
8 1 456079 KEY, PINION GEAR
9 1 540045 LOCKNUT, PINION SHAFT
10 1 540140 KEY, LOCK RING
11 1 540027 COVER PLATE
12 1 540028 FLINGER - INNER
13 1 540029 FLINGER - OUTER
14 12 070008 CAP SCREW HEX 3/8 16NC
15 12 078024 WASHER, LOCK, 3/8
16 3 070142 SETSCREW 3/8 X 3/8 NC SOC HD
17 1 084078 O-RING
18 1 070088 SET SCREW, 5/16-18NC X 1 G8

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 17

REFERENCE # 456285

TIR Assembly

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 18

REFERENCE # 456285

TIR Assembly

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 19

REFERENCE # 456285

TIR Assembly

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 20

REFERENCE # 456285

TIR Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 8 456275 CYL 6.00 BORE X 5.00 STROKE
2 3 456272 TIR CYLINDER SPACER LEFT HAND
3 3 456271 TIR CYLINDER SPACER RIGHT HAND
4 1 456273 TIR CYLINDER SPACER RH END
5 1 456274 TIR CYLINDER SPACER LH END
6 4 456284 GUARD CYLINDER HOSE
7 3 456283 GUARD CYLINDER HOSE
8 8 087090 VALVE RELIEF CARTRIDGE
9 32 083434 FS6400-16-16-O
10 3 083156 6405-16-08-O
11 2 083005 5502-08-08
12 1 083593 6410-16-08-O
13 1 083340 5406-08-06
14 1 083088 5602-06-06-06
15 1 087004 VALVE, RELIEF 3/8 SHORT BODY
16 16 084073 O-RING, PARKER 2-210
17 16 084074 O-RING, PARKER 2-222
18 16 079089 DOWEL PIN 7/16 X 1
19 7 082146 HOSE, PARKER, SEE TEXT
20 7 082147 HOSE, PARKER, SEE TEXT
21 32 070243 CAP SCREW HEX 1 8NC X 8 G8
22 32 076033 NUT, TOP LOCK, 1-8NC GC
23 64 078006 WASHER, FLAT 1
24 12 070196 CAPSCREW HEX 1/2 13NC X 7G5
25 12 076005 NUT NYLOCK 1/2-13NC
26 16 078019 WASHER, FLAT, 1/2
27 32 070008 CAP SCREW HEX 3/8 16NC X1G5
28 32 078017 WASHER, FLAT, 3/8
29 2 082145 HOSE, PARKER, SEE TEXT
31 1 083344 5406-P-06
32 4 070018 CAP SCREW HEX 1/2 13NC X2-1/2
33 1 083010 5502-04-04
34 4 078025 WASHER, LOCK, 1/2
35 8 546349 GASKET, CYLINDER
36 1 083594 6400-04-08-O
37 1 083526 0304-C-04

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 21

REFERENCE # 456123

Heater Assembly

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 22

REFERENCE # 456123

Heater Assembly
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
1 1 456124 HEATER COVER WELDMENT
2 1 540327 HEATER MACHINED,2000W,120V
3 1 540294 HEATER ELECTRICAL BOX COVER
4 1 020026 THERMO ON 60 DEG OFF 80 DEG.
5 2 540254 GASKET, HEATER
6 4 070032 CAP SCREW HEX 3/8 16NC X1-1/4
7 2 070008 CAP SCREW HEX 3/8 16NC X1G5
8 1 076042 NUT 1-1/2-6NC
9 1 070056 MACH SCREW RD HD #8-32NC X 3/4
10 2 020036 LUG, T & B C-10-8
11 2 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX
12 192 020033 CONDUIT, 3/4 FLEX, NON-METALLI
13 2 020041 DISCONNECT FEM 10-12 GA, NYLON
14 2 020042 DISCONNECT FEM 14-16 GA, NYLON
15 2 020043 DISCONNECT MALE 14-16GA NYLON
16 196 020028 WIRE, 10 GA THHN, WHITE
17 196 020029 WIRE, 10 GA, THHN RED
18 196 020030 WIRE, 16 GA MTW BLACK
19 196 020031 WIRE, 16 GA MTW BLUE
20 196 020032 WIRE, 16 GA MTW GREEN
21 1 076046 NUT, #8-32NC
22 1 078037 WASHER, LOCK, #8
23 4 078024 WASHER, LOCK, 3/8
24 2 020018 SEALING RING 5263
25 2 020019 LOCKNUT, RID METAL CON, 3/4 T
26 1 080032 PLUG, MAGNETIC

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 23

REFERENCE # 450497

Floating Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 450168 FLOATING PLATE
2 2 450312 FLOATING PLATE UPPER INSERT
3 2 450313 FLOATING PLATE LOWER INSERT
4 16 070039 CAP SCREW SOC 3/8 16NC X 3/4
5 2 450498 FLOATING PLATE UPPER INSERT

Rev. C JCI 24/7 Parts Number 888-474-0115 12/22/04

© 2003 JCI
 PAGE 24

REFERENCE # 456030

Hopper Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
3 2 620128 LIFTING EAR
5 1 456090 HOPPER RING
6 1 456091 RING, INNER HOPPER
7 1 456098 FLANGE, ROLLED, 54"ID
8 2 456092 RING, OUTER HOPPER
9 1 456102 RING, ROCK SHELF

Rev. C JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 25

REFERENCE # 456158

Hydraulic Power Unit Enclosure Base

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
4 4 070027 CAP SCREW HEX 1/2 13NC X1-1/4
5 4 076005 NUT NYLOCK 1/2-13NC
6 4 078019 WASHER, FLAT, 1/2

Rev. F JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2005 JCI
 PAGE 26

REFERENCE # 456200

Hydraulic Schematic

Rev. F JCI 24/7 Parts Number 888-474-0115 11/24/03

© 2003 JCI
 PAGE 27

REFERENCE # 456154

External Lubrication Panel Housing Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456152 EXT LUBE PANEL SIDES,FORMED
2 1 456153 EXT LUBE PANEL BASE,FORMED
3 1 540011 OIL FILTER BRACKET, DONALDSON
4 1 456167 MTG BRACKET,BY-PASS VALVE
5 1 456168 MOUNTING BRACKET,MOTOR
6 5 070016 CAP SCREW HEX 1/2 13NC X1-1/2
7 10 078019 WASHER, FLAT, 1/2
8 5 078025 WASHER, LOCK, 1/2
9 5 076024 NUT, 1/2-13NC
10 1 620128 LIFTING EAR

Rev. A JCI 24/7 Parts Number 888-474-0115 04/02/03

© 2003 JCI
 PAGE 28

REFERENCE # 456169

Lube Panel J-Box Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020136 BOX,HOFFMAN,A-806 CHNF,8.0X6.0
2 1 020137 PANEL, HOFFMAN, A-8P6
3 12 020500 TERM BLOCK (J4) AB1492-J4
4 2 020512 END STOP AB1492-EAJ35
5 4.75 020182 DIN MOUNTING RAIL, DIN #3
6 2 020510 END PLATES AB 1492-EBJ3
7 0.5 020103 GROUND BAR KIT, 14 POS
8 1 020505 CENTER JUMPER,2POLE (J4)
9 1 020145 TERMINAL BLOCK NO. TABS 0-9
10 2 070341 MACH SCREW RD HD 10-24 x .500
11 2 076072 NUT, 10-24 NC

Rev. D JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2005 JCI
 PAGE 29

REFERENCE # 456206

Lube Panel Cable

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 2 020018 SEALING RING 5263 3/4"
2 2 020019 LOCKNUT, RID METAL CON, 3/4 T
3 2 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX
4 300 020033 CONDUIT, 3/4 FLEX, NON-METALLI
5 324 020028 WIRE, 10 GA THHN, WHITE
6 324 020029 WIRE, 10 GA, THHN RED
7 324 020030 WIRE, 16 GA MTW BLACK
8 324 020031 WIRE, 16 GA MTW BLUE
9 324 020032 WIRE, 16 GA MTW GREEN
10 324 020177 WIRE, 16 GA MTW, ORANGE
11 324 020133 WIRE, 16 GA MTW BROWN
12 324 020179 WIRE, 16 GA MTW, YELLOW

Rev. B JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 30

REFERENCE # 456118

Decal Location

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 31

REFERENCE # 456118

Decal Location
PART
DESCRIPTION QTY COMMENTS
NUMBER
090023 DECAL, DRIVE GUARDS 1
090024 DECAL, EYE PROTECTION 1
090025 DECAL, HEARING PROTECTION 1
090026 DECAL, LOCKOUT 1
090027 DECAL, HARDHAT 1
090030 DECAL, JCI LOGO 2
090056 DECAL, MADE IN AMERICA 2
090064 DECAL -DANGER EXP DECOMPRESS 1
090065 DECAL-DANGER-SERIOUS INJURY 1
090066 DECAL-NOTICE-BLOCK CONE HD 1
090067 DECAL-NOTICE-DO NOT ALLOW MAT 1
090068 DECAL-CAUTION-CONSULT YR OPER 1
090074 DECAL - WORLD CLASS... 2
090150 SERIAL NUMBER PLATE RA CRUSHER 1
090180 DECAL, CRUSHING ZONE, 1200RA 2
090197 DECAL,KODIAK 300 2

Rev. E JCI 24/7 Parts Number 888-474-0115 7/19/06

© 2006 JCI
 PAGE 32

REFERENCE # 456294

Relief Cylinder Test Block

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 087093 BODY T16A-2 W/ GAUGE PORT
2 2 083156 ADAPTER, 16-8 SAE TO NPT
3 1 089016 GAUGE 0-5000 PSI
4 1 082142 HOSE F3010106-8-4-4-48
5 1 083081 PIPE NIPPLE 1/2 FP
6 1 083162 ADAPTER #4 JIC-M X 1/4 NPT-M
7 1 083037 BUSHING 1/2 X 1/4
8 2 083103 DISCONNECT, NIPPLE, 1/2 NPT
9 1 087091 CAVITY PLUG T16A-2 Not Shown

Rev. B JCI 24/7 Parts Number 888-474-0115 03/11/03

© 2003 JCI
 6/29/09

REF# 546467

Pin Clutch Assembly

Rev. A 33
 6/29/09

REF# 546467

Pin Clutch Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 546640 DRIVE BLOCK
2 1 546454 RATCHET BLOCK
3 6 546641 DRIVE PIN
4 1 546460 THRUST WASHER
5 6 090442 SPRING C0600-0490-1750 COMPRES
6 6 070496 CAPSCREW BUTTON 1/2-13NCX3/4
7 1 079052 RET RING SMALLEY WS-250

Rev. A 34