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ASTEC JCI LS Series Operation And Service Manual And Parts Book

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an Astec Company
Crusher Operation and
Service Manual
and Parts Book
JCI LS Series Crusher
S/N C060396
86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401
24/7 Parts Number 888-474-0115

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Summary of Contents for ASTEC JCI LS Series

  • Page 1 Astec Company Crusher Operation and Service Manual and Parts Book JCI LS Series Crusher S/N C060396 86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401 24/7 Parts Number 888-474-0115...
  • Page 2 1200LS Crusher Parts Book Serial Number: C060396 JCI 24/7 Parts Number 888-474-0115 © 2006 JCI...
  • Page 3 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 •...
  • Page 4 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. •...
  • Page 5 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.
  • Page 6 Factory Installed Counter Weight Configuration PART ITEM DESCRIPTION COMMENTS NUMBER 450034 LEADING 1200LS 450035 MEDIUM 1200LS 450035 MEDIUM 1200LS 450035 MEDIUM 1200LS 450035 MEDIUM 1200LS 450035 MEDIUM 1200LS + 1 1/4 SHIM 450089 - 1/4 SHIM 450035 MEDIUM 1200LS + 1 1/4 SHIM 450089 - 1/4 SHIM 450035 MEDIUM 1200LS + 2 1/4 SHIM...
  • Page 7 Factory Installed 1200LS Manganese Configuration PART ITEM DESCRIPTION COMMENTS NUMBER 450128X MANTLE 66lbs poured 450127X BOWL LINER 44lbs poured 110 lbs 090037 MANGANESE BACKING MATERIAL JCI 24/7 Parts Number 888-474-0115 © 2006 JCI...
  • Page 8 Drive Sheave and Miscellaneous Items PART ITEM DESCRIPTION COMMENTS NUMBER 060039 SHEAVE 6GR 8V 24.6 PD 24.8 OD 060005 QD BUSHING M 2 - 15/16 450076 SEAL, SHIM GUARD 450148 ADJ BOLT COUPLER 2 SPLITS 450358 ALIGNING WASHER-CLAMP CYL 084001 O-RING 6227-30 084065 O-RING PARK 2-329 2.375 OD...
  • Page 9 Decals PART ITEM DESCRIPTION COMMENTS NUMBER 090023 DECAL, DRIVE GUARDS 090024 DECAL, EYE PROTECTION 090025 DECAL, HEARING PROTECTION 090026 DECAL, LOCKOUT 090027 DECAL, HARDHAT 090090 DECAL - JCI 1200 LS 090064 DECAL -DANGER EXP DECOMPRESS 090065 DECAL-DANGER-SERIOUS INJURY 090066 DECAL-NOTICE-BLOCK CONE HD 090067 DECAL-NOTICE-DO NOT ALLOW MAT 090068...
  • Page 10 Kits and Additional Spare Parts Accumulator Kits PART ITEM DESCRIPTION COMMENTS NUMBER 450010 ACCUMULATOR KIT 2-1/2 OR 5 GALLON BAG 450014 ACCUMULATOR KIT 1 GALLON BAG 450178 ACCUMULATOR KIT 2-1/2 OR 5 GALLON BAG (W/O NUTS) 450179 ACCUMULATOR KIT 1 GALLON BAG (W/O NUTS) 450024 ACCUMULATOR BAG 1 GALLON...

  • Page 11: Table Of Contents

    Table of Contents Upper Assembly 1200LS/SS ................. 1 Clamp Cylinder Assembly ..................5 Adjusting Jack Assembly ..................6 Relief Cylinder Assembly 1200LS ................7 Lower Assembly 1200LS ..................8 Wedgeplate Assembly 1200LS ................11 Cone Assembly 1200LS/SS ................... 12 Pinion Assembly 1200LS ..................13 Floating Plate Assembly ..................

  • Page 12: Upper Assembly 1200Ls/Ss

    PAGE 1 REFERENCE # 450519 Upper Assembly 1200LS/SS JCI 24/7 Parts Number 888-474-0115 Rev. 0 06/19/03 © 2003 JCI...
  • Page 13 PAGE 2 REFERENCE # 450519 Upper Assembly 1200LS/SS JCI 24/7 Parts Number 888-474-0115 Rev. 0 06/19/03 © 2003 JCI...
  • Page 14 PAGE 3 REFERENCE # 450519 Upper Assembly 1200LS/SS PART ITEM DESCRIPTION COMMENTS NUMBER 450042 BONNET 450221 BONNET SUPPORT 450055 PRESSURE ROD 087001 VALVE, RELIEF, 3/8 450130 WEDGE, BOWL, CASTING 076011 NUT, JAM, ADJUSTING JACK 450006 FLUID CONNECTOR 080007 O-RING, 2-012 450065 MANIFOLD BLOCK 540166...
  • Page 15 PAGE 4 REFERENCE # 450519 Upper Assembly 1200LS/SS PART ITEM DESCRIPTION COMMENTS NUMBER 070086 CAP SCREW HEX 5/8 11NC X 5 G5 070134 CAP SCREW HEX 5/8 11NC X 6 G5 070014 CAP SCREW HEX 5/8 11NC X2-1/2 076001 NUT, NYLOCK 5/8-11 NC 076040 NUT HEAVY HEX JAM 2-1/4X4-1/2 070055...

  • Page 16: Clamp Cylinder Assembly

    PAGE 5 REFERENCE # 450109 Clamp Cylinder Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 450343 CLAMP CYLINDER 450359 INSERT CLAMP CYLINDER 080009 SEAL U-CUP CLAMP CYL 1870-2 079004 RETAINING RING BRG INC-UR262 079005 RETAINING RING SMALLEY-BS-437 080010 SEAL ANCHOR PK CLAMP CY 1870-4 450000 CLAMP CYLINDER PISTON 450479...

  • Page 17: Adjusting Jack Assembly

    PAGE 6 REFERENCE # 450116 Adjusting Jack Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 450114 RAM, ADJUSTING JACK 450003 CYL WELDMENT, ADJ JACK 450110 GUIDE, OUTER, ADJ JACK CYL 450113 GUIDE, INNER ADJ. JACK CYL 080013 SEAL ADJ JACK POLY, 2500-1 079006 SNAP RING SH100STPA (5100-100) 070029...

  • Page 18: Relief Cylinder Assembly 1200Ls

    PAGE 7 REFERENCE # 450215 Relief Cylinder Assembly 1200LS ITEM PART NUMBER DESCRIPTION COMMENTS 450214 RELIEF CYLINDER - 1200 540158 PISTON CORE 079002 SNAP RING, 5100-450 080046 SEAL, RELIEF CYLINDER 080041 SEAL, RELIEF CYLINDER RCII 080042 SEAL, SPLIT, RELIEF CYL, RCII JCI 24/7 Parts Number 888-474-0115 Rev.

  • Page 19: Lower Assembly 1200Ls

    PAGE 8 REFERENCE # 450242 Lower Assembly 1200LS JCI 24/7 Parts Number 888-474-0115 Rev. M 12/8/06 © 2006 JCI...
  • Page 20 PAGE 9 REFERENCE # 450242 Lower Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 450243 ASSY PL WEDGE 1200 LS 450244 ASSY CONE 1200 LS/SS 450268 ASSY PINION 1200 LS 450043 RING SEAL BASEFRAME 450068 PIN PUSH BASEFRAME 084009 O-RING 6227-27 450497 PL FLOATING W/ INSERTS 406087...
  • Page 21 PAGE 10 REFERENCE # 450242 Lower Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 083061 5503-08-08 083082 1404-08-08 082013 HOSE 939B 27.5 SS WIRE CON TFE 083079 CLAMP TUBE 3/4-PARK #3075 083035 PIPE SCH 40 1-1/4 X 4 NPT 070061 CAPSCREW HEX 1/4 20NC X 1/2 083005 5502-08-08 083068...

  • Page 22: Wedgeplate Assembly 1200Ls

    PAGE 11 REFERENCE # 450243 Wedgeplate Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 450207 WEDGE PLATE, 1200LS 450059 GEAR, RING (SPIRAL) 450007 SEAL RING - UPPER WEDGE PLATE 450008 SEAL RING - LOWER WEDGE PLATE 450021 BEARING, RADIAL 450228 UPPER RADIAL RETAINER 450022 BEARING, UPPER THRUST 450023...

  • Page 23: Cone Assembly 1200Ls/Ss

    PAGE 12 REFERENCE # 450244 Cone Assembly 1200LS/SS PART ITEM DESCRIPTION COMMENTS NUMBER 450247 CONE WITH STEM - 45 450151 MANTLE BOLT 450057 MANTLE NUT 450053 MANTLE NUT CAP - 45 INCH 450056 MANTLE WASHER 450018 SEAL RING - CONE 450052 RETAINER, CONE RADIAL BEARING 450021...

  • Page 24: Pinion Assembly 1200Ls

    PAGE 13 REFERENCE # 450268 Pinion Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 450267 PINION HOUSING 450058 GEAR, PINION (SPIRAL) 450033 PINION SHAFT 450111 NUT LOCK, PINION BEARING 450117 BEARING, PINION, CUP, OUTER 450118 BEARING, PINION, CONE, OUTER 450119 BEARING, PINION, CUP, INNER 450120 BEARING, PINION, CONE, INNER 450156...

  • Page 25: Floating Plate Assembly

    PAGE 14 REFERENCE # 450497 Floating Plate Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 450168 FLOATING PLATE 450312 FLOATING PLATE UPPER INSERT 450313 FLOATING PLATE LOWER INSERT 070039 CAP SCREW SOC 3/8 16NC X 3/4 450498 FLOATING PLATE UPPER INSERT JCI 24/7 Parts Number 888-474-0115 Rev.

  • Page 26: Pin Clutch Assembly

    PAGE 15 REFERENCE # 546467 Pin Clutch Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 12/8/06 © 2006 JCI...
  • Page 27 PAGE 16 REFERENCE # 546467 Pin Clutch Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 546640 DRIVE BLOCK 546454 RATCHET BLOCK 546641 DRIVE PIN 546460 THRUST WASHER 090442 SPRING C0600-0490-1750 COMPRES 070496 CAPSCREW BUTTON 1/2-13NCX3/4 079052 RET RING SMALLEY WS-250 JCI 24/7 Parts Number 888-474-0115 Rev.

  • Page 28: Heater Assembly 2000W 120V

    PAGE 17 REFERENCE # 450485 Heater Assembly 2000W 120V JCI 24/7 Parts Number 888-474-0115 Rev. A 06/19/03 © 2003 JCI...
  • Page 29 PAGE 18 REFERENCE # 450485 Heater Assembly 2000W 120V PART ITEM DESCRIPTION COMMENTS NUMBER 450254 HEATER COVER WELDMENT 540327 HEATER MACHINED,2000W,120V 540294 HEATER ELECTRICAL BOX COVER 020026 THERMO ON 60 DEG OFF 80 DEG. 540254 GASKET, HEATER 070032 CAP SCREW HEX 3/8 16NC X1-1/4 070008 CAP SCREW HEX 3/8 16NC X1G5 076042...

  • Page 30: Shim Guard

    PAGE 19 REFERENCE # 450141 Shim Guard ITEM PART NUMBER DESCRIPTION COMMENTS 450140 RING, SHIM GUARD 540130 LEG, SHIM GUARD 090039 TOGGLE, SHIM GUARD 620134 HANDLE 076043 NUT, 5/8-18NF JCI 24/7 Parts Number 888-474-0115 Rev. A 06/19/03 © 2003 JCI...

  • Page 31: Shim Stack Kit

    PAGE 20 450184 REFERENCE # 450184 Shim Stack Kit No Graphic Available ITEM PART NUMBER DESCRIPTION COMMENTS 450090 SHIM ADJUSTING .062 Lt Green 450091 SHIM ADJUSTING .125, WHITE 450092 SHIM ADJUSTING .188, YELLOW 450093 SHIM ADJUSTING .250, BLACK 450094 SHIM ADJUSTING .313, RED 450095 SHIM ADJUSTING .375, BLUE 450096...

  • Page 32: External Lube Panel Assembly 1200Ls

    PAGE 21 REFERENCE # 450197 External Lube Panel Assembly 1200LS JCI 24/7 Parts Number 888-474-0115 Rev. F 07/29/03 © 2003 JCI...
  • Page 33 PAGE 22 REFERENCE # 450197 External Lube Panel Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 060033 MTR 2HP1800TEFC60HZ 145T TOS 080024 PUMP, LUBE .761 CU IN/REV 089005 COUP LUBE ASSY LOVEJOY L090, S 080030 PUMP ADAPTOR (FIL-4AA) 085004 FILTER ASSY, DONALDSON HAK05 456154 EXT LUBE PANEL 080027...
  • Page 34 PAGE 23 REFERENCE # 450197 External Lube Panel Assembly 1200LS PART ITEM DESCRIPTION COMMENTS NUMBER 020138 COVER,RECEPT,FLIP LID 020139 OUTLET BOX, SINGLE GANG 020140 RECEPT,2P,3WIRE,15AMP,125V 083192 NIPPLE,PIPE,3/4 X 5.0 SCH 40 020014 "CONNECTOR,CGB 194,1/2"",.38-.50" 020038 SEALING RING, 1/2 (T&B 5262) 020039 LOCKNUT RID METAL CONDUIT 1/2 020147...

  • Page 35: Horn Assembly

    PAGE 24 REFERENCE # 450187 Horn Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 020001 HORN BASE 020002 HORN FED SIGNAL JCI 24/7 Parts Number 888-474-0115 Rev. A 02/26/04 © 2003 JCI...

  • Page 36: Lube Panel J-Box Assembly

    PAGE 25 REFERENCE # 456169 Lube Panel J-Box Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 020136 BOX,HOFFMAN,A-806 CHNF,8.0X6.0 020137 PANEL, HOFFMAN, A-8P6 020500 TERM BLOCK (J4) AB1492-J4 020512 END STOP AB1492-EAJ35 4.75 020182 DIN MOUNTING RAIL, DIN #3 020510 END PLATES AB 1492-EBJ3 020103 GROUND BAR KIT, 14 POS 020505...

  • Page 37: Bonnet Components

    10/20/08 REF# 450042 Bonnet Components Rev. D...
  • Page 38 10/20/08 REF# 450042 Bonnet Components PART ITEM DESCRIPTION COMMENTS NUMBER 450188 CASTING BONNET HD C1200LS 450219 EAR BONNET 12 090086 BUSH DRILL 2 ID X2.5025/2.5021 450489 RETAINER BUSHING 070016 CAPSCREW HEX 1/2 13NC X 1-1/2 Rev. D...

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