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ASTEC JCI Kodiak 300 Operation And Service Manual And Parts Book

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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

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Summary of Contents for ASTEC JCI Kodiak 300

  • Page 1 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...
  • Page 2 Kodiak 300 Crusher Parts Book Serial Number: C060369 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 ITEM PART NUMBER DESCRIPTION COMMENTS 456053 COUNTER WEIGHT 3.5 lb 456053 COUNTER WEIGHT 3.5 lb EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY Additional Counterweights available to purchase: Weight in Pounds Part Number 456043 456044...
  • Page 7 Factory Installed K300 Manganese Configuration PART ITEM DESCRIPTION COMMENTS NUMBER 456071X MANTLE 456073X LINER MANGANESE BACKING MATERIAL JCI 24/7 Parts Number 888-474-0115 © 2006 JCI...
  • Page 8 Drive Sheave and Rotation Stop Shim Configuration PART ITEM DESCRIPTION COMMENTS NUMBER HOPPER EXTENSION 060021 SHEAVE 10GR 8V 24.6 PD 24.8 OD Not Ordered 060012 QD BUSHING N 3-1/2 Not Ordered 456194 SHIM, ROT STOP BLOCK,18 GA 456195 SHIM, ROT STOP BLOCK,.312 THK Not Shown 090034 WRENCH ALLEN...
  • Page 9 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...

  • Page 10: Table Of Contents

    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 ....................

  • Page 11: Upper Assembly

    PAGE 1 REFERENCE # 456001 Upper Assembly JCI 24/7 Parts Number 888-474-0115 Rev. I 7/19/06 © 2005 JCI...
  • Page 12 PAGE 2 REFERENCE # 456001 Upper Assembly ITEM PART NUMBER DESCRIPTION COMMENTS 456003 BOWL 456254 BOWL SUPPORT 456008 LOCKING RING 456010 DRIVE RING 456103 TOP PLATE-GEAR SUPPORT ASSY SEE 456103 ON PAGE 4. 546015 GEAR DRIVE 14T, 2" DP 7" PD 456097 GEAR DRIVEN 546027...
  • Page 13 PAGE 3 REFERENCE # 456001 Upper Assembly ITEM PART NUMBER DESCRIPTION COMMENTS 070200 CAPSCREW HEX 1/2 20NF X1-1/2 456016 CLEVIS, BOWL LINER 546313 PULL PLATE, BOWL 546121 PIN, CLEVIS, BOWL 456216 HANGER ROD,RELIEF CYL,2.5 DIA 546204 COMPRESSION WASHER, POLY 546311 SPHERICAL WASHER, CLEVIS 546312 NUT, SPHERICAL...

  • Page 14: Top Plate-Gear Support Assembly

    PAGE 4 REFERENCE # 456103 Top Plate-Gear Support Assembly ITEM PART NUMBER DESCRIPTION COMMENTS 456198 TOP PLATE, MOTOR BASE 456105 SUPPORT, GEAR, PLATE JCI 24/7 Parts Number 888-474-0115 Rev. B 06/05/02 © 2003 JCI...

  • Page 15: Position Indicator Assembly

    PAGE 5 REFERENCE # 546132 Position Indicator Assembly JCI 24/7 Parts Number 888-474-0115 Rev. H 04/07/04 © 2003 JCI...
  • Page 16 PAGE 6 REFERENCE # 546132 Position Indicator Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 020114 CABLE, SENSOR 020047 SENSOR PROXI AB-871TM-DH8NN18 546129 MOUNT, PROXIMITY SENSORS 083055 MOUNTING CLIP, 1/4 TUBE 078022 WASHER, LOCK, 1/4 070061 CAP SCREW HEX 1/4 20NC X 1/2 020126 TERMINAL,SPADE,22-18,INSUL 546301...

  • Page 17: K300 Lower Assembly

    PAGE 7 REFERENCE # 456296 K300 Lower Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 06/27/03 © 2003 JCI...
  • Page 18 PAGE 8 REFERENCE # 456296 K300 Lower Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 06/27/03 © 2003 JCI...
  • Page 19 PAGE 9 REFERENCE # 456296 K300 Lower Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456257 BASE FRAME, MACHINED 456035 WEDGE PLATE ASSEMBLY SEE 456035 ON PAGE 12. 456187 CONE ASSEMBLY SEE 456187 ON PAGE 13. 456031 PINION ASSEMBLY SEE 456031 ON PAGE 16. 456285 TIR ASSEMBLY SEE 456285 ON PAGE 17.
  • Page 20 PAGE 10 REFERENCE # 456296 K300 Lower Assembly 546347 SPACER, CLUTCH 546270 SPRING SS .375 DIA .041 WIRE 079023 DOWEL PIN .187 X 1.00 SS 082011 HOSE 939B32.5 SS WIRE CON TFE 083033 NIPPLE PIPE BLACK 1-1/4 X 26 083032 ELBOW PIPE BLACK 1-1/4X90 DEG 456295 RETAINER, OIL FILL PIPE...

  • Page 21: Wedge Plate Assembly

    PAGE 11 REFERENCE # 456035 Wedge Plate Assembly JCI 24/7 Parts Number 888-474-0115 Rev. I 7/19/06 © 2006 JCI...
  • Page 22 PAGE 12 REFERENCE # 456035 Wedge Plate Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456036 WEDGE PLATE, MACHINED 450059 GEAR, RING (SPIRAL) 456041 SEAL RING, UPPER WP 456042 SEAL RING, LOWER WP 456021 GUARD, SEAL, ONE PIECE 450228 UPPER RADIAL RETAINER 456128 BEARING, THRUST, 1200RA 456040...

  • Page 23: Cone Assembly

    PAGE 13 REFERENCE # 456187 Cone Assembly JCI 24/7 Parts Number 888-474-0115 Rev. D 08/10/04 © 2003 JCI...
  • Page 24 PAGE 14 REFERENCE # 456187 Cone Assembly JCI 24/7 Parts Number 888-474-0115 Rev. D 08/10/04 © 2003 JCI...
  • Page 25 PAGE 15 REFERENCE # 456187 Cone Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456192 CONE WITH STEM 456191 MANTLE WASHER 456156 BEARING, RADIAL 456188 MANTLE BOLT 450257 PIN, .500 X 1.00 070105 CAP SCREW SOC 1-1/4 540103 FOAM, 1 450053 MANTLE NUT CAP - 45 INCH 456029 SEAL RING, CONE 456304...

  • Page 26: Pinion Assembly

    PAGE 16 REFERENCE # 456031 Pinion Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456034 PINION HOUSING 456032 PINION GEAR 456033 PINION SHAFT 540137 PINION NUT LOCK 540096 BEARING PINION CONE INNER-861 540095 BEARING PINION CONE OUTER-864 540097 BEARING PINION CUP - 854 456079 KEY, PINION GEAR 540045...

  • Page 27: Tir Assembly

    PAGE 17 REFERENCE # 456285 TIR Assembly JCI 24/7 Parts Number 888-474-0115 Rev. E 7/19/06 © 2006 JCI...
  • Page 28 PAGE 18 REFERENCE # 456285 TIR Assembly JCI 24/7 Parts Number 888-474-0115 Rev. E 7/19/06 © 2006 JCI...
  • Page 29 PAGE 19 REFERENCE # 456285 TIR Assembly JCI 24/7 Parts Number 888-474-0115 Rev. E 7/19/06 © 2006 JCI...
  • Page 30 PAGE 20 REFERENCE # 456285 TIR Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456275 CYL 6.00 BORE X 5.00 STROKE 456272 TIR CYLINDER SPACER LEFT HAND 456271 TIR CYLINDER SPACER RIGHT HAND 456273 TIR CYLINDER SPACER RH END 456274 TIR CYLINDER SPACER LH END 456284 GUARD CYLINDER HOSE 456283...

  • Page 31: Heater Assembly

    PAGE 21 REFERENCE # 456123 Heater Assembly JCI 24/7 Parts Number 888-474-0115 Rev. 0 06/06/02 © 2003 JCI...
  • Page 32 PAGE 22 REFERENCE # 456123 Heater Assembly ITEM PART NUMBER DESCRIPTION COMMENTS 456124 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 33: Floating Plate Assembly

    PAGE 23 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 34: Hopper Assembly

    PAGE 24 REFERENCE # 456030 Hopper Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 620128 LIFTING EAR 456090 HOPPER RING 456091 RING, INNER HOPPER 456098 FLANGE, ROLLED, 54"ID 456092 RING, OUTER HOPPER 456102 RING, ROCK SHELF JCI 24/7 Parts Number 888-474-0115 Rev. C 7/19/06 ©...

  • Page 35: Hydraulic Power Unit Enclosure Base

    PAGE 25 REFERENCE # 456158 Hydraulic Power Unit Enclosure Base PART ITEM DESCRIPTION COMMENTS NUMBER 070027 CAP SCREW HEX 1/2 13NC X1-1/4 076005 NUT NYLOCK 1/2-13NC 078019 WASHER, FLAT, 1/2 JCI 24/7 Parts Number 888-474-0115 Rev. F 7/19/06 © 2005 JCI...

  • Page 36: Hydraulic Schematic

    PAGE 26 REFERENCE # 456200 Hydraulic Schematic JCI 24/7 Parts Number 888-474-0115 Rev. F 11/24/03 © 2003 JCI...

  • Page 37: External Lubrication Panel Housing Assembly

    PAGE 27 REFERENCE # 456154 External Lubrication Panel Housing Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 456152 EXT LUBE PANEL SIDES,FORMED 456153 EXT LUBE PANEL BASE,FORMED 540011 OIL FILTER BRACKET, DONALDSON 456167 MTG BRACKET,BY-PASS VALVE 456168 MOUNTING BRACKET,MOTOR 070016 CAP SCREW HEX 1/2 13NC X1-1/2 078019 WASHER, FLAT, 1/2 078025...

  • Page 38: Lube Panel J-Box Assembly

    PAGE 28 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 39: Lube Panel Cable

    PAGE 29 REFERENCE # 456206 Lube Panel Cable PART ITEM DESCRIPTION COMMENTS NUMBER 020018 SEALING RING 5263 3/4" 020019 LOCKNUT, RID METAL CON, 3/4 T 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX 020033 CONDUIT, 3/4 FLEX, NON-METALLI 020028 WIRE, 10 GA THHN, WHITE 020029 WIRE, 10 GA, THHN RED 020030...

  • Page 40: Decal Location

    PAGE 30 REFERENCE # 456118 Decal Location JCI 24/7 Parts Number 888-474-0115 Rev. E 7/19/06 © 2006 JCI...
  • Page 41 PAGE 31 REFERENCE # 456118 Decal Location PART DESCRIPTION COMMENTS NUMBER 090023 DECAL, DRIVE GUARDS 090024 DECAL, EYE PROTECTION 090025 DECAL, HEARING PROTECTION 090026 DECAL, LOCKOUT 090027 DECAL, HARDHAT 090030 DECAL, JCI LOGO 090056 DECAL, MADE IN AMERICA 090064 DECAL -DANGER EXP DECOMPRESS 090065 DECAL-DANGER-SERIOUS INJURY 090066...

  • Page 42: Relief Cylinder Test Block

    PAGE 32 REFERENCE # 456294 Relief Cylinder Test Block PART ITEM DESCRIPTION COMMENTS NUMBER 087093 BODY T16A-2 W/ GAUGE PORT 083156 ADAPTER, 16-8 SAE TO NPT 089016 GAUGE 0-5000 PSI 082142 HOSE F3010106-8-4-4-48 083081 PIPE NIPPLE 1/2 FP 083162 ADAPTER #4 JIC-M X 1/4 NPT-M 083037 BUSHING 1/2 X 1/4 083103...
  • Page 43 6/29/09 REF# 546467 Pin Clutch Assembly Rev. A...
  • Page 44 6/29/09 REF# 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 Rev. A...

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