JCI Kodiak 200 Operation And Service Manual And Parts Book

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Kodiak Operation and Service

Manual and Parts Book

Kodiak Crusher

S/N C070417

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

24/7 Parts Number 888-474-0115

Table of Contents

Summary of Contents for JCI Kodiak 200

Page 1 Kodiak Operation and Service Manual and Parts Book Kodiak Crusher S/N C070417 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 JCI KODIAK CRUSHERS Kodiak 200 Crusher Parts Book Serial Number: C070417 JCI 24/7 Parts Number 888-474-0115 © 2007 JCI...
Page 3 2,000 hours of operation, whichever first occurs. JCI further warrants to the Distributor and Distributor’s customers on resale that any and all parts supplied by JCI will be free from defect in material and workmanship under normal use (excluding ordinary wear) for a period of six (6) months after installation. The sole and exclusive remedy for any breach of warranty, breach of contract, or any claim in tort (including, but not limited to, strict liability and negligence) shall be the repair or replacement (at JCI’s option) of any defective part, parts or equipment at...
Page 4 JCI KODIAK CRUSHERS 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!) •...
Page 5 • Support the crusher upper frame with hardwood blocking or steel safety spacers before entering the JCI 24/7 Parts Number 888-474-0115 © 2007 JCI...
Page 6 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.
Page 7 66lbs Poured 090037 MANGANESE BACKING MATERIAL Partial list of Items Contain in the “Spare Parts” Box PART ITEM DESCRIPTION COMMENTS NUMBER 090034 WRENCH ALLEN Not Shown 450132 WRENCH MANTLE NUT STD Not Shown JCI 24/7 Parts Number 888-474-0115 © 2007 JCI...
Page 8: Table Of Contents
Cone Assembly ...................... 13 Pinion Assembly ....................15 Upper Assembly ..................... 17 TIR Assembly ......................27 Decal Location JCI K200 ..................30 Hopper Assembly ....................33 Remote Control Panel .................... 34 Hydraulic Power Unit Assembly ................41 Electrical Schematic ....................42 Hydraulic Power Unit Assembly ................
Page 9: Final Assembly
PAGE 1 REFERENCE # 406000 Final Assembly JCI 24/7 Parts Number 888-474-0115 Rev. C 7/6/07 © 2007 JCI...
Page 10 Not Shown 546338 SHIM, 16 GA, BASEFRAME MOUNT Not Shown 090172 PAINT SPRAY - CAN Not Shown 060039 CRUSHER SIDE SHEAVE Not Shown 060005 CRUSHER SIDE BUSHING Not Shown JCI 24/7 Parts Number 888-474-0115 Rev. C 7/6/07 © 2007 JCI...
Page 13 WASHER, LOCK, 1/2 450043 SEAL RING - BASE FRAME 406192 WEDGE PLATE ASSEMBLY 450166 THRUST PLATE 070152 CAPSCREW HEX 1 14NF X 3 406087 SHAFT, CONE BRAKE 406110 BRAKE SHAFT KEY JCI 24/7 Parts Number 888-474-0115 Rev. C 7/6/07 © 2006 JCI...
Page 14: Lower Assembly
FS0304-C-088 080032 PLUG, MAGNETIC 1 450157 KEY, DRIVE SHEAVE 070141 SETSCREW 5/8 X 5/8 NC SOC HD 06005 BUSHING QD M-2-15/16 060039 SHEAVE 8V 8GR 24.8 OD 24.6 PD JCI 24/7 Parts Number 888-474-0115 Rev. C 7/6/07 © 2006 JCI...
Page 15: Baseframe With V-Seat Liner
10/6/09 REF# 406020 Baseframe with V-Seat Liner Rev. G...
Page 16 10/6/09 REF# 406020 Baseframe with V-Seat Liner Rev. G...
Page 17 10/6/09 REF# 406020 Baseframe with V-Seat Liner PART ITEM DESCRIPTION COMMENTS NUMBER 406028 BASEFRAME SPINDLE 450249 NUT SPINDLE 1200LS (AN-44) 456344 PLUG 1.625 DIA X 0.500 406016 LINER VSEAT 3.5 080122 FLANGE WELD 2 1/2NPT W/O PILOT 406027 CYL MOUNTING EYE 079119 PIN DOWEL .500 OD X 1.000 406069...
Page 18: Pin Clutch Assembly
PAGE 7 REFERENCE # 546467 Pin Clutch Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2006 JCI...
Page 19 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. A 7/6/07 © 2006 JCI...
Page 20: Wedge Plate Assembly
PAGE 9 REFERENCE # 406192 Wedge Plate Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2006 JCI...
Page 22 406009 COUNTERWEIGHT CAP 406013 COUNTERWEIGHT 2.5 LB 406012 COUNTERWEIGHT X 3.5 LB 083903 6408-24-H-0 070222 FH SCREW SOC 3/4-10NC X 1.75 070497 SET SCREW SOC 1 8NC X 1 JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2006 JCI...
Page 23: Floating Plate Assembly
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. C 12/22/04 © 2003 JCI...
Page 24: Cone Assembly
PAGE 13 REFERENCE # 406040 Cone Assembly JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2006 JCI...
Page 25 O-RING 6227-60 450056 WASHER MANTLE 450057 NUT MANTLE 450053 CAP NUT MANTLE 45 INCH 070105 CAPSCREW SOC 1-1/4 7NC X2-1/2 406113 BAND WEAR SKIRT CONE 450257 PIN .500 X 1.000 JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2006 JCI...
Page 26: Pinion Assembly
PAGE 15 REFERENCE # 406073 Pinion Assembly JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 27 450027 COVER PLATE 078024 WASHER, LOCK, 3/8 070032 CAP SCREW HEX 3/8 16NC X1-1/4 450029 FLINGER - OUTER 070142 SETSCREW 3/8 X 3/8 NC SOC HD 084055 O-RING 6227-74 JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 28: Upper Assembly
PAGE 17 REFERENCE # 406030 Upper Assembly JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 35 070045 CAPSCREW HEX 3/4 10NC X2-1/2 Z 078026 WASHER LOCK 3/4 406046 GEAR DRIVEN MACH 546027 EXTENSION REMOTE 070046 CAPSCREW HEX 3/4 10NC X 3-1/4 078021 WASHER FLAT 3/4 JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 36 SENSOR JBOX 4 X 6 070061 CAPSCREW HEX 1/4 20NC X 1/2 078022 WASHER LOCK 1/4 083104 DISCONNECT CPLR PLUG 1/2 NPT 083116 DISCONNECT PARKER 4050-15 083100 6400-08-10-O 083175 6809-08-08-NWO JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 37 PAGE 26 REFERENCE # 406030 Upper Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 083038 CPLR DISC QUICK PVV-14-F 083051 TMP-14 406205 FOAM LINER RET 406206 LINER CAP FILL HOLE JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 38: Tir Assembly
PAGE 27 REFERENCE # 406094 TIR Assembly JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 40 VALVE, RELIEF 3/8 SHORT BODY 083962 6405-08-06-O 083987 FS2501-04-04 083517 FS0304-C-08 083964 FS0304-C-04 090365 BRG SPHER 2-1/4 ID X 3-9/16 OD 070085 GREASE ZERK, 1/8PIPE-27 STR 083999 FS6400-04-08-O 087091 CAVITY PLUG T16A-2 JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 41: Decal Location Jci K200
PAGE 30 REFERENCE # 406118 Decal Location JCI K200 JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 42 PAGE 31 REFERENCE # 406118 Decal Location JCI K200 JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 43 DECAL, EYE AND EAR PROTECTION 090404 DECAL, WARNING: ROTATING SHAFT 090405 DECAL, WARNING: PINCH POINT 090406 DECAL, WARNING: FALL HAZARD 090407 DECAL, WARNING: MOVING PARTS 090405 DECAL ARROW CLOCKWISE ROTATION JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 44: Hopper Assembly
PAGE 33 REFERENCE # 406083 Hopper Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 406085 HOPPER RING INNER 406084 HOPPER RING 406070 HOPPER RING UPPER 456098 FLANGE, ROLLED, 54"ID " JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 45: Remote Control Panel
PAGE 34 REFERENCE # 406137 Remote Control Panel JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2007 JCI...
Page 50 TERM BLOCK CENTER JUMPER 2P J4 020513 MARKER TERM 6CMX12CM 070341 MACHSCREW RD HD 10-24 x .500 020135 "CABLE TIE 3.62"" TY523M " 040021 "TIE CABLE 7"" " 020198 CABLE TIE MOUNTING BASE JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2007 JCI...
Page 51 PART ITEM DESCRIPTION COMMENTS NUMBER 026739 CABLE 18/3 SHIELD 8770 020191 WIRE 16 MTW WHT 020191 WIRE 16 MTW WHT 020510 TERM BLOCK END PLATE 026500 MARKER SLEEVE PSPT-187-1W JCI 24/7 Parts Number 888-474-0115 Rev. A 7/6/07 © 2007 JCI...
Page 52: Hydraulic Power Unit Assembly
PAGE 41 REFERENCE # 406142 Hydraulic Power Unit Assembly PART ITEM DESCRIPTION COMMENTS NUMBER 406202 ELECTRICAL SCHEMATIC 456157 HYD POWER UNIT ASSY 406203 ELECTRICAL PANEL HPU JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 53: Electrical Schematic
PAGE 42 REFERENCE # 406202 Electrical Schematic JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 57: Hydraulic Power Unit Assembly
PAGE 46 REFERENCE # 456157 Hydraulic Power Unit Assembly JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 58 PAGE 47 REFERENCE # 456157 Hydraulic Power Unit Assembly JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 59 PAGE 48 REFERENCE # 456157 Hydraulic Power Unit Assembly JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 60 PAGE 49 REFERENCE # 456157 Hydraulic Power Unit Assembly JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 61 PAGE 50 REFERENCE # 456157 Hydraulic Power Unit Assembly JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 62 CAPSCREW HEX 1/2 13NC X 1-1/2 076005 NUT NYLOCK 1/2 13NC 083527 5406-24-12 540166 ACCUM 1GAL 1.25NPT 089034 CLAMP ACCUMULATOR 1 GAL 070066 CAPSCREW HEX 5/16-18NC X3/4 076027 NUT NYLOCK 5/16-18NC JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 63 DECAL HYD CONNECTION 090070 DECAL DANGER 120 VOLT 456205 LUG LIFTING 083052 5406-20-12 090194 DECAL ROTATION ARROW 060234 COUPLING HALF 1-3/8 M20011210 060315 OPTION 380/120V 50 HZ COUPLING HALF JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 64 HOSE F451TC3939-4-4-4-32.0-180 070442 CAPSCREW HEX 1/4-20NC X1-1/4G5 070064 CAPSCREW HEX 1/4 20NC X 2 G5 087031 GLAND CABLE DIN CONN 43650 026500 MARKER SLEEVE PSPT-187-1W 083065 5406-24-20 076024 NUT 1/2-13NC JCI 24/7 Parts Number 888-474-0115 Rev. R 7/6/07 © 2007 JCI...
Page 65: Hydraulic Manifold Assembly
PAGE 54 REFERENCE # 456184 Hydraulic Manifold Assembly JCI 24/7 Parts Number 888-474-0115 Rev. K 10/23/03 © 2003 JCI...
Page 66 ADAPTER #4 JIC-M X 1/4 NPT-M 083526 CAP 4 JIC 4FNTX 083522 TEE JIC SWIVEL RUN 12R6X 083524 REDUCER TUBE END JIC 12BTX 083523 NUT TUBE END JIC 12BTX 083525 CAP 6 JIC 6FNTX JCI 24/7 Parts Number 888-474-0115 Rev. K 10/23/03 © 2003 JCI...
Page 67: Horn Assembly
PAGE 56 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 © 2007 JCI...
Page 68: Electrical Panel Hpu
PAGE 57 REFERENCE # 406203 Electrical Panel HPU JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 71 020173 BASE,PANEL MT,DUST T&B PB232A 020511 END STOP AB1492-EBJ16 020198 MOUNTING BASE, CABLE TIE 020135 "CABLE TIE, 3.62"" " 040021 "CABLE TIE 7"" " 020148 "KNOCKOUT SEAL, 1/2"" " JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 72 PAGE 61 REFERENCE # 406203 Electrical Panel HPU PART ITEM DESCRIPTION COMMENTS NUMBER 020183 RELAY, TIME DELAY, OFF 026794 SOCKET,DIN RAIL MT,11 PIN 020506 CENTER JUMPER,3POLE (J4) JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2006 JCI...
Page 73: External Lube Assembly W/ Res
PAGE 62 REFERENCE # 406058 External Lube Assembly W/ Res JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 74 PAGE 63 REFERENCE # 406058 External Lube Assembly W/ Res JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 75 PAGE 64 REFERENCE # 406058 External Lube Assembly W/ Res JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 76 PAGE 65 REFERENCE # 406058 External Lube Assembly W/ Res JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 77 ASSY LUBE CABLE 25 026658 "RE 1"" X 3/4"" RB100-75 " 020517 "CORD GRIP 3/4"" .250-.375 " 020040 "CORD GRIP 3/4"" .50-.62 CGB295 " 020027 "CONN 3/4"" X 90 T&B 2272 " JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 78 DECAL OIL LEVEL GAUGE 090089 DECAL NOTICE RUN LUB 546289 VALVE COOLER BYPASS NOT SHOWN 070236 CAPSCREW HEX 3/8 16NC X 3 1/2 NOT SHOWN 076009 NUT NYLOCK 3/8-16NC NOT SHOWN JCI 24/7 Parts Number 888-474-0115 Rev. E 7/6/07 © 2006 JCI...
Page 79: External Lube Reservoir Weldt
PAGE 68 REFERENCE # 406059 External Lube Reservoir Weldt JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 80 CAP SCREW HEX 1/2 13NC X1-1/4 076005 NUT NYLOCK 1/2-13NC 078019 WASHER, FLAT, 1/2 083909 5404-N-40x4.000 083923 CAP BLACK PIPE 2 1/2 085019 FILTER BREATHER 080032 PLUG, MAGNETIC 1 JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 81: Jbox Lube Assembly
PAGE 70 REFERENCE # 406082 JBOX Lube Assembly JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 82 END PLATES AB 1492-EBJ3 020512 END STOP AB1492-EAJ35 020148 "KNOCKOUT SEAL, 1/2"" " 070341 MACH SCREW RD HD 10-24 x .500 076072 NUT, 10-24 NC 020513 MARKERS TERMINAL 6CM X 12CM JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2006 JCI...
Page 83: Lube Cable Assembly
WIRE 14 MTW RED 020179 WIRE 16 MTW WHT 0.038 020177 MARKER SLEEVE PSPT-187-1W 020031 WIRE 16 MTW BLU NOT SHOWN 026138 FLEX CONN 3/4" 90 NM NOT SHOWN JCI 24/7 Parts Number 888-474-0115 Rev. 0 7/6/07 © 2007 JCI...
Page 85: 150 Ft Sensor Cable
DESCRIPTION COMMENTS NUMBER 020116 PLUG 6 PIN 90DEG MS3108B14S-6P 020117 CABLE CLAMP W/BUSH MS3057-6A 020119 PLUG DUST CAP MS25042-14D 020130 CABLE 18/4 SHIELD EWCA25384 020131 CONN PLUG STR MS3106B14S-6P JCI 24/7 Parts Number 888-474-0115 Rev. B 7/6/07 © 2007 JCI...

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C070417