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ASTEC CO60369 Operation And Service Manual And Parts Book Download Page 10

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

Summary of Contents for CO60369

Page 1: ...any 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 Operation and Service Manual and Parts Book JCI Kodiak Series Crusher S N C060369 ...

Page 2: ...JCI 24 7 Parts Number 888 474 0115 2006 JCI Kodiak 300 Crusher Parts Book Serial Number C060369 ...

Page 3: ...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 t...

Page 4: ...ever 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 pr...

Page 5: ...ays 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 p...

Page 6: ...vailable to purchase 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 Weight in Pounds Part Number 1 0 456043 1 5 456044 2 0 456045 2 5 456046 3 0 456047 3 5 456053 ...

Page 7: ...JCI 24 7 Parts Number 888 474 0115 2006 JCI Factory Installed K300 Manganese Configuration ITEM QTY PART NUMBER DESCRIPTION COMMENTS 1 1 456071X MANTLE 2 1 456073X LINER 3 MANGANESE BACKING MATERIAL 1 2 ...

Page 8: ... 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 ...

Page 9: ...mulator 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 ...

Page 10: ...ssembly 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 ...

Page 11: ...JCI 24 7 Parts Number 888 474 0115 2005 JCI PAGE 1 7 19 06 Rev I REFERENCE 456001 Upper Assembly ...

Page 12: ...AP 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 ...

Page 13: ...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 NU...

Page 14: ... Parts Number 888 474 0115 2003 JCI PAGE 4 06 05 02 Rev B 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 ...

Page 15: ...JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 5 04 07 04 Rev H REFERENCE 546132 Position Indicator Assembly ...

Page 16: ...ITEM QTY PART NUMBER DESCRIPTION COMMENTS 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 ...

Page 17: ...JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 7 06 27 03 Rev A REFERENCE 456296 K300 Lower Assembly ...

Page 18: ...REFERENCE 456296 06 27 03 Rev A K300 Lower Assembly JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 8 ...

Page 19: ...66 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 LO...

Page 20: ...OW 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 ...

Page 21: ...JCI 24 7 Parts Number 888 474 0115 2006 JCI PAGE 11 7 19 06 Rev I REFERENCE 456035 Wedge Plate Assembly ...

Page 22: ...W 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 WE...

Page 23: ...JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 13 08 10 04 Rev D REFERENCE 456187 Cone Assembly ...

Page 24: ...REFERENCE 456187 08 10 04 Rev D Cone Assembly JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 14 ...

Page 25: ...R 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 ...

Page 26: ...K 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 R...

Page 27: ...JCI 24 7 Parts Number 888 474 0115 2006 JCI PAGE 17 7 19 06 Rev E REFERENCE 456285 TIR Assembly ...

Page 28: ...REFERENCE 456285 7 19 06 Rev E TIR Assembly JCI 24 7 Parts Number 888 474 0115 2006 JCI PAGE 18 ...

Page 29: ...REFERENCE 456285 7 19 06 Rev E TIR Assembly JCI 24 7 Parts Number 888 474 0115 2006 JCI PAGE 19 ...

Page 30: ...340 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...

Page 31: ...JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 21 06 06 02 Rev 0 REFERENCE 456123 Heater Assembly ...

Page 32: ...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 WIR...

Page 33: ... REFERENCE 450497 Floating Plate Assembly ITEM QTY PART NUMBER DESCRIPTION COMMENTS 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 ...

Page 34: ...4 7 19 06 Rev C REFERENCE 456030 Hopper Assembly ITEM QTY PART NUMBER DESCRIPTION COMMENTS 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 ...

Page 35: ... 0115 2005 JCI PAGE 25 7 19 06 Rev F REFERENCE 456158 Hydraulic Power Unit Enclosure Base ITEM QTY PART NUMBER DESCRIPTION COMMENTS 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 ...

Page 36: ...JCI 24 7 Parts Number 888 474 0115 2003 JCI PAGE 26 11 24 03 Rev F REFERENCE 456200 Hydraulic Schematic ...

Page 37: ...ESCRIPTION COMMENTS 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 ...

Page 38: ...FFMAN 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 ...

Page 39: ...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 ...

Page 40: ...JCI 24 7 Parts Number 888 474 0115 2006 JCI PAGE 30 7 19 06 Rev E REFERENCE 456118 Decal Location ...

Page 41: ...ION 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 09...

Page 42: ...ER DESCRIPTION COMMENTS 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 ...

Page 43: ...33 6 29 09 Rev A REF 546467 Pin Clutch Assembly ...

Page 44: ...TEM QTY PART NUMBER DESCRIPTION COMMENTS 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 ...

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