ASTEC JCI Kodiak 300 User manual

an Astec Company
86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax [phone]
24/7 Parts Number 888-474-0115
Kodiak 300 Crusher
Operation and Service Manual
and Parts Book
JCI Kodiak Series Crusher
S/N C060369

JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
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: [phone]
• Email: [email protected]
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.
Model No.
Serial No.

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
Additional Counterweights available to purchase:
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
1 1 456053 COUNTER WEIGHT 3.5 lb
2 1 456053 COUNTER WEIGHT 3.5 lb
30EMPTY EMPTY
40EMPTY EMPTY
50EMPTY EMPTY
60EMPTY EMPTY
70EMPTY EMPTY
80EMPTY EMPTY
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
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
1 1 456071X MANTLE
2 1 456073X LINER
3 MANGANESE BACKING MATERIAL
1
2

JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
Drive Sheave and Rotation Stop Shim Configuration
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
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
© 2005 JCI
PAGE 1
7/19/06Rev. I
REFERENCE # 456001
Upper Assembly

REFERENCE # 456001
7/19/06Rev. I
Upper Assembly
JCI 24/7 Parts Number 888-474-0115
© 2005 JCI
PAGE 2
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

REFERENCE # 456001
7/19/06Rev. I
Upper Assembly
JCI 24/7 Parts Number 888-474-0115
© 2005 JCI
PAGE 3
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
ITEM QTY PART NUMBER DESCRIPTION COMMENTS

JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 4
06/05/02Rev. 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

JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 5
04/07/04Rev. H
REFERENCE # 546132
Position Indicator Assembly

REFERENCE # 546132
04/07/04Rev. H
Position Indicator Assembly
JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 6
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

JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 7
06/27/03Rev. A
REFERENCE # 456296
K300 Lower Assembly

REFERENCE # 456296
06/27/03Rev. A
K300 Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 8

REFERENCE # 456296
06/27/03Rev. A
K300 Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 9
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
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

REFERENCE # 456296
06/27/03Rev. A
K300 Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2003 JCI
PAGE 10
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
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS