JCI Kodiak 200 User manual

86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax [phone]
24/7 Parts Number 888-474-0115
Kodiak Operation and Service
Manual and Parts Book
Kodiak Crusher
S/N C070417

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
JCI KODIAK CRUSHERS
Kodiak 200
Crusher Parts Book
Serial Number: C070417

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
JCI KODIAK CRUSHERS
New Parts and Equipment Warranty
1. Johnson Crushers International, Inc. (JCI) Warranty:
JCI warrants to the Distributor and Distributor’s customers on resale with respect to JCI products sold that the new
equipment will be free from defect in material and workmanship under normal use for a period of one (1) year after the
date of start-up or 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
JCI’s manufacturing plant in Lane County, Oregon. Any part(s) and/or equipment claimed to be defective shall be
returned, freight prepaid, to JCI’s manufacturing plant in Lane County, Oregon, following the receipt of JCI’s Returned
Goods Authorization. Written notice of any claimed defect must be provided to JCI within sixty (60) days of the discovery
of any claimed defect(s).
2. Disclaimer/Limitation of Warranties:
The expressed warranty described above is expressly in lieu of other warranties, expressed or implied
AND ANY AND ALL IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, ANY AND ALL
IMPLIED WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED.
NO PERSON(S), INCLUDING, BUT NOT LIMITEDTO, EMPLOYEES AND AGENTS OF JCI AND/OR
ITS DISTRIBUTORS ARE AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY
CONCERNING JCI PRODUCTS THAT ARE IN ANY WAY INCONSISTENT WITH THE FOREGOING
WARRANTY.
JCI MAKES NO WARRANTY OR WARRANTIES, EXPRESSED OR IMPLIED, WITH RESPECT TO
ANY ACCESSORIES, COMPONENTS OR PARTS NOT MANUFACTURED BY JCI, AND THE
INSTALLATIONOFANYPARTSORCOMPONENTSNOTMANUFACTUREDORSUPPLIEDBYJCI,
AND ANY ALTERATION OF EQUIPMENT OR PARTS SUPPLIED BY JCI WITHOUT JCI’S
EXPRESSED WRITTEN CONSENT SHALL VOID THE WARRANTY GRANTED HEREBY.
UNDER NO CIRCUMSTANCES SHALL JCI BE RESPONSIBLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR LOSS OF
USE.
3. Address for Notices:
Any and all inquiries and/or warranty claims should be reduced to writing and submitted to JCI at the
following address:
Johnson Crushers International, Inc., 86470 Franklin Blvd, Eugene OR 97405. 24/7 Parts Number:
888-474-0115

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
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!)
• 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
© 2007 JCI
JCI KODIAK CRUSHERS
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
© 2007 JCI
JCI KODIAK CRUSHERS
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.
Additional Counterweights available to purchase:

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
JCI KODIAK CRUSHERS
Factory Installed K200 Manganese Configuration
Partial list of Items Contain in the “Spare Parts” Box
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
1 1 456051X MANTLE 242lbs Poured
2 1 406053X LINER 66lbs Poured
3 374 090037 MANGANESE BACKING MATERIAL
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
6 1 090034 WRENCH ALLEN Not Shown
7 1 450132 WRENCH MANTLE NUT STD Not Shown
2
1

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
Table of Contents
Final Assembly ....................................................................................................... 1
Lower Assembly ..................................................................................................... 3
Baseframe with V-Seat Liner ..................................................................................6A
Pin Clutch Assembly .............................................................................................. 7
Wedge Plate Assembly .......................................................................................... 9
Floating Plate Assembly ........................................................................................ 12
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 ............................................................................. 46
Hydraulic Manifold Assembly ................................................................................. 54
Horn Assembly ....................................................................................................... 56
Electrical Panel HPU .............................................................................................. 57
External Lube Assembly W/ Res ............................................................................ 62
External Lube Reservoir Weldt .............................................................................. 68
JBOX Lube Assembly ............................................................................................ 70
Lube Cable Assembly ............................................................................................ 72
150 FT SENSOR CABLE ....................................................................................... 74

JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
PAGE 1
7/6/07Rev. C
REFERENCE # 406000
Final Assembly

REFERENCE # 406000
7/6/07Rev. C
Final Assembly
JCI 24/7 Parts Number 888-474-0115
© 2007 JCI
PAGE 2
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
1 1 406001 LOWER ASSEMBLY
2 1 406030 UPPER ASSEMBLY
3 3 406108 ROTATION STOP SPACER Not Shown
4 3 456195 SHIM, ROT STOP BLOCK,.312 THK Not Shown
5 1 406094 TIR ASSEMBLY
7 1 406118 DECAL LOCATION, JCI K200 See page for 406118
8 1 406083 HOPPER ASSEMBLY
13 4 076024 NUT, 1/2-13NC Not Shown
14 1 090034 WRENCH, ALLEN, 7/8 Not Shown
15 1 450133 EYE, CONE LIFTING Not Shown
16 1 450132 WRENCH, MANTLE NUT STD Not Shown
17 1 456294 RELIEF CYLINDER TEST BLOCK
18 1 087091 CAVITY PLUG T16A-2
19 1 083074 OIL SAMPLER NEEDLE W/TUBIN Not Shown
20 1 085001 FILTER ELEMENT, DONALDSON Not Shown
21 4 546338 SHIM, 16 GA, BASEFRAME MOUNT Not Shown
22 1 090172 PAINT SPRAY - CAN Not Shown
1 060039 CRUSHER SIDE SHEAVE Not Shown
1 060005 CRUSHER SIDE BUSHING Not Shown

JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 3
7/6/07Rev. C
REFERENCE # 406001
Lower Assembly

REFERENCE # 406001
7/6/07Rev. C
Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 4

REFERENCE # 406001
7/6/07Rev. C
Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 5
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
1 1 406020 BASE FRAME MACHINED
2 1 546467 PIN CLUTCH ASSEMBLY
3 1 079124 RET RING SMALLEY WHM-162
4 1 406014 CLUTCH GUIDE RING
5 4 070130 CAPSCREW HEX 5/16 24NF X 3/4
6 4 070203 CAPSCREW SOC 5/16-18NC X 1-1/2
7 1 406015 COVER, BRAKE HOUSING
8 12 070059 CAP SCREW HEX 1/2 13NC X 1-3/4
9 46 078025 WASHER, LOCK, 1/2
11 1 450043 SEAL RING - BASE FRAME
12 1 406192 WEDGE PLATE ASSEMBLY
13 1 450166 THRUST PLATE
14 6 070152 CAPSCREW HEX 1 14NF X 3
15 1 406087 SHAFT, CONE BRAKE
16 2 406110 BRAKE SHAFT KEY

REFERENCE # 406001
7/6/07Rev. C
Lower Assembly
JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 6
17 1 406109 CONE BRAKE PLATE
18 1 450497 FLOATING PLATE, W/ INSERTS
19 1 406018 WEDGEPLATE GUARD
20 10 070027 CAP SCREW HEX 1/2 13NC X1-1/4
21 10 078019 WASHER, FLAT, 1/2
22 1 406040 CONE ASSEMBLY
23 4 406112 STRUT GUARD, BF
24 1 406073 PINION ASSEMBLY
25 8 070010 CAP SCREW HEX 5/8 11NC X1-3/4
26 8 078014 WASHER, LOCK, 5/8
27 1 406216 PINION TUNNEL ACCESS COVER
28 18 070058 CAP SCREW HEX 1/2 13NC X 1 G5
32 8 406116 VSEAT SEAL RETAINER
33 8 406117 VSEAT SEAL RUBBER
34 16 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
35 1 083907 ELBOW ST 2 1/2 PIPE 90 DEG
36 2 083249 PLUG, PIPE 2 1/2 NPT SQ HEAD
37 1 083615 FS2503-08-08
38 1 083517 FS0304-C-088
40 2 080032 PLUG, MAGNETIC 1
42 1 450157 KEY, DRIVE SHEAVE
43 2 070141 SETSCREW 5/8 X 5/8 NC SOC HD
44 1 06005 BUSHING QD M-2-15/16
45 1 060039 SHEAVE 8V 8GR 24.8 OD 24.6 PD
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS

6A
10/6/09
Rev. G
REF# 406020
Baseframe with V-Seat Liner

REF# 406020
10/6/09
Rev. G
Baseframe with V-Seat Liner
6B

REF# 406020
10/6/09
Rev. G
Baseframe with V-Seat Liner
6C
ITEM QTY PART
NUMBER DESCRIPTION COMMENTS
21 406028 BASEFRAME SPINDLE
3 1 450249 NUT SPINDLE 1200LS (AN-44)
4 5 456344 PLUG 1.625 DIA X 0.500
5 4 406016 LINER VSEAT 3.5
7 2 080122 FLANGE WELD 2 1/2NPT W/O PILOT
9 6 406027 CYL MOUNTING EYE
10 12 079119 PIN DOWEL .500 OD X 1.000
11 1 406069 PL WEAR TUNNEL PINION
12 4 406112 STRUT GUARD BASE FRAME

JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 7
7/6/07Rev. A
REFERENCE # 546467
Pin Clutch Assembly

REFERENCE # 546467
7/6/07Rev. A
Pin Clutch Assembly
JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 8
ITEM 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

JCI 24/7 Parts Number 888-474-0115
© 2006 JCI
PAGE 9
7/6/07Rev. A
REFERENCE # 406192
Wedge Plate Assembly