Kodiak Operation and Service

Manual and Parts Book

Kodiak Crusher
S/N C080508
86470 Franklin Blvd, Eugene, OR 97405 • 800-314-4656 • 541-736-1400 • Fax 541-988-9401
24/7 Parts Number 888-474-0115
 JCI KODIAK CRUSHER

Kodiak 200
Crusher Parts Book
Serial Number: C0080508

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
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 LIMITED TO, 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
INSTALLATION OF ANY PARTS OR COMPONENTS NOT MANUFACTURED OR SUPPLIED BY JCI,
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 CRUSHER
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
•E-mail: parts@jcieug.com

Model No.

Serial No.

The Serial Number Plate for your crusher is usually located 180° from the pinion.
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.

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
*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.

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
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 violently should tramp iron be feed into the machine. Stay clear of feed and dis-
charge 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-cir-
cuit cameras if close observation of the feed arrangement is necessary for troubleshoot-
ing 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 cham-
ber 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, lubrica-
tion, maintenance or repair procedures. Also lockout power to all crusher feed and dis-
charge equipment. Be sure pressure is fully relieved before servicing the hydraulic
system.

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
•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. Lockout/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 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 con-
tact 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 suitable 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 run-
ning. 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 compo-
nents 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 alert-
ing crusher operators that the machine needs to be shut down immediately to prevent
permanent damage to crusher components. In addition, 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 immediately
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.

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
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 missing, 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 operation. A careful and well-trained operator is the best
insurance against an accident.

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
Factory Installed K200 Manganese Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 406051X MANTLE
2 1 406055X LINER
3 374 090037 MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
Factory Installed Counter Weight Configuration

11 10 9 8 7 6 5 4 3 2 1

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 0 N/A N/A
2 0 N/A N/A
3 0 N/A N/A
4 1 406012 3.40
5 1 406012 3.40
6 1 406012 3.40
7 1 406012 3.40
8 1 406012 3.40
9 0 N/A N/A
10 0 N/A N/A
11 0 N/A N/A

Additional Counterweights available to purchase:

WEIGHT IN
PART NUMBER
POUNDS

2.50 406013

3.40 406012

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 JCI KODIAK CRUSHER
Partial list of Items Contain in the “Auxiliary Parts” Box

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
N/A 1 090034 WRENCH ALLEN Not Shown
N/A 1 450132 WRENCH MANTLE NUT STD Not Shown
N/A 1 406133 EYE CONE LIFTING Not Shown

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 Table of Contents

Final Assembly ....................................................................................................... 1

Lower Assembly ..................................................................................................... 4

Baseframe with V-Seat Liner .................................................................................. 7A

Pin Clutch Assembly .............................................................................................. 8

Wedge Plate Assembly .......................................................................................... 10

Floating Plate Assembly ........................................................................................ 13

Cone Assembly ...................................................................................................... 14

Pinion Assembly .................................................................................................... 16

Upper Assembly ..................................................................................................... 18

Sensor JBox 4 X 6 ................................................................................................. 28

TIR Assembly ......................................................................................................... 30

Tramp Iron Relief Hose Kit ..................................................................................... 33

Decal Location JCI K200 ....................................................................................... 34

Hopper Assembly ................................................................................................... 37

Remote Control Panel ............................................................................................ 38

Electrical Schematic ............................................................................................... 45

Hydraulic Schematic .............................................................................................. 49

Hydraulic Power Unit ............................................................................................. 50

Hydraulic Power Unit Enclosure Base ................................................................... 63

Tank Oil Reservoir HPU ......................................................................................... 64

Hydraulic Manifold Assembly ................................................................................. 65

Horn Assembly ....................................................................................................... 67

Hoses and Fitting for Hydraulic Power Unit ........................................................... 68

Electrical Panel HPU .............................................................................................. 71

Lube Assembly w/ Reservoir .................................................................................. 76

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 Table of Contents

Lube Enclosure w/ Reservoir ................................................................................. 90

Exterior Lube Enclosure ......................................................................................... 94

Lube Hose Kit ........................................................................................................ 97

Oil Cooler Components OA123 ............................................................................. 98

150 FT Cable Remote ............................................................................................ 100

150 FT Sensor Cable ............................................................................................. 102

STD Hose Kit ......................................................................................................... 103

JCI 24/7 Parts Number 888-474-0115

© 2007 JCI
 PAGE 1

REFERENCE # 406000

Final Assembly

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 2

REFERENCE # 406000

Final Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 3

REFERENCE # 406000

Final Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 060039 CRUSHER SIDE SHEAVE
1 060005 CRUSHER SIDE BUSHING

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 4

REFERENCE # 406001

Lower Assembly

Rev. E JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 5

REFERENCE # 406001

Lower Assembly

Rev. E JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 6

REFERENCE # 406001

Lower Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. E JCI 24/7 Parts Number 888-474-0115 3/31/08

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REFERENCE # 406001

Lower Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
16 2 406110 BRAKE SHAFT KEY
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

Rev. E JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 10/6/09

REF# 406020

Baseframe with V-Seat Liner

Rev. G 7A
 10/6/09

REF# 406020

Baseframe with V-Seat Liner

Rev. G 7B
 10/6/09

REF# 406020

Baseframe with V-Seat Liner

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
2 1 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

Rev. G 7C
 PAGE 8

REFERENCE # 546467

Pin Clutch Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 9

REFERENCE # 546467

Pin Clutch Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 10

REFERENCE # 406192

Wedge Plate Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 11

REFERENCE # 406192

Wedge Plate Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 12

REFERENCE # 406192

Wedge Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 406193 WEDGE PLATE MACHINED
2 1 456156 BEARING, RADIAL
3 1 456128 BEARING, THRUST, 1200RA
4 1 450059 GEAR, RING (SPIRAL)
5 8 070025 CAPSCREW HEX 3/4 16NF X 2-1/2
6 1 450008 SEAL RING - LOWER WEDGE PLATE
7 2 406005 LOWER COUNTERWEIGHT
8 6 070277 CAPSCREW SOC 3/4 10NC X 3-1/2
9 1 406017 THRUST BEARING
10 1 450007 SEAL RING - UPPER WEDGE PLATE
13 3 450228 UPPER RADIAL RETAINER
14 6 070027 CAP SCREW HEX 1/2 13NC X1-1/4
15 1 406006 UPPER COUNTERWEIGHT
16 1 406007 UPPER COUNTERWEIGHT
17 6 070465 CAPSCREW SOC 3/4 10NC X 2
18 1 406008 COUNTERWEIGHT CAP
19 1 406009 COUNTERWEIGHT CAP
20 1 406013 COUNTERWEIGHT 2.5 LB
21 1 406012 COUNTERWEIGHT X 3.5 LB
22 11 083903 6408-24-H-0
23 4 070222 FH SCREW SOC 3/4-10NC X 1.75
24 4 070497 SET SCREW SOC 1 8NC X 1

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 13

REFERENCE # 450497

Floating Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 14

REFERENCE # 406040

Cone Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 15

REFERENCE # 406040

Cone Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 406041 CONE WITH STEM
2 1 456156 BRG RADIAL
3 1 456132 RETAINER BRG RADIAL CONE
4 4 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
5 1 406086 BOLT MANTLE
7 1 450258 PIN .875 X 2.000
8 1 456304 BAR TORQUE
9 2 070189 CAPSCREW SOC 7/8 9NC X 1-3/4
10 1 450018 RING SEAL CONE
12 1 540103 FOAM 1X2X44
13 1 084050 O-RING 6227-60
14 1 450056 WASHER MANTLE
15 1 450057 NUT MANTLE
16 1 450053 CAP NUT MANTLE 45 INCH
17 1 070105 CAPSCREW SOC 1-1/4 7NC X2-1/2
18 4 406113 BAND WEAR SKIRT CONE
19 1 450257 PIN .500 X 1.000

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 16

REFERENCE # 406073

Pinion Assembly

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 17

REFERENCE # 406073

Pinion Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 406074 PINION SHAFT
2 1 450156 KEY, PINION GEAR
3 1 450058 GEAR, PINION (SPIRAL)
4 1 450120 BEARING, PINION, CONE, INNER
5 1 450119 BEARING, PINION, CUP, INNER
6 1 406072 PINION HOUSING
7 1 450117 BEARING, PINION, CUP, OUTER
8 1 450118 BEARING, PINION, CONE, OUTER
9 2 076018 LOCKNUT AN-16
10 1 078013 LOCKWASHER W-16
11 1 450028 FLINGER - INNER
12 1 450027 COVER PLATE
13 8 078024 WASHER, LOCK, 3/8
14 8 070032 CAP SCREW HEX 3/8 16NC X1-1/4
15 1 450029 FLINGER - OUTER
16 1 070142 SETSCREW 3/8 X 3/8 NC SOC HD
17 1 084055 O-RING 6227-74

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 18

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 19

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 20

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 21

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 22

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 23

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 24

REFERENCE # 406030

Upper Assembly

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 25

REFERENCE # 406030

Upper Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 406034 SUPT BOWL MACHINED
2 3 406090 ROTATION STOP UPPER
3 4.5 053132 RD 1.625 TGP ACRALLOY
4 6 070180 CAPSCREW HEX 1 8NC X 5 G8 ZIN
5 14 078030 WASHER HT 1
6 6 406066 RETAINER SEAL DUST UPPER
7 12 406068 SEAL RBBR DUST
8 6 406067 RETAINER SEAL DUST LOWER
9 22 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
10 62 078025 WASHER LOCK 1/2
11 190 090428 SPONGE RBBR 9/16T X 1/2W
12 3 456207 PIN ANTI ROTATION
13 3 070216 SETSCREW SOC 1/2 13NC X 1.0
14 1 406036 BOWL CLAMP MACHINED
15 1 406050 SEAL PISTON
16 4 546192 ROD ACETAL SQ 7/8X7/8X48
17 6 406091 SEAL RING RETAINER DRIVE UPPR
18 12 406093 SEAL RING DRIVE RBBR
19 6 406092 SEAL RING RETAINER DRIVE LWR
20 36 070058 CAPSCREW HEX 1/2 13NC X 1 G5
21 1 083566 FS6400-04-06-O
22 1 088140 4G-4FFORX90S
23 1 088345 4G-FPX
24 31 088010 HOSE 4G2
25 1 406031 BOWL MACHINED
26 12.5167 084002 O-RING 1/4
27 1 406065 RING DRIVE FAB & MACHINING
28 16 070038 CAPSCREW HEX 5/8 11NC X 2
29 16 078014 WASHER LOCK 5/8
30 2 406060 GEAR SUPT
31 4 090105 BRG CAMROLL 2.000
32 4 078034 WASHER LOCK 7/8
33 4 076031 NUT 7/8-14NF
34 4 070205 ZERK GREASE ALEMITE 1728-B
35 4 070045 CAPSCREW HEX 3/4 10NC X2-1/2 Z
36 20 078026 WASHER LOCK 3/4
37 1 406046 GEAR DRIVEN MACH
38 4 546027 EXTENSION REMOTE
39 8 070046 CAPSCREW HEX 3/4 10NC X 3-1/4

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 26

REFERENCE # 406030

Upper Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
40 16 078021 WASHER FLAT 3/4
41 2 406061 ASSY PL TOP SUPT GEAR
42 8 070169 CAPSCREW HEX 1 8NC X 4 G8
43 16 076002 NUT 1-8NC G5
44 8 078027 WASHER LOCK 1
45 4 070336 BOLT SQ HD 1/2-13 NC X 2-1/4
46 4 076024 NUT 1/2-13NC
47 2 546602 REDUCER GEAR 4.43:1
48 1 546129 MNTG SENSORS PROXIMITY
49 1 020047 SENSOR PROX AB-871TM-DH8NN18
50 1 020114 SENSOR CABLE AB-889DR4AC2
51 3 020126 TERM SPADE 22-18 INSUL
52 2 083055 CLIP MNTG 1/4 TUBE
53 8 070133 CAPSCREW HEX 3/4 10NC X 3-3/4
54 8 076017 NUT 3/4-10NC G5
55 2 546048 MTR HYD MLHSB315-G4A REMOTE
56 2 084076 O-RING 2-242
57 2 546015 GEAR DRIVE 14T 2 DP 7 PD
58 4 070155 SETSCREW SOC 3/8 16NC X 3/4
59 2 546124 GEAR PL HOLD DOWN
60 4 070200 CAPSCREW HEX 1/2 20NF X1-1/2
61 2 546056 GUARD GEAR HYD DRIVE REMOTE
62 8 070008 CAPSCREW HEX 3/8 16NC X1G5
63 8 078024 WASHER LOCK 3/8
65 3 070003 CAPSCREW HEX 3/4 10NC X 1-1/2
66 3 076058 NUT JAM 3/4-10 NC
67 4 406204 FOAM UNDER BOWL RET RING
68 1 406077 RING RETAINER BOWL
69 8 406078 BOLT RING RETAINER BOWL
70 8 406080 LOCKNUT BOWL RETAINER
71 1 406079 RING LOCKING
72 8 406115 RING KEEPER LOCKING
73 16 070036 CAPSCREW HEX 3/4 10NC X 2G5
74 16 078011 WASHER HT 3/4
75 1 546301 SENSOR JBOX 4 X 6
76 4 070061 CAPSCREW HEX 1/4 20NC X 1/2
77 4 078022 WASHER LOCK 1/4
78 4 083104 DISCONNECT CPLR PLUG 1/2 NPT
79 4 083116 DISCONNECT PARKER 4050-15
80 4 083100 6400-08-10-O

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 27

REFERENCE # 406030

Upper Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
81 4 083175 6809-08-08-NWO
82 1 083038 CPLR DISC QUICK PVV-14-F
83 1 083051 TMP-14
84 3 406205 FOAM LINER RET
85 4 406206 LINER CAP FILL HOLE

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 28

REFERENCE # 546301

Sensor JBox 4 X 6

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 29

REFERENCE # 546301

Sensor JBox 4 X 6
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 20038 SEALING RING T&B 5262
2 1 20039 RIGID 1/2 LOCKNUT T&B 141
3 1 20115 RCPT 6PIN MS3102A14S-6S
4 1 20118 RCPT DUST CAP MS25043-14D
5 1 20120 TERMINAL BOARD 6 TERM TB3096-6
6 1 20121 ENCL 6X4X3 NEMA4/12/13
7 1 20122 ENCL PNL 6X4 A6P4
8 4 20126 TERM SPADE 22-18 INSUL1
9 1 20129 CORD GRIP .125-.187 CG1250
10 4 70230 SCREW RND HD #4-40 X 1/22
11 4 76069 NUT #4-404
12 4 78047 WASHER LOCK #43

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 30

REFERENCE # 406094

TIR Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 31

REFERENCE # 406094

TIR Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 32

REFERENCE # 406094

TIR Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 6 406095 TIR CYLINDER
2 6 406107 CLEVIS PIN TIR CYLINDER
3 6 406106 ROD BOOT TIR CYLINDER
4 6 406102 COLLAR TIR CYLINDER
5 6 406101 ROD END TIR CYLINDER
6 6 406104 COLLAR SPLIT TIR CYLINDER
7 6 406105 COUPLER RETAINER TIR CYLINDER
8 6 406103 WASHER SPHERICAL TIR CYLINDER
9 24 083595 FS6400-12-16-O
10 1 406235 KIT HOSE TIR
12 3 087090 VALVE RELIEF CARTRIDGE
13 6 078004 WASHER, HT 1/2
14 6 070027 CAP SCREW HEX 1/2 13NC X1-1/4
15 24 070061 CAP SCREW HEX 1/4 20NC X 1/2
16 2 083476 FS6400-08-08-O
17 8 083128 6408-H-08-O
18 1 087004 VALVE, RELIEF 3/8 SHORT BODY
19 1 083962 6405-08-06-O
20 1 083987 FS2501-04-04
21 2 083517 FS0304-C-08
22 2 083964 FS0304-C-04
24 6 090365 BRG SPHER 2-1/4 ID X 3-9/16 OD
25 6 070085 GREASE ZERK, 1/8PIPE-27 STR
26 1 083999 FS6400-04-08-O
27 3 087091 CAVITY PLUG T16A-2

Rev. D JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 33

REFERENCE # 406235

Tramp Iron Relief Hose Kit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 24 088213 12G-12FFORX45
2 306 088013 HOSE 12G2

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 34

REFERENCE # 406118

Decal Location JCI K200

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 35

REFERENCE # 406118

Decal Location JCI K200

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 36

REFERENCE # 406118

Decal Location JCI K200

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 090555 PL SERIAL NUMBER K200
2 2 090393 DECAL CRUSHING ZONE, K200
3 2 090568 DECAL KODIAK K200
4 1 090485 DECAL ISO1014/6011 CRSH/LOTO
5 2 090486 DECAL ISO6202/6115/6041 HRG/EP
6 2 090489 DECAL ISO6071/6046 LIFT PTS
7 2 090490 DECAL ISO5018 FALL HZD
8 2 090497 DECAL ISO6202 EYE PROT
9 2 090498 DECAL ISO6126 READ OPS MAN
10 2 090499 DECAL ISO1017 PINCH PT
11 1 090504 DECAL ARROW CLOCKWISE ROTATION
12 2 090506 DECAL KPI/JCI 22.00 X 5.00
13 2 090508 DECAL ISO1040 WRNG HIGHPRESS
14 2 090512 DECAL ISO1014 HAND ENTANGLEMNT
15 2 090056 DECAL MADE IN AMERICA
16 2 090523 DECAL ISO5066 CRSHR MVNG PARTS
17 1 090560 DECAL, ARROW 2 1/2

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 37

REFERENCE # 406083

Hopper Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
6 1 406085 HOPPER RING INNER
7 1 406084 HOPPER RING
8 1 406070 HOPPER RING UPPER
9 1 456098 FLANGE, ROLLED, 54"ID "

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 38

REFERENCE # 406137

Remote Control Panel

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 39

REFERENCE # 406137

Remote Control Panel

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 40

REFERENCE # 406137

Remote Control Panel

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 41

REFERENCE # 406137

Remote Control Panel

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 42

REFERENCE # 406137

Remote Control Panel

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 43

REFERENCE # 406137

Remote Control Panel

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456209 BOX PANEL REMOTE ELECTRICAL
2 1 020110 METER COUNTER CUB5R000
3 1 020157 METER 0-300A
4 1 020158 XTMR I 300:5 6RL-301
5 1 020164 PB E-STOP JUMBO 800T-FX6D4
6 2 020165 PB INDCTR LIGHT GRN 800T-Q10G
7 1 020166 PB INDCTR LIGHT RED 800T-Q10R
8 1 020167 PB S/S ILLUM 3POS
9 1 456185 PL FACE PANEL CONTROL
10 3 020163 PB MOM BLK BOOT 800H-R2B
11 1 020127 FUSE BLOCK AB1492H6
12 1 020128 FUSE 1/2A AGC 7085K42
13 40 020500 TERM BLOCK (J4) AB1492-J4
14 4 020512 TERM BLOCK END STOP
15 3 020072 RELAY TIME DELAY RTE-P1AF20
16 3 020074 RELAY SOCKET DIN MT 8PIN
18 24 020182 DIN MOUNTING RAIL DIN #3
19 1 020162 PWR SUPPLY 7.5W 12VDC PS5R-A12
20 12 020104 DUCT WIRING 2.25X3.00
21 12 020105 DUCT WIRING COVER T225CW
22 1 020115 RCPT 6PIN MS3102A14S-6S
23 1 020118 RCPT DUST CAP MS25043-14D
24 1 020168 CONN PIN INSERT F 1-16 T&B
25 1 020169 CONN PIN INSERT F 17-32 T&B
26 1 020173 CONN BASE PNL MT T&B PB232A
27 4 070056 MACH SCREW RD HD #8-32NC X 3/4
28 4 076046 NUT #8-32NC
29 4 078037 WASHER LOCK #8
30 4 070230 SCREW RND HD #4-40 X 1/2
31 4 076069 NUT #4-40
32 4 078047 WASHER LOCK #4
33 1 020181 ENCL PNL 20X16 A-20P16
34 1 020183 RELAY TIME DELAY P2AF20
35 1 020184 RELAY SOCKET DIN MT L15211PIN
36 2 020505 TERM BLOCK CENTER JUMPER 2P J4
37 0.5 020513 MARKER TERM 6CMX12CM
38 7 070341 MACHSCREW RD HD 10-24 x .500
40 50 020135 "CABLE TIE 3.62"" TY523M "
41 10 040021 "TIE CABLE 7"" "
42 20 020198 CABLE TIE MOUNTING BASE

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 44

REFERENCE # 406137

Remote Control Panel

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
43 600 026739 CABLE 18/3 SHIELD 8770
44 120 020191 WIRE 16 MTW WHT
45 192 020191 WIRE 16 MTW WHT
46 2 020510 TERM BLOCK END PLATE
47 190 026500 MARKER SLEEVE PSPT-187-1W

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 45

REFERENCE # 406202

Electrical Schematic

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 46

REFERENCE # 406202

Electrical Schematic

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 47

REFERENCE # 406202

Electrical Schematic

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 48

REFERENCE # 406202

Electrical Schematic

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 49

REFERENCE # 456413

Hydraulic Schematic

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 50

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 51

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 52

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 53

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 54

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 55

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 56

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 57

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 58

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 59

REFERENCE # 456157

Hydraulic Power Unit

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 60

REFERENCE # 456157

Hydraulic Power Unit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456158 BASE ENCLOSURE HPU
2 1 456163 TANK OIL RESERVOIR HPU
3 1 085021 STRAINER 100 MESH 20 GPM
4 1 089030 HEATER IMMERSION 1.5 KW
5 1 086090 PUMP GEAR FIXED DISPLACEMENT
6 1 060317 ADPTR PUMP 254TC X SAE A
7 1 060421 MTRE 15HP 254TC SEE TEXT
8 1 060314 CPLNG HALF 5/8 M30002005
9 1 089078 "GAUGE SIGHT LEVEL 12"" CENTERS "
10 3 020141 SW PRESSURE A9675-4-AA
11 6 070062 CAPSCREW HEX 1/4 20NC X 1 G5
12 14 076026 NUT NYLOCK 1/4-20NC
13 22 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
15 70 078019 WASHER FLAT 1/2
18 2 078024 WASHER LOCK 3/8
19 2 070008 CAPSCREW HEX 3/8 16NC X1G5
20 1 085004 FILTER ASSY DONALDSON HAK05
21 1 085022 DIFFUSER RET LINE 1-1/4
22 1 083109 PIPE SCH40 1-1/4 X 2 NPT
23 1 083521 CROSS 1-1/4 NPT BLACK PIPE
24 1 083174 5406-20-16
25 4 070055 CAPSCREW HEX 1/4 20NC X 3/4
26 1 456184 ASSY HYD MANIFOLD
27 8 070058 CAPSCREW HEX 1/2 13NC X 1 G5
28 22 078025 WASHER LOCK 1/2
29 1 456159 CVR ENCLOSURE HPU
30 1 456160 PANEL RIGHT SIDE HPU
31 1 456161 PANEL LEFT SIDE HPU
32 30 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
33 38 076005 NUT NYLOCK 1/2 13NC
34 1 083527 5406-24-12
35 2 540166 ACCUM 1GAL 1.25NPT
37 4 089034 CLAMP ACCUMULATOR 1 GAL
38 8 070066 CAPSCREW HEX 5/16-18NC X3/4
39 8 076027 NUT NYLOCK 5/16-18NC
40 2 083720 5406-SHP-20
41 1 083070 5406-SHP-12
42 2 083719 5000-20-20
43 1 085019 FILTER BREATHER

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 61

REFERENCE # 456157

Hydraulic Power Unit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
44 3 083188 FS2404-04-04
46 1 083329 FS6400-16-12-O
47 3 083536 FS6602-04-04-04
50 4 070340 MACHSCREW RD HD 8-32 x .50
51 4 076046 NUT #8-32NC
52 1 083570 FS6801-10-10-NWO
59 1 456162 DOOR ENCLOSURE HPU
60 2 090185 HINGE LIFT OFF WELDABLE
60 2 090185 HINGE LIFT OFF WELDABLE
61 1 090416 LATCH T HANDLE FLUSH W/ HOLES
62 1 090506 DECAL KPI/JCI 22.00 X 5.00
63 3 456204 ANGLE DOOR STOP
64 1 456164 CVR OIL RESERVOIR HPU
65 16 020014 "CORD GRIP 1/2"" .38-.50 CGB194 "
66 9 020038 SEALING RING T&B 5262
67 9 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
68 1 020175 CORD GRIP .625-.75 CGB296
69 1 020018 "SEALING RING 3/4"" T&B 5263 "
70 1 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
71 1 020176 CORD GRIP .625-.75 CGE296
72 156 026855 CORD 16/3 SOOW
73 264 020034 CORD 16/4 SO
74 72 020035 CORD 12/3 SO
75 72 020433 WIRE 16/6 S/O
77 8 078015 WASHER FLAT 1/4
78 1 090186 DECAL HYD CONNECTION
79 1 090521 DECAL ISO6010 ELECTRICALHAZARD
82 4 456205 LUG LIFTING
83 6 083052 5406-20-12
84 1 090194 DECAL ROTATION ARROW
85 1 060315 CPLNG HALF 1-5/8 M30012012
86 1 060316 CPLNG INSERT 370N
89 1 020203 ENCL DATA POCKET SMALL ADP1
90 1 456212 KIT TANK GASKET
91 4 083118 3474-08-08-NWO
92 4 083104 DISCONNECT CPLR PLUG 1/2 NPT
93 4 083116 DISCONNECT PARKER 4050-15
94 1 083466 6405-08-04-O
95 1 083051 TMP-14
96 1 083038 CPLR DISC QUICK PVV-14-F

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 62

REFERENCE # 456157

Hydraulic Power Unit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
98 138 020013 CORD 16/3 SJO
99 8 078016 WASHER FLAT 5/16
100 1 083160 5406-12-08
101 1 020217 SWITCH TEMPERATURE
104 1 450187 HORN ASSY 120V NO PROJECTOR
108 1 087008 VALVE HYDRA FORCE SV10-20-05
109 1 087033 VALVE BODY B10-2-A8T
110 2 083999 FS6400-04-08-O
111 1 546551 BRKT MNTG SV10-20
113 2 070442 CAPSCREW HEX 1/4-20NC X1-1/4G5
114 2 070064 CAPSCREW HEX 1/4 20NC X 2 G5
115 1 087031 GLAND CABLE DIN CONN 43650
117 2 083065 5406-24-20
118 10 076024 NUT 1/2-13NC
120 2 083471 FS2501-08-12
121 2 083684 FS2406-08-04
122 1 090491 ISO6041/6127 DECAL WRNG RTM
123 1 090502 ISO1024 DECAL HOT SUR CAUTION
124 1 090508 DECAL ISO1040 WRNG HIGHPRESS
125 1 090509 DECAL ISO6020 NO OPEN FLAME
126 1 090520 DECAL ISO4021 EXPL DECOMP
127 1 090522 DECAL ISO6058 SHUTOFF ELECTRIC
128 1 090551 DECAL ISO 110V YELLOW
129 1 406229 COMPONENT LABELS HPU (No BOM)
130 1 406230 KIT HOSE HPU

Rev. T JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 63

REFERENCE # 456158

Hydraulic Power Unit Enclosure Base

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. F JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 64

REFERENCE # 456163

Tank Oil Reservoir HPU

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
5 1 080114 WELD FLANGE, 2" NPT
6 2 083718 NIPPLE HALF 1 1/4 NPT X 3 1/2
7 3 083032 ELBOW SCH40 1-1/4 NPT 90
8 4 083178 PIPE SCH40 1-1/4 x 8 NPT

Rev. E JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 65

REFERENCE # 456184

Hydraulic Manifold Assembly

Rev. L JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 66

REFERENCE # 456184

Hydraulic Manifold Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456200 MANIFOLD HYD MACH
2 1 087030 VALVE DIR CONTROL w/ BOLTS
3 1 087028 VALVE DIR CONTROL w/ BOLTS
4 1 087029 VALVE DIR CONTROL w/ BOLTS
6 13 083127 6408-H-06-O
7 1 087046 VALVE RELIEF CARTRIDGE
8 2 087027 VALVE NEEDLE VALVE CART
9 1 087022 VALVE DIRECTIONAL CARTRIDGE
10 1 087023 VALVE CHECK CARTRIDGE
11 2 083244 6408-H-10-O
13 1 087025 VALVE SHUTTLE C10-3
14 2 083487 FS6801-04-06-NWO
15 2 083183 1405-06-06
17 1 083570 FS6801-10-10-NWO
18 1 083298 FS6801-12-10-NWO
19 3 089016 GAUGE 0-5000 PSI LOWER MOUNT
20 2 083184 6400-04-04-O
21 1 087031 GLAND CABLE DIN CONN 43650
22 2 087032 VALVE CHECK PO CARTRIDGE
23 1 083223 6805-06-04-NWO

Rev. L JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 67

REFERENCE # 450187

Horn Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020001 HORN BASE
2 1 020002 HORN FED SIGNAL

Rev. B JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 68

REFERENCE # 406230

Hoses and Fitting for Hydraulic Power Unit

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 69

REFERENCE # 406230

Hoses and Fitting for Hydraulic Power Unit

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 70

REFERENCE # 406230

Hoses and Fitting for Hydraulic Power Unit

HOSE No FITTING 1 FITTING 2 HOSE TYPE HOSE LG DESCRIPTION

H 04-01 088130 088130 088010 34" AC2 Accumulator to PS1 tee

H 04-02 088130 088130 088010 34" AC1 Accumulator to DV4 bottom face seal
H 04-03 088130 088130 088010 39" PS1 tee to port PS1 of Manifold

H 04-04 088130 088130 088010 27" PS3 tee to PS2 tee

H 04-05 088130 088130 088010 27" PS2 tee to port PS2 of Manifold
H 04-06 088140 088140 088010 32" Side of DV4 to PS3 tee

H 08-01 088315 088334 088012 29" Pump P2 to port P of Manifold

H 12-01 088133 088113 088013 63" Port T to inlet of filter HF1

H 16-01 088114 088164 088051 22" Reservoir to Pump P2

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 193 088010 HOSE 4G2
2 29 088012 HOSE 8G2
3 63 088013 HOSE 12G2
4 22 088051 HOSE 16GMV
5 10 088130 4G-4FFORX
6 2 088140 4G-4FFORX90S
7 1 088334 8G-10FFORX
8 1 088315 8G-10FFORX90L
9 1 088113 12G-12MPX
10 1 088133 12G-12FFORX
11 1 088114 16G-16MPX
12 1 088164 16G-16FFORX90L

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 71

REFERENCE # 406203

Electrical Panel HPU

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 72

REFERENCE # 406203

Electrical Panel HPU

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 73

REFERENCE # 406203

Electrical Panel HPU

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 74

REFERENCE # 406203

Electrical Panel HPU

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456241 BOX, ELECT PANEL,HYD. UNIT
2 1 020151 PANEL, HOFFMAN, A-16P14
4 62 020500 TERM BLOCK (J4) AB1492-J4
5 4 020510 END PLATES AB 1492-EBJ3
6 4 020512 END STOP AB1492-EAJ35
7 26 020182 DIN MOUNTING RAIL, DIN #3
8 1 020103 GROUND BAR KIT, 14 POS
9 10 020014 "CONNECTOR,CGB 194,1/2"",.38-.50"
10 10 020038 SEALING RING, 1/2 (T&B 5262)
11 10 020039 LOCKNUT RID METAL CONDUIT 1/2
12 1 020064 MINI-BREAKER,10A
13 3 020065 MINI-BREAKER,20A
18 2 020152 "KNOCKOUT SEAL, 1"" "
19 3 020156 RELAY, SPST-NO, 30A, 120 VAC
20 1 020175 CONNECTOR, CGB296, .625-.750
21 1 020018 "SEALING RING 5263 3/4"" "
22 1 020019 LOCKNUT, RID METAL CON, 3/4 T
23 13.5 020104 DUCT,WIRING,2.25 X 3.00 TY-DUC
24 13.5 020105 COVER, WIRE DUCT (TY-DUCT)
25 1 020069 METER, ELASPED HOUR
32 24 020028 WIRE, 10 GA THHN, WHITE
33 120 020029 WIRE, 10 GA, THHN RED
41 4 020501 TERM BLOCK (J16) AB1492-J16
42 2 020509 CENTER JUMPER, 2 POLE, (J16)
43 3 020505 CENTER JUMPER,2POLE (J4)
44 48 020191 WIRE, 16 GA MTW, WHITE
47 0.75 020513 MARKERS TERMINAL 6CM X 12CM
50 120 020132 WIRE, 16 GA MTW RED
51 0.5 020508 CENTER JUMPER,10P (J4)
52 6 070340 MACH SCREW RD HD 8-32 x .50
54 7 026601 MACH SCREW RD HD 10-24 x .500
56 1 020168 INSERT,FEMALE,1-16 T&B FS116A
57 1 020169 INSERT,FEMALE,17-32 T&B FS132A
58 1 020173 BASE,PANEL MT,DUST T&B PB232A
59 2 020511 END STOP AB1492-EBJ16
60 5 020198 MOUNTING BASE, CABLE TIE
61 15 020135 "CABLE TIE, 3.62"" "
62 5 040021 "CABLE TIE 7"" "
63 1 020148 "KNOCKOUT SEAL, 1/2"" "

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 75

REFERENCE # 406203

Electrical Panel HPU

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
64 1 020183 RELAY, TIME DELAY, OFF
65 1 026794 SOCKET,DIN RAIL MT,11 PIN
66 1 020506 CENTER JUMPER,3POLE (J4)

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 76

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 77

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 78

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 79

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 80

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 81

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 82

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 83

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 84

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 85

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 86

REFERENCE # 406058

Lube Assembly w/ Reservoir

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 87

REFERENCE # 406058

Lube Assembly w/ Reservoir

PART
ITEM QTY DESCRIPTION
NUMBER
1 1 406059 LUBE ENCLOSURE W/ RES
2 2 089077 HEATER 2 NPT 1.5KW 120V 60-80F
3 1 089078 "GAUGE SIGHT LEVEL 12"" CENTERS "
4 12 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
5 12 078019 WASHER FLAT 1/2
6 12 076005 NUT NYLOCK 1/2 13NC
7 1 083909 5404-N-40x4.000
8 1 083923 CAP PIPE BLACK 2 1/2
9 1 085019 FILTER BREATHER
10 2 080032 PLUG MAGNETIC 1
11 1 083068 5406-SHP-08
12 1 406217 MOTOR BASE
13 1 060539 MTR 3HP 182TC
14 1 406218 ADAPTER PLATE
15 1 080030 PUMP ADAPTOR (FIL-4AA)
16 1 089093 COUPLING LO95 .500x1.125
17 1 080043 COVER PLATE PUMP ADAPTOR
18 1 080024 PUMP LUBE .761 CU IN/REV
19 1 083977 5502-12-16
20 1 083482 FS2404-16-16
21 2 083495 FS2404-08-12
22 1 083496 FS2501-16-16
23 1 085004 FILTER ASSY DONALDSON HAK05
24 2 083527 5406-24-12
25 1 083193 5404-12-12
26 1 083326 TEE 3/4 NPT SIDE OUTLET
27 1 083255 NIPPLE SCH 40 3/4 X 2 NPT
28 1 083181 5000-12-12
29 1 080034 5406-12-04
30 1 083026 5502-04-02
31 1 083016 SAMPLER PLUG
32 1 083160 5406-12-08
33 1 080027 FLOW SWITCH 54
34 1 083062 5406-HP-08
35 1 083030 5404-12-08
36 1 090114 THERM 40-240F, 5' CAPILLARY
37 1 450187 HORN ASSY 120V NO PROJECTOR
38 1 406082 JBOX LUBE ASSY
39 10 026132 "FLEX 1/2"" CONDUIT NM TBLTC50 "
40 2 026141 "FLEX CONN 1/2"" 90 NM "

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 88

REFERENCE # 406058

Lube Assembly w/ Reservoir

PART
ITEM QTY DESCRIPTION
NUMBER
41 1 406146 CABLE LUBE PANEL
42 2 026658 "RE 1"" X 3/4"" RB100-75 "
43 1 020517 "CORD GRIP 3/4"" .250-.375 "
44 2 020040 "CORD GRIP 3/4"" .50-.62 CGB295 "
45 1 020027 "CONN 3/4"" X 90 T&B 2272 "
46 3 083469 FS2501-08-08
47 2 020515 CORD GRIP .50-.63 CGE295
48 2 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
49 50 020013 CORD 16/3 SJO
50 31 020034 CORD 16/4 SO
51 120 020035 CORD 12/3 SO
52 2 070056 MACH SCREW RD HD #8-32NC X 3/4
53 2 070055 CAPSCREW HEX 1/4 20NC X 3/4
54 2 070062 CAPSCREW HEX 1/4 20NC X 1 G5
55 8 070066 CAPSCREW HEX 5/16-18NC X3/4
56 4 070068 CAPSCREW HEX 5/16-18NC X1-1/2
57 4 070009 CAPSCREW HEX 3/8 16NC X 3/4 G5
58 4 070008 CAPSCREW HEX 3/8 16NC X1G5
59 2 078015 WASHER FLAT 1/4
60 12 078016 WASHER FLAT 5/16
61 6 078017 WASHER FLAT 3/8
62 4 078023 WASHER LOCK 5/16
63 8 078024 WASHER LOCK 3/8
64 4 076026 NUT NYLOCK 1/4-20NC
65 4 076022 NUT 5/16 18NC
66 8 076027 NUT NYLOCK 5/16-18NC
67 3 083517 FS0304-C-08
68 1 083249 PLUG PIPE NPT SQ HEAD 2 1/2
69 1 090194 DECAL ROTATION ARROW
70 1 090311 DECAL DANGER HIGH VOLTAGE
71 1 020519 SW LEVEL GEMS LS-7 TYPE 9
72 1 020520 "RIGID 1/2"" COUPLING THREADED "
73 1 020217 SWITCH TEMPERATURE
74 1 020199 "CORD GRIP 1/2"" .38-.50 CGE194 "
75 1 090430 DECAL OIL LEVEL GAUGE
76 1 090089 DECAL NOTICE RUN LUB
77 1 546289 VALVE COOLER BYPASS
78 2 070236 CAPSCREW HEX 3/8 16NC X 3 1/2
79 2 076009 NUT NYLOCK 3/8-16NC
80 1 083155 5602-08-08-08

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 89

REFERENCE # 406058

Lube Assembly w/ Reservoir

PART
ITEM QTY DESCRIPTION
NUMBER
81 3 083156 6405-16-08-O
82 2 083674 FS2404-08-08
83 4 070470 CAPSCREW SOC 1/2-13 X 1-1/4
84 0 456415 COMPONENT LABELS (NO BOM)
85 1 090502 ISO1024 DECAL HOT SUR CAUTION
86 1 090551 DECAL ISO 110V YELLOW
87 1 090508 DECAL ISO1040 WRNG HIGHPRESS
88 1 090522 DECAL ISO6058 SHUTOFF ELECTRIC
89 1 406237 KIT HOSE LUBE

Rev. J JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 90

REFERENCE # 406059

Lube Enclosure w/ Reservoir

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 91

REFERENCE # 406059

Lube Enclosure w/ Reservoir

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 92

REFERENCE # 406059

Lube Enclosure w/ Reservoir

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 93

REFERENCE # 406059

Lube Enclosure w/ Reservoir

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
14 3 080059 FLANGE WELD 1/2 NPT
15 1 080060 FLANGE WELD 3/4 NPT
16 3 080000 FLANGE WELDING 1 W/PILOT
17 2 080114 FLANGE WELD 2 NPT
18 2 080122 FLANGE WELD 2 1/2NPT W/O PILOT

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 94

REFERENCE # 405082C

Exterior Lube Enclosure

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 95

REFERENCE # 405082C

Exterior Lube Enclosure

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 96

REFERENCE # 405082C

Exterior Lube Enclosure

PART
ITEM QTY DESCRIPTION
NUMBER
1 1 020136 ENCL 8X6X3.5 NEMA4/12/13
2 1 020137 ENCL PNL 8X6 A8P6
3 1 020014 "CORD GRIP 1/2"" .38-.50 CGB194 "
4 3 020038 SEALING RING T&B 5262
5 3 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
6 2 020516 "CORD GRIP 1/2"" .250-.375 "
7 2 020040 "CORD GRIP 3/4"" .50-.62 CGB295 "
8 2 020018 "SEALING RING 3/4"" T&B 5263 "
9 2 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
10 6 020182 DIN MOUNTING RAIL DIN #3
11 1 020103 GROUND BAR KIT 14 POS GB14
12 18 020500 TERM BLOCK (J4) AB1492-J4
13 2 020510 TERM BLOCK END PLATE
14 2 020512 TERM BLOCK END STOP
15 1 020148 "KNOCKOUT SEAL 1/2"" 90050 "
16 2 070341 MACHSCREW RD HD 10-24 x .500
17 2 076072 NUT 10-24 NC
18 0.3 020513 MARKER TERM 6CMX12CM

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 97

REFERENCE # 406237

Lube Hose Kit

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

N/A 1 406237 KIT HOSE LUBE

Rev. 0 JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 98

REFERENCE # 546682

Oil Cooler Components OA123

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 99

REFERENCE # 546682

Oil Cooler Components OA123

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 546681 OIL COOLER OAI23-4
2 2 083593 6410-16-08-O
3 2 083475 FS6801-08-08-NWO

Rev. A JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 100

REFERENCE # 456277

150 FT Cable Remote

Rev. A JCI 24/7 888-474-0115 3/31/08

© 2007 JCI
 PAGE 101

456277

150 FT Cable Remote

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 2 020170 CONN PIN INSERT M 1-16 T&B
2 2 020171 CONN PIN INSERT M 17-32 T&B
3 2 020172 CONN HOOD SIDE ENT T&B LH132A
4 2 020174 "CORD GRIP KELL 1"" NPT "
5 150 020180 CORD 16/30 SO
6 2 020185 CONN CUST CVR HOOD DCL432A-1
7 2 079054 LANYARD 12 LONG
8 2 079055 RING SPLIT .430 OD SS

Rev. A JCI 24/7 888-474-0115 3/31/08

© 2007 JCI
 PAGE 102

REFERENCE # 546326

150 FT Sensor Cable

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020116 PLUG 6 PIN 90DEG MS3108B14S-6P
2 2 020117 CABLE CLAMP W/BUSH MS3057-6A
3 2 020119 PLUG DUST CAP MS25042-14D
4 150 020130 CABLE 18/4 SHIELD EWCA25384
5 1 020131 CONN PLUG STR MS3106B14S-6P

Rev. B JCI 24/7 888-474-0115 3/31/08

© 2007 JCI
 PAGE 103

REFERENCE # 406166

STD Hose Kit

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 104

REFERENCE # 406166

STD Hose Kit

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 105

REFERENCE # 406166

STD Hose Kit

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI
 PAGE 106

REFERENCE # 406166

STD Hose Kit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 8 083984 DISCONNECT PARKER 8010-15
2 8 083105 TF-12 DISCON NIPPLE DUST CAP
4 2 083360 FS2603-08-08-08
5 12 088132 8G-8FFORX
6 2 083039 NIPPLE QUICK DIS 3010-2 Parker
7 2 083081 CVR DUST QUICK DISCON
8 2 088100 4G-4MP
9 2160 088012 HOSE 8G2
10 288 088010 HOSE 4G2
11 8 088262 8G-8MB
12 1 083577 FS2408-08
13 2 088212 8G-8FFORX45 Not Shown

Rev. C JCI 24/7 Parts Number 888-474-0115 3/31/08

© 2007 JCI