Kodiak 300

Crusher Parts Book

Serial Number: C050316

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 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

© 2005 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: 541-988-9487
• Email: [email protected]

Model No.

Serial No.

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.

JCI 24/7 Parts Number 888-474-0115

© 2005 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

© 2005 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

© 2005 JCI
 Factory Installed Counter Weight Configuration

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 0 N/A EMPTY
2 0 N/A EMPTY
3 0 N/A EMPTY
4 1 456053 COUNTER WEIGHT 3.5 lb
5 1 456053 COUNTER WEIGHT 3.5 lb
6 1 456045 COUNTER WEIGHT 2.0 lb
7 0 N/A EMPTY
8 0 N/A EMPTY
Additional Counterweights available to purchase:

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

© 2005 JCI
 Factory Installed K300 Manganese Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456071X MANTLE 66 lbs Poured
2 1 456264X LINER 308 lbs Poured
3 374 090037 MANGANESE BACKING MATERIAL

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 Drive Sheave and Rotation Stop Shim Configuration

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 N/A HOPPER EXTENSION
2 1 060021 SHEAVE 10GR 8V 24.6 PD 24.8 OD
3 1 060012 QD BUSHING N 3-1/2
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 546299 SENSOR CABLE 100’ Not Shown
9 1 456182 REMOTE CABLE 100’ Not Shown
10 1 060074 V-BELT 8V1600 Not Shown
11 1 060078 SHEAVE 10GR 8V 18.8PD 19.0 OD Not Shown
12 1 060173 QD BUSHING N 3-1/2 Not Shown

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 Kits and Additional Spare Parts

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

Cone Skirt Ring 456256 456187 Cone Assembly

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 Table of Contents

Upper Assembly ..................................................................................................... 1

Top Plate-Gear Support Assembly ........................................................................ 6

Position Indicator Assembly ................................................................................... 7

K300 Lower Assembly ........................................................................................... 9

Wedge Plate Assembly .......................................................................................... 13

Cone Assembly ...................................................................................................... 15

Pinion Assembly .................................................................................................... 18

TIR Assembly ......................................................................................................... 19

Heater Assembly .................................................................................................... 23

Floating Plate Assembly ........................................................................................ 25

Hopper Assembly ................................................................................................... 26

Control Assembly ................................................................................................... 27

Electrical Assembly/Schematic .............................................................................. 32

Remote Electrical Panel ......................................................................................... 38

Electrical Panel Hydraulic Power Unit .................................................................... 44

Hydraulic Power Unit Assembly ............................................................................. 49

Hydraulic Power Unit Enclosure Base ................................................................... 57

Hydraulic Manifold Assembly ................................................................................. 58

Hydraulic Schematic .............................................................................................. 60

External Lube Panel Assembly .............................................................................. 61

External Lubrication Panel Housing Assembly ...................................................... 65

Horn Assembly ....................................................................................................... 66

Lube Panel J-Box Assembly .................................................................................. 67

Lube Panel Cable 24FT ......................................................................................... 68

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 Table of Contents

Decal Location ....................................................................................................... 69

Relief Cylinder Test Block ...................................................................................... 71

JCI 24/7 Parts Number 888-474-0115

© 2005 JCI
 PAGE 1

REFERENCE # 456001

Upper Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 2

REFERENCE # 456001

Upper Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 3

REFERENCE # 456001

Upper Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 4

REFERENCE # 456001

Upper Assembly
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 6.
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
40 4 070200 CAPSCREW HEX 1/2 20NF X1-1/2
41 4 456016 CLEVIS, BOWL LINER

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 5

REFERENCE # 456001

Upper Assembly
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
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 7.
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

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 6

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

Rev. B JCI 24/7 Parts Number 888-474-0115 06/05/02

© 2003 JCI
 PAGE 7

REFERENCE # 546132

Position Indicator Assembly

Rev. F JCI 24/7 Parts Number 888-474-0115 06/05/02

© 2003 JCI
 PAGE 8

REFERENCE # 546132

Position Indicator Assembly

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 9 020126 TERMINAL,SPADE,22-18,INSUL
12 1 546301 J-BOX,4 X 6,SENSOR

Rev. F JCI 24/7 Parts Number 888-474-0115 06/05/02

© 2003 JCI
 PAGE 9

REFERENCE # 456296

K300 Lower Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 10

REFERENCE # 456296

K300 Lower Assembly

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 11

REFERENCE # 456296

K300 Lower Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456257 BASE FRAME, MACHINED
2 1 456035 WEDGE PLATE ASSEMBLY SEE 456035 ON PAGE 13.
3 1 456187 CONE ASSEMBLY SEE 456187 ON PAGE 15.
4 1 456031 PINION ASSEMBLY SEE 456031 ON PAGE 18.
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 23.
11 20 070027 CAP SCREW HEX 1/2 13NC X1-1/4
12 1 456064 SHAFT, CONE BRAKE
13 1 450072 KEY, BRAKE SHAFT
14 1 450502 CONE BRAKE PLATE, UNHARDENED
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 25.
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

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 12

REFERENCE # 456296

K300 Lower Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. A JCI 24/7 Parts Number 888-474-0115 06/27/03

© 2003 JCI
 PAGE 13

REFERENCE # 456035

Wedge Plate Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 11/18/03

© 2003 JCI
 PAGE 14

REFERENCE # 456035

Wedge Plate Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456036 WEDGE PLATE, MACHINED
2 1 450059 GEAR, RING (SPIRAL)
3 1 456041 SEAL RING, UPPER WP
4 1 456042 SEAL RING, LOWER WP
5 1 456021 GUARD, SEAL, ONE PIECE
6 3 450228 UPPER RADIAL RETAINER
7 2 456128 BEARING, THRUST, 1200RA
8 0.5 456040 LOWER COUNTERWEIGHT WEDGE PL
9 8 070025 CAPSCREW HEX 3/4 16NF X 2-1/2
10 6 070027 CAP SCREW 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, WEDGEPLATE, 3.5LB
25 5 070017 CAP SCREW HEX 3/4 16NF X 4 G8
27 3 070329 SET SCREW SOC 3/4 10NC X 3/4
28 1 456156 BEARING, RADIAL, KOYO
29 5 456210 PIPE, OIL DRAIN, WP
30 1 070058 CAP SCREW HEX 1/2 13NC X 1 G5
31 1 078019 WASHER, FLAT, 1/2

Rev. G JCI 24/7 Parts Number 888-474-0115 11/18/03

© 2003 JCI
 PAGE 15

REFERENCE # 456187

Cone Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 16

REFERENCE # 456187

Cone Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 17

REFERENCE # 456187

Cone Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456192 CONE WITH STEM
2 1 456191 MANTLE WASHER
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

Rev. D JCI 24/7 Parts Number 888-474-0115 08/10/04

© 2003 JCI
 PAGE 18

REFERENCE # 456031

Pinion Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456034 PINION HOUSING
2 1 456032 PINION GEAR
3 1 456033 PINION SHAFT
4 1 540137 PINION NUT LOCK
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-RING
18 1 070088 SET SCREW, 5/16-18NC X 1 G8

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 19

REFERENCE # 456285

TIR Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 06/23/03

© 2003 JCI
 PAGE 20

REFERENCE # 456285

TIR Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 06/23/03

© 2003 JCI
 PAGE 21

REFERENCE # 456285

TIR Assembly

Rev. D JCI 24/7 Parts Number 888-474-0115 06/23/03

© 2003 JCI
 PAGE 22

REFERENCE # 456285

TIR Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 8 456275 CYL 6.00 BORE X 5.00 STROKE
2 3 456272 TIR CYLINDER SPACER LEFT HAND
3 3 456271 TIR CYLINDER SPACER RIGHT HAND
4 1 456273 TIR CYLINDER SPACER RH END
5 1 456274 TIR CYLINDER SPACER LH END
6 4 456284 GUARD CYLINDER HOSE
7 3 456283 GUARD CYLINDER HOSE
8 8 087090 VALVE RELIEF CARTRIDGE
9 32 083434 FS6400-16-16, ADAPTER STR THD
10 3 083156 2404-16-08, ADAPTER, 16-8
11 2 083061 ST ELBOW 45 DEG 1/2 HP
12 1 083435 5406-HP16, PLUG,ALLEN SAE#16
13 1 083340 BUSHING 1/2 X 3/8 NPT
14 1 083088 5602-06-06-06MALE RUN TEE, 3/8
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
20 7 082147 HOSE
21 32 070243 CAP SCREW HEX 1 8NC X 8 G8
22 32 076059 NUT, NYLOCK, 1-8 NC
23 64 078006 WASHER, FLAT 1
24 12 070196 CAPSCREW HEX 1/2 13NC X 7G5
25 12 076005 NUT NYLOCK 1/2-13NC
26 16 078019 WASHER, FLAT, 1/2
27 32 070008 CAP SCREW HEX 3/8 16NC X1G5
28 32 078017 WASHER, FLAT, 3/8
29 2 082145 HOSE
31 1 083344 PLUG HEX 3/8 NPT
32 4 070018 CAP SCREW HEX 1/2 13NC X2-1/2
33 1 083010 5502-04-04, ST ELBOW,90D 1/4
34 4 078025 WASHER, LOCK, 1/2
35 8 546349 GASKET, CYLINDER

Rev. D JCI 24/7 Parts Number 888-474-0115 06/23/03

© 2003 JCI
 PAGE 23

REFERENCE # 456123

Heater Assembly

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 24

REFERENCE # 456123

Heater Assembly
ITEM QTY PART NUMBER DESCRIPTION COMMENTS
1 1 456124 HEATER COVER WELDMENT
2 1 540327 HEATER MACHINED,2000W,120V
3 1 540294 HEATER ELECTRICAL BOX COVER
4 1 020026 THERMO ON 60 DEG OFF 80 DEG.
5 2 540254 GASKET, HEATER
6 4 070032 CAP SCREW HEX 3/8 16NC X1-1/4
7 2 070008 CAP SCREW HEX 3/8 16NC X1G5
8 1 076042 NUT 1-1/2-6NC
9 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 WIRE, 16 GA MTW BLUE
20 196 020032 WIRE, 16 GA MTW GREEN
21 1 076046 NUT, #8-32NC
22 1 078037 WASHER, LOCK, #8
23 4 078024 WASHER, LOCK, 3/8
24 2 020018 SEALING RING 5263
25 2 020019 LOCKNUT, RID METAL CON, 3/4 T
26 1 080032 PLUG, MAGNETIC

Rev. 0 JCI 24/7 Parts Number 888-474-0115 06/06/02

© 2003 JCI
 PAGE 19

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 10 070039 CAP SCREW SOC 3/8 16NC X 3/4
5 2 450498 FLOATING PLATE UPPER INSERT

Rev. B JCI 24/7 Parts Number 888-474-0115 06/19/03

© 2003 JCI
 PAGE 26

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

Rev. A JCI 24/7 Parts Number 888-474-0115 06/07/02

© 2003 JCI
 PAGE 27

REFERENCE # 456143

Control Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 28

REFERENCE # 456143

Control Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 29

REFERENCE # 456143

Control Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 30

REFERENCE # 456143

Control Assembly

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 31

REFERENCE # 456143

Control Assembly
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456144 ELECTRICAL ASSY/SCHEMATIC
2 1 456157 HYD POWER UNIT ASSY
3 1 456155 EXT LUBE PANEL ASSEMBLY
4 1 546162 OIL COOLER
6 4 083104 DISCONNECT COUPLER PLUG 1/2NPT
7 4 083116 DISCONNECT COUPLER #8 SAE
8 8 083103 DISCONNECT, NIPPLE, 1/2 NPT
9 8 083105 DISCONNECT NIPPLE PLUG, 1/2 NP
11 1 083051 1/4 DUST PLUG PARKER 3005-2
12 1 083038 COUPLER QUICK DISCON FLUSH FA
13 2 083039 NIPPLE QUICK COUPLER FLUSH FA
14 2 083081 DUST COVER QUICK DISCON
15 4 083100 ADAPTER, 8-10, FLARE TO SAE
16 4 083175 ELBOW, 90 DEG, 8-8 NWO ADJ
18 1 082010 HOSE 1X144 1M SWIVEL X 1M SW
19 3 082009 HOSE 1/2X160 1/2 M SWIVELX1/2M
20 4 082043 HOSE 1/2 X 288 NPT M-NPT M
21 1 082044 HOSE 1/4 X 288 NPT M-NPT M
26 1 082045 HOSE,PARKER F3011306-4-4-4-96"
27 2 042194 CLAMP,HOSE,3/4"DIA X 1/2" BOLT
29 1 083162 ADAPTER #4 JIC-M X 1/4 NPT-M
30 2 083151 REDUCER, BELL, 1-1/4 X 1/2 STD
31 4 082063 HOSE 1/2 x 132 NPT M-M
32 2 083060 TEE, 1/2 HP
34 1 456206 CABLE, LUBE PANEL, 24 FT

Rev. G JCI 24/7 Parts Number 888-474-0115 07/26/04

© 2003 JCI
 PAGE 32

REFERENCE # 456144

Electrical Assembly/Schematic

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 33

REFERENCE # 456144

Electrical Assembly/Schematic

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 34

REFERENCE # 456144

Electrical Assembly/Schematic

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 35

REFERENCE # 456144

Electrical Assembly/Schematic

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 36

REFERENCE # 456144

Electrical Assembly/Schematic

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 37

REFERENCE # 456144

Electrical Assembly/Schematic

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456146 ELECTRICAL PANEL,REMOTE
4 1 456145 ELECTRICAL PANEL,HYD UNIT

Rev. E JCI 24/7 Parts Number 888-474-0115 05/13/04

© 2004 JCI
 PAGE 38

REFERENCE # 456146

Remote Electrical Panel

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 39

REFERENCE # 456146

Remote Electrical Panel

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 40

REFERENCE # 456146

Remote Electrical Panel

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 41

REFERENCE # 456146

Remote Electrical Panel

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 42

REFERENCE # 456146

Remote Electrical Panel

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456209 BOX, ELECTRICAL PANEL REMOTE
2 1 020110 DIGITAL COUNTER, LCD, EEPROM
3 1 020160 METER, 0-500 A
4 1 020161 TRANSFORMER,CURRENT
5 1 020164 EMERG STOP BUTTON,JUMBO
6 2 020165 LIGHT, INDICATOR, GREEN
7 1 020166 LIGHT, INDICATOR, RED
8 1 020167 START/STOP, ILLUM, 3 POS
9 1 456185 FACE PLATE, CONTROL PANEL
10 3 020163 PUSH-BUTTON,MOMENTARY
11 1 020127 FUSE BLOCK
12 1 020128 FUSE,1/2 AMP,AGC
13 40 020084 TERMINAL BLOCK AB 1492-W4 600V
14 4 020086 END STOPS AB 1492-EA35
15 3 020072 RELAY, TIME DELAY, ON
16 3 020074 SOCKET, DIN RAIL MT, 8 PIN
18 24 020182 DIN MOUNTING RAIL, DIN #3
19 1 020162 POWER SUPPLY 7.5W, 12VDC
20 12 020104 DUCT,WIRING,2.25 X 3.00 TY-DUC
21 12 020105 COVER, WIRE DUCT (TY-DUCT)
22 1 020115 RECEPTACLE 6 PIN,MS3102A14S-6S
23 1 020118 DUST CAP,RECEPT,MS25043-14D
24 1 020168 INSERT,FEMALE,1-16 T&B FS116A
25 1 020169 INSERT,FEMALE,17-32 T&B FS132A
26 1 020173 BASE,PANEL MT,DUST 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, ROUND HEAD #4-40 X 1/2
31 4 076069 NUT, #4-40
32 4 078047 WASHER, LOCK, #4
33 1 020181 BACKPANEL, HOFFMAN A-20P16
34 1 020183 RELAY, TIME DELAY, OFF
35 1 020184 SOCKET,DIN RAIL MT,11 PIN
36 2 020144 CENTER JUMPER,2P, 1492-CJ6-2
37 0.5 020192 LABEL, TERM BLOCK, 1-50
38 7 070341 MACH SCREW RD HD 10-24 x .500
40 50 020135 "CABLE TIE, 3.62"" "
41 10 040021 "CABLE TIE 7"" "

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 43

REFERENCE # 456146

Remote Electrical Panel

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
42 20 020198 MOUNTING BASE, CABLE TIE
43 600 020132 WIRE, 16 GA MTW RED
44 120 020191 WIRE, 16 GA MTW, WHITE
45 192 020191 WIRE, 16 GA MTW, WHITE
46 2 020085 END PLATES AB 1492-EB3
47 190 025552 MARKING SLEEVES BRADY Not Shown

Rev. F JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 50

REFERENCE # 456145

Electrical Panel Hydraulic Power Unit

Rev. J JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 51

REFERENCE # 456145

Electrical Panel Hydraulic Power Unit

Rev. J JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 52

REFERENCE # 456145

Electrical Panel Hydraulic Power Unit

Rev. J JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 53

REFERENCE # 456145

Electrical Panel Hydraulic Power Unit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456241 BOX, ELECT PANEL,HYD. UNIT
2 1 020151 PANEL, HOFFMAN, A-16P14
4 62 020084 TERMINAL BLOCK AB 1492-W4 600V
5 4 020085 END PLATES AB 1492-EB3
6 4 020086 END STOPS AB 1492-EA35
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 1 020065 MINI-BREAKER,20A
14 1 020066 MINI-BREAKER,30A
18 2 020152 "KNOCKOUT SEAL, 1"" "
19 2 020156 RELAY, SPST-NO, 30A, 120 VAC
20 1 020175 CONNECTOR, CGB296, .625-.750
21 1 020018 SEALING RING 5263
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 020186 TERMINAL BLOCK AB 1492-W16S
42 2 020187 CENTER JUMPER, 2 POLE, (W16S)
43 4 020144 CENTER JUMPER,2P, 1492-CJ6-2
44 48 020191 WIRE, 16 GA MTW, WHITE
45 0.5 020192 LABEL, TERM BLOCK, 1-50
46 0.1 020193 LABEL, TERM BLOCK, 51-60
47 0.04 026053 MARKERS TERM 6CM X 12CM
50 120 020132 WIRE, 16 GA MTW RED
51 0.5 020194 CENTER JUMPER, 10 POLE (W4)
52 4 070340 MACH SCREW RD HD 8-32 x .50
53 4 076046 NUT, #8-32NC
54 7 070341 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 020202 END STOP 1492-EB10

Rev. J JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 54

REFERENCE # 456145

Electrical Panel Hydraulic Power Unit

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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"
64 1 020183 RELAY, TIME DELAY, OFF
65 1 020184 SOCKET,DIN RAIL MT,11 PIN

Rev. J JCI 24/7 Parts Number 888-474-0115 10/28/04

© 2004 JCI
 PAGE 55

REFERENCE # 456157

Hydraulic Power Unit Assembly

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 56

REFERENCE # 456157

Hydraulic Power Unit Assembly

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 57

REFERENCE # 456157

Hydraulic Power Unit Assembly

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 58

REFERENCE # 456157

Hydraulic Power Unit Assembly

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 59

REFERENCE # 456157

Hydraulic Power Unit Assembly

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 60

REFERENCE # 456157

Hydraulic Power Unit Assembly

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, VANE, FIXED DISPLACEMENT
6 1 060230 ADAPTER, PUMP, 215TC TO SAE A
7 1 020149 MOTOR 10 HP 215TC
8 1 060229 COUPLING,HALF,5/8 M20002005
9 1 089029 GAGE, SIGHT LEVEL
10 3 020141 SWITCH, PRESSURE, SINGLE SET
11 6 070062 CAP SCREW HEX 1/4 20NC X 1 G5
12 14 076026 NUT, NYLOCK 1/4-20NC
13 24 070027 CAP SCREW HEX 1/2 13NC X1-1/4
15 56 078019 WASHER, FLAT, 1/2
16 4 070043 CAP SCREW HEX 3/8 16NC X 2G5
17 4 076009 NUT, NYLOCK 3/8-16NC
18 2 078024 WASHER, LOCK, 3/8
19 2 070008 CAP SCREW HEX 3/8 16NC X1G5
20 1 085004 FILTER ASSY, DONALDSON HAK05
21 1 085022 DIFFUSER, RETURN 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 CAP SCREW HEX 1/4 20NC X 3/4
26 1 456184 HYDRAULIC MANIFOLD ASSEMBLY
27 8 070058 CAP SCREW HEX 1/2 13NC X 1 G5
28 22 078025 WASHER, LOCK, 1/2
29 1 456159 COVER, ENCLOSURE, HPU
30 1 456160 PANEL, RIGHT SIDE, HPU
31 1 456161 PANEL, LEFT SIDE, HPU
32 24 070016 CAP SCREW HEX 1/2 13NC X1-1/2
33 34 076005 NUT NYLOCK 1/2-13NC
34 1 083527 5406-24-12
35 2 540166 ACCUMULATOR, 1 GAL 1-1/4NPT
37 4 089034 CLAMP, ACCUMULATOR, 1 GAL
38 8 070066 CAP SCREW HEX 5/16-18NC X3/4
39 8 076027 NUT, NYLOCK 5/16-18NC
40 2 083180 PIPE SCH40 3/4 X 3.00 NPT
41 5 083070 5406-SHP-12

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 61

REFERENCE # 456157

Hydraulic Power Unit Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
42 2 083181 5000-12-12
43 1 085019 FILTER BREATHER
44 2 083162 2404-04-04
46 1 083182 6400-16-12-O
47 3 083167 2605-04-04-04
52 1 083205 6801-10-10-NWO
53 2 082055 "HOSE,PARKER F3010606-4-4-4-34"""
54 1 082056 "HOSE,PARKER F3010606-4-4-4-39"""
55 2 082057 "HOSE,PARKER F3010606-4-4-4-27"""
56 1 082058 "HOSE,PARK F301064110-10-10-29"""
57 1 082059 "HOSE,PARK F301130612-12-12-63"""
58 1 082060 "HOSE,PARK F301134116-16-16-20"""
59 1 456162 DOOR, ENCLOSURE, HPU
60 2 090185 HINGE, LIFT OFF, WELDABLE
61 1 090184 LATCH, T-HANDLE, FLUSH MOUNT
62 2 090030 DECAL, JCI LOGO
63 3 456204 ANGLE, DOOR STOP
64 1 456164 COVER, OIL RESERVOIR, HPU
65 16 020014 "CONNECTOR,CGB 194,1/2"",.38-.50"
66 9 020038 SEALING RING, 1/2 (T&B 5262)
67 9 020039 LOCKNUT RID METAL CONDUIT 1/2
68 1 020175 CONNECTOR, CGB296, .625-.750
69 1 020018 SEALING RING 5263
70 1 020019 LOCKNUT, RID METAL CON, 3/4 T
71 1 020176 CONNECTOR, CGE296, .625-.750
73 132 020034 WIRE, S/O, 16/4
74 60 020035 WIRE, S/O, 12/3
75 96 020433 WIRE, S/O, 16-6
77 8 078015 WASHER, FLAT, 1/4
78 1 090186 DECAL, HYDRAULIC CONNECTION
79 1 090070 DECAL-DANGER-120 VOLT
82 4 456205 LUG, LIFTING
83 5 083052 5406-20-12
84 1 090194 DECAL, ROTATION ARROW
85 1 060234 COUPLING,HALF,1-3/8 M20011210
86 1 060235 COUPLING INSERT, 270N
89 1 020203 DATA POCKET, SMALL
90 1 456212 KIT, TANK GASKET
91 4 083118 3474-08-08-NWO
92 4 083104 DISCONNECT COUPLER PLUG 1/2NPT

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 62

REFERENCE # 456157

Hydraulic Power Unit Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
93 4 083116 DISCONNECT COUPLER #8 SAE
94 1 083466 6405-08-04-O
95 1 083051 TMP-14
96 1 083038 COUPLER, QUICK DISC, PVV-14-F
97 2 083072 5406-06-04
98 170 020013 WIRE, S/O, 16/3
99 8 078016 WASHER, FLAT, 5/16
100 1 083160 5406-12-08
101 1 020217 SWITCH TEMPERATURE (SEE TEXT)
103 1 020148 "KNOCKOUT SEAL, 1/2"" "
104 1 450187 HORN ASSY, 115V - NO PROJECTOR
108 1 087008 VALVE HYDRA FORCE SV10-20-05
109 1 087033 VALVE BODY B10-2-A8T
110 2 083594 6400-04-08-O
111 1 546551 MOUNTING BRACKET SV10-20
112 1 082144 HOSE F451TC3939-4-4-4-32.0-180
113 2 070442 CAPSCREW HEX 1/4-20NC X1-1/4G5
114 2 070064 CAP SCREW HEX 1/4 20NC X 2 G5
115 1 087031 CABLE GLAND, DIN CONN 43650
116 50 026500 PERMASLEEVE MARKERS
117 2 083065 5406-24-20
118 10 076024 NUT, 1/2-13NC

Rev. Q JCI 24/7 Parts Number 888-474-0115 05/12/04

© 2004 JCI
 PAGE 57

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. E JCI 24/7 Parts Number 888-474-0115 03/06/03

© 2003 JCI
 PAGE 58

REFERENCE # 456184

Hydraulic Manifold Assembly

Rev. J JCI 24/7 Parts Number 888-474-0115 04/28/03

© 2003 JCI
 PAGE 59

REFERENCE # 456184

Hydraulic Manifold Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 456200 MANIFOLD, HYDRAULIC SEE 456200 ON PAGE 60.
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 PLUG, ALLEN SAE #6
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 PLUG, ALLEN SAE #10
13 1 087025 VALVE, SHUTTLE, CARTRIDGE
14 2 083169 ELBOW, 90 DEG, 4-6 C50X
15 2 083183 CONNECTOR 6 G6X
16 1 083173 CHECK VALVE, IN LINE, #10
17 1 083172 ELBOW, SWIVEL NUT, 10 C6X
18 1 083171 ELBOW, 90 DEG, 12-10 C50X
19 3 089016 GAUGE 0-5000 PSI
20 2 083184 CONNECTOR 6 F50X
21 1 087031 CABLE GLAND, DIN CONN 43650
22 2 087032 VALVE, CHECK, P.O. CARTRIDGE
23 1 083063 MALE RUN TEE 4-4-4 1/4 MRO
24 1 083162 ADAPTER #4 JIC-M X 1/4 NPT-M
25 1 083526 CAP 4 JIC 4FNTX
26 1 083522 TEE JIC SWIVEL RUN 12R6X
27 1 083524 REDUCER TUBE END JIC 12BTX
28 1 083523 NUT TUBE END JIC 12BTX
29 1 083525 CAP 6 JIC 6FNTX

Rev. J JCI 24/7 Parts Number 888-474-0115 04/28/03

© 2003 JCI
 PAGE 63

REFERENCE # 456200

Hydraulic Schematic

Rev. F JCI 24/7 Parts Number 888-474-0115 11/24/03

© 2003 JCI
 PAGE 65

REFERENCE # 456155

External Lube Panel Assembly

Rev. H JCI 24/7 Parts Number 888-474-0115 02/26/04

© 2003 JCI
 PAGE 66

REFERENCE # 456155

External Lube Panel Assembly

Rev. H JCI 24/7 Parts Number 888-474-0115 02/26/04

© 2003 JCI
 PAGE 67

REFERENCE # 456155

External Lube Panel Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 060033 MTR 2HP1800TEFC60HZ 145T TOS
2 1 080066 PUMP, LUBE, 1.0 CU IN/REV
3 1 089005 COUP LUBE ASSY LOVEJOY L090, S
4 1 080110 PUMP ADAPTER, SAE AA, SHORT
5 1 085004 FILTER ASSY, DONALDSON HAK05
6 1 456154 EXT LUBE PANEL
7 1 080027 FLOW SWITCH, 54
8 1 450187 HORN ASSY, 115V - NO PROJECTOR SEE 450187 ON PAGE 64.
9 1 456169 J-BOX 110V/60HZ 8.0 X 6.0 SEE 456169 ON PAGE 70.
10 1 546289 VALVE, COOLER BY-PASS
11 2 083527 BUSHING 1-1/2 NPT X 3/4 NPT
12 1 083030 PIPE NIPPLE 3/4X1/2FF 0101-8-1
13 2 083191 TEE,FEMALE 3/4 HP, 022T-12-12
14 1 080034 REDUCER 3/4P-1/4P HP 0102-12-4
15 1 083026 ST ELBOW 1/4X1/8 CD 2102-2-4
16 1 083016 SAMPLER PLUG
17 1 090114 THERM, 40-240F, 5' CAPILLARY
18 4 083005 ST ELBOW, 90 DEG, 1/2
19 1 083024 ST ELBOW 3/4 CD 2102-12-12
20 1 083067 ADAPTER, PIPE, 1F X 3/4M
21 3 083156 ADAPTER, 16-8 SAE TO NPT
22 1 083155 ST. TEE,8-8-8,NPT
23 1 020027 CONNECTOR, 3/4 X 90 T&B 2272
24 4 070224 CAPSCREW SOC 5/16 18NC X 1-1/4
25 4 076022 NUT, 5/16-18NC
26 4 078023 WASHER, LOCK, 5/16
27 4 070066 CAP SCREW HEX 5/16-18NC X3/4
28 4 076027 NUT, NYLOCK 5/16-18NC
29 2 070236 CAP SCREW HEX 3/8 16NC X 3 1/2
30 2 076023 NUT, 3/8-16NC
31 10 078024 WASHER, LOCK, 3/8
32 4 070008 CAP SCREW HEX 3/8 16NC X1G5
33 4 070062 CAP SCREW HEX 1/4 20NC X 1 G5
34 4 076026 NUT, NYLOCK 1/4-20NC
35 4 078015 WASHER, FLAT, 1/4
36 1 020019 LOCKNUT, RID METAL CON, 3/4 T
37 1 020018 SEALING RING 5263
38 1 083025 ST ELBOW 3/4X1/2 CD 2102-8-12
39 4 070009 CAP SCREW HEX 3/8 16NC X3/4G5

Rev. H JCI 24/7 Parts Number 888-474-0115 02/26/04

© 2003 JCI
 PAGE 68

REFERENCE # 456155

External Lube Panel Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
40 2 070056 MACH SCREW RD HD #8-32NC X 3/4
41 40 020034 WIRE, S/O, 16/4
42 1 080043 COVER PLATE PUMP ADAPTOR
43 1 083074 OIL SAMPLER NEEDLE W/TUBIN
44 2 082064 HOSE 1/2X28.5 1/2MX1/2M SWIVEL
45 1 083192 NIPPLE,PIPE,3/4 X 5.0 SCH 40
50 3 020014 "CONNECTOR,CGB 194,1/2"",.38-.50"
51 3 020038 SEALING RING, 1/2 (T&B 5262)
52 3 020039 LOCKNUT RID METAL CONDUIT 1/2
53 2 020147 "KNOCKOUT SEAL, 3/4"" "
54 1 020148 "KNOCKOUT SEAL, 1/2"" "
55 1 083193 NIPPLE,PIPE,3/4X3/4 (3/4FF)
56 2 083160 HEX BUSHING 3/4 X 1/2 PTR-S
57 3 020016 TERMINAL, LOCKING FORK, VINYL
58 1 090194 DECAL, ROTATION ARROW
59 3 083068 PLUG, PIPE, SQ HD 1/2NPT
60 1 090070 DECAL-DANGER-120 VOLT
61 1 090089 DECAL-NOTICE-RUN LUB

Rev. H JCI 24/7 Parts Number 888-474-0115 02/26/04

© 2003 JCI
 PAGE 69

REFERENCE # 456154

External Lubrication Panel Housing Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. A JCI 24/7 Parts Number 888-474-0115 04/02/03

© 2003 JCI
 PAGE 64

REFERENCE # 450187

Horn Assembly

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

Rev. A JCI 24/7 Parts Number 888-474-0115 02/26/04

© 2003 JCI
 PAGE 70

REFERENCE # 456169

Lube Panel J-Box Assembly

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 020136 BOX
2 1 020137 PANEL
3 12 020084 TERMINAL BLOCK
4 2 020086 END STOPS
5 4.75 020182 DIN MOUNTING RAIL, DIN #3
6 2 020085 END PLATES
7 0.5 020103 GROUND BAR KIT, 14 POS
8 1 020144 CENTER JUMPER,2P
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

Rev. C JCI 24/7 Parts Number 888-474-0115 06/11/02

© 2003 JCI
 PAGE 68

REFERENCE # 456206

Lube Panel Cable 24FT

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 2 020018 SEALING RING
2 2 020019 LOCKNUT, RID METAL CON, 3/4 T
3 2 020037 CONNECTOR 3/4X90 FITS 3/4 FLEX
4 288 020033 CONDUIT, 3/4 FLEX, NON-METALLI
5 312 020028 WIRE, 10 GA THHN, WHITE
6 312 020029 WIRE, 10 GA, THHN RED
7 312 020030 WIRE, 16 GA MTW BLACK
8 312 020031 WIRE, 16 GA MTW BLUE
9 312 020032 WIRE, 16 GA MTW GREEN
10 312 020177 WIRE, 16 GA MTW, ORANGE
11 312 020133 WIRE, 16 GA MTW BROWN
12 312 020179 WIRE, 16 GA MTW, YELLOW

Rev. A JCI 24/7 Parts Number 888-474-0115 06/26/02

© 2003 JCI
 PAGE 69

REFERENCE # 456118

Decal Location

Rev. C JCI 24/7 Parts Number 888-474-0115 03/05/03

© 2003 JCI
 PAGE 70

REFERENCE # 456118

Decal Location
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 090023 DECAL, DRIVE GUARDS
2 1 090024 DECAL, EYE PROTECTION
3 1 090025 DECAL, HEARING PROTECTION
4 1 090026 DECAL, LOCKOUT
5 1 090027 DECAL, HARDHAT
6 1 090064 DECAL -DANGER EXP DECOMPRESS
7 1 090065 DECAL-DANGER-SERIOUS INJURY
8 1 090066 DECAL-NOTICE-BLOCK CONE HD
9 1 090067 DECAL-NOTICE-DO NOT ALLOW MAT
10 1 090068 DECAL-CAUTION-CONSULT YR OPER
11 1 090150 SERIAL NUMBER PLATE
12 2 090056 DECAL, MADE IN AMERICA
13 2 090074 DECAL - WORLD CLASS...
14 2 090179 DECAL, GLOBE & JCI LOGO 16 x 9
15 2 090197 DECAL,KODIAK 300
16 4 090069 DECAL-NON-FLAMABLE GAS
17 2 090180 DECAL, CRUSHING ZONE

Rev. C JCI 24/7 Parts Number 888-474-0115 03/05/03

© 2003 JCI
 PAGE 74

REFERENCE # 456294

Relief Cylinder Test Block

PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
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

Rev. B JCI 24/7 Parts Number 888-474-0115 03/11/03

© 2003 JCI