Part Cono A

+
Kodiak Operation and Service

Manual and Parts Book
+
Kodiak 400 Crusher
S/N C100611
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 400+
Crusher Parts Book
Serial Number: C100611
Factory Installed Manganese Configuration
MANTLE 546034SX
LINER 546746SX
JCI 24/7 Parts Number 888-474-0115

2010 JCI
JCI Kodiak+ Crusher
JCI Warranty Policy

Kolberg-Pioneer, Inc. and Johnson Crushers International, Inc., (hereinafter referred to as "KPI-JCI") warrants
its products to its authorized Distributor, as specified herein, and Distributor agrees to extend this same
warranty (and no other) to each purchaser of the products of KPI-JCI at the time of sale and to notify each
purchaser of the terms and conditions of this Warranty. Distributor is not authorized by KPI-JCI to make any
other, different, or additional warranty on behalf of KPI-JCI, and any such warranty given by Distributor is not
binding on KPI-JCI. Distributor shall hold KPI-JCI harmless from any loss and/or costs (including attorneys'
fees) arising from failure to observe these conditions. KPI-JCI extends this same Warranty to those, in addition
to its authorized distributors, who buy the PRODUCTS of KPI-JCI directly rather than purchasing from an
authorized Distributor.
KPI-JCI warrants, commencing with the date of receipt of the goods by first end-user and for a period of one
(1) year or two thousand (2000) hours, whichever comes first, all machinery and parts manufactured by KPI-
JCI to be free from defects in workmanship and material. If, within such warranty period, any machinery or
parts shall be proved to the satisfaction of KPI-JCI to be defective, it shall be replaced or, at the option of KPI-
JCI, repaired at its factory, F.O.B. KPI's manufacturing plant in Yankton, South Dakota or JCI's manufacturing
plant in Eugene, Oregon, at no charge (providing the defective machinery or parts are returned to KPI or JCI's
manufacturing plant, SD or JCI's manufacturing plant , freight prepaid). At its option, KPI-JCI may repair, or
arrange to have repaired, any defective machinery or parts, at the location of the Distributor, at the yard
location or operating site of the first end-user, or at any other suitable location at no charge to first end-user
and at no charge to Distributor other than those specified in its Distributor's Agreement. The right to have
defective machinery or parts repaired or replaced shall constitute Distributor's and first end-user's sole and
exclusive remedy.
KPI-JCI may, at its sole discretion, refund the purchase price or defective machinery or parts in lieu of repairing
or replacing them, providing the defective machinery or parts are returned to KPI's or JCI's manufacturing plant
, freight prepaid, and providing such return is authorized by KPI-JCI. KPI-JCI may, at its sole discretion, waive
the requirement that defective machinery or parts be returned to its factory in connection with a warranty claim.
The obligation of KPI-JCI under the terms of this Warranty is limited to the described repair or replacement of
defective machinery or parts. Labor for warranty repair will be paid under a formula determined by KPI-JCI.
With regard to machinery, parts or accessories which are furnished by KPI-JCI, but not manufactured by it, the
warranty obligation of KPI-JCI shall be limited to and the same as that of its supplier. No warranty shall apply
to any used machinery or parts. No warranty shall apply to the products of KPI-JCI which, in its opinion, have
been adversely affected by the use, on or with its products, of parts, attachments, equipment or lubricants not
manufactured, sold or authorized by KPIJCI.
No warranty shall apply to machinery, parts or accessories which have been furnished, repaired or altered by
others so as (in the opinion of KPI-JCI) to have affected the same adversely. No warranty shall apply to
machinery, parts or accessories which (in the opinion of KPI-JCI) have been subject to accident, negligence,
or improper operation, installation, maintenance, storage, care or other-than-normal use during and after
shipment.
KPI-JCI warrants that field services conducted by it in connection with installation or repair of machinery and
parts will be performed in a good workmanlike manner. The obligation and liability of KPI-JCI in connection
with field services shall be limited to a refund of the amount it charged for such services, if any.
Inasmuch as the work to be performed by the buyer or end-user with the machinery or parts furnished by KPI-
JCI will vary according to the materials used, local conditions, and the results required and that such variation
will continue throughout the use of such machinery or parts, it is not possible to (and KPI-JCI does not) warrant
or represent that machinery and parts furnished by it will handle specific materials or will produce specific

2010 JCI
JCI Kodiak+ Crusher
results from such materials. Any application analysis and resultant equipment performance expectations are
provided as estimates only and are not to be construed in any manner as a production guarantee.
KPI-JCI is wholly discharged of all liability under the foregoing warranties in the event that purchaser of the
machinery or parts fails to pay for the goods promptly and in accordance with the terms of the purchase
agreement.
KPI-JCI's liability hereunder is conditioned upon Distributor (or in the event of a direct sale to a first end-user,
then first end-user) giving notice in writing to KPI-JCI of any alleged defect, and such notice must be given
immediately upon the discovery of such alleged defect; such notice must be received by KPI-JCI not later than
30 days after the expiration of the warranty period.
KPI-JCI does not warrant or represent that any machinery, parts, or accessories furnished by it meet any
Federal, State or Local statutes, codes, ordinances, rules, standard or other regulations covering safety,
pollution, noise, electrical wiring, etc.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED
(EXCEPT THE WARRANTY OF TITLE) INCLUDING BUT NOT LIMITED TO ANY WARRANTY OR
MERCHANTABILITY, KPI/JCI SHALL NOT BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES
WHATSOEVER WITH RESPECT TO MACHINERY, PARTS, ACCESSORIES, OR SERVICES
MANUFACTURED OR FURNISHED BY IT OR ANY UNDERTAKINGS, ACTS OR OMISSIONS RELATING
THERETO. UNDER NO CIRCUMSTANCES SHALL KPI/JCI BE LIABLE FOR ANY CONSEQUENTIAL OR
OTHER DAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER CAUSED. THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.
Any questions about your crushers warranty can be addressed to the following:
JCI
86470 Franklin Blvd.
Eugene, Oregon 97405
Voice Phone: 800-314-4656
Fax: 541-988-9401
24/7 Parts: 888-474-0115
Technical Support: 24/7 1-866-875-4058

2010 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
Email: parts@jcieug.com
The Serial Number Plate for your

Kodiak+ Crusher is located on the
side opposite the drive sheave.
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 oppo-
site 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.

2010 JCI
JCI Kodiak+ Crusher
Important Safety Precautions
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 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.

2010 JCI
JCI Kodiak+ Crusher
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 man-
tle 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
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.
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 oper-
ation. A careful and well-trained operator is the best insurance against an accident.

2010 JCI
JCI Kodiak+ Crusher
Available Liner Configurations for the K400+
K400+ Coarse Chamber

Bowl Liner: 546745SX A B C
Mantle: 546034SX
10 1/4 11 1/2 3/4
10 3/8 11 5/8 7/8
10 1/2 11 3/4 1
10 3/4 12 1 1/4
11 1/8 12 1/4 1 1/2
11 3/8 12 1/2 1 3/4
11 1/2 12 3/4 2
Reduction Ratio: 4:1 to 8:1 Max. (Based on no bowl float. If bowl float occurs Chamber Weights:
then you have gone beyond the allowable reduction ratio.) Liner: 2477lbs (1124kg)
Mantle: 2235lbs (1014kg)
Liner Hardware
1. 546779 Retaining Ring Foam Approximate Backing Material

2. 546780 Foam Liner
3. 406080 Retainer Locknut Liner Mantle Chamber
4. 406078 Retainer Bolt
5. 546781 Locking Ring 22 lb 3 4 6
6. 406206 Fill Hole Cap Buckets
7. 540103 Foam
8. 546361 Mantle Washer Weight (lb) 66 88 132
9. 540301 Pin
10. 546464 Mantle Nut Cap
11. 070103 Capscrew

2012 JCI
JCI Kodiak+ Crusher
K400+ Medium Chamber with Feed Slots

Mantle: 546034SX
8 1/8 9 1/2 5/8
8 1/4 9 5/8 3/4
8 3/8 9 3/4 7/8
8 1/2 9 7/8 1
8 3/4 10 1/4 1 1/4
Chamber Weights:
Liner: 2261lbs (1026kg)
Reduction Ratio: 3:1 to 6:1 Max. (Based on no bowl float. If bowl float occurs
then you have gone beyond the allowable reduction ratio.)
Liner Hardware

5. 546781 Locking Ring 22 lb 6 4 9
7. 540103 Foam
9. 540301 Pin
11. 070103 Capscrew

2012 JCI
JCI Kodiak+ Crusher
K400+ Medium Chamber

Mantle: 546034SX
6 5/8 8 1/8 5/8
6 3/4 8 1/4 3/4
6 7/8 8 3/8 7/8
7 8 1/2 1
7 3/8 8 3/4 1 1/4
Chamber Weights:
Liner Hardware

5. 546781 Locking Ring 22 lb 6 4 10
7. 540103 Foam
9. 540301 Pin
11. 070103 Capscrew

2012 JCI
JCI Kodiak+ Crusher
K400+ Medium Fine Chamber

Mantle: 546034SX
3 1/2 5 1/4 1/2
3 3/4 5 3/8 5/8
3 7/8 5 1/2 3/4
4 5 3/4 7/8
4 1/8 5 7/8 1
Chamber Weights:
Liner Hardware

5. 546781 Locking Ring 22 lb 8 4 12
7. 540103 Foam
9. 540301 Pin
11. 070103 Capscrew

2012 JCI
JCI Kodiak+ Crusher
K400+ Fine Chamber

Mantle: 546038SX
2 1/8 3 7/8 1/4
2 1/4 4 3/8
2 3/8 4 1/8 1/2
2 1/2 4 1/4 5/8
2 5/8 4 3/8 3/4
Chamber Weights:
Liner Hardware

5. 546781 Locking Ring 22 lb 9 6 15
7. 540103 Foam
9. 540301 Pin
11. 070103 Capscrew

2012 JCI
JCI Kodiak+ Crusher
Factory Installed Counterweight Configuration
20 21
18 19
16 17
14
15
13 12 11 10 9 8 7 6 5 4 3 2 1
16 18 20 21 19 17
Top View
ITEM QTY PART NUMBER DESCRIPTION COMMENTS

1 0 406012 COUNTERWEIGHT 3.40 LBS
14/15 1 EA 546708 LOWER COUNTERWEIGHT
16 1 546709 LH UPPER COUNTERWEIGHT
17 1 546710 RH UPPER COUNTERWEIGH
18/19 0 EA 546713 CWT SHIM 0.250
20 1 546711 LH CWT CAP
21 1 546712 RH CWT CAP
22/23 0 EA 546714 CWT SHIM 10 GA NOT SHOWN

2012 JCI
Table of Contents
Crusher Components ............................................................................................. 1
Lower Assembly ..................................................................................................... 4
Base Frame ........................................................................................................... 11
V-Seat Liner ........................................................................................................... 13
Pin Clutch Assembly .............................................................................................. 14
Wedge Plate Assembly .......................................................................................... 15
Floating Plate Assembly ........................................................................................ 19
Cone Assembly ...................................................................................................... 20
Pinion Assembly .................................................................................................... 23
Upper Assembly ..................................................................................................... 25
Bowl Support Assembly ......................................................................................... 32
Bowl Clamp ............................................................................................................ 33
Sensor JBox PLC ................................................................................................... 35
Upper Assembly Hose Kit ...................................................................................... 36
TIR Assembly ......................................................................................................... 37

TIR Cylinder Assembly ........................................................................................... 39
TIR Hose Kit ........................................................................................................... 41
Decal Location ....................................................................................................... 42
Hopper Assembly ................................................................................................... 47
Relief Cylinder Test Block ...................................................................................... 50
Eye Cone Lifting Assembly .................................................................................... 51
Kodiak Plus Electrical Components ....................................................................... 52
Remote Control Panel PLC .................................................................................... 56
Hydraulic Power Unit PLC ...................................................................................... 58

2010 JCI
Table of Contents
Hydraulic Schematic PLC ...................................................................................... 67
Manifold Assembly ................................................................................................. 68
Hydraulic Schematic .............................................................................................. 72
Manual Transfer Pump Assembly .......................................................................... 73
Electrical Enclosure Kodiak PLC ............................................................................ 74
Lube Assembly with Reservoir PLC ....................................................................... 79
Lube Enclosure w/ Reservoir ................................................................................. 86
Lube Panel Electrical Enclosure ............................................................................ 90
Lube Assembly Hose Kit ........................................................................................ 92
Oil Drain Line Fittings ............................................................................................. 93
Oil Cooler Components OA123-4JCI ..................................................................... 94
Standard Hose Kit .................................................................................................. 96
Lube Flow Sensor Kit ............................................................................................. 99
Turck Encoder Assembly .......................................................................................100
Milo Display Heater Components .......................................................................... 101

2010 JCI
8/11/10
REF# 546702
Crusher Components
Rev. C 1
8/11/10
REF# 546702
Crusher Components
PART
ITEM QTY DESCRIPTION COMMENTS
NUMBER
1 1 546704 LOWER ASSY
2 1 546703 UPPER ASSY
4 3 456195 SHIM ROT STOP BLOCK .312 THK
5 1 546782 TIR ASSEMBLY
6 1 546821 DECAL LOCATION JCI - K400
7 1 546785 HOPPER ASSY
8 4 540236 ANGLE CLIP 2X2X3/8
9 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
10 4 076024 NUT 1/2-13NC
11 4 078025 WASHER LOCK 1/2
12 4 078019 WASHER FLAT 1/2
13 1 090035 WRENCH ALLEN 1
15 1 450132 WRENCH MANTLE NUT STD
16 1 456294 BLOCK TEST CYL RELIEF
17 1 087091 PLUG CAVITY T16A-2
18 1 083074 NEEDLE OIL SAMPLER W/TUBING
19 1 085095 ELEMENT FILTER HMK04 14 MICRON
20 4 546338 SHIM 16 GA BASEFRAME MNTG
21 1 546849 CONE LIFTING EYE
22 1 546852 CONE LIFTING EYE ASSEMBLY
Rev. C 2
8/11/10
REF# 546702
Crusher Components
PART
NUMBER
1 1 060614 SPROCKET 56 TOOTH 9.824PD 125MM
2 1 060464 BUSHING TPRLK 4335 100MM BORE
N/A 1 060615 SPROCKET 90 TOOTH 15.79PD 125MM
N/A 1 060616 BUSHING TPRLK 5040 4.5 BORE
N/A 1 060617 BELT SYNCH DR 14MMP 2100X 125MM
Rev. C 3
8/11/10
REF# 546704
Lower Assembly
Rev. B 4
8/11/10
REF# 546704
Lower Assembly
Rev. B 5
8/11/10
REF# 546704
Lower Assembly
Rev. B 6
8/11/10
REF# 546704
Lower Assembly
Rev. B 7
8/11/10
REF# 546704
Lower Assembly
Rev. B 8
8/11/10
REF# 546704
Lower Assembly
Rev. B 9
8/11/10
REF# 546704
Lower Assembly
PART
NUMBER
1 1 546732 BASE FRAME MACHINED
2 1 546790 ASSY CLUTCH PIN
3 1 546773 CLUTCH GUIDE RING
4 4 070092 CAPSCREW SOC 1/2 13NC X 1-1/2
5 4 070130 CAPSCREW HEX 5/16-24NF X3/4
6 1 406015 CVR BRAKE HOUSING
7 28 078025 WASHER LOCK 1/2
8 12 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
9 2 080032 PLUG MAGNETIC 1
10 1 540043 BASEFRAME RING SEAL
11 1 540301 PIN .500 X 1.250
12 1 546705 WEDGE PLATE ASSY
13 1 540116 PL THRUST 54
14 8 070152 CAPSCREW HEX 1 14NF X 3
15 1 546772 SHAFT BRAKE CONE
16 2 546587 KEY BRAKE CONE
17 1 546568 CONE BRAKE PLATE
18 1 450497 FLOATING PLATE W/ INSERTS
19 1 546755 WEDGE PLATE GUARD
20 10 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
21 10 078019 WASHER FLAT 1/2
22 1 546716 CONE ASSY
23 1 546722 PINION ASSY
24 12 070010 CAPSCREW HEX 5/8 11NC X 1-3/4
25 12 078014 WASHER LOCK 5/8
26 2 070141 SETSCREW SOC 5/8 11NC X 5/8
27 1 546784 PINION TUNNEL ACCESS COVER
28 16 070058 CAPSCREW HEX 1/2 13NC X 1 G5
29 1 083907 ELBOW ST 2 1/2 PIPE 90 DEG
30 2 083249 PLUG PIPE NPT SQ HEAD 2 1/2
31 1 546277 KEY DRIVE SHEAVE
32 1 083556 FS2503-12-12
33 1 083508 FS0304-C-12
Rev. B 10
8/11/10
REF# 546732
Base Frame
Rev. D 11
8/11/10
REF# 546732
Base Frame
PART
NUMBER
1 1 546733 BASEFRAME FAB
2 1 546741 SPINDLE BASEFRAME
3 1 540100 NUT SPINDLE
4 5 456344 PLUG 1.625 DIA X 0.500
5 4 546612 LINER VSEAT K400 4.5
7 2 080122 FLANGE WELD 2 1/2NPT W/O PILOT
8 8 546892 CYL MOUNTING EYE
9 16 079119 PIN DOWEL .500 OD X 1.000
10 1 546743 PINION TUNNEL WEAR PLATE
11 4 406260 STRUT GUARD
12 1 546832 TUB LINER BURN-FORM
Rev. D 12
8/11/10
REF# 546612
V-Seat Liner
PART
NUMBER
N/A 617.627 052079 SH .25 X 48 X 120 C61400 AL-BN
Rev. 0 13
8/11/10
REF# 546790
Pin Clutch Assembly
PART
NUMBER
1 1 546791 BLOCK DRIVE
2 1 546792 BLOCK RATCHET
3 14 546641 PIN DRIVE
4 1 546585 WASHER THRUST
5 14 090442 SPRG COMPRES C0600-0490-1750
6 14 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
7 1 079100 RING RETAINING SMALLEY WSM 325
Rev. 0 14
8/11/10
REF# 546705
Wedge Plate Assembly
Rev. 0 15
8/11/10
REF# 546705
Rev. 0 16
10/30/12
REF# 546705
Rev. 0 17
8/11/10
REF# 546705

PART
NUMBER
1 1 546706 WEDGE PLATE MACHINED
2 1 546351 BRG LOWER RADIAL
3 1 546353 BRG LOWER THRUST
4 1 540040 GEAR RING SPIRAL
5 12 070138 CAPSCREW HEX 3/4 16NF X 1-1/2
6 1 540008 RING SEAL PL WEDGE LOWER
7 2 546708 CWT LOWER
8 6 070277 CAPSCREW SOC 3/4 10NC X 3-1/2
9 1 546774 BRG UPPER THRUST PINNED
10 1 546715 SEAL UPPER WEDGE PLATE
11 1 546923 CWT LOWER
12 1 070198 CAPSCREW SOC 3/4 10NC X 2-3/4
13 3 540159 RADIAL RACE RETAINER UPPER
14 6 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
15 1 546710 CWT UPPER RH
16 1 546709 CWT UPPER LH
17 6 070465 CAPSCREW SOC 3/4 10NC X 2
18 1 546712 CWT CAP RH
19 1 546711 CWT CAP LH
20 4 070222 BOLT FLAT HD SOC 3/4NC X 1-3/4
21 N/A 406013 CWT X 2.5 LB SEE NOTE BELOW
22 N/A 406012 CWT X 3.4 LB SEE NOTE BELOW
23 13 083903 6408-H-24-0
24 6 070497 SETSCREW SOC 1 8NC X 1
Note: Please refer to the Factory Installed Counterweight Configuration sheet in the front of this
manual for crusher counter weight configuration details.
Rev. 0 18
8/11/10
REF# 450497
Floating Plate Assembly
PART
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 19
8/11/10
REF# 546716
Cone Assembly
Rev. B 20
8/11/10
REF# 546716
Cone Assembly
Rev. B 21
8/11/10
REF# 546716
Cone Assembly
1 1 546717 CONE WITH STEM
2 1 546350 BRG UPPER RADIAL
3 1 540165 RADIAL RETAINER CONE UPPER
4 6 070032 CAPSCREW HEX 3/8 16NC X 1-1/4
6 1 546836 TORQUE BAR UNHARDENED
7 2 070120 CAPSCREW SOC 3/4 10NC X 1-3/4
8 1 546727 CONE SEAL
9 1 540103 FOAM 1X2X44
10 1 546361 WASHER MANTLE
11 1 546465 BOLT MANTLE
12 1 546464 CAP MANTLE BOLT
13 1 070103 CAPSCREW SOC 1-1/2 6NC X 4
14 2 540301 PIN .500 X 1.250
16 2 A025403490004 PIN, TORQUE BAR
Rev. B 22
8/11/10
REF# 546722
Pinion Assembly
Rev. A 23
8/11/10
REF# 546722
Pinion Assembly
PART
NUMBER
1 1 546736 SHAFT PINION
2 1 540138 KEY PINION GEAR
3 1 540039 GEAR PINION SPIRAL
4 1 546271 SPACER GEAR
5 1 070123 SETSCREW SOC 5/16-18NC X 3/8
6 1 660008 BRG CONE
7 2 660013 CUP BRG
8 1 546723 HOUSING PINION MACHINED
9 1 660009 BRG CONE
10 1 660027 LOCKNUT PINION SHAFT
11 1 660025 LOCKNUT PINION
12 1 660029 FLINGER INNER
13 1 546272 CVR PL
14 12 078024 WASHER LOCK 3/8
15 12 070008 CAPSCREW HEX 3/8 16NC X1G5
16 1 660030 FLINGER OUTER
17 4 070142 SETSCREW SOC 3/8 16NC X 3/8
18 1 084057 O-RING 6227-79
19 1 660026 KEY LOCK NUT PINION
20 1 070088 SETSCREW 5/16 18NC X 1 G8
Rev. A 24
8/11/10
REF# 546703
Upper Assembly
Rev. C 25
8/11/10
REF# 546703
Upper Assembly
Rev. C 26
8/11/10
REF# 546703
Upper Assembly
Rev. C 27
8/11/10
REF# 546703
Upper Assembly
Rev. C 28
8/11/10
REF# 546703
Upper Assembly
PART
NUMBER
1 1 546891 BOWL SUPT MACHINED
2 3 456207 PIN ANTI ROTATION
3 3 070216 SETSCREW SOC 1/2 13NC X 1.0
4 233 090428 SPONGE RBBR 9/16T X 1/2W
5 1 546728 BOWL CLAMP MACHINED
6 1 546191 SEAL PISTON 7/8x1-3/8x66.5 ID
7 5 546192 ROD ACETAL SQ 7/8X7/8X48
8 6 546769 DRIVE RING SEAL UPPER RETAINER
10 58 078025 WASHER LOCK 1/2
11 12 546770 DRIVE RING SEAL RUBBER
12 6 546771 DRIVE RING,SEAL,LOWER RETAINER
13 6 546766 BOWL SEAL, UPPER, RETAINER
14 12 546768 BOWL SEAL, RUBBER
15 6 546767 BOWL SEAL, LOWER, RETAINER
16 20 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
17 1 546757 MOTOR BASE
18 1 456401 MOTOR MOUNTING PLATE
19 4 070023 CAPSCREW HEX 3/4 10NC X 2-1/4
20 12 078026 WASHER LOCK 3/4
21 4 070024 CAPSCREW HEX 3/4 10NC X 2-3/4
22 8 078021 WASHER FLAT 3/4
23 8 076017 NUT 3/4-10NC G5
24 2 076097 NUT JAM 1/2-13NC
25 2 070336 BOLT SQ HD 1/2-13 NC X 2-1/4
26 1 546602 GEAR REDUCER 4.43:1
27 4 070046 CAPSCREW HEX 3/4 10NC X 3-1/4
28 1 084076 O-RING 2-242
29 1 546048 MTR HYD MLHSB315-G4A REMOTE
30 1 546015 GEAR DRIVE 14T 2 DP 7 PD
31 2 070155 SETSCREW SOC 3/8 16NC X 3/4
32 1 546124 GEAR HOLD DOWN PLATE
33 2 070363 CAPSCREW HEX 1/2-20NF X 1 G5
34 1 546056 GUARD GEAR HYD DRIVE REMOTE
36 4 078024 WASHER LOCK 3/8
37 1 546129 MOUNT PROXIMITY SENSORS
38 1 020445 SENSOR PROX AB-871TM-DH8NP18-D
39 1 020114 SENSOR CABLE AB-889DR4AC2
Rev. C 29
8/11/10
REF# 546703
Upper Assembly
PART
NUMBER
41 2 083055 CLIP MNTG 1/4 TUBE
42 1 200094 KODIAK PLC PROX J-BOX
44 4 076026 NUT NYLOCK 1/4-20NC
45 2 083104 DISCONNECT CPLR PLUG 1/2 NPT
46 2 083116 DISCONNECT PARKER 4050-15
47 2 083327 FS6809-08-08-NWO
48 2 083474 FS6400-08-10-O
49 1 083566 FS6400-04-06-O
50 1 083038 CPLR DISC QUICK PVV-14-F
51 1 083051 TMP-14
52 3 070083 CAPSCREW HEX 7/8 9NC X 2-1/2
53 3 546795 SPACER GEAR SUPPORT
54 3 546796 ROLLER GEAR SUPPORT
55 3 078034 WASHER LOCK 7/8
56 3 076063 NUT 7/8-9NC
57 1 546873 GEAR DRIVEN WELDMENT/MACH
59 6 070391 CAPSCREW HEX 1 1/4-7NC X 8 G5
60 6 078056 WASHER HT 1 1/4
61 3 546890 ROTATION STOP UPPER
62 3 546776 SHEAR PIN ROTATION STOP
63 1 546730 BOWL MACHINED
64 16 084002 O-RING 1/4
65 1 546763 DRIVE RING
66 4 070141 SETSCREW SOC 5/8 11NC X 5/8
67 24 070038 CAPSCREW HEX 5/8 11NC X 2
68 24 078014 WASHER LOCK 5/8
70 4 406206 LINER CAP FILL HOLE
71 3 070003 CAPSCREW HEX 3/4 10NC X 1-1/2
72 3 076058 NUT JAM 3/4-10 NC
73 1 546777 BOWL RETAINER RING
74 12 076002 NUT 1-8NC G5
75 12 406078 BOWL RETAINING RING BOLT
76 12 406080 BOWL RETAINER LOCK NUT
77 12 546778 LOCKING RING KEEPER
78 24 070036 CAPSCREW HEX 3/4-10 X 2 G5 ZNC
79 24 078011 WASHER HT 3/4
80 1 546781 RING LOCKING
81 4 546779 FOAM UNDER LINER RET RING
82 3 546780 FOAM LINER RET
Rev. C 30
8/11/10
REF# 546703
Upper Assembly
PART
NUMBER
83 1 456516 KIT HOSE UPPER ASSEMBLY
84 1 456503 BRACKET SENSOR POS LIMITER
85 1 078004 WASHER HT 1/2
86 1 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
87 1 020535 SENSOR PROX BI7Q08-AP6X2-V2131
88 1 020536 CABLE 2M M8-1 X 3
89 2 070522 MACHSCREW RD HD #4-40 X 3/8
Rev. C 31
8/11/10
REF# 546891
Bowl Support Assembly
PART
NUMBER
1 1 546726 CASTING BOWL SUPPORT
2 9 546179 INSERT 1.25 SQ BRASS ROLLED
3 2 546212 STOP THREAD
5 3 546794 GEAR SUPPORT
Rev. 0 32
8/11/10
REF# 546728
Bowl Clamp
Rev. 0 33
8/11/10
REF# 546728
Bowl Clamp
PART
NUMBER
1 1 546729 FORGING, BOWL CLAMP
2 2 546179 INSERT 1.25 SQ BRASS ROLLED
3 2 546212 STOP THREAD
Rev. 0 34
8/11/10
REF# 200094
Sensor JBox PLC
PART
NUMBER
1 1 020121 ENCL 6X4X3 NEMA4/12/13
2 1 020122 ENCL PNL 6X4
3 4.75 020182 DIN MOUNTING RAIL DIN #3
4 12 027301 TB QTC 2,5
5 2 027300 TB END STOP
6 3 027302 TB QTC 2,5 END COVER
7 2 027304 TB BRIDGE 2,5 3 POSITION
8 1 027314 TB MARKER 2,5
11 1 027538 CORD GRIP NM MULTIHOLE 1/2 NPT
12 1 027539 CORD GRIP LOCKNUT FOR 027538
13 1 027540 CORD GRIP RINGSEALT FOR 027538
14 1 020038 "SEALING RING 1/2"" T&B 5262 "
15 1 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
20 2 026601 "SCREW PANHEAD #10-32 1/2"" "
21 2 078061 WASHER FLAT #10
Rev. 0 35
8/11/10
REF# 456516
Upper Assembly Hose Kit

1 1 H04R2-04FFSLE90S-04FNPT-48 04 HOSE 100R2AT
Rev. B 36
8/11/10
REF# 546782
TIR Assembly
Rev. C 37
8/11/10
REF# 546782
TIR Assembly
PART
NUMBER
1 8 456425 TIR CYLINDER
2 8 406107 CYL PIN CLEVIS TIR
3 8 406106 CYL ROD BOOT TIR
4 8 406102 CYL COLLAR TIR
5 8 406101 ROD END CYL TIR
6 8 406104 CYL COLLAR SPLIT TIR
7 8 406105 CYL RETAINER COUPLER TIR
8 8 456477 CYL WASHER SPHERICAL TIR
9 32 083595 FS6400-12-16-O
10 1 546783 HOSE KIT TIR
11 8 078004 WASHER HT 1/2 YELLOW ZINC
12 8 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
13 32 070061 CAPSCREW HEX 1/4 20NC X 1/2
14 1 087004 VALVE RELIEF SHORT BODY 3/8
15 1 083962 6405-08-06-O
16 1 083188 FS2404-04-04
19 1 083999 FS6400-04-08-O
20 4 087091 PLUG CAVITY T16A-2
21 4 087090 VALVE RELIEF CARTRIDGE
22 2 083476 FS6400-08-08-O
23 2 083517 FS0304-C-08
Rev. C 38
8/11/10
REF# 456425
TIR Cylinder Assembly
Rev. A 39
8/11/10
REF# 456425
TIR Cylinder Assembly

PART
NUMBER
1 1 456426 BARREL TIR CYLINDER
2 1 456427 HEAD TIR CYLINDER
3 1 456428 PISTON TIR CYLINDER
4 1 456429 ROD TIR CYLINDER
5 2 070142 SET SCREW SOC 3/8 16NC X 3/8
6 1 080149 WIPER ROD 2.250 SEAL KIT 456430 AVAILABLE
7 1 080148 SEAL ROD 2.250 THAT INCLUDES ITEMS 6
8 1 080147 SEAL ROD BUFFER 2.250 THROUGH 14.
9 2 080166 WEAR BAND W2-2500-1000
10 1 084103 O-RING 2-437
11 1 084104 RING BACKUP 8-437
12 2 080163 SEAL POLYPAK 25006000
13 2 080164 WEAR BAND W2-6500-625
14 1 080165 SEAL CROWN 6.5 X .25 X.375
15 2 083128 6408-H-08-O
Rev. A 40
7/5/12
REF# 546783
TIR Hose Kit

1 8 H12R17-12FFSLE45-12FFSLE45-25.750 HYD HOSE K400+ TIR
2 8 H12R17-12FFSLE45-12FFSLE45-24.5 HYD HOSE K400+ TIR
3 1 H04R17-04FFSLE90S-04FFSL-13 HYD HOSE TIR BLEED
Rev. B 41
8/11/10
REF# 546821
Decal Location
Rev. A 42
8/11/10
REF# 546821
Decal Location
Rev. A 43
8/11/10
REF# 546821
Decal Location
Rev. A 44
8/11/10
REF# 546821
Decal Location
Rev. A 45
8/11/10
REF# 546821
Decal Location
PART
NUMBER
1 1 090150 PL SERIAL NUMBER K300/K400
2 3 090624 DECAL CRUSHING ZONE K400
3 2 090644 DECAL KODIAK K400+
4 1 090485 DECAL ISO1014/6011 CRSH/LOTO
5 2 090486 DECAL ISO6202/6115/6041 HRG/EP
6 2 090489 ISO6071/6046 DECAL LIFT PTS
7 2 090490 ISO5018 DECAL FALL HZD
8 2 090497 ISO6202 DECAL EYE PROT
9 2 090498 ISO6126 DECAL READ OPS MAN
10 2 090499 ISO1017 DECAL 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 1 090512 DECAL ISO1014 HAND ENTANGLEMNT
15 1 090056 DECAL BUILT IN USA SMALL
16 2 090523 DECAL ISO5066 CRSHR MVNG PARTS
17 1 090560 "DECAL, ARROW 2 1/2"
18 8 090625 DECAL ISO1017 PINCHPT 2 X 4
19 1 090626 DECAL LUBRICANTS
Rev. A 46
8/11/10
REF# 546785
Hopper Assembly
Rev. B 47
8/11/10
REF# 546785
Hopper Assembly
Rev. B 48
8/11/10
REF# 546785
Hopper Assembly
PART
NUMBER
5 1 546155 HOPPER RING INNER
6 1 546787 HOPPER RING
7 1 546788 HOPPER RING UPPER
8 1 546413 FLANGE ROLLED 66 ID
Rev. B 49
8/11/10
REF# 456294
Relief Cylinder Test Block

1 1 087093 BODY T16A-2 W/ GAUGE PORT
2 2 083156 6405-16-08-O
3 1 089016 GAUGE 0-5000 PSI LOWER MOUNT
4 1 H04R2-08MNPT-04FJICSVL- HOSE SAE 100R2AT
48
5 1 083031 5404-08-08
6 1 083162 2404-04-04
7 1 083037 5406-08-04
Rev. C 50
8/11/10
REF# 546852
Eye Cone Lifting Assembly
PART
NUMBER
1 1 546853 CONE LIFTING EYE BASE
2 1 078058 WASHER HT 1-1/2
3 1 070549 CAPSCREW SOC 1-1/2 6NC X 4-1/2
4 1 546854 CONE LIFTING EYE WELDMENT
5 4 078004 WASHER HT 1/2
6 4 070486 CAPSCREW HEX 1/2-13 X 1-3/4 G8
Rev. 0 51
8/11/10
Kodiak Plus Electrical Components
Rev. 0 52
8/11/10
Rev. 0 53
8/11/10
Rev. 0 54
8/11/10

PART
NUMBER
1 1 HMI PROGRAM
2 1 MASTER PLC PROGRAM
3 1 SLAVE PLC PROGRAM
73 1 027424 HARNESS HPU CTRL STD
81 1 027426 HARNESS LUBE HPU STD
110 1 200199 CABLE HYBRID ETHERNET 100 FT
130 1 027543 TURCK CABLE RSM-RKM86-10M/S101
140 120 027577 CORD 12/3 SOOW
141 300 027578 CORD 8/3 SOOW
150 1 027242 TXDR 600A 4-20MA AT3-420-24L-F
160 1 027521 SENSOR ULTRASONIC T30UIPB
161 1 027560 CABLE TURCK RK4.5-4-RS4.5T
Rev. 0 55
8/11/10
REF# 200089
Remote Control Panel PLC
Rev. D 56
8/11/10
REF# 200089
Remote Control Panel PLC

PART
NUMBER
1 1 027549 PENDANT ENCL 16X16 MAC INDUSTR
5 1 027550 PLC DISPLAY REDLION G306MS00
6 1 027240 PB E-STOP GE P9XER4RAW
7 1 027234 PB CON BLCK 1NC GE P9B01VN
8 1 026965 PB LEGEND E-STOP 22MM SIEMENS
10 3 027562 INDICATING LIGHT GRN 120V IDEC
11 4 026089 PB LED CLEAR 24V
15 1 027235 PB STRT/STOP ILL GE P9DPLVRG01
16 1 027236 PB BOOT FITS GE P9DPLVRG01
17 1 027237 PB INDCTR LAMPHLDR GE P9PDNVO
18 5 027233 PB CON BLCK 1NO GE P9B10VN
25 3 027383 PB GE MOM BLK P9CPNNG
26 3 027559 PB BOOT GE 080CPT
30 1 027607 HARTING HYBRID PANEL-FEED META
31 1 026984 PROFINET RJ45 FEMALE CAP
35 21 027954 DUCT W/ COVER 1 X 2 GRAY
36 6 026601 "SCREW PANHEAD #10-32 1/2"" "
38 4 078061 WASHER FLAT #10
40 2 027300 TB END STOP
41 4 027334 TB FUSED W/LED ST 4-FSI/C
42 3 026651 FUSE 1A ATO/ATC 46201
43 1 027448 FUSE 2A ATO/ATC 46202
44 1 027319 TB BRIDGE 6 4 POSITION
45 1 027308 TB QTC 2,5 TWIN
46 1 027309 TB QTC 2,5 TWIN END COVER
47 7 027301 TB QTC 2,5
50 1 027248 PLC TWIDO BASE CTRL MODULE
51 1 027251 PLC TWIDO RS485 COMM MODULE
52 1 200196 CABLE PATCH KODIAK PLC TWIDO
53 1 200197 CABLE PATCH PLC ETHERNET
Rev. D 57
8/11/10
REF# 456570
Hydraulic Power Unit PLC
Rev. B 58
8/11/10
REF# 456570
Rev. B 59
8/11/10
REF# 456570
Rev. B 60
8/11/10
REF# 456570
Rev. B 61
8/11/10
REF# 456570
Rev. B 62
8/11/10
REF# 456570
Rev. B 63
8/11/10
REF# 456570

PART
NUMBER
1 0 456578 HYD SCHEMATIC PLC
2 1 456571 HPU BASE W/ RES
3 1 085021 STRAINER 100 MESH 20 GPM
4 1 089078 "GAUGE SIGHT LEVEL 12"" CENTERS "
5 1 456504 COVER OIL RESERVOIR HPU
6 1 085019 FILTER BREATHER
7 1 089077 HEATER 2NPT 1.5KW 120V 80-100F
8 3 083032 ELBOW SCH 40 1-1/4 NPT 90
9 1 083078 5406-P-20
11 2 083174 5406-20-16
12 1 083482 FS2404-16-16
13 1 083681 FS2404-12-16
14 1 456505 MOTOR BASE HPU
15 1 060421 MTRE 15HP 254TC SEE TEXT
16 1 060317 ADPTR PUMP 254TC X SAE A
17 1 060314 CPLNG HALF 5/8 M30002005
18 1 060315 CPLNG HALF 1-5/8 M30012012
19 1 060316 CPLNG INSERT 370N
20 1 086090 PUMP GEAR FIXED DISPLACEMENT
21 1 083329 FS6400-16-12-O
22 1 083570 FS6801-10-10-NWO
23 1 085094 FILTER HEAD HMK04 SEE TEXT
25 2 083252 6405-16-12-O
26 2 083303 FS2404-12-12
27 2 083557 NIPPLE CLOSE GALV 3/4
28 1 083326 TEE 3/4 NPT SIDE OUTLET
29 1 083190 PIPE SCH 40 3/4 X 2 NPT
30 1 083313 CPLG FEM CAMLOK 3/4 NPTF
31 1 083318 PLUG CAMLOCK 3/4
32 1 083320 REDUCER BELL 3/4 X 1/2 STD
33 1 200218 SW TEMP 165F SETPOINT ASSY
34 1 456572 PANEL SIDES HPU
36 1 456574 PANEL TOP HPU
37 4 456205 LUG LIFTING
38 1 456162 DOOR ENCLOSURE HPU
39 2 090185 HINGE LIFT OFF WELDABLE
40 3 456204 ANGLE DOOR STOP
Rev. B 64
8/11/10
REF# 456570

PART
NUMBER
41 1 090416 LATCH T HANDLE FLUSH W/ HOLES
42 2 540166 ACCUM 1GAL 1.25NPT
43 4 089034 CLAMP ACCUMULATOR 1 GAL
44 2 083321 FS2404-04-06
45 1 090544 BOX MANUAL 9000-15
46 1 456502 MANIFOLD ASSY
47 1 083466 6405-08-04-O
48 1 083051 TMP-14
49 1 083038 CPLR DISC QUICK PVV-14-F
50 4 083118 3474-08-08-NWO
51 4 083104 DISCONNECT CPLR PLUG 1/2 NPT
53 1 456513 HOSE KIT HPU PLC
54 1 090506 DECAL KPI/JCI 22.00 X 5.00
55 1 090491 DECAL ISO6041/6127 WRNG RTM
57 1 090522 DECAL ISO6058 SHUTOFF ELECTRIC
58 1 090509 DECAL ISO6020 NO OPEN FLAME
59 1 090520 DECAL ISO4021 EXPL DECOMP
60 1 090502 DECAL ISO1024 HOT SUR CAUTION
61 1 090562 DECAL, HPU PRESSURES
62 1 090521 DECAL ISO6010 ELECTRICALHAZARD
63 1 090551 DECAL ISO 110V YELLOW
64 0 456492 COMP LABELS HPU PLC (NO BOM)
65 1 456577 PUMP TRANSFER MANUAL ASSY
66 2 083322 5406-20-06
68 1 090186 DECAL HYD CONNECTION
69 1 083195 BALL VALVE BRONZE 1-1/4
70 1 083302 FS2404-20-20
71 1 083422 FS0304-C-20
77 1 027071 HARNESS HPU PLC CTRL
80 4 070340 MACHSCREW RD HD 8-32 x .50
81 4 076046 NUT #8-32NC
82 4 070055 CAPSCREW HEX 1/4 20NC X 3/4
83 4 078015 WASHER FLAT 1/4
84 4 076026 NUT NYLOCK 1/4-20NC
85 8 070066 CAPSCREW HEX 5/16-18NC X3/4
86 8 076027 NUT NYLOCK 5/16-18NC
87 4 070009 CAPSCREW HEX 3/8 16NC X 3/4 G5
Rev. B 65
8/11/10
REF# 456570

PART
NUMBER
89 6 078024 WASHER LOCK 3/8
91 40 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
92 4 070016 CAPSCREW HEX 1/2 13NC X 1-1/2
94 12 078025 WASHER LOCK 1/2
95 55 078019 WASHER FLAT 1/2
96 44 076005 NUT NYLOCK 1/2 13NC
97 1 027647 CORP GRIP 0.55-1.00 NCG100-100
98 1 026834 CORD GRIP .35-.75 NCG75-75
100 1 027648 "LOCKNUT 3/4"" NPT 12N CORD GRIP"
Rev. B 66
8/11/10
REF# 456578
Hydraulic Schematic PLC
Rev. 0 67
8/11/10
REF# 456502
Manifold Assembly
Rev. C 68
8/11/10
REF# 456502
Manifold Assembly
Rev. C 69
8/11/10
REF# 456502
Manifold Assembly
Rev. C 70
8/11/10
REF# 456502
Manifold Assembly
PART
NUMBER
1 1 456200 MANIFOLD HYD MACH
2 1 087169 VALVE D05 DBL SOL 24V DIN
3 1 087170 VALVE D05 SGL SOL 24V DIN
4 1 087161 VALVE D05 DBL SOL 24V DIN
6 15 083127 6408-H-06-O
8 2 087027 VALVE NEEDLE VALVE CART
9 1 087064 VALVE DIRECTIONAL C10-2
11 3 083244 6408-H-10-O
13 1 087025 VALVE SHUTTLE C10-3
14 1 083487 FS6801-04-06-NWO
15 2 083881 6410-06-04
17 1 083549 FS6400-12-10-O
18 1 083325 FS6400-10-10-O
19 1 089016 GAUGE 0-5000 PSI LOWER MOUNT
22 2 087032 VALVE CHECK PO CARTRIDGE
23 1 083883 6835-06-06-06
24 1 087210 VALVE SV10-20Y-0-N-24-DG
25 2 027244 TXDR PRES
26 1 083566 FS6400-04-06-O
28 1 083588 6405-06-04-O
29 1 027245 TXDR PRES
30 1 083880 4601-06-04
Rev. C 71
8/11/10
REF# 456577
Manual Transfer Pump Assembly
PART
NUMBER
1 1 086164 PUMP TRANSFER MANUAL
2 1 083053 5406-12-06
3 1 083319 ADPTR MALE CAMLOK 3/4 NPT
Rev. 0 73
8/11/10
REF# 200088
Electrical Enclosure Kodiak PLC
Rev. G 74
8/11/10
REF# 200088
Rev. G 75
8/11/10
REF# 200088

PART
NUMBER
1 1 200100 MACH-CTRL/P KODIAK PLC
2 0 200082 ELECT SCHEM KODIAK PLC
4 1 026626 METER HOUR 10-30VDC
5 72 026740 DUCT 1.5X3 GRA
6 48 020182 DIN MOUNTING RAIL DIN #3
7 1 027251 PLC TWIDO RS485 COMM MODULE
8 1 027607 HARTING HYBRID PANEL-FEED META
9 1 026984 PROFINET RJ45 FEMALE CAP
10 1 027248 PLC TWIDO BASE CTRL MODULE
11 1 027250 PLC TWIDO RELAY OUTPUT MODULE
12 2 027249 PLC TWIDO ANALOG INPUT MODULE
13 1 027055 POWER SUPPLY 120/24VDC 20A
14 1 027078 CB 20A MINI 1 POLE SIEMENS
19 1 026829 RELAY 30A 120VAC CR420HPC022J
20 1 026830 RELAY SOCKET CR420HA
21 1 026407 GROUND BAR #6 - #14 WIRE
22 0.1 027531 RELAY MARKER WAGO
23 1 027427 HARNESS HPU PLC CTRL 23 PIN
24 1 027428 HARNESS HPU PLC CTRL 14 PIN
25 1 027525 RELAY SAFETY 24V DPDT WAGO
26 6 027526 RELAY W/SOCKET 24V SPDT WAGO
27 4 027556 RELAY WAGO AC115V 788-507
28 4 027558 RELAY JUMPER 4 PIN WIDE WAGO
29 1 027530 RELAY JUMPER 3 PIN WIDE WAGO
30 4 027324 TB ST 10
31 2 027325 TB ST 10 END COVER
33 1 027328 TB MARKER 10
34 2 027315 TB ST 6
39 1 027323 TB MARKER 6
41 2 027327 TB BRIDGE REDUCING 10-2,5/4
Rev. G 76
8/11/10
REF# 200088

PART
NUMBER
43 3 027310 TB QTC 2,5 HYBRID
44 1 027311 TB QTC 2,5 HYBRID END COVER
46 5 027302 TB QTC 2,5 END COVER
47 3 027309 TB QTC 2,5 TWIN END COVER
48 10 027308 TB QTC 2,5 TWIN
49 4 027314 TB MARKER 2,5
50 9 027334 TB FUSED W/LED ST 4-FSI/C
51 14 027300 TB END STOP
52 1 200197 CABLE PATCH PLC ETHERNET
53 1 026086 RESISTOR 820 OHM 1/2 WATT
55 3 026722 FUSE 10A ATO/ATC 46210
56 1 026886 FUSE 5A ATO/ATC 46205
57 1 027448 FUSE 2A ATO/ATC 46202
58 4 026651 FUSE 1A ATO/ATC 46201
60 2 020040 "CORD GRIP 3/4"" .50-.62 CGB295 "
61 3 020018 "SEALING RING 3/4"" T&B 5263 "
62 3 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
70 1 020153 "CORD GRIP 1-1/4"" 1.0-1.3 "
71 1 020154 "SEALING RING 1-1/4"" T&B 5265 "
72 1 020155 "RIGID 1-1/4"" LOCKNUT T&B 144 "
74 4 020038 "SEALING RING 1/2"" T&B 5262 "
75 4 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
76 2 020516 "CORD GRIP 1/2"" .25-.375 CGB193"
77 1 020129 CORD GRIP .125-.187 CG1250
78 1 026454 "CORD GRIP 3/4"" NPT .650-.750 "
80 1 020001 HORN BASE FED SIGNAL 020560
81 1 020002 HORN FED SIGNAL 350-120-30
85 1 027542 TURCK RKF 86-1M/14.5/NPT
86 1 027545 TURCK CAP RSFB-CC
90 80 020013 CORD 16/3 SJO
91 150 027052 WIRE 12 MTW BLACK
92 150 025387 WIRE 12 THHN WHT
93 150 025380 WIRE 12 THHN RED
94 72 025386 WIRE 12 THHN GRN
95 720 020031 WIRE 16 MTW BLU
96 360 020132 WIRE 16 MTW RED
100 40 026601 "SCREW PANHEAD #10-32 1/2"" "
101 40 078061 WASHER FLAT #10
Rev. G 77
8/11/10
REF# 200088

PART
NUMBER
106 2 078015 WASHER FLAT 1/4
107 2 076026 NUT NYLOCK 1/4-20NC
110 1 090558 DECAL ISO6010 DGR 120V 3 X 6
Rev. G 78
10/9/12
REF# 456510
Lube Assembly w/ Revervoir PLC
Rev. D 79
10/9/12
REF# 456510
Rev. D 80
10/9/12
REF# 456510
Rev. D 81
10/9/12
REF# 456510
Rev. D 82
10/9/12
REF# 456510

LUBEASSE
MBL
YJUNCTION BO
X
7 9
115 N N N
4 6
12 GA BLACK 2A WHITE N
HTR-A
12GA BLAC
K 2B WHITE N
HT
R-B
PART
NUMBER
1 1 406059 LUBE ENCLOSURE W/ RES
2 1 089078 GAUGE SIGHT LEVEL 12" CENTERS
3 1 200090 ASSY LUBE/P PLC 120V HTRS
5 8 076027 NUT NYLOCK 5/16-18NC
6 12 078016 WASHER FLAT 5/16
7 2 089077 HEATER 2NPT 1.5KW 120V 80-100F
8 2 026658 RE 1"X 3/4"" RB100-75
9 2 020040 "CORD GRIP 3/4"" .50-.62 CGB295 "
10 2 020515 CORD GRIP .50-.63 CGE295
11 2 020019 RIGID 3/4"" LOCKNUT T&B 142
12 120 020035 CORD 12/3 SO
13 1 083496 FS2501-16-16
14 1 020519 SW LEVEL GEMS LS-7 (SEE TEXT)
15 2 083037 5406-08-04
16 2 027389 TXDR TEMP TA3333
17 1 083155 5602-08-08-08
Rev. D 83
10/9/12
REF# 456510

PART
NUMBER
18 1 546289 VALVE COOLER BYPASS
19 1 083595 FS6400-12-16-O
20 3 083252 6405-16-12-O
21 2 083568 5602-12-12-12
23 1 083836 5604-12-12-12
24 1 083545 FS6801-12-16-NWO
25 2 070236 CAPSCREW HEX 3/8 16NC X 3 1/2
26 8 078017 WASHER FLAT 3/8
27 3 076009 NUT NYLOCK 3/8-16NC
28 1 085094 FILTER HEAD HMK04 SEE TEXT
29 1 027463 SW FILTER BYPASS (SEE TEXT)
30 1 020199 CORD GRIP 1/2" .38-.50 CGE194
32 1 083193 5404-12-12
33 1 083191 5605-12-12-12
34 2 080034 5406-12-04
35 2 083026 5502-04-02
36 2 083016 SAMPLER PLUG
37 4 083303 FS2404-12-12
38 1 027755 ENCODER TURCK TK182950
40 8 078024 WASHER LOCK 3/8
41 1 456566 TUBING ASSY 456510
42 1 060539 MTR 3HP 182TC
43 1 406218 ADAPTER PLATE
44 4 070470 CAPSCREW SOC 1/2-13 X 1-1/4
45 1 089093 COUPLING LO95 .500x1.125
46 1 080110 PUMP ADAPTER SAE AA SHORT
47 4 078007 WASHER HT 3/8 YELLOW ZINC
48 1 080066 PUMP LUBE 1.0 CU IN/REV
49 1 083977 5502-12-16
50 1 083482 FS2404-16-16
51 1 080043 COVER PLATE PUMP ADAPTOR
52 2 070056 MACH SCREW RD HD #8-32NC X 3/4
53 1 406217 MOTOR BASE
54 4 070066 CAPSCREW HEX 5/16-18NC X3/4
55 4 070068 CAPSCREW HEX 5/16-18NC X1-1/2
56 4 078023 WASHER LOCK 5/16
57 4 076022 NUT 5/16 18NC
58 12 070027 CAPSCREW HEX 1/2 13NC X 1-1/4
Rev. D 84
10/9/12
REF# 456510

PART
NUMBER
59 12 076005 NUT NYLOCK 1/2 13NC
60 12 078019 WASHER FLAT 1/2
61 1 083909 5404-N-40x4.000
62 1 083923 CAP PIPE BLACK 2 1/2
63 1 085019 FILTER BREATHER
64 1 083249 PLUG PIPE 2 1/2 NPT SQ HEAD
66 1 090311 DECAL WRNG HIGH VOLTAGE
67 1 090194 DECAL ROTATION ARROW
68 1 090502 DECAL ISO1024 HOT SUR CAUTION
69 1 090551 DECAL ISO 110V YELLOW
70 1 090522 DECAL ISO6058 SHUTOFF ELECTRIC
71 1 090430 DECAL OIL LEVEL GAUGE
72 1 090089 DECAL NOTICE RUN LUB
74 0 456575 COMPONENT LABELS (NO BOM)
75 1 456598 KIT HOSE LUBE ASSY PLC
76 1 027425 HARNESS LUBE SENSOR STD
77 1 027410 DEUTSCH 2 PIN SOCKET DT04-2P
78 1 027412 DEUTSCH 2 PIN WEDGELOCK W2P
79 2 027368 DEUTSCH SEALING PLUG 12-16
80 7 027366 DEUTSCH PIN 16 NICKEL 16-20AWG
81 1 027395 DEUTSCH 4 PIN RECPT DT04-4P
82 1 027534 DEUTSCH WEDGELOCK W4P
84 1 083508 FS0304-C-12
85 1 083478 FS6400-12-12-O
86 1 083550 6401-12-12-O
87 1 083293 FS6801-06-06-NWO
88 1 060696 MTRH 1.20 CU-IN HONOR
89 1 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
90 1 027358 DEUTSCH RECPT DT04-3P
92 1 076023 NUT 3/8-16NC
93 1 083025 5502-12-08
94 1 083304 FS2404-06-08
95 1 083475 FS6801-08-08-NWO
96 1 083565 6401-08-08-O
97 1 083674 FS2404-08-08
98 1 087033 VALVE BODY B10-2-A8T
Rev. D 85
8/11/10
REF# 406059
Lube Enclosure w/ Reservoir
Rev. H 86
8/11/10
REF# 406059
Rev. H 87
8/11/10
REF# 406059
Rev. H 88
8/11/10
REF# 406059
PART
NUMBER
14 4 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. H 89
8/11/10
REF# 200090
Lube Panel Electrical Enclosure
Rev. A 90
8/11/10
REF# 200090
Lube Panel Electrical Enclosure

PART
NUMBER
2 1 020010 ENCL PNL 10X8 A10P8
3 1 026407 GROUND BAR #6 - #14 WIRE
5 1 026454 "CORD GRIP 3/4"" NPT .650-.750 "
6 1 020516 "CORD GRIP 1/2"" .25-.375 CGB193"
7 2 020040 "CORD GRIP 3/4"" .50-.62 CGB295 "
8 1 027410 DEUTSCH 2 PIN SOCKET DT04-2P
9 1 027412 DEUTSCH 2 PIN WEDGELOCK W2P
10 2 027216 DEUTSCH 0460-202-1631
11 1 020038 "SEALING RING 1/2"" T&B 5262 "
12 3 020018 "SEALING RING 3/4"" T&B 5263 "
13 3 020019 "RIGID 3/4"" LOCKNUT T&B 142 "
14 10 025367 CORD 16/2 SEOW
16 1 020039 "RIGID 1/2"" LOCKNUT T&B 141 "
20 1 026830 RELAY SOCKET CR420HA
21 1 027646 RELAY 20A 24VDC CR420HPC0334
22 5 027315 TB ST 6
23 1 027323 TB MARKER 6
27 2 027312 TB ST 4
29 1 027314 TB MARKER 2,5
30 3 027300 TB END STOP
31 2 026601 "SCREW PANHEAD #10-32 1/2"" "
32 2 078061 WASHER FLAT #10
Rev. A 91
8/11/10
REF# 456576
Lube Assembly Hose Kit

1 1 H12R2-12FFSL- 12 HOSE-PUMP
12FFSLE90S-42.5
2 1 H16R4-16FFSLE90S- 16 HOSE-SUCTION
16FFSL-20
3 1 H08R2-08FFSL-08FFSL-20 08 HOSE-BYPASS
Rev. A 92
8/11/10
REF# 406212
Oil Drain Line Fittings
3
1
2
PART
NUMBER
1 2 083895 NIPPLE KING MALE 2 1/2 NPT
2 4 065039 CLAMP T-BOLT 2.5 ID HOSE
3 2 083907 ELBOW ST 2 1/2 PIPE 90 DEG
4 144 088062 HOSE 40GMV
Rev. A 93
8/11/10
REF# 546856
Oil Cooler Components OA123-4JCI
Rev. 0 94
8/11/10
REF# 546856
Oil Cooler Components OA123-4JCI

PART
NUMBER
1 1 546855 OIL COOLER OAI23-4JCI
2 2 083593 6410-16-08-O
3 2 083475 FS6801-08-08-NWO
Rev. 0 95
8/11/10
REF# 456468
Standard Hose Kit
Rev. E 96
8/11/10
REF# 456468
Standard Hose Kit
Rev. E 97
8/11/10
REF# 456468
Standard Hose Kit

2 6 083105 TF-12 DISCON NIPPLE DUST CAP
3 6 083039 NIPPLE QUICK DIS 3010-2 Parker
4 2 083081 CVR DUST QUICK DISCON
5 2 083579 FS2408-12
6 1 H04R2-04MNPT-04MNPT-288 04 HOSE 100R2AT
7 2 H08R2-08MORB-08MORB-420 08 HOSE 100R2AT
8 2 H08R2-08FFSLE45-08MORB-288 08 HOSE 100R2AT
9 2 H08R2-08FFSL-08FFSL-160 08 HOSE 100R2AT
10 1 H12R2-12FFSL-12FFSL-160 12 HOSE 100R2AT
Rev. E 98
8/30/12
REF# 456596
Lube Flow Sensor Kit
11
OUTPORT
OUTPORT
7 8
4 LUBEORING
6
LUBEORING
INPORT
13
A
9
B C
PINA: DC+BRO109
A
PINB: DCGROUNDW HT
PINC: RETURNGRN112
2 3
DETAIL A

1 1 083473 FS2501-06-08
2 2 078017 WASHER FLAT 3/8
3 1 076009 NUT NYLOCK 3/8-16NC
4 1 200323 ENCODER TURCK TK182950 ASSY
5 1 H06R2-06FFSLE90L- 06 HOSE 100R2
06FFSL-30.3
6 1 083478 FS6400-12-12-O
7 1 083550 6401-12-12-O
8 1 083293 FS6801-06-06-NWO
9 1 070042 CAPSCREW HEX 3/8 16NC X 1-1/2
10 1 027425 HARNESS LUBE SENSOR STD
11 1 060696 MTRH 1.20 CU-IN HONOR
13 1 076023 NUT 3/8-16NC
14 1 083741 FS0304-C-06
15 0 200324 PLC TWIDO MASTER PGM C.3
16 0 200326 PLC TWIDO HMI PGM C.3
Rev. A 99
8/30/12
REF# 200323
Turck Encoder Assembly
PART
NUMBER
1 1 027755 ENCODER TURCK TK182950
2 1 027358 DEUTSCH RECPT DT04-3P
3 3 027366 DEUTSCH PIN 16 NICKEL 16-20AWG
Rev. 0 100
8/30/12
REF# 200317
Milo Display Heater Components G306
PART
NUMBER
1 1 027758 PANEL BACK G306 HEATER
2 4 027757 RESISTOR 6 OHM 50 WATT
3 1 027756 THERMOSTAT 68F
4 2 027759 SCREW PANHEAD #6-32 X .25
5 8 027760 SCREW PANHEAD #4-40 X .25
7 3 076178 PUSH NUT 1/4 ID X 17/32 OD
Rev. A 101

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Kodiak Operation and Service

Factory Installed Manganese Configuration

JCI 24/7 Parts Number 888-474-0115

JCI Warranty Policy

JCI 24/7 Parts Number 888-474-0115

JCI 24/7 Parts Number 888-474-0115

JCI Parts Ordering Information

The Serial Number Plate for your

JCI 24/7 Parts Number 888-474-0115

Important Safety Precautions

Failure to adhere to the following

JCI 24/7 Parts Number 888-474-0115

JCI 24/7 Parts Number 888-474-0115

Available Liner Configurations for the K400+

K400+ Coarse Chamber

10 3/8 11 5/8 7/8

11 1/8 12 1/4 1 1/2

11 3/8 12 1/2 1 3/4

1. 546779 Retaining Ring Foam Approximate Backing Material

JCI 24/7 Parts Number 888-474-0115

K400+ Medium Chamber with Feed Slots

8 1/4 9 5/8 3/4

8 3/8 9 3/4 7/8

8 3/4 10 1/4 1 1/4

1. 546779 Retaining Ring Foam Approximate Backing Material

JCI 24/7 Parts Number 888-474-0115

K400+ Medium Chamber

6 3/4 8 1/4 3/4

6 7/8 8 3/8 7/8

7 3/8 8 3/4 1 1/4

1. 546779 Retaining Ring Foam Approximate Backing Material

JCI 24/7 Parts Number 888-474-0115

K400+ Medium Fine Chamber

3 3/4 5 3/8 5/8

3 7/8 5 1/2 3/4

1. 546779 Retaining Ring Foam Approximate Backing Material

JCI 24/7 Parts Number 888-474-0115

K400+ Fine Chamber

2 3/8 4 1/8 1/2

2 1/2 4 1/4 5/8

2 5/8 4 3/8 3/4

1. 546779 Retaining Ring Foam Approximate Backing Material

JCI 24/7 Parts Number 888-474-0115

Factory Installed Counterweight Configuration

ITEM QTY PART NUMBER DESCRIPTION COMMENTS

JCI 24/7 Parts Number 888-474-0115

Crusher Components ............................................................................................. 1

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

Base Frame ........................................................................................................... 11

V-Seat Liner ........................................................................................................... 13

Pin Clutch Assembly .............................................................................................. 14

Wedge Plate Assembly .......................................................................................... 15

Floating Plate Assembly ........................................................................................ 19

Cone Assembly ...................................................................................................... 20

Pinion Assembly .................................................................................................... 23

Upper Assembly ..................................................................................................... 25

Bowl Support Assembly ......................................................................................... 32

Bowl Clamp ............................................................................................................ 33

Sensor JBox PLC ................................................................................................... 35

Upper Assembly Hose Kit ...................................................................................... 36

TIR Assembly ......................................................................................................... 37

TIR Hose Kit ........................................................................................................... 41